GENERAL DESCRIPTION
Mechanical
1. General Description
S183001
S183001E49
A: SPECIFICATIONS
Engine
Type
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement
Belt driven, double overhead camshaft, 4-valve/ cylinder
Bore x Stroke mm (in)
92 x 75 (3.62 x 2.95)
Piston displacement cm3 (cu in)
1,994(121.67)
Compression ratio
8.0
Compression pressure (at 200 300 kPa (kg/cm2, psi) rpm)
981 1,177 (10 12, 142 171)
Number of piston rings
Pressure ring: 2, Oil ring: 1
Intake valve timing
Opening
3 BTDC
Closing
33 ABDC
Exhaust valve timing
Opening
33 BBDC
Closing
3 ATDC
Valve clearance
Intake mm (in)
0.200.02 (0.00790.0008)
Exhaust mm (in)
0.250.02 (0.00980.0008)
Idling speed [At neutral position on MT; "P" or "N" position on AT]
700100 (No load) 800150 (A/C switch ON)
Firing order
1 - 3 - 2 - 4
Ignition timing BTDC/rpm
1210/700 rpm
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter
OS: Oversize US: Undersize
ME(DOHC TURBO)-2
GENERAL DESCRIPTION
Mechanical
Belt tension 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.
18.0 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
0.2 0.55 mm (0.0079 0.0217 in)
Limit
0.81 mm (0.0319 in)
Camshaft
Bend limit
0.020 mm (0.0079 in)
Thrust clearance
STD
0.015 0.070 mm (0.0006 0.0028 in)
Limit
0.10 mm (0.0039 in)
Cam lobe height
Intake
STD
44.75 44.85 mm (1.7618 1.7657 in)
Limit
44.65 mm (1.759 in)
Exhaust
STD
44.60 44.70 mm (1.7559 1.7598 in)
Limit
44.50 mm (1.7520 in)
Jounal O.D.
STD
Front
37.946 37.963 mm (1.4939 1.4946 in)
Center rear
29.946 29.963 mm (1.1790 1.1796 in)
Oil clearance
STD
0.037 0.072 mm (0.0015 0.0028 in)
Limit
0.10 mm (0.0039 in)
Cylinder head
Surface warpage limit
0.05 mm (0.0020 in)
Surface grinding limit
0.3 mm (0.012 in)
Standard height
127.5 mm (5.02 in)
Valve seat
Refacing angle
90
Contacting width
Intake
STD
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
STD
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
Valve guide
Inner diameter
6.000 6.015 mm (0.2362 0.2368 in)
Protrusion above head
12.0 12.4 mm (0.472 0.488 in)
Valve
Head edge thickness
Intake
STD
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
STD
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Stem diameter
Intake
5.950 5.965 mm (0.2343 0.2348 in)
Exhaust
5.950 5.965 mm(0.2343 0.2348 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
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)
Valve spring
Free length
44.67 mm (1.7587 in)
Squareness
2.5, 2.0 mm (0.079 in)
Tension/spring height
220.715.7 N (22.51.6 kgf, 49.63.5 lb)/36.0 mm (1.417 in) 510.925.5 N (52.12.6 kgf, 114.95.7 lb)/26.6 mm (1.0.47 in)
ME(DOHC TURBO)-3
GENERAL DESCRIPTION
Mechanical
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)
?
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
STD
A
91.985 91.995 mm (3.6214 3.6218 in)
?
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)
Piston pin
Standard clearance between piston pin and hole in piston
STD
0.004 0.008 mm (0.0002 0.0003 in)
Limit
0.020 mm (0.0008 in)
Degree of fit
Piston pin must be fitted into position with thumb at 20C (68F).
