Honda civic 2003.pdf

(W 2002-2003
Service Manual
Hatchback

CIVIC

INTRODUCTION

How to Use This Man

Specifications

Maintenance

Engine

_ EA
|

==
Cooling

Fuel and Emissions PA

*Transaxle

| Suspension
*Brakes , EN

(Including ABS)

a >

QE

| «Body

*Heating, Ventilation
and Air Conditioning

“Body Electrical

*Restraints

General Information

Chassis and Paint Codes
-2002 Model „12

-2003 Model
Identification Number Locations.

Warning/Caution Label Locations ..... 1-5
Under-hood Emi

Control Label 17
Lift and Support Points 18
Towing 19
Parts Marking Locations .. . 110

General Information

Chassis and Pai

Vehicle Identification Number

Codes - 2002 Model

Engine Number

‘SHH EP 3 5.» 2 U 300001

| TTT

Le b edetoh

a. Manufacturer Make and Type of Vehicle
SH: HONDA OF THE UK MES. LTD. UX.
HONDA Passenger vehicle
». Une, Body and Engine Type
EP CIVICI208S
€: Bou Type and Tranamision Type
3.2.09, Mater speed Manual
4. Vebicle Grade (Series)
SUS,
SSR Canad)
8 Sivithside svbag system (US)
SIR win sid arog systor(Canaca)
2. Check Digit
Moda! Ya
22002
9. Factory Code
VMS of UK. Manufacturing in Sino,
Englend
ho. Serial Number

27

Ei tar Cotten

lab

a. Engine Type

08a: 20€ DOHC VTEC Sequera! Mato
Fuck injects engine

Seri u

‘Transmission Number

aia. 1000001

ab

a. Transmission Type
NS: 545006 Manus
b, Sais Number

Paint Code
Cade | ter TETE
BOP | Wafuhaws are i

NHSTE—] raser

MAG Satin

Rat Mian Red
Euro Yalow Peal

@ Chassis and Paint Codes - 2003 Model

Vehicle identification Number Engine Numbor

Shit EPs 3 5 + 3 400001 270001

DTT

a b cdefgh

+. Monufocturr, Make and Type of Voice Engine Type

SE HONDAOF EU. MES. LTD UK KARA. 292 DOHC VTEC Sequentia Mutiport
HONDA Passenger voice Fuatinieindengine
bo. Line Body and Engine Type Serial Number

Seyret rare ur
See,
Weise
En qm en
SY
taste
= —
she BEE
| 0 Honda of UK. Manufacturing in Swindon, » e

England
‘bs, Serial Number

85206 Vii Bl Por
RSS Tato vi

1-3

General Information

Identification Number Locations

1-4

Warning/Caution Label Locations

NOTE: FRONT PASSENGER AIRBAG WARNING TAG
(CHILD SEAT intl on Me ova box onthe US,
model

Passengers Compartment:
sasmroguanon
TN
on

estas

Eonia
Van

Steering What

(conta

1-5

General Information

Warning/Caution Label Locations (cont'd)

RYE WRORMATION LAL

menfomanen

1
sr
Een Among AUTOR

1-6

Under-hood Emission Control Label

Emission Group Identification

Example: 2002 modal

TS VENICLE CONFORMS TO US. EPAMER 28IN 5,
AND NLEV LEV REGULATIONS APPLICABLE TO 2007
MODEL VEAR NEW PASSENGER CARS AND
‘CALFORNIA REGULATIONS APPLICABLE TO 2002
MODEL YEAS NEW LEV LEV PASSENGER CARS.

Example: 2008 model

Engine and Evaporative Familie:

Engine Family

2 mx V 020 vor

FI Ik

ab cd e

a. Model
22002
32000,

bo Manufacturer Subcodo
HE HONDA.

+. Family Type
4. Displecement
+ Sequence Character
vor: 2002
RC 7008

Evaporative Fam

THIS VEHICLE CONFORMS TO US. EPA TIER 281N'5
AND NLEV LEV REGULATIONS APPLICABLE TO 2003
MODEL YEAR EM PASSENGER CARS AND
CAUFORNIA REGULATIONS APPLICABLE 10 2003
MODEL YEAR NEW LEV LEV PASSENGER CARS.

a. Model Yes
22002

. Manufacturer Subeode
i HONDA

+ Family Type
RrEVARORUR

4. Canister Work Capacty

© Sequence Characters
nes
re

General Information

Lift and Support Points

NOTE: you ae going 1 remove hna components
mencion othe ue
es Suppor th front

al weigh

of 1e vonice, me contr of gry
change ond cause the enr on te hist
Frame Hoist,

1. Postion the hoist it blocs LA), or safety stands,
under the vehicle's ran upparı port) and ear
‘suppor point

2. Rasa me nas few inches ans rock the vehicle
‘emily to be sre ie my upper

2. ais te hot ul eight rd nsouct ma.
po or eta contact to It Dock.

Safety Stands

To supone vehicle on tao stan, ute te sum
supper pain (Sand) ws tor atrae host Aways
{tee soy stands whan working on or nce ony
ah te supported ely oy jack

1-8

Floor Jack
1. Sette poking brake

2. Block the whee

re net bonged

3. When ing he ear ofthe vehicle, put ne
ren ever severo

Fosiianthe oor ac under me ton jsi
rack Alor ea jchingbr

sta rockt in teck platform (C
up he vena high enough

unser.

S

KB

5. Peston the sary sands under the support points
and just nem so tn vehele val eve,

6. Loner the voici ont he stands.

Towing

Line vice nnd tobe towed alo profesional
townog servo, over tou he vehicle Being another
Veh win usta rope or a. very dangerous

Emergeney Towing
“Thar ato Mrs popular methods of towing 9 voice,

Ft bed Equipment Te opero one the vehicle
‘onthe Baek ot A. Thin Ina bes way of

‘To accommedat tated equipment, ne vel s
tip vai towing hooks (A) and te down Pooks

‘Tne towing hookcan be usa vith winch to pl
delo ent me ruck at thet down oak sits con
196010 secure a vehicle otc

Wee Lt Equipment — The toe wack uses two
Poli risa! go under the tres tonto real ang
Fits mem olf ground Th tar o wes remain
on ve greung. Theis an accopable way of xing the
onl

Sing-vpe Equipment ~The tow ruck uss mein!
ables with hooks onthe and, Proa hooks go round
baits of te rams or suspension and he cable Ia
[td the vehicle of he ground. The vehicle's
SUsgension and bosy canbe serious damaged this
‘ethos of towing le empres

010 damos, in verte meat be owed
Hentai ar the ground do the folowing

he vehicle cannot be trarspories by Hard.
uid be towed with the om els ne ground. 1

+ Release the parting brace.
1 Shane varemison Note

‘vi ust to tw te vice no forth an 50 ios (80
kml and hosp the speed below 25 mph 55 kr

Bone
mpropertowingpresaraon wi demage he
Hanamıeio. Fol ne abova procedure ac. Il
You cannot ento transmision, to hl
betvereporedoneflat bes
“Frying or os tho vence bythe bumpers wll
ex ai damage. The Dumpors ae nat
designed support the VON MO

General Information

Parts Marking

To dre vehicle net, certain major componans are mare with the vence dan fiction number (VI) Original
ars have sucios anal, Replacement buy parte hav o ochesivo label. The original engine or
‘wansmission VIN plate ls translorndtoaseiscemen engin o lt

mission en anncned with break

NOTE Be caret note damage the pars marking labels during Body repair Mask ns buforerapaiing he par

1-10

L

Specifications

‘Standards and Service Limits
Engine Electrical
Engine Assembly
Cylinder Head
Engine Block .
Engine Lubrication
Cooling E
Fuel and Emissions.
CHU namen
Manual Transmission and Differential 21
Steering .. 7
Suspension
BARS anna
Air Conditioning

Design Specifications
Dimensions ..
Weight (USA)
Weight (CANADA)
Engine
Starter .

