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SECTION 1C1

1.4L/1.6L DOHC ENGINE MECHANICAL

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Engine Specifications

Application
Description (Manual and Automatic)
1.4L DOHC
1.6L DOHC
General Data:
Engine Type
F14D
F16D
Displacement
1399 cm³
1598 cm³ (97.51 in³)
Bore Stroke
77.9 x 73.4 mm (3.01 in. x 2.89 in.)
79.0 x 81.5 mm (3.1 in. X 3.21 in.)
Compression Ratio
9.5 ± 0.2:1
9.5 ± 0.2:1
Firing Oder
1-3-4-2
1-3-4-2
Cylinder Bore:
Diameter
77.9 mm (3.07 in.)
79 mm (3.1 in.)
Out of Round (Maximum)
0.0065 mm (0.00025 in.)
0.0065 mm (0.00025 in.)
Taper (Maximum)
0.07 x 30°
0.0065 mm (0.00025 in.)
Pistion:
Diameter
77.87 mm (3.07 in.)
78.970 mm (3.1090 in.)
Clearance to Bore
0.030 ± 0.010 mm (0.0012 ± 0.0004 in.)
0.030 ± 0.010 mm (0.0012 ± 0.0004 in.)
Piston Rings:
Ring, End Gap:
.
.
Top Compression
    0.15-0.30 mm (0.0059-0.0118 in.)
      0.2-0.3 mm (0.008-0.012 in.)
      2nd Compression
        0.3-0.5 mm (0.0118-0.0197 in.)
          0.5-0.6 mm (0.02-0.024 in.)
          Groove Clearance:
          .
          .
          Top Compression
            0.05-0.09 mm (0.00197-0.00354 in.)
              0.050-0.080 mm (0.002-0.003 in.)
              2nd Compression
                0.06-0.1 mm (0.00236-0.00393 in.)
                  0.050-0.082 mm (0.002-0.032 in.)
                  Piston Pin:
                  Diameter
                  17.990-17.995 mm (0.7083-0.7085 in.)
                  17.990-17.985 mm (0.7083-0.7085 in.)
                  Pin Off-Set
                  0.8 ± 0.1 mm (0.0315-0.0039 in.)
                  0.7-0.9 mm (0.028-0.036 in.)
                  Camshaft:
                  Lift Intake
                  7.2 mm (0.283 in.)
                  8.5 mm (0.335 in.)
                  Lift Exhaust
                  7.2 mm (0.283 in.)
                  8.5 mm (0.335 in.)
                  End Play
                  0.1-0.25 mm (0.00394-0.00787 in.)
                  0.10-0.25 mm (0.004-0.0089 in.)
                  Application
                  Description (Manual and Automatic)
                  1.4L DOHC
                  1.6L DOHC
                  Journal OD:
                  .
                  .
                  No. 1
                  29.935-29.95 mm (1.1785-1.1791 in.)
                  29.935-29.95 mm (1.1785-1.1791 in.)
                  No. 2
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  No. 3
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  No. 4
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  No. 5
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  26.935-26.95 mm (1.0604-1.0610 in.)
                  Crankshaft:
                  Main Journal:
                  .
                  .
                  Diameter (All)
                  55 mm (2.71 in.)
                  54.982-54.994 mm (2.164-2.165 in.)
                  Taper (Maximum)
                  Out of Round (Maximum)
                  0.005 mm (0.0001 in.)
                  0.004 mm (0.0001 in.)
                  0.005 mm (0.0001 in.)
                  0.004 mm (0.0001 in.)
                  Main Bearing Clearance (All)
                  0.026-0.042 mm (0.001-0.002 in.)
                  0.026-0.042 mm (0.001-0.002 in.)
                  Crankshaft End Play
                  0.1 mm (0.003 in.)
                  0.05-0.28 mm (0.002-0.011 in.)
                  Connecting Rod Journal:
                  .
                  .
                  Diameter (All)
                  43 mm (1.69 in.)
                  42.971-42.987 mm (1.691-1.692 in.)
                  Taper (Maximum)
                  0.005 mm (0.0001 in.)
                  0.005 mm (0.0001 in.)
                  Out of Round (Maximum)
                  0.004 mm (0.0001 in.)
                  0.004 mm (0.0001 in.)
                  Rod Bearing Clearance (All)
