4-cyl. injection engine (2.0 ltr.), mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  8
• 1.4 Assembly mounting
  10
• 1.5 Additional information and removal instructions for vehicles with air conditioner
  11
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview
  13
• 1.2 Removing and installing poly V-belt
  17
• 2 Removing and installing sealing flanges and flywheel or drive plate
  20
• 2.1 Renewing crankshaft oil seal - pulley end
  21
• 2.2 Removing and installing front sealing flange
  23
• 2.3 Removing and installing drive plate
  26
• 3 Dismantling and assembling pistons and conrods
  28
• 3.1 Assembly overview - Pistons and conrods
  28
• 3.2 Checking pistons, piston rings and cylinder bores
  31
• 3.3 Piston and cylinder dimensions
  33
• 4 Removing and installing crankshaft
  34
• 4.1 Colour identification
  35
• 4.2 Crankshaft dimensions
  35
• Cylinder head, valve gear
  37
• 1 Removing and installing cylinder head
  37
• 1.1 Removing, installing and tensioning toothed belt
  38
• 1.2 Checking semi-automatic toothed belt tensioning roller
  43
• 1.3 Removing and installing cylinder head
  44
• 1.4 Checking compression
  48
• 2 Repairing valve gear
  51
• 2.1 Reworking valve seats
  53
• 2.2 Renewing camshaft oil seal
  55
• 2.3 Removing and installing camshaft
  58
• 2.4 Checking hydraulic bucket tappets
  60
• 2.5 Checking valve guides
  61
• 2.6 Renewing valve guides
  62
• 2.7 Renewing valve stem seals
  63
• Lubrication
  66
• 1 Removing and installing parts of lubrication system
  66
• 1.1 Engine oil
  66
• 1.2 Assembly overview - Parts of lubrication system
  67
• 1.3 Assembly overview - Oil filter bracket
  69
• 1.4 Removing and installing sump
  70
• 1.5 Checking oil pressure and oil pressure switch
  72
• Cooling
  75
• 1 Removing and installing parts of cooling system
  75
• 1.1 Parts of cooling system - body side
  75
• 1.2 Parts of cooling system - engine side
  77
• 1.3 Coolant hose schematic diagram
  78
• 1.4 Draining and filling coolant
  81
• 1.5 Removing and installing radiator
  83
• 1.6 Removing and installing coolant pump
  85
• 1.7 Removing and installing thermostat
  86
• Fuel supply system
  89
• 1 Removing and installing parts of fuel supply system
  89
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  89
• 1.2 Removing, installing and checking suction jet pump: vehicles with four-wheel drive
  94
• 1.3 Safety precautions when working on fuel supply system
  97
• 1.4 Rules for cleanliness
  98
• 1.5 Removing and installing fuel delivery unit
  98
• 1.6 Removing and installing fuel gauge sender G
  101
• 1.7 Removing and installing fuel tank
  101
• 1.8 Crash fuel shut-off
  103
• 1.9 Checking fuel pump G23
  103
• 2 Activated charcoal filter system
  110
• 2.1 Function
  110
• 2.2 Repairing parts of activated charcoal filter system
  110
• 2.3 Checking solenoid valve 1 for activated charcoal filter system
  111
• 2.4 Checking fuel tank venting
  114
• 3 Checking electronic power control (EPC)
  116
• 3.1 Function of EPC system
  116
• 3.2 Checking accelerator pedal position sender
  117
• 4 Accelerator mechanism
  121
• 4.1 Repairing accelerator mechanism
  121
• 4.2 Adjusting throttle cable
  121
• Exhaust system
  123
• 1 Removing and installing parts of exhaust system
  123
• 1.1 Vehicles with front-wheel drive
  123
• 1.2 Vehicles with four-wheel drive
  126
• 1.3 Checking catalytic converter
  129
• 2 Secondary air system
  132
• 2.1 Function
  132
• 2.2 Removing and installing parts of secondary air system
  132
• 2.3 Checking combination valve
  134
• 2.4 Checking secondary air pump motor
  135
• 2.5 Checking secondary air inlet valve N112
  136