Text preview for : en_4j2_1c1.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004



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SECTION : 1C1

1.4L/1.6L DOHC ENGINE MECHANICAL
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . 1C1­2 Fastener Tightening Specifcations . . . . . . . . . . 1C1­5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­7 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 1C1­7 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1C1­9 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­9 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­10 Intake & Exhaust Manifold . . . . . . . . . . . . . . . . 1C1­12 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­13 Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . 1C1­14 MAINTENANCE AND REPAIR . . . . . . . . . . . . . 1C1­15 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1C1­15 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­15 Camshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­15 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­16 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C1­20 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C1­21 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­29 Timing Belt Check and Adjust . . . . . . . . . . . . . 1C1­30 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­34 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Gears . . . . . . . . . . . . . . . . . . . . . . . . . Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and Rods . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­38 1C1­40 1C1­43 1C1­45 1C1­46 1C1­48 1C1­53 1C1­58

Cylinder Head and Valve Train Components . 1C1­58 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­65 Crankshaft Bearing and Connecting Rod Beadings ­ Gauging Plastics . . . . . . . . . . . . 1C1­74 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Gasket . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 1C1­77 1C1­77 1C1­77

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77

1C1 ­ 2I1.4L/1.6L DOHC ENGINE MECHANICAL

SPECIFICATIONS
ENGINE SPECIFICATIONS
Application General Data: Engine Type Displacement Bore Stroke Compression Ratio Firing Oder Cylinder Bore: Diameter Out of Round (Maximum) Taper (Maximum) Pistion: Diameter Clearance to Bore Piston Rings: Ring, End Gap: Top Compression 2nd Compression Groove Clearance: Top Compression 2nd Compression Piston Pin: Diameter Pin Off­Set Camshaft: Lift Intake Lift Exhaust End Play Journal OD: No. 1 No. 2 No. 3 No. 4 No. 5 29.94 mm (1.179 in.) 26.94 mm (1.061 in.) 26.94 mm (1.061 in.) 26.94 mm (1.061 in.) 26.94 mm (1.061 in.) 30 mm (1.18 in.) 27 mm (1.06 in.) 27 mm (1.06 in.) 27 mm (1.06 in.) 27 mm (1.06 in.) 7.2 mm (0.283 in.) 7.2 mm (0.283 in.) 0.1­0.25 mm (0.00394­0.00787 in.) 8.5 mm (0.335 in.) 8.5 mm (0.335 in.) 0.10­0.25 mm (0.004­0.0089 in.) 18.00 mm (0.708 in.) 0.5 ± 0.1 mm (0.0197 ± 0.00787 in.) 18.00 mm (0.708 in.) 0.7­0.9 mm (0.028­0.036 in.) 0.05­0.09 mm (0.00197­0.00354 in.) 0.06­0.1 mm (0.00236­0.00393 in.) 0.016 mm (0.0006 in.) 0.066 mm (0.0026 in.) 0.15­0.30 mm (0.0059­0.0118 in.) 0.3­0.5 mm (0.0118­0.0197 in.) 0.2­0.3 mm (0.008­0.012 in.) 0.5­0.6 mm (0.02­0.024 in.) 77.87 mm (3.07 in.) 0.030 mm (0.0012 in.) 78.970 mm (3.1090 in.) 0.030 mm (0.0012 in.) 77.9 mm (3.07 in.) 0.0065 mm (0.00025 in.) 0.07 x 30° 79 mm (3.1 in.) 0.0065 mm (0.00025 in.) 0.0065 mm (0.00025 in.) F14D 1399 cm3 77.9 x 73.4 mm (3.01 in. x 2.89 in.) 9.5 ± 0.2:1 1­3­4­2 F16D 1598 cm3 (97.51 in3) 79.0 x 81.5 mm (3.1 in. X 3.21 in.) 9.5 ± 0.2:1 1­3­4­2 Description (Manual and Automatic) 1.4L DOHC 1.6L DOHC

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 3
Application Crankshaft: Main Journal: Diameter (All) Taper (Maximum) Out of Round (Maximum) Main Bearing Clearance (All) Crankshaft End Play Connecting Rod Journal: Diameter (All) Taper (Maximum) Out of Round (Maximum) Rod Bearing Clearance (All) Rod Side Clearance Valve System: Valve Lash Compensators Face Angle (All) Seat Angle (All) Seat Runout (Maximum, All) Face Runout (Maximum, All) Seat Width: Intake Exhaust Valve Guide Inside Diameter (All) Valve Stem Diameter (All) Valve Diameter (All): Intake Exhaust Valve Spring Loads: Valve Open Valve Closed Valve Spring Free Length Oil Pump: Gap Between Oil Pump Body and Out Rotor Out Rotor Side Clearance 0.400~0.484 mm (0.0157~0.019 in.) 0.045~0.100 mm (0.0018~0.0039 in.) 0.400~0.484 mm (0.0157~0.019 in.) 0.045~0.100 mm (0.02~0.004 in.) 580 ± 29N (426 ± 21 lbs) 260 ± 13N (191 ± 9.6 lbs) 41.2 mm (1.622 in.) 580­26N (428­19 lbs) @23.0 mm(0.90 in.) 260"13N(192" 9 lbs) @ 32.0mm(1.25 in.) 41.2 mm (1.622 in.) 28.57 mm (1.125 in.) 27.24 mm (1.074 in.) 28.6 mm (1.126 in.) 27.2 mm (1.072 in.) 1.17­1.57 mm (0.046­0.062 in.) 1.4­1.8 mm (0.055­0.071 in.) 6.00­6.02 mm (0.236­0.237 in.) 6 mm (0.236 in.) 1.17­1.57 mm (0.046­0.062 in.) 1.4­1.8 mm (0.055­0.071 in.) 6.00­6.02 mm (0.236­0.237 in.) 6 mm (0.236 in.) Hydraulic 45°~45.25° 44.5°~45° 0.05 mm (0.002 in.) 0.03 mm (0.0012 in.) Hydraulic 90°~90.5° 89°~90° 0.05 mm (0.002 in.) 0.03 mm (0.0012 in.) 43 mm (1.69 in.) 0.005 mm (0.0001 in.) 0.004 mm (0.0001 in.) 0.019­0.070 mm (0.0007­0.0028 in.) 0.070­0.242 mm (0.0027­0.009 in.) 42.971­42.987 mm (1.691­1.692 in.) 0.005 mm (0.0001 in.) 0.004 mm (0.0001 in.) 0.019­0.071 mm (0.0007­0.0028 in.) 0.070­0.242 mm (0.0027­0.009 in.) 55 mm (2.71 in.) 0.005 mm (0.0001 in.) 0.004 mm (0.0001 in.) 0.026­0.042 mm (0.001­0.002 in.) 0.1 mm (0.003 in.) 54.982­54.994 mm (2.164­2.165 in.) 0.005 mm (0.0001 in.) 0.004 mm (0.0001 in.) 0.026­0.042 mm (0.001­0.002 in.) 0.05­0.28 mm (0.002­0.011 in.) Description (Manual and Automatic) 1.4L DOHC 1.6L DOHC

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1C1 ­ 4I1.4L/1.6L DOHC ENGINE MECHANICAL
Application Inner Rotor Side Clearance Relief Valve Spring Free Length Sealants and Adhesives: Rear Main Bearing Cap Camshaft Carrier to Cylinder Head Oil Pan Bolts Oil Pump Bolts Oil Pan Pickup Tube Bolts Oil Gallery Plug Coolant Jacket Caps and Plugs (Freeze Plugs) Exhaust Manifold Studs/Nuts GE p/n RTV 159 HN 1581 (Loctite® 515) HN 1256 (Loctite® 242) HN 1256 (Loctite® 242) HN 1256 (Loctite® 242) HN 1256 (Loctite® 242) HN 1756 (Loctite® 176) Anti­seize Compound (HMC Spec HN1325) Description (Manual and Automatic) 1.4L DOHC 0.035~0.085 mm (0.001~0.003 in.) 81 mm (3.2 in.) 1.6L DOHC 0.035~0.085 mm (0.001~0.003 in.) 81 mm (3.2 in.)

