4-cyl. injection engine (5 valve)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  4
• 1 Removing and installing engine
  4
• 1.1 Notes on removing
  5
• 1.2 Securing the engine to the assembly stand
  10
• 1.3 Notes on installation
  11
• 1.4 Specified torques
  13
• 1.5 Aligning engine and gearbox mountings
  14
• 1.6 Assembly mountings
  15
• 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
  20
• 2 Sealing flange and flywheel/drive plate
  22
• 2.1 Assembly overview
  22
• 2.2 Renewing crankshaft oil seal -belt pulley end-
  24
• 2.3 Removing and installing sealing flange -belt pulley end-
  26
• 2.4 Removing and installing drive plate
  28
• 3 Crankshaft
  31
• 3.1 Assembly overview
  31
• 3.2 Crankshaft dimensions
  33
• 4 Pistons and conrods
  34
• 4.1 Assembly overview
  34
• 4.2 Piston and cylinder dimensions
  41
• Cylinder head, valve gear
  42
• 1 Cylinder head
  42
• 1.1 Assembly overview
  42
• 1.2 Removing, installing and tensioning toothed belt
  46
• 1.3 Removing and installing cylinder head
  50
• 1.4 Checking compression pressure
  56
• 2 Repairing valve gear
  60
• 2.1 Assembly overview
  60
• 2.2 Renewing camshaft oil seals
  64
• 2.3 Checking hydraulic bucket tappets
  69
• 2.4 Removing and installing camshafts
  70
• 2.5 Renewing valve stem seals
  75
• 2.6 Checking valve guides
  78
• 2.7 Reworking valve seats
  78
• Lubrication
  81
• 1 Parts of lubrication system
  81
• 1.1 Engine oil
  81
• 1.2 Assembly overview
  82
• 1.3 Removing and installing oil sump
  89
• 1.4 Checking oil pressure and oil pressure switch
  92
• Cooling system
  95
• 1 Parts of cooling system
  95
• 1.1 Assembly overview - parts of cooling system, body side
  95
• 1.2 Assembly overview - parts of cooling system, engine side
  97
• 1.3 Coolant hose schematic diagram
  101
• 1.4 Draining and filling coolant
  104
• 1.5 Removing and installing radiator
  108
• 1.6 Removing and installing coolant pump
  110
• 1.7 Removing and installing thermostat
  111
• 1.8 Checking continued coolant circulation pump
  113
• 1.9 Checking radiator fan
  114
• Fuel supply system
  116
• 1 Parts of fuel system
  116
• 1.1 Safety precautions when working on fuel supply system
  116
• 1.2 Rules for cleanliness
  117
• 1.3 Assembly overview - fuel tank with attachments and fuel filter
  117
• 1.4 Removing and installing fuel delivery unit
  124
• 1.5 Removing and installing fuel gauge sender
  126
• 1.6 Removing and installing fuel tank
  127
• 1.7 Crash fuel shut-off
  129
• 1.8 Checking fuel pump
  129
• 2 Electronic power control (EPC)
  138
• 2.1 Function of EPC system
  138
• 2.2 Assembly overview
  138
• 3 Activated charcoal filter system
  140
• 3.1 Functional description
  140
• 3.2 Parts of the activated charcoal filter system - Assembly overview
  141
• 3.4 Checking fuel tank breather
  144
• Charging
  148
• 1 Charge air system with turbocharger
  148
• 1.1 Safety precautions
  148
• 1.2 Rules for cleanliness
  148
• 1.3 General repair instructions
  149
• 1.4 Hose connections with connector couplings
  150
• 1.5 Assembly overview - turbocharger with attachments
  151
• 1.6 Removing and installing turbocharger
  156
• 1.7 Assembly overview - parts of charge air cooling
  164
• 1.8 Overview of charge pressure control and vacuum control
  165
• 2 Checking parts of charge air system
  169
• 2.1 Checking charge pressure control
  169
• 2.2 Checking charge pressure control valve pressure unit
  170
• 2.3 Checking fuel cut-off valve
  171
• Mixture preparation, injection
  173
• 1 Repairing injection system
  173
• 1.1 General notes on injection
  173
• 1.2 Safety precautions
  174
• 1.3 Rules for cleanliness
  174
• 1.4 Component location overview
  175
• 1.5 Parts of exhaust gas recirculation - Assembly overview
  178
• 1.6 Assembly overview - air filter
  186
• 1.7 Assembly overview - fuel rail with injectors
  187
• 1.8 Technical data
  187
• 2 Checking components
  189
• 2.1 Checking injectors for leaks and quantity injected
  189
• 2.2 Checking fuel pressure regulator and holding pressure
  191
• 3 Engine control unit
  195
• 3.1 Replacing engine control unit
  195
• 3.2 Adapting functions and components
  196
• 3.3 Reading and erasing engine control unit fault memory
  198
• Exhaust system
  200
• 1 Parts of exhaust system
  200
• 1.2 Assembly overview - silencers with mountings
  203
• 2 Secondary air system
  205
• 2.1 Functional description
  205
• 2.2 Parts of the secondary air system - Assembly overview
  205
• 2.3 Overview of the secondary air system
  207
• 2.4 Checking combination valve
  208
• 2.5 Removing and installing combi-valve
  209
• Ignition system
  211
• 1 Servicing ignition system
  211
• 1.1 General notes on ignition system
  211
• 1.2 Safety precautions
  211
• 1.3 Parts of the ignition system - Assembly overview
  212
• 1.4 Removing and installing ignition coils with final output stage
  214
• 1.5 Spark plug test data
  216