Workshop M

Service Manual2005 Matiz UNIT REPAIR Page 1 of 69
Matiz
UNIT REPAIR
Cylinder Head and Valve Train Components
(Typical Type Shown, Euro III Similar)
Tools Required
09916-14510 Valve Spring Compressor.

09916-37320 Valve Guide Reamer (5 mm).
09916-38210 Valve Guide Reamer (11 mm).
09916-44910 Valve Guide Remover.
09916-48210 Valve Spring Compressor Attachment.
09916-58210 Valve Guide Installer.
09917-88220 Valve Guide Installer Attachment.
KM 412Engine Overhaul Stand.
Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold
attached. Refer to "Cylinder Head and Gasket", "Intake Manifld" and "Exhaust
Manifold" in this section.
file://G:\AUTOCAR\GM-DEAWOO-CHEVROLET\CHEVROLET\DATA\Workshop ... 24/01/2024

2. Remove the rocker arm shaft and rocker arm.

 Remove the bolts (1).
 Remove the rocker arm shaft (2).
 Remove the rocker arm (3).
3. Remove the camshaft.

 Remove the screw (1).
 Remove the camshaft plate (2).
 Remove the camshaft (3).
Notice : Removing the camshaft, take extreme care to prevent any scratch, nick
or damage.
 Remove the camshaft front oil seal from housing hole (4).

4. Remove the valve keepers.

 Using the valve spring compressor 09916-14510 with the valve spring
compressor attachment 09916-48210, compress the valve springs (1).
 Remove the valve keepers (2).

5. Remove the valves.

 Remove the valve spring retainer and valve springs (1).
 Remove the valves (2).
6. Remove the valve stem oil seals.

 Remove the valve stem oil seals (1).
 Remove the valve spring seat (2).
Important : Do not reuse the removed oil seals. And the removed oil seals
should be replaced by new one.

7. Remove the valve guide.

 Position the valve guide remover 09916-44910 on the valve guide.
 Hammer and remove the valve guide from the combustion chamber to the
direction of the installed valve spring using the valve guide remover 09916-
44910.
Important : The removed valve guide should be replaced by new one of

oversized. Do not reuse the removed valve guide.

Inspection/Measurement/Adjustment Procedure
Abrasion of The Cam
1. Measure the height of the cam using a micrometer, and replace the camshaft when
the measured valve is less than the specified limit.
Unit : mm (in.)
Item Standard Limit
IN 35.156 (1.3841) 35.124 (1.3828)
Height of the cam
EX 34.814 (1.3706) 34.789 (1.3696)

Measuring The Camshaft Bend
1. Measure the bending of the camshaft using a dial gauge, and replace it when the
measured value is over the specified limit.
Unit : mm (in.)
Item Limit
Bending Limit 0.03 (0.0012)

Abrasion of The Camshaft Journal
1. Measure the outer diameter of each journal at the 4 different places (1).
2. Using a bore gauge, measure the inner diameter of the cylinder head journal at the 4
places (The clearance of journal is measured by the difference between the outer
diameter of camshaft journal and inner diameter of cylinder head journal part (2).
3. Replace the camshaft (or cylinder head, if necessary) of which limit is over the
specified limit.
Unit : mm (in.)
Item Standard Limit
Journal clearance 0.05-0.091 (0.0020-0.0036) 0.15 (0.0059)

Unit : mm (in.)
Item Outer diameter, camshaft journal Inner diameter, cylinder head journal part
Standard 43.425-43.450 (1.7096-1.7106) 43.500-43.516 (1.7126-1.7132)
a
Limit 43.375 (1.7077) 43.525 (1.7136)
Standard 43.625-43.650 (1.7175-1.7185) 43.700-43.716 (1.7205-1.7211)
b
Limit 43.575 (1.7156) 43.725 (1.7215)
Standard 43.825-43.850 (1.7254-1.7264) 43.900-43.916 (1.7283-1.7290)
c
Limit 43.775 (1.7234) 43.925 (1.7293)
Standard 44.025-44.050 (1.7333-1.7343) 44.100-44.116 (1.7362-1.7369)
d
Limit 43.975 (1.7313) 44.125 (1.7372)

