4-cylinder injection engine (direct injection)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Notes on removing
  4
• 1.3 Securing engine to assembly stand
  7
• 1.4 Notes on installing
  7
• 1.5 Tightening torques
  9
• 1.6 Assembly mountings
  9
• 1.7 Additional information and removal instructions for vehicles with air conditioner
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Dismantling and assembling engine
  12
• 1.2 Removing and installing ribbed belt
  20
• 2 Removing and installing cylinder block, sealing flange and flywheel
  22
• 2.1 Removing and installing cylinder block, sealing flange and flywheel
  22
• 2.2 Aluminium cylinder block
  22
• 2.3 Renewing crankshaft oil seal -belt pulley end-
  25
• 2.4 Renewing crankshaft sealing flange -flywheel end-
  27
• 3 Dismantling and assembling pistons and conrods
  36
• 3.1 Dismantling and assembling pistons and conrods
  36
• 3.2 Piston and cylinder dimensions
  41
• Cylinder head, Valve gear
  42
• 1 Removing and installing cylinder head
  42
• 1.1 Removing and installing cylinder head
  42
• 1.2 Checking valve timing
  48
• 1.3 Checking semi-automatic toothed belt tensioning roller
  51
• 1.4 Removing, installing and tensioning toothed belts
  54
• 1.5 Removing and installing camshaft housing
  61
• 1.6 Removing and installing cylinder head
  64
• 1.7 Checking compression pressures
  67
• 2 Servicing valve gear
  69
• 2.1 Servicing valve gear
  69
• 2.2 Reworking valve seats
  78
• 2.3 Removing and installing camshaft adjuster and exhaust camshaft sprocket
  80
• 2.4 Renewing camshaft oil seals
  87
• 2.5 Checking valve guides
  90
• 2.6 Renewing valve guides
  91
• 2.7 Renewing valve stem seals
  92
• Lubrication
  95
• 1 Removing and installing parts of the lubrication system
  95
• 1.1 Removing and installing parts of the lubrication system
  95
• 1.2 Removing and installing oil sump
  101
• 1.3 Removing and installing oil pump
  104
• 1.4 Checking oil pressure and oil pressure switch
  107
• Cooling system
  109
• 1 Removing and installing parts of cooling system
  109
• 1.1 Removing and installing parts of cooling system
  109
• 1.2 Parts of cooling system body side
  110
• 1.3 Checking coolant temperature sender -radiator outlet-
  113
• 1.4 Parts of cooling system engine side
  115
• 1.5 Coolant hose connection diagram
  120
• 1.6 Draining and filling cooling system
  122
• 1.7 Removing and installing radiator
  124
• 1.8 Removing and installing coolant pump
  126
• 1.9 Dismantling and assembling coolant distribution housing
  128
• Fuel supply system
  130
• 1 Removing and installing parts of fuel supply system
  130
• 1.1 Removing and installing parts of fuel supply system
  130
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  131
• 1.3 Safety precautions when working on the fuel supply system
  135
• 1.4 Rules for cleanliness
  136
• 1.5 Removing and installing fuel delivery unit
  136
• 1.6 Removing and installing fuel tank
  138
• 1.7 Checking fuel pump
  140
• 1.8 Removing and installing high-pressure pump
  146
• 2 Electronic power control (EPC)
  148
• 2.1 Electronic power control (EPC)
  148
• 2.2 Function of EPC system
  148
• 2.3 Servicing parts of electronic power control (EPC)
  149
• 3 Activated charcoal filter system
  150
• 3.1 Activated charcoal filter system
  150
• 3.2 Function
  150
• 3.3 Servicing parts of the activated charcoal filter system
  151
• 3.4 Checking fuel tank breather
  153
• Mixture preparation, Injection
  155
• 1 Servicing injection
  155
• 1.1 Servicing injection
  155
• 1.2 General notes on injection
  155
• 1.3 Removing and installing parts of the injection system
  156
• 1.4 Dismantling and assembling intake manifold
  161
• 1.5 Dismantling and assembling fuel rail with injectors
  169
• 1.6 Dismantling and assembling air cleaner
  172
• 1.7 Removing and installing injectors
  175
• 1.8 Safety precautions
  180
• 1.9 Rules for cleanliness
  181
• 1.10 Technical data
  181
• 2 Checking components
  182
• 2.1 Checking components
  182
• 2.2 Removing and installing fuel pressure regulator and fuel metering valve
  182
• 2.3 Checking fuel pressure regulator and holding pressure
  184
• 2.4 Removing and installing engine control unit
  187
• 2.5 Interrogating and erasing engine control unit fault memory
  188
• 2.6 Adapting functions and components
  189
• Exhaust system
  191
• 1 Removing and installing parts of exhaust system
  191
• 1.1 Removing and installing parts of exhaust system
  191
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  191
• 2 Exhaust gas recirculation system
  199
• 2.1 Exhaust gas recirculation system
  199
• 2.2 Servicing parts of exhaust gas recirculation system
  200
• Ignition system
  202
• 1 Servicing ignition system
  202
• 1.1 Servicing ignition system
  202
• 1.2 General notes on ignition system
  202
• 1.3 Removing and installing parts of the ignition system
  203
• 1.4 Safety precautions
  205
• 1.5 Test data, spark plugs
  206