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Indeks towaru: SILNIK 1,6
Realizacja zamówienia: 24

WYMIANA USZCZELKI GŁOWICY

 Labor Operations: Click to display a list of Labor Operations associated with this procedure
 Special Tools: Click to display a list of tools used in this procedure



NOTE: The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolt(s) should be replaced .

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced.

1. Clean the cylinder head (3) and cylinder block sealing surfaces

2. Position a new cylinder head gasket (2) on the locating dowels.

3. Position the cylinder head onto the engine block. Make sure the cylinder head seats fully over the locating dowels.

CAUTION: Avoid damaging spark plug tubes when installing/torquing cylinder head bolts.

4. Before installing cylinder head bolts, the threads should be oiled with engine oil.



5. Tighten the cylinder head bolts in the sequence shown. Using the 4 step torque method, tighten according to the following values:

Step One:

  1. Tighten the ten M10 bolts to 20 N·m (15 ft. lbs.)
  2. Tighten the two M8 bolts to 15 N·m (11 ft. lbs.)

Step Two:

  1. Tighten the ten M10 bolts to 41 N·m (30 ft. lbs.)

Step Three:

  1. Recheck the ten M10 bolts to 41 N·m (30 ft. lbs.)

Step Four:

  1. Do not use a torque wrench for this step. Tighten the ten M10 bolts an additional 90 degrees
  2. Tighten the two M8 bolts to 30 N·m (22 ft. lbs.)

6. Install timing chain guides (1,4). Torque fasteners (2) to 28 N·m (250 in. lbs.) .

7. Retrieve timing chain from crankcase with a magnet or fabricated hook.



8. Align triangular timing mark on cam sprocket (2) with the timing chain link that was painted (1) during disassembly. Install timing chain on cam sprocket.

9. Install camshaft sprocket on the camshaft.



CAUTION: Do Not use an impact wrench for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. Use a hand wrench only.

10. Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435 (1), torque bolt to 115 N·m (85 ft. lbs.).



11. Reset the timing chain tensioner by removing the oil reservoir cap (3) from timing chain tensioner (4).



12. Place the timing chain tensioner on a clean flat surface.

13. Place your palm against the tensioner and press down on the tensioner with continuous pressure until the fully extended tensioner bottoms out.



14. Installoil reservoir cap (3) onto timing chain tensioner.



15. Install timing chain tensioner (3) with oil reservoir cap (2) into engine block.

16. Install timing chain tensioner plug with seal ring (1). Torque plug to 62 N·m (46 ft. lbs.).



CAUTION: Do not pry directly on chain. Damage to timing chain may occur.

17. Using a long thin screwdriver, pry in on the right (movable) timing chain guide until the timing chain tensioner rachets out to tension the chain.

NOTE: Ensure the timing chain is properly positioned within the channel of the timing chain guides.



18. Install cylinder head plugs (3). Torque to 18 N·m (162 in. lbs.).



19. Install cylinder head cover (2)- INSTALLATION).

20. Install camshaft position sensor. Torque fastener to 10 N·m (85 in. lbs.). Reconnect connector.



21. Install right engine mount bracket

22. Lowerengine until right engine mount through bolt can be installed.

23. Install right engine mount through bolt (1).

24. Remove floor jack from under engine.

25. Install fastener securing power steering return line to right engine mount bracket.

26. Install fasteners securing power steering reservoir to right engine mount bracket.

27. Install upper torque strut (4).

28. Raise vehicle on hoist.

29. Install fasteners securing exhaust pipe to exhaust manifold. Torque fasteners to 28 N·m (250 in. lbs.).

30. Install lower torque strut (6).



31. Install accessory drive belt splash shield (3).

32. Install right front wheel.

33. Lower vehicle.

34. Connect upper radiator hose.

35. Install fastener securing heater return tube to thermostat housing.

36. Connect heater hoses to thermostat housing andheater return tube.

37. Connect the following electrical components:

  1. Upstream Oxygen Sensor
  2. Camshaft Position Sensor
  3. Ignition Coil and Capacitor
  4. Fuel Injectors
  5. MAP Sensor
  6. Knock Sensor
  7. Electronic Throttle Control Motor
  8. ECT Sensor
  9. Generator

38. Connect vacuum hoses to throttle body.

39. Connect ground strap to cylinder head.

 

 

 

 

 

 

 

 

 

 

