Em 3SZ

EM
ENGINE
ENGINE MECHANICAL
ENGINE MECHANICAL SYSTEM (3SZ-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-1
ENGINE MECHANICAL SYSTEM (K3-VE)
OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-4
FAN AND ALTERNATOR V BELT (3SZ -VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-7
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-8
FAN AND ALTERNATOR V BELT (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-11
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-12
VALVE CLEARANCE (3SZ -VE)
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-15
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-16
VALVE CLEARANCE (K3-VE)
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-25
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-26
PARTIAL ENGINE ASSEMBLY (3SZ -VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-35
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-54
PARTIAL ENGINE ASSEMBLY (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-70
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-89
CHAIN (3SZ -VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-104
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-109
CHAIN (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-112
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-117
CAMSHAFT (3SZ-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-120
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-126
CAMSHAFT (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-130
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-136
CYLINDER HEAD GASKET (3SZ -VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-140
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-145
TO INDEX
EM
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-155
CYLINDER HEAD GASKET (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-168
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-173
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-183
TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-196
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-199
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-200
TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-205
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-206
ENGINE REAR OIL SEAL (3SZ -VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-208
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-209
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-210
ENGINE REAR OIL SEAL (K3-VE)
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-212
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-213
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-214
ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (3SZ-VE)
EM1
EM
ENGINE ENGINE MECHANICAL
ENGINE MECHANICAL SYSTEM (3SZ-VE)
OPERATION CHECK
1. CHECK COOLANT (Ethylene glycol based anti-freeze solution)
(See page CO-1)
2. CHECK ENGINE OIL QUALITY (See page LU-1)
3. INSPECT BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard:
1.25 to 12.9 V (Liquid temperature: 20C)
HINT:
If the specific gravity is not as specified, charge the battery.
4. CHECK AIR CLEANER FILTER ELEMENT
(a) Check for dirt and blockage in the air cleaner pipe.
5. CHECK V-BELT TENSION AND DEFLECTION
(a) Check the V-belt tension and deflection using the belt tension
gauge.
Standard
NOTICE:
Measure the belt deflection between the specified
pulleys.
Crank the engine 2 times before measuring the tension.
To install a new belt, adjust the belt so that the tension
is in the middle of the specified value given for WHEN
INSTALLING NEW PART in the table above.
When installing a new belt, check the tension within 2.5
minutes after installation.
For the belt that has been used for 5 minutes or more,
check the tension using the specified value in WHEN
INSPECTION in the table above.
To reassemble the belt that has been used for 5 minutes
or more, adjust the belt so that the tension is in the
middle of the specified value given for WHEN
INSPECTING in the table above.
To use a belt tension gauge, check its accuracy with the
master gauge before measuring the tension.
6. CHECK IGNITION TIMING
(a) Check the timing with the DS-II.
(1) Connect the DS-II to the DLC.
A001259
Water Pump
Alternator
Measuring Position
Idler Pulley No. 2
Idler Pulley
Crankshaft A/C Compressor
A136268
Item
When Installing New
Part
When Inspecting
Tension [N (kgf)] 88349{905} 44198{4510}
Deflection (Thrust
power: 100 N (10.2 kg))
(mm)
9-11 13-15
EM2
EM
(2) Follow the prompts on the screen to display the DATA
LIST / IGNITION TIMING #1 screens, and measure the
ignition timing.
Standard:
BTDC 0-15CA
NOTICE:
Check the ignition timing with the A/C off, the
electrical fan off, and the shift lever in the N and P
positions.
(3) Check that the ignition timing advances immediately when
the engine speed is increased.
(b) Check the timing with commonly-used gauges.
(1) Using the diagnosis check wire, short-circuit between
terminals 12 (EFIT) and 4 (E) of the DLC.
NOTICE:
Do not short-circuit the wrong terminals. Doing so
may cause malfunctions.
Check the ignition timing with the A/C off, the
electrical fan off, and the shift lever in the N and P
positions.
(2) Connect the timing light clip to the coil connector wire
harness for the cylinder No. 1.
NOTICE:
Use a timing light that can detect the first signal.
(3) Check that the ignition timing is as the specified value.
Standard:
BTDC 4 to 8
(4) Open the circuit between terminals 12 (EFIT) and 4 (E) of
the DLC.
(6) Remove the timing light.
7. CHECK IDLE SPEED
(a) Connect the DS-II to the DLC.
(b) Follow the prompts on the screen to display the DATA LIST /
IGNITION TIMING #1 screens, and measure the engine speed
(r/min).
Specified value:
600 to 750 r/min
NOTICE:
Check the ignition timing with the A/C off, the electrical fan
off, and the shift lever in the N and P positions.
8. CHECK COMPRESSION
(a) Fully warm up the engine and then stop it.
NOTICE:
A warmed up engine should have an engine coolant
temperature of over 85C, have an engine oil temperature
of 60C, and the engine rpm should be stabilized.
(b) Remove the air cleaner assembly.
(c) Remove all the ignition coils.
(d) Remove all the spark plugs.
E
EFIT
G100942
EM3
EM
(e) Disconnect all the injector connectors.
NOTICE:
Stop fuel injection to prevent unburned fuel from damaging
the catalyst.
(f) Check the compression.
(1) Install a compression gauge to the plug hole.
(2) Fully open the throttle.
(3) Crank the engine, then check the compression.
Standard:
147 kPa (15.0 kgf/cm
2
)
Maximum limit:
1079 kPa (11.0 kgf/cm
2
)
Reference value:
Maximum difference between cylinders: 147 kPa
(1.5 kgf/cm
2
)
NOTICE:
The measurement must be done as quickly as
possible.
After all work is completed, be sure to clear all
DTCs and check that a normal code is output.
9. CHECK DENSITY OF CO AND HC
(a) Keep the engine speed at 2,500 r/min for 2 minutes and then
check the density of CO and HC at idle.
Standard:
CO density: 0.2%
HC density: 200 ppm
NOTICE:
As the specified value is used for reference only, no
adjustment is required.
Compression Gauge
A136273
EM4
ENGINE MECHANICAL - ENGINE MECHANICAL SYSTEM (K3-VE)
EM
ENGINE MECHANICAL SYSTEM (K3-VE)
OPERATION CHECK
1. CHECK COOLANT (Ethylene glycol based anti-freeze solution)
(See page CO-3)
2. CHECK ENGINE OIL QUALITY (See page LU-2)
3. INSPECT BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard:
1.25 to 12.9 V (Liquid temperature: 20C)
HINT:
If the specific gravity is not as specified, charge the battery.
4. CHECK AIR CLEANER FILTER ELEMENT
(a) Check for dirt and blockage in the air cleaner pipe.
5. CHECK V-BELT TENSION AND DEFLECTION
(a) Check the V-belt tension and deflection using the belt tension
gauge.
Standard
NOTICE:
Measure the belt deflection between the specified pul-
leys.
Crank the engine 2 times before measuring the tension.
To install a new belt, adjust the belt so that the tension
is at the middle of the specified value given for WHEN
When installing a new belt, check the tension within 2.5
minutes after installation.
For the belt that has been used for 5 minutes or more,
check the tension using the specified value in WHEN
To reassemble the belt that has been used for 5 minutes
or more, adjust the belt so that the tension is in the mid-
dle of the specified value given for WHEN INSPECTING
in the table above.
To use a belt tension gauge, check its accuracy with the
master gauge before measuring the tension.
6. CHECK IGNITION TIMING
(a) Check the timing with the DS-II.
A001259
Water Pump
Alternator
Measuring Position
Idler Pulley No. 2
Idler Pulley
Crankshaft A/C Compressor
A136268
Item
When Installing New
Part
When Inspecting
Tension [N (kgf)] 88349{905} 44198{4510}
Deflection (Thrust
power: 100 N (10.2 kg))
(mm)
9-11 13-15
EM5
EM
(2) Follow the prompts on the screen to display the DATA
LIST / IGNITION TIMING #1 screens, and measure the
ignition timing.
Standard:
BTDC 0-15CA
NOTICE:
Check the ignition timing with the A/C off, the electri-
cal fan off, and the shift lever in the N and P positions.
(b) Check the timing with commonly-used gauges.
(1) Using the diagnosis check wire, short-circuit between ter-
minals 12 (EFIT) and 4 (E) of the DLC.
NOTICE:
Do not short-circuit the wrong terminals. Doing so
may cause malfunctions.
Check the ignition timing with the A/C off, the elec-
trical fan off, and the shift lever in the N and P
positions.
(2) Connect the timing light clip to the coil connector wire har-
ness for the cylinder No. 1.
NOTICE:
Use a timing light that can detect the first signal.
(3) Check that the ignition timing is as the specified value.
Standard:
BTDC 4 to 8
(4) Open the circuit between terminals 12 (EFIT) and 4 (E) of
the DLC.
(6) Remove the timing light.
7. CHECK IDLE SPEED
(a) Connect the DS-II to the DLC.
(b) Follow the prompts on the screen to display the DATA LIST /
IGNITION TIMING #1 screens, and measure the engine speed
(r/min).
Standard:
600 to 750 r/min
NOTICE:
Check the ignition timing with the A/C off, the electrical fan
off, and the shift lever in the N and P positions.
8. CHECK COMPRESSION
(a) Fully warm up the engine and then stop it.
NOTICE:
A warmed up engine should have an engine coolant tem-
perature of over 85C, have an engine oil temperature of
60C, and the engine rpm should be stabilized.
(b) Remove the air cleaner assembly.
(c) Remove all the ignition coils.
(d) Remove all the spark plugs.
(e) Disconnect all the injector connectors.
NOTICE:
Stop fuel injection to prevent unburned fuel from damaging
the catalyst.
E
EFIT
G100942
EM6
EM
(f) Check the compression.
(1) Install a compression gauge to the plug hole.
(2) Fully open the throttle.
(3) Crank the engine, then check the compression.
Standard:
147 kPa (15.0 kgf/cm
2
)
Maximum limit:
1079 kPa (11.0 kgf/cm
2
)
Reference value:
Maximum difference between cylinders: 147 kPa
(1.5 kgf/cm
2
)
NOTICE:
The measurement must be done as quickly as
possible.
After all work is completed, be sure to clear all
DTCs and check that a normal code is output.
9. CHECK DENSITY OF CO AND HC
(a) Keep the engine speed at 2,500 r/min for 2 minutes and then
check the density of CO and HC at idle.
Standard:
CO density: 0.2%
HC density: 200 ppm
NOTICE:
As the specified value is used for reference only, no adjust-
ment is required.
Compression Gauge
A136273
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (3SZ-VE)
EM7
EM
FAN AND ALTERNATOR V BELT (3SZ-VE)
COMPONENTS
FAN AND ALTERNATOR V BELT
A137038J01
EM8
EM
REMOVAL
1. REMOVE FAN AND ALTERNATOR V BELT
(a) Loosen the alternator fixing bolt (B).
(b) Loosen the adjusting bar fixing bolt (A).
(c) Rotate the adjusting bolt (C) of the adjusting bar to reduce the
tension.
(d) Remove the fan and alternator V belt.
INSTALLATION
1. INSTALL FAN AND ALTERNATOR V BELT
(a) Temporarily install the fan and alternator V belt to each pulley
as shown in the illustration.
(b) Check that the fan and alternator V belt is correctly installed to
each pulley.
Bolt C
Bolt A
Bolt B
A108949J02
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A/C Pulley
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A137721
A088652
EM9
EM
2. ADJUST FAN AND ALTERNATOR V BELT
(a) Rotate adjusting bolt C to adjust the fan and alternator V belt
tension.
(b) Tighten fixing bolts A and B.
Torque: 19 N*m (194 kgf*cm) (Bolt A)
44 N*m (449 kgf*cm) (Bolt B)
3. CHECK FAN AND ALTERNATOR V BELT
(a) Check there is no cracks, deterioration or significant wear on
the fan and alternator V belt.
(b) Check the tension of the fan and alternator V belt using a belt
tension gauge.
HINT:
The deflection of the fan and alternator V belt is also available
to check the tension.
HINT:
Measure the belt deflection when the belt is pressed
between the water pump pulley and the idle pulley at a
strength of 100 N (10.2 kgf) and then measure the belt
deflection.
When measuring the tension after installing the belt, crank 2
times in the direction that the engine rotates.
To replace the belt with a new one, adjust the belt so that the
value is at the middle of the specified value given for WHEN
For the belt that has been used for 5 minutes or more, check
that the tension is within the specified value in WHEN
Bolt C
Bolt A
Bolt B
A108949J02
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A/C Pulley
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
Measurement
Position
Measurement
Position
A137722
When Installing New Part When Inspecting
Tension [N (kgf)] 88349{905} 44198{4510}
Deflection (mm) [100 N
(10.2 kgf)]
9-11 13-15
EM10
EM
To assemble the belt that has been used for 5 minutes or
more, adjust the belt so that the tension is in the middle of
the specified value given for WHEN INSPECTING in the
table above.
ENGINE MECHANICAL - FAN AND ALTERNATOR V BELT (K3-VE)
EM11
EM
FAN AND ALTERNATOR V BELT (K3-VE)
COMPONENTS
A137038J01
EM12
EM
REMOVAL
1. REMOVE FAN AND ALTERNATOR V BELT
(a) Loosen the alternator fixing bolt (B).
(b) Loosen the adjusting bar fixing bolt (A).
(c) Rotate the adjusting bolt (C) of the adjusting bar to reduce the
tension.
(d) Remove the fan and alternator V belt.
INSTALLATION
1. INSTALL FAN AND ALTERNATOR V BELT
(a) Temporarily install the fan and alternator V belt to each pulley
as shown in the illustration.
(b) Check that the fan and alternator V belt is correctly installed to
each pulley.
Bolt C
Bolt A
Bolt B
A108949J02
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A/C Pulley
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A137721
A088652
EM13
EM
2. ADJUST FAN AND ALTERNATOR V BELT
(a) Rotate adjusting bolt C to adjust the fan and alternator V belt
tension.
(b) Tighten fixing bolts A and B.
Torque: 19 N*m (194 kgf*cm) (Bolt A)
3. CHECK FAN AND ALTERNATOR V BELT
(a) Check there is no cracks, deterioration or significant wear on
the fan and alternator V belt.
(b) Check the tension of the fan and alternator V belt using a belt
tension gauge.
HINT:
The deflection of the fan and alternator V belt is also available
to check the tension.
HINT:
Measure the belt deflection when the belt is pressed
between the water pump pulley and the idle pulley at a
strength of 100 N (10.2 kgf) and then measure the belt
deflection.
When measuring the tension after installing the belt, crank 2
times in the direction that the engine rotates.
To replace the belt with a new one, adjust the belt so that the
value is at the middle of the specified value given for WHEN
For the belt that has been used for 5 minutes or more, check
that the tension is within the specified value in WHEN
Bolt C
Bolt A
Bolt B
A108949J02
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
A/C Pulley
Vane Pump
Idler Pulley
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley
Measurement
Position
Measurement
Position
A137722
When Installing New Part When Inspecting
Tension [N (kgf)] 63749{955} 44198{5410}
Deflection (mm) [100 N
(10.2 kgf)]
9-11 13-15
EM14
EM
To assemble the belt that has been used for 5 minutes or
more, adjust the belt so that the tension is in the middle of
the specified value given for WHEN INSPECTING in the
table above.
ENGINE MECHANICAL - VALVE CLEARANCE (3SZ-VE)
EM15
EM
VALVE CLEARANCE (3SZ-VE)
INSPECTION
1. DISCONNECT NEGATIVE BATTERY TERMINAL
(See page RS-160.)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (See page CO-9)
4. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15)
5. REMOVE AIR CLEANER ASSEMBLY (See page EM-146)
6. REMOVE RADIATOR HOSE NO. 1 (See page CO-15)
7. DISCONNECT ACCELERATOR CONTROL CABLE ASSEMBLY
(See page EM-147)
8. REMOVE VENTILATION HOSE (See page EM-147)
9. REMOVE VENTILATION HOSE NO. 2 (See page EM-147)
10. REMOVE ENGINE ROOM MAIN WIRE (See page EM-147)
11. REMOVE RADIATOR PIPE (See page EM-147)
12. REMOVE IGNITION COIL ASSEMBLY (See page EM-150)
13. REMOVE CYLINDER HEAD COVER (See page EM-151)
14. INSPECT VALVE CLEARANCE
NOTICE:
Check the valve clearance in cool conditions.
(a) Turn the crankshaft pulley clockwise and align the matchmarks
as shown in the illustration, and then set cylinder No. 1 to TDC /
compression.
HINT:
If the matchmarks are not aligned, turn the crankshaft to align
the marks again.
(b) Using a thickness gauge, measure the valve clearance at the
position shown in the illustration.
HINT:
The thickness gauge should be inserted from the spark plug
side (center).
Standard (in cool conditions)
Valves to be checked when cylinder No. 1 is set
to TDC / compression
Timing Marks
A133561
IN
EX
A133562
Intake side 0.145 to 0.235 mm
Exhaust side 0.275 to 0.365 mm
Cylinder No. 1 Cylinder No. 2 Cylinder No. 3 Cylinder No. 4
IN EX IN EX IN EX IN EX
- - - -
EM16
EM
HINT:
If not as specified, measure the clearance and record it.
(c) Turn the crankshaft pulley 360clockwise, and then set cylinder
No. 4 to TDC / compression.
(d) Using a thickness gauge, measure the valve clearance at the
HINT:
side (center).
Check the valves with cylinder No. 1 at TDC /
ventilation
HINT:
ADJUSTMENT
1. ADJUST VALVE CLEARANCE
(a) Remove the 2 bolts and the timing chain cover No. 2.
(b) Turn the crankshaft pulley clockwise and check that the timing
marks of the camshaft timing gear are positioned as shown in
the illustration.
NOTICE:
If the timing marks are not aligned, turn the crankshaft pul-
ley clockwise again and align the marks.
IN
EX
A133563
- - - -
A137452
Timing Marks
A133561
EM17
EM
(c) Place a paint mark on each plate of the chains at the points
where the camshaft timing gear and the timing mark of the cam-
shaft timing sprocket are aligned.
