.	Application	Unit	Description
Camshaft	Lift - Intake	mm	46.3
	Lift - Exhaust	mm	45.3
	Bending	mm	0.04
	Journal Outer Diameter : No.1	mm	Φ27.939-27.960
	Journal Outer Diameter : No.2	mm	Φ27.939-27.960
	Journal Outer Diameter : No.3	mm	Φ27.939-27.960
	Journal Outer Diameter : No.4	mm	Φ27.939-27.960
	Journal Outer Diameter : No.5	mm	Φ27.939-27.960
	Trust Clearance(End Play)	mm	0.13-0.215
Cylinder Head	Journal Inner Diameter : No.1	mm	28.000-28.021
	Journal Inner Diameter : No.2	mm	28.000-28.021
	Journal Inner Diameter : No.3	mm	28.000-28.021
	Journal Inner Diameter : No.4	mm	28.000-28.021
	Journal Inner Diameter : No.5	mm	28.000-28.021
	Journal Clearance	mm	0.04~0.082
	Height	mm	135.55
	Surface Flatness Deformation cover/Block	mm	0.02/50 / 0.025/150
	Manifolds Surface Deformation	mm	0.05
Valve	Deviation	mm	0.03
	Seat Inner Diameter - Intake	mm	30.7
	Seat Inner Diameter - Exhaust	mm	27.2
	Face Diameter - Intake	mm	Φ31.2+/-0.1
	Face Diameter - Exhaust	mm	Φ27.5+/-0.1
	GUIDE Inner Diameter - Intake	mm	Φ5.0-5.016
	GUIDE Inner Diameter - Exhaust	mm	Φ5.0-5.016
	Valve Stem Outer Diameter - Intake	mm	Φ4.965-4.980
	Valve Stem Outer Diameter - Exhaust	mm	Φ4.950-4.965
	Valve Length - Intake	mm	117.10 - 117.30
	Valve Length - Exhaust	mm	116.16 - 116.36
	Valve Spring - Straightness	°	Φ1.5
	Valve Spring - Free Length	mm	41.6
	Clearance (Intake)	mm	0.21-0.29 (nominal : 0.25 mm)
	Clearance (Exhaust)	mm	0.27-0.35 (nominal : 0.25 mm)
Oil pump	Axial clearance	mm	0.02-0.058
Piston	Diameter	mm	77.9 (nominal)
	Clearance	mm	0.030 ~ 0.060
Piston Ring	Groove Clearance - Top Ring	mm	0.04 ~ 0.08
	Groove Clearance - 2nd Ring	mm	0.03 ~ 0.07
	Groove Clearance - Oil Ring	mm	0.06 ~ 0.15
	End Gap - Top Ring	mm	0.15 ~ 0.30
	End Gap - 2nd Ring	mm	0.30 ~ 0.50
	End Gap - Oil Ring	mm	0.20 ~ 0.70
Piston Pin	Diameter	mm	19.000 ~ 19.005
	Length	mm	49.84 (-0.25~0.0)
	Clearance	mm	0.007 ~ 0.020
Connecting Rod	Thrust Clearance(End Play)	mm	0.07 ~ 0.242
	Width	mm	21.839 ~ 21.890
	Diameter - Piston Pin	mm	19.012 ~ 19.020
	Diameter - Crankshaft	mm	46.000 ~ 46.012
	Bending	mm	0.04
	Twist	mm	0.016
	Journal Bearing Oil Clearance	mm	0.019 ~ 0.063
Crankshaft	Thrust Clearance(End Play)	mm	0.1~0.202
	Journal Outer Diameter	mm	main : Φ54.980~54.997 pin : Φ42.971~42.987
	Journal Bearing Oil Clearance	mm	main : Φ0.0155~0.047 pin : Φ0.019~0.067
	Bending	mm	0.03
Cylinder Block	Diameter	mm	77.9
	Deck Surface Flatness	mm	0.025/65
	Cylindricity	mm	0.0065

