Hyundai ZPP 416 ENGINE DOHC &file=Hyundai
User Manual: Hyundai ZPP 416 ENGINE DOHC
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ZPP 416 - Engine DOHC GENERAL TIMING SYSTEM TIMING BELT CYLINDER HEAD ASSEMBLY CYLINDER HEAD MAIN MOVING SYSTEM CAM SHAFT CRANK SHAFT FLY WHEEL PISTON COOLING SYSTEM ENGINE COOLANT HOSE／PIPES ENGINE COOLANT PUMP RADIATOR RADIATOR CAP THERMOSTAT LUBRICATION SYSTEM OIL PUMP ENGINE BLOCK ENGINE BLOCK INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD INTAKE MANIFOLD ZENITH POWER PRODUCTS - 416 EM -2 ENGINE DOHC GENERAL SPECIFICATION E5EC07D6 Description General Type Number of cylinders Bore Stroke Total displacement Compression ratio Firing order Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Valve overlap Cylinder head Flatness of cylinder head surface Flatness of mainfold mounting surface Oversize rework dimension of valve seat hole Intake 0.3mm (0.012 in.) O.S. 0.6mm (0.024 in.) O.S. Exhaust 0.3mm (0.012 in.) O.S. 0.6mm (0.024 in.) O.S Specification Limit In-line, Double Over Head Camshaft 4 76.5mm (3.0118 in) 87mm (3.4252 in) 1599 cc (97.54 cu.in) 10 1-3-4-2 5 35 43 5 10 Max. 0.03mm (0.0012 in.) 0.15mm (0.0059 in.) 0.1 mm (0.0039in.) 0.2mm (0.008in.) 30.7 ~ 30.721 mm (1.2087 ~ 1.2095 in.) 31.0 ~ 31.021 mm (1.2205 ~ 1.2213 in.) 27.3 ~ 27.321mm (1.0748 ~ 1.0756 in.) 27.6 ~ 27.621mm (1.0866 ~ 1.0874 in.) Oversize rework dimensions of valve Guide hole 0.05mm (0.002 in.) O.S. 0.25mm (0.010 in.) O.S. 0.50mm (0.020 in.) O.S. 11.05 ~ 11.068mm (0.435 ~ 0.4357 in.) 11.25 ~ 11.268mm (0.443 ~ 0.4436 in.) 11.50 ~ 11.518mm (0.453 ~ 0.4535 in.) Camshaft Cam lobe height Intake 43.4484mm (1.7106 in.) Exhaust 43.8489mm (1.7263 in.) Joumal O.D Bearing oil clearance End play ø27mm (1.0630 in.) 0.035 ~ 0.072mm (0.0014 ~ 0.0028 in.) 0.1 ~ 0.2mm (0.004 ~ 0.008 in.) 42.9484mm (1.6909in.) 43.3489mm (1.7.66in.) ZENITH POWER PRODUCTS - 416 GENERAL EM -3 Description Valve Valve length Intake Exhaust Stem O.D. Intake Exhaust Face angle thickness of valve head (Margin) Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve guide Installed dimension O.D. Intake Exhaust Service size Valve seat Width of seat contact Intake Exhaust Seat angle Oversize Valve spring Free length Load Squareness Cylinder block Cylinder bore Out- of- round and taper of cylinder bore Clearance with piston Specification Limit 91.7mm (3.6102 in.) 92.3mm (3.6339 in.) 5.955 ~ 5.97mm (0.2344 ~ 0.2350 in.) 5.935 ~ 5.95mm (0.2337 ~ 0.2343 in.) 1.1mm (0.0433 in.) 1.3mm (0.0512 in.) 0.03 ~ 0.06mm (0.0012 ~ 0.0024 in.) 0.05 ~ 0.08mm (0.0020 ~ 0.0031 in.) 0.8mm (0.031in.) 1.0mm (0.039in.) 0.10mm (0.0039in.) 0.15mm (0.0059in.) 12.8mm (0.504 in.) 12.8mm (0.504 in.) 0.05, 0.25, 0.50mm (0.002, 0.010, 0.020 in.) oversize 0.8 ~ 1.2mm (0.031 ~ 0.047 in.) 1.3 ~ 1.7mm (0.051 ~ 0.066 in.) 45 0.3, 0.6mm (0.012, 0.024 in.) oversize 44.00mm (1.7323 in.) 21.6kg/ 35mm (47.6lb/1.3780 in.) 45.1kg/ 27.2mm (99.4lb/1.071 in.) 1.5 or less 76.50 ~ 76.53mm (3.0118 ~ 3.0130 in.) Less than 0.01mm (0.0004 in.) 0.025 ~ 0.045mm (0.0009 ~ 0.0017 in.) Piston O.D. Service size Piston ring Side clearance No. 1 No. 2 Endgap No. 1 No. 2 Oil ring side rail Service size 76.465 ~ 76.495mm (3.0104 ~ 3.0116 in.) 0.25 mm (0.010 in.) oversize 0.04 ~ 0.085 mm (0.0015 ~ 0.0033 in.) 0.04 ~ 0.085 mm (0.0015 ~ 0.0033 in.) 0.1 mm (0.004 in.) 0.1 mm (0.004 in.) 0.15 ~ 0.30 mm (0.0059 ~ 0.012 in.) 0.30 ~ 0.45 mm (0.012 ~ 0.0177 in.) 0.2 ~ 0.7 mm (0.0078 ~ 0.0275 in.) 0.25 mm (0.010 in.) oversize 1.0 mm (0.039 in.) 1.0 mm (0.039 in.) 1.0 mm (0.039 in.) ZENITH POWER PRODUCTS - 416 EM -4 ENGINE DOHC Description Connecting rod Bend Twist Connecting rod big end to crankshaft side clearance Connecting rod bearing oil clearance Undersize Specification 0.05mm (0.0020 in.) or less 0.1mm (0.0039 in.) or less 0.100-0.250mm (0.0039-0.0098 in.) 45 mm (1.77 in.) 50 mm (1.97 in.) 0.03 mm (0.0012 in.) or less 0.005 mm (0.0002 in.) or less 0.05- 0.175 mm (0.0019- 0.0068 in.) Undersize rework dimension of pin 0.25mm (0.010 in.) 0.50mm (0.020 in.) 0.75mm (0.030 in.) 44.725 ~ 44.74mm (1.7608 ~ 1.7614 in.) 44.475 ~ 44.49mm (1.7509 ~ 1.7516 in.) 44.225 ~ 44.24mm (1.7411 ~ 1.7417 in.) Undersize rework dimension of journal 0.25mm (0.010 in.) 0.50mm (0.020 in.) 0.75mm (0.030 in.) 49.727 ~ 49.742mm (1.9577 ~ 1.9583 in.) 49.477 ~ 49.492mm (1.9479 ~ 1.9485 in.) 49.227 ~ 49.242mm (1.9380 ~ 1.9386 in.) Flywheel Runout 0.1mm (0.0039 in.) 0.12 ~ 0.18mm (0.0047 ~ 0.0070 in.) 0.025 ~ 0.069mm (0.001 ~ 0.0027 in.) 0.04 ~ 0.085mm (0.0016 ~ 0.0033 in.) 0.04 ~ 0.09mm (0.0016 ~ 0.0035 in.) Engine oil pressure Engine at idle [Oil temperature is 90 to 100 C (194 to 215 F)] 147KPa (1.5 kg/ cm², 21.33psi) Relief spring Free height Load 46.6mm (1.8346 in.) 6.1kg at 40.1mm (13.42lb/ 1.578 in.) Cooling method Water-cooled, pressurized, forced circulation with electrical fan Coolant Quantity Radiator Type Radiator cap Main valve opening pressure 0.4mm (0.0157in.) 0.018-0.036mm (0.0007-0.0014 in.) 0.25, 0.50, 0.75mm (0.010, 0.020, 0.030 in.) Crankshaft Pin O.D. Journal O.D. Bend Out- of- round, taper of journal and pin End play Oil pump Clearance between outer circumference and front case (body clearance) Front case tip clearance Side clearance Inner gear Outer gear Limit 6.5 liter Pressurized corrugated fin type Vacuum valve opening pressure 81.4 ~ 108 kpa (11.8 ~ 15.6 psi.,0.83 ~ 1.1kg/cm² ) -6.86 kpa (-1.00 psi, -0.07 kg/cm² or less Coolant pump Centrifugal type impeller 0.13mm (0.0051in.) ZENITH POWER PRODUCTS - 416 GENERAL EM -5 Description Thermostat Type Valve opening temperature Full-opening temperature Engine coolant temperature sensor Type Resistance Specification Wax pellet type with jiggle valve 82 C (180 F) 95 C (203 F) Heat-sensitive thermistor type 2.31 ~ 2.59k at 20 C(68 F) 146.9 ~ 147.3 at 110 C(230 F) Air cleaner Type Element Dry type Un woven cloth type Exhaust pipe Muffler Suspension system Expansion resonance type Rubber hangers NOTE O.D. = Outer Diameter I.D. = Inner Diameter O.S. = Oversize Diameter U.S. = Undersize Diameter Limit ZENITH POWER PRODUCTS - 416 EM -6 ENGINE DOHC TIGHTENING TORQUE Item Cylinder Block Front engine support bracket bolt and nut Engine suppot bracket stay bolt Oil pressure switch Cylinder head Cylinder head bolt Intake manifold bolts or nuts Exhaust manifold nut Cylinder head cover bolt Camshaft bearing cap bolt Rear plate bolt Nm Kg.cm Ib.ft 45 ~ 55 45 ~ 55 13 ~ 15 450 ~ 550 450 ~ 550 130 ~ 150 33 ~ 41 33 ~ 41 10 ~ 11 30+(90 )+Release all bolts+30+(90 ) 15 ~ 20 25 ~ 30 8 ~ 10 12 ~ 14 32 ~ 35 300+(90 )+Release all bolts+300+(90 ) 150 ~ 200 250 ~ 300 80 ~ 100 120 ~ 140 320 ~ 350 22+(90 )+Release all bolts+22+(90 ) 11 ~ 15 18 ~ 22 6 ~ 7 9 ~ 10 24 ~ 26 Main Moving system Connecting rod cap nut Crankshaft bearing cap bolt Fly wheel M/T bolt Drive plate A/T bolt 32 55 120 120 Timing system Crankshaft pulley bolt Camshaft sprocket bolt Timing belt tensioner bolt Timing belt idle bolt Timing belt cover bolt Front case bolt Engine Mounting Right mounting insulator (large) bolt Right mounting insulator (small) nut Transmission mount insulator bolt Transmission insulator bracket to side member bolts Front roll stopper insulator bolt Front roll stopper bracket to sub frame bolt Rear roll stopper insulator bolt Rear roll stopper bracket to sub frame bolt Oil Oil Oil Oil filter pan bolts pan drain plug screen bolts ~ ~ ~ ~ 35 60 130 130 320 550 1200 1200 ~ ~ ~ ~ 350 600 1300 1300 24 41 89 89 ~ ~ ~ ~ 26 44 96 96 140 ~ 150 80 ~ 100 20 ~ 27 43 ~ 55 8 ~ 10 20 ~ 27 1400 ~ 1500 800 ~ 1000 200 ~ 270 430 ~ 550 80 ~ 100 200 ~ 270 103 59 15 32 6 15 ~ ~ ~ ~ ~ ~ 111 74 20 41 7 20 90 ~ 110 50 ~ 65 90 ~ 110 30 ~ 40 900 ~ 1100 500 ~ 650 900 ~ 1100 300 ~ 400 66 37 66 22 ~ ~ ~ ~ 81 48 81 30 45 30 45 30 ~ ~ ~ ~ 60 40 60 40 450 300 450 300 ~ ~ ~ ~ 600 400 600 400 33 22 33 22 ~ ~ ~ ~ 44 30 44 30 12 10 40 15 ~ ~ ~ ~ 16 12 45 22 120 100 400 150 ~ ~ ~ ~ 160 120 450 220 9 ~ 12 7 ~ 9 30 ~ 33 11 ~ 16 ZENITH POWER PRODUCTS - 416 GENERAL EM -7 Item Nm Kg.cm Ib.ft Alternator support bolt and nut Alternator lock bolt Alternator brace mounting bolt Coolant pump pulley Coolant pump bolt Coolant temperature sensor Coolant inlet fitting bolt Thermostat housing bolt 20 ~ 25 12 ~ 15 20 ~ 27 8 ~ 10 12 ~ 15 25 ~ 30 17 ~ 20 15 ~ 20 200 ~ 250 120 ~ 150 200 ~ 270 80 ~ 100 120 ~ 150 250 ~ 300 170 ~ 200 150 ~ 200 15 ~ 18 9 ~ 11 15 ~ 20 6 ~ 7 9 ~ 11 18 ~ 22 13 ~ 14 11 ~ 14 Air cleaner body mounting bolts Resonator mounting bolts Intake manifold to cylinder head nuts and bolts Surge tank stay to cylinder block bolts Throttle body to surge tank bolts Exhaust manifold to cylinder head nuts Exhaust manifold cover to exhaust manifold bolts Oxygen sensor to exhaust manifold Front exhaust pipe to exhaust manifold nuts Front exhaust pipe bracket bolts Front exhaust pipe to catalytic converter bolts 8 ~ 10 4 ~ 6 15 ~ 20 18 ~ 25 15 ~ 20 25 ~ 30 15 ~ 20 [80 ~ 100 40 ~ 60 150 ~ 200 180 ~ 250 150 ~ 200 250 ~ 300 150 ~ 200 6 3 11 13 11 18 11 ~ ~ ~ ~ ~ ~ ~ 7 4 14 18 14 22 14 50 30 30 40 500 300 300 400 37 22 22 30 ~ ~ ~ ~ 44 30 30 44 ~ ~ ~ ~ 60 40 40 60 ~ ~ ~ ~ 600 400 400 600 SERVICE STANDARD Standard value Antifreeze Mixture ratio of anti-freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM 50% ZENITH POWER PRODUCTS - 416 EM -8 ENGINE DOHC MAINTENANCE CHANGING ENGINE OIL CHECKING ENGINE OIL CAUTION 1. Position the vehicle on a level surface. 