1. General Description

S153001

A: SPECIFICATIONS

S153001E49

Engine

Type

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

Valve arrangement

Belt driven, single over-head camshaft, 4-valve/cylinder

Bore x Stroke mm (in)

92 x 75 (3.62 x 2.95)

Displacement cm3 (cu in)

1,994(121.67)

Compression ratio

10.0

Compression pressure (at 200 - 300 kPa (kg/cm2, psi) rpm)

1,020 - 1,275 (10.4 - 13.0, 148 - 185)

Number of piston rings

Pressure ring: 2, Oil ring: 1

Intake valve timing

Opening

4° BTDC

Closing

48° ABDC

Exhaust valve timing

Opening

48° BBDC

Closing

4° ATDC

Valve clearance

Intake mm (in)

0.20±0.02 (0.0079±0.0008)

Exhaust mm (in)

0.25±0.02 (0.0098±0.0008)

Idling speed [At neutral position on MT, or "P" or "N" position on rpm AT]

With OBD

700±100 (No load) 850±100 (A/C switch ON)

Without OBD

MT: 650±100 (No load) AT: 675±100 (No load) 800±100 (A/C switch ON)

Firing order

1 → 3 → 2 → 4

Ignition timing BTDC/rpm

With OBD

10°±1 0°/700

Without OBD

MT: 10°±1 0°/650 AT: 10°±1 0°/675

NOTE:

STD: Standard I.D.: Inner Diameter O.D.: Outer

Diameter US: Undersize OS: Oversize

Belt ten-sioner adjuster

Protrusion of adjuster rod

5.2 - 6.2 mm (0.205 - 0.244 in)

Belt ten-sioner

Spacer O.D.

17.955 - 17.975 mm (0.7069 - 0.7077 in)

Tensioner bush I.D.

18.00 - 18.08 mm (0.7087 - 0.7118 in)

Clearance between spacer and bush

STD

0.025 - 0.125 mm (0.0010 - 0.0049 in)

Limit

0.175 mm (0.0069 in)

Side clearance of spacer

STD

0.20 - 0.55 mm (0.0079 - 0.0217 in)

Limit

0.81 mm (0.0319 in)

Valve rocker arm

Clearance between shaft and arm

STD

0.020 - 0.054 mm (0.0008 - 0.0021 in)

Limit

0.10 mm (0.0039 in)

Camshaft

Bend limit

0.020 mm (0.0008 in)

Thrust clearance

STD

0.030 - 0.090 mm (0.0012 - 0.0035 in)

Limit

0.11 mm (0.0043 in)

Cam lobe height

Intake

STD

38.732 - 38.832 mm (1.5249 - 1.5288 in)

Limit

38.632 mm (1.5209 in)

Exhaust

STD

39.257 - 39.357 mm (1.5455 - 1.5495 in)

Limit

39.157 mm (1.5416 in)

Camshaft journal O.D.

31.928 - 31.945 mm (1.2570 - 1.2577 in)

Camshaft journal hole I.D.

32.000 - 32.018 mm (1.2598 - 1.2605 in)

Oil clearance

STD

0.055 - 0.090 mm (0.0022 - 0.0035 in)

Limit

0.10 mm (0.0039 in)

Cylinder head

Surface warpage limit

0.05 mm (0.0020 in)

Surface grinding limit

0.1 mm (0.004 in)

Standard height

97.5 mm (3.84 in)

Valve set

Refacing angle

90°

Contacting width

Intake

STD

1.0 mm (0.039 in)

Limit

1.7 mm (0.067 in)

Exhaust

STD

1.4 mm (0.055 in)

Limit

2.1 mm (0.083 in)

Valve guide

Inner diameter

6.000 - 6.012 mm (0.2362 - 0.2367 in)

Protrusion above head

Intake

20.0 - 20.5 mm (0.787 - 0.807 in)

Exhaust

16.5 - 17.0 mm (0.650 - 0.669 in)

Valve

Head edge thickness

Intake

STD

1.0 mm (0.039 in)

Limit

0.6 mm (0.024 in)

Exhaust

STD

1.2 mm (0.047 in)

Limit

0.6 mm (0.024 in)

Stem diameter

Intake

5.950 - 5.965 mm (0.2343 - 0.2348 in)

Exhaust

5.945 - 5.960 mm(0.2341 - 0.2346 in)

Stem oil clearance

STD

Intake

0.035 - 0.062 mm (0.0014 - 0.0024 in)

