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    16 views92 pages

    03-Engine (SOHC) PDF

    Uploaded by

    Wilson garcia

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    © All Rights Reserved
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    of 92
    Engine SOHC GENERAL SPECIFICATION voc SPECIALTOOLS ‘TROUBLE SHOOTING ENGINE AND TRANSAXLE ASSEMBLY TIMING SYSTEM TIMING BELT ‘COMPONENTS DISASSEMBLY .. INSPECTION REASSEMBLY CYLINDER HEAD ASSEMBLY CYLINDER HEAD ‘COMPONENTS DISASSEMBLY .. INSPECTION REASSEMBLY ROCKER ARM ‘COMPONENTS DISASSEMBLY MAIN MOVING SYSTEM ‘CAM SHAFT ‘COMPONENTS. DISASSEMBLY. INSPECTION. \_ REASSEMBLY. IK SHAFT COMPONENTS ... DISASSEMBLY .. INSPECTION. REPLACEMENT, REASSEMBLY FLY WHEEL, COMPONENTS. DISASSEMBLY .. INSPECTION. FEASSEMBLY PISTON ‘COMPONENTS: DISASSEMBLY .. INSTALLATION INSPECTION... REPLACEMENT. oe FEASSEMBLY “TEMA -62 COOLING SYSTEM ENGINE COOLANT HOST/PIPES ‘COMPONENTS INSPECTION .. REASSEMBLY ENGINE COOLANT PUMP) ‘COMPONENTS .. DISASSEMBLY. INSPECTION .. REASSEMBLY RADIATOR DISASSEMBLY. INSPECTION . REASSEMBLY RADIATOR CAP ‘COMPONENTS .. INSPECTION... ‘THERMOSTAT ‘COMPONENTS INSPECTION REASSEMBLY LUBRICATION SYSTEM IL PUMP ‘COMPONENTS .. DISASSEMBLY .. INSPECTION .. REASSEMBLY lL PRESSURE SWITCH. ENGINE BLOCK ENGINE BLOCK ‘COMPONENTS INSPECTION .. ENGINE MOUNTS | ‘COMPONENTS REMOVAL... INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD ‘COMPONENTS INSPECTION .. INTAKE MANIFOLD ‘COMPONENTS REMOVAL... INSPECTION INSTALLATION MUFFLER. COMPONENTS. REMOVAL ISPECTION INSTALLATION. AIR CLEANER (ACL} COMPONENTS . REMOVAL... INSPECTION INSTALLATION. EMA 84 EMA -64 EMA -65 EMA.-65 “EMA 68. “EMA 67 EMA-67 EMA -68 EMA -69 “EMA 69 EMA-70 “EMA-71 EMA-72 “EMA -72 EMA-73 EMA-2 ENGINE SOHC GENERAL SPECIFICATIONS | erscano: SPEC uM Generat Type Insine, SOHC No, of eyinder ‘s Bore 43k 71.5 mm (2.81 in.) aL 755 mm (2.87 in) ‘Stroke 83.5 mm (3.29 in.) Total displacement a3 1341 06 15 14985 oe Compression ratio ya 95 45L 10.0 Firing order 3-4-2 Valve timing Intake valve opens (STDC) 12 Intake valve closes (ABDC) 52° Exhaust valve opens (BBDC) a Exhaust valve closes (ATDC) 2 Valve overlap 2a Oylinder head Flatness of gasket surface ‘Max. 0.03 mm (0.0012 0.08 mm (0.00315 in.) Flatness of manifold mount'g surface Dimension for reworking oversize valve seat hole Max. 0.15 mm (0.0059 0.3 mm (0.0118 in.) Cam height intake Cam height exhaust Journal diameter Bearing oil clearance End play Intake 0.03 OS. 28.8 ~ 28.821 mm (1.194 ~ 1.195 in.) 0.06 OS. 2944 ~ 29.121 mm (1.146 ~ 1.1467 in.) Exhaust 0.03 OS. 34.3 ~ 34.325 mm (1.350 ~ 1.951 in.) 0.06 OS. 34.6 ~ 34.625 mm (1.362 ~ 1.363 in.) Valve guide hole diameter (intake/exhaus!) 0.05'O 8. 11.05 ~ 11.088 mm (0.435 ~ 0.436 in.) 025 OS, 11.25 ~ 11.268 mm (0.443 ~ 0.4436in.) 0.50 OS. 11.50 ~ 11.518 mm (0.453 ~ 0.4535in,) ‘Camshaft 42.8575 mm (1.687 in) 42.7354 mm (1.682 in.) 30 mm (1.181 in.) 0.045 ~ 0.085 mm (0.0018 ~ 0.0039 in.) 0.07 ~ 0.28 mm (0.0027 ~ 0.011 in.) 42.9575 mm (1.667 in.) 42.2624 mm (1.664 in.) GENERAL EMA-3 ‘Thickness of valve head (margin) Intake Exhaust Valve stem to valve guide clearance Intake 1.4 mm (0.049 in) 4.3 mm (0.051 in) 0.03 ~ 0.06 mm (9.0012 ~ .0024 in.) ‘SPEC Liar Grankshant Journal diameter 50 mm (1.97 in.) Pin diameter 45 mm (1.77 in.) Bend 0.03 mm (0.0018 in.) Out of roundness of journal and pin Max. 0.005 ‘Taper of journal and pin Max. 0.005 End play 0.05 ~ 0.175 mm (0.002 ~ 0.007 in) | 0.25 mm (0.0088 in} Undersize of Pin 025 (44,725 ~ 44,740 mm (1.76 ~ 1.761 in) 050 44.475 ~ 44.490 mm (1.75 ~ 1.751 in) 075 44.225 ~ 44.240 mm (1.74 ~ 1.741 in) Undersize of Journal 025 49.727 ~ 49.742 mm (1.987 ~ 1.988in) 050 49.477 ~ 49.482 mm (1.948 ~ 1.9485in.) 075 49.227 ~ 49.242 mm (1.938 ~ 1.9886in.) Main bearing oll clearance No. 12,45 0.022 ~ 0.040 mm (0.0086 ~ 0.0016 in) | 0.1 mm (0.00304 in.) No. 3. (0.028 ~ 0.048 mm (0.0011 ~ 0.0018 in.) Valve Stem diameter Intake 5.955 ~ 5.97 mm (0.294 ~ 0.235 in) Exhaust 5.835 ~ 5.95 mm (0.2836 ~ 0.234 in.) Face angle 45° - 455° 0.8mm (0.03tin.) 1 (0.039 in.) (0.1 mm (0.0089 in.) Free length (Installed height) Load Out of squareness, 44 mm (1.782 in.) 21.8kg/35mm, 45.1kg/27.2mm Max 1.5 Exhaust 0.05 ~ 0.08 mm (0.0020 ~ 0.0031 in.) | _ 0.15 mm (0.006 in) Valve guide Length Intake 12.8 mm (0.804 in.) Exhaust 42.8 mm (0.504 in.) Service oversize 0.08, 0.25, 0.50 Valve seat Wiath of seat contact Intake 0.8 ~ 1.2 mm (0.031 ~ 0.047 in.) Exhaust 1.3 ~ 1.7mm (0.051 ~ 0.067 in.) ‘Seat angle. 45° Service oversize 03, 06 Valve spring Cylinder block Cylinder bore 13 L 15L ut of roundness of cylinder bore Taper of cylinder bore Fiatness of gasket surface 71.5 ~ 71.53 mm (2.815 ~ 2.816 in) 75.5 ~ 75.59 mm (2.9724 ~ 2.9736 in.) Max. 0.01 Max. 0.05, 0.4. mm (0.0039 in.) EMA -4 ENGINE SOHC ‘SPEC uM Piston Dameter 13 71.47 ~ 71.50 mm (2.814 ~ 2.815 in.) 15L 75.47 ~ 75.50 mm (2.9713 ~ 2.9724 in) Piston to cylinder clearance 0.02 ~ 0.04 mm (0.0078 ~ 0.00187 in.) Piston ring No. of rings per piston ‘Compression ring Olt ring ‘Compression ring type No. 1 No. 2 Oil ring type Side clearance No. 1 No. 2 ll ring End gap No. 1 No. 2 il ring side rail Sevice oversize Connecting rod Bend “Twist Connecting rod big end to erankshatt side clearance 3 2 1 Inside bevel type, steel “Taper type piece type 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) (0.06 ~ 0.15 mm (0.0023 ~ 0.006 in.) 0.15 ~ 0.30 mm (0.0059 - 0.012 in) 0.90 ~ 0.45 mm (0.012 ~ 0.0177 in.) (0.2 ~ 0.7 mm (0.008 ~ 0.028 in.) 0.25, 0.50, 0.75, 1.0 Max. 0.05 per 100 mm Max. 0.1 por 100mm (0.10 ~ 0.25 mm (0.004 ~ 0.01 in) 0.1 mm (0.00394 in.) (0.1 mm (0.00394 in.) 1 mm (0.0994 in.) 4. mm (0.0394 in.) 11mm (0.0994 in.) (0.4mm(0.016in.) temp. 90-110°C) Piston pin press in load 1250 + 500 kg Bearing oil clearance 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.) | _0.1mm(0.0039in) Flywheel Runout 0.1mm 013mm (0.0014 in.) (0.008in.) Oil pressure at curd idle speed (oil 1 .Skgiem® Olt pump Clearance between outer circumference ‘and front Clearance between rotor axial side land front case Tip clearance between outer and inner rotor (0.12 ~ 0.18 mm (0.0047 ~ 0.0071 in.) 