CYLINDER HEAD
EM-199
< ON-VEHICLE REPAIR >[MR18DE]
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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.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-219, "
Inspec-
tion After Disassembly".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).
If it exceeds the limit, replace cylinder head.
INSTALLATION
1. Install cylinder head gasket.
2. Apply new engine oil to threads and seating surface of bolts.
CAUTION:
If cylinder head bolts re-used, check their outer diameters before installation. Follow the "Cylinder
Head Bolts Outer Diameter" measurement procedure.
3. Install cylinder head, follow the steps below to tighten cylinder
head bolts in numerical order as shown.Limit (“d1” – “d2”): 0.15 mm (0.0059 in)
PBIC3994E
Limit: 0.1 mm (0.004 in)
PBIC3207J
Step a : 40 N·m (4.1 kg-m, 30 ft-lb)
Step b : 100° clockwise
Step c : Loosen to 0 N·m in the reverse order of tight-
ening.
Step d : 40 N·m (4.1 kg-m, 30 ft-lb)
Step e : 100° clockwise
Step f : 100° clockwise
PBIC3206J
EM-200
< ON-VEHICLE REPAIR >[MR18DE]
CYLINDER HEAD
: Engine front
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Never judge by visual inspection without the
tool.
4. Installation of the remaining components is in the reverse order of removal.
ComponentINFOID:0000000001337806
Disassembly and AssemblyINFOID:0000000001337807
DISASSEMBLY
Tool number : KV10112100 (BT-8653-A)
PBIC3208J
1. Valve collet 2. Valve spring retainer 3.Va l v e s p r i n g ( E X H )
(with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve seat (EXH)
7. Valve (EXH) 8. Valve (INT) 9. Valve seat (INT)
10. Cylinder head 11. Valve guide (INT) 12. Spark plug
13.Valve spring (INT)
(with valve spring seat)
A. Refer to EM-202
B. Refer to EM-202
PBIC3543J
EM-208
< REMOVAL AND INSTALLATION >[MR18DE]
ENGINE ASSEMBLY
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 a 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 point at rear axle, refer to GI-48, "
Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
1. Remove engine undercover
2. Drain engine coolant from radiator. Refer to CO-35, "
Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
Do not spill engine coolant on drive belt.
3. Remove front fender protector (RH and LH); Refer to EXT-22, "
Removal and Installation".
4. Remove exhaust front tube; Refer to EX-10, "
Component".
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FA X - 7 , "
Removal and Installation".
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-207, "
Compo-
nent".
7. Remove rear torque rod (1).
8. Remove hood assembly. Refer to DLK-214, "
Removal and Installation".
9. Remove cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installation".
10. Release fuel pressure. Refer to EC-1035, "
Inspection".
11. Remove battery and battery tray; Refer to PG-6, "
Removal and Installation".
12. Remove drive belt; Refer to EM-142, "
Component".
13. Remove air duct and air cleaner case assembly; Refer to EM-154
.
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to CO-40, "
Component".
16. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag to protect against foreign materials during the operation.
17. Disconnect fuel feed hose at engine side. Refer to EM-162, "
Component".
18. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-47,
"Component".
19. Disconnect control cable from transaxle. Refer to TM-674, "
Exploded View".
20. Remove ground cable at transaxle side.
21. Remove ground cable between front cover and vehicle.
22. Remove generator. Refer to CHG-29, "
Removal and Installation".
23. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to HA-32, "
Removal and Installation of Compressor -
MR18DE".
LBIA0460E
ENGINE ASSEMBLY
EM-209
< REMOVAL AND INSTALLATION >[MR18DE]
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24. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-156, "Removal
and Installation".
25. Install engine slinger to cylinder head front left side (A) and rear
right side (B) and support the engine position with a hoist.
26. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
27. Use a manual lift table caddy (A) or equivalently rigid tool such
as a transmission jack. Securely support bottom of the engine
and the transaxle, and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
28. Remove torque rod (RH) (1), engine insulator (RH) (2) and
engine bracket (RH) (3).
29. Remove engine through bolt-securing nut (C).
30. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating sup-
porting tools.
CAUTION:
During the operation, make sure that no part interferes with the vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent the vehicle from falling off the lift due
to changes in the center of gravity.
If necessary, support the vehicle by setting jack or suitable tool at the rear.
During operation, securely support the engine by placing a piece of wood under the engine oil
pan and transaxle oil pan. Securely support the engine slingers with a hoist.
31. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left
side and rear right side. Refer to EM-207, "
Component".
32. Remove starter motor. Refer to STR-24, "
Removal and Installation".
