06.5MY RG COLT - Workshop Manual

GROUP 11A

ENGINE

MECHANICAL

<4A9>

CONTENTS

GENERAL INFORMATION . . . . . . . .

11A-2

SERVICE SPECIFICATIONS. . . . . . .

11A-3

SEALANTS . . . . . . . . . . . . . . . . . . . .

11A-3

SPECIAL TOOLS. . . . . . . . . . . . . . . .

11A-4

ON-VEHICLE SERVICE. . . . . . . . . . .

11A-6

DRIVE BELT TENSION CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . .

IGNITION TIMING CHECK . . . . . . . . . . . . .

11A-6

11A-9

IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-9

IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-10

VALVE CLEARANCE CHECK AND

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11A-10

COMPRESSION PRESSURE CHECK. . . . 11A-12

MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-13

CRANKSHAFT PULLEY . . . . . . . . . .

11A-14

REMOVAL AND INSTALLATION . . . . . . . . 11A-14

CAMSHAFT . . . . . . . . . . . . . . . . . . . .

11A-17


OIL PAN . . . . . . . . . . . . . . . . . . . . . . .

11A-24


CRANKSHAFT OIL SEAL . . . . . . . . .

11A-26


ENGINE ASSEMBLY . . . . . . . . . . . . .

11A-29

REMOVAL AND INSTALLATION <M/T> . . 11A-29

REMOVAL AND INSTALLATION <CVT> . . 11A-36

Main

Index

Group

TOC

11A-2

Item

Total displacement mL

Bore

× Stroke mm

Compression ratio

Compression chamber

Camshaft arrangement

Number of valve

Valve timing

Fuel system

Rocker arm

Auto-lash adjuster

ENGINE MECHANICAL <4A9>

GENERAL INFORMATION

GENERAL INFORMATION

Intake

Exhaust

Intake opening

Intake closing

Exhaust opening

Exhaust closing

M1111000100992

4A91

1,499

75.0

× 84.8

10.0

Pentroof

DOHC

8

8

BTDC 31

° − ATDC 19°

ABDC 21

° − ABDC 71°

BBDC 39

°

ATDC 5

°

Electronically controlled multipoint fuel injection

Not equipped

Not equipped

Main

Index

Group

TOC


SERVICE SPECIFICATIONS

11A-3

Item

Alternator and A/C drive belt tension (When adjusted)

Alternator and A/C drive belt tension (When replaced)

Basic ignition timing

SERVICE SPECIFICATIONS

Alternator and A/C drive belt tension (When checked)

M1112000300676

Vibration frequency Hz

Tension N

Standard value Limit

202

− 247

−

392

− 588

−

Deflection mm (Reference) 6.8

− 9.0

−

Vibration frequency Hz 214

− 237

−

Tension N 441

− 539

−


− 8.3

−

Vibration frequency Hz 286

− 319

−

Tension N 784

− 980

−


− 5.4

−

5

° BTDC ± 3°

−

Ignition timing

Idle speed r/min

Approximately

10

° BTDC

700

± 50

−

CO contents %

HC contents ppm

Valve clearance (at cold) mm Intake valve

Exhaust valve

Compression pressure (at engine speed of 300 r/min) kPa

Compression pressure difference of all cylinders kPa

Intake manifold vacuum kPa

0.1 or less

100 or less

0.22

± 0.04

0.30

± 0.04

1,200

−

−

−

−

−

−

−

Minimum

850

Maximum 98

Minimum 60

Main

Index

Group

TOC

Item

Timing chain tensioner cover

Cylinder head cover assembly

Engine oil pan

Crankshaft rear oil seal case assembly

Flywheel bolt <M/T>

Drive plate bolt <CVT>

SEALANTS

Specified Sealant

LOCTITE 5971 or exact equivalent

LOCTITE 2701 or equivalent

M1112000500766

Remark

Semi-drying sealant

11A-4

Tool

A

A

B

C


SPECIAL TOOLS

SPECIAL TOOLS

Number

MB992080

A: MB992081

B: MB992082

Name

Belt tension meter set

A: Belt tension meter

B: Microphone assembly

Main

Index

M1112000601164

Use

Drive belt tension check

Group

TOC

B

B992080

MB991824

MB991827

MB991955

A: MB991824

B: MB991827

C: MB991910

D: MB991911

E: MB991825

F: MB991826

M.U.T.-III sub assembly

A: Vehicle communication interface (V. C. I.)

B: M.U.T.-III USB cable

C: M.U.T.-III main harness

A (Vehicles with CAN communication system)

D: M.U.T.-III main harness

B (Vehicles without CAN communication system)

E: M.U.T.-III adapter harness

F: M.U.T.-III trigger harness

CAUTION

For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly.

• Drive belt tension check

• Checking the ignition timing

• Checking the idle speed

MB991910

D

DO NOT USE

MB991911

E

MB991825

F

MB991826

MB991955

MB991668 Belt tension meter set Drive belt tension check (used together with V.C.I.)

B991668

Tool

B991992


SPECIAL TOOLS

Number

MB991992

Name

Torque wrench adapter

11A-5

Use

Removal and installation of

V.V.T. sprocket assembly mounting bolt

Main

Index

Group

TOC

MD998727 Oil pan FIPG cutter Engine oil pan removal

D998727

MD998781

D998781

MB991993

Flywheel stopper

• Supporting the flywheel assembly <M/T>

• Supporting the drive plate assembly <CVT>

Crankshaft front oil seal guide

Crankshaft front oil seal installation

B991993

MB990699 Differential oil seal installer

B991527

MB991527

MB991454

Engine hanger

Engine hanger balancer

Supporting the engine and transmission assembly

For the engine hanger balancer

(MB991454), use a chain only.

NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.

B991454

11A-6 ENGINE MECHANICAL <4A9>

ON-VEHICLE SERVICE


DRIVE BELT TENSION CHECK AND

ADJUSTMENT

M1111003101433

ALTERNATOR AND A/C DRIVE BELT

TENSION CHECK

3. Press number key 1. Check to ensure that "No.

01" appears on the upper left of the display and that the following numeric values are displayed for individual items (M, W, and S):

M 000.9 g/m

Check the drive belt tension in the following procedure.

Item

Standard value:

When checked

When adjusted

When replaced

Vibration frequency

Hz

202

− 247

214

− 237 286 − 319

Tension N 392

− 588

441

− 539 784 − 980

Deflection mm

(Reference)

6.8

− 9.0

7.3

− 8.3

4.4

− 5.4

W 010.0 mm/R

S 0100 mm

If numeric values have not been entered (new tool), set them according to the belt specifications as shown below. Once you set them, you do not have to set them again. The settings remain undeleted even after battery replacement.

NOTE: This operation is to temporarily set the preset data such as the belt specifications, because if the measurement is taken without input of the belt specifications, conversion to tension value (N) cannot be made, resulting in judgement of error.

<When the vibration frequency is measured {Special tool (MB992080) is used}: Recommendation>

NOTE: The vibration frequency measuring method is recommended for check and adjustment of the drive belt tension.

Belt tension meter set (MB992080)

MB992081

MB992082

AC507219AB

1. Connect the Special tool microphone assembly

(MB992082) to the Special tool belt tension meter

(MB992081) of the Special tool belt tension meter set (MB992080).

2. Press the "POWER" button to turn on the power supply.

<Setting procedure>

(1) Press down the "MASS" button till the belt mass select display appears.

(2) Press the "UP" or "DOWN" button to select "01

1.5GT 0.9" and press the "MEASURE" button to decide it.

Check to ensure that "M 000.9 g/m" is displayed.