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.) Reliet spring Free length 46.6 mm (1.8346 in) Load 6.1kg at 40.1 mm (13.4216 at 1.578 in.) Cooling method Water-cooled, Pressurized, Forced circulation with electrical fan Gooling sys. Quantity iat 62 Ii (6.55 U.S ats 5.46 Imp ats) 8.5 lit (6.87 US. qut, 5.72 Imp ats) GENERAL, EMA -5 SPEC tin Thermostat ‘oe Wax pellet ype with jiggle valve Normal opening tomp. 82'c Opening temp. range 805 ~ 835°C Wide opening temp. 95°C Radiator cap Main valve opening pressure 86.1 ~ 1265 koa Main valve colseing pressure 83.4 ka ‘Vacuum valve opening preesur 266 ta ‘Air cleaner Type Dry type Element Unwoven cloth type Exhaust pipe Mutlor Expansion resonance type Suspension sys. ubber hanger type EMA-6 ENGINE SOHC TIGHTENING TORQUE (1.3 /1.5 L) item Nm kg.cm Ibstt Cylinder Block Left engine support bracket bolt 90 - 42 300 ~ 420 22-31 Oil pressure switch 13-15 430 ~ 150 96-11 Cylinder head Gylinder head bot (23-27) +(60°~ | (230 - 270) + (60°~ | (17 ~ 20) + (60"~ 62") + (60"- 62") | 62") + (60° ~ 62") | 62") + (60° ~ 62") Intake/manifold bolts or nuts, 15-20 150 ~ 200 11-15 Exhaust manifold nut 15 ~ 20 450 ~ 200 11-15 Recker cover bott 8-10 80 ~ 100 6-7 Recker arm shatt bolt 20 ~ 24 20 ~ 240 15-18 Camshaft bott 20 ~ 27 200 ~ 270 15-20 Rear plate bolt 8~10 80 - 100 6-7 Main Moving parts ‘Connecting rod cap nut 82 ~ 95 320 ~ 950 24 ~ 26 Crankshaft bearing cap bolt 55 - 60 550 ~ 600 a1 44 Flywheel M/T bolt 130 ~ 140 1300 ~ 1400 96 ~ 103 Drive plate A/T bolt 4930 ~ 140 1300 ~ 1400 96 ~ 103 Timing Belt Crankshatt sprocket bolt 140 ~ 150 1400 ~ 1500 103 - 111 Camshaft sprocket bott 80 ~ 100 ‘800 ~ 1000 59-74 Timing belt tensioner bot 20 - 27 200 ~ 270 15 ~ 20 Timing beit cover bott to - 12 400 ~ 120 7-9 Front case bot 12-15 420 ~ 150 oe Engine Mounting Engine mounting insulator bolt 90 ~ 110 900 ~ 1100 66.4 - 81.1 Engine mounting bracket to engine 50 ~ 65 1500 ~ 650 36.9 - 48.0 ruts and bolts Transaxle mount insulator bolt 90 ~ 110 900 ~ 1100 66.4 - 81.4 Transaxle insulator bracket to side 30 - 40 300 ~ 400 221-295 member botts Front roll stoper insulator bolt 45 - 60 450 ~ 600 392-443 Front roll stoper bracket to sub-trame bolt 30 - 40 300 ~ 400 22.4 ~ 295 Rear roll stoper insulator bot 45 ~ 60 4520 ~ 600 39.2 ~ 443 Rear roll stoper bracket to sub-frame bolt 30 ~ 40 300 ~ 400 221-295 Oi iter ? 2-16 120 ~ 160 9-12 il pan bots 6-8 60 - 80 4-6 il pan drain plug 35 - 45 350 ~ 450 28 ~ 33 Oil screen bolts 18 ~ 22 450 ~ 220 41-16 Timing belt upper cover bolts 10-12 100 - 120 7-8 ‘Timing belt lower cover bolts 10-12 100 ~ 120 7-9 Surge tank to inlet manifold nuts and bolts 18 ~ 20 450 ~ 200 11-45 ‘Alternator support and nut 20 - 25 7200 ~ 250 15-18 Alternator lock bott 15 ~ 22 450 ~ 220 14-16 ‘Aternator brace mounting bolt 20 ~ 28 200 ~ 280 15-21 GENERAL, EMA -7 tem Nm kg.em bat Cooling system Coolant pump pulley 8-10 80 ~ 100 6-7 Coolant pump bolt 12-15 120 ~ 150 e-11 Coolant temperature gauge unit 10 ~ 12 100 ~ 120, 7-9 Goolant temperature sensor 15 ~ 20 160 ~ 200 14-18 Coolant outiet fitting bolt 17 ~ 20 170 ~ 200 13-15, Thermostat housing bolt 15 ~ 20 180 - 200 11-15 Intake and Exhaust system Air cleaner body mounting bolts 8-10 80 ~ 100 6-7 Resonator mounting bots 4-6 40 ~ 60 29-43 Throttle body to surge tank bolts 15 ~ 20 160 ~ 200 14-15 ‘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 catalytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44 MT : Manual Transaxle AUT : Automatic Transaxle EMA 8 ENGINE SOHC ENGINE SOHE ‘SELECTION OF ENGINE OIL Recommended API classification : SH OR ABOVE SG Recommended SAE viscosity grades : ‘Temperature range anteipated before mended S imber antcatdt Recommended SAE viscosily number ‘c * 40 108 2ow| 15w| 10w tow -s0 | -50 50 20 20 60 40 | -40 40 10 50 sw 10 1“ — 40") sw" 45 6 30 | sw} 25 “13 = “1 Restricted by driving condition and environment. "2. SAESW-20 Not recommended for sustained high speed vehicle operation NOTE For best performance and maximum protection of all types of operation, select only those lubricants below 1. Satisty the requirements of the API classification, 2. Have proper SAE grade number for expected am- bient 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. GENERAL, EMA-9 MAINTENANCE CHECKING ENGINE OIL 1 2 Position the vehiclo on a level surface. Warm up the engine. Drore if a vehicle has been out of service for a prolonged ered of time, warm up the engine fr epproximatoly Poms. ‘Tun off the engine, and walt 2 or 3 minutes, then ‘check the oil level. Check that the engine oi evel is within the level ragne indicated on the oil dipstick it the oil level is found to have fallen to the lower limit (the "L* mark), refill tothe “F* mark. Lowertimt Upper mit cS Gaore When refiing, use the same typo of engin ot ‘Check that the oll is not dirty or contaminated with ‘coolant or gasoline and that it has proper viscosity. CHANGING ENGINE OIL @ warning Be careful not to brun yourself, as the engine oil Is hot. 1. Fun the enigne unti itreaches normal operating tem- perature. 2. Turn off the engine. 3. Remove the ol filer cap and the drain plug (on the oll pan). Drain the engine oil. 4. Install and tighten the drain plug to the specified torque. Tightening torque Drain plug 35 ~ 45 Nm (350 ~ 450 kg.cm, 33 bs) Whenever tightening the oil drain plug, use a new ‘rain plug gasket. 5. Fillthe crankcase with fresh engine oil through the oil filler cap opening. rain and Refill Without ol! fiter 3.0 itor (8.17 US. ats, 2.64 Imp. ats.) Drain and Rel With ol fiter 3.3 lor (8.48 US. qts., 2.90 Imp. gts.) 6. Install the oil filer cap. 7. Start and run the engine. 8. Turn off the engine and then check the oil level. Add oil it necessary. EMA -10 ENGINE SOHC FILTER SELECTION ‘All Hyundai engines are dqupped with a high quality, cis- ‘posable oll fier. This fitr is recommended as a replace- ‘ment fiter on all vehicles. The qualiy of replacement fi- ters varies considerably. Only high quality fiters should be used fo assure the most efficient service. Make sure that the rubber gasket irom the old ol iter is completely ‘emoved from the contact surface on the engine block be fore instaling the new fier. Part rumbor PROCEDURE FOR REPLACING THE OIL FILTER, Q) caution Be careful not to burn ylurself, as the engine and engine oil are not. 1. Use a fiter wrench to remove the oil iter 2. Before installing the new oilfiter on the engine, apply clean engine ol o the surface of the rubber gasket. 3, Tighten the oil fiter to the specified torque. Tightening torque Oil fier : 12 ~ 16 Nm (120 ~ 160 kg.om, 9 ~ 12 fost) 4, Run the engine to check for engine oil leaks. 5. Alter turing off the engine, check the il evel and add oll as necessary. CHECKING COOLANT LEAK 11. Wait until the engine is coot, then carefully remove the radiator cap, 2. Confirm that the coolant level is up tothe filer neck. 8 Insta a actor cap tester tothe rato flor nock and apply 140 KPa (14 kgfon?, 20 ps) pressure Holat for wo minutes in that condion, wnt chook ing for loakago trom tne radiator, hoses or connec: tons, Drore 1. Rakatr coolant may be extromely hot. Do not pen tho systom bocause ho or ecating water Ceuta gush ou causing personal hry. Atom the vehids o cool befor soning th ysl. 2. Bo suo to clean anay any moisture fom the Places checked completely. 2. When thotastoris removed be care not to spl any coolant fom t. 4. Be carol, when instling and removing the tester and when testing, not to deform the filler rock ofthe alata GENERAL, 4, there is leakag ate part. repair or replace with the apropri- RADIATOR CAP PRESSURE TEST Remove the radiator cap. Wet its seal with engine cootant, then install it on the tester. 2. Increase the pressure until the gauge stops moving. EMA -11 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. f any coolant spills, rinse It off immediately. 