tài liệu sửa chữa động cơ D4FA hyundai

Engine (D4FA DSL1.5)
GENERAL

ENGINE BLOCK

TIMING SYSTEM

COOLING SYSTEM

TIMING CHAIN

ENGINE AND TRANSAXLE ASSEMBLY

LUBRICATION SYSTEM

CYLINDER HEAD ASSEMBLY

INTAKE AND EXHAUST SYSTEM


EMA -2

ENGINE (D4FA - DSL1.5)

GENERAL
SPECIFICATIONS

E284EBC0

Description

Specifications (D4FA)

General
Type

In-line, DOHC

Number of cylinders

4

Bore

75mm (2.9528in)

Stroke

84.5mm (3.3268in)

Total displacement

1,493 cc (91.11 cu.in)

Compression ratio

17.8 : 1

Firing order

1-3-4-2

Valve timing
Intake valve

Exhaust valve

Opens (BTDC)

6

Closes (ABDC)

34

Opens (BBDC)

46

Closes (ATDC)

4

Cylinder head
0.03mm (0.0012in) for width
0.09mm (0.0035in) for length

Flatness of gasket surface
Flatness
of manifold
mounting

surface

Intake

0.025mm (0.0010in) for width
0.160mm (0.0063in) for length

Exhaust

0.025mm (0.0010in) for width
0.160mm (0.0063in) for length

Camshaft
LH
camshaft

Intake

35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

Exhaust

35.700 ~ 35.900mm (1.4055 ~ 1.4134in)

RH
camshaft

Intake

35.537 ~ 35.737mm (1.3991 ~ 1.4070in)

Exhaust

35.452 ~ 35.652mm (1.3957 ~ 1.4036in)

Cam height

Journal outer
Diameter

LH camshaft

20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

RH camshaft

20.944 ~ 20.960mm (0.8246 ~ 0.8252in)

Bearing oil clearance

0.040 ~ 0.077mm (0.0016 ~ 0.0030in)

End play

0.10 ~ 0.20mm (0.0039-0.0079in)

Valve
Valve length
Stem outer
diameter

Face angle

Intake

93.0mm (3.6614in)

Exhaust

93.7mm (3.6890in)

Intake

5.455 ~ 5.470mm (0.2148 ~ 0.2154in)

Exhaust

5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
45.5 ~ 45.75

Limit


GENERAL

EMA -3
Description

Specifications (D4FA)

Thickness of

valve head
(margin)

Intake

1.1mm (0.0433in)

Exhaust

1.2mm (0.0472in)

Valve stem to
valve guide
clearance

Intake

0.030 ~ 0.057mm (0.0012 ~ 0.0022in)

Exhaust

0.050 ~ 0.077mm (0.0020 ~ 0.0030in)

Intake

5.500 ~ 5.512mm (0.2165 ~ 0.2170in)

Exhaust

5.500 ~ 5.512mm (0.2165 ~ 0.2170in)

Intake

31.3 ~ 31.7mm (1.2323 ~ 1.2480in)

Exhaust

31.3 ~ 31.7mm (1.2323 ~ 1.2480in)

Intake

0.8 ~ 1.4mm (0.0315 ~ 0.0551in)

Exhaust

1.2 ~ 1.8mm (0.0472 ~ 0.0709in)

Intake

45 ~ 45 30’

Exhaust

45 ~ 45 30’

Limit

Valve guide
Inner diameter

Length
Valve seat
Width of seat
contact
Seat angle
Valve spring
Free length

44.9mm (1.7677in)
17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)

Load

31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)

Out of squareness

Less than 1.5

Cylinder block
Cylinder bore

75.000 ~ 75.030mm (2.9528 ~ 2.9539in)

Flatness of gasket surface

Less than 0.05mm (0.0020in) (Overhaul)
Less than 0.03mm (0.0012in) (Per 1 Cylinder)

Piston

Piston outer diameter

74.930 ~ 74.960mm (2.9500 ~ 2.9512in)

Piston to cylinder clearance

0.060 ~ 0.080mm (0.0024 ~ 0.0031in)

Ring groove
width

No. 1 ring groove

1.83 ~ 1.85mm (0.0720 ~ 0.0728in)

No. 2 ring groove

1.82 ~ 1.84mm (0.0717 ~ 0.0724in)

Oil ring groove

3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

No. 1 ring

0.09 ~ 0.13mm (0.0035 ~ 0.0051in)

