4 - Cyl. injection engine (2 valves, roller rocker fingers)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Engine: dismantling and fitting
  3
• 1.1 Dismantling: notes
  4
• 1.2 Engine: securing engine to assembly stand
  6
• 1.3 Installing: notes
  7
• 1.4 Tightening torques
  8
• 1.5 Engine brackets
  8
• 1.6 Additional information and installation work on vehicles with air conditioning
  9
• Crankshaft group
  11
• 1 Engine: dismantling and assembling
  11
• 1.1 Ribbed belt: dismantling and fitting
  14
• 2 Sealing flange and engine flywheel: dismantling and fitting
  18
• 2.1 Crankshaft oil seal -belt pulley end: renew
  19
• 2.2 Renewing crankshaft sealing flange flywheel end: renew
  21
• 3 Crankshaft: dismantling and fitting
  29
• 3.1 Identification conrod bearings
  30
• 3.2 Colour markings
  30
• 3.3 Crankshaft dimensions
  30
• 4 Piston and conrod: dismantling and assembling
  31
• 4.1 Piston and cylinder dimensions
  33
• Cylinder head, Valve gear
  34
• 1 Cylinder head: dismantling and fitting
  34
• 1.1 Checking semi-automatic toothed belt tensioning roller check
  36
• 1.2 Toothed belt: removing, installing and tensioning
  37
• 1.3 Cylinder head: dismantling and fitting
  41
• 1.4 Compression ratio: checking
  45
• 2 Servicing valve gear: repairing
  48
• 2.1 Rework valve seats: reworking
  50
• 2.2 Replacing camshaft oil seal change
  52
• 2.3 Remove and install the cylinder head cover and the cam shaft
  53
• 2.4 Valve guides: checking
  56
• 2.5 Renewing valve stem seals: renew
  57
• Lubrication
  60
• 1 Lubrication system components: dismantling and fitting
  60
• 1.1 Sump: dismantling and fitting
  63
• 1.2 Oil pump dismantling and fitting
  65
• 1.3 Oil pressure sender and oil pressure switch: checking
  68
• Cooling system
  70
• 1 Cooling system components: dismantling and fitting
  70
• 1.1 Parts of cooling system, body side
  70
• 1.2 Cooling system components, engine side
  72
• 1.3 Coolant hose connection diagram
  74
• 1.4 Coolant: draining and filling cooling system
  75
• 1.5 Radiator: dismantling and fitting
  77
• 1.6 Coolant pump: dismantling and fitting
  79
• Fuel supply system
  81
• 1 Fuel supply system components: dismantling and fitting
  81
• 1.1 Fuel tank with accessory parts and fuel filter: dismantling and fitting
  81
• 1.2 Safety precautions when working on the fuel supply system
  84
• 1.3 Rules for cleanliness
  84
• 1.4 Fuel delivery unit dismantling and fitting
  85
• 1.5 Fuel gauge sender: dismantling and fitting
  86
• 1.6 Fuel tank: dismantling and fitting
  87
• 1.7 Crash fuel shut off
  89
• 1.8 Fuel pump: checking
  89
• 2 Servicing parts of electronic power control (EPC): repairing
  96
• 2.1 Function of EPC system
  96
• 3 Activated charcoal filter system
  98
• 3.1 Function
  98
• 3.2 Servicing parts of the activated charcoal filter system: repairing
  98
• 3.3 Fuel tank breather: checking
  99
• Mixture preparation, Injection
  101
• 1 Injection system: repairing
  101
• 1.1 General notes on injection
  101
• 1.2 Fitting locations overview
  101
• 1.3 Injection system components: dismantling and fitting
  103
• 1.4 Intake manifold: dismantling and assembling
  106
• 1.5 Fuel rail with injectors: dismantling and assembling
  107
• 1.6 Air filter housing: dismantling and assembling
  107
• 1.7 Safety precautions
  109
• 1.8 Rules for cleanliness
  110
• 1.9 Technical data
  110
• 2 Checking components
  112
• 2.1 Injectors: checking
  112
• 2.2 Fuel pressure regulator and holding pressure: checking
  114
• 3 Engine control unit
  119
• 3.1 Remove and assemble engine control unit
  119
• 3.2 Adapting components
  119
• 3.3 Interrogate engine control unit fault memory
  120
• Exhaust system
  122
• 1 Exhaust system components: dismantling and fitting
  122
• 1.2 Silencer with mountings
  123
• Ignition system
  124
• 1 Ignition system: repairing
  124
• 1.1 General information: ignition system
  124
• 1.2 Ignition system components: dismantling and fitting
  124
• 1.3 Safety precautions
  125
• 1.4 Test data, spark plugs
  126