Bending of The Rocker Arm Shaft
1. Measure the bending of the rocker arm shaft by using the V block and dial gauge.
2. Replace the rocker arm shaft of which bending is over the limit.
Unit : mm (in.)
Item Limit
Bending Limit 0.10 (0.0039)

Clearance Between The Rocker Arm and The Rocker Arm Shaft
1. Measure the outer diameter of the rocker arm shaft using a micrometer (1).
2. Measure the inner diameter of the rocker arm using a bore gauge (2).
3. Replace the shaft or rocker arm (or both of them, if necessary) if the difference is
over the limit between the outer diameter and the inner diameter.
Unit : mm (in.)
Item Standard Limit
Clearance between the rocker arm and the 0.005-0.040 (0.0002-
0.06 (0.0024)
rocker arm shaft 0.0016)

Clearance Between The Valve Stem and The Valve Guide
1. Measure the outer diameter of the valve stem using a micrometer (1).
2. Measure the inner diameter of the valve guide using a bore gauge (at least 1 place in
the direction to valve length) (2).
3. Measure the clearance between the valve stem and the valve guide.

Unit : mm (in.)
Item Standard Limit
IN 5.465 - 5.480 (0.2152-0.2157) -
Valve stem outer diameter
EX 5.440 - 5.455 (0.2142-0.2148) -
IN 5.500 - 5.512 (0.2165-0.2170) 5.53 (0.2177)
Valve guide inner diameter
EX 5.500 - 5.512 (0.2165-0.2170) 5.53 (0.2177)
IN 0.020 - 0.047 (0.0008-0.0019) 0.07 (0.0028)
Clearance between stem and guide
EX 0.045 - 0.072 (0.0018-0.0028) 0.09 (0.0035)
4. If a bore gauge is not available, measure the clearance using a dial gauge by moving
the edge of the stem to the directions of (a), (b) (3).
5. Replace the valve stem or valve guide, if the measured valve is over the limit.
Unit : mm (in.)
Item Limit
IN 0.14 (0.0055)
Edge of the valve (a)↔(b) Clearance limit
EX 0.18 (0.0071)

Valve
1. Remove all carbon from the valve.

2. Check the valve or stem for abrasion, burn or bending, and replace as necessary.
3. Abrasion of the valve edge.
 Check the edge of each valve for abrasion. Some uneven abrasion would be
made on the edge because the rocker arm gets contacted at this surface when
operating. Repair the section within 0.05 mm (0.002 in.) as required, or replace
the valve if some modification is required more than that (1).

4. Deviation to the rotating direction (2).

 Measure the deviation to the rotating direction using a dial gauge and the V
block by turning the valve slowly.
 Replace valve, if the measured value exceeds the limit.
Unit : mm (in.)
Item Limit
Deviation limit of valve head to the rotating direction 0.08 (0.0031)

5. Checking the contact width (3).

 Clean the valve and the valve seat and apply red stamping ink thinly to the
contacting surface of the valve seat. Check the fitness after installing the valve
unit.
 A good contact shows the equal contact width within the specified.
Unit : mm (in.)
Item Limit
IN 1.46 - 1.66 (0.0575 - 0.0654)
Contact width on the surface of the valve seat
EX 1.46 - 1.66 (0.0575 - 0.0654)
6. Valve seat repair (4).

 Repair by grinding and cutting off the valve seat, and lap it if its contacting width
is not even or out of the specified.
 Upon applying a seat cutter, use the one of smaller angle first and increase the
angle of the using cutter up to the light and final modification of the contact. And
finish contact surface and its location with the cutter of 45 degrees.
Important : Upon cutting, take care of the contact width. Finish the cutting with
gradually reduced power for no cutting mark on the surface.

7. Valve lapping.
 Make lapping in two stages, first with normal lap and second with fine one for
the both sides.
 a. Intake side.
 b. Exhaust side.

Cylinder Head
1. Remove all carbon from the combustion chamber.

