1712-1U-01G(01-10B).fm
1 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
01–10B MECHANICAL [FS]
MECHANICAL LOCATION INDEX
[FS] . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT INSPECTION [FS]. . . . . . .
Drive Belt Deflection Inspection . . . . . .
Drive Belt Tension Inspection . . . . . . .
DRIVE BELT ADJUSTMENT [FS] . . . . .
VALVE CLEARANCE
INSPECTION [FS] . . . . . . . . . . . . . . . . .
VALVE CLEARANCE
ADJUSTMENT [FS]. . . . . . . . . . . . . . . .
COMPRESSION INSPECTION [FS] . . . .
Compression . . . . . . . . . . . . . . . . . . . .
TIMING BELT
REMOVAL/INSTALLATION [FS] . . . . .
Crankshaft Pulley Removal Note . . . . .
Cylinder Head Cover Removal Note . .
No.3 Engine Mount Rubber
Removal Note . . . . . . . . . . . . . . . . . .
Timing Belt Removal Note . . . . . . . . . .
Tensioner, Tensioner Spring
Installation Note . . . . . . . . . . . . . . . . .
Timing Belt Installation Note . . . . . . . .
Cylinder Head Cover
Installation Note . . . . . . . . . . . . . . . . .
Crankshaft Pulley Installation Note . . .
Water Pump Pulley Installation Note . .
CYLINDER HEAD GASKET
REPLACEMENT [FS] . . . . . . . . . . . . . .
01–10B–2
01–10B–3
01–10B–3
01–10B–3
01–10B–4
01–10B–5
01–10B–6
01–10B–8
01–10B–8
01–10B–8
01–10B–10
01–10B–10
01–10B–10
01–10B–10
01–10B–11
01–10B–12
01–10B–13
01–10B–14
01–10B–14
Camshaft Pulley Removal Note . . . . . . 01–10B–15
Camshaft Removal Note . . . . . . . . . . . . 01–10B–16
Cylinder Head Removal Note . . . . . . . . 01–10B–16
Cylinder Head Installation Note. . . . . . . 01–10B–16
Camshaft Installation Note . . . . . . . . . . 01–10B–17
Camshaft Pulley Installation Note . . . . . 01–10B–18
FRONT OIL SEAL
REPLACEMENT [FS] . . . . . . . . . . . . . . . 01–10B–19
Front Oil Seal Removal Note . . . . . . . . 01–10B–19
Front Oil Seal Installation Note . . . . . . 01–10B–19
REAR OIL SEAL
REPLACEMENT [FS] . . . . . . . . . . . . . . . 01–10B–20
Rear Oil Seal Removal Note . . . . . . . . . 01–10B–20
Rear Oil Seal Installation Note . . . . . . . 01–10B–20
ENGINE
REMOVAL/INSTALLATION [FS] . . . . . . 01–10B–21
Roll damper Installation Note . . . . . . . . 01–10B–22
No.3, No.4 Engine Mount Installation
Note. . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10B–23
ENGINE
DISASSEMBLY/ASSEMBLY [FS] . . . . . 01–10B–24
ENGINE TUNE-UP [FS] . . . . . . . . . . . . . . 01–10B–25
Engine Tune-up Preparation . . . . . . . . . 01–10B–25
Ignition Timing Inspection . . . . . . . . . . . 01–10B–25
Idle Speed Adjustment . . . . . . . . . . . . . 01–10B–26
Idle-up Speed Inspection . . . . . . . . . . . 01–10B–26
Idle Mixture Inspection . . . . . . . . . . . . . 01–10B–26
01–10B–14
End of Toc
01–10B–1
01–10B
1712-1U-01G(01-10B).fm
2 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
MECHANICAL LOCATION INDEX [FS]
A3U011001002W01
Z3U0110W100
.