(3) Press the "WIDTH" button to change to the belt width input display.

(4) Press number keys 0, 1, 0, and 0 sequentially, and press the "SELECT" button to apply them.

Check to ensure that "W 010.0 mm/R" appears on the display.

(5) Press the "SPAN" button to change to the span length input display.

(6) Press number keys 0, 1, 0, and 0 sequentially, and press the "SELECT" button to apply them.

Check to ensure that "S 0100 mm" appears on the display.

4. Press "Hz" button twice to change the display to the frequency display (Hz).

Main

Index

Group

TOC

CAUTION

MB992080

(Microphone)

Idler pulley

15˚

15˚

•



10 – 20 mm

Alternator pulley

Water pump pulley

11A-7

<When the vibration frequency is measured vehicle communication interface (V.C.I.) is used:

Recommendation>

NOTE: The vibration frequency measuring method is recommended for check and adjustment of the drive belt tension.

CAUTION

Main

Index

Group

TOC

Crankshaft pulley

A/C compressor pulley

AK600612 AB

The temperature of the surface of the belt should be as close as possible to normal temperature.

• Do not let any contaminants such as water or

oil get onto the microphone.

• If strong gusts of wind blow against the

microphone or if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while

the measurement is being made, the values measured by the microphone may not correspond to actual values.

• Do not take the measurement while the vehi-

cle's engine is running.

5. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10

− 15 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of

± 15 °).

6. Press the "MEASURE" button.

7. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

NOTE: To take the measurement repeatedly, fillip the belt again.

8. After the completion of the measurement, press and hold the "POWER" button to turn off the power supply.

MB991668

Diagnosis connector

MB991910

MB991824

AK600561 AB

To prevent damage to special tool V.C.I.

(MB991824), always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting special tool V.C.I. (MB991824).

1. Connect the special tool belt tension meter set

(MB991668) to the special tool V.C.I (MB991824).

2. Connect special tool M.U.T.-III main harness A

(MB991910) to special tool V.C.I. (MB991824).

3. Connect special tool M.U.T.-III main harness A

(MB991910) to the diagnosis connector.

4. Turn the ignition switch to the "ON" position and select "Belt Tension Measurement" from the menu screen.



<Belt deflection check>

CAUTION

• The temperature of the surface of the belt

should be as close as possible to normal temperature.

• Do not let any contaminants such as water or

oil get onto the microphone.

• If strong gusts of wind blow against the

microphone or if there is loud sources of noise nearby, the values measured by the microphone may not correspond to actual values.

• If the microphone is touching the belt while

the measurement is being made, the values measured by the microphone may not correspond to actual values.

• Do not take the measurement while the vehi-

cle's engine is running.

15˚

15˚

10 – 20 mm

MB992080

(Microphone)

Idler pulley

Alternator pulley

Water pump pulley

Crankshaft pulley

A/C compressor pulley

AK600612 AB

5. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10

− 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of

± 15 °).

6. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

<When using the tension gauge>

Tension gauge

Idler pulley

Alternator pulley

Water pump pulley

A/C compressor

pulley

Crankshaft pulley

AK402042 AC

Use a belt tension gauge to check that the belt tension is within the standard value.

NOTE: Before inspection, remove the oil level gauge guide.

Approximately 100 N

Idler pulley

Water pump pulley

Deflection

Alternator pulley

A/C compressor

pulley

Crankshaft pulley

AK402043

AC

Apply approx. 100 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Adjusting bolt

Alternator fixing nut

Nut for alternator pivot bolt

AK402420AC

If not within the standard value, adjust the belt tension by the following procedure.

1. Loosen the nut of the nut for alternator pivot bolt.

2. Loosen the alternator fixing nut.

3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values.

4. Tighten the nut of the nut for alternator pivot bolt.

Tightening torque: 47

± 5 N⋅m

5. Tighten the alternator fixing nut.


± 2 N⋅m

6. Tighten the adjusting bolt.

Tightening torque: 5.0

± 1.0 N⋅m

CAUTION

When checking the belt tension, turn the crankshaft clockwise one turn or more.

7. Check the belt tension, and readjust if necessary.

8. When the belt tension is adjusted by measuring the deflection, adjust it with a tool for vibration frequency measurement or tension measurement afterward.

Main

Index

Group

TOC

IGNITION TIMING CHECK

16-PIN

MB991910



M1111001701428

11A-9

10.Check that ignition timing is at the standard value.

Standard value: approximately 10

° BTDC

NOTE: .

•

The ignition timing may fluctuate within

±

7

°

BTDC. This is normal.

•

In higher altitude, the ignition timing is more advanced than the standard value by approximately 5

°

.

11.Remove the timing light.

12.Turn off the ignition switch and then remove the

M.U.T.-III.

Main

Index

Group

TOC

IDLE SPEED CHECK

M1111003501293

MB991824

16-PIN

MB991827

AK203215 AC

1. Before inspection, set the vehicle to the pre-inspection condition.

2. Turn the ignition switch to the "LOCK" (OFF) position and then connect the M.U.T.-III to the diagnosis connector.

3. Set the timing light to the power supply line

(terminal No.1) of the ignition coil No.1.

4. Start the engine and let it run at idle.

5. Select item No. 22 on the M.U.T.-III to measure engine idle speed and check that it is approximately 700 r/min.

6. Select No. 17 of the M.U.T.-III Actuator test.

7. Check that basic ignition timing is within the standard value.

Standard value: 5

° BTDC ± 3°

8. If the basic ignition timing is outside the standard value, inspect the MPI system (Refer to GROUP

13A

− Troubleshooting − Inspection chart for diagnosis code P.13A-20 ).

CAUTION

If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine.

9. Press the M.U.T.-III clear key (Select a forced driving cancel mode) to release the Actuator test.

MB991824

MB991910

MB991827

AK203215 AC


2. Turn the ignition switch to "LOCK" (OFF) position.

3. Connect the M.U.T.-III to the diagnosis connector.




6. Check that ignition timing is at the standard value.


° BTDC

7. Check the idle speed.

Standard value: 700

± 50 r/min

NOTE: .

•

The idle speed is controlled automatically by the idle speed control system.

•

When using the M.U.T.-III, select item No. 22 and take a reading of the idle speed.

11A-10

IDLE MIXTURE CHECK



8. If the idle speed is outside the standard value, inspect the MPI system (Refer to GROUP 13A

−

Troubleshooting

− Inspection chart for diagnosis code P.13A-20 ).

M1111002100965

VALVE CLEARANCE CHECK AND

ADJUSTMENT

M1111001500487

NOTE: Perform the valve clearance check and adjustment at the engine cold state.

1. Remove all ignition coils.

2. Remove the cylinder head cover.

CAUTION

Turn the crankshaft always clockwise.

Main

Index

Group

TOC

Timing mark

16-PIN

MB991910

MB991824

MB991827

AK203215 AC







6. Check that ignition timing is at the standard value.


° BTDC

7. Run the engine at 2,500 r/min for 2 minutes.

8. Set the CO, HC tester.

9. Check the CO contents and the HC contents at idle.

Standard value

CO contents: 0.1 % or less

HC contents: 100 ppm or less

10.If there is a deviation from the standard value, inspect the MPI system (Refer to GROUP 13A

−

Troubleshooting

− Inspection chart diagnosis code P.13A-20 )

AK306138AB

3. Turn the crankshaft clockwise, and align the timing mark on the exhaust camshaft sprocket against the upper face of the cylinder head as shown in Figure. Therefore, No.1 cylinder goes to the compression top dead centre.