2. Warm up the engine. Be careful not to burn yourself, as the engine oil is hot. 1. Run the engine until it reaches normal operating temperature. 2. Turn off the engine 3. Remove the oil filler cap and the drain plug (on the oil pan). Drain the engine oil. NOTE If a vehicle has been out of service for a prolonged period of time, warm up the engine for approximately 20 minutes. 3. Turn off the engine, and wait 2 or 3 minutes, then check the oil level. 4. Check that the engine oil level is within the level range indicated on the oil dipstick If the oil level is found to have fallen to the lower limit (the L mark), refill to the "F" mark. Lower limit L Upper limit F KCPC001B ECDA001A 4. NOTE When refilling, use the same type of engine oil. 5. Check that the oil is not dirty or contaminated with coolant or gasoline, and that it has the proper viscosity. Install and tighten the drain plug to the specified torque. Tightening torque Drain plug : 40 ~ 45 Nm (400 ~ 450 kg.cm, 30 ~ 33 lb.ft) 5. Fill the crankcase with fresh engine oil through the oil filler cap opening. Drain and Refill Without oil filter : 3.0 liter (3.17 U.S.qts, 2.64 lmp.quts) Draing and Refill With oil filter : 3.3 liter (3.48 U.S.qts, 2.64 lmp.quts) 6. Install the oil filler cap. 7. Start and run the engine. 8. Turn off the engine and then check the oil level. Add oil if necessary. ZENITH POWER PRODUCTS - 416 GENERAL EM -9 3. FILTER SELECTION Tighten the oil filter to the specified torque. All Hyundai engines are equipped with a high quality, disposable oil filter. This filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is completely removed from the contact surface on the engine block before installing the new filter. KCPC001C Tightening torque Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft) Part number EDDA063A PROCEDURE FOR REPLACING THE OIL FILTER CAUTION Be careful not to burn yourself, as the engine and engine oil are hot. 1. Use a filter wrench to remove the oil filter. 2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket. Apply engine oil to the surface EDDA063B 4. Run the engine to check for engine oil leaks. 5. After turning off the engine, check the oil level and add oil as necessary. ZENITH POWER PRODUCTS - 416 EM -10 ENGINE DOHC SELECTION OF ENGINE OIL Recommended API classification : SH OR ABOVE Recommended SAE viscosity grades : Temperature range anticipated before next oil change ˚C 40 ˚F 104 Recommended SAE viscosity number 20W 15W 10W 10W -50 -50 -50 -30 20 68 10 50 -10 14 -15 5 -25 -13 -40 -40 -40 5W -40 *1 5W -30 *1 5W -20 *1 *2 *1 Restricted by driving condition and environment. *2 Not recommended for sustained high speed vehicle operation EDA9990B NOTE For best performance and maximum protection of all types of operation, select only those lubricants which: 1. 2. Satisfy the requirements of the API classification. Have proper SAE grade number for expected ambient temperature range. Lubricant that does not have both an SAE grade number and an API service classification on the container should not be used. ZENITH POWER PRODUCTS - 416 GENERAL EM -11 CHECKING COOLANT LEAK RADIATOR CAP PRESSURE TEST 1. Wait until the engine is cool, then carefully remove the radiator cap. 1. Remove the radiator cap, wet its seal with engine coolant, then install it on the tester. 2. Confirm that the coolant level is up to the filler neck. 2. Increase the pressure until the gauge stops moving. 3. Install a radiator cap tester to the radiator filler neck and apply 140 KPa (1.4 kg/cm², 20psi ) pressure. Hold it for two minutes in that condition, while checking for leakage from the radiator, hoses or connections. NOTE 1. 2. 3. 4. 4. Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could gush out causing personal injury. Allow the vehicle to cool before servicing this system. Be sure to clean away any moisture from the places checked completely. When the tester is removed, be careful not to spill any coolant from it. Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator. Main valve opening pressure : 83 ~ 110 kPa (0.83 ~ 1.1 kg/cm², 12 ~ 16 psi) Vacuum valve opening pressure : -7 kPa (-0.07 kg/cm², -1.0 psi) 3. Check that the pressure level is maintained at or above the limit. 4. Replace the radiator cap if the reading does not remain at or above the limit. NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect reading. If there is leakage, repair or replace with the apropriate part. Adapter ECA9090A KDPC001F ZENITH POWER PRODUCTS - 416 EM -12 ENGINE DOHC SPECIFIC GRAVITY TEST 1. Measure the specific gravity of the coolant with a hydrometer. 2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference. KDPC001E RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperatur C ( F) and specific gravity Safe operating temperature C ( F) Coolant concentration (Specific volume) 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) Freezing temperature C ( F) 1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30% 1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35% 1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40% 1.079 1.074 1.069 1.064 1.058 -30 (-22) -25(-13) 45% 1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50% 1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55% 1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60% Example The safe operating temperature is -15 C (5 F) when the measured specific gravity is 1.058 at coolant temperature of 20 C (68 F) CAUTION • If the concentration is above 60%, both the anti-freeze and engine cooling property will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified ragne. • Do not use together with another brank’s product. • If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely affected. RECOMMENDED COOLANT Antifreeze Mixture ratio of anti freeze in coolant ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas] 40% [Tropical areas] ZENITH POWER PRODUCTS - 416 GENERAL EM -13 CHECKING COMPRESSION PRESSURE CHANGING ENGINE COOLANT CAUTION When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on electrical parts or 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. 3. Loosen the drain plug, and drain the coolant. 1. Before checking engine compression, check the engine oil level. Also check that the starter motor and battery are all in normal operating condition. 2. Check the DTC and note it. Use the scan tool to clear the ECM’S memory. 3. Start the engine and wait until engine coolant temperature reaches 80 ~ 95 C (176 ~ 205 F). 4. Disconnect the fule pump connector. 5. Turn off engine and disconnect the spark plug cables. KCDC002B KDDC008B 4. Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservior. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze. 6. Pour coolant into the radiator up to the base of the filler neck, and install the radiator cap loosely. 7. Start the engine and let it run until it warms up (the radiator fan comes on at least twice). 8. Turn off the engine. Check the level in the radiator, add coolant if needed. 9. Put the radiator cap on tightly, then run the engine again and check for leaks. 6. Remove the spark plugs. 7. Disonnect the I.G. connector. 8. Crank the engine to remove any foreign material in the cylinders. 9. Insert the compression gauge into the spark plug hole. KDPC001B 10. Depress the accelerator pedal to open the throttle fully. ZENITH POWER PRODUCTS - 416 EM -14 ENGINE DOHC 11. Crank the engine and read the gauge. 3. Remove the engine support bracket. (14mm bolt and 2nuts, 17mm bolt) Standard value : 1500kpa (15Kg/cm², 218 psi) Limit : 1400kpa (14Kg/cm², 203 psi) 12. Repeat steps 9 to 11 over all cylinders, ensuring that the pressure differential for each of the cylinders is within the specified limit. Limit Max 100 kpa (1.0 kg/cm², 14 psi) between cylinders 13. If a cylinder’s compression or pressure differential is outside the specification, add a small amount of oil through the spark plug hole, and repeat steps 9 to 12. 