Hyundai L4GC
Hyundai L4GC
Hyundai L4GC
SHOP MANUAL
(FOR INDUSTRIAL USE)
FORWORD
We would like to express our sincere gratitude to the patrons who have given us unwavering encouragement.
This manual covers shop manual and parts catalog in one volume for an easy reference of parts list, as
well as contains the accurate and efficient service procedures for HYUNDAI L4GC industrial engine.
This manual includes specifications, troubleshooting, removal, installation, disassembly and assembly in
each group and presents component illustrations and descriptions for an easy reference.
Accordingly, thoroughly read this manual, rapidly purchase the required parts and service the engine in
proper methods to extend its life and benefit.
Improper service methods and procedures may shorten the engine life resulting from its low performance.
Hyundai genuine parts are designed and built to provide the best performance in your engine. If your claim
is caused by using non-Hyundai genuine parts or servicing at places not recommended, your warranty is
not available.
Hyundai Motor Co., Inc. makes efforts to enhance quality and build better parts and service data for you.
We want to assist you in every way possible with this manual and your purchase of HYUNDAI engine is
highly appreciated.
October 2006
NOTE: Contents and specifications are subject to change according to design changes without notice.
IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all en-
gines as well as the personal safety during work. This manual provides general directions for the efficient service
methods and procedures.
There are numerous variations in procedure, techniques, tools and parts for servicing engines, as well as in the skill
of the individual technician.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instructions provided in this manual must establish that he comprises
neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
CAUTION: Information about an activity that could cause damage to the vehicle.
WARNING : Information about an activity that could cause injury or damage to the driver, occupants or
repairman.
[SAFETY INFORMATION]
The following list contains some general warnings that you should follow when you work on an engine.
Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
Operate the engine only in a well-ventilated area to avoid the danger carbon monoxide poisoning.
Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belt.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.
To avoid injury, always remove rings, watches, loose hanging jewelry and loose clothing before beginning to
work on an engine.
1. GENERAL 1-1
1. GENERAL .......................................................................... 1- 1
L4GC200A
1 2 3 4 5 6
1. Engine fuel
L : LPG
2. Engine range
4 : In line 4 cycle 4 cylinder
3. Engine development order
G : engine
4. Engine capacity
C: 1975 CC ( engine)
5. Production year
1 : 2001 2 : 2002 3 : 2003
4 : 2004 5 : 2005 6 : 2006
6. Engine production sequence number
000001 ~ 999999
1-2 GENERAL
SAFETY NOTICE
1. REMOVING AND DISASSEMBLING
After finding the malfunctioning reason and determining the
removal and disassembly if necessary, simultaneously with
checking the defect parts, start the job as the instruction of
the shop manual.
To prevent mal-assembly and to ease job, put punch marks
or identification marks on the places where not affect nor-
mal function and exterior.
L4GC201A
Arrange multi-piece parts and similar parts in order when
disassembling not to make a mistake while reassembling.
2. SPECIAL TOOL
Necessarily use the special tool as instruction to prevent
parts from damage as result of using other general tool.
L4GC202A
3. REPLACEMENT PARTS
The following parts should be replaced with new parts after
removing.
1) Oil seal
2) Gasket (except the locker cover gasket)
3) Packing
4) O-ring
5) Locker washer
6) Split pin
L4GC203A
GENERAL 1-3
4. PARTS
NOTE
• The torques shown in the table are standard val-
ues under the following conditions.
1. Nuts and bolt are made of steel bar and
galvanized.
2. Galvanized plain steel washers are inserted.
3. All nuts, bolts, plain washers are dry.
• The torques shown in the table are not applicable,
1. When spring washers, toothed washers and
the like are inserted.
2. If plastic parts are fastened.
3. If oil is applied to threads and surfaces.
• If you reduce the torques in the table to the per-
centage indicated below under the following
conditions, it will be the standard value.
1. If spring washers are used : 85%
2. If threads and bearing surfaces are stained
with oil: 85%
RECOMMENDED LUBRICANTS AND CAPACITIES 1-5
SCHEDULED MAINTENANCE
ENGINE OIL CLASSIFICATION
Recommended API classification: Above SG
˚C
20W 15W 10W 5W
(5W*1
-30)
-7
-13
-18
L4GC209A
L4GC210A
CAUTION
Over replenishing can happen oil saturation and
overpressure.
8. Stop the engine and after checking the oil level, add oil if
necessary.
1-8 SCHEDULED MAINTENANCE
1. Remove the spark plug from the cylinder head using a spark
plug wrench.
CAUTION
Prevent foreign material from getting in the spark
plug fitting hole.
3 4 5
L4GC303A
SCHEDULED MAINTENANCE 1-9
Clearance
L4GC304A
After connecting the spark plug to the high tension cable, con-
Insulation damaged
nect the outer terminal(main body) to the ground and crank the Insulation damaged
engine.
Because the discharging clearance is narrow in the air, only
slight spark will arise. But if the spark plug is defect, spark
does not arise because insulation is damaged.
Insulation damaged
L4GC217A
1-10 SCHEDULED MAINTENANCE
L4GC215A
COOLING SYSTEM
Check the cooling system hoses for damage and looseness or
inspect the joints for coolant leaks.
COOLANT
When the engine is delivered, the engine cooling system con-
tains mixture of antifreeze(40%) and water(60%).
Because the cylinder head and the water pump are made of
aluminum alloy, the mixture should contain antifreeze (ethylene
glycol) of 30~60% to prevent those from corrosion, freezing
and bursting.
NOTE
• If the coolant contains less than 30% of antifreeze,
anticorrosion is decreased.
• If the coolant contains more than 60% of
antifreeze, the engine will be fatally affected, re-
sulting from decreased anti-freezing and engine
cooling. Use only the recommended antifreeze
and do not mix with other production.
REPLACING COOLANT
CAUTION
If the coolant is hot, injury can happen, so when the
engine is hot, never open the radiator cap until the
coolant temperature is dropped. When open the ra-
diator cap, be careful of hot coolant or steam, sur-
round the upper portion of the cap with a rag, slightly
open it counterclockwise to drop the pressure
through the reservoir tank tube, and then slowly turn
the cap to open.
1. After opening the radiator cap, loosen the drain plug and the
engine drain plug and drain the coolant.