TABELA WARTOŚCI MOMENTÓW DOKRĘCANIA

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

A/C Compressor Mount-bolts 28 - 250
Camshaft Position Sensor 10 - 85
Crankshaft Position Sensor 10 - 85
Camshaft Sprocket-Bolt 115 85 -
Rocker Shaft/Camshaft Bearing Cap 25 - 225
Timing Chain Cover 12 - 105
Timing Chain Guide 28 - 250
Timing Chain Tensioner Plug 62 46 -
Connecting Rod Cap-Bolts 26 +¼ turn 19 +¼ turn -
Crankshaft Main Bearing Cap/Bed Plate - - -
Bedplate Bolts 30 22 -
Main Bearing Cap Bolts 61 45 -
Crankshaft Damper-Bolt 115 85 -
Cylinder Head-Bolts
Cylinder Head-Plugs 18 - 162
Cylinder Head Cover 12 - 105
Right Engine Mount Bracket - - -
M12-Fasteners 118 87 -
M10-Fasteners 68 50 -
Exhaust Manifold Heat Shield 28 - 250
Exhaust Manifold to Cylinder Head Bolts 23 - 200
Exhaust Pipe to Manifold-bolts 28 - 250
Ignition coil 12 - 105
Intake Manifold - Upper 12 - 105
Intake Manifold - Lower 26 - 230
Intake Manifold Support Bracket - - -
M6-Fasteners 19 - 165
M8-Fasteners 28 - 250
Oil Filter Cartridge Cap 25 18 -
Oil Filter Cartridge Housing 28 - 250
Oil Pan Bolts 31 - 275
Oil Pan Drain Plug 27 20 -
Oil Pump Pick-up Tube Bolt 12 - 105

  

 

1.6L SOHC ENGINE GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Type In-Line OHV, SOHC
Number of Cylinders 4
Compression Ratio 10.5:1
Firing Order 1-3-4-2
Max. Variation Between Cylinders 25%
  Metric Standard
Displacement 1.6 Liters 97.6 cu. in.
Bore 77.0 mm 3.03 in.
Stroke 85.8 mm 3.377 in.
Compression Pressure 1172-1551 kPa 170-225 psi

ENGINE BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard

Cylinder Bore Diameter 76.9924-77.0076 mm 3.031-3.0317 in.
Out-of-Round (Max.) 0.0076 mm 0.0002 in.
Taper (Max.) 0.051 mm 0.002 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston Diameter 76.956-76.974 mm 3.029-3.030 in.
Clearance @ 40.25 mm (1.58 in.) from top of piston 0.018-0.52 mm 0.0008-0.0020 in.
Weight 219-224 grams 7.5-8.8 oz.
Land Clearance (Diametrical) 0.758-0.790 mm 0.0299-0.0312 in.
Piston Length 46.25 mm 1.82 in.
Piston Pin Hole Diameter 19.008-19.015 mm .748-.750 in.
Piston Ring Groove Width - Top Compression Ring 1.215-1.235 mm 0.0478-0.0486 in.
Piston Ring Groove Width - 2nd Compression Ring 1.215-1.235 mm 0.0478-0.0486 in.
Piston Ring Groove Width - Oil Ring 2.521-2.541 mm 0.0993-0.1000 in.

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in Piston 0.008-0.015 mm 0.0003-0.0006 in.
Clearance in Connecting Rod Interference
Diameter 18.995-19.000 mm 0.7478-0.7480 in.
End Play None
Length 56.50-57.00 mm 2.224-2.2244 in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap-Top Compression Ring 0.20-0.36 mm 0.007-0.014 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-2nd Compression Ring 0.25-0.46 mm 0.009-0.018 in.
Wear Limit 1.0 mm 0.039 in.
Ring Gap-Oil Control Steel Rails 0.20-0.58 mm 0.0078-0.0228 in.
Wear Limit 1.0 mm 0.039 in.
Ring Side Clearance-Compression Rings 0.025-0.065 mm 0.0010-0.0026 in.
Wear Limit 0.10 mm 0.004 in.
Ring Side Clearance-Oil Ring Pack 0.004-0.178 mm 0.0002-0.0070 in.
Ring Width-Compression Rings 1.17-1.19 mm 0.046-0.047 in.
Ring Width-Oil Ring Pack 2.354-2.517 mm 0.093-0.099 in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing Clearance 0.023-0.067 mm 0.0009-0.0026 in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter-Piston Pin End 18.96-18.98 mm 0.746-0.747 in.
Bore Diameter-Crankshaft End 47.005-46.991 mm 1.8505-1.8500 in.
Connecting Rod - Length 135.6 mm 5.34 in.
Connecting Rod - Weight (less bearing) 241.32 grams 8.51 oz.
Side Clearance 0.13-0.38 mm 0.005-0.015 in.
Wear Limit 0.40 mm 0.016 in.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod Journal Diameter 43.992-44.008 mm 1.731-1.732 in.
Main Bearing Journal Diameter 47.922-48.008 mm 1.731-1.890 in.
Journal Out-of-Round (Max.) 0.006 mm 0.0002 in.
Journal Taper (Max.) 0.008 mm 0.0003 in.
End Play 0.09-0.24 mm 0.0035-0.0094 in.
Wear Limit 0.37 mm 0.015 in.
Main Bearing Clearance 0.022-0.062 mm 0.0008-0.0024 in.
Connecting Rod Bearing Clearance 0.023-0.067 mm 0.0009-0.0026 in.

