ENGINE

Return To Main Table of Contents

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 14

ENGINE AND TRANSAXLE ASSEMBLY . . . . . . 18

TIMING BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

CAMSHAFTS AND ROCKER ARMS . . . . . . . . . . 31

CYLINDER HEAD AND VALVES . . . . . . . . . . . . . 3 6
FRONT CASE, OIL PUMP . . . . . . . . . . . . . . . . . . . . 4 3
PISTON AND CONNECTING ROD . . . . . . . . . . . 4 8
CRANKSHAFT, FLYWHEEL . . . . . . . . . . . . . . . . . . . 5 3
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
20-2 GENERAL [1.6L Engine]

GENERAL
SPECIFICATIONS
Description Specification Limit

General
Type In-line, Double Over Head Camshaft
Number of cylinders 4
Bore 82.3 mm (3.240 in.)
Stroke 75.0 mm (2.953 in.)
Total displacement 1595 cc (97.3 cu. in.)
Compression ratio 9.2
Firing order 1-3-4-2
Idle R.P.M 750 ± 100 rpm
Ignition timing at idling speed BTDC 5o ± 2o

Valve timing
Intake valve
Opens (BTDC) 16o (For M/T), 26o (For A/T)
Closes (ABDC) 48o (For M/T), 38o (For A/T)
Exhaust valve
Opens (BBDC) 43o (For M/T), 53o (For A/T)
Closes (ATDC) 17o (For M/T), 7o (For A/T)

Cylinder head
Flatness of gasket surface Max. 0.05 mm (0.0020 in.) 0.1 mm (0.0039 in.)
Flatness of manifold mounting 0.15 mm (0.0059 in.) 0.2 mm (0.008 in.)
surface
Oversize rework dimensions of valve
seat hole
Intake 0.3 mm (0.012 in.) O.S. 35.300-35.325 mm (1.3898 - 1.3907 in.)
0.6 mm (0.024 in.) O.S 35.600-35.625 mm (1.4016 - 1.4026 in.)
Exhaust 0.3 mm (0.012 in.) O.S. 33.300-33.325 mm (1.3110 - 1.3120 in.)
0.6 mm (0.024) O.S. 33.600-33.625 mm (1.3228 - 1.3238 in.)
Oversize rework dimensions of valve
guide hole (both intake and exhaust)
0.05 mm (0.002 in.) O.S. 12.050 - 12.068 mm (0.4744 - 0.4751 in.)
0.25 mm (0.010 in.) O.S. 12.250 - 12.268 mm (0.4823 - 0.4830 in.)
0.50 mm (0.020 in.) O.S. 12.500 - 12.518 mm (0.4921 - 0.4928 in.)

Camshaft
Cam height
Intake 35.200 mm (1.3858 in.) 34.700 mm (1.3661 in.)
Exhaust 34.907 mm (1.3743 in.) 34.407 mm (1.3546 in.)
Journal O.D. 26 mm (1.02 in.)
Bearing oil clearance 0.05-0.09 mm (0.0020-0.0035)
End play 0.1-0.2 mm (0.004-0.008 in.)
 GENERAL [1.6L Engine] 20-3

Description Specification Limit

Valve
Valve length
Intake 109.5 mm (4.311 in.)
Exhaust 109.7 mm (4.319 in.)
Stem O.D.
intake 6.565-6.580 mm (0.2585-0.2591 in.)
Exhaust 6.530-6.550 mm (0.2571-0.2579 in.)
Face angle 45-45.50
Thickness of valve head (margin)
Intake 1.0 mm (0.039 in.) 0.7 mm (0.028 in.)
Exhaust 1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
Valve stem to valve guide
clearance
Intake 0.020-0.047 mm (0.0008-0.0019 in.) 0.10 mm (0.0039 in.)
Exhaust 0.050-0.085 mm (0.0020-0.0033 in.) 0.15 mm (0.0059 in.)

Valve guide
Length
Intake 45.5 mm (1.791 in.)
Exhaust 50.5 mm (1.988 in.)
Service size 0.05, 0.25, 0.50 mm
(0.002, 0.010, 0.020 in.) oversize

Valve seat
Width of seat contact 0.9-1.3 mm (0.035-0.051 in.)
Seat angle 44-44.50
Service size 0.3 mm (0.012 in.), 0.6 mm (0.024 in.)
oversize

Valve spring
Free length 48.3 mm (1.902 in,) 47.3 mm (1.862 in.)
Load 300 N (66 lb)/40 mm (1.575 in.)
Out of squareness Less than 1.5o 4o
Cylinder block
Cylinder bore 82.30-82.33 mm (3.2402-3.2413 in.)
Out-of-roundness and taper of Less than 0.01 mm (0.0004 in.)
cylinder bore
Flatness of gasket surface Less than 0.05 mm (0.0020 in.) 0.1 mm (0.0039 in.)

Piston
O.D. 82.27-82.30 mm (3.2390-3.2402 in.)
Piston-to-cylinder clearance 0.02-0.04 mm (0.0008-0.0016 in.)
Ring groove width
No. 1 1.22-1.24 mm (0.0480-0.0488 in.)
No. 2 1.52-1.54 mm (0.0598-0.0606 in.)
Oil 3.01-3.03 mm (0.1185-0.1193 in.)
Service size 0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize
20-4 GENERAL [1.6L Engine]

Description Specification Limit

Piston ring
Side clearance
No. 1, No. 2 0.03-0.07 mm (0.0012-0.0028 in.) 0.1 mm (0.004 in.)
End gap
No. 1 0.25-0.40 mm (0.0098-0.0157 in.) 0.8 mm (0.031 in.)
No. 2 0.35-0.50 mm (0.0138-0.0197 in.) 0.8 mm (0.031 in.)
Oil ring side rail 0.20-0.70 mm (0.0079-0.0276 in.) 1.0 mm (0.039 in.)
Service size 0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize

Connecting rod
Bend 0.05 mm (0.0020 in.)
Twist 0.1 mm (0.004 in.)
Connecting rod big end to crankshaft 0.10-0.25 mm (0.0039-0.0098 in.) 0.4 mm (0.0157 in.)
side clearance
Piston pin press-in load 7,500 - 17,500 N (1,653 - 3,858 lb)

Connecting rod bearing

Oil clearance 0.02-0.05 mm (0.0008-0.0020 in.) 0.1 mm (0.004 in.)

Crankshaft main bearing

Oil clearance 0.02-0.05 mm (0.0008-0.0020 in.) 0.1 mm (0.004 in.)

Crankshaft
Pin O.D. 45 mm (1.77 in.)
Journal O.D. 57 mm (2.24 in.)
Out-of-roundness of journal and Less than 0.015 mm (0.0006 in.)
pin
Taper of journal and pin Less than 0.005 (0.0002)
End play 0.05-0.18 mm (0.0020-0.0071 in.) 0.25 mm (0.0098 in.)

Flywheel
Runout 0.13 mm (0.0051 in.)

Oil pressure at curb idle speed 80 kPa (11.4 psi) or more

[Oil tempreature is 75 to 90°C (167 to 194oF)]

Oil pump
Tip clearance
Drive gear 0.16-0.21 mm (0.0063-0.0083 in.) 0.25 mm (0.0098 in.)
Driven gear 0.13-0.18 mm (0.0051-0.0071 in.) 0.25 mm (0.0098 in.)
Side clearance
Drive gear 0.08-0.14 mm (0.0031-0.0055 in.) 0.25 mm (0.0098 in.)
Driven gear 0.06-0.12 mm (0.0024-0.0047 in.) 0.25 mm (0.0098 in.)

