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

INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD

INTAKE MANIFOLD

EM -2 ENGINE DOHC

GENERAL

SPECIFICATION E5EC07D6

Description Specification Limit

General

Type

Number of cylinders

Bore

Stroke

Total displacement

Compression ratio

Firing order

In-line, Double Over Head Camshaft

76.5mm (3.0118 in)

87mm (3.4252 in)

1599 cc (97.54 cu.in)

1-3-4-2

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

Max. 0.03mm (0.0012 in.)

0.15mm (0.0059 in.)

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.)

0.1 mm (0.0039in.)

0.2mm (0.008in.)

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

Exhaust

Joumal O.D

Bearing oil clearance

End play

43.4484mm (1.7106 in.)

43.8489mm (1.7263 in.)

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 Specification Limit

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

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.)

Valve guide

Installed dimension O.D.

Intake

Exhaust

Service size

12.8mm (0.504 in.)

0.05, 0.25, 0.50mm

(0.002, 0.010, 0.020 in.) oversize

Valve seat

Width of seat contact

Intake

Exhaust

Seat angle

Oversize

0.8 ~ 1.2mm (0.031 ~ 0.047 in.)

1.3 ~ 1.7mm (0.051 ~ 0.066 in.)

0.3, 0.6mm (0.012, 0.024 in.) oversize

Valve spring

Free length

Load

Squareness

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

Cylinder block

Cylinder bore

Out- of- round and taper of cylinder bore

Clearance with piston

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 76.465 ~ 76.495mm (3.0104 ~ 3.0116 in.)

0.25 mm (0.010 in.) oversize

Piston ring

Side clearance

No. 1

No. 2

Endgap

No. 1

No. 2

Oil ring side rail

Service size

0.04 ~ 0.085 mm (0.0015 ~ 0.0033 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

0.1 mm (0.004 in.)

1.0 mm (0.039 in.)

ZENITH POWER PRODUCTS - 416

EM -4 ENGINE DOHC

Description Specification Limit

Connecting rod

Bend

Twist

Connecting rod big end to crankshaft

side clearance

Connecting rod bearing oil clearance

Undersize

0.05mm (0.0020 in.) or less

0.1mm (0.0039 in.) or less

0.100-0.250mm (0.0039-0.0098 in.)

0.018-0.036mm (0.0007-0.0014 in.)

0.25, 0.50, 0.75mm

(0.010, 0.020, 0.030 in.)

0.4mm (0.0157in.)

Crankshaft

Pin O.D.

Journal O.D.

Bend

Out- of- round, taper of journal and pin

End play

45 mm (1.77 in.)

50 mm (1.97 in.)

0.03 mm (0.0012 in.) or less

0.005 mm (0.0002 in.) or less

0.05- 0.175 mm (0.0019- 0.0068 in.)

Undersize rework dimension of pin

0.25mm (0.010 in.)

0.50mm (0.020 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.) 0.13mm (0.0051in.)

Oil pump

Clearance between outer circumference

and front case (body clearance)

Front case tip clearance

Side clearance

Inner gear

Outer gear

0.12 ~ 0.18mm (0.0047 ~ 0.0070 in.)

0.025 ~ 0.069mm (0.001 ~ 0.0027 in.)

0.04 ~ 0.085mm (0.0016 ~ 0.0033 in.)

0.04 ~ 0.09mm (0.0016 ~ 0.0035 in.)

Engine oil pressure

Engine at idle [Oil temperature is 90 to

100 C(194to215F)] 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

6.5 liter

Pressurized corrugated fin type

Radiator cap

Main valve opening pressure

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

ZENITH POWER PRODUCTS - 416

GENERAL EM -5

Description Specification Limit

Thermostat

Type

Valve opening temperature

Full-opening temperature

Waxpellettypewithjigglevalve

82 C (180 F)

95 C (203 F)

Engine coolant temperature sensor

Type

Resistance 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

ZENITH POWER PRODUCTS - 416

EM -6 ENGINE DOHC

TIGHTENING TORQUE

Item Nm Kg.cm Ib.ft

Cylinder Block

Front engine support bracket bolt and nut

Engine suppot bracket stay bolt

Oil pressure switch

45 ~ 55

13 ~ 15

450 ~ 550

130 ~ 150

33 ~ 41

10 ~ 11

Cylinder head

Cylinder head bolt

Intake manifold bolts or nuts

Exhaust manifold nut

Cylinder head cover bolt

Camshaft bearing cap bolt

Rear plate bolt

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 ~ 35

55 ~ 60

120 ~ 130

320 ~ 350

550 ~ 600

1200 ~ 1300

24 ~ 26

41 ~ 44

89 ~ 96

Timing system

Crankshaft pulley bolt

Camshaft sprocket bolt

Timing belt tensioner bolt

Timing belt idle bolt

Timing belt cover bolt

Front case bolt

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 ~ 111

59 ~ 74

15 ~ 20

32 ~ 41

6~7

15 ~ 20

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

90 ~ 110

50 ~ 65

90 ~ 110

30 ~ 40

45 ~ 60

30 ~ 40

45 ~ 60

30 ~ 40

900 ~ 1100

500 ~ 650

900 ~ 1100

300 ~ 400

450 ~ 600

300 ~ 400

450 ~ 600

300 ~ 400

66 ~ 81

37 ~ 48

66 ~ 81

22 ~ 30

33 ~ 44

22 ~ 30

33 ~ 44

22 ~ 30

Oil filter

Oil pan bolts

Oil pan drain plug

Oil screen bolts

12 ~ 16

10 ~ 12

40 ~ 45

15 ~ 22

120 ~ 160

100 ~ 120

400 ~ 450

150 ~ 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

50 ~ 60

30 ~ 40

40 ~ 60

[80 ~ 100

40 ~ 60

150 ~ 200

180 ~ 250

150 ~ 200

250 ~ 300

150 ~ 200

500 ~ 600

300 ~ 400

400 ~ 600

6~7

3~4

11 ~ 14

13 ~ 18

11 ~ 14

18 ~ 22

11 ~ 14

37 ~ 44

22 ~ 30

30 ~ 44

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

CHECKING ENGINE OIL

1. Position the vehicle on a level surface.

2. Warm up the engine.

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 Upper limit

ECDA001A

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 viscos-

ity.

