EM ENGINE MECHANICAL

TO INDEX 

 

 

 

 

 

 

 

 

 

 

 

EM

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ENGINE MECHANICAL ENGINE MECHANICAL SYSTEM (3SZ-VE) 

ENGINE MECHANICAL SYSTEM (3SZ-VE) 

MECHANICAL 

OPERATION CHECK 

EM–1 

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: 20°C) 

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. 

EM 

A001259 

Water Pump 

Measuring Position 

Idler Pulley No. 2 

5. CHECK V-BELT TENSION AND DEFLECTION 

(a) Check the V-belt tension and deflection using the belt tension 

gauge. 

Standard 

Alternator 

Crankshaft 

Idler Pulley 

A/C Compressor 

A136268 

Item 

When Installing New 

Part 

When Inspecting 

Tension [N (kgf)] 883±49{90±5} 441±98{45±10} 

Deflection (Thrust 

power: 100 N (10.2 kg)) 

(mm) 

9-11 13-15 

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.



(2) Follow the prompts on the screen to display the DATA 

LIST / IGNITION TIMING #1 screens, and measure the 

ignition timing. 

Standard: 

BTDC 0-15°CA 

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. 

M 

EFIT 

E 

G100942 

(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 85°C, have an engine oil temperature 

of 60°C, 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.



Compression Gauge 

A136273 

(e) 

(f) 

Disconnect all the injector connectors. 

NOTICE: 

Stop fuel injection to prevent unburned fuel from damaging 

the catalyst. 

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.


ENGINE MECHANICAL ENGINE MECHANICAL SYSTEM (K3-VE) 

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) 

M 

3. INSPECT BATTERY SPECIFIC GRAVITY 

(a) Check the specific gravity of each cell. 

Standard: 

1.25 to 12.9 V (Liquid temperature: 20°C) 

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. 

A001259 

Water Pump 

Alternator 

Measuring Position 

Idler Pulley No. 2 

Idler Pulley 

5. CHECK V-BELT TENSION AND DEFLECTION 

(a) Check the V-belt tension and deflection using the belt tension 

gauge. 

Standard 

Item 

When Installing New 

Part 

When Inspecting 

Tension [N (kgf)] 883±49{90±5} 441±98{45±10} 

Deflection (Thrust 

power: 100 N (10.2 kg)) 

(mm) 

9-11 13-15 

Crankshaft 

A/C Compressor 

A136268 

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 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 

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.



(2) Follow the prompts on the screen to display the DATA 

LIST / IGNITION TIMING #1 screens, and measure the 

ignition timing. 

Standard: 

BTDC 0-15°CA 

NOTICE: 

Check the ignition timing with the A/C off, the electrical 

fan off, and the shift lever in the N and P positions. 



EFIT 

E 

G100942 

(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). 

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 temperature 

of over 85°C, have an engine oil temperature of 

60°C, 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.



M 

Compression Gauge 

A136273 

(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 ) 


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.

ENGINE MECHANICAL FAN AND ALTERNATOR V BELT (3SZ-VE) 

FAN AND ALTERNATOR V BELT (3SZ-VE) 

ENGINE MECHANICAL 

COMPONENTS 



FAN AND ALTERNATOR V BELT 

A137038J01

M 


Bolt C 

Bolt A 

Bolt B 


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. 

A108949J02 

Water Pump Pulley 

Idler Pulley 

Vane Pump 


Idler Pulley 

Vane Pump 

Alternator Pulley 

Crankshaft Pulley 



A/C Pulley 

A137721 

(b) 

Check that the fan and alternator V belt is correctly installed to 

each pulley. 

A088652



Bolt C 

Bolt A 

Bolt B 

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. 


A108949J02 


Measurement 

Position 

Idler Pulley 

Vane Pump 


Measurement 

Position 

Idler Pulley 

Vane Pump 





A/C Pulley 

A137722 

(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. 

When Installing New Part When Inspecting 

Tension [N (kgf)] 883±49{90±5} 441±98{45±10} 

Deflection (mm) [100 N 

(10.2 kgf)] 

9-11 13-15 

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 

INSPECTION in the table above.



• 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. 

M

ENGINE MECHANICAL FAN AND ALTERNATOR V BELT (K3-VE) 

FAN AND ALTERNATOR V BELT (K3-VE) 


COMPONENTS 




A137038J01

M 


Bolt C 

Bolt A 

Bolt B 



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 


A108949J02 


Idler Pulley 

Vane Pump 


Idler Pulley 

Vane Pump 





A/C Pulley 

A137721 

(b) 

Check that the fan and alternator V belt is correctly installed to 

each pulley. 

A088652



Bolt C 

Bolt A 

Bolt B 

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. 


A108949J02 


Measurement 

Position 

Idler Pulley 

Vane Pump 


Measurement 

Position 

Idler Pulley 

Vane Pump 





A/C Pulley 

A137722 

(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. 

When Installing New Part When Inspecting 

Tension [N (kgf)] 637±49{95±5} 441±98{54±10} 

Deflection (mm) [100 N 

(10.2 kgf)] 

9-11 13-15 

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 

INSPECTION in the table above.



• 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. 

M

ENGINE MECHANICAL VALVE CLEARANCE (3SZ-VE) 


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. 

Timing Marks 

A133561 

IN 

(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) 

Intake side 

Exhaust side 

0.145 to 0.235 mm 

0.275 to 0.365 mm 

EX 

A133562 

Valves to be checked when cylinder No. 1 is set 

to TDC / compression 

Cylinder No. 1 Cylinder No. 2 Cylinder No. 3 Cylinder No. 4 

IN EX IN EX IN EX IN EX 

◦ ◦ ◦ - - ◦ - -



IN 

(c) 

(d) 

HINT: 

If not as specified, measure the clearance and record it. 

Turn the crankshaft pulley 360°clockwise, and then set cylinder 

No. 4 to TDC / compression. 



HINT: 




Intake side 

0.145 to 0.235 mm 

M 

EX 

A133563 

Exhaust side 

0.275 to 0.365 mm 

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. 

A137452 

(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 pulley 

clockwise again and align the marks. 

Timing Marks 

A133561



(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 camshaft 

timing sprocket are aligned. 

Paint Mark 

Paint Mark 

Timing Marks 


A107964J01 

(d) 

Using the hexagon head portion of the camshaft, loosen the 

camshaft timing sprocket installation bolt. 

A133812 

(e) 

Using a 10 mm socket hexagon wrench, remove the chain 

cover service hole screw plug. 

A137724 

(f) 

(g) 

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 camshaft 

a little to the right and left. 

Under the conditions noted at [*1], use the hexagon head portion 

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. 

A133813



(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. 

M 

A136104 

(i) 

Remove the timing chain from the camshaft timing sprocket. 

A133815 

Hold 

(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. 

A136076



90° 

A107973J01 

2 

(k) 

Remove the camshaft bearing cap No. 1 in the order indicated 

in the illustration. 


4 

3 

1 

A133124 

2 

10 

14 

6 

(l) 



HINT: 

Uniformly loosen the bolts keeping the camshaft level. 

4 

3 

12 

11 

16 

15 

8 

7 

(m) Remove the camshaft. 

(n) Remove the camshaft No. 2. 

1 

9 

13 

5 

A133125 

(o) 

(p) 

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. 

Remove the valve lifter. 

A133818 

Measurement 

Point B 

(q) 

Using a micrometer, measure the valve lifter thickness. 

A033166



Valve 

Thickness of Lifter 

Selection No. 

Marking 

A133819 

(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. 

M 

Number 

Lifter Thickness 

(mm) 

Number 


(mm) 

Number 


(mm) 

Number 


(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 - - 

(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. 

I2 

15 

13 

14 

I3 

7 

5 

6 

I4 

3 

1 

2 

I5 

11 

(w) 

Tighten the camshaft bearing cap No. 2 in the order shown in 


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 numbers 

are positioned as shown in the illustration. 

E2 

E3 

E4 

E5 

9 

10 

16 

8 

4 

12 

A133070



3 

1 

2 

4 

(x) 




NOTICE: 

Tighten the bolts after checking that the thrust part of the 

camshaft is aligned with the groove on camshaft bearing 

cap No. 1. 

A133071 

(y) 

(z) 

Position the timing marks of the camshaft timing sprocket and 

the camshaft timing gear as shown in the illustration. 

Position the timing mark (groove) of the crankshaft pulley so it is 

at 0°. 


Timing Marks 

Notch 

A137723 

Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(aa) Align the camshaft knock pin and the camshaft timing sprocket 

pin hole, and install the camshaft timing sprocket to the camshaft. 

NOTICE: 

• If the knock pin and pin hole do not align, use the hexagon 

head portion of the camshaft and rotate the camshaft 

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.



Hold 

(ab) Apply a small amount of engine oil to the camshaft timing 

sprocket installation bolt thread and seating surface to temporarily 

install them. 

(ac) Using the hexagon head portion of the camshaft, tighten the 


Torque: 47 N*m (480 kgf*cm) 

A136076 

M 

(ad) Install the chain so the matchmarks of the camshaft timing gear 

and the chain are aligned. 

Timing Marks 

A133561 

(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. 

A136104



Timing Marks 

(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. 


Notch 

A137746 

(ah) Using a 10 mm socket hexagon wrench, install the chain cover 

service hole screw plug. 


A137724 

Apply Liquid Gasket 

(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. 

A139347 

(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) 

A137452 

6. INSTALL VENTILATION HOSE (See page EM-166) 

7. INSTALL VENTILATION HOSE NO. 2 (See page EM-166)



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) 

M 

15. INSTALL ENGINE UNDER COVER (See page EM-69) 

16. CONNECT NEGATIVE BATTERY TERMINAL 

Torque: 5.4 N*m (55 kgf*cm)

ENGINE MECHANICAL VALVE CLEARANCE (K3-VE) 


VALVE CLEARANCE (K3-VE) 


INSPECTION 

















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. 

Timing Marks 

A133561 

IN 

(b) 



HINT: 




Intake side 

Exhaust side 

0.145 to 0.235 mm 

0.275 to 0.365 mm 

EX 

A133562 

Valves to be checked when cylinder No. 1 is set 

to TDC / compression 



◦ ◦ ◦ - - ◦ - -



IN 

(c) 

(d) 

HINT: 


Turn the crankshaft pulley 360° clockwise, and then set cylinder 

No. 4 to TDC / compression. 



HINT: 




Intake side 

0.145 to 0.235 mm 

M 

EX 

A133563 

Exhaust side 

0.275 to 0.365 mm 

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. 

A137452 

(b) 

Turn the crankshaft pulley clockwise and check that the timing 

marks of the camshaft timing gear are positioned as shown in 


NOTICE: 



Timing Marks 

A133561



(c) 




Paint Mark 

Paint Mark 

Timing Marks 


A107964J01 

(d) 



A133812 

(e) 



A137724 

(f) 

(g) 




NOTICE: 

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. 



and hold.[*2] 

HINT: 


plunger. 

A133813



(h) 




NOTICE: 





head portion. 



M 

A136104 

(i) 

Remove the timing chain from the camshaft timing sprocket. 

A133815 

Hold 

(j) 


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. 

A136076



90° 

A107973J01 

2 

(k) 




4 

3 

1 

A133124 

2 

10 

14 

6 

(l) 



HINT: 


4 

3 

12 

11 

16 

15 

8 

7 

(m) Remove the camshaft. 

(n) Remove the camshaft No. 2. 

1 

9 

13 

5 

A133125 

(o) 

(p) 

After removing the camshaft, attach the timing chain to a rope 

or wire hoist so that it does not drop. 

NOTICE: 


cover. 

Remove the valve lifter. 

A133818 

Measurement 

Point B 

(q) 

Using a micrometer, measure the valve lifter thickness. 

A033166



Valve 

Thickness of Lifter 

Selection No. 

Marking 

A133819 

(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. 

M 

Number 


(mm) 

Number 


(mm) 

Number 


(mm) 

Number 


(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 - - 

(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. 


