Engine Mechanical System

Engine Mechanical System

General Information
 2009 > D 1.6 TCI-U >

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Use

Torque angle adapter Installation of bolts & nuts needing an
(09221-4A000) angular method

Valve spring compressor Removal and installation of intake and

(09222-3K000) exhaust valves
Valve spring compressor
adapter
(09222-2A100)

Compression gauge Checking engine compression pressure

(09351-27000)

Compression gauge Checking engine compression pressure

adapter
(09351-2A000)

Valve stem oil seal Installation of valve stem oil seals

installer
(09222-2A000)

Injector remover Removal of injectors

(09351-4A200)
Injector remover adapter Removal of injectors
(09351-2A100)

High pressure pump Removal of high pressure pump sprocket

sprocket remover
(09331-2A000)

Crankshaft rear oil seal Installation of crankshaft rear oil seal

installer
(09231-H1200)
Handle
(09231-H1100)

Front cover oil seal Installation of front cover oil seal

installer
(09231-2A000)
Handle
(09231-H1100)

Flywheel stopper Removal and installation of crankshaft

(09231-2A100) pulley bolt.

Oil pan remover Removal of oil pan

(09215-3C000)

Engine support fixture and Engine fixing

adapter
(09200-38001,
09200-1C000)
 2009 > D 1.6 TCI-U >

TROUBLESHOOTING

Symptom Suspect area Remedy

Engine misfire with Repair or replace the flywheel as
Loose or improperly installed engine flywheel.
abnormal internal required.
lower engine noises.
Worn piston rings. Inspect the cylinder for a loss of
(Oil consumption may or may not cause the compression.
engine to misfire.) Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings.
as required.
Engine misfire with Stuck valves. Repair or replace as required.
abnormal valve train (Carbon buildup on the valve stem can cause
noise. the valve not to close properly.)
Replace the timing chain and
Excessive worn or mis-aligned timing chain.
sprocket as required.
Replace the camshaft and valve
Worn camshaft lobes.
lifters.
Engine misfire with •• Faulty cylinder head gasket and/or cracking •• Inspect the cylinder head and
coolant consumption or other damage to the cylinder head and engine block for damage to the
engine block cooling system. coolant passages and/or a faulty
•• Coolant consumption may or may not cause head gasket.
the engine to overheat. •• Repair or replace as required.
Engine misfire with Worn valves, valve guides and/or valve stem oil
Repair or replace as required.
excessive oil seals.
consumption
Worn piston rings. Inspect the cylinder for a loss of
(Oil consumption may or may not cause the compression
engine to misfire) Repair or replace as required.
Engine noise on Incorrect oil viscosity. Drain the oil.
start-up, but only Refill with the correct viscosity oil.
lasting a few
Worn crankshaft thrust bearing. Inspect the thrust bearing and
seconds.
crankshaft.
Repair or replace as required.
Upper engine noise, Low oil pressure. Repair or replace as required.
regardless of engine
Broken valve spring. Replace the valve spring.
speed.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and
damaged sprocket teeth. sprockets.
Replace the timing chain tensioner
Worn timing chain tensioner, if applicable.
as required.
Worn camshaft lobes. Inspect the camshaft lobes.
Replace the camshaft and valve
lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,
then repair as required.
 Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides,
valve seat may cause the valve to stay open.) then repair as required.
Lower engine noise, Low oil pressure. Repair or replace damaged
regardless of engine components as required.
speed.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump Inspect the oil pan.
screen. Inspect the oil pump screen.
Repair or replace as required.
Oil pump screen loose, damaged or restricted. Inspect the oil pump screen.
Repair or replace as required.
Excessive piston-to-cylinder bore clearance. Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance. Inspect the piston, piston pin and the
connecting rod.
Repair or replace as required.
Excessive connecting rod bearing clearance. Inspect the following components
and repair as required.
•• The connecting rod bearings.
•• The connecting rods.
•• The crankshaft.
•• The crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components
and repair as required.
•• The crankshaft bearings.
•• The crankshaft journals.
Incorrect piston, piston pin and connecting rod Verify the piston pins and connecting
installation. rods are installed correctly.
Repair as required.
Engine noise under Low oil pressure. Repair or replace as required.
load.
Excessive connecting rod bearing clearance. Inspect the following components
and repair as required.
•• The connecting rod bearings.
•• The connecting rods.
•• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components
and repair as required.
•• The crankshaft bearings.
•• The crankshaft journals.
•• The cylinder block crankshaft
bearing bore.
Engine will not Hydraulically locked cylinder. Remove injectors and check for fluid.
crank. (crankshaft •• Coolant/antifreeze in cylinder. Inspect for broken head gasket.
will not rotate) •• Oil in cylinder. Inspect for cracked engine block or
•• Fuel in cylinder. cylinder head.
Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Broken timing chain and/or timing chain gears. Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder. Inspect cylinder for damaged
•• Broken valve. components and/or foreign materials.
•• Piston material. Repair or replace as required.
•• Foreign material.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting
rod bearing.
Repair or replace as required.
Bent or broken connecting rod. Inspect connecting rods.
Repair or replace as required.
Broken crankshaft. Inspect crankshaft.
Repair or replace as required.
 2009 > D 1.6 TCI-U >

INSPECTION
COMPESSION PRESSURE

•• If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
•• Whenever removing injectors for compression pressure inspection, replace the gaskets with new ones
and tighten them with the specified torque.

1. Warm up engine until the normal operating temperature.

2. Remove the injectors. (Refer to FL Gr.)

3. Check the cylinder compression pressure.

(1) Insert a compression gauge SST(09351-27000, 09351-2A000) into the injector hole.

(2) Fully open the throttle.

(3) While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250rpm or more.

(4) Repeat step 1) though 3) for each cylinder.

 This measurement must be done in as short a time as possible.

Compression pressure :
2,157.45kPa (22.0kg/cm², 312.91psi) (200 rpm)
Minimum pressure :
1,863.25kPa (19kg/cm², 270.24psi)
Difference between each cylinder :
98.07kPa (1.0kg/cm², 14.22psi) or less

(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat step 1) through 3) for cylinders with low compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past
the gasket.