1) If the addition of oil makes the compression to rise, it is likely that there may be wear between the piston ring and cylinder wall. 2) If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes. KDDC003B 4. Remove the drive belts and the water pump pulley. (10 mm 4 bolts) Tightening torque Spark plug : 20 ~ 30 Nm (200 ~ 300 kg.cm, 14 ~ 22 lb.ft) ADJUSTING TIMING BELT TENSION 1. Rotate the throughly. steering wheel counter-clockwise KDDC004B 5. NOTE Remove the timing belt upper cover. (10 mm 4 bolts) Do watch not to over load. 2. Lift the vehicle by using of jack. KCDC002C KCDA125K ZENITH POWER PRODUCTS - 416 GENERAL 6. EM -15 11. Check that the teeth of the sprocket and belt coincide with each other. Remove the crankshaft pulley. 12. Tighten the slot side bolt first and then tighten the bolt of pivot side. 13. Check the tension of the timing belt. When the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11 lb)], the the timing belt log end is approx. half of the tensioner mounting bolt head radius (cross flats) away from the bolt head center. KDDC007B 7. Remove the timing belt lower cover. 8. Place the pistion of No. 1 cylinder to TDC of the compression stroke by rotating the crankshaft clockwise. NOTE Crankshaft is to be rotated clockwise otherwise, the tension is inadequately adjusted. EDKE108A 14. Rotate the crankshaft pulley two turns clockwise so that the timing belt positions on the pulleys. Idler pulley 15. Install the timing belt lower cover. 16. Install the crankshaft pulley. Tensioner pulley 17. Install the timing belt upper cover. 18. Install the water pump pulley and engine support bracket. EDDB091A 9. Loosen the tensioner bolt of pivot side and slotside. EDDA092A 10. Rotate the crankshaft clockwise as many as 2 teeth of camshaft sprocket. ZENITH POWER PRODUCTS - 416 EM -16 ENGINE DOHC ADJUSTING DRIVE BELT TENSION 1. Check that the belts are not damaged and are properly fit for the pulley grooves. 2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in the illustration, measure the amount of deflection with a tension gauge. Pulley V-ribbed belt Wrong Wrong Right CAUTION 1. 2. When installing the V-ribbed belt, check that the V-ribs are properly aligned. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact surface, and check the pulley for scoring. Also check the amount that the belt is deflected. ECA9980A STANDARD VALUE: Itmes For alternator For air conditioner For power steering Deflection mm (in.) Tension N (lb) Inspection Adjustment New Used 5.1~6.0(0.200~0.236) 4.0~4.4(0.157~0.173) 5.0~5.7(0.200~0.224) 350~500(79~112 650~750(143~165) 400~500(88~110) 8(0.31) 5.0~5.5(0.20~0.22) 6.0~7.0(0.24~0.28) Tension N (lb) 250~500(56~112) 470~570(106~128) 320~400(72~90) Deflection mm (in.) 6.0~9.0(0.24~0.35) - - Deflection mm (in.) ZENITH POWER PRODUCTS - 416 GENERAL EM -17 Typ B NOTE 1. 2. 3. 4. The belt tension must be measured half - way between the specified pulleys. When a new belt is installed, adjust the tension to the central value of the standard range indicated under "New" in the above table. Let the engine idle for 5 minutes or more, and check the standard value indicated under "Inspection." When adjusting a belt which has been used,or newly installed, after 5 minutes or more of operation, refer to the standard value indicated under "Used" in the above table. Refer to the standard value indicated under "Inspection" for periodic inspections. RESET button RESET position Spindle Hook V-ribbed belt ECA9980D ADJUSTING THE ALTERNATOR BELT Air conditioning compressor pulley CAUTION If the belt is too loose, it will cause noise or sudden wear. If the belt is too tight, the engine coolant pump bearing or the alternator can get damaged. Power steering oil pump pulley Coolant pump pulley 1. Loosen the alternator nut "A" and the tension adjuster lock bolt "B". 2. Using the tension adjuster bolt, adjust the belt tension to the specification. 3. Tighten the adjuster lock bolt "B". 4. Tighten the alternator nut "A". 5. Check the tension or the deflection of belt, readjust if necessary. Alternator Crankshaft pulley Tensioner pulley ECPD001B TYPE A TENSION GAUGE Do not let the dial section of the tension gauge contact other objects during measurement. Typ A Tightening torque Alternator support bolt and nut : 20 ~ 25 Nm (200 ~ 250 kg.cm, 14 ~ 18 lb.ft) Alternator lock bolt B : 12 ~ 15 Nm (120 ~ 150 kg.cm, 9 ~ 11 lb.ft) Alternator brace mounting bolt : 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 lb.ft) Indicated value Dial Spindle Hook Spindle V-ribbed belt Alternator brace Hook ECA9980C Coolant pump pulley B TYPE B TENSION GAUGE 1. 2. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET position. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension value after removing the gauge. 1 Crankshaft pulley A ECKA010H ZENITH POWER PRODUCTS - 416 EM -18 SPECIAL TOOLS ENGINE DOHC E0845550 Tool (Number and name) Illustration Use Crankshaft front oil seal installer (09231 - 22000) Installation of the front oil seal ECKA010C Crankshaft front oil seal guide (09231 - 22100) Guide of oil seal ECKA010D Camshaft oil seal installer (09221 - 21000) Installation of the camshaft oil seal EDDA005B Valve guide installer (09221 - 3F100 A/B) Removal and installation of valve guides ECKA010B Valve stem oil seal installer (09222 - 22001) Installation of valve stem oil seals ECKA010A ZENITH POWER PRODUCTS - 416 GENERAL Tool (Number and name) EM -19 Illustration Use Valve spring compressor (09222 - 28000) Valve spring compressor holder (09222 - 28100) Removal and installation of intake and exhaust valves EDDA005C Water temperature sensor socket wrench (09221 - 25100) Removal and installation of the water temperature sensor EDKD101B Crankshaft rear oil seal installer (09231 - 21000) Installation of engine real oil seal and crankshaft rear oil seal EDDA005F ZENITH POWER PRODUCTS - 416 EM -20 ENGINE DOHC TROUBLESHOOTING Symptom Low compression E6712BDA Probable cause Remedy Blown cylinder head gasket Replace gasket Worn or damaged piston rings Replace rings Worn piston or cylinder Repair or replace piston and/or cylinder block Worn or damaged valve seat Repair or replace valve and/or seat ring Low engine oil level Check engine oil level Faulty oil pressure switch Replace Clogged oil filter Replace Worn oil pump gears or cover Replace Thin or diluted engine oil Change and determine cause Oil relief valve stuck (open) Repair Excessive bearing clearance Replace High oil pressure Oil relief valve sutck (closed) Repair Excessive engine vibration Loose engine roll stopper (front, rear) Re-tighten Loose transaxle mount bracket Re-tighten Loose engine mount bracket Re-tighten Loose center member Re-tighten Broken transaxle mount insulator Replace Broken engine mount insulator Replace Broken engine roll stopper insulator Replace Thin or diluted engine oil (low oil pressure) Change Worn or damaged valve stem or valve guide Replace HLA abnormal operation Speed the engine up (for venting) or Replace the HLA Insufficient oil supply Check engine oil level Thin or diluted engine oil Change and determine cause Excessive bearing clearance Replace Timing belt noise Incorrect belt tension Adjust belt tension Low coolant level Leakage of coolant Low oil pressure Noisy valves Connecting rod and/or main bearing noise Clogged radiator 1. Heater or radiator hose Repair or replace parts 2. Faulty radiator cap Tighten or replace clamps 3. Thermostat housing Replace gasket or housing 4. Radiator Repair or replace 5. Engine coolant pump Replace parts Foreign material in coolant Replace coolant ZENITH POWER PRODUCTS - 416 GENERAL EM -21 Symptom Abnormally high coolant temperature Probable cause Remedy Faulty thermostat Replace parts Faulty radiator cap Replace parts Restricted flow in cooling system Clear restriction or replace parts Loose or missing drive belt Adjust or replace Faulty water pump Replace Faulty electric fan Repair or replace Insufficient coolant Refill coolant Faulty thermostat Replace Faulty temperature sensor wiring Repair or replace Inoperative electrical cooling fan Damaged thermo sensor, electrical motor, radiator fan relay and wiring, fuse Replace or repair Exhaust gas leakage Loose connections Retighten Broken pipe or muffler Repair or replace Detached baffle plate in muffler Replace Broken rubber hanger Replace Pipe or muffler contacting vehuicle body Correct Broken pipe or muffler Repair or replace Abnormally low coolant temperature Abnormal noise ZENITH POWER PRODUCTS - 416 EM -22 ENGINE DOHC TIMING SYSTEM TIMING BELT COMPONENTS E4B24FDE Cylinder head cover Camshaft sprocket Timing belt upper cover Timing belt 80 ~ 100 (800 ~ 1000, 59 ~ 74) Ten sioner Idler 43 ~ 55 (430 ~ 550, 32 ~ 40) 20 ~ 27 (200 ~ 270, 15 ~ 20) Flange 140 ~ 150 (1400 ~ 1500, 103 ~ 111) Crankshaft sprocket Timing belt lower cover Crankshaft pulley TORQUE : Nm (kgf·cm, lbf·ft) EDKD100A ZENITH POWER PRODUCTS - 416 TIMING SYSTEM DISASSEMBLY 1. EM -23 5. EE695E6A Remove the alternator belt. Lift the vehicle by using of jack. KBPD160A KCDA125K 2. Remove the engine support bracket. (14 mm bolt and 2 nuts, 17 mm bolt) KBPD160B 6. Remove the coolant pump pulley. KDDC003B 3. Remove the power steering belt. 4. Remove the air conditioning compressor belt. KDDC004B ZENITH POWER PRODUCTS - 416 EM -24 7. ENGINE Remove the crankshaft pulley. DOHC 10. Remove the timing belt. NOTE If the timing belt is reused, mark with an arrow to indicate direction of rotation (on the front of the engine) to make sure that the belt is reinstalled in the same direction as before. KDDC007B 8. Remove the timing belt cover. ECDA121B 11. Remove the camshaft from the camshaft sprocket. 