PROTON WAJA 1.6 ENGINE 4618 SERIES { : ' HAKMILIK WAH IAMOA WM WIN ASSNFEMME enaine <1600>* SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS | Items Type Number of cylinders Combustion chamber Total displacement Cylinder bore Specifications _ Indline SOHC 14 = |[Pentroof type 1584 cm? (96.655 c |76.0 mm (2.992 in) Piston stroke 87.3 mm (3.437 in) Compression ratio : 10.0 [Number of valve Intake a =e ass [exhaust 3 __ E Valve timing [intake opening BTDC 17° | Intake closing __ | ABDC 43° [Exhaust opening |BBDC 53° _ Exhaust closing ATOC?? Lubrication system Oil pump type full-flow filtration Trochoid type Cooling system Water pump type |Water-cooled forced circulation [Centrifugal impeller type _ SERVICE SPECIFICATIONS weorasrecsooa Items Limit Standard Rocker arms, rocker shafts, and cam- shaft : Camshaft cam height Intake 37.30 mm (1.468 in) |36.80 mm | (1.448 in) | | Exhaust 37.16 mm (1.462 in) | 36.66 mm Pe _|(1.443 in) Camshaft journal diameter 44.925-44,94 mm |— |0.768-1.769 in) | Cylinder head and valves Flatness of cylinder head gasket sur- 0.05 mm (0.001 in) |— face or less Cylinder head gasket surface grinding i 0.2 mm limit (including grinding of cylinder (0.007 in) block gasket surface) Cylinder head overall height 120 mm (4.724 in)=|— 0.1 mm (0.003 in) Cylinder head bolt nominal length = 103.2 mm a (4.082 in)ENGINE <1600> [IRE] SPECIFICATIONS a Standard | Valve margin. intake. 1 Om mm (0.039 0.5 mm Lo ~{(0.019 in) _| {Exhaust i 5 mm (0.059 in) yn Omm | oe a {(0.039 in) | Valve stem diameter [Intake a L Exhaust __ [5.5 mm (0.216 in)_|— | [Valve stem-to-guide clearance intake 0.020-0.047 mm (0-| 0.10 mm. i Exhaust | 0.030-0.057 mm 0.15 mm | ) | |(@.001-0.002 in) __|(0.005 in) | [Valve face angle ———asasss Overall valve length lintake ]112.56 mm (4.392 [111.06 mm | (4.372 in) | [174.21 mm _ |(4.496 in) Valve spring free height Intake 50.9 mm (2.003 in) |49.9 mm — __|(4.964 in) __| | Exhaust 50.9 mm (2.003 in) |49.9 mm | 1964 in) 22.0 kg (220N; | — 48.457 Ibs)/ 40.0 mm (1.574 in) | [22.0 kg (220N; | | 48.457 Ibs)’ 886mm 559i | Valve spring squareness |e ae | Valve seat contact width 0.9-1.3 mm (0.035- |— 0.051 in) —____}— Valve guide internal diamete 5.5 mm (0.216 in) | [23.0 mm (0.905 in) Valve guide projection Oil pump tip clearance 0,06-0.18 mm = | a (0.002-0.007 in) | a Oil pump side clearance |0.04-0,10 mm {Oil pump body clearance Pistons and connecting rods Piston outside diameter Piston ring side clearance 0.02-0.06 mm (0- 0.002 in) Piston ring and gap clearance No. 1 ring 0.20-0.35 mm {0.007-0.013 in) (@. 031 in)FEMME enaine <1600> SPECIFICATIONS _ items Standard Limit | No. 2 ring 0.35-0.50 mm 0.8 mm —___|(0.013-0.0197n) | (0.031 in) | Oil ring 0.20-0.50 mm 1.0 mm L _ | (0.007-0.019 in)__|(0.039 in) Piston pin 0.D. : 48.0 mm (0.708 in) |— Piston pin press-in load (at room '49.0-147.0 kg (490- | — temperature ) 1470 N; 107.927- : 323.782 Ibs) jae Crankshaft pin oil clearance 0.02-0.04 mm (0- |0.1 mm _ 0.001 in) (0.003 in) Connecting rod big end side clearance 0.10-0.25 mm 0.4mm [e i {(0.003-0.009 in) __|(0.015 in) Crankshaft and cylinder block - an Crankshaft end play 0.05-0.18 mm 0.25 mm | o |(0.001-0.007 in) __|(0.009 in) _| Crankshaft journal diameter _ [48.0 mm (1.889 in) |— | Crankshaft pin diameter - 42.0 mm (1.653 in) |— Crankshaft journal oil clearance 0.02-0.04 mm (0- [0.1 mm L rae _ 0.001 in) | (0.003 in) __ | Cylinder block gasket surface flatness 0.05 mm (0.001 in) |— | - _ or less Cylinder block gasket surface grind- = 0.2 mm ing limit (including grinding of cylin- (0.007 in) der head gasket surface) Cylinder block overall height 256mm (10.078 in)|— Cylinder block oylindricity _ 0.01 mm (0 in) _| Cylinder block 1.0. _ 76.0 mm (2.992 in) |— REWORK DIMENSIONS we01AsPECSO03 Items Standard Limit Cylinder head and valves Cylinder head oversize valve guide hole diameter|0.05 0.5. 10.550-10.586 mm - (0.415-0.416 in) 0.25 0.5. 10.750-10.768 mm = | (0.423-0.423 in) 0.50 0.5. 41.000-11.018 mm. = (0.433-0.433 in) Oversize valve seat Intake (primary) 03 05S. 30,300-30.321 mm - ring hole diameter (1,192-1.193 in) | 0.60.5. 30.600-30.621 mm i (1.204-1.205 in) Exhaust 0305. 28,300-28.321 mm a (1.114-1.114 in) 0.6 0.5. 28.600-30.621 mm 7 Lk (1,125-1.205 in)|Water pump pulley bolt [Alternator brace (alternator side) [alternator brace (tightened with water pump) Alternator pivot bolt Oil level gauge guide [Crankshaft bolt [Spark plug [Ignition coil "am position sensor [fining be Timing belt cover iri \Timing belt tensioner Engine support bracket (left) _|ftilbs) ENGINE <1600> [REI SPECIFICATIONS Weorrasrecsoos [0.7-1.1 kgm (7-11 Nm; 0.469-0.738 | | ftlbs) |2.0:2.5 kgm (20-25 Ni lbs) 14.2-1.5 kgm (12-15 Nm; 0.805-1.006 fulbs) |3.5+ i 1.342-1.677 | '5 kgm (35-55 Nm; 2.348-3.691 4.9-2.8 kgm (19-28 Nm; 1.275-1.879 filbs) | 12.0-13.5 kgm (120-135 Nm; 8.053-9.059| [ftlbs) .0 kgm (20-30 Nm; 1.342-2.013 ]0.8-1.0 kgm (8-10 Nm; 0.536-0.671 | flbs) — 1.0-1.2 kgm (10-12 Nm; 0.671-0.805 | | 1 =) et ae | 2.0-2.7 kgm (20-27 Nm; 1.342-1.811 | ulbs) 3.0-4,2 kgm (30-42 Nm; 2.013-2.818 ft.lbs) sl Idle pulley 3.0-4.2 kgm (30-42 Nm; 2.013-2.818 | flbs) Camshaft sprocket bolt 8.0-10.0 kgm (80-100 Nm; 5.368-6.711_ | ftlbs) Crank angle sensor 0.8-1.0 kgm (8-10 Nm; 0.536-0.671_ |[ftlbs) Fuel system and emission system Fuel pressure regulator 0.7-1.1 kgm (7-11 Nm; 0.469-0.738 ftilbs) Throttle body .006-1.476 1.5-2.2 kgm (15-22 Nm: ft.llbs) Delivery pipe 1.0-1.3 kgm (10-13 Nm; 0.671-0.872 ft.lbs) Vacuum hose and pipe assembly 0.8-1.2 kgm (8-12 Nm; 0.536-0.805 flbs) Pressure sensor 0.8.0.6 kgm (4-6 Nm; 0.268-0.402 ft.lbs) Detonation sensor 2.0-2.5 kgm (20-25 Nm; 1.342-1.677 ftlbs)ENGINE <1600> SPECIFICATIONS Items EGR valve ‘Water pump Water inlet fitting |Water inlet pipe assembly Thermostat case [Water temperature gauge unit Water temperature sensor Water pump [Exhaust manifold and intake manifold _ Intake manifold [Intake manifold stay xhaust manifold