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Zenith ZPP 416 Service Manual

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  • Page 2 ZPP 416 - Engine DOHC ENGINE COOLANT PUMP GENERAL RADIATOR RADIATOR CAP TIMING SYSTEM THERMOSTAT TIMING BELT LUBRICATION SYSTEM CYLINDER HEAD ASSEMBLY OIL PUMP CYLINDER HEAD ENGINE BLOCK MAIN MOVING SYSTEM ENGINE BLOCK CAM SHAFT CRANK SHAFT INTAKE AND EXHAUST SYSTEM...
  • Page 3 ZENITH POWER PRODUCTS - 416 EM -2 ENGINE DOHC GENERAL SPECIFICATION E5EC07D6 Description Specification Limit General Type In-line, Double Over Head Camshaft Number of cylinders 76.5mm (3.0118 in) Bore 87mm (3.4252 in) Stroke 1599 cc (97.54 cu.in) Total displacement Compression ratio...
  • Page 4 ZENITH POWER PRODUCTS - 416 GENERAL EM -3 Description Limit Specification Valve Valve length 91.7mm (3.6102 in.) Intake 92.3mm (3.6339 in.) Exhaust Stem O.D. Intake 5.955 ~ 5.97mm (0.2344 ~ 0.2350 in.) Exhaust 5.935 ~ 5.95mm (0.2337 ~ 0.2343 in.) Face angle thickness of valve head (Margin) 1.1mm (0.0433 in.)
  • Page 5 ZENITH POWER PRODUCTS - 416 EM -4 ENGINE DOHC Description Specification Limit Connecting rod 0.05mm (0.0020 in.) or less Bend 0.1mm (0.0039 in.) or less Twist Connecting rod big end to crankshaft 0.100-0.250mm (0.0039-0.0098 in.) 0.4mm (0.0157in.) side clearance 0.018-0.036mm (0.0007-0.0014 in.) Connecting rod bearing oil clearance 0.25, 0.50, 0.75mm...
  • Page 6 ZENITH POWER PRODUCTS - 416 GENERAL EM -5 Description Limit Specification Thermostat Wax pellet type with jiggle valve Type 82 C (180 F) Valve opening temperature 95 C (203 F) Full-opening temperature Engine coolant temperature sensor Heat-sensitive thermistor type Type Resistance 2.31 ~ 2.59k...
  • Page 7 ZENITH POWER PRODUCTS - 416 EM -6 ENGINE DOHC TIGHTENING TORQUE Item Kg.cm Ib.ft Cylinder Block 45 ~ 55 450 ~ 550 33 ~ 41 Front engine support bracket bolt and nut 45 ~ 55 450 ~ 550 33 ~ 41...
  • Page 8 ZENITH POWER PRODUCTS - 416 GENERAL EM -7 Item Kg.cm Ib.ft 20 ~ 25 200 ~ 250 15 ~ 18 Alternator support bolt and nut Alternator lock bolt 12 ~ 15 120 ~ 150 9 ~ 11 Alternator brace mounting bolt...
  • Page 9 ZENITH POWER PRODUCTS - 416 EM -8 ENGINE DOHC MAINTENANCE CHANGING ENGINE OIL CHECKING ENGINE OIL CAUTION Position the vehicle on a level surface. Be careful not to burn yourself, as the engine oil is hot. Warm up the engine.
  • Page 10 ZENITH POWER PRODUCTS - 416 GENERAL EM -9 Tighten the oil filter to the specified torque. FILTER SELECTION All Hyundai engines are equipped with a high quality, dis- posable oil filter. This filter is recommended as a replace- ment filter on all vehicles. The quality of replacement fil- ters varies considerably.
  • Page 11 ZENITH POWER PRODUCTS - 416 EM -10 ENGINE DOHC SELECTION OF ENGINE OIL Recommended API classification : SH OR ABOVE Recommended SAE viscosity grades : Temperature range anticipated before Recommended SAE viscosity number next oil change ˚C ˚F *1 Restricted by driving condition and environment.
  • Page 12 ZENITH POWER PRODUCTS - 416 GENERAL EM -11 CHECKING COOLANT LEAK RADIATOR CAP PRESSURE TEST Wait until the engine is cool, then carefully remove the Remove the radiator cap, wet its seal with engine radiator cap. coolant, then install it on the tester.
