EM-2 Engine MechanicalSystem

General lnformation
Speclflcations
Oeocñptlon Specllicatiofl Umit

Ge-•
T}'Pe
Number of cylinders
ln-line.OOHC
4
Bore
n.o nm (2.8346in)
St!oke 84.0 nm (3.3070in)
Total displacement 1.368 ce(83.48 cuJn)
Compression ratio 10.5 :1
Fwingorder 1-3-4-2
Valw timing
lntake vatve Opens ATDC 10• -BTOC 40•
lntake vatve Closes ABDC 66.6 -ABOC 1s.s•
Exhaust valve Opens BBDC 52.4• -BBOC 12.4•
Exhaust valve Closes ATDC 3• - BTOC 37•

C)1inder heed
Flatness of gasket surfa<:e Lessthan 0.05 mm(0.0025in)
Less than 002 mm(0.0008in) / 100 x 100

Flatness of manifold lntake Less than 0.1mm (0.0039in)

moootlng suñace EXhaust Less than 0.1mm (0.0039in)

Camol\aft
lntake
Camheight
EXhaust
36.4183 mm (1.4337in)
36.1543 mm (1.4233in)
_:..::':.
-
lntake/Exhaust 36.464 - 36.478 mm (1.4355 - 1.4361in)
No.1 ."!e ·. .;
Jouma& outer Oiameter
ln•ake/Exhaust
No.2-5
22.964 - 22.978 mm (0.9040- 0.9046 in),- .'
: '·." :.
<
.·.:·
- -.._"";-;:·C "

lntal<e 100.94 mm (39740;n}""

Val'Ve length
EXhaust 101.09 mm (39799 in)
lntake 5.465- 5.480 mm (0.2151 -0.2157 in)
Stem outer diameter
Exhaust 5.448- 5.460 mm (0.2144 -0.2149 in)
Faoe angle
Thickness of valva he- lntake 1.35- 1.65 mm (0.0531 -0.0649 in)
ad (ma<gin) Exhaust 1.60- 1.90 mm(0.0629 - 0.0748in)

,
.,.
v.....
,...., : . ..
.-..
General lnformation EM-3
Umlt
Valva stem to va1ve g-,_ 1_,,._ak_• _ o ._0_20-_o_.047_nm (_o_.000_8_- o._0_01_8_5_in_) _, _, uide clearance Exhaust
Valve op<ing
Freelength
 load
Out oí squareness
47.9 mm {1.8858 in)
16.7 ± 0.8kg/ 35.5mm(164 ± SN / 1.3976 fn)
29.6 ± 1.0 kg / 27.7 mm (290 ± 10N l 1.0905in)
Cytind&r bore 72.00 - 72.03 mm (2.8346- 2.8'358 in}
Aatness of gasket suñace lessthan 0.05 mm (0.0020in)

less than 0.02 mm (0.0008 in) / 100 x 100

Piston outer diameter
Piston to cyl nder clearance
No.1ring groove
71.97 - 72.00 mm (2.8334 - 2.8346in)
0.02 -0.04 nm (0.0008 -0.0016 in)
1.03 - 1.05nm (0.0405 -0.0413in)
R.inggroove Width No.2 ringgroove 1.23 - 1.25nm (0.0484 - 0.0492 in)
Oilringgroove 2.010 -2.025 mm (0.0791 -0.0797 in}
Side clearanoe
No. 1ring
No. 2 ring Oil ring
0.04 -0.08 nm (0.0015 -0.0031 in)
0.04 -0.08 nm(0.0015 -0.0031 in)
0.040 -0.115 mm {0.0015-0.0045in)
No. 1ring 0.13-0.25 mm (0.0051 - 0.00.98in)
End gap No. 2 ring 0.30 -0.45 nm (0.0118 -0.0177 in)

Oil ring 0.1-0.4 mm (0.0039- 0.0157 in) ·. ...

