SECTION 1B

1.2 SOHC ENGINE MECHANICAL

Caution : Disconnect the negative battery cable before removing or installing
any electrical unit or when a tool or equipment could easily come in contact
with exposed electrical erminals. Disconnecting this cable will help prevent
personal injury and damage to the vehicle. The ignition must also be in
LOCK unless otherwise noted.

SPECIFICATIONS
Engine Specifications
Application
General Data:
Engine Type
Displacement:
Bore Stroke:
Compression Ratio
Firing Order
Cylinder Bore:
Diameter
Out of Round (Maximum)
Taper (Maximum):
Piston :
Diameter
Clearance to Bore
Piston Rings:
Ring, End Gap:
Top Compression
2nd Compression
Groove Clearance:
Top Impression
2nd Impression
Piston Pin :
Diameter
Pin Off-Set
Camshaft:
Lift Intake:
Lift Exhaust
End Play

Description (Manual and Automatic)

.
4 Cylinder (In-Line)
1150 cm
68.5 x 78.0 mm (2.70 in. x 3.07 in.)
9.3 : 1
1-3-4-2
.
68.5 mm (2.70 in.)
0.005 mm (0.00020 in.)
0.005 mm (0.00020 in.)
.
68.465 ~ 68.485 mm (2.695 ~ 2.696 in.)
0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in.)
.
.
0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in.)
.
0.02 ~ 0.06 mm (0.0008 ~ 0.002 in)
0.02 ~ 0.06 mm (0.0008 ~ 0.002 in.)
.
16.995 ~ 17.000 mm (0.6691 ~ 0.6693 in.)
0.4 ~ 0.6 mm (0.016 ~ 0.024 in.)
.
5.42 mm (0.213 in)
5.38 mm (0.212 in.)
.

Application
Journal OD:
No. 1
No. 2
No. 3
No. 4
No. 5
Bearing OD:
No. 1
No. 2
No. 3
No. 4
No. 5
.
Crankshaft :
Main Journal
Diameter (All)
Taper (Maximum)
Out of Round
(Maximum)
Main Bearing
Clearance (All)
Crankshaft End Play
Connecting Rod Journal:
Diameter (All)
Taper (Maximum)
Out of Round (Maximum)
Rod Bearing Clearance (All)
Rod Side Clearance
.
Valve System:
Valve Lash Compensators
Face Angle (All)
Seat Angle (All)
Seat Runout (Maximum, All)
Face Runout (Maximum, All)
Seat Width:
Intake
Exhaust
Valve Guide Inside Diameter
(All)

Description (Manual and Automatic)

.
43.425 ~ 43.450 mm (1.710 ~ 1.711 in.)
43.625 ~ 43.650 mm (1.718 ~ 1.719 in.)
43.825 ~43.850 mm (1.725 ~ 1.726 in.)
44.025 ~ 44.050 mm (1.733 ~ 1.734 in.)
44.225 ~ 44.250 mm (1.741 ~ 1.742 in.)
.
43.500 mm (1.713 in.)
43.700 mm (1.720 in.)
43.900 mm (1.728 in.)
44.100 mm (1.736 in.)
44.300 mm (1.744 in.)
.
43.982 ~ 44.000 mm (1.7316 ~ 1.7323 in.)
0.005 mm (0.0002 in.)
0.005 mm (0.0002 in.)
0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
0.11 ~ 0.31 mm (0.004 ~ 0.012 in.)
.
37.982 ~ 38.000 mm (1.495 ~ 1.496 in.)
0.005 mm (0.0002 in.)
0.005 mm (0.0002 in.)
0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
0.10 ~ 0.25 mm (0.004 ~ 0.010 in.)
Mechanical
45
45
0.05 mm (0.0019 in.)
0.045 mm (0.0018 in.)
.
1.56 mm (0.061 in.)
1.56 mm (0.061 in. )
5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)

Application
Valve Stem Diameter
Intake
Exhaust
Valve Diameter (All):
Intake
Exhaust
Valve Spring Loads:

Description (Manual and Automatic)

.
5.465 ~ 5.480 mm (0.215 ~ 0.216 in.)
5.440 ~ 5.455 mm (0.214 ~ 0.215 in.)
.
35.5 ~ 35.7 mm (1.398 ~ 1.406 in.)
31.7 ~ 31.9 mm (1.248 ~ 1.256 in.)
.
55.0 3.3 Kgf (121.25 7.28 lbs) @ 36.2 mm
(1.425 in.)
25.2 1.8 Kgf (55.56 3.97 lbs) @ 44.2 mm
(1.740 in.)

Valve Open
Valve Closed
.
Oil Pump :
Gap Between Oil Pump Body
and Out Rotor
Out Rotor Side Clearance
Inner Rotor Side Clearance
Relief Valve Spring Free
Length

0.10 ~ 0.17 mm (0.0039 ~ 0.0067 in.)

0.065 ~ 0.115 (0.0026 ~ 0.0045 in.)
0.065 ~ 0.115 (0.0026 ~ 0.0045 in.)
52.4 mm (2.06 in.)