Piston ring
Piston ring gap
Top ring
STD
0.20 0.26 mm (0.0079 0.0102 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 between piston ring and piston ring groove
Top ring
STD
0.040 0.080 mm (0.0016 0.0031 in)
Limit
0.15 mm (0.0059 in)
Second ring
STD
0.030 0.070 mm (0.0012 0.0028 in)
Limit
0.15 mm (0.0059 in)
Connecting rod
Bend twist per 100 mm (3.94 in) in length
Limit
0.10 mm (0.0039 in)
Side clearance
STD
0.070 0.330 mm (0.0028 0.0130 in)
Limit
0.4 mm (0.016 in)
Connecting rod bearing
Oil clearance
STD
0.020 0.046 mm (0.0008 0.0018 in)
Limit
0.05 mm (0.0020 in)
Thickness at center portion
STD
1.492 1.501 mm (0.0587 0.0591 in)
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 rod bushing
Clearance between piston pin and bushing
STD
0 0.022 mm (0 0.0009 in)
Limit
0.030 mm (0.0012 in)
ME(DOHC TURBO)-4
GENERAL DESCRIPTION
Mechanical
Bend limit
0.035 mm (0.0014 in)
Crank pin and crank journal
Out-of-roundness
0.020 mm (0.0008 in) or less
Grinding limit
0.25 mm (0.0098 in)
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)
Crank pin outer diameter
0.05 mm (0.0020 in) US
51.934 51.950 mm (2.0466 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)
0.03 mm (0.0012 in) US
59.962 59.978 mm (2.3607 2.3613 in)
Crankshaft
#1, #3, #5
0.05 mm (0.0020 in) US
59.942 59.958 mm (2.3599 2.3605 in)
Crank journal outer diameter
0.25 mm (0.0098 in) US
59.742 59.758 mm (2.3520 2.3527 in)
59.992 60.008 mm (2.3619 2.3625 in)
STD
0.03 mm (0.0012 in) US
59.962 59.978 mm (2.3607 2.3613 in)
#2, #4
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)
0.03 mm (0.0012 in) US
2.017 2.020 mm (0.0794 0.0795 in)
#1,#3
0.05 mm (0.0020 in) US
2.027 2.030 mm (0.0798 0.0799 in)
Crankshaft bearing
Crankshaft bearing thickness
0.25 mm (0.0098 in) US
2.127 2.130 mm (0.0837 0.0839 in)
2.000 2.013 mm (0.0787 0.0793 in)
STD
0.03 mm (0.0012 in) US
2.019 2.022 mm (0.0795 0.0796 in)
#2, #4, #5
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)
ME(DOHC TURBO)-5
GENERAL DESCRIPTION
Mechanical
MEMO:
ME(DOHC TURBO)-6
GENERAL DESCRIPTION
Mechanical
B: COMPONENT
S183001A05
1. TIMING BELT S183001A0501
for_01_22-309.jpg
(1)
Right-hand belt cover No. 2
(9) Right-hand intake camshaft
(17) Right-hand belt cover
(2)
Timing belt guide (MT vehicles
sprocket
(18) Crankshaft pulley
only)
(10) Left-hand intake camshaft
(3)
Crankshaft sprocket
sprocket
Tightening torque: N-m (kgf-m, ft-lb)
(4)
Left-hand belt cover No. 2
(11) Left-hand exhaust camshaft
T1: 5 (0.5, 3.6)
(5)
Tensioner bracket
sprocket
T2: 10 (1.0, 7)
(6)
Automatic belt tension adjuster
(12) Timing belt
T3: 25 (2.5, 18.1)
ASSY
(13) Belt idler No. 2
T4: 39 (4.0, 28.9)
(7)
Belt idler
(14) Belt idler
T5: 98 (10, 72.4)
(8)
Right-hand exhaust camshaft
(15) Left-hand belt cover
T6: 127 (13, 94.0)
sprocket
(16) Front belt cover
ME(DOHC TURBO)-7
GENERAL DESCRIPTION
Mechanical
2. CYLINDER HEAD AND CAMSHAFT
S183001A0502
for_01_22-310.jpg
S2M1188A
ME(DOHC TURBO)-8
GENERAL DESCRIPTION
Mechanical
(1)    Rocker cover (RH)
(2)    Rocker cover gasket (RH)
(3)    Oil separator cover
