Kia Sorento 2001 General Information Manual

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Model : SORENTO

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Page 1 General Information General Information Model : SORENTO...
Page 2 2001 > 1.8L DOHC > FUNDAMENTAL PROCEDURES There are six primary symbols used to complement illustrations. There symbols indicate the areas to apply such materials during service. Symbol Meaning Type New engine oil or gear oil as Apply oil appropriate Apply brake fluid Only brake fluid Apply automatic transmission fluid...
Page 3 present you from making an error that could damaged the vehicle. Warnings remind you to be especially careful in specific areas where carelessness can cause personal injury. The following items contain general procedures you should alwys follow when working on a vehicle : PROTECTION OF THE VEHICLE •...
Page 4 DISASSEMBLY 1. If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that assembly can be performed easily and efficiently. 2.
Page 5 1. Oil seals 2. O-rings 3. Cotter pins 4. Gaskets 5. Lock washers 6. Nylon nuts Depending on location: 1. Sealant should be applied or new gaskets used. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before assembly. ADJUSTMENT 1.
Page 6 When checking the engine control module (ECM), never use a bulb exceeding 3.4W. 2. Jumper Wire The jumper wire is used for testing by shorting across switch terminals and ground connections. Do not connect a jumper wire from the power source line to a body ground. Such a connection may cause damage to harnesses or electronic components.
Page 7 1. Battery Cable Before disconnecting connectors replacing electrical parts, disconnect the negative battery cable. CONNECTORS 1. Removal of connector (1) Never pull on the wiring harness when disconnecting connectors. (2) Connectors can be removed by pressing or pulling the lock lever.. 2.
Page 8 • Use a fine wire to prevent damage to the terminal. • Do not damage the terminal when inserting the tester lead. Terminals 1. Inspection Pull lightly on individual wires to ensure that they are secured in the terminal. 2. Replacement or terminals Use the appropriate tools to remove the terminal as shown.
Page 9 4. Wiring color codes. Two-color wires are indicated by two color code symbols. The first code symbol indicates the base color of the wire, and the second the color of the stripe on the base color. Code Color Code Color Black Orange Brown...
Page 10 (1) Jack position : At the center of the rear crossmember 4. Safety stand positions : (1) On both sides of the side sills VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS 1. Front end / Rear end Side sills (both sides) 2. Rear end Side sills (both sides) TOWING •...
Page 11 With either automatic or manual transmission : 1. Set the ignition switch in the ACC position. 2. Place the selector lever or shift lever in N (Neutral). 3. Release the parking brake. • Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transmission.
Page 12 LENGTH inch (") 25.4 millimeters (mm) foot (ft.) 0.3048 meters (m) yard (yd.) 0.9144 meters mile 1.609 kilometers (km) AREA inch² (in²) 645.2 millimeters² (mm²) 6.45 centimeters² (cm²) Foot² (ft²) 0.0929 meters² (m²) yard² (yd³) 0.8361 meters² (m²) VOLUME inch³(in³) 16387 mm³...
Page 13 Ω Ohms (resistance) psi (kPa) Pressure inHg (mmHg) Pressure (usually negative/vacuum) Watts (electrical power) US qt (liters) Volume in (mm) Length ABBEREVIATIONS ABDC After bottom dead center Anti-lock braking system Air conditioner Accessories Automatic transaxle ATDC After top dead center Automatic transmission fluid BBDC Before bottom dead center...
Page 14 Switch on Positive crankcase ventilation Power steering Pressure regulator control Power window Right hand Sequential fuel injection system Special service tool Switch Traction control unit Top dead center Tail number side Throttle position sensor Three way catalyst WU-TWC Warm-up three-way catalyst Scheduled maintenance services Follow schedule if the vehicle is mainly operated where none of the following conditions apply.
Page 17 Engine Electrical System Engine Electrical System General Information...
Page 18 2001 > 1.8L DOHC > GENERAL DESCRIPTION Ignition system overview The Dual Overhead Cam(DOHC) Engine Ignition System is now a Distributorless Ignition System(DLI) type. This system is similar to the one currently used on Sephia/Shuma vehicles. The key components of this system are : •...
Page 19 In a conventional ignition system, the ignition coil produces a high voltage current and the disributor thenrelays this current at the required time, to each spark plug. In the disctributirless ignition system, two sensors the camshaft position sensor and the crankshaft position sensor, tell the Engine Control Module (ECM) which cylinder is ready to fire. The ECM then sends an ignition signal to an electronic ignition coil.
Page 20 High-tension leads The high-tension leads connect the two ignition coils to the spark plugs. Their function is basically the same as on the previous system. Because of their shorter length, the DLI high-tension leads enhance the ignition systems delivered voltage. In addition, they reduce the wave interference from one high tension wire to another. Spark plugs The spark plugs provide the air gap necessary to produce an arc from the electrical energy coming in from the ignition coil.
Page 21 2001 > 1.8L DOHC > DIAGNOSIS Problem Possible Cause Action Engine control module detects fault Check engine module. Repair as Engine light is "ON" in system required Engine runs rough Spark plug failure Check, clean or replace plugs High-tension lead arcing to ground Replace high-tension leads Ignition coil(s) faulty Check/replace ignition coil...
Page 22 2001 > 1.8L DOHC > SPECIFICATIONS Fastener tightening specifications Item Ignition coil bolt 5~7.2 lb-ft (7~10N·m, 0.7~10kg-m) Spark plugs 18~22lb-ft (25-30N·m, 2.5~3.0kg-m) SPECIFICATIONS General specifications Item Engine idle speed 800 ± 50 rpm Ignition coil Type Dual coil Primary coil resistance 0.45~0.55Ω...
Page 23 Engine Electrical System Engine Electrical System Ignition System...
Page 24 Engine Electrical System Engine Electrical System Ignition System - Ignition Coil...
Page 25 2001 > 1.8L DOHC > INSPECTION Voltage check 1. Disconnect negative battery cable. 2. Disconnect ignition coil connector. 3. Turn ignition switch to "ON". 4. Measure voltage at red and blue wires at ignition coil connector. Voltage : approximately 12volts 5.
Page 26 REMOVAL 1. Disconnect battery cable. 2. Disconnect high-tension leads. 3. Disconnect ignition coil connector. 4. Remove four ignition coil mounting bolts. 5. Remove ignition coils. INSTALLATION 1. Position two coils above No. 2 and No. 4 spark plugs, and firmly push down to connect. 2.
Page 27 Engine Electrical System Engine Electrical System Ignition System - Spark Plug...
Page 28 2001 > 1.8L DOHC > REMOVAL Do not attempt any maintenance on spark plugs if engine is hot. 1. Disconnect negative battery terminal. 2. Carefulley remove high-tension leads. 3. Use compressed air to blow any dirt or debris from around spark plug hole. 4.
Page 29 C. Worn or burnt electrode. If present, replace plug. D. Broken or burned ceramic insulator. If present replace plug. E. Damaged spark plug ring. If so, replace ring. F. Improper spark plug gap. Regap if possible, otherwise replace plug. Gap : 0.027~0.031in (07~0.8mm)
Page 30 Engine Electrical System Engine Electrical System Ignition System - Spark Plug Cable...
Page 31 2001 > 1.8L DOHC > INSPECTION High-tension leads 1. Disconnect from coil spark plugs. 2. Check for breaks in insulation. 3. Check inside high-tension lead connectors for corrosion or carbon deposits. 4. Connect high-tension lead to an ohmmeter and check resistance. Resistance : 16kΩ...
Page 32 2001 > 1.8L DOHC > INSPECTION Ignition timing Ignition timing can be thrown off for two reasons : A problem with a sensor, which will be detected by ECM or a misalignment of camshaft to crankshaft. This last problem indicates a problem with timing belt, which is covered in Group Engine. There is no need to adjust engine timing after replacement of a coil.
Page 33 Engine Electrical System Engine Electrical System Charging System...
Page 34 2001 > 1.8L DOHC > CIRCUIT DIAGRAM The generator has a self-diagnostic function that illuminates the generator warning light when there is low or no voltage output generated by the charging system.
Page 35 Engine Electrical System Engine Electrical System Charging System - Alternator...
Page 36 2001 > 1.8L DOHC > REMOVAL 1. Removal negative battery cable. 2. Open B terminal cover cap. 3. Remove B terminal nut. 4. Remove B terminal lead. 5. Disconnect generator L and S terminal connectors. 6. Loosen pivot bolt and tensioner mounting bolt. Do not remove. 7.
Page 37 7. Adjust belt tension by rotating adjustment bolt. Allowable deflection : New belt : 0.23~0.31in (6~8mm) Old belt : 0.28~0.35in (7~9mm) 8. Tighten tensioner bolt. Tighten tensioner bolt to : 14~19lb-ft (19~26N·m) 9. Tighten pivot bolt and bracket bolt. Tighten pivot and bracket bolt to : 28~38lb-ft (38~51N·m) 10.
Page 38 2. Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear housing. If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear housing fit together very tightly.
Page 39 5. If necessary, remove front bearing using a socket and a hand press or vise. 6. Remove rear bearing with a bearing puller. 7. Remove B terminal nut and insulating bushing. 8. Remove five screws holding the rectifier and brush holder. 9.
Page 40 11. Replace brushes. Remove solder from pigtail and then remove brush. INSPECTION 1. Rotor (1) Measure resistance between slip rings with a ohmmeter. If it is not within standard resistance, replace rotor. Standard resistance : 3.5~4.5Ω (2) Check for continuity between slip ring and core with a circuil tester. Replace rotor if there is continuity. (3) If slip ring surface is rough, smooth with a lathe or fine sandpaper.
Page 41 (3) Check for continuity between stator coil leads and core with a circuit tester. (4) Replace stator if there is continuity. 3. Rectifier (1) Check for continuity between each diode with an ohmmeter. Negative (Black) Positive (Red) Continuity Pn, P₁,P₂,P₃ ○...
Page 42 4. Brush If brushes are worn to or beyond, limit. replace them. Standard : 0.85in (21.5mm) Minimum : 0.32in (8.0mm) 5. Brush spring (1) Measure force of brush spring with a spring pressure gauge. (2) Replace the spring if necessary. Standard force : 0.71~0.93lb-ft (3.1~4.1N·m, 0.32~0.42kg-m) Minimum : 0.36~0.52lb-ft (1.60~2.4N·m, 0.16~0.24kg-m) Read spring pressure with brush tip projecting 0.08in (2mm).
Page 43 (2) Replace bearing(s) of if there is any abnormality. RESSEMBLY 1. Assemble brush and solder pigtail so that wear limit line of brush projects 0.079~0.118in (2~3mm) out of brush holder. 2. Assemble regulator and solder with rectifier and stator leads. Disconnect quickly.
Page 44 Make sure groove on bearing rim is facing slip ring side. 7. Assemble front bearing. Using a socket which exactly fits outer race of bearing, carefully push in front bearing. Use a hand press or vise. Insert protective material in the jaws of the vise.
Page 45 Engine Electrical System Engine Electrical System Charging System - Battery...
Page 46 2001 > 1.8L DOHC > RECHARGING 1. Slow charging It is not necessary to remove vent caps to perform a slow charge. Battery Slow charge (A) Quick charge (A) PT48 - 24GL MF Under 5 Maximum 20 2. Quick charging Remove battery from vehicle and remove vent caps to perform a quick charge.
Page 47 2001 > 1.8L DOHC > INSPECTION Terminal and cable 1. Check that battery terminal connections are tight to ensure good electrical connections. 2. Check for corroded or frayed battery cables. 3. Check rubber protector on positive terminal for proper coverage. 4.
Page 48 2001 > 1.8L DOHC > Circuit operation When the ignition switch is turned to ON or START, battery voltage is applied to the charge indicator and terminals B and S of the alternator. After the engine has started and is running, the generator produces alternating current.
Page 49 2001 > 1.8L DOHC > COMPONENTS...
Page 50 2001 > 1.8L DOHC > DIAGNOSTIC CHART Step Inspection Action Go to next step. Check battery voltage Specification : Above 12.4V Check battery Go to step 4. Start engine and check if generator warning light goes out Go to next step. Check if voltage at generator terminals are correct Check wiring harness between battery...
Page 51 2001 > 1.8L DOHC > INSPECTION 1. Check drive belt and pulley for wear, cracks, and fraying. Replace if necessary. 2. Measure drive tension with a tension gauge. Tension Drive belt Used Generator 85.8~103.4 (383~461N) 68.2~85.8lb (304~383N) A/C and P/S 110~132lb (491~589N) 95~110lb (422~491N) 3.
Page 52 5. Tighten all bolts to specification torque. Tightening torque Mounting bolt : 27~38lb-ft (37~52N·m, 3.8~5.3kg-m) Adjusting bolt : 14-18lb-ft (19~26N·m, 1.9~2.6kg-m) 6. Install A/C and P/S drive belt, if equipped, and adjust to specification.
Page 53 2001 > 1.8L DOHC > SPECIFICATION Generator Engine Item Battery Voltage Type PT48-24FL Capacity (20-hour rate) 60A-h Current draw* Maximum 20-0 Generator Type Output 12V-80A Regulator type Transistorized (Built-in IC regulator) Regulator voltage 14.1 - 14.7 Brush length Standard 0.846in (21.5mm) Minimum 0.315in (8.0mm) * Current draw is the residual flow of current that occurs when the ignition switch is OFF.
Page 54 Engine Electrical System Engine Electrical System Starting System...
Page 55 Engine Electrical System Engine Electrical System Starting System - Starter...
Page 56 2001 > 1.8L DOHC > COMPONENT...
Page 57 2001 > 1.8L DOHC > REMOVAL 1. Disconnect negative battery terminal. 2. Remove two upper intake manifold support bracket bolts. 3. Disconnect S terminal connector. 4. Disconnect B terminal connector. 5. Remove two upper starter bolts. 6. Raise vehicle support with safety stands. 7.
Page 58 8. Remove lower intake manifold support bracket bolt. 9. Remove intake manifold support bracket. 10. Remove lower starter bolt. 11. Remove starter. INSTALLATION 1. Place starter in engine. 2. Insert lower starter bolt and tighten. Tightening torque : 27~38lb-ft (37~52N·m, 3.7~5.3kg-m)
Page 59 3. Connect B terminal connector and tighten. Tightening torque : 7.2~8.9N·m, 1~1.2kg-m) 4. Connect S terminal connector. 5. Place intake manifold support bracket. 6. Insert three intake manifold support bracket bolts. and tighten lower intake manifold support brake bolts. Tightening torque : 27~38lb-ft (37~52N·m, 1~1.2kg-m) 7.
Page 60 B : 51~69lb-ft (69~94N·m, 6.9~9.4kg-m) C : 15.2~20.2lb-ft (20.6~27.4N·m, 2.8kg-m) 8. Lower vehicle. 9. Tighten two upper intake manifold support bracket bolts. Tightening torque : 27~38lb-ft (37~52N·m, 1~1.2kg-m) 10. Place two starter bolts and tighten. Tightening torque : 27~38lb-ft (37~52N·m, 1~1.2kg-m) 11.
Page 61 If pinion depth shims are found between soleniod and drive end housing, remove them and set aside. 3. Remove solenoid screws and magnetic switch. 4. Remove solenoid plunger spring. 5. Disengage plunger from lever and remove plunger. 6. Remove bolts from rear cover. Separate motor assembly from drive end housing. Also separate motor assembly from planetary gear set, if present.
Page 62 8. Drive stopper from snap ring using a deep well socket or similar tool. 9. Remove snap ring from its groove in pinion shaft. 10. Remove stopper and drive pinion from pinion shaft. 11. Remove two brush plate screws and rear cover. 12.
Page 63 INSPECTION 1. Solenoid (1) Check for continuity between S and M terminals with ohmmeter. Replace solenoid if there is no continuity. (2) Check for continuity between S terminal and solenoid body with ohmmeter. Replace solenoid if there is no continuity. (3) Check continuity between M and B terminal with ohmmeter.
Page 64 3. Brush If brush is worn to the wear limit, replace all brushes. Standard : 0.67in (17mm) Wear limit : 0.45in (11.5mm) 4. Field coil (1) Check for continuity between M terminal wire and brushes with ohmmeter. Replace yoke assembly if there is no continuity.
Page 65 (2) Check continuity between commutator and shaft with ohmmeter. Replace armature if there is continuity. (3) Place armature on V-blocks, and measure runout with a dial indicator. if runout is not within specification, repair armature with a lathe or replace armature. Runout : 0.002in (0.05mm) Maximum : 0.016in (0.4mm) (4) Replace armature if diameter or commutator mutator is at, or less than, grind limit.
Page 66 REASSEMBLY 1. Reassembly armature washers to the end of armature. 2. Reassembly armature in field coil housing. 3. Reassembly rear cover and tighten two brush two bruch plate screws. Tightening torque : 1.7~3.2lb-ft (2.4~4.4N·m) 4. Reassembly drive pinion and stopper on pinion shaft. 5.
Page 67 8. If present, reassembly planetary gear set to motor assembly. 9. Reassembly motor assembly in drive end housing. 10. Place bolts in rear cover and tighten. Tightening torque : 2.8~5.2lb-ft (3.8~7.1N·m, 0.39~0.72kg-m) 11. Engage plunger in lever. 12. Insert solenoid plunger spring. 13.
Page 68 Be careful not to let electricity flow continuously for more than 10 seconds. 16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers used between ordecreasing the number of washers used between solenoid and drive housing. The gap will become smaller if the number of washers increased.
Page 69 2001 > 1.8L DOHC > Circuit operation Battery voltage is at all times applied from the positive battery terminal to the ignition switch and the normally open starter solenoid contacts. When the ignition switch is turned to START and the transaxle is in park or neutral (automatic transaxle), battery voltage is applied to the starter solenoid coils.
Page 70 2001 > 1.8L DOHC > COMPONENTS...
Page 71 2001 > 1.8L DOHC > SYMPTOM GUIDE Will not crank-starter motor does not operate Will not crank-starter motor spins Cranks slowly Generator warning lights illiminates with engine running Discharged battery Misfire Synptom troubleshooting Will not crank-starter motor dose not operate Step Inspection Action...
Page 72 Step Inspection Action Check charging system. Check if engine cranks normally when fully charged. Go to next step. Check starter cable connection for Repair or replace connection. looseness and corrosion. Check for seized motor armature. Repair or replace as necessary. Generator warning lamp illuminates with engine running Step Inspection...
Page 73 2001 > 1.8L DOHC > INSPECTION 1. Disconnect starter clutch pedal position switch connector. 2. Connector an ohmmeter to switch connector. 3. Check continuity. Clutch pedal position Continuity Depressed Released 4. Replace switch if continuity is not as specified.
Page 74 Engine Mechanical System Engine Mechanical System...
Page 75 Engine Mechanical System Engine Mechanical System General Information...
Page 76 2001 > 1.8L DOHC > SPECIAL SERVISE TOOLS Tool (Number and name) Illustrator Used OK130 990 007 Used to disassemble and assemble Engine stand engine. OK710 101 002 Used to disassemble and assemble Hanger, engine stand engine. OK201 170 AA0 Used to remove engine Support, engine OK590 111 001...
Page 77 OK201 120 001 Used to replace valve seal and Valve spring compressor hook valve spring OK993 120 006 Used to remove valve seal Remover, valve seal OK2CA 120 005I(Intake)/OK2CA 120 005E(Exhaust) Used to install valve seal Installer, valve seal OK2CA 111 001 Used to Prevent camshaft pulley Holder, camshaft pulley rotation.
Page 78 OK130 283 021 Used to remove tie-rod end. Puller, ball joint...
Page 79 2001 > 1.8L DOHC > DESCRIPTION The TBD engine is a 4cylinder overhead dual camshaft engine with a compression ratio of 9.5 : 1.
Page 80 2001 > 1.8L DOHC > DIAGNOSTIC CHART Engine Problem Possible cause Action Engine will not crank Battery starting system or other Refer to starting system, charging electrical problems system, wiring Diagram Remove with suction gun, then crank Liquid combustion chamber engine over with spark plugs removed Seized engine...
Page 81 gasket Valve train noise Worn valve guides Repair Low oil pressure Refer to lubrication system Improper valve clearance Check HLA's Broken valve spring Replace Sticking valves Free valves Camshaft worn or faulty Replace Insufficient power Insufficient compression caused by : 1.
Page 82 Engine knocks when cold Execcive piston to wall clearance Replace pistons Loose or broken damper pulley Tighten or replace Knock increases with torque Excessive piston to bore clearance Replace piston Bent connecting rod Replace Engine has heavy knock when Broken damper pulley Replace hot and torque is applied Accessory belts too tight or damaged Adjust or replace belt...
Page 83 Remove tensioner spring and inspect Excessive belt tension Replace if necessary Oil or coolant is on the belt Inspect front oil seals Poor oil sealing Replace if necessary Inspect water pump Coolant leak at water pump Replace if necessary Remove timing belt cover and Poor belt cover sealing inspect Replace if necessary...
Page 84 Problem Possible cause Action Engine hard starting Improper engine oil Replace Insufficient engine oil Add oil Excssive oil consumption Internal wear : Worn rings worn valve guides, worn valve seals or failed Replace cylinder head gasket Oil leak Repair Oil pressure drop Insufficient oil Add oil Oil leakage...
Page 85 2001 > 1.8L DOHC > ENGINE TUNE-UP Ignition timing 1. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. 3. Connect the timing light to to No. 1 high-tension cord. 4. Check that the timing mark (white) on the crankshaft pulley and the timing mark on the timing belt cover are aligned. Ignition timing : 8°...
Page 86 (3) Check the installation condition of crank angle sensor A. Clearance : 0.019~0.059in (0.5~1.5mm) B. Check the alignment between crank angle sensor and target wheel. Compression If the engine exhibits low power, poor fuel econmy or poor idle check the following. 1.
Page 87 3. Drain engine coolant. 4. Remove data link connector upward from mass airflow sensor bracket. 5. Disconnect intake air temperature sensor connector and mass air flow sensor connector. 6. Disconnect air intake hose from throttle body. 7. Remove fresh air duct with two nuts. 8.
Page 88 13. Remove heater hoses. 14. Disconnect fuel hose from injector rail. KEEP OPEN FLAMES AND SPARKS AWAY FROM OPEN FUEL LINES OR A FIRE OR EXPLOSION MAY RESULT. 15. Disconnect IAC and throttle position sensor TPS connectors. 16. Disconnect injector connectors. 17.
Page 89 19. Disconnect generator B-terminal connector and C121 from generator. 20. Remove both right and left splash with three bolts and three fasteners each. 21. Loosen power steering pump lock bolt (A), nut (B), (C) and remove tension from power steering (P/S) pump and/or air conditioning (A/C) compressor drive belt by turn adjusting bolt(D).
Page 90 26. Remove four A/C compressir bolts and remove A/C compressor. 27. Position A/C compressor away from engine and affix it with wire. 28. Disconnect ground strap from top of transaxle. 29. Disconnnect input/turbine speed sensor connector(A/T). 30. Disconnect back-up light switch connector (M/T). 31.
Page 91 32. Remove U-clop from selector cable to transaxle linkage (A/T). 33. Remove nut and washer from transaxle linkage(A/T). 34. Remove manual transaxle linkage and extension bar (M/T). 35. Remove clutch release cylinder and pipe (M/T). 36. Disconnect transaxle ranges switch connector (A/T). 37.
Page 92 43. Remove both right and left stabilizer control link from bracket aggached to shock absorber after remove the control link nut. 44. Remove pinch bolt and nut from both right and left ball joints. 45. Remove both right and left ball joints from steering knuckles. 46.
Page 93 48. Remove two nuts from No.2 engine mount-to-mounting member. 49. Remove two and two nuts, then remove mounting member. 50. Remove three No.1 engine mount bolts. 51. support engine with engine hoist and floor jack. 52. Remove one bolt and one nut, then remove dynamic damper. 53.
Page 94 54. Remove three nuts from No. 4 engine mount. 55. Slowly lower engine/transaxle assembly under the engine room with engine hoist and floor jack. Be careful not to hurt the any other parts in the engine room. 56. Remove converter housing access cover and remove four drive plate-to-torque converter mounting nuts. Rotate at crank pulley to gain access to all four nuts.
Page 95 INSTALLATION Engine 1. Install transaxle to engine. Tightening torque : 4 Upper bolts (1, 2, 3, 4) : 65.8~86.1lb·ft (89~116N·m, 9.1~11.9kg-m) 4 Lower bolts (5, 6, 7, 8) : 27.5~38.3lb·ft (37~52N·m, 3.8~5.3kg-m) 2. Install starter. Tightening torque : 27~38lb·ft (37~52N·m, 3.7~5.8kg-m) 3.
Page 96 4. Slowly raise engine/transaxle assembly into the engine room with floor jack and engibe hoist. Be careful not to hurt the any other parts in the engine room. 5. Install three nuts to nut No. 4 engine mount. Tightening torque : Nut : 49.2~68.7lb·ft (66.7~93.2N·m, 6.8~9.5kg-m) Bolt : 47.0~65.8lb·ft (63.8~89.3N·m, 6.5~9.1kg-m) 6.
Page 97 8. Remove engine hoist and floor jack. 9. Install three No. 1 engine mount bolts. Tightening torque : 49.2~68.7lb·ft (66.7~93.2N·m, 6.8~9.5kg-m) 10. Install mounting member. Tightening torque : Mounting member bolts and nuts : (A) : 47.0~65.8lb-ft (63.8~89.3N·m, 6.5~9.1kg-m) No. 2 engine mount-to-mounting member nuts : (B) : 27.5~38.3lb·ft (37.3~51.9N·m, 3.8~5.3) 11.
Page 98 12. Install new clips on driveshaft. 13. Push driveshafts into transaxke with openng of clips pointing upward. 14. Install both right and left ball joint into steering knuckles then install pinch and nut. Tightening torque : 32~39lb·ft (43~52N·m, 4.4~5.3kg-m) 15. Install both right and left stabilizer control link to bracket attached to shock absorbar. Tightening torque : 31.8~44.8lb·ft (43.2~60.8N·m, 4.4~6.2kg-m) 16.
Page 99 20. Connect two ATF cooler hose (A/T). 21. Connect solenoid valve connector (A/T). 22. Connect transaxle range switch connector (A/T). 23. Install clutch release cylinder with two bolts and attach pipe to U-clip. Tightening torque : 13.7~18.8lb·ft (18.6~25.5N·m, 1.9~2.6kg-m) 24. Install manual transaxle linkage and extension bar (M/T). 25.
Page 100 30. Connect ground strap to top of transaxle. 31. Install A/C compressor with four bolts. Tightening torque : 28.2~38.3lb·ft (38.3~51.9N·m, 3.9~5.3kg-m) 32. Connect lower radiator hose. 33. Install P/S pump. 34. Install P/S pump and/or A/C compressor drive belt. 35. Adjust the belt deflection by turning the adjusting bolt (D). Belt deflection : New : 0.32~0.35in (8.0~9.0mm) Used : 0.35~0.39in (9.0~10.0mm)
Page 101 37. Install both right and left splash shield with three bolts and three fasteners each. Tightening torque : 10.1~11.6lb·ft (13.7~15.7N·m, 1.4~1.6kg-m) 38. Connect generator B-terminal connector and connector C121 from generator. 39. Connect engine ground strap. 40. Install connector bracket and connectect electric connectors.
Page 102 41. Connect injector connectors. 42. Connect IAC and throttle position sensor (TPS) connectors. 43. Connect fuel hose to injector rail. 44. Connect heater hoses. 45. Connect upper radiator hose. 46. Connect purge vacuum (PCV) hose to charcoal canister.
Page 103 47. Connect brake vacuum hose to brake master vac. 48. Install air cleaner assembly with two bolts and one nut. 49. Connect air intake hose to throttle body. 50. Install accelerator cable and cruise control cable if equipped. 51. Check accelerator cable deflection. If deflection is not correct, adjust by turning nut (A). Deflection : 0.04~0.12in (1~3mm) 52.
Page 104 1. Remove exhaust manifold and coolant bypass pipe. 2. Install engine to SST. 3. Drain engine oil. 4. Remove front and rear engine hangers. 5. Remove generator by loosening adjusting bolt and removing bolts and pivot bolt. 6. Remove intake manifold support bracket.
Page 105 7. Remove intake manifold. 8. Remove HLA's. 9. Store HLA's upside down is an oil filled container. 10. Loosen cylinder head bolts in two or three steps following order in figure. 11. Remove cylinder head by lifting it off from cylinder block. 12.
Page 106 14. Remove valve seals with SST or equivalent. 15. Repeat same procedure on all 16 valves. 16. Keep valves in correct order if they are to be reused. 17. Mark cylinder so that valves can be installed to their original positions. 18.
Page 107 25. Remove oil pan mounting bolts. 26. Remove oil pan with a screwdriver or suitable tool as shown in figure. • Do not force tools between cylinder block and oil pan as this may damage sealing surface. • Do not damage sealing surface when removing old sealant. 27.
Page 108 31. Remove rear cover. 32. Wrap a prying with a shop towel and slowly pry out rear oil seal. 33. Remove water pump. 34. Remove oil filter and oil pressure switch. 35. Check top of each cylinder for ridages. Failure to remove a ridage before removing piston will result in damaged ring-lands, cracked piston rings, or cracked piston.
Page 109 37. Rotate engine block so that crankshaft is at Top Dead Center (TDC). 38. Rotate crankshaft so that No.1 and No. 4 cylinders are at Bottom Dead Center (BDC). 39. Use a numbering starmp and mark rod cap and connecting rod their cprresponding cylinder number. Mark all rods on same side amd make a reference mark on block so that rods are installed in correct position and direction.
Page 110 49. If connecting rod does not move freely, check piston pin bore and connecting rod for straighness and deformation. 50. Remove piston pin clip from ends of piston pin bore. 51. Tilt piston pin clip to slide put to slide into your hand. Piston pins may need to be pressed out. Do not allow pins to drop to the ground.
