1992 Mazda MX-3 Workshop Manual FOREWORD This workshop manual is intended for use by service technicians of authorized Mazda dealers to help them service Mazda vehicles. It can also be useful to owners and operators of Mazda vehicles in diagnosing some problems and performing limited repair and maintenance ‘on Mazda vehicles. For proper repair and maintenance, a thor- ough familiarization with this manual is impor- tant, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings, and specifications, are the latest available at the time of printing. As modifica- tions affecting repair or maintenance occur, rel- evant information supplementary to this volume will be made available at Mazda dealers. This ‘manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice. Al rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical—including photocopying and recording and the use of any kind of information storage and retrieval sys- ter—without permission in writing ‘Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page. CONTENTS: Engine System Cooling System General Information Pre-Delivery Inspection and ‘Scheduled Maintenance Services B6 SOHC K8DOHC | Lubrication Bs SOHC KeDOHC [Bs SOHC K8 DOHC. Transaxle Fuel and Emission Control Systems Engine Electrical System ‘Automatic B6 SOHC | Electronically Controlled Front and Rear Axles Steering System Braking System ‘Wheels and Tires ‘Suspension Body % Refer to 1992 MX-3 Body Electrical Trou- bleshooting manual (form No. 1289-10-21) for servicing of the body elctrical components. © 1991 Mazda Motor Corporation PRINTED IN JAPAN, JULY, 91) 1281-10-916VEHICLE IDENTIFICATION NUMBERS (VIN) ‘JM EC43t « N¥ 100001 — i aX EXPENDABLE Ra : TORQUE amt ‘Oy ees Tamm a Le > ‘ a \ \ OX a \\ Sg ony] wen shows, ‘ eo OQ rutesnnn Binoy [doe A CO Point oF on, || \. Wel (au ETC, - i. \ yy SHOWS TIGHTENING Serenity ST . FoRQvE UNIT bea 18 Beog ues ca 2a ce sot gage M22 3 cau ip Gispect Gr dhaas ara an|-” —| sows visUAL snows | Estate _— ror WSPEETION RELATED 3 ccna 18: Sine pon INFORMATION Page FOR | ? Ware ‘ato, age thoes Sesvics |b Gries tage : epee sis 2 ii S Sat “tes ae “Kemer of ght ogee Mr ae xe ae oa omuaixeos “1: The numbering (ex @ ) shows service procedure, *2: Units shown in N:m (m-kg, ft-lb) unless otherwise specified. Gi-3GI___ HowTo USE THis MANUAL / FUNDAMENTAL PROCEDURES SYMBOLS There ara six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol ind Ws New engine lor gear oa sero Boy ocho oni te =| eaatomatcransmstion is ony ate oi Apel grease Appropriate greece cml Apply sealant Appropriate sealant © | soy patton joy Aoproprate pataeunjay Ae ‘OSUGIX-005 Note * When special oil or greases is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS ‘As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTE give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle. emucnxcas FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work,FUNDAMENTAL PROCEDURES Gl AWORD ABOUT SAFETY The following precautions must be followed when jacking up the vehicle. 1. Block the wheels, 2. Use only the specified jacking positions. 3. Support the vehicle with safety stands. Start the engine only after making certain the engine compartment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment ate available before starting any work. | aR SPECIAL TOOLS Use special tools when they are required. While correcting a problem, try also to determine Its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for | REMOVAL OF PARTS replacement or repait. aoe DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently. saan Gi-5Gl FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. 2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly. Be sure to Separate or otherwise identity the parts to be replaced from those that will be reused. 3. Cleaning parts for reuse All parts to be reused should be carefully and thorou- ghly cleaned in the appropriate method. TUSROTO REASSEMBLY Standard values, such as torques and certain adjust- ments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text. If removed, these parts should be replaced with new ones: 1.Qil seals 2. Gaskets 3. O-rings 4. Lock washers, 5. Cotter pins 6. Nylon nuts Depending on location: 1.Sealant should be applied or new gaskets used. 2.0il should be applied to the moving components of parts. 8.Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. Gi=6 eaaaeFUNDAMENTAL PROCEDURES Gl OS ADJUSTMENTS Use suitable gauges andior testers when making adjust- ment. RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing. GI-7Gl sack ano sareTy STAND POSITIONS/VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS JACK AND SAFETY STAND POSITIONS FRONT END Jack position: At the front crossmember REAR END Jack positions: At the center of the rear crossmember on Safety stand positions: On both sides of the body frame Safety stand positions: On both sides of the body frame wae VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT END Frame Side sills SHIGE REAR END Frame Side sills aaaTOWING G I TOWING Proper towing equipment is necessary to prevent damage to the vehicle. Laws and regulations applicable to vehicles in tow must always be observed. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use whee! dollies. With either automatic or manual transaxle: ] 4.Set the ignition switch in the ACC position; 2.Place the selector lever or shift lever in N (Neutral), 3.Release the parking brake. Caution * Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transaxles. + Do not use the hook loops under the front and rear of the vehicle for towing purposes. These hook loops are designed ONLY for transport tie~ down. If tie-down hook loops are used for towing, the front/rear bumper will be damaged. “TIE-DOWN HOOKS FRONT REAR Gi-9Gl IDENTIFICATION NUMBER LOCATIONS / UNITS / ABBREVIATIONS. IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFIGATION NUMBER (VIN) AUTOMATIC TRANSAXLE MODEL AND NUMBER UNIT TDS Nm (m-kg or om-kg fb or Torque Pi nenevaion per minuto SS ampere(s) (Natie) a ‘Qhin(s) (resistance) kPa igiom®, pal. Pressure {usualy posite) ee) (usually negative) ieee Caen cea ters (U8 Gh a Volume tiem (Monsees Length mmHg (inHg)... PEGI ABBREVIATIONS ABDC on After bottom dead ‘conter ‘Ar congitioner ‘Accessories ‘Automatic transaxle “Attar top desd center ‘Automatic transmission ‘uid Bypass air control, Before bottom dead ‘center Before top dead center ‘Central processing unit EC-AT. ecu, FGI .€ingine control unit ‘ulnterritent “Motor vncManualtransaxie Electronicaly-controlled ‘automatic transaxle Electronic gasoline injection Eiecttical load Exhaust Integrated circuit Ignition Intake Ile speed control Left hand “Malfunction indicator lamp “Overdtive ‘Switoh of ‘Switch on Positive crankcase entiation Pressure regulator con ‘rol Powor stearing Power window “Right hand -Spacial sorvice tool Start “Site «Top dead centerCAUTION GI CAUTION INSTALLATION OF MOBILE TWO-WAY RADIO SYSTEM if a mobile two-way radio system is installed improperly or if a high-powered type is used, the EGI sys- tem and other systems may be affected. When the vehicle is to be equipped with a mobile two-way radio, observe the following precautions: 1. Install the antenna at the farthest point from control units. 2, Install the antenna feeder as far as possible from the control unit harnesses (at least 30 em [11.8 inp. 3. Ensure that the antenna and feeder are properly adjusted. 4,Do not install a high-powerd mobile two-way radio system. FEEDER WIRE \\_ CONTROL UNIT HARNESS \ \ 7 H [AT LEAST 30 om (189) ENGINE ‘CONTAOL UNIT ABS CONTROL UNIT PASSIVE SHOULDEA BELT ‘CONTROL UNIT wuaaS REMOVAL OF IGNITION KEY ON AUTOMATIC ‘TRANSAXLE MODEL The selector lever must be in P (PARK) to turn the igni- tion key to the OFF position. if the switch seems to be off but the key cannot be removed, the switch may still be in the ACC position, or the selector lever may not be in P (PARK). Shift the selector lever to P (PARK), and turn the ignition key to the LOCK position. The key should now be free for removal. aauaRcees Gl-11 ‘Gl CAUTION AW or 3.400 | RAOEORS ered RED LEAD UNE GROUND ORSINETER, Gi-12 WOES ELECTRICAL TROUBLESHOOTING TOOLS Test Light The test light, as shown in the figure, uses a 12V bulb, The two lead wires should be connected to probes. The test light is used for simple voltage checks and for checking for short circuits. Caution ‘* When checking the control unit, never use a bulb over 3.4W. dumper Wire The jumper wire is used for testing by shorting across switch terminals and ground connections. Caution * Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to harnesses or electronic components. Voltmeter Tho DC voltmeter is used to measure of circuit voltage. A voltmeter with a range of 15V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (©) probe (black lead wire) to a body ground. Diagnosis Connector Insert the probe into the service hole when connecting a jumper wire to the diagnosis connector. Caution * Do not insert the jumper wire probe into the dia- gnosis connector terminal, which may damage the terminal. Ohmmeter The ohmmeter is used to measure the resistance between two points in a circuit and also to check for continuity and diagnosis of short circuits. Caution * Do not attempt to connect the ohmmeter to any circuit to which voltage is applied; this may burn or otherwise damage the ohmmeter.CAUTION Gl uence vanes OSES waa CAUTION WITH ELECTRICAL PARTS Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable. Connectors Removal of connector Never pull on the wiring harness when disconnecting connectors. Connectors can be removed by pressing or pulling the lock lever as shown Locking of connector When locking connectors, make sure to listen for a click that will indicate they are securely locked. Inspection 1.When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side. Gl-13Gl—14 BUSES CAUTION 2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wire harness side. Caution * Use fine wire to prevent damage to the terminal. * Do not damage the terminal when inserting the tester lead. Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal. Replacement of terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks securely. insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector. Same as the female type. Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.CAUTION Gl Fuse Replacement 1, When replacing a fuse, be sure to replace it with one of specified capacity. Ifa fuse again fails after it has been replaced, the circuit probably has a short circuit and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse (B6 SOHC 80A, K8 DOHC 100A). TPEGIR 3.When replacing a pullout fuse, use the fuse puller supplied in the fuse box cover. wena Wiring Harness Bn aay Wiring color codes Beo yetow | 1wo-color wires are indicated by a two-color code symbol. ys The first letter indicates the base color of the wire and the second the color of the stripe. ee BROWN CODE COLOR ‘CODE COLOR @ Black ° ‘Orange eR Brown P Pink UE 7 chal 2 ce ay Gray v Violet L Blue w write iB Light Bive Y Yeliow rr Light Green = a; GI-15SCHEDULED MAINTENANCE SERVICES ] lg se-0 u u snd weds |B Papuan er deb ond - eer = = a z ae Tala BRT ae ee {uy 000'98) Sep 900109 Kine eoedeu 16a 64 oubua 3-20 ius 92°0 % SN Ze°0) 18M EO HOO BY = oe bduisvomsnaroemzooHosea =| yu | elu tale la ly 10 sea 10 eufus oa ulefelulalalels po outuy reuyue SHOS 99 oe a sel 1 1 ‘syeq ang sie a8ourp 0 9901)» | a| 96 | ps |e og | om | oe | oe | a wy 000" < NOILWH3dO