Manual Tehnic - Motor Diesel Accent

Engine (D4FA -
DSL1.5)
GENERAL ENGINE BLOCK
TIMING SYSTEM COOLING SYSTEM

TIMING CHAIN
ENGINE AND TRANSAXLE ASSEMBLY LUBRICATION SYSTEM
CYLINDER HEAD ASSEMBLY INTAKE AND EXHAUST SYSTEM

EMA -2 ENGINE (D4FA - DSL1.5)
GENERAL
SPECIFICATIONS E284EBC0
Description Specifications (D4FA) Limit

General
Type In-line, DOHC
Number of cylinders 4
Bore 75mm (2.9528in)
Stroke 84.5mm (3.3268in)
Total displacement 1,493 cc (91.11 cu.in)
Compression ratio 17.8 : 1
Firing order 1-3-4-2
Valve timing
Opens (BTDC) 6
Intake valve
Closes (ABDC) 34
Opens (BBDC) 46
Exhaust valve
Closes (ATDC) 4
Cylinder head
0.03mm (0.0012in) for width
Flatness of gasket surface
0.09mm (0.0035in) for length
Flatness 0.025mm (0.0010in) for width

Intake
of manifold 0.160mm (0.0063in) for length
mounting 0.025mm (0.0010in) for width
surface Exhaust
0.160mm (0.0063in) for length
Camshaft
LH Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

camshaft Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Cam height
RH Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
camshaft Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Journal outer LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

Diameter RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Intake 93.0mm (3.6614in)
Valve length
Exhaust 93.7mm (3.6890in)
Stem outer Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)

diameter Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.5 ~ 45.75
GENERAL EMA -3

Thickness of Intake 1.1mm (0.0433in)
valve head
(margin) Exhaust 1.2mm (0.0472in)
Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)

valve guide
clearance Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Length
Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat
Width of seat Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)

contact Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
Intake 45 ~ 45 30’
Seat angle
Exhaust 45 ~ 45 30’
Valve spring
Free length 44.9mm (1.7677in)
17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
Load
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness Less than 1.5 3
Cylinder block
Cylinder bore 75.000 ~ 75.030mm (2.9528 ~ 2.9539in)
Less than 0.05mm (0.0020in) (Overhaul)
Flatness of gasket surface
Less than 0.03mm (0.0012in) (Per 1 Cylinder)
Piston
Piston outer diameter 74.930 ~ 74.960mm (2.9500 ~ 2.9512in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
No. 1 ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
Ring groove
No. 2 ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in)
width
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
No. 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
Side clearance No. 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No. 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
End gap No. 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)

Piston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end hole
28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
inner diameter
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance 0.050 ~ 0.302mm (0.0020 ~ 0.0119in) 0.4mm (0.0157in)
Crankshaft
Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm (0.0051in)
Oil pump
Inner rotor 0.040 ~ 0.085mm (0.0016 ~ 0.0033in)
Side clearance
Outer rotor 0.040 ~ 0.090mm (0.0016 ~ 0.0035in)
Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure 490±49.0kpa (5±0.5kg/cm², 71±7.1psi)
Engine oil
Oil quantity (Total) 5.3 L (5.60 US qt, 4.66 lmp qt)
Oil quantity (Oil pan) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil filter) 0.5 L (0.53 US qt, 0.44 lmp qt)
Oil quality Above API CH-4, Above ACEA B4
Oil pressure (Idle) (Oil temperature : 80 C) 78.4kpa (0.8kg/cm², 11.3psi)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt)
Type Wax pellet type
85±1.5 C (185.0±2.7 F)
Opening temperature
Thermostat (Lift : 0.35mm(0.0138in))
Pull opening 100 C (212 F)
temperature (Lift : 8mm(0.3150in))
Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve opening 0.98 ~ 4.90 kpa
pressure (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
GENERAL EMA -5

Water temperature sensor
Type Thermister type
20 C (68 F) 2.45±0.14 k
Resistance
80 C (176 F) 0.3222 k
TIGHTENING TORQUE
Tightening torque
Item Quantity
N.m kgf.m lb-ft
Cylinder block
Engine support bracket bolt 4 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Piston cooling oil jet bolt 4 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Drive belt auto tensioner bolt 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Drive belt auto tensioner mounting bracket bolt 3 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Engine mounting
Engine mounting bracket and body fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Engine mounting insulator and engine
1 68.6 ~ 93.2 7.0 ~ 9.5 50.6 ~ 68.7
mounting support bracket fixing nut
Engine mounting support bracket and engine
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
support bracket fixing bolt
Engine mounting support bracket and engine
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
support bracket fixing nut
Transaxle mounting bracket and body fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Transaxle mounting insulator and transaxle
2 68.6 ~ 93.2 7.0 ~9.5 50.6 ~68.7
support bracket fixing bolt
Front roll stopper bracket and sub
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
frame fixing bolt
Front roll stopper insulator and front roll stopper
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
support bracket fixing bolt,nut
Rear roll stopper bracket and sub
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
frame fixing bolt
Rear roll stopper insulator and rear roll stopper
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
support bracket fixing bolt,nut
Main moving system
Connecting rod cap bolt 8 12.7 + 90 1.3 + 90 9.4 + 90
Crankshaft main bearing cap bolt (long) 10 24.5 + 90 2.5 + 90 18.1 + 90
Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8
Flywheel bolt (M/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Drive plate bolt (A/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing chain
Timing chain cover bolt (8 X 70) 7 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain case bolt (8 X 22) 4 24.5 ~ 30.4 2.5 ~ 3.1 18.1 ~ 22.4
GENERAL EMA -7
Tightening torque
Item Quantity
N.m kgf.m lb-ft
Engine hanger (front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Crankshaft pulley bolt 1 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8
Camshaft chain sprocket bolt 1 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2
High pressure pump chain sprocket bolt 1 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Timing chain guide (1) bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide (2) bolt 1 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Timing chain "A" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain "C" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Engine cover bolt 4 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Cylinder head cover bolt 13 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2
Camshaft bearing cap bolt (Reamer bolt) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Camshaft bearing cap bolt (Standard bolt) 6 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Engine hanger bolt (Front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Engine hanger bolt (Rear) 1 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6
Cylinder head bolt 10 49.0+90 +120 5.0+90 +120 36.2+90 +120
Cooling system
Water pump pulley bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt (8 X 50) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water pump bolt (8 X 70) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Thermostat housing bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Thermostat housing nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water return pipe assembly bolt 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water temperature sensor 1 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Water outlet fitting nut 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Lubrication system
Oil filter assembly bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil cooler assembly bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil filter upper cap 1 24.5 2.5 18.1
Oil level gauge bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 65) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 85) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oil pan drain plug 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil screen nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Tightening torque
Item Quantity
N.m kgf.m lb-ft
Intake and exhaust system
Intake manifold and cylinder head fixing nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Intake manifold and cylinder head fixing bolt 7 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Exhaust manifold and cylinder head fixing nut 8 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Exhaust manifold heat cover and exhaust
3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
manifold fixing bolt
WCC assembly fixing nut 3 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Air cleaner lower cover fixing bolt 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Throttle body and surge tank fixing bolt 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Exhaust manifold and front muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler and center muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler and main muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
GENERAL EMA -9
COMPESSION PRESSURE NOTE

INSPECTION EA53A61E Always use a fully charged battery to obtain engine
speed of 300rpm or more.
NOTE
4) Repeat step 1) though 3) for each cylinder.
If the there is lack of power, excessive oil consump-
tion or poor fuel economy, measure the compression
pressure. NOTE
This measurement must be done in as short a time as
1. Warm up and stop engine. possible.
Allow the engine to warm up to normal operating tem-
perature. Compression pressure(Standard) :
2,353kPa (24.0kg/cm², 341psi) (260 rpm)
2. Remove the injectors(A). (Refer to FL Gr.)
Minimum pressure :
2,059kPa (21.0kg/cm², 298psi)
A Difference between each cylinder :
294.20kPa (3.0kg/cm², 42.67psi) 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
step 1) through 3) for cylinders with low compres-
sion.
• 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 stick-
ing or seating is improper, or there may be
LCGF003A leakage past the gasket.
3. Check the cylinder compression pressure. 4. Reinstall the injectors.
1) Insert a compression gauge into the injector hole.
ECKD001X
2) Fully open the throttle.
3) While cranking the engine, measure the com-

pression pressure.
TROUBLESHOOTING E2396869
Symptom Suspect area Remedy

Engine misfire with Repair or replace the flywheel
Loose or improperly installed engine flywheel.
abnormal internal as required.
lower engine noises.
Worn piston rings. Inspect the cylinder for a loss
(Oil consumption may or may not cause of compression.
the engine to misfire.) Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings.
as required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve (Carbon buildup on the valve stem can cause
train noise. the valve not to close properly.)
Replace the timing chain and
Excessive worn or mis-aligned timing chain.
sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or cracking • Inspect the cylinder head and
coolant consumption or other damage to the cylinder head and engine block for damage to
engine block cooling system. the coolant passages and/or a
• Coolant consumption may or may not faulty head gasket.
cause the engine to overheat. • Repair or replace as required.
Engine misfire Worn valves, valve guides and/or valve
Repair or replace as required.
with excessive oil stem oil seals.
consumption
Worn piston rings. Inspect the cylinder for a loss
(Oil consumption may or may not cause of compression
the engine to misfire) Repair or replace as required.
Engine noise on Incorrect oil viscosity. Drain the oil.
start-up, but only Refill with the correct viscosity oil.
lasting a few seconds.
Worn crankshaft thrust bearing. Inspect the thrust bearing and
crankshaft.
Upper engine noise, Low oil pressure. Repair or replace as required.
regardless of engine
Broken valve spring. Replace the valve spring.
speed.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth.
Replace the timing chain tensioner
Worn timing chain tensioner, if applicable.
as required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the camshaft and valve
lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,
then repair as required.
Stuck valves. (Carbon on the valve stem or valve Inspect the valves and valve guides,
seat may cause the valve to stay open.) then repair as required.
GENERAL EMA -11

Lower engine noise, Low oil pressure. Repair or replace damaged
regardless of engine components as required.
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 and cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance. Inspect the piston, piston pin and
the connecting rod.
Excessive connecting rod bearing clearance. Inspect the following components
and repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components
• The crankshaft bearings.
• The crankshaft journals.
Incorrect piston, piston pin and connecting Verify the piston pins and connecting
rod installation. rods are installed correctly.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
Excessive connecting rod bearing clearance. Inspect the following components
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
bearing bore.

