Engine GENERAL SPECIFICATION. EMA-2 SPECIAL TOOLS: EMA -20 TROUBLE SHOOTING. EMA -22 ENGINE AND TRANSAXLE AS EMA -24 TIMING SYSTME TIMING BELT COMPONENTS. EMA 31 COMPONENTS: EMA 32 DISASSEMBLY EMA 33 INSPECTION EMA “34 REASSEMBLY EMA 36 CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS ...... EMA -39 COMPONENTS, EMA “40 DISASSEMBLY EMA “a1 INSPECTION ... EMA -42 REASSEMBLY EMA -42 ROCKER ARM, ‘COMPONENTS EMA-44 COMPONENTS. EMA -45, OISASSEMaLY EMA 46 INSPECTION EMA “46 REASSEMBLY EMA “49 VALVES ‘COMPONENTS EMA -50 ‘COMPONENTS “ EMA 51 DISASSEMBLY EMA “52 INSPECTION . EMA 52 REASSEMBLY EMA “55 MAIN MOVING SYSTEM CAM SHAFT. ‘COMPONENTS: EMA -87 COMPONENTS: EMA 58 DISASSEMBLY EMA “59 INSPECTION EMA “59 REASSEMBLY EMA 60 CRANK SHAFT ‘COMPONENTS: .- EMA 62 DISASSEMBLY EMA 63 INSPECTION EMA 63 REPLACEMENT EMA “54 REASSEMBLY “EMA “68 FLY WHEEL COMPONENTS EMA -67 COMPONENTS EMA 68 DISASSEMBLY EMA -68 INSPECTION EMA 68 REASSEMBLY EMA 68 PISTON ‘COMPONENTS: EMA -69 GISASSEMBLY “EMA “69 INSTALLATION “EMA -70 INSPECTION EMA 71 REPLACEMENT EMA 71 REASSEMBLY EMA 73 (1.1/1.3 SOHC) COOLING SYSTEM ENGINE COOLANT HOST/PIPES ‘COMPONENTS: COMPONENTS, INSPECTION ~ REASSEMBLY ENGINE COOLANT PUMP ‘COMPONENTS. COMPONENTS: DISASSEMBLY INSPECTION REASSEMBLY RADIATOR DISASSEMBLY INSPECTION REASSEMBLY RADIATOR CAP ‘COMPONENTS INSPECTION THERMOSTAT ‘COMPONENTS COMPONENTS, INSPECTION REASSEMBLY LUBRICATION SYSTEM ‘OL PUMP COMPONENTS, COMPONENTS DISASSEMBLY INSPECTION REASSEMBLY OWL PRESSURE SwiTCH ENGINE BLOCK ENGINE BLOCK ‘COMPONENTS. COMPONENTS. INSPECTION ... ENGINE MOUNTS ‘COMPONENTS, REMOVAL .. INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD ‘COMPONENTS COMPONENTS INSPECTION, INTAKE MANIFOLD COMPONENTS REMOVAL... INSPECTION INSTALLATION MUFFLER COMPONENTS .. REMOVAL INSPECTION INSTALLATION AIR CLEANER (ACL) COMPONENTS" REMOVAL INSPECTION INSTALLATIONEMA -2 ENGINE MECHANICAL SYSTEM GENERAL SPECIFICATIONS | cemoxcu 1.3 SOHC [ 1.1 SOHC ‘SPEC uM SPEC ur General Type Invine, SHOC | « No. of eylinder 4 | e Bore 71.5 mm (281 in) 67 mm (2.64 in) Stroke 83.5 mm (3.29 in.) 77 mmm (3.03 in.) Total displacement 1341 co 1085 co Compression ratio 85 97 Firing order 3-4-2 < Valve timing Intake valve opens (BTDC) 12 5 Intake valve closes (ABDC) 82 3s Exhaust valve opens (BEDC) 52 43 Exhaust valve closes (ATDC) 12 5 Valve overlap 24 10 Cylinder head Flatness of gasket surtace Max 003mm | 0.08 mm Max._0.05mm OA mm (0.0012 in) (0.00818 in.) (0.002 in.) {0.00994 in.) Flatness of manifold mount’g Max. 0.15 mm 03 mm Max. 0.15mm 03 mm surface (0.0059 in) (0.0118 in) (0.0058 in) (0.0118 in) Dimension for reworking oversize valve seat hole Intake 0.03 OS. 288 - 28.821 mm 24.3 ~ 24.321 mm (1.134 ~ 1.135 in.) (0.857 ~ 0.9578 in) 0.08 OS. 28.1 ~ 29.121 mm 24.6 ~ 24.621 mm (1.146 ~ 1.1467 in) (0.968 ~ 0.969 in.) Exhaust 003 08. 3433 ~ 34,325 mm | 293 ~ 29.321 mm (1-350 ~ 1.351 in) (1-154 ~ 1.4544 in) 0.06 os. 346 ~ 34.625 mm 29.6 ~ 29.621 mm (1.362 ~ 1.383 in) | (1.165 = 1.166 in.) Valve guide hole diameter (intake“exhaust) 0.05 OS. 11.05 ~ 11,068 mm 10.05 ~ 10.068 mm (0.435 ~ 0.436 in.) (0396 ~ 0.3963 in) 025 08. 41.25 ~ 11.268 mm 10.25 ~ 10.268 mm (0.483 ~ 0.4436in.) (0-403 ~ 0.404 in.) 050 0s. 11.50 ~ 11.518 mm 10.50 ~ 10.518 mm (04453 ~ 0.4535in) (0.413 ~ 0.414 in)GENERAL EMA -3 1.3 SOHC 4.1 SOHC Camshaft Cam height intake 42,8575 mm 42.3575 mm 34.8728 mm 34.7729 mm (1.687 in.) (1.667 in.) (1.373 in.) (1,369 in.) Cam height exhaust 42.7354 mm 42.2624 35.1258 mm. 35.0258 mm (1.682 in) smim(1.664 in.) (1.383 in) (1.379 in) Journal diameter 90 mm (1.181 in) 41. mm (1.614 mm) Bearing oil clearance 0.045 ~ 0.085 mm 0.045 ~ 0.085 mm, (0.0018 ~ 0.0033 in.) (0.0018 ~ 0.0033 in.) End play 0.07 ~ 0.28 mm 0.07 ~ 0.19 mm (0.0027 ~ 0.011 in) (0.0027 ~ 0.0074 in.) Crankshaft Journal diameter, 50 mm (1.97 in) 42 mm (1.65 in) Pin diameter 45 mm (1.77 in) 38 mm (1.496 in.) Bend 0.03 mm (0.0018 in.) (0.03 mm (0.00118 in.) Out of roundness of journal Max. 0.005 « and pun Max. 0.005 e Taper of journal and pin 0.05 ~ 0.175 mm 025 0.05 ~ 0.25 mm End play {0.002 - 0.007 in.) | mm(0.0098 in.) | (0.002 ~ 0.0098 in.) Undersize of Pin 025 44.725 ~ 44.740 mm 97.735 ~ 97.75 mm (1.76 ~ 1.761 in.) (1.486 ~ 1.4862 in.) 0.50 44.475 ~ 44.490 mm 37.485 ~ 37.50 mm (1.75 ~ 1.781 in.) (1.4751.476 in.) 075 44.225 ~ 44.240 mm (1.74 ~ 1.741 in.) Undersize of Journal 0.25 49.727 ~ 49.742 mm 41.735 ~ 41.75 mm (1.957 ~ 1.958in) (1.643 ~ 1.644 in) 050 48.477 ~ 49.482 mm 41.485 ~ 41.50 mm (1.948 ~ 1.9485in.) (1.633 ~ 1.634 in.) 075 49.227 ~ 49.242 mm (1.938 ~ 1.9386in,) Main bearing oil clearance No. 1.2.45 0.022 ~ 0.040 mm | 0.1. mm 0.02 ~ 0.038 mm (0.0086 - 0.0016 in.) | (0.00394 in.)_| (0.00078 -0.0015 in.) No. 3. 0.028 - 0.046 mm 0.02 ~ 0.038 mm (0.0011 ~ 0.0018 in) (0.00078 ~ 0.0015in.) Valve Stom diameter Intake 5.955 ~ 5.97 mm 5.48 ~ 5.465 mm (0.294 ~ 0.235 in.) (0.216 ~ 0.2151 in.) Exhaust 5.935 ~ 5.95 mm 5.45 ~ 5.43 mm (0.2336 ~ 0.234 in.) (0.215 ~ 0.213 in) Face angle 45° ~ 45.5" ‘Thickness of valve head (margin) Intake 1.1 mm (0.048 in.) | 0.8mm(0.031in.)] 0.8 mm (0.031 in) | 0.5 mm (0.0197 in) Exhaust 4.3mm (0.051 in) | 1 (0.039 in.) | 1.2 mm (0.047 in.) 0.9 mm ‘Valve stom to valve guide (0.035 in.) clearance Intake 0.03 ~ 0.06 mm 0.4 mm 0.02 ~ 0.047 mm 0.1 mm (0.0012 - 0.0024 in.) } (0.0039 in.) | (0.008 ~ 0.0018 in.) | (0.0039 in) Exhaust 0.05 ~ 0.08 mm 015mm | 0.05 ~ 0.082 mm | 0.15 mm (0.0020 ~ 0.0031 in.) | (0.006 in) | (0.002 ~ 0.0032 in.) | (0.006 in.)EMA -4 ENGINE MECHANICAL SYSTEM 1.3 SOHC 1.1 SOHC Valve guide Length Intake 12.8 mm (0.504 in) 10.05 mm (0.396 in.) Exhaust 12.8 mm (0.504 in.) 10.05 mm (0.396 in.) Service oversize 0.05, 0.25, 0.50 « Valve seat Width of seat contact Intake 08 ~ 1.2 mm 0.9 ~ 1.3 mm (0.031 ~ 00047 in) | (0.095 ~ 0.05 in.) Exhaust 1.3 ~ 1.7mm } 09-13mm (0.051 ~ 0.067 in.) (0.035 ~ 0.08 in.) Seat angle as © Service oversize 03,06 © Valve spring Free length (Installed height) 44 mm (1.732 in) 40.5 mm (1.594in.) Load 21.6kg/35mm, 15.6kg// 32.0 mm, 45.1kg/27.2mm 93.9 kg / 24.5 mm Out of squareness Max 1.5 Valve clearance (cold | 20°C) Warm:80°C) j Intake Gold : 20°C. : 0.1 mm Warm : 80°C : 02 mm Exhaust Gold: 20°C. : | 017 mm Warm : 80°C : 0.25 mm Cylinder block Cylinder bore 71.5 ~ 71.53 mm 87 ~ 673mm (2.815 ~ 2.816 in) (2.64 ~ 2.65 in.) Out of roundness of cylinder bore Max. 0.01 Taper of cylinder bore : Flainess of gasket surface Max. 0.05 0.1 mm (0.0038 in.) Piston Dameter 71.47 ~ 71.50 mm 66.97 ~ 67.0 mm (2.814 ~ 2.815 in) (2.636 ~ 2.65 in.) Piston to cylinder clearance (0.02 ~ 0.04 mm « (0.0078 - 0.00187 in)GENERAL EMA. 1.3 SOHC Piston ring No. of rings per piston 3 « Compression ring 2 « il ring 1 © Compression ring type No. 1 lnside bevel type No. 2 Taper type Oil ring type Spiece type « Side clearance No. 1 0.04 ~ 0.085 mm 0.1 mm 0.03 ~ 0.07 mm (0.0016 ~ 0.0033 in) | (0.00394 in.) | (0.0012 ~ 0.0027 in No. 2 0.04 - 0.085 mm 0.1 mm 0.02 ~ 0.06 mm (0.0016 ~ 0.0033 in} | (0.00384 in.) | (0.0008 ~ 0.0023 in.) Ol ring (0.06 ~ 0.15 mm 0.08 ~ 0.15 mm (0.0023 ~ 0.006 in.) (0.008 ~ 0.006 in.) End gap No. 1 0.20 ~ 0.35 mm 1mm 0.15 ~ 0.30 mm (0.0079 - 6.9138 in) | (0.0394 in.) | (0.006 ~ 0.012 in.) No. 2 0.37 ~ 052 mm 1mm 0.30 ~ 0.50 mm (0.015 ~ 0.02 in) | (0.0394in) | (0.012 - 0.02 in) Oil ting side rail 0.2 ~ 0.7 mm (0.008 1mm « ~ 0.028 in.) (0.0394 in.) Sevice oversize 025, 0.50, 0.75, 1.0 e Connecting rod Bend Max. 0.05 per 100 mm Twist Max. 0.1 per 100mm Connecting rod big end to 0.10~0.25 mm | 0.4mm0.016in) + crankshaft side clearance (0.004 ~ 0,01 in.) Piston pin press in load 1250 + 500 kg Bearing oil clearance 0.018 ~ 0.036 mm 0.1mm 0.012 ~ 0.041 mm (0.0007 - 0.0014 in.) | _(0.0038in.) _| (0.0004 ~ 0.0016 in.) (19.4216 at 1.578 in.) (8.16 at 1.299 in.) Flywheel Runout 4mm, 0.13mm 0.1 mm (0.13 mm (0.005, (0.0014 in) (0.005in.) (0.004 in.) in) il pressure at curb idle speed 1.5kg/emé (oil emp. 90~110°C) il pump Clearance between outer circum | 0.12 ~ 0.18 mm 0.10 ~ 0.18 mm ference and front (0.0047 ~ 0.0071 in.) (0.0039 ~ 0.0071 in.) Clearance between roter axial 0.04 ~ 0.085 mm 0.04 ~ 0.095 mm side and front case (0.0016 ~ 0.0026 in) (0.0016 ~ 0.0037 in.) Tip clearance between outer 0.025 ~ 0.069 mm 0.18 ~ 0.060 mm and inner roter (0.0010 ~ 0.0027 in.) (0.007 ~ 0.0024 in.) Relief spring Free length 46.6 mm (1.8346 in.) 38.6 mm (1.519 in.) Load 6ikg at 40.1 mm 3.85 kg al 33.0 mm Cooling method ‘Water-cooled, Pressurized, Forced circulation with electrical fanEMA -6 ENGINE MECHANICAL SYSTEM 1.3 SOHC 1.1 SOHC Cooling sys. Quantity 62 lit (6.55 US ats 600 lit (6.34 US. gts, 5.46 Imp qts) 5.28 Imp ats) ‘Thermostat | Type Wax pellet type with « Normal opening temp. Opening temp. range Wide opening temp. Radiator cap Main valve opening pressure 86.1 ~ 124.5 ta + Main valve colseing pressure 83.4 kpa « Vacuum valve opening preesur “86.6 koa « ‘ir cleaner Type Dry type e Element Unwoven cloth type « Exhaust pipe Mutier Expansion resonance © type ‘Suspension sys. Rubber hanger type eGENERAL TIGHTENING TORQUE (1.3 L) EMA tem’ kg.om It Cylinder Block Left engine support bracket bolt 80 ~ 42 300 ~ 420 22-31 ll pressure switch 13-15 130 ~ 150 96-11 ‘Cylinder head Cylinder head bolt (23 ~ 27) + (60° ~ | (200 ~ 270) + (60° (17 ~ 20) + (60° ~ 62°) + (60° ~ 62°) 62°) + (60° ~ 62°) 62") + (60° ~ 62°) Intake/manifold bots or