4-cyl. injection engine (5-valve), 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
  9
• 1.4 Notes on installing
  10
• 1.5 Tightening torques
  14
• 1.6 Assembly mountings
  14
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  16
• Crankshaft group
  17
• 1 Dismantling and assembling engine
  17
• 1.1 Dismantling and assembling engine
  17
• 1.2 Removing and installing ribbed belt
  28
• 2 Removing and installing sealing flanges and flywheel/drive plate
  30
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  30
• 2.2 Renewing crankshaft oil seal -belt pulley end-
  34
• 2.3 Removing and installing sealing flange -belt pulley end-
  38
• 2.4 Removing and installing drive plate
  40
• 3 Removing and installing crankshaft
  43
• 3.1 Removing and installing crankshaft
  43
• 3.2 Colour markings
  47
• 3.3 Crankshaft dimensions
  47
• 4 Dismantling and assembling pistons and conrods
  48
• 4.1 Dismantling and assembling pistons and conrods
  48
• 4.2 Piston and cylinder dimensions
  55
• Cylinder head, Valve gear
  56
• 1 Removing and installing cylinder head
  56
• 1.1 Removing and installing cylinder head
  56
• 1.2 Removing, installing and tensioning toothed belts
  60
• 1.3 Removing and installing cylinder head
  68
• 1.4 Checking compression pressures
  75
• 2 Servicing valve gear
  77
• 2.1 Servicing valve gear
  77
• 2.2 Reworking valve seats
  87
• 2.3 Renewing camshaft oil seal
  89
• 2.4 Checking hydraulic bucket tappets
  95
• 2.5 Removing and installing camshaft
  96
• 2.6 Checking valve guides
  102
• 2.7 Replacing valve stem seals
  103
• Lubrication
  106
• 1 Removing and installing parts of the lubrication system
  106
• 1.1 Removing and installing parts of the lubrication system
  106
• 1.2 Dismantling and assembling oil filter bracket: engine code AJH
  113
• 1.3 Dismantling and assembling oil filter bracket: engine code AWC
  118
• 1.4 Removing and installing sump
  123
• 1.5 Checking oil pressure and oil pressure switch: engine code AJH
  126
• 1.6 Checking oil pressure and oil pressure switch: engine code AWC
  128
• Cooling system
  130
• 1 Removing and installing parts of cooling system
  130
• 1.1 Removing and installing parts of cooling system
  130
• 1.2 Parts of cooling system body side: engine code AJH
  131
• 1.3 Parts of cooling system body side: engine code AWC
  134
• 1.4 Parts of cooling system engine side: engine code AJH
  138
• 1.5 Parts of cooling system engine side: engine code AWC
  142
• 1.6 Coolant hose connection diagram: engine code AJH
  148
• 1.7 Coolant hose connection diagram: engine code AWC
  150
• 1.8 Draining and filling cooling system
  152
• 1.9 Removing and installing radiator
  156
• 1.10 Removing and installing coolant pump
  159
• 1.11 Removing and installing thermostat
  161
• 1.12 Checking coolant circulation pump
  162
• Fuel supply system
  166
• 1 Removing and installing parts of fuel supply system
  166
• 1.1 Removing and installing parts of fuel supply system
  166
• 1.2 Removing and installing fuel tank with attachments and fuel filter: engine code AJH
  167
• 1.4 Safety precautions when working on the fuel supply system
  182
• 1.5 Rules for cleanliness
  183
• 1.6 Removing and installing fuel delivery unit
  183
• 1.7 Removing and installing fuel gauge sender: engine code AWC
  185
• 1.8 Crash fuel shut-off: engine code AWC
  186
• 1.9 Checking fuel pump
  187
• 2 Accelerator mechanism: engine code AJH
  195
• 2.1 Accelerator mechanism: engine code AJH
  195
• 2.2 Servicing accelerator mechanism
  195
• 2.3 Adjusting throttle cable
  197
• 3 Electronic power control (EPC): engine code AWC
  199
• 3.1 Electronic power control (EPC): engine code AWC
  199
• 3.2 Function of EPC system
  199
• 3.3 Servicing parts of electronic power control (EPC)
  200
• 3.4 Checking accelerator pedal position sender
  201
• 4 Activated charcoal filter system
  204
• 4.1 Activated charcoal filter system
  204
• 4.2 Function
  204
• 4.3 Servicing parts of the activated charcoal filter system: engine code AJH
  206
• 4.4 Servicing parts of the activated charcoal filter system: engine code AWC
  209
• 4.5 Checking activated charcoal filter solenoid valve 1: engine code AWC
  212
• 4.6 Checking fuel tank breather: engine code AJH
  214
• 4.7 Checking fuel tank breather: engine code AWC
  215
• Charging
  218
• 1 Charge air system with turbocharger
  218
• 1.1 Charge air system with turbocharger
  218
• 1.2 Removing and installing turbocharger and attachments
  219
• 1.3 Removing and installing parts of charge air cooling: Engine code AJH
  225
• 1.4 Removing and installing parts of charge air cooling: engine code AWC
  228
• 1.5 Overview of turbocharging: engine code AJH
  233
• 1.6 Overview of turbocharging: engine code AWC
  236
• 1.7 Rules for cleanliness
  240
• 1.8 Safety precautions
  240
• 1.9 Removing and installing charge air cooler: engine code AWC
  240
• 2 Checking charge air system: engine code AJH
  242
• 2.1 Checking charge air system: engine code AJH
  242
• 2.2 Checking charge pressure regulation
  242
• 2.3 Checking charge pressure control solenoid valve
  243
• 2.4 Checking pressure unit for charge pressure regulating valve
  244
• 2.5 Checking overrun shut-off valve
  245
• 3 Checking charge pressure system: engine code AWC
  246
• 3.1 Checking charge pressure system: engine code AWC
  246
• 3.2 Checking charge pressure regulation
  246
• 3.3 Checking charge pressure control solenoid valve
  248
• 3.4 Checking charge pressure sender
  250
• 3.5 Checking pressure unit for charge pressure regulating valve
  253
• 3.6 Checking overrun shut-off valve
  254
• Exhaust system
  256
• 1 Removing and installing parts of exhaust system
  256
• 1.1 Removing and installing parts of exhaust system
  256
• 1.2 Front exhaust pipe and catalyst with attachments
  257
• 1.3 Silencer with mountings
  262
• 2 Secondary air system: engine code AJH
  263
• 2.1 Secondary air system: engine code AJH
  263
• 2.2 Function
  264
• 2.3 Removing and installing parts of the secondary air system
  264
• 2.4 Checking combi-valve
  268
• 3 Secondary air system: engine code AWC
  269
• 3.1 Secondary air system: engine code AWC
  269
• 3.2 Function
  269
• 3.3 Removing and installing parts of the secondary air system
  270
• 3.4 Checking secondary air pump motor
  274
• 3.5 Checking combi-valve
  276
• 4 Exhaust gas recirculation system: engine code AWC
  277
• 4.1 Exhaust gas recirculation system: engine code AWC
  277
• 4.2 Servicing parts of exhaust gas recirculation system
  278
• 4.3 Checking potentiometer for exhaust gas recirculation
  281