EM-180
< ON-VEHICLE REPAIR >[MR18DE]
TIMING CHAIN
19. Press stopper tab (A) in the direction shown to push the timing
chain slack guide (B) toward timing chain tensioner (for oil
pump) (1).
The slack guide (B) is released by pressing the stopper tab
(A). As a result, the slack guide (B) can be moved.
20. Insert stopper pin (D) into tensioner body hole (C) to secure tim-
ing chain slack guide (B).
NOTE:
Use a hard metal pin with a diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
21. Remove timing chain tensioner (for oil pump).
22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.
CAUTION:
Secure the oil pump shaft with the WAF part.
Never loosen the oil pump sprocket bolt by tightening the
oil pump drive chain.
23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set.
24. Remove timing chain tension guide (front cover side) from front cover if necessary.
INSPECTION AFTER REMOVAL
Timing Chain
PBIC5314E
1 : Oil pan (upper)
2 : Oil pump
: Engine front
PBIC3539J
CHARGE AIR COOLER
EM-271
< ON-VEHICLE REPAIR >[K9K]
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4. Remove air inlet hoses.
5. Release the clamp (A) securing the charge air cooler (1) to radi-
ator (2) and pull to release charge air cooler from the radiator
lower core support (3).
6. Remove charge air cooler (1) from underbody as shown.
CAUTION:
Avoid interference between the charge air cooler and con-
denser.
When removing charge air cooler, close opening on turbo
charger and throttle with shop cloth or other suitable
material.
INSTALLATION
Installation is in the reverse order of removal.
Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
Pay attention to identification mark and direction.
InspectionINFOID:0000000001381473
INSPECTION AFTER REMOVAL
1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
Be careful not to deform core fins.
MBIB9031E
MBIB9020E
TURBOCHARGER
EM-275
< ON-VEHICLE REPAIR >[K9K]
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TURBOCHARGER
Exploded ViewINFOID:0000000001381479
Removal and InstallationINFOID:0000000001381480
REMOVAL
1. Remove catalyst. Refer to EM-274, "Removal and Installation".
2. Remove turbocharger oil supply tube.
NOTE:
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
3. Remove turbocharger oil outlet tube.
NOTE:
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
4. Remove air duct (suction). Refer to EM-269, "
Exploded View".
5. Disconnect turbocharger vacuum hose.
6. Remove turbocharger from exhaust manifold.
CAUTION:
Do not disassemble or adjust the turbocharger body.
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Apply engine oil to lubricate the turbocharger oil tubes.
1. Washer 2. Turbocharger oil supply tube 3. O-ring
4. Turbocharger 5. Exhaust manifold 6. Gasket
7. Turbocharger oil outlet tube 8. Gasket
MBIB1418E
ENGINE ASSEMBLY
EM-303
< REMOVAL AND INSTALLATION >[K9K]
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Remove engine and transaxle assembly from vehicle down ward. Separate engine and transaxle.
Preparation
Remove the following parts.
Battery ground cable.
Engine undercover.
LH and RH front wheels. Refer to WT-6, "
Rotation".
LH and RH fender protectors. Refer to EXT-22, "
Removal and Installation".
Engine Room
1. Drain engine coolant. Refer to CO-58, "Draining".
CAUTION:
Perform when engine is cold.
2. Remove lower radiator hose. Refer to CO-62, "
Exploded View".
3. Drain transaxle fluid. Refer to TM-672, "
Draining".
4. Disconnect clutch tube at clutch housing and drain clutch fluid.
NOTE:
Cover clutch tube ends to prevent contamination.
5. Remove hood. Refer to DLK-214, "
Removal and Installation".
6. Remove cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installation".
7. Remove battery and battery trap. Refer to PG-6, "
Removal and Installation".
8. Disconnect engine room harness from the engine side and position aside.
9. Remove the air duct (inlet). Refer to EM-269, "
Exploded View".
10. Remove engine cover.
11. Remove blow-by hose.
12. Remove air cleaner case and air duct (suction). Refer to EM-269, "
Removal and Installation".
13. Remove reservoir tank and hoses. Refer to CO-62, "
Exploded View".
14. Remove charge air cooler hoses and tubes. Refer to EM-270, "
Exploded View".