Clutch ..

Manual Transmission
Steering
Suspension
Whee! Aonment
Brakes

Tires
Air Conditioning +.
Electrical Ratings

Body Specifications
Illustration

Standards and Service Limits

Engine Electrical

Messe te ondaa Eons it
onsen [Ei my 4
[Sata ie ROK arabe 4

cs Monte Tr
ETES [sr

émet ENT
comme o tr
mms 68 omnia med)
ET — EEE er 1 >|
Engine Assembly __
Ra ee u
pen Sees Speer [haran [ais eer” 2060)
me seiner | |

2-2

¡a

ecg en een

cer
| snare
ae [Fe
|e == >

23

Standards and Service Limits

Engine Bk
Prenant Baie ended tow Sere
a gro me DES CE
Bere tr oi 500 momen ana
ame 20
Bar momo Fosse)
Ten mod ut Bin am [Korea nam een:
Soma ern 5320 wn 27
ao 02s ccoo ne Emm on
A AT
osu
ETES Îles ETE
| ocu
|
308 os In aterm dain |
00: me 0006 Gomme
E More ojalas [0 Hal [ao mentir BEET Sans “USOT
pe io 2h

2-4

L

“

Engine Lubrication

co Meer ‘onion See
DRE] 226 € u6 term sut
Som moi Pca rn err mamma.
er TE DL rn
Rod | a0 9261 mme D [sm
nina maga | Déni u
naeh [Foe OO Se OE Bon E 200
Ba 679 0135 mm one nams.nı O wn Cosi
ner tan EE 0 boo
A E i 260 M)
Ta aa ems A ri oat
pepa ca tiger’) Tan SIR ihe gs
ling
en nara onto Sind Rew ET
Fe | ce eee Exes evshaul [a7 CO Us
oer eee =

2-5

Standards and Service Limits

Fuel and Emissions

= Tiemann Ta EI ET
a wnt ne agora Er
LES ea ET
Clutch
hewn [Ragan stor Ten
Era 6 mme ten)
Decre riores [ise tetera
pain trae OS Geese Eras
“sine [03 omnia nr tm
CETTE ot metre rm an
an circa Nauru [émane Dania —

2-6

rn

L|e

Manual Transmission and M/T Differential
sens [Essay — roratarge $81.8 0S
ETT jan ast 64 coer aa

Damen crac berga

26060 (596 SND

CEE

ESO

nn

Coane

onen an mono own een
ansanır [Case = adm Que cite) Con

(écarte “Lona

2-7

Standards and Service Limits

Manual Transmission and Differential (cont'd)

Measurement, ‘Service Une ~
Fre Pr
Re
Pd
A EL
RE — ava
om ne fu son firm
Per Hs ni
EA -
EA vóma À ©
aime rs |
pe [io D ee en
sae, Lo Sena aaa fae
RES

O ne

[aise rl

vais

Suspension

2-9

Standards and Service Limits

rakes.
EL mg Sam ACTI

ETC [muros Fer senna Yannasenı
Caller tenn Fr

Air Conditioning

em cerry ‘easton Tadudertow [Sant]
oto [Ta ani
egret yee irn

Tay nares toa [set enon

re al

E

2-10

Design Specifications

omega a

EST | Gover Woh aig Te
enone | Te — Fe on DORE VE ra

DOVE er

[STARTER Te
e i ——

vara he
¡rancio [Para
[ra Fe | Seg Fa
erase PEA

2-11

Design Specifications

nta)
co rent LT Er si
(RS [ne ve Pers errant en
ON [roe os u. ee
Douanes
se oi agp
NS
peanes meer 4

conos

snes Ties er 4
[our Frs Stes for >
TT

corp = Sangre
a les — =

2-12

«

¿10

Y]

co aria oo)

Body Specifications

2-14

Maintenance

Lubricants and Fluids ..

‘Maintenance Schedule for Normal
Conditions
Listed by Distance/Time ... un 34

Maintenance Schedule for Severe
Conditions

Listed by Distanco/Time 36
Maintenance Schedule

Listed by Maintenance Item for Normal

Conditions 38

Listed by Maintenance Item for Severe
Conditions . 39

Lubricants and Fluids

For etai of ubieston pointe and ype of lubmeans tobe apis, ra
Frecedares such ae Ausemb y/Reassomiy, Repacoment, Overhaul

arte ino and various work
ion ste) contained neath sesion.

"NO: LUBRICATION POINTS. LUBRICANT
LA engine Farida Wotor OT PN 08728 9020) Too cil comin
i must spin the AP Cartcation seat show below

Make suteitsays "For Gasoline Engines" SAE
sy. See char below.

ona WF" ev 0878850170
Fonda DOT Brake Fs" 06798 200
Ens
Release for anual rane sion) ‘Super High Temp Urea Gracia (PINES 3030)
“hate cable end unone nb) 7 -
Shi and elect able ond manual Sir grossa
rarsmision)

[popes ges

latch Booster cvs

Shit ver pivot

Pedal

Baer termina

Font cor

ood hinges and hood teh

orense

Door inge, upper and lower

elit piston bool.ta per pias and boots | Honda Caper Gi zum

iron compressor ‘Compressor SPP ABS PACTA Mor
se

or retgerant:HFC 194 8 (R 134 0) E

Always usa Hondo Manual Transmission Fi (MT

not consi he propa alas

+2: ways use Honda DOT Brake Fld, Using anon Honda broke ui can cause corrosion and crease th
ie system

Using motor can cause er siting menus does

wor

3-2

Li

3-3

Maintenance Schedule

Listed by Distance/Time for Normal Conditions e &
neta ee
Gene ati tute see evowtoumee AN eu)
1200000 m. MZ TO years then av 50,00 ri 96.000 A 6 yaar ~
AAA amet Te
a CO

3-4

a

3-5

Maintenance Schedule

Listed by Distance/Time for Severe Conditions

Sorgen ‘ine

O

Tansee tot aa Ut Hors IT spe
Mn

PORTER me
BE a Sins

ras repo 22 mt 028 mr 0009-0010. 2032 1 8H
od rigs eosin)

TS Ueto im
Ez Do
FRE an lt ar Cy AOS US end San Aronson Te?

3-6

L 4

3-7

Maintenance Schedule

Listed by Maintenance Item for Normal Conditions

managen. [mann e | DARE EICHE)
[ner engine où AS . T . =. el... T e ojo
el jej Rite 10 Te

| Ami
| Ise .