  • Page 13 ZENITH POWER PRODUCTS - 416 EM -12 ENGINE DOHC SPECIFIC GRAVITY TEST Measure the specific gravity of the coolant with a hy- drometer. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference.
  • Page 14 ZENITH POWER PRODUCTS - 416 GENERAL EM -13 CHANGING ENGINE COOLANT CHECKING COMPRESSION PRESSURE Before checking engine compression, check the en- CAUTION gine oil level. Also check that the starter motor and When pouring engine coolant, be sure to shut the battery are all in normal operating condition.
  • Page 15 ZENITH POWER PRODUCTS - 416 EM -14 ENGINE DOHC 11. Crank the engine and read the gauge. Remove the engine support bracket. (14mm bolt and 2nuts, 17mm bolt) Standard value : 1500kpa (15Kg/cm², 218 psi) Limit : 1400kpa (14Kg/cm², 203 psi) 12.
  • Page 16 ZENITH POWER PRODUCTS - 416 GENERAL EM -15 Remove the crankshaft pulley. 11. Check that the teeth of the sprocket and belt coincide with each other. 12. Tighten the slot side bolt first and then tighten the bolt of pivot side.
  • Page 17 ZENITH POWER PRODUCTS - 416 EM -16 ENGINE DOHC ADJUSTING DRIVE BELT TENSION Pulley Check that the belts are not damaged and are prop- erly fit for the pulley grooves. Apply 100 N (22 lbs.) force to the back and midway...
  • Page 18 ZENITH POWER PRODUCTS - 416 GENERAL EM -17 Typ B RESET button NOTE The belt tension must be measured half - way RESET position between the specified pulleys. When a new belt is installed, adjust the tension to the central value of the standard range indicated under "New"...
  • Page 19 ZENITH POWER PRODUCTS - 416 EM -18 ENGINE DOHC SPECIAL TOOLS E0845550 Tool (Number and name) Illustration Crankshaft front oil seal installer Installation of the front oil seal (09231 - 22000) ECKA010C Crankshaft front oil seal guide Guide of oil seal...
  • Page 20 ZENITH POWER PRODUCTS - 416 GENERAL EM -19 Tool (Number and name) Illustration Valve spring compressor Removal and installation of intake (09222 - 28000) and exhaust valves Valve spring compressor holder (09222 - 28100) EDDA005C Water temperature sensor socket Removal and installation of the water...
  • Page 21 ZENITH POWER PRODUCTS - 416 EM -20 ENGINE DOHC TROUBLESHOOTING E6712BDA Probable cause Remedy Symptom Low compression Blown cylinder head gasket Replace gasket Worn or damaged piston rings Replace rings Repair or replace piston and/or Worn piston or cylinder cylinder block...
  • Page 22 ZENITH POWER PRODUCTS - 416 GENERAL EM -21 Symptom Probable cause Remedy Abnormally high coolant temperature Faulty thermostat Replace parts Faulty radiator cap Replace parts Restricted flow in cooling system Clear restriction or replace parts Loose or missing drive belt...
  • Page 23 ZENITH POWER PRODUCTS - 416 EM -22 ENGINE DOHC TIMING SYSTEM TIMING BELT COMPONENTS E4B24FDE Cylinder head cover Camshaft sprocket Timing belt upper cover Timing belt 80 ~ 100 (800 ~ 1000, 59 ~ 74) Ten sioner Idler 43 ~ 55 (430 ~ 550, 32 ~ 40)
  • Page 24 ZENITH POWER PRODUCTS - 416 TIMING SYSTEM EM -23 Remove the alternator belt. DISASSEMBLY EE695E6A Lift the vehicle by using of jack. KBPD160A KCDA125K Remove the engine support bracket. (14 mm bolt and 2 nuts, 17 mm bolt) KBPD160B Remove the coolant pump pulley.
  • Page 25 ZENITH POWER PRODUCTS - 416 EM -24 ENGINE DOHC Remove the crankshaft pulley. 10. Remove the timing belt. NOTE If the timing belt is reused, mark with an arrow to in- dicate direction of rotation (on the front of the engine) to make sure that the belt is reinstalled in the same direction as before.
