Service Manual2006 Kalos UNIT REPAIR

Kalos/Aveo

UNIT REPAIR

Cylinder Head and Valve Train Components

Tools Required

09916-14510 Valve Spring Compressor

09916-37320 Valve Guide Reamer

09916-38210 Valve Guide Reamer

09916-44910 Valve Guide Remover

09916-48210 Valve Spring Compressor Attachment

09916-58210 Valve Guide Installer

09917-88220 Valve Guide Installer Attachment

KM 412 Engine Overhaul Stand

Disassembly Procedure

Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
Remove the bolt and the nuts in the water outlet case .
Remove the water outlet case.

Remove the exhaust manifold heat shield bolts.
Remove the exhaust manifold heat shield.

Remove the exhaust manifold nuts and the bolts.
Remove the exhaust manifold gasket.
Remove the exhaust manifold studs.

Remove the spark plugs.

Remove the intake manifold retaining bolts and the nuts.
Remove the intake manifold with the gasket.
Remove the intake manifold studs.

Remove the rocker arm shaft mounting bolts.

Remove the rocker arm spring and the rocker arm.

Remove the screws with the camshaft thrust plate.

Remove the camshaft.

Remove the camshaft front oil seal from housing hole.

Using the valve spring compressor 09916-14510, compress the valve spring
Remove the valve keepers.
Remove the valve spring retainer and valve spring.
Remove the valves.

Remove the valve stem oil seals.
Remove the valve spring seat.

Position the valve guide remover 09916-44910 on the valve guide.
Hammer and remove the valve guide from the combustion chamber to the direction of the installed valve spring using the valve guide remover 09916-44910.
Remove the valve guide.

Cylinder Head Inspection

Clean the sealing surfaces.
Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby.
Inspect the cylinder head for cracks.
Inspect the length and the width of the cylinder head using a feeler gauge and a straight edge.
Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat with in 0.05mm (0.0020 in.) maximum.

Inspect all threaded holes for damage.
Inspect the valve seats for excessive wear and burned spots.

Valve Inspection

Inspect valve stem tip wear.
Inspect the valve keeper grooves and oil seal grooves for chips and wear.
Inspect the valves for burns or cracks.
Inspect the valve stem for burrs and scratches.
Inspect the valve stem. The valve stem must be straight.
Inspect the valve facefor grooving. If the groove is so deep the refacing would result in a sharp edge, replace the valve.

Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
Measure the valve spring height. Refer to "Engine Specifications" in this section. If the valve spring height does not match the specifications, replace the valve spring.
Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.

Cleaning Procedure

Clean the cylinder head.
Clean the valve guides.
Clean all of the threaded holes.
Clean the valves of carbon, oil and varnish.

Cylinder Head Overhaul

Measuring The Camshaft Bend

Measure the bending of the camshaft using a dial gauge and replace it when the measured value is over the specified limit (0.03mm (0.0012 in.)).

Abrasion of The Camshaft Journal

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

Using a bore gauge, measure the inner diameter of the cylinder head jornal at the 5 places (The clear-ance of journal is measured by the difference be-tween the outer diameter of camshaft journal and inner diameter of cylinder head journal part.)
Replace the camshaft (or cylinder head, if necessary) of which limit is over the 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 journal part
a	43.425-43.450 mm (1.7096-1.7106 in.)	43.500-43.516 mm (1.7126-1.7132 in.)
b	43.625-43.650 mm (1.7175-1.7185 in.)	43.700-43.716 mm (1.7205-1.7211 in.)
c	43.825-43.850 mm (1.7254-1.7264 in.)	43.900-43.916 mm (1.7283-1.7290 in.)
d	44.025-44.050 mm (1.7333-1.7343 in.)	44.100-44.116 mm (1.7362-1.7369 in.)
e	44.225-44.250 mm (1.741-1.742 in.)	44.3-44.316 mm (1.744-1.745 in.)

Bending of The Rocker Arm Shaft

Check the bending of the rocker arm shaft by using the V block and dial gauge.
Replace the rocker arm shaft of which bending is over the specification (0.10mm (0.0039 inches)).