No. 2 ring

0.08 ~ 0.12mm (0.0031 ~ 0.0047in)

Oil ring

0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

No. 1 ring

0.20 ~ 0.35mm (0.0079 ~ 0.0138in)

No. 2 ring

0.35 ~ 0.50mm (0.0138 ~ 0.0197in)

Oil ring

0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston ring

Side clearance

End gap

Piston pin
Piston pin outer diameter

27.995 ~ 28.000mm (1.1022 ~ 1.1024in)

3

EMA -4

ENGINE (D4FA - DSL1.5)
Description

Specifications (D4FA)

Piston pin hole inner diameter

28.004 ~ 28.010mm (1.1025 ~ 1.1028in)

Piston pin hole clearance

0.004 ~ 0.015mm (0.0002 ~ 0.0006in)

Connecting rod small end hole
inner diameter

28.022 ~ 28.034mm (1.1032 ~ 1.1037in)

Connecting rod small end hole clearance

0.022 ~ 0.039mm (0.0009 ~ 0.0015in)

Limit

Connecting rod
Connecting rod big end inner diameter

49.000 ~ 49.018mm (1.9291 ~ 1.9298in)

Connecting rod bearing oil clearance

0.025 ~ 0.043mm (0.0010 ~ 0.0017in)

Side clearance

0.050 ~ 0.302mm (0.0020 ~ 0.0119in)

0.4mm (0.0157in)

Crankshaft
Main journal outer diameter

53.972 ~ 53.990mm (2.1249 ~ 2.1256in)

Pin journal outer diameter

45.997 ~ 46.015mm (1.8109 ~ 1.8116in)

Main bearing oil clearance

0.024 ~ 0.042mm (0.0009 ~ 0.0017in)

End play

0.08 ~ 0.28mm (0.0031 ~ 0.110in)

Flywheel

Runout

0.1mm (0.0039in)

Oil pump
Side clearance

Inner rotor

0.040 ~ 0.085mm (0.0016 ~ 0.0033in)

Outer rotor

0.040 ~ 0.090mm (0.0016 ~ 0.0035in)

Body clearance

0.120 ~ 0.185mm (0.0047 ~ 0.0073in)

Relief valve opening pressure

490±49.0kpa (5±0.5kg/cm², 71±7.1psi)

Engine oil
Oil quantity (Total)

5.3 L (5.60 US qt, 4.66 lmp qt)

Oil quantity (Oil pan)

4.8 L (5.07 US qt, 4.22 lmp qt)

Oil quantity (Oil filter)

0.5 L (0.53 US qt, 0.44 lmp qt)

Oil quality

Above API CH-4, Above ACEA B4

Oil pressure (Idle) (Oil temperature : 80 C)

78.4kpa (0.8kg/cm², 11.3psi)

Cooling system
Cooling method

Forced circulation with cooling fan

Coolant quantity

5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt)

Thermostat

Radiator cap

Type

Wax pellet type

Opening temperature

85±1.5 C (185.0±2.7 F)
(Lift : 0.35mm(0.0138in))

Pull opening
temperature

100 C (212 F)
(Lift : 8mm(0.3150in))

Main valve opening
pressure

93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)

Vacuum valve opening
pressure

0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)

0.13mm (0.0051in)


GENERAL

EMA -5

Description

Specifications (D4FA)

Water temperature sensor
Type
Resistance

Thermister type
20 C (68 F)

2.45±0.14 k

80 C (176 F)

0.3222 k

Limit


EMA -6

ENGINE (D4FA - DSL1.5)

TIGHTENING TORQUE
Item

Quantity

Tightening torque

N.m

kgf.m

lb-ft

Cylinder block
Engine support bracket bolt

4

42.2 ~ 53.9

4.3 ~ 5.5

31.1 ~ 39.8

Piston cooling oil jet bolt

4

8.8 ~ 12.7

0.9 ~ 1.3

6.5 ~ 9.4

Drive belt auto tensioner bolt

2

18.6 ~ 27.5

1.9 ~ 2.8

13.7 ~ 20.3

Drive belt auto tensioner mounting bracket bolt

3

18.6 ~ 27.5

1.9 ~ 2.8

13.7 ~ 20.3

Engine mounting bracket and body fixing bolt

3

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Engine mounting insulator and engine
mounting support bracket fixing nut

