GENERAL ‘SPECIICATIONS eu 2 COMPRESSION PRESSURE ~ Tins Bel FENG Trovetestootig Bris SPECIAL SERVICE TOOL ate ‘TING sySTEM INSPECTION EM. 26 CYLINDER HEAD ASSEMBLY REPLACEMENT. EMsae INSTALLATION. ane ENGINE AND TRANSAXLE ASSEMBLY ENGINE BLOCK INsPecTIon Eee Engine (G4ED/G4EE - GSL 1.6/1.4) ‘COOLING SYSTEM COMPONENTS Engine cova REFILL Aid BLECONG, PaDIATOR GaP TEsTWa LUBRICATION system ‘OIL AND FILTER REALACEWENT Stuschonorenene on isassenay INTAKE AND EXHAUST SYSTEM INTAKE MANIFOD et AUST EGS ‘ComPonenrs,eM2 ENGINE (GSEDIGAEE-GSL 1.6. GENERAL GENERAL cxce 4) SPECIFICATIONS Spectiatons Desatnion = Lit Ta DORE TeDORE General ye imine, BORE —] Number of eines 4 Bere [isaem@srzan) _[Tesmm (avvan) | Stok 7B. (30748) | B7rm (8.4252) Teal diplocomet 4,309 608537 un) | 1599 co (@757 eum) ‘compression rato 10054 Fring oer 1342 Valve timing | ‘mato ane R= TOO) = Ghses 800) | 3 3 rnoust vate FOP EERE) 49" = Closes ar00) [5 = Cylinder head Fisteas of asi suraca Tess an 005mm (0 00FD) ea Fatoss of Loss than 0.16 (0.00506) 02nm (0.0070) panto es Less than 0.1800 (2.00584) 0-20 (0.0079) 7.000 = T.oTenm (04551 ~ 0-98) | eve gute ote "11.050 = 1.066rm (04880 ~ 04357) fre "7.250 = 1.26600 (0.4829 = 044360) _ 77.800 = 11.518nm (04528 ~ 04508n) ‘yaw wae 30.400 ~ 30.421mm (1.1968 1.18770) seat rg bale 30 700 30 72mm (12087 = 1.2005) a) 0608 ‘31.000 = 3.02mm (12208 = 1.22%an) boast [S72 127.000 = 2.6mm (1.0830 ~ 1.08580) — seating ole [03 08 21-300 ~ 27 SP (1.0748 = 1.0756) oceee 2608 127.600 ~ 27 SF (7.0888 ~ 1.0974) Comshae ne malaise [ase ~ G Sean ao _|trroses—"7easom_| (1.708681 714500), a 9.5406 49.7486 | 2.7480 ~ 0.9480 (i7test = 17az3an)_| (1.72239 =| Ta0zTm). | eugene 28.984 ~ 26. 980rm (1.0816 ~ 1 0822n)GENERAL, ew Specteaione [ asin Sen ie tint Cana co Gann 32 = 008i (008 0. 008R) a OAT Ed ply (0.10 0 (0.0050 ~ arom) a | ‘iain aaa) awe tna Exhaust 92.4mm (3.6376in) Sen ior ae 86 - s70nm (a= OREO) dave” [sea 5905 6 950m (02807-02368) Foon oe se 50 Thikoes of “rin roan) carn aise Taogny_[ Exhaust 1.3mm (0.0512) “0mm (0.0396n) Vote sem [ae 008 = 0inm (02 =) 2 Onm (6.039) SEE [exaust (005 ~ 0B (0.0020 ~ 0.003%) 0.18mm (00088) vate guide Take 363 = 38 Tom (ai = L440) Leno au 400 «1 Bun (6069162200) Valve seat — vat ot eat [a = iin Oasis OONTaA) tact [es 13 1m (00612 = 90600n) lew le or Exo = 5wr Tae sg Fre ng : nm ce ei thine 24 WTO 25.142 24977 294849 GTO) ‘Out of saareness ‘inde block ytnder bore 7550-768imm | 7660- Tein (gsre~2srann) | Gotta = 367300) Fisnoss of gant euros Loss than .06mm (0.00200) Piston outer ameter Tea ~T6s0mm | 7847 ~ ToS (2ors*2or24n) | (ote ~sc18m) Psion io inde Searance (0.020 ~ 0.040nm (0.0008 = 0078) Bog soe No. tring groove | 1230 ~ 1 255mm (00488 = 0408) No.2 ing grove | 1230-~ 1-255rm (00484 = 0G4B4in) ‘Ol fing geove | 2.090 2058 00709 - 00808%) Piston rngEM-4 ENGINE (G4EDIGSEE-GSL 1.611 Description pecans Lit 1a bORE Te OOH ei od = conse (00018 = OOmRBH) Tire se ceaanoe [hota 0.0 = DoB5nm (00016 ~ 000380) 4 00898) Ono 08 = 075m (0.031 = 0.0696), ving [220-0350 015-030 lon ba Not rng (@007e~ 0.0138) | (0059 corny eel 037-0s2nm [035 - 08mm era gp [no 2me «(057,052 [08ST ORT | somm(aossen orn 220-O7onm 020 ~ 07am “omn pema @ {0.0079 - 0.02761) __| (0.0079 - 0.0276in) inn ") Fon pin Patni oer arson 0 = TT OORT 07RD Paton pine ne anicor | 1.016 ~18.024mm (0.7085 ~ 0708) aon nhl dese G01 = Doren Oo004~G000Te Sarena osama end nts | or ~ 7 9asnm (7078 - 0706 Serica es smal ens nae | 9033 —9ot6nm (0.0019 ~-2 005) ton pn rst od Bois ig (e305 B) Gonnesting rod ‘Connecing re big ond nner deter 40000 ~ 48 OF dre (1.8888 ~ 18005) Connesing red benng olclesrance | 2018 ~0.36r¥n (00007 = 000t4n) Site cere 0.40 ~ 0-26 (0.009 ~ 6.0088) Teen OOTSTH) Crankehat | sn nt ctr air [2.880 ~ 4.9mm (0665 18672) 7 [Pi ua outer mate 34.954 ~ 44 7am (7658 1 70K) Main bering ot [61-245 [0022 ~ 040m (00000 - 0.0016in “ine (556) siearnee [No 9 ~ [0.02 = o.o¢émen (20011 = 0.9018%9 ‘©: (00058) dy 005 ~ 0.175 (0.0020 ~ 00080) 2mm (20070) | Fino Runout [em aay Om (5) 1 pump Soceaance [etartier _[0ou0 = o.06snm 0076 ~ O00) [outer ter | 0.040 -0.090rm (0.006 ~ 0.0035) Boa Seorance 080 = 0 90m (1024 = 0.0005) Rela ave pening ensure | 00848 Ok (5140 Sklar, 72.527 98) Free engty | 46mm (1.8246) RetetsoeaLosd 120 gl i (194209 BTA) Engi of il quantity Tota) 331 G49 US at 2001p aGENERAL Em 5 Spesestone Desegton = Lit Tapers 480080 Si gon 0H a) TOL G.7 US @ 26tn@ a (i asnty (ON en 03 (052US a, 026 m9 [ores Above 8978. | va eaten ‘oT pe eee (08g 1.98) | gm 15.om) ‘cooing system Coorg methoe Forced crodaton wit coving in Coot uenty 55-581 (81-819 US @.4e4 510 mPa ioe Wax pete 998 Opera ' —4 hry [ezete crassa) Put opening "7 torowete [9 20°F) Maine opening | 83.56 = 22.5pa bres {095 25m 1958-17799) ciate a | Vuum vane [056 = 490 ws speningpressre_| (O01 — 005g! 0.44 ~ 074 ps) Water emperatr sensor oy Termite De OA [aasioa Resstance - co weer) [osaza xtEM6 ENGINE (G4EDIGAEE-GSL 1.6/1.4) ‘TIGHTENING TORQUE a ‘uan “Teen tue %y [wm] wwtm [ba yin block Engh sinport eit Bat 2 | wines | s5-55 | mame Engi support rata i] Maree | 45-65 | meen ooe Engine suppor orci wy Bok 2 | 4i-ms | 45-55 | 225-290 ear pale ot 1 | se-we [10-12 | vane Engine mounting Engine meuning bail ond boayingbok_| 3 | @0-0a7 | s0-68 | wea-w7o | Evene mouning wus ars enpne mounts |, | gag a - | suppor brah ang nt ne-o22 | 70-96 | s6-607 | Esene mouning nner paca araenane | | agp sear supp roi ng e-ex7 | so-e5 | 2-470 Eine mounting suppor tackeland enone |, | apg wear : : Sadeg cog Se so~es7 | 50-65 | 362-470 “Tansee moing baehl ond bos fing bot | S| @00~S7_| _SO=8E | waa=w7O “Fans mounting instr na ansale Z Tenente mewrg nul 2 | ene-02 | 70-05 | soe~oar Front rol stopper tact and sub rl spp a | wo-ar | so-es | as2-a70 Front topper maul and nto appar | sppot oka ng Bane ee | en Rear rot stopper edt and ab > ova wm fae fang bat a | o-sar os | s6a~470 | Rear ra stoppernalsor andar ol oper ‘ppt rect ing btm | ee Wain moving eye Connecing rod eam | saroa [38-38] wats enka man beara eas bak io_[ sa-s0a | ss=80 | manana Fyne bot UT) 5_[arr-sars | 0-190] esa 40 Deve pit bo (AT) = [w7r- tars | 10-130 | 958-040 Timing bet [Timing bt ran upp cor Bok 7 [cia-sa [oe 00 [sa Ting bot Font love over bat = |_7e-s8 | on-10 | sa-72 ning be eer wer Ut ov: bol 3 | ee-ne_| 10-12 | tae ining Be 65 Epo LH cover bot a [se-10 | 10-12 | 72-7 Timing el ee usper Rr Bl 2 | e-1e | 10-12 | tae raha puley bal 4 [era =ard_| 40150] vor 1088 Comat proail to [75-001 [80-100 | sr0~7as Ting bk ersiner bo | we-ass| 20-27 | wan 198 Ting bl er Bat [raacssa | aanss | t= a08GENERAL - = Tang ae ty [ett Syndr head Exgne cover ba [30-88 | oa-0e | z0-a8 yindr Rend cove ba re se [00-10 | 50-72 anata op ba a} ene _| ta-14 | e7= 108 waa0 > | a5ae > | 2300 > Cynder ned bat (14 DOHC) 10 | reso sts | Rees ot ts | Ratu a Scks 7 Soca |S Soo | SS aeseer ~ ‘oa-e0"- | s0ve0r> | a17000" > yer nod bo (18 DOH) 10 | retoan asa |raoose soot | Ronee a ate “ ‘Sear |S tow | Sarre Cootng aye Wor pnp puly bol 7] ve=ee | oans0 [sata Wer up ba (X28) a | e=4t | ta=n8 | e708 leone on aera brace ing + | we-zs | 20-27 | v4s-105 ie eg a eer be irs + | wo-m08 | 20-a7 | v4s-108 Theresa Nag A a [ar-ee_| 18-20 | oa as Water neta ove ng Ba 4 | te7=w0 | 17~20 | wa-v4s Woe enperaire sneer + [1sa=m2 | 20-40 | = a80 Wer pe fg bot +f ose-14r | s0=18 [72-100 Luton oystn OF mer 7 e-e7 [ia-16 | aro Fro case bok @ X22) +] W98-208 | 20-27 | 48-108 Front ose bot @ X30) 3 [9a=205 | 20-27 | 4s 108 Front case bot (x48) 1 [18-208 | 20-27 | 148-198 Fret case bat (@x eo) 1 [iss=265 | 20-27 | 4a~v08 OF ben bt we 90-11 | 19-12 | _Ya=ar ‘OF pa aan pug + | wea-a | 40-48 | beo-wea Ot 00 bo 2 [owr=ane | 18-22 | a= 180 ‘pseu evich +] Mr=ate | 18-22 | 108-180 ear ea cae =e [as-is] 18-12 | rer Irak and exhaust apse ite meno an ene handing nt | @ [aT =vea | 78-20] wa-was te anid and eer a 2 | 7-10 | ts-20 | to0-v4s tani ad oder eas 1 | 7-198 | 1-20 | e-s45 Ike mani dy Bok a [naa |e -28 | a Ei nani and eyinds esa oben |e | a04-a48 | 30-38 | 217-289M8 ENGINE (G4EDIG4EE-GSL 1.6/1.4) ton oom Tieng 7 [om ‘im mo i sor east raid + [cwo-ma | to-00 | waa [Expert mason pat cova | | vey-aie | 17-22 | 123-150 ‘A cere lower cor rg Bok a 7a-08 | oas10 | s0=72 Trt yard sue nk ng bot nat | 4 | var=108 | 18-20 | oa vas Exh rab ad ork miler fing nt | 2 | 294-092 00-40] 217-99 Font iar nd cris mato ing nat | 2 | 204302] 3040 | at7- 280 Gora mer andre i faingrat | 2 | 204-092] a0-40 | aur~m0GENERAL Emo COMPESSION PRESSURE 4. Cheek ne evnser comgcesion pressive INSPECTION exw Gnore 1 thre lack of power, excess of consump- {hn poor ful econemy, measure the compression press. 