JEM175G
3. Install camshaft brackets.
+Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N´m (0.2 kg-m, 17 in-lb).
+Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N´m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N´m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
+Camshaft sprockets are commonly used for RH and LH.
+Align camshaft sprocket and dowel pin on camshaft, and
install.
+Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-132,
ªValve Clearanceº.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
CYLINDER HEADYD
Installation (Cont'd)
EM-132
ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
QG
ENGINE LUBRICATION SYSTEM..................................3
Precautions ..................................................................3
LIQUID GASKET APPLICATION PROCEDURE............3
Preparation ..................................................................3
SPECIAL SERVICE TOOLS........................................3
Lubrication Circuit ........................................................4
Oil Pressure Check......................................................5
Oil Pump ......................................................................5
REMOVAL AND INSTALLATION.................................5
DISASSEMBLY AND ASSEMBLY................................6
INSPECTION.............................................................7
REGULATOR VALVE INSPECTION............................7
Changing Engine Oil....................................................8
Changing Oil Filter .......................................................9
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK..........................................10
OIL PUMP INSPECTION..........................................10
REGULATOR VALVE INSPECTION..........................10
OIL CAPACITY........................................................10
ENGINE COOLING SYSTEM........................................ 11
Precautions ................................................................ 11
LIQUID GASKET APPLICATION PROCEDURE.......... 11
Preparation ................................................................ 11
SPECIAL SERVICE TOOLS...................................... 11
Cooling Circuit ...........................................................12
System Check............................................................12
CHECKING COOLING SYSTEM HOSES...................12
CHECKING RADIATOR............................................13
CHECKING RADIATOR CAP....................................13
CHECKING COOLING SYSTEM FOR LEAKS............13
Water Pump ...............................................................14
REMOVAL AND INSTALLATION...............................14
INSPECTION...........................................................14
Thermostat .................................................................15
REMOVAL AND INSTALLATION...............................15
INSPECTION...........................................................16
Radiator .....................................................................16
COMPONENTS.......................................................16
Cooling Fan ...............................................................17
COMPONENTS.......................................................17
CONTROL SYSTEM................................................17
Changing Engine Coolant..........................................17
- DRAINING ENGINE COOLANT -............................17
- REFILLING ENGINE COOLANT -...........................18
- FLUSHING COOLING SYSTEM -............................19
Radiator (Aluminum type) ..........................................20
PREPARATION.......................................................20
DISASSEMBLY........................................................20
ASSEMBLY.............................................................21
INSPECTION...........................................................22
Overheating Cause Analysis .....................................23
Service Data and Specifications (SDS).....................24
THERMOSTAT........................................................24
RADIATOR..............................................................24
COOLANT CAPACITY..............................................24
YD
ENGINE LUBRICATION SYSTEM................................25
Precautions ................................................................25
LIQUID GASKET APPLICATION PROCEDURE..........25
Preparation ................................................................25
SPECIAL SERVICE TOOLS......................................25
Lubrication Circuit ......................................................26
Oil Pressure Check....................................................27
Oil Pump ....................................................................27
REMOVAL AND INSTALLATION...............................27
DISASSEMBLY AND ASSEMBLY..............................28
OIL PUMP INSPECTION..........................................28
REGULATOR VALVE INSPECTION..........................29
Changing Engine Oil..................................................30
Oil Filter Bracket ........................................................31
REMOVAL AND INSTALLATION...............................31
Changing Oil Filter .....................................................31
REMOVAL...............................................................32
INSTALLATION........................................................32
Oil Cooler ...................................................................33
REMOVAL AND INSTALLATION...............................33
Service Data and Specifications (SDS).....................34
OIL PRESSURE CHECK..........................................34
REGULATOR VALVE INSPECTION..........................34
OIL PUMP INSPECTION..........................................34
ENGINE OIL CAPACITY...........................................34
ENGINE COOLING SYSTEM........................................35
Precautions ................................................................35
LIQUID GASKET APPLICATION PROCEDURE..........35
Preparation ................................................................35
SPECIAL SERVICE TOOLS......................................35
Cooling Circuit ...........................................................36
System Check............................................................37
CHECKING COOLING SYSTEM HOSES...................37
CHECKING RADIATOR............................................37
CHECKING RADIATOR CAP....................................37
CHECKING COOLING SYSTEM FOR LEAKS............38
Water Pump ...............................................................38
REMOVAL AND INSTALLATION...............................38
REMOVAL...............................................................39
INSPECTION...........................................................39
INSTALLATION........................................................39
Thermostat .................................................................40
REMOVAL AND INSTALLATION...............................40
INSPECTION...........................................................41
Radiator .....................................................................41
COMPONENTS.......................................................41
REMOVAL AND INSTALLATION...............................42
Cooling Fan ...............................................................42
COMPONENTS.......................................................42
CONTROL SYSTEM................................................42
Changing Engine Coolant..........................................43
- DRAINING ENGINE COOLANT -............................43
- REFILLING ENGINE COOLANT -...........................43
- FLUSHING COOLING SYSTEM -............................45
Radiator (Aluminum type) ..........................................46
Overheating Cause Analysis .....................................46
Service Data and Specifications (SDS).....................47
THERMOSTAT........................................................47
RADIATOR..............................................................47
ENGINE COOLANT CAPACITY................................47
CONTENTS(Cont'd)
LC-2
6 CHECK IGNITION SPARK
1. Turn Ignition switch ªOFFº.
2. Disconnect ignition coil assembly from rocker cover.
3. Connect a known good spark plug to the ignition coil assembly.
4. Place end of spark plug against a suitable ground and crank engine.
5. Check for spark.
SEF575Q
OK or NG
OK©GO TO 7.