Gr BBE ETON

ne 106 WARUM re Te

3-8

L|e

Listed by Maintenance Item for Severe Conditions

gen Sie pr sp opere ving ne 1 ms
1 Drag heer bot er leed,

mem [x el ole »ln]s DE ne [us

[sine tr |

|
“ie ej oe .
|
1 L
. OO .
plc anis . .

[oes tte 24600 unin amy coton rss rra tacon

Deere errar
igo GO ee AAA

Er aco SG Gm

"estuco eng cook tnt ei TO yer Ben ery (OO BRO ss

3-9

Engine Electrical

Engine Electrical

Special Tools 42
Starting System
Component Location Index 43
Circuit Diagram 44

Starter Circuit Troubleshooting 45
Clutch interlock Switch Test ncn

Starter Solenoid Test mm
Starter Performance Test
Starter Replacoment un.
Starter Overhaul

Ignition System
‘Component Location Index 415
Circuit Diagram 416
Ignition Timing Inspection 417
Ignition Coil Removal/Installaion 418
Spark Plug Inspection as

Charging System
‘Component Location Index .
Circuit Diagram
Charging Circuit Troubleshooting ..
Drive Belt inspection
Drive Belt Replacement
Drive Belt Auto-tensioner Inspection.
Drive Bolt Auto-tensioner Replacement

Alternator Replacement mm 429
IO Ovanhaul 400
Cruise Control
Component Location Index 436
Circuit Diagram … ds 437
‘Symptom Troubleshooting Index 438
Cruise Control Unit Input Test 430
Main Switch Tost/Roplacoment 442

SetResume/Cancel Swit TesvRoplecoment . 442

Cruise Control Actuator Te 443
Cruise Control Actuator/Cable Replacement «... 4-44
Actuator Cable Adjustment 445
Clutch Pedal Position Switch Test 4

Engine Electrical

Toner Dose

sm

Ta 0010000

42

Starting System

& [@ component Location Index

RIBERA box

fe

43

Starting System

Circuit Diagram

4-4

Starter Circuit Troubleshooting

re must be between 59° and 100° AS

fd 36°C) during hi procedure

+ Ar hits, any subsequent repair, resattne
engine conce moule (ECM) to clear any agnostic
trouble ces DTCs) nee papa 31)

+The Dany must be in good sondtion and fall
charged

+ Ifyou dsconneet the battery, do me ECM ile
procedure seepage 1-135).

Facommendes Procedure:

esa sans system tester.

* Connect and operate the equipment in accordance
‘withthe manufctrer's inaction.

Alternate Procedure

4. Hook up follan equipment
ammeter, 0400 À
2 Vatimatr, 0-201 (accurate within 0.1 vo
‘Toehometer 01200 om

A E

2. Remove he No, 17 (SA) foso fem the under dan
tunejeayhox.

3. With the clon pod press, tun the ignition
sito ot

is ne starter crane the anne normal?
VES-The stating yctemis OK.

NO-Gote sp.

4, Check the baory conton.Chack letra
Sonrections at me batary, the negative battery
nb to body, the angina ground cables and tre
sites for looseness andcorosio. Then ty
Stoning the engine again.

Dia the starter crane he angina?

YES-Repsiring e loose connection fixed the
prebem Tne staring system snow OK

NO. Hstarer wil ot raro engine agote
era the ong ne ras 7100
Slowiy- goto sep 7. Amor heangage fromthe
Hat ing gaa when you release the ey, check

forthe following uni you ind ne cause

Soenold plunger and such meluncion
2 Din eve gar domage avertuning dutch

cons the anar subharmes 1 connector (A)
‘rome angina vire hamcss connector 8)
Connect junger wir Wom no batary postive
‘wrrinal tthe sorter subrarmess 1P connector.

(i no starter eran me engine?
YES-Goro stops

[No~checkthe LKAWHT var borren the slater
Suhnamess 1P connector andthe sorter Hits
OK remove tho star end repr replace os

cont)

45

Starting System

Starter Circuit Troubleshooting
(cont'd)

8. Check he following items inthe order stes un
outing the open creat,

+ Check he BLEANHT wire and connects
einen tr unrcaeh useiralay Box and the
igiton switch, end two the unde caeh
Wucomelaybox andthe starter

+ Check he igntion own so page 2253.

= Check Ihe cut itariek wit and connoctr,

2 Check he sorter cut ray (an page 2251)

2 Check LT GN wire besan the rotar cr clay’
Under-dashuselay box and he uch

+ Check the BLK ire baron acute inerlock
Soren and G01

Choi

ng voltage and cuen raw

Iscrani voltage greser than r aqua 108.7 Y
{and currant draw ess han e saul 10290 4

YES—Goro tons,

NO-Aepace the stare, or ramovo and
Giassemele kan exec eve ame un you id

+ Stoner armature dragging
2 Shorted armature wanting
2 Excessive dapin engine

8. Checktho engine spoed while ranking the engine.
Ise engine peed above 100 rpm?
YES—Goro steps,

{NO--Roplace he starter, or remove and
<sesombleit,and check orth olowing unl

+ Excessively worm star brushes
2 Open ereukin sommutster anushen

2 Open crew ns arta commutator
ogro

+ Diny or damages noia! splines or ve gear
2 Faulty dro ger eaten

move estare, and inspect its ive gear an
te mao ing gear or damage Replace any
‘damage are m

4-6

Clutch Interlock Switch Test - 4

1. Disconnect he euch interlock sith 2P connector

2. Remove the cluch ntriock ich (A . @

3. Check or continuity batean the terminals
seceding tthe wate.

+ the continuity not os paid, replace the
lute imeock srt

2 OK install utc interlock ith and wast
te paca height re pope 124

Kerr

Pe

= PO starter sotencia Test

1. Diszomnoetthe 8 and M conector rom th sarter
telonold

2. Chock the holdin co fr coninity econ mes
terminal and te armature hour (round. ere
nou be conti,

continuity, ot stop 3.
no contr, replace the sancid

144 i for continuity benween the $
and Merial, There shoul be
i

+ Hamre contiuity the solenoid is OK
2 Mare ino comin, replace the slono

47

Starting System

Starter Performance Test

1. Disconnect thaw

rom the termina and the M

6 below using a
tray equivalent to
“To veld demaging
sary connector

ler motor wt rom the son ai.
Inthe starter pinion moves ot, tis working

|
CMS

— tao)
XT)

4 Discomnest ih battery from te terminal the
pinion doos nt eta, ine haa cathe
{alone working propery.

y

No

4-8

5. Disconnac te baer rom the starter body. the
inion atrats immediately, tle working propery

6. Clampthe sanar fim ino viso

2. Connect the startete harry ae desenbedin
the Gaara below, and contr hat
star andkeops ring,

aho 7
SAtrenv

specications when he batry votage lt 11.5,
‘he storterie working prover

Spncitemion:

aaa
__—_| 3000 pm or more iMotorspeed)

O starter Repiacoment

0

1. Make sur you have the assaf oda forth adi,
one down the requencias for he radios
preset buttons

2, Disconnect he negative cable rom the bat,
{hen daconnect ne postive eat,

3. Diecannact the knock apor connector.

a. Remove the bolt (A geurng ne hamess braco,
thon remove to Intake manito racer (8),

5. Disconnect the stanor cable)
‘onthe soll, then daconneet th
{Bom he S terminal

8. Remove the ro bolts holding the starr, than
remove he ste.

tare inthe reverse order of removal.
he crmped sige of te rg terminal A)