Page 111 5. Install 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. Verify that piston and rod are assembled in same direction as they were prior to disassembly. 6.
Page 112 12. Align piston rin gaps as shown. 13. Inspect journals and bearing for any foreign material. Clean cranksjaft. Oil holes and main bearing jounrals thoroghly and dry components with compressed air. 14. Install grooved main bearing into saddles on engine block. 15.
Page 113 Do not rotate crankshaft with Plastigage® on crankshaft journals. 21. Remove main bearing cap and check bearing clearance. The widest point of Plastigage® is the smallest clearance, and the narrowest point of Plastigage is the largest clearance. 22. If oil clearance exceeds specification grind and polish crankshaft and use undersized main bearings. Oil clearance : 0.00095~0.00165in (0.024~0.042mm) 23.
Page 114 28. Rotate crankshaft to ensure it does not bind. 29. Place a dial indicator against front of cranksjaft and zero gauge. 30. Using a prying tool move crankshaft forward and zero dial indicator. 31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator. End play : 0.0032~0.0111in (0.080~0.282mm) 32.
Page 115 39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft. Follow thos procedure for remaining piston and connecting rod assembles. 40. Install a connecting rod bearing in each connecting rod cap. 41.
Page 116 connecting rod side clearance. Do not measure between connecting rod cap and crankshaft. Side clearance : 0.0044~0.0103in (0.110~0.262mm) Maximum : 0.012in (0.30mm) 49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap. 50. Apply a light coat of clean engine oil to rear oil real. 51.
Page 117 58. Press oil seal by hand. Oil seal must be pressed in untilit is nearly flush with front surface of oil pump body. Protrusion : -0.02~0in (-0.5~0mm) 59. Install a new O-ring seal. 60. Apply a besed of siloone sealant to oil pump body as shown. Thickness : ø0.04~0.08in (1~2mm) Oil pump body must be installed with 5 minutes after slicone sealant os applied.
Page 118 67. Install oil filter rubber seal contacts base amd then tghten filter 1 and 1/6 turn using an oil filter wrench. 68. Install oil strainer with a new gasket. Tightening torque : 5.8~8.7lb·ft (7.8~11.8N·m, 0.8~1.2kg-m) 69. Remove all foreign material from gasket surface. 70.
Page 119 73. Install separator plate onto cylinder block. Tightening torque : 13.7~22.4lb·ft (18.6~30.4N·m, 1.9~3.1kg-m) 74. Install flywheel (M/T) or drove plate/backing plate/adapter(A/T) assembly onto crankshaft. 75. Install bolts (apply sealant to reused bolts.) 76. Install locking tool. 77. Tighten bolt in two or three steps to the specified torque. Tightening torque : 71~75.9lb·ft (97~103N·m, 9.8~10.5kg-m) 78.
Page 120 Using a hammer will damage valve seals. 82. Remove the valve guide seal installer. 83. Install lower spring seat on cylinder head. 84. Install HLA protector SST if available. 85. Install valve spring with narrow spring coils (B) toward cylinder head and wider coils (A) toward upper spring seat. 86.
Page 121 C. Retighten cylinder head bolts in order shown. Tightening torque : 28.9lb·ft (39.2N·m, 4kg-m) D. Mark cylinder head bolts for rotational reference. E. Rotate cylinder head bolts 90° (1/4turn) in order shown. F. Rotate cylinder head bolt another 90° (1/4turn) in order shown. 94.
Page 122 Belt deflection : New : 0.24~0.32in (6.0~8.0mm) Used : 0.28~0.35in (7.0~9.0mm) 100. Tighten the mounting bolts (A), (B) Tightening torque : (A) : 27~38lb·ft (37~52N·m, 3.8~5.3kg-m) (B) : 14~19lb·ft (19~52N·m, 4kg-m) 101. Install front and rear engine hangers. 102. Hang engine with baby crane from engine stand. 103.
Page 123 2001 > 1.8L DOHC > SPECIFICATION Engine Engine model Item Type Gasoline, 4 cycle Cylinder arrangement and number In line, 4 cylinder Combustion chamber Pentroof Valve system DOHC, belt driven (IN : 2, EX : 2) Displacement 109.4cu-in (1,793cc) Bore and stroke 3.19×3.43in (81.0×87.0mm) Compression ratio 9.4 : 1...
Page 124 Heat dissipation capacity kcal/h 46,000 Type Double tube type Automatic transaxle Heat oil cooler dissipation 1,700 capacity kcal/h Type Electric Number of blades Cooling fan Outer diameter in(mm) 12.6 (320) Capacity W-V 160-12 Current A Lubrication system Item Specifications (TBD Engine) Lubrication system Force-fed type Oil pump...
Page 125 Engine Mechanical System Engine Mechanical System Timing System - Timing Belt...
Page 126 2001 > 1.8L DOHC > COMPONENTS...
Page 127 2001 > 1.8L DOHC > REMOVAL 1. Disconnect negative battery cable. 2. Remove right splash shield with three bolts and three fasteners. 3. Loosen power steering pump lock bolt (A), nuts (B), (C) and remove tension from power steering (P/S) pump and/or air conditioning (A/C) compressor drive belt by turn adjusting bolt (D).
Page 128 7. Remove generator drive belt. 8. Remove water pump pulley. 9. Remove four crankshaft pulley bolts and timing belt pulley lock bolt. 10. Remove crankshaft pulley and timing belt guide plate. 11. Reinstall timing belt pulley lock bolt. 12. Support engine with engine support bar SST (OK201 170 AA0). 13.
Page 129 14. Remove two No. 3 engine mount. 15. Remove generator bracket bolt. 16. Remove No. 3 engine mounting bracket with three bolts. 17. Remove upper and lower timing belt covers. 18. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
Page 130 19. 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. Do not move camshaft or crankshaft once timing marks have been correctly positioned. Prevent camshaft pulley rotation with SST (OK2CA 111 001).
Page 131 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. If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal. Prevent camshaft pulley rotation with SST (OK2CA 111 001).
Page 132 4. Install timing belt onto belt pulley first, then idler pulley exhaust camshaft pulley, intake camshaft pulley and tensioner pulley in that order. 5. Check that there is no loosensess in belt betweb idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys.
Page 133 10. If they are not aligned, remove timing belt and start process from tensioner installation. 11. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is not correct, repeat from tensioner installation. Deflection pressure : 22lb (98N, 10kg) Deflection : 0.36~0.45in.
Page 134 15. Tighten two nuts to No. 3 engine mount. Tightening torque : 54.2~75.9lb·ft (73.6~103N·m, 7.5~10.5kg-m) 16. Install dynamic damper. Tightening torque : 40.5~53.9lb·ft (54.9~80.4N·m, 5.6~8.2kg-m) 17. Remove timing belt pulley lock bolt. 18. Install timing belt guide plate and crankshaft pulley. 19.
Page 135 20. Install water pump pulley. Tightening torque : 6.5~9.4lb·ft (8.8~12.8N·m, 0.9~1.3kg-m) 21. Install generator drive belt. 22. Adjust the belt deflection by turning the adjusting bolt (C). Belt deflection New : 0.24~0.32in (6.0~8.0mm) Used : 0.28~0.35in (7.0~9.0mm) 23. Tighten the mounting bolt (A), (B). Tightening torque : (A) : 28~38lb·ft (37~52N·m, 3.8~5.3kg-m) (B) : 14~19lb·ft (19~25.4N·m, 1.9~2.6kg-m)
Page 136 26. Tighten the bolt (A), nut (B), nut (C). Tightening torque : (A) : 27~40lb·ft (36~52N·m, 3.7~5.5kg-m) (B) : 14~19lb·ft (19~25N·m, 1.9~5.2kg-m) (C) : 23~34lb·ft (31~46N·m, 3.2~4.7kg-m) 27. Instakk right splish shield with three bolts and three fasteners. Tightening : 10.1~11.6lb·ft (13.7~15.7N·m, 1.4~1.6kg-m) 28.
Page 137 2. Check timing belt for uneven wear, fraying, peeling, cracking and harding. Replace timing belt as necessary. 3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25mm). 4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation. 5.
Page 138 2. Check the timing belt for damage, wear, peeling, cracking and hardening. Replace timing belt if necessary. Timing belt tenioner pulley and idler pulley Do not clean tensioner pulley or idler pulley with cleaning fluids. If needed, use a soft rag to wipe tem clean.
Page 139 Do not clean pulleys with cleaning fluids. If needed use a soft cloth to wipe them clean, and avoid scratching the pulleys as it will affect integrity of the timing belt. 1. Check pulley teeth for wear deformities and other damage. Replace pulleys if necessary.
Page 140 Engine Mechanical System Engine Mechanical System Cylinder Head Assembly - Valve...
Page 141 2001 > 1.8L DOHC > REMOVAL 1. Driain engine coolant. 2. Remove timing belt. (Refer to Timing belt removal) 3. Remove center cover. 4. Remove ignition coils and high-tension cords. 5. Disconnect PCV hose and ventilation hose. 6. Remove accelerator cable and cruise control cable if equipped. 7.
Page 142 10. Remove upper radiator hose. 11. Remove heater hoses. 12. Disconnect fuel hose from injector rail. KEEP OPEN FLAMES AND SPARKS AWAY FROM OPEN FUEL LINES OR A FIRE OR EXPLOSION MAY RESULT. 13. Disconnect IAC and thorttle position sensor (TPS) connectors. 14.
Page 143 15. Disconnect electric connectors and remove connector bracket. 16. Disconnect engine ground strap. 17. Remove exhaust manifold heat shield. 18. Remove front exhaust pipe. 19. Remove exhaust manifold pipe. 20. Remove coolant bypass pipe.
Page 144 21. Remove intake manifold support bracket. 22. Remove cylinder head cover. Align camshaft and crankshaft timing alignment marks. 23. Loosen cylinder head bolts in two or three steps following order shown in figure.
Page 145 24. Remove cylinder head. INSTALLATION 1. Install new cylinder head gasket onto cylinder block and lower cylinder onto engine. 2. Install cylinder head bolts. 3. Tighten cylinder head bolts according to following procedurw : A. Tighten cylinder head bolts in order shown. B.
Page 146 5. Install intake manifold support bracket. Tightening torque : (A) : 11.6~16.6lb·ft (15.7~22.5N·m, 1.6~2.3kg-m) (B) : 26.8~39.8lb·ft (36.3~53.9N·m, 3.7~5.5kg-m) 6. Install coolant bypass pipe. 7. Install exhaust manifold pipe. Tightening torque : 28~34lb·ft (38~46N·m, 3.9~4.7kg-m) 8. Install front exhaust pipe. Tightening torque : (A), (B) : 27.5~38.3lb-ft (37.3~51.9N·m, 3.8~5.3kg-m) (C) : 31.1~44.8lb-ft (42.2~60.8N·m, 4.3~6.2kg-m)
Page 147 9. Install exhaust manifold heat shield. Tightening torque : 13.7~18.8lb·ft (18.6~25.5N·m, 1.9~2.6kg-m) 10. Reconnect engine ground strap. 11. Install connector bracket and connect electrical connectors. Tightening torque (engine hanger bolt): 27.5~38.3lb·ft (37.2~51.9N·m, 3.8~5.3kg-m) 12. Connect injector connectors.
Page 148 13. Connect IAC and throttle position sensor (TPS) connectprs. 14. Connect fuel hose to fuel injector rail. 15. Install heater hoses. 16. Install upper radiator hose. 17. Connect purge control vacuum (PCV) hose to charcoal canister. 18. Connect brake vacuum hose to brake master vac.
Page 149 19. Install air intake hose and freash air duct. 20. Install accelerator cable and cruise control cable if equipped. 21. Check accelerator cable deflection. If deflection is not correct adjust by turning nut/ (A). Deflection : 0.04~0.12in (1~3mm) 22. Connect PCV hose and ventilation hose. 23.
Page 150 27. Start engine and check for oil and coolant leaks. INSPECTION Cylinder head and cylinder head gasket 1. Check cylinder head gasket for obvious signs of leakage, coolant stains on gasket, or combustion burns across cylinder. 2. Clean cylinder head and cylinder block mounting surfaces of all gasket material. Do not allow gasket material to fall oil pressages or oil control plug.
Page 151 If cylinder head requires machining, remove intake and exhaust manifolds and check their mount surfaces for straightness. 7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure. Distortion : 0.008in (0.20mm) Maximum 8. If distortion exceeds specification resurface or replace cylinder head. Maximum material removal : 0.008in (0.20mm) 9.
Page 152 3. Grind cylinder head mating surface if distortion exceeds specification. Distortion : 0.004in (0.10mm) maximum 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. Height : 5.272~5.28in (133.9~134.1mm) 6.
Page 153 Engine Mechanical System Engine Mechanical System Cylinder Head Assembly - Cylinder Head...
Page 154 2001 > 1.8L DOHC > REMOVAL Valve seal 1. Removal HLA. 2. Set piston to TDC position for removing valve seal by rotate crankshaft. If timing mark on crankshaft pulley is aligned with timing mark on engine No.1 and No.4 piston are located on TDC position.
Page 155 Intake and exhaust valve seals are different. Only exhaust valve seals have four teeth. Using a hammer will damage valve seals. 2. Install valve spring with narrow spring coil (B) toward cylinder head. 3. Install upper spring seat and compress valve spring with SST(OK2CA 120 AA0, OK2CA 120 001). 4.
Page 156 3. Measure length of each valve. Length Intake : 4.052in (1.2mm) Exhaust : 0.0472 (1.2mm) 4. Measure diameter of each valve stem. Diameter Intake : 0.2350~0.2356in (5.970~5.985mm) Exhaust : 0.2348~0.2354in (5.965~5.980mm) 5. Measure inside diameter of each valve guide at points shown in figure. Diameter intake and exhaust valve guide : 0.2367~0.2374in (6.01~6.03mm) 6.
Page 157 Intake valve : 0.0019~0.0023in (0.05~0.0023in (0.05~0.060mm) Exhaust valve : 0.0012~0.0025in (0.030~0.065mm) Max : 0.008in (0.20mm) 7. If clearance exceeds specification, replace valve and or valve guide. 8. Measure protrusion height of each valve guide. Replace valve guide as needed. (A) : Intake : 0.539~0.536in (13.7~14.3mm) (B) : Exhaust : 0.658~0.681in (16.7~17.3mm) Intake and exhaust valve guides are different.
Page 158 2. Resurface valve seats with a 45° valve seat cutter. Resurface valve faces as needed. 3. Apply a coat of Dychem blue to valve face and valve seat amd allow to dry. 4. Inspect valve seating by pressing valve against seat and rotating valve 360°. A.
Page 159 Clean valves thoroughly before reassembly and insure that all traces of lapping compound has been removed. 9. Check for valve sink by measuring protruding length (Dimension L) of valve stem to lower valve spring seat. Dimension L measurement Action IN : 1.432~1.467in (36.37~37.27mm) No correction needed EX : 1.431~1.467in (36.36~37.26mm) IN : 1.467~1.495in (37.27~37.97mm)
Page 160 Runout : 0.0012in (0.03mm) maximum 4. Check camshaft for even wear patterns, cracks, or damage. 5. Measure cam lobe heights at two points as shown. Lobe height Intake : 1.6415in (41.6949mm) Exhaust : 1.6629in (42.2369mm) 6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in figure.
Page 161 15. Loosen camshaft cap bolts in five or six steps in order shown. 16. Remove camshaft caps. 17. Measure oil clearance. Oil clearance : 0.0014~0.0031in (0.035~0.081mm) Maximum : 0.006in (0.15mm) 18. If oil clearance exceeds specification, replace cylinder head. 19. Install camshafts. 20.
Page 163 Engine Mechanical System Engine Mechanical System Cylinder Head Assembly - HLA ( Hydraulic Lash Adjuster )
Page 164 2001 > 1.8L DOHC > REMOVAL 1. Remove timing belt. (Refer to timing belt removal) 2. Remove center cover. 3. Remove ignition coils and high-tension cords. 4. Disconnect PCV hose and ventilation hose. 5. Remove cylinder head cover. 6. Remove camshaft pulleys. 7.
Page 165 8. Remove camshafts. 9. Mark HLA's to identify their original position if they will be reused. Hydraulic Lash Adjusters (HLA) must be installed on location from which they were removed. Failure to install HLA's in their original location woll result in premature and uneven wear of HLA's and camshaft. 10.
Page 166 4. Apply clean engine oil to camshaft and camshaft bearing surfaces and install camshaft so that camshaft dowel pins point straight up. 5. Install camshaft bearing caps according to cap number with the directional arrows pointing forward. 6. Install bolts to camshaft bearing caps and tighten in five or six steps in order shown in figure. Tightening torque : 8.32~10.49lb·ft (11.28~14.22N·m, 1.15~1.45kg-m) 7.
Page 167 12. Install high tension cords and ignition coils. 13. Install center cover. Tightening torque : 2.9~5.1lb·ft (3.9~6.9N·m, 0.4~0.7kg-m) 14. Connect negative battery cable. (Refer to Timing belt replacement) INSPECTION 1. Check HLA face for wear or damage, and replace if necessary. 2.
Page 168 4. Measure HLA diameters (X and Y directions) at two points (A and B) as shown. Dimeter : 1.1795~1.1801in (29.959~29.975mm) 5. Calculate clearance between HLA diameter and related HLA bore. Replace HLA and/or cylinder head if necessary. Clearance : 0.00099~0.00259in (0.025~0.066mm) Maximum : 0.0071in.
Page 169 2001 > 1.8L DOHC > COMPONENT...
Page 170 Engine Mechanical System Engine Mechanical System Cylinder Block - Piston and Connecting Rod...
Page 171 2001 > 1.8L DOHC > INSPECTION Piston cooling jets 1. Apply compressed air to each piston cooling jet valve at (A) and verify that air passes through piston cooing jet valve at (B). if air dose not pass replace piston cooling jet valve. Air pressure : 24.2~32.7psi (166.8~225.6kpa, 1.7~2.3kg/cm²) maximum 2.
Page 172 3. Check piston-to-cylinder wall clearance by subtracing piston diameter from the large cylinder subtracing piston diameter from the largest cylinder wall diameter at each cylinder. Clearance : 0.00157~0.0021in (0.040~0.053mm) Maximum : 0.006in (0.15mm) 4. If clearance exceeds maximum, replace piston or rebore cylinders and fit oversized pistons to all cylinder. Piston ring 1.
Page 173 7. Replace a feeler gauge in end gap and check end gap clearance. End gap clearance Ring Specification Top ring 0.006~0.011in (0.15~0.30mm) Second ring 0.012~0.018in (0.30~0.45mm) Oil rail 0.008~0.027in (0.20~0.70mm) Maximum 0.039in (1.0mm) 8. Replace piston ring if necessary. Piston pin 1.
Page 174 3. Subtract piston pin diameter from pin hole diameter to determine piston to piston clearance. Clearance : 0.00004~0.0006in (0.001~0.015mm) 4. If clearance exceeds specification, replace piston and pinston pin. Piston and piston pin are a matched set. INSPECTION 1. Check connecting rod bushing inside diameter. Inside diameter : 0.7875~0.7880in (20.003~20.014mm) 2.
Page 175 Engine Mechanical System Engine Mechanical System Cylinder Block - Crankshaft...
Page 176 2001 > 1.8L DOHC > INSPECTION 1. Check crankshaft bearing and crank pin journal 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. Runout : 0.0016in (0.04mm) 5.
Page 177 0.010in (0.25mm) undersize 1.7594~1.7602in (44.690~44.708mm) 0.020in (0.50mm) undersize 1.7496~1.7503in (44.440~44.458mm) 0.030in (0.75mm) undersize 1.7308~1.7505in (44.190~44.208mm) Main bearing and connecting rod bearing 1. Check main and connecting rod bearing for peeling, scoring and other damage.
Page 178 Engine Mechanical System Engine Mechanical System Cylinder Block - Cylinder Block...
Page 179 2001 > 1.8L DOHC > INSPECTION 1. Check cylinder block for following conditions and repair or replace cylinder block as needed. (1) A. Leakage damage B. Cracks C. Scoring of cylinders 2. Check distortion of cylinder head mating surface (block deck) in six directions shown in figure. Distortion : 0.006i (0.15mm) maximum 3.
Page 180 6. Take cylinder measurements at top center an bottom of cylinder to check for cylinder diameter, taper and out of round. Taper : 0.0007in (0.019mm) Maximum Out-of-round : 0.0007in (0.019mm) Maximum Boring cylinder should be based on maximum oversized piston that can be installed without exceeding maximum overbore.
Page 181 2001 > 1.8L DOHC > COMPONENT COMPONENT...
Page 183 Engine Mechanical System Engine Mechanical System Cooling System...
Page 184 2001 > 1.8L DOHC > Circuit diagram...
Page 185 Engine Mechanical System Engine Mechanical System Cooling System - Coolant...
Page 186 2001 > 1.8L DOHC > Inspection • NEVER REMOVE RADIATOR CAP WHILE ENGINE IS HOT. • WRAP A THICK CLOTH AROUND RADIATOR CAP BEFORE REMOING. • WHEN REMOVING RADIATOR CAP, LOOSEN SLOWLY TO FIRS STOP AND WAIT UNTIL PRESSURE IN RADIATOR IS RELEASED, THEN COMPLETELY REMOVE. Level (engine cold) 1.
Page 187 • Do not use alcohol or methanol-based coolant. • Use only demineralized 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.
Page 188 Engine Mechanical System Engine Mechanical System Cooling System - Water Pump...
Page 189 2001 > 1.8L DOHC > Removal Do not disassemble water pump assembly. If a problem is found, replace assembly as a unit. 1. Disconnect negative battery cable. 2. Drain engine coolant. 3. Remove timing belt (Refer to timing belt removal). 4.
Page 190 To prevent dropping the gasket when installing, put sealant in gasket groove. But do not apply to sealing surfaces. 3. Install water pump. Tightening torque : 14~19 lb-ft(19~26 N·m, 1.9~2.6 kg-m) 4. Install tensioner, idler and timing belt.(Refer to timing belt replacement) 5.
Page 191 Engine Mechanical System Engine Mechanical System Cooling System - Thermostat...
Page 192 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable. 2. Drain engine coolant. 3. Remove bolt and nut of termostat housing. 4. Remove thermostat housing and thermostat. Installation 1. Install thermostat into cylinder head with jiggle pin positioned up. 2.
Page 193 3. Place thermostat housing and tighten bolt and nut. Tightening torque : 14~19 lb-ft(19~26 N·m, 1.9~2.6 kg-m) 4. Fill radiator with specified amount and type of engine coolant. 5. Connect negative battery cable. 6. Start engine and check for leaks. Inspection 1.
Page 194 Engine Mechanical System Engine Mechanical System Cooling System - Radiator...
Page 195 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable. 2. Drain engine coolant. 3. Remove fresh air duct.
Page 196 4. Disconnect upper radiator hose. 5. Disconnect cooling fan motor connector. 6. Disconnect condense fan motor connector. 7. Disconnect coolant reservoir hose. 8. Remove radiator upper brackets. 9. Disconnect Automatic Transaxle Fluid (ATF) inlet and outlet pipe. 10. Disconnect lower radiator hose. 11.
Page 197 11. Connect negative battery cable. 12. Fill engine coolant (Refer to engine coolant replacement) 13. Start engine and check for leaks. Inspection 1. Check for cracks, damage or wesr leakage. 2. Check for bent fins. if bent, repair with a fin comb or similar tool. 3.
Page 198 Engine Mechanical System Engine Mechanical System Cooling System - Radiator Cap...
Page 199 2001 > 1.8L DOHC > 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, 1.05 kg/cm²). 3. Wait about 10seconds. Verify that pressure has not decreased. 4.
Page 200 Engine Mechanical System Engine Mechanical System Cooling System - Drive Belt...
Page 201 2001 > 1.8L DOHC > INSPECTION Drive belt 1. Check the drive belts for wear cracks and fraying. Replace if necessary. 2. Verify that the drive belts are correctly mounted on the pulley. 3. Check the drive belt deflection by applying moderate pressure 98N(10kg, 22lb) midway between the pulleys.
Page 202 2. Tighten the mounting bolts (A), (B) Tightening torque (A) : 28~38lb·ft (37~52N·m, 3.8~5.3kg-m) (B) : 14~19lb·ft (19~25N·m, 1.9~2.6kg-m) Power steering + Air conditioner drive belt 1. Loosen the bolt (A), nut (B), nut (C), for power steering pump. 2. Adjust the belt deflection by turning the adjusting bolt (D) 3.
Page 203 Engine Mechanical System Engine Mechanical System Cooling System - Cooling Fan Motor Assembly...
Page 204 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable. 2. Drain engine coolant. 3. Remove fresh air duct.
Page 205 4. Disconnect cooling fan motor connector. 5. Remove upper radiator hose. 6. Remove upper two cooling fan cowling bolts. 7. Remove lower two cooing fan cowling bolts. 8. Lift cooling fan cowling from radiator. 9. Remove clip and fan. 10. Remove three fan motor bolts and nuts. Installation 1.
Page 206 7. Connect cooling fan motor connector. 8. Install fresh air duct and tighten bolt and nut. 9. Fill engine coolant (Refer to engine coolant replacement.) 10. Connect negative battery cable. 11. Start engine and check for leaks. Inspection 1. Check current as shown with an ammeter. Current (A) : 8~13A...
Page 207 2001 > 1.8L DOHC > Functional diagram...
Page 208 Engine Mechanical System Engine Mechanical System Lubrication System - Engine Oil...
Page 209 2001 > 1.8L DOHC > INSPECTION 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for 5 minutes. 4. Remove the oil level gauge and check the oil level and condition. 5.
Page 210 8. Check oil level and add oil if necessary. Oil pan capacity : 3.8US qt (3.6liters, 3.2lmp qt)
Page 211 Engine Mechanical System Engine Mechanical System Lubrication System - Oil Pan...
Page 212 2001 > 1.8L DOHC > REMOVAL 1. Disconnect negative battery cable. 2. Drain engine oil. 3. Remove LH and RH side splash shields. 4. remove front exhaust pipe. 5. Remove oil pan mounting bolts. 6. Remove oil pan with screwdriver or suitable tool as shown in figure.
Page 213 • Do not force tools between cylinder block and oil pan because this damage sealing surfaces. • Do not damage sealing surfaces when removing old sealant. 7. Remove oil strainer. INSTALLATION • If oil pan reused remove all foreign material from sealing surfaces of cylinder block and oil pan. •...
Page 214 3. Install oil pan. Tightening torque : (A), (B), (C), (D) : 5.8~8.0lb-ft (7.8~10.8N·m, 0.8~1.1kg-m) (E) : 28~38lb-ft (38~51N·m, 3.8~5.3kg-m) 4. Install front exhaust pipe. Tightening torque : (A), (B) : 27.5~38.3lb-ft (37.3~51.9N·m, 3.8~5.3kg-m) (C) : 31.1~44.8lb-ft (42.2~60.8N·m, 4.3~6.2kg-m) 5. Install LH and RH side splash shields. Tightening torque : 12~18lb-ft (16~24N·m, 1.6~2.4kg-m) 6.
Page 215 8. Start engine and check for leaks. 9. Check oil level and add oil if necessary.
Page 216 Engine Mechanical System Engine Mechanical System Lubrication System - Oil Pump...
Page 217 2001 > 1.8L DOHC > COMPONENT...
Page 218 2001 > 1.8L DOHC > REMOVAL 1. Disconnect negative battery cable. 2. Drain engine oil. 3. Remove timing belt.(Refer to timing belt removal) 4. Remove oil pan and oil strainer. 5. Remove generator. 6. Remove A/C compressor and A/C compressor bracket if equipped. 7.
Page 219 10. Remove oil pump. INSTALLATION 1. Apply a continuous bead of silcone sealant to oil pump sealing surface. The oil pump must be installaed no longer than 5minutes after silicone sealant is applied. 2. Apply gease to a new O-ring and install it in oil pump. 3.
Page 220 6. Install generator. Tightening torque : (A) : 28~38lb-ft (37~52N·m, 3.8~5.3kg-m) (B) : 14~19lb-ft (19~26N·m, 1.9~2.6kg-m) 7. Install oil strainer and oil pan. (Refer to oi pan replacement.) 8. Install timing belt. 9. Fill with specified amount and type of engine oil. 10.
Page 221 3. Remove outer rotor and inner rotor. INSPECTION 1. Check the following and replace any faulty parts. A. Distored or damaged oil punp body or cover. B. Worn or damaged plunger. C. Weak or broken plunger spring. 2. Measure side clearance. Clearance : 0.0035in (0.09mm) max.
Page 222 REASSEMBLY 1. Asemble outer rotor and inner rotor into oil pump body. 2. Apply thread locking compound to cover mounting screw threads. 3. Assemble oil pump cover to oil pump body. Tightening torque : 4.3~6.5lb-ft (6~9N·m, 0.6~0.9kg-m) 4. Apply engine oil to outsode of new oil seal and oil pump body. 5.
Page 223 Engine Mechanical System Engine Mechanical System Lubrication System - Oil Filter...
Page 224 2001 > 1.8L DOHC > REPLACEMENT 1. Raise vehicle. 2. Remove oil filter with oil filter wrench. If rubber seal is stuck to engine remove it. 3. Apply a small amount of clean engine oil to rubber seal of new filter. 4.
Page 225 6. Remove oil pressure gauge and install oil pressure switch. Tightening torque : 8.7~13.0lb-ft (12~18N·m, 1.2~1.8kg-m)
Page 226 2001 > 1.8L DOHC > GENERAL DESCRIPTION The engine lubrication system consists of an oil pan, oil pump, oil filter and various oil various oil passages. A rotor-type oil pump is driven by crankshaft. The oil pump has pump has a pressure relief valve which controls lubrication system pressure by bypassing oil back to oil pan.
