4-cylinder injection engine (natural gas)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Checking the gas system
  2
• 2.1 Test prerequisites for gas systems
  2
• 2.2 Checking gas system for leaks
  3
• Removing and installing engine
  5
• 1 Removing and installing engine
  5
• 1.1 Notes on removing
  5
• 1.2 Securing engine to assembly stand
  9
• 1.3 Notes on installing
  9
• 1.4 Specified torques
  11
• 1.5 Aligning engine and gearbox mountings
  11
• 1.6 Assembly mountings
  12
• 1.7 Additional information and assembly work for vehicles with air conditioner
  12
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Assembly overview - parts l and ll
  14
• 1.2 Assembly overview - part I, belt drive
  16
• 1.3 Assembly overview - part II, cylinder block
  17
• 1.4 Removing and installing poly V-belt
  18
• 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
  29
• 3.1 Assembly overview
  29
• 3.2 Colour coding
  30
• 3.3 Crankshaft dimensions
  31
• 4 Dismantling and assembling pistons and conrods
  32
• 4.1 Assembly overview
  32
• 4.2 Removing and installing oil scraper ring
  35
• 4.3 Piston and cylinder dimensions
  36
• Cylinder head, valve gear
  37
• 1 Cylinder head
  37
• 1.1 Assembly overview
  37
• 1.2 Removing, installing and tensioning toothed belt
  39
• 1.3 Checking semi-automatic toothed belt tensioning roller
  43
• 1.4 Removing and installing cylinder head
  44
• 1.5 Checking compression
  48
• 2 Repairing valve gear
  50
• 2.1 Assembly overview
  50
• 2.2 Reworking valve seats
  53
• 2.3 Renewing camshaft oil seal
  54
• 2.4 Removing and installing camshaft
  56
• 2.5 Checking hydraulic bucket tappets
  59
• 2.6 Checking valve guides
  60
• 2.7 Renewing valve guides
  60
• 2.8 Renewing valve stem seals
  61
• Lubrication
  65
• 1 Removing and installing parts of lubrication system
  65
• 1.1 Assembly overview
  65
• 1.2 Assembly overview - oil filter bracket
  68
• 1.3 Assembly overview - oil pump with balancer shaft gear assembly
  69
• 1.4 Removing and installing oil pump with balancer shaft gear assembly
  70
• 1.5 Removing and installing oil pan
  73
• 1.6 Checking oil pressure and oil pressure switch
  75
• Cooling
  78
• 1 Removing and installing 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
  86
• 1.6 Removing and installing coolant pump
  87
• 1.7 Removing and installing thermostat
  89
• Fuel supply system
  92
• 1 Removing and installing parts of fuel supply system (petrol)
  92
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  92
• 1.2 Safety precautions when working on fuel supply system
  95
• 1.3 Rules for cleanliness
  96
• 1.4 Removing and installing fuel delivery unit
  96
• 1.5 Removing and installing fuel gauge sender G
  98
• 1.6 Removing and installing fuel tank
  98
• 1.7 Crash fuel shut-off
  100
• 1.8 Checking fuel pump
  100
• 2 Accelerator mechanism
  107
• 2.1 Assembly overview
  107
• 2.2 Function of EPC system
  107
• 3 Activated charcoal filter system
  109
• 3.1 Function
  109
• 3.2 Assembly overview
  109
• 3.3 Checking fuel tank breather
  110
• 4 Removing and installing parts of fuel supply system (natural gas)
  112
• 4.1 Safety precautions when working on natural gas system
  112
• 4.2 Rules for cleanliness
  113
• 4.3 Natural gas system components
  114
• 4.4 Fuel line connections
  115
• 4.5 Assembly overview - support for fuel tank and securing straps
  116
• 4.6 Assembly overview - fuel tank with attachments
  117
• 4.7 Removing and installing fuel tank
  118
• 4.8 Removing and installing tank shut-off valve
  120
• 4.9 Removing and installing thermal fuse
  122
• 4.10 Assembly overview - filling connection
  123
• 4.11 Removing and installing filling connection
  124
• 5 Evacuating natural gas tank
  127
• Mixture preparation - injection
  128
• 1 Repairing injection system
  128
• 1.1 Assembly overview - intake manifold upper part
  128
• 1.2 Assembly overview - intake manifold lower part
  130
• 1.3 Assembly overview - fuel rail with injectors (petrol operation)
  131
• 1.4 Assembly overview - gas rail with gas injectors
  132
• 1.5 Assembly overview - gas pressure regulator
  133
• 1.6 Removing and installing gas pressure regulator
  133
• 1.7 Assembly overview - air filter
  135
• 1.8 Cleaning throttle valve module J338
  136
• 1.9 Safety precautions
  137
• 1.10 Rules for cleanliness
  138
• 1.11 Technical data
  138
• 2 Checking components
  139
• 2.1 Checking injectors for leaks and injection rate
  139
• 2.2 Checking fuel pressure regulator and holding pressure
  141
• 2.3 Checking intake manifold change-over
  144
• 3 Engine control unit
  147
• 3.1 Renewing engine control unit
  147
• 3.2 Adapting functions and components
  147
• 3.3 Reading and erasing engine control unit fault memory
  148
• Exhaust system
  150
• 1 Removing and installing parts of exhaust system
  150
• 1.1 Assembly overview - front exhaust pipe and catalytic converter with attachments
  150
• 1.2 Assembly overview - silencers with mountings
  152
• 2 Secondary air system
  154
• 2.1 Function
  154
• 2.2 Assembly overview - parts of secondary air system
  154
• 2.3 Checking combination valve
  155
• Ignition system
  157
• 1 Repairing ignition system
  157
• 1.1 Assembly overview - ignition system
  157
• 1.2 Safety precautions
  158
• 1.3 Test data, spark plugs
  159