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Kia Cerato 2009 Service Manual

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Engine Mechanical System
Engine Mechanical System
General Information

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Summary of Contents for Kia Cerato 2009

  • Page 1 Engine Mechanical System Engine Mechanical System General Information...

  • Page 2: Special Service Tools

    2009 > D 1.6 TCI-U > SPECIAL SERVICE TOOLS Tool (Number and name) Illustration Torque angle adapter Installation of bolts & nuts needing an (09221-4A000) angular method Valve spring compressor Removal and installation of intake and (09222-3K000) exhaust valves Valve spring compressor adapter (09222-2A100) Compression gauge...
  • Page 3 Injector remover adapter Removal of injectors (09351-2A100) High pressure pump Removal of high pressure pump sprocket sprocket remover (09331-2A000) Crankshaft rear oil seal Installation of crankshaft rear oil seal installer (09231-H1200) Handle (09231-H1100) Front cover oil seal Installation of front cover oil seal installer (09231-2A000) Handle...

  • Page 4: Troubleshooting

    2009 > D 1.6 TCI-U > TROUBLESHOOTING Symptom Suspect area Remedy Engine misfire with Repair or replace the flywheel as Loose or improperly installed engine flywheel. abnormal internal required. lower engine noises. Worn piston rings. Inspect the cylinder for a loss of (Oil consumption may or may not cause the compression.
  • Page 5 Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides, valve seat may cause the valve to stay open.) then repair as required. Lower engine noise, Low oil pressure. Repair or replace damaged regardless of engine components as required.
  • Page 6 Broken timing chain and/or timing chain gears. Inspect timing chain and gears. Repair as required. Foreign material in cylinder. Inspect cylinder for damaged components and/or foreign materials. •• Broken valve. Repair or replace as required. •• Piston material. •• Foreign material. Seized crankshaft or connecting rod bearings.
  • Page 7 2009 > D 1.6 TCI-U > INSPECTION COMPESSION PRESSURE •• If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. •• Whenever removing injectors for compression pressure inspection, replace the gaskets with new ones and tighten them with the specified torque.
  • Page 8 This measurement must be done in as short a time as possible. Compression pressure : 2,157.45kPa (22.0kg/cm², 312.91psi) (200 rpm) Minimum pressure : 1,863.25kPa (19kg/cm², 270.24psi) Difference between each cylinder : 98.07kPa (1.0kg/cm², 14.22psi) or less (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.

  • Page 9: Specifications

    2009 > D 1.6 TCI-U > SPECIFICATIONS Description Specifications (D4FB) Limit General Type In-line, DOHC Number of cylinders Bore 77.2mm (3.0394in) Stroke 84.5mm (3.3268in) Total displacement 1,582 cc (96.54 cu.in) Compression ratio 17.3 : 1 Firing order 1-3-4-2 Valve timing Opens (ATDC) 17°5' ±...
  • Page 10 valve head Exhaust 1.2mm (0.0472in) (margin) Valve stem to Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in) valve guide Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in) clearance Valve guide Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in) Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in) Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in) Length...
  • Page 11 Connecting rod small end hole inner 28.022 ~ 28.034mm (1.1032 ~ 1.1037in) diameter Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in) Connecting rod Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in) Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in) Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098in)

