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    45 views126 pages

    20221019185831371

    Uploaded by

    luis carhuarica romero

    Copyright:

    © All Rights Reserved
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    ENGINE (FE SOHC) reson 1OB> DESCRIPTION ... TROUBLESHOOTING GUIDE ‘TUNE-UP PROCEDURE ON-VEHICLE MAINTENANCE : 10A- 10 REMOVAL... DISASSEMBLY ..... INSPECTION AND REPAIR ASSEMBLY INSTALLATION SPECIFICATIONS .. SERVICE SPECIAL TOOL, 10A-74 10A- 72 _peschietion ENGINE (FE SOHC) 104-3 DESCRIPTION FE SOHC engine is a 4 cylinder overhead camshalt engine and its compression ralio Is 8.6. The cylinder head is made of the aluminium alloy ol good heat conduclivily and heat resistance and has a multispherical combustion chamber with 2 valves pér cylinder, shalt, and the front and ‘the cylinder block is cast-lon with no sleeves. Five main bearings suppor! the rear crainkshall oll seals are a one-piece design. Piston ping are pressed Into the small end of the connecting rod and float in the piston. The large end of the connéctitig tod has replaceable Inserl bearings, Grooves at the rod and cap parting face provide oll lo lubricate the cylinder wails and cool the plstons. we Pressutized oii Ybrication Is supplied by a pump located In the front of the crankshalt. The oil is routed through the pump Inlet screen, oll pump, and ull flow filter to the crank8halt maln and connecting rod bear- ings, fo the camshatl bearings and valve Focker arms. The 2.0L engine has a Sequential Multiport Fuel Injection (SFI) systern. Engine cooling is provided by a waler pump mounted on the front end of the engine cylinder block. A thermo- slat controls coolant temperature and Is located In the waler oullet housing at the front af the cylinder block. An thermo modulated fan is mounted on the front sldé of the engine, Thé fan IS controlled by the blmetal. Possible Caw Burned vaive Wow piston, piston Failed cylinder head gasket ‘Mlfunelion of fuel system allunetion of eleclrleal system 19, oF cylinder Mallunetion of engine-related componeiits Remedy Replace Replace or repair Replace Reler fo Seclion 22 Reler lo Section 30 Poor idling Mallunction of engine-relaled components: improper valve cosvanee Adjust Poor valve lo valve seat conlact Repair or replace Ht | Tailed cylinder head gasket Replace ee ~ Maitunction of fuel system yO Baceseie ol il working up Replace consumption Worn piston ring groove ar slicking piston ring Replace br tepairss L Worn piston or cylinder Olf working dowa Wow valve se Replace om valve sem or gue Repioee “Bil ienkage tr CAT snsileieni power ~ Tl clerk SimprovaTon meroper vale clearance Aust Compression leakago from valve seal Hoyisie Seiad ye stem ep ne | Weak oka abe sing Repl Failed cyt head gasket Replace Crackod or dilredcyindr head seplace | Sieking, damaged worn lon ng Replace Gracked or wom piston Replace i ~~)" Malfunetion of fuel system Reler to Section 22 Others Stoping obtch Rete fo Seton do Dragging brakes hetero Secon 52 trong size ties fale lo Secon 53 “Abnormal Malfunction of engine-related components: combustion Ueropor valve clonranee replace Sickng or burned vave Adjust Weak or broke va sing replace Carbon accumulation In combustion chamber Eliminate cabo | datuneton of fuel system Filer Section 24 ee Engine noise Possible Cause | ~ Crankshait or bearing related parts Excessive main bearing oil clearance | Main bearing seized or heat-damaged Excessive crankshaft end piay Excessive connecting tod bearing oil elearance Connecting rod bearing seized of heat.damaged Remedy Replace or fepair Replace Replace ot repair Replace ot repair Replace Piston related parts : Worn cylinder Replace or repair Malfunction of cooling system Matfunetion of fuel system others: Mallunction af water pump bearing Improper drive belt tension aitunction of alternator bearing Exhaust gas leakage ‘Wom piston or piston pin Replace Seized piston Replace Damaged piston ring Replace Bont connecting rod ie ‘ Replace Valve or timing related parts, Improper valve clearance ‘Adjust Broken valve spring Replace Excessive vaive guide clearance Replace Malfunction of ting belt tonsioner Replaca oler to Seciion 12 | fer to Section 22 Agjust Replace Repair i Sa (0A-6 ENGINE (FE SOHC) TuNE-up PROCEQURE ranaismicae Ae a i TUNE-UP PROCEDURE Tune the engine according to the procedures described below. Battery 1. Check for corrosion on the terminals, or foose cable connec- > tions. : ifnacessary, clean the clamps and tighten firmly 2. Check that the electrolyte Jevel is between the UPPER and LOWER marks Add distilled water if necessary. = - 3. Check'the specific gravity by using a hydrometer. If the specific gravity reading Is 1.200 or less, recharge the battery, (Refer to Section 33) Alr cleaner element Visually check the air cleaner element for excessive dirt, dam- age, of oil Clean or replace if necessary. Caution + When cleaning the air cleaner element, below dust off from the inside completely first, then below from the outside, 7 [ica Spark plug <— WEAR AND ADHESION Check the following points. Clean or replace if necessary. OF CAREON 1. Damaged insulation. 2. Wom electrodes. 3. Carbon deposits. Damaged gasket. Bumt spark insulator. | . Plug gap. DAMAGE AND. DETERIORATION | pamace Plug gap = 0.70~0.80 mm (0.028-0.031 in) Twists Engine oll Chéck the engine oil level and condition with the oil level gauge. Add oil, or change it, if necessary. Hune-ur PRULEDUNS HHG eee en Coolant level (Cold engine) Gainer 1. Check that the coolant level is near the radiator inlet port. 2. Check that the level in the coolant reservoir is between the FULL and LOW marks. Add coolant if necessary. Warning a) Never remove the radiator cap while the engine |s hot. b) Wrap a thick cloth around the cap and carefully remove it. Drive belt las "ALTERNATOR {. Check the drive belt for wear, cracks or fraying replace it | SSypnesson ranputtey —\. “necessary. PULLEY 2. Check the drive belt deflection by applying moderate pres- sure (98N, 10kg, 22!b) inidway between the pulleys. mm (In) Bei Naw Teed Riemalor | 6-8 02-087) 7-3 0R-035) me 5 10 (031 aii (05 Powe . ‘cRanKsHarT i sforeatos) [SHOE | | Pity iouetuwer BERS AC 7-9 (027-035 | 6-10 (a1-038) | a 2) High-tension lead - js, Check the following points, Clean or replace if necessary. |, 4. Damaged lead. Carbon deposits. HIGH-TENSION LEADS TATE NITION TIMING Warm up the engine and run it at ile. 2.» Tur all electric loads OFF. ¢ Ground the test connector to the vehicle with a jumper wire. Connect the timing light connector. ~ = Check that the ignition timing mark on the crankshatt pulley B= and the timing mark on the timing belt cover are aligned. & Caution + tis not necessary to adjust the ignition timing. EOF Zid (DLE SPEED ‘Connect the SST to the ECU. Check the idle speed. Idle speed : 80050 rpm Caution + The idle speed Is controlled automatically by the engine control unit through thé Idle speed cohtrol wopu (ISC) solenoid valve, it is not necessary to adjust the | Hanes idie speed. CONNECTOR sosst COMPRESSION 1, Check that the battery is fully charged. Recharge if necessary’ Warm up the engine to the normal operating temperature. Turn itoff for about 10 minutes to allow the exhaust manifold to cool. +. Disconnect the high tension leads from the cylinder head. Remove all spark plugs. Connect a compression gauge to No.1 spark hole. Fully depress the accelerator pedal and crank the engine. Note the maximum gauge reading. 1. Check each eylinder. Compression pressure kPa (kg/crm, psi)-rpm I ‘Standard ‘Minimum FE 7.128 (11.5, 164) - 270 720 (6.1, 114)-270_| TORT Possible cause [ ircompression is low, pour heavy oll into the cylinder and tum the crankshalt several times. Check compression once more. No Y ——_——. ig compression increased Yes, [1 Worn piston or pist 2. Worn cylinder wall No 5 Y aa (mf Delete afer head gaat is compression in adjacent cylinder iow ? fos |2. Distorted cylinder head, i} y | Improper valve sealing. (______s }p: Wate Skin in guide 5: Detective eytncer head gasket. VALVE CLEARANCE 1. Warm tp the engine to the normal operating temperature. 2. Tighten the cylinder head bolts in the order shown in the fig- ure. Tightening torque : 98-10 Nm (10,0-10.3 kg-m, 72-75 Ib-ft) With the pision of the No.1 cylinder at TDC of compression stroke. Adjust the vale Clearance. Valve clearance (valve side) IN + 0.30 mm (0.012 in) EX: 0.30 mm (0.012 in) |. Turn the crankshaft one {ull tum so that the position of the No.4 cylinder is at TDG of compression stroke. © Adjust the clearance of the reaming valves. Not IN No2itt Nott x Nog ex Tous ADJUST BOLT CO Lock nur | | 1 VALVE FoAMSHAFT CLEARANCE! (eee ecaneie mee os 10A-10 ENGINE (FE SOHC) ON-VEHICLE MAIN’ ON-VEHICLE MAINTENANCE PISTON & CONNECTING ROD Removal 4. Disconnect the negative battery cable 2. Remove the under cover and drain the engine coolant (Refer to Section 12) 3. Drain the engine oil (Refer to Section 11) Caution ~. “Start and stop the engine release fuel pressure by disconnecting the electrical connector of the fuel pump. ee. 4, Remove the fresh air duct. 5, Remove the accelerator cable, 6. Remove the upper water hose. SoU ENGINE (FE SOHC) 108-11 7. Disconnect the engine hamess connectors. Toa? . Oz sensor connector AlC compressor connector 5, , Ignition coil connector 6. Airflow meter connector a rage, soleree coneee injector connector 7. Alternator connector ISS connector Crank angle sensor 8. Throttle position sensor connector on 4. Purge hose a 5. A “ose Caution + Cover the hose with a rag because fuel will spray ‘out when disconnecting, + Keep inflammable out of fuel. + Plug the hose to avoid fuel leakage after removing the hose. 8. Remove the exhaust manifold insulator. exhaust MaNiFoUD e INSULATCA 0 10. Remove the exhaust manifold and then secure the exhaust manifold as shown in the figure. aT a 11. Remove the ignition coll and high tension leads. 12, Loosen the altemator mounting bolt and adjust bolt and then remove the 4-ribbed belt. SU-VEHICLE MAINTENANCE ENGIN& (FE SOHC) 10A-13 413. Remove the intake manifold stay. smeeqeiogty Remove the surge tank bracket. Remove the intake manifold and surge tank Remove the thermo modulator fan mounting bolls. Too ‘SURGE TANK BRACKET. cl. Day K SAW AE Seen \ PA Satine) XLS x Sy 18, Loosen the timing belt tensioner lock bolt. 19. Shift the tensioner outward as far as possible, then tem- porarly tighten it Caution + Before removing the timing belt, turn the crankshaft to align the mating mark ("ff 2") of the camshatt pulley with front housing timing mark. 20. Remove the timing belt rom the camshaft pulley. Caution + Remove the timing belt and secure it out of the way to prevent damage during removal and installation of the cylinder head. 21. Remove the cylinder head cover. 22. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. :3. Remove the front axle housing mounting bolts. (4 x 4) THING BELT ‘ON-VEHICLE MAINTENANCE INSPECTION 1. Before disassembling the pision and connecting rod, check the oscillalion-torque as shown in the figure. It the large end does not drop by its own weight, replace the piston or ihe piston pin. INSTALLATION, 1. Apply a liberal“amount of clean engine oil to the cylinder walls, piston, and rings. 2. Check the piston rings for the end gap alignment. 3. Insert each piston assembly into the cylinder block with the F mark facing the Iront of the engine. Use a piston installer tool (commercially available). 4, Align the matching mark in the large end of the connecting rod. 2 Tightening torqui oa 65~69 N-m (6.6-7.0 kg-m, 48-51 Ib-tt) Remove any dirt or other material from the contact surface. Apply 2 continuous bead of silicon sealant (TORAY SH760M EQUIVALENT OR LOCTITE ULTRA BLUE 587) to the stiffen- er along the inside of the bolt holes, and overlap the ends. 7. Install the stiffener. Tightening torque : 7-12 Nem (70-120 kg-cm, 61-104 Ib-in) 8. Install the oil strainer and a new gaskel. Tightening torqu 8-12 Nem (80-120 kg-cm, 69-104 Ib-in) MATCHING, Manik SILICON | SEALANT ENANCE ENGINE (FE SUnC) 104-15 Caution — — as + Secure the front axle and propellar shaft as shown in the figure, 24, Remove the gusset plate. (Prassus. | ks mA | [ve 25. Remove the oil pan and clutch under cover. i 26, Remove the oil strainer. here —a-} -})_stieFeNER 27, Remove the stiffener. oDs, rn te OIL STRAINER nea aA 8. Remove the connecting rod caps and connecting rod bear- e $.To remove, push up the large end of each connecting rod [7 ,,. | Ewith a hamimer handle and remove it from the tap side of the | Sar | = Cylinder block. Ble | ‘Caution \ ALP i * Be careful that the connecting rod bolt treads do not \ \s & i = damage the crank pins. | aA i Zi. Before removing the pistons and the connecting _ rods, write the cylinder numb="s. \e . | 3 Miter removal, leave the ‘necting rod caps, => attached to the connecting ru. 9. Apply a continudus bead of silicon sealant (TORAY SH780M EQUIVALENT OR LOCTITE ULTRA BLUE 587) to the oil pan along the inside of the boll holes, and overlap the ends. 10. Install the oil pan Tightening torque : 7=12. Nm (70-120 kg-cm, 61-104 Ib-in) 11, Before installation, apply silicon sealant (TORAY SH760M EQUIVALENT OR LOCTITE ULTRA BLUE 587) to the shad- ed area shown in the figure. Install the clutch under cover. 