4 Cylinder Carburettor Engine Mechanics (1.6L), 2004▸

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Self-diagnosis
  2
• 1 Self diagnosis
  2
• Engine assembly
  3
• 1 Removing and installing engine
  3
• 1.1 Work sequence
  3
• 1.2 Tightening torques
  6
• Crankshaft group
  7
• 1 Engine
  7
• 1.1 Exploded view of engine
  7
• 1.2 Removing and installing alternator V-belt
  11
• 1.3 Adjusting alternator V-belt tension
  11
• 2 Sealing flange and pressure plate
  13
• 2.1 Exploded view of sealing flange and pressure plate
  13
• 2.2 Removing and installing crankshaft oil seal (pulley end)
  14
• 3 Crankshaft
  16
• 3.1 Exploded view of crankshaft assembly
  16
• 3.2 Crankshaft dimensions
  17
• 4 Pistons and conrods
  18
• 4.1 Exploded view of piston and conrod
  18
• 4.2 Checking pistons
  19
• Cylinder head, Valve gear
  21
• 1 Cylinder head
  21
• 1.1 Exploded view of cylinder head
  21
• 1.2 Removing and installing toothed belt
  22
• 1.3 Checking and adjusting valve timing
  23
• 1.4 Removing and installing cylinder head
  25
• 1.5 Checking cylinder head for distortion
  27
• 1.6 Checking compression
  27
• 2 Servicing valve gear
  28
• 2.1 Exploded view of valve gear
  28
• 2.2 Checking components of valve gear
  29
• 2.3 Reworking valve seats
  31
• 2.4 Removing and installing camshaft oil seal
  33
• 2.5 Removing and installing camshaft
  34
• 2.6 Checking hydraulic lifters
  36
• 2.7 Checking valve guides
  37
• 2.8 Renewing valve guides
  37
• 2.9 Renewing valve stem seals (with cylinder head fitted)
  38
• Lubrication
  41
• 1 Lubrication system
  41
• 1.1 Exploded view of lubrication system
  41
• 1.2 Specifications and capacities
  42
• 1.3 Checking oil pump backlash
  42
• 1.4 Checking oil pump axial clearance
  43
• 1.5 Markings on oil dipstick
  43
• 1.6 Checking oil pressure and oil pressure switch
  43
• Cooling system
  46
• 1 Removing and installing parts of cooling system
  46
• 1.1 Exploded view of cooling system - body side
  46
• 1.2 Exploded view of cooling system - engine side
  48
• 1.3 Exploded view of coolant pump
  49
• 1.4 Draining and filling cooling system
  50
• 1.5 Removing and installing coolant pump
  52
• 1.6 Removing and installing radiator and radiator fan
  53
• Fuel supply system
  55
• 1 Removing and installing parts of fuel supply system
  55
• 1.1 Exploded view of fuel system
  55
• 1.2 Safety precautions when working on the fuel supply system
  58
• 1.3 Rules for cleanliness
  58
• 1.4 Removing and installing fuel gauge sender
  58
• 1.5 Removing and installing fuel tank
  59
• 1.6 Gravity valve
  59
• 1.7 Check valve
  60
• 1.8 Adjusting throttle cable
  60
• Mixture preparation, Carburettor
  61
• 1 Air cleaner
  61
• 2 Servicing Keihin carburettor
  62
• 2.1 Exploded view of carburettor - top part
  62
• 2.2 Exploded view of carburettor - bottom part
  63
• 2.3 Carburettor technical information
  64
• 2.4 Arrangement of jets in carburettor
  65
• 2.5 Checking and adjusting idling speed and CO content
  65
• 2.6 Checking and adjusting cold idle speed
  65
• 2.7 Checking and adjusting choke valve gap
  66
• 2.8 Checking and adjusting quantity injected by accelerator pump
  66
• 2.9 Basic setting of throttle valve stage II
  67
• 2.10 Checking and adjusting float level
  68
• 2.11 Adjusting choke cable
  68
• Exhaust system
  69
• 1 Exploded view of exhaust system
  69
• Ignition system
  71
• 1 Motronic injection and ignition system
  71
• 1.1 Exploded view of ignition system
  71
• 1.2 Safety precautions
  72
• 1.3 Test data, spark plug
  72
• 1.4 Removing and installing distributor
  72
• 1.5 Checking ignition timing
  73
• 1.6 Checking transistorized control ignition module (T.C.I Unit)
  74
• 1.7 Checking Hall sender
  75
• 1.8 Checking ignition transformer
  77