Engine Overhaul: Removal & Installation Kia Rio II

REMOVAL

Engine removal is not required for this procedure.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Remove the engine cover (A).
2. Remove the RH front wheel.
3. Remove the 2 bolts (B) and RH side cover (A).
4. Temporarily loosen the water pump pulley bolts.
5. Remove the alternator drive belt (A). (Refer to «CHARGING SYSTEM»(ref-269578) )
6. Remove the air conditioner compressor drive belt (B). (Refer to «AIR CONDITIONING SYSTEM»(ref-269657) )
7. Remove the power steering pump drive belt (C). (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-269605) )
8. Remove the 4 bolts and water pump pulley.
9. Remove the 4 bolts (B) and timing belt upper cover (A).
10. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1 cylinder compression TDC position)
11. Remove the crankshaft pulley bolt and crankshaft pulley (A).
12. Remove the crankshaft flange (A).
13. Remove the 4 bolts (B) and timing belt lower cover (A).
14. Remove the timing belt tensioner (A) and timing belt. NOTE: If the timing belt reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before.
15. Remove the bolt (B) and timing belt idler (A).
16. Remove the crankshaft sprocket (A).
17. Remove the cylinder head cover. Remove the wire harness bracket (A). Remove the ignition coil. 1.6 CVVT Remove the PCV (Positive Crankcase Ventilation) hose (A) and the breather hose (B) from the cylinder head cover. Remove the engine cover bracket (A). Loosen the cylinder head cover bolts (B) and then remove the cover (A) and gasket. 1.6 CVVT
18. Remove the camshaft sprocket. Hold the portion (A) of the camshaft with a hexagonal wrench, and remove the bolt (C) with a wrench (B) and remove the camshaft sprocket. CAUTION: Be careful not to damage the cylinder head and valve lifter with the wrench.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are evident, replace the belt. NOTE: Do not bend, twist or turn the timing belt inside out. Do not allow timing belt to come into contact with oil, water and steam.
3. Inspect the belt closely. If the following problems are evident, replace the belt with a new one. Hardened back surface of rubber. Back surface is glossy, non-elastic and so hard that when the nail of your finger is pressed into it, no mark is produced. Cracked back surface of rubber. Side of belt is badly worn. NOTE: A belt in good condition should have clear-cut sides as if it were cut with a sharp knife. Teeth are badly worn out. Initial stage: Canvas on load side of the tooth flank worn (fluffy canvas fibers, rubber gone, color changed to white, and unclear canvas texture) Last stage: Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width reduced). Missing tooth.

Scheme 35

1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise. Replace as necessary.
3. Replace the pulley if there is a grease leak from its bearing.

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Install the camshaft sprocket and tighten the bolt to the specified torque. Temporarily install the camshaft sprocket bolt (C). Hold the portion (A) of the camshaft with a hexagonal wrench, and tighten the bolt (C) with a wrench (B). Tightening torque : 78.5~98.1N.m (8.0~10.0kgf.m, 57.9~72.3lb-ft)
2. Install the cylinder head cover. Install the cylinder head cover (A) and bolts (B). Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft) 1.6 CVVT Install the engine cover bracket (A). Install the PCV (Positive Crankcase Ventilation) hose (A) and breather hose (B) to the cylinder head cover. Install the ignition coil. 1.6 CVVT
3. Install the crankshaft sprocket (A).
4. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No.1 piston placed at top dead center and its compression stroke.
5. Install the idler pulley (A) and tighten the bolt (B) to the specified torque. Tightening torque : 42.2~53.9N.m (4.3~5.5kgf.m, 31.1~39.8lb-ft)
6. Temporarily install the timing belt tensioner (A).
7. Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt. Crankshaft sprocket (A) --> idler pulley (B) --> camshaft sprocket (C) --> timing belt tensioner (D).
8. Adjust the timing belt tension. Loosen the tensioner pulley mounting bolt and apply tension to the timing belt. After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt (A) and (B) one by one. Tightening torque : 19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft) Then recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (111b)], the timing belt cog end is aprox. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center. Timing belt tension measuring procedure (by a sonic tension gauge) Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90° then measure the belt tension in the middle of tension side span (in arrow direction of above illustration) by free vibration method. CAUTION: Avoid rotating the crankshaft in a counter clockwise direction. Engine damage could occur. Conversion equation of frequency into tension: T = (4 / 9.8) xS 2 xMxWxf 2 / 100000000 S: Measured belt span (mm) M: Unit weight of belt (gf/cm 2 ) W: Belt width (mm) f: Transverse natural frequency of belt (Hz) TIMING BELT SPECIFICATIONS Item Specifications S (mm) 249.6 M (gf/cm 2 ) 0.4543 W (mm) 22 f (Hz) 70.4~87.9 T (kgf) 16 ± 3.5
9. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.
10. Install the timing belt lower cover (A) with 5bolts (B). Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft)
11. Install the flange and crankshaft pulley (A), and then tighten crankshaft pulley bolt. Make sure that crankshaft sprocket pin fits the small hole in the pulley. Tightening torque : 137.3~147.1 N.m (14.0~15.0kgf.m, 101.3~108.5lb-ft)
12. Install the timing belt upper cover (A) with 4 bolts (B). Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft)
13. Install the water pump pulley and 4 bolts.
14. Install the power steering pump drive belt (C). (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-269605) )
15. Install the air conditioner compressor drive belt (B). (Refer to «AIR CONDITIONING SYSTEM»(ref-269657) )
16. Install the alternator drive belt (A). (Refer to «CHARGING SYSTEM»(ref-269578) )
17. Install the RH side cover (A) with 2 bolts (B).
18. Install the RH front wheel. Tightening torque : 88.3~98.1 N.m (9.0~10.0kgf.m, 65.1~72.3lb-ft)
19. Install the engine cover with bolts. Tightening torque : 3.9~5.9N.m (0.4~0.6kgf.m, 2.9~4.3lb-ft)