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 5

FASTENER TIGHTENING SPECIFCATIONS
Application Air Cleaner Housing Bolts Camshaft Cap Bolts Camshaft Cover Nuts Connecting Rod Bearing Cap Bolts Coolant Temperature Sensor Crankshaft Bearing Cap Bolts Crankshaft Cover Nuts Crankshaft Pulley Bolt Cylinder Head Bolts (Cylinder Head Mounting Bolts) Direct Ignition System Coil Mounting Bolts Direct Ignition System Coil Mounting Bracket Bolts Engine Mount Attaching Bolts Engine Mount Bracket Attaching Bolts/Nuts Exhaust Camshaft Gear Bolt Exhaust Flex Pipe­to­Catalytic Converter or Connecting Pipe Retaining Nut Exhaust Flex Pipe­to­Exhaust Manifold Retaining Nuts Exhaust Gas Recirculation Valve Adapter Bolts Exhaust Manifold Heat Shield Bolts Exhaust Manifold Retaining Nuts Flexible Plate Bolts Flexible Plate Inspection Cover Bolts Flywheel Bolts Flywheel Inspection Cover Bolts Front Timing Belt Cover Bolts (Upper and Lower) Fuel Rail Assembly Retaining Bolts Fuel Rail Retaining Bolts Generator Upper Retaining Bolt Intake Camshaft Gear Bolt Intake Manifold Retaining Bolts/Nuts Intake Manifold Support Bracket Lower Bolt Intake Manifold Support Bracket Upper Bolts Lower Front Timing Belt Cover Bolts Oil Pan Flange Bolts Oil Pan Retaining Bolts Oil Pan Drain Plug OIl Pressure Switch
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NSm 10 16 10 25 + 30° + 15° 20 50 + 45° + 15° 5~8 95 NSm + 30° + 15° 25 + 70° + 70° + 50° 10 10 30 50 67.5 35 35 25 15 25 60 10 35 + 30° + 15° 12 10 25 25 20 67.5 25 25 25 10 75 10 35 40

Lb­Ft ­ 12 ­ 18 + 30° + 15° 15 37 + 45°+ 15° ­ ­ 18 + 70° + 70° + 50° ­ ­ 22 37 49 26 26 18 11 18 44 ­ 25 + 30° + 15° ­ ­ 18 18 15 49 18 18 18 ­ 55 ­ 26 30

Lb­In 89 ­ 89 ­ ­ ­ 44~71 ­ ­ 89 89 ­ ­ ­ ­ ­ ­ ­ ­ ­ 89 ­ 106 89 ­ ­ ­ ­ ­ ­ ­ 89 ­ 89 ­ ­

1C1 ­ 6I1.4L/1.6L DOHC ENGINE MECHANICAL
Application Oil Pump Bolts Oil Pump Rear Cover Bolts Oil Pump Retaining Bolts Oil Suction Pipe or Support Bracket Bolts Rear Timing Belt Cover Bolts Safety Relief Valve Bolt Spark Plugs Thermostat Housing Mounting Bolts Timing Belt Automatic Tensioner Bolts Timing Belt Idler Pulley Bolt Transaxle Bell Housing Bolts Transaxle Torque Converter Bolts Upper Front Timing Belt Cover Bolts Water Pump Retaining Bolts NSm 10 8 10 10 10 30 25 20 25 40 75 45 10 10 Lb­Ft ­ ­ ­ ­ ­ 3022 18 15 18 30 55 33 ­ ­ Lb­In 89 71 89 89 89 ­ ­ ­ ­ ­ ­ ­ 89 89

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 7

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J­42492 Timing Belt Adjuster

KM­571­B Gauge

KM­470­B Angular Torque Gauge

KM­340­0 Cutter Set Includes: KM­340­7 Guide Drift KM­340­13 Cutters KM­340­26 Cutters

J­28467­B Engine Assembly Support Fixture

KM­348 Valve Spring Compressor

KM­427 Piston Pin Service Set

KM­653 Adapter

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1C1 ­ 8I1.4L/1.6L DOHC ENGINE MECHANICAL

KM­805 Valve Guide Reamer

KM­635 Crankshaft Rear Oil Seal Installer

KM­412 Engine Overhaul Stand

J­36792 Crankshaft Rear Oil Seal Installer

KM­498­B Pressure Gauge

KM­135 Adapter

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 9

COMPONENT LOCATOR
CYLINDER HEAD

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Oil Filler Cap Engine Cover Camshaft Cover Camshaft Cover Gasket Camshaft Cover Bolt Hydraulic Tappet Adjuster Valve Key Valve Spring Cap Valve Spring Valve Stem Seal EGR Vaccum Hose EGR Valve EGR Valve Gasket EGR Valve Adaptor EGR Valve Adaptor Gasket

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Cylinder Head Front Camshaft Cap Valve Guide Plug Freeze Plug Oil Duct Cap Intake Valve Exhaust Valve Cylinder Head Gasket Engine Coolant Temperature Sensor Heat Take Off Pipe Camshaft Camshaft Seal Thermostat

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1C1 ­ 10I1.4L/1.6L DOHC ENGINE MECHANICAL

CYLINDER BLOCK

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 11
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Piston Ring Set Piston Piston Pin Connecting Rod Connecting Rod Bearing Set Oil Level Gauge Stick Gauge Stic Tube Sleeve Clutch Housing Sleeve Cylinder Block Plug Gap Bypass Valve Connecting Piece Oil Filter Oil Pump Body Gasket Water Inlet Neck Knock Sensor Fly Wheel (M/T) Flexible Plate (A/T) Shaft Seal Ring Crank Shaft Upper Bearing Set Crank Shaft 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. Crank Shaft Lower Bearing Set Transmitter Disc Crankshaft Bearing Cap Oil Pan Threaded Ring Washer Oil Pan Drain Plug Oil Pump Oil Pump Cover Oil Pump Inner Rotor Oil Pump Outer Rotor Oil Pump Plug Shaft Sealing Pressure Relief Valve Plunger Relief Valve Spring Sealing Relief Valve Oil Pressure Switch Sleeve Oil Suction Pipe Bracket Oil Suction Pipe Sealing

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1C1 ­ 12I1.4L/1.6L DOHC ENGINE MECHANICAL

INTAKE & EXHAUST MANIFOLD

1. 2. 3. 4. 5. 6. 7. 8.

