Page 41 of 241

A/C COMPRESSOR
HEATER, AIR CONDITIONING AND VENTILATION55-9
A/C COMPRESSORM2551001100268
HIGH EFFICIENCY COMPRESSOR WITH
INTEGRATED OIL SEPARATOR
High efficiency compressor with integrated oil sepa-
rator has been adopted to enhance fuel economy by
reducing the A/C operating rate.
MAGNETIC CLUTCH WITH THERMAL
FUSE
At the compressor lock, the thermal fuse integrated
in the magnet clutch is blown due to the frictional
heat against the compressor in order to reduce risk
of the drive belt breakage. The thermal fuse, together
with the coil, is coated with resin to enhance resis
-
tance to corrosion.
2-STEP PROFILE COMPRESSOR
The centre area of the scroll in the compressor pro-
vides 2-step profile, and thickness of area "B" shown
in the figure has been increased to enhance
strength. With this feature, thickness of area "A"
shown where lesser load is applied is reduced, thus
compressor performance is enhanced by compress
-
ing refrigerant even in central area, comparing to the
previous model.
CONDENSERM2551001400140
The condenser has been integrated with the radiator (cooling
module) to optimise ventilation and reduce weight.
AC507301
aa bbAA
BB
AC
Section a - aSection b - b Front viewFront view <2-step profile
compressor>
AC608768
Condenser
AB
Radiator
Page 47 of 241

BASE ENGINE
ENGINE MECHANICAL11A-3
BASE ENGINEM2112001001050
CYLINDER HEAD
A cylinder head made of an aluminum alloy, which is
lightweight and offers a high level of cooling effi
-
ciency, has been adopted. A pentroof combustion
chamber with a center spark plug has been adopted.
It has a small valve compound angle to realize a
compact chamber.
Cross-flow type intake and exhaust ports have been
adopted. Two intake ports and two exhaust ports are
provided independently on the right and left sides.
Five camshaft bearings are provided at the intake
and exhaust sides, respectively. The No. 4 bearing
sustains the thrust load of the camshaft. Only the No.
1 bearing uses a bearing cap that integrates both the
intake and exhaust sides.
VA LV E S E AT S
Sintered alloy valve seats have been adopted.The oversized (0.3 mm) service parts are available.
VA LV E G U I D E S
Valve guides that are common to both the intake and
exhaust have been adopted.The oversized (0.25 mm) service parts are available.
AK502483
Valve guide
AD
Exhaust side
Intake side
Page 49 of 241
BASE ENGINE
ENGINE MECHANICAL11A-5
CYLINDER BLOCK
A cylinder block made of an aluminum alloy has
been adopted for weight reduction.
5 bearings are used for the crankshaft journals and
the No. 3 bearing sustains the thrust load of the
crankshaft.
The water jacket is the full Siamese type.
An oil jet is used in front of the cylinder block to sup-
ply engine oil to the timing chain.
AK502486
Oil jetCylinder blockBearing cap
AE
Ladderframe
ITEMSPECIFICATIONS
Distance between top and
crankshaft center mm (in)230.1 (9.06)
Bore mm (in)86 (3.4)
Bore pitch mm (in)96 (3.8)
Stroke mm (in)86 (3.4)
Page 50 of 241
BASE ENGINE
ENGINE MECHANICAL11A-6
PISTONS
The pistons are made of a special aluminum alloy.
Their weight has been reduced by lowering their
overall height and increasing the depression at each
end of the piston pin.
The piston pin hole center is offset 0.8 mm (0.031 in)
towards the thrust side of the piston center.
The skirt portion along the perimeter of the piston is
finished with streaks that excel in oil retention and
seizure resistance.
PISTON PINS
The piston pins are the semi-floating type. Each pin
is press-fit and secured in the small end of the con
-
necting rod, while it floats in the piston.
20
A
AK603610
Front mark
Piston offset
AB
ITEMSPECIFICATIONS
Basic diameter mm (in)86 (3.4)
Pin hole diameter mm (in)21 (0.8)
Overall height mm (in)50.5 (1.99)
AK502996AE
D
hd1d2
ITEMSPECIFICATIONS
Outer diameter (D) mm
(in)21 (0.8)
Inner diameter (d1) mm
(in)12 (0.5)
Inner diameter (d2) mm
(in)10.5 (0.41)
Overall length (h) mm (in)58 (2.3)
Page 53 of 241