1
2
3
Drive belt
(See 01–10B–3 DRIVE BELT INSPECTION [FS])
(See 01–10B–4 DRIVE BELT ADJUSTMENT [FS])
Timing belt
(See 01–10B–8 TIMING BELT REMOVAL/
INSTALLATION [FS])
Cylinder head gasket
(See 01–10B–14 CYLINDER HEAD GASKET
REPLACEMENT [FS])
End Of Sie
01–10B–2
4
5
6
Front oil seal
(See 01–10B–19 FRONT OIL SEAL
REPLACEMENT [FS])
Rear oil seal
(See 01–10B–20 REAR OIL SEAL REPLACEMENT
[FS])
Engine
(See 01–10B–21 ENGINE REMOVAL/
INSTALLATION [FS])
(See 01–10B–24 ENGINE DISASSEMBLY/
ASSEMBLY [FS])
1712-1U-01G(01-10B).fm
3 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
DRIVE BELT INSPECTION [FS]
A3U011015800W01
Inspect the drive belt tension or deflection, as necessary.
Drive Belt Deflection Inspection
Note
• Inspect the drive belt deflection when the engine is cold, or at least 30 min after the engine has stopped.
01–10B
1. Apply moderate pressure 98 N {10 kgf, 22 lbf}
midway between the specified pulleys.
X3U110WF0
• If the deflection is not within the specification,
adjust it. (See 01–10B–4 DRIVE BELT
ADJUSTMENT [FS].)
Deflection
mm {in}
Drive belt
Generator
P/S, P/S+A/C
Limit
10.0 {0.39}
11.0 {0.43}
X3U110WF1
Drive Belt Tension Inspection
Note
• Belt tension can be inspected in place of belt deflection. Inspect the drive belt tension when the engine is
cold, or at least 30 min after the engine has been stopped.
1. Using the SST, inspect the belt tension between
any two pulleys.
• If the tension is not within the specification,
adjust it. (See 01–10B–4 DRIVE BELT
ADJUSTMENT [FS].)
Tension
N {kgf, lbf}
Drive belt
Generator
P/S, P/S+A/C
End Of Sie
Limit
390 {40, 88}
390 {40, 88}
X3U110WF2
01–10B–3
1712-1U-01G(01-10B).fm
4 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
DRIVE BELT ADJUSTMENT [FS]
A3U011015800W02
1. Loosen mounting bolt A and B.
X3U110WF3
2. Adjust the belt deflection or tension by turning the
adjusting bolt C.
Caution
• If the belt is replaced with a new one or
the belt has been on a running engine for
less than 5 minutes, adjust deflection or
tension to “New” specification.
• If the belt has been on a running engine
for more than 5 minutes, adjust
deflection or tension to “Used”
specification.
X3U110WF4
X3U110WF0
Deflection
mm {in}
Drive belt
New
Used
Generator
6.5—7.5 {0.26—0.29} 7.0—9.0 {0.28—0.35}
P/S, P/S+A/
7.5—9.0 {0.30—0.35} 8.0—9.5 {0.32—0.37}
C
X3U110WF1
01–10B–4
1712-1U-01G(01-10B).fm
5 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Tension
N {kgf, lbf}
Drive belt
Generator
P/S, P/S+A/
C
New
690—830 {70—85,
160—180}
590—780 {60—80,
140—170}
Used
500—680 {50—70,
110—150}
500—680 {50—70,
110—150}
01–10B
3. Tighten mounting bolt A and B.
4. Inspect the belt deflection or tension.
• If not as specified, repeat from Step 1.
End Of Sie
VALVE CLEARANCE INSPECTION [FS]
X3U110WF2
A3U011012010W01
1. Remove the cylinder head cover. (See 01–10B–10 Cylinder Head Cover Removal Note.)
2. Verify that the engine is in cold condition.
3. Measure the valve clearance.
(1) Turn the crankshaft clockwise so that the
No.1 piston is at TDC of the compression
stroke.
Y3U110WAC
(2) Measure the valve clearance at A in the
figure.
X3U110WF6
• If the valve clearance exceeds the
standard, replace the adjustment shim.
(See 01–10B–6 VALVE CLEARANCE
ADJUSTMENT [FS].)
Standard [Engine cold]
IN: 0.225—0.295 mm {0.0089—0.0116 in}
±0.035 mm {0.010±
±0.001 in})
(0.26±
EX: 0.225—0.295 mm {0.0089—0.0116 in}
±0.035 mm {0.010±
±0.001 in})
(0.26±
(3) Turn the crankshaft 360°° clockwise so that
X3U110WF7
the No.4 piston is at TDC of the compression
stroke.