Exhaust

0.040 - 0.067 mm (0.0016 - 0.0026 in)

Limit

-

0.15 mm (0.0059 in)

Overall length

Intake

120.6 mm (4.75 in)

Exhaust

121.7 mm (4.79 in)

Valve spring

Free length

54.30 mm (2.1378 in)

Squareness

2.5°, 2.4 mm (0.094 in)

Tension/spring height

218.7 - 242.5 N (22.3 - 24.7 kgf, 49.2 - 54.5 lb)/ 45.0 mm (1.772 in) 526.6 - 581.6 N (53.7 - 59.3 kgf, 118.4 - 130.8 lb)/34.7 mm (1.366 in)

Cylinder block

Surface warpage limit (mating with cylinder head)

0.05 mm (0.0020 in)

Surface grinding limit

0.1 mm (0.004 in)

Cylinder bore

STD

A

92.005 - 92.015 mm (3.6222 - 3.6226 in)

Â

91.995 - 92.005 mm (3.6218 - 3.6222 in)

Taper

STD

0.015 mm (0.0006 in)

Limit

0.050 mm (0.0020 in)

Out-of-roundness

STD

0.010 mm (0.0004 in)

Limit

0.050 mm (0.0020 in)

Piston clearance

STD

0.010 - 0.030 mm (0.0004 - 0.0012 in)

Limit

0.050 mm (0.0020 in)

Enlarging (boring) limit

0.5 mm (0.020 in)

Piston

Outer diameter

A

91.985 - 91.995 mm (3.6214 - 3.6218 in)

Â

91.975 - 91.985 mm (3.6211 - 3.6214 in)

0.25 mm (0.0098 in) OS

92.225 - 92.235 mm (3.6309 - 3.6313 in)

0.50 mm (0.0197 in) OS

92.475 - 92.485 mm (3.6407 - 3.6411 in)

Standard inner diameter of piston pin hole

23.000 - 23.006 mm (0.9055 - 0.9057 in)

Piston pin

Outer diameter

22.994 - 23.000 mm (0.9053 - 0.9055 in)

Standard clearance between piston pin and ton

hole

in pis-

0.004 - 0.008 mm (0.0002 - 0.0003 in)

Degree of fit

Piston pin must be fitted into position with thumb at 20°C (68°F).

Piston ring

Piston ring gap

Top ring

STD

0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit

1.0 mm (0.039 in)

Second ring

STD

0.35 - 0.50 mm (0.0138 - 0.0197 in)

Limit

1.0 mm (0.039 in)

Oil ring

STD

0.20 - 0.70 mm (0.0079 - 0.0276 in)

Limit

1.5 mm (0.059 in)

Clearance

STD

0.040 - 0.080 mm (0.0016 - 0.0031 in)

between piston

þð ring

Limit

0.15 mm (0.0059 in)

ring and piston

Second

STD

0.030 - 0.070 mm (0.0012 - 0.0028 in)

ring groove

ring

Limit

0.15 mm (0.0059 in)

Connecting

Bend twist per 100 mm (3.94 in) in length

Limit

0.10 mm (0.0039 in)

rod

Side clearance

STD

0.070 - 0.330 mm (0.0028 - 0.0130 in)

Limit

0.4 mm (0.016 in)

Oil clearance

STD

0.010 - 0.038 mm (0.0004 - 0.0015 in)

Limit

0.05 mm (0.0020 in)

Connecting

Thickness at center portion

STD

1.492 - 1.501 mm (0.0587 - 0.0591 in)

rod bearing

0.03 mm

(0.0012 in) US

1.510 - 1.513 mm (0.0594 - 0.0596 in)

0.05 mm

(0.0020 in) US

1.520 - 1.523 mm (0.0598 - 0.0600 in)

0.25 mm

(0.0098 in) US

1.620 - 1.623 mm (0.0638 - 0.0639 in)

Connecting

Clearance between piston pin

STD

0 - 0.022 mm (0 - 0.0009 in)

rod bushing

and bushing

Limit

0.030 mm (0.0012 in)

Crankshaft

Bend limit

0.035 mm (0.0014 in)

Crank pin and

Out-of-roundness

0.020 mm (0.0008 in) or less

crank journal

Grinding limit

0.250 mm (0.0098 in)

Crank pin outer diameter

STD

51.984 - 52.000 mm (2.0466 - 2.0472 in)