  • Page 26 ZENITH POWER PRODUCTS - 416 TIMING SYSTEM EM -25 INSPECTION E193FC6F SPROCKETS TENSIONER PULLEY, AND IDLER PULLEY Check the camshaft sporcket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise.
  • Page 27 ZENITH POWER PRODUCTS - 416 EM -26 ENGINE DOHC Description Flaw conditions 1. Hardened back surface • Back surface is glossy, non-elastic and so hard that when your fingernail is pressed into it. no mark is produced. EDDA093C 2. Cracked back surface rubber EDDA093D 3.
  • Page 28 ZENITH POWER PRODUCTS - 416 TIMING SYSTEM EM -27 Description Flaw conditions 6. Cracked tooth bottom Crack EDDA093J 7. Missing tooth Tooth missing and canvas fiber exposed EDDA093K 8. Side of belt badly worn NOTE Normal belt shluld have precisely cut sides as if cut by a sharp knife.
  • Page 29 ZENITH POWER PRODUCTS - 416 EM -28 ENGINE DOHC Align the timing marks of the camshaft sprocket (A) REASSEMBLY E6A34B7C and camshaft bearing cap (B). Install the flange and crankshaft sprocket as shown. Then align the timing marks of crankshaft sprocket Pay close attention to their mounting directions.
  • Page 30 ZENITH POWER PRODUCTS - 416 TIMING SYSTEM EM -29 Secure the tensioner, positioned towards the water 11. Then recheck the belt tension Verify that when the pump. tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx.
  • Page 31 ZENITH POWER PRODUCTS - 416 EM -30 ENGINE DOHC 14. Install the water pump pulley. KDDC004B 15. Install the alternator belt and adjust the belt tension. 16. Install the air conditioning compressor belt and adjust the belt tension. 17. Install the power steering belt and adjust the belt ten-...
  • Page 32 ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -31 CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS E804EE47 8 ~ 10 (80 ~ 100, 6 ~ 7.4) Cylinder head cover Gasket Cylinder head bolt 30(300, 22) + 90˚ → Release all bolts →...
  • Page 33 ZENITH POWER PRODUCTS - 416 EM -32 ENGINE DOHC Retainer lock Retainer Valve spring Timing chain Stem seal Spring seat Valve Chain sprocket Exhaust camshaft Intake camshaft 12 ~ 14 (120 ~ 140, 9 ~ 10) 80 ~ 100 (800 ~ 100,...
  • Page 34 ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -33 DISASSEMBLY INSPECTION EBCFA4C6 EE4FDB50 Using a tool remove the cylinder head bolts in the CYLINDER HEAD order shown in the illustration. Check the cylinder head for cracks, damage and coolant leakage.
  • Page 35 ZENITH POWER PRODUCTS - 416 EM -34 ENGINE DOHC VALVES VALVE SPRINGS Using a wire brush, clean the valve thoroughly. Check the free height of each valve spring. If they exceed the servicd limit, replace the springs. Using a square, test the squareness of each spring.
  • Page 36 ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -35 Enlarge the diameter of the valve seat so that it REPLACING THE VALVE SEAT RING matches the specified oversize hole diameter of the Cut away the inner face of the valve seat to reduce new valve seat ring.
  • Page 37 ZENITH POWER PRODUCTS - 416 EM -36 ENGINE DOHC Using the special tool (09221-3F100 A/B), press-fit After the valve guide is replaced, check that the valve the valve guide. The valve guide must be press-fitted is seated properly. Recondition the valve seats as from the upper side of the cylinder head.
  • Page 38 ZENITH POWER PRODUCTS - 416 CYLINDER HEAD ASSEMBLY EM -37 Using the special tool (09222-28000, 09222-28100), REASSEMBLY EC46B95A compress the spring and install the retainer locks. Af- ter installing the valves, ensure that the retainer locks NOTE are correctly in place before releasing the valve spring Clean each part before assembly.