CHANGING ENGINE OIL

CAUTION

Be careful not to burn yourself, as the engine oil

is hot.

1. Run the engine until it reaches normal operating tem-

perature.

2. Turn off the engine

3. Remove the oil filler cap and the drain plug (on the oil

pan). Drain the engine oil.

KCPC001B

4. 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

FILTER SELECTION

All Hyundai engines are equipped with a high quality, dis-

posable oil filter. This filter is recommended as a replace-

ment filter on all vehicles. The quality of replacement fil-

ters 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 be-

fore installing the new filter.

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

3. Tighten the oil filter to the specified torque.

KCPC001C

Tightening torque

Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)

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 :

Recommended SAE viscosity number

Temperature range

anticipated before

next oil change

*1 Restricted by driving condition and environment.

*2 Not recommended for sustained high speed vehicle operation

-10

-15

-25 -13

˚C

40 ˚F

104 15W

-50

-40

10W

-50

-40

20W

-50

-40

10W

-30

-20

-30 *1

-40 *1

EDA9990B

NOTE

For best performance and maximum protection of all

types of operation, select only those lubricants which:

1. Satisfy the requirements of the API classification.

2. Have proper SAE grade number for expected am-

bient 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

1. Wait until the engine is cool, then carefully remove the

radiator cap.

2. Confirm that the coolant level is up to the filler neck.

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 check-

ing for leakage from the radiator, hoses or connec-

tions.

NOTE

1. 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.

2. Be sure to clean away any moisture from the

places checked completely.

3. When the tester is removed, be careful not to spill

any coolant from it.

4. Be careful, when installing and removing the

tester and when testing, not to deform the filler

neck of the radiator.

4. If there is leakage, repair or replace with the apropri-

ate part.

KDPC001F

RADIATOR CAP PRESSURE TEST

1. Remove the radiator cap, wet its seal with engine

coolant, then install it on the tester.

2. Increase the pressure until the gauge stops moving.

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 re-

main 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.

Adapter

ECA9090A

ZENITH POWER PRODUCTS - 416

EM -12 ENGINE DOHC

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hy-

drometer.

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

10 (50) 20 (68) 30 (86) 40 (104) 50 (122)

Freezing

temperature

C(F)

Safe operating

temperature

C(F)

Coolant

concentration

(Specific

volume)

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(5F) when the

measured specific gravity is 1.058 at coolant temperature

of 20 C(68F)

CAUTION

•If the concentration of the coolant is below

30%, its anti-corrosion properties will be ad-

versely affected.

•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 con-

centration level within the specified ragne.

•Do not use together with another brank’s

product.

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

CHANGING ENGINE COOLANT

CAUTION

When pouring engine coolant, be sure to shut the

relay box lid and not to let coolant spill on electri-

cal parts or the paint. If any coolant spills, rinse it

off immediately.

1. Slide the heater temperature control lever to maxi-

mum 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.

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.

CHECKING COMPRESSION PRESSURE

1. Before checking engine compression, check the en-

gine 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 temper-

ature reaches 80 ~ 95 C (176 ~ 205 F).

4. Disconnect the fule pump connector.

5. Turn off engine and disconnect the spark plug cables.

KCDC002B

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.

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.

Tightening torque

Spark plug : 20 ~ 30 Nm (200 ~ 300 kg.cm, 14 ~ 22 lb.ft)

ADJUSTING TIMING BELT TENSION

1. Rotate the steering wheel counter-clockwise

throughly.

NOTE

Do watch not to over load.

2. Lift the vehicle by using of jack.

KCDA125K

3. Remove the engine support bracket. (14mm bolt and

2nuts, 17mm bolt)

KDDC003B

4. Remove the drive belts and the water pump pulley.

(10 mm 4 bolts)

KDDC004B

5. Remove the timing belt upper cover. (10 mm 4 bolts)

KCDC002C

ZENITH POWER PRODUCTS - 416

GENERAL EM -15

6. Remove the crankshaft pulley.

KDDC007B

7. Remove the timing belt lower cover.

8. Place the pistion of No. 1 cylinder to TDC of the com-

pression stroke by rotating the crankshaft clockwise.

NOTE

Crankshaft is to be rotated clockwise otherwise, the

tension is inadequately adjusted.

Tensioner

pulley

Idler pulley

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.

11. Check that the teeth of the sprocket and belt coincide

with each other.

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 ap-

prox. half of the tensioner mounting bolt head radius

(cross flats) away from the bolt head center.

EDKE108A

14. Rotate the crankshaft pulley two turns clockwise so

that the timing belt positions on the pulleys.

15. Install the timing belt lower cover.

16. Install the crankshaft pulley.

17. Install the timing belt upper cover.

18. Install the water pump pulley and engine support

bracket.

