Motor Daewod 1.0-1.2l Aveo, Spark, Matiz

8/10/2019 Motor Daewod 1.0-1.2l Aveo, Spark, Matiz

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SECTION 1B

1.2 SOHC ENGINE MECHANICALCaution : Disconn ect the negat ive battery cable before removing or instal l ing

any electr ical uni t or when a tool or equipment co uld easi ly com e in contactwi th expo sed electr ical erminals. Discon nect ing th is cable wi l l help prevent

personal injury and damage to the vehic le. The igni t ion mu st also be in

LOCK unless otherwise noted.

SPECIFICATIONSEngine Specifications

Application Description (Manual and Automatic)

General Data: .

Engine Type 4 Cylinder (In-Line)

Displacement: 1150 cm

Bore Stroke: 68.5 x 78.0 mm (2.70 in. x 3.07 in.)

Compression Ratio 9.3 : 1

Firing Order 1-3-4-2

Cylinder Bore: .

Diameter 68.5 mm (2.70 in.)

Out of Round (Maximum) 0.005 mm (0.00020 in.)

Taper (Maximum): 0.005 mm (0.00020 in.)

Piston : .

Diameter 68.465 ~ 68.485 mm (2.695 ~ 2.696 in.)

Clearance to Bore 0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in.)

Piston Rings: .

Ring, End Gap: .

Top Compression 0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)

2nd Compression 0.30 ~ 0.45 mm (0.012 ~ 0.018 in.)

Groove Clearance: .

Top Impression 0.02 ~ 0.06 mm (0.0008 ~ 0.002 in)

2nd Impression 0.02 ~ 0.06 mm (0.0008 ~ 0.002 in.)

Piston Pin : .

Diameter 16.995 ~ 17.000 mm (0.6691 ~ 0.6693 in.)

Pin Off-Set 0.4 ~ 0.6 mm (0.016 ~ 0.024 in.)

Camshaft: .

Lift Intake: 5.42 mm (0.213 in)

Lift Exhaust 5.38 mm (0.212 in.)

End Play .


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Journal OD: .

No. 1 43.425 ~ 43.450 mm (1.710 ~ 1.711 in.)

No. 2 43.625 ~ 43.650 mm (1.718 ~ 1.719 in.)

No. 3 43.825 ~43.850 mm (1.725 ~ 1.726 in.)

No. 4 44.025 ~ 44.050 mm (1.733 ~ 1.734 in.)

No. 5 44.225 ~ 44.250 mm (1.741 ~ 1.742 in.)

Bearing OD: .

No. 1 43.500 mm (1.713 in.)

No. 2 43.700 mm (1.720 in.)

No. 3 43.900 mm (1.728 in.)

No. 4 44.100 mm (1.736 in.)

No. 5 44.300 mm (1.744 in.)

Crankshaft : .

Main Journal .

Diameter (All) 43.982 ~ 44.000 mm (1.7316 ~ 1.7323 in.)

Taper (Maximum) 0.005 mm (0.0002 in.)

Out of Round(Maximum)

0.005 mm (0.0002 in.)

Main Bearing

Clearance (All)0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)

Crankshaft End Play 0.11 ~ 0.31 mm (0.004 ~ 0.012 in.)

Connecting Rod Journal: .

Diameter (All) 37.982 ~ 38.000 mm (1.495 ~ 1.496 in.)Taper (Maximum) 0.005 mm (0.0002 in.)

Out of Round (Maximum) 0.005 mm (0.0002 in.)

Rod Bearing Clearance (All) 0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.)

Rod Side Clearance 0.10 ~ 0.25 mm (0.004 ~ 0.010 in.)

Valve System: .

Valve Lash Compensators Mechanical

Face Angle (All) 45

Seat Angle (All) 45

Seat Runout (Maximum, All) 0.05 mm (0.0019 in.)Face Runout (Maximum, All) 0.045 mm (0.0018 in.)

Seat Width: .

Intake 1.56 mm (0.061 in.)

Exhaust 1.56 mm (0.061 in. )

Valve Guide Inside Diameter(All)

5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)


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Valve Stem Diameter .

Intake 5.465 ~ 5.480 mm (0.215 ~ 0.216 in.)

Exhaust 5.440 ~ 5.455 mm (0.214 ~ 0.215 in.)

Valve Diameter (All): .

Intake 35.5 ~ 35.7 mm (1.398 ~ 1.406 in.)

Exhaust 31.7 ~ 31.9 mm (1.248 ~ 1.256 in.)

Valve Spring Loads: .

Valve Open55.0 3.3 Kgf (121.25 7.28 lbs) @ 36.2 mm

(1.425 in.)

Valve Closed25.2 1.8 Kgf (55.56 3.97 lbs) @ 44.2 mm

(1.740 in.)

Oil Pump : .

Gap Between Oil Pump Body

and Out Rotor

0.10 ~ 0.17 mm (0.0039 ~ 0.0067 in.)

Out Rotor Side Clearance 0.065 ~ 0.115 (0.0026 ~ 0.0045 in.)

Inner Rotor Side Clearance 0.065 ~ 0.115 (0.0026 ~ 0.0045 in.)

Relief Valve Spring FreeLength

52.4 mm (2.06 in.)