I2 

15 

13 

14 

I3 

7 

5 

6 

I4 

3 

1 

2 

I5 

11 

(w) 




NOTICE: 





E2 

E3 

E4 

E5 

9 

10 

16 

8 

4 

12 

A133070



3 

1 

2 

4 

(x) 




NOTICE: 



cap No. 1. 

A133071 

(y) 

(z) 

Position the timing marks of the camshaft timing sprocket and 

the camshaft timing gear as shown in the illustration. 

Position the timing mark (groove) of the crankshaft pulley so it is 

at 0°. 


Timing Marks 

Notch 

A140652 

Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(aa) Align the camshaft knock pin and the camshaft timing sprocket 


NOTICE: 



a little to the right and left so they align. Do not 








Hold 

(ab) Apply a small amount of engine oil to the camshaft timing 


install them. 

(ac) Using the hexagon head portion of the camshaft, tighten the 



A136076 

M 

(ad) Install the chain so the matchmarks of the camshaft timing gear 


Timing Marks 

A133561 

(ae) Pull the 3 mm diameter bar out from the chain tensioner. 

NOTICE: 




A136104



Timing Marks 

(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: 



Notch 

A140612 

(ah) Using a 10 mm socket hexagon wrench, install the chain cover 



A137724 


(ai) 

Apply Three Bond TB1207B to the position shown in the illustration. 

NOTICE: 


• Install within 3 minutes of applying Three Bond 

TB1207B. 

• Do not start the engine within 2 hours of the installation. 

A139347 

(aj) 







A137452 


7. INSTALL VENTILATION HOSE NO. 2 (See page EM-193)











M 



Torque: 5.4 N*m (55 kgf*cm)

ENGINE MECHANICAL PARTIAL ENGINE ASSEMBLY (3SZ-VE) 

PARTIAL ENGINE ASSEMBLY (3SZ-VE) 


COMPONENTS 


AIR CLEANER ASSEMBLY 

BATTERY 

CLAMP 

BATTERY 

T=3.5{36} 

T=18{184} 

T=7.5{76} 

×2 

×2 

T=7.5{76} 

AIR CLEANER HOSE NO. 1 


FUEL HOSE NO. 2 

T=8.5{87} ×3 

ACCELERATOR CONTROL 

CABLE ASSEMBLY 

BATTERY CARRIER 

RADIATOR HOSE NO. 1 

HEATER OUTLET COOLANT HOSE 


HEATER INLET COOLANT HOSE 

OIL COOLER INLET HOSE NO. 1 

ENGINE UNDER COVER RR RH 

OIL COOLER OUTLET HOSE NO. 1 

×7 

T=5.4{55} 

×4 

T=5.4{55} 

ENGINE UNDER COVER RR LH 

T=5.4{55} ×11 

ENGINE UNDER COVER 

TIGHTENING TORQUE [N*m{kgf*cm}] 

A136755J01



A/T 

TRANSMISSION CONTROL 


CHARCOAL CANISTER PIPE NO. 1 

ENGINE ROOM R/B 

CYLINDER HEAD 

COVER GROUND 

WIRE HARNESS 

GROUND WIRE 

HARNESS 

M 

M/T 



T=7.5{76} 

VACUUM HOSE ASSEMBLY 

T=29.4{300} 


T=29.4{300} 

COOLER COMPRESSOR WITH 

MAGNETIC CLUTCH ASSEMBLY 

O-RING 

T=25{255} 

T=10{102} 

STEERING INTERMEDIATE SHAFT ASSEMBLY 

SPEED SENSOR FR LH 

O-RING 

COOLER REFRIGERANT 

SUCTION HOSE NO. 1 

T=25{225} 

T=8.4{86} 


DISCHARGE HOSE NO. 1 

EXHAUST PIPE SUPPORT BRACKET 

T=19{194} 

EXHAUST PIPE GASKET 

T=10{102} 

T=19{194} 


[N*m{kgf*cm}] 

TIGHTENING TORQUE 

EXHAUST PIPE ASSEMBLY FR 

T=46{469} 

NON-REUSEABLE PART 

A136756J02



2WD 

PROPELLER WITH CENTER 

BEARING SHAFT ASSEMBLY 

T=60{612} 

×4 

FRONT DISC BRAKE 

CYLINDER ASSEMBLY LH 

×2 

T=37{377} 

×2 

VANE PUMP WITH BRACKET 

FRONT SHOCK ABSORBER 

WITH COIL SPRING 

T=112.8{1150} 

T=20.6{210} 

T=97.5{976} 

×2 


CYLINDER ASSEMBLY RH 


T=20.6{210} 

×2 

T=112.8{1150} 

FRONT SUSPENSION 

CROSS MEMBER 

T=125{1275} 

×6 ×2 

4WD 

FRONT PROPELLER SHAFT ASSEMBLY 

T=60{612} 

×4 

×4 

T=60{612} 



×2 

T=37{377} 



×2 


T=112.8{1150} 

T=20.6{210} 



T=20.6{210} 

×2 

T=95.7{976} 

×2 

T=112.8{1150} 





T=125{1275} 

×6 

×2 


A137621J01



IGNITION COIL ASSEMBLY 

T=7.5{76} 

SPARK PLUG 

REAR END PLATE 

M 

FAN PULLEY 

T=7.5{76} 

T=11.5{117} 

×3 

T=44{449} 

ENGINE OIL PRESSURE 

SWITCH ASSEMBLY 

IDLER PULLEY NO. 1 

COMPRESSOR MOUNTING 

BRACKET NO. 1 

T=7.5{76} 

CRANKSHAFT POSITION SENSOR 

OIL FILTER BRACKET 

ENGINE MOUNTING 

INSULATOR FR RH 

T=37{377} 

×4 

T=48.1{490} 

×3 

T=28{286} 


BRACKET FR NO. 2 

A/T 

T=78{800} 

T=27.5{280} 

×6 

×6 

FLYWHEEL RING GEAR 

O-RING 

×2 

T=19{194} 

M/T 

CLUTCH DISC ASSEMBLY 

×3 

T=30.4{310} 

T=30.4{310} 


BRACKET FR NO. 1 RH 

×2 

×4 

T=18{184} 

ENGINE MOUNTING INSULATOR FR LH 

FLYWHEEL 

T=19.1{195} 

×6 

×6 

T=78{800} 

CLUTCH COVER ASSEMBLY 



A137889J01



4WD 

×7 

T=37{375} 

OIL COOLER 

HOSE 

T=36.8{375} 

T=7.9{80} 

OIL COOLER TUBE 

T=34.3{349} 

×2 

GASKET 


OIL COOLER HOSE 

T=58.8{596} 

TRANSFER ASSEMBLY 

TRANSMISSION ASSEMBLY 

T=58.8{596} 

TORQUE CONVERTER 

ASSEMBLY 

O-RING 

WIRE HARNESS 

x6 

T=84.5{85} 

T=27.5{280} 

T=58.8{596} 

TRANSMISSION 

REVOLUTION 

SENSOR 

T=36.8{375} 

T=36.8{375} 

T=84.5{85} 


BRACKET RR 

T=68{693} 

T=68{693} 

T=68{693} 

T=37{375} 


CROSS MEMBER LWR 

ENGINE REAR SUPPORT MEMBER 

APPLY MP GREASE 

APPLY ATF 



T=68{693} 

C139184J09



BACK-UP LIGHT SWITCH ASSEMBLY 


T=58.8{596} 

T=32{325} 

T=37{375} 

M 

T=58.8{596} 

T=18{185} 

T=58.8{596} 

T=36.8{375} 

T=36.8{375} 

T=68{693} 

T=68{693} 

FRONT SUSPENSION CROSS MEMBER LWR 



C140480J01



OIL LEVEL GAUGE GUIDE 

T=8.5{87} 

COOLANT BYPASS HOSE NO. 2 

COOLANT BYPASS HOSE 

THROTTLE BODY 


T=7.5{76} 

×2 

T=21{214} 

T=7.5{76} 

×2 

O-RING 

THROTTLE BODY BRACKET NO. 2 


T=19{194} 

×2 

T=19{194} 

×3 

O-RING 

T=21{214} 

×2 

THROTTLE BODY BRACKET 

VENTILATION HOSE NO. 2 

T=7.5{76} 

RADIATOR PIPE 

VENTILATION HOSE 

INTAKE MANIFOLD 

T=7.5{76} 

O-RING 

CAMSHAFT TIMING OIL CONTROL 

VALVE ASSEMBLY 

FANBELT ADJUSTING BAR 

T=10{102} 


TO HEAD GASKET 

T=8.5{87} 

EXHAUST MANIFOLD 

HEAT INSULATOR NO. 1 

T=8.5{87} 

T=19{194} 

T=19{194} 

T=44{449} 

ALTERNATOR ASSEMBLY 

T=35{357} 

MANIFOLD STAY 

×2 

×3 

EXHAUST MANIFOLD TO HEAD GASKET 

T=9.3{95} 

T=35{357} 




A137041J01




FUEL DELIVERY PIPE 

COOLANT TEMPERATURE 

SENSOR 

×2 

T=21{214} 


M 

CAMSHAFT POSITION 

SENSOR 

GASKET 

×4 

×4 

T=7.5{76} 

INJECTOR VIBRATION 

INSULATOR 

×4 

T=19.0{200} 

T=9.0{92} 

WATER INLET 

GASKET 

THERMOSTAT 

GASKET 

T=20{204} 

×2 

COOLANT BYPASS PLATE 

FUEL INJECTOR 


KNOCK CONTROL SENSOR 

T=20{204} 

T=8.8{90} 

WATER BYPASS HOSE NO. 4 

×2 

T=37{377} 

STARTER ASSEMBLY 


COOLANT RADIATOR HOSE NO. 3 



A137074J01



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)



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) 

A137622 

27. REMOVE COOLER COMPRESSOR WITH MAGNETIC CLUTCH 

ASSEMBLY (See page AC-51) 

M 

28. DISCONNECT HEATER INLET WATER HOSE 

(a) Detach the clamp and disconnect the heater inlet water hose. 

A136001 

29. DISCONNECT HEATER OUTLET WATER HOSE 

(a) Detach the clamp and disconnect the heater outlet water hose. 

A136002 

30. REMOVE CHARCOAL CANISTER PIPE NO. 1 

(a) Remove the bolt and the charcoal canister pipe No. 1. 



32. DISCONNECT VACUUM HOSE ASSEMBLY (See page EM-148) 

A133920 

33. DISCONNECT ENGINE WIRE HARNESS 

(a) Remove the glove compartment door assembly and then disconnect 

the connectors of the engine control computer. 

(b) 

Pull the wire harness out through the engine room side. 

A133249



(c) 

Remove the bolt and disconnect the ground wire harness. 

A133248 

(d) 

Remove the connectors and clamps from the engine room R/B, 

and then disconnect the wire harness. 


A133247 

(e) 

(f) 

(g) 

Disconnect the ground connector of the cylinder head cover. 


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 

A133250 

35. REMOVE EXHAUST PIPE ASSEMBLY FR 

(a) Remove the 2 nuts. 

A134988 

(b) 

Disconnect the oxygen sensor No. 2 connector. 

A133302



(c) 

(d) 

Remove the 2 bolts and 2 springs. 

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) 

A134989 

38. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) 


M 

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. 

C133716 

(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. 

C133715 

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 


C139221



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. 

C135148 

46. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION 

(a) Set the engine lifter. 


A133259 

(b) 

Remove the 4 bolts and disconnect the engine rear support 

member. 

A133258 

Vehicle Front 

(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. 

A133256 

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 transmission 

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. 

C135146



(B) 

M 

(A) 

C135145J01 

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 member. 

A137720 

(c) 

Remove the 3 bolts and nuts and disconnect the engine mounting 

insulator FR RH. 

A133261 

(d) 

Remove the 2 bolts and nut. Then disconnect the engine 

mounting bracket FR RH and remove the front suspension 

cross member. 

A133260



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 


A133263 

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. 


C136910J01 

SST 

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) 

A137592 

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) 

SST 

C136911J04 

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. 

