(KIA) Manual de Taller Kia Rio 2001 PDF

ENGINE
MECHANICAL
SYSTEM
GENERAL EM- 2
ENGINE BLOCK EM-11
MAIN MOVING SYSTEM EM-21
COOLING SYSTEM EM-39
LUBRICATION SYSTEM EM-47
INTAKE AND EXHAUST SYSTEM EM-52
CYLINDER HEAD ASSEMBLY EM-55
TIMING SYSTEM EM-64
ЕМ-2 ENGINE MECHANICAL SYSTEM
Specification
GENERAL EM-3
Special service tools

GENERAL EM-5
ЕМ-6
GENERAL EM-9
HLA(Hydraulic lash adjuster)

Problem Possible cause Action
1 . Noise when engine is started immediately after Oil leakage in Run engine at 2,000-3,000 rpm.
oil is changed. Oil passage If noise stops after 2 seconds - 10 minutes*, HLA
2. Noise when engine is started after setting approx. is normal.
one day. If not, replace HLA.
* Time required for engine oil to circulate within
3. Noise when engine is started after cranking for 3 Oil leakage in engine includes tolerance for engine oil
seconds or more. HLA condition and ambient temperature.
4. Noise when engine is started after new HLA is
installed.
5. Noise continues more than 10 minutes. Insufficient oil Check oil pressure.
pressure If lower than specification, check for cause.
Oil pressure: 43~57 Psi
(294-392 kpa, 3.0-4.0 kg/cm2) - 3,000 rpm
Faulty HLA Press down HLA by hand.

If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.

If more than 0 mm (0 in), replace HLA.
6. Noise during idle after high-speed running. Incorrect oil Check oil level.
amount Drain or add oil as necessary.
Deteriorated oil Check oil quality.

If deteriorated, replace with specified type and
amount of oil.
Lubrication system
Problem Possible Cause Action
Engine hard starting Improper engine oil Replace

Insufficient engine oil Add oil
Excessive oil Internal engine wear Refer to page EM-47

consumption Oil leak Repair
Oil pressure drop Insufficient oil Add oil

Oil leakage Repair
Worn and/or damaged oil pump gear Replace
Worn plunger (inside oil pump) or weak spring Replace
Clogged oil strainer Clean
Excessive main bearing or connecting rod bearing clearance Refer to page EM-47
Warning lamp Oil pressure drop As described above

illuminates while Malfunction of oil pressure switch (Refer to section BE, Electrical
engine is running diagnosis; Except for Europe)
(Refer to Wiring Diagram; For
Europe)
Malfunction of electrical system
Cooling system
Problem Possible Cause Action

Overheating Coolant level insufficient Add
Coolant leakage Repair
Radiator fins clogged Clean
Radiator cap malfunction Replace
Fan motor malfunction Replace
Thermostat malfunction Replace
Water passage clogged Clean
Water pump malfunction Replace
Corrosion Impurities in coolant Replace

ENGINE BLOCK EM-11
Engine Block
5.8-8.0(7.8-11,0.8-1.1)
5.8-8.0 (7.8-11. 0.8~1.1)
5.8-8.0 (7.8-11, 0.8~1.1)

32-47(44-64. 4.5-6.5)
lb-ft(N m, kg-m)
AB3010001
(1) Battery clamp (6) Air cleaner assembly

(2) Battery (7) Cooling fan
(3) Battery tray (8) Accelerator cable
(4) Battery bracket (9) Shift control cable
(5) Fresh air duct
(1) Exhaust pipe & catalytic converter (4) Knuckle

(2) Tie rod end (5) Driveshaft
(3) Lower arm (6) HO2S
ENGINE BLOCK EM-13
Engine mounting
44-63
(60~85, 6.1-8.7)
49-69
i~93. 6.8-9.5)
39-47
(53-64, 5.4-6.5)
47-66
(64-90, 6.5-9.1)
49—69
(66-93. 6.8-9.5) 8-38
(37-52. 3.8-5.3)
28-38
(37-52. 3.8-5.3)
44—66 28—38
(64—90,6.5—9.1) (37—52,3.8—5.3)
lb-ft(N m, kg-m)
AB3010004
(1) Engine Mounting Member (4) No.2 Engine Mounting Bracket

(2) No.1 Engine Mounting Bracket (5) No.3 Engine Mounting Bracket
(3) No.2 Engine Mounting Rubber
ENGINE BLOCK EM-15
Engine and transaxle assembly 6. Remove accelerator cable.

7. Disconnect fuel hose from fuel injector rail.
Removal 8. Remove heater hose.
1. Disconnect battery cables. 9. Disconnect brake vacuum hose and purge control
2. Remove battery and battery tray. vacuum hose from dynamic chamber.
10. Disconnect injector connectors.
11. Disconnect electric connectors.
AB3010016
3. Drain engine coolant.
AB3010002
4. Remove fresh air duct.
5. Remove upper and lower radiator hose. 12. Remove transaxle linkage (A/T).
13. Remove manual transaxle linkage and extension
bar (МЯ).
14. Remove clutch release cylinder and pipe (M/T).
AB3010002
16. Disconnect transaxle range switch connector (A/T). 21. Disconnect generator B-terminal connector from
17. Disconnect solenoid valve connector (A/T). generator.
18. Disconnect ATF cooler hose (A/T).
AB30110002
22. Remove four A/C compressor bolts.

