Escolar Documentos
Profissional Documentos
Cultura Documentos
GENERAL
SPECIFICATIONS EE49QA0A
Valve clearance
Cold (20°C[68°F])
0.20mm (0.0079in.) 0.12 - 0.28mm
Intake
(0.0047 - 0.0110in.)
0.28mm (0.0110 in,) 0.20 - 0.38mm
Exhaust
(0.0079 - 0.0150in.)
Cylinder head
0.06mm (0.0024in.)
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Flatness of gasket surface Max. 0.03mm (0.0012in.)
Flatness of manifold mounting surface Max. 0.15mm (0.0059in.) 0.03mm (0.0012in.)
Oversize rework dimensions of
valve seat hole
Intake
0.3mm (0.012in.) O.S. 33.300 - 33.325mm (1.3110 - 1.3120in.)
0.6mm (0.024in.) O.S. 33.600 ~ 33.625mm (1.3228 ~ 1.3238in.)
Exhaust
0.3mm (0.012in.) O.S. 28.800-28.821 mm (1.1338 - 1.1346in.)
0.6mm (0.024in.) O.S. 2 9 .1 0 0 - 29.121mm (1.1456 - 1.1465in.)
Oversize rework dimensions of valve
wt
guide hole (both intake and exhaust)
0.05mm (0.002in.) O.S 11.05 - 11.068mm (0.435 - 0.4357in.)
0.25mm (0.010in.) O.S 11.25 - 11.268mm (0.443 - 0.4436in.)
0.50mm (0.020in.) O.S 11.50 - 11.518mm (0.453 - 0.4535in.)
Cylinder block
Cylinder bore 82.00 - 82.03mm (3.2283 - 3.2295in.)
Out-of-round and taper of cylinder bore Less than 0.01mm (0.0004in.)
on
Oil pump
Clearance between outer circumference 0.120 ~ 0.185mm (0.0049 ~ 0.0073in.)
and front case.
Front case tip clearance 0.025 ~ 0.069mm (0.0009 ~ 0.0027in.)
Side clearance
Inner gear 0.04 ~ 0.085mm (0.0016 ~ 0.0033in.)
Outer gear 0.04 ~ 0.09mm (0.0016 ~ 0.0035in.)
Engine oil pressure at 1500 RPM 245KPa (2.5kg/cm2, 35.5psi)
[Oil temperature is 90 to 110°C
(194 to 230°F)j
GENERAL EM -5
SERVICE STANDRDS
Standard value
Antifreeze Maxture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50%
wt
on
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EM -6 ENGINE (G4GC - GSL 2.0)
TIGHTENING TORQUE
ECKD001X
y wore
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ECHE101A
4. Turn the crankshaft pulley, and align its groove with 6. Timing belt tension adjusting.
timing mark "T" of the timing belt cover.
1) Rotate crankshaft in regular direction (clock wise
view from front) through angle equivalent to two
teeth (18°) of camshaft sprocket(A).
on
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ECKD116B
ECKD106A
EM -10 ENGINE (G4GC - GSL 2.0)
2) Give tension to timing belt rotating tensioner in 7. Turn the crankshaft two turns in the operating direc
arrow direction tool and set timing belt not to give tion (clockwise) and realign crankshaft sprocket and
slack to tension side. camshaft sprocket timing mark.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7lbf.ft)
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Tightening torque
on
Tensioner bolt
ECKD105A
43 - 55Nm (430 - 550kgf.cm, 32 ~ 40lbf.ft)4
9. Install RH front wheel.
4) Recheck the belt tension, When the tension side
of timing belt is pushed horizontally with a mod 10. Install engine cover(A).
erate force [approx. 2kg (20N, 5lb)], the timing
belt cog end sags in approx. 4 - 6mm (0.16 -
0.24in.)
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ECHE101A
ECKD109E
GENERAL EM -11
VALVE CLEARANCE INSPECTION AND c. Disconnect the accelerater cable(A) from the
ADJUSTMENT cylinder head cover.
[ U note
]
ADIE002A
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ECKD112A
EM -12 ENGINE (G4GC - GSL 2.0)
4. Set No.1 cylinder to TDC/compression. 5. Inspect the valve clearance.
a. Turn the crankshaft pulley and align its groove a. Check only the valve indicated as shown. [No. 1
with the timing mark "T" of the lower timing belt cylinder: TDC/Compression] measure the valve
cover. clearance.
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EDKD888B
ECKD11OB
GENERAL EM -13
c. Check only valves indicated as shown. [NO. 4 c. Remove the adjusting shim with a small screw
cylinder: TDC/compressionj. Measure the valve driver(A) and magnet(B).
clearance. (See procedure in step (6))
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EDKB889C
EDKD888C
d. Measure the thickness of the removed shim using
6. Adjust the intake and exhaust valve clearance. a micrometer.
a. Turn the crankshaft so that the cam lobe of the
camshaft on the adjusting valve is upward.
on
09220-2D000
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EDKB889D
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EDKB889B
EM -14 ENGINE (G4GC - GSL 2.0)
e. Calculate the thickness of a new shim so that
the valve clearance comes within the speclflcifled
value.
( tpj note
)
perature : 20°C)
[Specification]
Intake : 0.20mm (0.0079in.)
Exhaust : 0.28mm (0.0110in.)