1. GENERAL ........................................................................ 2- 1
GENERAL
OUTLINE
L4GC001A
2-2 GENERAL
L4GC002A
GENERAL 2-3
GENERAL
SPECIFICATIONS
GENERAL
Type Series, DOHC
Cylinder number 4
Bore 82 mm
Stroke 93.5 mm
Displacement 1,975 cc
Compression ratio 9.4
Firing order 1-3-4-2
RPM 700 100 rpm
Ignition timing BTDC 8° 5 °
Valve timing
Intake
Open BTDC 2°
Close ABDC 16°
Exhaust
Open BBDC 18°
Close AT D C 2 °
Valve over rap 4 °
CYLINDER HEAD
Flatness of gasket surface 0.03 mm or less 0.06 mm
Flatness of manifold mounting surface 0.15 mm or less 0.3 mm
Oversize of valve seat hole
Intake
0.3 OS 33.3 ~ 33.325 mm 0.2 mm
0.6 OS 33.6 ~ 33.625 mm
Exhaust
0.3 OS 28.8 ~ 28.821 mm
0.6 OS 29.1 ~ 29.121 mm
Oversize of valve guide hole
0.05 OS 11.05 ~ 11.069 mm
0.25 OS 11.25 ~ 11.268 mm
0.50 OS 11.50 ~ 11.518 mm
CAMSHAFT
Cam height
Intake 43 mm 42.9 mm
Exhaust 43 mm 42.9 mm
Journal O.D 28
Bearing oil clearance 0.02 ~ 0.061 mm
End play 0.1 ~ 0.2 mm
2-4 GENERAL
VALVE
Stem O.D
Intake 5.965 ~ 5.980 mm
Exhaust 5.950 ~ 5.965 mm
Thickness of valve head (Margin)
Intake 1.15 mm 0.8 mm
Exhaust 1.35 mm 1.0 mm
Valve stem to guide clearance
Intake 0.02 ~ 0.05 mm 0.1 mm
Exhaust 0.035 ~ 0.065 mm 0.13 mm
VALVE GUIDE
Length
Installed size Intake : 46, Exhaust : 54.5
Over size 0.05, 0.25, 0.50
VALVE SEAT
Seat angle 45°
Over size 0.3, 0.6
VALVE SPRING
Free length 48.86 mm
Load 18.3kg/39 mm
40.0kg/30.5 mm
Installed height 39 mm
Out-of squareness 1.5 mm or less 3°
CYLINDER BLOCK
Cylinder I.D 82.00 ~ 82.03 mm
Out-of cylindricity of cylinder I.D Less than 0.01 mm
Cylinder block-to-piston clearance 0.02 ~ 0.04
PISTON
O.D 81.97 ~ 82.00 mm
Over size 0.25, 0.50, 0.75, 1.00
PISTON RING
Side clearance
No.1 0.04 ~ 0.08 mm 0.1 mm
No.2 0.03 ~ 0.07mm 0.1 mm
End gap
No.1 0.23 ~ 0.38 mm
No.2 0.33 ~ 0.48 mm 1.0 mm
Oil ring side rail 0.2 ~ 0.6 mm 1.0 mm
Over size 0.25, 0.50, 0.75, 1.00 1.0 mm
CONNECTING ROD
Bend 0.05 mm or less
Twist 0.10 mm or less
Side clearance 0.100 ~ 0.250 mm 0.4 mm
GENERAL 2-5
CRANKSHAFT
Pin O.D 45 mm
Journal O.D 57 mm
Bend Less than 0.03 mm
Out-of cylindricity of journal and pin Less than 0.01 mm
End play 0.06 ~ 0.260
Under size of pin
0.25 44.725 ~ 44.740 mm
0.50 44.475 ~ 44.490 mm
0.75 44.225 ~ 44.240 mm
Under size of journal
0.25 56.727 ~ 56.742 mm
0.50 56.477 ~ 56.492 mm
0.75 56.227 ~ 56.242 mm
OIL PUMP
O.D-to-front case clearance 0.12 ~ 0.185 mm
Front side clearance
Tip clearance 0.025 ~ 0.069 mm
Outer gear 0.04 ~ 0.09 mm
Inner gear 0.04 ~ 0.085 mm
Oil pressure (Oil temperature 90°C~100°C)
at idle (800rpm) 1.7kg/cm2
RELIEF SPRING
Free height 43.8 mm
Load 3.7kg/40.1 mm
THERMOSTAT
Valve open temperature 82°C 1.5°C
Fully open temperature 95°C
TORQUE SPECIFICATIONS
Description Standard (Kg·m)
Cylinder block
Engine support bracket bolt and nut 3.5 ~ 5.0
Engine support bracket spare bolt 4.3 ~ 5.5
Oil pressure switch 1.3 ~ 1.5
Cylinder head
Cylinder head bolt
M10 2.5+(60° ~ 65° ) + (60° ~ 65° )
M12 3.0+(60° ~ 65° ) + (60° ~ 65° )
Intake manifold bolt and nut 1.6 ~ 2.3
Exhaust manifold nut 4.3 ~ 5.5
Cylinder head cover bolt 0.8 ~ 1.0
Camshaft bearing cap bolt 1.4 ~ 1.5
Rear plate bolt 0.8 ~ 1.0
Main moving
Connecting rod cap nut 5.0 ~ 5.3
Crankshaft bearing cap bolt 2.7 ~ 3.3+(60° ~ 65° )
Flywheel manual transmission bolt 12.0 ~ 13.0
Drive plate automatic transmission bolt 12.0 ~ 13.0
Timing belt
Crankshaft pulley bolt 17 ~ 18
Camshaft sprocket bolt 10 ~ 12
Timing belt tensioner bolt 4.3 ~ 5.5
Timing belt idler bolt 4.3 ~ 5.5
Timing belt cover bolt 0.8 ~ 1.0
Front case bolt 2.0 ~ 2.7
Engine mounting
Oil filter 1.2 ~ 1.6
Oil pan bolt 1.0 ~ 1.2
Oil pan drain plug 3.5 ~ 4.5
Oil screen 1.5 ~ 2.2
Oil seal case 1.0 ~ 1.2
GENERAL 2-7
SPECIAL TOOLS
Tool (number and name) Illustration Use
L4GC006A
L4GC007A
L4GC008A
Stopper
L4GC009A
L4GC010A
GENERAL 2-9
(B)
L4GC011A
L4GC012A
Valve stem oil seal installer Installation of valve stem oil seal
(09222-22001)
L4GC013A
Valve spring compressor holder and Removal and installation of piston pin
adaptor (Use with 09234-33003)
(09222-28000, 09222-28100)
L4GC014A
L4GC015A
2-10 GENERAL
Crankshaft rear oil seal installer 1. Installation of engine rear oil seal
(09231-21000) 2. Installation of crankshaft rear oil seal
L4GC016A
Piston pin removal and installation kit Removal and installation of intake and
(09234-33001) exhaust valve
(Use with 09222-29000)
L4GC017A
Piston pin setting tool insert Removal and installation of piston pin
(09234-33003) (Use with 09234-33001)
L4GC018A
GENERAL 2-11
TROUBLESHOOTING
Symptom Possible cause Remedy
Low compression Cylinder head gasket damaged Replace gasket
Worn or damaged piston ring Replace ring
Worn piston or cylinder Repair or replace piston and cylinder block
Worn or damaged valve seat Repair or replace valve and seat ring
Low oil pressure Insufficient engine oil Check engine oil level
Oil pressure switch defective Replace oil pressure switch
Oil filter clogged Install new filter
Worn oil pump gear or cover Replace
Thin or diluted engine oil Replace engine oil
Oil relief valve clogged(Open) Replace or inspect
Excessive bearing clearance Replace bearing
High oil pressure Oil relief valve clogged(Closed) Repair relief valve
Noisy valve Thin or diluted engine oil Replace engine oil
Faulty HLA Replace HLA
Worn belt stem or valve guide Replace belt stem or valve guide
Noisy connecting rod or Insufficient engine oil Check engine oil level
timing belt Refer to too low oil pressure
Low oil pressure
Thin or diluted engine oil Replace engine oil
Excessive bearing clearance Replace bearing
Noisy timing belt Incorrect belt tension Correct belt tension
Low coolant level Coolant leak from
Heater or radiator hose Repair or replace parts
Defective radiator cap Retighten clamp or replace
Thermostat housing Replace gasket or housing
Radiator Replace
Water pump Replace parts
Radiator clogged Foreign material into coolant Replace coolant
Abnormally high cool- Thermostat defective Replace parts
ant temperature Radiator cap defective Replace parts
Abnormal flow in cooling system Clean or replace parts
Loose or missing driving belt Correct or replace
Loose water pump Replace
Water temperature wiring defective Repair or replace
Cooling pan defective Repair or replace
Radiator or thermostat switch defective Replace
Inefficient coolant Add coolant
2-12 GENERAL
L4GC019A
CAUTION
• At this time, necessarily screen the spark plug
hole with a rag. Because hot coolant, oil, fuel,
and other foreign material, being penetrated in
the cylinder through cracks can come into the
spark hole during checking compressed
pressure.