1) insert a compression gauge ino te spark pg 1. War up and stp engine ‘Alo teenie fo war pf nema eporting em 2. Disconnect he ipiton oll conectors an te spark ug eles. (Rater io EE group iglon syste) 2), Fy open the tote 3) Wie erating the engine, measure the com: pression essue Guore ‘Always 130 0 ly charged batry obtain engine ‘Speed of 25pm or mae. 4) Rapeat sep 1) trough 3} foreach eyindr ones (Gjnore This measurement mist be denen as short ine as 2. Rameve to spark tp. zs Gangs termptg ete, remove he sparks. Compression pose Standard 181808 (16S, 2359) (280-400 pm) Minium: rte (1.06%, 239s) Dieronoe tree on ince Soka (ong 14) FosEM 10 ENGINE (G4EDIGAEE-GSL 1.6/1.4) 5), ne oyincercomprestion in mere cyinders lelow, pura sma smount feng ono the {de eough he spark lig how nd raat ‘Stop 1) Beaugh 3) renders ith ow compres racing ones tne careresson tis sly that th piston ing endl syaner bore ae Worn o maged + presse stay low, a valve may be stk tng or seating is mproper, or there may be leakage past ne gas 5. Retnsa te spark sage {8 Comect te ignition cal connectors sd the spark ug eaten, (Rete to EE group gmoney) ‘TWMING BELT TENSION ADJUSTMENT 1 Remove te engine covet. 2. Remove he Rot whee ‘8, Remove the tos) and RH se cover),GENERAL Em t1 5 Remove the atrator sv boli). (Refer to EE 9. Turn th cankhat pulley. and align ts rove with pov alata) ‘Remove te a conlionr compressor ive bets) (otro HA group - ae conatone:comgresser) Remove the war pump puley Remove be 4 bts(6) nding bet oppercover (A),EM 12 ENGINE (G4EDIGAEE-GSL 1.6/1.4) 40, Remove the crankshaft ley), 13, Adjust the tining bet tesion, 1)Atarnspoctng tne rng Yet rpise tf nee ‘cesar, 2) Give tension toting bl using the tensioner laste ter oesanng ne mowing bot AB) 3) After checking the signment between each Sprocket and each tiring bot tooth, pen the ‘mounting bot (A) and) one by one Tighioning wra igo = 268m Bi Taf 1445-19509) 4) Then check the bl son ecm erty he when the fnsioner an te enson side of Be tring belt are pushed in harzon 12, Move the tensioner puley(C) to ow decton ater tay witha meget force approx. 40N (110), loosen the mourng bat). the timing et cog end is aprox. 12 fhe tn ‘na teporay ten moun Be (AB) ‘Sonor mourig belt hes radi (arose Ft) Sine \\ assGENERAL EM 13 45) Timing bet tension measuring procodire (by 8 16, ine he cranshat ple, fen ferson uoge) Rotae canis n cocvise dracon to set {ston ontop daa eenlr (TDC) an ote “rankstat ncounersosiwes 990" tenes “ure De bal onion the mids of tension se pan (m arow drecton of shove iustaton) by ‘fe wbraton method, iy cavrion When rotating te crankabat counterclockwise, be sre torte te crank ot tine ‘Conversion sauation of requeney io Tension TH (1 00)x5"xMx WF) 100000000 S: Measured bot span (mm) 1 Unit weight of be (er?) We Bot wits (re) 17 Isa te tring bet upper cover) wit Baits). TIMING BELT SPECIFICATIONS Tightening tora 187 GaNim(08~ LO¥gim, 58~ 726-8) Tere ‘Speccatons Sm) 2406 Mer) 045 We) 2 a) Toa ~o79 Toh 16235 14, Tur te cranksaf two tun in te operating dee- on (clockwise) and realign th cankshat speci and camshaft sprockt ting mark 15. Ista te ming bet ower cover) wi ots). 18, Instat the wate pump pully.en ENGINE (G4EDIGAEE-GSL 1.6/1.4) covert) wah ots, 05igim,29~ 43164) 20. Intl he atoratr cio bol). (Refro EE group “stemate) 2. Intl the RH side cover) wih ots) Tightening torque 88.3 07 SNm(~ thglm, 65.1 ~ 79.68)GENERAL EM45 TROUBLESHOOTING sci ‘Symptom ‘Suspect area Remedy “Engine mise wah anormal | Loose or improper tad opal or replace tho Ryo intra! ower engine roses. | engine tywncet at requted ‘wer psen nos (01 consumption may or ay not cause the eng to mise) Inspect the eye fra loss of Repato replace as rogues ‘ior enka tt beings ‘aplae ho crankshaft and bearings ax required. Engine rise wih aoc Suck vate (Carbon bulup on he valve stem can ause th valve nto Soa prope) Rak or repose required ‘Excessive worn or mil-ged fining chan epic the tring oto and socket as equred Worn caf bes epiae Be casi an ae os Engine wists wid cook consumption. * Fally cinder ead gasket andlor tracing oF oer damage tote Sind ead and engine boc xoing system + Coolant consumption may or may at eause the engine lo oven * Inspect te eynder head and ‘ene lock for damage 6 {ha celat passages andor 3 {uty hood gasket + Ropar or raplace as roqued. Engine mise with excessive Wer vaves, valve gudos andlor Ropar e replace as requed oi eoraumpten vale stem oso, Won piston ngs. inspection the efinds or ss (Oh censnption ray of way not__| of eompresson. cause the ange ois). pax rpc a8 roqured. coy onng stow seconde, | TEC of acs. fat Sect coy Inspect the test bearing and lon crankset rt bearing. ants. Fepai oF epace as required ‘Upper engine nie, regards | Low ol pressure palo pace required ‘of engine speed Broken valve sme Worn o ty va ers, place the vale sping Replace the vate ites ‘Seizhed Broken ining chan andlor damaged sprocat ech plete timing chain and sprockas Worn ting chain tensioner, appcable. Reps he tng dain onsoner as requred ‘lor eamnat aes. Tripect the casa obas Repco he camshaft and vate rs as raured ‘Worn vave gids or ave sts Inspect he valves and vave gues, then ropa a regard, ‘Suck vas. (Carbon onthe vave ‘stom of valve Sot may cals he ‘ove f eay pen) Inepet the valves and vate guides, then ropa a rquredEM -16 ENGINE (G4ED/G4EE-GSL 1.6/1.4) oonprnnmen| ara aoe Feral a a ce Damaged ol pan, contacting no (Fed We aan of pump acreen. Repair or replace as required. Sion contaa rem mpc traipopioee came feccuaeceai’ Casco paormgarem mp topes Os sexes Reems ere epee ae |r ferences pester asec prea mens eee seca cee ee Soe ecoeey as [Reems ins coe Sore ease seo Excessive cranksta bearing clearance, | Te earthen beerros acai ea rears pan oon ans | PLease 8 od een Repair as required. ieaemnarea —[orapoe oer cacao Excessive connecting rod ‘and repair ae required. Exess comeing rg bearng, | erence bean. "meme es ieee Excessive crankshaft bearing clearance, | * ns cariahet jonas in iensamsGENERAL em7 Smoion ery Brae Wl rt nk FRrove spr pgs ond chakra (Coan rt) apo for ben hand gst *Socanariteestn encar | pat rests ng Bok + Otten ener nea + Pal ine Ieper hing fa ecor Sor leing rs Bioko ig a adoring | peel tina chan and ge shan ge. par on rar | Feo ator nn ee fn: saneane ah Coponers andor ogy mats + Foreign matt opr orrepaco 2 rogurod ezed crankshaft connect Inspect ankshet and connecting e ° rai besring ro beseigs Fair or eptace as required. Inspect connecting ode. Rapa or epace as required. Inspect erankshatt Repair or opacs as requees ‘Bent or broken connecting rod ‘Broken ranks,EM 18, SPECIAL SERVICE TOOLS ENGINE (G4EDIG4EE-GSL 1. “oa Namib and name) rs ‘rankahat onl olson neta (osava-32000), ination of te onto sem | Granieneh onto sas quae (0221432100), Tnsalaon of he onto sl ‘Cama ol sal ataiar Insel of the casa seal (osz2"21000) ‘ave ae rover Feroval and heaton one va gue {oacnszer P00) cacao Nave ge aie (ovee"2e000) ee eo ‘Vai som oi selma Inston ofthe vaho ser a eal (222222001)GENERAL EM 19 Tol (Number and name) ‘ae sorng compressor {2222:28000) ‘Vane song compressor ‘teplor (09222-28100) Renova and instalation of aks ores! aie ‘ransahaverolsbainstaior Tsao of he eranaha rer of sea) (oana121000) Weal tonperature sensor ‘Removal and tiation of water secet wrench temperature senor (0022125100) (0 pan remover Removal of pan (osersacoca) A\ VeloEM 20 ENGINE (G4EDIGAEE-GSL 1.6/1 “ool umber and name) maton Ue “Tora angle adap Insaaon of bots & nuts need 09221-4000) san engular method me Engine suppor fae & ‘Sipper of Engne sspter (02200'38000)TIMING SYSTEM EM21 TIMING SYSTEM TIMMING BELT COMPONENT ce RSs | 8 ¢ & ZR . eS 7 aoe 7 \ sicerees So ‘ 8 19.6 ~ 26.5. AO azarae 20 ima-s0 Tanase nn at fomeeinee nae ims ee eee eee ees iene comarca eae ices eeEM 22 REMOVAL cose Engine eval ro requted fr is proce. 