CYLINDER HEAD
EM-65
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM
CYLINDER HEADPFP:11041
On-Vehicle ServiceBBS0059B
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to EC-49, "
FUEL PRESSURE RELEASE" .
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
surement.
4. Remove engine cover. Refer to EM-19, "
INTAKE MANIFOLD" .
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-31, "
IGNITION COIL" and EM-32,
"SPARK PLUG(PLATINUM-TIPPED TYPE)" .
6. Connect engine tachometer (not required in use of CONSULT-II).
7. Install compression tester with adapter onto spark plug hole.
Use compression gauge whose picking up end inserted to
spark plug hole is smaller than 20 mm (0.79 in) in diameter.
Otherwise, it may be caught by cylinder head during removal.
8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder.
Compression pressure:
Unit: kPa (bar, kg/cm2 , psi) /rpm
CAUTION:
Always use a fully changed battery to obtain specified engine speed.
PBIB2110E
PBIC2420E
SBIA0533E
Standard Minimum Differential limit between cylinders
1,190 (11.9, 12.1, 173) / 250 990 (9.9, 10.1, 144) / 250 100 (1.0, 1.0, 14) / 250
EM-66
[QR]
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 the 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, piston rings may be worn out or damaged. Check
piston rings and replace if necessary.
–If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace 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, cylinder head gasket is leaking. In such a case, replace cylin-
der head gasket.
9. After inspection is completed, install removed parts.
10. Start engine, and confirm that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-52, "
TROUBLE DIAGNOSIS" .
Removal and InstallationBBS0059C
REMOVAL
1. Release fuel pressure. Refer to EC-49, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant and engine oil. Refer to CO-10, "
Changing Engine Coolant" and LU-9, "Changing
Engine Oil" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant and engine oil on drive belt.
3. Remove the following components and related parts.
Exhaust manifold and three way catalyst assembly; Refer to EM-23, "EXHAUST MANIFOLD AND
THREE WAY CATALYST" .
Intake manifold and fuel tube assembly; Refer to EM-19, "INTAKE MANIFOLD" .
Water control valve and housing (water outlet); Refer to CO-24, "THERMOSTAT AND WATER CON-
TROL VALVE" .
1. Cylinder head assembly 2. Cylinder head gasket 3. Engine cover bracket (rear)
4. Cylinder head bolt
PBIC2424E
CYLINDER HEAD
EM-67
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM
NOTE:
Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to EM-53, "
TIMING CHAIN" .
5. Remove camshafts. Refer to EM-41, "
CAMSHAFT" .
6. Remove cylinder head loosening bolts in reverse order as
shown in the figure.
Using the following tool, loosen cylinder head bolts.
NOTE:
There are two types of cylinder head bolt because of parallel
manufacture.
7. Remove cylinder head gasket.
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
If reduction of outer diameter appears in a position other than
“d2”, use it as “d2” point.
NOTE:
When replacing any cylinder head bolts, it is possible to use them
with mixing flange bolt and bolt with washer.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-102, "
CYLIN-
DER BLOCK DISTORTION" .
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
If it exceeds the limit, replace cylinder head.Bolt with washer
: Hexagonal wrench [size 10 mm (0.39 in)]
Flange bolt
: TORX socket (size E20)
KBIA0058E
Limit (“d1” – “d2”): 0.23 mm (0.0091 in)
SBIA0269E
Limit : 0.1 mm (0.004 in)
PBIC0075E
EM-68
[QR]
CYLINDER HEAD
INSTALLATION
1. Install new cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown in the
figure with the following procedure to install cylinder head.
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Refer to EM-67, "
Cylinder Head
Bolts Outer Diameter" .
a. Apply new engine oil to threads and seating surface of mounting
bolts.
b. Tighten all bolts.
c. Turn all bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using angle
wrench (SST) or protractor. Avoid judgment by visual
inspection without the tool.
d. Completely loosen.
CAUTION:
In this step, loosen bolts in reverse order of that indicated
in the figure.
e. Tighten all bolts.
f. Turn all bolts 75 degrees clockwise (angle tightening).
g. Turn all bolts 75 degrees clockwise again (angle tightening).
3. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary. : 50.0 N·m (5.1 kg-m, 37 ft-lb)
: 0 N·m (0 kg-m, 0 ft-lb)
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
KBIA0058E
KBIA0059E
CYLINDER HEAD
EM-69
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
EM-78
[QR]
ENGINE ASSEMBLY
REMOVAL
Outline
Remove engine and transaxle assembly with front suspension member from vehicle downward. Separate
front suspension member, and then separate engine and transaxle.