Engine will not crank. Hydraulically locked cylinder. Remove injectors and check for fluid.
(crankshaft will not • Coolant/antifreeze in cylinder. Inspect for broken head gasket.
rotate) • Oil in cylinder. Inspect for cracked engine block
• Fuel in cylinder. or cylinder head.
Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Broken timing chain and/or timing chain gears. Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder. Inspect cylinder for damaged
• Broken valve. components and/or foreign materials.
• Piston material. Repair or replace as required.
• Foreign material.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting
rod bearing.
Bent or broken connecting rod. Inspect connecting rods.
Broken crankshaft. Inspect crankshaft.
GENERAL EMA -13
SPECIAL SERVICE TOOLS E986315E
Tool (Number and name) Illustration Use

Torque angle adapter Installation of bolts & nuts needing
(09221-4A000) an angular method
LCAC030A
Valve spring compressor Removal and installation of intake

(09222-3K000) 09222-3K000 and exhaust valves
Valve spring compressor adapter
(09222-2A100)
09222-2A100
LCGF059A
Valve stem oil seal installer Installation of valve stem oil seals
(09222-2A000)
LCAC030D

High pressure pump sprocket remover Removal of high pressure pump
(09331-2A000) sprocket
LCGF063B
Crankshaft rear oil seal installer Installation of crankshaft rear oil seal
(09231-H1200)
Handle
(09231-H1100)
09231-H1100
09231-H1200
LCGF157A
Front cover oil seal installer Installation of front cover oil seal
(09231-2A000) 09231-H1100
Handle
(09231-H1100)
09231-2A000
LCGF158A
GENERAL EMA -15

Flywheel stopper Removal and installation of
(09231-2A100) crankshaft pulley bolt.
B314A200
Oil pan remover Removal of oil pan

(09215-3C000)
ACJF125A
Engine support fixture ＆ adapter Support of engine

(09200-38001, 09200-1C000)
AMJF002B
TIMING SYSTEM
TIMING CHAIN
COMPONENT E85E1C8A
27.5 ~ 29.4
1 (2.8 ~ 3.0, 20.3 ~ 21.7)
2
3
6.9 ~ 9.8
4 (0.7 ~ 1.0, 5.1 ~ 7.2)
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
38.2 ~ 58.8 14.7 ~ 19.6
(3.9 ~ 6.0, 28.2 ~ 43.4) 9.8 ~ 11.8 (1.5 ~ 2.0, 10.8 ~ 14.5)
(1.0 ~ 1.2, 7.2 ~ 8.7)
15
13
6
7 14
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
12
9.8 ~ 11.8
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)
(1.0 ~ 1.2, 7.2 ~ 8.7)
42.2 ~ 53.9 19.6 ~ 24.5
(4.3 ~ 5.5, 31.1 ~ 39.8) (2.0 ~ 2.5, 14.5 ~ 18.1)
10 11
9
8
225.6 ~ 245.2 18.6 ~ 27.5 9.8 ~ 11.8
(23.0 ~ 25.0, 166.4 ~ 180.8) (1.9 ~ 2.8, (1.0 ~ 1.2, 7.2 ~ 8.7)
18.6 ~ 27.5 13.7 ~ 20.3)
(1.9 ~ 2.8, 13.7 ~ 20.3)
TORQUE : N.m(kgf.m, lbf.ft)
1. Injector 6. Water pump pulley 11. Oil pan
2. Injector clamp 7. Engine support bracket 12. Oil strainer
3. Cylinder head cover 8. Drive belt auto tensioner 13. Water pump
4. Cylinder head gasket 9. Crankshaft pulley 14. High pressure pump
5. Alternator 10. Key 15. Timing chain cover
LDJF001A
TIMING SYSTEM EMA -17
68.6 ~ 73.5
(7.0 ~ 7.5, 50.6 ~ 54.2)
24.5 ~ 30.4
(2.5 ~ 3.1, 18.1 ~ 22.4)
7.8 ~ 11.8 15
9.8 ~ 13.7
(1.0 ~ 1.4, 7.2 ~ 10.1) (0.8 ~ 1.2, 5.8 ~ 8.7)
14
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7) 6
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
3 5
4 13
10 11
1 8 9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)
7
12
64.7 ~ 74.5 (6.6 ~ 7.6, 47.7 ~ 55.0)
9
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)

9.8 ~ 11.8
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)
(1.0 ~ 1.2, 7.2 ~ 8.7)
1. Timing chain cover 6. Timing chain guide "2" 11. Timing chain "A" lever
2. Timing chain "C" 7. Timing chain "A" 12. Timing chain guide "1"
3. Timing chain "C" auto tensioner 8. High pressure pump sprocket 13. Timing chain case
4. Timing chain "C" lever 9. Crankshaft sprocket 14. Timing chain case gasket
5. Timing chain guide "1" 10. Timing chain "A" auto tensioner 15. Camshaft sprocket
LDJF002A
REMOVAL E5A01FA9 4. Remove the engine mounting support bracket.
Engine removal is not required for this procedure. 1) Set the jack to the engine oil pan
1. Remove the drive belt(A).
LDIF001A
ACGF031A
2) Remove the engine mounting support
bracket(A).
2. Remove the injector(A). (Refer to FL Gr.)
EDNG002A
LCGF003A
3. Remove the cylinder head cover(A). 5. Remove the alternator(A).
2
8
12
11 1
9
7
3 6 13
10
5
4
LCGF004A LCGF005A
6. Remove the water pump pulley(A). 9. Turn the crankshaft pulley, and align its groove with
timing mark "T" of the timing chain cover. (No.1 cylin-
der compression TDC position)
Mark
LCGF006A
7. Remove the engine support bracket(A). LCGF089A
A
10. Remove the crankshaft pulley bolt(B) and crankshaft
pulley(A).
LCGF007A
8. Remove the drive belt auto tensioner(A).

LCGF009A
NOTE
A Use the SST(flywheel stopper, 09231-2A100)(A) to
remove the crankshaft pulley bolt, after remove the
starter.
LCGF008A
12. Remove the high pressure pump pipe(A). (Refer to FL

Gr.)
LCGF090A
11. Remove the high pressure pump sprocket nut(B) after

ADJF034A
remove the timing chain cover plug(A).
13. Remove the high pressure pump(A) fixing bolts and
fuel hoses(B,C).
A B
C
A
LCGF091A
ADJF044A
NOTE
14. Install the SST(high pressure pump sprocket stopper,
• Use the SST(flywheel stopper, 09231-2A100) to
09331-2A000)(A) to sprocket rotating it clockwise.
remove the high pressure pump sprocket nut.
15. Remove the timing chain cover bolt(three bolts)(B).
LCGF090A
LCGF159A
• Replace O-ring of plug(A) with a new one when

reinstalling the plug.
16. Install the SST(high pressure pump sprocket remover, 21. Remove the jack from oil pan.
09331-2A000)(A) to timing chain cover with three long
bolts(B).
17. Fix the high pressure pump remover(A) and sprocket

stopper(C) with two fixing bolts(D).
18. Rotate the bolt(E) clockwise till high pressure pump is

pushed out.
19. Remove the SST(09331-2A000) after remove the

high pressure pump.
LDIF001A
D
22. Remove the oil pan(A).

A
23. Remove the oil strainer(B).
E C
LCGF160A
20. Install the SST(09200-38001, 09200-1C000), the en-

gine support fixture and the adapter, on the enine
hanger bracket.
B
09200-38001 LCGF010A
09200-1C000
NOTE
Using the SST(09215-3C000) and remove the oil pan.
Be careful not damage the contact surtaces of oil pan.
09215-3C000
LCGF150A
ACJF127B
24. Remove the timing chain cover(A) 26. Remove the timing chain "C" lever(A) and the timing
chain guide "1"(B).
A
B
B
F
D E D
E D B
D
D
B
C D
D A
B C
LCGF011A
LCGF013A
NOTE
27. Remove the timing chain guide "2"(A).
Remove thoroughly sealant and oil etc left at the seal-
ing surface after remove the chain cover and oil pan.
(If any impurities are left at the sealing face, oil may
leak after reassembly even with the sealant applica- A
tion.)
25. Remove the timing chain "C" auto tensioner(A).
LCGF014A
28. Remove the timing chain "C"(A).
Mark
A
B
LCGF012A
NOTE
Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner. A
Mark
LCGF015A
29. Remove the timing chain "A" auto tensioner(A). 31. Remove the timing chain "A"(A)with high pressure
pump sprocket(B) and crankshaft sprocket(C).
mark
B
mark
TDC
A
B C A
LCGF016A
LCGF024A
NOTE
32. Remove the power steering pump bracket(A).
Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner.
30. Remove timing chain "A" lever(A) and the timing chain
guide "1"(B).
A
TDC
LCGF025A
33. Remove the water pump(A).

B
LCGF017A
LCGF026A
34. Remove the timing chain case(A).

(Engine removal is required for this procedure)
B A
LCGF027A
35. Remove the camshaft sprocket.
1) Hold the portion(A) of the camshaft with a

hexagonal wrench, and remove the bolt(C) with
a wrench(B) and remove the camshaft sprocket.
LCGF028A
CAUTION
Be careful not to damage the cylinder head and
valve lifter with the wrench.
INSTALLATION E95FE08A
Engine removal is not required for this procedure.
1. Install the camshaft sprocket and tighten the bolt to

the specified torque.
1) Temporarily install the camshaft sprocket bolt(C). B
D
2) Hold the portion(A) of the camshaft with a
hexagonal wrench, and tighten the bolt(C) with C
a wrench(B).
Tightening torque : B A
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lb-ft)
LCGF027A
3. Install the water pump(A).
Tightening torque :
A
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
B
CAUTION
Apply coolant to the o-ring before installing the
water pump.
C
A
LCGF028A
2. Install the timing chain case(A) with new gasket.