SONVNBLNIVIL ooo cqujod uonoadsuy pus ep oansog | -22 | S28 | ev [eve] of [eee] st | ex | sou ooo os [ses] ov [sue] oe [eee] sr [oe | smuon | oyausin, “a Souioo nod (sie\eworm) somu 20 suwoW jo sequiny_| SONVIELINIVEL ae (suonipuog Burvug feunon) 4 ainpeyog ‘seteup pluny fjewonxe Jo;pue sauryeseduer poo Uy apoued peSuorosd oj Bung + ‘ojezedo peads-o) ‘p01 pen 1pasn 918 sjeuejew anysuucos04 ‘Aidde mojaq suowpuoo ou} jo Aue ‘Aide suogjpuoo Buyojoj ou yo @uou e1eum Aureus payesedo st jo1yan e SHOIAYAS JONVNALNIVW GAINdSHOSSCHEDULED MAINTENANCE SERVICES merece = jena woyeedo 7esserduo) ig adinbo y) waisks s2UoNpUOD # nd fee uerebuley ke f Mee Eq = wena we =| SS RTOS TERS |° Be ‘SyOG pu SNE oOo] ye UEBVN + | L (Pod PUE SISSEYD UO SIU PUE SOR EEA SEITE ue BURRIS =| 7 i og SS TUBER <= as) SERS He Ss—U8800) HeweG «| i ST wa UOENETS wo! = wari—o) woo" Fed only = at ee 1 ee ssovssoo) pub uoibladS wd Tayo o aU G88 Bed {ul go’9) wu g’z tou "wn ssauypulped + ord 12.0) wu 09 00H ' 9y029 950 id ore Eeououy uN + ' yea unig aGewep Jo 126m 20) BUJU + aSeyesi pu uojviedo puke O4NA + (ur $F'0—02'0) WI pi—=7S “ford Song + oH (u e0'8—Ze") wi 703-96 1 fepad YoInig. “odie uw) Blu ead + woneied | 7 Tipo RL Wane dong [1 T UOTTS Pie SST TAT OIS 1 vl Seung v aw poeds pL Fizz POT w BUTTS oa u 4 wes 20803 rea way Bu fat) 1 i 348 6ujo09 96 | v8 | 2 | 09 | Oy | oe | we | a wy 000'L *| ee ed saujod uopondsu pue sep soning | 22_|82e | se [eve | oe eee | ot | oe [samme ooo'= o9_| ses | sv oe sez] sr [sz] suwoW | caypuaunt JS4y S@ulod Jenayorym ‘(SsajoUIO{py) SeyUt 10 SyZUOW Jo 1equINN | ONVNSLNIVIN, + (pauoo) + ainpayas |SCHEDULED MAINTENANCE SERVICES (©16-01-6821/ON Wo) enue Bujooyse\qnoay [e2199913 APOE E-KW ZEEI O149}9Y 9M Se SE|OIYaA BLUOYED UO peUUOLed aq OSTe 1! 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UO PeULJO}Jed oq Ose }! JBYI PUBLLIODS: OM OASMOH "BILUO}IED jdooxe SAPEIS [fe UI Paxinos S| EOUEUATUIEUI SIL 1g 0} eBewrep ul ynso1 Aew 119g sILq Bozidos 0} oxnife-4 “(WW 000‘96) Se}|LU 000'09 Alone Ye pexinbe1 si yoq Guy ousGue ox jorueWededey 1. S[eAroqu papuewiuodes ety Je SOUBUAIUIEW Peql-0SEp ey}. Mojo} 0} eNURUCD “(WH 000'96) SAU 000'09 10 SYIUCW! 09 JONY uanyBiy 1ENGINE (B6 SOHC) TROUBLESHOOTING GUIDE Bi- 3 ENGINE TUNE-UP PROCEDUR! BI 5 PREPARATION BI 5 ENGINE OIL, BI- 5 BI- 5 BI- 5 HLA BI-7 IGNITION TIMING, IDLE SPEED...... B1~ 8 COMPRESSION. INSPECTION ON-VEHICLE MAINTENANCE. REAR OIL SEAL. REMOVAL, PROCEDURE . 1-28 ENGINE STAND MOUNTING. 1-35, PREPARATION 1-35 PROCEDURE .. 1-36 DISASSEMBLY PREPARATION AUXILIARY PARTS TIMING BELT. CYLINDER Hi CYLINDER BLOC! (EXTERNAL PARTS) CYLINDER BLOCK (INTERNAL PARTS). INSPECTION / REPAIR. PREPARATION .. CYLINDER HEAD .. VALVE MECHANISM PISTON, PISTON RING, AND PISTON PIN. CONNECTING ROD... CRANKSHAFT, BEARING TIMING BELT. TENSIONER, IDLER.. TENSIONER SPRING. PULLEY. CYLINDER BLOCK (INTERNAL PARTS). CYLINDER BLOCK (EXTERNAL PARTS) CYLINDER HEAD . TIMING BELT. AUXILIARY PARTS ENGINE STAND DISMOUNTING. PROCEDURE INSTALLATION .. PROCEDUREB1 INDEX INDEX j rear NEEAkO ue wee sonatas enaeee ay INSPECTION, PAGE 81-59 ENGINE COOLANT SERVICE, SECTION Et EXHAUST MANIFOLD TIGHTENING TORGUE: > 18-28 (18-23, 12-17) al G_ENGINE ON, H-] BvsPECTION™ REPLACEMENT? SeCTIONDT JZ a, DEFLECTION AT (98 N, 10g, 22 b) rm (in) ORWE BELT ADJUSTMENT, PAGE 81-6 DRIVESELTT NEW USED Gilt] COMPRESSION INSPECTIONPAGE B1-10__ KPa (glen ribrom ALTERNATOR [80-90 (021—055)| B6—100 (088-099) | 1130 86 SOHC PSPS AO [ao-so(aT—c0s)| 86199 (s5—930) | 115/08) | | Standard 7275 (13.0, 186)-500 Ac 0-g0(93i-a55) | Bota ose—as5 | 8.088) | [Minimum 87 {100, 142)-800 = ‘REDD 2 1. Timing belt 6. Engine Removal / Installation ese Page BI-12 REMOVAL .osssseeseeseseenneerens PQS BI-2B 2. Cylinder head gasket Engine stand mounting........... page B1-35 Replacement... .- page BI-16 Disassembly ...mmsnenennne Page B1-38 3. HLA Inspection / Repair. page B1-52 Removal / Installation em page B1~20 Assembly aro page B1~64 4. Front oil seal Engine stand dismou page 81-86 Replacement... page B1-28 Installation page B1-88 5. Rear oil seal Replacement ... page B1~25 B1-2OUTLINE, TROUBLESHOOTING GUIDE B1 OUTLINE ‘SPECIFICATIONS ay Engine Be Sone | i) ceeaeere Gasoline, cycle Cylinder arrangement and number Trine, 4 evlinders z Combustion chaber Pontoot Vale system SORE, beicdiven Tevalves | Displacement weleainy 1588 675) [eo Bore and stoke om fo) FEO K88. (807 S29] Compression rato 30 Compression press Wate pam TEE T30, HH)ROO a Open BDC * ‘Valve timing cose pave: ce ; Open BBC ee | Gd Cisse RDC e | W ar harenancetiee eve deen im On EX 0: Maintenance-free Idle speed tpn Me an ax 7aO—800 range) Tanto wag BT0e oar Firing order ee TROUBLESHOOTING GUIDE Possible Cause ‘ation Page ~~ | Malfunction of engine-related components | Burned vave Replace Bi-s3 Wort piston, piston rng, or cinder Replace orrepar | Bi-s8 60 Fated oyinder head gasket Fepiacs Bis Malfunction of fel system Refer to Secon Malfunction of ignition system Fete fo Secion G Poor ang Malfunction of engine-alated components Matuncion of eR Replace Poor valve tovalve seat contact Replace or repair Replace Refer to Section Ft ‘Malfunction of fuel system Malfunction of ignition system Refer to Section 6 Excessive oll oll working up consumption Wom piston rng groove or sticking piston ring Replace 1-60 Wom piston or cylinder Replace or repair | 81-68, 60 Oil working down Worn valve seal Replace BI, 45, Worn vaive stem or guide Replace Bis Oilleakage Refer to Section DI * Valve noise may occur if the engine has set idle for an extended period. ‘The noise should dissipate after the engine has reached normal operating termperature. (HLA troubleshooting: Refer to page B1~7) B1-3Bi TROUBLESHOOTING GUIDE Problem Possible Cause ‘Action Page