Engine (D4FA - DSL1.5)

Transcription

1 Engine (D4F - DSL1.5) GENERL TIMING SYSTEM TIMING CHIN ENGINE ND TRNSXLE SSEMLY CYLINDER HED SSEMLY ENGINE LOCK COOLING SYSTEM LURICTION SYSTEM INTKE ND EXHUST SYSTEM

2 EM -2 GENERL ENGINE (D4F - DSL1.5) SPECIFICTIONS E284EC0 General Type Description Specifications (D4F) Limit Number of cylinders 4 ore Stroke Total displacement In-line, DOHC 75mm (2.9528in) Compression ratio 17.8 : 1 Firing order Valve timing Intake valve Exhaust valve Cylinder head Flatness of gasket surface Flatness of manifold mounting surface Camshaft Cam height Opens (TDC) 6 Closes (DC) 34 Opens (DC) 46 Closes (TDC) 4 Intake Exhaust 84.5mm (3.3268in) 1,493 cc (91.11 cu.in) 0.03mm (0.0012in) for width 0.09mm (0.0035in) for length 0.025mm (0.0010in) for width 0.160mm (0.0063in) for length 0.025mm (0.0010in) for width 0.160mm (0.0063in) for length LH Intake ~ mm ( ~ in) camshaft Exhaust ~ mm ( ~ in) RH Intake ~ mm ( ~ in) camshaft Exhaust ~ mm ( ~ in) Journal outer LH camshaft ~ mm ( ~ in) Diameter RH camshaft ~ mm ( ~ in) earing oil clearance End play Valve Valve length Intake Exhaust ~ 0.077mm ( ~ in) 0.10 ~ 0.20mm ( in) 93.0mm (3.6614in) 93.7mm (3.6890in) Stem outer Intake ~ 5.470mm ( ~ in) diameter Exhaust ~ 5.450mm ( ~ in) Face angle 45.5 ~ 45.75

3 GENERL EM -3 Description Specifications (D4F) Limit Thickness of Intake 1.1mm (0.0433in) valve head (margin) Exhaust 1.2mm (0.0472in) Valve stem to Intake ~ 0.057mm ( ~ in) valve guide clearance Exhaust ~ 0.077mm ( ~ in) Valve guide Inner diameter Length Valve seat Intake Exhaust Intake Exhaust ~ 5.512mm ( ~ in) ~ 5.512mm ( ~ in) 31.3 ~ 31.7mm ( ~ in) 31.3 ~ 31.7mm ( ~ in) Width of seat Intake 0.8 ~ 1.4mm ( ~ in) contact Exhaust 1.2 ~ 1.8mm ( ~ in) Seat angle Valve spring Free length Load Intake 45 ~4530 Exhaust 45 ~ mm (1.7677in) 17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in) 31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in) Out of squareness Less than Cylinder block Cylinder bore Flatness of gasket surface Piston Piston outer diameter Piston to cylinder clearance Ring groove width Piston ring Side clearance End gap Piston pin No. 1 ring groove No. 2 ring groove Oil ring groove No. 1 ring No. 2 ring Oil ring No. 1 ring No. 2 ring Oil ring Piston pin outer diameter ~ mm ( ~ in) Less than 0.05mm (0.0020in) (Overhaul) Less than 0.03mm (0.0012in) (Per 1 Cylinder) ~ mm ( ~ in) ~ 0.080mm ( ~ in) 1.83 ~ 1.85mm ( ~ in) 1.82 ~ 1.84mm ( ~ in) 3.02 ~ 3.04mm ( ~ in) 0.09 ~ 0.13mm ( ~ in) 0.08 ~ 0.12mm ( ~ in) 0.03 ~ 0.07mm ( ~ in) 0.20 ~ 0.35mm ( ~ in) 0.35 ~ 0.50mm ( ~ in) 0.20 ~ 0.40mm ( ~ in) ~ mm ( ~ in)

4 EM -4 ENGINE (D4F - DSL1.5) Piston pin hole inner diameter Piston pin hole clearance Description Specifications (D4F) Limit Connecting rod small end hole inner diameter Connecting rod small end hole clearance Connecting rod Connecting rod big end inner diameter Connecting rod bearing oil clearance ~ mm ( ~ in) ~ 0.015mm ( ~ in) ~ mm ( ~ in) ~ 0.039mm ( ~ in) ~ mm ( ~ in) ~ 0.043mm ( ~ in) Side clearance ~ 0.302mm ( ~ in) 0.4mm (0.0157in) Crankshaft Main journal outer diameter Pin journal outer diameter Main bearing oil clearance End play Flywheel ~ mm ( ~ in) ~ mm ( ~ in) ~ 0.042mm ( ~ in) 0.08 ~ 0.28mm ( ~ 0.110in) Runout 0.1mm (0.0039in) 0.13mm (0.0051in) Oil pump Side clearance ody clearance Inner rotor Outer rotor Relief valve opening pressure Engine oil Oil quantity (Total) Oil quantity (Oil pan) Oil quantity (Oil filter) Oil quality Oil pressure (Idle) (Oil temperature : 80 C) Cooling system Cooling method Coolant quantity Thermostat Radiator cap Type Opening temperature Pull opening temperature Main valve opening pressure Vacuum valve opening pressure ~ 0.085mm ( ~ in) ~ 0.090mm ( ~ in) ~ 0.185mm ( ~ in) 490±49.0kpa (5±0.5kg/cm², 71±7.1psi) 5.3 L (5.60 US qt, 4.66 lmp qt) 4.8 L (5.07 US qt, 4.22 lmp qt) 0.5 L (0.53 US qt, 0.44 lmp qt) bove PI CH-4, bove CE kpa (0.8kg/cm², 11.3psi) Forced circulation with cooling fan 5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt) Wax pellet type 85±1.5 C (185.0±2.7 F) (Lift : 0.35mm(0.0138in)) 100 C (212 F) (Lift : 8mm(0.3150in)) ~ kpa (0.95 ~ 1.25kg/cm², ~ 17.78psi) 0.98 ~ 4.90 kpa (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)

