Santa Fe 2004 2.4L

2004 Hyundai Santa Fe
2002-04 ENGINES 2.4L 4-Cylinder - Santa Fe
2002-04 ENGINES
2.4L 4-Cylinder - Santa Fe
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description Specification Limit
General
Type In-line, Double Overhead
Camshaft
Number of cylinders 4
Bore 86.5 mm (3.41 in.)
Stroke 100 mm (3.94 in.)
Total displacement 2351 cc (143.5 cu.in.)
Compression ratio 10 : 1
Firing order 1-3-4-2
Valve timing
Intake valve
Open (BTDC) 12°
Close (ABDC) 56°
Exhaust valve
Open (BBDC) 54°
Close (ATDC) 14°
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.2 mm (0.008 in.)
Flatness of manifold mounting 0.15 mm (0.0059 in.) 0.3 mm (0.012 in.)
surface
Dimensions for reworking
oversize valve seat hole
Intake
0.3 mm (0.012 in.) O.S. 35.3 ~ 35.325 mm (1.39 ~ 1.3907
in.)
0.6 mm (0.024 in.) O.S. 35.6 ~ 35.625 mm (1.40 ~ 1.4026
in.)
Exhaust
0.3 mm (0.012 in.) O.S. 33.3 ~ 33.325 mm (1.31 ~ 1.3120
in)
0.6 mm (0.024 in.) O.S. 33.6 ~ 33.625 mm (1.32 ~ 1.3238
in.)
Dimensions for reworking
oversize valve guide hole (both
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intake and exhaust)

0.05 mm (0.002 in.) O.S. 12.05 ~ 12.068 mm (0.4751 in.)
0.25 mm (0.010 in.) O.S. 12.25 ~ 12.268 mm (0.4830 in.)
0.50 mm (0.020 in.) O.S. 12.50 ~ 12.518 mm (0.4928 in.)
Camshaft
Cam height
Intake 35.493 mm (1.3974 in.) 34.993 mm (1.3776 in.)
Exhaust 35.317 mm (1.3904 in.) 34.817 mm (1.3707 in.)
Journal O.D. 26 mm (1.02 in.)
Bearing oil clearancce 0.040 ~ 0.076 mm (0.0020 ~
0.0030 in.)
End play 0.1 ~ 0.15 mm (0.004 ~ 0.006 in.)
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° ~ 45.5°
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 ~ 0.1 mm (0.0039 in.)
0.0019 in.)
Exhaust 0.050 ~ 0.085 mm (0.0020 ~ 0.15 mm (0.0059 in.)
0.0033 in.)
Vavle guide
Length
Intake 45.5 mm (1.791 in.)
Exhust 50.5 mm (1.988 in.)
Service over size 0.05, 0.25, 0.50 mm (0.002, 0.010,
0.020 in.)
Valve seat
Width of seat contact 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Seat angle 44° ~ 44.5°
Service size 0.3 mm (0.012 in.) 0.6 mm (0.024
in.) oversize
Vavle sprin
Free length 45.82 mm (1.8039 in.)
Load 25.3kg / 40 mm (55.78 lb / 1.57
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in.) at installed height

Out-of-square Less than 1.5°
Cylinder block
Cylinder bore 86.5+0.03 mm (3.406+0.0012 in.)
Out-of-round and taper of cylinder Less than 0.01 mm (0.0004 in.)
bore
Flatness of gasket surface Less than 0.05 mm (0.0020 in.) 0.1 mm (0.0039 in.)
Piston
O.D. 86.47 ~ 86.5 mm (3.404 ~ 3.406
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 (0.048 ~ 0.049
in.)
No. 2 1.51 ~ 1.53 mm (0.059 ~ 0.060
in.)
Oil 2.81 ~ 2.83 mm (0.111 ~ 0.1114
in.)
Service size 0.25 mm (0.010 in.) oversize
Piston ring
Side clearnace
No. 1 0.03 ~ 0.07 mm (0.0012 ~ 0.0028
in.)
No. 2 0.02 ~ 0.06 mm (0.0008 ~ 0.0024
in.)
Oil ring 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 0.1 mm (0.0039 in.)
in.)
End gap No. 1 0.25 ~ 0.35 mm (0.0098 ~ 0.0138 0.8 mm (0.031 in.)
in.)
No. 2 0.40 ~ 0.55 mm (0.0157 ~ 0.0216 0.8 mm (0.031 in.)
in.)
Oil ring side rail 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 1.0 mm (0.039 in.)
in.)
Connecting rod
Bend 0.05 mm (0.0020 in.)
Twist 0.1 mm (0.004 in.)
Connecting rod big end to 0.10 ~ 0.25 mm (0.0040 ~ 0.0098 0.4 mm (0.0157 in.)
crankshaft in.)
Side clearance
Piston pis installation force 1250 ± 500 kg (2756 ± 1100 lb.ft)
Connecting rod pin O.D 48 ~ 48.015 mm (1.890 ~ 1.8903
in.)
Connecting rod bearing oil 0.015 ~ 0.048 mm (0.0006 ~ 0.1 mm (0.0039 in.)
clearance 0.0019 in.)
Crankshaft main bearing oil

clearance
No. 1, 2, 4, 5 journal 0.018 ~ 0.036 mm (0.0007 ~ 0.1 mm (0.0039 in.)
0.0014 in.)
No. 3 journal 0.024 ~ 0.042 mm (0.0009 ~
0.0017 in.)
Crankshaft
Journal O.D 56.982 ~ 57.000 mm (2.2434 ~
2.2441 in.)
Out - of - round of journal and pin Less than 0.015 mm (0.0006 in.)
Taper of journal and pin Less than 0.005 mm (0.0002 in.)
End play 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 0.25 mm (0.0098 in.)
in.)
Flywheel
Runout 0.13 mm (0.0051 in.)
Oil pressure at idle [Oil 80 kPa (11.6 psi)
temperature is 75-90°C (167-194°
F)]
Oil pump
Tip clearance
Drive gear 0.16 ~ 0.21 mm (0.0063 ~ 0.0083 0.25 mm (0.0098 in.)
in.)
Driven gear 0.18 ~ 0.21 mm (0.0071 ~ 0.0083 0.25 mm (0.0098 in.)
in.)
Side clearance
Drive gear 0.08 ~ 0.14 mm (0.0031 ~ 0.0055 0.25 mm (0.0098 in.)
in.)
Driven gear 0.06 ~ 0.12 mm (0.0024 - 0.0047 0.25 mm (0.0098 in.)
in.)
Relief spring
Free length 46.6 mm (1.835 in.)
Load [61 N (13.5 lb)] 40.1 mm (1.579 in.)
Right silent shaft
Front journal diameter 18.467 ~ 18.480 mm (0.7270 ~
0.7276 in.)
Rear journal diameter 40.951 ~ 40.967 mm (1.6516 -
1.6129 in.)
Oil clearance
Front 0.020 ~ 0.061 mm (0.0008 ~
0.0024 in.)
Rear 0.050 ~ 0.091 mm (0.0020 -
0.0036 in.)
Left silent shaft
Front journal diameter 18.467 ~ 18.480 mm (0.7270 ~
0.7276 in.)
Rear journal diameter 40.951 ~ 40.967 mm (1.6122 ~

1.6130 in.)
Oil clearance
Front 0.020 ~ 0.054 mm (0.0008 ~
0.0021 in.)
Rear 0.042 ~ 0.083 mm (0.0017 ~
0.0033 in,)
Cooling method Forced circulation with electric
fan
Cooling system quantity 7.0 lit (7.4 U.S.qts., 6.1 lmp.qts.)
[For DOHC]
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 82 °C (180°F)
Opening temperature range 80.5 ~ 83.5°C (176 ~ 183°F)
Wide open temperature 95 °C (203°F)
Radiator cap
Main valve opening pressure 107.9 ± 14.7 kPa 1.1 ± 0.15
kg/cm2 15.64 ± 2.13 psi)
Main valve closing pressure 83.4 kPa (0.85 kg/cm2 , 12.1 psi)
Vacuum valve opening pressure -6.86 kPa (-0.07 kg/cm2 , -1.00
psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
Coolant temperature sensor
Type Thermister type
Resistance
20°C (68°F) 2.37 ± 0.24 kohms
80°C (176°F) 0.29 ± 0.032 kohms
Service Standards
Fig. 1: Standard Value Table
Courtesy of HYUNDAI MOTOR CO.
Lubricant
Fig. 2: Engine Coolant Specification

Sealant
Fig. 3: Sealant Specification Table

NOTE: O.D.= Outer Diameter

I.D.= Inner Diameter
O.S.= Oversize Diameter
U.S. = Undersize Diameter
Torque Specifications
WARNING: For updated reuse guidelines and tightening procedures of cylinder head,
connecting rod and main bearing bolts, refer to TSB 02-20-002 CYLINDER
HEAD/CONNECTING ROD/MAIN BEARING BOLT REUSE GUIDELINES &
TORQUE SPECS .
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Alternator
Support Bolt 15-18 (20-25)
Brace Bolts
M8x90 mm (1)
M8x40 mm 15-18 (20-25)