19. Disconnect power steering pump hose. 23. Remove both front wheels.
24. Disconnect front exhaust pipe and catalytic
converter.
25. Remove both right and left tie rod ends from
steering Knuckles by removing one cottor pin and
one nut each.
AB30110002
20. Disconnect B-terminal and S-terminal connector
from starter.
ENGINE BLOCK EM-17
26. Remove bolt and nut from both right and left lower 30. Remove four nuts and four bolts from engine
arm and separate low arm from steering knuckles. mounting member.
27. Remove 2bolts and nuts from damper and separate
damper from steering knuckles.
AB3A1002
AB3042032 31. Remove two bolts from No.1 engine mounting

bracket.
28. Gently pry both driveshafts from transaxle. 32. Remove one nut from No.2 engine mounting rubber.
29. Support engine with engine hoist. 33. Remove four bolts from No.2 engine mounting
bracket.
34. Remove two nuts from No.3 engine mounting rubber.
35. Lift engine and transaxle out as a unit.
ARSA10010A
Installation
1. Install engine and transaxle into engine
compartment as a unit.
2. Install two No.3 engine mounting rubber.
Tightening torque:
49-68 Ib-ft (68-93 N-m, 6.8-9.5 kg-m)
3. Install No.2 engine mounting nut bracket bolts and

rubber.
Tightening torque:
Nut:49~68 Ib-ft (68-93 N-m, 6.8-9.5 kg-m)
Bolts:28~38lb-ft (39-52 N-m, 3.9-5.3 kg-m)
4. Install four engine mounting member bolts & nuts.

Tightening torque:
Nut:28~38 Ib-ft (39-52 N-m, 3.9-5.3 kg-m)
Bolts:47~66lb-ft (65-91 N«m, 6.5-9.1 kg-m)
ENGINE BLOCK EM-19
11. Install front exhsust pipe and catalytic converter. 18. Connect transaxle range switch connector(A/T).
Tightening torque:
27-38 Ib-ft (37.2-52 N-m, 3.8-5.3 kg-m)
12. Install A/C compressor.
AB3010002
19. Install clutch release cylinder and pipe(M/T).
Tightening torque:
13.7-18.8 Ib-ft (18.6-25.5 N-m, 1.9-2.6 kg-m)
AB3010002
13. Connect B-terminal connector to generator. 20. Install extension bar and manual transaxle
14. Connect B-terminal and S-terminal connector to linkage(M/T).
starter.
Tightening torque:
Extension bar: 27-38 Ib-ft (37.2-52 N-m,
3.8-5.3 kg-m)
Manual transaxle linkage: 12-17 Ib-ft (16-23 N-m)
21. Install transaxle linkage(A/T).
Tightening torque:
24~83lb-ft (32-46 N-m, 3.2-4.7 kg-m)
AB3010002
15. Connect power steering pump hose.

16. Connect ATF clooler hose(A/T).
17. Connect solenoid valve connector(ATr).
AB3010002
22. Connect electric connectors. 30. Install battery tray and battery.
Tightening torque:
10-12 Ib-ft (13.5-16 N-m, 1.4-1.6 kg-m)
23. Connect injector connectors to injector rail.

24. Connect brake vacuum hose and purge control
vacuum hose to dynamic chamber.
25. Install heater hose.
26. Connect fuel hose to injector rail.
27. Install accelerator cable.

28. Install upper and lower radiator hose.
29. Install fresh air duct.
Camshaft
Components(SOHC)
.Ф
3.6-6.5
(4.9-8.8. 0.5-0.9)
5.8-8.0
(7.8-11, 0.8-1.1)
5.8-8.0
(7.8-11, 0.8-1.1)
36-45
(49-61, 5.0-6.2)
Ib-ft (N-m, kg-m)

AB3AEM010
(1) Cylinder head cover (4) Camshaft

(2) Rocker arm shaft (5) Camshaft pulley
(3) Rocker arm (6) Cylinder head
Camshaft
Components (DOHC)
(1) Cylinder head cover (4) Cam carrier assembly

(2) Cylinder head cover (5) Cylinder head
(3) Cylinder head cover gasket
Disassembly 3. Install the camshaft after lubricating the journal of

1. Disconnect the breather hose and the PCV hose. camshaft with engine oil.
2. Remove the coolant pump pulley and crankshaft
pulley.
3. Remove the timing belt cover.
4. Loosen the timing bolt tensioner pulley and
temporarily secure it.
5. Remove the timing belt from the camshaft sprocket.
6. Loosen the center cover bolts and then remove the
center cover.
7. Remove the ignition coil assembly.
8. Loosen the cylinder head cover bolts and then
remove it.
9.Remove the camshaft pulley.
AB3AEM001
4. Install the cam carrier assembly.
BSX010A084
10. Remove the cam carrier assembly and timing belt.

11. Remove the camshaft.
12. Remove the H LA.
Reassembly
1. Install the HLA
2. Check that "I" mark on intake camshaft pulley is
aligned with mark on cylinder head cover and "E"
mark on exhaust camshaft pulley is aligned with
mark on cylinder head cover.
(A5D)
AS2A10054
5. Tighten the cam carrier bolts to the specified torque Inspection

in two or three steps. Camshaft
1. Set front and rear camshaft bearing journals on V-
Tightening torque:
blocks.
8.31-10.5 Ib-ft (11.2-14.2 N-m, 1.15-1.45 kg-m)
2. Position a dial indicator on center bearing journal
and zero dial.
3. Rotate camshaft in V-blocks and check runout.
Runout:
0.0012 In (0.03 mm) maximum
AB3AEM002
6. Using special tool, camshaft oil seal installer

(09221-21000), press the camshaft oil seal. Be
sure to apply engine oil to the external surface of
the oil seal. Insert the oil seal along the camshaft
front end install by driving the installer with a
hammer until the oil seal is fully seated.
6. Check camshaft bearing journal diameter (X and Y 8. Measure camshaft journal oil clearance with HLA's
directions) on both sides (A and B) of journal as removed.
shown in figure. 9. Remove all foreign material and oil from journals
and bearing surfaces.
Standard diameter: 10. Set camshafts onto cylinder head.
1.324-1326 In (33.961-34.0 mm) 11. Position Plastigage® on journals in axial direction.
Minimum diameter: 12. Do not rotate camshafts.
1.0594 In (26.910 mm) 13. Install cam carrier assembly.
Out-of-round:
0.0012 In (0.03 mm) maximum
AB3AEM002
OS2010036
7. Replace camshafts if necessary.
AB3AEM001
14. Install cam carrier bolts.
Tightening torque:
8.31-10.5 Ib-ft (11.2-14.2 N-m, 1.15-1.45 kg-m)
15. Loosen cam carrier assembly bolts.