  • Page 39 ZENITH POWER PRODUCTS - 416 EM -38 ENGINE DOHC MAIN MOVING SYSTEM CAM SHAFT COMPONENTS EE8F4E76 5 ~ 8 (50 ~ 80, 4 ~ 6) 8 ~ 10 (80 ~ 100, 6 ~ 7) Cylinder head Gasket 12 ~ 14 (50 ~ 80, 4 ~ 6)
  • Page 40 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -39 Remove the camshaft bearing caps and timing chain. DISASSEMBLY EBF99CFA Disconnect the breather hose and the P.C.V. hose. Loosen the center cover bolts and then remove the center cover. Remove the ignition coil assembly and the spark plug cables.
  • Page 41 ZENITH POWER PRODUCTS - 416 EM -40 ENGINE DOHC INSPECTION ECDFFBF8 Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft. Check the cam lobes for damage. If the lobe is dam- aged or worn excessively, replace the camshaft.
  • Page 42 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -41 HLA ( HYDRAULIC LASH ADJUSTER) With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA. For other specific trouleshooting regarding HLA, refer to the table below.
  • Page 43 ZENITH POWER PRODUCTS - 416 EM -42 ENGINE DOHC Install the bearing caps. The markings on the caps TIMING CHAIN are for intake/exhaust identification. Check the bushing and plate of timing chain for wear. Re- I: Intake camshaft place if wear is severe.
  • Page 44 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -43 Using the special tool, camshaft oil seal installer Install the cylinder head cover. (09221 - 21000), press fit the camshaft oil seal. Be susre to apply engine oil to the oil seal lip. Insert the...
  • Page 45 ZENITH POWER PRODUCTS - 416 EM -44 ENGINE DOHC CRANK SHAFT COMPONENTS ED67A7AC (ATA) 120 ~ 130 (1200 ~ 1300, 88 ~ 95) Washer (MTA) Drive plate Flywheel 10 ~ 12 (100 ~ 120, 7.3 ~ 8.8) Rear oil seal case...
  • Page 46 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -45 Measure the clearance by the value that subtract the DISASSEMBLY EA7E6C0F diameter of journal and pin and the thickness of bear- Remove the timing belt, front case, flywheel, cylinder ing from the diameter of bore.
  • Page 47 ZENITH POWER PRODUCTS - 416 EM -46 ENGINE DOHC REPLACEMENT CRANKSHAFT MAIN JOURNAL DIAMETER E8EBDEBC Check the cylinder block crankshaft bore size code. Size Main journal diameter Class code 49.968 ~ 49.962 mm Λ (1.9672 ~ 1.9670 in.) Crankshaft bore size code 49.962 ~ 49.956 mm...
  • Page 48 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -47 Make certain that the crankshaft turns freely and has REASSEMBLY E0ABCAB2 the proper clearance between the center main bear- Install the upper main bearing inserts in the cylinder ing thrust flange and the connecting rod big end bear- block.
  • Page 49 ZENITH POWER PRODUCTS - 416 EM -48 ENGINE DOHC FLY WHEEL COMPONENTS E3FB04C9 Ring gear Flywheel Drive plate Adaptor plate 120 ~ 130 (1200 ~ 1300, 89 ~ 96) 120-130 (1200-1300, 89-96) Adaptor plate TORQUE : Nm (kg.cm, lb.ft) EDDA030A...
  • Page 50 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -49 PISTON COMPONENTS E1D1ECDE Piston ring Piston pin Piston Connecting rod Connecting rod bearing Connecting rod bearing cap 32 ~ 35 (320 ~ 350, 24 ~ 26) TORQUE : Nm (kgf.cm, lbf.ft)
  • Page 51 ZENITH POWER PRODUCTS - 416 EM -50 ENGINE DOHC To remove the pin from the piston, place the piston DISASSEMBLY EEDFC26E in the support fixture with the rod resting on the fork CONNECTING ROD CAP inserts. Pass the remove tool through the top of the support fixture and use it to press out the pin.
  • Page 52 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -51 Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to force the piston pin through the rod little end. Continue pressing until the pin guide falls free and the installer tool seats against the top of the arch.
  • Page 53 ZENITH POWER PRODUCTS - 416 EM -52 ENGINE DOHC To measure the piston ring end gap, insert a piston INSPECTION E005DAEA ring into the cylinder bore. Position the ring at right PISTONS AND PISTON PINS angles in the cylinder wall by gently pressing it down with a piston.