2. Be sure not to make scratch on the intake and exhaust ports of the cylinder head, the
combustion camber, and the head surface together with and the valve seats.
3. Flatness of the cylinder head (1).
 Measure the flatness of the 6 different places using a straight ruler and the
thickness gauge. If the measurement is red over the limit of use, confirm the
deformed area by placing it on the flat plate and repair it with fine abrasives.
Replace the cylinder head of which repair is impossible.
Notice : The deformation of the cylinder head surface may cause the loss of
power due to the leakage of the compression.
 Measure the flatness of the cylinder head surface in the location of each 4 side
and diagonal.
Unit : mm (in.)
Item Limit
Deformation limit of the cylinder head flatness 0.05 (0.0020)

4. Deformation of the surface for manifold installation (2).

 Inspect the surface for installing manifold of the cylinder head using a straight
ruler and the thickness gauge and repair the installing surface or replace the
cylinder head if necessary.
Unit : mm (in.)
Item Limit
Limit of the manifold deformation 0.10 (0.0039)

Valve Springs
1. Weakened valve springs can be the cause of chatter, not be mentioned to possibility
of reducing the power output due to gas leakage caused by decreased seating
pressure.
2. Free length of the valve spring (1).
3. Replace the valve springs of which valve spring free length is less than than the limit.
Unit : mm (in.)
Item Standard Limit
Valve spring free length 54.45 (2.1437) 53.40 (2.1024)

4. Spring preload (2).

 Replace the valve springs of which valve spring preload is less than the limit.
Unit : mm (in.)
Item Standard Limit
Valve spring preload 23.4-27.0 (0.9213-1.0630) 22.0 (0.8661)

5. Spring squareness (3).

 Measure the squareness of each spring using a flat plate and the square.
 Replace the valve spring of which clearance is over the limit.
Unit : mm (in.)
Item Limit
Valve spring squareness 2.4 (0.0945)
Installation Procedure
1. Make the valve guide hole using a valve guide reamer 09916-38210.
 Before installing the new valve guide into the cylinder head, ream guide hole
with 11mm reamer to remove burrs. Make sure that the guide hole cones to a
complete roundness (1).

2. Install the valve guide.

 Heat the cylinder head uniformly at a temperature 80-100°C (176-212°F) not to
make the head deformed, and drive new valve guide completely into the hole
with the tools the valve guide installer 09916-58210 with the valve guide
installer attachment 09917-88220.
 Peen and install new valve guide (1).
 After installation, check the protruded part of the guide from the cylinder head
(2).
Important : Do not reuse the valve guide once disassembled, replace it with the
new oversized valve guide.
Unit : mm (in.)
Valve guide oversize 0.03 (0.0012)
Valve guide protrusion 14 (0.5512)

3. Repair the valve guide bore.

 Repair the valve guide bore with the valve guide reamer 09916-37320 (5 mm or
0.1969 in.) (1).
 Make the hole free from foreign material.

4. Install the new valve stem seals.

 Install the valve spring seats (1).
 Install new valve stem oil seal to the valve guide (2).
 After applying engine oil to seal and installing seal to the valve guide and make
sure that seal is properly fixed to the valve guide.
Important : Do not reuse the disassembled oil seal and replace it with new one.
When installing it, never tap or hit tool with a hammer or else. Install seal to
guide only by pushing special tool with hand. Tapping or hitting tool may
cause damage on seal.
5. Install the valves.
Important : Before installing it, coat engine oil to the stem seals, valve guide
bore and valve stem.
 Install the valve to the valve guide (1).

6. Install the valve springs and the spring retainers.

 Install the valve springs (1).
 Each valve spring has top end (large-pitch end) (a) and bottom end (small-pitch
end) (b). Be sure to position spring in place with its bottom end down to valve
spring seat side (2).
 Install the valve spring retainers (3).

7. Install the valve keepers.

 Using the valve spring compressor 09916-14510 with the valve spring
compressor attachment 09916-48210, compress the valve springs (1).
 Install the valve keeper (2).
Important : Coat engine oil to the valve stem oil seals, the valve guide hole, and
the valve stem.
8. Install the camshaft.

 Coat engine oil to the camshaft front oil seal, the cam, and the camshaft journal.
 Install the camshaft front oil seal to the housing hole (1).
 Install the camshaft to the cylinder head (2).
Notice : Installing the camshaft, take extreme care to prevent any scratch, nick
or damage.
 Install the camshaft plate (3).
Tighten
Tighten the screw to 9-12 N•m (80-106 lb-in).