nuts 15 ~ 20 150 ~ 200 11-15 Exhaust manifold nut 15 ~ 20 150 ~ 200 11 ~ 15 Recker cover bolt 8-10 80 ~ 100 6-7 Recker arm shatt bolt 20 ~ 24 20 ~ 240 15~18 ‘Camshatt boit 20 ~ 27 200 ~ 270 15 ~ 20 Rear plate bolt 8-10 80 ~ 100 6-7 Main Moving parts Connecting rod cap nut 32 ~ 35 320 ~ 350 24 ~ 26 Crankshaft bearing cap bolt 55 ~ 60 550 ~ 600 41-44 Flywheel! MT bott 130 ~ 140 1300 ~ 1400 96 ~ 103 Drive plate AT bolt 130 ~ 140 1300 ~ 1400 96 ~ 103 Timing Belt Crankshaft sprocket bolt 140 ~ 150 1400 ~ 1500 103 ~ 111 Camshaft sprocket bolt 80 ~ 100, 800 - 1000 59-74 Timing belt tensioner bolt 20 ~ 27 200 ~ 270 15 ~ 20 Timing belt cover bolt 10 ~ 12 100 ~ 120 7-9 Front case bolt 12-18 120 ~ 150 g-11 Engine Mounting Engine mounting insulator bolts 35 - 55 350 ~ 550 258 ~ 406 Engine mounting bracket to engine (large) nut 70 ~ 95 700 ~ 950 51.6 ~ 70 Engine mounting bracket to engine 35 ~ 55 350 ~ 550 258 ~ 40.6 ruts and bolts Transaxle mount insulator bolt 70 ~ 95 700 ~ 950 51.6 ~ 70 ‘Transaxle insulator bracket to side 95 ~ 55 350 ~ 550 258 ~ 40.6 ‘member bolts Rear roll rod bracket bolt 35 ~ 55 350 ~ 550 258 ~ 40.6 Rear roll rod bracket to cross member 70 ~ 95 700 ~ 950 51.6 ~ 70 Oil fiter 12-16 120 ~ 160 9-12 Oil pan bolts 6-8 60 ~ 80 4-6 Oil pan drain plug 35 ~ 45 350 ~ 450 26 ~ 33, Oil screen bolts 15 ~ 22 150 ~ 220 11-16 Timing belt upper cover bolts 10-12 100 ~ 120 7-9 Timing belt lower cover bolts 10-12 100 ~ 120 7-9 ‘Surge tank to inlet manifold nuts and bolts 15 ~ 20 150 ~ 200 11-15EMA -8 ENGINE MECHANICAL SYSTEM CL Item Nm kg.em oft Cooling system Generator support and nut 20 - 25 200 ~ 250 15-18 Generator lock bolt 15 ~ 22 150 - 220 1-16 Generator brace mounting bolt 20 ~ 26 200 - 260 15-21 Coolant pump pulley 8-10 80 ~ 100 6-7 Coolant pump bolt 12~15 120 ~ 150 9-11 Coolant temperature gauge unit 10 ~ 12 100 ~ 120 7-9 Coolant temperature sensor 15-20 150 ~ 200 11-15 Coolant outlet fitting bolt 17-20 170 ~ 200 13-15 Thermostat housing bolt 15-20 150 ~ 200 11-15 Intake and Exhaust system Air cleaner body mounting bots 8-10 80 ~ 100 6-7 Resonator mounting bolts 4-6 40 - 60 29-43 Throttle body to surge tank bolts 15 - 20 150 ~ 200 11-15 ‘Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 600 37 ~ 44 Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 30 Front exhaust pipe bracket bolts 30 ~ 40 300 ~ 400 22 ~ 30 Front exhaust pipe to cataiytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44 MIT : Manual Transaxle AIT: Automatic TransaxleGENERAL EMA -9 TIGHTENING TORQUE (1.1 L) tem Nm kg.cm batt ] Cylinder block Left engine support bracket 45 ~ 55 450 ~ 950 33-41 Oil pressure switch 15 ~ 22 150 ~ 220, 11-16 Cylinder head Cylinder head bolt Cold engine 60 ~ 70 600 ~ 700 44 ~ 52 Hot engine 70 ~ 78 700 ~ 750 52 ~ 56 Inkake/manifold to oylinder head nuts 15 ~ 20 150 ~ 200 1-15 ‘and bolts Exhaust manifold nut 15 ~ 20 150 ~ 200 1-15 Rocker cover bolt 8-10 80 ~ 100 6-7 Rocker arm shatt bolt 27 ~ 32 270 ~ 320 20 ~ 24 Main Moving Connecting rod cap nut 20 ~ 23, 200 ~ 230 15-17 Crankshaft bearing cap bolt 50 ~ 55 500 ~ 550 a7 - 41 Flywheel MT bolt 70 ~ 80 700 ~ 800 52 - 59 Timing Belt Crankshaft pulley bolt 140 ~ 150 1400 ~ 1500 103 ~ 111 Camshatt sprockot bolt 80 ~ 100 800 ~ 1000 59 - 74 ‘Timing belt tensioner bolt 22 ~ 30 220 ~ 300 16 ~ 22 Timing bett cover bolt 10 ~ 12 100 ~ 120, 7-9 Front case bolt 8-10 80 ~ 100 6-7EMA -10 ENGINE MECHANICAL SYSTEM tem Nm kg.em bt Engine Mounting Engine mount insulator bolts 935 ~ 55 350 ~ 550 258 ~ 406 Engine mounting bracket to engine (large)nut 70 ~ 95 700 ~ 950 51.6 ~ 70 Engine mounting bracket to engine 35 ~ 55 350 ~ 550 258 ~ 406 ruts and bolt Teransaxle mount insulator boit 70 ~ 95 700 ~ 950 51.6 ~ 70 Rear roll rod bracket bolt 35 ~ 55 350 ~ 550 25.8 ~ 40.6 Roar roll rod bracket to cross member bolt 70 ~ 95 700 ~ 950 51.6 ~ 70 Ot fiter 12-16 120 - 160, 9-12 Oil pan bots 6-8 60 ~ 80 4-6 Oil pan drain plug 35 ~ 45 350 ~ 450 28 ~ 37 Oil screen bolts 15 ~ 22 150 ~ 220 1-16 ‘Timing belt cover bolts 10 ~ 12 100 - 120 7-9 ‘Surge tank to inlet manifold nuts and bolts 15 ~ 20 150 ~ 200 11-15 Generator support bolt and nut 20 = 25 200 ~ 250) 15-18 Generator brace bolt 12 ~15 120 ~ 150 9-1 Geneator brace mounting bolt 20 -28 200 ~ 280 15 ~ 21 Coolant pump pulley 80 ~ 100 6-7 Coolant pump bot 120 ~ 150 g-11 Coolant temperature sender 100 ~ 120 7-9 Collant temperature sensor 150 ~ 200 11-15 Coolant outlet fiting bot 150 ~ 200 115 ‘Thermostat housing bolt 80 ~ 200, 6-7 Air cleaner body mounting bolts 80 ~ 100 6-7 Air intake hose clamp 30 ~ 50 2-4 Air duct assembly mounting bolt 80 ~ 100 6-7 Throttle body to surge tank bolts 150 ~ 200 1-15 Exhaust manifold cover to exhaust 80 ~ 100 6-7 ‘manifold bolts ‘Oxygen sensor to exhaust manifold 500 ~ 60 37 ~ 44 Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 - 30 Front exhaust pipe bracket bolts 30 ~ 40, 300 ~ 400 22 - 30 Front exhaust pipe to catalytic convrter bolts 40 ~ 60 400 ~ 600 30 ~ 44 Main muffler hanger support bracket bolts 10~15 100 ~ 150 7-11 WT : Manual TransaxleGENERAL EMA -11 SELECTION OF ENGINE OIL Rocommended API classification : SH OR ABOVE SG Recommended SAE viscosity grades : Temperature range anticipated before arteateseet Recommended SAE viscosity number c . 40 104 2ow| 1sw tow row -s0 | -so “50 -30 20 68 ~40 | -40 -40 10 50 sw 10 4 — 48 5 25 13 “1. Restricted by driving condition and environment. "2. SAESW-20 Not recommended for sustained high speed vehicle operation Qyore For best performance and maximum protection of all types of operation, select only those lubricants which 1. Satisfy the requirements of the API classification. 2. Have proper SAE grade number for expected am- bbient temperature range. Lubricant that does not have both an SAE grade num- ber and an API service classification on the container should not be used.EMA -12 MAINTENCE CHECKING ENGINE OIL 1. Position the vehicle on a level surface. 2. Warm up the engine. NOTE If a vehicle has been out of service for a prolonged period of time, warm up the engine for approximately 20 minutes. 3. Tum off the engine, and wait 2 or 3 minutes, then check the oil level. 4, Check that the engine oil level is within tha level ragne indicated on the oil dipstick if the oil leval is found to have fallen to the lower mit the °L* mark), refill to the *F mark. Lowortimit Upper mit (W nore When refiling, use the same type of engine oll 5. Check that the oil is not dirty or contaminated with coolant or gasoline and that it has proper viscosity. CHANGING ENGINE OIL © warning je careful not to brun yourself, as the engine oil hot. 1. Run the enigne until it reaches normal operating tem- perature. 2. Tum off the engine, ENGINE MECHANICAL SYSTEM 3. Remove the oil filler cap and the drain plug (on the oil pan). Drain the engine oil, crconte 4, Install and tighten the drain plug to the specified torque, Tightening torque Drain pug: 35 ~ 45 Nm (950 ~ 450 kg.om, 24 ~ 33 bt) NOTE Whenever tightening the oll arain plug, use a new drain plug gasket. 5. Fill he crankcase with fresh engine oil through the oil filer cap opening, Drain and Refll Without oil fiter 1.3L : 30 ter (3.17 US. q’s., 2.64 Imp. qts.) 1.1 L:28 iter (2.96 U.S. q’s., 2.46 Imp. ats.) Drain and Refill With oil fiter 1.3L :3.3 liter (8.48 US. qts., 2.90 Imp. ats.) 1.1L: 3.4 liter (8.28 US. qts., 2.73 Imp. ats.) 6. Insta the oi filer cap. 7. Start and run the engine. 8 Turn off the engine and then check the oil level. Add. oll if necessary. FILTER SELECTION ‘All Hyundai engines are dquipped with a high quality, dis- posable ol fite. This fiter is recommended as a replace- ‘ment fier on all vehicles. The qualty of replacement fi ters varies considerably. Only high quality fiters should be used to assure the most efficient service. Make sure that the rubber gasket trom the old oil fiter is completely removed from the contact surface on the engine block be fore instaling the new fiter.GENERAL Part rumbor PROCEDURE FOR REPLACING THE OIL FILTER Q caution Be careful not to burn ylurselt, as the engine and engine oil are not. Use a titer wrench to remove the ol iter. Before installing the new oll fer on the engine, apply clean engine oil to the surface of the rubber gasket. ‘Apply engine alte the surtace Tightening torque Oil fitor : 12 ~ 16 Nm (120 ~ 160 kg.om, 9 ~ 12 Ib.) 4. Run the engine to check for engine oil leaks. 5. After turning off the engine, check the oil level and add oil as necessary. CHECKING COOLANT LEAK 1. Wait until the engine is cool, then carefully remove the radiator cap. 2. Confirm that the coolant level is up to the filer neck. 3. Install a radiator cap tester to the radiator filer neck ‘and apply 140 KPa (1.4 kg/om?, 20 psi) pressure. Hold it for two minutes in that condition, while check- ing for leakage from the radiator, hoses or connec- tions. 9 NOTE Radiator coolant may be extremely hot. Do not ‘open the system because hot, or scaiding water ‘could gush out causing personal injury. Allow the vehicle 10 coo! before servicing this system. 2. Be sure to clean away any moisture from the places checked completely. 3. When the tester is removed, be careful not to spill any coolant from it. 4. Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.EMA -14 4, If there is leakage, repair or replace with the apropri- ate part RADIATOR CAP PRESSURE TEST 1. Remove the radiator cap. Wet its seal with engine Coolant, then install it on the tester. 