Fastener Tightening Specifcations

Application
Cylinder Head Bolts
Cylinder Head Cover Hexagon Bolts
Catalytic Converter To Exhaust Manifold Nuts
Heat Shield Mounting Bolts
Timing Belt Rear Cover Bolts
Lower Timing Belt Cover Bolts
Upper Timing Belt Cover Bolts
Crankshaft Pulley Bolts
Air Cleaner Housing Bolts
Camshaft Thrust Plate Screws
Rocker Arm Shaft Mounting Bolts
Water Outlet Case Nuts and the Bolt
Tensioner Bolts to
Timing Belt Tensioner Bolt
Timing Belt Front Lower Cover Bolts
Oil Level Gauge Guide Tube Bolt
Timing Belt Front Upper Cover Bolts
Air Cleaner Housing Bolts

Nm
65 - 70
9 - 12
25 - 35
8 - 12
9 - 12
9 - 12
9 - 12
85
7-9
10
10
10.5
19
19
10.5
10.5
10.5
12

Lb-Ft
48 - 52
18 - 25
62.7
14
14
-

Lb-In
80 - 106
71 - 106
80 - 106
80 - 106
80 - 106
62 - 80
89
89
93
93
93
93
106

Application
Oil Pump Bolts to
Oil Pump Strainer Bolts
Rear Timing Belt Cover Bolts
Camshaft Gear Bolt to
Oil Pan Retaining Bolts and the Nuts
Intake Manifold Retaining Nuts and Bolts
Exhaust Manifold Bolts and the Nuts
Front Exhaust Pipe Bracket Bolts
Catalytic Converter Lower Flange Nuts
Exhaust Manifold Heat Shield Bolts
Engine Mounting Bracket Bolt
Flywheel Bolt

Nm
10.5
10.5
10.5
55
10
17
22
40
40
10
55
42.5

Lb-Ft
41
44
13
16
30
41
31

Lb-In
93
93
93
30
89
-

SPECIAL TOOLS
Special Tools Table

09915-64510
Compression Pressure
Gauge

09915-67310
Vacuum Gauge

09915-77310
Oil Pressure Gauge

09916-14510
Valve Spring
Compressor
09916-48210
Valve Spring
Compressor Attachment

09916-34541
Reamer Handle

09916-37320
Valve Guide Reamer
(5mm or 0.1969 in.)

09916-38210
Valve Guide Reamer
(11mm or 0.4331 in.)

09916-44910
Valve Guide Remover

09916-58210
Valve Guide Installer

09916-77310
Piston Compressor

09917-68220
Camshaft Sprocket
Holder

09917-88220
Valve Guide Installer
Attachment

09918-08210
Vacuum Gauge Joint

09927-56020
Crankshaft Pully Holder

DW 100-010
Fuel Pressure Gauge

DW110-060
Engine Assembly
Support Fixture

DW 150-020
Distributor Case Nut
Remover/Installer

KM - 412
Engine Overhaul Stand

DW 010 - 010
Engine & Transaxle
Assembly Support
Remover/Installer

COMPONENT LOCATOR
Cylinder Head

1. Oil Filler Cap

2. Cylinder Head Cover
3. Cylinder Head Cover
4. Distributor Case
5. Camshaft
6. Exhaust Rocker Arm
7. Cylinder Head Gasket
8. Cylinder Head
9. Intake Rocker Arm
10. Exhaust Valve
11. Intake Valve

Engine Block

1. Oil Level Gauge Stick

2. Piston
3. Connecting Rod
4. Engine Block
5. Oil Filter
6. Flywheel
7. Crankshaft
8. Oil Pan
9. Oil Pump Strainer
10. Oil Pump Assembly

Manifold & Air Flow System

1. Intake Manifold
2. Exhaust Gas Recirculation (EGR) Pipe
3. Exhaust Gas Recirculation (EGR) Valve and Solenoid
4. Throttle Body Assembly
5. Air Filter Assembly
6. Resonator
7. Snorkel
8. Oxygen Sensor
9. Exhaust Manifold
10. Exhaust Manifold Heat Shield
11. Exhaust Manifold Heat Shield
12. Exhaust Manifold

Timing Belt

1. Engine Mount Damping Block

2. Engine Mount Intermediate Bracket
3. Engine Mount Brace Bracket
4. Transaxle Mount Bracket
5. Transaxle Mount Damping Block
6. Engine Mount Front Bracket
7. Engine Mount Front Damping Bush
8. Timing Belt
9. Timing Belt Tensioner
10. Crankshaft Gear
11. Timing Belt Upper Front Cover
12. Timing Belt Lower Front Cover

13. Crankshaft Pulley

14. Engine Mount Lower Bracket
15. Engine Mount Upper Bracket

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Cylinder Head Cover

Removal Procedure
1.
2.
3.
4.

Disconnect the negative battery cable.

Disconnect the PCV hose from the cylinder head cover.
Disconnect the ignition wires at the spark plug and the ignition coil.
Remove the ignition coil. Refer to Section 1F1, Engine Controls.

5. Remove the cylinder head cover hexagon bolts.

6. Remove the cylinder head cover with gasket.
7. Clean the sealing surfaces of the cylinder head cover and the cylinder
head.

Installation Procedure
1. Install the cylinder head cover with the new gasket.
2. Install the bolts to the cylinder head cover.
Tighten
Tighten the cylinder head cover hexagon bolts to 10.5 Nm (93 lb-in).

3. Connect the PCV hose to the cylinder head cover.

4. Install the ignition coil. Refer to Section 1F1, Engine Controls.
5. Connect the negative battery cable.

Cylinder Head and Gasket

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the
fuel system of fuel pressure.
3. Disconnect the negative battery cable.

4. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

5. Disconnect the PCV hose from the cylinder head cover.
6. Remove the ignition coil. Refer to Section 1F1, Engine Controls.

7. Remove the air cleaner housing bolts.

8. Remove the air cleaner housing.

9. Disconnect the main throttle idle actuator (MTIA) connector.

10. Disconnect the A/C pressure transducer connector.

11. Disconnect the intake air temperature (IAT) sensor connector.

12. Disconnect the throttle cable from the throttle body.
13. Disconnect the brake booster vacuum hose at the intake manifold.

