Engine Mechanical, Fuel Injection and Ignition

Chapter overview

• General, Technical Data
  1
• 1 Technical Data
  1
• 1.1 Engine Number
  1
• 1.2 Engine Data
  1
• Engine - Assembly
  4
• 1 Engine, Removing and Installing
  4
• 1.1 Engine, Removing
  5
• 1.2 Engine, Securing to Assembly Stand
  10
• 1.3 Engine, Installing
  11
• 1.4 Tightening Specifications
  13
• 1.5 Engine and Transmission Mounts, Aligning
  14
• 1.6 Assembly Mounts, Tightening Specifications
  15
• 1.7 Air Conditioning, General Information and Assembly Work
  15
• Engine - Crankshaft, Cylinder Block
  17
• 1 Engine, Disassembling and Assembling
  17
• 1.1 Assembly Overview
  17
• 1.2 Ribbed Belt, Removing and Installing
  20
• 2 Sealing Flanges and Flywheel/Drive Plate
  22
• 2.1 Assembly Overview
  22
• 2.2 Crankshaft Oil Seal, Belt Pulley End, Replacing
  24
• 2.3 Sealing Flange, Belt Pulley End, Removing and Installing
  26
• 2.4 Drive Plate, Removing and Installing
  28
• 3 Crankshaft, Servicing
  30
• 3.1 Crankshaft, Assembly Overview
  30
• 3.2 Crankshaft Dimensions
  32
• 4 Piston and Connecting Rod, Servicing
  33
• 4.1 Piston and Connecting Rod, Assembly Overview
  33
• 4.2 Piston and Cylinder Dimensions
  40
• Engine - Cylinder head, Valvetrain
  41
• 1 Cylinder Head, Servicing
  41
• 1.1 Cylinder Head, Assembly Overview
  42
• 1.2 Toothed Belt, Removing, Installing and Tensioning
  46
• 1.3 Cylinder Head, Removing and Installing
  51
• 1.4 Compression, Checking
  57
• 2 Valve Gear, Servicing
  61
• 2.1 Valve Gear, Assembly Overview
  61
• 2.2 Camshaft Oil Seal, Replacing
  65
• 2.3 Hydraulic Lifters, Checking
  70
• 2.4 Camshafts, Removing and Installing
  70
• 2.5 Valve Stem Seals, Replacing
  75
• 2.6 Valve Guides, Checking
  78
• 2.7 Valve Seats, Reworking
  78
• Engine - Lubrication
  81
• 1 Lubrication System, Servicing
  81
• 1.1 Engine Oil
  81
• 1.2 Lubrication System, Assembly Overview
  83
• 1.3 Oil Pan, Removing and Installing
  90
• 1.4 Oil Pressure and Oil Pressure Switch, Checking
  93
• Engine - Cooling system
  96
• 1 Cooling System, Servicing
  96
• 1.1 Cooling System Components on Body, Assembly Overview
  97
• 1.2 Cooling System Components on Engine, Assembly Overview
  99
• 1.3 Coolant Hose Connection Diagram
  103
• 1.4 Cooling System, Draining and Filling
  105
• 1.5 Radiator, Removing and Installing
  109
• 1.6 Coolant Pump, Removing and Installing
  111
• 1.7 Thermostat, Removing and Installing
  112
• 1.8 After-Run Coolant Pump, Checking
  113
• 1.9 Coolant Fan, Checking
  115
• Fuel supply
  116
• 1 Fuel Supply System Components
  116
• 1.1 Fuel Supply System, Safety Precautions
  116
• 1.2 Clean Working Conditions
  117
• 1.3 Fuel Tank with Attachments and Fuel Filter, Assembly Overview
  118
• 1.4 Fuel Delivery Unit, Removing and Installing
  121
• 1.5 Fuel Level Sensor, Removing and Installing
  123
• 1.6 Fuel Tank, Removing and Installing
  123
• 1.7 Crash Fuel Shut-Off
  125
• 1.8 Fuel Pump, Checking
  126
• 2 Electronic Power Control, Servicing
  133
• 2.1 Electronic Power Control System, Function
  133
• 2.2 Electronic Power Control System, Assembly Overview
  134
• 3 EVAP System, Servicing
  135
• 3.1 Functional Description
  135
• 3.3 EVAP System, Connection Diagram
  137
• Turbocharger, G-Charger
  139
• 1 Charge Air System with Turbocharger, Servicing
  139
• 1.1 Safety Precautions
  139
• 1.2 Clean Working Conditions
  140
• 1.3 Turbocharger with Attachments, Assembly Overview
  141
• 1.4 Charge Air Cooler System Components, Assembly Overview
  145
• 1.5 Charge Pressure Control and Vacuum Control, Overview
  146
• 2 Charge Air System Components, Checking
  149
• 2.1 Charge Pressure Control, Checking
  149
• 2.2 Charge Pressure Control Valve Pressure Unit, Checking
  150
• 2.3 Charge Pressure Bypass Valve, Checking
  151
• Multiport Fuel Injection (MFI)
  153
• 1 Injection System, Servicing
  153
• 1.1 Injection, General Information
  153
• 1.2 Safety Precautions
  154
• 1.3 Clean Working Conditions
  155
• 1.4 Component Locations, Overview
  155
• 1.5 Exhaust Gas Recirculation, Assembly Overview
  159
• 1.6 Air Filter Assembly, Overview
  167
• 1.7 Fuel Rail with Injectors, Assembly Overview
  168
• 1.8 Technical Data
  168
• 2 Components, Checking
  170
• 2.1 Injectors, Checking Injection Quantity and for Leaks
  170
• 2.2 Fuel Pressure Regulator and Residual Pressure
  173
• 3 Engine Control Module
  176
• 3.1 Engine Control Module, Replacing
  176
• 3.2 Adapting Functions and Components
  177
• 3.3 Engine Control Module DTC Memory, Checking and Erasing
  179
• Exhaust system, Emission controls
  181
• 1 Exhaust System Components, Servicing
  181
• 1.2 Muffler with Mounts, Assembly Overview
  184
• 2 Secondary Air Injection System
  186
• 2.1 Functional Description
  186
• 2.2 Secondary Air System Components, Assembly Overview
  187
• 2.3 Secondary Air System, Connection Diagram
  188
• 2.4 Combination Valve, Checking
  189
• 2.5 Combination Valve, Removing and Installing
  190
• Ignition/Glow plug System
  192
• 1 Ignition System, Servicing
  192
• 1.1 Ignition System, General Information
  192
• 1.2 Safety Precautions
  192
• 1.3 Ignition System Components, Assembly Overview
  194
• 1.4 Ignition Coils with Final Output Stage, Removing and Installing
  195
• 1.5 Spark Plug Test Data
  197