0.03 mm

(0.0012 in) US

51.954 - 51.970 mm (2.0454 - 2.0461 in)

0.05 mm

(0.0020 in) US

51.934 - 51.950 mm (2.0446 - 2.0453 in)

0.25 mm

(0.0098 in) US

51.734 - 51.750 mm (2.0368 - 2.0374 in)

STD

59.992 - 60.008 mm (2.3619 - 2.3625 in)

#1, #3

0.03 mm

(0.0012 in) US

59.962 - 59.978 mm (2.3607 - 2.3613 in)

0.05 mm

(0.0020 in) US

59.942 - 59.958 mm (2.3599 - 2.3605 in)

Crank journal

0.25 mm

(0.0098 in) US

59.742 - 59.758 mm (2.3520 - 2.3527 in)

outer diameter

STD

59.992 - 60.008 mm (2.3619 - 2.3625 in)

#2, #4, #5

0.03 mm

(0.0012 in) US

59.962 - 59.978 mm (2.3607 - 2.3613 in)

0.05 mm

(0.0020 in) US

59.942 - 59.958 mm (2.3599 - 2.3605 in)

0.25 mm

(0.0098 in) US

59.742 - 59.758 mm (2.3520 - 2.3527 in)

Thrust clearance

STD

0.030 - 0.115 mm (0.0012 - 0.0045 in)

Limit

0.25 mm (0.0098 in)

Oil clearance

STD

0.010 - 0.030 mm (0.0004 - 0.0012 in)

Limit

0.040 mm (0.0016 in)

STD

 

1.998 - 2.011 mm

(0.0787 - 0.0792 in)

#1, #3

0.03 mm

(0.0012 in) US

2.017 - 2.020 mm

(0.0794 - 0.0795 in)

0.05 mm

(0.0020 in) US

2.027 - 2.030 mm

(0.0798 - 0.0799 in)

Crankshaft

Crankshaft bear-

0.25 mm

(0.0098 in) US

2.127 - 2.130 mm

(0.0837 - 0.0839 in)

bearing

ing thickness

STD

 

2.000 - 2.013 mm

(0.0787 - 0.0793 in)

#2, #4, #5

0.03 mm

(0.0012 in) US

2.019 - 2.022 mm

(0.0795 - 0.0796 in)

0.05 mm

(0.0020 in) US

2.029 - 2.032 mm

(0.0799 - 0.0800 in)

0.25 mm

(0.0098 in) US

2.129 - 2.132 mm

(0.0838 - 0.0839 in)

B: COMPONENT

1. TIMING BELT S153001A0501

S153001A05

for_01-432.jpg

(1)    Belt cover No. 2 (RH)

(2)    Timing belt guide (MT vehicles only)

(3)    Crankshaft sprocket

(4)    Belt cover No. 2 (LH)

(5)    Camshaft sprocket No. 1

(6)    Belt idler (No. 1)

(7)    Tensioner bracket

(8)    Belt idler (No. 2)

(9)    Automatic belt tension adjuster ASSY

(10)  Belt idler No. 2

(11)  Camshaft sprocket No. 2

(12)  Timing belt

(13)  Front belt cover

(14)  Belt cover (LH)

(15)  Crankshaft pulley

Tightening torque: N-m (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 9.8 (1.0, 7.2) T3: 25 (2.5, 18.1) T4: 39 (4.0, 28.9) T5: 78 (8.0, 57.9) T6: 127 (13.0, 94)

2. CYLINDER HEAD AND CAMSHAFT

S153001A0502

for_01-433.jpg

(1)

Rocker cover (RH)

(11) Cylinder head (LH)

(2)

Intake valve rocker ASSY

(12) Camshaft (LH)

(3)

Exhaust valve rocker ASSY

(13) Camshaft cap (LH)

(4)

Camshaft cap (RH)

(14) Oil filler cap

(5)

Oil seal

(15) Gasket

(6)

Camshaft (RH)

(16) Oil filler pipe

(7)

Plug

(17) O-ring

(8)

Spark plug pipe gasket

(18) Rocker cover (LH)

(9)

Cylinder head (RH)

(19) Stud bolt

(10)

Cylinder head gasket

Tightening torque: N-m (kgf-m, ft-lb) T1: <Ref. to ME(SOHC)-60,>

INSTALLATION, Cylinder

Head Assembly.> T2: 5 (0.5, 3.6) T3: 10 (1.0, 7.2) T4: 18 (1.8, 13.0) T5: 25 (2.5, 18.1) T6: 6.4 (0.65, 4.7)