9. Install the rocker arms and the rock arm shafts.

 Coat engine oil to the rocker arms and the rocker arm shafts.
 Install the rocker arms and the rocker arm shafts (1).
 Install the bolt (2).
Tighten
Tighten the screw to 9-12 N•m (80-Tighten the bolts to 9-12 NSm (80-106 lb-in).
(Coat the Loctitte).

 Proceeding procedures when repairing the pistons and crankshaft unit :

- Remove the engine and the transaxle. Refer to "Engine Assembly" in this
section.
- Remove the transaxle from the engine. Refer to Section 5B1, Five-Speed
Manual Transaxle.
- Remove the fly wheel.
- Install the engine overhaul stand KM 412 to the engine assembly as the
figure.
- Drain engine oil from the engine.
- Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this
section.
- Remove the oil pump from the cylinder block. Refer to "Oil Pump" in this
section (In case of repairing the crankshaft unit).

Engine Block Components
Tools Required
09916-77310 Piston Compressor
Disassembly Procedure
1. Remove the components attached around the engine block.

 Remove the power steering/air conditioning belt.
 Remove the bolts and loosen one bolt (lower side) (1).
 Turn the A/C compressor downward.
 Remove the power steering rear bracket bolt/nut and the adjusting bolt (2).

 Remove the A/C compressor bracket bolts (3).

 Remove the A/C compressor, the power steering, and the bracket.
 Remove the bracket (5).
 Loosen the generator bolt (6).
 Loosen the generator lower bolts and the nut (7).
 Remove the generator and belt (8).

 Loosen the engine mount upper bracket bolts (9).

 Remove the generator shackle (10).
 Remove the upper bracket (11).
 Loosen the engine mount lower bracket bolts (12).
 Remove the lower bracket (13).

2. Remove the oil pan and the oil pump pickup tube.
 Remove the nuts (2).
 Remove the oil pan (3).
 Remove the oil pump pickup tube and the oil seal (5).
 Clean the surfaces of the oil pan and the engine block.

3. Remove the connecting rod bearing caps.

 Turn the crankshaft slowly to make the big end of the No.1 cylinder connecting
rod come on the top side.
 Remove the nuts (1).
 Remove the connecting rod bearing caps (2).
 Insert guide hose in the screw side of connecting rod stud bolt to prevent any
damage on the crankshaft pin and cylinder wall (3).
 Mark the order of the crankshaft bearing caps.
 Remove the connecting rod lower bearing.
4. Remove the piston and the connecting rod.

 Remove the piston and the connecting rod by pressing the connecting rod stud
bolt toward cylinder head.
 Remove the upper connecting rod bearing.
 Mark the order of cylinder on the piston and the connecting rod.
 Arrange the piston and the connecting rod of No.2 and No.3 cylinders according
to the sequence as above 2 to 4 procedure.


5. Remove the piston oil rings, and the compression rings, then remove the connecting
rod.
 Using a piston ring expander tool to expand the piston rings, remove the piston
rings.
a. Top compression ring (No.1).
b. Second compression ring (No.2).
c. Piston oil rings (No.3).
 Remove the circlip and pull out the piston pin to separate the piston and the
connecting rod.
d. Circlip.
e. Piston pin.
f. Piston.
g. Connecting rod.
h. Connecting rod bearing cap.
Inspection/Measurement/Adjustment Procedure
Cylinder
1. Wipe out the cylinder wall and check any scratch or excess abrasion on it. Apply
boring with oversize when such damage is over the limits.

 Measure the inner diameter of cylinder with bore gauge in longitudinal and
transverse directions (1).
 There are 3 measuring locations (a, b, c). If beyond specifications, rebore to
next oversize (2).
Unit : mm (in.)
Item Limit
Bore diameter of cylinder Ø 8.570 (2.700)
Taper 0.10 (0.0039) and less
Out of Round 0.05 (0.002) and less
Important : Specification of oversize shall be varied as 0.25, 0.50, 0.75 and 1.00,
and the oversize should be same for cylinder, piston and rings upon boring
and installing. The same oversize on the 3 cylinders should be maintained.

