5-cyl. injection engine, (4-valve), 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
  4
• 1.3 Notes on installing
  10
• 1.4 Tightening torques
  12
• 1.5 Assembly mountings
  12
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Dismantling and assembling engine
  14
• 1.2 Removing and installing ribbed belt
  30
• 2 Removing and installing sealing flange and dual mass flywheel/drive plate
  32
• 2.1 Removing and installing sealing flange and dual mass flywheel/drive plate
  32
• 2.2 Renewing crankshaft oil seal -vibration damper end-
  37
• 2.3 Removing and installing drive plate
  40
• 3 Removing and installing crankshaft
  42
• 3.1 Removing and installing crankshaft
  42
• 4 Dismantling and assembling pistons and conrods
  47
• 4.1 Dismantling and assembling pistons and conrods
  47
• 4.2 Piston and cylinder dimensions
  53
• 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 cover
  62
• 1.3 Removing and installing cylinder head cover
  66
• 1.4 Removing and installing cylinder head
  69
• 1.5 Checking valve timing
  76
• 1.6 Adjusting valve timing
  78
• 1.7 Checking compression pressures
  84
• 2 Servicing valve gear
  87
• 2.1 Servicing valve gear
  87
• 2.2 Reworking valve seats
  98
• 2.3 Removing and installing camshafts
  100
• 2.4 Checking camshaft adjustment
  107
• 2.5 Checking valve guides
  112
• 2.6 Renewing valve stem seals
  113
• Lubrication
  116
• 1 Removing and installing parts of the lubrication system
  116
• 1.1 Removing and installing parts of the lubrication system
  116
• 1.2 Dismantling and assembling oil filter housing/assembly mounting
  124
• 1.3 Dismantling and assembling oil pump
  127
• 1.4 Removing and installing sump
  130
• 1.5 Checking oil pressure and oil pressure switch
  136
• Cooling system
  139
• 1 Removing and installing parts of cooling system
  139
• 1.1 Removing and installing parts of cooling system
  139
• 1.2 Parts of cooling system body side
  140
• 1.3 Parts of cooling system engine side
  146
• 1.4 Dismantling and assembling compact bracket
  151
• 1.5 Coolant hose connection diagram
  155
• 1.6 Dismantling and assembling coolant thermostat housing
  157
• 1.7 Draining and filling cooling system
  159
• 1.8 Removing and installing radiator
  164
• 1.9 Removing and installing viscous fan coupling
  166
• 1.10 Removing and installing bush for viscous fan coupling
  168
• 1.11 Checking continued coolant circulation pump
  171
• Fuel supply system
  174
• 1 Removing and installing parts of fuel supply system
  174
• 1.1 Removing and installing parts of fuel supply system
  174
• 1.4 Safety precautions when working on the fuel supply system
  192
• 1.5 Rules for cleanliness
  193
• 1.7 Crash fuel shut-off
  196
• 1.8 Removing and installing fuel delivery unit: vehicles with front wheel drive
  196
• 1.9 Removing and installing fuel delivery unit: vehicles with four-wheel drive
  198
• 1.10 Removing and installing fuel gauge sender: vehicles with front wheel drive
  201
• 1.11 Removing and installing fuel tank
  201
• 1.12 Checking fuel pump
  204
• 2 Electronic power control (EPC)
  213
• 2.1 Electronic power control (EPC)
  213
• 2.2 Function of EPC system
  213
• 2.3 Servicing parts of electronic power control (EPC)
  214
• 2.4 Checking accelerator pedal position sender
  216
• 3 Activated charcoal filter system
  219
• 3.1 Activated charcoal filter system
  219
• 3.2 Function
  219
• 3.3 Servicing parts of the activated charcoal filter system
  221
• 3.4 Checking activated charcoal filter solenoid valve 1
  225
• 3.5 Checking fuel tank breather
  227
• Exhaust system
  230
• 1 Removing and installing parts of exhaust system
  230
• 1.1 Removing and installing parts of exhaust system
  230
• 1.2 Exhaust manifold, front exhaust pipe with catalyst and attachments
  231
• 1.3 Silencer with mountings: vehicles with front wheel drive
  238
• 1.4 Silencer with mountings: vehicles with four-wheel drive
  240
• 1.5 Checking catalyst
  242
• 2 Secondary air system
  245
• 2.1 Secondary air system
  245
• 2.2 Function
  245
• 2.3 Removing and installing parts of the secondary air system
  246
• 2.4 Checking secondary air system
  251
• 2.5 Checking secondary air pump motor
  253
• 2.6 Checking combi-valve
  255