(d) Using the hexagon head portion of the camshaft, loosen the
camshaft timing sprocket installation bolt.
(e) Using a 10 mm socket hexagon wrench, remove the chain
cover service hole screw plug.
(f) Using a screwdriver, access the tensioner stopper plate through
the chain tensioner service hole, move it downward and hold it
with the lock released.[*1]
NOTICE:
If it is difficult to release the stopper plate lock, use the
hexagon head portion of the camshaft and rotate the cam-
shaft a little to the right and left.
(g) Under the conditions noted at [*1], use the hexagon head por-
tion of the camshaft to rotate the camshaft a little to the right
and hold.[*2]
HINT:
Rotating the camshaft to the right will press the tensioner
plunger.
Paint Mark Paint Mark
Timing Marks
A107964J01
A133812
A137724
A133813
EM18
EM
(h) Under the conditions noted at [*2], remove the screwdriver from
the chain tensioner service hole, align the stopper plate and the
tensioner holes, and insert a bar of 3 mm in diameter.
NOTICE:
If the 3 mm diameter bar is difficult to insert, rotate the
camshaft a little to the left and then back a little to the
right and insert the bar again.
Hold the camshaft in the position using the hexagon
head portion.
Fix the 3 mm diameter bar using tape or similar so it
does not come out.
(i) Remove the timing chain from the camshaft timing sprocket.
(j) Remove the bolt and the camshaft timing sprocket.
NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft 90 (crank angle) in the direction that
the engine rotates from cylinder No. 1 TDC / compression
so the valve does not interfere with the piston.
A136104
A133815
Hold
A136076
EM19
EM
(k) Remove the camshaft bearing cap No. 1 in the order indicated
in the illustration.
(l) Remove the camshaft bearing cap No. 2 in the order indicated
HINT:
Uniformly loosen the bolts keeping the camshaft level.
(m) Remove the camshaft.
(n) Remove the camshaft No. 2.
(o) After removing the camshaft, attach the timing chain to a rope
or wire so that it does not drop.
NOTICE:
Do not allow any foreign matter to enter the timing chain
cover.
(p) Remove the valve lifter.
(q) Using a micrometer, measure the valve lifter thickness.
90
A107973J01
1
2
3
4
A133124
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
A133818
Measurement
Point B
A033166
EM20
EM
(r) Select and install a valve lifter so that the valve clearance is
within the specified range.
Standard:
Intake: :
(Selected lifter thickness) = (Removed lifter thickness)
+ [(Measured clearance) - 0.18 mm]
Exhaust: :
+ [(Measured clearance) -0.31mm]
HINT:
Shims are available in 41 increments of 0.02 mm (0.0008 in.),
from 5.120 mm to 5.680mm.
(s) Install the valve lifter.
(t) Apply engine oil to the cam of camshaft No. 2 and the journal of
the cylinder head, and then install the camshaft No. 2.
NOTICE:
Position it so the cam nose of cylinders No. 2 and 4 of the
camshaft sub-assembly No. 2 push down the lifter valve.
(u) Apply engine oil to the cam of the camshaft and the journal part
of the cylinder head, and then install the camshaft.
NOTICE:
camshaft sub-assembly No. 1 pushes down the lifter valve.
(v) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
(w) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
Torque: 12.5 N*m (130 kgf*cm)
NOTICE:
Uniformly tighten the bolts, keeping the camshaft level.
Position the cap so the arrow on it faces toward the
front of the engine, and install it so the punched num-
bers are positioned as shown in the illustration.
Valve
Thickness of Lifter
Selection No.
Marking
A133819
Number Lifter Thickness
(mm)
(mm)
(mm)
(mm)
12 5.120 28 5.280 44 5.440 60 5.600
14 5.140 30 5.300 46 5.460 62 5.620
16 5.160 32 5.320 48 5.480 64 5.640
18 5.180 34 5.340 50 5.500 66 5.660
20 5.200 36 5.360 52 5.520 68 5.680
22 5.220 38 5.380 54 5.540 - -
24 5.240 40 5.400 56 5.560 - -
26 5.260 42 5.420 58 5.580 - -
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
EM21
EM
(x) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
NOTICE:
Tighten the bolts after checking that the thrust part of the
camshaft is aligned with the groove on camshaft bearing
cap No. 1.
(y) Position the timing marks of the camshaft timing sprocket and
the camshaft timing gear as shown in the illustration.
(z) Position the timing mark (groove) of the crankshaft pulley so it is
at 0.
(aa) Align the camshaft knock pin and the camshaft timing sprocket
pin hole, and install the camshaft timing sprocket to the cam-
shaft.
NOTICE:
If the knock pin and pin hole do not align, use the hexa-
gon head portion of the camshaft and rotate the cam-
shaft a little to the right and left so they align.Do not
press too firmly on the camshaft timing sprocket as the
seal surface can be easily damaged by the end of the
knock pin which may cause the seal to fail.
Do not remove the 3 bolts.If the bolts are removed,
replace the camshaft timing sprocket.
1
2
3
4
A133071
Notch
Timing Marks
A137723
Pin Hole
Knock Pin
Do Not Remove
A136098
EM22
EM
(ab) Apply a small amount of engine oil to the camshaft timing
sprocket installation bolt thread and seating surface to tempo-
rarily install them.
(ac) Using the hexagon head portion of the camshaft, tighten the
Torque: 47 N*m (480 kgf*cm)
(ad) Install the chain so the matchmarks of the camshaft timing gear
and the chain are aligned.
(ae) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
Using the hexagon head portion of the camshaft, rotate the
camshaft a little to the left with the chain slightly slack on
the tensioner side, and pull out the 3 mm diameter bar.
Hold
A136076
Timing Marks
A133561
A136104
EM23
EM
(af) Make sure that each timing mark is positioned as shown in the
illustration.
(ag) Apply Amix TB1324 to the first 2 to 3 threads of the chain cover
service hole screw plug bolt.
NOTICE:
Clean and degrease the bolt and bolt hole.
(ah) Using a 10 mm socket hexagon wrench, install the chain cover
service hole screw plug.
(ai) Apply Amix TB1207B to the position shown in the illustration.
NOTICE:
Clean and degrease the installation surfaces.
Install within 3 minutes of applying Amix TB1207B.
Do not start the engine within 2 hours of the installation.
(aj) Install the timing chain cover No. 2 with the 2 bolts.
2. INSTALL CYLINDER HEAD COVER (See page EM-162)
3. INSTALL IGNITION COIL ASSEMBLY (See page EM-162)
4. INSTALL RADIATOR PIPE (See page EM-166)
5. INSTALL ENGINE ROOM MAIN WIRE (See page EM-165)
6. INSTALL VENTILATION HOSE (See page EM-166)
7. INSTALL VENTILATION HOSE NO. 2 (See page EM-166)
Notch
Timing Marks
A137746
A137724
Apply Liquid Gasket
A139347
A137452
EM24
EM
8. INSTALL ACCELERATOR CONTROL CABLE ASSEMBLY (See
page EM-165)
9. INSTALL RADIATOR HOSE NO. 1 (See page CO-18)
10. INSTALL AIR CLEANER ASSEMBLY (See page EM-167)
11. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-19)
12. ADD ENGINE COOLANT (See page CO-9)
13. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10)
14. CHECK COOLANT LEVEL (See page CO-10)
15. INSTALL ENGINE UNDER COVER (See page EM-69)
16. CONNECT NEGATIVE BATTERY TERMINAL
ENGINE MECHANICAL - VALVE CLEARANCE (K3-VE)
EM25
EM
VALVE CLEARANCE (K3-VE)
INSPECTION
(See page RS-164.)
(See page EM-175)
14. INSPECT VALVE CLEARANCE
NOTICE:
Check the valve clearance in cool conditions.
(a) Turn the crankshaft pulley clockwise and align the matchmarks
as shown in the illustration, and then set cylinder No. 1 to TDC /
compression.
HINT:
If the matchmarks are not aligned, turn the crankshaft to align
the marks again.
(b) Using a thickness gauge, measure the valve clearance at the
HINT:
side (center).
Valves to be checked when cylinder No. 1 is set
to TDC / compression
Timing Marks
A133561
IN
EX
A133562
- - - -
EM26
EM
HINT:
(c) Turn the crankshaft pulley 360 clockwise, and then set cylinder
No. 4 to TDC / compression.
(d) Using a thickness gauge, measure the valve clearance at the
HINT:
side (center).
Check the valves with cylinder No. 1 at TDC /
ventilation.
HINT:
ADJUSTMENT
1. ADJUST VALVE CLEARANCE
(a) Remove the 2 bolts and the timing chain cover No. 2.
(b) Turn the crankshaft pulley clockwise and check that the timing
marks of the camshaft timing gear are positioned as shown in
the illustration.
NOTICE:
If the timing marks are not aligned, turn the crankshaft pul-
ley clockwise again and align the marks.
IN
EX
A133563
- - - -
A137452
Timing Marks
A133561
EM27
EM
(c) Place a paint mark on each plate of the chains at the points
(d) Using the hexagon head portion of the camshaft, loosen the
(e) Using a 10 mm socket hexagon wrench, remove the chain
(f) Using a screwdriver, access the tensioner stopper plate through
NOTICE:
If it is difficult to release the stopper plate lock, use the
hexagon head portion of the camshaft and rotate the cam-
shaft a little to the right and left.
(g) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
Timing Marks
A107964J01
A133812
A137724
A133813
EM28
EM
(h) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
head portion.
does not come out.
(i) Remove the timing chain from the camshaft timing sprocket.
(j) Remove the bolt and the camshaft timing sprocket.
NOTICE:
When rotating the camshaft with the timing chain removed,
rotate the crankshaft 90 (crank angle) in the direction that
the engine rotates from cylinder No. 1 TDC / compression
so the valve does not interfere with the piston.
A136104
A133815
Hold
A136076
EM29
EM
(k) Remove the camshaft bearing cap No. 1 in the order indicated
(l) Remove the camshaft bearing cap No. 2 in the order indicated
HINT:
(m) Remove the camshaft.
(n) Remove the camshaft No. 2.
(o) After removing the camshaft, attach the timing chain to a rope
or wire hoist so that it does not drop.
NOTICE:
cover.
(p) Remove the valve lifter.
(q) Using a micrometer, measure the valve lifter thickness.
90
A107973J01
1
2
3
4
A133124
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
A133818
Measurement
Point B
A033166
EM30
EM
(r) Select and install a valve lifter so that the valve clearance is
within the specified range.
Standard:
Intake: :
+ [(Measured clearance) - 0.18 mm]
EXHAUST:
+ [(Measured clearance) -0.31mm]
HINT:
Shims are available in 41 increments of 0.02 mm (0.0008 in.),
from 5.120 mm to 5.680mm.
(s) Install the valve lifter.
(t) Apply engine oil to the cam of camshaft No. 2 and the journal of
the cylinder head, and then install the camshaft No. 2.
NOTICE:
camshaft sub-assembly No. 2 push down the lifter valve.
(u) Apply engine oil to the cam of the camshaft and the journal part
NOTICE:
camshaft sub-assembly No. 1 pushes down the lifter valve.
(v) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
(w) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
NOTICE:
Valve
Thickness of Lifter
Selection No.
Marking
A133819
(mm)
(mm)
(mm)
(mm)
12 5.120 28 5.280 44 5.440 60 5.600
14 5.140 30 5.300 46 5.460 62 5.620
16 5.160 32 5.320 48 5.480 64 5.640
18 5.180 34 5.340 50 5.500 66 5.660
20 5.200 36 5.360 52 5.520 68 5.680
22 5.220 38 5.380 54 5.540 - -
24 5.240 40 5.400 56 5.560 - -
26 5.260 42 5.420 58 5.580 - -
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
EM31
EM
(x) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
NOTICE:
cap No. 1.
(y) Position the timing marks of the camshaft timing sprocket and
the camshaft timing gear as shown in the illustration.
(z) Position the timing mark (groove) of the crankshaft pulley so it is
at 0.
(aa) Align the camshaft knock pin and the camshaft timing sprocket
shaft.
NOTICE:
shaft a little to the right and left so they align. Do not
1
2
3
4
A133071
Notch
Timing Marks
A140652
Pin Hole
Knock Pin
Do Not Remove
A136098
EM32
EM
(ab) Apply a small amount of engine oil to the camshaft timing
(ac) Using the hexagon head portion of the camshaft, tighten the
(ad) Install the chain so the matchmarks of the camshaft timing gear
(ae) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
Hold
A136076
Timing Marks
A133561
A136104
EM33
EM
(af) Make sure that each timing mark is positioned as shown in the
illustration.
(ag) Apply Three Bond TB1324 to the first 2 to 3 threads of the chain
cover service hole screw plug bolt.
NOTICE:
(ah) Using a 10 mm socket hexagon wrench, install the chain cover
(ai) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
NOTICE:
Install within 3 minutes of applying Three Bond
TB1207B.
Do not start the engine within 2 hours of the installation.
(aj) Install the timing chain cover No. 2 with the 2 bolts.
Notch
Timing Marks
A140612
A137724
Apply Liquid Gasket
A139347
A137452
EM34
EM
page EM-193)
ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (3SZ-VE)
EM35
EM
PARTIAL ENGINE ASSEMBLY (3SZ-VE)
COMPONENTS
TIGHTENING TORQUE
[N*m{kgf*cm}]
AIR CLEANER ASSEMBLY
T=3.5{36}
BATTERY
CLAMP
BATTERY
T=8.5{87} 3
BATTERY CARRIER
2
T=7.5{76}
T=18{184}
T=7.5{76}
2
AIR CLEANER HOSE NO. 1
ACCELERATOR CONTROL
CABLE ASSEMBLY
RADIATOR HOSE NO. 1
RADIATOR HOSE NO. 2
OIL COOLER INLET HOSE NO. 1
OIL COOLER OUTLET HOSE NO. 1
FUEL HOSE NO. 2
HEATER OUTLET COOLANT HOSE
HEATER INLET COOLANT HOSE
ENGINE UNDER COVER RR RH
T=5.4{55}
7
T=5.4{55}
4
ENGINE UNDER COVER RR LH
ENGINE UNDER COVER
T=5.4{55} 11
A136755J01
EM36
EM
[N*m{kgf*cm}] TIGHTENING TORQUE NON-REUSEABLE PART
T=46{469}
T=25{225}
T=8.4{86}
T=25{255}
T=7.5{76}
T=29.4{300}
T=10{102}
T=10{102}
T=19{194}
T=19{194}
T=29.4{300}
A/T
TRANSMISSION CONTROL
CABLE ASSEMBLY
CHARCOAL CANISTER PIPE NO. 1
ENGINE ROOM R/B
GROUND WIRE
HARNESS
VACUUM HOSE ASSEMBLY
COOLER COMPRESSOR WITH
MAGNETIC CLUTCH ASSEMBLY
SPEED SENSOR FR LH
STEERING INTERMEDIATE SHAFT ASSEMBLY
O-RING
COOLER REFRIGERANT
DISCHARGE HOSE NO. 1
EXHAUST PIPE SUPPORT BRACKET
COOLER REFRIGERANT
SUCTION HOSE NO. 1
EXHAUST PIPE ASSEMBLY FR
EXHAUST PIPE GASKET
EXHAUST PIPE GASKET
CABLE ASSEMBLY
M/T
CYLINDER HEAD
COVER GROUND
WIRE HARNESS
O-RING
A136756J02
EM37
EM
TIGHTENING TORQUE
T=60{612}
T=37{377}
T=112.8{1150}
T=112.8{1150}
T=97.5{976}
T=20.6{210}
T=20.6{210}
T=125{1275}
6
2
2
2
2
4
2
T=37{377}
T=60{612}
4
T=60{612}
4
T=112.8{1150}
2
T=95.7{976}
2
T=20.6{210}
T=112.8{1150}
2
T=125{1275}
6
T=20.6{210}
2
2
2WD PROPELLER WITH CENTER
BEARING SHAFT ASSEMBLY
FRONT DISC BRAKE
CYLINDER ASSEMBLY LH
VANE PUMP WITH BRACKET
FRONT SHOCK ABSORBER
WITH COIL SPRING
FRONT SUSPENSION
CROSS MEMBER
FRONT DISC BRAKE
CYLINDER ASSEMBLY RH
FRONT PROPELLER SHAFT ASSEMBLY
PROPELLER WITH CENTER
FRONT DISC BRAKE
WITH COIL SPRING
FRONT DISC BRAKE
FRONT SUSPENSION
CROSS MEMBER
4WD
A137621J01
EM38
EM
TIGHTENING TORQUE
NON-REUSEABLE PART [N*m{kgf*cm}]
T=7.5{76}
T=7.5{76}
T=7.5{76}
T=78{800}
T=27.5{280}
T=19{194}
2
6
6
6
6
T=78{800}
T=19.1{195}
T=30.4{310}
2
T=18{184}
4
T=48.1{490}
T=30.4{310}
3
T=37{377}
T=28{286}
3
4
T=11.5{117}
3
T=44{449}
IGNITION COIL ASSEMBLY
SPARK PLUG
FAN PULLEY
REAR END PLATE
ENGINE OIL PRESSURE
SWITCH ASSEMBLY
IDLER PULLEY NO. 1
COMPRESSOR MOUNTING
BRACKET NO. 1
CRANKSHAFT POSITION SENSOR
A/T
FLYWHEEL RING GEAR
O-RING
OIL FILTER BRACKET
ENGINE MOUNTING
BRACKET FR NO. 2
M/T
CLUTCH DISC ASSEMBLY
FLYWHEEL
CLUTCH COVER ASSEMBLY
ENGINE MOUNTING
INSULATOR FR RH
ENGINE MOUNTING
BRACKET FR NO. 1 RH
ENGINE MOUNTING INSULATOR FR LH
A137889J01
EM39
EM
T=84.5{85}
T=36.8{375}
T=36.8{375}
T=68{693}
T=68{693}
T=37{375}
T=68{693}
T=84.5{85}
T=34.3{349}
T=7.9{80}
T=36.8{375}
T=27.5{280}
x6
T=58.8{596}
4WD
7
T=37{375}
T=68{693}
T=58.8{596}
T=58.8{596}
2
OIL COOLER TUBE
APPLY ATF APPLY MP GREASE
ENGINE REAR SUPPORT MEMBER
ENGINE MOUNTING
BRACKET RR
TRANSMISSION
REVOLUTION
SENSOR
O-RING
WIRE HARNESS
FRONT SUSPENSION
CROSS MEMBER LWR
TORQUE CONVERTER
ASSEMBLY
TRANSMISSION ASSEMBLY
TRANSFER ASSEMBLY
GASKET
OIL COOLER HOSE
OIL COOLER
HOSE
[N*m{kgf*cm}]
TIGHTENING TORQUE NON-REUSEABLE PART
C139184J09
EM40
EM
T=36.8{375}
T=32{325}
T=18{185}
T=68{693}
T=36.8{375}
T=58.8{596}
T=68{693}
T=37{375}
T=58.8{596}
T=58.8{596}
BACK-UP LIGHT SWITCH ASSEMBLY
FRONT SUSPENSION CROSS MEMBER LWR
TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART
C140480J01
EM41
EM
TIGHTENING TORQUE
NON-REUSEABLE PART
COOLANT BYPASS HOSE NO. 2
COOLANT BYPASS HOSE
THROTTLE BODY
ASSEMBLY
T=7.5{76}
2
T=21{214}
2
T=7.5{76}
O-RING
T=19{194}
3
T=21{214}
2
THROTTLE BODY BRACKET NO. 2
THROTTLE BODY BRACKET
OIL LEVEL GAUGE GUIDE
O-RING
T=8.5{87}
VENTILATION HOSE NO. 2
INTAKE MANIFOLD
TO HEAD GASKET
T=7.5{76}
RADIATOR PIPE
EXHAUST MANIFOLD
HEAT INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=35{357}
2
MANIFOLD STAY
T=9.3{95}
3
T=35{357}
EXHAUST MANIFOLD
ALTERNATOR ASSEMBLY
T=44{449}
T=19{194}
T=19{194}
T=10{102}
FANBELT ADJUSTING BAR
CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
T=7.5{76}
O-RING
INTAKE MANIFOLD
VENTILATION HOSE
2
T=19{194}
EXHAUST MANIFOLD TO HEAD GASKET
A137041J01
EM42
EM
T=21{214}
2
T=20{204}
2
T=20{204}
T=8.8{90}
T=37{377}
2
T=9.0{92}
T=19.0{200}
T=7.5{76}
4
4
4
FUEL DELIVERY PIPE
RADIATOR HOSE NO. 4
INJECTOR VIBRATION
INSULATOR
COOLANT BYPASS PLATE
FUEL INJECTOR
ASSEMBLY
KNOCK CONTROL SENSOR
WATER BYPASS HOSE NO. 4
THERMOSTAT
WATER INLET
COOLANT TEMPERATURE
SENSOR
CAMSHAFT POSITION
SENSOR
GASKET
STARTER ASSEMBLY
COOLANT RADIATOR HOSE NO. 3
RADIATOR HOSE NO. 2
GASKET
GASKET
A137074J01
EM43
EM
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page EM-146)
2. CHECK THAT FRONT TIRES FACE STRAIGHT AHEAD
See page RS-164.