Page 227 2001 > 1.8L DOHC > REMOVAL Front oil seal 1. Remove oil pump.(Refer to oil pump remival) 2. Remove front oil seal. (Refer to oil pump disassembly) REMOVAL Rear oil seal 1. Disconnect negative battery cable. 2. Remove flywheel. (Refer to clutch removal) In case of A/T remove drive plate.(Refer to A/T removal).
Page 228 Protrusion : 0~0.02in (0~0.5mm) 3. Cut away silicon sealer that has been squeezed out from rear cover assembly toward oil pan mounting surface. Do not scratch rear cover assembly. 4. Install rear cover. Tightening torque : (A) : 5.8~8.0lb·ft (7.8~10.8N·m, 0.8~1.1kg-m) (B) : 29.7~40.5lb·ft (40.2~54.9N·m, 4.1~5.6kg-m) 5.
Page 229 Engine Mechanical System Engine Mechanical System Intake And Exhaust System - Air Cleaner...
Page 230 2001 > 1.8L DOHC > INSPECTION 1. Loosen air intake hose clamp at the mass air flow sensor. 2. Disconnect air hose from mass air flow sensor. 3. Remove six screws retaining air cleaner housing and lift housing unit. 4. Remove air cleaner from beneath air cleaner housing. Do not use compressed air to clean the air cleaner element.
Page 232 2001 > 1.8L DOHC > DESCRIPTION AND OPERATION Intake system The air induction system supplies filtered air to the engine to mix with the fuel for combustion. If contsists of : • Air cleaner assembly • Resonance chamber • Mass air flow sensor •...
Page 233 2001 > 1.8L DOHC > INSPECTION Accelerator cable. 1. Depress the accelerator pedal to the floor and check that the throttle valve is opened. Adjust with nut (A) if necessary. 2. Measure the free play of the accelerator cable. Free play : 0.16~0.28in (4~7mm) REMOVAL AND INSTALLATION 1.
Page 234 Exhaust system...
Page 235 Emission Control System Emission Control System General Information...
Page 236 2001 > 1.8L DOHC > Specifications Engine Item EVAP canister purge Resistance(at68°F{20°C})(Ω) 24~28 valve...
Page 237 Emission Control System Emission Control System Crankcase Emission Control System...
Page 238 Emission Control System Emission Control System Crankcase Emission Control System - Positive Crankcase Ventilation (PCV) Valve...
Page 239 2001 > 1.8L DOHC > System check 1. Warm up engine to normal operating temperature. 2. Run engine at idle. 3. Disconnect PCV valve ventilation hose from cylinder head cover. 4. Block PCV valve opening. 5. Verigy that vacuum is felt. 6.
Page 240 Emission Control System Emission Control System Evaporative Emission Control System...
Page 241 Emission Control System Emission Control System Evaporative Emission Control System - Canister...
Page 242 2001 > 1.8L DOHC > Charcoal canister 1. Visually check for damage and replace the charcoal canister necessary.
Page 243 Emission Control System Emission Control System Evaporative Emission Control System - Purge Control Solenoid Valve (PCSV)
Page 244 2001 > 1.8L DOHC > Inspection 1. Disconnect vacuum hosews from EVAP canister purge solenoid valve. 2. Verify that no air flows through valve. 3. Disconnect valve connector and apply 12 volt battery voltage as shown in figure. 4. Verify that air flows through valve. 5.
Page 245 Emission Control System Emission Control System Evaporative Emission Control System - Two-way Valve...
Page 246 2001 > 1.8L DOHC > Two-way check valve 1. Remove the valve. 2. Check the operation of valve with a vacuum pump. Specification: Apply approx. 5.1 kPa (37 mmHg. 1.5inHg) Vacuum at port A Airflow Apply apporx. 5.9 kPa (44 mmHg, 1.7 inHg) Vacuum at port B Airflow 3.
Page 247 2001 > 1.8L DOHC > Description Component description table Component Function Remark Evaporative emission Stores fuel tank vapors(engine stopped) canister EVAP canister purge valve Controls fyel vapor from EVAP emission canister to intake 1. For purge control manifold(dynamic chamber) 2. Actuated by intake manifold vacuum Outline of emission control system(Overview) To reduce CO, HC, Nox emissions, the following systems are incorporated in the Sephia/Shuma.
Page 248 Acheck valve is used to control pressure in the fuel tank and to prevent fuel spillage in the event of a roll-over. Positive crankcase ventilation(PCV) system The PCV valve is operated by the intake manifold vacuum. When the engine is running at idle, the PCV valve is opened slightly and a small amount of blowby gas is drawn into the dynamic chamber to be burned.
Page 249 2001 > 1.8L DOHC > System check 1. Warm up engine to normal operating temperature. 2. Disconnet vacuum hose from EVAP canister purge valve side of hose. 3. Verthat no vacuum is felt at EVAP canister purge control solenoid valve. 4.
Page 250 Fuel System Fuel System General Information...
Page 251 2001 > 1.8L DOHC > Engine control system...
Page 256 2001 > 1.8L DOHC > SPECIAL SERVICE TOOLS Tool (Number and Name) Illustration 0K2CA 089 HSP Hi-scan Pro Used for diagnosis and DTC retrieval and erasing. 0K2A1 131 AA1 Fuel pressure gauge Used for measuring fuel pressure. 0K9A4 400 001 Uses for removing and installing Sensor remover and installer 0K2A1 189 B0B / 0K2A1 189...
Page 257 2001 > 1.8L DOHC > Description System diagram...
Page 258 2001 > 1.8L DOHC > Components Vacuum hose routing...
Page 259 2001 > 1.8L DOHC > Diagnosis General Problem Possible Action Engine cranks but will not Fuel pressure problem Replace fuel pressure regulator start Replace leaking injector Replace injector O-ring Hard to start (cold engine) Idle air control valve not working Replace Defective throttle position sensor Replace throttle body...
Page 260 Leaking float Install new sender Sender or gauge calibration Test correct resistance value and replace component as needed. Fuel tank not filling to rated capacity Check fuel tank fill vent for kinks or obstructions. Correct as required and fill tank to verify proper capacity.
Page 261 2001 > 1.8L DOHC > Specifications Engine Item Idle speed (rpm) 800±50 Ignition timing (BTDC) 8°±5° Type Horizontal drift Throttle body Throat diameter in (mm) 1.8 (42) x 2 Type Rotary Idle air control Opening 16.5~18.5 Resistance(at valve 68°F[20°C])(Ω) Closing 14.5~16.5 Air cleaner element Dry, paper type...
Page 262 Idle Key ON/Engine OFF B01-4 Fuel injector control Fuel injector #4 Idle B01-5 B01-6 Injector ground Ground Constant <1.0V B01-7 Key ON/Engine OFF <1.0V B01-8 MIL control Malfunction indicator light Idle B01-9 B01-10 Constant <0.5V B01-11 Front HO2S sensor ground Front heated oxygen sensor Key ON/Engine OFF <0.5V...
Page 263 Key ON/Engine OFF B01-32 Fuel injector control Fuel injector #2 Idle B01-33 Key On/Engine OFF <1V B01-34 Output stage ground Ground Idle <1V B01-35 Key ON/Engine OFF EVAP canister purge B01-36 EVAP canister purge valve solenoid control idle Key ON/Engine OFF 0.0V B01-37 Front HO2S heater ground...
Page 264 B01-57 Key ON/Engine OFF B01-58 Ignition input Ignition switch Idle Key ON/Engine OFF Approx. 5V B01-59 Reference voltage Throttle position sensor Idle Approx. 5V B01-60 B01-61 Engine test B01-62 B01-63 Key ON, A/C operating <1V B01-64 A/C request input A/C switch Key ON, A/C not operating Approx.
Page 265 Idle <1V B01-87 B01-88 Using oscilloscope With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency IAC valve B01-2 4-6V 61~66% 100 HZ (Closing coil) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency B01-3 Injector #1 With engine Idling Terminal...
Page 266 HO2S B01-12 0-1V (front) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency Crankshaft B01-16 Position 1.6~2.4V Sensor (+) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency...
Page 267 B01-25 (Without Ignition immobilizer) coil B01-52 (Cylinder (with 1&4) immobilizer) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency valve B01-29 0.4~10V 30~35% 100 HZ (Opening coil) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency...
Page 268 Injector B01-31 With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency Injector B01-32 With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency...
Page 269 EVAP canister B01-36 solenoid valve With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency Throttle position B01-38 sensor 1.4V 100Hz (Pulse width modulation) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency...
Page 270 Crankshaft B01-43 Position 1.6~2.4V sensor (-) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency Camshaft B01-44 Position 4.3~4.6V sensor With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency...
Page 271 B01-52 Ignition (Without coil immobilizer) control B01-24 (Cylinder (With 2&3) immobilizer) With engine Idling Terminal Signal Waveform (With engine idling) Voltage Duty Frequency Torque reductiom B01-68 signal 1.5~1.8V 86-89% 200Hz (TCM to ECM) Specifications Item Specifications Accelerator cable free play (mm (in)) 3 (0.12) Fuel injection volume (cu in/min (cc/min)) 7.7 (126)
Page 272 Injector Type High ohmic electra mechanical Resistance (Ω) 14.5 ₁Fuel pressure with fuel pressure regulator ₂Minimum fuel pressure fifteen minutes after ignition key is switched "OFF".
Page 273 Fuel System Fuel System Engine Control System...
Page 274 Fuel System Fuel System Engine Control System - Engine Control Module (ECM)
Page 275 2001 > 1.8L DOHC > Removal 1. Remove three bolts retaining ECM to floorboard. 2. Remove ECM from mounting brackets. 3. Disconnect ECM connector. Installation 1. Attach connector to ECM. 2. Mount ECM onto mounting bracket in floorboard. 3. Install three bolts to retain ECM. 4.
Page 276 Fuel System Fuel System Engine Control System - Mass Air Flow Sensor (MAFS)
Page 277 2001 > 1.8L DOHC > Removal Do not drop or subject the sensor to shock. Do not put objects inside the sensor. 1. Disconnect mass air flow sensor connect. 2. Loosen air intake hose retaining clamps on both sides of mass air flow sensor. 3.
Page 278 Fuel System Fuel System Engine Control System - Engine Coolant Temperature Sensor (ECTS)
Page 279 2001 > 1.8L DOHC > Removal Engine coolant temperature sensor is located nesr thermostat. 1. Disconnect engine coolant temperature sensor connector. 2. Remove engine coolant temperature sensor. Installation 1. Install a new washer and engine coolant temperature sensor onto engine. Tightening torque:18-22 lb-ft(25-29 N·m, 2.5~2.9 kg-m) 2.
Page 280 Fuel System Fuel System Engine Control System - Accelerator Position Sensor (APS)
Page 281 2001 > 1.8L DOHC > Inspection Thottle posirion sensor 1. Disconnect connector from throttle position sensor. 2. Connect ohmmeter between sensor terminals A and B. 3. Verify that resistance increases linearly according to throttle angle. Specification:2kΩ±0.4kΩ(with throttle valve closed) 4. If resistance is not as specified, replace the throttle 5.
Page 282 Fuel System Fuel System Engine Control System - Heated Oxygen Sensor (HO2S)
Page 283 2001 > 1.8L DOHC > Inspection 1. Warm up the engine to normal operation temperature. 2. Run engine at idle speed. 3. Connect a voltween terminal D (YEL/GRN wire) and groung. 4. Increase and decrease engine speed quickly several times. 5.
Page 284 1. Disconnect heated oxygen sensor connector. 2. With standard oxygen sensor socket, remove heated oxygen sensor and washer. Installation 1. Install heated oxygen sensor and washer. Tightening lb-ft (30~49 N·m, 3~5 kg-m) 2. Reconnect heated oxygen sensor connector.
Page 285 Fuel System Fuel System Engine Control System - Idle Speed Control Actuator (InodeA)
Page 286 2001 > 1.8L DOHC > Inspection Ignition timing and idle speed Ignition timing 1. Apply parking brake. 2. Warm up engine to normal operating temperature. 3. Turn OFF all electrical loads. 4. Connect timing light to number one spark plug wire. A rubber inspection plug has been provided in the plastic coil cover (center of the cylinder head cover)directly over the number one(1) spark plug wire.
Page 287 The base idle speed is nor adjustable. The idle speed is automatically controlled by the engine control module. Incorrect idle speed indicates a potential problem with the IAC system or an intake manifold leak. 5. Check that idle speed is within specified range. Idle speed (transaxle in"NEUTRAL") : 800 ±...
Page 288 Fuel System Fuel System Engine Control System - Main Relay...
Page 289 2001 > 1.8L DOHC > Inspection 1. Remove cover from main fuse block. 2. Place a finger on main relay. 3. Verify that relay clivks when ignition switch is turned ON. 4. Verify that main relay cliks when ignition switch is tyrned ON and OFF. 5.
Page 290 Fuel System Fuel System Engine Control System - Fuel Pump Relay...
Page 291 2001 > 1.8L DOHC > Check operation THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FYEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS. Listen for fuel pump relay clicking as ignition switch is turned "ON".
Page 292 Fuel System Fuel System Engine Control System - Cooling Fan Relay...
Page 293 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable. 2. Remove cooling fan motor relay from engine compartment fuse/relay box. Installation 1. Install cooling fan motor relay from engine compartment fuse/relay box. 2. Connect negative battery cable. Inspection 1.
Page 294 2. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87. 3. If there is no continuity, replace cooling fan motor.
Page 295 2001 > 1.8L DOHC > Description Component description table Component Function Remark Controls A/C operation according to vehicle conditions and Controls condenser fan A/C relay sends A/C operation condition signals to ECM. operation A/C switch Controls battery power to A/C relay Normally open type Air cleaner Filters air entering throttle body...
Page 296 Engine coolant temperature Detects engine coolant temperature and sends signal to Installed near thermostat (ECT) sensor Intake air Detects intake temperature and sends signal to ECM Installed in air cleaner temperature(IAT)sensor thermostat Fuel filter (high pressure Filters fine dirt particles in fuel discharged from the fuel side) pump Fuel filter# (low pressure...
Page 297 Transaxle range switch(A/T) Detects shift lever position and sends to ECM 1. For idle speed control 2. Load/no/load determination OBD-II overview • Primary emission control system/components • Heated oxygen sensors (includes heater) • Catalyst • Fuel system • Evaporative emission system •...
Page 298 MIL illumination If any fault relating to HO2S is detected, then the MIL is only turned ON if the same fault is again detected during a second drive cycle. Three way catalytic converter (TWC) monitoring (System description) Fuel system monitoring (System description) •...
Page 299 Unlike Short FT which affects injection duration calculation in closed loop only, the Long FT correction factor affectsthe basic injection duration calculation in open and closed loop. Because Long FT is stored in a non-volatile RAM andis not erased when the ignition is switched OFF, the fuel system is able to correct for variances in engine and fuel conditions even during warm-up and wide open throttle conditions.
Page 300 2001 > 1.8L DOHC > Components Underhood emission control components...
Page 301 2001 > 1.8L DOHC > Diagnostic trouble codes retrieval procedure 1. Connect the Hi-scan pro to the Data Link Connector (DLC). 2. Turn the ignition switch ON. 3. Retrieve any DTC in ECM memory. Clearing diagnostic trouble codes 1. Connect Hi-scan pro to the Data Link connector(DLC). 2.
Page 302 PIN No. Terminal function Ground Ground Communication diagnosis terminal for Hi-Scan Pro Power supply Diagnostic trouble code Diagnostic trouble Condition code P0100 Mass air flow (MAF) circuit malfunction P0110 Intake air temperature (IAT) circuit malfunction P0116 Engine coolant temperature (ECT) circuit range/performance problem P0117 Engine coolant temperature (ECT) circuit low input P0118...
Page 303 P0340 Camshaft position CMP sensor circuit malfunction P0422 Main catalyst efficiency below threshold P0443 Evaporative emission control system purge control valve circuit malfunction P0501 Vehicle speed sensor circuit range/performance problem P0506 Idle speed system rpm lower than expected P0507 Idle speed system rpm higher than expected P0560 System voltage malfunction P0601...
Page 304 General description The Engine Control Module (ECM) operates the fuel system. If regulates ignition timing, air fuel ration, emission control devices, charging system, idle speed control, air conditioning clutch engagement, etc. The ECM has the ability to adapt to changing operating conditions. The ECM receives input signals from various switches and sensors.
Page 305 wire is heated to specific temperature differential above incoming air. Two wires inside the MAF Sensors are exposed to a portion of the airflow entering the engine : The ambient temperature wire or "cold wire" isn't heated so this wire is the temperature of the surrounding air and serves as the reference temperature.
Page 306: Table Of Contents
Fuel odor Gasoline odor in cabin High oil consumption Oil consumption excessive Kia Data Pro Scan Tool does not indicate Diagnostic Trouble MIL always ON Code but MIL always ON MIL never ON Kia Data Pro Scan Tool indicates malfunction...
Page 307: No Combustion
Stumble : Mild jerking during asseleration. Hesitation : Delay in increase in engine speed occrring just after the asselerator pedal is depressed. Surge : Continuous soft jerking during cruise. Precautions for symptom diagnosis Fuel system pressure release THE FUEL SYSTEM TRMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE TO VEHICLE COMPONENTS.
Page 308 3. Low fuel line pressure 4. Low engine compression pressure Step Check Action Check strong blue spark at each spark plug Go to step 5. cord disconnected. Go to next step. Is blue spark present? Malfunction indicator light is illuminated. Check that malfunction indicator light is Check for causes.
Page 309 Check engine condition : Engine compression pressure : 193 (1360 kPa, - Wear of pistion, piston rin and cylinder wall 13.6 kg/cm²) at 300 rpm - Defect of cylinder head gasket Is engine compression pressure within - Deformation of cylinder head specification? - Improper valve clearance - Valve stuck to guide...
Page 310 Go to next step. Check that battery voltage is applied on Does injector operate while cranking engine? injector connector and check wire between main relay and injector. Check resistance of injector. Go to next step. Resistance : 14.5Ω Replace injector. Is resistance within specification? Chank condition of IAC valve.
Page 311: Always
Step Check Action Warm up engine to normal operating temperature and stop engine. Connect the Replace fuel with another brand. data link connector terminals FUEL PUMP and B+ with a jumper wire for 3 minutes while ignition swithc is ON. Then check that engine starts.B+ with a jumper wire for3 minutes while Go to step 2.
Page 312 · Low fuel line pressure · Air leakage at intake system 2. Overrich air/fuel ratio · Clogged air cleaner element · Malfunction of manifold absofute pressure sensor 3. Spark plugs not in good condition Step Check Action Malfunction indicator light is illuminated. Check that malfunction indicator light is Check for causes.
Page 313 Check spark plug condition. Go to next step. Spark plug gap : 0.027~0.031 in (0.7~0.8mm) Check for exessive carbon deposit and correct contact with spark plug wires. Are spark plugs Clean or replace. Replace ECM and check for proper operation. Cranks normally, but hard to start - When engine is cold ·...
Page 314: Always
Cranks normally, but hard do start-After engine is warmed up · After engine is left hot after running, cranks normally, but cranking time up to starting is excessively long · Battery is OK Descirtion · Starts normally when engine is cold ·...
Page 315 7. Malfunction of throttle position sensor or related wiring Step Check Action Malfunction indicator light is illuminated. Check that malfunction indicator light is Check for causes. Refer to Troubleshooting illuminated while ignition switch is ON. with diagnostic trouble codes, page 21-18. Does the MIL illuminated longer than 3 seconds after ignition switch is turned ON? Go to next step.
Page 316 idling. Vacuum : 18.9 in.Hg (480 mmHg) at idle Check air leakage at intake system. Is intake manifold vacuum within specification? Go to next step. Check cleanness of air cleaner element. Is air cleaner element OK? Replace air cleaner element. Check terminal voltage of mass air flow Go to next step.
Page 317 Low pressure : Block return line and check if pressure rises. If pressure rises, replace pressure regulator. If pressure does not rise, check fuel filter at fuel delivery module. If it is OK, measure fuel pump max. Pressure and replace as necessary. Disconnect engine coolant temperature snesor Replace the engine coolant temperature connector and check that engine condition...
Page 318 Step Check Action Malfunction indicator light is illuminated. Check that malfunction indicator light is Check for causes. Refer to troubleshooting illuminated while ignition switch is ON. with diagnostic trouble codes, page21-18. Is MIL illuminated longer than 3 seconds after ignition switch is turned ON? Go to next step.
Page 319 · A/C switch input · Park/neutral input Replace as necessary. Are voltages correct? Replace ECM and check for proper operation. Variation of idle speed / Idle hunting Description · Periodic engine speed increase and decrease while engine is idling (Troubleshooting hint) 1.
Page 320: Engine Stalls On Deceleration
Do injecors leak? Go to next step. Replace ECM and check for roper operation. Engine stalls on deceleration · Engine stops unexpectedly during or after deceleration Description · Idling condition is normal (Troubleshooting hint) Engine speed decreases abruptly when accelerator pedal is released, which can cause connectors to come loose. 1.
Page 321 air flow sensor signals. Repair or replace. Are sensor signals OK? Check ECM terminal voltages for B01-2, Go to next step. B01-29, B01-59, B01-71 and B01-73. Check for causes and repair as necessary. Are voltages OK? Replace ECM and check for proper operation. Stumble / Hesistation on acceleration ·...
Page 322 If line is clear, try with new pressure regulator. If line is blocked, check for blockage in return line and clean or replace as necessary. Low pressure : Block return line and check if pressure rises. If pressure rises, replace pressure regulator. If pressure does not rise, check fuel filter at fuel delivery module.
Page 323 Is air cleaner element OK? Replace air cleaner element. Go to next step. High pressure : Disconnect return line from filter side. Blow through line towards tank. If line is clear, try with new pressure regulator. Check fuel line pressure while engine is idling. If line is blocked, check for blockage in return Fuel line pressure : 46~51 psi (320~350 kPa, line and clean or replace as necessary.
Page 324 Go to next step. Check the camshaft position sensor and DTC related. Replace camshaft position sensor or repair Is CMP sensor OK? related wire harness. Check throttle position sensor and related DTC Go to next step. Voltage between terminals : Idling condition : 0.4~0.6V Throttle valve full open : 4.1~4.3V Repair intake system or dynamic chamber.
Page 325 Check engine condition. Engine compression pressure : 193 psi (1360 - Wear of piston, piston ring and cylinder wall kPa, 13.6 kg/cm²) at 300 rpm - Defect of cylinder head gasket Is engine compression pressure within - Deformation of cylinder head specification? - Improper valve clearance - Valve guide stuck...
Page 326 Idling condition : 0.4~0.6V Throttle valve fully open:4.1~4.3V Replace throttle position sensor. Is TP sensor OK? Check vacuum in intake manifold while engine Go to next step. is idling. Check air leakage into intake system and Vacuum : more than 18.9 inHg (480 mmHg) repair as neessary..
Page 327 Check engine condition. Engine compression pressure : 193 psi (1360 - Wear of piston, piston ring and cylinder wall kPa, 13.6 kg/cm²) at 300 rpm - Defect of cylinder head gasket Is engine compression pressure within - Deformation of cylinder head specification? - Improper valve clearance - Valve guide stuck...
Page 328 Clean or replace as necessary. Check fuel leakage from injector. Do fuel injectors leak? Go to step 10. Replace ECM and check for proper operation. Knocking Description · Abnormal combustion occurs, accompanied by audible "pinging" noise (Troubleshooting hint) 1. Improper ignition timing 2.
Page 329 Is cooling system OK? Repair or replace. Road test and return vehicle to customer. Replace ECM and check for peoper operation. Is system operating correctly? Replace fuel with another brand. Fuel odor Description · Fuel odor in passenger compartment (Troubleshooting hint) 1.
Page 330 MIL remains illuminated. Check short circuit from meter set to ECM. Is MIL illuminated? MIL does not light Description · Kia power scan dispays malfunction code, but MIL does not illuminate (Troubleshooting hint) Blub is blown Open circuit...
Page 331 Fuel System Fuel System Fuel Delivery System - Fuel Tank...
Page 332 2001 > 1.8L DOHC > Removal FUEL IS EXPLOSIVE. AN EMPTY FUEL TANK CAN STILL CONTAIN EXPLOSIVE GASES. SUPPLY ADEQUATE VENTILATION TO THE WORK AREA. DO NOT SMOKE AND KEEP SPARKS AND OPEN FLAMES AWAY. PURGE FUMES FROM THE TANK AS SOON AS POSSIBLE. DTAIN THE FUEL FROM THEFUEL TANK BEFORE REMOVING THE TANK.
Page 333 17. Remove fuel tank from vehicle. Installation FUEL IS EXPLOSIVE. AN EMPTY FUEL TANK CAN STILL CONTAIN EXPLOSIVE GASES. SUPPLY ADEQUATE VENTILATION TH THE WORK ATEA. DO NOT SMOKE AND KEEP SPATKS AND OPEN FLAMES AWAY. PURGE FUMES FROM THE TANK AS SOON AS POSSIBLE. 1.
Page 334 13. Reconnect connector to fuel delivery module. 14. Position wires correctly and secure to floor with tape 15. Reinstall rear seat cushion. 16. Reconnect negative battery cable.
Page 335 Fuel System Fuel System Fuel Delivery System - Fuel Pump...
Page 336 2001 > 1.8L DOHC > Fuel pump inspection THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONECTS. Fuel pump operation 1.
Page 337 5. Connect negative battery terminal. THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS. 6. Connect data link connect terminals FUEL PUMP and B+ with jumper wire. 7.
Page 338 6. Remove rubber grommet and wires from access cover and remove access cover. 7. Disconnect to fuel hoses from to fuel delivery module. 8. Remove six screws attaching fuel delivery module and remove fuel delivery module from fuel tank. Installation Fuel delivery module 1.
Page 339 6. Position wires and secure to floor with tape. 7. Install rear seat cushion. 8. Connect negative battery cable.
Page 340 Fuel System Fuel System Fuel Delivery System - Fuel Filter...
Page 341 2001 > 1.8L DOHC > Removal FUEL IS EXPLOSIVE. WHEN WORKING ON FUEL SYSTEM MAKE SURE TO SUPPLY ADEUATE VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES AWAY. 1. Depressurize fuel system. Refer to “Releasing fuel system pressure”. 2.
Page 342 Tightening torque : 9.5lb-ft(12.9N·m 1.3kg-cm) 2. Connect fuel hoses. Installation Fuel filler pipe assembly FUEL IS EXPLOSIVE. WHEN WORKING ON FUEL SYSTEM PARTS, MAKE SURE TO SUPPLY ADEQUATE VENTIATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES AWAY.
Page 343 Fuel System Fuel System Fuel Delivery System - Injector...
Page 344 2001 > 1.8L DOHC > Check operation 1. Warm up engine and let engine idle. 2. Listen for found of each unjector running by using sound scope or screwdriver. FUEL IS EXPLOSIVE. WHEN WORKING ON FYEL SYSTEM, MAKE SURE TO WUPPLY ADEAUATE VENTILATION TO THE WORK ATEA.
Page 345 3. Reconnect injector connectors. 4. Connect jumper wire to injector ECM wires (BRN) and ground. 5. Turn ignition ON. 6. Turn injector volume with graduated container. Injector volume:130cm²(130 cc, 7.95 cu-in)/min 7. If not as specified, replace injectors. Refer to "On-Vehicle Service". When reassembling fuel rail and injectors: •...
Page 346 2. Disconnect negative battery cable. 3. Disconnect four injector connectors. 4. Disconnect fuel line quick connector. 5. Remove accelerator cable bracket won bolts and one nut. 6. Disconnect accelerator cable. 7. Remove the two bolts attaching fuel rail to intake manifold. 8.
Page 347 Fuel System Fuel System Fuel Delivery System - Fuel Pressure Regulator...
Page 348 2001 > 1.8L DOHC > Removal FUEL IS EXPLOSIVE. AN EMPTY FUEL TANK CAN STILL CONTAIN EXPLOSIVE GASES.SUPPLY ADEQUATE VENTILATION TO THE WORK AREA. DONOT SMOKE AND KEEP SPARKS AND OPEN FLAMES AWAY. PURGE FUMES FROM THE TANK AS SOON AS POSSIBLE. 1.
Page 349 7. Reconnect connector correctly to fuel delivery module. 8. Position wire and secure to floor with cushion tape. 9. Install rear seat cushion. 10. Reconnect negative battery cable.
Page 350 Fuel System Fuel System Fuel Delivery System - Fuel Line...
Page 351 2001 > 1.8L DOHC > Removal FUEL IS EXPLOSIVE.WHEN WORKING ON FUEL SYSTEM MAKE SURE TO SUPPLY ADEQUATE VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES AWAY. It may be necessary to remove other chassis brackets in order to gain access to fuel lines. If this is necessary, Refer to the appropriate sections for removal procedures.
Page 352 12. Clean mating surfaces. Installation FUEL IS EXPLOSIVE. WHEN WORKING ON FUEL SYSTEM, MAKE SURE TO SUPPLY ADEQUATE VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES AWAY. It may be necessary for transaxle assembly and other chassis brackets to be removed in order to reinstall fuel lines.
Page 353 2001 > 1.8L DOHC > Description Conventional Today's most engines have more than 90% of the returning fuel to the tank in normal operational condition. Temperature of the fuel being returned through the return line is raised by about 7~15°C as it absorbs cooling heat from underbody, fuel line, pipe friction, ect.
Page 354 Electric fuel pump The electric fuel pump is located in the fuel delivery module. It is mounted with and connected to the fuel sensor unit. The fuel pump is an electric pump controlled by the engine control module(ECM) through the pump relay. The motor rotates and impeller within the pump assembly.
Page 355 2001 > 1.8L DOHC > Component...
Page 356 2001 > 1.8L DOHC > Releasing fuel system pressure THE FUEL SYSTEM RENAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONECTS. 1.