8. Connsct he postive cable nnd negative cateo

9. Starts engine to mate sure th starter operates
propery.

10. Entorthe a tht enda fo the aio, hen enter
tacoma stato satin presets,

11, Setine clock

12. Pare the angine control module (ECM) i les
procedure es pago 1-139,

49

Starting System

Starter Overhaul

Disassombiy/Reassomby

4-10

€

x

Armature Inspection and Test 8. Crack ha commutator diameter. the ameter is
lowe the service replace the armature

1. Remove the tare (seo page 9
Commurator Diameter

2 Disassembl the tater as shown atthe beginning Standard ew 280 mm (130
ofthis procedure Serva Limit 27.0 mm (1.0850)

3. Inspecting armature for wea ordamage ram
contact In permanent magnet here west
‘damage, piace o arma

nes ep
in 300 07 7600 eanapaper (i

Commutator Runout
‘Standard Na 22 mm (0001 in.) max

Servic Limit 0.06 mm (0.02

‘conta

4-11

Starting System

Starter Overhaul (cont'd)

7. Chock hw mic dpth (fhe mes 10 high 8»
Undoreut the mica with a hacen bade tthe
proper cept. Cut away athe mica (between
Theeommutatoreogments The undercut should
not be 10 shallow too arrow, or Vehaped D)

‘commutator Mica Dept
Standard New): 050-030 mm (0020-0091 in)
‘Service Limit: 020 mm (0.008 in)

8. Choc for continuity between he segments ofthe
commutator ifn pon creat xt Detwoan any
segments epee the armature

4-12

3 Placa the armature A onan armature ester 8,
Hoi a Packs blade (C) on he amature cor.

1. Check with an ohmmeor tat no connut ens
‘between the commutato Alora armatire col
or (8), and pence the com
Armure shai Ch Weaning

e

0

Starter Brush napación

11, Measure the brush length. itis nat within tre
erie miro ace the brush or assembly.

rush Length
Standard New! 140-145 mm (055-0570)
ServoeLimit 9.0mm(0351n)

Starter Field Winding Test
12

cor comity between the brushes AL
ere ro conti, eps the armature
housing 18,

13. Check fr contol bowwoen cach brush) and
{he armature Rousing 0) here is continu.
place e smatwe housing

Starter Brush Holder Test

4. Check thst ther is no continuity wen +)
brush holder (A and rush oder 18 Ihave
ls conil, replace he brush older assembly.

Brush Spring Inspection

15. Iertho brut (Vin he brush hr, nd bring

the spring tensor
the brush. he pring tension isnot win
pecan, replace the pring.

Spring Tension: 1371771140 1.80 Kg,
20

im
eg.

icon

4-13

Starting System

Starter Overhaul (cont'd)

Planetary Geer inspection

Overruning Cute Inspection

17 Slide the overrunning cue along ho sha
Replica fito not ali moat,

leeks in bot dictan, replac le

SE

18, he starter rive ger (Be wer or damago,
replace na ovotruning lt samy: ges
ler ava ie sesoratay
Check he condition la yw! ing pea.
ina te storie dr geo teca
Somagos

4-14

Starter Resssembly

20. Pry hack each brush spin wih secte, hen
ion e buch about naway ou of hlder,
eleas the springta ola ere

NOTE To seat the now brushes, sip a tif 4500
or #600 sandpaper withthe grit side aut ooo
the comm

gain, and push a Brunn ou un a
apainctne commutcr, then lease the sing
against ine endothe brush

22. Istal te starter end cover to retina brut
holder.

Ignition System

~[@ ‘Component Location index

4-15

+

fe Ignition Timing Inspection

+, Connsetihe Honda PGM Testor tthe di
‘connector DTC! and chek for DTC's I 1
reten, diagnose ard repair the couse betere
Inspecting me ann iria,

‘gion timing under so ons
eastte, IOwer fn, oar and

"ion ming fers rom the specication,

2. Startthe engine, Hod the engine a 3000 rom with ere ae o engine contro! modu ECHIDTCE,
‘lena in Novia untisroradatorfoncomos on, copio he ECM ene page 154)
Sante ke
Vanition Timing:
3, Check te ide spa Is page 11-138, 8° 2 BTDC (RED mark [BI during log in neural

4 Follow the testes prompt inthe "SCS" menu
¡seo me tester operators manus.

5. Connoe the tiring ght othe service oo.

Turin anion switch OFF

8. Disconnest the Honds PGN Teter ans the timing
Nom

ue

4-17

Ignition System

Ignition Coil Removal/Installation

1. Remove the ignition cl cover Al. then remove the
fanion cols).

IT ersem ran
N

2 Instale ignition cols in me reverse order ot
removal

4-18

fe

‘Spark Plug Inspection

1. Inspect te olctodes and crami insulator.

Burned or wom eletrades maybe caused by:
Advanced ignition mino

1 Locse rk tug

+ Plug hestrange too not

2 insutficant cooing

Fouled plug maybe caused by
Petardos gallos timing

"Sin eombusten chamber

2 incorrect spark pla 99

lug host range tos cod

"Erz ing spsed running
+ Geggedairctesnere

2 Ont ¡gaticos

D no adjust tho gap of insur plus (N
‘ole rapa atte D FU

Electrode Gap:

Standard New 19-11 mm
(0099-0043 in)

ÉTAT CN)

3 Reploce he pi athe specie interval. ofthe
Cente crade rounded Al Use ony the spark
pugs ed Bow.

‘Spark Plugs: ZRII NG
‘SKL200R-4011 IDENSON

4 Apply a small quantity lasse compound to
the lug tveads, an acte 0 plage nt the
Oyindar head inge it. Then torque em te
SENS etm "Rt.

4-19

Charging System

Component Location Index

x

4-20

QRO circuit Diagram

«ie

Charging System

Charging Circuit Troubleshooting

Li enaraing system indicator doesnot come on or
(don nt goof or tre battery dead or low, test se
loma inte order sted below:
story 100 page 22-50
(Charing system indicator
Armar and opulatr cri
orar contre avant
‘Charging System Indicator Test
1. Tor the gniion site ON.
Dons a charging system idieaer core on?
YES~Goto sp 2
NO Gotostep3.
2, Sort the engine.

ows the energing sysiam isaeator 90117

‘YES~Charging ayer Iniesoreireutis OK. Go
to the Ateratar and Regular creat Te

NO-Gotostep3.

Trostlesncortho mulipox control yetom seo
page 22.772)

etna multas conto system OK?
VES-Gotosups
[NO Check ie mul contro system as

indietedby the dagnosic trouble code (OTC) (sce
stop on page 22-72.

5, Disconnact the engine wie harnns 8 connactor
rom ne starter sub mess 6P connector

4-22

6. Masore tha voltage atthe No termina of he
“angina wir harness 6 connactor wih the nition
vien ON

ENGINE MIRE HARNESS SP CONNECTOR

Le toro battery otage?
YES~Goto top?

