10316636

SPECIFICATIONS

Description	Specifications	Limit
General
Type	In-line, Double Overhead Camshaft
Number of cylinder	4
Bore	82mm (3.228in)
Stroke	93.5mm (3.681in.)
Total displacement	1975cc (120.52cu.in.)
Compression ratio	10.1
Firing order	1-3-4-2
Valve timing
Intake valve
Opens	ATDC 11° ~ BTDC 29°
Closes	ABDC 59° ~ 19°
Exhaust
Opens	BBDC 42°
Closes	ATDC 6°
Valve
Valve length
Intake	114.34mm (4.5016in.)
Exhaust	116.8mm (4.598in.)
Stem O.D.
Intake	5.965 ~ 5.98mm (0.2348 ~ 0.2354in.)
Exhaust	5.950 ~ 5.965mm (0.2343 ~ 0.2348in.)
Face angle thickness of valve head (Margin)
Intake	1.15mm (0.0452in.)	0.8mm (0.031in.)
Exhaust	1.35mm (0.0531in.)	1.0mm (0.039in.)
Valve stem to valve guide clearance
Intake	0.02 ~ 0.05mm (0.0008 ~ 0.0019in.)	0.10mm (0.0039in.)
Exhaust	0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)	0.13mm (0.0051in.)
Valve guide
Installed dimension O.D
Intake	46mm (1.811in.)
Exhaust	54.5mm (2.146in.)
Service oversize	0.05, 0.25, 0.50mm(0.002, 0.010, 0.020in.) oversize
Valve seat
Width of seat contact
Intake	1.1 ~ 1.5mm (0.043 ~ 0.059in.)
Exhaust	1.3 ~ 1.7mm (0.051 ~ 0.066in.)
Seat angle	45°
Oversize	0.3, 0.6mm (0.012, 0.024in.) oversize
Valve spring
Free length	48.86mm (1.9236in.)
Load	18.3kg/39mm (40.31lb/1.535in.)
Installed height	39mm (1.5354in.)
Squarences	1.5° or less
Valve clearance
Cold (20°C[68°F])
Intake	0.20mm (0.0079in.)	0.12 ~ 0.28mm(0.0047 ~ 0.0110in.)
Exhaust	0.28mm (0.0110 in,)	0.20 ~ 0.38mm(0.0079 ~ 0.0150in.)
Hot (80°C[176°F]) : only for reference
Intake	0.29mm (0.0014in.)
Exhaust	0.34mm (0.0134in.)
Cylinder head
Flatness of gasket surface	Max. 0.03mm (0.0012in.)	0.06mm (0.0024in.)
Flatness of manifold mounting surface	Max. 0.15mm (0.0059in.)	0.03mm (0.0012in.)
Oversize rework dimensions of valve seat hole
Intake
0.3mm (0.012in.) O.S.	33.300 ~ 33.325mm (1.3110 ~ 1.3120in.)
0.6mm (0.024in.) O.S.	33.600 ~ 33.625mm (1.3228 ~ 1.3238in.)
Exhaust
0.3mm (0.012in.) O.S.	28.800 ~ 28.821mm (1.1338 ~ 1.1346in.)
0.6mm (0.024in.) O.S.	29.100 ~ 29.121mm (1.1456 ~ 1.1465in.)
Oversize rework dimensions of valve guide hole (both intake and exhaust)
0.05mm (0.002in.) O.S	11.05 ~ 11.068mm (0.435 ~ 0.4357in.)
0.25mm (0.010in.) O.S	11.25 ~ 11.268mm (0.443 ~ 0.4436in.)
0.50mm (0.020in.) O.S	11.50 ~ 11.518mm (0.453 ~ 0.4535in.)
Cylinder block
Cylinder bore	82.00 ~ 82.03mm (3.2283 ~ 3.2295in.)
Out-of-round and taper of cylinder bore	Less than 0.01mm (0.0004in.)
Clearance with piston (To set limits to new parts)	0.02 ~ 0.04mm (0.0008 ~ 0.0016in.)
Piston
O.D (To set limits to new parts)	81.97 ~ 82.00mm (3.2271 ~ 3.2283in.)
Service oversize	0.25, 0.50mm (0.010, 0.020in.) oversize
Piston ring
Side clearance
No.1	0.04 ~ 0.08mm (0.0015 ~ 0.0031in.)	0.1mm (0.004in.)
No.2	0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
End gap
