Text preview for : en_4j2_1c2.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 : 1C2
1.8L 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 . . . . . . . . . . . . . . . . . . . . . . . . . 1C22 Engine Specifications . . . . . . . . . . . . . . . . . . . . . 1C22 Fastener Tightening Specifcations . . . . . . . . . . 1C24 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 1C26 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 1C26 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1C28 Upper End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C28 Lower End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C210 MAINTENANCE AND REPAIR . . . . . . . . . . . . . 1C212 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1C212 Camshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . 1C212 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C213 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C222 Timing Belt Check and Adjust . . . . . . . . . . . . . 1C224 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C228 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C232 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C233 Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C237 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C238 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Gears . . . . . . . . . . . . . . . . . . . . . . . . . Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistions and Rods . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train Components . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C241 1C243 1C244 1C246 1C251 1C256 1C256 1C263
Crankshaft Bearing and Connecting Rod Beadings Gauging Plastics . . . . . . . . . . . . 1C272 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C275 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C275 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C275 1C275 1C275 1C275
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C275 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C275 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C275
1C2 2I1.8L 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 Protrusion Piston Taper Piston Rings: Ring, End Gap: Top Compression Ring, End Gap: Second Compression Piston Pin: Diameter Pin Offset Clearance: In Piston Clearance: In Rod Length Camshaft: Lift Intake Lift Exhaust End Play Bearing Journal OD Crankshaft: Main Journal: Diameter (All) Out of Round (Maximum) Main Bearing Clearance (All) Crankshaft End Play Service Oversize Connecting Rod Journal:
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Description T18SED 1,799 cm3 (109.7 in3) 81.6 x 86 mm (3.21 in. x 3.38 in.) 9.6 ± 0.02:1 1342
1.8L DOHC 1.8L DOHC 1.8L DOHC
1.8L DOHC
81.575~81.625 mm (3.2116~3.2135 in.) 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.)
1.8L DOHC
81.575~82.105 mm (3.2115~3.2325 in.) 0.0100~0.0300 mm (0.00039~0.00110 in.) 0.5 mm (0.019 in.) Maximum 0.013 (0.0005 in.) 0.3~0.5 mm (0.011~ 0.019 in.) 0.3~0.5 mm (0.011~0.019 in.) 20.9970~20.9985 mm (0.82665~0.82671 in.) 0.8 mm (0.03 in.) Towards Thrust Side 0.0035~0.0140 mm (0.00013~0.00055 in.) Interference Fit in Rod 61.5 mm (2.42 in.) 9.2 mm (0.36 in.) 9.2 mm (0.36 in.) 0.040~0.14 mm (0.0015~0.0055 in.) 42.455~43.470 mm (1.6714~1.7114 in.)
57.974~57.995 mm (2.2824~2.2832 in.) 0.003 mm (0.0001 in.) 0.015~0.040 mm (0.00059~0.00157 in.) 0.070~0.302 mm (0.0027~0.0118 in.) Available in 2 sizes 0.25 mm and 0.50 mm (0.0098~0.0196 in.)
1.8L DOHC ENGINE MECHANICAL 1C2 3
Application Diameter (All) Out of Round (Maximum) Cylinder Head: Valve Stem Protrusion Valve Guide Height Overall Height Minimum Overall Height After Machining Valve System: Valve Lash Compensators Seat Runout (Maximum, All) Face Runout (Maximum, All) Valve Stem Diameter: Intake Exhaust Valve Diameter: Intake Exhaust Valve Seat Width: Intake Exhaust Valve Face Angle Valve Guide Inside Diameter Oil Pump: Gear Lash Outer Gear to Body Outer Gear to Crescent Inner Gear to Crescent End Clearance 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) 0.10~0.20 mm (0.003~0.007 in.) 0.11~0.19 mm (0.004~0.007 in.) 0.40~0.50 mm (0.015~0.019 in.) 0.35~0.40 mm (0.013~0.015 in.) 0.030~0.10 mm (0.001~0.003 in.) 1.0~1.5 mm (0.039~0.059 in.) 1.7~2.2 mm (0.066~0.086 in.) 44° 7.03~7.05 mm (0.276~0.277 in.) 32 ± 0.1 mm (1.2598 ± 0.0039 in.) 29 ± 0.1 mm (1.1417 ± 0.0039 in.) 5.945~5.960 mm (0.2341~0.2346 in.) 5.945~5.960 mm (0.2341~0.2346 in.) Hydraulic Tappet 0.03 mm (0.00118 in.) 0.03 mm (0.00118 in.) 39.2~39.8 mm (1.54~1.56 in.) 13.7~14.0 mm (0.54~0.57 in.) 134 ± 0.025 mm (5.2755~0.0009 in.) 133.9 mm (5.27 in.) Description 48.970~ 48.988 mm (1.9279~1.9287 in.) 0.004 mm (0.00015 in.)