4. REMOVE FRONT TIRE
6. REMOVE ENGINE UNDER COVER RR RH
7. REMOVE ENGINE UNDER COVER RR LH
8. REMOVE REFRIGERANT HFC - 134a (R134a) (Steering type:
LHD) (See page AC-27)
10. DRAIN ENGINE OIL
(a) After draining the engine oil, install the drain plug using a new
gasket.
11. DRAIN AUTOMATIC TRANSMISSION FLUID (AUTOMATIC
TRANSMISSION) (See page AT-69)
12. DRAIN MANUAL TRANSMISSION OIL (MANUAL TRANSMIS-
SION) (See page MT-9)
13. DRAIN TRANSFER OIL (for 4WD) (See page TF-7)
15. DISCONNECT FUEL HOSE NO. 2 (See page EM-148)
16. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC
TRANSMISSION) (See page CO-15)
17. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC
18. REMOVE BATTERY
(a) Remove the battery clamp.
(b) Remove the battery.
19. REMOVE BATTERY CARRIER (See page EM-146)
21. DISCONNECT RADIATOR HOSE NO.1(See page CO-15)
23. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)
EM44
EM
24. REMOVE VANE PUMP WITH BRACKET
(a) Remove the 3 bolts and the vane pump with bracket.
25. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.
1 (STEERING TYPE: LHD) (See page AC-51)
26. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1
(STEERING TYPE: LHD) (See page AC-51)
27. REMOVE COOLER COMPRESSOR WITH MAGNETIC CLUTCH
ASSEMBLY (See page AC-51)
28. DISCONNECT HEATER INLET WATER HOSE
(a) Detach the clamp and disconnect the heater inlet water hose.
29. DISCONNECT HEATER OUTLET WATER HOSE
(a) Detach the clamp and disconnect the heater outlet water hose.
30. REMOVE CHARCOAL CANISTER PIPE NO. 1
(a) Remove the bolt and the charcoal canister pipe No. 1.
(See page EM-147)
32. DISCONNECT VACUUM HOSE ASSEMBLY (See page EM-148)
33. DISCONNECT ENGINE WIRE HARNESS
(a) Remove the glove compartment door assembly and then dis-
connect the connectors of the engine control computer.
(b) Pull the wire harness out through the engine room side.
A137622
A136001
A136002
A133920
A133249
EM45
EM
(c) Remove the bolt and disconnect the ground wire harness.
(d) Remove the connectors and clamps from the engine room R/B,
and then disconnect the wire harness.
(e) Disconnect the ground connector of the cylinder head cover.
(f) Remove the bolt and disconnect the ground wire harness.
(g) Disconnect all the wire harnesses and connectors, and check
that the wire harness is not connected between the body and
the engine.
34. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY
35. REMOVE EXHAUST PIPE ASSEMBLY FR
(a) Remove the 2 nuts.
(b) Disconnect the oxygen sensor No. 2 connector.
A133248
A133247
A133250
A134988
A133302
EM46
EM
(c) Remove the 2 bolts and 2 springs.
(d) Remove the exhaust support cushion, and then remove the
exhaust pipe assembly FR.
36. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEM-
BLY (See page PR-6)
37. REMOVE FRONT SUSPENSION CROSS MEMBER LWR (for 4WD)
(See page PR-3)
38. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
(See page PR-3)
39. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(AUTOMATIC TRANSMISSION) (See page AT-70)
40. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (MAN-
UAL TRANSMISSION) (See page MT-26)
41. DISCONNECT SPEED SENSOR FR LH
(a) Remove the bolt, and disconnect the speed sensor FR LH from
the steering knuckle.
(b) Remove the bolt and nut, and disconnect the wire harness
clamp from the shock absorber.
42. DISCONNECT SPEED SENSOR FR RH
(a) Perform the same procedure for the RH as for the LH.
43. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY LH
(a) Remove the 2 bolts, and separate the front disc brake cylinder
assembly LH.
(b) Hang the disconnected front disc brake cylinder assembly LH
with wire or similar.
44. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY RH
A134989
C133716
C133715
C139221
EM47
EM
45. SEPARATE FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Remove the 4 bolts and 4 nuts, and disconnect the front shock
absorber with coil spring LH and RH from the steering knuckle.
46. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION
(a) Set the engine lifter.
(b) Remove the 4 bolts and disconnect the engine rear support
member.
(c) Remove the 6 bolts, operate the engine lifer, and then remove
the engine assembly with transaxle and the front suspension
crossmember from the vehicle.
47. REMOVE OIL COOLER TUBE (AUTOMATIC TRANSMISSION)
(a) Remove the 2 union bolts and disconnect the oil cooler tube.
(b) Remove the bolt and disconnect the clamp (A) from the trans-
mission assembly.
(c) Remove the bolt, and then remove the clamp (B) from the
engine mount bracket.
HINT:
The clamp (B) is tightened together with the ground cable.
C135148
A133259
A133258
Vehicle Front
A133256
C135146
EM48
EM
48. REMOVE FRONT SUSPENSION CROSS MEMBER
(a) Install the engine hanger No. 1 and No. 2 to the locations shown
(b) Use an engine sling device and chain block to hold the engine
assembly with transaxle and the front suspension cross mem-
ber.
(c) Remove the 3 bolts and nuts and disconnect the engine mount-
ing insulator FR RH.
(d) Remove the 2 bolts and nut. Then disconnect the engine
mounting bracket FR RH and remove the front suspension
cross member.
(B)
(A)
C135145J01
A137720
A133261
A133260
EM49
EM
49. REMOVE STARTER ASSEMBLY
(a) Remove the terminal cap.
(b) Remove the nut, then remove terminal 30.
(c) Disconnect the connector.
(d) Remove the 2 bolts and then remove the starter assembly.
50. REMOVE TORQUE CONVERTER SET BOLT (AUTOMATIC
51. SUPPORT TRANSMISSION ASSEMBLY (AUTOMATIC TRANS-
MISSION)
52. REMOVE TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-
SION)
(a) Remove the 9 bolts and the transmission assembly.
NOTICE:
To avoid damage to the knock pin, do not pry the contact
surfaces of the automatic transmission assembly and the
engine.
53. REMOVE FLYWHEEL RING GEAR (AUTOMATIC TRANSMIS-
SION)
(a) Using the SST, secure the flywheel ring gear.
SST 09210-87701
(b) Remove the 6 bolts and the flywheel ring gear.
54. SUPPORT TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-
SION)
55. REMOVE TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-
SION)
NOTICE:
Do not jolt the transmission assembly to avoid a damage to
the input shaft.
56. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-
SION) (See page CL-20)
57. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
(See page CL-20)
58. REMOVE FLYWHEEL (MANUAL TRANSMISSION)
(a) Using the SST, secure the flywheel.
SST 09210-87701
(b) Remove the 6 bolts and the flywheel.
A133263
C136910J01
SST
A137592
C136911J04
SST
A139357
EM50
EM
59. REMOVE REAR END PLATE
(a) Remove the bolt and the rear end plate.
60. REMOVE ENGINE WIRE HARNESS
(a) Disconnect the connectors and the wire harness clamps from
the engine assembly, and remove the engine wire harness.
(b) Detach the alternator connector and then disconnect the wire
harness clamp.
(c) Remove the cam position sensor and the water temperature
sensor connectors and then disconnect the wire harness clamp
bracket.
62. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See
page EM-150)
63. REMOVE MANIFOLD STAY (See page EM-150)
64. REMOVE EXHAUST MANIFOLD (See page EM-150)
65. REMOVE OIL LEVEL GAUGE GUIDE (See page EM-148)
68. REMOVE FUEL DELIVERY PIPE (See page FU-10)
69. REMOVE FUEL INJECTOR ASSEMBLY (See page FU-10)
70. REMOVE THROTTLE BODY ASSEMBLY (See page EM-148)
71. REMOVE THROTTLE BODY BRACKET (See page EM-149)
72. REMOVE INTAKE MANIFOLD (See page EM-149)
A133301
A133303
A133305
A133306
EM51
EM
73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a deep socket wrench (24 mm), remove the engine oil
pressure switch.
74. REMOVE IDLER PULLEY NO. 1
(a) Remove the nut, then remove idler pulley No. 1.
75. REMOVE CRANK POSITION SENSOR (See page IG-14)
76. REMOVE FAN PULLEY (See page CO-29)
77. REMOVE ALTERNATOR ASSEMBLY (See page CH-10)
78. REMOVE KNOCK CONTROL SENSOR
(a) Remove the nut, then remove the knock control sensor.
79. REMOVE RADIATOR HOSE NO. 4
(a) Loosen the clamp and then remove radiator hose No. 4.
(a) Loosen the clamp and then remove radiator hose No. 3.
A137321
A137714
A109109
A133307
A133408
EM52
EM
81. REMOVE WATER BY-PASS HOSE NO. 2
(a) Loosen the clamp and then remove the water by-pass hose No.
2.
(a) Loosen the clamp and then remove the water by-pass hose No.
4.
83. REMOVE WATER BY-PASS PLATE
(a) Remove the 2 bolts and the water by-pass plate.
84. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(See page EM-152)
85. REMOVE CAM POSITION SENSOR
(a) Remove the bolt, then remove the cam position sensor.
86. REMOVE WATER INLET
(a) Remove the bolt and nut and then remove the water inlet.
87. REMOVE THERMOSTAT
(a) Remove the thermostat.
A133407
A133308
A136155
A133309
A136151
EM53
EM
88. REMOVE WATER TEMPERATURE SENSOR
(a) Using a 19 mm deep socket wrench, remove the water temper-
ature sensor.
89. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the bolt and the ignition coil assembly.
90. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
(a) Remove the 4 bolts and the compressor mounting bracket No.
1.
91. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH
(a) Remove the 4 bolts and the engine mounting bracket FR No. 1
RH.
92. REMOVE ENGINE MOUNTING BRACKET FR NO. 2
(a) Remove the 4 bolts and the engine mounting bracket FR No. 2.
A136152
A133310
A133311
A133312
A133313
EM54
EM
93. REMOVE OIL FILTER BRACKET
(a) Remove the 2 bolts and the oil filter bracket.
(b) Remove the oil filter bracket gasket.
INSTALLATION
1. INSTALL OIL FILTER BRACKET
(a) Install the oil filter bracket with new O-rings attached by the 2
bolts. to the cylinder block.
HINT:
Apply a light coat of engine oil to the oil filter bracket union
insertion part.
2. INSTALL ENGINE MOUNTING BRACKET FR NO. 2
(a) Install the engine mounting bracket FR No. 2 with the 4 bolts.
HINT:
Tighten part A temporarily, and then tighten it fully after fully
tightening the other 3 bolts.
3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH
(a) Install the engine mounting bracket FR No. 1 RH with the 4
bolts.
HINT:
A133314
A133314
A
A139360
A
A139361
EM55
EM
4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
(a) Install the compressor mounting bracket No. 1 with the 3 bolts.
5. INSTALL IGNITION COIL ASSEMBLY
(a) Install the ignition coil assembly with the bolt.
6. INSTALL WATER TEMPERATURE SENSOR
(a) Using a new gasket and a 19 mm deep socket wrench, install
the water temperature sensor.
7. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Align the water inlet matchmark and the thermostat jiggle valve,
and install the thermostat.
8. INSTALL WATER INLET
(a) Install the water inlet with the bolt and nut.
9. INSTALL CAM POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring.
A133311
A133310
A136152
A133315
A133309
EM56
EM
(b) Install the cam position sensor with the bolt.
NOTICE:
Install the sensor so that the O-ring is not cut or pinched.
10. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(See page EM-162)
11. INSTALL WATER BY-PASS PLATE
(a) Install the water by-pass plate to the cylinder head with a gasket
and 2 bolts.
(b) Install the water by-pass plate to the water valve bracket with
the bolt.
12. INSTALL WATER BY-PASS HOSE NO. 2
(a) Install the water by-pass hose No. 2 with the clamp.
14. INSTALL RADIATOR HOSE NO. 3
(a) Install the radiator hose No. 3 with the clamp.
A136155
A133407
A133308
A133307
EM57
EM
16. INSTALL KNOCK CONTROL SENSOR
(a) Install the knock control sensor with the nut in the direction
shown in the illustration.
17. INSTALL ALTERNATOR ASSEMBLY (See page CH-10)
18. INSTALL FAN PULLEY (See page CO-29)
19. INSTALL CRANK POSITION SENSOR
(b) Install the crank position sensor with the bolt.
20. INSTALL IDLER PULLEY NO. 1
(a) Install the idler pulley No. 1 with the nut.
21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply Three Bond TB1344 to the first 2 to 3 threads of the
engine oil pressure switch assembly.
(b) Using a deep socket wrench (24 mm), install the engine oil
pressure switch assembly.
NOTICE:
Do not start the engine within 1 hour of installation.
22. INSTALL INTAKE MANIFOLD (See page EM-164)
23. INSTALL THROTTLE BODY ASSEMBLY (See page EM-164)
24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-11)
A133408
45
15
15
A107019J01
A137713
A137714
A137321
EM58
EM
25. INSTALL FUEL DELIVERY PIPE
(a) Temporarily install the fuel delivery pipe with the 2 bolts.
NOTICE:
Do not drop the fuel injector when installing the fuel deliv-
ery pipe.
(b) Check that the fuel delivery pipe rotates smoothly.
NOTICE:
If the fuel delivery pipe does not rotate smoothly, reinstall it
with a new O-ring.
(c) Tighten the 2 bolts.
26. INSTALL OIL LEVEL GAUGE GUIDE
(a) Apply engine oil to a new O-ring, then install it to the oil level
gauge guide.
(b) Install the oil level gauge guide with the 2 bolts.
27. INSTALL EXHAUST MANIFOLD (See page EM-162)
28. INSTALL MANIFOLD STAY (See page EM-163)
29. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See
page EM-163)
30. INSTALL ENGINE WIRE HARNESS
(a) Install the cam position sensor and the water temperature sen-
sor connectors, and then install the wire harness clamp bracket.
(b) Install the alternator connector, and then install the wire harness
clamp.
Torque: 10 N*m (102 kgf*cm) (Terminal B)
(c) Install the sensor connectors and wire harness clamps, and
then install the engine wire harness.
A136082
A133306
A133305
A133303
EM59
EM
34. INSTALL REAR END PLATE
(a) Install the rear end plate with the bolt.
35. INSTALL FLYWHEEL (MANUAL TRANSMISSION)
(a) Using SST, hold the crankshaft.
SST 09210-87701
(b) Apply Three Bond TB1344 to the first 2 to 3 threads of the fly-
wheel installation bolt.
NOTICE:
Clean and degrease the flywheel installation bolt and bolt
hole.
