Service Manual2005 1.8L DOHC ENGINE MECHANICAL To the top of the document
Nubira-Lacetti
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SECTION 1C2

1.8L DOHC 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 terminals. 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

Application
Description
General Data:
Engine Type
1.8L DOHC
T18SED
Displacement
1.8L DOHC
1,799 cm3 (109.7 in3)
Bore Stroke
1.8L DOHC
81.6 x 86 mm (3.21 in. x 3.38 in.)
Compression Ratio
9.6 ± 0.02:1
Firing Oder
1-3-4-2
Cylinder Bore:
Diameter
1.8L DOHC
81.575~81.625 mm (3.2116~3.2135 in.)
Out of Round (Maximum)
0.013 mm (0.0005 in.)
Taper (Maximum)
0.013 mm (0.0005 in.)
Pistion:
Diameter
1.8L DOHC
81.575~82.105 mm (3.2115~3.2325 in.)
Clearance to Bore
0.0100~0.0300 mm (0.00039~0.00110 in.)
Piston Protrusion
0.5 mm (0.019 in.) Maximum
Piston Taper
0.013 (0.0005 in.)
Piston Rings:
Ring, End Gap: Top Compression
0.2~0.35 mm (0.007~ 0.013 in.)
Ring, End Gap: Second Compression
0.33~0.48 mm (0.012~0.0176 in.)
Piston Pin:
Diameter
20.9970~20.9985 mm (0.82665~0.82671 in.)
Pin Offset
0.8 mm (0.03 in.) Towards Thrust Side
Clearance: In Piston
0.0035~0.0140 mm (0.00013~0.00055 in.)
Clearance: In Rod
Interference Fit in Rod
Length
61.5 mm (2.42 in.)
Camshaft:
Lift - Intake
9.2 mm (0.36 in.)
Lift - Exhaust
9.2 mm (0.36 in.)
End Play
0.040~0.14 mm (0.0015~0.0055 in.)
Bearing Journal OD
42.455~43.470 mm (1.6714~1.7114 in.)
Crankshaft:
Main Journal:
.
Diameter (All)
Out of Round (Maximum)
57.974~57.995 mm (2.2824~2.2832 in.)
0.003 mm (0.0001 in.)
Main Bearing Clearance (All)
0.015~0.040 mm (0.00059~0.00157 in.)
Crankshaft End Play
0.070~0.302 mm (0.0027~0.0118 in.)
Service Oversize
Available in 2 sizes
0.25 mm and 0.50 mm (0.0098~0.0196 in.)
Connecting Rod Journal:
.
Diameter (All)
Out of Round (Maximum)
48.970~ 48.988 mm (1.9279~1.9287 in.)
0.004 mm (0.00015 in.)
Cylinder Head:
Valve Stem Protrusion
39.2~39.8 mm (1.54~1.56 in.)
Valve Guide Height
13.7~14.0 mm (0.54~0.57 in.)
Overall Height
134 ± 0.025 mm (5.2755~0.0009 in.)
Minimum Overall Height After Machining
133.9 mm (5.27 in.)
Valve System:
Valve Lash Compensators
Hydraulic Tappet
Seat Runout (Maximum, All)
0.03 mm (0.00118 in.)
Face Runout (Maximum, All)
0.03 mm (0.00118 in.)
Valve Stem Diameter:
.
Intake
Exhaust
5.945~5.960 mm (0.2341~0.2346 in.)
5.945~5.960 mm (0.2341~0.2346 in.)
Valve Diameter:
.
Intake
Exhaust
32 ± 0.1 mm (1.2598 ± 0.0039 in.)
29 ± 0.1 mm (1.1417 ± 0.0039 in.)
Valve Seat Width:
.
Intake
Exhaust
1.0~1.5 mm (0.039~0.059 in.)
1.7~2.2 mm (0.066~0.086 in.)
Valve Face Angle
44°
Valve Guide Inside Diameter
7.03~7.05 mm (0.276~0.277 in.)
Oil Pump:
Gear Lash
0.10~0.20 mm (0.003~0.007 in.)
Outer Gear to Body
0.11~0.19 mm (0.004~0.007 in.)
Outer Gear to Crescent
0.40~0.50 mm (0.015~0.019 in.)
Inner Gear to Crescent
0.35~0.40 mm (0.013~0.015 in.)
End Clearance
0.030~0.10 mm (0.001~0.003 in.)
Sealants and Adhesives:
Rear Main Bearing Cap
GE p/n RTV 159
Camshaft Carrier to Cylinder Head
HN 1581 (Loctite® 515)
Oil Pan Bolts
HN 1256 (Loctite® 242)
Oil Pump Bolts
HN 1256 (Loctite® 242)
Oil Pan Pickup Tube Bolts
HN 1256 (Loctite® 242)
Oil Gallery Plug
HN 1256 (Loctite® 242)
Coolant Jacket Caps and Plugs (Freeze Plugs)
HN 1756 (Loctite® 176)
Exhaust Manifold Studs/Nuts
Anti-seize Compound (HMC Spec HN1325)