12. Remove the crankshaft sprocket and flange. 13. Remove the timing belt idler. 14. Remove the timing belt tensioner. KCDC002C 9. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. KDPC008C EDDA092A ZENITH POWER PRODUCTS - 416 TIMING SYSTEM INSPECTION EM -25 E193FC6F SPROCKETS TENSIONER PULLEY, AND IDLER PULLEY 1. Check the camshaft sporcket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace as necessary. 3. Replace the pulley if there is a grease leak from its bearing. EDKD106A TIMING BELT 1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent. 2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are evident, replace the belt with a new one. OIL WATER EDDA093B ZENITH POWER PRODUCTS - 416 EM -26 ENGINE Description DOHC Flaw conditions 1. Hardened back surface • Back surface is glossy, non-elastic and so hard that when your fingernail is pressed into it. no mark is produced. EDDA093C 2. Cracked back surface rubber EDDA093D 3. Cracked or separating canvas Crack EDDA093E Separation EDDA093F Crack Separation EDDA093G 4. Badly worn teeth (initial stages) • Canvas on load side of tooth flank worn (Fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture) Flank worn (On load side) EDDA093H 5. Badly worn teeth (last stage) • Canvas on load side of tooth flank worn down and rubber exposed (tooth width reduced) Rubber exposed EDDA093I ZENITH POWER PRODUCTS - 416 TIMING SYSTEM EM -27 Description Flaw conditions 6. Cracked tooth bottom Crack EDDA093J 7. Missing tooth Tooth missing and canvas fiber exposed EDDA093K 8. Side of belt badly worn NOTE Normal belt shluld have precisely cut sides as if cut by a sharp knife. 9. Side of belt cracked ZENITH POWER PRODUCTS - 416 EM -28 REASSEMBLY 1. ENGINE 4. E6A34B7C DOHC Align the timing marks of the camshaft sprocket (A) and camshaft bearing cap (B). Then align the timing marks of crankshaft sprocket and front case with the No.1 piston placed at top dead center on its compression stroke as shown in the illustration. Install the flange and crankshaft sprocket as shown. Pay close attention to their mounting directions. Special washer B Crankshaft Crankshaft sprocket A Flange ECNC094B 2. Install the camshaft sprocket and tighten the bolt to the specified torque. ECDD008F Tightening torque Camshaft sprocket bolt : 80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~74 lb.ft) 3. Install the idler and tighten the idler bolt to the specified torque. Tightening torque Idler bolt : 43 ~ 55 Nm (430 ~ 550 kg.cm, 32 ~ 41 lb.ft) EDKE107A 5. To install the timing belt tensioner, first mount the tensioner, spring, and spacer. Temporarily tighten the bolts. Next, temporarily tighten the tensioner long hole side washer and bolts. Install the bottom end of the spring against the front case as shown in the illustration. EDKE103A KDPC008D ZENITH POWER PRODUCTS - 416 TIMING SYSTEM 6. EM -29 Secure the tensioner, positioned towards the water pump. 11. Then recheck the belt tension Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11lb)], the timing belt cog end is aprox. 1/2 of the tensioner monting bolt head radius (across flats) away from the bolt head center. KDPC008E 7. Install the timing belt on the crankshaft sprocket. (1) Crankshaft sprocket → (2) Timing belt idler → (3) Camshaft sprocket → (4) Timing belt tensioner. EDKE108A 12. Install the timing belt cover. 3 2 4 EDDA094F Tightening torque Timing belt cover bolt : 8 ~10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft) 1 EDKE109A 8. 9. Install the timing belt on the camshaft sprocket. When the timing belt is installed on the camshaft sprocket, make sure that the tension side is tight. Then, check to ensure that when the tension side is tightened by turning the camshaft sprocket in a reverse direction and all timing marks are in line. Tighten the tensioner bolts. Tightening torque Tensioner attaching bolt : 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 lb.ft) 10. Turn the crankshaft two turns in its operating direction (clock-wise) and realign the camshaft sprocket timing mark with the top dead center position. 13. Install the crankshaft pulley. Make sure that the crankshaft sprocket pin fits the small hole in the pulley. Tightening torque Crankshaft pulley bolt : 140 ~ 150 Nm (1400 ~ 1500 kg.cm, 103 ~ 111 lb.ft) ZENITH POWER PRODUCTS - 416 EM -30 ENGINE 14. Install the water pump pulley. KDDC004B 15. Install the alternator belt and adjust the belt tension. 16. Install the air conditioning compressor belt and adjust the belt tension. 17. Install the power steering belt and adjust the belt tension. DOHC ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -31 CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS E804EE47 8 ~ 10 (80 ~ 100, 6 ~ 7.4) Cylinder head cover Gasket Cylinder head bolt 30(300, 22) + 90˚ → Release all bolts → 30(300, 22) + 90˚ Cylinder head Cylinder head gasket Cylinder block TORQUE : Nm (kgf.cm, lbf.ft) EDKD110A ZENITH POWER PRODUCTS - 416 EM -32 ENGINE DOHC HLA Retainer lock Valve spring Retainer Timing chain Stem seal Spring seat Valve Chain sprocket Exhaust camshaft Intake camshaft 12 ~ 14 (120 ~ 140, 9 ~ 10) 80 ~ 100 (800 ~ 100, 59 ~ 74) Camshaft sprocket TORQUE : Nm (kgf·cm, lbf·ft) EDKD111A ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY DISASSEMBLY 1. EM -33 INSPECTION EBCFA4C6 Using a tool remove the cylinder head bolts in the order shown in the illustration. 3 1 5 7 10 9 8 6 EE4FDB50 CYLINDER HEAD 1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head. 2. Remove scale, sealing compound and carbon deopsits completely. After cleaning the oil passages, apply compressed air to verify that the passages are not clogged. 2 4 EDKD115A 2. Using the special tool (09222-28000, 09222-28100), remove the valve retainer lock. Next remove the spring retainer, valve spring, spring seat and valve. NOTE Arrange these parts so that they can be reinstalled in their original positions. 09222-28100 09222-28000 ECKD001H EDKD116A 3. 3. Remove the valve stem seals with pliers. NOTE Do not reuse the valve stem seals. Check the cylinder head surface for flatness in the direction as shown in the illustration. If flatness exceeds the service limit in any direcftion, either replace the cylinder head or machine the cylinder head matching surface lightly. Flatness of cylinder head gasket surface Standard : Less than 0.03 mm (0.0012 in.) Limit : 0.05 mm (0.002 in.) EDDE088B ZENITH POWER PRODUCTS - 416 EM -34 ENGINE DOHC VALVES VALVE SPRINGS 1. 1. Check the free height of each valve spring. If they exceed the servicd limit, replace the springs. 2. Using a square, test the squareness of each spring. If a spring is excessively out - of - square, replace it. Using a wire brush, clean the valve thoroughly. ECA9281A 2. Check each valve for wear, damage and distortion of the head and the stem at B position. Replace, if necessary. If stem end, A, is hollowed out or worn, resurface as necessary. This correction must be limited to a minimum. Also resurface the valve face. Replace the valve if the margin has decreased to less than the service limit. Valve spring [Standard] Free height : 44 mm (1.7323 in.) Load : 21.6 kg/35 mm (47.6 lb/1.3780 in.) 45.1 kg/27.2 mm (99.4 lb/1.0709 in.) Out of square : 1.5 [Limit] Free height : - 1.0 mm (- 0.039 in.) Out of square : 3 Out-of-square 2˚ Margin [Standard] Intake : 1.1 mm (0.043 in.) Exhaust : 1.3 mm (0.051 in.) [Limit] Intake : 0.8 mm (0.028 in.) Exhaust : 1.0 mm (0.040 in.) Free height ECA9281C Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with the next oversize part. Margin ECKD221A Valve stem-to-clearance [Standard] Intake : 0.03 ~ 0.06 mm (0.0012 ~ 0.0024 in.) Exhaust : 0.05 ~ 0.08 mm (0.0020 ~ 0.0031 in.) [Limit] Intake : 0.1 mm (0.0040 in.) Exhaust : 0.15 mm (0.0059 in.) Valve guide Stem diameter Guide inside diameter ECA9281D ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -35 REPLACING THE VALVE SEAT RING 1. 2. Enlarge the diameter of the valve seat so that it matches the specified oversize hole diameter of the new valve seat ring. 3. Heat the cylinder head to about 250 C (480 F) and press - fit an oversize seat ring for the bore in the cylinder head. 4. Using lapping compound, lap the valve to the new seat. Cut away the inner face of the valve seat to reduce the wall thickness. 