1,8 litre Water Cooled Engine

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Engine list
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing and installing engine
  3
• 1.2 Removing
  3
• 1.3 Securing engine in repair stand
  4
• 1.4 Installing
  4
• 1.5 Tightening torques
  4
• Crankshaft group
  6
• 1 Dismantling and assembling engine
  6
• 1.1 Dismantling and assembling engine
  6
• 1.2 Installing toothed belt
  14
• 1.3 Adjusting alternator V-belt tension
  16
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  16
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  16
• 2.2 Removing and installing flywheell
  19
• 2.3 Renewing crankshaft oil seal - Flywheel end
  22
• 2.4 Renewing crankshaft oil seal - Pulley end
  23
• 2.5 Checking axial clearance (Crankshaft)
  24
• 2.6 Checking radial clearance (Crankshaft)
  25
• 2.7 Crankshaft dimensions
  25
• 2.8 Subsequent marking of ignition timing mark
  26
• 3 Dismantling and assembling pistons and conrods
  27
• 3.1 Dismantling and assembling pistons and conrods
  27
• 3.2 Checking radial clearance
  35
• 3.3 Piston and cylinder dimensions
  36
• Cylinder head, Valve gear
  37
• 1 Removing and installing cylinder head
  37
• 1.1 Removing and installing cylinder head
  37
• 1.2 Installing cylinder head
  39
• 1.3 Checking compressions
  40
• 2 Repairing valve gear
  41
• 2.1 Repairing valve gear
  41
• 2.2 Reworking valve seats
  48
• 2.3 Checking hydraulic bucket tappets
  49
• 2.4 Renewing camshaft oil seal
  50
• 2.5 Removing and installing camshaft
  51
• 2.6 Removing valve springs
  53
• 2.7 Checking valve guides
  54
• 2.8 Renewing valve guides
  54
• 2.9 Renewing valve stem seals
  55
• Lubrication
  57
• 1 Removing and installing parts of lubrication system
  57
• 1.1 Removing and installing parts of lubrication system
  57
• 1.2 Installing sump
  60
• 1.3 Optical and acoustic oil pressure warning system
  61
• Cooling system
  63
• 1 Removing and installing parts of cooling system
  63
• 1.1 Removing and installing parts of cooling system
  63
• 1.2 Removing and installing parts of cooling system
  66
• 1.3 Draining and filling cooling system
  68
• 1.4 Checking the cooling system and cap
  70
• Fuel supply system
  72
• 1 Removing and installing parts of the fuel system
  72
• 1.1 Removing and installing parts of the fuel system
  72
• 1.2 Part I
  72
• 1.3 Part II
  74
• 1.4 Part III
  76
• 1.5 Repairing accelerator cable
  78
• 1.6 Adjusting throttle controls
  79
• 1.7 Rules for cleanliness
  80
• 1.8 Removing fuel tank
  80
• 1.9 Removing and installing fuel gauge sender
  80
• 1.10 Checking fuel system for leaks
  81
• Mixture preparation, Carburetor
  83
• 1 Servicing Keihin carburettor
  83
• 1.1 Servicing Keihin carburettor
  83
• 1.2 Servicing Keihin carburettor (Carburettor top part)
  83
• 1.3 Servicing Keihin carburettor (Carburettor lower part)
  85
• 1.4 Carburettor data
  88
• 1.5 Idling speed adjustment
  89
• 1.6 Checking and adjusting cold idling speed
  90
• 1.7 Checking and adjusting choke valve gap
  91
• 1.8 Checking pulldown unit for leaks
  92
• 1.9 Checking vacuum reservoir for leaks
  92
• 1.10 Throttle valve basic setting stage II
  93
• 1.11 Checking and adjusting accelerator pump injection quantity
  93
• Exhaust system
  95
• 1 Servicing exhaust system
  95
• 1.1 Servicing exhaust system
  95
• Ignition system
  97
• 1 Servicing TCI-H ignition system
  97
• 1.1 Servicing TCI-H ignition system
  97
• 1.2 Distributor data spark plugs
  102
• 1.3 Installing distributor
  102
• 1.4 Adjusting ignition timing
  103
• 1.5 Checking distributor
  104
• 1.6 Checking voltage and resistance
  106
• 1.7 Checking ignition coil
  108
• 1.8 Checking TCI-H switch unit
  109
• 1.9 Checking Hall sender
  110
• 1.10 Removing and installing rotor
  111