1. General Description
S153001
A: SPECIFICATIONS
S153001E49
Engine |
Type |
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine |
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Valve arrangement |
Belt driven, single over-head camshaft, 4-valve/cylinder |
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Bore x Stroke mm (in) |
92 x 75 (3.62 x 2.95) |
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Displacement cm3 (cu in) |
1,994(121.67) |
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Compression ratio |
10.0 |
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Compression pressure (at 200 - 300 kPa (kg/cm2, psi) rpm) |
1,020 - 1,275 (10.4 - 13.0, 148 - 185) |
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Number of piston rings |
Pressure ring: 2, Oil ring: 1 |
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Intake valve timing |
Opening |
4° BTDC |
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Closing |
48° ABDC |
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Exhaust valve timing |
Opening |
48° BBDC |
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Closing |
4° ATDC |
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Valve clearance |
Intake mm (in) |
0.20±0.02 (0.0079±0.0008) |
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Exhaust mm (in) |
0.25±0.02 (0.0098±0.0008) |
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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) |
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Without OBD |
MT: 650±100 (No load) AT: 675±100 (No load) 800±100 (A/C switch ON) |
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Firing order |
1 → 3 → 2 → 4 |
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Ignition timing BTDC/rpm |
With OBD |
10°±1 0°/700 |
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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) |
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Tensioner bush I.D. |
18.00 - 18.08 mm (0.7087 - 0.7118 in) |
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Clearance between spacer and bush |
STD |
0.025 - 0.125 mm (0.0010 - 0.0049 in) |
|
Limit |
0.175 mm (0.0069 in) |
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Side clearance of spacer |
STD |
0.20 - 0.55 mm (0.0079 - 0.0217 in) |
|
Limit |
0.81 mm (0.0319 in) |
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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) |
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Thrust clearance |
STD |
0.030 - 0.090 mm (0.0012 - 0.0035 in) |
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Limit |
0.11 mm (0.0043 in) |
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Cam lobe height |
Intake |
STD |
38.732 - 38.832 mm (1.5249 - 1.5288 in) |
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Limit |
38.632 mm (1.5209 in) |
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Exhaust |
STD |
39.257 - 39.357 mm (1.5455 - 1.5495 in) |
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Limit |
39.157 mm (1.5416 in) |
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Camshaft journal O.D. |
31.928 - 31.945 mm (1.2570 - 1.2577 in) |
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Camshaft journal hole I.D. |
32.000 - 32.018 mm (1.2598 - 1.2605 in) |
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Oil clearance |
STD |
0.055 - 0.090 mm (0.0022 - 0.0035 in) |
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Limit |
0.10 mm (0.0039 in) |
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Cylinder head |
Surface warpage limit |
0.05 mm (0.0020 in) |
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Surface grinding limit |
0.1 mm (0.004 in) |
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Standard height |
97.5 mm (3.84 in) |
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Valve set |
Refacing angle |
90° |
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Contacting width |
Intake |
STD |
1.0 mm (0.039 in) |
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Limit |
1.7 mm (0.067 in) |
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Exhaust |
STD |
1.4 mm (0.055 in) |
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Limit |
2.1 mm (0.083 in) |
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Valve guide |
Inner diameter |
6.000 - 6.012 mm (0.2362 - 0.2367 in) |
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Protrusion above head |
Intake |
20.0 - 20.5 mm (0.787 - 0.807 in) |
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Exhaust |
16.5 - 17.0 mm (0.650 - 0.669 in) |
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Valve |
Head edge thickness |
Intake |
STD |
1.0 mm (0.039 in) |
Limit |
0.6 mm (0.024 in) |
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Exhaust |
STD |
1.2 mm (0.047 in) |
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Limit |
0.6 mm (0.024 in) |
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Stem diameter |
Intake |
5.950 - 5.965 mm (0.2343 - 0.2348 in) |
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Exhaust |
5.945 - 5.960 mm(0.2341 - 0.2346 in) |
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Stem oil clearance |
STD |
Intake |
0.035 - 0.062 mm (0.0014 - 0.0024 in) |
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Exhaust |
0.040 - 0.067 mm (0.0016 - 0.0026 in) |
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Limit |
- |
0.15 mm (0.0059 in) |
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Overall length |
Intake |
120.6 mm (4.75 in) |
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Exhaust |
