ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-1

SECTION 6A1

ENGINE MECHANICAL 6A1

(G13 AND G16 TYPE ENGINE)

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” un-
der “General Description” in air bag system section in order to confirm whether you are perform-
ing service on or near the air bag system components or wiring. Please observe all WARNINGS
and “Service Precautions” under “On-Vehicle Service” in air bag system section before perform-
ing service on or around the air bag system components or wiring. Failure to follow WARNINGS
could result in unintentional activation of the system or could render the system inoperative. Ei-
ther of these two conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to
the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the sys-
tem may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

NOTE:
Whether the following systems (parts) are used in the particular vehicle or not depends on specifica-
tions.
Be sure to bear this in mind when performing service work.
EGR control system
EVAP canister, EVAP canister purge valve and vacuum hose
Heated oxygen sensor
Three way catalytic converter

CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . 6A1- 2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A1-26
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A1- 5 Rocker Arms, Rocker Arm Shaft and
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . . 6A1- 5 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A1-31
Compression Check . . . . . . . . . . . . . . . . . . . . 6A1- 5 Valves and Cylinder Head . . . . . . . . . . . . . . . 6A1-37
Engine Vacuum Check . . . . . . . . . . . . . . . . . . 6A1- 6 Piston, Piston Rings, Connecting Rods and
Oil Pressure Check . . . . . . . . . . . . . . . . . . . . 6A1- 7 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A1-49
Valve Lash (Clearance) . . . . . . . . . . . . . . . . . 6A1- 8 UNIT REPAIR OVERHAUL . . . . . . . . . . . . . . . . 6A1-59
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6A1-10 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . 6A1-59
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . 6A1-10 Main Bearings, Crankshaft and
Air Cleaner Outlet Hose . . . . . . . . . . . . . . . . . 6A1-10 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . 6A1-64
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . 6A1-11 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6A1-77
Throttle Body and Intake Manifold . . . . . . . . 6A1-12
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . 6A1-15 REQUIRED SERVICE MATERIALS . . . . . . . . 6A1-78
Timing Belt and Belt Tensioner . . . . . . . . . . . 6A1-17 RECOMMENDED TORQUE
Oil Pan and Oil Pump Strainer . . . . . . . . . . . 6A1-23 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 6A1-79
6A1-2 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

GENERAL DESCRIPTION
ENGINE
The engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its S.O.H.C. (Single
Overhead Camshaft) valve mechanism arranged for “V”-type valve configuration and 16 valves (IN 2 and EX
2/one cylinder).
The single overhead camshaft is mounted over the cylinder head: it is driven from crankshaft through timing belt
and opens and closes its valves via the rocker arms.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-3

ENGINE LUBRICATION
The oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side.
Oil is drawn up through oil pump strainer and passed through pump to oil filter.
The filtered oil flows into two paths in cylinder block.
In one path, oil reaches crankshaft journal bearings.
Oil from crankshaft journal bearings is supplied to connecting rod bearings by means of intersecting passages
drilled in crankshaft, and then injected from a small hole provided on big end of connecting rod to lubricate piston,
rings, and cylinder wall.
In another path, oil goes up to cylinder head and lubricates camshaft journals, rocker arms, camshaft, etc., passing
through oil gallery in rocker arm shaft.
An oil relief valve is provided on oil pump. This valve starts relieving oil pressure when the pressure comes over
about 400 kPa (4.0 kg/cm2, 56.9 psi). Relieved oil drains back to oil pan.
6A1-4 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

CYLINDER BLOCK
The cylinder block is made of cast aluminum alloy and This allows a gradual change in thrust pressure against
has 4 cylinders arranged “In-Line”. A cylindrical cast the cylinder wall as the piston travels its path.
iron sleeve is installed in each cylinder. Pins, made of chromium steel, have a floating fit in the
pistons and in the connecting rods. The connecting
CRANKSHAFT AND MAIN BEAR- rods are made of forged steel, and the rod bearings are
INGS of precision insert type.

A monoblock casting crankshaft is supported by 5 main

bearings which are of precision insert type. Four crank CYLINDER HEAD AND VALVE TRAIN
pins on the crankshaft are positioned 180 apart. The cylinder head is made of aluminum casting. The
supporting part of the camshaft is an independent cap
PISTONS, RINGS, PISTON PINS AND type. The combustion chamber has 4 valves and uses
CONNECTING RODS the center plug type pent roof shape for higher intake
and exhaust efficiency.
The piston is cast aluminum alloy, and has two com-
As the intake side rocker arm is end pivot type, it swings
pression rings and one oil ring.
according to the camshaft movement to open and close
Among two compression rings (top and 2nd rings), the
the intake valve.
outer surface of the top ring is treated with nitriding for
On the other hand, the exhaust side rocker arm is see-
improvement in abrasion resistance.
saw type. It swings with the rocker arm shaft as its sup-
The oil ring consists of two rails and one spacer. The
porting point and according to the camshaft movement
piston pin is offset 0.5 mm towards the major thrust
to open and close the exhaust valve.
side.

1. Rocker arm shaft 5. Rocker arm (IN)

2. Rocker arm (EX) 6. Camshaft
3. Intake valve 7. Clip
4. Exhaust valve 8. Pivot
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-5

DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 6.

COMPRESSION CHECK
Check compression pressure on all four cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.
NOTE:
After warming up engine, place transmission gear shift le-
ver in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake and block drive wheels.

3) Disconnect ignition coil coupler.

WARNING:
Failure in disconnecting couplers from ignition coil
assemblies can cause spark to occur in engine room
possibly resulting in a dangerous explosion.

4) Disconnect high-tension cord from ignition coil assembly.

1. Ignition coil bolt
5) Remove ignition coil bolt, and then pull out ignition coil assem-
2. Ignition coil assembly 3. High tension cord bly.

6) Remove all spark plugs and disconnect fuel injector wire har-
ness at couplers.
7) Install special tool (Compression gauge) into spark plug hole.
Special Tool
(A): 09915-64510-001
(B): 09915-64510-002
(C): 09915-64530
(D): 09915-67010
1. Fuel injector coupler
6A1-6 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

8) Disengage clutch (to lighten starting load on engine) for M/T

model, and depress accelerator pedal all the way to make
throttle valve full-open.
9) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
NOTE:
For measuring compression pressure, crank engine at
least 250 r/min. by using fully charged battery.
Compression pressure
1400 kPa
Standard
(14.0 kg/cm2, 199.0 psi)
1100 kPa
Limit
(11.0 kg/cm2, 156.4 psi)
Max. difference between any 100 kPa
two cylinders (1.0 kg/cm 2, 14.2 psi)
10) Carry out steps 5) through 7) on each cylinder to obtain four
readings.
11) After checking, connect couplers to ignition coil assembly and
fuel injectors securely and install spark plugs.

ENGINE VACUUM CHECK

The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows:
1) Warm up engine to normal operating temperature.

2) With engine stopped, disconnect MAP sensor hose from intake

manifold and connect 3-way joint, hoses and special tool (vacu-
um gauge and joint) between intake manifold and MAP sensor
hose disconnected.
Special Tool
(A): 09367-04002
(B): 09355-35754-6010
(C): 09915-67310
1. MAP sensor (D): 09918-08210

3) Run engine at specified idle speed (see section 6E1), and read
vacuum gauge. Vacuum should be within the following specifi-
cation.
Vacuum specification: 52.6 – 65.8 kPa (40 – 50 cm·Hg,
15.7 – 19.7 in·Hg) at specified
idling speed
4) After checking, connect vacuum hoses.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-7

OIL PRESSURE CHECK

NOTE:
Prior to checking oil pressure, check the followings.
Oil level in oil pan.
If oil level is low, add oil up to Full level hole on oil level
gauge.
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.
Oil leaks.
1. Engine under If leak is found, repair it.
cover (RH)
1) Remove engine under cover of right side from body.
2) Remove oil pressure switch from cylinder block.

2. Oil pressure switch

3) Install special tool (Oil pressure gauge) to vacated threaded

hole.
Special Tool
(A): 09915-77310
(B): 09915-78211
4) Start engine and warm it up to normal operating temperature.
5) After warming up, raise engine speed to 4,000 r/min. and mea-
sure oil pressure.
Oil pressure specifications: 330 – 430 kPa (3.3 – 4.3
kg/cm2, 46.9 – 61.1 psi)
at 4,000 r/min. (rpm)
6) After checking oil pressure, stop engine and remove oil pres-
sure gauge.

7) Before reinstalling oil pressure switch, be sure to wrap its screw

threads with a sealing tape and tighten switch to specified
torque.
NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.
Tightening Torque
(a): 14 N·m (1.4 kg-m, 10.5 lb-ft)
1. Oil pressure switch
6A1-8 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

8) After installing oil pressure switch, start engine and check oil
pressure switch for oil leakage.
9) Install right side of engine under cover to body.

VALVE LASH (CLEARANCE)

1) Remove negative cable at battery.
2) Remove cylinder head cover referring to item “Cylinder Head
Cover” in this section.
3) Remove right side of engine under cover from body.
4) Open air cleaner upper case and shift case and hose position
to observe “V” mark on crankshaft pulley.
5) Using 17 mm socket, turn crankshaft pulley clockwise until “V”
mark (in white paint) on pulley aligns with “0” (zero) calibrated
1. “v” mark on pulley 2. Air cleaner case
on timing belt cover.
6) Remove CMP sensor and check camshaft rotor gear position.
If it is positioned as shown in figure (i.e. No.1 piston is at TDC
of compression stroke), check valve lashes at valves (1), (2), (5)
and (7).
If it isn’t positioned as shown in figure (i.e. it isn’t shown in the
hole for CMP sensor), check valve lashes at valves (3), (4), (6)
and (8).
NOTE:
When checking valve clearance, insert thickness gauge
1. Hole for CMP sensor between camshaft and cam-riding face of rocker arm.
2. Camshaft rotor gear
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-9

7) If valve lash is out of specification, adjust it to specification by

turning adjusting screw after loosening lock nut. After adjust-
ment, tighten lock nut to specified torque while holding adjusting
screw stationary, and then make sure again that valve lash is
within specification.
When cold When hot
(Coolant temperature (Coolant temperature
Valve is 15 – 25 C or is 60 – 68 C or
clearance 59 – 77 F) 140 – 154 F)
specifica- 0.13 – 0.17 mm 0.17 – 0.21 mm
Intake
tion (0.005 – 0.007 in) (0.007 – 0.008 in)
0.23 – 0.27 mm 0.27 – 0.31 mm
Exhaust
(0.009 – 0.011 in) (0.011 – 0.012 in)

(A): 09917-18211
Tightening Torque
(a): 12 N·m (1.2 kg-m, 9.0 lb-ft)

1. Thickness gauge

8) After checking and adjusting valve lashes at valves (1), (2), (5)
and (7), (or (3), (4), (6) and(8)) rotate crankshaft exactly one full
turn (360 ) and check the same at valves (3), (4), (6) and (8) (or
(1), (2), (5) and (7)). Adjust them as necessary.
9) After checking and adjusting all valves, reverse removal proce-
dure for installation.
6A1-10 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

ON-VEHICLE SERVICE
AIR CLEANER ELEMENT
This air cleaner element is of dry type. Remember that it needs
cleaning according to the following procedure.
REMOVAL
1) Remove air cleaner upper case from lower case after unhook-
ing clamps from upper case.
1. Air cleaner upper case 2. Clamp
2) Remove air cleaner element.
INSPECTION
Check air cleaner element for dirt.

