DRIVE BELTS
EM-13
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INSTALLATION
1. With box wrench, and while securely holding the hexagonal part in pulley center of drive belt auto-ten-
sioner, move the wrench handle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off.
2. Insert a rod approximately 6 mm (0.24 in) in diameter into retaining boss to fix auto-tensioner pulley.
3. Hook drive belt onto all pulleys except for water pump. Hook drive belt onto water pump pulley at the end.
CAUTION:
Confirm belts are completely set to pulleys.
4. Release auto-tensioner, and apply tensions to belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tensions of belt at indicator is within the allowable use range. Refer to EM-12, "
Checking Drive
Belts" .
Removal and Installation of Drive Belt Auto-TensionerEBS00KNA
REMOVAL
1. Remove splash cover on RH undercover.
2. Remove drive belt.
●Keep auto-tensioner pulley fixed with a tool such as a short-length screwdriver.
3. Remove drive belt auto-tensioner.
●Remove and install drive belt auto-tensioner by fixing auto-tensioner pulley.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
Install drive belt auto-tensioner carefully not to damage the water pump pulley.
SBIA0235E
OIL PAN AND OIL STRAINER
EM-27
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4. Insert Tool (Seal cutter) between lower and upper oil pan slide
tool by tapping on the side of the tool with a hammer.
5. Remove lower oil pan.
6. Remove drive belts. Refer to EM-12, "
DRIVE BELTS" .
7. Remove A/C compressor with piping connected. And locate it
aside temporarily with ropes or equivalent not to disturb the fol-
lowing work
8. Remove front exhaust tube and its support. Refer to EX-2,
"EXHAUST SYSTEM" .
9. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger.
10. Remove center member.
11. Remove rear plate cover, and four engine-to transaxle bolts.
12. Loosen bolts in reverse order of illustration to remove upper oil
pan.
●Disregard No. 1, 2 and 3 when loosening.
●Insert Tool (Seal cutter) between upper oil pan and cylinder
block. Slide tool by tapping on the side of the tool with a ham-
mer.
13. Remove oil strainer.
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install oil strainer.
2. Install upper oil pan in the order below.
SEM365EA
PBIC0257E
SBIA0233E
SEM365EA
EM-38
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TIMING CHAIN
REMOVAL
1. Remove the parts listed below.
●Engine hood
●Engine undercover
●PCV hose
●Ignition coil; Refer to EM-29, "IGNITION COIL" .
●Rocker cover; Refer to EM-35, "ROCKER COVER" .
●Engine coolant reservoir tank
●Drive belt; Refer to EM-12, "REMOVAL" .
●Alternator
●Drive belt auto-tensioner; Refer to EM-13, "REMOVAL" .
●Exhaust front tube; Refer to EX-2, "Removal and Installation" .
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Move power steering pump with piping connected, and secure it to vehicle side temporarily.
5. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
To avoid power steering fluid leakage, temporarily fix reservoir tank vertically.
6. Suspend engine with a hoist, and support the engine posture.
For installation of engine slingers, refer to EM-69, "
ENGINE ASSEMBLY" .
7. Remove RH engine mount insulator.
8. Remove center member and rear engine mounting bracket.
9. Drain engine oil.
10. Remove oil pan upper and lower, and oil strainer. Refer to EM-26, "
OIL PAN AND OIL STRAINER" .
11. Remove intake valve timing control cover.
a. Loosen bolts in reverse order shown in the figure.
b. Remove the cover using Tool (Seal cutter).
CAUTION:
Be careful not to damage mounting surface.
12. Pull chain guide between camshaft sprockets out through front
cover.
13. Set No. 1 cylinder at TDC on its compression stroke with the fol-
lowing procedure.
a. Rotate crankshaft pulley clockwise and align mating marks to
timid indicator on front cover.
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EM-44
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TIMING CHAIN
d. Tighten mounting bolts in the numerical order shown in the fig-
ure.
e. After all bolts are tightened, retighten them to specified torque.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
8. Install chain guide between camshaft sprockets.
9. Install intake valve timing control cover with the following procedure.
a. Install intake valve timing control solenoid valves to intake valve timing control cover.
b. Install oil rings to the intake camshaft sprocket insertion points on intake valve timing control backside
cover.
c. Install O-ring to front cover.
d. Apply liquid gasket to the positions in the figure.
Use Genuine Liquid gasket or equivalent.
e. Tighten mounting bolts in the numerical order shown in the fig-
ure.
10. Insert crankshaft pulley by aligning with crankshaft key.
●Tap its center with a plastic hammer to insert.
●Do not tap belt hook.
11. Tighten crankshaft pulley mounting bolt.
KBIA0083E
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EM-56
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OIL SEAL
OIL SEAL
PFP:12279
Removal and Installation of Valve Oil SealEBS00KNM
REMOVAL
1. Remove camshaft. Refer to EM-46, "CAMSHAFT" .
2. Remove valve lifter. Refer to EM-46, "
CAMSHAFT" .
3. Rotate crankshaft, and set piston whose oil seal is to be
removed to top dead center. This prevents valve from dropping
inside cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring the
front cover with the timing chain.
4. Remove valve collet, valve spring retainer and valve spring with
SST. Refer to EM-59, "
CYLINDER HEAD" .
