CHAPTER 2:

Engine Mechanical System

General information
 2004 > 1.8L DOHC >

ENGINE TUNE-UP
IGNITION TIMING
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect the timing light to the No.1 high-tension cord.
4. Check that the timing mark (white) on the crankshaft pulley and the timing mark on the timing belt cover are
aligned.

Ignition timing: 5°±10° (BTDC)

It is not necessary to adjust the ignition timing.

Idle speed
1. Warm up the engine to normal operating temperature.
2. Turn all electric loads OFF.
3. Connect a tachometer to the diagnosis connector. (O:RPM terminal)

4. Check that cooling fan does not operate.

5. Check the idle speed.

Ignition timing: 800±50 rpm

The idle speed is controlled automatically by Engine Control Unit(ECU) through the Idle Speed Control(ISC)
valve, it is not necessary to adjust the idle speed.

6. If not as specified, check the following items.

(1) Check diagnostic trouble code.
(2) Check vacuum in intake manifold while engine is idling.

Vacuum: more than 480 mmHg

Check air leakage at intake air system component, if not below specified.
 (3) Check the installation condition of crank angle sensor.
a. Clearance: 0.019~0.059 in (0.5~1.5 mm)
b. Check the alignment between crank angle sensor and target wheel.

COMPRESSION
1. Ignition system. (Refer to section EE)
2. Compression : 193 psi (1,333 kpa, 13.6 kg/cm²) - 300 rpm
3. Fuel system. (Refer to section FL)

INSPECTION
1. Check that the battery is fully charged. Recharge if necessary
2. Warm up the engine to the normal operating temperature.
3. Turn it off for about 10 minutes to allow the exhaust manifold to cool.
4. Remove all spark plugs.
5. Disconnect the high-tension cords.
6. Connect a compression gauge to No.1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Record the maximum gauge reading.

9. Check each cylinder.

10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings, or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck or seating improperly.
(3) If the compression in adjacent cylinder stays low, the cylinder head gasket may be defective or the cylinder
head distorted.

11. Connect the high-tension cords.

12. Install the spark plugs.

Tightening torque:
11~17 lb·ft (15~23 N·m, 1.5~2.3 kg-m)
 2004 > 1.8L DOHC >

SPECIAL SERVICE TOOLS

Tool
Illustration Use
(Number and Name)
0K130 990 007 Used to disassemble and assemble
Engine stand engine.

0K710 101 002 Used to disassemble and assemble

Hanger, engine stand engine.

0K201 170 AA0 Used to remove engine.

Support, engine

0K590 111 001 Used to prevent engine rotation.

Brake, ring gear

0K993 120 001 Used to remove and install valve.

Arm, valve spring lifter

0K993 120 004 Used to remove and install valve.

Pivot, valve spring lifter
0K2CA 120 AA0 Used to replace valve seal and valve
Valve spring compressor set spring.

0K2CA 120 001 Used to replace valve seal and valve

Valve spring compressor hook spring.

0K993 120 006 Used to remove valve seal.

Remover, valve seat

0K2CA 120 005I(Intake)/ Used to install valve seal.

0K2CA 120 005E(Exhaust)
Installer, valve seal

0K2CA 111 001 Used to prevent camshaft pulley

Holder, camshaft pulley rotation.

0K201 120 011 Used to remove and install valve

Remover installer, valve guide guide.

0K710 110 010 Used to remove and install piston pin.

0K710 110 010 Used to remove and install piston pin.
Remover installer, piston pin

0K410 111 012 Used to remove pilot bearing.

Puller, bearing

0K130 160 010 Used to install clutch disc.

Centering tool, clutch disc

0K130 283 021 Used to remove tie-rod end.

Puller, ball joint
 2004 > 1.8L DOHC >

DESCRIPTION

The T8 DOHC engine is a 4 cylinder overhead dual camshaft engine with a compression ratio of 9.5:1 The cylinder
head is made of aluminum alloy for good heat conductivity and heat resistance and utilizes a pentroof combustion
chamber with 4 valves (IN: 2, EX: 2) per cylinder. An aluminum oil pan is incorporated for reduced vibration and
improved coolingcapacity. Maintenance free hydraulic lash adjusters (HLA's) are used for reduced noise and vibration.
 2004 > 1.8L DOHC >

TROUBLESHOOTING GUIDE
ENGINE
Problem Possible cause Action
Engine will not crank Battery, starting system or other Refer to starting system, charging
electrical problems system, or electrical troubleshooting
manual
Liquid in combustion chamber Remove with suction gun, then crank
engine over with spark plugs removed
Seized engine Repair
Engine cranks normally,but does not Fuel system malfunction Refer to fuel system
star Ignition system malfunction Refer to ignition system
Improper valve clearance Check HLA's
Restricted exhaust system Refer to exhaust system
Timing belt and/or related parts Inspect timing belt and related parts;
replace if necessary
Low compression due to: stuck or Perform a compression test, as
burned valves; worn piston, piston outlined in this section; repair engine
ring or cylinder; failed cylinder head as necessary
gasket
Camshaft worn Replace
Poor idle quality Fuel system malfunction Refer to fuel system
Emission system malfunction Refer to emission control
Ignition system malfunction Refer to ignition system
Improper valve clearance Check HLA's
Uneven cylinder compression Perform a compression test, as
outlined in this section ; repair engine
as necessary
Poor valve-to-valve seat contact Repair or replace
Broken valve spring Repair
Failed cylinder head gasket Replace
White exhaust smoke Usually caused by water vapor, which None required
is a normal by-product of combustion
on cold days
Excessive white smoke with engine Repair or replace
warmed up could be caused by a
failed cylinder head or intake gasket.
Could also be a cracked block,
cylinder head or intake manifold
Black exhaust smoke Fuel system malfunction Refer to fuel system
Emission system malfunction Refer to emission control system
Blue exhaust smoke Usually caused by oil burning in the Replace
combustion chambers from:
worn rings, worn valve guides, worn
valve seals or failed cylinder head
gasket
Valve train noise Worn valve guides Repair
Low oil pressure Refer to lubrication system
Improper valve clearance Check HLA's
Broken valve spring Replace
 Broken valve spring Replace
Sticking valves Free valves
Camshaft worn or faulty Replace
Insufficient power Insufficient compression caused by:
1. Improper valve clearance Check HLA's
2. Leakage from valve seat Repair or replace
3. Seized valve stem Replace
4. Weak or broken valve spring Replace
5. Failed cylinder head gasket Replace
6. Cracked or distorted cylinder head Repair or replace
7. Sticking, damaged or worn piston Replace
ring Replace
8. Cracked or worn piston Refer to fuel system
Fuel system malfunction Refer to clutch system
Slipping clutch Refer to wheels and tires
Wrong tire size Refer to exhaust system
Restricted exhaust system
Abnormal combustion Improper valve clearance Check HLA's
Sticking or burned valve Replace
Weak or broken valve spring Replace
Carbon accumulation in combustion Eliminate carbon
chamber
Engine knocks at idle when hot Loose or worn accessory drive Check belts and tensioners
belt/tensioner Replace if necessary
A/C compressor or generator bearing Replace
Improper oil viscosity Install proper oil viscosity for expected
temperatures
Excessive piston pin clearance Install new piston, pin and/ or
connecting rod
Connecting rod clearance Check and replace rods if necessary
Engine knocks at idle when hot Insufficient piston-to-bore clearance Hone and replace rods if necessary
Faulty timing belt tensioner or guide Replace
Loose damper pulley Tighten or replace if necessary
Slight noise at idle, becomes louder Valve spring clicking on cap, off Repair or replacev
as engine speed is increased square or broken Repair
Excessive stem to guide clearance Repair
Excessive valve seat runout
Engine knocks when cold Excessive piston to wall clearance Replace pistons
Loose or broken damper pulley Tighten or replace
Knock increases with torque Excessive piston to bore clearance Replace piston
Bent connecting rod Replace
Engine has heavy knock when hot Broken damper pulley Replace
and torque is applied Accessory belts too tight or damaged Adjust or replace belt
Belt tensioned damaged Replace
Flywheel cracked or loose clutch plate Replace flywheel or clutch plate
Excessive main bearing clearance Repair
Excessive rod bearing clearance Repair
Engine has light knock when hot and Improper timing Check timing
under light load conditions Piston pin and/or connecting rod Replace piston pin and/or rod
Poor quality fue Use recommended or higher grade
fuel
 Exhaust leak at manifold Tighten bolts and/or replace exhaust
manifold gaskets if necessary
Excessive rod bearing clearance Repair
Engine knocks during initial start up Improper oil viscosity Install proper oil viscosity for expected
and lasts only a few seconds temperatures

TIMING BELT
Problem Possible cause Action
Tooth is broken or cracked Camshaft jamming Inspect camshaft by removing cylinder
head cover
Repair or replace if necessary
Back surface is cracked and/or worn Tensioner jamming Remove tensioner and inspect
Engine overheating Inspect cooling Refer to engine cooling system
system
Interference with timing belt cover Remove timing belt cover and inspect
Replace if necessary
Side surface is worn and/or frayed Improper installation of timing belt Remove timing belt and reinstall
Malfunction of timing belt guide plate Remove timing belt and inspect guide
plate
Teeth are worn Poor belt cover sealing Remove timing belt cover and inspect
Replace if necessary
Coolant leak at water pump Inspect water pump
Replace if necessary
Camshaft malfunction Inspect camshaft by removing the
cylinder head cover
Repair or replace if necessary
Excessive belt tension Remove tensioner spring and inspect
Replace if necessary
Oil or coolant is on the belt Poor oil sealing Inspect front oil seals
Replace if necessary
Coolant leak at water pump Inspect water pump
Replace if necessary
Poor belt cover sealing Remove timing belt cover and inspect
Replace if necessary

HLA(Hydraulic lash ajuster)

Problem Possible cause Action
1. Noise when engine is started Oil leakage in oil passage Run engine at 2,000~3,000 rpm.
immediately after oil is changed. If noise stops after 2 seconds - 10
2. Noise when engine is started after minutes*, HLA is normal.
setting approx one day. If not, replace HLA.
* Time required for engine oil to
3.Noise when engine is started after Oil leakage in HLA
circulate with in engine includes
cranking for 3 seconds or more.
tolerance for engine oil condition and
4. Noise when engine is started after ambient temperature.
new HLA is installed.
5. Noise continues more than 10 Insufficient oil pressure Check oil pressure.
minutes. If lower than specification, check for
cause.
 cause.
Oil pressure: 313.9~490.5 kPa
(3.2~5.0 kg/cm², 45.5~71.1 psi) -
3,000 rpm
Faulty HLA Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.