  • Page 12: Tightening Torque

    20°C (68°F) 2.45±0.14 k Resistance 80°C (176°F) 0.3222 k TIGHTENING TORQUE Tightening torque Item Quantity kgf.m lb.ft Cylinder block Engine support bracket bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8 Piston cooling oil jet bolt 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4 Drive belt auto tensioner bolt...
  • Page 13 Drive plate bolt (A/T) 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9 Timing chain Timing chain cover bolt (8 X 70) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing chain cover bolt (8 X 60) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing chain cover bolt (8 X 35)
  • Page 14 Oil filter upper cap 24.5 18.1 Oil level gauge bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Oil pan bolt (6 X 20) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7 Oil pan bolt (6 X 65) 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7...
  • Page 15 Engine Mechanical System Engine Mechanical System Timing System - Timing...
  • Page 16 2009 > D 1.6 TCI-U > COMPONENTS...
  • Page 18 2009 > D 1.6 TCI-U > REMOVAL Engine removal is not required for this procedure. 1. Remove the drive belt. 2. Remove the injector(A). (Refer to FL Gr.) 3. Remove the cylinder head cover(A). 4. Remove the engine mounting support bracket. (1) Set the jack to the engine oil pan...
  • Page 19 (2) Remove the engine mounting support bracket(A). 5. Remove the alternator(A). 6. Remove the water pump pulley(A). 7. Remove the engine support bracket(A).
  • Page 20 8. Remove the drive belt auto tensioner(A). 9. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position) 10. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).
  • Page 21 Use the SST(flywheel stopper, 09231-2A100)(A) to remove the crankshaft pulley bolt, after remove the starter. 11. Remove the high pressure pump sprocket nut(B) after remove the timing chain cover plug(A). •• Use the SST(flywheel stopper, 09231-2A100) to remove the high pressure pump sprocket nut. ••...
  • Page 22 13. Remove the mounting bolts of the high pressure pump(A) and the fuel hoses(B, C). 14. Install the SST(high pressure pump sprocket stopper, 09331-2A000)(A) to sprocket rotating it clockwise. 15. Remove the timing chain cover bolt(three bolts)(B). 16. Install the SST(high pressure pump sprocket remover, 09331-2A000)(A) to timing chain cover with three long bolts(B).
  • Page 23 20. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the enine hanger bracket. 21. Remove the jack from oil pan. 22. Remove the oil pan(A). 23. Remove the oil strainer(B).
  • Page 24 When removing the oil pan, use the SST(09215-3C000) in order not to damage the surface between the cylinder block and the oil pan. 24. Remove the timing chain cover(A) Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan.
  • Page 25 Before removing auto-tensioner, install a set pin(B) (ø2.5 mm steel wire) after compressing the tensioner. 26. Remove the timing chain "C" lever(A) and the timing chain guide "1"(B). 27. Remove the timing chain guide "2"(A). 28. Remove the timing chain "C"(A).
  • Page 26 29. Remove the timing chain "A" auto tensioner(A). Before removing auto-tensioner, install a set pin(B) (ø2.5 mm steel wire) after compressing the tensioner. 30. Remove timing chain "A" lever(A) and the timing chain guide "1"(B). 31. Remove the timing chain "A"(A)with high pressure pump sprocket(B) and crankshaft sprocket(C).
  • Page 27 32. Remove the power steering pump bracket(A). 33. Remove the water pump(A). 34. Remove the timing chain case(A). (Engine removal is required for this procedure)

  • Page 28: Installation

    35. Remove the camshaft sprocket. (1) Hold the portion(A) of the camshaft with a hexagonal wrench, and remove the bolt(C) with a wrench(B) and remove the camshaft sprocket. Be careful not to damage the cylinder head and valve lifter with the wrench. INSTALLATION Engine removal is not required for this procedure.
  • Page 29 2. Install the timing chain case(A) with new gasket. (Engine removal is required for this procedure) Tightening torque : Bolt(B,C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbf.ft) Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lbf.ft) 3.
  • Page 30 5. Install the high pressure pump(A), connecting the hoses(B, C). Tightening torque : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lbf.ft) 6. Install the high pressure pipe(A). 7. Set the key of crankshaft sprocket to be aligned with the timing mark of timing chain case. As a result of this, place the piston on No.1 cylinder at the top dead center on compression stroke.
  • Page 31 8. After install timing chain "A" with high pressure pump sprocket(B) 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.
  • Page 32 12. Align the timing mark(A) of camshaft sprocket on the vertical center line of crankshaft. 13. Install the timing chain "C"(A) 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.
  • Page 33 15. Install the timing chain "C" lever(A) and the timing chain guide "1"(B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 16. Install the timing chain "C" auto tensioner(A) and then remove set pin(B). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 17.
  • Page 34 Use the SST(flywheel stopper, 09231-2A100)(A) to tighten the high pressure pump sprocket nut, after remove the starter. 18. Apply 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. ••...
  • Page 35 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft) Bolt(D,E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 20. Install the front oil seal by using SST(09231-2A000, 09231-H1100)(A). 21. Install the oil strainer(B). Tightening torque : Bolts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft) Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 22.
  • Page 36 applying the liquid gasket. •• After assembly, wait at least 30 minutes before filling the engine with oil. •• Apply liquid gasket to T-joint before assembling oil pan. 23. Install the oil pan(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 24.
  • Page 37 26. Install the crankshaft pulley(A) and crankshaft pulley bolt(B). Tightening torque : 225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lbf.ft) Use the SST(flywheel stopper, 09231-2A100) to Install the crankshaft pulley bolt, after remove the starter. 27. Install the drive belt auto tensioner(A). Tightening torque : 18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lbf.ft)
  • Page 38 28. Install the engine support bracket(A). Tightening torque : 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lbf.ft) 29. Install the water pump pulley(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 30. Install the alternator(A). Tightening torque : 38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)
  • Page 39 31. Install the engine mounting support bracket(A). Tightening torque : Nut(D) : 68.6 ~ 93.2N.m(7.0 ~ 9.5kgf.m, 50.6~ 68.7lbf.ft) Bolt(B), Nut(C) : 49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft) 32. Remove the jack from oil pan 33. Install the cylinder head cover(A) with new head cover gasket. Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lbf.ft)
  • Page 40 •• Standard liquid gasket : LOCTITE 5900 •• Check that the mating surfaces are clean and dry before applying liquid gasket. •• Apply liquid gasket in a 3mm wide bead without stopping. •• Assemble the cylinder head cover in 5 minutes after applying the liquid gasket. ••...

