4-cyl. injection engine (2 valve without intermediate shaft), Mechanics

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
  4
• 1.3 Securing engine to assembly stand
  7
• 1.4 Notes on installing
  8
• 1.5 Tightening torques
  10
• 1.6 Assembly mountings
  11
• 1.7 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
  23
• 2 Removing and installing sealing flange and pressure plate/drive plate
  25
• 2.1 Removing and installing sealing flange and pressure plate/drive plate
  25
• 2.2 Renewing crankshaft oil seal -belt pulley end
  28
• 2.3 Removing and installing front sealing flange
  31
• 2.4 Removing and installing drive plate
  33
• 3 Removing and installing crankshaft
  36
• 3.1 Removing and installing crankshaft
  36
• 3.2 Crankshaft dimensions
  39
• 4 Dismantling and assembling pistons and conrods
  40
• 4.1 Dismantling and assembling pistons and conrods
  40
• 4.2 Piston and cylinder dimensions
  45
• Cylinder head, Valve gear
  46
• 1 Removing and installing cylinder head
  46
• 1.1 Removing and installing cylinder head
  46
• 1.2 Removing, installing and tensioning toothed belt
  49
• 1.3 Checking semi-automatic toothed belt tensioning roller
  54
• 1.4 Removing and installing cylinder head
  55
• 1.5 Checking compression pressures
  59
• 2 Servicing valve gear
  61
• 2.1 Servicing valve gear
  61
• 2.2 Reworking valve seats
  66
• 2.3 Replacing camshaft oil seal
  68
• 2.4 Removing and installing camshaft
  71
• 2.5 Checking hydraulic bucket tappets
  74
• 2.6 Checking valve guides
  75
• 2.7 Renewing valve guides
  76
• 2.8 Renewing valve stem seals
  77
• Lubrication
  80
• 1 Removing and installing parts of the lubrication system
  80
• 1.1 Removing and installing parts of the lubrication system
  80
• 1.2 Removing and installing sump
  88
• 1.3 Checking oil pressure and oil pressure switch
  91
• Cooling system
  93
• 1 Removing and installing parts of cooling system
  93
• 1.1 Removing and installing parts of cooling system
  93
• 1.2 Parts of cooling system body side
  94
• 1.3 Parts of cooling system engine side
  97
• 1.4 Coolant hose connection diagram
  102
• 1.5 Draining and filling cooling system
  104
• 1.6 Removing and installing radiator
  107
• 1.7 Removing and installing coolant pump
  108
• 1.8 Removing and installing thermostat
  110
• 1.9 Checking coolant circulation pump (V50)
  111
• Fuel supply system
  114
• 1 Removing and installing parts of fuel supply system
  114
• 1.1 Removing and installing parts of fuel supply system
  114
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  115
• 1.3 Safety precautions when working on the fuel supply system
  121
• 1.4 Rules for cleanliness
  122
• 1.5 Removing and installing fuel delivery unit
  122
• 1.6 Removing and installing fuel gauge sender
  124
• 1.7 Crash fuel shut-off
  124
• 1.8 Checking fuel pump
  125
• 2 Electronic power control (EPC)
  132
• 2.1 Electronic power control (EPC)
  132
• 2.2 Function of EPC system
  132
• 2.3 Servicing parts of electronic power control (EPC)
  133
• 2.4 Checking accelerator pedal position sender
  134
• 3 Activated charcoal filter system
  137
• 3.1 Activated charcoal filter system
  137
• 3.2 Function
  137
• 3.3 Servicing parts of the activated charcoal filter system
  138
• 3.4 Checking activated charcoal filter solenoid valve 1
  140
• 3.5 Checking fuel tank breather
  141
• Exhaust system
  144
• 1 Removing and installing parts of exhaust system
  144
• 1.1 Removing and installing parts of exhaust system
  144
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  145
• 1.3 Silencer with mountings
  149
• 2 Secondary air system
  151
• 2.1 Secondary air system
  151
• 2.2 Function
  151
• 2.3 Removing and installing parts of the secondary air system
  152
• 2.4 Checking secondary air pump motor
  155
• 2.5 Checking combi-valve
  157
• 3 Exhaust gas recirculation system
  157
• 3.1 Exhaust gas recirculation system
  157
• 3.2 Servicing parts of exhaust gas recirculation system
  158
• 3.3 Checking potentiometer for exhaust gas recirculation
  160