1

68.6 ~ 93.2

7.0 ~ 9.5

50.6 ~ 68.7

Engine mounting support bracket and engine
support bracket fixing bolt

2

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Engine mounting support bracket and engine
support bracket fixing nut

1

49.0 ~63.7

5.0 ~6.5

36.2 ~47.0

Transaxle mounting bracket and body fixing bolt

3

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Transaxle mounting insulator and transaxle
support bracket fixing bolt

2

68.6 ~ 93.2

7.0 ~9.5

50.6 ~68.7

Front roll stopper bracket and sub
frame fixing bolt

3

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Front roll stopper insulator and front roll stopper
support bracket fixing bolt,nut

1

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Rear roll stopper bracket and sub
frame fixing bolt

3

49.0 ~ 63.7

5.0 ~ 6.5

36.2 ~ 47.0

Rear roll stopper insulator and rear roll stopper
support bracket fixing bolt,nut

1

49.0 ~63.7

5.0 ~6.5

36.2 ~47.0

Connecting rod cap bolt

8

12.7 + 90

1.3 + 90

9.4 + 90

Crankshaft main bearing cap bolt (long)

10

24.5 + 90

2.5 + 90

18.1 + 90

Crankshaft main bearing cap bolt (short)

10

32.4 ~ 36.3

3.3 ~ 3.7

23.9 ~ 26.8

Flywheel bolt (M/T)

8

68.6 ~ 78.5

7.0 ~ 8.0

50.6 ~ 57.9

Drive plate bolt (A/T)

8

68.6 ~ 78.5

7.0 ~ 8.0

50.6 ~ 57.9

Timing chain cover bolt (8 X 70)

7

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Timing chain cover bolt (8 X 60)

2

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Timing chain cover bolt (8 X 35)

1

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Timing chain cover bolt (6 X 35)

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Timing chain cover bolt (6 X 28)

7

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Timing chain case bolt (8 X 22)

4

24.5 ~ 30.4

2.5 ~ 3.1

18.1 ~ 22.4

Timing chain case bolt (8 X 32)

1

18.6 ~ 27.5

1.9 ~ 2.8

13.7 ~ 20.3

Timing chain case bolt (6 X 35)

1

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Engine mounting

Main moving system

Timing chain


GENERAL

EMA -7
Item

Quantity

Tightening torque

N.m

kgf.m

lb-ft

Engine hanger (front)

2

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Crankshaft pulley bolt

1

225.6 ~ 245.2

23.0 ~ 25.0

166.4 ~ 180.8

Camshaft chain sprocket bolt

1

68.6 ~ 73.5

7.0 ~ 7.5

50.6 ~ 54.2

High pressure pump chain sprocket bolt

1

64.7 ~ 74.5

6.6 ~ 7.6

47.7 ~ 55.0

Timing chain guide (1) bolt

4

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Timing chain guide (2) bolt

1

9.8 ~ 13.7

1.0 ~ 1.4

7.2 ~ 10.1

Timing chain "A" auto tensioner bolt

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Timing chain "C" auto tensioner bolt

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Engine cover bolt

4

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Cylinder head cover bolt

13

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Camshaft bearing cap bolt (Reamer bolt)

16

12.7 ~ 13.7

1.3 ~ 1.4

9.4 ~ 10.1

Camshaft bearing cap bolt (Standard bolt)

6

12.7 ~ 13.7

1.3 ~ 1.4

9.4 ~ 10.1

Engine hanger bolt (Front)

2

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Engine hanger bolt (Rear)

1

47.1 ~ 51.0

4.8 ~ 5.2

34.7 ~ 37.6

Cylinder head bolt

10

49.0+90 +120

5.0+90 +120

36.2+90 +120

Water pump pulley bolt

3

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Water pump bolt (8 X 50)

2

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Water pump bolt (8 X 70)

1

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Thermostat housing bolt

1

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Thermostat housing nut

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Water return pipe assembly bolt

2

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Water temperature sensor

1

24.5 ~ 34.3

2.5 ~ 3.5

18.1 ~ 25.3

Water outlet fitting nut

2

19.6 ~ 24.5

2.0 ~ 2.5

14.5 ~ 18.1

Oil filter assembly bolt

4

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Oil cooler assembly bolt

4

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil filter upper cap

1

24.5

2.5

18.1

Oil level gauge bolt

1

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Oil pan bolt (6 X 20)

16

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil pan bolt (6 X 65)