Piaton pin
Piston pi_n outer diameter
Piston pln hole nner diametec
.:.. '; -- ·-

8.003nm (0.7086- 0.7087 In)..• :-f' ''"-·'··

18.013 - 18.017""'(0.7092 -0.709.3 ;f.._ .
Piston pin hole clearanoe 0.010-0.017 nm (0.00039-. óÍil67 in) .,
Connecting rod small end hole inner di
eter
Comecting rodsmall end hofe clearance Piston pin press-inload
Comecli.ng rod bigend inner diameter
COMecli:ngrodbeañng oilclearanc:e
17.974 - 17.985nm (0.7076--0.7474 in)
-0.015 --0.029 mm
(0.00059- 0.00114 in)
250 - 1050 kg (551- 2315lb)
42..000- 42 018 mm (16535-1.6542 in)
0.018 -0.036 mm (0.0007 -0.0014 in)

EM-4 Engine Mechani cal System

Deocrlptlon Specllic:ation Umit
Side dearance 0.1-0.25 mm(0.0039 -0.0098 in}
Ctanbhaft
Maln joumal outer diameter 42.942 -42.960 mm (1.6906-1.6913in)
Pinjoumal outer diameter 38.954 - 38.972 mm(1.5336-1.5343in)
Mainbearing oil clearance 0.006 -0.024 mm {0.0002-0.0009 in)
End play 0.05 -0.25 mm (0.0019-0.0098 in)
Oll pump
lnner rotor 0.040- 0.090 nm (0.0016 -00035 in)
Side olearance
Side olearance
Outer rotor 0.040- 0.090 nm (0.0016 -0.0035 in)
Free ength 58.3 nm (2.2952 in)
Relief spring
load 3.5bar ±0 5
Engina oil
TOlal 3.8 l (4.01 US qt.3.34 lmp qt) When replacing a 6hort
englne o
r a block assem-
bly

Oil pan 3.3 l (3.48 US qt.2.90 lmp qt)

Oraínand refill 3.5l (3.70 usqt, 308 lmp q1) lncluding oilfilte r
Oil quantity
Recommendation (except 1f not available, refer to
Middle E ast) the reoo mmended
APIor ILSAC
5W-20 / GF4 & SM clas&lfic-- ation and
SAE v isoosíty numbe!,
{

ClassJfication APIS ,SM or above Satisfy tt-.

tlSAC GF3.GF4 or above iret ihe A
. . isjqca tion.
SAE viscosity gr
ade .,-:- · (.tÓ Üie"lu-

Oil grade · Recommended SAE visoos ty numbe. ·:· : ,.m bl;:&itic.n .Syste
. _-.,, ..
00 temperature
inolpan:110 ±
Oil pressure (at 1000rpm)
--' 2•c (230 ± 3.6°F
0.9 bar or above )
Cooling method
Cooling system Forced drcu:lation wfth water pump
Coofant quantity MT :5.0 l(1.32 U.S.gal..528 U.S.qt.,4.39 lmp.qt.)
AT, CVT :5.1 l{1.35 U.S.9al.,5.39 U.S.qt.4.49 lmp.qt.)

General lnformation EM-5

Deoctlptian Spedflcation Umlt

Type Wax peOet type

Opening 88 ± 1.S'C (190.4 ± 2.7'F)

temperatura

Fu11 opening 1oo•c (212'FJ

temperatura
Thermootat
Mainvalve opeÑ 93.16 - 122.58 kpa
ng pressure (0.95 - 1.25 kglcm', 13.51 - 17.78 psi)
Vacuum valve o- 0.98- 4.90 kPa
Radimorcap
perting pressure (0.01 - 0.05 k!>'cm'.0.14 - 0.71 psi)
WatM temperatura eenaor
Type TherrnistOf type
20'C(68'F) 2.45 ± 0.14 kn
Resistance
eo•c (176'F) 0.3222 kn

\ -,. .s-:::
.,_;::;_::_:.