Application	N•m	Lb-Ft	Lb-In
Accessory Belt Tensioner Bolt	50	36.8	-
Alternator B+ Tightening Nut	15	11	-
Camshaft Adjuster Bolts	65+120°+15°	47.9+120°+15°	-
Camshaft Bearing Cap Bolts	8	-	70.8
Camshaft Sprocket Bolt Cap	50	36.8	-
Camshaft Sprocket Bolts	65	47.9	-
Closure Bolt	15	11	-
Connecting-Rod Caps Bolts	35+45°+15°	25.8+45°+15°	-
Coolant Pipe to Coolant Distributor Case Bolts	8	-	70.8
Crankshaft Cap Bolts	50+50°	36.8+50°	-
Crankshaft Pulley Bolt	25	18.4	-
Cylinder Head Bolts	25+90°+90°+90°+45°	18.4+90°+90°+90°+45°	-
Cylinder Head Cover Bolts	8	-	70.8
Engine Front Cover Assembly Bolts	20	14.7	-
Engine Mount Bolts and Nuts	55	40.5	-
Engine Mount Bracket Bolt	65	47.9	-
Exhaust Manifold Lower Bracket Bolts	20	14.7	-
Exhaust Manifold Nuts	20	14.7	-
Flywheel(Flexible Plate) Bolts	35+30°+15°	25.8+30°+15°	-
Ground Tightening Nut	12	8.8	-
Heat Exchanger Bolts	8	-	70.8
Heat Shield Bolts	8	-	70.8
Ignition Coil Bolt	8	-	70.8
Indicator Tube Tightening Bolt	10	7.3	-
Intake Manifold Bolts	20	14.7	-
Intake Manifold Lower Bracket Bolt	8	-	70.8
Oil Cooler Tightening Bolts	25	18.4	-
Oil Pan Baffle Bolts	10	7.3	-
Oil Pan Bolts	14	10.3	-
Oil Pan-to-Transmission Bolts	40	29.5	-
Reaction Rod-to-Bracket Bolt and Nut	80	59	-
Reaction Rod-to-Crossmember Bolts	55	40.5	-
Spark Plug	25	18.4	-
Starter Solenoid B+ Tightening Nut	10.5	7.7	-
Starter Solenoid Ground Tightening Nut	38	28	-
Timing Belt Idler Bolt	50	36.8	-
Timing Belt Lower Cover Bolts	6	-	53.1
Timing Belt Rear Cover Bolts	6	-	53.1
Timing Belt Tensioner Bolt	55	40.6	-
Timing Belt Upper Cover Bolts	4	-	35.4
Transmission Tightening Bolt	60	44.2	-

	EN-49152 Oil Pan Bolt Remover/Installer
	EN-49153 Cylinder Pressure Adapter
	KM-498-B Pressure Gauge
	KM-6340 Locking Tool
	KM-6333 Fixing Rod
	KM-422 Installer
	KM-6351 Assembly Sleeves
	EN-48244 Engine Assembly Remove/Install Pallet Supporter
	EN-49155 Valve Spring Compressing Adapter
	EN-49156 Engine Assembly Remove/Install Pallet
	EN-49153 Piston Installer(1.6L ONLY)
	EN-49077 Compression Pressure Gauge
	KM-232 Adapter
	KM-6628-A Locking Tool
	KM-6625 Flywheel Locking Device
	KM-845 Suction Device
	KM-652 Flywheel Locking Device
	F202C301 Engine Overhaul Stand
	EN-49074 Universal Valve Spring Compressor
	EN-48356 Engine Fixture
	EN-49204 Crankshaft Rear Oil Seal Remover

1. Review the system operations to familiarize yourself with the system functions, refer to Section 1A, General Engine Information and Section 1F2, Engine Control - 1.4 DOHC - G14D- General Information.
2. Perform an engine management Diagnostic System Check, refer to Section 1F2 Engine Control - 1.4 DOHC - G14D- Diagnosis.

1. Inspect the vehicle for aftermarket accessories which may adversely affect engine operation.
2. Inspect the easily accessible or visible system components for obvious signs of damage or conditions that may cause the symptom.
3. Check the engine lubrication system for the following :
• correct oil level,
• correct lubricant viscosity,
• correct oil filter application, and
• contaminated or burnt oil
4. Confirm the exact operating conditions under which the fault occurs. Note factors such as :
• engine speed (r.p.m),
• ambient temperature,
• engine temperature,
• engine warm–up time, and
• vehicle road speed
5. Compare the engine sounds, if applicable, to a known good engine, and ensure you are not trying to diagnose a normal operating condition.

• The engine should be at normal operating temperature.
• The battery must be at or near full charge.
• The engine cranking time for compression test should be less than 10 seconds at interval of 30 seconds.

3. Disconnect the CKP (Crankshaft Position Sensor) connector.
4. Disconnect the CKP (Crankshaft Position Sensor) connector.
4. Remove the fuel pump relay from the engine room fuse box.
5. Remove the fuel pump relay from the engine room fuse box.

3. Remove the ignition coil cover.
4. Remove the ignition coil and spark plugs.
• Tighten Ignition coil bolt: 8 N•m (70.8 lb-in).
• Tighten spark plug: 25 N•m (18.4 lb-ft).
5. Crank the engine with the start motor to remove a foreign substance in the cylinder within 5 seconds.