Oxygen Sensor Heat Shield Exhaust Manifold Exhaust Manifold Gasket Intake Manifold Main Throttle Idle Actuator (MTIA) Gasket MTIA Clamp

9. 10. 11. 12. 13. 14. 15. 16.

Intake Air Tube Breethe Hose Aircleaner Assembly Aircleaner Upper Hosing Aircleaner Eliment Aircleaner Lower Housing Resoinator Air Intet Hose

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 13

TIMING BELT

1. 2. 3. 4. 5. 6. 7.

Water Pump Sealing Water Pump Timing Belt Rear Cover Camshaft Position Sensor Auto Temsioner Camshaft Gear Idler pulley

8. 9. 10. 11. 12. 13. 14.

Crankshaft Gear Torque Roll Axis Support Timing Belt Timing Belt Front Upper Cover Timing Belt Front Lower Cover Crankshaft Pulley Crankshaft Position Sensor

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1C1 ­ 14I1.4L/1.6L DOHC ENGINE MECHANICAL

ENGINE MOUNTING

1. 2. 3. 4. 5.

Rear Power Unit Damping Block Rear Transaxle Mounting Bracket (A/T) Rear Transaxle Mounting Bracket (M/T) Transaxle Mounting Cage Transaxle Mounting Bracket (M/T)

6. 7. 8. 9.

Transaxle Mounting Bracket (A/T) Engine Undercover Hydro Mounting Engine Mounting Bracket

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 15

MAINTENANCE AND REPAIR
ON­VEHICLE SERVICE ENGINE COVER
Removal Procedure
1. 2. Remove the bolts and nuts from the engine cover. Remove the engine cover.

Installation Procedure
1. 2. Position the engine cover on the engine. Install the engine cover bolts and nuts.

Tighten
Tighten the engine cover bolts and nuts to 10 NSm(89 lb­ft).

CAMSHAFT COVER
Removal Procedure
1. 2. 3. Disconnect the negative battery cable. Remove the engine cover. Refer to "Engine" in this section. Remove the breather hose, ventilation hose and cam position sensor wiring connector from the camshaft cover.

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1C1 ­ 16I1.4L/1.6L DOHC ENGINE MECHANICAL
4. 5. 6. Remove the ignition wires from the spark plug. Remove the camshaft cover bolts and camshaft cover. Remove the camshaft cover gasket.

Installation Procedure
1. 2. 3. Install the camshaft cover gasket on the camshaft cover. Position the camshaft cover on the engine block. Install the camshaft cover bolts.

Tighten
4. Tighten the camshaft cover bolts to 10 NSm(89 lb­ft). Install the ignition wires to the spark plugs and connect the breather hose, ventilation hose and cam position sensor wiring connector to the canshaft cover. Install the engine cover. Connect the negative battery cable.

5. 6.

INTAKE MANIFOLD
Removal Procedure
1. 2. 3. 4. Remove the fuel pump fuse. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure. Disconnect the negative battery calbe. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

5.

Remove the engine cover and throttle body. Refer to Section 1F, Engine Control.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 17
6. Disconnect the intake manifold pressure sensor connector, attaching bolt and vaccum hose.

7.

Disconnect the intake manifold air temperature sensor(MAT) connector and remove the MAT sensor.

8. 9.

Remove the intake manifold upper bracket. Remove the fule rail bolt and the fuel rail.

10. Remove the all the vaccum hoses from the intake manifold including PCV hose and brake booster vaccum hose. 11. Remove the exhaust gas recirculation(EGR) pipe.

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1C1 ­ 18I1.4L/1.6L DOHC ENGINE MECHANICAL
12. Remove the alternator. Refer to Section 1E, Engine Electrical. 13. Remove the intake manifold support bracket.

14. Remove the intake manifold retaining bolts/nuts in the sequence shown. 15. Remove the intake manifold and gasket. 16. Clean the sealing surfaces of the intake manifold and the cylinder head.

Installation Procedure
1. Install the fule rail.

Tighten
2. Tighten the fule rail bolts to 25 NSm (18 lb­ft). Install the new intake manifold gasket and intake manifold.

Tighten
Tighten the intake manifold bolts and nuts to 25 NSm (18 lb­ft).

3.

Install the exhaust gas recirculation(EGR) pipe.

Tighten
Tighten the exhaust gas recirculation(EGR) pipe bolts to 10 NSm (89 lb­ft).

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 19
4. Install the intake manifold support bracket.

Tighten
Tighten the intake manifold support bracket upper bolts to 25 NSm (18 lb­ft) and lower bolts to 45 NSm (33 lb­ft). Install the alternater.

5.

6. 7. 8. 9.

Install the fuel rail. Install the fuel rail bolts. Install the intake manifold upper bracket. Install the intake manifold upper bracket bolts.

10. Install the intake manifold air temperature sensor(MAT) and connect the MAT sensor connecter.

11. Install the intake manifold pressure sensor and vaccum hose.

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1C1 ­ 20I1.4L/1.6L DOHC ENGINE MECHANICAL
12. Install the throttle body and engine cover. 13. Refill the engine cooling system. Refer to Section 1D, Engine Cooling. 14. Install the fuel pump fuse and connect the negative battery cable.

EXHAUST MANIFOLD
Removal Procedure
1. 2. 3. Disconnect the negative battery cable. Disconnect the oxygen sensor connecter. Remove the exhaust manifold heat shield.

4.

Remove the exhaust manifold nuts from the pup converter.

5. 6. 7.

Remove the exhaust manifold retaining nuts in the sequence shown and remove the exhaust manifold. Remove the exhaust manifold gasket. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 21 Installation Procedure
1. 2. Install the exhaust manifold and gasket. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm (18 lb­ft).

3.

Install the exhaust manifold nuts to the catalytic converter.

Tighten
Tighten the exhaust manifold nuts to 40 NSm (30 lb­ ft).

4.

Install the heat shield.

Tighten
5. 6. Tighten the the heat shield bolts to 13 NSm (10 lb­ft). Connect the oxygen sensor connecter. Connect the negative battery cable.

CYLINDER HEAD AND GASKET
Tools Required J­42492 Timing Belt Adjuster KM­470­B Angular Torque Gauge

Removal Procedure
1. 2. 3. 4. 5. Remove the fuel pump fuse. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure. Disconnect the negative battery calbe. Disconnect the electronic control module(ECM) ground terminal from the intake manifold. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

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1C1 ­ 22I1.4L/1.6L DOHC ENGINE MECHANICAL
6. 7. Drain the engine oil and remove the camshaft cover. Refer to this section. Remove the air cleaner housing.

8.

Remove the throttle cable and inlet/outlet coolant hoses.

9.

Remove the thermostat upper hose.

10. Remove the intake manifold pressure sensor, intake air temperature sensor and coolant temperature sensor. 11. Remove the intake manifold support bracket.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 23
12. Remove the all the vaccum hoses from the intake manifold including brake booster vaccum hose. 13. Remove the ignition cables from the spark plugs. 14. Remove the direct ignition coil(DIS) and the bracket from the cylinder head.

