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Engine
(G4GC - GSL 2.0)
GENERAL COOLING SYSTEM
SPECIFICATIO NS....................................................EM-2 C O M PO N EN TS..................................................... EM-83
TIGHTENING T O R Q U E ......................................... EM-6 ENGINE COOLANT REFILLING
CO M PR ESSIO N .......................................................EM-8 AND BLEE D IN G .................................................... EM-84
TIMING BELT TENSION AD JU STM EN T........... EM-8 RADIATOR CAP T E S T IN G ................................. EM-85
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VALVE CLEARANCE INSPECTION AND RADIATOR LEAKAGE TESTING ....................... EM-85
AD JU STM EN T.......................................................... EM-11 REMOVAL
TROUBLE - SHO O TING ........................................ EM-17 W ATER P U M P ...................................................EM-85
SPECIAL TO O LS......................................................EM-20 THERM O STAT...................................................EM-86
INSPECTION
TIMING BELT W ATER P U M P ...................................................EM-86
COM PONENTS.....................................................EM-22 THERM O STAT...................................................EM-87
R EM O VAL..............................................................EM-23 INSTALLATION
INSPECTION......................................................... EM-27 W ATER P U M P ...................................................EM-88
wt
INSTALLATION.....................................................EM-27 THERM O STAT...................................................EM-88

CYLINDER HEAD ASSEM BLY LUBRICATION SYSTEM

COM PONENTS.....................................................EM-33 C O M PO N EN TS..................................................... EM-89
R EM O VAL..............................................................EM-35 OIL AND FILTE R ...................................................EM-91
D ISASSEM BLY.....................................................EM-40 SELECTION OF ENGINE O IL .............................EM-92
INSPECTION......................................................... EM-41 R E M O V A L..............................................................EM-93
R EP LAC E M E N T...................................................EM-46 DISASSEMBLY...................................................... EM-94
on

R EASSEM BLY......................................................EM-47 IN SPEC TIO N ......................................................... EM-94

INSTALLATION.....................................................EM-48 REASSEMBLY....................................................... EM-96
IN STA LLATIO N ..................................................... EM-96
ENGINE AND TRANSAXLE ASSEMBLY
R EM O VAL..............................................................EM-55 INTAKE AND EXHAUST SYSTEM
INSTALLATION.....................................................EM-61 COMPONENTS
INTAKE M ANIFOLD..........................................EM-98
ENGINE BLOCK EXHAUST M ANIFOLD..................................... EM-99
C O M PO N EN TS...................................................EM-62 M U F F L E R .......................................................... EM-100
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DISASSEM BLY....................................................EM-64 REMOVAL

IN SPEC TIO N .......................................................EM-66 INTAKE M ANIFOLD..........................................EM-101
REASSEMBLY.....................................................EM-77 EXHAUST M ANIFOLD..................................... EM-102
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E M -2 ENGINE (G4GC - GSL 2.0)

GENERAL
SPECIFICATIONS EE49QA0A

Description Specifications Limit

General
Type In-line, Double Overhead Camshaft
Number of cylinder 4
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Bore 82mm (3.228in)
Stroke 93.5mm (3.681 in.)
Total displacement 1975cc ([Link].)
Compression ratio 10.1
Firing order 1-3-4-2
Valve timing
Intake valve
Opens (ATDC) 11°
Closes (ABDC) 59°
Exhaust
wt
Opens (BBDC) 42°
Closes (ATDC) 6°
Valve
Valve length
Intake 114.34mm (4.5016in.)
Exhaust 116.8mm (4.598in.)
Stem O.D.
on

Intake 5.965 ~ 5.98mm (0.2348 ~ 0.2354in.)

Exhaust 5.950 ~ 5.965mm (0.2343 ~ 0.2348in.)
Face angle thickness of valve
head (Margin)
Intake 1.15mm (0.0452in.) 0.8mm (0.031 in.)
Exhaust 1.35mm (0.0531 in.) 1.0mm (0.039in.)
Valve stem to valve guide clearance
Intake 0.02 ~ 0.05mm (0.0008 ~ 0.0019in.) 0.10mm (0.0039in.)
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Exhaust 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.) 0.13mm (0.0051 in.)

Valve guide
Installed dimension O.D
Intake 46mm (1.811 in.)
Exhaust 54.5mm (2.146in.)
Service oversize 0.05, 0.25, 0.50mm
(0.002, 0.010, 0.020in.) oversize
Valve seat
Width of seat contact
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Intake 1.1 - 1.5mm (0.043 ~ 0.059in.)

Exhaust 1.3 ~ 1.7mm (0.051 ~ 0.066in.)
Seat angle 45°
Oversize 0.3, 0.6mm (0.012, 0.024in.) oversize
Valve spring
Free length 48.86mm (1.9236in.)
Load 18.8kg/39mm (41.45lb/1.535in.)
Installed height 39mm (1.5354in.)
Squarences 1.5° MAX.
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GENERAL EM -3

Description Specifications Limit

Valve clearance
Cold (20°C[68°F])
0.20mm (0.0079in.) 0.12 - 0.28mm
Intake
(0.0047 - 0.0110in.)
0.28mm (0.0110 in,) 0.20 - 0.38mm
Exhaust
(0.0079 - 0.0150in.)
Cylinder head
0.06mm (0.0024in.)
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Flatness of gasket surface Max. 0.03mm (0.0012in.)
Flatness of manifold mounting surface Max. 0.15mm (0.0059in.) 0.03mm (0.0012in.)
Oversize rework dimensions of
valve seat hole
Intake
0.3mm (0.012in.) O.S. 33.300 - 33.325mm (1.3110 - 1.3120in.)
0.6mm (0.024in.) O.S. 33.600 ~ 33.625mm (1.3228 ~ 1.3238in.)
Exhaust
0.3mm (0.012in.) O.S. 28.800-28.821 mm (1.1338 - 1.1346in.)
0.6mm (0.024in.) O.S. 2 9 .1 0 0 - 29.121mm (1.1456 - 1.1465in.)
Oversize rework dimensions of valve
wt
guide hole (both intake and exhaust)
0.05mm (0.002in.) O.S 11.05 - 11.068mm (0.435 - 0.4357in.)
0.25mm (0.010in.) O.S 11.25 - 11.268mm (0.443 - 0.4436in.)
0.50mm (0.020in.) O.S 11.50 - 11.518mm (0.453 - 0.4535in.)
Cylinder block
Cylinder bore 82.00 - 82.03mm (3.2283 - 3.2295in.)
Out-of-round and taper of cylinder bore Less than 0.01mm (0.0004in.)
on

Clearance with piston 0.02 - 0.04mm (0.0008 - 0.0016in.)

(To set limits to new parts)
Piston
O.D (To set limits to new parts) 81.97 - 82.00mm (3.2271 - 3.2283in.)
Service oversize 0.25, 0.50mm (0.010, 0.020in.) oversize
Piston ring
Side clearance
No.1 0.04 - 0.08mm (0.0015 - 0.0031 in.) 0.1mm (0.004in.)
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No.2 0.03 - 0.07mm (0.0012 - 0.0027in.)

End gap
No.1 0.23 - 0.38mm (0.0090 - 0.0149in.) 1mm (0.039in.)
No.2 0.45 - 0.60mm (0.0177 - 0.0236in.) 1mm (0.039in.)
Oil ring side rail 0.20 - 0.60mm (0.0078 - 0.0236in.) 1mm (0.039in.)
Service oversize 0.25, 0.50mm
(0.010, 0.020in.) oversize
Connecting rod
Bend 0.05mm (0.0020in.) or less
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Twist 0.1mm (0.004in.) or less 0.4mm (0.0157in.)

Connecting rod big end to crankshaft 0.100 - 0.250mm (0.0039 - 0.010in.)
side clearance
Connecting rod bearing
Oil clearance (To seat limits to
0.024 - 0.042mm (0.0009 - 0.0016in.)
new parts)
0.25mm (0.01 in.)
Undersize
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E M -4 ENGINE (G4GC - GSL 2.0)

Description Specifications Limit

Camshaft
Cam height
Intake 44.618mm (1.7566in.) 44.518mm (1.7527in.)
Exhaust 44.518mm (1.7527in.) 44.418mm (1.7487in.)
Jourmal O.D. 28mm (1.1023in.)
Bearing oil clearance 0.02 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.1mm (0.0039in.)
End play 0.1 ~ 0.2mm (0.004 ~ 0.008in.)
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Crankshaft
Pin O.D. 45mm (1.77in.)
Journal O.D. 57mm (2.244in.)
Bend 0.03mm (0.0012in.) or less
Out-of-round, taper of journal and pin 0.005mm (0.0002in.) or less 0.030mm (0.0012in.)
End play 0.06 ~ 0.260mm (0.0023 ~ 0.010in.)
Undersize rework dimension of pin
0.25mm (0.010in.) 44.725 ~ 44.740mm (1.7608 ~ 1.7614in.)
Undersize rework dimension of journal
0.25mm (0.010in.) 56.727 ~ 56.742mm (2.2333 ~ 2.2339in.)
wt
Crankshaft bearing
Oil clearance 0.028 ~ 0.046mm (0.0011 ~ 0.0018in.)
Flywheel
Runout 0.1mm (0.0039in.) 0.13mm (0.0051 in.)
Cooling method Water-cooled, pressurized. Forced
circulation with electrical fan
on

Coolant
Quantity 6 liter (6.3U.S qts, 5.2lmp. qts)
Radiator
Type Pressurized corrugated fin type
Radiator cap
Main valve opening pressure 83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kg/cm2)
Vacuum valve opening pressure -7kpa (-100psi, -0.07kg/cm2) or less
Thermostat
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Type Wax pellet type with jiggle valve

Valve opening temperature 82°C (177°F)
Full-opening temperature 95°C (201 °F)
Coolant pump Centrifugal type impeller
Drive belt
Type V-ribbed belt
Engine coolant temperature sensor
Type Heat-sensitive thermistor type
Resistance 2.31 ~ 2.59KQ at 20°C (68°F)
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Oil pump
Clearance between outer circumference 0.120 ~ 0.185mm (0.0049 ~ 0.0073in.)
and front case.
Front case tip clearance 0.025 ~ 0.069mm (0.0009 ~ 0.0027in.)
Side clearance
Inner gear 0.04 ~ 0.085mm (0.0016 ~ 0.0033in.)
Outer gear 0.04 ~ 0.09mm (0.0016 ~ 0.0035in.)
Engine oil pressure at 1500 RPM 245KPa (2.5kg/cm2, 35.5psi)
[Oil temperature is 90 to 110°C
(194 to 230°F)j
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GENERAL EM -5

Description Specifications Limit

Relief spring
Free height 43.8mm (1.725in.)
Load 3.7±0.4kg at 40.1mm (3.15±0.88lb/1.578in.)
Air cleaner
Type Dry type
Element Unwoven doth type
Exhaust pipe
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Muffler Expansion resonance type
Suspension system Rubber hangers

SERVICE STANDRDS

Standard value
Antifreeze Maxture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50%
wt
on
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EM -6 ENGINE (G4GC - GSL 2.0)

TIGHTENING TORQUE

Item Nm [Link] [Link]

Cylinder Block
Front engine support bracket bolt and nut 35 ~ 50 350 - 500 25 - 37
Front roll stopper bracket bolt 70 ~ 90 700 - 900 51 - 65
Rear roll stopper bracket bolt 70 ~ 90 700 - 900 51 - 65
Rear engine support bracket bolt 40 - 50 400 - 500 30 - 37
Engine Mounting
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Right mounting insulator (large) nut 90 ~ 110 900 - 1100 65 - 80
Right mounting insulator (small) nut 45 ~ 60 450 - 600 33 - 44
Right mounting bracket to engine 50 - 65 500 - 650 36 - 48
nuts and bolts
Transmission mount insulator nut 90 ~ 110 900 - 1100 65 - 80
Transmission insulator bracket to 40 ~ 50 400 - 500 30 - 36
side member bolt
Rear roll stopper insulator nut 50 ~ 65 500 - 650 36 - 48
Rear roll stopper bracket to center 40 ~ 50 400 - 500 30 - 36
member bolts
wt
Front roll stopper insulator nut 50 - 65 500 - 650 36 - 48
Front roll stopper bracket to center 40 ~ 50 400 - 500 30 - 36
member bolts.
Main Moving
Connecting rod cap nut 50 ~ 53 500 - 530 36 - 39
Crankshaft bearing cap bolt 28-32 + (60°~64°) 280-320 + (60°~64°) 20.6-23.6 + (60°~64°)
Fly wheel M/T bolt 120 - 130 1200 - 1300 88 - 95
on

