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 Notes on installing
  7
• 1.3 Front engine mounting
  9
• 1.4 Additional information and assembly work for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview
  12
• 1.2 Removing and installing air conditioner compressor poly V-belt
  16
• 1.3 Removing and installing poly V-belt
  16
• 2 Removing and installing sealing flanges and flywheel or drive plate
  18
• 2.1 Renewing crankshaft oil seal on belt pulley end
  19
• 2.2 Removing and installing front sealing flange
  22
• 2.3 Removing and installing drive plate
  25
• 3 Removing and installing crankshaft
  28
• 3.1 Crankshaft dimensions
  29
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  30
• 4 Dismantling and assembling pistons and conrods
  32
• 4.1 Piston and cylinder dimensions
  34
• Cylinder head, valve gear
  35
• 1 Removing and installing cylinder head
  35
• 1.1 Removing, installing and tensioning toothed belt
  37
• 1.2 Removing and installing cylinder head
  41
• 1.3 Checking compression
  44
• 2 Repairing valve gear
  47
• 2.1 Reworking valve seats
  49
• 2.2 Renewing camshaft oil seals
  51
• 2.3 Checking hydraulic bucket tappets
  55
• 2.4 Removing and installing camshaft
  56
• 2.5 Checking valve guides
  65
• 2.6 Renewing valve stem seals
  66
• Lubrication
  71
• 1 Removing and installing parts of lubrication system
  71
• 1.1 Dismantling and assembling oil filter housing
  74
• 1.2 Dismantling and assembling oil pump with balancer shaft gear assembly
  75
• 1.3 Removing and installing oil pump with balancer shaft gear assembly
  76
• 1.4 Removing and installing oil sump
  79
• 1.5 Checking oil pressure and oil pressure switch
  84
• Cooling
  87
• 1 Removing and installing parts of cooling system
  87
• 1.1 Parts of cooling system, body side
  87
• 1.2 Parts of cooling system, engine side
  89
• 1.3 Coolant hose schematic diagram
  91
• 1.4 Removing and installing compact bracket
  92
• 1.5 Draining and filling coolant
  93
• 1.6 Removing and installing radiator
  96
• 1.7 Removing and installing coolant pump
  98
• 1.8 Removing and installing viscous fan coupling
  100
• 1.9 Removing and installing viscous fan mounting bush
  101
• 1.10 Dismantling and assembling coolant distribution housing
  102
• 1.11 Electronically regulated cooling system
  103
• 1.12 Checking map-controlled engine cooling thermostat
  104
• Fuel supply system
  105
• 1 Removing and installing parts of fuel supply system
  105
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  105
• 1.2 Safety precautions when working on fuel supply system
  108
• 1.3 Rules for cleanliness
  109
• 1.4 Removing and installing fuel delivery unit
  109
• 1.5 Removing and installing fuel gauge sender
  111
• 1.6 Removing and installing fuel tank
  112
• 1.7 Crash fuel shut-off
  113
• 1.8 Checking fuel pump
  113
• 2 Repairing parts of electronic power control (EPC)
  120
• 2.1 Function of EPC system
  120
• 3 Activated charcoal filter system
  122
• 3.1 Function
  122
• 3.2 Repairing parts of activated charcoal filter system
  122
• 3.3 Checking fuel tank breather
  123
• Mixture preparation - injection
  126
• 1 Repairing injection system
  126
• 1.1 General notes on injection
  126
• 1.2 Removing and installing parts of the injection system
  126
• 1.3 Dismantling and assembling intake manifold
  129
• 1.4 Dismantling and assembling air filter
  130
• 1.5 Dismantling and assembling intake hose
  131
• 1.6 Dismantling and assembling fuel rail with injectors
  132
• 1.7 Safety precautions
  132
• 1.8 Rules for cleanliness
  133
• 1.9 Technical data
  134
• 2 Checking components
  135
• 2.1 Checking injectors for leaks and injection rate
  135
• 2.2 Checking fuel pressure regulator and holding pressure
  137
• 2.3 Checking intake manifold change-over
  139
• 3 Engine control unit
  141
• 3.1 Renewing engine control unit
  141
• 3.2 Adapting components
  141
• 3.3 Reading and erasing engine control unit fault memory
  142
• Exhaust system
  144
• 1 Removing and installing parts of exhaust system
  144
• 1.2 Silencer with mountings
  146
• Ignition system
  148
• 1 Repairing ignition system
  148
• 1.1 General notes on ignition system
  148
• 1.2 Removing and installing parts of ignition system
  148
• 1.3 Safety precautions
  149
• 1.4 Test data, spark plugs
  150