2. Increase the pressure until the gauge stops moving. ‘Main valve opening pressure 78 ~ 108 kPa (0.8 ~ 1.1 kg/om®, 11.3 ~ 15.6 psi) Limit : 65 kPa (0.66 kg/cm, 9.2 psi) 3. Check that the pressure level is maintained at or above the limit. 4, Replace the radiator cap if the reading does not re- ‘main at or above the limit Bo sure that the cap is clean before testing, since rust Or other foreign material on the cap seal will cause an incorrect reading. ENGINE MECHANICAL SYSTEM CHANGING ENGINE COOLANT & caution When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on electri- ‘cal parts or the paint. If any coolant spills, rinse it off immediately. 1. Slide the heater temperature control lever to mas mum heat. Make sure the engine and radiator are co0I to the touch. 2. Remove the radiator cap. 3. Loosen the drain plug and drain the coolant. 4, Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservior. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze. 6. Pour coolant into the radiator up to the base of the ‘and install the radiator cap loosely. 7. Start the engine and et it run until it warms up (the radiator fan comes on at least twice) ‘8. Turn off the engine, Check the level in the radiator, ‘add coolant if needed. 9. Put the radiator cap on tightly, then run the engine again and check for leaks.GENERAL EMA -15 SPECIFIC GRAVITY TEST 1, Measure the specific gravity of the coolant with a hy- ‘Grometer, 2, Mesure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference. RELATION BERWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperature °C (°F) and specific gravity Freezing Sate operating Coolant temperature °C} temperature °C | Concentration 10 (50) | 20,68) | 30(86) | 40 (104) | 50(122) CF) CF) Specific volume) 1054 | 1.050 | 1.046 | 1.002 | 1.036 “16 (32) =11 (12.2) 30% 4063 | 1.058 | 1.054 | 1.049 | 1.044 20 (4) “15 (5) 35% tom | 1067 | 1.062 | 1057 | 1052 25 (19) 20 (4) 40% to7a | 1074 | 1.068 | 1064 | 1058 80 (22) 25 (13) 45% 1087 | 1082 | 1.076 | 1070 | 1068 | -36 (328) 31 (23.8) 50% 1095 | 1.0390 | 1084 | 1.077 | 1.070 42 (-44) 37 (35) 55% tos | 1.098 | tose | 1084 | 1.076 “50 (-58) 45 (-48) 60% Example + If the concentration is above 60%, both the The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant tem- perature of 20°C (68°F) AQ caution * If the concentration of the coolant is below 30%, its anti-corrosion properties will be ad- versely affected. RECOMMENDED COOLANT antifreeze and engine cooling property will decrease, affecting the engine adversely. For these reasons, be sure to maintain the con- centration level within the specified range. ‘+ Do not use together with another brand's Product. Antifreeze ‘Mixture ratio of anti freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM ‘50% [Except tropical areas] 40% [Tropical areas}EMA -16 CHECKING COMPRESSION PRESSURE 1. Belor checking engine compression, check the en- gine oil level. Also check that the starter motor and battery are all in normal operating condition. 2. Check the DTC and resetting the ECM will erase any stored DTCs. 3. Stert the engine and wait until engine coolant tomper- ature reaches 80-95°C (176-205°F). 4. Disconnect the fue! pump connector. 5. Tum off engine and disconnect the spark plug cables. 6. Remove the spark plug. 7. Disconnect the 1.G. connector. 8 Crank the engine to remove any foreign material in the cylinders. 9. Insert the compression gauge into the spark plug hole. ENGINE MECHANICAL SYSTEM 10. Depress the accelerator pedal to open the throttle fully. 11. Crank the engine and read the gauge. ‘Standard value; 1500 kpa (15.5 kgiom?, 220 psi) Limit : 1200 kpa (12.5 kg/cm, 178 psi 12. Repeat steps 9 to 11 over all cylinders, ensuring that the pressure differential for each of the cylinders is, within the specified limit. Limit: Max. 150 kpa (1.5 ka/or®, 21 psi between cylinders 13. If a cylinder’s compression or pressure differential is outside the specification, add a small amount of oil through the spark plug hole, and repeat steps 9 to 12. 1. If the addition of oil makes the compression to ris, itis likely that there may be wear between the piston ring and cylinder wall. 2. If compression remains the same, valve seizure, ‘poor valve seating or a compression leak from the cylinder hoad gasket are all possible causes. Tightening torque Spark plug : 20-30 Nm (200-300 kg.cm, 14-22 Io.)GENERAL ADJUSTING TIMING BELT TENSION 1. Tum the steering whee! fully counter clock wise, 2. Lift the vehicle by using of jack. 4, Loosen the coolant pump pulley mounting bolt and loosen the generator belt tension adjustment bot. 5. Romove the coolant pump pulley, generator belt, ower steering pulley and power steering belt. 6 Remove the timing cover upper side mounting bolt (4EA). 7. Remove the crankshatt pulley. EMA -17 8. Turn crankshaft to place clockwise in No.1 cylinder at, top head center on compression stroke, Gaore Tu the crankshaft cock wise. I counter lok wise, tensions ot avalabl. 9. Loosen the tensioner bolt 1-2 turn and tension the belt by tensioner spring, 10. Tur crankshaft clockwise as much as two camshaft ‘sprocket teeth. 14, Tighten the tensioner bolt of slot side of first and then tighten the bot of pivot side. 42. Rotate the crankshatt pulley two turns clockwise so that the timing belt positions on the pulleys. 13. Pust the arrow direction on tensioner, measure the engagement between camshaft sprocket 'A’ part belt and sprocketEMA -18 sae A/F 44, Check the tension of timing belt. (1.3L) When the tensioner and the tension side of the timing bolt are pushed in horizontally with a moderate force approx. 49N (11 Ib) the timing bet log ends approx. half of the tensioner mounting bolt head radius (cross flats) away trom the bolt head center. “Tensioner bot ENGINE MECHANICAL SYSTEM 16, Install the crankshaft pulley. 17. Install the coolant pump pulley. 18. Install V-belt and adjust the belt tension, ADJUSTING DRIVE BELT TENSION 1. Cheok that the belts are not damaged and are prop- arly fit for the pulley grooves. 2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in the illustration, measure the amount of deflection with a tension gauge. Q) caution 4. When installing the V-ribbed belt, check that the V-ribs are property aligned. 2. If noise or siippage is detected, check the belt for wear, damage, or breakage on the pul- ley contact surface, and check the pulley for scoring. Also check the amount that the belt ) 2a Puy ssenalon (across fa 16, Install the timing bott cover. Wong Vetobed bt wrong a Tightening torque : fa 40 ~ 12 Nm (100 ~ 120 kg.om, 7.2 7 STANDARD VALUE : ‘Adjustment tems Now Used For alternator 1.4 L : Deflection mm (in.) 8.5 ~ 95 (0.33 - 0.37) 410 (0.39) 1.3L : Deflection mm (in.) 7.5 ~ 9.0 (029 ~ 0.35) 10 (0.39) (U note 1. The belt tension must be measured hall - way between the specified pulleys. 2. When a new beltis installed, adjust the tension to the central value of the standard range indicated under "New’ in the above table. Let the engine idle for 5 minutes or more, and check the stan- dard value indicated under “inspection”. 3. When adjusting a belt which has been used, or newly installed, after 5 minutes or more of oper- ation, refer to the standard value indicated under “Used” in the above table. 4. Refer to the standard value indicated under *In- spection* for periodic inspections.GENERAL EMA ~19 TYPE A TENSION GAUGE 4 Tighton the atornator nut "A’ Do not let the dial section of the tension gauge contact 5. Check the tension or the deflection of bett, readjust it ‘other objicts during measurement. necessary. 13 Tightening torque Alternator support nut A: 20 ~ 25 Nm (200 ~ 250 kg.cm, 15 ~ 18 Ib.t) AAllernator lock bolt B = 15 ~ 22 nM (150 ~ 220 kg.cm, 11 ~ 16 Ibity ‘Alternator brace mounting bolt 20 ~ 28 Nm (200 ~ 280 kg.cm, 15 ~ 21 Ib.t) cameo Aerator ‘TYPE B TENSION GAUGE 1. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET position. 2. Ifthe tension gauge is removed from the belt, the nee- dio will stil indicate the tension. Read the tonsion coma value after removing the gauge. wae Tightening torque Alternator support bolt and nut 20 ~ 25 Nm (200 ~ 250 kg.cm, 14 ~ 18 bit) ‘Altomator lock bolt B : 12 ~ 15 Nm (120 ~ 150 kg.om, 9 ~ 11 Ib) ‘Alternator brace mounting bolt ADJUSTING THE ALTERNATOR BELT A) cauTiON It the belt is too loose, it will cause noise or sud- den wear. I the belt is too tight, the engine coolant pump bearing or the alternator can get damaged. 1. Loosen the alternator nut "A" and the tension adjuster lock the bolt *B* 2. Using the tension adjuster bolt, adjust the belt tension to the specification. 