BASE ENGINE
ENGINE MECHANICAL11A-9
CRANKSHAFT
A forged crankshaft has been adopted.
It has 5 main bearings and 8 balance weights.
The crankshaft pins are located at equal 180° inter-
vals.
The oil holes feed engine oil from the journals to the
pins.
A crankshaft sprocket and an oil pump drive shaft are
press-fit to the front of the crankshaft.
CRANKSHAFT BEARINGS, THRUST BEARINGS
The upper crankshaft bearings have oil grooves and
the lower crankshaft bearings do not.
Each crankshaft bearing is provided with a backing
plate. Its bearing portion is made of an aluminum
alloy and its backing plate is made of ordinary sheet
steel. A thrust bearing, which sustains the load in the
thrust direction, is provided at each end of the No. 3
bearing.
AK502493AD
Balance weight
Balance weightBalance weightOil hole
Oil hole
ItemSpecifications
Pin outer diameter mm
(in)48 (1.9)
Journal outer diameter
mm (in)52 (2.0)
AK602940AC
Groove
Front
Thrust bearing
Upper bearingLower bearing
Oil groove
Oil hole
Identification
colorIdentification
color
ItemSpecifications
Crankshaft bearingWidth mm
(in)18 (0.71)
Thickness
mm (in)2.0 (0.08)
Crankshaft thrust
bearingThickness
mm (in)2.0 (0.08)
Page 59 of 241

BASE ENGINE
ENGINE MECHANICAL11A-15
V.V.T. SPROCKET (VARIABLE VALVE TIMING SPROCKET)
The engine oil control valve controls the hydraulic
pressure in order to move the vane rotor in the V.V.T.
sprocket to optimally control valve timing.
CAMSHAFT
The camshaft are hollow for weight reduction.
Each camshaft is provided with an oil passage to
guide the hydraulic pressure from the engine oil con
-
trol valve to the V.V.T. sprocket.
A cam position sensing cam for detecting the cam
position (used by the cam position sensor) is inte
-
grated at the back of each camshaft.
AK503061
Timing mark
Vane housing
Vane housing
Sprocket
SprocketRetard oil chamberRetard oil chamber
Vane roter
Vane roter
Advance oil
chamber
Advance oil
chamber
Stopper pin
Stopper pin
V.V.T. sprocket
bolt
V.V.T. sprocket
boltVane
bushing
Vane bushing
Spring Intake V.V.T. sprocket
Exhaust V.V.T. sprocketTiming mark
AD
AK502506
Intake camshaft
Exhaust camshaft Retard
oil channel
Retard
oil channelAdvance
oil channel
Advance
oil channelDowel pin
Hollow sectionSealing capCam positon
sensing cam
AD
Page 85 of 241
INTAKE MANIFOLD
INTAKE AND EXHAUST15-3
INTAKE MANIFOLDM2150005000239
The intake manifold is made of plastic for weight
reduction, and the surface roughness of the inner
walls of the ports has been improved to reduce
intake resistance.
AK502555
Intake manifold
AD
Air intake plenum
tank resonator
Page 88 of 241

GENERAL INFORMATION
ENGINE COOLING14-2
GENERAL INFORMATIONM2140000100780
The cooling system is a water-cooled pressurized,
forced circulation type which offers the following fea
-
tures.
•To stabilize engine coolant temperature, the ther-
mostat is located at the coolant inlet port from the
radiator.
•To improve engine cooling performance and save
weight, a plastic tank and aluminum radiator fins
are used.
SPECIFICATIONS
CONSTRUCTION DIAGRAM
ItemSpecification
Cooling methodWater-cooled pressurized, forced
circulation with electrical fan
RadiatorTy p ePressurized corrugate type
Performance kJ/h (kcal/h)222,480 (53,148)
Water pumpTy p eCentrifugal impeller
Drive methodDrive belt
ThermostatTy p eWax pellet with jiggle valve
Valve open temperature °C (°F)82 (180)
AC608448
Condenser fan motor Radiator assemblyRadiator upper hose
assembly
Radiator condenser
tank assembly Radiator fan motor
Cooling fan shroud
Radiator lower hose Transmission oil
cooler line hose
and tube assembly
AB