Black plate (1,1)

Transmission & Clutch Overhaul

INTRODUCTION
3.1

F4A41, F5M41
00 GENERAL

Model YR 2006
English Edition RDWE-06HA080
Destination: MHR
April 2006 Printed in Malaysia

Copyright

Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)
 Black plate (2,1)

Printed in Malaysia 21 April 2006 Eng

 Black plate (3,1)

INTRODUCTION TC01
Content /I

00 GENERAL

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
WORKSHOP MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
PARTS CATALOGUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS . . . 00/1
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
DEFINITION OF TERMS ............................................... 00/1
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/1
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INDICATION OF TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
EXPLANATION OF MANUAL CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/3

ENGINE AND TRANSMISSION MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/6

ENGINE MODEL AND SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/6

ENGINE MODEL AND SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . 00/6

PRECAUTION BEFORE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/6

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7

STANDARD PARTS TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
TIGHTENING TORQUE OF FLANGE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
TIGHTENING TORQUE OF BOLT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/8
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/9
TIGHTENING TORQUE SCREW (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/9
TIGHTENING TORQUE STUD (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/9

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

Copyright

Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)

Printed in Malaysia 21 April 2006 Eng

 Black plate (4,1)

00 GENERAL
/1 FOREWORD / HOW TO USE THIS MANUAL

FOREWORD WTC000FWORD007

This Workshop Manual contains procedures for service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in the combination as required.
WORKSHOP MANUAL

Manual type Module Number Publication Number

CHASSIS Module 1.1 to 1.12 RDWE-06HA010
ENGINE OVERHAUL Module 2.1 to 2.3 RDWE-06HA020
TRANSMISSION AND CLUTCH
Module 3.1 to 3.3 RDWE-06HA080
OVERHAUL
ELECTRICAL WIRING Module 4.1, 4.2 & 4.3 RDWE-06HA030
FLATRATE Module 7.1 to 7.12 RDFE-06H040
PRE-DELIVERY INSPECTION Module 6.1, 6.2 & 6.3 RDPE-06HA050
BODY REPAIR Module 5.1, 5.2, 5.4, 5.6 RDBE-06H060
AIR CONDITION RDAE-06HA100

PARTS CATALOGUE

PART CATALOGUE RDGE-06HA070

All information, illustration and product descriptions contained in this manual are current as the time
of publication. We however reserve the right to make changes at any time without prior notice or
obligation.

HOW TO USE THIS MANUAL WTC000READS008

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations concerning the inspection, checking, adjustment, disassembly and
reassembly of the engine, transmission and major components after they have been removed from
the vehicle.
ON-VEHICLE SERVICE
‘‘On - Vehicle Service’’ is procedures for performing inspections and adjustments of particularly
important locations with regard to the construction and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance
LIMIT
Shown the standard for judging the quality of a part or assembly on inspection and means the
maximum or minimum value within which the part or assembly must be kept functionally or in
strength. It is a value established outside the range of standard value

Printed in Malaysia 21 April 2006 Eng

 Black plate (5,1)

GENERAL 00
HOW TO USE THIS MANUAL /2

REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
CAUTION
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.

INDICATION OF TIGHTENING TORQUE

The tightening torque shown in this manual is a basic value with a tolerance of F10% except the
followings cases when the upper and lower limits of tightening torque are given.
1. The tolerance of the basic value is within F10%
2. Special bolts or the like are in use.
3. Special tightening methods are used.

Printed in Malaysia 21 April 2006 Eng

 Black plate (6,1)

00 GENERAL
/3 HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS WTC000READS009

DOIIC000R9001

Printed in Malaysia 21 April 2006 Eng

 Black plate (7,1)

GENERAL 00
HOW TO USE THIS MANUAL /4

SYMBOL DESCRIPTION
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the
‘‘Tightening torque’’
H Symbol for lubrication sealants and adhesives.
Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.

Grease (multipurpose grease unless there is a brand

or type specified)
DOIIC000R9058

Sealant or adhesive

DOIIC000R9059

Brake fluid or automatic transmission fluid

DOIIC000R9060

Engine oil, gear oil or air condition compressor oil

DOIIC000R9061

Adhesive tape or butyl rubber tape.

DOIIC000R9062

Indicates procedures to be performed before the work in that section is started, and
J procedures to be performed after the work in that section is finished.

Printed in Malaysia 21 April 2006 Eng

 Black plate (8,1)

00 GENERAL
/5 HOW TO USE THIS MANUAL

SYMBOL DESCRIPTION
Maintenance and servicing Procedures
The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the
tightening torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.
Disassembly steps:
The part designation number correspond to the number in the illustration to indicate
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
major maintenance and service points and explained in detail.