1 Remove the engine cover 6. Romove he ar conditioner compressor ve bli). (Rater to HA guy = conetonscampresor, Remove the 4 bois and water pump pulley. Remove te dbo) anatiming ba upp cove) 2. Remove he RH ton whos.TIMING SYSTEM, patent “Torn the cankshatpuy, and agn ts grove wih) 10. Remove the re ksha pully baton crank pl ming mark" fe tring bet over Check hat ey), the tevng mark of camshaft proc aged wih tnetiming mark of onder hoa cover. Net eyindor )EM 24 ENGINE (G4EDIG4EE-GSL 1.6/1.4) 13, Remove the timing bet ensone). liming bet, 14, Remove the sot) and rng bat ile), s/h Aes | | ioe g ED aTIMING SYSTEM EM.25 16, Remove the ender head cover 3) Loosen hecyinderhoad cover bet) nd tn 4) Remove the gion el remove ecovers) and gost, 2). Remove the PCY (Postve Crankcase Venla- ttn) Rese) and the brother hose(8) fom the ‘jinde bead cover olEM 26 ENGINE (G4EDIGSEE-GSL 1.6/1.4) INSPECTION ewes ‘Tie BELT ‘SPROCKETS, TENSIONER, IDLER 1. Check ie bet for alo ust posts Feplace, i scectary, 1. Chock the camshat sprocket crankshaft sprocet, Smal epost shold be wiped away with a dy coh ‘ensioner pully and der pully fer sbrarmel west, ot paper Donel clean win svat. ‘acts. or damage. Repace as neces “= 2. Whan tha eigine is evemaule oF bet tension a 2. Inspect the tensioner puley andthe idler putey forte, chee carefly Hany ofthe fol Nas ‘and smooth oan and checkto payor noise. ‘re eden, piace he Ba. * Do not ten, twist ort the tring bet inside + Bonet aiow timing bao come into contac ith (wate and steam, 3. Replace the py i tae ism reas lak from ts earngTIMING SYSTEM, INSTALLATION cx 2. Intl he eyanar head cover 1. sa ne camshat sprocket and tghten te bok to_—_1)-Insal he einer hea cove ne ots) ‘he specie’ trae. 1) Temporary instal tne camshat proce! boc), 2) ‘Hold the pocond) of the camshaft with hexagonal wrench, angen the BoC) wih & wanes) 2) Intall tbe PCV{Postve Crankcase Venton) hosaia) and breather oso(B) fo the cylncerEM 28 ENGINE (G4EDIG4EE-GSL 1.6/1.4) 2) Intl he ton eo 4 lg ety rans of cana pct) and erankstatsprooket(6) wit the Nt psion paced at tp dead corer and Hs compression rote‘TIMING SYSTEM. EM 29 5. Inthe or pulley(A} and tighten hobo) tthe spoofed torque. Tightening torque 422" SUENM{S~ S.Skgtm, 31.1 ~ 385-0) 8. Acs he Unig et tension. 1) Give tension to ting bot using the tensioner’s ‘ast afer ooening te mating ba 7. Insta the bolt 0 a rt ge sack at ach contr of mm shaft. Use he folowing order when wstaling emg 2) Aer chaaing the allgnment between each bat ‘sprockat and wach ting bat tot, tighten te Crankshaft sproctlia) iter pulle(8) cams ‘mounting bat (A) sd () one by one. ‘sprocat(C) tig bat ersioner(0) Tihteing foreue $85" 20'Nim (20 ~27aghm, 165 ~1055b-)EM 30, ENGINE (G4EDIG4EE-GSL 1.6/1.4) 3) Then recheck he bl tron ‘erty tat whon tho teioner an the lenion Side of the tering elt aro pushod in hain {aly witha moderate ere [epprax.49N (1) {he ting bot og ond aprox. 172 of he ten loner mouning bt head radius (across fas) ‘ay from the Bo head canter 4) Tring bet tansion measuring procedure (a sone tension quog8) Rots cankonlln cctwise dracon toast ‘st pston ontop dead canter (TDC) an rota rans in countersockwia fo OF than mea Sur tebat enion nthe mil of tension ‘Span (narow decton of above lusaton) by ‘tee bration math A) caurion ‘When rotating the erankshat counterclockwise De sure to roate the crankha aati. ‘Goneraon equation of reqseny i tenalan Ter oa}xS eM x Wa 1 700000000 ‘5: Measured bt span (rn) 1M: Unit weight of alt (gem) We Bat wa in) 1 Traverse natura Fequency of ate) TIMING BELT SPECIFICATIONS Tern ‘Specieatons| 3 (on) 2408 (alert 04543 W (oe 2 Te) Toa - 78 T tof 138 8. Tum the ernest two tens the operating dec: en (cocks) and eaign crankshat sprocket and arrahat sproka ning mere 10. Ista the tng bet ower ever wth Sota), Tightening torque | T"aaNm(oe igh, 5 2) 11 instal be farge an crank pully, and than tater ean pulley bok Make eure at eanksut mena in Fx ha ama at the puley Tightening torque 1973" 147 Nm(4.0~ 150g, 1015 100.506)TIMING SYSTEM, EM 31 12 Ia tne timing Be upper cove wih ots(6). 16. Isat RH sis cover) with 2 bos) Tiahening torave a 18 Ista th water purppuley and 4 bts. 14 naa tea condionr compressor dive bet). (ofr 'e HA group ~ a conationer compressor) 18. Insta th aerator dive Baa) (Reforto EE group eet)EM 32 ENGINE (G4EDIGAEE.GSI. 1.6/1.4) CYLINDER HEAD ASSEMBLY COMPONENT scmee ] (08-10,58-72) 2 3 1343 (5,252) +90" Resease abot = 343 (65,258) 00° 1 Gyinder head cover 2 ase, 5. Gyinder heed botCYLINDER HEAD ASSEMBLY EM 33 s18-197 (12-14,87- 102, ‘785-981 Fol (@0- 100,578 - 723) ‘TORQUE : Wim (gt, bt) uA vave ra 8. Taming chain 1H (yeraute Lash Aute 2, ner nce 8. Exnaustcamsha 5. Rainer 10. Camshatsprocet 4. Vato sping 11. Intake cansnatt 12. Chan proce 5: Stem soa!M34 REMOVAL ersve Engin removals not equeed or hs preeadure + To avoid damage, unplug the wiring connec tors carefully whle holding the sonnector portion. Note + Mark al wing ard hoses 1 avoid msconnsc- + Inspec toting bot before ramavng the cyt ‘hor head + Tuite crankshaft puso thatthe No.1 piston \Gattop dead conor (olor lo EM - 23) 1. Remove th bate, ENGINE, DIGAEE-GSL 1. 2 Romve ho engine covert, 3. Drain sho engine coolant. (orto EM - 81) Ferme tho ator cap to spood rang. 4 Romove he wipar arm). Md, lon eeCYLINDER HEAD ASSEMBLY. EM 35 1, Remove he wiper motor ink assem (A). 9% Disooneet the radiator upper hose) and lowar ooeta)2. ge wee harness connetor sndwite __8)Dsconnetthe CKP(Crankshat Psion Sener) mos From ejinder head andthe nak 1) Disconnect ha knock sensor contr) 2), Olconneet ines conetonercomorestor sth connector). 3) Disconnect th njactor connect) 4) Disconnect the ground cable 0), 10) Osconnet ho ignition cot connec). 11) Disconnect the gnton col condenser cannec- ter). 12) Discomeat ne CMP(Camshat Postion Sensor) ‘comectoiC), 19) Discennet ho round eatie0) 5) Remove te scceeatr cabl(A) by loosening 14) Disconnet he water temperate senso con- ta eck ut thon sip he cable ord ou of the oer ‘vote inkape 6) Discennact the TPS (Trtle Peston Sensor) connectors), 7). Disconnect the MAP sensor connect) 18) Disconnect the font oxygen sensor connec: ra)CYLINDER HEAD ASSEMBLY 18, Disconnect he hose) othe PCSV (Purge Cont Selena Vato) ss 14, Remove be bake booster vacuum hose) Ie 15, Remove he tin col (Retro EE group -igaton system) 18, Remove he exhaust manos (Rel EM 108) 17, Remove the ake mans (Ree o EM 101) 18, Remove the ting bot. (Reforto EM-22) 19, Remove he cynder head cove (Refer EM -25) 20, Reenowe te cars sprocket. (Refer to EM -25) 21. Remove the camshat bearing capelA) and comshat). EM 37 22, Reenove the engine mounting support bracket hing bona. 23, Remove tho cinder head bls, then romove the cinder bea, 1) Using 8mm hoxagon wrench, uniform loosen andvenovethe 10 ender head bale covers asses, ihe soquonce shown Ay eavrion eed warpage or racing could esl om ‘moving Bos an neo rer 2) Lit te oynder head fom te dowels on the tlnder lek and replace te eynder head on ‘wooden lta on a Banc, Beamon 15s carel oto damage the contact suace of {re ylnder bed a eine ackEM 38 DISASSEMBLY sxc 2 nore a loony HLApyraule Lash Auster, vas, we) “pring a they are moved so ha each fom con be ‘states ints erga postion, 9 1. Remove the HLA ® 2. Remove he vas 1) Using me SST (8222 - 28000, 08222 - 28100, carroess the va spring and remove the re- tana oc ENGINE (G4ED/G4EE-GSL 1.6/1 Remove ho sping retainer. Remove he vahe sorng Remave eva. sng 2 redle-ose ples, remove We oa Using a magn ings, remove the spring satCYLINDER HEAD ASSEMBLY INSPECTION CYLINDER HEAD 1. npect tates. Using @ recsion sigh edge and flr gouce, easut the srtace the contacting the onder lk lind he manage warpage Fiatness of cylinder head gasket surface Standard: Less than 03m (0,0042in) Limit» 0.0seun (00200) Fiatness of manifold mating surace ‘Stangord Lose han 015m (0.00809) Unit 0.20 0.0079) 2. Inspector eras. Check ne combustion camber, nak ports exraust pts and naa bocksutoce freaks, raced, Feplce the eynder heed EM 39 ‘VALVE AND VALVE SPRING Inspect the vahe some and ave guides 1) Using caiper gauge, measure he inner am ter efvahe gue ‘Valve guide inet lamar 8.000 = Bots (0.2982 0.2388) Intake | 5.958 ~ 370mm (02344 ~ 02380) Eshaust: 6.996 ~ 5 850nn (02307 ~ 02348)EM 40, ENGINE (G4EDIGAEE-GSt 1.6/1 3) Subtract the are som outer dlameter measure: ‘ment fam te vale guide inne diameter Moa ‘Valve stem-to-guie clearance Standara Inte D03 ~ 008m (00012 ~ 00024) Eshavst: 0.08 ~ 0.08nen (9.0020 = 0.003n) Lim Inge: 0.0mm (00039) Exhavst 015mm (0.080) Ive cara is gosta than mma, replace the vee and ve guide 2. Inspecttne aioe, 1) Chock he vaio is grou to the caret vate face engl. 2). Check that he sutace of vaio fr wear. Ifthe vate fais worn rpise the wav, 3) Check be vale ead margin tikes. Ife marge ncknees less han minimum, = place te va. Margin Stand Inka 1mm (0.04310) Exhaust > 13mm (008t2A) Intro : 0.8mm (0.0318in) Exhaust! 10m (00994) 4) Check he surac of alo stom ip for wear. Ie ate stom tp ic wor, tpine th vo, 3. nape the ve seat 1) Chock ve soa for evidence of aerheatng ‘2nd improper contact wih th vale fee. Replace he set cons 2} Bor recononing the ses, check he vate (uie forwear Ite vate guides worn, epacs ‘Pen ecandion he aoe 3) Reconditon the valve set wih a vava sat igindor er cto. The va Seat cnc! width hau be win spoctentions nd canard on the vatvetaceGYLINDER HEAD ASSEMBLY 4 rape th va springs. 