Relief spring
Free length 46.6 mm (1.835 in.)
Load [61 N (13.5 lb)] 40.1 mm (1.579 in.)
NOTE
O.D. = Outer Diameter
I.D. = Inner Diameter
O.S. = Oversize Diameter
U.S. = Undersize Diameter
 GENERAL [1.6L Engine] 20-5

TIGHTENING TORQUE Nm kg.cm Ib.ft

Engine mount bracket nut and bolt 50-65 500-650 36-47
Engine mount insulator nut (large) 90-110 900-1100 65-80
Engine mount insulator nut (small) 45-60 450-600 33-43
Front roll stopper insulator nut 45-60 450-600 33-43
Rear roll stopper insulator nut 45-60 450-600 33-43
Fuel high pressure hose to delivery pipe 4-6 40-60 3-4
Accelerator cable adjusting bolt 4-6 40-60 3-4

Front engine support bracket bolt 50-70 500-700 36-51

Front exhaust pipe support bracket bolt 30-42 300-420 22-30
Left engine support bracket bolt 30-42 300-420 22-30
Front roll stopper bracket bolt 55-75 550-750 40-54
Rear roll stopper bracket bolt 110-130 1100-1300 80-94
Engine mount bracket to bracket 17-26 170-260 12-19
Front engine support bracket to bracket 17-26 170-260 12-19
Air conditioner compressor to bracket 23-27 230-270 17-20
Power steering oil pump to bracket 35-45 350-450 25-33

Front exhaust pipe to exhaust manifold 30-40 300-400 22-29

Rocker cover bolt 2.5-3.5 25-35 2-3
Center cover bolt 2.5-3.5 25-35 2-3
Camshaft sprocket bolt 80-100 800-1000 58-72
Camshaft bearing cap bolt 19-21 190-210 14-15
Crank angle sensor nut 10-13 100-130 7-9
Throttle body stay 15-22 150-220 11-16
Air cleaner body installation bolt 8-10 80-100 6-7
Crankshaft sprocket bolt 110-130 1100-1300 80-94
Crankshaft pulley to crankshaft sprocket 20-30 200-300 14-22
Cylinder head bolt (cold engine) 90-100 900-1000 65-72
Intake manifold stay 25-30 250-300 18-22
Tension rod to bracket 35-55 350-550 25-40
Tension pulley bracket bolt 23-27 230-270 17-20
Auto tensioner bolt 20-27 200-270 14-20
Tensioner pulley bolt 43-55 430-550 31-40
Idle pulley bolt 34-42 340-420 25-30
Front exhaust pipe clamp bolt 20-30 200-300 14-22
20-6 GENERAL [1.6L Engine]

Nm kg.cm Ib.ft
Oil pan 6-8 60-80 4-6
Oil pan drain plug 35-45 350-450 25-33
Oil screen 15-22 150-220 11-16
Oil pump sprocket nut 50-60 500-600 36-43
Oil pressure switch 8-12 80-120 6-9
Oil filter bracket bolt 15-22 150-220 11-16
Oil pump cover bolt 15-18 150-180 11-13
Oil seal case bolt 10-12 100-120 7-9
Plug cap 20-27 200-270 14-20
Front case bolt
M8 x 30 27-34 270-340 20-25
except M8 x 30 20-27 200-270 14-20
Driven gear bolt 34-40 340-400 25-29

Water pump pulley bolt 8-10 80-100 6-7

Timing belt upper cover 10-12 100-120 7-9
Timing belt lower cover 10-12 100-120 7-9
Relief plug 40-50 400-500 29-36
Flywheel 130-140 1300-1400 94-101
Drive plate 130-140 1300-1400 94-101
Timing belt rear right cover 10-12 100-120 7-9
Timing belt rear left cover (lower)
-bolt also securing left engine support bracket 30-42 300-420 22-30
Timing belt rear left cover (upper) 10-12 100-120 7-9
Connecting rod cap bolt 50-53 500-530 36-38
Crankshaft bearing cap bolt 65-70 650-700 47-51
Engine hanger 12-15 120-150 9-11
 GENERAL [1.6L Engine] 20-7

SPECIAL TOOLS

Tool
Illustration Use
(Number and name)

09214-32000 Installation of the crankshaft front oil seal

Crankshaft front oil seal (use with 09214-32100)
installer

09214-32100 Installation of the crankshaft front oil seal

Crankshaft front oil seal (use with 09214-32000)
guide

09221-21000 Installation of the camshaft oil seal (use with

Camshaft oil seal installer 09221-21100)

09221-21100 Used as a guide when pressing in the

Camshaft oil seal guide camshaft oil seal
(use with 09221--21000)

09221-32001 Removal and tightening of the cylinder head

Cylinder head bolt wrench

09222-28000 Removal and installation of the inlet or

Valve spring compressor exhaust valve
09222-28100
Valve spring compressor
holder

09222-28200 Installation of the valve stem oil seal

Valve stem oil seal installer
20-8 GENERAL [1.6L Engine]

Tool Use
Illustration
(Number and name)
09222-21200A Removal and installation of the valve guide
09222-21200B
Valve guide installer

09222-28400 Installation of the valve guide

Valve guide installer adapter

09231-21000 1. Installation of the engine rear oil seal

Crankshaft rear oil seal 2. Installation of the crankshaft rear oil seal
installer

09234-33001 Removal and installation of the piston pin

Piston pin remover and
installer kit

09234-33002 Removal and installation of the piston pin

Insert (use with 09234-33001)

09260-32000 Removal and installation of the oil pressure

Oil pressure switch wrench switch

09244-28000 Removal and installation of auto tensioner

Auto tensioner set screw

09244-28100 Adjustment of auto tensioner

Socket wrench
 GENERAL [1.6L Engine] 20-9

TROUBLESHOOTING

Symptom Probable cause Remedy

Low compression Blown cylinder head gasket Replace gasket

Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace piston
and/or cylinder block
Worn or damaged valve seat Repair or replace valve
and/or seat ring

Oil pressure drop Low engine oil level Check engine oil level
Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and determine cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace

High oil pressure Oil relief valve stuck (closed) Repair

Excessive engine rolling and Loose engine roll stopper (front, rear) Re-tighten
vibration Loose transaxle mount bracket Re-tighten
Loose engine mount bracket Re-tighten
Loose center member Re-tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace

Noisy valves Thin or diluted engine oil (low oil pressure) Change
Worn or damaged valve stem or valve guide Replace

Connecting rod and/main lnsufficient oil supply Check engine oil level
bearing noise Thin or diluted engine oil Change and determine cause
Excessive bearing clearance Replace

Timing belt noise Incorrect belt tension Adjust belt tension

20-10 GENERAL [1.6L Engine]

ENGINE [1.6L Engine]

CHECKING ENGINE OIL
Refer to 10 GROUP

REPLACING OIL FILTER

Refer to 10 GROUP

CHANGING ENGINE OIL

Refer to 10 GROUP

CHECKING COMPRESSION PRESSURE

1. Before checking compression, check the engine oil level.
Make sure the starter motor and battery are in normal
operating condition.
2. Start the engine and wait until engine coolant temperature
reaches 80-95o C (176-205 o F)
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign objects in the
cylinders.
6. Attach the compression gauge to the spark plug hole.
7. Depress the accelerator pedal to fully open the throttle.
8. Crank the engine and read the gauge.

Limit : 12.0 kg/cm2 (1.18 MPa, 171 psi)

[250-400 rpm]

9. Repeat steps 6 through 8 on all cylinders, making sure that

the pressure differential for each of the cylinders is within
the specified limit.