12. Install he gusset plate. Tightening torque : 37-52 N-m (3.8-5.3 kg-m, 28-38 Ib-fl) 43. Tighten the front axle housing mounting bolts. Tightening torque : 49~80 N-m (5.0-8.2 kg-m, 36~59 Ib-tt) 14, Install the under cover. 15. Thoroughly remove all dirt, oil or other material from the top of the cylinder block. 16. Place the new cylinder head gasket in position. 10A-18 ENGINE (FE SUNL) OtvEHiL 17. Install the cylinder head, 48. Apply engine oil to the bolt threads and seat faces 19. Tighten the cylinder head bolts in two or three steps in the order shown in the figure, Tightening torque : 80-86 N-m (8.2-8.8 kg-m, 59-64 Ib-ft) 20. Be sure that the liming mark on the front housing and the * $2" mark on the camshat{ pulley match. © + 21. Install the timing belt with it keeping stain at the tension side. ©. Caution + The timing belt must be reinstalled in the same direction of previous rotation, if itis to be reused. + Be sure that there is no oil, grease, or dirt on the timing belt. 22. Loasen the tensioner lock bolt. £23. Tum the crankshatt twice in the direction of rotation, align to =. the matching mark. 24. Chack to see that the timing marks are correctly aligned It not aligned, remove the timing belt and tensioner repeat the above-mentioned procedure. TENSIONER Lock Bout & ON-VEHICLE MAINTENANCE ENGINE (FE SOHC) 10A-19 26 Measure the tension between the crankshaft pulley and the camshatt pulley. a if the timing belt tension is not correct, loosen the tensioner lock boll and repeat steps 23-25 above or replace the ten- sioner spring. Standard timing belt deflection : 4-5 mm (0.16-0.20 in) / 98N (10kg, 2216) 27. Install the lower and upper timing belt cover with a new gas- ket Tightening torque : 7-10 Nem (0.7-1.0 kg-m, 61-87 Ib-in) 28. Adjust the valve clearance (Refer to page 10A-9). 29. Apply silicon sealant to the shaded areas shown in the fig- ure), 20. Install he cylinder head cover. Tightening torque : 6-8 N'm (60-80 kg-cm, 52-69 Ib-in) 31, Install the thermo modulator fan bracket bolls, Tightening torque : 6.4-8.9 Nem (65-91 kg-cm, 56~79 Ib-in) Tightening torque : Bolt : 19-30 N'm (1.9-3.1 kg-m, 14-22 tb-tt) Nut : 19-30 Nim (1.9-3.1 kg-m, 14-22 Ib-ft) i. Install the surge tank bracket ' Tightening torque : 19-30 N-m (1.9-3.1 kg-m, 14~22 Ib-ft) 4. Install the intake manifold stay. =. Tightening torque : 37-52 N-m (3.8-5.3 kg-m, 27-36 Ib-! 98N (10kg) feces | r= wy eS a “By 5 10A-20 ENGii& (FE Sizi1C) ON-VEHICLE MAINTENANCE 35. Place the new gasket in position with the ridge f cylinder head. Install the exhaust manifold and tighten the nuts in two or three steps. Tightening torque : 34-49 Nem (3.5-5.0 kg-m, 25~36 Ib-ft) 36. Install the exhaust manifold insulator, Tightening torque : 19-30 N-m (1.9-3.1 kg-m, 14-22 Ib-ft) - Install the ignition coil and connect the high tension leads, Tightening torque : 19-30 N-m (1.9-3.1 kg-m, 14-22 Ib-ft) 38. Connect each hoses as shown in the figure. Brake hose Heater hose Fuel filter hose | j | | i TORE UNVerILLe MAINIENANLE ENUING (TE SUNY) IvH-e! 39, Connect the engine harness connectors. waa? ‘AIC compressor connector Ignition coil connector ‘injector connector = Crank angle sensor cogs oaraeneres O, sensor connecter 9. Purge solenoid connector Airflow meter connector 10. ISC connector Alternator connector Throttle position sensor connector nnect the water upper hose. ution Position the hose clamp in the original location on the hose. [ghtening torque : BE 9.8-14.7N-m (1. Te suney or 42, Install the Iresh air duct. Tightening torque : 8-11N'm (80-110kg-cm, 69-80 Ib-ft) 43, Adjust the bell deflection. (Refer to page 104-7) 14, Connect the negative battery cable. ‘5. Add the specified amount of the engine coil. (Refer to Sectin 11) 6. Close the drain pug, fil the radiator and reservoir tank with the specified amount and type of coolant, (Reler to page 10A-7) 7. Warm up the engine to the removal operating temperature following + Engine oil and engine coolant leakage. + Recheck the engine oil and engine coolant levels. + Adjust the vaive levels. {OVAL sconnect the negalive battery cable, emove the undercover and drain the engine coolanl(Refer » Section 12). rain the engine oil{Refer to Section 11). aution Start and stop the engine and release fuel pressure by disconnecting the electrical connector of the fuel pump. emove the fresh air duct. - the accelerator cable, gjove the upper and lower water hose. jove the exhaust pipe, Toa , sensor connector 9. Purge solenoid connector Air flow meter connector 10.1SC connector Alternator connector Throtile position sensor connector . AIC compressor connector Ignition coil connector Injector connector . Crank angle sensor PeENe exon 8. Disconnect each hoses as shown in the figure. . Brake hose 4, Purge hose 2 Heater hose 5. Air hose 7 Fuel filter hose z = Caution a CavErthe hose with a rag because fuel will spray ~~ gut Wien disconnecting. Keep inflammable out of tuel. Plug the hose to avoid fuel leakage after removing the hose. 10, Remove the radiator gril 11, Remove the A/C condenser fan. 12, Remove the bonnet lock stay. 13. Remove the bonnet cable(Refer to Section 60). 14, Remove the front shroud pannel 'S, Remove the A/C condenser. 16. Remove the shroud and iadiator(Reler to Section 12). BONNET Lock say Tons or (8, Remove the front prapeller shalt 19, Disconnect the speed sensor connector. 