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Service Manual2005 UNIT REPAIR
Service Manual2005 UNIT REPAIR
Service Manual2005 UNIT REPAIR
Matiz
UNIT REPAIR
Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
2. Remove the bolt and the nuts in the water outlet case .
3. Remove the water outlet case.
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10. Remove the intake manifold retaining bolts and the nuts.
11. Remove the intake manifold with the gasket.
12. Remove the intake manifold studs.
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14. Remove the rocker arm spring and the rocker arm.
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17. Remove the camshaft front oil seal from housing hole.
18. Using the valve spring compressor 0991614510, compress the valve spring
19. Remove the valve keepers.
20. Remove the valve spring retainer and valve spring.
21. Remove the valves.
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24. Position the valve guide remover 0991644910 on the valve guide.
25. Hammer and remove the valve guide from the combustion chamber to the direction of the installed valve spring using the valve guide remover
0991644910.
26. Remove the valve guide.
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Valve Inspection
1. Inspect valve stem tip wear.
2. Inspect the valve keeper grooves and oil seal grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be straight.
6. Inspect the valve facefor grooving. If the groove is so deep the refacing would result in a sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to "Engine Specifications" in this section. If the valve spring height does not match the specifications,
replace the valve spring.
9. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.
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Cleaning Procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil and varnish.
1. Measure the bending of the camshaft using a dial gauge and replace it when the measured value is over the specified limit (0.03mm (0.0012 in.)).
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2. Using a bore gauge, measure the inner diameter of the cylinder head jornal at the 5 places (The clearance of journal is measured by the
difference between the outer diameter of camshaft journal and inner diameter of cylinder head journal part.)
3. Replace the camshaft (or cylinder head, if necessary) of which limit is over the specified limit.
Item Standard Limit
Journal 0.050.091 mm 0.15 mm
Clearance (0.00200.0036 inches) (0.0059 inches)
Item Outer diameter, Inner diameter cylinder head journal part
camshaft journal
a 43.42543.450 mm 43.50043.516 mm
(1.70961.7106 in.) (1.71261.7132 in.)
b 43.62543.650 mm 43.70043.716 mm
(1.71751.7185 in.) (1.72051.7211 in.)
c 43.82543.850 mm 43.90043.916 mm
(1.72541.7264 in.) (1.72831.7290 in.)
d 44.02544.050 mm 44.10044.116 mm
(1.73331.7343 in.) (1.73621.7369 in.)
e 44.22544.250 mm 44.344.316 mm
(1.7411.742 in.) (1.7441.745 in.)
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Clearance Between The Rocker Arm and The Rocker Arm Shaft
1. Check the outer diameter of the rocker arm shaft using a micrometer.
2. Check the inner diameter of the rocker arm using a bore gauge.
3. Replace the shaft or rocker arm (or both of them, if necessary) if the difference is over the limit between the outer diameter and the inner diameter
(0.005 0.040mm (0.0002 0.0016 in.)
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Intake : 5.465 5.480mm (0.2152 0.2157 in.)
Exhaust : 5.440 5.455mm (0.2142 0.2148 in.)
2. Check the inner diameter of the valve guide using a bore gauge (at least 1 place in the direction to valve length)
Intake : 5.500 5.512mm (0.2165 0.2170 in.)
Exhaust : 5.500 5.512mm (0.2165 0.2170 in.)
3. Check the clearance between the valve stem and the valve guide
Intake : 0.020 0.047mm (0.0008 0.0019 in.)
Exhaust : 0.0045 0.072mm (0.0018 0.0028 in.)
4. If a bore gauge is not available, measure the clearance using a dial gauge by moving the edge of the stem to the directions.
Intake : 0.14mm (0.0055 in.)
Exhaust : 0.18mm (0.0071 in.)
5. Replace the valve stem or valve guide, if the measured valve is over the limit.
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Valve
1. Inspect the valve. Refer to Valve Inspection in this section.
2. Check the valve or stem for abrasion, burn or bending, and replace as necessary.
3. Abrasion of the valve edge.
Check the edge of each valve for abrasion. Some uneven abrasion would be made on the edge because the rocker arm gets contacted at
this surface when operating. Repair the section within 0.05mm (0.002 in.) as required, or replace the valve if some modification is required
more than that.