16. Remove cam carrier assembly.
17. Measure oil clearances.
OH clearance:
0.0014-0.0031 in (0.035-0.081 mm)
Maximum:
0.006 In (0.15 mm)
18. If oil clearance exceeds specification, replace

cylinder head.
19. Install camshafts.
20. Place a dial indicator against end of camshaft.
21. Using a prying tool, move camshaft as far forward
as possible.
22. Zero dial.
23. Using prying tool, move camshaft as far rearward
as possible.
24. Check gauge to determine how much end play is
present.
End play:
0.0003-0.0004 In (0.08-0.10 mm)
Maximum:
0.008 In (0.20 mm)
Connecting rod
Component
22-24(29-34, 3.0-3.5)
Ib-ft (Mm, kgm)
(1) Piston ring (4) Connecting rod

(2) Piston (5) Connecting rod bearing
(3) Piston pin (6) Connecting rod cap
Diassembly 3. Remove connecting rod nuts and gently loosen rod

1. Use a numbering stamp and mark rod cap and caps by tapping cap with a light plastic mallet.
connecting rod with their corresponding cylinder 4. Remove rod caps.
number.
* Notice
H* Notice Coter connecting rod bolts to protect crankshaft
Mark connecting rods on same side and make a jounals.
reference mark on block so that rods are installed in
correct position and direction. Failure to install rods
properly with result in oil starvation, spun bearings,
or damaged internal engine components.
2. Rotate crankshaft so that cylinders No.2 and No.3

are at Bottom Dead Center (BDC) and repeat
marking procedure.
5. Push connecting rod and piston as far up into 11. If connecting rod does not move freely, check
cylinder as possible. Using a wooden dowel, tap piston pin bore and connecting rod for straightness
gently on piston to release it from cylinder. and deformation.
BSX010A101
9. Hold piston upright and gently move connecting

rod.
10. Release connecting rod and observe its movement.
Ф Notice
Do not swing connecting rod widely. Constant, hard
contact with piston will cause a bell-mouth condition
that will require piston replacement.
Inspection 7. Place a feeler gauge in end gap and check end gap
clearance.
Piston ring
1. Insert a new piston ring into a piston ring groove
and check clearance between piston ring and ring
end.Clearance between ring and ring end
Standard: A5D: 0.03~0.07 mm

A3E: 0.04~0.08 mm
Maximum: 0.10 mm
AS2A10082
End gap clearance

Ring A3E A5D
Top ring 0.008-0.013 in 0.006-0.011 in
(0.20-0.35 mm) (0.1 5 -0,30 mm)
AS2A10081 Second ring 0.01 4-0.028 in 0.016~0.02Tin
(0.37-0.52 mm) (0.40 - 0.55 mm)
2. If clearance exceeds the maximum, replace piston. 0.08-0.27 in
Oil rail 0.008 - 0.027 in
3. Inspect piston rings for damage, abnormal wear, or
breakage. (0.20-0.70 mm) (0.20 - 0.70 mm)
4. Replace piston rings if necessary. Maximum 0.039 in(1. Omm)
5. Insert piston ring into cylinder by hand.
6. Square ring in cylinder by inserting a piston into
cylinder and pushing ring to the bottom of its travel
in cylinder.
Reassembly
1. Insert connecting rod into piston and slide piston pin
through piston and through connecting rod until it
makes contact with the piston pin clip already
installed.
AS2A10097
Notice
Verify that piston and rod are assembled in same
direction as they were prior to disassembly.
2. Install second piston pin clip into clip grooves on

opposite side of piston.
AS2A10085
3. Hold piston upright and move connecting rod back

and forth. Check that rod moves freely.
4. Install three piece oil ring onto piston.
a. Apply clean engine oil to the oil ring expander
and upper and lower oil rings.
b. Install expander onto piston so that expander
ends face upward.
c. Install lower oil ring onto piston. Ring may be
installed with either face upward.
d. Install upper oil ring onto piston. Ring may be
installed with either face upward.
8. Align piston ring gaps as shown. 13. Rotate crankshaft so that crank pin journal for
specific cylinder is at its lowest point (bottom dead
center).
14. Lower piston and connecting rod assembly until
piston ring compressor makes contact with deck
surface of engine block.
15. Using butt end of a hammer, tap the top of piston
into cylinder and continue tapping until connecting
rod makes contact with crankshaft.
% Notice
Follow this procedure for remaining piston and
connecting rod assemblies.
16. Install a connecting rod bearing in each connecting

rod cap.
17. Place a piece of Plastigage® on crank pin journals.
18. Install connecting rod caps, aligning marks made
previous to disassembly and torque to specification.
Tightening torque:
47-51 Ib-ft (64-69 N-m, 6.5-7.0 kg-m)
*fr Notice
When installing the connecting rods, match marks
made on the connecting rod and cap to reference
mark made on cylinder block to prevent oil
starvation to the connecting rod bearings.
BSX010B102
12. Place piston (cylinder number one) with "F" mark

facing front of engine block, then slip piston and
connecting rod assembly into a piston ring
compressor.
BSX010B103
19. Loosen and remove connecting rod caps. 3)Connecting rod bearing thickness Unit:mm
20. Check the connecting rod bearing clearance. Connecting rod bearing bearing thickness
(Green) 1.506-1.509
Oil clearance:
Standard (Blue) 1.509-1.512
0.0010 ~ 0.0021 In (0.026 ~ 0.054 mm) bearing
Maximum: 0.004 In (0.10 mm) (Red) 1.512-1.515
Undersize 0.25 1.631-1.635
bearing 1.756-1.760
0.50
0.75 1.881-1.885
22. Apply a coat of clean engine oil to connecting rod

bearing in connecting rod cap.
23. Install connecting rod cap and torque to
specification.
Tightening torque:
47-51 Ib-ft (64-69 N«m, 6.5-7.0 kg-m)
24. Insert a thickness gauge between connecting rod

and crankshaft and check connecting rod side
clearance.
* Notice
Do not measure between connecting rod cap and
crankshaft.
Side clearance:
0.0044-0.0103 In (0.110-0.262 mm)
Maximum: 0.012 In (0.30 mm)
25. If side clearance exceeds maximum side clearance

specification, replace connecting rod and cap.
Crankshaft
Component
(1) Main bearing (3) Main bearing