                  0.019-0.070 mm (0.0007-0.0028 in.)
                  0.019-0.071 mm (0.0007-0.0028 in.)
                  Rod Side Clearance
                  0.070-0.242 mm (0.0027-0.009 in.)
                  0.070-0.242 mm (0.0027-0.009 in.)
                  Valve System:
                  Valve Lash Compensators
                  Hydraulic
                  Hydraulic
                  Face Angle (All)
                  45°~45.25°
                  45°~45.25°
                  Seat Angle (All)
                  44.5°~45°
                  44.5°~45°
                  Seat Runout (Maximum, All)
                  0.05 mm (0.002 in.)
                  0.05 mm (0.002 in.)
                  Face Runout (Maximum, All)
                  0.03 mm (0.0012 in.)
                  0.03 mm (0.0012 in.)
                  Seat Width:
                  .
                  .
                  Intake
                  Exhaust
                  1.17-1.57 mm (0.046-0.062 in.)
                  1.4-1.8 mm (0.055-0.071 in.)
                  1.17-1.57 mm (0.046-0.062 in.)
                  1.4-1.8 mm (0.055-0.071 in.)
                  Valve Guide Inside Diameter (All)
                  6.00-6.02 mm (0.236-0.237 in.)
                  6.00-6.02 mm (0.236-0.237 in.)
                  Application
                  Description (Manual and Automatic)
                  1.4L DOHC
                  1.6L DOHC
                  Valve Stem Diameter (All)
                  .
                  .
                  Intake
                  5.955-5.970 mm (0.2344-0.2350 in.)
                  5.955-5.970 mm (0.2344-0.2350 in.)
                  Exhaust
                  5.935-5.950 mm (0.2337-0.2343 in.)
                  5.935-5.950 mm (0.2337-0.2343 in.)
                  Valve Diameter (All):
                  .
                  .
                  Intake
                  28.57 ± 0.12 mm (1.125 ± 0.0047 in.)
                  28.57 ± 0.12 mm (1.125 ± 0.0047 in.)
                  Exhaust
                  27.24 ± 0.14 mm (1.074 ± 0.0055 in.)
                  27.24 ± 0.14 mm (1.074 ± 0.0055 in.)
                  Valve Spring Loads:
                  .
                  .
                  Valve Open
                  580 ± 29N (426 ± 21 lbs) @ 23mm
                  580 ± 26N (428 ± 19 lbs) @ 23.0 mm (0.90 in.)
                  Valve Closed
                  260 ± 13N (191 ± 9.6 lbs) @ 32 mm
                  260 ± 13N (192 ± 10 lbs) @ 32.0mm (1.25 in.)
                  Valve Spring Free Length
                  41.2 mm (1.622 in.)
                  41.2 mm (1.622 in.)
                  Oil Pump:
                  Gap Between Oil Pump Body and Out Rotor
                  0.400~0.484 mm (0.0157~0.019 in.)
                  0.400~0.484 mm (0.0157~0.019 in.)
                  Out Rotor Side Clearance
                  0.045~0.100 mm (0.0018~0.0039 in.)
                  0.045~0.100 mm (0.02~0.004 in.)
                  Inner Rotor Side Clearance
                  0.035~0.085 mm (0.001~0.003 in.)
                  0.035~0.085 mm (0.001~0.003 in.)
                  Relief Valve Spring Free Length
                  81 mm (3.2 in.)
                  81 mm (3.2 in.)
                  Sealants and Adhesives:
                  Rear Main Bearing Cap
                  GE p/n RTV 159
                  Oil Pan Bolts
                  HN 1256 (Loctite® 242)
                  Oil Pump Bolts
                  HN 1256 (Loctite® 242)
                  Oil Pan Pickup Tube Bolts
                  HN 1256 (Loctite® 242)
                  Oil Gallery Plug
                  HN 1256 (Loctite® 242)
                  Coolant Jacket Caps and Plugs (Freeze Plugs)
                  HN 1756 (Loctite® 962B)
                  Exhaust Manifold Studs/Nuts
                  Anti-seize Compound (HMC Spec HN1325)