No. 1

Exhaust valve side

No. 3

No. 1 No. 2

Intake valve side

AK305589 AB

4. Using a thickness gauge, measure the valve clearance with the arrow shown in Figure. If deviated from the standard value, make note for the valve clearance.

Standard value:

Intake valve 0.22

± 0.04 mm

Exhaust valve 0.30

± 0.04 mm

Timing mark



AK306139AB

5. Turn the crankshaft clockwise 360 degrees, and put the timing mark on the exhaust camshaft sprocket in position shown in Figure. Therefore,

No.4 cylinder goes to the compression top dead centre.

Identification mark

11A-11

9. Calculate the thickness of the newly installed valve tappet through the following equation.

A: thickness of newly installed valve tappet

B: thickness of removed valve tappet

C: measured valve clearance

Equation

Intake valve: A = B + (C

− 0.22 mm)

Exhaust valve: A = B + (C

− 0.30 mm)

NOTE:

Main

Index

Group

TOC

Exhaust valve side

No. 2 No. 4

No. 3

Intake valve side

No. 4

AK305589 AC

6. Check the valve clearance with the arrow shown in Figure. In the same procedure as 4.

7. If the valve clearance is deviated from the standard value, remove the camshaft and the valve tappet. For the camshaft removal, refer to

Camshaft Removal and Installation

P.11A-17

.

Wall thickness

AK305693 AB

The valve tappet ranges 2.70

−

3.30 mm and has

31 types per 0.02 mm. The thickness below a decimal point is stamped on the reverse side of the valve tappet.

Example: In case of 2.90 mm, "90" is stamped.

10.Install the valve tappet selected through the procedure 10, and put the camshaft in position.

For the camshaft installation, refer to Camshaft

Removal and Installation

P.11A-17 .

11.Remove any liquid gasket remaining on the cylinder head cover, the timing chain case and the cylinder head.

AK304938 AB

8. Using a micrometer, measure the thickness of the removed valve tappet.

AK304933AB

CAUTION

The cylinder head cover should be installed within 3 minutes of applying liquid gasket.

12.Apply a 4 mm bead of liquid gasket as illustrated.

Specified sealant:

LOCTITE 5971 or exact equivalent



4

10

7

1 5

3

Compression gauge

6

9

Timing chain side

2 8

AK401050 AB

13.Install the cylinder head cover and in accordance with the procedure shown in Figure, tighten the bolt of the cylinder head cover.


± 1.0 N⋅m

14.Install the ignition coils.

COMPRESSION PRESSURE CHECK

M1111002601491


2. Remove all of the ignition coils and spark plugs.

Injector connectors

AK305808AB

3. Disconnect the all of the injector connectors.

CAUTION

• Keep away from the spark plug hole when

cranking.

• If compression is measured with water, oil,

fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

4. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel.

AK305516AB

5. Set compression gauge to one of the spark plug holes.

6. Crank the engine with the throttle valve fully open and measure the compression pressure.

Standard value (at engine speed of 300 r/min):

1,200 kPa

Limit (at engine speed of 300 r/min): Minimum

850 kPa

7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit.

Limit: Maximum 98 kPa

8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps from 5 to 7.

(1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

(2) If the compression dose not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

9. Connect the crank angle sensor connector.

10.Install the spark plugs and spark plug cables.

11.Use the M.U.T.-III to erase the diagnosis codes.

NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.

Main

Index

Group

TOC

MANIFOLD VACUUM CHECK



11A-13


M1111002701119

PCV valve

Main

Index

Plug

Group

TOC

16-PIN

Vacuum gauge

MB991910

MB991824

MB991827

AK203215 AC



AK402145 AC

4. Disconnect the ventilation hose from the positive crankcase ventilation (PVC) valve, and then connect a vacuum gauge to the ventilation hose.

Plug the positive crankcase ventilation (PCV) valve.

5. Start the engine and check that idle speed is approximately 700 r/min.

6. Check the intake manifold vacuum.

Limit: Minimum 60 kPa

7. Turn off the ignition switch.

8. Remove the vacuum gauge and then connect the ventilation hose to the positive crankcase ventilation (PCV) valve.

9. Remove the M.U.T.-III.


CRANKSHAFT PULLEY


REMOVAL AND INSTALLATION

M1112001601060

Pre-removal Operation

• Front Under Cover Panel Assembly Removal (Refer to

GROUP 51, Front Bumper Assembly and Radiator Grille

P.51-2 ).

• Engine Room Side Under Cover (RH) Removal

Post-installation Operation

• Drive Belt Tension Check and Adjustment (Refer to

P.11A-6

).

• Engine Room Side Under Cover (RH) Installation

• Front Under Cover Panel Assembly Installation (Refer to


P.51-2 ).

Main

Index

Group

TOC

1

3

4

2

190 N·m

Removal steps

<<

<<

A

>> 1.

Drive belt

B

>> >>

A

<< 2.

Crankshaft pulley bolt

AC405868AB

Removal steps (Continued)

>>

A

<<

3.

Crankshaft pulley washer

>>

A

<<

4.

Crankshaft damper pulley

REMOVAL SERVICE POINTS

<<A>> DRIVE BELT REMOVAL



Adjusting bolt

Alternator fixing nut

11A-15

<> CRANKSHAFT PULLEY BOLT

REMOVAL

Use the used drive belt to fix the crankshaft damper pulley, and loosen the crankshaft pulley bolt.

CAUTION

• Do not use the drive belt set up on the vehi-

cles.

•

Do not use a cracked or damaged drive belt.

Main

Index

Group

TOC

AC310988


Nut for alternator pivot bolt

AC405869AB

1. Loosen the nut for alternator pivot bolt and alternator fixing nut.

CAUTION

To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.

2. Turn the adjusting bolt in the anti-clockwise direction (to the left) to remove the drive belt.

Cable band

Used drive belt

AC403118 AC

1. Set the used drive belt as shown and hold it with a cable band.

CAUTION

Do not hang the used drive belt for the crankshaft rotation stopper on the water pump pulley.

Used drive belt


AC403119 AC

2. Turning the crankshaft damper pulley to the anti-clockwise direction (to the left), loop the used drive belt around the water pump body, hold the crankshaft damper pulley and remove the crankshaft pulley bolt.



INSTALLATION SERVICE POINT

>>A<< CRANKSHAFT DAMPER PUL-

LEY/CRANKSHAFT PULLEY

WASHER/CRANKSHAFT PULLEY BOLT

INSTALLATION

CAUTION

• Do not use the drive belt set up on the vehi-

cles.

•

Do not use a cracked or damaged drive belt.

AC310988


Engine front

: Clean

: Apply engine oil

Crankshaft pulley bolt

Crankshaft pulley washer


Crankshaft

Cable band

Used drive belt

AC403118 AD

4. Set the used drive belt and hold it with a cable band as during removal.

Main

Index

Group

TOC

Clean

Clean

(Engine oil)

Clean

CAUTION

Do not hang the used drive belt for the crankshaft rotation stopper on the water pump pulley.

AC310991

Water pump


AC405912 AB

1. Clean the screw hole of the crankshaft, the crankshaft damper pulley, the crankshaft pulley bolt and the crankshaft pulley washer.

2. Install the crankshaft damper pulley.

3. Apply an appropriate quantity of new engine oil to the thread of crankshaft pulley bolt.

Used drive belt

AC403120 AC

5. Turning the crankshaft damper pulley to the clockwise direction (to the right), loop the used drive belt around the water pump body, hold the crankshaft damper pulley and tighten the crankshaft pulley bolt to the specified torque.

Tightening torque:190 N

⋅m



CAMSHAFT

CAMSHAFT

M1112007800111

1

11A-17

Main

Index

Apply engine oil to all moving parts before installation.