4. Reinstall the injectors. (Refer to FL Gr.)

 2009 > D 1.6 TCI-U >

SPECIFICATIONS

Description Specifications (D4FB) Limit

General
Type In-line, DOHC
Number of cylinders 4
Bore 77.2mm (3.0394in)
Stroke 84.5mm (3.3268in)
Total displacement 1,582 cc (96.54 cu.in)
Compression ratio 17.3 : 1
Firing order 1-3-4-2
Valve timing
Opens (ATDC) 17°5' ± 4°
Intake valve
Closes (ABDC) 14°6' ± 4°
Opens (BBDC) 23°25' ± 4°
Exhaust valve
Closes (ATDC) 20° ± 4°
Cylinder head
0.03mm (0.0012in) for width
Flatness of gasket surface
0.09mm (0.0035in) for length

Flatness of 0.025mm (0.0010in) for width

Intake
manifold 0.160mm (0.0063in) for length
mounting 0.025mm (0.0010in) for width
surface Exhaust
0.160mm (0.0063in) for length
Camshaft

LH Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

camshaft Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Cam height
RH Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
camshaft Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

Journal outer LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

Diameter RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Intake 93.0mm (3.6614in)
Valve length
Exhaust 93.7mm (3.6890in)

Stem outer Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)

diameter Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.5° ~ 45.75°
Thickness of Intake 1.1mm (0.0433in)
valve head
(margin) Exhaust 1.2mm (0.0472in)

Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)

valve guide
clearance Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)

Valve guide
Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Length
Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat

Width of seat Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)

contact Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
Intake 45° ~ 45°30'
Seat angle
Exhaust 45° ~ 45°30'
Valve spring
Free length 44.9mm (1.7677in)
17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
Load
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness Less than 1.5° 3°
Cylinder block
Cylinder bore 77.200 ~ 77.230mm (3.0394 ~ 3.0405in)
Flatness of gasket surface Less than 0.05mm (0.0020in)
Piston
Piston outer diameter 77.130 ~ 77.160mm (3.0366 ~ 3.0378in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
No. 1 ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
Ring groove
No. 2 ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in)
width
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
No. 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
Side clearance No. 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No. 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
End gap No. 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Piston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end hole inner
28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
diameter
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098in) 0.4mm (0.0157in)
Crankshaft
Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm (0.0051in)
Oil pump
Inner rotor 0.040 ~ 0.085mm (0.0016 ~ 0.0033in)
Side clearance
Outer rotor 0.040 ~ 0.090mm (0.0016 ~ 0.0035in)
Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure 490±49.0kpa (5±0.5kg/cm², 71±7.1psi)
Engine oil
Oil quantity (Total) 5.7 L (6.02 US qt, 5.01 lmp qt)
Oil quantity (Oil pan) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Drain and refill including oil
5.3 L (5.60 US qt, 4.66 lmp qt)
filter)
ABOVE API CH-4 or ACEA B4 (with
Oil quality
CPF:C3)
Oil pressure (Idle) (Oil temperature :
78.4kpa (0.8kg/cm², 11.3psi)
80°C)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 6.97 L (7.37 US qt, 6.13 lmp qt)
Type Wax pellet type
Opening temperature 85±1.5°C (185.0±2.7°F)
Thermostat
Pull opening
100°C (212°F)
temperature
Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve 0.98 ~ 4.90 kpa
openingpressure (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type
 20°C (68°F) 2.45±0.14 k

Resistance
80°C (176°F) 0.3222 k

TIGHTENING TORQUE
Tightening torque
Item Quantity
N.m kgf.m lb.ft
Cylinder block
Engine support bracket bolt 4 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Piston cooling oil jet bolt 4 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Drive belt auto tensioner bolt 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Drive belt auto tensioner mounting
3 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
bracket bolt
Engine mounting
Engine mounting bracket and body fixing
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
bolt
Engine mounting insulator and engine
1 68.6 ~ 93.2 7.0 ~ 9.5 50.6 ~ 68.7
mounting support bracket fixing nut
Engine mounting support bracket and
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
engine support bracket fixing bolt
Engine mounting support bracket and
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
engine support bracket fixing nut
Transaxle mounting bracket and body
4 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt
Transaxle mounting insulator and
1 88.3 ~ 107.9 9.0 ~11.0 65.1 ~79.6
transaxle support bracket fixing bolt
Front roll stopper bracket and sub frame
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt (10 X 45)
Front roll stopper bracket and sub frame
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt (10 X 25)
Front roll stopper insulator and front roll
1 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
stopper support bracket fixing bolt,nut
Rear roll stopper bracket and sub frame
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt (10 X 60)
Rear roll stopper bracket and sub frame
2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt (10 X 40)
Rear roll stopper insulator and rear roll
1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
stopper support bracket fixing bolt,nut
Main moving system
Connecting rod cap bolt 8 12.7 + (87~93°) 1.3 + (87~93°) 9.4 + (87~93°)
Crankshaft main bearing cap bolt (long) (22.6~26.5) + (2.3~2.7) + (16.6~19.5) +
10
(90~94°) (90~94°) (90~94°)
Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8
Flywheel bolt (M/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Drive plate bolt (A/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing chain
Timing chain cover bolt (8 X 70) 7 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (8 X 60) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (8 X 35) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (6 X 35) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain cover bolt (6 X 28) 7 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain case bolt (8 X 22) 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Timing chain case bolt (8 X 32) 1 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Timing chain case bolt (6 X 35) 1 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Engine hanger (front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Crankshaft pulley bolt 1 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8
Camshaft chain sprocket bolt 1 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2
High pressure pump chain sprocket bolt 1 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Timing chain guide (1) bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide (2) bolt 1 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Timing chain "A" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain "C" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Engine cover bolt 5 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Cylinder head cover bolt 13 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap bolt (mark 10) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Camshaft bearing cap bolt (mark 9) 6 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Engine hanger bolt 2 28.4 ~ 32.4 2.9 ~ 3.3 21.0 ~ 23.9
Cylinder head bolt (47.1~51.0) + (4.8~5.2) + (34.7~37.6) +
10 (88~92°) + (88~92°) + (88~92°) +
(118~122°) (118~122°) (118~122°)
Cooling system
Water pump pulley bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt (8 X 50) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water pump bolt (8 X 70) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Thermostat housing bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Thermostat housing nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water return pipe assembly bolt 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water temperature sensor 1 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Water inlet fitting nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Lubrication system
Oil filter assembly bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil cooler assembly bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil filter upper cap 1 24.5 2.5 18.1
Oil level gauge bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 65) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 85) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oil pan drain bolt 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil screen nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Intake manifold and cylinder head fixing
2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
nut
Intake manifold and cylinder head fixing
7 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
bolt
Exhaust manifold and cylinder head fixing
8 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
nut
Exhaust manifold heat protector bolt 3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
WCC assembly fixing nut 3 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Air cleaner lower cover fixing bolt 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Throttle body and surge tank fixing bolt 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Exhaust manifold and front muffler fixing
2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
bolt
Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler and center muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler and main muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
 Engine Mechanical System

Engine Mechanical System

Timing System - Timing *OHPU
2009 > D 1.6 TCI-U >

COMPONENTS
 2009 > D 1.6 TCI-U >

REMOVAL
Engine removal is not required for this procedure.
1. Remove the drive belt.

2. Remove the injector(A). (Refer to FL Gr.)

3. Remove the cylinder head cover(A).

4. Remove the engine mounting support bracket.

(1) Set the jack to the engine oil pan
 (2) Remove the engine mounting support bracket(A).

5. Remove the alternator(A).

6. Remove the water pump pulley(A).

7. Remove the engine support bracket(A).

8. Remove the drive belt auto tensioner(A).

9. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder
compression TDC position)

10. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).

 Use the SST(flywheel stopper, 09231-2A100)(A) to remove the crankshaft pulley bolt, after remove the
starter.