INO ec fra blown No. (104) ne in the
under das fuseelay bo. fine fus 8 OS o
‘pen nthe wire benne to alternator and he
Under isn use Box

7. Turm tne ignition site OFF.

8. Onconnact angina contol made ECM) connector
Bea

9. Check continuity between no ECM connector
‘orminsl 810 and angie wre nern 6 conan

NO -Ropsir open ia tho wire Betwoon the
Anaenatar and ma Ch.

+

ne

Jo

¿JO

10, Check continuity between the FOM connector
termina B10 and body ground

om CONNECTOR 21

Le ere connut?

YES —Ragai shor to grou
he ECM and the engine wie haınace BP connector
.

NO- Goto alternator and regates

‘Alternator and Regulator Circuit Test

1. Be ure the battery is suficientiy enarged angio
sped condition (ue page 2250) andthe
ometions atthe use box and altamar ara
‘leon ana naht

2. Rais the host to neigt.

3 Hookup the ammeter, 0400 À tothe tater
subpamess.

cone)

4-23

Charging System

Charging Circuit Troubleshooting (cont'd)

Hold the engine at 3,000 rpm ith
adn Neutra un te radiator fan comes on,
thon et tile

1. Raise the engine speed to 2.00 pm, and holt

8. Turm ine headlight high bear} or and measure
otage a th under poo art box emi

Le ne verge betwen 18.018 1.17
YES-Gotosten3.

INO—Rapairor role the alternator components
[eno page £301 m

9. Reed the amparage at 135V.

NOTE: juste voltage by turning ne bower
rotor, ear window defogger. brace igs te. ON,

‘ste amoorage 60A a mare?
YES. Atoratritegulaor operations OK.

NO Repair or piece te atemator components
lesa pago 420) m

4-24

‘Alternator Control System Test

NOTE: Ar toubleshooting perform tha engine
conto! medula (ECM) a Inn procedure one page
vi

1. Check fr proper operation ofthe leetical eae
‘Sesector 6.0) By checking me marfunenon
intr lam MIL) {seepage 3-3 8 DTC is
rase, diagnose aná rapar ho cause before
continuing with tito

2 Disconnse the engine wire harness SP connector
from tha saree subharnas SP connector

3 Storno engine, aná tum the height high
bam ON

4 Measure volape botwoon the angine wire harness
GP connector arrinal No. ? andthe postive
terminal oft toy.

ES

Lainere 1Vortess?
YES Goro.tops
NO-Go tros,

5. Turn tna nests ana igniion ste OFF

6 Disconnost ECM sonncetor 8 1247

cle

Lie

ue

2. Check for continuity banwoen ECM con
rms IE ana soy ground

10. Check or eotinuty borwoen ECM connector
termine! BTE nd engine wre harnas SP conne
terminal No.2

ECM CONNECTOR eur) KEMONNECTON nun
275 FCELISUET
DENT 2% DEA E MAT

IZA salía
A som man

I

La are continu

YES Moosic shorto ground in tho wire betwoen

{NO Cock athe torminais re my seated
‘thw ECM connactor 8 HOR, eubetute 2 known
oo FCM, nd chez eae page 1-6,

i prasrbnd voltages row aval abe re
Orginal ECM

3. Tur the hip an ignition aueh OF.

Disconnect ECM connector 248,

ENGINE MIRE HARNESS ar CONNECTOR.
Wie sd homo minis

thar continuity?

VES — Repair or replace he starter subharness or
the arena ‘sce pogo 301

NO Repair open in na wire between the
Aternetr on the ECM

4-25

Charging System

Drive Belt Inspection

4-26

Drive Belt Replacement

2. Install the new belt in the reve

cie

Drive Belt Auto-tensioner Inspection

Angie and ahr saring the eng ne.
‘hangs ne poston. replace ne auto ton nc

2. Check or abnermat noise from the tansione puy.
Fabnormsl ros hoord, rplac the tama
pally

Remove he dive bl (an page 426,

4, Move to auto tensioner wine imi wih ne
bet eran rase tool inthe cretion hos,

Check hat the tensiones moves smociy
‘without any abnormal ols. he tension” es

5. Ramove the sutotensione® ate page 420.

7. Clamp te ato

8. Satin organ ranch (D o ta pay Do

3. Align the indicator lon ho tensioner base with
Cantar man on na anslone stm by ing the
Focus weunch, and measure tra the

caso lue out sien, replace the

NOTE ithe indicator exceeds tha center mark,

Auto-tensione spring torque
265-303Nm ET AJkgm 105 ZUR)

4-27

Charging System

Drive Belt Auto-tensioner Replacement

4-28

2 Remove the sutosensoner,

Alternator Replacement

1. Mako sur you have the antro for tna rato,
thon write down the raquercies or he rao’
Proc buronı.

scab rm na bay fst
postive cable

3. Ramove he fone bumper eae page 20:51
4. Remove te right sie height ove page 22-79
5. Remove he recrear fom the bracket

6. Remove he drive bait ne pap 426

7, Remove me hte bolts securing the ateratr.

8. irconnoettn aterntorconnestr Al and BLK

1.

1

oy

Ina the atrnaor and ve bain he rovers
order of removal

Connost the postive cable and negative cable to
th aan.

Emer th athe: code forthe radi, tn tar
‘ne cuetmer’rado station presets.

Sattha cook

Perform the engine conto! module (ECM) ie
procuro eos page 1.130

4-29

Charging System

Alternator Overhaul
tejo
on eat
= EN penseur /
1 4 FRONT BEARING

D ol

à

Gog, —

ni”
> x

\ SAO
FT um
x Î
¿O
se of

ago

4-30

‘Special Tools Required
Driver 07728010000

<'Atachment, 82 x 55mm 077460010800

NOTE: Refer tothe Exploded View a needed during
this proved

Y. Tonne atenatorand guter otore you
rame them aos page 422)

Romeve the akemator (se page 429.

he front bearing needs replacing, remove no
pulleylockt with 10 men wreneh (A and a
22 mm ureneh (9 necessary, use an impact

4 Remove tn noross bracket A) neuter (8 eo
ge ute C) ando ser (D, then remove the
vial

5. Remove ha and cover {A and dust ses),

$ Remove the brush holder) voltage rgulsor 9),
fan the rubber sat.

4-31

Charging System

Alternator Overhaul (cont'd)

7. Ramave the four sews thn remove tha acti
Aland fou insulator (8.

8. Remove tho four lang nus then remove the rear

using (A and washer (8

4-32

wm

racommecilysveabie tools | 18. Support stator housing in vise, and déve out
"rer bang on te rotor mat. rot bering win 3 bra dit and hare,
NOTE inal te boring unger oe

15, with ahammorandthe special toos, stall new

corra

4-33

Charging System

Alternator Overhaul (cont'd)

Rect Test

16. Cheek fr continuity in each citctio, between the
der te
diode pe
inony one
¿lracon Because na ser codes ar designed

ontinuty wth an ehmater tet hoe cede
decking cape a of 1 chi

diodes fou, replace the ete
emy, Diodes ar nat vasblesepsrately.)
+ Malthe Gods are OK go to ep 17,

|
erg

4-34

Altornator Brush Inspection

17. assure me long one renos (Ay wat
varo eaipa (8

+ Meier bush is shorter tan the service Hm,
replace tre rush sssombly.
+ brash long OK. goto sto 18.

