4 Cyl injection engine (2 valve), Mechanics

Chapter overview

• Technical data
  1
• 1 Technichal data
  1
• 1.1 Technichal data
  1
• 1.2 Engine number
  1
• 1.3 Engine summary
  1
• Removing and installing engine
  4
• 1 Engine removal and installation
  4
• 1.1 Engine removal and installation
  4
• 1.2 Notes on engine removal
  4
• 1.3 Notes on installation
  5
• 1.4 Tightening torques
  6
• 1.5 Additional installation procedures and notes for vehicles with air conditioning
  6
• Crankshaft group
  8
• 1 Dismantling and assembling engine
  8
• 1.1 Dismantling and assembling engine
  8
• 1.2 Installing toothed belt
  19
• 1.3 Adjusting alternator V-belt tension
  21
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  22
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  22
• 2.2 Installing release plate retaining ring
  29
• 2.3 Renewing crankshaft oil seal -pulley end
  30
• 2.4 Crankshaft dimensions
  31
• 2.5 Installing drive plate
  32
• 2.6 Marking flywheel with ignition timing notch
  32
• 3 Dismantling and assembling pistons and conrods
  34
• 3.1 Dismantling and assembling pistons and conrods
  34
• 3.2 Piston and cylinder dimensions
  42
• Cylinder head, Valve gear
  44
• 1 Removing and installing cylinder head
  44
• 1.1 Removing and installing cylinder head
  44
• 1.2 Installing cylinder head
  48
• 1.3 Testing compression
  49
• 2 Servicing valve gear
  50
• 2.1 Servicing valve gear
  50
• 2.2 Reworking valve seats
  58
• 2.3 Checking hydraulic tappets
  60
• 2.4 Renewing camshaft oil seal
  61
• 2.5 Removing and installing camshaft
  61
• 2.6 Checking valve guides
  62
• 2.7 Renewing valve guides
  63
• 2.8 Renewing valve stem oil seal -with cylinder head installed
  63
• 2.9 Checking and adjusting valve clearance
  64
• Lubrication
  67
• 1 Removing and installing lubrication system components
  67
• 1.1 Removing and installing lubrication system components
  67
• 1.2 Oil cooler
  74
• 1.4 Checking oil pressure switch and oil pressure (engine code: EG)
  79
• Cooling system
  81
• 1 Removing and installing cooling system components
  81
• 1.1 Removing and installing cooling system components
  81
• 1.2 Draining and refilling with coolant
  89
• 1.3 Fan run-on for cooling injectors
  90
• 1.4 Repair air deflector installation
  90
• Fuel supply system
  91
• 1 Removing and installing fuel system components
  91
• 1.1 Removing and installing fuel system components
  91
• 1.6 Removing and installing fuel pump and fuel filter (engine code: 2H)
  107
• 1.7 Rules of cleanliness
  108
• 1.8 Connecting remote control V.A.G 1348/3A
  111
• 1.9 Checking fuel pumps (engine codes: DX, EG, JH, JJ, KT)
  111
• 1.10 Checking fuel pump (engine code: 2H)
  114
• 1.11 Checking fuel pump non-return valve (engine codes: DX, EG, JH, JJ, KT)
  117
• 1.12 Checking fuel pump relay (engine codes: DX, EG, JH, JJ, KT)
  118
• 1.13 Checking fuel pump relay (engine code: 2H)
  119
• 1.14 Retrotitting adapter plate for fuel pump relay (engine code: EG > 7/82)
  120
• 1.15 Removal and installation of fuel gauge sender, fuel lift pump
  121
• 1.17 Removing and installing fuel tank (> 1/84, 40- litre fuel tank)
  123
• 1.18 Removing and installing fuel tank (2/84 >, 55- litre fuel tank)
  125
• 1.19 Checking fuel system for leaks (> 1/84, 40-litre fuel tank)
  126
• 2 Servicing activated charcoal filter unit
  128
• 2.1 Servicing activated charcoal filter unit
  128
• 2.2 Engine code: JH > 7/86
  128
• 2.3 Engine code: JH 8/86 >
  130
• 2.4 Engine code: 2H
  132
• 3 Throttle-mechanism
  134
• 3.1 Throttle-mechanism
  134
• 3.2 Throttle cable adjustment, manual gearbox
  134
• 3.3 Servicing throttle controls, automatic gearbox (engine codes: JH, 2H)
  135
• 3.4 Adjusting throttle controls
  136
• Exhaust system
  139
• 1 Removing and installing exhaust system components
  139
• 1.1 Removing and installing exhaust system components
  139
• 1.2 Engine Codes: DX, EG JJ KT
  139
• 1.3 Engine Code: JH
  142
• 1.4 Engine Code: 2H
  145
• 1.5 Removing and installing spring clips (engine codes: DX 8/83 >, JH, KT)
  148
• 1.6 Tensioning and relaxing spring clips (engine codes: DX 8/83 >, JH, KT)
  148
• 2 Checking exhaust gas recirculation (EGR) (engine code: JJ)
  149
• 2.1 Checking exhaust gas recirculation (EGR) (engine code: JJ)
  149