Page 357 THE FUEL SYSTEM REMAINS UNDER PERSSURE WHEN THE ENGINE IS NOT PRUUING, RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONECTS. 2. Release fuel system pressure. Refer to "Releasing fuel system pressure". 3.
Page 358 5. Connect negative battery cable. 6. Connect data link connector terminals FUEL PUMP and B+ with jumper wire. 7. Turn ignition switch ON. 8. Inspect the fuel line pressure. Fuel line pressure:46~51psi(320~350 kPa, 3.2~3.5 kg/cm²) Pressure too high: A. Check for restricted fuel return line B.
Page 359 Driveshaft and Axle Driveshaft and Axle General Information...
Page 360 2001 > 1.8L DOHC > SERVICE SPECIAL TOOLS Tool (Number and name) Illustrator Used OK130 283 021 Used to remove ball joint. Ball joint puller OK930 331 AA0 Used to remove wheel hub. Wheel hub puller OK201 170 AA0 Used to support engine when Engine support transaxle removal.
Page 361 2001 > 1.8L DOHC > DESCRIPTION AND OPERATION Front axle The front suspension consists of MacPherson struts and a single wishbone lower control arm. The upper end of each strut is suspended from body's inner fender with a steering knuckle bolted to lower end of the strut. A forged steering knuckle bolts to shock absorber.
Page 362 Rear axle Rear suspension is fully independent utilizing a rear MacPherson strut at each wheel. A fored rear spindle bolts to shock absorber, double rear lateral links, and a single trailing arm. Both lateral links and trailing arm have rubber bushings at each end. Lateral links are attached to rear sub-frame and spindle with a common bolt and nut assembly at each end.
Page 363 2001 > 1.8L DOHC > GENERAL DIAGNOSTICS AND TESTS Front axle Problem Possible cause Action Steering wheel vibration Excessive wheel bearing play Adjust or replace Damaged or worn wheel bearing Replace Pulling to one side Excessive wheel bearing play Adjust or replace Damaged or worn wheel bearing Replace Excessive steering wheel play...
Page 364 2001 > 1.8L DOHC > SPECIFICATIONS Driveshaft and axle Engine TB DOHC Item Driveshaft Type of joint Inside Tripod Outside Ball joint Length of joint Left side 24.80in (630mm) 25.11in (638mm) Right side 25.02in (635.7mm) 25.02in (635.7mm) Shaft diameter Right side 0.95(ø)in (24mm) Left side 0.95(ø)in (24mm)
Page 365 Driveshaft and Axle Driveshaft Assembly Front Driveshaft...
Page 366 2001 > 1.8L DOHC > COMPONENT...
Page 367 2001 > 1.8L DOHC > DASSEMBLY 1) Install a protective material in a vice and secure CV joint in the vice. 2) Keep dust or foreign material from joint during procedure. 3) Do not disassemble wheel side ball joint. 4) Do not wash joint unless disassembling it. Do not disassemble boot band on wheel side unless necessary.
Page 368 9. Wrap splines of shaft with tape to prevent damaging boot. 10. Slide boot off shaft. Do not remove boot from outer joint unless necessary. 11. Using a boot band tool, draw hooks together and remove the boot band. 12. Using side cutters, cut boot band and remove them. 13.
Page 369 2. Cover splines of transaxle end tape. 3. Install inner dust boot. 4. Install outer boot. Do not damage bearing. 5. Align marks and carefully install tripod joint with a drift a hammer. 6. Install snap ring with snap-ring pliers. 7.
Page 370 10. Measure length of driveshaft. Length of driveshaft Right side Left side Item MTX0 TBDOHC 25.03in (637.7mm) 25.03in (635.7mm) 24.8in (630mm) 25.12in (638mm) 1) Always use new bands 2) Bands should installed so that their pointed ends initially point in forward direction of rotation. 11.
Page 372 2001 > 1.8L DOHC > COMPONENT...
Page 373 2001 > 1.8L DOHC > INSPECTION 1. Raise vehicle and support it with safety stands. 2. Check dust boots on driveshaft for cracks, damage, leaking grease, or loose boot bands. 3. Check driveshaft for a bent condition, carcks, and wear of joints or splines. 4.
Page 374 Do not damage the dust cover or oil seal. 8. Remove drivshaft from front hub after removing locknut. If driveshaft is frozen in front wheel hub, spray a penetrating solvent into splined area and then reinstall locknut so that it is flush with end of shaft. Tap nut a brass hammer to remove driveshaft. 9.
Page 375 Do not damage dust cover or oil seal. 1. Install driveshaft with circular clip gap facing upward as shown. 2. Install a new clip so that opening is facing upward. 3. Measure outer diameter of clip after installing and replace clip if it exceeds specification. Outer diameter : Manual transaxle : 1.22in (31mm) Auto transaxle : 1.06in, (27mm)
Page 376 Do not damage dust boot. Do not damage oil seal of trsaxle and CV joint shaft. 8. Install nut and secure it with a new cotter pin. Tightening torque : 21~32lb-ft (29~44N·m, 3.0~4.5kg-m) 9. Install a new driveshaft locknut and stake it, as shown. Tightening torque : 174~235lb-ft (235~319N·m, 24.0~32.5kg-m) 10.
Page 377 Driveshaft and Axle Front Axle Assembly...
Page 378 Driveshaft and Axle Front Axle Assembly Front Hub / Axle...
Page 379 2001 > 1.8L DOHC > COMPONENT...
Page 380 2001 > 1.8L DOHC > DISASSEMBLY 1. Remove oil seal from front wheel hub. 2. Remove front wheel hub assembly with suitable tool. 3. Remove retaining ring. If the bearing inner race remains on wheel hub, grind a section of inner race until approximately 0.020in (0.5mm) remains.
Page 381 6. Remove dust cover with a chisel. 1) Do not remove wheel studs unless necessary. 2) Do not reuse wheel studs if removed. 7. Remove wheel studs with a press. RESSEMBLY 1. Press in new wheel studs. 2. Mark new dust cover to match the removed dust cover.
Page 382 3. Align mark on new dust cover with knuckle. 4. Install new dust cover with suitable tool. 5. Install new wheel bearing with suitable tool. 6. Install front wheel hub assembly with suitable tool. 1) Use a new oil seal and apply grease to seal. 2) Install oil seal that it is flush with knuckle.
Page 384 2001 > 1.8L DOHC > COMPONENTS...
Page 385 2001 > 1.8L DOHC > INSPECTION Wheel bearing play 1. Raise vehicle and support it with safety stand. 2. Loosen and remove four wheel nuts. 3. Remove wheel and tire. 4. Loosen a locknut and two disk plate screws. 5. Remove brake caliper assembly and disk plate. 6.
Page 386 7. Loosen and remove nut and disconnect tie-rod end with SST (OK130 283 021). 8. Disconnect ball joint of lower control arm from steering knuckle. 9. Remove steering knuckle and wheel hub. 10. Inspect all parts and repair or replace as necessary. INSTALLATION 1.
Page 387 8. Install wheel and tire. 9. Tighten four wheel nuts. Tightening torque : 35~87lb-ft (88~118N·m, 9.0~12.0kg-m) 10. Install wheel speed sensor. Tightening torque : 5.8~7.2lb-ft (7.8~9.8N·m, 80~100kg-cm) 11. After assembly, check front wheel alignment.
Page 388 Driveshaft and Axle Rear Axle Assembly...
Page 389 2001 > 1.8L DOHC > COMPONENT...
Page 390 2001 > 1.8L DOHC > REMOVAL 1. Raise vehicle and support it with safety stand. 2. Loosen and remove four wheel nuts. 3. Remove wheel and tire. 4. Remove a dust cap, hub locknut and two brake drum screws. 5. Remove brake drum (or disk) from rear brake assembly. 6.
Page 391 Tightening torque : 9~13lb-ft (13~18N·m., 1.3~1.8kg-m) 6. Install hub and bearing assembly. 7. Put brake drum (or disc) into rear brake assembly and tighten two screws. Tightening torque : 7~11lb-ft (9.8~15N·m, 1.0~1.5kg-m) 8. Install a new hub locknut and stake it, as shown. Tightening torque : 154~205lb-ft (210~279N·m, 21.4~28.5kg-m) 9.
Page 392 Clutch System Clutch System General Information...
Page 393 2001 > 1.8L DOHC > Special service tools Tool(Name & Number) Illustration 0K130 160 010 Used to install clutch disc to the center of Clutch disc centering tool flywheel. 0K130 130 019 Used to remove clutch line. Flare nut wrench 0K410 111 012 Used to remove pilot bearing in flywheel.
Page 394 2001 > 1.8L DOHC > Symptom-related diagnostic procedure Problem Possible cause Action Clutch disc facing worn excessively Replace Clutch disc facing is oil contaminated Repair or replace Pressure plate damaged Repair or replace Clutch slips Diaphragm spring damaged or weakened Replace Insufficient clutch pedal play Adjust...
Page 395 2001 > 1.8L DOHC > Specifications Engine Item TB DOHC Clutch control Hydraulic Type Diaphragm Spring Clutch cover Set load lb(kg) 979 (445) Outer diameter in(mm) 8.85(225) Inner diameter in(mm) 5.91(150) Clutch disc Pressure plate side 0.183(3.5) in(mm) Thickness Flywheel side in(mm) 0.183(3.5) Type Suspended...
Page 396 Clutch System Clutch System Clutch System...
Page 397 2001 > 1.8L DOHC > Component...
Page 398 Clutch System Clutch System Clutch Master Cylinder...
Page 399 2001 > 1.8L DOHC > Component...
Page 400 2001 > 1.8L DOHC > Removal 1. Disconnect cable. 2. Pull locktab then remove fuse box. 3. Remove Snap pin and Joint pin from master cylinder push rod. 4. Remove master cylinder mounting nuts. Clutch brake fluid will damage painted surfaces so use a container or shop towels for fluid collection. If fluid gets on a painted surface, rinse immediately with clear water to prevent damage.
Page 401 Disassembly Do not damage push rod contact surface of piston. 1. Press push rod down and remove internal snap ring with snap ring pliers. 2. Remove push rod, piston assembly, piston stopper, spring, valve stopper, spring and valve assembly. Hold piston assembly to prevent if from flying apart. 3.
Page 402 Reassembly • Clean disassembled parts in solvent and blow through all parts and passages with compressed air. • Do no mix different brands of clutch fluid. • Apply specified clutch fluid to part of piston assembly and cylinder bore before assembly. •...
Page 404 Clutch System Clutch System Clutch Pedal...
Page 405 2001 > 1.8L DOHC > Component...
Page 406 2001 > 1.8L DOHC > Inspection 1. Measure distance from front surface of pedal to vehicle carpet. Pedal height : 8.78~8.98 in (223~28 mm) 2. If necessary, adjust pedal height. Inspection Clutch pedal free play 1. Lightly depress clutch pedal by hand until clutch resistance is felt. 2.
Page 407 Minimum clutch pedal reserve : 1.99 in (50.6 mm) 3. Tighten locknut Tightening torque : 104~147 lb-in (12~17 N·m, 120~170 kg-cm) 4. After adjustment, inspect pedal height. Removal 1. Remove parts in order shown in figure below. 2. Inspect all parts and repair or replace as necessary. Apply a thin coat of lithium grease to bushing and pins before installation.
Page 408 Clutch System Clutch System Clutch Release Bearing...
Page 409 2001 > 1.8L DOHC > Component Component...
Page 410 2001 > 1.8L DOHC > Removal • Clutch fluid will damage painted surfaces. Be sure to use a container or shop towels to collect it. • If fluid contacts a painted surface, rinse immediately with clear water to prevent damage. After removing the clutch line, plug the clutch line to avoid fluid leakage.
Page 411 1. Remove clutch cylinder boot and push rod. 2. Remove piston and cup assembly by applying compressed air through the clutch hydraulic line installation hole. Hold a rag over the opening of release cylinder piston bore to prevent piston assembly from flying out. Reassembly •...
Page 412 2001 > 1.8L DOHC > Removal • Remove clutch release cylinder with clutch line connected. • Do not remove pilot bearing unless necessary. • Wipe off residual grease when assembling the release bearing to nose part of transmission primary shaft. •...
Page 413 • Install pilot bearing flush with flywheel. • Wipe off residual grease when assembling the release bearing to nose part of transmission primary shaft. • Wipe off residual grease when assembling the clutch disc to transmission primary shaft. 1. Install pilot bearing flush with a suitable tool. Bearing outer diameter : 1.378 in (35 mm) 2.
Page 414 Clutch cover 1. Inspect contact surface of pressure plate for scoring, cracks, and burning. Resurface or replace as necessary. 2. Inspect release bearing contact surface (on the diaphragm spring fingers )for wear and cracks. if there is wear or cracks on diaphragm fingers, replace clutch cover assembly. Clutch disc 1.
Page 415 Pilot bearing 1. Turn bearing while applying force in axial direction. If bearing sticks or has excessive resistance, replace it. Flywheel Minor scoring or burning should be reoved with remery cloth. 1. Inspect contact surface of flywheel for scoring, cracks, and burning ; resurface or replace as necessary. 2.
Page 416 necessary. 2. Inspect release bearing contact surface (on the diaphragm spring fingers )for wear and cracks. if there is wear or cracks on diaphragm fingers, replace clutch cover assembly. Clutch disc 1. Inspect lining surface for burning oil contamination or other damage. Replace clutch disc if it is burned, oil soaked or other damaged.
Page 417 Flywheel Minor scoring or burning should be reoved with remery cloth. 1. Inspect contact surface of flywheel for scoring, cracks, and burning ; resurface or replace as necessary. 2. Inspect starter ring gear teeth for wear or damage. If necessary, replace ring gear.
Page 418 Steering System Steering System General Information...
Page 419 2001 > 1.8L DOHC > Service special tools Tool(Name & Number) Illustration 0K130 283 021 Used for removing tie rod end. Puller, ball joint 0K130 322 020 Attachment, steering worm Used for measuring pinion pre-load. bearing preload measuring 0K201 323 AA0 Used for measuring fluid pressure.
Page 420 2001 > 1.8L DOHC > Manual steering Power steering...
Page 422 2001 > 1.8L DOHC > General diagnostics and tests Manual steering Problem Possible cause Action Poor lubrication, foreign material in mechanism or damage of steering ball joint Repair Inadequate gear oil, foreign material in oil Lubricate or replace Improper steering gear preload Adjust Steering feels heavy Damaged steering gear...
Page 423 Looseness or damage of power steering Adjust or replace power steering belt belt Fluid fill up or air bleeding Insufficient power steering fluid or air Replace hoses insertion Replace pipes Crushed or twisted hoses Repair or replace leaking parts Pipe damage Repair or replace power steering Leakage of power steering fluid pump or gear...
Page 424 2001 > 1.8L DOHC > Specifications Type Item Outer diameter in(mm) 380(14.96) Steering wheel Lock-to-lock turns 3.93 3.09 Type Collapsible Steering column Joint type 2-cross joint Tilt stroke in(mm) NON TILT Type Rack-and-pinion Steering rack Gear ratio ∞ Rack travel in(mm) 5.51(140) Capacity US qt (liter) 0.64(0.6)
Page 425 Steering System Steering System Steering Column & Shaft...
Page 426 2001 > 1.8L DOHC > Component...
Page 427 2001 > 1.8L DOHC > Component...
Page 428 2001 > 1.8L DOHC > Removal 1. Disconnect (-) terminal of battery. 2. Place vehicle in a straight forward position. 3. Loosen four bolts from steering wheel and remove driver's air bag module. (Refer to section Air bag system) 4. Disconnect horn switch electrical connector. 5.
Page 429 Tightening torque : 13~20 lb-ft(18~26 N·m, 1.8~2.7 kg-m) 5. Connect the selector cable (Auto transaxle only). (Refer to section Auto transaxle) 6. Connect ignition switch electrical connector. 7. Install combination switch to steering column shaft. 8. Connect combination switch electrical connectors. 9.
Page 430 Steering shaft assembly - Column busing wear. Intermediate shaft - Excessive play in universal joint, abnormal noise, or sticking. Steering lock assembly Verify that cable connector cannnot be moved when key is in LOCK position, but that it will move freely with key in any other position.
Page 431 Steering System Steering System Manual Steering System - Gear Box...
Page 432 2001 > 1.8L DOHC > Component...
Page 433 2001 > 1.8L DOHC > Removal 1. Lift front of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Remove plastic undercover. 4. Turn wheels fully to left. 5. Pull out cotter pin, and remove nut. 6.
Page 434 14. Remove steering rack boot. 15. Remove boot clip. Installation 1. Put a small amount of grease into new tie rod dust boot. 2. Install dust boot onto tie roe end with suitable tool and a press. 3. Fill the new steering rack boot with specified grease. Specified grease : Approx.66 oz (30g) 4.
Page 435 2001 > 1.8L DOHC > Inspection Steering wheel play 1. With wheels in straight-ahead position, gently turn steering wheel left and right to determine if play is within specification. Play is measured at outer rim of wheel Play : 1.18 in (30 mm) Max. If play exceeds specification, either steering joints are worn or backlash in steering rack is excessive.
Page 436 Steering wheel effort : 33 lb (147 N)
Page 437 Steering System Steering System Hydraulic Power Steering System - Power Steer- ing Gear Box...
Page 438 2001 > 1.8L DOHC > Component Component...
Page 440 2001 > 1.8L DOHC > Removal Steering rock and linkage 1. Loosen wheel lug nuts. 2. Raise front of vehicle and support it with safety stands. 3. Remove wheels and tires. 4. Pull out cotter pins, and remove nuts. 5. Separate tie- rod from knuckle arm with SST(0K130 283 021). Replace nuts temporarily so that screw threads do not become damaged.
Page 441 Tightening torque : 27~38 lb-ft(37~52 N·m, 3.8~5.3 kg-m) 3. Tighten intermediate shaft bolt. Tightening torque : 13~20 lb-ft(18~26 N·m, 1.8~2.7 kg-m) 4. Install sealing covers and then tighten four steering column nuts in vehicle. 5. Tighten two universal joint pinch bolts. Tightening torque : 13~20 lb-ft(18~26 N·m, 1.8~2.7 kg-m) 6.
Page 442 After disonnecting pipes, use a plug o adhesive type tape to seal each port to prevent entiry of foreign materials. 2. Before removing tie rod ends. make a mark for proper installation. 3. Remove tie rod end from rack. 4. Remove spring pin with a pin-and hammer. 5.
Page 443 If rack is removed without using suitable tool, there is a possibility that rack housing may be damaged by rack teeth. 12. Install suitable tool to threaded part of rack a tube side of gear housing. 13. Remove rod seal at tube side while pulling out rack. 14.
Page 444 3. Use V blocks to support both ends of large-diameter part of rack ; check for excessive bending ; replace it if necessary. Bending : 0.006 in (0.15 mm) (near rack center) Reassembly Steering rack and linkage 1. Install mounting rubber. 2.
Page 445 8. Connect rod seal to grease coated surface of housing insert. 9. Apply ATF to inside and outside of housing insert and rod seal. 10. Set housing insert and rod seal on suitable tool. 11. Insert suitable tool from tube side of gear housing. 12.
Page 446 17. Remove suitable tool. 18. Apply sealant to thread area of rack bushing . 19. Install rack bushing assembly in rack housing. 20. Tighten tack busing as rod seal goes into tube. Tightening torque : 65~72 lb-ft (88~98 N·m, 9~10 kg-m) Rod seal is pushed to correct position in rack housing by tightening of rack bushing.
Page 447 28. Apply grease (lithium base, NLGI No.2) to teeth of pinion shaft. 29. Apply ATF to seal ring and friction surface of control valve. 30. Install pinion shaft in housing. 1) Be careful not to damage oil seal with pinion teeth. 2) Be careful not to damage edge of seal ring and control valve.
Page 448 Apply uniform force to oil seal when installing. 37. Temporarily install tie roe on tube side of rack housing. 38. Install locknut on pinion shaft assembly and turn it until tie rod contacts tube. 39. Tighten locknut. Tightening torque : 29~36 lb-ft(39~49 N·m, 4.0~5.0 kg-m) 40.
Page 449 46. Set rack in center position. 47. Tighten yoke plug to 14.4 lb-ft (20 N·m, 200 kg-cm) then loosen it. 48. Tighten again to 3.6 lb-ft (4.9N·m, 50 kg-cm), and then loosen it 67.5° 49. Apply thread sealant to exposed threads of yoke plug. 50.
Page 450 54. Fill new steering rack boot with specified grease. Specified grease (KTSG 06) ; Approx 66 oz (30g) 55. Apply a coat of sealant to inside of boot contact to rack housing contact area. 56. Apply grease to inner surface of small end of boot. 57.
Page 452 Steering System Steering System Hydraulic Power Steering System - Power Steer- ing Oil Pump...
Page 453 2001 > 1.8L DOHC > Componet Component...
Page 455 2001 > 1.8L DOHC > Removal 1. Loosen pivot bolt from P/S pump. 2. Loosen locknut from P/S pump. 3. Loosen bracket nut from P/S pump bracket. 4. Remove drive belt. 5. Loosen nut and remove high pressure hose from P/S pump. 6.
Page 456 10. Remove rear body. 11. Remove rear body O-ring. 12. Remove cam ring. 13. Remove rotor. 14. Remove valves. 15. Remove side plate. 16. Remove two O-rings from side plate. Inspection Replace pump assembly if necessary. 1. Check for cracks and damage of front and rear bodies, and for abnormal wear of moving surface of rotor. 2.
Page 457 3. Align side plate pin holes to ease installation of rear body. 4. Install rotor with rotor identification mark facing up. 5. Install ten vanes with flat portions facing inside rotor. 6. Install cam ring with identification mark facing down. 7.
Page 458 2001 > 1.8L DOHC > Inspection Steering wheel effort 1. With vehicle on a hard level surface. Turn wheels to straight-ahead position. 2. Start engine and warm power steering fluid to 122~140(50~60) Turn steering wheel flly left and right several times to warm fluid.
Page 459 Fluid leakage 1. Start engine. 2. Remember to run steering wheel fully left and right to build fluid pressure. 3. Check for fluid leakage. 1) To prevent damage, do not keep steering wheel fully turned rof more than 15 seconds. 2) Points wheel fluid leakage might occur are indicated by arrows in figure.
Page 460 1. Assemble SST(0K201 232 AA0) as shown in figure, and tighten its fittings. Tightening torque : 29~36 lb-ft (39~49 N·m, 4~5 kg-m) 2. Disconnect high-pressure hose from pump, and connect SST(0K210 323 AA0) between hose and pump. Before disconnecting hose, place marks at connections for proper reinstallation. 3.
Page 461 8. Remove SST(0K210 323 AA0). Replace and tightne high-pressure hose. Tighten to specified torque. Tightening torque : 29~36 lb-ft(39~49 Nm, 4~5kg-m) 9. Bleed air from system (Refer to steering system on-vehicle service). Drive belt 1. Check drive belt for wear, cracks, and fraying. Replace if necessary. 2.
Page 462 Drive belt 1. Loosen pivot bolt, locknut, and bracket nut. Turn adjusting bolt to set specified deflection. 2. Tighten, and to specified torques. Tightening torque Bolt : 28~38 lb-ft(37~52 Nm, 3.8~5.3 kg-m) Nut : 28~38 lb-ft (37~52 Nm, 3.8~5.3kg-m) Nut : 28~38 lb0ft (37~52 Nm, 3.8~5.3kg-m) Replacement 1.
Page 463 Manual Transaxle System Manual Transaxle System General Information...
Page 464 2001 > 1.8L DOHC > Structural view Component Cross-sectional view...
Page 465 Power flow...
Page 467 Manual Transaxle System Manual Transaxle System Manual Transaxle System...
Page 468 2001 > 1.8L DOHC > Component Component...
Page 470 5th/Reverse gear and housing parts 1. Measure 5th gear thrust clearance, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly note. 3. Assembly will be performed in reverse order of disassembly.
Page 471 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable(first) and positive battery cable (second). 2. Remove two nuts and remove fresh air duct. 3. To remove air cleaner assembly, disconnect hose from intake manifold, MAF sensor connector, air temperature sensor connector and two bolts, one nut and then remove air cleaner assembly.
Page 472 11. Remove No.4 engine mounting bolts (three to transaxle) and remove No.4 engine mount. 12. Loosen four lug nuts from both front wheels (LH, RH). 13. Raise and properly support vehicle. 14. Remove both front wheels. 15. Remove splash shield under the left side of vehicle. (three bolts and three fasteners). 16.
Page 473 22. Remove pinch bolt and front left ball joints and disconnect ball joints from steering knuckles. 23. Gently pry left driveshaft from transaxle. 24. Slide driveshaft assembly out of transaxle and install SST (0K201 270 014). 25. Remove four No.2 engine mounting bolts and remove No.2 engine mount. 26.
Page 474 Installation 1. Raise and suitable support vehicle. 2. Set transaxle on jack or floorjack and position transaxle under vehicle. 3. Raise transaxle and align transaxle with engine. 4. Connect transaxle to engine using six mounting bolts through clutch housing. Tightening torque : : 28~38 lb-ft (37~52 N·m, 3.8~5.3 kg-m) : 66~86 lb-ft (89~116 N·m, 9.1 ~11.9 kg-m) 5.
Page 475 Tightening torque : 32~45 lb-ft (43~61 N·m, 4.4~6.2kg-m) 12. Install left tie rod end to steering knukle then install tie rod end nuts. Tightening torque : 22~33 lb-ft(30~44 N·m, 3.0~4.5 kg-m) 13. Insert cotter pins. 14. Connect control rod with one nut and two bolts. 15.
Page 476 22. Install two No.2 engine mount-to mounting member nuts. Tightening torque : : 23~38 lb-ft (38~51 N·m, 3.8~5.3kg-m) 23. Install left splash shield (three bolts and three fasteners) 24. Install both ring and left wheels, then tighten both right and left lug nuts (four lug nuts each). Tightening torque : 65~87 lb-ft(88~118 N·m, 9~12 kg-m) 25.
Page 477 Tightening torque : 27~38 lb-ft(37~52 N·m, 3.8~5.3kg-m) 30. Reconnect crankshaft position sensor connector. 31. Reconnect ground strap with one bolt. 32. Reconnect vehicle speed sensor connector. 33. Reconnect back-up switch connector. 34. Reinstall air cleaner assembly. 35. Reconnect air temperature sensor connector. 36.
Page 478 2. Lock primary shaft using SST(0K201 323 021). 3. Shift to 1st gear to lock rotation of secondart shaft. 4. Uncramp tabs of locknuts. 5. Remove locknuts from primary and secondary shafts. Shift fork and shift rod assembly 1. Align ends of interlock sleeve and cotnrol leer (arrow). Turn shift rod counterclockwise. 2.
Page 479 Assembly 5th/Reverse gear and housing parts Assemble in order shown infigure, refer to Assembly note. Primary shaft assembly and secondary shaft assembly 1. Install primary shaft assembly and secondary shaft assembly in to clutch housing as a unit. Shift fork and shift rod assembly 1.
Page 480 Crank lever assembly and crank lever shaft 1. Install new O-ring to crank lever shaft. 2. Fit crank lever between change arm and control end, and insert crank lever shaft. 3. Align pin holes of crank lever shaft and clutch housing, and insert pin. 5th/reverse shift rod end and 5th/reverse shift rod 1.
Page 481 Secondary 5th gear 1. Install secondary 5th gear as shown. 5th/reverse clutch nub assembly and 5th/reverse shift fork 1. Install 5th/reverse clutch nub assembly and 5th/reverse shift fork together. Locknut 1. Shift to 1st gear. 2. Lock primary shaft using SST(0K201 323 021). 3.
Page 482 Bearing preload adjustment When replacing any of parts listed in table below, adjust bearing preload by selection and installing proper adjustment shim(s). Primary shaft assembly Secondary shaft assembly Differential · Transaxle case · Transaxle case · Transaxle case · Clutch housing ·...
Page 483 1. Install primary and secondary shaft bearing races into transaxle case (diaphragm springs and shims removed) 2. Mount clutch housing onto transaxle hanger, and set differential bearing race into clutch housing. Position piece of pipe against bearing race and tap it in until it contacts clutch housing. 3.
Page 484 7. Install transaxle case and tighten SST(0K130 191 A07) to specified torque. Tightening torque : 28~38 lb-ft(38~51 N·m, 3.8~5.3 kg-m) 8. To seat bearings, mount SST(0K130 175 A03) on parts of selectors, and turn selectors so gaps are widened. Then turn SST(0K130 175 A03) in reverse direction until gaps are eliminated. 9.
Page 485 Standard clearance : 0~0.002 in (0~0.05 mm) Example : 0.048 in (1.22 mm) - 0.026 in (0.065 mm) = 0.022 in (0.57 mm) Shim selection range : (0.022 in (0.57 mm) - 0.002 in (0.05 mm)) ~ (0.022 in (0.57 mm) - 0 mm (0 in)) = 0.020 in (0.52 mm) ~ 0.022 in (0.57 mm) Shim : 0.022 in (0.55 mm) Thickness (Shaft gears)
Page 486 Example : 0.013 in (0.32 mm) 0.013 in (0.32 mm) + 0.006 in (0.15 mm) + 0.019 in (0.47 mm). Nearest shim (on thick side) to 0.019 in (0.47 mm) is 0.020 in (0.50 mm). 5. Remove transaxle case and SST(0K900 175 AA0) 6.
Page 487 1. Install diaphragm spring as shown in figure. Bearing race (transaxle case) 1. Install adjustment shim(s) to primary and secondary shaft bearing seats in transaxle case. 2. Apply transaxle oil to each bearing race, and install themn to transaxle case by using pipe. Oil seal(change rod assembly) 1.
Page 488 Bearing preload Verify shaft gears and differential bearing preloads. Readjust bearing preloads if then are no within specification. 1. Set primary shaft gear assembly and differential into clutch hosing. 2. Install transaxle case, and tighten to specifed torque. Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.3 kg-m) 3.