Atternaor Bush Length:
Standard Mew! 10.5 mm (0.4 in}
Serves ute

15 mm (005i)

Rotor Sip Ring Test

18, Check ht eras continuity between testi sags
a

+ Hiro ls continuity, gto step 18
rocomtinty, rapes the lernt.

19. Check thatthor is ne continuity botwesn cach sip
Fin width rotor) an the rotor aha Ch.

+ ere iso continuity, got step 20.
2 itreicontiruty, replace vo atoratr.

le

ve

Stator Test

20, Chace matter scort Benen each part
ead

+ Heres cortiniy, go o sep 21
: ity replace he amor

21. Check or no continuity beten each lead andthe
Er

+ are no coniity, got stp 22
2 fière conunuity, replace he allerator.

22, Ascambie the ataraterinrovere oer ot
‘isos, ord mle Ine tome

+ Be crefl norto gar any grease roi one ip
“ras

+ you removed th pay, hen tocino
Am kal, 91.7 100 hon you int

4-35

Cruise Control

Component Location Index |.

itis Due een

ce

4-36

Circuit Diagram

Cruise Control

‘Symptom Troubleshooting Index

nom:

2 The rumbersintho table how the roubleshoting sequence

À Before oubleshsoting.

= checo No 107.3) ara No, 41104) fuses in the under lue ay box, and the No, 7134) use nthe
Unde'-hood fusil ba.
heck thatthe hots sounds
= Check he tachometer 0 soa: works property.
neck mo speedometer tose i wens properly

a Diagnostic procedure [ais theater
‘Grieconwalcarnaibe "1. Check mainawien ewe page 4 7 Poor ground
ot 2. Check SETMESUNECANCEL mute so page £4) sa
3. Testbvace pedal postion suis fe page 2214) and chock | + Open ui,
is adjustment eee page 19.01 loose or
4. Testeluch pedal poston sten (m page 445) anscheck | disconnected
is adjustment ac poge 124 terminas:
5. Checkeruise conte unit ses page 440) LTGRN,
5. Check vehive spood sensor VSS) (san pape 2.65) succor,

GRY/RED. BLU,
ira,
Sun.

‘rage contol con Bava
Butinelstr ight does
noigoon

Check ruse conv TE bu n gauge arr une
page 2263)
Chock cris control unt ie page 40)

+ Poor round
car

+ Open iu,
econrectes
‘erin:

noticeably higher or
Toner han wrt wae set

hei pa sensor WEST ne page 2-65)
cui conto stator eee page 4.48
{Chock ris contol unit (ne page € 401

Lauer

Excessive rershasing
ura wan
‘ying to et speed

Sora uctution one
arrondies
come set

Ti ris control actunor ene page 4-1
Check vehicle se sensor SS) eve page 2-65)
(Check eee contol ui seepage 440)

Check vano speed sensor VSS) Taco page 2.65)
Check ruse conta actuato 1508 sage 4:49)
Cheok erste control unit ees page 420)

‘eek SET RESUMETCANCEL awh
Check crue conte unt see page 440)

page 42)

‘Open cea 19030
‘eainconnectes

Pig nan uch peda
[isousnes

Ser speed does not
ane won broke pedal
isbushed

Toa brake posal

(Check ese contol unit 1500 pogo & 40)

fon Satoh RES page 2-88) nc crack
adjustment eee page 1901

(Chace rus santa unit see page 440)

secoringh when SET termi:
RESUMEICANGEL Burton SGRYIRED.
Iepushes LT RNB
Serspeeddoss |, Test EU pedal postion swieh (oe page 46) an check | Short ground it
[canal engine rpmstays | asjuriment ace page 124) LT BU wie

‘Open ere oe
ferdscornected

AA

4-38

¡0

ses

6

Symptom
Set pend does not
‘ance whan main
ispusted OFF

Set pees does rot
ance whan CANCE:

| Secspe0a wit nat
resume whoa RESUME
Dem i push th
‘ain ste on and a
peed tempora
Carcel by prstig he
brake pa

‘Diagnostic procedure
Crise (me pages 42)
Check rite conte unt ee page 440)

CEL sata ase pape ER
{Chee cute control uni ees pogo 40)

‘hack SETIRESUMEICANO
Cha ru conta ni

iso ewe for
Shortto power n
LT GRN wie

pan eut. one
| or&sconnectes
| Seven,

LTGRNBLK

“Open et 10000 |
or inconnnei

TOA

4-39

Cruise Control

Cruise Control Unit Input Test

SRS componente a

1. Disconnse the 14P connector fom the conta

located inthis ren Review ne SAS component cations (ses page 2-13) and precautions art
procedures (sen page 23-14 the SRS cacon Dolor performing repara sevi

2. Ingpect the connector and socket terminus tobe sure they rol making good contact

minal look OX, goto

uses (FEE

3. Wh the 14P connector discomected, make these input tees

inal are ba, oo, or orrede, rept hem ss necessary, and recheck he aster.

N
huss common ur

Gai] Wire Teener Fest Fi it
FT aRNWHT”Conncerbatery * Faulty actuator
ower magnete en Guen | + Poor ground (6207)
nou ek andoutputink | An open inte wire
shouldbe locked + Shortie ground ace when
_ power isconnected)
7 [BU gn wen ON |CheckTerveisgeiogreund: > Pauly brake pedal postion
mar saricn ON | There anoue DV Me caen
‘na brake pedal | pedal prassedanóhatlory + Anopan traite
| | presse, en Volago withthe poda. 2 Open in cuina control
‘ales released, saith
+ Blown No 410 A use athe
ss ‘ander/dath fur Pt box
3 [BK | Undarailcanations | Cheek or coninuiy io Poor ground (6501
grouns: Anger inthe ite
2 {Tone should va conti.
[aos gation switch ÓN [Chek or voltage to ground» Blown No 40 uve nt
| de Thoresrouls ae carry Under doch vee! box
volege + Anopen in nor.
| WHTIBLK | Brake pedal pressed, | Chek or vole to ground + Blow No, 755 A) use mi
nen ases ere shouts denen, under hood fuse ely box
voltage wth the pedal + Faulty bate pat pau on
presses. and DVnthine am
Pl ose „An open inno wire

4-40

Wire [Test conan ‘Test Dosage
$ GRVIRED | Ser button pushed | Chock or voltage o ground!
‘There shouldbe battery undortoastusialay box
votape + Faut hot relay
inentesting termina No.6, | + Faulty saesumelcancal
ther should oe ro otage on | switch
L termina No, 7 7 |» uly cab oe
7 | TGR Rerommbutios Check orvotapetogroure |: Anopen inthe wire
BLK | pushed There shouldbebatery | > Shortt ground thom sounds
vonsge, onen buon presos)
‘Wen tsaing termina! No.2
hare hou e novotage 9
termingt Ne 6.