[Limit] (After adjusting valve clearance)
Intake : 0.17 - 0.23mm (0.0067 - 0.0091 in.)
Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)
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GENERAL
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Adjusting Shim Selection Chart (Intake)
I g
Measured cleafanes' £
mm (in.)
0.000 - (0.0000 - 0.0008)
0.021 - (0.0008 - 0.0016)
wt
0.041 - (0.0016 - 0.0024)
0.061 - (0.0024 - 0.0031)
0.081 - (0.0032 - 0.0039)
0.101 - (0.0040 - 0.0047)
0 .1 2 0 - (0.0047 - 0.0110)
0.281 - (0.0111 -0.0118)
0.301 - (0.0119-0.0126)
0.321 - (0.0126 - 0.0134)
on
0.341 - (0.0134 -0.0142)
0.361 - (0.0142 - 0.0150)
0.381 -
0.401 - (0.0158 - 0.0165)
0.421 -
0.441 -
0.461 -
0.481 -
0.501 - (0.0197 - 0.0205)
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0.521 - New shim thickness mm(in.)
0.541 - (0.0213 - 0.0220)
Shim Shim
0.561 - Thickness Thickness
No. No.
0.581 - (0.0229 - 0.0236)
1 2.00 (0.0787) 11 2.40 (0.0945)
0.601 -
0.621 - (0.0244 - 0.0252)
2 2.04 (0.0803) 12 2.44 (0.0961)
0.641 - (0.0252 - 0.0260)
0.661 - (0.0260 - 0.0268) 3 2.08 (0.0819) 13 2.48 (0.0976)
0.681 - (0.0268 - 0.0276)
0.701 - 4 2.12 (0.0835) 14 2.52 (0.0992)
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0.721 - (0.0284 - 0.0291)
5 2.16 (0.0850) 15 2.56 (0.1008)
0.741 - (0.0292 - 0.0299)
0.761 - (0.0300 - 0.0307)
6 2.20 (0.0866) 16 2.60 (0.1024)
0.781 - (0.0307 - 0.0315)
0.801 - 7 2.24 (0.0882) 17 2.64 (0.1039)
0.821 - (0.0323 - 0.0331)
0.841 - 8 2.28 (0.0898) 18 2.68 (0.1055)
0.861 - (0.0339 - 0.0346)
9 2.32 (0.0913) 19 2.72 (0.1071)
0.881 - (0.0347 - 0.0354)
0.901 -
10 2.36 (0.0929) 20 2.76 (0.1087)
0.921 - (0.0363 - 0.0370)
Intake valve clearance (C old):
0.941 -
0.20 mm (Spec.) 0.12 ~ 0.28mm (Limit) HINT : New shims have the thickness in miliime-
0.961 - (0.0378 - 0.0386) ters imprinted on the face
Example : The 2.24 mm shim is installed, and the
measured clearance is 0.450 mm. Replace the
2.24mm shim with a new No. 13 shim.
EM -15
EDKB888D
EM -16____________________________________________________ ENGINE (G4GC - GSL 2.0)
Adjusting Shim Selection Chart (Exhaust)
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M easured c le a ra n c e
n (in.)
(0.0000-0.0008)
(0.0008-0.0016)
(0.0040-0.0047)
wt
(0.0048-0.0055)
(0.0071-0.0078)
(0.0079-0.0142)
(0.0150-0.0157)
(0.0158-0.0165)
on
(0.0174-0.0181)
(0.0197-0.0205)
(0.0205-0.0213)
(0.0221-0.0228)
(0.0229-0.0236)
New shim thickness mm(in.)
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Shim Shim
Thickness Thickness
No. No.
(0.0260-0.0268)
1 2.00 (0.0787) 11 2.40 (0.0945)
(0.0268-0.0276)
(0.0276-0.0283) 2 2.04 (0.0803) 12 2.44 (0.0961)
(0.0300-0.0307)
4 2.12 (0.0835) 14 2.52 (0.0992)
(0.0307-0.0315)
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5 2.16 (0.0850) 15 2.56 (0.1008)
(0.0323-0.0331)
(0.0331-0.0339) 6 2.20 (0.0866) 16 2.60 (0.1024)
(0.0339-0.0346)
7 2.24 (0.0882) 17 2.64 (0.1039)
(0.0370-0.0378)
9 2.32 (0.0913) 19 2.72 (0.1071)
(0.0378-0.0386)
Intake valve clearance (C old):
10 2.36 (0.0929) 20 2.76 (0.1087)
0.28 mm (Spec.), 0.20 ~ 0.38 mm (Limit)
(0.0394-0.0402)
Example : The 2.24 mm shim is installed, and the H IN T : New shim s have the th ickn ess in m ilim e-
(0.0402-0.0409)
measured clearance is 0.450 mm. Replace the te rs im p rin te d on th e fa ce
2.24 mm shim with a new No. 11 shim.
EDKB888E
GENERAL EM -17
TROUBLESHOOTING E6D36B0F
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.