3. Tighten the adjuster lock bolt *B*,EMA -20 ENGINE MECHANICAL SYSTEM SPECIAL TOOLS Too! (Number and name) Mustration Use Crankshaft front oil seal installer Installation of the crankshatt front oil seal 09231 - 22000 (1.3L) 6 (use with 09231 - 22100) Crankshaft front oil seal guide Installation of the crankshaft front oil seal 09231 - 22100 (1.3L) QO») (use with 09214 - 22000) ‘Camshaft oil seal installer (09221 - 21000 (1.3/1.1L) Installation of the camshaft oil seal (use with 09221 - 21100) Camshaft oil seal guide Used as a guide when pressing in 09221 - 21100 (1.9/1.1L) the camshaft oil seal (use with 09221 - 21000) Valve spring remover and installer 9222 - 22100 Removal and installation of the inlet ‘or exhaust valveGENERAL EMA -21 “Tool (Number and name) istration Use Valve stem oll sea! installer Installation of the valve stom oil seal (09222 - 22001 (1.3L) (09222 - 02000 (1.1L) Valve guide installer ‘Removal and installation fo the valve guide 09221-21200 A/B (1.3L) 09222 - 02100 (1.1L) SO 3 ‘Crankshait rear oil seal installer 1) Installation ofthe engine rear ol seal (09231 - 21000 (1.31) 2) Installation ofthe crankshatt rear oll seal il fter wrench Removal and installation ofthe oil fiter (08296 - 02000 (1.11) Leak down tester Leak down test of auto lash adjuster 8246 - 32000EMA -22 TROUBLE SHOOTING execu ENGINE MECHANICAL SYSTEM ‘Symptom Probable cause Remedy Low compression Blown cylinder head gasket Replace gasket Worn or damaged piston rings Replace rings Worn piston or cylinder Repair or replace the piston and/or cylinder block ‘Worn or damaged valve seat Repair or replace the valve and/or seat ring Low ol pressure | Low engine oil ovel ‘Cheek engine oil level Faulty oll pressure switch Replace Glogged ol iter Replace Worn oil pump gears or cover Replace Thin oF diuled engine oll ‘Change and find out cause Oil roiet valve stuck (open) Repair Excessive bearing clearance Replace High ol pressure | Oil rele! valve stuck (closed) Repair Excessive engine | Loose engine rol stopper (tron, rear) Retighien vibration Loose transaxie mount bracket Retighien Loose engine mount bracket Reitighten Loose center member Retighten Broken transaxle mount insulator Replace Broken engine mount insulator Replace Broken engine roll stopper insulator Replace Noigy valves ___| Thin or diluted engine oil (Low oll pressure) ‘Change ‘Wor or damaged valve stem or valve guide Replace ‘Connecting rod and ‘main bearing noise Insufficient ol supply (Check engine oil level Thin or diluted engine olf (Change and find out cause Excessive bearing clearance Replace Timing belt noise Incorrect bolt tension ‘Adjust belt tension ‘Low coolant level Leakage of coolant Heater or radiator hose Repair or replace parts Faulty radiator cap Tighten or replace clamps 4 2 3. Thermostat housing 4 5 Replace the gasket or housing Radiator Repair or replace Engine coolant pump Replace parts Clogged radiator Foreign mi ant Replace coolantGENERAL ‘Symptom Probable cause Remedy ‘Abnormally high | Faulty thermostat Replace parts coolant temperature | Fauity radiator cap Replace parts Restricted flow in cooling system Clear restriction or replace parts Loose or missing drive belt ‘Adjust or replace Faulty water pump Replace Faulty temperature sensor or wiring Repair or replace Faulty electric fan Repair or replace Insutficient coolant Refill coolant ‘Abnormally low coolant temperature Faulty thermostat Replace Faulty temperature sensor or wiring Ropiace or repair Leakage from oil cooling system Loose connections: Replace Cracked or damaged ; hoses, pipes or oil cooler Replace or repair inoperative electrical cooling tan Damaged : Thermo sensor, Electrical motor, Radiator tan relay, Wiring Replace or repair Exhaust gas leakage | Loose connections Retighten Broken pipe or muffior Repair or replace ‘Abnormal noise Detached bafile plate in muttier Replace Broken rubber hanger Replace Pipe or muffler contacting vehicle body Correct Broken pipe or muffior Repair or replaceEMA -24 ENGINE MECHANICAL SYSTEM ENGINE AND TRANSAXLE 3. Remove the cowl top cover. ASSEMBLY eoruce REMOVAL, 1. Remove the battery. @ WARNING Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct position on the engine. & caution Use fender covers to avoid damaging painted sur- face. Remove the windshiold wiper arms.GENERAL. EMA -25 6. Detach the air cleaner, 7. Disconnect the backup lamp and engine harness con- tau 9 noctors.EMA -26 ENGINE MECHANICAL SYSTEM 8. For vehicles with 5-speed manual ransaxies, remove __11._Disconnect the coolant temperature sensor and No.1 the clutch release cylinder. TDC sensor connector. 10. Disconnect the connectors for the rear Oxygen sensor harness and the ignition coil harness.GENERAL 13. Disconnect the brake booster vacuum hose. EMA -27 16. Drain the engine coolant from the radiator. 14, Remove the main fuel line and the return and vapor hoses form the engine side. To reduce the residual pressure in the hoses, refer to Group Fuel System “Fuel filter replacement." 16. For vehicles with automatic transaxles, disconnect transaxle ol cooler hoses. (1.3 L only) NOTE When disconnecting the hoses, make identification ‘marks to avoid making mistakes when reconnecting them. & cauTion Be caurful not to spill oll or fluid from hoses, Plug the openings to prevent foreign material from en- tering. 17. Disconnect the radiator upper and lower hoses on the ‘engine side, then remove the radiator assembly, 18. Disconnect the heater hoses (inlet and outlet) on the engine side. 19. Disconnect the accelerator cable at the engine side,EMA -28 ENGINE MECHANICAL SYSTEM 20. For vehicles with manual transaxles, remove the shift 23. Disconnect the air conditioning compressor from the control cable from the transaxle. ‘mounting bracket. 21. For vehicles with automatic transaxles, remove the 24, Remove the steering dust cover, the U-joint bolt and Control cable from the transaxle, (1.9 L only) the gear box assembly. (U) nore ‘Mark between U-joint and gear box before disassem- bing. WW hi 25. Jack up the vehicle and remove the front tir. 26. Remove the caliper assembly from knuckle and hold the upper side. 22. Disconnect the speedometer cable from the transaxle.GENERAL EMA -29 27. Loosen the strut lower bolt and separate from the 30, Attach a chains or cables to the engine. knuckle. Use an engine hoist or a chain hoist to slightly raise the engine (enough to support the engine’s weitht while processing with the following steps.) 28. Remove the wheel speed sensor from the knuckie. (with ABS) Qnore Use wire to suspend the exhaust pipe from the bottem of the vehicleEMA -30 ENGINE MECHANICAL SYSTEM 81. Remove the engine mounting bracket from the en- 34. Remove the cross member fixing bolts and nuts. 35, While directing the transmission side downward, lit 82. Slowly raise the engine to the extent that the weight of, the engine and transmission assembly up and out of the engien and transmission assembly is not applied the vehicles. to the mounting portions) and temporarily hold it in the. raised position. 33. Remove the caps from the inside of the right fender shield and remove the transaxle mount bracket bolt.TIMING SYSTEM EMA -31 TIMING SYSTEM TIMING BELT COMPONENTS | cxsxrse TORQUE : Nm (kg.cm, Ib.ft)EMA -32 ENGINE MECHANICAL SYSTEM COMPONENTS | exxerno we Knock pin ‘Camshaft sprockot ‘Timing mark {80 - 100 (800 - 1000, 59-74) ‘Tonsion sido of belt Loose side of belt _- Timing mark (Frent case) Tensioner spring Timing mark (Crankshaft sprockel) TORQUE : Nm (kg.cm, Ib.ft) CCrankshatt sprocketTIMING SYSTEM EMA -33 DISAESSEMBLY | «xcoone vk Loosen the coolant pump pulley bolt. Loosen the generator bolt. 1. Remove the coolant pump pulley and belt. Remove the timing belt cove. 1 2. 3 4, Remove the crankshaft pulley. 5. 6 ‘Align the timing marks of the camshaft sprocket and crankshaft sprocket, withthe No.1 piston placed at top fereeie «dead center on its compression stroke, 7. Move the timing belt tensioner pulley toward the ‘coolant pump and temporarily secure it.EMA -34 9. Remove the camshaft sprocket. 10. Remove the crankshaft sprocket bolts. Remove the crankshaft sprocket and flange. 11, Remove the timing belt tensioner. ENGINE MECHANICAL SYSTEM INSPECTION | corso TIMING BELT 1 Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry clath or paper. Do not clean with solvent. ‘When the engine is overhauled or belt tension ad- justed, caretully check the belt. any ofthe following flaws are evident, replace the belt. Deseription Flaw conditions 1. Hardened back suface Back suface glossy. Non-clastic and so hard that when your fingernail is pressed into it, no mark is produced. 2. Cracked back surlace rubber gy BG 3. Cracked or separating canvas crack = Separation crack SeparatonTIMING SYSTEM EMA -35 Deseription Flaw conditions 4, Badly worn teoty (initial stage) Canvas on load side tooth flank worn (Flutty canvas fibers, rubber gone and color changed to white, and unclear canvas texture) Fane wor (Ontoad side) | 5. Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced) 6. Cracked tooth bottom A GS crack 7. Missing tooth “Tooth missing and canvas fiber exposed 8. Sido of belt badly worn ‘A normal belt should have precisely cut sides as if cut by a sharp knito, 9. Side of belt cracked SPROCKETS AND TENSIONER 1 cracks, or damage. Replace as necessary. noise. Replace as necessary. Check the camshaft sprocket, crankshaft sprockst, tensioner pulley, and idler pulley for abnormal wear, Inspect the tensioner pulley and the idler pulley for ‘easy and smooth pulley rotation and check for play orEMA -36 REASSEMBLY 1. Install the flange and crankshaft sprocket as shown, ay close attention to their mounting directions. sab Chamiers ‘Special washor 4 Ccrankshatt crn “Ext une Tightening torque Crankshaft sprocket bolt 1.3L: 140 -150Nm (1400 ~ 1500kg.om, 103 ~ 11 fib.) u (00 Nm (700-1000 kg.c 4 tb.) 2. Install the camshaft sprocket and tighten the bolt to the specified torque. ENGINE MECHANICAL SYSTEM Tightening torque ‘Camshaft sprocket bolt : 80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~ 74 Ib.) 3, Align the timing marks of the camshaft sprocket and crank shaft sprocket, with the No.1 piston placed at top dead center on its compression stroke. Wore When installing camshaft sprocket. Make sure that cmashaft sprocket knock pin fits small hole in pulley as shown.TIMING SYSTEM EMA -37 4, Tentatively fasten timing belt tonsionor as such posi 6, install the timing bet tightly in the sequence shown, tion as to place its pulley nearest o water pump body. DCrankshatt sprocket -> @Camshaft sprocket > Timing belt tensioner. 