
SFA755B
2. Pack drive flange groove with grease, apply grease to O-ring
(two places) and mating surface of drive flange, and install
flange.
3. Install snap ring.
SFA759B
4. Install hub cap using a suitable tool.
Do not reuse hub cap. When installing, replace it with a new
one.
FA858
DISASSEMBLYNBAX0010IRemove grease seal and bearing outer races with suitable
brass bar.
INSPECTIONNBAX0011Thoroughly clean wheel bearings and wheel hub.
Wheel BearingNBAX0011S01IMake sure wheel bearing rolls freely and is free from noise,
crack, pitting and wear.
Wheel HubNBAX0011S02ICheck wheel hub for crack by using a magnetic exploration or
dyeing test.
SFA197-A
ASSEMBLYNBAX00121. Install bearing outer race with Tool until it seats in hub.
FRONT AXLE
Wheel Hub and Rotor Disc (Cont'd)
AX-8

BODY & TRIM
SECTION
BT
CONTENTS
PRECAUTIONS...............................................................2
Service Notice..............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............2
PREPARATION...............................................................3
Special Service Tools ..................................................3
Commercial Service Tools ...........................................3
SQUEAK AND RATTLE TROUBLE DIAGNOSES.........4
Work Flow ....................................................................4
CUSTOMER INTERVIEW...........................................4
DUPLICATE THE NOISE AND TEST DRIVE................5
CHECK RELATED SERVICE BULLETINS...................5
LOCATE THE NOISE AND IDENTIFY THE ROOT
CAUSE
.....................................................................5
REPAIR THE CAUSE.................................................5
CONFIRM THE REPAIR.............................................6
Generic Squeak and Rattle Troubleshooting ..............6
INSTRUMENT PANEL................................................6
CENTER CONSOLE..................................................6
DOORS.....................................................................6
TRUNK.....................................................................7
SUNROOF/HEADLINER.............................................7
SEATS......................................................................7
UNDERHOOD...........................................................7
Diagnostic Worksheet ..................................................8
CLIP AND FASTENER..................................................10
Description .................................................................10
BODY FRONT END.......................................................12
Removal and Installation ...........................................12
FRONT BUMPER ASSEMBLY..................................12
BODY REAR END AND OPENER................................15
Removal and Installation ...........................................15
REAR BUMPER ASSEMBLY....................................15
FRONT DOOR...............................................................18
Overhaul ....................................................................18
Front Door Limit Switch Reset ..................................19
RESET CONDITIONS..............................................19
RESET PROCEDURES............................................19
REAR DOOR.................................................................20
Overhaul ....................................................................20INSTRUMENT PANEL ASSEMBLY.............................21
Removal and Installation ...........................................21
SIDE AND FLOOR TRIM...............................................28
Removal and Installation ...........................................28
DOOR TRIM...................................................................30
Removal and Installation ...........................................30
ROOF TRIM...................................................................32
Removal and Installation ...........................................32
BACK DOOR TRIM.......................................................34
Removal and Installation ...........................................34
EXTERIOR.....................................................................35
Removal and Installation ...........................................35
FRONT SEAT................................................................41
Removal and Installation ...........................................41
HEATED SEAT........................................................43
REAR SEAT...................................................................44
Removal and Installation ...........................................44
SUNROOF......................................................................45
Adjustment .................................................................45
Removal and Installation ...........................................45
Trouble Diagnoses.....................................................49
DIAGNOSTIC TABLE................................................49
WIND DEFLECTOR.................................................49
ADJUSTMENT.........................................................50
DRAIN HOSES........................................................51
WEATHERSTRIP.....................................................51
LINK AND WIRE ASSEMBLY....................................52
WINDSHIELD AND WINDOWS....................................53
Removal and Installation ...........................................53
REMOVAL...............................................................53
INSTALLATION........................................................53
WINDSHIELD..........................................................54
REAR SIDE WINDOW..............................................55
DOOR MIRROR.............................................................56
Removal and Installation ...........................................56
BODY (ALIGNMENT)....................................................57
Alignment ...................................................................57
ENGINE COMPARTMENT........................................58
UNDERBODY..........................................................60
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TRUNK=NBBT0025S04Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINERNBBT0025S05Noises in the sunroof/headliner area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATSNBBT0025S06When isolating seat noises it's important to note the position the seat is in and the load placed on the seat
when the noise is present. These conditions should be duplicated when verifying and isolating the cause of
the noise.
Cause of seat noise include:
1. Headrest rods and holders
2. A squeak between the seat pad cushion and frame
3. The rear seat back lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOODNBBT0025S07Some interior noises may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noises include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
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SQUEAK AND RATTLE TROUBLE DIAGNOSES
Generic Squeak and Rattle Troubleshooting (Cont'd)
BT-7