(4) Measure the valve clearance at B in the figure.
• If the valve clearance exceeds the standard, replace the adjustment shim. (See 01–10B–6 VALVE
CLEARANCE ADJUSTMENT [FS].)
Standard [Engine cold]
±0.035 mm {0.010±
±0.001 in})
IN: 0.225—0.295 mm {0.0089—0.0116 in} (0.26±
±0.035 mm {0.010±
±0.001 in})
EX: 0.225—0.295 mm {0.0089—0.0116 in} (0.26±
4. Install the cylinder head cover. (See 01–10B–13 Cylinder Head Cover Installation Note.)
End Of Sie
01–10B–5
1712-1U-01G(01-10B).fm
6 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
VALVE CLEARANCE ADJUSTMENT [FS]
A3U011012010W02
Perform this same procedure for all camshafts requiring valve clearance adjustment.
1. Turn the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are
positioned straight up.
2. Remove the camshaft cap bolts as necessary.
Note
• Remove only one pair of cap bolts at a time.
• Reinstall the cap bolts before removing the
next pair.
— A: For EX side No.1, 2, 3 cylinder
adjustment shim removal.
— B: For IN side No.1, 2, 3 cylinder
adjustment shim removal.
— C: For EX side No.2, 3, 4 cylinder
adjustment shim removal.
— D: For IN side No.2, 3, 4 cylinder
adjustment shim removal.
X3U110WF8
Note
• For EX side No.2, 3 cylinder adjustment shim removal, remove bolts either A or C.
• For IN side No.2, 3 cylinder adjustment shim removal, remove bolts either B or D.
3. Install the SSTs on the camshaft using the
camshaft cap bolt holes.
X3U110WF9
Tightening torque
11.3—14.2 N·m {115—145 kgf·cm, 100—125
in·lbf}
X3U110WFA
4. Align the marks on the SSTs (shaft and shaft
clamp).
5. Tighten bolts A to secure the SST (shaft).
X3U110WFB
01–10B–6
1712-1U-01G(01-10B).fm
7 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
6. Face the SST (body) outside of the cylinder head,
and mount it on the SST (shaft) at the point of the
adjustment shim to be replaced.
01–10B
X3U110WFC
7. Face the notch of the tappet so that a fine
screwdriver can be inserted.
8. Set the SST on the tappet by its notch.
X3U110WFD
9. Tighten bolt B to secure the SST (body).
Caution
• Cylinder head can be damaged when the
tappet is pressed down.
10. Tighten bolt C, and press down the tappet.
X3U110WFE
11. Using a fine screwdriver, pry up the adjustment
shim through the notch on the tappet. Remove
the shim using a magnet.
12. Select proper adjustment shim.
New adjustment shim
= Removed shim thickness + Measured
valve clearance - Standard valve clearance
(0.26 mm {0.010 in})
13.
14.
15.
16.
Push the selected shim into the tappet.
Loosen bolt C to allow the tappet to move up.
Loosen bolt B and remove the SST (body).
Remove the SSTs and tighten the camshaft cap
bolts.
X3U110WFF
Tightening torque
11.3—14.2 N·m {115—145 kgf·cm, 100—125 in·lbf}
17. Verify the valve clearance. (See 01–10B–5 VALVE CLEARANCE INSPECTION [FS].)
End Of Sie
01–10B–7
1712-1U-01G(01-10B).fm
8 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
COMPRESSION INSPECTION [FS]
A3U011002000W01
Warning
• Hot engines and oil can cause severe burns. Be careful not to burn yourself during removal/
installation of each component.
1. Verify that the battery is fully charged.
• Recharge it if necessary. (See 01–17–1 BATTERY INSPECTION.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool off for about 10 min.
4. Perform “Fuel Line Safety Procedures”. Leave the fuel pump relay removed. (See 01–14–4 BEFORE REPAIR
PROCEDURE.)
5. Remove the ignition coils. (See 01–18–1 IGNITION COIL REMOVAL/INSTALLATION.)
6. Remove the spark plugs.
7. Connect a compression gauge into the No.1 spark plug hole.
8. Fully depress the accelerator pedal and crank the engine.
9. Note the maximum gauge reading.
10. Inspect each cylinder as above.
• If the compression in one or more cylinders is low or the compression difference between cylinders
exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the
compression.