Page 489 Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.3kg-m) 10. Install SST(0K130 171 A05) to secondary shaft gear assembly. 11. Connect torque wrench to SST(0K130 171 A5) and measure preload. Preload : 1.8~3.4 lb-in (0.2~0.4 N·m, 2.0~4.0 kg-cm)
Page 490 Manual Transaxle System Manual Transaxle System Manual Transaxle Case...
Page 491 2001 > 1.8L DOHC > Component...
Page 492 2001 > 1.8L DOHC > Disassembly CLUTCH housing and transaxle case Do not remove an oil seal if not necessary. 1. Disassemble in order on figure, refer to Disassembly note. 2. Assembly will be in reverse order of disassembly. Bearing outer race(primary shaft side) 1.
Page 493 • Insert screwdriver between clutch housing and bearing outer race. • Pry bearing outer race free. Oil seal(Primary shaft) Do not damage clutch housing. 1. Remove oil seal with screwdriver. Oil seal (Differential) 1. Remove oil seal with screwdriver. Bearing outer race (Differential) 1.
Page 494 1. Install SST(0K130 170 012) to bearing outer race. 2. Remove bearing outer race and adjust shim. Oil seal(Speedometer gear case) 1. Remove oil seal. Transaxle case oil seal (Differential side) 1. Assemble oil seal using SST (0K201 170 AA1).
Page 495 2001 > 1.8L DOHC > Oil inspection 1. Raise vehicle and support it with safety stands. Keep vehicle level when checking oil level. 2. Remove oil level plug and washer. 3. Verify that oil level is near bottom of plug hole. 4.
Page 496 3. Install new washer on drain plug and reinstall plug in case. Tightening torque : 29~43 lb-ft(40~58 N·m, 4.0~6.0 kg-m) 4. Remove oil level plug from transaxle case. 5. Add specified amount and type of oil into oil level plug hole until level reaches bottom of hole. Specified oil : Grade : API Service GL-4 Viscosity : SAE 75W-90...
Page 497 Do not damage dust boots. 6. Remove pinch bolt and pull lower arm downward to separate knuckle from lower cotnrol arm ball joint. 7. Loosen nut and disconnect tie-rod end with SST(0K130 283 021). Do not subject CV joint to shock when removing driveshaft. 8.
Page 498 11. Tap new oil seal into transaxle case with SST(0K201 170 AA1). 12. Replace driveshaft end clip and install driveshaft into transaxle with end-gap of clip facing upward.
Page 499 Manual Transaxle System Manual Transaxle System Manual Transaxle Gear System - Differential...
Page 500 2001 > 1.8L DOHC > Component Component...
Page 502 2001 > 1.8L DOHC > Disassembly Pre-inspection Do not remove side bearings unless necessary. Backlash of side gear and pinion gear 1. Before disassembly, measure backlash of side gears and pinion gears. If not within specification, replace differential assembly. Backlash Standard : 0.001~0.004 in (0.025~0.1 mm) Maximum : 0.020 in (0.5 mm) 2.
Page 503 6. Remove side bearing (ring gear side) from gearcase with SST (0K670 990 AA0). Reassembly 1. Set speedometer drive gear onto ring gear and case assembly. Do not reuse side bearings if they were removed. 2. Press side bearing (side opposite ring gear) into ring gear and case assembly with SST (0K990 175 AA1). 3.
Page 504 7. Install thrust washers and side gears into gear case at same time, then rotate them around pinion gears and align them with driveshaft holes. Be certain that both side gears are centered in their respective driveshaft holes. If not, remove both side gears and re-install them again.
Page 505 2. Set transaxle case on a stand and install SST (0K130 191 A07). 3. Tighten SST (0K130 191 A06) to specified torque. Tightening torque : 27~38 lb-ft (36~51 N·m, 3.7~5.3 kg-m) 4. Set differential assembly into converter housing. Eliminate gap (arrow) by turning either A or B of selector. Do not overtighten. 5.
Page 506 9. Insert SST through transaxle case and attach it to pinion shaft. 10. Install torque meter. Read preload when differential is rotating. 11. Adjust clearance between A and B to obtain specified preload reading. Preload : 4.3 lb-in (0.5 N·m, 0.05 kg) 12.
Page 507 14. Remove transaxle case. 15. Install required shim(s) and tap bearing race into transaxle case. 16. Install transaxle case. Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.1 kg-m) 17. Using SST (0K130 191 A05) and a torque meter, verify that preload is within specification. If not within specification, return to Step 1.
Page 508 Disassembly note Bearing (ring gear opposite side) Do not remove the bearing unless you are replaceing it. 1. Remove bearing by using SST(0K130 171 013). Side bearing inner race Be careful not to drop differential case. 1. Using SST (0K670 990 AA0), remove side bearing inner race (opposite side of ring gear). Bearing (ring gear side) 1.
Page 509 Bearing 1. Inspect for wear and rough rotation. If bearing is removed then replace it and bearing race together, and adjust bearing preload. Assembly note Bearing (ring gear side) 1. Install new bearing by using SST(0K011 270 A02). Bearing (ring gear opposite side) 1.
Page 510 Backlash of side gear and pinion gear Measure backlash by following procedure : 1. Install left driveshaft and right joint shaft in differntial assembly. 2. Support shafts on V-blocks as shonw in figure. 3. Measure backlash of both pinion gears. Backlash : 0.002 ~ 0.006 in (0.05~0.15 mm) 4.
Page 511 Manual Transaxle System Manual Transaxle System Manual Transaxle Shift Control...
Page 512 2001 > 1.8L DOHC > Component...
Page 514 2001 > 1.8L DOHC > Overhaul 1. Disassemble in the order shown in the figure. 2. Inspect all parts and repair or repalce as necessary. 3. Assemble in the reverse order of disassembly, refer to Assembly note. Assembly note Extension bar 1.
Page 515 Automatic Transaxle System Automatic Transaxle System General Information...
Page 516 2001 > 1.8L DOHC > Special service tools Automatic transaxle Tool (Name and Number) Illustration 0K2CA 089 HSP Hi-Scan pro 0K130 283 021 Used to remove tie-rod end. Puller, ball joint 0K130 990 007 Used to disassemble transaxle. Stand, engine 0K670 990 AA0 Used to remove bearing Puller set, bearing...
Page 517 0K130 175 011A Used to disassemble transaxle. Hanger, ttansaxle 0K130 170 012 Used to remove bearing outer race. Remover, bearing 0K201 170 AA0 Used to remove transaxle. Support, engine 0K201 190 016 Used to disassemble/assemble 3-4 clutch. Leak checker 0K130 322 020 Used to measure bearing preload.
Page 518 0K130 191 034 Used to adjust bearing preload. Holder, idler gear shaft 0K201 190 017 Used to remove oil seal Installer, oil seal 0K201 190 019 Used to remove/install turbine shaft. Holder, turbine shaft 0K201 175 AA0 Used to adjust preload. Selector set, shim 0K130 171 013 Used to remove differential bearing.
Page 519: 0K130 191
0K2CA 190 AA1 Spring retainer assembly Used to remove/install spring retainer assembly. SPEICIAL SERVICE TOOLS Tool(Number & Name) Illustrator 0K201 170 AA0 Used to support engine. Support, engine 0K130 990 007 Used to disassemble and assemble Engine stand transaxle. 0K201 323 321 Used to hold primary shaft.
Page 520: Puller, Bearing
0K130 171 013 Used to remove bearing Puller, bearing 0K130 283 021 Used to remove tie-rod end. Puller, ball joint 0K130 175 011A Used to disassemble and assemble Hanger, transaxle transaxle. 0K130 170 012 Used to remove bearing Remover, bearing 0K130 175 008 Used to remove gears.
Page 521 0K130 175 A11 Attachment B(Part of 0K900 Used to install bearing. 175 AA1) 0K011 270 A02 Attachment E(Part of 0K900 Used to install ear. 175 AA1) 0K900 175 AA0 Used to adjust bearing preload. Shim selector set 0K900 175 A01 Selector (Part of 0K900 175 Used to adjust bearing preload.
Page 522: 0K130 322 020
0K130 191 A05 Used to adjust bearing preload. Adapter, preload 0K130 322 020 Used to measure preload. Attachment 0K201 270 014 Used to hold differential side gears. Holder, differential side gear...
Page 523 2001 > 1.8L DOHC > Manual transaxle Diagnostic chart Problem Possible cause Action Seized shift lever ball seat Replace Shift lever does not shift Seized control rod joint Replace smoothly or is hard to shift Bent control rod Replace Worn control rod bushing Replace Too much play in shift lever Weak shift lever ball spring...
Page 524 2001 > 1.8L DOHC > Specifications Auto transaxle Engine Item F4A-EL TB DOHC EL Front wheel drive, 4-speed with electronic shift Type control Transaxle control Floor shift and "O/D system" feature Torque converter Type Lock-up with electronic control Stall torque ratio 2.08:1 Stall speed RPM 2200~2500...
Page 525 3.307 1.833 1.310 Gear ratio 1.030 0.795 Reverse 3.166 Final gear ration 4.105 Grade API Service GL-4 Viscosity SAE 75 W-90 Capacity US qt (liters, lmp qt) 2.58(2.7, 2.4)
Page 526 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle System...
Page 527 2001 > 1.8L DOHC > Circuit schematic...
Page 529 2001 > 1.8L DOHC > Oil seal Removal and replacement 1. Remove driveshaft. 2. Remove oil seal with a screwdriver. 3. Tap new oil seal into transaxle case with SST (0K201 170 AA1). 1) Tap in until SST (0K201 170 AA1) contacts case. 2) Coat oil seal lip with ATF.
Page 530 7. Remove oil pan (19 bolts) and gasket. 8. Disconnect all electrical connectors, remove eight bolts, and remove control valve body. Replacement 1. Install control valve body, (8) bolts, and wiring clips as shown. Bolt length (measured from below the head) : 1.18 in (30 mm) : 1.97 in (50 mm) Tightening torque : 69.6~94.8 lb-in (7.9~10.7 N·m, 80~110 kg-cm)
Page 532 2001 > 1.8L DOHC > Description and operation Cross-sectional view Power flow diagram...
Page 533 Component operation table : O/D OFF system...
Page 534 Solenoid valve operation table : O/D OFF system...
Page 535 Fluid passage locations (Transaxle case) Transaxle case...
Page 536 Clutch housing Clutch housing...
Page 537 Oil pump Hydraulic circuuit (P range)
Page 538 R range...
Page 539 N range...
Page 540 D range : 1st gear...
Page 541 D range : 2nd gear...
Page 542 D range : 3rd gear...
Page 543 D range : O/D gear converter OFF...
Page 544 D range : O/D gear torque converter clutch ON...
Page 545 2nd gear...
Page 546 1 range...
Page 548 2001 > 1.8L DOHC > Fluid leaks Check for transaxle fluid leaks at points shown below and repair or replace as necessary. Additionally, check all of following : 1. Gaskets, O-rings, and plugs. 2. Oil hoses, oil pipes, and connections. 3.
Page 550 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle System - Automatic Transaxle...
Page 551 2001 > 1.8L DOHC > Component...
Page 555 2001 > 1.8L DOHC > Disassembly General notice 1. Disassemble transaxle in a clean area (dustprool work space) to prevent entry of dust into mechanisms. 2. Inspect individual transaxle components in accordance with Quick Diagnosis Chart during disassembly. 3. Use only plastic hammers when applying force to separate light alloy case joints. 4.
Page 556 11. Remove vehicle speed sensor and driven gear. 12. Remove inlet pipe. 13. Remove outlet pipe. 14. Assemble SST (0K130 175 011A/0K 130 990 007). Do not lean transaxle to one side during disassembly. It may rotate suddenly and cause injury. Remove oil pan before turning transaxle over.
Page 557 18. Remove strainer (three bolts). 19. Remove A, B and C bolts and brackets shown in figure. Bolt length (Measured from below head) : A : 1.18 in (30 mm) B : 1.67 in (50 mm) C : 0.55 in (14 mm) 20.
Page 558 26. Remove oil pump assembly (10 bolts). 27. Remove reverse/forward clutch assembly. A. Remove turbine shaft snap ring. B. Pull reverse/forward drum and remove clutch assembly. 28. Removesmall sun gear and one-way clutch No. 1. Use a piece of wire to secure brake band so that it is not damaged by being stretched. 29.
Page 559 30. Pull anchor shaft holding strut. 31. Remove strut. 32. Remove servo with SST (0K2CA 190 AA2). A. Compress servo piston and remove snap ring. B. Remove servo retainer, servo piston, and spring. 33. Remove one-way clutch No. 2 and planetary carrier assembly. A.
Page 560 B. Remove internal gear from output shell. 35. Remove 3-4 clutch assembly. A. Remove O-ring from turbine shaft at converter housing side. B. Pull out turbine shaft to remove 3-4 clutch assembly. C. Remove 3-4 clutch assembly from turbine shaft. 36.
Page 561 38. Remove differential assembly. 39. Remove bearing housing. A. Remove roll pin with a pin punch. B. Remove (11) bolts securing bearing housing. C. Remove bearing housing by tapping lightly with a plastic hammer. 40. Remove idler gear assembly and output gear assembly by tapping out from torque converter side. 41.
Page 562 Install bearing outer race during reassembly to adjust preload. 42. Press out bearing outer races by using SST (0K130 170 012). Reassembly Precaution 1. If drive plates or brake band are replaced with new ones, soak new part in ATF for at least two hours before installation.
Page 563 Bearing and race at location 2, 3, 4, 6 and 7 are one-piece units. 1. Align bush cover with guide bolts as shown, and press it in. Tightening torque : 96~120 lb-in (10.8~13.7 N·m, 110~140 kg-cm)
Page 564 2. Install idler gear and output gear as an assembly by tapping it with a plastic hammer. 3. Install bearing housing. A. Install bearing housing on converter housing. B. Align groove on idler shaft with mark on bearing housing. C. Tap a new roll pin in with a pin punch and hammer. D.
Page 565 6. Install detent lever and return spring. 7. Install parking assist lever. 8. Install lever holder and bolt. Tightening torque : 69.6~94.8 lb-in (7.9~10.7 N·m, 80~110 kg-cm) 9. Install manual shaft and manual plate. A. Install manual plate, washer, and nut. B.
Page 566 10. Install differential assembly into converter housing. Install SST (0K201 270 014) or equivalent. 11. Install a new oil control ring onto output gear assembly. 12. Install output shell to output gear and install bearing race onto output shell. Thrust bearing outer diameter : 2.84 in (72.1 mm) 13.
Page 567 B. Verify that thrust bearing is properly installed. C. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly. 18. Install internal gear. A. Install internal gear to output shell. B. Install snap ring. 19. Install planetary carrier assembly. A.
Page 568 Installation order : Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive 21. Install retaining plate. 22. Install snap ring. 23. Install friction plate. 24. Install one-way clutch No. 2. A. Hold one-way clutch No. 2 horizontally. B. Install it by turning planetary carrier counterclockwise. C. Install snap ring. 25.
Page 569 27. Install small sun gear and one-way clutch No. 1. A. Verify that thrust bearing and bearing race are installed in correct position. B. Install small sun gear and one-way clutch No. 1 while rotating it. 28. Install reverse/forward clutch assembly. A.
Page 570 29. Install snap ring into bottom ring groove of turbine shaft. 30. Measure total end play select a suitable bearing race as follows : A. Set thrust bearing onto reverse/forward clutch assembly. B. Remove previously used race and gasket. C. Set thickest bearing race 0.089 in (2.2 mm) onto oil pump. D.
Page 571 0.004~0.011 (0.11~0.30) 0.079 (2.0) 0~0.003 (0~0.10) 0.087 (2.2) G. Remove oil pump. H. Place selected bearing race and a new gasket onto oil pump. I. Install oil pump onto transaxle assembly. Tightening torque : 14~18 lb-ft (N·m, 190~260 kg-cm) 31. Verify 2-4 brake band adjustment as follows : A.
Page 572 E. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure piston stem stroke. Air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum Stroke : 0.039~0.067 in (1.0~1.7 mm) F. If not within specification, select proper piston stem from below. Piston stem length in (mm) 3.740 (95.0) 3.760 (95.5)
Page 573 34. Connect solenoid valve and ATF temperature sensor connectors. 35. Connect solenoid connector. Attach magnets inside oil pan in positions shown on illustration (in oil pan). 36. Install a new gasket and oil pan tighten 19 bolts. Tightening torque : 74.4~94.8 lb-in (8.4~10.7 N·m, 80~110 kg-cm) 37.
Page 574 Tightening torque : 70~95 lb-in (7.9~10.7 N·m, 80~110 kg-cm) D. Verify that the selector lever range position and transaxle range switch correspond. 42. Remove transaxle from SST (0K 130 990 007/0K130 175 011A). 43. Install a new O-ring and install oil level gauge and oil filler tube to transaxle case. Tightening torque : 69.6~94.8 lb-in (7.9~10.7 N·m, 80~110 kg-cm) 44.
Page 575 1. Remove bearing outer race from bearing cover. 2. Install bearing cover with SST (0K201 190 017). 3. Align bearing cover with guide bolts as shown, and press it in. Torque bearing cover bolts. Tightening torque : 96~120 lb-in (10.8~13.7 N·m, 110~140 kg-cm) 4.
Page 576 9. Set four SST (0K130 191 A03) on converter housing in positions shown. 10. Set bearing housing on output gear assembly and install four SST (0K130 175 A04) ; then tighten them to specified torque. Tightening torque : 14~18 lb-ft (19~25 N·m, 1.9~2.6 kg-m) 11.
Page 577 2) Meausre clearance around entire circumference and select shims equivalent to maximum clearance. 3) The maximum allowable number of shims is 7. 15. Measure clearance. Select adjustment shim (s) equivalent to measured clearance. Thickness of shim in (mm) 0.020 (0.50) 0.022 (0.55) 0.024 (0.60) 0.026 (0.65)
Page 578 21. Install output gear assembly and bearing housing. Tightening torque : 14~18 lb-ft (19~25 N·m, 1.9~2.6 kg-m) Do not install idler gear at this time. 22. Using SST (0K130 191 A04) and a torque meter, verify that preload reading is within specification. Preload : 0.27~7.8 lb-in (0.03~0.8 N·m, 0.3~9.0 kg-cm) 23.
Page 579 2. Pour in ATF 0.5 US qt (0.5 liter, 0.44 lmp qt). 3. Shake converter to clean inside. Pour out ATF. 4. Pour in ATF. 5. Shake converter to clean inside. Pour out ATF. Replace torque converter if it contains any metallic particles.
Page 580 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle System - Kick Down Band...
Page 581 2001 > 1.8L DOHC > Component Brake band...
Page 582 2001 > 1.8L DOHC > Disassembly Brake band 1. Disassembly in order shown in figure. Use a piece of wire to secure 2-4 brake band so that it is not damaged by being allowed to fully expand. Inspection Brake band 2-4 Brake band 1.
Page 583 Reassembly Brake band Install spring exactly in direction shown. 1. Install orifice valve, orifice check spring, and orifice holder as shown. 2. Install orifice assembly and washer to transaxle case. 3. Tighten orifice assembly using a hexagonal wrench. Tightening torque : 29~39 lb-ft (40~53 N·m, 4.0~5.0 kg/cm²) 4.
Page 584 7. Insert piston stem into servo piston and secure it with a new spring clip. 8. Apply ATF to new O-ring and install it to servo retainer. O-ring inner diameter : 2.587 in (65.7 mm) 9. Assemble servo piston and servo retainer. Do not install servo piston and retainer into transaxle case at this time.
Page 585 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle System - o a ic an a...
Page 586 2001 > 1.8L DOHC > Component...
Page 587 2001 > 1.8L DOHC > Disassembly 1. Remove accumulator pistons and springs from clutch housing by applying compressed air through oil passage as shown in figure. Item Accumulator Location Oil passage 2-3 accumulator 1-2 accumulator N-D accumulator N-R accumulator Inspection Accumulator spring 1.
Page 588 Spec Spring Outer dia. Free length Number of Wire dia. Color in (mm) in (mm) coils in (mm) 2-3 accumulator spring 0.456 0.350 0.070 18.9 White (11.6) (59.7) (1.8) 2-3 accumulator spring 0591 2.827 0.047 11.8 White (15.0) (71.8) (1.2) 1-2 accumulator spring 0.433 3.216...
Page 589 N-D accumulator 1.176 (29.87) 0.862 (21.91) N-R accumulator 1.176 (29.87) 2. Install acuumulator pistons and springs. 3. Install stopper and snap ring.
Page 590 2001 > 1.8L DOHC > Symptom related diagnostic procedure Quick diagnosis chart The Quick Diagnosis Chart shows various problems and relationship of various components that may be cause. 1. Components indicated in "Self-diagnosis" row are diagnosed by transaxle control module self-diagnosis function. The Data Link connector can be used for retrieving diagnostic trouble codes with a scan tool (0K2A1 089 AA0).
Page 591 QuickDiagnosis Chart (II)
Page 592 Quick Diagnosis Chart (II-2)
Page 593 Quick Diagnosis Chart (II-2)
Page 594 Troubleshooting guide Most of the automatic transaxle control system is electrically controlled. This often makes it difficult to diagnose intermittent problems in system. Before undertaking actual checks, take a few minutes to talk with customers who approach you with a driveability complaint. the customer is often a good source of information regarding intermittent problems.
Page 595 Troubleshooting item # : Each troubleshooting item is assigned a number. There are 28 troubleshooting itmes. Choose item that most closely corresponds to actual symptom. Troubleshooting chart Will start in other than P and N ranges Description Engine starts in P, N and other ranges. (TROUBLESHOOTING HINTS) 1.
Page 596: Surges While Cruising
5. Action This recommends appropriate action to take as a result (Yes/No) of INSPECTION. How to perform action is described on reference page shown. Diagnostic index Troubleshooting item Description Trouble Will start in other than P and N range Engine starts in P, N, and other ranges Idle when shifted from Engine stops unexpectedly when shifted from N or P to N or P to other ranges...
Page 597 Down to downshift when accelerator pedal depressed No kickdown more than 7/8 within kickdown range When accelerating Engine speed flares up on acceleration Engine flares up when accelerator pedal depressed for Engine speed flares When upshifting upshifting and/or downshifting Engine flares up suddenly when accelerator pedal depressed for downshifting P, N to R and/or N to D Strong shift shock felt at idle when shift from N to range Excessive shift shock felt when accelerating at upshifting...
Page 598 Check transaxle range switch and wiring. • H-01/18, H-01/8, H-01/36, H-01/37 Terminal : Transaxle range switch Engine stalls when shifted from N or P to other ranges Description Engine stops unexpectedly when shifted from N or P to other ranges at idle (TROUBLESHOOTING HINTS) 1.
Page 599 Are resistance of torque converter clutch Go to next step. solenoid valve and output voltage of TCM terminal OK? Vb : Battery voltage If resistance is not OK, check for malfunctioning parts and wiring. · Torque converter clutch solenoid valve. If resistance is OK but voltage is not, check wiring and/or replace TCM.
Page 600: Poor Acceleration
Poor acceleration at drive-away Description Engine speed increases normally but vehicle speed slowly increases during acceleration (TROUBLESHOOTING HINTS) 1. ATF level low or high 2. Throttle position sensor malfunction or improperly adjusted 3. Line pressure incorrect 4. Torque converter clutch solenoid malfunction 5.
Page 601 Check EMS parts & Engine and/or replace TCM. Is engine stall speed OK? Stall speed : 2200~250 rpm Overhaul transaxle and repair or replace parts as necessary. Poor acceleration on acceleration Description Engine speed increases normally but vehicle speed slowly increases during acceleration (TROUBLESHOOTING HINTS) 1.
Page 602 If resistance is OK but Voltage is not, check wiring and/or replace TCM. Solenoid valve resistance : 14~18Ω Check Engine parts and/or replace TCM. Is engine stall speed OK? Overhaul transaxle and repair or replace parts Stall speed : 2200~2500 rpm as necessary.
Page 603 If resistance is OK but Voltage is not, check wiring and/or replace TCM. Solenoid valve resistance : 14~18Ω Poor fuel economy Description Fuel economy unsatisfactory (TROUBLESHOOTING HINTS) 1. ATF level low 2. Throttle position (TP) sensor malfunction or not adjusted correctly 3.
Page 604 wiring and/or replace TCM. Solenoid valve resistance : 14~18Ω Is Line pressure OK? Go to next step. Check linear solenoid valve. If line pressure is not within specifications after linear solenoid inspection, replace control valve body assembly. Check EMS parts & Engine and/or replace TCM.
Page 605 Go to next step. Operate selector lever; are selector lever and range indicator positions aligned? Adjust transaxle range switch. Go to next step. Operate selector lever; does transaxle operate normally and are selector lever and transaxle Overhaul transaxle and repair or replace parts position aligned? as necessary.
Page 606 Go to next step. Operate selector lever ; does transaxle operate normally and are selector lever and transaxle Overhaul transaxle and repair or replace parts position aligned? as necessary. Vehicle moves in P range Description • Vehicle rolls in P range (TROUBLESHOOTING HINTS) 1.
Page 607 5. Transaxle range switch worn or maladjusted 6. Line pressure low 7. Linear solenoid valve malfunction 8. O/D switch malfunction 9. Shift solenoid valve (A, B, C) malfunction 10. TCM malfunction 11. Control valve stuck 12. Powertrain damaged (forward clutch, 3-4 clutch, 2-4 band, one-way clutch 1) Step Inspection Action...
Page 608 Solenoid valve resistance : 14~18Ω • H-01/30 terminal : Shift solenoid A • H-01/33 terminal : Shift solenoid B • H-01/32 terminal : Shift solenoid C Are resistance and output voltage of shift solenoids (A,B,C) at TCM terminals OK? Vb : Battery voltage Go to next step.
Page 609 • H-01/38 terminal : Throttle position (TP) sensor • H-01/44 terminal : Input/turbine speed sensor ground • H-01/16 terminal : Input/turbine speed sensor signal • H-01/42 terminal : Vehicle speed sesnor • H-01/45 terminal : O/D switch • H-01/18, H-01/8, H-01/36, H01-37 terminal : Transaxle range switch Go to next step.
Page 610 Solenoid valve resistance : 14~18Ω • H-01/30 terminal : Shift solenoid A • H-01/33 terminal : Shift solenoid B • H-01/32 terminal : Shift solenoid C Are resistance and output voltage of throttle position (TP) sensor at TCM terminals OK? Go to next step.
Page 611 Are measurements at TCM terminals OK? Go to next step. Check for malfunctioning parts and wiring. • Throttle position (TP) sensor H-01/38 terminal : Throttle position (TP) sensor (from ECM) Replace TCM. Replace with known operational TCM. Is Replace control valve body assembly. problem corrected? If problem remains, overhaul transaxle and repair or replace parts as necessary.
Page 612 • H-01/38 terminal : Throttle position (TP) sensor ground • H-01/44 terminal : Input/turbine speed sensor ground • H-01/16 terminal : Input/turbine speed sensor signal Are measurements at TCM terminals OK? Go to next step. • H-01/21 terminal : Transaxle fluid Check transaxle fluid temperature sensor.
Page 613 Go to next step. Is continuity of transaxle range switch OK? Adjust and/or replace transaxle range switch. Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK? Go to next step. Vb : Battery Voltage If resistance is not OK, check for malfunctioning parts and wiring.
Page 614 wiring and or replace TCM. Solenoid valve resistance : 14~18Ω Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK? Vb : Battery Voltage Go to next step. If resistance is not OK, check for malfunctioning parts and wiring.
Page 615 range indicator positions aligned? Adjust transaxle range switch. Go to next step. Operate selector lever ; does transaxle operate normally and are selector lever and transaxle Overhaul transaxle and repair or replace parts position aligned? as necessary. Is line pressure OK? Go to next step.
Page 616 Engine speed flares up on acceleration Description Engine speed flares up on acceleration (TROUBLESHOOTING HINTS) 1. ATF level low 2. Line pressure low 3. Control valve stuck 4. Powertrain slippage (forward clutch, 2-4 brake band, one-way clutch No. 1 or No. 2, 3-4 clutch) 5.
Page 617 • Engine flares up when accelerator pedal depressed for upshifting Description • Engine flares up suddenly when accelerator pedal depressed for downshifting (TROUBLESHOOTING HINTS) 1. ATF level low 2. Line pressure incorrect 3. Throttle (TP) sensor malfunction or misadjusted 4. Input/turbine speed sensor malfunction 5.
Page 618 • H-01/38 terminal : Throttle position sensor • H-01/44 terminal : Input/turbine speed sensor ground • H-01/16 terminal : Input/turbine speed sensor signal Excessive shift shock at P, N to R and/or N to D Description Strong shift shcok felt at idle when shifting from P or N to D or R range (TROUBLESHOOTING HINTS) Step Inspection...
Page 619 Go to next step. Operate selector lever ; are selector lever and range indicator positions aligned? Adjust transaxle range switch. Go to next step. Operate selector lever ; does transaxle operate normally and are selector lever and transaxle Overhaul transaxle and repair or replace parts position aligned? as necessary.
Page 620 • H-01/38 terminal : Throttle position (TP) sensor • H-01/44 terminal : Input/turbine speed sensor ground • H-01/16 terminal : Input/turbine speed sensor signal • H-01/42 terminal : Vehicle speed sensor • H-01/18, H-01/8, H-01/36, H-01/37 terminal : Transaxle range switch Go to next step.
Page 621 (TROUBLESHOOTING HINTS) 1. ATF level low 2. Line pressure high 3. Throttle position sensor malfunction or misadjusted 4. Input/turbine speed sensor malfunction 5. Transaxle fluid temperature sensor malfunction 6. TCM malfunction 7. Shift solenoids valves (A, B, C) worn 8. Orifice valve malfunction 9.