20. Disconnect the backup tamp switch connector. 21. Disconnect the xd indication lamp switch connector, 22. Remove the release cylinder. gree the transmission tightening bolts. £ = Support the transmission with transmission jack Remove the cross member bolts and lower the transmission slowly. é Agmove the engine mounting bolts, Yafig a chain block on the engine hanger and raise the ec slowly, . Clutch cover (MTX), Backing plate (ATX) . Clutch disc (MTX), Drive plate (ATX) 2 Flywheel and crank angle-target (MTX) Adapter (ATX) End plate Olt pan 7. Oil strainer 8. Stifener 9. Rear cover 40. Water pump assembly 11. Oil pump assembly |. Ramove the clutch cover with the SST. 2, Remove the flywheel, 3. Remove the end plate attaching bolts and remove the end plate. 4. Remove the oil pan mounting bolts. 5.. Insert a scraper or a suitable tool between the oil pan and “=; the stiffener or the cylinder block to separate them, Remove the oil pan Remove the oil strainer. Remove the stiffener. E mie cuuTeH -COVER, Se STIFFENEAL ‘ 4 STRAINER ‘A-38 ENGINE (FE SOHC) oisasseMmaLy, Remove the rear cover. Remove the oil pump assembly. { lL PUMP ASSEMBLY _ 10A-40 ENGINE (FE SOHC) visassemaly 1 + Connecting rod side clearance. (Refer to page 104-56) + Grankpin oil clearance. (Refer to page 104-56) Before removing the main bearing caps, clean the bearings, main journals. eral caps, and measure the following points. + Crankshaft end play. (Refer to page 104-55) + Main journal oil clearance. (Refer to page 108-55) Remove the connecting rod cap and remove the connec: rod and piston. Remove the main bearing cap mounting bolls and remove the main bearing cap. Remove the crankshatt Remove the pilot bearing from the crankshatt with the SST. Before removing the connecting rod, clean the bearing, con necting rod, and crankpin, and measure the following points. MEASURING PLACE CYLINDER BLOCK-II Connecting rod cap Connecting rod bearing ton ring Main bearing cap Connecting rod, and piston pin - Crankshaft Pilot bearing Main bearing Cylinder biock oisasseMacy ENGINE (FE SOHC) 10A-41 check 7, Belore disassembiing the piston and connecting ro the oscillation torque as shown in the figure, It the large end does not drop by its own weight, replace the piston or the piston pin. 8. Remove the piston gin with the SST. ETE CeORTE-+7; CoE TORTS !0A-42 ENGINE (FE SOHC) INSPECTION AND REPAIR NSPECTION AND REPAIR Jean all parts, taking care lo remove any gasket Iragments. dirt, oil or grease, carbon, moisture residue or other foreign materials. Inspect and repair must be performed in the order specified, Caution + Be careful not to damage the joints or friction surfaces of aluminum alloy components (such as the cylinder head or pistons). cylinder head Inspect the cylinder head for damage, cracks, and leakage of water or oil. Replace if necessary. Measure the cylinder head distortion in the six directions shown in the figure. Distortion : 0.18 mm (0.006 in) max. It the cylinder head distortion exceeds specification, grind the cylinder head surface. Ifthe cylinder head height is not within specification, replace it Height : 91.95-92.05 mm (3.620-3.624 in) Grinding limit : 0.20 mm (0.008 in) max. Note + Before grinding the cylinder head, first check the following. Replace if necessary. + Sinking of valve seat + Damage of manifold contact surface. + Camshaft oil clearance and end play. Measure the manifold contact surface distortion in the six directions shown in the figure. Distortion : 0.15 mm (0.006 in) max. It distortion exceeds specification grind the surlace or replace the cylinder head, ALVE ra tive and valve guide S creutie Inspect each valve for the following. Replace or resurface if " necessary. ' + Damaged or bent stem «Roughness or damage to face. 1 + Damage or uneven wear of stem tio Check the valve head margin thickness. Replace if neces- | sary. 7 : vane rac = Margin thickness MARGML a cs a | IN : 0.5 mm (0.020 in) min. EX : 1.0 mm (0.039 in) min. INSPEU HUN nie 3. ateaaure the valve length, Lenath IN: 111.89mm (4.4051 in) EX : 111.69 mm (4.9972 in) 4, Measure the valve stem diameter. Diameter 5 IN : 7.980 mm (0.3142 in) s BX : 7.975 mm (0.3139 In) . Subtract the outer diameter of the valve stem from the inner ciameter of the corresponding valve guide. Maximum : 0.20 mm (9.0079 in) If the clearance exceeds the maximum, replace the valve and/or valve guide. Check that the valve guide projection height (dimension A in the figure). Replace if necessary. Gradually heat the cylinder head in water to approx. 39% (194 °F), vaLve Guide 1 wvesren | vatve } Gvunoen HEAD TORT 10A-44 ENGINE (FE SOHC) INSPECTION AND REPAIF Caution . + Although the shapes of the intake and exhaust valve guides are different. 2, Remove the valve guide from the side opposite the combus- tion chamber with the SST. Installation 1. Gradually heat-the cylinder head in water to approx. 900 (194°F). 2. Tap the valve guide in from the side opposite the combus- tion chamber with the SST until the projection height is as specified Valve spring 1. Inspect each valve spring for cracks or damage. 2. Check the free length and angle: Replace if necessary. Free length Outer : 52mm (2.047 in) Inner : 44mm (1.732 in) Angle ‘Outer : 4.8mm (0.07 in) Inner : 1.5mm (0.05 in) JSP LION AND REPAIR ENGINE (2S SUNC) WAS valve seat 1. Inspect the contact surface of the valve seal and valve face for the following, + Roughness . Damage 2. If necessary, resurface the valve seat with a 45° valve seat culter and/or resurface the valve face. wae 3. Apply @ thin coat of prussian blue to the valve face —s 4. Check the valve seating by rotating the valve against the | seat (1) If blue does not appear 360° around the valve face, replace the valve, (2) If blue does not appear 360° around the valve seat, resurface the seal. co 5, Check the seat contact width. 