(2) Crankshaft (4) Main bearing cap
Disassembly
1. Remove the timing belt, front case, flywheel cylinder head
assembly and oil pan. For details, refer to respective
chapters,
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
* Notice
Mark the main bearing caps to permit reassembly in the
original position and direction.
4. Remove the main bearing caps and remove the crankshaft.

Keep the bearings in order by cap number.
Main Bearing and Connecting Rod Bearings

Inspection
1. Check main and connecting rod bearings for
Crankshaft peeling, scoring and other damage.
1. Check crankshaft bearing and crank pin journals for
damage and scoring.
2. Check oil holes for clogging.
3. Set crankshaft on V-blocks.
4. Measure crankshaft run-out at center journal.
Replace crankshaft if it is not within specification.
AB3010024
Run-out:
0.0016 In (0.04 mm)
6. Grind crankshaft only if there is visible scoring, or if

out-of-round is excessive.
7. Only grind crankshaft amount necessary to correct
condition.
8. If a crankshaft must be ground 0.020 in (0.50 mm)
or more, heat-treat crankshaft to ensure durability.
Main journal diameter underslzes:

Reassembly
1. Inspect journals and bearings for any foreign
material. Clean crankshaft, oil holes, and main
bearing journals thoroughly, and dry components
with compressed air.
2. Install grooved main bearings into saddles on
engine block.
3. Install thrust bearings with oil groove facing
crankshaft.
AN7010A160
4. Set crankshaft on installed bearings.

5. Install remaining main bearings into main bearing
caps.
6. Position Plastigage® on crankshaft journals.
7. Install main bearing caps along with lower main
bearings according to cap number and 4- mark.
8. Tighten main bearing cap bolts.
AN7010A161
Tightening torque:
40-43 Ib-ft (54-59 N-m, 5.5-6.0 kg-m)
Caution
Do not rotate crankshaft with Plastigage® on
crankshaft Journals.
Main moving system

1) Standard main bearing selection
Engine block
code
Main journal
2) Main bearing housing bore size

ЕМ-38 NAIN MOVING SYSTEM
11. Lift crankshaft out of cylinder block and carefully 20. If end play exceeds specification, grind crankshaft
remove Plastigage® from main bearings and and install oversized thrust bearings, or replace
crankshaft journals. crankshaft and thrust bearings.
12. Apply a light coat of engine oil on main bearings oversize thrust bearing width
and install crankshaft by gently lowering it onto
bearings. Thrust bearing size Specification
13. Apply a light coat of oil on crankshaft main bearing Standard 0.0985-0.1 OOSin
journals and on main bearings on main bearing (2.5000-2.550 mm)
caps. Standard +0.010 in (0.25 mm) 0.1 034-0.1 053 in
14. Install main bearing caps along with lower main (2.625-2.675 mm)
bearings according to cap number and 4* mark. Standard +0.020 in (0.50 mm) 0.1083-0.1102 in
15. Tighten main bearing cap bolts according to the (2.750-2.800 mm)
following procedure: Standard +0.030 in (0.75 mm) 0.1132-0.1151 in
Tighten bolts in order shown (2.875-2.925 mm)
Tightening torque: 21. Install the oil seal in the crankshaft rear oil seal
40-43 Ib-ft (54-59 N-m, 5.5~6.0kg-m) case. Press fit the oil seal all the way in, being
careful not misalign it.
22. Install the rear plate and tighten the bolts.
23. Insall the connecting rod caps. Refer to "Piston and
Connecting Rods".
24. Install the flywheel, front case, oil pan and timing
belt. For further details, refer to the respective
chapters.
AN7010A162
16. Rotate crankshaft to ensure it does not bind.

17. Place a dial indicator against front of crankshaft and
zero gauge.
18. Using a prying tool, move crankshaft forward and
zero dial indicator.
19. Move the crankshaft toward the rear of block with
prying tool and check the amount of movement on
dial indicator.
End Play:
0.0032-0.0111 In (0.080-0.282 mm)
Engine coolant 5. Fill with proper mixture of ethylene glycol-based

coolant.
Inspection
Coolant Capacity: 6.3 gal (6.0L)
AwARNING
• NEVER REMOVE RADIATOR CAP WHILE
ENGINE IS HOT.
• WRAP A THICK CLOTH AROUND
RADIATOR CAP BEFORE REMOVING.
• WHEN REMOVING RADIATOR CAP,
LOOSEN SLOWLY TO FIRST STOP AND
WAIT UNTIL PRESSURE IN RADIATOR IS
RELEASED, THEN COMPLETELY REMOVE.
Level (engine cold)

1. Verify that there is no build-up of rust or scale
around radiator cap or radiator filler neck.
2. Verify that coolant is free of contaminants. Replace AS2A10006
coolant if necessary.
6. Run the engine with the radiator cap removed until
Coolant quality the upper radiator hose is hot.
7. With the engine idling, add coolant to the radiator
1. Verify that there is no build-up of rust or scale
until it reaches the bottom of the filler neck.
around radiator cap or radiator filler neck.
8. Install the radiator cap.
2. Verify that coolant is free of contaminants. Replace
9. Allow engine to cool and check coolant level.
coolant if necessary.
Replacement
AwARNING
• NEVER OPEN RADIATOR CAP WHILE
ENGINE IS HOT.
• WRAP A THICK CLOTH AROUND CAP
BEFORE LOOSENING.
• USE CAUTION WHEN DRAINING HOT
COOLANT.
^ Caution
• Do not use alcohol or methanol-based
coolant
• Use only demlnerallzed water In coolant
mixture.
1. Remove radiator cap and loosen drain plug.