ZENITH POWER PRODUCTS - 416

EM -16 ENGINE DOHC

ADJUSTING DRIVE BELT TENSION

1. Check that the belts are not damaged and are prop-

erly 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

atens

ion gauge.

CAUTION

1. When installing the V-ribbed belt, check that

the V-ribs are properly aligned.

2. If noise or slippage is detected, check the belt

for wear, damage, or breakage on the pul-

ley contact surface, and check the pulley for

scoring. Also check the amount that the belt

is deflected.

Pulley

V-ribbed belt

Wrong Wrong

Right

ECA9980A

STANDARD VALUE:

Adjustment

Itmes Inspection New Used

Deflection mm (in.) 5.1~6.0(0.200~0.236) 4.0~4.4(0.157~0.173) 5.0~5.7(0.200~0.224)

For alternator Tension N (lb) 350~500(79~112 650~750(143~165) 400~500(88~110)

Deflection mm (in.) 8(0.31) 5.0~5.5(0.20~0.22) 6.0~7.0(0.24~0.28)

For air conditioner Tension N (lb) 250~500(56~112) 470~570(106~128) 320~400(72~90)

For power steering Deflection mm (in.) 6.0~9.0(0.24~0.35) - -

ZENITH POWER PRODUCTS - 416

GENERAL EM -17

NOTE

1. The belt tension must be measured half - way

between the specified pulleys.

2. 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 stan-

dard value indicated under "Inspection."

3. When adjusting a belt which has been used,or

newly installed, after 5 minutes or more of oper-

ation, refer to the standard value indicated under

"Used" in the above table.

4. Refer to the standard value indicated under "In-

spection" for periodic inspections.

Power steering oil

pump pulley

Coolant pump pulley

Alternator

Crankshaft pulley

Air conditioning compressor pulley

Tensioner pulley

ECPD001B

TYPEATENSIONGAUGE

Do not let the dial section of the tension gauge contact

other objects during measurement.

Typ A Indicated value

Dial

Spindle

V-ribbed belt

Hook

Spindle Hook

ECA9980C

TYPE B TENSION GAUGE

1. When measuring, turn the reset button in the direction

of the arrow and set the gauge needle to the RESET

position.

2.If the tension gauge is removed from the belt, the nee-

dle will still indicate the tension. Read the tension

value after removing the gauge.

Typ B

Spindle

V-ribbed belt

Hook

RESET button

RESET position

ECA9980D

ADJUSTING THE ALTERNATOR BELT

CAUTION

If the belt is too loose, it will cause noise or sud-

den wear.

If the belt is too tight, the engine coolant pump

bearing or the alternator can get damaged.

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.

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)

Alternator brace

Coolant pump

pulley

Crankshaft

pulley

ECKA010H

ZENITH POWER PRODUCTS - 416

EM -18 ENGINE DOHC

SPECIAL TOOLS E0845550

Tool (Number and name) Illustration Use

Crankshaft front oil seal installer

(09231 - 22000)

ECKA010C

Installation of the front oil seal

Crankshaft front oil seal guide

(09231 - 22100)

ECKA010D

Guide of oil seal

Camshaft oil seal installer

(09221 - 21000)

EDDA005B

Installation of the camshaft oil seal

Valve guide installer

(09221 - 3F100 A/B)

ECKA010B

Removal and installation of valve guides

Valve stem oil seal installer

(09222 - 22001)

ECKA010A

Installation of valve stem oil seals

ZENITH POWER PRODUCTS - 416

GENERAL EM -19

Tool (Number and name) Illustration Use

Valve spring compressor

(09222 - 28000)

Valve spring compressor holder

(09222 - 28100)

EDDA005C

Removal and installation of intake

and exhaust valves

Water temperature sensor socket

wrench

(09221 - 25100)

EDKD101B

Removal and installation of the water

temperature sensor

Crankshaft rear oil seal installer

(09231 - 21000)

EDDA005F

Installation of engine real oil seal

and crankshaft rear oil seal

ZENITH POWER PRODUCTS - 416

EM -20 ENGINE DOHC

TROUBLESHOOTING E6712BDA

Symptom 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

Low compression

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

Low oil pressure

Excessive bearing clearance Replace

High oil pressure Oil relief valve sutck (closed) Repair

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

Excessive engine vibration

Broken engine roll stopper insulator Replace

Thin or diluted engine oil (low

oil pressure) Change

Worn or damaged valve stem

or valve guide Replace

Noisy valves

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

Connecting rod and/or main

bearing noise

Excessive bearing clearance Replace

Timing belt noise Incorrect belt tension Adjust belt tension

Leakage of coolant

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

Low coolant level

5. Engine coolant pump Replace parts

Clogged radiator Foreign material in coolant Replace coolant

ZENITH POWER PRODUCTS - 416

GENERAL EM -21

Symptom Probable cause Remedy

Faulty thermostat Replaceparts

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

Abnormally high coolant temperature

Insufficient coolant Refill coolant

Faulty thermostat ReplaceAbnormally low coolant temperature

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

Loose connections RetightenExhaust gas leakage

Broken pipe or muffler Repair or replace

Detached baffle plate in muffler Replace

Broken rubber hanger Replace

Pipe or muffler contacting

vehuicle body Correct

Abnormal noise

Broken pipe or muffler Repair or replace

ZENITH POWER PRODUCTS - 416

EM -22ENGINE DOHC

TIMING SYSTEM

TIMING BELT

COMPONENTS E4B24FDE

Cylinder head cover

Timing belt

Idler

43 ~ 55 (430 ~ 550, 32 ~ 40)