(c) Temporarily install the flywheel with the 6 bolts.
(d) Tighten the 6 bolts in the order shown in the illustration.
NOTICE:
Do not start the engine within 1 hour of the installation.
36. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
(See page CL-21)
37. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-
SION)
39. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-
SION)
(a) Ensure that the 2 knock pins are installed on the engine side.
(b) Using a high-mission jack, horizontally align the engine and the
automatic transmission assembly and then insert the knock pin
in the knock pin hole.
A133301
SST
A139359
A134237
6
1 3
5
2 4
A134238
EM60
EM
(c) Using a pri set torque wrench, temporarily install the transmis-
sion assembly with the 9 bolts.
NOTICE:
Do not jolt the transmission unit assembly to avoid a
damage to the input shaft.
(d) Tighten the transmission assembly installation bolt A.
(e) Tighten the transmission assembly installation bolts A, B and C
in order from A to C.
(1) Tighten bolt A.
NOTICE:
Tighten bolt A together with the water by-pass pipe
No. 2 clamp.
HINT:
Bolt A part number: 91619-61250 (Length under neck 57
mm)
(2) Tighten bolt B.
HINT:
Bolt B part number: 91619-61250 (Length under neck 57
mm)
(3) Tighten bolt C.
HINT:
Bolt C part number: 90119-10260 (Length under neck 40
mm)
C136911J04
A
C141309
A
A A
B
B
C
C
C C
C136911J03
EM61
EM
40. INSTALL FLYWHEEL RING GEAR (AUTOMATIC TRANSMISSION)
SST 09330-00021, 09213-54015 (91651-60855)
wheel ring gear installation bolt.
NOTICE:
Clean and degrease the flywheel ring gear installation bolt
and bolt hole.
(c) Temporarily install the flywheel ring gear with the 6 bolts.
NOTICE:
MISSION)
42. INSTALL TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-
SION)
(c) Temporarily install the transmission assembly with the 9 bolts.
NOTICE:
Do not jolt the transmission unit assembly to avoid a dam-
age to the input shaft.
SST
A137593
6
1 3
5
2
4
A134236
A
A
A A
C139312J02
EM62
EM
(d) Using a torque wrench (QL-100), tighten a new transmission
assembly installation bolt A.
HINT:
Bolt A part number: 91619-61250 (Length under neck 50 mm)
in order.
Torque: 59 N*m (602 kgf*cm) New bolt A
37 N*m (375 kgf*cm) Bolt B
37 N*m (375 kgf*cm) Bolt C
HINT:
mm)
Bolt A and B part number: 90041-19968 (Length under neck
57 mm)
mm)
43. INSTALL TORQUE CONVERTER SET BOLT (AUTOMATIC
44. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with 2 bolts.
(b) Connect the connector.
(c) Install terminal 30 with the nut.
(d) Close the terminal cap.
A
C141308
A
A
B
B
C
C
C C
C139312J03
A133263
EM63
EM
45. INSTALL FRONT SUSPENSION CROSS MEMBER
assembly with transmission.
(c) Install the left side front suspension cross member to the engine
assembly with transmission with the 2 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (Nut)
30.4 N*m (310 kgf*cm) (Bolt)
(d) Install the right side front suspension cross member to the
engine assembly with transmission with the 3 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (Nut)
30.4 N*m (310 kgf*cm) (Bolt)
46. INSTALL OIL COOLER TUBE (AUTOMATIC TRANSMISSION)
(a) Temporarily install the oil cooler tube to the transmission
assembly with the 2 union bolts.
(b) Temporarily install clamp A and B with the 2 bolts.
NOTICE:
The clamp (B) is tightened together with the ground wire,
and the ground wire comes on top.
A137720
A133260
A133261
C135146
EM64
EM
(c) Tighten the 2 union bolts.
(d) Tighten the bolts of clamp A and B.
Torque: 7.9 N*m (80 kgf*cm) (A)
Torque: 36.8 N*m (375 kgf*cm) (B)
47. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION
(b) Operate the engine lifer, and then temporarily install the engine
assembly with transmission and the front suspension cross
member to the vehicle with the 6 bolts.
(c) Tighten the bolts to the specified torque in several passes.
(d) Install the engine rear support member to the vehicle with the 4
bolts.
(e) Tighten the bolts to the specified torque in several passes.
A
B
C135145
A133259
Vehicle Front
A133256
A133258
EM65
EM
48. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Connect the front shock absorber with coil spring to the suspen-
sion knuckle assembly with the 2 bolts and nuts.
49. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH
(a) Connect the disc brake cylinder assembly with the 2 bolts.
50. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY RH
51. INSTALL SPEED SENSOR FR LH
(a) Install the speed sensor FR LH to the steering knuckle with the
bolt.
Torque: 18.2 N*m (185.5 kgf*cm)
NOTICE:
Tighten it together with the brake flexible hose clamp with
the bolt, with the flexible hose clamp on the top.
(b) Install the bolt and wire harness clamp to the shock absorber.
52. INSTALL SPEED SENSOR FR RH
53. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(MANUAL TRANSMISSION) (See page MT-23)
55. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See
page PR-4)
56. INSTALL FRONT SUSPENSION CROSS MEMBER LWR (See page
PR-4)
57. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEM-
BLY (See page PR-7)
C135148
C139221
C133716
C133715
EM66
EM
58. INSTALL EXHAUST PIPE ASSEMBLY FR
(a) With a new gasket inserted, install the exhaust pipe assembly
FR to the exhaust manifold with the 2 compression springs and
2 bolts.
NOTICE:
Make sure the gasket is installed in the correct direc-
tion.
Dropping the gasket may damage it.
Do not damage the sliding parts of the gasket.
(b) Using a new gasket, install the exhaust tail pipe assembly to the
exhaust pipe assembly FR with the 2 new nuts.
(c) Connect oxygen sensor No. 2 connector.
59. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY
60. CONNECT ENGINE WIRE HARNESS
(a) Connect the cylinder head cover ground connector, and then
install the ground wire harness with the 3 bolts.
(b) Connect the ground wire harness with the bolt.
Tail Pipe Side
Gasket
A031088J01
A133302
A133250
A133248
EM67
EM
(c) Connect the 3 engine room R/B connecters and clamp.
(d) Install the wire harness inside the engine room.
(e) Connect the engine control computer connector, and then install
the glove compartment door assembly.
61. CONNECT VACUUM HOSE ASSEMBLY (See page EM-165)
62. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY (See
page EM-165)
63. INSTALL CHARCOAL CANISTER PIPE NO. 1
(a) Install the charcoal canister pipe No. 1 with the bolt.
64. CONNECT HEATER OUTLET WATER HOSE
(a) Connect the heater outlet water hose.
65. CONNECT HEATER INLET WATER HOSE
(a) Connect the heater inlet water hose.
66. INSTALL COOLER COMPRESSOR WITH MAGNETIC CLUTCH
67. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1
68. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1
A133247
A133249
A133920
A136002
A136001
EM68
EM
69. INSTALL VANE PUMP WITH BRACKET
(a) Install the vane pump with bracket with the 3 bolts.
70. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)
71. ADJUST FAN AND ALTERNATOR V BELT (See page EM-9)
72. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)
74. CONNECT RADIATOR HOSE NO. 1 (See page CO-18)
76. INSTALL BATTERY CARRIER (See page EM-167)
77. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC
TRANSMISSION)(See page CO-18)
78. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC
79. CONNECT FUEL HOSE NO. 2 (See page EM-165)
80. CONNECT RADIATOR HOSE NO. 2
(a) Connect the radiator hose No. 2 with the clamp.
81. INSTALL BATTERY
(a) Connect the negative terminal with the nut and clamp.
83. INSTALL FRONT TIRE
84. CHECK FRONT TIRES FACING STRAIGHT AHEAD
85. ADD ENGINE OIL
87. ADD AUTOMATIC TRANSMISSION FLUID (AUTOMATIC TRANS-
MISSION)
88. ADD MANUAL TRANSMISSION OIL (MANUAL TRANSMISSION)
89. ADD TRANSFER OIL (for 4WD)
92. CHECK FOR FUEL LEAKS (See page EM-167)
93. CHECK FOR EXHAUST GAS LEAKS
94. CHECK FOR OIL LEAKS
95. CHECK ENGINE OIL LEVEL (See page EM-167)
96. CHECK ENGINE IDLE SPEED (See page EM-2)
97. CHECK IGNITION TIMING (See page EM-1)
98. CHECK DENSITY OF CO AND HC (See page EM-3)
99. CHARGE REFRIGERANT HFC - 134a [R134a] (STEERING TYPE:
A137622
A136170
EM69
EM
100. WARM UP ENGINE (STEERING TYPE: LHD) (See page AC-28)
101. CHECK FOR REFRIGERANT LEAKS (STEERING TYPE: LHD)
(See page AC-28)
102. INITIALIZE LEARNED VALUE IN DS-II (AUTOMATIC TRANSMIS-
SION)
See page AT-15.
103. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
See page SP-4.
104. INSTALL ENGINE UNDER COVER RR LH
(a) Install the engine under cover RR LH with the 4 bolts.
105. INSTALL ENGINE UNDER COVER RR RH
(a) Install the engine under cover RR RH with the 7 bolts.
106. INSTALL ENGINE UNDER COVER
(a) Install the engine under cover with the 11 bolts.
107. TEST MODE INSPECTION (SPEED SENSOR)
(See page BC-9.)
(See page BC-65.)
EM70
ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (K3-VE)
EM
PARTIAL ENGINE ASSEMBLY (K3-VE)
COMPONENTS
TIGHTENING TORQUE
[N*m{kgf*cm}]
T=3.5{36}
BATTERY
CLAMP
BATTERY
T=8.5{87} 3
BATTERY CARRIER
2
T=7.5{76}
T=18{184}
T=7.5{76}
2
ACCELERATOR CONTROL
CABLE ASSEMBLY
RADIATOR HOSE NO. 1
RADIATOR HOSE NO. 2
OIL COOLER OUTLET HOSE NO. 1
FUEL HOSE NO. 2
HEATER OUTLET COOLANT HOSE
HEATER INLET COOLANT HOSE
ENGINE UNDER COVER RR RH
T=5.4{55}
7
T=5.4{55}
4
ENGINE UNDER COVER RR LH
ENGINE UNDER COVER
T=5.4{55} 11
A136755J01
EM71
EM
TIGHTENING TORQUE
NON-REUSEABLE PART
T=46{469}
T=25{225}
T=8.4{86}
T=25{255}
T=7.5{76}
T=29.4{300}
T=29.4{300}
T=10{102}
T=10{102}
T=19{194}
T=19{194}
A/T
CABLE ASSEMBLY
CHARCOAL CANISTER PIPE NO. 1
ENGINE ROOM R/B
GROUND WIRE
HARNESS
VACUUM HOSE ASSEMBLY
COOLER COMPRESSOR WITH
MAGNETIC CLUTCH ASSEMBLY
SPEED SENSOR FR LH
STEERING INTERMEDIATE SHAFT ASSEMBLY
O-RING
COOLER REFRIGERANT
DISCHARGE HOSE NO. 1
EXHAUST PIPE SUPPORT BRACKET
COOLER REFRIGERANT
SUCTION HOSE NO. 1
EXHAUST PIPE ASSEMBLY FR
EXHAUST PIPE GASKET
EXHAUST PIPE GASKET
CABLE ASSEMBLY
M/T
CYLINDER HEAD
COVER GROUND
WIRE HARNESS
O-RING
A136756J01
EM72
EM
TIGHTENING TORQUE
T=60{612}
T=37{377}
T=112.8{1150}
T=112.8{1150}
T=97.5{976}
T=125{1275}
6
2
2
2
2
4
2
T=37{377}
T=60{612}
4
T=60{612}
4
T=112.8{1150}
2
T=95.7{976}
2
T=112.8{1150}
2
T=125{1275}
6
2WD PROPELLER WITH CENTER
FRONT DISC BRAKE
WITH COIL SPRING
FRONT SUSPENSION
CROSS MEMBER
FRONT DISC BRAKE
FRONT PROPELLER SHAFT ASSEMBLY
PROPELLER WITH CENTER
FRONT DISC BRAKE
WITH COIL SPRING
FRONT DISC BRAKE
FRONT SUSPENSION
CROSS MEMBER
4WD
A137621J02
EM73
EM
T=7.5{76}
T=7.5{76}
T=15{153}
T=19{194}
T=7.5{76}
T=11.5{117}
T=44{449}
T=28{286}
T=37{377}
T=48.1{490}
T=18{184}
T=30.4{310}
T=30.4{310}
T=78{800}
T=78{800}
T=27.5{280}
4
4
3
2
6
6
6
6
2
4
4
4
T=19.1{195}
T=43.2{440}
T=20.6{210}
2
FAN PULLEY
COMPRESSOR MOUNTING BRACKET NO. 1
IDLER PULLEY NO. 1
VANE PUMP
WITH BRACKET
ENGINE MOUNTING
INSULATOR FR RH
ENGINE MOUNTING
BRACKET FR NO. 2
FLYWHEEL RING GEAR
ENGINE MOUNTING
BRACKET FR NO. 1 RH
ENGINE MOUNTING INSULATOR
FRONT LH
FLYWHEEL
CLUTCH COVER
ASSEMBLY
M/T
A/T
REAR END PLATE
ENGINE OIL PRESSURE
SWITCH ASSEMBLY
OIL FILTER BRACKET
O-RING
SPARK PLUG
A137049J03
EM74
EM
T=84.5{85}
T=36.8{375}
T=36.8{375}
T=68{693}
T=68{693}
T=37{375}
T=68{693}
T=84.5{85}
T=34.3{349}
T=7.9{80}
T=36.8{375}
T=27.5{280}
x6
T=58.8{596}
4WD
7
T=37{375}
T=68{693}
T=58.8{596}
T=58.8{596}
2
OIL COOLER TUBE
APPLY ATF APPLY MP GREASE
ENGINE REAR SUPPORT MEMBER
ENGINE MOUNTING
BRACKET RR
TRANSMISSION
REVOLUTION
SENSOR
O-RING
WIRE HARNESS
FRONT SUSPENSION
CROSS MEMBER LWR
TORQUE CONVERTER
ASSEMBLY
TRANSFER ASSEMBLY
GASKET
OIL COOLER HOSE
OIL COOLER
HOSE
[N*m{kgf*cm}]
C139184J09
EM75
EM
T=36.8{375}
T=32{325}
T=18{185}
T=68{693}
T=36.8{375}
T=58.8{596}
T=68{693}
T=37{375}
T=58.8{596}
T=58.8{596}
BACK-UP LIGHT SWITCH ASSEMBLY
FRONT SUSPENSION CROSS MEMBER LWR
C140480J01
EM76
EM
TIGHTENING TORQUE
NON-REUSEABLE PART
COOLANT BYPASS HOSE
THROTTLE BODY
ASSEMBLY
T=7.5{76}
2
T=21{214}
2
T=7.5{76}
O-RING
T=19{194}
3
T=21{214}
2
THROTTLE BODY BRACKET NO. 2
THROTTLE BODY BRACKET
O-RING
T=8.5{87}
INTAKE MANIFOLD
TO HEAD GASKET
T=7.5{76}
RADIATOR PIPE
EXHAUST MANIFOLD
HEAT INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=35{357}
2
MANIFOLD STAY
T=9.3{95}
3
T=35{357}
EXHAUST MANIFOLD
ALTERNATOR ASSEMBLY
T=44{449}
T=19{194}
T=19{194}
T=10{102}
FANBELT ADJUSTING BAR
CAMSHAFT TIMING OIL CONTROL
VALVE ASSEMBLY
T=7.5{76}
O-RING
INTAKE MANIFOLD
VENTILATION HOSE
2
T=19{194}
EXHAUST MANIFOLD TO HEAD GASKET
A137041J01
EM77
EM
T=21{214}
2
T=20{204}
2
T=20{204}
T=8.8{90}
T=37{377}
2
T=9.0{92}
T=19.0{200}
T=7.5{76}
4
4
4
FUEL DELIVERY PIPE
RADIATOR HOSE NO. 4
INJECTOR VIBRATION
INSULATOR
COOLANT BYPASS PLATE
FUEL INJECTOR
ASSEMBLY
KNOCK CONTROL SENSOR
WATER BYPASS HOSE NO. 4
THERMOSTAT
WATER INLET
COOLANT TEMPERATURE
SENSOR
CAMSHAFT POSITION
SENSOR
GASKET
STARTER ASSEMBLY
COOLANT RADIATOR HOSE NO. 3
RADIATOR HOSE NO. 2
GASKET
GASKET
A137074J01
EM78
EM
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page EM-173)
See page RS-164.
4. REMOVE FRONT TIRE
6. REMOVE ENGINE UNDER COVER RR RH
7. REMOVE ENGINE UNDER COVER RR LH
8. REMOVE REFRIGERANT HFC - 134a (R134a) (Steering type:
11. DRAIN ENGINE OIL
(a) After draining the engine oil, install the drain plug using a new
gasket.
12. DRAIN AUTOMATIC TRANSMISSION FLUID (AUTOMATIC
13. DRAIN MANUAL TRANSMISSION OIL (MANUAL TRANSMIS-
SION) (See page MT-9)
14. DRAIN TRANSFER OIL (for 4WD) (See page TF-7)
16. DISCONNECT FUEL HOSE NO. 2 (See page EM-175)
19. REMOVE BATTERY
(a) Remove the battery clamp.
(b) Remove the battery.
22. DISCONNECT RADIATOR HOSE NO.1(See page CO-22)
EM79
EM
25. REMOVE VANE PUMP WITH BRACKET
(a) Remove the 3 bolts and the vane pump with bracket.
26. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.
1 (STEERING TYPE: LHD) (See page AC-51)
27. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1
28. DISCONNECT COOLER COMPRESSOR WITH MAGNETIC
CLUTCH ASSEMBLY (See page AC-51)
(a) Detach the clamp and disconnect the heater inlet water hose.
(a) Detach the clamp and disconnect the heater outlet water hose.
