4-cyl engine

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
  7
• 1.3 Torque settings
  8
• 1.4 Additional notes and assembly work for vehicles with air conditioner
  9
• 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
  12
• 1.3 Part II: Assembly overview - chain drive system
  13
• 1.4 Removing and installing poly V-belt
  16
• 1.5 Removing and installing valve timing housing
  17
• 2 Cylinder block, sealing flange
  22
• 2.1 Assembly overview
  22
• 2.2 Renewing crankshaft oil seal - belt pulley end
  24
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  26
• 2.4 Characteristics of the sealing flange and the assembly device T10134
  30
• 2.5 Renewing crankshaft sealing flange - flywheel end (assembly tool T10134)
  31
• 3 Removing and installing crankshaft
  42
• 3.1 Exploded view crankshaft
  42
• 3.2 Crankshaft bearings
  44
• 3.3 Crankshaft dimensions
  44
• 4 Pistons and conrods
  45
• 4.1 Assembly overview
  45
• 4.2 Checking piston
  47
• 4.3 Checking cylinder bores
  48
• 4.4 Piston and cylinder dimensions
  49
• Cylinder head, valve gear
  50
• 1 Cylinder head
  50
• 1.1 Assembly overview
  50
• 1.2 Checking valve timing
  52
• 1.3 Adjusting valve timing
  55
• 1.4 Removing and installing timing chain and chain drive for oil pump
  61
• 1.5 Removing and installing camshaft housing
  70
• 1.6 Removing and installing cylinder head
  76
• 1.7 Checking compression
  80
• 2 Valve gear
  83
• 2.1 Assembly overview
  83
• 2.2 Checking camshaft axial clearance
  86
• 2.3 Reworking valve seats
  86
• 2.4 Checking valve guides
  88
• 2.5 Renewing valve stem seals
  89
• Lubrication
  92
• 1 Parts of lubrication system
  92
• 1.1 Engine oil
  92
• 1.2 Assembly overview
  92
• 1.3 Removing and installing sump
  95
• 1.4 Removing and installing oil pump
  97
• 1.5 Checking oil pressure and oil pressure switch
  99
• Cooling
  102
• 1 Parts of cooling system
  102
• 1.1 Assembly overview - parts of cooling system, body side
  102
• 1.2 Assembly overview - parts of cooling system, engine side
  104
• 1.3 Coolant hose schematic diagram
  106
• 1.4 Draining and filling coolant
  107
• 1.5 Removing and installing radiator
  116
• 1.6 Removing and installing coolant pump
  118
• Fuel supply system
  120
• 1 Parts of fuel supply system
  120
• 1.1 Assembly overview - fuel tank with attachments
  120
• 1.2 Safety precautions when working on fuel supply system
  123
• 1.3 Rules for cleanliness
  124
• 1.4 Removing and installing fuel delivery unit
  124
• 1.5 Removing and installing fuel gauge sender G
  126
• 1.6 Removing and installing fuel tank
  127
• 1.7 Assembly overview - fuel filter with attachments
  129
• 1.8 Removing and installing fuel filter
  130
• 1.9 Crash fuel shut-off
  132
• 1.10 Checking fuel pump
  132
• 1.11 Bleeding fuel system
  138
• 2 Electronic power control (EPC)
  142
• 2.1 Assembly overview
  142
• 2.2 Removing and installing accelerator pedal module GX2
  142
• 3 Activated charcoal filter system
  145
• 3.1 Assembly overview
  145
• 3.2 Checking fuel tank breather
  146
• Mixture preparation - injection
  147
• 1 Injection system
  147
• 1.1 General notes on injection
  147
• 1.2 Assembly overview - intake manifold
  147
• 1.3 Removing and installing intake manifold
  148
• 1.4 Assembly overview - fuel rail with injectors
  151
• 1.5 Removing and installing injectors
  152
• 1.6 Assembly overview - air filter
  154
• 1.7 Removing and installing air filter housing
  156
• 1.8 Cleaning throttle valve module J338
  157
• 1.9 Safety precautions
  158
• 1.10 Rules for cleanliness
  159
• 1.11 Technical data
  160
• 2 Checking components
  161
• 2.1 Checking injectors for leaks and quantity injected
  161
• 2.2 Checking fuel pressure regulator and holding pressure
  164
• 3 Engine control unit J623
  168
• 3.1 Removing and installing engine control unit J623
  168
• 3.2 Vehicles with anti-theft secured engine control unit J623
  169
• Exhaust system
  171
• 1 Parts of the exhaust system
  171
• 1.1 Assembly overview - catalytic converters and attachments
  171
• 1.2 Assembly overview - silencers with mountings
  173
• Ignition system
  175
• 1 Ignition system
  175
• 1.1 Assembly overview - ignition system
  175
• 1.2 Removing and installing ignition coils with output stage
  176
• 1.3 Safety precautions
  178
• 1.4 Spark plug test data
  179