7 Width : 1.2-1.6 mm (0.047-0.063 in) | ‘SEAT CONTACT} Bibre sition the timing belt guide on the liming belt pulley. ming belt cover stall the lower timing belt cover, upper timing belt cover, and w gaskets. Tightening torque 7~10 Nem (70-100 kg-em, 61~87 Ib-in) ankshatt pulley stall the damper pulley. Tightening torque : 12-17 Nem (1.25~1.75 kg-m, 109-152 Ib-in) Ive clearance fi just the valve clearance. (Refer to page 104-9) inder head cover Apply silicon sealant to the shaded areas shown in the fig- ure. nstall the cylinder head cover. Tightening torque : 6~8 N-m (60~80 kg-cm, 52~69 Ib-in) LOWER THANG © cover ASSEMBLY ENGUVE(PE DUM} 1UA-99. AUXILIARY PARTS 1, Install the oil edoler housing. 2. Install the oil cooler and tighten the nuts. htening torque 29-39 N-m(3.0-4.0 kg-m, 22-29 Ib-ft) 3. Apply a small amount of engine oil fo the rubber seal of the oil filter. 4, Turn until the rubber seal contacts the oil cooler. Then tight- en it 1~1/6 turn with a wrench. 5. Install the intake manifold assembly Tighteriing torque : Bolt : 19 ~ 30 N'm(1.9-3.1 kg-m, 14-22 lb-ft) Nut 19 ~ 30 Nem(1.9-3.1 kg-m, 14-22 lb-ft) Connect the oil cooler hose. Install the intake manifold stay and then lighten bolts. Tightening torque : 37-52 N-m{3:8-5.3 kg-m, 27 ~ 38 Ib-fl) Install the thermostat, gasket and thermostat cover(Refer to Section 12). Install the engine hanger. Tightening torque : 19 ~ 30 N-m(1.9~3.1 kg-m, 14~22 lb-ft) Install the coolant inlet pipe and bypass pipe. Tightening torque : 19-30 N-m(1.9-3.1 kg-m, 14-22 Ib-ft) |. Install the ignition coil bracket, Tightening torque : £12. Install the ignition coil. Tightening torque : 49-30 Nem (1.9-3.1 kg-m, 14-22 Ib-ft) 3. Connect the high tension leads securely. 4. Install the exhaust manifold gasket. 5. Install the exhaust manifold. Tightening torque : 34~ 49 N-m(3.5~5.0 kg-m, 25-36 Ib-ft) 6. Install the exhaust manifold insulator. = Tightening torque : =. 19 ~ 30 Nem(1.9 ~3-1 kg-m, 14-22 lb-ft) A-66 ENGINE(FE SOHC) assematy Install the alternator bracket and then the allernator(Reler to Section 32). Install the power steering pump bracket and then the power steering pump(Refer to Section 31). Install the AJC compressor bracket and then the A/C com pressor. install the oil level gauge. Remove the SST from the cylinder bec and then install the engine mount. . Tightening torque : 31-46 Nem (3,2-4.7 kg-m, 23-34 Ib-tt) TORIES Addi ab LLATION SNGINE(FE SUM) 1UA-0/ INSTALLATION 1, Hang a chain block on the engine hanger and install the engine slowly in the engine room. 2. Tighten the engine mounting bolts. Tightening torque : 31-46 Nm (3.2 ~ 4.7 kg-m, 23-34 Ib-ft) 3, Install the transmission and gusset plate(Refer to Section 41), ee, 4, Install the starter motor(Reler fo Section 31). 5. Install the release cylinder. Tightening torque : 19-25 Nem (1.9 ~ 2.6 kg-m, 14-19 Ib-ft) Connect the 4x4 indication lamp switch connector. Connect the backup switch connector. Connect the speed sensor connector. 6 7 a Install the front propeller shaft(Refer to Section 43). 0. Connect the A/C pipe and tighten the bolts. t Install the AIC condenser(Refer to Section 62). 10A-68 ENGINE(FE SOHC) INSTALLATION 12. Connect the bonnet cable(Refer to Section 60). 18, Jnstall he bonnet lock stay(Reler to Section 60). 14, Install the AC condenser fan(Refer to Section 62). 45. Install the radiator aril 18. Connect each hoses as shown in the figure. — | | | | 1. Brake hose 4, Purge hase 2. Heater hose 5. Air hose | 3. Fuel filter hose - 47. Cornect each connectors as shown in the figure, 5. Q, sensor connector 9. Purge solenoid valve connector 2. Ignition coil connector 6. Airflow meter connector _—_10.ISC connector 3. Injector connector 7. Allemator connector 4, Crank angle sensor connector 8. Throttle position sensor connector 18, Install the exhaust manifold. Tightening torque : 40-55 Nm (4.1-5.8 kg-m, 30-33 Ib-ft) £19. Connect the upper and lower waler hose. $20. Install the accelerator cable and adjust the freeplay. ightening torque : = 9.8-14.7 Nim (1.0-1.5 kg-m, 7.2-10.8 lb-ft) Freeplay : 1-3 mm (0.099-0.118 in} 104-70 ENGI FE SOHC) INSTACLATION 21. Install the fresh air duct. Sonnect the negative battery cable. ad the specified emount of the coolant(Reler to Section 12) 24. Add the specified amount of the engine oil(Refer to Section 11). 25, Alter driving test, chéck the coolant and engine oil amount again. SPECIFICATION ENGIN! SPECIFICATION SERVICE DATA {FE SOHC) 108-71 agen FETE ‘ype in-line, 4 cylinders ‘Combustion chamber Mullispherical “Valve system OHC, belt - driven (Displacement ‘ce (eu in) 1998 (122) (Bore and stroke am {in} 86.0 x 86.0 (9.38 x 3.38) 1 corseaton ees ware | Tae ce sree vein M [eee iets Meas Close ‘ATOC 1 ae i 22 091 clearance mm (in) | EX | 0.3 (0.012), MTX { 800.50 waespert tof ME so inlet Beer 6 Firing order \A-72 ENGINE (FE SOHC) seAvice SPECIAL TOOL SERVICE SPECIAL TOOL (0K993 120011 xs80 11 001 for sina gear ene Le. fer sana brake set Engng rotation" spring ter See : 8 oKess 120 004 cso 160010 For ' fer Pivot, valve removal and Centering tool, ‘instatfation of ting ter instalation of clutch dso : Ghtch ise | : okato 111 012 | oxaa1 110 480 - i fer Polen, ‘ removalsi | Pistripn removal end ae fatewig | cote IQR: | fanunenr £ | piston pins oK710 120 011 ; 04201 169.069 { | | a) fer { Diagnostic ee fomoval’ | Kae FR] | scan a valve guide c=] insaliaion — | hates | oksa0 990007 | erie 101002 ror for Engine Gieessemtiy and | Engine disassembly ans stand ‘| assembly of | stand hanger | assembly of lr engine engine vy ek ENGINE (FE DOHC) [gggeeeiTe DESCRIPTION .. 108-3 TROUBLESHOOTING GUIDE 10B- 4 TUNE-UP PROCEDURE 10B- 6 DISASSEMBLY ....... 20B- 9 INSPECTION AND REPAIR 108-19 ASSEMBLY 108-31 SPECIFICATIONS .. 108-52 SERVICE SPECIAL TOOL . 108-53 DESCRIPTION ENGINE (FE DOHC) 108-3 DESCRIPTION FE DOHC engine is a 4 cylinder averhiead camshaft engine and its compression ratio is 9.2. The cylinder head is made of the aluminium alloy of good heat conductivity and heat resistance and has a pentroof combustion chamber with ¢ vaives (IN: 2 EX: 2) per cylinder. The cylinder block is cast-iron with no sleeves. Five main bearings support the i, and the front and rear crankshatt oil seals are a one-piece esign. Piston pins are pressed into the small end of the connecting rod and ffoat in the piston. The large end of the connecting rod has replaceable insert bearings. Grooves al ihe rod and cap parting face provide oil to lubricate the cylinder walls and coo! the pistons. Pressurized oil lubricalion is supplied by a pump located in the [ront of the orankshalt. The oil is routed through the pump inlet screen, oll pump, and full low filler to Mersvankshaft main and connecting rod bear- ings, to the camshaft bearings and vaive rocker arms. The 2.0L engine has a Sequential Multiport Fuel Injection (SFI) system. Hydraulic lash adjusters are used to reduce noise. Engine cooling is provided by a water pump mounted on the front end of the engine cylinder block. A therrmo- stat controls coolant temperalure and is (ocated in the water outlet housing at the front of the cylinder block. An thermo modulated fan is mounted on the front side of the engine. The fan is controlled by the bimetal. 