33. Lift with a hoist and position above engine.
34. Separate the engine and the transaxle. Refer to EM-207, "
Component" .
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 insu-
lator.
: Engine front
Slinger bolts : 25.5 N·m (2.6 kg-m, 19 ft-lb)
LBIA0461E
PBIC3223J
4 : Engine insulator (LH)
A : Engine front side
B : Transaxle side
WBIA0784E
EM-210
< REMOVAL AND INSTALLATION >[MR18DE]
ENGINE ASSEMBLY
When installation directions are specified, install parts according to the directions. Refer to EM-207, "Com-
ponent".
Prior to installing the upper torque rod, apply a light coat of silicone
lubricant (A) to the washer facing side of the bushing inner tube as
shown.
NOTE:
Apply silicone lubricant (A) by dabbing the outward facing tube
surface with a sponge or suitable tool.
Do not apply excess lubricant.
Make sure that each mounting insulator is seated properly, and tighten nuts and bolts.
Tighten engine mounting insulator (RH) bolts in the numerical
order shown.
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 LU-15, "
Inspection", CO-35, "Inspection".
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 leak-
age 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 includ-
ing 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 fluid, power steering fluid, brake fluid, etc.: Vehicle front
LBIA0470E
: Vehicle front
WBIA0785E
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-212
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
Disassembly and Assembly
INFOID:0000000001337812
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-207.
2. Install engine to engine stand as follows;
a. Remove flywheel.
Secure flywheel using Tool (A), and remove bolts.
CAUTION:
Be careful not to damage or scratch contact surface for
clutch disc of flywheel.
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Exhaust manifold; Refer to EM-159
.
- Rocker cover; Refer to EM-173, "
Removal and Installation".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel
removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
3. Remove oil pan (upper and lower). Refer to EM-166
.
4. Remove cylinder head. Refer to EM-198, "
Removal and Installation".
5. Remove thermostat housing. Refer to CO-45, "
Removal and Installation".
6. Remove knock sensor.
CAUTION:
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)
4.Crankshaft position sensor (POS)
cover5.Oil filter (for intake valve timing con-
trol)6. Knock sensor
7. Oil pressure switch 8. Top ring 9. Second ring
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing
16. Connecting rod bearing upper 17. Main bearing upper 18. Crankshaft key
19. Main bearing lower 20. Connecting rod bearing lower 21. Connecting rod bearing cap
22. Connecting rod bolt 23. Main bearing cap 24. Main bearing cap bolt
25. Crankshaft 26. Signal plate 27. Rear oil seal
28. Flywheel
A. Refer to EM-212
Tool number : KV 11105210 (J-44716)
AWBIA011 7ZZ
PBIC3227J
ENGINE UNIT
EM-213
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
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Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
CAUTION:
Avoid impacts such as a dropping.
Never disassemble.
Keep it away from metal particles.
Never place sensor in a location where it is exposed to magnetism.
8. Remove oil filter (for intake valve timing control).
9. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
NOTE:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-219, "
Inspection After Disassembly".
10. Remove connecting rod cap.
11. Using a suitable tool, push piston and connecting rod assembly
out to the cylinder head side.
CAUTION:
Be careful not to damage matching surface with connect-
ing rod cap.
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
12. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
13. Remove piston rings form piston.
Before removing piston rings, check the piston ring side clearance. Refer to EM-219, "
Inspection After
Disassembly".
14. Using a suitable tool (A) remove piston rings.
CAUTION:
When removing piston rings, be careful not to damage the
piston.
Be careful not to damage piston rings by expanding them
excessively.
15. Using snap ring pliers (A), remove snap rings.
PBIC0259E
PBIC3233J
PBIC3230J
EM-214
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
16. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool
(A).
17. Push out piston pin using a suitable tool of an outer diameter
approximately 18 mm (0.71 in).
18. Loosen main bearing cap bolts in reverse order as shown, and
remove them.
NOTE:
Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-219, "
Inspection After Disassembly".
19. Remove main bearing caps.
Tap main bearing caps lightly using a suitable tool for removal.
CAUTION:
Be careful not to damage the mounting surface.
20. Remove crankshaft.
CAUTION:
Be careful not to damage or deform signal plate (1)
mounted on rear end of crankshaft (A).
When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
Never remove signal plate unless it is necessary to do so.
21. Pull rear oil seal out from rear end of crankshaft.
22. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Identify installation positions, and store them without mix-
ing them up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
PBIC3231J
PBIC0262E
: Engine front
PBIC3235J
PBIC3234J