CLEANING
Blow off dust by compressed air from air outlet side of element.

INSTALLATION
1) Install air cleaner element to its lower case.
2) Install air cleaner upper case.
Hook clamps securely.

1. Air cleaner upper case 2. Clamp

AIR CLEANER OUTLET HOSE

REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect breather hose from air cleaner outlet hose.
3) Disconnect IAT sensor wire at coupler.
4) Remove air cleaner outlet hose after loosening its clamps.

1. Air cleaner outlet hose 3. IAT sensor

2. Clamp 4. Breather pipe

INSTALLATION
Reverse removal procedure for installation.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-11

CYLINDER HEAD COVER

REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect breather hose and PCV valve from head cover.
3) Remove ignition coil assemblies with high-tension cord.
1. Cylinder head 4) Remove cylinder head cover with cylinder head cover gasket
cover and O-rings.
2. Cylinder head
cover gasket
3. O-rings

INSTALLATION
1) Install O-rings and cylinder head cover gasket to cylinder head
cover.
NOTE:
Be sure to check each of these parts for deterioration or
1. Cylinder head
any damage before installation and replace if found defec-
cover tive.
2. Cylinder head
cover gasket
3. O-ring

2) Install cylinder head cover to cylinder head and tighten cover

bolts to specified torque.
Tightening Torque
(a): 11 N.m (1.1 kg-m, 8.0 lb-ft)
NOTE:
When installing cylinder head cover, use care so that cylin-
der head cover gasket or O-rings will not get out of place
or fall off.

3) Install ignition coil assemblies with high-tension cord.

4) Connect PCV valve and breather hose to head cover.
5) Connect negative cable at battery.

1. Ignition coil bolt 3. High-tension cord

2. Ignition coil assembly
6A1-12 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

THROTTLE BODY AND INTAKE MANIFOLD

1. Intake manifold 6. Fuel pressure regulator

2. Throttle body 7. EVAP canister purge valve
3. Gasket 8. MAP sensor
4. Fuel delivery pipe 9. Intake manifold stiffener
5. Fuel injector 10. EGR valve

REMOVAL
1) Relieve fuel pressure according to procedure described in Sec-
tion 6.
2) Disconnect negative cable at battery.

3) Drain cooling system.

WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
1. Drain plug
2. Radiator
3. A / T fluid hose (A / T only)

4) Disconnect accelerator cable from throttle body.

 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-13

5) Disconnect the following electric lead wires and release clamp:

Ground wires from intake manifold and throttle body
TP sensor
IAC valve
Fuel injectors
EVAP canister purge valve (if equipped)
MAP sensor
EGR valve (if equipped)

6) Disconnect the following hoses:

Brake booster hose from intake manifold
Canister purge hose from EVAP canister purge valve
Engine cooling water (coolant) hoses from IAC valve and in-
take manifold
PCV hose

7) Disconnect fuel feed hose from pipe and return hose from fuel
pressure regulator.

1. Fuel feed hose 3. Fuel pressure regulator

2. Fuel return hose

8) Remove intake manifold rear stiffener bolt, generator adjust

arm reinforcement bolt and right mounting bracket stiffener bolt
from intake manifold.

1. Intake manifold rear stiffener

2. Generator adjust arm reinforcement
3. Right mounting bracket stiffener

9) Remove intake manifold with throttle body from cylinder head,

and then its gasket.

1. Intake manifold gasket

6A1-14 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

INSTALLATION
Reverse removal procedure for installation noting the followings.
Use new intake manifold gasket.
When installing intake manifold, install clamps at positions as
they were.
Tightening Torque
(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)

Adjust accelerator cable play, referring to Section 6E1.

Adjust A /T throttle pressure control cable play, referring to Sec-
tion 7B.
Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
Refill cooling system, referring to “ENGINE COOLING” section.
Upon completion of installation, turn ignition switch ON but en-
gine OFF and check for fuel leaks.
Finally, start engine and check for engine coolant leaks.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-15

EXHAUST MANIFOLD

1. Exhaust manifold
2. Engine hook
3. Exhaust manifold cover
4. Oxygen sensor (if equipped)
5. Exhaust manifold gasket
6. Exhaust No.1 pipe gasket
7. Exhaust No.1 pipe
8. Exhaust manifold stiffener
9. Exhaust manifold lower cover

WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.

REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect exhaust No.1 pipe from exhaust manifold.

1. Exhaust No.1 pipe

3) Disconnect oxygen sensor coupler and release its clamps (if

equipped).
4) Remove exhaust manifold covers.

1. Exhaust manifold
cover 3. Oxygen sensor coupler
2. Clamp (if equipped)
6A1-16 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

5) Remove exhaust manifold and its gasket from cylinder head.

6) Remove exhaust pipe gasket from exhaust No.1 pipe.

1. Exhaust manifold

INSTALLATION
1) Install new gaskets to cylinder head and exhaust No.1 pipe.
2) Install exhaust manifold.
Tighten manifold bolts and nuts to specified torque.
Tightening Torque
(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)

1. Manifold nut

3) Install exhaust manifold covers.

4) Connect oxygen sensor coupler and clamp its wire securely.

1. Exhaust manifold cover 3. Oxygen sensor

2. Clamp coupler

5) Connect exhaust No.1 pipe to exhaust manifold.

Tightening Torque
(a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Connect negative cable at battery.
7) Check exhaust system for exhaust gas leakage.

1. Exhaust No.1 pipe

 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-17

TIMING BELT AND BELT TENSIONER

1. Timing belt
2. Tensioner
3. Tensioner plate
4. Tensioner spring
5. Camshaft timing pulley
6. Tensioner bolt
7. Pulley bolt
8. Seal
9. Inside cover seal
10. Inside cover
11. Outside cover seal
12. Outside cover
13. Tensioner stud
14. Dowel pin
15. Crankshaft pulley

REMOVAL
1) Disconnect negative cable at battery.
2) Remove right side of engine under cover.
3) Remove A/C compressor, P/S pump and drive belt with hoses
still attached, if equipped.
NOTE:
Suspend removed A/C compressor and P/S pump at a
place where no damage will be caused during removal and
1. Engine under cover (RH) installation of timing belt and belt tensioner.

4) Support engine by using lifting device.

5) Remove air cleaner case with air cleaner outlet hose.
6) Remove engine right mounting bracket and stiffener.

1. Engine right mounting bracket

2. Engine right mounting bracket stiffener

7) Remove water pump pulley and drive belt.

1. Water
pump
pulley
6A1-18 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

8) Remove crankshaft pulley by removing 5 pulley bolts.

1. Pulley bolt

9) Release harness clamps.

10) Remove timing belt outside cover.

11) For installation of timing belt, align 4 timing marks as shown in

figure by turning crankshaft.

1. “V” mark on cylinder

head cover
2. Timing mark by “E”
on camshaft timing
belt pulley
3. Arrow mark on oil
pump case
4. Punch mark on
crankshaft timing belt
pulley

12) Remove timing belt tensioner, tensioner plate, tensioner

spring and timing belt.

1. Timing belt 4. Tensioner

2. Tensioner plate stud
3. Tensioner bolt 5. Spring
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-19

CAUTION:
After timing belt is removed, never turn camshaft and
crankshaft independently more than such an extent as
shown in figure. If turned, interference may occur
among piston and valves, and parts related to piston
and valves may be damaged.
Never bend timing belt.

1. Camshaft allowable turning range – – – By timing mark,

within 90 from “V” mark on head cover on both right and
left.
2. Crankshaft allowable turning range – – – By punch mark,
within 90 from arrow mark on oil pump case on both
right and left.

INSPECTION
Inspect timing belt for wear or crack.
Replace it as necessary.

Inspect tensioner for smooth rotation.

INSTALLATION
1) Install tensioner plate to tensioner. Insert lug of tensioner plate
into hole in tensioner.

1. Lug
2. Hole
6A1-20 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

2) Install tensioner and tensioner plate:

Do not tighten tensioner bolt with wrench yet. Hand tighten only
at this time.
Check to ensure that plate movement in arrow direction as
shown in figure causes tensioner to move in the same direction.
If no associated movement between plate and tensioner oc-
curs, remove tensioner and plate again and reinsert plate lug
into tensioner hole.
1. Tensioner bolt 3. Tensioner plate
2. Tensioner

3) Check that timing mark on camshaft timing belt pulley is aligned

with “V” mark on cylinder head cover. If not, align two marks by
turning camshaft but be careful not to turn it more than its allow-
able turning range which is described on previous page.

1. “V” mark
2. Timing mark
by “E”

4) Check that punch mark on crankshaft timing belt pulley is

aligned with arrow mark on oil pump case. If not, align two marks
by turning crankshaft but be careful not to turn it more than its
allowable turning range which is described on previous page.

1. Arrow mark
2. Punch mark

5) Install timing belt and tensioner spring.

With two sets of marks aligned and tensioner plate pushed up,
install timing belt on two pulleys in such a way that drive side of
belt is free from any slack.
And then install tensioner spring as shown in figure, and hand-
tighten tensioner stud.
NOTE:
When installing timing belt, match arrow mark ( ) on
timing belt with rotating direction of crankshaft.
In this state, No.4 piston is at top dead center of com-
pression stroke.

1. Drive side of belt

2. Tensioner spring
3. Tensioner stud
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-21

6) To take up slack of timing belt, turn crankshaft two rotations

clockwise after installing it. After making sure that belt is free
from slack, tighten tensioner stud first and then tensioner bolt
to each specified torque. Then confirm again that two sets of
marks are aligned respectively.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
(b): 25 N·m (2.5 kg-m, 18.0 lb-ft)

7) Install timing belt outside cover.

Before installing, make sure that seal is between water pump
and oil pump case.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

8) Install crankshaft pulley.

Fit pin hole of pulley to dowel pin on crank timing belt pulley,
and tighten pulley bolts to specified torque.
Tightening Torque
(a): 16 N·m (1.6 kg-m, 11.5 lb-ft)

1. Dowel pin (crankshaft pulley pin)

2. Crankshaft pulley 3. Pulley bolt

9) Clamp harness securely.

10) Install water pump pulley and drive belt.

Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

1. Water
pump
pulley
6A1-22 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

11) Install engine right mounting bracket and stiffener.

Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
12) Install air cleaner case with air cleaner outer pipe.
13) Remove lifting device.

1. Engine right mounting bracket

2. Engine right mounting bracket stiffener.

14) Install A/C compressor and P/S pump.