Piston
1. Clean piston with soft cloth and check any damage to determine whether to replace
it.
 Use micrometer to measure the outer diameter of piston. Check the outer
diameter of the piston in the perpendicular direction of the piston pin at 15mm
(0.5906 in.) high from the skirt (1).
Unit : mm (in.)
Standard Ø68.465-Ø68.485 (2.6955 - 2.6963)
Outer diameter of
Oversize 0.25 Ø68.715 - Ø68.735 (2.7053 - 2.7061)
piston oversize
Oversize 0.50 Ø68.965 - Ø68.985 (2.7152 - 2.7160)

 Calculate the different value of the measurement between cylinder inner

diameter (50mm (1.9685 in.) below the head surface) and piston outer diameter
(15mm (0.5906 in.) above the piston skirt) (2).
Unit : mm (in.)
Piston clearance 0.025 - 0.045 (0.00098 - 0.00177)
Important : Upon measuring of cylinder bore diameter and piston outer

diameter, calculate the measured values both in the same directions of
crankshaft and piston pin.

Piston Ring
1. Remove carbon and make the groove clean before inserting the ring, and measure
the clearance between ring and ring land with thickness gauge. If the measured
exceeds the limit, replace the piston (1).
Unit : mm (in.)
Piston ring Standard Limit
0.02-0.06 (0.00079-
Compression ring 0.10 (0.0039)
Ring clearance in 0.0024)
the groove 0.02-0.06 (0.00079-
Second compression ring 0.10 (0.0039)
0.0024)
Piston oil ring 0.06 - 0.15 (0.0024-0.006) -

2. To measure the end gap, insert the piston ring into the cylinder bore with the piston,
locating it at the lowest part of the bore, then use a filler gauge to measure the gap. If
the gap measured exceeds the limit, replace the ring (2).
Unit : mm (in.)
Piston ring Standard Limit
Ring clearance in Compression ring 0.15-0.30 (0.0059-0.0120) 0.70 (0.0280)
the groove Second compression ring 0.3-0.45 (0.012-0.018) 0.70 (0.0280)
Piston oil ring 0.20-0.70 (0.0079-0.0280) 1.80 (0.0709)

Piston Pin
1. Measure the clearance between piston pin and piston boss part, and if the measured
exceeds the standard, replace the piston pin (1).
Unit : mm (in.)
Item Standard
15.995-16.000 (0.6297
Outer diameter of piston pin
0.6299)
16.006-16.014 (0.6302
Inner diameter of piston boss
0.6305)
0.006-0.019 (0.0002-
Piston pin clearance
0.0007)

Connecting Rods
1. Check the big end of each connecting rod for thrust clearance, with the rod fitted and
connected to the crank pin in the normal manner. If the measured clearance is found
to exceed the limit or any damage is found on the thrust surface of both ends, the
responsible connecting rod or the crankshaft must be replaced (1).
Unit : mm (in.)
Connecting rod big end thrust Standard Limit
clearance 0.10-0.25 (0.0039-0.010) 0.35 (0.0138)
2. Check the bending and the twist of connecting rod with the connecting rod aligner,
and if the limit is exceeded, replace it.

Unit : mm (in.)
Item Limit
Bending (a) 0.05 (0.0020) (in case of 100mm (3.937 in.))
Twist (b) 0.10 (0.0039) (in case of 100mm (3.937 in.))
3. Bearing clearance (3).
 Inspect the bearing shell for signs of damage, fusion, burn, etc. and observe the
contact pattern. Bearings found in defective condition through this inspection
must be replaced.
 Measure the oil clearance by using the plastigauge. Prepare, by cutting a length
of plastigauge equal to bearing width and place it axially on crank pin, avoiding
oil hole.
a. Plastigauge

 Install connecting rod bearing and bearing cap and tighten to the specified
torque. At this time, never turn or rotate the crankshaft.
b. Connecting rod bearing.
c. Bearing cap.
Tighten
Tighten the connecting rod bearing cap nuts to 31-35 N•m (23-25 lb-ft).
 Remove the cap, and measure the width of plastgauge with the scale marked
on the plastigauge case. The measurement must be taken at the widest part of
the compression and attention should be also paid to the different values
measured at the both ends of the plastigauge.