— If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is
required.
— If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
— If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the
cylinder head distorted and overhaul is required.
Compression
kPa {kgf/cm2, psi} [rpm]
Item
Standard
Minimum
Maximum difference
between cylinders
Engine type
FS
1,177 {12.0, 171} [300]
824 {8.4, 119} [300]
196 {2.0, 28}
1. Disconnect the compression gauge.
2. Install the spark plugs.
Tightening torque
15—22 N·m {1.5—2.3 kgf·m, 11—16 ft·lbf}
3. Connect the ignition coil connector.
4. Install the fuel pump relay.
End Of Sie
TIMING BELT REMOVAL/INSTALLATION [FS]
A3U011012040W01
1. Disconnect the negative battery cable.
2. Remove the CMP sensor and CKP sensor. (See 01–40B–34 CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION [FS].) (See 01–40B–34 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION [FS].)
3. Remove the ignition coils. (See 01–18–1 IGNITION COIL REMOVAL/INSTALLATION.)
4. Remove the spark plug.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Inspect the air gap. (See 01–40B–32 Air Gap Inspection.)
8. Adjust the drive belt deflection/tension. (See 01–10B–4 DRIVE BELT ADJUSTMENT [FS].)
9. Start the engine and:
(1) Inspect the pulleys and drive belt for runout and contact.
(2) Inspect the ignition timing. (See 01–10B–25 Ignition Timing Inspection.)
01–10B–8
1712-1U-01G(01-10B).fm
9 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
01–10B
Y3U110WAD
.
1
2
3
4
5
6
Drive belt
(See 01–10B–4 DRIVE BELT ADJUSTMENT [FS])
Water pump pulley
(See 01–10B–14 Water Pump Pulley Installation
Note)
Crankshaft pulley
(See 01–10B–10 Crankshaft Pulley Removal Note)
(See 01–10B–14 Crankshaft Pulley Installation
Note)
Guide plate
Cylinder head cover
(See 01–10B–10 Cylinder Head Cover Removal
Note)
(See 01–10B–13 Cylinder Head Cover Installation
Note)
Dipstick and pipe
7
8
9
10
11
Timing belt cover
No.3 Engine mount rubber
(See 01–10B–10 No.3 Engine Mount Rubber
Removal Note)
Timing belt
(See 01–10B–10 Timing Belt Removal Note)
(See 01–10B–12 Timing Belt Installation Note)
Tensioner, tensioner spring
(See 01–10B–11 Tensioner, Tensioner Spring
Installation Note)
Idler
01–10B–9
1712-1U-01G(01-10B).fm
10 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Crankshaft Pulley Removal Note
1. Remove the crankshaft using the SST.
X3U110WFH
Cylinder Head Cover Removal Note
1. Remove the cylinder head cover bolts a few turns
in the order shown.
X3U110WFJ
No.3 Engine Mount Rubber Removal Note
1. Suspend the engine using the SST.
Z3U110WFK
Timing Belt Removal Note
1. Install the pulley lock bolt.
2. Turn the crankshaft clockwise and align the timing
marks.
X3U110WFL
01–10B–10
1712-1U-01G(01-10B).fm
11 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
3. Turn the tensioner clockwise using an Allen
wrench.
4. Disconnect the tensioner spring from the hook
pin.
Caution
• Forcefully twisting the timing belt turning
it inside out, or allowing oil or grease on
it will damage the belt and shorten its life.
01–10B
X3U110WFM
Note
• Mark the timing belt rotation on the belt for
proper reinstallation.
X3U110WFN
Tensioner, Tensioner Spring Installation Note
1. Measure the tensioner spring free length.
• If not within the specification, replace the
tensioner spring.
Free length
36.6 mm {1.44 in}
2. Install the tensioner.
X3U110WFP
3. Rotate the tensioner.
• If tensioner rotates with no resistance or does
not rotate, replace the tensioner.