6. Install the compression pressure gauge(EN-49077)(a) and adapter(EN-49154)(b) in the spark plug hole for the cylinder that is being checked.
7. Using the vehicle’s starter motor, rotate or crank the engine for less than 4 seconds at interval of 30 seconds by an assistant.
8. Read the compression pressure gauge.
9. Compare the all cylinder’s values. Maximum pressure differential 100kPa(1 bar). Engine revs at least 300rpm.
10. Examine the gauge readings obtained after the four”puffs” per cylinder are obtained from cranking the starter motor. The readings are explained in the following descriptions :
• Normal Condition: Compression builds up quickly and evenly to the specified compression on each cylinder.
• Piston Rings Faulty: Compression is low on the first stroke and tends to build up on following strokes, but the compression pressure does not reach normal. The compression pressure improves considerably with the addition of oil into the cylinder.
• Valves Faulty: Low compression pressure on the first stroke. The compression pressure does not tend to build up on the following strokes. The compression pressure does not improve much with the addition of oil into the cylinder.
11. Repeat the above procedure in the rest cylinders.

1. Remove the exhaust manifold heat shield. Refer to the “Exhaust Manifold” in this section.

2. Unscrew the closure bolt.(Tighten bolt: 15 N•m (11 lb-ft))
2. Install the oil pressure gauge(KM-498-B)(a) and adapter(KM-232)(b) in the hole.
3. Start the engine.
4. Check the engine oil pressure.
• The engine oil pressure must be at least 130 kPa(1.3 bar) at idle speed and oil temperature must be >=80°.

1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
1. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper.
2. Wait a few minutes.
3. Find the approximate location of the leak by the drippings on the paper.
3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam, or spray solvent.
1. Thoroughly clean the area.
2. Dry the area.
3. Operate the vehicle for several miles at normal operating temperature and varying speeds.
4. After operating the vehicle, visually check the suspected component.
5. If you still cannot locate the leak, try using the powder or black light and dye method.

1. Clean the suspected area.
2. Apply an aerosol-type powder, (such as foot powder), to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.

1. Pour the specified amount of dye into the engine oil fill tube.
2. Operate the vehicle under normal operating conditions as directed in the kit.
3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

• The fluid level/pressure is too high.
• The crankcase ventilation system is malfunctioning.
• The fasteners are improperly tightened or the threads are dirty or damaged.
• The flanges or the sealing surface is warped.
• There are scratches, burrs or other damage to the sealing surface.
• The gasket is damaged or worn.
• There is cracking or porosity of the component.
• An improper seal was used, (where applicable).

• The fluid level/pressure is too high.
• The crankcase ventilation system is malfunctioning.
• The seal bore is damaged, scratched, burred or nicked.
• The seal is damaged or worn.
• Improper installation is evident.
• There are cracks in the component.
• The shaft surface is scratched, nicked or damaged.
• A loose or worn bearing is causing excess seal wear.

Condition	Action
Abnormalities (severe cracking, bumps or missing areas) in the accessory drive belt. Also worn, damaged, or misaligned accessory drive components or excessive pulley runout.	Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Loose and/or damaged crankshaft pulley	A misfire code may be present without an actual misfire condition. Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	A misfire code may be present without an actual misfire condition. Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	A misfire code may be present without an actual misfire condition. Inspect flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Restricted exhaust system	A severe restriction in the exhaust flow can cause significant loss of engine performance and may set a misfire code. Possible causes of restrictions include collapsed or dented pipes, plugged mufflers and/or catalytic converters. Repair or replace all damaged components.
Air in fuel system	Inspect fuel filter, fuel system for leaks and/or restrictions. Repair or replace all damaged components.
Bent and/or worn valve bridge and finger-follower.	Inspect valve bridge and valve finger-follower. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Damaged or misaligned timing gears	Inspect timing gears. Replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform compression tests. Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.
Faulty cylinder head gaskets and/or cracking or other damage to the cylinder heads and engine block cooling system passages. (Coolant consumption may or may not cause the engine to overheat.)	Perform compression tests. Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.

Condition	Action
Abnormalities (severe cracking, bumps or missing areas) in the accessory drive belt.	Abnormalities in the accessory drive belt and/or components may cause engine RPM variations, noises similar to a faulty lower engine and also lead to a misfire condition. A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Worn, damaged, or misaligned accessory drive components or excessive pulley runout	A misfire code may be present without an actual misfire condition. Inspect the accessory drive components. Repair or replace all damaged components.
Loose and/or damaged crankshaft pulley	A misfire code may be present without an actual misfire condition. Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	A misfire code may be present without an actual misfire condition. Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	A misfire code may be present without an actual misfire condition. Inspect flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform cylinder leak down and compression tests Inspect the piston, piston rings and cylinder bore. Repair or replace all damaged components.
Excessive crankshaft thrust bearing clearance	Severely worn thrust surfaces on the crankshaft and/or thrust bearing may permit for and aft movement of the crankshaft and create a misfire code without an actual misfire condition. Inspect the crankshaft end play and crankshaft thrust bearings. Repair or replace all damaged components.

Condition	Action
Loose, worn or damaged valve bridge and finger-follower	Inspect valve bridge and finger-follower. Repair or replace all damaged components.
Broken valve springs	Inspect valve springs. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. Repair or replace all damaged components.