  • Page 54 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -53 PISTON RING SERVICE SIZE AND MARK None Standard 0.25 mm (0.010 in.) O.S NOTE The mark can be found on the upper side of the ring next to the end.
  • Page 55 ZENITH POWER PRODUCTS - 416 EM -54 ENGINE DOHC REPLACEMENT 1.6 L EF4FCD8C Check the cylinder bore size code on the cylinder Size Piston outer diameter Class block bottom face. code 76.465~76.475mm (3.0104~3.0108in.) Cylinder bore side code 76.475~76.485mm (3.0108~3.0112in.) 76.485~76.495mm (3.0112~3.0116in.)
  • Page 56 ZENITH POWER PRODUCTS - 416 MAIN MOVING SYSTEM EM -55 Install the lower side rail by the same procedure de- REASSEMBLY ECCF87EF scribed in Step 2. Install the spacer. Piston upper Side rail Spacer Piston lower ECA9380B ECA9082A Apply engine oil around the piston and piston grooves.
  • Page 57 ZENITH POWER PRODUCTS - 416 EM -56 ENGINE DOHC Hold the piston rings firmly with a piston ring compres- 14. Check the connecting rod side clearance. sor as they are inserted into cylinder. Connecting rod side clearance No.1 ring Standard : 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.) Limit : 0.4 mm (0.0157 in.)
  • Page 58 ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -57 COOLING SYSTEM ENGINE COOLANT HOSE／PIPES COMPONENTS E2BAF9FA RADIATOR COOLANT PUMP THERMOSTAT BYPASS VALVE CYL/BLCOK CYL/HEAD HEATER ECKB001I...
  • Page 59 ZENITH POWER PRODUCTS - 416 EM -58 ENGINE DOHC 15 ~ 20 (150 ~ 200, 9 ~ 14) Thermostat housing Thermostat Coolant inlet fitting Gasket 20 ~ 27 (200 ~ 270, 12 ~ 20) 10 ~ 15 (100 ~ 150, 7 ~ 9)
  • Page 60 ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -59 INSPECTION REASSEMBLY E6CC2E0F E1DCE4A4 Check the coolant pipe and hoses for cracks, damage, or Fit on O-Ring in the groove provided at the coolant inlet restrictions. pipe end, wet the O-ring with coolant and insert the coolant inlet pipe.
  • Page 61 ZENITH POWER PRODUCTS - 416 EM -60 ENGINE DOHC ENGINE COOLANT PUMP COMPONENTS E8D2CBAD Coolant pump 8 - 10 (80 - 100, 6 - 7) Alternator brace 20 - 27 (200 - 270, 15 - 20) Coolant pump Coolant pump pulley Belt TORQUE : Nm (kg.cm, lb.ft)
  • Page 62 ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -61 INSPECTION REASSEMBLY E5229EB7 E0C24D31 Check each part for cracks, damage or wear, and re- Clean the gasket surfaces of the coolant pump body place the coolant pump assembly if necessary. and the cylinder block.
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  • Page 64 ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -63 INSPECTION REASSEMBLY EC662470 EF7E7B75 Check the radiator for bent, broken or plugged fins. Fill the radiator and reservoir tank with clean coolant mixture. Check the radiator for corrosion, damage, rust or scale.
  • Page 65 ZENITH POWER PRODUCTS - 416 EM -64 ENGINE DOHC RADIATOR CAP COMPONENTS EA37EA8B Radiator Cap Spring High - pressure valve Vacuum spring High - pressure valve When the pressure is peduced to the specified level When the pressure is peduced to the specified level [-6.86 Kpa (- 0.07 kg/cm, -1.00 psi)]...
  • Page 66 ZENITH POWER PRODUCTS - 416 COOLING SYSTEM EM -65 INSPECTION E7AA67F9 Check the radiator cap for damage, cracks and dete- rioration. Deterioration Deterioration ECDA068A Attach a radiator cap tester to the radiator Pump the tester until the pointer stabilizes. If the pointer stays constant for 10 sec. at a point exceeding the service limit, the radiator cap is good.