0B-4 ENGINE (FE OOHC) TROUBLESHOOTING GUIDE ‘ROUBLESHOOTING GUIDE PREEr T ~Possibie Cause : Retlon ; DIROn Rng iaaretan of angina nie Someta : | Burned valve Replace | ‘Warn piston, piston ing, 6 eyinder ace or repair ' Failed cyinder head casket | replace i Malfunction of fei system | Reterio Section ea _—~i| Malfunction of ignition system Refer ts fection 30 + Foor laiing ~ aifunction of engine-related componenia 7 - | Maitunction of HLAY =| Replace * * Poor valve-towalve sea! contact Replace or repair Falled cylinder head gasket Replace |_ Malfunction of fuel system 7 Reler to Section 22 [Citatanotion of anton system Fel te Seaton 30 | Excessive oll Oil working up 7 1 ‘iota piston or eyinder Replace or epair | Olt working down ~ ‘Worn valve seal Replace { | Worn vatve stem or guido Replace i | Olieakage | Beterio Seaton 11 InSovnclent power fae | iamullclen commeresstan = | Mallunctioh of HUY Replace } Compression leakage trom valve sest Repair j Seized valve stem Replace | ‘Weak or broken valve sping Replace Failed cyinder head gasket Replace Cracked or eistoted cylinder head | Reslace | Sticking, damaged, of wom piston ring Replace Cracked or worn piston Replace ‘Malfunction of fuel system Reler > Section 22 “failunction of ignition eysiem | Refer Section 30°) Others a Slipping clutch Reler to Section 40 i Dragging brakes Reler to Section 52 z Wrong sizo tires Reler to Section 53 Abnormal | “Malfunction of englne-related component combustl Mallunction of HLA* Replace Sticking or burned valve Replace ‘Weak or broken valve spring Replace Carbon accumulation in combustion chamber Eliminate carton | "Haitunetion offuel systems eter to Section 22 ~faltunction of ignition system — Fiero Section 30 i _ 2UBLESHOOTING GUIDE ENGINE (FE DONC) 108-5 Possible Cause of bearing-related paris Excessive main bearing oil clearance Action 1 ‘Crankshat ae Replace or repair Main bearing seized or heat-damaged Replace Excessive crankshalt end pl ness a Replace or repair Excessive connecting rod bearing oll clearance Connecting rod bearing seized or heat-damaged Piston-related parts Replace or repait Replace Worn eylinder Replace or repair ‘Worn piston oF piston pin : Replace Seized piston Replace ie Damaged piston cng Replace Bent connecting tod place Valves or timing-related paris Mellunction of HLA Broken valve spring Replace Replace Replace, Rotor io Section 12 Reler to Section 22 Excessive valve guide clearance Malfunction of cooling system Malfunction of fuel system | ‘others . Malluntion of water pump beating lmpeope div bl tension Maltuntin of alterator beating Sihaust gas leakage Matluntion of tiring belt tensioner Rater to Section 12 Adjust Rater to Section 20 Roter to Section 22 Replace 108-6 ENGINE (FE DOHC) TUNE. i PROCEQURE _ TUNE-UP PROCEDURE Tune the engine according to the procedures described below. Battery 1. Check for corrosion on the terminals, or loose cable connec: tions. ‘necessary, clean the clampt and tighten firmly. 2, neck that the electrolyte level is between the UPPER and LOWER. marks, Add distilled water if necessary. 3. Check the specific gravity by using a hydrometer, II the specific gravity reading is 1.200 or less, recharge the battery. (Refer to Section 22) Air cleaner element Visually check the air cleaner element for excessive dirt, dam- age. or oil, Clean cr replace if necessary. Caution + When cleaning the air cleaner element, below dust off from the inside completely first, then blow from the outside. WEAR AND ADHESION (OF CARBON Check the following points, Clean or replace if necessary. Spark plug Damaged insufation 1 2. Wor electrodes “BURNT 3. Gatbon deposits eee 4, Damaged gasket { BeresoRnore 8. Bumt spark insulator 8. Plug gap ~pamace, 1.0-1.1 mm (0.039-0.043 in) Engine oif \ Gheck the engine oil level and condition wih the of level gauge, Add oil, or change it, if necessary. TUNE-UP PROCEDURE ENGINE (FE DOHC) 108-7 Coolant level (cold engine) 1, Check that the cootant level is near the radialor inlet por. 2. Check that the level in the coolant reservoir is between the FULL and LOW marks, Warning + Never remove the radiator cap while the engine is hot. « Wrap a thick cloth around the cap and carefully remove it. ive belt 4. Check the drive belt for wear, cracks, or fraying, . Replace if necessary. 2. Check the drive belt deflection by applying moderate pres- sure (98 N, 10kg, 22 Ib) midway between the pulleys. a S 10 (0.31-0.39) | 9-11 (0.35-0.49) (.27-0.35) | 8-10 (0.31-0.39) ‘COOLANT RESERVOIA TANK ORDO IC COMPRESSOR FAN PULLEY ALTERNATOR PULLEY is PUMP . CRANK SHAFT PULLEY IDLE PULLEY PULLEY High-tension lead Check the following points. Clean or replace if necessary. 1. Damaged lead 2. Carbon deposits Hydraulic lash adjuster (HLA) Note + Tappet noise may occur if the engine is not operated for an extended period of time. The noise should stop after the engine has reached normal operating temperature. 1. Check for tappet noise, points. (1) Engine oil condition and level (2) Engine oil pressure (Refer to Section 11) It the noise does not stop, check for movement of each HLA by pushing it during disassembly. Ifthe HLA moves, replace the HLA. (Refer to page 108-25) IU noise exists, check the following Ignition timing and idle speed Warm up the engine and run it at idle. 2. Shit the selector lever to neutral position. 