5 GENERL EM -5 Description Specifications (D4F) Limit Water temperature sensor Type Thermister type Resistance 20 C(68F) 2.45±0.14 k 80 C(176F) k

6 EM -6 ENGINE (D4F - DSL1.5) TIGHTENING TORQUE Cylinder block Item Quantity Tightening torque N.m kgf.m lb-ft Engine support bracket bolt ~ ~ ~ 39.8 Piston cooling oil jet bolt ~ ~ ~ 9.4 Drive belt auto tensioner bolt ~ ~ ~ 20.3 Drive belt auto tensioner mounting bracket bolt ~ ~ ~ 20.3 Engine mounting Engine mounting bracket and body fixing bolt ~ ~ ~ 47.0 Engine mounting insulator and engine mounting support bracket fixing nut Engine mounting support bracket and engine support bracket fixing bolt Engine mounting support bracket and engine support bracket fixing nut ~ ~ ~ ~ ~ ~ ~ ~ ~47.0 Transaxle mounting bracket and body fixing bolt ~ ~ ~ 47.0 Transaxle mounting insulator and transaxle support bracket fixing bolt Front roll stopper bracket and sub frame fixing bolt Front roll stopper insulator and front roll stopper support bracket fixing bolt,nut Rear roll stopper bracket and sub frame fixing bolt Rear roll stopper insulator and rear roll stopper support bracket fixing bolt,nut Mainmovingsystem ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~47.0 Connecting rod cap bolt Crankshaft main bearing cap bolt (long) Crankshaft main bearing cap bolt (short) ~ ~ ~ 26.8 Flywheel bolt (M/T) ~ ~ ~ 57.9 Drive plate bolt (/T) ~ ~ ~ 57.9 Timing chain Timing chain cover bolt (8 X 70) ~ ~ ~ 19.5 Timing chain cover bolt (8 X 60) ~ ~ ~ 19.5 Timing chain cover bolt (8 X 35) ~ ~ ~ 19.5 Timing chain cover bolt (6 X 35) ~ ~ ~ 8.7 Timing chain cover bolt (6 X 28) ~ ~ ~ 8.7 Timing chain case bolt (8 X 22) ~ ~ ~ 22.4 Timing chain case bolt (8 X 32) ~ ~ ~ 20.3 Timing chain case bolt (6 X 35) ~ ~ ~ 8.7

7 GENERL EM -7 Item Quantity Tightening torque N.m kgf.m lb-ft Engine hanger (front) ~ ~ ~ 18.1 Crankshaft pulley bolt ~ ~ ~ Camshaft chain sprocket bolt ~ ~ ~ 54.2 High pressure pump chain sprocket bolt ~ ~ ~ 55.0 Timing chain guide (1) bolt ~ ~ ~ 8.7 Timing chain guide (2) bolt ~ ~ ~ 10.1 Timing chain "" auto tensioner bolt ~ ~ ~ 8.7 Timing chain "C" auto tensioner bolt ~ ~ ~ 8.7 Cylinder head Engine cover bolt ~ ~ ~ 8.7 Cylinder head cover bolt ~ ~ ~ 7.2 Camshaft bearing cap bolt (Reamer bolt) ~ ~ ~ 10.1 Camshaft bearing cap bolt (Standard bolt) ~ ~ ~ 10.1 Engine hanger bolt (Front) ~ ~ ~ 18.1 Engine hanger bolt (Rear) ~ ~ ~ 37.6 Cylinder head bolt Cooling system Water pump pulley bolt ~ ~ ~ 8.7 Waterpumpbolt(8X50) ~ ~ ~ 18.1 Waterpumpbolt(8X70) ~ ~ ~ 18.1 Thermostat housing bolt ~ ~ ~ 8.7 Thermostat housing nut ~ ~ ~ 8.7 Water return pipe assembly bolt ~ ~ ~ 18.1 Water temperature sensor ~ ~ ~ 25.3 Water outlet fitting nut ~ ~ ~ 18.1 Lubrication system Oil filter assembly bolt ~ ~ ~ 19.5 Oil cooler assembly bolt ~ ~ ~ 8.7 Oil filter upper cap Oil level gauge bolt ~ ~ ~ 19.5 Oil pan bolt (6 X 20) ~ ~ ~ 8.7 Oil pan bolt (6 X 65) ~ ~ ~ 8.7 Oil pan bolt (6 X 85) ~ ~ ~ 8.7 Oil pan and transaxle fixing bolt ~ ~ ~ 30.4 Oil pan drain plug ~ ~ ~ 32.5 Oil screen bolt ~ ~ ~ 19.5 Oil screen nut ~ ~ ~ 8.7 Oil pressure switch ~ ~ ~ 15.9

8 EM -8 ENGINE (D4F - DSL1.5) Item Intake and exhaust system Quantity Tightening torque N.m kgf.m lb-ft Intake manifold and cylinder head fixing nut ~ ~ ~ 14.5 Intake manifold and cylinder head fixing bolt ~ ~ ~ 14.5 Exhaust manifold and cylinder head fixing nut ~ ~ ~ 25.3 Exhaust manifold heat cover and exhaust manifold fixing bolt ~ ~ ~ 14.5 WCC assembly fixing nut ~ ~ ~ 25.3 ir cleaner lower cover fixing bolt ~ ~ ~ 7.2 Throttle body and surge tank fixing bolt ~ ~ ~ 20.3 Exhaust manifold and front muffler fixing nut ~ ~ ~ 43.4 Front muffler fixing clip bolt ~ ~ ~ 28.9 Front muffler and center muffler fixing nut ~ ~ ~ 43.4 Center muffler and main muffler fixing nut ~ ~ ~ 43.4

9 GENERL EM -9 COMPESSION PRESSURE INSPECTION E5361E If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up and stop engine. llow the engine to warm up to normal operating temperature. 2. Remove the injectors(). (Refer to FL Gr.) lways use a fully charged battery to obtain engine speed of 300rpm or more. 4) Repeat step 1) though 3) for each cylinder. This measurement must be done in as short a time as possible. Compression pressure(standard) : 2,353kPa (24.0kg/cm², 341psi) (260 rpm) Minimum pressure : 2,059kPa (21.0kg/cm², 298psi) Difference between each cylinder : kPa (3.0kg/cm², 42.67psi) or less 3. Check the cylinder compression pressure. LCGF003 5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step 1) through 3) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. Reinstall the injectors. 1) Insert a compression gauge into the injector hole. ECKD001X 2) Fully open the throttle. 3) While cranking the engine, measure the compression pressure.