• When cranking the engine to test compressed
pressure, necessarily open the throttle valve be-
fore cranking.
6. Install the compression gauge to the spark plug hole.
2-14 GENERAL
Standard 15kg/cm2
Standard(250~400rpm)
Limit 14kg/cm2
L4GC020A
Limit 1.0kg/cm2
CAUTION
If a large amount of incomplete combustion gaso-
line comes into the catalytic converter, emergency
such as a fire can occur due to overheating. So this
job should be done quickly with the engine not
operated.
GENERAL 2-15
CAUTION
At this time carefully raise the vehicle not to over-
load parts.
LCAC021A
CAUTION
If it is turned in reverse direction, be sure that the
tensioner may function abnormally.
L4GC023A
6. Tighten the tensioner fixing bolt with the arm indicator fixed.
8. If the arm indicator is out of the middle, loosen the bolt and
repeat the previous procedure.
LCAC021A
9. Install the timing belt upper cover(A) and tighten the bolt
(B).
TROUBLESHOOTING
1. Checking coolant leaks
2. Density test
1) Measure density of the coolant using a hydrometer.
2) After measuring the coolant temperature, calculate den-
sity using the following table of temperature and density.
CAUTION
• If the coolant contains less than 30% of
antifreeze, anticorrosion is decreased.
• If the coolant contains more than 60% of
antifreeze, the engine will be fatally affected,
resulting from decreased anti-freezing and
engine cooling.
Use only the recommended antifreeze and do
not mix with other production.
4. Recommended antifreeze
2) How to use
Insert the belt between the gauge hook and spindle Hook
and press the tension gauge handle. V-ribbed belt
Leave the handle and read the gauge. Spindle
Hook
Standard L4GC024A
RESET point
RESET button
Spindle
Hook
V-ribbed belt
L4GC025A
CAUTION
• The belt used over 5 minutes should be ad-
justed as used belt of standard. Pulley
Good
Bad Bad
L4GC026A
ADJUSTING
B
1. Loosen the alternator support bolt A nut and adjusting
lock bolt B .
Water pump pulley
2. Adjust the belt tension by moving the alternator brace ad-
justing bolt to T direction.
A
2. Check the belt surface for oil or grease contamination. Ribbed rubber
L4GC028A
2-20 CYLINDER BLOCK
CYLINDER BLOCK
COMPONENTS
REMOVAL
Adaptor
1. Remove the cylinder head, timing belt, front case, flywheel
and piston.
2. Remove the oil pressure switch.
L4GC030A
CYLINDER BLOCK 2-21
INSPECTION
CYLINDER BLOCK
1. Inspect the cylinder block for scratch, fur and rust visually,
check for invisible crack or other deformation using a proper
tool and repair or replace if necessary.
Items Size
0.25 OS 0.25mm
0.50 OS 0.50mm
0.75 OS 0.75mm
1.00 OS 1.00mm
INSTALLATION
Install the following parts in order.
1. Crankshaft
2. Flywheel
3. Piston
4. Cylinder head
CYLINDER BLOCK 2-23
Front case
T : 2~2.7
Relief plunger
T : 1.0~1.2
Relief spring Oil filter
Drain plug
T : 1.5~2.2 T : 3.5~4.5
Oil screen
REMOVAL
Mounting mark
1. Remove the timing belt.
8. Remove the plug and then remove the relief spring and
relief valve.
INSPECTION
FRONT CASE
1. Check the front case for crack and damage and replace if
necessary.
2. Check the front oil seal for wear and damage and replace it
defective.
1. Check the oil pan for defect, damage and crack and re-
place if necessary.
2. Check the oil screen for defect, damage and crack and re-
place if necessary.
Item Standard
Body clearance 0.12 ~ 0.185mm
Tip clearance 0.025 ~ 0.069mm
Outer gear 0.04 ~ 0.09mm
Side clearance L4GC034A
Inner gear 0.04 ~ 0.085mm
3. Check clearance between the outer gear tooth end and [Tip clearance]
inner gear tooth end.
L4GC035A
L4GC036A
Body clearance
Tip clearance
Side clearance
L4GC037A
2-26 CYLINDER BLOCK
INSTALLATION
Mounting mark
OIL PUMP
1. Install the outer and inner gears to the front case.
2. After installing the oil pump cover, tighten the bolt to the
specified torque. After tightening the bolt, check that the
gear rotates smoothly.
3. Install the relief valve and spring and after tightening the
plug to the specified torque, apply engine oil to the relief
valve.
FRONT CASE
B 3 pieces
1. Install the gasket and front case assembly and tighten the
C 1 pieces
bolt to the specified torque.
Items Values
A 25mm
B 20mm
Bolt length
C 45mm A 1 pieces D 2 pieces
D 38mm L4GC039A
OIL SEAL
1. Install the special tool crankshaft oil seal guide(09214- 09214-32100
32100) to the front end of the crankshaft. After applying
engine oil to the outer surface of the oil seal guide, insert a
new oil seal through the guide until it reaches the front case
by hand.
L4GC040A
2. Install the oil seal using the special tool crankshaft oil seal
installer(09214-32000) (in parallel with front case).
09214 - 32000
L4GC041A
7. Install the oil pan and tighten the bolt to the specified torque.
T : 0.25~0.35
Center cover
T : 0.8~1.0
Gasket
T : 0.8~1.0
Bearing cap(rear)
Chain guide
Intake camshaft
Bearing cap(front)
HLA
Camshaft sprocket
T : 10~12
REMOVAL
1. Remove the breeder hose and P.C.V hose.
L4GC046A
INSPECTION
CAMSHAFT
OIL SEAL
1. Check the oil seal surface for wear and if the seal lip por-
tion is worn, replace it.
2. Check the camshaft oil seal lip contact surface for partial
wear and replace it if necessary.
L4GC048A
CAUTION
1) Because HAL is precision parts, take care
not to come foreign materials such as a dust
from outside.
2) Do not disassemble HLA.
3) When cleaning HLA, use clean diesel oil.
4) Take care not to make scratches and sharp
edges to O.D of HLA.
5) With HLA filled with engine oil, grasp A and
press B by hand as shown in the illustration,
if the HLA is moving, replace the HLA.
3. Loosen the center cover bolt and remove the center cover.
L4GC045A
L4GC053A
2-34 MAIN MOVING SYSTEM
Intake side
IN. 1 IN. 2
Rear side
EX. 1 EX. 3
Exhaust side
L4GC054A
MAIN MOVING SYSTEM 2-35
Intake side
IN. 1 IN. 2
Rear side
EX. 1 EX. 3
Exhaust side
L4GC055A
L4GC056A
2-36 MAIN MOVING SYSTEM
L4GC057A
Magnet
L4GC058A
L4GC059A
NOTE
There are 20 shims up to 2.0mm at intervals of
0.04mm.
MAIN MOVING SYSTEM 2-37
REASSEMBLY
1. After cleaning sealant remnants of the cylinder head and
cylinder head cover, apply new sealant(LOCTITE NO.5999).