Fastener Tightening Specifcations

Application Nm Lb-Ft Lb-In

Cylinder Head Bolts 65 - 70 48 - 52 -

Cylinder Head Cover Hexagon Bolts 9 - 12 - 80 - 106

Catalytic Converter To Exhaust Manifold Nuts 25 - 35 18 - 25 -

Heat Shield Mounting Bolts 8 - 12 - 71 - 106

Timing Belt Rear Cover Bolts 9 - 12 - 80 - 106

Lower Timing Belt Cover Bolts 9 - 12 - 80 - 106

Upper Timing Belt Cover Bolts 9 - 12 - 80 - 106

Crankshaft Pulley Bolts 85 62.7 -

Air Cleaner Housing Bolts 7 - 9 - 62 - 80

Camshaft Thrust Plate Screws 10 - 89

Rocker Arm Shaft Mounting Bolts 10 - 89

Water Outlet Case Nuts and the Bolt 10.5 - 93

Tensioner Bolts to 19 14 -

Timing Belt Tensioner Bolt 19 14 -

Timing Belt Front Lower Cover Bolts 10.5 - 93

Oil Level Gauge Guide Tube Bolt 10.5 - 93

Timing Belt Front Upper Cover Bolts 10.5 - 93

Air Cleaner Housing Bolts 12 - 106


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Application Nm Lb-Ft Lb-In

Oil Pump Bolts to 10.5 - 93

Oil Pump Strainer Bolts 10.5 - 93

Rear Timing Belt Cover Bolts 10.5 - 93

Camshaft Gear Bolt to 55 41 -Oil Pan Retaining Bolts and the Nuts 10 44 -

Intake Manifold Retaining Nuts and Bolts 17 13 -

Exhaust Manifold Bolts and the Nuts 22 16 -

Front Exhaust Pipe Bracket Bolts 40 30 -

Catalytic Converter Lower Flange Nuts 40 - 30

Exhaust Manifold Heat Shield Bolts 10 - 89

Engine Mounting Bracket Bolt 55 41 -

Flywheel Bolt 42.5 31 -

SPECIAL TOOLSSpecial Tools Table

09915-64510

Compression PressureGauge
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09915-67310

Vacuum Gauge

09915-77310

Oil Pressure Gauge
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09916-14510

Valve Spring

Compressor

09916-48210Valve Spring

Compressor Attachment

09916-34541

Reamer Handle
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09916-37320

Valve Guide Reamer

(5mm or 0.1969 in.)

09916-38210

Valve Guide Reamer

(11mm or 0.4331 in.)
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09916-44910

Valve Guide Remover

09916-58210

Valve Guide Installer
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09916-77310

Piston Compressor

09917-68220

Camshaft Sprocket

Holder
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09927-56020

Crankshaft Pully Holder

DW 100-010

Fuel Pressure Gauge
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DW110-060Engine Assembly

Support Fixture

DW 150-020

Distributor Case NutRemover/Installer
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KM - 412

Engine Overhaul Stand

DW 010 - 010

Engine & Transaxle

Assembly SupportRemover/Installer

COMPONENT LOCATORCylinder Head
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1. Oil Filler Cap2. Cylinder Head Cover3. Cylinder Head Cover4. Distributor Case5. Camshaft6. Exhaust Rocker Arm7. Cylinder Head Gasket8. Cylinder Head9. Intake Rocker Arm10. Exhaust Valve11. Intake Valve
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Engine Block

1. Oil Level Gauge Stick2. Piston3. Connecting Rod4. Engine Block5. Oil Filter6. Flywheel7. Crankshaft8. Oil Pan9. Oil Pump Strainer10. Oil Pump Assembly
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Manifold & Air Flow System

1. Intake Manifold2. Exhaust Gas Recirculation (EGR) Pipe3. Exhaust Gas Recirculation (EGR) Valve and Solenoid4. Throttle Body Assembly5. Air Filter Assembly6. Resonator7. Snorkel8. Oxygen Sensor9. Exhaust Manifold10. Exhaust Manifold Heat Shield11. Exhaust Manifold Heat Shield12. Exhaust Manifold
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Timing Belt

1. Engine Mount Damping Block2. Engine Mount Intermediate Bracket3. Engine Mount Brace Bracket4. Transaxle Mount Bracket

5. Transaxle Mount Damping Block6. Engine Mount Front Bracket7. Engine Mount Front Damping Bush8. Timing Belt9. Timing Belt Tensioner10. Crankshaft Gear11. Timing Belt Upper Front Cover12. Timing Belt Lower Front Cover


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13. Crankshaft Pulley14. Engine Mount Lower Bracket15. Engine Mount Upper Bracket

MAINTENANCE AND REPAIRON-VEHICLE SERVICE

Cylinder Head CoverRemoval Procedure

1. Disconnect the negative battery cable.2. Disconnect the PCV hose from the cylinder head cover.3. Disconnect the ignition wires at the spark plug and the ignition coil.4. Remove the ignition coil. Refer toSection 1F1, Engine Controls.
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5. Remove the cylinder head cover hexagon bolts.6. Remove the cylinder head cover with gasket.7. Clean the sealing surfaces of the cylinder head cover and the cylinder

head.


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Installation Procedure

1. Install the cylinder head cover with the new gasket.2. Install the bolts to the cylinder head cover.

TightenTighten the cylinder head cover hexagon bolts to 10.5 Nm (93 lb -in).


