2015 > L 1.0 LPGi KAPPA > En; 1e Mechanical System > General Informa! n> Specificationénalish Please rate this document after reviewing at the bottom of this page. SPECIFICATIONS Description Specification Limit General Type Insiine, DOHC Number of cylinders 3 Bore. 71.0mm (2.7962in) Stroke 84,0mm (3.3070in) ‘Total displacement 998cc (60.9cu.in) ‘Compression ratio 10.5: 4 Firing order 4-23 Valve timing Opens BTDC 22,5° ~ ATDC 27.5° Inintake valve Closes ‘ABDC 3.7” ~ ABDC 53.7" Opens BBDC 24,2" ~ ABDC 15.8° Exhaust valve Closes BTDC 12,8" ~ ATDC 27,2° Cylinder head Less than 0.5mm (0.0020in) Flatness of gasket surface Less than 0.02mm (0.0008in) 1100x100 Flatness of manifold Intake Less than 0. 1mm (0.0039in) mounting surface Exhaust Less than 0. 1mm (0.0039in) ‘Camshaft Intake 41.79824mm (1.6456in) ‘Camheight Exhaust 40.39820mm (1-5905in) Intake/Exhaust No.1 36,464 ~ 36.478mm (1.4355 ~ 4.4361in) Journal outer Diameter past STamm (OSA IntakelExhaust No.2~5 ‘vassonn Valve Intake 92,86mm (8.6566in) Valve length Exhaust 98.37mm (8.6758in) 5.465 ~ 5,480mm (0.2151 ~ Inteke 0.2187in) Stem outer diameter Suse v5 asonm Oia ~s.460mm (0.2144 = Exhaust 0.2143in) Face ang 4.36 ~ 1.65mm (0.0531 ~ Thickness of valve Intake ‘0.0860in) feed 1.80 ~ 1.90mm (0.0630 (margin) n ~ 1.90 ~ (era Exhaust 0.0748in) Intake 0.020 ~ 0,047mm (0.00078 ~ 1347 of 199226.5120.96kgf/25.7mm (26028,4N/1.0118in) Valve stem to valve 0.00185in) Ean suide clearance Exhaust (0.040 ~ 0.064mm (0.00187 ~ 0.0025in) MLA outer diameter 27.964 ~ 27.980mm (1.1009 ~ 1.1016 in) Tappet bore inner diameter 28,000 ~ 28.025mm (1.1024 ~ 41.1033 in) MLA to tappet bore clearance 0,020 ~ 0,081mm (0.0008 ~ 0.0024 in) Valve spring Free length 47-9mm (1.8858in) 46,3020. 83kg1/94.2mm Load (15028. 1N/1.3465in) ‘Out of squareness MAX. Cylinder block ‘Cylinder bore 71.00~71,03 mm (2.7952 ~2.7964in) Flatness of gasket surface Less than 0.05mm (0.0020in) Less than 0.02mm (0.0008in) 1 400x100 Piston Piston outer diameter 70.97~71.00 mm(2.7940~2.7952in) Piston to cylinder clearance (0.02 ~ 0.4mm (0.0008 ~ 0.0016in) ; 4.03 ~ 1.05mm (0.0405 ~ No, 1 ring groove 0.0413in) 1.23 ~ 1.25mm (0.0484 ~ Ring groove width No, 2 ring groove 0.0492in) 2.010 ~ 2.025mm (0.0791 ~ Oil ring groove 0.0797in) Piston ring i (0.04 ~ 0,08mm (0.0015 ~ No. 4 ring 0.003tin) (0.04 ~ 0.08mm (0.0015 ~ Side clearance No, 2 ring 0.0031in) (0.040 ~ 0.115mm (0.0015 ~ Oil ing 10.0045in) (0.13 ~ 0,25mm (0.0051 ~ No. 4 ning 0.0048in) 0.30 ~ 0.45mm (0.0118 ~ End gap No. 2 ring 0.0177in) ol 0.1 ~ 0.4mm (0.0039 ~ il ring 0.0187in) Piston pin Piston pin outer diameter 18.000 ~ 18.003mm (0.7086 ~ 0.7087in) Piston pin hole inner diameter 18,013 ~ 18.017mm (0,7092 ~ 1348 of 19920.7093in) Piston pin hole clearance 0.010 ~ 0.017mm (0.00039 ~ 0.00067in) ‘Connecting rod small end hole inner diameter 17.974 ~ 17.985mm (0.7076 ~ 0.7474in) Piston pin press-in load 250 ~ 1050kg (551 ~ 2315Ib) ‘Connecting rod ‘Connecting rod big end inner diameter 42,000 ~ 42.018mm (1.6536~1.6542in) ‘Connecting rod bearing oil clearance 0.018 ~ 0.036 mm (0.0007 ~ 0.0014in) Side clearance 0.1 ~ 0.25 mm (0.0039 ~ (0.0098in) (Crankshaft Main journal outer diameter 47.942 ~ 47.980mm (1.8874 ~ 1.888in) Pin journal outer diameter 38,954 ~ 38.972mm (1.5396 ~ 1.5343in) Main bearing oil clearance (0.006 ~ 0.024mm (0.0002 ~ ‘0.0008in) End play (0.05 ~ 0.25mm (0.0020 ~ 0.0098in) (Oil pump. Relief valve opening pressure 294 ~ 392 kPa (3.0 ~ 4.0 kgicm?, 42.67 ~ 56.89 psi) ‘Oil pump boby width 7.02 ~ 7.05 mm (0.2763 ~ 0.2775 in.) Inner rotor width 6.96 ~ 6.98 mm (0.2740 ~ 0.2748 in.) Side clearance (0.040 ~ 0.090 mm (0.00157 ~ 0.00354 in.) Engine oil Total 3.3L (0.87 US.gal,, 3.49 U.S.qt., 2.90 Imp.at.) ‘When replacing a short engine or block assembly Oil quantity Oil pan 2.7L (0.71 US.gal., 2.85 ULS.qt., 2.37 Imp.qt.) Drain and refill 3.0L (0.79 US.gal., 3.17 U.S.qt., 2.64 Imp.at.) Including oil filter Recommended ILSAC GF- (API SM) or above / SWH20ACEA AS or above / 5W-30 Oil grade Allowed ILSAC GF-3, GF-4 (API SL, SM) or above ACEA A3, AS or above For information on SAE viscosity grades based on ambient temperatures, refer to| the "Lubrication System’ Usable if the recommended ‘engine oll is not available (Oil pressure (at 1,000%pm) 130.00 kPa (1.3 kgf/cm?, 18.85 psi) or above il temperature (oil pan) 11042°C (230835.6°F) 1349 of 1992Cooling method (Goaling system Foreeet circulation with water pump 5.1L (1.95 US gal., 5.39 ‘Coolant quantity US.ql, 4.49 Imp.at) Type Wax pellet type Thermostat Opening temperature 88 # 15°C (190.4 #2.7°F) Full opening temperature 400°C (212°F) 93.16 ~ 122.58kpa Main valve opening pressure | (0.95 ~ 1.25kg/cm?, 13.51 ~ 17.78psi) Radiator cap 0.98 ~ 4,90 kPa ‘Vacuum valve opening pressure | (0.01 ~ 0.05kg/cm?, 0.14 ~ 0.74 psi) Water temperature sensor Type Thermistor type 20°C (68°F) 2.4540.14 KO. Resistance 80°C (176°F) 0.3222 ka. Tightening Torque: Item Quantity Nm kgf.m Ib-tt Cylinder block Ladder frame bolt 8 19.6 ~ 23.5 2.0~24 14.5 ~ 17.4 Engine mounting Engine mounting bracket to body fixing bolt | ___3 48.0 ~ 63,7 5.0~6.5 36.2 ~ 47.0 Engine mounting support bracket to engine 4 88.3 ~ 107.0 90-110 651~ 79.6 ‘mounting insulator fixing nut Engine mounting support bracket to engine . . . ‘support bracket fixing bolt ‘ 48.0~ 68.7 50-85 $6.2 ~ 47.0 Engine mounting support bracket to engine 2 49.0 ~637 50-65 962-470 ‘support bracket fixing nut Transaxle mounting bracket fo boy fing 2 49.0~ 637 50-65 36.2 ~ 47.0 Transaxle mounting support bracket to . . . transaxle mounting insulator fixing bolt 2 49.0 ~ 63.7 50-88 $6.2 ~ 47.0 Roll rod bracket to sub frame fixing bolt 2 48.0 ~~ 63.7 50~65 36.2 ~ 47.0 Roll rod bracket to roll rod support bracket + 1079 ~ 1278 10-130 796 ~ 94,0 fixing bolt ‘Main moving system [10.8~14,7] + 4.5) + ag-aoy) (8010.8) + ‘Connecting rod bearing cap bolt 6 (98-904 [tt] + [88-923] in bearing (17.7-21.6] + 2.2) + [88~92"]| (13.0~15.9] + ‘Crankshaft main bearing cap bolt 8 [ae-92) (1.8-22]+ [88-929] Toy Fly wheel bolt (M/T) 6 68.6 ~ 78.5 7.0~80 50.6 ~ 67.9 Drive plate bolt (A/T) 6 68.6 ~ 78.5 7.0~80 50.6 ~ 67.9 Timing chain Timing chain cover bolt (A) 12 18.6 ~ 235 1.9~24 13.7174 1350 of 1992Timing chain cover bolt (B) 3 44.1 ~ 53.9 45~5.5 32.5 ~ 39.8 Timing chain cover bolt (C) 1 9.8~ 11.8 1.0~ 1.2 7.2~ 87 ‘Crankshaft pulley bolt 4 [55.9 aes + [38 | [5.7~ oo [38 ~ |[41.2~ on + [38 ~ cao 2 | sar-738 | ee-78 | aro-saa : 2 | sens | 10-12 72-87 [Tm cai terloner am bot 1 s-ne | 10-12 72-87 Timing chain guide bolt 2 18.6 ~ 21.6 1.9~ 2.2 13.7 ~ 15.9 Cylinder head ‘Cylinder head cover bolt 13, [3.9-5.9]--[7.8~9.8} |[0.4~0.6]-+[0.8~1.0]] (2. 