  • Page 42: Cylinder Head Assembly

    Engine Mechanical System Engine Mechanical System Cylinder Head Assembly...
  • Page 43 2009 > D 1.6 TCI-U > COMPONENTS...
  • Page 45 2009 > D 1.6 TCI-U > REMOVAL Engine removal is required for this procedure. •• 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.
  • Page 46 6. Disconnect the water hose(A) from thermostat housing. 7. Remove the thermostat housing(A). 8. Remove the vacuum pump(A). 9. Remove the camshaft bearing caps(A).
  • Page 47 Mark the camshaft bearing caps to be able to reassemble in the original position and direction. 10. Remove the camshaft(A). 11. Remove the cam follower(A). 12. Remove the HLA(Hydraulic Lash Adjust).

  • Page 48: Installation

    13. Remove the cylinder head bolts, then remove the cylinder head. (1) Using bit socket (12PT), uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.Remove the 10 cylinder head bolts. 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.
  • Page 49 •• Thoroughly clean all parts to be assembled. •• Always use a new cylinder head and manifold gasket. •• Always use a new cylinder head bolt. •• The cylinder head gasket is a metal gasket. Take care not to bend it. ••...
  • Page 50 Average of piston 0.035 ~ 0.105mm 0.105 ~ 0.175mm 0.175 ~ 0.245mm protrusion (0.0014 ~ 0.0041in) (0.0041 ~ 0.0069in) (0.0069 ~ 0.0096in) 1.00 ~ 1.15mm 1.05 ~ 1.20mm 1.10 ~ 1.25mm Gasket thickness (0.0394 ~ 0.0453in) (0.0413 ~ 0.0472in) (0.0433 ~ 0.0492in) Limit of each rank 0.14mm (0.0055in) 0.21mm (0.0083in)
  • Page 51 5. Install the cylinder head bolts. (1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. (2) Using bit socket (12PT), install and tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
  • Page 52 (1) Until installing HLA shall be held upright so that diesel oil in HLA should not spill and assured that dust does not adhere to HLA. (2) HLA shall be inserted tenderly to the cylinder head not to spill diesel oil from HLA. In case of spilling, air bent shall be done in accordance with the air bent procedure.
  • Page 53 10. Install the vacuum pump(A) with new gasket(B). Tightening torque : 10.8 ~ 14.7N.m (1.1 ~ 1.5kgf.m, 8.0 ~ 10.8lbf.ft) Apply engine oil to the O-ring(A) of vacuum pump shaft before assembling vacuum pump. 11. Install the thermostat housing(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft)
  • Page 54 12. Reconnect the water hose(A) to thermostat housing. 13. Install the glow plug(A) and glow plug plate. Tightening torque : Glow plug: 15 ~ 20N.m (1.5 ~ 2.0kgf.m, 11 ~ 14lbf.ft) Plate nut : 0.8~1.5N.m (0.08 ~ 0.15kgf.m, 0.6 ~ 1.1lbf.ft) 14.

  • Page 55: Cylinder Head

    15. Install the intake and exhaust manifold. 16. Install the timing chain. 17. Install the drive belt. DISASSEMBLY 1. Remove the valves. (1) Using the SST (09222-28000, 09222-28100)(A), compress the valve spring and remove the retainer lock. (2) Remove the spring retainer. (3) Remove the valve spring.