14. Disconnect the fuel injector harness connectors.

15. Disconnect the fuel line at the fuel rail.
16. Disconnect the fuel rail with the fuel injector attached.

17. Disconnect the camshaft position sensor connector.

18. Disconnect the engine coolant temperature (ECT) sensor connector.

19. Slightly loosen the power steering lower adjusting bolt.

20. Slightly loosen the power steering upper adjusting bolt.

21. Remove the A/C with power steering drive belt.

22. Remove the upper timing belt cover bolts.

23. Remove the upper timing belt cover.

24. Align the camshaft gear timing mark to the notch in the rear timing belt
cover.

25. Slightly loosen the alternator retaining bolts.

26. Remove the alternator drive belt.

27. Remove the engine under cover.

28. Remove the crankshaft pulley bolt.
29. Remove the crankshaft pulley.

30. Remove the lower timing belt cover bolts.

31. Remove the lower timing belt cover.

32. Remove the timing belt automatic tensioner bolt.

33. Remove the timing belt automatic tensioner.
34. Remove the timing belt. Refer to "Timing Belt" in this section.

35. Remove the camshaft gear bolt from the camshaft.

36. Remove the timing belt rear cover bolts.

37. Remove the timing belt rear cover from the cylinder head and cylinder
block.

38. Remove the heat shield mounting bolts.

39. Remove the heat shield.

40. Remove the retaining nuts from the catalytic converter at the exhaust
manifold flange.

41. Remove the cylinder head cover with the hexagon bolts.
42. Remove the cylinder head cover gasket.

43. Gradually loosen all of the cylinder head bolts in the sequence shown.
44. Remove the cylinder head bolts.
45. Remove the cylinder head assembly from the engine block, with the
intake/exhaust manifold, throttle body, water outlet case and cylinder head
gasket.

Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and the engine block.
2. Make sure the gasket surfaces of the cylinder head and the engine block
are free of nicks and heavy scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve
Train Components" in this section.

Installation Procedure
1. Install the cylinder head gasket.
2. Install the cylinder head with the intake manifold and the exhaust manifold
attached.
3. Install the cylinder head bolts in the sequence shown.
Tighten
Tighten the cylinder head bolts to 65-70 Nm (4852 lb-ft).

4. Install the cylinder head cover hexagon bolts.

Tighten
Tighten the cylinder head cover hexagon bolts to 912 Nm ( 80106 lbin).

5. Install the catalytic converter nuts at the exhaust manifold flange.

Tighten
Tighten the catalytic converter to exhaust manifold nuts to 2535 Nm (
18-25 lb-ft).

6. Install the heat shield.

7. Install the heat shield mounting bolts.
Tighten
Tighten the heat shield mounting bolts to 8-12 Nm (71-106 lb-in).

8. Install the timing belt rear cover to the cylinder head and cylinder block.
9. Install the timing belt rear cover bolts.
Tighten
Tighten the timing belt rear cover bolts to 9-12 Nm (80-106 lb-in).

10. Install the timing belt. Refer to "Timing Belt" in this section.
11. Install the lower timing belt cover.
12. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 9-12 Nm (80-106 lb-in).

13. Install the upper timing belt cover.

14. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 9-12 Nm (80-106 lb-in).

15. Install the crankshaft pulley.

16. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 85 Nm ( 62.7 lb-ft)

17. Install the A/C with power steering drive belt. Refer to Section 6B,
Accessory Belt.
18. Install the alternator drive belt.

19. Connect the engine coolant temperature (ECT) sensor connector.

20. Connect the camshaft position sensor connector.

21. Connect the fuel line at the fuel rail.

22. Connect the fuel injector harness connectors.

23. Connect the brake booster vacuum hose at the intake manifold.
24. Connect the throttle cable to the throttle body.
25. Connect the intake air temperature (IAT) sensor connector.

26. Connect the A/C Pressure transducer connector.

27. Connect the main throttle idle actuator (MTIA) connector.

28. Install the air cleaner housing.

29. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 7-9 Nm ( 6280 lb-in).

30. Connect the PCV hose from the cylinder head cover.
31. Install the ignition coil. Refer to Section 1F1, Engine Controls.
32. Connect the negative battery cable.
33. Install the fuel pump fuse.
34. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.

Camshaft
Removal Procedure
1. Remove the timing belt. Refer to "Timing Belt" in thissection.
2. Remove the ignition coil at the cylinder head cover.

3.
4.
5.
6.
7.

Drain the engine coolant. Refer to Section 1D, Engine Cooling.

Disconnect the camshaft position (CMP) sensor connector.
Disconnect the engine coolant temperature (ECT) sensor connector.
Disconnect the radiator upper hose at the water outlet case.
Disconnect the throttle body and heater feeding hoses.

8. Remove the cylinder head cover with gasket.

9. Remove the water outlet case nuts and the bolt.

10. Remove the water outlet case at the cylinder head.

11. Remove the rocker arm shaft mounting bolts.

12. Remove the rocker arm spring and the rocker arm.

13. Remove the screws with the camshaft thrust plate.

14. Remove the camshaft.

Installation Procedure
1. Install the camshaft.
2. Install the camshaft thrust plate.
3. Install the camshaft thrust plate screws.
Tighten
Tighten the camshaft thrust plate screws to 10 Nm ( 89 lb-in).

4. Install the rocker arm spring and the rocker arm.

5. Install the rocker arm shaft.
6. Install the rocker arm shaft mounting bolts.
Tighten
Tighten the rocker arm shaft mounting bolts to 10 Nm ( 89 lb-in).

7. Install the water outlet case at the cylinder head.

8. Install the water outlet case nuts and the bolt.
Tighten
Tighten the water outlet case nuts and the bolt to 10.5 Nm (93 lb-in).

9. Install the cylinder head cover gasket.

10. Install the cylinder head cover.
11. Install the cylinder head cover hexagon bolts.
Tighten
Tighten the cylinder head cover hexagon bolts to 10.5 Nm (93 lb-in).