121.7 mm (4.79 in) |
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Valve spring |
Free length |
54.30 mm (2.1378 in) |
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Squareness |
2.5°, 2.4 mm (0.094 in) |
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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) |
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Cylinder block |
Surface warpage limit (mating with cylinder head) |
0.05 mm (0.0020 in) |
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Surface grinding limit |
0.1 mm (0.004 in) |
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Cylinder bore |
STD |
A |
92.005 - 92.015 mm (3.6222 - 3.6226 in) |
|
 |
91.995 - 92.005 mm (3.6218 - 3.6222 in) |
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Taper |
STD |
0.015 mm (0.0006 in) |
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Limit |
0.050 mm (0.0020 in) |
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Out-of-roundness |
STD |
0.010 mm (0.0004 in) |
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Limit |
0.050 mm (0.0020 in) |
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Piston clearance |
STD |
0.010 - 0.030 mm (0.0004 - 0.0012 in) |
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Limit |
0.050 mm (0.0020 in) |
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Enlarging (boring) limit |
0.5 mm (0.020 in) |
Piston |
Outer diameter |
A |
91.985 - 91.995 mm (3.6214 - 3.6218 in) |
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 |
91.975 - 91.985 mm (3.6211 - 3.6214 in) |
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0.25 mm (0.0098 in) OS |
92.225 - 92.235 mm (3.6309 - 3.6313 in) |
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0.50 mm (0.0197 in) OS |
92.475 - 92.485 mm (3.6407 - 3.6411 in) |
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Standard inner diameter of piston pin hole |
23.000 - 23.006 mm (0.9055 - 0.9057 in) |
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Piston pin |
Outer diameter |
22.994 - 23.000 mm (0.9053 - 0.9055 in) |
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Standard clearance between piston pin and ton |
hole |
in pis- |
0.004 - 0.008 mm (0.0002 - 0.0003 in) |
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Degree of fit |
Piston pin must be fitted into position with thumb at 20°C (68°F). |
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Piston ring |
Piston ring gap |
Top ring |
STD |
0.20 - 0.35 mm (0.0079 - 0.0138 in) |
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Limit |
1.0 mm (0.039 in) |
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Second ring |
STD |
0.35 - 0.50 mm (0.0138 - 0.0197 in) |
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Limit |
1.0 mm (0.039 in) |
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Oil ring |
STD |
0.20 - 0.70 mm (0.0079 - 0.0276 in) |
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Limit |
1.5 mm (0.059 in) |
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Clearance |
STD |
0.040 - 0.080 mm (0.0016 - 0.0031 in) |
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between piston |
þð ring |
Limit |
0.15 mm (0.0059 in) |
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ring and piston |
Second |
STD |
0.030 - 0.070 mm (0.0012 - 0.0028 in) |
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ring groove |
ring |
Limit |
0.15 mm (0.0059 in) |
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Connecting |
Bend twist per 100 mm (3.94 in) in length |
Limit |
0.10 mm (0.0039 in) |
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rod |
Side clearance |
STD |
0.070 - 0.330 mm (0.0028 - 0.0130 in) |
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Limit |
0.4 mm (0.016 in) |
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Oil clearance |
STD |
0.010 - 0.038 mm (0.0004 - 0.0015 in) |
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Limit |
0.05 mm (0.0020 in) |
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Connecting |
Thickness at center portion |
STD |
1.492 - 1.501 mm (0.0587 - 0.0591 in) |
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rod bearing |
0.03 mm |
(0.0012 in) US |
1.510 - 1.513 mm (0.0594 - 0.0596 in) |
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0.05 mm |
(0.0020 in) US |
1.520 - 1.523 mm (0.0598 - 0.0600 in) |
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0.25 mm |
(0.0098 in) US |
1.620 - 1.623 mm (0.0638 - 0.0639 in) |
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Connecting |
Clearance between piston pin |
STD |
0 - 0.022 mm (0 - 0.0009 in) |
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rod bushing |
and bushing |
Limit |
0.030 mm (0.0012 in) |
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Crankshaft |
Bend limit |
0.035 mm (0.0014 in) |
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Crank pin and |
Out-of-roundness |
0.020 mm (0.0008 in) or less |
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crank journal |
Grinding limit |
0.250 mm (0.0098 in) |
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Crank pin outer diameter |
STD |
51.984 - 52.000 mm (2.0466 - 2.0472 in) |
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0.03 mm |
(0.0012 in) US |
51.954 - 51.970 mm (2.0454 - 2.0461 in) |
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0.05 mm |
(0.0020 in) US |
51.934 - 51.950 mm (2.0446 - 2.0453 in) |
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0.25 mm |
(0.0098 in) US |
51.734 - 51.750 mm (2.0368 - 2.0374 in) |
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STD |