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1C2 4I1.8L DOHC ENGINE MECHANICAL
FASTENER TIGHTENING SPECIFCATIONS
Application Air Cleaner Housing Bolts Automatic Tensioner Bolt Camshaft Bearing Bridge and Oil Pan Scraper Bolts Camshaft Bearing Cap Bolts Camshaft Cover Bolts Charcoal Canister Purge and Exhaust Gas Recirculation Solenoid Bracket Bolt Connecting Rod Bearing Cap Bolts Coolant Bypass Housing and Mounting Bolts Crankshaft Bearing Cap Bolts Crankshaft Pulley Bolts Crankshaft Gear Bolt Cylinder Head Bolts Direct Ignition System Coil and Exhaust Gas Recirculation Mounting Bracket Bolts Engine Mount Bracket Retaining Bolts and Nuts Engine Mount Retaining Bolts EnginetoIntake Manifold Support Bracket Bolts Exhaust Camshaft Gear Bolt Exhaust Flex PipetoCatalytic Converter or Connecting Pipe Retaining Nuts Exhaust Flex PipetoExhaust Manifold Retaining Nuts Exhaust Manifold Heat Shield Bolts Exhaust Manifold Retaining Nuts Flexible Plate Bolts Flywheel Bolts Front Timing Belt Cover Bolts GeneratortoIntake Manifold Strap Bracket Bolt GeneratortoIntake Manifold Support Bracket Bolts Intake Camshaft Gear Bolt Intake Manifold Retaining Bolt and Nuts Intake Manifold Support Bracket Lower Bolt Intake Manifold Support Bracket Upper Bolts Lower Block Support Bracket and Splash Shield Bolts Oil Pan Drain Plug Oil Pan FlangetoTransaxle Bolts NSm 10 25 20 + 45° 8 8 5 35 + 45° + 15° 15 50 + 45° + 15° 20 145 + 30° + 15° 25 + 90° + 90° + 90° 25 55 45 20 50 + 60° + 15° 35 35 8 22 45 65 + 30° + 15° 6 22 37 50 + 60° + 15° 22 25 25 35 35 40 LbFt 18 15 + 45° 26 + 45° + 15° 11 37 + 45° + 15° 15 107 + 30° + 15° 18 + 90° + 90° + 90° 18 41 33 15 37 + 60° + 15° 26 26 16 33 48 + 30° + 15° 16 27 37 + 60° + 15° 16 18 18 26 26 30 LbIn 89 71 71 44 71 53
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1.8L DOHC ENGINE MECHANICAL 1C2 5
Application Oil Pan Retaining Bolts Oil Pressure Switch Oil Suction Pipe Bolts Oil Suction Pipe Support Bracket Bolts Oil Pump Rear Cover Bolts Oil Pump Retaining Bolts Pulse Pickup Sensor Disc Rear Timing Belt Cover Bolts Safety Relief Valve Bolt Spark Plug Cover Bolts Spark Plugs Thermostat Housing Mounting Bolts Throttle Cable Bracket Bolts Timing Belt Automatic Tensioner Bolts Timing Belt Idler Pulley Bolt Timing Belt Idler Pulley Nut Transaxle Bell Housing Bolts Transaxle Torque Converter Bolts NSm 10 40 8 16 6 10 13 7 30 8 20 15 8 25 25 25 75 60 LbFt 30 10 22 15 11 18 18 18 55 44 LbIn 89 71 53 53 89 62 71 71
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1C2 6I1.8L DOHC ENGINE MECHANICAL
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM653 Adapter
KM571B Gauge
KM135 Adapter
DW110060 Engine Assembly Support Fixture
KM805 Valve Guide Reamer
KM412 Engine Overhaul Stand
J36792 Crankshaft Rear Oil Seal Installer
KM348 Valve Spring Compressor
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1.8L DOHC ENGINE MECHANICAL 1C2 7
KM635 Crankshaft Rear Oil Seal Installer
KM470B Angular Torque Gauge
KM427 Piston Pin Service Set
KM498B Pressure Gauge
J8087 Cylinder Bore Check Gauge
J8037 Universal Piston Ring Compressor
KM3400 Cutter Set Includes: KM3407 Guide Drift KM34013 Cutters KM34026 Cutters
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1C2 8I1.8L DOHC ENGINE MECHANICAL
COMPONENT LOCATOR
UPPER END
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1.8L DOHC ENGINE MECHANICAL 1C2 9
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Bolt Spark Plug Cover Oil Filler Cap Oil Filler Cap Seal Bolt Camshaft Cover Camshaft Cover Gasket Tappet Adjuster Valve Key Valve Spring Cap Valve Spring Valve Stem Seal Valve Spring Seat Valve Guide Intake Valve Seat Ring Exhaust Valve Seat Ring Intake Valve Exhaust Valve Bolt Front Camshaft Cap Head Bolt Bolt Intermediate Camshaft Cap Exhaust Gas Recirculation Adapter Exhaust Gas Recirculation Adapter Gasket Cylinder Head Exhaust Manifold Gasket 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. Exhaust Manifold Nut Exhaust Manifold Heat Shield Cylinder Head Gasket Bolt Thermostat Housing Thermostat Housing Gasket Stud Sleeve Plug Bolt Camshaft Position Sensor Oil Gallery Plug Exhaust Camshaft Seal Ring Camshaft Gear Washer Camshaft Gear Bolt Intake Camshaft Intake Manifold Gasket Intake Manifold Throttle Body Gasket Throttle Body Nut Charcoal Canister Purge Solenoid Exhaust Gas Recirculation Solenoid
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1C2 10I1.8L DOHC ENGINE MECHANICAL
LOWER END
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1.8L DOHC ENGINE MECHANICAL 1C2 11
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. Connecting Rod Bearing Set Connecting Rod Bolt Piston Ring Set Piston Pin Piston Engine Block Sleeve Water Jacket Cap Bolt (Manual Transaxle) Flywheel (Manual Transaxle) Flexible Plate (Automatic Transaxle) Bolt (Automatic Transaxle) Clamp Hose Clamp Engine Ventilation Pipe Bolt Gasket Needle Sleeve Crankshaft Rear Seal Crankshaft Transmitter Disk Bolt Oil Pan Scraper Oil Pan Drain Plug Washer Bolt Sleeve Gasket Bolt Oil Pump Cover Ring Gear Gear Oil Pressure Switch Washer Washer Oil Duct Outlet Plug Connecting Piece Seal Ring Oil Filter 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. Bypass Valve Pressure Relief Valve Plunger Pressure Relief Valve Spring Seal Ring Pressure Relief Valve Plug Seal Ring Bolt Oil Suction Pipe Bolt Rear Timing Belt Cover Bolt Special Bolt Idler Pulley Stud Nut Bolt Tensioner Bolt Thrust Inner Washer Woodruff Key Crankshaft Gear Thrust Outer Washer Bolt Camshaft Drive Belt Gasket Front Timing Belt Cover Bolt Bushing Plug Bushing Oil Gallery Plug Bolt Water Pump Seal Ring Crankshaft Position Sensor Bolt Knock Sensor* Bolt Bolt Crankshaft Bearing Bridge
* : 2.0L DOHC Engine
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1C2 12I1.8L DOHC ENGINE MECHANICAL
MAINTENANCE AND REPAIR
ONVEHICLE SERVICE CAMSHAFT COVER
Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Disconnect the breather tube from the valve cover. Disconnect all of the necessary vacuum lines. Remove the spark plug cover bolts. Remove the spark plug cover.