                  Fastener Tightening Specifications

                  Application
                  N•m
                  Lb-Ft
                  Lb-In
                  Air Cleaner Housing Bolts
                  10
                  -
                  89
                  Camshaft Cap Bolts
                  16
                  12
                  -
                  Camshaft Cover Nuts
                  10
                  -
                  89
                  Connecting Rod Bearing Cap Bolts
                  25 + 30° + 15°
                  18 + 30° + 15°
                  -
                  Coolant Temperature Sensor
                  20
                  15
                  -
                  Crankshaft Bearing Cap Bolts
                  50 + 45° + 15°
                  37 + 45° + 15°
                  -
                  Crankshaft Cover Nuts
                  5~8
                  -
                  44~71
                  Crankshaft Pulley Bolt
                  95 N•m + 30° + 15°
                  -
                  -
                  Cylinder Head Bolts (Cylinder Head Mounting Bolts)
                  25 + 70° + 70° + 50°
                  18 + 70° + 70° + 50°
                  -
                  Direct Ignition System Coil Mounting Bolts
                  10
                  -
                  89
                  Direct Ignition System Coil Mounting Bracket Bolts
                  10
                  -
                  89
                  Engine Mount Attaching Bolts
                  30
                  22
                  -
                  Engine Mount Bracket Attaching Bolts/Nuts
                  50
                  37
                  -
                  Exhaust Camshaft Gear Bolt
                  67.5
                  49
                  -
                  Exhaust Flex Pipe-to-Catalytic Converter or Connecting Pipe Retaining Nut
                  35
                  26
                  -
                  Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts
                  35
                  26
                  -
                  Exhaust Gas Recirculation Valve Adapter Bolts
                  25
                  18
                  -
                  Exhaust Manifold Heat Shield Bolts
                  15
                  11
                  -
                  Exhaust Manifold Retaining Nuts
                  25
                  18
                  -
                  Flexible Plate Bolts
                  60
                  44
                  -
                  Flexible Plate Inspection Cover Bolts
                  10
                  -
                  89
                  Flywheel Bolts
                  35 + 30° + 15°
                  25 + 30° + 15°
                  -
                  Flywheel Inspection Cover Bolts
                  12
                  -
                  106
                  Front Timing Belt Cover Bolts (Upper and Lower)
                  10
                  -
                  89
                  Fuel Rail Assembly Retaining Bolts
                  25
                  18
                  -
                  Fuel Rail Retaining Bolts
                  25
                  18
                  -
                  Generator Upper Retaining Bolt
                  20
                  15
                  -
                  Intake Camshaft Gear Bolt
                  67.5
                  49
                  -
                  Intake Manifold Retaining Bolts/Nuts
                  25
                  18
                  -
                  Intake Manifold Support Bracket Lower Bolt
                  25
                  18
                  -
                  Intake Manifold Support Bracket Upper Bolts
                  25
                  18
                  -
                  Lower Front Timing Belt Cover Bolts
                  10
                  -
                  89
                  Oil Pan Flange Bolts
                  75
                  55
                  -
                  Oil Pan Retaining Bolts
                  10
                  -
                  89
                  Oil Pan Drain Plug
                  35
                  26
                  -
                  OIl Pressure Switch
                  40
                  30
                  -
                  Oil Pump Bolts
                  10
                  -
                  89
                  Oil Pump Rear Cover Bolts
                  8
                  -
                  71
                  Oil Pump Retaining Bolts
                  10
                  -
                  89
                  Oil Suction Pipe or Support Bracket Bolts
                  10
                  -
                  89
                  Rear Timing Belt Cover Bolts
                  10
                  -
                  89
                  Safety Relief Valve Bolt
                  30
                  3022
                  -
                  Spark Plugs
                  25
                  18
                  -
                  Thermostat Housing Mounting Bolts
                  20
                  15
                  -
                  Timing Belt Automatic Tensioner Bolts
                  25
                  18
                  -
                  Timing Belt Idler Pulley Bolt
                  40
                  30
                  -
                  Transaxle Bell Housing Bolts
                  75
                  55
                  -
                  Transaxle Torque Converter Bolts
                  45
                  33
                  -
                  Upper Front Timing Belt Cover Bolts
                  10
                  -
                  89
                  Water Pump Retaining Bolts
                  10
                  -
                  89

                  SPECIAL TOOLS

                  Special Tools Table


                  J42492
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                  J-42492
                  Timing Belt Adjuster

                  KM470B
                  Display graphicTranslations of text in graphics


                  KM-470-B
                  Angular Torque Gauge

                  F202C312
                  Display graphicTranslations of text in graphics


                  DW110-060
                  Engine Support Fixture

                  KM427
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                  KM-427
                  Piston Pin Service Set

                  KM571B
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                  KM-571-B
                  Gauge

                  KM3400
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                  KM-340-0
                  Cutter Set Includes:
                  KM-340-7
                  Guide Drift
                  KM-340-13
                  Cutters
                  KM-340-26
                  Cutters

                  KM348
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                  KM-348
                  Valve Spring Compressor
                  Compressor

                  J3B11C01
                  Display graphicTranslations of text in graphics


                  KM-653
                  Adapter

                  J3B11C02
                  Display graphicTranslations of text in graphics


                  KM-805
                  Valve Guide Reamer

                  KM412
                  Display graphicTranslations of text in graphics


                  KM-412
                  Engine Overhaul Stand

                  KM498B
                  Display graphicTranslations of text in graphics


                  KM-498-B
                  Pressure Gauge

                  KM635
                  Display graphicTranslations of text in graphics


                  KM-635
                  Crankshaft Rear Oil Seal Installer

                  J36972
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                  J-36792
                  Crankshaft Rear Oil Seal Installer