  • Page 67 ZENITH POWER PRODUCTS - 416 EM -66 ENGINE DOHC THERMOSTAT REASSEMBLY E342AFA3 Check that the flange of the thermostat is correctly INSPECTION EE55C20B seated in the socket of the thermostat housing. Drain the coolant so its level is below thermostat.
  • Page 68 ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM EM -67 LUBRICATION SYSTEM OIL PUMP COMPONENTS EDF9B71D 20 ~ 27 (200 ~ 270, 15 ~ 20) Gasket Oil screen Front case Filter 15 ~ 22 (150 ~ 220, 11 ~ 16) Drain plug...
  • Page 69 ZENITH POWER PRODUCTS - 416 EM -68 ENGINE DOHC DISASSEMBLY INSPECTION E450CC2F E9D08BBC Remove the timing belt. FRONT CASE Check the front case for cracks or damage. Replace Remove all the oil pan bolts. as necessary. Remove the oil pan.
  • Page 70 ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM EM -69 Check the tip clearance on the pump roter. OIL PRESSURE SWITCH (Normally Closed type STD.) Use an ohmmeter to check the continuity between the terminal and the body. If there is no continuity, replace the oil pressure switch.
  • Page 71 ZENITH POWER PRODUCTS - 416 EM -70 ENGINE DOHC REASSEMBLY FRONT CASE E1BA8FB0 Install the front case assembly with a new gasket, and OIL PUMP tighten the bolts to the specified torque. Install the outer and inner gears into the front case...
  • Page 72 ZENITH POWER PRODUCTS - 416 LUBRICATION SYSTEM EM -71 CAUTION • Apply sealant approx. 4mm (0.16 in.) in thick- ness. • After application of sealant, do not exceed 15 minutes before installing the oil pan. ECDA018D Install the oil pan and tighten the bolts to the specified torque.
  • Page 73 ZENITH POWER PRODUCTS - 416 EM -72 ENGINE DOHC ENGINE BLOCK ENGINE BLOCK COMPONENTS E362FF2F Piston ring Piston pin Piston Connecting rod Cylinder block Connecting rod bearing Connecting rod bearing cap 32 ~ 35 (320 ~ 350, 24 ~ 26) TORQUE : Nm (kgf.cm, lbf.ft)
  • Page 74 ZENITH POWER PRODUCTS - 416 ENGINE BLOCK EM -73 DISASSEMBLY INSPECTION EE96372F EBADEC3C Remove the timing belt, cylinder head, front case, fly- Check the engine block for scores, rust and corrosion. wheel, pistons and crankshaft. Also check for cracks or any other defects. Replace the block if defective.
  • Page 75 ZENITH POWER PRODUCTS - 416 EM -74 ENGINE DOHC If a cylinder ridge exists, cut away with a ridge reamer. Oversize pistons are available in four sizes. Pistom service size and mark mm (in.) 0.25 (0.010) O.S. : 0.25 When boring the cylinder to the oversize, maintain the...
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  • Page 77 ZENITH POWER PRODUCTS - 416 EM -76 ENGINE DOHC INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS E6FBC7D4 Cylinder head Gasket Exhaust manifold 30 ~ 35 (300 ~ 350, 22 ~ 26) 15 ~ 20 (150 ~ 200, 11 ~ 15) Heat protector TORQUE : Nm (kgf.cm, lbf.ft)
  • Page 78 ZENITH POWER PRODUCTS - 416 INTAKE AND EXHAUST SYSTEM EM -77 DISASSEMBLY INSPECTION EAA67563 ED2622EE Disconnect the oxygen sensor connect. EXHAUST MANIFOLD Check for damage or cracking. Check for damage or cracking of welding between ex- haust manifold and converter.
  • Page 79 ZENITH POWER PRODUCTS - 416 EM -78 ENGINE DOHC INTAKE MANIFOLD COMPONENTS EF98EE9D Intake manifold Throttle body Gasket 15 ~ 20 (150 ~ 200, Gasket 11 ~ 15) 18 ~ 25 (180 ~ 250, 13 ~ 18) Intake manifold stay TORQUE : Nm (kg.cm, lb.ft)

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