11. Remove the high pressure pump sprocket nut(B) after remove the timing chain cover plug(A).

•• Use the SST(flywheel stopper, 09231-2A100) to remove the high pressure pump sprocket nut.
•• Replace O-ring of plug(A) with a new one when reinstalling the plug.

12. Remove the high pressure pipe(A).

13. Remove the mounting bolts of the high pressure pump(A) and the fuel hoses(B, C).

14. Install the SST(high pressure pump sprocket stopper, 09331-2A000)(A) to sprocket rotating it clockwise.
15. Remove the timing chain cover bolt(three bolts)(B).

16. Install the SST(high pressure pump sprocket remover, 09331-2A000)(A) to timing chain cover with three
long bolts(B).
17. Fix the high pressure pump remover(A) and sprocket stopper(C) with two fixing bolts(D).
18. Rotate the bolt(E) clockwise till high pressure pump is pushed out.
19. Remove the SST(09331-2A000) after remove the high pressure pump.
20. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the enine
hanger bracket.

21. Remove the jack from oil pan.

22. Remove the oil pan(A).

23. Remove the oil strainer(B).
 When removing the oil pan, use the SST(09215-3C000) in order not to damage the surface between
the cylinder block and the oil pan.

24. Remove the timing chain cover(A)

Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil
pan. (If any impurities are left at the sealing face, oil may leak after reassembly even with the sealant
application.)

25. Remove the timing chain "C" auto tensioner(A).

 Before removing auto-tensioner, install a set pin(B) (ø2.5 mm steel wire) after compressing the
tensioner.

26. Remove the timing chain "C" lever(A) and the timing chain guide "1"(B).

27. Remove the timing chain guide "2"(A).

28. Remove the timing chain "C"(A).

29. Remove the timing chain "A" auto tensioner(A).

Before removing auto-tensioner, install a set pin(B) (ø2.5 mm steel wire) after compressing the
tensioner.

30. Remove timing chain "A" lever(A) and the timing chain guide "1"(B).

31. Remove the timing chain "A"(A)with high pressure pump sprocket(B) and crankshaft sprocket(C).
32. Remove the power steering pump bracket(A).

33. Remove the water pump(A).

34. Remove the timing chain case(A).

(Engine removal is required for this procedure)
35. Remove the camshaft sprocket.
(1) Hold the portion(A) of the camshaft with a hexagonal wrench, and remove the bolt(C) with a wrench(B)
and remove the camshaft sprocket.

Be careful not to damage the cylinder head and valve lifter with the wrench.

INSTALLATION
Engine removal is not required for this procedure.
1. Install the camshaft sprocket and tighten the bolt to the specified torque.
(1) Temporarily install the camshaft sprocket bolt(C).
(2) Hold the portion(A) of the camshaft with a hexagonal wrench, and tighten the bolt(C) with a wrench(B).

Tightening torque :
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lbf.ft)
2. Install the timing chain case(A) with new gasket.
(Engine removal is required for this procedure)

Tightening torque :
Bolt(B,C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbf.ft)
Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbf.ft)

3. Install the water pump(A).

Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbf.ft)

4. Install the power steering pump bracket(A).

5. Install the high pressure pump(A), connecting the hoses(B, C).

Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft)

6. Install the high pressure pipe(A).

7. Set the key of crankshaft sprocket to be aligned with the timing mark of timing chain case. As a result of
this, place the piston on No.1 cylinder at the top dead center on compression stroke.
8. After install timing chain "A" with high pressure pump sprocket(B) equipped at the crankshaft sprocket(C),
and then install high pressure pump sprocket at the high pressure pump shaft.

The timing mark of high pressure pump sprocket should be aligned with timing mark on the timing chain
case.

9. Pretighten the high pressure pump sprocket nut.

10. Install timing chain "A" lever(A) and the timing chain guide "1"(B).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

11. Install the timing chain "A" auto tensioner(A) and then remove set pin(B).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)
12. Align the timing mark(A) of camshaft sprocket on the vertical center line of crankshaft.

13. Install the timing chain "C"(A) as following procedure. High pressure pump sprocket -> LH camshaft
sprocket -> RH camshaft sprocket

The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at
installing timing chain as shown below illustration.

14. Install the timing chain guide "2"(A).

Tightening torque :
9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lbf.ft)
15. Install the timing chain "C" lever(A) and the timing chain guide "1"(B).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

16. Install the timing chain "C" auto tensioner(A) and then remove set pin(B).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

17. Install the high pressure pump sprocket nut(A).

Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lbf.ft)
 Use the SST(flywheel stopper, 09231-2A100)(A) to tighten the high pressure pump sprocket nut, after
remove the starter.

18. Apply liquid gasket evenly to the mating surface of timing chain cover.

•• Standard liquid gasket : LOCTITE 5900

•• Check that the mating surfaces are clean and dry before applying liquid gasket.
•• Assemble the timing chain cover in 5 minutes after applying the liquid gasket.
•• Apply liquid gasket in a 3mm wide bead without stopping.

19. Install the timing chain cover(A).

Tightening torque :
Bolt (B,C,F) :
 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft)
Bolt(D,E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

20. Install the front oil seal by using SST(09231-2A000, 09231-H1100)(A).

21. Install the oil strainer(B).

Tightening torque :
Bolts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft)
Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

22. Apply liquid gasket evenly to the mating surface of oil pan.

•• Standard liquid gasket : LOCTITE 5900

•• Check that the mating surfaces are clean and dry before applying liquid gasket.
•• Apply liquid gasket in a 3mm wide bead without stopping.Assemble the oil pan in 5 minutes after
 applying the liquid gasket.
•• After assembly, wait at least 30 minutes before filling the engine with oil.
•• Apply liquid gasket to T-joint before assembling oil pan.

23. Install the oil pan(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

24. Set the jack to the engine oil pan

25. Remove the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, from the engine
hanger bracket.
26. Install the crankshaft pulley(A) and crankshaft pulley bolt(B).

Tightening torque :
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lbf.ft)

Use the SST(flywheel stopper, 09231-2A100) to Install the crankshaft pulley bolt, after remove the
starter.

27. Install the drive belt auto tensioner(A).

Tightening torque :
18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbf.ft)
28. Install the engine support bracket(A).

Tightening torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbf.ft)

29. Install the water pump pulley(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

30. Install the alternator(A).

Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)
31. Install the engine mounting support bracket(A).

Tightening torque :
Nut(D) : 68.6 ~ 93.2N.m(7.0 ~ 9.5kgf.m, 50.6~ 68.7lbf.ft)
Bolt(B), Nut(C) : 49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft)

32. Remove the jack from oil pan

33. Install the cylinder head cover(A) with new head cover gasket.

Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft)
 •• Standard liquid gasket : LOCTITE 5900
•• Check that the mating surfaces are clean and dry before applying liquid gasket.
•• Apply liquid gasket in a 3mm wide bead without stopping.
•• Assemble the cylinder head cover in 5 minutes after applying the liquid gasket.
•• After assembly, wait at least 30 minutes before filling the engine with oil.
•• Apply liquid gasket to T-joint before assembling cylinder head cover.