Clearance Between The Rocker Arm and The Rocker Arm Shaft

Check the outer diameter of the rocker arm shaft using a micrometer.

Check the inner diameter of the rocker arm using a bore gauge.
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 inner diameter (0.005 - 0.040mm (0.0002 - 0.0016 in.)

Clearance Between The Valve Stem and The Valve Guide

Check the outer diameter of the valve stem using a micrometer.

Intake : 5.465 - 5.480mm (0.2152 - 0.2157 in.)
Exhaust : 5.440 - 5.455mm (0.2142 - 0.2148 in.)

Check the inner diameter of the valve guide using a bore gauge (at least 1 place in the direction to valve length)

Intake : 5.500 - 5.512mm (0.2165 - 0.2170 in.)
Exhaust : 5.500 - 5.512mm (0.2165 - 0.2170 in.)

Check the clearance between the valve stem and the valve guide

Intake : 0.020 - 0.047mm (0.0008 - 0.0019 in.)
Exhaust : 0.0045 - 0.072mm (0.0018 - 0.0028 in.)

If a bore gauge is not available, measure the clearance using a dial gauge by moving the edge of the stem to the directions.

Intake : 0.14mm (0.0055 in.)
Exhaust : 0.18mm (0.0071 in.)

Replace the valve stem or valve guide, if the measured valve is over the limit.

Valve

Inspect the valve. Refer to Valve Inspection in this section.
Check the valve or stem for abrasion, burn or bending, and replace as necessary.
Abrasion of the valve edge.

Check the edge of each valve for abrasion. Some uneven abrasion would be made on the edge because the rocker arm gets contacted at this surface when operating. Repair the section within 0.05mm (0.002 in.) as required, or replace the valve if some modification is required more than that.

Deviation to the rotating direction. Measure the deviation to the rotating direction 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.)
Replace valve, if the measured value exceeds the limit.

Clean the valve and the valve seat and apply red stamping ink thinly to the contacting surface of the valve seat. Check the fitness after installing the valve unit.
Check the contact witdth on the surface of the valve seat.

Intake : 1.46 - 1.66mm (0.0575 - 0.0654 in.)
Exhaust : 1.46 - 1.66mm (0.0575 - 0.0654 in.)

Repair by grinding and cutting off the valve seat, and lap it if its contacting width is not even or out of the specified.
Upon applying a seat cutter, use the one of smaller angle first and increase the angle of the using cutter up to the light and final modification of the contact. And finish contact surface and its location with the cutter of 45 degrees.

Important : Upon cutting, take care of the contact width. Finish the cutting with gradually reduced power for no cutting mark on the surface.

Make lapping in two stages, first with normal lap and second with fine one for the both sides.

Assembly Procedure

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

Peen and install new valve guide

Caution : Heat the cylinder head uniformly at a temperature 80-100°C (176-212°F) not to make the head deformed, and drive new valve guide completely into the hole with the tools the valve guide installer attachment 09917-88220.

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

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

Valve guide oversize : 0.03mm (0.0012 in.)
Valve guide protrusion : 14mm (0.5512 in.)

Repair the valve guide bore with the valve guide reamer 09916-37320 (5mm or 0.1969 in.)
Make the hole free from foreign material.

Install the valve spring seats.
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 is properly fixed to the valve guide.

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

Install the valve to the valve guide.

Important : Before installing it, coat engine oil to the stem seal, valve guide bore and valve stem.

Install the valve springs and the spring retainers.
Using the valve spring compressor 09916-48210, compress the valve spring
Install the valve keepers.

Install the camshaft front oil seal from housing hole.

Coat the engine oil to the camshaft front oil seal, the cam, and the camshaft journal.
Install the camshaft front oil seal to the housing hole.
Install the camshaft to the cylinder head.

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

Install the screws with the camshaft thrust plate.

Tighten

Tighten the screws to 10 N•m (89 lb-in).

Coat the engine oil to the rocker arms and the rocker rocker arm shafts.
Install the rocker arm spring and the rocker arm.

Install the rocker arm shaft mounting bolts.