CAUTION
Don’t apply sealant too much, to prevent it from
coming out.
2-38
"A"
Head cover
"F" "D"
"B" "B"
"G"
"E"
"A"
Sealant
MAIN MOVING SYSTEM
Sealant
Cylinder head
L4GC060A
MAIN MOVING SYSTEM 2-39
4. Timing chain
Mounting mark
L4GC061A
L4GC065A
MAIN MOVING SYSTEM 2-41
L4GC066A
I5
I3
I2
I4
I1
E1
E1
E1
E1
E5
L4GC067A
L4GC068A
CAUTION
Align the timing marks on the camshaft sprocket
and the crankshaft sprocket. At this time piston no.
1 cylinder should be placed on the compression
dead point.
L4GC069A
2-42 MAIN MOVING SYSTEM
Apply engine oil to the oil seal lip to help install the cylinder
head cover oil seal to the spark plug pipe smoothly.
CAUTION
• Necessarily tighten the cylinder head cover bolt
L4GC045A
to the specified torque.
If it is tightened too much, the head cover can
be deformed resulting in oil leaks and the head
cover bolt can be broken resulting in cylinder
head replacement.
• When installing after head cover removing, nec-
essarily apply sealant to the head cover rear and
front portion.
• Because the head cover is made of plastic, take
care not to drop tools on the head cover upper
portion when removing/installing the engine
parts.
• When installing after head cover removing, af- L4GC071A
CRANKSHAFT
COMPONENTS
Crankshaft
Crankshaft lower
bearing
T : 2.7~3.3+(60 ~ 65 )
DISASSEMBLY
1. Remove the timing belt train, front case, flywheel, cylinder
head assembly, and oil pan.
2. Remove the rear plate and rear oil seal.
3. Disconnect the connecting rod cap.
NOTE
Put an identification mark on the main bearing cap
to refer to the original position and direction.
INSPECTION
1. Crankshaft
1) Check the oil hoe for clogging as well as crankshaft
journal pin for damage, uneven wear and crack. Repair
or replace parts if necessary.
2) Inspect out of circularity of the crankshaft journal
taper and pin.
4. Oil seal
Check the front and rear oil seal and replace it with new
parts if necessary.
ASSEMBLY
1. After checking the sensor wheel for damage and crack,
replace it if necessary.
2. Inspect the clearance between the sensor wheel and crank
position sensor.
5. Install the bearing cap and tighten the cap bolt to the speci-
fied torque from the center in order.
(Tighten the bearing cap bolts to the specified torque by
tightening bolts step by step 2-3 times equally)
6. Check that the crankshaft for free rotation and proper clear-
ance between the center main bearing thrust flange and
connecting rod big-end bearing.
L4GC075A
09231 - 21000
L4GC076A
8. Install the rear oil seal case and gasket and tighten 5 bolts.
When installing, apply engine oil to the oil seal round and
crankshaft.
9. Install the rear plate.
10. Install the flywheel, front case, oil pan, and timing belt train.
MAIN MOVING SYSTEM 2-47
Flywheel
T : 12~13
Ring gear
T : 8~10
T : 4.3~5.5
T : 0.8~1.2
T : 4.3~5.5
T : 4.3~5.5
REMOVAL
1. Remove the flywheel.
INSPECTION
1. Check the ring gear for damage and crack and replace it if
necessary.
ASSEMBLY
1. Install the flywheel housing and tighten the bolt to the speci-
fied torque.
Piston
Upper bearing
T : 5.0 ~ 5.3
DISASSEMBLY
Press ram
1. Remove the cylinder head assembly.
NOTE
Put an identification mark on the connecting rod Installer
and cap before disassembly to refer to the original
position and direction.
2. Remove the oil pan and remove the oil screen. Support 09234-33001
INSPECTION
PISTON AND PISTON PIN
PISTON RING
1. When measuring the side clearance of piston ring, if the
measured value is out of the limit, insert a new ring to the
ring groove and re-measure the side clearance.
Item Mark
STD None
0.25mm OS 25
Piston ring over size 0.50mm OS 50
0.75mm OS 75
1.00mm OS 1.00
NOTE
Size mark is placed on the top of the ring.
CONNECTING ROD
1. When installing the connecting rod cap, refer to the cylin-
der numbers on the rod end cap which are marked during
disassembly.
When installing a new connecting rod, align the bearing
with the notch.
2. If both end thrust surfaces of the connecting rod are
damaged, partially worn, or the inside of small end is too
rough, replace the connecting rod.
2-52 MAIN MOVING SYSTEM
L4GC081A
ASSEMBLY
1. Using the special tool piston pin setting tool (09234-
33001) , assemble the piston and connecting rod as below.
L4GC082A
Front mark
Piston side 0 (engraved)
Installer
Connecting rod side Number (embossed)
3) Using a press, press-fit the piston pin into the pin hole
Support 09234-33001
with the specified pressure on the pin end through the
push rod.
Remover
If the pressure is required more than the specified value,
Piston
follow the next step.
L4GC083A
MAIN MOVING SYSTEM 2-53
CAUTION
Side rail gap
• After installing 3 pieces of oil ring, check
the upper and lower side rails for smooth
rotation.
• The spacer expander gap should be away
from the rail gap to 45° or more.
L4GC085A
2-54 MAIN MOVING SYSTEM
CAUTION
• Face the size mark and manufacturer mark No.1
L4GC080A
CAUTION
No.2 ring gap Upper side
• Be sure that the piston ring gap is same as
and spacer rail gap
shown in the illustration. If the piston ring gap
L4GC087A
is normal, gaps are not aligned with direction
of piston and thrust and each gap is away from
gaps as far as possible.
• Apply enough engine oil to the piston and pis-
ton ring round.
L4GC088A
4. Install the connecting rod cap and tighten the cap nut to the
specified torque.
When installing the connecting rod cap, align the cylinder
number on the connecting rod big end with cylinder num-
ber on the cap.
L4GC089A
MAIN MOVING SYSTEM 2-55
L4GC090A
COOLING SYSTEM
COOLANT PIPE AND HOSE
COMPONENTS
T : 1.5~2.0
INSPECTION
Check the coolant pipe and hose for crack, damage, and clog-
ging and replace it if necessary.
INSTALLATION
After getting water around O-ring, insert it the groove in the
coolant intake pipe end and press-fit the pipe.
CAUTION
• Do not apply oil or grease to the O-ring.
• Take care not to dirt the coolant pipe connect-
ing part with sand or dust.
• Press-fit the coolant intake pipe completely.
2-58 COOLING SYSTEM
WATER PUMP
COMPONENTS
Water pump
Water pump pulley
T : 0.8~1.0
Gasket
T : 2.0~2.7
Belt
REMOVAL
1. Check each part for crack, damage, and wear and replace
the water pump if necessary.
2. Check the bearing for damage, abnormal noise and bad
rotation and replace the water pump if necessary.
3. Check the seal unit for leak and replace the water pump C
assembly if necessary.
L4GC093A
INSTALLATION
1. Clean the gasket surface of the water pump body and cyl-
inder block.
2. After getting water around new O-ring, install it the groove
in the coolant intake pipe front end. Do not apply oil or grease
to the O-ring.
3. Install a new water pump gasket and water pump assembly.
Tighten it to the specified torque.
