1999 FIAT PUNTO air filter

Maintenance procedures - diesel models ib.?
Every 10 000 miles (15 000 km) or 12 months
5 Brake warning lamp operation check 1
1 With Ihe ignition Key inserted and turned to the MAR position, open the bonnet and depress the button on the top of the brake
fluid
reservoir cap (see illustration). I
As
the button is pressed, the brake warning
lamp
on the instrument panel should light. 3 If Ihe lamp fails to illuminate, check the operation of the level switch using a continuity taster, then refer to Chapter t2, Section 5,
and
check the Instrument panel bulb.
6 Front brake pad check ^
I
1 firmly apply Ihe handbrake, then jack up the front of the car and support it securely on arie stands (see Jacking and vehicle support). Remove the front roadwheels. 2 Using a steel rule, measure the thickness of
the
friction material of the brake pads on both brakes. This must not be less than 1.5 mm. Ctefc the thickness of the pad friction material through the hole on the front of the caliper
|see
lustration), 3
For a
comprehensive check, the brake pads should be removed and cleaned. The operation of the caliper can then also bo checked, and the condition of the brake disc iteeil can be fully examined on both sides. Refer to Chapter 9 for further Information. 4 If any pad's friction material Is worn to the specified thickness or less, all lour pads must to renewed as a set. Refer to Chapter 9. 5 On completion refit the roadwheels and lower the car to the ground.
7 Underbody sealant check f^
1 Jack up the front and rear of the car and support on axle stands (see Jacking and
vehicle
support). Alternatively position the car over
an
Inspection pit. 2 Check the complete underbody, wheel housings and side sills for corrosion and/or damage to the underbody sealant. If evident,
rapairi

8
Hose
and fluid leak check
1 Visually inspect the engine Joint faces. g3skets and seals for any signs of water or oil leaks. Pay particular attention to the areas
5.1 Depress tho button on the top of the brake fluid reservoir cap
around the camshaft cover, cylinder head, oil filter and sump joint faces. Bear in mind that, over a period of time, some very slight seepage from these areas is to be expected -what you are really looking for is any indication of a serious leak (see Haynes Hint). Should a teak be found, renew the offending gasket or oil seal by referring to the appropriate Chapters In this manual, 2 Also check the security and condition of all the engine-related pipes and hoses. Ensure thai all cable-ties or securing clips are In place and in good condition. Clips which are broken or missing can lead to chafing of the hoses, pipes or wiring, which could cause more serious problems In the future. 3 Carefully check the radiator hoses and heater hoses along their entire length. Renew any hose which is cracked, swollen or deteriorated. Cracks will show up better If the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the cooling system components. Hose clips can pinch and puncture hoses, resulting in leaks. 4 Inspect all the cooling system components (hoses. )olnt faces etc.) for leaks. A leak in the cooling system will usually show up as white or rust-coloured deposits on the area adjoining the leak, Where any problems of this nature are found on system components, renew the component or gasket with reference to Chapter 3. 5 With the vehicle raised, inspect the fuel tank and filler neck for punctures, cracks and other damage, The connection between the filler neck and tank is especially critical. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deteriorated rubber. 6 Carefully check all rubber hoses and metal fuel lines leading away from the fuel tank. Check for loose connections, deteriorated hoses, crimped lines, and other damage. Pay particular attention to the vent pipes and hoses, which often loop up around the filler neck and can become blocked or crimped. Follow the lines to the front of the vehicle, carefully Inspecting them all the way. Renew damaged sections as necessary.
6.2 Check the thickness of the pad friction material through the hote on the front of the caliper
7 With the vehicle raised, check along the length of the underside for leaks from the metal brake lines, caused by damage or corrosion. 8 At each front brake caliper, check the area around the brake pipe unions and the bleed nipples for hydraulic fluid leakage, 9 Remove the front roadwheels and chock for fluid leakage from the area around the caliper piston seal. Check that the tip of the piston dust seal is correctly located in its groove. If it has been displaced, the brake caliper should be removed and overhauled as described in Chapter 9, to check for internal dirt Ingress or corrosion. 10 Check the area surrounding the master cylinder and vacuum servo unit for signs of corrosion, Insecurity or hydraulic fluid leakage. Examine the vacuum hose leading to the servo unit for signs of damage or chafing. 11 From within the engine compartment, check the security of all fuel hose attachments and pipe unions, and Inspect the fuel hoses and vacuum hoses for kinks, chafing and deterioration. 12 Where applicable, check the condition of the power steering fluid hoses and pipes.
A leak in the cooling system will usually show up as white or rust coloured deposits on the area adjoining the leak.