Tighten

Tighten the bolts to 10 N•m (89 lb-in).

Important : Rocker arm shaft for the intake valves and the exhaust valves are different and their directions of installation are different.

Install the intake manifold studs.
Install the intake manifold with the gasket.
Install the intake manifold.

Install the intake manifold nuts in the sequence order.

Tighten

Tighten the intake manifold nuts and the bolts to 17 N•m (13 lb-ft).
Tighen the intake manifold supprot bracket bolt to 10 N•m (89 lb-in).

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

Install the spark plugs.

Install the exhaust manifold gasket and the exhaust manifold.

Install the bolts and nuts in the sequence order as shown in the picture.

Tighten

Tighten the exhaust manifold nuts and bolts to 22 N•m (16 lb-ft).

Install the exhaust manifold heat shield.
Install the exhaust manifold heat shield bolts.

Tighten

Tighten the exhaust manifold heat shield bolts to 10 N•m (89 lb-in).

Install the water outlet case.
Install the water outlet case mounting bolts.

Tighten

Tighen the water outlet case mounting bolts to 10.5 N•m (93 lb-in).

Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

Crankshaft

Tools Required

KM-412 Engine Overhaul Stand

09916-77310 Piston Compressor

Disassembly Procedure

Removethe engine. Refer to "Engine"in this section.
Remove the transaxle from the engine. Refer to Section 5B, Five-Speed Manual Transaxle.
Remove the flywheel bolts.
Remove the flywheel.
Mount the engine assembly on the engine overhaul stand KM-412.

Remove the cylinder head. Refer to "Cylinder Head and Gasket" in this section.
Drain the engine oil from the engine.
Remove the power steering adjusting bolts.
Remove the power steering/air conditioning belt.

Turn the A/C compressor downward.
Remove the A/C compressor/power steering bracket bolts.
Remove the A/C compressor/power steering bracket.

Loosen the generator bolt.
Loosen the generator lower bolts and the nut.
Remove the generator and belt.

Loosen the engine mount upper bracket bolts.
Remove the generator shackle.
Remove the upper bracket.
Loosen the engine mount lower bracket bolts.
Remove the lower bracket.

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

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

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

Rotate the engine on the engine overhaul stand KM-412.
Remove the oil pan retaining bolts and the nuts.
Remove the oil pan.

Remove the oil pan pickup tube bolts.
Remove the oil pan pickup tube.

Remove the oil pump retaining bolts.
Remove the oil pump.

Remove the crankshaft rear oil seal housing screws and bolts.
Remove the gasket and the oil seal housing.

Mark the order of the rod bearing caps.
Remove the connecting rod cap nuts for all of the pistons.
Remove the connecting rod bearing caps and the lower connecting rod bearing.
Remove the upper connecting rod bearing.

Mark the order of the crankshaft bearing caps.
Remove the crankshaft bearing cap bolts.
Remove the crankshaft bearing cap.
Remove the crankshaft bearings from the crankshaft bearing caps.
Remove the crank shaft.
Remove the crankshaft bearings from the engine block.
Clean the parts, as necessary.

Assembly Procedure

With crankshaft and bearings in place, plastic gauge all bearing clearances. Refer to "Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic" in this section.
Inspect the crankshaft end play with the crankshaft bearings installed.
Check the Permissible crankshaft end play. Refer to "Engine Specifications" in this section.

With the crankshaft mounted on the front and the rear crankshaft bearings, Check the middle crankshaft journal for permissible out-of-round (runout). Refer to "Engine Specifications" in this section.

Coat the crankshaft bearings with engine oil.
Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
Install the crankshaft bearings in the engine block.
Install the crankshaft.

Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.

Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.

Install the crankshaft bearings to the crankshaft bearing caps.
Install the crankshaft bearing caps bolts.

Notice : Do not reuse the old crankshaft bearing cap bolts. Damage to the engine could result.

Tighten

Tighten the crankshaft bearing cap bolts to 57 N•m (42 lb-ft).

Remove the crankshaft bearing caps.
Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearances for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Inspection Precedure - Connecting Rods

Coat the connecting rod bearings with engine oil.

