EM-2 Engine MechanicalSystem

General lnformation
Speclflcations
Oeocñptlon Specllicatiofl Umit

Ge-• ln-line.OOHC
T}'Pe

Number of cylinders 4
Bore n.o nm (2.8346in)
St!oke 84.0 nm (3.3070in)
Total displacement 1.368 ce (83.48 cuJn)
Compression ratio 10.5 :1
Fwingorder 1-3-4-2
Valw timing
lntake vatve Opens ATDC 10• -BTOC 40•

lntake vatve Closes ABDC 66.6 -ABOC 1s.s•

Exhaust valve Opens BBDC 52.4• -BBOC 12.4•

Exhaust valve Closes ATDC 3• - BTOC 37•

C)1inder heed
Less than 0.05 mm(0.0025in)
Flatness of gasket surfa<:e
Less than 002 mm(0.0008in) / 100 x 100

Flatness of manifold lntake Less than 0.1mm (0.0039in)

moootlng suñace EXhaust Less than 0.1mm (0.0039in)

Camol\aft

Camheight
lntake 36.4183 mm (1.4337in) -
.,.
,

."!e ·. .; '
EXhaust 36.1543 mm (1.4233in) _:..:: :.

Jouma& outer Oiameter

lntake/Exhaust
No.1
36.464 - 36.478 mm (1.4355 - 1.4361in)
: . .·.:·
ln•ake/Exhaust -.._"";-;:·C "

.-..
22.964 - 22.978 mm (0.9040- 0.9046 in),- .'
No.2-5
- <

v... ,...., .
.. 100.94 mm (39740;n}""
Val'Ve length
lntal<e
EXhaust 101.09 mm (39799 in)
: ..
lntake 5.465- 5.480 mm (0.2151 -0.2157 in)
Stem outer diameter
Exhaust 5.448- 5.460 mm (0.2144 -0.2149 in)
Faoe angle

Thickness of valva he- lntake 1.35- 1.65 mm (0.0531 -0.0649 in)

ad (ma<gin) Exhaust 1.60- 1.90 mm (0.0629 - 0.0748 in)
General lnformation EM-3
Umlt
Valva stem to va1ve g-,_ 1_,,._ak_• _ o ._0_20-
_o_.047_nm (_o_.000_8_- o._0_01_8_5_in_) _, _,
uide clearance Exhaust 0.040- 0.064 mn (0.00157 -OJXl251 In)
Valve op<ing
Freelength
47.9 mm {1.8858 in)

load 16.7 ± 0.8kg/ 35.5mm (164 ± SN /

1.3976 fn)
Out oí 29.6 ± 1.0 kg / 27.7 mm (290 ± 10N l
squareness 1.0905in)

Cytind&r bore 72.00 - 72.03 mm (2.8346- 2.8'358 in}

lessthan 0.05 mm (0.0020in)

Aatness of gasket suñace less than 0.02 mm (0.0008 in) / 100 x 100

Piston outer diameter

71.97 - 72.00 mm (2.8334 - 2.8346in)
Piston to cyl nder
0.02 -0.04 nm (0.0008 -0.0016 in)
clearance
1.03 - 1.05nm (0.0405 -0.0413in)
No.1ring groove

R. ing groove Width No .2 ringgroove 1.23 - 1.25nm (0.0484 - 0.0492 in)

Oilringgroove 2.010 -2.025 mm (0.0791 -0.0797 in}

No. 0.04 -0.08 nm (0.0015 -0.0031 in)

Side 1ring 0.04 -0.08 nm (0.0015 -0.0031 in)
clearanoe
No. 2 0.040 -0.115 mm {0.0015-0.0045in)
ring Oil
ring
No. 1ring 0.13-0.25 mm (0.0051 - 0.00.98in)
End gap No. 2 ring 0.30 -0.45 nm (0.0118 -0.0177 in)
Oil ring 0.1-0.4 mm (0.0039- 0.0157 in) ·. ...
Piaton pin .:.. '; -
- ·-
Piston pi_n outer diameter
18.000 - 18.003nm (0.7086- 0.7087 In)..• :-f'
Piston pln hole nner
diametec
''"-·'··
18.013 - 18.017""'(0.7092 -0.709.3 ;f.._ .
Piston pin hole clearanoe 0.010-0.017 nm (0.00039-. óÍil67 in) .,
Connecting rod small end hole inner
di Comecli.ng rod bigend inner diameter
eter
COMecli:ngrodbeañng oilclearanc:e
Comecting rodsmall end hofe