9~4.3]—+[5.8~7.2] Camshaft bearing cap bolt (M6) 12. [5.9] — [11.8~12.7] } [0.6] + [1.2~1.3] | [4.3] + [8.7~9.4] Camshaft front bearing cap bolt (M8) 3 [9.8] — [18.6~22.6] | [1.0] — [1.92.3] | [7.2] [13.7~16.6] Ofer ned bot 2 | “mass |itetatsgo-ssi] eoctea fata (a2 cv bat 2 | se-n8 | 10-12 72-87 ov iter bot 1 | w2-s0 | atwen | 2e7-a98 cooing stm tr puno pul bt ¢ | ei=a7 [isis | ean Mtr puno bot ¢ | ts-ess | 20-27 | we=t08 Hester pipe bk & ra 2 | tes=as8 | 20-27 | we=t08 Tremostat housing bat & at 2 | 15-28 | 19-24 | ta7= 1104 Mtr fing bm & rt 2 | ts-2ss | 19-24 | 7-110 Lubrcaon system otter 7 were? [ate ats Ot pump ener sew © [50-80 | 06~09 43-65 lieve gee guide bat 2 | ee-137 | 08-14 | 5-101 tpn bak 2 | se-ne | 10-12 7287 ton sn pus 1 [| us-aer | as-as | eas Otscrentat 1 | se-nne | 10-12 72-87 tress sich 1 7e-ne | aaa 58=67 Take and exhaust atm Take mond bot at [| werws | te-aa | r= Exhaust mend ty 3 | 92-490 | 40-80 | za9- 361 Exhaust mend heat paecto 3 | se-ne | 10-12 72-87 Tite boy in sf ew «| ea-03 | o0s~088 | a7=01 Exes mented at @ | wearsas | s0-as | a= 288 Fen mer nat «| sea-s8 | a0-00 | 2s0-ana anermuterpoxninahmdiorsore |, | inynans | aacae | vwa-a0a 1351 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > General Information > Compressionetabth Please rate this document after reviewing at the bottom of this page. COMPRESSION PRESSURE INSPECTION NOTICE If there is lack of power, excessive oil consumption or poor fuel economy, measure te compression pressure. 1, Start the engine and allow to warm up to operating temperature (about five minutes), Stop the engine. 2. Remove the engine cover. 3. Disconnect the injector connectors (A) and ignition coil connectors (B). 5, Remove the three spark plugs using a 16mm spark plug wrench, 6. Check the cylinder compression pressure, (1) Insert @ compression gauge into the spark plug hole. 1352 of 1992(2) Fully open throttle English (3) While cranking the engine, measure the compression pressure. NOTICE Always use a fully charged battery to obtainengine speed of 200rpm or more. (4) Repeat step (1) through (3) for each cylinder. NOTIC This measurement must be done in as short atime as possible Compression pressure : 4,127.8 kPa (11.5 kg/om, 163.6 psi) Minimum pressure : 980.7 kPa (10.0 kgicm?, 142.2 psi) Difference between each cylinder 98.1 kPa (1.0 kglom?, 14.2 psi) or less. (6) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step (1) through (3) for cylinders with low compression. + If adding oll helps the compression, it is likely that the piston rings andlor cylinder bore are worn or damaged. + If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 7. Reinstall the spark plugs, Tightening torque 14,7 ~ 24.5N.m (1.5 ~ 2.8kgf.m, 10.8 ~ 18.1Ib-f) 8. Install the ignition coil Tightening torque 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 Ibstt) 9. Connect the injector connectors and ignition coil connectors. 10. Some DTC's may exist after the inspection test and may need to be manually cleard with GDS. 1353 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > General Information > Troubleshoofingish + Please rate this document after reviewing at the bottom of this page. TROUBLESHOOTING ‘Symptom Suspect area Remedy Engine misfire with abnormal internal lower engine noises. ‘Worn crankshaft bearings. Loose or damaged engine drive plate. Replace the crankshaft and bearings as required. Repair or replace the drive plate as required. ‘Wor piston rings. (Oil consumption may or may not cause the engine to misfire.) Inspect the cylinder for a loss of ‘compression.Repair or replace as required. ‘Worn crankshaft thrust bearings Replace the crankshaft and bearings as, required. Engine misfire with abnormal valve train noise. ‘Stuck valves. (Carbon buildup on the valve stem) Repair or replace as required Excessive wom or mis-aligned timing chain, Replace the timing chain and sprocket as required, ‘Worn camshaft lobes. Replace the camshaft and valve lifters. HLA sponge Run the engine at 2500~3000;pm within 15 minutes If it dosent disappear, refer to cylinder head assembly in this group. Engine misfire with coolant ‘consumption. + Faulty cylinder head gasket and/or ‘cranking or other damage to the cylinder head and engine block cooling system. + Coolant consumption may or may not cause the engine to overheat. + Inspect the cylinder head and engine block for damage to the coolant passages andlor a faulty head gasket + Repair or replace as required Engine misfire with excessive oil ‘consumption. ‘Worn valves, guides and/or valve stem oll seals, Repair or replace as required. ‘Wor piston rings. (Oil consumption may or may not cause! the engine to misfire) Inspect the cylinder for a loss of ‘compression. + Repair or replace as required, Engine noise on start-up, but only lasting a few seconds. Incorrect oil viscosity. + Drain the oil Install the correct viscosity oil ‘Worn crankshaft thrust bearing. Inspect the thrust bearing and crankshaft. + Repair or replace as required Upper engine noise, regardless of ‘engine speed. Low oil pressure. Repair or replace as required Broken valve spring, Replace the valve spring. Worn or dirty valve lifters. Replace the valve lifters, ‘Stretched or broken timing chain and/or damaged sprocket teeth. Replace the timing chain and sprockets. ‘Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as required. 1354 of 1992Worn camshaft lobes. + Inspect the camshaf Engtish + Replace the timing camshaft and valve lifters as required, ‘Worn valve guides or valve stems. Inspect the valves and valve guides, then repair as required, Stuck valves. Carbon on the valve stem ‘or valve seat may cause the valve to stay open. Inspect the valves and valve guides, then repair as required, ‘Worn drive belt, idler, tensioner and bearing, Replace as required Lower engine noise, regardless of ‘engine speed. Low oil pressure, Repair as required, Loose or damaged drive plate, Repair or replace the drive plate. Damaged oil pan, contacting the oil pump screen. + Inspect the oil pan. + Inspect the oll pump screen + Repair or replace as required ‘Oil pump screen loose, damaged or restricted. + Inspect the oil pump screen + Repair or replace as required. Excessive piston-to-cylinder bore clearance, + Inspect the piston, piston pin and cylinder bore, + Repair as required, Excessive piston pinto-piston clearance. + Inspect the piston, piston pin and the connecting rod. + Repair or replace as required, Excessive connecting rod bearing clearance Inspect the following components and repair as required, + The connecting rod bearings. + The connecting rods, + The crankshaft pin joumals. Excessive crankshaft bearing clearance, Inspect the following components, and repair as required. + The crankshaft bearings. + The crankshaft main journals. + The cylinder block. Incorrect piston, piston pin and ‘connecting rod installation + Verify the piston pins and connecting rods are installed correctly. + Repair as required. Engine noise under load. Low oil pressure