2. Drain coolant into a suitable container.
3. Flush cooling system with water until all traces of
color are gone; then let system drain completely.
4. Install drain plug.
Cooling fan relay Engine coolant temperature

Inspection Sensor
Inspection
* Notice 1. Check for resistance.
Cooling fan motor relay is located in the engine
compartment fuse/relay box.
1. Disconnect negative battery cable.

2. Remove cooling fan motor relay from engine
compartment fuse/relay box.
8SX012019
5. If there is no continuity, replace fan motor relay.

Radiator cap
Inspection
Radiator cap valve
1. Remove foreign material from radiator cap valve
and the valve seat.
2. Attach radiator cap to a radiator cap tester. Apply
pressure gradually to 15 psi (103 kPa).
BSX012004
3. Wait about 10 seconds. Verify that pressure has not

decreased.
4. Replace radiator cap as necessary.
Negative pressure valve

1. Pull negative pressure valve to open it. Verify that it
closes completely when released.
2. Check for damage on contact surfaces, and for a

cracked or deformed seal.
3. Replace radiator cap as necessary.
Radiator
(1) Radiator (5) Cooling fan connector

(2) Radiator bracket (6) Cooling fan
(3) Radiator hose (7) Oil cooler hose
(4) Coolant reservoir hose (8) Radiator hose
Removal
2. Remove fresh air duct.
3. Drain coolant.
4. Remove components in the order shown in the
above figure.
Installation
1. Install in the reverse order of removal.
2. After installation, fill engine coolant and check
coolant leakage
Cooling fan
Component
5.8~8.0
(1) Cooling fan connector (3) Cooling fan

(2) Radiator cowling (4) Fan motor
Removal
Remove components in the order shown in above figure.
Thermostat
Component
(1) Radiator upper hose (3) Gasket

(2) Thermostat cover (4) Thermostat
Removal
Inspection
1. Visually check that thermostat is airtight.
2. Place thermostat and a thermometer in water.
3. Gradually heat water and check following.
Initial opening temperature:

188-193 °F (86.5-89.5 °C)
Full open temperature:

212'F(100eC)
Full open lift:

0.31 In (8.0 mm) mln
Installation
1. Install thermostat into cylinder head with jiggle pin
positioned up.
2. Install in the reverse of removal.
BSX012010
Water pump
Component
(1) Water inlet pipe and gasket (3) Water pump assembly
(2) Water bypass pipe and 0-ring (4) Water pump gasket
Removal
r
J. Caution
Do not disassemble water pump assembly.
If a problem Is found, replaed assembly as a
unit.

2. Remove drive belt.
3. Remove timing belt.
4. Remove power steering pump in order to remove
water inlet pipe.
5. Remove components in the order shown in above
figure.
Lubrication system Oil filter replacement

Oil replacement 1. Raise vehicle.
2. Remove oil filter with oil filter wrench. If rubber seal
AwARNING is stuck to engine, remove it.
BE CAREFUL WHEN DRAINING BECAUSE 3. Apply a small amount of clean engine oil to rubber
OIL IS HOT AND COULD CAUSE seal of new filter.
PERSONAL INJURY. 4. Install oil filter and turn it by hand until rubber seal
contacts base.
1. Warm engine to normal operating temperature and 5. Tighten filter 1 -1 /6 turns with filter wrench.
turn engine off. Position a suitable container under 6. Start engine and check for leaks.
oil pan. 7. Turn engine off, and wait 5 minutes. Check oil level
2. Remove oil filler cap and oil pan drain plug. and add oil if necessary.
3. Allow oil to be fully drained.
4. Install drain plug with new gasket. Oil filter capacity:
0.21 U.S. qt (0.20 liter, 0.18 Imp qt)
Tightening torque:
22-30 Ib-ft (29-41 N-m, 3.0-4.2 kg-m)
5. Refill engine with specified type and amount of

engine oil.
6. Run engine and check for leaks.
AS2A10010
7. Check oil level and add oil if necessary.
Oil pan capacity:

3.2 U.S. qt (3.0 liters, 2.6 Imp qt)
8. Install oil filler cap.

Oil pressure check

1. Disconnect and remove oil pressure switch.
2. Install oil pressure gauge into oil pressure switch
installation hole.
3. Warm engine to normal operating temperature.
4. Run engine at 3,000 rpm, and note gauge readings.
OH pressure:
43-57 psl (294-392 kPa, 3.0-4.0 kg/cm')
AS2011002
5. If pressure is not within specification, check for

cause, and repair.
6. Remove oil pressure gauge and install oil pressure
switch.
Tightening torque:
104-156 Ib-ln (12-18 N-m, 1.2-1.8 kg-m)
Oil pan
Components
27-38
(37-52, 3.8-5.3)
5.8~8.0
,(7.8-11. 0.8-1.1)
27-38
(37-52, 3.8-5.3)
27-38
(37-52, 3.8-5.3)
5.8-8.0
Ib-ft (N m, kg m)
(7.8-11, 0.8-1.1)
AB3011001
(1) Front exhaust pipe & catalytic converter (3) Oil strainer
(2) Oil pan
Removal
2. Drain engine oil.
3. Remove as shown in figure above.
Oil pump
Component
(1) Alternator (5) Timing belt pulley