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3. Connect the PCV hose to the cylinder head cover.4. Install the ignition coil. Refer toSection 1F1, Engine Controls.5. Connect the negative battery cable.
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Cylinder Head and Gasket

1. Remove the fuel pump fuse.2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the

fuel system of fuel pressure.3. Disconnect the negative battery cable.


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4. Drain the engine coolant. Refer toSection 1D, Engine Cooling.5. Disconnect the PCV hose from the cylinder head cover.6. Remove the ignition coil. Refer toSection 1F1, Engine Controls.
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7. Remove the air cleaner housing bolts.8. Remove the air cleaner housing.


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9. Disconnect the main throttle idle actuator (MTIA) connector.10. Disconnect the A/C pressure transducer connector.
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11. Disconnect the intake air temperature (IAT) sensor connector.12. Disconnect the throttle cable from the throttle body.13. Disconnect the brake booster vacuum hose at the intake manifold.

14. Disconnect the fuel injector harness connectors.15. Disconnect the fuel line at the fuel rail.16. Disconnect the fuel rail with the fuel injector attached.


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17. Disconnect the camshaft position sensor connector.18. Disconnect the engine coolant temperature (ECT) sensor connector.


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19. Slightly loosen the power steering lower adjusting bolt.

20. Slightly loosen the power steering upper adjusting bolt.21. Remove the A/C with power steering drive belt.


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22. Remove the upper timing belt cover bolts.23. Remove the upper timing belt cover.


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24. Align the camshaft gear timing mark to the notch in the rear timing beltcover.


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25. Slightly loosen the alternator retaining bolts.26. Remove the alternator drive belt.


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27. Remove the engine under cover.28. Remove the crankshaft pulley bolt.29. Remove the crankshaft pulley.


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30. Remove the lower timing belt cover bolts.31. Remove the lower timing belt cover.


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32. Remove the timing belt automatic tensioner bolt.33. Remove the timing belt automatic tensioner.34. Remove the timing belt. Refer to"Timing Belt" in this section.
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35. Remove the camshaft gear bolt from the camshaft.


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36. Remove the timing belt rear cover bolts.37. Remove the timing belt rear cover from the cylinder head and cylinder

block.

38. Remove the heat shield mounting bolts.39. Remove the heat shield.


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40. Remove the retaining nuts from the catalytic converter at the exhaustmanifold flange.


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41. Remove the cylinder head cover with the hexagon bolts.42. Remove the cylinder head cover gasket.


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43. Gradually loosen all of the cylinder head bolts in the sequence shown.44. Remove the cylinder head bolts.45. Remove the cylinder head assembly from the engine block, with the

intake/exhaust manifold, throttle body, water outlet case and cylinder headgasket.


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Cleaning Procedure

1. Clean the gasket surfaces of the cylinder head and the engine block.2. Make sure the gasket surfaces of the cylinder head and the engine block

are free of nicks and heavy scratches.3. Clean the cylinder head bolts.4. Inspect the cylinder head for warpage. Refer to"Cylinder Head and Valve

Train Components" in this section.
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1. Install the cylinder head gasket.2. Install the cylinder head with the intake manifold and the exhaust manifold

attached.3. Install the cylinder head bolts in the sequence shown.

TightenTighten the cylinder head bolts to 65-70 Nm (4852 lb-ft).


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4. Install the cylinder head cover hexagon bolts.

TightenTighten the cylinder head cover hexagon bolts to 912 Nm ( 80106 lb-in).

5. Install the catalytic converter nuts at the exhaust manifold flange.

TightenTighten the catalytic converter to exhaust manifold nuts to 2535 Nm (18-25 lb-ft).


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6. Install the heat shield.7. Install the heat shield mounting bolts.

TightenTighten the heat shield mounting bolts to 8-12 Nm (71-106 lb-in).


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8. Install the timing belt rear cover to the cylinder head and cylinder block.9. Install the timing belt rear cover bolts.

Tighten

Tighten the timing belt rear cover bolts to 9-12 Nm (80-106 lb-in).


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10. Install the timing belt. Refer to"Timing Belt" in this section.11. Install the lower timing belt cover.12. Install the lower timing belt cover bolts.

TightenTighten the lower timing belt cover bolts to 9-12 Nm (80-106 lb-in).


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15. Install the crankshaft pulley.16. Install the crankshaft pulley bolts.

TightenTighten the crankshaft pulley bolts to 85 Nm ( 62.7 lb-ft)


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17. Install the A/C with power steering drive belt. Refer toSection 6B,Accessory Belt.

18. Install the alternator drive belt.
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19. Connect the engine coolant temperature (ECT) sensor connector.20. Connect the camshaft position sensor connector.


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21. Connect the fuel line at the fuel rail.22. Connect the fuel injector harness connectors.

23. Connect the brake booster vacuum hose at the intake manifold.24. Connect the throttle cable to the throttle body.

25. Connect the intake air temperature (IAT) sensor connector.


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26. Connect the A/C Pressure transducer connector.27. Connect the main throttle idle actuator (MTIA) connector.


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28. Install the air cleaner housing.29. Install the air cleaner housing bolts.