Repair or replace as required. Excessive connecting rod bearing clearance Inspect the following components and repair as required + The connecting rod bearings. + The connecting rods. + The crankshaft Excessive crankshaft bearing 1355 of 1992‘clearance. Inspect the following components, and repair as required, + The crankshaft bearings. + The crankshaft main journals. + The cylinder block, Engine will not crank-crankshaft will not rotate. Hydraulically locked cylinder. + Coolant/antifreeze in cylinder, + Oil in cylinder, + Fuel in cylinder. + Remove spark plugs and check for ‘uid. + Inspect for broken head gasket. + Inspect for cracked engine block cr oylinder head. + Inspect for a sticking fuel injector and/or leaking fuel regulator. Broken timing chain andor timing chain and/or timing chain gears, + Inspect timing chain and gears. + Repair as required. Material in cylinder, + Broken valve + Piston material + Foreign material + Inspect cylinder for damaged ‘components and/or foreign materials. + Repair or replace as required, Seized crankshaft or connecting rod bearings. + Inspect crankshaft and connecting rod bearing, + Repair as required. Bent or broken connecting rod. + Inspect connecting rads. + Repair as required. Broken crankshaft. + Inspect crankshatt. + Repair as required. 1356 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > General Informal n> Special ServiEesieols Please rate this document after reviewing at the bottom of this page. SPECIAL SERVICE TOOLS Tool (Number and name) Use ‘Crankshaft pulley adapter ‘A: 09231-03100 Holder B ; 09231-2/210, Used for keeping crankshaft pulley from rotating when removing / installing crankshaft pulley bolt ‘Crankshaft front oll seal installer ‘A: 09214-1R000 (Installer) B : 09231-H1100 (Handle) Torque angle adapter 09221-44000 Used for tightening torque-to-yield fasteners to al specified angle Valve stem seal remover (09222-29000 Valve stem seal installer (09222-03100 Valve spring compressor & holder A: 09222-3K000 (Compressor) B : 09222-8K 100 (Holer) Used for removing / installing intake or exhaust valve ‘Crankshaft rear oil seal installer A: 09214-03100 (Installer) B : 09231-H1100 (Handle) Oil pan remover (09215-3000 1357 of 1992English Oil fiter wrench (09263-02000 Used for removing / installing oil filter 1358 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Engine And Transaxle Assembly > Engine Mounting > Components and Components Location Please rate this document after reviewing at the bottom of this page. COMPONENTS 1 49.0~ 63.7 wo-s0 PA Soe (50-65, 49.0 ~ 63.7 sasua078! 36.1 ~ 47.0) SEUEATS (5.0 ~ 65, (9.0~ 11.0, 36.1 ~ 47.0) 65.1 ~ 79.6) AT 49,0 ~ 63.7 (5.0 ~ 6.5, 36.1 ~ 47.0) 107.9 ~ 127.5 49.0~ 63.7 49.0 ~63.7 eee 11.0 ~ 19.0, Paro (5.0 ~ 6.5, as es ‘5 96.1 47.0) 36.1 ~ 47.0) Bh 49.0 ~ 63.7 (5.0 ~6.5, = di R61 ~ 47.0) Fis a GS <—3 Torque : N.m (kgf.m, Ib-ft) 1, Transaxle mounting bracket 4, Engine mounting bracket 2, Roll rod bracket 5. Engine mounting support bracket 3. Sub frame 1359 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly > Repair procedures Please rate this document after reviewing at the bottom of this page. REMOVAL When servicing the part related to LPG fuel supply system, must abide by following items. + The LPG tank is charged with high pressure LPG gas, Never disasemble the LPG tank because it may cause the fire and explosion if disassembling the LPG tank arbitrarily + Be sure to remove inflammable materials around the LPG fuel supply system before servicing and ventilate the ‘work shop. Be sure not to service the LPG system in the a sealed place. + Be sure to remove the residual fuel gas completely first in the fuel line before servicing LPG fuel supply system and the fuel line. (Refer to FL group - ‘Release Residual Pressure in Fuel Line’) + Prevent skin contact with gas fuel, Wear Personal Protection Equipment (Safety Glasses, Fuel-resistant gloves) + When you removing the fuel supply and injection system, do not work with compressed air if this can be avoided. + Before opening the system cover a cloth around the connection part. After then, release pressure by loosening the connection part carefully. + Check the tightening condition of all part in the LPG fuel line for leakage with soapsude. + Use fender covers to avoid damaging painted surfaces. + To avoid damage, unplug the wiring connectors carefully while holding the connector portion + Mark all wiring and hoses to avoid misconnection. + To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump connector removed. And then tum off the ignition switch after engine stops. 1, Remove the engine cover (A). 2, Disconnect the battery terminals (A). Disconnect the negative terminal first. Tightening torque (+) terminal 7.8 ~ 8.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbeft) ( terminal (without battery sensor 1360 of 19927.8 ~ 9.8N.m (0.8 ~ 1,0kgf.m, 5.8 ~ 7.2Ib-ft) (terminal (with battery sensor): English 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4Ib-f) 3. Remove the battery (A) after removing the battery clamp bolt Tightening torque: 9,8 ~ 11,8N.m (1,0 ~ 1.2kgfm, 7.2 ~ 8.7lb-f) 4, Remove the battery tray (A). Tightening torqu 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-f) 5. Remove the air duct and air cleaner, (1) Remove the air duct (A). (2) Disconnect the breather hose (B), air intake hose (C).. Tightening torque : 2.9~4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft) (3) Remove the air cleaner (D) Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbeft) 1361 of 1992NOTICE + Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose. + Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib. 6. Remove the engine room under cover (A) and side covers (B). Tightening torque : 6.9~ 10.8N.m (0.7 ~ 1.tkgf.m, 5.1 ~ 8.0lb-ft) ‘oolant. Remove the radiator cap to help drain the coolant faster. 1362 of 1992Never remove the radiator cap when the engine is hot Serious scalding could be caused by hot fluid under high pressure escaping from the radiator. 8. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe (A). (Refer to Air conditioning system in HA Group.) NOTICE Install the radiator hoses as shown illustrations. 1363 of 1992Heater do ‘Sem |: & ewe wer 11. Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head. and intake manifold. (1) The exhaust OCV(Oil Control Valve) connector (A) 1364 of 1992(2) The front oxygen sensor connector (A) (8) The CKPS (Crankshaft Position Sensor) connector (B) (4) The condenser connector (C) (8) The ground line (0) (6) The intake OCV(Oil Control Valve) connector (A) (7) The knock sensor connector (B) (8) The alternator connector (C) (8) The ignition coil connectors (A) (10) The injector connectors (B) (11) The VIS (Variable Intake System) connector (C) (12) The wiring protector (D) 1365 of 1992(13) The exhaust CMPS (Camshaft Position Sensor) connector (A) (14) The rear oxygen sensor connector (B) (15) The ETC (Electronic Throttle Control) connector (A) (16) The MAPS (Manifold Absolute Pressure Sensor) connector (8) (17) The intake CMPS (Camshaft Position Sensor) connector (A) (18) The ECTS (Engine Coolant Temperature Sensor) connector (8) (19) The PCSV (Purge Control Solenoid Valve) connector (A) 1366 of 1992(20) The compressor switch connector (A) (21) The OPS (Oil Pressure Switch) connector (B) oe raven 4 \ 12. Disconnect the (+) cable (B) from the fuselrelay box and the front connector (A). 13. Disconnect the gasoline fuel hoses (A) 14. Disconnect the LPG fuel hose (A). 1367 of 1992e 418. Remove the front muffler (A). Tightening torque 39.2 ~ 58.8 Nam (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 Ib-t) 16, Remove the steering ujoint mounting bolt (A). (Refer to ST group) ee 17. Remove the front wheels. (Refer to SS group) 18. Remove the lower arms (A). (Refer to SS group) 19, Remove the stabilizer bar links (A). (Refer to SS group) 1368 of 199221. Disconnect the drive shafts from the axle hubs. (Refer to DS group) 22. Remove the roll rod bracket (A). Tightening torque Nut (B) 107.9 ~ 127.5N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 Ib-ft) Bolt (C) 49.0 ~ 63.7 Nim (5.0 ~ 6.5 kaf.m, 36.2 ~ 47.0 lb-ft) 1369 of 199224, Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. Tightening torqu 156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 Ib-t) + After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall downward, and so support them securely with floor jack, + Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly. 25. Disconnect the ground line (A), and then remove the engine mounting support bracket (B). Tightening torque Nut (C) 88.3 ~ 107.9N.m (9,0 ~ 11..0kgf.m, 65.1 ~ 79.6Ib-ft) Bolt (D), Nuts (E) 48.0~ 63.7Nim (.0~ 6 8kafim, 38.1 ~ 470s) A LD./ op ZEA 26. Disconnect the ground line (A), and then remove the transaxle mounting bracket bolts (B). Tightening torque: 49.0 ~ 63.7N.m (6.0 ~ 6.5kgf.m, 36,1 ~ 47.0lb-t) 1370 of 1992i 6 ‘When removing the engine and transaxleassembly, be careful not to damage any surrounding parts or body components. INSTALLATION Installation isin the reverse order of removal Perform the following + Adjust a shift cable + Refill engine with engine oil + Refi a transaxle with fluid + Refill power steering fluid + Refill a radiator and a reservoir tank with engine coolant. + Clean battery posts and cable terminals and assemble + Inspect for fuel leakage. ~ After assemble the fuel line, tum on the ignition switch (do not operate the starter) so that the fuel pump runs for ‘approximately two seconds and fuel line pressurizes. = Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line. + Bleed air from the cooling system, ~ Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) — Turn Off the engine, Check the level in the radiator, add coolant if needed, This will allow trapped air to be removed from the cooling system. = Put radiator cap on tightly, then run the engine again and check for leaks. 1371 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Timing System > Timing Chain > Cofmpishents* and Components Location Please rate this document after reviewing at the bottom of this page. COMPONENTS 98~11.8 (1.0 ~1.2, J 4 63.7 ~ 73.5 f / 3 18.6 ~ 216 (1.9 ~2 13.7 ~ 159) 9 Torque : N.m (kgf.m, Ib-ft) 4, Timing chain 4, Timing chain tensioner 7. Exhaust camshaft 2. Timing chain guide 5. Exhaust CVT 8, Intake camshaft 3, Timing chain tensioner arm 6. Intake CVVT 98, Sensor target wheel 1372 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Timing System > Timing Chain > Repaitish procedures Please rate this document after reviewing at the bottom of this page. REMOVAL + Use fender covers to avoid damaging painted surfaces. + To avoid damage, unplug the wiring connectors carefully while holding the connector portion. + Mark all wiring and hoses to avoid misconnection. + Tum the crankshaft pulley so that the No.1 piston is at top dead center, 1. Remove the engine cover. 2. Disconnect the battery negative terminal 3. Remove the air cleaner. (Refer to Engine and transaxle assembly in this group) 4, Remove the RH front wheel. (Refer to SS group) 5. Remove the under cover. (Refer to Engine and transaxle assembly in this group) 6. Disconnect the ground line (A), and then remove the engine mounting support bracket (B). Sy tl oO + Set a jack to support the engine before the mounting bracket is removed. + Place a rubber block between the jack and oil pan. 7. Remove the drive belt (1) Loosen the alternator mounting bolts (A, 8), (2) Loosen the tension by turning the tension adjusting bolt (C) counterclockwise. (3) Remove the drive belt (0). 1373 of 19928. Remove the altemator (A) and altemator brace assembly (B) 11. Remove the cylinder head cover (A). 1374 of 1992 English13. Tum the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No.1 cylinder to the top dead center on compression stroke. 14, Remove the crankshaft damper pulley. (1) Using the $$7(09231-03100, 09231-2210) to hold the crankshaft damper pulley (A). (2) Remove the crankshaft damper pulley bolt (B) and then remove the crankshaft damper pulley (A). ovaat-2i010 15. Remove the water pump (A) with the O-ring (B), 1375 of 1992Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark he timing chain wth an identification based onthe locaton ofthe CVVT because the identification mark on the chan for TOC (Top Dead Center ean be erased, 17. Install a set pin after compressing the timing chain tensioner by hold the ratchet clip (A) 1376 of 1992‘Then remove the tensioner (B) and the tensioner arm (C) + Insert a set pin surely and keep the tensioner clean, + Keep the tensioner clean. + Once disassemble the inner parts of tensioner, should not be used, 1377 of 1992INSPECTION Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm 1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary 2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary. 3. Check that the tensioner piston moves smoothly. ADJUSTMENT Drive belt tension measurement and adjustment Bolt tension measurement Measure the belt tension using a sonic tension meter Belt tension New belt 980.7 ~ 1078.7 N (100 ~ 110 kg, 220.5 ~ 242.5 Ib) Used belt 676.7 ~ 774.7 N (69 ~ 79 kg, 152.1 ~ 174.2 Ib) + If the engine has run for § minutes or more, the belt tension must be adjusted as a used belt + When installing the Veribbed belt, all grooves on the pulley should be covered with belt ris. + A loose belt causes slip noise. + Too tight belt cause bearing of altemator and water pump to damage. Using a sonic tension meter (U-505/507 type) 1. Input the belt specifications into the tension meter (A). Input data Location of measurement M (Mass, gim.rib) W (Width, rib) S (Span, mm) Crankshaft pulley to idler 13.4 6 180 Wes Measurement of S (Span): Calculate average value after measuring the distance 3~4 times. 