4-cylinder injection engine, 2005▸

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
  2
• 1.2 Installing engine
  8
• Crankshaft group
  11
• 1 Dismantling and assembling engine
  11
• 1.1 Assembly overview
  11
• 1.2 Removing and installing poly V-belt
  15
• 2 Dismantling and assembling pistons and conrods
  18
• 2.1 Assembly overview - Pistons and conrods
  18
• 2.2 Checking pistons, piston rings and cylinder bores
  21
• 2.3 Piston and cylinder dimensions
  23
• 3 Removing and installing crankshaft
  24
• 3.1 Colour identification
  25
• 3.2 Crankshaft dimensions
  25
• Cylinder head, Valve gear
  27
• 1 Removing and installing cylinder head
  27
• 1.1 Removing, installing and tensioning toothed belt
  28
• 1.2 Checking semi-automatic toothed belt tensioning roller
  33
• 1.3 Removing and installing cylinder head
  34
• 1.4 Checking compression
  38
• 2 Repairing valve gear
  41
• 2.1 Reworking valve seats
  43
• 2.2 Renewing camshaft oil seal
  45
• 2.3 Removing and installing camshaft
  48
• 2.4 Checking hydraulic bucket tappets
  50
• 2.5 Checking valve guides
  51
• 2.6 Renewing valve guides
  52
• 2.7 Renewing valve stem seals
  53
• Lubrication
  56
• 1 Removing and installing parts of the lubrication system
  56
• 1.1 Engine oil
  56
• 1.2 Assembly overview - Parts of lubrication system
  57
• 1.3 Assembly overview - Oil filter bracket
  59
• 1.4 Removing and installing sump
  60
• 1.5 Checking oil pressure and oil pressure switch
  62
• Cooling system
  65
• 1 Removing and installing parts of cooling system
  65
• 1.1 Assembly overview - parts of cooling system - engine side
  65
• 1.2 Assembly overview - parts of cooling system - body side
  68
• 1.3 Draining and filling coolant
  69
• 1.4 Removing and installing coolant pump
  72
• 1.5 Removing and installing thermostat
  73
• 1.6 Removing and installing radiator fan V7 and radiator fan 2 V177
  75
• 1.7 Removing and installing radiator
  76
• 1.8 Checking cooling system for leaks
  77
• Fuel supply system
  80
• 1 Fuel tank
  80
• 1.1 Safety precautions when working on the fuel supply system
  80
• 1.2 Rules for cleanliness
  80
• 1.3 Assembly overview - fuel tank
  80
• 1.4 Emptying fuel tank
  82
• 1.5 Removing and installing fuel tank
  84
• 2 Repairing fuel supply
  87
• 2.1 Safety precautions when working on the fuel supply system
  87
• 2.2 Rules for cleanliness
  87
• 2.3 Removing and installing fuel delivery unit
  88
• 2.4 Removing and installing fuel gauge sender G
  90
• 2.5 Checking fuel pump
  90
• 3 Checking electronic power control (EPC)
  100
• 3.1 Function of EPC system
  100
• 3.2 Assembly overview - accelerator pedal module
  100
• 3.3 Removing and installing accelerator module
  101
• 4 Active charcoal filter system
  103
• 4.1 Function
  103
• 4.2 Assembly overview - active charcoal filter system
  103
• 4.3 Checking fuel tank breather
  104
• Mixture preparation, Injection
  106
• 1 Repairing injection system
  106
• 1.1 General notes on injection
  106
• 1.2 Safety precautions
  107
• 1.3 Rules for cleanliness
  107
• 1.4 Technical data
  108
• 1.5 Dismantling and assembling intake manifold - upper part
  108
• 1.6 Dismantling and assembling intake manifold - lower part
  110
• 1.7 Fuel rail
  111
• 1.8 Dismantling and assembling air cleaner
  112
• 1.9 Removing and installing intake manifold
  112
• 1.10 Removing and installing fuel rail with intake manifold flaps
  113
• 1.11 Removing and installing injectors
  115
• 1.12 Renewing Teflon seal on injector
  117
• 1.13 Cleaning throttle valve module J338
  119
• 2 Engine control unit
  120
• 2.1 Removing and installing anti-theft engine control unit
  120
• 2.2 Reading and erasing engine control unit fault memory
  122
• Exhaust system
  123
• 1 Removing and installing parts of exhaust system
  123
• 1.1 Front exhaust pipe and catalytic converter with attachments
  123
• 1.2 Silencer with mountings
  125
• 1.3 Separating middle and rear silencers
  125
• 1.4 Aligning exhaust system stress free
  126
• Ignition system
  128
• 1 Repairing ignition system
  128
• 1.1 General notes on ignition system
  128
• 1.2 Safety precautions
  128
• 1.3 Assembly overview - ignition system
  128
• 1.4 Spark plugs
  129