Unit : mm (in.)
Standard Limit
Bearing oil clearance
0.020-0.040 (0.00079 - 0.00157) 0.065 (0.00256)
 If the oil clearance exceeds the limit, replace the bearings.
Unit : mm (in.)
Size Standard
Bearing size 37.982-38.000
Outer diameter of crank pin
(1.4954-1.4961)

Crankshaft
1. Remove the engine block.

2. Remove the crankshaft rear oil seal housing.
 Remove the bolts and the nuts (1).
 Remove the gasket and the oil seal housing (2).
3. Remove the crankshaft bearing cap.
 Remove the bearing and the bearing cap (4).
4. After removing the crankshaft, remove the upper bearing.

5. Crankshaft runout.
 Measure runout at center journal with block and dial gauge by turning
crankshaft slowly. If runout exceeds the limit, replace the crankshaft (1).
Unit : mm (in.)
Limit on runout 0.03 (0.0012)
Important : To measure runout, turn crankshaft once to be matched with dial

gauge on the journal part, and read and take 1/2 value of the maximum gauge.

6. Crankshaft thrust play

 Install crankshaft thrust bearings and journal bearings on the engine block, and
tighten bearing cap bolt to the specification, then measure the axial play of
crankshaft. If the measured exceeds the limit, replace the thrust bearing with
the new standard one or the one of the next oversize (2).
Unit : mm (in.)
Standard Limit
Crankshaft thrust play
0.11-0.31 (0.0043-0.0122) 0.4 (0.0157)

7. Out of round and taper (uneven wear) of journal.

 Measure the fluctuations of journal diameter in the axle and right angle direction
of crankshaft and confirm the condition of uneven wear. If some serious
damage is found, or the deviation and partial deviation exceeds the limit,
replace the crankshaft or repair it by polishing (3).
Unit : mm (in.)
Limit on out of round and taper 0.01 (0.00039)

8. Crankshaft bearing oil clearance (4).

 Check the surface in contact for wear, burn, scratch, etc. and if necessary,
replace it.
 Cut the plastigauge to the length equal to the width of the bearing and place it
axially on the journal, avoiding the oil hole.
a. Plastigauge.
 Install the crankshaft bearing and bearing cap and tighten it to the
specifications. Do not rotate the crankshaft at this moment.
b. Crankshaft bearing.
c. Bearing cap.
Tighten
Tighten the crankshaft bearing cap bolt to 55-60 N•m (41-44 lb-ft).
 Remove the caps and measure the width of plastigauge with the scale marked
on the plastigauge case. This measurement must be taken at the widest part of
the compression and attention should be also paid to the different values
measured at the both ends of the piastigauge. If the oil clearance exceeds the
limit, replace the bearing.
Unit : mm (in.)
Oil clearance for Standard Limit
crankshaft bearings 0.020-0.040 (0.00079-0.00157) 0.065 (0.00256)

Unit : mm (in.)
Item Standard
43.982-44.000 (1.7316
Outer diameter of crankshaft journal
1.7323)
 Inspect the oil seal lips for wear, damage and mixture of foreign material.
Repalce the deteriorated (5).

Flywheel
1. Inspect it for damage, crack and abnormal wear at the ring gear part, or at the
contacting surface to the clutch plate. Replace the flywheel if necessary.
2. Measure runout of the flywheel using block and dial gauge, and replace it if runout
exceeds the limit (1).
Unit : mm (in.)
Limit on runout 0.2 (0.0079)

Engine Block
1. Measure 6 different places using thickness gauge and straight scale in the same
method as for the cylinder head (1).
2. Polish and repair it, if the distortion, bent or twist exceeds the limit. If polishing needs
more than 0.15mm (0.0059 in.), replace it with new one.
Important : Pay attention to the flatness on the surface between combustion

chambers.
Unit : mm (in.)
Limit of cylinder distortion 0.05 (0.0020)
Standard flatness 0.03 (0.0012)

Notice : The deformation of the cylinder head surface may cause the loss of
power due to the leakage of the compression.
Important : Measure the flatness of the cylinder head surface in the location of
each 4 side and diagonal.