33. Set the wheels in the straigh-ahead position, 24, Turall electric loads OFF. £5. Connect a timing light and SST (KJ-t). ” HARNESS: CONNECTOR Fredicen i 20 rast ecu 08-8 ENGINE (FE DOHC) tune-up PROCEDURE Check, that the ignition timing mark (yellow) on the crankshaft pulley and the timing mark on the timing belt cover are aligned. Ignition timing : 4° +6" BTDC (at idle speed) Car + Itis not necessary to adjust the ignition timing. Check the idle speed. oe Idle speed : 800 + 50rpm Caution + The idle speed is controlled automatically by the engine control unit through the idle speed control {ISC) solenoid valve, it is not necessary to adjust the idle speed. ompression he engine exhibits low power, poor fuel economy, or poor 2, check the following Ignition system (Reler to Section 30) Compression Fuel system (Refer to Section 22) spection Check that the battery if fully charged. Recharge it it necessary. Warm up the engine to normal operating temperature. Remove the center cover. Disconnect the high tension lead and ignition coil Remove all spark plugs. Connect a compression gauge to the No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Record the maximum gauge reading. ° Check each cylinder. kPa (kgleme, pi-rom Standard 1285 (13.2, 188) ener [Ciniearn {807 (9.8, 139) co { the compression in one or more cylinders is low, pour a 7 small amount of engine oil into the cylinder and recheck the ompression, 1) If the compression increases, the piston, piston rings, or cylinder wall may be wom. 2) If the compression stays low, the valve may be stuck or seating improperly. , 5 3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be defective or the cylinder head distorted. ills isstt DISASSEMBLY 1, Remove in the sequence shown in the figure parts. Code all identical parts (such as pistons, piston rings, connecting rods, and vaive springs) so that they can be reinstalled in the cylinder from which they were removed. Clean the paris with steam, below off any remaining water with compressed alt. Note + Care should be taken during the disassembly of any part or system (0 study its order of assembly. + Any deformation, wear, or damage should also be noted. i 10B-10 ENGINE (FE DOHC) pisassemeLy Oil level gauge ‘Thermo modulator fan bracket EGR pipe Exhausi manifold insulator Exhaust manifold assembly Cootant inlet pipe and bypass pipe Engine hanger Allernator ‘Altemator strap and bracket Engine hanger ongine. move the exhaust manifold ; then connect the SST to the 10. Efigine mount bracket 11. Center cover 12. Intake manifold bracket 13. Intake manifold assembly 14, Oilfiter 15. Oil cooler adapter 16. Oilpressure switch Tee J SEE FiMING BELT e , ss = Crankshatt pulley 7.Timing bet ca hhermosiat assembly om peter ploy Jpper timing belt cover 9. Camehatt ite Lower timing belt cover 10. Timing bat ply Timing belt guide plate Timing belt tensioner and spring 108-12 ENGINE (FE DOHC) olsassematy Disassembly 1, Set the SST against the flywheel, 2, Remove the crankshait pulley. Timing helt 1. Loosen the tensioner lock bolt, and remove the tensioner spring. 2. Mark the timing belt rotation for proper reinstallation if it is reused. 3. Remove the timing belt. Caution + Be careful not to allow oil or grease on the belt Camshaft pulley Remove the pulley lock boll using a screw driver to prevent the camshaft from turning, MAKE THE DIRECTION OF ROTATION Tasos Ignition coil and high tension 7. Hydraulic lash adjuster 14, Inner valve shring leads 8. Cylinder head bolt 15. Lower spring seat .. Cylinder head cover 9. Cylinder head 16. Valve Phase sensor 10, Cylinder head gasket 17. Valve stem seal Seal plate 11, Vaive cotter 18 Valve guide Camshaft cap 12. Upper spring Seat ~ 13. Obler valve ecang 10B-14 ENGINE (FE DOHC) disassemeLy DISASSEMBLY mshaft 3efore removing the camshatt, clean the bearings and journals, and measure the following points. ‘Camshait end play. (Refer to page 108-24) Camshatt journal oil clearance. (Refer to page 108-24) 4ydraulic lash adjuster (HLA) jemove the HLA trom the cylinder head. tote Mark each HLA so that they can be reinstalled in the position from which they were removed. sylinder head bolt Sasen the cylinder head bolts in two or three steps in the order fhown in the figure alve emove the valves from the cylinder head with the SST. DISASSEMBLY ENGINE (FE DOHC) 108-15 CYLINDER BLOCK - | > Taba Clutch cover (MTX), Backing plate (ATX) 7. Oil strainer Clutch dise (MTX), Drive plate (ATX) 8 Sliffener Flywheel and crank angle-larget (MTX) 9. Rear cover ‘Adapter (ATX) 10. Water pump assembly End plate : 41. Oil pump assembly Oilpan 12. Oiljet 10B-16 ENGINE (FE DOHC) pisassemaLy 0} SSEMBLY Cit... cover and flywheel Remove the clutch cover and flywheel with the SST. Oil pan 4. Remove thé oil pan mounting bolts. 2. Insert a scraper or a suitable tool between the oil pan and the sliffener or the cylinder block to separate them. 3. Remove the oil pan. Caution + Do not bend the oil pan when prying loose. + Do not damage or scratch the contact surface when removing the oil sealant. DISASSEMBLY ENGINE (FE DOHC) 108-17 >YLINDER BLOCK-II Connecting rod cap 7. Crankshatt 1 2. Connecting rod bearing 8. Pilot bearing 3. Connecting rod and piston 9. Main bearing 4. Piston pin . 10. Cylinder block 3, Piston ring 11. Piston clip (Snap ring) 5. Main bearing cap 10B-18 ENGINE (FE DOHC) oisassematy DISASSEMBLY Connect rod and cap Before removing the connecting rod, necting rod, and crank pin, and measure the following points, {Connecting rod side clearance, (Refer to page 108-35) 2. Crankpin oll clearance. (Refer to page 108-33) clean the bearing, con- Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the following points, 1. Crankshaft end play. (Refer to page 108-34), 2. Main journal oii clearance, (Reler to page 108-33) Pilot bearing Remove the pilot bearing from the crankshaft with the SST. ?iston and connecting rod Betore disassembling the piston and connecting rod, check the oscilation torque as shown in the figure, Ii the large end does not drop by its own weight, replace the piston or the piston pin, Remove the piston pin with the SST, MEASURING PLACE INSPECTION ANO REPAIR ENGINE (FE DOHC) 108-19 |NSPECTION AND REPAIR 1. Clean alll parts, taking care to remove any gasket fragments, di, oll or greaée, carbon, moist or other foreign materials. 