Engine Mechanical System 2.0

Engine Mechanical System
Specifications
Description Specifications Limit
General
Type In-line, DOHC
Number of cylinders 4
Bore 81.0 mm (3.1890 in.)
Stroke 97.0 mm (3.8189 in.)
Total displacement 1999 cc (121.99 cu.in.)
Compression ratio 11.5 ± 0.2 : 1
Firing order 1-3-4-2
Valve timing
Open ATDC 10° ~ BTDC 40°
Intake valve
Close ABDC 67° ~ ABDC 17°
Open BBDC 54° ~ ABDC 6°
Exhaust valve
Close ATDC 1° ~ ATDC 61°
Camshaft
Intake 39.0 mm (1.5354 in.)
Cam height
Exhaust 38.7 mm (1.5236 in.)
No.1 : 35.959 ~ 35.975 mm
(1.41571 ~ 1.41634 in.)
Intake
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No.2,3,4,5 : 22.959 ~ 22.975 mm
Journal outer (0.90390 ~ 0.90453 in.)
diameter No.1 : 35.959 ~ 35.975 mm
(1.41571 ~ 1.41634 in.)
Exhaust
No.2,3,4,5 : 22.959 ~ 22.975 mm
(0.90390 ~ 0.90453 in.)
No.1 : 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)
Intake
No.2,3,4,5 : 0.032 ~ 0.062 mm
Bearing oil (0.00126 ~ 0.00244 in.)
clearance No.1 : 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)
Exhaust
No.2,3,4,5 : 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)
End play 0.10 ~ 0.19 mm (0.0039 ~ 0.0075 in.)
Valve
Intake 102.22 mm (4.0244 in.) 101.97 mm (4.0146 in.)
Valve length
Exhaust 104.04 mm (4.0961 in.) 103.79 mm (4.0862 in.)
Stem outer Intake 5.465 ~ 5.480 mm (0.21516 ~ 0.21575 in.)
diameter Exhaust 5.458 ~ 5.470 mm (0.21488 ~ 0.21535 in.)
Face angle 45.25° ~ 45.75°
Thickness of valve Intake 1.30 mm (0.0512 in.)
head
Exhaust 1.26 mm (0.0496 in.)
(margin)
Valve stem to Intake 0.020 ~ 0.047 mm (0.00079 ~ 0.00185 in.)
valve guide
clearance Exhaust 0.030 ~ 0.054 mm (0.00118 ~ 0.00213 in.)
Valve guide
Intake 43.8 ~ 44.2 mm (1.7244 ~ 1.7402 in.)
Length
Exhaust 43.8 ~ 44.2 mm (1.7244 ~ 1.7402 in.)
Intake 5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
Inner diameter
Exhaust 5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
Valve seat
Width of seat Intake 1.05 ~ 1.35 mm (0.0413 ~ 0.0532 in.)
contact Exhaust 1.35 ~ 1.65 mm (0.0532 ~ 0.0650 in.)
Intake 44° 45'' ~ 45° 6''
Seat angle
Exhaust 44° 45'' ~ 45° 6''
Valve spring
Free length 45.93 mm (1.8083 in.)
Load
19.6 ± 1.0 kg / 37.0 mm
(43.21 ± 2.20 lb / 1.4567 in.)
45.7 ± 1.8 kg / 27.0 mm
(100.75 ± 3.97 lb / 1.0630 in.)
Out of squareness Less than 1.5°
Cylinder head
Less than 0.05 mm (0.0020 in.) for total area
Flatness of gasket surface Less than 0.02 mm (0.0008 in.) for a section of 100 mm
(3.9370 in.) x 100 mm (3.9370 in.)
Flatness of Intake Less than 0.10 mm (0.0039 in.)
manifold mounting
surface Exhaust Less than 0.10 mm (0.0039 in.)
Piston
Piston outer diameter 80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)
Piston to cylinder clearance 0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
No. 1 ring 1.030 ~ 1.050 mm (0.04055 ~ 0.04134 in.)
Ring groove width No. 2 ring 1.230 ~ 1.250 mm (0.04843 ~ 0.04921 in.)
Oil ring 2.010 ~ 2.025 mm (0.07913 ~ 0.07972 in.)
Piston ring
No. 1 ring 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Side clearance No. 2 ring 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring 0.020 ~ 0.060 (0.00079 ~ 0.00236 in.)
No. 1 ring 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
End gap No. 2 ring 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
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Oil ring 0.20 ~ 0.50 mm (0.0079 ~ 0.0197 in.)
Piston pin
Piston pin outer diameter 19.997 ~ 20.000 mm (0.78728 ~ 0.78740 in.)
Piston pin hole inner diameter 20.008 ~ 20.013 mm (0.78771 ~ 0.78791 in.)
Piston pin hole clearance 0.004 ~ 0.016 mm (0.00016 ~ 0.00063 in.)
Connecting rod small end hole inner diameter 20.008 ~ 20.013 mm (0.78771 ~ 0.78791 in.)
Piston pin-to-connecting rod bushing oil
0.007 ~ 0.016 mm (0.00028 ~ 0.00063 in.)
clearance
Connecting rod
Connecting rod big end inner diameter 48.000 ~ 48.018 mm (1.88976 ~ 1.89047 in.)
Connecting rod bearing oil clearance 0.024 ~ 0.042 mm (0.00094 ~ 0.00165 in.)
Side clearance 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.)
Crankshaft
Main journal outer diameter 54.942 ~ 54.960 mm (2.16307 ~ 2.16378 in.)
Pin journal outer diameter 44.954 ~ 44.972 mm (1.76984 ~ 1.77055 in.)
Main bearing oil clearance 0.016 ~ 0.034 mm (0.00063 ~ 0.00134 in.)
End play 0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)
Cylinder block
Cylinder bore 81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)
Flatness of gasket surface Less than 0.02 mm (0.0008 in.) for a section of 100 mm
(3.9370 in.) x 100 mm (3.9370 in.)
Engine oil
When replacing a short engine or
Total 4.5 L (1.19 U.S.gal., 4.76 U.S.qt., 3.96 lmp.qt.)
block assembly
Oil quantity
Oil pan 3.7 L (0.98 U.S.gal., 3.91 U.S.qt., 3.26 lmp.qt.)
Drain and refill 4.0 L (1.06 U.S.gal., 4.23 U.S.qt., 3.52 lmp.qt.) Including oil filter
5W-20 / API SM& ILSAC GF-4 (or above) / ACEA A5 (or
above)
Specifications • API SL, ILSAC GF-3, ACEA A3 Class engine oil

can be used if the recommended engine oil is not
available.
• Refer to the "Lubrication System" for
recommended SAE viscosity number.
Oil temperature (oil pan) : 110 ± 2°C

Oil pressure (at 1,000rpm) 98.07 kPa (1.0 kgf/cm², 14.22 psi) or above
(230 ± 35.6°F)
Oil Pump
1st step :
115 ~ 185 kPa (1.17 ~ 1.89 kgf/cm², 16.68 ~ 26.83 psi)
Relief valve opening pressure
2nd step :
500 ~ 600 kPa (5.10 ~ 6.12 kgf/cm², 72.52 ~ 87.02 psi)
Side clearance 0.040 ~ 0.090 mm (0.00157 ~ 0.00354 in.)
Body clearance 0.200 ~ 0.292 mm (0.00787 ~ 0.01150 in.)
Guide clearance 0.030 ~ 0.075 mm (0.00118 ~ 0.00295 in.)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 7.5 L (1.98 U.S.gal., 7.92 U.S.qt., 6.59 lmp.qt.)
Type Wax pellet type
Opening
88 ± 1.5°C (190.4 ± 34.7°F)
Thermostat temperature
Full opening valve lift /
More than 8 mm (0.3 in.) / 100°C (212°F)
temperature
Main valve opening 93.16 ~ 122.58 kPa
pressure (0.95 ~ 1.25 kgf/cm², 13.51 ~ 17.78 psi)
Radiator cap
Vacuum valve opening
0 ~ 6.86 kPa (0 ~ 0.07 kgf/cm², 0 ~ 1.00 psi)
pressure
Liquid Gasket
Location Product
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Mating surface of timing chain cover
Front area of mating surface between cam carrier and cylinder head
Front area of mating surface between cylinder block and head
Upper area of mating surface between timing chain cover and cam carrier
Front upper area of cylinder block Threebond 1217H or equivalent
Front upper area of cylinder head gasket
Lower area of cam carrier
Lower area of cylinder block
Mating surface of oil pan
Mating surface of oil pressure switch THREEBOND 2403
Tightening Torques
Item N.m kgf.m lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Engine mounting support bracket to engine mounting insulator
88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
fixing nut
Engine mounting support bracket to engine support bracket fixing
88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
bolt
Engine mounting support bracket to engine support bracket fixing
88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
nut
Transaxle mounting bracket to body fixing bolt 63.7 ~ 83.4 6.5 ~ 8.5 47.0 ~ 61.5
Transaxle mounting support bracket to transaxle mounting
88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
insulator fixing bolt
Roll rod bracket to sub frame fixing bolt 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Roll rod bracket to roll rod support bracket fixing bolt & nut 107.9 ~ 127.5 11.0 ~ 13.0 79.6 ~ 94.0
Timing system
Crankshaft pulley bolt 196.1 ~ 205.9 20.0 ~ 21.0 144.7 ~ 151.9
Timing chain cover service plug bolt 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Timing chain cover bolt (M10×55) 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Timing chain cover bolt - Seal bolt (M6×38) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain cover bolt - Seal bolt (M8×50) 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Timing chain tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain tensioner arm bolt 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Timing chain guide bolt 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Cylinder head
Engine cover mounting bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Cylinder head cover bolt [3.9 ~ 5.9] + [7.8 ~ 9.8] [0.4 ~ 0.6] + [0.8 ~ 1.0] [2.9 ~ 4.3] + [5.8 ~ 7.2]
Fuel pump adaptor bolt 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5
CVVT bolt (LH/RH) 64.7 ~ 76.5 6.6 ~ 7.8 47.7 ~ 56.4
Camshaft bearing cap bolt (M6) 11.8 ~ 13.7 1.2 ~ 1.4 8.7 ~ 10.1
Camshaft bearing cap bolt (M8) 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Cam carrier bolt 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
[32.4 ~ 36.3] + [90 ~ 95°] [3.3 ~ 3.7] + [90 ~ 95°] + [23.9 ~ 26.8] + [90 ~ 95°]
Cylinder head bolt
+ [90 ~ 95°] [90 ~ 95°] + [90 ~ 95°]
Engine hanger bolt (Front/Rear) 34.3 ~ 39.2 3.5 ~ 4.0 25.3 ~ 28.9
Camshaft position sensor (LH/RH) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil control valve (OCV) bolt (LH/RH) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder block
Flywheel bolt (M/T) 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 93.9
Drive plate bolt (A/T) 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 93.9
Connecting rod bearing cap bolt [17.7 ~ 21.6] + [88 ~ 92°] [1.8 ~ 2.2] + [88 ~ 92°] [13.0 ~ 15.9] + [88 ~ 92°]
Lower crankcase bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
[27.5 ~ 31.4] + [120 ~ [20.3 ~ 23.1] + [120 ~
Main bearing cap bolt [2.8 ~ 3.2] + [120 ~ 125°]
125°] 125°]
Crankshaft position wheel screw 10.8 ~ 11.8 1.1 ~ 1.2 8.0 ~ 8.7
Knock sensor 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
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Lubrication system
Oil drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil filter 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Oil pan bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil screen bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil screen nut 11.8 ~ 13.7 1.2 ~ 1.4 8.7 ~ 10.1
Oil pressure switch 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cooling system
Water pump pulley bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water inlet fitting nut 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Water temperature control assembly bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Heater pipe bolt 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Intake and exhaust system
Air intake hose clamp bolt 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Air cleaner assembly bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Electronic throttle control (ETC) module bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Intake manifold stay bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Intake manifold bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Intake manifold nut 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Oxygen sensor (Front/Rear) 39.2 ~49.0 4.0 ~ 5.0 28.9 ~ 36.2
Exhaust manifold heat protector bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Exhaust manifold stay bolt 39.2 ~49.0 4.0 ~ 5.0 28.9 ~ 36.2
Exhaust manifold nut 34.3 ~ 39.2 3.5 ~ 4.0 25.3 ~ 28.9
Catalytic converter / muffler nut 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Compression Pressure Inspection
• If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up and stop engine.