X3U110WFQ
01–10B–11
1712-1U-01G(01-10B).fm
12 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Timing Belt Installation Note
1. Verify that the timing belt pulley mark and
camshaft pulley marks are aligned with the timing
marks as shown.
X3U110WFR
X3U110WFS
2. Install the timing belt so that there is no looseness
at the idler side.
X3U110WFT
3. Turn the crankshaft clockwise twice, and align the
timing marks.
4. Verify that all timing marks are correctly aligned.
• If not aligned, remove the timing belt and
repeat from Step 1.
Caution
• Be sure not to apply tension other than
that of the tensioner spring.
5. Turn the tensioner clockwise using an Allen
wrench.
01–10B–12
X3U110WFU
1712-1U-01G(01-10B).fm
13 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
6. Connect the tensioner to the hook pin.
01–10B
X3U110WFV
7. Turn the crankshaft clockwise twice, and verify
that all timing marks are aligned.
• If not aligned, repeat from Step 1.
X3U110WFL
Cylinder Head Cover Installation Note
1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material.
2. Install the cylinder head cover gasket into the cylinder head cover.
3. Apply silicone sealant to the cylinder head as
shown.
Z3U110WFW
4. Tighten the cylinder head cover bolts a few turns
in the order shown.
X3U110WFX
01–10B–13
1712-1U-01G(01-10B).fm
14 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Crankshaft Pulley Installation Note
1. Install the crankshaft using the SST.
X3U110WFY
Water Pump Pulley Installation Note
1. Install the water pump pulley by facing the “F”
marks outward.
End Of Sie
X3U110WGL
CYLINDER HEAD GASKET REPLACEMENT [FS]
A3U011010271W01
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedures”. (See 01–14–4 BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–2 COOLING SYSTEM SERVICE WARNINGS.) (See 01–12–3 ENGINE
COOLANT REPLACEMENT.)
3. Remove the timing belt. (See 01–10B–8 TIMING BELT REMOVAL/INSTALLATION [FS].)
4. Remove the front pipe. (See 01–15–1 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the air cleaner.
6. Remove the P/S oil pump and bracket with the oil hose still connected.
7. Remove the accelerator cable. (See 01–13B–17 ACCELERATOR CABLE ADJUSTMENT [FS].)
8. Disconnect the fuel hose. (See 01–14–4 BEFORE REPAIR PROCEDURE.) (See 01–14–4 BEFORE REPAIR
PROCEDURE.)
9. Remove in the order indicated in table.
10. Install in the reverse order of removal.
11. Inspect the engine oil level. (See 01–11–2 ENGINE OIL INSPECTION.)
12. Inspect for the engine oil, engine coolant, and fuel leakage.
13. Inspect the compression. (See 01–10B–8 COMPRESSION INSPECTION [FS].)
14. Start the engine and:
(1) Inspect the pulleys and the drive belt for runout and contact.
(2) Inspect the ignition timing. (See 01–10B–25 Ignition Timing Inspection.)
(3) Inspect the idle speed. (See 01–10B–26 Idle Speed Adjustment.)
01–10B–14
1712-1U-01G(01-10B).fm
15 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
01–10B
Y3U110WA6
.
1
2
3
Camshaft pulley
(See 01–10B–15 Camshaft Pulley Removal Note)
(See 01–10B–18 Camshaft Pulley Installation Note)
Camshaft
(See 01–10B–16 Camshaft Removal Note)
(See 01–10B–17 Camshaft Installation Note)
Intake manifold bracket
4
5
Cylinder head
(See 01–10B–16 Cylinder Head Removal Note)
(See 01–10B–16 Cylinder Head Installation Note)
Cylinder head gasket
Camshaft Pulley Removal Note
1. Hold the camshaft using a wrench on the cast
hexagon as shown.
X3U110WG0
01–10B–15
1712-1U-01G(01-10B).fm
16 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Camshaft Removal Note
1. Loosen the camshaft cap bolts a few turns in the
order shown.
Z3U110WG1
Cylinder Head Removal Note
1. Loosen the cylinder head bolts a few turns in the
order shown.
X3U110WG2
Cylinder Head Installation Note
1. Measure the length of each bolt. Replace any that
exceed the maximum length.