Every 10 000 miles - diesel models ib«9
4 Completely unscrew the filter and pour the remaining contents into the container. Ensure (hat the rubber sealing ring comes away with
me
fitter and unscrew the drain screw from the
bottom
of tho filter (see illustrations). 5 Wipe clean the contact surfaces then smear
a
ittfe fuel on the sealing rubber of the new Nter. 6 Screw on the new filter fully using the hands orty. 7 Prime the fuel system and start the engine wth reference to Chapter 4C. Check for any signs of fuel leakage around the new filter.
13 Air fitter renewal
t Release the retaining clips and withdraw
Ihe
air cleaner cover a little way from the main body. Leave the cover attached to the inlet duct. 2 Lift out the filter element (see illustration). 3 Remove any debris that may have collected Inside the air cleaner and wipe the Inner surfaces clean. 4 Fit a new air filter element in position, ensuring that the edges are securely seated. 6 Refit the air cleaner top cover and snap the retaining clips into position.
14 Pollen filter renewal
t
1 The pollen filter (where fitted) Is located under the engine bulkhead cover pane). 2 Refer to Chapter 12 and remove both windscreen wiper arms. 3 Undp tho rubber seal from the relevant end of
the top
of the engine compartment bulkhead. 4 Unscrew the retaining fastener screws and Duiout the fasteners securing the bulkhead eovar panel in position. Release the cover panel from the base of the windscreen and remove it from the vehicle. 5 Pivot the pollen filter cover upwards and away then release the retaining clips and withdraw the filter from Its housing (see lustration).
12.3 Using an olt filter strap to loosen the fuel filter 6 Wipe clean the filter housing then fit the new filter, Clip the filter securely In position and refit the cover. 7 Refit the trim cover, secunng it >n position with the fasteners, and seat Ihe rubber seal on the bulkhead.
12.4a Removing the fuel filter
15 Steering and §S> suspension check ^
Front suspension and steering check 1 Raise the front of the vehicle, and securely support it on axle stands (see Jacking and vehicle support). 2 Visually Inspect the balljoint dust covers and the steering rack-and-pinion gaiters for splits, chafing or deterioration. Any wear of Ihese components will cause loss of lubricant, together with dirt and water entry, resulting in rapid deterioration of the balljoints or steering gear. 3 On vehicles with power steering, check the fluid hoses for chafing or deterioration, and the pipe and hose unions for fluid leaks. Also check for signs of fluid leakage under pressure from the steering gear rubber gaiters, which would indicate failed fluid seals within the steenng gear. 4 Grasp the roadwheel at the 12 o'clock and 6 o'clock positions, and try to rock it (see illustration). Very slight free play may be felt, but if the movement is appreciable, further investigation is necessary to determine the
fplllll iHpjiiisisps fa^aJw a LJgr >
H58B92
12.4b Showing the drain screw components on the bottom of the fuel filter source. Continue rocking the wheel while an assistant depresses the footbrake. If the movement Is now eliminated or significantly reduced, it is likely that the hub bearings are at fault. If the free ptay is still evident with the footbrake depressed, then there Is wear In the suspension joints or mountings. 5 Now grasp the wheel at the 9 o'clock and 3 o'clock positions, and try to rock it as before. Any movement felt now may again be caused by wear in the hub bearings or the steering track-rod balljoints. If the inner or outer balljoint Is worn, the visual movemont will be obvious. 6 Using a large screwdriver or flat bar. check for wear in the suspension mounting bushes by levering between the relevant suspension component and its attachment point. Some movement is to be expected as the mountings are made of rubber, but excessive wear should be obvious. Also check the condition of any visible rubber bushes, looking for splits, cracks or contamination of the rubber.
13.2 Removing the air filter element 14.5 Location of pollen filter 15.4 Rocking a roadwheel to check for wear in the steering/suspension components