clearance Piston pin press-inload

 mm
17.974 - (0.00059- 0.00114 in)
17.985n
m 250 - 1050 kg (551- 2315lb)
(0.7076-
-0.7474
in) 42..000- 42 018 mm (16535-1.6542
in)
-0.015 0.018 -0.036 mm (0.0007 -0.0014
--0.029 in)
EM-4 Engine Mechani cal System
Deocrlptlon Specllic:ation Umit
Side dearance 0.1-0.25 mm(0.0039 -0.0098 in}
Ctanbhaft
Maln joumal outer diameter 42.942 -42.960 mm (1.6906-1.6913in)
Pinjoumal outer diameter 38.954 - 38.972 mm (1.5336-1.5343in)
Mainbearing oil clearance 0.006 -0.024 mm {0.0002-0.0009 in)
End play 0.05 -0.25 mm (0.0019-0.0098 in)
Oll pump
lnner rotor 0.040- 0.090 nm (0.0016 -00035 in)
Side olearance
Outer rotor 0.040- 0.090 nm (0.0016 -0.0035 in)
Free ength 58.3 nm (2.2952 in)
Relief spring
load 3.5bar ±0 5
Engina oil
When replacing
a 6hort englne
TOlal 3.8 l (4.01 US qt.3.34 lmp qt)
o
r a block assem-
Oil quantity
bly
Oil pan 3.3 l (3.48 US qt.2.90 lmp qt)
lncluding
Oraínand refill 3.5l (3.70 us qt, 308 lmp q1)
oilfilte r

1f not available,
refer to the reoo
Recommendation
mmended APIor
(except Middle E 5W-20 / GF4 & SM
ILSAC clas&lfic--
ast)
ation and SAE v
isoosíty numbe!, {
Oil grade
Satisfy tt-.
APIS ,SM or above
ClassJfication iret ihe A
tlSAC GF3.GF4 or above
. . isjqca tion.
.,-:- · (.tÓ Üie "lu-
SAE viscosity gr
·
ade Recommended SAE visoos ty numbe.
·:·
.. :,.bl;:&itic.n.Syst
. _-.,, em
00 temperature
--' inolpan:110 ±
Oil pressure (at 1000rpm) 0.9 bar or above
2•c (230 ±
3.6°F
Cooling method )

Cooling system Forced drcu:lation wfth water pump

MT :5.0 l(1.32 U.S.gal..528 U.S.qt.,4.39

Coofant quantity lmp.qt.)
AT, CVT :5.1 l{1.35 U.S.9al.,5.39 U.S.qt.4.49
General lnformation EM-5
Deoctlptian Spedflcation Umlt
Type Wax peOet type

Opening
88 ± 1.S'C (190.4 ± 2.7'F)
Thermootat temperatura
Fu11 opening
1oo•c (212'FJ
temperatura

Mainvalve opeÑ 93.16 - 122.58 kpa

ng pressure (0.95 - 1.25 kglcm', 13.51 - 17.78 psi)
Radimorcap
Vacuum valve o- 0.98- 4.90 kPa
perting pressure (0.01 - 0.05 k!>'cm'. 0.14 - 0.71 psi)
WatM temperatura eenaor
Type TherrnistOf type
20'C(68'F) 2.45 ± 0.14 kn
Resistance
eo•c (176'F) 0.3222 kn

\ -,. .s-:::
.,_;::;_::_:.
EM-6 Engine MechanicalSystem
Tighlening Ton¡ues
ltem Quantlty N.m lcgf.m tl>-ft
cyl nder block
Ladcler frame bolt 10 19.6 -23.5 2.0 - 2.4 14.5 - 17.4
Engina mounting
Engine mounting bracket and body fixing btot 3 49.0 -63.7 5.0- 6.5 36.1-47.0
Englne mounling insulator to engine mounting
1 63.7- 63.3 6.5- 8.5 47.0 -61.5
support bracket fixing nut

