Most of the work described in this section is based on the assumption that the engine is installed in the vehicle. Therefore, if this information is used during a complete engine rebuild when the engine is already removed, many of these tasks will not be performed.
Engine
The engine is a 4-cylinder, in-line, overhead camshaft engine, mounted transversely in the front of the vehicle.
The crankshaft is supported in the cylinder block on five main bearings. Thrust washers are installed in main bearing No.2, which regulate the axial clearance of the crankshaft.
The connecting rods are fixed to the crankshaft by means of connecting rod bearings with liners, and on the pistons - by piston pins, which are fixedly seated in the connecting rods. The pistons are made of aluminum alloy - and are equipped with three rings, two compression and one oil scraper.
The camshaft rotates in five bearings drilled directly into the cylinder head and is driven from the crankshaft by a toothed belt.
The camshaft controls the valves via tappets. Valve clearance is adjusted using washers that are mounted on the tappets. The intake and exhaust valves are closed by a single spring.
On early model engines, the intermediate shaft, mounted next to the crankshaft, is also driven by a timing belt and drives the oil pump. On later model engines (refer to Specifications) the oil pump is driven by a chain from the crankshaft: on these engines there is no intermediate shaft, only a gear wheel is left.
The high pressure fuel pump is driven by a toothed drive belt and is described in Chapter Power and exhaust systems.
The engines use a semi-closed crankcase ventilation system; crankcase gases are diverted from the oil separator on the cylinder block and pass through a second oil separator) to the air intake duct (refer to Chapter Power and exhaust systems).
Lubricant is supplied to the engine under pressure created by an oil pump installed below the crankshaft. Engine oil is supplied through an externally mounted oil filter to the main lubrication channel serving the crankshaft, intermediate shaft (where is available) and camshaft. The cylinder block is equipped with oil nozzles that spray oil from the back of the pistons. Some models are equipped with an engine oil cooler mounted on the cylinder block.
Repair procedures performed without removing the engine from the vehicle:
- a) Removing and installing the cylinder head.
- b) Removing and installing the toothed drive belt and toothed wheels.
- c) Replacing the camshaft seals.
- d) Removing and installing the camshaft.
- e) Removing and installing the pallet.
- f) Removal and installation of connecting rods and pistons.*
- g) Removing and installing the oil pump.
- h) Replacing the crankshaft seals.
- f) Replacement of engine mounts.
Note: Although procedures marked with an asterisk can be performed with the engine in the vehicle (after removing the pallet), it will be more convenient to do this with the engine removed.