Installation Procedure
1. Install the crankshaft thrust bearing and upper main bearing, then install the
crankshaft to the crankshaft journal.
 Coat engine oil in the oil groove and install the crankshaft thrust bearings to
place the oil groove in the outer part of the journal portion (1).
a. Oil groove.
 Install the upper crankshaft main bearings to the crankshaft journal with the
bearing oil port to direction of the oil filter (2). (Install the lower crankshaft
bearings identically when installing bearing cap).
b. Bearing oil port.
Important : Coat engine oil to the inner surface of bearing, or journal surface of
crankshaft (crank pin side) when installing bearing.
 Position the crankshaft on the engine block journal.

2. Install the crankshaft bearing cap with the lower crankshaft main bearing installed to
the crankshaft journal.
 On the bearing cap of the crankshaft journal part, Numbers 1 to 4 are marked in
sequence.
 Install the lower crankshaft main bearing to the crankshaft journal part (1).
 Install the bearing cap to the crankshaft journal part with the bolts according to
the sequence (2).
Tighten
Tighten the bearing cap bolts to 55-60 N•m (40-44 lb-ft).

3. Install the gasket and the crankshaft rear oil seal housing.
Important : Do not reuse the removed gasket and replace it with new one.
 Install the oil seal housing gasket (1).

 Install the crankshaft rear oil seal housing after coating engine oil to the oil seal
lip (2).
 Cut them with scraper, if the gasket edges are bulged.
Tighten
 Tighten the bolts to 9-12 N•m (80-106 lb-in).

 Tighten the screws to 9-12 N•m (80-106 lb-in). (Coat the Loctitte)

4. Install the oil pump with the gasket. (In case of the crankshaft unit repair)
Important : Do not reuse the removed gasket and replace it with new one.
 Install the oil pump gasket (1).

 Insert the hose in the crankshaft to prevent and damage on the oil pump seal
when installing the oil pump (2).
 Install the oil pump housing with the bolts (3).
Tighten
Tighten the bolts to 9-12 N•m (80-106 lb-in).
 Cut them with scraper, if the gasket edges are bulged.

5. Assemble the piston and the connecting rod.
Important : There are assembling directions for the piston and the connecting
rod. Direct the piston front mark (→) (a) on the piston head toward the
crankshaft pulley and toward the inlet manifold (b) on the connecting rod
toward the exhaust manifold to assemble the piston and the connecting rod.
 Install the piston pin (1).

 Retain the piston pin with the circlips (2).

6. Install the compression ring and the oil ring to the piston.
 When installing oil ring, insert the spacer first and two rails later (1).
 Install the second compression ring to direct the marked R side upward (2).
 Install the compression ring (3).
 Install three rings and position their openings as shown in Fig K5B11BS4.
a. Opening of compression ring (No.1).
b. Opening of compression ring (No.2)
c. Opening of oil ring rail (upper rail)
d. Opening of oil ring spacer

e. Opening of oil ring rail (lower rail)

f. Mark
g. Piston head
7. Install the piston and the connecting rod assembly.

 Coat engine oil to piston, ring, cylinder wall and bearing crank pin of connecting
rod.
 Position piston into cylinder to make the arrow point direct toward the
crankshaft pulley (1).
 Confirm the hose inserted in connecting rod stud bolt to prevent the damage of
the cylinder wall and the crankshaft bearing crank pin before installing the
piston and connecting rod assembly.
 Pucker the piston ring with the piston compressor 09916-77310 and insert the
connecting rod and the piston to the cylinder properly. In this time, push the
piston compressor 09916-77310 against the engine block and insert the piston
lightly (2).
 Install the connecting rod according to the sequence.
 Install the upper connecting rod bearing to the connecting rod bearing journal.

8. Install the bearing cap with the lower bearing installed to crankshaft crank pin part.
 Install the lower crankshaft main bearing to the crank pin part (1).
 Position the bearing cap on the crankshaft crank pin part to make the arrow
point direct toward the crank pulley according to the sequence after positioning
the piston on BDC (Bottom Dead Center) (2).
Tighten
Tighten the bearing cap nuts to 31-35 N•m (23-25 lb-ft).