cover | Exhaust manifold M10 Value 4.7.2.6 kgm ("7-26 Nm 114-1744 | | fells) | 1.7-2.6 kgm (17-26 Nm; 1.14-1.744 | Ibs) | 1.0-1.5 kgm (10-15 Nm; 0.671-1.006 | ftulbs) 4.9-2.8 kgm (19-28 Nm; 1.275-1.879 [ftilbs) | 100-1.2 kgm (10-12 Nm; 0.671-0.805 | ft.lbs) 2.0-4.0 kgm (20-40 Nm; 1.342-2.684 | | ftlbs) | 4.2-1.5 kgm (12-15 Nm 0.805-1.006 | ft.lbs) _ ]1.5-2.0 kgm (15-20 Nm; 1.006-1.342 | |fulbs) 1.5-2.0 kgm (15-20 Nm; ftlbs) 1.8-2.5 kgm (18-25 Nm; | feb) " 2,7-3.3 kgm (27-33 Nm; ft.lbs) .5-2.0 kgm (15-20 Nm; ftlbs) 1.006-1.342 | = 1.207-1.677 | 182214 | 1.006-1.342 | Rocker arms, rocker shafts, and camshaft -811-2.214 Rocker cover | Rocker shaft assembly ‘Adjusting screw ftlbs) 2.9-3.5 kgm (29-35 Nm; 1.946-2.348 ftlbs) _ 0.8-1.0 kgm (8-10 Nm; 0.536-0.671 ft.lbs) 0.31-0.41 kgm (3.1-4.1 Nm; 0.208-0.275 | Cylinder head and valves Cylinder head bolt Tighten to 4.9 kgm (49 Nm; 3.288 ft.lbs), then completely loosen and retighten as described. 20+90°+90° Oil pump and oil pan ‘Oil pan 1.8 kgm (6-8 Nm; 0.402-0.536 ft.lbs) Drain plug [3.9 kgm (39 Nm; 2.617 ft.lbs) Oil screen 5 4.5-2.2 kgm (15-22 Nm; 1.006-1.476 ft.lbs) Front case 4.2-1.5 kgm (12-15 Nm; 0.805-1.006 ftulbs)ENGINE <1600> [IEE] SPECIFICATIONS _ Ite ind connecting rods [Connecting rod nut Crankshaft and cylinder block Flywheel Drive plate |13.0-14.0 kgm (130-140 Nm; 8.724-9.395 | _ _ ftps) = 2 | Rear plate |0.8-1.2 kgm (8-12 Nm; 0.536-0.805 | P a tts) _— | Bell housing cover 0.8-1.2 kgm (8-12 Nm; 0.536-0.805, ftlbs) | [Rear oil seal case 1.0-1.2 kgm (10-12 Nm; 0.671-0.805 _ft.lbs) |Bearing cap bolt ” "73.5 kgm (35 Nm; 2.348 ft.lbs) ene eee ee 10.2 kgm (2 Nm; 0.134 ft-lbs) [oit pressure switch 4.5-2.2 kgm (15-22 Nm; 1.006-1.476 [ftlbs) | NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS — weorasescsoos Part of the engine use plastic region tightening bolts. The tightening procedure for these is different from that of conventional bolts and is described in relevant parts of this manual. Note that plastic region tightening bolts have fixed service limits. These are indicated in relevant parts of this manual and must be strictly observed: * Plastic region tightening bolts are used for the following applications: 1. Cylinder head bolts 2. Connecting rod cap bolts © The tightening procedure is basically as follows: After tightening a bolt to the specified torque, t 100" The exact tightening procedure differs depending on the bolt and is described in relevant parts of this manual ten it by a further 90° + 90° or by a further 90- SEALANTS Items Specified sealant [Quantity _ Water pump. Part No. MD970389 or equivalent As required Oil pan Engine coolant temperature sensor |3M Nut Locking Part No.4171 or equivalent E “ Engine coolant temperature 9249 | sy arp pare No.8660 or equivalent Camshaft bearing cap | Semi-circular packing Rocker cover _ _ Front oil seal case Part No. MD970389 or equivalent Oil pump Oil pressureswitch 3M ATD Part No.8660 or equivalentENGINE <1600> = { SPECIAL TOOLS FORM-IN-PLACE GASKET ‘WEOI 1ASPECSOO6 The engine has several areas where the form-in place gasket (FIPG is in use. To ensure that the gasket, fully serves purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks, Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore , it is absolutely necessary to apply the gasket evenly without a break, while observing the correct bead size. The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 100~ gram tube (Part No. MD970389 or MD9971110). Since the RTV hardens as it reacts with the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for sealing both engine oil and coolant, while Part No. 997110 can only be used for engine oil sealing. Disassembly The parts assembled with the FIPG can be easily disassembled without use of a special method. In some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover" (MD998727) is available. Be sure to use the special tool to remove the oil pan. Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant remained in the bolt holes. Place Gasket Application When assembling parts with the FIPG, you must observe some precautions, but the procedures is very simple as in the case of a conventional precut gasket. Applied FIPG bead should be of the specified size and without breaks. also be sure to encircle the bolt hole circumference with a completely continuous bead. The FIPG-can be wiped away unless it is hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time (about one hour) has passed after installation is completed. The FIPG application procedure may vary on different areas. Observe the procedure described in the text when applying the FIPG. From-i SPECIAL TOOLS wrortasTootoot PP | Number | Name Use ] ™B990767 | End yoke holder —_| Holding camshaft sprocket, when loosening or tighten- ing bolt (used with MD998715) one) raRv002ENGINE <1600> JRE] SPECIAL TOOLS Number | Name Use “| MD998011 Installation «f crankshaft | | seal installer rear oil seal . MD998054 Oil pressure switch | Removal and installation of | wrench oil pressure switch | a - | | | ponersans002 | ail | | Ne | Crankshaft front oil | installation of crankshaft | seal installer front oil seal | | | } { " MiD998304 ‘ones vAR9O0S | MD998305 | Crankshaft front oil | Guide for installation of | | seal guide crankshaft front oil seal | >») | D7 | | | ___ cores | | MD998713 Camshaft oil seal Installation of camshaft oil installer seal | ‘boner aso? ~ [Holding camshaft sprocket hen loosening or tightening SD bolt (used with MB990767) SS | { ™MD998715_|Pin (2-off)EER nine <1600> * SPECIAL TOOLS __Tool Number [ "Name Use M0998727 Oil pan remover —_| Removal oil pan oe 1ARB009 | MD998735 | Valve spring com- _| Compression of valve springs) oh pressor | | |" R | | ouervanso%0 | _ | _ a __ | | mD998760 | valve stem seal Installation of valve stem OS installer seals ouersansors = ~~ | _MD998780 [Piston pin setting [Removal and pressitting of 6 Q ae tool piston pins 00 £ | MB991659 | Guide-D