4-cyl. injection engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  5
• 1.3 Notes on installing
  9
• 1.4 Tightening torques
  11
• 1.5 Front engine mounting
  11
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Removing and installing ribbed belt for air conditioner compressor
  23
• 1.3 Removing and installing ribbed belt
  24
• 2 Removing and installing sealing flanges and flywheel/drive plate
  25
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  25
• 2.2 Renewing crankshaft oil seal -belt pulley end
  29
• 2.3 Removing and installing front sealing flange
  33
• 2.4 Removing and installing drive plate
  37
• 3 Removing and installing crankshaft
  39
• 3.1 Removing and installing crankshaft
  39
• 3.2 Crankshaft dimensions
  43
• 3.3 Pulling needle bearing out of crankshaft and driving in
  44
• 4 Dismantling and assembling pistons and conrods
  46
• 4.1 Dismantling and assembling pistons and conrods
  46
• 4.2 Piston and cylinder dimensions
  52
• Cylinder head, Valve gear
  53
• 1 Removing and installing cylinder head
  53
• 1.1 Removing and installing cylinder head
  53
• 1.2 Removing, installing and tensioning toothed belts
  57
• 1.3 Removing and installing cylinder head
  63
• 1.4 Checking compression pressure
  66
• 2 Servicing valve gear
  68
• 2.1 Servicing valve gear
  68
• 2.2 Reworking valve seats
  76
• 2.3 Renewing camshaft oil seal
  78
• 2.4 Checking hydraulic bucket tappets
  83
• 2.5 Removing and installing camshaft
  85
• 2.6 Checking valve guides
  92
• 2.7 Replacing valve stem seals
  93
• Lubrication
  98
• 1 Removing and installing parts of the lubrication system
  98
• 1.1 Removing and installing parts of the lubrication system
  98
• 1.2 Dismantling and assembling oil filter housing
  105
• 1.3 Dismantling and assembling oil pump with balancer shaft gear assembly
  108
• 1.4 Removing and installing oil pump with balancer shaft gear assembly
  111
• 1.5 Removing and installing sump
  116
• 1.6 Checking oil pressure and oil pressure switch
  122
• Cooling system
  124
• 1 Removing and installing parts of cooling system
  124
• 1.1 Removing and installing parts of cooling system
  124
• 1.2 Parts of cooling system body side
  125
• 1.3 Parts of cooling system engine side
  129
• 1.4 Coolant hose connection diagram
  134
• 1.5 Removing and installing compact bracket
  136
• 1.6 Draining and filling cooling system
  139
• 1.7 Removing and installing radiator
  142
• 1.8 Removing and installing coolant pump
  144
• 1.9 Removing and installing viscous fan coupling
  146
• 1.10 Removing and installing viscous fan coupling bearing bush
  147
• 1.11 Dismantling and assembling coolant distribution housing
  149
• 1.12 Electronically regulated cooling system
  150
• 1.13 Checking thermostat for map-controlled engine cooling
  151
• Fuel supply system
  153
• 1 Removing and installing parts of fuel supply system
  153
• 1.1 Removing and installing parts of fuel supply system
  153
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  154
• 1.3 Safety precautions when working on the fuel supply system
  161
• 1.4 Rules for cleanliness
  162
• 1.5 Removing and installing fuel delivery unit
  163
• 1.6 Removing and installing fuel gauge sender
  165
• 1.7 Removing and installing fuel tank
  166
• 1.8 Crash fuel shut-off
  168
• 1.9 Checking fuel pump
  168
• 2 Servicing parts of electronic power control (EPC)
  176
• 2.1 Servicing parts of electronic power control (EPC)
  176
• 2.2 Function of EPC system
  177
• 3 Activated charcoal filter system
  177
• 3.1 Activated charcoal filter system
  177
• 3.2 Function
  177
• 3.3 Servicing parts of the activated charcoal filter system
  178
• 3.4 Checking fuel tank breather
  181
• Mixture preparation, Injection
  184
• 1 Servicing injectors
  184
• 1.1 Servicing injectors
  184
• 1.2 General notes on injection
  184
• 1.3 Removing and installing parts of the injection system
  185
• 1.4 Dismantling and assembling intake manifold
  191
• 1.5 Dismantling and assembling air cleaner
  195
• 1.6 Dismantling and assembling intake hose
  197
• 1.7 Dismantling and assembling fuel rail with injectors
  199
• 1.8 Safety precautions
  200
• 1.9 Rules for cleanliness
  202
• 1.10 Technical data
  202
• 2 Checking components
  203
• 2.1 Checking components
  203
• 2.2 Checking injector delivery and checking injectors for leaks
  203
• 2.3 Checking fuel pressure regulator and holding pressure
  205
• 2.4 Checking intake manifold change-over
  208
• 3 Engine control unit
  209
• 3.1 Engine control unit
  209
• 3.2 Replacing engine control unit
  209
• 3.3 Adapting components
  210
• 3.4 Interrogating and erasing engine control unit fault memory
  210
• Exhaust system
  212
• 1 Removing and installing parts of exhaust system
  212
• 1.1 Removing and installing parts of exhaust system
  212
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  213
• 1.3 Silencer with mountings
  217
• Ignition system
  220
• 1 Servicing ignition system
  220
• 1.1 Servicing ignition system
  220
• 1.2 General notes on ignition system
  220
• 1.3 Removing and installing parts of the ignition system
  221
• 1.4 Safety precautions
  223
• 1.5 Test data, spark plugs
  224