1378 of 1992owe [eee X :Dislanea af corte (rm) 1D: Putty diameter (mn) 4: Pulley diameter (mn) 2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2~3 times. Read a value on the display. [With a/c] [Without A/C] If adjustment is necessary: 1, Loosen the mounting bolts (A, 8). 2, Tighten the adjusting bolt (C) counterclockwise in loose tension; loosen the bolt clockwise in high tension 1379 of 19923, Recheck tension of the belt 4. After adjusting tension, tighten the mounting bolts Tightening torque M10 bolt 29.4 ~ 41.2Nm .0~42kgfm, 21.7 ~ 30.4 Ib) M8 bolt: 21.6 ~ 32.4Nim (2.2 ~ 3.3 kaf.m, 15.9 ~ 23.9 Ib-t) INSTALLATION 1, Set the dowel pin (A) of crankshaft about 3° with virtical center line, As a result of this, the piston of No, cylinder is placed at the top dead center on compression stroke. 2. Align the mark of CVVT on the top surface of cylinder head. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke. 3. Install the timing chain guide (A). Tightening torque : 18,6 ~ 21,6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-f) 1380 of 19924, Install the timing chain (A). NOTICE Install the timing chain with no stack and recommend the below procedure. Crankshaft sprocket —> Timing chain guide —> Intake CVVT —» Exhaust CVVT. The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at during installation, 55. Install the timing chain tensioner arm (B) and the timing chain tensioner (A) and then remove the set pin, Tightening torque : 9,8 ~ 11.8N.m (1,0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-f) 1381 of 19926, After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark ‘Any tun the crankshaft clockwise ‘Tuming the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner ‘may result in the chain disengaging from the sprocket teeth 7. Install the timing chain cover. (1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block) must be free of engine oil and etc. (2) Before assembling the timing chain cover, the liquid sealant MS721-40AA should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied Boad width : 4.0mm (0,16in,) (3) After applying liquid sealant MS721-40AA(for oil) and equivalent to 812828 or T81216E (for water) on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied in a continuous bead in each of the areas indicated below. Boad width A: 1,5 ~ 2.5mm (0.06 ~ 0,10in,) B25 ~ 3.5mm (0.09 ~ 0.14in.) ©: 3.0~ 4.0mm (0.12 ~ 0.16in.) 1382 of 1992During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts. (4) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover correctly. Tightening torque A 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-t) 1EA B 18,6 ~ 23.5N.m (1.9 ~ 2.4kgh.m, 13.7 ~ 17.4lb-tt) 12EA c 44.1 ~ 63,9N.m (4.5 ~ 5.Skaf.m, 32.5 ~ 39.8lb-t) -3EA The engine starting or pressuer tests should not be performed within 30 minutes after the timing chain cover was assembled. 8, Install the water pump (A) with the O-ring (B), NOTIC Always use a new O-ing. 9. Replace the front oil seal if necessary. (1) Apply engine oil on the edge of new oil seal NOTICE Remove any debris from the lip portion of the il seal (2) Install the front cil seal (A) using a SST (09214-1000, 09231-H1100).. 1383 of 1992ast 1100 a ei Do not reuse the front oil seal. 10. Install the crankshaft damper pulley. (1) Install the crankshaft damper pulley (A). (2) Using the SST(09231-03100, 09231-2210) to hold the crankshaft damper pulley (A). (3) Install the crankshaft damper pulley bolt (B).. Tightening torque : 55.9 ~ 61.8 Nm (5.7 ~ 6.3 kgf.m,41.2 ~ 45.6 Ib-ft)] + 29 ~ 31° 09221-03100 poe ‘11. Install the idler (A) and water pump pulley (B), Tightening torque Ieler 53.9 ~ 63.7N.m (5.5 ~ 6.Skaf.m, 39.8 ~ 47.Olbst) Water pump pulley 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8 7Ib-t) 12. Install the cylinder head cover, (1) Install new cylinder head cover gasket on the cylinder head cover. 1384 of 1992Do not reuse the cylinder head cover gasket. (2) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover. (3) After applying sealant (MS721-40AA), it should be assembled within § minutes, Bead width : 2.0 ~ 3.0 mm (0,08 ~ 0.12 in.) (4) Install the cylinder head cover bolts as following method with two steps. Tightening torque Step 1 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3Ib-) Step 2 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2Ib-) + Do not reuse cylinder head cover gasket. + The firing andlor blow out test should not be performed within 30 minutes after the cylinder head cover was assembled. 18, Install the ignition coils (A). Tightening torqu: 8~ 11.8N.m (1.0 ~ 1.2kghm, 7.2 ~ 8.7lbst) 1385 of 1992416. Install the altemator brace assembly (B). Tightening torqu 21.8 ~ 82.4N.m (2.2 ~ 3.3kgf.m, 15.9 ~ 23.9Ib-) 16, Preassemble the alternator (A) temporarily, 17. Install the drive belt (1) Install the drive belt (0). ‘When install the belt, must install on the water pump pulley finally. (2) Adjust the tension by turing the tension adjusting bolt (C) clockwise, (Refer to EE group - “Altemator’) Belt tension New belt: 980.7 ~ 1078.7N (100 ~ 110 kgf, 220.5 ~ 242.5 Ib) Used belt: 676.7 ~ 774,7N (69 ~ 79 kgf, 182.1 ~ 174.2 Ibf) (3) Fasten the altemator mounting bolts (A, B) Tightening torque 1386 of 1992Bolt (A) 29.4 ~ 41.2N.m (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4Ib-tt) Bolt (8) 24.6 ~ 32.4N.m (2.2 ~ 3.3kgf.m, 15.9 ~ 23.9Ib-tt) 18. Install the engine mounting support bracket (B) and connect the ground line (A). Tightening torque Nut (C) 88.3 ~ 107.9N.m (9,0 ~ 11..0kgf.m, 65.1 ~ 79.6Ib-ft) Bolt (D), Nuts (E) 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47-Olb-t) 19. Remove the jack from the oil pan. 20. Install the under cover. (Refer to Engine and transaxle assembly in this group) 24. Install the RH front wheel. (Refer to SS group) 22. Install the air cleaner, (Refer to Engine and transaxle assembly in this group) 23. Connect the battery negative terminal Tightening torque Without battery sensor 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2Ib-f) With battery sensor 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-f) 24, Install the engine cover. 1387 of 19922015 > L. 1.0 LPGi KAPPA > Engine Mechanical System > Cylinder Head Assembly > Valve Cléaminbe Adjustment Please rate this document after reviewing at the bottom of this page. VALVE CLEARANCE INSPECTION AND ADJUSTMENT Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C (68°F) and cylinder head is installed on the cylinder block. 