Measure valve clearance.

If more than 0 mm (0 in), replace
HLA.
6. Noise during idle after high-speed Incorrect oil amount Check oil level.
running Drain or add oil as necessary.
Deteriorated oil Check oil quality.
If deteriorated, replace with specified
type and amount of oil.
2004 > 1.8L DOHC >

SPECIFICATION
ENGINE
Timing system

Timing belt
2004 > 1.8L DOHC >

COMPONENT
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Remove right splash shield with three bolts and three fasteners

3. Loosen power steering pump lock bolt (A), nuts (B),(C) and remove tension from power steering (P/S) pump and/or
air conditioning (A/C) compressor drive belt by turn adjusting bolt (D).

4. Remove P/S pump and/or A/C compressor drive belt.

5. Loosen water pump pulley bolts.

6. Loosen generator mounting bolt (A) and remove tension from generator drive belt by turn adjusting bolt (B).
7. Remove generator drive belt.
8. Remove water pump pulley.

9. Remove four crankshaft pulley bolts and timing belt pulley lock bolt.

10. Remove crankshaft pulley and timing belt guide plate.

11. Reinstall timing belt pulley lock bolt.

12. Support engine with engine support bar SST(0K201 170 AA0).
13. Remove one bolt and one nut, then remove dynamic damper.

14. Remove two No.3 engine mount.

15. Remove generator bracket bolt.

16. Remove No.3 engine mounting bracket with three bolts.

17. Remove upper and lower timing belt covers.

18. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.

19. Check that "l"mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E"mark on exhaust
camshaft pulley is aligned with mark on cylinder head cover.

a. Do not move camshaft or crankshaft once timing marks have been correctly positioned.
b. Prevent camshaft pulley rotation with SST (0K2CA 111 001).
20. Remove tensioner pulley lock bolt and remove tensioner pulley and tensioner spring.

21. Remove timing belt.

Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.

INSPECTION

Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing
belt.

1. Replace timing belt if it is contaminated with oil or grease.

2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.

3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.

Do not clean tensioner pulley or idler pulley with cleaning fluids. If needed, use a soft rag to wipe them clean.
Avoidscratching tensioner pulley or idler pulley as it can affect integrity of timing belt.

5. Check the free lenght of tensioner spring. Replace tensioner spring if necessary.

Free Length : 1.402 in (35.6 mm)

6. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.

a. Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.
b. Do not clean pulleys with cleaning fluids. If needed, use a soft cloth to wipe them clean, and avoid
scratching the pulleys as it will affect integrity of the timing belt.
 REPLACEMENT
1. Install tensioner pulley.

Replace tensioner spring whenever timing belt is replaced.

2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.

4. Check that "I" mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on exhaust
camshaft pulley is aligned with mark on cylinder head cover.
 a. If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
b. Prevent camshaft pulley rotation with SST(0K2CA 111 001).

5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and
tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and
exhaust camshaft pulleys.

7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.

Do not add additional tension.

8. Tighten tensioner pulley lock bolt to specified torque.

Tightening torque:
28~38 lb-ft (37~52 N·m, 3.8~5.3 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark
on engine block.

10. Check that "I" mark on intake camshaft pulley "E" mark on exhaust camshaft pulley are aligned with marks on
cylinder head cover.

11. If they are not aligned, remove timing belt and start process from tensioner installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is
not correct, repeat from tensioner installation.

Deflection pressure:
22 lb. (98 N, 10 kg)
Deflection:
0.36~0.45 in. (9.0~11.5 mm)

13. Install lower and upper timing belt covers.

 Tightening torque:
5.8~7.9 lb-ft (7.8~10.8 N·m, 0.8~1.1 kg-m)

14. Install No.3 engine mounting bracket with three bolts.

Tightening torque:
49.2~68.7 lb-ft (66.7~93.2 N·m, 6.8~9.5 kg-m)

15. Install generator bracket bolt.

16. Tighten two nuts to No.3 engine mount.

Tightening torque:
54.2~75.9 lb-ft (73.6~103 N·m, 7.5~10.5 kg-m)
17. Install dynamic damper.

Tightening torque:
40.5~59.3 lb-ft (54.9~80.4 N·m, 5.6~8.2kg-m)

18. Remove timing belt pulley lock bolt.

19. Install timing belt guide plate and crankshaft pulley.

20. Tighten four crankshaft pulley bolts and timing belt pulley lock bolt.

Tightening torque:
Crankshaft pulley bolts : 9.0~12.7 lb·ft
(12.3~17.2 N·m, 1.25~1.75 kg-m)
Timing belt pulley lock bolt:
116~123lb·ft(157~167 N·m, 16~17 kg-m)

21. Install water pump pulley.

Tightening torque:
6.5~9.4 lb·ft (8.8~12.8 N·m, 0.9~1.3 kg-m)
22. Install generator drive belt.
23. Adjust the belt deflection by turning the adjusting bolt (C).

Belt deflection
New: 0.24~0.32 in (6.0~8.0 mm)
Used: 0.28~0.35 in (7.0~9.0 mm)

24. Tighten the mounting bolts (A),(B).

Tightening torque:
(A) : 28~38 Ib·ft (37~52 N·m, 3.8~5.3 kg-m)
(B) : 14~19 Ib·ft (19~25 N·m, 1.9~2.6 kg-m)

25. Install P/S pump and/or A/C compressor drive belt.

26. Adjust the belt deflection by turning the adjusting bolt (D).

Belt deflection:
New: 0.32~0.35 in (8.0~9.0 mm)
Used: 0.35~0.39 in (9.0~10.0 mm)

27. Tighten the bolt (A), nut (B), nut (C).

Tightening torque:
(A) : 27~40 Ib·ft (36~54 N·m, 3.7~5.5 kg-m)
(B) : 14~19 Ib·ft (19~25 N·m, 1.9~2.6 kg-m)
 (C) : 23~34 Ib·ft (31~46 N·m, 3.2~4.7 kg-m)

28. Install right splash shield with three bolts and three fasteners.

Tightening torque:
10.1~11.6 Ib·ft (13.7~15.7 N·m, 1.4~1.6 kg-m)

29. Connect negative battery cable.

Cylinder Head Assembly
Camshaft
 2004 > 1.8L DOHC >

INSPECTION
1. Set front and rear camshaft bearing journals on V-blocks.
2. Position a dial indicator on center bearing journal and zero dial.
3. Rotate camshaft in V-blocks and check runout.

Runout:
0.0012 in (0.03 mm) maximum

4. Check camshaft for uneven wear patterns, cracks, or damage.

5. Measure cam lobe heights at two points as shown.

Lobe height
Intake: 1.6415 in (41.6949 mm)
Exhaust: 1.6629 in (42.2369 mm)

6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in figure.

Standard diameter:
1.0606~1.0616 in (26.940~26.965 mm)
Minimum diameter:
1.0594 in (26.910 mm)
Out-of-round:
0.002 in (0.05 mm) maximum
7. Replace camshafts if necessary.
8. Measure camshaft journal oil clearance with HLAs removed.
9. Remove all foreign material and oil from journals and bearing surfaces.
10. Set camshafts onto cylinder head.
11. Position Plastigage® on journals in axial direction.
12. Do not rotate camshafts.
13. Install camshaft caps according to cap number and arrow mark.
14. Install cap bolts. Tighten them in five or six steps in order shown.

Tightening torque:
8.32~10.49 Ib·ft
(11.28~14.22 N·m, 1.15~1.45 kg-m)

15. Loosen camshaft cap bolts in five or six steps in order shown.
16. Remove camshaft caps.

17. Measure oil clearances.

Oil clearance:
0.0014~0.0031 in (0.035~0.081 mm)
Maximum:
0.006 in (0.15 mm)
18. If oil clearance exceeds specification, replace cylinder head.

19. Install camshafts.

20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward as possible.
24. Check gauge to determine how much end play is present.

End play:
0.0003~0.0004 in (0.08~0.10 mm)
Maximum:
0.008 in (0.20 mm)
Valve
 2004 > 1.8L DOHC >

REMOVAL
1. Drain engine coolant.

2. Remove timing belt.

(Refer to Timing belt removal)
3. Remove center cover.

4. Remove ignition coils and high-tension cords.

5. Disconnect PCV hose and ventilation hose.

6. Remove accelerator cable and cruise control cable if equipped.
7. Remove air intake hose and fresh air duct.
8. Disconnect brake vacuum hose from brake master vac.
9. Disconnect purge control vacuum (PCV) hose from charcoal canister.

10. Remove upper radiator hose.

11. Remove heater hoses.

12. Disconnect fuel hose from injector rail.

KEEP OPEN FLAMES AND SPARKS AWAY FROM OPEN FUEL LINES OR A FIRE OR EXPLOSION MAY
RESULT.

13. Disconnect IAC and throttle position sensor (TPS) connectors.

14. Disconnect injector connectors.

15. Disconnect electric connectors and remove connector bracket.

16. Disconnect engine ground strap.

17. Remove exhaust manifold heat shield.

18. Remove front exhaust pipe.

19. Remove exhaust manifold pipe.

20. Remove coolant bypass pipe.

21. Remove intake manifold support bracket.

22. Remove cylinder head cover.

 Align camshaft and crankshaft timing alignment marks.

23. Loosen cylinder head bolts in two or three steps following order shown in figure.

24. Remove cylinder head.

INSPECTION
1. Inspect cylinder head for damage, cracks, and leakage of oil and water, Replace cylinder head if necessary.
2. Clean cylinder head and cylinder block mounting surfaces of all gasket material.

Do not allow gasket material to fall into oil passages or oil control plug.

3. Measure cylinder head for straightness in six directions as shown in figure.

Distortion:
0.004 in (0.10 mm) Maximum
4. If distortion exceeds specification, resurface or replace cylinder head. Only remove the amount of material required
to achieve a flat surface.

Maximum material removal:

0.004 in (0.1 mm)

5. Check cylinder head height.

Height:
5.272~5.280 in (133.9~134 mm)

6. If cylinder head height is not within specification, replace cylinder head.

If cylinder head requires machining, remove intake and exhaust manifolds and check their mounting surfaces
for straightness.

7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure.

Distortion:
0.008 in (0.20 mm) Maximum

8. If distortion exceeds specification, resurface or replace cylinder head.

Maximum material removal:

 0.008 in (0.20 mm)

9. Check cylinder block for distortion of cylinder head mating surface (block deck) in six directions shown in figure.

Distortion:
0.006 in (0.15 mm) Maximum

10. If distortion exceeds specification, resurface block deck.

Maximum material removal:

0.008 in (0.20 mm)

REPLACEMENT
1. Install new cylinder head gasket onto cylinder block and lower cylinder head onto engine.
2. Install cylinder head bolts.
3. Tighten cylinder head bolts according to following procedure:
a. Tighten cylinder head bolts in order shown.