Limit : Max. 1.0 kg/cm2 (100 kpa, 14 psi) between cylinders

10. If a cylinder’s compression or pressure differential is below

the specification, add a small amount of oil through the spark
plug hole and repeat steps 6 through 9.
1) If the addition of oil brings the compression up, it is
possible that there is wear between the piston ring and
cylinder wall.
2) If compression remains the same, valve seizure, poor
valve seating or a compression leak from the cylinder
head gasket are all possible causes.

Tightening torque
Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30 Nm (200-300 kg.cm, 15-21 Ib.ft)
 GENERAL [1.6L Engine] 20-11

DRIVE BELTS TENSION ADJUSTMENT

1. Check that the belts are not damaged and are properly fit
into the pulley grooves.

CAUTION
1. When installing the V-ribbed belt, check that the
V-ribs are properly in alignment.
2. If noise or slippage is detected, check the belt for
wear, damage, or breakage on the pulley contact
surface, and check the pulley for scoring. Also check
for the proper belt deflection measurement.

2. Apply 100 N (22 Ibs.) force to the belt back midway between
the pulleys as shown in the illustration, measure the amount
of deflection with a tension gauge.

Standard value :

NOTE
1. The belt tension must be measured between the specified
pulleys.
2. When a new belt is installed, adjust the tension to the
center of the standard range indicated under “New”.
And then let the engine idle for 5 minutes or more, and
check the standard value indicated under “Inspection”.
3. When adjusting a belt which has been used or a belt newly
installed after 5 minutes or more of operation, refer to the
standard value indicated under “Used”.
4. Refer to the standard value indicated under “Inspection”
for periodic inspections.

Type A tension gauge

Do not let the dial section of the tension gauge contact other
objects during measurement.
20-12 GENERAL [1.6L Engine]

Type B tension gauge

1. When measuring, be sure to turn reset button in the arrow
direction to set the gauge needle to the RESET position.
2. If the tension gauge is removed from the belt, the needle
will still indicate the tension. Read the tension after removing
the gauge.

Alternator Belt Adjustment

CAUTION
If the belt is too loose, there will cause noise or premature
wear. If the belt is too tight, the water pump bearing or
the alternator will get damaged.

1. Loosen the alternator nut “A” and the tension adjuster lock
bolt "B".
2. Using the tension adjuster bolt, adjust the belt tension to
specification.
3. Tighten the adjuster lock bolt “B”.
4. Tighten the alternator nut “A”.
5. Check the tension or the deflection of belt, readjust if
necessary.

Tightening torque
Alternator nut A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-25 Nm (200-250 kg.cm, 14-18 Ib.ft)
Adjuster lock bolt B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-15 Nm (120-150 kg.cm, 9-11 Ib.ft)
Tension adjuster bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12 Nm (80-120 kg.cm, 6-8 Ib.ft)

Power Steering Oil Pump Belt Adjustment

1. Loosen the adjustment bolt of the power steering oil pump.
 GENERAL [1.6L Engine] 20-13

2. Adjust the deflection or the tension of the power steering

pump to specification.
3. Tighten the adjustment bolt.
4. Crank the engine one or more revolutions.
5. Check the belt deflection, readjust if necessary.

Air Conditioner Compressor Belt Adjustment

1. Loosen the tension pulley adjustment bolt A.
2. Adjust the belt deflection with adjustment bolt B.
3. Tighten the fixing bolt A.
4. Re-check the belt deflection and re-adjust, if necessary.

NOTE
Before re-checking, crank the engine one or more
revolutions.

Lash Adjusters Check

If an abnormal noise is heard from the lash adjusters (tappets),
check as follows;
1. While installed to the cylinder head, press the part where
the rocker arm contacts the lash adjuster at the very top. If
the adjuster is normal, the part pressed will feel very hard.
2. If it easily moves all the way downward when pressed, there
is a malfunction of the lash adjuster and it should be
replaced with a new one.
3. If it feels spongy or elastic, probably oil with air mixed in
it has entered the lash adjuster, so follow the steps below:
o Check whether the amount of oil is too much or is not
enough.
o Check whether the cause of air becoming mixed into the
oil is a damaged oil screen or oil screen gasket. After
repairing the cause of the air leak, warm up the engine
and then drive the vehicle at low speed for a while.
Stop the engine and leave it off for a few minutes; then
re-start the engine and drive at low speed. Repeat this
procedure several times during the course of about one
hour so as to remove the air from the oil.
20-14 ENGINE MOUNTING [1.6L Engine]

ENGINE MOUNTING
COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

 ENGINE MOUNTING [1.6L Engine]

REMOVAL
Attach an engine hoist to the engine hooks, and raise just
enough so that there is no pressure on the insulators.

Engine Mounting
1. Remove the engine mount insulator bolts.
2. Remove the engine mount bracket from the engine.

Transaxle Mounting
1. For vehicles with a 5-speed manual transaxle, remove the
select control valve.
2. Remove the transaxle mount bolt.

3. Detach the cap from the inside of the right fender shield,
remove the transaxle mounting bolts.
4. Remove the transaxle bracket.

Front Roll Stopper

Remove the front roll stopper bracket from the center member.
20-16 ENGINE MOUNTING [1.6L Engine]

Rear Roll Stopper

Remove the rear roll stopper from the center member.

Center member
1. Remove the under cover (R.H.).
2. Remove the front roll stopper mounting bolts.
3. Remove the rear roll stopper mounting bolts.
4. Remove the center member from the body.
 ENGINE MOUNTING [1.6L Engine] 20-17

INSPECTION ITEMS

Transaxle mounting Engine mounting

Front roll stopper Rear roll stopper

Center menber
20-18 ENGINE AND TRANSAXLE ASSEMBLY [1.6L Engine]

ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp and engine
harness.
4. For a vehicle with a 5-speed manual transaxle, disconnect
the select control valve connector.

5. Disconnect the connectors for the alternator harness and the

oil pressure gauge wiring.
6. Drain the engine coolant.
7. For vehicles with an automatic transaxle, disconnect the
transaxle oil cooler hoses.

NOTE
When disconnecting the hoses, make identification marks
to avoid making any mistakes in reconnecting them.

CAUTION
Be careful not to spill any of the oil or fluid out of the
hoses, and plug the openings to prevent the entrance of
foreign material.

8. Disconnect the radiator upper and lower hoses on the engine

side, and then remove the radiator assembly.
9. Disconnect the high tension cable from the ignition coil
section.
10. Disconnect the engine ground.
11. Disconnect the brake booster vacuum hose.
12. Remove the main fuel line, and the return and vapor hoses
from the engine side.

CAUTION
To reduce the residual pressure in the hoses, refer to
Group Fuel System “Fuel filter replacement”.

13. Disconnect the heater hoses (inlet and outlet) on the engine
side.
14. Disconnect the accelerator cable at the engine side.
15. For vehicles with a manual transaxle, remove the clutch
cable from the transaxle.
16. For vehicles with an automatic transaxle, remove the control
cable from the transaxle.

17. Disconnect the speedometer cable from the transaxle.

18. Disconnect the air conditioner from the mounting bracket.
 ENGINE AND TRANSAXLE ASSEMBLY [1.6L Engine] 20-19

19. Jack up the vehicle.

20. Drain the transaxle oil (or fluid).
21. Disconnect the front exhaust pipe from the manifold.

NOTE
Use wire to suspend the exhaust pipe from the bottom of
the vehicle.