Allow the engine to warm up to normal operating temperature.
2. Disconnect the injector extension connector (A).
3. Remove the spark plugs.
(Refer to Engine Electrical System - "Spark Plug")
4. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
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(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.
• Always use a fully charged battery to obtain engine speed of 200 rpm or more.
(4) Repeat steps (1) through (3) for each cylinder.
• This measurement must be done in as short a time as possible.
Compression pressure :
1,373 kPa (14.0 kgf/cm², 199 psi)
Minimum pressure :
1,226 kPa (12.5 kgf/cm², 178 psi)
Difference between each cylinder :
100 kPa (1.0 kgf/cm², 15 psi) or less
(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole
and repeat steps (1) through (3) for cylinders with low compression.
• If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5. Install the other parts reverse order of removal.

6. Some DTCs may exist after the inspection test and may need to be manually cleared with GDS.
Troubleshooting
Symption Suspect area Remedy
• Worn crankshaft bearings • Replace the crankshaft and bearings as required.
Engine misfire with abnormal • Loose or out of specification engine flywheel • Repair or replace the flywheel as required.
internal lower engine noises Worn piston rings Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the Repair or replace as required.
engine to misfire.)
Worn crankshaft thrust bearings Replace the crankshaft and bearings as required
Engine misfire with abnormal Stuck valves Repair or replace as required.
valve train noise (Carbon buidup on the valve stem)
Excessive worn or mis-aligned timing chain Replace the timing chain and sprocket as required.
Worn camshaft lobes Replace the camshaft.
Engine misfire with coolant • Faulty cylinder head gasket or other damage • Inspect the cylinder head and engine block for damage
consumption to the cylinder head and engine block cooling to the coolant passages and/or a faulty head gasket.
system • Repair or replace as required.
• Coolant consumption may or may not cause
the engine to overheat
Engine misfire with excessive Worn valves, guides and/or valve stem oil seals Repair or replace as required.
oil consumption Worn piston rings • Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the • Repair or replace as required.
engine to misfire)
Engine noise on start-up, but Incorrect oil viscosity • Drain the oil.
only lasting a few seconds • Install the correct viscosity oil.
(Check and compare with Worn crankshaft thrust bearing • Inspect the thrust bearing and crankshaft.
known good vehicle to
• Repair or replace as required.
determine normal condition.)
Upper engine noise, regardless Low oil pressure Repair or replace as required.
of engine speed Broken valve spring Replace the valve spring.
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Worn or dirty valve tappet (MLA) Replace the valve tappet (MLA).
Stetched or broken timing chain and/or damaged Replace the timing chain and sprockets.
sprocket teeth
Worn timing chain tensioner, if applicable Replace the timing chain tensioner as required.
Worn camshaft lobes • Inspect the camshaft lobes.
• Replace the camshaft as required.
• Out of specification valve clearances (MLA) Inspect the valves and valve guides, then repair or replace
• Worn valve guides or valve stems as required.
Stuck valves (Carbon on the valve stem or valve Inspect the valves and valve guides, then repair or replace
seat may cause the valve to stay open.) as required.
Worn drive belt, idler, tensioner and bearing Replace as required.
Lower engine noise, regardless Low oil pressure Repair or required.
of engine speed Loose or damaged flywheel Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen • Inspect the oil pan.
• Inspect the oil pump screen.
Oil pump screen loose, damaged or restricted • Inspect the oil pump screen.
Excessive piston-to-cylinder bore clearance • Inspect the piston, piston pin and cylinder bore.
Excessive piston pin-to-piston clearance • Inspect the piston, piston pin and the connecting rod.
Excessive connecting rod bearing clearance Inspect the following components and repair or replace as
required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft pin journals.
Excessive crankshaft bearing clearance Inspect the following components, and repair or replace as
required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block
Incorrect piston, piston pin and connecting rod • Verify the piston pins and connecting rods are installed
installation correctly.
• Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Excessive connecting rod bearing clearance Inspect the following components and repair or replace as
required:
• The connecting rod bearings
• The connecting rods
• The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair or replace as
required:
• The crankshaft bearings
• The crankshaft main journals
• The cylinder block
Engine is not cranked. 1) Remove spark plugs and check for fluid.
Hydraulically locked cylinder
Crankshaft does not rotate. 2) Inspect for broken head gasket.
• Coolant/antifreeze in cylinder
3) Inspect for cracked engine block or cylinder head.
• Oil in cylinder
4) Inspect for a sticking fuel injector and/or leaking fuel
• Fuel in cylinder
regulator.
Broken timing chain and/or timing chain gears 1) Inspect timing chain and gears.
2) Repair as required.
Material in cylinder 1) Inspect cylinder for damaged components and/or foreign
• Broken valve materials.
• Piston material 2) Repair or replace as required.
• Foreign material
Seized crankshaft or connecting rod bearings 1) Inspect crankshaft and connecting rod bearing.
Bent or broken connecting rod 1) Inspect connecting rods.
Broken crankshaft 1) Inspect crankshaft.
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Special Service Tools

Tool (Number and name) Illustration Use
Crankshaft front oil seal installer Installation of the front oil seal
(09231-2E000) 09231-2E000 (installer)
Valve stem seal installer Installation of the valve stem oil seal
(09222-2E000)
Valve spring compressor Removal and installation of the intake or exhaust

(09222-3K000) valve
(09222-3K100) A : 09222-3K000 (compressor)
B : 09222-3K100 (holder)
Crankshaft rear oil seal installer Installation of the rear oil seal
(09214-2E000) A : 09214-2E000 (installer)
(09231-H1100) B : 09231-H1100 (handle)
Ring gear stopper Holding ring gear so that engine doesn''t turn/move
(09231-2B100) after the starter is removed
(09231-3N100)
Ring gear stopper Holding ring gear so that engine doesn''t turn/move
(09231-3D100) after the service cover is removed
(09231-2W100)
Torque angle adapter Installation of bolts & nuts needing an angular method
(09221-4A000) of adjustment
Oil pan remover • Removal of oil pan

(09215-3C000) • Must use this tool to separate the oil pan from the
lower crankcase assembly without damage to the
sealing surfaces
Tensioner stopper pin Holding compressed piston of tensioner

(09240-2E100)
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Oil filter wrench Removal and installation of oil filter
(09263-2E000)
Removal and Installation

1. Remove the engine cover (A).
• To avoid damage, remove the engine cover on room temperature.

• To avoid damage of the engine cover, do not disengage both front and rear mounting point at the same time.
2. Install in the reverse order of removal.

1. Remove the engine room under cover (A).
Tightening torque :
7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)
Components
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1. Engine mounting support bracket 3. Roll rod bracket

2. Engine mounting bracket 4. Transaxle mounting bracket

Engine Mounting Bracket
1. Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
2. Install the jack to the edge of oil pan to support the engine.
• Insert the rubber block between jack and oil pan.
3. Disconnect the ground cable (A).

Tightening torque :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
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4. Remove the engine mounting support bracket (A).
Tightening torque :
Nuts (B), bolt (C)
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 Ib-ft)
5. Remove the engine mounting bracket (A).

Tightening torque :
63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
Roll Rod Mounting Bracket

2. Remove the roll rod bracket (A).
Tightening torque
Nut (B) :
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolts (C) :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
3. Remove the roll rod mounting support bracket (A).

Tightening torque :
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)
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Transaxle Mounting Bracket

1. Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
2. Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3. Install the jack to the edge of transaxle.
4. Remove the front wheel guard.
(Refer to Body - "Body Side Molding")
5. Remove the service cover (A).
6. Remove the transaxle mounting bracket bolts (A).

Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
7. Remove the transaxle mounting support bracket (A).

Tightening torque :
58.9 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.8 lb-ft)
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8. Remove the transaxle mounting bracket (A).
Tightening torque :
63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
Removal
• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.

• For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. and then turn off
the ignition switch after engine stops.
1. Remove the engine cover.

(Refer to Engine and Transaxle Assembly - "Engine Cover")
4. Drain the engine coolant.
(Refer to Cooling System - "Coolant")
5. Remove the holder clip (A) and then disconnect the radiator upper hose quick connector (B).
6. Remove the holder clip (A) and then disconnect the radiator lower hose quick connector (B).
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7. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
(Refer to Heating, Ventilation Air conditioning - "Compressor")
8. Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
9. Disconnect the brake booster vacuum hose (A).
10. Disconnect the heater hoses (A).

• When installing the heater hoses, install as shown in illustrations.
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11. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
12. Disconnect the reservoir tank water hose (A).

13. Disconnect the wiring harness from the engine room.
(1) Disconnect the battery positive wiring (A).
(2) Disconnect the battery connector (B).
(3) Remove the wiring protector (C).
14. Disconnect the wiring connectors and harress clamps and remove the connector brackets around the engine and transaxle assembly.
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15. Remove the steering U-joint mounting bolt.
(Refer to Steering System - "Steering Column and Shaft")
16. Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
17. Remove the roll rod bracket (A).
Tightening torque
Nut (B) :
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolts (C) :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
18. Remove the roll rod mounting support bracket (A).

Tightening torque :
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)
19. Remove the sub frame.
(Refer to Suspension System - "Sub Frame")
• After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them
securely with floor jack.
• Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
20. Disconnect the ground cable (A).

Tightening torque :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
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21. Remove the engine mounting support bracket (A).
Tightening torque
Nuts (B), bolt (C) :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 Ib-ft)
22. Disconnect the ground line (A).