insufficient power Insufficient compression Malfunction of HLA Replace Bi-20 Compression leakage from valve seat Repair I-55 Seized valve siem Replace Bi-63 Weak or broken valve spring Replace Bi-36 Failed cylinder head gasket Replace Bi-té (Cracked or distorted cylinder head Replace Bis Sticking, damaged, or worn piston ring Replace Bi-80 Gracked or worn piston Replace I-60 Malfunction of fuel system Refer to Section Ft Malfunction of ignition system Rafer to Section G Others Stioping clutch Refer to Section H Dragging brakes Refer to Section P Wrong size tres Fifer to Section @ ‘Abnormal Malfunction of engine-related components combustion Malfunction of HLA Replace 81-20 Sticking or burned valve Replace Biss Weak or broken valve spring Replace Bi86 Carbon accumulation in combustion chamber Eliminate carbon - Malfunction of fuel system Refer to Section Fi Het Malfunction of ignition system Rieter to Section @ Engine noise ‘Grankshatt- or bearing-related parts Excessive main bearing oll clearance Replace or repair Bi-68 ‘Main bearing seized or heat-damaged Replace Bi-68 [Excessive crankshatt end play Replace or repair 81-69 Excessive connecting rod bearing oil clearance Replace or repair Bi-69 Connecting red bearing seized 0° heat-damaged Replace Bi-69 Piston-rolated parts Worn cylinder Replace or repair Bi-sa Worn piston or piston pin Replace 31-60 Saized piston Replace 81-60 Damaged piston ring Replace Bi-60 Bant connecting roo Replace 51-61 ‘Valves or timing-related parts Masfunction of HLA* Replace 31-20 Broken valve spring Replace Bi-66 Excessive valve guide clearance: Replace 81-63 Malfunction of cooling system Refer to Section £1 aifunction of fuel system Bieter to Section Fi ‘Others Malfunction of water pump bearing Refer to Section Et Improper drive belt tension Adjust BI-5 Malfunction of alternator beating Refer to Section @ Exhaust gas leakago Refer to Section Ft Maltunction of timing belt tensioner Replace Bt-13 TPECBT OCH * Valve noise may occur if the engine has set idle for an extended period. The noise should dissipate after the engine has reacted normal operating temperature. (HLA troubleshooting: Reler to page B17) B1-4ENGINE TUNE-UP PROCEDURE ENGINE TUNE-UP PROCEDURE B1 PREPARATION ssT 49 9200 020 For 49 B019 940 For inspection of inspection of Tension gauge, rive belt tension | System selector ignition timing Veribbed belt and icle speed “su8% a leeerereeeeee ENGINE OIL | Inspection | 1.Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature | and stop it 8. Wait for 5 minutes. 4, Remove the oil level gauge and check the oil level and condition, 5.Add or replace oil if necessary. é Pee UOT deal x \V-RIBBED BELT Levent) aaeale ° x TBUOBR OR Note © The distance between the L and F marks on the level gauge represents 0.8 liter (0.85 US qt, 0.70 Imp qt). ENGINE COOLANT Inspection Coolant level (engine cold) Warning « Never remove the radiator cap while the engine is hot. «Wrap a tl removing it. k cloth around the cap when 1. Verify that the coolant level is near the radiator filler neck. 2. Check that the coolant level in the coolant reservoir is, between the FULL and LOW marks. 3. Add coolant if necessary. Coolant quality 1. Verify that there is no buildup of rust or scale around the radiator cap or radiator filer neck. 2. Verify that the coolant is free of oil. 3. Replace the coolant if necessary. DRIVE BELT Inspection 1. Remove the air intake pipe. 2. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 3. Verify that the drive belts are correctly mounted on the pulleys. B1-5Bi ENGINE TUNE-UP PROCEDURE [ALTERNATOR \ ay \ Aas (Pune Cy \euey ALTERNATOR ey =) a4 eat i prs JoRANKSHAET AOS, \ J AULLEY La are Ks oR RRRBHAET / PULLEY ‘COMPRESSOA pgttey 7 ( = \___doombressdn| PULLEY Ss Re fon vie (PULLEY), \ dé PIS AND ANG PET Ie o) 7 WHEN SET E061 000 4. Check the drive belt deflection by applying moderate pressure (98 N, 10kg, 22 Ib) midway between the pulleys. Note * Measure the belt deflection between the specified pulleys. * A belt is considered “New” if it has been used on a running engine for less than 5 minutes. Set the deflection specified below accordingly. * Check the belt deflection when the engine is cold, or at least 30 minute after the engine has stopped. Deflection oer Drive bor New Used Tint 30-80 So—106 115 Alternator (o3i—o.3s) | 0.35~0.39) (0.48) 8.09.0 9,010.0 15 PIS,PIS+AC] 31-035) | 035-039) (0.45) a 80-90 2010.0 115 (0310.95) | (0.35-0.39) (0.45) 5.1f the deflection is not within specification, adjust it 6. Install the air intake pipe. Drive belt tension check Note © Belt tension can be checked in place of belt deflection. © Belt tension can be measured between any two pulleys. 1. Remove the air intake pipe. 2. Using the SST, check the belt tension. 1606-007 Tension N (ig. b) Drive belt New Limit or BOTS jAternator | foo47,058—1004)| (50-76, 110-167) 491580 22491 PIS, PIS +N] 50 eo 110192) | us—80. 96-110) | (30, 85—110) ie 1589 422401 | 422401 ooo, 110-13) | use, 96110) | 43-80, 05—10) 2. If the tension is not within specification, adjust it. 4. Install the air intake pipe. Adjustment Caution * Ifa new belt is used, adjust the belt deflection at the midpoint of new belt specification. Altemator belt 1. If necessary, loosen the alternator mounting bolts @ and adjusting lock bolt ®. 