15. Remove the serpentine accessory drive belt by rotating the tensioner pulley bolt to clockwise using DW110­080. Refer to Section 6B, Power Steering Pump.

16. Remove the front passenger side tire. Refer to Section 2E, Tires and Wheels. 17. Remove front wheel housing shield.

18. 19. 20. 21. 22.

Remove the upper front timing belt cover bolts. Remove the upper front timing belt cover. Align the camshaft gear timing marks. Remove the crank shaft pulley. Remove the lower front timing belt cover bolts and cover.

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1C1 ­ 24I1.4L/1.6L DOHC ENGINE MECHANICAL
23. Slightly loosen the water pump retaining bolts. 24. Rotate the water pump counterclockwise using the timing belt adjuster J­42492 to relieve the timing belt tension. 25. Remove the timing belt.Refer to "Timing Belt" in this section.

26. Remove the engine mounting bracket.Refer to "Engine Mount" in this section. 27. Remove the camshaft cover. Refer to "Camshaft Cover" in this section.

28. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and gear. 29. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and gear. Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

30. Remove the timing belt automatic tensioner. 31. Remove the timing belt idler pulley. 32. Remove the right engine mount. Refer to "Engine Mount" in this section. 33. Remove the rear timing belt cover.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 25
34. Remove the intake/exhaust manifold. Refer to "Intake/Exhaust Manifold" in the section. 35. Remove the cylinder head bolts gradually in the sequence shown and remove the cylinder head. Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head. 36. Remove the cylinder head gasket.

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

3. 4.

Installation Procedure
1. 2. Install the new cylinder head gasket. Install the intake/exhaust manifold to the cylinder head. Refer to "Intake/Exhaust Manifold" in the section. Install the cylinder head bolts gradually in the sequence shown.

3.

Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb­ft) and retighten the cylinder head bolts 70 degrees plus 70 degrees plus 50 degrees using the angular torque gauge KM­470­B. Install the right engine mount. Refer to "Engine Mount" in this section.

4.

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1C1 ­ 26I1.4L/1.6L DOHC ENGINE MECHANICAL
5. 6. Connect the throttle cable at the throttle body and the intake manifold. Install the intake manifold support bracket upper bolts to the intake manifold.

Tighten
7. 8. Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 NSm (18 lb­ft). Connect the surge tank coolant hose at the throttle body. Connect the heater inlet hose to the cylinder head.

9.

Install the generator upper retaining bolt.

Tighten
Tighten the generator upper retaining bolt to 20 NSm (15 lb­ft). 10. Connect the fuel feed line at the fuel rail. 11. Connect all the disconnected vacuum hoses and the brake booster vacuum hose at the intake manifold.

12. Install the catalytic converter retaining nuts at the exhaust manifold flange.

Tighten
Tighten the catalytic converter to exhaust manifold flange nuts to 40 NSm (30 lb­ft).

13. Install the rear timing belt cover. 14. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89 lb­in).

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 27
15. Install the timing belt automatic tensioner.

Tighten
Tighten the timing belt automatic tensioner bolts to 25 NSm (18 lb­ft). 16. Install the timing belt idler pulley.

Tighten
Tighten the timing belt idler pulley bolt to 25 NSm(18 lb­ft).

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 17. Install the intake/exhaust camshaft gear.

Tighten
Tighten the intake/exhaust camshaft gear bolts to 67.5 NSm (49 lb­ft).

18. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover­to­cylinder head seal. 19. Install the camshaft cover and the gasket. Refer to "Camshaft Cover" in this section.

20. Connect the ignition wires to the spark plugs. 21. Install the oil filler cap. 22. Connect the engine ventilation hose to the camshaft cover. 23. Align the timing marks on the camshaft gears. 24. Align the mark on the crank shaft gear with the notch at the bottom of the rear timing belt cover.

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1C1 ­ 28I1.4L/1.6L DOHC ENGINE MECHANICAL
25. Install the timing belt. 26. Rotate the water pump clockwise using the timing belt adjuster J­42492 to apply tension to the timing belt.

Tighten
Tighten the water pump retaining bolts to 10 NSm (89 lb­in). 27. Check and adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.

28. Install the upper and lower front timing belt covers.

Tighten
Tighten the upper and lower front timing belt covers bolts to 10 NSm (89 lb­in). 29. Install the crank shaft pulley bolt.

Tighten
Tighten the crank shaft pulley bolt to 95 NSm (70 lb­ft) and retighten 30 degrees plus 15 degrees.

30. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 31. Connect the upper radiator hose to the thermostat housing. 32. Install the front wheel and splash shield. Refer to Section 2E, Tires and Wheels.

33. Install the air cleaner housing.

Tighten
34. 35. 36. 37. Tighten the air cleaner housing bolts to 10 NSm (89 lb­ in). Connect the breather tube to the cam shaft cover. Install the crank shaft pulley bolt. Connect the MAT sensor connector. Connect the intake manifold pressure sensor, intake air temperature sensor and coolant temperature sensor connector.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 29
38. Connect the DIS coil connector. 39. Connect the fuel injector harness connectors. 40. Connect the oxygen sensor connector and the ECM ground terminal at the intake manifold. 41. Install the fuel pump fuse. 42. Connect the negative battery ground cable. 43. Refill the engine cooling system. Refer to Section1D, Engine Cooling.

CAMSHAFTS
Removal Procedure
1. 2. Remove the camshaft cover. Refer to "Camshaft Cover" in this section. Remove the timing belt. Refer to "Timing Belt" in this section.

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 3. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and gear. 4. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and gear.

5.

Remove the camshaft cap bolts gradually in the sequence shown for each camshaft cap.

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1C1 ­ 30I1.4L/1.6L DOHC ENGINE MECHANICAL
6. 7. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation. Remove the intake/exhaust camshaft.

Installation Procedure
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 1. 2. 3. Lubricate the camshaft journals and the camshaft caps with engine oil. Install the intake/exhaust camshafts. Install the intake/exhaust camshaft caps in their original positions.

Tighten
Tighten the intake/exhaust camshaft caps bolts to 16 NSm (12 lb­ft). 4. 5. 6. Measure the intake/exhaust camshaft end play.Refer to the "Engine Specifications" in this section. Install the intake/exhaust camshaft gear. While holding the intake/exhaust camshafts firmly in place, install the intake/exhaust camshaft gear bolts.

Tighten
Tighten the intake/exhaust camshaft gear bolts to 67.5 NSm (49 lb­ft).

7. 8.

Install the timing belt. Refer to "Timing Belt" in this section. Install the camshaft cover. Refer to "Camshaft Cover" in this section.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 31

TIMING BELT CHECK AND ADJUST
Tools Required J­42492 Timing Belt Adjuster KM­470­B Angular Torque Gauge

Adjustment Procedure
1. 2. 3. 4. 5. 6. 7. Disconnect the negative battery cable. Remove the air cleaner outlet hose from the throttle body. Remove the breather tube from the camshaft cover. Remove the air cleaner housing bolts. Remove the air cleaner housing. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. Remove the right front wheel well splash shield.

8.

Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 9. Remove the crankshaft pulley bolt. 10. Remove the crankshaft pulley.

11. 12. 13. 14. 15.