6. 7. 8.
Disconnect the ignition wires from the spark plugs. Disconnect the camshaft position sensor connector. Remove the camshaft cover bolts.
9. Remove the camshaft cover. 10. Remove the camshaft cover gasket from the camshaft cover.
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1.8L DOHC ENGINE MECHANICAL 1C2 13 Installation Procedure
1. 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. Install the new camshaft cover gasket to the camshaft cover.
2.
3. 4.
Install the camshaft cover. Install the camshaft cover bolts.
Tighten
5. 6. Tighten the camshaft cover bolts to 8 NSm (71 lbin). Connect the ignition wires to the spark plugs. Install the spark plug cover.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lbin).
7. 8. 9. 10. 11.
Install the spark plug cover bolts. Connect the camshaft position sensor connector. Connect all of the necessary vacuum lines. Connect the breather tube to the camshaft cover. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required KM470B Angular Torque Gauge J28467B Engine Assembly Support Fixture
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 cable. Disconnect the electronic control mdule (ECM) ground terminal. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
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1C2 14I1.8L DOHC ENGINE MECHANICAL
6. 7. 8. Disconnect the manifold air temperature (MAT) sensor connector. Disconnect the breather tube from the camshaft cover. Disconnect the air cleaner outlet hose from the throttle body.
9. 10. 11. 12. 13. 14.
Disconnect the direct ignition system (DIS) coil connector. Disconnect the oxygen (O2) sensor connector, if equipped. Disconnect the idle air control (IAC) valve connector. Disconnect the throttle position sensor (TPS) connector. Disconnect the engine coolant temperature (ECT) sensor connector. Disconnect the coolant temperature sensor (CTS) connector.
15. Remove the air cleaner housing bolts. 16. Remove the air cleaner housing. 17. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. 18. Remove the right front wheel well splash shield. 19. Install the engine assembly support fixture J28467B. 20. Remove the right engine mount bracket and bolts.
21. Disconnect the upper radiator hose at the thermostat housing. 22. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 23. Remove the crankshaft pulley bolts. 24. Remove the crankshaft pulley.
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1.8L DOHC ENGINE MECHANICAL 1C2 15
25. Remove the front timing belt cover bolts. 26. Remove the front timing belt cover.
27. Remove the timing belt. Refer to Timing Belt" in this section. 28. Disconnect the breather tube at the camshaft cover. 29. Remove the spark plug cover bolts. 30. Remove the spark plug cover. 31. Disconnect the ignition wires from the spark plugs. 32. Remove the camshaft cover bolts. 33. Remove the camshaft cover and the camshaft cover gasket.
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 34. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt. 35. Remove the intake camshaft gear. 36. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt. 37. Remove the exhaust camshaft gear.
38. Remove the timing belt automatic tensioner bolts. 39. Remove the timing belt automatic tensioner.
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1C2 16I1.8L DOHC ENGINE MECHANICAL
40. 41. 42. 43. Remove the timing belt idler pulley bolt and nut. Remove the timing belt idler pulleys. Remove the engine mount bolts. Remove the engine mount.
44. Remove the rear timing belt cover bolts. 45. Remove the rear timing belt cover.
46. Remove the exhaust flex pipe retaining nuts at the exhaust manifold studs. 47. Disconnect all of the necessary vacuum hoses.
48. Disconnect the fuel feed line at the fuel rail. 49. Remove the generator adjusting bracket retaining bolt and the bracket. 50. Disconnect the coolant hose at the rear cylinder head and ignition coil exhaust gas recirculation (EGR) bracket. 51. Disconnect the surge tank coolant hose at the throttle body. 52. Remove the fuel rail assembly. Refer to Section 1F, Engine Controls.
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1.8L DOHC ENGINE MECHANICAL 1C2 17
53. Remove the generatortointake manifold support bracket bolts at the cylinder head and the intake manifold. 54. Remove the generator support bracket. 55. Remove the intake manifoldtogenerator strap bracket bolt and loosen the bolt on the generator. 56. Move the strap clear of the intake manifold. 57. Remove the charcoal canister purge (CCP) and EGR solenoid bracket bolt and move the bracket clear.
58. Disconnect the throttle cable at the throttle body and the intake manifold. 59. Loosen all of the cylinder head bolts gradually and in the sequence shown. 60. Remove the cylinder head bolts. 61. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head. 62. Remove the cylinder head gasket.
Cleaning Procedure
1. 2. Clean the gasket surfaces of the cylinder head and the engine block. Make sure the gasket 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. 3. 4. Install the cylinder head gasket. Install the cylinder head with the intake manifold and the exhaust manifold attached. Install the cylinder head bolts. Tighten the cylinder head bolts gradually and in the sequence shown.
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1C2 18I1.8L DOHC ENGINE MECHANICAL Tighten
Tighten the cylinder head bolts to 25 NSm (18 lbft) and turn the bolts another 3 turns of 90 degrees using the angular torque gauge KM470B.
5. 6. 7.
Connect the throttle cable at the throttle body and the intake manifold. Install the generatortointake manifold support bracket. Install the intake generatortomanifold support bracket bolts.
Tighten
Tighten the generatortointake manifold support bracket bolts to the intake manifold to 37 NSm (27 lb ft). Install the intake manifold support bracket bolt to the generator.
8.