31. REMOVE CHARCOAL CANISTER PIPE NO. 1
(a) Remove the bolt and the charcoal canister pipe No. 1.
(See page EM-175)
33. DISCONNECT VACUUM HOSE ASSEMBLY (See page EM-175)
34. DISCONNECT ENGINE WIRE HARNESS
(a) Remove the glove compartment door assembly and then dis-
connect the connectors of the engine control computer.
(b) Pull the wire harness out through the engine room side.
A137622
A136001
A136002
A133920
A133249
EM80
EM
(c) Remove the bolt and disconnect the ground wire harness.
(d) Remove the connectors and clamps from the engine room R/B,
and then disconnect the wire harness.
(e) Disconnect the ground connector of the cylinder head cover.
(f) Remove the bolt and disconnect the ground wire harness.
(g) Disconnect all the wire harnesses and connectors, and check
that the wire harness is not connected between the body and
the engine.
35. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (See
page PS-11)
36. REMOVE EXHAUST PIPE ASSEMBLY FR
(a) Remove the 2 nuts.
(b) Disconnect the oxygen sensor No. 2 connector.
A133248
A133247
A133250
A134988
A133302
EM81
EM
(c) Remove the 2 bolts and 2 springs.
(d) Remove the exhaust support cushion, and then remove the
exhaust pipe assembly FR.
37. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEM-
BLY (See page PR-6)
38. REMOVE FRONT SUSPENSION CROSS MEMBER LWR (for 4WD)
(See page PR-3)
39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
(See page PR-3)
42. DISCONNECT SPEED SENSOR FR LH
(a) Remove the bolt, and disconnect the speed sensor FR LH from
the steering knuckle.
(b) Remove the bolt and nut, and disconnect the wire harness
clamp from the shock absorber.
43. DISCONNECT SPEED SENSOR FR RH
44. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY LH
(a) Remove the 2 bolts, and disconnect the front disc brake cylin-
der assembly LH.
(b) Hang the disconnected front disc brake cylinder assembly LH
with wire or similar.
45. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY RH
A134989
C133716
C133715
C139221
EM82
EM
(a) Remove the 4 bolts and 4 nuts, and disconnect the front shock
absorber with coil spring LH and RH from the steering knuckle.
47. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION
(b) Remove the 4 bolts and disconnect the engine rear support
member.
(c) Remove the 6 bolts, operate the engine lifer, and then remove
the engine assembly with transaxle and the front suspension
crossmember from the vehicle.
48. REMOVE OIL COOLER TUBE (AUTOMATIC TRANSMISSION)
(a) Remove the 2 union bolts and disconnect the oil cooler tube.
(b) Remove the bolt and disconnect the clamp (A) from the trans-
mission assembly.
(c) Remove the bolt, and then remove the clamp (B) from the
engine mount bracket.
HINT:
The clamp (B) is tightened together with the ground cable.
C135148
A133259
A133258
Vehicle Front
A133256
C135146
EM83
EM
49. REMOVE FRONT SUSPENSION CROSS MEMBER
assembly with transaxle and the front suspension cross mem-
ber.
(c) Remove the 3 bolts and nuts and disconnect the engine mount-
ing insulator FR RH.
(d) Remove the 2 bolts and nut. Then disconnect the engine
mounting bracket FR RH and remove the front suspension
cross member.
(B)
(A)
C135145J01
A137720
A133261
A133260
EM84
EM
50. REMOVE STARTER ASSEMBLY
(a) Remove the terminal cap.
(b) Remove the nut, then remove terminal 30.
(c) Disconnect the connector.
(d) Remove the 2 bolts and then remove the starter assembly.
51. REMOVE TORQUE CONVERTER SET BOLT (AUTOMATIC
MISSION)
SION)
NOTICE:
To avoid damage to the knock pin, do not pry the contact
surfaces of the automatic transmission assembly and the
engine.
SION)
(a) Using the SST, secure the flywheel ring gear.
SST 09210-87701
(b) Remove the 6 bolts and the flywheel ring gear.
SION)
SION)
NOTICE:
Do not jolt the transmission assembly to avoid a damage to
the input shaft.
(See page CL-20)
A133263
C136910J01
SST
A137592
C136911J04
EM85
EM
59. REMOVE FLYWHEEL (MANUAL TRANSMISSION)
(a) Using the SST, secure the flywheel.
SST 09210-87701
(b) Remove the 6 bolts and the flywheel.
60. REMOVE REAR END PLATE
(a) Remove the bolt and the rear end plate.
61. REMOVE ENGINE WIRE HARNESS
(a) Disconnect the connectors and the wire harness clamps from
the engine assembly, and remove the engine wire harness.
(b) Detach the alternator connector and then disconnect the wire
harness clamp.
(c) Remove the cam position sensor and the water temperature
sensor connectors and then disconnect the wire harness clamp
bracket.
63. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See
page EM-177)
64. REMOVE MANIFOLD STAY (See page EM-177)
65. REMOVE EXHAUST MANIFOLD (See page EM-178)
SST
A139357
A133301
A133303
A133305
A133306
EM86
EM
66. REMOVE OIL LEVEL GAUGE GUIDE (See page EM-175)
69. REMOVE FUEL DELIVERY PIPE (See page FU-15)
70. REMOVE FUEL INJECTOR ASSEMBLY (See page FU-15)
71. REMOVE THROTTLE BODY ASSEMBLY (See page EM-176)
72. REMOVE THROTTLE BODY BRACKET (See page EM-176)
73. REMOVE INTAKE MANIFOLD (See page EM-176)
74. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a deep socket wrench (24 mm), remove the engine oil
pressure switch.
76. REMOVE CRANK POSITION SENSOR (See page IG-16)
79. REMOVE KNOCK CONTROL SENSOR
(a) Remove the nut, then remove the knock control sensor.
A137321
A137714
A109109
EM87
EM
(a) Remove the clamp and then remove radiator hose No. 4.
(a) Remove the clamp and then remove radiator hose No. 3.
(a) Remove the clamp and then remove the water by-pass hose
No. 2.
(a) Remove the clamp and then remove the water by-pass hose
No. 4.
84. REMOVE WATER BY-PASS PLATE
(a) Remove the 2 bolts and the water by-pass plate.
(See page EM-180)
86. REMOVE CAM POSITION SENSOR
(a) Remove the bolt, then remove the cam position sensor.
A133408
A133307
A133407
A133308
A136155
EM88
EM
87. REMOVE WATER INLET
(a) Remove the bolt and nut and then remove the water inlet.
88. REMOVE THERMOSTAT
(a) Remove the thermostat.
89. REMOVE WATER TEMPERATURE SENSOR
(a) Using a 19 mm deep socket wrench, remove the water temper-
ature sensor.
(a) Remove the bolt and the ignition coil assembly.
91. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
(a) Remove the 4 bolts and the compressor mounting bracket No.
1.
A133309
A136151
A136152
A133310
A133311
EM89
EM
92. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH
(a) Remove the 4 bolts and the engine mounting bracket FR No. 1
RH.
93. REMOVE ENGINE MOUNTING BRACKET FR NO. 2
(a) Remove the 4 bolts and the engine mounting bracket FR No. 2.
94. REMOVE OIL FILTER BRACKET
(a) Remove the 2 bolts and the oil filter bracket.
(b) Remove the oil filter bracket gasket.
INSTALLATION
1. INSTALL OIL FILTER BRACKET
(a) Install the oil filter bracket with new O-rings attached by the 2
bolts. to the cylinder block.
HINT:
Apply a light coat of engine oil to the oil filter bracket union
insertion part.
2. INSTALL ENGINE MOUNTING BRACKET FR NO. 2
(a) Install the engine mounting bracket FR No. 2 with the 4 bolts.
HINT:
A133312
A133313
A133314
A133314
A
A139360
EM90
EM
3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH
(a) Install the engine mounting bracket FR No. 1 RH with the 4
bolts.
HINT:
4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
(a) Install the compressor mounting bracket No. 1 with the 3 bolts.
6. INSTALL WATER TEMPERATURE SENSOR
(a) Using a new gasket and a 19 mm deep socket wrench, install
the water temperature sensor.
7. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Align the water inlet matchmark and the thermostat jiggle valve,
and install the thermostat.
A
A139361
A133311
A133310
A136152
A133315
EM91
EM
8. INSTALL WATER INLET
(a) Install the water inlet with the bolt and nut.
9. INSTALL CAM POSITION SENSOR
(b) Install the cam position sensor with the bolt.
NOTICE:
(See page EM-189)
11. INSTALL WATER BY-PASS PLATE
(a) Install the water by-pass plate to the cylinder head with a gasket
and 2 bolts.
(b) Install the water by-pass plate to the water valve bracket with
the bolt.
A133309
A136155
A133407
A133308
EM92
EM
16. INSTALL KNOCK CONTROL SENSOR
(a) Install the knock control sensor with the nut in the direction
21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Apply Three Bond TB1344 to the first 2 to 3 threads of the
engine oil pressure switch assembly.
A133307
A133408
45
15
15
A107019J01
A137713
A137714
EM93
EM
(b) Using a deep socket wrench (24 mm), install the engine oil
pressure switch assembly.
NOTICE:
22. INSTALL INTAKE MANIFOLD (See page EM-191)
23. INSTALL THROTTLE BODY ASSEMBLY (See page EM-192)
24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-16)
(a) Temporarily install the fuel delivery pipe with the 2 bolts.
NOTICE:
Do not drop the fuel injector when installing the fuel deliv-
ery pipe.
(b) Check that the fuel delivery pipe rotates smoothly.
NOTICE:
If the fuel delivery pipe does not rotate smoothly, reinstall it
with a new O-ring.
(c) Tighten the 2 bolts.
(a) Apply engine oil to a new O-ring, then install it to the oil level
gauge guide.
(b) Install the oil level gauge guide with the 2 bolts.
27. INSTALL EXHAUST MANIFOLD (See page EM-190)
28. INSTALL MANIFOLD STAY (See page EM-191)
29. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (See
page EM-191)
30. INSTALL ENGINE WIRE HARNESS
(a) Install the cam position sensor and the water temperature sen-
sor connectors, and then install the wire harness clamp bracket.
(b) Install the alternator connector, and then install the wire harness
clamp.
Torque: 10 N*m (102 kgf*cm) (Terminal B)
A137321
A136082
A133306
A133305
EM94
EM
(c) Install the sensor connectors and wire harness clamps, and
then install the engine wire harness.
34. INSTALL REAR END PLATE
(a) Install the rear end plate with the bolt.
35. INSTALL FLYWHEEL (MANUAL TRANSMISSION)
SST 09210-87701
wheel installation bolt.
NOTICE:
Clean and degrease the flywheel installation bolt and bolt
hole.
(c) Temporarily install the flywheel with the 6 bolts.
NOTICE:
(See page CL-21)
A133303
A133301
SST
A139359
A134237
6
1 3
5
2 4
A134238
EM95
EM
SION)
39. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSAXLE)
NOTICE:
Do not jolt the transmission unit assembly to avoid a
damage to the input shaft.
(d) Using a pri set torque wrench, tighten the transmission assem-
bly installation bolt A.
in order.
(1) Tighten bolt A.
NOTICE:
Tighten bolt A together with the water by-pass pipe
No. 2 clamp.
HINT:
Bolt A part number: 91619-61250 (Length under neck
57m)
(2) Tighten bolt B.
C136911J04
A
C141309
A
A A
B
B
C
C
C C
C136911J03
EM96
EM
HINT:
Bolt B part number: 91619-61250 (Length under neck 57
mm)
(3) Tighten bolt C.
HINT:
mm)
SST 09330-00021, 09213-54015 (91651-60855)
wheel ring gear installation bolt.
NOTICE:
Clean and degrease the flywheel ring gear installation bolt
and bolt hole.
(c) Temporarily install the flywheel ring gear with the 6 bolts.
NOTICE:
MISSION)
SION)
NOTICE:
Do not jolt the transmission unit assembly to avoid a dam-
age to the input shaft.
SST
A137593
6
1 3
5
2
4
A134236
A
A
A A
C139312J02
EM97
EM
(d) Using a torque wrench (QL-100), tighten a new transmission
assembly installation bolt A.
HINT:
Bolt A part number: 91619-61250 (Length under neck 50 mm)
in order.
Torque: 59 N*m (602 kgf*cm) New bolt A
37 N*m (375 kgf*cm) Bolt B
37 N*m (375 kgf*cm) Bolt C
HINT:
mm)
Bolt A and B part number: 90041-19968 (Length under neck
57 mm)
mm)
43. INSTALL TORQUE CONVERTER SET BOLT (AUTOMATIC
44. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with 2 bolts.
(b) Connect the connector.
(c) Install terminal 30 with the nut.
(d) Close the terminal cap.
A
C141308
A
A
B
B
C
C
C C
C139312J03
A133263
EM98
EM
45. INSTALL FRONT SUSPENSION CROSS MEMBER
assembly with transmission.
(c) Install the left side front suspension cross member to the engine
assembly with transmission with the 2 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (nut)
30.4 N*m (310 kgf*cm) (bolt)
(d) Install the right side front suspension cross member to the
engine assembly with transmission with the 3 bolts and nut.
Torque: 48.1 N*m (490 kgf*cm) (nut)
30.4 N*m (310 kgf*cm) (bolt)
46. INSTALL OIL COOLER TUBE (AUTOMATIC TRANSMISSION)
(a) Temporarily install the oil cooler tube to the transmission
assembly with the 2 union bolts.
(b) Temporarily install clamp A and B with the 2 bolts.
NOTICE:
The clamp (B) is tightened together with the ground wire,
and the ground wire comes on top.
A137720
A133260
A133261
C135146
EM99
EM
(c) Tighten the 2 union bolts.
(d) Tighten the bolts of clamp A and B.
Torque: 7.9 N*m (80 kgf*cm) (A)
Torque: 36.8 N*m (375 kgf*cm) (B)
47. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION
(b) Operate the engine lifer, and then temporarily install the engine
assembly with transmission and the front suspension cross
member to the vehicle with the 6 bolts.
(c) Tighten the bolts to the specified torque in several passes.
(d) Install the engine rear support member to the vehicle with the 4
bolts.
(e) Tighten the bolts to the specified torque in several passes.
A
B
C135145
A133259
Vehicle Front
A133256
A133258
EM100
EM
48. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Connect the front shock absorber with coil spring to the suspen-
sion knuckle assembly with the 2 bolts and nuts.
49. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY LH
(a) Connect the disc brake cylinder assembly with the 2 bolts.
50. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY RH
51. INSTALL SPEED SENSOR FR LH
(a) Install the speed sensor FR LH to the steering knuckle with the
bolt.
NOTICE:
Tighten it together with the brake flexible hose clamp with
the bolt, with the flexible hose clamp on the top.
(b) Install the bolt and wire harness clamp to the shock absorber.
52. INSTALL SPEED SENSOR FR RH
55. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See
page PR-4)
PR-4)
57. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEM-
BLY (See page PR-7)
C135148
C139221
C133716
C133715
EM101
EM
58. INSTALL EXHAUST PIPE ASSEMBLY FR
(a) With a new gasket inserted, install the exhaust pipe assembly
FR to the exhaust manifold with the 2 compression springs and
2 bolts.
NOTICE:
Make sure the gasket is installed in the correct direc-
tion.
Dropping the gasket may damage it.
Do not damage the sliding parts of the gasket.
(b) Using a new gasket, install the exhaust tail pipe assembly to the
exhaust pipe assembly FR with the 2 new nuts.
(c) Connect oxygen sensor No. 2 connector.
59. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (See
page PS-25)
60. CONNECT ENGINE WIRE HARNESS
(a) Connect the cylinder head cover ground connector, and then
install the ground wire harness with the 3 bolts.
(b) Connect the ground wire harness with the bolt.
Tail Pipe Side
Gasket
A031088J01
A133302
A133250
A133248
EM102
EM
(c) Connect the 3 engine room R/B connecters and clamp.
(d) Install the wire harness inside the engine room.
(e) Connect the engine control computer connector, and then install
the glove compartment door assembly.
61. CONNECT VACUUM HOSE ASSEMBLY (See page EM-193)
62. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY (See
page EM-193)
63. INSTALL CHARCOAL CANISTER PIPE NO. 1
(a) Install the charcoal canister pipe No. 1 with the bolt.
66. INSTALL COOLER COMPRESSOR WITH MAGNETIC CLUTCH
67. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1
68. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1
A133247
A133249
A133920
A136002
A136001
EM103
EM
69. INSTALL VANE PUMP WITH BRACKET
(a) Install the vane pump with bracket with the 3 bolts.
Torque: 20.6 N*m (210 kgf*cm) (Bolt A)
43.2 N*m (440 kgf*cm) (Bolt B)
79. CONNECT FUEL HOSE NO. 2 (See page EM-193)
80. CONNECT RADIATOR HOSE NO. 2
(a) Connect the radiator hose No. 2 with the clamp.
81. INSTALL BATTERY
(a) Connect the negative terminal with the nut and clamp.
83. INSTALL FRONT TIRE
85. ADD ENGINE OIL
87. ADD AUTOMATIC TRANSMISSION FLUID (AUTOMATIC TRANS-
MISSION)
88. ADD MANUAL TRANSMISSION OIL (MANUAL TRANSMISSION)
89. ADD TRANSFER OIL (for 4WD)
90. CHARGE REFRIGERANT HFC - 134a [R134a] (STEERING TYPE:
91. WARM UP ENGINE (STEERING TYPE: LHD) (See page AC-28)
92. CHECK FOR REFRIGERANT LEAKS (STEERING TYPE: LHD)
(See page AC-28)
95. CHECK FOR FUEL LEAKS (See page EM-195)
97. CHECK FOR OIL LEAKS
A
B
A
A140646
A136170
EM104
EM
102. INITIALIZE LEARNED VALUE IN DS-II (AUTOMATIC TRANSMIS-
SION)
See page AT-15.
103. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
See page SP-4.
104. INSTALL ENGINE UNDER COVER RR LH
(a) Install the engine under cover RR LH with the 4 bolts.