Auto Tensioner Bolts 15-20 (20-27)
A/C Compressor-To-Bracket Bolts 17-20 (23-27)
Balance Shaft Bolts 25-30 (34-40)
Block Plug Caps 15-20 (20-27)
Camshaft Bearing Cap Bolts 14-15 (19-20)

Camshaft Sprocket Bolts 59-74 (80-100)
CMPS Cylinder Bolt 11-16 (11-22)
Coolant Pump Bolts 15-20 (20-27)
Coolant Temperature Sensor 15-30 (20-40)
Connecting Rod Cap Bolts
Step 1 15 (20)
Step 2 Tighten An Additional 90 Degrees
Crankshaft Pulley Bolt 118-125 (160-170)
Cylinder Head Bolts (2)
Using New Bolts (2)
Step 1 47 (64)
Step 2 (3)
Fully Loosen Bolts
Step 3 15 (20)
Using Original Bolts (2)
Step 1 15 (20)
Damper Pulley-To-Crankshaft Sprocket 15-22 (20-30)
Driven Gear Bolts 25-30 (34-40)
Drive Plate Bolts 96-103 (130-140)
Engine Mounting Components
Engine Hanger Bolts
M8 18-22 (25-30)
M10 25-41 (35-55)
Engine Mounting Bracket Bolts & Nuts 44-59 (60-80)
Engine Mount Insulator Bolts 66-81 (90-110)
Engine Support Bracket Fasteners 41-48 (55-65)
Front Roll Stopper Bracket-To- 30-41 (40-55)
Crossmember Bolts
Front Roll Stopper Insulator Fasteners 36-48 (50-65)
Rear Roll Stopper Bracket-To- 36-48 (50-65)
Crossmember Bolts
Rear Roll Stopper Insulator Fasteners 36-48 (50-65)
Exhaust Components
Center Exhaust Pipe-To-Catalytic Converter 22-30 (30-40)
Bolts
Center Exhaust Pipe-To-Main Muffler 22-30 (30-40)
Exhaust Manifold Cover Bolts 9-11 (12-15)
Exhaust Manifold
M8 Nuts 18-22 (25-30)
M10 Nuts 25-40 (34-54)
Front Exhaust Pipe Clamp Bolt 15-22 (20-30)
Front Exhaust Pipe-To-Exhaust Manifold 30-37 (40-50)
Bolts
Front Exhaust Pipe Bracket Bolts 15-22 (20-30)
Front Exhaust Manifold Bolt-To-Cylinder 15-22 (20-30)
Head
Main Muffler Hanger Support Bracket Bolt 7-14 (10-20)
Flywheel-To-Crankshaft Bolts 96-103 (130-140)
Front Case Bolts 15-20 (19-27)
Idler Pulley Bolts 22-31 (30-42)
Intake Manifold
Bracket Bolts (Stay) 13-18 (18-25)
Mounting Bolts/Nuts
Bolts 11-15 (15-20)
Nuts 22-31 (30-42)
Main Bearing Cap Bolts
Step 1 18 (25)
Oil Drain Plug 25-33 (34-45)
Oil Filter Bracket Bolts 15-20 (20-27)
Oil Pump
Cover Bolts 11-13 (15-18)
Sprocket Nuts 37-44 (50-60)
Oil Screen Bolts 11-16 (15-22)
Oxygen Sensor 29-37 (40-50)
Power Steering Pump Bracket Bolts 25-33 (35-45)
Relief Plug 29-37 (40-50)
Starter Bolts 20-25 (27-34)
Stud Bolts 22-30 (30-40)
Tension Rod Bracket Bolt-To-Tension Rod 25-40 (35-55)
Tensioner Arm Assembly Bolts 12-19 (17-26)
Tensioner Pulley Bolts 31-41 (42-54)
Tensioner Pulley Bracket Bolts 17-20 (23-27)
Throttle Body Stay Bolts 11-16 (15-22)
Throttle Body-To-Intake Manifold Bolts 11-16 (15-22)
Timing Belt Idler Bolts 22-30 (30-40)
Timing Belt Tensioner Bolts 31-40 (42-54)
Torque Converter-To-Drive Plate Bolts 33-39 (45-53)
Transaxle Mount
Bracket Bolts 44-59 (60-80)
Insulator Bolts 66-81 (90-110)
INCH Lbs. (N.m)
Air Cleaner Body Bolts 71-89 (8-10)
Air Cleaner Bracket Bolts 88-115 (10-13)
Center Cover Bolts 35-44 (4-5)
Coolant Inlet Fitting 89-133 (10-15)
Coolant Pump Pulley Bolts 71-89 (8-10)
Delivery Pipe-To-Cylinder Block Bolts 89-115 (10-13)
Exhaust Hanger Bolts
Hanger Bolt-To-Body 88-133 (10-15)
Hanger Bolt-To-Main Muffler 88-133 (10-15)
Heat Protector-To-Exhaust Manifold Bolts 106-133 (12-15)
Ignition Coil Bolts 71-106 (8-12)
Oil Level Gauge 106-133 (12-15)
Oil Pan Bolts 89-106 (10-12)
Oil Pressure Switch 71-106 (8-12)
Oil Seal Case Bolts 89-106 (10-12)
Power Transistor Bolts 89-106 (10-12)
Radiator Fan Motor Bolts 71-89 (8-10)
Rear Oil Seal Case Bolts 89-106 (10-12)
Resonator Mounting Bolts 71-89 (8-10)
Rocker Cover Bolts 71-89 (8-10)
Timing Belt Cover
Lower & Upper Cover Bolts 71-88 (8-10)
Rear Cover Bolts
Upper 88-106 (10-12)
Right 88-106 (10-12)
Valve Cover Bolts 71-89 (8-10)
(1) Tighten to 71-106 INCH lbs. (8-12 N.m).
(2) Tighten in sequence with engine cold. See Fig. 4.

(3) Fully loosen bolts in correct order. See Fig. 5.
(4) Tighten to 71-89 INCH lbs. (8-10 N.m).
(5) Tighten to 89-106 INCH lbs. (10-12 N.m)
Fig. 4: Cylinder Head Bolt Removal Sequence

Courtesy of NISSAN MOTOR CO., U.S.A.
Fig. 5: Cylinder Head Bolt Tightening Sequence

Checking Engine Oil
1. Position a vehicle on a level surface.

2. Turn off the engine.
NOTE: If a vehicle that has not been used for a prolonged period, run the engine
for several minutes.
Turn off the engine and wait for 5 minutes at least, and then check the oil
level.
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is
found to have fallen to the lower limit (the "L" mark), refill to the "F" mark.
NOTE: When refilling, use the proper grade of engine oil.
4. Check that the oil is not dirty or mixed with coolant or gasoline and it has the proper viscosity.
Fig. 6: Identifying Good Oil Level

Selection Of Engine Oil
Recommended API classification: SH OR ABOVE
RECOMMENDED SAE VISCOSITY GRADES :
Fig. 7: Recommended SAE Viscosity Grades

NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which:
1. Satisfy the requirements of the API classification.

2. Have the proper SAE grade number for expected ambient temperature
range.
Lubricants which do not have both SAE grade number and an API service
classification on the container should not be used.
Changing Engine Oil
1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine.

3. Remove the oil filler cap and the drain plug. Drain the engine oil.
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug : 35 ~ 45 Nm (350 ~ 450 kg.cm, 25 ~ 33 lb.ft)
NOTE: Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill new engine oil through the oil filler cap opening.
Capacity
Drain and refill : 4.3 lit (4.53 U.S.qts., 3.78 lmp.qts.)
NOTE: Do not overfill. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.

7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
Replacing The Oil Filter
All Hyundai Motor Company engines are equipped with a high quality, disposable oil filter. This filter is
recommended as a replacement filter for all vehicles. The quality of after market replacement filters very
considerably.
High quality replacement filters should be used to assure the most efficient service. Make sure that the rubber
gasket from the old oil filter is completely removed from the contact surface on the engine block before
installing a new filter.
Fig. 8: Identifying Oil Filter Part Number

Procedure For Replacing The Oil Filter
1. Use a filter wrench to remove the oil filter.

2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
Fig. 9: Applying Engine Oil To Oil Filter Rubber Gasket

3. Tighten the oil filter to the specified torque.
Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)
4. Start and run the engine and check for engine oil leak.
5. After turning off the engine, check the oil level and add oil as necessary.
Checking Coolant Leak
1. Loosen the radiator cap.