23. Remove the front wheel guard.
(Refer to Body - "Body Side Molding")
24. Remove the service cover (A).
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25. Remove the transaxle mounting bracket bolts (A).
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 Ib-ft)
26. Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle.
• When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
Installation
Installation is in the reverse order of removal.
Perform the following :
• Adjust shift cable.
• Adjust throttle cable.
• Refill engine with engine oil.
• Refill transaxle with fluid.
• Refill radiator and reservoir tank with engine coolant.
• Place heater control knob on "HOT" position.
• Bleed air from the cooling system.
– Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
– Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling
system.
– Put radiator cap on tightly, then run the engine again and check for leaks.
• Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
• Inspect for fuel leakage.
– After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds
and fuel line pressurizes.
– Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Components
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1. Intake camshaft 8. Timing chain guide

2. Exhaust camshaft 9. Timing chain cover
3. Intake CVVT assembly 10. Service plug bolt & gasket
4. Exhaust CVVT assembly 11. Front oil seal
5. Timing chain 12. Crankshaft damper pulley
6. Timing chain tensioner arm
7. Timing chain tensioner
Removal
1. Remove the drive belt.
(1) Disconnect the drive belt (B) by turning the drive belt tensioner (A) counterclockwise.
(2) After removing the drive belt tensioner (A), remove the drive belt.
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Inspection
1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
• Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
Installation
1. Install the drive belt.
(1) Install the drive belt to the drive belt tensioner.
(2) Install the drive belt tensioner (A).
(3) Connect the drive belt (B) by turning the drive belt tensioner (A) counterclockwise.
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Components
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1. Drive belt tensioner

(Refer to Timing System - "Drive Belt")
2. Remove the drive belt tensioner (A).
Tightening torque
Bolt (B) :
39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
Bolt (C) :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7~ 30.4 lb-ft)
Components
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1. Crankshaft damper pulley

1. Remove the RH front wheel.
(Refer to Suspension System - "Wheel")
4. Remove the crankshaft damper pulley (A).
Tightening torque :
196.1 ~ 205.9 N.m (20.0 ~ 21.0 kgf.m, 144.7 ~ 151.9 lb-ft)
• Do not press the pulley or apply the excessive force to prevent the rubber part from being deformed.
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There are two methods to hold the ring gear when removing the crankshaft damper pulley.
• Install the SST (09231-2B100, 09231-3N100) to hold the ring gear after removing the starter.
• Install the SST (09231-3D100, 09231-2W100) to hold the ring gear after removing the service cover.
1) Remove the transaxle mounting bolt (A) and the service cover (B) on the bottom of the lower crankcase.
2) Remove the transaxle mounting bolt (C) on the bottom of the lower crankcase.
3) Adjust the length of the holder (A) so that the grooves of the holder puts into the ring gears (B) at the closest position.
4) Adjust the angle and length of the links (C) so that the two transaxle mounting bolts can be fastened into the original mounted
holes.
5) Install the SST using the two transaxle mounting bolts. Tighten the bolts and nuts of the holder and links securely.
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Inspection
Check the crankshaft damper pulley for vibration in rotation, oil dust deposit of V-ribbed part. Replace if necessary.
Components
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1. Front oil seal
Replacement
1. Remove the crankshaft damper pulley.
(Refer to Timing System - "Crankshaft Damper Pulley")
2. Remove the front oil seal (A).
3. Apply engine oil on the edge of new oil seal.
• Remove any debris from the lip portion of the oil seal.
4. Using the SST (09231-2E000), install a front oil seal.
• Do not reuse the front oil seal.
5. Install the crankshaft damper pulley.

Components
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1. Timing chain cover 2. Service plug bolt & gasket

Removal
Engine removal is not required for this procedure.

1. Disconnect the battery negative terminal.

2. Remove the RH front wheel.
(Refer to Suspension System - "Wheel")
5. Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
6. Drain engine oil and remove the oil pan.
(Refer to Lubrication System - "Oil Pan")
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7. Remove the engine mounting bracket.
(Refer to Engine and Transaxle Assembly - "Engine Mounting")
9. Remove the water pump.
(Refer to Cooling System - "Water Pump")
10. Remove the A/C compressor.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
11. Remove the front engine hanger (A).
12. Remove the alternator.

(Refer to Engine Electrical System - "Alternator")
13. Remove the timing chain cover (A) by gently prying the gaps between the cylinder head and cylinder block.
• Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
Installation
1. Install the timing chain cover.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) The sealant locations on the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be
free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
(3) Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder
block.
Bead width :3.0 ~ 5.0 mm (0.11 ~ 0.20 in.)
Sealant :Threebond 1217H or equivalent
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(4) After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead
of sealant should be applied to prevent any path from oil leakage.
Bead width
Whole section : 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)
Section A : 4.5 ~ 5.5 mm (0.18 ~ 0.22 in.)
Section B : 8.0 ~ 9.0 mm (0.32 ~ 0.35 in.)
(5) Install the timing chain cover. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in
order to assemble the timing chain cover in exact position.
Tightening torque
Bolts (A, B) :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Bolt (C) :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)
Bolts (D, E) :
39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
Bolt (F) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• Do not reuse the seal bolts (C,F).
• The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.
2. Replace the front oil seal if necessary.

(Refer to Timing System - "Front Oil Seal")
3. Install the front engine hanger (A).
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Tightening torque :
34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)

5. Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.

• Clean battery posts and cable terminals and assemble.
– After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately
two seconds and fuel line pressurizes.
Components
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1. Intake camshaft 5. Timing chain
2. Exhaust camshaft 6. Timing chain tensioner arm
3. Intake CVVT assembly 7. Timing chain tensioner
4. Exhaust CVVT assembly 8. Timing chain guide
Removal
2. Set No.1 cylinder to TDC (Top dead center) on compression stroke.
(1) Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
(2) Check that the TDC marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown in the
illustration. If not, turn the crankshaft by one revolution (360°) more.
• Do not turn the crankshaft pulley counterclockwise.
3. Remove the timing chain cover.

(Refer to Timing System - "Timing Chain Cover")
4. Remove the timing chain tensioner (A).
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• Do not reuse the detached tensioner.
• If need to reuse the tensioner, remove the tensioner, make the piston (A) to protrude maximally, push the piston (A) to the end,
and then mount the stopper pin.
At this time, the tensioner fixing pin should be placed in the same way as when the product was first delivered from the factory.
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5. Remove the timing chain tensioner arm (A).
6. Remove the timing chain (A).

7. Remove the timing chain guide (A).
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the CVVT sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace if necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace if necessary.
3. Check that the tensioner piston moves smoothly.
Installation
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1. The TDC marks of the intake and exhaust CVVT sprockets are slightly turned from the TDC position as shown when the timing chain is
removed.
2. Turn the crankshaft clockwise (about 1~2 pitches) from the TDC position (the dowel pin (A) of crankshaft is about 3° with the engine vertical
line) as rotation of the intake CVVT sprocket from the TDC position.
3. Install the timing chain guide (A).

Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
4. Install the timing chain tensioner arm (A).
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
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5. Install the timing chain.
Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D)
(1) Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
• The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing
chain.
(2) Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.
• The timing mark of the exhaust CVVT sprocket should be matched with timing mark (color link) of timing chain when installing
the timing chain.
• Press down the timing chain links on the exhaust CVVT sprocket to prevent the sprocket from spinning.
6. Install the timing chain auto tensioner (A) and remove the stopper pin (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• When reinstall the tensioner, check the ratchet function of the tensioner after removing the fixing pin by retracting the tensioner
arm (A) maximally as shown below.
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• When maximally retracted, there should be no interference between the tensioner arm (A) and tensioner housing (B).
7. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks on the intake and
exhaust CVVT sprockets are aligned with the top surface of cylinder head.

– After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two
seconds and fuel line pressurizes.

Components
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1. Fuel pump adaptor 7. Intake CVVT assembly 13. Valve spring
2. Camshaft bearing cap 8. Cam carrier 14. Valve stem seal
3. Camshaft front bearing cap 9. Cylinder head 15. Valve
4. Exhaust camshaft 10. Cylinder head gasket 16. Swing arm
5. Intake camshaft 11. Retainer lock 17. HLA (Hydraulic lash adjuster)
6. Exhaust CVVT assembly 12. Retainer
Components
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1. Cylinder head cover 3. Fuel pump bracket gasket
2. Cylinder head cover gasket
Removal


3. Disconnect the wiring connectors and harness clamps and remove the connector brackets around the cylinder head cover.
(Refer to Intake and Exhasut System - "Air Cleaner")
5. Disconnect the PCV (Positive crankcase ventilation) hose (A).
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6. Disconnect the fuel hose (A) and PCSV (Purge Control Solenoid Valve) hose (B).
7. Remove the vacuum pipe (A).
8. Remove the high pressure pipe (A) and the PCSV (Purge Control Solenoid Valve) bracket (B).
(Refer to Engine Control / Fuel System - "High Pressure Fuel Pump")
9. Remove the high pressure fuel pump.
(Refer to Engine Control/Fuel System - "High Pressure Fuel Pump")
10. Remove the ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
11. Remove the engine oil level gauge.
(Refer to Lubrication System - "Oil Level Gauge & Pipe")
12. Remove the cylinder head cover (A).
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• Unfasten the bolts in the sequence as shown.
Installation
1. Install cylinder head cover.
(1) The hardening sealant located on the cylinder head cover and the gap between the timing chain cover and the cam carrier should be
removed before assembling cylinder head cover.
(2) Apply engine oil on the lip portion of the oil seal on the cover and outer surface of the spark plug pipes.
(3) After applying sealant on the gap between the timing chain cover and the cam carrier, it should be assembled within 5 minutes.
Bead width :2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)
(4) Install the cylinder head cover by tightening the bolts, in several passes, in the sequence as shown.
Tightening torque
1st step :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
2nd step :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
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• Do not reuse cylinder head cover gasket.
• Before installing the cylinder head cover, make sure the cylinder head cover gasket is not separated from the cylinder head cover
gasket groove.
• The engine running or pressure test should not be performed within 30 minutes after the cylinder head cover was assembled.
Components
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1. Fuel pump adaptor 5. Intake camshaft
2. Camshaft bearing cap 6. Exhaust CVVT assembly
3. Camshaft front bearing cap 7. Intake CVVT assembly
4. Exhaust camshaft
Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with the
ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC) and
improves engine performance through reduction of pumping loss, internal EGR effect, improvement of combustion stability, improvement of
volumetric efficiency, and increase of expansion work.
This system consist of
– the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or runs out the engine oil from the cam phaser in
accordance with the ECM PWM (Pulse With Modulation) control signal,
– the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,
– and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite
direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.
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Operation Principle
The CVVT has the mechanism rotating the rotor vane with hydraulic force generated by the engine oil supplied to the advance or retard
chamber in accordance with the CVVT oil control valve control.
[CVVT System Mode]

(1) Low Speed / Low Load (2) Part Load
(3) Low Speed / High Load (4) High Speed / High Load
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Exhaust Valve Intake Valve
Driving
Valve Valve
Condition Effect Effect
Timing Timing
(1) Low Speed Completely * Valve Under-lap Completely * Valve Under-lap
/Low Load Advance * Improvement of combustion stability Retard * Improvement of combustion stability
* Increase of expansion work
(2) Part Load Retard * Reduction of pumping loss Retard * Reduction of pumping loss
* Reduction of HC
(3) Low Speed * Prevention of intake back flow (Improvement
Retard * Increase of expansion work Advance
/High Load of volumetric efficiency)
(4) High Speed
Advance * Reduction of pumping loss Retard * Improvement of volumetric efficiency
/High Load
Removal


• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
• Timing chain cover removal is not required for this procedure.
2. Remove the fuel pump adaptor (A).
3. Set No.1 cylinder to TDC (Top dead center) on compression stroke.