15) Adjust drive belt tension, referring to Section 6B.
16) Adjust power steering pump belt tension or A/C compressor
belt tension, if equipped.
Refer to Section 0B.
17) Connect negative cable at battery.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-23

OIL PAN AND OIL PUMP STRAINER

1. Oil pan
2. Oil pump strainer
3. O-ring
4. CKP sensor
5. Drain plug gasket
6. Drain plug

REMOVAL
1) Raise vehicle.
2) Drain engine oil by removing drain plug.
3) Remove CKP sensor from oil pan.

1. Drain plug

4) Remove engine under covers (2WD only)

5) Remove exhaust No.1 pipe.
6) Remove transmission stiffener.
7) Support engine and transmission. (2WD only)
8) Remove mounting member. (2WD only)

9) Remove oil pan and then oil pump stainer.

2. O-ring
1. Oil pump stainer 3. Oil pan
6A1-24 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

CLEANING
Clean mating surface of oil pan and cylinder block. Remove oil,
old sealant, and dusts from mating surfaces and oil pan inside.
Clean oil pump strainer screen.
CKP sensor, inside of oil pan and oil pump strainer screen.

INSTALLATION
1) Apply sealant to oil pan mating surface continuously as shown
in figure.
“A” Sealant: 99000-31150
Width “a” : 3 mm, 0.15 in.
Height “b” : 2 mm, 0.1 in.

1. Oil pump strainer 2) Install oil pump strainer and oil pan.
2. O-ring
3. Oil pan
Install O-ring into cylinder block securely as shown in figure.
With oil pump strainer inserted into oil pan, install stainer to cyl-
inder block.
Tighten strainer bolt first and then bracket bolt to specified
torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
After fitting oil pan to cylinder block, run in securing bolts and
start tightening at the center: move wrench outward, tightening
one bolt at a time.
Tighten bolts to specified torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

3) Install gasket and drain plug to oil pan.

Tighten drain plug to specified torque.
Tightening Torque
(a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
4) Check to make sure that CKP sensor and pulley tooth is free from
any metal particles and damage, install CKP sensor to oil pan.
Tightening Torque
10 N·m (1.0 kg-m, 7.5 lb-ft)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-25

5) Install mounting member. (2WD only)

Tighten bolts and nut to specified torque.

Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
(b): 45 N·m (4.5 kg-m, 32.5 lb-ft)
6) Remove lifting device. (2WD only)

1. Mounting member
2. Engine front torque bush
3. Engine rear mounting
4. Body

7) Install transmission stiffener.

Tightening Torque
(a): 50 N·m (5.0 kg-m, 36.5 lb-ft)

1. Transmission stiffener
2. Transmission 3. Cylinder block

8) Install exhaust No.1 pipe.

Tighten bolts to specified torque.
Tightening Torque
(a): 50 N·m (5.0 kg-m, 36.5 lb-ft)
(b): 43 N·m (4.3 kg-m, 31.5 lb-ft)
NOTE:
Use new gasket for exhaust No.1 pipe.
9) Install engine under covers.
10) Refill engine with engine oil, referring to item “ENGINE OIL
CHANGE” in Section 0B.

1. Exhaust No. 1 pipe

6A1-26 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

OIL PUMP

1. Rotor plate 6. Pin

2. Inner rotor 7. Relief valve
3. Outer rotor 8. Spring
4. Gasket 9. Retainer
5. Pin 10. Retainer ring

REMOVAL
1) Disconnect negative cable at battery.
2) Remove timing belt as previously outlined.
3) Remove generator and its bracket.
NOTE:
When installing bracket, tighten nut (A) first.

4) Remove power steering pump bracket or A/C compressor

bracket, if equipped.

1. Mounting member 5) Remove oil pan and oil pump strainer as previously outlined.
2. Engine front torque bush
3. Engine rear mounting 6) Install mounting member (2WD only).
4. Body
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
(b): 45 N·m (4.5 kg-m, 32.5 lb-ft)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-27

7) Remove crankshaft timing belt pulley and timing belt guide.

With crankshaft locked, remove crankshaft timing belt pulley
bolt.

1. Flat head rod

2. Pulley bolt
3. Timing belt guide
4. Crank timing belt pulley

8) Remove oil pump assembly after removing bolts.

1. Oil pump
2. Bolt

1. Oil pump DISASSEMBLY

2. Oil level gauge
guide 1) Remove oil level gauge guide bolt and pull out guide from oil
3. Guide bolt pump.
4. O-ring

2) Remove rotor plate.

1. Rotor plate

3) Remove outer rotor and inner rotor.

1. Outer rotor
2. Inner rotor
6A1-28 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

INSPECTION
Check oil seal lip for fault or other damage. Replace as neces-
sary.

NOTE:
When installing oil seal, press-fit it till its end face is flush with
oil pump case end face.

1. Oil seal
2. Oil pump case

Check outer and inner rotors, rotor plate, and oil pump case for
excessive wear or damage.

1. Outer rotor MEASUREMENT

2. Inner rotor
Radial clearance
Check radial clearance between outer rotor and case, using
thickness gauge.
If clearance exceeds its limit, replace outer rotor or case.
Limit on radial clearance between outer rotor and case:
0.310 mm (0.0122 in.)

Side clearance
Using straight edge and thickness gauge, measure side clear-
ance.
Limit on side clearance: 0.15 mm (0.0059 in.)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-29

ASSEMBLY
1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip
portion, and inside surfaces of oil pump case and plate.
3) Install outer and inner rotors to pump case.

1. Outer rotor
2. Inner rotor

4) Install rotor plate. Tighten 5 screw securely.

After installing plate, check to be sure that gears turn smoothly
by hand.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

1. Oil pump 5) Apply engine oil to O-ring and install O-ring and guide.
2. Oil level gauge
guide
3. O-ring

INSTALLATION
1) Install two oil pump pins and oil pump gasket to cylinder block.
Use a new gasket.
2) To prevent oil seal lip from being damaged or upturned when
installing oil pump to crankshaft, fit special tool (Oil seal guide)
to crankshaft, and apply engine oil to special tool.
Special Tool
(A): 09926-18210

1. No.1 bolts (short) 3) Install oil pump to cylinder block.

2. No.2 bolts (long)
As there are 2 types of oil pump bolts, refer to figure for their cor-
rect use and tighten them to specified torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
6A1-30 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

4) Install rubber seal between oil pump and water pump.

5) Install timing belt guide, key, and crank timing belt pulley. Refer
to figure for proper installation of these parts. Install timing belt
guide in such a way that its concave side faces oil pump.
With crankshaft locked, tighten crank timing belt pulley bolt to
specified torque.
Tightening Torque
(a): 130 N·m (13.0 kg-m, 94.0 lb-ft)
1. Timing belt guide
2. Key
3. Crank timing belt pulley
4. Pulley bolt

5. Flat head rod

6) Support engine and remove mounting member. (2WD only)

7) Install timing belt, tensioner, oil pump strainer, oil pan and oth-
er parts as previously outlined.
8) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
9) Adjust water pump drive belt tension, referring to Section 6B.
10) Adjust power steering pump belt tension or A/C compressor
belt tension, if equipped.
Refer to SECTION 0B.
11) Refill engine with engine oil, referring to item “ENGINE OIL
CHANGE” in SECTION 0B.
12) Connect negative cable at battery
13) After completing installation, check oil pressure by running en-
gine.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-31

ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT

1. Camshaft
2. Camshaft oil seal
3. Rocker arm shaft
4. O-ring
5. Rocker shaft bolt
6. Rocker arm (IN)
7. Rocker arm No.1 (EX)
8. Rocker arm No.2 (EX)
9. Valve adjusting screw
10. Valve adjusting screw
11. Clip
12. Lock nut
13. Rocker arm spring
14. Intake valve
15. Exhaust valve
16. Valve spring
17. Valve spring retainer
18. Valve cotter
19. Valve spring seat
20. Valve stem seal

REMOVAL
1) Disconnect negative cable at battery.

2) Remove timing belt as previously outlined and remove cam-

shaft timing belt pulley by using special tool.
Special Tool
(A): 09917-68221
3) Remove cylinder head cover as previously outlined.

1. Camshaft pulley
6A1-32 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

4) Disconnect CMP sensor coupler from CMP sensor.

5) Disconnect high tension cords and couplers from ignition coil
assemblies and then remove ignition coil assembly of exhaust
manifold side.
Remove CMP sensor case from cylinder head.
Place a container or rag under CMP sensor case, for a small
amount of oil flows out during removal of case.

1. CMP sensor case

2. Ignition coil assembly

6) After loosening all valve adjusting screw lock nuts, turn adjust-
ing screws back all the way to allow all rocker arms to move free-
ly.

1. Valve adjusting screw

2. Lock nut
3. Rocker arm

7) Remove camshaft housing and camshaft.

NOTE:
To remove camshaft housing bolts, loosen them in such or-
der as indicated in figure, a little at a time.

1. Oil gallery plug 8) Remove timing belt inside cover.

2. Timing belt
inside cover

9) Remove intake rocker arm with clip from rocker arm shaft.
NOTE:
Do not bend clip when removing intake rocker arm.

1. Rocker arm (IN)

2. Clip
3. Rocker arm shaft
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-33

10) Remove rocker arm shaft bolts.

1. Rocker arm shaft bolt

2. Rocker arm shaft

11) Push off rocker arm shaft end to ignition coils side and remove
O-ring from shaft.

1. Rocker arm spring 2. Rocker arm (EX)

12) Remove exhaust rocker arms and rocker arm spring by pulling
out rocker arm shaft to battery side after removing battery.

1. Rocker arm (EX)

2. Rocker arm spring

INSPECTION
Cam Wear
Using a micrometer, measured height of cam. If measured height
is below limit, replace camshaft.

Cam height Standard Limit

36.184 – 36.344 mm 36.084 mm
Intake cam
(1.4246 – 1.4308 in.) (1.4207 in.)
35.900 – 36.060 mm 35.800 mm
Exhaust cam
(1.4134 – 1.4196 in.) (1.4095 in.)
6A1-34 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

INSTALLATION
1) Apply engine oil to rocker arm shaft and rocker arms.
2) Install rocker arm shaft, rocker arm (exhaust side) and rocker
arm spring.

1. Rocker arm spring 2. Rocker arm (EX)

1. Rocker arm shaft 3) Check O-ring for damage or deterioration. With O-ring groove
2. O-ring
in rocker arm shaft exposed to transmission side once, Install
O-ring to rocker arm shaft.

1. Parallel 4) Set rocker arm shaft so that its cut part faces down and be-
comes in parallel with head cover mating surface.

5) Install rocker arm shaft bolts and tighten them to specified

torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

6) Fill small amount of engine oil into arm pivot holding part of rock-
er arm shaft. Install rocker arm (intake side) with clips to rocker
arm shaft.