A139357



59. REMOVE REAR END PLATE 

(a) Remove the bolt and the rear end plate. 

A133301 

M 

60. REMOVE ENGINE WIRE HARNESS 

(a) Disconnect the connectors and the wire harness clamps from 

the engine assembly, and remove the engine wire harness. 

A133303 

(b) 

Detach the alternator connector and then disconnect the wire 

harness clamp. 

A133305 

(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 


63. REMOVE MANIFOLD STAY (See page EM-150) 

A133306 

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)



73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 

(a) Using a deep socket wrench (24 mm), remove the engine oil 

pressure switch. 

A137321 

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) 

A137714 

78. REMOVE KNOCK CONTROL SENSOR 

(a) Remove the nut, then remove the knock control sensor. 

A109109 

79. REMOVE RADIATOR HOSE NO. 4 

(a) Loosen the clamp and then remove radiator hose No. 4. 

A133307 


(a) Loosen the clamp and then remove radiator hose No. 3. 

A133408



81. REMOVE WATER BY-PASS HOSE NO. 2 

(a) Loosen the clamp and then remove the water by-pass hose No. 

2. 

A133407 

M 


(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 


A133308 

85. REMOVE CAM POSITION SENSOR 

(a) Remove the bolt, then remove the cam position sensor. 

A136155 

86. REMOVE WATER INLET 

(a) Remove the bolt and nut and then remove the water inlet. 

A133309 

87. REMOVE THERMOSTAT 

(a) Remove the thermostat. 

A136151



88. REMOVE WATER TEMPERATURE SENSOR 

(a) Using a 19 mm deep socket wrench, remove the water temperature 

sensor. 

A136152 

89. REMOVE IGNITION COIL ASSEMBLY 

(a) Remove the bolt and the ignition coil assembly. 


A133310 

90. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1 

(a) Remove the 4 bolts and the compressor mounting bracket No. 

1. 

A133311 

91. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH 

(a) Remove the 4 bolts and the engine mounting bracket FR No. 1 

RH. 

A133312 

92. REMOVE ENGINE MOUNTING BRACKET FR NO. 2 

(a) Remove the 4 bolts and the engine mounting bracket FR No. 2. 

A133313



93. REMOVE OIL FILTER BRACKET 

(a) Remove the 2 bolts and the oil filter bracket. 

(b) Remove the oil filter bracket gasket. 

INSTALLATION 

A133314 

M 

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. 

A133314 

A 

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. 

A139360 

A 

3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH 

(a) Install the engine mounting bracket FR No. 1 RH with the 4 

bolts. 


HINT: 



A139361



4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1 

(a) Install the compressor mounting bracket No. 1 with the 3 bolts. 


A133311 

5. INSTALL IGNITION COIL ASSEMBLY 

(a) Install the ignition coil assembly with the bolt. 



A133310 

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. 

A136152 

(b) 

Align the water inlet matchmark and the thermostat jiggle valve, 

and install the thermostat. 

A133315 

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. 

A133309



(b) 

Install the cam position sensor with the bolt. 


NOTICE: 

Install the sensor so that the O-ring is not cut or pinched. 

M 

A136155 

10. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 


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. 

A133407 



A133308 

14. INSTALL RADIATOR HOSE NO. 3 

(a) Install the radiator hose No. 3 with the clamp. 

A133307





A133408 

16. INSTALL KNOCK CONTROL SENSOR 

(a) Install the knock control sensor with the nut in the direction 

shown in the illustration. 



45° 

15° 

17. INSTALL ALTERNATOR ASSEMBLY (See page CH-10) 

18. INSTALL FAN PULLEY (See page CO-29) 

15° 

A107019J01 

19. INSTALL CRANK POSITION SENSOR 


(b) 

Install the crank position sensor with the bolt. 


A137713 

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. 

A137714 

(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) 

A137321 

24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-11)



A136082 

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 delivery 

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. 


M 

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 


30. INSTALL ENGINE WIRE HARNESS 

(a) Install the cam position sensor and the water temperature sensor 

connectors, and then install the wire harness clamp bracket. 

A133306 

(b) 

Install the alternator connector, and then install the wire harness 

clamp. 

Torque: 10 N*m (102 kgf*cm) (Terminal B) 

A133305 

(c) 

Install the sensor connectors and wire harness clamps, and 

then install the engine wire harness. 



33. INSTALL VENTILATION HOSE NO. 2 (See page EM-166) 

A133303



34. INSTALL REAR END PLATE 

(a) Install the rear end plate with the bolt. 


A133301 

SST 

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 flywheel 

installation bolt. 

NOTICE: 

Clean and degrease the flywheel installation bolt and bolt 

hole. 


A139359 

(c) 

Temporarily install the flywheel with the 6 bolts. 

A134237 

5 

3 

1 

2 4 

6 

(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) 


37. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS- 


A134238 


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.



(c) 

Using a pri set torque wrench, temporarily install the transmission 

assembly with the 9 bolts. 

NOTICE: 

• Do not jolt the transmission unit assembly to avoid a 

damage to the input shaft. 

C136911J04 

M 

(d) Tighten the transmission assembly installation bolt A. 


A 

C141309 

B 

B 

C 

C 

A 

A 

C C C136911J03 

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)



SST 

40. INSTALL FLYWHEEL RING GEAR (AUTOMATIC TRANSMISSION) 


SST 09330-00021, 09213-54015 (91651-60855) 


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. 

A137593 

5 

3 1 

6 

2 4 

A134236 

(d) 



NOTICE: 



MISSION) 

42. INSTALL TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS- 

SION) 




in the knock pin hole. 


A 

A 

A 

(c) 

Temporarily install the transmission assembly with the 9 bolts. 

NOTICE: 

Do not jolt the transmission unit assembly to avoid a damage 

to the input shaft. 

A 

C139312J02



(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) 

A 

M 

C141308 

B 

B 

C 

C 

A 

A 

C C C139312J03 

(e) 


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: 

• Bolt A part number: 90041-19968 (Length under neck 57 

mm) 

• Bolt A and B part number: 90041-19968 (Length under neck 

57 mm) 

• Bolt C part number: 91612-61040 (Length under neck 40 

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. 

A133263



45. INSTALL FRONT SUSPENSION CROSS MEMBER 





assembly with transmission. 


A137720 

(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) 

A133260 

(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) 

A133261 

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. 

C135146



B 

M 

A 

C135145 

(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 


A133259 

Vehicle Front 

(b) 

(c) 

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. 

Tighten the bolts to the specified torque in several passes. 


A133256 

(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. 


A133258



48. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING 

(a) Connect the front shock absorber with coil spring to the suspension 

knuckle assembly with the 2 bolts and nuts. 


C135148 

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 



C139221 

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. 

C133716 

(b) 

Install the bolt and wire harness clamp to the shock absorber. 


52. INSTALL SPEED SENSOR FR RH 


53. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 


C133715 


(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)



M 

Tail Pipe Side 

Gasket 

A031088J01 

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 direction. 

• 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 

A133302 

60. CONNECT ENGINE WIRE HARNESS 

(a) Connect the cylinder head cover ground connector, and then 

install the ground wire harness with the 3 bolts. 


A133250 

(b) 

Connect the ground wire harness with the bolt. 


A133248



(c) 

Connect the 3 engine room R/B connecters and clamp. 

A133247 

(d) 

(e) 

Install the wire harness inside the engine room. 

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 


A133249 

63. INSTALL CHARCOAL CANISTER PIPE NO. 1 

(a) Install the charcoal canister pipe No. 1 with the bolt. 


A133920 

64. CONNECT HEATER OUTLET WATER HOSE 

(a) Connect the heater outlet water hose. 

A136002 

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 


A136001 

68. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 

(STEERING TYPE: LHD) (See page AC-55)



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) 


A137622 

74. CONNECT RADIATOR HOSE NO. 1 (See page CO-18) 


M 

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. 


A136170 

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: 

LHD) (See page AC-27)



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.)


ENGINE MECHANICAL - PARTIAL ENGINE ASSEMBLY (K3-VE) 

PARTIAL ENGINE ASSEMBLY (K3-VE) 