(1) Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
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(2) Check that the TDC marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown in the
illustration. If not, turn the crankshaft by one revolution (360°) more.
(3) Mark the timing chains corresponding to the timing marks of the CVVT sprockets.

5. Remove the service plug bolt (A) with the gasket (B).
6. Remove the tensioner arm bolt (A).
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7. Push down the tensioner arm (A).
8. Remove the camshaft bearing caps.
9. Remove the exhaust camshaft (A) first, then intake camshaft (B).
10. Remove the tensioner arm (A).
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• To hold the timing chain, tie it with strap.
11. Remove the CVVT assembly (A) from the camshaft.
• When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.
Inspection
Camshaft
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
If the cam lobe height is less than specification, replace the camshaft.
Cam height
Intake : 39.0 mm (1.5354 in.)
Exhaust : 39.0 mm (1.5354 in.)
2. Check the surface of the camshaft journal for wear.
If the journal is worn excessively, replace the camshaft.
3. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
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(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque
M6 bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
M8 bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
• Do not turn the camshaft.
(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.
If the oil clearance is greater than specification, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
Bearing oil clearance
Standard :
0.032 ~ 0.062 mm (0.00126 ~ 0.00244 in.)
4. Inspect the camshaft end play.

(1) Install the camshaft bearing caps.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
If the end play is greater than specification, replace the camshaft.
If necessary, replace the bearing caps and cylinder head as a set
Camshaft end play
Standard :
0.10 ~ 0.19 mm (0.0039 ~ 0.0075 in.)
(3) Remove the camshafts.
CVVT (Continuous Variable Valve Timing) Assembly

1. Inspect the CVVT for smooth rotation.
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(1) Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals in the vise.
(2) Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate.
(3) Intake CVVT : Seal one of the two advance holes in the camshaft journal with tape.
Exhaust CVVT : Seal one of the two retard holes in the camshaft journal with tape.
(4) Intake CVVT : Apply approx. 150kPa (1.5kgf/cm², 21psi) of compressed air into the unsealed advance hole to release the lock.
Exhaust CVVT : Apply approx. 150kPa (1.5kgf/cm², 21psi) of compressed air into the unsealed retard hole to release the lock.
• Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.
(5) Intake CVVT : With compressed air applied, rotate CVVT into the advance direction (counterclockwise) within its phasing range and
check that the CVVT turns smoothly.
Exhaust CVVT : With compressed air applied, rotate CVVT into the retard direction (clockwise) and check that the CVVT turns smoothly.
CVVT phasing range
Intake : 25° ± 0°30'' (from the most retarded position to the most advanced position)
Exhaust : 20° ± 0°30'' (from the most advanced position to the most retarded position)
(6) Intake CVVT : Rotate the CVVT into the most retarded position(clockwise) and then check that the CVVT is locked.
Exhaust CVVT : Rotate the CVVT into the most advanced position(counterclockwise) and then check that the CVVT is locked.
Installation
1. Install the CVVT assembly (A) to the camshaft.
Tightening torque :
64.7 ~ 76.5 N.m (6.6 ~ 7.8 kgf.m, 47.7 ~ 56.4 lb-ft)
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• When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.
2. Compress the piston of the tensioner using a handy bar (A) and then insert a stopper pin (B) into the hole on the tensioner to hold the
compressed piston.
3. Place the intake camshaft (A) and then insert the tensioner arm (B) along the timing chain.
4. Place the exhaust camshaft (A).
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• The timing marks of each CVVT sprocket should be matched with timing marks (painted link) of timing chain when installing the
timing chain.
5. Install the camshaft bearing caps.
Tighten the bolts, in several passes, in the sequence as shown.

Tightening torque
M6 bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
M8 bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
• Be careful not to change the position and direction of bearing caps.
6. Using a suitable tool, move the tensioner arm to align the tensioner bolt hole with the service hole.
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7. Install the tensioner arm bolt (A).
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
8. Remove the stopper pin from the tensioner.

9. Turn the crankshaft two turns in the operating direction (clockwise), and then check that the TDC marks of the CVVT sprockets are in
straight line on the cylinder head surface.
10. Install a service plug bolt (A) with a gasket.

Tightening torque :
29.4 ~ 39.2 N.m (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
• Do not reuse the service plug bolt and gasket.
11. Install the crankshaft damper pulley.

(Refer to Timing System - “Crankshaft Damper Pulley”)
12. Install the cylinder head cover.
(Refer to Cylinder Head Assembly - “Cylinder Head Cover”)
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Components
1. Cam carrier 6. Valve spring
2. Cylinder head 7. Valve stem seal
3. Cylinder head gasket 8. Valve
4. Retainer lock 9. Swing arm
5. Retainer 10. Hydraulic lash adjuster (HLA)
Removal
Engine removal is not required for this procedure.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before
removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

• Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).
1. Remove the Battery.
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3. Remove the battery tray.
5. Remove the vacuum pipe (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Remove the condenser (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
7. Remove the high pressure fuel pump.
(Refer to Engine Control/Fuel System - "High Pressure Fuel Pump")
9. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
10. Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
11. Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
12. Remove the delivery pipe.
(Refer to Engine Control/Fuel System - "Delivery Pipe")
13. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
14. Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).
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15. Remove the camshaft.

(1) Remove the camshaft bearing cap (A) by loosening the bolts in the sequence as shown.
(2) Remove the camshafts (A).
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16. Remove the cam carrier (A).
17. Remove the hydraulic lash adjuster (HLA) (A) and the swing arm (B).
• The HLA and swing arm should be kept together as pairs during storage after removal and reinstallation.
18. Remove the oil control adapter (A) with the gasket (B).
19. Remove the intake oil control valve (OCV) (A).
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20. Remove the exhaust oil control valve (OCV) (A).
21. Remove the rear engine hanger (A).
22. Remove the spark plugs.

(Refer to Engine Electrical System - "Spark Plug")
23. Remove the cylinder head.
(1) Using bit socket (12PT), uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence as shown.
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• Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
• Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(3) Remove the cylinder head gasket (B).
Disassembly
• Identify, valves and valve springs as they are removed so that each item can be reinstalled in its original position.
1. Remove the valves.

(1) Using the SST (09222-3K000, 09222-3K100), compress the valve spring and remove the retainer lock (A).
• When installing the SST, insert the front support (A) directly into the bolt hole on the cylinder head.
• Do not press valve retainer more than 12mm (0.47in.).
(2) Remove the spring retainer (B).

(3) Remove the valve spring (C).
(4) Remove the valve (D).
(5) Using needle-nose pliers, remove the valve stem seal (E).
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• Do not reuse the valve stem seals.
Inspection
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the contacting surface of the cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface :
Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) x 100 mm (3.9370 in.)
Flatness of manifold mounting surface :
Less than 0.10 mm (0.0039 in.)
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2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Valve and Valve Spring

1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide inner diameter
Intake : 5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
Exhaust : 5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
(2) Using a micrometer, measure the diameter of the valve stem.

Valve stem outer diameter
Intake : 5.465 ~ 5.480 mm (0.21516 ~ 0.21575 in.)
Exhaust : 5.458 ~ 5.470 mm (0.21488 ~ 0.21535 in.)
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
If the clearance is greater than specification, replace the valve or the cylinder head.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047 mm (0.00079 ~ 0.00185 in.)
Exhaust : 0.030 ~ 0.054 mm (0.00118 ~ 0.00213 in.)
2. Inspect the valves.

(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
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(3) Check the valve head margin thickness.
If the margin thickness is less than specification, replace the valve.
Margin
[Standard]
Intake : 1.30 mm (0.0512 in.)
Exhaust : 1.26 mm (0.0496 in.)
(4) Check the valve length.

Valve length
[Standard]
Intake : 102.22 mm (4.0244 in.)
Exhaust : 104.04 mm (4.0961 in.)
[Limit]
Intake : 101.97 mm (4.0146 in.)
Exhaust : 103.79 mm (4.0862 in.)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats and the valve guides.

(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace the cylinder head.
(2) Check the valve guide for wear.If the valve guide is worn, replace the cylinder head.
4. Inspect the valve springs.

(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
If the free length is not as specified, replace the valve spring.
Valve spring
[Standard]
Free height : 45.93 mm (1.8083 in.)
Out-of-square : Less than 1.5°
Hydraulic Lash Adjuster (HLA)

With the HLA filled with engine oil, hold A and press B by hand.
If B moves, replace the HLA.
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Problem Possible cause Action
This noise will disappear after the oil in the
1. Temporary noise when starting a cold engine Normal
engine reaches the normal pressure.
2. Continuous noise when the engine is started Oil leakage of the high pressure chamber on
after parking more than 48 hours the HLA, allowing air to get in
3. Continuous noise when the engine is first Noise will disappear within 15 minutes when
Insufficient oil in cylinder head oil gallery engine runs at 2000 ~ 3000 rpm.
started after rebuilding cylinder head
4. Continuous noise when the engine is started If it doesn’t disappear, refer to step 7 below.
after excessively cranking the engine by the
starter motor or band
• Oil leakage of the high-pressure chamber in
the HLA, allowing air to get in
5. Continuous noise when the engine is running • Insufficient oil in the HLA
• Do not run engine at a speed higher
after changing the HLA
than 3000 rpm, as this may damage the
HLA.
• Check oil level.

Engine oil level too high or too low
• Drain or add oil as necessary.
6. Continuous noise during idle after high Excessive amount of air in the oil at high
Check oil supply system.
engine speed engine speed
Check oil quality.
Deteriorated oil
If deteriorated, replace with specified type.
Check oil pressure and oil supply system of
Low oil pressure
each part of engine.
7. Noise continues for more than 15 minutes Remove the cylinder head cover and press
Faulty HLA HLA down by hand.
If it moves, replace the HLA.
Reassembly
•
Thoroughly clean all parts to be assembled.
• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace oil seals with new ones.
1. Install the valves.

(1) Using the SST (09222-2E000), push in a new stem seal (A).
• Do not reuse old valve stem seals.