Tighten
Tighten the generatortointake manifold support bracket bolt at the generator to 22 NSm (16 lbft). 9. Connect the surge tank coolant hose at the throttle body. 10. Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket. 11. 12. 13. 14. Connect the fuel feed line at the fuel rail. Connect the fuel return line at the fuel rail. Connect all of the necessary vacuum hoses. Install the fuel rail assembly. Refer to Section 1F, Engine Controls.
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1.8L DOHC ENGINE MECHANICAL 1C2 19
15. Install the exhaust flex pipe retaining nuts at the exhaust manifold studs.
Tighten
Tighten the exhaust flex pipetoexhaust manifold retaining nuts to 35 NSm (26 lbft). 16. Install the rear timing belt cover. 17. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 7 NSm (62 lbin). 18. Install the engine mount and the retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm (33 lbft). 19. Install the timing belt automatic tensioner. 20. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolts to 25 NSm (18 lbft). 21. Install the timing belt idler pulleys. 22. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm (18 lbft).
23. Install the camshaft gears with the timing marks at the front. 24. Insert the guide pin of the intake camshaft into the "IN" bore. 25. Insert the guide pin of the exhaust camshaft into the "EX" bore.
26. Install the camshaft gears by counterholding on the hex of the camshaft with an openended wrench. 27. Install the camshaft gear with a new bolt to the camshaft.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37 lbft) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge. 28. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
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1C2 20I1.8L DOHC ENGINE MECHANICAL Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37 lbft) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge.
29. 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. 30. Install the camshaft cover and the camshaft cover gasket. 31. Install the camshaft cover washers. 32. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lbin).
33. Connect the ignition wires to the spark plugs. 34. Install the spark plug cover. 35. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lbin). 36. Connect the breather tube to the camshaft cover. 37. Align the timing marks on the camshaft gears to the notches on the camshaft cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
38. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
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1.8L DOHC ENGINE MECHANICAL 1C2 21
39. Install the timing belt. 40. Check and adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.
41. Install the front timing belt cover. 42. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53 lbin). 43. Install the crankshaft pulley. 44. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 12 NSm (106 lb in).
45. Install the right engine mount bracket and retaining bolts.
Tighten
46. 47. 48. 49. 50. Tighten the engine mount bracket retaining bolts to 55 NSm (41 lbft). Remove the engine assembly lift support J28467B. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. Connect the upper radiator hose to the thermostat housing. Install the right front wheel well splash shield. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
51. Install the air cleaner housing. 52. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb in). 53. Connect the air cleaner outlet hose to the throttle body. 54. Connect the breather tube to the camshaft cover. 55. Connect the MAT sensor connector.
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1C2 22I1.8L DOHC ENGINE MECHANICAL
56. 57. 58. 59. 60. Connect the CTS connector. Connect the engine CTS connector. Connect the IAC valve connector. Connect the TPS connector. Install the CCP and the EGR solenoid bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 NSm (44 lbin).
61. 62. 63. 64. 65. 66.
Connect the DIS coil connector. Connect the O2 sensor connector, if equipped. Connect the ECM ground terminal. Install the fuel pump fuse. Connect the negative battery ground cable. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the timing belt. Refer to "Timing Belt" in this section. Disconnect the breather tube at the camshaft cover. Disconnect the engine ventilation hose at the camshaft cover. Remove the spark plug cover bolts. Remove the spark plug cover. Disconnect the ignition wires from the spark plugs. Remove the camshaft cover bolts. Remove the camshaft cover washers. Remove the camshaft cover and the camshaft cover gasket.
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt. 11. Remove the intake camshaft gear. 12. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt. 13. Remove the exhaust camshaft gear.
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1.8L DOHC ENGINE MECHANICAL 1C2 23
14. Loosen the camshaft bearing cap bolts in stages of onehalf to one turn. 15. Remove the camshaft bearing cap bolts from the cylinder head. 16. Remove the camshafts. 17. Remove the seal ring from the camshafts. Important : The camshaft must detach evenly from the bearing seats in the front guide bearing. 18. Check the camshaft and bearing seats for wear and replace them if necessary.
Installation Procedure
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 1. Lubricate the camshaft journals and the camshaft caps with engine oil. 2. Install the intake camshaft. 3. Install the intake camshaft caps in their original positions. 4. Install the intake camshaft cap bolts. 5. Install the exhaust camshaft. 6. Install the exhaust camshaft caps in their original positions. 7. Install the exhaust camshaft cap bolts. 8. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.
Tighten
Tighten the camshaft bearing cap bolts to 8 NSm (71 lbin). 9. Measure the intake camshaft end play and the exhaust camshaft end play. Refer to "Engine Specifications" in this section. 10. Install the intake camshaft gear. 11. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37 lbft) plus 60 degrees and 15 degrees using the angular torque gauge KM470B.
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1C2 24I1.8L DOHC ENGINE MECHANICAL
12. Install the exhaust camshaft gear. 13. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37 lbft) plus 60 degrees and 15 degrees using the angular torque gauge KM470B.
14. Install the camshaft cover and the camshaft cover gasket. 15. Install the camshaft cover washers. 16. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lbin).
17. Connect the ignition wires to the spark plugs. 18. Install the spark plug cover. 19. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lbin). 20. Connect the breather tube to the camshaft cover. 21. Connect the engine ventilation hose to the camshaft cover. 22. Install the timing belt. Refer to "Timing Belt" in this section.
TIMING BELT CHECK AND ADJUST
(LeftHand Drive Shown, RightHand Drive Similar) Adjustment Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Disconnect the manifold air temperature (MAT) sensor connector. Remove the air cleaner outlet hose from the throttle body. Remove the breather tube from the camshaft cover.
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5. 6. 7. 8. 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.
Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 10. Remove the crankshaft pulley bolts. 11. Remove the crankshaft pulley. 12. Remove the right engine mount bracket. Refer to "Engine Mount" in this section.
9.
