CAMSHAFT
EM-67
< ON-VEHICLE REPAIR >
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14. Install timing chain with the following procedure.
• Install by aligning matching marks on each sprocket and tim-ing chain.
• If these matching marks are not aligned, rotate the camshaft
slightly to correct the position.
CAUTION:
• Check matching mark positi on of each sprocket and tim-
ing chain again after instal ling the timing chain, keep
matching marks aligned by holding them with a hand.
• To avoid skipped teeth, never rotate crankshaft and cam-
shaft until front cover is installed.
15. Install timing chain tension guide (2) and timing chain slack guide (1).
16. Install chain tensioner (1). • Fix the plunger at the most compressed position using a stop-per pin (A), and then install it.
• Securely pull out the stopper pin after installing the chain ten-
sioner.
17. Check matching mark position of timing chain and each sprocket again. A : Dark blue link
B : Matching mark (stamp)
C : Orange link
D : Matching mark (stamp)
E : Crankshaft key (point straight up)
F : Matching mark (peripheral stamp line)
G : Dark blue link PBIC3721E
PBIC3714E
PBIC3722E
EM-70< ON-VEHICLE REPAIR >
[HR16DE]
CAMSHAFT
c. Tighten bolts in the numerical order shown.
d. After all bolts are tightened, retighten them to specified torque in numerical order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface.
22. Insert crankshaft pulley by aligning with crankshaft key. • When inserting crankshaft pulley with a plastic hamme r, tap on its center portion (not circumference).
CAUTION:
Never damage front oil seal lip section.
23. Tighten crankshaft pulley bolt with the following procedure: • Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
c. Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange
(1).
d. Turn another 60 degrees clockwise (angle tightening). • Check the tightening angle with movement of one angle mark.
24. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
25. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
• Tighten bolts with it seated completely.
26. Check and adjust valve clearance. Refer to EM-20, " Inspection and Adjustment " .
27. Installation of the remaining components is in the reverse order of removal.
Inspection INFOID:0000000004784301
INSPECTION AFTER REMOVAL
Oil Filter KBIA3429J
Crankshaft pulley bolt : 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
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• If items or work required are not covered by the
engine section, follow the procedures in the applica-
ble sections.
• Always use the support poin t 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 prepar ation for the backward shif t of center of gravity.
• For supporting points fo r lifting and jacking point at rear axle, refer to GI-38, " Garage Jack and
Safety Stand and 2-Pole Lift " .
REMOVAL
Outline Remove the engine and the transaxle assembly from t he vehicle downward. Separate the engine and the tran-
saxle.
Preparation 1. Remove the hood assembly. Refer to BL-14, " Removal and Installation " .
2. Remove the cowl top cover and cowl top extension assembly. Refer to EI-22, " Removal and Installation " .
3. Release fuel pressure. Refer to EC-498, " Inspection " .
4. Drain engine coolant from radiator. Refer to CO-11, " Changing Engine Coolant " .
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
5. Drain the transmission fluid. Refer to MT-10, " Draining " (M/T),
AT-17, " Changing A/T Fluid " (A/T).
6. Remove the following parts. • Engine undercover
• Front road wheels and tires: Refer to WT-7, " Rotation " .
• Front fender protector (RH and LH): Refer to EI-24, " Removal and Installation " .
• Battery and battery tray: Refer to SC-7, " Removal and Installation " .
• Drive belt: Refer to EM-15, " Removal and Installation " .
• Air duct and air cleaner case assembly: Refer to EM-26, " Exploded View " .
• Radiator hose (upper and lower): Refer to CO-16, " Component " .
• Disconnect cooling fan controller wiring harness.
• Remove coolant reservoir tank.
• Remove fan shroud and cooling fan assembly. Refer to CO-18, " Component (Models with A/C) " or
CO- 18, " Component (Models without A/C) " .
Engine Room LH 1. 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 against foreign materials.
2. Remove ground cable at transaxle side.
3. Disconnect fuel feed hose at engine side. Refer to EM-34, " Exploded View " .
4. Disconnect EVAP purge hose and brake booster vacuum hose.
5. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-16," Component " .
6. Disconnect control linkage from transaxle. Refer to AT-212, " Control Device Removal and Installation " (A/
T), MT-13, " Exploded View " (M/T).
7. Disconnect the clutch tube at tr ansmission side (if equipped). Refer to CL-14, " Removal and Installation " .
Engine Room RH 1. Remove ground cable between front cover and vehicle.
