4 cyl. carburetor engine, mechanics (1.5, 1.6 and 1.8 litre engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Engine number
  1
• 1.3 Characteristic engine features
  1
• Removing and installing engine
  4
• 1 Removing and installing engine
  4
• 1.1 Removing and installing engine
  4
• 1.2 Notes on removing
  4
• 1.3 Taking engine off gearbox
  8
• 1.4 Attaching engine to repair stand
  10
• 1.5 Notes on installing
  10
• 1.6 Tightening torques
  12
• 1.7 Additional operations and instructions for vehicles with air conditioner
  12
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Dismantling and assembling engine
  15
• 1.2 Installing toothed belt
  22
• 1.3 Adjusting V belt tension for alternator
  25
• 2 Dismantling and assembling cylinder block, crankshaft and flywheel
  26
• 2.1 Dismantling and assembling cylinder block, crankshaft and flywheel
  26
• 2.2 Renewing crankshaft oil seal - pulley end
  33
• 2.3 Crankshaft dimensions
  35
• 2.4 Installing drive plate
  35
• 2.5 Subsequent machining of ignition timing notch
  37
• 3 Dismantling and assembling pistons and conrods
  39
• 3.1 Dismantling and assembling pistons and conrods
  39
• 3.2 Piston and cylinder dimensions
  47
• Cylinder head, Valve gear
  50
• 1 Removing and installing cylinder head
  50
• 1.1 Removing and installing cylinder head
  50
• 1.2 Installing cylinder head
  54
• 1.3 Checking compression pressure
  55
• 2 Servicing valve gear
  56
• 2.1 Servicing valve gear
  56
• 2.2 Reworking valve seats
  66
• 2.3 Removing and installing camshaft
  69
• 2.4 Checking hydraulic bucket tappets
  70
• 2.5 Renewing valve stem oil seals
  71
• 2.6 Checking valve guides
  72
• 2.7 Renewing valve guides
  72
• 2.8 Renewing camshaft oil seal
  72
• 2.9 Checking and adjusting valve clearance
  73
• Lubrication
  76
• 1 Removing and installing parts of lubrication system
  76
• 1.1 Removing and installing parts of lubrication system
  76
• 1.2 Checking oil pressure switch and oil pressure
  83
• Cooling system
  85
• 1 Removing and installing parts of cooling system
  85
• 1.1 Removing and installing parts of cooling system
  85
• 1.2 Draining and filling cooling system
  91
• 1.3 Checking cooling system and cap
  92
• 1.4 Modified radiator attachment
  92
• 1.5 Installing service cardboard air deflectors
  93
• Fuel supply system
  95
• 1 Removing and installing parts of fuel system
  95
• 1.1 Removing and installing parts of fuel system
  95
• 1.2 Removing and installing fuel tank with attachments
  97
• 1.3 Modified fuel tank with modified breather system
  106
• 1.4 Removing and installing fuel tank with attachments
  107
• 1.5 Removing and installing fuel tank
  110
• 1.6 Adjusting throttle cable - manual gearbox
  111
• 2 Servicing throttle controls - automatic gearbox
  113
• 2.1 Servicing throttle controls - automatic gearbox
  113
• 2.2 Adjusting throttle cable
  115
• 2.3 Adjusting accelerator pedal cable
  116
• 2.4 Adjusting throttle controls - automatic gearbox
  116
• Exhaust system
  119
• 1 Removing and installing parts of exhaust system
  119
• 1.1 Removing and installing parts of exhaust system
  119
• 1.2 Removing and installing clamping springs
  128
• 1.3 Tightening/loosening clamping springs
  128
• 1.4 Checking exhaust gas recirculation and exhaust afterburning
  129
• 2 Vehicles with 2B2 carburettor and air pump for exhaust afterburning (01.76 >)
  130
• 2.1 Vehicles with 2B2 carburettor and air pump for exhaust afterburning (01.76 >)
  130
• 2.2 Checking exhaust gas recirculation
  133
• 2.3 Checking exhaust afterburning
  134
• 3.2 Checking exhaust gas recirculation
  137
• 3.3 Checking exhaust afterburning
  137
• 4 Vehicles with engine code FN > 07.79, Keihin carburettor and manual gearbox
  139
• 4.1 Vehicles with engine code FN > 07.79, Keihin carburettor and manual gearbox
  139
• 4.2 Checking exhaust gas recirculation
  141
• 5 Vehicles with PICT carburettor and exhaust afterburning without air pump (03.78 >)
  143
• 5.1 Vehicles with PICT carburettor and exhaust afterburning without air pump (03.78 >)
  143
• 5.2 Checking exhaust gas recirculation
  145
• 5.3 Checking exhaust afterburning
  145