12. Connect the throttle body and heater feeding hose.

13. Connect the radiator upper hose.
14. Connect the CMP and ECT sensor connectors.

15. Install the ignition coil. Refer to Section 1F1, Engine Controls.
16. Connect the PCV hose to the cylinder head cover.
17. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.
18. Connect the negative battery cable.
19. Install the timing belt. Refer to "Timing Belt" in thissection.

Adjustment of Valve Clearance

Removal Procedure
1. Remove the cylinder head cover hexagon bolts and remove the cover.
2. Turn over the crankshaft to make NO.1 cylinder matched with the
compression top dead center. When the camshaft sprocket notch is
aligned with the timing belt rear cover triangle pointer and the crankshaft
sprocket point is aligned with the oil pump housing point, the compression
top dead center is on the ignition sequence for NO.1 cylinder.

3. Check the valve clearance for NO.1 cylinder compression top dead center.
4. If the checking for the valve clearance of No1 cylinder compression top
dead center is over, position No.1 cylinder on the exhaust top dead center
as rotating the crankshaft in a 360degree arc. When the camshaft
sprocket point is aligned with the timing belt rear cover triangle pointer, the
exhaust top dead center is on the ignition sequence for No.1 cylinder.

5. Check the valve clearance for the No.1 cylinder exhaust top dead center.
Condition

Cylinder No.
1 2 3
Intake
.
.
O
Exhaust top dead center of No.1 cylinder
Exhaust
.
O .
* O marks indicates the place where the valve clearance can be checked
and adjusted.

4
O
O

6. Check the adjust the valve clearance using thickness gauge. The
measured value of valve clearance should meet the specified value. If not,
adjust the valve clearance.
Important : In case of hot engine, warm up the engine until the
electric cooling fan begins to work and stop engine to adjust the
clearance with 20-30 minutes there from.
Unit : mm (in.)
Item
Specified value
Cold
Intake
0.150.02 (0.00590.0008)
.
Exhaust
0.20.02 (0.007870.0008)
Valve Clearance
Hot
Intake
0.250.02 (0.00980.0008)
.
Exhaust
0.30.02 (0.01180.0008)

7. When adjusting the valve clearance, loosen the adjust nut and then
tighten or loosen the adjust rod properly.

Valve Timing Check and Adjustment

1. After removing the air cleaner housing, loosen the bolts and remove the
timing belt front upper cover.

2. Turning the crankshaft clockwise twice, align the notch on the crankshaft
pulley with the mark 0 for the timing check on the timing belt front lower
cover.

3. Check if the notch on the camshaft sprocket is aligned with the triangle
pointer on the timing belt rear cover.
Important : Notch should be aligned with pointer to set the valve
timing normally.

4. Loosen the bolt and remove the timing belt pulley. In loosening the bolt,
use the driver in the picture shown.

5. Remove the oil level gauge guide tube and the timing belt front lower
cover.

6. Remove the timing belt tensioner and the timing belt.

7. Using the bolt, turn the crankshaft clockwise to align the mark on the
crankshaft sprocket with the pointer on the oil pump housing. Then, turn
the camshaft to align the notch with the pointer.

8. Install the timing belt and the tensioner.

9. Turning the crankshaft clockwise twice, align the mark with the pointer and
tighten the tensioner bolt.
Tighten
Tighten the tensioner bolt to 19 Nm (14 lb-ft).

Timing Belt
1.
2.
3.
4.
5.
6.

Disconnect the negative battery cable.

Disconnect the air cleaner outlet hose from the throttle body.
Remove the air cleaner housing bolts.
Remove the air cleaner housing.
Remove the right front wheel. Refer to Section 2E,Tires and Wheels.
Remove the right front wheel well splash shield.

7. Remove the A/C compressor drive belt.

8. Remove the alternator drive belt.
9. Remove the upper timing belt cover bolts.
10. Remove the upper timing belt cover.

11. Align the mark on the camshaft gear with the notch on the rear timing belt
cover by turning the crankshaft pulley.

12. Remove the crankshaft pulley bolt.

13. Remove the crankshaft pulley.
14. Remove the lower timing belt cover bolts.
15. Remove the lower timing belt cover.

16. Loosen the timing belt tensioner bolt.

17. Remove the timing belt.

Installation Procedure
Important : If the camshaft or crankshaft rotates in the process of
installing the timing belt, Perform the valve timing setting necessary.
Refer to "Valve Timing Check and Adjustment"in this section.
1. Install the timing belt tensioner bolt.
Tighten
Tighten the timing belt tinsioner bolt to 19 Nm ( 14 lb-ft).

Important : Turn the crankshaft twice to align the notch on the

camshaft with the pointer on the rear cover and tighten the tensioner
bolt.
2. Install the lower timing belt cover.
Tighten
Tighten the lower timing belt cover bolts to 10.5 Nm ( 93 lb-in).

3. Install the oil level gauge guide tube bolt.

Tighten
Tighten the oil level gauge guide tube bolt to 10.5 Nm (93 lb-in).

4. Install the upper timing belt cover.

Tighten
Tighten the upper timing belt cover bolts to 10.5 Nm ( 93 lb-in).

5. Install the crankshaft pulley bolt.

Tighten
Tighten the crankshaft pulley bolts to 70 Nm (52 lb-ft).

6. Install the alternator drive belt.

7. Install the A/C compressor drive belt.
8. Install the right front wheel. Refer to Section 2E,Tires and Wheels.
9. Install the air cleaner housing.
10. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 12 Nm (106 lb-in).