Englne mounting support bracket and engine 1

49.0 -63.7 5.0- 6.5 36.1 -47.0
support bracket fixing bolt
Engine mounUng support brac:ket and eng ne 2
49.0 -63.7 5.0- 6.5 36.1 -47.0
support bracket fixingout
Tran'&axle mounting bracket end body fixing 3
49.0 -63.7 5.0- 6.5 36.1 -47.0
I> olt
Tran'6axle mounting nsu:lator and t:ransaxfe su- 2 88.3- 107.9 9.0 -11.0 47.0 -61.5
pport bracket fixingbolt
Roll rodbrac:ket and subframe fixing boJt 1 49.0 -63.7 5.0- 6.5 36.1-47.0
Rear ron stopper bracket and roH rod support 1
107.9 - 11.0 - 13.0 79.6 -94.0
bracket bott
12.75
Mail\ movlng aystem

Connedlng rodbea.ring cap bott

8 (10.8 - 14.7] + (1.1 - 1.5] + (88 (8.0 - 10.8) +
(88 - (88 -
- 92º) 92') 92']
10. 117.7 -21.6)+ (88 (1.8 - 2.2) + (88 (13.0 - 15.9) +
Crankshaft main beañng cap bott (88
- 92'] -
92') - 92•1
Fly wtiee4 bolt (M/Tj 6 68.6 - 78.5 7.0- 8.0 50.6 - 57.9
Orive plate boh (AIT) 6 68.6 - 78.5 7.0- 8.0 50.6 - 57.9 - {
Timingd'lain -;:.:
Tmingchai:n cover bolt (A) 6 18.6 -23.5 1.9-2.4 ., r;.. 7.4
Tlmingchain oover bolt (8) 3 44.1-53.9 4.5- 5.5 e, '·32 7,39.8
Tming chain cover bolt (C) 8 9.8- 11.8 1.0- J. :.:...'.·r2 - a.1
Tming chain cowr bolt {O) 1 18.6 -23.5 :;:.·
1·'!'?;:i.4 13.7 - 17.4
-._. ,;
1 (55.9-61.8) + (39 1a,;o::::.3J + (38 (41.2 -45.5] + (39
Crankshaft pulley bo(t
- 42'] - - 42•1
42']
cvvr bol• 2 63.7 - 73.5 6.5- 7.5 47.0 - 54.2
Tming chatn teosioner bott 2 9.8-11.8 1.0 - 1.2 7.2 -8.7
Tming chain cam guida boh 2 9.8-11.8 1.0- 1.2 7.2 - 8.7
Tlmingchain craM guida bolt 2 9.8-11.8 1.0-1.2 7.2 -8.7
Tming chain teosionec ann bolt 1 9.8- 11.8 1.0- 1.2 7.2 - 8.7
Tming chain guida bolt 2 18.6 -21.6 1.9-2.2 13.7 - 15.9
General lnformation EM-7
,,_ N.m kgf.tn lb-ft
Cytlnder hNd
C)tinder head cover bott 16 (3.9 -5.9) - [0.4- 0.6)- [2.9 -4.3) -
[7.8 -9.8) [0.8 - 1.0) [5.8- 7.2)
Camshaft beari:ng cap boh 16 [5.9) - [11.8 - [0.6) - [1.2 - [4.3) - [8.7
13. 1.4) -10.1)
7)
Camshafl front bearing cap bolt 3 [9.8) • [18.6 - [1.0J • [1 9 - [7.2) • [13.7 -
22. 6) 2.3) 16. 6)
[12.7- 16.7) + [1.3- 1.7]+ [90- [9.4- 12.3)+
Cylinder head bolt 10 -951 + [12() - 95') + [120- 125 95') + [12() -
5') ) 125')
OCV boh 2 9.8- 11.8 1.0- 1.2 7.2- 8.7
Coollng syetem
Water pump pulley bott 4 9.8- 118 1.0 - 1.2 7.2- 8.7
Water pump boh 3 9.8- 11.8 1.0- 1.2 7.2- 8.7
Heater pipe bott & nut 2 19.6 - 26.5 2.0 - 2.7 14.5 - 19.5
Thermoestat hous.ing boit & nul 3 9.8- 118 1.0 - 1.2 7.2- 8.7
Water intet fitling boft & nut 2 18.6 - 23.5 1.9 -2.4 13.7 - 17.3
Lubrication ayatem
011 filler 1 11.8 -15.7 1.2 - 1.6 8.7 - 1 1.6
011 pump 3 9.8- 11.8 1.0- 1.2 7.2- 8.7
Oil pan bolt 10 9.8- 11.8 1.0 - 1.2 7.2- 8.7
011 pandrain plug 1 34.3 -44.1 3.5 - 4.5 25.2- 32.4
011 screen boH 2 9.8- 11.8 1.0- 1.2 7.2- 8.7 -
Oilpressure switch 1 7.8 -9.8 0.8- 1.0 5.8 - 7.2 ·:
::-. ·
lntake and axhaust ayatem -::::::. .:
lntake manifold bolt & n.it 5 18.6 - 23.5 1.9 -2.4 ."!üa.7_-17.4
Exhaust manifold stay 3 39.2 -49.0 -:..;1!::36.2
..-·6.5-7.9
4.0 - 5.0
Ext\aust manifold heat protector 3 8.8- 10.8 0.9.- ·i'Y"' <

