5-cyl. fuel injection engine, Mechanics

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
  3
• 1.3 Securing engine to assembly stand
  6
• 1.4 Notes on installing
  6
• 1.5 Tightening torques
  8
• 1.6 Additional information and work instructions for vehicles with air conditioner
  8
• Crankshaft group
  9
• 1 Dismantling and assembling engine
  9
• 1.1 Dismantling and assembling engine
  9
• 1.2 Removing and installing ribbed belt
  26
• 1.3 Removing and installing toothed belt
  28
• 1.4 Adjusting alternator V-belt tension
  32
• 1.5 Removing and installing ribbed belt tensioning device
  33
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  36
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  36
• 2.2 Renewing crankshaft oil seal -pulley end-
  42
• 2.3 Crankshaft dimensions
  43
• 2.4 Removing and installing drive plate
  44
• 3 Dismantling and assembling pistons and conrods
  47
• 3.1 Dismantling and assembling pistons and conrods
  47
• 3.2 Piston and cylinder dimensions
  52
• Cylinder head, Valve gear
  54
• 1 Removing and installing cylinder head
  54
• 1.1 Removing and installing cylinder head
  54
• 1.2 Removing and installing cylinder head
  60
• 1.3 Checking compressions
  61
• 2 Servicing valve gear
  62
• 2.1 Servicing valve gear
  62
• 2.2 Reworking valve seats
  68
• 2.3 Checking hydraulic bucket tappets
  70
• 2.4 Removing and installing camshaft
  71
• 2.5 Removing and installing camshaft oil seal
  73
• 2.6 Checking valve guides
  73
• 2.7 Renewing valve guides
  74
• 2.8 Renewing valve stem seals
  74
• Lubrication
  77
• 1 Removing and installing parts of the lubrication system
  77
• 1.1 Removing and installing parts of the lubrication system
  77
• 1.2 Checking oil pressure and oil pressure switch
  90
• Cooling system
  92
• 1 Removing and installing parts of cooling system
  92
• 1.1 Removing and installing parts of cooling system
  92
• 1.2 Parts of cooling system body side
  93
• 1.3 Parts of cooling system - engine side
  101
• 1.4 Coolant hose connection diagram
  104
• 1.5 Draining and filling cooling system
  107
• 1.6 Removing and installing radiator and radiator fan
  109
• 1.7 Checking thermo switch and continued coolant circulation pump
  111
• Fuel supply system
  113
• 1 Removing and installing parts of fuel supply system
  113
• 1.1 Removing and installing parts of fuel supply system
  113
• 1.2 Removing and installing fuel tank with its attachments
  114
• 1.3 Removing and installing fuel delivery unit
  117
• 1.4 Safety precautions when working on the fuel supply system
  121
• 1.5 Rules for cleanliness
  121
• 1.6 Removing and installing fuel delivery unit
  121
• 1.7 Dismantling and assembling fuel delivery unit
  123
• 1.8 Checking fuel pump
  124
• 1.9 Removing and installing fuel tank
  128
• 1.10 Servicing accelerator mechanism
  130
• 1.11 Adjusting throttle cable
  132
• 1.12 Servicing the activated charcoal filter system
  134
• 1.13 Checking activated charcoal filter system control
  137
• 2 Checking electronic power control (EPC)
  139
• 2.1 Checking electronic power control (EPC)
  139
• 2.2 Function of EPC system
  140
• 2.3 Checking electronic accelerator warning lamp
  140
• 2.4 Checking accelerator pedal position sender
  143
• Exhaust system
  146
• 1 Removing and installing parts of exhaust system
  146
• 1.1 Removing and installing parts of exhaust system
  146
• 1.2 Retrofitting front exhaust pipe stop plate
  155
• 1.3 Checking catalyst
  156
• 2 Exhaust gas recirculation system
  157
• 2.1 Exhaust gas recirculation system
  157
• 2.2 Removing and installing parts of exhaust gas recirculation system
  158
• 2.3 Checking exhaust gas recirculation valve (mechanical)
  161
• 2.4 Secondary air system
  162
• 2.5 Removing and installing parts of secondary air system
  163
• 2.6 Checking combi valve and non return valve
  165
• 2.7 Checking secondary air pump
  166
• 2.8 Checking secondary air inlet valve
  167