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SECTION 1B2

1.4/1.5 SOHC ENGINE MECHANICAL

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Engine Specifications (1.4 SOHC)

Application
Description (Manual and Automatic)
General Data:
.
Engine Type
4 Cylinder (In-Line)
Displacement:
1399 cm³ (85.37 in³)
Bore Stroke:
77.9 x 73.4 mm (3.07 in. x 2.89 in.)
Compression Ratio
9.5 ± 0.2 :1
Firing Order
1-3-4-2
Cylinder Bore:
.
Diameter
77.9 mm (3.07 in.)
Out of Round (Maximum)
0.0065 mm (0.00025 in.)
Taper (Maximum):
0.0065 mm (0.00025 in.)
Piston :
.
Diameter
77.870 mm (3.066 in.)
Clearance to Bore
0.030 ± 0.010 mm (0.0012 ± 0.0004 in.)
Piston Rings:
.
Ring, End Gap:
.
Top Compression
0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)
2nd Compression
0.30 ~ 0.50 mm (0.012 ~ 0.020 in.)
Groove Clearance:
.
Top Impression
0.060 ~ 0.100 mm (0.0024 ~ 0.0039 in)
2nd Impression
0.050 ~ 0.090 mm (0.002 ~ 0.0035 in.)
Piston Pin :
.
Diameter
17.990 ~ 17.995 mm (0.7083 ~ 0.7085 in.)
Pin Off-Set
0.5 ± 0.1 mm (0.020 ± 0.004 in.)
Camshaft:
.
Lift Intake:
.
1.5 SOHC
4.773 mm (0.188 in.)
Lift Exhaust
5.267 mm (0.207 in.)
End Play
0.09 ~ 0.21 mm (0.0035 ~ 0.0082 in.)
Journal OD:
.
No. 1
39.435 ~ 39.455 mm (1.552 ~ 1.553 in.)
No. 2
39.685 ~ 39.705 mm (1.562 ~ 1.553 in.)
No. 3
39.935 ~ 39.955 mm (1.572 ~ 1.573 in.)
No. 4
40.185 ~ 40.205 mm (1.582 in.)
No. 5
40.435 ~ 40.455 mm (1.591 ~ 1.592 in.)
Bearing OD:
.
No. 1
39.500 ~ 39.525 mm (1.555 ~ 1.556 in.)
No. 2
39.750 ~ 39.775 mm (1.564 ~ 1.565 in.)
No. 3
40.000 ~ 40.025 mm (1.574 ~ 1.575 in.)
No. 4
40.250 ~ 40.275 mm (1.584 ~ 1.585 in.)
No. 5
40.500 ~ 40.525 mm (1.594 ~ 1.595 in.)
Crankshaft :
.
Main Journal
.
Diameter (All)
54.982 ~ 54.994 mm (2.164 ~ 2.165 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
Out of Round (Maximum)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)
0.026 ~ 0.046 mm (0.0010 ~ 0.0181 in.)
Crankshaft End Play
0.1 mm (0.003 in.)
Connecting Rod Journal:
.
Diameter (All)
42.971 ~ 42.987 mm (1.691 ~ 1.692 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
Out of Round (Maximum)
0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)
0.019 ~ 0.070 mm (0.0007 ~ 0.0027 in.)
Rod Side Clearance
0.070 ~ 0.242 mm (0.0027 ~ 0.009 in.)
Valve System:
.
Valve Lash Compensators
Hydraulic
Face Angle (All)
46° ± 7′30″
Seat Angle (All)
45°
Seat Runout (Maximum, All)
0.05 mm (0.0197 in.)
Face Runout (Maximum, All)
0.03 mm (0.0012 in.)
Seat Width:
.
Intake
1.3 ~ 1.5 mm (0.051 ~ 0.059 in.)
Exhaust
1.6 ~ 1.8 mm (0.063 ~ 0.071 in. )
Valve Guide Inside Diameter (All)
6.000 ~ 6.015 mm (0.236 ~ 0.237 in.)
Valve Stem Diameter
.
Intake
5.9970 ~ 5.984 mm (0.235 ~ 0.236 in)
Exhaust
5.960 ~ 5.974 mm (0.234 ~ 0.235 in)
Valve Diameter (All):
.
Intake
38.0 ± 0.1 mm (1.49 ± 0.0039 in.)
Exhaust
31.0 ± 0.1 mm (1.22 ± 0.0039 in.)
Valve Spring Free Length:
.
SOHC
40.9 mm
Valve Spring Loads:
.
Valve Open
625 ± 25 N (461 ± 18 lbs) @ 21.5 mm (0.846 in.)
Valve Closed
275 ± 15 N (202 ± 11 lbs) @ 31.5 mm (1.240 in.)
Oil Pump :
.
Gap Between Oil Pump Body and Out Rotor
0.400 ~ 0.484 mm (0.0157 ~ 0.0191 in.)
Out Rotor Side Clearance
0.045 ~ 0.100 mm (0.0018 ~ 0.0039 in.)
Inner Rotor Side Clearance
0.035 ~ 0.085 mm (0.0014 ~ 0.0033 in.)
Relief Valve Spring Free Length
81 mm (3.2 in.)