TightenTighten the air cleaner housing bolts to 7-9 Nm ( 6280 lb-in).

30. Connect the PCV hose from the cylinder head cover.31. Install the ignition coil. Refer toSection 1F1, Engine Controls.32. Connect the negative battery cable.33. Install the fuel pump fuse.34. Refill the engine cooling system. Refer toSection 1D, Engine Cooling.
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CamshaftRemoval Procedure

1. Remove the timing belt. Refer to"Timing Belt"in thissection.2. Remove the ignition coil at the cylinder head cover.


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3. Drain the engine coolant. Refer toSection 1D, Engine Cooling.4. Disconnect the camshaft position (CMP) sensor connector.5. Disconnect the engine coolant temperature (ECT) sensor connector.6. Disconnect the radiator upper hose at the water outlet case.7. Disconnect the throttle body and heater feeding hoses.
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8. Remove the cylinder head cover with gasket.


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9. Remove the water outlet case nuts and the bolt.10. Remove the water outlet case at the cylinder head.

11. Remove the rocker arm shaft mounting bolts.12. Remove the rocker arm spring and the rocker arm.


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13. Remove the screws with the camshaft thrust plate.


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14. Remove the camshaft.


1. Install the camshaft.2. Install the camshaft thrust plate.3. Install the camshaft thrust plate screws.

TightenTighten the camshaft thrust plate screws to 10 Nm ( 89 lb-in).


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4. Install the rocker arm spring and the rocker arm.5. Install the rocker arm shaft.6. Install the rocker arm shaft mounting bolts.

TightenTighten the rocker arm shaft mounting bolts to 10 Nm ( 89 lb -in).


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7. Install the water outlet case at the cylinder head.8. Install the water outlet case nuts and the bolt.

TightenTighten the water outlet case nuts and the bolt to 10.5 Nm (93 lb-in).


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9. Install the cylinder head cover gasket.10. Install the cylinder head cover.11. Install the cylinder head cover hexagon bolts.

Tighten

Tighten the cylinder head cover hexagon bolts to 10.5 Nm (93 lb -in).


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12. Connect the throttle body and heater feeding hose.13. Connect the radiator upper hose.14. Connect the CMP and ECT sensor connectors.
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15. Install the ignition coil. Refer toSection 1F1, Engine Controls.16. Connect the PCV hose to the cylinder head cover.17. Refill the engine cooling system. Refer toSection 1D, Engine Cooling.18. Connect the negative battery cable.19. Install the timing belt. Refer to"Timing Belt"in thissection.
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Adjustment of Valve ClearanceRemoval Procedure

1. Remove the cylinder head cover hexagon bolts and remove the cover.2. Turn over the crankshaft to make NO.1 cylinder matched with the

compression top dead center. When the camshaft sprocket notch isaligned with the timing belt rear cover triangle pointer and the crankshaftsprocket point is aligned with the oil pump housing point, the compressiontop dead center is on the ignition sequence for NO.1 cylinder.


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3. Check the valve clearance for NO.1 cylinder compression top dead center.4. If the checking for the valve clearance of No1 cylinder compression top

dead center is over, position No.1 cylinder on the exhaust top dead centeras rotating the crankshaft in a 360degree arc. When the camshaftsprocket point is aligned with the timing belt rear cover triangle pointer, theexhaust top dead center is on the ignition sequence for No.1 cylinder.


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5. Check the valve clearance for the No.1 cylinder exhaust top dead center.

Condition Cylinder No. 1 2 3 4

Exhaust top dead center of No.1 cylinderIntake . . O O

Exhaust . O . O

* O marks indicates the place where the valve clearance can be checked

and adjusted.


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6. Check the adjust the valve clearance using thickness gauge. Themeasured value of valve clearance should meet the specified value. If not,adjust the valve clearance.

Important : In case of hot engine, warm up the engine until theelectric cooling fan begins to work and stop engine to adjust theclearance with 20-30 minutes there from.

Unit : mm (in.)

Item Specified value

Valve Clearance

Cold Intake 0.150.02 (0.00590.0008)

. Exhaust 0.20.02 (0.007870.0008)

Hot Intake 0.250.02 (0.00980.0008)

. Exhaust 0.30.02 (0.01180.0008)


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7. When adjusting the valve clearance, loosen the adjust nut and thentighten or loosen the adjust rod properly.


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Valve Timing Check and Adjustment

1. After removing the air cleaner housing, loosen the bolts and remove thetiming belt front upper cover.


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2. Turning the crankshaft clockwise twice, align the notch on the crankshaftpulley with the mark 0 for the timing check on the timing belt front lowercover.
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3. Check if the notch on the camshaft sprocket is aligned with the trianglepointer on the timing belt rear cover.

Important : Notch should be aligned with pointer to set the valvetiming normally.

4. Loosen the bolt and remove the timing belt pulley. In loosening the bolt,use the driver in the picture shown.


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5. Remove the oil level gauge guide tube and the timing belt front lowercover.
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6. Remove the timing belt tensioner and the timing belt.

7. Using the bolt, turn the crankshaft clockwise to align the mark on thecrankshaft sprocket with the pointer on the oil pump housing. Then, turnthe camshaft to align the notch with the pointer.


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8. Install the timing belt and the tensioner.9. Turning the crankshaft clockwise twice, align the mark with the pointer and

tighten the tensioner bolt.