(Engine removal is required for this procedure)
Tightening torque :
Bolt(B) :24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m,
18.1 ~ 22.4lb-ft)
Bolt(C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m,
13.7 ~ 20.3lb-ft)
Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
LCGF026A
4. Install the power steering pump bracket(A). 7. Set the key of crankshaft sprocket to be aligned with
the timing mark of timing chain case. As a result of
this, place the piston on No.1 cylinder at the top dead
center on compression stroke.
TDC
LCGF025A
5. Install the high pressure pump(A) and connect fuel

hoses (B, C). LCGF093A
Tightening torque : 8. After install timing chain "A" with high pressure pump
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft) sprocket(B) equipped at the crankshaft sprocket(C),
and then install high pressure pump sprocket at the
high pressure pump shaft.
NOTE
B
The timing mark of high pressure pump sprocket
should be aligned with timing mark on the timing
chain case.
mark
C B
A
mark
ADJF044A
6. Install the high pressure pipe(A).(Refer to FL Gr) TDC
C A
LCGF024A
A
9. Pretighten the high pressure pump sprocket nut.
ADJF034A
10. Install timing chain "A" lever(A) and the timing chain 12. Align the timing mark(A) of camshaft sprocket on the
guide "1"(B). vertical center line of crankshaft.
Tightening torque : A
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
TDC
LCGF094A
B
13. Install the timing chain "C"(A) as following procedure.
High pressure pump sprocket LH camshaft sprocket
LCGF017A
RH camshaft sprocket
11. Install the timing chain "A" auto tensioner(A) and then
remove set pin(B). NOTE
The timing mark of each sprockets should be matched
Tightening torque : with timing mark (color link) of timing chain at installing
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) timing chain as shown below illustration.
Mark
A
B
Mark
LCGF016A LCGF015A
14. Install the timing chain guide "2"(A). 16. Install the timing chain "C" auto tensioner(A) and then
remove set pin(B).
Tightening torque :
9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lb-ft) Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
A
B
LCGF014A
LCGF012A
15. Install the timing chain "C" lever(A) and the timing
chain guide "1"(B). 17. Install the high pressure pump sprocket nut(A).
Tightening torque : Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft)
LCGF013A LCGF095A
NOTE 19. Install the timing chain cover(A).
Use the SST(flywheel stopper, 09231-2A100)(A) to Tightening torque :

tighten the high pressure pump sprocket nut, after re- Bolt (B,C,F) :
move the starter. 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Bolt(D,E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
A
B
B
A F
D E D
E D
D
D
B
C D
D
B C
LCGF090A
B
18. Apply liquid gasket evenly to the mating surface of LCGF011A
timing chain cover.

20. Install the front oil seal by using SST(09231-2A000,
09231-H1100)(A).
NOTE
• Standard liquid gasket : LOCTITE 5900
• Check that the mating surfaces are clean and dry
before applying liquid gasket.
• Assemble the timing chain cover in 5 minutes af-
ter applying the liquid gasket.
• Apply liquid gasket in a 3mm wide bead without
stopping.
Liquid
gasket A
LCGF097A
LCGF096A
21. Install the oil strainer(B).
Tightening torque : Timing chain

Bolts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) Bed plate
cover
Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
T - joint
Timing chain
case
LCGF099A
B
23. Install the oil pan(A).
A Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
LCGF010A
24. Set the jack to the engine oil pan

22. Apply liquid gasket evenly to the mating surface of oil
pan.
NOTE
stopping.Assemble the oil pan in 5 minutes after
applying the liquid gasket.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
• Apply liquid gasket to T-joint before assembling
oil pan.
LDIF001A
Liquid gasket
25. Remove the SST(09200-38001, 09200-1C000), the
engine support fixture and the adapter, from the en-
gine hanger bracket.
09200-38001
09200-1C000
LCGF098A
LCGF150A
26. Install the crankshaft pulley(A) and crankshaft pulley 27. Install the drive belt auto tensioner(A).
bolt(B).
Tightening torque :
Tightening torque : 18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lb-ft)
A
A
LCGF008A
LCGF009A
28. Install the engine support bracket(A).

NOTE
Use the SST(flywheel stopper, 09231-2A100)(A) to Tightening torque :
Install the crankshaft pulley bolt, after remove the 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
starter.
LCGF090A LCGF007A
29. Install the water pump pulley(A). 31. Install the engine mounting support bracket(A).

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) Nut(D) : 68.6 ~ 93.2N.m(7.0 ~ 9.5kgf.m, 50.6~ 68.7lb-ft)
Bolt(B), Nut(C) : 49.0 ~ 63.7N.m(5.0 ~
6.5kgf.m, 36.2 ~ 47.0lb-ft)
A
LCGF006A
30. Install the alternator(A).

ADJF027A
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft) 32. Remove the jack from oil pan
LCGF005A LDIF001A
33. Install the cylinder head cover(A) with new head cover 34. Install the injector(A). (Refer to FL Gr.)
gasket.
A
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
12
6
2
3 13
5
7
11 8 1
4
9
10
LCGF003A
35. Install the drive belt(A).
A
LCGF161A
NOTE
stopping.
• Assemble the cylinder head cover in 5 minutes
after applying the liquid gasket.
• Apply liquid gasket to T-joint before assembling
cylinder head cover. ACGF031A
T - joint
Apply
liquid
gasket
LCGF100A
ENGINE AND TRANSAXLE 3. Remove the under cover(A).
ASSEMBLY
A
REMOVAL E01A6338
CAUTION
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion.
NOTE
• Mark all wiring and hoses to avoid misconnec- ACJF006A
tion.
4. Drain the engine coolant. (Refer to EMA- 77)
1. Remove the battery(A). Remove the radiator cap to speed draining.
5. Drain the engine oil. (Refer to EMA- 87)

Remove the oil filler cap to speed draining.
6. Remove the intake air hose and air cleaner assembly.
A 1) Disconnect the AFS(Air Flow Sensor) connec-

OX
EB tor(A).
FUS
2) Remove the air cleaner upper cover(B).
ADJF001A
2. Remove the engine cover(A).

A
ADJF003A
ADJF002A
ENGINE AND TRANSAXLE ASSEMBLY EMA -35
3) Disconnect the ECM connector(A) and ECM con- 8. Remove the inter cooler upper hose(A).
nector(B) (A/T only).
4) Remove the air cleaner element and air cleaner

lower cover(C). A
ADJF005A
9. Remove the inter cooler lower hose(A) and ATF oil

C
cooler hose(B).
ACJF008A
5) Disconnect the air intake hose(A).
ADJF006A
10. Remove the upper radiator hose(A) and lower radiator

ADJF004A hose(B).
7. Remove the battery tray(A).
A
B
ADJF007A
ACJF009A
11. Remove the fuel hose(A). 14. Remove the heater hose(A).
ADJF008A ADJF011A
12. Remove the brake booster vacuum hose(A). 15. Disconnect the battery (+) terminal (A) from fuse box.
ADJF009A ADJF012A
13. Remove the VGT actuator vacuum hose(A). 16. Disconnect the engine harness (A) and harness con-
nector(B) from fuse box.
ADJF010A B
ADJF013A
17. Remove the engine wire harness connectors and wire 8) Remove the engine wire harness bracket(D).
harness clamps from cylinder head and the intake
manifold. A
1) Disconnect the common rail pressure regulator

connector (A).
2) Disconnect the oxygen sensor connector (B).

D
B
B
A ADJF016A
9) Disconnect the MAP sensor connector(A).
10) Disconnect the multi purpose check connec-

tor(B).
ADJF014A B
3) Disconnect the injector connector(A).
4) Disconnect the EGR(Emission Gas Recircula-

tion) solenoid valve connector(B).
ADJF017A
11) Disconnect the vacuum solenoid valve connec-

tor(A).
ADJF015A
5) Disconnect the CMP(Camshaft position sensor)

connector(A).
6) Disconnect the common rail pressure sensor

connector(B).
7) Disconnect the water temperature sensor con-

nector(C). A
ADJF018A
12) Disconnect the swirl valve actuator connector(A).
13) Disconnect the fuel pressure regulator connector

B
(B).
14) Disconnect the fuel temperature sensor connec-

tor (C).
C
A
A
ADJF021A
3) Disconnect the output shaft speed sensor con-

nector (A).
B
ADJF019A
15) Remove the ground cable(A) from the engine

mounting and body. A
A
ADJF022A
4) Disconnect the solenoid valve connector(A).
5) Disconnect the input shaft speed sensor connec-

tor (B).
ADJF020A 6) Remove the ground cable(C) from the transaxle

and body.
18. Remove the transaxle wire harness connectors and
control cable from transaxle (A/T).
1) Disconnect the transaxle range switch connector B

(A).
2) Disconnect the vehicle speed sensor connec- C

tor(B).
ADJF023A
7) Remove the transaxle control cable(A). 21. Recovering refrigerant and remove the high & low
pressure pipe. (Refer to HA group - air conditioner
compressor)
22. Remove the inter cooler lower hose(A).
ADJF024A
19. Remove the power steering oil hose(A) and drain the A
power steering oil.
ADJF025A
23. Remove the front muffler heat protector(A).
24. Remove the front muffler(B).
A
A
ACJF026A
20. Remove the power steering return hose(A). B
ADJF026A
ACJF027A
25. Remove the nuts(B,D), bolt(C) and engine mounting 28. Remove the ABS wheel speed sensor(A).
support bracket(A).
Tightening torque :
Nut (B) : 68.6 ~ 93.2N.m (7.0~ 9.5kgf.m,
50.6 ~ 68.7lb-ft)
Bolt(C),Nut(D):49.0~63.7N.m(5.0~6.5kgf.m,36.2~47.0lb-ft) A
LCGF138A
29. Remove the caliper and hang assembly(A).

A
ADJF027A
26. Remove the transaxle mounting bracket(A).
Tightening torque :
Bolt (B) : 68.6 ~ 93.2N.m (7.0~ 9.5kgf.m,
50.6 ~ 68.7lb-ft)
LCGF139A
LDJF010A
27. Remove the front tires.(Refer to DS group)
LCGF140A
30. Remove the knuckle mounting bolts(A).
KDNF001A
LCGF141A 33. Remove the sub frame bolts and nuts.
31. Remove the steering u-joint mounting bolt(A). Tightening torque :

Bolt(A), Nut(B) : 93.2 ~ 117.7N.m
(9.5 ~ 12.0kgf.m, 68.7 ~ 86.8lb-ft)
LCGF142A B
A
32. Using a floor jack, support the engine and transaxle
assembly. ACJF033A
NOTE 34. Remove the engine and transaxle assembly by lifting

vehicle.
After removing the sub frame mounting bolt , the en-
gine and transaxle assembly may fall downward, and
so support them securely with floor jack. NOTE
Verify that the hoses and connectors are discon- When remove the engine and transaxle assembly, be
nected before removing the engine and transaxle careful not to damage any surrounding parts or body
assembly. components.
INSTALLATION ECD86743
Installation is in the reverse order of removal.

Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator and reservoir tank with engine
coolant.
• Place the 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 radia-
tor, add coolant if needed. This will allow trapped
air to be removed from the cooling system.
- Put the radiator cap on tightly, then run the engine
again and check for leaks.
• Clean the 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.
CYLINDER HEAD ASSEMBLY EMA -43
CYLINDER HEAD
ASSEMBLY
COMPONENT E9EC962A
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)
2 3
5 10.8 ~ 14.7
(1.1 ~ 1.5, 8.0 ~ 10.8)
0.8 ~ 1.5
(0.08 ~ 0.15, 0.6 ~ 1.1)
15 ~ 20
(1.5 ~ 2.0, 11 ~ 14) 1
14.7 ~ 21.6
(1.5 ~ 2.2, 10.8 ~ 15.9)
1. Common rail 5. Thermostat housing

2. Glow plug connector 6. Vacuum pump
3. Glow plug plate 7. Cylinder head
4. Glow plug
LDJF003A
12.7 ~ 13.7
(1.3 ~ 1.4, 9.4 ~ 10.1)
68.6 ~ 73.5
(7.0 ~ 7.5, 50.6 ~ 54.2)
10 5
6
7
11
12

1. Camshaft bearing cap 5. Valve spring retainer lock 9. Valve
2. Camshaft 6. Valve spring retainer 10. HLA(Hydraulic Lash Adjuster)
3. Camshaft sprocket 7. Valve spring 11. Cylinder head
4. Cam follwer 8. Valve stem seal 12. Cylinder head gasket
LCGF039A
REMOVAL E7827144 5. Remove the glow plug(A).
Engine removal is required for this procedure.
CAUTION
• To avoid damaging the cylinder head, wait un-
til the engine coolant temperature drops be-
low normal temperature before removing it.
• When handling a metal gasket, take care not
to fold the gasket or damage the contact sur-
face of the gasket.
NOTE
A
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. LCGF041A
6. Disconnect the water hose(A) from thermostat hous-

1. Remove the drive belt(A). ing.
A
ACGF031A
ADJF047A
2. Remove the timing chain. (Refer to EMA-18) 7. Remove the thermostat housing(A).
3. Remove the intake and exhaust manifold. (Refer to

EMA-96)
4. Remove the delivery pipe(A).

A
ADJF046A
LCGF040A
8. Remove the vacuum pump(A). 11. Remove the cam follower(A).
A A
LCGF044A LCGF047A
9. Remove the camshaft bearing caps(A). 12. Remove the HLA(Hydraulic Lash Adjust)(A).
NOTE A
Mark the camshaft bearing caps to be able to re-

assemble in the original position and direction.
LCGF048A
13. Remove the cylinder head bolts, then remove the

cylinder head.
1) Using socket (12PT), uniformly loosen and

LCGF045A remove the 10 cylinder head bolts, in several
passes, in the sequence shown.Remove the 10
10. Remove the camshaft(A). cylinder head bolts.
4
8
9
5
3
1
7
10
6
2
LCGF046A LCGF049A
DISASSEMBLY EBC5B0B5
CAUTION
Head warpage or cracking could result from re- 1. Remove the valves.
moving bolts in an incorrect order.
1) Using the SST (09222-3K000, 09222-2A100)(A),
2) Lift the cylinder head from the dowels on the compress the valve spring and remove the re-
cylinder block and replace the cylinder head(A) tainer lock.
on wooden blocks on a bench.
LCGF101A
LCGF050A
2) Remove the spring retainer.
CAUTION
3) Remove the valve spring.
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block. 4) Remove the valve.
5) Using a needle-nose pliers, remove the stem oil

seal.
INSPECTION E45A23A8 VALVE AND VALVE SPRING
CYLINDER HEAD 1. Inspect the valve stems and valve guides.
1. Inspect for flatness. 1) Using a caliper gauge, measure the inner diam-
Using a precision straight edge and feeler gauge, eter of valve guide.
measure the surface the contacting the cylinder block
and the manifolds for warpage. Valve guide inner diameter :
Intake : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Flatness of cylinder head gasket surface : Exhaust : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Less than 0.03mm (0.0012in) for width
Less than 0.09mm (0.0035in) for length
Flatness of manifold mating surface :
Less than 0.025mm (0.0010in) for width
Less than 0.160mm (0.0063in) for length
ECKD219A
2) Using a micrometer, measure the outer diameter

of valve stem.
Valve stem outer diameter

Intake : 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
Exhaust : 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
ECKD001H
2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust
ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
ECKD220A
3) Subtract the valve stem outer diameter measure- 3. Inspect the valve seats.
ment from the valve guide inner diameter mea-
surement. 1) Check the valve seat for evidence of overheating
and improper contact with the valve face.
Valve stem- to-guide clearance Replace the seat if necessary.
Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Exhaust : 0.050 ~ 0.077mm (0.0020 ~ 0.0030in) 2) Before reconditioning the seat, check the valve
guide for wear. If the valve guide is worn, replace
it, then recondition the seat.
If the clearance is greater than specification, re-
place the valve and valve guide. 3) Recondition the valve seat with a valve seat
grinder or cutter. The valve seat contact width
2. Inspect the valves. should be within specifications and centered on
the valve face.
1) Check the valve is ground to the correct valve
face angle.
2) Check that the surface of valve for wear.

If the valve face is worn, replace the valve. Cutter
3) Check the valve head margin thickness. If the Pilot

margin thickness is less than specification, re-
place the valve.
Margin
Intake : 1.1mm (0.0433in) 1.2 ~ 1.8 mm 0.8 ~ 1.4 mm
Exhaust : 1.2mm (0.0472in)
Exhaust Intake
BCGE009B
Margin
ECKD221A
4) Check the valve length.
Length
Intake : 93.0mm (3.6614in)
Exhaust : 93.7mm (3.6890in)
5) Check the surface of valve stem tip for wear.

If the valve stem tip is worn, replace the valve.
4. Inspect the valve springs. CAMSHAFT
1) Using a steel square, measure the out-of-square 1. Inspect the cam lobes.
of valve spring. Using a micrometer, measure the cam lobe height.
2) Using a vernier calipers, measure the free length Cam height

of valve spring. LH Camshaft
Intake : 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Valve spring Exhaust : 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Standard RH Camshaft
Free height : 44.9mm (1.7677in) Intake : 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Load : 17.5±0.9kg/32.0mm (38.6±2.0lb/1.2598in) Exhaust : 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
31.0±1.6kg/23.5mm (68.3±3.5lb/0.9252in)
Out of square : Less than 1.5
Limit
Out of square : 3
ECKD223A
If the cam lobe height is less than specification, re-

place the camshaft.
ECKD222A
2. Inspect the camshaft journal clearance.
If the loads is not as specified, replace the valve
spring. 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.
ECKD224A
4) Install the bearing caps and tighten the bolts with 3. Inspect the camshaft end play.
specified torque. (Refer to EMA-56)
1) Install the camshafts. (Refer to EMA-56)
Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lb-ft) 2) Using a dial indicator, measure the end play while
moving the camshaft back and forth.
CAUTION Camshaft end play

Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
Do not turn the camshaft.
5) Remove the bearing caps.
6) Measure the plastigage at its widest point.
Bearing oil clearance

0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
LCGF127A
If the end play is greater than specification, re-

place the camshaft. If necessary, replace the
bearing caps and cylinder head as a set.
3) Remove the camshafts.

ECKD225A
If the oil clearance is greater than specificaiton,

replace the camshaft. If necessary, replace the
bearing caps and cylinder head as a set.
7) Completely remove the plastigage.
8) Remove the camshafts.

HLA (HYDRAULIC LASH ADJUSTER)
With the HLA filled with engine oil, hold A and press B by
hand. A
If B moves, replace the HLA.
LCGF128A
Problem Possible cause Action

1. Temporary noise when starting Normal This noise will disappear after
a cold engine the oil in the engine reaches the
normal pressure.
2. Continuous noise when the Oil leakage of the high ressure Noise will disapapear within 15
engine is started after parking chamber on the HLA, allowing minutes when engine runs at
more than 48 hours. air to get in. 2000-3000 rpm.
If it doesn’ t disappear, refer
3. Continuous noise when the Insufficient oil in cylinder head
to step 7 below.
engine is first started after rebuilding oil gallery.
cylinder head.
CAUTION
4. Continuous noise when the Oil leakage of the high-pressure
engine is started after excessively chamber in the HLA, allowing Do not run engine at a speed
cranking the engine by the starter air to get in. higher than 3000 rpm, as this
motor or band. Insufficient oil in the HLA. may damage the HLA.
5. Continuous noise when the engine
is running after changing the HLA.
6. Continuous noise during idle Engine oil level too high or too low. Check oil level.
after high engine speed. Drain or add oil as necessary.
Excessive amount of air in the oil Check oil supply system.
at high engine speed.
Deteriorated oil. Check oil quality.
If deteriorated, replace with
specified type.
7. Noise continues for more Low oil pressure. Check oil pressure and oil supply
than 15 minutes. system of each part of engine.
Faulty HLA. Remove the cylinder head cover and
press HLA down by hand.
If it moves, replace the HLA.
WARNING
Be careful with the hot HLAS.
REASSEMBLY EB6B9E0F 3) Using the SST(09222-2A100, 09222-3K000)(A),

compress the spring and install the retainer locks.
NOTE After installing the valves, ensure that the retainer
locks are correctly in place before releasing the
• Thoroughly clean all parts to be assembled. valve spring compressor.
• Before installing the parts, apply fresh engine oil
to all sliding and rotating surface.
• Replace oil seals with new ones.
A
1. Install the valves.
1) Using the SST (09222-2A000)(A), push in a new

stem oil seal.
NOTE
Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leak-
age past the valve guides.
LCGF101A
4) Lightly tap the end of each valve stem two or

three times with the wooden handle of a hammer
to ensure proper seating of the valve and retainer
lock.
A
LCGF102A
2) Install the valve, valve spring and spring retainer.
NOTE
Place the valve springs so that the side coated with
enamel faces toward the valve spring retainer and
then installs the retainer.
INSTALLATION EEFE8B3B
NOTE
• Thoroughly clean all parts to be assembled.
• Always use a new cylinder head and manifold
gasket.
• Always use a new cylinder head bolt.
• The cylinder head gasket is a metal gasket. Take
care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC.
1. Cylinder head dowel pins must be aligned.
LCGF129A
2. Select the cylinder head gasket.
2) Select the gasket in the table below using the av-
1) Measure the piston protrusion from the upper erage value of piston protrusions. Although even
cylinder block face (I) on 8 places (A ~ H) at T.D.C. the only 1 point is over than the each rank limit,
Measure on the crankshaft center line consider- use 1 rank upper gasket than specified in the ta-
ing the piston migration. ble below.
A C E G
B D F H
Identification code
I
ACGF012A LCGF104A
Displacement 1.5 L
0.035 ~ 0.105mm 0.105 ~ 0.175mm 0.175 ~ 0.245mm
Average of piston protrusion
(0.0014 ~ 0.0041in) (0.0041 ~ 0.0069in) (0.0069 ~ 0.0096in)
1.00 ~ 1.15mm 1.05 ~ 1.20mm 1.10 ~ 1.25mm
Gasket thickness
(0.0394 ~ 0.0453in) (0.0413 ~ 0.0472in) (0.0433 ~ 0.0492in)
Limit of each rank extant 0.14mm (0.0055in) 0.21mm (0.0083in) -
Identification code
LCGF130A LCGF132A LCGF131A

