4-cyl. injection engine with timing chain

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 Removing engine
  4
• 1.2 Securing engine to assembly stand
  6
• 1.3 Installing engine
  6
• 1.4 Specified torques
  9
• 1.5 Assembly mountings
  9
• 1.6 Additional notes and assembly work for vehicles with air conditioner
  10
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview - parts l and ll
  11
• 1.2 Part I Assembly overview - belt drive
  13
• 1.3 Part II: Assembly overview - chain drive system
  14
• 1.4 Removing and installing poly V-belt
  16
• 1.5 Removing and installing valve timing housing
  17
• 2 Cylinder block, sealing flange
  21
• 2.1 Assembly overview
  21
• 2.2 Renewing crankshaft oil seal - belt pulley end
  22
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  24
• 2.4 Characteristics of the sealing flange and the assembly device T10134
  26
• 2.5 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
  27
• 3 Removing and installing crankshaft
  35
• 3.1 Exploded view crankshaft
  35
• 3.2 Crankshaft bearings
  36
• 3.3 Crankshaft dimensions
  36
• 4 Pistons and conrods
  37
• 4.1 Assembly overview
  37
• 4.2 Checking piston
  38
• 4.3 Checking cylinder bores
  39
• 4.4 Piston and cylinder dimensions
  39
• Cylinder head, valve gear
  40
• 1 Cylinder head
  40
• 1.1 Assembly overview
  40
• 1.2 Checking valve timing
  43
• 1.3 Adjusting valve timing
  44
• 1.4 Removing and installing timing chain and chain drive for oil pump
  48
• 1.5 Removing and installing camshaft housing
  56
• 1.6 Removing and installing cylinder head
  60
• 1.7 Checking compression
  63
• 2 Valve gear
  65
• 2.1 Assembly overview
  65
• 2.2 Checking camshaft axial clearance
  67
• 2.3 Reworking valve seats
  67
• 2.4 Checking valve guides
  68
• 2.5 Renewing valve stem seals
  69
• Lubrication
  71
• 1 Parts of lubrication system
  71
• 1.1 Engine oil
  71
• 1.2 Assembly overview
  71
• 1.3 Removing and installing sump
  73
• 1.4 Removing and installing oil pump
  75
• 1.5 Checking oil pressure and oil pressure switch
  77
• Cooling
  80
• 1 Parts of cooling system
  80
• 1.1 Assembly overview - parts of cooling system, body side
  80
• 1.2 Assembly overview - parts of cooling system, engine side
  82
• 1.3 Coolant hose schematic diagram
  84
• 1.4 Draining and filling coolant
  85
• 1.5 Removing and installing radiator
  87
• 1.6 Removing and installing coolant pump
  88
• Fuel supply system
  91
• 1 Parts of fuel supply system
  91
• 1.1 Assembly overview - fuel tank with attachments
  91
• 1.2 Safety precautions when working on fuel supply system
  94
• 1.3 Rules for cleanliness
  94
• 1.4 Removing and installing fuel delivery unit
  94
• 1.5 Removing and installing fuel gauge sender G
  96
• 1.6 Removing and installing fuel tank
  97
• 1.7 Assembly overview - fuel filter with attachments
  99
• 1.8 Removing and installing fuel filter
  100
• 1.9 Crash fuel shut-off
  101
• 1.10 Checking fuel pump
  101
• 1.11 Bleeding fuel system
  106
• 2 Electronic power control (EPC)
  109
• 2.1 Assembly overview
  109
• 3 Activated charcoal filter system
  110
• 3.1 Assembly overview
  110
• 3.2 Checking fuel tank breather
  111
• Mixture preparation - injection
  112
• 1 Injection system
  112
• 1.1 General notes on injection
  112
• 1.2 Assembly overview - intake manifold
  112
• 1.3 Assembly overview - fuel rail with injectors
  114
• 1.4 Removing and installing injectors
  114
• 1.5 Assembly overview - air filter
  115
• 1.6 Removing and installing air filter housing
  117
• 1.7 Cleaning throttle valve module J338
  118
• 1.8 Safety precautions
  119
• 1.9 Rules for cleanliness
  120
• 1.10 Technical data
  120
• 2 Checking components
  121
• 2.1 Checking injectors for leaks and quantity injected
  121
• 2.2 Checking fuel pressure regulator and holding pressure
  123
• 3 Engine control unit J623
  126
• 3.1 Removing and installing engine control unit J623
  126
• 3.2 Vehicles with anti-theft secured engine control unit J623
  126
• Exhaust system
  128
• 1 Parts of the exhaust system
  128
• 1.1 Assembly overview - catalytic converters and attachments
  128
• 1.2 Assembly overview - silencers with mountings
  130
• Ignition system
  131
• 1 Ignition system
  131
• 1.1 Assembly overview - ignition system
  131
• 1.2 Removing and installing ignition coils with output stage
  132
• 1.3 Safety precautions
  133
• 1.4 Spark plug test data
  134