5-cylinder injection engine (4-valve), mechanics

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Notes on removing
  4
• 1.2 Notes on installing
  9
• 1.3 Assembly mountings
  11
• 1.4 Additional information and assembly work for vehicles with air conditioner
  12
• Crankshaft group
  13
• 1 Dismantling and assembling engine
  13
• 1.1 Part I
  14
• 1.2 Part II
  17
• 1.3 Removing and installing poly V-belt
  19
• 2 Removing and installing sealing flange and dual mass flywheel/drive plate
  21
• 2.1 Renewing crankshaft oil seal, vibration damper end
  23
• 2.2 Removing and installing drive plate
  25
• 3 Removing and installing crankshaft
  27
• 3.1 Fitting sender wheel to crankshaft
  28
• 4 Dismantling and assembling pistons and conrods
  29
• 4.1 Installing piston
  31
• 4.2 Piston and cylinder dimensions
  32
• Cylinder head, valve gear
  33
• 1 Cylinder head
  33
• 1.1 Removing and installing
  36
• 1.2 Removing and installing cylinder head cover
  39
• 1.3 Removing and installing cylinder head
  41
• 1.4 Checking valve timing
  48
• 1.5 Adjusting valve timing (installing timing chains)
  48
• 1.6 Checking compression
  53
• 2 Valve gear
  57
• 2.1 Valve dimensions
  60
• 2.2 Camshaft identification, valve timing
  61
• 2.3 Dismantling and assembling valve timing housing
  61
• 2.4 Reworking valve seats
  61
• 2.5 Removing and installing camshafts
  63
• 2.6 Checking camshaft timing control/adjustment
  69
• 2.7 Checking valve guides
  74
• 2.8 Renewing valve stem seals
  74
• Lubrication
  77
• 1 Removing and installing parts of lubrication system
  77
• 1.1 Engine oil
  77
• 1.2 Assembly overview - sump
  77
• 1.3 Dismantling and assembling oil filter housing/engine mounting
  80
• 1.4 Dismantling and assembling oil pump
  81
• 1.5 Removing and installing oil sump
  82
• 1.6 Checking oil pressure and oil pressure switch
  87
• Cooling
  90
• 1 Removing and installing parts of cooling system
  90
• 1.1 Parts of cooling system, body side
  90
• 1.2 Parts of cooling system, engine side
  93
• 1.3 Dismantling and assembling compact bracket
  94
• 1.4 Coolant hose schematic diagram
  96
• 1.5 Dismantling and assembling thermostat housing
  97
• 1.6 Draining and filling coolant
  99
• 1.7 Removing and installing radiator
  103
• 1.8 Removing and installing viscous fan coupling
  105
• 1.9 Removing and installing viscous fan mounting bush
  106
• 1.10 Checking continued coolant circulation pump
  110
• Fuel supply system
  112
• 1 Removing and installing parts of fuel supply system
  112
• 1.3 Safety precautions when working on fuel supply system
  118
• 1.4 Rules for cleanliness
  119
• 1.5 Removing, installing and checking suction-jet pump: vehicles with four-wheel drive
  119
• 1.6 Crash fuel shut-off
  121
• 1.7 Removing and installing fuel delivery unit: front-wheel drive vehicles
  122
• 1.8 Removing and installing fuel delivery unit: four-wheel drive vehicles
  123
• 1.9 Removing and installing fuel gauge sender: vehicles with front-wheel drive
  126
• 1.10 Removing and installing fuel tank
  126
• 1.11 Checking fuel pump
  128
• 2 Electronic power control (EPC)
  137
• 2.1 Function of EPC system
  137
• 2.2 Repairing parts of electronic power control (EPC)
  137
• 2.3 Checking accelerator position sender
  139
• 3 Activated charcoal filter system
  143
• 3.1 Function
  143
• 3.2 Repairing parts of activated charcoal filter system
  143
• 3.3 Test solenoid valve 1 for activated charcoal filter
  145
• 3.4 Checking fuel tank breather
  147
• Exhaust system
  150
• 1 Removing and installing parts of exhaust system
  150
• 1.2 Silencers with mountings: vehicles with front-wheel drive
  154
• 1.3 Silencers with mountings: vehicles with four-wheel drive
  155
• 1.4 Checking catalytic converter
  156
• 2 Secondary air system
  159
• 2.1 Removing and installing parts of secondary air system
  159
• 2.2 Checking secondary air system
  161
• 2.3 Checking secondary air pump motor
  164
• 2.4 Checking combination valve
  166