10 EM -10 ENGINE (D4F - DSL1.5) TROULESHOOTING E Symptom Suspect area Remedy Engine misfire with abnormal internal lower engine noises. Engine misfire with abnormal valve train noise. Engine misfire with coolant consumption Engine misfire with excessive oil consumption Engine noise on start-up, but only lasting a few seconds. Upper engine noise, regardless of engine speed. Loose or improperly installed engine flywheel. Worn piston rings. (Oil consumption may or may not cause the engine to misfire.) Worn crankshaft thrust bearings. Stuck valves. (Carbon buildup on the valve stem can cause the valve not to close properly.) Excessive worn or mis-aligned timing chain. Worn camshaft lobes. Faulty cylinder head gasket and/or cracking or other damage to the cylinder head and engine block cooling system. Coolant consumption may or may not cause the engine to overheat. Worn valves, valve guides and/or valve stem oil seals. Worn piston rings. (Oil consumption may or may not cause the engine to misfire) Incorrect oil viscosity. Worn crankshaft thrust bearing. Low oil pressure. roken valve spring. Worn or dirty valve lifters. Stretchedorbrokentimingchainand/or damaged sprocket teeth. Worn timing chain tensioner, if applicable. Worn camshaft lobes. Worn valve guides or valve stems. Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open.) Repair or replace the flywheel as required. Inspect the cylinder for a loss of compression. Repair or replace as required. Replace the crankshaft and bearings as required. Repair or replace as required. Replace the timing chain and sprocket as required. Replace the camshaft and valve lifters. Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket. Repair or replace as required. Repair or replace as required. Inspect the cylinder for a loss of compression Repair or replace as required. Drain the oil. Refill with the correct viscosity oil. Inspect the thrust bearing and crankshaft. Repair or replace as required. Repair or replace as required. Replace the valve spring. Replace the valve lifters. Replace the timing chain and sprockets. Replace the timing chain tensioner as required. Inspect the camshaft lobes. Replace the camshaft and valve lifters as required. Inspect the valves and valve guides, then repair as required. Inspect the valves and valve guides, then repair as required.

11 GENERL EM -11 Symptom Suspect area Remedy Lower engine noise, regardless of engine speed. Engine noise under load. Low oil pressure. Loose or damaged flywheel. Damaged oil pan, contacting the oil pump screen. Oil pump screen loose, damaged or restricted. Excessive piston-to-cylinder bore clearance. Excessive piston pin-to-bore clearance. Excessive connecting rod bearing clearance. Excessive crankshaft bearing clearance. Incorrect piston, piston pin and connecting rod installation. Low oil pressure. Excessive connecting rod bearing clearance. Excessive crankshaft bearing clearance. Repair or replace damaged components as required. Repair or replace the flywheel. Inspect the oil pan. Inspect the oil pump screen. Repair or replace as required. Inspect the oil pump screen. Repair or replace as required. Inspect the piston and cylinder bore. Repair as required. Inspect the piston, piston pin and the connecting rod. Repair or replace as required. Inspect the following components and repair as required. The connecting rod bearings. The connecting rods. The crankshaft. The crankshaft journal. Inspect the following components and repair as required. The crankshaft bearings. The crankshaft journals. Verify the piston pins and connecting rods are installed correctly. Repair as required. Repair or replace as required. Inspect the following components and repair as required. The connecting rod bearings. The connecting rods. The crankshaft. Inspect the following components and repair as required. The crankshaft bearings. The crankshaft journals. The cylinder block crankshaft bearing bore.

12 EM -12 ENGINE (D4F - DSL1.5) Symptom Suspect area Remedy Engine will not crank. (crankshaft will not rotate) Hydraulically locked cylinder. Coolant/antifreeze in cylinder. Oil in cylinder. Fuel in cylinder. roken timing chain and/or timing chain gears. Foreign material in cylinder. roken valve. Piston material. Foreign material. Seized crankshaft or connecting rod bearings. ent or broken connecting rod. roken crankshaft. Remove injectors and check for fluid. Inspect for broken head gasket. Inspect forcrackedengineblock or cylinder head. Inspect forastickingfuelinjector and/or leaking fuel regulator. Inspect timing chain and gears. Repair as required. Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required. Inspect crankshaft and connecting rod bearing. Repair or replace as required. Inspect connecting rods. Repair or replace as required. Inspect crankshaft. Repair or replace as required.

13 GENERL EM -13 SPECIL SERVICE TOOLS E986315E Tool (Number and name) Illustration Use Torque angle adapter ( ) Installation of bolts & nuts needing an angular method LCC030 Valve spring compressor ( K000) Valve spring compressor adapter ( ) K000 Removal and installation of intake and exhaust valves Valve stem oil seal installer ( ) LCGF059 Installation of valve stem oil seals LCC030D

14 EM -14 ENGINE (D4F - DSL1.5) Tool (Number and name) Illustration Use High pressure pump sprocket remover ( ) Removal of high pressure pump sprocket LCGF063 Crankshaft rear oil seal installer (09231-H1200) Handle (09231-H1100) Installation of crankshaft rear oil seal H H1200 Front cover oil seal installer ( ) Handle (09231-H1100) H1100 LCGF157 Installation of front cover oil seal LCGF158

15 GENERL EM -15 Tool (Number and name) Illustration Use Flywheel stopper ( ) Removal and installation of crankshaft pulley bolt Oil pan remover ( C000) Removal of oil pan CJF125 Engine support fixture adapter ( , C000) Support of engine MJF002

