4-cylinder injection engine (5-valve)

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 Notes on removing
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  9
• 1.4 Torque settings
  11
• 1.5 Assembly mountings
  11
• 1.6 Additional notes and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Assembly overview
  14
• 1.2 Removing and installing poly V-belt
  18
• 2 Removing and installing sealing flanges and flywheel or drive plate
  20
• 2.1 Renewing crankshaft oil seal - belt pulley end
  21
• 2.2 Removing and installing front sealing flange
  23
• 2.3 Removing and installing drive plate
  26
• 3 Removing and installing crankshaft
  28
• 3.1 Crankshaft dimensions
  29
• 4 Dismantling and assembling pistons and conrods
  30
• 4.1 Conventional conrods
  30
• 4.2 Industrially cracked conrods
  32
• 4.3 Piston and cylinder dimensions
  35
• Cylinder head, valve gear
  36
• 1 Removing and installing cylinder head
  36
• 1.1 Removing, installing and tensioning toothed belt
  38
• 1.2 Removing and installing cylinder head
  42
• 1.3 Checking compression
  46
• 2 Repairing valve gear
  49
• 2.1 Reworking valve seats
  52
• 2.2 Renewing camshaft oil seal
  53
• 2.3 Checking hydraulic bucket tappets
  59
• 2.4 Removing and installing camshafts
  60
• 2.5 Checking valve guides
  64
• 2.6 Renewing valve stem seals
  65
• Lubrication
  67
• 1 Removing and installing parts of lubrication system
  67
• 1.1 Engine oil
  67
• 1.2 Assembly overview - parts of lubrication system
  67
• 1.3 Assembly overview - oil filter bracket
  69
• 1.4 Removing and installing oil sump
  70
• 1.5 Checking oil pressure and oil pressure switch
  73
• Cooling
  76
• 1 Removing and installing parts of cooling system
  76
• 1.1 Parts of cooling system - body side
  76
• 1.2 Parts of cooling system - engine side
  78
• 1.3 Coolant hose schematic diagram
  79
• 1.4 Draining and filling coolant
  83
• 1.5 Removing and installing radiator
  85
• 1.6 Removing and installing coolant pump
  87
• 1.7 Removing and installing thermostat
  88
• Fuel supply system
  91
• 1 Removing and installing parts of fuel supply system
  91
• 1.1 Removing and installing fuel tank with attachments and fuel filter
  91
• 1.2 Safety precautions when working on fuel supply system
  96
• 1.3 Rules for cleanliness
  97
• 1.4 Removing and installing fuel delivery unit
  97
• 1.5 Removing and installing fuel gauge sender
  98
• 1.6 Removing and installing fuel tank
  99
• 1.7 Crash fuel shut-off
  101
• 1.8 Checking fuel pump
  101
• 2 Accelerator mechanism
  107
• 2.1 Repairing accelerator mechanism
  107
• 2.2 Adjusting accelerator cable
  107
• 3 Checking electronic power control (EPC)
  110
• 3.1 Function of EPC system
  110
• 4 Active charcoal filter system
  112
• 4.1 Function
  112
• 4.2 Repairing parts of the active charcoal filter system
  112
• 4.3 Checking fuel tank breather system
  113
• Turbocharging/supercharging
  115
• 1 Charge air system with turbocharger
  115
• 1.1 Removing and installing turbocharger with attachments
  115
• 1.2 Removing and installing parts of charge air cooling
  118
• 1.3 Schematic diagram of turbocharging system
  119
• 1.4 Rules for cleanliness
  121
• 1.5 Safety precautions
  121
• 2 Checking charge pressure system
  122
• 2.1 Checking charge pressure regulation
  122
• 2.2 Checking charge pressure regulating valve pressure actuator
  124
• 2.3 Checking overrun shut-off valve
  124
• 2.4 Checking charge air system for leaks
  125
• Mixture preparation - injection
  127
• 1 Repairing injection system
  127
• 1.1 Engine codes overview ARZ, AUM and AUQ
  127
• 1.2 Fitting locations overview AGN
  128
• 1.3 Fitting locations overview AGU
  130
• 1.4 Fitting locations overview AQA
  131
• 1.5 General notes on injection
  132
• 1.6 Removing and installing parts of injection system for ARZ, AUM, AUQ engines
  132
• 1.7 Removing and installing parts of the injection system for AGN engine
  135
• 1.8 Removing and installing parts of the injection system for AGU engine
  137
• 1.9 Removing and installing parts of the injection system for AQA engine
  139
• 1.10 Dismantling and assembling intake manifold upper part for AGN engine
  141
• 1.11 Dismantling and assembling intake manifold lower part for AGN engine
  142
• 1.12 Dismantling and assembling air cleaner
  144
• 1.13 Dismantling and assembling fuel rail with injectors
  145
• 1.14 Safety precautions
  145
• 1.15 Rules for cleanliness
  147
• 1.16 Technical data
  147
• 2 Checking components
  148
• 2.1 Checking intake manifold change-over
  148
• 2.2 Adapting components
  148
• 2.3 Reading and erasing engine control unit fault memory
  149
• 2.4 Checking injectors
  150
• 2.5 Checking fuel pressure regulator and holding pressure
  154
• Exhaust system
  158
• 1 Removing and installing parts of exhaust system
  158
• 1.1 Vehicles with turbocharger
  158
• 1.2 Engine code AGN with front-wheel drive
  160
• 1.3 Engine code AGN with four-wheel drive
  161
• 2 Secondary air system
  164
• 2.1 Function
  164
• 2.2 Removing and installing parts of secondary air system
  164
• 2.3 Secondary air pump relay J299
  166
• 2.4 Checking combination valve
  166
• Ignition system
  168
• 1 Repairing ignition system
  168
• 1.1 General notes on ignition system
  168
• 1.2 Removing and installing parts of ignition system
  168
• 1.3 Safety precautions
  172
• 1.4 Test data, spark plugs
  174