Drive plate A/T bolt 120 - 130 1200 - 1300 88 - 95

Engine cover 4 -6 40 - 60 3 -4
Heat protector 15 - 20 150 - 200 11 -1 5
Water pipe bracket bolts 12 - 15 120 - 150 9-11
Cooling system
Alternator support bolt and nut 20 - 25 200 - 250 14 - 18
Alternator lock bolt 12 - 15 120 - 150 9-11
Alternator brance mounting bolt 20 - 27 200 - 270 15 - 20
Coolant pump pulley bolts 8 -1 0 80 - 100 6 -7
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Coolant pump bolts 20 - 27 200 - 270 14 - 19

Coolant temperature sensor 20 - 40 200 - 400 15 - 30
Coolant inlet fitting nuts 15 - 20 150 - 200 11 - 14
Thermostat housing bolts and nuts 15 - 20 150 - 200 11 - 14
Lubrication system
Oil filter 12 - 16 120 - 160 9 -1 2
Oil pan bolts 10 - 12 100 - 120 7 -9
Oil pan drain plug 40 - 45 400 - 450 30 -3 3
Oil screen bolts 15 - 22 150 - 220 11 -1 6
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Oil pressure switch 13 - 15 130 - 150 9.7 -11

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GENERAL EM -7

Item Nm [Link] [Link]

Intake and Exhaust system
Air cleaner body mounting bolts 8~ 10 80 - 100 6 -7
Resonator mounting bolts 4 -6 40 - 60 3 -4
Intake manilbld to cylinder head 16 - 23 160 - 230 12 - 17
nuts and bolts
Intake manilbld stay to cylinder 18 - 25 180 - 250 13 - 18
block bolts
Throttle body to surge tank nuts 15 - 20 150 - 200 11 - 14
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Exhaust manilbld to cylinder head nuts 43 - 55 430 - 550 32 - 40
Exhaust manilbld cover to exhaust 17 - 22 170 - 220 12.5 - 16
manilbld bolts
Oxygen sensor to front muffler 50 - 60 500 - 600 36 - 43
Oxygen sensor to exhaust manilbld 50 - 60 500 - 600 36 - 43
Front exhaust pipe to exhaust 30 - 40 300 - 400 22 - 29
manifold nuts
Front exhaust pipe bracket bolts 30 - 40 300 - 400 22 - 29
Front exhaust pipe to catalytic 40 - 60 400 - 600 29 - 43
converter bolts
wt
Main muffler hanger support 10 - 15 100 - 150 7-11
bracket bolts
Cylinder head
Cylinder head bolts - M10 25 + (60°~65°) + 250 + (60°~65°) + 18 + (60°~65°) +
(60°~65°) (60°~65°) (60°~65°)
Cylinder head bolts - M12 30 + (60°~65°) + 300 + (60°~65°) + 22 + (60°~65°) +
(60°~65°) (60°~65°) (60°~65°)
on

Intake manilbld nuts 18 - 25 180 - 250 13 - 18

Exhaust manifold nuts 43 - 55 430 - 550 32 - 41
Cylinder head cover bolts 8-10 80 - 100 6-7
Camshaft bearing cap bolts 14 - 15 140 - 150 10-11
Oil control valve bolt 10 - 12 100 - 120 7.3 - 8.8
OCV Filter 41 - 51 410 - 510 30 - 37.6
C W T unit to exhaust camshaft bolt 66 - 78 660 - 780 48.7- 57.5
Rear plate bolts 8-10 80 - 100 6-7
Timing Belt
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Crankshaft pulley bolt 160 - 170 1600 - 1700 120 - 125

Camshaft sprocket bolt 100 - 120 1000 - 1200 74 - 89
Timing belt tensioner bolts 43 - 550 430 - 550 31 - 40
Timing belt cover bolts 8-10 80 - 100 6 -7
Front case bolts 20 - 27 200 - 270 14 - 20
Timing belt idler bolt 43 - 55 430 - 550 31 - 40

M/T : Manual Transmission

A /T : Automatic Transmission
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EM -8 ENGINE (G4GC - GSL 2.0)

COMPRESSION d. Repeat steps (a) through (c) for each cylinder.

y wore (U] wore

If the there is lack o f power, excessive oil consump­ This measurement must be done in as short a time as
tion or poor fuel economy, measure the compression possible.
pressure.
Compression pressure :
1. Warm up and stop engine. 1,420kPa (14.5kgf/cm*2*5
, 206psi)
6
Allow the engine to warm up to normal operating tem­ Minimum pressure :
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perature. 1,270kPa (13kgf/cm2, 184psi)
Difference between each cylinder:
2. Remove ignition coils. (See EE group - ignition) 100kPa (1.0kgf/cm2, 15psi) or less
3. Remove spark plugs.
Usinga 16mm plug wrench, remove the 4 spark plugs. e. If the cylinder compression in 1 or more cylinders
is low, pour a small amount of engine oil into the
4. Check cylinder compression pressure. cylinder through the spark plug hole and repeat
a. Insert a compression gauge into the spark plug steps (a) through (c) for cylinders with low com­
hole. pression.
• If adding oil helps the compression, it is likely
wt
that the piston rings and/or cylinder bore are
worn or damaged.
• If pressure stays low, a valve may be stick­
ing or seating is improper, or there may be
leakage past the gasket.

5. Reinstall spark plugs.

on

6. Install ignition coils. (See EE group - ignition)

TIMING BELT TENSION ADJUSTMENT

1. Remove the engine cover(A).

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ECKD001X

b. Fully open the throttle.

c. While cranking the engine, measure the com­
pression pressure.

y wore
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Always use a fully charged battery to obtain engine

speed o f 250 rpm or more.

ECHE101A

2. Remove RH front wheel.

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GENERAL EM -9
3. Remove the 4bolts(B) and timing belt upper cover(A). 5. Temperarily loosen tensioner pulley(A) by center bolt.
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wt

ECKD105A ECKD109A

4. Turn the crankshaft pulley, and align its groove with 6. Timing belt tension adjusting.
timing mark "T" of the timing belt cover.
1) Rotate crankshaft in regular direction (clock wise
view from front) through angle equivalent to two
teeth (18°) of camshaft sprocket(A).
on
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ECKD116B

ECKD106A
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EM -10 ENGINE (G4GC - GSL 2.0)

2) Give tension to timing belt rotating tensioner in 7. Turn the crankshaft two turns in the operating direc­
arrow direction tool and set timing belt not to give tion (clockwise) and realign crankshaft sprocket and
slack to tension side. camshaft sprocket timing mark.

8. Install the timing belt upper cover(A) with 4bolts(B).

Tightening torque
8 ~ 10Nm (80 ~ [Link], 6 ~ [Link])
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wt

3) Tightening tensioner bolt.

Tightening torque
on

Tensioner bolt
ECKD105A
43 - 55Nm (430 - [Link], 32 ~ [Link])4
9. Install RH front wheel.
4) Recheck the belt tension, When the tension side
of timing belt is pushed horizontally with a mod­ 10. Install engine cover(A).
erate force [approx. 2kg (20N, 5lb)], the timing
belt cog end sags in approx. 4 - 6mm (0.16 -
0.24in.)
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ECHE101A

ECKD109E
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GENERAL EM -11
VALVE CLEARANCE INSPECTION AND c. Disconnect the accelerater cable(A) from the
ADJUSTMENT cylinder head cover.

MLA (MECHANICAL LASH ADJUSTER)

[ U note
]

Inspect and adjust the valve clearance when the en­

gine is cold (Engine coolant temperature: 20°C) and
cylinder head is installed on the cylinder block.
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1. Remove the engine cover. (See page EM - 8)

2. Remove the upper timing belt cover.

(See page EM - 9)
a. Loosen the upper timing cover bolts and then re­
move the cover.

3. Remove the cylinder head cover.

a. Disconnect the spark plug cables and do not pull
on the spark plug by force.
wt

lU j W O T E ECKD111A
Pulling on orbending the cables may damage the con-
nductor inside. d. Loosen the cylinder head cover bolts(B) and then
remove the cover(A) and gasket.
b. Disconnect the P.C.V hose(A) and the breather
hose(B) from the cylinder head cover.
on
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ADIE002A
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ECKD112A
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EM -12 ENGINE (G4GC - GSL 2.0)

4. Set No.1 cylinder to TDC/compression. 5. Inspect the valve clearance.
a. Turn the crankshaft pulley and align its groove a. Check only the valve indicated as shown. [No. 1
with the timing mark "T" of the lower timing belt cylinder: TDC/Compression] measure the valve
cover. clearance.
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wt

EDKD888B

■ Using a thickness gauge, measure the clear­

ance between the tappet shim and the base cir­
on

cle of camshaft.
ECKD106A
• Record the out-of-specification valve clearance
measurements. They will be used later to deter­
b. Check that the hole of the camshaft timing pul-
ley(A) is aligned with the timing mark of the bear­ mine the required replaement adjusing shim.
ing cap.
Valve clearance
If not, turn the crankshaft one revolution (360°)
Specification
Engine coolant temperature : 20°C [68°F]
Intake : 0.20mm (0.0079in.)
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Exhaust : 0.28mm (0.0110in.)

Limit
Intake : 0.12 ~ 0.28mm (0.0047 - 0.0110in.)
Exhaust: 0.20 - 0.38mm (0.0079 - 0.0150in.)

b. Turn the crankshaft pulley one revolution (360°)

and align the groove with timing mark "T" of the
lower timing belt cover.
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ECKD11OB
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GENERAL EM -13
c. Check only valves indicated as shown. [NO. 4 c. Remove the adjusting shim with a small screw
cylinder: TDC/compressionj. Measure the valve driver(A) and magnet(B).
clearance. (See procedure in step (6))
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EDKB889C
EDKD888C
d. Measure the thickness of the removed shim using
6. Adjust the intake and exhaust valve clearance. a micrometer.
a. Turn the crankshaft so that the cam lobe of the
camshaft on the adjusting valve is upward.
on

b. Using the SST(09220-2D000), press down the

valve lifter and place the stopper between the
camshaft and valve lifter and remove the special
tool.

09220-2D000
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EDKB889D
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EDKB889B
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EM -14 ENGINE (G4GC - GSL 2.0)

e. Calculate the thickness of a new shim so that
the valve clearance comes within the speclflcifled
value.

Valve clearance (Engine coolant tem­

perature : 20°C)
T : Thickness of removed shim
A : Measured valve clearance
N : Thickness of new shim
Intake : N = T + [A - 0.20mm(0.0079in.)]
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Exhaust: N = T + [A-0.28mm (0.0110in.)]

f. Select a new shim with a thickness as close as

possible to the caculated value. [Refer to the Ad­
justing shim selection chart]

( tpj note
)

Shims are available in 20size increments o f 0.04mm

(0.0016in.) from 2.00mm (0.079in.) to 2.76mm
wt
(0.1087in.)

g. Place a new adjusting shim on the valve lifter.

h. Using the SST(09220-2D000), press down the
valve lifter and remove the stopper.
i. Recheck the valve clearance.

Valve clearance (Engine coolant tem­

on

perature : 20°C)
[Specification]
Intake : 0.20mm (0.0079in.)
Exhaust : 0.28mm (0.0110in.)
[Limit] (After adjusting valve clearance)
Intake : 0.17 - 0.23mm (0.0067 - 0.0091 in.)
Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)
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GENERAL
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Adjusting Shim Selection Chart (Intake)

I g
Measured cleafanes' £
mm (in.)
0.000 - (0.0000 - 0.0008)
0.021 - (0.0008 - 0.0016)

wt
0.041 - (0.0016 - 0.0024)
0.061 - (0.0024 - 0.0031)
0.081 - (0.0032 - 0.0039)
0.101 - (0.0040 - 0.0047)
0 .1 2 0 - (0.0047 - 0.0110)
0.281 - (0.0111 -0.0118)
0.301 - (0.0119-0.0126)
0.321 - (0.0126 - 0.0134)

on
0.341 - (0.0134 -0.0142)
0.361 - (0.0142 - 0.0150)
0.381 -
0.401 - (0.0158 - 0.0165)
0.421 -
0.441 -
0.461 -
0.481 -
0.501 - (0.0197 - 0.0205)

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0.521 - New shim thickness mm(in.)
0.541 - (0.0213 - 0.0220)
Shim Shim
0.561 - Thickness Thickness
No. No.
0.581 - (0.0229 - 0.0236)
1 2.00 (0.0787) 11 2.40 (0.0945)
0.601 -
0.621 - (0.0244 - 0.0252)
2 2.04 (0.0803) 12 2.44 (0.0961)
0.641 - (0.0252 - 0.0260)
0.661 - (0.0260 - 0.0268) 3 2.08 (0.0819) 13 2.48 (0.0976)
0.681 - (0.0268 - 0.0276)
0.701 - 4 2.12 (0.0835) 14 2.52 (0.0992)

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0.721 - (0.0284 - 0.0291)
5 2.16 (0.0850) 15 2.56 (0.1008)
0.741 - (0.0292 - 0.0299)
0.761 - (0.0300 - 0.0307)
6 2.20 (0.0866) 16 2.60 (0.1024)
0.781 - (0.0307 - 0.0315)
0.801 - 7 2.24 (0.0882) 17 2.64 (0.1039)
0.821 - (0.0323 - 0.0331)
0.841 - 8 2.28 (0.0898) 18 2.68 (0.1055)
0.861 - (0.0339 - 0.0346)
9 2.32 (0.0913) 19 2.72 (0.1071)
0.881 - (0.0347 - 0.0354)
0.901 -
10 2.36 (0.0929) 20 2.76 (0.1087)
0.921 - (0.0363 - 0.0370)
Intake valve clearance (C old):
0.941 -
0.20 mm (Spec.) 0.12 ~ 0.28mm (Limit) HINT : New shims have the thickness in miliime-
0.961 - (0.0378 - 0.0386) ters imprinted on the face
Example : The 2.24 mm shim is installed, and the
measured clearance is 0.450 mm. Replace the
2.24mm shim with a new No. 13 shim.