1, Remove the cylinder head cover, (Refer to Timing system in this group) 2. Set No.1 cylinder to TDC/compression (1) Tum the crankshaft pulley and align its groove with the timing mark "T" of the timing chain cover. (2) Check that the TOC marks of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration, If not, turn the crankshaft one revolution (360°) 3. Inspect the valve clearance. (1) Check only the valve indicated as shown (Intake 1st and Exhaust ‘st, 2nd). Measure the valve clearance, 1388 of 1992English Intake {No.1 cylinder :TOCICompression} + Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft. + Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting tappet. Valve clearance Specification Engine coolant temperature : 20°C [68°F] Limit Intake : 0.20 ~ 0.26mm (0.0079 ~ 0.0102in) Exhaust : 0.27 ~ 033mm (0.0 106 ~ 0.0129in.) (2) Rotate the intake and exhaust camshafts by 210” in clockwise direction Fosato by 210° (3) Check only valves indicated as shown. (Intake 2nd, 3rd and Exhaust 3rd) Measure the valve clearance. [Rotate by 2107 4, Adjust the intake and exhaust valve clearance. (1) Set the No.1 cylinder to the TDC/compression. (2) Remove the timing chain. (Refer to Timing system in this group) (3) Remove the camshaft bearing caps with the order below. 1389 of 1992(4) Measure the thickness of the removed tappet using a micrometer, (6) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value. Valve clearance [Engine coolant temperature : 20°C(68°F)] T: Thickness of removed tappet ‘A: Measured valve clearance N: Thickness of new tappet Intake : N= T + [A - 0.20mm (0.0079in.)] Exhaust : N= T+ [A -0.25mm (0.0098in.)} (©) Select a new tappet with a thickness as close as possible to the calculated value. ean Shims are available in 41 size increments of 0.015mm (0.0006in.) from 2.850mm (0.112in.) to 3.450mm (0.136in.) (7) After applying engine oil on the selected tappet at the periphery and top surface, insert tappet into cylinder head gently. (6) Install the intake and exhaust camshafts. (@) Install the camshaft bearing caps with the order below, Tightening torque Step 1 M6 bolts: 5.9N.m (0.6kgf.m, 4.3lb-f) M8 bolts: 9.8N.m (1.Okgf.m, 7.2Ibt) Step 2 M6 bolts: 11.8 ~ 12.7Nm (1.2 ~ 1.3kgfm, 8.7 ~ 9b) M8 bolts: 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-f) 1390 of 1992(10) Tum the crankshaft two tums in the operating direction(clockwise), and then check that the TDC marks of the CWT sprockets are in straight line on the cylinder head surface. (11) Recheck the valve clearance, Valve clearance Specification Engine coolant temperature : 20°C [68°F] Limit Intake : 0.20 ~ 0.26mm (0.0079 ~ 0.0102in) Exhaust : 0.27 ~ 0.3mm (0.0 106 ~ 0.0129in.) 55. Inatall the timing chain. (Refer to Timing system in this group) 1391 of 19922015 > L. 1.0 LPGi KAPPA > Engine Mechanical System > Cylinder Head Assembly > Cylinderltgtish> Components and Components Location Please rate this document after reviewing at the bottom of this page. COMPONENTS —@ Lo 2 5) 78-98 é . (0.8 - 1.0,5.6~ 7.2) — ll Hee ——se o SS Ss ae ig Q rw, So! | 8 2 (9.8(1.0,7.2)) + ° [18.6-22.6 (1.9-2.3, 13.7~16.6)] 15.9 (0.64.3))+ [11.8127 (1.2-1.3,8.7-9.4)) m 1127-167 (13-4 “I +190-95"] + [120-125] Torque : N.m (kgfm, Ib-ft) 4. Oil filler cap 7. Intake CVVTassembly | 13, Valce spring seat 2. Cylinder head cover 8. MLA(Mechanical Lash | 14. Intake OCV (Oil control valve) 3. Cylinder head cover gasket Adjuster) 48, Exhaust OCV (Oil control valve) 4, Camshaft bearing cap '8, Retainer lock 16, OCV filter 5. Front camshaft bearing cap 10, Retainer 17. Valve 16. Exhaust CVT assembly 11. Valve stem seal 18. Cylinder head gasket 12, Valve spring 418, Cylinder head bolt 1392 of 19922015 > L. 1.0 LPGi KAPPA > Engine Mechanical System > Cylinder Head Assembly > Cylinderltgtish> Repair procedures Please rate this document after reviewing at the bottom of this page. REMOVAL When servicing the part related to LPG fuel supply system, must abide by following items. + The LPG tank is charged with high pressure LPG gas, Never disasemble the LPG tank because it may cause the fire and explosion if disassembling the LPG tank arbitrarily + Be sure to remove inflammable materials around the LPG fuel supply system before servicing and ventilate the ‘work shop. Be sure not to service the LPG system in the a sealed place. + Be sure to remove the residual fuel gas completely first in the fuel line before servicing LPG fuel supply system and the fuel line. (Refer to FL group - ‘Release Residual Pressure in Fuel Line’) + Prevent skin contact with gas fuel, Wear Personal Protection Equipment (Safety Glasses, Fuel-resistant gloves) + When you removing the fuel supply and injection system, do not work with compressed air if this can be avoided. + Before opening the system cover a cloth around the connection part. After then, release pressure by loosening the connection part carefully. + Check the tightening condition of all part in the LPG fuel line for leakage with soapsude. + Use fender covers to avoid damaging painted surfaces + To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F] before removing it, + When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket + To avoid damage, unplug the wiring connectors carefully while holding the connector portion + Mark all wiring and hoses to avoid misconnection. + Tum the crankshaft pulley so that the No. 1 piston is at top dead center. 1. Remove the timing chain. (Refer to Timing system in this group) 2. Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group) 3. Remove the delivery pipe & injector assembly (A). (Refer to FL group) 1393 of 1992English 6. Remove the CMPS (Camshaft Position Sensor) (A). 1394 of 1992| Head warpage or cracking could result from removing bolts in an incorrect order. Lift the cylinder head(A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench. And remove the cylinder head gasket (B). 1395 of 1992Be careful not to damage the contact surfaces of the cylinder head and cylinder block. DISASSEMBLY NOTICE Identify MLA (Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position. 1, Remove the mechanical lash adjuster (A). 