EM-6 Engine MechanicalSystem

Tighlening Ton¡ues
ltem Quantlty N.m lcgf.m tl>-ft
cyl nder block
Ladcler frame bolt 10 19.6 -23.5 2.0 - 2.4 14.5 - 17.4
Engina mounting
Engine mounting bracket and body fixing btot 3 49.0 -63.7 5.0- 6.5 36.1-47.0
Englne mounling insulator to engine mounting 1 63.7- 63.3 6.5- 8.5 47.0 -61.5
support bracket fixing nut
Englne mounting support bracket and engine 1 49.0 -63.7 5.0- 6.5 36.1 -47.0
support bracket fixing bolt

Engine mounUng support brac:ket and eng ne support bracket 2 49.0 -63.7 5.0- 6.5 36.1 -47.0
fixingout

Tran'&axle mounting bracket end body fixing I> olt 3 49.0 -63.7 5.0- 6.5 36.1 -47.0

Tran'6axle mounting nsu:lator and t:ransaxfe su- pport bracket 2 88.3- 107.9 9.0 -11.0 47.0 -61.5
fixingbolt

Roll rodbrac:ket and subframe fixing boJt 1 49.0 -63.7 5.0- 6.5 36.1-47.0
Rear ron stopper bracket and roH rod support bracket bott 1 107.9 - 12.75 11.0 - 13.0 79.6 -94.0

Mail\ movlng aystem

Connedlng rodbea.ring cap bott 8 (10.8 - 14.7] + (88 (1.1 - 1.5] + (88 - (8.0 - 10.8) + (88 -
- 92º) 92') 92']
Crankshaft main beañng cap bott 10 117.7 -21.6)+ (88 (1.8 - 2.2) + (88 - (13.0 - 15.9) + (88
- 92'] 92') - 92•1
Fly wtiee4 bolt (M/Tj 6 68.6 - 78.5 7.0- 8.0 50.6 - 57.9
Orive plate boh (AIT) 6 68.6 - 78.5 7.0- 8.0
50.6 - 57.9 -{
Timingd'lain -;:.:
Tmingchai:n cover bolt (A) 6 18.6 -23.5 1.9-2.4
Tlmingchain oover bolt (8) 3 44.1-53.9 4.5- 5.5 ., r;..
e,'·32 7,39.87.4
Tming chain cover bolt (C) 8 9.8- 11.8 1.0- J . :;:.·
Tming chain cowr bolt {O) 1 18.6 -23.5
:.:...'.·r2
13.7 - 17.4
-a.1
1·'!'?;:i.4 -._. ,;
Crankshaft pulley bo(t 1 (55.9-61.8) + (39 1a,;o::::.3J + (38 - (41.2 -45.5] + (39
- 42'] 42'] - 42•1

cvvr bol• 2 63.7 - 73.5 6.5- 7.5 47.0 - 54.2

Tming chatn teosioner bott 2 9.8-11.8 1.0 - 1.2 7.2 -8.7
Tming chain cam guida boh 2 9.8-11.8 1.0- 1.2 7.2 - 8.7
Tlmingchain craM guida bolt 2 9.8-11.8 1.0-1.2 7.2 -8.7
Tming chain teosionec ann bolt 1 9.8- 11.8 1.0- 1.2 7.2 - 8.7
Tming chain guida bolt 2 18.6 -21.6 1.9-2.2 13.7 - 15.9

General lnformation EM-7

,,_
N.m kgf.tn lb-ft
Cytlnder hNd
C)tinder head cover bott 16 (3.9 -5.9) - [0.4- 0.6)- [2.9 -4.3) -
[7.8 -9.8) [0.8 - 1.0) [5.8- 7.2)
Camshaft beari:ng cap boh 16 [5.9) - [11.8 - 13. [0.6) - [1.2 - 1.4) [4.3) - [8.7 -10.1)
7)

