Hyundai: Engine D4FA. Manual — part 8
Engine (D4FA -
DSL1.5)
GENERAL
TIMING SYSTEM
TIMING CHAIN
ENGINE AND TRANSAXLE ASSEMBLY
CYLINDER HEAD ASSEMBLY
ENGINE BLOCK
COOLING SYSTEM
LUBRICATION SYSTEM
INTAKE AND EXHAUST SYSTEM
EMA -2
ENGINE (D4FA - DSL1.5)
GENERAL
SPECIFICATIONS
E284EBC0
Description
Specifications (D4FA)
Limit
General
Type
In-line, DOHC
Number of cylinders
4
Bore
75mm (2.9528in)
Stroke
84.5mm (3.3268in)
Total displacement
1,493 cc (91.11 cu.in)
Compression ratio
17.8 : 1
Firing order
1-3-4-2
Valve timing
Opens (BTDC)
6
Intake valve
Closes (ABDC)
34
Opens (BBDC)
46
Exhaust valve
Closes (ATDC)
4
Cylinder head
Flatness of gasket surface
0.03mm (0.0012in) for width
0.09mm (0.0035in) for length
Intake
0.025mm (0.0010in) for width
0.160mm (0.0063in) for length
Flatness
of manifold
mounting
surface
Exhaust
0.025mm (0.0010in) for width
0.160mm (0.0063in) for length
Camshaft
Intake
35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
LH
camshaft
Exhaust
35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Intake
35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Cam height
RH
camshaft
Exhaust
35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
LH camshaft
20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Journal outer
Diameter
RH camshaft
20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance
0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play
0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Intake
93.0mm (3.6614in)
Valve length
Exhaust
93.7mm (3.6890in)
Intake
5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
Stem outer
diameter
Exhaust
5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle
45.5 ~ 45.75
GENERAL
EMA -3
Description
Specifications (D4FA)
Limit
Intake
1.1mm (0.0433in)
Thickness of
valve head
(margin)
Exhaust
1.2mm (0.0472in)
Intake
0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Valve stem to
valve guide
clearance
Exhaust
0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Intake
5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Inner diameter
Exhaust
5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Intake
31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Length
Exhaust
31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat
Intake
0.8 ~ 1.4mm (0.0315 ~ 0.0551in)
Width of seat
contact
Exhaust
1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
Intake
45 ~ 45 30’
Seat angle
Exhaust
45 ~ 45 30’
Valve spring
Free length
44.9mm (1.7677in)
17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
Load
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness
Less than 1.5
3
Cylinder block
Cylinder bore
75.000 ~ 75.030mm (2.9528 ~ 2.9539in)
Flatness of gasket surface
Less than 0.05mm (0.0020in) (Overhaul)
Less than 0.03mm (0.0012in) (Per 1 Cylinder)
Piston
Piston outer diameter
74.930 ~ 74.960mm (2.9500 ~ 2.9512in)
Piston to cylinder clearance
0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
No. 1 ring groove
1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
No. 2 ring groove
1.82 ~ 1.84mm (0.0717 ~ 0.0724in)
Ring groove
width
Oil ring groove
3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
No. 1 ring
0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No. 2 ring
0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Side clearance
Oil ring
0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No. 1 ring
0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No. 2 ring
0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
End gap
Oil ring
0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter
27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
EMA -4
ENGINE (D4FA - DSL1.5)
Description
Specifications (D4FA)
Limit
Piston pin hole inner diameter
28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance
0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end hole
inner diameter
28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
Connecting rod small end hole clearance
0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter
49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance
0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance
0.050 ~ 0.302mm (0.0020 ~ 0.0119in)
0.4mm (0.0157in)
Crankshaft
Main journal outer diameter
53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter
45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance
0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play
0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Flywheel
Runout
0.1mm (0.0039in)
0.13mm (0.0051in)
Oil pump
Inner rotor
0.040 ~ 0.085mm (0.0016 ~ 0.0033in)
Side clearance
Outer rotor
0.040 ~ 0.090mm (0.0016 ~ 0.0035in)
Body clearance
0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure
490±49.0kpa (5±0.5kg/cm², 71±7.1psi)
Engine oil
Oil quantity (Total)
5.3 L (5.60 US qt, 4.66 lmp qt)
Oil quantity (Oil pan)
4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil filter)
0.5 L (0.53 US qt, 0.44 lmp qt)
Oil quality
Above API CH-4, Above ACEA B4
Oil pressure (Idle) (Oil temperature : 80 C)
78.4kpa (0.8kg/cm², 11.3psi)
Cooling system
Cooling method
Forced circulation with cooling fan
Coolant quantity
5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt)
Type
Wax pellet type
Opening temperature
85±1.5 C (185.0±2.7 F)
(Lift : 0.35mm(0.0138in))
Thermostat
Pull opening
temperature
100 C (212 F)
(Lift : 8mm(0.3150in))
Main valve opening
pressure
93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve opening
pressure
0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
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