No.1	0.23 ~ 0.38mm (0.0090 ~ 0.0149in.)	1mm (0.039in.)
No.2	0.33 ~ 0.48mm (0.0130 ~ 0.0189in.)	1mm (0.039in.)
Oil ring side rail	0.20 ~ 0.60mm (0.0078 ~ 0.0236in.)	1mm (0.039in.)
Service oversize	0.25, 0.50mm(0.010, 0.020in.) oversize
Connecting rod
Bend	0.05mm (0.0020in.) or less
Twist	0.1mm (0.004in.) or less	0.4mm (0.0157in.)
Connecting rod big end to crankshaft side clearance	0.100 ~ 0.250mm (0.0039 ~ 0.010in.)
Connecting rod bearing
Oil clearance (To seat limits to new parts)	0.024 ~ 0.044mm (0.0009 ~ 0.0017in.)
Undersize	0.25, 0.50, 0.75mm (0.01, 0.02, 0.03in.)
Camshaft
Cam height
Intake	44.618mm (1.7566in.)	44.518mm (1.7527in.)
Exhaust	44.518mm (1.7527in.)	44.418mm (1.7487in.)
Jourmal O.D.	28mm (1.1023in.)	0.1mm (0.0039in.)
Bearing oil clearance	0.02 ~ 0.061mm (0.0008 ~ 0.0024in.)
End play	0.1 ~ 0.2mm (0.004 ~ 0.008in.)
Crankshaft
Pin O.D.	45mm (1.77in.)
Journal O.D.	57mm (2.244in.)
Bend	0.03mm (0.0012in.) or less
Out-of-round, taper of journal and pin	0.01mm (0.0004in.) or less	0.030mm (0.0012in.)
End play	0.06 ~ 0.260mm (0.0023 ~ 0.010in.)
Undersize rework dimension of pin
0.25mm (0.010in.)	44.725 ~ 44.740mm (1.7608 ~ 1.7614in.)
0.50mm (0.020in.)	44.475 ~ 44.490mm (1.7509 ~ 1.7516in.)
0.75mm (0.030in.)	44.225 ~ 44.240mm (1.7411 ~ 1.7417in.)
Undersize rework dimension of journal
0.25mm (0.010in.)	56.727 ~ 56.742mm (2.2333 ~ 2.2339in.)
0.50mm (0.020in.)	56.477 ~ 56.492mm (2.2235 ~ 2.2240in.)
0.75mm (0.030in.)	56.227 ~ 56.242mm (2.2136 ~ 2.2142in.)
Crankshaft bearing
Oil clearance	0.028 ~ 0.046mm (0.0011 ~ 0.0018in.)
Flywheel
Runout	0.1mm (0.0039in.)	0.13mm (0.0051in.)
Cooling method	Water-cooled, pressurized. Forced circulation with electrical fan
Coolant
Quantity	6 liter (6.3U.S qts, 5.2lmp. qts)
Radiator
Type	Pressurized corrugated fin type
Radiator cap
Main valve opening pressure	83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kg/cm²)
Vacuum valve opening pressure	-7kpa (-100psi, -0.07kg/cm²) or less
Thermostat
Type	Wax pellet type with jiggle valve
Valve opening temperature	82°C (177°F)
Full-opening temperature	95°C (201°F)
Coolant pump
Drive belt
Type	V-ribbed belt
Engine coolant temperature sensor
Type	Heat-sensitive thermistor type
Resistance	2.31 ~ 2.59KΩ at 20°C (68°F)
Oil pump
Clearance between outer circumference and front case.	0.120 ~ 0.185mm (0.0049 ~ 0.0073in.)
Front case tip clearance
Side clearance	0.025 ~ 0.069mm (0.0009 ~ 0.0027in.)
Inner gear
Outer gear	0.04 ~ 0.085mm (0.0016 ~ 0.0033in.)
Engine oil pressure at 1500 RPM	0.04 ~ 0.09mm (0.0016 ~ 0.0035in.)
[Oil temperature is 90 to 110°C (194 to 230°F)]	245KPa (2.5kg/cm², 35.5psi)
Relief spring
Free height	43.8mm (1.725in.)
Load	3.7kg at 40.1mm (3.15lb/1.578in.)
Air cleaner
Type	Dry type
Element	Unwoven cloth type
Exhaust pipe
Muffler	Expansion resonance type
Suspension system	Rubber hangers