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil pan bolt (6 X 85)

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil pan and transaxle fixing bolt

3

29.4 ~ 41.2

3.0 ~ 4.2

21.7 ~ 30.4

Oil pan drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Oil screen bolt

1

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Oil screen nut

2

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil pressure switch

1

14.7 ~ 21.6

1.5 ~ 2.2

10.8 ~ 15.9

Cylinder head

Cooling system

Lubrication system


EMA -8

ENGINE (D4FA - DSL1.5)
Item

Quantity

Tightening torque
N.m

kgf.m

lb-ft

Intake and exhaust system
Intake manifold and cylinder head fixing nut

2

14.7 ~ 19.6

1.5 ~ 2.0

10.8 ~ 14.5

Intake manifold and cylinder head fixing bolt

7

14.7 ~ 19.6

1.5 ~ 2.0

10.8 ~ 14.5

Exhaust manifold and cylinder head fixing nut

8

29.4 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

Exhaust manifold heat cover and exhaust
manifold fixing bolt

3

14.7 ~ 19.6

1.5 ~ 2.0

10.8 ~ 14.5

WCC assembly fixing nut

3

29.4 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

Air cleaner lower cover fixing bolt

3

7.8 ~ 9.8

0.8 ~ 1.0

5.8 ~ 7.2

Throttle body and surge tank fixing bolt

4

18.6 ~ 27.5

1.9 ~ 2.8

13.7 ~ 20.3

Exhaust manifold and front muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Front muffler fixing clip bolt

1

29.4 ~ 39.2

3.0 ~ 4.0

21.7 ~ 28.9

Front muffler and center muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Center muffler and main muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4


GENERAL

EMA -9

COMPESSION PRESSURE
INSPECTION EA53A61E

NOTE
Always use a fully charged battery to obtain engine
speed of 300rpm or more.

NOTE
4)

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
1.

2.

Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
Remove the injectors(A). (Refer to FL Gr.)
A

NOTE
This measurement must be done in as short a time as
possible.
Compression pressure(Standard) :
2,353kPa (24.0kg/cm², 341psi) (260 rpm)
Minimum pressure :
2,059kPa (21.0kg/cm², 298psi)
Difference between each cylinder :
294.20kPa (3.0kg/cm², 42.67psi) or less
5)

LCGF003A

3.

4.

Check the cylinder compression pressure.
1)

Insert a compression gauge into the injector hole.

ECKD001X

2)

Fully open the throttle.

3)

While cranking the engine, measure the compression pressure.

Repeat step 1) though 3) for each cylinder.

If the cylinder compression in 1 or more cylinders
is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat
step 1) through 3) for cylinders with low compression.
• If adding oil helps the compression, it is likely
that the piston rings and/or cylinder bore are
worn or damaged.
• If pressure stays low, a valve may be sticking or seating is improper, or there may be
leakage past the gasket.

Reinstall the injectors.


EMA -10

ENGINE (D4FA - DSL1.5)

TROUBLESHOOTING

E2396869

Symptom
Engine misfire with
abnormal internal
lower engine noises.

Engine misfire with
abnormal valve
train noise.

Engine misfire with
coolant consumption

Suspect area

Remedy

Loose or improperly installed engine flywheel.

Repair or replace the flywheel
as required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire.)

Inspect the cylinder for a loss
of compression.
Repair or replace as required.

Worn crankshaft thrust bearings.

Replace the crankshaft and bearings
as required.

Stuck valves.
(Carbon buildup on the valve stem can cause
the valve not to close properly.)

Repair or replace as required.

Excessive worn or mis-aligned timing chain.

Replace the timing chain and
sprocket as required.

Worn camshaft lobes.

Replace the camshaft and valve lifters.

• Faulty cylinder head gasket and/or cracking
or other damage to the cylinder head and
engine block cooling system.
• Coolant consumption may or may not
cause the engine to overheat.

• Inspect the cylinder head and
engine block for damage to
the coolant passages and/or a
faulty head gasket.
• Repair or replace as required.

Engine misfire
with excessive oil
consumption

Worn valves, valve guides and/or valve
stem oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire)

Inspect the cylinder for a loss
of compression
Repair or replace as required.

Engine noise on
start-up, but only
lasting a few seconds.

Incorrect oil viscosity.

Drain the oil.
Refill with the correct viscosity oil.

Worn crankshaft thrust bearing.