Guide for removal and press-| fitting of piston pins Dower anaor3 [ 998772 |Valve spring com- | Compression of valve springs pressorENGINE <1600> JRE) SPECIAL TOOLS | __ Number _Name Use MD998781 Flywheel stopper [Locking flywheel in fixed | | | position 8991653 | Cylinder head bolt Removal and installation of | wrench (10) |qylinder head bolt { | |FRMBE encine <1600> ALTERNATOR AND IGNITION SYSTEM ALTERNATOR AND IGNITION SYSTEM REMOVAL AND INSTALLATION Douessansn noose[Removal steps | ENGINE <1600> ER) ALTERNATOR AND IGNITION SYSTEM 1. Orive belt* 7. Spark plug cable | | 2. Water pump pulley 8. Ignition coil * | 3. Alternator brace 9. Spark plug \ 4, Alternator 10. Cam position sensor | Bi 5. Crankshaft bolt Hd 11. Cam position sensor support 6._Crankshaft pulley _ 12. Cam position sensing cylinder | 1: 12.0-13.5 kgm (120-135 Nm; 8.053-9.059 ft.lbs) | T6 72: 0.7-1.1 kgm (7-11 Nm; 0.469-0.738 ft.lbs) 7 TB: 1.2-1.5 kgm (12-15 Nm; 0.805-1.006 ft.lbs) |18 T4 : 2.0-2.5 kgm (20-25 Nm; 1.342-1.67 ft.lbs) \T9 5: 3.5-5.5 kgm (35-55 Nm; 2.348-3.691 ft.lbs) | NOTE: | t For details of adjustment, refer to the relevant model's chassis workshop manual [710 : 0.8-1.2 kgm (8-12 Ni 2.0-3.0 kgm (20-30 Nm; 1.342-2.013 ft.lbs) | 2 1.7-2.6 kgm (17-26 Nm; 1.14-1.744 ft.lbs) 1.2-1.5 kgm (12-15 Nm; 0.805-1.006 ft.lbs) 0.8-1.0 kgm (8-10 Nm; 0.536-0.671 ft.lbs) 536-0.805 ft.lbs)ENGINE <1600> ALTERNATOR AND IGNITION SYSTEM REMOVAL SERVICE POINT HES CRANKSHAFT BOLT REMOVAL 1, Use the special tool to hold the flywheel or the drive plate, and then loosen the crankshaft mounting bolts. INSTALLATION SERVICE POINTS HEB CAM POSITION SENSOR SUPPORT INSTALLATION 1, Apply a 3 mm (0.118 in) bead of from-in- place gasket (FIPG) to the area shown. Specified sealant: Part No. MD970389 or equivalent. HJ CRANKSHAFT BOLT INSTALLATION 1. Use the special tool to hold the flywheel or the drive plate, and then tighten the crankshaft mounting bolts } oer rans |ENGINE <1600> (RE) ALTERNATOR AND IGNITION SYSTEMTIMING BELT ENGINE <1600> TIMING BELT REMOVAL AND INSTALLATION OWED LARSO21 o98%ENGINE <1600> [ER TIMING BELT [Removal steps 7 | 1. Timing belt upper cover | 6. Crankshaft sprocket 2. Timing belt lower cover |B 7. Camshaft sprocket bolt” | EU 3. Timing belt 8, Camshaft sprocket HJ 4. Tensioner spring | 9. Engine support bracket | HB 5. Timing belt tensioner | 10. Timing belt rear cover Ti: 1.0-1.2 kgm (10-42 Nm; 0.671-0.805 ft.lbs) |T3 : 2.0-2.7 kgm (20-27 Nm; 1.342-1.811 ft.lbs) [2 :8.0-10.0 kgm (80-100 Nm; 5.368-6.711 ft.lbs) T4 : 3.0-4.2 kgm (30-42 Nm; 2.013-2.818 ft.lbs)ENGINE <1600> TIMING BELT | ces MBS90767 { onesransoze | REMOVAL SERVICE POINTS JEW TIMING BELT / TENSIONER SPRING / TIMING BELT TENSIONER REMOVAL 1. Using pliers, grip the tensioner spring projection (marked “A” in the diagram) and remove it from the oil pump case stopper. Then, remove the tensioner spring. 2. Remove the timing belt tensioner. 3. If the timing belt is to be reused, chalk an arrow on the belt to indicate the direction of rotation before removing it. This will ensure the timing belt is fitted correctly when reused. HE CAMSHAFT SPROCKET BOLT REMOVAL 1. Using the special tools shown in the illustration, lock the camshaft sprocket in position 2. Loosen the camshaft sprocket bolt. INSPECTION TIMING BELT Check the timing belt closely. Replace the belt with a new one if any of the following defects is evident: 1. Hardened backing rubber (the backing rubber is glossy, non-elastic, and so hard that scratching with fingernails leaves no mark)ENGINE <1600> ER TIMING BELT 2. Surface cracks in the backing rubber, sym- bo! (2) 3. Splits in the canvas and/or separation of the canvas and rubber, symbol(3) Cracks at the bases of teeth , symbol (4). Cracks in the side of the belt , symbol (5). 6. Abnormal wear on the belt's sides, symbol (6) NOTE The sides of the belt are normal if they are sharp as if cut by a knife. 7. Abnormal wear on teeth, symbol (7). Initia! stage: Canvas worn (fluffy canvas fibers, rubbery texture gone white discoloration, canvas texture indistinct). Final stage Canvas worn, exposing rubber (tooth width reduced) 8 Missing teeth, symbol (8). ‘TENSIONER PULLEY AND IDLER PULLEY 1. Check that the pulleys turn smoothly with- out play and are not abnormally noisy. Replace either or both of the pulleys if necessary.EER encine <1600> TIMING BELT INSTALLATION SERVICE POINTS HE CAMSHAFT SPROCKET BOLT INSTALLATION 1. Using the special tools shown in the illustration, lock the camshaft sprocket in position. 2. Tighten the camshaft sprocket bolt to the specified torque. IE TIMING BELT TENSIONER / TENSIONER SPRING INSTALLATION 1. Lock the timing belt tensioner (A) in the illustrated position. 2, Fit one of the tensioner spring projections cover the hooked portion of the timing belt tensioner onto the oil pump case. 3. Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown in the illustration. 4, Move the timing belt tensioner in the direction shown and temporarily tighten the bolt.poner anso3a | pouenaRo03s ENGINE <1600> [ER] TIMING BELT MM TIMING BELT INSTALLATION 1. Align the camshaft timing mark with the timing mark on the cylinder head 2. Align the crankshaft timing mark with the timing mark on the front case 3. Keeping the tension side of the timing belt tight, fit the timing belt onto the crank- shaft sprocket, camshaft sprocket, and ten- sioner pulley in that order. 4. Loosen the tensioner pulley mounting bolts by 1/4 to 1/2 of a turn and allow the tensioner spring to apply tension to the timing belt 5. Turn the crankshaft twice in the normal rotating direction (clockwise) and check that the timing marks are correctly aligned CAUTION This procedure utilizes the camshaft's driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft in reverse. 