1. Rocker arm
2. Clip
3. Pivot holding part
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-35

7) Apply engine oil to cams and journals on camshaft and put cam-
shaft on cylinder head. Install camshaft housing to camshaft
and cylinder head.
Apply engine oil to sliding surface of each housing against
camshaft journal.
Apply sealant to mating surface of No.6 housing which will
mate with cylinder head.
1. Timing belt side “A”: Sealant 99000-31110
2. Flywheel side

Embossed marks are provided on each camshaft housing,

indicating position and direction for installation.
Install housing as indicated by these marks.
As camshaft housing No. 1 retains camshaft in proper posi-
1. Indicates position from timing
tion as to thrust direction, make sure to first fit No. 1 housing
belt side. Install in numerical to No. 1 journal of camshaft securely.
order starting from timing belt
side.
2. Indicates direction of housing.
Install so that arrow is directed
toward timing belt side.

After applying engine oil to housing bolts, tighten them tempo-

rarily first. Then tighten them by the following sequence as indi-
cated in figure.
Tighten a little at a time and evenly among bolts and repeat tight-
ening sequence three to four times before they are tightened to
specified torque.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)

8) Install camshaft oil seal.

After applying engine oil to oil seal lip, press-fit camshaft oil seal
till oil seal surface becomes flush with housing surface.

1. Camshaft oil seal

9) Install timing belt inside cover.

6A1-36 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

10) Install camshaft timing belt pulley to camshaft while fitting pin
on camshaft into slot at “E” mark.

1. Camshaft timing belt pulley 2. Dwell pin

11) Using special tool, tighten pulley bolt to specified torque.

Tightening Torque
(a): 60 N·m (6.0 kg-m, 43.5 lb-ft)
Special Tool
(A): 09917-68221
12) Install belt tensioner, timing belt, outside cover, crankshaft
pulley and water pump belt as previously outlined.

13) After applying sealant to part “A” as shown in figure, install

CMP sensor case (Distributorless ignition coil case) to cylinder
head and tighten its fixing bolts to specified torque.
“A” Sealant: 99000-31110
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
Install ignition coil assembly to CMP sensor case.
1. O-ring

14) Adjust valve clearance as previously outlined.

15) Install cylinder head cover and air cleaner outlet hose.
16) Check to ensure that the following parts are back in place:
high tension cords
CMP sensor coupler
Couplers to ignition coil assembly
Other removed parts which have not been reinstalled
17) Connect negative cable at battery.
18) Confirm that ignition timing is within specification referring to
Section 6F3.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-37

VALVES AND CYLINDER HEAD

1. Valve cotters
2. Valve spring retainer
3. Valve spring
4. Valve stem seal
5. Valve spring seat
6. Exhaust valve
7. Intake valve

REMOVAL
1) Relieve fuel pressure according to procedure described in
“FUEL PRESSURE RELIEF PROCEDURE” of Section 6.
2) Disconnect negative cable at battery.

3) Drain cooling system.

4) Remove air cleaner outlet hose as previously outlined.

1. Drain plug 3. A/T fluid hose

2. Radiator (A/T only)

5) Remove intake manifold rear stiffener bolt, generator adjust

arm reinforcement bolt and right mounting bracket stiffener bolt
from intake manifold.

1. Intake manifold rear stiffener

2. Generator adjust arm reinforcement bolt
3. Right mounting bracket stiffener
6A1-38 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

6) Disconnect exhaust No.1 pipe from exhaust manifold.

1. Exhaust No.1 pipe

7) Disconnect the following electric wires:

Ignition coil
ECT sensor
Ground wire from intake manifold
EGR valve (if equipped)
Injectors
TP sensor
IAC valve
Oxygen sensor (if equipped)
EVAP canister purge valve (if equipped)
and then release above wire harnesses from clamps.

8) Disconnect the following vacuum hoses:

EVAP canister purge hose from canister purge valve (if
equipped)
Brake booster hose from intake manifold

9) Disconnect fuel feed hose from feed pipe and disconnect fuel
return hose from fuel pressure regulator.

1. Fuel feed hose

2. Fuel return hose 3. Fuel pressure regulator

10) Remove cylinder head cover as previously outlined.

Loosen all valve lash adjusting screws fully.
11) Disconnect the following engine cooling water (coolant)
hoses.
Radiator inlet hose
Heater inlet hose
IAC valve outlet hose
1. Cylinder head cover
2. Gasket
3. O-ring
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-39

12) Remove timing belt and camshaft as previously outlined.

13) Loosen cylinder head bolts in such order as indicated in figure

and remove them.
Special Tool
(A): 09900-00415
(B): 09900-00411
14) Check all around cylinder head for any other parts required to
be removed or disconnected and remove or disconnect what-
“1”: Camshaft pulley side ever necessary.
“2”: Distributor side

15) Remove cylinder head with intake manifold, exhaust manifold

and distributor, using lifting device.
6A1-40 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

DISASSEMBLY
1) For ease in servicing cylinder head, remove CMP sensor case,
intake manifold with throttle body and exhaust manifold from
cylinder head.
2) Remove camshaft as previously outlined and remove rocker
arms and washers by pulling its shaft out to transmission side.
3) Using special tool (Valve lifter), compress valve springs and
then remove valve cotters by using special tool (Forceps) as
shown.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511
4) Release special tool, and remove spring retainer and valve
spring.
5) Remove valve from combustion chamber side.

1. Valve cotters

6) Remove valve stem oil seal from valve guide, and then valve
spring seat.
NOTE:
Do not reuse oil seal once disassembled. Be sure to use
new oil seal when assembling.

1. Valve stem oil seal

2. Valve spring seat

7) Using special tool (Valve guide remover), drive valve guide out
from combustion chamber side to valve spring side.
Special Tool
(A): 09916-44910
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.
8) Place disassembled parts except valve stem seal and valve
guide in order, so that they can be installed in their original posi-
tion.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-41

INSPECTION
Valve Guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance.
Be sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.

Item Standard Limit

5.465 – 5.480 mm
In –
Valve stem (0.2152 – 0.2157 in.)
diameter 5.440 – 5.455 mm
Ex –
(0.2142 – 0.2148 in.)
Valve guide
g In 5.500 – 5.512 mm
–
I.D. Ex (0.2166 – 0.2170 in.)
0.020 – 0.047 mm 0.07 mm
In
Stem-to-guide (0.0008 – 0.0018 in.) (0.0027 in.)
clearance 0.045 – 0.072 mm 0.09 mm
Ex
(0.0018 – 0.0028 in.) (0.0035 in.)

If bore gauge is not available, check end deflection of valve stem

with a dial gauge instead.
Move stem end in directions A and B to measure end deflection.
If deflection exceeds its limit, replace valve stem and valve guide.

Valve stem end deflection In 0.14 mm (0.005 in.)

limit Ex 0.18 mm (0.007 in.)

Valves
Remove all carbon from valves.
Inspect each valve for wear, burn or distortion at its face and
stem and, as necessary, replace it.
Measure thickness of valve head. If measured thickness ex-
ceeds limit, replace valve.
Valve head thickness
Standard Limit
IN 0.8 – 1.2 mm 0.6 mm (0.024 in.)
EX (0.03 – 0.047 in.) 0.7 mm (0.027 in.)

1. Valve head thickness

2. 45
6A1-42 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

Inspect valve stem end face for pitting and wear. If pitting or wear
is found there, valve stem end may be resurfaced, but not so
much as to grind off its chamfer. When it is worn so much that
its chamfer is gone, replace valve.

Seating contact width:

Create contact pattern on each valve in the usual manner, i.e.,
by giving uniform coat of marking compound to valve seat and
by rotatingly tapping seat with valve head. Valve lapper (tool
used in valve lapping) must be used.

Pattern produced on seating face of valve must be a continuous

ring without any break, and the width of pattern must be within
specified range.

Standard seating width In

1.1 – 1.3 mm
revealed by contact pattern
Ex (0.0433 – 0.0512 in.)
on valve face

Valve seat repair:

A valve seat not producing a uniform contact with its valve
or showing width of seating contact that is out of specified range
must be repaired by regrinding or by cutting and
regrinding and finished by lapping.
1. EXHAUST VALVE SEAT: Use valve seat cutters to make two
cuts as illustrated in figure. Two cutters must be used: the first
for making 15 angle, and the second for making 45 angle.
The second cut must be made to produce desired seat width.
Seat width for exhaust valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)

1. Valve seat cutter

 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-43

2. INTAKE VALVE SEAT: Cutting sequence is the same as for ex-

haust valve seats.
Seat width for intake valve seat:
1.1 – 1.3 mm (0.0433 – 0.0512 in.)
3. VALVE LAPPING: Lap valve on seat in two steps, first with
coarse size lapping compound applied to face and the second
with fine-size compound, each time using valve lapper accord-
ing to usual lapping method.
1. Valve seat

Cylinder Head
Remove all carbon from combustion chambers.
NOTE:
Do not use any sharp-edged tool to scrape off carbon. Be
careful not to scuff or nick metal surfaces when decarbon-
ing. The same applies to valves and valve seats, too.

Check cylinder head for cracks in intake and exhaust ports, com-
bustion chambers, and head surface.

Flatness of gasketed surface:

Using a straightedge and thickness gauge, check surface at a
total of 6 locations. If distortion limit, given below, is exceeded,
correct gasketed surface with a surface plate and abrasive pa-
per of about #400 (Waterproof silicon carbide abrasive paper):
place paper on and over surface plate, and rub gasketed surface
against paper to grind off high spots. Should this fail to reduce
thickness gauge readings to within limit, replace cylinder head.
Leakage of combustion gases from this gasketed joint is often
due to warped gasketed surface: such leakage results in re-
duced power output.
Limit of distortion: 0.05 mm (0.002 in.)
6A1-44 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

Distortion of manifold seating faces:

Check seating faces of cylinder head for manifolds, using a
straightedge and thickness gauge, in order to determine wheth-
er these faces should be corrected or cylinder head replaced.
Limit of distortion: 0.10 mm (0.004 in.)

Valve Springs
Referring to data given below, check to be sure that each spring
is in sound condition, free of any evidence of breakage or weak-
ening. Remember, weakened valve springs can cause chatter,
not to mention possibility of reducing power output due to gas
leakage caused by decreased seating pressure.

Item Standard Limit

Valve spring free 36.83 mm 35.67 mm
length (1.4500 in.) (1.4043 in.)
10.7 – 12.5 kg for 9.3 kg for
Valve spring 31.5 mm 31.5 mm
preload (23.6 – 27.5 lb/ (20.5 lb/
1.24 in.) 1.24 in.)

Spring squareness:
Use a square and surface plate to check each spring for square-
ness in terms of clearance between end of valve spring and
square. Valve springs found to exhibit a larger clearance than
limit given below must be replaced.
Valve spring squareness limit: 2.0 mm (0.079 in.)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-45

ASSEMBLY
1) Before installing valve guide into cylinder head, ream guide hole
with special tool (11 mm reamer) so remove burrs and make it
truly round.
Special Tool
(A): 09916-34542
(B): 09916-38210
2) Install valve guide to cylinder head.
Heat cylinder head uniformly at a temperature of 80 to 100 C
(176 to 212 F) so that head will not be distorted, and drive new
valve guide into hole with special tools. Drive in new valve guide
until special tool (Valve guide installer) contacts cylinder head.
After installing, make sure that valve guide protrudes by 11.5
mm (0.45 in.) from cylinder head.
Special Tool
(C): 09916-56011
(D): 09916-58210
NOTE:
Do not reuse valve guide once disassembled.
Install new valve guide (Oversize).
Intake and exhaust valve guides are identical.
Valve guide oversize: 0.03 mm (0.0012 in.)
Valve guide protrusion (In and Ex): 11.5 mm (0.45 in.)