Page 622 • H-01/38 terminal : Throttle position (TP) sensor • H-01/44 terminal : Input/turbine speed sensor ground • H-01/16 terminal : Input/turbine speed sensor signal • H-01/22 terminal : Transaxle fluid temperature sensor • H-01/21 terminal : Ground Are resistance and output voltage of shift solenoids (A, B, C) at TCM terminals OK? Go to next step.
Page 623 No engine braking • Engine speed drops to idle but vehicle does not slow when accelerator pedal released while cruising at medium to high speed Description • Engine speed drops to idle but vehicle does not slow when accelerator pedal released when in 1 range at low vehicle speed (TROUBLESHOOTING HINTS) 1.
Page 624 Is line pressure OK? Go to next step. Check linear solenoid valve. If line pressure is not within specifications after linear solenoid valve inspection, replace control valve body assembly. Are measurements at TCM terminals OK? Vb : Battery voltage Go to next step. Check transaxle range switch and wiring.
Page 625 Transaxle overheats Description ATF smells burnt and/or is discolored (TROUBLESHOOTING HINTS) 1. ATF leve low 2. TCM malfunction Step Inspection Action Go to next step. Are ATF level and condition OK? If ATF level is not OK, add fluid as necessary Do transaxle seals, sealant, and gaskets If ATF condition is not OK, repair as follows : prevent leakage?
Page 626 Diagnostic trouble code Code No. Diagnosed circuit P0712 Oil temperature sensor low P0713 Oil temperature sensor high P0717 Input/turbine speed sensor circuit malfunction P0727 Engine speed input malfunction P0743 Torque converter clutch system circuit malfunction P0748 Linear solenoid electrical P0753 Shift solenoid A electrical P0758 Shift solenoid B electrical...
Page 627 Procedure 1. Start engine. 2. Check idle speed in P range. (Refer to emission control system) Idle speed : 750~850 rpm (with parking brake applied) 3. Shift selector lever to R range.
Page 628 Perform steps 4 and 5 within 5 seconds to prevent possible transaxle damage. 4. Firmly depress foot brake with left foot and gradually depress accelerator pedal fully with right foot. 5. When engine speed no longer increases, quickly read engine to speed and release accelerator. 6.
Page 629 1. Start engine. 2. Check idle speed in P range, refer to emission control system. Idle speed : 750~850 rpm (with parking brake applied) 3. Shift from N range to D range. 4. Use a stopwatch to measure time it takes from shifting until shock is felt. 5.
Page 630 N→2 range More than specification Excessive line pressure Insufficient line pressure Forward clutch slipping 2-4 brake band slipping One-way clutch No. 1 slipping Less than specification 1-2 accumulator not operating properly Excessive line pressure N→R shift More than specification Insufficient line pressure Low and reverse brake slipping Reverse clutch slipping Less than specification...
Page 631 1. Start engine. 2. Check idle speed in P range, refer to emission control. Idle speed : 750~850 rpm (with parking brake applied) 3. Shift selector lever to D range and read line pressure at idle. Perform steps 4 and 5 within 5 seconds to prevent possible transaxle damage. 4.
Page 632 are as shown in graph below The torque converter clutch will not operate in following conditions : 1) The engine coolant temperature is below 144°F (62°C). 2) The closed throttle position switch is ON. 3) The brake switch is ON. The transaxle fluid temperature is over 262°F (128°C) the torque converter clutch will operate in 3nd gear and 4th gear.
Page 634 2001 > 1.8L DOHC > Inspection [Automatic transaxle fluid (ATF)] Place vehicle on a flat surface. 1. Apply parking brake and position wheel chocks securely to prevent vehicle from rolling after roller test. 2. Warm-up engine until ATF reaches 140~158°F (60~70°C). 3.
Page 635 3. Install drain plug with specified torque. Tightening torque : 29~40 lb-ft (39~54 N·m, 4.0~5.5 kg-m) 4. Remove ATF level gauge, then pour specified ATF. ATF type : M-III or Dexron III Capacity : 5.7 US qt (5.4 liter, 4.7 lmp qt) Do not over fill above Hot range.
Page 636 5. Pull data link connector upward from mass air flow sensor. 6. To remove air cleaner assembly, disconnect hose from intake manifold, air temperature sensor connector, MAF sensor connector then remove two air cleaner assembly mounting bolts and one nut. 7.
Page 637 12. Disconnect auto transaxle range switch connector. 13. Disconnect solenoid valve connector. 14. Disconnect crankshaft position sensor connector. 15. Disconnect oxygen sensor connector. 16. Disconnect two ATF cooler hoses. 17. Remove two upper converter housing bolts. (top two) 18. Remove two upper starter bolts. 19.
Page 638 21. Remove splash shield from under engine. (three bolts and three fastners) 22. Remove left tir rod end from steering knuckle by removing one cotter pin and one nut. 23. Remove stabilizer control link from bracket attached to shock absorber assembly after loosening one nut. 24.
Page 639 28. Install SST (0K201 270 014) to prevent side gear from becoming misaligned. 29. Remove two nuts from U-bolt. 30. Remove five nuts (three front, two rear) then remove catalytic converter. 31. Remove converter housing access cover and remove four drive plate-to-torque converter mounting nuts. Rotate engine at crank pulley to gain access to all four nuts.
Page 640 35. Remove three No. 2 engine mounting bolts then remove No. 2 engine mounting from auto transaxle. 36. Support (and secure if possible) auto transaxle with a transaxle jack or suitable floor jack. 37. Remove two remaining converter housing bolts on front and rear sides of transaxle. 38.
Page 641 4. Remove floor jack from auto transaxle. 5. Remove SST (0K201 270 014). 6. Install No.2 engine mounting to auto transaxle then install three bolts. 7. Install four drive plate-to-torque converter mounting nuts. Rotate engine at crank pulley to gain access to all four nuts. Tightening torque : 25~36 lb-ft (34~49 N·m, 3.5~5.0 kg-m) 8.
Page 642 11. Install new clip on left driveshaft. 12. Push driveshaft into transaxle with opening of clip pointing upward. Tightening torque : 32~46 lb-ft (43~52 N·m, 4.4~5.3 kg-m) 13. Install left lower ball joint into spindle then install pinch bolt. Tightening torque : 32~39 lb-ft (43~54 N·m, 4.4~5.5 kg-m) 14.
Page 643 17. Install engine mounting member-to-chassis bolts (two front) and nuts. (two rear) Tightening torque : 48~65 lb-ft (64~89 N·m, 6.5~9.1 kg-m) 18. Install two nuts to No.2 engine mount-to-mounting member. Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.3 kg-m) 19. Install catalytic converter. (five nuts) Tightening torque : 27.4~38.3 lb-ft (37.2~51.9 N·m, 3.8~5.3 kg-m) 20.
Page 644 Tightening torque : 65~87 lb-ft (88~118 N·m, 9~12 kg-m) 23. Lower vehicle. 24. Remove SST (0K201 170 AA0). 25. Slide ATF inlet and outlet hose onto ATF cooler pipe until it is fully seated against the ridge. 26. Install hose clamp onto hose at center of mark and at angle shown. 27.
Page 645 35. Install air cleaner assembly. 36. Connect air temperature sensor connector. 37. Connect MAF sensor connector. 38. Insert diagnosis connector. 39. Connect negative and positive battery cable. 40. Fill transaxle with ATF. (Refer to automatic transaxle fluid) 41. Adjust auto transaxle control cable. (Refer to selector lever)
Page 646 Automatic Transaxle System Automatic Transaxle System Hydraulic System - Oil oo...
Page 647 2001 > 1.8L DOHC > Component...
Page 648 2001 > 1.8L DOHC > Removal 1. Raise vehicle and support it with safety stands. 2. Remove RH side gravel shield (seven bolts) from under engine. 3. Place a drain pan under radiator. 4. Disconnect ATF inlet hose and outlet hose. 5.
Page 649 Automatic Transaxle System Automatic Transaxle System Hydraulic System - Oil Pump...
Page 650 2001 > 1.8L DOHC > Component...
Page 651 2001 > 1.8L DOHC > Disassembly 1. Remove bearing race. 2. Remove four seal rings. 3. Loosen six mounting bolts evenly in pattern shown and remove oil pump cover from oil pump housing. Do not use a punch to mark outer and inner rotors. 4.
Page 652 Inner diameter - Standard : 0.00157~0.00453 in (0.04~0.115 mm) Maximum : 0.0049 in (0.125 mm) 5. If not within specification, replace oil pump as an assembly. Spring 1. Meausre spring free length. Specification Outer diameter - in (mm) 0.465 (11.8) Free length - in (mm) 2.087 (53.0) Number of coils...
Page 653 3. Align marks and install outer and inner rotors. 4. Install oil pump flange. 5. Mount oil pump cover onto oil pump housing. 6. Tighten six bolts evenly and gradually in order shown. Tightening torque : 72~97.2 lb-in (8.1~10.9 N·m, 82~112 kg-m) 7.
Page 655 Automatic Transaxle System Automatic Transaxle System...
Page 656 2001 > 1.8L DOHC > Component Control valve body...
Page 657 Component (Main control valve body)
Page 659 2001 > 1.8L DOHC > Disassembly Control valve body 1) Be especially careful when handling control valve because it consists of most precise and delicate parts of transaxle. 2) Neatly arrange removed parts to avoid confusing similar parts. 3) Clean removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes and passages with compressed air.
Page 660 8. Remove two screws from upper control valve body. 9. Remove gasket B, upper separator plate, oil filter, oil strainer and gasket A. 10. Remove seven main control valve body bolts then remove main control valve. 11. Remove gasket D, main separator plate, and gasket C. 12.
Page 661 14. Remove six bolts then remove premain control valve body. 15. Remove gasket E, lower separator plate, oil filter, and gasket F. 16. Remove oil strainer from lower control valve body. Disassembly 1) Each valve should slide in/out under its own weight. 2) When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hammer.
Page 662 Premain control valve body Lower control valve body side Main control valve body side Main control valve body Premain control valve body side...
Page 663 Upper control valve body side Upper control valve body Bolt installation positions and external parts locations...
Page 664 Identification Tightening torque lb-in Length in (mm) mark (N·m, kg-cm) 70~95 (7.9~10.7, 80~110) 0.551 (14) 1.181 (30) 1.575 (40) 1.969 (50) 3.228 (82) 3.543 (90) 3.740 (95)
Page 665 1. Install oil strainer into lower control valve body, refer to oil strainer installation positions. 2. Set oil filter into lower separator plate. Gasket F and gasket E are not interchangeable. They are dientified by their shape in area designated in illustration. 3.
Page 666 6. Install rubber balls into their proper positions in main control valve body. (Refer to main control valve body.) Gasket C and gasket D are not interchangeable. They are identified by their shape in area designated in illustration. 7. Set the new gasket C, main separator plate, and gasket D onto main control valve body. 8.
Page 667 Match bolt head letters as shown. 10. Loosely tighten bolts, refer to bolt installation positions and external parts locations. 11. Set the oil filter in upper separator plate. Gasket A and gasket B are not interchangeable. They are identified by their shape in area designated in illustration. 12.
Page 668 Match bolt head letters as shown. 15. Loosely tighten lower control valve body bolts. (Refer to bolt installation positions and external parts locations.) 16. Install linear solenoid valve. Tightening torque : 69.6~94.8 lb-in (7.9~10.7 N·m, 80~110 kg-cm) 17. Install shift solenoids B and C, oil strainers, and bracket. 18.
Page 669 21. Apply ATF to new O-rings and install them onto oil pipe assembly. 22. Install oil pipe assembly. Tightening torque : 69.6~94.8 lb-in (7.9~10.7 N·m, 80~110 kg-cm) 23. Apply ATF to new O-ring and install it onto oil strainer assembly. 24.
Page 670 5. Insert 2-3 timing valve and 2-3 timing spring. Secure them with spring retainer. 6. Proceed to insert manual valve. Inspection 1. Measure spring free lengths. Spring Item Outer diameter Free length Wire diameter Number of coils Color in (mm) in (mm) in (mm) 0.453...
Page 671 Automatic Transaxle System Automatic Transaxle System Valve Body System - Upper Control Valve Body...
Page 672 2001 > 1.8L DOHC > Component...
Page 673 2001 > 1.8L DOHC > Disassembly 1) Each valve should slide in/out under its own weight. 2) When a valve will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hammer. 3) If a valve surface or bore is scratched or damaged, replace control valve body.
Page 674 Automatic Transaxle System Automatic Transaxle System ain on o a...
Page 675 Automatic Transaxle System Automatic Transaxle System on o o noid a...
Page 676 2001 > 1.8L DOHC > Component...
Page 677 2001 > 1.8L DOHC > Disassembly 1) Each valve should slide in/out under its own weight. 2) When a vavle will not slide in/out under its own weight, depending on valve, push it out with a wire or replace valve body open-side down and lightly tap it with a soft hammer. 3) If a valve surface or bore is scratched or damaged, replace control valve body.
Page 678 3. Insert converter relief valve and converter relief spring. Secure them with spring retainer. 4. Insert lock-up control spring, lock-up control valve and stop plug. Secure them with stop pin.
Page 679 2001 > 1.8L DOHC > Inspection Solenoid valves Resistance inspection 1. Disconnect negative battery cable. 2. Disconnect solenoid valve connector. 3. Measure resistance between each terminal and a ground. Resistance : 14~18Ω 1) 2 : Torque converter clutch solenoid 2) 3 : Shift solenoid valve A 3) 6 : Shift solenoid valve B 4) 9 : Shift solenoid valve C 4.
Page 680 4. If not connect, check wiring for an open or short circuit, replace pressure control valve. 5. Connect solenoid valve connector. 6. Connect negative battery cable.
Page 681 Automatic Transaxle System Automatic Transaxle System Clutch & Brake - Reverse and Overdrive Clutch...
Page 682 2001 > 1.8L DOHC > Component Forward & coasting & reverse clutch...
Page 683 2001 > 1.8L DOHC > Reverse/forward clutch assembly Pre-inspection Clutch operation 1. Set reverse/forward clutch assembly onto oil pump. 2. Check clutch operation by applying compressed air through fluid passages shown. Applied air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum Clutch clearance Reverse clutch 1.
Page 684 2. Measure clearance between retaining plated and snap ring. Clearance : 0.039~0.047 in (1.0~1.2 mm) 3. If not as specified, replace parts as necessary. Inspection Forward & coasting & reverse clutch Drive plates 1. Measure facing thickness in three places and determine average of three readings. Standard : 0.063 in (1.6 mm) Minimum : 0.055 in (1.4 mm) 2.
Page 685 Coasting clutch piston 1. Verity that there is no air leakage when applying compressed air through oil hole opposite return spring. 2. Verity that there is air flow when applying compressed air through oil hole on return spring side. Air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum Reverse/forward drum 1.
Page 686 10. Remove snap ring. 11. Remove retaining plate. 12. Remove coasting clutch drive plates and driven plates. (each two) 13. Remove coasting clutch drum from reverse/forward drum by applying compressed air through fluid passage. 14. Remove coasting clutch piston from coasting clutch drum by applying compressed air through fluid passage.
Page 687 20. Remove SST (0K201 190 AA1) from reverse/forward drum. 21. Remove snap ring with a screwdriver. 22. Remove retaining plate. 23. Remove reverse clutch driven plates and driven plates. (each two) 24. Remove snap ring. 25. Remove return spring stopper and piston. 26.
Page 688 2. Install piston return spring with tabs facing away from reverse clutch piston. 3. Install return spring stop with step facing upward. 4. Install snap ring half-way down reverse/forward drum as shown. 5. Install SST (0K201 190 AA1) on reverse/forward drum. 6.
Page 689 13. Measure reverse clutch clearance. A. Measure clearance between snap ring and retaining plate of reverse clutch. B. If clearance is not within specification, adjust it by selecting correct thickness snap ring. Reverse clutch clearance : 0.035~0.047 in (0.9~1.2 mm) Reverse clutch snap ring sizes in (mm) 0.079 (2.0) 0.087 (2.2)
Page 690 A. Apply ATF to inner and outer faces of seals and install them onto coasting clutch piston. B. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation into durm. 16. Install spring and retainer assembly. 17.
Page 691 A. Measure clearance between snap ring and retaining plate of coasting clutch. B. If clearance is not within specification, adjust it by selecting correct thickness snap ring. Coasting clutch clearance : 0.039~0.048 in (1.0~1.2 mm) Coasting clutch snap ring sizes in (mm) 0.071 (1.80) 0.077 (1.95) 0.083 (2.10)
Page 692 Coasting clutch snap ring sizes in (mm) 0.063 (1.60) 0.069 (1.75) 0.075 (1.90) 0.087 (2.20) 0.081 (2.05) 0.093 (2.35) 31. Check clutch operation as follows : A. Set clutch assembly onto oil pump. B. Check clutch operation by applying compressed air though fluid passages shown. Air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum 32.
Page 693 Automatic Transaxle System Automatic Transaxle System Clutch & Brake - One Way Clutch...
Page 694 2001 > 1.8L DOHC > Component One-way clutch No. 1 One-way clutch No. 2 and planetary carrier assembly...
Page 696 2001 > 1.8L DOHC > Disassembly One-way clutch No. 1 1. Remove thrust bearing from small sun gear. 2. Remove snap ring with a snap ring pliers. 3. Remove one-way clutch inner race from sun gear drum. 4. Remove thrust bearing. 5.
Page 697 1. Check for following and repair or replace as necessary. Assembly one-way clutch and inner race, then verify that one-way clutch rotates only clockwise and smoothly. A. Damaged or worn one-way clutch and operation. B. Detached roller. Planetary carrier 1. Check for following and repair or replace as necessary. A.
Page 698 Install one-way clutch into outer race with spring cage facing as shown. 4. Install one-way clutch No. 1 into one-way clutch outer race. Align splines of one-way clutch inner race and small sun gear clutch hub. 5. Install one-way clutch inner race into one-way clutch outer race by tuming inner race counterclockwise. 6.
Page 699 9. Apply petroleum jelly to thrust bearing, and secure it to sun gear drum. Thrust bearing outer diameter : 3.39 in (86.0 mm) Reassembly One-way clutch No.2 and planetary carrier assembly 1. Assembly planetary carrier to inner race. 2. Install snap ring. Install tangs of bearing race into alignment holes.
Page 701 Automatic Transaxle System Automatic Transaxle System Clutch & Brake - Low and Reverse Brake...
Page 702 2001 > 1.8L DOHC > Component...
Page 703 2001 > 1.8L DOHC > Pre-inspection Low and reverse brake operation 1. Check low and reverse brake operation by applying compressed air as shown. Air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum Brake clearance 1. Measure clearance between retaining plate and snap ring. 2.
Page 704 9. Remove outer seal and inner seal from low and reverse brake piston. Inspection Drive plates 1. Measure facing thickness in three places, and determine average of three readings. Standard : 0.063 in (1.6 mm) Minimum : 0.055 in (1.4 mm) 2.
Page 705 C. Install low and reverse brake piston by pushing evenly around circumference, being careful not to damage outer seal. 2. Install spring and retainer assembly. 3. Install SST (0K2CA 190 AA1) in transaxle case. 4. Compress spring and retainer assembly. 5.
Page 706 Installation order : Driven-Drive-Driven-Drive-Driven-Drive 10. Install retaining plate. 11. Install snap ring. 12. Measure low and reverse brake clearance. A. Measure clearance between snap ring and low and reverse brake retaining plate. B. If clearance is not within specification, adjust it by selecting a proper snap ring. Low and reverse brake clearance : 0.094~0.083 in (2.1~2.4 mm) Snap ring size in (mm) 0.079 (2.0)
Page 708 Automatic Transaxle System Automatic Transaxle System Clutch & Brake - B ak on n...
Page 709 2001 > 1.8L DOHC > Component...
Page 710 2001 > 1.8L DOHC > Disassembly Coutch operation 1. Install SST (0K201 190 016) as shown, and check clutch operation by applying compressed air. Air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum Clutch clearance 1. Measure clearance between snap ring and retaining plate of 3-4 clutch. 2.
Page 711 air pressure : 57 psi (392 kPa, 4.0 kg/cm²) maximum 10. Remove SST (0K201 190 016). 11. Remove outer seal and inner seal 3-4 clutch piston. Inspection Drive plate 1. Measure facing thickness in three places, and determine average of three readings. Standard : 0.063 in (1.6 mm) Minimum : 0.055 in (1.4 mm) 2.
Page 712 Reassembly 1. Install 3-4 clutch piston. A. Apply ATF to inner and outer seals, and install them onto 3-4 clutch piston. B. Install piston by pushing evenly around circumference, being careful not to damage seal rings. 2. Install return spring and spring retainer. 3.
Page 713 10. Measure 3-4 clutch clearance. A. Measure clearance between snap ring and retaining plate of 3-4 clutch. B. If clearance is not within specification, adjust it by selecting correct thickness snap ring. 3-4 clutch clearance : 0.051~0.063 in (1.3~1.6 mm) 3-4 clutch snap ring size in (mm) 0.055 (1.4) 0.063 (1.6)
Page 715 Automatic Transaxle System Automatic Transaxle System Gear System - nput Shaft...
Page 716 2001 > 1.8L DOHC > Component Component...
Page 718 2001 > 1.8L DOHC > Disassembly Primary shaft assembly 1. Measure thrust clearance of all gears before disassembly, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly note. Check thrust clearance of all gas before disassembly and after assembly. Preinspection 3rd gear throust clearance 1.
Page 719 3rd/4th clutch hub assembly, 3rd synchronizer ring and 3rd gear 1. Remove retaining ring. 2. Remove 3rd/4th clutch nub asembly, 3rd synchronizer ring, and 3rd gear by using SST (0K130 175 008). Bearing (1st end) 1. Remove bearing by using SST(0K670 990 AA0). Assembly Primary shaft assembly Assemble in order shown in figure, refer to Assembly note.
Page 720 4th synchronizer ring, primary 4th gear and bearing(4th gear end) 1. Install 4th synchronizer ring. 4th gear, and new bearin by uisng SST(0K130 175 008/0k011 270 A02) 2. Measure clearance between primary 3rd gear and 2nd gear. Clearance : 0.002~0.009 in (0.05~0.20 mm) Maximum : 0.010 (0.25 mm) 3.
Page 721 Automatic Transaxle System Automatic Transaxle System Gear System - d...
Page 722 2001 > 1.8L DOHC > Component...
Page 723 2001 > 1.8L DOHC > Disassembly Use protective plates in vise to prevent damage to SST (0K130 191 034). 1. Secure idler shaft in a vise with SST (0K130 191 034), and remove locknut. 2. Remove bearing outer race from idler gear with SST (0K130 170 012). Reassembly 1.
Page 724 Use protective plates in vise to prevent damage to idler gear. 4. Check and adjust idler gear bearing preload. A. Turn idler gear assembly and SST (0K130 191 034) over and secure gear in vise. B. Attach SST (0K130 191 034) and spring scale or torque wrench and measure preload while tightening locknut. 1) Read preload when idler shaft is rotating.
Page 726 Automatic Transaxle System Automatic Transaxle System Gear System - Output...
Page 727 2001 > 1.8L DOHC > Component Component...
Page 729 2001 > 1.8L DOHC > Disassembly Secondary shaft assembly 1. Measure thrust clearance of 1st gear and 2nd gear before disassembly, refer to Preinspection. 2. Disassemble in order shown in figure, refer to Disassembly note. Preinspection Secondary 1st gear thrust clearance 1.
Page 730 Secondary 3rd gear and Secondary 2nd gear 1. Remove retaining ring. 2. Shift gears to 1st gear. 3. Remove secondary 3rd gear and secondary 2nd gear by using SST(0K201 172 008) 1st/2nd clutch nub assembly, 1st synchronizer ring, and secondary 1st gear 1.
Page 731 4. Measure clearance between clutch nub sleeves and shift forks. Clearnace Standard (in (mm)) Maximum (in(mm)) 1st/2nd 0.004~0.018 (1.01~0.45) 0.037(0.95) 3rd/4th 0.004~0.016(0.10~0.40) 0.035(0.90) 5th/Rev. 0.004~0.014(0.10~0.36) 0.034(0.86) Reverse idle gear and reverse lever 1. Inspect gear teeth for damage, wear and cracks. 2.
Page 732 Primary shaft and ssecondary shaft 1. Inspect gear contact surface for damage and wear. 2. Inspect splines for damage and wear. 3. Inspect gear teeth for damage, wear and cracks. 4. Inspect oil passenger for clogging. 5. Measure primary and secondary shaft runout. Primary shaft runout : 0.002 in (0.05 mm) max.
Page 733 Vehicle speed sensor (speedometer driven gear) 1. Inspect teeth for damage and wear. 2. Inspect O-ring for damage and wear. Inspection Inspect all parts and repair or replsce as necessary. Gears 1. Inspect synchronzer cones for wear. 2. Inspect gear teeth for damage, wear and cracks. 3.
Page 734 3. Set synchronizer ring squarely in gear. 4. Measure clearance between synchronizer ring and flank surface of gear. Standard clearance : 0.059 in (1.5 mm) Minimum : 0.031 in (0.8 mm) Secondary shaft assembly Assembly Precaution 1. Replace all O-rings and gaskets. 2.
Page 735 1. Install new bearing by using SST(0K130 175 A11). Secondary 1st gear, 1st synchronizer ring and 1st/2nd clutch nub assembly The 1st synchronizer ring has teeth missing at three places around its outer edge to help distinguish it from other synchronizer rings. 1.
Page 736 Secondary 4th gear and bearing 1. Install secondary 74th gear and bearing by using SST(0K130 175 A13/0K011 270 A02/0K130 175 A11). 2. Measure clearance between 1st gear and differential drive gear. Clearance : 0.002~0.011 in (0.05~0.28 mm) Maximum : 0.013 in (0.33 mm) 3.
Page 737 Automatic Transaxle System Automatic Transaxle System Gear System - B a in...
Page 738 2001 > 1.8L DOHC > Component...
Page 739 2001 > 1.8L DOHC > Disassembly 1. Remove oil seal. 2. Remove bearing outer race with a pin punch and hammer as shown. 3. Remove O-ring. Reassembly 1. Apply ATF to new O-ring and install O-ring. 2. Press bearing outer race into the cover. 3.
Page 740 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control System...
Page 741 2001 > 1.8L DOHC > Component Component...
Page 743 2001 > 1.8L DOHC > Shift mechanism Selector lever Operation inspection Shift selector lever from P range to other ranges with ignition switch ON and brake pedal depressed. 1. Verify that selector lever can only be shifted as shown in figure. 2.
Page 744 9. Remove two undercover bolts after loosening parking cable puller nut and then disconnect two connectors. 10. Remove change lever and return spring after loosening bolt, nut and two retainer rings. 11. Disconnect O/D switch attached to column shaft bracket. Installation 1.
Page 745 6. Remove retaining nut and snap ring from the end of steering shaft. 7. Remove steering wheel with a suitable puller. Do not remove steering wheel by hitting end of shaft with a hammer. Damage to shaft threads and shaft support bearings could occur.
Page 746 column shaft bracket. 17. Remove change lever bracket, change lever arm and bush after loosening three screws. 18. Remove clamp assembly from column shaft after loosening three bolts. 19. Separate clamp assembly after removing washer and E-ring. 20. Remove U-clip from selector cable to auto transaxle linkage. 21.
Page 747 Tightening torque : 24~83 lb-ft (32~46 N·m, 3.2~4.7 kg-m) 4. Assemble clamp assembly with washer and E-ring and then insert it into the column shaft and tighten three bolts. 5. Insert U-clip to fix control cable to column shaft bracket. 6.
Page 748 12. Tighten two undercover bolts after installing parking cable puller and connecting two harness connectors. 13. Tigh three lower steering column panel screws after installing upper and lower steering column panels. Tightening torque : 12~17 lb-ft (16~23 N·m, 1.6~2.3 kg-m) 14.
Page 749 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control System wi c...
Page 750 2001 > 1.8L DOHC > Inspection Operation inspection 1. Turn ignition switch ON. 2. Verify that the O/D OFF indicator light is not illuminated. Depress O/D OFF switch and verify that the O/D OFF indicator light illuminates. 3. If O/D OFF indicator light does not operate, continue with inspection of voltage test. Voltage 1.
Page 752 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control System...
Page 753 2001 > 1.8L DOHC > Inspection Input/Turbine speed sensor Resistance inspection 1. Disconnect negative battery cable. 2. Pull data link connector upward from MAF sensor. 3. Disconnect air temperature sensor connector and MAF sensor connector. 4. Remove air cleaner assembly. 5.
Page 754 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control Syste...
Page 755 2001 > 1.8L DOHC > Inspection Voltage inspection 1. Turn ignition to ON and use a voltmeter to back probe pin. 1. 2. Have an assistant rotate one drive wheel, checking other drive wheel, if necessary. This will rotate vehicle speed sensor.
Page 756 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control Syste an a on o...
Page 757 2001 > 1.8L DOHC > Transaxle control module (TCM) TCM terminal voltage chart Possible Terminal Signal Connected to Test condition Voltage malfunction H-01/1 H-01/2 H-01/3 Torque Torque converter During shifting Torque converter clutch solenoid H-01/4 converter clutch solenoid valve, refer solenoid clutch solenoid Others control...
Page 758 H-01/20 Transaxle fluid temperature H-01/21 Constant sensor (Ground) Transaxle fluid Transaxle fluid Approx. Refer to ATF sensor temperature temperature Transaxle fluid 20°C (68°F) Ignition switch H-01/22 temperature Transaxle fluid sensor Approx. temperature 130°C (266°F) Input/Turbine Input/turbine speed sensor H-01/23 Constant speed sensor (Shield ground)
Page 759 ECM "47" (43) Approx. H-01/40 Engine rpm Idle *1 terminal 8.0~8.5 ECM "68" (13) Approx. H-01/41 Torque signal Idle *1 terminal 1.5~1.8 Ignition switch ON Vehicle speed H-01/42 Vehicle speed Refer to ETM sensor Driving 0~B+ H-01/43 Input/turbine Input/turbine TCM H-01/16 Below H-01/44 speed sensor...
Page 760 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control Syste an a...
Page 761 2001 > 1.8L DOHC > Inspection Resistance inspection 1. Remove air cleaner assembly. 2. Connect ohmmeter between terminals 5 and 8 of connector. 3. Measure resistance while warming up ATF (driving vehicle). 4. Verify that the resistance drops as shown in following table and graph. 5.
Page 762 Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Control Syste n i i wi c...
Page 763 2001 > 1.8L DOHC > Inspection Operation inspection 1. Verify that the starter operates only with ignition switch in START position and selector lever in P or N position. 2. Verify that the back-up lights illuminate when shifted to R position with ignition switch in ON position. 3.
Page 764 Tightening torque : 70~95 lb-in (7.9~10.7 N·m, 80~110 kg-cm) 12. Verify that the selector lever range position and transaxle range switch correspond. 13. Connect transaxle range switch connector. 14. Connect selector cable and tighten nut. Tightening torque : 24~33 lb-ft (32~46 N·m, 3.2~4.7 kg-m) 15.
Page 765 Restraint Restraint General Information...
Page 766 2001 > 1.8L DOHC > Circuit diagram...
Page 767 2001 > 1.8L DOHC > Air bag deployment and disposal 1) FAILURE TO FOLLOW ALL WARNINGS, CAUTIONS, NOTICES AND PROCEDURES COULD RESULT IN PERSONAL INJURY OR DEATH. 2) SURFACE OF A DEPLOYED AIR BAG MAY CONTAIN SMALL AMOUNTS OF SODIUM HYDROXIDE(NAOH).PREVENT CONTACT OF AIR BAG MODULE WITHLIQUIDS, COMBUSTIBLES, AND FLAMMABLE MATERIALS.IMMEDIATELY WASH HANDS AND EXPOSED SKIN AREAS WITH MILD SOAP AND WATER.FLUSH EYES WITH WATER IF EXPOSED TO BY PRODUCTS.
Page 768 3. Disconnect appropriate Air Bag Module, and remove from vehicle. For Driver air bag module. For passenger Air Bag Module. 4. Locate air bag in an area that will provide protection to personnel when it deploys. An example of a safe deployment site is a stack of used tires, 6-8 high, with undeployed bag located inside column of tires.
Page 769 2001 > 1.8L DOHC > Description and operation Air Bag-Supplemental restraint system Air Bag-Supplemental Restrain System (SRS) is designed to supplement driver seat belts during front end collisions, reducing risk of serious injury or death. Two collision-sensitive sensors are located in Air bag Diagnostic Unit (ADU). These two sensors (Safing sensor and G-sensor) are electrically connected in series with air bag and battery.
Page 770 Do not cut or otherwise remove the air bag module connector. Connector contains a safety shunt which, if disabled, couldcause an unintended deployment. This may cause severs personal injury or death. Air bag module handling A live (undeployed) air bag may accidently deploy during handling. When carrying a live air bag module, point plastic trim cover away from your body to lessen chance of injury in case of accidental deployment.
Page 771 2001 > 1.8L DOHC > Air bag system 1. Turn ignition switch to ON. 2. The air bag indicator should illuminates. If it does not, see Air bag indicator Service. 3. The Air Bag Indicator should go out within 4~6 seconds. If it stays out, system is OK. 4.
Page 772 Replace it with another 10A fuse and check for short circuits in its associated Use fuse extraction tool in passenger wiring harnesses. Repair as necessary and compartment fuse box to extract meter then go to step 8. fuse. Is it open? Go to next step.
Page 773 2001 > 1.8L DOHC > Mechanical specifications Item Specifications Driver air bag installation bolts 69~104 lb-in (8~12 N·m, 80~120 kg-cm) Passenger air bag installation bolts 69~104 lb-in (8~12 N·m, 80~120 kg-cm) Steering wheel installation nut 29~36 lb-ft (39~49 N·m, 4.0~5.0 kg-m) ADU installation nuts 69~120 lb-in (8~14 N·m, 80~140 kg-cm) Connector pin...
Page 774 Restraint Restraint Supplemental Restraint System Control Module (SRnodeM)
Page 775 2001 > 1.8L DOHC > Air bag diagnostic trouble code (DTC) chart Diagnostic Warning Trouble Fault Description Possible Cause Light Corrective Action Code Mode 01~03 Replace Air Bag Diagnostic ADU Fault Internal Fault 10~15 Unit (ADU) 18~29 Replace Air Bag Diagnostic ADU Fault Internal Fault 31~32...
Page 776 SERVICING AIR BAG SYSTEM INPROPERLY MAY CAUSE IT TO DEPLOY, WHICH CAUSE SERIOUS INJURY OR DEATH.MUST READ AND FOLLOW ALL SERVICE WARNINGS, BEFORE SERVICING. Never service wiring or electrical components when air bag is connected. Air bag diagnostic trouble code erasure Disconnecting battery will not erase Air Bag Diagnostic Trouble Codes.
Page 777 2001 > 1.8L DOHC > Removal air bag diagnostic unit (ADU) IMPROPER HANDLING OF ADU MAY RESULT IN UNEXPECTED AIR BAG DEPLOYMENT, WHICH CAN CAUSE SERIOUS INJURY. READ ALL SERVICE WARNINGS BEFORE PERFORMING SERVICE. 1. Follow General Procedures. 2. Remove ashtray. 3.
Page 778 1. Install ADU on three mounting studs. Install three nuts and torque to specification. Tightening torque:69~120 lb-in (8~14N·m, 80~140 kg-cm) 2. Connect wiring harness connector(s) to ADU. 3. Install console and its five mounting screws and two bolts. 4. Install center panel trim. 5.
Page 779 Restraint Restraint Airbag Module...
Page 780 Restraint Restraint Airbag Module - Driver Airbag (DAB) Module and Clock Spring...
Page 781 2001 > 1.8L DOHC > Removal Driver air bag module HANDLING AIR BAG IMPROPERLY MAY CAUSE IT TO DEPLOY, WHICH MAY CAUSE SERIOUS INJURY. READ ALL SERVICE WARNINGS, BEFORE SERVICING. • Never service wiring or electrical components when any air bag is connected. •...
Page 782 1. Remove four air bag module retaining bolts from backside of steering wheel. 2. Pull air bag module away from steering wheel. 3. Disconnect air bag module connector from clockspring assembly and remove driver air bag module from vehicle. 4. If necessary, dispose of air bag module. Refer to Air Bag Deployment and Disposal. Removal Clockspring assembly...
Page 783 Clockspring connectors is part of combination switch and is not serviced as a separate part. 1. Remove driver air bag module. 2. Remove steering wheel nut. Mark steering wheel and steering shaft so that their relative positions will be known during re-installation.
Page 784 If clockspring assembly has been removed, please refer to page 60-1-18 for proper assembly. Installation Clockspring assembly 1. Temporarily install steering wheel and turn front wheel so that front wheels are pointing straight ahead. An alignment pin is used to aid in alignment of clockspring connector when installing steering wheel onto steering column.
Page 785 Restraint Restraint Airbag Module - Passenger Airbag (PAB) Module...
Page 786 2001 > 1.8L DOHC > Removal HANDLING AIR BAG IMPROPERLY MAY CAUSE IT TO DEPLOY, WHICH MAY CAUSE SERIOUS INJURY. READ SERVICE WARMINGS. BEFORE SERVICING. • Never service wiring or electrical components when any air bag is connected. • Follow General Procedures guidelines on page. 1.
Page 787 KEEP AREA CLEAR OF PARTS, TOOLS AND DEBRIS. 6) NEVER PLACE ITEMS ON OR ABOVE TRIM COVER OF A LIVE AIR BAG MODULE.IN CASE OF ACCIDENTAL DEPLOYMENT, SUTCH ITEMS MAY CAUSE SERIOUS INJURY OR DEATH. 4. Remove module from instrument panel. 5.
Page 788 Suspension System Suspension System General Information...
Page 789 2001 > 1.8L DOHC > Service special tools Tool(Name & Number) Illustration 0K201 170 AA0 Used to supprot engine. Engine supprot 0K2A1 341 001 Used to remove and install coil spring. Coil spring comp 0K130 322 020 Used to support engine Attachment 0K2A1 342 AA0 Used to remove and install lower arm.
Page 790 2001 > 1.8L DOHC > Suspension system Problem Possible cause Action Deteriorated stabilizer bar Replace Worn or deteriorated stabilizer bar bushing Replace Body rolls Worn or deteriorated lower arm bushing Replace Shock absorber malfunction Replace Weak coil spring Replace Poor riding comfort Shock absober malfunction Replace Poor lubrication or wear of lower arm ball...
Page 791 Troubleshooting guide Wheel and tire Problem Possible cause Action Incorrect toe adjust ment Refer to suspension Excessive or irregular tire wear Mafunction of brake system Refer to brake system Excessive tire pressure Adjust Premature tire wear Insufficient tire pressure and high-speed Adjust Incorrect tire pressure Adjust...
Page 792 2001 > 1.8L DOHC > Wheel alignment preinspection 1. Set tire inflation pressures to recommended pressure, if necessary.(Refer to Wheel and tires) 2. Inspect front wheel bearing play ; replace bearing if necessary. (Refer to Driveshaft system) 3. Inspect wheel and tire runout. (Refer to wheel and tires) 4.
Page 793 2. If readings do not meet specifications, lift front of vehicle until front wheels clear floor, and supprot with safety stands. 3. Remove four mounting block nuts. 4. Push mounting block downward to disengage studs, and turn it to position that corresponds to the difference between the initial reading and the specification.
Page 794 1. Measure toe angle with a toe angle gauge, per manufacturer instructions. 2. If measurement does not meet specification, loosen left and right tie rod jam nuts, then turn each tie rod as needed to achieve proper toe angle. 1) Left and right tie-rods are right hand threaded. To decrease toe angle thread right and left side tie-rods into tie-rod ends.
Page 795 One turn of link changes toe approximately 0.12 in (3 mm) 5. Repeat for other side if necessary. 6. Tighten lateral link jam nuts to specified torque. Tightening torque : 85~115 lb-ft(116~157 N·m, 11.8~16kg-m)
Page 796 2001 > 1.8L DOHC > Specifications Item Specifications Inner 39°30' Steering angle maximum Outer 32°30' Single wheel (Degree) -2'52"±10' Toe in(mm) Total 185/65R14 -0.039±0.12 in (-1±3 mm) Camber angle Degree 0°±30' Caster angle Degree 2°27'±45' Kingpin angle Degree 12°35' Rear wheel alignment (No passenger load) Item Specifications Single wheel (Degree)
Page 797 Suspension System Suspension System Front Suspension System - Front Strut Assembly...
Page 798 2001 > 1.8L DOHC > Component...
Page 799 2001 > 1.8L DOHC > Disassembly 1. Remove the front spring and shock absorver refer to the procedure in this section. 2. Loosen the four mounting bolts. 3. Place the mounting block in a vise. Use protective pates to cover jaws of vise. 4.
Page 800 Reassembly 1. Secure the shock absorber in a vise. Use protective plates to cover jaws of vise. 2. Compress the coil spring with SST(0K2A1 341 001). 3. Install the coil spring, inserting the bottom end of the spring into the recess of the lower seat. 4.
Page 801 Suspension System Suspension System Front Suspension System - Front Shock Absorber...
Page 802 2001 > 1.8L DOHC > Component...
Page 803 2001 > 1.8L DOHC > Removal 1. Lift front of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Disconnect front flexible hose from the bracket. 4. Remove control link from the shock absorber assembly. 5. Remove four flange nuts. 6.
Page 804 Suspension System Suspension System Front Suspension System - Front Lower Arm...
Page 805 2001 > 1.8L DOHC > Component...
Page 806 2001 > 1.8L DOHC > Removal 1. Lift front of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Remove pivot bolt. 4. Remove lower arm ball joint bolt and nut from steering knuckle. 5. Remove three mounting bolts 6.
Page 807 Tightening torque : 69~86 lb-ft(93~117N·m, 9.5~11.9 kg-m) 40~50 lb-ft(54~68 N·m, 5.5~6.9 kg-m) 6. Put the ball joint into the knuckle and tighten the lower arm bal joint pinch bolt and nut. Tightening torque : 32~40 lb-ft(43~54N·m, 4.4~.55kg-m) 7. Tighten the pivot bolt after installing the front control arm bushing. Tightening torque : 69~86 lb-ft(93~117 N·m, 9.5~11.9 kg-m) Inspection Ball joint rotation torque...
Page 808 Suspension System Suspension System Front Suspension System - Front Stabilizer Bar...
Page 809 2001 > 1.8L DOHC > Component...
Page 810 2001 > 1.8L DOHC > Removal 1. Lift front of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Remove plastic undercover. 4. Remove stabilizer from control link. 5. Remove stabilizer bracket bolt. 6. Support engine with SST(0K201 170 AA0), and remove six subframe mounting bolts. 7.
Page 811 2001 > 1.8L DOHC > Component...
Page 812 Suspension System Suspension System Rear Suspension System - Rear Strut Assembly...
Page 813 2001 > 1.8L DOHC > Component...
Page 814 2001 > 1.8L DOHC > Disassembly 1. Remove rear spring and shock absorber. Refer to procedure in this section. 2. Loosen the two mounting bolts. 3. Place the mounting block in a vise. Use protective plates to over jaws of vise. 4.
Page 815 Reassembly 1. Place the strut in a vise. Use protective plates to cover jaws of vise. 2. Install the lower spring isolator into the spring seat on the part of strut. 3. Compress the oil spring with SST(0K2A1 341 001). 4.
Page 816 Suspension System Suspension System Rear Suspension System - Rear Shock Absorber...
Page 817 2001 > 1.8L DOHC > Component...
Page 818 2001 > 1.8L DOHC > Removal 1. Lift rear of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Remove the clip and disconect rear flexible hose from the racket. 4. Remove two flange nuts. 5. Remove the control link from the stabilizer bracket. 6.
Page 819 Suspension System Suspension System Rear Suspension System - Trailling Arm...
Page 820 2001 > 1.8L DOHC > Component...
Page 821 2001 > 1.8L DOHC > Removal Later link and trailing link 1. Lift rear of vehicle and support it with safety stand. 2. Remove wheel and tire. 3. Loosen the font lateral link retaining bolt and washer from crossmember. 4. Loosen the rear lateral link retaining bolt and washer from cross member. 5.
Page 822 Suspension System Suspension System Rear Suspension System - Rear Stabilizer Bar...
Page 823 2001 > 1.8L DOHC > Component...
Page 824 2001 > 1.8L DOHC > Removal 1. Lift rear of vehicle and support it with safety stands. 2. Remove wheel and tire. 3. Loosen the control-link nut from stabilizer bar. 4. Loosen the control-link bolt from control link bracket of the suspension assembly and remove control link. 5.
Page 825 Suspension System Suspension System Rear Suspension System - Rear Cross Member...
Page 826 2001 > 1.8L DOHC > Component...
Page 827 2001 > 1.8L DOHC > Removal 1. Lift rear of vehicle and support it with safety stand. 2. Remove wheel and tire. 3. Loosen the front lateral link retaining bolt and washer from the crossmember 4. Loosen the rear lateral link retaining bolt and washer from the crossemmber. 5.
Page 828 Tightening torque : 69~86 lb-ft(93~117N·m, 9.5~11.9 kg-m) 10. Install the front lateral link to the crossmember with a retaining bolt and lock washer. Tightening torque : 69~86 lb-ft(93~117 N·m, 9.5~11.9 kg-m) 11. Install the rear lateral link to the crossmember with a retaining bolt and lock washer. Tightening torque : 969~86 lb-ft(93~117 N·m, 9.5~11.9 kg-m) 12.
Page 829 2001 > 1.8L DOHC > Component...
Page 830 Suspension System Suspension System Tires/Wheels...
Page 831 2001 > 1.8L DOHC > Notes on wheels and tires 1. Do not use wheels or tires other than specified types. 2. Aluminum wheels are easily scratched. Use a soft cloth when washing them, never a wire brush. If vehicle is steam cleaned, do not allow boiling water to contact wheels.
Page 832 • Do not use more than two balance weights on the inner or outer side of a wheel. • If the total weight exceeds 220 oz (100g), move tire around on rim and rebalance. • Attach balance weights securely to wheel. •...
Page 833 2001 > 1.8L DOHC > Irregular tire wear Refer to the chart for possible causes and remedies of irregular tire wiear. Where lack of tire rotation is offered as acause, consider previous tire location as possible source of trouble. Problem Possible cause Remedy ·...
Page 834 2001 > 1.8L DOHC > Inspection/Adjustment Air pressure 1. Check air pressure of all tires, including the spare tire, with an air pressure gauge. If necessary, adjust air pressure. Air pressure bar Tire size Front Tires Rear Tires 185/65R14 86H Air leakage 1.
Page 835 Tire and wheel 1. Tire should be replaced if any deep cracks, damage, deformation, or local baldness is found. Tire runout 1. Raise vehicle and place it on safety stands. 2. Set dial indicator probe against wheel, and measure tunout through one full revolution. Runout : Radial runout : 0.059 in (1.5 mm) maximum Lateral runout : 0.059 in (1.5 mm) maximum 3.
Page 836 Removal/Installation 1. Contact surface between wheel and hub must be clean. 2. Tighten lug nuts to specified torque. Tightening torque : 65~87 lb-ft (88~118 N·m, 9~12 kg-m)
Page 837 Brake System Brake System General Information...
Page 838 2001 > 1.8L DOHC > Special tool Tool Illustration (Number and Name) 0K130 430 019 Used to remove and install brake pipe. Flare nut wrench 0K130 430 017 Used to assemble disc pad. Disc brake expander 0K670 990 AA0 Used to remove sensor rotor. Bearing installer set 0K9A4 430 001 Used to adjust push rod gap.
Page 839 2001 > 1.8L DOHC > Troubleshooting guide Troubleshooting guide Possible cause Action Poor braking Leakage of brake fluid Repair Air in system Bleed air Worn pad or lining Replace Brake fluid, grease, oil or water on pad or lining Clean or replace Hardening of pad or lining surface or poor contact Grind or replace Malfunction of disc brake piston...
Page 840 vibration during braking Deteriorated pad or lining Grind or replace Brakes do not release Repair Foreign material or scratches on disc plate or drum Clean contact surface Loose backing plate/dust cover or caliper mounting Tighten bolts Damaged discdrum contact surface Replace Poor contact of pad or lining Repair or replace...
Page 841 2001 > 1.8L DOHC > Specification Model Specifications Item Type Suspended Brake pedal Pedal lever ratio 4.12 : 1 Maximum stroke (in(mm)) 5.31 (135) Type Tandem (with level sensor) Master cylinder Cylinder inner diameter (in(mm)) 0.937 (23.81) Type Ventilated disc Cylinder bore (in(mm)) 2.12 (54) Pad dimensions (area ×...
Page 842 Brake System Brake System Brake System...
Page 843 2001 > 1.8L DOHC > Air bleeding 1. Jack up vehicle and support it with safety stands. Brake fluid reservoir must be 3/4 full during air bleeding. 2. Remove bleeder cap and attach a vinyl hose to bleeder plug. 3. Place other end of vinyl tube in a clear container. 4.
Page 844 2001 > 1.8L DOHC > Description Hydraulic brake system The hydraulic brake system uses principles of fluid power to apply the front and rear brakes. The system operates as follows: • The brake pedal is connected to a hydraulic servo called the master cylinder. •...
Page 845 2001 > 1.8L DOHC > Component...
Page 846 Brake System Brake System Brake System - Brake Booster...
Page 847 2001 > 1.8L DOHC > Component...
Page 848 2001 > 1.8L DOHC > Removal 1. Remove brake master cylinder. 2. Disconnect master vacuum hose from master vacuum. 3. Front inside vehicle, remove spring clip from clevis pin. 4. Remove four master vacuum nuts. Secure master vacuum to bulkhead. 5.
Page 849 Brake System Brake System Brake System - Master Cylinder...
Page 850 2001 > 1.8L DOHC > Component...
Page 851 2001 > 1.8L DOHC > Removal 1. Disconnect negative battery cable. 2. Disconnect brake fluid level switch connectors. 3. Disconnect two brake lines with SST (0K 130 430 019) and plug master cylinder ports to prevent entry of contaminants. Brake fluid will damage painted surfaces so use a container or shop towels for fluid collection. If fluid gets on a painted surface, rinse immediately with clean water to prevent damage.
Page 852 2. Invert the adjustment gauge used in step 1 and place it on the power brake unit. 3. Messure the clearance between the end of the gauge and push rod of the power brake unit. If it is not 0 in (0mm) loosen the push rod locknut and turn the push rod to make the adjustment.
Page 853 Brake System Brake System Brake System - Brake Pedal...
Page 854 2001 > 1.8L DOHC > Component...
Page 855 2001 > 1.8L DOHC > Inspection Brake pedal height 1. Verify that distance from the center of the pedal to the engine compartment bulkhead is as specified. Specification: 7.06~7.72 in (193~196 mm) Inspection Brake pedal free play 1. Pump pedal a few times (with engine off) to eliminate any slack in system. 2.
Page 856 3. Loosen locknut D and turn C to adjust height of to prevent it from contacting pedal. 4. Rotate brake pedal switch A in until plunger is completely compressed, then rotate it out about 1/2 turn. Tighten locknuts B and D. 5.
Page 857 Brake System Brake System Brake System - Front Dinode Brake...
Page 858 2001 > 1.8L DOHC > Component...
Page 859 2001 > 1.8L DOHC > Removal 1. Raise front of vehicle and properly support it. 2. Remove front wheels. 3. Remove two bolts and remove caliper. 4. Remove brake pads and guide plate. 5. Messure brake pad thickness. Minimum brake pad thickness : 0.08 in (2.0 mm) 6.
Page 860 1. Check facing for oil or grease abnormal wear, cracks, and deterioration or damage from heat. Measure thickness of lining. Specified thickness: 0.39 in (10 mm) Minimum: 0.08 in (2.0 mm) 2. Visually check for damage or wear on the guide plate. Disc plate 1.
Page 861 Brake System Brake System Brake System - Rear Dinode Brake...
Page 862 2001 > 1.8L DOHC > Component...
Page 863 2001 > 1.8L DOHC > Removal 1. Remove parking cable and clip. 2. Remove brake hose connecting bolt from caliper. 3. Clamp rear brake hose. 4. Remove two lock bolts from caliper. 5. Remove caliper from rotor. 6. Remove two V-springs from disc pads. 7.
Page 864 Runout: Maximum: 0.0039 in (0.08 mm) Thickness: Specified thickness:0.4 in (10 mm) Minimum : 0.32 in (8 mm)
Page 865 Brake System Brake System Brake System - Rear Drum Brake...
Page 866 2001 > 1.8L DOHC > Component Rear drum brake Wheel cylinder...
Page 868 2001 > 1.8L DOHC > Removal 1. Raise and suitably support rear of vehicle. 2. Remove rear wheels and release parking brake. 3. Using an impact driver, remove two mounting screws holding the drum and remove brake the drum. If brake drum is difficult to remove, thread two 0.3 in (8 mm) jacking bolts into two threaded holes provided on drum face and tighten evenly.
Page 869 Inspection Rear drum brake 1. Raise and suitably support rear of vehicle. 2. Remove rear wheels and release parking brake. 3. Using an impact driver, remove two mounting screws holding brake drum. Remove drum. If brake drum is difficult to remove, thread two 0.3 in (8 mm) jacking bolts into two threaded holes provided on drum face and tighten evenly.
Page 870 Disassembly Wheel cylinder 1. Remove the brake shoe assembly. Removal and replacement procedure. 2. Disconnect the brake line using a flare nut wrench. Be prepared to catch escaping fluid. 3. Remove two wheel cylinder mounting bolts. Remove the wheel cylinder. 4.
Page 871 2001 > 1.8L DOHC > Inspection Brake pipe 1. Check for cracks, damage, and corrosion of brake pipe. Replace pipe of flare nut(s) if necessary. Flexible hose 1. Check for scars, cracks, and swelling of flexible hose. Replace hose if necessary. Brake fluid (Leakage inspection) 1.
Page 872 1. Step 1 (1) With engine off, and depress the pedal a few times. (2) Start engine. (3) If pedal moves downward immediately after engine starts; it will be an indication for operation of power brake unit. 2. Step 2 (1) Start engine.
Page 873 Connect a pressure gauge, vacuum gauge, and pedal depression force gauge as shown in figure below. After bleeding air from pressure gauge, conduct test as described in next 3 steps. Use commercially available gauges and pedal depression force gauge. 1. Checking for vacuum loss (1) Unloaded condition A.
Page 874 Pedal force Fluid pressure 44 lb(196 N, 20 kg) 171 psi(1.177 kPa, 12 kg/cm²) Min (2) Start engine. Depress brake pedal when vacuum reaches 19.7 inHg (500 mmHg). If fluid pressure is within specification, unit is operating. Pedal force Fluid pressure 44 lb(196 N, 20 kg) 171 psi(1.177 kPa, 12 kg/cm²) Min Removal...
Page 875 1) verify that hose is not twisted. 2) verify that hose does not touch other parts when vehicle bounces or when steering wheel is turned fully right or left. Tightening torque: 9~16 lb-ft (13-22 N-m, 1.3-2.2 kg-m) Replacement 1. Follow procedure outline in air bleeding. 2.
Page 876 Brake System Brake System Parking Brake System...
Page 877 2001 > 1.8L DOHC > Component...
Page 878 2001 > 1.8L DOHC > Removal Install parking brake switch so that it contacts parking brake lever when the lever fully release. 1. Remove the console. 2. Disconnect the parking brake switch. 3. Remove adjuster nut. 4. Remove two mounting bolts holding lever assembly to floorpan. If vehicle has recently been running, exhaust system will be extremely hot.
Page 879 12. Install console. Turn ignition switch ON and check that parking brake warning lamp illuminates with lever pulled back one notch.
Page 880 2001 > 1.8L DOHC > Inspection Parking brake (Lever type) 1. Check that stroke is within specification when parking brake lever is pulled with a force of 22 lb-ft(98 N-m, 10 kg-m). Stroke : 5~7 notches Adjustment Parking brake (Lever type) 1.
Page 881 Brake System Brake System ABS(Anti-Lock Brake System)
Page 882 2001 > 1.8L DOHC > Wire harness diagram structure...
Page 883 2001 > 1.8L DOHC > Description and operation Anti-lock brake system (ABS) The anti-lock brake system (ABS) is designed for prevents wheels from locking due to excessive brake efforts. Main functions of the ABS are; • To reduce braking distance by avoiding wheels from locking. •...
Page 884 Hydraulic control unit (HCU) 1. The HCU consists of a motor pump assembly in which motor sensor is built, and valve block for controlling ABS pressure. Motor sensor is built in motor, and output signal, which detects condition of a motor pump assembly, is sent to ABS control unit.
Page 885 For vehicles with ABS, the following symptoms can occur, but indicate normal operation of the ABS. Symptom Descriptions Motor noise Noise can be heard when ABS hydraulic unit is operated. Since braking is done in 3 steps during operation of ABS, noise from suspension Noise from suspension system system can be heard.
Page 886 When the brake pedal is depressed, the power brake unit closes the central valve of the master cylinder and generates pressure on the brake hydraulic pressure line. This opens the solenoid inlet valve and closes the outlet valve and transmits hydraulic pressure from the master cylinder to the wheel cylinders. ABS braking (2.1 Maintaining pressure)
Page 887 After the ABS control unit detects wheel lock due to excessively increased pressure, the ABS control unit closes the inlet valve to avoid further increase in hydraulic pressure. ABS braking (2.2 Decreasing pressure)
Page 888 If lock wheel continues, the ABS control unit opens the corresponding outlet valve so that brake fluids flow to the pressure accumulator. This reduces pressure only for wheels that are locked. ABS braking (2.3 Increasing pressure)
Page 889 When wheels have been returned to normal speed from locking, the ABS control unit stops operating the solenoid valve and returns to standard braking operation. Hydraulic circuits Operation Since teeth of sensor rotor change magnetic field of sensor, it generates alternative voltage. This Voltage is proportional to rotating speed and its period can be changed.
Page 891 2001 > 1.8L DOHC > Component...
Page 892 Brake System Brake System ABS(Anti-Lock Brake System) - ABS Control Module...
Page 893 2001 > 1.8L DOHC > Removal Hydraulic control unit (HCU) assembly 1. Disconnect the negative battery cable from the battery 2. Pill up the locker to remove the unit connector. 3. Disconnect the six brake lines (2 inlet and 4 outlet) using a flare nut wrench. Be prepared to catch escaping brake fluid.
Page 894 Brake System Brake System ABS(Anti-Lock Brake System) - Front Wheel Speed Sensor...
Page 895 2001 > 1.8L DOHC > Removal 1. Disconnect the negative battery cable from the battery. 2. After removing trim, remove the wheel speed sensor and connector in the engine room. Removal 1. Remove the drive shaft assembly from the vehicle. 2.
Page 896 Installation 1. Install the sensor rotor with a suitable tool. Inspection 1. Measure the resistance of the wheel speed sensor. Resistance : 1.0~1.3 KΩ 2. Replace the wheel speed sensor if necessary. Inspection 1. Check rotor for damage. 2. Check if gap between rotor and sensor meets the specified value. Gap : 0.0287~0.0578 in (0.73~1.47 mm) 3.
Page 897 Brake System Brake System ABS(Anti-Lock Brake System) - Rear Wheel Speed Sensor...
Page 898 2001 > 1.8L DOHC > Inspection 1. Measure the resistance of the wheel speed sensor. Resistance : 1.0~1.3 KΩ 2. Replace the wheel speed sensor if necessary. Inspection 1. Check rotor for damage. 2. Check if gap between the rotor and sensor meets the specified value. Gap:0.0125~0.0503 in (0.32 ~ 1.28 mm) 3.