L4GC094A
WATERPUMP AND CYLINDER BLOCK
A 2.0 ~ 2.7 kg·m
B 2.0 ~ 2.4 kg·m
THERMOSTAT
COMPONENTS
Gasket
Thermostat housing Thermostat
Gasket
INSPECTION
1. Check the valve closed at room temperature.
2. Check for defect or damage.
3. Heat the thermostat as shown in the illustration and mea-
sure the valve open temperature and full open temperature.
Valve open temperature
Open 82°C
Full open 95°C L4GC096A
INSTALLATION
1. Check that the thermostat flange is correctly inserted to
the thermostat housing socket.
2. Install a new gasket and water inlet fitting.
3. Add coolant.
COOLING SYSTEM 2-61
FAN DRIVE
COMPONENTS
T : 4.3~5.5
T : 2.0~2.5
T : 2.0~2.5
REMOVAL
1. Remove the fan pulley.
2. Remove the fan bracket.
INSTALLATION
Installation is the reverse order of removal.
2-62 LUBRICATION SYSTEM
LUBRICATION SYSTEM
OIL PRESSURE SWITCH
Oil pressure switch is located on the front right side of the en-
gine and if oil pressure in the lubrication system drops less
than 0.29kg/cm2, the oil pressure warning lamp illuminates.
Hexagonal width of this switch is 24mm.
L4GC030A
INSPECTION
1. Using an ohmmeter, measure an electric current and re-
place the oil pressure switch if an electric current is not
detected.
L4GC098A
L4GC099A
LUBRICATION SYSTEM 2-63
5. Timing belt
6. Timing belt cover
2-64 INTAKE AND EXHAUST SYSTEM
Exhaust manifold
T : 1.5~2.0
REMOVAL
1. Remove the heat protector.
L4GC101A
INSPECTION
1. Check the exhaust manifold for damage and crack.
2. Check the welding part between the exhaust manifold and
catalyst for crack and damage.
INSTALLATION
1. Installation is the reverse order of removal.
CAUTION
Do not reuse the exhaust manifold gasket nut.
2. Exhaust manifold gasket
Check the gasket for tear or damage.
L4GC102A
2-66 INTAKE AND EXHAUST SYSTEM
INTAKE MANIFOLD
COMPONENTS
T : 5.0 ~ 6.0
T : 4.3 ~ 5.5
T : 1.5 ~ 2.0
CAUTION
Do not tighten parts excessively, observe the speci-
fied torque.
INTAKE AND EXHAUST SYSTEM 2-67
REMOVAL
1. Disconnect the map sensor and the connector.
L4GC105A
INSPECTION
1. Intake manifold
Check each component for damage and crack.
2. Air hose
Check each component for damage and crack.
2-68 INTAKE AND EXHAUST SYSTEM
INSTALLATION
1. After replacing the intake manifold gasket, install it to the
cylinder head and then to the intake manifold.
2. Install the delivery pipe and injector assembly to the intake
manifold.
L4GC105A
CAUTION
Check that the injector is interfered with the injec-
tor hole in the intake manifold.
3. Install the fuel injector connector and wiring harness.
4. Connect the high-pressure fuel hose.
T : 0.8 ~ 1.0
1
18
2 T : 0.8~1.0
17
3
4
5
6 16
7 15
8
14
T : 4.1~5.1
13
T : 1.4~1.5
12
11
T : 10.0~12.0
10
DISASSEMBLY
1. Using the special tool cylinder head bolt wrench (09221- 7 3 1 6 10
32001) , tighten the cylinder head bolts in order by tighten-
ing 2-3 times as shown in the illustration. 9 5 2 4 8
• Take care not to come the cylinder head gasket
debris into the cylinder.
09221 - 32001
L4GC109A
NOTE
Arrange parts in order disassembling not to make
a mistake while reassembling.
09222-28000
L4GC110A
NOTE
09222-28100
Do not reuse the stem seal.
09222-28000
L4GC111A
2-72 CYLINDER HEAD ASSEMBLY
INSPECTION
CYLINDER HEAD
VALVE
1. Clean the valve with a wire brush.
2. Check each valve for wear and damage and inspect the
head and stem for torsion.
If the stem end A is cave or worn, trim it.
At this time, trim it least.
Also, trim the valve surface.
If the margin is less than the limit, replace the valve.
Intake 1.15mm
Standard
Exhaust 1.35mm
Intake 0.8mm
Limit
Exhaust 1.0mm
Margin
L4GC114A
CYLINDER HEAD ASSEMBLY 2-73
VALVE SPRING
Check the valve seat for overheat and inspect contact with valve
Cutter
surface. Correct or replace it if necessary. When correcting,
Pilot
check the valve guide for wear, if it is worn, replace the guide
and correct the seat ring. Using a grinder or a cutter, correct
the valve seat to make the seat contact width to the standard.
When correcting the exhaust valve seat, must use the valve 1.3~1.7mm 1.1~1.5mm
seat voce and pilot, after correcting, must apply a light coat of
compound to the valve and valve seat. 73˚ 65˚
25˚ 28˚
45˚ 45˚
L4GC117A
2-74 CYLINDER HEAD ASSEMBLY
0.15~0.3mm A B
L4GC118A
2. After removing the seat ring, Cut the seat insert bore as
same size as the following table using a reamer or cutter.
3. Heat the cylinder head to 250°C and press-fit the oversize
seat.
At this time the oversize seat ring maintains a normal room
temperature.
After installing a new valve seat, correct the valve seat
surface.
Valve seat ring oversize
09221-3F100B
L4GC119A
5. After installing the valve guide, insert a new valve and check
for perturbation.
6. When replacing the valve guide, check the valve for con-
tact and correct the valve seat if necessary.
Valve guide oversize
ASSEMBLY
09222-22001
CAUTION
• Prior to assembly, clean each component.
• Apply a new engine oil to the perturbation part
and rotation part.
L4GC120A
1. After installing the spring seat, insert the stem seal to the
valve guide.
Install the stem seal by tapping on it with the special tool Enamel plate Spring retainer
valve stem oil seal installer (09222-22001)
Wrong installation of the seal can affect oil leak from the Spring
Valve stem seal
valve guide, so use the special tool to install it to exact
position and take care not to twist it. Do not reuse it.
2. After applying engine oil to each valve, insert the valve into Valve spring
seat
the valve guide.
L4GC121A
3. Install the spring and spring retainer. Face the enamel-
plated side toward the valve spring retainer side.
4. Taking care not to press the valve stem seal down to the
retainer bottom, press-fit the spring with the special tool
valve spring compressor (09222-28000, 09222-28100) .
09222-28100
09222-28000
L4GC122A
CYLINDER HEAD ASSEMBLY 2-77
5. Clean out all gasket surfaces of the cylinder block and cyl-
inder head.
8 6 1 3 9
6. Put new cylinder head gaskets on the cylinder block with
the identification marks faced upward. Do not apply seal-
M12
ant to the gasket and do not reuse the used cylinder head
gasket. Take care not to make a mistake of gasket.
8. Apply a slight coat of engine oil to the spiral portion of bolt. L4GC123A
10. Using the special tool cylinder head bolt wrench (09221-
32001)” , install the cylinder head bolt as shown in the
illustration.