Fastener Tightening Specifcations

Application
N•m
Lb-Ft
Lb-In
Air Cleaner Housing Bolts
10
-
89
Automatic Tensioner Bolt
25
18
-
Camshaft Bearing Bridge and Oil Pan Scraper Bolts
20 + 45°
15 + 45°
-
Camshaft Bearing Cap Bolts
8
-
71
Camshaft Cover Bolts
8
-
71
Charcoal Canister Purge and Exhaust Gas Recirculation Solenoid Bracket Bolt
5
-
44
Connecting Rod Bearing Cap Bolts
35
+ 45° + 15°
26
+ 45° + 15°
-
Coolant Bypass Housing and Mounting Bolts
15
11
-
Crankshaft Bearing Cap Bolts
50
+ 45° + 15°
37
+ 45° + 15°
-
Crankshaft Pulley Bolts
20
15
-
Crankshaft Gear Bolt
145
+ 30° + 15°
107
+ 30° + 15°
-
Cylinder Head Bolts
25 + 90°
+ 90° + 90°
18 + 90°
+ 90° + 90°
-
Direct Ignition System Coil and Exhaust Gas Recirculation Mounting Bracket Bolts
25
18
-
Engine Mount Bracket Retaining Bolts and Nuts
55
41
-
Engine Mount Retaining Bolts
45
33
-
Engine-to-Intake Manifold Support Bracket Bolts
20
15
-
Exhaust Camshaft Gear Bolt
50
+ 60° + 15°
37
+ 60° + 15°
-
Exhaust Flex Pipe-to-Catalytic Converter or Connecting Pipe Retaining Nuts
35
26
-
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts
35
26
-
Exhaust Manifold Heat Shield Bolts
8
-
71
Exhaust Manifold Retaining Nuts
22
16
-
Flexible Plate Bolts
45
33
-
Flywheel Bolts
65
+ 30° + 15°
48
+ 30° + 15°
-
Front Timing Belt Cover Bolts
6
-
53
Generator-to-Intake Manifold Strap Bracket Bolt
22
16
-
Generator-to-Intake Manifold Support Bracket Bolts
37
27
-
Intake Camshaft Gear Bolt
50
+ 60° + 15°
37
+ 60° + 15°
-
Intake Manifold Retaining Bolt and Nuts
22
16
-
Intake Manifold Support Bracket Lower Bolt
25
18
-
Intake Manifold Support Bracket Upper Bolts
25
18
-
Lower Block Support Bracket and Splash Shield Bolts
35
26
-
Oil Pan Drain Plug
35
26
-
Oil Pan Flange-to-Transaxle Bolts
40
30
-
Oil Pan Retaining Bolts
10
-
89
Oil Pressure Switch
40
30
-
Oil Suction Pipe Bolts
8
-
71
Oil Suction Pipe Support Bracket Bolts
16
-
53
Oil Pump Rear Cover Bolts
6
-
53
Oil Pump Retaining Bolts
10
-
89
Pulse Pickup Sensor Disc
13
10
-
Rear Timing Belt Cover Bolts
7
-
62
Safety Relief Valve Bolt
30
22
-
Spark Plug Cover Bolts
8
-
71
Spark Plugs
20
15
-
Thermostat Housing Mounting Bolts
15
11
-
Throttle Cable Bracket Bolts
8
-
71
Timing Belt Automatic Tensioner Bolts
25
18
-
Timing Belt Idler Pulley Bolt
25
18
-
Timing Belt Idler Pulley Nut
25
18
-
Transaxle Bell Housing Bolts
75
55
-
Transaxle Torque Converter Bolts
60
44
-

SPECIAL TOOLS

Special Tools Table


J3B11C01
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KM-653
Adapter

KM135
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KM-135
Adapter

J3B11C02
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KM-805
Valve Guide
Reamer

J36972
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J-36792
Crankshaft Rear
Oil Seal Installer

KM571B
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KM-571-B
Gauge

DW110060
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DW110-060
Engine Assembly
Support Fixture

KM412
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KM-412
Engine Overhaul
Stand