• Incorrect installation of the seal could result in oil leakage past the valve guides.
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(2) Install the valve, valve spring and spring retainer.
• Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the
retainer.
(3) Using the SST (09222-3K000, 09222-3K100), compress the spring and install the retainer locks.
Before releasing the valve spring compressor, ensure that the retainer locks are correctly in place after pushing down and releasing the
compressor handle 2~3 times.
• When installing the SST, insert the front support (A) directly into the bolt hole on the cylinder head.
• Do not press valve retainer more than 12mm (0.47in.).
Installation
• Thoroughly clean all parts to be assembled.

• Always use new cylinder head and manifold gaskets.
• Always use new cylinder head bolts.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft to set the No.1 piston at TDC (Top dead center) on compression stroke.
1. Install the cylinder head gasket (B) on the cylinder block.
(1) Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the cylinder block and the cylinder head.
(2) Apply liquid gasket on the edge of the cylinder block.
(3) Install the cylinder head gasket with the dowel pins of the cylinder block.
(4) Apply liquid gasket on the edge of the cylinder head gasket.
• Apply liquid gasket on the edge of the cylinder block and cylinder head gasket.
Sealant :
Threebond 1217H or equivalent
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• Assemble the cylinder head gasket and the cylinder head within 5 minutes after applying sealant.
2. Place the cylinder head (A) carefully to protect damage to the head gasket during installation.
3. Install the cylinder head bolts with washers.

Using SST (09221-4A000), install and tighten the 10 cylinder head bolts, in several passes, in the sequence as shown.
Tightening torque
1st step :
32.4 ~ 36.3 N.m (3.3 ~ 3.7 kgf.m, 23.9 ~ 26.8 lb-ft)
2nd step : 90~95°
3rd step : 90~95°
• Do not reuse the cylinder head bolts.
• Do not apply engine oil on the bolt threads to achieve correct torque.
• Remove the extruded sealant within 5 minutes after installing cylinder head bolts.
• The engine running or pressure test should not be performed within 30 minutes after installing cylinder head bolts.
• Be careful not to change the installing position of the preassembled washer bolts and non-preassembled washer bolts.
• When installing the washer of the non-preassembled washer bolts, the round and chamfer of washers should be faced up.
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4. Install the rear engine hanger (A).
Tightening torque :
34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)
5. Install the exhaust oil control valve (OCV) (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Install the intake oil control valve (OCV) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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• Do not reuse the OCV when dropped.
• Keep the OCV filter clean.
• Do not hold the OCV sleeve (A) during servicing.
• When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
7. Install the oil control adapter (A) with a new gasket (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
8. Install the water temperature control assembly.

(Refer to Cooling System - "Water Temperature Control Assembly")
9. Install the hydraulic lash adjuster (HLA) (A) and the swing arm (B).
(1) When installing HLA, it should be held upright so that engine oil in HLA may not spill and assured that dust does not adhere to HLA.
(2) HLA should be inserted carefully to the cylinder head not to spill engine oil.
• In case of spilling, air bleed should be done in accordance with the air bleed procedure. Stroke HLA in diesel oil 4~5 times by
pushing its cap while pushing the ball down slightly with a hard steel wire. (Take care not to severely push a hard steel wire
down since ball is several grams.)
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10. Install the cam carrier.
(2) The sealant locations on the cam carrier and the cylinder head must be free of harmful foreign materials, oil, dust and moisture. Spray
cleaner on the surface and wipe with a clean duster.
(3) After applying liquid sealant on the bottom surface of the cam carrier, assemble the cam carrier. Continuous bead of sealant should be
applied to prevent any path from oil leakage.
Bead width :2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)
(4) Place the cam carrier (A) on the cylinder head. The dowel pins on the cam carrier and holes on the cylinder head should be used as a
reference in order to assemble the cam carrier in exact position.
(5) Fasten the cam carrier bolts.
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
• Assemble the cam carrier within 5 minutes after applying sealant.
• Assemble the camshaft bearing cap within 5 minutes after assembling the cam carrier.
• The engine running or pressure test should not be performed within 30 minutes after assembling the cam carrier.
11. Install the camshafts.

(1) Place the intake and exhaust camshafts (A) on the cam carrier.
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(2) Install the camshaft bearing cap (A).
Tighten the bolts, in several passes, in the sequence as shown.

Tightening torque
M6 bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
M8 bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
• Be careful not to change the position and direction of bearing caps.
12. Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).
Tightening torque :
64.7 ~ 76.5 N.m (6.6 ~ 7.8 kgf.m, 47.7 ~ 56.4 lb-ft)
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14. Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.

• Refill a radiator and a reservoir tank with engine coolant.
– After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two
seconds and fuel line pressurizes.
– Start engine and let it run until it warms up (until the radiator fan operates 3 or 4 times).
–
Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling
system.
– Put radiator cap on tightly, then run the engine again and check for leaks.
Components
1. Piston ring 8. Connecting rod bearing cap 15. Drive plate

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2. Snap ring 9. Cylinder block 16. Adapter plate
3. Piston pin 10. Crankshaft upper bearing 17. Lower crankcase
4. Piston 11. Crankshaft thrust bearing 18. Gasket
5. Connecting rod 12. Crankshaft 19. Rear oil seal
6. Connecting rod upper bearing 13. Crankshaft lower bearing
7. Connecting rod lower bearing 14. CKPS (Crankshaft position sensor) wheel
Components
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1. Adapter plate 2. Drive plate

1. Remove the automatic transaxle.
2. Remove the drive plate (A) and the adapter plate (B).
Tightening torque :
117.7 ~ 127.5 N.m (12.0 ~ 13.0 kgf.m, 86.8 ~ 94.0 lb-ft)
• Do not reuse the drive plate bolts.
Components
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1. Rear oil seal
Removal
1. Remove the automatic transaxle.
2. Automatic transaxle : Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
3. Remove the rear oil seal (A).
Installation
1. Install a new rear oil seal.
(1) Apply engine oil on the edge of new oil seal.
(2) Using SST (09231-H1100, 09214-2E000) and a hammer, tap in the oil seal (A) until the SST face is aligned with the cylinder block
assembly rear face.
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Components
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1. Piston ring 5. Connecting rod
2. Snap ring 6. Connecting rod upper bearing
3. Piston pin 7. Connecting rod lower bearing
4. Piston 8. Connecting rod bearing cap
Disassembly
Engine removal is required for this procedure.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.

• Turn the crankshaft pulley so that the No.1 piston is at TDC (Top dead center).
1. Remove the engine assembly from the vehicle.

(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2. Remove the transaxle assembly from the engine assembly.
Automatic Transaxle
3. Automatic Transaxle : Remove the drive plate.
4. Remove the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
5. Install the engine to engine stand for disassembly.
(Refer to Timing System - "Timing Chain")
7. Remove the water pump assembly.
(Refer to Cooling System - "Water Pump")
8. Remove the water inlet fitting and the thermostat assembly.
(Refer to Cooling System - "Thermostat")
12. Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
13. Remove the oil filter.
(Refer to Lubrication System - "Engine Oil")
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14. Remove the oil screen.
(Refer to Lubrication System - "Oil Pan")
15. Remove the knock sensor (A).
16. Remove the oil pressure switch (OPS) (B).
17. Remove the crankshaft position sensor (CKPS) (C).
18. Check the connecting rod side clearance.

19. Check the connecting rod bearing cap oil clearance.
20. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Remove the connecting rod bearing caps (A).
• Mark the connecting rod, and caps to be able to reassemble in the original position and direction.
(3) Push the piston and connecting rod assembly with upper bearing through the top of the cylinder block.
• Keep the connecting rod ands cap with their bearings assembled together.
• Arrange the piston and connecting rod assemblies in the correct order.
• Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
21. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. Remove piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove 2 side rails and the oil ring by hand.
• Arrange the piston rings in the correct order.
23. Disassemble the connecting rod from the piston.

(1) Remove the snap ring (A) from the piston.
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(2) Remove the piston pin (B) from piston.
(3) Disassemble the piston (C) and connecting rod (D).
Inspection
Connecting Rod
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
• If out-of-tolerance, install a new connecting rod.
• If still out-of-tolerance, replace the crankshaft.
Side clearance
Standard : 0.10~ 0.25 mm (0.0039 ~ 0.0098 in.)
2. Check the connecting road bearing oil clearance.

(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crank pin and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and torque the bolts.
Tightening torque
1st step :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft)
2nd step : 88 ~ 92°
• Do not turn the crankshaft.

– Do not turn the crankshaft.
– Do not reuse the connection rod cap bolts.
(7) Remove the connecting rod cap and lower bearing.

(8) Measure the width of the plastigage at its widest point.
Oil clearance :
0.024 ~ 0.042 mm (0.00094 ~ 0.00165 in.)
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(9) If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then install new bearings
with the same color mark. Recheck the oil clearance.
• Do not file, shim, of scrape the bearings or the caps to adjust clearance.
(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance.
• If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and
repeat the check procedure.
• If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.
Connecting Rod Identification Mark

Connecting Rod Specifications
Class Mark Inside Diameter
48.000 ~ 48.006 mm
0 A
(1.88976 ~ 1.89000 in.)
48.006 ~ 48.012 mm
1 B
(1.89000 ~ 1.89023 in.)
48.012 ~ 48.018 mm
2 C
(1.89023 ~ 1.89047 in.)
Crankshaft Pin Identification Mark
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• Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class Mark Outside Diameter of Pin
44.966 ~ 44.972 mm
I 1
(1.77031 ~ 1.77055 in.)
44.960 ~ 44.966 mm
II 2
(1.77008 ~ 1.77031 in.)
44.954 ~ 44.960 mm
III 3
(1.76984 ~ 1.77008 in.)
Connecting Rod Bearing Identification Mark

Connecting Rod Bearing Specifications
Class Mark Thickness of Bearing
1.511 ~ 1.514 mm
A Light Blue
(0.05948 ~ 0.05960 in.)
1.508 ~ 1.511 mm
B Black
(0.05937 ~ 0.05948 in.)
1.505 ~ 1.508 mm
C White
(0.05925 ~ 0.05937 in.)
1.502 ~ 1.505 mm
D Light Green
(0.05913 ~ 0.05925 in.)
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1.499 ~ 1.502 mm
E Pink
(0.05901 ~ 0.05913 in.)
(11) Select a connecting rod bearing using selection chart.
Selection Chart For Connecting Rod Bearings

Connecting Rod Identification Mark
Assembling Classification of Bearing
0 1 (B) 2(C)
E
I (1) D (Light Green) C (White)
Crankshaft Identification (Pink)
Mark II (2) D (Light Green) C (White) B (Black)
III (3) C (White) B (Black) A (Light Blue)
3. Check the connecting rods.

(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting
rod is installed, make sure that the notches for holding the bearing in place are on the same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside
diameter of the small end is apparent, the rod must be replaced as well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by
a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod :
0.05 mm (0.0020 in.) or less for 100 mm (3.94 in.)
Allowable twist of connecting rod :
0.10 mm (0.0039 in.) or less for 100 mm (3.94 in.)
• When the connecting rods are installed without bearings, there should be no difference on side surface.
Piston
1. Clean piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
•
Do not use a wire brush.
2. Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
(1) Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Cylinder bore diameter :
81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)
• Measure position points (from the top of the cylinder block):
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30mm (1.1811in.) / 60mm (2.3622in.) / 90mm (3.5433in.)
(2) Measure the piston outside diameter at 35mm (1.3780in) from top land of the piston.
Piston outside diameter :
80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)
3. Select the piston matching with cylinder bore class.