TightenTighten the tensioner bolt to 19 Nm (14 lb-ft).


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Timing Belt

1. Disconnect the negative battery cable.2. Disconnect the air cleaner outlet hose from the throttle body.

3. Remove the air cleaner housing bolts.4. Remove the air cleaner housing.5. Remove the right front wheel. Refer toSection 2E,Tires and Wheels.6. Remove the right front wheel well splash shield.
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7. Remove the A/C compressor drive belt.8. Remove the alternator drive belt.9. Remove the upper timing belt cover bolts.10. Remove the upper timing belt cover.


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11. Align the mark on the camshaft gear with the notch on the rear timing beltcover by turning the crankshaft pulley.


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12. Remove the crankshaft pulley bolt.13. Remove the crankshaft pulley.14. Remove the lower timing belt cover bolts.15. Remove the lower timing belt cover.


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16. Loosen the timing belt tensioner bolt.17. Remove the timing belt.


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Installation ProcedureImportant : If the camshaft or crankshaft rotates in the process ofinstalling the timing belt, Perform the valve timing setting necessary.Refer to"Valve Timing Check and Adjustment"in this section.

1. Install the timing belt tensioner bolt.

TightenTighten the timing belt tinsioner bolt to 19 Nm ( 14 lb-ft).
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Important : Turn the crankshaft twice to align the notch on thecamshaft with the pointer on the rear cover and tighten the tensionerbolt.

2. Install the lower timing belt cover.

TightenTighten the lower timing belt cover bolts to 10.5 Nm ( 93 lb-in).

3. Install the oil level gauge guide tube bolt.

TightenTighten the oil level gauge guide tube bolt to 10.5 Nm (93 lb -in).


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4. Install the upper timing belt cover.

TightenTighten the upper timing belt cover bolts to 10.5 Nm ( 93 lb-in).

5. Install the crankshaft pulley bolt.

TightenTighten the crankshaft pulley bolts to 70 Nm (52 lb-ft).


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6. Install the alternator drive belt.7. Install the A/C compressor drive belt.8. Install the right front wheel. Refer toSection 2E,Tires and Wheels.9. Install the air cleaner housing.10. Install the air cleaner housing bolts.

TightenTighten the air cleaner housing bolts to 12 Nm (106 lb -in).

UNIT REPAIRCylinder Head and Valve Train ComponentsTools Required

09916-14510 Valve Spring Compressor09916-37320 Valve Guide Reamer

09916-38210 Valve Guide Reamer09916-44910 Valve Guide Remover09916-48210 Valve Spring Compressor Attachment09916-58210 Valve Guide Installer09917-88220 Valve Guide Installer AttachmentKM 412 Engine Overhaul Stand
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Disassembly Procedure

1. Remove the cylinder head with the intake manifold and the exhaustmanifold attached. Refer to"Cylinder Head and Gasket" in this section.

2. Remove the bolt and the nuts in the water outlet case .3. Remove the water outlet case.
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4. Remove the exhaust manifold heat shield bolts.5. Remove the exhaust manifold heat shield.
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6. Remove the exhaust manifold nuts and the bolts.7. Remove the exhaust manifold gasket.8. Remove the exhaust manifold studs.

9. Remove the spark plugs.
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10. Remove the intake manifold retaining bolts and the nuts.11. Remove the intake manifold with the gasket.12. Remove the intake manifold studs.


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13. Remove the rocker arm shaft mounting bolts.

14. Remove the rocker arm spring and the rocker arm.
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15. Remove the screws with the camshaft thrust plate.
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16. Remove the camshaft.

17. Remove the camshaft front oil seal from housing hole.
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18. Using the valve spring compressor 09916-14510, compress the valvespring

19. Remove the valve keepers.20. Remove the valve spring retainer and valve spring.21. Remove the valves.
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22. Remove the valve stem oil seals.23. Remove the valve spring seat.
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24. Position the valve guide remover 09916-44910 on the valve guide.25. Hammer and remove the valve guide from the combustion chamber to the

direction of the installed valve spring using the valve guide remover09916-44910.

26. Remove the valve guide.

Cylinder Head Inspection

1. Clean the sealing surfaces.2. Inspect the cylinder head gasket and the mating surfaces 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 with in 0.05mm (0.0020 in.) maximum.
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6. Inspect all threaded holes for damage.7. Inspect the valve seats for excessive wear and burned spots.

Valve Inspection
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1. Inspect valve stem tip wear.2. Inspect the valve keeper grooves and oil seal grooves for chips and wear.3. Inspect the valves for burns or cracks.4. Inspect the valve stem for burrs and scratches.5. Inspect the valve stem. The valve stem must be straight.

6. Inspect the valve facefor grooving. If the groove is so deep the refacingwould result in a sharp edge, replace the valve.

