4-cylinder injection engine (5-valve without intermediate shaft)

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Notes on removing
  5
• 1.2 Notes on installing
  10
• 1.3 Specified torques
  12
• 1.4 Assembly overview - front engine mounting
  12
• 1.5 Additional information and assembly work for vehicles with air conditioner
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview
  15
• 1.2 Removing and installing air conditioner compressor poly V-belt
  19
• 1.3 Removing and installing poly V-belt
  20
• 2 Removing and installing sealing flanges and flywheel or drive plate
  21
• 2.1 Assembly overview
  21
• 2.2 Renewing crankshaft oil seal - pulley end
  22
• 2.3 Removing and installing front sealing flange
  24
• 2.4 Removing and installing drive plate
  27
• 3 Removing and installing crankshaft
  30
• 3.1 Assembly overview
  30
• 3.2 Pulling needle roller bearing out of and driving into crankshaft
  32
• 3.3 Crankshaft dimensions
  33
• 4 Dismantling and assembling pistons and conrods
  35
• 4.1 Assembly overview
  35
• 4.2 Piston and cylinder dimensions
  38
• Cylinder head, valve gear
  39
• 1 Removing and installing cylinder head
  39
• 1.1 Assembly overview
  39
• 1.2 Removing, installing and tensioning toothed belt
  41
• 1.3 Removing and installing cylinder head
  45
• 1.4 Checking compression
  48
• 2 Repairing valve gear
  51
• 2.1 Assembly overview
  51
• 2.2 Reworking valve seats
  55
• 2.3 Renewing inlet camshaft oil seal
  57
• 2.4 Renewing exhaust camshaft oil seal
  59
• 2.5 Checking hydraulic bucket tappets
  62
• 2.6 Removing and installing camshafts
  63
• 2.7 Checking valve guides
  67
• 2.8 Renewing valve stem seals
  68
• Lubrication
  71
• 1 Removing and installing parts of lubrication system
  71
• 1.1 Engine oil
  71
• 1.2 Assembly overview
  72
• 1.3 Removing and installing oil sump
  76
• 1.4 Checking oil pressure and oil pressure switch
  81
• Cooling
  84
• 1 Removing and installing parts of cooling system
  84
• 1.1 Assembly overview - parts of cooling system, body side
  84
• 1.2 Assembly overview - parts of cooling system, engine side
  86
• 1.3 Assembly overview - compact bracket
  88
• 1.4 Coolant hose schematic diagram
  89
• 1.5 Draining and filling coolant
  91
• 1.6 Checking cooling system for leaks
  94
• 1.7 Removing and installing radiator
  96
• 1.8 Removing and installing coolant pump
  98
• 1.9 Removing and installing viscous fan coupling
  99
• 1.10 Removing and installing viscous fan mounting bush
  100
• 1.11 Removing and installing thermostat
  101
• 1.12 Removing and installing lower coolant pipe
  103
• Fuel supply system
  105
• 1 Removing and installing parts of fuel supply system - front wheel drive vehicles
  105
• 1.1 Safety precautions when working on fuel supply system
  105
• 1.2 Rules for cleanliness
  106
• 1.3 Assembly overview - fuel tank with attachments: engine code AWT
  106
• 1.4 Draining fuel tank: engine code AWT
  109
• 1.5 Removing and installing fuel delivery unit: engine code AWT
  110
• 1.6 Removing and installing fuel gauge sender: engine code AWT
  112
• 1.7 Assembly overview - fuel tank with attachments: engine codes AUG, AWM
  113
• 1.8 Draining fuel tank: engine codes AUG, AWM
  116
• 1.9 Removing and installing fuel delivery unit: engine codes AUG, AWM
  117
• 1.10 Removing and installing fuel gauge sender: engine codes AUG, AWM
  122
• 1.11 Removing and installing fuel tank
  122
• 1.12 Crash fuel shut-off
  124
• 1.13 Checking fuel pump
  124
• 2 Removing and installing parts of fuel supply system - four wheel drive vehicles