16 EM -16 TIMING SYSTEM ENGINE (D4F - DSL1.5) TIMING CHIN COMPONENT E85E1C ~ 29.4 (2.8 ~ 3.0, 20.3 ~ 21.7) 38.2 ~ 58.8 (3.9 ~ 6.0, 28.2 ~ 43.4) 19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 6.9 ~ 9.8 (0.7 ~ 1.0, 5.1 ~ 7.2) 14.7 ~ 19.6 (1.5 ~ 2.0, 10.8 ~ 14.5) ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 42.2 ~ 53.9 (4.3 ~ 5.5, 31.1 ~ 39.8) 19.6 ~ 24.5 (2.0 ~ 2.5, 14.5 ~ 18.1) ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) ~ (23.0 ~ 25.0, ~ 180.8) TORQUE : N.m(kgf.m, lbf.ft) 1. Injector 2. Injector clamp 3. Cylinder head cover 4. Cylinder head gasket 5. lternator ~ 27.5 (1.9 ~ 2.8, 13.7 ~ 20.3) 6. Water pump pulley 7. Engine support bracket 8. Drive belt auto tensioner 9. Crankshaft pulley 10. Key ~ 27.5 (1.9 ~ 2.8, 13.7 ~ 20.3) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 11. Oil pan 12. Oil strainer 13. Water pump 14. High pressure pump 15. Timing chain cover LDJF001

17 TIMING SYSTEM EM ~ 73.5 (7.0 ~ 7.5, 50.6 ~ 54.2) 9.8 ~ 13.7 (1.0 ~ 1.4, 7.2 ~ 10.1) 7.8 ~ 11.8 (0.8 ~ 1.2, 5.8 ~ 8.7) 24.5 ~ 30.4 (2.5 ~ 3.1, 18.1 ~ 22.4) ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) ~ 74.5 (6.6 ~ 7.6, 47.7 ~ 55.0) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) TORQUE : N.m(kgf.m, lbf.ft) 1. Timing chain cover 2. Timing chain "C" 3. Timing chain "C" auto tensioner 4. Timing chain "C" lever 5. Timing chain guide "1" 6. Timing chain guide "2" 7. Timing chain "" 8. High pressure pump sprocket 9. Crankshaft sprocket 10. Timing chain "" auto tensioner 11. Timing chain "" lever 12. Timing chain guide "1" 13. Timing chain case 14. Timing chain case gasket 15. Camshaft sprocket LDJF002

18 EM -18 REMOVL E501F9 ENGINE (D4F - DSL1.5) 4. Remove the engine mounting support bracket. Engine removal is not required for this procedure. 1) Set the jack to the engine oil pan 1. Remove the drive belt(). LDIF Remove the injector(). (Refer to FL Gr.) CGF031 2) Remove the engine mounting support bracket(). 3. Remove the cylinder head cover(). LCGF Remove the alternator(). EDNG LCGF004 LCGF005

19 TIMING SYSTEM EM Remove the water pump pulley(). 9. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position) Mark LCGF Remove the engine support bracket(). LCGF Remove the crankshaft pulley bolt() and crankshaft pulley(). LCGF Remove the drive belt auto tensioner(). LCGF009 Use the SST(flywheel stopper, )() to remove the crankshaft pulley bolt, after remove the starter. LCGF008

20 EM -20 ENGINE (D4F - DSL1.5) 12. Remove the high pressure pump pipe(). (Refer to FL Gr.) LCGF Remove the high pressure pump sprocket nut() after remove the timing chain cover plug(). DJF Remove the high pressure pump() fixing bolts and fuel hoses(,c). C LCGF091 Use the SST(flywheel stopper, ) to removethehighpressurepumpsprocketnut. DJF Install the SST(high pressure pump sprocket stopper, )() to sprocket rotating it clockwise. 15. Remove the timing chain cover bolt(three bolts)(). LCGF090 Replace O-ring of plug() with a new one when reinstalling the plug. LCGF159

21 TIMING SYSTEM EM InstalltheSST(highpressurepumpsprocketremover, )() to timing chain cover with three long bolts(). 21. Remove the jack from oil pan. 17. Fix the high pressure pump remover() and sprocket stopper(c) with two fixing bolts(d). 18. Rotate the bolt(e) clockwise till high pressure pump is pushed out. 19. Remove the SST( ) after remove the high pressure pump. D LDIF Remove the oil pan(). 23. Remove the oil strainer(). E C LCGF Install the SST( , C000), the engine support fixture and the adapter, on the enine hanger bracket C000 LCGF010 Using the SST( C000) and remove the oil pan. e careful not damage the contact surtaces of oil pan C000 LCGF150 CJF127

22 EM Remove the timing chain cover() ENGINE (D4F - DSL1.5) 26. Remove the timing chain "C" lever() and the timing chain guide "1"(). F D E D C E D D D D D C LCGF011 Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If any impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.) 25. Remove the timing chain "C" auto tensioner(). 27. Remove the timing chain guide "2"(). LCGF013 LCGF Remove the timing chain "C"(). Mark LCGF012 efore removing auto-tensioner, install a set pin() (ø2.5 mm steel wire) after compressing the tensioner. Mark LCGF015

23 TIMING SYSTEM EM Remove the timing chain "" auto tensioner(). 31. Remove the timing chain ""()with high pressure pump sprocket() and crankshaft sprocket(c). mark mark TDC C LCGF016 efore removing auto-tensioner, install a set pin() (ø2.5 mm steel wire) after compressing the tensioner. 30. Remove timing chain "" lever() and the timing chain guide "1"(). 32. Remove the power steering pump bracket(). LCGF024 TDC LCGF Remove the water pump(). LCGF017 LCGF026

24 EM -24 ENGINE (D4F - DSL1.5) 34. Remove the timing chain case(). (Engine removal is required for this procedure) D C LCGF Remove the camshaft sprocket. 1) Hold the portion() of the camshaft with a hexagonal wrench, and remove the bolt(c) with a wrench() and remove the camshaft sprocket. C LCGF028 CUTION e careful not to damage the cylinder head and valve lifter with the wrench.