7. Inspect the valve spring. If the valve spring ends are not parallel, replacethe valve spring.

8. Measure the valve spring height. Refer to"Engine Specifications" in thissection. 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 orgouges. Replace as required.
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Cleaning Procedure

1. Clean the cylinder head.2. Clean the valve guides.3. Clean all of the threaded holes.4. Clean the valves of carbon, oil and varnish.
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Cylinder Head OverhaulMeasuring The Camshaft Bend

1. Measure the bending of the camshaft using a dial gauge and replace itwhen the measured value is over the specified limit (0.03mm (0.0012 in.)).
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Abrasion of The Camshaft Journal

1. Measure the outer diameter of each journal at the 5 different places.

2. Using a bore gauge, measure the inner diameter of the cylinder headjornal at the 5 places (The clear-ance of journal is measured by thedifference be-tween the outer diameter of camshaft journal and innerdiameter of cylinder head journal part.)

3. Replace the camshaft (or cylinder head, if necessary) of which limit is overthe specified limit.

Item Standard Limit

Journal

Clearance

0.05-0.091 mm

(0.0020-0.0036 inches)

0.15 mm

(0.0059 inches)

Item Outer diameter,camshaft journal

Inner diameter cylinder head journalpart

a43.425-43.450 mm

(1.7096-1.7106 in.)

43.500-43.516 mm

(1.7126-1.7132 in.)

b43.625-43.650 mm

(1.7175-1.7185 in.)

43.700-43.716 mm

(1.7205-1.7211 in.)

c 43.825-43.850 mm 43.900-43.916 mm


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(1.7254-1.7264 in.) (1.7283-1.7290 in.)

d44.025-44.050 mm

(1.7333-1.7343 in.)

44.100-44.116 mm

(1.7362-1.7369 in.)

e44.225-44.250 mm(1.741-1.742 in.)

44.3-44.316 mm(1.744-1.745 in.)

Bending of The Rocker Arm Shaft

1. Check the bending of the rocker arm shaft by using the V block and dialgauge.

2. Replace the rocker arm shaft of which bending is over the specification(0.10mm (0.0039 inches)).
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Clearance Between The Rocker Arm and The Rocker Arm Shaft

1. Check the outer diameter of the rocker arm shaft using a micrometer.
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2. Check the inner diameter of the rocker arm using a bore gauge.3. Replace the shaft or rocker arm (or both of them, if necessary) if the

difference is over the limit between the outer diameter and the innerdiameter (0.005 - 0.040mm (0.0002 - 0.0016 in.)

Clearance Between The Valve Stem and The Valve Guide

1. Check the outer diameter of the valve stem using a micrometer.oIntake : 5.465 - 5.480mm (0.2152 - 0.2157 in.)oExhaust : 5.440 - 5.455mm (0.2142 - 0.2148 in.)
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2. Check the inner diameter of the valve guide using a bore gauge (at least 1place in the direction to valve length)

oIntake : 5.500 - 5.512mm (0.2165 - 0.2170 in.)oExhaust : 5.500 - 5.512mm (0.2165 - 0.2170 in.)

3. Check the clearance between the valve stem and the valve guideoIntake : 0.020 - 0.047mm (0.0008 - 0.0019 in.)oExhaust : 0.0045 - 0.072mm (0.0018 - 0.0028 in.)
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4. If a bore gauge is not available, measure the clearance using a dial gaugeby moving the edge of the stem to the directions.

oIntake : 0.14mm (0.0055 in.)oExhaust : 0.18mm (0.0071 in.)

5. Replace the valve stem or valve guide, if the measured valve is over thelimit.
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Valve

1. Inspect the valve. Refer to Valve Inspection in this section.2. Check the valve or stem for abrasion, burn or bending, and replace as

necessary.3. Abrasion of the valve edge.

oCheck the edge of each valve for abrasion. Some uneven abrasionwould be made on the edge because the rocker arm gets contactedat this surface when operating. Repair the section within 0.05mm(0.002 in.) as required, or replace the valve if some modification isrequired more than that.
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4. Deviation to the rotating direction. Measure the deviation to the rotatingdirection using a dial gauge and the V block by turning the valve slowly.Deviation limit of valve head to the rotating direction within 0.08mm(0.0031 in.)

5. Replace valve, if the measured value exceeds the limit.
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6. Clean the valve and the valve seat and apply red stamping ink thinly to thecontacting surface of the valve seat. Check the fitness after installing thevalve unit.

7. Check the contact witdth on the surface of the valve seat.oIntake : 1.46 - 1.66mm (0.0575 - 0.0654 in.)oExhaust : 1.46 - 1.66mm (0.0575 - 0.0654 in.)
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8. Repair by grinding and cutting off the valve seat, and lap it if its contactingwidth is not even or out of the specified.

9. Upon applying a seat cutter, use the one of smaller angle first andincrease the angle of the using cutter up to the light and final modificationof the contact. And finish contact surface and its location with the cutter of45 degrees.

Important : Upon cutting, take care of the contact width. Finish thecutting with gradually reduced power for no cutting mark on thesurface.
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10. Make lapping in two stages, first with normal lap and second with fine onefor the both sides.

Assembly Procedure


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1. Make the valve guide hole using a valve guide reamer 09916-38210.Before Installing The new valve guide into the cylinder head, ream guidehole with 11mm reamer to remove burrs. Make sure that the guide holecones to a complete roundness

2. Peen and install new valve guide

Cautio n : Heat the cy lind er head unif orm ly at a t emp eratur e 80-100C

(176-212F) not to make th e head defo rmed, and dri ve new valve

guide completely into the hole with the tools the valve guide installer

attachment 09917-88220.

