Bravo & Brava • 1995 To 2000

Chapter 2 Part E:
Engine removal and overhaul procedures
Contents
Auxiliary shaft (1.6 litre engines) - removal, inspection and refitting . 7
Crankshaft - refitting and main bearing running clearance check ... 11
Crankshaft - removal and inspection 6
Cylinder block/crankcase - cleaning and inspection 8
Cylinder head - dismantling, cleaning, inspection and reassembly . 4
Engine - initial start-up after overhaul and reassembly 12
Engine and transmission removal - preparation and precautions ... 1
Degrees of difficulty
Easy, suitable for §k
novice with little
experience gj^
Fairly easy, suitable |k
for beginner with
some experience g^
Specifications
Engine codes
Refer to Specifications in relevant Part of Chapter 2.
Fairty difficult, ^
suitable for competent g^
DIY mechanic g^
Cylinder head
Camshaft bearing diameters:
1.2 and 1.6 litre engines See Chapter 2A or 2C
1.4 and 1.8 litre engines 26.045 to 26.070 mm
Valve seat angle:
Except 1.2 litre engine 45° ± 5'
1.2 litre engine 45° ± 20'
Tappet running clearance in head:
1.4 litre engine 0.016 to 0.055 mm
1.8 litre engine 0.025 to 0.066 mm
Valves
Valve stem diameter:
Inlet:
1.2 litre engine 5.974 to 5.992 mm
1.4 and 1.6 litre engines 6.982 to 7.000 mm
1.8 litre engine 6.975 to 6.990 mm
Exhaust:
1.2 litre engine 5.974 to 5.992 mm
1.4 litre engine 6.982 to 7.000 mm
1.6 litre engine 6.974 to 6.992 mm
1.8 litre engine 6.960 to 6.975 mm
Valve face angle:
Except 1.2 litre engine 45° 30' ± 5'
1.2 litre engine 45° 30'± 20'
Valve stem-to-guide clearance:
1.2 litre engine 0.030 to 0.066 mm
1.4 and 1.6 litre engines 0.022 to 0.058 mm
1.8 litre engine 0.032 to 0.065 mm
Camshaft
Camshaft bearing running clearance (1.4 and 1.8 litre engines) 0.030 to 0.070 mm
Camshaft endfloat (1.4 and 1.8 litre engines) 0.100 to 0.230 mm
Auxiliary shaft (1.6 litre engine)
Shaft bearing running clearance 0.040 to 0.091 mm
Shaft bearing diameters:
Innermost bearing 35.593 to 35.618 mm
Outermost bearing 31.940 to 31.960 mm
2E»1
Engine and transmission - removal, separation, connection and
refitting 2
Engine overhaul - preliminary information 3
Engine overhaul - reassembly sequence 10
Main and big-end bearings - inspection and selection 9
Pistons and connecting rods - removal, inspection, and big-end
running clearance check 5
Difficult, suitable for ^
experienced DIY 3*
mechanic g^
Very difficult,
suitable for expert DIY 3*
or professional g^