4-cylinder injection engine (2-valve, roller rocker finger)

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
  5
• 1.3 Notes on installing
  5
• 1.4 Specified torques
  7
• 1.5 Assembly mountings
  7
• 1.6 Additional information and assembly work for vehicles with air conditioner
  8
• Crankshaft group
  9
• 1 Dismantling and assembling engine
  9
• 1.1 Part I: assembly overview - toothed belt drive
  10
• 1.2 Part II: assembly overview - cylinder block
  11
• 1.3 Removing and installing poly V-belt
  12
• 2 Removing and installing cylinder block, sealing flange and flywheel
  15
• 2.1 Assembly overview - aluminium cylinder block
  15
• 2.2 Renewing crankshaft oil seal - belt pulley end
  17
• 2.3 Renewing crankshaft sealing flange - flywheel end
  18
• 2.4 Crankshaft dimensions
  26
• 3 Dismantling and assembling pistons and conrods
  28
• 3.1 Assembly overview
  28
• 3.2 Piston and cylinder dimensions
  31
• Cylinder head, valve gear
  32
• 1 Dismantling and assembling cylinder head
  32
• 1.1 Assembly overview
  32
• 1.2 Removing, installing and tensioning toothed belt
  35
• 1.3 Checking semi-automatic toothed belt tensioning roller
  37
• 1.4 Removing and installing cylinder head
  39
• 1.5 Checking compression
  44
• 2 Repairing valve gear
  47
• 2.1 Assembly overview
  47
• 2.2 Reworking valve seats
  49
• 2.3 Renewing camshaft oil seal
  51
• 2.4 Removing and installing cylinder head cover and camshaft
  52
• 2.5 Checking valve guides
  55
• 2.6 Renewing valve stem seals
  56
• Lubrication
  59
• 1 Removing and installing parts of lubrication system
  59
• 1.1 Engine oil
  59
• 1.2 Assembly overview
  59
• 1.3 Removing and installing oil sump
  61
• 1.4 Removing and installing oil pump
  63
• 1.5 Checking oil pressure and oil pressure switch
  66
• Cooling
  69
• 1 Removing and installing parts of cooling system
  69
• 1.1 Assembly overview - parts of cooling system, body side
  69
• 1.2 Assembly overview - parts of cooling system, engine side
  71
• 1.3 Coolant hose schematic diagram
  73
• 1.4 Draining and filling coolant
  74
• 1.5 Removing and installing radiator
  76
• 1.6 Checking cooling system for leaks
  77
• Fuel supply system
  79
• 1 Removing and installing parts of fuel supply system
  79
• 1.2 Safety precautions when working on fuel supply system
  81
• 1.3 Rules for cleanliness
  82
• 1.4 Crash fuel shut-off
  82
• 1.5 Removing and installing fuel delivery unit
  82
• 1.6 Removing and installing fuel tank
  84
• 1.7 Checking fuel pump
  85
• 2 Electronic power control (EPC)
  92
• 2.1 Assembly overview
  92
• 2.2 Function of EPC system
  92
• 3 Activated charcoal filter system
  94
• 3.1 Function
  94
• 3.2 Assembly overview - repairing activated charcoal filter system components
  94
• 3.3 Checking fuel tank breather
  95
• Mixture preparation - injection
  98
• 1 Repairing injection system
  98
• 1.1 General notes on injection
  98
• 1.2 Safety precautions
  98
• 1.3 Rules for cleanliness
  99
• 1.4 Technical data
  100
• 1.5 Assembly overview - dismantling and assembling intake manifold
  100
• 1.6 Assembly overview - dismantling and assembling fuel rail with injectors
  102
• 1.7 Assembly overview - dismantling and assembling air filter housing
  102
• 1.8 Cleaning throttle valve module J338
  104
• 2 Checking components
  106
• 2.1 Checking intake air preheating
  106
• 2.2 Check injectors for spray pattern and leakage
  106
• 2.3 Checking injection rate of injectors
  109
• 2.4 Checking fuel pressure regulator and holding pressure
  112
• 2.5 Checking vacuum valve
  115
• 3 Engine control unit
  117
• 3.1 Removing and installing engine control unit
  117
• 3.2 Adapting function and components
  117
• 3.3 Reading and erasing engine control unit fault memory
  118
• Exhaust system
  120
• 1 Removing and installing parts of exhaust system
  120
• 1.2 Assembly overview - silencer with mountings
  122
• 2 Exhaust gas recirculation system
  123
• 2.1 Assembly overview - repairing parts of exhaust gas recirculation system
  123
• Ignition system
  124
• 1 Repairing ignition system
  124
• 1.1 General notes on ignition system
  124
• 1.2 Assembly overview - ignition system components
  124
• 1.3 Safety precautions
  125
• 1.4 Test data, spark plugs
  126