1) Using aso square, measure ne oot quate fave png, 2) Using averier calpers, measwe te fe length of vabe soeng ates sping ‘ta Fre neg: 4mm (1.7329) (aid 21 81.135 Orem (47842 40/1. 3780) {4512224927 2mm (9 424907008) (Out of sus : Loss han 15° Lit (Outet square: 3° EM 41 ‘CAMSHAFT 1. Ingpect ne cam bes. Using a micrmoar,meosuro the cam be eight. ‘Gam height (16 DOHC) Irak 43.3484 ~ 43 5484rum (1.70863 ~ 1745010) Exhaust: 43.7489 43,9486rn (172280173027) ‘cam neigh (1.4 DOHC) Irak 4.3404 ~ 43.5484 (1.70869 ~ 1.71480.) Exh 49.5400- 43 7ea6rn (177451 ~ 1 72236) fhe cam ibe height lass then speed, repisce the camshaft 2. nape ne carshat ual clearance 1) Clean ne bearing caps and camshat journals. 2) race te camshats on the ender heed. 8) Lay a ship of pasigage accoss each of the camshat jouralEM 42 ENGINE (G4EDIGAEE-GSL 1.6/1 14) natal the bearing caps and ightan hats weh 3. Ingpect he camshaft end play speced torque (Rete EM = 28) 1) sia te cama, (ete to EM - 48) & caurion 2) Using aatinaeator, measure the end pay wee ‘Do not turn the camshar ‘moving the carat back ana forth 15) Remove the bearing cape 16) Mestue tne plastigage ats widest point Bearing oll clearance Slandaté0020"=006inen (0.0008 ~ 0.0028) Limit Am (0.0038) Ith on play is gosto han spect replace the carat necessary rope the bearing ‘aps andoyinder head as a te ol earance is greater than speci, c= pace bs cash nocesary, replace the boaring cap and clncer hood a est. 8), Remove he cams 1) Completely move he plstigage 8) Remove he casas,CYLINDER HEAD ASSEMBLY. HLA (HYDRAULIC LASH ADJUSTER) tn no HLA med win engine o, old A nd press B by hand: 8 moves, rpico the HLA EM -43 Tonporary noise when Staring 03d engine erat hi nae wll ieppesr ater ne ol the enghe reaches the norma peste. engin started ater parting ‘ileakage othe igh pressize | Nose wit dsappear win 15 chamber on the HLA, allowing ‘arto get Contos oie when te engine fest salad ater rebulding ender head Insuficent ol in eyindor head ot aly. ‘Continuous noise when tho ange sated ator excessively cranking the ge bythe taro moter ‘Contnuous noise when the engines running ater hanging the HLA. ‘Gi eakage othe hgh pressure chamber the HLA. aloweg fr to gt Inaufigent of inthe HLA. rine when engme ins at 2000-3000 mitt doesnt Ssoppesr, rer slop 7 belo, & caution Donot nn engine ata speed higher than” 3,000 "pm, as ‘is may damage tho HLA. ‘enteuoue noise ug a aio: igh gine spec Engin al oveltoo igh oteolow. Gheck of eve ran fa ol a necessary. ‘Excessive anount of arin he at high engine seed. [Check ol supply system Deterorste ol Fereck ot ast 1 Soaroate,rplace wit epeced pe. 7 | Nese conte forme [Law oF pressure [Crack ot presse aa soppy than 18 mnutee, sysom ofeach prt of engine Foul HO Remove te onder need cover and procs HLA down by hand Irioves eplace te HLA, @warwnc Be careful withthe hot HLAsEM 44 REPLACEMENT acu VALVE GUIDE 1. Use the SS1109221 - 31008), wnarw te od ‘ae guide lowaré he boom of ender nead 2. Recondlion the vahe gude hole of ender head 20 ‘halt ean match he newly press ted oversize ae use. ENGINE (G4EDIGAEE-GSL_ Vatve guide late 903 3 tm (1420 = 1440) 4. Atertne vlvegudols presse, nse anow valve tnd check far pope lamang larance 5. Alor the vate guides repaced, check hat heave Is seated prop.” Recandton the vale ste a8 recessary. 3. Using the SST (00221-1008, 06221-26000), ress.t the valve gue. The valve gue must be poss te rom he upper ie of te inca hea, Kopin rn tht he ink anc exaust ave guide fr erent in eng. VALVE GUIDE OVERSIZE me ‘sue | VOR BU FOI | vane gaan Vat guide tom ec Inner ameter” | ae Qvide oe | prorusion height mak | tom to Lr (rn) Fio00~ 11018 | +1050~ 11.080 se (04991-04338) | (04950-04954) $080 Those | 11.100~ 1,410 vem Bos toonz)os | | (ouss0 = 04367) | (o4ar0~04a74) = oS = 128 (0.5036) ozsmowos | 2 | 11280-11260 [ 11200-11310 0.429 04436) | (03449-04453) G “7.500~ 11.578 | 11580 11.560 so(oczmos | 8 | «saa 0.4585) | (03547 ~ 04551)GYLINDER HEAD ASSEMBLY VALVE SEAT RING EM 45 2. Enlarge the sat rng hole of eyndorhoad so that ‘atons th spectid onder head Nae inser am. ee ee erate eee acer ec Sara 2. Hk ner sa 2004807 nt See ee a ae = Pla coer sere ee eee reer Y: 4 are ee nn eee | euonan | Sestinaniinne | Seat ng om Twn [Oma mtn] te men [Sena = Scams |poeoe=seoe | prance CS | BE, | ol, naa cesar | saimasae | ater ots, |_c2emace Cater taoan | Ger teren |atne e200 aume=auoer | Pespicvt [7 eied= en ‘aepennoe (1.2205 ~ 1.2213) | (1.2240~1.2246) | (0.2126 ~ 0.2205) = rom serarigl pera Z ea | as Zom Fase real lPcione sist [reas sae a pawsencia| prance nay | pesozem ce inaoraart|Saranza 768) Namozend ommnaae) oo (1.0866 ~ 1.0874) | (1.0904~ 1.0911) | (0.2559 ~ 0.2638)EM 46 ENGINE (G4EDIGAEE-GSL. 1.6/1.4) REASSEMBLY esecie + Thorough lean al paso be asconbies + Bate instting the pars apply fash engine of ‘pal slang ana aang suroce. + Foplace of seas wih new anes 1. Insta he vas, 1) estat the sping seat 2). Using the SST (08222-22001), pushinanew ot 5) Light tip ed of each valve stam two oF Do not use at va slo of son treo ties wih he woeden nando shane: Inconotinsttation of te sea could resut in eok- twensureproper seating of vale andes ge pat te vale gues Took 3) nstalthevave, valve sang and epringrtsiner. 2. ial ho HLAHydrau Lash Austere (Check ht the HUA oles smash by hand. [Gore Place tho vao springs so that he sie coted with ‘name faces toward the val sping retaner ard {hon ints th retainer 4) Using me ss1(09272- 28000, 09222 - 28100), ‘compre tha spring andnstal ho etsine ook ‘Aer tling heaves, ere tt heresies lec ae correct in place before releasing tho salve song compressor.GYLINDER HEAD ASSEMBLY EM 47 INSTALLATION eeu Nore Thorough clean al paso be essombied. * Avays use naw eyinder heed and mans ashe + Atvays uso a now onder head bt + Mecyndernead gasket sa meta gasket. Tke ae not f band + Rotate the cranks, stthe Na pston a 2. 1 stl the oyndee head gaska(A) on te ender ‘oc Guore 4 Be coef ofthe instalon directo, 4 Install the engine mauntng support back fring bats Tightening torque 44153 Nm (45 ~ 6.5 kgm, 32.5 ~ 3.86.4) 2. Places onder head que in ordornotto damage the osket wth the botom pate he en, 8. Install he cynder ead bts 1) Aopy ait coat engine ot on he treads and Under he noes fe cpr ead Uae 2). Using Brim and 10m hexagon wren, instal ‘and ighton ho 10 cylin Read bls ai pate washers, soveral passes, in te sequence ‘Tightoning torque (18 DOHC) 2eaNm (0kgtm, 21.7.4) + 90" Release a bets '20.aNim (3.0m, 21.74) + 90" Tightening torgue (1.4 DONEC): 2 3Nim @ Sigim, 253A) + 80" ~+ Release al bots 34 3Nm (3.hatm, 25.6) + 90"EM 43 5. Intl he camshats 5. Using the SSF (0922 - 21000), inal he cama bang ot se. 1) Allan the cash tering chain with th ako timing chan sproctat and exust leg cela Sproat as shown. 7. Insta be canst sprocket. (Refer to EM 27) 5. Inte be eynder heed caver (Refer to EM 27) 1) sta he cylinder head cover gasket) i ne (poove ote eee head ove). Gvore * Before intating the cinder head cover gaat thoroughly cean the cyngor oad cove and tbe grove. + When ingating, make sure the cyngor hood over gasol i onto socirey nthe comers of the recesses wih no gap.CYLINDER HEAD ASSEMBLY EM 49 2). Apply Iu! patet tothe head cover gaskel at 8. Inst the tng bl. (Refer to EM 27) the corre of recess 10, nest te ike mano (Retort EM - 101) 14, Insta ne extst anil. (Raoro EM. 104) 1 Isa the gniton col. (Refer to EE grou - gion ‘ster. 12, Isat te ra Booster nse(@) 14. Connect ine hose(A ofthe POSV (Puxge Conta So lonid Vas) nde + Use squid gost, otto No 5908. + check nat the mating surfaces are clean and cry ofr sppvng aud gasket. + Aor assombhy, wat a fast 30 mutes bore ‘ming te engine wit 8) Instat th einer head ceri) wih bots). Unity then to ots saver passes. Protgon” all bots by. 39-aaNm {04-05igtm, 29-3.) and thon tenon by {he spectid torque. Tighioning torque 78~9BNm(08~ 1Okgim, 54EM 50 ENGINE (G4EDIGAEE-GSL. 1.6/1.4) 18. Install te engine wie harness connectors and wre 8) Cannac: tne MAP sensor canned), lamps te te onde: head ana the nak 8}. Connacthe TPS (Threte Poston Sener) com owe) 1) Connect he water tpertie sensor connec: oe 10) Intl te acalrator abe). 2) Connect he ground etie(0}, 8) Comect be CNP (Camshat positon sensor) connector), 4) Connect the ipnien eat condenser connec: ie) {5} Conect he ignilon cot connector). 49) Connective ground ei(0) 12) Connect tne injector connectors (). 13) Connect he lr condone compressor si connect) 14) Connect nock sensor connect). 8) Comect te CKP(Cranksh Postion Sensor) nner). 7) Conect th ront oxigen sensor connector A)CYLINDER HEAD ASSEMBLY EM 51 46. Connect he el noe 18, Intl he ar cleaner assombly( 17, Connect he hear hoses),EM 52 ENGINE (G4EDIGSEE-GSL 1.6/1.4) 22, Intl he cow op cover. 