Engine Specifications (1.5 SOHC)

Application
Description (Manual and Automatic)
General Data:
.
Engine Type
4 Cylinder (In-Line)
Displacement:
1,498 cm³ (91.41 in³)
Bore Stroke:
76.5 x 81.5 mm (3.012 in. x 3.209 in.)
Compression Ratio
9.5:1
Firing Order
1-3-4-2
Cylinder Bore:
.
Diameter
76.5 mm (3.012 in.)
Out of Round (Maximum)
0.0065 mm (0.00025 in.)
Taper (Maximum):
0.0065 mm (0.00025 in.)
Piston :
.
Diameter
77.870 mm (3.066 in.)
Clearance to Bore
0.030 mm (0.0012 in.) ± 0.01 mm
Piston Rings:
.
Ring, End Gap:
.
Top Compression
0.3 ~ 0.5 mm (0.012 ~ 0.020 in.)
2nd Compression
0.3 ~ 0.5 mm (0.012 ~ 0.020 in.)
Groove Clearance (Side Clearance)
.
Top Compression
0.060 ~ 0.092 mm (0.0024 ~ 0.0036 in)
2nd Compression
0.050 ~ 0.082 mm (0.0020 ~ 0.0032 in.)
Piston Pin :
.
Diameter
17.990 ~ 17.995 mm (0.7083 ~ 0.7085 in.)
Pin Off-Set
0.5 ± 0.1 mm (0.019 ± 0.039 in.)
Camshaft:
.
Lift Intake:
.
1.5 SOHC
4.773 mm (0.188 in.)
Lift Exhaust
5.267 mm (0.207 in.)
End Play
0.09 ~ 0.21 mm (0.0035 ~ 0.0082 in.)
Journal OD:
.
No. 1
39.435 ~ 39.455 mm (1.552 ~ 1.553 in.)
No. 2
39.685 ~ 39.705 mm (1.562 ~ 1.553 in.)
No. 3
39.935 ~ 39.955 mm (1.572 ~ 1.573 in.)
No. 4
40.185 ~ 40.205 mm (1.582 in.)
No. 5
40.435 ~ 40.455 mm (1.591 ~ 1.592 in.)
Bearing OD:
.
No. 1
39.500 ~ 39.525 mm (1.555 ~ 1.556 in.)
No. 2
39.750 ~ 39.775 mm (1.564 ~ 1.565 in.)
No. 3
40.000 ~ 40.025 mm (1.574 ~ 1.575 in.)
No. 4
40.250 ~ 40.275 mm (1.584 ~ 1.585 in.)
No. 5
40.500 ~ 40.525 mm (1.594 ~ 1.595 in.)
Crankshaft :
.
Main Journal
.
Diameter (All)
54.982 ~ 54.994 mm (2.164 ~ 2.165 in.)
Taper (Maximum)
0.005 mm (0.00020 in.)
Out of Round (Maximum)
0.004 mm (0.00016 in.)
Main Bearing Clearance (All)
0.026 ~ 0.042 mm (0.0010 ~ 0.00165 in.)
Crankshaft End Play
0.1 mm (0.0039 in.)
Connecting Rod Journal:
.
Diameter (All)
42.971 ~ 42.987 mm (1.691 ~ 1.692 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
Out of Round (Maximum)
0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)
0.019 ~ 0.071 mm (0.0007 ~ 0.0028 in.)
Rod Side Clearance
0.070 ~ 0.242 mm (0.0027 ~ 0.0095 in.)
Valve System:
.
Valve Lash Compensators
Hydraulic
Face Angle (All)
46° ± 7′30″
Seat Angle (All)
45°
Seat Runout (Maximum, All)
0.03 mm (0.0012 in.)
Face Runout (Maximum, All)
0.03 mm (0.0012 in.)
Seat Width:
.
Intake
1.3 ~ 1.5 mm (0.051 ~ 0.059 in.)
Exhaust
1.6 ~ 1.8 mm (0.063 ~ 0.071 in. )
Valve Guide Inside Diameter (All)
6.000 ~ 6.015 mm (0.236 ~ 0.237 in.)
Valve Stem Diameter
.
Intake
5.977 ± 0.007 mm (0.235 ± 0.000276 in)
Exhaust
5.967 ± 0.007 mm (0.235 ± 0.000276 in)
Valve Diameter (All):
.
Intake
38.0 ± 0.1 mm (1.49 ± 0.0039 in.)
Exhaust
31.0 ± 0.1 mm (1.22 ± 0.0039 in.)
Valve Spring Free Length:
.
SOHC
40.9 mm
Valve Spring Loads:
.
Valve Open
625 ± 25 N (461 ± 18 lbs) @ 21.5 mm (0.846 in.)
Valve Closed
275 ± 15 N (202 ± 11 lbs) @ 31.5 mm (1.240 in.)
Oil Pump :
.
Gap Between Oil Pump Body and Out Rotor
0.400 ~ 0.484 mm (0.0157 ~ 0.0191 in.)
Out Rotor Side Clearance
0.045 ~ 0.100 mm (0.0018 ~ 0.0039 in.)
Inner Rotor Side Clearance
0.035 ~ 0.085 mm (0.0014 ~ 0.0033 in.)
Relief Valve Spring Free Length
81 mm (3.2 in.)

