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Camshaft sprocket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59
Camshaft thrust fork retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12
Crankshaft pulley retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Crankshaft sprocket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 81
Cylinder head bolts (aluminium block engine):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten through a further 240°
Cylinder head bolts (cast-iron block engine):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten through a further 120°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten through a further 120°
Cylinder head cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12
Flywheel retaining nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48
Engine-to-transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Engine/transmission left-hand mounting:
Mounting bracket-to-transmission nuts . . . . . . . . . . . . . . . . . . . . . . . 20 15
Mounting bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Mounting rubber nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Centre nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48
Engine/transmission rear mounting:
Mounting-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30
Mounting link-to-mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52
Mounting link-to-body bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Engine/transmission right-hand mounting bracket nuts . . . . . . . . . . . . 45 33
Oil pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Sump retaining nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Timing belt cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Timing belt tensioner pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
1 General information
How to use this Chapter
This Part of Chapter 2 describes those
repair procedures that can reasonably be
carried out on the TU series engine while it
remains in the car. If the engine has been
removed from the car and is being dismantled
as described in Part D, any preliminary
dismantling procedures can be ignored. Refer
to Part A and B for information on the XV, XW
and XY series and XU series engines.
Part D describes the removal of the
engine/transmission from the vehicle, and the
full overhaul procedures that can then be
carried out.
Engine description
The engine is of the in-line four-cylinder,
overhead camshaft type, mounted
transversely at the front of the car and inclined
forward by 6°. The clutch and transmission
are attached to its left-hand end. The 205
range is fitted with 954 cc (TU9), 1124 cc
(TU1), and 1360 cc (TU3) versions of the
engine in either carburettor or fuel-injected
configuration.
The crankshaft runs in five main bearings.
Thrustwashers are fitted to No 2 main bearing
(upper half) to control crankshaft endfloat.
The connecting rods rotate on horizontally-
split bearing shells at their big-ends. The
pistons are attached to the connecting rods
by gudgeon pins, which are an interference fit
in the connecting rod small-end eyes. The
aluminium-alloy pistons are fitted with three
piston rings - two compression rings and an
oil control ring.
On all except TU3FM engines, the cylinder
block is made of aluminium, and replaceable
wet liners are fitted to the cylinder bores.
Sealing O-rings are fitted at the base of each
liner, to prevent the escape of coolant into the
sump.
On TU3FM engines, the cylinder block is
made from cast-iron, and the cylinder bores
are an integral part of the cylinder block. On
this type of engine, the cylinder bores are
sometimes referred to as having dry liners.
The inlet and exhaust valves are each
closed by coil springs, and operate in guides
pressed into the cylinder head; the valve seat
inserts are also pressed into the cylinder
head, and can be renewed separately if worn.
The camshaft is driven by a toothed timing
belt, and operates the eight valves via rocker
arms. Valve clearances are adjusted by a
screw-and-locknut arrangement. The
camshaft rotates directly in the cylinder head.
The timing belt also drives the coolant pump.
Lubrication is by means of an oil pump,
which is driven (via a chain and sprocket) off
the right-hand end of the crankshaft. It draws
oil through a strainer located in the sump, and
then forces it through an externally-mounted
filter into galleries in the cylinder
block/crankcase. From there, the oil is
distributed to the crankshaft (main bearings)
and camshaft. The big-end bearings are
supplied with oil via internal drillings in the
crankshaft, while the camshaft bearings also
receive a pressurised supply. The camshaft
lobes and valves are lubricated by splash, as
are all other engine components.
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) Cylinder head cover - removal and
refitting.
c) Valve clearances - adjustment.
d) Timing belt covers - removal and refitting
e) Timing belt - removal, refitting and
adjustment.
f) Timing belt tensioner and sprockets -
removal, inspection and refitting.
g) Camshaft oil seal - renewal.
h) Camshaft and rocker arms - removal,
inspection and refitting.
i) Cylinder head - removal and refitting.
j) Cylinder head and pistons -
decarbonising.
k) Sump - removal and refitting.
l) Oil pump - removal, inspection and
refitting.
m)Crankshaft oil seals - renewal.
n) Flywheel - removal, inspection and
refitting.
o) Engine/transmission mountings -
inspection and renewal.
2C•2 TU series engine in-car repair procedures