  • Page 56: Valve And Valve Spring

    2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. VALVE AND VALVE SPRING 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 : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in) Exhaust : 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
  • Page 57 Valve stem outer diameter Intake : 5.455 ~ 5.470mm (0.2148 ~ 0.2154in) Exhaust : 5.435 ~ 5.450mm (0.2140 ~ 0.2146in) (3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement. Valve stem- to-guide clearance Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in) Exhaust : 0.050 ~ 0.077mm (0.0020 ~ 0.0030in) If the clearance is greater than specification, replace the valve and valve guide.
  • Page 58 (4) Check the valve length. Length Intake : 93.0mm (3.6614in) Exhaust : 93.7mm (3.6890in) (5) Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve. 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.
  • Page 59 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 Out of square : 3° If the loads is not as specified, replace the valve spring. CAMSHAFT 1. Inspect the cam lobes. Using a micrometer, measure the cam lobe height.
  • Page 60 (2) Place the camshafts on the cylinder head. (3) Lay a strip of plastigage across each of the camshaft journal. (4) Install the bearing caps and tighten the bolts with specified torque. Tightening torque : 12.7 ~ 13.7N.m (1.3 ~ 1.4kgf.m, 9.4 ~ 10.1lbf.ft) Do not turn the camshaft.
  • Page 61 (8) Remove the camshafts. 3. Inspect the camshaft end play. (1) Install the camshafts. (2) Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in) If the end play is greater than specification, replace the camshaft.
  • Page 62 4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band. Oil leakage of the high-pressure chamber in the HLA, allowing air to get in. 5. Continuous noise when the Insufficient oil in the HLA. Do not run engine at a speed engine is running after changing higher than 3000 rpm, as this...
  • Page 63 (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. (3) Using the SST(09222-2A100, 09222-3K000)(A), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
  • Page 64 Engine Mechanical System Engine Mechanical System...
  • Page 65 2009 > D 1.6 TCI-U > REMOVAL •• 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. Disconnect the battery terminals(A). 2.
  • Page 66 5. Remove the air duct(A). 6. Remove the intake hose(A). 7. Remove the air cleaner assembly. (1) Disconnect the AFS(Air Flow Sensor) connector(A).
  • Page 67 (2) Remove the air cleaner upper cover(B). (3) Remove the air hose(C). (4) Remove the air cleaner element. (5) Remove the bolts(B) and air cleaner lower cover(A). 8. Remove the main relay box(A). 9. Remove the wiring(A) from fuse box. 10.
  • Page 68 11. Remove the ground cable from transaxle(A) and cylinder head(B). 12. Remove the coolant reservoir tank hose(A). 13. Remove the radiator upper hose(A).
  • Page 69 14. Remove the radiator lower hose(A). 15. Remove the fuel hose(A). 16. Remove the brake vacuum hose(A). 17. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the...
  • Page 70 intake manifold. (1) Disconnect the glow plug connector(A). (2) Disconnect the injector connector(B). (3) Disconnect the vacuum solenoid valve connector(A) and vacuum hose(B). (4) Disconnect the CMP(Camshaft position sensor) connector(A). (5) Disconnect the EGR(Emission Gas Recirculation) solenoid valve connector(B). (6) Disconnect the water temperature sensor connector(C). (7) Disconnect the common rail pressure sensor connector(D).
  • Page 71 (11) Disconnect the fuel temperature sensor connector(A). (12) Disconnect the fuel pressure regulator connector(B). 18. Remove the heater hose(A). 19. Remove the power steering oil hose(A) and drain the power steering oil.
  • Page 72 20. Remove the power steering return hose(A). 21. Remove the transaxle wire harness connectors and control cable from transaxle(M/T). (1) Remove the clutch release cylinder(A). (2) Remove the transaxle control cable(A). (3) Disconnect the vehicle speed sensor connector(A). (4) Disconnect the back lamp switch connector(B). (5) Disconnect the neutral switch connector(C).
  • Page 73 22. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine and transaxle assembly. 23. Remove the engine mounting support bracket(A). Tightening torque : Nut(D) : 68.6 ~ 93.2N.m (7.0 ~ 9.5kgf.m, 50.6 ~ 68.7lbf.ft) Bolt(B),Nut(C) : 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lbf.ft) 24.
  • Page 74 25. Remove the front tires. 26. Remove the ABS wheel speed sensor(A). 27. Remove the caliper and hang assembly(A). 28. Remove the knuckle mounting bolts(A).
  • Page 75 29. Remove the steering u-joint mounting bolt(A). 30. Remove the front muffler(A). 31. Using a floor jack, support the engine and transaxle assembly. After 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.