5. Remove valve oil seal with SST.
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the position shown in the figure with
SST.
3. Install followings in the reverse order of removal.
Removal and Installation of Front Oil SealEBS00KNN
REMOVAL
1. Remove the parts listed below.
●Under cover (with splash cover).
●Drive belts. Refer to EM-12, "DRIVE BELTS" .
●Crank pulley. Refer to EM-37, "TIMING CHAIN" .
2. Remove front oil seal.
CAUTION:
Be careful not to damage front cover and crankshaft.
PBIC0277E
SEM093F
SBIA0270E
EM-60
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CYLINDER HEAD
●If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
●If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
●If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
–If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
–If the compression pressure remains at low level despite the addition of engine oil, the valves may be
malfunctioning. Check the valves for damage. Replace the valve or valve seat accordingly.
●If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, the gaskets are leaking. In such a case, replace the cylinder
head gaskets.
8. Install spark plug, ignition coil and harness connectors.
Removal and InstallationEBS00KNQ
REMOVAL
1. Release fuel pressure. Refer to EC-775, "FUEL PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)],
EC-1139, "
FUEL PRESSURE RELEASE" [QR20DE (WITHOUT EURO-OBD)], EC-42, "FUEL PRES-
SURE RELEASE" [QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE RELEASE" [QR25DE
(WITHOUT EURO-OBD)].
2. Drain engine coolant and engine oil.
3. Remove the following components and related parts.
●Engine hood and engine undercover.
●Air cleaner case and air duct assembly; Refer to EM-14, "AIR CLEANER AND AIR DUCT" .
●Ignition coils; Refer to EM-29, "IGNITION COIL" .
●Rocker cover; Refer to EM-35, "ROCKER COVER" .
●Engine coolant reservoir tank
●Drive belt; Refer to EM-12, "REMOVAL" .
●Alternator
●Drive belt auto-tensioner; Refer to EM-13, "REMOVAL" .
●Exhaust front tube; Refer to EX-2, "Removal and Installation" .
●Exhaust manifold; Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" .
KBIA0250E
1. Cylinder head assembly 2. Cylinder head gasket 3. Cylinder head bolt
EM-70
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ENGINE ASSEMBLY
1. Release fuel pressure. Refer to EC-775, "FUEL PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)],
EC-1139, "
FUEL PRESSURE RELEASE" [QR20DE (WITHOUT EURO-OBD)], EC-42, "FUEL PRES-
SURE RELEASE" [QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE RELEASE" [QR25DE
(WITHOUT EURO-OBD)].
2. Remove engine hood.
3. Drain engine coolant from radiator drain plug. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
4. Remove the following parts.
●LH/RH undercovers
●LH/RH front wheels
●Battery
●Drive belts; Refer to EM-12, "REMOVAL" .
●Air duct and air cleaner case assembly; Refer to EM-14, "REMOVAL" .
●Alternator
●Radiator and radiator fan assembly; Refer to CO-11, "RADIATOR" .
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room LH
7. Disconnect fuel hose, and plug it to prevent fuel from draining. Refer to EM-16, "
INTAKE MANIFOLD"
8. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
9. Disconnect select cable from transaxle (A/T models).
10. Remove clutch operating cylinder from transaxle, and move it aside (M/T models).
11. Disconnect shift cable from transaxle (M/T models).
Engine room RH
12. Remove engine coolant reservoir tank.
13. Remove air conditioner compressor with piping connected from engine. Temporarily secure it on body
with a rope to avoid putting load on it.
Vehicle underbody
14. Remove exhaust front tube.
15. Remove propeller shaft.
16. Remove steering shaft from steering gear.
17. Disconnect power steering fluid cooler piping at a point between body and engine.
18. Remove ABS sensor from brake caliper.
19. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it.
20. Remove LH/RH suspensions from steering knuckle under strut.
Removal
21. Install engine slingers into front left of cylinder head and rear right of cylinder head.
●Use alternator bracket mounting bolt holes for the front side.
22. Lift with hoist and secure the engine in position.Slinger bolts:
Front
: 51.0 - 64.7 N·m (5.2 - 6.6 kg-m, 38 - 47 ft-lb)
Rear
: 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
SBIA0271E
EM-98
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00KNX
GENERAL SPECIFICATIONS
DRIVE BELTS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in) Engine typeQR20DE QR25DE
Cylinder arrangement4.in-line
Displacement
cm
3 (cu in)1,998 (121.92) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 80.3 (3.504 x 3.161) 89.0 x 100.0 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Compression ratio 9.0 9.5
Compression pressure
kPa (bar, kg/cm
2 , psi) / 250 rpmStandard 1,190 (11.9, 12.1, 173) 1,250 (12.5, 12.8, 181.3)
Minimum 990 (9.9, 10.1, 144) 1,060 (10.6, 10.8, 153.7)
Differential limit between cylinders 100 (1.0, 1.0, 14)
Tension of drive belts Auto adjustment by auto-tensioner
Item Limit
Surface distortionIntake manifold collector 0.1 (0.004)
Intake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
MakeNGK
Standard typeLFR5A-11
Hot typeLFR4A-11
Cold typeLFR6A-11
Spark plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
Item Limit
Head surface distortion 0.1 (0.004)
PBIC0283E