  130
• 2.1 Assembly overview - fuel tank with attachments: engine code AWT
  130
• 2.2 Assembly overview - fuel tank with attachments: engine codes AUG, AWM
  133
• 2.3 Assembly overview - fuel filter
  138
• 2.4 Emptying fuel tank
  139
• 2.5 Removing and installing fuel delivery unit
  141
• 2.6 Removing and installing fuel gauge sender G
  146
• 2.7 Removing and installing fuel gauge sender 2 G169
  147
• 2.8 Removing and installing fuel gauge sender 3 G237
  149
• 2.9 Removing, installing and checking suction-jet pumps
  151
• 2.10 Removing and installing fuel tank
  152
• 2.11 Checking fuel pump
  154
• 3 Electronic power control (EPC)
  160
• 3.1 Function of EPC system
  160
• 3.2 Assembly overview
  160
• 4 Active charcoal filter system: engine code AWT
  162
• 4.1 Function
  162
• 4.2 Assembly overview - parts of activated charcoal filter system
  162
• 4.3 Schematic diagram of activated charcoal filter system
  164
• 4.4 Checking fuel tank breather
  164
• 5 Activated charcoal filter system: engine codes AUG, AWM
  166
• 5.1 Description of leakage diagnosis
  166
• 5.2 Assembly overview - parts of activated charcoal filter system
  166
• 5.3 Schematic diagram of activated charcoal filter system
  168
• 5.4 Checking fuel system for leaks
  168
• Turbocharging/supercharging
  171
• 1 Charge air system with turbocharger
  171
• 1.1 Safety precautions
  171
• 1.2 Rules for cleanliness
  172
• 1.3 Assembly overview - turbocharger with attachments
  172
• 1.4 Removing and installing turbocharger
  174
• 1.5 Assembly overview - parts of charge air cooling
  179
• 1.6 Schematic diagram of turbocharging system
  181
• 2 Checking charge pressure system
  183
• 2.1 Checking vacuum unit for charge pressure control valve
  183
• 2.2 Checking overrun shut-off valve
  183
• 2.3 Checking charge air system for leaks
  184
• Mixture preparation - injection
  187
• 1 Repairing injection system
  187
• 1.1 General notes on injection
  187
• 1.2 Safety precautions
  187
• 1.3 Rules for cleanliness
  188
• 1.4 Overview of fitting locations
  188
• 1.5 Assembly overview - air filter
  191
• 1.6 Assembly overview - fuel rail with injectors
  192
• 1.7 Assembly overview - intake manifold
  193
• 1.8 Removing and installing intake manifold
  193
• 1.9 Technical data
  196
• 2 Removing and installing air mass meter G70
  198
• 2.1 Removing air mass meter G70 (with no housing)
  198
• 2.2 Removing air mass meter G70 (with housing)
  198
• 2.3 Installing air mass meter G70
  198
• 3 Checking components
  200
• 3.1 Checking injectors
  200
• 3.2 Checking fuel pressure regulator and holding pressure
  202
• 4 Engine control unit
  205
• 4.1 Reading and erasing engine control unit fault memory
  205
• 4.2 Adapting functions and components
  206
• 4.3 Renewing engine control unit
  207
• Exhaust system
  208
• 1 Removing and installing parts of exhaust system
  208
• 1.1 Assembly overview - parts of exhaust system: front-wheel drive vehicles
  210
• 1.2 Assembly overview - parts of exhaust system: four-wheel drive vehicles
  212
• 2 Secondary air system
  215
• 2.1 Function
  215
• 2.2 Assembly overview: parts of secondary air system
  215
• 2.3 Checking combination valve
  217
• Ignition system
  219
• 1 Repairing ignition system
  219
• 1.1 General notes on ignition system
  219
• 1.2 Safety precautions
  219
• 1.3 Assembly overview - parts of ignition system
  219
• 1.4 Removing and installing ignition coils with output stage
  221
• 1.5 Test data, spark plugs
  222