  • Page 76: Installation

    33. Remove the engine support fixture and the adapter. 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. INSTALLATION Installation is in the reverse order of removal. Perform the following : ••...

  • Page 77: Cylinder Block

    Engine Mechanical System Engine Mechanical System Cylinder Block...
  • Page 78 2009 > D 1.6 TCI-U > COMPONENTS...
  • Page 79 2009 > D 1.6 TCI-U > DISASSEMBLY 1. M/T : Remove the fly wheel. 2. A/T : Remove the drive plate. 3. Install the engine to engine stand for disassembly. 4. Remove the timing chain. 5. Remove the intake manifold and exhaust manifold. 6.
  • Page 80 11. Remove the connecting rod cap(A). Mark the connecting rod caps to be able to reassemble in the original position and direction. 12. Remove the piston and connecting rod assemblies. (1) Using a ridge reamer, remove all the carbon from the top of the cylinder. (2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

  • Page 81: Connecting Rod

    14. Remove the oil jet. 15. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. 16. Remove the piston rings. (1) Using a piston ring expender, remove the 2 compression rings.
  • Page 82 A. If out-of-tolerance, install a new connecting rod. B. If still out-of-tolerance, replace the crankshaft. 2. Check the connecting rod bearing oil clearance. (1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly. (2) Remove the 2 connecting rod cap bolts.
  • Page 83 Do not file, shim, of scrape the bearings or the caps to adjust clearance. (10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
  • Page 84 Discrimination of crankshaft pin journal Crankshaft pin journal Mark outer diameter 46.009 ~ 46.015mm (1.8114 ~ 1.8116in) 46.003 ~ 46.009mm (1.8111 ~ 1.8114in) 45.997 ~ 46.003mm (1.8109 ~ 1.8111in) Connecting rod bearing mark location Discrimination of connecting rod bearing Color Connecting rod bearing thickness Blue 1.477 ~ 1.480mm (0.0581 ~ 0.0583in)
  • Page 85 should be replaced. Allowable bend of connecting rod : 0.05mm / 100mm (0.0020in / 3.94in ) or less Allowable twist of connecting rod : 0.1mm / 100mm (0.0039in / 3.94in) or less CRANKSHAFT 1. Check the crankshaft bearing oil clearance. (1) To check main bearing-to-journal oil clearance, remove the bed plate and lower bearings.
  • Page 86 If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION Letters have been stamped on the front face of block as a mark for the size of each of the 5 main journal bores.
  • Page 87 Crankshaft main bearing mark location Discrimination of crankshaft main bearing Color Crankshaft main bearing thickness Blue 1.990 ~ 1.993mm (0.0783 ~ 0.0785in) Black 1.993 ~ 1.996mm (0.0785 ~ 0.0786in) None 1.996 ~ 1.999mm (0.0786 ~ 0.0787in) Green 1.999 ~ 2.002mm (0.0787 ~ 0.0788in) Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in) (8) Select the bearing by using selection table.
  • Page 88 If the end play is greater than specification, replace the center main bearings as a set. Thrust washer thickness of center main beaing : 2.335 ~ 2.385mm (0.0919 ~ 0.0939in) End play Standard : 0.08 ~ 0.28mm (0.0031 ~ 0.110in) Limit : 0.30mm (0.0118in) 3.
  • Page 89 1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean the cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
  • Page 90 Discrimination of cylinder bore size Mark Cylinder bore inner diameter 77.200 ~ 77.210mm (3.0394 ~ 3.0398in) 77.210 ~ 77.220mm (3.0398 ~ 3.0402in) 77.220 ~ 77.230mm (3.0402 ~ 3.0405in) 7. Check the piston size mark(A) on the piston top face. Discrimination of piston outer diameter Mark Piston outer diameter 77.130 ~ 77.140mm (3.0366 ~ 3.0370in)

  • Page 91: Piston And Piston Rings

    2. Measure the outside diameter of the piston to be used. 3. According to the measured O.D(Outer Diameter), calculate the new bore size. New bore size = piston O.D + 0.060 to 0.080mm (0.0024 to 0.0031in) (clearance between piston and cylinder) - 0.01mm (0.0004in) (honing margin.) 4.
  • Page 92 3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter. Piston-to-cylinder clearance : 0.06 ~ 0.08mm (0.0024 ~ 0.0031in) 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove. Piston ring side clearance No.1 : 0.09 ~ 0.13mm (0.0035 ~ 0.0051in) No.2 : 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)