Camshafl front bearing cap bolt 3 [9.8) • [18.6 - 22. [1.0J • [1 9 - 2.3) [7.2) • [13.7 - 16.
6) 6)
[12.7- 16.7) + [90 [1.3- 1.7]+ [90- [9.4- 12.3)+ [90-
-951 + [12() - 12 95') + [120- 125 ) 95') + [12() - 125')
Cylinder head bolt 10 5')
OCV boh 2 9.8- 11.8 1.0- 1.2 7.2- 8.7
Coollng syetem
Water pump pulley bott 4 9.8- 118 1.0 - 1.2 7.2- 8.7
Water pump boh 3 9.8- 11.8 1.0- 1.2 7.2- 8.7
Heater pipe bott & nut 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Thermoestat hous.ing boit & nul 3 9.8- 118 1.0 - 1.2 7.2- 8.7
Water intet fitling boft & nut 2 18.6 - 23.5 1.9 -2.4 13.7 - 17.3
Lubrication ayatem
011 filler 1 11.8 -15.7 1.2 - 1.6 8.7 - 1 1.6
011 pump 3 9.8- 11.8 1.0- 1.2 7.2- 8.7
Oil pan bolt 10 9.8- 11.8 1.0 - 1.2 7.2- 8.7
011 pandrain plug 1 34.3 -44.1 3.5 - 4.5 25.2- 32.4
011 screen boH 2 9.8- 11.8 1.0- 1.2 7.2- 8.7
Oilpressure switch 1 7.8 -9.8 0.8- 1.0 5.8 - 7.2 ::-. ·
-
lntake and axhaust ayatem -::::::. .:
lntake manifold bolt & n.it 5 18.6 - 23.5 1.9 -2.4 ."!üa.7_-17.4
Exhaust manifold stay 3 39.2 -49.0
4.0 - 5.0 .·-:- -:.;1!::36.2
Ext\aust manifold heat protector 3 8.8- 10.8 0.9.- ·i'Y"' ;.
Throttle body fixing salísaew 4 6.4 -8.3 }. 1:6,S o.8-S:·'·
.. -·6.5-7.9
4.7-6.1
<
Exhaust manifold out 5 29.4 - 34.3 21.7- 25.3
-±-' ;.;.:3.0 - 3.5
Exh.aust manifold and front muffler & catalytic 2 39.2 - 58.8 4.0 - 6.0 28.9-43.4
converter fixing nut
·:

EM-8 Engine MechanicalSystem

Compression Pressure lnspection
+:1.111aw
lf there is lack or power , excessive oil ooosumption or

poor fuel ecooorny,measure te compression pressure.

1. Start the engjne and a.Uow to warm up to operating

temperatura .(about fNe minutes)

Stop the engine.

2. Remove ttle air cleaner assembl'y.

(Refer to Engine and Transaxfe Assembl'y • "Engi.ne ard Transax.ie Assembl)'"')

3. Disconnect the ignition coll connectors {A).

5. Oi'5COmed the njector connectors (A).

SRBEM351:0
6. Remove the four spark plugs using a 16mm
sparkptug wrench.
7. Check the qfinder compression pressure.
(1) lnsert a compcession gauge into the spark ptug
llole.
4. Remove the ignition cOOs (A).
SFIBElill001O
(2) Fully open throdle.

\ -,. .s-:::
.,_::;,::.:.

/Wtays use a fulfy" charged battery to obta n

 engine speed of 250rpm01 more.

General lnformation EM-9

(4) Repeat step (1) throug.h (3) for each cyUnder.

+c.1119+
This measurement must be done i:n as short

ea.n_...,.,.........:
1,373 kPa (14.0 kglan'.199 0 poi)

Minimumpr..ure :

1.226 kPa (12.5kg/an',178.0 psi)

oor..rence _,, oac:ll c:ytlnd« :

98 kPa (10 kg/cm2, 14 psi) or less

(5} lf the cylinder ressionin 1or moie cylinders islow.pour a smaU amount of engine oil into the cyHnder through the spark plug hole and repeat step {1) through (3) ror cy

compression.

ff adding oilhelps the compression.his likely that lhe piston rings andlot cylinder bOie are worn or damaged.

lf pressure stays Jow, a valve may be sticki:ng or seating is improper, or there may be leakage past the ga:Sket.

8. Reinstall the spatk plugs.

Tlghtening t«que :

14.7 - 24.5 N.m (1.5 -2.5 kgf .m. 10.8 - 18.111>-ft)

9. Connect theinjector oonnectors.

10.Connect the lgnition ooll connector and the spark

plug cables.(Nal ISG type)

11.Snstall the ignition coil.(ISG type)

Tlghtening t«que :

9.8 - 11.8 N.m (1.0 - 1.2 kgl.m, 7.2 -8.7 lb-ft)

12. Conned the igniion coil connectors. {ISG iype)

13.Sorne DTC's may exist after the inspection test and
rnay need to be manu-ally deard with GOS.
 .,_;:;_::_:.

