Service Manual Picanto Ion g3hg

Compression Pressure Inspection
If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Start the engine and allow to warm up to operating temperature (about five minutes).
Stop the engine.
2. Disconnect the ignition coil connector(A) and the spark plug cables(B).
3. Remove the four spark plugs using a 16mm spark plug wrench.
4 Check the cylinder compression pressure.
. (1) Insert a compression gauge into the spark plug hole.
(2) Fully open throttle.
(3) While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 250rpm or more.
(4 Repeat step (1) through (3) for each cylinder.

)
This measurement must be done in as short a time as possible.
Compression pressure:
1,422kPa (14.5kg/cm², 206psi) / 370rpm
Minimum pressure:
1,275kPa (13.0kg/cm², 185psi)
Difference between each cylinder :
98kPa (1.0kg/cm², 14psi) or less
(5 If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step (1) through (3) fo
) A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5. Reinstall the spark plugs.

6. Connect the ignition coil connector and the spark plug cables.
Valve Clearance Inspection And Adjustment
Warm up the engine (80 ~ 95°C [176 ~ 203°F]), and then inspect and adjust the valve clearance with the cylinder head installed on the cylinder block.
1. Remove the timing belt upper cover (A).
2. Remove the cylinder head cover (A). (Refer to Cylinder head in this group)
3 Set No. 1 cylinder to TDC/compression.
. (1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover.
(2) Check that timing mark of the camshaft sprocket (A) is aligned with the timing mark of the cylinder head.
If not, turn the crankshaft one revolution (360°).
4. Inspection the valve clearance.
(1) Check only the valve indicator as shown. [No. 1 cylinder: TDC/Compression]. Measure the valve clearance.
Cylinder No. 1 2 3
Intake O O
Exhaust O O
(2) Using a thickness gauge, measure the clearance between the adjusting screw and the valve stem end.
Valve clearance
Engine coolant temperature : 20°C[68°F]
Intake: 0.15 ~ 21mm (0.0059 ~ 0.0083in)
Exhaust: 0.19 ~ 0.25mm (0.0075 ~ 0.0098in)
(3) Using the adjusting screw, adjust valve clearance by the specification value after loosen lock nut.
(4) If the adjustment is completed, tighten the lock nut.
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(5) Rotete crankshaft 25 teeth (crank 1 revolution + 2 teeth, crank angle about 360° + 31.3°) to the clock wise.
(6) Check only valves indicator as shown. Measure the valve clearance. (Refer to procedure step (1))
Cylinder No. 1 2 3
Intake O
Exhaust O
(7) Rotate crankshaft to the clockwise more than 2 revolutions.

Repeat process 1) ~ 6) and recheck valve clearance .
Troubleshooting
Symp
Suspect area
tom
Engin Loose or improperly installed engine flywheel.

e
misfir Worn piston rings.
(Oil consumption may or may not cause the engine to misfire.)
e with
abnor
mal
intern
al
lower Worn crankshaft thrust bearings.
engin
e
noise
s.
Engin Stuck valves.

e (Carbon buildup on the valve stem can cause the valve not to close properly.)
misfir
e with Excessive worn or mis-aligned timing belt.
abnor
mal
valve Worn camshaft lobes.
train
noise.
Engin • Faulty cylinder head gasket and/or cranking or other damage to the cylinder head and engine block cooling system .
e • Coolant consumption may or may not cause the engine to overheat.
misfir
e with
coola
nt
consu
mptio
n
Engin Worn valves, valve guides and/or valve stem oil seals.
e
misfir
e with
exces
sive Worn piston rings.
oil (Oil consumption may or may not cause the engine to misfire)
consu
mptio
n
Engin
Incorrect oil viscosity.
e
noise
on Worn crankshaft thrust bearing.
start-
up,
but
only
lastin
ga
few
secon
ds.
Upper Low oil pressure.

engin
e Broken valve spring.
noise,
Worn or dirty valve lifters.
regar
dless Stretched or broken timing belt and/or damage sprocket teeth.
of
Worn timing belt tensioner, if applicable.
engin Worn camshaft lobes.
e
speed
. Worn valve guides or valve stems.
Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open.)
Lower Low oil pressure.

engin
e Loose or damaged flywheel.
noise,
Damaged oil pan, contacting the oil pump screen.
regar
dless
of
engin Oil pump screen loose, damaged or restricted.
e
speed
. Excessive piston-to-cylinder bore clearance.
Excessive piston pin-to bore clearance.
Excessive connecting rod bearing clearance.
Excessive crankshaft bearing clearance.

Incorrect piston, piston pin and connecting rod installation.
Engin Low oil pressure.

e
noise Excessive connecting rod bearing clearance.
under
load.
Excessive crankshaft bearing clearance.
Engin Hydraulically locked cylinder.

e will • Coolant/antifreeze in cylinder.
not • Oil in cylinder.
crank • Fuel in cylinder.
(cran
kshaft Broken timing belt and/or timing belt sporckets.
will
not
rotate Foreign material in cylinder.
) • Broken valve.
• Piston material.
• Foreign material.
Seized crankshaft or connecting rod bearings.
Bent or broken connecting rod.

Broken crankshaft.

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Compression Pressure Inspection

(4 Repeat step (1) through (3) for each cylinder.

This measurement must be done in as short a time as possible.

5. Reinstall the spark plugs.

1. Remove the timing belt upper cover (A).

(4) If the adjustment is completed, tighten the lock nut.

(7) Rotate crankshaft to the clockwise more than 2 revolutions.

Engin Loose or improperly installed engine flywheel.

Engin Stuck valves.

Upper Low oil pressure.

Lower Low oil pressure.

Excessive piston pin-to bore clearance.

Excessive connecting rod bearing clearance.

Excessive crankshaft bearing clearance.

Engin Low oil pressure.

Excessive crankshaft bearing clearance.

Engin Hydraulically locked cylinder.

Seized crankshaft or connecting rod bearings.

Bent or broken connecting rod.

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