Tightening torque:
36.1 lb-ft (49N·m, 5 kg-m)

b. Loosen bolts in reverse of order shown.

c. Retighten cylinder head bolts in order shown.

Tightening torque:
28.9 lb-ft (39.2 N·m, 4 kg-m)

d. Mark cylinder head bolts for rotational reference.

e. Rotate cylinder head bolts 90?(1/4 Turn) in order shown.
f. Rotate cylinder head bolts another 90?(1/4 Turn) in order shown.

4. Install cylinder head cover.

Tightening torque:
5.8~8.7Ib·ft (7.8~11.8N·m, 0.8~1.2kg-m)
5. Install intake manifold support bracket.

Tightening torque:
(A) - 11.6~16.6Ib·ft
(15.7~22.5N·m, 1.6~2.3 kg-m)
(B) : 26.8~39.8 Ib·ft
(36.3~53.9N·m, 3.7~5.5 kg-m)

6. Install coolant bypass pipe

7. Install exhaust manifold pipe.

Tightening torque:
28~34 lb-ft (38~46 N·m, 3.9~4.7 kg-m)
8. Install front exhaust pipe.

Tightening torque:
(A), (B) : 27.5~38.3Ib·ft
(37.3~51.9N·m, 3.8~5.3 kg-m)
(C) : 31.1~44.8Ib·ft
(42.2~60.8N·m, 4.3~6.2kg-m)

9. Install exhaust manifold heat shield.

Tightening torque:
13.7~18.8Ib·ft (18.6~25.5N·m, 1.9~2.6 kg-m)

10. Reconnect engine ground strap.

11. Install connector bracket and reconnect electrical connectors.

Tightening torque (engine hanger bolt):

27.5~38.3Ib·ft (37.2~51.9N·m, 3.8~5.3kg-m)
12. Connect injector connectors.

13. Connect IAC and throttle position sensor (TPS) connectors.

14. Connect fuel hose to fuel injector rail.

15. Install heater hoses.

16. Install upper radiator hose.
17. Connect purge control vacuum (PCV) hose to charcoal canister.

18. Connect brake vacuum hose to brake master vac.

19. Install air intake hose and fresh air duct.

20. Install accelerator cable and cruise control cable if equipped.
21. Check accelerator cable deflection. If deflection is not correct, adjust by turning nut (A).

Deflection : 0.04~0.12 in (1~3mm)

22. Connect PCV hose and ventilation hose.

23. Install ignition coils and high-tension cords.
24. Install center cover.

Tightening torque:
2.9~5.1Ib·ft (3.9~6.9N·m, 0.4~0.7kg-m)

25. Connect negative battery cable.

(Refer to Timing belt replacement)
26. Fill engine coolant with specified type and amount.
(Refer to cooling system)
27. Start engine and check for oil and coolant leaks.
Cylinder Head
 2004 > 1.8L DOHC >

VALVE SEAL(REMOVAL)
1. Remove HLA.
2. Set piston to TDC position for removing valve seal by rotate crankshaft.

If timing mark on crankshaft pulley is aligned with timing mark on engine, No.1 and No.4 piston are located on
TDC position.

3. Install SST(0K2CA 120 AA0, 0K2CA 120 001)on cylinder head.

4. Compress valve spring with SSTand allow enough room to remove valve locks.
5. Slowly release pressure and remove upper spring seat and valve spring from cylinder head.
6. Remove valve seal with SST(0K993 120 006).

VALVE MECHANISM(INSPECTION)
1. Inspect each valve for following:
a. Damaged or bent valve stem
b. Rough or damaged face
c. Damaged or unevenly worn stem tip
2. Resurface or replace valve as needed.

Margin thickness
 Intake: 0.0472 in (1.2 mm)
Exhaust: 0.0472 in (1.2 mm)

3. Measure length of each valve.

Length
Intake: 4.052 in (102.92 mm)
Exhaust: 3.993 in (101.42 mm)

4. Measure diameter of each valve stem.

Diameter
Intake:0.2350~0.2356 in (5.970~5.985 mm)
Exhaust: 0.2348~0.2354 in (5.965~5.980 mm)

5. Measure inside diameter of each valve guide at points shown in figure.

Diameter intake and exhaust valve guide:

0.2367~0.2374 in (6.01~6.03 mm)
6. Calculate valve stem-to-valve guide clearance. Subtract outer diameter of valve stem from inside diameter of
respective valve guide.

Clearance
Intake valve:
0.0019~0.0023 in (0.050~0.060 mm)
Exhaust valve:
0.0012~0.0025 in (0.030~0.065 mm)
Max: 0.008 in (0.20 mm)

7. If clearance exceeds specification, replace valve, and/or valve guide.

8. Measure protrusion height of each valve guide. Replace valve guide as needed.

A: Intake: 0.539~0.563 in (13.7~14.3 mm)

B: Exhaust: 0.658~0.681 in (16.7~17.3 mm)

Intake and exhaust valve guides are different. Be sure to use correct valve guide.
VALVE SEAT (INSPECTION)
1. Inspect contact surface of each valve seat and valve face for following:
a. Roughness
b. Damage
c. Pitting
d. Cracks

2. Resurface valve seats with a 4??5?° ???? valve seat cutter. Resurface valve faces as needed.

3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat and rotating valve 360°.
a. If Dychem blue is not removed 360° around valve face, replace valve.
b. If Dychem blue is not removed 360°around valve seat, resurface valve seat.
5. Measure seat contact width.

Width: 0.078~1.059 in (1.98~2.69 mm)

6. Check that valve seat contact area is at center of valve face.
a. If valve seating position is too high, correct valve seat with a 63° valve seat cutter, and a 45° cutter.
b. If seating position is too low, correct valve seat with a 0°and a 45°cutter.

7. Complete seat-cutting process by lapping valve to seat using valve-lapping compound.

8. Inspect valve seat for sinking.

Clean valves thoroughly before reassembly, and insure that all traces of lapping compound have been
removed.

9. Check for valve sink by measuring protruding length (Dimension L) of valve stem to lower valve spring seat.
Dimentsion L measurement Action
IN : 1.432-1.467 in No correction needed
(36.37-37.27 mm)
EX : 1.431-1.467 in
(36.39-37.26 mm)
IN : 1.467-1.495 in Adjust with washer on spring seat area of cylinder head
(37.27-37.97 mm)
EX : 1.467-1.494 in
(37.26-37.96 mm)
IN:1.495 in (37.97 mm) Replace the cylinder head
 EX:1.494 in (37.96 mm)

VALVE SPRING (INSPECTION)

1. Inspect each valve spring for cracks and damage.
2. Measure free length and out-of-square. Replace valve springs as needed.

Free length: 1.77 in (44.92 mm)

Out-of-square: 0.0618 in (1.57 mm) maximum

VALVE SEAL(REPLACEMENT)
1. Install valve seal with SST(0K2CA 120 005I-Intake / 0K2CA 120 005E-Exhaust).

Intake and exhaust valve seals are different. Only exhaust valve seals have four teeth.

Using a hammer will damage valve seals.

2. Install valve spring with narrow spring coils (B) toward cylinder head.
3. Install upper spring seat and compress valve spring with SST(0K2CA 120 AA0, 0K2CA 120 001).

4. Install valve locks and release SST from valve spring.

5. Tap end of valve stem lightly two or three times with a plastic hammer to verify that valve locks are fully seated.
6. Install HLA.(Refer to HLA replacement)
HLA (Hydraulic Lash
Adjuster)
 2004 > 1.8L DOHC >

REMOVAL
1. Remove timing belt.
(Refer to timing belt removal)
2. Remove center cover.

3. Remove ignition coils and high-tension cords.

4. Disconnect PCV hose and ventilation hose.

5. Remove cylinder head cover.

6. Remove camshaft pulleys.

7. Loosen camshaft bearing cap bolts in five or six steps in order shown in figure.
8. Remove camshafts.
9. Mark HLA´s to identify their original position if they will be reused.

Hydraulic Lash Adjusters (HLA) must be installed in location from which they were removed. Failure to install
HLA's in their original location will result in premature and uneven wear of HLA's and camshafts.

10. Remove HLA's from cylinder head.

11. Store HLA's upside-down in an oil-filled container.

INSPECTION
1. Check HLA face for wear or damage, and replace if necessary.
2. With HLA filled with engine oil, hold (A) and press down on (B) by hand. If (B) moves, replace HLA.

Never attempt to repair or disassemble an HLA.

3. Measure HLA bore diameters (X and Y directions) at two points (A and B) as shown.

Distortion:
1.1812~1.1820 in (30.000~30.025 mm)

4. Measure HLA diameters (X and Y directions) at two points (A and B) as shown.

Diameter:
1.1795~1.1801 in (29.959~29.975 mm)

5. Calculate clearance between HLA diameter and related HLA bore. Replace HLA and/or cylinder head if necessary.

Clearance:
0.00099~0.00259 in (0.025~0.066 mm)
Maximum:
0.0071 in (0.180 mm)

REPLACEMENT
1. Apply a coat of clean engine oil to friction surfaces of HLA.
2. Install HLA into cylinder head bore.

If HLA is being reused, install it in its original position.

3. Check that HLA moves smoothly in its bore.

4. Apply clean engine oil to camshaft and camshaft bearing surfaces and install camshaft so that camshaft dowel pins
point straight up.
5. Install camshaft bearing caps according to cap number with the directional arrows pointing forward.
6. Install bolts to camshaft bearing caps and tighten in five or six steps in order shown in figure.

Tightening torque:
8.32~10.49 lb-ft
(11.28~14.22 N·m, 1.15~1.45 kg-m)

7. Apply a coat of clean engine oil to the lip of new camshaft seal.
8. Seat camshaft seal by hand and tap the seal in place until it is flush with the edge of camshaft bearing cap.

9. Install camshaft pulleys onto camshaft, aligning "I" mark with the intake camshaft dowel pin, and "E"mark with
exhaust camshaft dowel pin.

Tightening torque:
36.2~44.8 lb-ft ( 49~60.8 N·m, 5.0~6.2 kg-m)
10. Install cylinder head cover.