6. Tighten the tensioner pulley mounting bolts.ENGINE <1600> FUEL AND EMISSION CONTROL SYSTEMS FUEL AND EMISSION CONTROL SYSTEMS Weor1asassyoos REMOVAL AND INSTALLATION OWE? 1ARs0N6 @98%ENGINE <1600> [RRR] FUEL AND EMISSION CONTROL SYSTEMS [Removal steps | 1. Throttle body assembly El 8. injector 2 Gasket 3. ong | 3, Fuel return pipe 10. Grommet HH 4. Fuel pressure regulator | 41. Delivery pipe 5. O-ring 12. EGR valve 6. Insulator | 13. Gasket 7. Insulator | Pressure sensor [71 1.0-1.3 kgm (10-13 Nm; 0.671-0.872 ftlbs) | 13 [12 : 1.5-2.2 kgm (15-22 Nm; 1.006-1.476 ftlbs) | T4 : 0.FEMME encine <1600> FUEL AND EMISSION CONTROL SYSTEMS INSTALLATION SERVICE POINTS INJECTORS INSTALLATION 1. Apply a small amount of new engine oil to the O-ring CAUTION Be sure not to let engine oil get into the delivery pipe. 2. While turning the injector to the left and right, install it to the delivery pipe. 3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the injector and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again 4. Check that the clearance between the injector connector (C) and the delivery pipe (D) is uniform (A = B). IE FUEL PRESSURE REGULATOR INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Insert the fuel pressure regulator into the delivery pipe being careful not to damage the O-ring. CAUTION Be sure not to let engine oil get into the delivery pipe. 2. Check that the fuel pressure regulator turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the fuel pressure regulator and check the O-ring for damage, and then re-insert it into the delivery pipe and check once again.ENGINE <1600> [ERI FUEL AND EMISSION CONTROL SYSTEMSFEMME encine <1600> WATER PUMP AND WATER HOSE WATER PUMP AND WATER HOSE eos REMOVAL AND INSTALLATION aaa - oe onerransoaa 293% |moval steps _ 1. Water hose 2, Water hose Water temperature sensor Water temperature gauge unit Water inlet fitting Thermostat Thermostat case Gasket Water inlet pipe EB 10. O-ring Ha 11. O-ring Bg 12. Water pump TH: 1,0-1.5 kgm (10-15 Nm; 0.671-1.006 ft.lbs) T2 : 2.0-4.0 kgm (20-40 Nm; 1.342-2.684 ft.lbs) 73: 1.7-2.6 kgm (17-26 Nm; 1.14-1.744 ft.lbs) TA: 1.0-1.2 kgm (10-12 Nm; 0.671-0.805 ft.lbs) T5 : 1.9-2.8 kgm (19-28 Nm; 1.275-1.879 ft.lbs) T6 : 1.2-1.5 kgm (12-15 Nm; 0.805-1.006 ft.lbs) ENGINE <1600> [EE] WATER PUMP AND WATER HOSE fFMB encine <1600> WATER PUMP AND WATER HOSE = = INSTALLATION SERVICE POINTS | WATER PUMP INSTALLATION oO | 1. Apply a 3 mm (0.118 in) bead of from-in- place gasket (FIPG) to the mounting sur- | face. Specified sealant: Part No. MD970389 or equivalent. Hd O-RING / WATER PIPE INSTALLATION Replace the water inlet pipe O-rings with new ones, then apply water to O-rings so that they can be inserted easily into the water pump and thermostat case. CAUTION (1) Do not apply engine oil or any other oily substance to the O-rings. (2) Secure the water pipe after the ther- mostat case has been installed. IEW THERMOSTAT INSTALLATION 1. Fit the thermostat such that its jiggle valve is at the top. WATER TEMPERATURE GAUGE UNIT INSTALLATION If the water temperature gauge unit is to be reused, apply the specified sealant to its thread. Specified sealant: 3M ATD Part No. 8660 or equivalent. ower ansoet|ENGINE <1600> [RE] WATER PUMP AND WATER HOSE i WATER TEMPERATURE SENSOR | INSTALLATION | 1. If the water temperature sensor is to be reused, apply the specified sealant to its thread Specified sealant: 3M Nut Locking Part No. 4171 or equivalent.FEMME enaine <1600> INTAKE AND EXHAUST MANIFOLDS INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION Donen ARg0s2 @58%ENGINE JRE? INTAKE AND EXHAUST MANIFOLDS. Removal steps | fy. Engine hanger |2. Intake manifold stay 3. Intake manifold ' 4. Intake manifold gasket 5. Exhaust manifold cover 6. Exhaust manifold i Exhaust manifold gasket [1 :4.5-2.0 kgm (15-20 Ni 1.006-1.342 ftbs) 12 :2.7-3.3 kgm (27-33 Nm; 1.811-2.214 ft.lbs) [13:1.8:2.5 kam (18-25 Nm; 1.207-1.677 ft.lbs)FEMME enaine <1600> ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT REMOVAL AND INSTALLATION Weonasassyans DoHer ARaoe8 a98%%ENGINE <1600> [EE] ROCKER ARMS AND CAMSHAFT % Lubricate all internal parts with engine oil during reassembly, . [Removal steps 1, Breather hose 10, Rocker arm B 2. P.CV. hose 11. Rocker arm A. 3. Oil filler cap | 12. Rocker arm shaft 4, Rocker cover Hl 13. Adjusting screw 5, - Racker cover gasket He 14. Nut 6. Oil seal m7. oil seal 15. Rocker arm C - HIB 16. Rocker arm shaft Hy & Rocker arms and rocker arm shaft IN] pay 17, adjusting screw 9. Rocker arms and rocker arm shaft EX | 18. Nut E 19, Camshaft 0.31-0.41 kgm (3.1-4.1 Nm; 0.208-0.275 ft.lbs) 12: 2.8-3.4 kgm (28-34 Nm; 1.879-2.281 ft.lbs) ‘73 :0.7-1.1 kgm (7-11 Nm; 0.469-0,738 ft.lbs)ERR encine <1600> ROCKER ARMS AND CAMSHAFT INSTALLATION SERVICE POINTS i ADJUSTING SCREW INSTALLATION 1. Install provisionally the screw to the rocker arm. Insert it so that the end of the screw is flush with the edge of the rocker arm projects slightly 1 mm (0,039 in) or less(A). HEM ROCKER ARM SHAFT INSTALLATION 1, Place the end with the larger chamfered side (8) toward the timing belt side (A). NOTE The rocker arm shaft for intake valves eight oil holes. 2. Jace the section of the shaft with the oil holes (C) toward the cylinder head. HEB ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION 1. Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts. NOTE Move the rocker arms until they touch the rocker arm shaft mounting bosses on the cylinder head. OIL SEAL INSTALLATIONENGINE <1600> ED ROCKER ARMS AND CAMSHAFT INSPECTION CAMSHAFT 1. Measure the cam heights and replace the camshaft if any height exceeds the specified limit, Standard value: Identification mark: A Intake: 37.30 mm (1.468 in) Exhaust: 37.16 mm (1.462 in) Limitintake: 36.80 mm (1.448 in) ~ exhaust: 36.66 mm (1.443 in) VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance by the following procedure Adjustment values (when engine is cold): Inta- ke valve : 30 OF mm (6.005-n) Exhaust valve : 30 048mm (0.067) 1. Turn the crankshaft in the Clockwise direc- tion to align the camshaft sprocket timing marks(A) and to set the No.1 cylinder (B) to the compression top dead centre position. 