2. Lever the alternator outward and apply tension to the belt.ENGINE TUNE-UP PROCEDURE J95C WM Bi yaaa Beer seeaes SEE TaGBT oe HLA Tightening torque ® @ :37—52 Nam (3.85.3 m-kg, 27-38 ft-lb) ay @® : 19-25 Nm (1.92.6 m-kg, 14—19 ft-lb) wv ee ree P/S belt, P/S + A/C belt ae \_4£, ® If necessary, loosen the P/S oil pump bolts @ and nut ®) cance a Za and © and adjust the belt deflection by turning the eae | adjusting bolt © Nee z Tightening torque oe @® :36—54 N-m (3.7—5.5 m-kg, 27—40 ft-Ib) TPEOBI-010 © : 19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb) © :31—46 Nm (3.2—4,7 m-kg, 23—34 ft-1b) AIC belt WT If necessary, loosen the locknut @ and adjust the belt MY deflection by turning the adjusting bolt ®) . Vics ‘ Tightening torque: fenankseaet (NG S 4 I (ruter |" — (coupheston 31—34 Nim (3.2—3.5 m-kg, 2325 ft-lb) Problem Possible cause Ration 7, Noise when engine is started immediately after oll is charged. 2, Noise when engine Is started after setting approx. one day. Gil leakage in oil passage 3. Noise when engine is started after cranking for 3 seconds or more. 4, Noise when engine is started after new HLA is installed. ‘Gil Teakage in HLA Fun engine at 2,000—3,000 rpm. noise stops after 2 second—10 minutes (*), HLA is normal. not, replace HLA, "Time required for engine oil to circulate within engine, includes tolerance for engine oil condition and ambient temperature, '5 Noise continues more than 10 minutes, Tnsufcient all pressure Check oll pressure, {flower than specification, check for cause. Oil pressure: 294392 kPa (B.0—4.0 kgiem?, 43—57 psi)-3,000 rpm Faulty HLA (Refer to page 81-59.) ross down HLA by hang. it does not move, HLA Is normal It it moves, replace HLA. Measure valve clearance, more than Om (0 in), replace HLA. . Noise occurs during idle after high speed running, Tnoorrect al amount ‘Check ol level Drain or add oli as necessary Beteriorated of (Check cil quality. I deteriorates, replace with spectied type and amount of oi PEGETOT Bi-7ENGINE TUNE-UP PROCEDURE Sas To cONNEST TACHOMETER, FETE Teno Lock BOLTS B1-8 aL oo IGNITION TIMING, IDLE SPEED Preparation 4. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. 3. Connect the SST to the diagnosis connector, 4. Connect the timing light. 5.Connect a tachometer to the diagnosis connector IG- terminal as shown. 6. Set switch A to position 1. 7. Set TEST SW to SELF-TEST. Note © If the SST is not used, jump across the (TEN) terminal and the (GND) terminal of the diagnosis connector. Ignition Timing inspection / Adjustment 1. Perform preparation. (Refer to above.) 2. Check if the timing mark (Yellow) on the crankshaft pulley and the mark on the timing belt cover are aligned. Ignition timing: 9—11° (10 + 1°) BTDC 3.f the marks are not aligned, loosen the distributor lock bolts and turn the distributor to make the adjustment. 4. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 Nem (1.92.6 m-kg, 14—19 ft-lb) 5. Disconnect the SST.ENGINE TUNE-UP PROCEDURE B1 \ Ale ‘ADUUSTING SCREW weaa 18 Idle Speed 4, Perform "Preparation’. (Refer to page 81-8.) 2. Apply parking brake. 3. Check that the idle speed is within specification Idle speed (Neutral or P range): ‘700—800 (750 =: 50) rpm Caution * Check the idle speed without the electric cooling fan operating. 4.1f not within the specification, adjust the idle by turning the air adjusting screw. 5. Disconnect the SST. B1-9Bi COMPRESSION COMPRESSION Ifthe engine exhibits low power, poor fuel economy, or poor idle, check the following: 4. Ignition system (Refer to Section G.) 2. Compression 3. Fuel system (Refer to Section F1.) TPEwBTOTS PEGI OTe Bi—-10 Ew sPeoBt-o18 INSPECTION 1. Check that the battery is fully charged. Recharge it if necessary. (Refer to Section G.) 2. Warm up the engine to normal operating temperature. 3. Tum the engine OFF. 4, Remove all spark plugs. 5. Disconnect the ignition coil connector. 8.Conneet a compression gauge to the No.1 spark plug ole. 7.Fully depress the accelerator pedal and crank the engine. 8. Record the maximum gauge reading. 9. Check each cylinder. Compression kPa (kg/om’, psi} BESOHE Sandad 1275 (18.0, 1665-500 Minimum 98 (10.0, 149)-00, grees 196 (2.0, 28) 10. f the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and recheck the compression, (1) If the compression increases, the piston, piston rings, of cylinder wall may be worn. (2) If the compression stays low, the valve may be stuck or seating improperly. (8) If the compression in adjacent oylinders stays low, the cylinder head gasket may be defective or the cylinder head distorted. weoe1 126 12. Install the spark plugs. Tightening torque: 15—23 Nem (1.52.3 m-kg, 11—17 ft-lb)ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE B1 PREPARATION ssT 49 Do11 102 For 49 E011 1A0 For removal / prevention of Lock tool, Z staiaton of | Brake set, ring engine rotation corankshat & timing belt pulley | gear = $ 49 E011 103 For 49 E011 108 For prevention of prevention of Shaft ‘engine rotation | Collar @ engine rotation (Past of (Partof AQEOI1 140) 49 £011 1A0) 49 £011 105 For 49 SEO1 310A For prevention of installation of Stopper engine rotation | Centering tool, clutch disc (Part of teh disc 49 E011 108) TPECBT OTeBi TIMING BELT Removal / Installation 1. Disconnect the negative battery cable. 2. Lift up the vehicle. ON-VEHICLE MAINTENANCE 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to Installation Note. OW rast nm toms caste) @® ett Ne aS @ Saree) NHN 1. Undercover and side cover 2. P/S and/or A/C drive beit Inspection omen .. page BI 5 3. Alternator drive bel IMspeCtiOR oer page BI1~ 5 Adjustment . page B1- 6 4, Water pump pulley 5. Plate 6. Pulley lock bolt Removal Note page 1-13 Installation Note ws .. page B1-15. 7. Crankshaft pulley and pulley boss 8. Pullyey boss 9. Timing belt cover, upper B1-12 157107 1647, 15122) See Dy actin a LE Qe ; 7-41 Nom wos 0emAg, | 995i) wo ES eae 217 (135-15, 09-152) ~®) i re ay 40. Timing belt cover, lower 41. High-tension leads 12. Spark plugs 43. Timing belt Removal Note . page BI-13 Inspection... page B1-13 Inspection Note page B1-14 14, Tensioner Inspection... page B1-64 Installation Note 15. Tensioner spring Inspection Instalatio page B1-14 page B1~64 page 81-14ON-VEHICLE MAINTENANCE B1 MARK pinEcTiON GE ROTATION. a jy DAMAGE, hi | | Pewee Removal Note Pulley lock bolt 1. Remove the plate mounting bolts, and then the plate. 