Group

TOC

2

8

5

9.0 ± 1.0 N·m

3

11 ± 1 N·m

20 ± 1 N·m

6

15

7.6 ± 0.6 N·m

65 ± 5 N·m

N

7

(Engine oil)

8.4 ± 0.6 N·m

10

88 ± 10 N·m

14

15

12

13

11

15

8.4 ± 0.6 N·m

8.4 ± 0.6 N·m

49 ± 9 N·m

9

Camshaft removal steps

•

Air cleaner assembly removal

(Refer to GROUP 15, Air Cleaner

P.15-5 ).

1.

Engine cover

<<

A

>>

4

5

11 ± 1 N·m

15

16

(Engine oil)

19

N

7.6 ± 0.6 N·m

17

22

N

21

44 ± 5 N·m

18

20

AC507705 AB


•

Ignition coil (Refer to GROUP 16,

Ignition System

− Ignition Coil

P.16-36 ).

•

Cowl top panel (Refer to GROUP

42, Loose Panel P.42-81 ).


CAMSHAFT


2.

Breather hose connection

3.

PCV hose connection

4.

Fuel injector connector

5.

Control harness clamp connection

6.

Engine oil level gauge and guide assembly

<<

7.

O-ring

B

>> >>

F

<<

8.

Cylinder head cover assembly

9.

Tensioner pulley

•

Valve clearance adjustment (Refer to

P.11A-10

).

>>

E

<<

10. Timing chain tensioner cover

<<

C

>> >>

D

<< 11. Timing chain tensioner

<<

D

>> >>

C

<< 12. Camshaft sprocket


<<

D

>> >>

C

<<

13. V.V.T. sprocket assembly

<<

D

>> >>

C

<<

14. Front camshaft bearing cap

<<

D

>> >>

C

<<

15. Camshaft bearing cap

<<

D

>> >>

C

<<

16. Camshaft

Oil control valve removal steps

<<

17. Oil control valve connector

E

>>

>>

B

<<

18. Oil control valve

>>

B

<<

19. O-ring

20. Oil control valve filter bolt

<<

21. Gasket

E

>>

>>

A

<<

22. Oil control valve filter

Main

Index

Group

TOC


<<A>> COWL TOP PANEL REMOVAL

CAUTION

After removing the cowl top panel, perform operation with care not to damage the windshield.

AC311000

<<C>> TIMING CHAIN TENSIONER

REMOVAL

CAUTION

Never turn the crankshaft anti-clockwise.

Timing mark

(2 concave parts)

Timing mark

(Slot portion)

Protection tape

Windshield

AC403071AB

After removing the cowl top panel, attach a protection tape for the windshield on the lower area of the windshield.

<> CYLINDER HEAD COVER

ASSEMBLY REMOVAL

Camshaft sprocket

V.V.T. sprocket assembly


7

1

4

10 6

8

5

9 3

2

Engine front

AC405036 AB

Loosen the cylinder head cover assembly mounting bolts in the order of the numbers shown in the illustration.

Timing mark

(Slot portion)

AC311261 AC

1. Turn the crankshaft clockwise, and align the timing mark of the camshaft sprocket (2 conceive areas in front of the camshaft sprocket) and that of the V.V.T. sprocket assembly (the groove of

V.V.T. sprocket assembly side face). Then set

No.1 cylinder to the TDC.

Exhaust camshaft


CAMSHAFT

11A-19

<<D>> CAMSHAFT SPROCKET/ V.V.T.

SPROCKET ASSEMBLY/FRONT

CAMSHAFT BEARING CAP/CAMSHAFT

BEARING CAP/CAMSHAFT REMOVAL

Cable band

Main

Index

Group

TOC

Timing chain

Hexagon part of the inlet camshaft

AC311262 AC

2. While holding the inlet camshaft hexagonal area with a wrench or a similar tool, slightly turn the exhaust camshaft clockwise to tighten the timing chain at the timing chain tensioner side and shorten the plunger of the timing chain tensioner.

Timing chain tensioner

Timing chain

Camshaft sprocket

AC312249 AB

1. Fix the camshaft sprocket and the timing chain using a cable band or a similar tool.

Hexagon part of the exhaust camshaft

Pin

AC311263 AB

3. With the plunger of the tensioner shortened, insert a pin or a similar tool (3 mm or less in diameter) to the hole shown in the illustration of the timing chain tensioner.

CAUTION

Do not turn the crankshaft after removing the timing chain tensioner.

4. Loosen the timing chain tensioner mounting bolts, and remove the timing chain tensioner from the timing chain case hole.

Camshaft sprocket mounting bolt

AC311264 AB

2. While holding the exhaust camshaft hexagonal area with a wrench or a similar tool, loosen the camshaft sprocket mounting bolt.



MB991992

AC311265 AC

3. While holding the inlet camshaft hexagonal area using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to loosen the

V.V.T. sprocket assembly mounting bolt.

11A-20

Engine front

Front camshaft bearing cap

3

2

1

4

3

3

4

Camshaft bearing cap

7

7

8

8

6

5

5

6


2

2

1

1


CAMSHAFT

6. In the same way as Step 5, disconnect the V.V.T. sprocket assembly and timing chain assembly from the inlet camshaft.

CAUTION

After disconnecting the camshaft sprocket and the V.V.T. sprocket assembly (with the timing chain for each) from the camshaft, do not dislocate the camshaft sprocket, the V.V.T. sprocket assembly, and the timing chain.

7. After removal, place the camshaft sprocket and timing chain assembly, and the V.V.T. sprocket assembly and timing chain assembly on the timing chain case assembly

Main

Index

Group

TOC

<<E>> OIL CONTROL VALVE/OIL

CONTROL VALVE FILTER REMOVAL

CAUTION

After removing the oil control valve and the oil control valve filter, be careful that no dust or other objects enter the oil passage in the cylinder head.

AC403719 AD

4. Loosen the front camshaft bearing cap mounting bolts, and then loosen each camshaft bearing cap mounting bolts in the order shown. Remove the front camshaft bearing cap and each camshaft bearing cap.

CAUTION

Do not turn the crankshaft after removing the camshaft sprocket assembly with the timing chain.

Camshaft sprocket and timing chain assembly

Exhaust camshaft


AC312250 AB

5. Slightly raise the exhaust camshaft with the camshaft sprocket and timing chain assembly from the cylinder head, remove the camshaft sprocket mounting bolt, and disconnect the camshaft sprocket and timing chain assembly from the exhaust camshaft.


CAMSHAFT

INSTALLATION SERVICE POINTS

>>A<< OIL CONTROL VALVE FILTER

INSTALLATION

CAUTION

When installing the oil control valve filter, exercise special care to avoid adhesion of foreign objects and damage/deformation of the filter.

11A-21

>>C<< CAMSHAFT/CAMSHAFT BEARING

CAP/FRONT CAMSHAFT BEARING CAP/

V.V.T. SPROCKT ASSEMBLY/CAMSHAFT

SPROCKET INSTALLATION


Dowel pin

Main

Index

Group

TOC

>>B<< O-RING/OIL CONTROL VALVE

INSTALLATION

1. Cover the oil groove of the oil control valve with a cardboard.

CAUTION

When installing the O-ring to the oil control valve, take care not to damage the O-ring.

2. Apply the engine oil to the O-ring and install it to the oil control valve.

CAUTION

When installing the oil control valve to the cylinder head, take care not to damage the O-ring.