Page 899 Removal 1. Remove the rear wheel hub assembly from the vehicle. 2. Remove the sensor rotor with SST(0K 0670 990AA0). Installation 1. Install wheel speed sensor. Tightening torque: 6~7 lb-ft (8~10 N-m, 0.8~1.0 kg-m) 2. Install wheel sensor connector. 3. Connect battery cable. A shield wire is used to prevent input signal from the wheel speed sensor.
Page 900 2001 > 1.8L DOHC > General diagnostics and tests Self-diagnosis The ABS control unit starts self-diagnostic functions after the ignition is switched ON. The ABS control unit detects failure for each circuit and component by comparing condition of the system with limited condition set inside the ABS control unit.
Page 901 If the system is operating normally (no malfunction) the warning lamp ill blink once every 0.25 second. After-repair procedures 1. After repair, erase all diagnostic trouble codes stored in the ABS control unit with Kia power scan. (Refer to Kia power scan operating manual) 2.
Page 902 mode. 2) After diagnostic trouble code are erased, if there is still problem in the system, ABS warning lamp will stay as "ON" state. If not, normal code will be read out. How to use diagnosis and troubleshooting Precaution before repairing 1.
Page 903 Air bleeding (CBS) After finishing repair on a hydraulic line (removing brake pipe), bleed air out of the line. Refer to the following: 1. When bleeding air from lines, keep fluid level in reservoir to Max position. 2. Bleed air in the following order: Right front wheel, Left front wheel, Right rear wheel, Left rear wheel 3.
Page 904 Check if each "ABS" (30A) fuse is properly Go to next step. connected. - Opened or shorted Replace it. - Connection Check if following component is properly Check functions. connected. - Wheel speed sensor - Hydraulic control unit (Include ECU) Connect it again.
Page 905 ● Open or short between wheel speed sensor and Wheel speed sensor (FR) ABS control unit. ● Missing sensor signal because of loosen wheel Wheel speed sensor (FL) speed sensor (Sensor notinserted, shorted sensor Wheel speed sensor (RR) coil). - Air gap too large. Wheel speed sensor (RL) - Tooth wheel not installed.
Page 906 O-01-22 Wheel speed sensor (RR) Wheel speed sensor (+) Ignition switch OFF 1.0~1.3 kΩ O-01-23 Wheel speed sensor (RR) Wheel speed sensor (-) O-01-24 Ground Ground Constant O-01-25 Power supply (ABS Motor) Battery Constant...
Page 907 Body (Interior and Exterior) Body (Interior and Exterior) General Information...
Page 908 2001 > 1.8L DOHC > Description and operation Assist handles There are three assist handles on CARENS. They can also be used to hand objects such as clothes on hangers. They are removable, replaceable items.
Page 909 2001 > 1.8L DOHC > General Bumper Problem Possible cause Action Front face damaged Accident Replace Energy absorbing foam damaged Accident or exposure Replace or deteriorated Reinforcement damaged Accident Replace Brackets or stays damaged Accident Repair or replace Missing attaching hardware Accident or vibration Replace Seat belts...
Page 910 2001 > 1.8L DOHC > Tightening specifications Description Tightening torque Item Front bumper mounting bolts 23~34 lb-ft (31~46 N-m, 3.2~4.7 kg-m) Bumper Rear bumper mounting bolts 23~34 lb-ft (31~46 N-m, 3.2~4.7 kg-m) Door checker bolts (Door side) 7~9 lb-ft (9~13 N-m, 0.9~1.3 kg-m) Door checker mounting bolts (Body side) 16~20 lb-ft (22~27 N-m, 2.2~2.8 k-m) Door hinge mounting bolts (Door side)
Page 911 Body (Interior and Exterior) Body (Interior and Exterior) Body Dimension...
Page 912 2001 > 1.8L DOHC > Body dimensions Projected dimensions The projected dimension indicates a dimension from a reference point on the body. (Height may be different in some cases) Straight-line dimensions (Actual measured dimensions) The straight-line dimension indicates an actual measured dimension between the measurement reference points. Straight-line dimensions Front body...
Page 914 Dimension 1445 1366 1554 1031 1043 (mm) Dimension 1043 (mm) Side frame panel...
Page 916 Dimension 1200 2165 1081 2090 2055 1030 1999 1089 1112 2014 (mm) Dimension 1026 1089 1674 1332 1003 1641 1131 (mm) Interior A...
Page 918 Dimension 1162 1376 1375 1182 1385 1178 1182 1131 1207 (mm) Interior B (RH)
Page 920 Dimension 1212 1255 1046 1227 1663 1583 2227 2121 (mm) Interior B (LH)
Page 922 Dimension 1197 1239 1026 1213 1653 1572 2219 2113 (mm) Interior C...
Page 924 Dimension 1445 1299 1062 1157 (mm) Rear body...
Page 926 Dimension 1052 1220 1447 1220 1447 (mm) Dimension 1257 1310 1080 (mm) Under body dimensions Projected dimensions Measurement Points Description Size of hole Under cover mounting hole of No.1 crossmember Ø 9.8 mm Inner hole of front frame Ø 16 mm Sub frame mounting hole of torque box Ø...
Page 927 Straight-line dimensions Measurement Points Description Size of hole Under cover mounting hole of No.1 crossmember Ø 9.8 mm Inner hole of front frame Ø 16 mm Sub frame mounting hole of torque box Ø 14 mm Hole of rear frme Ø...
Page 928 Drain hole of No.4 crossmember Ø 28 mm Hole of rear side frame Ø 16 mm Hole of rear side frame Ø 18 mm...
Page 929 Body (Interior and Exterior) Body (Interior and Exterior) Exterior - Hood...
Page 930 2001 > 1.8L DOHC > Component...
Page 931 2001 > 1.8L DOHC > Removal Hood 1. Raise hood and support with prop. 2. Support hood so it will not fall when hinges are removed. Have an assistant help remove hood. 3. Remove hinges from hood by removing four bolts. 4.
Page 932 Have an assistant help install hood. 1. Install in reverse order of removal. 2. Tighten four hinge bolts to just over finger-tight. Tightening torque : 14~19 lb-ft (19~26 N-m, 1.9~2.6 kg-m) 3. Lower and lock hood. 4. Check fit and adjust as required in accordance with illustrated specifications. 5.
Page 933 Body (Interior and Exterior) Body (Interior and Exterior) Exterior - Trunk Lid...
Page 934 2001 > 1.8L DOHC > Component Rear hatch The rear hatch is attached to the body by two pin-type hinges rivted to the body and bolted to the hatch. A damper stay on either side of the hatch provides an assist in raising the hatch and fully supports it when it is open. A latch at the center-bottom of the opening secures the hatch in the closed position.
Page 935 2001 > 1.8L DOHC > Removal Rear hatch 1. Disconnect battery. 2. Raise the rear hatch. 3. Remove the cover from the rear hatch high-mounted stop light. 4. Disconnect the high-mounted stop light. 5. Remove two bolts from high-mounted stop light assembly. 6.
Page 936 The last step in the removal of the rear hatch is a two-man job. Have an assistant help remove the hatch. 24. Remove the last two bolts from the hatch 25. Remove the rear hatch. Installation Rear hatch 1. Install in reverse order of removal. Adjustment Rear hatch 1.
Page 937 Body (Interior and Exterior) Body (Interior and Exterior) Exterior - Front Door...
Page 938 2001 > 1.8L DOHC > Component...
Page 939 2001 > 1.8L DOHC > Removal Front door 1. Disconnect negative battery cable. 2. Remove door trim. Refer to "Trim" in this section. 3. Remove one screw on pull handle bracket. 4. Remove pull handle bracket. 5. Remove door speaker. A.
Page 940 C. Turn ignition "OFF". D. Remove two glass mounting bolts from power window regulator. E. Remove glass carefully; hold glass from both its inner and outer surfaces. While tilting it toward hinge side of door, pull it out from outisde door frame. 9.
Page 941 12. Remove door lock assembly. A. Disconnect two remote control rods from outside door handle assembly. B. Remove three screws from door lock assembly and remove assembly from access hole. C. Remove two mounting nuts from outside door handle. D. Remove outside door handle. 13.
Page 942 B. Pull out wiring harness from access hole. 15. Remove door checker installation bolt from body. 16. Remove door by removing bolts on both hinges. Installation Front door 1. Install door. A. Position door on vehicle properly. B. Install bolts on both hinges. Tightening torque : 13~22 Ib·ft (18~29 N·m, 1.8~3.0 kg·m) 2.
Page 943 B. Install three mounting screws. Tightening torque : 34~52 Ib·in (4~6 N·m, 40~60 kg·cm) 7. Install outside door handle. A. Connect two control rods of door lock assembly. B. Install two mounting nuts. 8. Install glass guide. A. Position glass guide as originally positioned through access hole. B.
Page 944 C. Connect electrical connector for motor of regulator assembly. 11. Install window glass. A. Position glass carefully: Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, place it on small bracket on window regulator assembly. B.
Page 945 14. Install door speaker with three mounting screws. 15. Install pull handle bracket with one mounting screws. 16. Install door trim. 17. Install inner door handle cover with one mounting screw. 18. Fasten door trim. Refer to "Trim" in this section. 19.
Page 946 Body (Interior and Exterior) Body (Interior and Exterior) Exterior - Rear Door...
Page 947 2001 > 1.8L DOHC > Component...
Page 948 2001 > 1.8L DOHC > Removal 1. Remove door trim. Refer to "Trim" in this section. 2. Remove one screw on pull handle bracket. 3. Remove inside door handle assembly. A. Remove one screw from inside door handle. B. Disconnect two control rods. C.
Page 949 G. Disconnect negative battery cable. 8. Remove harness connector. 9. Remove two nuts on outside door handle from access hole. 10. Remove outside door handle. 11. Remove three screws on door lock assembly. 12. Remove door lock assembly from access hole. 13.
Page 950 A. Remove one bolt on checker pin assembly. B. Remove checker pin assembly from access hole. 22. Remove weatherstrip. 23. Remove door: A. Remove bolts on both hinges. B. Remove door. INSTALLATION 1. Install door. A. Position door on vehicle properly. B.
Page 951 16. Install glass guide. A. Position glass guide as originally positioned through access hole. B. Install one bolt. Tightening torque : 61~86 lb-in (7~10 N-m, 70~100 kg-cm) 17. Install glass piece carefully. A. Use lubricant around window opening edges. B. Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, push it in from outside door frame and place on glass mounting bracket of regulator assembly.
Page 952 25. Connect harness connector. 26. Install trim. Refer to "Trim" in this section. 27. Connect negative battery cable. 28. Move window glass to maximum upper position.
Page 953 Body (Interior and Exterior) Body (Interior and Exterior) Exterior - Mirror...
Page 954 2001 > 1.8L DOHC > Component Outside rearview mirror assembly is comprised of mirror glass, a mirror frame (which holds mirror glass), a motor and a wire harness. Each outside rearview mirror can be adjusted in four directions from inside vehicle.
Page 955 2001 > 1.8L DOHC > Removal Outside rearview mirror assembly 1. Disconnect negative battery cable. 2. Remove garnish. 3. Remove three rearview mirror assembly retaining bolts. 4. Pull out outside rearview mirror assembly and disconnect harness connector.
Page 956 5. Remove outside rearview mirror assembly. Removal Outside rearview mirror glass 1. Heat frame and mirror glass using a heat gun. 2. Loosen mirror glass y inserting a plstic scraper between frame and mirror glass.
Page 957 3. Remove adhesive from behind mirror glass and remove mirror glass. Gloves and safety glasses should be worn when removing broken mirror glass Installation Outside rearview mirror assembly 1. Position outside rearview mirror assembly on door. 2. Install three retaining bolts. 3.
Page 958 Installation Outside rearview mirror glass 1. Install mirror glass with appropriate adhesive. 2. Heat frame and mirror glass using a heat gun. 3. Fasten mirror glass in mirror frame.
Page 959 Body (Interior and Exterior) Body (Interior and Exterior) Sunroof...
Page 960 2001 > 1.8L DOHC > Sunroof system...
Page 962 2001 > 1.8L DOHC > Circuit operation Front room lamp Battery voltage is always applied from "ROOM (10A)" fuse to the front room lamp through the R wire. When the front room lamp switch in turned to "ON" position, the front room lamp is grounded through the switch and B wire.
Page 963 2001 > 1.8L DOHC > Troubleshooting Front room lamps do not operate Preliminary check: Check an open lamp filament before proceeding with diagnosis. If bulb is damaged, check connection of the bulb and replace bulb. In addition, check "ROOM (10A)" fuse. If open, check for short to ground though the wire, replace fuse and check that all system electrical connectors mated correctly.
Page 964 1. Disconnect the room lamp & sunroof switch. 2. Check for continuity between terminal as indicated. 3. If not as specified, replace the power window main switch assembly.
Page 965 Body (Interior and Exterior) Body (Interior and Exterior) Interior - Console...
Page 966 2001 > 1.8L DOHC > Removal 1. Remove one mounting screw from left side of console. 2. Repeat right side. 3. Remove console. Installation 1. Position console and install two mounting screws.
Page 967 Body (Interior and Exterior) Body (Interior and Exterior) Interior - Crash Pad...
Page 968 2001 > 1.8L DOHC > Description Instrument panel Instrument panel houses instrument cluster, center panel and a numberof special switches and controls. Instrument panel electrical system is discussedin Rio Electrical troubleshooting Manual. Ducts installed in instrument panelare discussedin this section. Radio and antenna cable When a radio is installed in vehicle, user instructions are supplied.Radio is located in center panel.
Page 969 2001 > 1.8L DOHC > Component Ducts Instrument panel assembly...
Page 971 2001 > 1.8L DOHC > Removal Ducts 1. Remove mounting screws holding duct parts to instrument panel. 2. Remove defroster grille. 3. Remove LH,RH vent duct. 4. Remove center vent duct. 5. Remove LH, RH demist grille. Removal Floor-mounted ducts 1.
Page 972 12. Remove cup holder assembly. 13. Remove passenger air bag module. Refer to "Passenger Air Bag Module" in this section. 14. Remove two mounting bolts on right side of T-bar as shown. 15. Remove two mounting bolts from right of instrument panel assembly as shown. 16.
Page 973 7. Remove ventilation control panel from instrument panel. Installation Ducts 1. Install LH, RH demist grille. 2. Install center vent duct. 3. Install LH,RH vent duct. 4. Install defroster grille. 5. Install mounting screws holding duct parts to instrument panel. Installation Floor-mounted ducts 1.
Page 974 12. Install two bolts and side cover on left side of T-bar. Tightening torque : 14~19 lb-ft (19~26 N-m, 1.9~2.6 kg-m) 13. Install lower panel. Refr to "Lowr panel" in this section. 14. Install section of T-bar with two mounting screws. 15.
Page 975 Body (Interior and Exterior) Body (Interior and Exterior) Interior - Roof Trim...
Page 976 2001 > 1.8L DOHC > Component Headliner is a cloth cushion that serves as a buffer between passengers and top of vehicle. It also covers thermal and acoustic insulation in top of vehicle and wiring for room light. Both headliner and insulation are replaceable.
Page 977 2001 > 1.8L DOHC > Removal 1. Unscrew two mounting screws from sunvisors. 2. Remove sunvisors and sunvisors retaining clips. 3. Remove assist handle covers, unscrew mounting screws. 4. Remove three assist handles. 5. Gently remove lens assembly on room light. 6.
Page 978 INSTALLATION 1. Check that five insulation pads are properly placed in headliner. 2. Reverse remove procedure.
Page 979 Body (Interior and Exterior) Body (Interior and Exterior) Interior - Trunk Trim...
Page 980 2001 > 1.8L DOHC > Removal Rear hatch trim 1. Remove high-mounted stop light assembly. Refer to "Exterior light" in this section. 2. Remove two screws on assist handle. 3. Remove assist handle. 4. Unfasten rear hatch trim. 5. Remove rear hatch trim. Removal Rear quarter trim 1.
Page 981 2. Remove rear scuff plate. Installation Rear hatch trim 1. Positon rear hatch trim. 2. Install rear hatch trim. 3. Install assist handle. 4. Install high-mounted stop light assembly. Installation Rear quarter trim 1. Position rear quarter trim. 2. Install two screws and one fastener on rear quarter trim. 3.
Page 982 Installation Rear scuff plate 1. Position rear scuff plate. 2. Press in rear scuff plate.
Page 983 Body (Interior and Exterior) Body (Interior and Exterior) Interior - Interior Trim...
Page 984 2001 > 1.8L DOHC > Component Trim is a plastic component thermoses molding and is used to cover interior of vehicle. It assists vehicle insulation by covering it in addition to hiding vehicle metal frame. It also acts as a sound barrier. It is used on all four doors of vehicle door opening sills, A, B, and C pillars, front side, rear side and end trim.
Page 985 2001 > 1.8L DOHC > Removal A-pillar trim 1. Unfasten A-pillar trim with a trim removal tool. 2. Remove A-pillar trim. Removal B-pillar lower trim 1. Remove two fastener from front scuff plate. 2. Remove front scuff plate. 3. Remove one fastener from rear scuff plate. 4.
Page 986 3. Remove one fastener on front side trim. 4. Remove front side trim. Removal B-pillar upper trim 1. Unfasten B-pillar lower trim. 2. Remove B-pillar lower trim. 3. Remove seat belt anchor bolt: A. Unfasten seat belt. 4. Remove one screw from B-pillar upper trim. 5.
Page 987 Removal C-pillar trim 1. Remove trunk end trim. 2. Remove two screw and one fastener from rear quarter trim. 3. Remove rear quarter trim. 4. Remove seat belt anchor bolt. Tightening torque : 40~47 lb-ft (54~64 N-m, 5.5~6.5 kg-m) 5. Remove seat belt. 6.
Page 988 Removal Footrest trim 1. Remove rubber cap. 2. Remove one nut. 3. Remove footrest trim. Removal Front door trim 1. Remove garnish. 2. Remove one screw on inside door handle cover. 3. Remove inside door handle cover. 4. Remove one screw on pull door handle . 5.
Page 989 6. Remove two fasteners on front trim. 7. Remove one screw on front trim. 8. Unfasten front door trim. 9. Remove front door trim by lifting front door trim up. 10. Disconnect window operating switch connectors. Removal Front scuff plate 1.
Page 990 Removal Rear door trim 1. Remove one screw on inside door handle cover. 2. Remove inside door handle cover. 3. Remove one screw in pull door handle. 4. Remove pull door handle. 5. Install one screw on rear door trim. 6.
Page 991 Front side trim 1. Position front side trim. 2. Install one fastener on front side trim. 3. Install front scuff plate. Installation B-pillar upper trim 1. Position B-pillar upper trim 2. Install one screw. 3. Install seat belt anchor: A. Install one bolt on seat belt anchor. Tightening torque : 40~47 lb-ft (54~64 N-m, 5.5~6.5 kg-m) 4.
Page 992 2. Install seat belt anchor. 3. Install seat belt anchor bolt. Tightening torque : 40~47 lb-ft (54~64 N-m, 5.5~6.5 kg-m) 4. Install rear quarter trim. 5. Install two screw and one fastener from rear quarter trim. Tightening torque : 40~47 lb-ft (54~64 N-m, 5.5~6.5 kg-m) Installation Footrest trim 1.
Page 993 3. Press in front door trim. 4. Install inside door handle cover. 5. Install one screw on inside door handle cover. 6. Install pull door handle . 7. Install one screw on pull door handle. 8. Install one screw of door trim. 9.
Page 994 6. Place pull door handle. 7. Install one screw on pull door handle.
Page 995 Body (Interior and Exterior) Body (Interior and Exterior) Bumper - Front Bumper...
Page 996 2001 > 1.8L DOHC > Component...
Page 997 2001 > 1.8L DOHC > Inspection 1. Inspect front bumper face for damage and check that front bumper is securely mounted. 2. Inspect front bumper for missing attaching hardware. Removal 1. Remove radiator grille. 2. Remove left turn signal light assembly. 3.
Page 998 10. Repeat for right side. 11. Remove four fasteners from bottom of bumper. 12. Remove two bolts from left-hand bumper stay. 13. Repeat for right side. 14. Remove front bumper. Installation 1. Install front bumper in reverse order of removal. Tightening torque : 23~34 lb-ft 31~46 N-m, 3.2~4.7 kg-m)
Page 999 Body (Interior and Exterior) Body (Interior and Exterior) Bumper - Rear Bumper...
Page 1000 2001 > 1.8L DOHC > Component...
Page 1001 2001 > 1.8L DOHC > INSPECTION 1. Inspect rear bumper face for damage and check that it is securely mounted. 2. Inspect rear bumper for missing attaching hardware. Removal 1. Remove left rear combination light assembly. 2. Repeat for right side. 3.
Page 1002 Body (Interior and Exterior) Body (Interior and Exterior) Seat & Power Seat...
Page 1003 2001 > 1.8L DOHC > Description Front seat Front seat consists of a seat back and a cushion. Both items are replaceable or serviceable. Both seats can be reclined or adjusted front-to-rear by two levers, adjusting lever and reclining lever. Head restraint can also be adjusted or removed.
Page 1004 2001 > 1.8L DOHC > Component...
Page 1005 Body (Interior and Exterior) Body (Interior and Exterior) Seat & Power Seat - Front Seat...
Page 1006 2001 > 1.8L DOHC > Removal Front seat 1. Pull reclining lever and let seatback spring forward. 2. Pull seat adjuster and push seat all of the way back. 3. Remove front two mounting bolts. 4. Move seat forward. 5. Remove rear mounting bolt and nut. 6.
Page 1007 5. Remove head restraint and pull off holding catches. Replace catches. 6. Remove five hog rings on seatback cover. 7. Slide seat trim up and off seatback. Removal Cushion cover 1. Remove reclining lever. 2. Remove hog rings on underside of seat cushion. 3.
Page 1008 1. Follow seat back cover removal steps 1-8. 2. Pull up trim until upper two knuckle mounting bolts are exposed. 3. Remove upper two hex head bolts and remove seatback. 4. Pull knuckle lever and push seat into reclining position. 5.
Page 1009 Head restraint 1. Insert head restraint in holes and push down until it locks. 2. Release lock and adjust position for comfort. Installation Reclining knuckle 1. Reverse removal procedures. Tightening torque : 25~41 lb-ft (34~56 N-m, 3.5~5.7 kg-m) Inspection Front seat 1.
Page 1010 Body (Interior and Exterior) Body (Interior and Exterior) Seat & Power Seat - Rear Seat...
Page 1011 2001 > 1.8L DOHC > Removal 1. Remove front two mounting bolts. 2. Remove rear two mounting nuts. 3. Remove seat. Installation 1. Reverse removal procedures.
Page 1012 Body (Interior and Exterior) Body (Interior and Exterior) Seat Belt - Front Seat Belt...
Page 1013 2001 > 1.8L DOHC > DESCRIPTION Seat belt system consists of five restraints. Outboard passengers(front and rear) have both shoulder and lap seat belts. Inboard passenger(rear) has only a lap seat belt. Driver's seat belt is equipped with awarning light on dash and an audible chime to remind driver to fasten seat belt.
Page 1014 2001 > 1.8L DOHC > Component...
Page 1015 2001 > 1.8L DOHC > INSPECTION 1. Inspect buckle assembly mounting to ensure that it is secure. 2. Inspect anchor assembly mounting to ensure that it is secure. 3. Remove B-pillar lower trim. Refer to "Trim" in this section. 4. Inspect retractor assembly mounting to ensure that it is secure. 5.
Page 1016 5. Remove front scuff plate and rear scuff plate. Refer to "trim" in this section. 6. Remove B-pillar lower trim panel. 7. Remove belt guide. 8. Remove one bolt and one sheet metal screw to remove retractor assembly. 9. Remove B-pillar upper trim. Refer to "trim" in this section. 10.
Page 1017 Installation Front buckle assembly 1. Install one bolt through mounting bracket. Tightening torque : 40~47 lb-ft (54~64 N-m, 5.5~6.5 k-m) 2. Install screw cover. Installation Front lap/shoulder belt assembly 1. Install shoulder adjuster. 2. Install two bolts to attach shoulder adjuster.
Page 1018 3. Install B-pillar upper trim. Refer to "trim" in this section. 4. Install one bolt and one sheet metal screw to attach retractor assembly. Tightening torque : bolt - 40~47 lb-ft (54~64 N-m, 5.5~6.5 kg-m)
Page 1019 EXERCISE CARE TO INSTALL BELT SO THERE ARE NO TWISTS IN IT. A TWISTED BELT MAY BE HARMFUL TO A PASSENGER IN A SERIOUS ACCIDENT. A TWISTED BELT ALTERS DISTRIBUTION OF FORCE RESULTING FROM SUDDEN DECELERATION. 5. Install belt guide. 6.
Page 1020 Tightening bolt to 40~47 Ib·ft (54~64 N·m, 5.5~6.5 kg·m)
Page 1021 Body (Interior and Exterior) Body (Interior and Exterior) Seat Belt - Rear Seat Belt...
Page 1022 2001 > 1.8L DOHC > Removal Rear buckle assembly 1. Pull safety belts to rear through seats. 2. Remove one bolt from rear buckle assembly mounting bracket. Removal Rear lap/shoulder belt assembly 1. Remove one bolt from lap belt mounting bracket. 2.
Page 1023 Body Electrical System Body Electrical System General Information...
Page 1024 2001 > 1.8L DOHC > Elelctrical wiring schematic Ground points...
Page 1025 Starting and charging system...
Page 1026 Diagnosis connector...
Page 1027 Common connector...
Page 1031 2001 > 1.8L DOHC > Ground points ● This shows ground points of the hareness. System circuit diagram/connector diagram ● These diagrams show the circuis for each system, from the power supply to the ground. The power supply side is on the upper part of the page, the ground side on the lower part.
Page 1033 Routing diagram ● The routing diagram shows where electrical components are on the system circuit diagrma by call outline and connector symbols. ● Specified values are listed beside the routing diagram or on he following page.
Page 1034 Symbols...
Page 1036 Logic symbols...
Page 1037 In-line connectors 1. The following illustrations show typical electrical connectors and their disengagements. A. Insert a flat blade screwdriver in the locking tab and twist. B. Grasp the connector housing and pull until the locking tab is on the ramp. Turn the connector over and repeat the procedure on the opposite side of the connector.
Page 1038 Inspection 1. When a tester is used to check the continuity or to check the voltage, insert the tester probe from the wire harness side. Wiring color codes 1. Two-color wires are indicated by a two-color code symbol. The first color code indicates the base color of the wire and the second indicates the color of the stripe.
Page 1039 signals or interference. For example: A. Ignition coil signal B. Heated Oxygen sensor(HO2S) signal. Replacement of terminals Use the appropriate tools to remove the terminal, as shown in the illustrations. When installing a terminal, be sure to press it in until it locks securely. Female type 1.
Page 1040 2001 > 1.8L DOHC > Diagnostics Exterior lights Refer to 1999 CARENS Wiring Diagram Manual. Windshield wiper/washer Refer to 1999 CARENS Wiring Diagram Manual. Horn Refer to 1999 CARENS Wiring Diagram Manual. Problem Possible cause Action Horn does not operate Fuse "HORN"...
Page 1041 Power door If power door does not operate, refer to 1999 CARENS Wiring Diagram Manual. Power mirror If power mirror does not operate, refer to 1999 CARENS Wiring Diagram Manual. Power window If power window does not operate, refer to 1999 CARENS Wiring Diagram Manual. Radio Problem Possible cause...
Page 1042 Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuit that contain solid-state devices. Damage to the devices may result. Test light and DVOM On circuits without solid-state devices, use a test light to check for voltage.
Page 1043 1. Connect on lead of a test light to a known good ground, or if you are using a voltmeter, be sure you connect its negative lead to ground. 2. Connect the other lead of the test light or voltmeter to the point you want to check. 3.
Page 1044 Testing for voltage drop This test checks for voltage drop along a wire, or through a connection or switch. 1. Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to the battery.
Page 1045 Testing for a short to ground with a self-powered test light or ohmmeter 1. Remove the open fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal load side. 3.
Page 1046 moving. Check around this area to locate the cause of the short circuit.
Page 1047 Body Electrical System Body Electrical System Audio...
Page 1048 2001 > 1.8L DOHC > Audio...
Page 1049 2001 > 1.8L DOHC > Circuit operation Battery voltage is always applied to the terminal C(R) of AUDIO throgh "ROOM (10A)" fuse. With the ignition switch in "ACC" or "ON", battery voltage is applied to the terminal A(O) of AUDIO through the "AUDIO (10A)" fuse.
Page 1050 Body Electrical System Body Electrical System Horn...
Page 1051 2001 > 1.8L DOHC > Horn, stop and back-up lights...
Page 1052 2001 > 1.8L DOHC > DESCRIPTION AND OPERATION The vehicle is equipped with one horn mounted behind front bumper near the center. Operation of horn is controlled by aswitch (horn button) located on steering wheel. Electrical power from positive side of battery is applied to a horn relaylocated in the engine compartment fuse box.
Page 1053 2001 > 1.8L DOHC > Troubleshooting Horn does not operate Preliminary check: Check "HORN (15A)" fuse and horn relay. If open, check for short to ground though wire, replace fuse or relay and check that all system electrical connectors mated correctly. Step Inspection Action...
Page 1054 2001 > 1.8L DOHC > Removal Horn relay 1. Disconnect negative battery cable. 2. Disconnect horn relay from fuse box in engine compartment...
Page 1055 2001 > 1.8L DOHC > Component Vehicle is equipped with one horn mounted behind front bumper on center side. Operation of horn is controlled by a switch (horn button) located on steering wheel. Electrical power from positive side of battery is applied to a horn relaylocated in fuse box.

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