1. Valve guide protrusion (11.5 mm)

3) Ream valve guide bore with special tool (5.5 mm reamer).

After reaming, clean bore.
Special Tool
(A): 09916-34542
(B): 09916-34550

4) Install valve spring seat to cylinder head.

6A1-46 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

5) Install new valve stem seal to valve guide.

After applying engine oil to seal and spindle of special tool
(Valve guide installer handle), fit oil seal to spindle, and then
install seal to valve guide by pushing special tool by hand.
After installing, check to be sure that seal is properly fixed to
valve guide.
Special Tool
(A): 09917-98221
(B): 09916-58210
NOTE:
Do not reuse seal once disassembled. Be sure to install
new seal.
When installing, never tap or hit special tool with a ham-
mer or else. Install seal to guide only by pushing special
tool by hand. Tapping or hitting special tool may cause
damage to seal.

1. Valve stem seal

6) Install valve to valve guide.

Before installing valve to valve guide, apply engine oil to stem
seal, valve guide bore, and valve stem.

1. Large-pitch 7) Install valve spring and spring retainer.

2. Small-pitch
3. Valve spring retainer
Each valve spring has top end (large-pitch end) and bottom end
side (small-pitch end). Be sure to position spring in place with its bot-
4. Valve spring seat
side tom end (small-pitch end) facing the bottom (valve spring seat
side).

8) Using special tools (Valve lifter), compress valve spring and fit
two valve cotters into groove in valve stem.
Special Tool
(A): 09916-14510
(B): 09916-14910
(C): 09916-84511

1. Valve cotters
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-47

9) Install rocker arms, washers, rocker arm shaft and camshaft

as previously outlined.
10) Install CMP sensor case, intake manifold and exhaust man-
ifold.

INSTALLATION
1) Remove oil gasket and oil on mating surfaces and install new
head gasket as shown in figure, that is, “TOP” mark provided on
gasket comes to crankshaft pulley side, facing up (toward cylin-
der head side).

1. Cylinder head gasket

2. Crankshaft pulley side
3. Flywheel side

2) Check to make sure that oil jet (venturi plug) is installed and if
it is, that it is not clogged.
When installing it, be sure to tighten to specified torque.
Tightening Torque
(a): 3.5 N·m (0.35 kg-m, 2.5 lb-ft)

3) Apply engine oil to cylinder head bolts and tighten them gradu-
ally as follows.
a) Tighten all bolts to 35 N·m (3.5 kg-m, 25.0 lb-ft) according to
numerical order in figure.
b) In the same manner as in 1), tighten them to 55 N·m
(5.5 kg-m, 40.0 lb-ft).
c) In the same manner as in 1) again, tighten them to specified
torque.
Tightening Torque
(a): 68 N·m (6.8 kg-m, 49.5 lb-ft)
Special Tool
(A): 09900-00415
(B): 09900-00411

“1”: Camshaft pulley side

“2”: Distributor side
6A1-48 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

4) Reverse removal procedure for installation.

5) Adjust drive belt tension, referring to Section 6B.
6) Adjust power steering pump belt tension or A/C compressor
belt tension, if equipped.
Refer to Section 0B.
7) Adjust intake and exhaust valve lashes as previously outlined.
8) Adjust accelerator cable play. Refer to Section 6E1.
9) Adjust A/T throttle pressure control cable play. Refer to Sec-
tion 7B (3 A/T).
10) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
11) Refill cooling system referring to Section 6B.
12) Connect negative cable at battery.
13) Adjust ignition timing referring to Section 6F.
14) Verify that there is no fuel leakage, water leakage and exhaust
gas leakage at each connection.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-49

PISTON, PISTON RINGS, CONNECTING

RODS AND CYLINDERS

6. Connecting rod
1. Top ring bearing cap
2. 2nd ring 7. Connecting rod
3. Oil ring bearing
4. Piston 8. Piston pin
5. Connecting rod 9. Piston pin circlip

REMOVAL
1) Remove cylinder head from cylinder block as previously out-
lined.
2) Install engine right mounting bracket.
3) Drain engine oil.
4) Remove oil pan and oil pump strainer as previously outlined.
5) Mark cylinder number on all pistons, connecting rods and rod
bearing caps, using silver pencil or quick drying paint.

6) Remove rod bearing caps.

7) Install guide hose over threads of rod bolts.
This is to prevent damage to bearing journal and rod bolt
threads when removing connecting rod.
8) Decarbon top of cylinder bore before removing piston from cyl-
inder.
9) Push piston and connecting rod assembly out through the top
of cylinder bore.
1. Guide hoses
6A1-50 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

DISASSEMBLY
1) Using piston ring expander, remove two compression rings (Top
and 2nd) and oil ring from piston.

2) Remove piston pin from connecting rod.

Ease out piston pin circlips, as shown.

1. Piston pin circlip

Force piston pin out.

CLEANING
Clean carbon from piston head and ring grooves, using a suitable
tool.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-51

INSPECTION
Cylinders
Inspect cylinder walls for scratches, roughness, or ridges which
indicate excessive wear. If cylinder bore is very rough or deeply
scratched, or ridged, rebore cylinder and use oversize piston.

Using a cylinder gauge, measure cylinder bore in thrust and ax-

ial directions at two positions as shown in figure.
If any of the following conditions is noted, rebore cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper
limit.
3) Difference between thrust and axial measurements exceeds
out-of-round limit.
1. 50 mm (1.96 in.)
2. 95 mm (3.74 in.) Cylinder bore dia. limit (1.3 liter) : 74.15 mm (2.9196 in.)
Cylinder bore dia. limit (1.6 liter) : 75.15 mm (2.9586 in.)
Tapper and out-of-round limit : 0.10 mm (0.0039 in.)
NOTE:
If any one of four cylinders has to be rebored, rebore all
four to the same next oversize. This is necessary for the
sake of uniformity and balance.

Pistons
Inspect piston for faults, cracks or other damaged. Damaged or
faulty piston should be replaced.
Piston diameter:
As indicated in figure, piston diameter should be measured at a
position 23 mm (0.91 in.) from piston skirt end in the direction
perpendicular to piston pin.
Piston diameter
Engine 74.970 – 74.990 mm
Standard
displacement (2.9516 – 2.9523 in.)
73.970 – 73.990 mm
Standard
(2.9122 – 2.9130 in.)
Oversize: 74.220 – 74.230 mm
1.3 Liter
0.25 mm (0.0098 in.) (2.9220 – 2.9224 in.)
74.470 – 74.480 mm
0.50 mm (0.0196 in.)
(2.9319 – 2.9323 in.)
74.970 – 74.990 mm
Standard
(2.9516 – 2.9523 in.)
Oversize: 75.220 – 75.230 mm
1.6 Liter
0.25 mm (0.0098 in.) (2.9614 – 2.9618 in.)
1. 23 mm (0.91 in.) 75.470 – 75.480 mm
0.50 mm (0.0196 in.)
(2.9712 – 2.9716 in.)
6A1-52 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

Piston clearance:
Measure cylinder bore diameter and piston diameter to find their
difference which is piston clearance. Piston clearance should be
within specification as given below. If it is out of specification, re-
bore cylinder and use oversize piston.
Piston clearance: 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
NOTE:
Cylinder bore diameters used here are measured in thrust
direction at two positions.

1. 23 mm (0.91 in.)

Ring groove clearance:

Before checking, piston grooves must be clean, dry and free of
carbon.
Fit new piston ring into piston groove, and measure clearance
between ring and ring land by using thickness gauge. If clear-
ance is out of specification, replace piston.
Ring groove clearance:
1. Piston ring Top: 0.03 – 0.07 mm (0.0012 – 0.0027 in.)
2. Thickness gauge 2nd: 0.02 – 0.06 mm (0.0008 – 0.0023 in.)

Piston Pin
Check piston pin, connecting rod small end bore and piston bore
for wear or damage, paying particular attention to condition of
small end bore bush. If pin, connecting rod small end bore or pis-
ton bore is badly worn or damaged, replace pin, connecting rod
or piston.
Piston pin clearance:
Check piston pin clearance in small end. Replace connecting
rod if its small end is badly worn or damaged or if measured
clearance exceeds limit.
Item Standard Limit
Piston clearance in 0.003 – 0.016 0.05 mm
small end (0.0001 – 0.0006 in.) (0.0020 in.)

Small-end bore:
19.003 – 19.011 mm (0.7482 – 0.7486 in.)
Piston pin dia.:
18.995 – 19.000 mm (0.7479 – 0.7480 in.)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-53

Piston Rings
To measure end gap, insert piston ring into cylinder bore and then
measure the gap by using thickness gauge.
If measured gap is out of specification, replace ring.
NOTE:
Decarbon and clean top of cylinder bore before inserting pis-
ton ring.

Item Standard Limit

0.2 – 0.35 mm 0.7 mm
Top ring
(0.0079 – 0.0137 in.) (0.0275 in.)
Piston
0.2 – 0.35 mm 0.7 mm
ring end 2nd ring
(0.0079 – 0.0137 in.) (0.0275 in.)
gap
ga
0.2 – 0.7 mm 1.7 mm
Oil ring
(0.0079 – 0.0275 in.) (0.0669 in.)

1. Cylinder block
2. Feeler gauge
3. Piston ring
4. 120 mm (4.72 in.)

Connecting Rod
Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod
fitted and connected to its crank pin in the normal manner. If
measured clearance is found to exceed its limit, replace con-
necting rod.

Item Standard Limit

Big-end side 0.10 – 0.20 mm 0.35 mm
clearance (0.0039 – 0.0078 in.) (0.0137 in.)
Connecting rod alignment:
Mount connecting rod on aligner to check it for bow and twist
and, if limit is exceeded, replace it.
Limit on bow : 0.05 mm (0.0020 in.)
Limit on twist: 0.10 mm (0.0039 in.)
6A1-54 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

Crank Pin and Connecting Rod Bearings

Inspect crank pin for uneven wear or damage. Measure crank
pin for out-of-round or taper with a micrometer. If crank pin is
damaged, or out-of-round or taper is out of limit, replace crank-
shaft or regrind crank pin to undersize and use undersize bear-
ing.

Engine dis- Connecting rod

Crank pin diameter
placement bearing size
41.982 – 42.000 mm
Standard
1.3 liter (1.6528 – 1.6535 in.)
engine 0.25 mm (0.0098 in.) 41.732 – 41.750 mm
undersize (1.6430 – 1.6437 in.)
43.982 – 44.000 mm
Standard
1.6 liter (1.7316 – 1.7322 in.)
engine 0.25 mm (0.0098 in.) 43.732 – 43.750 mm
undersize (1.7218 – 1.7224 in.)