22. For vehicles with a manual transaxle, remove the shift

control rod and extension rod.
23. Remove the lower arm ball joint bolts and the stabilizer bar
at the point where it is mounted to the lower arm.
24. Remove the drive shafts from the transaxle case.

CAUTION
1) Plug the holes of the transaxle case to prevent entry
of foreign material.
2) Install new circlips on the drive shafts when
reassembling.

25. Hang the lower arm and drive shaft from the body with a
string.
26. Attach a cable to the engine, and use a chain hoist to lift
the engine only enough to pull cable tight.

27. Remove the front roll stopper.

28. Separate the rear roll stopper.

29. Remove the engine mounting insulator bolts.

30. Remove the engine mounting bracket from the engine.

31. Slowly raise the engine (to the extent that the engine and
transaxle weights are not applied to the mounting portions)
and temporarily hold it in the raised condition.

CAUTION
Check that all of the cables, hoses, harnesses, connectors
etc. are disconnected from the engine.

32. Remove the caps from inside the right fender shield and
remove the transaxle mount bracket bolts.
33. Remove the left mount insulator bolt.
34. While directing the transaxle side downward, lift the engine
and transaxle assembly up and out of the vehicles.
20-20 ENGINE AND TRANSAXLE ASSEMBLY [1.6L Engine]

INSTALLATION
1. While checking the connections of the harnesses, pipes,
hoses, etc., and making sure that none of them are being
caught, damaged, etc., install the engine and transaxle
assembly.
2. Install the mounting stoppers with the arrows on them
pointing in the direction shown.

3. When the engine and transaxle assembly is in place

temporarily tighten the front roll stopper.

4. The front and rear center member rubber bushings and

collars are different.

5. After the weight of the engine and transaxle assembly has

been put on each insulator, tighten to specified torque.
6. Reassemble all of the components removed during disas-
sembly. Be especially careful to properly secure all
components, including fuel, electrical and fluid pipe
connections.
7. Refill the coolant and check for leaks.
8. Refill the transaxle fluid, test its operation, and check for
leaks.
9. Check the operation of the transaxle control cable and
accelerator cable. Adjust as necessary.
10. Check for proper operation of each of the various gauges.
 TIMING BELT [1.6L Engine] 20-21

TIMING BELT

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft).

20-22 TIMING BELT [1.6L Engine]

REMOVAL
1. Remove the crankshaft pulley, water pump pulley and drive
belt.
2. Remove the timing belt cover.

3. Turn the crankshaft clockwise and align the timing marks so

as to bring the No. 1 cylinder to compression top-dead-center
position.
At this time the timing marks of the camshaft sprocket and
the upper surface of the cylinder head should coincide, and
the dowel pin of the camshaft sprocket should be at the
upper side.
Remove the auto tensioner.

CAUTION
Rotate the crankshaft clockwise.

4. Remove the timing belt.

NOTE
If the timing belt is reused, make an arrow mark indicating
the turning direction (or the front of the engine) to make
sure that the belt is reinstalled in the same direction as
before.

5. Remove the camshaft sprockets.

NOTE
Be careful not to damage the cylinder head with the
wrench.
 TIMING BELT [1.6L Engine] 20-23

INSPECTION
Sprockets, Tensioner Pulley, and Idler Pulley
1. Check the camshaft sprocket, crankshaft sprocket, tensioner
pulley, and idler pulley for abnormal wear, cracks, or
damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and
smooth pulley rotation and check for play or noise. Replace
as necessary.
3. Replace if there is a grease leak.

Auto Tensioner
1. Check the auto tensioner for leaks and replace as necessary.
2. Check the rod end for wear or damage and replace as
necessary.

3. Measure the rod protrusion. If it is out of specification,

replace the auto tensioner.

Standard value . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.47 in.)

4. Using a vise soft jaws push in the auto tensioner rod. If the
rod can be easily retracted, replace the auto tensioner. You
should feel a fair amount of resistance when pushing the
rod in.

CAUTION
1. Clamp the auto tensioner in the vise so that it is level.
Use soft jaws in the vise to avoid damaging the auto
tensioner.

2. If the plug is at the bottom of the auto tensioner,

insert a plain washer to prevent direct contact if the
plug with the vise.
20-24 TIMING BELT [1.6L Engine]

Timing Belt
1. Check the belt for oil or dust deposits. Replace if necessary.
Small deposits should be wiped away with a dry cloth or
paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted,
check the belt in detail. If the following flaws are evident,
replace the belt with a new one.
 TIMING BELT [1.6L Engine] 20-25

Description Flaw conditions

1. Hardened back surface rubber Back surface glossy. Non-elastic and so hard that when a finger
nail is forced into it, no mark is produced.

2. Cracked back surface rubber

3. Cracked or separating canvas

4. Badly worn teeth (initial stage) Canvas on load side tooth flank worn
(Fluffy canvas fibers, rubber gone and color changed to white,
and unclear canvas texture)

Flank worn
(On load side)

5. Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber exposed
(tooth width reduced)

Rubber exposed

6. Cracked tooth bottom

Crack
20-26 TIMING BELT [1.6L Engine]

Description Flaw conditions

7. Missing tooth Tooth missing and

canvas fiber exposed

Rounded belt side

8. Side of belt badly worn

NOTE Abnormal wear (Fluffy canvas fiber)

Normal belt should have precisely cut sides as if produced by
9. Side of belt cracked a sharp knife.
 TIMING BELT [1.6L Engine] 20-27

INSTALLATION
1. Install the flange and crankshaft sprocket as shown. Pay
close attention to their mounting directions.

Tightening torque
Crankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110-130 Nm (1100-1300 kg.cm, 80-94 lb.ft)

2. Install the camshaft sprocket and tighten the bolt to the

specified torque.

Tightening torque
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-100 Nm (800-1000 kg.cm, 56-72 Ib.ft)

3. Install the auto tensioner.

CAUTION
Leave the wire installed in the auto tensioner

NOTE
If the auto tensioner rod is in its fully extended position,
reset it as follows.

1. Clamp it in the vise with soft jaws in a level position.

Apply a plain washer if there is a plug at the bottom
of the auto tensioner.
2. Push in the rod slowly with the vise until the set hole
A in the rod is aligned with the set hole B in the
cylinder.

4. Install the tensioner pulley onto the tensioner arm. And

locate the pinhole in the tensioner pulley shaft to the left
of the center bolt and then tighten the center bolt
finger-tight.

CAUTION
Leave the wire installed in the auto tensioner.
20-28 TIMING BELT [1.6L Engine]

5. Turn the two sprockets so that their dowel pins are located
on top. Then, align the timing marks facing each other with
the top surface of the cylinder head.

NOTE
The same camshaft sprocket is used for the intake and
exhaust camshafts and is provided with two timing marks.
When the sprocket is mounted on the exhaust camshaft,
use the timing mark on the right with the dowel pin hole
on top. For the intake camshaft sprocket, use the one on
the left with the dowel pin hole on top.

6. Align the crankshaft sprocket timing marks.

7. Align the oil pump sprocket timing marks.
 TIMING BELT [1.6L Engine] 20-29

8. Install the timing belt around the tensioner pulley and

crankshaft sprocket. Then secure the timing belt onto the
tensioner pulley with your left hand.
9. Pulling the belt with your right hand, install it around the
oil pump sprocket.
10. Install the belt around the idler pulley.
11. Install it around the intake camshaft sprocket.
12. Turn the exhaust camshaft sprocket one tooth clockwise to
align its timing mark with the cylinder head top surface [see
illustration in step 5]. Then, pulling the belt with both hands,
install it around the exhaust camshaft sprocket.
13. Gently raise the tensioner pulley as shown by the arrow, so
that the belt does not sag, and temporarily tighten the center
bolt.

