Page 1857 of 2453

LU(H6DO)-8
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.
3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain engine coolant.
DRAINING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
6) Lower the vehicle.
7) Remove the radiator.
REMOVAL, Radiator.>
8) Remove the V-belts.
REMOVAL, V-belt.>
9) Remove the front chain cover.
ME(H6DO)-42, REMOVAL, Front Chain Cover.>
10) Remove the timing chain.
44, REMOVAL, Timing Chain Assembly.>
11) Remove the crank sprocket.
12) Remove the oil pump cover.
13) Remove the inner rotor and outer rotor.
B: INSTALLATION
1) Apply a coat of engine oil to the whole area of in-
ner rotor and outer rotor.
2) Set the inner rotor onto opening edge of crank
shaft, and install the inner rotor, and then assemble
the outer rotor.
3) Install the oil pump cover.
4) Tighten the bolts in the numerical order as
shown in the figure.
CAUTION:
Make sure that the bolt is installed in correct
position.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
5) Install the crank sprocket.
6) Install the timing chain.
INSTALLATION, Timing Chain Assembly.>
7) Install the front chain cover.
Chain Cover.>
8) Install the V-belts.
STALLATION, V-belt.>
9) Install the radiator.
STALLATION, Radiator.>
10) Install the under cover.
11) Fill engine coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
LU-02012
LU-02032
Bolt installing position Bolt dimension
(1) and (3) 6 × 14 × 14
(2) and (4) 6 × 35 × 18
(5), (6), (7), (8), (9), (10) and (11) 6 × 35 × 15
(12), (15), (16) and (17) 6 × 16 × 16
(13) and (14) 6 × 26 × 15
LU-02013
(3)(7)
(2)
(4)
(9)
(5)
(8)(1)(6)(12)
(13)(14)(15)
(16)(17)
(11)(10)
Page 1871 of 2453
ME(H6DO)-5
General Description
MECHANICAL
B: COMPONENT
1. V-BELT
(1) V-belt (6) Generator plateTightening torque: N·m (kgf-m, ft-lb)
(2) Collector cover bracket (7) A/C compressor stayT1: 6.4 (0.65, 4.7)
(3) Belt tension adjuster ASSY (8) Idler pulleyT2: 20 (2.0, 14)
(4) Power steering pump bracket (9) Idler pulley coverT3: 25 (2.5, 18)
(5) GeneratorT4: 33 (3.4, 24.3)
Page 1880 of 2453

ME(H6DO)-14
General Description
MECHANICAL
8. ENGINE MOUNTING
C: CAUTION
•Wear work clothing, including a cap, protective
goggles and protective shoes during operation.
•Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
•Keep the disassembled parts in order and pro-
tect them from dust and dirt.
•Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
•Be careful not to burn yourself, because each
part on the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shop jacks or rigid racks at the specified
points.
•Before disconnecting connectors of sensors or
units, be sure to disconnect the ground cable from
the battery.
•All parts should be thoroughly cleaned, paying
special attention to engine oil passages, pistons
and bearings.
•Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
•Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
•All removed parts, if to be reused, should be re-
installed in the original positions and directions.
•Bolts, nuts and washers should be replaced with
new ones as required.
•Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
•Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
•Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fender, as re-
quired, for protection.
•Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
•Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
(1) Front cushion rubber Tightening torque: N·m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 75 (7.6, 55.3)
(1)
T2
T1
T1T2
ME-00445
Page 1897 of 2453
ME(H6DO)-31
V-belt
MECHANICAL
9. V-belt
A: REMOVAL
1) Install the tool to belt tension adjuster assembly
installation bolt.
2) Rotate the tool clockwise and loosen the V-belt
to remove.
3) Remove the V-belt cover.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Replace the V-belt, if cracks, fraying or wear is
found.
2) Make sure that the V-belt automatic belt tension
indicator (A) is within the range (D).
(1) Power steering oil pump pulley
(2) Belt tension adjuster ASSY
(3) Crank pulley
(4) A/C compressor
(5) Belt idler
(6) Generator
ME-00473
(1)(6)
(4)
(5)(2)
(3)ME-00474
(A) Indicator
(B) Generator
(C) Power steering oil pump pulley
(D) Service limit
(B)
(A)
(D)
(C)
ME-00475
Page 1898 of 2453