3) Install the gasket so that the identification mark 5. Install the cylinder head bolts.
faces toward the timing chain side.
1) Apply a light coat if engine oil on the threads and
3. Install the cylinder head gasket(A) on the cylinder under the heads of the cylinder head bolts.
block.
2) Using socket (12PT), install and tighten the 10
NOTE cylinder head bolts, in several passes, in the se-
quence shown.
Be careful of the installation direction.
Tightening torque :
A 49.0N.m (5.0kgf.m, 36.2lb-ft)+90 + 120
NOTE
Do not reuse the cylinder head bolts.
9
5
1
4
10
8
6
2
3
7
ACGF013A
4. Place the cylinder head (A) quietly in order not to dam- LCGF153A
age the gasket with the bottom part of the end.
6. Istall the HLA(Hydraulic Lash Adjust)(A).
A
A
LCGF050A
LCGF048A
1) Until installing HLA shall be held upright so that

diesel oil in HLA should not spill and assured that
dust does not adhere to HLA.
2) HLA shall be inserted tenderly to the cylinder

head not to spill diesel oil from HLA. In case of
spilling, air bent shall be done in accordance with
the air bent procedure.
NOTE 9. Install the camshaft bearing caps(A).
Stroke HLA in diesel oil 4~5 times by pushing its cap Tightening torque :
while pushing the ball down slightly by hard steel wire. 12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lb-ft)
(Take care not to severely push hard steel wire down
since ball is several grames.)
Steel wire A
LCGF045A
LCGF133A
10. Install the vacuum pump(A) with new gasket(B).
7. Install the cam follower(A).
Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lb-ft)
Apply liquid
A gasket
B
A
LCGF047A
8. Install the camshaft(A). LCGF154A
LCGF046A
NOTE 12. Reconnect the water hose(A) to thermostat housing.
Apply engine oil to the O-ring(A) of vacuum pump

shaft before assembling vacuum pump.
A
A
ADJF047A
13. Install the glow plug(A) and glow plug plate.

LCGF126A
Tightening torque :
11. Install the thermostat housing(A). Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft)
Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lb-ft)
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
LCGF041A
ADJF046A
14. Install the delivery pipe(A).
Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
LCGF040A
15. Install the intake and exhaust manifold. (Refer to

EMA-96)
16. Install the timing chain. (Refer to EMA-25)
17. Install the drive belt.

ENGINE BLOCK EMA -59
ENGINE BLOCK
CYLINDER BLOCK E80C8E3F
COMPONENT
19.6 ~ 24.5
(2.0 ~ 2.5, 14.5 ~ 18.1)
7 5
4
8 6
68.6 ~ 78.5
(7.0 ~ 8.0, 50.6 ~ 57.9)
10 2
16
11 3
14
15
8.8 ~ 12.7
(0.9 ~ 1.3, 6.5 ~ 9.4)
13 19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
32.4 ~ 36.3
(3.3 ~ 3.7, 23.9 ~ 26.8) 12

1. Oil filter cap 7. Flywheel 12. Bed plate
2. Oil filter 8. Crankshaft rear oil seal 13. Crankshaft main bearing
3. Oil filter housing & oil cooler assembly 9. Piston & connecting rod 14. Crankshaft
4. Water pipe 10. Connecting rod bearing 15. Oil jet
5. Clutch disk cover 11. Connecting rod cap 16. Cylinder block
6. Clutch disk
LDJF004A
DISASSEMBLY E69CD7DF 9. Remove the bed plate(A).
1. M/T : Remove the fly wheel.

A
2. A/T : Remove the drive plate.
3. Install the engine to engine stand for disassembly.
4. Remove the timing chain. (Refer to EMA-18)
5. Remove the intake manifold and exhaust manifold.

(Refer to EMA-94)
6. Remove the cylinder head. (Refer to EMA-45)
7. Remove the water pipe(A).
LCGF054A
10. Remove the rear oil seal(A).
LCGF052A
8. Remove the oil filter and oil cooler assembly(A).
LCGF055A
11. Remove the connecting rod cap(A).

A
NOTE
Mark the connecting rod caps to be able to reassem-
ble in the original position and direction.
A
ACGF053A
LCGF056A
12. Remove the piston and connecting rod assemblies. 15. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston
1) Using a ridge reamer, remove all the carbon from pin.
the top of the cylinder. If any movement is felt, replace the piston and pin as
a set.
2) Push the piston, connecting rod assembly and
upper bearing through the top of the cylinder 16. Remove the piston rings.
block.
1) Using a piston ring expender, remove the 2 com-
NOTE pression rings.
• Keep the bearings, connecting rod and cap to- 2) Remove the 2 side rails and oil ring by hand.
gether.
• Arrange the piston and connecting rod assem-
NOTE
blies in the correct order.
Arrange the piston rings in the correct order only.
13. Lift the crankshaft(A) out of the engine, being careful
not to damage journals. 17. Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.
NOTE
Arrange the main bearings and thrust bearings in the
correct order.
LCGF057A
14. Remove the oil jet(A).
LCGF058A
INSPECTION ECA43B76 9) If the plastigage measures too wide or too nar-

row, remove the upper and lower bearing and
CONNECTING ROD then install a new bearings with the same color
mark. (Refer to connecting rod bearing selection
1. Check the connecting rod bearing oil clearance. table. EMA-63)
Recheck the oil clearance.
1) Check the match marks on the connecting rod
and cap are aligned to ensure correct reassem- CAUTION
bly.
Do not file, shim, of scrape the bearings or the
caps to adjust clearance.
2) Remove the 2 connecting rod cap bolts.
10) If the plastigage shows the clearance is still in-
3) Remove the connecting rod cap and lower bear- correct, try the next larger or smaller bearing.(
ing. Refer to connecting rod bearing selection table.
EMA-63)
4) Clean the crankshaft pin journal and bearing. Recheck the oil clearance.
5) Place a plastigage across the crankshaft pin jour-
NOTE
nal.
If the proper clearance cannot be obtained by using
6) Reinstall the lower bearing and cap, and tighten the appropriate larger or smaller bearings, replace the
the nuts. crankshaft and start over.
Tightening torque : CAUTION

12.7N.m (1.3kgf.m, 9.4lb-ft) + 90
If the marks are indecipherable because of an ac-
cumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
NOTE solvent or detergent.
Do not turn the crankshaft.
Do not reuse the connection rod cap bolts. CONNECTING ROD MARK LOCATION
7) Remove the 2bolts, connecting rod cap and lower

bearing .
8) Measure the plastigage at its widest point.
Standard oil clearance

0.025 ~ 0.043mm (0.0010 ~ 0.0017in) Front
U
Mark
LCGF108A
DISCRIMINATION OF CONNECTING ROD
Connecting rod big-end

Mark
inner diameter
A 49.000 ~ 49.006mm (1.9291 ~ 1.9294in)
B 49.006 ~ 49.012mm (1.9294 ~ 1.9296in)
C 49.012 ~ 49.018mm (1.9296 ~ 1.9298in)
LCGF107A
CRANKSHAFT PIN JOURNAL MARK LOCATION CONNECTING ROD BEARING SELECTION TABLE
Connecting rod Connecting rod mark

bearing A B C
Crank A Blue Black None
shaft
B Black None Green
pin
journal
C None Green Yellow
mark
2. Check the connecting rods.
1) When reinstalling, make sure that cylinder num-

Pin journal bers put on the connecting rod and cap at dis-
mark "U" mark assembly match. When a new connecting rod is
ACAE163B1 installed, make sure that the notches for holding
the bearing in place are on the same side.
DISCRIMINATION OF CRANKSHAFT PIN JOURNAL
2) Replace the connecting rod if it is damaged on
Crankshaft pin journal the thrust faces at either end. Also if step wear
Mark
outer diameter or a severely rough surface of the inside diameter
A 46.009 ~ 46.015mm (1.8114 ~ 1.8116in) of the small end is apparent, the rod must be
replaced as well.
B 46.003 ~ 46.009mm (1.8111 ~ 1.8114in)
C 45.997 ~ 46.003mm (1.8109 ~ 1.8111in) 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.
CONNECTING ROD BEARING MARK LOCATION
Any connecting rod that has been severely bent
or distorted should be replaced.
Allowable bend of connecting rod :

0.05mm / 100mm (0.0020in / 3.94in ) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039in / 3.94in) or less
Color
LCGF143A
DISCRIMINATION OF CONNECTING ROD BEARING
Color Connecting rod bearing thickness

Blue 1.477 ~ 1.480mm (0.0581 ~ 0.0583in)
Black 1.480 ~ 1.483mm (0.0583 ~ 0.0584in)
None 1.483 ~ 1.486mm (0.0584 ~ 0.0585in)
Green 1.486 ~ 1.489mm (0.0585 ~ 0.0586in)
Yellow 1.489 ~ 1.492mm (0.0586 ~ 0.0587in)
11) Select the bearing by using selection table.

CRANKSHAFT 7) If the plastigage shows the clearance is still in-

correct, try the next larger or smaller bearing.
1. Check the crankshaft bearing oil clearance. (Refer to crankshaft main bearing selection table.
EMA-65)
1) To check main bearing-to-journal oil clearance, Recheck the oil clearance.
remove the bed plate and lower bearings.
NOTE
2) Clean each main journal and lower bearing with
a clean shop towel. If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
3) Place one strip of plastigage across each main crankshaft and start over.
journal.
CAUTION
4) Reinstall the lower bearings and bed plate, then If the marks are indecipherable because of an ac-
tighten the bolts. cumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
Tightening torque : solvent or detergent.
Long bolts : 24.5N.m(2.5kgf.m, 18.1lb-ft) + 90
Short bolts : 32.4~36.3N.m(3.3~3.7kgf.m, CYLINDER BLOCK CRANKSHAFT JOURNAL
23.9~26.8lb-ft) BORE MARK LOCATION
Letters have been stamped on the front face of

NOTE block as a mark for the size of each of the 5 main
Do not turn the crankshaft. journal bores.
5) Remove the bed plate and lower bearing again, Use them, and the numbers or letters stamped on
and measure the widest part of the plastigage. the crank (marks for main journal size), to choose
the correct bearings.
Standard oil clearance :
0.024 ~ 0.042mm (0.0009 ~ 0.0017in) Crankshaft journal
bore mark
LCGF144A
DISCRIMINATION OF CYLINDER BLOCK

CRANKSHAFT JOURNAL BORE
LCGF109A
Cylinder block crankshaft journal

6) If the plastigage measures too wide or too nar- Mark
bore inner diameter
row, remove the upper and lower bearing and
then install a new bearings with the same color A 58.000 ~ 58.006mm (2.2835 ~ 2.2837in)
mark. (Refer to crankshaft main bearing selec- B 58.006 ~ 58.012mm (2.2837 ~ 2.2839in)
tion table, EMA-65)
Recheck the oil clearance. C 58.012 ~ 58.018mm (2.2839 ~ 2.2842in)
CAUTION
Do not file, shim, or scrape the bearings or the
cap to adjust clearance.
CRANKSHAFT MAIN JOURNAL MARK LOCATION CRANKSHAFT MAIN BEARING SELECTION TABLE
Cylinder block crankshaft

Crankshaft main journal bore mark
bearing
A B C
Crank A Blue Black None
shaft
B Black None Green
main
journal
C None Green Yelllow
mark
2. Check the crankshaft end play.