(4)    Gasket
(5)    Intake camshaft cap (Front RH)
(6)    Intake camshaft cap (Center RH)
(7)    Intake camshaft cap (Rear RH)
(8)    Intake camshaft (RH)
(9)    Exhaust camshaft cap (Front RH)
(10)  Exhaust camshaft cap (Center RH)
(11)  Exhaust camshaft cap (Rear RH)
(12)  Exhaust camshaft (RH)
(13)  Cylinder head bolt
(14)  Oil seal
(15)  Cylinder head (RH)
(16)  Cylinder head gasket (RH)
(17)  Cylinder head gasket (LH)
(18)  Cylinder head (LH)
(19)  Intake camshaft (LH)
(20)  Exhaust camshaft (LH)
(21)  Intake camshaft cap (Front LH)
(22)  Intake camshaft cap (Center LH)
(23)  Intake camshaft cap (Rear LH)
(24)  Exhaust camshaft (Front LH)
(25)  Exhaust camshaft cap (Center LH)
(26)  Exhaust camshaft cap (Rear LH)
(27)  Rocker cover gasket (LH)
(28)  Rocker cover (LH)
(29)  Oil filler cap
(30)  Gasket
(31)  Oil filler duct
(32)  O-ring
(33)  Stud bolt
Tightening torque: N-m (kgf-m, ft-lb) T1: <Ref. to ME(DOHC TURBO)-
63, INSTALLATION, Cylinder
Head Assembly.> T2: 5 (0.5, 3.6) T3: 10 (1.0, 7) T4: 6.4 (0.65, 4.7)
ME(DOHC TURBO)-9
GENERAL DESCRIPTION
Mechanical
3. CYLINDER HEAD AND VALVE ASSEMBLY
S183001A0503
for_01_22-311.jpg
(1)    Exhaust valve
(2)    Intake valve
(3)    Cylinder head
(4)    Valve spring seat
(5)    Intake valve oil seal
(6)    Valve spring
(7)    Retainer
(8)    Retainer key
(9)    Valve lifter
(10)  Shim
(11)  Exhaust valve oil seal
(12)  Intake valve guide
(13)  Exhaust valve guide
ME(DOHC TURBO)-10
GENERAL DESCRIPTION
Mechanical
4. CYLINDER BLOCK
S183001A0504
for_01_22-312.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 cooler
(16)  Waster by-pass pipe
(17)  Connector
(18)  Oil strainer
(19)  Gasket
(20)  Oil pan
(21)  Drain plug
(22)  Metal gasket
(23)  Oil level gauge guide
(24)  Oil filter
(25)  Gasket
(26)  Water pump hose
(27)  Plug
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) T11: 55 (5.5, 40)
ME(DOHC TURBO)-11
GENERAL DESCRIPTION
Mechanical
5. CRANKSHAFT AND PISTON
S183001A0505
for_01_22-313.jpg
(1)
Flywheel (MT vehicles only)
(9)
Piston pin
(2)
Ball bearing (MT vehicles only)
(10)
Circlip
(3)
Reinforcement (AT vehicles only)
(11)
Connecting rod
bolt
(4)
Drive plate (AT vehicles only)
(12)
Connecting rod
(5)
Top ring
(13)
Connecting rod
bearing
(6)
Second ring
(14)
Connecting rod
cap
(7)
Oil ring
(15)
Crankshaft
(8)
Piston
(16)
Woodruff key
(17)  Crankshaft bearing #1, #3
(18)  Crankshaft bearing #2, #4
(19)  Crankshaft bearing #5
Tightening torque: N-m (kgf-m, ft-lb) T1: 44.6 (4.55, 32.9) T2: 72 (7.3, 52.8)
ME(DOHC TURBO)-12
GENERAL DESCRIPTION
Mechanical
6. ENGINE MOUNTING
S183001A0506
for_01_22-314.jpg
(1)    Hear shield cover
(2)    Front cushion rubber
(3)    Front engine mounting bracket
Tightening torque: N-m (kgf-m, ft-lb)
T1:
35
(3.6,
25.8)
T2:
42
(4.3,
30.9)
T3:
85
(8.7,
62.7)
ME(DOHC TURBO)-13
GENERAL DESCRIPTION
Mechanical
C: CAUTION
S183001A03
   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.
  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.
  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.