EM -15
EDKB888D
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EM -16____________________________________________________ ENGINE (G4GC - GSL 2.0)

Adjusting Shim Selection Chart (Exhaust)

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M easured c le a ra n c e
n (in.)
(0.0000-0.0008)
(0.0008-0.0016)

(0.0040-0.0047)

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(0.0048-0.0055)

(0.0071-0.0078)
(0.0079-0.0142)

(0.0150-0.0157)
(0.0158-0.0165)

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(0.0174-0.0181)

(0.0197-0.0205)
(0.0205-0.0213)

(0.0221-0.0228)
(0.0229-0.0236)
New shim thickness mm(in.)

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Shim Shim
Thickness Thickness
No. No.
(0.0260-0.0268)
1 2.00 (0.0787) 11 2.40 (0.0945)
(0.0268-0.0276)
(0.0276-0.0283) 2 2.04 (0.0803) 12 2.44 (0.0961)

3 2.08 (0.0819) 13 2.48 (0.0976)

(0.0300-0.0307)
4 2.12 (0.0835) 14 2.52 (0.0992)
(0.0307-0.0315)

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5 2.16 (0.0850) 15 2.56 (0.1008)
(0.0323-0.0331)
(0.0331-0.0339) 6 2.20 (0.0866) 16 2.60 (0.1024)
(0.0339-0.0346)
7 2.24 (0.0882) 17 2.64 (0.1039)

8 2.28 (0.0898) 18 2.68 (0.1055)

(0.0370-0.0378)
9 2.32 (0.0913) 19 2.72 (0.1071)
(0.0378-0.0386)
Intake valve clearance (C old):
10 2.36 (0.0929) 20 2.76 (0.1087)
0.28 mm (Spec.), 0.20 ~ 0.38 mm (Limit)
(0.0394-0.0402)
Example : The 2.24 mm shim is installed, and the H IN T : New shim s have the th ickn ess in m ilim e-
(0.0402-0.0409)
measured clearance is 0.450 mm. Replace the te rs im p rin te d on th e fa ce
2.24 mm shim with a new No. 11 shim.
EDKB888E
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GENERAL EM -17
TROUBLESHOOTING E6D36B0F

Symption Suspect area Remedy (See page)

Engine misfire with Loose or improperly installed engine flywheel. Repair or replace the flywheel as required.
abnormal internal
Worn piston rings Inspect the cylinder for a loss of compression.
lower engine noises.
(Oil cousnmption may or may not cause Repair or replace as required.
the engine to misfire.)
Worn crankshaft thrust bearings Replace the crankshaft and bearings
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as required
Engine misfire with Stuck valves. Repair or replace as required
abnormal valve (Carbon buidup on the valve stem)
train noise.
Excessive worn or mis-aligned timing chain Replace the timing chain and sprocket
as required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with • Faulty cylinder head gasket and/or • Inspect the cylinder head and engine
coolant consumption cranking or other damage to the cylinder block for damage to the coolant passages
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head and engine block cooling system. and/or a faulty head gasket.
• Coolant consumption may or may not • Repair or replace as required.
cause the engine to overheat.
Engine misfire Worn valves, guides and/or valve Repair or replace as required.
with excessive oil stem oil seals.
consumption
Worn piston rings. • Inspect the cylinder for a loss of
(Oil consumption may or may not cause compression.
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the engine to misfire) • Repair or replace as required.

Engine noise on Incorrect oil viscosity • Drain the oil.
start-up, but only • Install the correct viscosity oil.
lasting a few seconds.
Worn crankshaft thrust bearing. • Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Upper engine noise, Low oil pressure Repair or repalce as required.
regardless of engine
Broken valve spring. Replace the valve spring.
speed.
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Worn or dirty valve lifters. Replace the valve lifters.

Stetched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner
as required.
Worn camshaft lobes. • Inspect the camshaft lobes.
• Replace the timing camshaft and
valve lifters as required.
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Worn valve guides or valve stems. Inspect the valves and valve guides,
then repair as required.
Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides,
valve seat may cause the valve to stay open. then repair as required.
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EM -18 ENGINE (G4GC - GSL 2.0)

Symption Suspect area Remedy (See page)

Lower engine noise, Low oil pressure. Repair or required.
regardless of engine
Loose or damaged flywheel. Repair or replace the flywheel.
speed
Damaged oil pan, contacting the oil • Inspect the oil pan.
pump screen. • Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged or restircted. • Inspect the oil pump screen.
• Repair or replace as required.
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Excessive piston-to-cylinder bore clearance. * Inspect the piston, piston pin and
cylinder bore.
• Repair as required.
Excessive piston pin-to-piston clearance • Inspect the piston, piston pin and
the connecting rod.
• Repair or replace as required.
Excessive connecting rod bearing clearance Inspect the following components and
repair as required.
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• The connecting rod bearings.
• The connecting rods.
• The crankshaft pin journals.
Excessive crankshaft bearing clearance Inspect the following components, and
repair as required.
* The crankshaft bearings.
• The crankshaft main journals.
on

Incorrect piston, piston pin and connecting • Verify the piston pins and connecting
rod installation rods are installed correctly.
• Repair as required.
Engine noise under Low oil pressure Repair or replace as required.
load
Excessive connecting rod bearing clearance Inspect the following components and
repair as required :
• The connecting rod bearings.
• The connecting rods.
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• The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and
repair as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
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GENERAL EM -19

Symption Suspect area Remedy (See page)

Engine will not Hydraulically locked cylinder 1. Remove spark plugs and check for fluid.
crank-crankshaft • Coolant/antifreeze in cylinder. 2. Inspect lor broken head gasket.
will not rotate • Oil in cylinder. 3. Inspect for cracked engine block
• Fuel in cylinder or cylinder head.
4. Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain 1. Inspect timing chain and gears.
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and/or timing chain gears. 2. Repair as required.
Material in cylinder 1. Inspect cylinder for damaged
• Broken valve components and/or foreign materials.
• Piston material 2. Repair or replace as required.
• Foreign material
Seized crankshaft or connecting rod bearings. 1. Inspect crankshaft and connecting
rod bearing.
2. Repair as required.
Bent or broken connecting rod. 1. Inspect connecing rods.
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2. Repair as required.
Broken crankshaft 1. Inspect crankshaft.
2. Repair as required.
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E M -20 ENGINE (G4GC - GSL 2.0)

SPECIAL TOOLS EC4DCBF2

Tool (Number and name) Illustration Use

Crankshaft front oil seal installer Installation of the front oil seal
(09214-33000)

CD
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EDKA010A

Valve clearance adjust tool set Removal and installation of the tappet shim
(09220-2D000) P li e r

S to p p e r
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EDKB001A

Camshaft oil seal installer Installation of the camshaft oil seal

(09221-21000)
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EDDA005B

Valve guide installer Remove and installation of the valve guide

(09221-3F100 A/B)
l _______________________
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ECKA010B

Valve stem oil seal installer Installation of the valve stem oil seal
(09222-22001)
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ECKA010A
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GENERAL EM -21

Tool (Number and name) Illustration Use

Valve spring compressor Removal and installation of the intake
& adaptor or exhaust valve
(09222-28000, 09222-28100)
"H
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EDDA005C

Crankshaft rear oil seal installer 1. Installation of the engine rear oil seal
(09231-21000) 2. Installation of the crankshaft rear oil seal

EDDA005F
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E M -22____________________________________________________ENGINE (G4GC - GSL 2.0)

TIMING SYSTEM
COMPONENT
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UCOG001A
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TIMING SYSTEM EM -23

REMOVAL EA165A14 2) Remove the bolt(B), 3nuts(C, D) and engine
mount bracket(A).
Engine removal is not required for this procedure.

1. Remove the engine cover. (See page EM - 8)

2. Remove RH front wheel.

3. Remove 2bolts(B) and RH side cover(A).

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ECHE105A

3) Remove the bolt(B) and stay plate(A).

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ECKD102A

[ U j NOTE
Place wooden block between the jack and engine oil
pan.
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E M -24 ENGINE (G4GC - GSL 2.0)

5. Temporarily loosen the water pump pulley bolts. 12. Remove the crankshaft pulley bolt(B) and crankshaft
pulley(A).

A
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ECKD104B
ECKD107A

6. Remove alternator belt. (See EE group - alternator)

13. Remove the crankshaft flange(A).
7. Remove air compressor belt. (See HA group - air
compressor)
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8. Remove power steering belt. (See ST group - power

steering pump)

9. Remove 4bolts and water pump pulley.

10. Remove the 4bolts and timing belt upper cover. (See
page EM - 9)

11. Turn the crankshaft pulley, and align its groove with
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timing mark "T" of the timing belt cover. (See page

EM - 9)

ECKD108A
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TIMING SYSTEM EM -25

14. Remove the 5bolts(B) and timing belt lower cover(A).
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ECKD109B

ECKD108B
[X o Jj NOTE
15. Remove the timing belt tensioner(A) and timing If the timing belt is reused, make an arrow indicating
belt(B). the turning direction to make sure that the belt is rein­
stalled in the same direction as before.

16. Remove the bolt(B) and timing belt idler(A).

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ECKD109A
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ECKD109C
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E M -26 ENGINE (G4GC - GSL 2.0)

17. Remove the crankshaft sprocket(A). 19. Remove camshaft sprocket.

1) Hold the hexagonal head wrench(A) portion of

the camshaft with a wrench(B), and remove the
bolt and camshaft sprocket(C).
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ECKD110A

18. Remove the cylinder head cover.

1) Remove the spark plug cable. ECKD114A

2) Remove the accelerator cable from the cylinder

CAUTION
on

head cover. (See page EM -1 1 )

Be careful not to damage the cylinder head and
3) Remove the PCV(Positive Crankcase ventilation) valve lifter with the wrench.
hose and breather hose. (See page EM -1 1 ) 4

4) Remove the 12bolts and cylinder head cover.

(See page EM -1 1 )
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TIMING SYSTEM EM -27

INSPECTION E1D945CE INSTALLATION E708FC0E

SPOCKETS, TENSIONER, IDLER 1. Install the camshaft sprocket and tighten the bolt to
the specified torque.
1. Check the camshaft sprocket, crankshaft sprocket,
tensioner pulley, and idler pulley for abnormal wear, 1) Temporarily install the camshaft sprocket bolt.
cracks, or damage. Replace as necessary.
2) Hold the hexagonal head wrench(A) portion of
2. Inspect the tensioner pulley and the idler pulley for the camshaft with a wrench(B), and tighten the
easy and smooth rotation and check for play or noise. camshaft sprocket(C) bolt.
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Replace as necessary.
Tightening torque
Camshaft sprocket bolt
100 - 120Nm (1000 - [Link], 74 ~ [Link])
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bearing.
ECKD114A
TIMING BELT
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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 ad­

justed, check the belt carefully. If any of the following
flaws are evident, replace the belt.

f U ] NOTE
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• Do not bend, twist or turn the timing belt inside

out.
• Do not allow the timing belt to come into contact
with oil, water and steam.
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E M -28 ENGINE (G4GC - GSL 2.0)

2. Install cylinder head cover. 3) Install the accelerator cable(A) from the cylinder
head cover.
1) Install cylinder head cover(A) and 12bolts(B).
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ADIE003A
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2) Install the PCV hose(A) and breather hose(B).

ECKD111A

4) Install the spark plug cable.

