1. SERVICE TRAINING MANUAL ENGINE 2004. 2. 23 LACETTI

2. CONTENTS I. Basic Structure 1. General Information ………………………………………… 3 2. FAM I Mechanical ………………………………………… 10 3. FAM II Mechanical ………………………………………… 18 4. Mounting ….………………………………………………… 25 5. Lubrication ….………….…………………………………… 26 6. Intake ………………………………………………………… 27 7. Exhaust ……………………………………………………… 28 8. Cooling ……………………………………………………… 29 9. Fuel Delivery system ……………………………………… 30 II. FAM I Engine (1.6L DOHC) 1. Engine Control ….………………….……………………… 33 2. Diagnosis …………………………………………………… 65 III. FAM II Engine (1.8L DOHC) 1. Engine Control ….………………….…………………….… 71 2. Diagnosis ………………………………………………….… 99

4. BASIC STRUCTURE 3 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER

5. BASIC STRUCTURE 4 GENERAL INFORMATION ENGINE NUMBER 1. FAM I 2. FAM II [ FAM I ] [ FAM II ]

6. BASIC STRUCTURE 5 GENERAL INFORMATION ENGINE and ECM 1. Engine 1) FAM I : GMDAT engine 2) FAM II : Holden engine 2. ECM 1) Siemens - SIRIUS-D4 :16bits 90 pins 2) Delphi - MR-140 : 32 bits 128 pins - HV-240 : 32 bits 64 pins

7. BASIC STRUCTURE 6 GENERAL INFORMATION SPECIFICATION

8. BASIC STRUCTURE 7 GENERAL INFORMATION SPECIFICATION

9. BASIC STRUCTURE 8 GENERAL INFORMATION SPECIFICATION

10. BASIC STRUCTURE 9 GENERAL INFORMATION FLUIDS & LUBRICANTS

11. BASIC STRUCTURE 10 ENGINE OVERVIEW FAM I MECHANICAL FAM I engine, previously called “E-TEC” engine, has been modified mechanically from J200 series for better performance and fuel consumption etc. E-TEC is newly named E-TEC II.

12. BASIC STRUCTURE 11 E-TEC II ENGINE IMPROVEMENT CAMSHAFT VGIS CYL.HEAD CYL. HEAD GASKET PISTON CYL. BLOCK OIL PAN FAM I MECHANICAL

13. BASIC STRUCTURE 12 EXPLODED VIEW 1. Oil Filler Cap 2. Engine Cover 3. Camshaft Cover 4. Camshaft Cover Gasket 5. Camshaft Cover Bolt 6. Hydraulic Tappet Adjuster 7. Valve Key 8. Valve Spring Cap 9. Valve Spring 10. Valve Stem Seal 11. EGR Vaccum Hose 12. EGR Valve 13. EGR Valve Gasket 14. EGR Valve Adaptor 15. EGR Valve Adaptor Gasket 16. Cylinder Head 17. Front Camshaft Cap 18. Valve Guide 19. Plug 20. Freeze Plug 21. Oil Duct Cap 22. Intake Valve 23. Exhaust Valve 24. Cylinder Head Gasket 25. Engine Coolant Temperature Sensor 26. coolant Temperature Sensor 27. Heat Take Off Pipe 28. Camshaft 29. Camshaft Seal 30. Thermostat FAM I MECHANICAL

14. BASIC STRUCTURE 13 EXPLODED VIEW FAM I MECHANICAL

15. BASIC STRUCTURE 14 EXPLODED VIEW 1. Piston Ring Set 2. Piston 3. Piston Pin 4. Connecting Rod 5. Connecting Rod Bearing Set 6. Oil Level Gauge Stick 7. Gauge Stic Tube 8. Sleeve 9. Clutch Housing Sleeve 10. Cylinder Block 11. Plug 12. Gap 13. Bypass Valve 14. Connecting Piece 15. Oil Filter 16. Oil Pump Body Gasket 17. Water Inlet Neck 18. Knock Sensor 19. Fly Wheel (M/T) 20. Flexible Plate (A/T) 21. Shaft Seal Ring 22. Crank Shaft Upper Bearing Set 23. Crank Shaft 24. Crank Shaft Lower Bearing Set 25. Transmitter Disc 26. Crankshaft Bearing Cap 27. Oil Pan 28. Threaded Ring 29. Washer 30. Oil Pan Drain Plug 31. Oil Pump 32. Oil Pump Cover 33. Oil Pump Inner Rotor 34. Oil Pump Outer Rotor 35. Oil Pump Plug 36. Shaft Sealing 37. Pressure Relief Valve Plunger 38. Relief Valve Spring 39. Sealing 40. Relief Valve 41. Oil Pressure Switch 42. Sleeve 43. Oil Suction Pipe Bracket 44. Oil Suction Pipe 45. Sealing FAM I MECHANICAL