Out-of-round and taper limit: 0.01 mm (0.0004 in.)

Rod bearing:
Inspect bearing shells for signs of fusion, pitting, burn or flaking
and observe contact pattern. Bearing shells found in defective
condition must be replaced.
Two kinds of rod bearing are available; standard size bearing
and 0.25 mm undersize bearing. To distinguish them,
0.25 mm undersize bearing has the stamped number (US025)
on its backside as indicated in figure, but standard size one has
no number.

Rod bearing clearance;

1) Before checking bearing clearance, clean bearing and crank
pin.
2) Install bearing in connecting rod and bearing cap.
3) Place a piece of gaging plastic to full width of crank-pin as
contacted by bearing (parallel to crankshaft), avoiding oil
hole.

1. Gaging plastic

4) Install rod bearing cap to connecting rod.

When installing cap, be sure to point arrow mark on cap to
crankshaft pulley side, as shown in figure. After applying engine
oil to rod bolts, tighten cap nuts to specified torque. DO NOT
turn crankshaft with gaging plastic installed.
Tightening Torque
(a): 35 N·m (3.5 kg-m, 25.5 lb-ft)
1. Rod bearing cap
2. Arrow mark 3. Crankshaft pulley side
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-55

5) Remove cap and using a scale on gaging plastic envelope,

measure gaging plastic width at the widest point (clearance).
If clearance exceeds its limit, use a new standard size bearing
and remeasure clearance.
Item Standard Limit
Bearing 0.020 – 0.050 mm 0.0080 mm
clearance (0.0008 – 0.0019 in.) (0.0031 in.)

6) If clearance can not be brought to within its limit even by using

a new standard size bearing, regrind crankpin to undersize and
use 0.25 mm undersize bearing.

1. Gaging plastic
2. Scale

ASSEMBLY
NOTE:
Two sizes of piston are available as standard size spare part
so as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has stamped number 1 or 2 as shown. It represents
outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder
block as shown. The first number represents inner diameter of
No.1 cylinder, the second number of No.2 cylinder, the third
number of No.3 cylinder and the fourth number of No.4 cylinder.
6A1-56 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

C) Stamped number on piston and that on cylinder block should

correspond. That is, install number 2 stamped piston to cylinder
which is identified with number 2 and a number 1 piston to cylin-
der with number 1.
Unit: mm (in.)
Piston Cylinder
Engine Piston to
Piston-to-
Number
displace- Number cylinder
at the top Outer diameter Bore diameter
ment (mark) clearance
(mark)

73.98 – 73.99 74.01 – 74.02

1 1
(2.9126 – 2.9130) (2.9138 – 2.9142)
1 3 liter
1.3
73.97 – 73.98 74.00 – 74.01
2 2 0.02 – 0.04
(2.9122 – 2.9126) (2.9134 – 2.9138)
(0 0008 –
(0.0008
74.98 – 74.99 75.01 – 75.02 0.0015)
1 1
(2.9520 – 2.9524) (2.9531 – 2.9535)
1 6 liter
1.6
74.97 – 74.98 75.00 – 75.01
2 2
(2.9516 – 2.9520) (2.9528 – 2.9531)

Also, a letter A, B or C is stamped on piston head but ordinarily

it is not necessary to discriminate each piston by this letter

1) Install piston pin to piston and connecting rod:

After applying engine oil to piston pin and piston pin holes in pis-
ton and connecting rod, fit connecting rod to piston as shown in
figure and insert piston pin to piston and connecting rod, and
install piston pin circlips.
1. Piston
2. Arrow mark
3. Connecting rod
NOTE:
4. Oil hole Circlip should be installed with its cut part facing either up
The oil hole should or down as shown in figure.
come on intake side

2) Install piston rings to piston:

As indicated in figure, 1st and 2nd rings have “RN”, “T” or “R”
mark respectively. When installing these piston rings to piston,
direct marked side of each ring toward top of piston.
1st ring differs from 2nd ring in thickness, shape and color of sur-
face contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
1. 1st ring When installing oil ring, install spacer first and then two rails.
2. 2nd ring
3. Oil seal

3) After installing three rings (1st, 2nd and oil rings), distribute their
end gaps as shown in figure.
1. Arrow mark
2. 1st ring end
gap
3. 2nd ring end
gap and oil ring
spacer gap
4. Oil ring upper
rail gap
5. Oil ring lower
rail gap
6. Intake side
7.Exhaust side
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-57

INSTALLATION OR CONNECTION
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod
bearings and crankpins.
NOTE:
Do not apply oil between connecting rod and bearing or be-
tween bearing cap and bearing.

2) Install guide hoses over connecting rod bolts.

These guide hoses protect crankpin and threads of rod bolt from
damage during installation of connecting rod and piston assem-
bly.

3) When Installing piston and connecting rod assembly into cylin-

der bore, point arrow mark on piston head to crankshaft pulley
side.

1. Crankshaft pulley side

2. Flywheel side

4) Install piston and connecting rod assembly into cylinder bore.

Use special tool (Piston ring compressor) to compress rings.
Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until all
piston rings have entered cylinder bore.
Special Tool
(A): 09916-77310

5) Install bearing cap:

Point arrow mark on cap to crankshaft pulley side.
Tighten cap nuts to specification.
Tightening Torque
(a): 35 N·m (3.5 kg-m, 25.5 lb-ft)

1. Rod bearing cap

2. Arrow mark 3. Crankshaft pulley side
6A1-58 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

6) Reverse removal procedure for installation, as previously out-

lined.
7) Adjust water pump drive belt tension, referring to Section 6B.
8) Adjust power steering pump belt tension or A/C compressor
belt tension, if equipped.
Refer to Section 0B.
9) Adjust accelerator cable play. Refer to Section 6E1.
10) Adjust A/T throttle pressure control cable play. Refer to Sec-
tion 7B (3 A/T).
11) Check to ensure that all removed parts are back in place. Rein-
stall any necessary parts which have not been reinstalled.
12) Refill engine with engine oil, referring to item “ENGINE OIL
CHANGE” in Section 0B.
13) Refill cooling system referring to Section 6B.
14) Connect negative cable at battery.
15) Check ignition timing and adjust as necessary, referring to
Section 6F.
16) Verify that there is no fuel leakage, coolant leakage, oil leak-
age and exhaust gas leakage at each connection.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-59

UNIT REPAIR OVERHAUL

ENGINE ASSEMBLY
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.

4) Drain cooling system

WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
1. Drain plug
2. Radiator 5) Remove radiator with cooling fan. Refer to Section 6B.
3. A / T fluid hose (A / T only)

6) Remove cleaner outlet hose as previously outlined.

7) Remove air cleaner case by removing its fastening bolts.

8) Disconnect the following cables.

Accelerator cable from throttle body.
A/T throttle pressure control cable from A/ T (3 A/ T).
Clutch cable from transmission (M /T).
Gear select cable from transmission (A /T).
Shift and select cable from transmission (4WD).

9) Disconnect the following vacuum hose.

Brake booster hose from intake manifold.
Canister purge hose from EVAP canister purge valve.
(if equipped)

1. Canister purge
hose (if equipped)
2. Brake booster
hose
6A1-60 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

10) Disconnect the following electric wires:

Ignition coil assembly
Ground wires from intake manifold and throttle body
Engine oil pressure switch
EGR valve (if equipped)
EVAP canister purge valve (if equipped)
Engine coolant temp. sensor
Fuel injectors
Power steering pressure switch (if equipped)
Oxygen sensor (if equipped)
Back-up light switch (M /T)
Transmission range switch (A /T)
Forward clutch revolution sensor (4 A/ T)
A/T vehicle speed sensor (A /T)
Generator
Starter
Battery negative cable from transmission
Vehicle speed sensor
TP sensor
IAC valve
MAP sensor
CMP sensor
CKP sensor
and release above wire harnesses from clamps.

11) Remove clutch operating cylinder from transmission with hose

still attached (M /T).
NOTE:
Suspend removed clutch operating cylinder at a place
where no damage will be caused during removal and
installation of engine assembly.

12) Disconnect fuel feed hose from feed pipe and return hose from
fuel pressure regulator.
13) Disconnect heater inlet and outlet hoses (if equipped).

1. Fuel feed hose 3. Fuel pressure regulator

2. Fuel return hose

14) Remove right and left engine under covers.

15) Remove jacking front panel (4WD).
16) Remove exhaust No.1 pipe.
17) Remove gear shift control shaft from transmission remove ex-
tension rod (2WD with M /T).
18) Drain engine and transmission oil.

1. Exhaust No.1 pipe

 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-61

19) Remove propeller shaft No.1 from transmission case flange

referring to Section 4B.

1. Propeller shaft No.1 pipe

20) Remove drive shaft joints from differential gear of transmis-

sion.
Refer to Section 4 or 4A (DRIVE SHAFT) for procedure to dis-
connect drive shaft joint.
For engine and transmission removal, it is not necessary to re-
move drive shafts from steering knuckle.

21) Remove A/ C compressor from compressor bracket with hose

still attached. (if equipped)
NOTE:
Suspend removed compressor at a place where no dam-
age will be caused during removal and installation of en-
gine assembly.
22) Disconnect P /S hose from P /S oil pump and remove high
pressure hose clamp from bracket. (if equipped)
NOTE:
Plug pipe, hose and pump port.
23) Install lifting device.
24) Remove mounting member from front member and suspen-
sion frame (2WD).
25) Remove suspension frame from body with stabilizer bar at-
tached (4WD).
26) Remove engine left mounting from body.
27) Remove engine right mounting from right mounting bracket
and stiffener.

1. Mounting member Front side

2. Left mounting 1. Sedan & WAGON
3. Right mounting A. 3 A / T
4. To front member B. 4 A / T
5. Suspension frame C. M / T
6. To body
7. Right mounting bracket
8. Right mounting bracket stiffener
6A1-62 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

28) Before removing engine with transmission from body, recheck

to make sure all hoses, electric wires and cables are discon-
nected from engine and transmission.
29) Lower engine with transmission from body.

INSTALLATION
1) Lift engine with transmission into engine compartment, but do
not remove lifting device.
2) Install engine right mounting to right mounting bracket and
stiffener.
3) Install engine left mounting to body.
4) Install mounting member to front member and suspension
frame (2WD).
5) Install suspension frame with stabilizer bar to body, referring
to Section 3D (4WD).
6) Tighten bolts and nuts of all parts installed in above steps 2),
3) and 4) or 5) to specified torque.
Tightening Torque
(a): 55 N·m (5.5 kg-m 40.0 lb-ft)
(b): 45 N·m (4.5 kg-m, 32.5 lb-ft)
(c): 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Remove lifting device.
8) Reverse removal procedures for installation of remainder.
Push in each drive shaft joint fully so that snap ring engages
with differential gear or center bearing support.
Use care not to damage oil seal lip when inserting.
Clamp electric wire securely.
Install propeller shaft to transmission case flange referring
to Section 4B (4WD).