3. Install the crankshaft sprocket(A).

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ECKD112A
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ECKD110A
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TIMING SYSTEM EM -29

4. Align the timing marks of the camshaft sprocket(A) 5. Install the idler pulley(A) and tighten the bolt(B) to the
and crankshaft sprocket(B) with the No.1 piston specified torque.
placed at top dead center and its compression
stroke. Tightening torque
Idler pulley bolt
43 ~ 55Nm (430 ~ 550kgf.m, 32 - [Link])
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ECKD110B

ECKD109C
on

6. Temporarily install the timing belt tensioner(A) with

plain washer(B).
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ECKD116A
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E M -30 ENGINE (G4GC - GSL 2.0)

7. Install the timing belt so as not to give excessive slack 2) Give tension to timing belt by rotating tensioner
at the center of the belt. Install the timing belt with the in direction of the arrow with tool and set timing
following procedure. belt not to give slack to tension side.
Crankshaft sprocket (A) —• Idler pulley (B) —•
Camshaft sprocket (C) >timing belt tensioner (D).
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ACGE003A

3) Tightening tensioner bolt.

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Tightening torque
ECKD109D
Tensioner bolt
43 - 55Nm (430 - [Link], 32 - [Link])4
8. Temporarily fasten tensioner pulley by center bolt to
add force at belt.

9. Timing belt tension adjusting 4) Recheck the belt tension. When the tension side
of timing belt is pushed horizontally with a mod­
1) Rotate crankshaft In regular direction (clock wise erate force [approx. 2kg (20N, 5lb)], the timing
view from front) through angle equivalant to two belt cog end sags in approx. 4 - 6mm (0.16 -
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teeth (18°) of camshaft sprocket(A). 0.24in.)

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ECKD116B ECKD109E
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TIMING SYSTEM EM -31

10. Turn the crankshaft two turns in the operating direc­ 12. Install the flange and crankshaft pulley(A).
tion (clockwise) and realign crankshaft sprocket and Make sure that crankshaft sprocket pin fits the small
camshaft sprocket timing mark. hole in the pulley.

11. Install the timing belt lower cover(A) with 5 bolts(B).*8 Tightening torque
Crankshaft pulley bolt
Tightening torque 160 ~ 170Nm (1600 ~ [Link], 120 ~ [Link])
Timing belt cover bolt
8 - 10Nm (80 ~[Link], 6 ~ [Link])
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ECKD107A

ECKD108B 13. Install the timing belt upper cover with 4bolts. (See
page EM -1 0 )

14. Install the coolant pump pulley with 4bolts.

15. Install power steering belt. (See ST group - power

steering pump)
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16. Install air compressor belt. (See HA group - air com-

perssor)

17. Install alternator belt. (See EE group-alternator)

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E M -32 ENGINE (G4GC - GSL 2.0)

18. Install the engine mount bracket. 19. Install RH side cover(A) with 2bolts(B).

1) Install the stay plate(A) with bolt(B).

Tightening torque
Stay plate bolt
43 - 55Nm (430 - [Link] 32 - [Link])
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ECKD104A

2) Install engine mount bracket(A) with 3nuts and

bolt.

Tightening torque
Bolt(B), Nuts(C)
50 ~ 60Nm (500 ~ [Link], 37 - [Link])
N ut(D ): 60 ~ 80Nm (600 ~ 800kgf.m 44 ~ [Link])
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ECHE105A
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CYLINDER HEAD ASSEMBLY E M -33

CYLINDER HEAD
ASSEMBLY
COMPONENTS EAFF5C56
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Cylinder head cover

8 - 1 0 (8 0 - 1 0 0 ,6 -7 .4 )

Gasket
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_ ,. J u J t „ /M 1 0 : 25(250,18) + (60 -6 5 ) + (60 -6 5 )

Cylinder head bolt< M 1 2 . 30(300 22) + (60 _65 } + (6() _65 }

Cylinder head
on

Cylinder head gasket

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✓ Cylinder block
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TORQUE : Nm ([Link], [Link])

ECKD002A
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E M -34 ENGINE (G4GC - GSL 2.0)

,M LA

— ^ R e t a i n e r lock-<~
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Retainer W
Auto Tensioner
Valve spring-
CVVT only
Stem seal^*g,
Spring seat— > ©
Timing chain

v — i
Chain sprocket^- Camshaft bearing cap
wt
Intake camshaft CVVT assembly

O CV filter C W T only
4 1 -5 1
(4 1 0 -5 1 0 , 3 0 -3 7 .6 )
Washer
on

O CV (Oil Control Valve)

100 -1 20 '
(1 0 0 0 -1 2 0 0 ,7 4 -8 9 )/ k

Camshaft sprocket
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TORQUE : Nm ([Link], [Link])

ECKD003A
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CYLINDER HEAD ASSEMBLY E M -35

REMOVAL EDB1594A 4. Remove the intake air hose and air cleaner assembly.

Engine removal is not required for this procedure. 1) Disconnect the AFS connector.

2) Disconnect the breather hose from air cleaner

A CAUTION hose.
• Use fender covers to avoid damaging painted
surfaces. 3) Remove the intake air hose and air cleaner as­
• To avoid damaging the cylinder head, wait un­ sembly.
til the engine coolant temperature drops be­
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5. Remove the upper radiator hose(A) and lower radiator
low normal temperature before removing it.
hose(B).
• When handling a metal gasket, take care not
to fold the gasket or damage the contact sur­
face o f the gasket.
• To avoid damage, unplug the wiring connec­
tors carefully while holding the connector
portion.

(Qj) NOTE
wt
• Mark all wiring and hoses to avoid misconnec-
tion.
• Inspect the timing belt before removing the cylin­
der head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EM - 9)

1. Disconnect the negative terminal from the battery.

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ECKD201A

6. Remove the heater hoses(A).3

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2. Remove the engine cover. (See page EM - 8)

3. Drain the engine coolant.

Remove the radiator cap to speed draining.
ECKD202A
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E M -36 ENGINE (G4GC - GSL 2.0)

7. Remove the engine wire harness connectors and wire 7) CMP(Camshaft Position Sensor) connector(A).
harness clamps from the cylinder head and the intake
manifold. 8) Four fuel injector connectors(B).

1) OCV(Oil control Valve) connector(A). 9) Knock sensor connector(C).

2) Oil temperature sensor connector(B). 10) Disconnect ground cable(D) from the intake man­
ifold.
3) ECT(Engine Coolant Temperature) sensor con­
nector^).
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4) Ignition coil connector(D).
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ECKD205A

11) Front heated oxygen sensor connector(A).

ECKD203A

5) TPS(Throttle Position Sensor) connector(A).

6) ISA(ldle Speed Actuator) connector(B).

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ECKD206A

EDQF197A
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CYLINDER HEAD ASSEMBLY E M -37

12) PCSV(Purge Control Solenoid Valve) connec- 9. Remove the PCSV hose(A).
tor(A).
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ECKD209A
ECKD207A
10. Remove the brake booster vacuum hose(A).
8. Remove the fuel inlet hose(A) from delivery pipe.
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11. Remove the accelerator cable by loosening the lock­

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nut, then slip the cable end out of the throttle linkage.

12. Remove the power steering pump. (See ST group -

power steering pump)
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E M -38 ENGINE (G4GC - GSL 2.0)

13. Remove the power steering pump bracket bolts(A). 21. Remove the timing chain auto tensioner(A).
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ECKD211A

14. Remove the spark plug cable. (See EE group - igni­ ECKD212A

tion)
22. Remove the camshaft bearing caps(A) and
15. Remove the PCV hose. (See page EM -11) camshafts(B).
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16. Remove the cylinder head cover. (See page EM -11 )

17. Remove the timing belt. (See page EM - 23)

18. Remove the exhaust manifold. (See page EM -102)

19. Remove the intake manifold. (See page EM -101)

20. Remove the camshaft sprocket. (See page EM - 26)

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ECKD213A
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CYLINDER HEAD ASSEMBLY E M -39

23. Remove the OCV(oil control valve)(A). 25. Remove the water hose(B) from the water pipe(A).
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ECKD214A ACGE009A

24. Remove the OCV(oil control valve) filter(A). 26. Remove the cylinder head bolts, then remove the
cylinder head.

1) Using 8mm and 10mm hexagon wrench, uni­

formly loosen and remove the 10 cylinder head
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bolts, in several passes, in the sequence shown.

Remove the 10 cylinder head bolts and plate
washers.
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ECKD215A
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ECKD216A

/?\ CAUTION
Head warpage or cracking could result from re­
moving bolts in an Incorrect order.
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E M -40 ENGINE (G4GC - GSL 2.0)

2) Lift the cylinder head from the dowels on the DISASSEMBLY E437D6BD

cylinder block and place the cylinder head on

wooden blocks on a bench.
(ij) no te

Identify MLA(Mechanical Lash Adjuster), valves,

CAUTION
valve springs as they are removed so that each Item
Be careful not to damage the contact surfaces o f can be reinstalled in its original position.
the cylinder head and cylinder block.
1. Remove MLAs(A).
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ECKD217A

2. Remove valves.

1) Using SST(09222-28000, 09222-28100), com­

press the valve spring and remove retainer lock.
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ECKD218A

2) Remove the spring retainer.

3) Remove the valve spring.

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CYLINDER HEAD ASSEMBLY E M -41

4) Remove the valve. INSPECTION EE22AEEF

5) Using needle-nose pliers, remove the oil seal. CYLINDER HEAD

6) Using a magnetic finger, remove the spring seat. 1. Inspect for flatness.
Using a precision straight edge and feeler gauge,
measure the surface the contacting the cylinder block
and the manifolds for warpage.

Flatness of cylinder head gasket surface

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Standard : Less than 0.03mm(0.0012in.)
Limit : 0.05mm ( 0.0020in.)
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ECKD001H

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust
ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
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E M -42 ENGINE (G4GC - GSL 2.0)

VALVE AND VALVE SPRING 3) Subtract the valve stem diameter measurement
from the valve guide inside diameter measure­
1. Inspect valve stems and valve guides. ment.
Valve stem-to-guide clearance
1) Using a caliper gauge, measure the inside diam­
eter or the valve guide. [Standard]
Intake : 0.02 - 0.05mm (0.0008 ~ 0.0020in.)
Exhaust: 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)
[Lim it]
Intake : 0.1mm (0.0040in.)
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Exhaust : 0.13mm (0.0051 in.)

If the clearance is greater than maximum, replace

the valve and valve guide.

2. Inspect valves.

1) Check the valve is ground to the correct valve

face angle.
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2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.

3) Check the valve head margin thickness.

If the margin thickness is less than minimum, re­
place the valve.
ECKD219A

Margin
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2) Using a micrometer, measure the diameter of the

[Standard]
valve stem.
Intake : 1.15mm(0.0453in.)
Exhaust : 1.35mm(0.0531in.)
[Limit]
Intake : 0.8mm(0.0315in.)
Exhaust : 1.0mm(0.040in.)
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ECKD220A

ECKD221A
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CYLINDER HEAD ASSEMBLY E M -43

4) Check the surface of the valve stem tip for wear. CAMSHAFT
If the valve stem tip is worn, replace the valve.
1. Inspect cam lobes.
3. Inspect valve seats Using a micrometer, measure the cam lobe height.
Check the valve seat for evidence of overheating and
improper contact with the valve face. Cam height
Replace the seat if necessary. [Standard value]
Before reconditioning the seat, check the valve guide Intake : 44.618mm (1.7566in.)
for wear. If the valve guide is worn, replace it, then E xhaust: 44.518mm (1.7527in.)
recondition the seat. Recondition the valve seat with [Limit]
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a valve seat grinder or cutter. The valve seat contact Intake : 44.518mm (1.7527in.)
width should be within specifications and centered on E xhaust: 44.418mm (1.7487in.)
the valve face.

4. Inspect valve springs.

1) Using a steel square, measure the out-of-square

of the valve spring.

2) Using a vernier calipers, measure the free length

wt
of the valve spring.

Valve spring
[Standard]
Free h eigh t: 48.86mm (1.9236in.)
Load : 18.8kg/39 mm (41.45lb/1.535in.)
[Limit]
Free h e ig h t: -1.0mm(-0.0394in.)
on

Out-of-square : 3°

ECKD223A

If the cam lobe height is less than minimum, replace

the camshaft.
Ne

2. Inspect camshaft journal clearance.

1) Clean the bearing caps and camshaft journals.

2) Place the camshafts on the cylinder head.

t

ECKD222A

If the free length is not as specified, replace the

valve spring.
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E M -44 ENGINE (G4GC - GSL 2.0)

3) Lay a strip of plastigage across each of the If the oil clearance is greater than maximum, re­
camshaft journal. place the camshaft. If necessary, replace the
bearing caps and cylinder head as a set.

7) Completely remove the plastigage.

8) Remove the camshafts.

3. Inspect camshaft end play.

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1) Install the camshafts. (See page EM - 50)

2) Using a dial indicator, measure the end play while

moving the camshaft back and forth.