2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 kpa (21 psi, 1.53 kg/cm2 ) pressure.
Hold it for two minutes in that condition while checking for leakage from the radiator, hoses or
connections.
NOTE: 1. Radiator coolant may be extremely hot. Do not open the system
because hot, or scalding water could gush out causing personal
injury. Allow the vehicle to cool before servicing this system.
2. When the tester is removed, be careful not to spill any coolant from
it.
3. Be sure to clean away completely any from the area.

4. Be careful when installing and removing the tester and when testing,
not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace with the appropriate part.
Fig. 10: Pressure Testing Cooling System

Radiator Cap Pressure Test
1. Use an adapter to attach the cap to the tester.

2. Increase the pressure until the gauge stops moving.
Main valve opening pressure : 107.9kPa+/-14.7kPa (1.1 +/- 0.15 kg/cm2 , 15.64 +/- 2.13)
Main valve closing pressure : 83.4 kPa (0.85 kg/cm2 , 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
NOTE: Be sure that the cap is clean before testing, since rust or other foreign
material on the cap seal will cause an incorrect reading.
Fig. 11: Pressure Testing Radiator Cap

Specific Gravity Test
1. Measure the specific gravity of the coolant with a hydrometer.

2. Measure the coolant temperature and calculate the concentration from the relation between the specific
gravity and temperature, using the following table for reference.
Fig. 12: Checking Coolant With Hydrometer

Fig. 13: Coolant Concentration Table

Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant
temperature of 20°C (68°F)
CAUTION: If the concentration of the coolant is below 30%, its anti-corrosion

properties will be adversely affected.
If the concentration is above 60%, both the anti-freeze and engine
cooling property will decrease, affecting the engine adversely. For
these reasons, be sure to maintain the concentration level within the
specified range.
Do not mix types of anti-freeze.
Fig. 14: Recommended Coolant

Checking Compression Pressure
1. Before checking engine compression, check the engine oil level. Also check that the starter motor and
battery are all in normal operating condition.
2. Start the engine and wait until the engine coolant temperature reaches 80 ~ 95°C (176 ~ 205°F).
3. Turn off the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Insert the compression gauge into the spark plug hole.
7. Depress the accelerator pedal to open the throttle fully.
8. Crank the engine and read the gauge.
Standard value : 1200 kpa (12.2 kg / cm2 , 170 psi)
Fig. 15: Reading Compression Gauge

9. Repeat steps 6 to 8 for all cylinders, ensuring that the pressure difference for each of the cylinders is
within the specified limit.
Limit
Max. 100 kpa (1.0 kg / cm2 , 14 psi) between cylinder
10. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil
through the spark plug hole, and repeat steps 6 to 9.
1. If the addition of oil causes the compression to rise, it is likely that there may be 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, 14 ~ 22 lb.ft)
Adjusting Drive Belt Tension
1. Check that the belts are not damaged and are properly placed for the pulley grooves.
2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in
the illustration and measure the amount of deflection with a tension gauge.
Fig. 16: Locating Belt On Pulley

CAUTION: 1. When installing the V-ribbed belt, check that the V-ribs are properly
aligned.
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 the amount that the belt is deflected.
Fig. 17: Standard Value Table

NOTE: 1. The belt tension must be measured half-way between the specified
pulleys.
2. When a new belt is installed, adjust the tension to the central value of the
standard range indicated under "New" in the above table. 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 installed newly after
5 minutes or more of operation, refer to the standard value indicated under
"Used" in Fig. 17.
4. Refer to the standard value indicated under "Inspection" for periodic
inspections.
Fig. 18: Identifying Belts & Pulleys

Type A Tension Gauge
Do not let the dial section of the tension gauge contact other objects during measurement.
Fig. 19: Identifying Type A Tension Gauge

Type B Tension Gauge
1. When measuring, turn the reset button in the direction of the arrow and 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
value after removing the gauge.
Fig. 20: Identifying Type B Tension Gauge

ADJUSTING THE ALTERNATOR BELT
CAUTION: If the belt is too loose, it will cause noise or sudden wear.
If the belt is too tight, the engine coolant pump bearing or the alternator
can be 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 the specification.
3. Tighten the adjuster lock bolt "B".
4. Tighten the alternator nut "A".
5. Check the tension or the deflection of belt, and read just if necessary.
Tightening torque
Alternator nut A :
35 ~ 55 Nm (350 ~ 550 kg.cm, 25 ~ 40 lb.ft)
Adjuster lock bolt B :
20 ~ 25 Nm (200 ~ 250 kg.cm, 14 ~ 18 lb.ft)
Fig. 21: Identifying Alternator Belt Tensioner Bolt

Adjusting Power Steering & Air Conditioner Belts
1. Loosen the tension pulley adjustment bolt A.

2. Adjust the belt deflection with adjustment bolt B.
3. Tighten bolt A.
4. Recheck the belt deflection and readjust, if necessary.
NOTE: Before rechecking, crank the engine one more revolution.
Fig. 22: Identifying Power Steering & Air Conditioner Belt Tensioner
SPECIAL TOOLS
Fig. 23: Identifying Special Tools (1 Of 3)



TROUBLESHOOTING
Fig. 26: Trouble Shooting Table (1 Of 2)

Fig. 27: Trouble Shooting Table (2 Of 2)

ENGINE BLOCK
ENGINE BLOCK
Components
Fig. 28: Engine Block Components

Disassembly
Remove the following :
Cylinder head. See CYLINDER HEAD.

Timing belt. See TIMING BELT.
Front case. See FRONT CASE.
Flywheel.
Pistons. See PISTON.
Crankshaft. See CRANKSHAFT.
Inspection
1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects.
Replace the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated and in the directions of A
and B.
Level 1: No. 1 piston ring position at TDC
Level 2 : Center of cylinder
Level 3 : Bottom of cylinder
Fig. 29: Measuring The Cylinder Bore

3. If the cylinder bores show more than specified out-of-round or taper, or if the cylinder walls are badly
scuffed or scored, the cylinder block should be rebored and honed. New oversize piston and rings should
be installed.
Standard value
Cylinder bore : 86.5 + 0.03 mm (3.41 + 0.0012 in.)
Out - of - round and taper of cylinder bore :
Max. 0.01 mm (0.0004 in.)
4. If a ridge exists at the top of the cylinder, cut it away with a ridge reamer.
Piston service size and mark mm (in.)
Identification Mark : 25
Size : 0.25 (0.010) O.S.
5. To rebore the cylinder bore to oversize, maintain 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 16 mm (0.63 in.) from the center of pin hole and across the
thrust faces.
Piston - to - cylinder clearance
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)
Fig. 30: Measuring Point On Piston Skirt

6. Check for damage and cracks.

7. Check the top surface of the cylinder block for flatness. If the top surface exceeds limits, surface to
minimum limit or replace.
Standard value
Flatness of cylinder block : Max. 0.05mm (0.0020 in.)
Service limit
Flatness of cylinder block: 0.1 mm (0.0039 in.)
NOTE: When the cylinder head is assembled, grinding less than 0.2 mm (0.008 in.) is
permissible.
Fig. 31: Checking Top Surface Of Cylinder Block

Boring Cylinder
1. Oversize pistons should be selected according to the largest cylinder bore.
Identification Mark : 25
Size : 0.25 mm (0.010 in.) O.S.
NOTE: The size of a piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. On the basis of the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.02 to 0.04 mm (0.0008 to 0.0016 in.) (clearance between piston and
cylinder) - 0.02 mm (0.0008 in.) (honing margin.)
4. Bore each of cylinders to the calculated size.
NOTE: To prevent distortion that may result from temperature rise during honing,
bore the cylinders, holes in the firing order sequence.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Verify the clearance between the piston and cylinder.
NOTE: When boring cylinders, finish all four cylinders to the same oversize. Do
not bore only one cylinder to the oversize.
Reassembly
Install the following parts by referring to their respective paragraphs.
1. Crankshaft
2. Flywheel
3. Piston
4. Cylinder head
5. Timing belt train
6. Front case
ENGINE MOUNTS
Components
Fig. 32: Engine Mount Components

Removal
Attach a chain or cable to the engine hooks and lift enough so that there is no pressure on the motor mounts.
Fig. 33: Lifting Engine

Engine Mounting
1. Remove the engine mounting insulator bolts.

2. Remove the engine mounting bracket from the engine.
Fig. 34: Identifying Engine Mounting Bracket

Transaxle Mounting
1. Remove the transaxle mounting insulator bolts.

2. Remove the transaxle mounting bracket from the transaxle.
Fig. 35: Identifying Transaxle Bracket

Front Roll Stopper
Remove the front roll stopper bracket from the sub-frame.
Fig. 36: Identifying Front Roller Stopper Bracket

Rear Roll Stopper
1. Remove the bolt from the rear roll stopper.

2. Remove the rear roll stopper from the subframe.
Fig. 37: Identifying Rear Roller Stopper Bracket

Inspection Items
Fig. 38: View Of Inspection Items

ENGINE AND TRANSAXLE ASSEMBLY
Removal
1. Remove the battery.