25. Install ho batery(. 26, Filwih engi cool Retro EM 81) 27, Star he engine and check or loaks. 28, Recheck enghe coolant ve! and ove,ENGINE AND TRANSAXLE ASSEMBLY ENGINE AND TRANSAXLE ASSEMBLY REMOVAL coe cavion * Use fndercovers eared damaging panied «+ Tovotd damage, unpig the wing connec: {ors carefully while hong the connector portion. nove + hak a wing sna hose fo avoid miscomnec- ton 1. Remove th beter. 8. Remove he undercover), 4 Brann enn ont. oer E81) dato cap 1 speed daring 5 Ramove the wpor arm).M54 ENGINE (G4EDIGAEE-GSL 1.6/1.4) 16, Remve the cowl op covet 4 11 Remove the upper radiator hse(A) andlowerraator Fao) 19, Ramo the sir leaner assay ()ENGINE AND TRANSAXLE ASSEMBLY 48, Disconnect the neater hosof +4, Disconnect the us nase) 15, Remove the engin wienarsess connectors anwire harness clamps fom cylinder head and tho ako mano 1) Disconnect ho knock sensor connector 2), Disconnect tes condone compressor owt fennecor®). 3), Disconnect te ctr connector) 4) Disconnect the ground cable (0) 5) Remove the scclerator eate(A) by loosening the Tocerut, then sip Be cable end ou ofthe ‘rote inka, ° TPS (Troe Poston Sensor) M55 7), Diconnsc the MAP sensrconnectrC). 8) Disconnect tne front oxygen sensor connec ‘ora 9) Diconmst ne CKP(Crankshet Postion Sensr) connect (8). 10) Dison gto col connect 11) Disconnsct te fnton col condenser connec tore) 12) Disconnsct ne CHP(Camshaf Poston Sensor) ‘conmea(C) 13) Disconnst te round eabe0)EM 56. ENGINE (G4EDIGAEE-GSL 1.6/1.4) 18) Disconnect he wal lamparatue sensor con- nocior(), 18) Remove he contol cable ru) from ransade range sutch, 18, Remove he vaneade wire harness connectors and ‘onl eal rom teraole (V7). 9), Remove he conto cae) 1) Disconnect he ransale range suitch connec- wal ‘7. isconnect the nose) of he PCSV (Purge Con ‘Snenn Val te 18, Remove he rake booster vacuum hes). 4) Disconnect the vehi spoed sensor connec: ot) 5) Disconnect tha band server ete connector) 18) Disconnect tha use generator) connect), 17) Disconnect th pulse generator) connectrO},ENGINE AND TRANSAXLE ASSEMBLY 49, Recovering retigerant and remave the high & low pressure pps. (Roo © HA group - ar conitoner compe 20, Install be $S7(09200800%, 09200-10000), heen ‘de tupport fire andthe pte. onthe engine evger back “Tightening torgue Nut(s):88.6~83.2N m7 0-9.8kg.80.6~ 68.7.0) BoAlC)NutD} 40.063 7Nm(s. 0-8 Sig 362-47 Ob) 22, Remove te ransaxie mounting back). Tightening tore Bat (8) 888 "882Nm (7.0- 8.8m, 506 = 68,76.) M57 nal)EM 58 ENGINE (G4EDIGAEE-GSL 1.6/1.4) 28, Remove the caper and hang assent) 28, Remove the sering int mounting bot 21. Remove tre trukle mounting Bot) and te tabi Ter nk)ENGINE AND TRANSAXLE ASSEMBLY 21. Ramove he cross member mounting bls and ms Tiohtning torque Ge GSANM7O~8Skgtms06~ 697-4) 82, Remove the $$7(00200:8001, 09200-10000), the ‘eng suppert ature andthe adapter 38, Remove the engine and wansaieassombly by iting vehi hore When remove the engine ad rantavoassomby, be {artnet to damage any suoundg pats body components. INSTALLATION. « EM 59 ‘nstalaton fn te reverse oder of eos Peso te flowing Adjust sat cable. ‘jst he rot cai. Refine ona wih engine 1 Refi he raneao wih fue 1 Rofl he raator and reson ark with engine + Place te hestorcontrlkneb on HOT” peston. + Bled a rom the conn stor = Start engine ane tun unl a warms up. ant the racic fan operates 3 or tines) = Tum orrne engine. Chace vein here: {or add coolant need. This wi alow rapped ‘arto beremoved tom fe cooing syste urtheraiatr cap on ight hen une engne ‘an ard eneck or aks, + Clean the battery posts and cab terminals with fandpeger essemble them, then apply ease 12 prevent corsion + Inspect fr tt eakape Per aazombie the fle, ta onthe ignition ‘Sc (donot parte estar so ha Bes up rns fer appraxtaly wo seconds and Foe ine pressures, = Rapeat his operation Wo or free tes, then ‘Sheol leakage a ay pin he ne.M80 ENGINE (G4EDIGAEE-GSL. 1.6/1.4) ENGINE BLOCK COMPONENT ences st we ee CTT) (15-22,108- 188) ; 02-44) ss, ¢ o-asaicas ‘TORQUE : Wm (kgf, ot) 50, Grankshat 8. Conte bearing 12, Oyinderbiock 4 Otseron 13, Roa ol ea cate 5. Dan pug 14. Eines 6 Gasket 45. Dv late 7 Olean 16. Washer 8: Malnbosira ip 47 Rear pate 9. Main beaang|ENGINE BLOCK EM.61 | a 1 Piston ing Connecting od 2 Piston 5. Connecting rod baning 3. Piston pln 8 Connocing red bering capEM -62 ENGINE (G4EDIG4EE-GSL 1.6/1.4) DISASSEMBLY ene 1 2 3 5. 6 MT : Ramee to fy whoo. AT Remove he are pat, Install ho gine to engine sand for dsassonbly Rernove te ting bat, (Refer to EM 22) Remove the cinder eae, (Refer to EM 34) Remove he olevl gauge tbat). 8. Remove the i pressure swicnA) 9, Reenove he wate pump, (Refer fo EM - 83) 10, Remove the ot pana), 1%, Remove the a sree, Remove the 2015(0), ol sxen(A) and gasket).ENGINE BLOCK 12. Checthe connecting oxen pay. (Refer to EM 64) 13. Remove the conocing red caps an chock ol car ‘nce, (Ree o EM 68) 14, Remove the piston and connecting rd assem 1) Using age eames, remove athe eaon tom te of te ender 2) Push he piston, conectng rod assembly ant Upper Bearng troup the tap ofthe cyte ‘ook Guore * Kap to Bernas, connecting rod an cap goer + Sra te pion and conecing rod ase 15, Remove ent ci. fro EM 82) 16. Remove the re ol ea aso. Romane ie Sots(8) ang ool al caso). 17, Remove the crankshat bearing cap and check ol (cearanee. (Rar 0 EM 68) 18, Check to crankshat od play. (Refer to EM - 68) a. 2, otto damage one Guore ‘Arrange the nen bearings and thrust bearings nthe ‘omeeterdet (Gheck ete piston and piston i, “ry to move he psn back and fort cn the piston pn any movements ft. replace the piston ad pln as ase Remove the piston ings. 1) Using son ring expend, rove th 2 om pression rings. 2), Remove he 2 sl als an ol rng by hand rag pon ing tha esac er oly Remove he connecting fs rom te piston, Using pros, remove tne aston pn For pitlon (Pressin fad 600 = 5001102 33068)EM 64 INSPECTION crue: CONNECTING ROD AND CRANKSHAFT 1. Cheek ne comeing rod ond play ‘Using eter gauge, neasre te ne pay while mov Ing te connacingvos back an ert Ere pay Slander’: 0.1 025m (0038 ~ 00008) mum: Oéran (00187) ENGINE (G4ED/GAEE-GSL 1.6/1.4) 7) Remove he 2, connecting rod ap and ower bearing 8), Measurethepasigage at its Wiest point (0.018 ~ 0.036rre (0.0007 ~ 0.0014) + Hout tolerance saa new connecting fo. + itl eutertotrace, repiaca tha canker. 2. Check the connesng ros bearing of cearance 1) Check te match marks on the connecting rod ‘and cap ar aged io ensure cect raseom a 2) Remove he? connecting ro oap nus '3) Remove he connecting ro cap and iow bor 4) Clean he crnkshat pin journal and bearing 5) Placoaplasigage across ne crankshatpinjour- ©), Reinstal th ower bearing an cap and bghien Tieng wrens S14 243m .2~SSigim, 251-253) Guore 1 not the eons 9) the pasigage measure to wie o foo ner- row, remove the upper and lover Dearing ‘han tl @ new bearings wi he sara colo ‘mark (Refer fo EM = 85, coating oa bearing ‘aecten abe) Recheck ol learance. Q caution Do not Ml, shim, of serape the bearings or the ‘aps fo adjust clearance. 10) We plsigage shows te clearance i sil in feted iy te nat ager or smatar bearing Refer to EM 6, cornocing fod bearing se fon tbe RRecnecs of lsarance nore 11 tne proper desrance cant be obtained by using the appropriate larger or smatlorboanngs, replace tho A caution ‘1 marks ae ingaipherabe Daca of an 2e- Cumuladon of dean et, do ot sera hom thai brash or scraper Caan hem nt With ‘olventordtrgentENGINE BLOCK EM 65 ‘CONNECTING ROD MARK LOCATION DISCRIMINATION OF CRANKSHAFT PIN JOURNAL ‘Crankshaft pin joural ‘outer diameter . 966 ~ 44 gran (17708 4.77080) (Ion 17703) (17608 ~ 1.7701) CONNECTING ROD BEARING MARK LOCATION DISCRIMINATION OF CONNECTING ROD ‘Connecting rod big-ond| cS ner damotar 5 “8.0 ~ 48. 006mm et (1.8906 ~ + 88000) " “4.006 ~ 48 oF2m com (8000 80020) 48012 = a2.0temm © (18002 +8908) ‘CRANKSHAFT PIN JOURNAL WARK LOCATION piscRIMINATION OF CONNECTING ROD BEARING vo] Connecting rd bearing marx | cok Ae | ome | (00596 ~ o0sariny 1511 = 1 Stamm A | 8% | cosas —co805in) B | tere | wsae~ososny ; 1.508 —1.nm (01585-00594) 1.502 ~1.805mm | eso S| ter | conse ~0.0588m)EM 66 11 Select he bearing by using selection aie ‘CONNECTING ROD BEARING SELECTION TABLE Sonia k ego | 2 [oan [oon | lay shat c 8 A ral? [rote | to | can coe Py ae wow | oer | ide Check he connecting rads. 1) When eintsing, make sue that eye num bors put en the connocting vod and cap a ‘eae math When 8 new connecting rod = Instatles,mako sur hatte notes or holding ‘he Dear place aa on he same se. 2}, Replace tho connectng rod if ts damages on the tat tae al ether ond, Also sep wae or aceeray ugh surace ofheinise date 2 fe smal ends apparent, the rod must be repaoed aswel 53)_Using a connecting 08 aging oo, check ne ‘ed te bare and ws the meatired vv ‘Sse he repr imi. coet ne rod press. ‘Any connecting rod tat ha boon saver Bon ‘or ditorod shoul be epoca “Mwabia band of canning v8 06mm 100mm (000200! 