SERVICE STANDRDS

Standard value
Antifreeze	Maxture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM	50%

Engine oil

Description		Specifications	Limit
Oil quantity	Total	4.1L (4.33US qt, 3.60lmp qt)	When replacing a short engine or a block assembly
	Oil pan	3.7L (3.91US qt, 3.26lmp qt)
	Drain and refill	4.0L (4.23US qt, 3.52lmp qt)	Including oil filter
Oil grade	Recommendation (except Middle East)	5W-20/GF4&SM	If not available, refer to the recommended API or ILSAC classification and SAE viscosity number.
	Classification	API SL, SM or above ILSAC GF3, GF4 or above	Satisfy the requirement of the API classification.
	SAE viscosity grade	Recommended SAE viscosity number	Refer to the "Lubrication System"
Oil pressure (at 800rpm)		100kPa (1.0kg/cm², 14.5psi) or above	Oil temperature in oil pan : 90 ~ 100°C (194 ~ 212°F)

TIGHTENING TORQUE

Item	Nm	kgf.cm	lbf.ft
Cylinder Block
Front engine support bracket bolt and nut	35 ~ 50	350 ~ 500	25 ~ 37
Front roll stopper bracket bolt	70 ~ 90	700 ~ 900	51 ~ 65
Rear roll stopper bracket bolt	70 ~ 90	700 ~ 900	51 ~ 65
Rear engine stopper bracket bolt	35 ~ 50	350 ~ 500	25 ~ 37
Engine Mounting
Right mounting insulator (large) nut	90 ~ 110	900 ~ 1100	65 ~ 80
Right mounting insulator (small) nut	45 ~ 60	450 ~ 600	33 ~ 44
Right mounting bracket to engine nuts and bolts	50 ~ 65	500 ~ 650	36 ~ 48
Transmission mount insulator nut	90 ~ 110	900 ~ 1100	65 ~ 80
Transmission insulator bracket to side member bolt	40 ~ 50	400 ~ 500	30 ~ 36
Rear roll stopper insulator nut	50 ~ 65	500 ~ 650	36 ~ 48
Rear roll stopper bracket to center member bolts	40 ~ 50	400 ~ 500	30 ~ 36
Front roll stopper insulator nut	50 ~ 65	500 ~ 650	36 ~ 48
Front roll stopper bracket to center member bolts.	40 ~ 50	400 ~ 500	30 ~ 36
Main Moving
Connecting rod cap nut	50 ~ 53	500 ~ 530	36 ~ 39
Crankshaft bearing cap bolt	(27.5~31.4) + (60~65°)	(280~320) + (60~65°)	(20.3~23.1) + (60~65°)
Fly wheel M/T bolt	120 ~ 130	1200 ~ 1300	88 ~ 95
Drive plate A/T bolt	120 ~ 130	1200 ~ 1300	88 ~ 95
Engine cover	4 ~ 6	40 ~ 60	3 ~ 4
Heat protector	15 ~ 20	150 ~ 200	11 ~15
Water pipe bracket bolts	12 ~ 15	120 ~ 150	9 ~ 11
Cooling system
Alternator support bolt and nut	20 ~ 25	200 ~ 250	14 ~ 18
Alternator lock bolt	12 ~ 15	120 ~ 150	9 ~ 11
Alternator brance mounting bolt	20 ~ 27	200 ~ 270	15 ~ 20
Coolant pump pulley bolts	8 ~ 10	80 ~ 100	6 ~ 7
Coolant pump bolts	20 ~ 27	200 ~ 270	14 ~ 19
Coolant temperature sensor	20 ~ 40	200 ~ 400	15 ~ 30
Coolant inlet fitting nuts	15 ~ 20	150 ~ 200	11 ~ 14
Thermostat housing bolts and nuts	15 ~ 20	150 ~ 200	11 ~ 14
Lubrication system
Oil filter	12 ~ 16	120 ~ 160	9 ~ 12
Oil pan bolts	10 ~ 12	100 ~ 120	7 ~ 9
Oil pan drain plug (Aluminum)	39.2 ~ 49.0	400 ~ 500	28.9 ~ 36.2
