CYLINDER HEAD
EM-65
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3. Install cylinder head, follow the steps below to tighten cylinder
head bolts in numerical order as shown.
: 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:0000000001702504
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
Tool number : KV10112100 (BT-8653-A)
PBIC3206J
PBIC3208J
PBIC3543J
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
ENGINE ASSEMBLY
EM-73
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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
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
ENGINE ASSEMBLY
EM-75
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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 —
CYLINDER BLOCK
EM-77
< SERVICE INFORMATION >
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Disassembly and AssemblyINFOID:0000000001702510
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-72.
2. Install engine to engine stand as follows;
a. Remove flywheel (M/T models) or drive plate (1) (A/T or CVT
models).
• Secure flywheel (M/T models) or drive plate (A/T or CVT mod-
els) using Tool (A), and remove bolts.
CAUTION:
Be careful not to damage or scratch drive plate (A/T or CVT
models) and contact surface for clutch disc of flywheel (M/T
models).
NOTE:
Figure shows drive plate (A/T or CVT models)
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-21
.
- Rocker cover; Refer to EM-30
.
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (A/T or CVT models) 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-24
.
4. Remove cylinder head. Refer to EM-62
.
5. Remove thermostat housing. Refer to CO-17
.
6. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
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. Pilot converter (A/T or CVT models) 27. Signal plate
28. Rear oil seal 29. Drive plate (A/T or CVT models) 30. Reinforcement plate (A/T or CVT
models)
31. Flywheel (M/T models) 32. Block heater (Canada only) A. Refer to EM-77
Tool number : KV 11105210 (J-44716)
PBIC3226J
PBIC3227J
CYLINDER BLOCK
EM-79
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16. Using snap ring pliers (A), remove snap rings.
17. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool
(A).
18. Push out piston pin using a suitable tool of an outer diameter
approximately 18 mm (0.71 in).
19. 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-93, "
Inspection After Disassembly".
20. Remove main bearing caps.
• Tap main bearing caps lightly using a suitable tool for removal.
CAUTION:
Be careful not to damage the mounting surface.
21. Remove crankshaft.
CAUTION:
PBIC3230J
PBIC3231J
PBIC0262E
: Engine front
PBIC3235J
EM-80
< SERVICE INFORMATION >
CYLINDER BLOCK
• 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.
22. Pull rear oil seal out from rear end of crankshaft.
23. 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.
2. Install water drain plug (1) to cylinder block.
• Apply liquid gasket to the drain plug thread.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-42, "
Recommended Chemical Product and Sealant".
3. Remove dust, dirt, and engine oil on the bearing mating sur-
faces of cylinder block and main bearing cap.
4. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block.
• Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).
5. Install the main bearings paying attention to the direction.
CAUTION:
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not
apply new engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing to the center position of cylinder block and main bearing
cap.
PBIC3234J
: Engine front
9.8 N·m (1.0 kg-m, 87 in-lb)
PBIC3228J
: Engine front
PBIC3258J