34. Install the injector(A). (Refer to FL Gr.)

35. Install the drive belt.

 Engine Mechanical System

Engine Mechanical System

Cylinder Head Assembly
2009 > D 1.6 TCI-U >

COMPONENTS
 2009 > D 1.6 TCI-U >

REMOVAL
Engine removal is required for this procedure.

•• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
•• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the
gasket.

•• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Remove the drive belt.

2. Remove the timing chain.

3. Remove the intake and exhaust manifold.
4. Remove the delivery pipe(A).

5. Remove the glow plug(A).

6. Disconnect the water hose(A) from thermostat housing.

7. Remove the thermostat housing(A).

8. Remove the vacuum pump(A).

9. Remove the camshaft bearing caps(A).

 Mark the camshaft bearing caps to be able to reassemble in the original position and direction.

10. Remove the camshaft(A).

11. Remove the cam follower(A).

12. Remove the HLA(Hydraulic Lash Adjust).

13. Remove the cylinder head bolts, then remove the cylinder head.
(1) Using bit socket (12PT), uniformly loosen and remove the 10 cylinder head bolts, in several passes, in
the sequence shown.Remove the 10 cylinder head bolts.

Head warpage or cracking could result from removing bolts in an incorrect order.

(2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden
blocks on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION
 •• Thoroughly clean all parts to be assembled.
•• Always use a new cylinder head and manifold gasket.
•• Always use a new cylinder head bolt.
•• The cylinder head gasket is a metal gasket. Take care not to bend it.
•• Rotate the crankshaft, set the No.1 piston at TDC.

1. Cylinder head dowel pins must be aligned.

2. Select the cylinder head gasket.
(1) Measure the piston protrusion from the upper cylinder block face (I) on 8 places (A ~ H) at T.D.C.
Measure on the crankshaft center line considering the piston migration.

(2) Select the gasket in the table below using the average value of piston protrusions. Although even the
only 1 point is over than the each rank limit, use 1 rank upper gasket than specified in the table below.

Displacement 1.6 L
 Average of piston 0.035 ~ 0.105mm 0.105 ~ 0.175mm 0.175 ~ 0.245mm
protrusion (0.0014 ~ 0.0041in) (0.0041 ~ 0.0069in) (0.0069 ~ 0.0096in)
1.00 ~ 1.15mm 1.05 ~ 1.20mm 1.10 ~ 1.25mm
Gasket thickness
(0.0394 ~ 0.0453in) (0.0413 ~ 0.0472in) (0.0433 ~ 0.0492in)
Limit of each rank
0.14mm (0.0055in) 0.21mm (0.0083in) -
extant

Identification code

(3) Install the gasket so that the identification mark faces toward the timing chain side.

3. Install the cylinder head gasket(A) on the cylinder block.

Be careful of the installation direction.

4. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
5. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using bit socket (12PT), install and tighten the 10 cylinder head bolts, in several passes, in the
sequence shown.

Tightening torque :
47.1~51.0Nm (4.8~5.2kgf.m, 34.7~37.6lb-ft) + (88~92°) + (118~122°)

Do not reuse the cylinder head bolts.

6. Istall the HLA(Hydraulic Lash Adjust).

 (1) Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust
does not adhere to HLA.
(2) HLA shall be inserted tenderly to the cylinder head not to spill diesel oil from HLA. In case of spilling, air
bent shall be done in accordance with the air bent procedure.

Stroke HLA in diesel oil 4~5 times by pushing its cap while pushing the ball down slightly by hard
steel wire. (Take care not to severely push hard steel wire down since ball is several grames.)

7. Install the cam follower(A).

8. Install the camshaft(A).

9. Install the camshaft bearing caps(A).

Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lbf.ft)
10. Install the vacuum pump(A) with new gasket(B).

Tightening torque :
10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lbf.ft)

Apply engine oil to the O-ring(A) of vacuum pump shaft before assembling vacuum pump.

11. Install the thermostat housing(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)
12. Reconnect the water hose(A) to thermostat housing.

13. Install the glow plug(A) and glow plug plate.

Tightening torque :
Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lbf.ft)
Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lbf.ft)

14. Install the delivery pipe(A).

Tightening torque :
14.7 ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lbf.ft)
15. Install the intake and exhaust manifold.
16. Install the timing chain.
17. Install the drive belt.

DISASSEMBLY
1. Remove the valves.
(1) Using the SST (09222-28000, 09222-28100)(A), compress the valve spring and remove the retainer
lock.

(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
(5) Using a needle-nose pliers, remove the stem oil seal.

INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and
the manifolds for warpage.

Flatness of cylinder head gasket surface :

Less than 0.03mm (0.0012in) for width
Less than 0.09mm (0.0035in) for length
Flatness of manifold mating surface :
Less than 0.025mm (0.0010in) for width
Less than 0.160mm (0.0063in) for length
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.

Valve guide inner diameter :

Intake : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)

(2) Using a micrometer, measure the outer diameter of valve stem.

 Valve stem outer diameter
Intake : 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
Exhaust : 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)

(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter
measurement.

Valve stem- to-guide clearance

Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Exhaust : 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)

If the clearance is greater than specification, replace the valve and valve guide.

2. Inspect the valves.

(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness. If the margin thickness is less than specification, replace the
valve.

Margin
Intake : 1.1mm (0.0433in)
Exhaust : 1.2mm (0.0472in)
 (4) Check the valve length.

Length
Intake : 93.0mm (3.6614in)
Exhaust : 93.7mm (3.6890in)

(5) Check the surface of valve stem tip for wear.

If the valve stem tip is worn, replace the valve.

3. Inspect the valve seats.

(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be
within specifications and centered on the valve face.

4. Inspect the valve springs.

(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.
 Valve spring
Standard
Free height : 44.9mm (1.7677in)
Load : 17.5±0.9kg/32.0mm (38.6±2.0lb/1.2598in)
31.0±1.6kg/23.5mm (68.3±3.5lb/0.9252in)
Out of square : Less than 1.5°
Limit
Out of square : 3°

If the loads is not as specified, replace the valve spring.

CAMSHAFT
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.

Cam height
Intake : 44.518 ~ 44.718mm (1.7527 ~ 1.7605in)
Exhaust : 44.418 ~ 44.618mm (1.7487 ~ 1.7566in)

If the cam lobe height is less than specification, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps and tighten the bolts with specified torque.

Tightening torque :
12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lbf.ft)

Do not turn the camshaft.

(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.

Bearing oil clearance

0.040 ~ 0.077mm (0.0016 ~ 0.0030in)

If the oil clearance is greater than specificaiton, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
(7) Completely remove the plastigage.
 (8) Remove the camshafts.

3. Inspect the camshaft end play.

(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)

If the end play is greater than specification, replace the camshaft. If necessary, replace the bearing caps
and cylinder head as a set.
(3) Remove the camshafts.

HLA (HYDRAULIC LASH ADJUSTER)

With the HLA filled with engine oil, hold A and press B by hand.
If B moves, replace the HLA.