(2) Compressor assembly (6) Oil strainer
(3) Compressor bracket (7) Oil pump assembly
(4) Timing belt pulley lock bolt
Removal
2. Drain engine oil.
3. Remove Drive belt.
5. Remove components in the order shown in above figure.
Reassembly
4.3~6.5
8.8, 0.6~0.9)
Replace
(1) Oil seal (6) Spring seat

(2) Pump cover (7) Pressure spring
(3) Outer rotor (8) Control plunger
(4) Inner rotor (9) Pump body
(5) Snap ring
Inspection
1. Clean all components and clean off dust from all
components.
2. Check all components with specifications and
replace as necessary.
Intake and exhaust system

Accelerator cable
Inspection/Adjustment
1. Depress the accelerator pedal to the floor and
check that the throttle valve is fully opened.
Adjust with nut ® , if necessary.
2. Measure the free play of the accelerator cable.
Free play: 0.16~0.28 In (4~7 mm)
Л/of/ce
L/se a compressed air to clean the element from the
internal side to the external side, or from the upper
to the lower.
INTAKE AND EXHAUST SYSTEM EM-53
Intake system
Component
5.8-8.0
1.1)
5.8-8.0
(7.8-11. 0.8~1.1)
(1) Fresh air duct (3) Accelerator

(2) Air cleaner assembly
Removal
Exhaust system
Component
(1) Front pipe assembly (3) Pre silencer assembly

(2) Catalytic converter (4) Main silencer assembly
Removal
Installation
Install front exhaust as follows:
© Tighten ® temporarily
(D Tighten ® temporarily
(D Tighten ® fully
© Check the connection between the pipe of ® and bracket
(D Tighten ® fully
Cylinder head assembly

Compression
If the engine exhibits low power, poor fuel economy, or
poor idle, check the following :
1. Ignition system
2. Compression
3. Fuel system
Inspection
1. Check that the battery if fully charged. Recharge it
if necessary.
2. Warm up the engine to normal operating
temperature.
3. Remove the center cover.
4. Disconnect the high tension lead and ignition coil.
5. Remove all spark plugs.
6. Connect a compression gauge to the No.1 spark
plug hole.
7. Fully depress the accelerator pedal and crank the

engine.
8. Record the maximum gauge reading.
9. Check each cylinder.
kPa (kg/cm2, psi)-rpm
10. If the compression in one or more cylinders is low,

pour a small amount of engine oil into the cylinder
and recheck the compression.
(1) If the compression increases, the piston, piston
rings, or cylinder wall may be worn.
(2) If the compression stays low, the valve may be
stuck or seating improperly.
(3) If the compression in adjacent cylinders stays
low, the cylinder head gasket may be defective
or the cylinder head distorted.
Cylinder head
Components (A3E)
(1) Cylinder head (9) Valve cotter

(2) Thermostat cover (10) Valve spring seat
(3) Thermostat (11) Valve spring
(4) Cylinder head gasket (12) Valve seal
(5) Cylinder head cover (13) Valve guide
(6) Rocker arm shaft (14) Camshaft pulley
(7) Rocker arm (15) HLA
(8) Camshaft
Cylinder head
(1) Cylinder head cover (4) Cam carrier assembly

(2) Cylinder head cover (5) Cylinder head
(3) Cylinder head cover gasket
Disassembly Inspection
1. Drain the coolant and disconnect the upper radiator 1. Clean all components.
hose. 2. Remove gasket fragments, dirt, oil, grease, carbon,
2. Remove the breather hose (beween the air cleaner and moisture, residue, and other foreign materials.
the head cover).
3. Remove the air-intake hose. Cylinder head
4. Remove the vacuum hose, fuel hose and coolant hose 1. Inspect cylinder head for damage, cracks, and
5. Remove the cables from the spark plugs. The cables leakage of oil and water. Replace cylinder head if
should be removed by holding the boot portion.
necessary.
6. Remove the ignition coil.
2. Measure cylinder head mating surface in six
7. Remove the power steering oil pump and bracket.
directions as shown in figure.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold
assembly. Distortion:
10. Remove the coolant pump pulley and the crankshaft A5D: 0.001 In (0.03 mm) maximum
pulley. A3E: 0.002 In (0.05 mm) maximum
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover and cam carrier assembly.
15. Remove the cylinder head assembly. The cylinder head
bolts should be removed by using Special Tool, Cylinder
Head Bolt Wrench, in the sequence as shown in the
illustration in two or three steps.
OS2010011
Notice
Before resurfacing cylinder head, check following
repair or replace cylinder head if necessary
• Sunken valve seats
• Damage at intake and exhaust manifold
mating surfaces.
16. Remove the gasket pieces from cylinder block top • Camshaft oil clearances and end play.
surface and cylinder head bottom surface.
_ r~k
Notice
Make sure tnat the gasket pieces do not fall in the
engine
3. Grind cylinder head mating surface if distortion Reassembly

exceeds specification. 1. Clean all gasket surfaces of the cylinder block and
the cylinder head.
Distortion: 2. Install a new cylinder head gasket onto the cylinder
A5D: 0.001 In (0.03 mm) maximum head assembly. Do not reuse the old cylinder head
A3E: 0.002 In (0.05 mm) maximum gasket.
a. Tighten cylinder head bolts in order shown.
Tightening torque:
36.1 Ib-in (49 N-m, 5 kg-m)
b. Loosen bolts in reverse of order shown.

c. Retighten cylinder head bolts in order shown.
Tightening torque:
18 Ib-ln (25 N-m, 2.5 kg-m)
d. Mark cylinder head bolts for rotational

reference.
e. Rotate cylinder head bolts 90° (1/4 Turn) in
OS2010012 order shown.
4. Check cylinder head height by measuring from

cylinder deck surface to cylinder head cover gasket
surface.
5. If cylinder head height is not within specification,
replace cylinder head.
Might:
A5D: 5.031-5.039 In (127.8-128 mm)
A3E: 4.228-4.236 In (107.4-107.6 mm)
6. Measure intake and exhaust manifold mating

surface distortion at two directions shown in figure.
Distortion:
0.002 in (0.05 mm) maximum
7. If distortion exceeds specification, resurface or

replace cylinder head. Caution
a) Do not rotate crankshaft without timing belt.
Distortion: b) Make sure that all pistons are positioned In
0.002 In (0.05 mm) maximum the middle of cylinder before Installing
cylinder head.
c) Two bolts (No.7 and No.8) are shorter than
other bolts. Never Install the two bolts In
other position. (forASD)
d) Do not reuse the old cylinder head bolts.
3. Install the timing belt tensioner pulley.