0.3 - 0.6 mm (0.0118 - 0.0236 in.) 0.3 mm (0.012 in. R) D∅ New hole Valve seat contact width Intake : 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in.) Exhaust : 1.3 ~ 1.7 mm (0.0512 ~ 0.0670 in.) H Old hole Remove 0.15 - 0.3 mm (0.006 - 0.0118 in.) A B ECA9281F VALVE SEAT INSERT OVERSIZES Description Size mm (in.) Size mark Seat ring height H mm (in.) Oversize hole diameter I.D. mm (in.) Intake valve Seat ring 0.3 (0.012) O.S. 30 5.1~5.3(0.2008~0.2087) 30.7~30.721 (1.2087~1.2095 0.6 (0.024) O.S. 60 5.4~5.6(0.2126~0.2205) 31.0~31.021(1.2205~1.2213) Exhaust valve Seat ring 0.3 (0.012) O.S. 30 6.2~6.4(0.2441~0.2520) 27.3~27.321(1.0748~1.0756) 0.6 (0.024) O.S. 60 6.5~6.7(0.2560~0.2638) 27.6~27.621(1.0866~1.0874) REPLACING VALVE GUIDE 1. Using the special tool (09221-3F100 A/B), withdraw the old valve guide toward the bottom of cylinder head. 2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide. (09221-3F100B) Valve guide installer adapter Valve guide installer (09221-3F100A) 14mm (0.5512 in.) Valve guide Cylinder head Valve guide installer ECDE109C ZENITH POWER PRODUCTS - 416 EM -36 ENGINE DOHC 3. Using the special tool (09221-3F100 A/B), press-fit the valve guide. The valve guide must be press-fitted from the upper side of the cylinder head. 4. After the valve guide is press-fitted, insert a new valve and check for proper the clearance 5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary. VALVE GUIDE OVERSIZES Over size mm (in.) Size mark Oversize valve guide hole size mm (in.) 0.05 (0.002) 5 11.05~11.068 (0.4350~0.4357) 0.25 (0.010) 25 11.25~11.268 (0.4429~0.4436) 0.50 (0.020) 50 11.50~11.518 (0.4528~0.4535) ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY REASSEMBLY EM -37 4. EC46B95A NOTE 1. 2. 1. Clean each part before assembly. Apply engine oil to the sliding and rotating parts. Install the spring seats. Using a special tool (09222-22001), tap the seal in position lightly. Using the special tool (09222-28000, 09222-28100), 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. 09222-28100 NOTE • Do not reuse old valve stem seals. • Incorrect installation of the seal could result in oil leakage past the valve guides. 2. 09222-28000 Apply engine oil to each valve. Insert the valve into the valve guide. Avoid pushing the valve into the seal by force. After inserting the valve, check that it moves smoothly. EDKD116A NOTE When the spring is compressed, Check that the valve stem seal is not pressed against the bottom of the retainer. 09222-22001 Valve stem seal Valve spring seat ECHB930A 3. Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer. 5. Clean both gasket surfaces of the cylinder block and cylinder head. 6. Verify the identification marks on the cylinder head gasket. 7. Install the gasket so that the surface with the identification mark faces toward the cylinder head. 8. Tighten the bolts to the specified torque in the sequence shown. 8 6 1 10 4 2 3 9 Spring Retainer Enamel coated side Spring Stem seal Spring seat 5 7 EDKD700A ECA9290B Cylinder head bolt 30 Nm (300 kg.cm, 22 lb.ft)+90 +Release all bolts + 30 Nm(300kg.cm, 22 lb.ft)+90 ZENITH POWER PRODUCTS - 416 EM -38 ENGINE DOHC MAIN MOVING SYSTEM CAM SHAFT COMPONENTS EE8F4E76 5 ~ 8 (50 ~ 80, 4 ~ 6) 8 ~ 10 (80 ~ 100, 6 ~ 7) Cylinder head Gasket 12 ~ 14 (50 ~ 80, 4 ~ 6) Bearing cap (rear) Bearing cap (front) 80 ~ 100 (800 ~ 1000, 59 ~ 74) Camshaft oil seal Intake camshaft Exhaust camshaft HLA Camshaft sprocket TORQUE : Nm (kg.cm, lb.ft) EDDA018A ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM DISASSEMBLY EM -39 6. EBF99CFA 1. Disconnect the breather hose and the P.C.V. hose. 2. Loosen the center cover bolts and then remove the center cover. 3. Remove the ignition coil assembly and the spark plug cables. Remove the camshaft bearing caps and timing chain. EDKE124A KCDC002B 4. Loosen the cylinder head cover bolts and then remove the cylinder head cover. EDKE104A 5. Remove the camshaft sprocket. 7. Remove the camshaft. 8. Remove the HLA. ZENITH POWER PRODUCTS - 416 EM -40 INSPECTION ENGINE DOHC ECDFFBF8 1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft. 2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft. Standard value Intake : 43.4484 mm (1.7106 in.) Exhaust : 43.8489 mm (1.7263 in.) Limit Intake : 42.9484 mm (1.6909 in.) Exhaust : 43.3489 mm (1.7066 in.) ECKD223A 3. Check the cam surface for abnormal wear or damage, and replace if necessary. 4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary. Camshaft end play : 0.1 - 0.2 mm (0.0039 - 0.0079 in.) OIL SEAL 1. Check the lips for wear. If the lip threads are worn, replace. 2. Check the oil seal lip contacting surface of the camshaft. If it is worn, replace the camshaft. ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -41 A HLA ( HYDRAULIC LASH ADJUSTER) With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA. For other specific trouleshooting regarding HLA, refer to the table below. B EDDA020B Possible cause Problem Action Temporary noise on starting a cold engine. Normal This noise will disappear after the oil in the engine has reached normal pressure. Continuous noise when engine is running after sitting more than 48 hours. Oil leakage of the high pressure chamber on HLA, allowing air to get in. Continuous noise when engine is first started after rebuilding cylinder head. Insufficient oil in cylinder head oil gallery. Noise will disappear within 15 minutes when engine runs at 2000~3000 rpm If it doesn’t disappear, refer to item 7 below Continuous noise when engine is running after excessive cranking. Oil drain out of the high-pressure chamber in HLA, allowing air to get in. Insufficient oil in HLA. Continuous noise when engine is running after changing HLA. CAUTION Do not run engine at a speed higher than 3000 rpm as this may damage HLA. Continuous noise during idle after high speed running. Noise continuous for more than 15 minutes. Engine oil level too high or too low. Check oil level. Drain or add oil as necessary. Excessive amount of air in the oil at high engine speed. Check oil supply system Deteriorated oil Check oil quality. Low oil pressure Check oil pressure and oil supply system of each part of engine Faulty HLA. Remove the cylinder head cover and press down on the HLA by hand. If it move, replace HLA. CAUTION Be careful of hot HLA. NOTE HLA noise could occur to your engine due to malfunction of HLA if you use additives besides engine oil regulated to HMC. ZENITH POWER PRODUCTS - 416 EM -42 ENGINE DOHC 4. TIMING CHAIN Check the bushing and plate of timing chain for wear. Replace if wear is severe. Install the bearing caps. The markings on the caps are for intake/exhaust identification. I: Intake camshaft E: Exhaust camshaft Cap number Symbol identifying intake EDDA020C REASSEMBLY EDDA021C 5. E1337F9D 1. Install the HLA. 2. Align the camshaft timing chain with intake timing chain sprocket and exhaust timing chain sprocket as shown. Tighten the bearing caps to the specified torque in two or three steps as shown. Tightening torque Bearing cap bolt : 12 ~ 14 Nm (120 ~ 140 kg.cm, 9 ~ 10 lb.ft) Camshaft sprocket side Timing chain Intake timing chain sprocket I3 I4 E3 E1 E5 I2 EDDA021D EDDA021A 3. E2 Timing mark I1 Timing mark E1 I5 Exhaust timing chain sprocket Install the camshaft after lubricating the camshaft journals with engine oil. EDDA021B ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM 6. EM -43 Using the special tool, camshaft oil seal installer (09221 - 21000), press fit the camshaft oil seal. Be susre to apply engine oil to the oil seal lip. Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is fully seated. 9. Install the cylinder head cover. Tightening torque Cylinder head cover bolts : 8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft) 09221-21000 EDKD125A 7. Install the camshaft sprocket bolts to the specified torque. Tightening torque Camshaft sprocket bolt : 80 ~ 100Nm (800 ~ 1000 kg.cm, 59 ~ 74 lb.ft) EDKE104A 10. Install the spark plug cables, ignition coil assembly and cylinder head center cover. 11. Install the timing belt and then tighten the timing belt tensioner pulley. 12. Install the timing belt cover. Tightening torque Timing belt cover : 8 ~ 10Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft) EDKE105A 8. Align the camshaft sprocket and crankshaft sprocket timing marks. Place the poston in the No.1 cylinder to top dead center on the compression strokie. (Refer to the timing belt) ZENITH POWER PRODUCTS - 416 EM -44 ENGINE DOHC CRANK SHAFT COMPONENTS ED67A7AC (ATA) Washer 120 ~ 130 (1200 ~ 1300, 88 ~ 95) (MTA) Drive plate Flywheel 10 ~ 12 (100 ~ 120, 7.3 ~ 8.8) Rear oil seal case Gasket 20 ~ 27 (200 ~ 270, 14.7 ~ 20) Cylinder block Center bearing Oil seal Crankshaft Front case Main bearing Main bearing cap 55 ~ 60 (550 ~ 600, 41 ~ 44) Gasket Oil screen 15 ~ 22 (150 ~ 220, 11 ~ 16) Drain plug 40 ~ 45 (400 ~ 450, 30 ~ 33) 10 ~ 12 (100 ~ 120, 7.3 ~ 8.8) Gasket Oil pan TORQUE : Nm (kgf.cm, lbf.ft) EDKD140A ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM DISASSEMBLY 1. EA7E6C0F Remove the timing belt, front case, flywheel, cylinder head assembly and oil pan. For details, refer to the respective chapters. EM -45 4. Measure the clearance by the value that subtract the diameter of journal and pin and the thickness of bearing from the diameter of bore. Connecting rod bearing oil clearance : 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.) Crankshaft main bearing oil clearance NO. 1,2,4,5 : 0.022 ~ 0.040 mm (0.0009 ~ 0.0018 in.) NO.3 : 0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.) 