Inspection	Action
Definition : Base engine misfire with coolant consumption
Preliminary Inspection	Verify that there are no external coolant leaks. Refer to Section1D1, Engine Cooling – 2.0Diesel.
Isolate Affected Cylinders	Cylinder balance test with scan tool Cooling system pressurization Inspection of glow plugs Compression test
EGR System Inspection	Inspect EGR valve and intake system for evidence of coolant leakage. Replace the EGR cooler if any problem is found.
Cylinder Head Gasket Leakage	Remove cylinder heads of the affected cylinder bank and inspect for damage. Replace components as necessary.
Cylinder Head or Engine Block Damage	Inspect the cylinder heads for cracks. Inspect the cylinder block for damage. Inspect the cylinder block to head mating surface for staightness. Replace components as necessary.

Condition	Action
Worn valve guides	Inspect the valves and valve guides. Repair or replace all damaged components.
Worn valve stem oil seals	Inspect the valve stem oil seals. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Perform compression tests to determine the cause. Inspect the piston rings for low ring tension, broken or worn rings. Inspect cylinder bore. Repair or replace all damaged components.

Condition	Action
Incorrect oil viscosity	Drain the oil. Install the correct viscosity oil.
Excessive piston-to-cylinder bore clearance	Inspect the piston and piston skirt, connecting rod, and cylinder bore. Repair or replace all damaged components.

Condition	Action
Low oil pressure	Insufficient or poor oil supply to valve train. Perform oil pressure test. Repair or replace all damaged components.
Improper lubrication to the valve finger-follower	Inspect valve finger-follower, valve bridge, valve finger follower lifter, oil pump and engine block oil galleries. Repair or replace all damaged components.
Worn or damaged valve finger-follower	Inspect valve bridge and finger-follower. Repair or replace all damaged components.
Sticking valve	Carbon on the valve stem or valve seat may cause the valve to stick. Inspect valves and valve guides. Repair or replace all damaged components.
Worn or faulty camshaft lobes	Inspect camshaft lobes. If damaged replace camshaft and all valve finger-followers.
Damaged or misaligned timing gears	Inspect timing gears. Replace all damaged components.

Condition	Action
Worn accessory drive components (abnormalities such as severe cracking, bumps or missing areas in the accessory drive belt and/or misalignment of the system components.)	Inspect the accessory drive components. Repair or replace all damaged components.
Low oil pressure	Insufficient or poor oil supply to crankshaft and connecting rod bearings. Perform oil pressure test. Repair or replace all damaged components.
Leaking and/or sticking fuel injection nozzle (A stuck fuel injection nozzle can cause a noise similar to a damaged piston, rod or rod bearing.)	Inspect the cylinder balance with scan tool to help locate the cylinder that is the source of the noise. If you cannot locate the cylinder that is the source of the noise, diagnose the engine for mechanical damage. If it has been determined that the fuel injection nozzle is causing the noise, replace the fuel injection nozzle.
Loose and/or damaged crankshaft pulley	Inspect crankshaft pulley and pulley bolt. Repair or replace all damaged components.
Loose torque converter bolts	Inspect torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	Inspect flywheel and flyweel attaching bolts. Repair or replace all damaged components.
Excessive piston pin-to-bore clearance	Inspect the piston, piston pin, and the connecting rod. Repair or replace all damaged components.
Misaligned or bent connecting rod	Inspect connecting rod and connecting rod bearings. Repair or replace all damaged components.
Excessive connecting rod bearing clearance	Inspect the connecting rod bearings, connecting rods, crankshaft and crankshaft journals. Repair or replace all damaged components.
Excessive crankshaft bearing clearance	Inspect the crankshaft bearings and crankshaft journals. Repair or replace all damaged components.

Cause	Correction
Low oil pressure	Insufficient or poor oil supply to components. Perform oil pressure test. Repair or replace all damaged components.
Loose torque converter bolts	Inspect the torque converter bolts and flywheel. Repair or replace all damaged components.
Loose and/or damaged flywheel	Inspect the flywheel and flywheel attaching bolts. Repair or replace all damaged components.
Excessive piston-to-cylinder bore clearance	Inspect the piston rings for low ring tension, broken or worn rings, inspect cylinder bore. Repair or replace all damaged components.
Excessive crankshaft thrust bearing clearance	Inspect the crankshaft end play and crankshaft thrust bearings. Repair or replace all damaged components.
Excessive crankshaft bearing clearance	Inspect the crankshaft bearings and crankshaft journals. Repair or replace all damaged components.

Cause	Correction
Seized accessory drive system component	Inspect the accessory drive system components. Repair or replace all damaged components.
Hydraulically locked cylinder Coolant/antifreeze in cylinder Oil in cylinder Fuel in cylinder	Inspect for broken head gasket(s). Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector.
Seized automatic transmission torque converter	Remove the engine assembly. The torque converter bolts are not accessible with the engine installed to the transmission. Rotate crankshaft at the pulley.
Seized manual transmission	Disengage the clutch. Rotate crankshaft at the pulley. Refer to Unit Repair Manual - Manual Transmission.
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 bearings. . Repair as required.
Bent or broken connecting rod	Inspect connecting rods. Repair as required.
Broken crankshaft	Inspect crankshaft. Repair as required.

