4-cylinder injection engine (5-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
  2
• 1 Removing and installing engine
  2
• 1.1 Notes on removing
  4
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  8
• 1.4 Assembly mountings
  12
• 1.5 Additional information and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Part I
  15
• 1.2 Part II
  17
• 1.3 Removing and installing poly-V belt
  18
• 2 Removing and installing sealing flanges and flywheel or drive plate
  21
• 2.1 Renewing crankshaft oil seal - pulley end
  22
• 2.2 Removing and installing sealing flange - pulley end
  25
• 2.3 Removing and installing drive plate
  27
• 3 Removing and installing crankshaft
  30
• 3.1 Colour coding
  31
• 3.2 Crankshaft dimensions
  31
• 4 Dismantling and assembling pistons and conrods
  33
• 4.1 Checking pistons, piston rings and cylinder bores
  34
• 4.2 Piston and cylinder dimensions
  36
• Cylinder head, valve gear
  37
• 1 Cylinder head
  37
• 1.1 Removing, installing and tensioning toothed belt
  38
• 1.2 Removing and installing cylinder head
  50
• 1.3 Checking compression
  55
• 2 Repairing valve gear
  58
• 2.1 Reworking valve seats
  62
• 2.2 Renewing camshaft oil seals
  63
• 2.3 Checking hydraulic bucket tappets
  68
• 2.4 Removing and installing camshafts
  69
• 2.5 Checking valve guides
  74
• 2.6 Renewing valve stem seals
  74
• Lubrication
  77
• 1 Removing and installing parts of lubrication system
  77
• 1.1 Engine oil:
  77
• 1.2 Assembly overview - parts of lubrication system
  77
• 1.3 Dismantling and assembling oil filter bracket
  79
• 1.4 Removing and installing sump
  83
• 1.5 Checking oil pressure and oil pressure switch
  86
• Cooling
  91
• 1 Removing and installing parts of cooling system
  91
• 1.1 Parts of cooling system, body side
  92
• 1.2 Parts of cooling system - engine side
  95
• 1.3 Connection diagrams for coolant hoses
  99
• 1.4 Draining and adding coolant
  101
• 1.5 Removing and installing radiator and fan
  104
• 1.6 Removing and installing coolant pump
  107
• 1.7 Removing and installing thermostat
  108
• Fuel supply system
  113
• 1 Removing and installing parts of fuel supply system
  113
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  113
• 1.2 Safety measures when working on fuel supply
  119
• 1.3 Rules for cleanliness
  120
• 1.4 Removing and installing fuel delivery unit
  120
• 1.5 Removing and installing fuel gauge sender: engine code AWC
  123
• 1.6 Crash fuel shut-off: engine code AWC
  123
• 1.7 Checking fuel pump
  123
• 2 Accelerator pedal
  131
• 2.1 Repairing accelerator mechanism
  131
• 2.2 Adjusting accelerator cable
  131
• 3 Electronic power control (EPC): engine code AWC
  134
• 3.1 Function of EPC system
  134
• 3.2 Repairing parts of electronic power control (EPC)
  134
• 3.3 Checking accelerator position sender
  136
• 4 Activated charcoal filter system
  140
• 4.1 Function
  140
• 4.2 Repairing parts of activated charcoal filter system
  141
• 4.3 Activated charcoal filter solenoid valve 1 N80 : engine code AWC
  143
• 4.4 Checking fuel tank breather
  145
• Turbocharging/supercharging
  148
• 1 Charge air system with turbocharger
  148
• 1.1 Removing and installing turbocharger with attachments
  148
• 1.2 Removing and installing parts of charge air cooling
  151
• 1.3 Schematic diagram of turbocharging system
  154
• 1.4 Rules for cleanliness
  156
• 1.5 Safety precautions
  156
• 1.6 Removing and installing charge air cooler: engine code AWC
  157
• 2 Checking charge air system
  159
• 2.1 Checking charge air system: engine code AJH
  159
• 2.2 Checking charge pressure system: engine code AWC
  162
• Exhaust system
  171
• 1 Removing and installing parts of exhaust system
  171
• 1.1 Front exhaust pipe and catalytic converter with attachments
  171
• 1.2 Silencer with mountings
  173
• 2 Secondary air system
  174
• 2.1 Secondary air system: engine code AJH
  174
• 2.2 Secondary air system: engine code AWC
  177
• 3 Exhaust gas recirculation system: engine code AWC
  181
• 3.1 Repairing parts of exhaust gas recirculation system
  181
• 3.2 Checking exhaust gas recirculation potentiometer G212
  183