13. Remove the front timing belt cover bolts. 14. Remove the front timing belt cover.
15. Rotate the crankshaft at least one full turn clockwise using the crankshaft gear bolt. 16. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
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1C2 26I1.8L DOHC ENGINE MECHANICAL
17. Align the camshaft gear timing marks. Use the exhaust gear mark for the exhaust gear and the intake gear mark for the intake gear, since the gears are interchangeable
18. Loosen the automatic tensioner bolt. To relieve the belt tension, turn the hexkey tab counterclockwise. 19. Rotate the automatic tensioner hexkey tab clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.
20. Tighten the automatic tensioner bolt. 21. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt. 22. Check the automatic tensioner pointer.
23. When the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch on the timing belt automatic tensioner bracket, the belt is tensioned correctly.
Tighten
Tighten the automatic tensioner bolt to 25 NSm (18 lb ft).
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24. Install the front timing belt cover. 25. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53 lbin).
26. Install the crankshaft pulley. 27. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 20 NSm (15 lbft). 28. Install the right engine mount bracket. Refer to "Engine Mount" in this section. 29. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
30. Install the right front wheel well splash shield. 31. Install the right front wheel. Refer to Section 2E, Tires and Wheels. 32. Install the air cleaner housing. 33. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb in). 34. Connect the air cleaner outlet hose to the throttle body.
35. Connect the breather tube to the camshaft cover. 36. Connect the MAT sensor connector. 37. Connect the negative battery cable.
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1C2 28I1.8L DOHC ENGINE MECHANICAL
TIMING BELT
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Disconnect the manifold air temperature (MAT) sensor connector. Disconnect the air cleaner outlet hose from the throttle body. Disconnect the breather tube from the camshaft cover.
5. 6. 7. 8.
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.
Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 10. Remove the crankshaft pulley bolts. 11. Remove the crankshaft pulley. 12. Remove the right engine mount bracket. Refer to "Engine Mount" in this section.
9.
13. Remove the front timing belt cover bolts. 14. Remove the front timing belt cover.
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15. Using the crankshaft gear 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.
Notice : The camshaft gears must align with the notch on the camshaft cover or damage to the engine could result. 16. Align the camshaft gears with the notch on the camshaft cover. Important : Use the intake gear mark for the intake camshaft gear and the exhaust gear mark for the exhaust camshaft gear since both gears are interchangeable.
17. Remove the timing belt. 18. Loosen the automatic tensioner bolt. Turn the hex key tab to relieve belt tension.
Installation Procedure
1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
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1C2 30I1.8L DOHC ENGINE MECHANICAL
2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
3.
Install the timing belt.
4.
5.
Turn the hexkey tab in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch. Install the automatic tensioner bolt.
Tighten
6. 7. Tighten the automatic tensioner bolt to 25 NSm (18 lb ft). Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt. Recheck the automatic tensioner pointer.
8. 9.
Install the front timing belt cover. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53 lbin). 10. Install the right engine mount bracket. Refer to "Engine Mounts" in this section.
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11. Install the crankshaft pulley. 12. Install the crankshaft pulley bolts.
Tighten
13. 14. 15. 16. 17. Tighten the crankshaft pulley bolts to 20 NSm (15 lb ft). Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. Install the right front wheel well splash shield. Refer to Section 9R, Body Front End. Install the right front wheel. Refer to Section 2E, Tires and Wheels. Install the air cleaner housing. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb in). 18. Connect the air cleaner outlet hose to the throttle body. 19. Connect the breather tube to the camshaft cover. 20. Connect the MAT sensor connector. 21. Connect the negative battery cable.
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1C2 32I1.8L DOHC ENGINE MECHANICAL
OIL PAN
Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Drain the engine oil from the engine crankcase. Remove the exhaust flex pipe retaining nuts from the exhaust manifold. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe. Remove the exhaust flex pipe.
6.
Remove the oil pan flangetotransaxle retaining bolts.
7. 8.
Remove the oil pan retaining bolts. Remove the oil pan from the engine block.
Cleaning Procedure
1. 2. 3. 4. 5. 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. Clean the oil pan scraper.
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1.8L DOHC ENGINE MECHANICAL 1C2 33 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 flangetotransaxle retaining bolts.
Tighten
Tighten the oil pan flangetotransaxle bolts to 40 NSm (30 lbft).
5. 6.
Install the exhaust flex pipe. Install the exhaust flex pipe retaining nuts to the exhaust manifold.
Tighten
7. Tighten the exhaust flex pipetoexhaust manifold retaining nuts to 35 NSm (26 lbft). Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.
Tighten
8. 9. Tighten the exhaust flex pipetocatalytic converter or connecting pipe retaining nuts to 35 NSm (26 lbft). Connect the negative battery cable. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 35 NSm (26 lbft). 10. Refill the engine crankcase with engine oil.
OIL PUMP
Tools Required KM498B Pressure Gauge KM135 Adapter
Engine Oil Pressure Inspection Procedure
1. 2.
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Remove the right front wheel well oil pan scraper. Refer to Section 9R, Body Front End. Disconnect the oil pressure switch connector.
1C2 34I1.8L DOHC ENGINE MECHANICAL
3. 4. 5. 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.
6.
7.
Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lbft). 8. Connect the electrical connector to the oil pressure switch. 9. Install the right front wheel well oil pan scraper. Refer to Section 9R, Body Front End. 10. Check the oil level. Add oil until it reaches the full mark.
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. 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.
5. 6. 7.
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.
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Remove the oil pump retaining bolts. Carefully separate the oil pump and gasket from the engine block and oil pan. 10. Remove the oil pump. 8. 9.
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. 7.
Remove the oil pump rear cover bolts. Remove the rear cover. 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 6 NSm (53 lb in). 11. Install the safety relief valve, spring, washer and bolt.
Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lbft).
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1C2 36I1.8L DOHC ENGINE MECHANICAL 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 retaining bolts to 10 NSm (89 lb in).