Tightening torque:
5.8~8.7 lb-ft (7.8~11.8 N·m, 0.8~1.2 kg-m)

11. Connect PCV hose and ventilation hose.

12. Install high tension cords and ignition coils.

13. Install center cover.

Tightening torque:
2.9~5.1 lb-ft (3.9~6.9 N·m, 0.4~0.7 kg-m)

14. Connect negative battery cable.

(Refer to timing belt replacement)
Engine And Transaxle
Assembly
 2004 > 1.8L DOHC >

REMOVE
1. Relieve fuel system pressure.(Refer to Fuel system)
2. Disconnect negative battery cable(first) and positive battery cable(second).

3. Drain engine coolant.

4. Remove data link connector upward from mass airflow sensor bracket.

5. Disconnect intake air temperature sensor connector and mass air flow sensor connector.
6. Disconnect air intake hose from throttle body.
7. Remove fresh air duct with two nuts.
8. Remove accelerator cable and cruise control cable if equipped.
9. Remove air cleaner assembly with two bolts and one nut.
10. Disconnect brake vacuum hose from brake master vac.

11. Disconnect purge control vacuum (PCV) hose from charcoal canister.
12. Remove upper radiator hose.

13. Remove heater hoses.

14. Disconnect fuel hose from injector rail.

KEEP OPEN FLAMES AND SPARKS AWAY FROM OPEN FUEL LINES OR A FIRE OR EXPLOSION MAY
RESULT.

15. Disconnect IAC and throttle position sensor (TPS) connectors.

16. Disconnect injector connectors.

17. Disconnect electric connectors, remove bracket and reinstall engine hanger.

18. Disconnect engine ground strap.

19. Disconnect generator B-terminal connector and connector C121 from generator.

20. Remove both right and left splash shield with three bolts and three fasteners each.

21. Loosen power steering pump lock bolt (A), nuts (B), (C) and remove tension from power steering (P/S) pump
and/or air conditioning (A/C) compressor drive belt by turn adjusting bolt(D).
22. Remove P/S pump and/or A/C compressor drive belt.
23. Remove P/S pump lock bolt (A), nut (C) and remove P/S pump.
24. Position P/S pump away from engine and affix it with wire.
25. Disconnect lower radiator hose.

26. Remove four A/C compressor bolts and remove A/C compressor.

27. Position A/C compressor away from engine and affix it with wire.

28. Disconnect ground strap from top of transaxle.

29. Disconnect input/turbine speed sensor connector(A/T).

30. Disconnect back-up light switch connector (M/T).

31. Disconnect vehicle speed sensor connector.

32. Remove U-clip from selector cable to transaxle linkage (A/T).

33. Remove nut and washer from transaxle linkage(A/T).

34. Remove manual transaxle linkage and extension bar (M/T).

35. Remove clutch release cylinder and pipe (M/T).
36. Disconnect transaxle range switch connector (A/T).

37. Disconnect solenoid valve connector (A/T).

38. Disconnect two ATF cooler hose (A/T).
39. Remove both front wheels (four lug nuts each).
40. Disconnect oxygen sensor connector.
41. Remove front exhaust pipe.

42. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.

43. Remove both right and left stabilizer control link from bracket attached to shock absorber after remove the control
link nut.
44. Remove pinch bolt and nut from both right and left ball joints.

45. Remove both right and left ball joints from steering knuckles.

46. Gently pry both driveshafts from transaxle.

47. Disconnect B-terminal connector and S-terminal connector from starter.

48. Remove two nuts from No.2 engine mount-to-mounting member.

49. Remove two bolts and two nuts, then remove mounting member.
50. Remove three No.1 engine mount bolts.

51. Support engine with engine hoist and floor jack.

52. Remove one bolt and one nut, then remove dynamic damper.

53. Remove two nuts from No.3 engine mount.

54. Remove three nuts from No.4 engine mount.

55. Slowly lower engine/transaxle assembly under the engine room with engine hoist and floor jack.

Be careful not to hurt the any other parts in the engine room.

56. Remove converter housing access cover and remove four drive plate-to-torque converter mounting nuts. Rotate
engine at crank pulley to gain access to all four nuts (A/T)

57. Remove starter bolts and transaxle mounting bolts.

58. Separate transaxle from engine.

 REPLACEMENT
1. Install transaxle to engine.

Tightening torque:
4 Upper bolts (1,2,3,4):
65.8~86.1lb·ft(89~116N·m, 9.1~11.9 kg-m)
4 Lower bolts (5,6,7,8):
27.5~38.3lb·ft(37~52N·m, 3.8~5.3 kg-m)

2. Install starter.

Tightening torque:
27~38lb·ft(37~52N·m, 3.7~5.8 kg-m)

3. Install four drive plate-to-torque converter mounting nuts then install access cover. Rotate engine at crank pulley to
gain access to all four nuts (A/T).

Tightening torque:
25~36lb·ft(34~49N·m, 3.5~5.0 kg-m)
4. Slowly raise engine/transaxle assembly into the engine room with floor jack and engine hoist.

Be careful not to hurt the any other parts in the engine room.

5. Install three nuts to No.4 engine mount.

Tightening torque:
Nuts : 49.2~68.7lb·ft
(66.7~93.2N·m, 6.8~9.5 kg-m)
Bolt : 47.0~65.8Ib·ft
(63.8~89.3N·m, 6.5~9.1 kg-m)

6. Install two nuts to No.3 engine mount.

Tightening torque:
54.2~75.9lb·ft(73.6~103N·m, 7.5~10.5 kg-m)

7. Install dynamic damper.

 Tightening torque (Bolt and nut):
40.5~59.3lb·ft(54.9~80.4N·m, 5.6~8.2 kg-m)

8. Remove engine hoist and floor jack.

9. Install three No.1 engine mount bolts.

Tightening torque:
49.2~68.7lb·ft(66.7~93.2N·m, 6.8~9.5 kg-m)

10. Install mounting member.

Tightening torque:
Mounting member bolts and nuts:
(B) : 49.2~68.7lb·ft(66.7~93.2N·m, 6.8~9.5 kg-m)
No.2 engine mount-to-mounting member nuts
(A) : 27.5~38.3b·ft(37.3~51.9N·m, 3.8~5.3 kg-m)

11. Connect B-terminal connector and S-terminal connector to starter.

12. Install new clips on driveshaft.
13. Push driveshafts into transaxle with opening of clips pointing upward.
14. Install both right and left ball joints into steering knuckles then install pinch bolt and nut.

Tightening torque:
32~39lb·ft(43~52N·m, 4.4~5.3kg-m)

15. Install both right and left stabilizer control link to bracket attached to shock absorber.

Tightening torque:
31.8~44.8lb·ft(43.2~60.8N·m, 4.4~6.2kg-m)

16. Install both right and left tie rod ends to steering knuckles then insert cotter pins.

Tightening torque:
27.7~32.5lb·ft(29.4~44.1N·m, 3.0~4.5kg-m)

17. Install front exhaust pipe.

Tightening torque:
(A), (B) : 27.5~38.3Ib·ft
(37.3~51.9N·m, 3.8~5.3 kg-m)
(C) : 31.1~44.8Ib·ft
(42.2~60.8N·m, 4.3~6.2kg-m)
18. Connect oxygen sensor connector.
19. Install both front wheels (four lug nuts each).

Tightening torque:
65.1~86.8lb·ft(88.3~117.7N·m, 9~12kg-m)

20. Connect two ATF cooler hose(A/T).

21. Connect solenoid valve connector(A/T).

22. Connect transaxle range switch connector(A/T).
23. Install clutch release cylinder with two bolts and attach pipe to U-clip.

Tightening torque:
13.7~18.8lb·ft(18.6~25.5N·m, 1.9~2.6kg-m)

24. Install manual transaxle linkage and extension bar(M/T).

25. Install transaxle linkage with washer(A/T).

26. Attach selector cable to U-clip (A/T).

27. Connect vehicle speed sensor connector.

28. Connect back-up light switch connector(M/T).

29. Connect input/turbine speed sensor connector (A/T).

30. Connect ground strap to top of transaxle.

31. Install A/C compressor with four bolts.

Tightening torque:
28.2~38.3lb·ft(38.3~51.9N·m, 3.9~5.3kg-m)

32. Connect lower radiator hose.

33. Install P/S pump.
34. Install P/S pump and/or A/C compressor drive belt.
35. Adjust the belt deflection by turning the adjusting bolt(D).

Belt deflection:
New:0.32~0.35 in(8.0~9.0mm)
Used:0.35~0.39 in(9.0~10.0mm)

36. Tighten the bolt (A), nut(B), nut(C).

Tightening torque:
(A) : 27~40lb·ft(36~54N·m, 3.7~5.5kg-m)
(B) : 14~19lb·ft(19~25N·m, 1.9~2.6kg-m)
(C) : 23~34lb·ft(31~46N·m, 3.2~4.7kg-m)

37. Install both right and left splash shield with three bolts and three fasteners each.

Tightening torque:
10.1~11.6lb·ft(13.7~15.7N·m, 1.4~1.6kg-m)

38. Connect generator B-terminal connector and connector C121 from generator.
39. Connect engine ground strap.

40. Install connector bracket and connect electric connectors.

41. Connect injector connectors.

42. Connect IAC and throttle position sensor (TPS) connectors.

43. Connect fuel hose to injector rail.

44. Connect heater hoses.

45. Connect upper radiator hose.

46. Connect purge control vacuum(PCV) hose to charcoal canister.

47. Connect brake vacuum hose to brake master vac.

48. Install air cleaner assembly with two bolts and one nut.

49. Connect air intake hose to throttle body.

50. Install accelerator cable and cruise control cable if equipped.
51. Check accelerator cable deflection. If deflection is not correct, adjust by turning nut (A).

Deflection: 0.04~0.12 in (1~3 mm)

52. Install fresh air duct with two nuts.

53. Connect intake air temperature sensor connector and mass air flow sensor connector.
54. Insert data link connector into mass air flow sensor bracket.
55. Fill engine coolant with specified type and amount.
56. Connect both battery cables.
57. Check and/or fill all fluids.
58. Test run engine and perform an overall check.

DISASSEMBLY
1. Remove exhaust manifold and coolant bypass pipe.

2. Install engine to SST.

3. Drain engine oil.
4. Remove front and rear engine hangers.
5. Remove generator by loosening adjusting bolt and removing mounting bolts and pivot bolt.
6. Remove intake manifold support bracket.

7. Remove intake manifold.

8. Remove HLAs (Refer to HLA Removal procedure).

9. Store HLAs upside down in an oil filled container.

10. Loosen cylinder head bolts in two or three steps following order shown in figure.
11. Remove cylinder head by lifting it off from cylinder block.