Remove the upper front timing belt cover bolts. Remove the upper front timing belt cover. Remove the lower front timing belt cover bolts. Remove the lower front timing belt cover. Install the crankshaft pulley bolt.

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1C1 ­ 32I1.4L/1.6L DOHC ENGINE MECHANICAL
16. Rotate the crankshaft at least one full turn clockwise using the crankshaft pulley bolt. 17. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover. 18. Align the camshaft gear timing marks.

19. Slightly loosen the water pump retaining bolts. 20. Rotate the water pump clockwise using the timing belt adjuster J­42492.

21. Rotate the water pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.

22. Tighten the water pump retaining bolts. 23. Rotate the crankshaft two full turns clockwise using the crankshaft pulley. 24. Loosen the water pump retaining bolts.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 33
25. Using the timing belt adjuster J­42492, rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.

26. Tighten the water pump retaining bolts.

Tighten
Tighten the water pump retaining bolts to 10 NSm (89 lb­in). 27. Remove the crankshaft pulley bolt. 28. Install the upper and lower front timing belt covers. 29. Install the upper and lower front timing belt cover bolts.

Tighten
Tighten the front timing belt cover bolts to 10 NSm (89 lb­in).

30. Install the crankshaft pulley. 31. Install the crankshaft pulley bolt.

Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb­ft) and retighten 30 degrees plus 15 degrees. 32. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.

33. Install the right front wheel well splash shield. 34. Install the right front wheel. Refer to Section 2E, Tires and Wheels. 35. Install the air cleaner housing. 36. Install the air cleaner housing bolts.

Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb­ in).

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1C1 ­ 34I1.4L/1.6L DOHC ENGINE MECHANICAL
37. Connect the air cleaner outlet hose to the throttle body. 38. Connect the breather tube to the camshaft cover. 39. Connect the negative battery cable.

TIMING BELT
Tools Required J­42492 Timing Belt Adjuster KM­470­B Angular Torque Gauge

Removal Procedure
1. 2. 3. Disconnect the negative battery cable. Disconnect the air cleaner outlet hose from the throttle body. Disconnect the breather tube from the camshaft cover. Remove the air cleaner housing bolts. Remove the air cleaner housing. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. Remove the right front wheel well splash shield.

4. 5. 6. 7.

Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 9. Remove the crankshaft pulley bolt. 10. Remove the crankshaft pulley.

8.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 35
11. 12. 13. 14. 15. Remove the upper front timing belt cover bolts. Remove the upper front timing belt cover. Remove the lower front timing belt cover bolts. Remove the lower front timing belt cover. Install the crankshaft pulley bolt.

16. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.

17. Slightly loosen the water pump retaining bolts. 18. Using the timing belt adjuster J­42492, rotate the water pump counterclockwise to release the tension on the timing belt. 19. Remove the right engine mount bracket. Refer to "Engine Mount" in this section.

20. Remove the timing belt.

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1C1 ­ 36I1.4L/1.6L DOHC ENGINE MECHANICAL Installation Procedure
1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover. Align the timing marks on the camshaft gears.

2.

3. 4.

Install the timing belt. Install the right engine mount bracket. Refer to "Engine Mount" in this section.

5. 6.

Rotate the water pump clockwise using the timing belt adjuster J­42492. Rotate the water pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.

7. 8.

Tighten the water pump retaining bolts. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt. 9. Loosen the water pump retaining bolts. 10. Rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 37
11. Tighten the water pump retaining bolts.

Tighten
Tighten the water pump retaining bolts to 10 NSm (89 lb­in).

12. Remove the crankshaft pulley bolt. 13. Install the upper and lower front timing belt covers. 14. Install the upper and lower front timing belt cover bolts.

Tighten
Tighten the front timing belt cover bolts to 10 NSm (89 lb­in).

15. Install the crankshaft pulley. 16. Install the crankshaft pulley bolt.

Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb­ft) and retighten 30 degrees plus 15 degrees. 17. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 18. Install the right front wheel well splash shield. 19. Install the right front wheel. Refer to Section 2E, Tires and Wheels.

20. Install the air cleaner housing. 21. Install the air cleaner housing bolts.

Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb­ in). 22. Connect the air cleaner outlet hose to the throttle body. 23. Connect the breather tube to the camshaft cover. 24. Connect the negative battery cable.

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1C1 ­ 38I1.4L/1.6L DOHC ENGINE MECHANICAL

OIL PAN
Removal Procedure
1. 2. 3. Disconnect the negative battery cable. Drain the Engine oil from the engine crankcase. Remove the catalytic converter retaining nuts from the exhaust pipe.

4. 5.

Remove the lower crossmember bracket. Remove the exhaust connecting pipe.

6.

Remove the oil pan bolts to the transaxle case.

7. 8.

Remove the oil pan retaining bolts to the engine block. Remove the oil pan from the engine block.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 39 Cleaning Procedure
1. 2. 3. 4. Clean the oil pan sealing surface. Clean the engine block sealing surface. Clean the oil pan retaining bolts. Clean the oil pan attaching bolt holes in the engine block.

Installation Procedure
1. Coat the new oil pan gasket with sealant. Important : Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan. 2. Install the oil pan to the engine block. 3. Install the oil pan retaining bolts.

Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb­in).

4.

Install the oil pan bolts to the transaxle case.

Tighten
Tighten the oil pan to the transaxle case bolts to 31 NSm (23 lb­ft).

5. 6.

Install the exhaust connecting pipe. Install the catalytic converter retaining nuts to the exhaust pipe.

Tighten
Tighten the catalytic converter to exhaust pipe retaining nuts to 40 NSm (30 lb­ft). 7. 8. 9. Install the lower crossmember bracket. Connect the negative battery cable. Install the oil pan drain plug.

Tighten
Tighten the oil pan drain plug to 55 NSm (40 lb­ft). 10. Refill the engine crankcase with engine oil.

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1C1 ­ 40I1.4L/1.6L DOHC ENGINE MECHANICAL

OIL PUMP
Tools Required KM­498­B Pressure Gauge KM­135 Adapter

Engine Oil Pressure Inspection Procedure
1. 2. Remove the right front wheel, wheel well splash shield and engine undercover. Disconnect the oil pressure switch connector.

3. 4. 5.

6.

Install the adapter KM­135 in place of the oil pressure switch. Connect the pressure gauge KM­498­B to the adapter. Start the engine and check the oil pressure at idle speed and engine temperature of 80°C (176°F). The minimum oil pressure should be 30 kPa (4.35 psi). Stop the engine and remove the pressure gauge KM­498­B and the adapter KM­135.

7.

Install the oil pressure switch.

Tighten
Tighten the oil pressure switch to 40 NSm (30 lb­ft). Connect the oil pressure switch connector. Install the right front wheel well splash shield, engine undercover and wheel. 10. Check the oil level. Pour oil until it reaches the full mark. 8. 9.

Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the power steering pump, if equipped. Refer to Section 6A, Power Steering System. Remove the timing belt. Refer to"Timing Belt" in this section. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section. Disconnect the oil pressure switch connector.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 41
6. 7. 8. Remove the oil pan. Refer to "Oil Pan" in this section. Remove the oil suction pipe and support bracket bolts. Remove the oil suction pipe.