15. Remove vacuum hose. Refer to EM-280, "
Removal and Installation".
16. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
17. Remove radiator upper hose. Refer to CO-62, "
Exploded View".
18. Disconnect heater hoses.
19. Disconnect transaxle side harness.
20. Disconnect breather hose transaxle side.
21. Disconnect shift cable and select cable. Refer to TM-674, "
Exploded View".
22. Remove cooling fan. Refer to CO-64, "
Removal and Installation".
23. Remove radiator. Refer to CO-62, "
Exploded View".
24. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Vehicle Underbody
1. Remove drive shaft assembly RH and LH. Refer to Removal and Installation.
2. Remove exhaust front tube. Refer to EX-14, "
Component".
3. Remove drive belt. Refer to EM-263, "
Removal and Installation".
4. Remove A/C compressor and position aside.
NOTE:
Secure it to body with a rope to avoid putting load on A/C lines.
5. Remove lower torque rod. Refer to EM-302, "
Exploded View".
Removal
EM-304
< REMOVAL AND INSTALLATION >[K9K]
ENGINE ASSEMBLY
1. Install engine slingers (1) into front right of cylinder head and
engine slinger (2) into rear left of cylinder head.
2. Remove upper torque rod.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a jack or trestle. Securely support bot-
tom of engine and transaxle.
CAUTION:
Put a piece of wood or something similar at the supporting
surface to secure a stable condition.
4. Remove RH and LH engine mounting bolts.
5. Remove engine and transaxle assembly from vehicle downward
by carefully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with body 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 a jack or equivalent tool at the rear.
Separation Work
CAUTION:
During the operation, secure the engine by placing a piece of wood under the engine oil pan and tran-
saxle and lift the engine using a suitable tool.
1. Remove starter motor.
2. Separate engine and transaxle.
3. Lift the engine with a suitable tool and separate the engine from the transaxle assembly. Refer to EM-302,
"Exploded View".
INSTALLATION
Installation is in the reverse order of removal.
Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
When installation directions are specified, install parts according to the direction marks on them referring to
exploded views.
Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
InspectionINFOID:0000000001381506
INSPECTION AFTER INSTALLATION
Before starting engine check the levels of coolant, lubricants and oils. Fill to the specified level.
Before starting engine, bleed air from fuel piping. Refer to EM-287, "
Removal and Installation".
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, oil, fuel and exhaust
gas.
Bleed air from passages in pipes and tubes of applicable lines.
MBIB9022E
CYLINDER BLOCK
EM-323
< DISASSEMBLY AND ASSEMBLY >[K9K]
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The connecting rod bearing are installed using bearing assem-
bling set [SST: KV113B0140 (Mot. 1492)] and bearing assem-
bling adapter [SST: KV113B0150 (Mot. 1492-03)].
a. Slide the connecting rod bearing support (A) of bearing assem-
bling adapter [SST: KV113B0150 (Mot. 1492-03)] (positioning
the engraved mark (B) as shown)] into the groove (C) of the
base of bearing assembling set [SST: KV113B0140 (Mot.
1492)].
b. Install the guide (D) of bearing assembling adapter [SST:
KV113B0150 (Mot. 1492-03)] onto the base (as shown).
c. Lay the body of the connecting rod on the base of the tool (as
shown in the diagram). Check that the lower part (E) of the small
end is touching the centering pin and push the guide (G) in the
direction of the arrow.
MBIB0461E
MBIB0352E
MBIB0462E
MBIB0463E
MBIB0464E
EM-324
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER BLOCK
d. Lay the connecting rod bearing [with a width of 20.625 mm
(0.8120 in)] (F) on the connecting rod bearing support, then
push it in the direction of the arrow (as shown).
e. Bring the connecting rod support up against the base of the con-
necting rod body.
f. Remove the connecting rod body support and repeat the opera-
tion for the remaining connecting rod bodies.
g. Position the connecting rod bearing support either on the
engraved mark (C) if the width of the connecting rod bearing is
equal to 20.625 mm (0.8120 in).
h. Position the connecting rod bearing support either on the
engraved mark (D) if the width of the connecting rod bearing is
equal to 17.625 mm (0.6939 in).
i. Install the connecting rod cap as shown.
j. Push the guide (in the direction of the arrow) until the connecting
rod cap is in contact with the pins (I) on the base of the tool.