1, Slide the heater temperature control lever to maxi mum heat. Make sure the engine and radiator are ‘cool to the touch. 2. Remove the radiator cap. 3. Loosen the drain plug and drain the coolant. ‘Main valve opening pressure = 78 ~ 108 kPa (0.8 ~ 1.1 kg/cm, 11.3 ~ 15.6 psi) Limit : 65 kPa (0.66 kg/om#, 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. Guore Bo sue tha th caps clean btore esting, snc st ‘or other foreign material on the cap seal will cause an Incorrect reading. 4, Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservior. Fillthe tank hatfway to the MAX mark with water, then up to the MAX mark with antitreaze. 6. Pour coolant into the radiator up to the base of the filler neck, and instal the radiator cap loosely. 7. Start the engine and fet it run until it warms up (the radiator fan comes on at least twice) 8 Tum off the engine. Chack 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. EMA -12 ‘SPECIFIC GRAVITY TEST 1. Measure the specific gravity of the coolant with a hy- drometer. 2. Mesure the coolant temperature and calculate the ‘concentration from the relation between the specific gravity and temperature, using the following table for reference. ENGINE SOHC RELATION BERWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperature °C (°F) and specific gravity Freezing Sale operaing Coolant temperature °C_| temperature °C | concent 1060) | 20(68) | 30(86) | 40(104) | 50(122) CF F) (Specitic volume) 1054 |” 1.050 | 1046 | 1042 | 1.036 “16 (8.2) “14 (12.2) 30% 1063 | 1058 | 1054 | 1049 | 1.048 20 (-4) 15 (8) 35% 1071 | 1067 | 1.062 | 1.057 | 1.052 -25 (-43) 20 (-4) 40% 1079 | 1.074 |” 1.069 | 1.064 |” 1.058 -30 (-22) -25 (-13) 45% 1087 | 1082 | 1.076 | 1.070 | 1.068 96 (-32.8) “31 (23.8) 50% 1.095 |" 1.090 |" 1.084 |” 4.077 | 4.070 42 (-44) “37 (35) 55% 103 [1.098 |” 1.092 |” 1.084 | 1.076 “50 (-58) 45 (-49) 60% Example ‘+ It the concentration is above 60%, both the ‘The sate operating temperature is -15°C (5°F) when. the measured spectic gravity is 1.058 at coolant tem- perature of 20°C (68°F) Q) caution ‘ If the concentration of the coolant Is below Its anti-corrosion properties will be ad- versely affected. RECOMMENDED COOLANT antifreeze and engine cooling property will centration level within the specified range. * Do not use together with another brand's product. Antitreeze Mixture ratio of antifreeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM ‘50% [Except tropical areas} 40% [Tropical areas) GENERAL, EMA-13 CHECKING COMPRESSION PRESSURE 1. Befor checking engine compression, check the en sine ol level. ‘Also check that the starter motor and battery are all in normal operating condition. Check the DTC and resetting the ECM will erase any stored DTCs. 3, Stsrt the engine and walt until engine coolant temper- ature reaches 80-95°C (176~205°F). Disconnect the fuel pump connector. “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. 8. Insert the compression gauge into the spark plug hole. 10. Depress the accelerator pedal to open the throttle fully. 11. Crank the engine and read the gauge. ‘Standard value : 1500 kpa (18.5 kg/em?, 220 psi) Limit : 1200 kpa (12.5 kg/omé, 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 (7.5 kg/em®, 21 psi) between cylinders 13, ta cylinder’s compression or pressure diferential is ‘Outside the specification, add a small amount of oll through the spark plug hole, and repeat steps 9 to 12. 1. Ifthe addition of oil makes the compression to rise, itis likely that there may be wear between the piston ring and cylinder wall 2. compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes. Tightening torque ‘Spark plug : 20-30 Nm (200-300 kg.cm, 14~22 Ib) ADJUSTING TIMING BELT TENSION 1. Tum the steoring whee! fully counter clock wise. 2. iff the vehicle by using of jack. ENGINE SOHC 7. Remove the crankshaft pulley. 4, Loosen the coolant pump pulley mounting bolt and 8. Turn crankshaft to place clockwise in No.1 cylinder at loosen the generator belt tension adjustment bol. top head center on compression stroke, 5. Remove the coolant pump pulley, generator belt, ower steering pulley and power steering belt. 6. Remove the timing cover upper side mounting bot. Daore Tun the crankshat clock wise. If counter lok wiso, tension fs not avaiable GENERAL EMA -15 9. Loosen the tensioner bolt 1 ~ 2 tum and tension the bolt by tensioner spring. 10. Turn crankshaft clockwis ‘sprocket teeth. 15 Much as two camshaft 111. Tighten the tensioner bot of slot side of frst and then tighten the bolt of pivot side. 12, Rotate the crankshaft pulley two turns clockwise so that the timing bett positions on the pulleys. 13. Check the tension of timing belt. When the tensioner and the tension side of the timing Tightening torque 40 ~ 12 Nm (100 ~ 120 kg.om, 7.2 ~ 8.7 Ibs) 15, neti the crankshatt pul. 16, inetl the coolant pump ply. 17, Install V-belt and adjust the bet tension. ADJUSTING DRIVE BELT TENSION Chock that the belts are not damaged and are prop- erly fit for the pulley grooves. 2. Apply 100 N (22 Ibs.) force to the back and midway pportion of the belt between the pulleys as shown in the llustration, measure the amount of deflection with a tension gauge. Q caution 4. When installing the V-ribbed belt, check that the Veribs are properly aligned. 2. Itnoise or slippage 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 thatthe belt belt are pushed in horizontally with a moderate force is deflected, approx. 49N (11 Ib] the timing bet og endis approx. half ofthe tensioner mounting botthead radius (cross Pay flats) away from the bott head center. l Wong Vatbed batt Weng Font 14, Install the timing belt cover. STANDARD VALUE : th ‘Adjustment “me New Used For alternator Deflection mm (n.) 7.5 ~ 9.0 (0.29 - 0.35) 40 (0.39) EMA -16 GDrore 1. Tho bol tension must be measured hall - way botwoen tho spect putes. 2. Wnenanow bos insted, aust the tonsion to tho conta value of he standard ange ndeatod Under ‘Now n the above fale. Let the engine ide fr 5 minutes or mor, and check the stan Card valve indicated under "Inspec a. When adustng a bet which has been used, or nom installed, ator 5 minutes or more of oper ‘on, aor tothe standard vale Indated under “Used inno above tabla. 4. Refer tothe standard value indicated under “In -Spection” for periodic inspections. ‘TYPE A TENSION GAUGE Do not let the dial section of the tension gauge contact ‘other objicts during measurement. Tea ‘TVPE B TENSION GAUGE 1. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET positon, 2. Ifthe tension gauge is removed from the belt, the nee- le will stil indicate the tension. Read the tension value after removing the gauge. 