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 Removing
  3
• 1.2 Installing
  5
• 1.3 Specified torques
  7
• 1.4 Additional information and assembly work for vehicles with air conditioner
  8
• Crankshaft group
  10
• 1 Dismantling and assembling engine
  10
• 1.1 Assembly overview - parts l and ll
  10
• 1.2 Assembly overview - part I, belt drive
  12
• 1.3 Part II: assembly overview - chain drive system
  13
• 1.4 Removing and installing poly V-belt
  15
• 1.5 Removing and installing valve timing housing (timing case)
  16
• 2 Cylinder block, sealing flange
  20
• 2.1 Assembly overview
  20
• 2.2 Renewing crankshaft oil seal - pulley end
  22
• 2.3 Poly V-belt pulley securing bolt tightening procedure
  23
• 2.4 Renewing crankshaft sealing flange - flywheel end
  26
• 2.5 Crankshaft dimensions
  33
• 3 Pistons and conrods
  35
• 3.1 Assembly overview
  35
• 3.2 Checking piston
  36
• 3.3 Checking cylinder bores
  37
• 3.4 Piston and cylinder dimensions
  37
• Cylinder head, valve gear
  38
• 1 Cylinder head
  38
• 1.1 Assembly overview
  38
• 1.2 Checking valve timing
  41
• 1.3 Adjusting valve timing
  42
• 1.4 Removing and installing timing chain and chain drive for oil pump
  46
• 1.5 Removing and installing camshaft housing
  53
• 1.6 Removing and installing cylinder head
  57
• 1.7 Checking compression
  60
• 2 Valve gear
  62
• 2.1 Assembly overview
  62
• 2.2 Checking camshaft axial clearance
  64
• 2.3 Reworking valve seats
  64
• 2.4 Checking valve guides
  66
• 2.5 Renewing valve stem seals
  66
• Lubrication
  69
• 1 Parts of lubrication system
  69
• 1.1 Engine oil
  69
• 1.2 Assembly overview
  69
• 1.3 Removing and installing sump
  72
• 1.4 Removing and installing oil pump
  73
• 1.5 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 Coolant hose schematic diagram
  82
• 1.4 Draining and filling coolant
  83
• 1.5 Removing and installing radiator
  85
• 1.6 Removing and installing coolant pump
  86
• Fuel supply system
  89
• 1 Safety precautions
  89
• 1.1 Safety precautions when working on fuel supply system
  89
• 1.2 Releasing pressure in high-pressure area
  90
• 2 Parts of fuel supply system
  91
• 2.1 Assembly overview - fuel tank with attachments
  91
• 2.2 Safety precautions when working on fuel supply system
  94
• 2.3 Rules for cleanliness
  94
• 2.4 Removing and installing fuel delivery unit
  94
• 2.5 Removing and installing fuel gauge sender G
  96
• 2.6 Removing and installing fuel tank
  97
• 2.7 Crash fuel shut-off
  99
• 2.8 Checking fuel pump
  99
• 3 Electronic power control (EPC)
  106
• 3.1 Function of EPC system
  106
• 3.2 Assembly overview
  106
• 4 Activated charcoal filter system
  108
• 4.1 Function
  108
• 4.2 Assembly overview
  108
• 4.3 Checking fuel tank breather
  109
• Mixture preparation - injection
  111
• 1 Injection system
  111
• 1.1 General notes on injection
  111
• 1.2 Assembly overview - intake manifold
  111
• 1.3 Assembly overview - fuel rail with injectors
  114
• 1.4 Checking vacuum reservoir in intake manifold for leaks
  115
• 1.5 Assembly overview - air filter
  116
• 1.6 Removing and installing air filter
  117
• 1.7 Cleaning throttle valve module J338
  117
• 1.8 Removing and installing injectors
  118
• 1.9 Removing and installing high-pressure pump
  121
• 1.10 Safety precautions
  123
• 1.11 Rules for cleanliness
  124
• 1.12 Technical data
  124
• 2 Checking components
  126
• 2.1 Checking intake air preheating
  126
• 3 Engine control unit J623
  127
• 3.1 Removing and installing engine control unit J623
  127
• 3.2 Removing and installing anti-theft engine control unit J623 (vehicles ► model year 2007)
  127
• 3.3 Removing and installing anti-theft engine control unit J623 (vehicles model year 2007▸)
  129
• Exhaust system
  131
• 1 Parts of the exhaust system
  131
• 1.1 Assembly overview - catalytic converters and attachments
  131
• 1.2 Assembly overview - silencers with mountings
  133
• 2 Exhaust gas recirculation system
  134
• 2.1 Assembly overview - exhaust gas recirculation system
  134
• 2.2 Removing and installing exhaust gas recirculation valve N18
  135
• Ignition system
  137
• 1 Ignition system
  137
• 1.1 Assembly overview - ignition system
  137
• 1.2 Removing and installing ignition coils with output stage
  138
• 1.3 Safety precautions
  139
• 1.4 Test data, spark plugs
  140