4-cylinder injection engine (2-valve), mechanics

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  4
• 1 Removing and installing engine
  4
• 1.1 Notes on removing
  4
• 1.2 Notes on installing
  5
• 1.3 Specified torques
  7
• 1.4 Assembly mountings
  7
• 1.5 Renewing engine carrier rubber mounting
  8
• 1.6 Additional information and assembly work for vehicles with air conditioner
  8
• Crankshaft group
  10
• 1 Crankshaft group
  10
• 1.1 Dismantling and assembling engine
  10
• 1.2 Removing and installing poly V-belt
  15
• 1.3 Removing, installing and tensioning toothed belt (adjusting valve timing)
  16
• 2 Removing and installing sealing flange and pressure plate/drive plate
  19
• 2.1 Renewing crankshaft oil seal - pulley end
  21
• 2.2 Removing and installing drive plate
  23
• 2.3 Removing and installing crankshaft
  24
• 3 Dismantling and assembling pistons and conrods
  27
• 3.1 Piston and cylinder dimensions
  29
• Cylinder head, valve gear
  30
• 1 Removing and installing cylinder head
  30
• 1.1 Removing and installing cylinder head
  31
• 1.2 Checking compression
  33
• 2 Repairing valve gear
  34
• 2.1 Assembly overview - valve gear
  34
• 2.2 Reworking valve seats
  38
• 2.3 Renewing camshaft oil seal
  40
• 2.4 Removing and installing camshaft
  42
• 2.5 Checking hydraulic bucket tappets
  43
• 2.6 Checking valve guides
  44
• 2.7 Renewing valve guides
  44
• 2.8 Renewing valve stem seals
  45
• Lubrication
  46
• 1 Lubrication
  46
• 1.1 Removing and installing parts of lubrication system
  46
• 1.2 Checking oil pressure and oil pressure switch
  49
• Cooling
  50
• 1 Removing and installing parts of cooling system
  50
• 1.1 Parts of cooling system, body side
  50
• 1.2 Parts of cooling system, engine side
  52
• 1.3 Dismantling and assembling coolant pump
  53
• 1.4 Draining and filling with coolant
  53
• 1.5 Removing and installing radiator and fan
  55
• Fuel supply system
  57
• 1 Removing and installing parts of fuel supply system
  57
• 1.2 Removing and installing fuel tank with attachments and fuel filter, four-wheel drive
  60
• 1.3 Safety precautions when working on fuel supply system
  61
• 1.4 Rules for cleanliness
  62
• 1.5 Removing and installing fuel tank, four-wheel drive
  62
• 1.6 Adjusting accelerator cable
  65
• 1.7 Removing and installing fuel delivery unit
  66
• 1.8 Checking fuel pump
  67
• 1.9 Removing and installing parts of activated charcoal filter system
  71
• Exhaust system
  74
• 1 Removing and installing parts of exhaust system, front-wheel drive
  74
• 1.3 Silencer with mountings - engine codes AAM, ANN
  77
• 1.4 Silencer with mountings - engine codes ABS, ADZ, ANP
  78
• 1.5 Silencer with mountings - engine codes 2E, ADY, AGG, AKR
  79
• 2 Removing and installing parts of exhaust system, four-wheel drive
  81
• 2.2 Silencer with mountings
  82