2. Remove the rear plate and the rear oil seal. 3. Remove the connecting rod caps. 4. Remove the main bearing caps and remove the crankshaft. OIL SEAL Remove the crankshaft position sensor wheel. Check front and rear oil seals for damage or wear. Replace any seal that is defective. 5. CAUTION CRANKSHAFT SENSOR WHEEL Mark the main bearing caps to permit reassembly in the original position and direction. INSPECTION 2. Remove the sensor wheel. 2. Check the sensor wheel for damage, cracks and wear, and replace if necessary. 3. Check the clearance between the sensor wheel and the crank position sensor with a depth gage. E76DB219 CRANKSHAFT 1. 1. Check the crankshaft journals and pins for damage, uneven wear, and cracks. Also check oil holes for clogging. Correct or replace any defective part. Inspect the crankshaft journal for taper and out - of round. Standard value Clearance between sensor wheel and crank position sensor : 0.5 ~ 1.1 mm (0.020 ~ 0.043 in.) Standard value Crankshaft journal O.D : 50 mm (1.9685 in.) Crankshaft pin O.D : 45 mm (1.7717 in.) Crankshaft journal, pin out-of-roundness and taper : 0.005 mm (0.0002 in.) or less MAIN BEARINGS AND CONNECTING ROD BEARINGS Visually inspect each bearing for peeling, melting, seizure, and improper contact. Replace the defective bearings. EDDA028C OIL CLEARANCE MEASUREMENT 1. Measure the diameter of the crankshaft journal and pin. 2. Measure the diameter of the crankshaft bore and connecting rod bore. 3. Measure the thickness of the crankshaft bearing and connecting rod bearing. NOTE 1. 2. 3. Measure the depth of the top of sensor wheel tooth and the cylinder block mounting block. Measure the difference between sensor length and depth. Sensor length is the distance between the end of the sensor and the inner point of the contacting face. ZENITH POWER PRODUCTS - 416 EM -46 ENGINE REPLACEMENT 1. DOHC CRANKSHAFT MAIN JOURNAL DIAMETER E8EBDEBC Check the cylinder block crankshaft bore size code. Class Main journal diameter Size code I 49.968 ~ 49.962 mm (1.9672 ~ 1.9670 in.) Λ II 49.962 ~ 49.956 mm (1.9670 ~ 1.9667 in.) b III 49.956 ~ 49.950 mm (1.9667 ~ 1.9665 in.) c Crankshaft bore size code MAIN JOURNAL BEARING THICKNESS No. 1, 2, 4, 5 (MAIN BEARING) EDPC004C Color Main journal bearing thinckness Yellow 2.002 ~ 2.005 mm (0.0788 ~ 0.0789 in.) Green 2.005 ~ 2.008 mm (0.0789 ~ 0.0790 in.) No color 2.008 ~ 2.011 mm (0.0790 ~ 0.0791 in.) Black 2.011 ~ 2.014 mm (0.0791 ~ 0.0793 in.) Blue 2.014 ~ 2.017 mm (0.0793 ~ 0.0794 in.) NOTE Record the cylinder block crankshaft bore size code letters on cylinder block as shown. Reading order is from left to right with front crankshaft bore size code shown first. Class Crankshaft bore diameter Size code a 54~54.006mm (2.1259~2.1262in.) A b 54.006~54.012mm (2.1262~2.1264in.) B c 54.012~54.016mm (2.1264~2.1266in.) C 2. NO.3 (CENTER BEARING) Color Main journal bearing thickness Yellow 1.999 ~ 2.002 mm (0.0787 ~ 0.0788 in.) Green 2.002 ~ 2.005 mm (0.0788 ~ 0.0789 in.) No color 2.005 ~ 2.008 mm (0.0788 ~ 0.0790 in.) Black 2.008 ~ 2.011 mm (0.0790 ~ 0.0791 in.) Blue 2.011 ~ 2.014 mm (0.0791 ~ 0.0793 in.) Check the crankshaft main journal size code. NOTE Record the main journal size code letters on the crankshaft balance weight. Reading order is from left to right as shown, with No.1 main journal size code shown first. Main journal size code ECPC004B 3. Choose proper main journal bearing in table. ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM REASSEMBLY 1. EM -47 4. E0ABCAB2 Install the upper main bearing inserts in the cylinder block. When reusing the main bearings, remember to install them by referring to the location marks made at the time of disassembly. 2. Install the crankshaft. Apply engine oil to the journals. 3. Install bearing caps and tighten cap bolts to the specified torque in the following sequence; center, No.2, No.4, front, and rear caps. Cap bolts should be tightened evenly in 2 to 3 stages before they are tightened to the specified torque. The caps should be installed with the arrow mark directed toward the crank pulley side of engine. Cap numbers must be correct. Tightening torque Main bearing cap bolt : 55 ~ 60 Nm (550 ~ 600 kg.cm, 41 ~ 44 lb.ft) Connecting rod cap bolt : 32 ~ 35 Nm (320 ~ 350 kg.cm, 24 ~ 26 lb.ft) Make certain that the crankshaft turns freely and has the proper clearance between the center main bearing thrust flange and the connecting rod big end bearing. Standard value Crankshaft end play : 0.05 ~ 0.175 mm (0.0019 ~ 0.0068 in.) ECKD001B 5. Install the oil seal in the crankshaft rear oil seal case. Use the Special Tool, Crankshaft Rear Oil Seal Installer (09231 - 21000) as shown. Press fit the oil seal all the way in, being careful not to misalign it. 09231-21000 EDKE151A ECKD326A 6. Install the rear plate and tighten the bolts. 7. Install the connecting rod caps. 8. Install the flywheel, front case, oil pan and timing belt. For further details, refer to the respective chapters. ZENITH POWER PRODUCTS - 416 EM -48 ENGINE DOHC FLY WHEEL COMPONENTS E3FB04C9 Ring gear Flywheel 120 ~ 130 (1200 ~ 1300, 89 ~ 96) Drive plate Adaptor plate 120-130 (1200-1300, 89-96) Adaptor plate M/T A/T TORQUE : Nm (kg.cm, lb.ft) EDDA030A M/T : Manual Transmission Vehicles A/T : Automatic Transmission Vehicles 3. DISASSEMBLY REASSEMBLY E543FBCD 1. Remove the Transmission and clutch. 2. Remove the flywheel. INSPECTION EB2E8F43 1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively damaged or worn. 2. Check the clutch disc contacting surface of the flywheel for runout. Standard value Flywheel run - out : 0.1 mm (0.0039 in.) Check the ring gear for damage, cracks, and wear, and replace if necessary. E650BE51 Install the flywheel assembly and tighten the bolts to the specified torque. Tightening torque Flywheel bolt : 120 ~ 130 Nm (1200 ~ 1300 kg.cm, 89 ~ 96 lb.ft) ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -49 PISTON COMPONENTS E1D1ECDE Piston ring Piston pin Piston Connecting rod Connecting rod bearing Connecting rod bearing cap 32 ~ 35 (320 ~ 350, 24 ~ 26) TORQUE : Nm (kgf.cm, lbf.ft) EDKD141A ZENITH POWER PRODUCTS - 416 EM -50 ENGINE DISASSEMBLY 4. EEDFC26E CONNECTING ROD CAP DOHC To remove the pin from the piston, place the piston in the support fixture with the rod resting on the fork inserts. Pass the remove tool through the top of the support fixture and use it to press out the pin. CAUTION Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly. 1. 2. Remover Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing. Support fixture Push each piston connecting rod assembly toward the top of the cylinder. Support fork EDA9048A Notches KFW3049A DISASSEMBLY AND REASSEMBLY OF THE PISTON PIN 1. Using the special tools, disassemble and reassemble the piston and connecting rod. 2. The piston pin is press fit into the rod little end, and the piston floats on the pin. 3. The tool consists of a support fixture with fork inserts, guides, adapters, an installer and a remover. The piston is supported in the support fixture while the pin is being installed or removed. Guides help position the pin as it is installed or removed, while the rod is supported by fork inserts. 5. To install a new pin, the proper fork inserts must be in place to support the rod. 6. Position the rod inside the piston. Insert the proper pin guide through one side of the piston and through the rod. Hand tap the pin guide so it is held by the piston. Insert the new pin into the piston from the other side and set the assembly into the support fixture with the pin guide facing down. NOTE The pin guide should be centered on the connecting rod through the piston. If assembled correctly, the pin guide will sit exactly under the center of the hole in the tool’s arch, and rest evenly on the fork inserts. If the wrong size pin guide is used, the piston and pin will not line up with the support fixture. Pin guide Installer Piston pin ECA9361C ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM 7. EM -51 Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to force the piston pin through the rod little end. Continue pressing until the pin guide falls free and the installer tool seats against the top of the arch. CAUTION Do not exceed 1250 ± 500 kg (2765 ± 1102 lb) of force when the installing tool seats against the top of the arch. Press Installer Support fix Adapter Piston pin Piston Connecting rod Universal fork insert Pin guide HEW20A55 ZENITH POWER PRODUCTS - 416 EM -52 INSPECTION ENGINE DOHC 2. E005DAEA PISTONS AND PISTON PINS 1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective. 