EM-10 Engine MechanicalSystem

Troubleshoollng
Symp4om
SOapect ...
Ramody
Engine misfire with abnormal nternal Wom crankshaft beari:ngs.
bwer englne nolses. Loose a damaged engine drive plate.
Reptace the crankshaft and bearings
as requ.ired.
Repair or replaoe the drive plata as re-
qui.red.
Worn pistoo rings. lnsped the cylinder for eloss of com
(Oiloonsumption may or may oot cau- ression.Repair oc replaoe as required.
se the engine lo nisfire.)
Wom crankshaft Uvust bearings Reptace the crankshaft and bearings
as requjred.
Engine misfire .,,.;th abnormal wlw lra·Studt valvas.
in noise. (Carbon buiklup onlhe valve stem)
Repair or replace as required.
.... --<..... .....
Exee&.Sive wom or mis-aflgned tining Repface the timing chain andsprocket
chaln. as required.
Wom camshaft lobes. Replace the camshaftand vaJveliflers.
HlA sponge Run the engine at 2S00-3000rpm with·
in 15 minutes.
lf ildosen•t disappear.refer to cylinder
head assembtyinthis group.
kel and/or • lnsped the cyli:nder head ancl engi
on. cran.k.ing or other damage to the
cyOnder head and engine block c:o
olingsystem.
Coolant oonsumptkin may ot may •
not cause the englne to overheat.
ne block ror damage to the coolanl
paS&ages and/or a faulty head gas kel.
Repair or replace as required.
Engine rrisfirewith excess ve oll cons- Wom valves,gu.ides aod/ot valva stem Repair or replace 85 requ red.
umption.
1º--ª_..a1_s_ 11--------------
Wom pistanrin.gs.
(Oil consumption may or may oot cau
se the engine to rrisfue)
lnsped the cylinder for aloss 9f'Qif. ·
mpression. - .:.;:.: ·
Repa.ir oc replace as .
Englne noise on start-up,but only lasti·lnoxrect oilvisoosity.
Orain the oil.
_ _ -... • ·.:·
ng a few seconda.
Wom crankshaft thrust bearWlg..
ln.statl the coét'Pvi. oi.
lnspect.th\f "&taring and era·
n.k&!:iaft: ...
·· ,,,
•.. liepair 01 replace as required.

General lnformation EM-11

 symplom &_.,t a,.. Rafl'8dy
Upper engine noise. regardless of enir Low oi.IpJessure. Repair or replace as required.
ine speed.
Stokenvalva spring. Replace lheva1ve sprlng.
Wom or diny valve lifters. Replaoe the valva 6fters.
Stretched or broken timing chain andl
or damaged sprocket teeth.

Wom ü-mlng cllain tens.ioner, if applG

•.R eplace ihe ürring chain and sprocket-
Replaoe the timing chain tensloner as required.
ble.
Wom camshaft lobes. lnspect the camshaft klbes. Replace the timing
camshaft and valve Uftecs as required.

Wom valve guides or vatve stems. 1nspect the vatves snd vafve guidas,
then repair es required.
Stuck vatves Cafbon on the valve stem or valve seat lnspect the valves and vatve guidas,
may cause the vaive to stay open. then repair as required.

Wom dñve beft.idler.1ensioner and Replace as required.

bearing .
lower engine noise, regardless of enir Low oi.IPfessure. Repair as required .
ine speed.
l Loose or damag.ed drive plate. Repab or replace lhe driveplate.
Oamaged oll pan,contacting the oil • lnspect the oil pan.
mp screen. lnspect the oll pump acreen.
Repair 01 replaoe as required.

Oil pufl1> screen loose,damaged or re- • lnspect the oilpump acreen.

stricted. Repair 01 replaoe as required.

rance.
SOS!-
Exoessive piston-to-cy(inder bore clea- • lnspect the piston.piston pin
cylinder bore. Repair as required.
....;-. .5
Excessive piston pln-t1>piston clearan- • lnspect lhe plston, pin and
.,.
ce. the connecting !fU!- ·•.
Repair Of rep,ljtpe·a,s tJ: red.
Excessive oonnecting rod beañng de- aranoe lnspect . ,:tOVO" Y(iQV·COmponents and

' repa,ir.aire(¡w;.ea-:,..
•·"*'Trie 00.nting rod bearings.
Y..;.;.7he connecting rcds.
· The crank&haft pinjoumals.
Exoessive crankshaft bearing deara..n- lnspect the following oomponents, and rapa.ir as
ca. requlred.
The aankshaft bearings.
The crankshaft mainjoumals.
The cyhnder b>oclL

ncorrect pistan, plston pin and cono.e- • Verify the piston pins andoonn
ctlng rodinstallatlon ng ro:ls are lnstafledc:orrectly. Repair as requlred.