EM -18 ENGINE (G4GC - GSL 2.0)
• The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and
repair as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
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GENERAL EM -19
CD
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EDKA010A
Valve clearance adjust tool set Removal and installation of the tappet shim
(09220-2D000) P li e r
S to p p e r
wt
EDKB001A
EDDA005B
ECKA010B
Valve stem oil seal installer Installation of the valve stem oil seal
(09222-22001)
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ECKA010A
GENERAL EM -21
Crankshaft rear oil seal installer 1. Installation of the engine rear oil seal
(09231-21000) 2. Installation of the crankshaft rear oil seal
EDDA005F
wt
on
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E M -22____________________________________________________ENGINE (G4GC - GSL 2.0)
TIMING SYSTEM
COMPONENT
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on
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UCOG001A
TIMING SYSTEM EM -23
REMOVAL EA165A14 2) Remove the bolt(B), 3nuts(C, D) and engine
mount bracket(A).
Engine removal is not required for this procedure.
ECKD102A
[ U j NOTE
Place wooden block between the jack and engine oil
pan.
E M -24 ENGINE (G4GC - GSL 2.0)
5. Temporarily loosen the water pump pulley bolts. 12. Remove the crankshaft pulley bolt(B) and crankshaft
pulley(A).
A
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ECKD104B
ECKD107A
10. Remove the 4bolts and timing belt upper cover. (See
page EM - 9)
11. Turn the crankshaft pulley, and align its groove with
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ECKD108A
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TIMING SYSTEM EM -25
14. Remove the 5bolts(B) and timing belt lower cover(A).
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ECKD109B
ECKD108B
[X o Jj NOTE
15. Remove the timing belt tensioner(A) and timing If the timing belt is reused, make an arrow indicating
belt(B). the turning direction to make sure that the belt is rein
stalled in the same direction as before.
ECKD109A
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ECKD109C
E M -26 ENGINE (G4GC - GSL 2.0)
17. Remove the crankshaft sprocket(A). 19. Remove camshaft sprocket.
SPOCKETS, TENSIONER, IDLER 1. Install the camshaft sprocket and tighten the bolt to
the specified torque.
1. Check the camshaft sprocket, crankshaft sprocket,
tensioner pulley, and idler pulley for abnormal wear, 1) Temporarily install the camshaft sprocket bolt.
cracks, or damage. Replace as necessary.
2) Hold the hexagonal head wrench(A) portion of
2. Inspect the tensioner pulley and the idler pulley for the camshaft with a wrench(B), and tighten the
easy and smooth rotation and check for play or noise. camshaft sprocket(C) bolt.
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Replace as necessary.
Tightening torque
Camshaft sprocket bolt
100 - 120Nm (1000 - 1200kgf.cm, 74 ~ 89lbf.ft)
wt
on
bearing.
ECKD114A
TIMING BELT
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f U ] NOTE
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ADIE003A
wt
2) Install the PCV hose(A) and breather hose(B).
ECKD111A
ECKD112A
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ECKD110A
TIMING SYSTEM EM -29
4. Align the timing marks of the camshaft sprocket(A) 5. Install the idler pulley(A) and tighten the bolt(B) to the
and crankshaft sprocket(B) with the No.1 piston specified torque.
placed at top dead center and its compression
stroke. Tightening torque
Idler pulley bolt
43 ~ 55Nm (430 ~ 550kgf.m, 32 - 40lbf.ft)
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ECKD110B
ECKD109C
on
ECKD116A
E M -30 ENGINE (G4GC - GSL 2.0)
7. Install the timing belt so as not to give excessive slack 2) Give tension to timing belt by rotating tensioner
at the center of the belt. Install the timing belt with the in direction of the arrow with tool and set timing
following procedure. belt not to give slack to tension side.
Crankshaft sprocket (A) —• Idler pulley (B) —•
Camshaft sprocket (C) >timing belt tensioner (D).
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ACGE003A
9. Timing belt tension adjusting 4) Recheck the belt tension. When the tension side
of timing belt is pushed horizontally with a mod
1) Rotate crankshaft In regular direction (clock wise erate force [approx. 2kg (20N, 5lb)], the timing
view from front) through angle equivalant to two belt cog end sags in approx. 4 - 6mm (0.16 -
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ECKD116B ECKD109E
TIMING SYSTEM EM -31
10. Turn the crankshaft two turns in the operating direc 12. Install the flange and crankshaft pulley(A).
tion (clockwise) and realign crankshaft sprocket and Make sure that crankshaft sprocket pin fits the small
camshaft sprocket timing mark. hole in the pulley.
11. Install the timing belt lower cover(A) with 5 bolts(B).*8 Tightening torque
Crankshaft pulley bolt
Tightening torque 160 ~ 170Nm (1600 ~ 1700kgf.cm, 120 ~ 125lbf.ft)
Timing belt cover bolt
8 - 10Nm (80 ~100kg.cm, 6 ~ 7lbf.ft)
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on
ECKD107A
ECKD108B 13. Install the timing belt upper cover with 4bolts. (See
page EM -1 0 )
Tightening torque
Stay plate bolt
43 - 55Nm (430 - 550kgf.cm 32 - 40lbf.ft)
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on
ECKD104A
Tightening torque
Bolt(B), Nuts(C)
50 ~ 60Nm (500 ~ 600kgf.ft, 37 - 48lbf.ft)
N ut(D ): 60 ~ 80Nm (600 ~ 800kgf.m 44 ~ 59lbf.ft)
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ECHE105A
CYLINDER HEAD ASSEMBLY E M -33
CYLINDER HEAD
ASSEMBLY
COMPONENTS EAFF5C56
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Cylinder head cover
8 - 1 0 (8 0 - 1 0 0 ,6 -7 .4 )
Gasket
wt
_ ,. J u J t „ /M 1 0 : 25(250,18) + (60 -6 5 ) + (60 -6 5 )
Cylinder head bolt< M 1 2 . 30(300 22) + (60 _65 } + (6() _65 }
Cylinder head
on
✓ Cylinder block
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,M LA
— ^ R e t a i n e r lock-<~
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Retainer W
Auto Tensioner
Valve spring-
CVVT only
Stem seal^*g,
Spring seat— > ©
Timing chain
v — i
Chain sprocket^- Camshaft bearing cap
wt
Intake camshaft CVVT assembly
O CV filter C W T only
4 1 -5 1
(4 1 0 -5 1 0 , 3 0 -3 7 .6 )
Washer
on
100 -1 20 '
(1 0 0 0 -1 2 0 0 ,7 4 -8 9 )/ k
Camshaft sprocket
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Engine removal is not required for this procedure. 1) Disconnect the AFS connector.