COMPONENTS 


M 

BATTERY 

CLAMP 

BATTERY 

T=3.5{36} 

T=18{184} 

T=7.5{76} 

×2 

×2 

T=7.5{76} 


FUEL HOSE NO. 2 

T=8.5{87} ×3 

ACCELERATOR CONTROL 




HEATER OUTLET COOLANT HOSE 


HEATER INLET COOLANT HOSE 


ENGINE UNDER COVER RR RH 

OIL COOLER OUTLET HOSE NO. 1 

×7 

T=5.4{55} 

×4 

T=5.4{55} 

ENGINE UNDER COVER RR LH 

T=5.4{55} ×11 



A136755J01



A/T 



CHARCOAL CANISTER PIPE NO. 1 

ENGINE ROOM R/B 

CYLINDER HEAD 

COVER GROUND 

WIRE HARNESS 

GROUND WIRE 

HARNESS 

M/T 



T=7.5{76} 


VACUUM HOSE ASSEMBLY 

T=29.4{300} 


T=29.4{300} 

COOLER COMPRESSOR WITH 

MAGNETIC CLUTCH ASSEMBLY 

O-RING 

T=25{255} 

T=10{102} 

STEERING INTERMEDIATE SHAFT ASSEMBLY 

SPEED SENSOR FR LH 

O-RING 


SUCTION HOSE NO. 1 

T=25{225} 

T=8.4{86} 


DISCHARGE HOSE NO. 1 

EXHAUST PIPE SUPPORT BRACKET 

T=19{194} 


T=10{102} 

T=19{194} 



EXHAUST PIPE ASSEMBLY FR 

T=46{469} 


A136756J01



2WD 



T=60{612} 

×4 



×2 

T=37{377} 

×2 




T=112.8{1150} 

M 

T=97.5{976} 

×2 



T=112.8{1150} 



T=125{1275} 

×6 ×2 

4WD 

FRONT PROPELLER SHAFT ASSEMBLY 

T=60{612} 

×4 

×4 

T=60{612} 



×2 

T=37{377} 



×2 

T=112.8{1150} 




T=95.7{976} 

×2 



T=112.8{1150} 



T=125{1275} 

×6 

×2 


A137621J02




×4 

T=7.5{76} 

×4 

×4 

SPARK PLUG 

FAN PULLEY 


T=7.5{76} 


T=11.5{117} 

T=44{449} 


T=20.6{210} 

×2 

ENGINE OIL PRESSURE 

SWITCH ASSEMBLY 

T=15{153} 

T=43.2{440} 

COMPRESSOR MOUNTING BRACKET NO. 1 


INSULATOR FR RH 

VANE PUMP 

WITH BRACKET 

T=7.5{76} 


A/T 

T=27.5{280} 

T=78{800} 

×6 

OIL FILTER BRACKET 

O-RING 

×2 

T=19{194} 

T=37{377} 

×3 

×4 

T=30.4{310} 

T=48.1{490} 


BRACKET FR NO. 1 RH 

T=30.4{310} 

×2 

T=28{286} 


BRACKET FR NO. 2 

×4 

T=18{184} 

×6 


M/T 


T=78{800} 

×6 

T=19.1{195} 

×6 

ENGINE MOUNTING INSULATOR 

FRONT LH 

FLYWHEEL 

CLUTCH COVER 


TIGHTENING TORQUE NON-REUSEABLE PART 

A137049J03



4WD 

×7 

T=37{375} 

OIL COOLER 

HOSE 

T=36.8{375} 

T=7.9{80} 

M 

OIL COOLER TUBE 

T=34.3{349} 

×2 

GASKET 

TRANSFER ASSEMBLY 

OIL COOLER HOSE 

T=58.8{596} 


T=58.8{596} 

TORQUE CONVERTER 


WIRE HARNESS 

O-RING 

T=84.5{85} 

x6 

T=27.5{280} 

T=58.8{596} 

TRANSMISSION 

REVOLUTION 

SENSOR 

T=36.8{375} 

T=36.8{375} 

T=84.5{85} 


BRACKET RR 

T=68{693} 

T=68{693} 

T=68{693} 

T=37{375} 



ENGINE REAR SUPPORT MEMBER 


APPLY ATF 



T=68{693} 

C139184J09



BACK-UP LIGHT SWITCH ASSEMBLY 


T=58.8{596} 

T=32{325} 

T=37{375} 

T=58.8{596} 


T=18{185} 

T=58.8{596} 

T=36.8{375} 

T=36.8{375} 

T=68{693} 

T=68{693} 

FRONT SUSPENSION CROSS MEMBER LWR 



C140480J01




T=8.5{87} 


M 


THROTTLE BODY 


T=7.5{76} 

×2 

T=21{214} 

T=7.5{76} 

×2 

O-RING 

THROTTLE BODY BRACKET NO. 2 

T=19{194} 

×2 

T=19{194} 

×3 

O-RING 

T=21{214} 

×2 

THROTTLE BODY BRACKET 


T=7.5{76} 

RADIATOR PIPE 



T=7.5{76} 

O-RING 

CAMSHAFT TIMING OIL CONTROL 

VALVE ASSEMBLY 

FANBELT ADJUSTING BAR 

T=10{102} 


TO HEAD GASKET 

T=8.5{87} 


HEAT INSULATOR NO. 1 

T=8.5{87} 

T=19{194} 

T=19{194} 

T=44{449} 


T=35{357} 

MANIFOLD STAY 

×2 

×3 

EXHAUST MANIFOLD TO HEAD GASKET 

T=9.3{95} 

T=35{357} 




A137041J01




FUEL DELIVERY PIPE 

COOLANT TEMPERATURE 

SENSOR 

×2 

T=21{214} 


CAMSHAFT POSITION 

SENSOR 

GASKET 

×4 

×4 


T=7.5{76} 

INJECTOR VIBRATION 

INSULATOR 

×4 

T=19.0{200} 

T=9.0{92} 

WATER INLET 

GASKET 

THERMOSTAT 

GASKET 

T=20{204} 

×2 

COOLANT BYPASS PLATE 

FUEL INJECTOR 


KNOCK CONTROL SENSOR 

T=20{204} 

T=8.8{90} 

WATER BYPASS HOSE NO. 4 

×2 

T=37{377} 

STARTER ASSEMBLY 


COOLANT RADIATOR HOSE NO. 3 



A137074J01




1. DISCHARGE FUEL SYSTEM PRESSURE (See page EM-173) 



See page RS-164. 

4. REMOVE FRONT TIRE 


6. REMOVE ENGINE UNDER COVER RR RH 

M 

7. REMOVE ENGINE UNDER COVER RR LH 

8. REMOVE REFRIGERANT HFC - 134a (R134a) (Steering type: 





(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) 


24. REMOVE FAN AND ALTERNATOR BELT (See page EM-12)



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 


A137622 

28. DISCONNECT COOLER COMPRESSOR WITH MAGNETIC 

CLUTCH ASSEMBLY (See page AC-51) 


(a) Detach the clamp and disconnect the heater inlet water hose. 


A136001 


(a) Detach the clamp and disconnect the heater outlet water hose. 

A136002 

31. REMOVE CHARCOAL CANISTER PIPE NO. 1 

(a) Remove the bolt and the charcoal canister pipe No. 1. 



33. DISCONNECT VACUUM HOSE ASSEMBLY (See page EM-175) 

A133920 

34. DISCONNECT ENGINE WIRE HARNESS 

(a) Remove the glove compartment door assembly and then disconnect 

the connectors of the engine control computer. 

(b) 

Pull the wire harness out through the engine room side. 

A133249



(c) 


A133248 

M 

(d) 

Remove the connectors and clamps from the engine room R/B, 

and then disconnect the wire harness. 

A133247 

(e) 

(f) 

(g) 

Disconnect the ground connector of the cylinder head cover. 


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) 

A133250 

36. REMOVE EXHAUST PIPE ASSEMBLY FR 

(a) Remove the 2 nuts. 

A134988 

(b) 

Disconnect the oxygen sensor No. 2 connector. 

A133302



(c) 

(d) 

Remove the 2 bolts and 2 springs. 

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) 


A134989 

39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) 







42. DISCONNECT SPEED SENSOR FR LH 

(a) Remove the bolt, and disconnect the speed sensor FR LH from 

the steering knuckle. 

C133716 

(b) 

Remove the bolt and nut, and disconnect the wire harness 

clamp from the shock absorber. 

43. DISCONNECT SPEED SENSOR FR RH 


C133715 

44. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY LH 

(a) Remove the 2 bolts, and disconnect the front disc brake cylinder 

assembly LH. 

(b) Hang the disconnected front disc brake cylinder assembly LH 

with wire or similar. 

45. SEPARATE FRONT DISC BRAKE CYLINDER ASSEMBLY RH 


C139221




(a) Remove the 4 bolts and 4 nuts, and disconnect the front shock 

absorber with coil spring LH and RH from the steering knuckle. 

C135148 

M 

47. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION 


A133259 

(b) 

Remove the 4 bolts and disconnect the engine rear support 

member. 

A133258 

Vehicle Front 

(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. 

A133256 

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 transmission 

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. 

C135146



(B) 

(A) 


C135145J01 

49. REMOVE FRONT SUSPENSION CROSS MEMBER 





assembly with transaxle and the front suspension cross member. 

A137720 

(c) 

Remove the 3 bolts and nuts and disconnect the engine mounting 

insulator FR RH. 

A133261 

(d) 

Remove the 2 bolts and nut. Then disconnect the engine 

mounting bracket FR RH and remove the front suspension 

cross member. 

A133260



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 


A133263 


MISSION) 

M 


SION) 


NOTICE: 

To avoid damage to the knock pin, do not pry the contact 

surfaces of the automatic transmission assembly and the 

engine. 

C136910J01 

SST 


SION) 

(a) Using the SST, secure the flywheel ring gear. 

SST 09210-87701 

(b) Remove the 6 bolts and the flywheel ring gear. 


SION) 

A137592 


SION) 


NOTICE: 

Do not jolt the transmission assembly to avoid a damage to 

the input shaft. 



C136911J04 


(See page CL-20)



SST 

59. REMOVE FLYWHEEL (MANUAL TRANSMISSION) 

(a) Using the SST, secure the flywheel. 

SST 09210-87701 

(b) Remove the 6 bolts and the flywheel. 

A139357 

60. REMOVE REAR END PLATE 

(a) Remove the bolt and the rear end plate. 


A133301 

61. REMOVE ENGINE WIRE HARNESS 

(a) Disconnect the connectors and the wire harness clamps from 

the engine assembly, and remove the engine wire harness. 

A133303 

(b) 

Detach the alternator connector and then disconnect the wire 

harness clamp. 

A133305 

(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 


64. REMOVE MANIFOLD STAY (See page EM-177) 

A133306 

65. REMOVE EXHAUST MANIFOLD (See page EM-178)



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) 

M 

74. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 

(a) Using a deep socket wrench (24 mm), remove the engine oil 

pressure switch. 

A137321 



76. REMOVE CRANK POSITION SENSOR (See page IG-16) 



A137714 

79. REMOVE KNOCK CONTROL SENSOR 

(a) Remove the nut, then remove the knock control sensor. 

A109109




(a) Remove the clamp and then remove radiator hose No. 4. 

A133408 


(a) Remove the clamp and then remove radiator hose No. 3. 


A133307 


(a) Remove the clamp and then remove the water by-pass hose 

No. 2. 

A133407 


(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. 



A133308 

86. REMOVE CAM POSITION SENSOR 

(a) Remove the bolt, then remove the cam position sensor. 

A136155



87. REMOVE WATER INLET 

(a) Remove the bolt and nut and then remove the water inlet. 

A133309 

M 

88. REMOVE THERMOSTAT 

(a) Remove the thermostat. 

A136151 

89. REMOVE WATER TEMPERATURE SENSOR 

(a) Using a 19 mm deep socket wrench, remove the water temperature 

sensor. 

A136152 


(a) Remove the bolt and the ignition coil assembly. 

A133310 

91. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1 

(a) Remove the 4 bolts and the compressor mounting bracket No. 

1. 

A133311



92. REMOVE ENGINE MOUNTING BRACKET FR NO. 1 RH 

(a) Remove the 4 bolts and the engine mounting bracket FR No. 1 

RH. 

A133312 

93. REMOVE ENGINE MOUNTING BRACKET FR NO. 2 

(a) Remove the 4 bolts and the engine mounting bracket FR No. 2. 


A133313 

94. REMOVE OIL FILTER BRACKET 

(a) Remove the 2 bolts and the oil filter bracket. 

(b) Remove the oil filter bracket gasket. 

INSTALLATION 

A133314 

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. 

A133314 

A 

2. INSTALL ENGINE MOUNTING BRACKET FR NO. 2 

(a) Install the engine mounting bracket FR No. 2 with the 4 bolts. 


HINT: 



A139360



A 

3. INSTALL ENGINE MOUNTING BRACKET FR NO. 1 RH 

(a) Install the engine mounting bracket FR No. 1 RH with the 4 

bolts. 


HINT: 



A139361 

M 

4. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1 

(a) Install the compressor mounting bracket No. 1 with the 3 bolts. 


A133311 




A133310 

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. 

A136152 

(b) 

Align the water inlet matchmark and the thermostat jiggle valve, 

and install the thermostat. 

A133315



8. INSTALL WATER INLET 

(a) Install the water inlet with the bolt and nut. 


9. INSTALL CAM POSITION SENSOR 


A133309 

(b) 

Install the cam position sensor with the bolt. 


NOTICE: 





A136155 

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. 




A133407 



A133308





A133307 

M 



A133408 

45° 

15° 

16. INSTALL KNOCK CONTROL SENSOR 

(a) Install the knock control sensor with the nut in the direction 





15° 

A107019J01 



(b) 



A137713 




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. 

A137714



(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) 

A137321 

24. INSTALL FUEL INJECTOR ASSEMBLY (See page FU-16) 

A136082 


(a) Temporarily install the fuel delivery pipe with the 2 bolts. 

NOTICE: 

Do not drop the fuel injector when installing the fuel delivery 

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 


30. INSTALL ENGINE WIRE HARNESS 

(a) Install the cam position sensor and the water temperature sensor 

connectors, and then install the wire harness clamp bracket. 


A133306 

(b) 

Install the alternator connector, and then install the wire harness 

clamp. 

Torque: 10 N*m (102 kgf*cm) (Terminal B) 

A133305



(c) 

Install the sensor connectors and wire harness clamps, and 

then install the engine wire harness. 




A133303 

M 

34. INSTALL REAR END PLATE 

(a) Install the rear end plate with the bolt. 


A133301 

SST 

35. INSTALL FLYWHEEL (MANUAL TRANSMISSION) 


SST 09210-87701 


installation bolt. 

NOTICE: 

Clean and degrease the flywheel installation bolt and bolt 

hole. 

A139359 

(c) 

Temporarily install the flywheel with the 6 bolts. 

A134237 

5 

3 

1 

2 4 

6 

(d) 



NOTICE: 






A134238




SION) 

39. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSAXLE) 





(c) 


NOTICE: 

• Do not jolt the transmission unit assembly to avoid a 

damage to the input shaft. 


C136911J04 

(d) 

Using a pri set torque wrench, tighten the transmission assembly 

installation bolt A. 


A 

C141309 

B 

B 

C 

C 

A 

A 

C C C136911J03 

A 

(e) 


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. 

Torque: 59 N*m (602 kgf*cm)



M 

SST 

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) 



SST 09330-00021, 09213-54015 (91651-60855) 


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. 

A137593 

5 

3 1 

6 

2 4 

A134236 

(d) 



NOTICE: 



MISSION) 


SION) 





A 

A 

A 

(c) 


NOTICE: 

Do not jolt the transmission unit assembly to avoid a damage 

to the input shaft. 