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

Install the upper connecting rod bearings into the connecting rod journals.
Install the lower connecting rod bearings into the connecting rod bearing caps.
Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).

Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod bearing.
Install the connecting rod bearing caps.
Install the connecting rod bearing cap nuts.

Tighten

Tighten the connecting rod bearing cap nuts to 33 N•m (24 lb-ft).

Remove the connecting rod bearing caps.
Measure the width of th flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Inspection Precedure - Piston

Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
Inspect the connecting rod bearings.
Inspect the connecting rod lower end for wear.
Inspec the connecting rod upper end for scoring.
Inspect the piston for scoring, cracks and wear.
Inspect pistion for taper using a micrometer.

Inspect the piston for fit to the connecting rod.

Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section.
Inspect the engine block cylinder bore for wear, runout ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

Installation Procedure

Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
Install the pistion pin guide through the piston and the connecting rod.
Coat the piston pin with clean oil.
Install the piston pin into the opposite side of the pistion.
Install the pistion pin into the pistion and connecting rod assembly.

Select a set of new pistion rings.
Measure the piston ring gap using a feeler gauge.
Increase the piston ring gap by carefully filling off excess material if the piston ring gap is below specifications.

Measure the pistion ring side clearance using a feeler gauge. Refer to "Engine Specifications" in this section.
If the pistion ring is too thick, try another pistion ring.
If no piston ring can be found that fits to specifications the pistion ring may be ground to size with emery paper placed on a sheet of glass.

Install a piston oil ring, the expander and the second piston oil ring to the bottom ring groove of the pistion.
Install the second compression ring to the middle ring groove of the piston.
Install the top compression ring to the top ring groove of the pistion.

Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the pistion.

Lubricate the cylinder wall and the pistion rings with clean engine oil.
Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
Install the connecting rod cap and the bearing. Refer to "Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic"in this section.

Install the connecting rod bearing cap nuts.

Tighten

Tighten the connecting rod bearing cap nuts to 33 N•m (24 lb-ft).

Install the oil pump/pickup tube.
Install the oil pump pickup tube bolts.

Tighten

Tighten the oil pump pickup tube bolts to 10 N•m (89 lb-in).

Install the oil pan.
Install the oil pan bolts and nuts.

Tighten

Tighten the oil pan bolts and nuts to 10 N•m (89 lb-in).

Install the lower engine mount bracket and the generator with the bolts

Tighten

Tighten the lower engine mount bracket bolts to 38 N•m (28 lb-ft).

Install the upper engine mount bracket and the generator shackle with the bolts.

Tighten

Tighten the upper engine mount bracket and generator shackle bolts to 38 N•m (28 lb-ft).

Install the generator with the bolts and the nut.
Install the generator belt.

Tighten

Tighten the generator lower bolts and the nut to 23 N•m (17 lb-ft).

Tighten the generator belt tension adjusting bolt to 23 N•m (17 lb-ft).

Install the engine mount bracket.
Install the A/C compressor/Power steering Pump and the bracket with the bolts.

Tighten

Tighten the engime mount bracket bolts to 20 N•m (15 lb-ft).

Tighten the A/C compressor/Power steering Pump bracket bolts to 38 N•m (28 lb-ft).

Install the power steering pump bracket with the bracket bolt/nut and adjusting bolt.

Tighten

Tighten the adjusting bolt and the power steering rear bracket nut to 22 N•m (16 lb-ft).

Install the power steering/air conditioning belt.
Install the cylinder head with the intake manifold, the exhaust manifold, and distributor/adaaptor attached. Refer to "Cylinder Head and Gasket" in this section.
Install the timing belt and component. Refer to "Timing Belt" in this section.
Install the clutch and the transaxle to the engine then engine assembly to the engine compartment. Refer to " Engine Assembly" in this section.

Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.
Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual Control Hearing, Ventilation, and Air Conditioning System.
Refill the transaxle oil as necessary.
Connect the negative battery cable.
Start the engine and operate all systems.
Operate the idle air contril valve reset procedure as necessary.