Camshaft end play

[Standard va lu e ]: 0.1 - 0.2mm(0.004 - 0.008in.)
wt

ECKD224A

4) Install the bearing caps. (See page EM - 50)

/t\ CAUTION
on

Do not turn the camshaft

5) Remove the bearing caps.

6) Measure the plastigage at its widest point.

Bearing oil clearance

[Standard value]: 0.02 - 0.061mm (0.0008 - 0.0024in.)
[Limit] : 0.1mm (0.0039in.)*3
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ECKD226A

If the end play is greater than maximum, replace

the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

3) Remove the camshafts.

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ECKD225A
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CYLINDER HEAD ASSEMBLY E M -45

C W T ASSEMBLY 4) Under the condition of (3), turn the C W T assem­
bly to the advance angle side (the arrow marked
1. Inspect C W T assembly. direction in the illustration) with your hand.
Depending on the air pressure, the C W T assem­
1) Check that the C W T assembly will not turn. bly will turn to the advance side without applying
force by hand. Also, under the condition that the
2) Apply vinyl tape to all the parts except the one
pressure can be hardly applied because of the
indicated by the arrow in the illustration.
air leakage from the port, there may be the case
that the lock pin could be hardly released.
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wt
on

EDKD270B

BCGE010A
3) Wind tape around the tip of the air gun and apply
air of approx. 100kpa(1kgf/cm2,14psi)totheport
5) Except the position where the lock pin meets at
of the camshaft.
the maximum delay angle, let the CVVT assem­
(Perform this order to release the lock pin lor the
bly turn back and forth and check the movable
maximum delay angle locking.)
range and that there is no disturbance.

[U| n o t e Standard: Movable smoothly in the range about 20°6

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When the oil splashes, wipe it o ff with a shop rag and

the likes. 6) Turn the C W T assembly with your hand and lock
it at the maximum delay angle position.
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E M -46 ENGINE (G4GC - GSL 2.0)

REPLACEMENT EDD51F66 3. Using the SST(09221-3F100A/B), press-fit the valve
guide. The valve guide must be press-fitted from the
VALVE GUIDE upper side of the cylinder head. Keep in mind that
the intake and exhaust valve guides are different in
1. Using the SST(09221-3F100A), withdraw the old length.
valve guide toward the bottom of cylinder head.
Over size Size Oversize valve guide
mm(in.) mark hole size mm(in.)
11.05 ~ 11.068
0.05 (0.002) 5
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(0.4350 ~ 0.4357)
11.25 - 11.268
0.25 (0.010) 25
(0.4429 ~ 0.4436)
11.50 - 11.518
0.50 (0.020) 50
(0.4528 - 0.4535)

Valve guide length

Intake : 46mm (1.8in.)
Exhaust : 54.5mm (2.15in.)
wt
on

ECHE600A

2. Recondition the valve guide hole so that it can match

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the newly press-fitted oversize valve guide.

09221-3F100B
t

ECHE600B

4. After the valve guide is press-fitted, insert a new valve

and check for proper stem -to-guide clearance.5

5. After the valve guide is replaced, check that the valve

is seated properly. Recondition the valve seats as
necessary.
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CYLINDER HEAD ASSEMBLY E M -47

REASSEMBLY E4AEFFED 4) Using the SST(09222-28000, 09222-28100),
compress the spring and install the retainer
(uj) NOTE locks. After installing the valves, ensure that
the retainer locks are correctly in place before
Thoroughly clean all parts to be assembled. releasing the valve spring compressor.
Before installing the parts, apply fresh engine oil to all
sliding and rotating surfaces.
Replace oil seals with new ones.

1. Install valves.
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1) Install the spring seats.

2) Using SST(09222-22001), push in a new oil seal.

| U ] NOTE
Do not reuse old valve stem seals.
Incorrect installation o f the seal could result in oil leak­
age past the valve guides.
wt

ECKD218A

5) Lightly tap the end of each valve stem two or

on

three times with the wooden handle of a hammer

to ensure proper seating of the valve and retainer
lock.
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ECKD229A

3) Install th e valve, valve spring and spring retainer.

( □ ) NOTE
Place valve springs so that the side coated with
enamel faces toward the valve spring retainer and
t

then installs the retainer.

ECKD230A
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E M -48 ENGINE (G4GC - GSL 2.0)

2. Install MLAs. INSTALLATION EB0A0CEF

Check that the MLA rotates smoothly by hand.

[y] wore
• Thoroughly clean all parts to be assembled.
• Always use a new head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take
care not to bend it.
• Rotate the crankshaft, set the No. 1 piston at TDC.
(See page EM - 9)
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1. Install the cylinder head gasket(A) on the cylinder
block.
wt

ECKD217A
on

ECKD231A

y note
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Be careful o f the installation direction.

2. Place the cylinder head carefully in order not to dam­

age the gasket with the bottom part of the end.

3. Install cylinder head bolts.

1) Apply a light coat if engine oil on the threads and

under the heads of the cylinder head bolts.
t
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CYLINDER HEAD ASSEMBLY E M -49

2) Using 8mm and 10mm hexagon wrench, install
[Qj] n o t e
and tighten the 10 cylinder head bolts and plate
washers, in several passes, in the sequence Always use a new OCV filter gasket.
shown. Keep clean the OCV filter.

Tightening torque 5. Install OCV(A).

M10 :
25Nm ([Link], [Link]) + (60° - 65°) + (60° ~ 65°) Tightening torque
M12 : 10 ~ 12Nm(100 ~ [Link], 7.3 ~ [Link])
30Nm ([Link], [Link]) + (60° ~ 65°) + (60° ~ 65°)
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8 6 1 3 9
wt
on

ECKD214A

ECKD232A
CAUTION
4. Install OCV filter(A).
• Do not reuse the OCV when dropped.
Tightening torque
• Keep clean the OCV.
• Do not hold the OCV sleeve during servicing.
41 - 51 Nm (410 ~ [Link], 30 ~ [Link])
• When the OCV is installed on the engine, do
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not move the engine with holding the OCV

yoke.
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ECKD215A
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EM -50 ENGINE (G4GC - GSL 2.0)

6. Install the camshafts. 3) Install the timing chain auto tensioner(A).

1) Align the camshaft timing chain with the intake Tightening torque
timing chain sprocket and exhaust timing chain 8 - 10Nm (80 ~ [Link], 6 - [Link])
sprocket as shown.
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wt

ECKD233A

ECKD212A
2) Install the camshafts(A) and bearing caps(B).
on

4) Remove the auto tensioner stopper pin(B).

Tightening torque
14 - 15Nm (140 ~ [Link], 10 ~ [Link]) 7. Check and adjust valve clearance. (See page EM -*8
11)

8. Using the SST(09221-21000), install the camshaft

bearing oil seal.
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ECKD234A

ECKD235A

9. Install the camshaft sprocket. (See page EM - 27)

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CYLINDER HEAD ASSEMBLY EM -51

10. Install the timing belt. (See page EM - 27) f g j] w o r £
11. Install the cylinder head cover. • Use liquid gasket, loctite No. 5999.
• Check that the mating surfaces are clean and dry
1) Install the cylinder head cover gasket(A) in the before applying liquid gasket
groove of the cylinder head cover(B). • After assembly, wait at least 30 minutes before
filling the engine with oil.

3) Install the cylinder head cover(A) with the

12bolts(B). Uniformly tighten the bolts in several
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passes.

Tightening torque
8 - 10Nm (80 - [Link], 6 - [Link])
wt

ECKD236A
on

[u] NOTE
• Before installing the head cover gasket, thor­
ADIE003A
oughly clean the head cover gasket and the
groove. 12. Install the intake manifold.
• When installing, make sure the head cover gas­
ket is seated securely in the corners o f the re­ 13. Install the exhaust manifold.
cesses with no gap.2
14. Install the PCV. (See page EM - 28)
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2) Apply liquid gasket to the head cover gasket at

the corners of the recess. 15. Install the spark plug cable. (See EE group - ignition)
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ECKD237A
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EM -52 ENGINE (G4GC - GSL 2.0)

16. Install the power steering pump bracket bolts(A). 20. Install the PCSV hose(A).

Tightening torque
35 - 50Nm (350 - [Link], 26 ~ [Link])
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wt

ECKD209A

21. Install the fuel inlet hose(A).

ECKD211A

17. Install the power steering pump. (See ST group -

on

power steering pump)

18. Install the accelerator cable.

19. Install the bake booster hose(A).

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ECKD208A
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ECKD210A
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CYLINDER HEAD ASSEMBLY EM -53

22. Install the engine wire harness connectors and wire 6) CMP connector(A).
harness clamps to the cylinder head and the intake
manifold.

1) PCSV connector(A).
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wt

ECKD205A

7) ISA connector(B).

ECKD207A 8) TPS connector(A).

2) Front heated oxygen sensor connedor(A).

on
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EDQF197A
t

ECKD206A 9) Ignition coil connector(D).

3) Connect the ground cable to the intake mani- 10) ECT sensor connector(C).
fold(D).
11) Oil temperature sensor connector(B).
4) Knock sensor connector(C).

5) Four fuel injector connectors(B).

 Made with Xodo PDF Reader and Editor

EM -54 ENGINE (G4GC - GSL 2.0)

12) OCV connector(A). 24. Install the upper radiator hose(A) and lower radiator
hose(B).
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wt

ECKD203A

ECKD201A
23. Install the heater hoses(A).
25. Install the Intake air hose and air cleaner assembly.

26. Install the engine cover. (See page EM -1 0 )

on

27. Connect the negative terminal to the battery.

28. Filll with engine coolant.

29. Start the engine and check for leaks.

30. Recheck engine coolant level and oil level.

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ECKD202A
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ENGINE AND TRANSAXLE ASSEMBLY EM -55

ENGINE AND TRANSAXLE 5. Remove the upper radiator hose(A) and lower radiator
hose(B).
ASSEMBLY
REMOVAL EDFA091F

/]\ CAUTION
• Use fender covers to avoid damaging painted
Ne
surfaces.
• To avoid damage, unplug the wiring connec­
tors carefully while holding the connector
portion.

M N0TE
• Mark all wiring and hoses to avoid misconnec-
tion.
• Inspection the timing belt before removing the
cylinder head.
wt
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EM - 9)
ECKD201A

1. Disconnect the neagative terminal from the battery.

6. Remove the heater hoses(A).
on
Ne

ECKD202A
t

2. Remove the engine cover. 7. Remove the engine wire harness connectors and wire
harness clamps from the cylinder head and the intake
3. Drain the engine coolant. manifold.
Remove the radiator cap to speed draining.
1) OCV(Oil Control Valve) connector(A).
4. Remove the intake air hose and air cleaner assembly.
2) Oil temperature sensor connector(B).
1) Disconnect the AFS connector.
3) ECT(Engine Coolant Temperature) sensor(C)
2) Disconnect the breather hose from air cleaner connector.
hose.3

3) Remove the intake air hose and air cleaner.

 Made with Xodo PDF Reader and Editor

EM -56 ENGINE (G4GC - GSL 2.0)

4) Ignition coil connector(D). 11) Compressor switch(F).
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wt

ECKD203A ACGE006A

5) TPS(Throttle Position Sensor) connector(A). 12) Front heated oxygen sensor(A) connector.

6) ISA(ldle Speed Actuator) connector(B). 13) CKP sensor(B) connector.

14) Oil pressure switch(C) connector.

on
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EDQF197A
t

7) CMP(Camshaft Position Sensor) connector(A). ACGE056A

8) Four fuel injector connectors(B).

9) Knock sensor connedor(C).

10) Disconnect ground cable(D) from the intake man­

ifold.
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ENGINE AND TRANSAXLE ASSEMBLY EM -57

15) PCSV(Purge Control Solenoid Valve)(A) connec- 9. Remove the PCSV hose(A).
tor.
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wt

ECKD209A
ECKD207A

10. Remove the brake booster vacuum hose(A).

8. Remove the fuel inlet from delivery pipe(A).
on
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11. Remove the accelerator cable by loosening the lock­

t

nut, then slip the cable end out of the throttle linkage.

12. Remove the power steering pump. (See page ST

group - power steering pump)

13. Remove the battery body bracket.

 Made with Xodo PDF Reader and Editor

EM -58 ENGINE (G4GC - GSL 2.0)

14. Disconnect the transaxle wire harness connector. 15. Remove the control cable(A) transaxle range switch.
a. Disconnect the inhibitor switch connector(A).
b. Disconnect the transaxle range connector(B).
c. Disconnect the input shaft speed connector(C).
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wt

EDQF018A

16. Remove the transaxle oil cooler hose(A) (A/T).

EDQF035A

d. Disconnect the output shaft speed connector(A).

e. Disconnect the vehicle speed sensor connec­
on

to r^ ).
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EDQF034A
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EDQF031A
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ENGINE AND TRANSAXLE ASSEMBLY EM -59

17. Remove the under cover. 20. Remove the front strut lower mounting bolts and nuts.
(See SS griup - front strut)
18. Remove the front exhaust pipe(A).
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wt

EDQF023A
EDQF192A
21. Remove the caliper and hang the caliper assem-
19. Disconnect the ABS wheel speed sensor(A) from both bly(A).
front knuckle. (See DS group - front axle)
on

A
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KXDSE03A

ECKD612A
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EM -60 ENGINE (G4GC - GSL 2.0)

22. Remove the steering u-joint mounting bolt(A). (See 25. Remove the transaxle mounting bracket(A).
ST group - steering)
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wt

EDQF016A
ECKD616A

23. Install the jack for supporting engine and transaxle

assembly.