Inspection	Action
Definition : Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage.
Preliminary Inspection	Verify that there are no external coolant leaks. Refer to Section 1D, Engine Cooling.
Isolate Affected Cylinders	Cylinder balance test with scan tool Cooling system pressurization Compression test
EGR System Inspection	Inspect EGR valve and intake system for evidence of coolant leakage. Replace the EGR cooler if any problem is found.
Cylinder Head Gasket Leakage	Remove cylinder heads of the affected cylinder bank and inspect for damage. Replace components as necessary.
Cylinder Head or Engine Block Damage	Inspect the cylinder heads for cracks. Inspect the cylinder block for damage. Inspect the cylinder block to head mating surface for straightness. Replace components as necessary.

Cause	Correction
Definition : Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may cause engine component damage. Contaminated engine oil and oil filter should be changed. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage. Refer to "Lower Engine Noise, Regardless of Engine Speed" in this section. Inspect by performing a Cylinder Leak-Down Test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block with low compression may indicate a failed cylinder head gasket. Refer to "Engine Compression Test" in this section.
Faulty cylinder head gasket	Replace the head gasket and components as required. Refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D.
Warped cylinder head	Replace the cylinder head gasket. Refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D.
Cracked cylinder head	Replace the cylinder head and gasket.
Cracked engine block	Replace the components as required.
Cylinder head, block, or manifold porosity	Replace the components as required.
Leaking engine oil cooler	Replace components as required.

1. Remove the oil level indicator and allow oil to drop onto a clean white paper towel.
2. If the oil is diluted with fuel, it will become apparent as the towel wicks the fuel away from the drop of oil on the towel. The fuel will expand out in a ring around the oil droplet.
3. If fuel dilution is apparent, inspect the vehicle for aftermarket performance accessories that may cause damage to the injection pump. After repairs are completed, perform the test again to verify the condition is corrected.
4. If no fuel dilution is present, verify the oil level and correct as needed.

2. The noise may not be engine related. This step is to confirm the engine is making the noise. If the engine is not making the noise, do not proceed further with this diagnostic procedure.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Inspect all drive pump pulleys for pilling.

6. Misalignment of the accessory drive system pulleys may be caused by incorrect mounting of an accessory drive component (A/C compressor, generator etc.) or pulley. Misalignment may also be caused by incorrect installation of a pulley during a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures.
10. Inspecting the fasteners can eliminate the possibility that an incorrect fastener has been installed.
12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface when the back end of the belt is used as the driving surface.
14. Replacing the drive belt when it is not damaged and there is no excessive pilling will only be a temporary repair.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a chirping noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Operate the engine for no more than 40 seconds. Does the chirping noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis of the noise	Go to Step 4
4	Inspect for severe pilling, i.e. in excess of 33% of the belt groove depth. Do the belt grooves have pilling?	-	Go to Step 5	Go to Step 6
5	Clean the drive belt pulleys with a wire brush. Are the belt pulleys clean?	-	Go to Step 15	Go to Step 6
6	Inspect for misalignment of the pulleys. Are the pulleys misaligned?	-	Go to Step 7	Go to Step 8
7	Replace or repair misaligned pulleys. Did you complete the repair?	-	Go to Step 15	-
8	Inspect for any bent or damaged accessory drive component mounting brackets. Did you find any bent or damaged brackets?	-	Go to Step 9	Go to Step 10
9	Replace or repair any bent or damaged Brackets. Did you complete the repairs?	-	Go to Step 15	-
10	Inspect for missing, loose or incorrect fasteners. Did you find any missing, loose or incorrect fasteners?	-	Go to Step 11	Go to Step 12
11	Tighten any loose fasteners to the torque specification. Replace any incorrect or missing fasteners. Did you complete the repairs?	-	Go to Step 15	-
12	Inspect for a bent pulley. Did you find any bent pulleys?	-	Go to Step 13	Go to Step 14
13	Replace bent pulleys as required. Did you complete the repair?	-	Go to Step 15	-
14	Replace the accessory drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Did you complete the repair?	-	Go to Step 15	-
15	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the chirp noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. The noise may not be engine related. This step is to confirm the engine is making the noise. If the engine is not making the noise, do not proceed further with this diagnostic procedure.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Confirms an accessory drive component does not have a seized bearing. With the belt removed, test the bearings in the accessory drive components spin free and smooth.
5. Confirms the drive belt tensioner is operating correctly. If the drive belt tensioner is not operating correctly, drive belt tension will not be maintained, resulting in a belt squealing noise.
6. Confirms the belt is not too long, which would prevent the tensioner from working as intended. Also, if an excessively long belt has been fitted, it may also be routed incorrectly and may be turning an accessory drive component in the wrong direction.
7. Misalignment of the pulleys may be caused by one of the following :
• Incorrect mounting of an accessory drive component,
• Incorrect installation of an accessory drive pulley or,
• Bent or damaged pulley.
Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to the relevant component service information for the correct installation and removal procedures.
8. This test is to confirm the pulleys are the correct diameter and/or width. Using a known good vehicle, compare the pulley sizes.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a squealing noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Operate the engine for no more than 40 seconds. Does the squealing noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis of the noise	Go to Step 4
4	Inspect the accessory drive components for a seized bearing and general malfunctions. Did you find and correct any seized bearings or general malfunctions in the accessory drive system?	-	Go to Step 9	Go to Step 5
5	Test the accessory drive belt tensioner for correct operation, refer to Drive Belt Tensioner Diagnosis. Did you find and repair any problems with the tensioner?	-	Go to Step 9	Go to Step 6
6	Inspect the accessory drive belt is the correct length. Did you find and repair any problems with the drive belt length?	-	Go to Step 9	Go to Step 7
7	Inspect the accessory drive pulleys for misalignment. Did you find and correct any misaligned accessory drive pulleys?	-	Go to Step 9	Go to Step 8
8	Check the accessory drive pulleys are the correct size. Did you find and replace any incorrect pulleys?	-	Go to Step 9	Refer to Diagnostic Aids in this Section
9	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the squeal noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