Cylinder head bolt
M10 2.5kg·m + (60° ~ 65° ) + (60° ~ 65° )
M12 3.0kg·m + (60° ~ 65° ) + (60° ~ 65° )
2-78 TIMING BELT
TIMING BELT
COMPONENTS
3
2
T : 10.0 ~ 12.0
T : 2.3 ~ 2.9
7 T : 4.3 ~ 5.5
T : 0.8 ~ 1.0
10
T : 16.0 ~ 17.0
REMOVAL
1. Loosen the water pump pulley belt.
Water pump pulley
2. Loosen the alternator bolt.
3. Remove the water pump pulley and belt.
drive belt
L4GC125A
4. Crankshaft pulley.
5. Remove the timing belt cover.
L4GC126A
Tensioner pulley
Idler pulley
L4GC127A
11. Loosen the camshaft sprocket bolt and remove the cam-
shaft sprocket.
L4GC129A
12. Remove the crankshaft sprocket bolt and remove the crank-
shaft sprocket and flange.
13. Remove the timing belt tensioner.
TIMING BELT 2-81
INSPECTION
SPROCKET, TENSIONER, IDLER
TIMING BELT
L4GC131A
Description Specification
L4GC132A
L4GC133A
Detached
Detached
L4GC134A L4GC135A L4GC136A
4. Tooth is excessively worn out (initial step) Tooth loaded from canvas is Worn out
worn (elastic canvas fiber rubber is (loaded
worn, color is faded in white, canvas side)
structure is deformed)
L4GC137A
5. Tooth is excessively worn out (final step) Tooth loaded from canvas is worn Rubber is
and rubber is worn off (tooth worn off
width is narrowed)
L4GC138A
Crack
L4GC139A
L4GC140A
Abnormal wear
(Canvas fiber is cracked) L4GC141A
ASSEMBLY
1. Install the flange and crankshaft sprocket taking care of
Special washer
installation direction as shown in the illustration.
Crankshaft
sprocket Flange
L4GC143A
3. Install the idler and tighten the bolt to the specified torque.
D B
A
L4GC144A
10) With the arm indicator fixed not to move, tighten the
tensioner fixing bolt. A
L4GC146A
1. GENERAL ........................................................................ 3- 1
GENERAL
SPECIFICATIONS
#1 TDC SENSOR
Item Specification
Type Non-contacting type
Advance system Controlled by ECU
Ignition order 1 3 4 2
Item Specification
Type Non-contacting type
Advance system Controlled by ECU
Ignition order 1 3 4 2
IGNITION COIL
Item Specification
st
1 coil resistance 0.58 10%( )
2nd coil resistance 8.8 15%( )
SPARK PLUG
Item Specification
NGK PFR6N
Type
CHAMPION RC8PYPB
Spark plug gap 0.7 ~ 0.8mm
STARTER MOTOR
Item Specification
Output 1.7 kW
Pinion tooth number 8
Terminal voltage 11V
No-load characteristic Maximum current 90A
Minimum speed 2600 rpm
3-2 GENERAL
ALTERNATOR
Item Specification
Type Battery voltage sensing type
Rated output 13.5V 90A
RPM 1,000 ~ 18,000rpm
Regulator adjusting voltage 14.4 0.3V/20°C
Temperature compensation -10 3mV/°C
Voltage regulator type Electro-magnetic, Built-in type
NOTE
1. Cold cranking ampere : It means that terminal
voltage is maintained 7.2V or more at a certain
temperature and battery current is supplied for
30 seconds.
2. Reserve capacity : It represents the time can be
supplied 25A from battery with minimum termi-
nal voltage maintained 10.5V at 26.7°C.
IGNITION SYSTEM 3-3
IGNITION SYSTEM
GENERAL
1. If the ignition switch is ON, the battery voltage is supplied
to 1st coil of ignition coil.
2. By rotation of the crank position sensor wheel, ignition sig-
nal in ECU is actuated the power transistor and repeat ground
or shut off of 1st current of ignition coil.
3. This causes high pressure in 2nd coil, the induced current
from ignition coil to 2nd, coil is grounded though the spark
plug and each cylinder is ignited.
TROUBLESHOOTING
When it is hard to start engine, there can be problem with fuel
system or engine itself as well as ignition system.
Because main function of ignition system is to supply suffi-
cient electronic spark at a proper timing, when inspecting this
system, necessarily contains spark checking and ignition tim-
ing measurement. When inspecting ignition system installed to
the vehicle, check for possible trouble symptoms from faulty
circuit, power, 1st low voltage circuit, high voltage circuit, etc..
1. ENGINE IS NOT STARTED OR HARD TO START.
(CRANKING O.K.)
A spark of spark plug is weak or not at all
1) Check Ignition coil
2) Crankshaft position sensor
3) Spark plug
A spark is normal
Check ignition timing (Ignition timing is automatically con-
trolled by ECU)
2. IDLING IS UNSTABLE
- Spark plug
- Ignition timing
- Ignition coil
3. ACCELERATION IS INSUFFICIENT.
- Check Ignition timing
4. ENGINE IS OVERHEATED AND FUEL CONSUMPTION IS
EXCESSIVE.
- Check Ignition timing
3-4 IGNITION SYSTEM
2. Inspection
1) Connect the timing light. L4GC300A
CAUTION
Take care not to disconnect the connector.
3) Measure RPM.
RPM
NOTE
If RPM is not normal, it is impossible to measure
the proper ignition timing, so measure it at a
normal RPM.
4) Inspect the standard ignition timing.
BTDC 2° 6°
NOTE
Affective ECU input to Ignition timing control
1. Coolant temperature sensor (WTS)
2. Oxygen sensor
3. Battery voltage
4. Vehicle speed sensor
5. Map sensor (Engine load)
6. Crankshaft position sensor
7. Throttle position sensor
8. Intake sensor
6) Check that actual ignition timing is changed with engine
RPM increased.
IGNITION SYSTEM 3-5
CAUTION
When measuring 2nd coil resistance, remove the ig-
nition coil connector.
3-6 IGNITION SYSTEM
2. Remove all spark plugs from the cylinder head using a spark
plug wrench.
CAUTION L4GC302A
Take care not to come foreign materials into spark-
plug mounting hole.
3. Check the spark plug as below.
1) Insulator broken 1
2) Terminal worn 2
3) Carbon deposit
4) Gasket damaged or broken
5) Porcelain insulator of spark plug clearance
3 4 5
L4GC303A
Clearance
L4GC304A
L4GC305A
IGNITION SYSTEM 3-7
Insulation
Insulation
damaged
damaged
Insulation damaged
L4GC306A
3-8 IGNITION SYSTEM
2. Measure resistance.
3. Inspect resistance.
Spark plug cable
NO.2 9.5kΩ
NO.3 6.9kΩ
NO.4 5.5kΩ
TEST
1. With the engine at idle, disconnect the spark plug cable one
by one and inspect change of the engine performance each
time.
CAUTION
At this time, put on the gloves.
2. If engine performance is not changed, inspect the spark
plug cable for resistance and the spark plug itself.
L4GC308A
CHARGING SYSTEM 3-9
CHARGING SYSTEM B
GENERAL
G A
Charging system consists of battery, alternator with a built-in D E
regulator, charging warning lamp and wire. E
Because there are 6 diodes (3 (+) diodes, 3(-) diodes) built in
alternator, AC current is rectified to DC current and DC current C F
is detected in B terminal of alternator. Charging voltage from
alternator is controlled by battery voltage detection unit. L4GC309A
COMPONENTS
Alternator assembly
Bolt
T : 2.0 ~ 2.5
Nut-flange
Brace assembly-alternator
T : 2.0 ~ 2.8
Bolt-flange
T : 1.2 ~ 1.5
TROUBLESHOOTING
Charging system defect is almost caused by lack of pan belt
tension and faulty function of wiring, connector, and voltage
regulator.