Oil pan drain plug (Steel)	34.3 ~ 44.1	350 ~ 450	25.3 ~ 32.5
Oil screen bolts	15 ~ 22	150 ~ 220	11 ~16
Oil pressure switch	13 ~ 15	130 ~ 150	9.7 ~11
Intake and Exhaust system
Air cleaner body mounting bolts	8~ 10	80 ~ 100	6 ~ 7
Resonator mounting bolts	4 ~ 6	40 ~ 60	3 ~ 4
Intake manifold to cylinder head nuts and bolts	16 ~ 23	160 ~ 230	12 ~ 17
Intake manifold stay to cylinder block bolts	18 ~ 25	180 ~ 250	13 ~ 18
Throttle body to surge tank nuts	15 ~ 20	150 ~ 200	11 ~ 14
Exhaust manifold to cylinder head nuts	43 ~ 55	430 ~ 550	32 ~ 40
Exhaust manifold cover to exhaust manifold bolts	15 ~ 20	150 ~ 200	11 ~ 14
Oxygen sensor to front muffler	50 ~ 60	500 ~ 600	36 ~ 43
Oxygen sensor to exhaust manifold	50 ~ 60	500 ~ 600	36 ~ 43
Front exhaust pipe to exhaust manifold nuts	30 ~ 40	300 ~ 400	22 ~ 29
Front exhaust pipe bracket bolts	30 ~ 40	300 ~ 400	22 ~ 29
Front exhaust pipe to catalytic converter bolts	40 ~ 60	400 ~ 600	29 ~ 43
Main muffler hanger support bracket bolts	10 ~ 15	100 ~ 150	7 ~ 11
Cylinder head
Cylinder head bolts - M10	(22.6~26.5) + (60~65°) + (60~65°)	(230~270) + (60~65°) + (60~65°)	(16.6~19.5) + (60~65°) + (60~65°)
Cylinder head bolts - M12	(27.5~31.4) + (60~65°) + (60~65°)	(280~320) + (60~65°) + (60~65°)	(20.3~23.1) + (60~65°) + (60~65°)
Intake manifold nuts	18 ~ 25	180 ~ 250	13 ~ 18
Exhaust manifold nuts	43 ~ 55	430 ~ 550	32 ~ 41
Cylinder head cover bolts	8 ~ 10	80 ~ 100	6 ~ 7
Camshaft bearing cap bolts	14 ~ 15	140 ~ 150	10 ~ 11
Oil control valve bolt	10 ~ 12	100 ~ 120	7.3 ~ 8.8
OCV Filter	41 ~ 51	410 ~ 510	30 ~ 37.6
CVVT unit to exhaust camshaft bolt	66 ~ 78	660 ~ 780	48.7~ 57.5
Rear plate bolts	8 ~ 10	80 ~ 100	6 ~ 7
Timing Belt
Crankshaft pulley bolt	170 ~ 180	1700 ~ 1800	125 ~ 133
Camshaft sprocket bolt	100 ~ 120	1000 ~ 1200	74 ~ 89
Timing belt auto tensioner bolt	23 ~ 29	230 ~ 290	17 ~ 21
Timing belt cover bolts	8 ~ 10	80 ~ 100	6 ~ 7
Front case bolts	20 ~ 27	200 ~ 270	14 ~ 20
Timing belt idler bolt	43 ~ 55	430 ~ 550	31 ~ 40

M/T : Manual Transmission

A/T : Automatic Transmission

COMPRESSION

note

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

Warm up and stop engine.

Allow the engine to warm up to normal operating temperature.

Remove ignition coils. (See EE group - ignition)

Remove spark plugs.

Using a 16mm plug wrench, remove the 4 spark plugs.

Check cylinder compression pressure.

Insert a compression gauge into the spark plug hole.

Fully open the throttle.

While cranking the engine, measure the compression pressure.

note

Always use a fully charged battery to obtain engine speed of 250 rpm or more.

Repeat steps (a) through (c) for each cylinder.

note

This measurement must be done in as short a time as possible.