3.
Install a new oil pumptocrankshaft seal. Coat the lip of the seal with a thin coat of grease.
4. 5.
Coat the threads of the oil suction pipe and support bracket bolts with Loctite® 242. Install the oil suction pipe and the bolts.
Tighten
Tighten the oil suction pipe bolts to 10 NSm (89 lbin) and support bracket bolts to 6 NSm (53 lbin).
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. Connect the negative battery cable.
6. 7. 8.
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1.8L DOHC ENGINE MECHANICAL 1C2 37
ENGINE MOUNT
Tools Required J28467B Engine Assembly Support Fixture X28467560 Engine Assembly Support Channel
Removal Procedure
1. 2. Disconnect the negative battery cable. Support the engine assembly using the engine assembly support fixture J28467B, and the engine assembly support channel X28467560. Disconnect the manifold air temperature (MAT) sensor connector. Disconnect the air cleaner outlet hose from the throttle body. Remove the air cleaner housing bolts. Remove the air cleaner housing.
3. 4. 5. 6. 7.
Remove the right front splash shield. Refer to Section 9R, Body Font End. 8. Remove the engine mount bracket retaining bolts. 9. Remove the engine mount bracket. 10. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
11. Remove the front timing belt cover bolts. 12. Align the crankshaft pulley timing mark with the pointer, and the camshaft gears with the timing marks on the rear cover, by turning the crankshaft gear bolt. 13. Loosen the timing belt automatic tensioner bolt. 14. Turn the hexkey tab to relieve belt tension. 15. Remove the timing belt idler pulley bolt and nut. 16. Remove the timing belt idler pulley. 17. Remove the engine mount retaining bolts. 18. Remove the engine mount.
Installation Procedure
1. 2. Install the engine mount. Install the engine mount retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm (33 lbft).
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1C2 38I1.8L DOHC ENGINE MECHANICAL
3. 4. Install the timing belt idler pulleys. Install the timing belt idler pulley bolt and nut.
Tighten
5. Tighten the timing belt idler pulley bolt and nut to 25 NSm (18 lbft). Tension the timing belt by turning the timing belt automatic tensioner hexkey tab counterclockwise until the pointer is aligned to the indicator.
Tighten
Tighten the timing belt automatic tensioner bolt to 25 NSm (18 lbft).
6. 7.
Install the front timing belt cover. Install the front timing belt cover bolts.
Tighten
8. Tighten the front timing belt cover bolts to 6 NSm (53 lbin). Install the engine mount bracket and retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55 NSm (41 lbft). 9. Remove the engine assembly support fixture J28467B, and the channel X28467560. 10. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 11. Connect the negative battery cable.
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 cable. Disconnect the charcoal canister purge (CCP) and exhaust gas recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt. Drain the engine coolant. Refer to Section 1D, Engine Cooling. Disconnect the manifold air temperature sensor (MAT) connector. Disconnect the air cleaner outlet hose from the throttle body.
5. 6. 7.
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8. Disconnect the idle air control (IAC) valve connector. 9. Disconnect the throttle position sensor (TPS) connector. 10. Disconnect the manifold absolute pressure (MAP) sensor connector. 11. Disconnect the coolant hoses at the throttle body.
12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold. 13. Disconnect the throttle cable from the throttle body and the intake manifold. 14. Remove the throttle cable bracket bolts from the intake manifold. 15. Remove the throttle cable bracket. 16. Remove the generatortointake manifold strap bracket bolts and strap.
17. Remove the fuel rail as an assembly. Refer to Section 1F, Engine Controls. 18. Remove the generatortointake manifold support bracket bolts. 19. Remove the generatortointake manifold support bracket. 20. Remove the intake manifold support bracket bolt at the engine block and the intake manifold. 21. Remove the intake manifold support bracket.
22. Remove the intake manifold retaining bolt and nuts in the sequence shown. 23. Remove the intake manifold. 24. Remove the intake manifold gasket. 25. Clean the sealing surfaces of the intake manifold and the cylinder head.
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1C2 40I1.8L DOHC ENGINE MECHANICAL Installation Procedure
1. 2. 3. Install the intake manifold gasket. Install the intake manifold. Install the intake manifold retaining bolt and nuts in the sequence shown.
Tighten
4. Tighten the intake manifold retaining bolt and nuts to 22 NSm (16 lbft). Install the generatortointake manifold strap bracket and bolts.
Tighten
Tighten the generatortointake manifold strap bracket bolts to 22 NSm (16 lbft). 5. 6. Install the intake manifold support bracket. Install the intake manifold support bracket upper bolts to the intake manifold.
Tighten
7. Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 NSm (18 lbft). Install the intake manifold support bracket lower bolt to the engine block.
Tighten
8. Tighten the intake manifold support bracket lower bolt to the engine block to 25 NSm (18 lbft). Install the generatortointake manifold support bracket and bolts.
Tighten
Tighten the generatortointake manifold support bracket bolts to 37 NSm (27 lbft). Install the fuel rail and injector cover as an assembly. Refer to Section 1F, Engine Controls. 10. Install the throttle cable bracket. 11. Install the throttle cable bracket bolts. 9.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm (71 lbin). 12. Connect the throttle cable to the intake manifold and the throttle body. 13. Connect all of the necessary vacuum lines that were previously disconnected.
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14. 15. 16. 17. Connect the MAP sensor connector. Connect the coolant hoses to the throttle body. Connect the IAC valve connector. Connect the TPS connector.
18. Connect the air cleaner outlet hose to the throttle body. 19. Connect the MAT sensor connector. 20. Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 NSm (44 lbin). 21. Install the fuel pump fuse. 22. Connect the negative battery cable. 23. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.
EXHAUST MANIFOLD
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Disconnect the oxygen (O2) sensor connector, if equipped. Remove the exhaust manifold heat shield bolts. Remove the exhaust manifold heat shield.