SL URN |Conneetbanary [Checkin speraon ofa» Fauiiyacsior

TI] BANYET | power tomes | ecustarmotorYou shouls > Aopen ine ware

beable to naar tro motor

39 | BLUVELaniion switch ON | Arachto ground asin No 100.5 Ve in
ao Crusoindcnor lghinihe | tha under dash ere ay box

sui owsemolyshoulsome ; + Blown crate indicator bala
ES + Faulty gauge assembly
An open inthe

7 Iention swe ON | Code Fauty VSS. |
{itandenainsvten | the ELUNWHT Con BK |: An open nthe wire
ON: aie the front of | (tem nal: Shortie ground

¡ thevehicle, and | Thee should eo SVor
Slow we hai,
| te thor sere _

137] IE [Ignition swnten ON Creckforvalageiogreund: |» Blown No. 21104 use
bendmainswiten There should be baten, ‘under dash user Box
on vote. 2 Fauy mai sch

| Amapaninthe ite

ve [era [cian peas Check or continuo au cuen pedal position

talented ground: en
nero ehauabncantmity. |» Poor ground (Ot)
NOTE: Thera should be ro | + Incrrectclren switch

continuity when te LR

pedals pressed

adusimen:
2 Anopen inthe wie j

4 Ian tat ineates aproba and corset the causo, hon rachack he sytem Fo he

¡tres prove OX,

ho rune corto ut may o hy Subsite a known good cruise Corto ei and res. the system works

4-41

Cruise Control

Main Switch Test/Replacement

1. Remove the ver dashboard ower cove (sae
age 2058)

2. Polgaco 1h lia of the main switch and pone
main enn (A outofine pana, then disconnect
{he SP Connector) tom the main awen.

\

3. Check for coninty between he terminals in oct
sien positon according tothe tabla, the
Santini aot ae spe, place lamination
le Cor the sate,

Set/Resume/Cancel Switch Test/
Replacement

2. Checkfor continuity berweon the trina nach
EN poston azording ost.

conti ani vecs the abe, ut
fale oeuted on acuse control unt
input et, check and epat the Sarah eeu

+ ifthe fee conhruty In one er both poate,

4-42

NAAA em

hae | nia j
[980 ce an
ow DISI05I0IS-0) ‘canes. (om

Cruise Control Actuator Test

1. Disonnact ne 4P connector trom the crite
coro rate

2, Remove me cover (A) an check he output iio
Dior smooth movement

3. Connoet battery pow tothe No.2 terminal an
sroundte ren. termina

a. Check fora ccking sound rom the magnetic cute
Tr oututInkage should be asked

Ha output tirkage not ack, replace the
‘huis cnt! getan: assembly.

a operation of the atuator motor in cosa
kage position szoreing tomo able You

nou be abeto hear ne motor

Fran Output age postion}
alee

JE se Vu

we (ma

Tena | Teint

wor

ru cost

2. ie actuator motor does nat parte as specie,

‘place ine nie control setustor assembly.

4-43

Cruise Control

Cruise Control Actuator/Cable Replacement 10

3. Remove he sctuator cover

& Install inthe vers orde of emoval and act
y atthe rre linkago aor connecting
Ir cat,

cle

ve

4-44

Actuator Cable Adjustment

+. Cheex tna the sctuator able A moves smeothiy
‘th no binding axing.

2, Sarthe angine.

3. Measure me amount of movement ofthe output
e] ant he engine speed ear to nor.
he ouput nia shoul be locate at ne
{uly dosed costo Ch. The re play D) should be
27505mm00.15=0.02i},

snot thin spect loosen
rand um he acjusung rat)

Clutch Pedal Position Switch Test

+, Disconnect thw 2° sonnestor from the lr pedal
poston sich

‘Luten PEDAL POSMTONSMITON 2P CONECTOR

2, Remove tre cute pedal postion switch,

3. Check for comiruty between the terminals
Ssteordng tothe able.

+ KOK neta th lato pedi postion ston and
dst he pedal height ene page 12

4-45

Engine Mechanical

Engine Assembly
Engine Removal
Engine Installation

Cylinder Head

Engine Block ..

Engine Lubrication ..

Intake Manifold/Exhaust System ..

Engine Assembly

5-2

Engine Removal

Special Tools Required
‘Front subframe adapter E0S020000011

Nore:

* Use fender covers avoid damaging panes
surfaces

+ Toma domage ual the wing commons

1. Secure ho honin the wide open position (support
‘odin te lower hola

2. Moke sre you have ne anti the cd forte sa,
Han write down te mequeneie for re tia
preset batons

3, Disconnect ne negative cable rm the bay te.
‘han disconnect he postive cable

4, Remove the beter.

5. Remove the intake mil cover.

[eo

5. Disconnee the intake ar temperature AT) sensor
‘connector, romeve te breather hose (8) ans

housing coverimake ar cut assembly (D

ue

8. Remove heintak air aut

11, Pole ue! pressure (se page 1-148

12, Fame te fu ine (oe page 11-189)

one)

5-3

Engine Assembly

Engine Removal (cont'd)

18, Remove the uch slave cyúndor (A and elt ine
rockt mounting bolt

7

A

5-4

16, Disconnect the angine corto! modulo ECM)
rors (A) and main ware namass connector

us

wd

55

Engine Assembly

Engine Removal (cont'd)

5-6

Engine Assembly

Engine Removal (cont'd)

43. Usp à marker to mate alignment maxon the
relance Ins (A as align withthe contre ofthe
‘oar subframe mounting bol

45, Disconnect the compresor cu connector,
‘than roma the AL compressor Bh without
‘lsconnacting ne NC Roses

42. Remove th rant eublame (O

5-8

46. Chockthattheengineivansmisioniscompletay
acum hosen, fel and ecola Posts, and

2. Stow tonne te angine about 160 mm in.
Cok once again Ihr all Moses andes ao
‘dssonnecte from na engitransmissen

“.

Lowers lie wey. Remove the chain
host om he angina.

48, Remova the engin rom under the vehi

-[®

jo

QRO Engine installation

Special Tools Required
Frontsubtrame adapter EOSO2C00001"

1. intl te accessory rocks, and tight her bots and ura the specifi org,

LS AS

(conta

5-9

Engine Assembly

Engine Installation (cont'd)

2. Posiion the engine under the veil Attach tho
inhoist othe ngine the th engine to
boston nine vice,

Reinstall the mounting blssuppor nutein
‘the sequence given. Faure folew tio

cause excessive nise and
Vibration, and reduce bushing te

3 Instale AC comprossor AL and connect the
compressor citen connector 48

ET kot. one

A Suppor the subframe with he subframe adapter

5-10

SL

5. neal he suba

-Algn th roetence marks

7, Loosely tighten the font mount bracket mounting
bolt

8 Lower the hoist

3. Tien th upper racha mounting Bot and rut

pin
UT in

10. Tight
boten

un racto support

EA Tamm

lornove te enain hoe fom the engine.

15 naa the adito is page 10:10.

16. Raina me poto her

1 tng one endotesen aves,
M ir venhat, Make sur anc ing

"ele" nto place inthe diront and

(eons)

5-11

Engine Assembly

Engine Installation (cont'd)

18, Connaet ne su
sp on page 18-191

5-12

lower arm ball jointe soo

23 instalo splash sto.

cle

Ue

27. ist the upper radiator hose (A and heater hoses
El

28, state harness lems)

30, Connact he SCM conne
harmass conector BL

31. nal he tht cable eco pogo 1-164 thon
cute cab ee page 11.168,

22. Intl ne cruise contol cable see page 4-44 thon

ct no cable ene nage 48)

icon

5-13

Engine Assembly

Engine Installation (cont'd)

35. Intl ne ceectcato LA ane shift cabe (9 using
the plastic wabnars(C), washers D) ard now eter
pine

Shien kat,

36. Ital machen slave ptr LA and len ine
racket mounting bol Bh

5-14

57. instalo barry cables (A) on the under hood
ela box, Men tal te narnase camp

38. Instale ground cable

16

Par

40. instale air cleaner hovsng.

mint o7itro

41, instal ne at lanes housing cover A) and
Sonneetthe ntake ir temperatura HAT} sensor
‘onneetor

42. Intl he breatner hose (and vacuum hose (Di

43, Intl he nt manifold cove.