14. After turning the crankshaft 1/4 turn counterclockwise, turn

it clockwise to move the No. 1 cylinder to top dead center.
15. Loosen the center bolt, and then, as shown in the
illustration, attach the special tool and a torque wrench and
apply a torque of 2.6-2.8 Nm (1.88-2.03 Ib.ft.).
If the body interferes with the special tool and the torque
wrench, use a jack to slightly raise the engine assembly.

NOTE
Use a torque wrench measuring within a range of 0-3
Nm (0-2.2 Ib.ft.).

16. Holding the tensioner pulley with the special tool and torque
wrench, tighten the center bolt to specification. Screw the
special tool into the engine left support bracket until its end
makes contact with the tensioner arm. At that point, screw
the special tool some more and then remove the set wire
attached to the auto tensioner.
17. Remove the special tool.

18. Rotate the crankshaft two complete turns clockwise and

leave it as is for about 15 minutes. Then, measure the auto
tensioner protrusion “A” (distance between the tensioner
arm and auto tensioner body) to ensure that it is up to
specification.

Standard value : 3.8-4.5 mm (0.15-0.18 in.)

If it is out of specification, repeat steps 14 through 18 until

the specified value is obtained.
20-30 TIMING BELT [1.6L Engine]

NOTE
If the clearance “A” between the tensioner arm and the
auto tensioner body cannot be measured (When the engine
is mounted on the vehicle, for example), the following
alternative method may be used.

1. Screw in the special tool until its end makes contact

with the tensioner arm.

2. Starting with that position, screw in the special tool

some more to retract the auto tensioner push rod while
counting the number of turns of the tool makes until
the tensioner arm is brought into contact with the auto
tensioner body.
Make sure that the number of turns the special tool
makes conforms with the standard value.

Standard value : 2.5-3 turns

19. Install the rubber plug to the timing belt rear cover.

20. Install the timing belt lower cover and the timing belt upper
cover.
 CAMSHAFTS AND ROCKER ARMS [1.6L Engine] 20-31

CAMSHAFTS AND ROCKER ARMS

COMPONENTS

TORQUE : Nm (kg.cm, lb.ft)

20-32 CAMSHAFTS AND ROCKER ARMS [1.6L Engine]

REMOVAL
1. Disconnect the negative terminal from battery.
2. Drain the engine coolant.
3. Remove the breather hose between the air cleaner and the
rocker cover.
4. Remove the air cleaner.
5. Remove the timing belt cover.
6. Remove the rocker cover, crank angle sensor.
7. Loosen the camshaft, sprocket bolts and remove the
camshaft sprockets.

8. Loosen the bearing cap bolts and remove the bearing caps,
camshafts, rocker arms, lash adjusters.

INSPECTION
Rocker Arms
1. Check rotation of the roller. If it does not rotate smoothly or
if looseness is evident, replace it.
2. Check the roller. Replace there are any dents, damage or
evidence of seizure.
3. Check the valve contact surface for possible damage or
seizure and replace as necessary.

Camshafts
1. Check the camshaft journals for wear. If the journals are
badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or
worn excessively, replace the camshaft.

Cam height
[Standard]
Intake . . . . . . . . . . . . . . . . . . . . . . . 35.200 mm (1.3858 in.)
Exhaust . . . . . . . . . . . . . . . . . . . 34.907 mm (1.3743 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . 34.700 mm (1.3661 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . 34.407 mm (1.3546 in.)
 CAMSHAFTS AND ROCKER ARMS [1.6L Engine] 20-33

INSTALLATION
1. Install the camshafts on the cylinder head.

NOTE
1. Apply engine oil to journals and cams of the
camshafts.
2. The intake camshaft has a slit on its rear end for
driving the crank angle sensor.

2. Install the bearing caps. Check the markings on the caps for
intake/exhaust identification symbol.
L : Intake camshaft
R : Exhaust camshaft

3. Check that the camshaft can be easily turned by hand. After

checking, remove the bearing caps and the camshafts, and
then install the rocker arms.

4. Make sure that the dowel pins on the camshaft sprocket end
are located on the top.

5. Tighten the bearing caps to the specified torque in two or

three steps as shown.

NOTE
Tighten the rocker arms uniformly.

Tightening torque
Rocker arm bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19-21 Nm (190-210 kg.cm, 14-15 Ib.ft)
20-34 CAMSHAFTS AND ROCKER ARMS [1.6L Engine]

6. Using special tools, Camshaft Oil Seal Installer and guide

(09221-21000, 09221-21100), press fit the camshaft oil
seal. Be sure to apply engine oil to the external surface of
the oil seal.
Insert the oil seal along the camshaft front end and install
by driving the installer with a hammer until the oil seal is
fully seated.

7. Install the camshaft sprockets to the specified torque.

Tightening torque
Camshaft sprocket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-100 Nm (800-1000 kg.cm, 58-72 Ib.ft)

8. Install the rocker cover. Apply sealant as shown.

Tightening torque
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5-3.5 Nm (25-35 kg.cm, 2-3 Ib.ft)
Sealant
A Portion : Threebond No. 10 or equivalent
B Portion : Threebond No. 1212D or equivalent
 CAMSHAFTS AND ROCKER ARMS [1.6L Engine] 20-35

Bolt length x Diameter

* : 25 mm x 6 mm
* : 20 mm x 6 mm
~1 15mm
:6x

9. Install the spark plugs, center cover and the rubber as shown
in the illustration.

10. Locate the dowel pin on the sprocket side of the intake
camshaft at the top.

11. Align the punch mark on the crank angle sensor housing
with the notch in plate.

NOTE
The crank angle sensor can be installed even when the
punch mark is positioned opposite the notch; however, the
position results in incorrect fuel injection and ignition
timings.

12. Install the crank angle sensor on the cylinder head.

20-36 CYLINDER HEAD AND VALVES [1.6L Engine]

CYLINDER HEAD AND VALVES

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

 CYLINDER HEAD AND VALVES [1.6L Engine] 20-37

REMOVAL
1. Using the special tool, Cylinder Head Bolt Wrench
(09221-32001), remove the cylinder head bolts as shown
in the illustration.

2. Using the special tool, Valve Spring Compressor

(09222-28000, 09222-28100), remove the retainer lock.
Next remove the spring retainer, valve spring, spring seat
and valve.

NOTE
Keep these parts in order so that they can be reinstalled
in their original positions.

3. Remove the valve stem seals with pliers, and discard.

NOTE
Do not reuse the valve stem seals.

INSPECTION
Cylinder head
1. Check the cylinder head for cracks, damage and coolant
leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon deposits
completely. After cleaning oil passages, apply compressed air
to make certain that the passages are not clogged.
20-38 CYLINDER HEAD AND VALVES [1.6L Engine]

3. Check the cylinder head gasket surface for flatness by using

a straight edge in the direction of A, B, ... as shown.
If flatness exceeds service limit in any direction, either
replace the cylinder head, or lightly machine the cylinder
head gasket surface.

Flatness of cylinder head gasket surface

[Standard dimension] ... Less than 0.05 mm (0.002 in.)
[Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 in.)

Valves
I. Using a wire brush, clean the valve thoroughly.
2. Check each valve for wear, damage and distortion of head
and stem at B. Repair or correct if necessary.
If stem end A is pitted or worn, resurface as necessary. This
correction must be limited to a minimum. Also resurface the
valve-face.
Replace the valve if the margin has decreased to less than
the service limit.