25 TIMING SYSTEM EM -25 INSTLLTION E95FE08 Engine removal is not required for this procedure. 1. Install the camshaft sprocket and tighten the bolt to the specified torque. 1) Temporarily install the camshaft sprocket bolt(c). 2) Hold the portion() of the camshaft with a hexagonal wrench, and tighten the bolt(c) with a wrench(). D C 68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lb-ft) LCGF Install the water pump() ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft) C CUTION pply coolant to the o-ring before installing the water pump. LCGF Install the timing chain case() with new gasket. (Engine removal is required for this procedure) olt() :24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m, 18.1 ~ 22.4lb-ft) olt(c) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft) olt(d) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) LCGF026

26 EM Install the power steering pump bracket(). ENGINE (D4F - DSL1.5) 7. Set the key of crankshaft sprocket to be aligned with the timing mark of timing chain case. s a result of this, place the piston on No.1 cylinder at the top dead center on compression stroke. TDC LCGF Install the high pressure pump() and connect fuel hoses (, C) ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft) LCGF fter install timing chain "" with high pressure pump sprocket() equipped at the crankshaft sprocket(c), and then install high pressure pump sprocket at the high pressure pump shaft. The timing mark of high pressure pump sprocket should be aligned with timing mark on the timing chain case. C mark DJF044 mark 6. Installthehighpressurepipe().(RefertoFLGr) TDC C LCGF Pretighten the high pressure pump sprocket nut. DJF034

27 TIMING SYSTEM EM Install timing chain "" lever() and the timing chain guide "1"(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 12. lign the timing mark() of camshaft sprocket on the vertical center line of crankshaft. TDC LCGF094 LCGF Install the timing chain "" auto tensioner() and then remove set pin(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 13. Install the timing chain "C"() as following procedure. High pressure pump sprocket LH camshaft sprocket RH camshaft sprocket The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain as shown below illustration. Mark Mark LCGF016 LCGF015

28 EM Install the timing chain guide "2"(). 9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lb-ft) ENGINE (D4F - DSL1.5) 16. Install the timing chain "C" auto tensioner() and then remove set pin(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) LCGF Install the timing chain "C" lever() and the timing chain guide "1"(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 17. Install the high pressure pump sprocket nut() ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft) LCGF012 LCGF013 LCGF095

29 TIMING SYSTEM EM -29 Use the SST(flywheel stopper, )() to tighten the high pressure pump sprocket nut, after remove the starter. 19. Install the timing chain cover(). olt (,C,F) : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) olt(d,e) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) F D E D D C E D D D D C LCGF pply liquid gasket evenly to the mating surface of timing chain cover. Standard liquid gasket : LOCTITE 5900 Check that the mating surfaces are clean and dry before applying liquid gasket. ssemble the timing chain cover in 5 minutes after applying the liquid gasket. pply liquid gasket in a 3mm wide bead without stopping. LCGF Install the front oil seal by using SST( , H1100)(). Liquid gasket LCGF097 LCGF096

30 EM -30 ENGINE (D4F - DSL1.5) 21. Install the oil strainer(). olts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) Timing chain cover ed plate T - joint Timing chain case LCGF pply liquid gasket evenly to the mating surface of oil pan. 23. Install the oil pan(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 24. Set the jack to the engine oil pan LCGF099 Standard liquid gasket : LOCTITE 5900 Check that the mating surfaces are clean and dry before applying liquid gasket. pply liquid gasket in a 3mm wide bead without stopping.ssemble the oil pan in 5 minutes after applying the liquid gasket. fter assembly, wait at least 30 minutes before filling the engine with oil. pply liquid gasket to T-joint before assembling oil pan. Liquid gasket LDIF Remove the SST( , C000), the engine support fixture and the adapter, from the engine hanger bracket C000 LCGF098 LCGF150

31 TIMING SYSTEM EM Install the crankshaft pulley() and crankshaft pulley bolt() ~ 245.2N.m (23.0 ~ 25.0kgf.m, ~ 180.8lb-ft) 27. Install the drive belt auto tensioner() ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft) LCGF009 Use the SST(flywheel stopper, )() to Install the crankshaft pulley bolt, after remove the starter. 28. Install the engine support bracket() ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft) LCGF008 LCGF090 LCGF007

32 EM Install the water pump pulley(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) ENGINE (D4F - DSL1.5) 31. Install the engine mounting support bracket(). Nut(D) : 68.6 ~ 93.2N.m(7.0 ~ 9.5kgf.m, 50.6~ 68.7lb-ft) olt(), Nut(C) : 49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft) C LCGF Install the alternator() ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft) 32. Remove the jack from oil pan DJF027 LCGF005 LDIF001

33 TIMING SYSTEM EM Install the cylinder head cover() with new head cover gasket. 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) 34. Installtheinjector().(RefertoFLGr.) LCGF Install the drive belt(). LCGF161 Standard liquid gasket : LOCTITE 5900 Check that the mating surfaces are clean and dry before applying liquid gasket. pply liquid gasket in a 3mm wide bead without stopping. ssemble the cylinder head cover in 5 minutes after applying the liquid gasket. fter assembly, wait at least 30 minutes before filling the engine with oil. pply liquid gasket to T-joint before assembling cylinder head cover. CGF031 T - joint pply liquid gasket LCGF100

34 EM -34 ENGINE ND TRNSXLE SSEMLY REMOVL E Remove the under cover(). ENGINE (D4F - DSL1.5) CUTION Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. 1. Remove the battery(). 4. Drain the engine coolant. (Refer to EM- 77) Remove the radiator cap to speed draining. 5. Drain the engine oil. (Refer to EM- 87) Remove the oil filler cap to speed draining. CJF Remove the intake air hose and air cleaner assembly. 1) Disconnect the FS(ir Flow Sensor) connector(). 2) Remove the air cleaner upper cover(). DJF Removetheenginecover(). DJF003 DJF002

