Engine (1.1 / 1.3 SOHC) GENERAL SPECIFICATION. SPECIAL TOOLS: ‘TROUBLE SHOOTING ENGINE AND TRANSAXLE ASSEMBLY TIMING SYSTME, TIMING BELT. COMPONENTS. COMPONENTS DISASSEMBLY INSPECTION REASSEMBLY CYLINDER HEAD ASSEMBLY ‘CYLINDER HEAD. COMPONENTS. COMPONENTS. DISASSEMBLY INSPECTION REASSEMBLY ROCKER ARM, ‘COMPONENTS ‘COMPONENTS, DISASSEMBLY .. INSPECTION REASSEMBLY VALVES COMPONENTS: COMPONENTS: DISASSEMBLY INSPECTION REASSEMBLY MAIN MOVING SYSTEM CAM SHAFT. COMPONENTS COMPONENTS DISASSEMBLY INSPECTION REASSEMBLY CRANK SHAFT ‘COMPONENTS: DISASSEMBLY INSPECTION REPLACEMENT REASSEMBLY FLY WHEEL COMPONENTS .. COMPONENTS DISASSEMBLY .. INSPECTION. REASSEMBLY PISTON ‘COMPONENTS: SISASSEMBLY INSTALLATION INSPECTION REPLACEMENT REASSEMBLY EMA.2 COOLING SYSTEM ENGINE COOLANT HOSTIPIPES. ‘COMPONENTS, COMPONENTS, INSPECTION REASSEMBL ENGINE COOLANT PuNiP™ ‘COMPONENTS, COMPONENTS DISASSEMBLY INSPECTION REASSEMBLY RADIATOR DISASSEMBLY INSPECTION REASSEMBLY RADIATOR CAP ‘COMPONENTS INSPECTION THERMOSTAT ‘COMPONENTS. COMPONENTS. INSPECTION REASSEMBLY LUBRICATION SYSTEM ‘lL PUMP COMPONENTS: ‘COMPONENTS, EMA “89 DISASSEMBLY EMA “30 INSPECTION EMA “90 REASSEMBLY OIL PRESSURE SwiTGH ENGINE BLOCK ENGINE BLOCK. ‘COMPONENTS. COMPONENTS, INSPECTION ENGINE MOUNTS ‘COMPONENTS: REMOVAL INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD ‘COMPONENTS .. COMPONENTS. INSPECTION INTAKE MANIFOLD COMPONENTS REMOVAL INSPECTION INSTALLATION MUFFLER ‘COMPONENTS: REMOVAL INSPECTION INSTALLATION EMA -108 AIR CLEANER (ACL) COMPONENTS: EMA -107 REMOVAL EMA “108 INSPECTION EMA -109 INSTALLATION: EMA “109 EMA 75 EMA-76, EMA 96 EMA “97 EMA -99 EMA -100 EMA -101 EMA -102 EMA 103 EMA 104 “TEMA “104 EMA -105 EMA “105 EMA “108EMA -2 ENGINE MECHANICAL SYSTEM GENERAL SPECIFICATIONS | ccncoeu 1.3 SOHC 1.1 SOHC SPEC umn SPEC ur General Type Insine, SHOC + No. of cylinder ‘ < Bore 71.5 mm (281 in) 67 mm (2.64 in) Stroke 835 mm (329 in) 77 mm (3.03 in) Total cisplacement 1341 co 1085 cc Compression ratio 95 97 Firing order 123-4-2 < Valve timing Intake valve opens (BTOC) 12 5 Intake vaive closes (ABDC) 52 35 Exhaust valve opens (BBDC) 52 43 Exhaust valve closes (ATDC) 12 5 Valve overlap 24 10 Cylinder head Flatnoss of gasket surface Max. 0.03 mm | 0.08 mm Max. 0.05mm 04 mm (0.0012 in) | (0.00818 in) (0.002 in) (0.00394 in.) Flatness of manifold mount’ Max. 0.15 mm 03 mm Max. 0.15mm 03 mm surface (0.0059 in.) (0.0118 in) (0.0059 in.) (0.0118 in) Dimension for reworking oversize valve seat hole Intake 0.03 Os, 0.06 Os, Exhaust 0.03 0.8, 0.06 OS. Valve guide hole diameter (intake/exhaust) 0.05 OS. 0.25 OS, 0.50 OS, 28.8 ~ 28.821 mm (1.134 ~ 1.135 in.) 29.1 ~ 29.121 mm (1.148 ~ 1.1487 in) 34,3 ~ 34,325 mm (1.350 ~ 1.351 in.) 34.6 ~ 34.625 mm (1.362 ~ 1.963 in.) 11.05 ~ 11.088 mm (0.435 ~ 0.436 in.) 11.25 ~ 11.268 mm (0.443 ~ 0:4436in.) 11.50 ~ 11.518 mm (0.453 ~ 0.4535in.) 24.3 ~ 24.921 mm (0.957 ~ 0.9575 in.) 24.6 ~ 24.621 mm (0.968 ~ 0.969 in.) 29.3 ~ 29.321 mm (1.154 ~ 1.1544 in) 29.6 ~ 29.621 mm (1.165 ~ 1.166 in.) 10.05 ~ 10.068 mm (0.396 ~ 0.3963 in.) 10.25 ~ 10.268 mm (0.403 ~ 0.404 in.) 10.50 ~ 10.518 mm (0.413 ~ 0.414 in.)GENERAL EMA -3 1.3 SOHC. 4.1 SOHC Camshaft Cam height intake 42.8575 mm 42.9875 mm 34.8729 mm. 94.729 mm (1.687 in.) (1.687 in.) (1.373 in.) (1.369 in.) Cam height exhaust 42.7354 mm 42.2624 35.1258 mm_ 95.0258 mm. (1,682 in.) smm(1.664 in.) (1,383 in.) (1.379 in.) Journal diameter 30 mm (1.181 in.) 41 mm (1.614 mm) Bearing oil clearance 0.045 ~ 0.085 mm 0.045 ~ 0.085 mm (0.0018 ~ 0.0033 in.) (0.0018 ~ 0.0033 in) End play 0.07 ~ 0.28 mm 0.07 ~ 0.19 mm (0.0027 ~ 0.011 in.) (0.0027 ~ 0.0074 in.) Crankshaft Journal diameter ‘50 mm (1.97 in.) 42 mm (1.65 in.) Pin diameter 45 mm (1.77 in.) 38 mm (1.496 in.) Bond 0.03 mm (0.0018 in.) 0.03 mm (0.00118 in.) Out of roundness of journal ‘Max. 0.005 « and pun Max. 0.005 e Taper of journal and pin 0.05 ~ 0.175 mm 0.25 0.05 ~ 0.25 mm End play (0.002 ~ 0.007 in.) | mmn(0.0098 in.) | (0.002 ~ 0.0098 in.) Undersize of Pin 0.25 44.725 ~ 44.740 mm. 87.735 ~ 37.75 mm (1.76 ~ 1.761 in.) (1.486 ~ 1.4862 in.) 0.50 44.475 ~ 44.490 mm 37.485 ~ 37.50 mm (1.75 ~ 1.751 in) (1.4751.476 in.) 075 44.225 ~ 44.240 mm (1.74 ~ 1.741 in) Undersize of Journal 025 49.727 ~ 49.742 mm 44.735 ~ 41.75 mm (1.957 ~ 1.958in.) (1.643 ~ 1.644 in.) 0.50 49.477 ~ 49.492 mm 41.485 ~ 41.50 mm (1,948 ~ 1.9485in.) (1.633 ~ 1.634 in.) O75 49.227 ~ 49.242 mm (1.938 ~ 1.9386in.) Main bearing oil clearance No. 1,245 0.022 ~ 0.040 mm 0.1 mm 0.02 ~ 0.038 mm (0.0086 ~ 0.0016 in.) | (0.00394 in.) | (0.00078 ~ 0.0015 in.) No. 3, 0.028 ~ 0.046 mm 0.02 - 0.038 mm (0.0011 ~ 0.0018 in) (0.00078 - 0.0015in.) Valve ‘Stem diameter Intake 5.955 ~ 5.97 mm 5.48 ~ 5.465 mm (0.234 ~ 0.235 in.) (0.216 ~ 0.2151 in.) Exhaust 5,935 ~ 5.95 mm 5.45 ~ 5.43 mm (0.2336 ~ 0.234 in.) (0.215 ~ 0.213 in) Face angle 45° ~ 455° e Thickness of valve head (margin) Intake 41.1 mm (0.043 in.) | 0.8mm(0.031in.}] 0.8 mm (0.031 in.) 0.5 mm (0.0197 in.) Exhaust 1.9 mm (0.051 in.) | 1 (0.039 in.) | 1.2 mm (0.047 in.) 0.9 mm Valve stem to valve guide (0.035 in.) clearance Intake 0.03 ~ 0.06 mm 0.1 mm 0.02 ~ 0.047 mm 0.4 mm (0.0012 ~ 0,0024 in.) } (0.0039 in.) | (0.008 ~ 0.0018 in.) | (0.0039 in.) Exhaust 0.05 ~ 0.08 mm 0.15 mm (0.05 ~ 0.082 mm 0.15 mm (0.0020 ~ 0.0031 in) | _ (0.006 in.) | (0.002 ~ 0.0032 in.) | (0.006 in.)EMA -4 ENGINE MECHANICAL SYSTEM 1.3 SOHC 4.1 SOHC Valve guide Length Intake 12.8 mm (0.504 in.) 10.05 mm (0.996 in.) Exhaust 12.8 mm (0.504 in.) 10.05 mm (0.396 in) Service oversize 1005, 0.25, 0.50 e Valve seat Width of seat contact Intake 0.8 - 1.2mm 09 - 1.3 mm (0.031 ~ 0.047 in.) (0.035 ~ 0.05 in) Exhaust 1.3 ~ 1.7mm 09 - 1.3 mm (0.051 ~ 0.087 in) (0.035 ~ 0.05 in) Seat angle 45° e Service oversize 03, 06 « Valve spring Free length (Installed height) 444 mm (1.782 in.) 40.5 mm (1.594in) Load 21.6kg/35mm, 15,6kg / 32.0 mm, 45.1kg/27.2mm 33.3 kg / 24.5 mm ut of squareness Max 1.5 Valve clearance (cold 20°C) Warm:80°C) intake God : 20°C : 0.4 mm Warm : 80% : 02 mm Exhaust Gold : 20° : 0.17 mm Warm : 80°C : 0.25 mm Cylinder block Cylinder bore 71.5 ~ 71.59 mm 67 - 67.3 mm (2815 - 2.816 in) (2.64 ~ 265 in) Outof roundness of cylinder bore | Max. 0.01 Taper of cylinder bore . Flatness of gasket surface Max. 0.05 0.1 mm (0.0038 in) Piston Dameter 71.47 ~ 71.50 mom 66.97 ~ 67.0 mm (2.814 ~ 2815 in) (2.636 ~ 2.65 in) Piston to cylinder clearance (0.02 ~ 0.04 mm « (0.0078 ~ 0.00187 in.)GENERAL EMA-5 ference and front Clearance between roter axial side and front case Tip clearance between outer and inner roter (0.0047 ~ 0.0071 in.) 0.04 ~ 0.085 mm (0.0016 ~ 0.0026 in.) 0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.) (0.0039 ~ 0.0071 in.) 0.04 ~ 0.095 mm (0.0016 ~ 0.0037 in.) 0.18 ~ 0.060 mm (0.007 ~ 0.0024 in.) 1.3 SOHC 1.1 SOHC Piston ring No. of rings per piston 3 « Compression ring 2 « il ring 1 « Compression ring type No. 4 Inside bevel type No. 2 Taper type Gil ring type Spiece type ‘ Side clearance No. 1 0.04 ~ 0.085 mm 0.1 mm 0.08 ~ 0.07 mm (0.0016 - 0.0033 in) | (0.00394 in) | (0.0012 - 0.0027 in.) No. 2 0.04 ~ 0.085 mm 0.1 mm 0.02 ~ 0.08 mm (0.0016 ~ 0.0083 in.) | (0.00394 in.) | (0.0008 - 0.0028 in.) ll ring 0.06 ~ 0.15 mm 0.08 ~ 0.15 mm (0.0028 ~ 0.006 in.) (0.003 ~ 0.006 in.) End gap No. 1 0.20 ~ 0.85 mm 1mm 0.18 ~ 0.30 mm (0.0079 ~ 0.0138 in) | (0.0394 in.) | (0.006 ~ 0.012 in.) No. 2 0.37 ~ 0.52 mm 4mm 0.30 ~ 0.50 mm (0.015~0.02 in) | (0.0394in) | (0.012 ~ 0.02 in) it ring side rail 02 ~0.7 mm (0.008 | 1 mm « ~ 0.028 in.) (0.0394 in.) Sevice oversize 0.25, 0.50, 0.75, 1.0 < Connecting rod Bend Max. 0.05 per 400 mm Twist Max. 0.1 per 100mm Connecting rod big end to 0.10~ 025mm | 0.4mm(0.016in.} « crankshatt side clearance (0.004 ~ 0.01 in) Piston pin press in load 1250 + 500 kg Bearing oil clearance 0.018 ~ 0.036 mm O.tmm 0.012 ~ 0.041 mm (0.0007 ~ 0.0014 in.) | _(0.0039in,) _| (0.0004 ~ 0.0016 in.) Flywheel Runout o.tmm 0.13mm 0.1. mm 0.13 mm (0.005 (0.0014 in) (0.005in.) (0.004 in) in) Oil pressure at curb idle speed 1.5kglom? (oil temp. 90-110°C) lt pump Clearance between outer circum | 0.12 ~ 0.18 mm 0.10 ~ 0.18 mm Relief spring Free length Load 46,6 mm (1.8346 in.) 61kg at 40.1 mm (13.4216 at 1.578 in.) 38.6 mm (1.519 in.) 3.65 kg at 33.0 mm (8.16 at 1.299 in.) Cooling method Water-cooled, Pressurized, Forced circulation with electrical fanEMA -6 ENGINE MECHANICAL SYSTEM 1.3 SOHC 14 SOHC Cooling sys. Quantity 6.2 lit (6.55 US ats 6.0 it (6.34 US. ts, 5.46 Imp ats) 5.28 Imp ats) Thermostat Type Wax pellet type with © jiggle valve Normal opening temp. 82°C. e Opening temp. range 805 ~ 835°C e Wide opening temp. 95°C 2 Radiator cap Main valve opening pressure 86.1 ~ 124.5 kpa © Main valve colseing pressure 83.4 kpa, . Vacuum valve opening preesur 86.6 kpa e Air cleaner Type Dry type « Element Unwoven cloth type s Exhaust pipe Muttior Expansion resonance « type Suspension sys. Rubber hanger type «GENERAL EMA-7 TIGHTENING TORQUE (1.3 L) tem Nm kg.cm Ibft | Cylinder Block Left engine support bracket bolt 30 ~ 42 300 ~ 420 22-31 Oil pressure switch 13-15 130 ~ 150 96-11 Cylinder head Cylinder head bolt (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 ~ 200 115 Exhaust manifold nut 15 ~ 20 150 ~ 200 1-15 Recker cover bolt 8-10 80 ~ 100 6-7 Recker arm shaft bolt 20 ~ 24 20 ~ 240 15-18 ‘Camshatt bott 20 ~ 27 200 ~ 270 15 ~ 20 Rear plate bolt 8-10 80 ~ 100 6-7 ‘Main Moving parts Connecting rod cap nut 32 ~ 35 320 ~ 350 24 ~ 26 Crankshaft bearing cap bolt 55 ~ 60 550 ~ 600 41 ~ 44 Flywheel M/T bolt 130 ~ 140 1300 ~ 1400 98 ~ 103 Drive plate A/T bolt 130 - 140 1300 ~ 1400 96 ~ 103 Timing Belt Crankshaft sprocket bolt 140 ~ 150 1400 ~ 1500 103 ~ 111 Camshatt sprocket bolt 80 ~ 100 800 ~ 1000 59-74 Timing belt tensioner bolt 20 ~ 27 200 - 270 15 - 20 Timing belt cover bolt 10-12 100 ~ 120 7-9 Front case bolt 12-15 120 - 150 =" Engine Mounting Engine mounting insulator bolts 35 ~ 55 350 ~ 550 258 ~ 406 Engine mounting bracket to engine (large) nut 70 ~ 95 700 ~ 950 51.6 ~ 70 Engine mounting bracket to engine 35 ~ 55 950 ~ 550 25.8 ~ 406 nuts and bolts Transaxle mount insulator bolt 70 ~ 95 700 ~ 950 51.6 ~ 70 Transaxle insulator bracket to side 95 ~ 55 350 - 550 25.8 ~ 40.6 member bolts Rear roll rod bracket bolt 35 ~ 55 350 ~ 550 25.8 ~ 40.6 Rear roll rod bracket to cross member 70 ~ 95 700 ~ 950 51.6 ~ 70 i fiter 12-16 120 ~ 160 9-12 Oil pan bolts 6-8 60 ~ 80 4-6 Oil pan drain plug 35 ~ 45 350 ~ 450 26 ~ 33 Oil screen bolts 15 ~ 22 150 ~ 220 11-16 Timing belt upper cover bolts 10 = 12 100 ~ 120 7-9 Timing belt lower cover bolts 10-12 100 - 120 7-9 Surge tank to inlet manifold nuts and bolts 15 - 20 150 ~ 200 11-15EMA-8 ENGINE MECHANICAL SYSTEM tem’ Nm kgm ‘bit Cooling system Generator support and nut 20 - 25 200 ~ 250 15-18 Generator lock bolt 15 ~ 22 150 ~ 220 1-16 Generator brace mounting bott 20 - 28 200 ~ 280 15-21 Coolant pump pulley 8-10 80 ~ 100 6-7 Coolant pump bolt 12-15 120 ~ 150 9-11 Coolant temperature gauge unit 10-12 400 ~ 120 7-9 Coolant temperature sensor 15 ~ 20 150 ~ 200 11-15 Coolant outst fiting bolt 17 ~ 20 170 ~ 200 13 ~15 ‘Thermostat housing bolt 15 ~ 20 150 ~ 200 11-15 Intake and Exhaust system Air cleaner body mounting bolts 8-10 80 ~ 100 6-7 Resonator mounting bolts 4-6 40 ~ 60 29-43 Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 11-15 (Oxygen sensor to exhaust manifold 50 - 60 500 - 600 37 ~ 44 Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 30 Front exhaust pipe bracket bolts 30 ~ 40, 300 ~ 400 22 ~ 30 Front exhaust pipe to cataiytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44 MIT : Manual Transaxle AUT : Automatic TransaxleGENERAL EMA-9 TIGHTENING TORQUE (1.1 L) tem - kg.cm bt Cylinder block Left engine support bracket 45 ~ 55 450 ~ 550 33-41 ii pressure switch 15 ~ 22 150 ~ 220 11-16 Cylinder head Cylinder head bolt Cold engine 60-70 600 ~ 700 44-52 Hot engine 70 ~ 75 700 ~ 750 52 ~ 56 Inkake/manifold to cylinder head nuts 15 - 20 10 ~ 200 1-15 and bolts Exhaust manifold nut 15 ~ 20 150 ~ 200 1-15 iocker cover bolt 8-10 80 ~ 100 6-7 locker arm shaft bolt 27 ~ 32 270 - 320 20 ~ 24 Main Moving Connecting rod cap nut 20 ~ 23 200 ~ 230 18-17 Crankshaft bearing cap bolt 50 ~ 55 500 ~ 550 37-41 Flywheel M/T bott 70 ~ 80 700 ~ 800 52 ~ 59 Timing Bolt Crankshaft pulley bolt 140 ~ 150 1400 ~ 1500 103 - 111 Camshaft sprocket bott 80 ~ 100 ‘800 ~ 1000 59-74 Timing belt tensioner bolt 22-30 220 ~ 300 16 ~ 22 Timing belt cover bolt 10 ~ 12 100 ~ 120 7-9 Front case bolt 8-10 80 ~ 100 6-7EMA -10 ENGINE MECHANICAL SYSTEM tem Nm kg.em bt Engine Mounting Engine mount insulator bolts 95 - 85 350 ~ 550 25.8 ~ 406 Engine mounting bracket to engine (large)nut 70-95 700 ~ 950 51.6 ~ 70 Engine mounting bracket to engine 35 ~ 55, 350 ~ 550 258 - 40.6 ruts and bolt Teransaxle mount insulator bolt 70 ~ 95 700 ~ 950 51.6 ~ 70 Rear roll rod bracket bolt 35 ~ 55 350 ~ 550 25.8 ~ 40.6 Rear roll rod bracket to cross member bolt 70 ~ 95 700 ~ 950 51.6 ~ 70 Olt fiter 12-16 120 ~ 160 9-12 Oil pan bolts 6-8 60 ~ 80 4-6 il pan drain plug 35 ~ 45 350 ~ 450 26 ~ 37 Oil screen bolts 16 ~ 22 160 ~ 220 11-16 Timing belt cover bolts 10 ~ 12 100 ~ 120 7-9 Surge tank to inlet manifold nuts and bolts 15 ~ 20 150 ~ 200 1-15 Generator support bolt and nut 20 - 25 200 ~ 250) 15 18 Generator brace bolt 12-18 120 ~ 180 9-11 Geneator brace mounting bolt 20 ~28 200 ~ 280 18 ~ 21 Coolant pump pulley 8~ 10 80 ~ 100 6-7 Coolant pump bolt 12 ~15 120 ~ 150 9-11 Coolant temperature sender 10 ~ 12 100 ~ 120, 7-9 Collant temperature sensor 15 ~ 20 150 ~ 200 11-15 Coolant outlet fitting bott 15 ~ 20 150 - 200 11-15 Thermostat housing bolt 8-10 80 ~ 200 6-7 Air cleaner body mounting bolts 8-10 80 ~ 100 6-7 Air intake hose clamp 3-5 30 ~ 50 2-4 Air duct assembly mounting bolt 8-10 80 ~ 100 6-7 Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 1-15 Exhaust manifold cover to exhaust 8-10 80 ~ 100 6-7 manifold bolts Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 60 37 ~ 44 Front exhaust pipe to exhaust manifold nuts, 30 ~ 40 300 ~ 400 22 ~ 30 Front exhaust pipe bracket bolts 30 ~ 40 300 ~ 400 22 - 30 Front exhaust pipe to catalytic convrter bolts 40 ~ 60 400 ~ 600 30 ~ 44 Main muffler hanger support bracket bolts 10-15 100 ~ 150 7-11 MIT : Manual TransaxleGENERAL EMA -11 ‘SELECTION OF ENGINE OIL. Recommended API classification : SH OR ABOVE SG. Recommended SAE viscosity grades : ‘Temperature range anticipated before Recommended SAE viscosity number next oll change ce - 40 104 ow} 15w 10.W 10W 50 | 50 -50 -30 20 68 -40 | -40 40 10 50 sw “10 4 | -40 — 15 5 -30 | sw} 25 13 -207 "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 which 1. Satisfy the requirements of the API classification. 2. Have proper SAE grade number for expected am- bbient temperature range. Lubricant that does not have both an SAE grade num- ber and an API service classification on the container should not be used.EMA -12 MAINTENCE CHECKING ENGINE On. 1. Psion the vehicle on aleve surace. 2. Warm up the engi nore Ifa vehicle has been out of service for a prolonged ‘period of time, warm up the engine for approximately 20 minutes. 3. Tum off the engine, and wait 2 or 3 minutes, then ‘check the oil level 4, Check that the engine oil level is within the level ragne indicated on the oil dipstick if the cil level is found to have fallen to the lower limit (the *L* mark), refill to the “F* mark, Lower tit When refiling, use the same type of engine ol. 5. Check that the oil is not dirty or contaminated with Coolant or gasoline and that it has proper viscosity. CHANGING ENGINE OIL © warnine Be careful not to brun yourself, as the engine oil Is hot. 1. Run the enigne until it reaches normal operating tem- perature. 