6.4 -8.3 ;.
}. 1:6,S o.8- 4.7-6.1
Throttle body fixing salísaew 4
S:·'·
Exhaust manifold out 5 29.4 - 34.3 -±-' ;.;.: 3.0 - 3.5 21.7- 25.3
Exh.aust manifold and front muffler &
2 39.2 - 58.8 4.0 - 6.0 28.9-43.4
catalytic converter fixing nut
EM-8 Engine MechanicalSystem
Compression Pressure lnspection
5. Oi'5COmed the njector connectors (A).
+:1.111aw
lf there is lack or power , excessive oil ooosumption
or
poor fuel ecooorny,measure te compression pressure.
1. Start the engjne and a.Uow to warm up to
operating
temperatura .(about fNe minutes)
Stop the engine.
2. Remove ttle air cleaner assembl'y.
(Refer to Engine and Transaxfe Assembl'y •
"Engi.ne ard Transax.ie Assembl)'"')
3. Disconnect the ignition coll connectors {A).

SRBEM351:0

6. Remove the four spark plugs using a 16mm

sparkptug wrench.

7. Check the qfinder compression pressure.

(1) lnsert a compcession gauge into the spark ptug
llole.

SFIBElill001O
4. Remove the ignition cOOs
(A).

\ -,. .s-:::
.,_::;,::.:.

(2) Fully open throdle.

/Wtays use a fulfy" charged battery to obta n

engine speed of 250rpm01 more.
General lnformation EM-9
(4) Repeat step (1) throug.h (3) for each
cyUnder.

+c.1119+
This measurement must be done i:n as short

ea.n_...,.,.........:
atime as poss

1,373 kPa (14.0 kglan'.199 0 poi)

Minimumpr..ure :
1.226 kPa (12.5kg/an',178.0 psi)
oor..rence _,, oac:ll c:ytlnd« :
98 kPa (10 kg/cm2, 14 psi) or less

(5} lf the cylinder ressionin 1 or moie

cylinders islow.pour a smaU amount of
engine oil into the cyHnder through the spark
plug hole and repeat step {1) through (3)
ror cylinders with low
compression.
ff adding oilhelps the compression.his
likely that lhe piston rings andlot cylinder
bOie are worn or damaged.
Jow, a valve may be sticki:ng
lf pressure stays
or seating is improper, or there may
be leakage past the ga:Sket.
8. Reinstall the spatk plugs.

Tlghtening t«que :
14.7 - 24.5 N.m (1.5 -2.5 kgf .m. 10.8 - 18.111>-ft)

9. Connect theinjector oonnectors.

10.Connect the lgnition ooll connector and the spark
plug cables.(Nal ISG
type)
11.Snstall the ignition coil.(I SG type)

\ -,.
Tlghtening t«que :
9.8 - 11.8 N.m (1.0 - 1.2 kgl.m, 7.2 -8.7 lb-ft)
.,_;:;_::_:.