(1) Check the cylinder bore size code on the cylinder block side surface.
Cylinder Bore Inner Diameter

Size Code Cylinder Bore Inner Diameter
A 81.00 ~ 81.01 mm (3.1890 ~ 3.1894 in.)
B 81.01 ~ 81.02 mm (3.1894 ~ 3.1898 in.)
C 81.02 ~ 81.03 mm (3.1898 ~ 3.1902 in.)
(2) Check the piston size mark on the piston top face.
Piston Outer Diameter

Size Code Piston Outer Diameter
A 80.97 ~ 80.98 mm (3.1878 ~ 3.1882 in.)
B 80.98 ~ 80.99 mm (3.1882 ~ 3.1886 in.)
C 80.99 ~ 81.00 mm (3.1886 ~ 3.1890 in.)
Piston Rings
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1. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
If the clearance is greater than maximum, replace the piston.
Piston ring side clearance
[Standard]
No.1 ring :
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
No.2 ring :
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring :
0.020 ~ 0.060 (0.00079 ~ 0.00236 in.)
If the clearance is greater than maximum, replace the piston.

2. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently
pressing it down with a piston. Measure the gap with a feeler gauge.
Piston ring end gap
[Standard]
No.1 ring : 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
No.2 ring : 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
Oil ring : 0.20 ~ 0.50 (0.0079 ~ 0.0197)
If the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is
over the service limit, the cylinder block must be replaced.
Piston Pins
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1. Measure the diameter of the piston pin.
Piston pin diameter :
19.997 ~ 20.000 mm (0.78728 ~ 0.78740 in.)
2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :
0.004 ~ 0.016 mm (0.00016 ~ 0.00063 in.)
3. Check the clearance between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod clearance :
0.007 ~ 0.016mm(0.00028 ~ 0.00063 in.)
Reassembly

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1. Assemble the piston and the connecting rod.

(1) Install the snap ring (A) in one side of the piston pin hole.
(2) Align the piston front mark and the connecting rod front mark.
(3) Insert the piston pin (B) into the piston pin hole and the small end bore of connecting rod.
(4) Install the snap ring (C) in the other side after inserting the piston pin.
• Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the
connecting rod before inserting the piston pin.
• Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.
• Set the snap ring firmly so that the snap ring can contact with the whole groove of the piston pin hole.
2. Install the piston rings.

(1) Install the oil ring spacer and 2 side rails by hand.
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(2) Using a piston ring expander, install the 2 compression rings with the maker mark facing upward.
(3) Position the piston rings so that the ring ends are as shown. (The No.1 ring should be on the opposite side of the No.2 ring.)
Example)
• Check to ensure that the oil ring can be turned smoothly.
3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings (A) in the connecting rod and connecting rod cap (B).
• Be careful not to change the position of bearing caps.

4. Install the piston and connecting rod assemblies.
• Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
• Install the piston and connecting rod assembly with the front marks facing the front of the engine.
(1) Install the ring compressor, check that the rings are securely in place, and then position the piston in the cylinder, and tap it in using the
wooden handle of a hammer.
(2) Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.
Tightening torque
1st step :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft)
2nd step : 88 ~ 92°
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Using the SST (09221-4A000), tighten the connecting rod cap bolts.
• Do not reuse the connecting rod cap bolts.
• Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
5. Check the connecting rod end play.

6. Assemble the other parts in the reverse order of disassembly.
Components
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1. Crankshaft upper bearing 5. CKPS (Crankshaft position sensor) wheel
2. Crankshaft thrust bearing 6. Lower crankcase
3. Crankshaft 7. Gasket
4. Crankshaft lower bearing
Disassembly

removing it.

• Turn the crankshaft pulley so that the No.1 piston isat TDC (Top dead center).

(Refer to Engine and Transaxle Assembly - “Engine and Transaxle Assembly”)
Automatic Transaxle
(Refer to Cylinder Block - “Rear Oil Seal”)
(Refer to Timing System - “Timing Chain”)
(Refer to Cooling System - “Water Pump”)
(Refer to Cooling System - “Thermostat“)
(Refer to Lubrication System - “Engine Oil”)
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(Refer to Lubrication System - “Oil Pan”)
(Refer to Cylinder Block - "Piston and Connecting Rod")
16. Remove the oil pressure switch (OPS) (A).
17. Remove the crankshaft position sensor (CKPS) (B).
18. Check the crankshaft bearing oil clearance.

19. Disassemble the connecting rod from the piston.
(1) Remove the lower crankcase mounting bolts.
(2) Remove the main bearing cap bolts.

20. Check the crankshaft end play.
21. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
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• Arrange the main bearings and thrust bearings in the correct order.
Inspection
1. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the lower crankcase and lower bearings.
(2) Clean each main journal and bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower crankcase and lower bearings, and then tighten the main bolts.
Tightening torque
1st step :
27.5 ~ 31.4 N.m (2.8~3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
2nd step : 120 ~ 125°
• Do not turn the crankshaft.
(5) Remove the lower crankcase and lower bearings.

(6) Measure the width of the plastigage at its widest point.
Oil clearance :
0.016 ~ 0.034 mm (0.00063 ~ 0.00134 in.)
(7) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same
color mark. Recheck the oil clearance.
• Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(8) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance.
• If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and
start over.
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• If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.
Crankshaft Bore Identification Mark
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Cylinder Block Specifications

Calss Mark Inside Diameter
59.000 ~ 59.006 mm
a A
(2.32283 ~ 2.32307 in.)
59.006 ~ 59.012 mm
b B
(2.32307 ~ 2.32330 in.)
59.012 ~ 59.018 mm
c C
(2.32330 ~ 2.32354 in.)
Crankshaft Journal Identification Mark

• Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class Mark Outside Diameter of Journal
54.954 ~ 54.960 mm
I 1
(2.16354 ~ 2.16378 in.)
54.948 ~ 54.954 mm
II 2
(2.16330 ~ 2.16354 in.)
54.942 ~ 54.948 mm
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III 3
(2.16307 ~ 2.16330 in.)
Crankshaft Bearing Identification Mark
Crankshaft Bearing Specifications

Class Mark Thickness of Bearing
2.021 ~ 2.024 mm
A Blue
(0.07957 ~ 0.07968 in.)
2.018 ~ 2.021 mm
B Black
(0.07945 ~ 0.07957 in.)
2.015 ~ 2.018 mm
C None
(0.07933 ~ 0.07945 in.)
2.012 ~ 2.015 mm
D Green
(0.07921 ~ 0.7933 in.)
2.009 ~ 2.012 mm
E Yellow
(0.07909 ~ 0.07921 in.)
(9) Select a crankshaft bearing using the selection chart.
Selection Chart For Crankshaft Bearings

Crankshaft Bore Identification Mark
Assembling Classification of Bearing
a b (B) c (C)
I (1) E (Yellow) D (Green) C (None)
Crankshaft Identification
II (2) D (Green) C (None) B (Black)
Mark
III (3) C (None) B (Black) A (Blue)
2. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
If the end play is greater than maximum, replace the center bearing.
End play
Standard : 0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)
3. Inspect main journals and crank pins.

Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
54.942 ~ 54.960 mm (2.16307 ~ 2.16378 in.)
Crank pin diameter :
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44.954 ~ 44.972 mm (1.76984 ~ 1.77055 in.)
Reassembly

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1. Install the crankshaft main bearings.
• Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1) Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A).
(2) Align the bearing claw with the groove of the lower crankcase (B), and push in the 5 lower bearings (A).
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2. Install the thrust bearings.
Install the 2 thrust bearings (A) on both sides of the No.3 journal of the cylinder block with the oil groove facing out.
3. Place the crankshaft (A) on the cylinder block.
4. Apply liquid sealant on the top surface of the lower crankcase.

(2) The sealant locations on the lower crankcase and the cylinder block must be free of harmful foreign materials, oil, dust and moisture.
Spraying cleaner on the surface and wiping with a clean duster.
(3) Assemble a new rubber gasket (A) on the top of lower crankcase.
(4) Apply liquid sealant on the bottom of the cylinder block. Continuous bead of sealant should be applied to prevent any path from oil
leakage.
Bead width :2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)
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• Assemble the lower crankcase within 5 minutes after applying sealant.
• The engine running or pressure test should not be performed within 30 minutes after assembling the lower crankcase.
• Excess sealant on application surface of sealant of following process should be removed before hardening.
• If the sealant is applied to the top surface of the lower crankcase, it should be the same position as the cylinder block.
• To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
5. Place the lower crankcase on the cylinder block.

6. Install the main bearing cap bolts.
Using SST (09221-4A000), install and tighten the 10 main bearing cap bolts, in several passes, in the sequence as shown.
Tightening torque
1st step :
27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
2nd step : 120 ~ 125°
• Do not reuse the bearing cap bolts.
• Do not apply engine oil on the bolt threads to achieve correct torque.
• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts is broken or deformed, replace it.
• Be sure to assemble the main bearing cap bolts in correct order.
7. Install the lower crankcase bolts, in several passes, in sequence as shown.
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Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Check that the crankshaft turns smoothly.

8. Check the crankshaft end play.
9. Install the crankshaft position sensor (CKPS) (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
10. Install the oil pressure switch (OPS) (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

• In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on
the crankshaft.
– Connecting rod bearing selection
Disassembly

removing it.

• Turn the crankshaft pulley so that the No.1 piston isat TDC (Top dead center).

(Refer to Engine and Transaxle Assembly - “Engine and Transaxle Assembly”)
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Automatic Transaxle
(Refer to Cylinder Block - “Rear Oil Seal”)
(Refer to Timing System - “Timing Chain”)
(Refer to Cooling System - “Water Pump”)
(Refer to Cooling System - “Thermostat“)
(Refer to Lubrication System - “Engine Oil”)
(Refer to Lubrication System - “Oil Pan”)
16. Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
17. Remove the knock sensor (A).
Inspection
1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard :
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Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) x 100 mm (3.9370 in.)
4. Inspect the cylinder bore

Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Cylinder bore diameter :
81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)
• Measure position points (from the top of the cylinder block) :

30mm (1.1811in.) / 60mm (2.3622in.) / 90mm (3.5433in.)
Installation
1. Install the knock sensor (A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
• In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the
crankshaft journal bore mark and the cylinder bore mark on the cylinder block.
– Crankshaft main bearing selection
(Refer to Cylinder Block - "Crankshaft")
– Piston selection
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Refilling and Bleeding
• Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping
from the radiator.
• When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any
coolant spills, rinse it off immediately.
1. Make sure the engine and radiator are cool to the touch.
2. Remove the reservoir tank cap (A).