MBIB0465E
MBIB0466E
MBIB0467E
MBIB0468E
MBIB0469E
EXL-2
FLASHER : CONSULT-III Function (BCM -
FLASHER) ..............................................................
27
COMB SW .................................................................28
COMB SW : CONSULT-III Function (BCM -
COMB SW) .............................................................
28
BATTERY SAVER ....................................................28
BATTERY SAVER : CONSULT-III Function (BCM
- BATTERY SAVER) ..............................................
28
DIAGNOSIS SYSTEM (IPDM E/R) ....................30
CONSULT - III Function (IPDM E/R) ......................30
DIAGNOSIS SYSTEM (HEADLAMP LEVEL-
IZER) ..................................................................
31
CONSULT-III Function ...........................................31
COMPONENT DIAGNOSIS ........................32
POWER SUPPLY AND GROUND CIRCUIT .....32
BCM (BODY CONTROL MODULE) .........................32
BCM (BODY CONTROL MODULE) : Diagnosis
Procedure ...............................................................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) .............................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure .....................................................................
32
HEADLAMP (HI) CIRCUIT ................................33
HEADLAMP (HALOGEN) .........................................33
HEADLAMP (HALOGEN) : Description ..................33
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
33
HEADLAMP (HALOGEN) : Diagnosis Procedure ...33
HEADLAMP (XENON) ..............................................34
HEADLAMP (XENON) : Description .......................34
HEADLAMP (XENON) : Component Function
Check .....................................................................
34
HEADLAMP (XENON) : Diagnosis Procedure .......35
HEADLAMP (LO) CIRCUIT ...............................37
HEADLAMP (HALOGEN) .........................................37
HEADLAMP (HALOGEN) : Description ..................37
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
37
HEADLAMP (HALOGEN) : Diagnosis Procedure ...37
HEADLAMP (XENON) ..............................................38
HEADLAMP (XENON) : Description .......................38
HEADLAMP (XENON) : Component Function
Check .....................................................................
38
HEADLAMP (XENON) : Diagnosis Procedure .......39
FRONT FOG LAMP CIRCUIT ...........................41
Description ..............................................................41
Component Function Check ...................................41
Diagnosis Procedure ...............................................41
REAR FOG LAMP CIRCUIT .............................43
Description ..............................................................43
Component Function Check ...................................43
Diagnosis Procedure ...............................................43
PARKING LAMP CIRCUIT ................................46
WITH DAYTIME LIGHT SYSTEM .............................46
WITH DAYTIME LIGHT SYSTEM : Description .....46
WITH DAYTIME LIGHT SYSTEM : Component
Function Check .......................................................
46
WITH DAYTIME LIGHT SYSTEM : Diagnosis Pro-
cedure .....................................................................
46
WITHOUT DAYTIME LIGHT SYSTEM .....................48
WITHOUT DAYTIME LIGHT SYSTEM : Descrip-
tion ..........................................................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Compo-
nent Function Check ...............................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Diagno-
sis Procedure ..........................................................
49
TURN SIGNAL LAMP CIRCUIT ........................52
Description ..............................................................52
Component Function Check ...................................52
Diagnosis Procedure ...............................................52
LIGHT & RAIN SENSOR ...................................55
Description ..............................................................55
Component Function Check ...................................55
Diagnosis Procedure ...............................................55
HEADLAMP AIMER SWITCH ...........................57
Description ..............................................................57
Diagnosis Procedure ...............................................57
HEADLAMP (HALOGEN) .................................58
Wiring Diagram .......................................................58
HEADLAMP (XENON) .......................................59
Wiring Diagram .......................................................59
AUTO LIGHT SYSTEM .....................................60
Wiring Diagram .......................................................60
HEADLAMP AIMING SYSTEM (MANUAL) ......61
Wiring Diagram .......................................................61
HEADLAMP AIMING SYSTEM (AUTOMAT-
IC) ......................................................................
62
Wiring Diagram .......................................................62
DAYTIME LIGHT SYSTEM ...............................63
Wiring Diagram .......................................................63
FRONT FOG LAMP ...........................................64
Wiring Diagram .......................................................64
REAR FOG LAMP .............................................65
Wiring Diagram .......................................................65