59.992 - 60.008 mm (2.3619 - 2.3625 in) |
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#1, #3 |
0.03 mm |
(0.0012 in) US |
59.962 - 59.978 mm (2.3607 - 2.3613 in) |
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0.05 mm |
(0.0020 in) US |
59.942 - 59.958 mm (2.3599 - 2.3605 in) |
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Crank journal |
0.25 mm |
(0.0098 in) US |
59.742 - 59.758 mm (2.3520 - 2.3527 in) |
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outer diameter |
STD |
59.992 - 60.008 mm (2.3619 - 2.3625 in) |
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#2, #4, #5 |
0.03 mm |
(0.0012 in) US |
59.962 - 59.978 mm (2.3607 - 2.3613 in) |
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0.05 mm |
(0.0020 in) US |
59.942 - 59.958 mm (2.3599 - 2.3605 in) |
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0.25 mm |
(0.0098 in) US |
59.742 - 59.758 mm (2.3520 - 2.3527 in) |
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Thrust clearance |
STD |
0.030 - 0.115 mm (0.0012 - 0.0045 in) |
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Limit |
0.25 mm (0.0098 in) |
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Oil clearance |
STD |
0.010 - 0.030 mm (0.0004 - 0.0012 in) |
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Limit |
0.040 mm (0.0016 in) |
STD |
|
1.998 - 2.011 mm |
(0.0787 - 0.0792 in) |
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#1, #3 |
0.03 mm |
(0.0012 in) US |
2.017 - 2.020 mm |
(0.0794 - 0.0795 in) |
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0.05 mm |
(0.0020 in) US |
2.027 - 2.030 mm |
(0.0798 - 0.0799 in) |
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Crankshaft |
Crankshaft bear- |
0.25 mm |
(0.0098 in) US |
2.127 - 2.130 mm |
(0.0837 - 0.0839 in) |
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bearing |
ing thickness |
STD |
|
2.000 - 2.013 mm |
(0.0787 - 0.0793 in) |
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#2, #4, #5 |
0.03 mm |
(0.0012 in) US |
2.019 - 2.022 mm |
(0.0795 - 0.0796 in) |
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0.05 mm |
(0.0020 in) US |
2.029 - 2.032 mm |
(0.0799 - 0.0800 in) |
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0.25 mm |
(0.0098 in) US |
2.129 - 2.132 mm |
(0.0838 - 0.0839 in) |
B: COMPONENT
1. TIMING BELT S153001A0501
S153001A05
(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
(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
(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
(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
(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
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
(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
498267800
CYLINDER HEAD TABLE
- Used for replacing valve guides.
- Used for removing and installing valve springs.
B2M3850
498457000
ENGINE STAND ADAPTER RH
Used with ENGINE STAND (499817000).
B2M3851
498457100
ENGINE STAND ADAPTER LH
Used with ENGINE STAND (499817000).
B2M3852
498497100
CRANKSHAFT STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
B2M3853
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498747100
PISTON GUIDE
Used for installing piston in cylinder.
B2M3854
498857100
VALVE OIL SEAL GUIDE
Used for press-fitting of intake and exhaust valve guide oil seals.
B2M3855
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
B2M3856
499037100
CONNECTING ROD BUSHING REMOVER & INSTALLER
Used for removing and installing connecting rod bushing.
B2M3857
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499097700
PISTON PIN
REMOVER
ASSY
Used for removing piston pin.
B2M3858
499207100
CAMSHAFT SPROCKET WRENCH
Used for removing and installing camshaft sprocket. (LH side)
B2M3859
499207400
CAMSHAFT SPROCKET WRENCH
Used for removing and installing camshaft sprocket. (RH side)
B2M4158
499587700
CAMSHAFT OIL
SEAL
INSTALLER
Used for installing cylinder head plug.
B2M3860
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499587200
CRANKSHAFT OIL SEAL INSTALLER
- Used for installing crankshaft oil seal.
- Used with CRANKSHAFT OIL SEAL GUIDE (499597100).
B2M3861
499597000
OIL SEAL GUIDE
- Used for installing camshaft oil seal.
- Used with CAMSHAFT OIL SEAL INSTALLER (499587100).
B2M3862
499597100
CRANKSHAFT OIL SEAL GUIDE
- Used for installing crankshaft oil seal.
- Used with CRANKSHAFT OIL SEAL INSTALLER (499587200).
B2M3863
499718000
VALVE SPRING REMOVER
Used for removing and installing valve spring.
B2M3864
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499767700
(Intake side)
499767800
(Exhaust side)
VALVE GUIDE ADJUSTER
Used for installing valve guides.
B2M3865
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
B2M3867
499767400
VALVE GUIDE REAMER
Used for reaming valve guides.
B2M3868
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
499977300
CRANK PULLEY WRENCH
Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts.
B2M4157
499987500
CRANKSHAFT SOCKET
Used for rotating crankshaft.
B2M3871
498547000
OIL FILTER WRENCH
Used for removing and installing oil filter.
B2M3872
499497000
TORX PLUS
Used for removing and installing camshaft cap.
B2M3873
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499587500
OIL SEAL INSTALLER
Used for installing front camshaft oil seal.
B2M3874
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
B2M3875
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
B3M2043
24082AA150
(Newly adopted
tool)
CARTRIDGE
Troubleshooting for electrical systems.
B2M3876
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
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