16. BASIC STRUCTURE 15 TIMING BELT ADJUSTMENT 1. Water Pump Sealing 2. Water Pump 3. Timing Belt Rear Cover 4. Camshaft Position Sensor 5. Auto Temsioner 6. Camshaft Gear 7. Idler pulley 8. Crankshaft Gear 9. Torque Roll Axis Support 10. Timing Belt 11. Timing Belt Front Upper Cover 12. Timing Belt Front Lower Cover 13. Crankshaft Pulley 14. Crankshaft Position Sensor * Replacement : 60,000km, 48 months FAM I MECHANICAL

17. BASIC STRUCTURE 16 1. Removing the timing belt a. Remove the front cover b. Rotate the crankshaft clockwise aligning the timing mark of the crankshaft sprocket to the rear cover notch. e. Loosen the fixing bolts (3 EA) of the water pump. f. Rotate the water pump with the SST (J42492) to release belt tension. g. Remove the timing belt I E TIMING BELT ADJUSTMENT c. Align the “I” mark of the intake cam sprocket and “E” of the exhaust. d. Hold the engine assembly and remove the engine mounting bracket. FAM I MECHANICAL

18. BASIC STRUCTURE 17 2. Installing the timing belt a. Align the timing mark of the crankshaft sprocket to the rear cover notch. b. Align the “I” mark of the intake cam sprocket and “E” of the exhaust. c. Install the timing belt as below order. ( ① → ② → ③ → ④ → ⑤ → ⑥ ) 1 2 3 45 6 TIMING BELT ADJUSTMENT d. Rotate the water pump clockwise with the SST (KM-421-A) to make the adjusting pointer of the Auto- tensioner aligned to the notch of the Auto-tensioner bracket. e. Tighten the water pump bolts. f. Rotate the crankshaft 2 turns. g. Confirm the timing mark aligned. h. Loosen the water pump bolts. i. Rotate the water pump counterclockwise with the SST (KM- 421-A) to make the adjusting pointer of the auto-tensioner aligned to the notch of the auto-tensioner bracket. j. Tighten the water pump bolts. (100kgfcm) FAM I MECHANICAL

19. BASIC STRUCTURE 18 ENGINE OVERVIEW FAM II MECHANICAL

20. BASIC STRUCTURE 19 EXPLODED VIEW FAM II MECHANICAL

21. BASIC STRUCTURE 20 1. Bolt 2. Spark Plug Cover 3. Oil Filler Cap 4. Oil Filler Cap Seal 5. Bolt 6. Camshaft Cover 7. Camshaft Cover Gasket 8. Tappet Adjuster 9. Valve Key 10. Valve Spring Cap 11. Valve Spring 12. Valve Stem Seal 13. Valve Spring Seat 14. Valve Guide 15. Intake Valve Seat Ring 16. Exhaust Valve Seat Ring 17. Intake Valve 18. Exhaust Valve 19. Bolt 20. Front Camshaft Cap 21. Head Bolt 22. Bolt 23. Intermediate Camshaft Cap 24. Exhaust Gas Recirculation Adapter 25. Exhaust Gas Recirculation Adapter Gasket 26. Cylinder Head 27. Exhaust Manifold Gasket 28. Exhaust Manifold 29. Nut 30. Exhaust Manifold Heat Shield 31. Cylinder Head Gasket 32. Bolt 33. Thermostat Housing 34. Thermostat Housing Gasket 35. Stud 36. Sleeve 37. Plug 38. Bolt 39. Camshaft Position Sensor 40. Oil Gallery Plug 41. Exhaust Camshaft 42. Seal Ring 43. Camshaft Gear 44. Washer 45. Camshaft Gear Bolt 46. Intake Camshaft 47. Intake Manifold Gasket 48. Intake Manifold 49. Throttle Body Gasket 50. Throttle Body 51. Nut 52. Charcoal Canister Purge Solenoid 53. Exhaust Gas Recirculation Solenoid EXPLODED VIEW FAM II MECHANICAL

22. BASIC STRUCTURE 21 EXPLODED VIEW FAM II MECHANICAL

23. BASIC STRUCTURE 22 EXPLODED VIEW 1. Connecting Rod 2. Bearing Set 3. Connecting Rod Bolt 4. Piston Ring Set 5. Piston Pin 6. Piston 7. Engine Block 8. Sleeve 9. Water Jacket Cap 10. Bolt (Manual Transaxle) 11. Flywheel (Manual Transaxle) 12. Flexible Plate (Automatic Transaxle) 13. Bolt (Automatic Transaxle) 14. Clamp 15. Hose 16. Clamp 17. Engine Ventilation Pipe 18. Bolt 19. Gasket 20. Needle Sleeve 21. Crankshaft Rear Seal 22. Crankshaft 23. Transmitter Disk 24. Bolt 25. Oil Pan Scraper 26. Oil Pan 27. Drain Plug 28. Washer 29. Bolt 30. Sleeve 31. Gasket 32. Bolt 33. Oil Pump Cover 34. Ring Gear 35. Gear 36. Oil Pressure Switch 37. Washer 38. Washer 39. Oil Duct Outlet Plug 40. Connecting Piece 41. Seal Ring 42. Oil Filter 43. Bypass Valve 44. Pressure Relief Valve Plunger 45. Pressure Relief Valve Spring 46. Seal Ring 47. Pressure Relief Valve Plug 48. Seal Ring 49. Bolt 50. Oil Suction Pipe 51. Bolt 52. Rear Timing Belt Cover 53. Bolt 54. Special Bolt 55. Idler Pulley 56. Stud 57. Nut 58. Bolt 59. Tensioner 60. Bolt 61. Thrust Inner Washer 62. Woodruff Key 63. Crankshaft Gear 64. Thrust Outer Washer 65. Bolt 66. Camshaft Drive Belt 67. Gasket 68. Front Timing Belt Cover 69. Bolt 70. Bushing Plug 71. Bushing 72. Oil Gallery Plug 73. Bolt 74. Water Pump 75. Seal Ring 76. Crankshaft Position Sensor 77. Bolt 78. Knock Sensor* 79. Bolt 80. Bolt 81. Crankshaft Bearing Bridge FAM II MECHANICAL