Indicates that there are essentials point for removal

or disassembly.
DOIIC000R9052

Indicates that there are essential point for installa-

tion or reassembly
DOIIC000R9051

Indicates that there are essential points for both

DOIIC000R9053

M Operating procedures, caution etc. on removal, installation disassembly and

reassembly and reassembly are described.
N Table for graphic explaination

Printed in Malaysia 21 April 2006 Eng

 Black plate (9,1)

GENERAL 00
ENGINE AND TRANSMISSION MODEL / ENGINE MODEL AND SERIAL NUMBER / PRECAUTION BEFORE SERVICE /6

ENGINE AND TRANSMISSION MODEL WTC000GINFO010

Vehicle model Engine Fuel system Transmission

Model Camshaft Model Type
BS3 S4PE ( F5M41 5-M/T
1332 cm3 F4A41 5-A/T
(81.278 cu.in) MPI
Double
S4PH ( F5M41 5-M/T
BS6 1597 cm3 F4A41 5-A/T
(97.448 cu.in))

ENGINE MODEL AND SERIAL

NUMBER WTC000GINFO011

ENGINE MODEL AND SERIAL NUMBER

LOCATION
1. The engine model number is stamped at
the cylinder block as shown in the follow-
ing.

Engine Model Engine Displacement

S4PE 1332 cm3 (81.278 cu.in)
DOIKC000R03002
S4PH 1597 cm3 (97.448 cu.in)
2. The engine serial number is stamped near
the engine model number.

Engine serial number [Example]

AA0201 to YY9999

PRECAUTION BEFORE SERVICE WTC000BSERV007

When the engine or transmission is disassembled and reassembled, pay attention to the following.

Removal and Disassembly For prevention of Special Tool Be sure to use

wrong installation Special Tools
or reassembly and when their use is
for ease of opera- specified for the
tion, put mating operation. Use of
mark (A) to the substitute tools
parts where no will resulting
function is malfunction of
adversely affected. the part or
damage it.

DOIIE00AR9001 DOIIE00AR9005

Printed in Malaysia 21 April 2006 Eng

 Black plate (10,1)

00 GENERAL
/7 TIGHTENING TORQUE

Tightening Torque Tighten the part Sealant Use specified

properly to speci- brand of sealant.
fied torque. Use of sealant
other than speci-
fied sealant may
cause water or
oil leaks.

DOIIE00AR9002 DOIIE00AR9006

Replacement Part When oil seal, O- Rubber Part Do not stain tim-
ring, packing and ing belt and V-
gasket have been belt with oil or
removed, be sure water.
to replace them Therefore, do
with new parts. not cleaned the
However, rocker pulley and
cover gasket may sprocket with
be reused if it is detergent.
not damaged.

DOIIE00AR9003 DOIIE00AR9007

Oil and Grease Before reassembly, Genuine Part When the part is
apply specified oil replace, be sure
to the rotating and to use Proton
sliding parts. genuine part.
For selection of
appropriate part,
refer to the Parts
Catalog.

DOIIE00AR9004 DOIIE00AR9008

TIGHTENING TORQUE WTC000TTORQ005

General tightening torque is as shown in the following table.

The specified part tightening torque is shown at the beginning of each group.
STANDARD PARTS TIGHTENING TORQUE
TIGHTENING TORQUE OF FLANGE BOLT

Classification
Flange bolt (Dia.) Thread size (Pitch x length) Specified torque
M5 0.6 mm (0.023 in) F
0.8x30 mm (0.031x1.181 in)
0.1 kgm (1 Nm; 0.067 ft.lbs)

Printed in Malaysia 21 April 2006 Eng

 Black plate (11,1)

GENERAL 00
TIGHTENING TORQUE /8

Classification
Flange bolt (Dia.) Thread size (Pitch x length) Specified torque
1.0x10 mm (0.039x0.393 in)
1.0x12 mm (0.039x0.472 in)
1.0x18 mm (0.039x0.708 in)
M6 1.0x20 mm (0.039x0.787 in) 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)
1.0x25 mm (0.039x0.984 in)
1.0x35 mm (0.039x1.377 in)
1.0x50 mm (0.039x1.968 in)
1.25x16 mm (0.049x0.629 in)
1.25x25 mm (0.049x0.984 in)
2.2-2.6 kgm (22-26 Nm; 1.476-1.744 ft.lbs)
1.25x30 mm (0.049x1.181 in)
M8
1.25x40 mm (0.049x1.574 in)
1.25x70 mm (0.049x2.755 in) 1.2 kgm (12 Nm; 0.805 ft.lbs) F
1.25x100 mm (0.049x3.937 in) 0.1 kgm (1 Nm; 0.067 ft.lbs)
1.25x18 mm (0.049x0.708 in) SP 4.5-5.2 kgm (45-52 Nm; 3.019-3.489 ft.lbs)
1.25x25 mm (0.049x0.984 in) 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)
M10 1.25x35 mm (0.049x1.377 in) 3.3-3.7 mm (0.129-0.145 in)
1.25x50 mm (0.049x1.968 in) 2.8-3.2 kgm (28-32 Nm; 1.879-2.147 ft.lbs)
1.25x90 mm (0.049x3.543 in) 4.8-5.2 kgm (48-52 Nm; 3.221-3.489 ft.lbs)