9. Install the oil pump pickup tube and the oil pan.
 Install the oil pump pickup tube with the bolts (1).
Tighten
Tighten the oil pump pickup tube bolts to 9-12 N•m (80-106 lb-in).
 Coat the liquefied gasket on the engine block.

 Install the oil pan with the bolts and the nuts (2).
Tighten
Tighten the nuts and bolts to 9-12 N•m (80-106 lb-in). (Coat the Loctitte)

10. Install the components removed.

 Install the lower alternator bracket and the generator with the bolts (1).
Tighten
Tighten the bolts to 35-41 N•m (25-30 lb-ft) (a).
 Install the upper engine mount bracket and the generator shackle with the bolts
(2).
Tighten
Tighten the bolts to 35-41 N•m (25-30 lb-ft) (b).
 Install the generator with the bolts and the nut (3).
 Install the generator belt.

Tighten
 Tighten the generator lower bolts and the nut loosely to 18-28 N•m (13-21 lb-ft)
(c).
 Tighten the generator belt tension adjusting bolt to 18-28 N•m (13-21 lb-ft) (d).
 Install the engine mount bracket (4).
 Install the A/C compressor/power steering pump and the bracket with the bolts
(5).
Tighten
 Tighten the bracket bolt to 18-22 N•m (13-16 lb-ft) (e).

 Tighten the bracket bolts to 35-41 N•m (25-30 lb-ft) (f).

 Install the power steering pump bracket with the bracket bolt/nut and the
adjusting bolt (6).
Tighten
 Tighten the power steering rear bracket bolt to 18-22 N•m (13-16 lb-ft) (g).
 Tighten the adjusting bolt and the power steering rear bracket nut to 20-24 N•m
(15-18 lb-ft) (h).
 Position the A/C compressor into the normal location.
Tighten
 Tighten the bolts to 18-22 N•m (13-16 lb-ft) (i).

 Tighten the bolt to 20-24 N•m (15-18 lb-ft) (j).

 Install the power steering/air conditioning belt.

 Install the cylinder head with the intake manifold, the exhaust manifold, and
distributor/adaptor attached. Refer to "Cylinder Head and Gasket" in this
section.
 Install the timing belt and components. Refer to "Timing Belt" in this section.
 Install the clutch and the transaxle to the engine, then engine assembly to the
engine compartment. Refer to "Engine Assembly" in this section.
 Refill the engine crankcase with engine oil.
 Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
 Bleed the power steering system as necessary. Refer to Section 6A, Power
Steering System.
 Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual
Control Heating, Ventilation, and Air Conditioning System.
 Refill the transaxle oil as necessary.
 Connect the negative battery cable.
 Start the engine and operate all systems.
 Operate the idle air control valve reset procedure as necessary.
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Service Manual2005 Matiz UNIT REPAIR Page 1 of 69

Cylinder Head and Valve Train Components

(Typical Type Shown, Euro III Similar)

09916-14510 Valve Spring Compressor.

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2. Remove the rocker arm shaft and rocker arm.

3. Remove the camshaft.

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4. Remove the valve keepers.

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5. Remove the valves.

6. Remove the valve stem oil seals.

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7. Remove the valve guide.

Important : The removed valve guide should be replaced by new one of

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Abrasion of The Cam

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Measuring The Camshaft Bend

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Abrasion of The Camshaft Journal

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Bending of The Rocker Arm Shaft

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Clearance Between The Valve Stem and The Valve Guide

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1. Remove all carbon from the valve.

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4. Deviation to the rotating direction (2).

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5. Checking the contact width (3).

6. Valve seat repair (4).

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1. Remove all carbon from the combustion chamber.

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4. Deformation of the surface for manifold installation (2).

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4. Spring preload (2).

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5. Spring squareness (3).

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2. Install the valve guide.

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3. Repair the valve guide bore.

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4. Install the new valve stem seals.

5. Install the valves.

 Install the valve to the valve guide (1).

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6. Install the valve springs and the spring retainers.

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7. Install the valve keepers.

8. Install the camshaft.

 Install the camshaft plate (3).

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9. Install the rocker arms and the rock arm shafts.

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 Proceeding procedures when repairing the pistons and crankshaft unit :

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