2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston requires replacement, its rings should also be replaced. 3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective. The piston pin must be smoothly pressed by hand into the pin hole (at room temperature). To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles in 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 ring. Piston ring end gap [Standard dimensions] No. 1 : 0.15 ~ 0.30 mm (0.0059 ~ 0.012 in.) No. 2 : 0.30 ~ 0.45 mm (0.012 ~ 0.018 in.) Oil ring side rail : 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.) [Limit] No. 1, No. 2 : 1.0 mm (0.039 in.) Oil ring side rail : 1.0 mm (0.0.39 in.) PISTON RINGS 1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings together. If it is less than the service limit, replace the piston rings only. Piston ring side clearance No.1 : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) No. 2 : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) Limit No. 1 : 0.1 mm (0.004 in.) No. 2 : 0.1 mm (0.004 in.) ECKD001K ECKD001G When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the low part of cylinder that is less worn out. ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -53 PISTON RING SERVICE SIZE AND MARK Standard None 0.25 mm (0.010 in.) O.S 25 NOTE The mark can be found on the upper side of the ring next to the end. CONNECTING RODS 1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at disassembly, match. When a new connecting rod is installed, make sure that the notches holding the bearing in place are on the same side. 2. Replace the connecting rod if it is damaged at either end of the thrust faces. If it has a stratified wear in, or if the surface of the inside diameter of the small end is severely rough, replace the rod. Notches KFW3049A ZENITH POWER PRODUCTS - 416 EM -54 ENGINE REPLACEMENT 1. 1.6 L EF4FCD8C Check the cylinder bore size code on the cylinder block bottom face. Class Piston outer diameter Size code A 76.465~76.475mm (3.0104~3.0108in.) A B 76.475~76.485mm (3.0108~3.0112in.) B C 76.485~76.495mm (3.0112~3.0116in.) C Cylinder bore side code 3. Select the piston related to cylinder bore class. Oil clearance 0.025 ~ 0.045mm (0.00098 ~ 0.00177in.) EDPE004B 1.6 L Class Cylinder bore inner diameter Size code A 76.5~76.51mm (3.0118~3.0121in.) A B 76.51~76.52mm (3.0121~3.0126in.) B C 76.52~76.53mm (3.0126~3.0129in.) C 2. DOHC Check the piston size code on the piston top face. KDPC005Z NOTE Stamp the grade mark of basic diameter with rubber stamp. ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM REASSEMBLY 1. EM -55 3. ECCF87EF Install the lower side rail by the same procedure described in Step 2. Install the spacer. Piston upper Side rail Spacer Piston lower ECA9380B ECA9082A Upper side rail Lower side rail ˚ 45˚ 45 90˚ Position from the gap of No. 2 ring 4. Apply engine oil around the piston and piston grooves. 5. Using a piston ring expander, install the No.2 piston ring. 6. Install the No. 1 piston ring. ˚ 45 45˚ Inside bevel Gap position of upper spacer No.1 Gap position of lower side rail Berrel type Spacer Gap position of spacer No.2 EDJA490A 2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with a finger on the portion to be inserted into the groove (as illustrated). CAUTION Do not use a piston ring expander when installing side rail. Taper type EDDA037B 7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions. ZENITH POWER PRODUCTS - 416 EM -56 8. ENGINE Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder. Gap of upper side rail DOHC 14. Check the connecting rod side clearance. Connecting rod side clearance Standard : 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.) Limit : 0.4 mm (0.0157 in.) No.1 ring gap Front of engine No.2 ring gap and spacer expander gap Gap of lower side rail ECA9380D 9. Install the upper main bearings in the cylinder block. 10. Install the lower main bearings in the main bearing caps. 11. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine. 12. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side. 13. When assembling, bolts should be fastened by the angle - torque controlled method as the following. 1) Apply oil to the thread of nuts and spot areas. 2) Tighten the connecting rod bolt. Tightening torque Connecting rod cap nut : 32 ~ 35 Nm (320 ~ 350 kg.cm, 24 ~ 26 lb.ft) CAUTION After removing the connecting rod bolt, do not use if again. When using a new bolt, do not tighten the bolt more than 3 times. EDKD145A 15. Install the oil screen. 16. Install the oil pan. 17. Install the cylinder head. ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -57 COOLING SYSTEM ENGINE COOLANT HOSE／PIPES COMPONENTS E2BAF9FA RADIATOR COOLANT PUMP THERMOSTAT BYPASS VALVE CYL/HEAD CYL/BLCOK HEATER ECKB001I ZENITH POWER PRODUCTS - 416 EM -58 ENGINE DOHC 15 ~ 20 (150 ~ 200, 9 ~ 14) Thermostat housing Thermostat Coolant inlet fitting Gasket 20 ~ 27 (200 ~ 270, 12 ~ 20) 10 ~ 15 (100 ~ 150, 7 ~ 9) Coolant inlet pipe O-ring Water pump 12 ~ 15 (120 ~ 150, 8.8 ~ 11) TORQUE : Nm (kgf.cm, lbf.ft) EDKD180A ZENITH POWER PRODUCTS - 416 COOLING SYSTEM INSPECTION E6CC2E0F Check the coolant pipe and hoses for cracks, damage, or restrictions. Replace if necessary. EM -59 REASSEMBLY E1DCE4A4 Fit on O-Ring in the groove provided at the coolant inlet pipe end, wet the O-ring with coolant and insert the coolant inlet pipe. NOTE 1. 2. 3. 4. Do not apply oil or grease to the coolant pipe O-ring. Keep the coolant pipe connections free of sand, dust, etc. Insert the coolant pipe fully into the cylinder block. Do not reuse the O-ring. Replace it with a new part. Cylinder block Coolant pump assembly Coolant inlet pipe ECKA040A ZENITH POWER PRODUCTS - 416 EM -60 ENGINE DOHC ENGINE COOLANT PUMP COMPONENTS E8D2CBAD Coolant pump 8 - 10 (80 - 100, 6 - 7) Alternator brace Coolant pump 20 - 27 (200 - 270, 15 - 20) Belt Coolant pump pulley TORQUE : Nm (kg.cm, lb.ft) EDDA046A DISASSEMBLY EA98DF28 1. Drain the coolant and disconnect the coolant inlet pipe connection hose from the coolant pump. 2. Remove the drive belt and engine coolant pump pulley. 3. Remove the timing belt covers and the timing belt idler. 4. Remove the coolant pump mounting bolts, then remove the alternator brace. EDKE181A 5. Remove the coolant pump assembly from the cylinder block. ZENITH POWER PRODUCTS - 416 COOLING SYSTEM INSPECTION EM -61 REASSEMBLY E5229EB7 E0C24D31 1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary. 1. Clean the gasket surfaces of the coolant pump body and the cylinder block. 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary. 2. Install a new coolant pump gasket to the coolant pump and tighten the bolts to the specified torque. 3. Check for coolant leakage. If coolant leaks then the seal is defective. Replace the coolant pump assembly. Tightening torque Coolant pump to cylinder block : A : 12 ~ 15 Nm (120 ~ 150 kg.cm, 9 ~ 11 lb.ft) B : 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 lb.ft) Alternatorstrebe B A A A A EDKB051A ECKA040B 3. Install the timing tensioner and timing belt. Adjust the timing belt tension. 4. Install the timing belt covers. 5. Install the coolant pump pulley and drive belt, and then adjust the belt tension. 6. Refill the system with clean coolant. 7. Run the engine and check for leaks. ZENITH POWER PRODUCTS - 416 THIS PAGE INTENTIONALLY LEFT BLANK ZENITH POWER PRODUCTS - 416 COOLING SYSTEM INSPECTION EM -63 REASSEMBLY EC662470 EF7E7B75 1. Check the radiator for bent, broken or plugged fins. 1. 2. Check the radiator for corrosion, damage, rust or scale. Fill the radiator and reservoir tank with clean coolant mixture. 2. Check the radiator hoses for cracks, damage or deterioration. Run the engine until the thermostat opens, and then stop the engine. 3. Remove the radiator cap, and add coolant up to the filler neck of the radiator, and then fill the reservoir tank to the upper level. Replace the radiator cap. 4. Check that there are no leaks from the radiator, hoses or connections. 3. 4. Check the reservoir tank for damage. 5. Check the radiator cap spring for damage. 6. Test the pressure of the cap using a cooling system checker. 