  • Page 93: Piston Pins

    No.2 : 0.35 ~ 0.50mm (0.0138 ~ 0.0197in) Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in) PISTON PINS 1. Measure the outer diameter of piston pin. Piston pin diameter : 27.995 ~ 28.000mm (1.1022 ~ 1.1024in) 2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance : 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)

  • Page 94: Oil Pressure Switch

    3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter. Piston pin-to-connecting rod interference : 0.022 ~ 0.039mm (0.0009 ~ 0.0015in) OIL PRESSURE SWITCH 1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil pressure switch.
  • Page 95 •• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. •• Replace all gaskets, O-rings and oil seals with new parts. 1. Assemble the piston and connecting rod. (1) Use a hydraulic press for installation (2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
  • Page 96 4. Install the crankshaft main bearings. Upper 1, 2, 4, 5 bearings have an oil groove of oil holes ; Lower bearings do not. (1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A). (2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
  • Page 97 6. Place the crankshaft on the cylinder block. 7. Place the bed plate on the cylinder block. •• Standard liquid gasket : LOCTITE 5205, HYLOMAR3000, Dreibond 5105 •• Check that the mating surfaces are clean and dry before applying liquid gasket. ••...
  • Page 98 (1) Apply a light coat of engine oil on the threads and under the bed plate bolts. (2) Install and uniformly tighten the bed plate bolts(A),in several passes, in the sequence shown. Tightening torque : Long bolts(1~10) : 22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 90~94° Short bolts(11~20) : 32.4~36.3N.m (3.3~3.7kgf.m, 23.9~26.8lbf.ft) Always use new main bearing cap bolts.
  • Page 99 •• Always use new connecting rod bearing cap bolts. •• Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore. 11. Install the rear oil seal. (1) Apply engine oil to a new oil seal lip. (2) Using the SST(09231-H1200, 09231-H1100)(A) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
  • Page 100 Tightening torque : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lbf.ft) 13. Install the water pipe(A). Tightening torque : 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbf.ft) 14. Install the cylinder head. 15. Install the intake manifold and exhaust manifold. 16.

  • Page 101: Cooling System

    Engine Mechanical System Engine Mechanical System Cooling System...
  • Page 102 2009 > D 1.6 TCI-U > COMPONENT...

  • Page 105: Water Pump

    2009 > D 1.6 TCI-U > REMOVAL WATER PUMP 1. Drain the engine coolant. System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool. 2.
  • Page 106 RADIATOR 1. Drain the engine coolant. Remove the radiator cap to speed draining. 2. Disconnect the battery terminals(A). 3. Remove the air duct(A).
  • Page 107 4. Remove the radiator upper hose(A). 5. Remove the radiator lower hose(A). Remove the clamp on the cooling fan cover. 6. Remove automatic transaxle fluid(ATF) cooler hose.(Refer to 'AT' group). 7. Disconnect the fan motor connector(A). 8. Disconnect the hose(A) between the reservoir and the radiator.
  • Page 108 9. Remove the radiator mounting bolts(A) and remove the radiator from condenser. 10. Remove the radiator upper bracket(A), then pull up the radiator. 11. Remove the cooling fan(B) from the radiator(A).

  • Page 109: Engine Coolant

    REPLACEMENT ENGINE COOLANT Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator. When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts of the paint.

  • Page 110: Installation

    4. Tighten the radiator drain plug(A) securely. 5. Remove the coolant reservoir tank. Drain the coolant and reinstall the coolant reservoir tank. Fill the coolant reservoir tank to the MAX mark with the coolant. 6. Fill fluid mixture with coolant and water slowly through the radiator cap. Gently squeeze the upper/ lower hoses of the radiator so as to bleed air easily.
  • Page 111 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lbf.ft) 2. Install the water pump pulley(A). Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lbf.ft) 3. Install the drive belts. 4. Fill with engine coolant. 5. Start engine and check for leaks. 6.
  • Page 112 3. Fill with engine coolant. 4. Start engine and check for leaks. RADIATOR 1. Install the cooling fan(B) to the radiator(A). Tightening torque : 8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0 lbf.ft) 2. Install the radiator to the air conditioning condenser and the radiator upper bracket(A). 3.
  • Page 113 4. Connect the fan motor connector(A). 5. Install the upper and the lower radiator hoses(A) and the automatic transaxle fluid(ATF) cooler hose. 6. Fill with engine coolant and install the air duct(A).
  • Page 114 7. Start engine and check for leaks. INSPECTION WATER PUMP 1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary. 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.