2. Remove the valves. (1) Using the SST(09222-3K000, 09222-3K 100), press the valve spring and remove retainer lock. 0822 aKoe0 (2) Remove the spring retainer. (3) Remove the valve spring. (4) Remove the valve. (6) Using the SST(09222-28000), remove the valve stem seal 1396 of 1992ei Do not reuse old valve stem seals INSPECTION Cylinder Head 1, Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard : Less than 0.05mm (0.0020in) Less than 0.02mm (0,0008in) / 100x100 Flatness of manifold gasket surface Standard : Less than 0.1mm (0.0039in) —~ 2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. Valve And Valve Spring 1397 of 19921, Inspect valve stems and valve guides. (1) Using a caliper gauge, measure the inside diameter of the valve guide, Valve guide ILD. Intake / Exhaust 5.500 ~ §.512mm (0.2165 ~0.2170in) (2) Using a micrometer, measure the diameter of the valve stem. Valve stem 0.0. Intake : 5.465 ~ 5.480mm ( 0.2151 ~ 0.2157in) Exhaust : 5.448 ~ 5.460mm (0.2144 ~ 0.2149in) (3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement. Valve stem-to-guide clearance Intake : 0,020 ~ 0,047mm (0,00078 ~ 0,0018Sin) Exhaust :0.040 ~ 0.064mm (0.00157 ~ 0.00251in) 2. Inspect valves. (1) Check the valve is ground to the correct valve face angle. Valve face ang! Intake/Exhaust : 45.25° ~ 45.75° (2) Check that the surface of the valve for wear. If the valve face is worn, replace the valve. (3) Check the valve head margin thickness, If the margin thickness is less than minimum, replace the valve. Margin Intake : 1.36 ~ 1.65mm (0.0531 ~ 0.0850in) Exhaust : 1.60 ~ 1.90mm (0.0630 ~ 0.0748in) 1398 of 1992a te (4) Check the valve length, Length Intake : 92.85mm (3.6555in) Exhaust ; 93.37mm (3.6758in) (6) Check the surface of the valve stem tip for wear. If the valve stem tip is wor, replace the valve, 3. Inspect valve seats. (1) Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is wom, replace cylinder head. (2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is wom, replace cylinder head. (@) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face. Valve seat contact width : Intake : 0.85 ~ 1.5mm ( 0.0334 ~ 0.0452in) Exhaust : 1.35 ~ 1.65mm (0.0531 ~ 0.0649 in) Valve seat ang Intake / Exhaust : 44,75" ~ 45.10° 4, Inspect valve springs. (1) Using a steel square, measure the out-of-square of the valve spring 2) Using vernier calipers, measure the free length of the valve spring, Valve spring Free height : 47.9mm (1.8858in) Out-of-square : 1.5° (MAX) Nfs MLA (Mechanical Lash Adjuster) 4. Inspect the MLA. Using a micrometer, measure the MLA outside diameter MLA outside diameter Intake/Exhaust 1399 of 199227.964 ~ 27.980mm (1.1009 ~ 1.1016in) Using a caliper gauge, masure MLA tappet bore inner diameter of cylinder head ‘Tappet bore inner diameter Intake/Exhaust 28.000 ~ 28.025mm (1.1024 ~ 1.1033in) ‘Subtract MLA outside diameter measurement from tappet bore inside diameter measurement, MLA to tappet bore clearance [Limit] Intake/Exhaust 0,020 ~ 0,061mm (0,008 ~ 0,0024in) Camshaft 1. Inspect cam lobes. Using @ micrometer, measure the cam lobe height. Cam height Intake : 41,79824mm (1.6456in) Exhaust : 40,39820mm (1.5905in) If the cam lobe height is less than standard, replace the camshatt 2. Inspect the camshaft journal clearance. (1) Clean the bearing caps and camshaft journals. 2) Place the camshafts on the cylinder head. (3) Lay a strip of plastigage across each of the camshaft journals, (4) Install the front camshaft bearing cap (A) and the camshaft bearing cap (B) as following method with specified torque, Tightening torque : Step 1 A: 9.8N.m (1.0kgf.m, 7.2lb-tt) B- 5.9N.m (O.6kaf.m, 4.31b-t) Step 2 A: 18.6 ~ 22.6N.m (1.9 ~ 2.3kghm, 13.7 ~ 16.6\b-) 1400 of 1992B: 11.8 ~ 12.7Nim (1.2 ~ 1.3kgf.m, 8.7 ~ 9.4lb-t) Wein Do not tum the camshaft. When cam caps are installed, arrows on the top of caps must point to out side of engine, (6) Remove the bearing caps. (6) Measure the plastigage at its widest point. Camshaft bearing oil clearance Intake : 0.027 ~ 0.057mm (0.0010 ~ 0.0022in) Exhaust ; 0.027 ~ 0.057mm (0.0010 ~ 0.0022in) Camshaft journal outer diameter Intake / Exhaust No.1 36.464 ~ 36.478mm (1.4356 ~ 1.4364in) Intake / Exhaust No.2~5 20,964 ~ 20.878mm (0.8254 ~ 0.8259in) Camshaft journal bore inner diameter Intake / Exhaust No.1 36,505 ~ 36.521mm (1.4372 ~ 1.4378in) Intake / Exhaust No.2~5 21.005 ~ 21.021mm (0.8270 ~ 0.8276in) If the oil clearance is greater than maximum, replace the camshatt. If necessary, replace cylinder head (7) Completely remove the plastigage. (8) Remove the camshafts, 3, Inspect the camshaft end play. (1) Install the camshafts (A). 1401 of 1992(2) Install the camshaft front bearing caps (A) and the camshaft bearing cap (B) as following method with specified torque. Tightening torqu Step 1 ‘A: 8.8Num (1,0kgf.m, 7.2lb-tt B: 5.9Nm (O.6kgf.m, 4.31b-t) Step 2 A: 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft) B: 11.8 ~ 12.7N.m (1.2 ~ 1.3kaf.m, 8.7 ~ 9.4lb-) Kl = Rees Do not turn the camshaft. When cam caps are installed, arrows on the top of caps must point to out side of engine, (3) Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play = Intake : 0.1 ~ 0.2mm (0.0039 ~ 0.0078in) Exhaust : 0.1 ~ 0.2mm (0.0039 ~ 0.0078in) 1402 of 1992If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head. (4) Remove the camshafts, Continuously variable valve timing(CVVT) Assembly 4. Inspect the CWT for smooth rotation. (1) Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals in the vise. (2) Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate, (3) Intake CVVT : Seal one of the two advance holes in the camshaft journal with tape, Exhaust CVVT : Seal one of the two retard holes in the camshaft joumal with tape, [Intake] a (peter ME (advance) [Exhaust] (@) Intake CVVT : Apply approx. 150 kPa (1.5 kaficm, 21 psi ) of compressed air into the unsealed advance hole to release the lock Exhaust CVT : Apply approx. 150 kPa (1.5 kaf/cm*, 21 psi ) of compressed air into the unsealed retard hole to release the lock. WD information Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying, (5) 1403 of 1992Intake CVVT : With compressed air applied, rotate the CVVT into the advance direction (counterclockwise) within its phasing range and check that the CVVT tums smoothly. Exhaust CVT : With compressed air applied, rotate the CVVT into the retard direction (clockwise) and check that the CWT tums smoothly CWT phasing range Intake: 25°41° (from the most retarded position to the most advanced position) Exhaust : 20°21" (from the most advanced position to the most retarded position) ©) Intake CVVT : Rotate the CVVT into the most retarded position (clockwise) and then check that the CVVT is locked. Exhaust CVT : Rotate the CVVT into the most advanced position (counterclockwise) and then check that the CWT is locked. REASSEMBLY + Thoroughly clean all parts to be assembled. + Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. 1. Install the valves. (1) Using the SST(03222-03100), push in a new valve stem seal. + Do not reuse old valve stem seals. + Incorrect installation of the seal could result in oil leakage past the valve guides. (2) Install the valve, valve spring and spring retainer. 1404 of 1992Place valve springs so that the cone shape side is upward retainer side, (@) Using the SST(09222 - 3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor 0822 aKoe0 (4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock. 2. Install the mechanical lash adjuster (A). MLA can be reinstalled in its original position. However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the cylinder block. Refer to General information in EM section for Valve Clearance checking and adjustment procedure. INSTALLATION + Thoroughly clean all parts to be assembled + Always use a new head and manifold gasket. + The cylinder head gasket is a metal gasket, Take care not to bend it. + Rotate the crankshaft, set the No.1 piston at TDC. 1. Install the cylinder head gasket. (1) The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oll and ete. (2) Apply sealant TB1217 or LT5900 on the cylinder block top surface (Refer to below illustration) before assembling the cylinder head gasket. 