12. Conned the igniion coil connectors. {I SG iype)

13.Sorne DTC's may exist after the inspection test and
rnay need to be manu-ally deard with GOS.
EM-10 Engine MechanicalSystem
Troubleshoollng
Symp4om SOapect ... Ramody
Engine misfire with abnormal nternal Wom crankshaft beari:ngs.
Reptace the crankshaft and bearings
bwer englne nolses. Loose a damaged engine drive
as requ.ired.
plate.
Repair or replaoe the drive plata as re-
qui.red.
Worn pistoo rings. lnsped the cylinder for eloss of com
(Oiloonsumption may or may oot cau- ression.Repair oc replaoe as required.
se the engine lo nisfire.)
Wom crankshaft Uvust bearings Reptace the crankshaft and bearings
as requjred.

Engine misfire .,,.;th abnormal wlw lra·Studt valvas.

in noise. (Carbon buiklup onlhe valve Repair or replace as required.
stem)
.... --<..... .....
Exee&.Sive wom or mis-aflgned tining Repface the timing chain and sprocket
chaln. as required.
Wom camshaft lobes. Replace the camshaft and vaJve liflers.

HlA sponge Run the engine at 2S00-3000rpm with·

in 15 minutes.
lf il dosen•t disappear.refer to cylinder
head assembtyinthis group.

Englne misfire wtth ooolant COOSUIT"1ti·• Fautty cylinder he.ad gaskel and/or • lnsped the cyli:nder head ancl engi
on. cran.k.ing or other damage to the ne block ror damage to the
cyOnder head and engine block c:o coolanl paS&ages and/or a faulty
olingsystem. head gas kel.
Coolant oonsumptkin may ot may Repair or replace as required.
•
not cause the englne to overheat.
Engine rrisfire with excess ve oll cons- Wom valves,gu.ides aod/ot valva stem Repair or replace 85 requ red.

umption.
1º--ª_..a1_s_----------11--------------
Wom pistan rin.gs. lnsped the cylinder for aloss 9f'Qif. ·
(Oil consumption may or may oot cau mpression. - .:.;:.: ·
se the engine to rrisfue) Repa.ir oc replace as .
Englne noise on start-up,but only lasti·lnoxrect
oilvisoosity. Orain the _ _ -... • ·.:·
oil.
ng a few ln.statl the coét'Pvi. oi.
seconda. lnspect.th\f "&taring and era·
Wom crankshaft thrust bearWlg..
n.k&!:iaft: ...
·· ,,,
•.. liepair 01 replace as required.
 General lnformation EM-11
symplom &_.,t a,.. Rafl'8dy
Upper engine noise. regardless of Low oi.IpJessure. Repair or replace as required.
enir
Stokenvalva spring. Replace lheva1ve sprlng.
ine speed.
Wom or diny valve lifters. Replaoe the valva 6fters.
Stretched or broken timing chain
andl
or damaged sprocket teeth.
Wom ü-mlng cllain tens.ioner, if
applG
•. R eplace ihe ürring chain and
Replaoe the timing chain tensloner
as required.
ble.
Wom camshaft lobes. lnspect the camshaft klbes.
Replace the timing camshaft and
valve Uftecs as required.

Wom valve guides or vatve stems. 1nspect the vatves snd vafve guidas,
then repair es required.

Stuck vatves Cafbon on the valve lnspect the valves and vatve
stem or valve seat may cause the guidas,
vaive to stay open. then repair as required.

Wom dñve beft.idler.1ensioner Replace as required.

