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EM-68
< SERVICE INFORMATION >
CYLINDER HEAD
Measure the diameter of valve stem with a micrometer (A).
Valve Guide Inner Diameter
Measure the inner diameter of valve guide with a bore gauge.
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
• If it exceeds the limit, replace valve guide and/or valve.
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110° to 130°C
(230° to 266°F) by soaking in heated oil (A).
2. Drive out valve guide using suitable tools.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.Standard
Intake : 5.465 - 5.480 mm (0.2152 - 0.2157 in)
Exhaust : 5.455 - 5.470 mm (0.2148 - 0.2154 in)
PBIC3213J
Standard
: 5.500 - 5.518 mm (0.2165 - 0.2172 in)
Valve guide clearance:
Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
: 0.1 mm (0.004 in)
PBIC3214J
SEM931C
Page 1746 of 2771
CYLINDER HEAD
EM-69
< SERVICE INFORMATION >
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3. Ream cylinder head valve guide hole using suitable tool (A).
4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking
in heated oil (A).
5. Press valve guide (1) from camshaft side to dimensions as
shown.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
6. Apply reamer finish to valve guide using suitable tool (A).
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-
dure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.Valve guide hole diameter (for service parts):
: 9.675 - 9.696 mm (0.3809 - 0.3817 in)
PBIC3215J
PBIC3214J
2 : Cylinder head
Projection “H” : 13.35 - 13.65 mm (0.526 - 0.537 in)
PBIC3217J
Standard
: 5.500 - 5.518 mm (0.2165 - 0.2172 in)
PBIC3215J
Page 1747 of 2771

EM-70
< SERVICE INFORMATION >
CYLINDER HEAD
• Check if the contact area band is continuous all around the circum-
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions even after the re-check, replace
valve seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-104, "
Standard and Limit".
2. Ream cylinder head (1) recess diameter for service valve seat.
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking
in heated oil (A).
4. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
• Never touch cold valve seats directly.
• Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set or valve seat grinder, finish valve
seat to the specified dimensions. For dimensions, refer to EM-
104, "Standard and Limit".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Follow the "VALVE SEAT CONTACT" procedure.
SBIA0322E
2: Valve seat
Oversize [0.5 mm (0.020 in)]
Intake : 35.200 - 35.227 mm (1.3858 - 1.3869 in)
Exhaust : 29.200 - 29.227 mm (1.1496 - 1.1507 in)
PBIC3218J
PBIC3214J
SEM934C
Page 1748 of 2771

CYLINDER HEAD
EM-71
< SERVICE INFORMATION >
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VALVE SPRING SQUARENESS
• Set try square along the side of valve spring and rotate the spring.
Measure the maximum clearance between the top of valve spring
and try square.
CAUTION:
Never remove valve spring seat from valve spring.
• If it exceeds the limit, replace valve spring (with valve spring seat).
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION:
Never remove valve spring seat from valve spring.
Standard:
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).Limit: 1.9 mm (0.075 in)
PBIC0080E
SEM113
Items Intake Exhaust
Free height 44.90 - 45.10 mm (1.7677 - 1.7755 in) 45.74 - 45.94 mm (1.8007 - 1.8086 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 153 - 173 N (15.6 - 17.6 kg, 34 - 39 lb) 139 - 157 N (14.2 - 16 kg, 10 - 35 lb)
Height during valve open 26.36 mm (1.0377 in) 27.80 mm (1.0944 in)
Load with valve open 335 - 377 N (34.2 - 38.5 kg, 75 - 85 lb) 266 - 297 N (27.1 - 3.03 kg, 60 - 67 lb)
Identification color White Orange
Page 1749 of 2771
EM-72
< SERVICE INFORMATION >
ENGINE ASSEMBLY
ENGINE ASSEMBLY
ComponentINFOID:0000000001702507
Removal and InstallationINFOID:0000000001702508
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 applicable procedures.
• Always use the support point specified for lifting.
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
Page 1750 of 2771

ENGINE ASSEMBLY
EM-73
< SERVICE INFORMATION >
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• 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-38, "
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-8, "
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 EI-23
.
4. Remove exhaust front tube; Refer to EX-4
.
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-8
.
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to AT-226
(A/T models),
CVT-178
(CVT) or MT-16 (M/T models).
7. Remove rear torque rod (1).
NOTE:
A/T model shown CVT and M/T models similar.
8. Remove hood assembly. Refer to BL-13
.
9. Remove cowl top cover and cowl top extension assembly. Refer to EI-21
.
10. Release fuel pressure. Refer to EC-78, "
Fuel Pressure Check".
11. Remove battery and battery tray; Refer to SC-4
.
12. Remove drive belt; Refer to EM-13, "
Component".
13. Remove air duct and air cleaner case assembly; Refer to EM-16
.
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to CO-11
.
16. Disconnect A/T, CVT fluid cooler hoses. Refer to CO-11
.
17. 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.
18. Disconnect fuel feed hose at engine side. Refer to EM-33, "
Component".
19. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-19,
"Component".
20. Disconnect control cable from transaxle. Refer to CVT-167
(CVT) or AT-203 (A/T), MT-13 (MT).
21. Remove ground cable at transaxle side.
22. Remove ground cable between front cover and vehicle.
23. Remove generator. Refer to SC-20
.
24. 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 MTC-78, "
Removal and Installation of Compressor".
25. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-18, "
Component".
LBIA0460E
Page 1751 of 2771

EM-74
< SERVICE INFORMATION >
ENGINE ASSEMBLY
26. Install engine slinger to cylinder head front left side (A) and rear
right side (B) and support the engine position with a hoist.
27. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
28. 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.
29. Remove torque rod (RH) (1), engine insulator (RH) (2) and
engine bracket (RH) (3).
30. Remove engine through bolt-securing nut (C).
31. 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.
32. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left
side and rear right side. Refer to EM-72, "
Component".
33. Remove starter motor. Refer to SC-8
.
34. Lift with a hoist and position above engine.
35. Separate the engine and the transaxle. Refer to AT-226
(A/T models), CVT-178 (CVT models) or MT-16
(M/T models).
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
Page 1752 of 2771

ENGINE ASSEMBLY
EM-75
< SERVICE INFORMATION >
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• When installation directions are specified, install parts according to the directions. Refer to EM-72, "Compo-
nent".
• 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 MA-10
.
• 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/CVT 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 —