3. VALVE ROCKER ASSEMBLY

S153001A0503

for_01-434.jpg

(1)    Intake valve rocker arm

(2)    Valve rocker nut

(3)    Valve rocker adjust screw

(4)    Spring

(5)    Rocker shaft support

(6)    Intake rocker shaft

(7)    Exhaust rocker shaft

(8)    Exhaust valve rocker arm

Tightening torque: N-m (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 10 (1.0, 7.2) T3: 25 (2.5, 18.1)

4. CYLINDER HEAD AND VALVE ASSEMBLY

S153001A0504

for_01-435.jpg

(1)    Exhaust valve

(2)    Intake valve

(3)    Intake valve guide

(4)    Intake valve spring seat

(5)    Intake valve oil seal

(6)    Valve spring

(7)    Retainer

(8)    Retainer key

(9)    Exhaust valve guide

(10)  Exhaust valve spring seat

(11)  Exhaust valve oil seal

5. CYLINDER BLOCK

S153001A0505

for_01-436.jpg

(1)    Oil pressure switch

(2)    Cylinder block (RH)

(3)    Service hole plug

(4)    Gasket

(5)    Oil separator cover

(6)    Water by-pass pipe

(7)    Oil pump

(8)    Front oil seal

(9)    Rear oil seal

(10)  O-ring

(11)  Service hole cover

(12)  Cylinder block (LH)

(13)  Water pump

(14)  Baffle plate

(15)  Oil filter connector

(16)  Oil strainer

(17)  Gasket

(18)  Oil pan

(19)  Drain plug

(20)  Metal gasket

(21)  Oil level gauge guide

(22)  Water pump sealing

(23)  Oil filter

(24)  Gasket

(25)  Water pump hose

Tightening torque: N-m (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7) T4: 25 (2.5, 18.1) T5: 47 (4.8, 34.7) T6: 69 (7.0, 50.6) T7: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7) T8: 16 (1.6, 11.6) T9: 44 (4.5, 33) T10: 25 (2.5, 18.1)

6. CRANKSHAFT AND PISTON

S153001A0506

for_01-437.jpg

B2M3429A

(1)

Flywheel (MT)

(9) Circlip

(2)

Reinforcement (AT)

(10) Connecting rod bolt

(3)

Drive plate (AT)

(11) Connecting rod

(4)

Top ring

(12) Connecting rod bearing

(5)

Second ring

(13) Connecting rod cap

(6)

Oil ring

(14) Crankshaft

(7)

Piston

(15) Woodruff key

(8)

Piston pin

(16) Crankshaft bearing #1, #3

(17)  Crankshaft bearing #2, #4

(18)  Crankshaft bearing #5

Tightening torque: N-m (kgf-m, ft-lb) T1: 44.6 (4.55, 32.9) T2: 72 (7.3, 52.8)

7. ENGINE MOUNTING

S153001A0507

for_01-438.jpg

(1)    Front cushion rubber

(2)    Front engine mounting bracket

C: CAUTION

S153001A03

Wear working clothing, including a cap, protective goggles, and protective shoes during operation.

-   Remove contamination including dirt and corrosion before removal, installation or disassembly.

-   Keep the disassembled parts in order and protect them from dust or dirt.

-   Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.

-   Be careful not to burn your hands, because each part in the vehicle is hot after running.

-   Be sure to tighten fasteners including bolts and nuts to the specified torque.

-   Place shop jacks or safety stands at the specified points.

-   Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.

Tightening torque: N-m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.2, 31.0) T3: 85(8.7, 63)

All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings.

-   Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.

-   Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel.

-  All removed parts, if to be reused, should be reinstalled in the original positions and directions.

-   Bolts, nuts and washers should be replaced with new ones as required.

-   Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks.

-   Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use.

-   Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.

-   Prior to starting work, prepare the following:

Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.

- Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

D: PREPARATION TOOL 1. SPECIAL TOOLS

S153001A17

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-439.jpg

498267800

CYLINDER HEAD TABLE

-  Used for replacing valve guides.

-  Used for removing and installing valve springs.

B2M3850

for_01-440.jpg

498457000

ENGINE STAND ADAPTER RH

Used with ENGINE STAND (499817000).