Standard length
104.2—104.8 mm {4.103—4.125 in}
Maximum length
105.5 mm {4.153 in}
X3U110WG3
2. Tighten the cylinder head bolts a few turns in the
order shown.
Tightening torque
17.5—22.5 N·m {1.79—2.29 kgf·m, 13.0—16.5
ft·lbf}
X3U110WG4
01–10B–16
1712-1U-01G(01-10B).fm
17 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
3. Put a paint mark on each bolt head.
4. Using the marks as a reference, tighten the bolts
by turning each 85°°—95°° in the sequence shown.
5. Further tighten each bolt by turning another 85°°—
95°° in the sequence shown.
01–10B
Y3U110WA7
Camshaft Installation Note
Caution
• Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is
installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust
receiving area of the cylinder head journal. To avoid this, the following procedure must be
observed.
1. Assemble camshaft onto the cylinder head, facing
the cam noses at No.1 and No.3 cylinders as
shown.
X3U110WG6
2. Apply silicone sealant to the areas shown.
Note
• Keep the camshaft sliding surface free of
sealant to prevent engine damage.
3. Apply engine oil to the camshaft and the cylinder
head journals.
4. Install the camshaft caps to the positions from
which they were removed.
Z3U110WG7
5. Hand tighten the camshaft cap bolts marked 5, 7,
2, and 4.
6. Tighten the camshaft cap bolts a few turns in the
order shown.
7. Verify that the camshaft settles horizontally when
2 bearing cap bolts at No.3 journal are tightened.
8. Apply clean engine oil to the camshaft oil seal.
9. Push the oil seal slightly in by hand.
Z3U110WG8
01–10B–17
1712-1U-01G(01-10B).fm
18 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
10. Tap the oil seals in evenly using the SST and a
hammer.
X3U110WG9
Camshaft Pulley Installation Note
1. Install the camshaft pulleys, positioning the dowel
pins as shown.
X3U110WGA
2. Hold the camshaft using a wrench on the cast
hexagon as shown.
End Of Sie
X3U110WG0
01–10B–18
1712-1U-01G(01-10B).fm
19 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
FRONT OIL SEAL REPLACEMENT [FS]
A3U011010602W01
1. Disconnect the negative battery cable.
2. Remove the timing belt. (See 01–10B–8 TIMING BELT REMOVAL/INSTALLATION [FS].)
3. Remove in the order indicated in the table.
1
2
3
Timing belt pulley
Key
Front oil seal
(See 01–10B–19 Front Oil Seal Removal Note)
(See 01–10B–19 Front Oil Seal Installation Note)
01–10B
4. Install in the reverse order of removal.
X3U110WGB
Front Oil Seal Removal Note
1. Cut the oil seal lip using a razor.
2. Remove the oil seal using a screwdriver protected
with a rag.
X3U110WGC
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
End Of Sie
Y3U110WA8
01–10B–19
1712-1U-01G(01-10B).fm
20 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
REAR OIL SEAL REPLACEMENT [FS]
A3U011011399W01
1. Remove the flywheel. (MTX) (See 05–10–11 CLUTCH UNIT REMOVAL/INSTALLATION.)
2. Remove the drive plate. (ATX) (See 05–17–46 DRIVE PLATE REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1
Rear oil seal
(See 01–10B–20 Rear Oil Seal Removal Note)
(See 01–10B–20 Rear Oil Seal Installation Note)
4. Install in the reverse order of removal.
X3U110WGE
Rear Oil Seal Removal Note
1. Cut the oil seal lip using a razor.
2. Remove the oil seal using a screwdriver protected
with a rag.
X3U110WGF
Rear Oil Seal Installation Note
1. Apply clean engine oil to the new oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
End Of Sie
Y3U110WA9
01–10B–20
1712-1U-01G(01-10B).fm
21 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
ENGINE REMOVAL/INSTALLATION [FS]
A3U011002000W02
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedures”.
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–2 COOLING SYSTEM SERVICE WARNINGS.) (See 01–12–3 ENGINE
COOLANT REPLACEMENT.)
