Contents
GeneralInformation...........................1
GeneralInformation.............................................1
GeneralPrecautions...........................................1
SafetyInstructions..............................................2
EnvironmentalPrecautions..................................3
GeneralFittingInstructions.................................5
BallandRollerBearings......................................6
OilSeals............................................................7
JointsandJointFaces..........................................8
LockingDevices.................................................8
ScrewThreads...................................................9
FastenersIdentication.......................................9
FlexiblePipesandHoses...................................11
FuelHandlingPrecautions.................................12
ElectricalPrecautions.......................................13
SupplementaryRestraintSystem
Precautions......................................................14
SRSComponentReplacementPolicy.................20
AirConditioningSystemPrecautions................21
AirConditioningCompressor
Replacement....................................................23
VehicleIdenticationNumber...........................24
VehicleIdentication........................................24
OtherIdenticationPlateLocations..................25
Lifting&T owing...................................................26
Lifting..............................................................26
VehicleRecovery..............................................27
Lubrication&Maintenance................................29
Capacities........................................................29
Fluids...............................................................29
Lubrication......................................................30
Engine.................................................31
EngineMechanical-1.8T......................................31
Specications...................................................31
T orque.........................................................31
Reference.....................................................32
DescriptionandOperation...............................39
EngineComponentLayout............................39
Description..................................................52
Operation....................................................54
ServiceProcedures...........................................56
CylinderHeadOverhaul-withCylinder
HeadRemoved.............................................56
CrankshaftOverhaul-withEngine
Removed......................................................61
ConnectingRodBearingsOverhaul...............65
Pistons&Liners............................................67
CrankshaftRearOilSeal...............................70
CrankshaftFrontOilSeal..............................71
Flywheel-ManualT ransmission.....................72
T orqueConverterDrivePlate-Automatic
T ransmission................................................72
CylinderHeadGasketOverhaul-with
EngineRemoved...........................................73
CamshaftCoverGasket................................77
Valves..........................................................78
HydraulicT appets.........................................82
Camshafts-InletorExhaust.........................82
IntakeManifoldGasket..................................84
ExhaustManifoldGasket...............................86
OilPump.....................................................89
EngineOilandOilFilter................................90
EngineOilPressureCheck............................91
OilPick-UpStrainer...................................92
EngineSump.................................................92
CamshaftDriveBeltCover-Front
Upper..........................................................93
CamshaftDriveBeltCover-Rear
Upper..........................................................94
CrankshaftPulley..........................................95
EngineMounting-RH...................................96
EngineMountingLowerTieRod...................96
CamshaftFrontOilSeal-Exhaust.................97
CamshaftFrontOilSeal-Inlet......................98
CamshaftDriveBelt.....................................99
EngineandManualT ransmission..................102
EngineandAutomaticT ransmission.............110
CylinderHeadGasket.................................119
T urbocharger.............................................123
Hose-CoolantDrain-T urbocharger...........126
Hose-CoolantIntake-T urbocharger...........126
Pipe-OilReturn-T urbocharger.................127
Hose-AirIntake-T urbocharger................127
Pipe-OilFeed-T urbocharger....................128
Hose-AirIntake-Electronic
Throttle.....................................................128
Intercooler.................................................129
Hose-AirIntake-Intercooler....................130
SpecialT ools..................................................131
EngineMechanical-1.8VCT.............................134
Specications.................................................134
T orque.......................................................134
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