2A«1
Chapter 2 Part A:
SOHC (8-valve) petrol
engine in-car repair procedures
Contents
Auxiliary drivebelts • removal and refitting See Chapter 1A Gamstaft cover - removal and refitting 6 Camshaft oil seal - renewal 7 Camshaft • removal and refitting See Chapter 20 Crankshaft oil seals - renewal 8 Cylinder compression test 3 Cylinder head - dismantling and overhaul See Chapter 20 Cylinder head - remove] and refitting 9 Engine mountings - Inspection and renewal 11 Engine oil and filter • renewal See Chapter 1A
Degrees of difficulty
Engine oil level check See Weekiy checks Flywheel/driveplate • removal, inspection and refitting 10 General Information 1 Location of TOC on No 1 cylinder 2 Oil pump and pick-up tube - removal, inspection and refitting 13 Sump • removal and refitting 12 Timing belt and covers • removal and refitting .. 4 Timing belt tensioner and sprockets - removal, inspection and refitting 5 Vafve clearance check and adjustment See Chapter 1A
Easy, suitable (or twics with little |g experience ^
Fairty easy, suitable jk for beginner with & some experience ^
Fatrty difficult, ^ suitable for competent ^ CKYmechanic ^
Difficult, suitable for ^ experienced DIY « mechanic ^
Veiy difficult, ^ aiitabte for expert DIY « or professional
Specifications
General Engine code:' 1108 cc engine (55 models): Up to May 1997 176.A6.000 May 1d97 onwards • . 176.B2.000 1242 cc engine (60 models): Up to May 1997 176.B1.000 May 1997 onward 176.B4.000 1242 cc engine (75 modete) 176.A8.000
•Note:
See Vehicle Identification for the location of code marking on the engine. 8cre: 11O0OC engine 70.0 mm 1242 cc engine 70.8 mm Stroke: 1108 cc engine 72.0 mm 1242 cc engine 78.86 mm Compression ratio: 1108 cc engine 9.6:1 1242 cc engine with single-point injection 9.6:1 1242 cc engine with multi-point injection 9.8:1 Rrlng order 1-3-4-2
No 1
cylinder location Timing belt end of engine
TnUng
belt tension See text
Lubrication system
Oil
pump type By-rotor driven from front of crankshaft Outer rotor-to-housing clearance 0.080to0.186mm
Axial
clearance 0.025 to 0.056 mm

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
Torque wrench settings Nm
IM
ft Camshaft cover 8 6 Camshaft sprocket 70 52 Cylinder head; Stage 1 30 22 Stage 2 Angle-lighten a further 90° Siege 3 Angle-tighten a further 90B Crankshaft sprocket centre bott 100 74 Engine mounting bolt: M10X1.25 69 44 MB 25 18 Engine mounting nut (M10x 1.25) 60 44 Flywheet/driveplate 44 32 Sump 10 7 Timing belt tensJoner 28 21
1 General information
Using this Chapter Chapter 2 is divided Into four Parts: A. 8. C and D. Repair operations that can be carried out with the engine in the vehicle are described in Part A. SOHC (8-valve) petrol engines, Part B. DOHC (18-valve) petrol engines and Part C, diesel engines. Part 0 covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A, 9 and C, the assumption Is made lhat the engine is Installed in the vehicle, with sll ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling Information which precedes each operation may be ignored.
Engine description Throughout this Chapter, engines are identified by their capacities. A listing of all engines covered, together with their code letters, is given in the Specifications. The engines covered In this Part of Chapter 2 are water-cooled, single overhead camshaft, in-line four-cylinder units, with cast Iron cylinder Mocks and aluminium-alloy cylinder heads. All are mounted transversely at the front ot the vehicle, with the transmission bolted to the left-hand side of the engine, The cylinder head carries the camshaft which is driven by a toothed timing belt and runs In three bearings. It also houses the inlet and exhaust valves, which are closed by single coil springs, and which run in guides pressed Into the cylinder head. The camshaft actuates the vatves directly via cam followers mounted in the cylinder head. Adjustment of the valve clearances is by means of shims located on top of the followers. The cylinder head contains Integral oitways which supply and lubricate the tappets. The crankshafl Is supported by five main bearings, and endftoat is controlled by a thrust bearing fitted to the upper section of the centre main bearing.
Engine coolant is circulated by 8 pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from ihe front of the crankshaft. Oil Is drawn from the sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, It is distributed to the cylinder head, where It lubricates the camshaft journals and tappets, and also to the crankcase, where il lubricates the main bearings, connecting rod big and smell-ends, gudgeon pins and cylinder bores. On 1242 cc engines, oil jets are fitted lo the base of each cylinder bore -these spray oil onto the underside of the pistons, to Improve cooling.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the car a) Compression pressure - testing b) Auxiliary drivebelt - removal and refitting (refer to Chapter 1A) c) Vatve clearances - checking and adjustment (refer to Chapter I A) d) Camshaft cover - removal and refitting e) Timing belt and covens - removal and refitting f) Timing belt tensioner and sprockets -removal and refitting g) Cylinder head - removal and refitting' h) Camshaft and cam followers • removal and refitting' t) Camshaft oil seal - renews/ j) Crankshaft oil seals - renewal k) Flywheel/dnvepfate • removal, inspection and refitting l) Engine mountings - inspection and renewal m)Sump - removal and refitting n) Oil pump and pick-up tube assembly
•
removai. inspection and refitting *Cylinder head dismantling procedures are detailed In Chapter SO, with details of camshaft and cam follower removal. Note: It is possible to remove the pistons and connecting rods (after removing the cylinder head and sump) without removing the engine. However, this is not recommended. Work of
this nature is more easily and thoroughly completed with the engine on the bench, as described In Chapter 2D.
2 Location of
TDC
on % No
1
cylinder
General Information 1 The camshaft Is driven by the crankshaft, by means of sprockets and a timing belt. Both sprockets rotate In phase with each other and this provides the correct valve timing as the engine rotates. When (he liming belt is removed during servioing or repair, it Is possible for the camshaft and crankshaft to rotate Independently of each other and the correct valve timing Is then lost. 2 The design of the engines covered In this Chapter are such lhat potentially damaging piston-to-valve contact may occur if the camshaft is rotated when any of the pistons are stationary at, or near, the top of their stroke. 3 For this reason it is important lhat Ihe correct phasing between the camshaft and crankshaft is preserved whilst the timing belt Is off the engine. This is achieved by setting the engine In a reference position (known as Top Dead Centre or TDC) before the timing belt Is removed and then preventing the camshaft and crankshaft from rotating until the belt is refitted. Similarly, if ths engine has been dismantled for overhaul, the engine can be set to TOC during reassembly to ensure that Ihe correct shaft phasing is restored. 4 TDC is the highest point In the cylinder that each piston reaches as the crankshaft turns. Each piston reaches TDC at Ihe end of the compression stroke and again at the end of the exhaust stroke. However, for the purpose of timing the ongine. TDC refers to the position of No 1 piston at the end of Its compression stroke. On ail engines In this manual, No 1 piston (and cylinder) Is at the timing belt end of the engine. 5 The camshaft sprocket Is equipped with a marking which, when aligned with a reference marking on the cylinder head, indicates that the camshaft is correctly positioned for cyl-inder No 1 al TDC on its compression stroke.