4. Deviation to the rotating direction. Measure the deviation to the rotating direction using a dial gauge and the V block by turning the valve slowly.
Deviation limit of valve head to the rotating direction within 0.08mm (0.0031 in.)
5. Replace valve, if the measured value exceeds the limit.
6. Clean the valve and the valve seat and apply red stamping ink thinly to the contacting surface of the valve seat. Check the fitness after installing
the valve unit.
7. Check the contact witdth on the surface of the valve seat.
Intake : 1.46 1.66mm (0.0575 0.0654 in.)
Exhaust : 1.46 1.66mm (0.0575 0.0654 in.)
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8. Repair by grinding and cutting off the valve seat, and lap it if its contacting width is not even or out of the specified.
9. Upon applying a seat cutter, use the one of smaller angle first and increase the angle of the using cutter up to the light and final modification of the
contact. And finish contact surface and its location with the cutter of 45 degrees.
Important : Upon cutting, take care of the contact width. Finish the cutting with gradually reduced power for no cutting mark on the
surface.
10. Make lapping in two stages, first with normal lap and second with fine one for the both sides.
Assembly Procedure
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1. Make the valve guide hole using a valve guide reamer 0991638210. Before Installing The new valve guide into the cylinder head, ream guide hole
with 11mm reamer to remove burrs. Make sure that the guide hole cones to a complete roundness
Caution : Heat the cylinder head uniformly at a temperature 80100°C (176212°F) not to make the head deformed, and drive new valve
guide completely into the hole with the tools the valve guide installer attachment 0991788220.
3. Check the protruded part of the guide from the cylinder head.
Important : Do not reuse the valve guide once disassembled, replace it with the new oversized valve guide.
4. Repair the valve guide bore with the valve guide reamer 0991637320 (5mm or 0.1969 in.)
5. Make the hole free from foreign material.
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Important : Do not reuse the disassembled oil seal and replace it with new one. When installing it, neer tap or hit tool with a hammer or
else. Install seal to guide only by pushing special tool with hand. Tapping or hitting tool may cause damage on seal.
Important : Before installing it, coat engine oil to the stem seal, valve guide bore and valve stem.
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10. Using the valve spring compressor 0991648210, compress the valve spring
11. Install the valve keepers.
12. Install the camshaft front oil seal from housing hole.
13. Coat the engine oil to the camshaft front oil seal, the cam, and the camshaft journal.
14. Install the camshaft front oil seal to the housing hole.
15. Install the camshaft to the cylinder head.
Notice : Installing the camshaft, take extreme care to prevent any screatch, nick or damage.
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Tighten
Tighten the screws to 10 N•m (89 lbin).
17. Coat the engine oil to the rocker arms and the rocker rocker arm shafts.
18. Install the rocker arm spring and the rocker arm.
Tighten
Tighten the bolts to 10 N•m (89 lbin).
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Important : Rocker arm shaft for the intake valves and the exhaust valves are different and their directions of installation are different.
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Tighten
Tighten the intake manifold nuts and the bolts to 17 N•m (13 lbft).
Tighen the intake manifold supprot bracket bolt to 10 N•m (89 lbin).
Important : Before tightening the intake manifold nuts, first of all, tighten the intake manifold support bracket nut.
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25. Install the exhaust manifold gasket and the exhaust manifold.
26. Install the bolts and nuts in the sequent order as shown in the picture.
Tighten
Tighten the exhaust manifold nuts and bolts to 22 N•m (16 lbft).
Tighten
Tighten the exhaust manifold heat shield bolts to 10 N•m (89 lbin).
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Tighten
Tighen the water outlet case mounting bolts to 10.5 N•m (93 lbin).
31. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
Crankshaft
Tools Required
Disassembly Procedure
1. Removethe engine. Refer to "Engine" in this section.
2. Remove the transaxle from the engine. Refer to Section 5B, FiveSpeed Manual Transaxle.
3. Remove the flywheel bolts.
4. Remove the flywheel.
5. Mount the engine assembly on the engine overhaul stand KM412.
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6. Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this section.