5.
Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
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1C2 42I1.8L DOHC ENGINE MECHANICAL
6. 7. 8. 9. Remove the exhaust manifold retaining nuts in the sequence shown. Remove the exhaust manifold. Remove the exhaust manifold gasket. Clean the sealing surfaces of the exhaust manifold and the cylinder head.
Installation Procedure
1. 2. 3. Install the exhaust manifold gasket. Install the exhaust manifold. Install the exhaust manifold retaining nuts and tighten in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts 22 NSm (16 lbft).
4.
Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.
Tighten
Tighten the exhaust flex pipetoexhaust manifold retaining nuts to 35 NSm (26 lbft).
5. 6.
Install the exhaust manifold heat shield. Install the exhaust manifold heat shield bolts.
Tighten
7. 8. Tighten the exhaust manifold heat shield bolts to 8 NSm (71 lbin). Connect the O2 sensor connector, if equipped. Connect the negative battery.
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1.8L DOHC ENGINE MECHANICAL 1C2 43
CAMSHAFT GEARS
Removal Procedure
1. 2. 3. 4. 5. 6. Disconnect the negative battery cable. Remove the timing belt. Refer to "Timing Belt" in this section. Remove the spark plug cover bolts. Remove the spark plug cover. Disconnect the ignition wires from the spark plugs. Disconnect the breather tubes from the camshaft cover. Remove the camshaft cover bolts. Remove the camshaft cover washers. Remove the camshaft cover and the camshaft cover gasket.
7. 8. 9.
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt. 11. Remove the intake camshaft gear. 12. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt. 13. Remove the exhaust camshaft gear.
Installation Procedure
Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts. 1. 2. Install the intake camshaft gear. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37 lbft) plus 60 degrees and 15 degrees using the angular torque gauge KM470B.
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1C2 44I1.8L 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 50 NSm (37 lbft) plus 60 degrees and 15 degrees using the angular torque gauge KM470B.
5.
6. 7. 8.
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 washers. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lbin).
9.
Connect the crankcase breather tubes to the camshaft cover. 10. Connect the ignition wires to the spark plugs. 11. Install the spark plug cover. 12. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lbin). 13. Install the timing belt. Refer to "Timing Belt" in this section. 14. Connect the negative battery cable.
REAR TIMING BELT COVER
Tools Required KM470B Angular Torque Gauge
Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the timing belt. Refer to "Timing Belt" in this section. Remove the camshaft gears. Refer to "Camshaft Gears" in this section. Remove the timing belt automatic tensioner bolt. Remove the timing belt automatic tensioner.
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1.8L DOHC ENGINE MECHANICAL 1C2 45
6. 7. 8. 9. 10. 11. Remove the timing belt idler pulley bolt and nut. Remove the timing belt idler pulleys. Remove the engine mount retaining bolts. Remove the engine mount. Remove the crankshaft gear bolt. Remove the crankshaft gear.
12. Remove the rear timing belt cover bolts. 13. 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 7 NSm (62 lbin). 3. Install the engine mount and retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm (33 lbft). 4. 5. Install the timing belt idler pulleys. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm (18 lbft). Tighten the timing belt idler pulley nut to 25 NSm (18 lbft). Install the crankshaft timing belt drive gear and bolt.
6.
Tighten
Tighten the crankshaft gear bolt to 145 NSm (107 lb ft) plus 30 degrees and plus 15 degrees using the angular torque gauge KM470B.
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1C2 46I1.8L DOHC ENGINE MECHANICAL
7. 8. Install the timing belt automatic tensioner and bolt. Install the camshaft gears. Refer to "Camshaft Gears" in this section. 9. Install the timing belt and timing belt cover. Refer to "Timing Belt" in this section. 10. Connect the negative battery cable.
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.
6.
Discharge the air conditioning (A/C) system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems. 7. Disconnect the manifold air temperature (MAT) sensor connector. 8. Remove the air cleaner outlet hose from the throttle body and air cleaner housing. 9. Disconnect the breather tubes from the camshaft cover. 10. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. 11. Remove the right front wheel well splash shield. Refer to Section 9R, Body Font End. 12. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 13. Drain the engine coolant. Refer to Section 1D, Engine Cooling. 14. Remove the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling. 15. Disconnect the upper radiator hose from the thermostat housing. 16. Disconnect the power steering return hose from the power steering pump. 17. Disconnect the power steering pressure hose from the power steering pump. 18. Disconnect the electrical connector at the direct ignition system (DIS) coil and the electronic control module (ECM) ground terminal and at the starter motor.
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19. Disconnect the oxygen (O2) sensor connector, if equipped. 20. Disconnect the idle air control (IAC) valve connector. 21. Disconnect the throttle position sensor (TPS) connector. 22. Disconnect the engine coolant temperature sensor (CTS) connector. 23. Disconnect the CTS connector. 24. Disconnect the generator voltage regulator connector and power lead.
25. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose. 26. Disconnect the fuel return line at the fuel rail. 27. Disconnect the fuel feed line at the fuel rail. 28. Remove the fuel rail and injector channel cover as an assembly. Refer to Section 1F, Engine Controls.
29. Disconnect the throttle cable from the throttle body and the intake manifold bracket. 30. Disconnect the coolant hose at the throttle body. 31. Disconnect the heater outlet hose at the coolant pipe. 32. Disconnect the coolant bypass hose from the cylinder head. 33. Disconnect the surge tank coolant hose from the coolant pipe. 34. Disconnect the lower radiator hose from the coolant pipe. 35. Disconnect the starter solenoid "S" terminal wire and power lead. 36. Remove the A/C compressor. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems. 37. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs. 38. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe. 39. Remove the exhaust flex pipe.