105. INSTALL ENGINE UNDER COVER RR RH
(a) Install the engine under cover RR RH with the 7 bolts.
106. INSTALL ENGINE UNDER COVER
(a) Install the engine under cover with the 11 bolts.
107. TEST MODE INSPECTION (SPEED SENSOR)
(See page BC-9.)
(See page BC-65.)
ENGINE MECHANICAL - CHAIN (3SZ-VE)
EM105
EM
CHAIN (3SZ-VE)
COMPONENTS
.....
TIGHTENING TORQUE [N*m{kgf*cm}]
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
ACCELERATOR CONTROL CABLE ASSEMBLY
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM106
EM
.....
T=11.5{117}
T=44{449}
T=130{1326}
T=7.5{76}
T=7.5{76}
T=20{204}
4
4
4
T=7.5{76}
T=7.5{76}
3
T=20.6{210}
3
VENTILATION HOSE
CAMSHAFT TIMING OIL
CONTROL VALVE ASSEMBLY
IDLER PULLEY NO. 1
IDLER PULLEY
CRANKSHAFT PULLEY VANE PUMP ASSEMBLY
O-RING
RADIATOR PIPE
SPARK PLUG
O-RING
A136904J02
EM107
EM
TIGHTENING TORQUE [N*m{kgf*cm} NON-REUSEABLE PART
.....
OIL FILLER CAP
CYLINDER HEAD COVER
T=11{112}
T=9.0{92}
11
CYLINDER HEAD COVER GASKET
CHAIN TENSIONER PLUNGER
TIMING CHAIN
CHAIN
T=9.0{92}
TIMING GEAR (CHAIN)
T=19{195}
T=23{235}
2
T=44{449}
T=12{122}
9
3
TIMING CHAIN (BELT) COVER OIL SEAL
CRANKSHAFT ANGLE SENSOR PLATE NO. 1
T=7.5{76}
2
TIMING CHAIN GUIDE NO. 2
TIMING CHAIN GUIDE
T=7.5{76}
COVER GASKET
TENSIONER ARM
APPLY MP GREASE
A136905J03
EM108
EM
REMOVAL
(See page SS-10.)
4. DRAIN ENGINE OIL
8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See
page EM-147)
11. REMOVE VANE PUMP ASSEMBLY (See page EM-44)
12. REMOVE IDLER PULLEY NO. 1 (See page EM-150)
13. DISCONNECT VENTILATION HOSE (See page EM-147)
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147)
19. REMOVE CRANKSHAFT PULLEY (See page EM-151)
20. REMOVE CAM POSITION SENSOR (See page EM-152)
(See page EM-152)
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-152)
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-153)
24. REMOVE CRANK ANGLE SENSOR PLATE NO. 1
(a) Remove the crank angle sensor plate No. 1.
25. REMOVE CHAIN TENSIONER PLUNGER
(a) Move the stopper plate downward and hold it with the lock
released.[*1]
HINT:
If it is difficult to release the stopper plate lock, use the hexagon
head portion of the camshaft and rotate the camshaft a little to
the right and left.
D-MARK
A135998
EM109
EM
(b) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
(c) Under the conditions noted at [*2], align the stopper plate and
the chain tensioner plunger hole.[*3]
HINT:
If the stopper plate and the chain tensioner plunger hole are dif-
ficult to align, rotate the camshaft a little to the left and then
back a little to the right again to align them.
(d) Under the conditions noted at [*3], insert a bar of 3 mm in diam-
eter into the stopper plate and the chain tensioner plunger hole.
(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
26. REMOVE TIMING CHAIN TENSION ARM
(a) Remove the bolt and the timing chain tensioner arm.
27. REMOVE TIMING CHAIN GUIDE
(a) Remove the 2 bolts and the timing chain guide.
A108005
Stopper Plate Plunger
A108555J02
A108556
A108557
A108558
EM110
EM
28. REMOVE TIMING CHAIN GUIDE NO. 2
(a) Remove the 2 bolts and the timing chain guide No. 2.
29. REMOVE CHAIN
INSTALLATION
1. INSTALL CHAIN
(a) Align the mark plate (yellow) and the timing mark as shown in
the illustration and install the chain.
2. INSTALL TIMING CHAIN GUIDE NO. 2
(a) Install the timing chain guide No. 2 with the 2 bolts.
A108559
Mark Plate Mark Plate
Timing Mark
Timing Mark
Mark Plates
Timing Mark
A137742
A108559
EM111
EM
3. INSTALL TIMING CHAIN GUIDE
(a) Install the timing chain guide with the 2 bolts.
4. INSTALL TIMING CHAIN TENSION ARM
(a) Install the timing chain tension arm with the bolt.
5. INSTALL CHAIN TENSIONER PLUNGER
(a) Install the chain tensioner plunger with the bolt and nut.
HINT:
Using the hexagon wrench head portion of the camshaft, rotate
the camshaft a little to the left, and with the chain slightly slack
on the chain tensioner plunger side, attach the chain tensioner
plunger.
(b) Pull the 3 mm diameter bar out from the chain tensioner
plunger.
6. INSTALL CRANK ANGLE SENSOR PLATE NO. 1
(a) Install the crank angle sensor plate No. 1 so that the D mark is
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-160)
8. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
200)
9. INSTALL CRANK POSITION SENSOR (See page EM-57)
(See page EM-162)
11. INSTALL CRANKSHAFT PULLEY (See page EM-161)
13. INSTALL SPARK PLUG (See page EM-162)
A108558
A108557
A108556
D-MARK
A135998
EM112
EM
19. INSTALL IDLER PULLEY NO. 1 (See page EM-163)
20. INSTALL VANE PUMP ASSEMBLY (See page EM-68)
page EM-165)
30. INSTALL BATTERY
33. ADD ENGINE OIL
35. INSPECT ENGINE OIL LEAKS
38. CHECK IDLE SPEED (See page EM-2)
ENGINE MECHANICAL - CHAIN (K3-VE)
EM113
EM
CHAIN (K3-VE)
COMPONENTS
.....
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM114
EM
.....
T=11.5{117}
T=44{449}
T=130{1326}
T=7.5{76}
T=7.5{76}
T=20{204}
4
4
4
T=7.5{76}
T=7.5{76}
3
T=20.6{210}
3
VENTILATION HOSE
CAMSHAFT TIMING OIL
IDLER PULLEY NO. 1
IDLER PULLEY
O-RING
RADIATOR PIPE
SPARK PLUG
O-RING
A136904J02
EM115
EM
NON-REUSEABLE PART
.....
OIL FILLER CAP
CYLINDER HEAD COVER
T=11{112}
T=9.0{92}
11
TIMING CHAIN
CHAIN
T=9.0{92}
TIMING GEAR (CHAIN)
T=19{195}
T=23{235}
2
T=44{449}
T=12{122}
9
3
T=7.5{76}
2
TIMING CHAIN GUIDE
T=7.5{76}
MP GREASE
COVER GASKET
TENSIONER ARM
A136905J05
EM116
EM
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-173 )
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT (See page CO-11 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-173 )
7. REMOVE RADIATOR HOSE NO. 1 (See page CO-22 )
8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See
page EM-175 )
9. REMOVE FAN AND ALTERNATOR V BELT (See page EM-12 )
10. REMOVE VANE PUMP WITH BRACKET (See page EM-79 )
11. REMOVE FAN PULLEY (See page CO-33 )
12. REMOVE IDLER PULLEY NO. 1 (See page EM-177 )
13. DISCONNECT VENTILATION HOSE (See page EM-174 )
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174 )
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM-175 )
16. REMOVE RADIATOR PIPE (See page EM-174 )
17. REMOVE IGNITION COIL ASSEMBLY (See page EM-178 )
18. REMOVE CYLINDER HEAD COVER (See page EM-178 )
19. REMOVE CRANKSHAFT PULLEY (See page EM-179 )
20. REMOVE CAM POSITION SENSOR (See page EM-179 )
(See page EM-180 )
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-180 )
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-180 )
released.[*1]
HINT:
the right and left.
D-MARK
A135998
EM117
EM
and hold.[*2]
HINT:
plunger.
HINT:
(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
A108005
A108555J02
A108556
A108557
A108558
EM118
EM
29. REMOVE CHAIN
INSTALLATION
1. INSTALL CHAIN
A108559
Timing Mark
Timing Mark
Mark Plates
Timing Mark
A137742
A108559
EM119
EM
HINT:
plunger.
plunger.
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-188 )
206 )
9. INSTALL CRANK POSITION SENSOR (See page EM-92 )
(See page EM-189 )
11. INSTALL CRANKSHAFT PULLEY (See page EM-189 )
12. INSTALL CYLINDER HEAD COVER (See page EM-190 )
13. INSTALL SPARK PLUG (See page EM-190 )
14. INSTALL IGNITION COIL ASSEMBLY (See page EM-190 )
15. INSTALL RADIATOR PIPE (See page EM-194 )
17. INSTALL VENTILATION HOSE (See page EM-193 )
A108558
A108557
A108556
D-MARK
A135998
EM120
EM
18. INSTALL VENTILATION HOSE NO. 2 (See page EM-193 )
19. INSTALL IDLER PULLEY NO. 1 (See page EM-191 )
20. INSTALL FAN PULLEY (See page CO-33 )
21. INSTALL VANE PUMP WITH BRACKET (See page EM-103 )
22. INSTALL FAN AND ALTERNATOR V BELT (See page EM-12 )
23. ADJUST FAN AND ALTERNATOR V BELT (See page EM-13 )
24. CHECK FAN AND ALTERNATOR V BELT (See page EM-13 )
page EM-193 )
26. INSTALL RADIATOR HOSE NO. 1 (See page CO-25 )
27. INSTALL AIR CLEANER ASSEMBLY (See page EM-194 )
28. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26 )
29. INSTALL BATTERY CARRIER (See page EM-194 )
30. INSTALL BATTERY
32. ADD ENGINE COOLANT (See page CO-11 )
33. ADD ENGINE OIL
34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-12 )
35. CHECK FOR ENGINE OIL LEAKS
36. CHECK ENGINE OIL LEVEL (See page EM-195 )
37. CHECK IGNITION TIMING (See page EM-4 )
38. CHECK IDLE SPEED (See page EM-5 )
39. INSTALL ENGINE UNDER COVER (See page EM-104 )
ENGINE MECHANICAL - CAMSHAFT (3SZ-VE)
EM121
EM
CAMSHAFT (3SZ-VE)
COMPONENTS
.....
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM122
EM
T=7.5{76}
T=11{112}
T=9.0{92}
T=12.5{130}
T=12.5{130}
T=47{480}
T=17{173}
T=8.5{87}
4
8
16
4
4
11
2
T=7.5{76}
VENTILATION HOSE
CYLINDER HEAD COVER
CYLINDER HEAD COVER
GASKET
CAMSHAFT BEARING CAP NO. 1
CAMSHAFT
CAMSHAFT TIMING
SPROCKET
TIMING CHAIN (BELT) COVER NO. 2
RADIATOR PIPE
CHAIN COVER SERVICE HOLE
SCREW PLUG
CAMSHAFT NO. 2
A137081J01
EM123
EM
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-146 )
4. DRAIN ENGINE COOLANT (See page CO-9 )
5. REMOVE RADIATOR HOSE NO. 1 (See page CO-15 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-146 )
7. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15 )
(See page EM-147 )
9. DISCONNECT VENTILATION HOSE (See page EM-147 )
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147 )
12. REMOVE RADIATOR PIPE (See page EM-147 )
13. REMOVE IGNITION COIL ASSEMBLY (See page EM-150 )
14. REMOVE CYLINDER HEAD COVER (See page EM-151 )
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2
(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
(a) Rotate the crankshaft pulley clockwise to align the timing mark
(groove) so it is at 0.Make sure that each timing mark is posi-
tioned as shown in the illustration.
HINT:
If the timing marks are not aligned, turn the crankshaft pulley
clockwise again and align the marks.
Notch
Timing Marks
A137746
EM124
EM
(b) Place a paint mark on each plate of the chains at the points
(c) Using the hexagon head portion of the camshaft, loosen the
(d) Using a 10 mm socket hexagon wrench, remove the chain
(e) Using a screwdriver, access the tensioner stopper plate through
HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
Timing Marks
A107964J01
A133812
A137724
A133813
EM125
EM
(g) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
head portion.
does not come out.
(h) Remove the chain from the camshaft timing sprocket.
17. REMOVE CAMSHAFT TIMING SPROCKET
(a) Remove the bolt and the camshaft timing sprocket.
18. REMOVE CAMSHAFT BEARING CAP NO. 1
NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90 clockwise with the valve fully open and check that the
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
(a) Remove the camshaft bearing cap No. 1 in the order indicated
NOTICE:
HINT:
Be sure to keep the removed parts separate according to the
installation areas.
20. REMOVE CAMSHAFT
(a) Remove the camshaft.
A133879
A133815
90
A137743
1
2
3
4
A133124
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
EM126
EM
21. REMOVE CAMSHAFT NO. 2
(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
cover.
22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Do not damage the camshaft.
Do not tighten the vise too firmly.
Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm
2
) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
A133818
Advance Angle Port
Retard Angle Port
A033448J02
A033449J01
EM127
EM
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
1. INSTALL CAMSHAFT NO. 2
(a) When installing camshaft No. 2, rotate the crankshaft 90 (crank
angle) in the direction that the engine rotates from cylinder No.
1 TDC/compression so the lifted valve does not interfere with
the piston.
(b) Apply engine oil to the cam part of camshaft No. 2 and the jour-
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
camshaft No. 2 push down the lifter valve.
2. INSTALL CAMSHAFT
(a) Apply engine oil to the cam of the camshaft and the journal part
NOTICE:
camshaft push down the lifter valve.
3. INSTALL CAMSHAFT BEARING CAP NO. 2
(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
(b) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
NOTICE:
Position the cap so the arrows on it face toward the
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
EM128
EM
(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
NOTICE:
Tighten it after checking that the thrust part of the camshaft
is aligned with the groove on camshaft bearing cap No. 1.
5. INSTALL CAMSHAFT TIMING SPROCKET
(a) Apply engine oil to the installation surface to the camshaft.
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
1
2
3
4
A133071
Pin Hole
Knock Pin
Do Not Remove
A136098
Timing Marks
A133561
A109220
EM129
EM
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
(e) Using a 10 mm socket hexagon wrench, install the chain cover
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2
(a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
TB1207B.
Do not start the engine within 2 hours of installation.
(b) Install the timing chain cover No. 2 with the 2 bolts.
8. INSTALL CYLINDER HEAD COVER (See page EM-162 )
9. INSTALL IGNITION COIL ASSEMBLY (See page EM-162 )
10. INSTALL RADIATOR PIPE (See page EM-166 )
11. INSTALL RADIATOR HOSE NO. 1 (See page CO-18 )
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-166 )
Notch
Timing Marks
A137746
A137724
Apply Liquid Gasket
A139347
A107960
EM130
EM
14. CONNECT VENTILATION HOSE (See page EM-166 )
page EM-165 )
16. INSTALL AIR CLEANER ASSEMBLY (See page EM-167 )
17. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-19 )
18. ADD ENGINE COOLANT (See page CO-9 )
20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10 )
21. CHECK COOLANT LEVEL (See page CO-10 )
22. INSTALL ENGINE UNDER COVER (See page EM-69 )
24. CHECK IGNITION TIMING (See page EM-1 )
25. CHECK ENGINE IDLE SPEED (See page EM-2 )
26. CHECK DENSITY OF CO AND HC (See page EM-3 )
ENGINE MECHANICAL - CAMSHAFT (K3-VE)
EM131
EM
CAMSHAFT (K3-VE)
COMPONENTS
.....
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM132
EM
T=7.5{76}
T=11{112}
T=9.0{92}
T=12.5{130}
T=12.5{130}
T=47{480}
T=17{173}
T=8.5{87}
4
8
16
4
4
11
2
T=7.5{76}
VENTILATION HOSE
CYLINDER HEAD COVER
CYLINDER HEAD COVER
GASKET
CAMSHAFT
CAMSHAFT TIMING
SPROCKET
TIMING CHAIN (BELT) COVER NO. 2
RADIATOR PIPE
CHAIN COVER SERVICE HOLE
SCREW PLUG
CAMSHAFT NO. 2
A137081J01
EM133
EM
REMOVAL
(See page RS-164.)
(See page EM-175)
9. DISCONNECT VENTILATION HOSE (See page EM-174)
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174)
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2
(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
HINT:
Notch
Timing Marks
A140612
EM134
EM
(b) Place a paint mark on each plate of the chains at the points
(c) Using the hexagon head portion of the camshaft, loosen the
(d) Using a 10 mm socket hexagon wrench, remove the chain
(e) Using a screwdriver, access the tensioner stopper plate through
HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
Timing Marks
A107964J01
A133812
A137724
A133813
EM135
EM
(g) Under the conditions noted at [*2], remove the screwdriver from
NOTICE:
Hold the camshaft in the position using the hexagonal
head portion.
does not come out.
(h) Remove the chain from the camshaft timing sprocket.
(a) Remove the bolt and the camshaft timing sprocket.
NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90 clockwise with the valve fully open and check that the
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
NOTICE:
HINT:
Be sure to keep the removed parts separate according to the
installation areas.
20. REMOVE CAMSHAFT
(a) Remove the camshaft.
A133879
A133815
90
A137743
1
2
3
4
A133124
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
EM136
EM
21. REMOVE CAMSHAFT NO. 2
(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
cover.
22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Do not damage the camshaft.
Do not tighten the vise too firmly.
Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm
2
) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
A133818
Advance Angle Port
Retard Angle Port
A033448J02
A033449J01
EM137
EM
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
the piston.
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
2. INSTALL CAMSHAFT
NOTICE:
(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
(b) Tighten the camshaft bearing cap No. 2 in the order indicated in
the illustration.
NOTICE:
Position the cap so the arrows on it face toward the
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
EM138
EM
(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
NOTICE:
Tighten it after checking that the thrust part of the camshaft
is aligned with the groove on camshaft bearing cap No. 1.