Crankshaft sprocket

Ten sioner

20 ~ 27

(200 ~ 270,

15 ~ 20)

Timing belt lower cover

Crankshaft pulley

140 ~ 150

(1400 ~ 1500,

103 ~ 111)

Flange

Timing belt upper cover

80 ~ 100

(800 ~ 1000,

59 ~ 74)

Camshaft sprocket

TORQUE : Nm (kgf·cm, lbf·ft)

EDKD100A

ZENITH POWER PRODUCTS - 416

TIMING SYSTEM EM -23

DISASSEMBLY EE695E6A

1. Lift the vehicle by using of jack.

KCDA125K

2. Remove the engine support bracket. (14 mm bolt and

2nut

s, 17 mm bolt)

KDDC003B

3. Remove the power steering belt.

4. Remove the air conditioning compressor belt.

5. Remove the alternator belt.

KBPD160A

KBPD160B

6. Remove the coolant pump pulley.

KDDC004B

ZENITH POWER PRODUCTS - 416

EM -24 ENGINE DOHC

7. Remove the crankshaft pulley.

KDDC007B

8. Remove the timing belt cover.

KCDC002C

9. Move the timing belt tensioner pulley toward the

coolant pump and temporarily secure it.

EDDA092A

10. Remove the timing belt.

NOTE

If the timing belt is reused, mark with an arrow to in-

dicate direction of rotation (on the front of the engine)

to make sure that the belt is reinstalled in the same

direction as before.

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.

KDPC008C

ZENITH POWER PRODUCTS - 416

TIMING SYSTEM EM -25

INSPECTION 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 ad-

justed, 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 DOHC

Description 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

Crack

EDDA093E

Separation

EDDA093F

3. Cracked or separating canvas

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

asharpknife.

9. Side of belt cracked

ZENITH POWER PRODUCTS - 416

EM -28 ENGINE DOHC

REASSEMBLY E6A34B7C

1. Install the flange and crankshaft sprocket as shown.

Pay close attention to their mounting directions.

Special washer

Crankshaft

Flange

Crankshaft

sprocket

ECNC094B

2. Install the camshaft sprocket and tighten the bolt to

the specified torque.

Tightening torque

Camshaftsprocketbolt:

80 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~74 lb.ft)

3. Install the idler and tighten the idler bolt to the speci-

fied torque.

Tightening torque

Idler bolt : 43 ~ 55 Nm (430 ~ 550 kg.cm, 32 ~ 41 lb.ft)

EDKE103A

4. Align the timing marks of the camshaft sprocket (A)

and camshaft bearing cap (B).

Then align the timing marks of crankshaft sprocket

andfrontcasewiththeNo.1pistonplacedattopdead

center on its compression stroke as shown in the illus-

tration.

ECDD008F

EDKE107A

5. To install the timing belt tensioner, first mount the ten-

sioner, 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.

KDPC008D

ZENITH POWER PRODUCTS - 416

TIMING SYSTEM EM -29

6. Secure the tensioner, positioned towards the water

pump.

KDPC008E

7. Install the timing belt on the crankshaft sprocket.

(1) Crankshaft sprocket →(2) Timing belt idler →(3)

Camshaft sprocket →(4) Timing belt tensioner.

EDKE109A

8. 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.

9. 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.

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.

EDKE108A

12. Install the timing belt cover.

EDDA094F

Tightening torque

Timing belt cover bolt :

8 ~10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft)

13. Install the crankshaft pulley. Make sure that the crank-

shaft 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 DOHC

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 ten-

sion.

ZENITH POWER PRODUCTS - 416

CYLINDER HEAD ASSEMBLY EM -31

CYLINDER HEAD

ASSEMBLY

CYLINDER HEAD

COMPONENTS E804EE47

Cylinder head cover

Gasket

Cylinder head bolt

30(300, 22) + 90˚ → Release all bolts →

30(300, 22) + 90˚

8 ~ 10 (80 ~ 100, 6 ~ 7.4)

Cylinder head

Cylinder head gasket

Cylinder block

TORQUE : Nm (kgf.cm, lbf.ft)

EDKD110A

ZENITH POWER PRODUCTS - 416

EM -32ENGINE DOHC

HLA

Retainer

lock

Valve spring

Spring seat

Valve

Stem seal Timing chain

Chain sprocket

Exhaust camshaft

Camshaft

sprocket

80 ~ 100 (800 ~ 100,

59 ~ 74)

12 ~ 14

(120 ~ 140, 9 ~ 10)

Intake

camshaft

TORQUE : Nm (kgf·cm, lbf·ft)

EDKD111A

ZENITH POWER PRODUCTS - 416

CYLINDER HEAD ASSEMBLY EM -33

DISASSEMBLY EBCFA4C6

1. Using a tool remove the cylinder head bolts in the

order shown in the illustration.

3 5 10 8 2

1 7 9 6 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

EDKD116A

3. Remove the valve stem seals with pliers.

NOTE

Do not reuse the valve stem seals.

EDDE088B

INSPECTION 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 deop-

sits completely. After cleaning the oil passages, ap-

ply compressed air to verify that the passages are not

clogged.

ECKD001H

3.Check the cylinder head surface for flatness in the di-

rection 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.)

ZENITH POWER PRODUCTS - 416

EM -34 ENGINE DOHC

VALVES

1. 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 nec-

essary. If stem end, A, is hollowed out or worn, resur-

face as necessary. This correction must be limited to

amin

imum. Also resurface the valve face.

Replace the valve if the margin has decreased to less

than the service limit.

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.)

