EM-158
< ON-VEHICLE REPAIR >[MR18DE]
INTAKE MANIFOLD
3. Tighten intake manifold bolt (A). Then tighten intake manifold
bolt (B).
4. Install electronic throttle control actuator
5. Install water hoses (3), (5) to electronic throttle control actuator
as shown.
6. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant. Refer to CO-35, "Inspection".
Start and warm up the engine. Visually check for engine coolant leaks.
1 : Intake manifold
: Engine front
PBIC3939E
1 : Electronic throttle control actuator
2: Clamp
4 : Water outlet
A: Paint Mark
B : The clamp shall not interfere with the bulged section.
C : 3 - 7 mm (0.12 - 0.28 in)
AWBIA011 5GB
CAMSHAFT
EM-193
< ON-VEHICLE REPAIR >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
10. Install camshaft sprocket (EXH) (2).
NOTE:
Secure the hexagonal part (A) of camshaft (EXH) using wrench
to tighten bolt.
11. Install timing chain and related parts. Refer to EM-176
.
12. Inspect and adjust valve clearance. Refer to EM-148, "
Valve Clearance".
13. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
The following are procedures for checking fluids leak, lubricates 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 GI-27, "
Recommended Chemical Products and Sealants".
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.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, 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.
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-796, "
Diagnosis Pro-
cedure".
Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-15, "
Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Remove intake manifold. Refer to EM-156, "
Component".
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-176, "
Component".
1 : Camshaft sprocket (INT)
Camshaft sprocket
bolt (EXH): 88.2 N·m (9.0 kg-m, 65 ft-lb)
PBIC3454J
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-194
< ON-VEHICLE REPAIR >[MR18DE]
CAMSHAFT
4. Clean the mating area of intake valve timing control solenoid
valve. Insert a clean shop cloth (with no oil adhesion) into the oil
hole (A) of the cylinder head.
5. Install engine mounting bracket (RH), engine mounting insulator,
and torque rod (RH) under the Step 4 condition. (With intake
valve timing control solenoid valve removed, and a shop cloth
inserted into the oil hole.) Refer to EM-207, "
Component".
6. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End crank after checking.
Check engine oil leakage by oil amount adhered to the waste inserted into the oil hole.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
Do not perform cranking without installing right engine mount bracket, right engine mount insu-
lator, and right torque rod.
Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-186, "
Component".
Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-11,
"Lubrication Circuit".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
Clean oil groove if necessary. Refer to LU-11, "
Lubrication Circuit".
9. Installation of the remaining components is in the reverse order of removal
1 : Front cover
:Vehicle front
WBIA0781E
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 UNIT
EM-213
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
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
ENGINE UNIT
EM-219
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
NOTE:
Install the rear oil seal after installing the oil pan (upper).
27. Install rear oil seal. Refer to EM-166
.
28. Install flywheel.
Secure crankshaft using Tool. (A), and tighten bolts crosswise
over several times.
29. Install knock sensor (1) with connector facing toward the rear of
engine.
CAUTION:
Never tighten bolts while holding the connector.
If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
Make sure that knock sensor does not interfere with other parts.
30. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
Avoid impacts such as a dropping.
Keep it away from metal particles.
Never place sensor in a location where it is exposed to magnetism.
31. Install oil filter (for intake valve timing control) (1) in the direction
shown.
Make sure that the oil filter does not protrude from the upper
surface of cylinder block (2) after installation.
32. Assemble in the reverse order of disassembly.
Inspection After DisassemblyINFOID:0000000001337814
CRANKSHAFT END PLAY
Tool number : KV11105210 (J-44716)
AWBIA011 7ZZ
A : Cylinder block left side
: Engine front
PBIC3246J
PBIC3260J
EM-228
< DISASSEMBLY AND ASSEMBLY >[MR18DE]
ENGINE UNIT
Measure the outer diameters (“d1”, “d2”) at two positions as shown.
If reduction appears in places other than “B” range, regard it as
“d
2”.
If it exceeds the limit (a large difference in dimensions), replace
main bearing cap bolt with a new one.
CONNECTING ROD BOLT OUTER DIAMETER
Measure the outer diameter “d” at position as shown.
If reduction appears in a position other than “d”, regard it as “d”.
When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with a new one.
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)
Make sure that there is no foreign material on the oil filter and
check it for clogging.
- Clean it if necessary.
Check the oil filter for damage.
- Replace it if necessary.
FLYWHEEL DEFLECTION (M/T MODELS)
Measure the deflection of flywheel contact surface to clutch with a
dial indicator (A).
Measure the deflection at 210 mm (8.27 in) diameter.
If measured value is out of the standard, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)
CAUTION:
Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
A : “d1” measuring position
B : “d2” measuring position
Limit (“d1” – “d2”): 0.15 mm (0.0059 in)
PBIC4015E
Limit: 7.75 mm (0.3051 in)
PBIC4016E
PBIC3273J
Limit : 0.45 mm (0.0177 in) or less.
PBIC4006E
Standard : 1.8 mm (0.071 in) or less
EM-238
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR18DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and LimitINFOID:0000000001337815
GENERAL SPECIFICATIONS
DRIVE BELT
WATER CONTROL VALVE
EXHAUST MANIFOLD
Unit: mm (in)
THERMOSTAT
SPARK PLUG
Unit: mm (in)
CYLINDER HEAD
Engine typeMR18DE
Cylinder arrangementIn-line 4
Displacement
cm
3 (cu in)1,798 (109.71)
Bore and stroke mm (in) 84.0 x 81.1 (3.307 x 3.192)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Compression ratio9.9
Compression pressure
kPa (bar, kg/cm
2 , psi) / 250 rpmStandard 1,500 (15.0, 15.3, 217.6)
Minimum 1,200 (12.0, 12.2, 174)
Differential limit between cylinders 100 (1.0, 1.0, 15)
Tension of drive belt Auto adjustment by auto-tensioner
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Maximum valve lift 8 mm/ 108°C (0.315 in/ 226°F)
Valve closing temperature More than 90°C (194°F)
Items Limit
Surface distortionEach exhaust port 0.3 (0.012)
Entire part 0.7 (0.028)
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F)
Valve closing temperature More than 77°C (171°F)
Plug typePlatinum-tipped TYPE
MakeNGK
Standard typePLZKAR6A-11
Spark plug gapNominal: 1.1 (0.043)