and
bearing .
lower engine noise, regardless of enir Low oi.IPfessure. Repair as required .
ine speed.
Loose or damag.ed drive plate. Repab or replace lhe driveplate.
Oamaged oll pan,contacting the oil • lnspect the oil pan.
mp screen. lnspect the oll pump acreen.
Repair 01 replaoe as required.
Oil pufl1> screen loose,damaged or re- • lnspect the oilpump acreen.
stricted. Repair 01 replaoe as required.
Exoessive piston-to-cy(inder bore clea- • lnspect the piston.piston pin
-.
rance. cylinder bore.
....;
Repair as .5 .
required.
Excessive piston pln-t1>piston clearan- • lnspect lhe plston, pin and
ce. the connecting !fU!- ·•.
Repair Of rep,ljtpe·a,s tJ: red.
Excessive oonnecting rod beañng lnspect . ,:tOVO" Y(iQV·COmponents
de- aranoe
and repa,ir.aire(¡ w;.ea-:,..
•·"*'Trie 00.nting rod bearings.
Y..;.;.7he connecting rcds.
'· The crank&haft pinjoumals.
Exoessive crankshaft bearing lnspect the following oomponents,
deara..n- and rapa.ir as requlred.
ca. The aankshaft bearings.
The crankshaft mainjoumals.
The cyhnder b>oclL
ncorrect pistan, plston pin and cono.e- • Verify the piston pins
ctlng rodinstallatlon ng ro:ls are
lnstafledc:orrectly. Repair
as requlred.
EM-12 Engine MechanicalSystem
Symplom SUapect al'88 Remody
E.ngine noise under bad. low oilpressure Repeir or rep ace as requtred.
Excessive connecting rod bearíng de- lnspec:t the fol owing oomponents
arance . and repair as required :
The oonnecting rod bearings.
The OOMecting rods.
The crankshaft.

Excessive crankshaft bearing clearan- lnspect the following oomponerrts, end

E.ngine wíll not aank-crankshaft
not total.e.
ce. repalr as requlred.
Thecrankshaft bearings.
The crankshaft
mainjournals. The
cy1inder btock.
Wlll Hydra\Aically locked cylinder. Remove spark ptugs and check for
Cootantlantifreeze in ílu: d.
cylinder. Oil in cylincler. lnsped for broken head gaskel
Fuel in cylindeJ. lnspect for cracked engine b1ock or
c)'linder head.
lnspect for a sticking fvel injeaor
and/or leakingfuel regulatof.
Broken timiogdlain and/or tim ng chaj.. • lnspect timing chain and
n and/or timingchaingears.. Repair as required.
Mate!ialIncytinder. lnspect cy1inder for dainaged oom-
Broken valve ponents and/or foreign
Pistan material materials. Repair or replaoe
Forelgn material as required.
Seizecl crankshaft or c:onnecting lnsped crankshaft and connecting
rod bearings. rod bearing.
Repair as
required.
lnspect oonneding rods.
Bent or broken connectlng rod.
Repair as required. -{
Broken cra.nkshafl lnspect crankshafl
Repair as required. "-·. .,_:::;:::_:
. ·-
General lnformation EM-13
SpedalServlce Tools
Tool (Nl.Wnber -name)
Flywheel stopper
··-ation u..
/;'.SI Removal aldinstallatioo of the flywheet
and cmnkstlaft pufley

't
(09231-28100)

... Jfif
.

SHOEM&lOlO
Engine and Transaxle Assembly EM-14

Engine and Transaxle Assembly

Englne Mounting
Components

1.Transaxle mount
4.Engine mountlng bracket
ngbrac:.ket 2.Rollrod bracket
5.Engine mountlng support
3.Sub frame
brackel

DJ 5.0 - 6.5

9.0 -11.0
'·

Tlghtenlng torque :N.m(kgf.m, 11>-ft)

EM-15 Engine MechanicalSystem

Engine and Transaxle Assembly

Removal
2. Oi:Sconnect the battery terminals {A). Oi'SOOOnect the
A CAUTION negativa terminalfirst.
Use tender covers to avoid damag ng
pc1inted
surfaces. Tlghtaring totqua
{+) terminal :
To evoid damage, unp!ug the wiring
7.8- 9.8 N.m(0.8- 1.0 kgf.m,5.8 -7.2lb-ft)
oonnectors
carefulty whi e holding the oonnector portien. (-) term nal (without battery sen.sor):

•: '· ' ' 'ª

7.8 - 9.8 N.m(0.8 - 1.0 kgf.m,5.8 -7.2lb-ft)

M < r i: all wirlng snd hoses to avoid

misconnection.
To release the fuel system pressure before
removing the engine assembl'y, start the engine
wrth lhe fuel pump relay removed. and then tum
off the ig.nition switch áter engioe stops.

1. Remove the engioe cover (A).

SRB1iMO

3. Remove the under covers

(A).
Tlghtoring torquo :
6.9- 10.8 NJn (0.7 -1.1kgf.m, 5.1 - 8.0 lb-ft)

SRflEM30030

SRBE