7. Drain the engine oil from the engine.
8. Remove the power steering adjusting bolts.
9. Remove the power steering/air conditioning belt.
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35. Remove the crankshaft rear oil seal housing screws and bolts.
36. Remove the gasket and the oil seal housing.
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Assembly Procedure
1. With crankshaft and bearings in place, plastic gauge all bearing clearances. Refer to "Crankshaft Bearings and Connecting Rod Bearings
Gauging Plastic" in this section.
2. Inspect the crankshaft end play with the crankshaft bearings installed.
3. Check the Permissible crankshaft end play. Refer to "Engine Specifications" in this section.
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4. With the crankshaft mounted on the front and the rear crankshaft bearings, Check the middle crankshaft journal for permissible outofround
(runout). Refer to "Engine Specifications" in this section.
Important : Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread
does not tear when the crankshaft bearing caps are removed.
9. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
10. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
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Notice : Do not reuse the old crankshaft bearing cap bolts. Damage to the engine could result.
Tighten
Tighten the crankshaft bearing cap bolts to 57 N•m (42 lbft).
Important : Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread
does not tear when the connecting rod bearing caps are removed.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod bearing caps.
4. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
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5. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod
bearing.
6. Install the connecting rod bearing caps.
7. Install the connecting rod bearing cap nuts.
Tighten
Tighten the connecting rod bearing cap nuts to 33 N•m (24 lbft).
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Inspection Precedure Piston
1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspec the connecting rod upper end for scoring.
5. Inspect the piston for scoring, cracks and wear.
6. Inspect pistion for taper using a micrometer.
8. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
9. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section.
10. Inspect the engine block cylinder bore for wear, runout ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
11. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.
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Installation Procedure
1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
2. Install the pistion pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the pistion.
5. Install the pistion pin into the pistion and connecting rod assembly.
9. Measure the pistion ring side clearance using a feeler gauge. Refer to "Engine Specifications" in this section.
10. If the pistion ring is too thick, try another pistion ring.
11. If no piston ring can be found that fits to specifications the pistion ring may be ground to size with emery paper placed on a sheet of glass.
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12. Install a piston oil ring, the expander and the second piston oil ring to the bottom ring groove of the pistion.
13. Install the second compression ring to the middle ring groove of the piston.
14. Install the top compression ring to the top ring groove of the pistion.
15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of
the pistion.
17. Lubricate the cylinder wall and the pistion rings with clean engine oil.
18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
19. Install the connecting rod cap and the bearing. Refer to "Crankshaft Bearings and Connecting Rod Bearings Gauging Plastic" in this section.
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Tighten
Tighten the connecting rod bearing cap nuts to 33 N•m (24 lbft).
Tighten
Tighten the oil pump pickup tube bolts to 10 N•m (89 lbin).
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24. Install the oil pan bolts and nuts.
Tighten
Tighten the oil pan bolts and nuts to 10 N•m (89 lbin).
25. Install the lower engine mount bracket and the generator with the bolts
Tighten
Tighten the lower engine mount bracket bolts to 38 N•m (28 lbft).
26. Install the upper engine mount bracket and the generator shackle with the bolts.
Tighten
Tighten the upper engine mount bracket and generator shackle bolts to 38 N•m (28 lbft).
27. Install the generator with the bolts and the nut.
28. Install the generator belt.
Tighten
Tighten the generator lower bolts and the nut to 23 N•m (17 lbft).
Tighten the generator belt tension adjusting bolt to 23 N•m (17 lbft).
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Tighten
Tighten the engime mount bracket bolts to 20 N•m (15 lbft).
Tighten the A/C compressor/Power steering Pump bracket bolts to 38 N•m (28 lbft).
31. Install the power steering pump bracket with the bracket bolt/nut and adjusting bolt.
Tighten
Tighten the adjusting bolt and the power steering rear bracket nut to 22 N•m (16 lbft).
36. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
37. Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.
38. Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual Control Hearing, Ventilation, and Air Conditioning System.
39. Refill the transaxle oil as necessary.
40. Connect the negative battery cable.
41. Start the engine and operate all systems.
42. Operate the idle air contril valve reset procedure as necessary.
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