8 Spine Hook ENGINE SOHC. ADJUSTING THE ALTERNATOR BELT & caution 1f the belt is too loose, It will cause noise or sud- den wear. It 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 bott, adjust the belt tension to the specification 8. Tighton the adjuster lock bolt *B. 4, Tighten the alternator nut “A* 5. Check the tension or the deflection of belt, readjust it necessary. Tightening torque ‘Alternator support nut A: 20 ~ 25 Nm (200 ~ 250 kg.cm, 15 ~ 18 Ib.) ‘Alternator lock bolt 15 ~ 22 Nm (150 ~ 220 kg.om, 11 ~ 16 Ib.t) ‘Atlernator brace mounting bolt: 20 ~ 28 Nm (200 ~ 280 kg.cm, 15 ~ 21 Ib.) GENERAL SPECIAL TOOLS ccouso Tool (Number and name) ‘Crankshaft front ol seal installer (09231 - 22000 Mlustration Use Installation of the crankshaft front oll seal (use with 09231 - 22100) ‘Crankshaft front oll seal guide 09231 - 22100 Installation of the crankshaft front oll seal (use with 09214 - 22000) ‘Camshaft oil seal installer 09221 - 21000 Installation of the camshatt oll seat (use with 08221 - 21100) ‘Camshaft oll seal guide (09221 - 21100 ‘Valve spring remover and installer 8222 - 22100 Valve stem oil seal installer 9222 - 22001 =) 07 QD o a {Used as a guide when pressing in the camshaft oll soal (use with 09221 - 21000) Removal and installation of the inlet or exhaust valve Installation of the valve stem oil seal EMA -18 ENGINE SOHC ‘Tool (Number and name) Mlustration| Use Valve guide installer Removal and installation fo the valve guide 09221 - 21200 A/B e A 8 Crankshaft rear ol seal installer 1) Installation of the engine rear oll seal 09281 - 21000 2) Installation of the crankshaft rear oll seal Leak down tester 09246 - 32000 ‘Leak down test of auto lash adjuster GENERAL, EMA-19 TROUBLESHOOTING cxwice ‘Worn piston or cylinder ‘Symptom Probable cause Remedy Low compression | Blown cylinder head gasket Replace gasket Worn or damaged piston rings Replace rings Repair or replace the piston andor ‘main bearing noise t “Timing bett noise ‘Low coolant level Clogged radiator Thin or dituted engine Excessive bearing clearance Incorrect belt tension Leakage of coolant 11. Heater or radiator hose 2. Faull radiator cap 3, Thermostat housing Radiator 5. Engine coolant pump Foreign material in coolant cylinder block ‘Worn or damaged valve seat Repair or replace the valve andlor soat ring {Low oil pressure | Low engine oll level ‘Check engine oil evel Faulty oil pressure switch Popace Clogged oi fiter Replace ‘Worn oll pump gears or cover Replace Thin oF uted engine oll Change and find out cause (Oil relist valve stuck (open) Repair Excossive bearing clearance Replace High ol pressure | Oil roiet valve stuck (closed) Repair Exoossive engine | Loose engine roll stopper (front, rear) Retighton becimal {Loose transaxle mount bracket [Rotten {Loose engine mount bracket Retighton Loose center member Rtighton Broken transaxle mount insulator Replace Broken engine mount insulator Replace Broken engine rol stopper insulator Replace Noisy valves “Thin oF dluted engine ol (Low ol pressure) Change Worn or damaged valve stom or valve guide Replace ‘Connecting rod and | Insufficient oll supply Check engine ol lovel ‘Change and find out cause Replace ‘Adjust belt tension Repair or replace parts ighten or replace clamps Replace the gasket or housing [Repatrorrepace Replace parts Replace coolant EMA, ENGINE SOHC ENGINE SOHC ‘Symptom Probable cause Remedy ‘Abnormally high | Faulty thermostat Replace parts coolant temperature Faulty radiator cap Replace parts Restricted flow in cooling system Clear restriction or replace parts ‘Loose or missing drive belt ‘Adjust oF replace Faulty water pump Replace Faulty temperature sensor or wiring Repair or replace Faulty electric fan Repair or replace Insufficient coolant Refll coolant ‘Abnormally low Faulty thermostat Replace coolant temperature | Faulty temperature sensor or wiring Replace or repair Leakage from ol! | Loose connections Replace cooling system (Cracked or damaged ; hoses, pipes or oll cooler __| Replace or repair Inoperative electrical | Damaged : Thermo sensor, Electrical motor, Replace or repair cooling fan Radiator fan rolay, Wiring Exhaust gas leakage | Loose connections: otighten Broken pipe or mutfier Repair or replace ‘Abnormal noise Detached battle plate in muller Replace Broken rubber hanger Replace Pipe or muffler contacting vehicle body Correct Broken pipe or muffler Repair or replace GENERAL, EMA -21 ENGINE AND TRANSAXLE 2. Detach the air cleaner. ASSEMBLY | ccucre REMOVAL, 1. Remove the battery. @ wannne Make sure jacks ond safety stands are placed properly and holst brackets are attached to the correct position on the engine. Q) cauTion Us¢' tender covers to avoid damaging painted sur- face. EMA -22 ENGINE SOHC 6. Disconnect the connectors for the rear Oxygen sensor harness and the ignition coil harness. 7. Disconnect the coolant temperature sensor and No.1 TDC sensor connector. GENERAL EMA -23 8. Disconnect the brake booster vacuum hose. 10. For vehicles with’ automatic transaxles, disconnect transaxle oll cooler hoses. 9. Remove the main fuel line and the return and vapor hoses form the engine side. NOTE When the hoses, make identification ‘marks to avold making mistakes when reconnecting them, Q caution Be caurful not to spill oll or fluid from hoses, Plug the openings to prevent foreign material from en- tering. 11. Drain the engine coolant from the radiator. 12. Disconnect the radiator uppor and lower hoses on the ‘engine side, then remove the radiator assembly. & caurion Toreduce the residual pressure in the hoses, refer to Group Fuel System “Fuel filter replacement.” EMA -24 ENGINE SOHC 18. Disconnect the heater hoses (inlet and outlet) on the 17. For vehicles with automatic transaxles, remove the engine side. Control cable from the transaxle. 14, Disconnect the accelerator cable at the engine side. 15. For vehicles with 5-speed manual ransaxles, remove the clutch release cylinder. 18. Disconnect the speedometer cable from the transaxle. 16. For vohicios with manual transaxles, remove the shift ‘control eable from the transaxle. 19. Disconnect the air conditioning compressor from the ‘mounting bracket. GENERAL, EMA -25 20. Disconnect the starter motor connector and ground. 23. Remove the caliper assembly from knuckle and hold the upper side. 21. Remove the stesring dust cover, the Ujoint bolt and the gear box assembly. Gnore ‘Mark between Ujoint and gear box before disassem- (with ABS) 22. Jack up the vehicle and remove the front tire. EMA -26 26, Disconnect the front exhaust pipe from the manifold Dore Use wire to suspendine exhaust ppe rom the bottom ofthe venice. 27. Attach a chains or cables to the engine. 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. 29. ENGINE SOHC Remove the engine mounting bracket from the en- gine, ‘Slowly raise the engine (to the extent that the weight of the engien and transmission assembly is not applied tothe mounting portions) and temporarily hold tin the raised position. GENERAL, EMA -27 30. Remove the caps from the inside of the right fender 92, While directing the transmission side downward, lift shield and remove the transaxle mount bracket bolts. the engine and transmission assembly up and out of the vehicles. ENGINE SOHC. EMA -28 TIMING SYSTEM TIMING BELT COMPONENTS caus: TORQUE : Nm (kg.cm, Ib.ft) TIMING SYSTEM EMA -29 DISAESSEMBLY ewxoxe 6. Align the timing marks of the camshaft sprocket and. ‘crankshaft sprocket, with the No.1 piston placed at top 1. Loosen the coolant pump pulley bot. ‘dead center on its compression stroke. 