2. Detach the air cleaner.
Fig. 39: View Of Air Cleaner

3. Disconnect the engine harness connectors.

1. Engine wiring connectors (alternator, starter, etc.)
2. TPS connector
3. Power steering switch connector, oil pressure gauge connector.
4. Back up lamp switch connector.
5. A/T solenoid, inhibitor switch connector.
6. Coolant temperature sensor.
7. Ignition coil, power TR connector.
8. Idle speed control valve (ISC) connector.
9. MAP and ATS connectors.
10. Oxygen sensor connector.
Fig. 40: View Transmission Range Sensor

Fig. 41: View Engine Coolant Temperature Sensor

4. Drain the engine coolant.

5. For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses.
NOTE: When disconnecting hoses, make identification marks to avoid making

any mistake when installing them again.
CAUTION: Be careful not to spill any of oil or fluid out of the hoses. Plug the
openings to prevent the entry of foreign material.
6. Disconnect the radiator upper and lower hoses on the engine side then remove the radiator assembly.
Fig. 42: Removing Upper Radiator Hose

7. Disconnect the engine ground.

8. Disconnect the brake booster vacuum hose.
Fig. 43: Identifying Brake Booster Vacuum Hose

9. Disconnect the heater hoses (inlet and outlet) on the engine side.
10. Disconnect the accelerator cable at the engine side.
Fig. 44: Identifying Accelerator Cable

11. Using a special tool, remove the main fuel line at the delivery pipe (supply/return).
12. Disconnect the speedometer cable from the transaxle.
13. Disconnect the clutch cable or control cable from the transaxle.
Fig. 45: Identifying Clutch Cable Or Control Cable

14. Disconnect the power steering suction hose and return hose from the pump.
Fig. 46: Identifying Power Steering Hoses

15. Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint
bolt.
NOTE: Make sure to make identification marks between the universal joint and the
gear box for reassembly.
Fig. 47: Identifying Steering Column Through Floor Board Location

16. Raise the vehicle and then remove the front tire.
17. Remove the calliper assembly from the knuckle. Tie it using wire, hang it from the suspension.
Fig. 48: Supporting Brake Caliper

18. Loosen the strut lower bolt and then remove it.
Fig. 49: Removing Knuckle From Strut

19. Drain the transaxle oil.
Fig. 50: Identifying Drain Plug Bolt

20. Remove the front muffler bolts.
Fig. 51: Identifying Front Muffler Bolts

21. Remove the transaxle control rod and extension rod (M/T only).
Fig. 52: Identifying Transaxle Control Rod & Extension Rod

22. Put the special fixture on the T/M jack and then adjust it to the sub-frame.
NOTE: Check that all the cables, harness connector and hose are disconnected
from the engine and transaxle assembly.
Fig. 53: Identifying T/M Jack

23. Remove the engine mounting bracket and the transaxle mounting bracket.
Fig. 54: Identifying Engine Mount Bracket

Fig. 55: Identifying Transaxle Mounting Bracket

24. Remove the sub-frame installation bolts.
Fig. 56: Identifying Sub-Frame Bolts

25. After removing the drive shaft, lower the engine and transaxle assembly on the jack then, remove the
front roll stopper and the rear roll stopper.
26. Remove the engine and transaxle assembly as a unit.
Fig. 57: Removing Engine

Installation
1. When installing the engine and transaxle, check the connections of harnesses, pipes, hoses, etc. make sure
that none of them are caught, damaged, etc.
2. Install the front roll stopper to the bracket roughly.
Tightening torque
Service standard : 50 ~ 65 Nm (500 ~ 650 kg.cm, 36 ~ 47 lb.ft)
Fig. 58: Installing Front Roll Stopper

3. Install the rear roll stopper to the bracket.
Tightening torque
Service standard : 50 ~ 65 Nm (500 ~ 650 kg.cm, 36 ~ 47 lb.ft)
Fig. 59: Installing Rear Roll Stopper

4. Install the engine/transaxle to the sub-frame assembly. Use the T/M jack to raise the assembly slowly
adjust it to the vehicle body.
Fig. 60: View Of Engine On T/M Jack

5. Install the transaxle mounting bracket.
Tightening torque
Service standard:
90 ~ 110 Nm (900 ~ 1100 kg.cm, 65 ~ 80 lb.ft)
Fig. 61: Identifying Transaxle Mounting Bracket

6. Install the engine bracket (right side).
Tightening torque
Service standard :
60 ~ 80 Nm (600 ~ 800 kg.cm, 43 ~ 58 lb.ft)
Fig. 62: Identifying Engine Bracket

7. To install all of parts, follow the removal procedures in the reverse order.
8. Refill the coolant and then check for leaks.
9. Refill the transaxle oil and check for leaks, then test its operation.
10. Check the operation of the transaxle control cable and accelerator cable.
11. Check the proper operation of each gauge.
FRONT CASE
Components
Fig. 63: Front Case Components

Disassembly
1. Remove the timing belt. Refer to TIMING BELT.

2. Remove all the oil pan bolts.
3. Tap the oil pan with a rubber hammer and remove the pan. (upper and lower parts)
4. Remove the oil screen and gasket.
5. Remove the front case assembly.
6. Remove the oil pressure switch.
Fig. 64: Removing Oil Pressure Switch

7. Remove the oil filter bracket and gasket.

8. Using the special tool (09213-33000) remove the plug cap from the oil pump portion of the front case.
Fig. 65: Removing Plug Cap

9. Remove the plug on the left side of the cylinder block and insert a screw driver with an 8 mm (0.32 in.)
diameter into the plug hole. The screwdriver must be inserted more than 60 mm (2.4 in.)
Fig. 66: Identifying Plug On Left Side Of Motor

10. Remove the oil pump driven gear and the left counter balance shaft retaining bolt.
Fig. 67: Removing Counter Balance Shaft Retaining Bolt

11. Remove the front case mounting bolts and remove the front case assembly and gasket and then remove
the two counter balance shafts from the cylinder block.
Fig. 68: Removing Front Case

12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.
Fig. 69: Identifying Oil Pump Gears

14. Remove the screw driver.
(Used in Step 9)
Inspection
1. Check all oil holes for clogging. Clean the holes if necessary.
2. Check the counter balance shaft front bearing for wear, damage and seizure. If there is anything wrong
with the bearing, replace the front case.
3. Check the front case for cracks and other damage.
4. Replace a cracked or damaged front case.
Counter Balance Shaft
1. Check the journals for wear or seizure.

2. If excessive wear or seizure is evident, check the bearing carefully.
3. If necessary, replace the counter balance shaft bearing or the shaft itself.
Fig. 70: Identifying Counter Balance Shaft

Oil Seal
1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.
Oil Pressure Switch
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
Fig. 71: Checking Oil Pressure Switch Continuity

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is
operating properly. Check for an air leak. If air leaks, the diaphragm is broken. Replace the switch.
Fig. 72: Checking Oil Pressure Switch Continuity With Fine Wire
Oil Pump
1. Assemble the oil pump gear to the front case and rotate it to verify smooth rotation with no looseness.
2. Make sure that there is no ridge wear on the contact surface between the front case and the gear surface of
the oil pump cover.
3. Install the drive and driven gears to 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 : 0.18 ~ 0.21 mm (0.0071 ~ 0.0083 in.)
[Limit]
Drive gear : 0.25 mm (0.0098 in)
Drive gear : 0.25 mm (0.0098 in.)
Fig. 73: Measuring Tip Clearance Of Drive & Driven Gears

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 (0.0098 in)
Driven gear : 0.25 mm (0.0098 in.)
Fig. 74: Checking Side Clearance

Counter Balance Shaft Bearing
Replacement
1. Using a special tool, remove the front bearing of the right counter balance shaft from the cylinder block.
Fig. 75: Removing Right Front Bearing

2. Using a special tool, remove the rear bearing of the right counter balance shaft from the cylinder block.
Fig. 76: Removing Right Rear Bearing

3. Using a special tool, remove the rear bearing of the left counter balance shaft from the cylinder block. At
this time, install a special tool on the front surface of cylinder block to hold the bearing puller.
Fig. 77: Removing Left Rear Bearing

4. Using a special tool, install the rear bearing of the left counter balance shaft to the cylinder block.
NOTE: 1. Apply engine oil to the outside of rear bearing and bearing hole in
cylinder block.
2. The left rear bearing has no oil holes.
Fig. 78: Installing Left Rear Bearing

5. Using a special tool, install the rear bearing of the right counter balance shaft to the cylinder block.
NOTE: 1. Apply engine oil to the outside surface of the bearing.