3. Remove the radiator. (See 01–12–4 RADIATOR REMOVAL/INSTALLATION.)
4. Remove the air cleaner.
5. Remove the accelerator cable. (See 01–13B–17 ACCELERATOR CABLE INSPECTION [FS].) (See 01–13B–
17 ACCELERATOR CABLE ADJUSTMENT [FS].)
6. Disconnect the fuel hose. (See 01–14–4 BEFORE REPAIR PROCEDURE.) (See 01–14–5 AFTER REPAIR
PROCEDURE.)
7. Remove the front pipe. (See 01–15–1 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the rods, cables and pipes related to the transaxle.
9. Remove the battery.
10. Remove the fuse box.
11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
12. Remove the A/C compressor with the pipe still connected. position the A/C compressor so that it is out of the
way.
13. Remove the drive shaft. (See 03–13–9 DRIVE SHAFT REMOVAL/INSTALLATION.)
14. Remove in the order indicated in the table.
15. Install in the reverse order of removal.
16. Start the engine and
(1) Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.
(2) Inspect the ignition timing, idle speed and idle mixture. (See 01–10B–25 Ignition Timing Inspection.) (See
01–10B–26 Idle Speed Adjustment.) (See 01–10B–26 Idle Mixture Inspection.)
17. Perform a road test.
01–10B–21
01–10B
1712-1U-01G(01-10B).fm
22 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
Z3U0110W997
1
2
3
4
Roll damper
Engine mount member
No.3 Engine mount
(See 01–10B–23 No.3, No.4 Engine Mount
Installation Note)
No.1 Engine mount
5
6
7
No.2 Engine mount
No.4 Engine mount
(See 01–10B–23 No.3, No.4 Engine Mount
Installation Note)
Engine, transaxle
Roll damper Installation Note
1. Assemble the rod and roll damper as shown in
the figure.
Z3U0110W991
01–10B–22
1712-1U-01G(01-10B).fm
23 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
No.3, No.4 Engine Mount Installation Note
1. Hand tighten the No.3 and No.4 engine mount
rubber bolts and nuts (A—M).
2. Tighten the No.4 engine mount rubber bolts and
nuts (A—H).
3. Tighten the No.3 engine mount rubber bolts and
nuts (I—N)
4. Measure the No.4 engine mount rubber
clearance.
• If not within the specification, repeat from step
1.
01–10B
Standard clearance
3.0—4.0 mm {0.12—0.15 in}
End Of Sie
Z3U0110W996
01–10B–23
1712-1U-01G(01-10B).fm
24 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
ENGINE DISASSEMBLY/ASSEMBLY [FS]
A3U011002000W03
1. Disconnect the engine and transaxle. (See 05–15B–4 MANUAL TRANSAXLE (MTX) REMOVAL/
INSTALLATION [G15M-R].) (See 05–17–31 AUTOMATIC TRANSAXLE (ATX) REMOVAL/INSTALLATION.)
2. Remove the intake-air system. (See 01–13B–6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [FS].)
3. Remove the exhaust system. (See 01–15–1 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
4. Remove the oil filter. (See 01–11–3 OIL FILTER REPLACEMENT.)
5. Remove the thermostat. (See 01–12–5 THERMOSTAT REMOVAL/INSTALLATION.)
6. Remove the ignition coil.
7. Remove the generator.
8. Disassemble in the order indicated in the table.
9. Assemble in the reverse order of disassembly.
X3U110WGK
.
1
2
3
P/S oil pump bracket
A/C compressor bracket
Water bypass pipe
End Of Sie
01–10B–24
4
5
6
Water outlet
Thermostat housing
Generator bracket
1712-1U-01G(01-10B).fm
25 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
ENGINE TUNE-UP [FS]
A3U011002000W04
Engine Tune-up Preparation
1. Warm up the engine to normal operating temperature.
2. Shift the transaxle into neutral.
3. Turn off all electrical loads.
• Headlight switch
• Fan switch
• Rear window defroster switch
• A/C switch
4. Verify that the steering wheel is at straight ahead position.
5. Connect the SSTs (WDS or equivalent) to the
DLC-2.
6. Access RPM PID.
7. Wait until the electrical fan stops.
01–10B
Z3U110WA5
Ignition Timing Inspection
1. Perform “Engine Tune-up Preparation”.
2. Verify that the RPM PID is within the specification.
• If not as specified, adjust the idle speed. (See 01–10B–26 Idle Speed Adjustment.)
