4-cylinder injection engine (2-valve without intermediate shaft), mechanics

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
  6
• 1.3 Specified torques
  8
• 1.4 Front engine mounting
  8
• 1.5 Additional notes and assembly work for vehicles with air conditioner
  9
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Assembly overview
  10
• 1.2 Removing and installing air conditioner compressor poly V-belt
  13
• 1.3 Removing and installing poly V-belt
  14
• 2 Sealing flange and flywheel or drive plate
  16
• 2.1 Assembly overview - sealing flange and flywheel/drive plate
  16
• 2.2 Renewing crankshaft oil seal - belt pulley end
  17
• 2.3 Removing and installing front sealing flange
  19
• 2.4 Removing and installing drive plate
  21
• 3 Crankshaft
  23
• 3.1 Assembly overview - crankshaft
  23
• 3.2 Pulling needle bearing out of and driving into crankshaft
  24
• 3.3 Crankshaft dimensions
  25
• 4 Pistons and conrods
  27
• 4.1 Assembly overview - pistons and conrods
  27
• 4.2 Piston and cylinder dimensions
  30
• Cylinder head, valve gear
  31
• 1 Cylinder head
  31
• 1.1 Assembly overview - cylinder head
  31
• 1.2 Removing and installing cylinder head
  34
• 1.3 Removing, installing and tensioning toothed belt
  37
• 1.4 Checking semi-automatic tensioning roller for toothed belt
  40
• 1.5 Checking compression
  40
• 2 Valve gear
  43
• 2.1 Assembly overview
  43
• 2.2 Reworking valve seats
  45
• 2.3 Renewing camshaft oil seal
  46
• 2.4 Removing and installing camshaft
  49
• 2.5 Checking hydraulic bucket tappets
  51
• 2.6 Checking valve guides
  52
• 2.7 Renewing valve guides
  52
• 2.8 Renewing valve stem oil seals
  53
• Lubrication
  57
• 1 Parts of lubrication system
  57
• 1.1 Engine oil
  57
• 1.2 Assembly overview - parts of lubrication system
  57
• 1.3 Assembly overview - oil filter bracket
  59
• 1.4 Removing and installing sump
  61
• 1.5 Checking oil pressure and oil pressure switch
  66
• Cooling
  69
• 1 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 Assembly overview - compact bracket
  73
• 1.4 Coolant hose schematic diagram
  74
• 1.5 Draining and filling coolant
  76
• 1.6 Removing and installing radiator
  79
• 1.7 Removing and installing coolant pump
  81
• 1.8 Removing and installing viscous fan coupling
  82
• 1.9 Removing and installing viscous fan mounting bush
  83
• Fuel supply system
  86
• 1 Parts of fuel system
  86
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  86
• 1.2 Removing and installing suction-jet pump
  92
• 1.3 Safety precautions when working on fuel supply system
  94
• 1.4 Rules for cleanliness
  95
• 1.5 Removing and installing fuel delivery unit
  95
• 1.6 Removing and installing fuel gauge sender G
  99
• 1.7 Removing and installing fuel tank
  100
• 1.8 Crash fuel shut-off
  102
• 1.9 Checking fuel pump
  102
• 2 Checking electronic power control (EPC)
  109
• 2.1 Function of EPC system
  109
• 2.2 Checking accelerator pedal position sender
  110
• 3 Activated charcoal filter system
  114
• 3.1 Function
  114
• 3.2 Assembly overview - activated charcoal filter system
  114
• 3.3 Checking activated charcoal filter system solenoid valve 1 N80
  115
• 3.4 Checking fuel tank breather
  118
• Exhaust system
  120
• 1 Parts of exhaust system
  120
• 1.2 Assembly overview - silencer with mountings
  122
• 1.3 Checking catalytic converter
  124
• 2 Secondary air system
  126
• 2.1 Function
  126
• 2.2 Assembly overview - parts of secondary air system
  126
• 2.3 Check secondary air system
  128
• 2.4 Checking combination valve
  130
• 2.5 Checking secondary air pump motor V101
  130