UNIT REPAIR
Cylinder Head and Valve Train Components
Tools Required
09916-14510 Valve Spring Compressor
09916-37320 Valve Guide Reamer
09916-38210 Valve Guide Reamer
09916-44910 Valve Guide Remover
09916-48210 Valve Spring Compressor Attachment
09916-58210 Valve Guide Installer
09917-88220 Valve Guide Installer Attachment
KM 412 Engine Overhaul Stand

Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust
manifold attached. Refer to "Cylinder Head and Gasket" in this section.
2. Remove the bolt and the nuts in the water outlet case .
3. Remove the water outlet case.

4. Remove the exhaust manifold heat shield bolts.

5. Remove the exhaust manifold heat shield.

6. Remove the exhaust manifold nuts and the bolts.

7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.

9. Remove the spark plugs.

10. Remove the intake manifold retaining bolts and the nuts.
11. Remove the intake manifold with the gasket.
12. Remove the intake manifold studs.

13. Remove the rocker arm shaft mounting bolts.

14. Remove the rocker arm spring and the rocker arm.

15. Remove the screws with the camshaft thrust plate.

16. Remove the camshaft.

17. Remove the camshaft front oil seal from housing hole.

18. Using the valve spring compressor 09916-14510, compress the valve
spring
19. Remove the valve keepers.
20. Remove the valve spring retainer and valve spring.
21. Remove the valves.

22. Remove the valve stem oil seals.

23. Remove the valve spring seat.

24. Position the valve guide remover 09916-44910 on the valve guide.
25. 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.
26. Remove the valve guide.

Cylinder Head Inspection

1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and the mating surfaces for leaks,
corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head using a feeler gauge
and a straight edge.
5. Check the sealing surfaces for deformation and warpage. The cylinder
head sealing surfaces must be flat with in 0.05mm (0.0020 in.) maximum.

6. Inspect all threaded holes for damage.

7. Inspect the valve seats for excessive wear and burned spots.

Valve Inspection

1.
2.
3.
4.
5.
6.

Inspect valve stem tip wear.

Inspect the valve keeper grooves and oil seal grooves for chips and wear.
Inspect the valves for burns or cracks.
Inspect the valve stem for burrs and scratches.
Inspect the valve stem. The valve stem must be straight.
Inspect the valve facefor grooving. If the groove is so deep the refacing
would result in a sharp edge, replace the valve.

7. Inspect the valve spring. If the valve spring ends are not parallel, replace
the valve spring.
8. Measure the valve spring height. Refer to "Engine Specifications" in this
section. If the valve spring height does not match the specifications,
replace the valve spring.
9. Inspect the valve spring seating surface of the valve rotators for wear or
gouges. Replace as required.

Cleaning Procedure
1.
2.
3.
4.

Clean the cylinder head.

Clean the valve guides.
Clean all of the threaded holes.
Clean the valves of carbon, oil and varnish.

Cylinder Head Overhaul

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 (0.03mm (0.0012 in.)).

Abrasion of The Camshaft Journal

1. Measure the outer diameter of each journal at the 5 different places.

2. Using a bore gauge, measure the inner diameter of the cylinder head
jornal at the 5 places (The clear-ance of journal is measured by the
difference be-tween the outer diameter of camshaft journal and inner
diameter of cylinder head journal part.)
3. Replace the camshaft (or cylinder head, if necessary) of which limit is over
the specified limit.
Item
Journal
Clearance
Item
a
b
c

Standard
0.05-0.091 mm
(0.0020-0.0036 inches)

Outer diameter,
camshaft journal
43.425-43.450 mm
(1.7096-1.7106 in.)
43.625-43.650 mm
(1.7175-1.7185 in.)
43.825-43.850 mm

Limit
0.15 mm
(0.0059 inches)
Inner diameter cylinder head journal
part
43.500-43.516 mm
(1.7126-1.7132 in.)
43.700-43.716 mm
(1.7205-1.7211 in.)
43.900-43.916 mm

d
e

(1.7254-1.7264 in.)
44.025-44.050 mm
(1.7333-1.7343 in.)
44.225-44.250 mm
(1.741-1.742 in.)

(1.7283-1.7290 in.)
44.100-44.116 mm
(1.7362-1.7369 in.)
44.3-44.316 mm
(1.744-1.745 in.)

Bending of The Rocker Arm Shaft

1. Check 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 specification
(0.10mm (0.0039 inches)).

Clearance Between The Rocker Arm and The Rocker Arm Shaft
1. Check the outer diameter of the rocker arm shaft using a micrometer.

2. Check the inner diameter of the rocker arm using a bore gauge.
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 (0.005 - 0.040mm (0.0002 - 0.0016 in.)

Clearance Between The Valve Stem and The Valve Guide

1. Check the outer diameter of the valve stem using a micrometer.
o Intake : 5.465 - 5.480mm (0.2152 - 0.2157 in.)
o Exhaust : 5.440 - 5.455mm (0.2142 - 0.2148 in.)

2. Check the inner diameter of the valve guide using a bore gauge (at least 1
place in the direction to valve length)
o Intake : 5.500 - 5.512mm (0.2165 - 0.2170 in.)
o Exhaust : 5.500 - 5.512mm (0.2165 - 0.2170 in.)
3. Check the clearance between the valve stem and the valve guide
o Intake : 0.020 - 0.047mm (0.0008 - 0.0019 in.)
o Exhaust : 0.0045 - 0.072mm (0.0018 - 0.0028 in.)

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.
o Intake : 0.14mm (0.0055 in.)
o Exhaust : 0.18mm (0.0071 in.)
5. Replace the valve stem or valve guide, if the measured valve is over the
limit.

Valve
1. Inspect the valve. Refer to Valve Inspection in this section.
2. Check the valve or stem for abrasion, burn or bending, and replace as
necessary.
3. Abrasion of the valve edge.
o 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 0.05mm
(0.002 in.) as required, or replace the valve if some modification is
required more than that.