A 

C139312J02



(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) 

A 


C141308 

B 

B 

C 

C 

A 

A 

C C C139312J03 

(e) 


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: 

• Bolt A part number: 90041-19968 (Length under neck 57 

mm) 

• Bolt A and B part number: 90041-19968 (Length under neck 

57 mm) 

• Bolt C part number: 91612-61040 (Length under neck 40 

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. 

A133263



45. INSTALL FRONT SUSPENSION CROSS MEMBER 





assembly with transmission. 

M 

A137720 

(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) 

A133260 

(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) 

A133261 

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. 

C135146



B 

A 


C135145 

(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 


A133259 

Vehicle Front 

(b) 

(c) 

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. 

Tighten the bolts to the specified torque in several passes. 


A133256 

(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. 


A133258



48. INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING 

(a) Connect the front shock absorber with coil spring to the suspension 

knuckle assembly with the 2 bolts and nuts. 


C135148 

M 

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 


C139221 

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. 

C133716 

(b) 

Install the bolt and wire harness clamp to the shock absorber. 


52. INSTALL SPEED SENSOR FR RH 




C133715 



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)



Tail Pipe Side 

Gasket 

A031088J01 

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 direction. 

• 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) 


A133302 

60. CONNECT ENGINE WIRE HARNESS 

(a) Connect the cylinder head cover ground connector, and then 

install the ground wire harness with the 3 bolts. 


A133250 

(b) 

Connect the ground wire harness with the bolt. 


A133248



(c) 

Connect the 3 engine room R/B connecters and clamp. 

A133247 

M 

(d) 

(e) 

Install the wire harness inside the engine room. 

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 


A133249 

63. INSTALL CHARCOAL CANISTER PIPE NO. 1 

(a) Install the charcoal canister pipe No. 1 with the bolt. 


A133920 



A136002 



66. INSTALL COOLER COMPRESSOR WITH MAGNETIC CLUTCH 


67. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1 


A136001 

68. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 

(STEERING TYPE: LHD) (See page AC-55)



A 

A 

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) 



B 

A140646 







TRANSMISSION)(See page CO-25) 




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. 



(a) Connect the negative terminal with the nut and clamp. 


A136170 

83. INSTALL FRONT TIRE 





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 

98. CHECK ENGINE OIL LEVEL (See page EM-195)






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. 

M 

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.)

CHAIN (3SZ-VE) 


COMPONENTS 

ENGINE MECHANICAL - CHAIN (3SZ-VE) 



T=3.5{36} 

BATTERY 

BATTERY CLAMP 

×2 

T=7.5{76} 


T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 



ACCELERATOR CONTROL CABLE ASSEMBLY 




T=5.4{55} ×11 

..... TIGHTENING TORQUE [N*m{kgf*cm}] 

A136903J01





M 


T=7.5{76} 

×4 

SPARK PLUG 

T=20{204} 

CAMSHAFT TIMING OIL 

CONTROL VALVE ASSEMBLY 

×4 

T=7.5{76} 

×4 

O-RING 

T=7.5{76} 

IDLER PULLEY 


T=11.5{117} 

×3 

RADIATOR PIPE 

T=44{449} 

T=130{1326} 

T=20.6{210} 

×3 

O-RING 

T=7.5{76} 

CRANKSHAFT PULLEY 

VANE PUMP ASSEMBLY 




A136904J02



OIL FILLER CAP 

CYLINDER HEAD COVER 

T=11{112} 

×11 

T=9.0{92} 

CHAIN TENSIONER PLUNGER 


TIMING GEAR (CHAIN) 

COVER GASKET 

T=9.0{92} 

CYLINDER HEAD COVER GASKET 

TIMING CHAIN 

TENSIONER ARM 

TIMING CHAIN GUIDE 

CHAIN 

T=23{235} 

T=12{122} 

×9 

×2 

T=44{449} 

×3 

T=19{195} 

T=7.5{76} 

T=7.5{76} 

×2 

TIMING CHAIN (BELT) COVER OIL SEAL 

TIMING CHAIN GUIDE NO. 2 

CRANKSHAFT ANGLE SENSOR PLATE NO. 1 


..... TIGHTENING TORQUE [N*m{kgf*cm} NON-REUSEABLE PART 

A136905J03





(See page SS-10.) 






M 


8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See 


D-MARK 

A135998 

9. REMOVE FAN AND ALTERNATOR BELT (See page EM-8) 


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) 



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.



(b) 



and hold.[*2] 

HINT: 


plunger. 

A108005 

(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 difficult 

to align, rotate the camshaft a little to the left and then 

back a little to the right again to align them. 


Stopper Plate 

Plunger 

A108555J02 

(d) 

(e) 

Under the conditions noted at [*3], insert a bar of 3 mm in diameter 

into the stopper plate and the chain tensioner plunger hole. 

Remove the bolt and nut and then remove the chain tensioner 

plunger. 

A108556 

26. REMOVE TIMING CHAIN TENSION ARM 

(a) Remove the bolt and the timing chain tensioner arm. 

A108557 

27. REMOVE TIMING CHAIN GUIDE 

(a) Remove the 2 bolts and the timing chain guide. 

A108558



28. REMOVE TIMING CHAIN GUIDE NO. 2 

(a) Remove the 2 bolts and the timing chain guide No. 2. 

29. REMOVE CHAIN 

INSTALLATION 

A108559 

M 

Mark Plate 

Mark Plate 

1. INSTALL CHAIN 

(a) Align the mark plate (yellow) and the timing mark as shown in 

the illustration and install the chain. 

Timing Mark 

Timing Mark 

Mark Plates 

Timing Mark 

A137742 

2. INSTALL TIMING CHAIN GUIDE NO. 2 

(a) Install the timing chain guide No. 2 with the 2 bolts. 


A108559



3. INSTALL TIMING CHAIN GUIDE 

(a) Install the timing chain guide with the 2 bolts. 


A108558 

4. INSTALL TIMING CHAIN TENSION ARM 

(a) Install the timing chain tension arm with the bolt. 



A108557 

A108556 

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. 

D-MARK 

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) 

A135998 



11. INSTALL CRANKSHAFT PULLEY (See page EM-161) 


13. INSTALL SPARK PLUG (See page EM-162) 




17. INSTALL VENTILATION HOSE (See page EM-166)




19. INSTALL IDLER PULLEY NO. 1 (See page EM-163) 

20. INSTALL VANE PUMP ASSEMBLY (See page EM-68) 





M 













35. INSPECT ENGINE OIL LEAKS 

36. CHECK ENGINE OIL LEVEL (See page EM-167) 


38. CHECK IDLE SPEED (See page EM-2) 

39. INSTALL ENGINE UNDER COVER (See page EM-69)

CHAIN (K3-VE) 


COMPONENTS 

ENGINE MECHANICAL - CHAIN (K3-VE) 



T=3.5{36} 

BATTERY 

BATTERY CLAMP 

×2 

T=7.5{76} 


T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 







T=5.4{55} ×11 


A136903J01





M 


T=7.5{76} 

×4 

SPARK PLUG 

T=20{204} 



×4 

T=7.5{76} 

×4 

O-RING 

T=7.5{76} 

IDLER PULLEY 


T=11.5{117} 

×3 

RADIATOR PIPE 

T=44{449} 

T=130{1326} 

T=20.6{210} 

×3 

O-RING 

T=7.5{76} 






A136904J02





T=11{112} 

×11 

T=9.0{92} 




COVER GASKET 

T=9.0{92} 


TIMING CHAIN 

TENSIONER ARM 


CHAIN 

T=23{235} 

T=12{122} 

×9 

×2 

T=44{449} 

×3 

T=19{195} 

T=7.5{76} 

T=7.5{76} 

×2 




MP GREASE 



A136905J05






2. REMOVE BATTERY CARRIER (See page EM-173 ) 



5. DRAIN ENGINE COOLANT (See page CO-11 ) 

6. REMOVE AIR CLEANER ASSEMBLY (See page EM-173 ) 

M 

7. REMOVE RADIATOR HOSE NO. 1 (See page CO-22 ) 

8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See 

page EM-175 ) 

D-MARK 

A135998 

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.



(b) 



and hold.[*2] 

HINT: 


plunger. 

A108005 

(c) 



HINT: 





Stopper Plate 

Plunger 

A108555J02 

(d) 

(e) 



Remove the bolt and nut and then remove the chain tensioner 

plunger. 

A108556 



A108557 



A108558






INSTALLATION 

A108559 

M 

Mark Plate 

Mark Plate 




Timing Mark 

Timing Mark 

Mark Plates 

Timing Mark 

A137742 




A108559






A108558 





A108557 

A108556 




HINT: 




plunger. 


plunger. 

D-MARK 



visible. 

7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-188 ) 


206 ) 

9. INSTALL CRANK POSITION SENSOR (See page EM-92 ) 

A135998 



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 )



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 ) 

M 



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 ) 




32. ADD ENGINE COOLANT (See page CO-11 ) 


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 )

CAMSHAFT (3SZ-VE) 


COMPONENTS 

ENGINE MECHANICAL - CAMSHAFT (3SZ-VE) 



T=3.5{36} 

BATTERY 

BATTERY CLAMP 

×2 

T=7.5{76} 


T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 







T=5.4{55} ×11 


A136903J01



VENTILATION HOSE VENTILATION HOSE NO. 2 

T=11{112} 

×2 

T=7.5{76} 


×4 

×4 


T=7.5{76} 

M 

T=9.0{92} 


GASKET 

×11 

CAMSHAFT BEARING CAP NO. 1 

T=12.5{130} 

RADIATOR PIPE 

×4 

T=12.5{130} 

×16 


×8 

CAMSHAFT TIMING 

SPROCKET 

CAMSHAFT 

CAMSHAFT NO. 2 

T=47{480} 

TIMING CHAIN (BELT) COVER NO. 2 

T=8.5{87} 

T=17{173} 

CHAIN COVER SERVICE HOLE 

SCREW PLUG 


A137081J01






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 ) 




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. 

Timing Marks 


(a) Rotate the crankshaft pulley clockwise to align the timing mark 

(groove) so it is at 0°.Make sure that each timing mark is positioned 


HINT: 



Notch 

A137746



(b) 




Paint Mark 

Paint Mark 

M 

Timing Marks 

A107964J01 

(c) 



A133812 

(d) 



A137724 

(e) 

(f) 




HINT: 



the right and left. 



and hold.[*2] 

HINT: 


plunger. 

A133813



A133879 

(g) 




NOTICE: 





head portion. 



(h) 

Remove the chain from the camshaft timing sprocket. 

17. REMOVE CAMSHAFT TIMING SPROCKET 

(a) Remove the bolt and the camshaft timing sprocket. 


A133815 

90° 

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. 

A137743 

(a) 



2 

4 

3 

1 

A133124 

2 

4 

3 

1 

10 

12 

11 

9 

14 

16 

15 

13 

6 

8 

7 

5 

A133125 


(a) Remove the camshaft bearing cap No. 2 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.



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. 

A133818 

M 

Advance Angle Port 

Retard Angle Port 

A033448J02 

22. INSPECT CAMSHAFT TIMING SPROCKET 

(a) Cover all the ports except one advance port shown in the illustration 

with plastic tape. 

(b) Secure the service hexagon wrench head portion of the camshaft 

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 

A033449J01 

(d) 

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. 

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.



(e) 

(f) 

(g) 

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°. 

Rotate the camshaft timing sprocket by hand and lock it in the 

most retarded position. 


Camshaft NO. 1 

(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

A137596 

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 journal 

part of the cylinder head, and then install camshaft No. 2. 

NOTICE: 


camshaft No. 2 push down the lifter valve. 



(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

A137596 

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. 

I2 

15 

13 

14 

I3 

7 

5 

6 

I4 

3 

1 

2 

I5 

11 

(b) 




NOTICE: 

• Position the cap so the arrows on it face toward the 




E2 

E3 

E4 

E5 

9 

10 

16 

8 

4 

12 

A133070



3 

1 

2 

4 

A133071 


(a) Tighten the camshaft bearing cap No. 1 in the order shown in 



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. 