2. Tum off the engine. ENGINE MECHANICAL SYSTEM 3, Remove the oll filer cap and the drain plug (on the oil 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, 24 ~ 33 Ib.t) WGnore Whenever tightening the oll drain plug, use a new drain plug gasket. 5. Fillthe crankcase with fresh engine oil through the oll filer cap opening, Drain and Refill Without oll fiter 1.3L : 30 iter (3.17 US. qts., 2.64 Imp. ats.) 1.1 L:2.8 liter (2.96 US. ats., 2.46 Imp. ats.) Drain and Refill With oil fiter 1.3L : 33 iter (3.48 US. ats., 2.90 Imp. ats.) 1.1 L:3.1 liter (8.28 US. ats., 2.73 Imp. ats.) 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 if necessary. FILTER SELECTION All Hyundai engines are dquipped with a high quality, dis- posable oil filter. This fiter is recommended as a replace- ment filter on all vehicles, The quality of replacement fil ters varies considerably. Only high quality filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil iter is completely. removed from the contact surface on the engine block be fore installing the new filter.GENERAL PROCEDURE FOR REPLACING THE OIL FILTER Q caution Be careful not to burn ylurself, engine oil are not. the engine and 1. Use a filler wrench to remove the oll filter. 2. Before installing the new oil fer on the engine, apply ‘clean engine oil to the surtace of the rubber gasket. 3, Tighten the out fiter to the specified torque. Tightening torque Oil fiter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 Ib.) 4, Run the engine to chack for engine oil leaks. 5. After turning off the engine, check the oil level and add oll as necessary. CHECKING COOLANT LEAK 1. Wait until the engine is cool, then carefully remove the radiator cap. 2. Confirm that the coolant level is up to the filler neck. 3, Install a radiator cap tester to the radiator filler neck and apply 140 KPa (1.4 kg/cm?, 20 psi) pressure. Hold it for two minutes in that condition, while check- ing for leakage from the radiator, hoses or connec: tions. nore 1. Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could gush out causing personal injury. Aliow the vehicle to coo! before servicing this system. 2. Be sure to clean away any moisture from the places cheoked completely 3. When the tester is removed, be careful not to spill any coolant from i 4. Be careful, when installing and removing the tester and when testing, not to deform the filer neck of the radiator.EMA -14 4. If there is leakage, repair or replace with the apropri: ate part RADIATOR CAP PRESSURE TEST 1, Remove the radiator cap. Wet its seal with engine ‘coolant, then install it on the tester. 2. Increase the pressure until the gauge stops moving, Main valve opening pressure 78 ~ 108 kPa (0.8 ~ 1.1 kglom®, 11.3 - 15.6 psi) Limit : 65 kPa (0.66 kg/em®, 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 OG) nore Be sure thatthe cap is clean before testing, since rust ‘or other foreign material on the cap seal will cause an incorrect reading ENGINE MECHANICAL SYSTEM CHANGING ENGINE COOLANT A 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. It 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. 4, Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservior. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze. 6. Pour coolant into the radiator up to the base of the filer neck, and install the radiator cap loosely. 7. Start the engine and fot it run until it warms up (the radiator fan comes on at least twice) 8 Tum off the engine. Check the level in the radiator, add coolant if needed. 9. Put the radiator cap on tightly, then run the engine again and check for leaks.GENERAL EMA-15 SPECIFIC GRAVITY TEST 1. Measure the specific gravity of the coolant with a hy- 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. RELATION BERWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperature °C (°F) and specific gravity Freezing Safe operating co aot on temperature °C | temperature °C 10 (50) | 20,68) | 30 (86) | 40(104) | 50 (122) _ o (Specific volume) tosa_[ 1.050 | 1046 | 1.002 | 1.098 “16 (8.2) -11 (122) 30% t063_| 1.058 | 1054 | 1.049 | 1.004 20 (-4) 15 6) 35% so71_| 1.067 | 1082 | 1.057 | 1.052 25 (13) 20 (4) 40% tore | 1074 | 1069 | 1068 | 1.058 80 (-22) 25 (-19) 45% 1087 | 1.082 | 1076 | 1.070 | 1.064 | 26 (228) “31 (23.8) 50% 109s | 1.090 | 1084 | to77 | 1.070 42 (-44) 7 (35) 55% t10s | 1.008 | 1092 | 1088 | 1.078 “50 (58) “45 (-49) 60% Example + Ifthe concentration is above 60%, both the ‘The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant tom- perature of 20°C (68°F) caution ‘* If the concentration of the coolant is below 30%, its antl-corrosion properties will be ad- versely affected. RECOMMENDED COOLANT antifreeze and engine cooling property will decrease, affecting the engine adversely. For these reasons, be sure to maintain the con- centration level within the specified range. * Do not use together with another brand's product. Antifreeze Mixture ratio of anti freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas} 40% [Tropical areas}EMA -16 CHECKING COMPRESSION PRESSURE 4. Befor checking engine compression, check the en- gine oil level. Also check that the starter motor and battery are all in normal operating condition. 2. Check the DTC and resetting the ECM will erase any stored DTCs. 3. Stsrt the engine and wait until engine coolant temper- ature reaches 80-95°C (176~205°F). 4, Disconnect the fuel pump connector. 5. Tum off engine and disconnect the spark plug cables. 6 Remove the spark plug. 7. Disconnect the I.G. connector. 8. Crank the engine to remove any foreign material in the cylinders. 9. Insert the compression gauge into the spark plug hole. ENGINE MECHANICAL SYSTEM 10. Depress the accelerator pedal to open the throttle fully 11. Crank the engine and read the gauge. Standard value : 1500 kpa (15.5 kglemé, 220 psi) Limit : 1200 kpa (12.5 kg/om?, 178 psi) 12, Repeat steps 9 to 11 over all cylinders, ensuring that the pressure cifferential for each of the cylinders is within the specified limit. Limit: Max. 150 kpa (1.5 kglom, 21 psi) between cylinders 13, If a cylinder’s compression or pressure differential is ‘outside the specification, add a small amount of oil through the spark plug hole, and repeat steps 910 12. 