2. Make sure that the bearing oil hole is aligned with the oil hole of
cylinder block.
Fig. 79: Installing Right Rear Bearing

6. Using a special tool, install the front bearing of the right counter balance shaft to the cylinder block.
Fig. 80: Installing Right Front Bearing

NOTE: Make sure that the bearing oil hole is aligned with the oil hole cylinder block.
Fig. 81: Identifying Oil Hole

Reassembly
1. Apply engine oil to the gear and align the two timing marks.
Fig. 82: Identifying Timing Marks

2. Using the special tool, the crankshaft front oil seal installer (09214-32000), install the crankshaft front oil
seal into the front case.
Fig. 83: Installing Front Crankshaft Oil Seal

3. Set the special tool (09214-32100) on the front end of the crankshaft and apply a thin coat of engine oil to
the outer circumference of the special tool to install the front case.
Fig. 84: Identifying Special Tool

4. Install a new front case gasket to the front case assembly and tighten the flange bolts temporarily.
Fig. 85: Installing Front Case

5. Install the front case assembly with a new gasket. Tighten bolts to the specified torque.
Front case assembly
Tightening torque :
20 ~ 27 Nm (200 ~ 270 kg.cm, 14 ~ 20 lb.ft)
Fig. 86: Identifying Front Case Bolts

6. Insert a screw driver into the plug hole in left side of cylinder block. After verifying that the shaft is in the
proper position, replace the bolt and tighten it.
Fig. 87: Verifying Shaft Position

7. Install a new O-ring to the groove of the front case.

8. Using a special tool, install the plug case and tighten it to the specified torque.
Fig. 88: Installing Plug Case

Plug cap
Tightening torque : 20 ~ 27 Nm (200 ~ 270 kg.cm, 14 ~ 20 lb.ft)
9. Apply sealant to the groove of the pan flange as shown.
NOTE: 1. Apply sealant approximately 4 mm (0.16 in.) in thickness.

2. After the application of the sealant, install the oil pan within 15
minutes.
Fig. 89: Oil Pan Bolt Tightening Sequence

10. Note the difference in bolt lengths at the locations shown.
Install the upper and lower oil pans and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt : 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft)
11. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant : Threebond 1104 or equivalent
NOTE: Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch :
8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb.ft)
Fig. 90: Installing Oil Pressure Switch

MAIN MOVING SYSTEM

CAMSHAFT
Components
Fig. 91: Camshaft Components

Disassembly
1. Disconnect the negative terminal from the 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 and camshaft position sensor.
7. Loosen the camshaft sprocket bolts then remove the camshaft sprockets.
8. Loosen the camshaft bearing cap bolts and remove the bearing caps, camshafts, rocker arms and lash
adjusters.
CAUTION: Loosen the cap bolts in increments to avoid bending the camshafts.
Fig. 92: Loosening Camshaft Sprocket Bolt

Inspection
Rocker Arms
1. Check rotation of the roller. If they do not rotate smoothly or are loose, replace them.
2. Check the roller surface. Replace if there is any dent, damage or evidence of seizure.
3. Check the valve contact surface for possible damage or evidence of seizure. Replace if necessary.
Fig. 93: Identifying Rocker Arms

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 : 35.493 mm (1.3974 in.)
Exhaust : 35.317 mm (1.3904)
[Limit]
Intake : 34.993 mm (1.3776 in.)
Exhaust : 34.817 mm (1.3707 in.)
Fig. 94: Identifying Camshaft Journals & Lobes

Reassembly
1. Install the camshafts on the cylinder head. Do not install the rocker arms yet.
NOTE: 1. Apply engine oil to journals and cams of the camshafts.

2. The exhaust camshaft has a slit on its rear end for the crankshaft
position sensor.
Fig. 95: Identifying Camshafts

2. Install the bearing caps. The markings on the caps are for intake/exhaust identification.
I : Intake camshaft. E : Exhaust camshaft
Fig. 96: Identifying Camshaft Bearing Caps

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.
Fig. 97: Checking Rotational Force Of Camshaft

4. Make sure that the dowel pins on the camshaft sprocket ends are located on the top.
Fig. 98: Identifying Dowel Pins

5. Tighten the bearing caps to the specified torque in two or three increments as shown.
NOTE: Tighten the rocker arms uniformly.
Tightening torque
Bearing cap bolts :
19 ~ 21 Nm (190 ~ 210 kg.cm, 14 ~ 15 lb.ft)
Fig. 99: Identifying Camshaft Bearing Cap Tightening Sequence

6. Using the special tools, camshaft oil seal Installer and guide (09221-21000, 09221-21100). 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 it by driving the installer with a hammer until
the oil seal is fully seated.
Fig. 100: Installing Camshaft Oil Seal

7. Install the camshaft sprocket bolts to the specified torque.
Tightening torque
Camshaft sprocket bolts :
80 ~ 100 Nm (800 ~ 1000 kg.cm, 58 ~ 72 lb.ft)
Fig. 101: Tightening Camshaft Sprocket

Fig. 102: View Of Camshafts

8. Install the rocker cover. Apply sealant as shown.
Tightening torque
Rocker cover bolts : 8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft)
Center cover bolts : 4 ~ 5 Nm (40 ~ 50 kg.cm, 3 ~ 4 lb.ft)
Sealant
A Portion : Threebond No. 10 or equivalent
B Portion : Threebond No. 1212D or equivalent
Fig. 103: Identifying Rocker Cover

Bolt
A : 13EA (Rocker cover bolts)
B : 4EA (Center cover bolts)
Fig. 104: Identifying Rocker Cover Bolts

9. Install the spark plugs, and ignition coils. Connect the secondary wires and then install the center cover.
Fig. 105: View Of Rocker Cover Installed

10. Install the dowel pin on the sprocket side of the intake cam shaft.
Fig. 106: Identifying Dowel Pin

11. Install the cam position sensor support assembly after installing the cam position sensor cylinder on the
exhaust camshaft.
Fig. 107: View Cam Position Sensor Support Assembly

PISTON
Components
Fig. 108: Piston Components

Disassembly
Connecting Rod Cap
NOTE: Keep the bearings in order with their corresponding connecting rods (according
to cylinder numbers) for proper reassembly.
1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing. Mark for
reassembly.
2. Push each piston-connecting rod assembly toward the top of the cylinder.
Fig. 109: Identifying Connecting Rod Bearing Notches

Disassembly & Reassembly Of Piston Pin
1. Use the special tools 09234 - 33001 and 09234 - 33002, disassemble and reassemble the piston and
connecting rod.
Fig. 110: Identifying Special Tools

2. The piston pin is a press fit in the rod little end, and the piston floats on the pin.
3. The tool consists of a support fixture with fork inserts, guides, adapters, an installer and a remover. The
piston is supported in the support fixture while the pin is being installed or removed. Guides help position
the pin as it is installed or removed, while the rod is supported by fork inserts.
4. To remove the pin from the piston, place the piston in the support fixture while the rod resting on the fork
inserts. Pass the remover tool through the top of the support fixture and use it to press out the pin.
Fig. 111: Removing Piston Pin

5. To install a new pin, the proper fork inserts must be in place to support the rod.
6. Position the rod inside the piston. Insert the proper pin guide through on side of the piston and through the
rod. Hand tap the pin guide so it is held by the piston. Insert the new pin into the piston from the other
side and set the assembly into the support fixture with the pin guide facing down.
NOTE: The pin guide should be centered on the connecting rod though the
piston. If assembled correctly, the pin guide will sit exactly under the
center of the hole in the tool's arch, and rest evenly on the fort inserts. If
the wrong size pin guide is used, the piston and pin will not line up with
the support fixture.
Fig. 112: Installing Piston Pin

7. Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to
force the piston pin through the rod little end. Continue pressing until the pin guide falls free and the
installer tool seats against the top of the arch.
CAUTION: Do not exceed 1250 +/- 500 kg (2756 +/- 1102 lb) of force when
stopping the installing arbor sleeve against the arch.
Fig. 113: Installing Piston Pin

Inspection
Piston & 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 that the piston pin fits 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).
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 only the piston ring only.
Standard value
Piston ring side clearance :
No. 1 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
No. 2 : 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.)
Oil ring : 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in.)
Fig. 114: Measuring Piston Ring Side Clearance

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 dimensions]
No.1 : 0.25 - 0.35 mm (0.0098 - 0.0138 in.)
No.2 : 0.40 - 0.55 mm (0.0157 - 0.0216 in.)
[Limit]
No.1, No.2 : 0.8 mm (0.031 in.)
Oil ring side rail : 1.0 mm (0.039 in.)
Fig. 115: Measuring Piston Ring End Gap

Connecting Rods
1. When the connecting rod cap is installed, make sure that cylinder numbers, marked 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 at either end of the thrust faces. If it has stratified wear in, or
if the surface of, the inside diameter of the small end is severely rough, replace the rod.