5, Hang the tensioner spring on the tensioner bracket ‘and.nser the other spring side inthe front case using camshaft spockot the screw driver. 7. Install timing belt s0 as not to give salck to tension side. [W) Nore Then make sure that timing marks are at correct po- sition respectively with tension side in strained state _by applying force to camshatt sprocket in reversing d- rection. 8. Loosen the tensioner mounting bolt in the order as, shown tio give the timing bett spring tension. Tensioner springEMA -38 9, Rotate crankshatt in regular direction (clock wise view from 8 front) through angle duivalent to two teeth (18°) of camshaft sprocket. 10. Add force to tensioner in direction of regular rotation G direction) so as to bring belt teeth in perfect con- tact with sprocket teeth without gap. 11, After marking sure of this state Fix tensioner in state that only tensioner spring is movable. 12, Rotate the crankshatt pulley two or four turns conter clockwise so that the timing belt positions on the pul leys, 13. Thon recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with 2 moderate force [approx. 49N (11 tb)], the timing belt is offest from bolt head center by approxmately bolt of the tensioner adjusting bolt head radius. (1.3L) ‘V2 otbott head radius (across tat) 14, 15. 16. 17. 18. ENGINE MECHANICAL SYSTEM Make sure that gap between back side of belt and tim ing belt cover mounting hole center of cylinder block is about 20 mm, when holing the center of tension side with @ thumb and a foretingor. (1.1 L) wg Install the timing belt cover. Install the crankshaft pulley. Install the air condition belt and adjust belt tension. Install the coolant pump pulley. Install V-belt and adjust the belt tension.CYLINDER HEAD ASSEMBLY EMA -39 CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS | sxexsor 13k Gylinder head bot = 23 ~ 27 (230 ~ 270, 17 ~ 20) + 60°+45" e@ Cylinder head Cylinder head gaskot TORQUE : Nm (kg.cm, Ib.ft)EMA -40 COMPONENTS | exrcon: ENGINE MECHANICAL SYSTEM TORQUE : Nm (kg.cm, Ib-ft)CYLINDER HEAD ASSEMBLY EMA -41 DISASSEMBLY cco 5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. |. Drain the coolant and disconnect the upper radiator escent 6. Remove the ignition coil. Remove the breather hose (between the air cleaner 7. Remove the surge tank stay. land the rocker cover). 8. Remove the intake manifold 8. Remove the heat protector and exhaust manifold as- sembly. 10. Remove the coolant pump pulley and the crankshaft pulley. 11. Remove the timing belt cover. 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 43. Remove the timing belt. 3, Remove the air-intake hose. ‘14. Remove the rocker cover 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Cylinder Head Bolt Wrench, in the sequence as shown in the ius tration, 4, Remove the vacuum hose, fuel hose and coolant hose.EMA -42 ENGINE MECHANICAL SYSTEM ‘Crankshaft pully sido 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. (WO nore ‘Make sure that the gasket pieces do not fll into the engine. INSPECTION corceers 1. Check the cylinder head for cracks, damage and ‘coolant leakage. 2. Remove scale, sealing compound and carbon de- posits completely. After cleaning oil passages, apply compressed aor to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, ..as shown, It flaess exceeds service limit in any direction, re- place the cylinder head, or lightly machine the cylin- der head surface. Cylinder head flatness Standard value 1.3 L : Less than 0.03 mm (0.012 in.) 1.1L: Less tha 0.05 mm (0.002 in.) Limit 1.3 L : 0.08 mm (0.0031 in.) 4.4.0.1 mm (0.004 in.) REASSEMBLY cro 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket into the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket. 3. Install the cylinder head bolts. Starting at top center. tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench. Repeat the procedure, retightening all cylinder head bolt to the specified torque.CYLINDER HEAD ASSEMBLY CYLINDER HEAD FLATNESS “Tightening torque 4.3L: 28-27NM (230-270kg.em, 17-20ib.t)+60°+60° 47 ‘When cold : 60-70 Nm (600-700 kg.em, 43~51 Ib.) When hot : 70-75 Nm (700-750 kg.cm, 51-54 ibs) sat Crankshaft pay side tak ‘Granksat ply ete EMA -43 4, Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 5. Install the timing belt on the camshaft sprocket, mak- ing sure that the tension side is tightened by turning the camshaft sprocket in reverse. Make sure all tim- jing marks are in alignment. 6. Adjust the timing according to the "Timing Belt” sec- tion. 7. Install the rocker cover and tighten the bolts to the specified torque. Tightening torqu Rocker cover bolt : 8 ~ 10. Nm (80 ~ 100 kg.cm, 6 ~ 7 Ibs) Install the timing bett cover. ©. Install the now intake manifold gasket and the intake manifold, Tighton the nuts and botts to the specified torque. Tightening torque Manifold nuts and bolts (both intake and exhaust) 15 ~ 20 Nm (10 ~ 200 kg.cm, 11 ~ 15 lb) 10. install the new exhaust maniflid gasket and the ex- haust manifold. Tighten the exhaust manifold attach: ing nuts to the specified torque. 11. Install the surge tank and tighten the nuts and bolts to the specified torque. Tightening torque Surge tank to inlet manifold nuts and bolts : 15 = 20 Nm (250 ~ 200 kg.cm, 11 ~ 15 lb.t) 12, Install the ignition coil 19. Install the air intake hose. 14, Connect the vacuum hose, {uel hose and coolant hose. 15. Install breather hose.ENGINE MECHANICAL SYSTEM EMA -44 ROCKER ARM COMPONENTS | écsirces 3b i tockerarm locker shatt spring jockerarm shaft (inlet) A (2) jockerarm 1 SA ft § A Pa cm te i \ Wi i 9 O TORQUE : Nm (kg-cm, Ib-ft)CYLINDER HEAD ASSEMBLY COMPONENTS | ernsoro TORQUE : Nm (kg.cm, Ib.ft)EMA -46 ENGINE MECHANICAL SYSTEM DISASSEMBLY | cwssoo INSPECTION | ccsosess 1. Remove the brdather hose and PCV valve. ROCKER ARM aL rANy 1. Check the rocker face, Ic WW BSF Replace it it damaged or pressed. Check the contact surtace on the cam and viave stem. If badly worn or damaged, replace it. 3, Check hydraulic lash adjust (HLA) face that contact the valve stom if badly worn or damaged, replace the HLA. (1.3 only) 2. Remove the timing belt cover. 3. Remove the rocker cover. 4. Loosen the flange bolts and remove the rocker arm shaft, rocker arms and rocker arm shal springs as an assembly, 5. Remove the bolts, the rocker arms and arm shaft springs from the rocker arm shat soon ROCKER ARM SHAFT 1. Check the rocker arm shafts for damage, Replace as. necessary. 2. Check the oil hole whether clogged or not.CYLINDER HEAD ASSEMBLY EMA -47 HLA (1.3 L ONLY) With the HLA filed with engine oil, hold A and press Othole B by hand. If B moves, Replace the HLA ig For other specific trouleshooting regarding HLA, refer to the table below. Problem Possible cause ‘Action + Temporary noise on startin a cold engine Normal This noise will disappear after the oil in the engine has reached normal pressure, * Continuous noise when engine is started after loger than 48 hours parking. Oil drain out of the high pressure | Noise will disappear within 15 minutes chamber on HLA, allowing when engine run at 2000-3000 rpm air to get in. lfnot disappear, refer to item 7 below * Continuous noise when engine is first started after rebuilding cylinder head. Insuffecient oll in cylinder head oil gallory. + Continuous noise when engine is after excessive craking the engine by starter motor or band, + Continuous noise when engine is after changing HLA. Oil drain out of the high-pressure chamber in HLA, allowing air to got in. Q caution Do not run engine all a speed higher than 3000 rpm as this may damage HLA. * Continuous noise during idle after high speed running. Engine oil level too high or too low. | Check oil level Drain or add oll as necessary. Execssive amount of air in the lat high engine speed. Check oil supply system Deteriorated oil ‘Check oil quality. Ht deteriorated, replace with specified type and amount of oil. * Noise cotinues more than 15 minutes. Check oil pressure and oil supply tow oil pressure system of each part of engin Faulty HLA. Remove the cylinder head over and press down HLA by band. It it moves, replace HLA, Q caution Be careful of hot HLA.EMA -48 ENGINE MECHANICAL SYSTEM VALVE CLEARANCE ADJUSTABLE PROCEDURE 5. Turn crankshatt just one revorution to nomal direction (1.1L ONLY) (ight turn at engine front view) stop it at No. 4 com- pression top dead center. 1. Warm up engine, Ingert clearance gauge between rocker arm adjusting ‘screw and viave stem end, 2. Flomove the rockor cover Them fix screw with lock nut ater adusting valve clearance. 