5-cyl. 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
  2
• 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
  9
• 1.4 Tightening torques
  11
• 1.5 Assembly mountings
  11
• 1.6 Additional information and removal instructions for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Dismantling and assembling engine
  13
• 1.2 Checking valve timing
  19
• 1.3 Adjusting valve timing
  21
• 1.4 Removing and installing ribbed belt
  37
• 2 Removing and installing sealing flange and twin mass flywheel/drive plate
  39
• 2.1 Removing and installing sealing flange and twin mass flywheel/drive plate
  39
• 2.2 Renewing crankshaft oil seal -vibration damper end-
  43
• 2.3 Removing and installing drive plate
  46
• 3 Removing and installing crankshaft
  48
• 3.1 Removing and installing crankshaft
  48
• 4 Dismantling and assembling pistons and conrods
  52
• 4.1 Dismantling and assembling pistons and conrods
  52
• 4.2 Piston and cylinder dimensions
  58
• Cylinder head, Valve gear
  59
• 1 Removing and installing cylinder head
  59
• 1.1 Removing and installing cylinder head
  59
• 1.2 Removing and installing cylinder head cover
  65
• 1.3 Removing and installing cylinder head
  68
• 1.4 Checking compression pressures
  72
• 2 Servicing valve gear
  74
• 2.1 Servicing valve gear
  74
• 2.2 Reworking valve seats
  79
• 2.3 Removing and installing camshafts
  81
• 2.4 Checking hydraulic bucket tappets
  84
• 2.5 Checking valve guides
  85
• 2.6 Renewing valve guides
  86
• 2.7 Renewing valve stem seals
  88
• Lubrication
  91
• 1 Removing and installing parts of the lubrication system
  91
• 1.1 Removing and installing parts of the lubrication system
  91
• 1.2 Dismantling and assembling oil filter housing/assembly mounting
  96
• 1.3 Dismantling and assembling oil pump
  98
• 1.4 Removing and installing oil sump
  101
• 1.5 Checking oil pressure and oil pressure switch
  105
• Cooling system
  107
• 1 Removing and installing parts of cooling system
  107
• 1.1 Removing and installing parts of cooling system
  107
• 1.2 Parts of cooling system body side
  108
• 1.3 Parts of cooling system engine side
  112
• 1.4 Removing and installing compact bracket
  116
• 1.5 Coolant hose connection diagram
  120
• 1.6 Dismantling and assembling coolant thermostat housing
  122
• 1.7 Draining and filling with coolant
  125
• 1.8 Removing and installing radiator
  129
• 1.9 Removing and installing viscous fan coupling
  131
• 1.10 Removing and installing bush for viscous fan coupling
  133
• 1.11 Checking continued coolant circulation pump (V51)
  137
• 1.12 Checking radiator fan (V7)
  138
• Fuel supply system
  140
• 1 Removing and installing parts of fuel supply system
  140
• 1.1 Removing and installing parts of fuel supply system
  140
• 1.2 Removing and installing fuel tank with its attachments and fuel filter
  141
• 1.3 Removing and installing suction jet pump
  148
• 1.4 Safety precautions when working on the fuel supply system
  158
• 1.5 Rules for cleanliness
  159
• 1.6 Crash fuel shut-off
  159
• 1.7 Removing and installing fuel delivery unit
  159
• 1.8 Removing and installing fuel tank
  165
• 1.9 Checking fuel pump
  168
• 1.10 Servicing accelerator mechanism
  176
• 1.11 Adjusting throttle cable
  180
• 1.12 Servicing parts of the activated charcoal filter system
  182
• 1.13 Checking fuel tank breather
  184
• Exhaust system
  187
• 1 Removing and installing parts of exhaust system
  187
• 1.1 Removing and installing parts of exhaust system
  187
• 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
  187
• 1.3 Silencer with mountings
  192
• 2 Secondary air system
  197
• 2.1 Secondary air system
  197
• 2.2 Function
  197
• 2.3 Removing and installing parts of the secondary air system
  198
• 2.4 Checking combi-valve
  202
• 2.5 Removing and installing combi-valve
  204