ENGINE ASSEMBLY
EM-91
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1. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-83, "Removal and
Installation".
2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-24, "
Component".
3. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-7, "
Removal and Installation".
4. Remove exhaust front tube. Refer to EX-5, "
Component".
5. Remove rear torque rod.
NOTE:
A/T models shown.
6. Remove A/T cooler hoses from transmission (A/T models).
7. Preparation for the separation work of transaxle is as follows:
Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-89, "
Exploded
View".
Removal
1. Install engine slinger to cylinder head front left side (A) and rear
right side (B) and support the engine with a hoist.
2. Lift with a hoist and secure the engine in appropriate position.
3. Use a suitable tool to securely support bottom of the engine and
the transaxle assembly and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
PBIC3737E
PBIC3738E
PBIC3223J
CYLINDER BLOCK
EM-115
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
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When main bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing
must protrude. Refer to EM-101, "
Disassembly and Assembly".
If the standard is not met, replace main bearings.
CONNECTING ROD BEARING CRUSH HEIGHT
When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-101, "
Disassembly
and Assembly".
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
If reduction appears in a position other than “d
2 ”, regard it as “d2”.
If it exceeds the limit (a large difference in dimensions), replace
main bearing cap bolt with a new one.
CONNECTING ROD CAP BOLT OUTER DIAMETER
Measure the outer diameter “d” at position as shown in the figure.
If reduction appears in a position other than “d”, regard it as “d”.
When “d” falls below the limit (when it becomes thinner), replace
connecting rod cap bolt with a new one.
FLYWHEEL DEFLECTION
Standard: There must be crush height.
SEM502G
Standard: There must be crush height.
PBIC1646E
Limit (“d1”–“d2”): 0.2 mm (0.008 in)
PBIC3768E
Limit: 7.75 mm (0.3051 in)
PBIC3769E
PRECAUTIONS
EM-135
< PRECAUTION >[MR18DE]
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3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precaution for Drain CoolantINFOID:0000000001337765
Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001337766
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000001337767
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
where noted in the step.
Precaution for Inspection, Repair and ReplacementINFOID:0000000001337768
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001337769
Use torque wrench to tighten bolts or nuts to specification.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
Parts Requiring Angular TighteningINFOID:0000000001337770
Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Camshaft sprocket (INT)
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Do not use a torque value for final tightening. Tool number : KV10112100 (BT-8653-A)
ENGINE ASSEMBLY
EM-207
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REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
ComponentINFOID:0000000001337809
Removal and InstallationINFOID:0000000001337810
WARNING:
Situate the vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and coolant are cool enough.
If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
1. Engine mounting Insulator (RH) 2. Engine mounting shim (RH) (if equipped) 3. Engine mounting bracket (RH)
4. Bracket 5. Rear torque rod 6. Engine through bolt
7. Engine mounting bracket (LH) 8. Engine mounting insulator (LH) 9. Torque rod (RH)
A. Front mark B. Silicone lubricant
WBIA0846E
ENGINE UNIT
EM-229
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
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If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover bolt (1) to clutch cover mating hole, and
place a torque wrench (A) on the extended line of the flywheel
(2) center line.
Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side.
If measured value is out of the standard, replace flywheel.Limit: 33.2 mm (1.307 in) or less.
PBIC4007E
EM-252
< PRECAUTION >[K9K]
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Precaution for Drain CoolantINFOID:0000000001381450
Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001381451
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000001381452
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precaution for Inspection, Repair and ReplacementINFOID:0000000001381453
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001381454
Use torque wrench to tighten bolts or nuts to specified value.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly same as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assemble, spread the oil on sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
Parts Requiring Angular TighteningINFOID:0000000001381455
Use an angle wrench for the final tightening of the following engine parts.
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
TIMING BELT
EM-291
< ON-VEHICLE REPAIR >[K9K]
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TIMING BELT
Exploded ViewINFOID:0000000001381499
Removal and InstallationINFOID:0000000001381500
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
Replace any belt that has been removed.
Never turn the engine in the direction opposite to that of normal operation.
When replacing the timing belt, be sure to replace the timing belt tensioner.
Do not run the engine without the drive belts to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove front wheel RH. Refer to WT-6, "Rotation".
2. Remove fender protector RH. Refer to EXT-22, "
Removal and Installation".
3. Remove engine cover.
4. Remove drive belt. Refer to EM-291, "
Removal and Installation".
5. Support the engine using suitable tool.
6. Remove RH engine torque rod.
7. Remove RH engine mounting support bracket and RH engine mounting insulator.
1. Timing belt inner cover 2. Timing belt 3. Camshaft sprocket
4. Camshaft sprocket stud bolt 5. Timing belt tensioner 6. Timing belt cover
7. Cylinder head suspended bracket 8. Crankshaft pulley 9. Crankshaft sprocket (timing belt)
10. Oil seal 11. Crankshaft cover 12. Gasket
A. 30.0 N·m (3.1 kg-m, 22 ft-lb) and 86 degrees
B. 120.0 N·m (12 kg-m, 89 ft-lb) and 95 degrees
E1BIA0022GB
EM-302
< REMOVAL AND INSTALLATION >[K9K]
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded ViewINFOID:0000000001381504
Removal and InstallationINFOID:0000000001381505
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and coolant are cool enough.
If items or work required are not covered by the main engine section, follow the procedures in the
applicable sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking rear axle, refer to GI-48, "
Garage Jack and Safety Stand
and 2-Pole Lift" or GI-49, "Board-On Lift".
REMOVAL
Description of Work
1. Engine mounting insulator LH 2. Engine mounting frame support LH 3. Engine mounting bracket LH
4. Upper torque rod 5. Engine mounting insulator RH 6. Engine mounting bracket RH (upper)
7. Engine mounting bracket RH (lower) 8. Lower torque rod bracket 9. Lower torque rod
: Vehicle front
AWBIA0162GB