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
require cutting with a sharp Knife to release
the sump.
Clean away all old gasket material. Refitting
5
Wwn refitting, a bead of RTV silicone nsiant gasket 3 mm in diameter should be applied lo the sump flange. Fit the sump, screw in tha fixing screws and tighten to the spscabed torque. Note the flange end fixing
nuts
(see illustrations).
6
'//ait one hour for the gasket compound to henjai before filling with engine oil. 7 Refit the flywheel housing cover plate and tohaust system front pipe.
8
lower the vehicle to the ground and fill the eng'rewith oil (see Chapter 1A). Check the oil
fevai
alter running the engine for a few minutes.

13 Oil
pump and pick-up tube - >>>
removal,
inspection and ^ refitting ^
Removal 1 Drain tho engine oil and remove the sump adsswibed in Section 12.
%
Unscrew and remove the oil filter cartridge .
(see
Chapter 1A|. 3 Remove the timing belt as described In
Section A.
4
Lock
the crankshaft against rotat>on either by tfacng a block of wood between a crankshaft wb and the inside of the crankcase, or by jjmning the flywheel starter ring gear with a
lutabfe
tool.
I3v8a Removing the oil pump pressure relief valve
12.5a Tightening a sump fixing screw
5 Unscrew and remove the crankshaft sprocket boll and take off the sprocket. If it is tight, use two screwdrivers to lever it off, or use a two or three-legged puller. 6 Unbolt and remove the oil pick-up/filter screen assembly. Note the sealing washer. 7 Extract the oil pump fixing bolts and withdraw the pump. Remove the gasket.
Inspection 8 The oil pump incorporates a pressure relief valve, which can be removed for examination by depressing the spring plunger and pulling out the keeper plate (see illustrations). 9 If pump wear Is suspected, check the gears in the following way. Extract the fixing screws and remove the rear cover plate. The screws are very tight, and will probably require the use of an impact screwdriver (see illustration).
pressure relief valve
12.5b Sump fixing screw and flange end fixing nut
10 Check the clearance between the outer gear and the pump housing using feeler blades. Check the gear endtloat by placing a straightedge across the pump body, and checking the gap between the straight-edge and gear face (see illustrations). If the clearances are outside the specified tolerance, renew the oil pump complete. 11 If the pump is unworn, refit the rear cover plate and tighten the screws fully. 12 Apply air pressure from a tyre pump to the oil pump oil ducts, to clear any sludge or other material. Prime the pump by pouhng clean engine oil into its inlet duct, at the same time turning the oil pump inner gear with the fingers. 13 Lever out the oil seal and drive a new one squarely into the oil pump casing (see illustrations). Lubricate the oil seal lips.
13.9 Using an impact screwdriver to remove the oil pump rear cover pfate screws
13,19s Measuring oil pump outer gear-to- 13.10b Measuring oil pump gear endtloat pump housing clearance