Main journal Using a dial indicator, measure the thrust clearance
mark "U" mark while prying the crankshaft back and forth with a
screwdriver.
ACAE163B2
DISCRIMINATION OF CRANKSHAFT MAIN End play

JOURNAL Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
Mark Crankshaft main journal outer diameter
A 53.984 ~ 53.990mm (2.1254 ~ 2.1256in)
B 53.978 ~ 53.984mm (2.1251 ~ 2.1254in)
C 53.972 ~ 53.978mm (2.1249 ~ 2.1251in)
CRANKSHAFT MAIN BEARING MARK LOCATION
ECKD001B
If the end play is greater than maximum, replace the

center main bearing as a set.
Color Thrust washer thickness of center main beaing :

2.335 ~ 2.385mm (0.0919 ~ 0.0939in)
BCGE030A1
DISCRIMINATION OF CRANKSHAFT MAIN

BEARING
Color Crankshaft main bearing thickness

Blue 1.990 ~ 1.993mm (0.0783 ~ 0.0785in)
Black 1.993 ~ 1.996mm (0.0785 ~ 0.0786in)
None 1.996 ~ 1.999mm (0.0786 ~ 0.0787in)
Green 1.999 ~ 2.002mm (0.0787 ~ 0.0788in)
Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in)
8) Select the bearing by using selection table.

3. Inspect the crankshaft main journals and pin journals. CYLINDER BLOCK
Using a micrometer, measure the diameter of each
main journal and pin journal. 1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material
Main journal diameter : from the top surface of the cylinder block.
53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal diameter : 2. Clean the cylinder block
45.997 ~ 46.015mm (1.8109 ~ 1.8116in) Using a soft brush and solvent, thoroughly clean the
cylinder block.
3. Inspect the 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

Less than 0.05mm (0.0020in)
ECKD001E
ECKD001L
4. Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder
block.
5. Inspect the cylinder bore diameter. 7. Check the piston size mark(A) on the piston top face.
Using a cylinder bore gauge, measure the cylinder
bore diameter at position in the thrust and axial di- Size
mark
rection.
Standard diameter :
75.00 ~ 75.03mm (2.9528 ~ 2.9539in)
Front
mark
LCGF110A
DISCRIMINATION OF PISTON OUTER DIAMETER
Mark Piston outer diameter

A 74.930 ~ 74.940mm (2.9500 ~ 2.9504in)
ECKD318A B 74.940 ~ 74.950mm (2.9504 ~ 2.9508in)
6. Check the cylinder bore size code on the cylinder C 74.950 ~ 74.960mm (2.9508 ~ 2.9512in)
block front face.
8. Select the piston related to cylinder bore class.
Cylinder bore mark
Piston-to-cylinder clearance :
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
LCGF155A
DISCRIMINATION OF CYLINDER BORE SIZE
Mark Cylinder bore inner diameter

A 75.000 ~ 75.010mm (2.9528 ~ 2.9531in)
B 75.010 ~ 75.020mm (2.9531 ~ 2.9535in)
C 75.020 ~ 75.030mm (2.9535 ~ 2.9539in)
BORING CYLINDER PISTON AND PISTON RINGS
1. Oversize pistons should be selected according to the 1. Clean the piston.

largest bore cylinder.
1) Using a gasket scraper, remove the carbon from
the piston top.
NOTE
The size of piston is stamped on top of the piston. 2) Using a groove cleaning tool or broken ring, clean
the piston ring grooves.
2. Measure the outside diameter of the piston to be
used. 3) Using solvent and a brush, thoroughly clean the
piston.
3. According to the measured O.D(Outer Diameter), cal-
culate the new bore size. NOTE
New bore size = piston O.D + 0.02 to 0.04mm (0.0008 Do not use a wire brush.
to 0.0016in) (clearance between piston and cylinder)
- 0.01mm (0.0004in) (honing margin.) 2. The standard measurement of the piston outside di-
ameter is taken 10mm (0.39in) from bottom land of
the piston.
4. Bore each of the cylinders to the calculated size.
Standard diameter :
CAUTION 74.93 ~ 74.96mm (2.9500 ~ 2.9512in)
To prevent distortion that may result from temper-
ature rise during honing, bore the cylinder holes
in the firing order.
5. Hone the cylinders, finishing them to the proper di-

mension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
NOTE
When boring the cylinders, finish all of the cylinders
to the same oversize. Do not bore only one cylinder
to the oversize. ECKD001D
3. Calculate the difference between the cylinder bore in-

ner diameter and the piston outer diameter.
Piston-to-cylinder clearance :
0.06 ~ 0.08mm (0.0024 ~ 0.0031in)
4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between
new piston ring and the wall of ring groove.
Piston ring side clearance

No.1 : 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No.2 : 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
PISTON PINS
1. Measure the outer diameter of piston pin.
Piston pin diameter :

27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
ECKD001G
If the clearance is greater than maximum, replace the

piston.
5. Inspect the piston ring end gap.

To measure the piston ring end gap, insert a piston
ring into the cylinder bore. Position the ring at right
ECKD001Z
angles to the cylinder wall by gently pressing it down
with a piston. Measure the gap with a feeler gauge. If 2. Measure the piston pin-to-piston clearance.
the gap exceeds the service limit, replace the piston
rings. If the gap is too large, recheck the cylinder bore Piston pin-to-piston clearance :
inner diameter. If the bore is over the service limit, the 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
cylinder block must be rebored. (Refer to EMA-67)
Piston ring end gap 3. Check the difference between the piston pin outer di-
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in) ameter and the connecting rod small end inner diam-
No.2 : 0.35 ~ 0.50mm (0.0138 ~ 0.0197in) eter.
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)
Piston pin-to-connecting rod interference :
0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
ECKD001K
OIL PRESSURE SWITCH REASSEMBLY EFACC32C
1. Check the continuity between the terminal and the

NOTE
body with an ohmmeter. If there is no continuity, re-
place the oil pressure switch. • Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil
to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with
new parts.
1. Assemble the piston and connecting rod.
1) Use a hydraulic press for installation
2) The piston front mark and the connecting rod

front mark must face the timing belt side of the
engine.
Mark
ECKD001W
2. Check the continuity between the terminal and the

body when the fine wire is pushed. If there is con-
tinuity even when the fine wire is pushed, replace the
switch.
BCGE018A
2. Install the piston rings.
1) Install the oil ring expander and 2 side rails by

hand.
2) Using a piston ring expander, install the 2 com-

pression rings with the code mark facing upward.
ECKD001Y
3) Position the piston rings so that the ring ends are
as shown.
3. If there is no continuity when a 49.0kpa (0.5kg/cm²,
7.1psi) vacuum is applied through the oil hole, the
switch is operating properly.
Check for air leakage. If air leaks, the diaphragm is
broken. Replace it.
LCGF145A
3. Install the connecting rod bearings. 5. Install the oil jet(A).
1) Align the bearing claw with the groove of the con- Tightening torque :
necting rod or connecting rod cap. 8.8 ~ 12.7N.m (0.9 ~ 1.3kgf.m, 6.5 ~ 9.4lb-ft)
2) Install the bearings(A) in the connecting rod and
connecting rod cap(B).
A
LCGF058A
ECKD322A
6. Place the crankshaft (A) on the cylinder block.
4. Install the crankshaft main bearings.
NOTE
A
Upper 1, 2, 4, 5 bearings have an oil groove of oil
holes ; Lower bearings do not.
1) Align the bearing claw with the claw groove of the

cylinder block, push in the 5 upper bearings(A).
LCGF057A
7. Place the bed plate (A) on the cylinder block.
ECKD323A
2) Align the bearing claw with the claw groove of

the main bearing cap, and push in the 5 lower
bearings.
LCGF054A
NOTE 9. Check the crankshaft end play. (EMA-65)
• Standard liquid gasket : LOCTITE 5205, HYLO- 10. Install the piston and connecting rod assemblies.
MAR3000, Dreibond 5105
• Check that the mating surfaces are clean and dry NOTE
• Apply liquid gasket in a 3mm wide bead without Before installing the piston, apply a coat of engine oil
stopping. to the ring grooves and cylinder bores.
• Assemble the bed plate in 5 minutes after apply-
1) Remove the connecting rod caps, and slip short
ing the liquid gasket.
sections of rubber hose over the threaded ends
of the connecting rod bolts.
2) Install the ring compressor, check that the rings
8. Install the bed plate bolts. are securely in place, then position the piston in
the cylinder, and tap it in using the wooden han-
NOTE dle of a hammer.
• The bed plate bolts are tightened in 2 progressive
3) Stop after the ring compressor pops free, and
steps.
check the connecting rod-to-crank journal align-
• If any of the bed plate bolts in broken or de-
ment before pushing the piston into place.
formed, replace it.
4) Apply engine oil to the bolt threads. install the rod
1) Apply a light coat of engine oil on the threads and caps(A) with bearings, and tighten the bolts.
under the bed plate bolts.
Tightening torque :
2) Install and uniformly tighten the bed plate bolts,
12.7N.m (1.3kgf.m, 9.4lb-ft) + 90
in several passes, in the sequence shown.
a. Tighten the 11,17, 20 bolts.
b. Tighten the 1 ~ 10 bolts in the sequence
shown by the specified torque.
c. Loosen the 11, 17, 20 bolts.
d. Tighten the 11 ~ 20 bolts in the sequence A
shown by the specified torque.
Tightening torque :
Long bolts(1~10) : 24.5N.m (2.5kgf.m, 18.1lb-ft) + 90
Short bolts(11~20) : 32.4~36.3N.m (3.3~3.7kgf.m,
23.9~26.8lb-ft)
19
15 7
11 3 8
14 2 LCGF056A
20
4
18 6
1 16
10 12
5
13
9
17
LCGF111A
3) Check that the crankshaft turns smoothly.

