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
  3
• 1.2 Installing
  5
• 1.3 Torque settings
  7
• 1.4 Additional notes and assembly work for vehicles with air conditioner
  8
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Assembly overview - parts l and ll
  10
• 1.2 Part I Assembly overview - belt drive
  12
• 1.3 Part II: Assembly overview - chain drive system
  13
• 1.4 Removing and installing poly V-belt
  15
• 1.5 Removing and installing valve timing housing
  16
• 2 Cylinder block, sealing flange
  20
• 2.1 Assembly overview
  20
• 2.2 Renewing crankshaft oil seal - belt pulley end
  22
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  23
• 2.5 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
  27
• 2.6 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
  35
• 2.7 Crankshaft dimensions
  42
• 3 Pistons and conrods
  44
• 3.1 Assembly overview
  44
• 3.2 Checking piston
  45
• 3.3 Checking cylinder bores
  46
• 3.4 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview
  47
• 1.2 Checking valve timing
  50
• 1.3 Adjusting valve timing
  51
• 1.4 Removing and installing timing chain and chain drive for oil pump
  55
• 1.5 Removing and installing camshaft housing
  63
• 1.6 Removing and installing cylinder head
  67
• 1.7 Checking compression
  70
• 2 Valve gear
  72
• 2.1 Assembly overview
  72
• 2.2 Checking camshaft axial clearance
  74
• 2.3 Reworking valve seats
  74
• 2.4 Checking valve guides
  76
• 2.5 Renewing valve stem seals
  76
• Lubrication
  79
• 1 Parts of lubrication system
  79
• 1.1 Engine oil
  79
• 1.2 Assembly overview
  79
• 1.3 Removing and installing sump
  82
• 1.4 Removing and installing oil pump
  83
• 1.5 Checking oil pressure and oil pressure switch
  85
• Cooling
  88
• 1 Parts of cooling system
  88
• 1.1 Assembly overview - parts of cooling system, body side
  88
• 1.2 Assembly overview - parts of cooling system, engine side
  90
• 1.3 Coolant hose schematic diagram
  92
• 1.4 Draining and filling coolant
  93
• 1.5 Removing and installing radiator
  95
• 1.6 Removing and installing coolant pump
  96
• Fuel supply system
  99
• 1 Parts of fuel supply system
  99
• 1.1 Assembly overview - fuel tank with attachments
  99
• 1.2 Safety precautions when working on fuel supply system
  102
• 1.3 Rules for cleanliness
  102
• 1.4 Removing and installing fuel delivery unit
  102
• 1.5 Removing and installing fuel gauge sender G
  104
• 1.6 Removing and installing fuel tank
  105
• 1.7 Assembly overview - fuel filter with attachments
  107
• 1.8 Removing and installing fuel filter
  108
• 1.9 Crash fuel shut-off
  109
• 1.10 Checking fuel pump
  109
• 1.11 Bleeding fuel system
  114
• 2 Electronic power control (EPC)
  117
• 2.1 Assembly overview
  117
• 3 Activated charcoal filter system
  118
• 3.1 Assembly overview
  118
• 3.2 Checking fuel tank breather
  119
• Mixture preparation - injection
  120
• 1 Injection system
  120
• 1.1 General notes on injection
  120
• 1.2 Assembly overview - intake manifold
  120
• 1.3 Assembly overview - fuel rail with injectors
  122
• 1.4 Removing and installing injectors
  122
• 1.5 Assembly overview - air filter
  123
• 1.6 Removing and installing air filter housing
  125
• 1.7 Cleaning throttle valve module J338
  126
• 1.8 Safety precautions
  127
• 1.9 Rules for cleanliness
  128
• 1.10 Technical data
  128
• 2 Checking components
  129
• 2.1 Checking injectors for leaks and quantity injected
  129
• 2.2 Checking fuel pressure regulator and holding pressure
  131
• 3 Engine control unit J623
  134
• 3.1 Removing and installing engine control unit J623
  134
• 3.2 Vehicles with anti-theft secured engine control unit J623
  134
• Exhaust system
  136
• 1 Parts of the exhaust system
  136
• 1.1 Assembly overview - catalytic converters and attachments
  136
• 1.2 Assembly overview - silencers with mountings
  138
• Ignition system
  139
• 1 Ignition system
  139
• 1.1 Assembly overview - ignition system
  139
• 1.2 Removing and installing ignition coils with output stage
  140
• 1.3 Safety precautions
  141
• 1.4 Spark plug test data
  142