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

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Tools
  3
• 1.2 Notes on removing
  4
• 1.3 Notes on installing
  5
• 1.4 Specified torques
  6
• 1.5 Assembly mountings
  7
• 1.6 Additional notes and assembly work for vehicles with air conditioner
  8
• Crankshaft group
  9
• 1 Crankshaft group
  9
• 1.1 Dismantling and assembling engine
  9
• 1.2 Removing and installing poly V-belt
  13
• 1.3 Removing, installing and tensioning toothed belt
  14
• 1.4 Checking semi-automatic toothed belt tensioning roller
  16
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  19
• 2.1 Cast iron cylinder block
  19
• 2.2 Aluminium cylinder block
  20
• 2.3 Renewing crankshaft oil seal - belt pulley end
  22
• 2.4 Vehicles with Duocentric oil pump
  23
• 2.5 Crankshaft dimensions
  25
• 3 Dismantling and assembling pistons and conrods
  26
• 3.1 Engine code
  26
• 3.2 Piston and cylinder dimensions
  31
• Cylinder head, valve gear
  33
• 1 Cylinder head, valve gear
  33
• 1.1 Assembly overview - cylinder head
  33
• 1.2 Removing and installing cylinder head
  35
• 1.3 Checking compression
  39
• 2 Repairing valve gear
  40
• 2.1 Assembly overview - valve gear
  40
• 2.2 Reworking valve seats
  43
• 2.3 Renewing camshaft oil seal
  46
• 2.4 Checking hydraulic bucket tappets
  48
• 2.5 Removing and installing camshaft
  49
• 2.6 Checking valve guides
  50
• 2.7 Renewing valve guides
  51
• 2.8 Renewing valve stem seals
  52
• Lubrication
  55
• 1 Lubrication
  55
• 1.1 Removing and installing parts of lubrication system
  55
• 1.2 Removing and installing sump
  60
• 1.3 Removing and installing Duocentric oil pump
  62
• 1.4 Checking oil pressure and oil pressure switch
  64
• Cooling
  67
• 1 Cooling
  67
• 1.1 Removing and installing parts of cooling system
  67
• 1.2 Parts of cooling system, body side
  67
• 1.3 Parts of cooling system, engine side
  69
• 1.4 Draining and filling coolant
  71
• 1.5 Removing and installing radiator
  74
• Fuel supply system
  76
• 1 Fuel supply system
  76
• 1.1 Removing and installing parts of fuel supply system
  76
• 1.2 Safety precautions when working on fuel supply system
  79
• 1.3 Rules for cleanliness
  79
• 1.4 Checking fuel pump
  80
• 1.5 Removing and installing fuel delivery unit
  85
• 1.6 Removing and installing fuel tank
  86
• 1.7 Adjusting accelerator cable
  87
• 1.8 Removing and installing parts of activated charcoal filter system
  87
• 1.9 Checking fuel tank breather
  89
• Exhaust system
  92
• 1 Exhaust system
  92
• 1.1 Removing and installing parts of exhaust system
  92