2. Inspect and repair must be performed in the order specified, lure residue, Caution + Be careful not to damage the Joints or friction surfaces of aluminum alloy components as the cylinder head or pistons). (such Cylinder head fe. 1. Inspect the cylinder head for damage, cracks, and leakage of water or oil. Replace if necessary. 2. Measure the cylinder head distortion in the six directions shown in the figure, Distortion : 0.15 mm (0.006 in) max. TAT 3. If the cylinder head distortion exceeds specification, grind the cylinder head surface. I the cylinder head height is not within specification, replace it Height : 133.95~134.05 mm (5.274~5.278 in) Grinding timit : 0.20 mm (0.008 in) max. Note + Before grinding the cylinder head, first check the following. Repiace if necessary. + Sinking of valve seat + Damage of manifold contact surface + Camshaft oil clearance and end play |. Measure the manifold contact surface distortion in the six directions shown in the figure. Distortion.: 0.15 mm (0.006 in) max. = ae (©0081) SBS Naas . It distortion exceeds specification grind the surface or PSE eT] replace the cylinder head. | RG 10B-20 ENGINE (FE DOHC) INSPECTION ANO REPAIR, (1) Damaged or bent stem (2) Roughness or damage to face (3) Damage or uneven wear of stem tip 2. Cheok the valve head margin thickness, Fleplace if neces- sary. Margin thickness IN : 0.85 mm (0.033 in) min. EX : 0.9 mm (0.035 in) min. Valve and Valve guide 1. Inspect each valve for the following. Fleplace or resurface if BS necessary. Mancina ; THICKNESS = yale ea s 4 3. Measure the vaive fength. Length IN: 103.18 mm (4.0622 in) EX : 103.94 mm (4.0921 in) 4, Measure the valve stem diameter, Diameter N EX 970~5.985 mm (0.2350-0.2356 in) .965~5.980 mm (0.2348-0.2354 in) 5. Measure the valve guide inner diameter. Inner diameter {NM : 6.01-6.03 mm (0.2366~0.2374 in) EX : 6.01~6.03 mm (0.2366-0.2374 in) 6. Measure the vaive stem to guide clearance by subtract the outer diameter of the valve stem from the inner diameter of era the corresponding valve guide. 2 Clearance ae |: = iN : 0.025~0.060 mm (0.0010-0.0024 in) ae es 2 EX : 0.030-0.085 mm (0,0012-0.0026 in) cueanance Maximum : 0.20 mm (0.0079 in) ; “3 wal INSPECTION AND ABPAI ENGINE (FE 99 ~ = = HC) 108. SNC) 108-24 7, Ifthe clearance exceeds the maximum, replace the valve andor valve guide - Check that (he valve guide projection height (dimension A in the figure). Replace if necessary. 4 Height : 11.4~11.9 mm (0.449~0,469 in) Replacement of valve guide Note + Although the shapes of the intake and exhaust valve guides are different. ro OT 7 Santer ——$——_ 1. Gradually heat the cylinder head in water to approx. 90% Cer ceg yy al (194°F). 2, Remove the valve guide from the side opposite the cambus- tion chamber with the SST. Installation 1. Gradually heat the cylinder head in water to approx. 90% (194°F). . Tap the valve guide in from the side opposite the combus- tion chamber with the SST until the projection height is as specified. 108-22 ENGINE (FE DOHC) INSPECTION AND REPAIR Valve Seat - +. Inspect the contact surface of the valve seat and valve face for the following (1) Roughness {2) Damage 2. ifnecessary, resurface the valve seat with a 45° valve seat cutter and/or resuriace the valve face. Apply a thin coat of prussian blue to the valve face. Check the valve seating by rotating the valve against the seat (1) Ib blue does not appear 360° around the valve face, replace the valve. 2) If blue does not appear 360° around the valve seal, resurface the seal 5. Check the seat contact width, Width ; 1.2-1.6 mm (0.047-0.063 in) 6. Check that the valve seating position is at the center of the valve face, (1) If the seating position is too high, correct the valve seal, with a 60" cutter and a 45° cutter. (2) If the seating position is too fow, correct the valve seat with a 38° (IN) or 15° (EX) cutter and a 45° cutter. Seat the valve to the valve seat with a lapping compound. Check the sinking of the valve seal. Measure protruding length (dimension L) of each valve stem. ex Dimension L : 36.8 mm (1.449 in) {1) If Lis as below, itcan be used as itis. IN ; 36.37~37.27 mm (1.432~1.467 in) EX : 36.36~37.26 mm (1.431-1.467 in) (2) If Lis as below, insert a spacer between the spring seat and cylinder head to adjust. IN : 37.27-37.97 mm (1.467~1.495 in) EX : 37.26-37.96 mm (1.467~-1.494 in) (9) If Lis more than as below, replace the cylinder head. IN ; 37.97 mm (1.495 in) EX: 37.96 mm (1.494 in) SEAT CONTACT ‘widTH 7a ive spring inspect each valve spring for cracks or damage Check the free length and angle. Replace it necessary. Free length Outer Standard : 39.1 mm (1.539 in) Minimum : 38.7 mm (1.524 in) Inner Standard : 38.0 mm (1.496 in) Minimum : 37.7 mim (1.484 ia) ‘Outer : 1.36 mm (0,053 in) max. Inner : 1.33 mm (0.052 in) max, Set the front and rear joumals on V-blocks. B Check the camshaft runout. Replace if necessary leight : 45.052 mm (1.7737 in) BMinimum : 44.852 mm (1.7658 in) E 29.940-29.965 mm (1.1787~1.1797 in) Eepoul-of-round : 0.05 mm (0.002 in) max. 408-24 ENGINE (FE DOHC) INSPECTION ano repatn 5, Measure the oil clearance of the camshaft and camshalt caps. (1) Remove any oil or dirt from the journals and bearing sur- face. (2) Set the camshaft onto the cylinder head. (3) Position plasti-gauge on top of the journals ‘in the axial direction. Fe. (4) Place camshaft caps accoding the cap number and arrow, and tighten them in the order shown in the figure. Tightening torque : 18-26 Nim (1.8-2.7 kg-m, 13~20 Ib-ft) (5) Loosen the camshaft cap bolls in the order shown in the figure. (6) Measure the oil clearance at each cap. ii clearance : 0.035-9.985 mm (0.0014~0.0033 in) Maximum : 0.15 mm (0,0059 in) (7) If the oil clearance exceeds the maximum, replace the camshaft and/or the cylinder head. 6. Measure the camshaft end play. If it exceeds the maximum, teplace the camshaft andlor the cylinder head. End play : 0.08~0.10 mm (0.003~0.004 in) Maximum : 0.20 mm (0.008 in) 5 ¥ po INSPECTION ANO REPAIR ENGINE (FE Dove) tote: hydraulic lash adjuster (HLA) f == 1 Check the HLA face for wear ar damage. + Fold the HLA between your fingers and press it

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