4-cylinder injection engine (direct injection)

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 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Aligning engine and gearbox mountings
  8
• 1.5 Specified torques
  9
• 1.6 Assembly mountings
  10
• 1.7 Additional information and assembly work for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - parts l and ll
  12
• 1.2 Assembly overview - part I, belt drive
  14
• 1.3 Assembly overview - part II, cylinder block
  15
• 1.4 Removing and installing poly V-belt
  17
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  19
• 2.1 Assembly overview
  19
• 2.2 Removing and installing engine speed sender G28
  20
• 2.3 Crankshaft dimensions
  21
• 2.4 Renewing crankshaft oil seal - belt pulley end
  21
• 2.5 Tightening procedure for poly V-belt pulley securing bolt
  23
• 2.6 Renewing crankshaft sealing flange - flywheel end
  24
• 3 Dismantling and assembling pistons and conrods
  32
• 3.1 Assembly overview
  32
• 3.2 Piston and cylinder dimensions
  34
• Cylinder head, valve gear
  36
• 1 Cylinder head
  36
• 1.1 Assembly overview
  36
• 1.2 Checking valve timing
  39
• 1.3 Checking semi-automatic toothed belt tensioner
  40
• 1.4 Removing, installing and tensioning toothed belt
  43
• 1.5 Removing and installing camshaft housing
  49
• 1.6 Removing and installing cylinder head
  52
• 1.7 Checking compression
  55
• 2 Repairing valve gear
  58
• 2.1 Assembly overview
  58
• 2.2 Reworking valve seats
  61
• 2.3 Removing and installing camshaft adjuster and exhaust camshaft pulley
  62
• 2.4 Removing and installing spring in camshaft adjuster
  69
• 2.5 Renewing camshaft oil seals
  74
• 2.6 Checking valve guides
  77
• 2.7 Renewing valve guides
  78
• 2.8 Renewing valve stem seals
  78
• Lubrication
  81
• 1 Removing and installing parts of lubrication system
  81
• 1.1 Assembly overview
  81
• 1.2 Removing and installing oil sump
  84
• 1.3 Removing and installing oil pump
  86
• 1.4 Checking oil pressure and oil pressure switch
  89
• Cooling
  91
• 1 Removing and installing parts of cooling system
  91
• 1.1 Assembly overview - parts of cooling system, body side
  91
• 1.2 Assembly overview - parts of cooling system, engine side
  93
• 1.3 Assembly overview - coolant distributor housing
  95
• 1.4 Coolant hose schematic diagram
  96
• 1.5 Draining and filling coolant
  97
• 1.6 Removing and installing radiator
  99
• 1.7 Removing and installing coolant pump
  100
• Fuel supply system
  103
• 1 Removing and installing parts of fuel supply system
  103
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  103
• 1.2 Safety precautions when working on fuel supply system
  106
• 1.3 Rules for cleanliness
  106
• 1.4 Removing and installing fuel gauge sender G
  107
• 1.5 Removing and installing fuel delivery unit
  107
• 1.6 Removing and installing fuel tank
  109
• 1.7 Crash fuel shut-off
  110
• 1.8 Checking fuel pump
  110
• 1.9 Removing and installing high-pressure pump
  116
• 2 Checking electronic power control (EPC)
  119
• 2.1 Assembly overview
  119
• 3 Activated charcoal filter system
  120
• 3.1 Assembly overview
  120
• 3.2 Checking fuel tank breather
  121
• Mixture preparation - injection
  123
• 1 Repairing injection system
  123
• 1.1 Assembly overview - parts of injection system
  123
• 1.2 Assembly overview - intake manifold
  125
• 1.3 Assembly overview - fuel rail with injectors
  128
• 1.4 Assembly overview - fuel pressure regulator and fuel metering valve
  130
• 1.5 Assembly overview - air filter
  131
• 1.6 Cleaning throttle valve module J338
  131
• 1.7 Removing and installing injectors
  132
• 1.8 Safety precautions
  136
• 1.9 Rules for cleanliness
  137
• 1.10 Technical data
  137
• 2 Checking components
  138
• 2.1 Checking fuel pressure regulator and holding pressure
  138
• 3 Engine control unit
  141
• 3.1 Removing and installing engine control unit
  141
• 3.2 Adapting components
  141
• 3.3 Reading and erasing engine control unit fault memory
  142
• Exhaust system
  144
• 1 Removing and installing parts of exhaust system
  144
• 1.1 Assembly overview - exhaust manifold with catalytic converter and add-on parts
  144
• 1.2 Assembly overview - silencers with mountings
  147
• 2 Exhaust gas recirculation system
  149
• 2.1 Assembly overview - exhaust gas recirculation system
  149
• Ignition system
  151
• 1 Repairing ignition system
  151
• 1.1 Assembly overview - ignition system
  151
• 1.2 Removing and installing ignition coils with output stage
  152
• 1.3 Safety precautions
  153
• 1.4 Test data, spark plugs
  153