9. Remove the oil pump retaining bolts. 10. Carefully separate the oil pump and gasket from the engine block and the oil pan. 11. Remove the oil pump.

Inspection Procedure
1. 2. 3. 4. Clean the oil pump and the engine block gasket mating surface areas. Remove the safety relief valve bolt. Remove the safety relief valve and the spring. Remove the oil pump­to­crankshaft seal.

5. 6.

Remove the oil pump rear cover bolts. Remove the oil pump rear cover bolts.

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1C1 ­ 42I1.4L/1.6L DOHC ENGINE MECHANICAL
7. Clean the oil pump housing and all the oil pump parts. 8. Inspect all the oil pump parts for signs of wear. Refer to "Engine Specifications" in this section. Replace the worn oil pump parts. Notice : Pack the oil pump gear cavity with petroleum jelly to ensure an oil pump prime, or engine damage could result. 9. Coat all the oil pump parts with clean engine oil. Install the oil pump parts. 10. Apply Loctite® 242 to the oil pump rear cover bolts and install the cover and bolts.

Tighten
Tighten the oil pump rear cover bolts to 8 NSm (71 lb­ in). 11. Install the safety relief valve, spring, washer and bolt.

Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lb­ft).

Installation Procedure
1. Apply Loctite® 242 to the oil pump bolts and room temperature vulcanizing (RTV) sealant to the new oil pump gasket. Install the gasket to the oil pump and install the oil pump to the engine block with the bolts.

2.

Tighten
Tighten the oil pump bolts to 10 NSm (89 lb­in).

3.

Install a new oil pump­to­crankshaft seal. Coat the lip of the seal with a thin coat of grease.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 43
4. 5. Coat the threads of the oil suction pipe and support bracket bolts with Loctite® 242. Install the oil suction pipe and bolts.

Tighten
Tighten the oil suction pipe and support bracket bolts to 10 NSm (89 lb­in).

6. 7. 8.

Install the oil pan. Refer to "Oil Pan" in this section. Connect the oil pressure switch connector. Install the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section. 9. Install the timing belt. Refer to "Timing Belt" in this section. 10. Install the power steering pump, if equipped. Refer to Section 6A, Power Steering System. 11. Connect the negative battery cable.

ENGINE MOUNT
Tools Required DW110­060 Engine Support Fixture

Removal Procedure
1. 2. Disconnect the negative battery cable. Support the engine assembly using the engine support fixture DW110­060.

3. 4.

Remove the engine mount bracket attaching bolts/ nuts. Remove the front timing belt cover. Refer to "Timing Belt" in this section.

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1C1 ­ 44I1.4L/1.6L DOHC ENGINE MECHANICAL
5. 6. Remove the engine mount attaching bolts/nuts. Remove the engine mount.

Installation Procedure
1. 2. Install the engine mount. Install the engine mount retaining bolts.

Tighten
3. Tighten the engine mount attaching bolts to 30 NSm (22 lb­ft). Install the front timing belt cover. Refer to "Timing Belt" in this section.

4.

Install the engine mount bracket attaching bolts/ nuts.

Tighten
Tighten the engine mount bracket attaching bolts/ nuts to 55 NSm (41 lb­ft).

5. 6.

Remove engine assembly support fixture DW110­060. Connect the negative battery cable.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 45

CAMSHAFT GEARS
Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the engine cover. Remove the timing belt. Refer to "Timing Belt" in this section. Disconnect the ignition wires from the spark plugs. Disconnect the engine ventilation hoses from the camshaft cover.

6. 7.

Remove the camshaft cover bolts. Remove the camshaft cover and the camshaft cover gasket.

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 8. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt. 9. Remove the intake camshaft gear. 10. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt. 11. Remove the exhaust camshaft gear.

Installation Procedure
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 1. Install the intake camshaft gear. 2. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm (49 lb­ft).

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1C1 ­ 46I1.4L/1.6L DOHC ENGINE MECHANICAL
3. 4. Install the exhaust camshaft gear. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm (49 lb­ft).

5.

6. 7.

Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover­to­cylinder head seal. Install the camshaft cover and the camshaft cover gasket. Install the camshaft cover bolts.

Tighten
Tighten the camshaft cover nuts to 10 NSm (89 lb­in).

8.

Connect the engine ventilation hoses to the camshaft cover. 9. Connect the ignition wires to the spark plugs. 10. Install the timing belt. Refer to "Timing Belt" in this section. 11. Install the engine cover. Refer to "Engine Cover" in this section. 12. Connect the negative battery cable.

REAR TIMING BELT COVER
Removal Procedure
1. 2. 3. 4. 5. Remove the timing belt and the timing belt cover. Refer to "Timing Belt" in this section. Remove the camshaft gears. Refer to "Camshaft Gears" in this section. Remove the crankshaft gear. Remove the timing belt automatic tensioner bolts. Remove the timing belt automatic tensioner.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 47
6. 7. Remove the timing belt idler pulley bolt. Remove the timing belt idler pulley.

8. 9.

Remove the rear timing belt cover bolts. Remove the rear timing belt cover.

Installation Procedure
1. 2. Install the rear timing belt cover. Install the rear timing belt cover bolts.

Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89 lb­in).

3. 4.

Install the timing belt idler pulley. Install the timing belt idler pulley bolt.

Tighten
Tighten the timing belt idler pulley bolt to 40 NSm (30 lb­ft).

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1C1 ­ 48I1.4L/1.6L DOHC ENGINE MECHANICAL
5. 6. Install the timing belt automatic tensioner. Install the timing belt automatic tensioner bolts.

Tighten
Tighten the timing belt automatic tensioner bolts to 25 NSm (18 lb­ft). 7. Install the crankshaft gear. Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 8. 9. Install the camshaft gears. Refer to "Camshaft Gears" in this section. Install the timing belt and timing belt cover. Refer to "Timing Belt" in this section.

ENGINE
Removal Procedure
1. 2. 3. 4. 5. Remove the fuel pump fuse. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure. Remove the hood. Refer to Section 9R, Body Front End. Drain the engine oil. Disconnect the negative battery cable.

Remove the air cleaner outlet hose from the throttle body and air cleaner housing. 7. Disconnect the breather tubes from the camshaft cover. 8. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 9. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. 10. Remove the right front wheel well splash shield.

6.

11. Drain the engine coolant. Refer to Section 1D, Engine Cooling. 12. Remove the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling. 13. Disconnect the upper radiator hose from the thermostat housing. 14. Disconnect the power steering return hose from the power steering pump. Refer to Section 6A, Power Steering System. 15. Disconnect the power steering pressure hose from the power steering pump. Refer to Section 6A, Power Steering System. 16. Disconnect the electrical connector at the direct ignition system (DIS) coil and the electronic control module (ECM) ground terminal at the intake manifold and at the starter motor.
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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 49
17. Disconnect the oxygen (O2) sensor connector, if equipped. 18. Disconnect the fuel injector harness connectors. 19. Disconnect the MAT, MAP sensor connectors. 20. Disconnect the throttle position sensor (TPS) connector. 21. Disconnect the generator voltage regulator connector and power lead. 22. Remove the electrical harness clamp bolt.

23. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose. 24. Disconnect the fuel feed line at the fuel rail.