Removal and InstallationNBBT0009CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.
1. Remove front and rear seats. Refer to ªFRONT SEATº and ªREAR SEATº for details, BT-41, BT-44.
2. Remove front and rear seat belts. Refer to RS-4 and RS-5, ªFront Seat Beltº and ªRear Seat Beltº for
details.
3. Remove front and rear kicking plates.
4. Remove dash side lower finishers.
5. Remove front and rear body side welts.
6. Remove front pillar garnishes.
7. Remove center assist grips.
8. Remove center pillar lower garnishes.
9. Remove center pillar upper garnishes.
10. Remove rear gate kicking plate.
11. Remove rear net hooks.
12. Remove tonneau cover assembly and rear parcel holder.
13. Remove rear side lower garnishes.
14. Remove rear side upper garnishes.
SBT694
SIDE AND FLOOR TRIM
Removal and Installation
BT-28

Removal and InstallationNBBT00111. Remove front and rear seats. Refer to ªFRONT SEATº and ªREAR SEATº for details, BT-41, BT-44.
2. Remove front and rear seat belts. Refer to RS-4 and RS-5, ªFront Seat Beltº and ªRear Seat Beltº for
details.
3. Remove body side trim. Refer to ªSIDE AND FLOOR TRIMº for details, BT-28.
4. Remove roof console assembly.
5. Remove inside mirror assembly.
6. Remove sun visors.
7. Remove interior lamp assembly and luggage room lamp assembly.
8. Remove assist grips.
9. Remove clips securing headlining.
10. Remove rear roof garnish.
11. Remove headlining from vehicle through either back door.
ROOF TRIM
Removal and Installation
BT-32

5 CHECK IGNITION SPARK
1. Disconnect ignition wire from spark plug.
2. Connect a known good spark plug to the ignition wire.
3. Place end of spark plug against a suitable ground and crank engine.
4. Check for spark.
SEF575Q
OK or NG
OK©GO TO 6.
NG©Check ignition coil, power transistor and their circuits. Refer to ªDTC P1320 IGNITION
SIGNALº, EC-499
6 CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG
OK©GO TO 7.
NG©Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to
MA-13, ªENGINE MAINTENANCEº.
7 CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-14, ªMeasurement of Compression Pressureº.
Standard:
1,275 kPa (13.0 kg/cm
2, 185 psi)/300 rpm
Minimum:
981 kPa (10.0 kg/cm
2, 142 psi)/300 rpm
Difference between each cylinder:
98 kPa (1.0 kg/cm
2, 14 psi)/300 rpm
OK or NG
OK©GO TO 8.
NG©Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
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DTC P0300 - P0306 NO.6-1CYLINDER MISFIRE, MULTIPLE CYLINDER
MISFIRE
Diagnostic Procedure (Cont'd)
EC-323