1. Mounting member 6. To body

2. Left mounting 7. Right mounting
3. Right mounting bracket
4. To front member 8. Right mounting
5. Suspension frame bracket stiffener
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-63

9) Adjust clutch pedal free travel, referring to Section 7C.

(2WD with M/T)
Adjust gear select cable and oil pressure control cable,
referring to Section 7B or 7B1. (A/T)
10) Adjust gear shift control lever, referring to Section 7A.
(2WD with M/T)
11) Adjust gear shift control cable, referring to Section 7A1.
(4WD)
12) Refill transmission with gear oil. (A/T fluid for A/T model), refer-
ring to Section 0B.
13) Refill engine with engine oil, referring to Section 0B.
14) Refill cooling system, referring to Section 6B.
15) Adjust A/C compressor and/or P/S pump drive belt, referring
to Section 0B. (if equipped)
16) Check P/S fluid level, referring to Section 3B1. (if equipped)
17) Upon completion of installation, verify that there is no fuel leak-
age, coolant leakage, transmission oil leakage or exhaust gas
leakage at each connection.
18) Adjust accelerator cable play, referring to Section 6E1.
19) Adjust throttle pressure control cable play, referring to Section
7B (3 A/T).
6A1-64 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK

1. Cylinder block 7. Crankshaft 12. Oil seal housing

2. Front oil seal 8. Thrust bearing 13. Housing bolt
3. Main bearing 9. Rear oil seal 14. Input shaft bearing
4. Bearing cap 10. Pin 15. Flywheel
5. Cap bolt 11. Oil seal housing 16. Flywheel bolt
6. Timing pulley key gasket
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-65

REMOVAL
1) Remove engine assembly from body as previously outlined.
2) Remove clutch cover, clutch disc and flywheel (drive plate for
A/T).
Special Tool
(A): 09924-17810

1. Flywheel bolt

3) Remove crankshaft pulley, timing belt and crankshaft timing

pulley.
4) Remove cylinder head assembly.
5) Remove oil pan and oil pump strainer.
6) Remove oil pump.

1. Oil pump
2. Bolt

7) Remove oil seal housing.

8) Remove connecting rod bearing caps.

9) Loosen crankshaft bearing cap bolts in such order as indicated

in figure a little at a time and remove bearing caps.
10) Remove crankshaft from cylinder block.
6A1-66 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

INSPECTION
Crankshaft
Crankshaft runout
Using a dial gauge, measure runout at center journal. Rotate
crankshaft slowly. If runout exceeds its limit, replace crankshaft.
Limit on runout: 0.06 mm (0.0023 in.)

Crankshaft thrust play

Measure this play with crankshaft set in cylinder block in the normal
manner, that is, with thrust bearing and journal bearing caps
installed.

1. Thrust bearing

Use a dial gauge to read displacement in axial (thrust) direction of

crankshaft.
If its limit is exceeded, replace thrust bearing with new standard
one or oversize one to obtain standard thrust play.

Item Standard Limit

Crankshaft thrust 0.11 – 0.31 mm 0.38 mm
play (0.0044 – 0.0122 in.) (0.0149 in.)

2.500 mm
Standard
Thickness of crankshaft (0.0984 in.)
thrust bearing 0.125 mm 2.563 mm
Oversize:
(0.0049 in.) (0.1009 in.)

Out-of-round and taper (uneven wear) of journals

An unevenly worn crankshaft journal shows up as a difference in
diameter at a cross section or along its length (or both). This differ-
ence, if any, is determined by taking micrometer readings.
If any one of journals is badly damaged or if amount of uneven wear
in the sense explained above exceeds its limit, regrind or replace
crankshaft.
Limit on out-of-round and taper: 0.01 mm (0.0004 in.)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-67

Main Bearings
General information
Service main bearings are available in standard size and 0.25
mm (0.0098 in.) undersize, and each of them has 5 kinds of
bearings differing in tolerance.
Upper half of bearing has oil groove as shown in figure. Install
1. Cylinder block
this half with oil groove to cylinder block.
2. Upper half of
bearing
3. Oil groove

On each main bearing cap, arrow mark and number are em-
bossed as shown in figure.
When installing each bearing cap to cylinder block, point arrow
mark toward crankshaft pulley side and install each cap from
that side to flywheel side in ascending order of numbers “1”, “2”,
“3”, “4” and “5”. Tighten cap bolts to specified torque.

Inspection
Check bearings for pitting, scratches, wear or damage. If any mal-
condition is found, replace both upper and lower halves. Never re-
place one half without replacing the other half.

Main bearing clearance

Check clearance by using gaging plastic according to following
procedure.
1) Remove bearing caps.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (parallel
to crankshaft) on journal, avoiding oil hole.

1. Gaging plastic

4) Install bearing cap as previously outlined and evenly torque cap

bolts to specified torque.
Bearing cap MUST be torqued to specification in order to as-
sure proper reading of clearance.
Tightening Torque
(a): 54 N·m (5.4 kg-m, 39.0 lb-ft)
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
6A1-68 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

5) Remove cap and using scale on gaging plastic envelope, mea-

sure gaging plastic width at its widest point. If clearance ex-
ceeds its limit, replace bearing. Always replace both upper and
lower inserts as a unit.
A new standard bearing may produce proper clearance. If not,
it will be necessary to regrind crankshaft journal for use of 0.25
mm undersize bearing.
After selecting new bearing, recheck clearance.

Standard Limit
0.020 – 0.040 mm 0.060 mm
1.3L
(0.0008 – 0.0016 in.) (0.0023 in.)
Bearing clearance
0.016 – 0.036 mm 0.060 mm
1.6L
(0.0006 – 0.0014 in.) (0.0023 in.)

1. Gaging plastic
2. Scale

Selection of main bearings

STANDARD BEARING:
If bearing is in malcondition, or bearing clearance is out of specifi-
cation, select a new standard bearing according to the following
procedure and install it
1) First check journal diameter by using the following procedure.
As shown in figure, crank webs of No.2 and No.3 cylinders have
five stamped numerals.
Three kinds of numerals (“1”, “2” and “3”) represent the follow-
ing journal diameters
Engine Numeral
Journal diameter
displacement stamped
44.994 – 45.000 mm
1
(1.7714 – 1.7716 in.)
44.988 – 44.994 mm
1.3 liter 2
(1.7712 – 1.7714 in.)
44.982 – 44.988 mm
3
(1.7709 – 1.7712 in.)
51.994 – 52.000 mm
1
(2.0470 – 2.0472 in.)
51.988 – 51.994 mm
1.6 liter 2
(2.0468 – 2.0470 in.)
51.982 – 51.988 mm
3
(2.0465 – 2.0468 in.)

The first, second, third, fourth and fifth (left to right) stamped nu-
merals represent journal diameters at bearing caps “1”, “2”, “3”,
“4” and “5” respectively. For example, in figure, the first (left-
most) numeral “3” indicates that journal dia. at bearing cap “1”
is within 44.982 – 44.988 (for 1.3 liter engine) or 51.982 – 51.988
mm (for 1.6 liter engine), and second one “1” indicates that jour-
nal dia. at cap “2” is within 44.994 – 45.000 mm (for 1.3 liter en-
1. Crank webs of No.2 and No.3 cylinders
gine) or 51.994 – 52.000 mm (for 1.6 liter engine)
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-69

2) Next, check bearing cap bore diameter without bearing. On

mating surface of cylinder block, four alphabets are stamped as
shown in figure.
Three kinds of alphabets (“A”, “B” and “C”) represent the follow-
ing cap bore diameters.
Engine Numeral
Journal diameter
displacement stamped
49.000 – 49.006 mm
A
(1.9291 – 1.9294 in.)
49.006 – 49.012 mm
1.3 liter B
(1.9294 – 1.9296 in.)
49.012 – 49.018 mm
C
(1.9296 – 1.9298 in.)
56.000 – 56.006 mm
A
(2.2047 – 2.2050 in.)
56.006 – 56.012 mm
1.6 liter B
(2.2050 – 2.2052 in.)
56.012 – 56.018 mm
C
(2.2052 – 2.2054 in.)

The first, second, third, fourth and fifth (left to right) stamped al-
phabets represent cap bore diameters of bearing caps “1”, “2”,
“3”, “4” and “5”, respectively. For example, in figure, the first (left-
most) alphabet “B” indicates that cap bore dia. of bearing cap
“1” is within 49.006 – 49.012 mm (1.3 liter engine) or 56.006-
56.012 mm (1.6 liter engine), and the fifth (rightmost) alphabet
“A” indicates that cap bore dia. of cap “5” is within 49.000 –
49.006 mm (1.3 liter engine) or 56.000-56.006 mm (1.6 liter en-
gine).
6A1-70 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

3) There are five kinds of standard bearings differing in thickness.

To distinguish them, they are painted in the following colors at
the position as indicated in figure Each color indicates the fol-
lowing thickness at the center of bearing.
1.3 liter
Color painted Bearing thickness
1.996 – 2.000 mm
Green
(0.0786 – 0.0787 in.)
1.999 – 2.003 mm
Black
(0.0787 – 0.0789 in.)
Colorless 2.002 – 2.006 mm
(no paint) (0.0788 – 0.0790 in.)
2.005 – 2.009 mm
Yellow
(0.0790 – 0.0791 in.)
2.008 – 2.012 mm
Blue
(0.0791 – 0.0792 in.)

1.6 liter

1. Paint
Color painted Bearing thickness
1.998 – 2.002 mm
Green
(0.0787 – 0.0788 in.)
2.001 – 2.005 mm
Black
(0.0788 – 0.0789 in.)
Colorless 2.004 – 2.008 mm
(no paint) (0.0789 – 0.0791 in.)
2.007 – 2.011 mm
Yellow
(0.0790 – 0.0792 in.)
2.010 – 2.014 mm
Blue
(0.0791 – 0.0793 in.)

4) From numerals stamped on crank webs of No.2 and No.3 cylin-

ders and the alphabets stamped on mating surface of cylinder
block, determine new standard bearing to be installed to jour-
nal, by referring to table given below. For example, if numeral
stamped on crank web is “1” and alphabet stamped on mating
surface is “B”, install a new standard bearing painted in “Black”
to its journal.
Numeral stamped on crank
web (Journal diameter)
1 2 3
1. Crank webs of No.2 and No.3 cylinders
Alphabet stamped A Green Black Colorless
on mating
i surface
f
B Black Colorless Yellow
cap bore
(Bearing ca
dial.) C Colorless Yellow Blue

New standard bearing to be installed.