Margin
[Standard dimension]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm (0.028 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)

Valve Springs
I. Check the valve spring free length and tension. If they
exceed the service limit, replace the spring.
2. Using a square, test the squareness of each spring. If the
spring is excessively out of square, replace it.

Valve spring
[Standard Value]
Free height . . . . . . . . . . . . . . . . . . . . . 48.3 mm (1.902 in.)
L o a d . . . . . . . . . . . . . . . 300 N (66 lb)/40 mm (1.575 in.)
Out of square . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5o or less
[Limit]
Free height . . . . . . . . . . . . . . . . . . -1.0 mm (-0.039 in.)
Out of square . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4o
 CYLINDER HEAD AND VALVES [1.6L Engine] 20-39

Valve Guides
Check the valve stem-to-guide clearance. If the clearance
exceeds the service limit, replace the valve guide with the next
oversize part.

Valve stem-to-guide clearance

[Standard dimension]
Intake . . . . . . . . . . . 0.020-0.047 mm (0.0008-0.0019 in.)
Exhaust . . . . . . . . . 0.050-0.085 mm (0.0020-0.0033 in.)
[Limit]
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)

Valve Seat Insert

Check the valve seat for evidence of overheating and improper
contact with the valve face. Recondition or replace the seat if
necessary.
Before reconditioning the seat, check the valve guide for wear.
If the valve guide is worn, replace it, then recondition the seat.
Recondition the valve seat with a valve seat grinder or cutter.
The valve seat contact with should be within specifications and
centered on the valve face.

Valve Seat Insert Replacement Procedure

I. Any valve seat insert that has been worn over the service
limit should be removed at normal temperature after cutting
away most of the insert wall, using valve seat cutters, as
shown in Fig. “A”.
20-40 CYLINDER HEAD AND VALVES [1.6L Engine]

2. After removing the seat insert, machine the seat insert bore
using a reamer or a cutter. Cut to the size shown in the table.
3. Heat the cylinder head to about 250°C (480oF) and press in
the oversize seat insert. The oversize seat insert should be
at normal room temperature for installation. After installation
of a new valve seat insert, resurface the valve seat using
the same procedure as in paragraph I. in Valve Seat Insert.

Valve Seat Insert Oversizes

Valve Guide Replacement Procedures

The valve guide is installed using a press fit. Using a Valve Guide
Installer (09222-28400, 09222-21200) or suitable tool,
replace the valve guide by the following procedure.
1. Using the push rod of the Valve Guide Installer, push the
valve guide out toward the cylinder block with a press.
2. Machine the valve guide insert hole in the cylinder head to
the specified oversize of the new valve guide.

3. Using the Valve Guide Installer or suitable tool, press fit the
valve guide. The use of the valve guide installer makes it
possible to press fit the valve guide to a predetermined
height. The valve guide should be installed from the top of
the cylinder head. Note that intake and exhaust valve guides
are different in length [45.5 mm (1.791 in.) for intake and
50.5 mm (1.988 in.) for exhaust.]
4. After the valve guides have been installed, insert new valves
and check the clearance.
5. Whenever valve guides are replaced, check for valve to seat
contact and recondition the valve seats as necessary.

Valve Guide Oversizes

 CYLINDER HEAD AND VALVES [1.6L Engine] 20-41

INSTALLATION
NOTE
1) Clean each part before assembly.
2) Apply engine oil to sliding and rotating parts.

1. After installing the spring seat, fit the stem seal onto the
valve guide.
To install, fit the seal in by lightly tapping the Special Tool,
Valve Stem Oil Seal Installer (09222-28200).
The seal is installed in the specified position by means of
the special tool. Incorrect installation of the seal will
adversely affect the lip I.D. and eccentricity, resulting in oil
leakage down the valve guides. When installing, therefore,
be careful not to twist the seal. Do not reuse old stem seals.
2. Apply engine oil to each valve. Insert the valves into the
valve guides. Avoid inserting the valve into the seal with
force.
After insertion, check to see if the valve moves smoothly.

3. Install springs and spring retainers.

Valve springs should be installed with the enamel coated
side toward the valve spring retainer.

4. Using the special tool, Valve Spring Compressor

(09222-28000, 09222-28100), remove the retainer lock.
Next remove the spring retainer, valve spring, spring seat
and valve.

NOTE
Keep these parts in order so that they can be reinstalled
in their original positions.

5. Clean all gasket surfaces of the cylinder block and cylinder

head.
6. Install a new cylinder head gasket onto the cylinder head
assembly. Do not apply sealant to the gasket and do not
reuse the old cylinder head gasket.
20-42 CYLINDER HEAD AND VALVES [1.6L Engine]

7. Using the special tool, Cylinder Head Bolt Wrench

(09221-32001). install the cylinder head bolts as shown in
the illustration.

Tightening torque
Cylinder head bolt [cold engine]. . . . . . . . . . . . . . . . . . . . . . .
90-100 Nm (900-1000 kg.cm, 65-72 Ib.ft)
 FRONT CASE, OIL PUMP [1.6L Engine] 20-43

FRONT CASE, OIL PUMP

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

REMOVAL
1. Remove the timing belt. Refer to “Timing Belt”.
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the oil pressure switch.
20-44 FRONT CASE, OIL PUMP [1.6L Engine]

6. Remove the oil filter bracket and gasket.

7. Remove the front case assembly.
8. Remove the relief spring and relief valve.

INSPECTION
Front Case
1. Check oil holes for clogging and clean if necessary.
2. Check the front case for cracks and other damage. Replace
cracked or damaged front case.

Oil Seal
1. Check the oil seal lip for wear and damage. Replace oil seal
if necessary.
2. Check the oil seal lip for deterioration. Replace oil seal if
necessary.

Oil Pressure Switch

Check the continuity between the terminal and the body with
an ohmmeter.
If there is continuity, replace the oil pressure switch.

Check the continuity between the terminal and the body

when the fine wedge is pushed. If there is continuity even
when the fine wedge is pushed, replace it.
Or, if there is no continuity when a 50 kPa (70 psi) vacuum
is applied through the oil hole, the switch is operating
properly. Check to see that air doesn’t leak. If air leaks, the
diaphragm is broken. Replace the switch.
 FRONT CASE, OIL PUMP [1.6L Engine] 20-45

Oil Pump
1. Assemble the oil pump gear to the front case and rotate it
to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface
between the front case and gear surface of the oil pump
cover.

3. With the drive and driven gears installed into the front case,
measure the tip clearance of the gears.

[Standard value]
Drive gear . . . . . . . . 0.16-0.21 mm (0.0063-0.0083 in.)
Driven gear . . . . . . . 0.13-0.18 mm (0.0051-0.0071 in.)
[Limit]
Drive gear . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Driven gear . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)

4. Check the side clearance.

[Standard value]
Drive gear . . . . . . . . 0.08-0.14 mm (0.0031-0.0055 in.)
Driven gear . . . . . . . 0.06-0.12 mm (0.0024-0.0047 in.)
[Limit]
Drive gear . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.9098 in.)
Driven gear . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)

INSTALLATION
1. Apply engine oil to the gear and align the two timing marks.

2. Using the special tool, Crankshaft Front Oil Seal Installer

(09214-32000), install the crankshaft front oil seal into the
front case.
20-46 FRONT CASE, OIL PUMP [1.6L Engine]

3. Set the special tool (09214-32100) on the front end of

crankshaft and apply a thin coat of engine oil to outer
circumference of the special tool to install the front case.

