5-cylinder injection engine, mechanics

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Notes on removing
  4
• 1.2 Securing engine to assembly stand
  8
• 1.3 Notes on installing
  9
• 1.4 Aligning engine and gearbox mountings
  10
• 1.5 Specified torques
  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 Parts l and ll - assembly overview
  13
• 1.2 Part I: Assembly overview - chain drive
  15
• 1.3 Part II: Assembly overview - crankshaft drive
  17
• 1.4 Removing and installing poly V-belt
  18
• 2 Removing and installing sealing flange and dual mass flywheel/drive plate
  21
• 2.1 Assembly overview
  21
• 2.2 Renewing crankshaft oil seal, vibration damper end
  22
• 2.3 Removing and installing drive plate
  23
• 2.4 Removing and installing seal, flywheel end
  25
• 3 Removing and installing crankshaft
  28
• 3.1 Assembly overview
  28
• 4 Dismantling and assembling pistons and conrods
  30
• 4.1 Assembly overview
  30
• 4.2 Piston and cylinder dimensions
  33
• Cylinder head, valve gear
  34
• 1 Removing and installing cylinder head
  34
• 1.1 Assembly overview
  34
• 1.2 Removing and installing cylinder head cover
  37
• 1.3 Removing and installing cylinder head
  41
• 1.4 Checking valve timing
  45
• 1.5 Adjusting valve timing
  47
• 1.6 Checking compression
  52
• 2 Repairing valve gear
  54
• 2.1 Assembly overview
  54
• 2.2 Reworking valve seats
  56
• 2.3 Removing and installing camshafts
  57
• 2.4 Checking hydraulic bucket tappets
  60
• 2.5 Checking valve guides
  61
• 2.6 Renewing valve guides
  61
• 2.7 Renewing valve stem seals
  62
• Lubrication
  65
• 1 Removing and installing parts of lubrication system
  65
• 1.1 Engine oil
  65
• 1.2 Assembly overview
  66
• 1.3 Assembly overview - oil filter bracket
  68
• 1.4 Assembly overview - oil pump
  69
• 1.5 Removing and installing sump
  70
• 1.6 Checking oil pressure and oil pressure switch
  71
• Cooling
  74
• 1 Removing and installing parts of cooling system
  74
• 1.1 Assembly overview - parts of cooling system, body side
  74
• 1.2 Assembly overview - parts of cooling system, engine side
  76
• 1.3 Coolant hose schematic diagram
  77
• 1.4 Assembly overview - thermostat housing
  78
• 1.5 Draining and filling coolant
  79
• 1.6 Removing and installing radiator
  82
• 1.7 Checking continued coolant circulation pump V51
  83
• 1.8 Checking radiator fan V7 and radiator fan, right V35
  85
• 1.9 Removing and installing coolant pump
  86
• Fuel supply system
  88
• 1 Removing and installing parts of fuel supply system
  88
• 1.1 Assembly overview - fuel tank with attachments and fuel filter
  88
• 1.2 Safety precautions when working on fuel supply system
  93
• 1.3 Rules for cleanliness
  93
• 1.4 Removing and installing suction jet pump
  94
• 1.5 Removing and installing fuel delivery unit
  96
• 1.6 Removing and installing fuel gauge sender G
  97
• 1.7 Removing and installing fuel tank
  97
• 1.8 Crash fuel shut-off
  99
• 1.9 Checking fuel pump
  99
• 2 Accelerator mechanism
  106
• 2.1 Assembly overview
  106
• 2.2 Adjusting throttle cable
  107
• 3 Activated charcoal filter system
  109
• 3.1 Assembly overview
  109
• 3.2 Checking fuel tank breather
  110
• Exhaust system
  112
• 1 Removing and installing parts of exhaust system, front-wheel drive
  112
• 1.1 Assembly overview
  112
• 2 Removing and installing parts of exhaust system, four-wheel drive
  115
• 2.1 Assembly overview
  115
• 3 Secondary air system
  118
• 3.1 Function
  118
• 3.2 Assembly overview - parts of secondary air system
  118
• 3.3 Checking combination valve
  120
• 3.4 Removing and installing combination valve
  121