3. Check the protruded part of the guide from the cylinder head.

Important : Do not reuse the valve guide once disassembled, replaceit with the new oversized valve guide.

oValve guide oversize : 0.03mm (0.0012 in.)oValve guide protrusion : 14mm (0.5512 in.)
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4. Repair the valve guide bore with the valve guide reamer 09916-37320(5mm or 0.1969 in.)

5. Make the hole free from foreign material.
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6. Install the valve spring seats.7. Install the valve stem oil seal to the valve guide. After applying engine oil

to seal and installing seal to the valve guide and make sure that seal isproperly fixed to the valve guide.

Important : Do not reuse the disassembled oil seal and replace it withnew one. When installing it, neer tap or hit tool with a hammer orelse. Install seal to guide only by pushing special tool with hand.Tapping or hitting tool may cause damage on seal.

8. Install the valve to the valve guide.

Important : Before installing it, coat engine oil to the stem seal, valveguide bore and valve stem.
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9. Install the valve springs and the spring retainers.10. Using the valve spring compressor 09916-48210, compress the valve

spring11. Install the valve keepers.


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12. Install the camshaft front oil seal from housing hole.
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13. Coat the engine oil to the camshaft front oil seal, the cam, and thecamshaft journal.

14. Install the camshaft front oil seal to the housing hole.15. Install the camshaft to the cylinder head.

Notice : Installing the camshaft, take extreme care to prevent anyscreatch, nick or damage.

16. Install the screws with the camshaft thrust plate.

TightenTighten the screws to 10 Nm (89 lb-in).
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17. Coat the engine oil to the rocker arms and the rocker rocker arm shafts.18. Install the rocker arm spring and the rocker arm.
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19. Install the rocker arm shaft mounting bolts.

TightenTighten the bolts to 10 Nm (89 lb-in).

Important : Rocker arm shaft for the intake valves and the exhaust

valves are different and their directions of installation are different.
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20. Install the intake manifold studs.21. Install the intake manifold with the gasket.22. Install the intake manifold.


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23. Install the intake manifold nuts in the sequence order.

Tighten

oTighten the intake manifold nuts and the bolts to 17 Nm (13 lb-ft).oTighen the intake manifold supprot bracket bolt to 10 Nm (89 lb-in).

Important : Before tightening the intake manifold nuts, first of all,tighten the intake manifold support bracket nut.


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24. Install the spark plugs.

25. Install the exhaust manifold gasket and the exhaust manifold.
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26. Install the bolts and nuts in the sequence order as shown in the picture.

TightenTighten the exhaust manifold nuts and bolts to 22 Nm (16 lb -ft).
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27. Install the exhaust manifold heat shield.28. Install the exhaust manifold heat shield bolts.

TightenTighten the exhaust manifold heat shield bolts to 10 Nm (89 lb-in).
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29. Install the water outlet case.30. Install the water outlet case mounting bolts.

TightenTighen the water outlet case mounting bolts to 10.5 Nm (93 lb-in).

31. Install the cylinder head with the intake manifold and exhaust manifoldattached. Refer to"Cylinder Head and Gasket" in this section.
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CrankshaftTools Required

KM-412 Engine Overhaul Stand09916-77310 Piston Compressor

Disassembly Procedure

1. Removethe engine. Refer to"Engine"in this section.2. Remove the transaxle from the engine. Refer toSection 5B, Five-Speed

Manual Transaxle.3. Remove the flywheel bolts.4. Remove the flywheel.5. Mount the engine assembly on the engine overhaul stand KM-412.
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6. Remove the cylinder head. Refer to"Cylinder Head and Gasket" in thissection.

7. Drain the engine oil from the engine.8. Remove the power steering adjusting bolts.9. Remove the power steering/air conditioning belt.
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10. Turn the A/C compressor downward.11. Remove the A/C compressor/power steering bracket bolts.12. Remove the A/C compressor/power steering bracket.

13. Loosen the generator bolt.

14. Loosen the generator lower bolts and the nut.15. Remove the generator and belt.
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16. Loosen the engine mount upper bracket bolts.17. Remove the generator shackle.18. Remove the upper bracket.19. Loosen the engine mount lower bracket bolts.20. Remove the lower bracket.
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21. Remove the upper timing belt cover bolts.22. Remove the upper timing belt cover.
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23. Remove the lower timing belt cover bolts.24. Remove the lower timing belt cover.

25. Loosen the timing belt automatic tensioner bolt.26. Remove the automatic tensioner from the timing belt.

27. Remove the timing belt.


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28. Rotate the engine on the engine overhaul stand KM-412.29. Remove the oil pan retaining bolts and the nuts.30. Remove the oil pan.
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31. Remove the oil pan pickup tube bolts.32. Remove the oil pan pickup tube.

33. Remove the oil pump retaining bolts.34. Remove the oil pump.
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35. Remove the crankshaft rear oil seal housing screws and bolts.36. Remove the gasket and the oil seal housing.
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37. Mark the order of the rod bearing caps.38. Remove the connecting rod cap nuts for all of the pistons.39. Remove the connecting rod bearing caps and the lower connecting rod

bearing.40. Remove the upper connecting rod bearing.