One of most important thing during troubleshooting of charging
system is determining the reason between overcharging and
lack of charging. So, prior to inspection of alternator, check the
battery for charging. Faulty alternator causes the following
symptoms.
TROUBLESHOOTING PROCEDURE
INSPECTION BEFORE STARTING
1. Charging warning lamp inspection
Replace alternator
L4GC311A
Re-adjust tension
L4GC312A
3-12 CHARGING SYSTEM
L4GC313A
L4GC314A
Replace generator
L4GC317A
L4GC318A
L4GC319A
3-14 CHARGING SYSTEM
PREPARATION
1. Turn the ignition switch OFF.
Ammeter
2. Disconnect the battery ground cable.
3. Disconnect the alternator output wire from the alternator
B terminal.
V
4. Connect a DC ampere meter (0-100A) between the terminal Battery
Voltmeter
and the disconnected output wire.
Connect (+) lead wire to the terminal B and (-) lead wire L4GC320A
to the disconnected output wire.
NOTE
In case of using a clamp type ammeter, it is possible
to measure current without disconnecting the
harness.
5. Connect a digital voltmeter between the alternator B
terminal and the battery (+) terminal.
Connect (+) lead wire to the terminal B and (-) lead wire
to the battery (+) terminal.
TEST
1. Start the engine.
RESULT
1. If voltmeter reading is within the standard, it is normal.
PREPARATION
1. Prior to test, inspect the following items and repair if
necessary.
TEST
1. Be sure that voltmeter reading is identified with battery
voltage.
If voltmeter reading is 0V, it means short circuit of wire
between B terminal and the battery (-) terminal, fusible
link cut off or ground fault.
2. Turn the headlight ON and start the engine.
3. With the engine running at 2,500 rpm, turn ON the high beam
headlights, place the heater blower switch at HIGH mea-
sure the maximum output current using a ammeter.
NOTE
This test should be done as soon as possible to mea-
sure the exact maximum current because output
current drops rapidly after starting the engine.
CHARGING SYSTEM 3-17
RESULT
1. Ammeter reading should be higher than the limit. If the read-
ing is low even though the alternator output wire is normal,
remove the alternator from the vehicle and inspect it.
NOTE
• The rated output current is represented on the
name plate in the alternator body.
• Output current varies according to electrical load
or temperature of the alternator, so during test,
lack of electrical load causes impossibility of
measuring the rated output current. In this case,
turn on headlight to induce the battery discharg-
ing or turn on other lights to increase the electri-
cal load. If alternator temperature or ambient tem-
perature is too high, it is impossible to measure
the rated output current, so prior to re-test, nec-
essarily drop the temperature.
Ambient temperature of
Voltage adjust (V)
voltage regulator (°C)
-20 14.2 ~ 15.4
20 13.8 ~ 15.0
60 13.4 ~ 14.6
80 13.2 ~ 14.4
2. After test, adjust the engine speed at idle and turn the light
and ignition switch OFF.
8
7
5
3
4
1 2
19
13
14
10
20
9 18
16
17
15
11 12
L4GC322A
L4GC323A
L4GC324A
3. Loosen the alternator tension adjusting bolt (A) and the al-
ternator fixing bolt (B).
A B
L4GC325A
DISASSEMBLY
B
1. After removing the mounting nuts (B), remove the genera-
tor cover (A) using a screwdriver.
L4GC326A
L4GC327A
L4GC328A
L4GC329A
CHARGING SYSTEM 3-21
L4GC330A
L4GC048A
3-22 CHARGING SYSTEM
INSPECTION
ROTOR
1. Inspect the rotor coil for continuity and check for continuity
between slip rings.
If resistance is too low, circuit is short and if the resistance
is too high, circuit is opened. So replace the rotor assembly
in both cases.
L4GC332A
STATOR
L4GC333A
L4GC334A
CHARGING SYSTEM 3-23
RECTIFIER
1. (+) rectifier
When inspecting continuity between (+) rectifier and stator
coil lead connecting terminal using an ohmmeter, there must
have only one direction continuity. If there is both direction
continuity, replace the rectifier assembly owing to short cir-
cuit of diode.
L4GC335A
2. (-) rectifier
When inspecting continuity between (-) rectifier and stator
coil lead connecting terminal using an ohmmeter, there must
have only one direction continuity. If there is both direction
continuity, replace the rectifier assembly owing to short cir-
cuit of diode.
L4GC336A
BRUSH REPLACEMEMENT
If the brush is worn out to the limit, replace the brush as the
following order.
Wear limit
L4GC337A
INSTALLATION
Installation is the reverse order of disassembly. Take care of
the following items.
1. Before installing the rotor to the bracket, insert the wire into
the small bore of rear bracket and fix the brush.
L4GC338A
3-24 CHARGING SYSTEM
INSTALLATION
1. After placing the alternator, insert the support bolt. (At this
time do not insert the nut.)
Alternator
2. After pressing forward the alternator, Contact the alternator
Nut
front bracket with front case (A) as shown in the illustration.
3. Insert and install the nut by tightening it to the specified Support bolt
torque. A
Front case
L4GC339A
STARTING SYSTEM 3-25
STARTING SYSTEM
GENERAL
Starting system consists of battery, start motor, solenoid switch,
ignition switch, inhibiter switch (Only for A/T), contact wire, and
battery case. When the ignition key is turned to “ST” position,
current is sending to start motor solenoid coil, the solenoid
plunger and clutch shift lever is actuated, and the clutch pinion
is engaged with the ring gear resulting in cranking.
L4GC340A
When starting the engine, the clutch pinion is overrun to pre-
vent the armature coil from damage by excessive rotation.
COMPONENTS
Start motor
T : 4.3 ~ 5.5
T : 1.0 ~ 1.6
TROUBLESHOOTING
Starting system problem can be classified into Start motor is
not operating , Start motor is operating but engine is not
starting , and There is a lot of time taken to start engine .
START MOTOR
Snap ring
REMOVAL AND INSTALLATION
1. Disconnect the battery ground cable.
2. Remove the speedometer cable.
3. Separate the start motor connector and terminal.
COMPONENTS
11
8
7 9
14
15
13
12
19
10
3
2
20
18
17
16
L4GC343A
Stopper
Pinion
clearance
Pinion
L4GC345A
CAUTION
This test should be done as soon as possible not to
damage the coil (in 10 seconds).
CAUTION
This test should be done as soon as possible not to
damage the coil (in 10 seconds).
Stop ring
L4GC342A
L4GC349A
3-30 STARTING SYSTEM
L4GC350A
L4GC351A
L4GC352A
L4GC353A
STARTING SYSTEM 3-31
6. BRUSH
If the brush is worn out to the limit, replace the brush.
Wear limit
L4GC354A
7. BRUSH HOLDER
Check continuity between the (+) side brush holder and the
base. If there is continuity, replace the brush holder
assembly.
L4GC355A
8. OVERRUNNING GLUTCH
1) Check the pinion and spline teeth for wear and damage Loosen
and replace it if necessary. Also, inspect the flywheel
for wear and damage.
Lock
2) Rotate the pinion. The pinion must be rotated clockwise
but counterclockwise.
L4GC356A
9. BRUSH REPLACEMENT
Pigtail
1) Remove the worn brush taking care not to damage the
pigtail.
2) For better welding, correct the pigtail end with a sand
paper.