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
13.13b Using a socket to lit a new oil sea! to the oil pump
Refitting 14 Bolt the pump into position using a new joint gasket (see illustrations). Note that on© bolt Is longer than the others. 15 Bolt on the oil pick-up assembly using a
13.14a Using a new gasket. ..
new sealing washer. 16 Lock the crankshaft as described in paragraph 4, then fit the crankshaft sprocket and bghlen the bolt to the specified torque. 17 Fit the sumpaa described in Section 12. Screw on a new oil filter cartridge.
13.14b ... reftt the oil pump
18 Fit and tension the timing belt as described in Section 4. 19 Fill the engine with oil (see Chapter 1A>. 20 Run the engine for a few minutes, then check and top-up the oil level (see Weekly checks).
expert22 f
a http://rutracker.org

2B»1
Chapter 2 Part B:
DOHC (16-valve) petrol
engine in-car repair procedures
Contents
Auxiliary drlvebelts - removal and refitting See Chapter 1A Camshaft oil seal - renewal 6 Camshafts and cam followers - removal, inspection and refitting .. 9 Crankshaft oil seals • renewal 7 Cylinder compression test 3 Cylinder head - dismantling and overhaul See Chapter 2D Cylinder head • removal and refitting 10 Cylinder head extension • removal and refitting 8 Engine assembly/Valve timing holes - general information and usage 2
Engine mountings - inspection and renewal 12 Engine oil and filter - renewal See Chapter 1A Engine oil level - check See Weekly checks Flywheel - removal, Inspection and refitting 11 General Information 1 Oil pump and pick-up tube - removal, inspection and refitting 14 Sump - removal and refitting 13 Timing belt and covers - removal and refitting 4 Timing belt tensioner and sprockets • removal and refitting 5
Degrees of difficulty

Easy,
sitable
for
J; Fairly
easy,
suitable Fairtydifflcutt, ^
Difficult,
aitabtefcr Very
difficult,
^ nwice
wim
(ttls for beginner with £
suitable
for competent KYmechanic ^ experienced DIY > suitable
for
expert DIY« experience
some
experience £
suitable
for competent KYmechanic ^ mechanic > or professional ^
Specifications
General Engine code* 176.09.000 •Note: See Vehicle Identification for the location of code marking on the engine. Bore 70.8 mm Stroke 78.86 mm Capacity 1242 cc Compression ratio 10.2:1 Firing order 1-3-4-2 No
1
cylinder location Timing belt end of engine Timing belt tension See text
Camshaft Orlve Toothed belt
No
of bearings 3 Camshaft bearing journal diameters: Ho
1
bearing 35.000 to 35.015 mm
Mo
2 bearing 48.000 to 48.015 mm No 3 bearing 49.000 to 49.015 mm Camshaft bearing Journal running clearance 0.030 to 0.070 mm Camshaft endfloat 0.15 to 0.34 mm
Cylinder head extension Camshaft bearing diamelers: No
1
bearing 35.045 to 35.070 mm No 2 bearing 48,045 to 48.070 mm No 3 bearing 49.045 to 49.070 mm
Cam
follower (tappet) type Hydraulic
Cam
follower (tappet) diameter 28.353 to 28.370 mm
Cam
follower (tappet) bore diameter in cylinder head extension 28.400 to 28.421 mm
Cam
follower (tappet) running clearance 0.046 to
0.051
mm