Inspect the thrust bearing and

crankshaft.
Repair or replace as required.

Upper engine noise,
regardless of engine
speed.

Low oil pressure.

Repair or replace as required.

Broken valve spring.

Replace the valve spring.

Worn or dirty valve lifters.

Replace the valve lifters.

Stretched or broken timing chain and/or
damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if applicable.

Replace the timing chain tensioner
as required.

Worn camshaft lobes.

Inspect the camshaft lobes.
Replace the camshaft and valve
lifters as required.

Worn valve guides or valve stems.

Inspect the valves and valve guides,
then repair as required.

Stuck valves. (Carbon on the valve stem or valve
seat may cause the valve to stay open.)

Inspect the valves and valve guides,
then repair as required.


GENERAL

EMA -11

Symptom
Lower engine noise,
regardless of engine
speed.

Engine noise under
load.

Suspect area

Remedy

Low oil pressure.

Repair or replace damaged
components as required.

Loose or damaged flywheel.

Repair or replace the flywheel.

Damaged oil pan, contacting the oil pump screen.

Inspect the oil pan.
Inspect the oil pump screen.
Repair or replace as required.

Oil pump screen loose, damaged or restricted.

Inspect the oil pump screen.
Repair or replace as required.

Excessive piston-to-cylinder bore clearance.

Inspect the piston and cylinder bore.
Repair as required.

Excessive piston pin-to-bore clearance.

Inspect the piston, piston pin and
the connecting rod.
Repair or replace as required.

Excessive connecting rod bearing clearance.

Inspect the following components
and repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.

Excessive crankshaft bearing clearance.

Inspect the following components
and repair as required.
• The crankshaft bearings.
• The crankshaft journals.

Incorrect piston, piston pin and connecting
rod installation.

Verify the piston pins and connecting
rods are installed correctly.
Repair as required.

Low oil pressure.

Repair or replace as required.

Excessive connecting rod bearing clearance.

Inspect the following components
and repair as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components
and repair as required.
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
bearing bore.


EMA -12
Symptom
Engine will not crank.
(crankshaft will not
rotate)

ENGINE (D4FA - DSL1.5)
Suspect area

Remedy

Hydraulically locked cylinder.
• Coolant/antifreeze in cylinder.
• Oil in cylinder.
• Fuel in cylinder.

Remove injectors and check for fluid.
Inspect for broken head gasket.
Inspect for cracked engine block
or cylinder head.
Inspect for a sticking fuel injector
and/or leaking fuel regulator.

Broken timing chain and/or timing chain gears.

Inspect timing chain and gears.
Repair as required.

Foreign material in cylinder.
• Broken valve.
• Piston material.
• Foreign material.

Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.

Seized crankshaft or connecting rod bearings.

Inspect crankshaft and connecting
rod bearing.

Repair or replace as required.

Bent or broken connecting rod.

Inspect connecting rods.
Repair or replace as required.

Broken crankshaft.

Inspect crankshaft.
Repair or replace as required.


GENERAL
SPECIAL SERVICE TOOLS
Tool (Number and name)

EMA -13
E986315E

Illustration

Use

Torque angle adapter
(09221-4A000)

Installation of bolts & nuts needing
an angular method

LCAC030A

Valve spring compressor
(09222-3K000)
Valve spring compressor adapter
(09222-2A100)

Removal and installation of intake
and exhaust valves

09222-3K000

09222-2A100
LCGF059A

Valve stem oil seal installer
(09222-2A000)

Installation of valve stem oil seals

LCAC030D


EMA -14
Tool (Number and name)

ENGINE (D4FA - DSL1.5)
Illustration

Use

High pressure pump sprocket remover
(09331-2A000)

Removal of high pressure pump
sprocket

LCGF063B

Crankshaft rear oil seal installer
(09231-H1200)
Handle
(09231-H1100)

Installation of crankshaft rear oil seal

09231-H1100
09231-H1200

LCGF157A

Front cover oil seal installer
(09231-2A000)
Handle
(09231-H1100)

Installation of front cover oil seal
09231-H1100

09231-2A000

LCGF158A


GENERAL
Tool (Number and name)

EMA -15
Illustration

Use

Flywheel stopper
(09231-2A100)

Removal and installation of
crankshaft pulley bolt.