Margin

ECKD221A

VALVE SPRINGS

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.

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.)

Outofsquare: 1.5

[Limit]

Free height : - 1.0 mm (- 0.039 in.)

Out of square : 3

2˚

Free

height

Out-of-square

ECA9281C

Check the valve stem-to-guide clearance. If the clearance

exceeds the service limit, replace the valve guide with the

next oversize part.

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

Guide inside diameter

Stem diameter

ECA9281D

ZENITH POWER PRODUCTS - 416

CYLINDER HEAD ASSEMBLY EM -35

REPLACING THE VALVE SEAT RING

1. 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)

0.15 - 0.3 mm

(0.006 - 0.0118 in.)

Old hole

Remove

D∅

New hole

ECA9281F

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(480F) 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.

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.)

VALVE SEAT INSERT OVERSIZES

Description Size mm (in.) Size

mark Seat ring height H

mm (in.) Oversize hole diameter

I.D. mm (in.)

0.3 (0.012) O.S. 30 5.1~5.3(0.2008~0.2087) 30.7~30.721 (1.2087~1.2095

Intake valve

Seat ring 0.6 (0.024) O.S. 60 5.4~5.6(0.2126~0.2205) 31.0~31.021(1.2205~1.2213)

0.3 (0.012) O.S. 30 6.2~6.4(0.2441~0.2520) 27.3~27.321(1.0748~1.0756)

Exhaust valve

Seat ring 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 valveguide toward the bottom of cylinder head.

2. Recondition the valve guide hole so that it can match

the newly press-fitted oversize valve guide.

Valve guide

Valve guide installer

(09221-3F100A)

Cylinder head

Valve guide installer

(09221-3F100B)

Valve guide installer

adapter

14mm (0.5512 in.)

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) 511.05~11.068 (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 EM -37

REASSEMBLY EC46B95A

NOTE

1. Clean each part before assembly.

2. Apply engine oil to the sliding and rotating parts.

1. Install the spring seats.

Using a special tool (09222-22001), tap the seal in

position lightly.

NOTE

•Do not reuse old valve stem seals.

•Incorrect installation of the seal could result in oil

leakage past the valve guides.

2. 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.

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.

Enamel

coated

side

Spring

Spring Retainer

Stem seal

Spring seat

ECA9290B

4. Using the special tool (09222-28000, 09222-28100),

compress the spring and install the retainer locks. Af-

ter installing the valves, ensure that the retainer locks

are correctly in place before releasing the valve spring

compressor.

09222-28100

09222-28000

EDKD116A

NOTE

When the spring is compressed, Check that the valve

stem seal is not pressed against the bottom of 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 identifi-

cation mark faces toward the cylinder head.

8. Tighten the bolts to the specified torque in the se-

quence shown.

8 6 1 3 9

10 4 2 5 7

EDKD700A

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

TORQUE : Nm (kg.cm, lb.ft)

5 ~ 8 (50 ~ 80, 4 ~ 6)

8 ~ 10 (80 ~ 100, 6 ~ 7)

12 ~ 14 (50 ~ 80, 4 ~ 6)

Bearing cap (rear)

Exhaust camshaft

HLA

80 ~ 100

(800 ~ 1000, 59 ~ 74) Camshaft oil seal

Bearing cap (front) Intake camshaft

Cylinder head

Gasket

Camshaft sprocket

EDDA018A

ZENITH POWER PRODUCTS - 416

MAIN MOVING SYSTEM EM -39

DISASSEMBLY 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.

KCDC002B

4. Loosen the cylinder head cover bolts and then remove

the cylinder head cover.

EDKE104A

5. Remove the camshaft sprocket.

6. Remove the camshaft bearing caps and timing chain.

EDKE124A

7. Remove the camshaft.

8. Remove the HLA.

ZENITH POWER PRODUCTS - 416

EM -40ENGINE DOHC

INSPECTION 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 dam-

aged 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 neces-

sary.

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

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.

EDDA020B

Problem Possible cause 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.

Continuous noise when engine is

running after excessive cranking.

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 changing HLA.

Oil drain out of the high-pressure

chamber in HLA, allowing

air to get in.

Insufficient oil in HLA.

CAUTION

Do not run engine at a speed

higher than 3000 rpm as this

may damage HLA.

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

Continuous noise during idle after

high speed running.

Deteriorated oil Check oil quality.

Low oil pressure Check oil pressure and oil supply

system of each part of engine

Noise continuous for more than

15 minutes.

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 malfunc-

tion of HLA if you use additives besides engine oil reg-

ulated to HMC.

ZENITH POWER PRODUCTS - 416

EM -42ENGINE DOHC

TIMING CHAIN

Check the bushing and plate of timing chain for wear. Re-

place if wear is severe.

EDDA020C

REASSEMBLY E1337F9D

1. Install the HLA.

2. Align the camshaft timing chain with intake timing

chain sprocket and exhaust timing chain sprocket as

shown.

Exhaust timing chain sprocket

Intake timing chain sprocket

Timing

mark

Timing

mark

Timing chain

EDDA021A

3. Install the camshaft after lubricating the camshaft

journals with engine oil.

EDDA021B

4. Install the bearing caps. The markings on the caps

are for intake/exhaust identification.

I: Intake camshaft

E: Exhaust camshaft

Symbol identifying intake

Cap number

EDDA021C

5. 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

EDDA021D

ZENITH POWER PRODUCTS - 416

MAIN MOVING SYSTEM EM -43

6. 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.