M 

Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(b) 

Install the camshaft knock pin and the camshaft timing sprocket. 

NOTICE: 








replace the camshaft timing sprocket. 


(a) Install the chain so the matchmarks of the camshaft timing gear 


Timing Marks 

A133561 

(b) 

Pull the 3 mm diameter bar out from the chain tensioner. 

NOTICE: 




A109220



Timing Marks 

(c) 

(d) 

Make sure that each timing mark is positioned as shown in the 

illustration. 

Apply TB1324 to the first 2 to 3 threads of the chain cover service 

hole screw plug bolt. 

NOTICE: 



Notch 

A137746 

(e) 

Using a 10 mm socket hexagon wrench, install the chain cover 



A137724 


7. INSTALL TIMING CHAIN (BELT) COVER NO. 2 

(a) Apply Three Bond TB1207B to the position shown in the illustration. 

CAUTION: 



TB1207B. 

• Do not start the engine within 2 hours of installation. 

A139347 

(b) 



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 ) 

A107960 


13. CONNECT VENTILATION HOSE NO. 2 (See page EM-166 )



14. CONNECT VENTILATION HOSE (See page EM-166 ) 



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 ) 

M 

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 )

CAMSHAFT (K3-VE) 


COMPONENTS 

ENGINE MECHANICAL - CAMSHAFT (K3-VE) 



T=3.5{36} 

BATTERY 

BATTERY CLAMP 

×2 

T=7.5{76} 


T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 







T=5.4{55} ×11 


A136903J01



VENTILATION HOSE VENTILATION HOSE NO. 2 

T=11{112} 

×2 

T=7.5{76} 


×4 

×4 


T=7.5{76} 

M 

T=9.0{92} 


GASKET 

×11 


T=12.5{130} 

RADIATOR PIPE 

×4 

T=12.5{130} 

×16 


×8 

CAMSHAFT TIMING 

SPROCKET 

CAMSHAFT 


T=47{480} 

TIMING CHAIN (BELT) COVER NO. 2 

T=8.5{87} 

T=17{173} 

CHAIN COVER SERVICE HOLE 

SCREW PLUG 


A137081J01















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. 

Timing Marks 





HINT: 



Notch 

A140612



(b) 




Paint Mark 

Paint Mark 

M 

Timing Marks 

A107964J01 

(c) 



A133812 

(d) 



A137724 

(e) 

(f) 




HINT: 






and hold.[*2] 

HINT: 


plunger. 

A133813



A133879 

(g) 




NOTICE: 




• Hold the camshaft in the position using the hexagonal 

head portion. 



(h) 

Remove the chain from the camshaft timing sprocket. 


(a) Remove the bolt and the camshaft timing sprocket. 


A133815 

90° 


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. 

A137743 

(a) 



2 

4 

3 

1 

A133124 

2 

4 

3 

1 

10 

12 

11 

9 

14 

16 

15 

13 

6 

8 

7 

5 

A133125 




NOTICE: 


HINT: 

Be sure to keep the removed parts separate according to the 

installation areas. 

20. REMOVE CAMSHAFT 

(a) Remove the camshaft.



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. 

A133818 

M 

Advance Angle Port 

Retard Angle Port 

A033448J02 

22. INSPECT CAMSHAFT TIMING SPROCKET 

(a) Cover all the ports except one advance port shown in the illustration 

with plastic tape. 

(b) Secure the service hexagon wrench head portion of the camshaft 

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 

A033449J01 

(d) 

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. 

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.



(e) 

(f) 

(g) 

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°. 

Rotate the camshaft timing sprocket by hand and lock it in the 

most retarded position. 



(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

A137596 

INSTALLATION 





the piston. 

(b) Apply engine oil to the cam part of camshaft No. 2 and the journal 

part of the cylinder head, and then install camshaft No. 2. 

NOTICE: 





(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

A137596 




NOTICE: 




(a) Confirm the front mark and number of the camshaft bearing cap 

No. 2 and install it. 

I2 

15 

13 

14 

I3 

7 

5 

6 

I4 

3 

1 

2 

I5 

11 

(b) 

Tighten the camshaft bearing cap No. 2 in the order indicated in 



NOTICE: 

• Position the cap so the arrows on it face toward the 




E2 

E3 

E4 

E5 

9 

10 

16 

8 

4 

12 

A133070



3 

1 

2 

4 

A133071 


(a) Tighten the camshaft bearing cap No. 1 in the order shown in 



NOTICE: 

Tighten it after checking that the thrust part of the camshaft 

is aligned with the groove on camshaft bearing cap No. 1. 



M 

Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(b) 

Install the camshaft knock pin and the camshaft timing sprocket. 

NOTICE: 

• If the knock pin and pin hole do not align, use the hexagonal 









(a) Install the chain so the matchmarks of the camshaft timing gear 


Timing Marks 

A133561 

(b) 

Pull the 3 mm diameter bar out from the chain tensioner. 

NOTICE: 




A109220



Timing Marks 

(c) 

(d) 

Make sure that each timing mark is positioned as shown in the 

illustration. 

Apply TB1324 to the first 2 to 3 threads of the chain cover service 

hole screw plug bolt. 

NOTICE: 



Notch 

A140612 

(e) 

Using a 10 mm socket hexagon wrench, install the chain cover 



A137724 


7. INSTALL TIMING CHAIN (BELT) COVER NO. 2 

(a) Apply Three Bond TB1207B to the position shown in the illustration. 

CAUTION: 



TB1207B. 


A139347 

(b) 







A107960 


13. CONNECT VENTILATION HOSE NO. 2 (See page EM-193)



14. CONNECT VENTILATION HOSE (See page EM-193) 








M 







26. CHECK DENSITY OF CO AND HC (See page EM-6)

ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE) 

CYLINDER HEAD GASKET (3SZ-VE) 


COMPONENTS 



T=3.5{36} 

BATTERY 

BATTERY CLAMP 

×2 

T=7.5{76} 


T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 







T=5.4{55} ×11 


A136903J01





M 


T=7.5{76} 

×4 

SPARK PLUG 

T=20{204} 



×4 

T=7.5{76} 

×4 

O-RING 

T=7.5{76} 

IDLER PULLEY 


T=11.5{117} 

×3 

RADIATOR PIPE 

T=44{449} 

T=130{1326} 

T=20.6{210} 

×3 

O-RING 

T=7.5{76} 






A136904J02





T=7.5{76} 

THROTTLE BODY ASSEMBLY 

×2 

T=21{214} 


×2 

T=7.5{76} 

T=19{194} 

O-RING 

T=21{214} 


THROTTLE BODY 

BRACKET NO. 2 

T=19{194} 

×2 ×3 ×2 

THROTTLE BODY 

BRACKET 

T=8.5{87} 


GASKET 

O-RING 


INSULATOR NO. 1 

T=8.5{87} 

T=8.5{87} 

T=19{194} 

T=10{102} 

GASKET 

T=32{326} 

T=44{449} 

T=35{357} 

×2 


×3 

T=9.3{95} 

EXHAUST 

MANIFOLD 

T=35{357} 

..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART 

A140623J01





T=11{112} 

×11 

T=9.0{92} 

M 



COVER GASKET 

T=9.0{92} 


TIMING CHAIN 

TENSIONER ARM 


CHAIN 

T=23{235} 

T=12{122} 

×9 

×2 

T=44{449} 

×3 

T=19{195} 

T=7.5{76} 

T=7.5{76} 

×2 






A136905J03





×4 

T=12.5{130} 

×8 

×16 

T=12.5{130} 

CAMSHAFT 

CAMSHAFT TIMING SPROCKET 


T=47{480} 

×10 

CYLINDER HEAD BOLT 

CYLINDER HEAD 


×10 

WASHER 

CYLINDER HEAD GASKET 

PLASTIC REGION TIGHTENING METHOD 


A137085J01




1. DISCHARGE FUEL SYSTEM PRESSURE 

(a) Procedure required when removing the F/P relay 

(1) Turn the ignition switch to the LOCK position. 

M 

F/P Relay 

Instrument Panel J/B 

A135986J01 

(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. 



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. 

A136001




(a) Loosen the clip, then disconnect the heater outlet water hose. 

A136002 

15. REMOVE RADIATOR PIPE 

(a) Remove the 2 bolts, loosen the clip and then remove the radiator 

pipe. 


A133397 

16. REMOVE VENTILATION HOSE 

(a) Loosen the clip and remove the ventilation hose. 

A134307 

17. REMOVE VENTILATION HOSE NO. 2 

(a) Loosen the clip and remove ventilation hose No. 2. 

A134308 


(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. 

A131808



(d) 

Remove the 2 bolts and disconnect the ground wire. 

A133250 

M 

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. 

A134989 

21. REMOVE FUEL HOSE NO. 2 

(a) Loosen the clip, then disconnect fuel hose No. 2. 

A133396 

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 vacuum 

tube. 

A136065 

24. REMOVE THROTTLE BODY ASSEMBLY 

(a) Remove the 2 bolts and bracket. 

(b) Disconnect the throttle body assembly connector and wire harness 

clamp. 

A131805



Blue Paint 

(c) 

(d) 

(e) 

Loosen the clamp, then disconnect the water hose. 

Remove the 3 bolts and the throttle body assembly. 


A131806 

BOLT 

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. 


A134311 

26. REMOVE THROTTLE BODY BRACKET 

(a) Remove the 2 bolts and the throttle body bracket. 

A109106 

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. 

O-ring 

(b) 

Remove the O- ring and insulator from the fuel injector assembly. 

28. REMOVE INTAKE MANIFOLD 

(a) Disconnect the water by-pass hose from the cylinder head. 

(b) Disconnect the wire harness from the intake manifold. 

Insulator 

A107004J02 

(c) 

(d) 

Remove the 3 bolts and 2 nuts, then remove the intake manifold. 

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) 

A109108





A137714 

M 

34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

(a) Remove the 5 bolts and the exhaust manifold heat insulator No. 

1. 

A133399 

35. REMOVE MANIFOLD STAY 

(a) Remove the 2 bolts and the manifold stay. 

A136071 

36. REMOVE EXHAUST MANIFOLD 

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust manifold. 


(a) Disconnect the ignition coil connector. 

A133400



(b) 

Remove the bolt and the ignition coil assembly. 

A133310 

38. REMOVE CYLINDER HEAD COVER 

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head 

cover. 


A132251 

Timing Marks 

39. REMOVE CRANKSHAFT PULLEY 




HINT: 



Notch 

A137746 

(b) 

Using the SST, hold the crankshaft pulley and loosen the bolt. 

SST 09278-87201 

SST 

A139349



SST 

(c) 

Using the SST and the crankshaft pulley bolt, remove the crankshaft 

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. 

A137589 

M 

40. REMOVE CRANK POSITION SENSOR 

(a) Remove the bolt and the crank position sensor. 

A137713 


(a) Remove the bolt and the camshaft timing oil control valve 

assembly. 

A136191 

42. REMOVE TIMING CHAIN (BELT) COVER 

(a) Remove the 13 bolts and 2 nuts. 

A133402



(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. 

A133404 

43. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL 

(a) Using a screwdriver, pry out the timing chain (belt) cover oil 

seal. 


Protective Tape 

Wooden 

Block 

A033132J01 

D-MARK 



A135998 

A108005 



released.[*1] 

HINT: 




(b) Under the conditions noted at [*1], use the hexagon head portion 


and hold.[*2] 

HINT: 


plunger.



(c) 



HINT: 




Stopper Plate 

Plunger 

A108555J01 

M 

(d) 

(e) 



Remove the bolt and nut and then remove the water inlet. 

A108556 



A108557 



A108558 




A108559



Hold 


(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. 

