5-cylinder injection engine (2.5 l engine, 4-valve)

Chapter overview

• Technical data
  1
• 1 Safety instructions
  1
• 1.1 Safety precautions when working on fuel supply system
  1
• 1.3 Safety precautions when working on cooling system
  2
• 1.4 Safety precautions when working on ignition system
  3
• 2 Identification
  4
• 2.1 Engine number, engine data
  4
• 3 General notes
  6
• 3.1 Numbering of cylinders
  6
• 4 Repair instructions
  7
• 4.1 Rules for cleanliness
  7
• 4.2 Foreign objects in engine
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  15
• 1.3 Securing engine on engine and gearbox support
  20
• 1.4 Installing engine
  22
• 2 Assembly mountings
  24
• 2.1 Assembly overview - assembly mountings
  24
• 2.2 Removing and installing engine mountings
  24
• 2.3 Supporting engine in installation position
  30
• 2.4 Adjusting assembly mountings
  35
• 2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
  39
• 3 Engine cover panel
  40
• Crankshaft group
  41
• 1 Cylinder block (pulley end)
  41
• 1.1 Assembly overview - poly V-belt drive
  41
• 1.2 Removing and installing poly V-belt
  44
• 1.3 Removing and installing tensioner for poly V-belt
  46
• 1.4 Removing and installing vibration damper
  46
• 1.5 Removing and installing ancillary bracket
  48
• 1.6 Removing and installing engine bracket
  50
• 1.7 Renewing crankshaft oil seal - belt pulley end
  50
• 2 Cylinder block, gearbox end
  54
• 2.1 Assembly overview - cylinder block, gearbox end
  54
• 2.2 Assembly overview - drive plate
  55
• 2.3 Assembly overview - flywheel
  56
• 2.4 Removing and installing drive plate
  56
• 2.5 Removing and installing flywheel
  57
• 2.6 Renewing crankshaft oil seal - gearbox end
  58
• 2.7 Removing and installing sealing flange on gearbox side
  60
• 3 Crankshaft
  64
• 3.1 Assembly overview - crankshaft
  64
• 3.2 Locking crankshaft
  65
• 3.3 Crankshaft dimensions
  67
• 3.4 Allocation of main bearing shells
  68
• 3.5 Measuring axial clearance of crankshaft
  68
• 3.6 Measuring radial clearance of crankshaft
  69
• 4 Pistons and conrods
  70
• 4.1 Assembly overview - pistons and conrods
  70
• 4.2 Removing and installing pistons
  72
• 4.3 Checking piston and cylinder bore
  73
• 4.4 Separating new conrod
  75
• Cylinder head, valve gear
  77
• 1 Cylinder head
  77
• 1.1 Assembly overview - cylinder head
  77
• 1.2 Assembly overview - cylinder head cover
  79
• 1.3 Removing and installing cylinder head
  81
• 1.4 Removing and installing cylinder head cover
  86
• 1.5 Removing and installing vacuum pump
  87
• 1.6 Checking compression
  89
• 2 Cover for timing chain
  91
• 2.1 Removing and installing cover for timing chain
  91
• 2.2 Renewing oil seal for timing chain cover
  94
• 3 Chain drive
  97
• 3.1 Assembly overview - camshaft timing chains
  97
• 3.2 Assembly overview - timing chain
  98
• 3.3 Exploded view - drive chain for valve gear
  99
• 3.4 Checking valve timing
  100
• 3.5 Adjusting valve timing
  101
• 4 Valve gear
  108
• 4.1 Assembly overview - valve gear
  108
• 4.2 Removing and installing camshaft
  110
• 4.3 Removing and installing valve stem seals
  114
• 5 Inlet and exhaust valves
  119
• 5.1 Checking valve guides
  119
• 5.2 Valve dimensions
  119
• Lubrication
  120
• 1 Sump, oil pump
  120
• 1.1 Engine oil
  120
• 1.2 Assembly overview - sump and oil pump
  120
• 1.3 Removing and installing bottom section of sump
  122
• 1.4 Removing and installing top section of sump
  124
• 1.5 Removing and installing oil pump
  127
• 2 Oil filter, oil pressure switch
  132
• 2.1 Assembly overview - oil filter housing, oil pressure switch
  132
• 2.2 Draining oil filter housing
  134
• 2.3 Checking oil pressure and oil pressure switch
  135
• 2.4 Removing and installing oil filter housing
  141
• Cooling
  142
• 1 Cooling system, coolant
  142
• 1.1 Coolant hose schematic diagram
  142
• 1.2 Assembly overview - engine preheater
  144
• 1.3 Checking cooling system for leaks
  144
• 1.4 Draining and filling coolant
  146
• 2 Coolant pump, regulation of cooling system
  154
• 2.1 Assembly overview - coolant pump, thermostat
  154
• 2.2 Removing and installing coolant pump
  158
• 2.3 Removing and installing thermostat
  164
• 3 Radiator and radiator fan
  167
• 3.1 Assembly overview - radiator and radiator fan
  167
• 3.2 Removing and installing radiator
  169
• 3.3 Removing and installing radiator cowl
  171
• 3.4 Removing and installing radiator fan
  172
• Mixture preparation - injection
  173
• 1 Injection system
  173
• 1.1 Overview of fitting locations - injection system
  173
• 1.2 Filling and bleeding fuel system
  174
• 2 Injectors
  178
• 2.1 Assembly overview - fuel rail with injectors
  178
• 2.2 Removing and installing injectors
  178
• 2.3 Checking injectors
  180
• 3 Air filter
  185
• 3.1 Assembly overview - air filter housing
  185
• 3.2 Removing and installing air filter housing
  186
• 4 Intake manifold
  187
• 4.1 Assembly overview - intake manifold
  187
• 4.2 Removing and installing throttle valve module J338
  188
• 4.3 Removing and installing intake manifold
  189
• 5 Engine control unit
  193
• 5.1 Removing and installing engine control unit J623
  193
• 5.2 Removing and installing engine control unit J623 with protective housing
  194
• Exhaust system
  197
• 1 Exhaust pipes, silencers
  197
• 1.1 Assembly overview - silencers
  197
• 1.2 Removing and installing silencer
  198
• 1.3 Aligning exhaust system free of tension
  200
• 2 Emission control
  202
• 2.1 Assembly overview - emission control
  202
• 2.2 Removing and installing catalytic converter
  206
• 3 Secondary air system
  209
• 3.1 Assembly overview - secondary air system
  209
• 3.2 Removing and installing secondary air pump motor V101
  210
• 3.3 Checking secondary air inlet valve
  211
• 4 Exhaust manifold
  213
• 4.1 Assembly overview - exhaust manifold
  213
• Ignition system
  214
• 1 Ignition system
  214
• 1.1 Assembly overview - ignition system
  214
• 1.2 Removing and installing ignition coils with output stage
  216
• 1.3 Removing and installing knock sensor I G61
  217
• 1.4 Test data, spark plugs
  218