ME(H6DO)-32
Engine Assembly
MECHANICAL
10.Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Change the bolt mounting position from (A) to
(B), then completely open the front hood.
3) Remove the collector cover.
4) Collect the refrigerant from A/C system.
AC-20, PROCEDURE, Refrigerant Recovery Pro-
cedure.>
5) Release the fuel pressure.
PRESSURE, PROCEDURE, Fuel.>
6) Remove the battery from vehicle.
SC(H6DO)-25, REMOVAL, Battery.>
7) Remove the air intake duct, air cleaner case and
air intake chamber.
Case.>
take Chamber.>
8) Remove the engine front cover.
9) Remove the radiator from the vehicle.
CO(H6DO)-15, REMOVAL, Radiator.>
NOTE:
Protect the condenser so that it will not be dam-
aged.
10) Remove the fuel hose bracket.
11) Remove the V-belts.
REMOVAL, V-belt.>
12) Disconnect the A/C pressure hoses from A/C
compressor.
Tube.>
13) Remove the engine ground terminal.
14) Disconnect the following connector.
(1) Engine harness connectors
(2) Generator connector, terminal and A/C
compressor connector
(3) Power steering switch connector
ME-02652
(A)
(B)
CO-02176
ME-02653
ME-00476
ME-02654
Page 1904 of 2453

ME(H6DO)-38
Engine Assembly
MECHANICAL
20) Install the reservoir tank.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
21) Connect the following hoses.
(1) Fuel delivery hose and evaporation hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
22) Connect the following connectors.
(1) Engine harness connectors
(2) Generator connector and terminal
(3) A/C compressor connector
(4) Power steering switch connector
23) Connect the engine ground terminal.
Tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb)
24) Install the A/C pressure hoses.
25) Install the V-belts.
STALLATION, V-belt.>
26) Install the radiator to vehicle.
CO(H6DO)-17, INSTALLATION, Radiator.>
27) Install the battery to vehicle.
SC(H6DO)-25, REMOVAL, Battery.>
28) Fill engine coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
29) Check the ATF level and replenish it if neces-
sary.
mission Fluid.>
30) Charge the A/C system with refrigerant.
to AC-21, PROCEDURE, Refrigerant Charging
Procedure.>
31) Install the engine front cover.
32) Install the air intake duct, air cleaner case and
air intake chamber.
LATION, Air Intake Duct.>
INSTALLATION, Air Cleaner Case.>
IN(H6DO)-6, INSTALLATION, Air Intake Cham-
ber.>
33) Install the collector cover.
34) Change the bolt mounting position from (B) to
(A), then close the front hood.
35) Lower the vehicle from the lift.
C: INSPECTION
1) Check the pipes and hoses are installed firmly.
2) Check the engine coolant and ATF are at speci-
fied levels.
3) Start the engine and check for leaks of fuel, ex-
haust gas, engine coolant, etc. Also check for noise
and vibrations.
ME-02657
ME-02654
ME-00476
ME-02663
(A)
(B)
Page 1956 of 2453

ME(H6DO)-90
Engine Noise
MECHANICAL
29.Engine Noise
A: INSPECTION
(NOTE*)
When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, carry out the clear memory mode and inspection
mode after connecting the fuel injector connector.
Ty p e o f s o u n d C o n d i t i o n P o s s i b l e c a u s e
Regular clicking soundSound increases as engine
speed increases.
•Valve mechanism is defective.
•Incorrect valve clearance
•Worn valve rocker
•Worn camshaft
•Broken valve spring
•Trouble of tappet
Heavy and dull clankOil pressure is low.•Worn camshaft main bearing
•Worn connecting rod bearing (large end)
Oil pressure is normal. Damaged engine mounting
High-pitched clank
Sound is noticeable when
accelerating with an overload
condition.
•Ignition timing advanced
•Accumulation of carbon inside combustion chamber
•Wrong spark plug
•Improper gasoline
Clank when engine speed is
between 1,000 and 2,000
rpms.
Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)
•Worn crankshaft main bearing
•Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm
Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)
•Worn cylinder liner and piston ring
•Broken or stuck piston ring
•Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*)
•Unusually worn valve lifter
•Worn cam gear
•Worn camshaft journal bore in crankcase
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Poor contact of generator brush and rotor
Gear scream when starting
engine—•Defective ignition starter switch
•Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—•Loose drive belt
•Defective water pump shaft
Hissing sound —•Insufficient compression
•Air leakage in air intake system, hose, connection or manifold
Timing belt noise —•Loose timing belt
•Belt contacting with case/adjacent part
Va l ve t a p p e t n o i s e —•Incorrect valve clearance
•Trouble of tappet
Page 1977 of 2453
SC(H6DO)-19
Generator
STARTING/CHARGING SYSTEMS
3. Generator
A: REMOVAL
1) Remove the collector cover.
2) Disconnect the ground cable from battery.
3) Disconnect the connector and terminal from
generator.
4) Remove the V-belts.
REMOVAL, V-belt.>
5) Remove the bolts which install the generator
onto bracket.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
C: DISASSEMBLY
1) Remove the four through-bolts.
2) Heat the portion (A) of rear cover to 50°C
(122°F) with a heater drier.
3) Then insert the tip of a flat tip screwdriver into the
gap between stator core and front cover. Pry them
apart to disassemble.
4) Hold the rotor with a vise and remove pulley nut.
SC-02003
SC-02098
SC-02098
(A) Screwdriver
SC-00078
SC-00079
(A)
SC-00080
(A)
(A)
SC-00035