35 ENGINE ND TRNSXLE SSEMLY EM -35 3) Disconnect the ECM connector() and ECM connector() (/T only). 4) Remove the air cleaner element and air cleaner lower cover(c). 8. Remove the inter cooler upper hose(). DJF005 C CJF Remove the inter cooler lower hose() and TF oil cooler hose(). 5) Disconnect the air intake hose(). DJF006 DJF Remove the upper radiator hose() and lower radiator hose(). 7. Remove the battery tray(). DJF007 CJF009

36 EM Remove the fuel hose(). 14. Remove the heater hose(). ENGINE (D4F - DSL1.5) DJF008 DJF Remove the brake booster vacuum hose(). 15. Disconnect the battery (+) terminal () from fuse box. DJF009 DJF Remove the VGT actuator vacuum hose(). 16. Disconnect the engine harness () and harness connector() from fuse box. DJF010 DJF013

37 ENGINE ND TRNSXLE SSEMLY EM Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold. 8) Remove the engine wire harness bracket(d). 1) Disconnect the common rail pressure regulator connector (). 2) Disconnect the oxygen sensor connector (). D C DJF016 9) Disconnect the MP sensor connector(). 10) Disconnect the multi purpose check connector(). DJF014 3) Disconnect the injector connector(). 4) Disconnect the EGR(Emission Gas Recirculation) solenoid valve connector(). DJF017 11) Disconnect the vacuum solenoid valve connector(). DJF015 5) Disconnect the CMP(Camshaft position sensor) connector(). 6) Disconnect the common rail pressure sensor connector(). 7) Disconnect the water temperature sensor connector(c). DJF018

38 EM -38 ENGINE (D4F - DSL1.5) 12) Disconnect the swirl valve actuator connector(). 13) Disconnect the fuel pressure regulator connector (). 14) Disconnect the fuel temperature sensor connector (C). C DJF021 3) Disconnect the output shaft speed sensor connector (). DJF019 15) Remove the ground cable() from the engine mounting and body. DJF022 4) Disconnect the solenoid valve connector(). 5) Disconnect the input shaft speed sensor connector (). DJF Remove the transaxle wire harness connectors and control cable from transaxle (/T). 1) Disconnect the transaxle range switch connector (). 2) Disconnect the vehicle speed sensor connector(). 6) Remove the ground cable(c) from the transaxle and body. C DJF023

39 ENGINE ND TRNSXLE SSEMLY EM -39 7) Remove the transaxle control cable(). 21. Recovering refrigerant and remove the high & low pressure pipe. (Refer to H group - air conditioner compressor) 22. Remove the inter cooler lower hose(). DJF Remove the power steering oil hose() and drain the power steering oil. 23. Remove the front muffler heat protector(). 24. Remove the front muffler(). DJF025 CJF Remove the power steering return hose(). DJF026 CJF027

40 EM Remove the nuts(,d), bolt(c) and engine mounting support bracket(). Nut () : 68.6 ~ 93.2N.m (7.0~ 9.5kgf.m, 50.6 ~ 68.7lb-ft) olt(c),nut(d):49.0~63.7n.m(5.0~6.5kgf.m,36.2~47.0lb-ft) ENGINE (D4F - DSL1.5) 28. Remove the S wheel speed sensor(). C LCGF Remove the caliper and hang assembly(). DJF Remove the transaxle mounting bracket(). olt () : 68.6 ~ 93.2N.m (7.0~ 9.5kgf.m, 50.6 ~ 68.7lb-ft) LCGF139 LDJF Remove the front tires.(refer to DS group) LCGF140

41 ENGINE ND TRNSXLE SSEMLY EM Remove the knuckle mounting bolts(). KDNF001 LCGF Remove the sub frame bolts and nuts. 31. Remove the steering u-joint mounting bolt(). olt(), Nut() : 93.2 ~ 117.7N.m (9.5 ~ 12.0kgf.m, 68.7 ~ 86.8lb-ft) LCGF Using a floor jack, support the engine and transaxle assembly. CJF033 fter removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly. 34. Remove the engine and transaxle assembly by lifting vehicle. When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

42 EM -42 ENGINE (D4F - DSL1.5) INSTLLTION ECD86743 Installation is in the reverse order of removal. Perform the following : djust the shift cable. djustthethrottlecable. Refill the engine with engine oil. Refill the transaxle with fluid. Refill the radiator and reservoir tank with engine coolant. Place the heater control knob on HOT position. leed air from the cooling system. - Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped airtoberemovedfromthecoolingsystem. - Put the radiator cap on tightly, then run the engine again and check for leaks. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion. Inspect for fuel leakage. - fter assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

43 CYLINDER HED SSEMLY EM -43 CYLINDER HED SSEMLY COMPONENT E9EC ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) ~ 14.7 (1.1 ~ 1.5, 8.0 ~ 10.8) ~ 1.5 (0.08 ~ 0.15, 0.6 ~ 1.1) 4 15 ~ 20 (1.5 ~ 2.0, 11 ~ 14) ~ 21.6 (1.5 ~ 2.2, 10.8 ~ 15.9) TORQUE : N.m(kgf.m, lbf.ft) 1. Common rail 2. Glow plug connector 3. Glow plug plate 4. Glow plug 5. Thermostat housing 6. Vacuum pump 7. Cylinder head LDJF003

44 EM -44 ENGINE (D4F - DSL1.5) ~ 13.7 (1.3 ~ 1.4, 9.4 ~ 10.1) ~ 73.5 (7.0 ~ 7.5, 50.6 ~ 54.2) TORQUE : N.m(kgf.m, lbf.ft) 1. Camshaft bearing cap 2. Camshaft 3. Camshaft sprocket 4. Cam follwer 5. Valve spring retainer lock 6. Valve spring retainer 7. Valve spring 8. Valve stem seal 9. Valve 10. HL(Hydraulic Lash djuster) 11. Cylinder head 12. Cylinder head gasket LCGF039

45 CYLINDER HED SSEMLY EM -45 REMOVL E Remove the glow plug(). Engine removal is required for this procedure. CUTION To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. Turn the crankshaft pulley so that theno. 1piston is at top dead center. LCGF Remove the drive belt(). 6. Disconnect the water hose() from thermostat housing. CGF031 DJF Remove the timing chain. (Refer to EM-18) 7. Remove the thermostat housing(). 3. Remove the intake and exhaust manifold. (Refer to EM-96) 4. Remove the delivery pipe(). DJF046 LCGF040

