4-cyl. injection engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  5
• 1 Removing and installing engine
  5
• 1.1 Notes on removing
  6
• 1.2 Aligning engine and gearbox mountings
  10
• 1.3 Notes on installation
  11
• 1.4 Specified torques
  13
• 1.5 Aligning engine and gearbox mountings
  14
• 1.6 Assembly mountings
  14
• 1.7 Additional notes and assembly work for vehicles with air conditioner
  15
• Crankshaft group
  17
• 1 Dismantling and assembling engine
  17
• 1.1 Assembly overview
  17
• 1.2 Removing and installing poly V-belt
  21
• 2 Sealing flange and flywheel/drive plate
  23
• 2.1 Assembly overview
  23
• 2.2 Renewing crankshaft oil seal -belt pulley end-
  26
• 2.3 Removing and installing sealing flange -belt pulley end-
  28
• 2.4 Removing and installing drive plate
  31
• 3 Crankshaft
  33
• 3.1 Assembly overview
  33
• 3.2 Crankshaft dimensions
  37
• 4 Dismantling and assembling pistons and conrods
  39
• 4.1 Assembly overview
  39
• 4.2 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview
  47
• 1.2 Removing, installing and tensioning toothed belt
  51
• 1.3 Checking semi-automatic toothed belt tensioning roller
  56
• 1.4 Removing and installing cylinder head
  56
• 1.5 Checking compression pressure
  61
• 2 Repairing valve gear
  64
• 2.1 Assembly overview
  64
• 2.2 Renewing camshaft oil seal
  67
• 2.3 Checking hydraulic bucket tappets
  70
• 2.4 Removing and installing camshaft
  70
• 2.5 Renewing valve stem seals
  73
• 2.6 Checking valve guides
  76
• 2.7 Renewing valve guides
  77
• 2.8 Reworking valve seats
  78
• Lubrication
  80
• 1 Parts of lubrication system
  80
• 1.1 Engine oil
  80
• 1.2 Assembly overview
  81
• 1.3 Removing and installing oil pump
  92
• 1.4 Oil pump with balancer shaft gear assembly
  92
• 1.5 Removing and installing oil sump
  97
• 1.6 Checking oil pressure and oil pressure switch
  101
• Cooling system
  104
• 1 Parts of cooling system
  104
• 1.1 Assembly overview - parts of cooling system, body side
  104
• 1.2 Assembly overview - parts of cooling system, engine side
  107
• 1.3 Coolant hose schematic diagram
  111
• 1.4 Draining and filling coolant
  113
• 1.5 Removing and installing radiator
  117
• 1.6 Removing and installing coolant pump
  118
• 1.7 Removing and installing thermostat
  120
• 1.8 Checking radiator fan
  122
• Fuel supply system
  124
• 1 Parts of fuel system
  124
• 1.1 Safety precautions when working on fuel supply system
  124
• 1.2 Rules for cleanliness
  125
• 1.3 Assembly overview - fuel tank with attachments and fuel filter
  125
• 1.4 Removing and installing fuel delivery unit
  132
• 1.5 Removing and installing fuel gauge sender
  135
• 1.6 Removing and installing fuel tank
  135
• 1.7 Crash fuel shut-off
  138
• 1.8 Checking fuel pump
  139
• 1.9 Bleeding fuel system (engine codes BEV and BGD only)
  153
• 2 Repairing accelerator mechanism
  156
• 2.1 Vehicles without electronic power control (EPC)
  156
• 2.2 Vehicles with electronic power control (EPC)
  159
• 3 Activated charcoal filter system
  161
• 3.1 Functional description
  161
• 3.2 Parts of the activated charcoal filter system - Assembly overview
  162
• 3.4 Checking fuel tank breather
  165
• Mixture preparation, injection
  170
• 1 Repairing injection system
  170
• 1.1 General notes on injection
  170
• 1.2 Safety precautions
  171
• 1.3 Rules for cleanliness
  171
• 1.4 Component location overview
  172
• 1.5 Intake manifold upper part - Assembly overview
  184
• 1.6 Removing and installing upper section of intake manifold
  190
• 1.7 Intake manifold lower part, fuel rail, injectors - Assembly overview
  195
• 1.8 Dismantling and assembling fuel rail with injectors
  203
• 1.9 Assembly overview - air filter
  204
• 1.10 Technical data
  205
• 2 Checking components
  206
• 2.1 Checking injectors for leaks and quantity injected
  206
• 2.2 Checking fuel pressure regulator and holding pressure
  211
• 2.3 Checking intake manifold change-over, only for vehicles with intake manifold change-over
  218
• 3 Engine control unit
  220
• 3.1 Replacing engine control unit
  220
• 3.2 Adapting functions and components
  221
• 3.3 Reading and erasing engine control unit fault memory
  223
• Exhaust system
  225
• 1 Parts of exhaust system
  225
• 1.2 Assembly overview - silencers with mountings
  230
• 1.3 Removing and installing exhaust manifold
  232
• 2 Secondary air system
  233
• 2.1 Functional description
  233
• 2.2 Parts of the secondary air system - Assembly overview
  233
• 2.3 Checking combination valve
  238
• 2.4 Removing and installing combi-valve
  240
• Ignition system
  242
• 1 Servicing ignition system
  242
• 1.1 General notes on ignition system
  242
• 1.2 Safety precautions
  242
• 1.3 Parts of the ignition system - Assembly overview
  243
• 1.4 Spark plug test data
  246