4. Deviation to the rotating direction. Measure the deviation to the rotating

direction using a dial gauge and the V block by turning the valve slowly.
Deviation limit of valve head to the rotating direction within 0.08mm
(0.0031 in.)
5. Replace valve, if the measured value exceeds the limit.

6. 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.
7. Check the contact witdth on the surface of the valve seat.
o Intake : 1.46 - 1.66mm (0.0575 - 0.0654 in.)
o Exhaust : 1.46 - 1.66mm (0.0575 - 0.0654 in.)

8. Repair by grinding and cutting off the valve seat, and lap it if its contacting
width is not even or out of the specified.
9. 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.

10. Make lapping in two stages, first with normal lap and second with fine one
for the both sides.

Assembly 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

2. Peen and install new valve guide

Caution : Heat the cylinder head uniformly at a temperature 80-100C
(176-212F) not to make the head deformed, and drive new valve
guide completely into the hole with the tools the valve guide installer
attachment 09917-88220.
3. Check the protruded part of the guide from the cylinder head.
Important : Do not reuse the valve guide once disassembled, replace
it with the new oversized valve guide.
o Valve
o Valve

guide oversize : 0.03mm (0.0012 in.)

guide protrusion : 14mm (0.5512 in.)

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

6. Install the valve spring seats.

7. Install the valve stem oil seal to the valve guide. 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, neer 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.

8. Install the valve to the valve guide.

Important : Before installing it, coat engine oil to the stem seal, valve
guide bore and valve stem.

9. Install the valve springs and the spring retainers.

10. Using the valve spring compressor 09916-48210, compress the valve
spring
11. Install the valve keepers.

12. Install the camshaft front oil seal from housing hole.

13. Coat the engine oil to the camshaft front oil seal, the cam, and the
camshaft journal.
14. Install the camshaft front oil seal to the housing hole.
15. Install the camshaft to the cylinder head.
Notice : Installing the camshaft, take extreme care to prevent any
screatch, nick or damage.

16. Install the screws with the camshaft thrust plate.

Tighten
Tighten the screws to 10 Nm (89 lb-in).

17. Coat the engine oil to the rocker arms and the rocker rocker arm shafts.
18. Install the rocker arm spring and the rocker arm.

19. Install the rocker arm shaft mounting bolts.

Tighten
Tighten the bolts to 10 Nm (89 lb-in).

Important : Rocker arm shaft for the intake valves and the exhaust
valves are different and their directions of installation are different.

20. Install the intake manifold studs.

21. Install the intake manifold with the gasket.
22. Install the intake manifold.

23. Install the intake manifold nuts in the sequence order.

Tighten
o Tighten the intake manifold nuts and the bolts to 17 Nm (13 lb-ft).
o Tighen the intake manifold supprot bracket bolt to 10 Nm (89 lb-in).

Important : Before tightening the intake manifold nuts, first of all,

tighten the intake manifold support bracket nut.

24. Install the spark plugs.

25. Install the exhaust manifold gasket and the exhaust manifold.

26. Install the bolts and nuts in the sequence order as shown in the picture.
Tighten
Tighten the exhaust manifold nuts and bolts to 22 Nm (16 lb-ft).

27. Install the exhaust manifold heat shield.

28. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 10 Nm (89 lb-in).

29. Install the water outlet case.

30. Install the water outlet case mounting bolts.
Tighten
Tighen the water outlet case mounting bolts to 10.5 Nm (93 lb-in).

31. Install the cylinder head with the intake manifold and exhaust manifold
attached. Refer to "Cylinder Head and Gasket" in this section.

Crankshaft
Tools Required
KM-412 Engine Overhaul Stand
09916-77310 Piston Compressor

Disassembly Procedure
1. Removethe engine. Refer to "Engine"in this section.
2. Remove the transaxle from the engine. Refer to Section 5B, Five-Speed
Manual Transaxle.
3. Remove the flywheel bolts.
4. Remove the flywheel.
5. Mount the engine assembly on the engine overhaul stand KM-412.

6. Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this
section.
7. Drain the engine oil from the engine.
8. Remove the power steering adjusting bolts.
9. Remove the power steering/air conditioning belt.

10. Turn the A/C compressor downward.

11. Remove the A/C compressor/power steering bracket bolts.
12. Remove the A/C compressor/power steering bracket.

13. Loosen the generator bolt.

14. Loosen the generator lower bolts and the nut.
15. Remove the generator and belt.

16. Loosen the engine mount upper bracket bolts.

17. Remove the generator shackle.
18. Remove the upper bracket.
19. Loosen the engine mount lower bracket bolts.
20. Remove the lower bracket.

21. Remove the upper timing belt cover bolts.

22. Remove the upper timing belt cover.

23. Remove the lower timing belt cover bolts.

24. Remove the lower timing belt cover.

25. Loosen the timing belt automatic tensioner bolt.

26. Remove the automatic tensioner from the timing belt.
27. Remove the timing belt.

28. Rotate the engine on the engine overhaul stand KM-412.

29. Remove the oil pan retaining bolts and the nuts.
30. Remove the oil pan.

31. Remove the oil pan pickup tube bolts.

32. Remove the oil pan pickup tube.

33. Remove the oil pump retaining bolts.

34. Remove the oil pump.

35. Remove the crankshaft rear oil seal housing screws and bolts.
36. Remove the gasket and the oil seal housing.

37. Mark the order of the rod bearing caps.

38. Remove the connecting rod cap nuts for all of the pistons.
39. Remove the connecting rod bearing caps and the lower connecting rod
bearing.
40. Remove the upper connecting rod bearing.