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
If the knock pin and pin hole do not align, use the hex-
agonal head portion of the camshaft and rotate the cam-
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
1
2
3
4
A133071
Pin Hole
Knock Pin
Do Not Remove
A136098
Timing Marks
A133561
A109220
EM139
EM
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
(e) Using a 10 mm socket hexagon wrench, install the chain cover
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2
(a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
TB1207B.
(b) Install the timing chain cover No. 2 with the 2 bolts.
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-193)
Notch
Timing Marks
A140612
A137724
Apply Liquid Gasket
A139347
A107960
EM140
EM
14. CONNECT VENTILATION HOSE (See page EM-193)
page EM-193)
ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE)
EM141
EM
CYLINDER HEAD GASKET (3SZ-VE)
COMPONENTS
.....
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM142
EM
.....
T=11.5{117}
T=44{449}
T=130{1326}
T=7.5{76}
T=7.5{76}
T=20{204}
4
4
4
T=7.5{76}
T=7.5{76}
3
T=20.6{210}
3
VENTILATION HOSE
CAMSHAFT TIMING OIL
IDLER PULLEY NO. 1
IDLER PULLEY
O-RING
RADIATOR PIPE
SPARK PLUG
O-RING
A136904J02
EM143
EM
.....
T=8.5{87}
T=8.5{87}
T=35{357}
T=35{357}
T=9.3{95}
T=44{449}
T=19{194}
T=32{326}
T=10{102}
T=8.5{87}
T=21{214}
T=7.5{76}
T=21{214}
T=7.5{76}
T=19{194}
T=19{194}
2
3 2
2
2
2
3
COOLANT BYPASS HOSE
THROTTLE BODY ASSEMBLY
INTAKE MANIFOLD
GASKET
ALTERNATOR ASSEMBLY
THROTTLE BODY
BRACKET
THROTTLE BODY
BRACKET NO. 2
EXHAUST MANIFOLD
INSULATOR NO. 1
EXHAUST
MANIFOLD
O-RING
O-RING
GASKET
A140623J01
EM144
EM
.....
OIL FILLER CAP
CYLINDER HEAD COVER
T=11{112}
T=9.0{92}
11
TIMING CHAIN
CHAIN
T=9.0{92}
TIMING GEAR (CHAIN)
T=19{195}
T=23{235}
2
T=44{449}
T=12{122}
9
3
T=7.5{76}
2
TIMING CHAIN GUIDE
T=7.5{76}
COVER GASKET
TENSIONER ARM
APPLY MP GREASE
A136905J03
EM145
EM
TIGHTENING TORQUE
10
T=12.5{130}
T=12.5{130}
T=47{480}
8
10
16
4
CAMSHAFT TIMING SPROCKET
CAMSHAFT
CAMSHAFT NO. 2
CYLINDER HEAD BOLT
WASHER
CYLINDER HEAD
CYLINDER HEAD GASKET
PLASTIC REGION TIGHTENING METHOD
A137085J01
EM146
EM
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
(3) Start up the engine.
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
DTC P0171/25 lean malfunction may be detected.
(5) Crank the engine again, then check that the engine does
not start.
(6) Remove the fuel tank cap to discharge pressure from the
fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.
(See page RS-164.)
3. REMOVE BATTERY CARRIER
(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-43)
7. REMOVE RADIATOR RESERVE TANK ASSEMBLY (See page CO-
15)
8. REMOVE CHARCOAL CANISTER ASSEMBLY (See page CO-16)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-17)
12. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
Instrument Panel J/B
F/P Relay
A135986J01
A136001
EM147
EM
(a) Loosen the clip, then disconnect the heater outlet water hose.
15. REMOVE RADIATOR PIPE
(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe.
16. REMOVE VENTILATION HOSE
(a) Loosen the clip and remove the ventilation hose.
17. REMOVE VENTILATION HOSE NO. 2
(a) Loosen the clip and remove ventilation hose No. 2.
(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE
(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
A136002
A133397
A134307
A134308
A131808
EM148
EM
(d) Remove the 2 bolts and disconnect the ground wire.
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR
(a) Remove the 2 bolts and 2 springs, then disconnect the exhaust
pipe assembly FR from the exhaust manifold.
21. REMOVE FUEL HOSE NO. 2
(a) Loosen the clip, then disconnect fuel hose No. 2.
22. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.
23. DISCONNECT VACUUM HOSE ASSEMBLY
(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
24. REMOVE THROTTLE BODY ASSEMBLY
(a) Remove the 2 bolts and bracket.
(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
A133250
A134989
A133396
A136065
A131805
EM149
EM
(c) Loosen the clamp, then disconnect the water hose.
(d) Remove the 3 bolts and the throttle body assembly.
(e) Remove the 2 bolts and the throttle body assembly.
25. REMOVE FUEL DELIVERY PIPE
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove.
26. REMOVE THROTTLE BODY BRACKET
(a) Remove the 2 bolts and the throttle body bracket.
27. REMOVE FUEL INJECTOR ASSEMBLY
(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
The O-ring may be stuck, but even if it is, do not apply
sideways force to the fuel injector assembly.
If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
29. REMOVE FAN AND ALTERNATOR V BELT (See page EM-8)
32. REMOVE VANE PUMP WITH BRACKET (See page EM-44)
Blue Paint
A131806
BOLT
A134311
A109106
O-ring
Insulator
A107004J02
A109108
EM150
EM
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
1.
35. REMOVE MANIFOLD STAY
(a) Remove the 2 bolts and the manifold stay.
36. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.
(a) Disconnect the ignition coil connector.
A137714
A133399
A136071
A133400
EM151
EM
(b) Remove the bolt and the ignition coil assembly.
38. REMOVE CYLINDER HEAD COVER
(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover.
39. REMOVE CRANKSHAFT PULLEY
HINT:
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
A133310
A132251
Notch
Timing Marks
A137746
SST
A139349
EM152
EM
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
Install the SST to the crankshaft pulley so that the fixing
bolts for the SST do not contact with the chain cover.
40. REMOVE CRANK POSITION SENSOR
(a) Remove the bolt and the crank position sensor.
(a) Remove the bolt and the camshaft timing oil control valve
assembly.
42. REMOVE TIMING CHAIN (BELT) COVER
(a) Remove the 13 bolts and 2 nuts.
SST
A137589
A137713
A136191
A133402
EM153
EM
(b) Using a screwdriver wrapped with protective tape, lever off and
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
43. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL
(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal.
released.[*1]
HINT:
the right and left.
and hold.[*2]
HINT:
plunger.
A133404
Protective Tape
Wooden
Block
A033132J01
D-MARK
A135998
A108005
EM154
EM
HINT:
(e) Remove the bolt and nut and then remove the water inlet.
49. REMOVE CHAIN
A108555J01
A108556
A108557
A108558
A108559
EM155
EM
(a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90 (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
NOTICE:
53. REMOVE CYLINDER HEAD
(a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra-
tion, then remove the cylinder head bolt and washer.
NOTICE:
When removing the bolt, do not drop the washer into
the head.
Failure to remove the bolts in the specified order may
damage the cylinder head.
(b) Remove the cylinder head.
54. REMOVE CYLINDER HEAD GASKET
Hold
A136076
1
2
3
4
A133124
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
1
2 3
4
5
6 7
8
9
10
A132854
EM156
EM
INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
within the range indicated by A in the illustration.
Maximum limit:
8.75 mm
HINT:
Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Install the cylinder head gasket within 3 minutes and tighten
the cylinder head bolts within 15 minutes after applying
Three Bond TB1207B.
(a) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
Check that it is installed in the correct direction.
Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD
NOTICE:
Inspect and clean the cylinder head and installation hole.
Tighten the cylinder head using the plastic area tightening
method.
Do not allow oil to get on the lower surface of the cylinder
head.
(a) Install the cylinder head.
NOTICE:
Take care not to damage the cylinder head gasket when
installing it.
Install the cylinder head bolt to the same place it was
removed from.
25mm
20mm
A
A108575J01
Cylinder Head
Cylinder Head
Gasket
Cylinder Block
21-27 mm
0-4 mm
17-23 mm
2.0 mm
2.5 mm
A083197J02
Front
A033157J01
EM157
EM
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
(c) Using an 8 mm double hexagon wrench, temporarily install the
cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec-
ified torque.
(d) Put paints mark on the engine front side of heads of the cylinder
head bolts.
(e) Using the paint mark as a reference, tighten the cylinder head
bolts 180 in the specified order.
(f) Check all the paint marks are now moved 180.
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the seal packing black, do not allow it to
enter the bolt hole or knock pin hole.
the piston.
nal part of the cylinder head, and then install the camshaft No.
2.
NOTICE:
Apply Engine Oil
A133007
3 1 6 8
7 5 2 4 10
9
A133008
180
Paint Mark
Tighten
A140645
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
EM158
EM
5. INSTALL CAMSHAFT
NOTICE:
(a) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
the illustration.
NOTICE:
(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
NOTICE:
cap No. 1.
(b) Align the camshaft knock pin and the camshaft timing sprocket
shaft.
NOTICE:
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
1
2
3
4
A133071
Pin Hole
Knock Pin
Do Not Remove
A136098
EM159
EM
(c) Apply a small amount of engine oil to the camshaft timing
(d) Using the hexagon head portion of the camshaft, tighten the
9. INSTALL CHAIN
HINT:
Install so that the mark plate is on the engine front side.
Hold
A136076
Timing Mark
Timing Mark
Mark Plates
Timing Mark
A137742
A108559
A108558
EM160
EM
HINT:
plunger.
plunger.
visible.
15. INSTALL TIMING CHAIN (BELT) COVER
(a) Install a new gasket to the timing chain (belt) cover.
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
NOTICE:
Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
TB1207B.
A108557
A108556
D Mark
A133073
A108562
Apply Liquid Gasket
A108563J02
EM161
EM
Do not add engine oil within 2 hours of installation.
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
44 N*m (449 kgf*cm) (Bolts 13 to 15)
200)
17. INSTALL CRANKSHAFT PULLEY
(a) Using the SST, hold the crankshaft pulley and tighten the bolt.
SST 09278-87201
B B
A A
3-4 mm 3-4 mm
Apply Liquid Gasket
3-4 mm Diameter 3 mm Diameter
6 mm Diameter
6 mm Diameter
A139363
1
2
7
8
10
13
14
15
3
4
5
6
9
11
12
A136081
SST
A137588
EM162
EM
NOTICE:
(b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
20. INSTALL CYLINDER HEAD COVER
(a) Apply seal packing black to the position shown in the illustra-
tion.
NOTICE:
TB1207B.
Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
several passes in the order shown in the illustration.
Torque: 11 N*m (112 kgf*cm) (Nut)
9.0 N*m (92 kgf*cm) (Bolt)
21. INSTALL SPARK PLUG
23. INSTALL EXHAUST MANIFOLD
(a) Install the exhaust manifold using a new gasket.
A137713
A136191
Apply Liquid Gasket
A079650J02
1
2
3
4
5
6
7
8
9
10 11
12 13
A133409
A133310
EM163
EM
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
24. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (Bolt)
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
29. INSTALL VANE PUMP WITH BRACKET (See page EM-68)
A133400
A136071
A133399
A137714
EM164
EM
33. INSTALL INTAKE MANIFOLD
(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
(b) Tighten the bolts and nuts in the order shown in the illustration.
34. INSTALL THROTTLE BODY ASSEMBLY
(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
(f) Connect the engine wire harness.
35. INSTALL FUEL INJECTOR ASSEMBLY
(a) Install a new injector vibration insulator.
(b) Apply gasoline to the new fuel injector assembly O-ring.
A109108
A079976J02
A109106
O-ring
Insulator
A107004J01
EM165
EM
(c) Install the fuel delivery pipe while rotating the fuel injector
assembly to the left and right.
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
Do not drop the fuel injector when installing the fuel
delivery pipe.
If the tip of the sensor is hit or dropped, replace it with a
new one.
Make sure there is no foreign matter in or damage to the
insertion part of the injector assembly (cylinder head).
(c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
37. CONNECT VACUUM HOSE ASSEMBLY
(a) Connect the vacuum hose assembly to the brake booster
assembly.
39. CONNECT FUEL HOSE NO. 2
(a) Connect the fuel hose No. 2.
NOTICE:
Before proceeding, check that there is no damage to or
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-66)
41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY
(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
(c) Adjust the wire cable and tighten the nut.
A107005
A136082
A133250
EM166
EM
43. INSTALL VENTILATION HOSE
(a) Install the ventilation hose.
44. INSTALL VENTILATION HOSE NO. 2
(a) Install ventilation hose No. 2.
45. INSTALL RADIATOR PIPE
(a) Install the radiator pipe with the 2 bolts and connect the hose.
48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-29)
50. INSTALL CHARCOAL CANISTER ASSEMBLY (See page CO-18)
51. INSTALL RADIATOR RESERVE TANK ASSEMBLY (See page CO-
18)
Yellow Paint
A131812
White Paint
Yellow Paint
A131807
A133397
A136002
A136001
EM167
EM
52. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY
54. CONNECT BATTERY NEGATIVE TERMINAL
55. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor.
57. ADD ENGINE OIL
61. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, stop the engine and wait 5 minutes. Check
that the oil level is between the F mark and L marks. If low,
check for leakage and add oil up to the F mark.
63. CHECK FOR FUEL LEAKS
(a) Check the fuel pump operation.
(2) Follow the prompts on the screen to select ACTIVE TEST
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(b) Check for fuel leaks.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
A
A
B
A136084
EM168
ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE)
EM
CYLINDER HEAD GASKET (K3-VE)
COMPONENTS
.....
T=3.5{36}
BATTERY CLAMP
T=8.5{87}
BATTERY CARRIER
3
BATTERY
T=18{184}
T=7.5{76}
T=7.5{76}
2
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} 11
2
A136903J01
EM169
EM
.....
T=11.5{117}
T=44{449}
T=130{1326}
T=7.5{76}
T=7.5{76}
T=20{204}
4
4
4
T=7.5{76}
T=7.5{76}
3
T=20.6{210}
3
VENTILATION HOSE
CAMSHAFT TIMING OIL
IDLER PULLEY NO. 1
IDLER PULLEY
O-RING
RADIATOR PIPE
SPARK PLUG
O-RING
A136904J02
EM170
EM
T=8.5{87}
T=8.5{87}
T=35{357}
T=35{357}
T=9.3{95}
T=44{449}
T=19{194}
T=32{326}
T=10{102}
T=8.5{87}
T=21{214}
T=7.5{76}
T=21{214}
T=7.5{76}
T=19{194}
T=19{194}
2
3
2
2
2
2
3
COOLANT BYPASS HOSE
THROTTLE BODY ASSEMBLY
INTAKE MANIFOLD
THROTTLE BODY
BRACKET
THROTTLE BODY
BRACKET NO. 2
EXHAUST MANIFOLD HEAT
INSULATOR NO. 1
EXHAUST
MANIFOLD
ALTERNATOR ASSEMBLY
O-RING
GASKET
O-RING
GASKET
A140623J02
EM171
EM
.....
OIL FILLER CAP
CYLINDER HEAD COVER
T=11{112}
T=9.0{92}
11
TIMING CHAIN
CHAIN
T=9.0{92}
TIMING GEAR (CHAIN)
T=19{195}
T=23{235}
2
T=44{449}
T=12{122}
9
3
T=7.5{76}
2
TIMING CHAIN GUIDE
T=7.5{76}
COVER GASKET
TENSIONER ARM
APPLY MP GREASE
A136905J03
EM172
EM
TIGHTENING TORQUE
10
T=12.5{130}
T=12.5{130}
T=47{480}
8
10
16
4
CAMSHAFT TIMING SPROCKET
CAMSHAFT
CAMSHAFT NO. 2
CYLINDER HEAD BOLT
WASHER
CYLINDER HEAD
CYLINDER HEAD GASKET
PLASTIC REGION TIGHTENING METHOD
A137085J01
EM173
EM
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
NOTICE:
Always discharge fuel system pressure before removing any
fuel system components.
As some pressure will remain in the fuel line even after the
fuel system pressure has been discharged, cover the open-
ing with a shop rag or a similar to prevent fuel from splash-
ing.
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
(3) Start up the engine.
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
DTC P0171/25 lean malfunction may be detected.
(5) Crank the engine again, then check that the engine does
not start.
(6) Remove the fuel tank cap to discharge pressure from the
fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.
(See page RS-164.)
3. REMOVE BATTERY CARRIER
(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-78)
22)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-24)
12. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
Instrument Panel J/B
F/P Relay
A135986J01
EM174
EM
(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
(a) Loosen the clip, then disconnect the heater outlet water hose.
15. REMOVE RADIATOR PIPE
(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe.
16. REMOVE VENTILATION HOSE
(a) Loosen the clip and remove the ventilation hose.
17. REMOVE VENTILATION HOSE NO. 2
(a) Loosen the clip and remove ventilation hose No. 2.
A136001
A136002
A133397
A134307
A134308
EM175
EM
(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE
(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
(d) Remove the 2 bolts and disconnect the ground wire.
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR
(a) Remove the 2 bolts and 2 springs, then disconnect the exhaust
pipe assembly FR from the exhaust manifold.
21. REMOVE FUEL HOSE NO. 2
(a) Loosen the clip, then disconnect fuel hose No. 2.
22. REMOVE OIL LEVEL GAUGE GUIDE
(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.
23. DISCONNECT VACUUM HOSE ASSEMBLY
(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
A131808
A133250
A134989
A133396
A136065
EM176
EM
24. REMOVE THROTTLE BODY ASSEMBLY
(a) Remove the 2 bolts and bracket.
(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
(c) Loosen the clamp, then disconnect the water hose.
(d) Remove the 3 bolts and the throttle body assembly.
(e) Remove the 2 bolts and the throttle body assembly.
25. REMOVE FUEL DELIVERY PIPE
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove.
26. REMOVE THROTTLE BODY BRACKET
(a) Remove the 2 bolts and the throttle body bracket.