(Qj) NOTE
wt
• Mark all wiring and hoses to avoid misconnec-
tion.
• Inspect the timing belt before removing the cylin
der head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EM - 9)
ECKD201A
2) Oil temperature sensor connector(B). 10) Disconnect ground cable(D) from the intake man
ifold.
3) ECT(Engine Coolant Temperature) sensor con
nector^).
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4) Ignition coil connector(D).
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on
ECKD205A
ECKD203A
ECKD206A
EDQF197A
CYLINDER HEAD ASSEMBLY E M -37
12) PCSV(Purge Control Solenoid Valve) connec- 9. Remove the PCSV hose(A).
tor(A).
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ECKD209A
ECKD207A
10. Remove the brake booster vacuum hose(A).
8. Remove the fuel inlet hose(A) from delivery pipe.
on
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nut, then slip the cable end out of the throttle linkage.
14. Remove the spark plug cable. (See EE group - igni ECKD212A
tion)
22. Remove the camshaft bearing caps(A) and
15. Remove the PCV hose. (See page EM -11) camshafts(B).
on
16. Remove the cylinder head cover. (See page EM -11 )
ECKD213A
CYLINDER HEAD ASSEMBLY E M -39
23. Remove the OCV(oil control valve)(A). 25. Remove the water hose(B) from the water pipe(A).
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ECKD214A ACGE009A
24. Remove the OCV(oil control valve) filter(A). 26. Remove the cylinder head bolts, then remove the
cylinder head.
ECKD215A
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ECKD216A
/?\ CAUTION
Head warpage or cracking could result from re
moving bolts in an Incorrect order.
E M -40 ENGINE (G4GC - GSL 2.0)
2) Lift the cylinder head from the dowels on the DISASSEMBLY E437D6BD
ECKD217A
2. Remove valves.
ECKD218A
6) Using a magnetic finger, remove the spring seat. 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.
ECKD001H
2. Inspect valves.
Margin
on
2) Using a micrometer, measure the diameter of the
[Standard]
valve stem.
Intake : 1.15mm(0.0453in.)
Exhaust : 1.35mm(0.0531in.)
[Limit]
Intake : 0.8mm(0.0315in.)
Exhaust : 1.0mm(0.040in.)
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ECKD220A
ECKD221A
CYLINDER HEAD ASSEMBLY E M -43
4) Check the surface of the valve stem tip for wear. CAMSHAFT
If the valve stem tip is worn, replace the valve.
1. Inspect cam lobes.
3. Inspect valve seats Using a micrometer, measure the cam lobe height.
Check the valve seat for evidence of overheating and
improper contact with the valve face. Cam height
Replace the seat if necessary. [Standard value]
Before reconditioning the seat, check the valve guide Intake : 44.618mm (1.7566in.)
for wear. If the valve guide is worn, replace it, then E xhaust: 44.518mm (1.7527in.)
recondition the seat. Recondition the valve seat with [Limit]
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a valve seat grinder or cutter. The valve seat contact Intake : 44.518mm (1.7527in.)
width should be within specifications and centered on E xhaust: 44.418mm (1.7487in.)
the valve face.
Valve spring
[Standard]
Free h eigh t: 48.86mm (1.9236in.)
Load : 18.8kg/39 mm (41.45lb/1.535in.)
[Limit]
Free h e ig h t: -1.0mm(-0.0394in.)
on
Out-of-square : 3°
ECKD223A
ECKD222A
/t\ CAUTION
on
Do not turn the camshaft
ECKD226A
ECKD225A
CYLINDER HEAD ASSEMBLY E M -45
C W T ASSEMBLY 4) Under the condition of (3), turn the C W T assem
bly to the advance angle side (the arrow marked
1. Inspect C W T assembly. direction in the illustration) with your hand.
Depending on the air pressure, the C W T assem
1) Check that the C W T assembly will not turn. bly will turn to the advance side without applying
force by hand. Also, under the condition that the
2) Apply vinyl tape to all the parts except the one
pressure can be hardly applied because of the
indicated by the arrow in the illustration.
air leakage from the port, there may be the case
that the lock pin could be hardly released.
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on
EDKD270B
BCGE010A
3) Wind tape around the tip of the air gun and apply
air of approx. 100kpa(1kgf/cm2,14psi)totheport
5) Except the position where the lock pin meets at
of the camshaft.
the maximum delay angle, let the CVVT assem
(Perform this order to release the lock pin lor the
bly turn back and forth and check the movable
maximum delay angle locking.)
range and that there is no disturbance.