A136076 

2 





4 

3 

1 

A133124 

2 

4 

3 

10 

12 

11 

14 

16 

15 

6 

8 

7 




NOTICE: 


1 

9 

13 

5 

A133125 

4 6 9 7 1 

2 8 10 5 3 

A132854 

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 illustration, 

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 

M 

21-27 mm 

A 

25mm 

0-4 mm 

20mm 

A108575J01 

Cylinder Head 

2.5 mm 

1. INSPECT CYLINDER HEAD BOLT 

(a) Using vernier calipers, measure the diameter of the thread 

within the range indicated by A in the illustration. 


8.75 mm 

HINT: 

• Measure the diameter at several locations. If the smallest 

measured value is above the limit, the engine may be damaged. 

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 illustration. 

Cylinder Head 

Gasket 

17-23 mm 

2.0 mm 

Cylinder Block 

A083197J02 

(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. 

Front 

A033157J01 

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. 

Apply Engine Oil 

A133007 

7 5 2 4 10 

(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 specified 

torque. 



9 

3 1 6 8 

A133008 

Paint Mark 

180° Tighten 

A140645 

(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. 


(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

(b) 

Apply engine oil to the cam part of camshaft No. 2 and the journal 

part of the cylinder head, and then install the camshaft No. 

2. 

NOTICE: 



A137596




(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 




NOTICE: 



A137596 

M 

I2 

15 

13 

14 

16 

I3 

7 

5 

6 

8 

I4 

3 

1 

2 

4 

I5 

11 

9 

10 

12 


(a) Confirm the front mark and number of camshaft bearing cap No. 


(b) Tighten the camshaft bearing cap No. 2 in the order shown in 



NOTICE: 





E2 

E3 

E4 

E5 

A133070 

3 

1 

2 

4 


(a) Tighten the camshaft bearing cap No. 1 in the order indicated in 



NOTICE: 



cap No. 1. 

A133071 



Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(b) 

Align the camshaft knock pin and the camshaft timing sprocket 


NOTICE: 











Hold 

(c) 

(d) 

Apply a small amount of engine oil to the camshaft timing 


install them. 

Using the hexagon head portion of the camshaft, tighten the 



A136076 

Mark Plate 

Timing Mark 

Mark Plate 

Timing Mark 




HINT: 

Install so that the mark plate is on the engine front side. 


Mark Plates 

Timing Mark 

A137742 




A108559 




A108558






A108557 

M 

A108556 




HINT: 




plunger. 


plunger. 

D Mark 



visible. 

A133073 

15. INSTALL TIMING CHAIN (BELT) COVER 

(a) Install a new gasket to the timing chain (belt) cover. 

A108562 


A108563J02 

(b) 

Apply Three Bond TB1207B to the locations shown in the illustration. 

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. 


6 mm Diameter 

B 

B 

6 mm Diameter 


3-4 mm Diameter 3 mm Diameter 

A 

A 

3-4 mm 

3-4 mm 


A139363 

4 

3 

11 

12 

13 

2 

10 

15 

14 

(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) 

5 

1 

6 

9 

7 8 

A136081 

SST 

17. INSTALL CRANKSHAFT PULLEY 

(a) Using the SST, hold the crankshaft pulley and tighten the bolt. 

SST 09278-87201 




A137588



(b) 



NOTICE: 


A137713 

M 



(b) Install the camshaft timing oil control valve assembly with the 

bolt. 


NOTICE: 


A136191 

8 

2 


A079650J02 

4 

12 13 

10 11 

6 

9 

20. INSTALL CYLINDER HEAD COVER 

(a) Apply seal packing black to the position shown in the illustration. 

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 


5 

3 

1 

7 

A133409 




23. INSTALL EXHAUST MANIFOLD 

(a) Install the exhaust manifold using a new gasket. 

A133310



(b) 

Install the intake manifold with the 3 bolts and 2 nuts in the 

order shown in the illustration. 



A133400 

24. INSTALL MANIFOLD STAY 

(a) Install the manifold stay with the bolt. 

Torque: 9.3 N*m (95 kgf*cm) (Bolt) 

A136071 

25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts. 




A133399 




29. INSTALL VANE PUMP WITH BRACKET (See page EM-68) 




A137714



33. INSTALL INTAKE MANIFOLD 

(a) Temporarily install the intake manifold with the 3 bolts and 2 

nuts using a new gasket. 

A109108 

M 

(b) 

Tighten the bolts and nuts in the order shown in the illustration. 


A079976J02 

A109106 

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. 

O-ring 

35. INSTALL FUEL INJECTOR ASSEMBLY 

(a) Install a new injector vibration insulator. 

(b) Apply gasoline to the new fuel injector assembly O-ring. 

Insulator 

A107004J01



(c) 

(d) 

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. 

Check that the fuel injector assembly rotates smoothly. 

NOTICE: 

If the fuel injector assembly does not rotate smoothly, reinstall 

it with a new O-ring. 

A107005 


(a) Install the fuel pipe insulator. 

A136082 

(b) 

(c) 

(d) 

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). 

Check that the fuel injectors rotate smoothly. 

NOTICE: 

If a fuel injector does not rotate smoothly, reinstall it with a 

new O-ring. 

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. 

A133250 

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. 

Yellow Paint 

A131812 

M 

White Paint 

Yellow Paint 

44. INSTALL VENTILATION HOSE NO. 2 

(a) Install ventilation hose No. 2. 

A131807 

45. INSTALL RADIATOR PIPE 

(a) Install the radiator pipe with the 2 bolts and connect the hose. 


A133397 



A136002 



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) 

A136001



52. INSTALL BATTERY CARRIER 

(a) Install the battery carrier with the 3 bolts. 



54. CONNECT BATTERY NEGATIVE TERMINAL 


A 

B 

A 

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. 



A136084 





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. 

(1) Connect the DS-II to the DLC. 

(2) Follow the prompts on the screen to select ACTIVE TEST 

/ CIRCUIT RELAY / ON, and check the fuel pump operation. 

(b) Check for fuel leaks. 

(1) Check that there are no leaks in the fuel system with fuel 

pressure applied. 







ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE) 

CYLINDER HEAD GASKET (K3-VE) 


COMPONENTS 


T=3.5{36} 

BATTERY 

M 

BATTERY CLAMP 

×2 

T=7.5{76} 

T=8.5{87} 

×3 

T=18{184} 

T=7.5{76} 

×2 







T=5.4{55} ×11 


A136903J01






T=7.5{76} 

×4 

SPARK PLUG 

T=20{204} 




×4 

T=7.5{76} 

×4 

O-RING 

T=7.5{76} 

IDLER PULLEY 


T=11.5{117} 

×3 

RADIATOR PIPE 

T=44{449} 

T=130{1326} 

T=20.6{210} 

×3 

O-RING 

T=7.5{76} 






A136904J02



M 


T=7.5{76} 


×2 

THROTTLE BODY ASSEMBLY 

O-RING 

T=19{194} 

T=21{214} 

T=19{194} 

×2 

×3 

×2 

T=21{214} 

T=7.5{76} 

×2 


THROTTLE BODY 

BRACKET NO. 2 

THROTTLE BODY 

BRACKET 

T=8.5{87} 


GASKET 

O-RING 

EXHAUST MANIFOLD HEAT 

INSULATOR NO. 1 

T=8.5{87} 

T=8.5{87} 

T=19{194} 

T=10{102} 

GASKET 

T=32{326} 

T=44{449} 


T=35{357} 

T=9.3{95} 

×2 

×3 

T=35{357} 

EXHAUST 

MANIFOLD 



A140623J02





T=11{112} 

×11 

T=9.0{92} 




COVER GASKET 

T=9.0{92} 


TIMING CHAIN 

TENSIONER ARM 


CHAIN 

T=23{235} 

T=12{122} 

×9 

×2 

T=44{449} 

×3 

T=19{195} 

T=7.5{76} 

T=7.5{76} 

×2 






A136905J03





×4 

T=12.5{130} 

×8 

×16 

T=12.5{130} 

CAMSHAFT 

CAMSHAFT TIMING SPROCKET 

M 

T=47{480} 

×10 

CYLINDER HEAD BOLT 

CYLINDER HEAD 


×10 

WASHER 

CYLINDER HEAD GASKET 

PLASTIC REGION TIGHTENING METHOD 


A137085J01

F/P Relay 

Instrument Panel J/B 


A135986J01 



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 opening 

with a shop rag or a similar to prevent fuel from splashing. 

(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. 




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.




(a) Loosen the clip, then disconnect the heater inlet water hose 

from the radiator pipe. 

A136001 

M 


(a) Loosen the clip, then disconnect the heater outlet water hose. 

A136002 

15. REMOVE RADIATOR PIPE 

(a) Remove the 2 bolts, loosen the clip and then remove the radiator 

pipe. 

A133397 

16. REMOVE VENTILATION HOSE 

(a) Loosen the clip and remove the ventilation hose. 

A134307 

17. REMOVE VENTILATION HOSE NO. 2 

(a) Loosen the clip and remove ventilation hose No. 2. 

A134308




(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. 

A131808 

(d) 

Remove the 2 bolts and disconnect the ground wire. 


A133250 

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. 

A134989 

21. REMOVE FUEL HOSE NO. 2 

(a) Loosen the clip, then disconnect fuel hose No. 2. 

A133396 

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 vacuum 

tube. 

A136065



24. REMOVE THROTTLE BODY ASSEMBLY 

(a) Remove the 2 bolts and bracket. 

(b) Disconnect the throttle body assembly connector and wire harness 

clamp. 

A131805 

M 

Blue Paint 

(c) 

(d) 

(e) 

Loosen the clamp, then disconnect the water hose. 



A131806 

BOLT 

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. 

A134311 

26. REMOVE THROTTLE BODY BRACKET 

(a) Remove the 2 bolts and the throttle body bracket. 

A109106 

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. 

O-ring 

(b) 

Remove the O- ring and insulator from the fuel injector assembly. 

28. REMOVE INTAKE MANIFOLD 

(a) Disconnect the water by-pass hose from the cylinder head. 

(b) Disconnect the wire harness from the intake manifold. 

Insulator 

A107004J02



(c) 

(d) 

Remove the 3 bolts and 2 nuts, then remove the intake manifold. 

Remove the gasket from the intake manifold. 


30. REMOVE VANE PUMP WITH BRACKET (See page EM-79) 



A109108 




A137714 

34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

(a) Remove the 5 bolts and the exhaust manifold heat insulator No. 

1. 

A133399 

35. REMOVE MANIFOLD STAY 

(a) Remove the 2 bolts and the manifold stay. 

A136071



36. REMOVE EXHAUST MANIFOLD 

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust manifold. 


(a) Disconnect the ignition coil connector. 

M 

A133400 

(b) 

Remove the bolt and the ignition coil assembly. 

A133310 

38. REMOVE CYLINDER HEAD COVER 

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head 

cover. 

A132251



Timing Marks 





HINT: 




Notch 

A140612 

(b) 

Using the SST, hold the crankshaft pulley and loosen the bolt. 

SST 09278-87201 

SST 

A139349 

SST 

(c) 


pulley. 

SST 09306-87501 

NOTICE: 



A137589 

40. REMOVE CRANK POSITION SENSOR 

(a) Remove the bolt and the crank position sensor. 

A137713




(a) Remove the bolt and the camshaft timing oil control valve 

assembly. 

A136072 

M 

42. REMOVE TIMING CHAIN (BELT) COVER 


A133402 

(b) 


remove the timing chain (belt) cover. 

NOTICE: 

Do not damage the timing chain cover, cylinder block or 

cylinder head. 

A133404 


(a) Using a screwdriver, pry out the timing chain (belt) cover oil 

seal. 


Wooden 

Block 

A033132J01



D-MARK 



A135998 

A108005 



released.[*1] 

HINT: 




(b) Under the conditions noted at [*1], use the hexagon head portion 


and hold.[*2] 

HINT: 


plunger. 


(c) 



HINT: 




Stopper Plate 

Plunger 

A108555J01 

(d) 

(e) 



Remove the bolt and nut and then remove the water inlet. 

A108556





A108557 

M 



A108558 




A108559 

Hold 


(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. 