D: PREPARATION TOOL
S183001A17
1. SPECIAL TOOLS
S183001A1701
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
EN0147
498267600
CYLINDER HEAD TABLE
Used for replacing valve guides. Used for removing and installing valve springs.
B2M3851
498457000
ENGINE STAND ADAPTER RH
Used with ENGINE STAND (499817000).
ME(DOHCTURBO)-14
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-315.jpg
498457100
ENGINE STAND ADAPTER LH
Used with ENGINE STAND (499817000).
B2M3852
for_01_22-316.jpg
498497100
CRANKSHAFT STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
B2M3853
for_01_22-317.jpg
498277200
STOPPER SET
Used for removing and installing automatic transmission assembly to engine
B3M2043
for_01_22-318.jpg
398744300
PISTON GUIDE
Used for installing piston in cylinder.
B2M3854
ME(DOHCTURBO)-15
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-319.jpg
498857100
VALVE OIL SEAL GUIDE
Used for press-fitting of intake and exhaust valve guide oil seals.
B2M3855
for_01_22-320.jpg
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
B2M3856
for_01_22-321.jpg
499037100
CONNECTING ROD BUSHING REMOVER & INSTALLER
Used for removing and installing connecting rod bushing.
B2M3857
for_01_22-322.jpg
499097700
PISTON PIN REMOVER ASSY
Used for removing piston pin.
B2M3858
ME(DOHC TURBO)-16
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-323.jpg
499207400
CAMSHAFT SPROCKET WRENCH
Used for removing and installing camshaft sprocket.
B2M4158
for_01_22-324.jpg
499587700
CAMSHAFT OIL SEAL INSTALLER
Used for installing cylinder head plug.
B2M3860
for_01_22-325.jpg
499587200
CRANKSHAFT OIL SEAL INSTALLER
  Used for installing crankshaft oil seal.
  Used with CRANKSHAFT OIL SEAL GUIDE (499597100).
B2M3861
for_01_22-326.jpg
499597100
CRANKSHAFT OIL SEAL GUIDE
  Used for installing crankshaft oil seal.
  Used with CRANKSHAFT OIL SEAL INSTALLER (499587200).
B2M3863
ME(DOHC TURBO)-17
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-327.jpg
499718000
VALVE SPRING REMOVER
Used for removing and installing valve spring.
B2M3864
for_01_22-328.jpg
498267700
VALVE GUIDE ADJUSTER
Used for installing intake and exhaust valve guides.
B2M3865
for_01_22-329.jpg
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
B2M3867
for_01_22-330.jpg
499767400
VALVE GUIDE REAMER
Used for reaming valve guides.
B2M3868
ME(DOHC TURBO)-18
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-331.jpg
499817000
ENGINE STAND
  Stand used for engine disassembly and assembly.
  Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).
B2M3869
for_01_22-332.jpg
499977300
CRANK PULLEY WRENCH
Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts.
B2M4157
for_01_22-333.jpg
499987500
CRANKSHAFT SOCKET
Used for rotating crankshaft.
B2M3871
for_01_22-334.jpg
498547000
OIL FILTER WRENCH
Used for removing and installing oil filter.
B2M3872
ME(DOHC TURBO)-19
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-335.jpg
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
B2M3875
for_01_22-336.jpg
499587600
OIL SEAL GUIDE
Used for installing camshaft oil seal.
499597200
OIL SEAL GUIDE
Used for installing camshaft oil seal. Used with OIL SEAL GUIDE (499587600).
EN0168
for_01_22-337.jpg
49818200
SHIM REPLACER
Used for correct valve clearance.
EN0169
ME(DOHC TURBO)-20
GENERAL DESCRIPTION
Mechanical
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
for_01_22-338.jpg
24082AA150 (Newly adopted tool)
CARTRIDGE
Troubleshooting for electrical systems.
B2M3876
for_01_22-339.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
S183001A1702
TOOL NAME
REMARKS
Compression Gauge
Used for measuring compression.
Timing Light
Used for measuring ignition timing.
E: PROCEDURE
S183001E45
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
  Camshaft
  Cylinder Head
ME(DOHC TURBO)-21