ECHE600A
09221-3F100B
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ECHE600B
1. Install valves.
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1) Install the spring seats.
| U ] NOTE
Do not reuse old valve stem seals.
Incorrect installation o f the seal could result in oil leak
age past the valve guides.
wt
ECKD218A
ECKD229A
( □ ) NOTE
Place valve springs so that the side coated with
enamel faces toward the valve spring retainer and
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ECKD230A
E M -48 ENGINE (G4GC - GSL 2.0)
2. Install MLAs. INSTALLATION EB0A0CEF
ECKD231A
y note
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8 6 1 3 9
wt
on
ECKD214A
ECKD232A
CAUTION
4. Install OCV filter(A).
• Do not reuse the OCV when dropped.
Tightening torque
• Keep clean the OCV.
• Do not hold the OCV sleeve during servicing.
41 - 51 Nm (410 ~ 510kgf.cm, 30 ~ 37.6lbf.ft)
• When the OCV is installed on the engine, do
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ECKD215A
EM -50 ENGINE (G4GC - GSL 2.0)
6. Install the camshafts. 3) Install the timing chain auto tensioner(A).
1) Align the camshaft timing chain with the intake Tightening torque
timing chain sprocket and exhaust timing chain 8 - 10Nm (80 ~ 100kgf.cm, 6 - 7.4lbf.ft)
sprocket as shown.
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ECKD233A
ECKD212A
2) Install the camshafts(A) and bearing caps(B).
on
ECKD234A
ECKD235A
Tightening torque
8 - 10Nm (80 - 100kgf.cm, 6 - 7.4lbf.ft)
wt
ECKD236A
on
[u] NOTE
• Before installing the head cover gasket, thor
ADIE003A
oughly clean the head cover gasket and the
groove. 12. Install the intake manifold.
• When installing, make sure the head cover gas
ket is seated securely in the corners o f the re 13. Install the exhaust manifold.
cesses with no gap.2
14. Install the PCV. (See page EM - 28)
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ECKD237A
EM -52 ENGINE (G4GC - GSL 2.0)
16. Install the power steering pump bracket bolts(A). 20. Install the PCSV hose(A).
Tightening torque
35 - 50Nm (350 - 500kgf.cm, 26 ~ 37lbf.ft)
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ECKD209A
ECKD208A
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ECKD210A
CYLINDER HEAD ASSEMBLY EM -53
22. Install the engine wire harness connectors and wire 6) CMP connector(A).
harness clamps to the cylinder head and the intake
manifold.
1) PCSV connector(A).
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ECKD205A
7) ISA connector(B).
EDQF197A
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3) Connect the ground cable to the intake mani- 10) ECT sensor connector(C).
fold(D).
11) Oil temperature sensor connector(B).
4) Knock sensor connector(C).
ECKD201A
23. Install the heater hoses(A).
25. Install the Intake air hose and air cleaner assembly.
ECKD202A
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ENGINE AND TRANSAXLE ASSEMBLY EM -55
ENGINE AND TRANSAXLE 5. Remove the upper radiator hose(A) and lower radiator
hose(B).
ASSEMBLY
REMOVAL EDFA091F
/]\ CAUTION
• Use fender covers to avoid damaging painted
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surfaces.
• To avoid damage, unplug the wiring connec
tors carefully while holding the connector
portion.
M N0TE
• Mark all wiring and hoses to avoid misconnec-
tion.
• Inspection the timing belt before removing the
cylinder head.
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• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EM - 9)
ECKD201A
ECKD202A
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2. Remove the engine cover. 7. Remove the engine wire harness connectors and wire
harness clamps from the cylinder head and the intake
3. Drain the engine coolant. manifold.
Remove the radiator cap to speed draining.
1) OCV(Oil Control Valve) connector(A).
4. Remove the intake air hose and air cleaner assembly.
2) Oil temperature sensor connector(B).
1) Disconnect the AFS connector.
3) ECT(Engine Coolant Temperature) sensor(C)
2) Disconnect the breather hose from air cleaner connector.
hose.3
5) TPS(Throttle Position Sensor) connector(A). 12) Front heated oxygen sensor(A) connector.
EDQF197A
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nut, then slip the cable end out of the throttle linkage.
to r^ ).
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EDQF034A
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EDQF031A
ENGINE AND TRANSAXLE ASSEMBLY EM -59
17. Remove the under cover. 20. Remove the front strut lower mounting bolts and nuts.
(See SS griup - front strut)
18. Remove the front exhaust pipe(A).
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EDQF023A
EDQF192A
21. Remove the caliper and hang the caliper assem-
19. Disconnect the ABS wheel speed sensor(A) from both bly(A).
front knuckle. (See DS group - front axle)
on
A
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KXDSE03A
ECKD612A
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EM -60 ENGINE (G4GC - GSL 2.0)
22. Remove the steering u-joint mounting bolt(A). (See 25. Remove the transaxle mounting bracket(A).
ST group - steering)
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EDQF016A
ECKD616A
ECKD103A
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ENGINE AND TRANSAXLE ASSEMBLY EM -61
26. Remove the sub frame mounting bolts and nuts. INSTALLATION EC1DBCCB
ECKD618A
ENGINE BLOCK
COMPONENTS E3E04B86
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ECKD004A
ENGINE BLOCK EM -63
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on
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ECKD005A
EM -64 ENGINE (G4GC - GSL 2.0)
DISASSEMBLY E0A2AFBC 8. Remove oil pressure sensor(A).