Reassembly
1. Install the spacer.
Fig. 117: Identifying Spacer Installation (1 Of 2)

Fig. 118: Identifying Spacer Installation (2 Of 2)

2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring
groove and spacer, hold it firmly, then press down with your finger the portion to be inserted into groove
as illustrated.
WARNING: Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure as described in Step No. 2.
Fig. 119: Installing Side Rail

4. Apply engine oil around the piston and piston grooves.

5. Using piston ring expander, install the No. 2 piston ring.
6. Install the No. 1 piston ring.
Fig. 120: Identifying Piston Rings

7. Place each piston ring end gap as far apart from its neighboring gaps as possible. Make sure that gaps are
not positioned in the thrust and pin directions.
8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
Fig. 121: Identifying Piston Installation

9. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod
are directed toward the front of the engine.
10. When the connecting rod cap is installed, make sure that the cylinder numbers put on the rod and cap at
disassembly match.
11. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on
the same side.
12. Tighten the connecting rod cap nuts.
Tightening torque
Connecting rod cap nuts :
20 Nm (200 kg.cm, 15 lb.ft) + 90°

13. Check the connecting rod side clearance.
Connecting rod side clearance
Standard : 0.10 ~ 0.25 mm (0.004 ~ 0.0098 in.)
Limit : 0.4 mm (0.0157 in.)
CRANKSHAFT
Components
Fig. 123: Crankshaft Components

Disassembly
1. Remove the following components :

Timing belt. See TIMING BELT.
Front case. See FRONT CASE.
Flywheel.
Cylinder head assembly. See CYLINDER HEAD.
Oil pan.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
NOTE: Mark the main bearing caps to be able to reassemble in the original
position and direction.
4. Remove the main bearing caps and the crankshaft. Keep the bearings in order according to the cap
number.
Inspection
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective part.
2. Inspect the crankshaft journal for taper and out-of-round.
Standard value
Crankshaft journal O.D :
56.982 ~ 57.000 mm (2.2434 ~ 2.2441 in.)
Crankshaft pin O.D :
44.980 - 45.000 mm (1.7709 - 1.7717 in.)
Fig. 124: Checking Crankshaft Journal

Main Bearings & Connecting Rod Bearings
Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace any defective
bearings.
Measuring Oil Clearance
Check the oil clearance by measuring the outside diameter of the crankshaft journal as well as the inside
diameter of the bearing. The clearance can be obtained by calculating the difference between the measured
diameters.
Standard value
Oil clearance
Crankshaft main bearing
No. 1,2,4,5 : 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.)
No.3 : 0.024 ~ 0.042 mm (0.0009 ~ 0.0017 in.)
Fig. 125: Measuring Outside Diameter Of Crankshaft Journal

Reassembly
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
Fig. 126: Installing Grooved Main Bearings

2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Both upper and lower center thrust bearings.
Fig. 127: Installing Thrust Bearings

4. Apply engine oil to journals and pins. Install the crankshaft.

5. Install the bearing caps with the arrow mark directed toward the front of the engine. The cap number must
be correct.
6. Tighten the cap bolts to the specified torque.
Tightening torque
Main bearing cap bolts : 25 Nm (250 kg.cm, 18lb.ft) + (90°)
7. Cap bolts should be tightened evenly in 4 to 5 increments before they are tightened to the specified
torque.
8. Make sure that the crankshaft turns freely and check the end play of the crankshaft.
9. Using a special tool (09231 - 21000). Install the oil seal in the oil seal case. A new oil seal should be
used.
Fig. 128: Installing Oil Seal In Case

10. Install the oil seal into the oil seal case so that the oil hole in the separator may be directed downward
(arrow in illustration).
Fig. 129: Identifying Oil Separator

11. Install the new oil seal case gasket and oil seal case assembly.
Tightening torque
Oil seal case : 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft)
(For M/T)
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 (1300 ~ 1400 kg.cm, 94 ~ 101 lb.ft)
(For A/T)
14. Install the adapter plate to the cylinder block.
15. Install the drive plate and tighten the bolts to the specified torque.
Tightening torque
Driver plate : 130 ~ 140 Nm (1300 ~ 1400 kg.cm, 94 ~ 101 lb.ft)
INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD
Components
Fig. 130: Exhaust Manifold Components

Removal
1. Remove the heat protector.

2. Remove the exhaust manifold.
3. Remove the exhaust manifold gasket.
Inspection
1. Check for damage or cracking.

2. Using a straight edge and feeler gauge, check for distortion on the cylinder head matching surface.
Standard value : 0.15 mm (0.006 in.)
Service limit : 0.3 mm (0.012 in.)
3. Check the exhaust manifold for damage and cracking.
Installation
1. Install the exhaust manifold with its gasket.
Tightening torque
Exhaust manifold
M8 : 25 ~ 30 Nm (250 ~ 300 kg.cm, 18 ~ 22 lb.ft)
M10 : 35 ~ 35 Nm (350 ~ 550 kg.cm, 25 ~ 40 lb.ft)
NOTE: Do not use the used exhaust manifold gasket.
INTAKE MANIFOLD
Components
Fig. 131: Intake Manifold Components

Removal
1. Remove the air breather hose connected to the throttle body.
Fig. 132: Removing Air Breather Hose

2. Remove the accelerator cable.
Fig. 133: Identifying Accelerator Cable

3. Remove the engine coolant hose and throttle body.

4. Remove the P.C.V. valve and brake boost vacuum hose.
Fig. 134: Identifying Brake Booster Vacuum Hose

5. Disconnect the vacuum hose connector.

6. Remove the injector cover.
Fig. 135: Removing Injector Cover

7. Bleed off pressure in the fuel pipe line to prevent fuel from spilling and then disconnect the high pressure
hose.
8. Disconnect the fuel injector harness connector.
Fig. 136: View Of Injector Harness Connector

9. Remove the delivery pipe with fuel injectors and the pressure regulator.
NOTE: When the delivery pipe is removed, do not drop the injectors.
Fig. 137: Removing Fuel Delivery Pipe

10. Remove the intake manifold stay.
Fig. 138: Identifying Intake Manifold Stay

11. Remove the intake manifold.
Inspection
Intake Manifold & Surge Tank
1. Check the parts for damage or cracking.

2. Check for restrictions in the vacuum outlet port, water or gas passages.
3. Check for flatness using a straight edge and feeler gauge.
Standard value : 0.15 mm (0.06 in.) or less
Service limit : 0.2 mm (0.0078 in.)
Installation
1. Install the intake manifold and new gasket to the specified torque.
Tightening torque
Intake manifold
Bolt : 15 ~ 20 Nm (150 ~ 120 kg.cm, 11 ~ 14 lb.ft)
Nut : 30 ~ 42 Nm (300 ~ 420 kg.cm, 22 ~ 30 lb.ft)
2. Install the delivery pipe and injector assembly to the intake manifold.
NOTE: Make certain that there is no interferences between the injectors and
injector ports on the intake manifold.
Fig. 139: Installing Fuel Delivery Pipe

3. Install the surge tank stay.

4. Connect the fuel injector connector and wiring harness and then install the cover.
5. Connect the high pressure hoses.
Fig. 140: Identifying High Pressure Hose

6. Connect the vacuum hoses.
Tightening torque
Intake manifold stay and cylinder block :
18 ~ 25 Nm (180 ~ 250 kg.cm, 13 ~ 18 lb.ft)
7. Connect the PCV valve and brake boost hoses.

8. Install the air breather hose.
9. Install the accelerator cable.
MUFFLER
Components
Fig. 141: Muffler Components

Removal
Main Muffler
CAUTION: Before removing or inspecting the exhaust system, ensure that the
exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.
Fig. 142: View Of Exhaust Muffler

2. Remove the rubber hangers and remove the main muffler.
Fig. 143: View Of Muffler Hangers

Fig. 144: View Of Muffler Hangers

FRONT EXHAUST PIPE (INCLUDING CATALYTIC CONVERTER)
1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe bolts and exhaust manifold pipe mounting nuts.
Fig. 145: View Of Exhaust Pipe

3. Remove the front exhaust pipe from the rubber hanger.
Fig. 146: View Of Front Exhaust Pipe & Rubber Hanger

Fig. 147: View Of Front Exhaust Pipe & Rubber Hangers

Inspection
1. Check the mufflers and pipes for leaks, corrosion and damage.
2. Check the rubber hangers for deterioration and cracks.
Installation
1. Temporarily install the front exhaust pipe (catalytic converter assembly), the center exhaust pipe and the
main muffler in this order.
2. Install the rubber hangers so that they hang equally (left and right).
3. Tighten the parts securely and then confirm that there is no interference with any of components.
AIR CLEANER (ACL)
Components
Fig. 148: Air Cleaner Components

Removal
1. Disconnect the air flow sensor connector.