3. Apply the engine oil to the O-ring and install the oil control valve to the cylinder head.

Hole

Camshaft sprocket

Inlet camshaft

Dowel pin

Groove

Exhaust camshaft

AC312251 AC

1. First, lift the V.V.T. sprocket assembly side of the camshaft sprocket, V.V.T. sprocket assembly and the timing chain assembly. Then align the dowel pin of the inlet camshaft with the V.V.T. sprocket assembly hole, and assemble the inlet camshaft and the V.V.T. sprocket assembly. Temporarily tighten the mounting bolt.

2. Next, lift the camshaft sprocket side of the camshaft sprocket, V.V.T. sprocket assembly and the timing chain assembly. Then align the dowel pin of the exhaust camshaft with the camshaft sprocket groove, and assemble the exhaust camshaft and the camshaft sprocket. Temporarily tighten the mounting bolt.

3. Place the inlet camshaft and exhaust camshaft on the installing location of the cylinder head.


CAMSHAFT

Engine front

Front camshaft bearing cap

1

3

5


1

3

6

6

2

2

4

4

7

8

8

2

5

1

3

7


AC403719 AE

4. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order shown, and then tighten the front camshaft bearing cap mounting bolts as well.

Tightening torque:

11

± 1 N⋅m (Camshaft bearing cap mounting

bolts)

20

± 1 N⋅m (Front camshaft bearing cap

mounting bolts)


Main

Index

MB991992


AC311267 AC

5. While holding the inlet camshaft hexagonal area using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to tighten the

V.V.T. sprocket assembly mounting bolt to the specified torque. Since the V.V.T. sprocket assembly mounting bolt is tightened by special tool (MB991992), calculate the tightening torque by the following formula.

Tightening torque: (65

± 5) × {L ÷ (L + 150)}

N

⋅m

65

± 5: Tightening torque of the V.V.T. sprocket

assembly mounting bolt (unit: N

⋅m)

L: Distance between the centre of a torque wrench drive and of its handle (unit: mm)

150: Length of special tool (unit: mm)

Group

TOC

Hexagon part of the exhaust camshaft


AC311268 AB

6. While holding the exhaust camshaft hexagonal area using a wrench or similar tool, tighten the camshaft sprocket mounting bolt to the specified torque.


± 10 N⋅m

>>D<< TIMING CHAIN TENSIONER

INSTALLATION

Timing chain tensioner


CAMSHAFT

>>F<< CYLINDER HEAD COVER

ASSEMBLY INSTALLATION

11A-23

1. Remove the sealant from the cylinder head cover assembly and the matching area of the cylinder head assembly and the timing chain case assembly.

Main

Index

Group

TOC

Cylinder head assembly

Timing chain case assembly

A A

Section A - A

φ 4 mm

Pin

AC311263 AB

1. Install the timing chain tensioner with the pin or the similar tool to the cylinder block through the timing chain case hole, and tighten the timing chain tensioner mounting bolts to the specified torque.


± 0.6 N⋅m

2. Pull out the pin or the similar tool of the timing chain tensioner.

>>E<< TIMING CHAIN TENSIONER

COVER INSTALLATION

1. Remove the sealant from the installation face of the timing chain tensioner cover and the timing chain case assembly.

Timing chain case assembly

AC311270 AC

2. Apply specified sealant to the matching area of the cylinder head assembly and the timing chain case assembly as shown, and install the cylinder head cover assembly to the cylinder head assembly within 3 minutes.

Specified sealant: LOCTITE 5971 or exact equivalent

4

10

7

A A

1 5

3

φ 2 mm

3 mm

AC311269 AC

2. Apply a bead of the specified sealant to the mating surface of the timing chain case assembly.

Then, install the timing chain tensioner cover to the timing chain case assembly within 3 minutes.


6

9

Engine front

2 8

AC405036 AC

3. Tighten the cylinder head cover assembly mounting bolts to the specified torque in the order of the numbers shown in the illustration.


± 1.0 N⋅m


OIL PAN

OIL PAN


M1112002801443




P.51-2 ).

• Engine Room Side Under Cover (RH) Removal

• Engine Oil Draining (Refer to GROUP 12, On-vehicle

Service

− Engine Oil Replacement

P.12-3 ).

• Crankshaft Damper Pulley Removal (Refer to

P.11A-14 ).


• Crankshaft Damper Pulley Installation (Refer to

P.11A-14 ).

• Engine Oil Refilling (Refer to GROUP 12, On-vehicle

Service


P.12-3 ).

• Engine Room Side Under Cover (RH) Installation



P.51-2 ).

Main

Index

Group

TOC

11.5 ± 0.5 N·m

1

N

6

5

11.5 ± 0.5 N·m

2

39 ± 5 N·m

N

3

•

Removal steps

Engine oil level gauge

1.

Bell housing cover

2.

Engine oil pan drain plug

7.6 ± 0.6 N·m

7.6 ± 0.6 N·m

4

7.6 ± 0.6 N·m

AC403072 AB


<<

3.

Engine oil pan drain plug gasket

A

>> >>

B

<< 4.

Engine oil pan

>>

A

<< 5.

Engine oil screen assembly

>>

A

<< 6.

O-ring


OIL PAN

REMOVAL SERVICE POINT

<<A>> ENGINE OIL PAN REMOVAL

1. Remove the engine oil pan mounting bolts.

11A-25

CAUTION

As oil leak is likely to occur at both ends of the rear side of the engine oil pan, be sure to apply the specified sealant as shown.

MD998727

MD998727

Main

Index

Group

TOC

Both engine oil pan rear side edge parts

Engine oil pan

AC102324 AB

2. Use special tool oil pan FIPG cutter (MD998727) to remove the engine oil pan.


>>A<< O-RING/ENGINE OIL SCREEN

ASSEMBLY INSTALLATION

O-ring

Engine oil screen assembly

5.5 mm

5.5 mm

Groove portion

AC311273 AC

Confirm that the O-ring is securely fitted in the engine oil screen assembly groove without causing any torsion or damage. Then install the engine oil screen assembly.

>>B<< ENGINE OIL PAN INSTALLATION

1. Remove sealant from the engine oil pan and cylinder block surfaces.

φ 2 mm

φ 4 mm

AC403646 AC

2. Apply a bead of the specified sealant to the cylinder block mating surface of the engine oil pan, and install the engine oil pan to the cylinder block within 3 minutes.


CAUTION

Then wait at least one hour. Never start the engine or let engine oil or coolant touch the sealant surface during that time.

3. Tighten the engine oil pan mounting bolts to the specified torque.


± 0.6 N⋅m


CRANKSHAFT OIL SEAL



M1112003101384

3

<M/T>

7.6 ± 0.6 N·m

N

7

AC403073

Main

Index

Group

TOC

2

<CVT>

100 ± 5 N·m

N

1

5

4

6

Crankshaft front oil seal removal steps

• Crankshaft damper pulley (Refer to

>>

P.11A-14 ).

C

<<

1.

Crankshaft front oil seal

Crankshaft rear oil seal removal steps <M/T>

• Transmission assembly (Refer to

GROUP 22A, Transmission

Assembly P.22A-7 ).

• Clutch cover and clutch disc (Refer to GROUP 21B, Clutch P.21B-3 ).

<<

• Engine oil pan (Refer to

P.11A-24

).

A

>> >>

B

<<

2.

Flywheel bolt

>>

B

<<

3.

Flywheel assembly

>>

A

<<

7.


AC601259AB

Crankshaft rear oil seal removal steps <CVT>

• Transmission assembly (Refer to

GROUP 23A, Transmission

Assembly P.23A-150 ).

<<

• Engine oil pan (Refer to

P.11A-24

).

A

>> >>

B

<<

4.