ECKD301A
P
ECKD304A
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ECKD302A
ENGINE BLOCK EM -65
11. Remove oil screen. 16. Remove rear oil seal case.
Remove the 2bolts(C), oil screen(A) and gasket(B). Remove the 5 bolts(B) and rear oil seal case(A).
A
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ECKD305A ECKD306A
12. Check the connecting rod end play. (See page EM - 17. Remove crankshaft bearing cap and check oil clear
66) ance. (See page EM - 69)
13. Remove the connecting rod caps and check oil clear 18. Check the crankshaft end play. (See page EM - 71)
on
ance. (See page EM - 67)
19. Lift the crankshaft(A) out of the engine, being careful
14. Remove piston and connecting rod assemblies. not to damage journals.
block.
M no te
ECKD307A
EM -66_________________________________ ________________ ENGINE (G4GC - GSL 2.0)
20. Check fit between piston and piston pin. INSPECTION EC8FCA1F
u) no te
ECKD308A
Tightening torque
50 - 53Nm (500 - 530kgf.cm, 36.9 - 39lbf.ft)
(O) n o t e
Do not turn the crankshaft.
ENGINE BLOCK EM -67
7) Remove 2 nuts, connecting rod cap and bearing CONNECTING ROD MARK LOCATION
half.
M ark
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BDQE003A
4 8 .0 0 6 - 48.012mm
9) If the plastigage measures too wide or too nar b B
(1.8899 - 1.8902in.)
row, remove the upper half of the bearing, in
4 8 .0 1 2 - 48.018mm
stall a new, complete bearing with the same color c C
(1.8902 - 1.8904in.)
mark (select the color as shown in the next col
umn), and recheck the clearance.
,/;\ CAUTION
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[Uji] NOTE
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/?\ CAUTION
If the marks are indecipherable because o f an ac
cumulation o f dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent.
EM -68 ENGINE (G4GC - GSL 2.0)
CRANKSHAFT PIN MARK LOCATION PLACE OF IDENTIFICATION MARK (CONNECTING
ROD BEARING)
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ECKD311A
ECKD313A
DISCRIMINATION OF CRANKSHAFT
DISCRIMINATION OF CONNECTING ROD BEARING
OUTSIDE
CLSASS MARK
DIAMETER OF PIN THICKNESS OF
CLASS MARK
BEARING
44.960 - 44.966mm
on
I 1
(1.7 70 0 - 1.7703in.) 1.514 - 1.517mm
AA BLUE
(0.0596 - 0.0597in.)
44.952 - 44.960mm
II 2
(1.7 69 8 - 1.7700in.) 1.511 - 1.514mm
A BLACK
(0.0595 - 0.0596in.)
44.946 - 44.952mm
III 3
(1.7 69 5 - 1.7698in.) 1.508 - 1.511mm
B NONE
(0.0594 - 0.0595in.)
1.505 - 1.508mm
C GREEN
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(0.0593 - 0.0594in.)
1.502 - 1.505mm
D YELLOW
(0.0591 - 0.0593in)
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ENGINE BLOCK EM -69
11) Selection 5) Remove the cap and bearing again, and measure
the widest part of the plastigage.
CONNECT ASSEMBING
CRANKSHAFT
ING ROD CLASSIFI Standard oil clearance
INDENTIFICATION
IDENTIFICA CATION OF 0.028 - 0.046mm (0.0011 - 0.0018in.)
MARK
TION MARK BEARING
a (WHITE) D (YELLOW)
I (YELLOW) b (NONE) C (GREEN)
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c (YELLOW) B (NONE)
a (WHITE) C (GREEN)
II (NONE) b (NONE) B (NONE)
c (YELLOW) A (BLACK)
a (WHITE) B (NONE)
III (WHITE) b (NONE) A (BLACK)
c (YELLOW) AA (BLUE)
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3. Check the crankshaft bearing oil clearance.
u ] note
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
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/t\ CAUTION
If the marks are indecipherable because o f an ac
cumulation o f dirt and dust, do not scrub them
with a wire brush o r scraper. Clean them only with
solvent or detergent.
EM -70 ENGINE (G4GC - GSL 2.0)
CONNECTING RODS DISCRIMINATION OF CYLINDER BLOCK
1. When reinstalling, make sure that cylinder numbers CALSS MARK INSIDE DIAMETER
put on the connecting rod and cap at disassembly
61.000 ~ 61.006mm
match. When a new connecting rod is installed, make a A
(2.4015-2.4018in.)
sure that the notches for holding the bearing in place
are on the same side. 61.006 ~ 61.012mm
b B
(2.4018-2.4020in.)