46 EM Remove the vacuum pump(). 11. Remove the cam follower(). ENGINE (D4F - DSL1.5) LCGF044 LCGF Remove the camshaft bearing caps(). 12. Remove the HL(Hydraulic Lash djust)(). Mark the camshaft bearing caps to be able to reassemble in the original position and direction. LCGF Remove the cylinder head bolts, then remove the cylinder head. 10. Remove the camshaft(). LCGF045 1) Using socket (12PT), uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.remove the 10 cylinder head bolts LCGF046 LCGF049

47 CYLINDER HED SSEMLY EM -47 CUTION Head warpage or cracking could result from removing bolts in an incorrect order. 2) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head() on wooden blocks on a bench. DISSSEMLY 1. Remove the valves. EC505 1) Using the SST ( K000, )(), compress the valve spring and remove the retainer lock. LCGF050 CUTION e careful not to damage the contact surfaces of the cylinder head and cylinder block. 2) Remove the spring retainer. 3) Remove the valve spring. 4) Remove the valve. LCGF101 5) Using a needle-nose pliers, remove the stem oil seal.

48 EM -48 INSPECTION E45238 VLVE ND VLVE SPRING ENGINE (D4F - DSL1.5) CYLINDER HED 1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface : Less than 0.03mm (0.0012in) for width Less than 0.09mm (0.0035in) for length Flatness of manifold mating surface : Less than 0.025mm (0.0010in) for width Less than 0.160mm (0.0063in) for length 1. Inspect the valve stems and valve guides. 1) Using a caliper gauge, measure the inner diameter of valve guide. Valve guide inner diameter : Intake : ~ 5.512mm ( ~ in) Exhaust : ~ 5.512mm ( ~ in) ECKD219 2) Using a micrometer, measure the outer diameter of valve stem. Valve stem outer diameter Intake : ~ 5.470mm ( ~ in) Exhaust : ~ 5.450mm ( ~ in) ECKD001H 2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. ECKD220

49 CYLINDER HED SSEMLY EM -49 3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement. Valve stem- to-guide clearance Intake : ~ 0.057mm ( ~ in) Exhaust : ~ 0.077mm ( ~ in) If the clearance is greater than specification, replace the valve and valve guide. 2. Inspect the valves. 1) Check the valve is ground to the correct valve face angle. 2) Check that the surface of valve for wear. If the valve face is worn, replace the valve. 3) Check the valve head margin thickness. If the margin thickness is less than specification, replace the valve. Margin Intake : 1.1mm (0.0433in) Exhaust : 1.2mm (0.0472in) 3. Inspect the valve seats. 1) Check the valve seat for evidence of overheating and improper contact with the valve face. Replace the seat if necessary. 2) efore reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat. 3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face. Pilot Cutter 1.2 ~ 1.8 mm 0.8 ~ 1.4 mm Exhaust Intake CGE009 Margin ECKD221 4) Check the valve length. Length Intake : 93.0mm (3.6614in) Exhaust : 93.7mm (3.6890in) 5) Checkthesurfaceofvalvestemtipforwear. If the valve stem tip is worn, replace the valve.

50 EM -50 ENGINE (D4F - DSL1.5) 4. Inspect the valve springs. 1) Using a steel square, measure the out-of-square of valve spring. 2) Using a vernier calipers, measure the free length of valve spring. Valve spring Standard Free height : 44.9mm (1.7677in) Load : 17.5±0.9kg/32.0mm (38.6±2.0lb/1.2598in) 31.0±1.6kg/23.5mm (68.3±3.5lb/0.9252in) Out of square : Less than 1.5 Limit Outofsquare: 3 CMSHFT 1. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Cam height LH Camshaft Intake : ~ mm ( ~ in) Exhaust : ~ mm ( ~ in) RH Camshaft Intake : ~ mm ( ~ in) Exhaust : ~ mm ( ~ in) ECKD223 ECKD222 If the loads is not as specified, replace the valve spring. If the cam lobe height is less than specification, replace the camshaft. 2. Inspect the camshaft journal clearance. 1) Clean the bearing caps and camshaft journals. 2) Place the camshafts on the cylinder head. 3) Lay a strip of plastigage across each of the camshaft journal. ECKD224

51 CYLINDER HED SSEMLY EM -51 4) Install the bearing caps and tighten the bolts with specified torque. (Refer to EM-56) 12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lb-ft) CUTION Do not turn the camshaft. 3. Inspect the camshaft end play. 1) Install the camshafts. (Refer to EM-56) 2) Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play Standard : 0.1 ~ 0.2mm ( ~ in) 5) Remove the bearing caps. 6) Measure the plastigage at its widest point. earing oil clearance ~ 0.077mm ( ~ in) LCGF127 If the end play is greater than specification, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 3) Remove the camshafts. ECKD225 If the oil clearance is greater than specificaiton, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 7) Completely remove the plastigage. 8) Remove the camshafts.

52 EM -52 ENGINE (D4F - DSL1.5) HL (HYDRULIC LSH DJUSTER) With the HL filled with engine oil, hold and press by hand. If moves, replace the HL. LCGF128 Problem Possible cause ction 1. Temporary noise when starting acold engine 2. Continuous noise when the engine is started after parking more than 48 hours. 3. Continuous noise when the engine is first started after rebuilding cylinder head. 4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band. 5. Continuous noise when the engine is running after changing the HL. 6. Continuous noise during idle after high engine speed. 7. Noise continues for more than 15 minutes. Normal Oil leakage of the high ressure chamber on the HL, allowing air to get in. Insufficient oil in cylinder head oil gallery. Oil leakage of the high-pressure chamber in the HL, allowing air to get in. Insufficient oil in the HL. Engine oil level too high or too low. Excessive amount of air in the oil at high engine speed. Deteriorated oil. Low oil pressure. Faulty HL. This noise will disappear after the oil in the engine reaches the normal pressure. Noise will disapapear within 15 minutes when engine runs at rpm. If it doesn t disappear, refer to step 7 below. CUTION Do not run engine at a speed higher than 3000 rpm, as this may damage the HL. Check oil level. Drain or add oil as necessary. Check oil supply system. Check oil quality. If deteriorated, replace with specified type. Check oil pressure and oil supply system of each part of engine. Remove the cylinder head cover and press HL down by hand. If it moves, replace the HL. WRNING e careful with the hot HLS.