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)

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)

9. Install the cylinder head cover.

Tightening torque

Cylinder head cover bolts :

8~10Nm(80~100kg.cm,6~7lb.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)

ZENITH POWER PRODUCTS - 416

EM -44 ENGINE DOHC

CRANK SHAFT

COMPONENTS ED67A7AC

(ATA)

(MTA)

120 ~ 130

(1200 ~ 1300,

88 ~ 95)

Washer

Drive plate

Flywheel

10 ~ 12 (100 ~ 120,

7.3 ~ 8.8)

Rear oil seal case

Gasket

Cylinder block

Center bearing

Crankshaft

Main bearing

Main bearing cap

55 ~ 60 (550 ~ 600, 41 ~ 44)

10 ~ 12 (100 ~ 120, 7.3 ~ 8.8)

Oil pan

Drain plug

40 ~ 45

(400 ~ 450,

30 ~ 33) Gasket

15 ~ 22 (150 ~ 220, 11 ~ 16)

Oil screen

Gasket

Front case

Oil seal

20 ~ 27 (200 ~ 270,

14.7 ~ 20)

TORQUE : Nm (kgf.cm, lbf.ft)

EDKD140A

ZENITH POWER PRODUCTS - 416

MAIN MOVING SYSTEM EM -45

DISASSEMBLY EA7E6C0F

1. Remove the timing belt, front case, flywheel, cylinder

head assembly and oil pan. For details, refer to the

respective chapters.

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 crank-

shaft.

5. Remove the crankshaft position sensor wheel.

CAUTION

Mark the main bearing caps to permit reassembly

in the original position and direction.

INSPECTION E76DB219

CRANKSHAFT

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.

2. Inspect the crankshaft journal for taper and out - of -

round.

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.

OIL CLEARANCE MEASUREMENT

1. Measure the diameter of the crankshaft journal and

pin.

2. Measure the diameter of the crankshaft bore and con-

necting rod bore.

3. Measure the thickness of the crankshaft bearing and

connecting rod bearing.

4. Measure the clearance by the value that subtract the

diameter of journal and pin and the thickness of bear-

ing 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.)

OIL SEAL

Check front and rear oil seals for damage or wear. Replace

any seal that is defective.

CRANKSHAFT SENSOR WHEEL

1. 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.

Standard value

Clearance between sensor wheel and crank

position sensor :

0.5 ~ 1.1 mm (0.020 ~ 0.043 in.)

EDDA028C

NOTE

1. Measure the depth of the top of sensor wheel

tooth and the cylinder block mounting block.

2. Measure the difference between sensor length

and depth.

3. 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 DOHC

REPLACEMENT E8EBDEBC

1. Check the cylinder block crankshaft bore size code.

Crankshaft bore size code

EDPC004C

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

a54~54.006mm (2.1259~2.1262in.) A

b54.006~54.012mm

(2.1262~2.1264in.) B

c54.012~54.016mm

(2.1264~2.1266in.) C

2. 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

CRANKSHAFT MAIN JOURNAL DIAMETER

Class Main journal diameter Size

code

I49.968 ~ 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

MAIN JOURNAL BEARING THICKNESS

No.1,2,4,5(MAINBEARING)

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.)

NO.3 (CENTER BEARING)

Color Main journal bearing thickness

Yellow 1.999 ~ 2.002 mm (0.0787 ~ 0.0788 in.)

Green2.002 ~ 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.)

3. Choose proper main journal bearing in table.

ZENITH POWER PRODUCTS - 416

MAIN MOVING SYSTEM EM -47

REASSEMBLY E0ABCAB2

1. Install the upper main bearing inserts in the cylinder

block.

When reusing the main bearings, remember to in-

stall 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 spec-

ified 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 di-

rected 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)

EDKE151A

4. Make certain that the crankshaft turns freely and has

the proper clearance between the center main bear-

ing thrust flange and the connecting rod big end bear-

ing.

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 In-

staller (09231 - 21000) as shown. Press fit the oil seal

all the way in, being careful not to misalign it.

09231-21000

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

TORQUE : Nm (kg.cm, lb.ft)

M/T A/T

EDDA030A

M/T : Manual Transmission Vehicles

A/T : Automatic Transmission Vehicles

DISASSEMBLY E543FBCD

1. Remove the Transmission and clutch.

2. Remove the flywheel.

INSPECTION EB2E8F43

1. Check the clutch disc contacting surface of the fly-

wheel for damage and wear. Replace the flywheel if

excessively damaged or worn.

2. Check the clutch disc contacting surface of the fly-

wheel for runout.

Standard value

Flywheel run - out : 0.1 mm (0.0039 in.)

3. Check the ring gear for damage, cracks, and wear,

and replace if necessary.

REASSEMBLY 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

Connecting rod

Piston pin

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 DOHC

DISASSEMBLY EEDFC26E

CONNECTING ROD CAP

CAUTION

Keep the bearings in order with their correspond-

ing connecting rods (according to cylinder num-

bers) for proper reassembly.

1. Remove the connecting rod cap bolts, then remove

the caps and the big end lower bearing.

2. Push each piston connecting rod assembly toward the

top of the cylinder.

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

thepistonfloatsonthepin.

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.

4. 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.

Remover

Support fixture

Support fork

EDA9048A

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 EM -51

7. 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 -52ENGINE DOHC

INSPECTION 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).

PISTON RINGS

1. Measure the piston ring side clearance. If the mea-

sured 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.)

ECKD001G

2. 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.

Pistonringendgap

[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.)

ECKD001K

When replacing the ring without correcting the cylin-

der 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

thesameside.