4. Loosen the drain plug (A) and drain the coolant.
5. Tighten the radiator drain plug securely.
6. After draining engine coolant in the reservoir tank, clean the tank.
7. Fill the radiator with water through the radiator cap and tighten the cap.
• To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.
8. Start the engine and allow to come to normal operating temperature. Wait for the cooling fans to turn on several times. Accelerate the engine
to aid in purging trapped air. Shut engine off.
9. Wait until the engine is cool.
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10. Repeat step 1 to 9 until the drained water runs clear.
11. Fill fluid mixture with coolant and water (55~60%) (except for North America, Europe and China: 45~50%) slowly through the radiator cap.
Push the upper/lower hoses of the radiator so as bleed air easily.
• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration must be maintained year-round at 55% (except for North America,
Europe and China: 45%) minimum.
Coolant concentrations less than 55% (except for North America, Europe and China: 45%) may not provide sufficient protection
against corrosion or freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.
• Do not mix different brands of antifreeze / coolants.

• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
12. Start the engine and run until coolant circulates.When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
13. Repeat step 12 until the cooling fan 3 ~ 5 times and bleed air sufficiently out of the cooling system.
14. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.
15. Run the vehicle under idle until the cooling fan operates 2~3 times.
16. Stop the engine and wait coolant gets cool.
17. Repeat step 11 to 16 until the coolant level doesn''t fall any more, bleed air out of the cooling system.
• It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, then recheck the
coolant level in the reservoir tank for 2~3 days after replacing coolant.
Coolant capacity
7.5 L (1.98 U.S.gal., 7.92 U.S.qt., 6.59 lmp.qt.)
Components
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1. Cooling fan 3. Cooling fan shroud
2. Fan motor 4. Cooling fan controller (PWM)
Specifications
Item Specification
Motor capacity (W) 170
Fan type PULLER
Fan speed control PWM
Current consumption 14.2 + 10% MAX.
Circuit Diagram
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Cooling fan assembly
2. Remove the air duct and air cleaner assembly.
4. Disconnect the wire harness connector (A).
5. Remove the radiator upper hose fixing bracket bolt (A).
Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
6. Remove the radiator lower hose fixing bracket bolt (A).

Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
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7. Remove the cooling fan (A).
Tightening torque :
4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)
Cooling fan controller (PWM)

1. Disconnect the wire harness connector (A) and the fan motor connector (B).
2. Remove the PWM (A) from the cooling fan shroud.
Tightening torque :
2.8 ~ 3.2 N.m (0.28 ~ 0.33 kgf.m, 2.1 ~ 2.4 lb-ft)
Disassembly
1. Remove the cooling fan (A) from the cooling fan assembly.
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2. Disconnect the fan motor connector (A) from the PWM.
3. Loosen the screws and then remove the fan motor (A) from the cooling fan shroud.
Tightening torque :
4.2 ~ 4.7 N.m (0.43 ~ 0.48 kgf.m, 3.1 ~ 3.5 lb-ft)
4. Assemble in the reverse order of disassembly.
Inspection
Fan Motor
1. Disconnect the fan motor connector from the PWM.
2. Connect the battery voltage to the "+" terminal and ground to "-" terminal.
3. Check the cooling fan motor operates well.
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Components
1. Radiator 4. Radiator upper hose
2. Radiator upper mounting bracket 5. Radiator lower hose
3. Lower mounting insulator

1. Loosen the drain plug and drain the engine coolant.
2. Remove the cooling fan.
(Refer to Cooling System - "Cooling Fan")
3. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
4. Remove the air duct shield (A).
5. Remove the radiator upper air guard (B).
Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
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6. Remove the air guards (A).
[RH]
[LH]
7. Remove the radiator upper mounting brackets (A).

Tightening torque :
7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)
[RH]
[LH]
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8. Remove the over flow hose (A).
9. Remove the radiator upper hose (A).
10. Remove the radiator lower hose (A).

11. Remove the A/C condenser from the radiator assembly and then lift up the radiator assembly (A).
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13. Fill the radiator with coolant and check for leaks.

– Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
– Turn off engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling
system.
– Put the radiator cap on tightly, then run engine again and check for leaks.
Components
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1. Water temperature control assembly 3. Throttle body coolant hose (if equipped)
2. Engine coolant temperature sensor

2. Drain the engine coolant.
4. Disconnect the radiator upper hose.
(Refer to Cooling System - "Radiator")
5. Disconnect the heater hose.
(Refer to Engine and Transmission Assembly - "Engine and Transmission Assembly")
6. Disconnect the bypass hose (A) and the throttle body coolant hose (B) (if equipped).
7. Remove the water temperature control assembly (A) with the O-ring.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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• Install a new O-ring.
• Clean surface on the O-ring and install the O-ring after wetting with water.

9. Fill the engine coolant.
10. Start engine and check for leaks.
Components
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1. Water pump pulley 3. Water pump gasket
2. Water pump

1. Loosen the drain plug, and then drain the engine coolant. Remove the radiator cap to help drain the coolant faster.
3. Remove the water pump pulley (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
4. Remove the water pump assembly (A) with the gasket (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• Install a new water pump gasket.

7. Start the engine and check for leaks.
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8. Recheck the coolant level.
Inspection
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly.
• A small amount of "weeping" from the bleed hole is normal.
Troubleshooting
Symptoms Possible Causes Remedy
Coolant leakage • From the bleed hole of Visually check • Check leaks after about • If coolant still leaks, replace a
the water pump ten-minute warming up. water pump.
• If leakage stops, reuse the
water pump (Do not replace the
pump with a new one).
• From gaskets or bolts • Check the tightening of • Retighten the mounting bolts.
the water pump
mounting bolts.
• Check damage of • Replace the gasket and clean
gaskets or inflow of dust. dust off.
• From outer surface of • Check the material or • Poor material. If any crack
water pump any cracks of the water found, replace the water pump.
pump.
Noise • From bearings Inspection with a • After starting the engine, • If there is no noise, reuse the
• From mechanical seals stethoscope check noise with a water pump (do not replace it).
stethoscope. • If there is any noise from the
• Impeller interference
water pump, remove the drive
belt and recheck.
Inspection after removing a • After removing a water • If there is noise, reuse the water
drive belt pump and a drive belt, pump. Check other drive line
check noise again. parts.
• If there is no noise, replace the
water pump with a new one.
Inspection after removing a • •
water pump
After removing a water If there is any interference
pump and a drive belt, between them, replace the
check noise again. water pump with a new one.
Overheating • Damaged impeller Loosened impeller • Corrosion of the impeller • Check engine coolant.
• Loosened impeller wing • Poor coolant quality /
Maintenance check
• Impeller seperation from • Replace the water pump.
the shaft
Components
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1. Water inlet fitting 3. Bypass hose
2. Thermostat 4. Heater pipe & hose assembly
• Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat,
even if the engine tends to overheat.
1. Drain engine coolant so its level is below thermostat.

2. Disconnect the radiator lower hose.
(Refer to Cooling System - "Radiator Hose")
3. Remove the water inlet fitting (A) and thermostat (B).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

5. Remove the bypass hose (A).
6. Unfasten the heater pipe mounting bolts (B) and then remove the heater pipe.
Tightening torque :
19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)
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• Do not reuse the seal bolts.
• Install the thermostat with the jiggle valve upward.

• When assembling the thermostat, place the thermostat on the housing with a protrusion of thermostat matching with a groove of
the housing and install the inlet fitting. Be careful the thermostat doesn’t get out of the groove on the housing.
• Clean surface on the rubber packing contact surface.

9. Start the engine and check for leaks.
10. Recheck the coolant level.
Inspection
1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature.
If the valve opening temperature is not as specified, replace the thermostat.
Valve opening temperature:
88 ± 1.5°C (190.4 ± 34.7°F)
Full opening temperature:100°C (212°F)
3. Check the valve lift.

If the valve lift is not as specified, replace the thermostat.
Valve lift :8 mm (0.3 in.) or more at 100°C (212°F)
Troubleshooting
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Symptoms Possible Causes Remedy
Coolant leakage • From the thermostat Check the mounting • Check the torque of the mounting • Retighten the bolts and check
gasket nuts bolts leakage again.
Check the gasket for • Check gasket or seal for damage • Replace gaskets and reuse the
damage thermostat.
Cooled • Low heater Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
excessively performance (cool air removing the radiator
blows-out) cap.
• Thermogauge GDS check&Starting • Check DTCs • Check the engine coolant
indicates ''LOW'' engine • Check the fan motor performance sensor, wiring and connectors.
as temperature varies. • Check the fan motor, the relay
• Check connection of the fan and the connector.
clutch or the fan motor. • Replace the componants.
※ If the fan clutch is always
connected, there will be a noise at
idle.
Remove the thermostat • Check if there are dusts or chips • Clean the thermostat valve and
and inspect in the thermostat valve. reuse the thermostat.
• Check adherence of the • Replace the thermostat, if it
thermostat. doesn''t work properly.
Heated • Engine overheated Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
excessively • Thermogauge removing the radiator ※ Be careful when removing a • Check the cylinder head
indicates ''HI'' cap. radiator cap of the overheated gaskets for damage and the
vehicle. tightening torque of the
• Check air in cooling system. mounting bolts.
GDS check&Starting • Check DTCs • Check the engine coolant
engine • Check the fan motor performance sensor, wiring and connectors.
as temperature varies. • Check the fan motor, the relay
• Check if the fan clutch slips. and the connector.
• Check the water pump • Replace the fan clutch, if it
adherence or impeller damaged. doesn''t work properly.
• Replace the water pump, if it
doesn''t work properly.
Immerse the thermostat • After removing the thermostat, • Replace the thermostat, if it
in boiling water and check it works properly. doesn''t work properly.
inspection. ※ Check the thermostat opens at
the valve opening temperature.
Components
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1. Timing chain cover 8. O-ring (suction side)
2. Outer roter 9. O-ring (discharge side)
3. Inner roter 10. Oil screen gasket
4. Oil pump cover 11. Oil screen
5. Relief plunger 12. Oil pan
6. Relief spring 13. Oil filter
7. Relief plug 14. Oil pressure switch (OPS)
Engine Oil Schemetics

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Oil and Filter Replacement
• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.
1. Park the car on level ground.

2. Drain engine oil.
(1) Remove the oil filler cap.
(2) After lifting the car, remove the oil drain plug (A) and drain oil into a container.
3. Replace the oil filter (A).

(1) Using the SST (09263-2E000), remove the oil filter.
(2) Check and clean the oil filter installation surface.
(3) Check the part number of the new oil filter is as same as old one.
(4) Apply clean engine oil to the gasket of a new oil filter.
(5) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
(6) Tighten it with the torque below.
Tightening torque :
11.8 ~ 15.7 N.m (1.2 ~ 1.6 kgf.m, 8.7 ~ 11.6 lb-ft)
4. Install the oil drain plug with a new gasket.

Tightening torque :
34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)
5. Fill with new engine oil, after removing the engine oil level gauge.
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Capacity
Total :
Oil pan : 3.7 L (0.98 U.S.gal., 3.91 U.S.qt., 3.26 lmp.qt.)
Drain and refill including oil filter :
6. Install the oil filler cap.