ENGINE MECHANICAL
SECTION
EM
CONTENTS
PRECAUTIONS...............................................................3
Parts Requiring Angular Tightening .............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION...............................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................8
NVH Troubleshooting - Engine Noise .........................9
OUTER COMPONENT PARTS.....................................10
Removal and Installation ...........................................10
TIGHTENING PROCEDURES...................................12
MEASUREMENT OF COMPRESSION PRESSURE....14
OIL PAN.........................................................................15
Components...............................................................15
Removal .....................................................................15
Installation ..................................................................18
TIMING CHAIN..............................................................20
Components...............................................................20
POSITION FOR APPLYING LIQUID GASKET............21
Removal .....................................................................23
Inspection...................................................................29
Installation ..................................................................29
OIL SEAL.......................................................................35
Replacement ..............................................................35
VALVE OIL SEAL.....................................................35
OIL SEAL INSTALLATION DIRECTION.....................36
FRONT OIL SEAL....................................................36
REAR OIL SEAL......................................................36
CYLINDER HEAD..........................................................38
Components...............................................................38
Removal .....................................................................39
Disassembly...............................................................41
Inspection...................................................................42
CYLINDER HEAD DISTORTION...............................42
CAMSHAFT VISUAL CHECK....................................42
CAMSHAFT RUNOUT..............................................42
CAMSHAFT CAM HEIGHT.......................................42
CAMSHAFT JOURNAL CLEARANCE........................42
CAMSHAFT END PLAY............................................43
CAMSHAFT SPROCKET RUNOUT...........................43
VALVE GUIDE CLEARANCE....................................43
VALVE GUIDE REPLACEMENT................................44
VALVE SEATS.........................................................45
REPLACING VALVE SEAT FOR SERVICE PARTS....45
VALVE DIMENSIONS...............................................46
VALVE SPRING.......................................................46
VALVE LIFTER........................................................46
Assembly ...................................................................47
Installation ..................................................................47
Valve Clearance.........................................................52
CHECKING.............................................................52
ADJUSTING............................................................54
ENGINE ASSEMBLY.....................................................57
Removal and Installation ...........................................57
REMOVAL...............................................................58
INSTALLATION........................................................60
CYLINDER BLOCK.......................................................61
Components...............................................................61
CYLINDER BLOCK HEATER....................................62
Removal and Installation ...........................................62
Disassembly...............................................................62
PISTON, CRANKSHAFT AND OIL JET......................62
Inspection...................................................................63
PISTON AND PISTON PIN CLEARANCE..................63
PISTON RING SIDE CLEARANCE............................64
PISTON RING END GAP..........................................64
CONNECTING ROD BEND AND TORSION...............65
CYLINDER BLOCK DISTORTION AND WEAR...........65
PISTON-TO-BORE CLEARANCE..............................66
CRANKSHAFT.........................................................67
BEARING CLEARANCE...........................................67
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
..........................................................70
DRIVE PLATE RUNOUT..........................................70
Assembly ...................................................................71
PISTON..................................................................71
OIL JET..................................................................71
CRANKSHAFT.........................................................71
REPLACEMENT OF PILOT CONVERTER.................74
DRIVE PLATE.........................................................74
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SEM934C
VALVE SEATSNBEM0019S10Check valve seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively.
IBefore repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
IUse both hands to cut uniformly.
SEM795A
REPLACING VALVE SEAT FOR SERVICE PARTSNBEM0019S111. Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 38.500 - 38.516 mm (1.5157 - 1.5164 in)
Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in)
Be sure to ream in circles concentric to the valve guide
center.
This will enable valve seat to fit correctly.
SEM892B
3. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) by soaking
in heated oil.
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-79).
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle ªaº: 45É
Contacting width ªWº:
Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in)
Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)
SEM621F
8. Use a depth gauge to measure the distance between the
mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit ªLº:
Intake 41.07 - 41.67 mm (1.6169 - 1.6405 in)
Exhaust 41.00 - 41.60 mm (1.6142 - 1.6378 in)
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CYLINDER HEAD
Inspection (Cont'd)
EM-45