Problem Possible cause Action

This noise will disappear after the
1. Temporary noise when starting a
Normal oil in the engine reaches the normal
cold engine
pressure.
2. Continuous noise when the Oil leakage of the high ressure
engine is started after parking more chamber on the HLA, allowing air to Noise will disappear within 15
than 48 hours. get in. minutes when engine runs at
2000-3000 rpm.
3. Continuous noise when the If it doesn’’t disappear, refer to step
Insufficient oil in cylinder head oil
engine is first started after 7 below.
gallery.
rebuilding cylinder head.
4. Continuous noise when the
engine is started after excessively
cranking the engine by the starter
motor or band. Oil leakage of the high-pressure
chamber in the HLA, allowing air to
get in.
5. Continuous noise when the Insufficient oil in the HLA.
engine is running after changing Do not run engine at a speed
the HLA. higher than 3000 rpm, as this
may damage the HLA.

Check oil level.

Engine oil level too high or too low.
Drain or add oil as necessary.
Excessive amount of air in the oil at
6. Continuous noise during idle Check oil supply system.
high engine speed.
after high engine speed.
Check oil quality.
Deteriorated oil. If deteriorated, replace with
specified type.
Check oil pressure and oil supply
Low oil pressure.
system of each part of engine.
7. Noise continues for more than 15
minutes. Remove the cylinder head cover
Faulty HLA. and press HLA down by hand.
If it moves, replace the HLA.

REASSEMBLY

•• Thoroughly clean all parts to be assembled.

•• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
•• Replace oil seals with new ones.

1. Install the valves.

(1) Using the SST (09222-2A000)(A), push in a new stem oil seal.

Do not reuse old valve stem oil seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.
(2) Install the valve, valve spring and spring retainer.

Place the valve springs so that the side coated with enamel faces toward the valve spring retainer
and then installs the retainer.

(3) Using the SST(09222-2A100, 09222-3K000)(A), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve
spring compressor.

(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure
proper seating of the valve and retainer lock.
 Engine Mechanical System

Engine Mechanical System

,UNPUL(UK;YHUZH_SL(ZZLTIS`
 2009 > D 1.6 TCI-U >

REMOVAL

•• Use fender covers to avoid damaging painted surfaces.

•• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

•• Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery terminals(A).

2. Remove the battery(A) and battery tray(B).

3. Remove the engine cover.

4. Drain the engine coolant. Remove the radiator cap to speed draining.
5. Remove the air duct(A).

6. Remove the intake hose(A).

7. Remove the air cleaner assembly.

(1) Disconnect the AFS(Air Flow Sensor) connector(A).
 (2) Remove the air cleaner upper cover(B).
(3) Remove the air hose(C).
(4) Remove the air cleaner element.
(5) Remove the bolts(B) and air cleaner lower cover(A).

8. Remove the main relay box(A).

9. Remove the wiring(A) from fuse box.

10. Remove the connector(A).

11. Remove the ground cable from transaxle(A) and cylinder head(B).

12. Remove the coolant reservoir tank hose(A).

13. Remove the radiator upper hose(A).

14. Remove the radiator lower hose(A).

15. Remove the fuel hose(A).

16. Remove the brake vacuum hose(A).

17. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
(1) Disconnect the glow plug connector(A).
(2) Disconnect the injector connector(B).

(3) Disconnect the vacuum solenoid valve connector(A) and vacuum hose(B).

(4) Disconnect the CMP(Camshaft position sensor) connector(A).

(5) Disconnect the EGR(Emission Gas Recirculation) solenoid valve connector(B).
(6) Disconnect the water temperature sensor connector(C).
(7) Disconnect the common rail pressure sensor connector(D).
(8) Disconnect the CKP(Crankshaft Position Sensor) connector(E).
(9) Remove the engine wire harness bracket(F).

(10) Disconnect the MAP sensor connector(A).

 (11) Disconnect the fuel temperature sensor connector(A).
(12) Disconnect the fuel pressure regulator connector(B).

18. Remove the heater hose(A).

19. Remove the power steering oil hose(A) and drain the power steering oil.
20. Remove the power steering return hose(A).

21. Remove the transaxle wire harness connectors and control cable from transaxle(M/T).
(1) Remove the clutch release cylinder(A).

(2) Remove the transaxle control cable(A).

(3) Disconnect the vehicle speed sensor connector(A).

(4) Disconnect the back lamp switch connector(B).
(5) Disconnect the neutral switch connector(C).
22. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine and
transaxle assembly.

23. Remove the engine mounting support bracket(A).

Tightening torque :
Nut(D) : 68.6 ~ 93.2N.m (7.0 ~ 9.5kgf.m, 50.6 ~ 68.7lbf.ft)
Bolt(B),Nut(C) : 49.0 ~ 63.7N.m
(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft)

24. Remove the transaxle mounting bracket(A).

Tightening torque :
Bolt(B) : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lbf.ft)
25. Remove the front tires.
26. Remove the ABS wheel speed sensor(A).

27. Remove the caliper and hang assembly(A).

28. Remove the knuckle mounting bolts(A).

29. Remove the steering u-joint mounting bolt(A).

30. Remove the front muffler(A).

31. Using a floor jack, support the engine and transaxle assembly.

After removing the sub frame mounting bolt , the engine and transaxle assembly may fall downward,
and so support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle
assembly.

32. Remove the sub frame bolts and nuts.

Tightening torque :
Bolt(A) : 39.2 ~ 53.9N.m (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8lbf.ft)
Nut(B),Bolt(C) : 156.9 ~ 176.5N.m
(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lbf.ft)
33. Remove the engine support fixture and the adapter.
34. Remove the engine and transaxle assembly by lifting vehicle.

When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or
body components.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
•• Adjust the shift cable.
•• Adjust the throttle cable.
•• Refill the engine with engine oil.
•• Refill the transaxle with fluid.
•• Refill the radiator and reservoir tank with engine coolant.
•• Place the heater control knob on "HOT" positon.
•• Bleed air from the cooling system
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to
be removed from the cooling system.
- Put the radiator cap on tightly, then run the engine again and check for leaks.
•• Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
•• Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump
runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
 Engine Mechanical System

Engine Mechanical System

Cylinder Block
2009 > D 1.6 TCI-U >

COMPONENTS
 2009 > D 1.6 TCI-U >

DISASSEMBLY
1. M/T : Remove the fly wheel.
2. A/T : Remove the drive plate.
3. Install the engine to engine stand for disassembly.
4. Remove the timing chain.
5. Remove the intake manifold and exhaust manifold.
6. Remove the cylinder head.
7. Remove the water pipe.

8. Remove the oil filter and oil cooler assembly(A).

9. Remove the bed plate(A).

10. Remove the rear oil seal(A).

11. Remove the connecting rod cap(A).

Mark the connecting rod caps to be able to reassemble in the original position and direction.

12. Remove the piston and connecting rod assemblies.

(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

•• Keep the bearings, connecting rod and cap together.

•• Arrange the piston and connecting rod assemblies in the correct order.

13. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.
14. Remove the oil jet.

15. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
16. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.
(2) Remove the 2 side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

17. Remove the connecting rod from the piston.

Using a press, remove the piston pin from piston.

INSPECTION
CONNECTING ROD
1. Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.

End play
Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in)
Maximum : 0.4mm (0.0157in)
 A. If out-of-tolerance, install a new connecting rod.
B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and cap, and tighten the nuts.

Tightening torque :
12.7Nm (1.3kgf.m, 9.4lb-ft) + (87~93°)

Do not turn the crankshaft.

Do not reuse the connection rod cap bolts.

(7) Remove the 2bolts, connecting rod cap and lower bearing .
(8) Measure the plastigage at its widest point.

Standard oil clearance

0.025 ~ 0.043mm (0.0010 ~ 0.0017in)

(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install
a new bearings with the same color mark.
Recheck the oil clearance.
 Do not file, shim, of scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting rod mark location

Discrimination of connecting rod

Connecting rod big-end

Mark
inner diameter
A 49.000 ~ 49.006mm (1.9291 ~ 1.9294in)
B 49.006 ~ 49.012mm (1.9294 ~ 1.9296in)
C 49.012 ~ 49.018mm (1.9296 ~ 1.9298in)

Crankshaft pin journal mark location

 Discrimination of crankshaft pin journal

Crankshaft pin journal

Mark
outer diameter
A 46.009 ~ 46.015mm (1.8114 ~ 1.8116in)
B 46.003 ~ 46.009mm (1.8111 ~ 1.8114in)
C 45.997 ~ 46.003mm (1.8109 ~ 1.8111in)

Connecting rod bearing mark location

Discrimination of connecting rod bearing

Color Connecting rod bearing thickness

Blue 1.477 ~ 1.480mm (0.0581 ~ 0.0583in)
Black 1.480 ~ 1.483mm (0.0583 ~ 0.0584in)
None 1.483 ~ 1.486mm (0.0584 ~ 0.0585in)
Green 1.486 ~ 1.489mm (0.0585 ~ 0.0586in)
Yellow 1.489 ~ 1.492mm (0.0586 ~ 0.0587in)

(11) Select the bearing by using selection table.

Connecting rod bearing selection table

Connecting rod mark

Connecting rod bearing
A B C
A Blue Black None
Crank shaft pin
B Black None Green
journal mark
C None Green Yellow

3. Check the connecting rods.

(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make sure that the notches for holding the bearing in
place are on the same side.
(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as
well.
(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to
the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted
 should be replaced.

Allowable bend of connecting rod :

0.05mm / 100mm (0.0020in / 3.94in ) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039in / 3.94in) or less

CRANKSHAFT
1. Check the crankshaft bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the bed plate and lower bearings.
(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the lower bearings and bed plate, then tighten the bolts.

Tightening torque :
Long bolts : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94°
Short bolts : 32.4~36.3N.m(3.3~3.7kgf.m, 23.9~26.8lbf.ft)

Do not turn the crankshaft.

(5) Remove the bed plate and lower bearing again, and measure the widest part of the plastigage.

Standard oil clearance :

0.024 ~ 0.042mm (0.0009 ~ 0.0017in)

(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install
a new bearings with the same color mark.
Recheck the oil clearance.

Do not file, shim, or scrape the bearings or the cap to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.
 If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with
a wire brush or scraper. Clean them only with solvent or detergent.

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION

Letters have been stamped on the front face of block as a mark for the size of each of the 5 main journal
bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the
correct bearings.

Discrimination of cylinder block crankshaft journal bore

Mark Cylinder block crankshaft journal bore inner diameter

A 58.000 ~ 58.006mm (2.2835 ~ 2.2837in)
B 58.006 ~ 58.012mm (2.2837 ~ 2.2839in)
C 58.012 ~ 58.018mm (2.2839 ~ 2.2842in)

Crankshaft main journal mark location

Discrimination of crankshaft main journal

Mark Crankshaft main journal outer diameter

A 53.984 ~ 53.990mm (2.1254 ~ 2.1256in)
B 53.978 ~ 53.984mm (2.1251 ~ 2.1254in)
C 53.972 ~ 53.978mm (2.1249 ~ 2.1251in)
 Crankshaft main bearing mark location

Discrimination of crankshaft main bearing

Color Crankshaft main bearing thickness

Blue 1.990 ~ 1.993mm (0.0783 ~ 0.0785in)
Black 1.993 ~ 1.996mm (0.0785 ~ 0.0786in)
None 1.996 ~ 1.999mm (0.0786 ~ 0.0787in)
Green 1.999 ~ 2.002mm (0.0787 ~ 0.0788in)
Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in)

(8) Select the bearing by using selection table.

Crankshaft main bearing selection table

Cylinder block crankshaft

Crankshaft main bearing journal bore mark
A B C
A Blue Black None
Crank shaft main
B Black None Green
journal mark
C None Green Yelllow

2. Check the crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)
 If the end play is greater than specification, replace the center main bearings as a set.

Thrust washer thickness of center main beaing :

2.335 ~ 2.385mm (0.0919 ~ 0.0939in)
End play
Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Limit : 0.30mm (0.0118in)

3. Inspect the crankshaft main journals and pin journals.

Using a micrometer, measure the diameter of each main journal and pin journal.

Main journal diameter :

53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal diameter :
45.997 ~ 46.015mm (1.8109 ~ 1.8116in)

CYLINDER BLOCK
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.

Flatness of cylinder block gasket surface

Less than 0.05mm (0.0020in)

4. Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5. Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :
77.200 ~ 77.230mm (3.0394 ~ 3.0405in)

6. Check the cylinder bore size code on the cylinder block front face.
 Discrimination of cylinder bore size

Mark Cylinder bore inner diameter

A 77.200 ~ 77.210mm (3.0394 ~ 3.0398in)
B 77.210 ~ 77.220mm (3.0398 ~ 3.0402in)
C 77.220 ~ 77.230mm (3.0402 ~ 3.0405in)

7. Check the piston size mark(A) on the piston top face.

Discrimination of piston outer diameter

Mark Piston outer diameter

A 77.130 ~ 77.140mm (3.0366 ~ 3.0370in)
B 77.140 ~ 77.150mm (3.0370 ~ 3.0374in)
C 77.150 ~ 77.160mm (3.0374 ~ 3.0378in)

8. Select the piston related to cylinder bore class.

Piston-to-cylinder clearance :
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)

Boring cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.

The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D(Outer Diameter), calculate the new bore size.

New bore size = piston O.D + 0.060 to 0.080mm (0.0024 to 0.0031in) (clearance between piston and
cylinder) - 0.01mm (0.0004in) (honing margin.)

4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the
firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Standard : 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder
to the oversize.

PISTON AND PISTON RINGS

1. Clean the piston.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 10mm (0.39in) from bottom land of the
piston.

Standard diameter :
77.13 ~ 77.16mm (3.0366 ~ 3.0378in)
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance :
0.06 ~ 0.08mm (0.0024 ~ 0.0031in)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.