27. REMOVE FUEL INJECTOR ASSEMBLY
(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
The O-ring may be stuck, but even if it is, do not apply
sideways force to the fuel injector assembly.
If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
A131805
Blue Paint
A131806
BOLT
A134311
A109106
O-ring
Insulator
A107004J02
EM177
EM
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
30. REMOVE VANE PUMP WITH BRACKET (See page EM-79)
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
1.
35. REMOVE MANIFOLD STAY
(a) Remove the 2 bolts and the manifold stay.
A109108
A137714
A133399
A136071
EM178
EM
36. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.
(a) Disconnect the ignition coil connector.
(b) Remove the bolt and the ignition coil assembly.
38. REMOVE CYLINDER HEAD COVER
(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover.
A133400
A133310
A132251
EM179
EM
HINT:
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
40. REMOVE CRANK POSITION SENSOR
(a) Remove the bolt and the crank position sensor.
Notch
Timing Marks
A140612
SST
A139349
SST
A137589
A137713
EM180
EM
(a) Remove the bolt and the camshaft timing oil control valve
assembly.
42. REMOVE TIMING CHAIN (BELT) COVER
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal.
A136072
A133402
A133404
Protective Tape
Wooden
Block
A033132J01
EM181
EM
released.[*1]
HINT:
the right and left.
and hold.[*2]
HINT:
plunger.
HINT:
(e) Remove the bolt and nut and then remove the water inlet.
D-MARK
A135998
A108005
A108555J01
A108556
EM182
EM
49. REMOVE CHAIN
(a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90 (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
A108557
A108558
A108559
Hold
A136076
1
2
3
4
A133124
EM183
EM
NOTICE:
53. REMOVE CYLINDER HEAD
(a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra-
tion, then remove the cylinder head bolt and washer.
NOTICE:
When removing the bolt, do not drop the washer into
the head.
Failure to remove the bolts in the specified order may
damage the cylinder head.
(b) Remove the cylinder head.
54. REMOVE CYLINDER HEAD GASKET
INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
within the range indicated by A in the illustration.
Maximum limit:
8.75 mm
HINT:
Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Install the cylinder head gasket within 3 minutes and tighten
the cylinder head bolts within 15 minutes after applying
Three Bond TB1207B.
tration.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A133125
1
2 3
4
5
6 7
8
9
10
A132854
25mm
20mm
A
A108575J01
Cylinder Head
Cylinder Head
Gasket
Cylinder Block
21-27 mm
0-4 mm
17-23 mm
2.0 mm
2.5 mm
A083197J02
EM184
EM
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
Check that it is installed in the correct direction.
Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD
NOTICE:
Inspect and clean the cylinder head and installation hole.
Tighten the cylinder head using the plastic area tightening
method.
Do not allow oil to get on the lower surface of the cylinder
head.
(a) Install the cylinder head.
NOTICE:
Take care not to damage the cylinder head gasket when
installing it.
Install the cylinder head bolt to the same place it was
removed from.
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
(c) Using an 8 mm double hexagon wrench, temporarily install the
cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec-
ified torque.
(d) Put paint marks on the engine front side of heads of the cylinder
head bolts.
(e) Using the paint mark as a reference, tighten the cylinder head
bolts 180 in the specified order.
(f) Check all the paint marks are now moved 180.
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the Three Bond TB1207B, do not allow it
to enter the bolt hole or knock pin hole.
Front
A033157J01
Apply Engine Oil
A133007
3 1 6 8
7 5 2 4 10
9
A133008
180
Paint Mark
Tighten
A140645
EM185
EM
the piston.
nal part of the cylinder head, and then install the camshaft No.
2.
NOTICE:
5. INSTALL CAMSHAFT
NOTICE:
(a) Confirm the front mark and number of camshaft bearing cap No.
2 and install it.
the illustration.
NOTICE:
(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
NOTICE:
cap No. 1.
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
Camshaft NO. 1
(In Side)
Camshaft NO. 2
(Ex Side)
NO. 3 NO. 4 NO. 4 NO. 2
A137596
E
2
E
3
E
4
E
5
I
2
I
3
I
4
I
5
9
10
11
12
13
14
15
16
5
6
7
8
1
2
3
4
A133070
1
2
3
4
A133071
EM186
EM
(b) Align the camshaft knock pin and the camshaft timing sprocket
shaft.
NOTICE:
(c) Apply a small amount of engine oil to the camshaft timing
(d) Using the hexagon head portion of the camshaft, tighten the
9. INSTALL CHAIN
HINT:
Install so that the mark plate is on the engine front side.
Pin Hole
Knock Pin
Do Not Remove
A136098
Hold
A136076
Timing Mark
Timing Mark
Mark Plates
Timing Mark
A137742
EM187
EM
HINT:
plunger.
plunger.
visible.
A108559
A108558
A108557
A108556
D Mark
A133073
EM188
EM
15. INSTALL TIMING CHAIN (BELT) COVER
(a) Install a new gasket to the timing chain (belt) cover.
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
NOTICE:
Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
TB1207B.
Do not add engine oil within 2 hours of installation.
A108562
Apply Liquid Gasket
A108563J02
B B
A A
3-4 mm 3-4 mm
Apply Liquid Gasket
3-4 mm Diameter 3 mm Diameter
6 mm Diameter
6 mm Diameter
A139363
EM189
EM
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
44 N*m (449 kgf*cm) (Bolts 13 to 15)
206)
SST 09278-87201
NOTICE:
(b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
1
2
7
8
10
13
14
15
3
4
5
6
9
11
12
A136081
SST
A137588
A137713
A136072
EM190
EM
20. INSTALL CYLINDER HEAD COVER
tration.
NOTICE:
TB1207B.
Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
several passes in the order shown in the illustration.
21. INSTALL SPARK PLUG
23. INSTALL EXHAUST MANIFOLD
(a) Install the exhaust manifold using a new gasket.
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
Apply Liquid Gasket
A079650J02
1
2
3
4
5
6
7
8
9
10 11
12 13
A133409
A133310
A133400
EM191
EM
24. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (bolt)
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
29. INSTALL VANE PUMP WITH BRACKET (See page EM-103)
33. INSTALL INTAKE MANIFOLD
(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
(b) Tighten the bolts and nuts in the order shown in the illustration.
A136071
A133399
A137714
A079976J02
EM192
EM
34. INSTALL THROTTLE BODY ASSEMBLY
(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
(f) Connect the engine wire harness.
35. INSTALL FUEL INJECTOR ASSEMBLY
(a) Install a new injector vibration insulator.
(b) Apply gasoline to the new fuel injector assembly O-ring.
(c) Install the fuel delivery pipe while rotating the fuel injector
assembly to the left and right.
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
Do not drop the fuel injector when installing the fuel
delivery pipe.
If the tip of the sensor is hit or dropped, replace it with a
new one.
Make sure there is no foreign matter in or damage to the
insertion part of the injector assembly (cylinder head).
(c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
A109106
O-ring
Insulator
A107004J01
A107005
A136082
EM193
EM
37. CONNECT VACUUM HOSE ASSEMBLY
(a) Connect the vacuum hose assembly to the brake booster
assembly.
39. CONNECT FUEL HOSE NO. 2
(a) Connect the fuel hose No. 2.
NOTICE:
Before proceeding, check that there is no damage to or
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-101)
41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY
(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
(c) Adjust the wire cable and tighten the nut.
43. INSTALL VENTILATION HOSE
(a) Install the ventilation hose.
44. INSTALL VENTILATION HOSE NO. 2
(a) Install ventilation hose No. 2.
A133250
Yellow Paint
A131812
White Paint
Yellow Paint
A131807
EM194
EM
45. INSTALL RADIATOR PIPE
(a) Install the radiator pipe with the 2 bolts and connect the hose.
48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-24)
25)
52. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY
54. CONNECT BATTERY NEGATIVE TERMINAL
55. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
NOTICE:
Check that the O-ring is installed correctly to the throt-
tle body joint.
Check that there is no foreign matter in the throttle
body opening.
Check that there is no foreign matter on the clean side
part of the air cleaner.
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor.
A133397
A136002
A136001
A
A
B
A136084
EM195
EM
57. ADD ENGINE OIL
61. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, stop the engine and wait 5 minutes. Check
that the oil level is between the F mark and L marks. If low,
check for leakage and add oil up to the F mark.
63. Check for fuel leaks.
(a) Check the fuel pump operation.
(2) Follow the prompts on the screen to select ACTIVE TEST
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(b) Check for fuel leaks.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
EM196
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
EM
TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
COMPONENTS
11
2
T=7.5{76}
T=5.4{55}
ENGINE UNDER COVER
FRONT BUMPER COVER
FOG LIGHT ASSEMBLY RH
FOG LIGHT ASSEMBLY LH
.....
A136654J01
EM197
EM
T=7.5{76}
T=7.5{76}
T=7.5{76}
T=7.5{76}
T=5.0{51}
2
2
2
2
4
T=5.0{51}
T=5.0{51}
T=5.0{51}
RADIATOR HOSE NO. 1
CHARCOAL CANISTER
ASSEMBLY
WITH WATER
FAN ASSEMBLY
RADIATOR SUPPORT CUSHION
DRAIN COCK SUB-ASSEMBLY
OIL COOLER
OUTLET HOSE NO. 1
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
RADIATOR ASSEMBLY
RADIATOR CAP
RADIATOR HOSE NO. 2
CHARCOAL CANISTER NO. 1
RADIATOR RESERVE
TANK ASSEMBLY
RADIATOR SUPPORT UPR
A/T
A136655J01
EM198
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
EM199
EM
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page CO-15)
5. REMOVE FOG LIGHT ASSEMBLY RH
6. REMOVE FRONT BUMPER COVER (See page CO-15)
8. REMOVE SEAL PLATE (See page CO-15)
15)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-16)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See
page CO-16)
17. REMOVE RADIATOR ASSEMBLY (See page CO-17)
(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
(a) Using a cutter knife, cut off the lip of the oil seal.
SST
A139349
SST
A137589
EM200
EM
remove the oil seal.
NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign mat-
ter.
Wipe off any grease on the crankshaft.
(b) Using the SST, drive in a new timing chain (belt) cover oil seal
to the position shown in the illustration.
SST 09223-87202
NOTICE:
Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
(c) Standard
(1) Press fit margin
Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)
6. INSTALL RADIATOR ASSEMBLY (See page CO-17)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page
CO-18)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-18)
18)
Protective Tape
A107954J01
SST
A137591
SST
A139349
EM201
EM
15. INSTALL SEAL PLATE (See page CO-19)
17. INSTALL ENGINE UNDER COVER (See page CO-19)
18. INSTALL FRONT BUMPER COVER (See page CO-19)
19. INSTALL FOG LIGHT ASSEMBLY LH
20. INSTALL FOG LIGHT ASSEMBLY RH
21. CONNECT NEGATIVE BATTERY TERMINAL (See page CO-19)
EM202
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
EM
TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
COMPONENTS
11
2
T=7.5{76}
T=5.4{55}
ENGINE UNDER COVER
FRONT BUMPER COVER
FOG LIGHT ASSEMBLY RH
FOG LIGHT ASSEMBLY LH
.....
A136654J01
EM203
EM
T=7.5{76}
T=7.5{76}
T=7.5{76}
T=7.5{76}
T=5.0{51}
2
2
2
2
4
T=5.0{51}
T=5.0{51}
T=5.0{51}
RADIATOR HOSE NO. 1
CHARCOAL CANISTER
ASSEMBLY
WITH WATER
FAN ASSEMBLY
DRAIN COCK SUB-ASSEMBLY
OIL COOLER
OUTLET HOSE NO. 1
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
RADIATOR ASSEMBLY
RADIATOR CAP
RADIATOR HOSE NO. 2
CHARCOAL CANISTER NO. 1
RADIATOR RESERVE
TANK ASSEMBLY
RADIATOR SUPPORT UPR
A/T
A136655J01
EM204
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
EM205
EM
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page LI-33)
5. REMOVE FOG LIGHT ASSEMBLY RH
6. REMOVE FRONT BUMPER COVER (See page ET-2)
8. REMOVE SEAL PLATE (See page AC-57)
22)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-23)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See
page CO-23)
17. REMOVE RADIATOR ASSEMBLY (See page CO-24)
(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
(a) Using a cutter knife, cut off the lip of the oil seal.
SST
A139349
SST
A137589
EM206
EM
remove the oil seal.
NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign mat-
ter.
Wipe off any grease on the crankshaft.
(b) Using the SST, pressure fit a new timing chain (belt) cover oil
seal vertically.
SST 09223-87202
NOTICE:
Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
(c) Standard
(1) Press fit margin
Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)
6. INSTALL RADIATOR ASSEMBLY (See page CO-24)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page
CO-25)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-25)
25)
Protective Tape
A107954J01
SST
A137591
SST
A139349
EM207
EM
15. INSTALL SEAL PLATE (See page CO-26)
18. INSTALL FRONT BUMPER COVER (See page ET-5)
19. INSTALL FOG LIGHT ASSEMBLY LH (See page LI-34)
20. INSTALL FOG LIGHT ASSEMBLY RH
21. CONNECT NEGATIVE BATTERY TERMINAL (See page EM-103)
EM208
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
EM
ENGINE REAR OIL SEAL (3SZ-VE)
COMPONENTS
T=19.1{195}
T=78{800}
T=78{800}
T=27.5{280}
T=8.5{86}
T=8.5{86}
T=68{693}
T=7.5{76}
4
4
10
6
6
6
6
T=10{102}
7
A/T
APPLY MP GREASE
OIL PAN
FRONT SUSPENSION
CROSS MEMBER LWR
ENGINE REAR OIL SEAL RETAINER
FLYWHEEL RING GEAR
M/T
FLYWHEEL
REAR END PLATE
ENGINE REAR OIL SEAL
A139030J01
EM209
EM
REMOVAL
SION)
HINT:
See IP-8 for the procedure leading up to the removal of the transmis-
sion assembly.
SION) (See page EM-49)
SION)
HINT:
sion assembly.
(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
49)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for
4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.
(See page EM-47)
10. REMOVE REAR END PLATE (See page EM-50)
11. REMOVE OIL PAN
(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
Be careful not to damage the oil pan and the cylinder
block.
When removing, take care not to deform the oil pan
flange.
A139023
EM210
EM
12. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 7 bolts and then the engine rear oil seal retainer.
13. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver, pry out the engine rear oil seal.
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
(b) Using the SST, drive in a new engine rear oil seal to the position
NOTICE:
Be careful not to tap the engine rear oil seal at an angle.
After installing it, check that the engine rear oil seal has
been driven in right to the end face.
2. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply Three Bond TB1207B to the engine rear oil seal retainer
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
3. INSTALL OIL PAN
tration (3 to 4 mm diameter).
NOTICE:
Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
Tighten the oil pan to the specified torque within 15
minutes of applying Three Bond TB1207B.
A139034
A139035
SST
Wooden Block
-0.5-1 mm
A139032
3-4 mm
A139033
Liquid Gasket Thickness 3.0-4.0 mm
18 mm
17 mm Liquid Gasket Thickness 1.3-1.5 mm
:Apply Liquid Gasket A139022
EM211
EM
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-59)
PR-4)
6. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
HINT:
See IP-8 for the procedure leading up to the installation of the front
differential carrier assembly.
7. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
HINT:
drive shaft assembly.
8. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
59)
(See page CL-21)
SION)
HINT:
See IP-8 for the procedure leading up to the installation of the trans-
mission assembly.
(See page EM-61)
SION)
HINT:
mission assembly.
EM212
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
EM
ENGINE REAR OIL SEAL (K3-VE)
COMPONENTS
T=19.1{195}
T=78{800}
T=78{800}
T=27.5{280}
T=8.5{86}
T=8.5{86}
T=68{693}
T=7.5{76}
4
4
10
6
6
6
6
T=10{102}
7
A/T
APPLY MP GREASE
OIL PAN
FRONT SUSPENSION
CROSS MEMBER LWR
ENGINE REAR OIL SEAL RETAINER
FLYWHEEL RING GEAR
M/T
FLYWHEEL
REAR END PLATE
ENGINE REAR OIL SEAL
A139030J01
EM213
EM
REMOVAL
SION)
HINT:
sion assembly.
SION) (See page EM-84)
SION)
HINT:
sion assembly.
(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
85)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for
4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.
9. REMOVE REAR END PLATE (See page EM-85)
10. REMOVE OIL PAN
(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
Be careful not to damage the oil pan and the cylinder
block.
When removing, take care not to deform the oil pan
flange.
A139023
EM214
EM
11. REMOVE ENGINE REAR OIL SEAL RETAINER
(a) Remove the 7 bolts and then the engine rear oil seal retainer.
12. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver, pry out the engine rear oil seal.
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
(b) Using the SST, drive in a new engine rear oil seal to the position
NOTICE:
Be careful not to tap the engine rear oil seal at an angle.
After installing it, check that the engine rear oil seal has
been driven in right to the end face.
2. INSTALL ENGINE REAR OIL SEAL RETAINER
(a) Apply Three Bond TB1207B to the engine rear oil seal retainer
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
3. INSTALL OIL PAN
tration (3 to 4 mm diameter).
NOTICE:
Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
Tighten the oil pan to the specified torque within 15
minutes of applying Three Bond TB1207B.
A139034
A139035
SST
Wooden Block
-0.5-1 mm
A139032
3-4 mm
A139033
Liquid Gasket Thickness 3.0-4.0 mm
18 mm
17 mm Liquid Gasket Thickness 1.3-1.5 mm
:Apply Liquid Gasket A139022
EM215
EM
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-94)
5. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
HINT:
differential carrier assembly.
6. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
HINT:
drive shaft assembly.
7. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
94)
(See page CL-21)
SION)
HINT:
mission assembly.
(See page EM-96)
SION)
HINT:
mission assembly.
TO INDEX TO NEXT SECTION

Em 3SZ

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Em 3SZ

Enviado por

Direitos autorais:

Formatos disponíveis

EM

Você também pode gostar