A136076 

2 




4 

3 

1 

A133124



2 

4 

3 

10 

12 

11 

14 

16 

15 

6 

8 

7 




NOTICE: 


1 

9 

13 

5 

A133125 

4 6 9 7 1 

2 8 10 5 3 

A132854 

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 illustration, 

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 

A 

25mm 

20mm 

A108575J01 

1. INSPECT CYLINDER HEAD BOLT 

(a) Using vernier calipers, measure the diameter of the thread 

within the range indicated by A in the illustration. 


8.75 mm 

HINT: 

• Measure the diameter at several locations. If the smallest 

measured value is above the limit, the engine may be damaged. 

Replace the bolt with a new one. 

• If there is any damage to the thread on the bolt, replace the 

cylinder head bolt. 

21-27 mm 

0-4 mm 

Cylinder Head 

2.5 mm 

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. 


Cylinder Head 

Gasket 

17-23 mm 

2.0 mm 

Cylinder Block 

A083197J02



(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. 

M 

Front 

A033157J01 

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. 

Apply Engine Oil 

A133007 

7 5 2 4 10 

(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 specified 

torque. 


9 

3 1 6 8 

A133008 

(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. 

Paint Mark 

180° Tighten 

A140645







the piston. 


(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 

(b) 

Apply engine oil to the cam part of camshaft No. 2 and the journal 

part of the cylinder head, and then install the camshaft No. 

2. 

NOTICE: 



A137596 



(In Side) 


(Ex Side) 

NO. 3 NO. 4 NO. 4 NO. 2 




NOTICE: 



A137596 

I2 

15 

13 

14 

16 

I3 

7 

5 

6 

8 

I4 

3 

1 

2 

4 

I5 


(a) Confirm the front mark and number of camshaft bearing cap No. 


(b) Tighten the camshaft bearing cap No. 2 in the order shown in 



NOTICE: 





E2 

E3 

E4 

E5 

11 

9 

10 

12 

A133070 

3 

1 

2 

4 


(a) Tighten the camshaft bearing cap No. 1 in the order indicated in 



NOTICE: 



cap No. 1. 

A133071 


(a) Apply engine oil to the installation surface to the camshaft.



Pin Hole 

Knock Pin 

Do Not Remove 

A136098 

(b) 

Align the camshaft knock pin and the camshaft timing sprocket 


NOTICE: 









M 

Hold 

(c) 

Apply a small amount of engine oil to the camshaft timing 


install them. 

(d) 

Using the hexagon head portion of the camshaft, tighten the 



A136076 

Mark Plate 

Timing Mark 

Mark Plate 

Timing Mark 




HINT: 

Install so that the mark plate is on the engine front side. 

Mark Plates 

Timing Mark 

A137742






A108559 





A108558 




A108557 

A108556 




HINT: 




plunger. 


plunger. 

D Mark 



visible. 

A133073



15. INSTALL TIMING CHAIN (BELT) COVER 

(a) Install a new gasket to the timing chain (belt) cover. 

A108562 

M 


A108563J02 

(b) 

Apply Three Bond TB1207B to the locations shown in the illustration. 

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. 


B 

B 

6 mm Diameter 

6 mm Diameter 

A 

A 

3-4 mm Diameter 3 mm Diameter 

3-4 mm 

3-4 mm 


A139363



4 

3 

11 

12 

13 

2 

10 

15 

14 

(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) 

5 

1 

9 

6 

7 8 

A136081 


SST 



SST 09278-87201 




A137588 

(b) 



NOTICE: 


A137713 



(b) Install the camshaft timing oil control valve assembly with the 

bolt. 


NOTICE: 


A136072




A079650J02 

20. INSTALL CYLINDER HEAD COVER 


NOTICE: 



TB1207B. 

• Tighten the cylinder head cover to the specified torque 

within 15 minutes of applying Three Bond TB1207B. 


M 

8 

2 

4 

12 13 

6 

9 

(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 


10 11 

5 

3 

1 

7 

A133409 




23. INSTALL EXHAUST MANIFOLD 

(a) Install the exhaust manifold using a new gasket. 

A133310 

(b) 

Install the intake manifold with the 3 bolts and 2 nuts in the 

order shown in the illustration. 


A133400



24. INSTALL MANIFOLD STAY 

(a) Install the manifold stay with the bolt. 

Torque: 9.3 N*m (95 kgf*cm) (bolt) 


A136071 

25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts. 




A133399 




29. INSTALL VANE PUMP WITH BRACKET (See page EM-103) 




A137714 

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. 


A079976J02



M 

O-ring 

A109106 

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. 

Insulator 

A107004J01 

(c) 

(d) 

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. 

Check that the fuel injector assembly rotates smoothly. 

NOTICE: 

If the fuel injector assembly does not rotate smoothly, reinstall 

it with a new O-ring. 

A107005 


(a) Install the fuel pipe insulator. 

A136082 

(b) 

(c) 

(d) 

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). 

Check that the fuel injectors rotate smoothly. 

NOTICE: 

If a fuel injector does not rotate smoothly, reinstall it with a 

new O-ring. 

Tighten the 2 bolts. 

Torque: 21 N*m (214 kgf*cm)



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. 


A133250 

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. 

Yellow Paint 

A131812 

White Paint 

Yellow Paint 

44. INSTALL VENTILATION HOSE NO. 2 

(a) Install ventilation hose No. 2. 

A131807



45. INSTALL RADIATOR PIPE 

(a) Install the radiator pipe with the 2 bolts and connect the hose. 


A133397 

M 



A136002 



48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-24) 




25) 

A136001 

52. INSTALL BATTERY CARRIER 

(a) Install the battery carrier with the 3 bolts. 



54. CONNECT BATTERY NEGATIVE TERMINAL 


A 

B 

A 

A136084 

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 throttle 

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. 

56. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26)







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. 

(1) Connect the DS-II to the DLC. 

(2) Follow the prompts on the screen to select ACTIVE TEST 

/ CIRCUIT RELAY / ON, and check the fuel pump operation. 

(b) Check for fuel leaks. 

(1) Check that there are no leaks in the fuel system with fuel 

pressure applied. 








ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE) 

TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE) 


COMPONENTS 

M 


T=7.5{76} 

×2 

FRONT BUMPER COVER 


FOG LIGHT ASSEMBLY RH 

FOG LIGHT ASSEMBLY LH 

T=5.4{55} 

×11 


A136654J01



RADIATOR RESERVE 

TANK ASSEMBLY 

CHARCOAL CANISTER NO. 1 


T=7.5{76} 


T=7.5{76} 

CHARCOAL CANISTER 


RADIATOR SUPPORT UPR 

T=7.5{76} 

×2 

RADIATOR CAP 


×2 

×2 

WITH WATER 

FAN ASSEMBLY 

RADIATOR SUPPORT CUSHION 

T=7.5{76} 

×4 

RADIATOR ASSEMBLY 

T=5.0{51} 

T=5.0{51} 

DRAIN COCK SUB-ASSEMBLY 

×2 


A/T 

OIL COOLER 

OUTLET HOSE NO. 1 

T=5.0{51} 

T=5.0{51} 

CONDENSER ASSEMBLY 

(WITH RESERVOIR) 

SEAL PLATE 



A136655J01



M 


T=130{1326} 




A137089J02








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 

SST 

A139349 

SST 

(b) 


pulley. 

SST 09306-87501 

NOTICE: 




(a) Using a cutter knife, cut off the lip of the oil seal. 

A137589




(b) 


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). 

M 

A107954J01 

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 matter. 

• Wipe off any grease on the crankshaft. 

SST 

A137591 

(b) 

(c) 

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. 

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) 



SST 


A139349 

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) 


TRANSMISSION)(See page CO-18)






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) 




24. CHECK COOLANT LEVEL (See page CO-10)


ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE) 

TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE) 


COMPONENTS 

M 


T=7.5{76} 

×2 

FRONT BUMPER COVER 


FOG LIGHT ASSEMBLY RH 

FOG LIGHT ASSEMBLY LH 

T=5.4{55} 

×11 


A136654J01



RADIATOR RESERVE 

TANK ASSEMBLY 

CHARCOAL CANISTER NO. 1 


T=7.5{76} 


T=7.5{76} 

CHARCOAL CANISTER 


RADIATOR SUPPORT UPR 

T=7.5{76} 

×2 

RADIATOR CAP 


×2 

×2 

WITH WATER 

FAN ASSEMBLY 


T=7.5{76} 

×4 

RADIATOR ASSEMBLY 

T=5.0{51} 

T=5.0{51} 

DRAIN COCK SUB-ASSEMBLY 

×2 


A/T 

OIL COOLER 

OUTLET HOSE NO. 1 

T=5.0{51} 

T=5.0{51} 

CONDENSER ASSEMBLY 

(WITH RESERVOIR) 

SEAL PLATE 



A136655J01



M 


T=130{1326} 




A137089J02








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 

SST 

A139349 

SST 

(b) 


pulley. 

SST 09306-87501 

NOTICE: 




(a) Using a cutter knife, cut off the lip of the oil seal. 

A137589




(b) 


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). 

M 

A107954J01 

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 matter. 

• Wipe off any grease on the crankshaft. 

SST 

A137591 

(b) 

(c) 

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. 

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) 



SST 


A139349 

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) 


TRANSMISSION)(See page CO-25)






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) 




24. CHECK COOLANT LEVEL (See page CO-12)


ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE) 

ENGINE REAR OIL SEAL (3SZ-VE) 


COMPONENTS 


ENGINE REAR OIL SEAL 

T=7.5{76} 

M 

×7 

T=10{102} 

ENGINE REAR OIL SEAL RETAINER 

×4 

T=68{693} 

T=8.5{86} 

×10 

T=8.5{86} 

×4 

OIL PAN 



M/T 


T=19.1{195} 

A/T 

T=27.5{280} 

T=78{800} 

×6 

×6 

×6 

×6 


FLYWHEEL 

T=78{800} 





A139030J01





SION) 

HINT: 

See IP-8 for the procedure leading up to the removal of the transmission 

assembly. 


SION) (See page EM-49) 


SION) 

HINT: 


assembly. 






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 differential 

carrier assembly. 



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 cylinder 

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



12. REMOVE ENGINE REAR OIL SEAL RETAINER 

(a) Remove the 7 bolts and then the engine rear oil seal retainer. 

A139034 

M 

A139035 

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. 

Wooden Block 

SST 

-0.5-1 mm 

A139032 

3-4 mm 

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. 


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 

3. INSTALL OIL PAN 

(a) Apply Three Bond TB1207B to the locations shown in the illustration 

(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. 

• Do not start the engine within 2 hours of installation.



(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) 






SION) 

HINT: 

See IP-8 for the procedure leading up to the installation of the transmission 

assembly. 




SION) 

HINT: 


assembly.


ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE) 

ENGINE REAR OIL SEAL (K3-VE) 


COMPONENTS 


ENGINE REAR OIL SEAL 

T=7.5{76} 

M 

×7 

T=10{102} 

ENGINE REAR OIL SEAL RETAINER 

×4 

T=68{693} 

T=8.5{86} 

×10 

T=8.5{86} 

×4 

OIL PAN 



M/T 


T=19.1{195} 

A/T 

T=27.5{280} 

T=78{800} 

×6 

×6 

×6 

×6 


FLYWHEEL 

T=78{800} 





A139030J01





SION) 

HINT: 


assembly. 


SION) (See page EM-84) 


SION) 

HINT: 


assembly. 






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 differential 

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 cylinder 

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



11. REMOVE ENGINE REAR OIL SEAL RETAINER 

(a) Remove the 7 bolts and then the engine rear oil seal retainer. 

A139034 

M 

A139035 

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. 

Wooden Block 

SST 

-0.5-1 mm 

A139032 

3-4 mm 

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. 


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 

3. INSTALL OIL PAN 

(a) Apply Three Bond TB1207B to the locations shown in the illustration 

(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. 

• Do not start the engine within 2 hours of installation.



(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) 







SION) 

HINT: 


assembly. 




SION) 

HINT: 


assembly. 

TO INDEX 

TO NEXT SECTION

EM ENGINE MECHANICAL

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