Scheme 42

Scheme 43

Engine removal is not required for this procedure.

Note. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center. (Refer to REMOVAL )

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Disconnect the terminals (A) from battery and remove the battery.
2. Remove the engine cover (A).
3. Remove the under cover (A).
4. Drain the engine coolant. (Refer to «ENGINE COOLANT REFILLING AND BLEEDING»(ref-270970-S18016133742007110800000) ) Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly. Disconnect the AFS (Air Flow Sensor) connector (A). Disconnect the breather hose (B) from intake air hose (D). Remove the intake air hose (D) and air cleaner upper cover (C). Disconnect the ECM connector (A) and ECM connector (B) (A/T only). Remove the air cleaner element and air cleaner lower cover (C).
6. Remove the battery tray (A).
7. Remove the upper radiator hose (A) and lower radiator hose (B).
8. Remove the heater hoses (A).
9. Remove the fuel hose (B).
10. Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
11. Disconnect the TPS (Throttle Position Sensor) connector (B).
12. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold. Disconnect the rear oxygen sensor connector (A). Disconnect the air conditioner compressor switch connector (B). Disconnect the knock sensor connector (C). Disconnect the injector connectors (No.3,4) (D). Disconnect the injector connectors (No.1,2) (E) Remove the wire harness bracket (A). Disconnect the ISA (Idle Speed Actuator) connector (B). Disconnect the front oxygen sensor connector (A). Disconnect the CKP (Crankshaft Position Sensor) connector (B). Disconnect the OCV (Oil Control Valve) connector (C). Disconnect the ignition coil connector (A). Disconnect the ignition coil condenser connector (A). Disconnect the CMP (Camshaft Position Sensor) connector (C). Disconnect the ground cable (D). Remove the wire harness bracket (E). 1.6 CVVT
13. Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
14. Remove the brake booster vacuum hose (B).
15. Remove the power steering pump and fix the pump to vehicle with a wire. (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-269605) )
16. Remove the ignition coil. (Refer to «ENGINE ELECTRICAL SYSTEM - IGNITION SYSTEM»(ref-269577) )
17. Remove the exhaust manifold. (Refer to «REMOVAL»(ref-270970-S37528631752007110800000) )
18. Remove the intake manifold. (Refer to «REMOVAL»(ref-270970-S24249625152007110800000) )
19. Remove the timing belt. (Refer to «REMOVAL»(ref-270970-S36025144572007110800000) )
20. Remove the cylinder head cover. (Refer to «REMOVAL»(ref-270970-S36025144572007110800000) )
21. Remove the camshaft sprocket. (Refer to «REMOVAL»(ref-270970-S36025144572007110800000) )
22. Remove the timing chain auto tensioner (A). 1.6 CVVT
23. Remove the camshaft bearing caps (A) and camshafts (B). 1.6 CVVT
24. Remove the OCV (Oil Control Valve) (A). 1.6 CVVT
25. Remove the OCV (Oil Control Valve) filter (A). 1.6 CVVT
26. Remove the engine mounting support bracket fixing bolts (A).
27. Remove the cylinder head bolts, then remove the cylinder head. Using 8mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. 1.6 CVVT CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench. CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION

Note. Thoroughly clean all parts to be assembled. Always use a new cylinder head and manifold gasket. Always use a new cylinder head bolt. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

1. Install the cylinder head gasket (A) on the cylinder block. NOTE: Be careful of the installation direction.
2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install the cylinder head bolts. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Tightening torque : 29.4N.m (3.0kgf.m, 21.7lb-ft) + 90° --> Release all bolts --> 29.4N.m (3.0kgf.m, 21.7lb-ft) + 90° 1.6 CVVT
4. Install the engine mounting support bracket fixing bolts (A).
5. Install the OCV (Oil Control Valve) filter (A). Tightening torque : 40.2~50.0N.m (4.1~5.1kgf.m, 29.7~36.9lb-ft) 1.6 CVVT NOTE: Always use a new OCV (Oil Control Valve) filter gasket. Keep clean the OCV (Oil Control Valve) filter.
6. Install the OCV (Oil Control Valve) (A). Tightening torque : 9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft) 1.6 CVVT CAUTION: Do not reuse the OCV (Oil Control Valve) when dropped. Keep clean the OCV (Oil Control Valve). Do not hold the OCV (Oil Control Valve) sleeve during servicing. When the OCV (Oil Control Valve) is installed on the engine, do not move the engine with holding the OCV (Oil Control Valve) yoke.
7. Install the camshafts. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown. 1.6 CVVT Install the camshaft (A) and bearing caps (B). Tightening torque : 11.8~13.7N.m (1.2~1.4kgf.m, 8.7~10.1lb-ft) Install the timing chain auto tensioner (A). Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft) 1.6 CVVT
8. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
9. Install the camshaft sprocket. (Refer to «REMOVAL»(ref-270970-S36025144572007110800000) )
10. Install the cylinder head cover. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B). 1.6 CVVT NOTE: Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove. When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap. Apply liquid gasket to the head cover gasket at the corners of the recess. 1.6 CVVT NOTE: Use liquid gasket, loctite No. 5999. Check that the mating surfaces are clean and dry before applying liquid gasket. After assembly, wait at least 30 minutes before filling the engine with oil. Install the cylinder head cover (A) with bolts (B). Uniformly tighten the bolts in several passes. Pre-tighten all bolts by 3.9~4.9N.m (0.4~0.5kgf.m, 2.9~3.6lb-ft) and then tighten by the specified torque. Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft) 1.6 CVVT
11. Install the timing belt. (Refer to «INSTALLATION»(ref-270970-S19627895942007110800000) )
12. Install the intake manifold. (Refer to «REMOVAL»(ref-270970-S24249625152007110800000) )
13. Install the exhaust manifold. (Refer to «REMOVAL»(ref-270970-S37528631752007110800000) )
14. Install the ignition coil. (Refer to «ENGINE ELECTRICAL SYSTEM - IGNITION SYSTEM»(ref-269577) ).
15. Install the power steering pump. (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-269605) )
16. Install the brake booster hose (B).
17. Connect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
18. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold. Install the wire harness bracket (E). Connect the ground cable (D). Connect the CMP (Camshaft position sensor) connector (C). Connect the ignition coil condenser connector (A). Connect the ignition coil connector (A). 1.6 CVVT Connect the OCV (Oil Control Valve) connector (C). Connect the CKP (Crankshaft Position Sensor) connector (B). Connect the front oxygen sensor connector (A). Connect the ISA (Idle Speed Actuator) connector (A). Install the wire harness bracket (A). Connect the injector connectors (No.1,2) (E). Connect the injector connectors (No.3,4) (D). Connect the knock sensor connector (C). Connect the air conditioner compressor switch connector (B). Connect the rear oxygen sensor connector (A).
19. Connect the TPS (Throttle Position Sensor) connector (B).
20. Install the accelerator cable (A).
21. Install the fuel hose (B).
22. Install the heater hoses (A).
23. Install the upper radiator hose (A) and lower radiator hose (B).
24. Install the battery tray (A).
25. Install the intake air hose and air cleaner assembly. Install the air cleaner element and air cleaner lower cover (C). Tightening torque : 7.8~9.8N.m (0.8~1.0kgf.m, 5.8~7.2lb-ft) Connect the ECM connector (A) and ECM connector (B) (A/T only). Install the intake air hose (D) and air cleaner upper cover (C). Connect the breather hose (B) to intake air hose (D). Connect the AFS (Air Flow Sensor) connector (A).
26. Install the under cover (A).
27. Install the engine cover (A). Tightening torque : 3.9~5.9N.m (0.4~0.6kgf.m, 2.9~4.3lb-ft)
28. Install the battery and connect the battery terminals (A).
29. Fill with engine coolant. (Refer to «ENGINE COOLANT REFILLING AND BLEEDING»(ref-270970-S18016133742007110800000) )
30. Start the engine and check for leaks.
31. Recheck engine coolant level and oil level.

Scheme 74

Note. Mark all wiring and hoses to avoid misconnection.

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Disconnect the terminals (A) from battery and remove the battery.
2. Remove the engine cover (A).
3. Remove the under cover (A).
4. Drain the engine coolant. (Refer to «ENGINE COOLANT REFILLING AND BLEEDING»(ref-270970-S18016133742007110800000) ) Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly. Disconnect the AFS (Air Flow Sensor) connector (A). Disconnect the breather hose (B) from intake air hose (D). Remove the intake air hose (D) and air cleaner upper cover (C). Disconnect the ECM connector (A) and ECM connector (B) (All only). Remove the air cleaner element and air cleaner lower cover (C).
6. Remove the battery tray (A).
7. Disconnect the upper radiator hose (A) and lower radiator hose (B).
8. Disconnect the ATF oil cooler hoses (C).
9. Disconnect the heater hoses (A).
10. Disconnect the fuel hose (B).
11. Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
12. Disconnect the TPS (Throttle Position Sensor) connector (B).
13. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold. Disconnect the rear oxygen sensor connector (A). Disconnect the air conditioner compressor switch connector (B). Disconnect the knock sensor connector (C). Disconnect the injector connectors (No.3,4) (D). Disconnect the injector connectors (No.1,2) (E) Remove the wire harness bracket (A). Disconnect the ISA (Idle Speed Actuator) connector (B). Disconnect the front oxygen sensor connector (A). Disconnect the CKP (Crankshaft Position Sensor) connector (B). Disconnect the OCV (Oil Control Valve) connector (C). Disconnect the ignition coil connector (A). Disconnect the ignition coil condenser connector (A). Disconnect the CMP (Camshaft Position Sensor) connector (C). Disconnect the ground cable (D). Remove the wire harness bracket (E). 1.6 CVVT Remove the ground cable (A) between engine mounting and vehicle body. Remove the ground cable (A) between transaxle housing and vehicle body.
14. Remove the transaxle wire harness connectors and control cable from transaxle (A/T). Disconnect the transaxle range switch connector (A). Disconnect the solenoid valve connector (B). Disconnect the ATF oil temperature sensor connector (C). Disconnect the vehicle speed sensor connector (A). Disconnect the band server switch connector (B). Disconnect the pulse generator (A) connector (C). Disconnect the pulse generator (B) connector (D). Remove the control cable nut (A) from transaxle range switch. Remove the control cable (B).
15. Remove the transaxle wire harness connectors and control cable from transaxle (M/T). Disconnect the vehicle speed sensor connector (A). Disconnect the neutral switch connector (B). Disconnect the back-up lamp switch connector (A). Remove the control cable (A).
16. Move the disconnected wire harnesses to the fuse box side so as to prevent interfering with other parts.
17. Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
18. Remove the brake booster vacuum hose (B).
19. Remove the power steering oil hose (A) and drain the power steering oil.
20. Remove the power steering return hose (A).
21. Recovering refrigerant and remove the high & low pressure pipe. (Refer to «AIR CONDITIONING SYSTEM»(ref-269657) )
22. Remove the nuts (B, D), bolt (C) and engine mounting support bracket (A). Tightening torque: Nut (B): 68.6~93.2N.m (7.0~9.5kgf.m, 50.6~68.7lb-ft) Bolt (C), Nut (D): 49.0~63.7N.m (5.0~6.5kgf.m,36.2~47.0lb-ft)
23. Remove the transaxle mounting bracket (A). Tightening torque: Bolt, Nut (B): 68.6~93.2N.m (7.0~9.5kgf.m, 50.6~68.7lb-ft) AT * A/T: Remove the wire harness protector (B) on the transaxle mounting support bracket. M/T * M/T: Remove the clutch release cylinder oil hose (B) on the transaxle mounting support bracket.
24. Disconnect the alternator connector (A) and "B" terminal (B).
25. Remove the front tires.
26. Remove the ABS wheel speed sensor (A).
27. Remove the caliper and hang assembly (A).
28. Remove the knuckle mounting bolts (A).
29. Remove the steering u-joint mounting bolt (A).
30. Remove the front muffler heat protector (A).
31. Remove the front muffler (B). Tightening torque: 29.4~39.2N.m (3.0~4.0kgf.m, 21.7~28.9lb-ft)
32. Using a floor jack, support the engine and transaxle assembly. NOTE: After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
33. Remove the sub frame bolts and nuts. Tightening torque: Bolt (A), Nut (B): 93.2~117.7N.m (9.5~12.0kgf.m, 68.7~86.8lbf.ft)
34. Remove the engine and transaxle assembly by lifting vehicle. NOTE: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation is in the reverse order of removal.

Perform the following

1. Adjust the shift cable.
2. Adjust the throttle cable.
3. Refill the engine with engine oil.
4. Refill the transaxle with fluid.
5. Refill the radiator and reservoir tank with engine coolant.
6. Place the heater control knob on "HOT" position.
7. Bleed air from the cooling system Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put the radiator cap on tightly, then run the engine again and check for leaks.
8. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
9. Inspect for fuel leakage. After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

1. M/T: Remove the fly wheel.
2. A/T: Remove the drive plate.
3. Install the engine to engine stand for disassembly.
4. Remove the timing belt. (Refer to «REMOVAL»(ref-270970-S36025144572007110800000) )
5. Remove the cylinder head. (Refer to «REMOVAL»(ref-270970-S40312627182007110800000) )
6. Remove the oil level gauge tube (A).
7. Remove the knock sensor (A).
8. Remove the oil pressure switch (A).
9. Remove the water pump. (Refer to «REMOVAL»(ref-270970-S30039815862007110800000) )
10. Remove the oil pan (A).
11. Remove the oil screen. Remove the 2bolts (C), oil screen (A) and gasket (B).
12. Check the connecting rod end play. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-270970-S22194336572007110800000) )
13. Remove the connecting rod caps and check oil clearance. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-270970-S22194336572007110800000) )
14. Remove the piston and connecting rod assemblies. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
15. Remove the front case. (Refer to «OIL PUMP»(ref-270970-S16478491552007110800000) )
16. Remove the rear oil seal case. Remove the 5bolts (B) and rear oil seal case (A).
17. Remove the crankshaft bearing cap and check oil clearance. (Refer to «CONNECTING ROD BEARING SELECTION TABLE»(ref-270970-S12467042002007110800000) )
18. Check the crankshaft end play. (Refer to «CRANKSHAFT MAIN BEARING SELECTION TABLE»(ref-270970-S23982504322007110800000) )
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals. NOTE: Arrange the main bearings and thrust bearings in the correct order.
20. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
21. Remove the piston rings. Using a piston ring expender, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
22. Remove the connecting rod from the piston. Using a press, remove the piston pin from piston. (Press-in load: 500~1,500kg (1,102~3,306lb))

Scheme 106

Scheme 107

1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. End play Standard: 0.1~0.25mm (0.0039~0.0098in) Maximum: 0.4mm (0.0157in) If out-of-tolerance, install a new connecting rod. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance. Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap nuts. Remove the connecting rod cap and lower bearing. Clean the crankshaft pin journal and bearing. Place a plastigage across the crankshaft pin journal. Reinstall the lower bearing and cap, and tighten the nuts. Tightening torque: 31.4~34.3N.m (3.2~3.5kgf.m, 23.1~25.3lb-ft) NOTE: Do not turn the crankshaft. Remove the 2nuts, connecting rod cap and lower bearing. Measure the plastigage at its widest point. Standard oil clearance 0.018~0.036mm (0.0007~0.0014in) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to , «CONNECTING ROD BEARING SELECTION TABLE»(ref-270970-S12467042002007110800000) ) Recheck the oil clearance. CAUTION: Do not File, shim, of scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to , «CONNECTING ROD BEARING SELECTION TABLE»(ref-270970-S12467042002007110800000) ) Recheck the oil clearance. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Scheme 108

OIL AND FILTER REPLACEMENT

1. Drain the engine oil. Remove the oil filler cap. Remove the oil drain plug, and drain the oil into a container.
2. Replace the oil filter. Remove the oil filter. Check and clean the oil filter installation surface. Check the part number of the new oil filter is as same as old one. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Tighten it an additional 3/4 turn.
3. Refill with engine oil. Clean and install the oil drain plug with a new gasket. Tightening torque: 39.2~44.1 N.m (4.0~4.5kgf.m, 28.9~32.5lb-ft) Fill with fresh engine oil. Oil Capacity Total: 3.3 L (3.49 US qt, 2.90 lmp qt) Oil pan: 3.0 L (3.17 US qt, 2.64 lmp qt) Oil filter: 0.3 L (0.32 US qt, 0.26 lmp qt) Install the oil filler cap.
4. Start engine and check for oil leaks.
5. Recheck the engine oil level.