41. Mark the order of the crankshaft bearing caps.

42. Remove the crankshaft bearing cap bolts.
43. Remove the crankshaft bearing cap.
44. Remove the crankshaft bearings from the crankshaft bearing caps.
45. Remove the crank shaft.
46. Remove the crankshaft bearings from the engine block.
47. Clean the parts, as necessary.

Assembly Procedure
1. With crankshaft and bearings in place, plastic gauge all bearing
clearances. Refer to "Crankshaft Bearings and Connecting Rod Bearings Gauging Plastic" in this section.
2. Inspect the crankshaft end play with the crankshaft bearings installed.
3. Check the Permissible crankshaft end play. Refer to "Engine
Specifications" in this section.

4. With the crankshaft mounted on the front and the rear crankshaft
bearings, Check the middle crankshaft journal for permissible out-of-round
(runout). Refer to "Engine Specifications" in this section.

5. Coat the crankshaft bearings with engine oil.

6. Apply a bead of adhesive sealing compound to the grooves of the rear
crankshaft bearing cap.
7. Install the crankshaft bearings in the engine block.
8. Install the crankshaft.

Important : Grease the crankshaft journals and lubricate the

crankshaft bearings slightly so that the plastic gauging thread does
not tear when the crankshaft bearing caps are removed.
9. Inspect all of the crankshaft bearing clearances using a commercially
available plastic gauging (ductile plastic threads).
10. Cut the plastic gauging threads to the length of the bearing width. Lay
them axially between the crankshaft journals and the crankshaft bearings.

11. Install the crankshaft bearings to the crankshaft bearing caps.

12. Install the crankshaft bearing caps bolts.
Notice : Do not reuse the old crankshaft bearing cap bolts. Damage
to the engine could result.
Tighten
Tighten the crankshaft bearing cap bolts to 57 Nm (42 lb-ft).

13. Remove the crankshaft bearing caps.

14. Measure the width of the flattened plastic thread of the plastic gauging
using a ruler. (Plastic gauging is available for different tolerance ranges.)
15. Inspect the bearing clearances for permissible tolerance ranges. Refer to
"Engine Specifications" in this section.

Inspection Precedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.
Important : Grease the connecting rod journals and lubricate the
connecting rod bearings slightly so that the plastic gauging thread
does not tear when the connecting rod bearing caps are removed.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod bearing
caps.
4. Inspect all of the connecting rod bearing clearances using a commercially
available plastic gauging (ductile plastic threads).

5. Cut the plastic gauging threads to the length of the bearing width. Lay
them axially between the connecting rod journals and the connecting rod
bearing.
6. Install the connecting rod bearing caps.
7. Install the connecting rod bearing cap nuts.
Tighten
Tighten the connecting rod bearing cap nuts to 33 Nm (24 lb-ft).

8. Remove the connecting rod bearing caps.

9. Measure the width of th flattened plastic thread of the plastic gauging
using a ruler. (Plastic gauging is available for different tolerance ranges.)
10. Inspect the bearing clearance for permissible tolerance ranges. Refer to
"Engine Specifications" in this section.

Inspection Precedure - Piston

1. Inspect the connecting rod for bending or twisting. If the connecting rod is
bent or twisted, replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspec the connecting rod upper end for scoring.
5. Inspect the piston for scoring, cracks and wear.
6. Inspect pistion for taper using a micrometer.

7. Inspect the piston for fit to the connecting rod.

8. Inspect the engine block deck surface for flatness using a straight edge
and a feeler gauge. Refer to "Engine Specifications" in this section.
9. Inspect the bearing bore for concentricity and alignment using a bore
gauge. Refer to "Engine Specifications" in this section.
10. Inspect the engine block cylinder bore for wear, runout ridging and taper
using a bore gauge. Refer to "Engine Specifications" in this section.
11. Inspect the engine block cylinder bore for glazing. Lightly hone the
cylinder bore as necessary.

Installation Procedure
1. Align the notch on the piston and connecting rod so that the proper sides
will be facing the front of the engine.
2. Install the pistion pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the pistion.
5. Install the pistion pin into the pistion and connecting rod assembly.

6. Select a set of new pistion rings.

7. Measure the piston ring gap using a feeler gauge.
8. Increase the piston ring gap by carefully filling off excess material if the
piston ring gap is below specifications.

9. Measure the pistion ring side clearance using a feeler gauge. Refer to
"Engine Specifications" in this section.
10. If the pistion ring is too thick, try another pistion ring.
11. If no piston ring can be found that fits to specifications the pistion ring may
be ground to size with emery paper placed on a sheet of glass.

12. Install a piston oil ring, the expander and the second piston oil ring to the
bottom ring groove of the pistion.
13. Install the second compression ring to the middle ring groove of the piston.
14. Install the top compression ring to the top ring groove of the pistion.

15. Use a piston ring expander to install the piston rings. Do not expand the
piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the second compression
ring, and the top compression ring in relation to the notch on the top of the
pistion.

17. Lubricate the cylinder wall and the pistion rings with clean engine oil.
18. Install the piston using a ring compressor and a wood handle. Guide the
lower connecting rod end to prevent damaging the crankshaft journal.
19. Install the connecting rod cap and the bearing. Refer to "Crankshaft
Bearings and Connecting Rod Bearings - Gauging Plastic"in this section.

20. Install the connecting rod bearing cap nuts.

Tighten
Tighten the connecting rod bearing cap nuts to 33 Nm (24 lb-ft).

21. Install the oil pump/pickup tube.

22. Install the oil pump pickup tube bolts.
Tighten
Tighten the oil pump pickup tube bolts to 10 Nm (89 lb-in).

23. Install the oil pan.

24. Install the oil pan bolts and nuts.
Tighten
Tighten the oil pan bolts and nuts to 10 Nm (89 lb-in).

25. Install the lower engine mount bracket and the generator with the bolts
Tighten
Tighten the lower engine mount bracket bolts to 38 Nm (28 lb-ft).

