4cyl. Injection Engine, (2.0 ltr. Engine) (Mexico)

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 Fastening the engine to the assembly stand
  8
• 1.4 Notes on installation
  8
• 1.5 Aligning engine and gearbox mountings
  10
• 1.6 Prescribed torque's
  11
• 1.7 Assembly mounting
  12
• Crankshaft group
  15
• 1 Dismantling and assembling the engine
  15
• 1.1 Dismantling and assembling the engine
  15
• 1.2 Removing and installing poly V-belt
  24
• 2 Removing and installing sealing flanges and flywheel/drive plate
  26
• 2.1 Removing and installing sealing flanges and flywheel/drive plate
  26
• 2.2 Renewing crankshaft oil seal -pulley end
  31
• 2.3 Removing and installing front sealing flange
  34
• 2.4 Removing and installing drive plate
  37
• 3 Removing and installing crankshaft
  39
• 3.1 Removing and installing crankshaft
  39
• 3.2 Colour markings
  45
• 3.3 Crankshaft dimensions
  45
• 4 Dismantling and assembling piston and conrod
  45
• 4.1 Dismantling and assembling piston and conrod
  45
• 4.2 Piston and cylinder dimensions
  51
• Cylinder head, Valve gear
  52
• 1 Removing and installing cylinder head
  52
• 1.1 Removing and installing cylinder head
  52
• 1.2 Removing, installing and tensioning toothed belts
  56
• 1.3 Checking semi-automatic toothed belt tensioning roller
  64
• 1.4 Removing and installing cylinder head
  65
• 1.5 Check compression pressures
  69
• 2 Servicing valve gear
  71
• 2.1 Servicing valve gear
  71
• 2.2 Reworking valve seats
  78
• 2.3 Removing and installing camshaft
  79
• 2.4 Checking hydraulic bucket tappets
  81
• 2.5 Checking valve guides
  82
• 2.6 Renewing valve guides
  82
• 2.7 Renewing valve stem seals
  83
• Lubrication
  87
• 1 Removing and installing parts of the lubrication system
  87
• 1.1 Removing and installing parts of the lubrication system
  87
• 1.2 Dismantling and assembling oil filter housing
  92
• 1.3 Removing and installing oil pan
  95
• 1.4 Removing and installing oil pump
  98
• 1.5 Checking oil pressure and oil pressure switch
  99
• Cooling system
  102
• 1 Removing and installing parts of cooling system
  102
• 1.1 Removing and installing parts of cooling system
  102
• 1.2 Parts of cooling system body side
  102
• 1.3 Parts of cooling system engine side
  107
• 1.4 Coolant hose connection diagram
  111
• 1.5 Draining and filling coolant system
  112
• 1.6 Removing and installing the radiator
  115
• 1.7 Removing and installing coolant pump
  117
• 1.8 Removing and installing thermostat
  119
• Fuel supply system
  122
• 1 Removing and installing parts of fuel supply system
  122
• 1.1 Removing and installing parts of fuel supply system
  122
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  123
• 1.3 Safety precautions when working on the fuel supply system
  129
• 1.4 Rules for cleanliness
  130
• 1.5 Removing and installing fuel delivery unit
  130
• 1.6 Removing and installing fuel gauge sender
  134
• 1.7 Removing and installing fuel filter
  134
• 1.8 Removing and installing fuel tank
  136
• 1.9 Crash fuel shut-off
  139
• 1.10 Checking fuel pump
  140
• 1.11 Bleed fuel system
  147
• 2 Accelerator mechanism
  150
• 2.1 Accelerator mechanism
  150
• 2.2 Servicing accelerator mechanism
  151
• 2.3 Function of EPC system
  152
• 3 Activated charcoal canister system
  153
• 3.1 Activated charcoal canister system
  153
• 3.2 Function
  153
• 3.3 Servicing parts of the activated charcoal canister system
  154
• 3.4 Assembly overview of activated charcoal canister system
  157
• Mixture preparation, Injection
  160
• 1 Servicing injection system
  160
• 1.1 Servicing injection system
  160
• 1.2 Fitting locations overview
  160
• 1.3 General notes on injection
  169
• 1.4 Dismantling and assembling intake manifold upper part
  170
• 1.5 Dismantling and assembling intake manifold lower part
  172
• 1.6 Dismantling and assembling air cleaner
  174
• 1.7 Safety precautions
  176
• 1.8 Rules for cleanliness
  177
• 1.9 Removing and installing intake manifold upper part
  178
• 1.10 Technical data
  180
• 2 Checking components
  180
• 2.1 Checking components
  180
• 2.2 Checking injectors for leaks and quantity injected
  181
• 2.3 Checking fuel pressure regulator and holding pressure
  183
• 3 Engine control unit
  188
• 3.1 Engine control unit
  188
• 3.2 Replace engine control unit
  188
• 3.3 Adapting components and functions
  189
• 3.4 Interrogating and erasing engine control unit fault memory
  190
• Exhaust system
  193
• 1 Removing and installing parts of exhaust system
  193
• 1.1 Removing and installing parts of exhaust system
  193
• 1.2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments
  193
• 1.3 Silencer with mountings
  198
• 2 Secondary air system
  202
• 2.1 Secondary air system
  202
• 2.2 Function
  202
• 2.3 Removing and installing parts of the secondary air system
  202
• 2.4 Checking combination valve
  206
• Ignition system
  207
• 1 Servicing ignition system
  207
• 1.1 Servicing ignition system
  207
• 1.2 General notes on ignition system
  207
• 1.3 Removing and installing parts of the ignition system
  207
• 1.4 Safety precautions
  210
• 1.5 Test data, spark plugs
  211