2. Hold the pulley boss with the SST. 3. Using the SST, loosen the pulley lock bolt. 4, Remove the pulley lock bolt and pulley. Timing belt 4. Install the pulley lock bolt and turn the crankshaft. (the pin on the pulley boss faces up-right) Caution © Do not turn the crankshaft while removing the pulley lock bolt. 2, Remove the timing belt. Note * Mark the timing belt rotation for proper reinstallation. Inspection Referring to page B1-84, inspect the following parts: 4. Timing belt 2, Timing belt tensioner and spring 3, Timing belt pulley 4, Camshatt pulley B1-13950 WM ON-VEHICLE MAINTENANCE © TIMING MARK A /f Brea Bi-14 UCB TTS Installation note Tensioner, tensioner spring 1. Install the tensioner and the tensioner spring. 2. Temporally secure the tensioner with the spring fully extended. Timing belt 1. Verify that the timing belt pulley mark is aligned with the timing mark. 2. Install the timing belt so that there is no looseness at the tension side. Caution © Do not turn the crankshaft counterclockwise. 3. Install the pulley boss and pulley lock bolt. 4. Tum the crankshaft two turns clockwise, and face the pin on the pulley boss up-right. 5. Verify that the camshaft pulley marks are aligned with the cylinder head cover marks. If not aligned, remove the timing belt and repeat from tensioner installation. 6. Loosen the tensioner lock bolt to apply tension to the timing belt. Caution * Be sure not to apply tension other than that of the tensioner spring. 7. Tighten the tensioner lock bolt. Tightening torque: 1925 Nem (1.92.6 m-kg, 14—19 ft-lb)osc WM ON-VEHICLE MAINTENANCE B1 cen (10 i, 22 1) cee BiEwER DNS PED Steps After Installation 1, Connect the negative battery cable. 2, Start the engine and check as follows: * Ignition timing. (Refer to page B1-8.) 8. Turn the crankshaft 2 turns clockwise and verify that the marks are correctly aligned. 9. Check the timing belt deflection by applying moderate pressure (98N, 10kg, 22 Ib) midway between the crankshatt pulley and the camshaft pulley. if the timing belt deflection is not correct, temporarily secure tensioner lock bolt so the spring is fully extended and repeat steps 4—8 above or replace the tensioner spring. Deflection: 11.0—13.0mm (0.43—0.51 in) at 98 N (10 kg, 22 Ib) 10.Remove the pulley lock bolt and pulley boss using the SST. Pulley lock bolt Install the crankshaft pulley and tighten the pulley lock bolt using the SST. Tightening torque: 157—167 N.m (16—17 m-kg, 116-123 ft-lb) Spark plug Install the spark plugs. Tightening torque: 15—23 Nem (1.5—2.3 m-kg, 11—17 ft-lb) sPe0at023 B1-15 | |B1 ON-VEHICLE MAINTENANCE CYLINDER HEAD GASKET Replacement Warning « Release the fuel pressure. (Refer to Section F1.) * Keep sparks and open flame away from the fuel area. Caution © Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3, Remove in the order shown in the figure, referring to Removal Note. 4, Install in the reverse order of removal, referring to Installation Note. 49-0.9 Nm (60-00 cms, 42-70 nib) oO 7241 Nm eet emag, oO omg, 69—95imb) 3782 (98-59,27-29) Hm (mg) reve oa8 B1-16ON-VEHICLE MAINTENANCE Under cover and side cover . Air hose assembly Resonance chamber duct Accelerator cable Installation Note... . Throttie cable (ATX) Removal / Installation... . Hoses Removal / Installation Note... 7. Harnesses Removal / Installation Note. 8. Water bypass pipe nut 9. Drive belt 10. Water pump pulley page BI-19 Section K1, K2 2 7 seNe sone below page B1-18 Remove / Installation note Hoses Disconnect the hoses shown in the figure. 11. Cylinder head cover 12, Timing belt cover, upper 13, Timing belt Removal / installation . .. page B1~12 14, Front exhaust pipe 15. Intake manifold bracket 16. Cylinder head bolt Removal Note page B1-18 Installation Note .sssemnenee PAGE BI 17..Cylinder head Disassembly ..... page B1~43, Inspection .. snnenee page BI-S1 Assembly “.- page B1~78 18. Cylinder head gasket 1E001.025 1, Brake vacuum hose 2. Fuel hose | | | | | corre 3, Vacuum hose (Purge control) 4, Heater hose B1-17B1 ON-VEHICLE MAINTENANCE Harnesses Disconnect the harness connectors shown in the figure. panne Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. Bi—18 conserON-VEHICLE MAINTENANCE B1 © ® © © @ DaUGEN OKs Steps After Installation Installation note Cylinder head bolt 1. Apply clean engine oil to the bolt threads seat faces, 2. Install the cylinder head bots. 3, Tighten the cylinder head bolts in two or three steps in the order shown in the figure. Tightening torque: 76—81 Nim (7.78.3 m-kg, 56—60 ft-lb) Accelerator cable 4. Install the accelerator cable. 2. Check the accelerator cable deflection. If the deflection is not correct, adjust by tuning nut ®. Deflection: 1—3mm (0.04—0.12 in) 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E1.) 2. Connect the negative battery cable. 3. Start the engine and check as follows: (1) Engine oil and engine coolant leakage. (2) Ignition tir ing, idle speed. (Refer to page 81-8.) (3) Operation of emission control system. (Refer to Section F1.) 4, Recheck the engine coolant levels. 1Pe08%.026 B1-19B1 HLA Removal / Installation 1. Disconnect the negative battery cable. ON-VEHICLE MAINTENANCE 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. 159-98 nib) tion gmk E00 027 1. Cylinder head cover 4, Rocker arm spring Installation Note... page B1-21 5, Rocker shaft 2. Rocker arm and rocker shaft assembly 6.HLA Removal Note...... page B1-21 Installation Note...... soe page B1-21 Installation Note.. page Bi-21 7. O-ring 3. Rocker arm B1—20ON-VEHICLE MAINTENANCE B1 YeLLow iN edi al x SEALANT, HeAD COVER ay GasKer e \wh ® Cony Removal note Rocker arm and rocker shaft assembly 1, Loosen the bolts in the order shown in the figure. 