EM -2 ENGINE MECHANICAL SYSTEM GENERAL SPECIFICATION coucere Description Specification General Type Inline, Double Over Head Camshaft Number of cylinders 4 Bore 4161 76.5mm (3.0118 in) 15 L 75.5mm ( 2.972 in.) Stroke 1.6L 87mm (3.4252 in) 15 83.5mm (3.287 in.) Total displacement 1.6L 1599 cc (97.54 cu.in) 15 1495 ce (91.27 cu.in) Compression ratio 10 Firing order 1-3-4.2 Valve timing Intake vaive Opens (BTDC) s Closes (ABDC) 35° Exhaust valve Opens (BBDC) 4s Closes (ATDC) s Valve overiap 10° Cylinder head Flatness of cylinder head surface Max. 0.03mm (0.0012 in.) 0.1 mm (0.0038in.) Flatness of mainfold mounting surface 0.15mm (0.0058 in.) ‘0.2mm (0.008in.) Oversize rework dimension of valve seat hole Intake 0.3mm (0.012 in.) OS. 29.8 ~ 29.821 mm (1.173 ~ 1.174 in.) 0.6mm (0.024 in.) OS. 30.1 ~ 30.121 mm (1.185 ~ 1.186 in.) Exhaust 0.3mm (0.012 in.) OS. 27.3 ~ 27.324mm (1.0748 ~ 1.0756 in.) 0.6mm (0.024 in.) OS 27.6 ~ 27.621mm (1.0866 ~ 1.0874 in.) (Oversize rework dimensions of valve Guide hole 0.05mm (0.002 in.) OS. 11.05 ~ 11.068mm (0.435 ~ 0.4357 in.) 0.25mm (0.010 in.) OS, 11.25 ~ 11.268mm (0.443 ~ 0.4436 in.) 0.50mm (0.020 in) OS. 11.50 ~ 11.518mm (0.453 ~ 0.4535 in.) Camshaft Camiobe height Intake 43.4484mm (1.7106 in) 42,9484mm (1.6909in.) Exhaust 43.8489mm (1.7263 in) 43,3489mm (1.7.66in.) Joumat 0.0 ‘927mm (1.0830 in.) Bearing oil clearance (0.035 ~ 0.072mm (0.0014 ~ 0.0028 in.) End play 0.1 ~ 0.2mm (0.004 ~ 0.008 in.)GENERAL EM-3 Description Specitication Limit Valve Valve length Intake Exhaust Stem 0.0. Intake Exhaust Face angle thickness of vaive head (Margin) Intake Exhaust Valve stem to valve guide clearance Intake Exhaust 91.7mm (3.6102 in.) 92.3mm (3.6339 in.) 5.955 ~ 5.97mm (0.2344 ~ 0.2350 in.) 5.935 ~ 5.95mm (0.2337 ~ 0.2343 in.) 1.1mm (0.0433 in.) 1.3mm (0.0512 in.) 0.03 ~ 0.06mm (0.0012 ~ 0.0024 i 0.05 - 008mm (0.0020 - 0.0081 in) 0.8mm (0.03tin.) 1.0mm (0.039in.) 0.10mm (0.0038in.) 0.15mm (0.0058in.) Valve guide Intake 12.8mm (0.504 in.) Exhaust 12.8mm (0.504 in.) Service size 0.05, 0.25, 0.50mm (0.002, 0.010, 0.020 in.) oversize Valve seat Width of seat contact Intake 0.8 ~ 1.2mm (0.031 ~ 0.047 in.) Exhaust 4.3 ~ 1.7mm (0.051 ~ 0.066 in.) Seat angle 45° Oversize 0.3, 0.6mm (0.012, 0.024 in.) oversize Valve spring Free length -44.00mm (1.7323 in.) Load 21.6kg/ 35mm (47.6lb/1.3780 in.) 48.1kg/ 27.2mm (99.4b/1.7089 in.) Squarenoss 1.5° oF less Cylinder block Cylinder bore 16 76.50 ~ 76.59mm (9.0118 ~ 3.0130 in.) 15 75.50 ~ 75.53 mm (2.9724 ~ 2.9736 in.) Out- of- round and taper of cylinder bore Clearance with piston Less than 0.01mm (0.0004 in.) 16 0.025 ~ 0.045mm (0.0009 ~ 0.0017 in.) 15L 0.02 ~ 0.04 mm (0.00078 ~ 0.0016 in.) Piston OD. 16 76.465 ~ 76.495mm (3.0104 ~ 3.0116 in.) 15 75.465 ~ 75.495mm (2.9710 ~ 2.9722 in.) Service size 0.25, 0.50, 0.75, 1.00mm (0.010, 0.020, 0.030, 0.039 in.) oversize Piston ring Side clearance No. 1 0.04-0.085mm (0.0015-0.0033 in.) 0.1mm (0.004in.) No. 2 0.04-0.085mm (0.0015-0.0033 in.) 0.1mm (0.004in.) Endgap No.1 0.20-0.35mm (0.0079- 0.0138 in.) 1.0mm (0.033in.) No. 2 0.37-0.52mm (0.0146-0.02 in.) 1.0mm (0.038in.) Oil ring side rail 0.2-0.7mm (0.0078- 0.0275 in.) 1.0mm (0.039in.) Service size 0.25, 0.50, 0.75, 1.00mm (0.010, 0.020, 0,030, 0.039 in.) oversizeENGINE MECHANICAL SYSTEM Specification Limit EM-4 Description Connecting rod Bend ‘Twist Connecting rod big end to crankshaft side clearance Connecting rod bearing oil clearance Undersize 0.05mm (0.0020 in.) oF less 0.1mm (0.0039 in.) oF less 0.100-0.250mm (0.0039-0.0098 in.) 0.018-0.036mm (0.0007-0.0014 in.) 0.25, 0.50, 0.75mm (0.010, 0.020, 0.030 in.) 0.4mm (0.0157in.) Crankshaft Pin OD. Journal O.D. Bend ‘Out- of round, taper of journal and pin End play 45 mm (1.77 in.) 50 mm (1.97 in.) 0.03 mm (0.0012 in.) or less 0.005 mm (0.0002 in.) or less 0.05- 0.175 mm (0.0019- 0.0068 in.) Undersize rework dimension of pin’ 0.25mm (0.010 in.) 0.50mm (0.20 in.) 0.75mm (0.030 in.) 44,725 ~ 44.74mm (1.7608 ~ 1.7614 in.) 44,475 ~ 44.49mm (1.7509 ~ 1.7516 in.) 44.205 ~ 44.24mm (1.7411 ~ 1.7417 in.) Undersize rework dimension of journal 0.25mm (0.010 in) 0.0mm (0.20 in.) 0.75mm (0.030 in.) 49.727 ~ 49.742mm (1.9577 ~ 1.9583 in.) 49.477 ~ 49.492mm (1.9479 ~ 1.9485 in.) 49.227 ~ 49.242mm (1.9380 ~ 1.9386 in.) Flywheel Runout 0.1mm (0.0039 in.) 0.13mm (0.0051in.) ll pump Clearance between outer circumference and front case (body clearance) Front case tip clearance Side clearance Inner gear Outer gear 0.12 ~ 0.18mm (0.0047 ~ 0.0070 in.) 0.025 ~ 0.069mm (0.001 ~ 0.0027 in.) 0.04 ~ 0.085mm (0.0016 ~ 0.0033 in.) 0.08 ~ 0.11mm (0.0024 ~ 0.0043 in.) Engine oil pressure Engine at idle (Oil temperature is 90 to 100°C (194 to 215°F)] 147KPa (1.5 kg/ om, 21.33psi) Relief spring Free height Load 46,6mm (1.8346 in.) 6.1kg at 40.1mm (13.421b/ 1.578 in.) Cooling method Water-cooled, pressurized, forced circulation with electrical fan Main valve opening pressure Vacuum valve opening pressure Coolant Quantity 65 liter Radiator Type Pressurized corrugated fin type Radiator cap 81.4 ~ 108 kpa (11.8 ~ 15.6 psi,0.83 = 1-Akgiem® ) 8.86 kpa (-1.00 psi, -0.07 kg/cm or less Coolant pump Centrifugal type impellerGENERAL EM -5 Description Specification Limit ‘Thermostat Type Valve opening temperature Full-opening temperature Wax peliet type with jiggle valve 82°C (180°F) 95°C (203°F) Engine coolant temperature sensor ‘Suspension system Type Heat-sensitive thermistor type Resistance 2.31 ~ 2.59k 0 at 20°C(68"F) 146.9 ~ 147.3 2 at 110°C(230°F) ‘Air cleaner ‘Type Dry type Element Un woven cloth type Exhaust pipe Muttior Expansion resonance type Rubber hangersEM -6 ENGINE MECHANICAL SYSTEM TIGHTENING TORQUE [ Hem Nm Kg.em bt Cylinder Block Front engine support bracket bolt and nut 45 ~ 55 450 ~ 550 33 ~ 41 Engine suppot bracket stay bolt 45 ~ 55 450 ~ 550 