B314A200

Oil pan remover
(09215-3C000)

Removal of oil pan

ACJF125A

Support of engine

adapter
Engine support fixture

(09200-38001, 09200-1C000)

AMJF002B


EMA -16

ENGINE (D4FA - DSL1.5)

TIMING SYSTEM
TIMING CHAIN
COMPONENT

E85E1C8A

27.5 ~ 29.4
(2.8 ~ 3.0, 20.3 ~ 21.7)

1
2
3

6.9 ~ 9.8
(0.7 ~ 1.0, 5.1 ~ 7.2)

4
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
38.2 ~ 58.8
(3.9 ~ 6.0, 28.2 ~ 43.4)

14.7 ~ 19.6
(1.5 ~ 2.0, 10.8 ~ 14.5)

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

5

15
6

13

7

14
19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
12
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

42.2 ~ 53.9
(4.3 ~ 5.5, 31.1 ~ 39.8)

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

19.6 ~ 24.5

(2.0 ~ 2.5, 14.5 ~ 18.1)

11

10
9
8
225.6 ~ 245.2
(23.0 ~ 25.0, 166.4 ~ 180.8)

18.6 ~ 27.5
(1.9 ~ 2.8, 13.7 ~ 20.3)

18.6 ~ 27.5
(1.9 ~ 2.8,
13.7 ~ 20.3)

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

TORQUE : N.m(kgf.m, lbf.ft)
1.
2.
3.
4.
5.

Injector
Injector clamp
Cylinder head cover

Cylinder head gasket
Alternator

6.
7.
8.
9.
10.

Water pump pulley
Engine support bracket
Drive belt auto tensioner
Crankshaft pulley
Key

11.
12.
13.
14.
15.

Oil pan
Oil strainer
Water pump
High pressure pump
Timing chain cover
LDJF001A


TIMING SYSTEM

EMA -17

68.6 ~ 73.5
(7.0 ~ 7.5, 50.6 ~ 54.2)

24.5 ~ 30.4
(2.5 ~ 3.1, 18.1 ~ 22.4)
15

7.8 ~ 11.8
9.8 ~ 13.7
(1.0 ~ 1.4, 7.2 ~ 10.1) (0.8 ~ 1.2, 5.8 ~ 8.7)
14

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

6

19.6 ~ 26.5
(2.0 ~ 2.7, 14.5 ~ 19.5)
2
3

10

5

13

4
11

1

8
7

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

12
64.7 ~ 74.5 (6.6 ~ 7.6, 47.7 ~ 55.0)
9
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)
9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

9.8 ~ 11.8
(1.0 ~ 1.2, 7.2 ~ 8.7)

TORQUE : N.m(kgf.m, lbf.ft)
1.
2.
3.
4.
5.

Timing chain cover

Timing chain "C"
Timing chain "C" auto tensioner
Timing chain "C" lever
Timing chain guide "1"

6.
7.
8.
9.
10.

Timing chain guide "2"
Timing chain "A"
High pressure pump sprocket
Crankshaft sprocket
Timing chain "A" auto tensioner

11.
12.
13.
14.
15.

Timing chain "A" lever
Timing chain guide "1"
Timing chain case
Timing chain case gasket
Camshaft sprocket
LDJF002A

EMA -18

ENGINE (D4FA - DSL1.5)

REMOVAL

4.

E5A01FA9

1)

Engine removal is not required for this procedure.
1.

Remove the engine mounting support bracket.
Set the jack to the engine oil pan

Remove the drive belt(A).
A

LDIF001A
ACGF031A

2.

2)

Remove the injector(A). (Refer to FL Gr.)

Remove the
bracket(A).

engine

mounting

support

A

A
EDNG002A

LCGF003A

3.

5.

Remove the cylinder head cover(A).

12

8

2

11

9

7

1

13

6

3

Remove the alternator(A).

10
5

4

A

A

LCGF004A

LCGF005A


TIMING SYSTEM

6.

EMA -19

Remove the water pump pulley(A).

9.

Turn the crankshaft pulley, and align its groove with
timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position)

Mark

A

LCGF006A

7.

Remove the engine support bracket(A).

LCGF089A

10. Remove the crankshaft pulley bolt(B) and crankshaft
pulley(A).

A

A
B

LCGF007A

8.

Remove the drive belt auto tensioner(A).
LCGF009A

NOTE
A

Use the SST(flywheel stopper, 09231-2A100)(A) to
remove the crankshaft pulley bolt, after remove the
starter.