24. Remove the engine mounting bracket(A).

on
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ECKD103A
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ENGINE AND TRANSAXLE ASSEMBLY EM -61

26. Remove the sub frame mounting bolts and nuts. INSTALLATION EC1DBCCB

Tightening torque Installation is in the reverse order of removal.

A : 160 - 180Nm (1600 - [Link], 118 ~ [Link])
B : 70 - 90Nm (700 - [Link], 52 - [Link]) Perform the following :
• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator with engine coolant.
Ne
• Bleed air from the cooling system with the heater
valve open.
• Clean the battery posts and cable terminals with
sandpaper assemble them, then apply grease to
prevent corrosion.
• Inspect for fuel leakage.
After assembling 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 pressureizes.
wt
Repeat this operation two or three times, then check
EDOF001A
for fuel leakage at any point in the fuel line.
on
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ECKD618A

27. Jack up the vehicle.

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EM -62____________________________________________________ ENGINE (G4GC - GSL 2.0)

ENGINE BLOCK
COMPONENTS E3E04B86
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wt
on
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ECKD004A
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ENGINE BLOCK EM -63

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wt
on
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ECKD005A
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EM -64 ENGINE (G4GC - GSL 2.0)

DISASSEMBLY E0A2AFBC 8. Remove oil pressure sensor(A).

1. M/T : remove flywheel.

2. AIT : remove drive plate.

3. Install engine to engine stand for disassembly.

4. Remove timing belt. (See page EM - 23)

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5. Remove cylinder head. (See page EM - 35)

6. Remove oil level gauge assembly(A).

wt

ECKD303A

9. Remove water pump. (See page EM - 85)

10. Remove oil pan(A).

on

ECKD301A

7. Remove knock sensor(A).

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P
ECKD304A
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ECKD302A
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ENGINE BLOCK EM -65

11. Remove oil screen. 16. Remove rear oil seal case.
Remove the 2bolts(C), oil screen(A) and gasket(B). Remove the 5 bolts(B) and rear oil seal case(A).

A
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wt

ECKD305A ECKD306A

12. Check the connecting rod end play. (See page EM - 17. Remove crankshaft bearing cap and check oil clear­
66) ance. (See page EM - 69)

13. Remove the connecting rod caps and check oil clear­ 18. Check the crankshaft end play. (See page EM - 71)
on

ance. (See page EM - 67)

19. Lift the crankshaft(A) out of the engine, being careful
14. Remove piston and connecting rod assemblies. not to damage journals.

1) Using a ridge reamer, remove all the carbon from

the top of the cylinder.
[uj NOTE
Arrange the main bearings and thrust bearings in the
2) Push the piston, connecting rod assembly and correct order.
upper bearing through the top of the cylinder
Ne

block.

M no te

• Keep the bearings, connecting rod and cap to­

gether.
• Arrange the piston and connecting rod assem­
blies in the correct order.

15. Remove front case. (See page EM - 93)

t

ECKD307A
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EM -66_________________________________ ________________ ENGINE (G4GC - GSL 2.0)

20. Check fit between piston and piston pin. INSPECTION EC8FCA1F

Try to move the piston back and forth on the piston

pin. If any movement is felt, replace the piston and CONNECTING ROD AND CRANKSHAFT
pin as a set.
1. Check the connecting rod end play.
21. Remove piston rings. Using a feeler gauge, measure the end play while
moving the connecting rod back and forth.
1) Using a piston ring expender, remove the 2 com­
pression rings. Standard end play : 0 .1- 0.25mm(0.004 - 0.01 Oin.)
Maximum end play : 0.4mm(0.016in.)
Ne
2) Remove 2 side rails and the spacer by hand.

u) no te

Arrange the piston rings in the correct order only.

22. Disconnect connecting rod from piston.

wt
on

ECKD308A

• If out-of-tolerance, install a new connecting rod.

• If still out-of-tolerance, replace the crankshaft.
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2. Check the connecting road bearing oil clearance.

1) Check the matchmarks on the connecting rod

and cap are aligned to ensure correct reassem­
bly.

2) Remove 2 connecting rod cap nuts.

3) Remove the connecting rod cap and bearing half.

4) Clean the crank pin and bearing.

t

5) Place plastigage across the crank pin.

6) Reinstall the bearing half and cap, and torque the

nuts.

Tightening torque
50 - 53Nm (500 - [Link], 36.9 - [Link])

(O) n o t e
Do not turn the crankshaft.
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ENGINE BLOCK EM -67

7) Remove 2 nuts, connecting rod cap and bearing CONNECTING ROD MARK LOCATION
half.

8) Measure the plastigage at its widest point.

Standard oil clearance

0.024 - 0.042mm(0.0009 - 0.0017in.)

M ark
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wt

BDQE003A

DISCRIMINATION OF CONNECTING ROD

CLASS MARK INSIDE DIAMETER

48.00 ~ 48.006mm
a A
(1.8 89 6 - 1.8899in.)
on

ECKD309A

4 8 .0 0 6 - 48.012mm
9) If the plastigage measures too wide or too nar­ b B
(1.8899 - 1.8902in.)
row, remove the upper half of the bearing, in­
4 8 .0 1 2 - 48.018mm
stall a new, complete bearing with the same color c C
(1.8902 - 1.8904in.)
mark (select the color as shown in the next col­
umn), and recheck the clearance.

,/;\ CAUTION
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Do not file, shim, or scrape the bearings or the

caps to adjust clearance.

10) If the plastigage shows the clearance is still in­

correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.

[Uji] NOTE
t

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 o f an ac­
cumulation o f dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent.
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EM -68 ENGINE (G4GC - GSL 2.0)

CRANKSHAFT PIN MARK LOCATION PLACE OF IDENTIFICATION MARK (CONNECTING
ROD BEARING)
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wt

ECKD311A

ECKD313A
DISCRIMINATION OF CRANKSHAFT
DISCRIMINATION OF CONNECTING ROD BEARING
OUTSIDE
CLSASS MARK
DIAMETER OF PIN THICKNESS OF
CLASS MARK
BEARING
44.960 - 44.966mm
on

I 1
(1.7 70 0 - 1.7703in.) 1.514 - 1.517mm
AA BLUE
(0.0596 - 0.0597in.)
44.952 - 44.960mm
II 2
(1.7 69 8 - 1.7700in.) 1.511 - 1.514mm
A BLACK
(0.0595 - 0.0596in.)
44.946 - 44.952mm
III 3
(1.7 69 5 - 1.7698in.) 1.508 - 1.511mm
B NONE
(0.0594 - 0.0595in.)
1.505 - 1.508mm
C GREEN
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(0.0593 - 0.0594in.)
1.502 - 1.505mm
D YELLOW
(0.0591 - 0.0593in)
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ENGINE BLOCK EM -69

11) Selection 5) Remove the cap and bearing again, and measure
the widest part of the plastigage.
CONNECT­ ASSEMBING
CRANKSHAFT
ING ROD CLASSIFI­ Standard oil clearance
INDENTIFICATION
IDENTIFICA­ CATION OF 0.028 - 0.046mm (0.0011 - 0.0018in.)
MARK
TION MARK BEARING
a (WHITE) D (YELLOW)
I (YELLOW) b (NONE) C (GREEN)
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c (YELLOW) B (NONE)
a (WHITE) C (GREEN)
II (NONE) b (NONE) B (NONE)
c (YELLOW) A (BLACK)
a (WHITE) B (NONE)
III (WHITE) b (NONE) A (BLACK)
c (YELLOW) AA (BLUE)
wt

3. Check the crankshaft bearing oil clearance.

1) To check main bearing-to-journal oil clearance,

remove the main caps and bearing halves.

2) Clean each main journal and bearing half with a ECKD0011

clean shop tower.

on

6) If the plastigage measures too wide or too nar­

3) Place one strip of plastigage across each main row, remove the upper half of the bearing, in­
journal. stall a new, complete bearing with the same color
mark (select the color as shown in the next col­
4) Reinstall the bearings and caps, then torque the umn), and recheck the clearance.
bolts.
/jX CAUTION
Tightening torque
30Nm ([Link], [Link]) + 60° ~ 65° Do not file, shim, or scrape the bearings or the
Ne

caps to adjust clearance.

(53) NOTE 7) If the plastigage shows the clearance is still in­

Do not turn the crankshaft. correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.

u ] note
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
t

crankshaft and start over.

/t\ CAUTION
If the marks are indecipherable because o f an ac­
cumulation o f dirt and dust, do not scrub them
with a wire brush o r scraper. Clean them only with
solvent or detergent.
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EM -70 ENGINE (G4GC - GSL 2.0)

CONNECTING RODS DISCRIMINATION OF CYLINDER BLOCK

1. When reinstalling, make sure that cylinder numbers CALSS MARK INSIDE DIAMETER
put on the connecting rod and cap at disassembly
61.000 ~ 61.006mm
match. When a new connecting rod is installed, make a A
(2.4015-2.4018in.)
sure that the notches for holding the bearing in place
are on the same side. 61.006 ~ 61.012mm
b B
(2.4018-2.4020in.)
2. Replace the connecting rod if it is damaged on the
61.012 - 61.018mm
thrust faces at either end. Also if step wear or a c C
Ne
(2.4020 ~ 2.4023in.)
severely rough surface of the inside diameter of the
small end is apparent, the rod must be replaced as
well. CRANKSHAFT JOURNAL MARK LOCATION

3. Using a connecting rod aligning tool, check the rod for

bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting
rod that has been severely bent or distorted should be
replaced.
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Allowable bend of connecting rod :
0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039 in./3.94 in.) or less

Crankshaft bore mark location

Letters have been stamped on the end of the block as
on

a mark for the size of each of the 5 main journal bores.

Use them, and the numbers or bar stamped on the

crank (marks for main journal size), to choose the cor­
rect bearings. ECKD312B

DISCRIMINATION OF CRANKSHAFT

OUTSIDE
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CLASS MARK DIAMETER OF

JOURNAL
56.956 ~ 56.962mm
I YELLOW
(2.2423 ~ 2.2426in.)
56.948 - 56.956mm
II NONE
(2.2420 ~ 2.2423in.)
56.942 - 56.948mm
III WHITE
(2.2418 ~2.2420in.)
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ECKD314A
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ENGINE BLOCK EM -71

PLACE OF IDENTIFICATION MARK (CRANKSHAFT SELECTION
BEARING)
CRANK­ ASSEM­
CRANKSHAFT
SHAFT BORE BLING CLAS­
IDENTIFICATION
IDENTIFICA­ SIFICATION
MARK
TION MARK OF BEARING
a (A) D (YELLOW)
I (YELLOW) b (B) C (GREEN)
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c (C) B (NONE)
a (A) C (GREEN)
II (NONE) b (B) B (NONE)
c (C) A (BLACK)
a (A) B (NONE)
III (WHITE) b (B) A (BLACK)
c (C) AA (BLUE)
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4. Check crankshaft end play.

ECKD316A Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
DISCRIMINATION OF CRANKSHAFT BEARING screwdriver.

THICKNESS OF Standard end play

CLASS MARK
BEARING 0.06 ~ 0.26mm (0.0023 ~ 0.01 Oin.)
on

2 .0 1 4 - 2.017mm Limit : 0.30mm (0.0118in.)

AA BLUE
(0.0793 - 0.0794in.)
2.011 - 2.014mm
A BLACK
(0.0791 - 0.0793in.)
2.008 - 2.011mm
B NONE
(0.0790-0.0791 in.)
2.005 - 2.008mm
C GREEN
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(0.0789 - 0.790in.)
2.002 - 2.005mm
D YELLOW
(0.0788 - 0.0789in.)
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ECKD001B

If the end play is greater than maximum, replace the

thrust bearings as a set.