3. Tumcrankshattonomal rection (ighttura at engine Hii ahaltahs the pee ean Valve clearance adjustable at No. 4 compression top ter, shown in fig, Valve clearance adustable at No.1 oad conter. compression top dead center. Pression WP cvunperNo. [| 1 | 2 | 3 | 4 CYLINDERNO. | 1 | 2 | 3 , INTAKE olfo INTAKE olo EXHAUST 0 ° EXHAUST ° ° Tring 4, Insert clearance gauge between rocker arm adjusting screw and viave stem end. ‘Then fix screw with lock nut after adjusting valve clear- ance, INTAKE | EXHAUST Standard Clearance (War) Reference Clearance (Cold) 02mm | 025mm O.tmm | 0.17 mmCYLINDER HEAD ASSEMBLY REASSEMBLY | cccsosc 1. Install the rocker arms and rocker arm shaft springs to the rocker arm shafts, install the rocker arm shaft to the cylinder head. ‘Tighten the rocker arm shaft mounting bolts to the specified torque. Tightening torque Rocker arm shaft mounting bolt 1.3 L : 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 Ib.t) 1.1 L: 27 ~ 32 Nm (270 ~ 320 kg.cm, 20 ~ 24 Ib) 13L Timing bel side ‘entiation mark 2. When installing the rocker arm, shaft and spring, mark the difference of left and right part. Use the spring without distinction of intake and ex- hhaust valve. ‘Must set the part that is small chamfer side between tow parts of rocker arm shaft to the timing belt. EMA -49 3, Install the air rocker cover and tighten the bolts to the specified torque. Tightening torque Rockr cover bolt 8 ~ 10. Nm (80 ~ 100 kger 7 tb.) A) caution 1. Sealant must be applied to top surface of cylinder head and cam cap and area of appli- cation is shown in figure. 2. The proper amount of sealant must be used to prevent the sealant from pushing excessive amounts. Use sealant of specitied brands or equivalant. Sealant (Three bond No. 1212D aluminum color or equivalent) application place (4 place). as 10mm (0.4m) 30mm (04 in) 4. Install the timing belt cover. Tightening torque Timing belt cover bolt : 10 ~ 12 Nm (100 ~ 120 kg.cm, 5. _Installthe breather hose, PCV hose, blow by hose and spark plug cable. 6. _ Install the air intake hose and aor duct.EMA -50 VALVES COMPONENTS | sscieu ENGINE MECHANICAL SYSTEM at @—— fuaner ex Z]_— eve spring retainer Retainer lock ————€ Vv spring tanar 2? — Vato sping vase song —@ arto 5 ©] ave sping ont vn teat Valve spring seat j- ——— exhaust valve guide is Intake valve guide eo sk va seat nau vao seat edCYLINDER HEAD ASSEMBLY COMPONENTS | crccr EMA -51 ak Aetharlock a) Vane Sing Vane stem sea! ©} Valve spring seat Intake valve guide S] / Exhaust abe coat $y a vad seat mmf ato Exhaust locket arm wn — ey Qo so Valve pring Valve stem seal Vatve spring seat Exhaust valve guideEMA -52 DISASSEMBLY 1. Using the special tool, Valve Spring Remover and in- staller, remove the retainer lock. Next, remove the Vlave spring, spring seat and valve. NOTE Keep these parts in order so that they can be rein- stalled in their original positions. 2. Remove the valve stom seals with pliers, and discard them (note Do not reuse the valve stem seals. INSPECTION cxcrows VALVE SPRING 1. Check the vaive spring free length and tension. If they exceed the service limit, replace the spring 2. Using a square, test the squareness of each spring. Ita spring is excessively out of square, replace it. 13L ENGINE MECHANICAL SYSTEM VALVE SPRING Standard viaue Free height 1.3L: 42.03 mm (1.656 in.) 4.1L: 40.50 mm (1.594 in.) Load 1.3L: 24.7 kg at 34.5 mm 1.1L: 15.60 + 0.9 kg/32.0 mm Out of square : 1.5° or less VALVE GUIDES Check the valve stem-to-guide clearance. If the clearance ‘exceeds the service limit, replace the viave guide with the next oversize part VALVE STEM-TO-GUIDE CLEARANCE ‘Standard viaue Intake 4.3L : 0.030 ~ 0.060 mm (0.0012 ~ 0.0024 in.) 4.1L :0.020 ~ 0.047 mm (0.0008 ~ 0.0018 in.) Exhaust 1.3L: 0.035 ~ 0.085 mm (0.0014 ~ 0.0026 in.) 1.1L: 0.050 ~ 0.082 mm (0.0019 ~ 0.0032 in.) VALVE GUIDE OVERSIZES Size mm (in.) Size mark Cylinder head hole size mm (in.) 0.05 (0.002) OS. 5 11.05 ~ 11.058 (0.495 ~ 0.4354) 0.25 (0.010) OS. 25 11.25 ~ 11.258 (0.429 ~ 0.4432) 0.50 (0.020) OS. 50. 11.50 ~ 11.508 (0.4528 ~ 0.4531) 1a Size mm (in.) ‘Size mark Cylinder head hole size mm (in.) (0.05 (0.002) OS. 5 10.05 ~ 10.068 (0.395 ~ 0.396) 0.25 (0.010) OS. 25 1.025 ~ 10.268 (0.403 ~ 0.404) 0.50 (0.020) OS. 50 10.50 ~ 10.518 (0.413 - 0.414)CYLINDER HEAD ASSEMBLY VALVE GUIDE REPLACEMENT PROCEDURES, Tho valve guide is installed using a press fit. Using Value Guide installer (09221-21200 AB (1.3L), 09222-02100 (1.1L) or suitable too), replace the valve guide described in the following procedure. 1. Using the Vaive Guide installer push rod, push the valve guide out toward the cylinder block with a press. ave gue tar vate ge woes Cider nea Vale gue tater ave guide RR {\ 2. Machine the valve guide insert hole in the cylinder head to the specified oversize of the new valve guide. 3. Using the Valve Guide installer or suitable tool, press fit the valve guide. Using the vlaive guide installer makes it passinle to press ft the valve guide to a pre- determined height. Install the viave guide from the top of the cylinder head. Note that intake and exhaust valve guides difer in length. EMA -53 4. Alter installing the valve guides, insert new valves and check the clearance. + eraser) (| vate pute rttr adopter a (022212200098) ‘Hom (0381210) | | ‘Valve guide U4 Cylinder hoad Valve guide instaler 5. Whenever valve guides are replaced, check for valve-to-seat contact, and recondition the valve seats, as necessary, VALVE SEAT INSERT ‘Check the valve seat for evidence of overheating and im- prioper contact with the valve face. Recondition or replace the seat, if necessary. Before reconditioning the seat, check the valve guide for ‘wear. Ifthe viave guide is worn, replace i, then recondi- tion the seat. Recondition the viave seat with a valve seat grinder or cutter, The valve seat contact width should be with within specifications and centered on the valve face,EMA -54 08-42mm (0.03%-0.087 in) VALVE SEAT INSERT REPLACEMENT PROCEDURE. Any valve seat insert that has been worn over the ser- Vice limit should be removed at normal temperature after culting away most of the insort wall, using valve Seat cutters, as shown in Fig A. ENGINE MECHANICAL SYSTEM 2. After removing the seat insert, machine the seatinsert bore using a reamer or a cutter. Cut to the size shown in the table. 3. Heat the cylinder head to about 250°C (480°F) and press in the oversize seat insert. The oversize seat insert should be at normal room temperature for in stallation. Alter installing a new valve seat insert, resurface the valve seat using the same procedure described in the first paragraph of *Valve Seat Insert” (above), ‘.3rym (0.012 In.) etm (0090) aan LY ] a m one O.5-1mm A B aT VALVE SEAT INSERT OVERSIZES 13 Size | Seat insett height H Description | Sizemm in.) | Si6. mm tin) Cylinder head 1.0. mm (in.) Intake valve [03(0.012)0S.[ 80 | 5.15.3 (0.201-0.2069) 26.80-28 B21(1.134~1.135) seat insert | 0.6(0.024) 0.8. | 60 54-56 (0.213-0.220) 29.10-29.121(1.146-1.147) Exhaust vaive [09(0.012)08.| 30 59-61 (0.232-0.240) 34,90-84.925(1.50-1.351) seat [0.6(0.024)08.| 60 6.2-6.4(0.244-0.252) 34.60~94.625(1.362-1.363) ak Size | Seat insett height H Description | Sizemm (in) | Sue. wn (in Cylinder head 1.0. mm (in.) Intako vane [0.3(0.012)0S.[ 30 62-644 (0.248-0.252) 24.90-24,921(0.957-0.958) seatinsert | 0.6(0.024)0.8. | 60 6.5-6.7 (0.0256-0.264) 24,60-24.621(0.968-0.969) Exhaust valve [03(0.012)0S.| 30 6.2-6.4 (0.244-0.252) 29.30-29.921(1.159-1.154) seat [os oros.| 60 6.5-6.7(0.256-0.264) 29,60-29,621 (1.165-1.166)CYLINDER HEAD ASSEMBLY VALVES Check each vaive for wear, damage and distortion of head and stem at B. Repair or correct, f necessary. If stem end A\spitted or worn, resurface as necessary. This correction ‘must be limited to a minimum. Also resurface the valve face. Replace the vaive if the margin has decreased to less than the service limit. a ast Margin MARGIN Standard value Intake 1.3L: 1.1 mm (0.043 in.) 1.1L: 0.8 mm (0.031 in.) Exhaust 1.3L: 1.4 mm (0.056 in.) 4.4L 1.2 mm (0.047 in.) Limit Intake 1.3L: 0.8 mm (0.031 in.) 4.4L: 0.5 mm (0.019 in.) Exhaust 1.3L: 1.1 mm (0.043 in.) 4.4. 0.9 mm (0.035 in) EMA -55 REASSEMBLY NOTE 1. Though clean each pat before assembly 2. Apply engine ol to sling and rotating parts. 1. Alter instaling the spring seat, fit the stem seal into the valve guide, To install, fit the seal in by lightly tapping the Special Tool, Valve Stem Oil Seal installer. The seals installedin the specified position by means. of the special tool. Incorrect installation ofthe seal will adversely affect the lip I.D. and eccentricity, resulting in oil leaking down the valve guides. Therefore, when installing, be careful not to twist the seal. Donot reuse ‘old stem seals. Valve Valve pring 2. Apply engine oil to each valve. Insert the vaives into the valve guides. Avoid using force when inserting the valve into the seal. Alter insertion, check to see if the valve moves smoothly. 