2. Replace the connecting rod if it is damaged on the
61.012 - 61.018mm
thrust faces at either end. Also if step wear or a c C
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(2.4020 ~ 2.4023in.)
severely rough surface of the inside diameter of the
small end is apparent, the rod must be replaced as
well. CRANKSHAFT JOURNAL MARK LOCATION
DISCRIMINATION OF CRANKSHAFT
OUTSIDE
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ECKD314A
ENGINE BLOCK EM -71
PLACE OF IDENTIFICATION MARK (CRANKSHAFT SELECTION
BEARING)
CRANK ASSEM
CRANKSHAFT
SHAFT BORE BLING CLAS
IDENTIFICATION
IDENTIFICA SIFICATION
MARK
TION MARK OF BEARING
a (A) D (YELLOW)
I (YELLOW) b (B) C (GREEN)
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c (C) B (NONE)
a (A) C (GREEN)
II (NONE) b (B) B (NONE)
c (C) A (BLACK)
a (A) B (NONE)
III (WHITE) b (B) A (BLACK)
c (C) AA (BLUE)
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4. Check crankshaft end play.
ECKD316A Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
DISCRIMINATION OF CRANKSHAFT BEARING screwdriver.
(0.0789 - 0.790in.)
2.002 - 2.005mm
D YELLOW
(0.0788 - 0.0789in.)
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ECKD001B
ECKD001L
ECKD320B
,U) NOTE
Stamp the grade mark o f basic diameter with rubber
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Size
Class Piston outer diameter
code
81.97 - 81.98mm
A A
(3.2271 - 3.2275in.)
81.98 - 81.99mm
B None
(3.2275 - 3.2279in.)
81.99 - 82.00mm
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C C
(3.2279 - 3.2283in.)
3. According to the measured O.D., calculate the new 2. The standard measurement of the piston outside di
bore size. ameter is taken 47 mm (1.85 in.) from the top land of
the piston.
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New bore size = Piston O.D + 0.02 to 0.04mm
(0.0008 to 0.0016in.) (clearance between piston and Standard diameter
cylinder) - 0.01mm (0.0004in.) (honing margin.) 81.97 - 82.00mm (3.2272 ~ 3.2283in.)
,4\ CAUTION
on
[lj] n o t e
When boring the cylinders, finish all o f the cylinders
to the same oversize. Do not bore only one cylinder
to the oversize. ECKD001D
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ENGINE BLOCK EM -75
3. Calculate the difference between the cylinder bore di 5. Inspect piston ring end gap.
ameter and the piston diameter. To measure the piston ring end gap, insert a piston
ring into the cylinder bore. Position the ring at right
Piston-to-cylinder clearance angles to the cylinder wall by gently pressing it down
0.02 - 0.04mm(0.0008 - 0.0016in.) with a piston. Measure the gap with a feeler gauge. If
the gap exceeds the service limit, replace the piston
ring. If the gap is too large, recheck the cylinder bore
4. Inspect the piston ring side clearance.
diameter against the wear limits on page EM - 73 If
Using a feeler gauge, measure the clearance between
the bore is over the service limit, the cylinder block
new piston ring and the wall of the ring groove.
must be rebored. (See page EM - 74)
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Piston ring side clearance
Piston ring end gap
No. 1 : 0.04 - 0.08mm (0.0016 - 0.0031 in.)
Standard
No. 2 : 0.03 ~ 0.07mm (0.0012 - 0.0028in.)
No.1 : 0.23 ~ 0.38mm (0.0091 - 0.0150in.)
Limit
No.2 : 0.45 ~ 0.60mm (0.0177 ~ 0.0236in.)
No. 1 : 0.1mm (0.004in.)
Limit
No. 2 : 0.1mm (0.004in.)
No. 1, 2, oil ring : 1.0mm (0.039in.)
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ECKD001K
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EM -76 ENGINE (G4GC - GSL 2.0)
PISTON PINS OIP PRESSURE SWITCH
1. Measure the diameter of the piston pin. 1. Check the continuity between the terminal and the
body with an ohmmeter.
Piston pin diameter If there is no continuity, replace the oil pressure
20.001 - 20.006mm (0.7874 - 0.7876in.) switch.
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ECKD001Z ECKD001W
on
2. Measure the piston pin-to-piston clearance. 2. Check the continuity between the terminal and the
body when the fine wire is pushed. If there is con
Piston pin-to-piston clearance tinuity even when the fine wire is pushed, replace the
0.01 - 0.02mm (0.0004 - 0.0008in.) switch.
3. Check the difference between the piston pin diameter 3. If there is no continuity when a 50kpa (7psi) vacuum
and the connecting rod small end diameter. is applied throgh the oil hole, the switch is operaing
properly.
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Piston pin-to-connecting rod interference Check for air leakage. If air leaks, the diaphragm is
0.016 ~ 0.032mm (0.00063 ~ 0.00126in.) broken. Replace it.
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ECKD001Y
ENGINE BLOCK EM -77
REASSEMBLY EFF6CDF3 3) Position the piston rings so that the ring ends are
as shown.
(uj) NOTE
• 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.
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1. Assemble piston and connecting rod.
BDQE001A
ECKD322A
EM -78 ENGINE (G4GC - GSL 2.0)
4. Install main bearings. 5. Install thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal
\ J \ no te position of the cylinder block with the oil grooves fac
ing outward.
Upper 1,2,4,5 bearings have an oil groove o f oil holes;
Lower bearings do not.
ECKD324A
{Uj\ note
• The main bearing cap bolts are tightened in 2
progressive steps.
• If any o f the bearing cap bolts in broken or de
formed, replace it.1
ECHE200A
on
3) Retighten the bearing cap bolts by 60°~65° in the
numerical order shown. ECKD001F
4) Check that the crankshaft turns smoothly. 11. Install a new gasket and rear oil seal case(A) with 5
bolts(B).