41. Mark the order of the crankshaft bearing caps.42. Remove the crankshaft bearing cap bolts.43. Remove the crankshaft bearing cap.44. Remove the crankshaft bearings from the crankshaft bearing caps.45. Remove the crank shaft.46. Remove the crankshaft bearings from the engine block.47. Clean the parts, as necessary.


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Assembly Procedure

1. With crankshaft and bearings in place, plastic gauge all bearingclearances. Refer to"Crankshaft Bearings and Connecting Rod Bearings -Gauging Plastic" in this section.

2. Inspect the crankshaft end play with the crankshaft bearings installed.3. Check the Permissible crankshaft end play. Refer to"Engine

Specifications" in this section.
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4. With the crankshaft mounted on the front and the rear crankshaftbearings, Check the middle crankshaft journal for permissible out-of-round(runout). Refer to"Engine Specifications" in this section.
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5. Coat the crankshaft bearings with engine oil.6. Apply a bead of adhesive sealing compound to the grooves of the rear

crankshaft bearing cap.7. Install the crankshaft bearings in the engine block.8. Install the crankshaft.

Important : Grease the crankshaft journals and lubricate thecrankshaft bearings slightly so that the plastic gauging thread doesnot tear when the crankshaft bearing caps are removed.

9. Inspect all of the crankshaft bearing clearances using a commerciallyavailable plastic gauging (ductile plastic threads).

10. Cut the plastic gauging threads to the length of the bearing width. Laythem axially between the crankshaft journals and the crankshaft bearings.
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11. Install the crankshaft bearings to the crankshaft bearing caps.12. Install the crankshaft bearing caps bolts.

Notice : Do not reuse the old crankshaft bearing cap bolts. Damageto the engine could result.TightenTighten the crankshaft bearing cap bolts to 57 Nm (42 lb-ft).


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13. Remove the crankshaft bearing caps.14. Measure the width of the flattened plastic thread of the plastic gauging

using a ruler. (Plastic gauging is available for different tolerance ranges.)15. Inspect the bearing clearances for permissible tolerance ranges. Refer to

"Engine Specifications" in this section.
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Inspection Precedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.

Important : Grease the connecting rod journals and lubricate theconnecting rod bearings slightly so that the plastic gauging threaddoes not tear when the connecting rod bearing caps are removed.

2. Install the upper connecting rod bearings into the connecting rod journals.3. Install the lower connecting rod bearings into the connecting rod bearing

caps.4. Inspect all of the connecting rod bearing clearances using a commercially

available plastic gauging (ductile plastic threads).
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5. Cut the plastic gauging threads to the length of the bearing width. Laythem axially between the connecting rod journals and the connecting rodbearing.

6. Install the connecting rod bearing caps.7. Install the connecting rod bearing cap nuts.

Tighten

Tighten the connecting rod bearing cap nuts to 33 Nm (24 lb -ft).
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8. Remove the connecting rod bearing caps.9. Measure the width of th flattened plastic thread of the plastic gauging

using a ruler. (Plastic gauging is available for different tolerance ranges.)10. Inspect the bearing clearance for permissible tolerance ranges. Refer to

"Engine Specifications" in this section.
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Inspection Precedure - Piston

1. Inspect the connecting rod for bending or twisting. If the connecting rod isbent or twisted, replace the connecting rod.

2. Inspect the connecting rod bearings.3. Inspect the connecting rod lower end for wear.4. Inspec the connecting rod upper end for scoring.5. Inspect the piston for scoring, cracks and wear.6. Inspect pistion for taper using a micrometer.
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7. Inspect the piston for fit to the connecting rod.


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8. Inspect the engine block deck surface for flatness using a straight edgeand a feeler gauge. Refer to"Engine Specifications" in this section.

9. Inspect the bearing bore for concentricity and alignment using a boregauge. Refer to"Engine Specifications" in this section.

10. Inspect the engine block cylinder bore for wear, runout ridging and taper

using a bore gauge. Refer to"Engine Specifications" in this section.11. Inspect the engine block cylinder bore for glazing. Lightly hone thecylinder bore as necessary.


1. Align the notch on the piston and connecting rod so that the proper sideswill be facing the front of the engine.

2. Install the pistion pin guide through the piston and the connecting rod.3. Coat the piston pin with clean oil.4. Install the piston pin into the opposite side of the pistion.5. Install the pistion pin into the pistion and connecting rod assembly.
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6. Select a set of new pistion rings.7. Measure the piston ring gap using a feeler gauge.8. Increase the piston ring gap by carefully filling off excess material if the

piston ring gap is below specifications.
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9. Measure the pistion ring side clearance using a feeler gauge. Refer to"Engine Specifications" in this section.

10. If the pistion ring is too thick, try another pistion ring.

11. If no piston ring can be found that fits to specifications the pistion ring maybe ground to size with emery paper placed on a sheet of glass.

12. Install a piston oil ring, the expander and the second piston oil ring to thebottom ring groove of the pistion.

13. Install the second compression ring to the middle ring groove of the piston.14. Install the top compression ring to the top ring groove of the pistion.
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15. Use a piston ring expander to install the piston rings. Do not expand thepiston rings beyond the expansion necessary for installation.

16. Stagger the piston oil rings, the oil ring rail gaps, the second compressionring, and the top compression ring in relation to the notch on t

Motor Daewod 1.0-1.2l Aveo, Spark, Matiz

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