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
  5
• 1.2 Notes on installing
  8
• 1.3 Specified torques
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Part I - Assembly overview
  14
• 1.2 Part II - Assembly overview
  15
• 1.3 Part lll: assembly overview - old toothed belt tensioner
  16
• 1.4 Part lV: assembly overview - new toothed belt tensioner
  18
• 1.5 Removing and installing air conditioner compressor poly V-belt
  19
• 1.6 Removing and installing poly V-belt
  20
• 2 Removing and installing sealing flanges and flywheel or drive plate
  21
• 2.1 Assembly overview - sealing flanges and flywheel
  21
• 2.2 Renewing crankshaft oil seal - pulley end
  22
• 2.3 Removing and installing drive plate
  24
• 3 Removing and installing crankshaft
  26
• 3.1 Assembly overview - crankshaft
  26
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  28
• 3.3 Crankshaft dimensions
  29
• 4 Dismantling and assembling pistons and conrods
  30
• 4.1 Assembly overview - pistons and conrods
  30
• 4.2 Checking pistons, piston rings and cylinder bores
  31
• Cylinder head, valve gear
  33
• 1 Cylinder head
  33
• 1.1 Assembly overview - cylinder head
  33
• 1.2 Removing and installing cylinder head
  35
• 1.3 Removing, installing and tensioning toothed belt
  38
• 1.4 Checking compression
  46
• 2 Repairing valve gear
  48
• 2.1 Assembly overview - valve gear
  48
• 2.2 Checking camshaft axial clearance
  50
• 2.3 Reworking valve seats
  51
• 2.4 Renewing camshaft oil seals
  52
• 2.5 Checking hydraulic bucket tappets
  57
• 2.6 Removing and installing camshafts
  58
• 2.7 Checking valve guides
  62
• 2.8 Renewing valve stem seals
  63
• Lubrication
  66
• 1 Parts of lubrication system
  66
• 1.1 Engine oil
  66
• 1.2 Assembly overview - parts of lubrication system
  67
• 1.3 Removing and installing oil sump
  71
• 1.4 Checking oil pressure and oil pressure switch
  75
• Cooling
  78
• 1 Parts of cooling system
  78
• 1.1 Assembly overview - parts of cooling system, body side
  78
• 1.2 Assembly overview - parts of cooling system, engine side
  80
• 1.3 Assembly overview - coolant pump and compact bracket
  82
• 1.4 Assembly overview - coolant pump
  84
• 1.5 Coolant hose schematic diagram
  84
• 1.6 Draining and filling coolant
  87
• 1.7 Removing and installing radiator
  90
• 1.8 Removing and installing viscous fan coupling
  92
• 1.9 Removing and installing viscous fan mounting bush
  92
• 1.10 Removing and installing coolant pump V-belt
  94
• Fuel supply system
  96
• 1 Removing and installing parts of fuel supply system
  96
• 1.1 Assembly overview - fuel tank with attachments
  96
• 1.2 Safety precautions when working on fuel supply system
  102
• 1.3 Rules for cleanliness
  102
• 1.4 Removing and installing fuel delivery unit, front-wheel drive vehicles
  103
• 1.5 Removing and installing fuel delivery unit, four-wheel drive vehicles
  105
• 1.6 Removing and installing fuel tank
  107
• 1.7 Checking fuel pump
  110
• 2 Activated charcoal filter system
  117
• 2.1 Function
  117
• 2.2 Assembly overview - activated charcoal filter system
  117
• 2.3 Checking fuel tank breather
  118
• 3 Assembly overview - electronic power control (EPC)
  121
• 4 Accelerator mechanism (throttle cable)
  122
• 4.1 Assembly overview - accelerator mechanism
  122
• 4.2 Adjusting accelerator cable
  123
• Turbocharging/supercharging
  126
• 1.1 Rules for cleanliness
  126
• 1.2 Safety precautions
  126
• 1.3 Assembly overview - turbocharger with attachments
  127
• 1.4 Assembly overview - charge air cooling
  130
• 1.5 Schematic diagram of turbocharging system
  130
• 2 Checking charge pressure system
  134
• 2.1 Checking charge pressure control, vehicles without EPC system
  134
• 2.2 Checking vacuum unit for charge pressure control valve
  135
• 2.3 Checking overrun shut-off valve
  136
• 2.4 Checking charge air system for leaks
  137
• Mixture preparation - injection
  139
• 1 Repairing injection system
  139
• 1.1 General notes on injection
  139
• 1.2 Overview of fitting locations
  139
• 1.3 Assembly overview - parts of injection system
  143
• 1.4 Assembly overview - air filter
  147
• 1.5 Assembly overview - fuel rail with injectors
  149
• 1.6 Assembly overview - intake manifold change-over
  149
• 1.7 Assembly overview - throttle valve control module
  151
• 1.8 Safety precautions
  152
• 1.9 Rules for cleanliness
  154
• 1.10 Technical data
  154
• 2 Checking components
  156
• 2.2 Checking intake manifold change-over
  156
• 2.3 Checking injectors for leaks and quantity injected
  156
• 2.4 Checking fuel pressure regulator and holding pressure
  159
• 3 Engine control unit
  162
• 3.1 Renewing engine control unit
  162
• 3.2 Adapting functions and components
  162
• 3.3 Reading and erasing engine control unit fault memory
  163
• Exhaust system
  165
• 1 Parts of exhaust system
  165
• 1.1 Assembly overview - front-wheel drive vehicles
  165
• 1.2 Assembly overview - four-wheel drive vehicles
  169
• 2 Secondary air system
  171
• 2.1 Function
  171
• 2.2 Assembly overview - secondary air system
  171
• 2.3 Checking combination valve
  172
• 2.4 Checking secondary air inlet valve
  173
• Ignition system
  174
• 1 Repairing ignition system
  174
• 1.1 General notes on ignition system
  174
• 1.2 Assembly overview - ignition system
  174
• 1.3 Safety precautions
  179
• 1.4 Test data, spark plugs
  180