9. Check crankshaft end play. (See page EM - 71)
ECKD306A
EM -80 ENGINE (G4GC - GSL 2.0)
14. Install oil screen.
( 0 ) NOTE
Install a new gasket(A) and oil screen(B) with 2
Check that the mating surfaces are clean and dry. bolts(C).
ECKD305A
on
[ y ] NOTE
Check that the mating surfaces are clean and dry be
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y NOTE
• To prevent leakage o f oil, apply liquid gasket to
the inner threads o f the bolt holes.
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ECKD302A
ECKD304A
ECKD303A ECKD301A
EM -82 ENGINE (G4GC - GSL 2.0)
20. Install cylinder head. (See page EM - 48)
Tightening torque
120 ~ 130Nm (1200 - 1300kgf.cm, 89 - 96lbf.ft)
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24. M/T : Install flywheel.
Tightening torque
120 ~ 130Nm (1200 - 1300kgf.cm, 89 ~ 96lbf.ft)
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COOLING SYSTEM EM -83
COOLING SYSTEM
COMPONENT E80DAED3
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10. Run the vehicle under idle until the cooling fan oper
o WARNING ates 2 - 3 times.
Never remove the radiator cap when the engine is
11. Stop the engine and wait coolant gets cool.
hot. Serious scalding could be caused by hot fluid
under high pressure escaping from the radiator.
12. Repeat 6 to 11 until the coolant level doesn’t fall any
more, bleed air out of the cooling system.
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,/j\ CAUTION
When pouring engine coolant, be sure to shut the (u) n o t e
relay box lid and not to let coolant spill on the Recheck the coolant level in the reservoir tank f b r 2 ~
electrical parts or the paint. If any coolant spills, 3 days after replacing coolant.
rinse it off immediately.
\J \N O T E
• Use only genuine antifreese/coolant.
• For best corrosion protection, the coolant con
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/t\ CAUTION
• Do not mix different brands o f an-
t
tifreeze/coolants.
• Do not use additional rust inhibitors or anti
rust products; they may not be compatible
with the coolant
1. Remove the radiator cap, wet its seal with engine WATER PUMP
coolant, then install it no pressure tester.
1. Drain the engine coolant.
© WARNING
System is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
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coolant, remove the cap only when the engine is
cool.
TESTING
[U] NOTE
Check for engine oil in the coolant and/or coolant in
the engine oil.
EM -86 ENGINE (G4GC - GSL 2.0)
THERMOSTAT INSPECTION EE14792C
\W \ n o t e WATER PUMP
Removal o f the thermostat would have an adverse 1. Check each part for cracks, damage or wear, and re
effect, causing a lowering o f cooling efficiency. Do place the coolant pump assembly if necessary.
not remove the thermostat, even if the engine tends
to overheat. 2. Check the bearing for damage, abnormal noise and
sluggish rotation, and replace the coolant pump as
1. Drain engine coolant so its level is below thermostat. sembly if necessary.
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2. Remove water inlet(A), gasket and thermostat.
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ECKD503A
fkj] NOTE
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ECKD503B
1. Install the water pump. 1) Install the thermostat with the jiggle valve up
ward.
1) Install the water pump(B) and a new gasket with
the 3 bolts. 2) Install a new gasket(A) to the thermostat(B).
Tightening torque
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20 ~ 27Nm (200 ~ 270kgf.cm, 15 ~ 20lbf.ft)
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ECKD510A
ECKD501B
LUBRICATION SYSTEM
COMPONENT E2A4EA3F
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ECKD007A
LUBRICATION SYSTEM E M -91
OIL AND FILTER ECF1A5FC INSPECTION
Tightening torque
40 - 45Nm (400 - 450kgf.cm, 30 - 33lbf.ft)
Capacity
Drain and refill
W/Oil filter change : 4.0I (4.23U.S.qts, 3.52lmp qts)
W/O Oil filter change : 3.7I (3.90U.S.qts, 3.26lmp qts)
°C
40
20 —
wt
10 -
- 7 —
■13 —
on
-1 8 —
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g j ) NOTE
For best performance and maximum protection o f all
types o f operation, select only those lubricants which
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ECKD411A
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ECKD402A
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E M -94 ENGINE (G4GC - GSL 2.0)
DISASSEMBLY E65B43FC INSPECTION EDACC2F5
E C K D 404A
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ECKD405A ECKD406A
on
If the tip clearance is greater than maximum, replace If the body clearance is greater than maximum, re
the rotor as a set. place the rotors as a set. If necessary, replace the
front case.
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E M -96 ENGINE (G4GC - GSL 2.0)
REASSEMBLY E158FA78 INSTALLATION EC494CD5
ECKD401A
Tighttening torque
20 ~ 27Nm (200 ~ 270kg.cm, 14.5 ~ 19.8lb.ft)
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INTAKE MANIFOLD
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I.S.A
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ECOC170A
INTAKE AND EXHAUST SYSTEM EM -101
REMOVAL ec8 do2 fd 5. Remove the delivery pipe(A).
INTAKE MANIFOLD
ECKD112A
EDQF195A
INTAKE AND EXHAUST SYSTEM EM -103
5. Remove the exhaust manifold.
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ACGE035A
on
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