12. Protect HLA bore with SST(K95A-1000-E) or equivalent. Compress valve springs with SST or equivalent and
allow enough room to remove valve locks.
13. Slowly release pressure and remove valve spring from cylinder head.
14. Remove valve seals with SST or equivalent.

15. Repeat same procedure on all 16 valves.

16. Keep valves in correct order if they are to be reused.
17. Mark cylinder so that valves can be installed to their original positions.
18. Remove valves from cylinder head.
19. Remove lower spring seals from cylinder head.
20. Install SST or equivalent.
(Clutch disc centering tool and ring gear brake)
21. Loosen each bolt one turn at a time, in a crisscross pattern, until spring tension is released then remove clutch
cover and disc.
22. Remove pilot bearing with SST (Bearing puller) or equivalent if necessary.
23. Hold flywheel with SST (Ring gear brake) or equivalent.

24. Remove six bolts to remove flywheel.

25. Remove oil pan mounting bolts.

26. Remove oil pan with a screwdriver or suitable tool as shown in figure.

a. Do not force tools between cylinder block and oil pan as this may damage sealing surface.
b. Do not damage sealing surface when removing old sealant.
27. Remove oil strainer.

28. Remove timing belt pulley.

29. Remove oil pump mounting bolt and oil pump.

30. Using a screwdriver covered by a rag, remove oil seal from pump cover side.

31. Remove rear cover.

32. Wrap a prying tool with a shop towel and slowly pry out rear oil seal.
33. Remove water pump.

34. Remove oil filter and oil pressure switch.

35. Check top of each cylinder for ridges.

Failure to remove a ridge before removing piston will result in damaged ring-lands, cracked piston rings, or
cracked piston.

36. If a ridge can be felt, use a ridge reamer to remove ridge before attempting to remove piston from cylinder.
 Rotate engine block so that crankshaft is at Top Dead Center (TDC).
37. Rotate crankshaft so that No.1 and No.4 cylinders are at Bottom Dead Center (BDC).
38. Use a numbering stamp and mark rod cap and connecting rod with their corresponding cylinder number.

Mark all rods on same side and make a reference mark on block so that rods are installed in correct position
and direction. Failure to install rods properly with result in oil starvation, spun bearings, or damaged internal
engine components.

39. Rotate crankshaft so that cylinders No.2 and No.3 are at Bottom Dead Center (BDC) and repeat marking
procedure.
40. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.
41. Remove rod caps.

Cover connecting rod bolts to protect crankshaft journals.

42. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston to
release it from cylinder.
43. Repeat this procedure for each cylinder.

44. Mark tops of pistons with corresponding cylinder numbers they were removed from.
45. Using a piston ring expander, remove piston rings.

46. Hold piston upright and gently move connecting rod.

47. Release connecting rod and observe its movement.
 Do not swing connecting rod wildly. Constant, hard contact with piston will cause a bell-mouth condition that
will require piston replacement.

48. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and
deformation.
49. Remove piston pin clip from ends of piston pin bore.
50. Tilt piston and allow piston pin to slide out into your hand. Piston pins may need to be pressed out.

Do not allow pins to drop to the ground.

51. Remove connecting rod from piston. Keep individual piston, piston pin, and piston pin clips together for
reassembly.
52. Mark main bearing caps (front to back) including direction.

Each main bearing cap is matched to that particular journal. Installing a cap on wrong journal will cause an
align boreproblem that will require an expensive machine process to correct.

53. Loosen main bearing caps in two or three steps following order shown in figure.

54. Remove main bearing caps.

55. Grasp crankshaft and lift straight out.
56. Remove main bearings and thrust bearings from cylinder block saddles.

REASSEMBLY
1. Clean all parts before assembly.
2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
3. Replace main bearings and rod bearings if they are peeling, burned or otherwise damaged.

Do not reuse old gaskets or seals.

4. Install one piston pin clip into clip grooves on piston.

5. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes
contact with the piston pin clip already installed.

Verify that piston and rod are assembled in same direction as they were prior to disassembly.
6. Install second piston pin clip into clip grooves on opposite side of piston.

7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
8. Install three piece oil ring onto piston.
a. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
b. Install expander onto piston so that expander ends face upward.
c. Install lower oil ring onto piston. Ring may be installed with either face upward.
d. Install upper oil ring onto piston. Ring may be installed with either face upward.

9. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.

10. Use a ring expander and install second ring.

11. Use a ring expander and install top ring.

Top ring and second ring should be installed with "R" mark facing up.
12. Align piston ring gaps as shown.

13. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes and main bearing journals
thoroughly, and dry components with compressed air.
14. Install grooved main bearings into saddles on engine block.
15. Install thrust bearings with oil groove facing crankshaft.

16. Set crankshaft on installed bearings.

17. Install remaining main bearings into main bearing caps.
18. Position Plastigage on crankshaft journals.

19. Install main bearing caps along with lower main bearings according to cap number and mark.
20. Tighten main bearing cap bolts according to the following procedure:
a. Tighten bolts in order shown.

Tightening torque:
28.9 lb-ft (39.2 N·m, 4kg-m)

b. Loosen bolts in reverse of order shown.

 c. Retighten bolts in order shown.

Tightening torque:
14.5 lb-ft (19.6 N·m, 2kg-m)

d. Mark bolts for rotational reference.

e. Rotate bolts 90°(1/4 Turn) in order shown.
f. Rotate bolts another 60°(1/6 Turn) in order shown.

Do not rotate crankshaft with Plastigage® on crankshaft journals.

21. Remove main bearing caps and check bearing clearance.

The widest point of Plastigage® is the smallest clearance, and the narrowest point of Plastigage is the largest
clearance.

22. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings.

Oil Clearance:
0.00095-0.00165 in (0.024-0.042 mm)

23. Lift crankshaft out of cylinder block and carefully remove Plastigage from main bearings and crankshaft journals.
24. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
25. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
26. Install main bearing caps along with lower main bearings according to cap number and ← mark.
27. Tighten main bearing cap bolts according to the following procedure:
a. Tighten bolts in order shown.

Tightening torque:
28.9 lb-ft (39.2 N·m, 4kg-m)

b. Loosen bolts in reverse of order shown.

c. Retighten bolts in order shown.

Tightening torque:
14.5 lb-ft (19.6 N·m, 2kg-m)
 d. Mark bolts for rotational reference.
e. Rotate bolts 90°(1/4 Turn) in order shown.
f. Rotate bolts another 60°(1/6 Turn) in order shown.

28. Rotate crankshaft to ensure it does not bind.

29. Place a dial indicator against front of crankshaft and zero gauge.
30. Using a prying tool, move crankshaft forward and zero dial indicator.
31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator.

End Play:
0.0032-0.0111 in (0.080-0.282 mm)

32. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft and
thrust bearings.
Thrust bearing width
Thrust bearing size Specification
Standard 0.0985~0.1003 in
(2.500~2.550 mm)
Standard + 0.010 in (0.25 mm) 0.1034~0.1053 in
(2.625~2.675 mm)
Standard + 0.020 in (0.50 mm) 0.1083~0.1102 in
(2.750~2.800 mm)
Standard + 0.030 in (0.75 mm) 0.1132~0.1151 in
(2.875~2.925 mm)

33. Install a bearing into connecting rod.

34. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.

35. Check piston rings for correct end gap stagger.

36. Place piston (cylinder number one) with"F"mark facing front of engine block, then slip piston and connecting rod
assembly into a piston ring compressor.
37. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
38. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine
block.

39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes
contact with crankshaft.

Follow this procedure for remaining piston and connecting rod assemblies.

40. Install a connecting rod bearing in each connecting rod cap.

41. Place a piece of Plastigage® on crank pin journals.
42. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.

Tightening torque:
34.7-36.9 lb-ft (47-50 N·m, 4.8~5.1 kg·m)

When installing the connecting rods, match marks made on the connecting rod and cap to reference mark
made on cylinder block to prevent oil starvation to the connecting rod bearings.

43. Loosen and remove connecting rod caps.

44. Check the connecting rod bearing clearance.

Oil clearance:
0.0008-0.0019 in (0.020-0.05 mm)
Maximum : 0.004 in (0.10 mm)

45. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting
rod bearings.
46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
47. Install connecting rod cap and torque to specification.

Tightening torque:
34.7-36.9 lb-ft (47~50 N·m, 4.8-5.1 kg-m)

48. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance.

Do not measure between connecting rod cap and crankshaft.

Side clearance:
0.0044-0.0103 in (0.110-0.262 mm)
Maximum: 0.012 in (0.30 mm)

49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
50. Apply a light coat of clean engine oil to rear oil seal.
51. Install rear oil seal into rear cover by hand.
52. Press oil seal into rear cover.

Oil seal must be pressed in until it is nearly flush with surface of rear cover.

Protrusion: 0-0.02 in (0~0.5 mm)

53. Apply a coat of silicone sealer to rear cover.

Thickness: ø0.08 in (2 mm)

54. Install the rear cover.

Tightening torque:
5.8-8.0 lb-ft (7.8-10.8 N·m, 0.8-1.1 kg-m)

55. Remove any sealant that protrudes from rear cover onto oil pan mounting surface.

56. Apply clean engine oil to new front oil seal and oil pump body.
57. Install front oil seal by hand.
58. Press oil seal into oil pump body.

Oil seal must be pressed in until it is nearly flush with front surface of oil pump body.

Protrusion: -0.02-0 in (-0.5-0 mm)

59. Install a new O-ring seal.

60. Apply a bead of silicone sealant to oil pump body as shown.

Thickness: ø0.04-0.08 in (1-2 mm)

Oil pump body must be installed within 5 minutes after silicone sealant is applied.
61. Install oil pump with six bolts.

Tightening torque:
14-19 lb-ft (19-26 N·m, 1.9-2.6 kg-m)

62. Remove any sealant that protrudes from oil pump onto oil pan mounting surface.
63. Remove all foreign material from water pump mounting surface.
64. Install water pump with a new gasket and torque to specification.

Tightening torque:
14-19 lb-ft (19-26 N·m, 1.9-2.6 kg-m)

65. Install oil pressure switch.

Tightening torque:
8.7-13.7 lb-ft (11.7-17.6 N·m, 1.2-1.8 kg-m)

66. Apply a small amount of engine oil to rubber seal of oil filter.
67. Install oil filter until rubber seal contacts base and then tighten filter 1 and 1/6 turn using an oil filter wrench.

68. Install oil strainer with a new gasket.

Tightening torque:
5.8-8.7 lb-ft (7.8-11.8 N·m, 0.8~1.2kg·m)
69. Remove all foreign material from gasket surface.
70. Apply a continuous bead of silicone sealant to oil pan contact surfaces.