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1C2 48I1.8L DOHC ENGINE MECHANICAL
40. Remove the crankshaft pulley bolts. 41. Remove the crankshaft pulley. 42. Disconnect the vacuum lines at the charcoal canister purge solenoid. 43. Disconnect the electrical connector at the charcoal canister purge (CCP) and the exhaust gas recirculation (EGR) solenoid. 44. Disconnect the electrical connector at the oil pressure switch. 45. Disconnect the crankshaft position sensor (CPS) connector. 46. Disconnect the knock sensor connector.
47. Remove the transaxle torque converter bolts, if automatic transaxle equipped. 48. Remove the transaxle bell housing bolts and the oil pan flange bolts. 49. Support the transaxle with a floor jack. 50. Install the engine lifting device.
51. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt. 52. Remove the right engine mount bracket from the engine block and frame mount. Refer to Section 5B, Five Speed Manual Transaxle, or Section 5A, Automatic Transaxle. 53. Separate the engine block from the transaxle. 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 oil pan flangetotransaxle bolts.
Tighten
Tighten the oil pan flangetotransaxle bolts to 40 NSm (30 lbft).
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5. 6. Install the right engine mount to the engine block mount and the frame mount. Install the right engine mount bracket retaining bolts and nuts.
Tighten
Tighten the engine mount bracket retaining bolts and nuts to 55 NSm (41 lbft).
7. 8. 9.
Remove the floor jack used for support of the transmission. Remove the engine lifting device. Install the transaxle torque converter bolts, if automatic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 60 NSm (44 lbft).
10. Connect the vacuum lines at the CCP solenoid. 11. Connect the electrical connector to the CCP and the EGR solenoid. 12. Connect the oil pressure switch connector. 13. Install the crankshaft pulley. 14. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 20 NSm (15 lb ft) using a torque wrench.
15. Connect the CPS connector. 16. Install the exhaust flex pipe. 17. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.
Tighten
Tighten the exhaust flex pipetoexhaust manifold retaining nuts to 35 NSm (26 lbft).
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18. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipetocatalytic converter or connecting pipe retaining nuts to 35 NSm (26 lbft). 19. Connect the power steering pressure hose. 20. Connect the power steering return hose. 21. Install the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
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 the fuel return line to fuel rail. 27. Install the fuel rail and injector channel cover as an assembly. Refer to Section 1F, Engine Controls.
28. Connect all of the necessary vacuum lines including the brake booster vacuum hose. 29. Connect the O2 sensor connector, if equipped. 30. Connect the starter solenoid "S" terminal wire and power lead. 31. Connect the generator voltage regulator connector. 32. Connect the CTS connector. 33. Connect the engine CTS connector. 34. Connect the TPS connector. 35. Connect the IAC valve connector. 36. Connect the MAP sensor connector. 37. Connect the knock sensor, if necessary
38. Connect the electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor. 39. Install the air cleaner outlet hose between the throttle body and the air cleaner housing. 40. Connect the breather tubes to the camshaft cover. 41. Connect the MAT sensor connector. 42. Install the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.
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43. Connect the lower radiator hose to the coolant pipe. 44. Connect the upper radiator hose to the thermostat housing. 45. Connect the heater inlet hose to the cylinder head. 46. Connect the heater outlet hose to the coolant pipe. 47. Connect the coolant surge tank hose to the coolant pipe. 48. Connect the coolant hose to the throttle body.
49. Connect the throttle cable to the throttle body and the intake manifold bracket. 50. Install the fuel pump fuse. 51. Connect the negative battery cable. 52. Refill the engine crankcase with engine oil. 53. Refill the engine coolant system. Refer to Section 1D, Engine Cooling. 54. Bleed the power steering system. Refer to Section 6A, Power Steering. 55. Refill the A/C refrigerant system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. 56. Install the hood. Refer to Section 9R, Body Front End.
PISTONS AND RODS
Tools Required J8037 Universal Piston Ring Compressor J8087 Cylinder Bore Check Gauge KM427 Piston Pin Service Set KM470B Angular Torque Gauge
Removal Procedure
1. Remove the cylinder head with the intake manifold and 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 and support bracket bolts. Remove the oil suction pipe. Remove the crankshaft bearing bridge and the oil pan scraper bolts. Remove the crankshaft bearing bridge and the oil pan scraper.
2. 3. 4. 5. 6.
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7. 8. 9. 10. 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. 11. Remove the upper piston connecting rod bearing. 12. Ridge ream the cylinder wall.
CAUTION : Use care when handling the piston. Worn piston rings are sharp and may cause injury. 13. Remove the piston. 14. Use a piston ring expander tool to expand the piston rings. 15. Remove the piston rings.
16. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM427. 17. 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.
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8. Inspect the piston for fit to the connecting rod.
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 cylinder bore check gauge J8087. 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
Important : For ease of installation of the piston pin, the connecting rod should be heated to 2805C. Heat the upper connecting rod only. Use commercial thermocolor material to determine the correct temperature. When the thermocolor material changes from black to green, the temperature is correct for installation. 1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine. 2. Install the piston pin guide through the piston and the connecting rod. 3. Coat the piston pin with clean oil. 4. Install the piston pin into the opposite side of the piston. 5. 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.
6. 7. 8.
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9. 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.
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 the universal piston ring compressor J8037 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.
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20. Install the connecting rod cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 35 NSm (26 lbft). Using the angular torque gauge KM470B, tighten the bolts one turn of 45 degrees plus one turn of 15 degrees. 21. Install the crankshaft bearing bridge/oil pan scraper bolts.
Tighten
Tighten the crankshaft bearing bridge/oil pan scraper bolts to 20 NSm (15 lbft) plus 45 degrees using the angular torque gauge KM470B. 22. Install the oil suction pipe. 23. Install the oil suction pipe bolts.
Tighten
Tighten the oil suction pipe bolts to 8 NSm (71 lbin) and the oil suction pipe bracket bolt to 6 NSm (53 lb in). 24. Install the oil pan. Refer to "Oil Pan" in this section. 25. Install the cylinder head with the intake manifold and 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 th