1405 of 1992im ra arm tte (0458) (8883in) (3) Install the cylinder head gasket (A) on the cylinder block, Saslant Be careful of the installation direction. (4) Apply sealant TB1217 or LT5900 on the cylinder head gasket top surface (Refer to below illustration) after assembling the cylinder head gasket. OS vem 7" item (05633!) (8888in) (6) Remove the extruded sealant after assembling the cylinder head assembly, 2. Install the cylinder head assembly. (1) Place the cylinder head assembly (A) quietly in order not to damage the gasket with the bottom part of the end. 1406 of 1992(2) Using SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown, Tightening torque : 12.7~16.7Nm (1.3~1.7kgf.m, 9.4~12.Slb-ft) + 90~95° + 120~125° Do not reuse the cylinder head bolts. 3. Install the CMPS (Camshaft Position Sensor) (A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-f) 4, Install the intake / exhaust OCV (Oil Control Valve)(A) and the OCV (Oil Control Valve) fiter (B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 1407 of 19926. Install the front camshaft bearing cap (A) and the camshaft bearing caps (B) as following method with specified torque Tightening torque Step 1 A: 9.8N.m (1.0kgf.m, 7.2lb-tt) B: 5.9N.m (0.6kgf.m, 4.31b-f) Step 2 A: 18,6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.61b-f) Be 11.8 ~ 12.7Nm (1.2 ~ 1.3kgf.m, 8.7 ~ 8.4lb-f) 1408 of 19927. Install the delivery pipe (A) Tightening torque : 18.6 ~ 28.5 Nm (1.9 ~ 2.4 kgfim, 13.7 ~ 17.4 Ib-t) 8. Install the intake and exhaust manifold. (Refer to Intake and exhaust system in this group) 9, Install the timing chain, (Refer to Timing system in this group) 1409 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Cylinder Block > Cylinder Block > English + Components and Components Location Please rate this document after reviewing at the bottom of this page. COMPONENTS [58.8 (6.0, 49.4)] + [29-31] Torque : N.m (kgf.m, Ib-ft) [17.7-21.6 (1.8-2.2, 18.0-15.9)] + [88-9217 1, Piston ring 2. Piston 3. Piston pin ‘4, Connecting rod 5. Connecting rod bearing (Upper) '6. Connecting rod bearing (Lower) 7. Connecting rod cap 8. Cylinder block 8, O-ring 10. Crankshaft pulley ‘11 .Thnust bearing 12, Main bearing (Upper) 13. Crankshaft 14, Main bearing (Lower) 15, Main bearing cap 16. Flywheel 1410 of 19922015 > L 1.0 LPGi KAPPA > Engine Mechanical System > Cylinder Block > Cylinder Block > Repaitth procedures Please rate this document after reviewing at the bottom of this page. DISASSEMBLY + Use fender covers to avoid damaging painted surfaces + To avoid damage, unplug the wiring connectors carefully while holding the connector portion. + Mark all wiring and hoses to avoid misconnection. + Inspect the timing belt before removing the cylinder head. + Tum the crankshaft pulley so that the No.‘ piston is at top dead center. + Engine removal is required for this procedure. 1. Remove the engine assembly from the vehicle. (Refer to Engine and transaxle assembly in this group) 2. Remove the flywheel (A). 3. Install the engine to engine stand for disassembly. 4, Remove the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group) 5, Remove the timing chain, (Refer to Timing system in this group) 6. Remove the cylinder head, (Refer to Cylinder head in this group) 7, Remove the water inlet fitting (A), thermostat (B) and thermostat housing (C). 1411 of 19928 Remove the oill pan (A). English Insert the blade of SST(09216-3C000) between the ladder frame and the oil pan. Cut off applied sealer anu vesnuve we oil pan. 182163000 + Insert the SST between the ladder frame and the oll pan by tapping it with a plastic hammer in the direction of (1) arrow, After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame, + Do not tum over the SST abruptly without tapping. It be result in damage of the SST. Be careful not to damage the contact surfaces of ladder frame and cil pan. 9, Remove the oil screen (A). 10. Remove the ladder frame (A) Insert the blade of SST(09215-3C000) between the cylinder block and the ladder frame. Cut off applied sealer and remove the ladder frame, 1412 of 1992Insert the SST between the cylinder block and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow. + After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the ladder frame, remove it from the cylinder block. + Do not turn over the SST abruptly without tapping. It be result in damage of the SST. + Be careful not to damage the contact surfaces of cylinder block and ladder frame. ‘11. Check the connecting rod end play. 12. Remove the connecting rod caps and check oil clearance. 13. Check the crankshaft and connecting rod bearing oil clearance. 14. Remove the piston and connecting rod assemblies, (1) Using a ridge reamer, remave all the carbon from the top of the cylinder. (2) Remove the connecting rod cap, (3) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block, re + Keep the bearings, connecting rod and cap together, + Arrange the piston and connecting rod assemblies in the correct order. 15. Remove the main bearing caps and check oil clearance. 16. Check the crankshaft end play. 417. Lift the crankshaft (A) out of engine, being careful not to damage journals NOTICE ‘Arrange the main bearings and center bearings in the correct order. 1413 of 199218. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a set 19, Remove the piston rings. (1) Using a piston ring expander, remove the 2 compression rings. (2) Remove 2 side rails and the spacer by hand, NOTICE Arrange the piston rings in the correct order only. 20. Remove the connecting rod from the piston. Using a press, remove the piston pin from the piston. Press-in load : 250 ~ 1050kg (551 ~ 2315Ib) INSPECTION Connecting Rod And Crankshaft 1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth, Standard end play : 0.10 ~ 0.25mm (0.0038 ~ 0.0098in) (1) It out-of tolerance, install a new connecting rod. (2) H stil outottolerance, replace the crankshaft. 2, Check the connecting rod bearing ol clearance. (1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly. (2) Remove the 2 connecting rod cap bolts. (@) Remove the connecting rod cap and lower bearing (4) Clean the crank pin journal and bearing (6) Place a plastigage across the crankshaft pin journal (6) Reinstall the lower bearing and cap, and tighten the bolts. Tightening torque 10.8~14.7Nm (1.1~1.5kgf.m, 8.0~10.8lb-ft) + 88-92" 1414 of 1992