2. Remove the air intake hose at the air cleaner and the resonator.
3. Remove the three bolts attaching the air cleaner mounting brackets.
4. Detach the air cleaner.
Fig. 149: View Of Air Cleaner

5. Remove the air flow sensor from the air intake hose.
CAUTION: Do not pull on the air flow sensor wires.
Inspection
1. Check the air cleaner body, cover, or filter for distortion, corrosion or damage.
2. Check the air duct for damage.
Fig. 150: Identifying Air Cleaner Cover Assembly

3. Check the air cleaner element for restriction, contamination or damage. If the element is slightly
restricted, remove the dust and debris by blowing compressed air from the inside of the element.
Fig. 151: Cleaning Air Filter

Installation
Install the air cleaner assembly following the reverse order of removal.
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD
Components
Fig. 152: Cylinder Head Components

Disassembly
1. Using a tool, remove the cylinder head bolts in the order shown in the illustration.
Fig. 153: Cylinder Head Bolt Removal Sequence

2. Using the special tool (09222-28000, 09222-28100), remove the valve spring retainer lock. Then remove
the spring retainer, valve spring, spring seat and valve.
NOTE: Arrange these parts so that they can be reinstalled in their original
positions.
Fig. 154: Removing Valve Spring Retainer Locks

3. Remove the valve stem seals with pliers.
NOTE: Do not reuse the valve stem seals.
Fig. 155: Removing Valve Stem Seals

Inspection
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 the oil passages, apply
compressed air to verify that the passages are not clogged.
Fig. 156: Cleaning Cylinder Head Surface

3. Check the cylinder head surface for flatness in the direction as shown in the illustration. If flatness
exceeds service limit in any direction, either replace the cylinder head or machine the cylinder head
matching surface lightly.
Flatness of cylinder head gasket surface
Standard : Less than 0.03 mm (0.0012 in.)
Limit : 0.2 mm (0.008 in.)
Fig. 157: Checking Cylinder Head Flatness

Valves
1. Using a wire brush, clean the valve thoroughly.
Fig. 158: Cleaning Valve

2. Check each valve for wear, damage and distortion of the head and the stem at B Position. Replace, if
necessary. If stem end is hollowed out 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]
Intake : 1.0 mm (0.040 in.)
Exhaust : 1.5 mm (0.059 in.)
[Limit]
Intake : 0.7 mm (0.028 in.)
Exhaust : 1.0 mm (0.040 in.)
Fig. 159: Identifying Valve Margin

Valve Springs
1. Check the free height of each valve spring. If they exceed the service limit, replace the springs.
2. Using a square, test the squareness of each spring. If a spring is excessively out-of-square, replace it.
Valve spring
[Standard]
Free height : 45.82 mm (1.804 in.)
Load : 23.3kg / 40 mm (55.8 lb / 1.57 in.)
Out of square : 1.5° or less
[Limit]
Free height : 44.82 mm (1.7646 in.)
Out of square : 4°
Fig. 160: Checking Valve Spring

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]
Intake : 0.020 ~ 0.047 mm (0.0008 ~ 0.0020 in.)
Exhaust : 0.050 ~ 0.085 mm (0.0020 ~ 0.0033 in.)
[Limit]
Intake : 0.1 mm (0.0040 in)
Exhaust : 0.15 mm (0.0059 in.)
Fig. 161: Checking Valve Guides

Fig. 162: Measuring Valve Stems

Replacing Valve Seat Ring
1. Cut away the inner face of the valve seat to reduce the wall thickness.
Fig. 163: Cutting Inner Face Of Valve Seat

2. Enlarge the diameter of the valve seat so that it matches the specified oversize hole diameter of the new
valve seat ring.
3. Heat the cylinder head to about 250°C (480°F) and press-fit an oversize seat ring for the bore in the
cylinder head.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width
0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Fig. 164: Valve Seat Insert Oversizes

Replacing Valve Guide
1. Using the special tool (09221-3F000 A/B), withdraw the old valve guide toward the bottom of cylinder
head.
2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
Fig. 165: Press Fit Valve Guide

3. Using the special tool (09221-3F000 A/B), press-fit the valve guide. The valve guide must be press-fitted
from the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are
different in length.
NOTE: Do not install a valve guide unless it is oversize.
Fig. 166: Checking If Valve Is Fully Seated

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.
Fig. 167: Valve Guide Oversizes

Reassembly
NOTE: 1. Clean each part before assembly.

2. Apply engine oil to the sliding and rotating parts.
1. Install the spring seats.

2. Using a special tool (09222-28200), tap the seal in position lightly.
NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the
valve guides.
3. Apply engine oil to each valve. Insert the valve into the valve guide. Avoid pushing the valve into the seal
by force. After inserting the valve, check that it moves smoothly.
Fig. 168: Installing Valve Stem Seal

4. Place valve springs so that the side coated with enamel faces the valve spring retainer and then install the
retainer.
Fig. 169: Identifying Valve Spring Installation

5. Using the special tool (09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve
spring compressor.
Fig. 170: Installing Valve Spring Retainer Locks

NOTE: When the spring is compressed, Check that the valve stem seal is not
pressed against the bottom of the retainer.
6. Clean both gasket surfaces of the cylinder block and cylinder head.
7. Verify the identification marks on the cylinder head gasket.
8. Install the gasket so that the surface with the identification mark faces toward the cylinder head.
NOTE: Check and measure the length of each head bolt. Maximum length : 99.4
mm (3.9 in.)
9. Tighten the bolts to the specified torque.
Fig. 171: Cylinder Head Bolt Tightening Sequence

Tightening torque
With used parts (head bolt, cylinder head cylinder block) :
20Nm (200 kg.cm, 15 lb.ft) + 90° + 90°
With new parts (even if only one thing is replaced) :
64Nm (640 kg.cm, 47 lb.ft) + release + 20Nm
(200 kg.cm, 14 lb.ft) + 90° + 90°
TIMING SYSTEM
TIMING BELT
Components
Fig. 172: Timing Belt Components

Removal
CAUTION: Rotate the crankshaft clockwise and align the timing marks to set the No. 1
cylinder's piston to TDC.
At this time, the timing marks of the camshaft sprocket and cylinder head
cover should coincide with each other and the dowel pin of the camshaft-
sprocket should be at the upper side.
1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
2. Remove the timing belt cover.
3. Remove the auto tensioner.
Fig. 173: Identifying Timing Belt & Pulleys
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.
In this case the timing marks on the camshaft sprocket and on the locker
cover should be aligned and the dowel pins on the camshaft sprockets
should be positioned upward.
4. Remove the timing belt.
Fig. 174: View Of Timing Belt

5. Remove the camshaft sprockets.
NOTE: Be careful not to damage the cylinder head and camshaft sprocket with
the wrench.
Fig. 175: Removing Camshaft Sprockets

6. When the oil pump sprocket nut is removed, first remove the plug at the left side of the cylinder block
and insert a screwdriver to keep the left counter balance shaft in position. Use a screwdriver with a shaft
measuring 8 mm (0.3in.) in diameter which can be inserted by more than 60 mm (2.36 in.)
7. Remove the oil pump sprocket retaining nut and the oil pump sprocket.
Fig. 176: Securing Counter Balance Shaft

8. Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
9. Next, remove the tensioner "B" and then the timing belt "B".
CAUTION: After the timing belt "B" is removed, do not attempt to loosen bolts
while holding the sprocket with pliers or any other tool.
10. Remove the crankshaft sprocket "B" from the crankshaft.
Fig. 177: Removing Crankshaft Sprocket "B"

Inspection
Sprockets, Tensioner Pulley & Idler Pulley
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear,
cracks or damage. Replace if necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise.
Replace if necessary.
3. Replace the pulley if there is a grease leak from its bearing.
Fig. 178: Checking Pulley For Smooth Rotation

Auto Tensioner
1. Check the auto tensioner for leaking and replace if necessary.