Install oil pan within five minutes of applying silicone sealer.

71. Install oil pan and tighten oil pan bolts.

Tightening torque:
5.8-8.0 lb-ft (7.8-10.8 N·m, 0.8-1.1 kg-m)

72. Clean thread sealant from flywheel bolts and bolt holes in crankshaft.

If thread sealant cannot be removed from bolt, replace flywheel bolt. If you are using new flywheel bolts, do
not applysealant: new bolts have sealant already applied to threads.

73. Install separator plate onto cylinder block.

 Tightening torque:
13.7-22.4 lb-ft (18.6-30.4 N·m, 1.9-3.1 kg-m)

74. Install flywheel (M/T) or drive plate/backing plate/adapter (A/T) assembly onto crankshaft.
75. Install bolts (apply sealant to reused bolts).
76. Install locking tool.
77. Tighten bolts in two or three steps to the specified torque.

Tightening torque:
71-75.9 lb-ft (97-103 N·m, 9.8-10.5 kg-m)

78. Install clutch disc and clutch cover (M/T).

79. Center the clutch disc with SST or equivalent and torque clutch cover bolts to specification (M/T).

Tightening torque:
16-24 lb-ft (22-32 N·m, 2.2-3.3 kg-m)

80. Remove locking tool.

81. Install valve, then slide valve seal over valve stem and onto valve guide.
82. Install valves guide seal installer over valve seal.

Intake and exhaust valve seals are different. Only exhaust valve seals have four teeth.
 Using a hammer will damage valve seals.

83. Remove the valve guide seal installer.

84. Install lower spring seat on cylinder head.
85. if available.
86. Install valve spring with narrow spring coils (B) toward cylinder head, and wider coils (A) toward upper spring
seat.

87. or equivalent.

88. or equivalent from valve spring.

89. Tap end of valve stem lightly two or three times with a plastic hammer to verify that valve locks are fully seated.
90. Remove HLA protector if used.
Repeat procedure for remaining valve assembles.
91. Remove all foreign material from contact surface of cylinder head and cylinder bolck.
92. Place cylinder head gasket onto cylinder block and lower cylinder head onto cylinder block.

93. Install cylinder head bolts.

94. Tighten cylinder head bolts according to following procedure:
a. Tighten cylinder head bolts in order shown.

Tightening torque:
36.1 lb-ft (49N·m, 5 kg-m)

b. Loosen bolts in reverse of order shown.

c. Retighten cylinder head bolts in order shown.

Tightening torque:
28.9 lb-ft (39.2 N·m, 4 kg-m)

d. Mark cylinder head bolts for rotational reference.

e. Rotate cylinder head bolts 90°(1/4 Turn) in order shown.
f. Rotate cylinder head bolts another 90°(1/4 Turn) in order shown.

95. Install HLAs (Refer to HLA replacement procedure).

96. Install new intake manifold gasket.
97. Install intake manifold.

Tightening torque:
13.7-18.8 lb-ft (18.6-25.5 N·m, 1.9-2.6 kg-m)

98. Install intake manifold bracket.

Tightening torque:
(A) - 11.6~16.6 lb·ft
(15.7~22.5 N·m, 1.6~2.3 kg-m)
(B) - 26.8~39.8 lb·ft
(36.3~53.9 N·m, 3.7~5.5 kg-m)

99. Install generator and generator mounting bolts and adjusting bolt.
100. Install generator drive belt and adjust the belt deflection by turning the adjust bolt(C).
 Belt deflection:
New: 0.24~0.32 in (6.0~8.0 mm)
Used: 0.28~0.35 in (7.0~9.0 mm)

101. Tighten the mounting bolts (A), (B)

Tightening torque:
(A) : 27~38 lb·ft (37~52 N·m, 3.8~5.3 kg-m)
(B) : 14~19 lb·ft (19~52 N·m, 1.9~2.6 kg-m)

102. Install front and rear engine hangers.

103. Hang engine with baby crane from engine stand.
104. Install exhaust manifold and coolant bypass pipe.

Tightening torque:
A : 28.2~34 lb·ft(38.2~46.1 N·m, 3.9~4.7 kg-m)

105. Fill with specified type and amount engine oil and check for leaks.
Cylinder Block
Piston and Connecting Rod
 2004 > 1.8L DOHC >

INSPECTION
1. Check connecting rod bushing inside diameter.

Inside diameter:
0.7875~0.7880 in (20.003~20.014 mm)

2. Subtract piston pin diameter from connecting rod bushing inside diameter to determine piston pin fit.

Clearance:
0.0004~0.0010 in (0.010~0.027 mm)

3. If clearance is not within specification, replace connecting rod bushing.

4. Check each connecting rod for bending.

5. Replace connecting rods if necessary.

Connecting rods must always be replaced as an assembly. Rod cap, rod, bolts and nuts are a matched set.

MAIN BEARING AND CONNECTING ROD BEARINGS

1. Check main and connecting rod bearings for peeling, scoring and other damage.
 PISTON COOLING JETS(INSPECTION)
1. Apply compressed air to each piston cooling jet valve at (A) and verify that air passes through piston cooling jet
valve at (B). If air does not pass, replace piston cooling jet valve.

Air pressure:
24.2~32.7 psi (166.8~225.6 kpa, 1.7~2.3 kg/cm²) maximum

2. Check piston cooling jet nozzle for clogs. Replace nozzle if necessary.

PISTON(INSPECTION)

Replacing a piston also requires replacing piston rings.

1. Check circumference of piston for damage, scoring, or unusual wear patterns. Replace piston as needed.

2. Check outside diameter of each piston at a 90º ight angle to piston pin, 0.846 in. (21.5 mm) below oil ring land's
lower edge.
Piston diameter:
3.1872-3.1879 in
Standard
(80.954-80.9720 mm)
3.197-3.1977 in
Standard + 0.010 in (0.25 mm)
(81.204-81.222 mm)
3.2069-3.2076 in
Standard + 0.020 in (0.50 mm)
(81.454-81.472 mm)

If piston is collapsed or bell mouthed, replace piston.

3. Check piston-to-cylinder wall clearance by subtracting piston diameter from the largest cylinder wall diameter, at
each cylinder.

Clearance:
0.00157~0.0021 in (0.040~0.053 mm)
Maximum:
0.006 in (0.15 mm)

4. If clearance exceeds maximum, replace piston or rebore cylinders and fit oversized pistons to all cylinders.

PISTON RINGS(INSPECTION)
1. Insert a new piston ring into a piston ring groove and check piston ring-to-side clearance.
Standard Maximum
Ring
clearance clearance
0.002-0.003 in 0.006 in
Top
(0.04-0.08 mm) (0.15 mm)
0.001-0.003 in 0.006 in
Second
(0.03-0.07 mm) (0.15 mm)

2. If clearance exceeds the maximum, replace piston.

3. Inspect piston rings for damage, abnormal wear, or breakage.
4. Replace piston rings if necessary.
5. Insert piston ring into cylinder by hand.
6. Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom of its travel in cylinder.

7. Place a feeler gauge in end gap and check end gap clearance.
End gap clearance:
Ring Specification
0.006~0.011 in
Top ring
(0.15~0.30 mm)
0.012~0.018 in
Second ring
(0.30~0.45 mm)
0.008~0.027 in
Oil rail
(0.20~0.70 mm
Maximum 0.039 in (1.0 mm)

8. Replace piston ring if necessary.

PISTON PIN(INSPECTION)
1. Measure each piston pin hole diameter at X and Y directions in four locations shown in figure.

Diameter:
0.7872~0.7875 in (19.994~20.002 mm)

2. Measure each piston pin diameter at X and Y direction at four locations shown.
 Diameter:
0.7869~0.7871 in (19.987~19.993 mm)

3. Subtract piston pin diameter from pin hole diameter to determine piston pin to piston clearance.

Clearance:
0.00004~0.00006 in (0.001~0.015 mm)

4. If clearance exceeds specification, replace piston and piston pin.

Piston and piston pin are a matched set.

Crankshaft
 2004 > 1.8L DOHC >

INSPECTION
1. Check crankshaft bearing and crank pin journals for damage and scoring.
2. Check oil holes for clogging.
3. Set crankshaft on V-blocks.
4. Measure crankshaft run-out at center journal.
Replace crankshaft if it is not within specification.

Run-out:
0.0016 in (0.04 mm)

5. Use a micrometer to measure crankshaft main bearing journals and crank pin journals at X and Y direction as
shown.
Crankshaft journal diameter:
Journal Diameter Out of round
2.1629~2.1639 in 0.0020 in
Main (54.938~54.956 mm) (0.05 mm)
Maximum
1.7693~1.77 in 0.0020 in
Crank pin (44.940~44.958 mm) (0.05 mm)
Maximum

6. Grind crankshaft only if there is visible scoring, or if out-of-round is excessive.

7. Only grind crankshaft amount necessary to correct condition.
8. If a crankshaft must be ground 0.020 in (0.50 mm) or more, heat-treat crankshaft to ensure durability.
Main journal diameter undersizes:
Bearing size Journal diameter
0.010 in (0.25 mm) 2.1531~2.1538 in
undersize (54.688~54.706 mm)
0.020 in (0.50 mm) 2.1432~2.1439 in
 undersize (54.438~54.456 mm)
0.030 in (0.75 mm) 2.1334~2.1341 in
undersize (54.188~54.206 mm)

Crank pin journal diameter undersizes:

Bearing size Journal diameter
0.010 in (0.25 mm) 1.7594~1.7602 in
undersize (44.690~44.708 mm)
0.020 in (0.50 mm) 1.7496~1.7503 in
undersize (44.440~44.458 mm)
0.030 in (0.75 mm) 1.7398~1.7405 in
undersize (44.190~44.208 mm)
Cylinder Block
 2004 > 1.8L DOHC >

INSPECTION
1. Check cylinder block for following conditions and repair or replace cylinder block as needed.
a. Leakage damage
b. Cracks
c. Scoring of cylinders
2. Check distortion of cylinder head mating surface (block deck) in six directions shown in figure.

Distortion:
0.006 in (0.15 mm) maximum

3. Repair block deck by surface grinding block, or in extreme cases replace cylinder block.

Maximum resurface amount:

0.008 in (0.20 mm)

4. If deck is at or below this specification, replace cylinder block.

Before surfacing cylinder block, check deck height from center line of crankshaft to deck surface.

