4-cylinder injection 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 Notes on removing
  3
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  8
• 1.4 Torque settings
  9
• 1.5 Assembly mountings
  10
• 1.6 Additional notes and repair work on vehicles with air conditioning
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Assembly overview
  13
• 1.2 Removing and installing poly V-belt
  17
• 2 Removing and installing sealing flange and flywheel or drive plate
  20
• 2.1 Renewing crankshaft oil seal - pulley end-
  21
• 2.2 Removing and installing front sealing flange
  23
• 2.3 Removing and installing drive plate
  26
• 3 Removing and installing crankshaft
  28
• 3.1 Crankshaft dimensions
  29
• 4 Dismantling and assembling pistons and conrods
  31
• 4.1 Checking pistons, piston rings and cylinder bores
  32
• 4.2 Piston and cylinder dimensions
  34
• Cylinder head, valve gear
  35
• 1 Cylinder head
  35
• 1.1 Removing, installing and tensioning toothed belt
  36
• 1.2 Checking semi-automatic toothed belt tensioning roller
  41
• 1.3 Removing and installing cylinder head
  42
• 1.4 Checking compression
  46
• 2 Repairing valve gear
  49
• 2.1 Reworking valve seats
  51
• 2.2 Renewing exhaust camshaft seal
  52
• 2.3 Removing and installing camshafts
  55
• 2.4 Checking hydraulic tappets
  57
• 2.5 Checking valve guides
  58
• 2.6 Renewing valve guides
  58
• 2.7 Renewing valve stem seals
  59
• Lubrication
  62
• 1 Removing and installing parts of lubrication system
  62
• 1.1 Engine oil
  62
• 1.2 Assembly overview - parts of lubrication system
  62
• 1.3 Dismantling and assembling oil filler bracket
  65
• 1.4 Dismantling and assembling oil pump with balancer shaft gear assembly
  66
• 1.5 Removing and installing oil pump with balancer shaft gear assembly
  67
• 1.6 Removing and installing oil sump
  70
• 1.7 Checking oil pressure and oil pressure switch
  72
• Cooling
  74
• 1 Removing and installing parts of cooling system
  74
• 1.1 Parts of cooling system - body side
  74
• 1.2 Parts of cooling system - engine side
  76
• 1.3 Coolant hose schematic diagram
  78
• 1.4 Draining and filling coolant
  79
• 1.5 Removing and installing radiator
  81
• 1.6 Removing and installing coolant pump
  83
• 1.7 Removing and installing thermostat
  84
• Fuel supply system
  87
• 1 Removing and installing parts of lubrication system
  87
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  87
• 1.3 Safety precautions when working on fuel supply system
  95
• 1.4 Rules for cleanliness
  96
• 1.5 Removing and installing fuel delivery unit
  96
• 1.6 Removing and installing fuel gauge sender G
  99
• 1.7 Removing and installing fuel tank
  99
• 1.8 Crash fuel shut-off
  101
• 1.9 Checking fuel pump
  101
• 2 Power control
  108
• 2.1 Repairing power control
  108
• 2.2 Function of EPC system
  108
• 3 Activated charcoal filter system
  110
• 3.1 Function
  110
• 3.2 Repairing parts of activated charcoal filter system
  110
• 3.3 Checking fuel tank breather
  111
• Mixture preparation - injection
  113
• 1 Repairing injection system
  113
• 1.1 Overview of installation locations
  113
• 1.2 General notes on injection
  116
• 1.3 Dismantling and assembling top part of intake manifold
  116
• 1.4 Dismantling and assembling bottom part of intake manifold
  118
• 1.5 Dismantling and assembling fuel rail with injectors
  119
• 1.6 Dismantling and assembling air filter
  120
• 1.7 Safety precautions
  120
• 1.8 Rules for cleanliness
  122
• 1.9 Technical data
  122
• 2 Checking components
  123
• 2.1 Checking injection rate and injectors for leaks
  123
• 2.2 Checking fuel pressure regulator and holding pressure
  125
• 2.3 Checking variable intake manifold change-over
  128
• 3 Engine control unit
  131
• 3.1 Renewing engine control unit
  131
• 3.2 Adapting functions and components
  131
• Exhaust system
  134
• 1 Removing and installing parts of exhaust system
  134
• 1.1 Vehicles with front wheel drive
  134
• 1.2 Vehicles with all-wheel drive
  137
• 2 Secondary air system
  140
• 2.1 Function
  140
• 2.2 Removing and installing parts of lubrication system
  140
• 2.3 Checking combination valve
  141
• Ignition system
  143
• 1 Repairing ignition system
  143
• 1.1 General notes on ignition system
  143
• 1.2 Removing and installing parts of ignition system
  143
• 1.3 Safety precautions
  145
• 1.4 Test data, spark plugs
  145