  • Page 115: Radiator Cap

    2. Check the valve opening temperature. Valve opening temperature : 82±1.5°C (179.6±2.7°F) Full opening temperature : 95°C (203°F) If the valve opening temperature is not as specified, replace the thermostat. 3. Check the valve lift. Valve lift : 8mm(0.3in) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat.
  • Page 116 Check for engine oil in the coolant and/or coolant in the engine oil.

  • Page 117: Lubrication System

    Engine Mechanical System Engine Mechanical System Lubrication System...
  • Page 118 2009 > D 1.6 TCI-U > COMPONENTS...
  • Page 119 2009 > D 1.6 TCI-U > REMOVAL OIL PUMP 1. Drain the engine oil. 2. Remove the drive belts. 3. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. 4. Remove the timing chain cover. 5.
  • Page 120 Inspect the threads and O-ring(C). Wipe off the seat on the oil filter cap, then apply a light coat of oil to the oil filter upper cap O-ring(C). (3) Install the new oil filter by hand to the upper cap. (4) After the rubber seal seats, tighten the oil filter clockwise.

  • Page 121: Selection Of Engine Oil

    1. Remove the relief plunger. Remove the plug(A), spring(B) and relief plunger(C). INSPECTION 1. Inspect the relief plunger. Coat the plunger with engine oil and check that it falls smoothly into the plunger hole by its own weight. If it does not, replace the relief plunger. If necessary, replace the front case. 2.

  • Page 122: Engine Oil

    For best performance and maximum protection of all types of operation, select only those lubricants which : •• Satisfy the requirement of the API classification. •• Have proper SAE grade number for expected ambient temperature range. Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.
  • Page 123 Install relief plunger(C) and spring(B) into the front case hole, and install the plug(A). Tightening torque : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lbf.ft)
  • Page 124 Engine Mechanical System Engine Mechanical System Intake And Exhaust System - Intake Manifold...
  • Page 125 2009 > D 1.6 TCI-U > COMPONENTS...

  • Page 126: Intake Manifold

    2009 > D 1.6 TCI-U > REMOVAL INTAKE MANIFOLD 1. Remove the engine harness protector(A) mounting bolts. Tightening torque : 7.8 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) 2. Remove the high pressure pipe(A). (Refer th FL Gr.) 3.
  • Page 127 5. Remove the intake manifold. Tightening torque : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) 6. Remove the intake manifold gasket(A). 7. Installation is in the reverse order of removal.
  • Page 128 Engine Mechanical System Engine Mechanical System Intake And Exhaust System - Exhaust Manifold...
  • Page 129 2009 > D 1.6 TCI-U > COMPONENTS...

  • Page 130: Exhaust Manifold

    2009 > D 1.6 TCI-U > REMOVAL EXHAUST MANIFOLD 1. Remove the heat protector(A). Tightening torque : 14.7 ~ 19.6 Nm (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft) 2. Remove the water hose (A) from the EGR cooler and the thermostat housing. 3.
  • Page 131 4. Remove the catalytic converter stay(A). Tightening torque : 21.6 ~ 27.5 Nm (2.2 ~ 2.8 kgf.m, 15.9 ~ 20.3 lb-ft) 5. Remove the catalytic converter(A). Tightening torque : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) 6.
  • Page 132 7. Remove the eye bolt(A) from the turbo charger oil feeding pipe. Tightening torque : 13.7 ~ 18.6 Nm (1.4 ~ 1.9 kgf.m, 10.1 ~ 13.7 lb-ft) 8. Remove the turbo charger(B) first and then exhaust manifold assembly(A). Tightening torque : 29.4 ~ 34.3 Nm (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) 9.
  • Page 133 10. Installation is in the reverse order of removal.

  • Page 134: Intake And Exhaust System

    Engine Mechanical System Engine Mechanical System Intake And Exhaust System -...
  • Page 135 2009 > D 1.6 TCI-U > COMPONENTS...
  • Page 136 THIS IS MADE BY FIXYOURCAR 2008@AOL.COM NO DUPLICATION ALLOWED!

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