LCGF008A


EMA -20

ENGINE (D4FA - DSL1.5)
12. Remove the high pressure pump pipe(A). (Refer to FL
Gr.)

A

A

LCGF090A

11. Remove the high pressure pump sprocket nut(B) after
remove the timing chain cover plug(A).

ADJF034A

13. Remove the high pressure pump(A) fixing bolts and
fuel hoses(B,C).

B

A

B
C

LCGF091A

A
ADJF044A

NOTE
• Use the SST(flywheel stopper, 09231-2A100) to
remove the high pressure pump sprocket nut.

14. Install the SST(high pressure pump sprocket stopper,
09331-2A000)(A) to sprocket rotating it clockwise.
15. Remove the timing chain cover bolt(three bolts)(B).
B

A

A

LCGF090A
LCGF159A

• Replace O-ring of plug(A) with a new one when
reinstalling the plug.


TIMING SYSTEM

EMA -21

16. Install the SST(high pressure pump sprocket remover,
09331-2A000)(A) to timing chain cover with three long
bolts(B).

21. Remove the jack from oil pan.

17. Fix the high pressure pump remover(A) and sprocket
stopper(C) with two fixing bolts(D).
18. Rotate the bolt(E) clockwise till high pressure pump is
pushed out.
19. Remove the SST(09331-2A000) after remove the
high pressure pump.
B

LDIF001A

D

22. Remove the oil pan(A).
A

23. Remove the oil strainer(B).
E

C

LCGF160A

20. Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the enine
hanger bracket.
B

A
09200-38001
09200-1C000

LCGF010A

NOTE
Using the SST(09215-3C000) and remove the oil pan.
Be careful not damage the contact surtaces of oil pan.

09215-3C000
LCGF150A

ACJF127B

EMA -22

ENGINE (D4FA - DSL1.5)

24. Remove the timing chain cover(A)

A

B
F
D

26. Remove the timing chain "C" lever(A) and the timing
chain guide "1"(B).

B
D

E

D

B
C

D

B

B

D

E

D

D

A

C
B
LCGF011A
LCGF013A

NOTE
Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan.
(If any impurities are left at the sealing face, oil may
leak after reassembly even with the sealant application.)

27. Remove the timing chain guide "2"(A).

A

25. Remove the timing chain "C" auto tensioner(A).

LCGF014A

28. Remove the timing chain "C"(A).
A

Mark
B
LCGF012A

NOTE
Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner.

A

Mark
LCGF015A


TIMING SYSTEM

EMA -23

29. Remove the timing chain "A" auto tensioner(A).

31. Remove the timing chain "A"(A)with high pressure
pump sprocket(B) and crankshaft sprocket(C).
mark
B

mark

TDC

A
B

A

C
LCGF016A

LCGF024A

NOTE

32. Remove the power steering pump bracket(A).

Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner.
30. Remove timing chain "A" lever(A) and the timing chain
guide "1"(B).
A

A

TDC

LCGF025A

33. Remove the water pump(A).

B

LCGF017A

A

LCGF026A


EMA -24

ENGINE (D4FA - DSL1.5)

34. Remove the timing chain case(A).
(Engine removal is required for this procedure)

B
D
C

A

B

LCGF027A

35. Remove the camshaft sprocket.
1)

Hold the portion(A) of the camshaft with a
hexagonal wrench, and remove the bolt(C) with
a wrench(B) and remove the camshaft sprocket.

A
B

C

LCGF028A

CAUTION
Be careful not to damage the cylinder head and
valve lifter with the wrench.


TIMING SYSTEM
INSTALLATION

EMA -25
E95FE08A

Engine removal is not required for this procedure.
1.

Install the camshaft sprocket and tighten the bolt to
the specified torque.
1)

Temporarily install the camshaft sprocket bolt(C).

2)

Hold the portion(A) of the camshaft with a
hexagonal wrench, and tighten the bolt(C) with
a wrench(B).

B
D
C

A

B

Tightening torque :
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lb-ft)

LCGF027A

3.

Install the water pump(A).

Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

A
B

CAUTION
Apply coolant to the o-ring before installing the
water pump.
C

A
LCGF028A

2.

Install the timing chain case(A) with new gasket.
(Engine removal is required for this procedure)

Tightening torque :
Bolt(B) :24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m,
18.1 ~ 22.4lb-ft)
Bolt(C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m,
13.7 ~ 20.3lb-ft)
Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

LCGF026A