B2M3851

for_01-441.jpg

498457100

ENGINE STAND ADAPTER LH

Used with ENGINE STAND (499817000).

B2M3852

for_01-442.jpg

498497100

CRANKSHAFT STOPPER

Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.

B2M3853

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-443.jpg

498747100

PISTON GUIDE

Used for installing piston in cylinder.

B2M3854

for_01-444.jpg

498857100

VALVE OIL SEAL GUIDE

Used for press-fitting of intake and exhaust valve guide oil seals.

B2M3855

for_01-445.jpg

499017100

PISTON PIN GUIDE

Used for installing piston pin, piston and connecting rod.

B2M3856

for_01-446.jpg

499037100

CONNECTING ROD BUSHING REMOVER & INSTALLER

Used for removing and installing connecting rod bushing.

B2M3857

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-447.jpg

499097700

PISTON PIN

REMOVER

ASSY

Used for removing piston pin.

B2M3858

for_01-448.jpg

499207100

CAMSHAFT SPROCKET WRENCH

Used for removing and installing camshaft sprocket. (LH side)

B2M3859

for_01-449.jpg

499207400

CAMSHAFT SPROCKET WRENCH

Used for removing and installing camshaft sprocket. (RH side)

B2M4158

for_01-450.jpg

499587700

CAMSHAFT OIL

SEAL

INSTALLER

Used for installing cylinder head plug.

B2M3860

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-451.jpg

499587200

CRANKSHAFT OIL SEAL INSTALLER

-  Used for installing crankshaft oil seal.

-  Used with CRANKSHAFT OIL SEAL GUIDE (499597100).

B2M3861

for_01-452.jpg

499597000

OIL SEAL GUIDE

-  Used for installing camshaft oil seal.

-  Used with CAMSHAFT OIL SEAL INSTALLER (499587100).

B2M3862

for_01-453.jpg

499597100

CRANKSHAFT OIL SEAL GUIDE

-  Used for installing crankshaft oil seal.

-  Used with CRANKSHAFT OIL SEAL INSTALLER (499587200).

B2M3863

for_01-454.jpg

499718000

VALVE SPRING REMOVER

Used for removing and installing valve spring.

B2M3864

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-455.jpg

499767700

(Intake side)

499767800

(Exhaust side)

VALVE GUIDE ADJUSTER

Used for installing valve guides.

B2M3865

for_01-456.jpg

499767200

VALVE GUIDE REMOVER

Used for removing valve guides.

B2M3867

for_01-457.jpg

499767400

VALVE GUIDE REAMER

Used for reaming valve guides.

B2M3868

for_01-458.jpg

499817100

ENGINE STAND

-  Stand used for engine disassembly and assembly.

-  Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).

B2M3869

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-459.jpg

499977300

CRANK PULLEY WRENCH

Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts.

B2M4157

for_01-460.jpg

499987500

CRANKSHAFT SOCKET

Used for rotating crankshaft.

B2M3871

for_01-461.jpg

498547000

OIL FILTER WRENCH

Used for removing and installing oil filter.

B2M3872

for_01-462.jpg

499497000

TORX PLUS

Used for removing and installing camshaft cap.

B2M3873

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-463.jpg

499587500

OIL SEAL INSTALLER

Used for installing front camshaft oil seal.

B2M3874

for_01-464.jpg

499587100

OIL SEAL INSTALLER

Used for installing oil pump oil seal.

B2M3875

for_01-465.jpg

498277200

STOPPER SET

Used for installing automatic transmission assembly to engine.

B3M2043

for_01-466.jpg

24082AA150

(Newly adopted

tool)

CARTRIDGE

Troubleshooting for electrical systems.

B2M3876

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

for_01-467.jpg

22771AA030

SELECT MONITOR KIT

Troubleshooting for electrical systems.

-  English: 22771AA030 (Without printer)

-  German: 22771AA070 (Without printer)

-  French: 22771AA080 (Without printer)

-  Spanish: 22771AA090 (Without printer)

B2M3877

2. GENERAL PURPOSE TOOLS

S153001A1702

TOOL NAME

REMARKS

Compression Gauge

Used for measuring compression.

Tachometer (Secondary pick-up type)

Used for measuring idle speed.

Timing Light

Used for measuring ignition timing.

E: PROCEDURE

S153001E45

It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle.

-  V-belt

-  Timing Belt

-  Valve Rocker Assembly

-  Camshaft

-  Cylinder Head