2. Loosen the alternator bol. |. Remove the coolant pump pulley and belt. Remove the crankshaft pulley 7. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. EMA -30 8. Remove the timing belt. 1 coos 2 9. Remove the camshaft sprocket. " INSPECTION TIMING BELT ENGINE SOHC 10. Remove the crankshaft sprocket bolts. Remove the ‘crankshatt sprocket and flange. Remove the timing belt tensioner. ‘Check the bett for oil or dust deposits. Replace, if ‘necessary. Small deposits should be wiped away with, ‘a dry cloth or paper. Do not clean with solvent, When the engine is overhauled or belt tension ad- justed, carefully check the belt. If any of the following flaws are evident, replace the belt Description 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 surface rubber 3. Cracked or separating canvas rack = ‘Sepafton Crack ‘Separation TIMING SYSTEM EMA -31 Description Flaw conditions 4. Badly worn tooth (initial stage) Canvas on load side tooth flank worn (Flity canvas fibers, rubber ‘rank wor {gone and color changed to white, and unclear canvas texture) (rls ay | 5. Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber rubber exposed (tooth wicth reduced) ‘ipod | 6. Cracked tooth bottom onde 7. Missing tooth “oot ising an cars toa 8. Side of belt badly worn Grore A normal belt should have precisely cut sides as it cut by @ sharp fn. 9. Sid@ of bolt cracked ‘SPROCKETS AND TENSIONER 1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2. Inspect the tensioner pulley and the idler pulley for ‘easy and smooth pulley rotation and check for play or noise. Replace as necessary. EMA -32 REASSEMBLY | ccozo 1. Install the flange and crankshaft sprocket as shown. Pay close attention to their mounting directions. =n ‘Special washer Ei U Crankshaft pocket Tightening torque Crankshaft sprocket bolt: 1140 ~150Nm (1400 ~ 1500kg.cm, 103 ~ 1111b:A) 2. Install the camshaft sprocket and tighten the bolt to the specified torque. Tightening torque ‘Camshatt sprocket bolt : 80 ~ 100 Nm (800 ~ 1000 kg.em, 59 ~ 74 ib) ENGINE SOHC. ‘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. When installing camshaft sprocket. ‘Make sure that cmashaft sprocket knock pin fits small hole in pulley as shown. ‘4. Tentatively fasten timing belt tensioner as such posi tion as to place its pulley nearest to water pump body. |G SYSTEM Hang the tensioner spring on the tensioner bracket and insert the other spring side in the front case using the screw driver 6. Install the timing bet tightly in the sequence shown. ©orankshalt sprocket + @Camshalt sprocket -> GTiming bet tension 7. Install timing belt so as not to give salck to tension side, Then make sure that timing marks are at correct po- sition respectively with tension side in strained stato by applying force to camshatt sprocket in reversing di- rection. 8. Loosen the tensioner mounting bolt in the order as shown tio give the timing belt spring tension. 10. Add 11. 12, 13. 14, 15. 16. 17, 18, Rotate crankshaft in regular direction (lock wise view from 8 front) through angle dquivatent to two tooth (15°) of camshatt sprocket. {force to tensioner in direction of regular rotation (© direction) so as to bring belt teeth in perfect con- tact with sprocket teeth without gap. ‘After marking sure of this state. Fix tensioner in state that only tensioner spring is. movable, Rotate tho crankshaft pulley two or four turns conter clockwise so that the timing belt positions on the pul- leys. ‘Then recheck the belt tension. Verity that when the tensioner and the tension side of the timing belt are pushed in horizontally with a modorate force [approx. 49N (11 Ib), the timing belt is offest from bolt head ‘center by approxmataly bot ofthe tensioner adjusting bolt head radius. “Tenslener bot Ee ‘v2 ot bot head radius (across a} Install the timing belt cover. Install the erankshatt pully. Insta the air condition belt and adjust bet tension. Install the coolant pump pulley. Install V-belt and adjust the belt tension. EMA -34 ENGINE SOHC. CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS ecnoe (Cylinder head bolt jaz 23 ~ 27 (250 ~ 270, 17 ~ 20) + 60°+ 60" Cylinder head gasket TORQUE : Nm (kg.cm, Ib.ft) CYLINDER HEAD ASSEMBLY DISASSEMBLY sommace 1 Drain the coolant and disconnect the upper radiator hose. Rc ep move the breather hose. (between the air cleaner ‘and the rocker cover) Rlomove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Rembve the cables from the spark plugs. The cables, ‘should be removed by holding the boot portion. EMA -35 Remove the ignition coil 3. Remove the intake manifold. Remove the heat protector and exhaust manifold as- sembly. Remove the coolant pump pulley and the crankshaft pulley. |. Remove the timing belt cover. Move the timing belt tensioner pulley toward the ‘coolant pump and temporarily secure it. Remove the timing belt. Flemove the rocker cover. EMA -36 ENGINE SOHC. 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 illus- tration. @1 @7 Os oa @3 Os O10 Oo 2 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surlace, ‘Mako sure that the gasket pieces do not fallin to the engine. INSPECTION 1 Check the cylinder head for cracks, damage and coolant leakage. 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. ‘Check the cylinder head surtace for flatness using a straight edge in the direction of A,B, ..as shown, IW flatness exceeds service limit in any direction, ro- place the cylinder head, or lightly machine the cylin- der head surface. Cylinder head flatness ‘Standard value : Less than 0.03 mm (0.012 in.) Limit : 0.08 mm (0.0024 in) CYLINDER HEAD ASSEMBLY REASSEMBLY | eseness 1. Clean all gasket surfaces of the cylinder block and the oylinder 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 from the top ‘center, tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench. Repeat the procedure, retightening all cylin- der head bolt to the specified torque. Tightening torque 23-27NM (290-270kg.cm, 17-20Ib.ft)+60"+60" @0 O41 O2 Os 7 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- ing marks are in alignment. 6. Adjust the timing according to the "Timing Belt" sec- tion, EMA -37 7. Install the rocker cover and tighten the bolts to the specified torque. Tightening torque Rocker cover bolt: 8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 Ib.t) 8. Install the timing belt cover. 