3.94 ) ores ‘Alowabla twat of eonnecng fod ‘tem 100mm (0.0080 7 3.94) or los 1) To check man bearing journal clearance, remove ie main bearing caps and ower Best™ gs 2) Coan esch main cure! an lower bearing wih 23 Gan sop towel 2), Place one stip of pastigoge across each main Jour. 4). Reinsial the lover beatings and cape, then then he bots Tahteing eae 559" S0aNIn6 5 ~GOkgim. 298 ~ 49.4.8) ENGINE (G4EDIGAEE-GSL 4 nore Do nat tum te cranksnat 15) Ramove te cap and lower beatng agi, snd eascre the widest pr ofthe plasgage. “Standard oll Gewance No.2, 4,5 "0022 ~ 0.040 (0.0000 ~0.0%6in) 65) ‘Ifthe pasigage messurs too wie o 100 na row, remove the upper and lower bear ane {hon ntl @ new bearing wh he sare clot mark (Foro EM = 68, craniahant main boa Ing aeocion te) Recheck al lesrance, Ay enuTion Do not, shim, or serape the bearings or the ap fo afusi clearance. 17) tine plesigage shows he cesrance sin ‘oct ty fhe net anger or sal bearing. fet EM 6, eankatat man bearing elec: ton tae Recheck ol clearance. Gnore 1 proper dearance cant be etaned by using Ihe appropri argaroramater bosring, place ‘ankahat and stat ver A caution ‘ee mark ae indecipherable because of ac- Cumulation & air and dust, donot serub them ‘tha wire brash or scraper Clean thom ony with ‘olventordetargent.ENGINE BLOCK Cylinder block crankshat journal bore mark Lets nove boon stamped on the end ofthe Dock asa marker nessa each ofthe Sain Journal bores. Use them, andthe numbers crleters stamped on thecrank ark rmainjcural sz), to cooee tne sorect beaenge EM 87 DISCRIMINATION OF CRANKSHAFT MAIN SoURNAL ‘Crankshaft main journal outer elamoter 7.062 (198r0~ 196720) “8.680 “49.086 — (9668-96700), “9.62mi i “49.950— ¥9.086nm (1.9585 ~ 1.9850) ‘CRANKSHAFT WAIN BEARING MARK LOCATION DISCRIMINATION OF CYLINDER BLOCK CRANKSHAFT JOURNAL BORE Cylinder block eanksha rns Mane journal bore DISCRIMINATION OF CRANKSHAFT MAIN Inner dlametor pec 5 ‘i000 ~ s.008m (a.io60 2 2600) nan oor | Sanhata man bearing ides 5 156.006 ~ 84 mmr No, 2 45 No.3 (2.1262 ~ 2.12650) oa | eve | 29%~2007 | 201-2018 G ‘5.012 ~ 64 016mm L 2.0793 0.0794) | ore 00793) (2.1268 ~ 2.267) ® [omu| 2911-2018 | 2000-2011 @07e2~007es) | over ~0.07e2) (CRANKSHAFT MAIN JOURNAL MARK LOCATION Toe] 2008201) 200s =z008 0781 - 00782) | 0780-00701) © lena] 2005~2.008 | 2.002 ~2.005 ao7as = ore | 0788 0.0760) > | w= | 2002=2.005 | 1.909 ~2.002 tow | 9.0788~ 0.078) | 0078700789)EM 63 8), Select he bearing by using selection tbe (CRANKSHAFT MAIN BEARING SELECTION TABLE ‘liner book erankehat Journal bore mark 7 fo c @ Crank vate) | (orean) |_ ene) es c . x main | = (creen) | were) | wey mae |, |B a | aw one) | ieee) |e) 5. Chock te canksha nd iy Ug al nleatr, mogsute the evust larancs while prying tbe cankshah back an ferth wih 9 Ene play Standere: 0.05 ~ 017mm (0.0020 ~ 0.0080) Limit 020mm (00078), Ifthe ond pays geatr than maximum, rope the center bearing. ENGINE (G4EDIG4EE-GSL 1.6/1.4) 6. nspecthe crankshaft man our ne pinouts Using micrometer. moasur the dametar of eh ‘an journal and pi our ‘an journal danater {91950 ~ 49.966 (19665 ~ 19672) Pn aural camaer 48.054~ 44 972ne (1.7608, 708i)ENGINE BLOCK EM 69 5. Inspect he ojindor bor ameter. ‘CYLINDER BLOCK 1. Remove the gaskot maori Using gasha separ, remove athe gasket materat from ts ep suse of he cyngor Dock, 2. Clan he cyindr tock Using aso rush and stent, heroughly dean the eynder book. 3. Inspect he top surface of einer lok fr anes Using precision straight edge and fois geuge, Imoasure the surace conacing the oyinde” head ‘ost or warpage Fates of eying: Bock gash srace 6.08mi (.000in) 4 Inspect te oye bore. Visual check te eyinder for vricalseratehs. VW doop seratcs are present, replace the cyindr ook Using one bore gauge measure te elder bore ameter at postion in tbe trust and sll rection ‘Sandard dametr 1.8 DONC :78.50~ 76 Sane (0118 ~ 30130) 1A DONG : 7550 ~75 53mm (29724 ~ 297388) 8. Chock the cynder ore size cade on the cyindr Bock baton feEM 70 ENGINE (G4EDIGAEE-GSL. 1.6/1.4) DISCRIMINATION OF CYLINDER BORE SIZE DISCRIMINATION OF PISTON OUTER DIAMETER (recone) fscoone) Wark ‘Cynder bore inner diameter] ark Piston euler diameter B 7350-T65im0m | a 7847 - 768mm Gotta ~30122m) (60106 ~ 30110) [— 7851 ~ 7652 2 7648 ~ T6490 Got22 ~ 30:28) (0110~ sort) o 7652 ~76.55mm C 7e9 ~ 76.50nm (3.0126 ~30130m) (o1e~'sor16m) DISCRIMINATION OF CYLINDER BORE SIZE DISCRIMINATION OF PISTON OUTER DIAMETER are ~2e738n) Ga pone) Ga bone) ark ‘ylinder bore inner aomator Tiare Piston outer damater n 75350 ~ 755mm a 75.47 ~ 78.48 ean 297280) aris ~29710n) 2 7551 ~ 752mm 2 7546 ~ 78.49mm @ane-2era2m) @arie~ 2a720n) : 7582 ~7553m0m c 7540 ~ 7.50rm @2arz0~ 2724) 7. Cheek the piston ie mar(A) one piston top foe. 8. Sect the pin relate to opin bore dss. Piston o-tndedeararee 102 0.04mm (2.0008 ~ 0.0018)ENGINE BLOCK BORING CYLINDER. 1. Oversize pistons should be selected scoring othe Targest bore cyngor. The sz of piston stamped on topo he piston, 2. Measure the outise diameter ofthe piston to be ‘According ote measured 0 D(Outer Diameter, ca “ew bore azo = pion OD +002 wo 004m (0.0008 {0.0K (eearanea between paton and eying. toot (0.0008 ening mara.) 4, Bor each of te eyinders tothe cleusted sie Ay ewvriow Toproventlstorton tat may rest rom tompse ‘tiers dring honing. bree ender oles ine ing or Hone the cyindes, ising ther to the proper ‘ansin ston cule dareer gap wit onde) 6, Check ne cearanc between th piston and eylnder, ‘Standard 0.02 ~ 0 04mm (010008 = 0.0076) Gore ‘Wen boring the ender, tic ao the eyngors {otha some oversize Donat bore ont one ender (0 he oversize (14 DOHC Useable over size 0.28, 0.50 0 116 DOHC : Dont use over sz) EM71 PISTON AND PISTON RINGS 1 Gioan the pion 1) Using @ gasket scraper, remove te con rom the piston fp, 2) Using a goove cleaning toler broken ring, dean the piston ring roves, 2) lng aovant end # brush throughly aan the sion. Gwore Do not use aie brush 2. The sndare messuroment ofthe piston cutee ameter i token 30 87ren% 5537H)1.8 OOHC), '59-15qm(1 513! DOHC) fom top land of be ison ‘Slander damenr DOHC: Ta ~ 78.somm (3.0108 ~3.0118r) SNDOHG : 7547 ~ 75.S0mm (20713-20720) 3. Calculate te flerence betwoen the onder bora ‘er diameter and De piston over darter. Psto-cynde dearance ~ (002 ~ Cos (0008 = 0.00165)EM72 ENGINE (G4ED/GAEE-GSL 1.6/1.4) Ingpect te piston ng ade cesrance ‘sng afeeergauge, measure the lsrancebetween ‘ew piston ring andthe wall of ig oor. Piston rg ide cnarance Noting 008 = 0.085 (0.0018 ~ 0.0033) Ne2 rng 004 - 0.085 (0.0018 ~ 0.00331) ‘Oring 008 ~0.175nm (9.0081 ~ 0.0060), Crt Noli rig : 0.1mm (0039) [N02 tng: 0.1mm (00039) Ito cosrance i greater han maximum, rolacathe piston. 5. Inspect he pion ng end gap, ‘To messure be piston ringed gp, ist a piston fing in the efinoor bore. Poston te rg at ih ‘ngs to the ender wa by gentyprosing i own {wih piston. Measure the gaa wh a eater gauge. The gap exces the service tnt, replace he sion rings the gp so large rechecktne ener bore Inner ameter he bres over the srvice it. the Syinder lock musi be ebored. (Rar fo EM 68), Piston ing end gap (15 DOHC) Standars Nevting : 0.15 ~ 030mm (0.0059 ~ 0.0118) Noa ring. 0:35 - 050mm (0.0138 - 001a7m) Ot rag 020 o.zoran(0.0078 ~ 0.0276n) Ui No, 2, ong: 1.omea.0394in) Piston ing end gap (14 DOHC) Standard ‘Now eg: 020-035 (00079 - 00138) NoZrng 037 -Oszmm (00348 ~ 0.0205") Of fing 020 ~ 0 Omm(0.0079 ~00276in) ing: 1. Oren 03040)ENGINE BLOCK PISTON PINS 1. Maasur he exter damotor of ton pin 1 Piston pin dlametor "cot = 18007 (07087 ~0:788in) 2, Measure he piston pnto-piston dearance Piston pinto-pision clearance 0.08%" 0.0t8mm (00008 = 6.0007) 8. Chack ne dference between te piston pin out amor and the eonnectng red small end inner am ston pine onnectng od rieerence ‘em (0.0018 = 0.0008) EM73 lL PRESSURE SWITCH Check the canteuty bevean the tinal and the boy with an otter. there i no canny, piece he 0 ressure sh Check the cently betwaen the terminal and te Boy when fe fin wre spushod, H tere score ily even when hee wites pushad, replace ho ‘th, If hare i no cont when a 48.0498 (0.Skgen, Apa) vacuum i app’ treugh the of Ro, tho ‘ute opening propery (Chock for ar wakage. I a faks the caphragm is broken, RepsEM74 REASSEMBLY asic Dnore * Thoroughly ean a parts to assombied {Batre insaling te parts, Spey teen engine of foal sang and riatng surtces + Replace al gaskets, Ovnge and of seals wah 1. Assen the piston and connecting rd 1) Use merous prose for nstalaion 2). Tne psn front mark and the connecting toa front mare mus fee the tning bal co ofthe ong 2. Insta tho piston rings. 