ROCKER ARM SHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Rocker Arm Shaft Diameter 18.966-18.984 mm 0.7466-0.7474 in.

ROCKER ARM/HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATIONS

Metric

Standard

Rocker Arm Inside Diameter (Shaft Bore) 19.00-19.02 mm 0.7480-0.7488 in.
Rocker Arm Shaft Clearance 0.016-0.054 mm 0.0006-0.0021 in.
Lash Adjuster Body Diameter 11.978-11.966 mm 0.4716-0.4711 in.
Plunger Travel Minimum (Dry) 2.2 mm 0.087 in.
Dry Lash-Intake 1.50 mm 0.059 in.
Dry Lash-Exhaust 1.46 mm 0.057 in.
Rocker Arm Ratio (Camshaft at Base Circle)  
Intake 1.8 to 1
Exhaust 1.5 to 1

CYLINDER HEAD CAMSHAFT BEARING BORE

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing Bore Diameter 25.359-25.380 mm 0.9984-0.9992 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal Diameter 25.290-25.309 mm 0.9957-0.9964 in.
Bearing Clearance-Diametrical 0.050-0.090 mm 0.0027-0.003 in.
Bearing Clearance (Max. allowable) 0.12 mm 0.0047 in.
End Play 0.05-0.39 mm 0.002-0.015 in.
Lift (Zero Lash)    
Intake 8.55 mm 0.337 in.
Exhaust 8.00 mm 0.314 in.
Exhaust Valve Timing*  
Closes (BTDC) -0.5°
Opens (BBDC) 37.7°
Duration 218.2°
Intake Valve Timing*  
Closes (ABDC) 37.7°
Opens (BTDC) -4.4°
Duration 213.3°
Valve Overlap -3.9°
*All readings in crankshaft degrees, at 0.5 mm (0.019 in.) of valve lift.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material Cast Aluminum
Gasket Thickness (Compressed) 0.60-0.70 mm 0.023-0.0275 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle 45°
Seat Diameter-Intake 31.975-31.950 mm 1.258-1.257 in.
Seat Diameter-Exhaust 25.20-25.175 mm 0.992-0.991 in.
Runout (Max.) 0.05 mm 0.002 in.
Valve Seat Width-Intake and Exhaust 0.90-1.30 mm 0.035-0.051 in.
Service Limit 1.50 mm 0.059 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

standard

Inside Diameter 5.975-6.000 mm 0.235-0.236 in.
Guide Height (spring seat to guide tip) 13.25-13.75 mm 0.521-0.541 in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle Intake and Exhaust 45-45.5°
Head Diameter - Intake 30.10-30.36mm 1.185-1.195 in.
Head Diameter-Exhaust 23.13-23.39mm 0.910-0.920 in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake 1.16-1.50 mm 0.0457-0.0591 in.
Service Limit 0.95 mm 1/32 in.
Exhaust 1.61-1.95 mm 0.063-0.077 in.
Service Limit 1.05 mm 3/64 in.

VALVE LENGTH

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake 109.28-109.78 mm 4.302-4.322 in.
Exhaust 118.08-118.58 mm 4.649-4.669 in.

VALVE STEM TIP HEIGHT

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake 49.16 mm 1.935 in.
Exhaust 49.19 mm 1.937 in.

VALVE STEM DIAMETER

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake 5.934-5.952 mm 0.2337-0.2344 in.
Exhaust 5.906-5.924 mm 0.2326-0.2333 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake 0.023-0.066 mm 0.0009-0.0026 in.
Max. Allowable 0.076 mm 0.003 in.
Service Limit 0.25 mm 0.010 in.
Exhaust 0.051-0.094 mm 0.002-0.0037 in.
Max. Allowable 0.101 mm 0.004 in.
Service Limit 0.25 mm 0.010 in.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length (Approx.) 51.3 mm 2.02 in.
Nominal Force (Valve Closed) 286-319 N @ 43.0 mm 64.3-71.71 lbs. @ 1.6 in.
Nominal Force (Valve Open) 759-833 N @ 34.45 mm 170.63-187.27 lbs. @ 1.28 in.
Installed Height 43.0 mm 1.69 in.

OIL PUMP

DESCRIPTION

SPECIFICATION

Metric

Standard

Relief Valve Opening Pressure 413.69 kPa 60 psi

OIL PRESSURE

DESCRIPTION

SPECIFICATION

Metric

Standard

(NOTE: At Normal Operating Temperatures)
Pressure @ Curb Idle Speed* 25 kPa 4 psi
Pressure @ 3000 RPM 170-550 kPa 25-80 psi
*If pressure is ZERO at idle, DO NOT run engine at 3000 RPM.