2. The valve clearances at the places indicated by arrows in the illustration can be adjusted 3. Use a thickness gauge to adjust the clea ance between the ends of the valve shafts and the adjusting screws. 4. Hold the adjusting screws with a screwdri- ver so that they do not turn, and then tighten the lock nuts. ] 5. Turn the crankshaft once in the clockwise c | direction to set the No.4 cylinder (C) to the compression top dead centre position, 6. Adjust the valve clearances indicated by arrows in the illustration by the same procedure as in steps (3) and (4) above.FRR enaine <1600> CYLINDER HEAD AND VALVES CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION e {ENGINE <1600> [BEE] CYLINDER HEAD AND VALVES [Removal steps FA 1. Cylinder head bolt 2. Cylinder head assembly Gylinder head gasket Retainer lock Intake valve Valve stem seal Valve spring seat Valve stem seal Valve spring retainer : 3. 4. 5 Valve spring seat 6 Valve spring 7 8. 9. 1 Exhaust valve guide Intake Exhaust valve Exhaust valve seat Intake valve seat 20. Cylinder head Exhaust.valve Retainer lock Valve spring retainer + 0. Valve springENGINE <1600> CYLINDER HEAD AND VALVES REMOVAL SERVICE POINTS IEW CYLINDER HEAD BOLT REMOVAL HG RETAINER LOCK REMOVAL 1. Store the removed valves, springs and othe: parts, tagged to indicate their cylinder No and to aid reassembly. VALVE STEM SEAL REMOVAL 1. Do not reuse valve steam seal INSTALLATION SERVICE POINTS fl VALVE STEM SEAL INSTALLATION 1. Install the valve spring seat. 2. Use the special tool to install the valve stet seal. Improper installation could result in ¢ leaking past the valve guide. CAUTION Do not reuse removed valve stem seals.One: 1aRa060 ENGINE <1600> [BRR CYLINDER HEAD AND VALVES MIB VALVE SPRING INSTALLATION 1. Install the valve spring with te painted end on the rocker arm sides ‘Symbol | Desc _A [Painted end | B Spring retainer _| [-c__[Stem seal _| D___|Spring seat HEJ RETAINER LOCK INSTALLATION 1. The valve spring, if excessively compressed, causes the bottom end of retainer to be in contact with the stem seal, and damage it. [EW CYLINDER HEAD BOLT INSTALLATION 1. When installing the cylinder head bolts, check that the shank length (A) of each bolt meets the limit. If the limit is exceeded, replace the bolt. Limit:Max. 103.2 mm (4.062 in) 2. Install the washers as illustrated, 3. Apply engine oil to the bolt threads and — washers. Aa — : Phacs Symbol ___ Description B Timing belt side one tAR5064: 4, According to the tightening sequence, tighten the bolts to the specified torque 4.9 kgm (49 Nm; 3.288 ftibs). 5. . Loosen all bolts fully. 6. Retighten the loosened bolts to a torque of 2.0 kgm (20 Nm; 1.342 ft.lbs) in the specified tightening sequence. 7, Make paint marks on the cylinder head bolt heads and cylinder head.ERM enaine <1600> CYLINDER HEAD AND VALVES 8, Give a 90° turn to the cylinder head bolts in the specified tightening sequence. 9. Give another 90° turn to the cylinder head bolts and make sure that the paint marks on the head of each cylinder head bolts and that on the cylinder head are on the same straight line. CAUTION (1) If the bolt is turned less than 90°, proper fastening performance may not be expected. When tightening the bolt, there- fore, be careful to give a sufficient turn to it, -y (2) If the bolt is overtightened, loosen the bolt completely and then retighten it by repeat- ing the tightening procedure from step (1). (Symbot_[—besetpatn | _A__| ___| INSPECTION CYLINDER HEAD 1. Check the cylinder head gasket surface for flatness by using a straightedge and thick- hess gauge. Standard value: 0.03 mm (0.001 in) Limit: 0.2 mm (0.007 in) 2. If the service limit is exceeded, correct to meet the specification. Grinding limi 0.2 mm (0.007 in) *Includes / combined with cylinder block ouetaRsess. grinding — Cylinder head height (Specification when new): 120.0 mm (4.724 in) VALVE 1. Check the valve face for correct contact (A) If incorrect, reface using a valve refacer. | Valve should make a uniform contact with | the seat at the centre of valve face. A 2. If the margin (8) is smaller than the service limit, replace the valve. Standard value: intake: 1.0 mm (0.039 in) 8 Exhaust: 1.5 mm (0.059 in) Limit: Intake: 0.5 mm (0.019 in) ouethanaoe | Exhaust: 1.07mi (0.039 in)ENGINE <1600> (ERI CYLINDER HEAD AND VALVES ] VALVE SPRING —elpe A | 1, Measure the free height of the spring, and | if itis smaller then the limit, replace | Standard value: ‘50.9 mm (2.003 in) | ¥ Limit: 49.9 mm (1.964 in) | \ Pes ] le \ [symbol | __Description _ } | | ares Out of square j | [es a | | 2. Measure the squareness of the spring and, | if the limit is exceeded, replace. Le ——___________ done ansoss | Standard value: 2° or less Limit: & TO VALVE GUIDE 1. Measure the clearance between the valve guide (A) and valve stem. If the limit is exceeded, replace the valve guide or valve, or both. Standard value: Intake: 0.02-0.047 mm (0-0.001 in) Exhaust: 0.03-0.057 mm (0.001-0.002 in) Limit:intake: 0.10 mm (0.003 in) Exhaust: 0.15 mm (0.005 in) VALVE SEAT RECONDITIONING PROCEDURES. 1. Before correcting the valve seat, check for clearance between the valve guide and valve . If necessary, replace the valve guide. 2. Correct to obtain the specified seat width and angle. 3. After correction, valve and valve seat should be lapped with a lapping com- poundFRR enaine <1600> CYLINDER HEAD AND VALVES VALVE SEAT REPLACEMENT PROCEDURE. 1, Cut the valve seat to be replaced from the inside to thin the’ wall thickness. Then, remove the valve seat. [symbol | Des A |Cut away 2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter. |valve seat height ‘Oversize valve seat hole dia- [meter 30,300-30.321 mm (1.192-1.193 0.6 ©.5. : 30,600-30.621 mm (1.204-1.205 in) Exhaust valve seat hole diameter: 0.3 0.5. 