1, Ifthe addition of oil makes the compression to rise, its likely that there may be wear between the piston ring and cylinder wal. 2. If compression remains the same, valve seizure, oor valve seating or a compression leak from the cylinder head gasket are all possible causes. htening torque Spark plug : 20-30 Nm (200-300 kg.cm, 14~22 Ib.ft)GENERAL EMA -17 ADJUSTING TIMING BELT TENSION 8 1 2 Tum the steering whee! fully counter clock wise. Lift the vehicle by using of jack. 9 Loosen the coolant pump pulley mounting bolt and loosen the generator bolt tension adjustment bolt. 10. Remove the coolant pump pulley, generator bel, power steering pulley and power steering belt. " Remove the timing cover upper side mounting bolt (GEA). 12. Remove the crankshaft pulley. 13. Turn crankshaft to place clockwise in No.1 cylinder at top head center on compression stroke, Turn the crankshaft clock wise. If counter clock wise, tension is not available. Loosen the tensioner bolt 1~2 turn and tension the belt by tensioner spring, ‘Tum crankshaft clockwise as much as two camshaft ‘sprocket teeth. Tighten the tensioner bolt of slot side of first and then tighten the bott of pivot side. Rotate the crankshatt pulley two turns clockwise so that the timing belt positions on the pulleys. Pust the arrow direction on tensioner, measure the engagement between camshatt sprocket 'A’ part belt and sprocket20mm 14, Check the tension of timing belt. (1.9L) ‘When the tensioner and the tension side ofthe timing bett are pushed in horizontally with a moderate force [approx. 49N (11 ib), the timing beltlog endis approx. half of the tensioner mounting bolt head radius (cross. flats) away from the bolt head center. “Tensioner bot ENGINE MECHANICAL SYSTEM 16. Install the crankshaft pulley. 17. Install the coolant pump pulley. 18. Install V-belt and adjust the belt tension. ADJUSTING DRIVE BELT TENSION 1. Check that the belts are not damaged and are prop- erly fit for the pulley grooves. 2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in the illustration, measure the amount of deflection with a tension gauge. Q cauTion 1. When installing the V-ribbed belt, check that the V-ribs are properly aligned. 2. Ifnoise 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 that the belt Oh ) cae = wos 16. Install the timing belt cover. Wrong V-ibbed bet Wrong — —_ Right Adjustment = = NOTE The belt tension must be measured half - way between the specified pulleys. 2 When a new belts installed, adjust the tension to the central value of the standard range indicated under "New" in the above table, Let the engine idle for 5 minutes or more, and check the stan- dard value indicated under "inspection". 3. When adjusting a belt which has been used, or newly installed, after § minutes or more of oper- ation, refer to the standard value indicated under “Used” in the above table. 4. Refer to the standard value indicated under " ‘spection* for periodic inspections.