5. Measure cylinder bore with a dial bore gauge at X and Y vectors shown in figure.

Cylinder bore size

Standard:
3.1892~3.1897 in (81.006~81.019 mm)
Bore + 0.010 in (0.25 mm):
3.1990~3.1996 in (81.256~81.269 mm)Bore + 0.020 in. (0.50 mm):
6. Take cylinder measurements at top, center and bottom of cylinder to check for cylinder diameter, taper and out-of-
round.

Taper:
0.0007 in (0.019 mm) Maximum
Out-of-round:
0.0007 in (0.019 mm) Maximum

Boring cylinders should be based on maximum oversized piston that can be installed without exceeding
maximum overbore.
Engine Mounts
2004 > 1.8L DOHC >

COMPONENTS
Cooling system
2004 > 1.8L DOHC >

Functional diagram
Water Pump
 2004 > 1.8L DOHC >

REMOVAL

Do not disassemble water pump assembly. If a problem is found, replace assembly as a unit.

1. Disconnect negative battery cable.

2. Drain engine coolant.

3. Remove timing belt (Refer to timing belt removal).

4. Remove tensioner and idler.

5. Remove water pump.

REPLACEMENT
1. Remove any gasket fragments, dirt or oil from sealing surfaces.
2. Install new gasket on water pump.
 To prevent dropping the gasket when installing, put sealant in gasket groove. But do not apply to sealing
surfaces.

3. Install water pump.

Tightening torque:
14~19 lb-ft (19~26 N·m, 1.9~2.6 kg-m)

4. Install tensioner, idler and timing belt.

(Refer to timing belt replacement).
5. Fill engine coolant.

6. Connect negative battery cable.

7. Start engine and check for leaks.

INSPECTION
1. Check water pump for cracks and damage.
2. Check for abnormal noise, bearing sticking or loose.
3. Replace water pump if necessary.
Thermostat
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Drain engine coolant.

3. Remove bolt and nut of thermostat housing.

4. Remove thermostat housing and thermostat.

REPLACEMENT
1. Install thermostat into cylinder head with jiggle pin positioned up.
2. Install new gasket.
3. Place thermostat housing and tighten bolt and nut.

Tightening torque:
14~19 lb-ft (19~26 N·m, 1.9~2.6 kg-m)

4. Fill radiator with specified amount and type of engine coolant.

5. Connect negative battery cable.

6. Start engine and check for leaks.

INSPECTION
1. Visually check that thermostat is airtight.
2. Place thermostat and a thermometer in water.
3. Gradually heat water and check following.

Initial opening temperature:

188~193 °F (86.5~89.5 °C)
Full open temperature:
212 °F (100 °C)
Full open lift:
0.31 in (8.0 mm) min.
Radiator
2004 > 1.6L DOHC >

COMPONENT
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Drain engine coolant.

3. Remove fresh air duct.

4. Disconnect upper radiator hose.

5. Disconnect cooling fan motor connector.

6. Disconnect condenser fan motor connector.
7. Disconnect coolant reservoir hose.
8. Remove radiator upper brackets.
9. Disconnect Automatic Transaxle Fluid (ATF) inlet and outlet pipe.
10. Disconnect lower radiator hose.
11. Lift radiator assembly from engine compartment.
12. Remove cooling fan assembly and condenser fan assembly.

INSPECTION
1. Check for cracks, damage or water leakage.
2. Check for bent fins. If bent, repair with a fin comb or similar tool.

3. Check for damaged radiator inlet and outlet and hose connections.

REPLACEMENT
1. Install cooling fan assembly and condenser fan assembly.
2. Install radiator assembly into engine compartment.
3. Connect lower radiator hose.
4. Connect ATF inlet and outlet pipes.

5. Install radiator upper brackets.

6. Connect coolant reservoir hose.
7. Connect condenser fan motor connector.
8. Connect cooling fan motor connector.
9. Connect upper radiator hose.
10. Install fresh air duct.
11. Connect negative battery cable.

12. Fill engine coolant (Refer to engine coolant replacement).

13. Start engine and check for leaks.

Drive Belt
 2004 > 1.8L DOHC >

DRIVE BELT
INSPECTION
1. Check the drive belts for wear, cracks, and fraying.
Replace if necessary.
2. Verify that the drive belts are correctly mounted on the pulleys.

3. Check the drive belt deflection by applying moderate pressure 98N (10kg, 22Ib) midway between the pulleys.

DEFLECTION
Drive belt New Used
Generator 0.24~0.32 in 0.28~0.35 in
(6.0~8.0 mm) (7.0~9.0 mm)
P/S, P/S+A/C 0.32~0.35 in 0.36~0.39 in
(8.0~9.0 mm) (9.0~10.0 mm)

a. Measure the belt deflection between the specified pulleys.

b. Consider the belt as a new one if it has been used on a running engine for less than five minutes.
c. Check the belt deflection when the engine is cold or at least 30 minutes after the engine is stopped.

ADJUSTMENT
GENERATOR DRIVE BELT
1. Loosen the mounting bolt (A), (B) and adjust the belt deflection by turning the adjusting bolt (C).
2. Tighten the mounting bolts (A), (B).

Tightening torque:
(A) : 28~38 lb·ft (37~52 N·m, 3.8~5.3 kg-m)
(B) : 14~19 lb·ft (19~25 N·m, 1.9~2.6 kg-m)

POWER STEERING + AIR CONDITIONER DRIVE BELT

1. Loosen the bolt (A), nut (B), nut (C), for power steering pump.

2. Adjust the belt deflection by turning the adjusting bolt (D).

3. Tighten the bolt (A), nut (B), nut (C).

Tightening torque:
(A) : 27~40 lb·ft (36~54 N·m, 3.7~5.5 kg-m)
(B) : 14~19 lb·ft (19~25 N·m, 1.9~2.6 kg-m)
(C) : 23~34 lb·ft (31~46 N·m, 3.2~4.7 kg-m)
Radiator Cap
 2004 > 1.6L DOHC >

INSPECTION
RADIATOR CAP VALVE
1. Remove foreign material from radiator cap valve and the valve seat.
2. Attach radiator cap to a radiator cap tester. Apply pressure gradually to 15 psi (103 kPa, 1.05 kg/cm²).

3. Wait about 10 seconds. Verify that pressure has not decreased.

4. Replace radiator cap as necessary.

NEGATIVE PRESSURE VALVE

1. Pull negative pressure valve to open it. Verify that it closes completely when released.

2. Check for damage on contact surfaces, and for a cracked or deformed seal.
3. Replace radiator cap as necessary.
Cooling Fan Motor
Assembly
2004 > 1.8L DOHC >

COMPONENT
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Drain engine coolant.

3. Remove fresh air duct.

4. Disconnect cooling fan motor connector.

5. Remove upper radiator hose.

6. Remove upper two radiator cowling bolts.

7. Remove lower two radiator cowling bolts.
8. Lift radiator cowling from engine compartment.
9. Remove clip and fan.
10. Remove three fan motor bolts and nuts.

REPLACEMENT
1. Install fan motor and tighten three fan motor bolts and nuts.
2. Install fan and clip.
3. Install radiator cowling to radiator.
4. Install and tighten two upper radiator cowling bolts.

Tightening torque:
5.8~7.9 lb-ft (7.8~10.8 N·m, 0.8~1.1 kg-m)

5. Install and tighten lower two radiator cowling bolts.

Tightening torque:
5.8~7.9 lb-ft(7.8~10.8 N·m, 0.8~1.1 kg-m)

6. Install upper radiator hose.

7. Connect cooling fan motor connector.

8. Install fresh air duct and tighten bolt and nut.
9. Fill engine coolant (Refer to engine coolant replacement).

10. Connect negative battery cable.

11. Start engine and check for leaks.

INSPECTION
1. Check current as shown with an ammeter.

Current (A): 8~13A

 2004 > 1.8L DOHC >

TROUBLESHOOTING GUIDE
Problem Possible Cause Action
Overheating Coolant level insufficient Add
Coolant leakage Repair
Radiator fins clogged Clean
Radiator cap malfunction Replace
Fan motor malfunction Replace
Thermostat malfunction Replace
Water passage clogged Clean
Water pump malfunction Replace
Corrosion Impurities in coolant Replace
2004 > 1.8L DOHC >

SPECIFICATION
COOLING SYSTEM
Lubrication System
Engine Oil
 2004 > 1.8L DOHC >

REPLACEMENT

Be careful when draining because oil is hot and could cause personal injury.

1. Warm engine to normal operating temperature and turn engine off. Position a suitable container under oil pan.
2. Remove oil filler cap and oil pan drain plug.

3. Allow oil to be fully drained.

4. Install drain plug with new gasket.

Tightening torque:
28.9~32.5 lb-ft (39.2~44.1 N·m, 4.0~4.5 kg-m)

5. Refill engine with specified type and amount of engine oil.

6. Install oil filler cap.

7. Run engine and check for leaks.

8. Check oil level and add oil if necessary.

Oil pan capacity: 3.8 U.S. qt (3.6 liters, 3.2 lmp qt)

INSPECTION
1. Be sure vehicle is on level ground.
2. Warm engine to normal operating temperature and turn engine off.
3. Wait for five minutes.
4. Remove oil level dipstick and check oil level and condition.
5. Add or replace oil as necessary.
Oil Pan
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Drain engine oil.

3. Remove LH and RH side splash shields.

4. Remove front exhaust pipe.

5. Remove oil pan mounting bolts.

6. Remove oil pan with screwdriver or suitable tool as shown in figure.

a. Do not force tools between cylinder block and oil pan because this may damage sealing surfaces.
b. Do not damage sealing surfaces when removing old sealant.

7. Remove oil strainer.

REPLACEMENT

a. If oil pan is reused, remove all foreign material from sealing surfaces of cylinder block and oil pan.
b. If bolts are reused, remove old sealant from bolt threads.

1. Install oil strainer.

Tightening torque:
5.8~8.7 lb-ft (7.8~11.8 N·m, 0.8~1.2 kg-m)
2. Apply a continuous bead of silicone sealant to baffle plate along inside of bolt holes on contact surfaces.

The oil pan must be installed no longer than 5 minutes after silicone sealant is applied.

3. Install oil pan.

Tightening torque:
A, B ,C, D: 5.8~8.0 lb-ft
(7.8~10.8 N·m, 0.8~1.1 kg-m)
E: 28~38 lb-ft (38~51 N·m, 3.8~5.3 kg-m)

4. Install front exhaust pipe.

Tightening torque:
A, B : 27.5~38.3 Ib·ft
(37.3~51.9 N·m, 3.8~5.3 kg·m)
C : 31.3~44.8 Ib·ft
(42.2~60.8 N·m, 4.3~6.2 kg·m)
5. Install LH and RH side splash shields.