7. Start engine and check for oil leaks and check the oil gauge or light for an indication of oil pressure.
8. Recheck the engine oil level.
Inspection
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning. If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After engine warm up stop the engine wait 5 minutes then check the oil level. Oil level should be between the "L" and "F" marks on the
dipstick. If low check for leakage and add oil up to the "F" mark.
• Do not fill with engine oil above the "F" mark.
Selection of Engine Oil

Specifications :
5W-20 / API SM & ILSAC GF-4 (or above) / ACEA A5 (or above)
• API SL, ILSAC GF-3, ACEA A3 Class engine oil can be used if the recommended engine oil is not available.
Allowed SAE Viscosity

• For best performance and maximum protection of all types of operation, select only those lubricants which:
1) Satisfy the requirement of the API, ILSAC or ACEA classification.
2) Have proper SAE grade number for expected ambient temperature range.
3) Lubricants that do not have both an SAE grade number and API, ILSAC or ACEA service classification on the container should not
be used.
Components
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1. Oil screen gasket 3. Oil pan

2. Oil screen
Removal
2. Drain engine oil.
(Refer to Lubrication System - "Engine Oil")
3. Remove the oil pan (A).
(1) Unfasten the bolts.
(2) Insert the blade of SST (09215-3C000) between the lower crankcase and the oil pan. Separate the applied sealer and remove the oil
pan.
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• Loosen one oil pan bolt near each corner of the oil pan leaving the bolts held in by about 2 threads. Then remove all other pan
bolts.
• Insert the SST between the oil pan and the lower crankcase by tapping it with a plastic hammer in the direction of arrow.
• After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it
from the lower crankcase.
• Do not turn over the SST abruptly without tapping. It is result in damage of the SST.
• Be careful not to damage the contact surfaces of the lower crankcase and the oil pan.
4. Remove the oil screen (A) with the gasket (B).
Installation
1. Install the oil screen (A) with a new gasket (B).
Tightening torque
Bolt :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
Nuts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
2. Install the oil pan.
(2) The sealant locations on the oil pan and the lower crankcase must be free of harmful foreign materials, oil, dust and moisture.
Spraying cleaner on the surface and wiping with a clean duster.
(3) After applying liquid sealant on the oil pan, assemble it within 5 minutes after sealant was applied. Continuous bead of sealant should be
applied to prevent any path of oil leakage.
Bead width
Whole section : 4.0 ~ 5.0 mm (0.16 ~ 0.20 in.)
Section A : 1.5 ~ 2.5 mm (0.06 ~ 0.10 in.)
Sealant :Threebond 1217H (Hyundai Gray RTV)
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• When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
• If the sealant is applied to the bottom surface of the lower crankcase, it should be the same position as the oil pan.
(4) Install the oil pan (A). Uniformly tighten the bolts in several passes.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• After assembly, wait at least 30 minutes before filling the engine with oil.
• Always use a new drain plug gasket.

3. Refill engine with engine oil.
Components
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1. Timing chain cover 6. Relief spring
2. Outer roter 7. Relief plug
3. Inner roter 8. O-ring (suction side)
4. Oil pump cover 9. O-ring (discharge side)
5. Relief plunger

1. Remove the timing chain cover.
(Refer to Timing System - "Timing Chain Cover")
2. Remove the oil pump cover (A).
Tightening torque
Screws :
5.9 ~ 8.8 N.m (0.6 ~ 0.9 kgf.m, 4.3 ~ 6.5 lb-ft)
Bolts :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
3. Remove the inner rotor (A) and outer rotor (B).
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Inspection
1. Remove the relief plunger.
Remove the plug (A), spring (B) and relief plunger (C).
Tightening torque
Plug (A) :
39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
2. Inspect the relief plunger.

Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If necessary, replace timing chain cover.
3. Inspect the relief valve spring.
Inspect for distortion or breakdown of the relief valve spring.
4. Inspect the rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the inner rotors and precision straight edge.
If the side clearance is greater than maximum, replace the rotors as a set.
If necessary, replace the timing chain cover.
Side clearance :
0.040 ~ 0.090 mm (0.00157 ~ 0.00354 in.)
5. Inspect the rotor body clearance.
Using a feeler gauge, measure the clearance between the outer rotor and body.
If the body clearance is greater than maximum, replace the rotors as a set.
If necessary, replace the timing chain cover.
Body clearance :
0.200 ~ 0.292 mm (0.00787 ~ 0.01150 in.)
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6. Inspect the rotor guide clearance.
(1) Measure the outer diameter of the inner rotor guide.
Inner rotor diameter :
41.550 ~ 41.570 mm (1.63582 ~ 1.63661 in.)
(2) Measure the inner diameter of the timing chain cover hole.
Timing chain cover hole diameter :
41.600 ~ 41.625 mm (1.63779 ~ 1.63878 in.)
(3) Check the clearance between the timing chain cover hole inner diameter and the inner rotor guide outer diameter.
Guide clearance :
0.030 ~ 0.075 mm (0.00118 ~ 0.00295 in.)

1. Disconnect the oil pressure switch connector (A) and then remove the oil pressure switch (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• When installing the oil pressure switch, apply seal lock to the thread.
Seal lock :THREEBOND 2403

Thickness :0.2 ~ 0.4 mm (0.008 ~ 0.016 in.)
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Inspection
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is
pushed, replace the switch.
3. If there is no continuity when a 50kPa (0.50kgf/cm², 7.25psi) is applied through the oil hole, the switch is operaing properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

1. Remove the oil level gauge (A).
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Components
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1. Air intake hose 4. Air duct
2. Air cleaner element 5. Clamp
3. Air cleaner body

2. Disconnect the battery negative terminal and the positive terminal.
3. Remove the air duct (A).
4. Disconnect the breather hose (A) and brake booster vacuum hose (B).
5. Disconnect the intake hose (C) and air cleaner assembly (D).
Tightening torque
Hose clamp :
2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
Air cleaner bolts :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
• Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
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Air Cleaner Element Replacement
1. Pull the clamp to open the service cover (A).
2. Turn the fixing lever of the element to the "UNLOCK" direction to unlock it. Then pull the element to take it out.
3. Replace the air cleaner element (A) with a new one.

4. Insert the element to the inside of the air cleaner completely. Turn the lever to the "LOCK" direction to lock it firmly. Then close the service
cover (A).
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Components
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1. Intake manifold assembly 3. Electronic throttle body
2. Intake manifold gasket 4. Intake manifold stay

(Refer to Intake and Exhasut System - "Air Cleaner")
5. Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.
6. Disconnect the positive crankcase ventilation (PCV) hose (A).
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7. Disconnect the reservoir tank water hose pipe (A).
8. Disconnect the vacuum hose (A) and purge control solenoid valve (PCSV) hose (B).
9. Unfasten the electric throttle body control (ETC) module bolts.

(Refer to Engine Control/Fuel System - "ETC (Electric throttle body control) System")
10. Remove the intake manifold stay (A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
11. Remove the intake manifold (A) with the gasket (B).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
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• When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with
specified torque in the sequence shown.

1. Disconnect the vacuum hose (A).
2. Remove the variable Intake solenoid (VIS) actuator (B)
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Components
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1. Heat protector 3. Exhaust manifold

2. Exhaust manifold gasket 4. Exhaust manifold stay

3. Disconnect the front oxygen sensor connector (A) and then remove it from the bracket.

(Refer to Engine and Transaxle Assembly - “Engine Room Under Cover”)
5. Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
6. Remove the exhaust manifold heat protector (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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7. Remove the driveshaft heat protector (A).
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
8. Remove the exhaust manifold stay (A).

Tightening torque :
39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
9. Remove the exhaust manifold (A) with the gasket (B).
Tightening torque :
34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)
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• When installing the intake manifold, tighten the nuts with pre-torque first, and then tighten the nuts with specified torque in the
sequence shown.
• When installing, replace with a new gasket.
Components
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1. Front muffler 4. Gasket
2. Catalytic converter & center muffler assembly 5. Hanger
3. Main muffler

Front Muffler
1. Disconnect the heated oxygen sensor connector (A) and then remove it from the bracket.
2. Remove the engine room under rear cover assembly (A).

3. Detach the rubber hanger (A) from the front muffler.
4. Remove the front muffler (B).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
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• When installing, replace with new gaskets.
5. Install in the revers order of removal.
Center Muffler
1. Remove the heated oxygen sensor.
(Refer to Engine Control/Fuel System - "Heated Oxygen Sensor (HO2S)")
2. Remove the catalytic converter and the center muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
3. Install in the revers order of removal.
Main Muffler
1. Remove the main muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
Replacement procedure of center muffler using clamp

Under warranty : Replace the center muffler assembly.
Out of warranty : It is available to replace the center muffler as the procedure below.
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1. Check that the clamping part of the center muffler assembly is damaged or deformed.
If the muffler is too corroded to clamp, replace the center muffler assembly.
2. Record the gap (A, B, C, D, E, F) between the tail pipe (or tail trim) and the rear bumper.
[Pipe type]
[Trim type]
[Bumper-integrated trim type]
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3. Remove the catalytic converter & center muffler (A).
4. Cut the center muffler as the instruction below.

[With dent]
– Cut the front dent of the muffler.
[Without dent]
– Cut the muffler by reffering to the front dent of A/S muffler as shown in the image below.
[A/S muffler]
– Cut the rear dent of the A/S muffler.
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• To prevent a leak, remove the rust on the clamping part or the burr on the cutting part.
• Cut the pipe vertically.
• Pipe cutter available to cut the pipe vertically.
• Use a hacksaw as the procedure below, if a pipe cutter is unavailable.

1) Mark the cutting position to cut the pipe vertically.
2) Cut the pipe along the marking line by using hacksaw.

5. Install the center muffler.
(1) Install the catalytic converter (A) and the center muffler (B) for A/S by tightening the nuts lightly, not completely.
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• When installing the muffler, replace the gasket with new one.
(2) Put the clamp (A) between the cutting part of each pipe and tighten the clamp lightly, not completely.
(3) Tighten the catalytic converter and the center muffler with specified torque.
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
(4) Compare the gap between the tail pipe(or tail trim) and the rear bumper with the record measured before removing the center muffler
assembly.
• If the tail pipe is installed differently compared to the initial position, the bumper might be damaged by the pipe heat or
interfere between the tail pipe and the rear bumper.
(5) Do not tighten the clamp at a time. Tighten the clamp nuts to the specified torque, by turns.
Tightening torque :
17.6 ~ 23.5 N.m (1.8 ~ 2.4 kgf.m, 13.0 ~ 17.4 lb-ft)
• Do not reuse the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.
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Engine Mechanical System 2.0

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Engine Mechanical System 2.0

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Engine Mechanical System 2.0

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Engine Mechanical System

Specifications • API SL, ILSAC GF-3, ACEA A3 Class engine oil

Oil temperature (oil pan) : 110 ± 2°C