4. Install the timing belt on the camshaft sprocket,
marking sure that the tension side is tightened by
turning the camshaft sprocket in reverse, all timing
marks are in alignment.
5. Adjust the timing according to "Timing Belt".
6. Install the rocker cover and tighten the bolts to the
specififed torque.
Tightening torque:
Rocker cover bolt
3.6-6.5 Ib-ft (5-9 N-m, 0.5-0.9 kg-m)
7. Install the timing belt cover.

8. Install the new intake manifold gasket and the
intake manifold. Tighten the nuts and bolts to the
specified torque.
9. Install the exhaust manifold gasket and the exhaust
manifold. Tighten the exhaust manifold attaching
nuts to the Specified torque.
10. Install the surge tank and tighten the nuts and bolts
to the specified torque.
Tightening torque:
Manifold nuts and bolts (both Intake and
exhaust)
11-14 Ib-ft (15-20 N-m, 150-200 kg-m)
Tightening torque:
Surge tank to Inlet manifold nuts and bolts
11-14 Ib-ft (15-20 N-m, 150-200 kg-m)
11. Install the power steering oil pump and bracket.

12. Install the ignition coil.
13. Install the air intake hose.
14. Connect the vacuum hose, fuel hose and water
hose.
15. Install breather hose.
4. Measure diameter of each valve stem.

Valves
Inspection Diameter
Intake: 0.2131-0.21372 In (5.465-5.48 mm)
Valve mechanism Exhaust: 0.2117-0.2125 In (5.43-5.45 mm)
1. Inspect each valve for following:
a. Damaged or bent valve stem
b. Rough or damaged face
c. Damaged or unevenly worn stem tip
2. Resurface or replace valve as needed.
Margin thickness
Intake: 0.0394 In (1.0mm)
Exhaust: 0.0394 In (1.0mm)
7. If clearance exceeds specification, replace valve,

and/or valve guide.
8. Measure protrusion height of each valve guide.
Replace valve guide as needed.
A5D
Intake: 0.511&-0.5196 In (13.0-13.2 mm)
Exhaust: 0.5118-0.5196 In (13.0-13.2 mm)
A3E
Intake: 0.4094-0.4173 In (10.4-10.6 mm)
Exhaust: 0.4094-0.4173 In (10.4-10.6 mm)
BSX010B080
* Notice
Intake and exhaust valve guides are different.
Be sure to use correct valve guide.
Valve seat
1. Inspect contact surface of each valve seat and
valve face for following:
a. Roughness
b. Damage
c. Pitting
d. Cracks
2. Resurface valve seats with a 45° valve seat cutter.
Resurface valve faces as needed.
OS2010031
3. Apply a coat of Dychem blue to valve face and

valve seat and allow to dry.
4. Inspect valve seating by pressing valve against seat
and rotating valve 360°.
a. If Dychem blue is not removed 360° around valve
face, replace valve.
Valve spring
1. Inspect each valve spring for cracks and damage.
2. Measure free length and out-of-square. Replace
valve springs as needed.
Free length: Standard: 1.653 In (42.4 mm)

Limit: 1.646 In (42.2 mm)
Oufrotequare: 0.433 In (1.11 mm)
Timing belt
Component
(1) Crankshaft pulley (6) Body Timing belt

(2) Water pump pulley (7) Timing belt guide plate
(3) Timing belt cover (lower) (8) Timing belt pulley
(4) Timing belt cover (upper) (9) Idler
(5) Timing belt Tensioner & spring (10) Camshaft pulley
TIMING SYSTEM EM-65
Removal 11. Loosen tensioner pulley lock bolt.

A5D
2. Loosen power steering lock bolts and nuts accordingly
and remove tension from power steering (PIS) and/or
air conditioning (A/C) compressor drive belt.
12. Protect timing belt with a rag.

13. Remove tensioner pulley.
AB3010013
*К Notice
3. Remove P/S and/or A/C drive belt. Mark the direction of timing belt rotation (on the
4. Loosen generator mounting bolts and adjusting bolt. timing belt) for proper reinstallation.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley and timing belt guide
plate.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt

pulley is aligned with timing mark on engine.
10. Check that Т mark on intake camshaft pulley is
A5D
Notice
Do not move camshaft or crankshaft once timing
marks have been correctly positioned.
Inspection 5. Inspect camshaft pulleys and timing belt pulley for

broken teeth or damage.
# Notice
Never forcefully twist, turn inside out or bend timing
belt. Do not allow oil or grease to come in contact
with timing belt.
1. Replace timing belt if it is contaminated with oil or

grease.
2. Check timing belt for uneven wear, fraying, peeling,
cracking and hardening. Replace timing belt as
necessary.
Notice
Replace any component that shows damage,
excessive wear, or that appears prone to a
possible failure.
3. Bend timing belt into a "U" shape as shown in

figure. Distance "A" must be at least 1.0 in (25
mm).
4. Inspect both idler pulley and tensioner pulley for
uneven wear and smooth bearing operation.
TIMING SYSTEM EM-67
Installation 6. Check that there is no looseness in belt between