                  KM135
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                  KM-135
                  Adapter

                  COMPONENT LOCATOR

                  Cylinder Head


                  J3D11C01
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                  1. Oil Filler Cap
                  2. Engine Cover
                  3. Camshaft Cover
                  4. Camshaft Cover Gasket
                  5. Camshaft Cover Bolt
                  6. Hydraulic Tappet Adjuster
                  7. Valve Key
                  8. Valve Spring Cap
                  9. Valve Spring
                  10. Valve Stem Seal
                  11. EGR Vaccum Hose
                  12. EGR Valve
                  13. EGR Valve Gasket
                  14. EGR Valve Adaptor
                  15. EGR Valve Adaptor Gasket
                  16. Cylinder Head
                  17. Front Camshaft Cap
                  18. Valve Guide
                  19. Plug
                  20. Freeze Plug
                  21. Oil Duct Cap
                  22. Intake Valve
                  23. Exhaust Valve
                  24. Cylinder Head Gasket
                  25. Engine Coolant Temperature Sensor
                  26. Heat Take Off Pipe
                  27. Camshaft
                  28. Camshaft Seal
                  29. Thermostat

                  Cylinder Block


                  J3B11CA2
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                  1. Piston Ring Set
                  2. Piston
                  3. Piston Pin
                  4. Connecting Rod
                  5. Connecting Rod Bearing Set
                  6. Oil Level Gauge Stick
                  7. Gauge Stic Tube
                  8. Sleeve
                  9. Clutch Housing Sleeve
                  10. Cylinder Block
                  11. Plug
                  12. Gap
                  13. Bypass Valve
                  14. Connecting Piece
                  15. Oil Filter
                  16. Oil Pump Body Gasket
                  17. Water Inlet Neck
                  18. Knock Sensor
                  19. Fly Wheel (M/T)
                  20. Flexible Plate (A/T)
                  21. Shaft Seal Ring
                  22. Crank Shaft Upper Bearing Set
                  23. Crank Shaft
                  24. Crank Shaft Lower Bearing Set
                  25. Transmitter Disc
                  26. Crankshaft Bearing Cap
                  27. Oil Pan
                  28. Threaded Ring
                  29. Washer
                  30. Oil Pan Drain Plug
                  31. Oil Pump
                  32. Oil Pump Cover
                  33. Oil Pump Inner Rotor
                  34. Oil Pump Outer Rotor
                  35. Oil Pump Plug
                  36. Shaft Sealing
                  37. Pressure Relief Valve Plunger
                  38. Relief Valve Spring
                  39. Sealing
                  40. Relief Valve
                  41. Oil Pressure Switch
                  42. Sleeve
                  43. Oil Suction Pipe Bracket
                  44. Oil Suction Pipe
                  45. Sealing

                  Intake & Exhaust Manifold


                  J3B11CA3
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                  1. Oxygen Sensor
                  2. Heat Shield
                  3. Exhaust Manifold
                  4. Exhaust Manifold Gasket
                  5. Intake Manifold
                  6. Main Throttle Idle Actuator (MTIA) Gasket
                  7. MTIA
                  8. Clamp
                  9. Intake Air Tube
                  10. Breethe Hose
                  11. Aircleaner Assembly
                  12. Aircleaner Upper Hosing
                  13. Aircleaner Eliment
                  14. Aircleaner Lower Housing
                  15. Resoinator
                  16. Air Intet Hose

                  Timing Belt


                  J3B11CA4
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                  1. Water Pump Sealing
                  2. Water Pump
                  3. Timing Belt Rear Cover
                  4. Camshaft Position Sensor
                  5. Auto Temsioner
                  6. Camshaft Gear
                  7. Idler pulley
                  8. Crankshaft Gear
                  9. Torque Roll Axis Support
                  10. Timing Belt
                  11. Timing Belt Front Upper Cover
                  12. Timing Belt Front Lower Cover
                  13. Crankshaft Pulley
                  14. Crankshaft Position Sensor

                  Engine Mounting


                  J3B11CA5
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                  1. Rear Power Unit Damping Block
                  2. Rear Transaxle Mounting Bracket (A/T)
                  3. Rear Transaxle Mounting Bracket (M/T)
                  4. Transaxle Mounting Cage
                  5. Transaxle Mounting Bracket (M/T)
                  6. Transaxle Mounting Bracket (A/T)
                  7. Engine Undercover
                  8. Hydro Mounting
                  9. Engine Mounting Bracket


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