Piston ring side clearance

No.1 : 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No.2 : 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

If the clearance is greater than maximum, replace the piston.

5. Inspect the piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If
the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore
inner diameter. If the bore is over the service limit, the cylinder block must be rebored.

Piston ring end gap

No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
 No.2 : 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)

PISTON PINS
1. Measure the outer diameter of piston pin.

Piston pin diameter :

27.995 ~ 28.000mm (1.1022 ~ 1.1024in)

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :

0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner
diameter.

Piston pin-to-connecting rod interference :

0.022 ~ 0.039mm (0.0009 ~ 0.0015in)

OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace
the oil pressure switch.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity
even when the fine wire is pushed, replace the switch.

3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) vacuum is applied through the oil hole, the
switch is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

REASSEMBLY

•• Thoroughly clean all parts to assembled.

 •• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
•• Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble the piston and connecting rod.

(1) Use a hydraulic press for installation
(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

2. Install the piston rings.

(1) Install the oil ring expander and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).
4. Install the crankshaft main bearings.

Upper 1, 2, 4, 5 bearings have an oil groove of oil holes ; Lower bearings do not.

(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).

(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

5. Install the oil jet.

Tightening torque :
8.8 ~ 12.7N.m (0.9 ~ 1.3kgf.m, 6.5 ~ 9.4lbf.ft)
6. Place the crankshaft on the cylinder block.

7. Place the bed plate on the cylinder block.

•• Standard liquid gasket : LOCTITE 5205, HYLOMAR3000, Dreibond 5105

•• Check that the mating surfaces are clean and dry before applying liquid gasket.
•• Apply liquid gasket in a 3mm wide bead without stopping.
•• Assemble the bed plate in 5 minutes after applying the liquid gasket.
•• After assembly, wait at least 30 minutes before filling the engine with oil.

8. Install the bed plate bolts.

•• The bed plate bolts are tightened in 2 progressive steps.

•• If any of the bed plate bolts in broken or deformed, replace it.
 (1) Apply a light coat of engine oil on the threads and under the bed plate bolts.
(2) Install and uniformly tighten the bed plate bolts(A),in several passes, in the sequence shown.

Tightening torque :
Long bolts(1~10) : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94°
Short bolts(11~20) : 32.4~36.3N.m (3.3~3.7kgf.m, 23.9~26.8lbf.ft)

Always use new main bearing cap bolts.

(3) Check that the crankshaft turns smoothly.

9. Check the crankshaft end play.

10. Install the piston and connecting rod assemblies.

Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.

(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the
connecting rod bolts.
(2) Install the ring compressor, check that the rings are securely in place, then position the piston in the
cylinder, and tap it in using the wooden handle of a hammer.
(3) Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment
before pushing the piston into place.
(4) Apply engine oil to the bolt threads. install the rod caps with bearings, and tighten the bolts.

Tightening torque :
12.7Nm (1.3kgf.m, 9.4lb-ft) + (87~93°)
 •• Always use new connecting rod bearing cap bolts.
•• Maintain downward force on the ring compressor to prevent the rings from expending before
entering the cylinder bore.

11. Install the rear oil seal.

(1) Apply engine oil to a new oil seal lip.
(2) Using the SST(09231-H1200, 09231-H1100)(A) and a hammer, tap in the oil seal until its surface is
flush with the rear oil seal retainer edge.

12. Install the oil filter and oil cooler assembly(A).

 Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft)

13. Install the water pipe(A).

Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbf.ft)

14. Install the cylinder head.

15. Install the intake manifold and exhaust manifold.
16. Install the timing chain.
17. Remove the engine stand.
18. A/T :install the drive plate.

Tightening torque :
68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lbf.ft)

19. M/T :install the fly wheel.

Tightening torque :
68.6 ~ 78.5N.m (7.0 ~ 8.0kgf.m, 50.6 ~ 57.9lbf.ft)
 Engine Mechanical System

Engine Mechanical System

Cooling System

2009 > D 1.6 TCI-U >

COMPONENT
 2009 > D 1.6 TCI-U >

REMOVAL
WATER PUMP
1. Drain the engine coolant.

System is under high pressure when the engine is hot.

To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.

2. Remove the drive belts.

3. Remove the water pump pulley(A).

4. Remove the water pump(A).

THRMOSTAT

Disassembly of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.

1. Drain the engine coolant so its level is below thermostat.

2. Remove the water inlet fitting(A), gasket and thermostat.
RADIATOR
1. Drain the engine coolant. Remove the radiator cap to speed draining.

2. Disconnect the battery terminals(A).

3. Remove the air duct(A).

4. Remove the radiator upper hose(A).

5. Remove the radiator lower hose(A).

Remove the clamp on the cooling fan cover.

6. Remove automatic transaxle fluid(ATF) cooler hose.(Refer to 'AT' group).

7. Disconnect the fan motor connector(A).

8. Disconnect the hose(A) between the reservoir and the radiator.

9. Remove the radiator mounting bolts(A) and remove the radiator from condenser.

10. Remove the radiator upper bracket(A), then pull up the radiator.

11. Remove the cooling fan(B) from the radiator(A).

 REPLACEMENT
ENGINE COOLANT

Never remove the radiator cap when the engine is hot.

Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical
parts of the paint. If any coolant spills, rinse it off immediately.

1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to
the touch.
2. Remove the radiator cap(A).

3. Loosen the drain plug(A), and drain the coolant.

4. Tighten the radiator drain plug(A) securely.
5. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant
reservoir tank to the MAX mark with the coolant.
6. Fill fluid mixture with coolant and water slowly through the radiator cap. Gently squeeze the upper/ lower
hoses of the radiator so as to bleed air easily.

•• Use only genuine antifreeze/coolant.

•• For best corrosion protection, the coolant concentration must be maintained year-round at 50%
minimum. Coolant concentrations less than 50% may not provide sufficient protection against
corrosion of freezing.
•• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

•• Do not mix different brands of antifreeze/coolants.

•• Do not use additional rust inhibitors or antirust products; they may not be compatible with the
coolant.

7. Start the engine and allow coolant to circulate. When the cooling fan operates and coolant circulates, refill
coolant through the radiator cap.
8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system.
9. Fill the reservoir to the "MAX" line with coolant.
10. Stop the engine and allow coolant to be cool.
11. Repeat step 6 to 10 until the coolant level stays constant and all air is bleed out of the cooling system.

Recheck the coolant level in the reservoir tank for 2 ~ 3 days after replacing coolant.

Coolant capacity : 6.97 liters(7.37 US qt, 6.13 lmp qt)

INSTALLATION
WATER PUMP
1. Install the water pump(A) and a new gasket.

Tightening torque :
 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbf.ft)

2. Install the water pump pulley(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)

3. Install the drive belts.

4. Fill with engine coolant.
5. Start engine and check for leaks.
6. Recheck engine coolant level.

THERMOSTAT
1. Place the thermostat in thermostat housing with new gasket.
2. Install the water inlet fitting(A).

Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.