9. Install the new intake manifold gasket and the intake ‘manifold. Tighten the nuts and bolts to the specified torque. Tightening torque Manifold nuts and botts (both intako and exhaust): 415 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 15 Ibs) 10. install the new exhaust manifld 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 botts to the specified torque. Tightening torque ‘Surge tank to inlet manifold nuts and bolts 45 ~ 20 Nm (250 ~ 200 kg.cm, 11 ~ 15 Ib 412. Install the ignition col. 13. Install the air intake hose. 14. Connect the vacuum hose, fuel hose and coolant hose. 416. Install breather hose. ENGINE SOHC ROCKER ARM EMA -38 COMPONENTS cess Fockerarm shaft (net) Rockeram A Rocker shat spring Rocker arm shaft (exhaust) TORQUE : Nm (kg-cm, Ib-ft) 2. Remove the timing belt cover. DISASSEMBLY oes CYLINDER HEAD ASSEMBLY. EMA -39 INSPECTION cxsso ROCKER ARM SHAFT ROCKER ARM 1. Cheok the rocker arm shafts for damage. Replace as necessary. 1. Check the rocker face. Replace it if damaged or pressed. 2. Check the oll hole whether clogged or not. 2. Check the contact surface on the cam and viave stem. badly wom or damaged, replace it. ono 3. Check hydraulic lash adjust (HLA) face that contact the valve stam if badly worn or damaged, replace the EMA ~40, ENGINE SOHC HLA a With the HLA filed with engine oil, hold A and press B by hand. If B moves, Replace the HLA. For othor specific trouleshooting regarding HLA, refer to the ta ble below. 5 Problem Possible cause ‘Action * Temporary noise on starting ‘Normal This noise will disappear after a cold engine the oil in the engine has reached * Continuous noise when engine is started afer longer than 48, hours parking. * Continuous noise when engine is fist started after rebuilding cylinder head. * Continuous noise when engine is after excessive craking the engi by starter motor oF band. * Continuous noise when engine is after changing HLA. * Continuous noise during idle after high speed running. * Noise cotinues more than 15 minutes. (Ol drain out of the high pressure chamber on HLA, allowing ai to get in. Insutfecient ol hhoad oil gallery. cylinder ‘ll drain out of the high-pressure ‘chamber in HLA, allowing ali to get in Engine ol evel too high or too low. Execssive amount of air in the: oil at high engine speed. Deteriorated oi! Low oil pressure Faulty HLA. normal pressure, Noise will disappear within 15 minutos ‘when engine run at 2000-3000 rpm not disappear, refer to item 7 below Q caution Do not run engine all a speed higher than 3000 rpm as this may damage HLA. ‘Check oil level. Drain or add oil as necessary. Check oll supply system Check oil quality. If deteriorated, replace with specified type and amount of oil. ‘Check oil pressure and oil supply system of each part of engine, Romove the cylinder head over and press down HLA by band. Hit moves, replace HLA. Q) caution Bo careful of hot HLA. EMA -41 CYLINDER HEAD ASSEMBLY REASSEMBLY | cwroae 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 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 it) denteaton mask 2. When installing the rocker arm, shaftand spring, mark. the difference of left and right part. Use the spring without distinction of intake and x= haust valve. ‘Must sot the part that is small chamfer side between, ‘tow parts of rocker arm shaft to the timing belt. 3. Install the air rocker cover and tighten the bolts to the specified torque. Tightening torque Flockr cover bolt : 8 ~ 10 Nm (60 ~ 100 kg, 7 tom) Q caution 1. Sealant must be applied to top surtace of cylinder head and cam cap and area of appll- tation is shown in figure. 2. Theproperamountof sealant must be used to prevent the sealant from pushing excessive ‘amounts. Use sealant of specified brands or equivalant. Sealant (Three bond No. 12120 aluminum color or equivalent) application place (4 place) ae JOmm(O4In) 10 mm(04 In) ‘4, Install the timing bett cover. Tightening torque Timing belt cover bott : 10 ~ 12. Nm (100 ~ 120 kg.cm, 7 ~ 9 Ibs) 5. _Installthe breather hose, PCV hose, blow by hose and, ‘spark plug cable. 6. Install the ar intake hose and aor duct. EMA ~42 ENGINE SOHC. VALVES COMPONENTS cewou @&— retainer lock GS vate sing tarer Retainer lock ———€ ate oping retainer —@D ‘Vato spring Vane spring 3 Valve stom seal © resins Valve spring seat Exhaust valve guide Intake vat gue 7 Valve stem seat Js eae eerere(ctteesesznaaa ——ff \-- CYLINDER HEAD ASSEMBLY DISASSEMBLY cunic Using the spocial tool, Valve Spring Remover and In- staller, remove the retainer lock. Next, remove the spring retainer, viave spring, spring seat and valve. Gore ‘Keep these parts in order so that they can be rein- Stalled in ther original postions. Remove the valve stem seals with pliers, and discard them, Grore Do not reuse the valve stem seals. EMA -43, INSPECTION VALVE SPRING Check the valve spring free length and tension. Itthey ‘exceed the service limit, replace the spring, Using a square, tost the squareness of each spring. Wa spring is excessively out of square, replace it. VALVE SPRING ‘Standard viaue Free height : 42.03 mm (1.655 in.) Load : 24.7 kg at 34.5 mm Out of square : 1.5° or less VALVE GUIDES Check the vaive stom-to-guide clearance. I he clearance exceeds the service limit, replace the viave guide with the ext ovorsize par. VALVE STEM-TO-GUIDE CLEARANCE Standard viaue Intake : 0.030 ~ 0.060 mm (0.0012 ~ 0.0024 in.) Exhaust : 0.095 ~ 0.065 mm (0.0014 ~ 0.0028 in.) Valve gui 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 ~ 0.4954) 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) EMA -44 ENGINE SOHC VALVE GUIDE REPLACEMENT PROCEDURES: ‘The valve guide is installed using a press fit. Using Value Guide installer (09221- 21200 AVB or suitable tool, replace the valve guide described in the folowing procedure. 41. Using the Valve Guide installer push rod, push the valve guide out toward the cylinder block with a press. + Ml Valve gui instar corsa too! yindor head Valve ude Vat guid ectalor 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 vialve guide installer ‘makes it possinle to press fit the valve guide to a pre- deterthined height. Install the viave guide from the {op of the cylinder head. Note that intake and exhaust valve guides ditfer in length, 4. After installing the valve guides, insert new valves and ‘check the clearance. Kl 10 Vike gace ner Vato a instar one saresy vomossemT| vite oe Ove et 5. Whenever valve guides are replaced, check for valve-to-seat contact, and recondition the valve seats as necessary. CYLINDER HEAD ASSEMBLY VALVE SEAT INSERT ‘Check the valve seat for evidence of overheating and im- prioper contact withthe valve face. Fecondition or replace tho seat, if necessary. Before reconditioning the seat, check the valve guide for wear. Ifthe viave guide is worn, replace it, then recondi- tion the seat. Recondition the viave seat with a valve seat ‘tinder or cutter. The valve seat contact width should be with within specifications and centered on the valve face. 08-12mm (0031 0.047 my EMA -45 VALVE SEAT INSERT REPLACEMENT PROCEDURE 1. Any valve seat insert that has been worn over the ser- ‘vice limit should be removed at normal temperature after cutting away most of the insert wall, using valve seat cutters, as shown in Fig A. 2. Afterremoving the seat insert, machine the seat insert bore using a reamer or acutter. Cutto 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 ingert should be at normal room temperature for in~ stalation. After installing a new valve seat insert, resurface the valve seat using the same procedure described in the first paragraph of "Valve Seat insert* (above). (0.3mm (0012 in.) (05mm (0.02-.059 in) ¢ The - 5.1mm (02008) VALVE SEAT INSERT OVERSIZES Size | Seat insett height H Description | Sizemm(in.) | S26. ‘mn (in) Cylinder head ILD. mm (In.) intakd vatve | 0:3(0.01208.