Thrust bearing thickness

2.44 - 2.47mm(0.096 - 0.097in.)
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EM -72 ENGINE (G4GC - GSL 2.0)

5. Inspect main journals and crank pins 3. Inspect top surface of cylinder block for flatness.
Using a micrometer, measure the diameter of each Using a precision straight edge and feeler gauge,
main journal and crank pin. measure the surface contacting the cylinder head
gasket for warpage.
Main journal diam eter: 57mm (2.165in.)
Crank pin diam eter: 45mm (1.77in.) Flatness of cylinder block gasket surface
Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm (0.0020 in.)
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ECKD001L

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
ECKD001E If deep scratches are present, replace the cylinder
block.
CYLINDER BLOCK

1. Remove gasket material.

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Using a gasket scraper, remove all the gasket material

from the top surface of the cylinder block.2

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the
cylinder block.
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ENGINE BLOCK EM -73

5. Inspect cylinder bore diameter Size
Using a cylinder bore gauge, measure the cylinder Class Cylinder bore inner diameter
code
bore diameter at position in the thrust and axial di­
rections. 82.00 - 82.01mm
A A
(3.228- 3.2287in.)
Standard diameter 82.01 - 82.02mm
B B
82.00 ~ 82.03mm (3.2283 ~ 3.2295in.) (3.2287- 3.2291 in.)
82.02 - 82.03mm
C C
(3.2291- 3.2295in.)
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7. Check the piston size code on the piston top face.
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ECKD318A

6. Check the cylinder bore size code on the cylinder

block bottom face.

ECKD320B

,U) NOTE
Stamp the grade mark o f basic diameter with rubber
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Size
Class Piston outer diameter
code
81.97 - 81.98mm
A A
(3.2271 - 3.2275in.)
81.98 - 81.99mm
B None
(3.2275 - 3.2279in.)
81.99 - 82.00mm
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C C
(3.2279 - 3.2283in.)

8. Select the piston related to cylinder bore class.

ECKD314A Clearance : 0.02 - 0.04mm (0.00078 - 0.00157in.)

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EM -74 ENGINE (G4GC - GSL 2.0)

BORING CYLINDER PISTON AND RINGS

1. Oversize pistons should be selected according to the 1. Clean piston

largest bore cylinder.
1) Using a gasket scraper, remove the carbon from
Identification Mark Size the piston top.
0.25 0.25mm (0.010in.) 2) Using a groove cleaning tool or broken ring, clean
0.50 0.50mm (0.020in.) the piston ring grooves.
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3) Using solvent and a brush, thoroughly clean the
(IlJ| wore piston.
The size o f piston is stamped on top o f the piston.
(0) wore
2. Measure the outside diameter of the piston to be
Do not use a wire brush.
used.

3. According to the measured O.D., calculate the new 2. The standard measurement of the piston outside di­
bore size. ameter is taken 47 mm (1.85 in.) from the top land of
the piston.
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New bore size = Piston O.D + 0.02 to 0.04mm
(0.0008 to 0.0016in.) (clearance between piston and Standard diameter
cylinder) - 0.01mm (0.0004in.) (honing margin.) 81.97 - 82.00mm (3.2272 ~ 3.2283in.)

4. Bore each of the cylinders to the calculated size.

,4\ CAUTION
on

To prevent distortion that may result from temper­

ature rise during honing, bore the cylinder holes
in the firing order.

5. Hone the cylinders, finishing them to the proper di­

mension (piston outside diameter+ gap with cylinder).

6. Check the clearance between the piston and cylinder.

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Standard : 0.02 ~ 0.04mm (0.0008 - 0.0016in.)

[lj] n o t e
When boring the cylinders, finish all o f the cylinders
to the same oversize. Do not bore only one cylinder
to the oversize. ECKD001D
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ENGINE BLOCK EM -75

3. Calculate the difference between the cylinder bore di­ 5. Inspect piston ring end gap.
ameter and the piston diameter. To measure the piston ring end gap, insert a piston
ring into the cylinder bore. Position the ring at right
Piston-to-cylinder clearance angles to the cylinder wall by gently pressing it down
0.02 - 0.04mm(0.0008 - 0.0016in.) with a piston. Measure the gap with a feeler gauge. If
the gap exceeds the service limit, replace the piston
ring. If the gap is too large, recheck the cylinder bore
4. Inspect the piston ring side clearance.
diameter against the wear limits on page EM - 73 If
Using a feeler gauge, measure the clearance between
the bore is over the service limit, the cylinder block
new piston ring and the wall of the ring groove.
must be rebored. (See page EM - 74)
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Piston ring side clearance
Piston ring end gap
No. 1 : 0.04 - 0.08mm (0.0016 - 0.0031 in.)
Standard
No. 2 : 0.03 ~ 0.07mm (0.0012 - 0.0028in.)
No.1 : 0.23 ~ 0.38mm (0.0091 - 0.0150in.)
Limit
No.2 : 0.45 ~ 0.60mm (0.0177 ~ 0.0236in.)
No. 1 : 0.1mm (0.004in.)
Limit
No. 2 : 0.1mm (0.004in.)
No. 1, 2, oil ring : 1.0mm (0.039in.)
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ECKD001K
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EM -76 ENGINE (G4GC - GSL 2.0)

PISTON PINS OIP PRESSURE SWITCH

1. Measure the diameter of the piston pin. 1. Check the continuity between the terminal and the
body with an ohmmeter.
Piston pin diameter If there is no continuity, replace the oil pressure
20.001 - 20.006mm (0.7874 - 0.7876in.) switch.
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ECKD001Z ECKD001W
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2. Measure the piston pin-to-piston clearance. 2. Check the continuity between the terminal and the
body when the fine wire is pushed. If there is con­
Piston pin-to-piston clearance tinuity even when the fine wire is pushed, replace the
0.01 - 0.02mm (0.0004 - 0.0008in.) switch.

3. Check the difference between the piston pin diameter 3. If there is no continuity when a 50kpa (7psi) vacuum
and the connecting rod small end diameter. is applied throgh the oil hole, the switch is operaing
properly.
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Piston pin-to-connecting rod interference Check for air leakage. If air leaks, the diaphragm is
0.016 ~ 0.032mm (0.00063 ~ 0.00126in.) broken. Replace it.
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ECKD001Y
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ENGINE BLOCK EM -77

REASSEMBLY EFF6CDF3 3) Position the piston rings so that the ring ends are
as shown.
(uj) NOTE
• Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil
to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with
new parts.
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1. Assemble piston and connecting rod.

1) Use a hydraulic press for installation.

2) The piston front mark and the connecting rod

front mark must face the timing belt side of the
engine.
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ECKD321A

3. Install connecting rod bearings.

1) Align the bearing claw with the groove of the con­

necting rod or connecting rod cap.2
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2) Install the bearings(A) in the connecting rod and

connecting rod cap(B).
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BDQE001A

2. Install piston rings.

1) Install the oil ring spacer and 2 side rails by hand.

2) Using a piston ring expander, install the 2 com­

pression rings with the code mark facing upward.
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ECKD322A
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EM -78 ENGINE (G4GC - GSL 2.0)

4. Install main bearings. 5. Install thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal
\ J \ no te position of the cylinder block with the oil grooves fac­
ing outward.
Upper 1,2,4,5 bearings have an oil groove o f oil holes;
Lower bearings do not.

1) Align the bearing claw with the claw groove of the

cylinder block, push in the 5 upper bearings(A).
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ECKD324A

6. Place crankshaft on the cylinder block.

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7. Place main bearing caps on cylinder block.

ECKD323A

8. Install main bearing cap bolts.

2) Align the bearing claw with the claw groove of
the main bearing cap, and push in the 5 lower Tightening torque
bearings. Main bearing cap bolt
28 - 32Nm (280 - [Link], 20.6 -
[Link]) + 60° - 64°
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{Uj\ note
• The main bearing cap bolts are tightened in 2
progressive steps.
• If any o f the bearing cap bolts in broken or de­
formed, replace it.1

1) Apply a light coat of engine oil on the threads and

under the bearing cap bolts.
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ENGINE BLOCK EM -79

2) Install and uniformly tighten the 10 bearing cap 4) Apply engine oil to the bolt threads. Install the
bolts(A), in several passes, in the sequence rod caps with bearings, and torque the nuts : 50
shown. ~ 53Nm (500 ~ [Link], 36.9 ~ [Link])

Tightening torque : 30Nm ([Link], [Link]) \U }N O T E

Maintain downward force on the ring compressor to
prevent the rings from expanding before entering the
cylinder bore.
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ECHE200A
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3) Retighten the bearing cap bolts by 60°~65° in the

numerical order shown. ECKD001F

4) Check that the crankshaft turns smoothly. 11. Install a new gasket and rear oil seal case(A) with 5
bolts(B).
9. Check crankshaft end play. (See page EM - 71)

10. Install piston and connecting rod assemblies. Tightening torque

10 - 12Nm (100 - [Link], 7.3 - [Link])
(u) NOTE
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Before installing the pistons, apply a coat o f engine oil

to the ring grooves and cylinder bores.

1) Remove the connecting rod caps, and slip short

sections of rubber hose over the threaded ends
of the connecting rod bolts.

2) Install the ring compressor, check that the bear­

ing is securely in place, then position the piston in
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the cylinder, and tap it in using the wooden han­

dle of a hammer.3

3) Stop after the ring compressor pops free, and

check the connecting rod-to-check journal align­
ment before pushing the piston into place.

ECKD306A
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EM -80 ENGINE (G4GC - GSL 2.0)

14. Install oil screen.
( 0 ) NOTE
Install a new gasket(A) and oil screen(B) with 2
Check that the mating surfaces are clean and dry. bolts(C).

12. Install rear oil seal. Tightening torque

15 ~ 22Nm (150 ~ [Link], 11 ~ [Link])
1) Apply engine oil to a new oil seal lip.

2) Using SST(09231-21000) and a hammer, tap in

the oil seal until its surface is flush with the rear
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oil seal retainer edge.
A
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ECKD305A
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15. Install oil pan.

1) Using a razor blade and gasket scraper, remove

all the old packing material from the gasket sur­
13. Install front case. (See page EM - 99) faces.

[ y ] NOTE
Check that the mating surfaces are clean and dry be­
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fore applying liquid gasket.

2) Apply liquid gasket as an even bead, centered

between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.

y NOTE
• To prevent leakage o f oil, apply liquid gasket to
the inner threads o f the bolt holes.
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• Do not install the parts if five minutes or more

have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
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ENGINE BLOCK EM -81

3) Install the oil pan(A) with the 19 bolts. 18. Install knock sensor(A).
Uniformly tighten the bolts in several passes. _______________________________________
______________________________________________ Tightening torque
Tightening torque 17 - 27Nm (170 ~ [Link], 12.5 ~ [Link])
10 - 12Nm (100 - [Link], 7.3 - [Link]) ------------------------------------------------------------------
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ECKD302A
ECKD304A

19. Install oil level gauge assembly.

on

16. Install water pump. (See page EM - 88)

1) Install a new O-ring on the oil level gauge.
17. Install oil pressure sensor.
2) Apply engine oil on the O-ring.
1) Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(B) or equivalent.
3) Install the oil level gauge assembly(A) with the
2) Install the oil pressure sensor (A). bolt.

Tightening torque Tightening torque

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15 ~ 22Nm (150 ~ [Link], 11 ~ [Link]) 12 - 15Nm (120 - [Link], 9 - [Link])

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ECKD303A ECKD301A
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EM -82 ENGINE (G4GC - GSL 2.0)

20. Install cylinder head. (See page EM - 48)

21. Install timing belt. (See page EM - 27)

22. Remove engine stand.

23. A/T : Install drive plate.

Tightening torque
120 ~ 130Nm (1200 - [Link], 89 - [Link])
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24. M/T : Install flywheel.

Tightening torque
120 ~ 130Nm (1200 - [Link], 89 ~ [Link])
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COOLING SYSTEM EM -83

COOLING SYSTEM
COMPONENT E80DAED3
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TORQUE : Nm ([Link], [Link])

ECKD012A
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EM -84 ENGINE (G4GC - GSL 2.0)

ENGINE COOLANT REFILLING AND 9. Install the radiator cap and fill the reservoir tank to the
BLEEDING E4F4EB98 "MAX" line with coolant.

10. Run the vehicle under idle until the cooling fan oper­
o WARNING ates 2 - 3 times.
Never remove the radiator cap when the engine is
11. Stop the engine and wait coolant gets cool.
hot. Serious scalding could be caused by hot fluid
under high pressure escaping from the radiator.
12. Repeat 6 to 11 until the coolant level doesn’t fall any
more, bleed air out of the cooling system.
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,/j\ CAUTION
When pouring engine coolant, be sure to shut the (u) n o t e
relay box lid and not to let coolant spill on the Recheck the coolant level in the reservoir tank f b r 2 ~
electrical parts or the paint. If any coolant spills, 3 days after replacing coolant.
rinse it off immediately.

1. Slide the heater temperature control lever to maxi­

mum heat. Make sure the engine and radiator are
cool to the touch.
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2. Remove radiator cap.