28.300-28.321 mm (1.114-1.114 in) 0.6 O.S. : 28.600-30.621 mm (1.125-1.205 in) 3. Before fitting the valve seat, either heat the gylinder head up to approximately 250 °C (482 °F) or cool the valve seat in liquid nitrogen, to prevent the cylinder head bore from galling 4. Correct the valve seat to the specified width and angle. VALVE GUIDE REPLACEMENT 1. Force the valve guide out toward the cylinder block using a press. 2. Machine the valve guide hole in the cylinder head to the size of the oversize valve guide to be installed. CAUTION Do not use the valve guide of the same size as the removed one. Valve guide hole diameters in cylinder head: 0.05 0. 11.05-11.07 mm (0.435-0.435 in) 0.25 0.S.: 11.25-11.27 mm (0.442-0.443 in) 0.50 0.5: 11.50-11.52 mm (0.452-0.453 in)3 ENGINE <1600> (ER) CYLINDER HEAD AND VALVES Press-fit the valve guide until it protrude (A) specified value (14 mm (0.551 in)) as shown in the illustration, CAUTION (1) Press the valve guide from the cylinder head top surface. (2) Valve guide for intake valve and that for exhaust valve are different in length. (45.5 mm (1.791 in) for intake valve 0.5 mm (1.988 in) for exhaust valve) After the valve guide has been installed, insert a new valve to check for smooth sliding motion.GEMM ENGINE <1600> OIL PUMP AND OIL PAN OIL PUMP AND OIL PAN REMOVAL AND INSTALLATION Does ARs07s 959%ENGINE <1600> (EE) OIL PUMP AND OIL PAN | Removal steps | 1. Oil filter 9. Relief plunger 2. Drain plug | KB 10. Front cil seal | HM. Gasket | IEE 11. Front case | Ea 4. Oil pan | 12. O-ring | it tes 13, Oil pump cover | é ce ia oil a outer rotor | 7. Relief valve | 15. Oil pump inner rotor | 8._ Relief valve spring | FT: 4.0 kgm (10 Nm; 0.671 ftlbs) Ta: 3.9 kgm (39 Nm; 2.617 ftlbs) 72: 1.5-2.2 kgm (15-22 Nm; 1,006-1.476 ft.lbs)| TS : 4.4 kgm (44 Nm; 2.952 ft.lbs) | TB :0.6-0.8 mm (0.023-0.031 in) _ 76 :1.2-1.5 kgm (12-15 Nm; 0.805-1.006 ft.lbs) |ERM encine <1600> OIL PUMP AND OIL PAN REMOVAL SERVICE POINTS | EOL PAN REMOVAL 1, Remove the oil pan mounting bolts. 2. Knock the special tool between the oil pan and cylinder block as shown in the illustra- tion 3. Tapping the side of the special tool, slide the tool along the oil panicylinder block seal and thus remove the oil pan 0398727 = INSPECTION ol PUMP 1, Fit the rotor into the front case. 2. Check the tip clearance using a thickness gauge. Standard value: 0.06-0.18 mm (0.002-0.007 in) Rover range | 3. Check the side clearance using a straight ‘edge and thickness gauge, Standard value: 0.04-0.10 mm (0.001-0.003 in) pouervanso7? 4. Check the body clearance using a thickness gauge. Standard value: 0.04-0.10 mm (0.001-0.003 in) Limit: 0.35 mm (0.013 in)a | 3), MD9S83 oy SS5 owe rvaRsox? ENGINE <1600> [ERY OIL PUMP AND OIL PAN INSTALLATION SERVICE POINTS Hi FRONT OIL SEAL CASE INSTALLATION 1. Clean the sealant application surfaces on the cylinder block and front oil seal case 2. Apply a 3 mm (0.118 in) bead of from-in- place gasket to the entire circumference of the oil pan flange. Specified sealant: Part No. MD970389 or equivalent. Hid FRONT OIL SEAL INSTALLATION 1. Place the special tool on the crankshaft’s front end and apply engine oil to the its outer circumference. Apply engine oil to the oil seal lip, then push the oil seal along the guide by hand until it touches the front case. Tap the oil seal into place using the special tool. HH] OIL PAN INSTALLATION 1. Clean the mating surfaces of the cylinder block and oil pan. 2. Apply a 4 mm (0.157 in) bead of from-in- place gasket to the outer circumference of the oil pan flange. Specified sealant: Part No. MD970389 or equivalent.FER encine <1600> OIL PUMP AND OIL PAN | ggg pain PLus Gasier Instautation 1, Replace the drain plug gasket with a new | one. Fit the new gasket as shown. | cy i HG OIL FILTER INSTALLATION 4. Clean the filter mounting surface on the front case. 2. Apply engine oil to the oil filter's O-ring 3. Screw on the oil filter until the O-ring is seated on the mounting surface. Then, give the oil filter one further turn such that it is torqued to approximately 4.2-1.6 kgm (12-16 Nm; 0.805-1.073 ft.lbs), CAUTION The oil filter must be tightened using a commercially available filter wrench. If the filter is tightened by hand only, it will be insufficiently torqued, resulting in oil leaks.FEMME enaine <1600> PISTONS AND CONNECTING RODS. PISTONS AND CONNECTING RODS REMOVAL AND INSTALLATION weorrasassyon9 ‘DOUEI1ARSOBS 258%ENGINE <1600> [ERI PISTONS AND CONNECTING RODS a Apply engine oil to all moving parts before installation 5 Removal steps 1 BB 1. Connecting rod nut FB 2. Connecting rod cap Piston ring No. 2 BB’. EB 8. Oilting Bes | | HJ 3. Connecting rod bearing | Piston pin I 4. Piston and connecting rod assembly 10. Piston | 5. Connecting rod bearing 11. Connecting rod | Ha 6. Piston ring No. 1 12. BoltPISTONS AND CONNECTING RODS 2 oo CeO Th em oe wr ENGINE <1600> —bouersansoer | REMOVAL SERVICE POINTS IEW CONNECTING ROD CAP REMOVAL 1. Mark the cylinder number (A) on the side of, the connecting rod big to facilitate reas- sembly Fg PISTON PIN REMOVAL 1, Insert the Push Rod (A) (special tool) from the front arrow mark side, then fit guide D © 2. Mount the piston and connecting rod assembly on the Piston Pin Setting Base (D) (special tool) with the piston’s front mark (8) pointing upward. 3. Remove the piston pin using a press. NOTE After removing the piston pin, keep the piston, piston pin, and connecting rod together. Do not allow pistons, piston pin, and connecting rods from different cylin- ders to become mixed up. INSPECTION PISTON RINGS. 