| 30 | _5.1-5.3 (0.201-0.2069) 28,80-28.821(1.134~1.135) seat insert ['9.6(0.028)0.8.| 60 ‘5.4-5.6 (0.213-0.220) 29.10-29.121(1.146-1.147) Exhaust valve |0:3(0.012)08.| 30 5.9-6.1 (0.282-0.240) '34,30-34.$25(1.950~1.351) seat 0.6 (0.024) O.S. 60 6.2~6.4(0.244~0.252) 34.60-34.625(1.362~1.363) EMA ~46 ENGINE SOHC. VALVES, ‘Check each valve for wear, damage and distortion of head ‘and stem at B. Repair or correct, if necessary. If stem end Ais pitted or worn, resurface as necessary. This correction ‘must be limited to a minimum. Also resurface the valve face. Replace the valve ifthe margin has decreased toless than the service limit asf Margin MARGIN ‘Standard value Intake : 1.1 mm (0.043 in.) Exhaust : 1.4 mm (0.085 in.) Lit Intake : 0.8 mm (0.031 in.) Exhaust : 1.1 mm (0.043 in.) REASSEMBLY ere. 1 2 3a. NOTE 1. Thoughly clean each part before assembly. 2. Apply engine oil to sliding and rotating parts. Aer installing the spring seat, fit the stom seal into the valve guide, ‘To install, ft the soal in by lightly tapping the Special ‘Tool, Vaive Stem Oil Seal installer. ‘The sealis installed n the specitiod position by means ‘of the special tool. incorrect installation of the seal will adversely affect the lip .D. and eccentricity, resulting in oll leaking down the valve guides. Therefore, when installing, be careful not to twist the seal, Do not reuse. ld stem seals. Valve eal vane ering Apply engine oil to each valve. Insort the valves into the valve guides. Avoid using force when inserting the. valve into the seal. After insertion, check to see i the valve moves smoothly. 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 enamel coated side toward the valve spring retainer. ssn a ESS of — = = Valve spring soat CYLINDER HEAD ASSEMBLY EMA -47 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. Alter installa tion of the valves, make certain thatthe retainer locks are propery installed. ‘5. Install the cylinder head. Refer to “Cylinder Head EMA -48 ENGINE SOHC MAIN MOVING SYSTEM CAM SHAFT COMPONENTS | ccormno Bott 5.8mm (0.28 in) {80-100 (200-1000, 59-74) Camshatt 45mm 0.18 in) ‘TORQUE : Nm (kg.cm,{b.ft) MAIN MOVING SYSTEM. EMA -49 DISASSEMBLY esas 8 Remove the rocker arm shaft assembly, Reler to “Rocker Arms and Rocker Arm Shafts" section. 1. Disconnect the breather hose and the PCV hose. 2. Remove the coolant pump pulley and crankshaft pul- ley. 4, Move the timing belt tensioner pulley toward the ‘coolant pump and temporarily secure it. 5. Remove the timing bel from the camshatt sprocket. 6. Remove the camshaft sprocket. 7. Remove the rocker cover. EMA -50 INSPECTION. souram CAMSHAFT 1. Check the cagmsha journals for wear. i the journals are badly worn, replace the camshaft. 2. Check the cam olbes for damage. If the lobe is dam- ‘aged or worn excessively, replace the camshaft. ‘Cam height Standard value Intake : 42.8575 mm (1.6873 in.) Exhaust : 42.7354 mm (1.6825 in.) Limit Intake : 42.9575 mm (1.8676 in.) Exhaust : 42.2953 mm (1.6628 in.) ‘8. Check the cam surface for dbnormal wear or damag and replace it necessary. 4, Check each bearing for damage. Ifthe boaring sur- aco is excessively damaged, Replace the cyinder head assembly or camshaft bearing cap, as neces- sary, ‘OIL SEAL (CAMSHAFT FRONT) 1. Check the lips for wear. If lip threads are worn, re- place. 2 Check the oil seal lip contacting surface of the camshaft. If it is wor in stages, replace the ‘camshatt. ‘Camshaft end play = 0.07 ~ 0.28 mm (0.0003 ~ 0.0011 in.) ENGINE SOHC REASSEMBLY 41. Install the camshaft after lubricating the journal of the camshaft with engine oil 2. Install the camshaft bearing caps. Install the rocker arm and rocker arm shat Reler to the "Rocker Arms and Rocker Arm Shafts" section. 4. Using the Special Toots, Camshaft Oil Seal Installer (09221-21000), press and fit the camshattoil seal. Bo ‘ure to apply engine oil to the external surface of the. ouil seal. 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. 5. Install the camshaft sprockot and tighten the bolts to the specified torque. Tightening torque Camshaft sprocket bot: ‘80 ~ 100 Nm (800 ~ 1000 kg.em, 59 ~ 74 Ib.) MAIN MOVING SYSTEM EMA -51 6. Align the camshaft sprocket and crankshaft sprocket timing marks. The piston in the No. 1 cylinder willthen be at top doad center on the compression stroke. 7. Intall a gasket in the rocker cover groove. 8. Temporarily install the rocker cover. 9. Start the engine and run at idle. 10. Install the rocker cover and tighten the bolts to the specified torque. Tightenting torque ockar cover bolt: 8-10Nm (80-100 kg.cm, 6-7 bt) 11, Install the timing belt cover. 12. Install the coolant pump pulley and crankshatt pulley. EMA -52 MAIN MOVING SYSTEM DISASSEMBLY | cerone 1. Remove the timing belt train, front case, flywheel cylinder head assembly and oll pan. For detais, refer to related chapters. 2, Remove the rear plate and the rear cl seal 3. Remove the connecting rod caps. 4, Remove the main bearing caps and remove the crank- shaft. Keep the bearings in order according tothe cap umber. 5, Remove the crankshaft position sensor whee! Q cauTion ‘Mark the main bearing caps topermit reassembly In the original position and direction. INSPECTION (CRANKSHAFT 1. Check the crankshaft journals and pins for damage, Uneven wear and cracks. Also check ollholes for clog- ‘ging. Correct or replace any defective part. 2. Inspect out-of-roundness and taper of crankshaftjour- nal and pin, ‘Standard value Crankshaft journal O.D. : 50 mm (1.9685 in.) Crankshaft pin O.D. : 45 mm (1.7717 in.) Crankshaft journal, pin out-of-roundness and tapor 0.01 mm (0.0004 in.) of less MAIN BEARINGS AND CONNECTING ROD BEARINGS. ‘ Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace the defective bearings. OIL CLEARANCE MEASUREMENT ‘To check the oil clearance, measure outside diameter of the crankshaft journal and the crank pin and inside diam- ‘ter of the bearing. The clearance measurement is the difference between the measured outside and inside di- ameters. ‘Standard value Journal oll clearance No. 1, 2, 4, 5: 0.028 ~ 0.046 mm (0.0011 - 0.0018 in.) Journal oil clearance No. 3 (center) 0.034 ~ 0.52 mm (0.0013 ~ 0.002 in) Pin oll clearance : 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in) EMA 53 PLASTIC GAUGE METHOD A plastic gauge may be used to measure the clearance. 1. Remove oll, reass and any other dirt rom bearings ‘and journals. 