RADIATOR
1. Install the cooling fan(B) to the radiator(A).

Tightening torque :
8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0 lbf.ft)

2. Install the radiator to the air conditioning condenser and the radiator upper bracket(A).

3. Connect the hose(A) between the radiator and the reservoir.

4. Connect the fan motor connector(A).

5. Install the upper and the lower radiator hoses(A) and the automatic transaxle fluid(ATF) cooler hose.

6. Fill with engine coolant and install the air duct(A).

7. Start engine and check for leaks.

INSPECTION

WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump
assembly if necessary.

3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump
assembly.

A small amount of "weeping" from the bleed hole is normal.

THERMOSTAT
1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature.

Valve opening temperature : 82±1.5°C (179.6±2.7°F)

Full opening temperature : 95°C (203°F)

If the valve opening temperature is not as specified, replace the thermostat.

3. Check the valve lift.

Valve lift : 8mm(0.3in) or more at 95°C (203°F)

If the valve lift is not as specified, replace the thermostat.

RADIATOR CAP
1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.

2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

RADIATOR LEAKAGE
1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then
install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51
~ 17.78psi).

3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.
Check for engine oil in the coolant and/or coolant in the engine oil.
 Engine Mechanical System

Engine Mechanical System

Lubrication System
2009 > D 1.6 TCI-U >

COMPONENTS
 2009 > D 1.6 TCI-U >

REMOVAL
OIL PUMP
1. Drain the engine oil.
2. Remove the drive belts.
3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover.
4. Remove the timing chain cover.
5. Remove the oil pump cover(A) from the timing chain cover.

6. Remove the inner rotor and outer rotor.

REPLACEMENT
OIL AND FILTER

•• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which
may cause skin cancer.
•• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner,
to remove any used engine oil. Do not use gasoline, thinners, or solvents.
•• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal
sites.

1. Drain the engine oil.

(1) Remove the oil filler cap.
(2) Remove the oil drain plug, and drain the oil into a container.

2. Replace the oil filter(B).

(1) Remove the oil filter upper cap(A).

(2) Replace the O-ring(C) of oil filter cap with a new one.
 Inspect the threads and O-ring(C). Wipe off the seat on the oil filter cap, then apply a light coat of oil to the oil filter
upper cap O-ring(C).
(3) Install the new oil filter by hand to the upper cap.
(4) After the rubber seal seats, tighten the oil filter clockwise.

Tightening torque :
24.5N.m(2.5kgf.m, 18.1lbf.ft)

3. Refill with engine oil.

(1) Clean and install the oil drain plug with a new gasket.

Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lbf.ft)

(2) Fill wih fresh engine oil.

Oil Capacity
Total : 5.7 L (6.02 US qt, 5.01 lmp qt)
Oil pan : 4.8 L (5.07 US qt, 4.22 lmp qt)
Drain and refill including oil filter : 5.3 L (5.60 US qt, 4.66 lmp qt)
Oil quality : ABOVE API CH-4 or ACEA B4 (with CPF:C3)

(3) Install the oil filler cap.

4. Start engine and check for oil leaks.

5. Recheck the engine oil level.

INSTALLATION
OIL PUMP
1. Install the oil pump.
(1) Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
(2) Install the oil pump cover(A) to timing chain cover with the screws.

Tightening torque :
5.9 ~ 8.8N.m (0.6 ~ 0.9kgf.m, 4.3 ~ 6.5lbf.ft)

2. Check that the oil pump turns freely.

3. Install the timing chain cover.
4. Install the drive belts.
5. Fill with engine oil.

DISASSEMBLY
RELIEF PLUNGER
1. Remove the relief plunger.
Remove the plug(A), spring(B) and relief plunger(C).

INSPECTION
1. Inspect the relief plunger.
Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight.
If it does not, replace the relief plunger. If necessary, replace the front case.
2. Inspect the rotor side clearance.
Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight
edge.

0.04 ~ 0.09mm
Outer rotor
(0.0016 ~ 0.0035in)
Side clearance
0.04 ~ 0.085mm
Inner rotor
(0.0016 ~ 0.0033in)

If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front case.

SELECTION OF ENGINE OIL

Recommended API classification : CH-04
Recommended ACEA classification : B4
Recommended SAE viscosity grades :
 For best performance and maximum protection of all types of operation, select only those lubricants which :
•• Satisfy the requirement of the API classification.
•• Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should not be
used.

ENGINE OIL
1. Check the engine oil quality.
Check the oil deterioration, entry of water, discoloring of thinning.
If the quality is visibly poor, replace the oil.
2. Check the engine oil level.
After warning up the engine and then 5 minutes after the engine stop, oil level should be between the ““L”” and ““F””
marks in the dipstick.
If low, check for leakage and add oil up to the ““F”” mark.

Do not fill with engine oil above the ““F”” mark.

REASSEMBLY
RELIEF PLUNGER
1. Install the relief plunger.
Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A).

Tightening torque :
25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lbf.ft)
 Engine Mechanical System

Engine Mechanical System

Intake And Exhaust System - Intake Manifold
2009 > D 1.6 TCI-U >

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 2009 > D 1.6 TCI-U >

REMOVAL
INTAKE MANIFOLD
1. Remove the engine harness protector(A) mounting bolts.

Tightening torque :
7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

2. Remove the high pressure pipe(A). (Refer th FL Gr.)

3. Remove the fuel temperature sensor mounting bolt(A). (Refer th FL Gr.)

4. Remove the EGR cooler and EGR valve assembly(A).

Tightening torque :
Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft)
Bolt & Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
5. Remove the intake manifold.

Tightening torque :
14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

6. Remove the intake manifold gasket(A).

7. Installation is in the reverse order of removal.

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Engine Mechanical System

Intake And Exhaust System - Exhaust Manifold
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 2009 > D 1.6 TCI-U >

REMOVAL

EXHAUST MANIFOLD
1. Remove the heat protector(A).

Tightening torque :
14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

2. Remove the water hose (A) from the EGR cooler and the thermostat housing.

3. Remove the EGR cooler and the EGR valve assembly(A).

Tightening torque :
Nut(B) : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
Bolt(C) : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft)
Bolt & Nut(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
4. Remove the catalytic converter stay(A).

Tightening torque :
21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft)

5. Remove the catalytic converter(A).

Tightening torque :
29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)

6. Remove the inter cooler hose(A) and the oil return pipe(B).

Tightening torque :
Nut(C) : 9.8 ~ 14.7 Nm (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
Bolt(D) : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
7. Remove the eye bolt(A) from the turbo charger oil feeding pipe.

Tightening torque :
13.7 ~ 18.6 Nm (1.4 ~ 1.9 kgf.m, 10.1 ~ 13.7 lb-ft)

8. Remove the turbo charger(B) first and then exhaust manifold assembly(A).

Tightening torque :
29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)

9. Remove the exhaust manifold gasket(A) .

10. Installation is in the reverse order of removal.
 Engine Mechanical System

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Intake And Exhaust System - -YVU[,_OH\Z[7PWL
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COMPONENTS
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