2. Remove generator and generator bracket; Refer to SC-25, " Removal and Installation " .
3. Remove A/C compressor with piping connected from t he engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. (if equipped) Refer to MTC-78, " Removal and Installation of Com-
pressor - HR16DE " .
Vehicle Underbody
" Removal and Installation " (ABS).
2. Remove brake caliper assembly with piping connected fr om steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-25, " Component " .
3. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-9, " Removal and Installation (Left
Side) " and
FAX-10, " Removal and Installation (Right Side) " .
4. Remove exhaust front tube. Refer to EX-5, " Component " .
5. Remove rear torque rod. NOTE:
A/T models shown.
6. Remove A/T cooler hoses from transmission (if equipped).
7. Preparation for the separation work of transaxle is as follows: • Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-42, " Compo-
nent " .
Removal
1. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine with a hoist.
2. Lift with a hoist and secure the engine in appropriate position.
3. Use a suitable tool (A) to securely support bottom of the engine and the transaxle assembly and simultaneously adjust hoist ten-
sion.
CAUTION:
Put a piece of wood or someth ing similar as the supporting
surface, secure a completely stable condition. PBIC3223J
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4. Remove engine mounting insulator (RH) (1), engine mounting
bracket (RH) (2) and engine mounting stay (3).
5. Remove engine mounting insulator (LH) (4) through bolt secur- ing nut (A).
6. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. CAUTION:
• Make sure that no part interferes with the vehicle side.
• Before and during this lifting, alw ays check if any harnesses are left connected.
• During the removal, 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.
Separation 1. Remove starter motor. Refer to SC-19, " Removal and Installation HR16DE " .
2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to EM-88, " Exploded View " .
INSTALLATION Installation is 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.
• 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 INFOID:0000000004784309
INSPECTION AFTER INSTALLATION
Inspection for Leaks • Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, " Fluids and Lubricants " .
• 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 leak age 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.
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DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
Setting INFOID:0000000004784310
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-88, " Exploded View " .
2. Remove clutch cover and clutch disc (if equipped). Refer to CL-15, " Removal and Installation " .
3. Remove flywheel or driveplate. • Secure flywheel or driveplate with Tool, and remove bolts.
CAUTION:
• Never disassemble flywheel.
• Never place flywheel or driveplate with signal plate facing down.
• When handling signal plate, take car e not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
4. 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.
- Intake manifold: Refer to EM-28, " Exploded View " .
- Exhaust manifold: Refer to EM-31, " Exploded View " .
- Rocker cover: Refer to EM-46, " Exploded View " .
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transaxle with flywheel or drive-
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to LU-8, " Draining " .
6. Drain engine coolant by removing water drain plug (1) from RH side of the engine. Tool number : KV11105210 (J-44716)
Inspection " .
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts in several steps.
c. Then turn all bolts 60 degrees clockwise (angle tightening). CAUTION:
Confirm the tightening angle by using Tool (A) or protractor.
Avoid judgment by visual inspection without the tool.
• After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-103, " Inspection " .
15. Install oil pan (upper). Refer to EM-42, " Removal and Installation " .
NOTE:
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Refer to EM-77, " REAR OIL SEAL : Removal and Installation " .
17. Install flywheel. • Secure crankshaft with Tool, and tighten bolts crosswise over several times.Tool number : EM03470000 (J-8037)
PREPARATION
EM-131
< SERVICE INFORMATION >
[MR18DE] C
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ST16610001
(J-23907)
Pilot bushing puller Removing crankshaft pilot bushing
KV11103000
( — )
Pulley puller Removing crankshaft pulley
KV991J0050
(J-44626)
Air fuel sensor Socket Loosening or tightening air fuel ratio sen-
sor
a: 22 mm (0.87 in)
KV10114400
(J-38365)
Heated oxygen sensor wrench Loosening or tightening rear heated oxy-
gen sensor
a: 22 mm (0.87 in)
KV11105210
(J-44716)
Stopper plate Securing drive plate and flywheel
KV10115600
(J-38958)
Valve oil seal drift Installing valve oil seal
Use side A.
a: 20 (0.79) dia .
b: 13 (0.51) dia.
c: 10.3 (0.406) dia .
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
KV10115801
( — )
Oil filter wrench Removing and installing oil filter
a: 64.3 mm (2.531 in)
Tool number
(Kent-Moore No.)
Tool name DescriptionNT045
NT676
LBIA0444E
NT636
ZZA0009D
S-NT603
S-NT375