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 DOHC

REPLACEMENT EF4FCD8C

1. Check the cylinder bore size code on the cylinder

block bottom face.

Cylinder bore side code

EDPE004B

1.6 L

Class Cylinder bore inner diameter Size

code

A76.5~76.51mm (3.0118~3.0121in.) A

B76.51~76.52mm (3.0121~3.0126in.) B

C76.52~76.53mm (3.0126~3.0129in.) C

2. Check the piston size code on the piston top face.

KDPC005Z

NOTE

Stamp the grade mark of basic diameter with rubber

stamp.

1.6 L

Class Piston outer diameter Size

code

A76.465~76.475mm

(3.0104~3.0108in.) A

B76.475~76.485mm

(3.0108~3.0112in.) B

C76.485~76.495mm

(3.0112~3.0116in.) C

3. Select the piston related to cylinder bore class.

Oil clearance

0.025 ~ 0.045mm (0.00098 ~ 0.00177in.)

ZENITH POWER PRODUCTS - 416

MAIN MOVING SYSTEM EM -55

REASSEMBLY ECCF87EF

1. Install the spacer.

Piston upper

Piston lower

Side rail

Spacer

ECA9082A

Upper side rail

45˚

Lower side rail

90˚ Position

from the gap

of No. 2 ring

Gap position of

lower side rail

Gap position of spacer

Gap position

of upper

spacer Spacer

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.

3. Install the lower side rail by the same procedure de-

scribedinStep2.

ECA9380B

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.

No.1

No.2

Berrel type

Inside bevel

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 direc-

tions.

ZENITH POWER PRODUCTS - 416

EM -56 ENGINE DOHC

8. Hold the piston rings firmly with a piston ring compres-

sor as they are inserted into cylinder.

Gap of upper

side rail

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.

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.)

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

CYL/HEAD CYL/BLCOK

BYPASS VALVE

HEATER

THERMOSTAT

COOLANT PUMP

ECKB001I

ZENITH POWER PRODUCTS - 416

EM -58 ENGINE DOHC

Thermostat housing

Thermostat

15 ~ 20 (150 ~ 200,

9 ~ 14)

Coolant inlet

fitting

Gasket

10 ~ 15 (100 ~ 150, 7 ~ 9)

Coolant inlet pipe

O-ring

Water pump

12 ~ 15

(120 ~ 150, 8.8 ~ 11)

20 ~ 27

(200 ~ 270,

12 ~ 20)

TORQUE : Nm (kgf.cm, lbf.ft)

EDKD180A

ZENITH POWER PRODUCTS - 416

COOLING SYSTEM EM -59

INSPECTION E6CC2E0F

Check the coolant pipe and hoses for cracks, damage, or

restrictions.

Replace if necessary.

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. Do not apply oil or grease to the coolant pipe

O-ring.

2. Keep the coolant pipe connections free of sand,

dust, etc.

3. Insert the coolant pipe fully into the cylinder

block.

4. Do not reuse the O-ring. Replace it with a new

part.

Cylinder block

Coolant inlet pipe

Coolant pump assembly

ECKA040A

ZENITH POWER PRODUCTS - 416

EM -60ENGINE DOHC

ENGINE COOLANT PUMP

COMPONENTS E8D2CBAD

Coolant pump

Alternator brace

Coolant pump pulley

Belt

8 - 10 (80 - 100, 6 - 7)

20 - 27 (200 - 270, 15 - 20)

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 pul-

ley.

3. Removethetimingbeltcoversandthetimingbelt

idler.

4. Remove the coolant pump mounting bolts, then re-

move the alternator brace.

EDKE181A

5. Remove the coolant pump assembly from the cylinder

block.

ZENITH POWER PRODUCTS - 416

COOLING SYSTEM EM -61

INSPECTION E5229EB7

1. Check each part for cracks, damage or wear, and re-

place the coolant pump assembly if necessary.

2. Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the coolant pump as-

sembly if necessary.

3. Check for coolant leakage. If coolant leaks then the

seal is defective. Replace the coolant pump assem-

bly.

EDKB051A

REASSEMBLY E0C24D31

1. Clean the gasket surfaces of the coolant pump body

and the cylinder block.

2. Install a new coolant pump gasket to the coolant pump

and tighten the bolts to the specified torque.

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

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 EM -63

INSPECTION EC662470

1. Check the radiator for bent, broken or plugged fins.

2. Check the radiator for corrosion, damage, rust or

scale.

3. Check the radiator hoses for cracks, damage or dete-

rioration.

4. Check the reservoir tank for damage.

5. Check the radiator cap spring for damage.

6. Test thepressureofthecapusingacoolingsystem

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.

REASSEMBLY EF7E7B75

1. Fill the radiator and reservoir tank with clean coolant

mixture.

2. 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.

ZENITH POWER PRODUCTS - 416

EM -64 ENGINE DOHC

RADIATOR CAP

COMPONENTS EA37EA8B

High - pressure valve High - pressure valve Vacuum spring

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)]

When the pressure is peduced to the specified level

[-6.86 Kpa (- 0.07 kg/cm, -1.00 psi)]

Radiator Cap Spring

ECDA066A

ZENITH POWER PRODUCTS - 416

COOLING SYSTEM EM -65

INSPECTION E7AA67F9

1. Check the radiator cap for damage, cracks and dete-

rioration.

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 DOHC

THERMOSTAT

INSPECTION EE55C20B

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

2. Remove the inlet fitting and gasket.

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(177C)

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(68F) : 2.31 ~ 2.59 kΩ

REASSEMBLY E342AFA3

1. Check that the flange of the thermostat is correctly

seated in the socket of the thermostat housing.