2. Cut plastic gauge to the same length as the width of the bearing and place ot parallel with the journal, off ‘rom the oll holes. 3. Install the crankshaft , bearings, and caps. Tighten’ them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastic gauge at the widest Point using the scale printed on the gauge package. It the clearance exceeds the repair limit, replace the bearing. ‘Should the standard clearance not be obtained even, after bearing replacement, the journal should be fround to a recommended undersize, and a bearing of the same size should be installed. OL SEAL (Check front and re Replace any seat tl oil seals for damage or worn lips. tis defective. EMA -54 ENGINE SOHC ENGINE SOHC CRANKSHAFT POSITION SENSOR WHEEL Remove the crankshaft position sensor wheel. Check the crankshaft position sensor whee! for dam- age, cracks and wear, and replace if necessary. ‘Check the clearance between the crankshaft position ‘sensor wheel and the crankshaft position sensor with ‘a depth gage. ‘Standard value Cearance between the crankshaft position sensor wheel and crankshaft position sensor : 0.5 ~ 1.5 mm (0.0020 ~ 0.059 in) @aore 1. Measure the depth of the top of the crankshaft ‘Position sensor wheel teeth and the outside of transaxle housing. 2. Measure the difference between the crankshaft ‘Position sensor langth and depth. 3. The crankshaft position sensor length is the distance between the end of crankshaft position ‘sensor and inner point of contacting face. REPLACEMENT | csucore 1. Check the cylinder block stamping crankshaft bore size code, Record the cylinder block crankshaft bore size code letters on cylinder block as shown. ‘Reading order is from lef to right wth front crankshaft bore size code shown first. Cylinder block crankshaft bore diameter Cylinder block crankshaft bore diameter ‘54 ~ 54.006 mm (2.1259 ~ 2.1262 in.) b 154.006 ~ 64.012 mm (2.1262 ~ 2.1264 in.) 54.012 ~ 54.016 mm (2.1264 ~~ 2.1268 in.) Class ‘Size cod A b 2. Check the crankshaft main journal MAIN MOVING SYSTEM Record the main journal size code letters on the crankshaft blance weight. Reading order s from lett to right as shown, with n0.1 ‘main journal size code shown first. CRANKSHAFT MAIN JOURNAL DIAMETER ; he ‘Size Class Main journal diameter oe 1 49.968 - 49.962 mm A 7 49,962 ~ 49.956 mm . (1.9670 ~ 1.9667 in) 49,956 ~ 49.950 mm (1.9667 ~ 1.9665 in.) MAIN JOURNAL BEARING THICKNESS, NO. 1,2, 4,5 Color ‘Main journal bearing thickness Yellow | 2.002-2.005mm (0.0788-0.0789in.) Green | 2.005~2.008mm (0.0789-0.0790in.) No color _ | 2.008-2.01 1mm (0.0790-0.0791in.) Black | 2.011-2.014mm (0.0791-0.0793in. Blue 2.014-2.017mm (0.0783-0.0794in.) EMA -55 REASSEMBLY 1. Install the upper main bearing inserts in the eylinder block. ‘When reusing the main bearings, remember to In- ‘stall them by referring to the location marks made at the time of disassembly. 2. _Installthe crankshaft. Apply engine oil to the journals. ‘3. Install bearing caps and tighten cap bolts to the spec- ied torque in the sequence of the center, No.2, 4, ‘ront and rear caps. Cap bolts should should be tightoned evenly in 2 to 3 stages before 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 bolt 55 ~ 60 Nm (550 ~ 600 kg.om, 41 ~ 44 Ib) Connecting rod cap bolt: 32 - 35 Nm (820 ~ 950 kg.om, 24 ~ 26 at) 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. Nos (CENTER BEARING) Standard value Crankshaft end play = ‘Color Main journal bearing thickness 0.05 ~ 0.475 mm (0.002 ~ 0,008 in.) Yellow | 1.999-2.00amm (0.0787-0.0768in, Green | 2.002-2.005mm (0.0788-0.0788in,) No color | 2.005-2.008mm (0.0789-0.0790in) Bide | 2.008-2.01 mm (0.0790-0.0791in) Bi 2.011-2.014mm (0.0791~0.0793in.) ‘8. Choose proper main journal bearing in table. EMA -56 ENGINE SOHC. Install the ol seat in the crankshaft rear oll seal case. Use the Special Tool, Crankshaft Rear Oil Seal in- staller (08231 - 21000) as shown. Press and fit the oil seal in all the way, being careful not to misalign it. 6. Install the rear oll seal case and gasket. Tighten the five bolts. ‘Apply engine oll to the oil seal lips and crankshaft of the time of installation, 7. Install the rear plate and tighten the bolts. 8. Install the connecting rod caps. Refer to the Piston ‘and Connecting Rods" section 9. Install the ffywheo|, front case, oll pan and timing bet For further details, refer to the respective chapters. MAIN MOVING SYSTEM. FLY WHEEL COMPONENTS | cxeusce ing rear FORT TORQUE : Nm (kg.cm, Ib.ft) 1130-140 (1300-1400, 96 - 103) ‘Adaptor plato 130-140 (1300-1400, 96-103) Drive plato Adaptor plato FoR AT DISASSEMBLY | cxzicon 1. Remove the transaxle and clutch, 2. Remove the flywheel. INSPECTION | cairo 1. Check the clutch dise contacting surtace of the fly wheel for damage and wear. Replace the flywhee! it excessively damaged or worn. 2. Check the clutch disc contacting surface of the fly wheo! for runout ‘Standard value Flywheel run-out : 0.1mm (0,004 in.) 8. Check the ring gear for damage, crack and wear, and replace if neces REASSEMBLY | crocec Install the flywheel assembly and tighten the bolts to the ‘specified torque Tightening torque Flywheel bolt : 10 ~ 140 Nm (1300 ~ 1400 kg.cm, 96 ~ 103 Ib.t) EMA -58 ENGINE SOHC PISTON COMPONENTS = excess Wo. Pton ing a2 toning ting _ — 2 Pio pn conan {- wot Upper bearing —*) @— 32-25 200-350, 24 ~ 26) TORQUE : Nm (kg.cm, Ib.ft) MAIN MOVING SYSTEM. DISASSEMBLY 1. Use the Special Tools (09234-33001) to disassemble ‘and reassemble the piston and connecting rod. Forkingert fore Soo hose >. srenten SP on 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. (Wynore Center the piston, rod and pin assembly with the re- ‘moval arbor. ‘4, Press the piston pin out of the connecting rod, INSTALLATION 1 Install propor 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. (G) Nore The pin guide contors the connecting rod inthe pis- ton. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of tho tool, th pin guide wil also center this assembly in the toolfto0 small a pin guide is used, the piston assem- ‘by wil not be located contralyin the tool, and damage ‘may occur tothe fork andor insert of the too SF Installer Install piston assembly onto fork assembly of too}. ‘Too! will supprot connecting rod at the piston pin. Bo ‘sure to slide the piston assombly into the fork until the pin guide contacts the fork insert. ‘Adjust the installing arbor to the proper length by turn ing the numbered sleeve on the lottored shaft until the specified alpha-numeric setting from the application chart is obtained. Turn knurled nut to lock numbered sleeve on shaft. EMA -60 ENGINE SOHC 4, Insert the installing arbor through the hole in the arch of the tool. Press piston pin into the connecting od Until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the ‘connecting rod as the piston pin is pressed in, &) caution Do not exceed 5000 pounds of force when stop- ping the installing arbor sleeve against the arch. Piston a

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