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

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  8
• 1.3 Installing engine
  11
• 1.4 Assembly mountings
  13
• Crankshaft group
  14
• 1 Dismantling and assembling engine
  14
• 1.1 Assembly overview - add-on parts
  14
• 1.2 Assembly overview - chain drive
  20
• 1.3 Removing and installing poly V-belt
  24
• 1.4 Removing and installing exhauster pump for brake servo
  25
• 2 Sealing flange and flywheel or drive plate
  28
• 2.1 Assembly overview - sealing flange
  28
• 2.2 Renewing crankshaft sealing flange - belt pulley end
  29
• 2.3 Removing and installing valve timing housing
  32
• 2.4 Removing and installing seal on gearbox side
  35
• 2.5 Removing and installing drive plate
  36
• 3 Crankshaft
  38
• 3.1 Assembly overview - crankshaft
  38
• 3.2 Crankshaft dimensions
  39
• 3.3 Locking crankshaft
  40
• 4 Pistons and conrods
  43
• 4.1 Assembly overview - pistons and conrods
  43
• 4.2 Separating new conrod
  44
• 4.3 Checking pistons, piston rings and cylinder bores
  45
• 4.4 Piston and cylinder dimensions
  46
• Cylinder head, valve gear
  47
• 1 Cylinder head
  47
• 1.1 Assembly overview - cylinder head
  47
• 1.2 Removing and installing cylinder head cover
  49
• 1.3 Removing and installing chain guard cover
  50
• 1.4 Renewing chain guard cover seal
  54
• 1.5 Checking valve timing
  56
• 1.6 Adjusting valve timing
  57
• 1.7 Removing and installing cylinder head
  61
• 1.8 Checking compression
  67
• 2 Valve gear
  69
• 2.1 Assembly overview - valve gear
  69
• 2.2 Valve dimensions
  71
• 2.3 Checking valve guides
  71
• 2.4 Renewing valve stem seals
  72
• 2.5 Removing and installing camshafts
  75
• Lubrication
  80
• 1 Parts of lubrication system
  80
• 1.1 Engine oil
  80
• 1.2 Assembly overview - parts of lubrication system
  80
• 1.3 Assembly overview - oil filter bracket
  82
• 1.4 Draining oil filter housing
  83
• 1.5 Removing and installing lower part of sump
  84
• 1.6 Removing and installing upper part of sump
  85
• 1.7 Removing and installing oil pump, vehicles to model year 2007
  88
• 1.8 Removing and installing oil pump, vehicles from model year 2008
  92
• 1.9 Checking oil pressure and oil pressure switch
  96
• Cooling
  99
• 1 Parts of cooling system
  99
• 1.1 Assembly overview - parts of cooling system, engine side
  99
• 1.2 Assembly overview - parts of cooling system, body side
  103
• 1.3 Coolant hose schematic diagram
  104
• 1.4 Draining and filling with coolant
  105
• 1.5 Removing and installing coolant pump
  108
• 1.6 Removing and installing thermostat
  115
• 1.7 Removing and installing fan shroud with radiator fans V7
  117
• 1.8 Removing and installing radiator
  118
• 1.9 Checking cooling system for leaks
  120
• 1.10 Checking radiator fan
  123
• Fuel supply system
  125
• 1 Parts of fuel supply system - engine code BPS (plastic fuel tank)
  125
• 1.1 Safety precautions when working on fuel supply system
  125
• 1.2 Rules for cleanliness
  126
• 1.3 Assembly overview - fuel tank with attachments and fuel filter
  126
• 1.4 Emptying fuel tank
  129
• 1.5 Removing and installing fuel delivery unit
  134
• 1.6 Removing and installing fuel gauge sender
  136
• 1.7 Removing and installing fuel tank
  136
• 1.8 Assembly overview - fuel filter with attachments
  139
• 1.9 Removing and installing fuel filter
  140
• 1.10 Checking fuel pump
  141
• 1.11 Bleeding fuel system
  149
• 2 Parts of fuel supply system - engine code BPR (metal fuel tank)
  153
• 2.1 Safety precautions when working on fuel supply system
  153
• 2.2 Rules for cleanliness
  154
• 2.3 Assembly overview - fuel tank with attachments and fuel filter
  154
• 2.4 Emptying fuel tank
  157
• 2.5 Removing and installing fuel delivery unit
  160
• 2.6 Removing and installing fuel gauge sender
  163
• 2.7 Removing and installing fuel tank
  163
• 2.8 Removing and installing fuel filter
  166
• 2.9 Checking fuel pump
  167
• 2.10 Bleeding fuel system
  175
• 3 Electronic power control (EPC)
  179
• 3.1 Function of EPC system
  179
• 3.2 Assembly overview - accelerator module
  179
• 4 Activated charcoal filter system
  181
• 4.1 Function
  181
• 4.2 Overview of activated charcoal filter system
  182
• 4.3 Assembly overview - parts of activated charcoal filter system
  185
• 4.4 Removing and installing activated charcoal filter and fuel system diagnostic pump V144
  187
• 4.5 Checking fuel system for leaks
  188
• Mixture preparation - injection
  196
• 1 Injection system
  196
• 1.1 General notes regarding injection
  196
• 1.2 Safety precautions
  197
• 1.3 Rules for cleanliness
  197
• 1.4 Technical data
  198
• 1.5 Overview of fitting locations
  198
• 1.6 Assembly overview - intake manifold with attachments
  201
• 1.7 Assembly overview - fuel rail with injectors
  203
• 1.8 Assembly overview - air filter
  204
• 1.9 Removing and installing throttle valve module J338
  205
• 1.10 Removing and installing intake manifold
  206
• 1.11 Removing and installing injectors
  209
• 2 Checking components
  212
• 2.1 Checking injectors for leaks and quantity injected
  212
• 2.2 Checking fuel pressure regulator and holding pressure, engine code BPS
  214
• 2.3 Checking fuel pressure regulator and holding pressure, engine code BPR
  217
• 3 Engine control unit
  222
• 3.1 Reading and erasing engine control unit fault memory
  222
• 3.2 Removing and installing engine control unit
  223
• Exhaust system
  224
• 1 Parts of the exhaust system
  224
• 1.1 Assembly overview - exhaust manifold with attachments
  226
• 1.2 Removing and installing exhaust manifold
  226
• 1.5 Assembly overview - silencers with mountings
  232
• 1.6 Removing and installing front exhaust pipe with catalytic converter
  233
• 1.7 Separating and joining front and rear silencers
  234
• 1.8 Aligning exhaust system free of stress
  235
• 2 Secondary air system
  237
• 2.1 Function
  237
• 2.2 Assembly overview - secondary air system
  237
• 2.3 Removing and installing secondary air pump motor V101
  239
• 2.4 Checking secondary air inlet valve N112
  240
• Ignition system
  242
• 1 Ignition system
  242
• 1.1 General notes on ignition system
  242
• 1.2 Safety precautions
  242
• 1.3 Assembly overview - ignition system
  242
• 1.4 Removing and installing ignition coils with output stage
  244
• 1.5 Test data, spark plugs
  245