33 ~ 41 Oil pressure switch 13-15 190 ~ 150 10-11 Cylinder head Cylinder head bot 164 301(90"}+Release | 300+(90")+Release all | 22+(90°}+Rolease all bolts+30+(80") botts+300+(90") all botts+22+(80") 15 35+90°+Release | 350+90"sRelease all | 26+90°Release all all bolts+35+90° bolts+350+90° olts+26+90" Intake manifold bolts or nuts 15 ~ 20 150 ~ 200 11-15 Exhaust manifold nut 25 ~ 30 250 ~ 300 18 22 Cylinder head cover bot 8-10 80 ~ 100 6-7 Camshaft bearing cap bolt 12-14 120 ~ 140 9-10 Rear plate bolt 32 ~ 35 320 ~ 350 24 ~ 26 Main Moving system Connecting rod cap nut 32 ~ 35 320 ~ 350 24 ~ 26 Crankshaft bearing cap bolt 55 ~ 60 550 ~ 600 41 ~ 44 Fly wheel M/T bolt 120 ~ 130 1200 - 1300 89 ~ 96 Drive plate A/T bolt 120 ~ 130 1200 ~ 1300 89 ~ 96 Timing system Crankshaft pulley bott 140 ~ 150 1400 ~ 1500 403 ~ 111 Camshaft sprocket bott 80 ~ 100 1800 ~ 1000 59 - 74 Timing belt tensioner bolt 20 - 27 200 ~ 270 15 ~ 20 Timing belt idle bolt 43 ~ 55 430 ~ 550 32-41 Timing belt cover bolt 8-10 80 ~ 100 6-7 Front case bolt 20 ~ 27 200 ~ 270 15 ~ 20 | Engine Mounting Right mounting insulator (large) nut 70 ~ 95 700 ~ 950 52 ~ 70 Right mounting insulator (small) nut 35 ~ 55 350 ~ 550 26 ~ 40 Right mounting bracket to engine 35 ~ 55 350 ~ 550 26 ~ 40 nuts and bolts ‘Transmission mount insulator nut 35 ~ 55 350 ~ 550 26 ~ 40 ‘Transmission insulator bracket to side 35 ~ 55 350 ~ 550 26 ~ 40 member bolts Rear roll stopper insulator nut 35 ~ 55 350 ~ 550 26 ~ 40 Rear roll stopper bracket cross member bolt 70 ~ 95 700 ~ 950 52-70 i fiter 12-16 20 ~ 160 9-2 il pan bolts 10-12 400 - 120 7-8 Oil pan drain plug 35 ~ 45 350 ~ 450 25 ~ 33 Oil screen bolts 15 - 22 150 ~ 220 11-16GENERAL Hem Nm Kg.cm Iba ‘Alternator support bolt and nut 20 ~ 25 200 ~ 250) 16-18 Alternator lock bolt 12-15 120 ~ 10 g-tt Alternator brace mounting bolt 20 ~ 27 200 ~ 270 15 ~ 20 Coolant pump pulley 8-10 80 ~ 100 6-7 Coolant pump bolt 12-18 120 ~ 150 9-11 Coolant temperature sensor 25 ~ 30 250 ~ 300 18 - 22 Coolant inlet fitting bolt 17 ~ 20 170 ~ 200 13-14 Thermostat housing bolt 15 ~ 20 150 ~ 200 W-14 Air cleaner body mounting bolts 8-10 [80 ~ 100 6-7 Resonator mounting bolts 4-6 40 ~ 60 3-4 Intake manifold to cylinder head nuts and bolts 15 ~ 20 150 ~ 200 n-14 ‘Surge tank stay to cylinder block bolts 18 ~ 25 180 ~ 250 13-18 ‘Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 1-14 Exhaust manifold to cylinder head nuts 25 ~ 30 250 ~ 300 18 ~ 22 Exhaust manifold cover to exhaust 15 ~ 20 150 ~ 200 W148 manifold bolts Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 600 37 ~ 44 Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 30 Front exhaust pipe bracket bolts 30 ~ 40, 300 ~ 400 22 ~ 30 Front exhaust pipe to catalytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44 ‘SERVICE STANDARD Standard value Antifreeze Mixture ratio of anti-freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM ‘50%