26. Install the upper engine mount bracket and the generator shackle with the
bolts.
Tighten
Tighten the upper engine mount bracket and generator shackle bolts to 38
Nm (28 lb-ft).

27. Install the generator with the bolts and the nut.
28. Install the generator belt.
Tighten
Tighten the generator lower bolts and the nut to 23 Nm (17 lb-ft).
Tighten the generator belt tension adjusting bolt to 23 Nm (17 lb-ft).

29. Install the engine mount bracket.

30. Install the A/C compressor/Power steering Pump and the bracket with the
bolts.
Tighten
Tighten the engime mount bracket bolts to 20 Nm (15 lb-ft).
Tighten the A/C compressor/Power steering Pump bracket bolts to 38 Nm
(28 lb-ft).

31. Install the power steering pump bracket with the bracket bolt/nut and
adjusting bolt.
Tighten
Tighten the adjusting bolt and the power steering rear bracket nut to 22
Nm (16 lb-ft).

32. Install the power steering/air conditioning belt.

33. Install the cylinder head with the intake manifold, the exhaust manifold,
and distributor/adaaptor attached. Refer to "Cylinder Head and Gasket" in
this section.
34. Install the timing belt and component. Refer to "Timing Belt" in this
section.
35. Install the clutch and the transaxle to the engine then engine assembly to
the engine compartment. Refer to " Engine Assembly" in this section.
36. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
37. Bleed the power steering system as necessary. Refer to Section 6A,
Power Steering System.
38. Refill the A/C refrigerant system as necessary. Refer to Section 7B,
Manual Control Hearing, Ventilation, and Air Conditioning System.
39. Refill the transaxle oil as necessary.
40. Connect the negative battery cable.
41. Start the engine and operate all systems.
42. Operate the idle air contril valve reset procedure as necessary.

43. SECTION
44.
45. GENERAL

DESCRIPTION AND SYSTEM

OPERATION

46. Cylinder Head and Valve Train

47. The cylinder head is made of cast aluminum alloy for better strength in
hardness with lightweight, and camshaft and rocker arm shaft arranged inline support.
48. The combustion chambers are formed into the manifold combustion
chambers with increased squish parts for better combustion efficiency and
its intake and exhaust parts are installed in the cross flow arrangement.
The rocker arm operates in seesaw motion to close and open the intake
and exhaust valves with camshaft by turning the rocker arm shaft of each
intake and exhaust part.
49. Engine Block
50. As the largest part of the engine components. the block has all the
necessary parts attached to outer surface of it.
51. On the inside surface of block, there are bore surfaces by horning, which
are cylinders, and on the periphery of the cylinders, there are the
passages to prevent the over-heated and to lubricate the engine block.
52. Crankshaft
53. The crankshaft is to convert the rectilinear motion into the rotation motion
through the connecting rod which transmits the power generated by
combustion.
54. On the one side of it, oil pump, crankshaft pulley and timing belt pulley are
attached, and oil seal housing and flywheel are on the other side.
55. A special steel of high grade cast iron is used for the material to stand the
bending load and distortion. The material of the main bearing is aluminum
alloy. The split thrust bearings are inserted in the journal bearing part.
56. Connecting Rod
57. The connecting rods are made of forged steel, and its section is typed ""
with its big end connected to crankshaft and its small end to piston pin to
transmit the power.
58. The big end is detachable, and its upper and lower parts are fastened by
bolting after the metal bearings are inserted.
59. Piston, Piston Ring and Piston Pin
60. Piston
61. The piston is of the open skirt type and its crown is exposed in the
combustion chamber to generate power. Its land and skirt parts are made
of coat aluminum alloy which is light and has excellent heat conductivity in
order to meet its continuous and high speed reciprocation movement.
62. Piston Ring
63. It is composed of two compression rings and one oil ring and installed
between the grooves of the piston to make the high speed reciprocating

movement maintaining a remarkable air tightness as well as cylinders. It is

a critical parts to affect the compression pressure, oil consumption,
compression, blow by pressure and engine performance.
64. Piston Pin
65. The pin is not fixed to the piston or connecting rod and its both ends are
assembled by the circlip in the full floating type. The pin is used to transmit
the power from the crown part of piston to connecting rod.
66. Timing Belt and Pulley
67. The timing belt connects the camshaft timing pulley and the crankshaft
timing pulley. The timing belt coordinates the crankshaft and the camshaft
and keeps them synchronized. The timing belt also turns the coolant
pump. The timing belt and the pulleys are toothed so that there is no
slippage between them. There is a tension pulley that maintains the
correct timing belt tension. The timing belt is made of a tough reinforced
rubber similar to that used on the serpentine drive belt. The timing belt
requires no lubrication.
68. Engine Mount
69. This is to absorb or reduce the engine vibration and impact from the
wheeled road. Engine mount is attached to the engine-front side, the
engine-right side and the engine-rear side and one transaxle mount is
attached to the transaxle side.
70. Exhaust Gas Recirculation Valve
71. The exhaust gas recirculation (EGR) system is used tolower oxides of
nitrogen (NOX) emission levels causedby high combustion temperatures.
The main element ofthe system is the EGR valve which is operated
electrically by the ECM.
72. The EGR valve feeds small amounts of exhaust gas intothe intake
manifold to decrease the combustion temperature.The amount of exhaust
gas recirculated is controlledby variations in electrical signal and exhaust
backpressure. If too much exhaust gas enters, combustionwill not take
place. For this reason, very little exhaustgas is allowed to pass through
the valve, especially atidle.
73. The EGR valve is controlled precisely by ECM according to various
operating condition of the engine