3. Install springs and spring retainers. Valve springs should be installed with the enamel coated side to- ward the valve spring retainer. Valve springs should be installed with the enamat coated side toward the valve spring retainer. ‘Spring retainer stom seal a vos Valve spring seatEMA -56 4 Using special tool, Valve Spring Remover and In: staller, compress the spring. Be careful that the valve stem seal is not distorted by the bottom of the retainer. Then install the retainer locks. After installa- tion of the valves, make certain that the retainer locks. are property installed. Install the cylinder head. Refer to "Cylinder Head” ENGINE MECHANICAL SYSTEMMAIN MOVING SYSTEM MAIN MOVING SYSTEM CAM SHAFT COMPONENTS «xo. EMA -57 13L Bolt £80 - 100 (800 - 1000, 59- 74) sa | ~ Dowel pin Camshatt TORQUE : Nm (kg.cm,lb-ft) 5.8 mm (0.23 in.) 45mm (0.18In)EMA -58 ENGINE MECHANICAL SYSTEM COMPONENTS | exvcsrcMAIN MOVING SYSTEM. DISASSEMBLY 1 2 Disconnect the breather hose and the PCV hose. Remove the coolant pump pulley and crankshaft pul ley. Remove the timing belt cover. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. Remove the timing belt from the camshaft sprocket. Remove the camshatt sprocket Remove the ignition coil assembly. (1.1 Lonly) Remove the rocker cover. Remove the rocker arm shaft assembly, Refer to "Rocker Arms and Rocker Arm Shafts" section. sae 10. Remove the camshaft bearing caps. (1.3 L) Remove the camshaft from front side to rear. (1.1 L) EMA -59 11. Remove the camshaft. INSPECTION CAMSHAFT 1. Check the cagmshaft journals for wear. Ifthe journals are badly worn, replace the camshaft. 2. Check the cam olbes for damage. Ifthe lobe is dam- aged or worn excessively, replace the camshaft ‘Cam hoight Standard value Intake 1.3L: 42.8575 mm (1.6873 in) 4.1L: 34.8729 mm (1.3729 in.) Exhaust 1.3L: 42.7354 mm (1.6825 in.) 4.4L: 35.1258 mm (1.3829 in.) Limit Intake 1.3 L : 42.9575 mm (1.6676 in.) 4.1 L:: 34.7729 mm (1.3690 in.) Exhaust3. Check the cam surface for dbnormal wear or damage, and repiace if necessary. 4. Check each bearing for damage. If the bearing sur- face is excessively Gamagedm, Replace the cylinder head assembly or camshaft bearing cap, as neces- sary. OIL SEAL (CAMSHAFT FRONT) ‘Check the lips for wear. Il lip threads are worn, re- place. 2. Check the oil seal lip contacting surface of the camshatt. If it is wom in stages, replace the camshatt. ‘Camshatt end play 1.9 L : 0.07 ~ 0.28 mm (0.0003 ~ 0.0011 in.) 1.1L: 0.07 ~ 0.19 mm (0.0003 ~ 0.0007 in.) REASSEMBLY cxemo 1. Install the camshaft after lubricating the journal of the camshaft with engine oil. 2. Install the camshaft bearing caps. (1.3 L) Install the ignition coil (1.1 L) 3. Install the rocker arm and rocker arm shaft. Refer to the "Rocker Arms and Rocker Arm Shafts" section. 4. Using the Special Tools, Camshaft Oil Seal Installer (09221-21000), press and fittne camshaft seal. Be Sure to apply engine oil to the external surface of the ouil seat. Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is fully seated. ENGINE MECHANICAL SYSTEM 5. Install the camshatt sprocket and tighten the bolts to the specified torque. Tightening torque Camshatt sprocket bolt : 80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~ 74 Ibs) 6. Align the camshatt sprocket and crankshaft sprocket timing marks. The piston in the No. 1 cylinder wil then be at top dead center on the compression stroke. ming markMAIN MOVING SYSTEM EMA 61 7. _Intall a gasket in the rocket cover groove, 8 Temporarily install the rocker cover. 9. Start the engine and run at idie. 10. Install the rocker cover and tighten the bolts to the ‘Specified torque. Tightening torque Rocker cover bolt -10Nm (80-100 kg.om, 6-7 ib) 11. Install the timing belt cover. 12, Install the coolant pump pulley and crankshaft pulley.EMA -62 ENGINE MECHANICAL SYSTEM CRANK SHAFT COMPONENTS | exzycace Crankshaft upper thrust bearing Crankshaft position sensor whee! (131 only) AY 5 - 6 (60 ~ 60,97 - 4.4) (Crankshaft upper bearing AY ‘Crankshaft lower beating L oe an R w&— Msn oan cap TUS S ems a7 oa TORQUE : Nm (kg.cm, Ib-ft)MAIN MOVING SYSTEM DISASSEMBLY 1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective chapters. 2. Remove the rear plate and the rear oil seal 3. Remove the connecting rod caps. 4, Remove the main bearing caps and remove the crank- shaft. Keep the bearings in order according to the cap number. 5. Remove the crankshatt position sensor wheel. caution Mark the main bearing caps topermit reassembly in the original position and direction. INSPECTION | escsoses CRANKSHAFT 1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for cog” ing. Correct or replace any detective part. 2. Inspect out-of-roundness and taper of crankshattjour- ral and pin. ‘Standard value Crankshaft journal O.D. 4.3 L: 50 mm (1.9685 in.) 1.1L: 42 mm (1.664 in.) Crankshaft pin 0.0. 4.3L: 45 mm (1.7717 in) 1.1L: 38 mm (1.496 in.) Crankshaft journal, pin out-of-roundness and taper 0.01 mm (0.0004 in.) or less MAIN BEARINGS AND CONNECTING ROD BEARINGS, Visually inspect each bearing for peeling, melting, seizure land improper contact. Replace the detective bearings. OIL CLEARANCE MEASUREMENT To check the oil clearance, measure outside diameter of the crankshatt journal and the crank pin and inside diam- eter of the bearing. The clearance measuromont is the difference between the measured outside and inside oi- ameters. EMA 63 13k Standard value Journal oll clearance No. 1, 2, 4,5 0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.) Journal oll clearance No. 3 (center) 0.034 ~ 0.52 mm (0.0013 ~ 0.002 in.) Pin oil clearance : 0.024 ~ 0.042 mm (0.0009 ~ 0.0017 in.) wk Standard value Journal oll clearance No. 1, 2, 3, 4, 5 0.020 ~ 0.038 mm (0.0007 ~ 0.0014 in.) Pin oil. clearance : 0.012 ~ 0.041 mm (0.0005 ~ 0.0016 in.) PLASTIC GAUGE METHOD A plastic gauge may be used to measure the clearance. 1, Remove oil, greass and any other dirt trom bearings and journals. 2. Cut plastic gauge to the same length as the width of the bearing and piace ot parallel with the journal, off trom the oil holes. Plasticgauge 3. Install the crankshaft , bearings, and caps. Tighten them to the specified torques. During this operation, do not tum the crankshaft. Remove the caps. Measure the width of the plastic gauge at the widest point using the scale printed on the gauge package. I the clearance exceeds the repair limit, replace the bearing ‘Should the standard clearance not be obtained even atter bearing replacement, the journal should be {round to a recommended undersize, and a bearing of the same size should be installed.OIL SEAL, ‘Check front and rear oil seals for damage or worn lips. Replace any seat that is defective CRANKSHAFT POSITION SENSOR WHEEL 1. Remove the crankshaft position sensor wheel. 2. Check the crankshaft position sensor wheel for dam- ‘age, cracks and wear, and replace if necessary, 3. Check the clearance between the crankshaft position ‘sensor wheel and the crankshaft position sensor with ‘a depth gage. Standard value Clearance between the crankshaft position sensor wheel and crankshaft position sensor 0.5 ~ 1.5 mm (0.0020 ~ 0.059 in.) NOTE ‘Measure the depth ofthe top of the crankshaft pposition sensor whee! teeth and the outside of transaxle housing. 2. Measure the diference between the crankshaft position sensor length and depth. 3. The crankshaft position sensor length is the distance between the end of crankshaft postion ‘sensor and inner point of contacting face. ENGINE MECHANICAL SYSTEM REPLACEMENT 1. Check the cylinder biock stamping crankshaft bore size code. ast Record the cylinder block crankshaft bore size code letters on cylinder block as shown. Reading order is from eft to right with front crankshaft bore size code shown first Cylinder block crankshaft bore diameter 1.3L Cylinder block crankshaft | Size Class bore diameter code. ‘54 ~ 54.006 mm a (2.1259 ~ 2.1262 in) ‘ » | 54006 ~ 54.012 mm 2.1262 | ~ 2.1264 in) | SOI 58016 mm etzea |S ~ 2.1266 in)MAIN MOVING SYSTEM. EMA -65 at MAIN JOURNAL BEARING THICKNESS. Class | °viinder biock crankshaft Sie | NO. 1,2,4,5 bore diameter code. _ _ 46 ~ 46.006 mm Color Main journal bearing thickness a 1.811 ~ 1.8112 in A (1.811 ~ ) Yellow | 2.002~2.005mm (0.0788~0.0789in.) b 46,006 ~ 46.012 mm (1.8112 B Green 2.005-2.008mm (0.0789-0.0790in.) ~ 1.8115 in.) No color | 2.008-2.011mm (0.0780-0.0781in) A 46.012 ~ 46,018 mm (1.8115 c { = 1.8117 in) Black 2.011-2.014mm (0.0791-0.0793in.) Blue 2.014-2.017mm (0.0783-0.0794in.) 2. Check the crankshaft main journal 13L Main journal size code nore Record the main journal size code letters on the crankshaft blanco weight. Reading order is from left o right as shown, with no.1 ‘main journal size code shown first. CRANKSHAFT MAIN JOURNAL DIAMETER Class Main journal diametor on ; 49.968 ~ 49.962 mm A (1.9672 ~ 1.9670 in.) 49.962 ~ 49.956 mm > (1.9670 ~ 1.9687 in.) 49.956 ~ 49.950 mm (1.9867 ~ 1.9665 in.) NO.3 (CENTER BEARING) Color Main journal bearing thickness Yellow | 1.999-2.002rn (0.0787-0.0788in) Green 2.002~2.005mm (0.0788~0.0789in.) No color 2.005~2.008mm (0.0789~0.0790in.) Black 2.008~2.011mm (0.0790-0.0791in.) Blue 2.011-2.014mm (0.0791-0.0793in,) WGanor 1a Record the main jouranl size code painted on the crankshaft as shown. CRANKSHAFT MAIN JOURNAL DIAMETER Class | Main journal diameter | Classifica || reeset esaainy | Ym aes im [te Cs etEMA -66 MAIN JOURNAL BEARING THICKNESS Color “Main journal bearing thickness Biue | 2.002-1.999mm (0.0788-0.0787in.) ENGINE MECHANICAL SYSTEM 4, Make certain that the crankshaft turns freely and has the proper clearance between the center main bear- ing thrust flange and the connecting rod big end bear- ing. No color | 1.999-1.996mm (0.0789-0.0780in.) Yellow 1,996~1.993mm (0.0780-0.0791in.) Green 1,993-1.990mm (0.0785-0.0783in.) Pink 1,990-1.987mm (0.0783-0.0762in.) 3. Choose proper main journal bearing in table. REASSEMBLY cocoon 41. Install the upper main bearing inserts in the cylinder block. When reusing the main bearings, remember to in- stall them by referring to the location marks made at the time of disassembly. 