7. Check the radiator cap seal for cracks or damage. RADIATOR FAN MOTOR 1. Check that the radiator fan rotates when the battery voltage is applied to the terminals. ECDA064A 2. Check that abnormal noises are not produced while the motor is turning. ZENITH POWER PRODUCTS - 416 EM -64 ENGINE DOHC RADIATOR CAP COMPONENTS EA37EA8B Radiator Cap High - pressure valve When the pressure is peduced to the specified level [81.4 - 1.8 Kpa (0.83 - 1.1 kg/cm, 11.8 - 15.6 psi)] Spring High - pressure valve Vacuum spring When the pressure is peduced to the specified level [-6.86 Kpa (- 0.07 kg/cm, -1.00 psi)] ECDA066A ZENITH POWER PRODUCTS - 416 COOLING SYSTEM INSPECTION 1. EM -65 E7AA67F9 Check the radiator cap for damage, cracks and deterioration. Deterioration Deterioration ECDA068A 2. Attach a radiator cap tester to the radiator 3. Pump the tester until the pointer stabilizes. 4. If the pointer stays constant for 10 sec. at a point exceeding the service limit, the radiator cap is good. Adapter ECDA068B ZENITH POWER PRODUCTS - 416 EM -66 ENGINE THERMOSTAT INSPECTION REASSEMBLY DOHC E342AFA3 1. Check that the flange of the thermostat is correctly seated in the socket of the thermostat housing. EE55C20B 1. Drain the coolant so its level is below thermostat. 2. Install a new gasket and the coolant inlet fitting. 2. Remove the inlet fitting and gasket. 3. Refill the system with clean coolant. Tightening torque Coolant temperature sensor : 25 ~ 30 Nm (250 ~ 300 kg.cm, 18 ~ 22 lb.ft) EDKE182A 3. Remove the thermostat. 4. Immerse thermostat in hot coolant to check proper valve opening temperature. Replace if necessary. Valve opening temperature : 82 C (177 C) Full opening temperature : 95 C (205 F) Thermometer Water ECDA070A COOLANT TEMPERATURE SENSOR 1. Heat the sensor by submerging it in hot engine coolant. 2. Check that the resistance is within the specified range. Resistance At : 20 C (68 F) : 2.31 ~ 2.59 kΩ ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM EM -67 LUBRICATION SYSTEM OIL PUMP COMPONENTS EDF9B71D 20 ~ 27 (200 ~ 270, 15 ~ 20) Gasket Oil screen Front case Filter 15 ~ 22 (150 ~ 220, 11 ~ 16) Drain plug 40 ~ 45 (400 ~450, 30 ~ 33 ) Gasket 10 ~ 12 (100 ~ 120, 7.3 ~ 8.8) Oil pan TORQUE : Nm (kgf.cm, lbf.ft) EDKD200A ZENITH POWER PRODUCTS - 416 EM -68 DISASSEMBLY ENGINE INSPECTION E450CC2F DOHC E9D08BBC 1. Remove the timing belt. FRONT CASE 2. Remove all the oil pan bolts. 1. Check the front case for cracks or damage. Replace as necessary. 3. Remove the oil pan. 2. 4. Remove the oil screen. Check the front oil seal for worn or damaged lips. Replace if defective. 5. Remove the front case assembly. OIL PAN AND OIL SCREEN 1. Check the oil pan for failure, damage or cracks. Replace if defective. 2. Check the oil screen for failure, damage and cracks and replace if defective. FRONT CASE AND OIL PUMP COVER Check the surfaces contacting the gears for damage or wear. OIL PUMP GEARS EDKE208A 6. Remove the oil pump cover. 1. Check the gear tooth surfaces for wear or damage. 2. Measure the clearance between outer gear and front case. Body clearance : 0.12 ~ 0.185 mm (0.0047 ~ 0.0073 in.) Tip clearance : 0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.) Side clearance Inner gear : 0.06 ~ 0.11 mm (0.0023 ~ 0.0043 in.) Outer gear : 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) EDKE202A 7. Remove the inner and outer gears from the front case. The matching marks on the inner and outer gears indicate the direction of installation. EDKD207A ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM 3. EM -69 Check the tip clearance on the pump roter. OIL PRESSURE SWITCH (Normally Closed type STD.) 1. Use an ohmmeter to check the continuity between the terminal and the body. If there is no continuity, replace the oil pressure switch. EDKD206A EDDA061A EDKD205A RELIEF VALVE AND SPRING 1. Check sliding condition of the relief valve inserted in the front case. 2. Inspect for distorted or broken relief valve spring. Standard value Free height : 46.6 mm (1.8346 in.) Load : 6.1 kg/40.1 mm (13.42 lb/1.578 in.) 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 50 kPa (7 psi) pressure is applied through the oil hole, the switch is operating properly. Check for air leaks. If air does leak, the diaphragm is broken. Replace the switch. Fine wire EDDA061B ZENITH POWER PRODUCTS - 416 EM -70 REASSEMBLY ENGINE DOHC FRONT CASE E1BA8FB0 1. OIL PUMP 1. 2. Install the outer and inner gears into the front case Make sure that the inner and outer gears are installed in the same direction as shown. Install the oil pump cover and tighten the bolts to the specified torque. After the bolts have been tightened, check to ensure that the gear turns smoothly. Tightening torque Oil pump cover bolt : 8~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb.ft) Install the front case assembly with a new gasket, and tighten the bolts to the specified torque. Tightening torque 20 ~ 27 Nm (200 ~ 270 kg.cm, 15 ~ 20 lb.ft) Length A : 30 mm (1.18 in.) B : 45 mm (1.77 in.) C : 60 mm (2.36 in.) D : 22 mm (0.89 in.) D A B A C A ECKA020E OIL SEAL EDKE202A 3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve. 1. Using the special tool, Crankshaft guide(09231 - 22100), install the oil seal. 2. Using the special tool, Crankshaft front oil seal installer (09231-22000), install the oil seal. Relief valve plug 40 ~ 50 Nm (400 ~ 500 kg.cm, 30 ~ 37 lb.ft) oil seal 09231-22000 EDKE209A 3. Install the oil screen. 4. Clean both gasket surfaces of the oil pan and the cylinder block. 5. Apply sealant into the groove of the oil pan flange as shown. EDKE204A ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM EM -71 CAUTION • Apply sealant approx. 4mm (0.16 in.) in thickness. • After application of sealant, do not exceed 15 minutes before installing the oil pan. ECDA018D 6. Install the oil pan and tighten the bolts to the specified torque. Tightening torque Oil pan bolt : 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft) ZENITH POWER PRODUCTS - 416 EM -72 ENGINE DOHC ENGINE BLOCK ENGINE BLOCK COMPONENTS E362FF2F Piston ring Piston pin Piston Connecting rod Cylinder block Connecting rod bearing Connecting rod bearing cap 32 ~ 35 (320 ~ 350, 24 ~ 26) TORQUE : Nm (kgf.cm, lbf.ft) ECDE141A ZENITH POWER PRODUCTS - 416 ENGINE BLOCK DISASSEMBLY EM -73 INSPECTION EE96372F 1. Remove the timing belt, cylinder head, front case, flywheel, pistons and crankshaft. 2. Remove the oil pressure switch. EBADEC3C 1. Check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Replace the block if defective. 2. Using a straight edge and feeler gauge, check the top surface of the block for warpage. Make sure that the surface is free from gasket chips or other foreign material. Adapter Standard : 0.03 mm (0.0012 in.) or less Limit : 0.06 mm (0.0024 in.) or less EDDA008A ECKD001L 3. Measure the cylinder bore with a cylinder gauge at three levels in the direction of A and B. If the cylinder bores show more than the specified out-of-round or taper or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. Oversize pistons and rings must be fitted. Cylinder I.D : 76.5 ~ 76.53 mm (3.0118 ~ 3.0130 in.) Cylinder I.D taper : 0.01 mm (0.0004 in.) or less ECKD318A ZENITH POWER PRODUCTS - 416 EM -74 ENGINE 4. If a cylinder ridge exists, cut away with a ridge reamer. 5. Oversize pistons are available in four sizes. Pistom service size and mark mm (in.) 0.25 (0.010) O.S. : 0.25 6. When boring the cylinder to the oversize, maintain the specified clearance between the oversize piston and the bore, and make sure that all pistons used are the same oversize. The standard measurment of the piston’s outside diameter is taken 39.35 mm (1.55 in.) from the top land of the piston. Piston - to - cylinder clearance 0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in.) ECKD001D DOHC ZENITH POWER PRODUCTS - 416 THIS PAGE INTENTIONALLY LEFT BLANK ZENITH POWER PRODUCTS - 416 EM -76 ENGINE DOHC INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS E6FBC7D4 Cylinder head Gasket Exhaust manifold 30 ~ 35 (300 ~ 350, 22 ~ 26) 15 ~ 20 (150 ~ 200, 11 ~ 15) Heat protector TORQUE : Nm (kgf.cm, lbf.ft) EDKD251A ZENITH POWER PRODUCTS - 416 INTAKE AND EXHAUST SYSTEM DISASSEMBLY 1. EM -77 INSPECTION EAA67563 ED2622EE EXHAUST MANIFOLD Disconnect the oxygen sensor connect. 1. Check for damage or cracking. 2. Check for damage or cracking of welding between exhaust manifold and converter. REASSEMBLY E1BC9FEF Install the exhaust manifold in the reverse order of removal. CAUTION KDPC007D 2. Remove the exhaust manifold heat protector. 3. Remove the exhaust manifold assembly from the cylinder head. 4. Remove the exhaust manifold gasket. Replace the exhaust manifold gasket and lock nut when reassembling. ZENITH POWER PRODUCTS - 416 EM -78 ENGINE DOHC INTAKE MANIFOLD COMPONENTS EF98EE9D Intake manifold Gasket Throttle body ISA TPS Gasket 15 ~ 20 (150 ~ 200, 11 ~ 15) 18 ~ 25 (180 ~ 250, 13 ~ 18) Intake manifold stay TORQUE : Nm (kg.cm, lb.ft) ECDE087A
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