Compression pressure :

1,420kPa (14.5kgf/cm², 206psi)

Minimum pressure :

1,270kPa (13kgf/cm², 184psi)

Difference between each cylinder :

100kPa (1.0kgf/cm², 15psi) or less

If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.

●

If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.

●

If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.

Reinstall spark plugs.

Install ignition coils. (See EE group - ignition)

Timing Belt Tension Adjustment

Remove RH front wheel.

Remove the 4bolts and timing belt upper cover (A).

Slacker the tensioner bolt.

note

When check the timing belt tension or install the timing belt tensioner, must it the engine oil temperature is between 15°C(59°F) and 25°C(77°F)

Using a hex wrench, turn the adjuster counterclockwise to make the indicator of the arm(A) located at the center of the base notch.

caution

Do not rotate the adjuster clockwise.

It will result in auto tensioner's functional problem.

Tightening tensioner bolt with fixing the indicator not to move.

Tightening torque

Tensioner bolt :

23 ~ 28Nm (230 ~ 280kgf.cm, 17 ~ 21lb-ft)

Turn the crankshaft two revolutions in the operating direction (clockwise) and check that the indicator is in the center of base.

If the indicator is not located at the center of base, slacken the bolt and repeat the above procedure.

Install the timing belt upper cover (A).

Tightening torque :

8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7lb-ft)

Install RH front wheel.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

MLA (MECHANICAL LASH ADJUSTER)

note

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder head is installed on the cylinder block.

Remove the engine cover.

Remove the upper timing belt cover.

Loosen the upper timing cover bolts and then remove the cover.

Remove the cylinder head cover.

Disconnect the spark plug cables and do not pull on the spark plug by force.

note

Pulling on or bending the cables may damage the connductor inside.

Disconnect the P.C.V hose(A) and the breather hose(B) from the cylinder head cover.

Disconnect the accelerater cable(A) from the cylinder head cover.

Loosen the cylinder head cover bolts(B) and then remove the cover(A) and gasket.

Set No.1 cylinder to TDC/compression.

Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover.

Check that the hole of the camshaft timing pulley(A) is aligned with the timing mark of the bearing cap.

If not, turn the crankshaft one revolution (360°)

Inspect the valve clearance

Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

●

Using a thickness gauge, measure the clearance between the tappet shim and the base circle of camshaft.

●

Record the out-of-specification valve clearance measurements. They will be used later to determine the required replaement adjusing shim.

Valve clearance

Specitication

Engine coolant temperature : 20°C [68°F]

Intake : 0.20mm (0.0079in.)

Exhaust : 0.28mm (0.0110in.)

Engine coolant temperature : 80°C [176°F]

Intake : 0.29mm (0.0114in.)

Exhaust : 0.34mm (0.0134in.)

Limit

Intake : 0.12 ~ 0.28mm (0.0047 ~ 0.0110in.)

Exhaust : 0.20 ~ 0.38mm (0.0079 ~ 0.0150in.)

Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the lower timing belt cover.

Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance. (See procedure in step (6))

Adjust the intake and exhaust valve clearance.

Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.

Using the SST(09220-2D000), press down the valve lifter and place the stopper between the camshaft and valve lifter and remove the special tool.

Remove the adjusting shim with a small screw driver(A) and magnet(B).

Measure the thickness of the removed shim using a micrometer.

Calculate the thickness of a new shim so that the valve clearance comes within the specificified value.

Valve clearance (Engine coolant temperature : 20°C)

T : Thickness of removed shim

A : Measured valve clearance

N : Thickness of new shim

Intake : N = T + [A - 0.20mm(0.0079in.)]

Exhaust : N = T + [A-0.28mm (0.0110in.)]

Select a new shim with a thickness as close as possible to the caculated value. [Refer to the Adjusting shim selection chart]

note

Shims are available in 20size increments of 0.04mm (0.0016in.) from 2.00mm (0.079in.) to 2.76mm (0.1087in.)

Place a new adjusting shim on the valve lifter.

Using the SST(09220-2D000), press down the valve lifter and remove the stopper.

Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C)

[Specification]

Intake : 0.20mm (0.0079in.)

Exhaust : 0.28mm (0.0110in.)

[Limit] (After adjusting valve clearance)

Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)

Exhaust : 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)