3. The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. The inspection of bearings should include the following accessory drive components :
• drive belt tensioners,
• drive belt idlers,
• generator,
• power steering pump,
• A/C compressor.
The drive belt may need to be installed and the accessory drive components operated separately, at varying loads to confirm the location of the faulty bearing, refer to the relevant Sections for component inspection and repair procedures.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a whining noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Operate the engine for no more than 40 seconds. Does the whining noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive components for a faulty or seized bearings and general malfunctions. Did you find and correct any faulty/seized bearings or general malfunctions in the accessory drive system?	-	Go to Step 5	Refer to Diagnostic Aids in this Section
5	Reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the whine?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise.
3. Confirms the accessory drive belt is the cause of the noise. Drive belt rumbling is often confused with an internal engine noise due to the similarity in the description. Removing the u and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. Inspecting the drive belt is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise and are not justification alone to replace the belt. Belt separation can be identified by the ply of the belt separating and may be seen at the edge of the belt or felt as lumps under the belt.
5. Small amounts of pilling is a normal condition and is deemed acceptable. When the pilling is severe (33% of the belt groove depth), the belt does not have a smooth surface to run on and should be replaced.

• pilling or strings in the drive belt grooves,
• separation of the drive belt, or
• a damaged or faulty drive belt.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a rumbling noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Operate the engine for no more than 40 seconds. Does the rumbling noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive belt for damage, separation or sections of missing ribs. Did you find any damaged, separated or missing ribs?	-	Go to Step 7	Go to Step 5
5	Inspect the accessory drive belt for severe pilling (exceeding 33% of the belt groove depth). Did you find sever pilling?	-	Go to Step 6	Go to Step 5
6	Clean the drive belt using a suitable wire brush and reinstall to the engine, refer to Section 1B, Engine Mechanical – 2.0 Diesel. Did you complete the repairs?	-	Go to Step 8	-
7	Install a new accessory drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Did you replace the accessory drive belt?	-	Go to Step 8	-
8	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the rumbling noise?	-	Accessory drive system OK	Go to Symptoms, and restart the diagnosis

2. Confirms the symptom exists at the time of diagnosis. Other vehicle components may be causing the noise.
3. Confirms the accessory drive belt is the cause of the noise. Drive belt rumbling is often confused with an internal engine noise due to the similarity in the description. Removing the drive belt and operating the engine briefly will confirm whether or not the noise is related to the drive belt.
4. The drive belt may cause a vibration. Inspecting the drive belt is considerably easier while the drive belt is removed.
6. Inspecting the fasteners can eliminate the possibility that an incorrect fastener has been installed.
8. This step should only be performed if the coolant pump is driven by the drive belt. Inspect the coolant pump for a bent shaft. Also inspect the coolant pump bearings for smooth operation and excessive play. Compare the coolant pump with a known good pump.
9. Accessory drive component brackets that are bent, cracked or loose may put extra strain on the accessory component causing it to vibrate.