Fastener Tightening Specifcations

Application
N•m
Lb-Ft
Lb-In
A/C Compressor Hose Assembly Retaining Bolt
33
24
-
A/C Compressor Mounting Bolts
27
20
-
A/C Compressor Mounting Bracket Bolts
50
37
-
Air Filter Housing Bolts
8
-
71
Alternator Adjusting Bolt
25
18
-
Alternator Adjusting Bracket Retaining Bolt
25
18
-
Auxiliary Catalytic Converter-to-Exhaust Manifold Nuts and Bracket Bolts
40
30
-
Camshaft Gear Bolt
45
33
-
Camshaft Pressure Plate Bolts
10
-
89
Connecting Rod Bearing Cap Bolts
25 + 30°
18 + 30°
-
Coolant Pump Retaining Bolts
10
-
89
Coolant Temperature Sensor
20
15
-
Crankshaft Bearing Cap Bolts
50
+ 45° + 15°
37
+ 45° + 15°
-
Crankshaft Pulley Bolt
95 + 30° + 15°
70 + 30° + 15°
-
Crankshaft Position Sensor Retaining Bolt
10
-
89
Cylinder Head Bolts (Camshaft Support Housing & Cylinder Head Mounting Bolts)
25 + 70°
+ 70° + 30°
18 + 70°
+ 70° + 30°
-
Electronic Ignition System Ignition Coil Mounting Bolts
10
-
89
Electronic Ignition System Ignition Coil Mounting Plate Bolts
10
-
89
Engine Lift Bracket Bolt
25
18
-
Engine Mount Attaching Nuts
40
30
-
Engine Mount Bracket Retaining Bolt
65
48
-
Engine Mount Bracket-to-Engine Mount Retaining Bolts
60
44
-
Exhaust Manifold Heat Shield Bolts
15
11
-
Exhaust Manifold Nuts
25
18
-
Flexible Plate Bolts
60
44
-
Flexible Plate Inspection Cover Bolts
10
-
89
Flywheel Bolts
35
+ 30° + 15°
26
+ 30° + 15°
-
Flywheel Inspection Cover Bolts
12
-
106
FrontMuffler-to-Main Catalytic Converter Nuts
30
22
-
Fuel Rail Retaining Bolts
25
18
-
Intake Manifold Retaining Nuts
25
18
-
Intake Manifold Support Bracket Retaining Bolts
25
18
-
Lower Timing Belt Cover Bolts
10
-
89
Oil Pan Retaining Bolts
10
-
89
Oil Pan Drain Plug
35
25
-
Oil Pressure Switch
40
30
-
Oil Pump Retaining Bolts
10
-
89
Oil Pump/Pickup Tube and Support Bracket Bolts
10
-
89
Oil Pump Safety Relief Valve Bolt
30
22
-
Oil Pump Rear Cover Bolts
6
-
53
Power Steering Pump Mounting Bolts
25
18
-
Power Steering Pump Pulley Bolts
25
18
-
Rear Timing Belt Cover Bolts
10
-
89
Right Transaxle Brace Bolts
60
44
-
Spark Plugs
25
18
-
Thermostat Housing Mounting Bolts
20
15
-
Throttle Cable Bracket Bolts
8
-
71
Timing Belt Automatic Tensioner Bolt
20
15
-
Transaxle Bell Housing Bolts
75
55
-
Transaxle Torque Converter Bolts
65
48
-
Upper Timing Belt Cover Bolts
10
-
89
Valve Cover Bolts
9
-
80