2. Remove the rocker arms and rocker shatt assembly. 3.Code all rocker arms and springs so that they can be reinstalled in the same places from which they were removed. Installation note HLA 1. Pour engine oll into the oil reservoir in the rocker arm, 2. Apply engine oil to the new HLA. 3. Install the HLA in the rocker arm. Caution * Be careful not to damage the O-ring when installating. Rocker arm and rocker shatt assembly 4. Assemble the rocker arm and rocker shaft assembly as ‘shown in the figure. Caution © Face the rocker shaft identification mark upward. © The installation bolt holes are different for the exhaust and intake sides. Identification mark Yellow green Pink 2. Install the rocker arm and rocker shaft assembly. 3. Tighten the bolts in the order shown in the figure. Tightening torque: 22-28 N-m (2.2—% .9 m-kg, 16—21 ft-lb) Cylinder head cover Install the cylinder head cover. Tightening torque Bolt@: 4.9—8.8 N-m (S0—90 cm-kg, 43—78 in-Ib) Bolt@®): 7.8—11 N-m (80—110 cm-kg, 69—95 in-Ib) Caution © If the head cover gasket is reused, apply sealant in the groove as shown. B1-21J95c WM B1 ON-VEHICLE MAINTENANCE Steps After Installation 4. Connect the negative battery cable. 2. Start the engine and fully warm up. 3. Verify that there is no tappet noise. B1-22 sPE0at-031ON-VEHICLE MAINTENANCE B 1 FRONT OIL SEAL Replacement 4. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. om ok, TPEDBT 2 1, Timing belt 3, Timing belt pulley Removal / Installation... page B1-12 Installation Note.. - page B1-24 2. Timing lock bott 4. Oil seal Installation Not page B1-24 Removal Note.. below Installation Note. Bi-24 Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. | | Removal note |B1 ON-VEHICILE MAINTENANCE DiEOBR OS? ‘aEDBI-r Steps After Installation 1. Lower the vehicle. 2. Connect the negative battery cable. Installation note Oil seal 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. Caution © The oil seal must be tapped in until it is flush with the edge of the oil pump body. 3. Tap the oil seal in evenly with a suitable pipe and a hammer. il seal outer diameter: 50.5mm (1.98 in) Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley Woodruff key with the tapered side toward the oil pump body. Pulley lock bolt Hold the crankshaft with the SST and tighten the pulley lock bott. Tightening torque: 157—167 Nim (16—17 m-kg, 116—123 ft-lb) 3. Start the engine and check, and if necessary adjust, the ignition timing. B1-24 ‘9€081.019ON-VEHICLE MAINTENANCE B1 REAR OIL SEAL Replacement 4. Disconnect the negative battery cable. 2, Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. 75 (eae, Sacto, Ne ok fb) P08 1. Transaxle 3. Flywheel (MTX) MTX Removal Note.. .. below Senvice .. vw. Seotion J1, J2 Installation Not "page B1-26 ATX 4, Drive plate (ATX) Service... Section K Removal Note... page B1-26 2, Clutch cover, clutch disc installation Not page B1-27 Service .. Section 5, Oil seal Removal Note.. . page B1-26 Installation Not page B1-26 Removal note Flywheel (MTX) 1. Hold the flywheel with the SST or equivalent. 2. Remove the flywheel lock bolts. 3. Remove the flywheel. POET CHR B1—25ON-VEHICLE MAINTENANCE BPE OCR SURES wauee oe PRUDET OSE Drive plate (ATX) 1. Hold the drive plate with the SST or equivalent. 2. Remove the drive plate lock bolts. 3. Remove the backing plate, drive plate, and adapter. Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal with a screwdriver protected with a rag. Installation note Oil seal 1. Apply a small amount of clean engine oll to the lip of a new oil seal. 2, Push the oil seal slightly in by hand. Caution ‘* The oil seal must be tapped in until itis flush with the edge of the rear cover. 3. Tap the oll seal in evenly with a suitable pipe and a hammer. Oil seal outer diameter: 100mm (3.94 in) Flywheel (MTX) 1. Remove the sealant from the flywheel bolt holes in the crankshaft and from the flywheel bolts. Caution © If all the previous sealant cannot be removed from a bolt, replace the bolt. ‘* Do not apply sealant if a new bolt is used. 2, Set the flywheel onto the crankshatt. 3. Apply sealant to the flywheel bolts and install them. 4. Hold the flywheel with the SST or equivalent 5. Tighten the bolts in two or three steps in the order shown in the figure, Tightening torque: ‘96—103 N-m (9.8—-10.5 m-kg, 71—76 ft-lb)ON-VEHICLE MAINTENANCE Bi Tae os UOT OTS Step After Installation 1. Connect the negative battery cable. Drive plate (ATX) 1. Remove the sealant from the drive plate bolt holes in the crankshaft and from the drive plate bolts. Caution © If all the previous sealant cannot be removed from a bolt, replace the bolt. © Do not apply new sealant if a new bolt is used. 2. Install the adapter, drive plate, and backing plate onto the crankshaft. 3. Apply sealant to the drive plate bolts and install them, 4, Hold the drive plate with the SST or equivalent. 6. Tighten the bolts in two or three steps in the order ‘shown in the figure. Tightening torque: ‘96—103 Nim (9.8—10.5 m-kg, 71—76 ft-lb) 2. Start the engine and perform engine adjustments as necessary. csuoex.ore Bi-27B1 REMOVAL REMOVAL Warning © Release the fuel pressure. (Refer to Section Ft.) PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant and transaxle oil. 8. Remove in the order shown in the figure, referring to Removal Note. Step 1 FEET 1. Undercover and side cover 8. PIS and/or AC drive belt 2. Air cleaner assembly Removal page B1-5 3. Battery and battery cover 9. PIS oil pump ai 4, Battery carrier Removal Note.. .. page B1~29 8. Accelerator cable 10. A/G compressor 6. Resonance chamber Removal Note. . page B1-29 7. Radiator hose B1-28Step 2 alas REMOVAL Bi Removal note PIS oil pump Caution ‘¢ Do not damage the hoses. 