Tightening torque:
12~18 lb-ft (16~24 N·m, 1.6~2.4 kg-m)

6. Fill with specified amount and type of engine oil.

7. Connect negative battery cable.

8. Start engine and check for leaks.

9. Check oil level and add oil if necessary.
Oil Pump
2004 > 1.8L DOHC >

COMPONENT
 2004 > 1.8L DOHC >

REMOVAL
1. Disconnect negative battery cable.

2. Drain engine oil.

3. Remove timing belt. (Refer to timing belt removal).

4. Remove oil pan and oil strainer. (Refer to oil pan removal).
5. Remove generator.

6. Remove A/C compressor and A/C compressor bracket if equipped.

7. Remove crankshaft pulley lock bolt.

8. Remove timing belt pulley.
9. Remove oil pump mounting bolt.

10. Remove oil pump.

FRONT OIL SEAL

REMOVAL
1. Remove oil pump (Refer to oil pump removal).
2. Remove front oil seal (Refer to oil pump disassembly).

REPLACEMENT
1. Install oil seal (Refer to Oil pump reassembly).
2. Install oil pump (Refer to Oil pump replacement).

REAR OIL SEAL

REMOVAL
1. Disconnect negative battery cable.
2. Remove flywheel (Refer to clutch removal). In case of A/T, remove drive plate (Refer to A/T removal).

Use a flywheel locking tool or equivalent when removing flywheel or drive plate.

3. Remove rear cover.

4. Wrap a prying tool with a shop towel and slowly pry old seal out.
REPLACEMENT
1. Apply engine oil to rear cover, oil seal and oil seal lip.
2. Press oil seal into rear cover.

Oil seal must be tapped in until it is nearly flush with surface of rear cover.

Protrusion:
0~0.02 in (0~0.5 mm)

3. Cut away silicon sealer that has been squeezed out from rear cover assembly toward oil pan mounting surface.

Do not scratch rear cover assembly.

4. Install rear cover.

Tightening torque:
A: 5.8~8.0 lb-ft ( 7.8~10.8 N·m, 0.8~1.1 kg-m)
B: 29.7~40.5 lb-ft (40.2~54.9 N·m, 4.1~5.6 kg-m)

5. Install flywheel and manual transaxle (Refer to clutch replacement). In case of A/T, install drive plate and automatic
transaxle (Refer to automatic transaxle replacement).
6. Connect negative battery cable.

REPLACEMENT
1. Apply a continuous bead of silicone sealant to oil pump sealing surface.

The oil pump must be installed no longer than 5 minutes after silicone sealant is applied.

2. Apply grease to a new O-ring and install it in oil pump.

3. Install oil pump.

Tightening torque:
14-19 lb-ft (19-26 N·m, 1.9-2.6 kg-m)

4. Install timing belt pulley and crankshaft pulley lock bolt.

Tightening torque:
115.7-122.9 lb-ft (156.8-166.6 N·m, 16-17 kg-m)

5. Install A/C compressor bracket and A/C compressor.

Tightening torque:
A/C compressor mounting bolts
28.2~38.3 lb-ft (38.3~51.9 N·m, 3.9~5.3 kg-m)
6. Install generator.

Tightening torque:
(A) : 28~38 lb-ft (37~52 N·m, 3.8~5.3 kg-m)
(B) : 14~19 lb-ft (19~25 N·m, 1.9~2.6 kg-m)

7. Install oil strainer and oil pan.

(Refer to oil pan replacement).
8. Install timing belt.
(Refer to timing belt replacement).
9. Fill with specified amount and type of engine oil.
10. Connect negative battery cable.

11. Start engine and check for leaks.

12. Check oil level and add oil if necessary.

DISASSEMBLY
1. Remove oil seal using a screwdriver covered by a rag to protect sealing surface from pump cover side.
2. Remove seven screws and remove pump cover.

3. Remove outer rotor and inner rotor.

INSPECTION
1. Check the following and replace any faulty parts.
a. Distorted or damaged oil pump body or cover.
b. Worn or damaged plunger.
c. Weak or broken plunger spring.
2. Measure side clearance.

Clearance: 0.0035 in (0.09 mm) Max.

3. Measure tooth tip clearance.

Clearance: 0.007 in (0.18 mm) Max.

4. Measure outer rotor to pump body clearance.

Clearance: 0.015 in (0.376 mm) Max.

REASSEMBLY
1. Assemble outer rotor and inner rotor into oil pump body.

2. Apply thread locking compound to cover mounting screw threads.

3. Assemble oil pump cover to oil pump body.

Tightening torque:
4.3~6.5 lb-ft (6~9 N·m, 0.6~0.9 kg-m)

4. Apply engine oil to outside of new oil seal and oil pump body.
5. Press oil seal into oil pump body.

Oil seal must be pressed in until it is protruding with front face of oil pump body.

Protrusion: -0.02~0 in (-0.5~0 mm)

Oil Filter
 2004 > 1.8L DOHC >

REPLACEMENT
1. Raise vehicle.
2. Remove oil filter with oil filter wrench. If rubber seal is stuck to engine, remove it.
3. Apply a small amount of clean engine oil to rubber seal of new filter.

4. Install oil filter and turn it by hand until rubber seal contacts base.
5. Tighten filter 1-1/6 turns with filter wrench.
6. Start engine and check for leaks.
7. Turn engine off, and wait 5 minutes.
Check oil level and add oil if necessary.

Oil filter capacity:

0.21 U.S. qt (0.2 liter, 0.18 lmp qt)

OIL PRESSURE CHECK

1. Disconnect and remove oil pressure switch.

2. Install oil pressure gauge into oil pressure switch installation hole.

3. Warm engine to normal operating temperature.

4. Run engine at 3,000 rpm, and note gauge readings.
 Oil pressure:
43~57 psi (294~392 kPa, 3.0~4.0 kg/cm²)

5. If pressure is not within specification, check for cause, and repair. (Refer to troubleshooting guide)
6. Remove oil pressure gauge and install oil pressure switch.

Tightening torque:
8.7~13.0 lb-ft(12-18 N·m, 1.2-1.8 kg-m)
 2004 > 1.8L DOHC >

GENERAL DESCRIPTION
Pressurized oil is first directed through a full-flow paper element where impurities are removed, and then to a main oil
gallery. Oil in this gallery is divided into two passages. In one passage, oil is pumped to the crankshaft main bearings.
Oil is supplied to the connecting rod bearings through intersecting passages drilled in the crankshaft. Piston cooling
jets in each cylinder provide additional piston cooling and lubrication. In the second passage, oil flows to the cylinder
head to lubricate valve train components.
After passing through the cylinder block and cylinder head, oil is returned by gravity to the oil pan. Those internal parts
that have no direct oil feed are supplied with lubrication by either gravity or splash from other direct feed components.
 2004 > 1.8L DOHC >

TROUBLESHOOTING GUIDE
Problem Possible Cause Action
Engine hard starting Improper engine oil Replace
Insufficient engine oil Add oil
Excessive oil consumption Internal engine wear Repair
Oil leak Repair
Oil pressure drop Insufficient oil Add oil
Oil leakage Repair
Worn and/or damaged oil pump gear Replace
Worn plunger (inside oil pump) or Replace
weak spring
Clogged oil strainer Clean
Excessive main bearing or connecting Replace
rod bearing clearance
Warning lamp illuminates while Oil pressure drop As described above
engine is running
Malfunction of oil pressure switch Inspection
Malfunction of electrical system Inspection
 2004 > 1.8L DOHC >

SPECIFICATION
LUBRICATION SYSTEM
Item Specifications
Lubrication system Force-fed type
Type Duo-Centric rotor
Oil pump Relief pressure 64~78 (441~539, 4.5~5.5)
psi (kPa, kg/cm²)
Oil filter Type Full-flow, paper element
Relief pressure differential 11~17 (78~118, 0.8~1.2)
psi (kPa, kg/cm²)
Oil pressure switch activation pressure 3.6 (25, 0.25)
psi (kPa, kg/cm²)
Oil capacity Total (dry engine) 4.2 (4.0, 3.5)
US qt (liters, lmp qt)
Oil pan 3.8 (3.6, 3.2)
US qt (liters, lmp qt)
Oil filter 0.21 (0.20, 0.18)
US qt (liters, lmp qt)
Engine oil API service SG or SH
Intake and Exhaust System
Air Cleaner
2004 > 1.8L DOHC >

COMPONENT
 2004 > 1.8L DOHC >

INSPECTION
ACCELERATOR CABLE
1. Depress the accelerator pedal to the floor and check that the throttle valve is fully opened.
Adjust with nut (A), if necessary.

2. Measure the free play of the accelerator cable.

Free play: 0.16~0.28 in (4~7 mm)

AIR CLEANER ELEMENT

1. Check the air cleaner element for excessive dirt, damage, or oil, and replace or clean if necessary.

Use a compressed air to clean the element from the internal side to the external side, or from the upper to the
lower.
Front Exhaust Pipe
2004 > 1.8L DOHC >

EXHAUST PIPE
COMPONENT
 2004 > 1.8L DOHC >

DESCRIPTION
INTAKE SYSTEM
a. Air cleaner assembly
b. Resonance chamber
c. Mass air flow sensor
d. Throttle body
e. Intake manifold
f. Idle air control (IAC) valve
The mass air flow sensor is used to measure mass air flow passing into the engine. The mass air flow sensor detects
themass of air flow and notifies the ECM with an input signal.
The resonance chamber suppress air inlet noise caused by airflow pulsation.
The throttle body controls intake air quantities and consists of:
Throttle position (TP) sensor
Idle air control (IAC) valve
The idle air control system supplies small quantities of air during engine idle by regulating the bypass air amount that
passes through the throttle body.
The throttle position (TP) sensor detects the throttle valve position and provides the ECM with this information.

EXHAUST SYSTEM

Do not touch the catalytic converter heat shield when the engine is running. The conversion process produces
high heat.Even when the engine is not running, it remains hot a long time. It will remain hot after other pipes
have cooled. Touching the heat shield may produce a serious burn.
 2004 > 1.8L DOHC >

TROUBLESHOOTING GUIDE
EXHAUST SYSTEM
Problem Possible cause Action
Exhaust noise Hole in front exhaust pipe Replace
Hole in three-way catalytic (TWC) Replace
Hole in muffler Replace
Leaking gasket(s) Replace
Engine sluggish and will not pass Three-way catalytic (TWC) converter Replace
smog test even after a tune up
Exhaust system rattle Broken support(s) Replace
2004 > 1.8L DOHC >

SPECIFICATIONS