3. Loosen the drain plug, and drain the coolant.

4. Tighten the radiator drain plug(A) securely.

5. Remove, drain and reinstall the reservoir. Fill the tank

halfway to the MAX mark with water, then up to the
MAX mark with antifreeze.
on

6. Fill fluid mixture with coolant and water(4 : 6) slowly

through the radiator cap. Push the upper/lower hoses
of the radiator so as bleed air easily.

\J \N O T E
• Use only genuine antifreese/coolant.
• For best corrosion protection, the coolant con­
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centration must be maintained year-round at 50%

minimum. Coolant concentrations less than 50%
may not provide sufficient protection against cor­
rosion or freezing.
• Coolant concentrations greater then 60% will im­
pair cooling efficiency and are not recommended.

/t\ CAUTION
• Do not mix different brands o f an-
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tifreeze/coolants.
• Do not use additional rust inhibitors or anti­
rust products; they may not be compatible
with the coolant

7. Start the engine and run coolant circulates.

When the cooling fan operates and coolant cumu­
lates, refill coolant through the radiator cap.8

8. Repeat 7 until the cooling fan 3 ~ 5times and bleed air

sufficiently out of the cooling system.
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COOLING SYSTEM EM -85

CAP TESTING REMOVAL EA21BA67

1. Remove the radiator cap, wet its seal with engine WATER PUMP
coolant, then install it no pressure tester.
1. Drain the engine coolant.

© WARNING
System is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine
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coolant, remove the cap only when the engine is
cool.

2. Remove drive belts.

3. Remove the timing belt. (See page EM - 23)

4. Remove the timing belt idler. (See page EM - 25)

5. Remove the water pump.

wt
1) Remove the 4 bolts and pump pulley.

2) Remove the 2 bolts(C), then remove the alterna­

tor brace(A).
ECKD501X
3) Remove the water pump(B) and gasket.
2. Apply a pressure of 93 - 1 23kPa (0.95 - 1.25kgf/cm2,
14 - 19psi)
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3. Check for a drop in pressure.

4. If the pressure drops, replace the cap.

TESTING

1. Wait until engine is cool, then carefully remove the

radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.
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2. Apply a pressure tester to the radiator and apply a

pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm2 14 -
18psi).3
4

3. Inspect for engine coolant leaks and a drop in pres­

sure.

4. Remove the tester and reinstall the radiator cap.

ECKD501A
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[U] NOTE
Check for engine oil in the coolant and/or coolant in
the engine oil.
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EM -86 ENGINE (G4GC - GSL 2.0)

THERMOSTAT INSPECTION EE14792C

\W \ n o t e WATER PUMP

Removal o f the thermostat would have an adverse 1. Check each part for cracks, damage or wear, and re­
effect, causing a lowering o f cooling efficiency. Do place the coolant pump assembly if necessary.
not remove the thermostat, even if the engine tends
to overheat. 2. Check the bearing for damage, abnormal noise and
sluggish rotation, and replace the coolant pump as­
1. Drain engine coolant so its level is below thermostat. sembly if necessary.
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2. Remove water inlet(A), gasket and thermostat.
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ECKD503A

ECKD501B 3. Check lor coolant leakage. If coolant leaks from hole,

the seal is defective. Replace the coolant pump as­
sembly

fkj] NOTE
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A small amount o f "weeping" from the bleed hole is

normal.
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COOLING SYSTEM EM -87

THERMOSTAT

1. Immerse the thermostat in water and gradually heat

the water.
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ECKD503B

2. Check the valve opening temperature.

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Valve opening temperature : 82°C (177°F)

Full opening temperature : 95°C (205°F)

If the valve opening temperature is not as specified,

replace the thermostat.

3. Check the valve lift.

Valve lift: 8mm (0.3in.) or more at 95°C (205°F)

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If the valve lift is not as specified, replace the thermo­

stat.
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EM -88 ENGINE (G4GC - GSL 2.0)

INSTALLATION EC133513 THERMOSTAT

WATER PUMP 1. Place thermostat in thermostat housing.

1. Install the water pump. 1) Install the thermostat with the jiggle valve up­
ward.
1) Install the water pump(B) and a new gasket with
the 3 bolts. 2) Install a new gasket(A) to the thermostat(B).

Tightening torque
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20 ~ 27Nm (200 ~ [Link], 15 ~ [Link])
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ECKD510A

2. Install water inlet(A).

ECKD501A
Tightening torque
2) Install the alternator brace(A) with the 2 bolts(C). 15 ~ 20Nm (150 ~ [Link], 9 ~ [Link])

3) Install the 4 bolts and pump pulley.

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2. Install the timing belt idler. (See page EM - 29)

3. Install the timing belt. (See page EM - 27)

4. Install drive belts.

5. Fill with engine coolant.

6. Start engine and check for leaks.

7. Recheck engine coolant level.

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ECKD501B

3. Fill with engine coolant.

4. Start engine and check for leaks.

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LUBRICATION SYSTEM EM -89

LUBRICATION SYSTEM
COMPONENT E2A4EA3F
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TORQUE : Nm ([Link], [Link])

ECKD006A
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E M -90 ENGINE (G4GC - GSL 2.0)

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ECKD007A
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LUBRICATION SYSTEM E M -91

OIL AND FILTER ECF1A5FC INSPECTION

1. Check engine oil quality

,/t\j CAUTION
Check the oil for deterioration, entry of water, discol­
• Prolonged and repeated contact with mineral oring or thinning.
oil will result in the removal o f natural fats If the quality is visibly poor, replace the oil.
from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil 2. Check engine oil level.
contains potentially harmful contaminants After warming up the engine and then 5 minutes after
which may cause skin cancer. the engine stop, oil level should be between the "L"
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• Exercise caution in order to minimize the and "F" marks on the dipstick.
length and frequency o f contact o f your skin If low, check for leakage and add oil up to the "F" mark.
to used oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap [0) NOTE
and water, or use water-less hand cleaner,
Do not fill with engine oil above the "F" mark.
to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil
and used oil filter must be disposed o f only at
designated disposal sites.
wt

1. Drain engine oil.

a. Remove the oil filter cap.
b. Remove the oil drain plug, and drain the oil into
a container.

2. Replace oil filter.

a. Remove the oil filter.
on

b. Check and clean the oil filter installation surface.

c. Check the part number of the new oil filter is as
same as old one.
d. Apply clean engine oil to the gasket of a new oil
filter.
e. Lightly screw the oil filter into place, and tighten
it until the gasket contacts the seat.
f. Tighten it an additional 3/4 turn.
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3. Refill with engine oil filter.

a. Clean and install the oil drain plug with a new
gasket.

Tightening torque
40 - 45Nm (400 - [Link], 30 - [Link])

b. Fill with fresh engine oil

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Capacity
Drain and refill
W/Oil filter change : 4.0I ([Link], 3.52lmp qts)
W/O Oil filter change : 3.7I ([Link], 3.26lmp qts)

c. Install the oil filter cap.

4. Start engine and check for oil leaks.

5. Recheck engine oil level.

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EM -92 ENGINE (G4GC - GSL 2.0)

SELECTION OF ENGINE OIL

R eco m m e n d e d ILS A C classification : G F 3 O R A B O V E

R eco m m e n d e d A P I classification : SJ / S L O R A B O V E
R eco m m e n d e d S A E viscosity g rades :

Tem peratu re range

anticipated before R eco m m e n d e d S A E viscosity n um ber
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next oil ch an g e

°C
40

20 —
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10 -

- 7 —

■13 —
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-1 8 —
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*1 : Recommended regardless of environment.

If not available, refer to the recommended SAE viscosity numbers.
LC8F002A

g j ) NOTE
For best performance and maximum protection o f all
types o f operation, select only those lubricants which
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1. Satisfy the requirement o f the API classification.

2. Have proper SAE grade number for expected am­
bient temperature range.
3. Lubricants that do not have both an SAE grade
number and API service classification on the con­
tainer should not be used.
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LUBRICATION SYSTEM E M -93

REMOVAL e 8bd e 9d i 1) Remove the screws(B) from the pump housing,
then separate the housing and cover(A).
1. Drain engine oil.

2. Remove the drive belts.

3. Turn the crankshaft and align the white groove on the

crankshaft pulley with the pointer on the lower cover.
(See page EM - 9)
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4. Remove the timing belt. (See page EM - 23)

5. Remove the oil pan and oil screen. (See page EM -

64, 65)

6. Remove the front case.

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ECKD401A

2) R e m o ve the inner(A ) and outer(B ) rotors.

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ECKD411A
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ECKD402A
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E M -94 ENGINE (G4GC - GSL 2.0)

DISASSEMBLY E65B43FC INSPECTION EDACC2F5

1. Remove the relief plunger. 1. Inspect relief plunger.

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

2. Inspect relief valve spring.

Inspect for distorted or broken relief valve spring.
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Standard value
Free h e ig h t: 43.8mm (1.724 in.)
Load : 3.7±0.4kg/40.1mm (8.14±0.88lb/1.579 in.)

3. Inspect rotor side clearance.

Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and
precision straight edge.
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Outer 0.04 - 0.09mm

gear (0.0016 ~0.0035in.)
Side clearance
Inner 0.04 - 0.085mm
ECKD403A gear (0.0016 ~0.0033in.)
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E C K D 404A
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If the side clearance is greater than maximum, replace

the rotors as a set. If necessary, replace the front
case.
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LUBRICATION SYSTEM E M -95

4. Inspect rotor tip clearance. 5. Inspect rotor body clearance.
Using a feeler gauge, measure the tip clearance be­ Using a feeler gauge, measure the clearance between
tween the inner and outer rotor tips. the outer rotor and body.

Tip clearance Body clearance

0.025 - 0.069 mm(0.0010 - 0.0027 in.) 0.12 - 0.185 mm(0.0047 - 0.0073 in.)
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ECKD405A ECKD406A
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If the tip clearance is greater than maximum, replace If the body clearance is greater than maximum, re­
the rotor as a set. place the rotors as a set. If necessary, replace the
front case.
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E M -96 ENGINE (G4GC - GSL 2.0)

REASSEMBLY E158FA78 INSTALLATION EC494CD5

1. Install relief plunger. 1. Install oil pump.

Install relief plunger(A) and spring(B) into the front
case hole, and install the plug(A). 1) Place the inner and outer rotors into front case
with the marks facing the oil pump cover side.
Tightening torque
40 - 50Nm (400 - [Link], 30 ~ [Link]) 2) Install the oil pump cover(A) to front case with the
7 screws(B).
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Tightenig torque
6 - 9Nm (60 - [Link], 4.4 - [Link])
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ECKD401A

2 Check that the oil pump turns freely.

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LUBRICATION SYSTEM E M -97

3. Install the oil pump on the cylinder block. 5. Using the SST(09214-33000), install the oil seal.
Place a new front case gasket on the cylinder block.
Apply engine oil to the lip of the oil pump seal. Then,
install the oil pump onto the crankshaft. When the
pump is in place, clean any excess grease off the
crankshaft and check that the oil seal lip is not dis­
torted.
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ECHE600C

6. Install the oil screen. (See page EM - 80)

7. Install the oil pan. (See page EM - 81)

ECKD411A [tj] NOTE

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Body length Clean the oil pan gasket mating surfaces.

( A ) : 25mm (0.98in)
(B ) : 20mm (0.787in)
( C ) : 38mm (1.496in)
( D ) : 45mm (1.771 in)

Tighttening torque
20 ~ 27Nm (200 ~ [Link], 14.5 ~ [Link])
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4. Apply a light coat of oil to the seal lip.

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E M -98 ENGINE (G4GC - GSL 2.0)

INTAKE AND EXHAUST

SYSTEM
COMPONENT E26D8E3D

INTAKE MANIFOLD
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I.S.A
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TORQUE : Nm ([Link], [Link])

ECKD008A
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INTAKE AND EXHAUST SYSTEM E M -99

EXHAUST MANIFOLD
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17 - 22 (170 - 220,12.5 - 16)

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TORQUE : Nm ([Link], [Link])

ECKD009A
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EM -100 ENGINE (G4GC - GSL 2.0)

MUFFLER
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ECOC170A
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INTAKE AND EXHAUST SYSTEM EM -101

REMOVAL ec8 do2 fd 5. Remove the delivery pipe(A).

INTAKE MANIFOLD

1. Remove the engine cover. (See page EM - 8) @

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ECKD112A

4. Remove the accelerator cable by loosening the lock­

nut, then slip the cable end out of the throttle linkage.
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EM -102 ENGINE (G4GC - GSL 2.0)

7. Remove the intake manifold stay(A). EXHAUST MANIFOLD

1. Remove the engine cover. (See page EM - 8)

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EDQF195A
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INTAKE AND EXHAUST SYSTEM EM -103

5. Remove the exhaust manifold.
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ACGE035A
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