1), aa he ot ng eapaerand 2 se ats Oy hana 2), Using a pston sng expander, ntl he 2 com- reten rings win he code mark acing upwat ENGINE (G4EDIGAEE-GSL_ 4) 3) Pasion fe piston rings thatthe rng ents ae Insta ho comecng rod bearings. 1) Alen he bearing) cow wi he grove of he Canned roo connecting rod expe), 2) Insta he bearings) in te connecting rod ane ‘connecting rod c2p()ENGINE BLOCK {Insta ne erankshat main besrnge. Nove Upper bearings hav anol groove ofl hles; Lower ‘oarngs oo not. 1) An he bearing claw wih ne claw groove ofthe ‘nde ack, push nthe 4 upper bearings 2) ‘Agr te bearing dow with he cow groove of the main Bemng cap, and push Inthe § lower Deargs. 5. ntl he conta bearing. Install the contr bearing) unde the No jour poston ofthe eyinde Bek wan te al groove oc- Ing oar 1. Place the crankshaf onthe cinder lok 7. Pace the main bearing caps on the cinder boc 2. Insta he main bearing ea bos, Grore Themainbeaing cop bots are tahtoredin2progres- he steps any ofthe baring cap bats n broken or deemed, replece 1) Aoply 2tghicoatotengine aon he treads and (Shor he bearing cap bot 2) Insta an uniormy tighten th 10 boating cap bota(a}n sever! pastes, in the. soquerce 3) Check he rasan ums smooth 8. Check ne crankshaft en pis. (Refer to EM - 68) 10. Instat the piston and connecting ro asconbies, Grore ‘Before insaog the piston apply a coat of engine ot ‘otha ing graves and clade bres. 1) Romove he connecting rod caps, an slp short ‘sectors of bbe hose ove the vended ends ofthe comeing ros ats 2) Insta tering compressor, check hat the rags sr seca plea, ten poston the piston 2 {he lng and tap tin using Be wooden han {ofa tamer.IE (G4EDIGAEE-GSL.1.6/1 3) Stop aftr tho ring compressor pops rea, 9nd 3) Intl he rear of soa cas) wth S bo), check the connecting rato an uma ain ‘nent before pushing te piston no pans Tightening torque 38 BN m (10 = *24gfm,72~ 8:70) 4) Applyengine oto he bot tress caps wih Bearings, and hen the tana rod Tightening torque Suit 343MM (32~25ighm, 23.1~25.30.) Gore Mahia downward fe onthe ng compressor ‘rovent tering rom expending Dele anerng tho 12 tnt the oof 1) Aoaly enine lo anew ot sal p 2) Using t9837(09231-21000) and ahammar 1p ‘nao va unt sta fen wth ero (sea reine eage 11 instal th ear eal case 1) Using 2 razr bate ane gasetsaper,remove a he olé pacing materi fom the gael Su ‘soos Grore (heck te ig tes nn ca a ym ‘reaping is gst 2) hoply lui gasket as an oven bead, contred etween te aps ofthe mating surace Cid gasket MS 721-408. equalort fateenas pe retest nee eetoT)ENGINE BLOCK M77 14 sta the al seen 3) Insta he ot part) wih he bots Inaiall Aew gaskB) and ol szreenA) with 2 Unigene bots sovera passes, bos). eee ee Tigttning forge Tighining torque 9B THAN (C= 12kghm,. 727 147 = 210N im (15 ~224g1m, 108 ~ 1596-4) “16. instal tne water pump. (Refer io EM 87) 17 instal th ot pressure svt 18. Insta te i pan. 41) Using a razor bade end gost seape, move ‘ithe 0 poking materi fom the gaia ur. 1)” Aly chive to 2 or teats, ‘been en “aha = WS 72391) o eva Gyore Check inate mating sures are clon andy be- 2) he reser sc), fre sppbing I gost ————————— 2) Appl liquid gasket 0s an even bead, centered betwoen the eapes of the mag suace. Liu gaset» MS T21-40A or equivalent (Qyore * To prevent leakage ofa apply uid gasket fo the ior trad fhe bot hole. + Biotin te pats re mints or mor hve ‘lapsed since appiying the uid gate.M78 ENGINE (G4EDIG4EE-GSL 1.6/1.4) 18, Insta he koack sensei. That, 129 ~ 18.568) 19st the of ve gave Wet) 1) Insta anew O--g on theo tavel gouge ibe 2) Apply engine oon the xing 3), tal neo ove gauge tuda(A whe bt TTiahtoning torave HiB= MMMM (12 ~1Sighm, 07 ~ 10.0048) 20, instal he cylinder heed (Refer to EM = 47) 21. ntalthe ting belt. (Refer to EM - 27) 22, Remove he engine and, 23, AIT insta he de pate. Tightaning wraie = HITT = 127 Shim (120 ~ 120g, 86:8 ~ 9400-8) Pe 24, MIT naa ey whe Tightening torave Tear SN (20.COOLING SYSTEM COOLING SYSTEM COMPONENT szscusEM -80 ENGINE (G4EDIGAEE-GSL 1. w47-196 (15-20,108- 148) ce < wo (ox 45),6+65):196-208\ C/ cS) lo \ WS ax SY (29 118-147 2-15,87- 108) ‘TORQUE : Nam hg, tt) 4. Thermostat housing 5, Water inet pe 2: Thames, 8 Ong) 5. Gasket 7. Wate pump 4 Water ne tingCOOLING SYSTEM, ENGINE COOLANT REFILLING AND BLEEDING srovcr warns Never move the radator cap when the engines hot ‘Serious scalding could be caused by hot Mud un- ‘er high pressure escaping from th radiate & caurion ‘When pouring engine coolant, be sure fo shut the {lay box Id and not to let coolant spi on the ‘lectrial pars ofthe pain. any coolant spl, ‘nse lof immectately 1. Slide me heater temperature conto! lever to mse ‘man haat. Make sur ho engine and radar are (hott the tue 2, Remove the radiator cap Loosen te dale plug) and rin the coolant EM-21 4 Tahten te redator ran pug) secure. ‘5. Remove he coolant servo nk. Orin he ezlant fndreinsal hecoolatresertane Fate coolant reser tank the MAX mark with he cota. (6 Fale coolant nt he radiator othe base of flee rock. Gonty squeeze be uppertower hoses fra ‘tors ae bed! a eo, Gaore + Mie the recommended antrosz wih an equal ‘omount of mater in clan cota, 7. Starthe engne and aw coolant to cross. ‘Wen to cooing fn operates and cootst erates, ‘ot cocant bveugh the radiate ler nook. 18, Repeat unt te cooling fon 3-5 tines andoed ar ‘lan ou te contin syst 8, natal be raat cap onthe eseratanko the "WAX" ne with cola, 10. Run th vil uncer ao unt the coog fen ope ses 299 tosEM 82 11, Stop he engine a alow colant to coo 12, Repeat stops 61011 unt ne coolant eve stays con- Sant and ala blood auto te cong syst Gwore Recheck calat ila th sero anor 22 days ter pcg cot ‘Gosantcapscy 55-86 ors 6-61 US 48-5. rpg) RADIATOR CAP TESTING 1. Romove ho rsatr cap, wet ts seal wih engine ‘coolant then rata pressure ete. 2. Apnly a prassura of 93.18 ~ 122584pa (095 ~ {skate 198% ~ 17-7098) 3. Check ora eeap in pressure. the pressure cops, replace the cap. ENGINE (G4ED/G4EE-GSL. RADIATOR LEAKGE TEST 2 3 4 Wat unt engine is coo, hen caetty remove the radar cap ana fle radiator wie engine can, "hen ina onthe pressure tester, Appt 2 prossur tstr to tho rato and apy 8 prseur of 8.16 = 122.58pa (0.95 ~ 1 28kgcm, Yast ar reps, QA Qeoat wx Inspect fr engine coolant leaks and opin pres- Remove the ietor and renee raiatr cap, Gnore ‘Check for ene ol in tho coolant andor coat in the engine of(GOOLING SYSTEM REMOVAL corn WATER PUMP 1. Drain he engine cota @ warnne ‘system Is under high pressure when the engine Iehot ‘To avoid danger of releasing scalsing engine pisoe tne cole pump assenbly i necessary. 2. Check he beaing for damage, abel noise snd ‘Suggs vlate, and replace De coolant pump a Somby Wf ncessary Check or coca leakage coolnteaks rom hele, ‘ha seals defective. Replace te coolant pup 2s: sorb pore ‘A smal oun of" weeping” tom te bleed Poe ‘s noma,ENGINE (G4EDIGAEE-GSL 1.6/1.4) EM 86 ‘THERMOSTAT ‘COOLING FAN (1 FAN TYPE) 1 Immerse te thermosiatn water and gradually heat 1. Disconnect he cooing fan moter connect, the wate 2. Chock that he radar fan oats when bay vol 2 Chack the valve opening tomparture ‘220 apes Between the terminals. Tine oy ona GREAT Ging adr Hraaiaomane ot coon Ceang in [Cota eter cnssir_T pe i reopen peated, [bee]? | ow snes Raa St open 2. hk ea it a| = 3 vin po of en Vato i Bran) or more af 65 GO) ‘th vate itis nota spect replace he therno-GOOLING SYSTEM INSTALLATION rns WATER PUMP: 1. aa me water pump 1) sa te water pup) and anew gacket with the bot), Tighining tora, B= MIN (12~15igln, 87 ~ 1000-4) EM 87 “THERMOSTAT 1. Place te hemostatin thermostat housing. 1) sa the hermosa) with hojage valve up va 2) Install a new gasket) ote hermosia) 2. Intl he wale inetfing(). Tightening torque = 147 = 180NIm (18 ~2.0hgim, 108 ~ 145-4) 2) instal he atenator aco) with he both) Tighining torque 196 ~ 268Nm (20 2.74ghm, 145 ~ 19.56.) 2. Intl he tiring bet itr, 3. Insta he timing bot. (Refer to EM - 27) 4 Insta he water pump pty. 5. Int he drive bots 8. Tighon the water pump putey bots. ‘Tightening toraue = 78~8eNm (08 ~ 10kgtm, 58~ 720-8) 7. Fawah engine colon, 8. Start engine end check for leaks. 9. Rachec engine coon 3. Fil win engine coolant. 4. Start engine an eneck or leaks,EM 28 ENGINE (G4EDIGAEE-GSL 1.6/1.4) RADIATOR 1. nstal the cooing fan assay (A) Tightening toraue EST I0BNM OT = 2. Intl he conan reser tank (A. Tightening torque 69" OBR (07 ~ 1.1m, 81 ~ 8b.) 6. Install ne upper rcitor hose) and ower raitor rose). 