KM348
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KM-348
Valve Spring
Compressor

KM635
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KM-635
Crankshaft Rear
Oil Seal Installer

KM427
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KM-427
Piston Pin
Service Set

J3B11C04
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J-8087
Cylinder Bore
Check Gauge

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

KM470B
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KM-470-B
Angular Torque Gauge

KM498B
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KM-498-B
Pressure Gauge

J3B11C05
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J-8037
Universal Piston
Ring Compressor

COMPONENT LOCATOR

Upper End


J3B11C06
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  1. Bolt
  2. Spark Plug Cover
  3. Oil Filler Cap
  4. Oil Filler Cap Seal
  5. Bolt
  6. Camshaft Cover
  7. Camshaft Cover Gasket
  8. Tappet Adjuster
  9. Valve Key
  10. Valve Spring Cap
  11. Valve Spring
  12. Valve Stem Seal
  13. Valve Spring Seat
  14. Valve Guide
  15. Intake Valve Seat Ring
  16. Exhaust Valve Seat Ring
  17. Intake Valve
  18. Exhaust Valve
  19. Bolt
  20. Front Camshaft Cap
  21. Head Bolt
  22. Bolt
  23. Intermediate Camshaft Cap
  24. Exhaust Gas Recirculation Adapter
  25. Exhaust Gas Recirculation Adapter Gasket
  26. Cylinder Head
  27. Exhaust Manifold Gasket
  28. Exhaust Manifold
  29. Nut
  30. Exhaust Manifold Heat Shield
  31. Cylinder Head Gasket
  32. Bolt
  33. Thermostat Housing
  34. Thermostat Housing Gasket
  35. Stud
  36. Sleeve
  37. Plug
  38. Bolt
  39. Camshaft Position Sensor
  40. Oil Gallery Plug
  41. Exhaust Camshaft
  42. Seal Ring
  43. Camshaft Gear
  44. Washer
  45. Camshaft Gear Bolt
  46. Intake Camshaft
  47. Intake Manifold Gasket
  48. Intake Manifold
  49. Throttle Body Gasket
  50. Throttle Body
  51. Nut
  52. Charcoal Canister Purge Solenoid
  53. Exhaust Gas Recirculation Solenoid

Lower End


J3B11C07
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  1. Connecting Rod
  2. Bearing Set
  3. Connecting Rod Bolt
  4. Piston Ring Set
  5. Piston Pin
  6. Piston
  7. Engine Block
  8. Sleeve
  9. Water Jacket Cap
  10. Bolt (Manual Transaxle)
  11. Flywheel (Manual Transaxle)
  12. Flexible Plate (Automatic Transaxle)
  13. Bolt (Automatic Transaxle)
  14. Clamp
  15. Hose
  16. Clamp
  17. Engine Ventilation Pipe
  18. Bolt
  19. Gasket
  20. Needle Sleeve
  21. Crankshaft Rear Seal
  22. Crankshaft
  23. Transmitter Disk
  24. Bolt
  25. Oil Pan Scraper
  26. Oil Pan
  27. Drain Plug
  28. Washer
  29. Bolt
  30. Sleeve
  31. Gasket
  32. Bolt
  33. Oil Pump Cover
  34. Ring Gear
  35. Gear
  36. Oil Pressure Switch
  37. Washer
  38. Washer
  39. Oil Duct Outlet Plug
  40. Connecting Piece
  41. Seal Ring
  42. Oil Filter
  43. Bypass Valve
  44. Pressure Relief Valve Plunger
  45. Pressure Relief Valve Spring
  46. Seal Ring
  47. Pressure Relief Valve Plug
  48. Seal Ring
  49. Bolt
  50. Oil Suction Pipe
  51. Bolt
  52. Rear Timing Belt Cover
  53. Bolt
  54. Special Bolt
  55. Idler Pulley
  56. Stud
  57. Nut
  58. Bolt
  59. Tensioner
  60. Bolt
  61. Thrust Inner Washer
  62. Woodruff Key
  63. Crankshaft Gear
  64. Thrust Outer Washer
  65. Bolt
  66. Camshaft Drive Belt
  67. Gasket
  68. Front Timing Belt Cover
  69. Bolt
  70. Bushing Plug
  71. Bushing
  72. Oil Gallery Plug
  73. Bolt
  74. Water Pump
  75. Seal Ring
  76. Crankshaft Position Sensor
  77. Bolt
  78. Knock Sensor*
  79. Bolt
  80. Bolt
  81. Crankshaft Bearing Bridge
* : 2.0L DOHC Engine


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