1. Install tensioner pulley. idler pulley and exhaust camshaft pulley or
between intake and exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow
# Notice tensioner spring to apply tension to timing belt.
Replace tensioner spring whenever timing belt is
replaced.
Ф Notice
2. Pull tensioner pulley to its furthest point and tighten Do not add additional tension.
lock bolt.
8. Tighten tensioner pulley lock bolt to specified
torque.
Tightening torque:
28-38 Ib-ft (38-51 N-m, 3.9-5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise

only) and align timing mark on timing belt pulley
with timing mark on engine block.
10. Check that Т mark on intake camshaft pulley "E"
mark on exhaust camshaft pulley are aligned with
marks on cylinder head cover.
11. If they are not aligned, remove timing belt and start
process from tensioner installation.
12. Measure timing belt deflection by applying
moderate pressure midway between camshaft
pulleys. If deflection is not correct, repeat from
tensioner installation.
Deflection pressure:
22 Ib. (98 N, 10 kg)
Deflection:
0.39-0.50 In. (11-13mm)
* Notice
If existing timing belt is being reused, install belt in
proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then

idler pulley, exhaust camshaft pulley, intake
camshaft pulley, and tensioner pulley in that order.
13. Install lower and upper timing belt covers in that

order.
Tightening torque:
70-96 Ib-ft (7.9-10.7 N-m, 0.8-1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:
9.0-12.6 Ib-ft (12.3-17.2 N-m, 1.3-1.8 kg-m)
15. Install water pump pulley.
Tightening torque:
9.0-12.6 Ib-ft (12.3-17.2 N-m, 1.3-1.8 kg-m)
16. Install generator belt and adjust the tension.

17. Install P/S and/or A/C drive belt and adjust the
tension.
18. Connect negative battery cable.
TIMING SYSTEM EM-69
Installation
1. Install tensioner pulley.
Ф Notice
Replace tensioner spring whenever timing belt is
replaced.
2. Pull tensioner pulley to its furthest point and tighten

lock bolt.
3. Check that timing mark on timing belt pulley is
aligned with timing mark on engine.
4. Check that Т mark on intake camshaft pulley is

* Notice
If existing timing belt is being reused, install belt in
proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then

idler pulley, exhaust camshaft pulley, intake
camshaft pulley, and tensioner pulley in that order.
6. Check that there is no looseness in belt between
idler pulley and exhaust camshaft pulley or
between intake and exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow
tensioner spring to apply tension to timing belt.
* Notice
Do not add additional tension.
8. Tighten tensioner pulley lock bolt to specified

torque.
Tightening torque:
28-38 Ib-ft (38-51 N-m, 3.9-5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise

only) and align timing mark on timing belt pulley
with timing mark on engine block.
10. Check that Т mark on intake camshaft pulley "E"
mark on exhaust camshaft pulley are aligned with
marks on cylinder head cover.
11. If they are not aligned, remove timing belt and start
process from tensioner installation.
12. Measure timing belt deflection by applying
moderate pressure midway between camshaft
pulleys. If deflection is not correct, repeat from
tensioner installation.
Deflection pressure:
22 Ib. (98 N, 10 kg)
Deflection:
0.39-0.50 In. (11-13 mm)

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What are the main components of an engine discussed in the document?

What are the main components of an engine discussed in the document?

What are some common problems related to an engine's lubrication system mentioned in the document?

What are some common problems related to an engine's lubrication system mentioned in the document?

ENGINE

Special service tools

HLA(Hydraulic lash adjuster)

Faulty HLA Press down HLA by hand.

Measure valve clearance.

Deteriorated oil Check oil quality.

Engine hard starting Improper engine oil Replace

Excessive oil Internal engine wear Refer to page EM-47

Oil pressure drop Insufficient oil Add oil

Warning lamp Oil pressure drop As described above

Problem Possible Cause Action

Corrosion Impurities in coolant Replace

5.8-8.0 (7.8-11. 0.8~1.1)

5.8-8.0 (7.8-11, 0.8~1.1)

(1) Battery clamp (6) Air cleaner assembly

(1) Exhaust pipe & catalytic converter (4) Knuckle

(1) Engine Mounting Member (4) No.2 Engine Mounting Bracket

Engine and transaxle assembly 6. Remove accelerator cable.

22. Remove four A/C compressor bolts.

AB3042032 31. Remove two bolts from No.1 engine mounting

3. Install No.2 engine mounting nut bracket bolts and

4. Install four engine mounting member bolts & nuts.

12. Install A/C compressor.

21. Install transaxle linkage(A/T).

15. Connect power steering pump hose.

23. Connect injector connectors to injector rail.

27. Install accelerator cable.

Ib-ft (N-m, kg-m)

(1) Cylinder head cover (4) Camshaft

(1) Cylinder head cover (4) Cam carrier assembly

Disassembly 3. Install the camshaft after lubricating the journal of

4. Install the cam carrier assembly.

10. Remove the cam carrier assembly and timing belt.

5. Tighten the cam carrier bolts to the specified torque Inspection

6. Using special tool, camshaft oil seal installer

14. Install cam carrier bolts.

15. Loosen cam carrier assembly bolts.

18. If oil clearance exceeds specification, replace

(1) Piston ring (4) Connecting rod

Diassembly 3. Remove connecting rod nuts and gently loosen rod

2. Rotate crankshaft so that cylinders No.2 and No.3

9. Hold piston upright and gently move connecting

Standard: A5D: 0.03~0.07 mm

End gap clearance

2. Install second piston pin clip into clip grooves on

3. Hold piston upright and move connecting rod back

16. Install a connecting rod bearing in each connecting

12. Place piston (cylinder number one) with "F" mark

22. Apply a coat of clean engine oil to connecting rod

24. Insert a thickness gauge between connecting rod

25. If side clearance exceeds maximum side clearance

(1) Main bearing (3) Main bearing

4. Remove the main bearing caps and remove the crankshaft.

Main Bearing and Connecting Rod Bearings

6. Grind crankshaft only if there is visible scoring, or if