NOTE 12. Install the oil filter and oil cooler assembly(A).
Maintain downward force on the ring compressor to Tightening torque :

prevent the rings from expending before entering the 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
cylinder bore.
ACGF053A
ECKD001F
11. Install the rear oil seal. 13. Install the water pipe(A).
1) Apply engine oil to a new oil seal lip. Tightening torque :

19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
2) Using the SST(09231-H1200, 09231-H1100)(A)
and a hammer, tap in the oil seal until its surface
is flush with the rear oil seal retainer edge.
ACGF052A
LCGF112A
14. Install the cylinder head. (Refer to EMA-54)
15. Install the intake manifold and exhaust manifold. (Re-

fer to EMA-96)
16. Install the timing chain. (Refer to EMA-25)
17. Remove the engine stand.
18. A/T :install the drive plate.
Tightening torque :
68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)
19. M/T :install the fly wheel.
Tightening torque :
68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lb-ft)
COOLING SYSTEM EMA -75
COOLING SYSTEM
COMPONENT E5292B02
4
3
7 8
1. Coolant reservoir tank 6. ATF oil cooler hose

2. Radiator 7. Cooling fna
3. Radiator mounting bracket 8. Cooling fan shroud
4. Radiator upper hose 9. Cooling fan motor
5. Radiator lower hose
LDJF005A
19.6 ~ 24.5
(2.0 ~ 2.5, 14.5 ~ 18.1)
3
2
1
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7) 19.6 ~ 24.5
(2.0 ~ 2.5, 14.5 ~ 18.1)

1. Water pump pulley 3. Water pipe
2. Water pump
LDJF006A
ENGINE COOLANT REFILLING AND 5. Remove the coolant reservoir tank. Drain the coolant
and reinstall the coolant reservoir tank. Fill the coolant
BLEEDING E4CE2B97
reservoir tank to the MAX mark with the coolant.
WARNING
Never remove the radiator cap when the engine is
hot.
Serious scalding could be caused by hot fluid un-
der high pressure escaping from the radiator.
CAUTION
When pouring engine coolant, be sure to shut the
relay box lid and not to let coolant spill on the
electrical parts of the paint. If any coolant spills,
rinse it off immediately.
1. Slide the heater temperature control lever to maxi-

mum heat. Make sure the engine and radiator are
ACJF037A
cool to the touch.
2. Remove the radiator cap(A). 6. Fill fluid mixture with coolant and water slowly through
the radiator cap. Gently squeeze the upper/ lower
hoses of the radiator so as to bleed air easily.
NOTE
• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant con-
centration must be maintained year-round at 50%
A
minimum. Coolant concentrations less than 50%
may not provide sufficient protection against cor-
rosion of freezing.
• Coolant concentrations greater then 60% will im-
pair cooling efficiency and are not recommended.
CAUTION
ACJF034A
• Do not mix different brands of an-
3. Loosen the drain plug(A), and drain the coolant. tifreeze/coolants.
• Do not use additional rust inhibitors or an-
tirust products; they may not be compatible
with the coolant.
7. Start the engine and allow coolant to circulate. When

the cooling fan operates and coolant circulates, refill
coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air

sufficiently out of the cooling system.
A
9. Install the radiator cap and fill the reservoir tank to the
"MAX" line with coolant.
10. Run the vehicle under idle until the cooling fan oper-
ACJF036A ates 2 ~ 3 times.
4. Tighten the radiator drain plug(A) securely. 11. Stop the engine and allow coolant to cool.
12. Repeat step 6 to 11 until the coolant level stays con- RADIATOR CAP TESTING
stant and all air is bleed out of the cooling system.
1. Remove the radiator cap, wet its seal with engine
coolant, then install it no pressure tester.
NOTE
Recheck the coolant level in the reservoir tank for 2 ~
3 days after replacing coolant.
Coolant capacity : 5.3 ~ 5.51 liters(5.60 ~ 5.81

US qt, 4.66 ~ 4.84 lmp qt)
ECKD501X
2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~

1.25kg/cm², 13.51 ~ 17.78psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

RADIATOR LEAKGE TEST REMOVAL E04044C3
1. Wait until engine is cool, then carefully remove the WATER PUMP
radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester. 1. Drain the engine coolant.
2. Apply a pressure tester to the radiator and apply a WARNING

pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm²,
13.51 ~ 17.78psi). System is under high pressure when the engine
is hot.
To avoid danger of releasing scalding engine
coolant, remove the cap only when the engine is
cool.
2. Remove the drive belts.
3. Remove the water pump pulley(A).
ACJF035A
3. Inspect for engine coolant leaks and a drop in pres-

sure.
A
4. Remove the tester and reinstall the radiator cap.
NOTE
LCGF006A
Check for engine oil in the coolant and/or coolant in
the engine oil. 4. Remove the water pump(A).
LCGF026A
THRMOSTAT RADIATOR
NOTE 1. Drain the engine coolant.

Remove the radiator cap to speed draining.
Disassembly of the thermostat would have an adverse
effect, causing a lowering of cooling efficiency. 2. Remove the upper radiator hose (A) and lower radia-
tor hose(B).
1. Drain the engine coolant so its level is below thermo-
stat. 3. Remove the ATF (Automatic Transaxle Fluid) oil
cooler hoses(C). (A/T)
2. Remove the water outlet fitting(A), gasket and ther-
mostat.
B
C
ACJF010A
ADJF048A
4. Disconnect the fan motor connector(A).
ACJF042A
5. Remove the cooling fan mounting bolt (A,B) and re- 6. Remove the radiator upper bracket (A,B), then pull up
move cooling fan. the radiator.
ACJF043A ACJF045A
B
B
ACJF044A ACJF046A
INSPECTION EBB47DC5 THERMOSTAT
WATER PUMP 1. Immerse the thermostat in water and gradually heat

the water.
1. Check each part for cracks, damage or wear, and re-
place the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the coolant pump(A)
assembly if necessary.
ECKD503B
2. Check the valve opening temperature.
Valve opening temperature : 85±1.5 C (185.0±2.7 F)

(Measurement lift : 0.35mm(0.0138in))
LCGF026A Full opening temperature : 100 C (212 F)
3. Check for coolant leakage. If coolant leaks from hole,

If the valve opening temperature is not as specified,
the seal is defective. Replace the coolant pump as-
replace the thermostat.
sembly.
3. Check the valve lift.
NOTE
A small amount of "weeping" from the bleed hole is Valve lift : 8mm(0.3in) or more at 100 C (212 F)
normal.
If the valve lift is not as specified, replace the thermo-
stat.
COOLING FAN 3. Install the water pump pulley(A).
1. Disconnect the cooling fan motor connector. Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
1 2
3 4
ACJF124A
2. Check if motor speed is low when power and ground LCGF006A
are connected to the NO.1 and NO.3 terminals.

4. Install the drive belts.
3. Check if motor speed is high when power and ground
are connected to the NO.2 and NO.3 terminals. 5. Fill with engine coolant.
6. Start engine and check for leaks.

INSTALLATION E6AB5146
7. Recheck engine coolant level.
WATER PUMP
1. Replace the O-ring of the water pipe with a new one.
2. Install the water pump(A) with a new O-ring.
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
CAUTION
Apply coolant to the O-ring before installing the
water pump.
LCGF026A
THERMOSTAT RADIATOR
1. Place the thermostat in thermostat housing with new 1. Install the radiator.
gasket.
2. Install the radiator upper brack(A, B).
2. Install the water outlet fitting(A).
Tightening torque :
Tightening torque : 6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft)
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1 lb-ft)
ACJF045A
ADJF048A
3. Fill with engine coolant.
ACJF046A
3. Install the cooling fan mounting bolts(A, B) 5. Install the upper radiator hose(A) and lower radiator
hose(B).
Tightening torque :
6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft) 6. Install the ATF(Automatic Transaxle Fluid) Oil cooler
hoses(C).
A A
B
C
ACJF043A
ACJF010A
7. Fill with engine coolant.
ACJF044A
4. Connect the fan motor connector(A).
ACJF042A
LUBRICATION SYSTEM
COMPONENT E206D0D5
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)
1
2
4
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
6 19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7) 5
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)
1. Oil filter cap 4. Timing chain cover

2. Oil filter 5. Oil pan
3. Oil filter housing & oil cooler assembly 6. Oil strainer
LCGF124A
LUBRICATION SYSTEM EMA -87
OIL AND FILTER REPLACEMENT EF3CA4CE 4) After the rubber seal seats, tighten the oil filter
clockwise.
CAUTION
Tightening torque :
• Prolonged and repeated contact with mineral 24.5N.m(2.5kgf.m, 18.1lb-ft)
oil will result in the removal of natural fats
from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil 3. Refill with engine oil.
contains potentially harmful contaminants
1) Clean and install the oil drain plug with a new
which may cause skin cancer.
gasket.
• Exercise caution in order to minimize the
length and frequency of contact of your skin
Tightening torque :
to used oil. Wear protective clothing and
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
gloves. Wash your skin thoroughly with soap
and water, or use water-less hand cleaner,
to remove any used engine oil. Do not use 2) Fill wih fresh engine oil.
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil Oil Capacity
and used oil filter must be disposed of only at Total : 5.3 L (5.60 US qt, 4.66 lmp qt)
designated disposal sites. Oil pan : 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil filter : 0.5 L (0.53 US qt, 0.44 lmp qt)
1. Drain the engine oil.
1) Remove the oil filler cap. CAUTION

When filling engine oil, fill half of full capacity and
2) Loosen the oil filter cap until O-ring(C) appears.
do the remainings in 10 minutes.
Be careful for oil not to overflow.
3) Install the oil filler cap.
3) Remove the oil drain plug, and drain the oil into
a container. 4. Start engine and check for oil leaks.
2. Replace the oil filter(B). 5. Recheck the engine oil level.
1) Remove the oil filter upper cap(A). INSPECTION
1. Check the engine oil quality.

A Check the oil deterioration, entry of water, discoloring
of thinning.
If the quality is visibly poor, replace the oil.
C
2. Check the engine oil level.
B After warning up the engine and then 5 minutes after
the engine stop, oil level should be between the "L"
D and "F" marks in the dipstick.
If low, check for leakage and add oil up to the "F" mark.
NOTE
Do not fill with engine oil above the "F" mark.
ACGF035A
2) Replace the O-ring(C,D) of oil filter cap with a

new one.
Inspect the threads and O-ring(C,D). Wipe off the
seat on the oil filter cap, then apply a light coat of
oil to the oil filter upper cap O-ring(C,D).
3) Install the new oil filter by hand to the upper cap.