7. Intl te ATF(Atoratc Transaxle Fuld) ol cooler roses(C), 3. Int he racer 4 Int he actor upper racket, 8. Filwit engine cota, 8. Start engine and chock for oaks.LUBRICATION SYSTEM EM 29 LUBRICATION SYSTEM COMPONENT ssoucs L 196-265 @0-27,145-195) 47-218 (15-22, 108-158) 202-441 (40-45,288 328) L oe 119, (io-12.72-87) 4. Frontease ‘5. Drain plug 2 Fier 6 Gasiet 3 Gasket 7. Otpan 4 OlsereenM90 ENGINE (G4ED/G4EE-GSL 1.6/1.4)LUBRICATION SYSTEM. OIL, AND FILTER REPLACEMENT eon A caution + Prolonged and repeated contact with mineral ‘wil resut nthe removal of natural fats {rom the skin, Teadng to dryness, itation {nd dermatis. In adtion, used engine oil Contains potently harmful contaminants Which may cause akin cancer «+ Exercise cation in onder to minimize the length and frequency of contact of your skin {0 used oll Wear protective clothing and loves. Wash your skin thoroughly with soap Sind woter or use waterless hand cleaner {o remove any used engine ol Do not use {Gasoline tnners, or solvents Inorderto preserve te environment, used oll and used oi iter must be daposed of only at designated clsposal sites, 1 Drain the engine ol 1) Remove the a lr cap, 2) Remove he ol ala slug ad eain he ol to s eoninee Replace hoot fit. 1) Remove the ol te 2) Check and clean he al tr ntaliaion sutace. 3) Check he pert umber ofthe now or as 4). Aepy clan engin ito ho gaskat of now ‘ier 15) Lghty screw the of iter into place, and ighten 18) Tighon ian ational 34 tr eta wih engine of 1) Can and tal the ot cin pg wit 9 ne gestet Tiptenng rave 38.2 = 44 tNkm (4.0~ 454g! m,280~ 325) EM.o1 2) Fitwity heshengine ot (1 Gapacty Teta 3'3U (6.49 US af 290 mp a) Ol pan: SOL G17 US ah 254 mp @) Oi er: 0:3 L (432 US a, 0.28 Imp a 23) Intl hei rca, 4. Start engine and check for ot oaks. 5. Recheck the engine ol eve. INSPECTION 1. Check the engin quit. (Check a stration, eri of waar, dcaaring or teeing, He qual vay poo, replace tne ob. 2. Cheek he engine of ave ‘Afar waring vp he eng and then 5 minutes at ‘he engine sp, a lov! shed be between the ‘2nd"F* maran the dpc low chock leakage andadél upto tho" mark Gwore Donat wih engine ol above tho "F* markEM ENGINE (G4EDIG4EE-GSL 1.6/1 SELECTION OF ENGINE O1L Recommended ILSAC dssfeton: GF3 OR ABOVE Recommended API eassicton S1/SL OR ABOVE Recommended SAE vscosy grades Temperature range antopatod ble Recommended SAE vecosiy number rest ot change 1: Reconmandod regardoss of anvienment rt avalabl, ero Be recommended SAE vcoaty rumba For bos perormsnce and maximum protection o ‘ypes of epration selec chy tase brcants WAC 1 Satis he requrement othe AP assfeaton, 2. Have proper SAE grade number fr expect am ‘Dnt tomporture range. Lubricant at do nt have bath an SAE grade ‘umber andAP! cence dacaeston onthe cn faner shuld not bo ws.LUBRICATION SYSTEM REMOVAL WL PAN 1. Brain tne engine ot 2. Disconnect the ear oxygen sensor connec).EM 04 ENGINE (G4EDIGAEE-GSL 1.6/1 ot PUMP 8. Remove the Fen ase 1. rain ne engine 1) Remove ne scr fom the pump housing, en Separate the Housing and ever). 2, Remove the evo bats Tum the crankaat pulley an align is groove wah Airng mar" of tg bel coer Retove the tring be. (Retr to EM -2) Remove he tiring bet tensioner), 8. Remove he oi pan and ol seeon, 7. Remove the aerator (Refer to EE group - ens: ‘erLUBRICATION SYSTEM DISASSEMBLY xian RELIEF PLUNGER 1. Remove the rl plunger Remove the put), sng) and rel pongo). INSPECTION crn 3 Inapect he rela pnger M95 ‘Coat te plunger wit engine ol ang chock thet ale ‘smoot intoe plunger hot by scum weight I" tdose nt pace te ral punper It necssary, replace he ent cae. Inepect he ret ve soem Inspec for dso or roo eval pring, ‘Sander value Free height 463rm (1.83465) Lg 620.440, rm (13.420 9 6797) Inspec th oso coarse. Using foala” gauge snd precision aaight eg, measure the coarance bawoan the 119 ed preston straightedge Side deatance rma) 008 OBE (0.0016 ~ 0.0083) Caer oot ithe side cearancels reser tan maxirum, rpc tho rotors as 8 sot. Ir nocessary, replace he ontM96 ENGINE (G4EDIG4EE-GSL 4. Inspect ne rer tip learance REASSEMBLY cam: Using a foe gauge, measure the clearanos be- oon he Inner and tert tp. RELIEF PLUNGER “Tp cearance ta roi lar 0.625 ~ 0.050mm (0.0010 ~ 2onzriny Insist ret punge(c) and sprint) nt the Font case ol, and insta Pe UGA). Tightening rave 11 tp coarance is greater than species place the roars as 8st 5. Inspct te rtr body cearanoe Using afoot gauge, measure theclearance between {he utr rir snd body, tibody clearance rete han specie, opsce {he role as 8 et. Irnecessay pace the ontLUBRICATION SYSTEM EM.o7 INSTALLATION xc 3) When the purp isin plac, clean any exesse (ese of he cankahat an check that he o ont PUMP eal pent deters 4. Int the al puro 1) Place te inner and outer rote into ton case ih he marks facing the ol pump cove 2} Insta the ol pump cover(A ont case wh he Bat loth (A): Son (1.181), (8): 2aren (86) (6): 48mm (1.772), (0): Bm @ 382m) ‘Tigtningtoreve 1015~25 iim 20 ~27Aghm, 145 ~ 19.5.6) 4. Aoply aight cat of alto ont case od gee ip 5. Using the SST100214:32000) intl the Fant cage al soa. 2. Check athe ol pup fens ooh 3. Instal be ol pump on he einer tok 1) Place 8 naw font case gasket on the ener book 2). Apply angne oft he tp ofthe ol pup se “Ter, nstal he i pup onto the cantar.EM 9% ENGINE (G4EDIG4EE-GSL 1.6/1.4) {6 natal ho ir condtionar compressor tensioner Ol PAN race (a, 1 instal te ipa, 1) Using 2 razor ade and gasket spar, move alte ol pacing mater fom the gasket su Grore eka mang sure areca nd be ‘wong i gost 2) ply iad gstt asa een bond, ores ovate eons te tn ie Lig gasiet | NS 72I-408 or equator comet nore: 7. instal atornator. (Roe to EE group - aernaer) + To proves leakage of, apy quid gasket o {he inner teas ote ot holes, 8. Insta hoo seen, +e not natal the parte fv mines o more —— nave elapsed since apphing te gui gasket. “Tinting tra 147 = 246M (15 = 224m, 108 ~ 1590-8) Instead. eopey faut gost alr removing the + Aller assy, wal at east 30 minutes before 2. Int he ot pn. ‘ng te engine wit ot “Tahteing tore 7 3) ntal he pani) wih he bots. 9" TN (sO ~ 124gkm, 72 = 87) Unio uaten ne bts n several pastes. Gore ‘lean ie ol pan gasket mating suraces. 10. Ista th ting ba trsoner. 11 Int the timing bl (eter to EM- 27) 42, Insta he are bats 13, Flwih engineLUBRICATION SYSTEM EM 99 2. Insta the exist manifold end claye cwerter 4, Connect ne rer oxygen sensor connector) ‘som (Rete 6 EM = 104) 5. Falwih eng otEM +100, ENGINE (GSEDIGAEE-GSL. 1.6/1.4) INTAKE AND EXHAUST SYSTEM INTAKE MANIFOLD COMPONENT exmn a7 -248 (18-25,130- 183) TORQUE : Nenyegtm, bs) 1 ake manos 5. Gasket 2. Tote booy 8. Gylndo beac 3 ISA Spoed actuator) 7, intake marl star 4 Dolvey apeINTAKE AND EXHAUST SYSTEM. EM 101 REMOVAL son 7. connec te iectorconnctr (A). 1. Remove the engine cove). emma 8. Remove thaeatarhas(A), PCSVIPuge Cont So- Toro Valve) and the brakovecuum hose(C) Kom 2. Remove the wer maar an be cow under panel. tote aay snake maniod (ere) 8 Diconnet th POSVIPurge Conte Solenoid Va) 2 Ramove he sealers ait). (©) and water tapes seo: comecso) Disconect the TPS (Thote Poston Sensor) con: ect) 5. Disconnect the ISA Speed Actus) connec. ie) Disconnect ine PCVIPosive Crankcase Vetlaton) hoeo(D) and brea hosel.EM 102 ENGINE (G4EDIGSEE-GSL 1.6/1.4) 10, Remove the diver pipe). 12, Remove the make Tightening torau Tighien fee 27sNm(9. Torque 147 = 1BENm si) 11, Romow te take antl stay) 13 Instalton's th rovers ode of emoval wth now eee eee at Tightening toraue ATT = 24SNm(18~25kgtm, 130 ~ 18.1.8)INTAKE AND EXHAUST SYSTEM EM -103 EXHAUST MANIFOLD COMPONENT ssw ‘TORQUE : Nm (kgm, ot) © Oyinder bead 3 Gasket 2 Heat protec 4 Beau manosEM 104 ENGINE (G4EDIGAEE-GSL 1, REMOVAL exon 4. Remove tho 52) of tho exaust mantlé ar cat ‘ye cone essembyy 1 Remove the engine cover ——e Tightening torave Bolo(a) 249" S0.2N-m (2.6 ~ SSkgtm, 252 28008) Bota(@) «20.4 - 382Nm (30 = 5Skghm, 2h 22a) Tightening toraue 204~302Nm(S0~ 4.0Kgtm, 21.7 ~2891-)INTAKE AND EXHAUST SYSTEM 15. Remove he exhaust manifold and cai corvrter seoorby(A “iohtoning torque = Trr= Bhs (18 =25ighm, 130 ~ 18.1b-8) 7. ntatation sn the verse order of removalEM -106 ENGINE (G4ED/GSEE-GSL. EXHAUST PIPE COMPONENT esses: [LTOROUE : Nm (eto, bt) 5. Front mater 2 Cantor mutor "3 Main ator 2oa- @o- 302 40,217 - 289)INTAKE AND EXHAUST SYSTEM. EM 107 REMOVAL sou |. Remove fhe nan mutA) 4. Remove the ont mutes). Tianening reas tn iim .0~ angie 217 ~2890.8) 2. Remove the centr miei) Tihiening torque 254 302m @.0~40kgim, 217 ~ 269004)