Specification
±50) rpm
650—750 (700±
3. Connect the timing light to the high-tension lead of the No.1 cylinder.
4. Verify that the timing mark (yellow) on the crankshaft pulley is within the specification.
• If not as specified, inspect following.
— CMP sensor
— CKP sensor
— TP sensor
— ECT sensor
— Neutral switch (MTX)
— Clutch switch (MTX)
— TR switch (ATX)
• If the devices are normal, replace the PCM. (See 01–40B–7 PCM REMOVAL/INSTALLATION [FS].)
Ignition timing
°±1°
BTDC 9°°—11°° (10°±
°± °) (TIMING MARK [YELLOW])
5. Connect the SST (System selector) to the DLC.
6. Set switch A to position 1.
7. Set the test switch to SELF TEST.
X3U110WGQ
01–10B–25
1712-1U-01G(01-10B).fm
26 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
8. Verify that the timing mark (yellow) on the
crankshaft pulley is within the specification.
• If not as specified, inspect the following.
— CMP sensor
— CKP sensor
— TP sensor
— ECT sensor
— Neutral switch (MTX)
— Clutch switch (MTX)
— TR switch (ATX)
• If the devices are normal, replace the PCM.
(See 01–40B–7 PCM REMOVAL/
INSTALLATION [FS].)
X3U110WGN
Specification
BTDC 6°°—18°°
Idle Speed Adjustment
1. Perform “Engine Tune-up Preparation”.
2. Verify that the RPM PID is within the specification.
• If not as specified, adjust the idle speed by
turning the AAS.
Specification
±50) rpm
650—750 (700±
Caution
• The TAS is set at the factory and must
not be adjusted. Any adjustment will
negatively effect the engine performance.
3.
4.
5.
6.
7.
Connect the SST (System selector) to the DLC.
Set switch A to position 1.
Set the test switch to SELF TEST.
Press CLEAR to clear previously selected items.
Disconnect the SSTs.
X3U110WGP
Idle-up Speed Inspection
1. Perform “Engine Tune-up Preparation”.
2. Connect the SST (System selector) to the DLC.
3. Set switch A to position 1.
4. Set the test switch to SELF TEST.
5. Verify that the idle speed is normal. (See 01–10B–26 Idle Speed Adjustment.)
6. Verify that the RPM PID is within the specification.
• If not as specified with all load conditions, inspect the IAC valve.
• If not as specified with some load condition, inspect the related input switches, harnesses, and connectors.
Specification
Load condition
E/L ON*2
650—750
3
P/S operating*
A/C ON*
*1
*2
*3
*4
Idle-up speed (rpm)*1
4
700—800
700—800
: Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on.
: Headlight is on, Fan switch is above 1st, Cooling fan is operating, Rear window defroster is on.
: Steering wheel is fully turned.
: A/C switch and fan switch are on.
Idle Mixture Inspection
1. Perform “Engine Tune-up Preparation”.
2. Verify that the idle speed and ignition timing are within the specification. (See 01–10B–25 Ignition Timing
Inspection.) (See 01–10B–26 Idle Speed Adjustment.)
3. Turn the test mode off.
4. Warm up the engine by holding the engine speed at 2,500—3,000 rpm for approx. 3 min.
5. Insert an exhaust gas analyzer to the tailpipe.
01–10B–26
1712-1U-01G(01-10B).fm
27 ページ
2001年6月29日 金曜日 午前9時39分
MECHANICAL [FS]
6. Verify that the CO and HC concentrations are within the specified limits.
• If not within the specified limits, inspect the following:
— On-board diagnostic system (See 01–02B–15 DTC TABLE [FS].)
— HO2S (See 01–40B–37 HEATED OXYGEN SENSOR (HO2S) INSPECTION [FS].)
— Intake manifold vacuum (See 01–03B–56 Intake Manifold Vacuum Inspection.)
— Fuel line pressure (See 01–14–6 FUEL PRESSURE INSPECTION.)
— Ignition timing control
• If the systems and devices are normal, replace the TWC. (See 01–15–1 EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
End Of Sie
01–10B–27
01–10B
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