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ENGINE MECHANICAL
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GENERAL .................................................................................. 2 ENGINE MOUNTING ................................................................ 13 ENGINE AND TRANSAXLE ASSEMBLY ................................ 18 TIMING BELT ........................................................................... CAMSHAFT ANDROCKER ARMS ......................................... CYLINDER HEAD AND VALVES ............................................. FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT .................................................................... PISTON AND CONNECTING ROD .......................................... CRANKSHAFT, FLY WHEEL ................................................... 21 33 38

45 5358 CYLINDER BLOCK .................................................................. 63

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GENERAL

GENERAL
SPECIFICATIONS
Description General Type Number of cylinders Specification In-line, Double Over Head Camshaft 4 1.6L Eng. 82.3 mm (3.240 in.) 75.0 mm (2.953 in.) 1595 cc (97.3 cu.in.) 9.2 1-3-4-2 750 ± 100 rpm BTDC 5o ± 2o 1.8L Eng. 81.5 mm (3.209 in.) 88 mm (3.465 in.) 1836 cc(112.04 cu.in.) 9.2 700 ± 100 rpm Limit

Bore Stroke Total displacement Compression ratio Firing order Idle R.P.M Ignition timing at idling speed Valve timing Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Cylinder head Flatness of gasket surface Flatness of manifold mounting surface Oversize rework dimensions of valve seat hole Intake 0.3 mm (0.912 in.) O.S. 0.6mm (0.024 in.) O.S Exhaust 0.3 mm (0.012 in.) O.S. 0.6 mm (0.024) O.S. Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05 mm (0.002 in.) O.S. 0.25 mm (0.010 in.) O.S. 0.50 mm (0.020 in.) O.S. Camshaft 1.6L Eng. Cam height intake Exhaust Journal O.D. Bearing oil clearance End play 1.8L Eng. Cam height Intake Exhaust Journal O.D. Bearing oil clearance End play

1.6LEng. 16o 48o 43o 17o

1.8L Eng. 26o 46o 55 o 9o 0.1 mm (0.0039 in.) 0.2 mm (0.008 in.)

Max. 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.)

35.300-35.325 35.600-35.625 33.300-33.325 33.600-33.625

mm mm mm mm

(1.3898-1.3907 (1.4016-1.4026 (1.3110-1.3120 (1.3228-1.3238

in.) in.) in.) in.)

12.050-12.068 mm (0.4744-0.4751 in.) 12.250-12.268 mm (0.4823-0.4830 in.) 12.500-12.518 mm(0.4921-0.4928 in.)

35.200 mm (1.3858 in.) 34.907 mm (1.3743 in.) 26 mm (1.02 in.) 0.05-0.09 mm (0.0020-0.0035) 0.1-0.2 mm (0.004-0.008 in.)

34.700 mm (1.3661 in.) 34.407 mm (1.3546 in.)

35.493 mm (1.3974 in.) 35.200 mm (1.3858 in.) 26 mm (1.02 in.) 0.05-0.09 mm (0.0020-0.0035 in.) 0.1-0.2 mm (0.004-0.008 in.)

34.993 mm (1.3777 in.) 34.700 mm (1.3661 in.)

GENERAL

20-3

Description ValveValve length Intake Exhaust Stem O.D. Intake Exhaust Face angle Thickness of valve head (margin) Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve guide Length Intake Exhaust Service size Valve seat Width of seat contact Seat angle Service size

Specification

Limit

109.5 mm (4.311 in.) 109.7 mm (4.319 in.) 6.565-6.580 mm (0.2585-0.2591 in.) 6.530-6.550 mm(0.2571-0.2579 in.) 45-45.5o 1.0 mm (0.039 in.) 1.5 mm (0.059 in.) 0.7 mm (0.028 in.) 1.0 mm (0.039 in.)

0.020-0.047 mm (0.0008-0.0019 in.) 0.050-0.085 mm (0.0020-0.0033 in.)

0.10 mm (0.0039 in.) 0.15 mm (0.0059 in.)

45.5 mm (1.791 in.) 50.5 mm (1.988 in.) 0.05, 0.25, 0.50 mm (0.002, 0.010, 0.020 in.) oversize 0.9-1.3 mm (0.035-0.051 in.) 44-44.5o 0.3 mm (0.012 in.), 0.6 mm (0.024 in.) oversizeValve spring Free length Load Out of squareness Cylinder block Cylinder bore Out-of-roundness and taper of cylinder bore Flatness of gasket surface Piston O.D. Piston-to-cylinder clearance Ring groove width No. 1 No. 2 Oil Service size

48.3 mm (1.902 in,) 300 N (66 lb)/40 mm (1.575 in.) Less than 1.5o

47.3 mm (1.862 in.) 4o

82.30-82.33 mm (3.2402-3.2413 in.)[1.6L Eng.] 81.50-81.53 mm...