Preparation
1. Release fuel pressure. Refer to EC-49, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant from radiator. Refer to CO-10, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belt.
3. Remove the following parts.
Hood assembly; Refer to BL-13, "HOOD" .
Undercover and splash guards (RH and LH)
Front road wheels and tires
Battery, battery tray and battery tray bracket; Refer to SC-4, "BATTERY" .
Drive belt; Refer to EM-14, "DRIVE BELTS" .
Air duct (inlet); Refer to EM-17, "AIR CLEANER AND AIR DUCT" .
Air cleaner case (upper) with mass air flow sensor and air duct assembly; Refer to EM-17, "AIR
CLEANER AND AIR DUCT" .
Alternator and alternator bracket; Refer to SC-27, "CHARGING SYSTEM" .
Radiator and radiator cooling fan assembly, reservoir tank of radiator and system hoses; Refer to CO-
13, "RADIATOR" .
4. Disconnect engine room harness connector from ECM side and set it aside for easier work.
5. Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine Room LH
1. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to CO-24,
"THERMOSTAT AND WATER CONTROL VALVE" .
2. Disconnect fuel feed hose, and plug it to prevent fuel from draining. Refer to EM-34, "
FUEL INJECTOR
AND FUEL TUBE" .
3. Disconnect control cable from transaxle. Refer to AT- 2 1 3 , "
SHIFT CONTROL SYSTEM" .
4. Disconnect B terminal harness of starter motor. Refer to SC-14, "
STARTING SYSTEM" .
Engine Room RH
1. Remove IPDM E/R and bracket. Refer to PG-17, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION
MODULE ENGINE ROOM)" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on vehicle side with a
rope to avoid putting load on it. Refer to ATC-134, "
Removal and Installation of Compressor" .
3. Remove reservoir tank of power steering oil pump. Temporarily secure it on engine side with a rope. Refer
to PS-39, "
HYDRAULIC LINE" .
Vehicle Underbody
1. Remove RH and LH front drive shafts. Refer to FAX-8, "FRONT DRIVE SHAFT" .
2. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
3. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter.
Refer to EM-26, "
OIL PAN AND OIL STRAINER" and AT- 2 4 1 , "TRANSAXLE ASSEMBLY" .
4. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to AT- 2 4 1 , "
TRAN-
SAXLE ASSEMBLY" .
5. Disconnect connecting rod for front stabilizer. Refer to FSU-5, "
FRONT SUSPENSION ASSEMBLY" .
6. Remove steering lower joint from steering gear. Refer to PS-12, "
STEERING COLUMN" .
7. Remove power steering fluid piping from front suspension member. Refer to PS-39, "
HYDRAULIC LINE"
.
8. Disconnect power steering fluid piping at a point between vehicle and engine, and install plug it to prevent
power steering fluid. Refer to PS-39, "
HYDRAULIC LINE" .
ENGINE ASSEMBLY
EM-79
[QR]
C
D
E
F
G
H
I
J
K
L
MA
EM
Removal
1. 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.
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equiva-
lently rigid tool such as transmission jack. Securely support bot-
tom of front suspension member, and simultaneously adjust
hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Separate RH engine mounting insulator and RH engine mounting bracket.
5. Pull LH engine mounting through-bolt out.
6. Remove front suspension member mounting nuts and bolts. Refer to FSU-5, "
FRONT SUSPENSION
ASSEMBLY" .
7. Remove engine and transaxle assembly with front suspension member from vehicle downward by care-
fully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support vehicle by setting jack or equivalent tool at the rear.
8. Remove power steering oil pump with piping connected from engine. Refer to PS-29, "
POWER STEER-
ING OIL PUMP" .
9. Remove front engine mounting and rear engine mounting through-bolts to remove front suspension mem-
ber.
10. Remove starter motor. Refer to SC-14, "
STARTING SYSTEM" .
11. Remove each engine mounting insulator and each engine mounting bracket from engine, transaxle and
front suspension member.
12. Separate engine and transaxle. Refer to AT- 2 4 1 , "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Note the following, and install in the reverse order of removal.
Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting
insulator.
When installation directions are specified, install parts according to the direction marks on them referring
to the figure of components. Refer to EM-77, "
Removal and Installation" .
Make sure that each engine mounting insulator is seated properly, and tighten mounting nuts and bolts.Slinger bolts:
Front
: 57.9 N·m (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0271E
PBIC2484E
EM-80
[QR]
ENGINE ASSEMBLY
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —