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1C1 – 54I1.4L/1.6L DOHC ENGINE MECHANICAL
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CAUTION : Use care when handling the piston. Worn
piston rings are sharp and may cause injury.
11. Remove the piston.
12. Use a piston ring expander tool to expand the pis-
ton rings.
13. Remove the piston rings.
14. Remove the piston pin from the piston and connect-
ing rod assembly using the piston pin service set
KM–427.
15. Separate the piston from the connecting rod.
Inspection Procedure
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. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear.
Refer to ”Engine Specifications” in this section.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.
8. Inspect the piston for fit to the connecting rod.
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9. Inspect the engine block deck surface for flatness
using a straight edge and a feeler gauge. Refer to
”Engine Specifications” in this section.
10. Inspect the bearing bore for concentricity and align-
ment using a bore gauge. Refer to ”Engine Specifi-
cations” in this section. If the bearing bore is be-
yond specifications, replace the engine block.
11. Inspect the engine block cylinder bore for wear,
runout, ridging and taper using a bore gauge. Refer
to ”Engine Specifications” in this section.
12. Inspect the engine block cylinder bore for glazing.
Lightly hone the cylinder bore as necessary.
Installation Procedure
1. Align the notch on the piston and the connecting
rod so that the proper sides will be facing the front
of the engine.
2. Install the piston 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
piston.
5. Install the piston pin into the piston and connecting
rod assembly using the piston pin service set
KM–427.
6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gauge.
Refer to ”Engine Specifications” in this section.
8. Increase the piston ring gap by carefully filing off
excess material if the piston ring gap is below spec-
ifications.
9. Measure the piston ring side clearance using a feel-
er gauge. Refer to ”Engine Specifications’’ in this
section.
10. If the piston ring is too thick, try another piston ring.
11. If no piston ring can be found that fits to specifica-
tions, the piston ring may be ground to size with
emery paper placed on a sheet of glass.
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1C1 – 56I1.4L/1.6L DOHC ENGINE MECHANICAL
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12. Install a piston oil ring, the expander, then the sec-
ond piston oil ring to the bottom ring groove of the
piston.
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 piston.
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 compres-
sion ring in relation to the notch on the top of the
piston.
17. Lubricate the cylinder wall and the piston 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 bearings. Refer
to ”Crankshaft Bearings and Connecting Rod Bear-
ings – Gauging Plastic” in this section.
20. Install the connecting rod cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb–ft). Using the angular torque gauge
KM–470–B, tighten the bolts one turn of 30 degrees
plus one turn of 15 degrees.
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21. Install the oil suction pipe.
22. Install the oil suction pipe bolts.
Tighten
Tighten the oil suction pipe bolts to 10 NSm (89 lb–in).
23. Install the oil pan. Refer to ”Oil Pan” in this section.
24. Install the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
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1C1 – 58I1.4L/1.6L DOHC ENGINE MECHANICAL
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UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
Tools Required
MKM–571–B Gauge
KM–340–0 Cutter Set
KM–340–7 Guide Drift
KM–340–13 Cutters
KM–340–26 Cutters
KM–348 Valve Spring Compressor
KM–653 Adapter
KM–805 Valve Guide Reamer
Disassembly Procedure
1. Remove the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
2. Remove the engine coolant temperature sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the
sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.
9. Remove the thermostat housing mounting bolts.
10. Remove the thermostat housing assembly.
11. Remove the fuel rail retaining bolts and the fuel rail
assembly.
12. Remove the intake manifold retaining nuts and re-
taining bolts in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold studs.
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15. Remove the direct ignition system (DIS) coil mount-
ing bolts.
16. Remove the DIS coil with the ignition wires at-
tached.
17. Remove the DIS coil mounting bracket bolts.
18. Remove the DIS coil mounting bracket.
19. Remove the electrical exhaust gas recirculation
(EEGR) valve adapter bolts.
20. Remove the EEGR valve adapter.
21. Remove the EEGR valve adapter gasket.
22. Remove the spark plugs.
23. Remove the camshaft cap bolts gradually and in
the sequence shown for each camshaft cap.
24. Remove the intake camshaft caps. Maintain the
correct positions for installation.
25. Remove the intake camshaft.
26. Remove the intake valve tappet adjusters.
27. Remove the exhaust camshaft caps. Maintain the
correct positions for installation.
28. Remove the exhaust camshaft.
29. Remove the exhaust valve tappet adjusters.
30. Compress the valve springs with the valve spring
compressor KM–348 and the adapter KM–653.
31. Remove the valve keys.
32. Remove the valve spring compressor KM–348 and
the adapter KM–653.
33. Remove the valve spring caps.
34. Remove the valve springs. Maintain the original
position of the valve springs for installation.
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35. Remove the valves. Maintain the original position of
the valves for installation.
36. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.050 mm (0.002 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 134.08 to 134.23 mm. If the cylin-
der head height is less than 134.08 mm, replace
the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the 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 face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.
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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 re-
quired.
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.
Cylinder Head Overhaul
Valve Grind–in
1. Lubricate the valve stem using a fine–grained
paste.
2. Lift the valve rhythmically from the seat with a com-
mercially available valve grinding tool in order to
distribute the paste.
3. Check the contact pattern on the valve head and in
the cylinder head.
4. Clean the valves, the valve guides, and the cylinder
head.