2. Check the rod end for wear or damage and replace if necessary.
Fig. 179: Identifying Auto Tensioner

3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Standard value : 14.5 mm (0.57 in)
Fig. 180: Measuring Rod Protrusion

4. Using a soft jaw vise , compress the auto tensioner rod. slowly. If the rod can be easily retracted, replace
the auto tensioner. You should feel extensive resistance when pushing the rod in. And it must be
compressed in several steps.
NOTE: Clamp the auto tensioner in the vise so that it is level. Use soft jaws in the
vise to avoid damaging the auto tensioner.
Fig. 181: Compressing Auto Tensioner Rod

Timing Belt
1. Check the belt for oil or dust deposit. 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 is adjusted, check the belt carefully. If any of the following
flaws are evident, replace the belt with a new one.
Fig. 182: Checking Belt Surface With Finger Nail

Fig. 183: Checking Belt For Damage (1 Of 2)

Fig. 184: Checking Belt For Damage (2 Of 2)

Installation
1. Install the crankshaft sprocket "B" into the crankshaft.
CAUTION: Pay attention to the direction of the flange. if it is installed in the

wrong direction, a broken belt could result.
Fig. 185: Identifying Crankshaft Sprocket "B"

2. Apply engine oil to the outer surface of the spacer lightly and then install the spacer to the right counter
balance shaft. Be sure to install in the direction shown in the illustration.
3. Install the counter balance shaft sprocket onto the right counter balance shaft and then tighten its flange
bolt by hand tightly.
Fig. 186: Installing Counter Balance Shaft

4. Align the timing mark on each sprocket with the corresponding timing mark on the front case.
Fig. 187: Identifying Timing Marks

5. When the timing belt "B" is installed, make certain that its tension side has no slack.
Install the tensioner "B" so the center of the pulley is located on the left side of the mounting bolt and in
the pulley flange faces the front of the engine.
Align the timing mark on the right counter balance shaft sprocket with the timing mark on the front case.
Fig. 188: Installing Timing Belt "B"

6. Lift the tensioner "B" to tighten the timing belt "B" so that its tension side is pulled tight. In this
condition, tighten the bolt to secure tensioner "B". As the bolt is tightened, be careful to prevent the shaft
from turning. If the shaft is turned, the belt will be tightened excessively.
Fig. 189: Tightening Tensioner "B"

7. Check to ensure that the timing marks are in alignment.

8. Verify the tension of the timing belt.
Method 1 : Verify that, when the center of the span on the tension side is depressed with an index finger
in the direction of arrow, the deflection of the belt is within specification.
Belt deflection : 5 ~ 7 mm (0.20 ~ 0.28 in)
Method 2 : Measure the tension of the timing belt by using a tension gauge.
Fig. 190: Belt Tension Specification Table

Fig. 191: View Of Timing Belt & Alignment Marks
9. Install the flange and crankshaft sprocket onto the crankshaft. Be sure to install the as shown in the
illustration.
CAUTION: Pay attention to the direction of the flange. If it is installed in the

wrong direction, a broken belt could result.
Fig. 192: Installing Crankshaft Sprocket

10. Install the special washer and sprocket bolt to the crankshaft and then tighten the sprocket bolt.
Tightening torque
Crankshaft sprocket bolt :
160 ~ 170 Nm (1600 ~ 1700 kg.cm, 116 ~ 123 lb.ft)
11. Insert a screwdriver through the plug hole in the left side of the cylinder block to keep the shaft in
position.
Fig. 193: Identifying Screw Driver In Plug Hold

12. Install the oil pump sprocket and tighten the nut to the specified torque.
Fig. 194: Tightening Oil Pump Sprocket

Tightening torque
Oil pump sprocket
50 ~ 60 Nm (500 ~ 600 kg.cm, 36 ~ 43 lb.ft)
13. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque
Camshaft sprocket bolt :
80 ~ 100 Nm (800 ~ 1000 kg.cm, 58 ~ 72 lb.ft)
14. Install the auto tensioner.
CAUTION: Leave the set pin installed in the auto tensioner.
Fig. 195: Installing Auto Tensioner

NOTE: If the auto tensioner rod is in its fully extended position, reset it as follows.
1. Clamp it in a vise equipped with soft jaws, in a level position. Use a plain
washer if there is a plug at the bottom of the auto tensioner.
2. Compress the rod slowly with the vise until the set hole in the rod is
aligned with set hole in the cylinder.
Fig. 196: Compressing Rod In A Vise

3. Insert a set pin through the auto tensioner body and rod.
CAUTION: Leave the set pin installed in the auto tensioner.
15. Install the tensioner pulley onto the tensioner arm.
Tightening torque
Tensioner pulley
43 ~ 55 N.m (430 ~ 550 kg.cm, 31 ~ 40 lb.ft)
Fig. 197: Identifying Tensioner Pulley

16. Rotate the camshaft sprockets so that the dowel pin of the camshaft sprocket is at the upper side. Set the
timing mark of sprocket correctly.
NOTE: 1. Before installing the timing belt, if the timing mark of the cam sprocket
doesn't coincide with that of the rocker cover, do not rotate the cam
sprocket more than 2 teeth of the sprocket in any direction. Rotating the
sprocket more than 2 teeth may make the valve and piston touch each
other.
2. If it is necessary to rotate the cam sprocket more than 2 teeth, rotate the
crank sprocket counter clock wise first based on the timing mark.
After the cam sprocket is properly timed return the crankshaft to TDC.
Fig. 198: Identifying Dowel Pin & Camshaft Timing Marks

3. When exhaust and intake camshaft sprocket is used and install it after
checking I.D mark depending on the engine debasement.
Fig. 199: Identifying Camshaft Sprocket I.D. Mark

17. Align the timing mark on each sprocket with the corresponding timing mark and install the belt as the
following order.
Crankshaft sprocket - Oil pump sprocket - Idler pulley - Exhaust camshaft sprocket - Intake camshaft
sprocket Tensioner pulley
Fig. 200: Identifying Timing Belt & Pulleys

NOTE: 1. Be sure that the piston of No. 1 cylinder is located in TDC position
(Compression stroke).
2. When aligning the timing mark on oil pump sprocket, remove the left plug
of cylinder block, and then check that the count balance shaft is in the
specified position by inserting the screwdriver (Diameter : 8 mm,
inserting length : 60 mm or more)
Fig. 201: Checking Counter Balance Shaft Position

3. After checking the timing mark, install the left plug of cylinder block.
Tightening torque : 2.7 - 3.4 kgf.m
(Apply the liquid gasket : THREE BOND NO. 1212B or equivalent)
18. Pull out the set pin.

19. Rotate the crankshaft two turns clockwise and leave it for about 5 minutes. Then, measure the auto
tensioner protrusion "A" (Distance between the tensioner arm and auto tensioner body) to ensure that it is
within the specification.
Standard value : 5.5-9 mm (0.22 - 0.35 in)
Fig. 202: Measuring Auto Tensioner Protrusion

20. Install the timing belt lower cover and the timing belt upper cover.
Fig. 203: Identifying Timing Belt Cover Bolts


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2004 Hyundai Santa Fe

2002-04 ENGINES 2.4L 4-Cylinder - Santa Fe

2.4L 4-Cylinder - Santa Fe

viernes, 19 de febrero de 2021 07:49:07

intake and exhaust)

in.) at installed height

Crankshaft main bearing oil

Rear journal diameter 40.951 ~ 40.967 mm (1.6122 ~

Fig. 1: Standard Value Table

Courtesy of HYUNDAI MOTOR CO.

Fig. 2: Engine Coolant Specification

Fig. 3: Sealant Specification Table

NOTE: O.D.= Outer Diameter

M8x40 mm 15-18 (20-25)

Camshaft Bearing Cap Bolts 14-15 (19-20)

(2) Tighten in sequence with engine cold. See Fig. 4.

Fig. 4: Cylinder Head Bolt Removal Sequence

Fig. 5: Cylinder Head Bolt Tightening Sequence

Checking Engine Oil

1. Position a vehicle on a level surface.

NOTE: When refilling, use the proper grade of engine oil.

Fig. 6: Identifying Good Oil Level

Selection Of Engine Oil

Recommended API classification: SH OR ABOVE

RECOMMENDED SAE VISCOSITY GRADES :

Fig. 7: Recommended SAE Viscosity Grades

1. Satisfy the requirements of the API classification.

Changing Engine Oil

1. Run the engine until it reaches normal operating temperature.

2. Turn off the engine.

Oil pan drain plug : 35 ~ 45 Nm (350 ~ 450 kg.cm, 25 ~ 33 lb.ft)

Drain and refill : 4.3 lit (4.53 U.S.qts., 3.78 lmp.qts.)

6. Install the oil filler cap.

Replacing The Oil Filter

Fig. 8: Identifying Oil Filter Part Number

Procedure For Replacing The Oil Filter

1. Use a filter wrench to remove the oil filter.

Fig. 9: Applying Engine Oil To Oil Filter Rubber Gasket

3. Tighten the oil filter to the specified torque.

Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)

Checking Coolant Leak

1. Loosen the radiator cap.

3. Be sure to clean away completely any from the area.

4. If there is leakage, repair or replace with the appropriate part.

Fig. 10: Pressure Testing Cooling System

Radiator Cap Pressure Test

1. Use an adapter to attach the cap to the tester.

3. Check that the pressure level is maintained at or above the limit.

material on the cap seal will cause an incorrect reading.

Fig. 11: Pressure Testing Radiator Cap

Specific Gravity Test

1. Measure the specific gravity of the coolant with a hydrometer.

Fig. 12: Checking Coolant With Hydrometer

Fig. 13: Coolant Concentration Table

CAUTION: If the concentration of the coolant is below 30%, its anti-corrosion

Fig. 14: Recommended Coolant

Checking Compression Pressure

Standard value : 1200 kpa (12.2 kg / cm2 , 170 psi)