4. Remove the P/S oil pump with the hose still connected. 2. Position the pump away from the engine and affix it with wire. AIC compressor Caution ® Do not damage the hoses. 1.Remove the A/C compressor with the hoses still connected. 2. Position the compressor away from the engine and affix it with wire, Disconnect the hamess connectors shown in the figure. ere, B1-29B1 REMOVAL Step 3 Disconnect the hoses shown in the figure. \ Peter a3s 1. Brake vacuum hose 3. Vacuum hose (Purge control) 2. Fuel hose 4; Heater hose Removal Note.. .. below Removal Note... below Removal note Fuel hoses Warning * Keep sparks and open flame away from the fuel area. Caution * Cover the hose with a rag because fuel will spray out when disconnecting. * Plug the disconnected hoses to avoid fuel leak- age Disconnect the fuel hoses. Heater hose Caution © Heater hose joint has O-rings and spacer. * Do not lose them when removing. Push the heater hose retainer and remove the heater hose. \ B1—30 SPEDOTGRTREMOVAL B 1 Step 4 PED ORD 1. Speedometer cable 7. Stablizer 2. Clutch release cylinder 8. Tie rod end Removal Note. .. page B1-32 3, Shift control rod (MTX) 9, Lower arm 4, Extension bar (MTX) 10. Engine mount member 5. Shift control cable (ATX) Removal Note... . page B1-32 6. Front exhaust pipe 11, Driveshaft Removal Note....... sa page B1-82 Removal note Clutch release cylinder (MTX) 1, Remove the release cylinder pipe bracket from the transaxle. 2.Position the release cylinder away from the transaxle for easier removal with the hose still connected. Caution Do not damage the pipe or hose. B1-31REMOVAL ened ) .No2 ENGINE MOUNT //T] ae i \ =| ENGINE MOUNT BROT ToT Tae ea? Tie-tod end 1,Remove the cotter pin and loosen the nut so that it flushes with the ball joint edge. 2. Separate the knuckle arm and ball-joint with the SST. Caution © Do not reuse the cotter pin. Engine mount member 4. Suspend the engine with a chain block. 2, Remove the No.1 and No.2 engine mount nuts. 3. Remove the engine mount member bolts and nuts and the engine mount member. Caution © Be careful so that the engine does not fall when removing the member. Driveshaft 1, Remove the bolts and nuts at the left and right lower arm ball joints. 2, Pull the lower arm downward to separate them from the knuckles, Caution * Do not damage the ball joint dust boots. 3. Separate the driveshafts from the transaxle by prying with a bar inserted between the shaft and the case, Caution * Do not damage the oil seal.REMOVAL B1 Step 5 or 4. Dynamic damper 4, Engine and transaxle assembly 2. No.3 engine mount rubber Removal note below 3. No.4 engine mount rubber and bracket Removal note Engine and transaxle assembly Caution : : « Do not damage any components in the engine compartment. Lift the engine and transaxle assembly out as a unit. PEELE B1-33B1 REMOVAL Step 6 Separate the engine and transaxle in the order shown in the figure. Tx ATX Panarow 4. Starter and bracket 4, Torque converter nuts (ATX) 2. Throttle cable (ATX) 5, Transaxle mounting bolts 3. No.2 engine mount rubber and bracket 6. Transaxle B1-34ENGINE STAND MOUNTING B1 ENGINE STAND MOUNTING PREPARATION Sst 49.0107 680A For | 49 LO10 1A0_ For A] | disassembly and | STP | esassembiy and Engine stand assomby ot | Hanger set = asoombly of engine engine stand (Cg | ensine 49 L010 10% For 49 L010 102 For cisessembly and disassembiy and Pato aecemby of | Arme assombly of ar ot engine Par ot engine foL010 140) 488 LO10 1A0) 49 Lo10 109 For 49 Loto 104 For Gsassombly and cisassembly and ‘Hooks fo) assembly of ‘Nuts 6 assembly of Cantor engine (Partot engine $0 1L010 140) #9 L010 140) ooo Oy le _ [ewowm rs Seer oo: © Never forcefully twist, turn inside out, or bend the timing belt. ‘© Do not allow oil or grease on the belt. Bae 1. Replace the timing belt if there is any oil or grease on it. 2.Check the timing belt for damage, wear, peeling, aus cracks, and hardening. Replace the timing belt if WEAR necessary. oar TENSIONER, IDLER Caution * Do not clean the tensioner or idler with cleaning fluids. If necessary, use a soft rag to wipe them clean, and avoid scratching them. Cheek the tensioner and idler for smooth rotation and abnormal noise. Replace the tensioner or idler if necessary. weer TPEDBT OS TENSIONER SPRING Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length: 64.0mm (2.520 in) PULLEY Timing Belt Pulley, Camshaft Pulley Caution Do not clean the pulleys with cleaning fluids. If necessary, use a soft rag to wipe them clean, and avoid scratching them. Inspect the pulley teeth for wear, deforrhation, and other damage. Replace the pulley if necessary. B1-64 TPEDBT-OGSASSEMBLY B1 ASSEMBLY PREPARATION Sst ¥ 40! AOR: i For 49 L011 001 a For ont “ removal and S. removal and. Peston pn seting Irtalatorot | Sport back Intaaton o tool set SSS piston pins body piston pins ee ar S& SouDtt oom) so.oit008 for 491011 005 For ae dee screw Froalatorot | Stopper bot Iter ot ancl focnnho. | Gator poenies OLDE onoA) {Ott on0A) 491011 008 For soto11 007 For eee dare Par & instar Insalatorot | Guide Insslaton of arat foenpie | Carat pons {eLbi1 onon) {eLbI1 onan) so.oi1 o10 For sotott ott for nee ree a rete g saa Genie A sealant | ioe, iain 49 L011 OAOA) 49 LO11 OAOA) ag HOTT O78 For 49 E011 1A0 For ’ eee ee Support block Irtalatonot | Ring gear brake Bigot reed > foonpee. | set soeoit 108 For soot 105 For oa ae Shat Srgerclaton | Stopper Sige thon (Part of (Part of 49 £017 1A0) 49 E011 1A0) 49011 108 For 491012080 ae nena Fealtion of Colar @ Grgreroteton | instar oot, ce (Part of valve seal & (peor 110) oe souor20o1 fw douorz ce For Fetal of etalon ot instar ete valve sete Patol Cater SSlote ono) {oot ono) Revised 2/93 (1992 K-33) B1—65