25. Disconnect the throttle cable from the throttle body and the intake manifold bracket. 26. Disconnect the surge tank coolant hose at the throttle body. 27. Disconnect the heater outlet hose at the coolant pipe. 28. Disconnect the heater inlet hose from the cylinder head. 29. Disconnect the surge tank coolant hose from the coolant pipe. 30. Disconnect the lower radiator hose from the coolant pipe. Disconnect the starter solenoid "S" terminal wire. Remove the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems. 31. Remove the catalytic converter retaining nuts from the exhaust pipe. 32. Remove the exhaust pipe.

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1C1 ­ 50I1.4L/1.6L DOHC ENGINE MECHANICAL
33. Remove the crankshaft pulley bolt. 34. Remove the crankshaft pulley. 35. Disconnect the vacuum lines at the charcoal canister purge solenoid. 36. Disconnect the electrical connector at the charcoal canister purge (CCP) solenoid and at the knock sensor. 37. Disconnect the electrical connector at the oil pressure switch and at the exhaust gas recirculation (EGR) solenoid. 38. Disconnect the crankshaft position sensor (CPS) connector.

39. Remove the transaxle torque converter bolts, if automatic transaxle equipped. 40. Remove the stater motor. Refer to Section 1E, Engine Electrical. 41. Remove the transaxle bell housing bolts. 42. Support the transaxle with a floor jack. 43. Install the engine lifting device.

44. Disconnect the right engine mount bracket from the engine mount and the engine by removing the attaching bolts and the nuts. 45. Remove the right engine mount from the engine block. Refer to "Engine Mount" in this section. 46. Separate the engine block from the transaxle. 47. Remove the engine.

Installation Procedure
1. 2. 3. Install the engine into the engine compartment. Align the engine alignment pins to the transaxle. Install the transaxle bell housing bolts.

Tighten
4. Tighten the transaxle bell housing bolts to 75 NSm (55 lb­ft). Install the right engine mount to the engine block. Refer to "Engine Mount" in this section.

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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 ­ 51
5. Connect the right engine mount bracket to the engine mount and the engine by installing the attaching bolts and the nuts.

Tighten
Tighten the engine mount bracket attaching bolts and the nuts to 55 NSm (41 lb­ft).

6. 7. 8.

Remove the floor jack used for support of the transaxle. Remove the engine lifting device. Install the transaxle torque converter bolts, if automatic transaxle equipped.

Tighten
9. Tighten the transaxle torque converter bolts to 45 NSm (33 lb­ft). Install the starter motor. Refer to Section 1E, Engine Electrical.

10. Connect the vacuum lines at the CCP solenoid. 11. Connect the electrical connector at the CCP solenoid and at the knock sensor. 12. Connect the oil pressure switch and the EGR solenoid connectors. 13. Install the crankshaft pulley. 14. Install the crankshaft pulley bolt.

Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb­ft) and retighten 30 degrees plus 15 degrees.

15. Connect the CPS connector. 16. Install the exhaust front pipe. 17. Install the catalytic converter retaining nuts to the exhaust pipe.

Tighten
Tighten the catalytic converter to exhaust pipe retaining nuts to 35 NSm (26 lb­ft).

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1C1 ­ 52I1.4L/1.6L DOHC ENGINE MECHANICAL
18. Connect the power steering pressure hose. 19. Connect the power steering return hose. 20. Install the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems.

21. Install the generator. Refer to Section 1E, Engine Electrical. 22. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 23. Install the right front wheel well splash shield. 24. Install the right front wheel. Refer to Section 2E, Tires and Wheels. 25. Connect the fuel feed line to the fuel rail.

26. Connect all of the necessary vacuum lines, including the brake booster vacuum hose. 27. Connect the O2 sensor connector, if equipped. 28. Connect the starter solenoid "S" terminal wire and power lead. 29. Connect the generator voltage regulator connector and power lead. 30. Connect the CTS connector. 31. Connect the MAP, MAT sensor connectors. 32. Connect the TPS connector. 33. Install the electrical wiring harness clamp at the intake manifold support bracket.

34. Connect the fuel injector harness connectors. 35. Connect the electrical connector at the DIS coil and the ECM ground terminal at the starter. 36. Install the air cleaner outlet hose between the throttle body and the air cleaner housing. 37. Connect the breather tubes to the camshaft cover. 38. Install the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.

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39. Connect the lower radiator hose to the coolant pipe. 40. Connect the upper radiator hose to the thermostat housing. 41. Connect the surge tank coolant hose to the radiator. 42. Connect the heater inlet hose to the cylinder head. 43. Connect the heater outlet hose to the coolant pipe. 44. Connect the coolant surge tank hose to the coolant pipe. 45. Connect the surge tank coolant hose to the throttle body.

46. Connect the throttle cable to the throttle body and the intake manifold bracket. 47. Install the fuel pump fuse. 48. Connect the negative battery cable. 49. Refill the engine crankcase with engine oil. 50. Refill the engine coolant system. Refer to Section 1D, Engine Cooling. 51. Bleed the power steering system. Refer to Section 6A, Power Steering System. 52. Refill the A/C refrigerant system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. 53. Install the hood. Refer to Section 9R, Body Front End.

PISTONS AND RODS
Tools Required KM­427 Piston Pin Service Set KM 470­B Angular Torque Gauge

Removal Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section. Remove the oil pan. Refer to "Oil Pan" in this section. Remove the oil suction pipe bolts. Remove the oil suction pipe.

2. 3. 4. 5. 6. 7. 8.

Move the piston to the bottom of the piston stroke. Mark the connecting rod cap for position. Remove the connecting rod cap bolts. Remove the connecting rod cap and the lower connecting rod bearing. 9. Remove the upper piston connecting rod bearing. 10. Ridge ream the cylinder wall.

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CAUTION : Use care when handling the piston. Worn piston rings are sharp and may cause injury. 11. Remove the piston. 12. Use a piston ring expander tool to expand the piston rings. 13. Remove the piston rings.

14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM­427. 15. Separate the piston from the connecting rod.

Inspection Procedure
1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod. Inspect the connecting rod bearings. Inspect the connecting rod lower end for wear. Inspect the connecting rod upper end for scoring. Inspect the crankshaft rod bearing journal for wear. Refer to "Engine Specifications" in this section. Inspect the piston for scoring, cracks, and wear. Inspect the piston for taper using a micrometer.

2. 3. 4. 5. 6. 7.

8.

Inspect the piston for fit to the connecting rod.

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Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section. 10. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section. If the bearing bore is beyond specifications, replace the engine block. 11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section. 12. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary. 9.

Installation Procedure
1. Align the notch on the piston and the connecting rod so that the proper sides will be facing the front of the engine. Install the piston pin guide through the piston and the connecting rod. Coat the piston pin with clean oil. Install the piston pin into the opposite side of the piston. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM­427. Select a set of new piston rings. Measure the piston ring gap using a feeler gauge. Refer to "Engine Specifications" in this section. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.

2. 3. 4. 5.

6. 7. 8.

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

9.

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

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

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

20. Install the connecting rod cap bolts.

Tighten
Tighten the connecting rod bearing cap bolts to 25 NSm (18 lb­ft). Using the angular torque gauge KM­470­B, tighten the bolts one turn of 30 degrees plus one turn of 15 degrees.