4. Install the front case assembly through a new front case

gasket and temporarily tighten the flange bolts (other than
those for tightening the filter bracket).

5. Install the front case assembly with a new gasket, and

tighten the bolts to the specified torque.

Front case assembly

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* : 27-34 Nm (270-340 kg.cm, 20-25 Ib.ft)
All except* : 20-27 Nm (200-270 kg.cm, 14-20 Ib.ft)
Oil filter bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-22 Nm (150-220 kg.cm, 11-16 Ib.ft)

6. Apply sealant into the groove of the pan flange as shown.

NOTE
1) Apply sealant approx. 4 mm (0.16 in.) in thickness.
2) After application of sealant, do not exceed 15 minutes
before installing the oil pan.

7. Note the difference in bolt lengths at the location shown.

8. Install the oil pan and tighten the bolts to the specified
torque.

Tightening torque
Oil pan bolt . . . . . 6-8 Nm (60-80 kg.cm, 4-6 Ib.ft)
 FRONT CASE, OIL PUMP [1.6L Engine] 20-47

9. Using the special tool (09260-32000). install the oil

pressure switch after applying sealant to the threaded area.

Sealant . . . . . . . . . . . . . . . . . . Threebond 1104 or equivalent

NOTE
Do not over torque the oil pressure switch.

Tightening torque
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12 Nm (80-120 kg.cm, 6-8 Ib.ft)
20-48 PISTON AND CONNECTING ROD [1.6L Engine]

PISTON AND CONNECTING ROD

COMPONENTS

TORQUE : Nm (kg.cm. Ib.ft)

REMOVAL
Connecting Rod Cap
NOTE
Keep the bearings in order with their corresponding
connecting rods (according to cylinder numbers) for proper
reassembly.

1. Removethe connecting rod cap nuts and then remove the

caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top
of the cylinder.

Piston Pin Removal and Installation Procedures

1. Use the special tools (09234-33001), to disassemble and
re-assemble the piston and connecting rod.
2. Place the proper insert in the fork of the tool. Position the
insert between the connecting rod and the piston.
 PISTON AND CONNECTING ROD [1.6L Engine] 20-49

3. Insert the proper removal tool through the hole in the arch
of the tool.

NOTE
Center the piston, rod and pin assembly with the removal
arbor.

4. Press the piston pin out of the connecting rod.

5. Install proper pin guide (refer to application chart) through

piston and into connecting rod. Hand tap pin guide into
piston for proper retention. Drop piston pin into the other
side of the piston.

NOTE
The pin guide centers the connecting rod in the piston.
When the piston, connecting rod, piston pin and pin guide
assembly are positioned on the fork of the tool, the pin
guide will also center this assembly in the tool. If a pin
guide that is too small is used, the piston assembly will
not be located centrally in the tool, and damage may occur
to the fork and/or the insert of the tool.
6. Install piston assembly onto fork assembly of tool. Tool will
support connecting rod at the piston pin. Be sure piston
assembly is slid onto the fork until the pin guide contacts
the fork insert.
7. Adjust the installing arbor to the proper length by turning
the numbered sleeve on the lettered shaft until the specified
alphanumeric setting from the application chart is obtained.
Turn knurled nut to lock numbered sleeve on shaft.
8. Insert the installing arbor through the hole in the arch of
the tool. Press piston pin into the connecting rod until the
sleeve on the installing arbor contacts the top of the tool
arch. The pin guide will fall out of the connecting rod as the
piston pin is pressed in.

CAUTION
Do not exceed 5000 pounds of force when stopping the
installing arbor sleeve against the arch.

INSPECTION
Piston and Piston Pins
1. Check each piston for scuffing, scoring, wear and other
defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal
wear. Replace the defective rings. When the piston requires
replacement, its rings should also be replaced.
3. Check the piston pin fit in the piston pin hole. Replace any
piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into the
pin hole at room temperature.
20-50 PISTON AND CONNECTING ROD [1.6L Engine]

Piston Rings
1. Measure the piston ring side clearance. If the measured
value exceeds the service limit, insert a new ring in a ring
groove to measure the side clearance. If the clearance still
exceeds the service limit, replace the piston and rings
together. If it is less than the service limit, replace the piston
rings only.

[Standard value]
Piston ring side clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.03-0.07 mm (0.0012-0.0028 in.)
[Limit]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

2. To measure the piston ring end gap, insert a piston ring into
the cylinder bore. Position the ring at right angles to the
cylinder wall by gently pressing it down with a piston.
Measure the gap with a feeler gauge. If the gap exceeds the
service limit, replace the piston ring.

Piston ring end gap

[Standard dimension]
No. 1 . . . . . . . . . . . . 0.25-0.40 mm (0.0098-0.0157 in.)
No.2 . . . . . . . . . . . . 0.35-0.50 mm (0.0138-0.0197 in.)
Oil ring side rail 0.20-0.70 mm (0.0079-0.0276 in.)
[Limit]
No.1, No.2 . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in.)
Oil ring side rail . . . . . . . . . . . . . . . . 1.0 mm (0.039 in.)

Connecting Rods
1. When the connecting rod cap is installed, make sure that
cylinder numbers put on the rod end cap at disassembly
match.
When a new connecting rod is installed, make sure that the
notches for holding the bearing in place are on the same
side.
2. Replace the connecting rod if it is damaged on the thrust
faces at either end, and also if it has a step wear in, or
severely rough surface of, the inside diameter of the small
end.
 PISTON AND CONNECTING ROD [1.6L Engine] 20-51

INSTALLATION
1. Install the spacer.

2. Install upper side rail. To install side rail, first put one end
of side rail between piston ring groove and spacer, hole it
down firmly, and then press down the portion which is to
be inserted into groove with a finger as illustrated.

NOTE
Do not use piston ring expander when installing side rail.
3. Install lower side rail by same procedure as Step 2.

4. Using piston ring expander, install No.2 piston ring.

5. Install No.1 piston ring.
6. Apply engine oil around piston and piston rings.

7. Position each piston ring end gap as for apart from

neighboring gaps as possible. Make sure that gaps are not
positioned in thrust and pin directions.
8. Hold piston rings firmly in a piston ring compressor as they
are inserted into cylinder.

9. Make sure that front mark of piston and front mark

(identification mark) of connecting rod are directed toward
front of engine.
10. When connecting rod cap is installed, make sure that
cylinder numbers put on rod and cap at disassembly match.
11. When new connecting rod is installed, make sure that
notches for holding bearing in place are on same side.
12. Tighten the connecting rod cap nuts.

Tightening torque
Connecting rod cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-53 Nm (500-530 kg.cm, 36-38 Ib.ft)
20-52 PISTON AND CONNECTING ROD [1.6L Engine]

13.Check connecting rod side clearance.

Side clearance . . . . . . . 0.10-0.25 mm (0.004-0.0098 in.)

Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157 in.)
 CRANKSHAFT, FLYWHEEL [1.6L Engine] 20-53

CRANKSHAFT, FLYWHEEL

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

20-54 CRANKSHAFT, FLYWHEEL [1.6L Engine]

REMOVAL
1. Remove the timing belt train, front case, flywheel cylinder
head assembly and oil pan. For details, refer to respective
chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.

NOTE
Mark the main bearing caps to permit reassembly in the
original position and direction.

4. Remove the main bearing caps and remove the crankshaft.

Keep the bearings in order by cap number.

