Page 2305 of 3051
SEM887F
10. Install cylinder head front cover.
+Apply liquid gasket to cylinder head front cover.
+Use Genuine Liquid Gasket or equivalent.
SEM889F
11. Install camshaft position sensor (PHASE).
SEM888F
12. Before installing rocker cover, apply a continuous bead of liq-
uid gasket to mating surface of cylinder head.
SEM105G
13. Install rocker cover with rocker cover gasket and tighten bolts
in numerical order as shown in the figure.
14. Install spark plugs.
15. Install ignition coils.
16. Install exhaust manifold.
17. Install intake manifold rear supports.
18. Connect vacuum hoses, fuel hoses, water hose, wire, harness,
connectors and so on.
19. Install front exhaust tube.
20. Install front undercovers.
21. Install air duct to intake manifold collector.
22. Drive belts.
For adjusting drive belt deflection, refer to ªCheckingº, EM-17.
23. Reinstall parts in reverse order of removal.
CYLINDER HEADQG
Installation (Cont'd)
EM-48
Page 2306 of 3051
Removal and InstallationNLEM0022
NEM346
1. RH engine mounting
2. RH engine mounting bracket
3. LH engine mounting
4. Rear engine mounting bracket5. Rear engine mounting
6. Dynamic damper (Specific models
only)
7. Center member8. Front engine mounting bracket
9. Front engine mounting
ENGINE ASSEMBLYQG
Removal and Installation
EM-49
Page 2307 of 3051

WARNING:
+Position vehicle on a flat and solid surface.
+Place chocks at front and back of rear wheels.
+Do not remove engine until exhaust system has com-
pletely cooled off, otherwise, you may burn yourself
and/or fire may break out in fuel line.
+Before disconnecting fuel hose, release pressure.
Refer to EC-43, ªFuel Pressure Releaseº.
+Be sure to lift engine and transaxle in a safe manner.
+For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
+When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.
+When lifting the engine, always use engine slingers in a
safe manner.
+When removing drive shaft, be careful not to damage
grease seal of transaxle.
+Before separating engine and transaxle, remove crank-
shaft position sensor (POS) from the cylinder block
assembly.
+Always be extra careful not to damage edge of crankshaft
position sensor (POS), or signal plate teeth.
Engine cannot be removed separately from transaxle. Remove
engine with transaxle as an assembly.
REMOVALNLEM0022S011. Drain coolant from radiator and cylinder block. Refer to LC-18,
ªChanging Engine Coolantº.
2. Remove coolant reservoir tank and bracket.
3. Drain engine oil.
4. Remove battery and battery tray.
5. Remove air cleaner and air duct.
6. Remove drive belts.
7. Remove alternator and air conditioner compressor from
engine.
8. Remove power steering oil pump from engine and position
aside.
Power steering oil pump does not need to be disconnected
from power steering tubes.
ENGINE ASSEMBLYQG
Removal and Installation (Cont'd)
EM-50
Page 2308 of 3051

SEM174D
9. Remove the following parts:
+RH and LH front tires
+Splash covers
+RH and LH brake caliper assemblies
Refer to BR-24, ªFRONT DISC BRAKEº.
Brake hose does not need to be disconnected from brake
caliper assembly. Never depress brake pedal.
+RH & LH drive shaft. Refer to AX-10, ªDrive Shaftº.
When removing drive shaft, be careful not to damage tran-
saxle side grease seal.
SEM109G
+Disconnect control rod and support rod from transaxle.
Refer to MT-23, ªTRANSAXLE GEAR CONTROLº.
SEM108G
+Center member
+Front exhaust tube
+Stabilizer bar
+Cooling fan
+Radiator
+Disconnect wires, harness, pipes, hoses and so on.
10. Lift up engine slightly and disconnect or remove all engine
mountings.
When lifting engine, be sure to clear surrounding parts. Use
special care near brake tubes and brake master cylinder.
11. Remove engine with transaxle as shown.
SEM420D
INSTALLATIONNLEM0022S02+Install in reverse order of removal.
ENGINE ASSEMBLYQG
Removal and Installation (Cont'd)
EM-51
Page 2309 of 3051
ComponentsNLEM0023
NEM347
1. Oil level gauge guide
2. Cylinder block
3. Rear oil seal retainer
4. Rear oil seal
5. Rear plate
6. Flywheel
7. Drain plug
8. Buffle plate
9. Top ring10. 2nd ring
11. Oil ring
12. Piston
13. Snap ring
14. Piston pin
15. Connecting rod
16. Connecting rod bearing
17. Connecting rod cap18. Key
19. Main bearing
20. Thrust bearing
21. Crankshaft
22. Main bearing cap
23. Knock sensor
24. Crankshaft position sensor (POS)
25. Signal plate
CYLINDER BLOCKQG
Components
EM-52
Page 2310 of 3051

Removal and InstallationNLEM0024CAUTION:
+When installing sliding parts such as bearings and
pistons, apply engine oil on the sliding surfaces.
+Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
+When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.
+Do not allow any magnetic materials to contact the signal
plate teeth of flywheel or drive plate, and rear plate.
+Remove the crankshaft position sensor (POS).
+Be careful not to damage sensor edges and single plate
teeth.
SEM927F
DisassemblyNLEM0025PISTON AND CRANKSHAFTNLEM0025S011. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing chain.
Refer to EM-23.
SEM877B
4. Remove pistons with connecting rod.
+When disassembling piston and connecting rod, remove snap
ring first. Then heat piston to 60 to 70ÉC (140 to 158ÉF) or use
piston pin press stand at room temperature.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+When replacing piston rings, if there is no punch mark,
install with either side up.
SEM165DB
5. Loosen main bearing caps in numerical order as shown in fig-
ure.
6. Remove bearing caps, main bearings and crankshaft.
+Before removing bearing caps, measure crankshaft end
play. Refer to EM-61.
+Bolts should be loosened in two or three steps.
CYLINDER BLOCKQG
Removal and Installation
EM-53
Page 2311 of 3051

SEM928F
7. Remove signal plate from crankshaft.
AEM023
InspectionNLEM0026PISTON AND PISTON PIN CLEARANCENLEM0026S011. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
18.993 - 19.005 mm (0.7478 - 0.7482 in)
AEM024
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
18.989 - 19.001 mm (0.7476 - 0.7481 in)
3. Calculate piston pin clearance.
Dp - dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
SEM024AA
PISTON RING SIDE CLEARANCENLEM0026S02Side clearance:
Refer to SDS, EM-73.
Max. limit of side clearance:
Refer to SDS, EM-73.
If out of specification, replace piston and/or piston ring assembly.
AEM096
PISTON RING END GAPNLEM0026S03End gap:
Refer to SDS, EM-73.
Max. limit of end gap:
Refer to SDS, EM-73.
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings.
Refer to SDS, EM-73.
+When replacing the piston, check the cylinder bore surface for
CYLINDER BLOCKQG
Disassembly (Cont'd)
EM-54
Page 2312 of 3051

scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
SEM150B
CONNECTING ROD BEND AND TORSIONNLEM0026S04Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM003F
SEM486C
CYLINDER BLOCK DISTORTION AND WEARNLEM0026S05Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure.
Block surface flatness:
Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.004 in)
If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
of cylinder head resurfacing.
SEM102F
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
213.95 - 214.05 mm (8.4232 - 8.4271 in)
If necessary, replace cylinder block.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-55