NG©Check ignition coil, power transistor and their circuits. Refer to EC-451.
7 CHECK SPARK PLUGS
Remove the spark plugs and check for fouling, etc.
SEF156I
OK or NG
OK©GO TO 8.
NG©Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to
EM-18, ªChecking and changingº.
8 CHECK COMPRESSION PRESSURE
Refer to EM section.
+Check compression pressure.
Standard:
1,324 kPa (13.24 bar, 13.5 kg/cm
2, 192 psi)/350 rpm
Minimum:
1,128 kPa (11.28 bar, 11.5 kg/cm
2, 164 psi)/350 rpm
Difference between each cylinder:
98 kPa (0.98 bar, 1.0 kg/cm
2, 14 psi)/350 rpm
OK or NG
OK©GO TO 9.
NG©Check pistons, piston rings, valves, valve seats and cylinder head gaskets.
DTC P0300 - P0304 NO.4-1CYLINDER MISFIRE, MULTIPLE CYLINDER
MISFIRE
QG
Diagnostic Procedure (Cont'd)
EC-265
MANUAL TRANSAXLE
SECTION
MT
CONTENTS
RS5F30A
PREPARATION...............................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................6
RS5F70A
PREPARATION...............................................................7
Special Service Tools ..................................................7
Commercial Service Tools ...........................................9
RS5F50A
PREPARATION.............................................................10
Special Service Tools ................................................10
Commercial Service Tools .........................................12
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................13
NVH Troubleshooting Chart.......................................13
MANUAL TRANSAXLE.............................................13
RS5F30A, RS5F70A
M/T OIL..........................................................................14
Changing M/T Oil.......................................................14
Checking ....................................................................14
OIL LEAK AND OIL LEVEL.......................................14
RS5F50A
M/T OIL..........................................................................15
Changing M/T Oil.......................................................15
Checking ....................................................................15
OIL LEAK AND OIL LEVEL.......................................15
DESCRIPTION...............................................................16
Cross-sectional View - RS5F30A ..............................16Cross-sectional View - RS5F70A ..............................17
Cross-sectional View - RS5F50A ..............................18
DOUBLE-CONE SYNCHRONIZER............................19
ON-VEHICLE SERVICE................................................20
Replacing Oil Seal .....................................................20
DIFFERENTIAL OIL SEAL........................................20
STRIKING ROD OIL SEAL.......................................21
Position Switch Check ...............................................21
BACK-UP LAMP SWITCH........................................21
PNP SWITCH..........................................................22
BACK-UP LAMP SWITCH AND PNP SWITCH...........22
RS5F30A, RS5F70A
REMOVAL AND INSTALLATION.................................23
Removal .....................................................................23
Installation ..................................................................24
MODEL QG15DE ENGINE.......................................24
MODEL QG18DE ENGINE.......................................25
RS5F50A
REMOVAL AND INSTALLATION.................................26
Removal .....................................................................26
Installation ..................................................................28
MODEL YD ENGINE................................................28
TRANSAXLE GEAR CONTROL...................................29
Components...............................................................29
RS5F30A
OVERHAUL...................................................................30
Case Components .....................................................30
Gear Components .....................................................31
Shift Control Components .........................................32
DISASSEMBLY..............................................................33
REPAIR FOR COMPONENT PARTS...........................36
Input Shaft and Gears ...............................................36
DISASSEMBLY........................................................36
SMA145AA
SMT512C
Changing M/T OilNJMT00861. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F30A 2.8 - 3.0!(4-7/8 - 5-1/4 Imp pt)
RS5F70A 3.0!(5-1/4 Imp pt)
Oil level (Reference data):
RS5F30A 58 - 66 mm (2.28 - 2.60 in)
RS5F70A 75.5 - 80.5 mm (2.969 - 3.166 in)
Drain plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA066C
CheckingNJMT0087OIL LEAK AND OIL LEVELNJMT0087S011. Check that oil is not leaking from transaxle or around it.
2. Check oil level.
Never start engine while checking oil level.
Filler plug:
: 10 - 19 N´m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
M/T OILRS5F30A, RS5F70A
Changing M/T Oil
MT-14
SMA067C
Changing M/T OilNJMT00881. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, ªRECOMMENDED FLUIDS AND
LUBRICANTSº.
Capacity:
RS5F50A 4.5 - 4.8!(7-7/8 - 8-1/2 Imp pt)
Drain plug:
: 15 - 20 N´m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SMA066C
CheckingNJMT0089OIL LEAK AND OIL LEVELNJMT0089S01Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
: 25 - 34 N´m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
M/T OILRS5F50A
Changing M/T Oil
MT-15
SAT767B
A/T Fluid CheckNJAT0025FLUID LEAKAGE CHECKNJAT0025S011. Clean area suspected of leaking. Ð for example, mating sur-
face of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in ªDº posi-
tion and wait a few minutes.
3. Stop engine.
SAT288G
4. Check for fresh leakage.
SAT638A
FLUID CONDITION CHECKNJAT0025S02
Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material
Milky pink Water contamination Ð Road water
entering through filler tube or breather
Varnished fluid, light to dark brown
and tackyOxidation Ð Over or under filling, Ð
Overheating
FLUID LEVEL CHECKNJAT0025S03Refer to ªChecking A/T Fluidº, AT-15.
SAT647B
Stall TestNJAT0026STALL TEST PROCEDURENJAT0026S011. Check A/T fluid and engine oil levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature.
ATF operating temperature:
50 - 80ÉC (122 - 176ÉF)
TROUBLE DIAGNOSIS Ð BASIC INSPECTION
A/T Fluid Check
AT-78