SELECTION OF ENGINE OIL
Recommended API classification : CH-04 OR ABOVE

Recommended ACEA classification : B4 OR ABOVE
Recommended SAE viscosity grades :
Temperature range
anticipated before
Recommended SAE viscosity number
next oil change
40 104 30 20W 15W

10W 5W
-30
-30
40 68 -40 -40
20 50
10 32
0 14
0W
-10 5
-30
-20 -4
-25 -13
*1
*2
*1 Restricted by driving condition and environment.

Not recommended for sustained high speed vehicle operation
LDJF007A
NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants which
:
1. Satisfy the requirement of the API classification.
2. Have proper SAE grade number for expected am-
bient temperature range.
3. Lubricants that do not have both an SAE grade
number and API service classification on the con-
tainer should not be used.
REMOVAL E706E185 DISASSEMBLY E4CE52B1
OIL PUMP RELIEF PLUNGER
1. Drain the engine oil. 1. Remove the relief plunger.

Remove the plug(A), spring(B) and relief plunger(C).
2. Remove the drive belts.
3. Turn the crankshaft pulley, and align its groove with

timing mark "T" of the timing chain cover.
4. Remove the Oil pan
5. Remove the timing chain cover. (Refer to

EMA-18~22, step1~24)
6. Remove the oil pump cover(A) from the timing chain

cover.
C
B
A
A
ACGF116A
LCGF115A
7. Remove the inner rotor and outer rotor.

INSPECTION E1596F2A REASSEMBLY E7FFCFF4
1. Inspect the relief plunger. RELIEF PLUNGER

Coat the plunger with engine oil and check that it falls
smoothly into the plunger hole by its own weight. 1. Install the relief plunger.
If it does not, replace the relief plunger. If necessary, Install relief plunger(C) and spring(B) into the front
replace the front case. case hole, and install the plug(A).
2. Inspect the rotor side clearance. Tightening torque :

Using a feeler gauge and precision straight edge, 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft)
measure the clearance between the rotors and
precision straight edge.
0.04 ~ 0.09mm
Outer rotor
Side (0.0016 ~ 0.0035in)
clearance 0.04 ~ 0.085mm
Inner rotor
(0.0016 ~ 0.0033in)
If the side clearance is greater than maximum, replace

the rotors as a set. If necessary, replace the front
case. C
B
A
ACGF116A
INSTALLATION E465BA84
OIL PUMP
1. Install the oil pump.
1) Place the inner and outer rotors into front case

with the marks facing the oil pump cover side.
2) Install the oil pump cover(A) to timing chain cover

with the screws.
Tightening torque :
5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lbf.ft)
LCGF115A
2. Check that the oil pump turns freely.
3. Install the timing chain cover. (Refer to EMA-29~33)
4. Install the oil pan.
5. Install the drive belts.
6. Fill with engine oil.

INTAKE AND EXHAUST

SYSTEM
INTAKE MANIFOLD E57F3CD0
COMPONENT
21.6 ~ 27.5
(2.2 ~ 2.8, 15.9 ~ 20.3)
29.4 ~ 34.3
(3.0 ~ 3.5, 21.7 ~ 25.3) 4
29.4 ~ 34.3
29.4 ~ 34.3 (3.0 ~ 3.5,
21.7 ~ 25.3) 7
(3.0 ~ 3.5, 6
21.7 ~ 25.3) 14.7 ~ 19.6
(1.5 ~ 2.0, 10.8 ~14.5)
14.7 ~ 19.6
(1.5 ~ 2.0,
10.8 ~14.5) 1
5
9.8 ~ 14.7
(1.0 ~ 1.5, 2
7.2 ~ 10.8)
8
14.7 ~ 19.6
21.6 ~ 27.5 3 (1.5 ~ 2.0,
(2.2 ~ 2.8, 15.9 ~ 20.3) 10.8 ~14.5)
9.8 ~ 11.8
(1.0 ~ 1.2,
9.8 ~ 11.8 7.2 ~ 8.7)
(1.0 ~ 1.2,
7.2 ~ 8.7)
TORQUE : Nm(kgf.m, Ib-ft)
1. Intake manifold 5. Catalytic converter assembly

2. Intake manifold gasket 6. Turbo charger oil return pipe
3. Swirl valve actuator 7. Turbo charger & exhaust manifold assembly
4. EGR valve & pipe assembly 8. Exhaust manifold gasket
LDJF008A
INTAKE AND EXHAUST SYSTEM EMA -93
EXHAUST PIPE
COMPONENT
3
29.4 ~ 39.2
(3.0 ~ 4.0, 21.7 ~ 28.9)
2
29.4 ~ 39.2
(3.0 ~ 4.0, 21.7 ~ 28.9)
1
TORQUE : Nm(kgf.m, Ib-ft)
1. Front muffler 3. Main muffler

2. Center muffler
LDJF009A
REMOVAL E7366CB8 3. Remove the swirl valve actuator rod(A).
INTAKE MANIFOLD
1. Remove the vacuum solenoid valve(A). A
Tightening torque :
7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
KDNF001B
A 4. Remove the swirl valve actuator(A).
Tightening torque :
Bolt(B) : 9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Bolt(C) : 6.9 ~ 10.8 Nm (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
ADJF030A
2. Remove the engine harness protector(A) mounting

bolts.
Tightening torque :
7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
B
A
ADJF033A
A
5. Remove the high pressure pipe(A). (Refer to FL Gr.)
ADJF031A
ADJF034A
6. Remove the fuel temperature sensor mounting

bolt(A). (Refer to FL Gr.)
D
C
A
A C
ADJF053A
ADJF035A 9. Remove the intake manifold(A).
7. Remove the vacuum pipe(A) mounting bolt. Tightening torque :

14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
Tightening torque :
6.9 ~ 10.8 Nm (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
EDNG001A
ADJF036A
10. Remove the intake manifold gasket(A).

8. Remove the EGR cooler and EGR valve assembly(A).
Tightening torque :
Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m,
21.7 ~ 25.3 lb-ft)
Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, A
15.9 ~ 20.3 lb-ft)
Bolt ＆ Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0
kgf.m, 10.8 ~ 14.5 lb-ft)
LCGF033A
11. Installation is in the reverse order of removal.

EXHAUST MANIFOLD
1. Remove the heat protector(A).

B
Tightening torque :
14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) D
D
C
A C
ADJF053A
4. Remove the catalytic converter stay(A).
Tightening torque :
A
21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft)
LCGF117A
2. Remove the water hose (A) from the EGR cooler and
the thermostat housing.
ADJF040A
A
5. Remove the catalytic converter(A).
ADJF038A
Tightening torque :
29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
3. Remove the EGR cooler and the EGR valve assem-
bly(A).
Tightening torque :
Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m,
21.7 ~ 25.3 lb-ft)
Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m,
15.9 ~ 20.3 lb-ft)
Bolt ＆ Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0
kgf.m, 10.8 ~ 14.5 lb-ft)
A
ADJF041A
6. Remove the inter cooler hose(A) and the oil return 8. Remove the turbo charger and exhaust manifold as-
pipe(B). sembly(A).

Nut(C) : 9.8 ~ 14.7 Nm (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft) 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
Bolt(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m,
10.8 ~ 14.5 lb-ft)
B
A
A
ADJF043A
D
ADJF051A 9. Remove the exhaust manifold gasket(A) .
7. Remove the eye bolt(A) from the turbo charger oil

feeding pipe.
Tightening torque :
13.7 ~ 18.6 Nm (1.4 ~ 1.9 kgf.m, 10.1 ~ 13.7 lb-ft)
LCGF037A
10. Installation is in the reverse order of removal.
LCGF118A
EXHAUST PIPE 4. Remove the main muffler(A).
1. Remove the front muffler heat protector(A). Tightening torque :

29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
Tightening torque :
7.8 ~ 11.8 Nm (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
2. Remove the front muffler(B).
Tightening torque :
29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
ACJF054A
A 5. Installation is in the reverse order of removal.
ADJF026A
3. Remove the center muffler(A).
Tightening torque :
29.4 ~ 39.2 Nm (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
ACJF050A

Manual Tehnic - Motor Diesel Accent

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Engine (D4FA -

TIMING SYSTEM COOLING SYSTEM

ENGINE AND TRANSAXLE ASSEMBLY LUBRICATION SYSTEM

CYLINDER HEAD ASSEMBLY INTAKE AND EXHAUST SYSTEM

Description Specifications (D4FA) Limit

Flatness 0.025mm (0.0010in) for width

LH Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

Journal outer LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

Stem outer Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)

Description Specifications (D4FA) Limit

Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)

Width of seat Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)

Description Specifications (D4FA) Limit

Description Specifications (D4FA) Limit

COMPESSION PRESSURE NOTE

5) If the cylinder compression in 1 or more cylinders

3. Check the cylinder compression pressure. 4. Reinstall the injectors.

1) Insert a compression gauge into the injector hole.

2) Fully open the throttle.

3) While cranking the engine, measure the com-

Symptom Suspect area Remedy

Symptom Suspect area Remedy

Symptom Suspect area Remedy

SPECIAL SERVICE TOOLS E986315E

Tool (Number and name) Illustration Use

Valve spring compressor Removal and installation of intake

Tool (Number and name) Illustration Use

Tool (Number and name) Illustration Use

Oil pan remover Removal of oil pan

Engine support fixture ＆ adapter Support of engine

9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)

TORQUE : N.m(kgf.m, lbf.ft)

REMOVAL E5A01FA9 4. Remove the engine mounting support bracket.

1. Remove the drive belt(A).

3. Remove the cylinder head cover(A). 5. Remove the alternator(A).

7. Remove the engine support bracket(A). LCGF089A

8. Remove the drive belt auto tensioner(A).

12. Remove the high pressure pump pipe(A). (Refer to FL

11. Remove the high pressure pump sprocket nut(B) after

• Replace O-ring of plug(A) with a new one when

17. Fix the high pressure pump remover(A) and sprocket

18. Rotate the bolt(E) clockwise till high pressure pump is

19. Remove the SST(09331-2A000) after remove the

22. Remove the oil pan(A).

20. Install the SST(09200-38001, 09200-1C000), the en-

25. Remove the timing chain "C" auto tensioner(A).

28. Remove the timing chain "C"(A).

33. Remove the water pump(A).

34. Remove the timing chain case(A).

35. Remove the camshaft sprocket.

1) Hold the portion(A) of the camshaft with a

Engine removal is not required for this procedure.

1. Install the camshaft sprocket and tighten the bolt to

1) Temporarily install the camshaft sprocket bolt(C). B

3. Install the water pump(A).

2. Install the timing chain case(A) with new gasket.

5. Install the high pressure pump(A) and connect fuel

6. Install the high pressure pipe(A).(Refer to FL Gr) TDC

Tightening torque : Tightening torque :

NOTE 19. Install the timing chain cover(A).