INSPECTION
Crankshaft
1. Check the crankshaft journals and pins for damage, uneven
wear and cracks. Also check oil holes for clogging. Correct
or replace any defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and
pin.

Standard value
Crankshaft journal O.D . . . . . . . . . . . . . . . 57 mm (2.24 in.)
Crankshaft pin O.D. . . . . . . . . . . . . . . . . . . 45 mm (1.77 in.)

Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melt, seizure and
improper contact. Replace the defective bearings.

Oil Clearance Measurement

To check the oil clearance, measure the outside diameter of the
crankshaft journal and the crank pin and the inside diameter of
the bearing. The clearance can be obtained by calculating the
difference between the measured outside and inside diameters.

Standard value
Oil clearance
Crankshaft main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.02-0.05 mm (0.0008-0.0020 in.)
Connecting rod bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.02-0.05 mm (0.0008-0.0020 in.)
Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)
 CRANKSHAFT, FLYWHEEL [1.6L Engine] 20-55

Plastigauge Method
Plastigauge may be used to measure the clearance.
1. Remove oil and grease and any other dirt from bearings and
journals.
2. Cut plastigauge to the same length as the width of the
bearing and place it in parallel with the journal, off oil holes.
3. Install the crankshaft, bearings and caps and tighten them
to the specified torques. During this operation, do not turn
the crankshaft. Remove the caps. Measure the width of the
plastigauge at the widest part by using a scale printed on
the gauge package.

If the clearance exceeds the repair limit, the bearing should

be replaced or an undersize bearing should be used.
When installing a new crankshaft, be sure to use standard
size bearings.

Should the standard clearance not be obtained even after

bearing replacement, the journal and pin should be ground
to undersize and a bearing of the same size should be
installed.

Oil Seal
Check front and rear oil seals for damage or worn lips. Replace
any seat that is defective.

Bearing Caps
After installing the bearing caps, make sure that the crankshaft
turns smoothly and the end play is correct. If the end play
exceeds the limit, replace crankshaft bearings.

Standard value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.05-0.18 mm (0.0020-0.0071 in.)
Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)

Drive Plate
Replace deformed, damaged, or cracked drive plates.
20-56 CRANKSHAFT, FLYWHEEL [1.6L Engine]

Flywheel
1. Check the clutch disc contacting surface of the flywheel for
damage and wear. Replace the flywheel if excessively
damaged or worn.
2. Check the clutch disc contacting surface of the flywheel for
run-out.

Limit
Flywheel run-out . . . . . . . . 0.13 mm (0.0051 in.)

3. Check the ring gear for damage, cracks and wear, and
replace if necessary.

INSTALLATION
1. Install grooved main bearing (upper bearing) on cylinder
block side.
2. Install grooveless main bearing (lower bearing) on main
bearing cap side.
3. Both upper and lower bearings for center are grooveless.

4. Install crankshaft. Apply engine oil to journal and pin.

5. Caps should be installed with arrow mark directed toward
front of engine. Cap number must be correct.
6. Tighten cap bolts to specified torque in sequence of center
No.2, No.4, front and rear caps.

Tightening torque
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65-70 Nm (650-700 kg.cm, 47-51 Ib.ft)

7. Cap bolts should be tightened evenly in 4 to 5 stages before

they are tightened to specified torque.
8. Make certain that crankshaft turns freely and has proper end
play.

9. Using special tool (09231-21000), install oil seal in oil seal

case.
 CRANKSHAFT, FLYWHEEL [1.6L Engine] 20-57

10. Install the oil separator into the oil seal so that the oil hole
in the separator is directed downward (arrow in illustration).

11. Install the new oil seal case gasket and oil seal case
assembly.
12. Install the rear plate to the cylinder block.

13. Install the flywheel assembly and tighten the bolts to the
specified torque.

Tightening torque
Flywheel bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130-140 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)
20-58 CYLINDER BLOCK (1.6L Engine]

CYLINDER BLOCK

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

REMOVAL
Remove the cylinder head, timing belt train, front case, flywheel,
piston and crankshaft.
For further details, refer to the respective chapters.
 CYLINDER BLOCK [1.6L Engine]

INSPECTION
Cylinder Block
1. Visually check the cylinder block for scores, rust and
corrosion. Also check for cracks or any other defects. Correct
or replace the block if defective.
2. Measure cylinder bore with a cylinder gauge at three levels
in directions of A and B.

Level 1 : No.1 piston ring position with piston at TDC

Level 2 : Center of cylinder
Level 3 : Bottom of cylinder

3. If cylinder bores show more than specified out-of-round or

taper, or if cylinder walls are badly scuffed or scored, cylinder
block should be rebored and honed, and new oversize piston
and rings are fitted.

Standard value
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82.3-82.33 mm (3.2402-3.2413 in.)
Out-of-roundness and taper of cylinder bore . . . . . . . . . . .
Max. 0.01 mm (0.0004 in.)

4. If cylinder top ridge is worn in stages, cut away with ridge

reamer.
5. Oversize pistons are available in four sizes.

Piston service size and mark mm (in.)

0.25 (0.010) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25
0.50 (0.020) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
0.75 (0.030) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75
1.00 (0.039) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00

6. To rebore the cylinder to oversize, keep the specified

clearance between the oversize piston and the bore, and
make sure that all pistons used are of the same oversize.
The standard measurement of the piston outside diameter is
taken at a level 2 mm (0.08 in.) above the bottom of the
piston skirt and across the thrust faces.

Piston-to-cylinder wall clearance . . . . . . . . . . . . . . . . . . . . . . . .

0.02-0.04 mm (0.0008-0.0016 in.)

7. Check for damage and cracks.

20-60 CYLINDER BLOCK [1.6L Engine]

8. Check top surface for flatness. If excessive flatness is

evident, grind to minimum limit or replace.

Standard value
Flatness of gasket surface . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. 0.05 mm (0.0020 in.)
Overall height . . . . . . . . . . . . . . . . . . . . . 284 mm (11.18 in.)
Service limit
Flatness of gasket surface . . . . . . . . . 0.1 mm (0.0039 in.)
Overall height . . . . . . . . . . . . . . . . . -0.2 mm (-0.0079 in.)

NOTE
The cylinder block gasket surface should be ground to
within -0.2 mm (-0.0079 in.) even with the grind of
cylinder head gasket surface.

Boring Cylinder

1. Oversize pistons to be used should be determined on the

basic of the largest bore cylinder.

Size Identification mark

0.25 mm (0.010 in.) O.S 0.25
0.50 mm (0.020 in.) O.S 0.50
0.75 mm (0.030 in.) O.S 0.75
1.00 mm (0.039 in.) O.S 1.00

NOTE
Size mark is stamped on top of piston.

2. Measure outside diameter of piston to be used.

3. Based on measured piston O.D., calculate boring finish
dimension.

Boring finish dimension = Piston O.D + 0.02-0.04 mm

(0.0008-0.0016 in.) (clearance between O.D and cylin-
der)-0.02 mm (0.008 in.) (honing margin.)

4. Hone each of the cylinders to the calculated size.

NOTE
To prevent distortion that may result from. temperature
rise during honing, bore cylinders, working from No.2 to
No.4 to No.1 to No.3.

5. Hone the cylinders, finishing them to the proper dimension

(piston outside diameter + gap with cylinder).
6. Check clearance between piston and cylinder.

NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.
 CYLINDER BLOCK [1.6L Engine] 20-61

INSTALLATION
1. Install the following parts by referring to the respective
paragraphs.
1) Crankshaft
2) Flywheel
3) Piston
4) Cylinder head
5) Timing belt train
6) Front case