• the vibration is engine speed related, or
• the vibration is sensitive to accessory drive system load.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Confirm the customer complaint. Is there a rumbling noise?	-	Go to Step 3	Refer to Diagnostic Aids in this Section
3	Remove the drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Operate the engine for no more than 40 seconds. Does the vibration noise still exist?	-	Accessory drive system OK. Go to Symptoms, and restart the diagnosis	Go to Step 4
4	Inspect the accessory drive belt for damage, wear, debris build-up or sections of missing ribs. Did you find any damage, wear, debris build-up or missing ribs?	-	Go to Step 5	Go to Step 6
5	Install a new accessory drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Did you replace the accessory drive belt?	-	Go to Step 9	-
6	Inspect for incorrect, loose, missing or damaged fasteners. Did you find any incorrect, loose, missing or damaged fasteners?	-	Go to Step 7	Go to Step 8
7	Tighten any loose fasteners to the correct torque specification. Replace any incorrect or missing fasteners. Did you complete the repairs?	-	Go to Step 9	-
8	Inspect for bent, cracked or damaged accessory drive component mounting brackets. Did you find and repair any bent brackets?	-	Go to Step 9	Refer to Diagnostic Aids in this Section
9	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the vibration?	-	Accessory drive system OK	Refer to Diagnostic Aids in this Section

• an incorrect drive belt length,
• a faulty drive belt tensioner, or
• a stretched or faulty drive belt.

2. Confirms the condition of the drive belt. Damage may have occurred to the drive belt when it first fell off or it may have been damaged which caused the belt to fall off.
4. Misalignment of the pulleys may be caused by :
• the incorrect installation or mounting of an accessory drive component,
• the incorrect installation of an accessory drive component pulley, or
• a damaged or bent accessory drive pulley.
Test for a misaligned pulley using a suitable straight edge in the pulley grooves across two or more pulleys. If a misaligned pulley is found, refer to the service information for the particular component, for the correct pulley replacement procedures.
5. Inspecting the pulleys should include an inspection for dents or other damage that would prevent the drive belt from seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used.
6. Accessory drive component mounting brackets that are bent will cause the drive belt to fall off.
7. Inspection of the fasteners can eliminate the possibility that an incorrect fastener was installed. Missing, loose or incorrect fasteners may cause pulley misalignment from the fasteners moving under load. Over-tightening of the fasteners may cause deflection of mounting brackets and result in misaligned accessory drive pulleys.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Inspect for a damaged accessory drive belt. Did you find any damage on the drive belt?	-	Go to Step 3	Go to Step 4
3	Install a new accessory drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Does the drive belt continue to fall off?	-	Go to Step 4	Go to Step 12
4	Inspect the accessory drive system pulleys for misalignment. Did you find and repair any misaligned drive system pulleys?	-	Go to Step 12	Go to Step 5
5	Inspect for a dented or cracked accessory drive system pulley. Did you find and repair any dented or cracked drive system?	-	Go to Step 12	Go to Step 6
6	Inspect for bent accessory drive component mounting brackets. Did you find and repair any bent mounting brackets?	-	Go to Step 12	Go to Step 7
7	Inspect for incorrect, loose, missing or damaged fasteners. Did you find any incorrect, loose, missing or damaged fasteners?	-	Go to Step 8	Go to Step 9
8	Tighten any loose fasteners to the correct torque specification. Replace any incorrect or missing fasteners. Does the drive belt continue to fall off?	-	Go to Step 9	Go to Step 12
9	Test the accessory drive belt tensioner for correct operation, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Did you accessory drive belt tensioner operate correctly?	-	Go to Step 11	Go to Step 10
10	Replace the drive belt tensioner, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Does the drive belt continue to fall off?	-	Go to Step 11	Go to Step 12
11	Inspect for a failed drive belt idler and drive belt tensioner bearings. Did you find and repair any failed bearings?	-	Go to Step 12	Refer to Diagnostic Aids in this Section
12	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Does the drive belt continue to fall off?	-	Go to Step 2	Accessory drive system OK

2. Confirms the drive belt is correctly installed onto all of the accessory drive system pulleys. Wear on the drive belt may be caused by incorrectly positioning the drive belt by one or more grooves to a particular pulley.
3. The installation of the drive belt that is the incorrect width will cause wear on the drive belt. The drive belt ribs should match all the grooves on all the pulleys in the accessory drive system.
4. Confirms the drive belt is not contacting any parts of the engine or body while the engine is running. There should be sufficient clearance when the accessory drive component loads varies. The drive belt should not come into contact with any engine or body parts.

Step	Action	Value(s)	Yes	No
1	Did you review the information provided in Symptoms, and perform the required inspections.	-	Go to Step 2	Go to Symptoms
2	Inspect the accessory drive belt for correct installation. Is the drive belt installed correctly?	-	Go to Step 5	Go to Step 3
3	Ensure that the drive belt is the correct one for the application. Is the correct drive belt installed?	-	Go to Step 5	Go to Step 4
4	Is the drive belt contacting any engine or body components with the engine running?	-	Go to Step 6	Refer to Diagnostic Aids in this Section
5	Install a new accessory drive belt, refer to Section 1C2, Engine Mechanical – 1.4 DOHC - G14D. Did you replace the accessory drive belt?	-	Go to Step 6	-
6	If required, reinstall the accessory drive belt and operate the system to confirm the repair. Did you correct the excessive wear?	-	Accessory drive system OK	Go to Step 2