TIGHTENING TORQUE OF BOLT (SPECIAL)

Classification
Bolt (Dia.) Thread size (Pitch x length) Specified torque
M8 43 mm (1.692 in) 2.0 kgm (20 Nm; 1.342 ft.lbs) + 608
2.0 kgm (20 Nm; 1.342 ft.lbs) F
0.2 kgm (2 Nm; 0.134 ft.lbs) +
4.0 kgm (40 Nm; 2.684 ft.lbs) F
160 mm (6.299 in) F 0.2 kgm (2 Nm; 0.134 ft.lbs) +
M9
0.35 mm (0.013 in) 5.0 kgm (50 Nm; 3.355 ft.lbs) F
0.2 kgm (2 Nm; 0.134 ft.lbs) + 608(min),
648 (max) and 608(min), 648 (max).
1.25x55 mm (0.049x2.165 in) 4.8-5.2 kgm (48-52 Nm; 3.221-3.489 ft.lbs)
1.25x105 mm (0.049x4.133 in) 3.3-3.7 mm (0.129-0.145 in)
M10
4.91 kgm (49.1 Nm; 3.295 ft.lbs) F
69 mm (2.716 in) 5.39 kgm (53.9 Nm; 3.617 ft.lbs)
17.5 mm (0.688 in) 5.0 kgm (50 Nm; 3.355 ft.lbs) F
26 mm (1.023 in) 0.2 kgm (2 Nm; 0.134 ft.lbs) + 608F 28
M12
3.0 kgm (30 Nm; 2.013 ft.lbs) F
30 mm (1.181 in)
0.2 mm (0.007 in) + 40 F 28
3.0 kgm (30 Nm; 2.013 ft.lbs) F
M14 70 mm (2.755 in) 0.2 kgm (2 Nm; 0.134 ft.lbs) +1208 F 48

Printed in Malaysia 21 April 2006 Eng

 Black plate (12,1)

00 GENERAL
/9 TIGHTENING TORQUE

TIGHTENING TORQUE OF FLANGE NUT (SPECIAL)

Classification
Flange nut (Dia.) Thread size (Pitch) Specified torque
M6 1.0 mm (0.039 in) 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)
M8 1.25 mm (0.049 in) 2.2-2.6 kgm (22-26 Nm; 1.476-1.744 ft.lbs)
M10 1.25 mm (0.049 in) 3.3-3.7 kgm (33-37 Nm; 2.214-2.483 ft.lbs)

TIGHTENING TORQUE SCREW (SPECIAL)

Classification
Screw (Dia.) Thread size (Pitch) Specified torque
M4 0.7x16 mm (0.027x0.629 in) 0.2-0.3 kgm (2-3 Nm; 0.134-0.201 ft.lbs)
1.0x16 mm (0.039x0.629 in) 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)
M6
1.0x25 mm (0.039x0.984 in) 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)

TIGHTENING TORQUE STUD (SPECIAL)

Classification
Stud (Dia.) Thread size (Pitch x length) Specified torque
M6 1.0x50 mm (0.039x1.968 in) 0.5 kgm (5 Nm; 0.335 ft.lbs)
M8 1.25x27 mm (0.049x1.062 in) 0.6-1.1 kgm (6-11 Nm; 0.402-0.738 ft.lbs)
1.25x40 mm (0.049x1.574 in)
M10 1.25x60 mm (0.049x2.362 in) 1.1-1.3 kgm (11-13 Nm; 0.738-0.872 ft.lbs)
1.25x65 mm (0.049x2.559 in)

Printed in Malaysia 21 April 2006 Eng

 Black plate (13,1)

INTRODUCTION TC01
INDEX /1

Printed in Malaysia 21 April 2006 Eng

 3
Content

Printed in Malaysia 21 April 2006 Eng

Black plate (14,1)

F4A41, F5M41 Model YR 2006 English Edition RDWE-06HA080 April 2006 Printed in Malaysia