2A*10 SOHC (8-valve) petrol engine in-car repair procedures
Lubrication system Oil pump type By-rotor driven from front of crankshaft Outer rotor-io-houslng clearance 0.100 to 0.210 mm Axial clearance 0.025 to 0.070 mm
Torque wrench settings Nm itrf ft Camshaft driven gears 120 89 Camshaft sprocket 120 89 Crankshaft sprocket centre bolt: Stage
1
20 15 Stage 2 Angle-tighten a further 90® Cylinder head: Stage
1
30 22 Stage 2 Angle-tighten a further 90" Stage 3 Angle-tighten a further 90° Cylinder head extension to cylinder head 15 11 Engine mounting bolt: M10
x
1.25 59 44 M8 25 18 Engine mounting nut (MlOx 1.25) 60 44 Flywheel 44 32 Timing belt tensioner 25 18 Sump 10 7
1 General information
Using this Chapter Chapter 2 is divided into four Parts; A, B. C and O. Repair operations that can be carried out with the engine hi the vehicle are described in Part A. SOHC (8-valve) petrol engines. Part B, DOHC (16-valve) petrol engines and Pari C, dlesei engines. Part D covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A, B and C, the assumption Is made that the engine is Installed In the vehicle, with all ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored.
Engine description Throughout this Chapter, engines are identified by their capacities. A listing of all engines covered, together with their code letters, Is given in the Specifications. The engine covered in this Part of Chapter 2 is a water-cooled, double overhead camshaft, in-line four-cylinder unit, with cast iron cylinder block and aluminium-alloy cylinder head. The unit is mounted transversely at the front of the vehicle, with the transmission bolted to the left-hand side of the engine. The cylinder head houses the eight inlet and eight exhaust valves, which are closed by single coil springs, and which run in guides pressed Into the cylinder head. The two camshafts are housed in 8 cylinder head extension which is bolted to the top of the cylinder head. The exhaust camshaft is driven by a toothed timing belt and In turn drives the inlet camshaft via a pair of gears located at the left-hand end of the cylinder head extension.
The camshafts actuate the valves directly via self-adjusting hydraulic cam followers mounted in the cylinder head extension. The crankshaft is supported by five main bearings, and endfioat is controlled by a thrust bearing fitted to (he upper section of the centre main bearing. Engine coolanl is circulated by a pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from Ihe sump through a strainer, and then forced through an externally-mounted, replaceable screw-on filter. From there, It is distributed to the cylinder head and cylinder head extension, where it lubricates the camshaft journals and cam followers, and also to the crankcase, where it lubricates the main bearings, connecting rod big and small-ends. gudgeon pins and cylinder bores. Oil Jets are fitted to the base of each cylinder bore - these spray oil onto the underside of the pistons, to improve cooling.
Repair operations possible with the engine in the car The following work can be carried out with the engine in the car: a) Auxiliary drivebett - removal and refitting (refer to Chapter 1A) b) Oil pump and pick-up tube assembly -removal, Inspection and refitting c) Timing belt and covers • removal and refitting d) Timing belt tensioner and sprockets -removal and refitting e) Cylinder head - removal and refitting' f) Cylinder hoad extension - removal and refitting g) Camshaft and cam followers - removal and refitting h) Camshaft oil seal - renewal i) Crankshaft oil seals • renewal
f) Flywheel - removal, inspection and
refitting
k) Engine mountings - Inspection and
renews'
f) Sump • removal and refitting 'Cylinder head dismantling procedures are detailed In Chapter 2D. Note 1: It is possible to remove the
pistons
and connecting rods (after removing (to cylinder head and sump) without removing
tt*»
engine. However, this Is not recommended. Work of this nature is more easily and thoroughly completed with the engine on fix bench, as described in Chapter 20. Note
2x
Many of the procedures in this Ctopfer entail the use of numerous special tools. Whet possible, suitable alternatives are descnbei with details of their fabrication. Before starring any operations on the engine, read through
tto
entire procedure first to familiarise yourself
wft
the work involved, tools to be obtained mi new parts that may be necessary.
2 Engine assembly/ valve timing holes -genera! information
and
usage
Note: Do not attempt to rotate the angint whilst the camshafts are locked In position,
il
the engine is to be left in this state foratofi$ period of time. It Is a good idea to plect suitable warning notices inside the vehicle, and in the engine compartment. This wfl reduce the possibility of the engine being accidentally cranked on the starter motor, which is likely to cause damage with the locking tools In place. 1 To accurately set the valve timing for ell operations requiring removal and refitting of
the
timing belt, liming holes are drilled in ihe camshafts and cylinder head extension. Ihe holes are used In conjunction with camshaft locking tools and crankshaft positioning
rods w
lock the camshafts when all the pistons me positioned at the mid-point of their stroke. Ths