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21. Install the oil suction pipe. 22. Install the oil suction pipe bolts.

Tighten
Tighten the oil suction pipe bolts to 10 NSm (89 lb­in). 23. Install the oil pan. Refer to "Oil Pan" in this section. 24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

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UNIT REPAIR CYLINDER HEAD AND VALVE TRAIN COMPONENTS
Tools Required MKM­571­B Gauge KM­340­0 Cutter Set KM­340­7 Guide Drift KM­340­13 Cutters KM­340­26 Cutters KM­348 Valve Spring Compressor KM­653 Adapter KM­805 Valve Guide Reamer

Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section. Remove the engine coolant temperature sensor. Remove the exhaust manifold heat shield bolts. Remove the exhaust manifold heat shield. Remove the exhaust manifold retaining nuts in the sequence shown. Remove the exhaust manifold. Remove the exhaust manifold gasket. Remove the exhaust manifold studs.

2. 3. 4. 5. 6. 7. 8.

9. Remove the thermostat housing mounting bolts. 10. Remove the thermostat housing assembly. 11. Remove the fuel rail retaining bolts and the fuel rail assembly.

12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown. 13. Remove the intake manifold. 14. Remove the intake manifold studs.

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15. Remove the direct ignition system (DIS) coil mounting bolts. 16. Remove the DIS coil with the ignition wires attached. 17. Remove the DIS coil mounting bracket bolts. 18. Remove the DIS coil mounting bracket. 19. Remove the electrical exhaust gas recirculation (EEGR) valve adapter bolts. 20. Remove the EEGR valve adapter. 21. Remove the EEGR valve adapter gasket. 22. Remove the spark plugs.

23. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

24. Remove the intake camshaft caps. Maintain the correct positions for installation. 25. Remove the intake camshaft. 26. Remove the intake valve tappet adjusters. 27. Remove the exhaust camshaft caps. Maintain the correct positions for installation. 28. Remove the exhaust camshaft. 29. Remove the exhaust valve tappet adjusters.

30. Compress the valve springs with the valve spring compressor KM­348 and the adapter KM­653. 31. Remove the valve keys. 32. Remove the valve spring compressor KM­348 and the adapter KM­653. 33. Remove the valve spring caps. 34. Remove the valve springs. Maintain the original position of the valve springs for installation.

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35. Remove the valves. Maintain the original position of the valves for installation. 36. Remove the valve stem seals.

Cylinder Head Inspection
1. 2. 3. 4. 5. Clean the sealing surfaces. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blowby. Inspect the cylinder head for cracks. Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.050 mm (0.002 inch) maximum.

6.

7. 8.

Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 134.08 to 134.23 mm. If the cylinder head height is less than 134.08 mm, replace the cylinder head. Inspect all threaded holes for damage. Inspect valve seats for excessive wear and burned spots.

Valve Inspection
1. 2. 3. 4. 5. 6. Inspect the valve stem tip for wear. Inspect the valve key grooves and the oil seal grooves for chips and wear. Inspect the valves for burns or cracks. Inspect the valve stem for burrs and scratches. Inspect the valve stem. The valve stem must be straight. Inspect the valve face for grooving. If the groove is so deep that refacing the valve would result in a sharp edge, replace the valve.

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

9.

Cleaning Procedure
1. 2. 3. 4. Clean the cylinder head. Clean the valve guides. Clean all of the threaded holes. Clean the valves of carbon, oil, and varnish.

Cylinder Head Overhaul
Valve Grind­in 1. 2. Lubricate the valve stem using a fine­grained paste. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.

3. 4.

Check the contact pattern on the valve head and in the cylinder head. Clean the valves, the valve guides, and the cylinder head.

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Valve Grind 1. Ensure that there are no crater line burns on the valve cone. 2. The valve may be reground only two times. Do not grind the valve stem end. 3. The angle at the valve face is 45 degrees. 4. Inspect the assembly height of the intake valves and the exhaust valves.

Valve Guide ­ Ream 1. Measure the diameter of the valve guide using the gauge MKM­571­B and a commercially available inside micrometer.

Important : Valve oversizes may already have been fitted in production. 2. An oversize service code is on the valve guide and the valve stem end. The following table gives the correct size, reamer, and production code for each service. Size Normal 0.075 0.150 3. 4. Reamer ­ KM­805 ­ Production Code ­ 1 2 Service Code K K1 K2

Ream the valve guide from the upper side of the cylinder head to the next oversize. After reaming, cross out the code and emboss the valve guide with the new code.

Valve Seat ­ Cut 1. 2. Place the cylinder head on wooden blocks. Cut the intake and the exhaust valve seats using the guide drift KM­340­7 as follows: S Valve seat ­ A 45­degree surface using the cutter KM­340­13. S Upper correction angle ­ A 30­degree surface using the cutter KM­340­13. S Lower correction angle ­ A 60­degree surface using the cutter KM­340­26. Clean the chippings from the cylinder head.
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4. Inspect the dimension for the valve seat width. S Intake: 1.17 to 1.57 mm (0.046 to 0.062 inch). S Exhaust: 1.4 to 1.8 mm (0.055 to 0.071 inch). Inspect the assembly height of the intake valves and the exhaust valves. If the dimension is exceeded, install new valves. Inspect the assembly height of the intake valves and the exhaust valves again. If the valve assembly height is still too large despite replacing the valves, replace the cylinder head.

5.

Assembly Procedure
1. 2. 3. 4. 5. Install the valve stem seals. Lubricate the valve stems with engine oil. Carefully install the valves in their original positions. Do not damage the valve stem seals. Install the valve springs in their original positions. Install the valve spring caps.

6. 7. 8.

Compress the valve springs with the valve spring compressor KM­348 and adapter KM­653. Install the valve keys. Remove the valve spring compressor KM­348 and adapter KM­653.

9. Lubricate the valve tappet adjusters with engine oil. 10. Install the valve tappet adjusters.

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11. Install the intake camshaft. 12. Install the intake camshaft caps in their original positions. 13. Install the exhaust camshaft. 14. Install the exhaust camshaft caps in their original positions. 15. Install the camshaft cap bolts. 16. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.

Tighten
Tighten the camshaft cap bolts to 16 NSm (12 lb­ft).

17. Install the spark plugs.

Tighten
Tighten the spark plugs to 25 NSm (18 lb­ft). 18. Install the EGR valve adapter gasket. 19. Install the EGR valve adapter. 20. Install the EGR valve adapter bolts.

Tighten
Tighten the exhaust gas recirculation valve adapter bolts to 25 NSm (18 lb­ft). 21. Install the DIS coil mounting bracket. 22. Install the DIS coil mounting bracket bolts.

Tighten
Tighten the direct ignition system coil mounting bracket bolts to 10 NSm (89 lb­in). 23. Install the DIS coil with the ignition wires attached. 24. Install the DIS coil mounting bolts.

Tighten
Tighten the direct ignition system coil mounting bolts to 10 NSm (89 lb­in). 25. Install the intake manifold studs. 26. Install the intake manifold. 27. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

Tighten
Tighten the intake manifold retaining nuts and retaining bolts to 25 NSm (18 lb­ft).

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