Drive plate bolt

>>

B

<<

5.

Adapter plate

>>

B

<<

6.

Drive plate assembly

>>

A

<<

7.




REMOVAL SERVICE POINT

<<A>> FLYWHEEL BOLT/DRIVE PLATE

BOLT REMOVAL

Cylinder block

B

B

A A

11A-27

Main

Index

Group

TOC

MD998781

Flywheel assembly or


AK305392AF

1. Use special tool flywheel stopper (MD998781) to secure the flywheel assembly or drive plate assembly.

2. Remove the flywheel bolts or drive plate bolts.


>>A<< CRANKSHAFT REAR OIL SEAL

CASE ASSEMBLY INSTALLATION

1. Remove sealant from the cylinder block surfaces.

A

Section A - A

A

(Engine oil)

Section A - A

1 mm

3.5 mm

2 mm

2 mm

AC311772 AB

3. Apply a bead of specified sealant to the crankshaft rear oil seal case assembly mating surface of the cylinder block as shown.


CAUTION

Install the crankshaft rear oil seal case assembly not to damage the crankshaft rear oil seal.

4. Within 3 minutes after applying the specified sealant, install the crankshaft rear oil seal case assembly to the cylinder block, and tighten the mounting bolts to the specified torque.


± 0.6 N⋅m


AC403772 AB

2. Apply a small amount of engine oil to all areas around the oil seal lip.

Cylinder block

Section B - B

11A-28

>>B<< DRIVE PLATE

PLATE BOLT/FLYWHEEL

ASSEMBLY/FLYWHEEL BOLT

INSTALLATION



ASSEMBLY/ADAPTER PLATE/DRIVE

1. Remove the sealant, the engine oil, and other adhering materials from the flywheel assembly or drive plate assembly installation face, adapter plate, crankshaft screw hole, and flywheel bolts or drive plate bolts.

2. Install the flywheel assembly or drive plate assembly to the crankshaft.

>>C<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION

MB991993

MB990699

Crankshaft

(Engine oil)

Oil seal

AC311773 AB

Cylinder block

MD998781

Flywheel assembly or


AK305392AF

1. Apply a small amount of engine oil to the outer circumference of special tool crankshaft front oil seal guide (MB991993) and install it to the crankshaft.

2. Apply a small amount of engine oil to the entire inner circumference of the oil seal lip.

CAUTION

Install the crankshaft front oil seal not to damage the crankshaft front oil seal.

3. Using special tool differential oil seal installer

(MB990699), drive the oil seal so that it is flush with the timing chain case assembly.

3. Use special tool flywheel stopper (MD998781) to secure the flywheel assembly or drive plate assembly in the same manner as removal.

4. Apply a small amount of engine oil to the face of the flywheel bolts or drive plate bolts and the crankshaft screw holes.

Main

Index

Group

TOC

AK102300

5. Apply specified sealant to the flywheel bolt or drive plate bolt threads.

Specified sealant: LOCTITE 2701 or equivalent

6. Tighten the flywheel bolts or drive plate bolts to the specified torque in a crisscross pattern.


± 5 N⋅m


ENGINE ASSEMBLY

11A-29

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION <M/T>

M1112001002942

Main

Index

CAUTION

When the engine assembly replacement is performed, use the M.U.T.-III to initialise the learning value

(Refer to GROUP 00, Precautions Before Service

− Initialisation Procedure for Learning Value in MPI

Engine P.00-20 ).

Group

TOC


• Fuel Line Pressure Reduction [Refer to GROUP 13A,

On-vehicle Service

− Fuel Pump Connector Disconnection

(How to Reduce Pressurized Fuel Lines) P.13A-357 ].



P.51-2 ).

• Engine Room Side Under Cover Removal

• Engine Coolant Draining (Refer to GROUP 14, On-vehicle

Service

− Engine Coolant Replacement

P.14-4 ).


Service


P.12-3 ).

• Transmission Oil Draining (Refer to GROUP 22A,

On-vehicle Service

− Transmission Oil Replacement

P.22A-4 ).

• Air Cleaner Assembly Removal (Refer to GROUP15, Air

Cleaner P.15-5 ).

• Battery and Battery Tray Removal

• Alternator and Alternator Brace Removal (Refer to

GROUP 16, Charging System

− Alternator Assembly

P.16-13 ).

• Drive Shaft Removal (Refer to GROUP 26, Drive Shaft

Assembly P.26-16 ).

• Front Bumper Face Assembly Removal (Refer to GROUP

51, Front Bumper Assembly and Radiator Grille P.51-2 ).

• Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-22 ).

• Exhaust Manifold Removal (Refer to GROUP15, Exhaust

Manifold P.15-14 ).


• Exhaust Manifold Installation (Refer to GROUP 15,

Exhaust Manifold P.15-14 ).

• Radiator Assembly Installation (Refer to GROUP 14,

Radiator P.14-22 ).

• Front Bumper Face Assembly Installation (Refer to


P.51-2 ).

• Drive Shaft Installation (Refer to GROUP 26, Drive Shaft

Assembly P.26-16 ).

• Alternator and Alternator Brace Installation (Refer to



P.16-13 ).

• Battery and Battery Tray Installation

• Air Cleaner Assembly Installation (Refer to GROUP 15,

Air Cleaner P.15-5 ).

• Transmission Oil Refilling (Refer to GROUP 22A,

On-vehicle Service

− Transmission Oil Replacement

P.22A-4 ).

• Engine Oil Refilling (Refer to GROUP12, On-vehicle Service


P.12-3 ).

• Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service


P.14-4 ).


P.11A-6

).

• Engine Room Side Under Cover Installation



P.51-2 ).

• Fuel Leak Check

11A-30

12

1


ENGINE ASSEMBLY

23 ± 2 N·m

2

12

11 10

13 ± 2 N·m

12 ± 2 N·m

9

8

9.0 ± 2.0 N·m

9.0 ± 2.0 N·m

12 ± 2 N·m

8

3

5

9.0 ± 2.0 N·m

4

5

<<

A

>>

>>

Removal steps

C

<<

•

Initialisation <Installation only>

1.

Brake booster vacuum hose connection

2.

Gearshift cable and select cable connection

3.

Earth cable connection

4.

Fusible link box cover

5.

Battery cable connection

6

7

AC601328AB


6.

Control wiring harness connection

7.


8.

Engine-ECU connector

9.

Engine-ECU

<<

10. Purge solenoid hose connection

B

>> >>

B

<<

11. Fuel high-pressure hose connection

12. Heater hose connection

Main

Index

Group

TOC

68 ± 7 N·m

18

18

18

68 ± 7 N·m

18

N


ENGINE ASSEMBLY

N

17

43 ± 4 N·m

17

N

11A-31

Main

Index

Group

TOC

19

<<

C

>>

<<

D

>>

16

24 ± 4 N·m

13

15

20

7.6 ± 0.6 N·m

Removal steps

13. A/C compressor connector

14. A/C compressor and magnet clutch assembly

15. Bell housing cover

16. Clutch release cylinder assembly

•

Engine roll stopper rod assembly

(Refer to GROUP 32, Engine Roll

Stopper Rod P.32-11 ).