53 CYLINDER HED SSEMLY EM -53 RESSEMLY E69E0F Thoroughly clean all parts to be assembled. efore installing the parts, apply fresh engine oil to all sliding and rotating surface. Replace oil seals with new ones. 1. Install the valves. 3) Using the SST( , K000)(), compress the spring and install the retainer locks. fter installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. 1) Using the SST ( )(), push in a new stem oil seal. Do not reuse old valve stem oil seals. Incorrect installation of the seal could result in oil leakage past the valve guides. LCGF101 4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock. LCGF102 2) Install the valve, valve spring and spring retainer. Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.

54 EM -54 ENGINE (D4F - DSL1.5) INSTLLTION EEFE83 Thoroughly clean all parts to be assembled. lways use a new cylinder head and manifold gasket. lways use a new cylinder head bolt. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No.1 piston at TDC. 1. Cylinder head dowel pins must be aligned. 2. Select the cylinder head gasket. 1) Measure the piston protrusion from the upper cylinder block face (I) on 8 places ( ~ H) at T.D.C. Measure on the crankshaft center line considering the piston migration. LCGF129 2) Selectthegasketinthetablebelowusingtheaverage value of piston protrusions. lthough even the only 1 point is over than the each rank limit, use 1 rank upper gasket than specified in the table below. C D E F G H I Identification code CGF012 LCGF104 Displacement verageofpistonprotrusion Gasket thickness ~ 0.105mm ( ~ in) 1.00 ~ 1.15mm ( ~ in) 1.5 L ~ 0.175mm ( ~ in) 1.05 ~ 1.20mm ( ~ in) ~ 0.245mm ( ~ in) 1.10 ~ 1.25mm ( ~ in) Limit of each rank extant 0.14mm (0.0055in) 0.21mm (0.0083in) - Identification code LCGF130 LCGF132 LCGF131

55 CYLINDER HED SSEMLY EM -55 3) Install the gasket so that the identification mark faces toward the timing chain side. 3. Install the cylinder head gasket() on the cylinder block. e careful of the installation direction. 5. Install the cylinder head bolts. 1) pply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. 2) Using socket (12PT), install and tighten the 10 cylinder head bolts, in several passes, in the sequence shown. 49.0N.m (5.0kgf.m, 36.2lb-ft) Do not reuse the cylinder head bolts CGF Place the cylinder head () quietly in order not to damage the gasket with the bottom part of the end. 6. Istall the HL(Hydraulic Lash djust)(). LCGF153 LCGF050 LCGF048 1) Until installing HL shall be held upright so that diesel oil in HL should not spill and assured that dust does not adhere to HL. 2) HL shall be inserted tenderly to the cylinder head not to spill diesel oil from HL. In case of spilling, air bent shall be done in accordance with the air bent procedure.

56 EM -56 Stroke HL in diesel oil 4~5 times by pushing its cap while pushing the ball down slightly by hard steel wire. (Take care not to severely push hard steel wire down since ball is several grames.) 9. Install the camshaft bearing caps(). ENGINE (D4F - DSL1.5) 12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lb-ft) Steel wire LCGF Install the cam follower(). LCGF Install the vacuum pump() with new gasket() ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lb-ft) pply liquid gasket LCGF Install the camshaft(). LCGF154 LCGF046

57 CYLINDER HED SSEMLY EM -57 pply engine oil to the O-ring() of vacuum pump shaft before assembling vacuum pump. 12. Reconnect the water hose() to thermostat housing. DJF Install the thermostat housing(). 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) LCGF Install the glow plug() and glow plug plate. Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lb-ft) Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lb-ft) LCGF041 DJF046

58 EM -58 ENGINE (D4F - DSL1.5) 14. Install the delivery pipe() ~ 21.6N.m (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft) LCGF Install the intake and exhaust manifold. (Refer to EM-96) 16. Install the timing chain. (Refer to EM-25) 17. Install the drive belt.

59 ENGINE LOCK EM -59 ENGINE LOCK CYLINDER LOCK E80C8E3F COMPONENT ~ 24.5 (2.0 ~ 2.5, 14.5 ~ 18.1) ~ 78.5 (7.0 ~ 8.0, 50.6 ~ 57.9) ~ 12.7 (0.9 ~ 1.3, 6.5 ~ 9.4) ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5) 32.4 ~ 36.3 (3.3 ~ 3.7, 23.9 ~ 26.8) 12 TORQUE : N.m(kgf.m, lbf.ft) 1. Oil filter cap 2. Oil filter 3. Oil filter housing & oil cooler assembly 4. Water pipe 5. Clutch disk cover 6. Clutch disk 7. Flywheel 8. Crankshaft rear oil seal 9. Piston & connecting rod 10. Connecting rod bearing 11. Connecting rod cap 12. ed plate 13. Crankshaft main bearing 14. Crankshaft 15. Oil jet 16. Cylinder block LDJF004

60 EM -60 DISSSEMLY E69CD7DF 9. Remove the bed plate(). ENGINE (D4F - DSL1.5) 1. M/T : Remove the fly wheel. 2. /T : Remove the drive plate. 3. Install the engine to engine stand for disassembly. 4. Remove the timing chain. (Refer to EM-18) 5. Remove the intake manifold and exhaust manifold. (Refer to EM-94) 6. Remove the cylinder head. (Refer to EM-45) 7. Remove the water pipe(). LCGF Remove the rear oil seal(). LCGF Remove the oil filter and oil cooler assembly(). LCGF Remove the connecting rod cap(). Marktheconnectingrodcapstobeabletoreassemble in the original position and direction. CGF053 LCGF056