1. Check the piston ring side clearance. If the clearance exceeds the specified limit, replace the ring or piston, or booth. Standard value: No. 1 ring : 0.02-0.06 mm (0-0.002 in) No. 2 ring: 0.02-0.06 mm (0-0.002 in)ENGINE <1600> [ER PISTONS AND CONNECTING RODS 2. Insert the piston ring into the cylinder bore and push it down with a piston (A). Ensure that the piston’s crown is in contact with the ring such that the ring is at 90° to the cylinder wall. Then, measure the end gap (Q with a thickness gauge. If the gap is too large, replace the piston ring (8). Standard values: No. 1 ring: 0,20-0.35 mm (0.007- No. 2 ring: 0.35-0.50 mm (0.013. Oil ring: 0.20-0.50 mm (0.007-0.019 in) Limits: No. 1 0.8 mm (0.031 in) No. 2 ring 0.8 mm (0.031 in) Oil ring 4.0 mm (0.039 in) CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) 1. Wipe all oil off the crankshaft pin and connecting rod bearing, 2. On the pin, place a plastic gauge that is cut to the same length as the bearing’s width. The plastic gauge must be centered on the pin in parallel with the pin’s axis. 3. Gently place the connecting rod cap in position and tighten the bolts to the specified torque. 4, Remove the bolts and gently remove the connecting rod cap. 5. Measure the compressed part of the plastic gauge at its widest point using the scale printed on the plastic gauge bag Standard value: 0.02-0.04 mm (0-0.001 in) Limit: 0.1 mm (0.003 in)FRM enaine <1600> PISTONS AND CONNECTING RODS INSTALLATION SERVICE POINTS | EM PISTON PIN INSTALLATION | 1. Measure the following lengths (as shown): rT ! A; Piston boss-to-piston boss outside | dimension, oe | B: Piston boss-to-piston boss inside dimen- TT c ee - G Piston pin length | D: Connecting rod small end eye thickness. LJ | 2. Enter the measured values into the follow- | ing formula L=(A-C) — (B-D) = 3. Insert the Push Rod (special tool) into the piston pin, then fit Guide A (special tool) 4. Fit the piston and connecting rod together such that their front marks are on the same side. Apply engine oil to the outside of the piston pin. 6. Into the front-mark side of the piston, insert the guide A, piston pin, and Push Rod, starting with quide A. 7. Screw guide B (F) into guide A (E). Leave a gap between the two guides of 3 mm (0.118 in) plus the value (L) calculated in step (2). ones nans0s1ENGINE <1600> JERI PISTONS AND CONNECTING RODS LILLE ( Li 8. Mount the piston and connecting rod on the Piston Pin Setting Base (special tool) with the piston’s front mark pointing upward. symbol | ] —£ (Guide A Lf Guide 8 | 6 ir [Frontmark L1 [Base 9. Install the piston pin using a press. If the press-fitting load is out of specifications, replace the piston pin and piston assembly or the connecting rod, or both. Standard value: 4900-14700 kg (49000-147000 N; 10792.74- 32378.22 Ibs) HE OIL RING INSTALLATION 1. Fit the oil ring spacer (8) into the piston ring groove. Then, fit the upper and lower side rails (A). NOTE (1) The spacer and side rails may be fitted in either direction. No distinction is made between top and bottom. 2. To install a side rail, fit one end of the rail (Q into the groove then press the rest of the rail into position by hand as shown. CAUTION Do not fit side rails using a piston ring expander since they may break. 3. After installing the side rails, check that they move smoothly in both directions.ERM encine <1600> PISTONS AND CONNECTING RODS a | JEM PISTON RING No. 2 / PISTON RING No. 1 INSTALLATION 1. Using a ring expander (A), fit ring No. 2 and ring No. 1 with their identification marks facing upward (on the piston crown side) ones rans Identification marks: No. 1 ring: 1 (B). a > | No. 2 ring: T2 (C). NOTE | Piston rings are stamped with size marks (D) as follows: | } PISTONS AND CONNECTING RODS 4. Compress the piston rings tightly with a suitable ring compression tool, then press the piston and connecting rod fully into the cylinder. Do not strike the piston hard since the piston rings may break and the crank pin may be nicked Done taRs098 CONNECTING ROD BEARING INSTALLATION | | 1. Select bearings according to the crankshaft | and connecting rod identification marks or | color codes, referring to the following table. ymbol | __Description —_—_—| Al___ |Color code positions = A2___ [Identification mark positions] Bearing (Identification mark). Crankshaft 1g (identification mark). ntification mark). fae adie | a (White) { cyellow) aici) I (Yellow ort) | b (None) ¢ (Yellow) 1a) 7 __< (Yellow) __ B (None) ~_U@) a (White) is (Yellow) 14) MW (None or tt) _b (None) 8 (None) NQ@) [<(Yellow) A (Blue) m@)| EER encine <1600> PISTONS AND CONNECTING RODS | Crankshaft | Connecting rod | dintfication mark), | (Identification mark). | | I a (White) 8 (None) HQ) | eae ute) ees (h pees (2) Eee 1 (White or I) bb (None) | < (Yellow) _ J [> Turn identification mark | | [front side. } SSS | | | | } { | a | Symbol Description _ | E [Pain the identification mark CONNECTING ROD CAP INSTALLATION 1. Aligning the marks made during disassem- bly, fit the bearing cap onto the connecting rod, If the connecting rod is new and has no index mark, ensure that the bearing locking | A | notches aré both on the same side. | ———_- —— _Symbol_| Description A__[Gylinder nN | 8 Locking note | poversansra2GEMM ENGINE <1600> CRANKSHAFT AND CYLINDER BLOCK CRANKSHAFT AND CYLINDER BLOCK weoriasassyoro REMOVAL AND INSTALLATIONENGINE <1600> [REI CRANKSHAFT AND CYLINDER BLOCK Removal step 1, Flywheel bolt 10. Rear oil seal case I 2. Flywheel |11. Bearing cap bolt | 3. Drive plate bolt 12. Bearing cap | 4, Adapter plate 13. Crankshaft bearing (Lower | 5. Drive plate 14. Crankshaft | 6. Crankshaft bushing 15. Crankshaft bearing (upper) 7. Rear plate 16. Oil pressure switch 8. Bell housing cover 17. Cylinder block 9._ Rear oil seal TH: 1.5-2.2 kgm (15-22 Nm; 1.006-7:476 ft.lbs) |T4: 72: 1.0-1.2 kgm (10-12 Nm; 0.671-0.805 ft.lbs) | 13.0-14.0 kgm (130-140 Nm; 8.724-9.395 ft.lbs) 13 : 0.8-1.2 kgm (8-12 Nm; 0.536-0.805 ft.lbs)__|T5 : 3.5 kgm (35 Nm; 2.348 ft-lbs) = |0.2 kgm (2. Nm; 0.134 ft.lbs)KEM ENGINE <1600> CRANKSHAFT AND CYLINDER BLOCK ouerrAnsr0s. REMOVAL SERVICE POINTS HE] OIL PRESSURE SWITCH REMOVAL 1. Disconnect the oil pressure switch term inals. 