 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-71

5) Using gaging plastic, check bearing clearance with newly se-

lected standard bearing.
If clearance still exceeds its limit, use next thicker bearing and
recheck clearance
6) When replacing crankshaft or cylinder block due to any reason,
select new standard bearings to be installed by referring to nu-
merals stamped on new crankshaft or alphabets stamped on
mating surface of new cylinder block.
1. Gaging plastic
2. Scale

UNDERSIZE BEARING (0.25 mm):

0.25 mm undersize bearing is available, in five kinds varying in
thickness.
To distinguish them, each bearing is painted in the following col-
ors at such position as indicated in figure. Each color represents
following thicknesses at the center of bearing.
1.3liter
Color painted Bearing thickness
2.121 – 2.125 mm
Green & Red
(0.0835 – 0.0837 in.)
2.124 – 2.128 mm
Black & Red
(0.0836 – 0.0838 in.)
2.127 – 2.131 mm
Red only
(0.0837 – 0.0839 in.)
2.130 – 2.134 mm
Yellow & Red
(0.0839 – 0.0840 in.)
2.133 – 2.137 mm
Blue & Red
(0.0840 – 0.0841 in.)
1. Paint
1.6 leter
Color painted Bearing thickness
2.123 – 2.127 mm
Green & Red
(0.0836 – 0.0837 in.)
2.126 – 2.130 mm
Black & Red
(0.0837 – 0.0839 in.)
2.129 – 2.133 mm
Red only
(0.0838 – 0.0840 in.)
2.132 – 2.136 mm
Yellow & Red
(0.0839 – 0.0841 in.)
2.135 – 2.139 mm
Blue & Red
(0.0841 – 0.0842 in.)
6A1-72 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

If necessary, regrind crankshaft journal and select undersize

bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished diameter
1.3 liter engine: 44.732 – 44.750 mm
(1.7611 – 1.7618 in.)
1.6 liter engine: 51.732-51.750 mm
(2.0367-2.0373 in.)

2) Using micrometer, measure reground journal diameter. Mea-

surement should be taken in two directions perpendicular to
each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on mating surface of cylinder block, select an under-
size bearing by referring to table given below. Check bearing
clearance with newly selected undersize bearing.

Engine displacement Measured journal diameter

44.744 – 44.750 mm 44.738 – 44.744 mm 44.732 – 44.738
1.3 liter
(1.7616 – 17618 in.) (1.7613 – 1.7616 in.) (1.7611 –1.7613 in.)
51.744 – 51.750 mm 51.738 – 51.744 mm 51.732 – 51–738 mm
1.6 liter
(2.0371 – 2.3773 in.) (2.0369 – 2.0371 in.) (2.0367 – 2.0369 in.)

Alphabets stamped A Green & Red Black & Red Red only
on mating surface B Black & Red Red only Yellow & Red
of cylinder block C Red only Yellow & Red Blue & Red
Undersize bearing to be installed

Rear Oil Seal

Carefully inspect oil seal for wear or damage. If its lip is worn or
damaged, replace it.

1. Rear oil seal

For oil seal installation, press-fit rear oil seal so that oil seal housing
end face is flush with oil seal end face.

1. Oil seal
2. Oil seal housing
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-73

Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or excessively
worn, replace flywheel.
Check flywheel for face runout with dial gauge. If runout exceeds
its limit, replace flywheel.
Limit on runout: 0.2 mm (0.0078 in.)

Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed surface
for distortion and, if flatness exceeds its limit, correct it.

Item Standard Limit

0.03 mm 0.06 mm
Flatness
(0.0012 in.) (0.0024 in.)

Honing or reboring cylinders

1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Engine displace-
Size Piston diameter
ment
74.220 – 74.230 mm
O/S 0.25
(2.9220 – 2.9224 in.)
1 3 liter
1.3
74.470 – 74.480 mm
O/S 0.50
(2.9319 – 2.9323 in.)
75.220 – 75.230 mm
O/S 0.25
(2.9614 – 2.9618 in.)
1 6 liter
1.6
75.470 – 75.480 mm
O/S 0.50
(2.9712 – 2.9716 in.)

3) Using micrometer, measure piston diameter.

1. 15 mm (0.59 in.)
6A1-74 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

4) Calculate cylinder bore diameter to be rebored.

D=A+B-C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm
(0.0008 – 0.0015 in.)
C: Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install all main bearing caps in place and
tighten to specification to avoid distortion of bearing
bores.
6) Measure piston clearance after honing.

INSTALLATION
NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings, thrust
bearings, crankpins, connecting rod bearings, pistons, pis-
ton rings and cylinder bores.
Journal bearings, bearing caps, connecting rods, rod bear-
ings, rod bearing caps, pistons and piston rings are in com-
bination sets. Do not disturb such combination and make
sure that each part goes back to where it came from, when
installing.

1) Install main bearings to cylinder block.

One of two halves of main bearing, has an oil groove. Install it
to cylinder block, and the other half without oil groove to bearing
cap.
Make sure that two halves are painted in the same color.

1. Cylinder block
2. Upper half of
bearing
3. Oil groove

1. Thrust bearing 2) Install thrust bearings to cylinder block between No.2 and No.3
2. Oil groove
cylinders. Face oil groove sides to crank webs.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-75

3) Install crankshaft to cylinder block.

4) Install bearing cap to cylinder block, making sure to point arrow
mark (on each cap) to crankshaft pulley side. Fit them sequen-
tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley
side.
After installing bearing cap stiffeners, tighten bearing cap bolts
in such order as shown in figure a little at a time and repeat It
till they are tightened to specified torque.
Tightening Torque
(a): 54 N·m (5.4 kg-m, 39.0 lb-ft)
NOTE:
After tightening cap bolts, check to be sure that crankshaft
rotates smoothly when turning it by 8.0 N·m (0.8 kg, 5.8 lb-
ft) torque or below.

5) Install new gasket and oil seal housing.

Do not reuse gasket removed in disassembly. Apply engine oil
to oil seal lip before installation. Tighten housing bolts to specifi-
cation.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
NOTE:
As there are 2 types of housing bolts, refer to figure for their
correct use.
After installing oil seal housing, gasket edges might bulge out;
if so, cut them off to make them flush with cylinder block and oil
seal housing.
6) Install oil pump.
Refer to item “Oil pump” for installation of oil pump.

1. Short bolts
2. Long bolts

7) Install flywheel (M/T model) or drive plate (A/T model). Using

special tool, lock flywheel or drive plate, and torque its bolts to
specification.
Special Tool
(A): 09924-17810
Tightening Torque
(a): 78 N·m (7.8 kg-m, 56.5 lb-ft) (Flywheel bolts)
(a): 95 N·m (9.5 kg-m, 69.0 lb-ft) (Drive plate bolts)
6A1-76 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

8) Install pistons and connecting rods as previously outlined.

9) Install oil pump strainer and oil pan as previously outlined.

10) Install cylinder head assembly to cylinder block as previously

outlined.
NOTE:
Tighten cylinder head bolts to specified torque as pre-
viously outlined. Whenever installing cylinder head to
new cylinder block, use the following procedure to tighten
cylinder head bolts.
Tighten cylinder head bolts to specified torque as pre-
viously outlined and loosen them once till tightening
torque becomes “zero”. And then torque them to speci-
fication again.
11) Install camshaft, crankshaft timing belt pulley, timing belt,
crankshaft pulley, water pump pulley, etc., as previously out-
lined.
12) Install clutch to flywheel (for M/T vehicle). For clutch installa-
tion, refer to “CLUTCH” section.

13) Install engine mountings and brackets.

Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
(b): 45 N·m (4.5 kg-m, 32.5 lb-ft)
(c): 23 N·m (2.3 kg-m, 17.0 lb-ft)
14) Install engine assembly to vehicle as previously outlined.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-77

SPECIAL TOOLS

1. 09915-64510-001
Compression gauge
2. 09915-64510-002
Connector
09918-08210
3. 09915-64530 Hose
4. 09915-67010 09915-67310 Vacuum gauge hose 09915-77310
Attachment Vacuum gauge joint Oil pressure gauge

1. 09900-00415 09926-18210
8 mm hexagon wrench bit
09917-18211 2. 09900-00411 Oil seal guide 09917-68221
Tappet adjuster wrench Hexagon wrench socket (Vinyl resin) Camshaft pulley holder

1. 09916-14510
Valve lifter
2. 09916-14910 09916-84511 09916-44910 09916-34542
Valve lifter attachment Forceps Valve guide remover Reamer handle

09916-58210 09916-56011
09916-38210 Valve guide installer Valve guide installer 09916-34550
Reamer (11 mm) handle attachment Reamer (5.5 mm)
6A1-78 ENGINE MECHANICAL (G13/G16 TYPE ENGINE)

09917-98221 09916-77310 09924-17810 09915-47330

Valve stem seal installer Piston ring compressor Flywheel holder Oil filter wrench

REQUIRED SERVICE MATERIALS

RECOMMENDED
MATERIALS USE
SUZUKI PRODUCT
SUZUKI BOND NO. 1207C
Sealant Mating surfaces of cylinder block and oil pan.
(99000-31150)
Mating surfaces of camshaft housings (No.6).
SUZUKI BOND NO. 1215
Sealant Mating surfaces of CMP sensor case and cylinder
(99000-31110)
block.
 ENGINE MECHANICAL (G13/G16 TYPE ENGINE) 6A1-79

RECOMMENDED TORQUE SPECIFICATIONS

TIGHTENING TORQUE
FASTENING PARTS
N·m kg-m lb-ft
Oil pressure switch 14 1.4 10.5
Valve adjusting screw lock nuts 12 1.2 9.0
Cylinder head cover bolts
Water pump pulley bolts 11 1.1 8.0
Timing belt tensioner stud
Timing belt tensioner bolt 25 2.5 18.0
Timing belt cover bolts and nut 11 1.1 8.0
Exhaust manifold bolts and nuts 23 2.3 17.0
Exhaust manifold to No.1 pipe bolt 50 5.0 36.5
Exhaust No.1 pipe to No.2 pipe bolts 43 4.3 31.5
Crankshaft pulley bolt 16 1.6 11.5
Oil pump strainer bolt and stay bolt
11 11
1.1 80
8.0
Oil pan bolts and nuts
Oil pan drain plug 35 3.5 25.5
Transmission stiffener bolts 50 5.0 36.5
Oil pump rotor plate screws 11 1.1 8.0
Oil pump case bolts 11 1.1 8.0
Crankshaft timing belt pulley bolt 130 13.0 94.0
Camshaft housing bolts
Rocker arm shaft bolts 11 1.1 8.0
Rocker arm shaft plug
Camshaft timing belt pulley bolt 60 6.0 43.5
Cylinder head venturi plug 3.5 0.35 2.5
Cylinder head bolts 68 6.8 49.5
Connecting rod bearing cap nuts 35 3.5 25.5
Bolt and nuts fastening T/M and cylinder block 90 9.0 65.0
Torque converter bolts (A/T) 19 1.9 14.0
Crankshaft main bearing cap bolts 54 5.4 39.0
Flywheel bolts 78 7.8 56.5
Drive plate bolts 95 9.5 69.0
CKP sensor bolt 10 1.0 7.5
Oil galley plug 33 3.3 24.0
CMP sensor case bolt 11 1.1 8.0
Intake manifold bolts and nuts 23 2.3 17.0
Engine mounting & bracket bolts and nuts Refer to INSTALLATION of “ENGINE ASSEMBLY”.