24. BASIC STRUCTURE 23 TIMING BELT CHECK & ADJUST a. Remove the front cover b. Rotate the crankshaft clockwise one full turn and align the timing mark of the crankshaft sprocket to the rear cover notch. d. Loosen the automatic tensioner fixing bolt( ① ). e. Rotate the tensioner hex-key tab( ② ) counterclockwise to give the highest tension c. Align the timing mark of the intake cam sprocket and the exhaust f. Rotate the hex-key tab clockwise until the adjust arm pointer is aligned with the notch of the tensioner bracket ① ② FAM II MECHANICAL

25. BASIC STRUCTURE 24 TIMING BELT CHECK & ADJUST g. Tighten the tensioner bolt h. Rotate the crankshaft two turns clockwise i. Check the tensioner pointer for the right position * Replacement : 60,000km, 48months FAM II MECHANICAL

26. BASIC STRUCTURE 25 MOUNTING * TRA (Torque Roll Axis) mounting system * Two hydraulic main mounts and torque reactions 1 2 3 5 4 6 7 8 9 10 1. Rod Reaction Lower 2. Rear Transaxle Mounting Bracket (A/T) 3. Rear Transaxle Mounting Bracket (M/T) 4. Transaxle Mounting 5. Transaxle Mounting Bracket (M/T) 6. Transaxle Mounting Bracket (A/T) 7. Engine Mounting 8. Engine Mounting Bracket 9. Reaction Bracket (1.8DOHC) 10. Rod Reaction (1.8DOHC) MOUNTING

27. BASIC STRUCTURE 26 LUBRICATION

28. BASIC STRUCTURE 27 INTAKEINTAKE SYSTEM * The main resonator is installed inside the RH fender. 1. Air Inlet Hose 2. Main Resonator 3. Air Cleaner 4. Air outlet Hose (1.6DOHC) 5. Breathe Hose (1.6DOHC) 1 2 3 4 5 6 9 10 6. Air outlet Hose (1.8DOHC) 7. Auxiliary Resonator (1.8DOHC) 8. Auxiliary Resonator (1.8DOHC) 9. Auxiliary Resonator (1.8DOHC) 10. Breather Hose (1.8DOHC) 7 8 1.8DOHC)

29. BASIC STRUCTURE 28 EXHAUST SYSTEM EXHAUST 1. Exhaust Rear Muffler 2. Muffler Gasket 3. Exhaust Front Muffler 4. Muffler Gasket 5. Exhaust Front Pipe (1.8D) 6. Exhaust Front Pipe (1.6D) 7. 3 rd Muffler 8. Exhaust Front Pipe Gasket 9. Exhaust Front Pipe Gasket 10. Exhaust Manifold 11. Catalytic Converter Protective Shield 12. Front Muffler Protective Shield 13. Rear Muffler Protective Shield

30. BASIC STRUCTURE 29 COOLING SYSTEM COOLING Main Thermostat Drain Plug Heater Core Water Pump Throttle BodySingle (1.4D MT) AUX. ( ← : Coolant Flow )

31. BASIC STRUCTURE 30 FUEL TANK FUEL DELIVERY SYSTEM Fuel filter Roll over valve * If the ignition key is turned on, the fuel pump will operates for the first two seconds to improve engine start-ability. * Fuel level signal is detected by ECM and ECM modulates the cluster gage by PWM.

32. BASIC STRUCTURE 31 FUEL PUMP [ Fuel Pump Side ] 1. Fuel pump resistance 2. Fuel pump connector FUEL DELIVERY SYSTEM Float Level Sender Pressure Regulator

33. BASIC STRUCTURE 32 Ball Seat Fuel Inlet Fuel Outlet Diaphragm Spring Ball O-ring Ball Spring [ Fuel Pressure Regulator ] FUEL PUMP FUEL DELIVERY SYSTEM 3. Fuel Pressure Regulator The fuel pressure regulator is installed inside the fuel pump. It is referenced by the fuel tank pressure instead of the vacuum pressure, which is roughly the same as the atmospheric pressure. 4. Fuel Level Gage Control The fuel level signal is sent to ECM. ECM modulates the fuel level gage in the cluster by PWM 128 Hz.