CAUTION:The camshafts must be lubricated with engine oil prior to installation.
CAUTION:The camshaft bearing caps are tightened in stages following the tightening sequence.
NOTE:The camshaft timing belt pulleys are not positively located on the camshafts.
If new camshafts are installed, the bearing surfaces must be checked. If damage is found, the cylinder head and the camshaft bearing caps should be renewed as necessary.
The exhaust camshaft is fitted with an additional cam for the camshaft position sensor (CMP sensor).
The two camshafts have a forged 21 mm hexagon for use when turning them.
Both ends of the camshafts have a slot into which the tool for setting TDC fits.
CAUTION:Thread repairs are not permitted on the cylinder head.
CAUTION:Do not skim the cylinder head mating face.
CAUTION:Machining the valve seats and stem guides is not permitted.
CAUTION:Do not damage the pin contact when installing the new CHT sensor.
NOTE:The cylinder head temperature (CHT) sensor is located next to the spark plug for the third cylinder. This measures the cylinder head temperature directly, i.e. not using the coolant temperature. When it is installed, the sensor becomes permanently deformed and must not be re-used once removed.
NOTE:If new valves are installed, they are to be ground in without re-cutting the seats.
The cylinder head is made of aluminium and is accurately positioned on the cylinder block with two guide sleeves.
On renewal, the cylinder head is supplied complete with valves and camshaft bearing caps already installed.
The studs must be renewed.
To ensure that the cylinder head is properly sealed, the maximum permitted unevenness on the cylinder block mating face is 0,05 mm.
Cylinder Head Gasket
NOTE:The cylinder head gasket can only be installed properly in one position.
The cylinder head gasket is a multi-layer steel gasket which must be renewed on every removal.
Cylinder block
CAUTION:To prevent damage to the cylinder head mating face, the cylinder block should always be placed on a soft surface
CAUTION:As opposed to the 1.6 variant, thread repairs on the 1.4 variant are not permitted.
CAUTION:Machining the cylinder block mating faces is not permitted.
CAUTION:Do not damage the coolant pump impeller during installation and removal.
The cylinder block is of die-cast aluminium with cylinder liners made of cast iron.
On renewal, the cylinder block is supplied complete with crankshaft drive and pistons together with oil gallery blanking plugs and coolant drain plugs.
- For north European countries a heating coil can be inserted in the hole for the core plug (formerly frost plug).
- On the 1,6L cylinder block, a threaded bore for the coolant pump may be repaired by installation of a thread insert. In doing this, the core hole depth of 14 mm and thread depth of 11 mm must not be exceeded.
Do not reuse the coolant drain plug. From build month 9/1999 the cylinder block is no longer equipped with coolant drain plugs.
To ensure that the cylinder head is properly sealed, the maximum permitted unevenness on the cylinder block mating face is 0,05 mm.
Crank Drive
CAUTION:The pistons must not be removed.
There are no oversize pistons available.
The pistons are made of aluminium alloy and are fitted with three piston rings:
Rectangular ring (top)
Stepped ring (middle)
Oil scraper ring (bottom)
Oil Sump
The oil sump is made of aluminium.
When fitting, align the sump so that the sump and the cylinder block are flush.
Spacer washers are not provided.
When tightening, the tightening sequence and the specified torque must be observed.
Engines built until 10/1999 inclusive
The oil sump gasket must be renewed every time the sump is refitted.
Apply the specified sealant to the cylinder block joints, the oil pump flange and the mounting surface of the rear crankshaft oil seal carrier before refitting the sump.
Engines built from 11/1999
The sump gasket is discontinued, and is superseded by a liquid gasket.
Valve Train
The two overhead camshafts are driven by the crankshaft via a timing belt, and they control the valves via bucket tappets.
The valve clearances are adjusted using shims which are located on top of the bucket tappets. They must be checked every 100,000 Km.
Two timing belt tensioners are used.
Timing belt tensioner with cam
The timing belt must be renewed after 150,000 km or 10 years.
Crankshaft Pulley/Vibration Damper
CAUTION:After the crankshaft pulley/vibration damper bolt is loosened or tightened, the camshaft and the crankshaft, i.e. the valve timings must be checked.
CAUTION:Only use the crankshaft pulley/vibration damper bolt once.
CAUTION:Any gaskets which are removed together with engine components must be renewed when the engine components are reassembled.