2. Install the crankshaft. Apply engine oilto the journals. 3. Install bearing caps and tighten cap bolts to the spec ified torque in the sequence of the center, No.2, 4, front and rear caps. Cap bolts should should be tightened evenly in 2 t0 3 stages batore they are tightened to the specified torque. ‘The caps should be installed with the arrow mark di rected toward the crank pulley side of engine. Cap numbers must be correct. Tightening torque Main bearing cap bott 1.3L: 55 ~ 60 Nm (550 ~ 600 kg.cm, 41 - 44 Ibs 1.1L 50 ~ 85 Nm (500 ~ 550 kg.cm, 37 ~ 41 Ib.) Connecting rod cap bolt 4.3 L: 82 ~ 95 Nm (820 ~ 350 kg.cm, 24 ~ 26 Ibs} 1.1L: 20 23 Nm (200 ~ 280 kg.cm, 15 ~ 17 Ibst) Standard value Crankshatt end play 1.3L : 0.05 ~ 0.175 mm (0.002 ~ 0.005 in.) 1.1L: 0.05 ~ 0.25 mm (0.002 ~ 0.010 in.) ‘5. Install the oil seal in the crankshatt rear oil seal case, Use the Special Tool, Crankshaft Rear Oil Seal in- staller (09231 - 21000) as shown. Press and fit the oil seal in all the way, being careful not to misalign it. 6. Install the rear oil seal case and gasket. Tighten the five bots, Apply engine oil to the oll seal ips and erankshatt of the time of installation. 7. Install the rear plate and tighten the botts. 8. Install the connecting rod caps. Refer to the "Piston and Connecting Rods" section. 98. Install the flywheel, front case, cil pan and timing bett For further details, refer to the respective chapters.MAIN MOVING SYSTEM FLY WHEEL COMPONENTS | ccoccinsr EMA 67 1.3L ceptor pate TORQUE : Nm (kg.cm, Ib.ft) 130-140 (1300 - 1400, 96 - 103) Ring rear Flywheel 190-140 (1300-1400, 96 - 103) Drive plate Adaptor plateEMA -68 ENGINE MECHANICAL SYSTEM COMPONENTS. esmners Wik 70 ~ 80 (700 ~ 800, 52-59) 70 ~ 80 (700 ~ 800, 52 ~ 59) Ring gear Drive ~ a } Ohh y Flywheel Adaptor plate TORQUE : Nm (kg.cm, Ib.ft) MT : Manual Transaxle Vehicles Standard value DISASSEMBLY | cssssm 1 2 INSPECTION 1 Remove the transaxle and clutch, Remove the flywheel. Check the clutch disc contacting surtace of the tly whee! for damage and wear. Replace the flywheel it excessively damaged or worn, Check the clutch dise contacting surtace of the fly ‘wheel for runout. Fiywheel run-out : 0.1 mm (0.004 in) 3. Check the ring gear for damage, crack and wear, and replace if necessary. REASSEMBLY | sescraxs Install the flywheel assembly and tighten the bolts to the specified forque. Tightening torque Flywheel bolt 1,3L : 130-140Nm (1300-1400 kg.cm, 96-103 tb.t) 1.1L : 80-80Nm (700-800 kg.cm, 52-59 Ib)MAIN MOVING SYSTEM EMA 69 PISTON COMPONENTS | sa:cx0 No. 1 Piston ring No. 2 Piston ring il ring Piston, Piston pin Connecting rod é Bolt Upper bearing Lower beating —\ @ tab wae ~ 35 (900 ~ 350, 24 ~ 26) ~ 23 (200 ~ 290, 15 ~ 17) TORQUE : Nm (kg.cm, Ib.ft) DISASSEMBLY cxoson0 1. Use the Special Tools (09234-33001) to disassemble and reassemble th piston and connecting rod Sy Pine (6 G- AcsorEMA -70 2 Place the proper fork inserts in the fork of the tool Between the connecting rod and the piston. 3. Insert the proper removal tool through the hole in the arch of the tool. Center the piston, rod and pin assembly with the re- ‘moval arbor. 4. Press the piston pin out of the connecting rod INSTALLATION | esscio Install proper pin guide through piston and into con- necting rod. Hand tap pin guide into piston for proper retention. Drop piston pin into the other side of the piston. NOTE The pin guide centers the connecting rod in the pis- ton. When the piston, connecting rod, piston pin and in guide assembly are positioned on the fork of the fool, the pin guide will aso center this assembly in the tool. Ift00 small a pin guide is used, the piston assem- ‘bly willnotbe located centrally in the tool, and damage ‘may occur to the fork and/or insert of the tool 2. ENGINE MECHANICAL SYSTEM Install piston assembly onto fork assembly of tool ‘Too! will supprot connecting rod at the piston pin. Be sure to slide the piston assembiy into the fork until the pin guide contacts the fork insert. ‘Adjust the installing arbor tothe proper length by turn ing he numbered sleeve on the lettered shaft until the specitied alpha-numeric setting from the application chart is obtained. Turn knurled nut to lock numbered sleeve on shaft Insert the installing arbor through the hole in the arch of the tool. Press piston pin into the connecting rod Until the sleeve on the installing arbor contacts the top of the too! arch. The pin guide wil fallout of the connecting rod as the piston pin is pressed in. & caurion Do not exceed 5000 pounds of force when stop- ing the installing arbor sleeve against the arch. Piston Fa Loading “ direction Piston pin before preseingin Guide pin Piston pin ator prossing-in -L— connecting rod aseombly ¢ SupportMAIN MOVING SYSTEM EMA -71 INSPECTION PISTON AND PISTON PINS 1. Check each piston for scuffing, scoring wear, and other defects. Replace any piston that is defective. 2. Check each piston ring for breakage, damage and ab- normal wear, Replace the defective rings. When the piston requires replacement, also repiace the rings. 3. Check the piston pin fit in the piston pin hole. Re- place any defective piston and pin assembly that is defective. The piston pin must be smoothly pressed by hand into the pin hole (at room temperature}. PISTON RINGS 1, Measure the piston ring side clearance. If the mea- sured value exceeds the service limit, insert a new ring in a ring groove to measure the side clearance. Ifthe clearance stil exceeds the service limit, replace the piston and rings together. If it is less than the ser- vice limit, replace only the piston rings. Piston ring side clearance Standard value No. 1 1.3 L : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 4.4L: 0.03 ~ 0.07 mm (0.001 ~ 0.003 in.) No2 4.8L: 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 4.4L: 0.02 ~ 0.06 mm (0.0007 ~ 0.0024 in.) Limit No. 1 : 0.1 mm (0.004 in.) No. 2: 0.1 mm (0.004 in.) 2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston Measure the gap with a feeler gauge. It the gap exceeds the service limit, replace the piston ring tem Standard - mm (in,) Limit - mm (in) Piston ring end gap No.t 13 0.20 ~ 0.35 (0.0079 ~ 0.0138) 1 (0.039) wait 0.15 ~ 0.30 (0.0059 ~ 0.0118) Piston ring end gap No.2 413 037 ~ 0.52 (0.016 ~ 0.02) 1 (0.039) 1b 0.30 ~ 0.50 (0.012 ~ 0.02) Oil ring side rail ond gap 0.20 - 0.70 (0.078 - 0.0275) 1 (0.039) ‘When replacing the ring without correcting the cyline der bore, check the gap with the ring positioned at the bottom of the ring travel ‘When replacing a ring, use a ring of the same size, Piston ring service size and mark STD : None 0.25 mm (0.010 in) OS. : 25 0.50 mm (0.020 in.) O.S. : 50 0.75 mm (0.030 in) OS. : 75 1.00 mm (0.039 in.) OS. : 100 The mark can be found on the upper side of the ring. REPLACEMENT 1. Check the cylinder bore size code on the cylinder block top face (1.9L) Cinder bore size cose Check the cylinder bore size code on the cylinder block bottom face. (1.1 L)lo ‘Cynder bore size coda 13t ' Size Ciass. | Cylinder bore inner diameter | SZ® 715-7151 mm ‘ (2.815 ~ 2.8153 in) A 7151 71.52 mm 8 (7.8153 ~ 2.8157 in.) None 71.52 = 71.53 mm © (2.8157 - 28161 in) ° ak Class | cylinder bore inner diameter | Sz° a 67 ~ 67.01 mm A (2.6978 ~ 2.6981 in) > 67.01 ~ 67.02 mm . (2.6381 ~ 2.6385 in) : 67.02 ~ 67.03 mm c (2.6985 ~ 2.6369 in) 2. Check the piston size code on the piston top face, wae ENGINE MECHANICAL SYSTEM ciass | Piston outer dametwr | Sue 71.47 ~ 71.48 mm T a (2.8138 ~ 2.814 in) a 71.48 ~ 71.49 mm 8 (28141 ~ 2.8145 in.) None 71.49 = 71.50 mm c (2.8145 ~ 2.8149 in.) c nae fE | \)) \ Up Class Piston outer diameter Size A 66.97 ~ 66.98 mm A (2.6966 ~ 2.6970 in) 86.98 ~ 66.99 mm 8 (2.6370 ~ 2.6374 in.) None c (66.9 ~ 67.00 mm c 2.6974 - 2.6978 n) 3. Selce the piston related to cylinder bore class. Oilclearance : 0.02 ~ 0.04 mm (0.00078 ~MAIN MOVING SYSTEM REASSEMBLY 1. Install the spacer. W Sido eal Spacer 2. Install upper side rail. To install side rail, first put ‘one end of side rail between piston ring groove and spacer, hold it down firmly, then prass down the por- tion to be inserted with your finger into groove as il lustrated Side al gap S x Do not use piston ring expander when installing side rail, 3. Install lower side rail using same procedure as Step 2. 4. Using piston ring expander, install No. 2 piston ring, EMA -73 5. Install No. 1 piston ring. BZ Barrel type “id Taper ype 6. Apply engine oil around piston and piston rings. 7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that gaps fe not positioned in side rail thrust and pin directions. 8. Hold piston rings firmly in a piston ring compressor as you insert them into cylinder. coun FS ms af © J Saoytie BARE QF? spate ee 9. Make sure that the front mark of piston and the front mark (identitication mark) of connecting rod are di- rected toward frront of engine. 10. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly ‘match each other. 11. When new connecting rod is installed, make sure that ‘notches for holding bearing in place are on same side.