1. Cylinder Head
2. Cylinder Head Gasket
3. Intake Valve
4. Intake Valve Seat Ring
5. Exhaust Valve
6. Exhaust Valve Seat Ring
7. Closure Plug
8. Exhaust Camshaft Seal Ring
9. Intake Camshaft Seal Ring
10. Dowel Pin
11. Valve Guide
12. Valve Spring Seat
13. Valve Spring
14. Valve Spring Retainer
15. Valve Key
16. Valve Tappet
17. Cylinder Head Bolt
18. Intake Camshaft Position Sensor
19. Exhaust Camshaft Position Sensor
20. Exhaust Camshaft
21. Intake Camshaft
22. Exhaust Camshaft Sensor Target Wheel
23. Intake Camshaft Sensor Target Wheel
24. Camshaft Cap
25. Camshaft Front Cap
26. Cylinder Head Cover Gasket
27. PCV pipe
28. Cylinder Head Cover
29. Cylinder Head Cover Bolt
30. Engine Oil Cap
31. Ignition Coil Cover
32. Ignition Coil
33. Ignition Coil Bolt
34. Spark Plug
35. Thermostat Housing
36. Thermostat
37. Thermostat Housing Gasket
38. Plug
39. Seal
40. Retainer
41. Engine Coolant Distributor
42. Engine Coolant Temperature Sensor
43. Retainer
44. Engine Coolant Distributor Gasket

1. Cylinder Block
2. Engine Oil Level Indicator
3. Oil Level Indicator Tube
4. Oil Switch
5. Oil Pan
6. Oil Pump Filter
7. Crankshaft Balancer(Pulley)
8. Water Pump
9. Water Pump Gasket
10. Oil Pump Plug
11. Check Valve
12. Crankshaft Front Seal
13. Engine Front Cover
14. Engine Oil Pump Cover
15. Engine Front Cover Gasket
16. Retainer
17. Engine Oil Level Switch Connector
18. Engine Oil Level Switch
19. Oil Plug
20. Oil Plug Washer
21. Oil Pressure Relief Valve
22. Oil Pressure Relief Valve Spring
23. Oil Pressure Relief Valve Spring Plug
24. Oil Overpressure Relief Valve
25. Oil Overpressure Relief Valve Spring
26. Oil Overpressure Relief Valve Spring Plug
27. Oil Filter Cap
28. Oil Filter Cap Seal
29. Oil Filter
30. Oil Filter Housing Assembly
31. Oil Cooler Pipe Seal
32. Oil Cooler Pipe
33. Oil Filter Housing Gasket
34. Oil Cooler Gasket
35. Oil Cooler Seal
36. Engine Oil Cooler
37. Engine Oil Cooler Outlet Pipe
38. Engine Oil Cooler Outlet Pipe Seal
39. Crankshaft
40. Crankshaft Journal Bearings
41. Crankshaft Flywheel Retainer
42. Crankshaft Rear Oil Seal Housing and Seal Ring
43. Crankshaft Position Sensor Bracket
44. Crankshaft Position Sensor
45. Flexible Plate(A/T only)
46. Flexible Plate Retainer(A/T only)
47. Flywheel
48. Piston
49. Piston Rings
50. Piston Pin Retainer
51. Piston Pin
52. Connecting Rod
53. Connecting Rod Bearing
54. Crankshaft Journal Bearing Cap
55. Crankshaft Journal Bearing Cap Bolt
56. Knock Sensor

1. Intake Manifold Assembly
2. Intake Manifold Gasket
3. Throttle Body Seal
4. MAP Sensor
5. EVAP Canister Purge Solenoid Valve
6. EVAP Pipe
7. Intake Manifold Mount
8. Intake Manifold Mount Bracket
9. Oxygen Sensor
10. Exhaust Manifold
11. Exhaust Manifold Gasket
12. Exhaust Manifold Shield
13. Throttle Body
14. Throttle Body Heater Coolant Inlet Pipe
15. Throttle Body Heater Coolant Outlet Hose
16. Fuel Rail Retaining Bolt
17. Throttle Body Heater Coolant Outlet Pipe
18. Fuel Injector
19. Injector Retainer
20. Fuel Rail
21. Intake Camshaft Position Actuator Solenoid Valve
22. Exhaust Camshaft Position Actuator Solenoid Valve
23. Timing Belt Rear Cover
24. Intake Camshaft Sprocket
25. Timing Belt Rear Cover Bolt
26. Exhaust Camshaft Sprocket
27. Timing Belt Idler
28. Timing Belt Tensioner
29. Crankshaft Sprocket
30. Timing Belt
31. Timing Belt Front Upper Cover
32. Timing Belt Front Center Cover
33. Timing Belt Sheet Part
34. Timing Belt Front Lower Cover
35. Crankshaft Balancer(Pulley)
36. Washer
37. Crankshaft Balancer Bolt