Welding
3) Weld the pigtail end. portion
Marked surface
L4GC357A
3-32 STARTING SYSTEM
L4GC358A
ASSEMBLY
1. Install the overrunning clutch to the armature shaft front
end.
2. Install the stop ring and snap ring to the armature shaft Stop ring
front end and completely press the stop ring toward the
Overrunning clutch
snap ring.
Stop ring clutch
Snap ring
L4GC359A
L4GC360A
CHAPTER 4. FULE SYSTEM AND OTHER
1. GENERAL ........................................................................ 4- 1
2. INJECTOR ....................................................................... 4- 14
GENERAL
SPECIFICATIONS
Item Specification
SEALANTS
INSPECTION STANDARD
Item Standard
TIGHTENING TORQUE
Item Specified value (kg·m)
SPECIAL TOOLS
Special tool Configuration Use
Fuel pressure gauge and hose Connection of fuel pressure gauge and
(09353-24100) fuel supply pipe
L4GC250A
L4GC251A
L4GC252A
GENERAL 4-3
TROUBLESHOOTING
When inspecting and repairing the engine, start from the basic
unit. If symptoms happen such as (A) engine is not starting (B)
irregular idling (C) insufficient acceleration, inspect the basic
unit as below.
1. POWER
1) Battery
2) Fusible link
3) Fuse
4) Injector
2. BODY GROUND
3. FUEL SUPPLY
1) Fuel line
2) Fuel filter
3) Fuel pump
4. IGNITION SYSTEM
1) Spark plug
2) High tension cable
3) Ignition coil
4) Crankshaft position sensor
5. EMISSIONS CONTROL SYSTEM
1) PCV system
2) Vacuum leak
6. OTHER
1) Ignition timing check
2) RPM
7. In case of faulty MPI system, it is caused by bad contact of
harness sometimes, so inspect the connecting portion.
4-4 GENERAL
o Battery
Power check
1. Connection
2. Specific gravity
3. Driving belt
4. Voltage
o Fusible link
L4GC253A
Continued
4-6 GENERAL
o Wiring connection
o ECU power
1. Fusible link
2. Fuse
Ignition timing inspection 3. MPI main relay
BTDC 2 5 /700rpm o Engine cooling temperature sensor
o Intake temperature sensor
o Injection signal circuit
1. Injector wiring
2. ECU
o Throttle position sensor (TPS)
o MAP sensor
MPI electronic circuit inspection o Crankshaft position sensor
L4GC254A
Continued
GENERAL 4-7
L4GC255A
Continued
4-8 GENERAL
L4GC256A
GENERAL 4-9
TROUBLESHOOTING GUIDE
• The following number represents inspection order.
Item
Starter relay
Starter
Flywheel
Compression
Piston ring
Ignition timing
Injector
ECU
Water temperature sensor
Crankshaft bearing
Connecting rod bearing
Fuel pressure regulator
Timing belt
A/C circuit
Fuel chamber
Main symptom
Sub symptom
Not cranking 1 2
Incomplete combustion 1 2 3 4 5 6 7 8 9
Starting
Increasingly cranking 1 2 3 4
Low RPM 2 1 3 4
Irregular idling 9 4 7 8 10 11 12 14 1
Fuel over-consumption 11 10 6 7 8 9 14 12 1 5
4-10 GENERAL
Item
Spark plug
Fuel pump
Fuel line
Cylinder head
Fuel leak
Crankshaft position sensor
Sub symptom
Not cranking
Incomplete combustion
Starting
Increasingly cranking
Low RPM
Irregular idling 3 5 6 13 2 15
Fuel over-consumption 4 13 2 3
Radiator and radiator cap
Coolant leak
Cooling pan
Timing belt
Water pump
Spark plug
Oil pump
Cylinder block
Thermostat
Cylinder head
Item
Main symptom
Sub symptom
1 2 3 4 5 6 7 8 9 10 11 12
Other
Engine is overheated
Engine is supercooled 1 2 3
GENERAL 4-11
SENSOR CHARACTERISTICS
• OXYGEN SENSOR
Item Detail
Item Detail
Criterion • During 4 camshaft signals, if there is no CKP pulse signal, determine it as fault
and after this, increase counter per crankshaft signal.
(Determine it together with camshaft position sensor every time)
Faulty sensor manage- • When fault is detected, there is no corresponding method (Impossible to start
ment engine)
[NOTE]
After 4 CKP signals, operate main relay and if signal is stopped after 1.8-3.7
seconds, shut off main relay power.
(To determine CKP code in comparison with camshaft position sensor value)
position sensor.
Main relay
3.7
I.e. to determine if crankshaft position sen-
1.8 sor is faulty or not, start motor should be
rotating for about 3.7 seconds with IG ON
L4GC257A
[CAUTION]
If camshaft position sensor is faulty, it is impossible to determine CKP fault
Criterion • During 4 camshaft signals, there is no • When 400rpm or more, (-) pressure of
signal changed at camshaft position 574mb or more, and negative pressure
sensor limit is less than 121mb, there is no
sensor signal over 3 seconds
Troubleshooting No.1 cylinder TDC sensor/related circuit Vehicle speed sensor/Related circuit
1. Display fault of cylinder TDC 1. Display fault of vehicle speed sensor
detecting sensor (CMP sensor) and related circuit
related circuit 2. Inspect bad connection of connector,
2. Check connector for bad connection faulty wiring
and wiring for fault 3. Inspect speedometer cable
3. Inspect sensor contact surface for 4. Inspect vehicle speed sensor
cleanness - With vehicle stopped : 0Hz
4. Inspect sensor output While driving at about 300km/h :
- At idle: 5-9Hz(0-5V) 20-30Hz
- 3000rpm : 20-30Hz(0-5V)
INJECTOR
INSPECTION
FUNCTION AND OPERATING PRINCIPLE
Injector as a electronic controlled fuel injection unit, is solenoid
valve which supplies exactly calculated fuel as a spray to en-
gine to best combustion under the condition of various engine
load and speed.
For fuel consumption reduction, engine performance enhance- L4GC258A
CIRCUIT DIAGRAM
2
Main relay INJECTOR #3 (CBG24-3)
Terminal Connecting area Function
INJECTOR #4 (CBG24-4)
Terminal Connecting area Function
2 1
CBG24-1,2,3,4
Injector #1,2,3,4
L4GC259A
PARTS INSPECTION
1. Turn the ignition switch OFF.
PCV VALVE
OUTLINE AND OPERATING PRINCIPLE
Intake Manifold Side (No Vacuum) Intake Manifold Side (High Vacuum)
Intake Manifold Side (Sufficient Vacuum) Intake Manifold Side (Low Vacuum)
Engine condition Proper operating Engine condition High speed and overload
PCV valve Proper operating PCV valve Light operating
Vacuum path Big Vacuum path Very big
PCV VALVE 4-17
SERVIE PROCEDURE
REMOVAL
1. After disconnecting the vacuum hose(A), remove the PCV
valve(B).
A
B
L4GC264A
INSTALLATION
Install the PCV valve and connect the vacuum hose.
INSPECTION A
1. Remove the PCV valve. B
L4GC265A
TROUBLESHOOTING
1. Disconnect the vacuum hose from the PCV valve. Discon-
nect the PCV valve from the locker cover and reconnect
the vacuum hose.
2. With the engine at idle, Check the intake manifold for
vacuum when clogging the opened end of PCV valve.
NOTE
The plunger in PCV valve will move back and forth.
L4GC266A
3. If vacuum is not detected, clean or replace PCV valve and
vacuum hose.