.
EM-12 Engine MechanicalSystem
Symplom SUapect al'88 Remody
E.ngine noise under bad. low oilpressure Repeir or rep ace as requtred.

Excessive connecting rod bearíng de- lnspec:t the fol owing oomponents and repair as
arance . required :
The oonnecting rod bearings.
The OOMecting rods.
The crankshaft.

Excessive crankshaft bearing clearan- lnspect the following oomponerrts, end

ce. repalr as requlred.
Thecrankshaft bearings.
The crankshaft mainjournals. The cy1inder btock.
E.ngine wíll not aank-crankshaft Wlll
not total.e.
Repair as required. "- ·.
General lnformation
SpedalServlce Tools
Tool (Nl.Wnber -name)
Flywheel stopper
(09231-28100)
Engine and Transaxle Assembly
Engine and Transaxle Assembly
Englne Mounting
Components
Hydra\Aically locked cylinder. Remove spark ptugs and check for
Cootantlantifreeze in cylinder. Oilincylincler. ílu:d.
Fuel in cylindeJ. lnsped for broken head gaskel
lnspect for cracked engine b1ock or c)'linder head.
lnspect for a sticking fvel injeaor
and/or leakingfuel regulatof.
Broken timiogdlain and/or tim ngchaj.. • lnspect timing chain and gears..
n and/or timingchaingears.. Repair as required.
Mate!ialIncytinder. lnspect cy1inder for dainaged oom-
Broken valve Pistan material Forelgn material ponents and/or foreign materials. Repair or replaoe
as required.
Seizecl crankshaft or c:onnecting rod bearings. lnsped crankshaft and connecting
rod bearing. Repair as required.
Bent or broken connectlng rod. lnspect oonneding rods.
Repair as required. -
Broken cra.nkshafl lnspect crankshafl .,_:::;:::_:.
·-
EM-13
u..
··-ation /;'.SI Removal aldinstallatioo of the flywheet and cmnkstlaft pufley
't ... Jfif
.
SHOEM&lOlO
EM-14
DJ 5.0 - 6.5
9.0 -11.0
'·
Tlghtenlng torque :N.m(kgf.m, 11>-ft)

1.Transaxle mount ngbrac:.ket

2.Rollrod bracket
3.Sub frame
4.Engine mountlng bracket
5.Engine mountlng support brackel

EM-15 Engine MechanicalSystem

Engine and Transaxle Assembly
Removal
A CAUTION
Use tender covers to avoid damag ng pc1inted
surfaces.

To evoid damage, unp!ug the wiring oonnectors

carefulty whi e holding the oonnector portien.

•: '· ' ' 'ª

M < r i: all wirlng snd hoses to avoid misconnection.

To release the fuel system pressure before removing the engine assembl'y, start the engine wrth lhe fuel pump relay removed. and then tum off the ig.nition switch áter engioe

1. Remove the engioe cover (A).

2. Oi:Sconnect the battery terminals {A). Oi'SOOOnect the

negativa terminalfirst.
Tlghtaring totqua
{+) terminal :
7.8- 9.8 N.m(0.8- 1.0 kgf.m,5.8 -7.2lb-ft)
(-) term nal (without battery sen.sor):
7.8 - 9.8 N.m(0.8 - 1.0 kgf.m,5.8 -7.2lb-ft)
3. Remove the under covers (A).
Tlghtoring torquo :
SRB1iMO
SRflEM30030
6.9- 10.8 NJn (0.7 -1.1kgf.m, 5.1 - 8.0 lb-ft)
SRBE
earance Exhaust 0.040- 0.064 mn (0.00157 -OJXl251 In)
peat step {1) through (3) ror cylinders with low
.....
ff the ig.nition switch áter engioe stops.