2. Using the special tool, remove the oil pressure switch. INSPECTION CRANKSHAFT OIL CLEARANCE The crankshaft oil clearance can’ be measured easily using a plastic gauge (A). To check the crankshaft oil clearance with a plastic Gauge, carry out the following proce- dure: 1. Wipe all oil off the crankshaft journal and the bearing’s inside surface. 2. Install the crankshait 3. Cut the plastic gauge such that its length matches the width of the bearing, then place it on the journal along the journal's axis. 4. Gently fit the crankshaft bearing cap and tighten the bolt to the specified torque. 5. Remove the bolts and gently remove the crankshaft bearing cap. 6. Using the scale printed on the plastic gauge bag, measure the plastic gauge’s crushed section at its widest point. Standard value: 0.02-0.04 mm (0-0.001 in) Limit: 0.1 mm (0.003 in)ENGINE <1600> [ERI CRANKSHAFT AND CYLINDER BLOCK NOTE The crankshaft pins and journals are fillet-rolled | (8) and must. not be machined to undersize \ | dimensions. | a } CYLINDER BLOCK 1. Visually check for cracks, rust, and corro- sion, and inspect the cylinder block using a flaw detecting agent. Rectify defects where possible or replace the cylinder block. 2. Ensure that the top surface is free of gasket chips and other foreign material. Check the cylinder block's top surface for distortion using a straight edge and thickness gauge Standard value: 0.05 mm (0.001 in) Limit: 0.1 kgm (1 Nm; 0.067 ft.tbs) 3. Check the cylinder walls for cracks and seizure marks. If defects are evident, bore all the cylinders to oversize or replace the gylinder block. 4. Using a cylinder gauge, measure each gylinder’s bore and cylindricity. If any gylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly. Take measure- ments at the points shown. Standard value: Cylinder bore: 76.0 mm (2.992 in) Cylindricity: 0.01 mm (0 in) or less ponersaR9i09KEM ENGINE <1600> CRANKSHAFT AND CYLINDER BLOCK —— MDS9988054 1 BORING CYLINDER 1. Oversize pistons to be used should be determined on the basis of the cylinder with the largest bore 2. Oversize pistons are available with the following oversize dimensions: 0.25 mm (0.009 in), 0.75 mm (0.029 in), and 1.00 mm (0.039 in). Measure the diameter of the piston to be used. Boring must be carried out such that the piston-to-cylinder clearance complies with the standard value The piston ’s diameter should be measured at the points shown. 3. Calculate the boring finish dimension based on the piston diameter dimension. * [Boring finish dimension] = [piston 0.0. (A)] + [piston-to-cylinder clearance ( 0.02-0.04 mm (0-0.001 in))] - [honing mar- gin (0.02 mm (0 in))] 4, Bore each cylinder to the calculate boring finish dimension. CAUTION To prevent distortion caused by heat increases during boring bore the cylinders in the following order: No.2, No. 4, No. 1, No. 3. 5. Hone the cylinders to the final finish dimension (piston O.D. (A) + piston-to- cylinder clearance) 6. Check the clearance between the pistons and cylinders. Standard value: 0.02-0.04 mm (0-0.001 in) INSTALLATION SERVICE POINTS HE OIL PRESSURE SWITCH INSTALLATION 1. Apply the specified sealant (A) to the thread, then fit the oil pressure switch using the special tool shown in the illustration. Specified sealant: 3M ATD Part No. 8660 or equivalent. CAUTION (1) Apply sealant such that none is squeezed out past end of the thread. (2) Do not over-tighten the oil pressure switch.ENGINE <1600> [ER] CRANKSHAFT AND CYLINDER BLOCK BEB CRANKSHAFT BEARING INSTALLATION | 1. Select bearings accordirg to the crankshaft identification marks or color codes, refer: ring to the following table. If they are not identifiable, measure the crankshaft jour- nals and choose bearings to match the measurements, 43 a a - \ Symbol _| Al & AZ je positions C : Identification mark posi- | 8 2 j 32 A2 i 1 A 0 foONa 1 B one 18R9112 Crank journal side Cylinder block bore diameter | — Install class of bearing (identification mark) (identification mark) (Identification mark) 0) 1a) 1 (Yellow or 1) 1) We) al HQ) m@) 0 (0) a HQ) a M1 (No color or 2) on 1a) MQ) mW) Vv@)FEB enaine <1600> CRANKSHAFT AND CYLINDER BLOCK | Crank journal side Cylinder block bore diameter | Install class of bearing | (Identification mark) (identification mark) _(identification mark) 1 0) ue) IIL (White or 3) a 10) va) l aee(2) L v (5) 2. Identification marks showing the cylinder block bearing bore diameter are stamped in the position shown, with No. 1 at the front of the engine. Bearings must be selected and installed in accordance with these identification marks. — - , } Symbol | Description D | cylinder block journal bore diameter Timing belt side 3. Based on the identification markings ver- ified in step (1) and (2), select bearings from table above. See the following example: | 3.1 If the measured crankshaft journal diameter is 48.000 mm (1.889 in), this corresponds to classification 1 in the above table. 3.2 If the identification mark on the i gylinder block bearing hole is "1", select a bearing with an identifica- tion mark of "2". 4. Except for the center bearing, all the upper bearings are grooved. The center bearings are grooveless and have flanges. The center bearings are the same at the top and bottom E ‘symbol Description ” E__ |Grooveless | F__ [Grooved | 1 G [Lower bearing (No. 1,2,4, and 5) Doug anons} H Upper bearing (No. 1,2,4, and 5) 1 Upper and lower bearings (Center No. 3)_ 5. The lower bearing are all grooveless.ENGINE <1600> [ER] A Hl BEARING CAP INSTALLATION 1. On the bottom surface of each bearing cap is the cap's number (A) and an arrow (8). Starting at the timing belt side, fit the bearing caps in numerical order. Ensure that the arrows (B) point toward the timing belt side. PERT Were | 2. After fitting the bearing caps, measure the end play in the crankshaft. If the measure- ment exceeds the specified limit, replace the crankshaft bearings. Standard value: 0,05-0.18 mm (0.001-0.007 in) Limit: 0.25 mm (0.009 in) BE REAR OIL SEAL INSTALLATION 1. Press-fit the rear oil seal (A) using the special tool shown in the illustration.",4>