14

AC601329AB


<<

E

>>

>>

A

<<

17. Transmission mounting insulator

<< connecting bolt and nut

E

>>

>>

A

<<

18. Engine mounting insulator


E

>>

>>

A

<<


<<

F

>>

>>

A

<<

20. Engine and transmission assembly

11A-32

21


ENGINE ASSEMBLY

N

23

23 ± 3 N·m

24 ± 3 N·m

Main

Index

Group

TOC

11 ± 1 N·m

22

Removal steps

21. Control wiring harness

22. Starter assembly

24

23 ± 3 N·m

23

N

<<

G

>>

<<

G

>>

AC601330 AB


23. Transmission connecting bolt

24. Engine assembly


<<A>> GEARSHIFT AND SELECT CABLE

DISCONNECTION


ENGINE ASSEMBLY

<> FUEL HIGH-PRESSURE HOSE

REMOVAL

Section A - A Gearshift and select cables

Fuel high-pressure hose

11A-33

Main

Index

Group

TOC

Cable A

Lever

A

A

A

Transmission lever

AC311252AB

1. Disconnect the transmission assembly-transmission lever from the ends of the gearshift and select cables.

2. With the bracket installed, remove the gearshift and select cables from the transmission assembly.

3. After removing the gearshift and the select cables, tie them in a place where it will not be a hindrance when removing and installing the engine and transmission assembly.

Stopper

1. Remove the stopper.


AC403077AB

Retainer

AC403078 AB

2. Raise the retainer, and pull out the fuel high-pressure hose.

NOTE: If the retainer comes off, install it securely after pulling out the fuel high-pressure hose.

<<C>> A/C COMPRESSOR AND MAGNET

CLUTCH ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C compressor and magnet clutch assembly from the cylinder block.

2. Secure the removed A/C compressor and magnet clutch assembly with cord or rope at a position where they will not interfere with the removal of the engine and transmission assembly.

<<D>> CLUTCH RELEASE CYLINDER


1. With the hose installed, remove the clutch release cylinder assembly from the transmission assembly.

2. Secure the removed clutch release cylinder assembly with cord or rope at a position where they will not interfere with the removal of the engine and transmission assembly.


ENGINE ASSEMBLY

<<E>> TRANSMISSION MOUNTING

INSULATOR CONNECTING BOLT AND

NUT/ENGINE MOUNTING INSULATOR

CONNECTING BOLT AND NUT/ENGINE

MOUNTING INSULATOR REMOVAL

<<F>> ENGINE AND TRANSMISSION


1. Confirm that the cable, the hose, and the harness connector are all disconnected.

CAUTION

Do not bend the fuel high-pressure hose.

2. Raise the body slowly with a lift, and remove the engine and transmission assembly.

Main

Index

Group

TOC

<<G>> TRANSMISSION CONNECTING

BOLT/ENGINE ASSEMBLY REMOVAL

MB991527

AC403079

1. Place a cart below the engine and transmission assembly.

2. Lower the lift to the position where the weight of the engine and transmission assembly is not applied to the transmission mounting insulator and the engine mounting insulator.

3. Remove the self-locking nuts, transmission mounting insulator mounting bolt and engine mounting insulator mounting bolts.

CAUTION

Because the engine assembly is installed with tilted toward the rear side, support the engine and transmission assembly after removing the engine mounting insulator.

4. Remove the engine mounting insulator.

MB991454

AC311780 AB

1. Install the chain of special tool engine hanger balancer (MB991454) and special tool engine hanger (MB991527), and set the chain block.

2. Remove the transmission assembly connecting bolts.

CAUTION

When lifting the engine assembly, operate with care not to lift the transmission assembly.

3. Lift the engine assembly slowly using the chain block, and remove the transmission assembly when the engine assembly is lifted a little.


ENGINE ASSEMBLY


>>A<< ENGINE AND TRANSMISSION

ASSEMBLY/ENGINE MOUNTING INSULA-

TOR/ENGINE MOUNTING INSULATOR

CONNECTING BOLT AND NUT/TRANS-

MISSION MOUNTING INSULATOR CON-

NECTING BOLT AND NUT INSTALLATION

11A-35

>>B<< FUEL HIGH-PRESSURE HOSE

INSTALLATION

CAUTION

3 mm

Fuel delivery pipe

Main

Index

Group

TOC

AC403079

1. Place the engine and transmission assembly on the cart below the lifted vehicle.

2. Lower the lift to the position where the mounting bolts of the engine mounting insulator and the transmission mounting insulator, and the self-locking nuts are installed.

3. Install the engine mounting insulator.

4. Tighten the new self-locking nuts of engine mounting insulator and transmission mounting insulator to the specified torque, and tighten the new mounting bolts of engine mounting insulator and transmission mounting insulator to the specified torque.


68

± 7 N⋅m <Engine mounting insulator

mounting bolts and nuts>

43

± 4 N⋅m <Transmission mounting insulator

mounting bolt and nuts>


AC208465AE

• After connecting the fuel high-pressure hose,

check that it has been securely installed by slightly pulling in the removal direction. At this time, also check that there is approximately 3-mm play.

• When applying the engine oil, make sure not

to allow the engine oil to enter the fuel delivery pipe.

Apply a small amount of the engine oil to the fuel delivery pipe, and then install the fuel high-pressure hose.

>>C<< INITIALISATION

When the engine-ECU is removed, initialise the electronic-controlled throttle valve system according to the following procedure after installing the engine-ECU.

Turn the ignition switch from "ON" position to

"LOCK" (OFF) position, and then hold "LOCK"

(OFF) position for approximately 10 seconds or more.


ENGINE ASSEMBLY

REMOVAL AND INSTALLATION <CVT>

M1112001002953

CAUTION

When the engine assembly replacement is performed, use the M.U.T.-III to initialise the learning value

(Refer to GROUP 00, Precautions Before Service

− Initialisation Procedure for Learning Value in MPI

Engine P.00-20 ).

Main

Index

Group

TOC


• Fuel Line Pressure Reduction [Refer to GROUP 13A,

On-vehicle Service

− Fuel Pump Connector Disconnection

(How to Reduce Pressurized Fuel Lines) P.13A-357 ].



P.51-2 ).

• Engine Room Side Under Cover Removal

• Engine Coolant Draining (Refer to GROUP 14, On-vehicle

Service


P.14-4 ).


Service


P.12-3 ).

• Transmission Fluid Draining [Refer to GROUP 23A,

On-vehicle Service

− Transmission Fluid (CVT Fluid)

Replacement P.23A-133 ].

• Air Cleaner Assembly Removal (Refer to GROUP15, Air

Cleaner P.15-5 ).

• Battery and Battery Tray Removal

• Alternator and Alternator Brace Removal (Refer to



P.16-13 ).

• Drive Shaft Removal (Refer to GROUP 26, Drive Shaft

Assembly P.26-16 ).

• Front Bumper Face Assembly Removal (Refer to GROUP

51, Front Bumper Assembly and Radiator Grille P.51-2 ).

• Radiator Assembly Removal (Refer to GROUP 14, Radiator P.14-22 ).

• Exhaust Manifold Removal (Refer to GROUP15, Exhaust

Manifold P.15-14 ).


• Exhaust Manifold Installation (Refer to GROUP 15,

Exhaust Manifold P.15-14 ).

• Radiator Assembly Installation (Refer to GROUP 14,

Radiator P.14-22 ).

• Front Bumper Face Assembly Installation (Refer to


P.51-2 ).

• Drive Shaft Installation (Refer to GROUP 26, Drive Shaft

Assembly P.26-16 ).

• Alternator and Alternator Brace Installation (Refer to



P.16-13 ).

• Battery and Battery Tray Installation

• Air Cleaner Assembly Installation (Refer to GROUP 15,

Air Cleaner P.15-5 ).

• Transmission Fluid Refilling [Refer to GROUP 23A,

On-vehicle Service

− Transmission Fluid (CVT Fluid)

Replacement P.23A-133 ].

• Engine Oil Refilling (Refer to GROUP12, On-vehicle Service


P.12-3 ).

• Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service


P.14-4 ).


P.11A-6

).

• Engine Room Side Under Cover Installation



P.51-2 ).

• Fuel Leak Check

11

1

10


ENGINE ASSEMBLY

2

12 ± 2 N·m

9

11

12 ± 2 N·m

3

7

13 ± 2 N·m

7

12 ± 2 N·m

11A-37

Main

Index

Group

TOC

4

9.0 ± 2.0 N·m

12

>>

Removal steps

D

<<

• Initialisation <Installation only>

1.

Brake booster vacuum hose connection

2.

Transmission control cable connection

3.

Earth connection

4.


5.

Fusible link box cover

5

12 ± 2 N·m

6

9.0 ± 2.0 N·m

8

9.0 ± 2.0 N·m

6

6

9.0 ± 2.0 N·m

6

AC405872AD


6.

Control harness connection

7.

Engine-CVT-ECU mounting bolt and nut

8.

Engine-CVT-ECU connector

<<

9.

Purge solenoid hose connection

A

>> >>

C

<<

10. Fuel high-pressure hose connection

11. Heater hose connection

12. Water hose connection


ENGINE ASSEMBLY

68 ± 7 N·m

18

18* 1

18* 2

68 ± 7 N·m

18

68 ± 7 N·m

18

N

17

63 ± 7 N·m

17

63 ± 7 N·m

Main

Index

Group

TOC

19

13

15

16

20

49 ± 3 N·m

7.6 ± 0.6 N·m

14

<>

<<

C

>>

NOTE

*

*

Removal steps

13. A/C compressor connector

14. A/C compressor and magnet clutch assembly

15. Bell housing cover

16. Torque converter and drive plate connecting bolt

• Engine roll stopper rod assembly

(Refer to GROUP 32, Engine Roll

Stopper Rod Assembly P.32-11 ).

AC600593 AB


<<

D

>> >>

B

<<

17. Transmission mounting insulator


D

>> >>

B

<<



D

>> >>

B

<<


<<

E

>>

>>

B

<<

20. Engine and transmission assembly

22


ENGINE ASSEMBLY

24

11A-39

Main

Index

Group

TOC

23 ± 3 N·m

25

24 ± 3 N·m

Removal steps

21. Cable band

22. Control harness

23. Starter assembly

N

21

Inhibitor switch

23

AC403076 AC


<<

<<

F

>>

24. Transmission connecting bolt

F

>>

>>

A

<<

25. Engine assembly

11A-40



ENGINE ASSEMBLY


<<A>> FUEL HIGH-PRESSURE HOSE

REMOVAL

<> A/C COMPRESSOR AND MAGNET

CLUTCH ASSEMBLY REMOVAL

1. With the hose installed, remove the A/C compressor and magnet clutch assembly from the cylinder block.

2. Secure the removed A/C compressor and magnet clutch assembly with cord or rope at a position where they will not interfere with the removal of the engine and transmission assembly.

Main

Index

Group

TOC

Stopper

1. Remove the stopper.

AC403077AB

<<C>> TORQUE CONVERTER AND

DRIVE PLATE CONNECTING BOLT

REMOVAL

Manual control lever


Inhibitor switch

Retainer

AC403078 AB

2. Raise the retainer, and pull out the fuel high-pressure hose.

NOTE: If the retainer comes off, install it securely after pulling out the fuel high-pressure hose.

N position

AC207401AB

1. Set the transmission in N (neutral) and remove each coupling bolt while turning the crankshaft.

NOTE: The N (Neutral) state of the transmission can be checked with the position of the manual control lever.

2. Push in the torque converter into the transmission side and make a point to ensure that the torque converter does not remain on the engine side.


ENGINE ASSEMBLY

<<D>> TRANSMISSION MOUNTING


NUT/ENGINE MOUNTING INSULATOR

CONNECTING BOLT AND NUT/ENGINE

MOUNTING INSULATOR REMOVAL

11A-41

<<F>> TRANSMISSION CONNECTING

BOLT/ENGINE ASSEMBLY REMOVAL

MB991527

Main

Index

Group

TOC

MB991454

AC403079

1. Place a cart below the engine and transmission assembly.

2. Lower the lift to the position where the weight of the engine and transmission assembly is not applied to the transmission mounting insulator and the engine mounting insulator.

3. Remove the self-locking nuts, transmission mounting insulator mounting bolt and engine mounting insulator mounting bolts.

CAUTION

Because the engine assembly is installed with tilted toward the rear side, support the engine and transmission assembly after removing the engine mounting insulator.

4. Remove the engine mounting insulator.

<<E>> ENGINE AND TRANSMISSION


1. Confirm that the cable, the hose, and the harness connector are all disconnected.

CAUTION

Do not bend the fuel high-pressure hose.

2. Raise the body slowly with a lift, and remove the engine and transmission assembly.

AC311780 AB

1. Install the chain of special tool engine hanger balancer (MB991454) and special tool engine hanger (MB991527), and set the chain block.

2. Remove the transmission assembly connecting bolts.

CAUTION

• When lifting the engine assembly, operate

with care not to lift the transmission assembly.

• When working, make sure that the torque

converter will not be detached with the engine.

3. Lift the engine assembly slowly using the chain block, and remove the transmission assembly when the engine assembly is lifted a little.


>>A<< ENGINE ASSEMBLY INSTALLA-

TION

A

AC105798AB

Before installing the engine assembly, ensure that the dimension A from the torque converter housing end to the front end of the torque converter mounting boss shall be minimum 12.2 mm and the torque converter is securely installed.


ENGINE ASSEMBLY

>>B<< ENGINE AND TRANSMISSION

ASSEMBLY/ENGINE MOUNTING

INSULATOR/ENGINE MOUNTING


NUT/TRANSMISSION MOUNTING


NUT INSTALLATION

>>C<< FUEL HIGH-PRESSURE HOSE

INSTALLATION

CAUTION

3 mm

Fuel delivery pipe

Main

Index

Group

TOC

AC403079

1. Place the engine and transmission assembly on the cart below the lifted vehicle.

2. Lower the lift to the position where the mounting bolts of the engine mounting insulator and the transmission mounting insulator, and the self-locking nuts are installed.

3. Install the engine mounting insulator.

4. Tighten the new self-locking nuts of engine mounting insulator and transmission mounting insulator to the specified torque, and tighten the new mounting bolts of engine mounting insulator and transmission mounting insulator to the specified torque.


68

± 7 N⋅m <Engine mounting insulator mount-

ing bolts and self locking nuts>

63

± 7 N⋅m <Transmission mounting insulator

mounting bolt and self locking nuts>


AC208465AE

• After connecting the fuel high-pressure hose,

check that it has been securely installed by slightly pulling in the removal direction. At this time, also check that there is approximately 3-mm play.

• When applying the engine oil, make sure not

to allow the engine oil to enter the fuel delivery pipe.

Apply a small amount of the engine oil to the fuel delivery pipe, and then install the fuel high-pressure hose.

>>D<< INITIALISATION

When the engine-CVT-ECU is removed, initialise the electronic-controlled throttle valve system according to the following procedure after installing the engine-CVT-ECU.

Turn the ignition switch from "ON" position to

"LOCK" (OFF) position, and then hold "LOCK"

(OFF) position for approximately 10 seconds or more.

06.5MY RG COLT - Workshop Manual

GROUP 11A

ENGINE

MECHANICAL

<4A9>

CONTENTS

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ON-VEHICLE SERVICE

CRANKSHAFT PULLEY

CAMSHAFT

OIL PAN

CRANKSHAFT OIL SEAL

ENGINE ASSEMBLY

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