2. Install a new gasket and the coolant inlet fitting.

3. Refill the system with clean coolant.

Tightening torque

Coolant temperature sensor :

25 ~ 30 Nm (250 ~ 300 kg.cm, 18 ~ 22 lb.ft)

ZENITH POWER PRODUCTS - 416

LUBRICATION SYSTEM EM -67

LUBRICATION SYSTEM

OIL PUMP

COMPONENTS EDF9B71D

20 ~ 27 (200 ~ 270, 15 ~ 20)

Front case

Filter

15 ~ 22 (150 ~ 220,

11 ~ 16)

Gasket

Oil screen

Drain plug

40 ~ 45 (400 ~450,

30 ~ 33 ) Gasket

Oil pan

10 ~ 12 (100 ~ 120, 7.3 ~ 8.8)

TORQUE : Nm (kgf.cm, lbf.ft)

EDKD200A

ZENITH POWER PRODUCTS - 416

EM -68 ENGINE DOHC

DISASSEMBLY E450CC2F

1. Remove the timing belt.

2. Remove all the oil pan bolts.

3. Remove the oil pan.

4. Remove the oil screen.

5. Remove the front case assembly.

EDKE208A

6. Remove the oil pump cover.

EDKE202A

7. Remove the inner and outer gears from the front case.

The matching marks on the inner and outer gears in-

dicate the direction of installation.

INSPECTION E9D08BBC

FRONT CASE

1. Check the front case for cracks or damage. Replace

as necessary.

2. Check the front oil seal for worn or damaged lips. Re-

place if defective.

OIL PAN AND OIL SCREEN

1. Check the oil pan for failure, damage or cracks. Re-

place 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

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.)

EDKD207A

ZENITH POWER PRODUCTS - 416

LUBRICATION SYSTEM EM -69

3. Check the tip clearance on the pump roter.

EDKD206A

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.)

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.

EDDA061A

2. Check the continuity between the terminal and the

body when the fine wire is pushed. If there is con-

tinuity 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

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EM -70ENGINE DOHC

REASSEMBLY E1BA8FB0

OIL PUMP

1. 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.

2. 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)

EDKE202A

3. Install the relief valve and spring. Tighten the plug

to the specified torque. Apply engine oil to the relief

valve.

Relief valve plug

40 ~ 50 Nm (400 ~ 500 kg.cm, 30 ~ 37 lb.ft)

EDKE204A

FRONT CASE

1. 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:60mm(2.36in.)

D:22mm(0.89in.)

ECKA020E

OIL SEAL

1. Using the special tool, Crankshaft oil seal

guide(09231 - 22100), install the oil seal.

2. Using the special tool, Crankshaft front oil seal in-

staller (09231-22000), install the 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.

ZENITH POWER PRODUCTS - 416

LUBRICATION SYSTEM EM -71

CAUTION

•Apply sealant approx. 4mm (0.16 in.) in thick-

ness.

•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)

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EM -72ENGINE DOHC

ENGINE BLOCK

COMPONENTS E362FF2F

Piston ring

Piston

Connecting rod

Piston pin

Connecting rod bearing

Connecting rod bearing cap

32 ~ 35 (320 ~ 350, 24 ~ 26)

TORQUE : Nm (kgf.cm, lbf.ft)

Cylinder block

ECDE141A

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ENGINE BLOCK EM -73

DISASSEMBLY EE96372F

1. Remove the timing belt, cylinder head, front case, fly-

wheel, pistons and crankshaft.

2. Remove the oil pressure switch.

Adapter

EDDA008A

INSPECTION 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.

Standard : 0.03 mm (0.0012 in.) or less

Limit : 0.06 mm (0.0024 in.) or less

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

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EM -74 ENGINE DOHC

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 di-

ameter 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

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INTENTIONALLY LEFT

BLANK

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EM -76 ENGINE DOHC

INTAKE AND EXHAUST

SYSTEM

EXHAUST MANIFOLD

COMPONENTS E6FBC7D4

15 ~ 20 (150 ~ 200,

11 ~ 15)

30 ~ 35 (300 ~ 350,

22 ~ 26)

Heat protector

Exhaust manifold

Gasket

Cylinder head

TORQUE : Nm (kgf.cm, lbf.ft)

EDKD251A

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INTAKE AND EXHAUST SYSTEM EM -77

DISASSEMBLY EAA67563

1. Disconnect the oxygen sensor connect.

KDPC007D

2. Remove the exhaust manifold heat protector.

3. Remove the exhaust manifold assembly from the

cylinder head.

4. Remove the exhaust manifold gasket.

INSPECTION ED2622EE

EXHAUST MANIFOLD

1. Check for damage or cracking.

2. Check for damage or cracking of welding between ex-

haust manifold and converter.

REASSEMBLY E1BC9FEF

Install the exhaust manifold in the reverse order of removal.

CAUTION

Replace the exhaust manifold gasket and lock nut

when reassembling.

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EM -78 ENGINE DOHC

INTAKE MANIFOLD

COMPONENTS EF98EE9D

Intake manifold Gasket Throttle body

ISA

TPS

15 ~ 20 (150 ~ 200,

11 ~ 15)

Gasket

Intake manifold stay

18 ~ 25 (180 ~ 250,

13 ~ 18)

TORQUE : Nm (kg.cm, lb.ft)

ECDE087A

ZENITH POWER PRODUCTS - 416

Hyundai ZPP 416 ENGINE DOHC &file=Hyundai

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