SPECIAL TOOLS

Special Tools Table


KM565A
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KM-565-A
Valve Spring
Compressor

J42492
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J-42492
Timing Belt Adjuster

J28467B
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J-28467-B
Engine Assembly Support Fixture

KM427
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KM-427
Piston Pin Service Set

MKM571B
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MKM-571-B
Gauge

KM253
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KM-253
Valve Guide Reamer

KM254
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KM-254
Valve Guide Reamer

KM255
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KM-255
Valve Guide Reamer

KM3400
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KM-340-0
Cutter Set
Includes: KM-340-7
KM-340-13
KM-340-26

KM348
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KM-348
Valve Spring Compressor

KM419
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KM-419
Distance Gauge

KM635
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KM-635
Crankshaft Rear Oil Seal Installer

MKM412
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MKM-412
Engine Overhaul Stand

KM498B
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KM-498-B
Pressure Gauge

KM470B
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KM-470-B
Angular Torque Gauge

J36972
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J-36972
Crankshaft Rear Oil Seal Installer

KM135
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KM-135
Adapter

COMPONENT LOCATOR

Upper End


T3B11B18
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  1. Bolt
  2. Cap, Bayonet Joint
  3. Valve Cover
  4. Bolt
  5. Throttle Position Sensor
  6. Idle Air Control Valve
  7. Throttle Body
  8. Throttle Body Gasket
  9. Nut
  10. Intake Manifold
  11. Camshaft Position Sensor
  12. EGR Valve
  13. Bolt
  14. EGR Gasket
  15. Shaft Seal Ring
  16. Camshaft Support
  17. Valve Cover Gasket
  18. Tube
  19. Cylinder Head Bolt
  20. Washer
  21. Camshaft
  22. Camshaft Pressure Plate
  23. Bolt
  24. Bolt-Stud
  25. Intake Manifold Gasket
  26. Bolt-Stud
  27. Valve Key
  28. Valve Spring Plate
  29. Valve Spring
  30. Valve Stem Seal
  31. Exhaust Valve Spring Seat
  32. Valve Guide
  33. Roller Follower
  34. Roller Follower Lifter
  35. Intake Valve Spring Seat
  36. Bolt
  37. Thermostat Housing
  38. Thermostat Housing Seal Ring
  39. Thermostat
  40. Screw Plug
  41. Oil Duct Cap
  42. Oil Duct Cap
  43. Adapter
  44. Coolant Temperature Sensor
  45. Exhaust Valve
  46. Intake Valve
  47. Cylinder Head Oil Duct Sleeve
  48. Bolt-Stud
  49. Exhaust Manifold Gasket
  50. Cylinder Head Gasket
  51. Exhaust Manifold
  52. Nut
  53. Exhaust Oxygen Sensor
  54. Exhaust Manifold Heat Shield
  55. Bolt
  56. EGR Solenoid
  57. Bracket

Lower End


T3B11B19
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  1. Piston Ring Seat
  2. Piston
  3. Piston Pin
  4. Connecting Rod
  5. Connecting Rod Bearing Set
  6. Connecting Rod Bolt
  7. Oil Level Gauge Stick
  8. Gauge Stick Tube
  9. Connecting Piece
  10. Oil Filter
  11. Camshaft Gear Bolt
  12. Washer
  13. Camshaft Gear
  14. Rear Cover Bolt
  15. Rear Timing Belt Cover
  16. Bolt
  17. Coolant Pump
  18. Oil Pump
  19. Seal Ring
  20. Oil Pump Body Gasket
  21. Engine Block
  22. Bolt
  23. Auto Tensioner
  24. Bolt
  25. Crankshaft Gear
  26. Pressure Relief Valve Plunger
  27. Spring
  28. Oil Pump Seal Ring
  29. Bolt Plug
  30. Crankshaft Bearing Set
  31. Crankshaft
  32. Shaft Seal Ring
  33. Flywheel (Manual Transaxle)
  34. Bolt (Manual Transaxle)
  35. Bolt
  36. Washer
  37. Drain Plug
  38. Bolt
  39. Oil Pan
  40. Main Bearing Cap Bolt
  41. Main Bearing
  42. Bolt
  43. Bracket
  44. Oil Pickup Tube
  45. Timing Belt
  46. Upper Timing Belt Front Cover
  47. Bolt
  48. Lower Timing Belt Front Cover
  49. Crankshaft Pulley
  50. Washer
  51. Bolt
  52. Bolt
  53. Crankshaft Position Sensor
  54. Gear
  55. Gear
  56. Cover
  57. Bolt
  58. Seal
  59. Knock Sensor


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