/

caper, an nein
‘hor and apply reono to proven’ corrosion

45, Chackthat the tranemiecion shits no gor

ao any Soin are

efile engine with engine ol eee page 1),

ef ranemision vith fis eee page 133

48. Refilhe rad ator wih engine cooint, and blend
air from te coo! system wäh ho ht valve
‘pen tes page 10.6)

Perform the engine contol module ECM) learn
procedure ses paga 1-138)

St napect the ido sp006 (seo page 1-138,
82. Impset the ignition timing (ses page 417.
53. Chace ne vos! algamont seepage 184

54. morte on theft cose forthe radi, then enter
Ue custemars aci mation preset

55. Satin clot

Engine Mechanical

\der Head

Special Tools .. 62
Component Location Index 63
Engine Compression Inspection 66
VTEC Rocker Arm Test me 67
VTC Actuator Inspection 68
Valve Clearance Adjustment 69
Crankshaft Pulley Removal and Installation en

Cam Chain Removal
Carn Chain Installation .
Auto-Tensioner Removaliinstallation .
Chain Caso Oil Seal Installation .
Cylinder Head Cover Removal
Gylinder Head Removal a
VIC Actuator, Exhaust Camshaft Sprocket

Replacement = 2 624
Cylindor Head Inspection for Warpage reves 628
Rocker Arm Assembly REMOVAL mn 628
Rocker Arms and Shafts

Disassembly/Reassembly = 627
Rocker Arms and Shafts Inspection 628

Camshaft Inspection 629
Valves, Springs, and Vaive Seals Removal 631
Valve Inspection I 682
Valve Stem-to-Guide Clearance Inspection 632
Valve Guide Replacement 633
Valve Seat Reconditioning 635
Valves, Springs, and Valve Seals Installation «cana... 6:37
Rocker Arm Assembly Installation 6:38

Cylinder Head installation
Cylinder Head Cover Installation

Cylinder Head

Special Tools
LA Tosi Romar T Design
TD” | oran érina io [airPresie Regato
3 [oaerons Valve Guide Reamer, 55 mm
| orsanooto208 Socke. rm
© | orsaB-ooroz0n Helder and
5

> | tanaBorosoa older Austen. 9 mm
| envaccoronon Vals Spring Compresor Arachmen
BEE Vite AL Ador
rani ana TEE Ar Sapper
Centres) dit Adapter
@ [orme ane Gude omo 55m
lores sorou0e Insets 5235 mn
fe Lera anne Dar
e 3 o o
o o & ö
2 LP pa AD
> a w o

6-2

.

e

Component Location Index

Cylinder Head

Component Location Index (cont'd)

6-4

SC)

Res | Sn

Eau veuve

>
Ara

PS: ES
N

6-5

Cylinder Head

Engine Compression Inspection

wre coking an comes on).
2. Turn te ignition suteh OFF,

2. Remove rte mali cove lee step on
Pe

4 Oissonnee a four injetor connectors

$. Start the engine,

run unit stati
$. Remove the our gain col Isa 9990418
7. Remavethe four spark igs.

8. Amen he comproston gauge tothe ask plug

6-6

8, Open me thrnlo fly. han crank the engine with

”

no starter motor and measure th compression

Compression Pressure
‘Above 930 pa (38 kflem!, 135 pil

‘Masta the compression on he remaining
Orders

Maximum variacion
in 200 kPa (20 len 28 pai

tre compressionis not witinspecitations,
chest tee Rema thon remeosuro mo

+ Damaged or worn valves and seas
* Damaged eyinder head gasket
* Damages ar worn piston ings
À Damages ar worn ston anaeviner bore

us

VTEC Rocker Arms Test

Special Toole Required
"fir pressure regulator 0784 PNAMOO
VTEC a adaptar 072A, PNAAIOO
TEC air stopper 072A. PNAAZOO
SR jint adapter 0?2A-PNAASDO

1. Remove the cdo headcover ‘seepage 6221

2. Setthe No.1 piston attop dead center TDCI see
sep on page 6-1)

3. Verify that eh primary rocker arm A) moves.
Independently af th ake cacondary rocker arm
e

+ Ifthe intake primary rocher um doesnot move,
remove the primary ans secondary rocker arms
‘ean assembly and Eng that he ston inthe
‘eandary ane primary rocker arma move
smooth Ilan char am needs replacing,
‘place the primary and sosondary rocker arme
5 an assembly, and test,

+ the intake primary rocker stm moves fes, go

A. Rapes steno emanate primary
Primary roster sera pas ha et go 1 1 5.

$ Choc thatthe si prosuro on 1e shop air
«compresor gauge incicats over 100 KPa
[egin 57 pe

6 Inpec he valve carece eee gage 69)

7. Remove the sealing BoA rom the ait ol,
nd install VTEC stopp LE

Jimsmone Papsroson

LE > Vi i
LE

8. Ramove he No, 2 an No. camshaft holder bls,
and intl the VTEC oi adapters (hier.

8. Connact ne air jl adapter 1), and ai pressure
Fagulatr urn 0100 px gauge (E

6-7

Cylinder Head

VTEC Rocker Arms Test (cont'd)

10. Leosen the volve onthe regulator, and apply the
species ir pressure.

Spaciod ar preesure:
230 PA OK em 2 pal

[NOTE:ltthesynohranitngpletondoss nat move
she: eppiing ar pressure, move tn primary or
Secondary roer arm up and down manual By
rotating the crankshaft ei,

11, With the spcitied a pressure api, mova the

arm (A forth No. ying
he primary roer arm and secondary rock ar
(Bou move regener

He intake secondary rocker arm dose nat move,
remove pimary ad secondary rocker arme 22
an aesambly, and hock hat the piston inthe
Primary and secondary rocker arms move
Smooth any rocker mm need replacing
Faplace the primary and secondory rocker arme se
nano, andes

12 Remove tne pocitos

13. Tight ne camshaft elder mounting bots 1e
22Nm 22 Lot, To,

14, Tighton the selig boll to 20 Num 2 Hg,
vei

15. Ineal he linde naa cover (eae page 6-41

VTC Actuator Inspection

Remove the elder ec cover (ase page 6:2,

Remove the sto tersioner eee page 6-1

Loosen the rocker em juni res
on page 628)

Remove the comarat holder [ses step 2 on ue 6
28

Remove the intake cares.

‘Chace hat he varie valve timing contol VTC)
‘tutor locked by ting he VIE SELS
ocio and countetlcche, Hn VTC actor
Is Pot locked, replace the VTC season

Scale novanco has Land retard holes (Bn
ANG No: Tease journal wih pe.

Lie

3. Asply sr tothe advance hole ro release tho lock

Valve Clearance Adjustment

NOTE: Adjust he vives any wha the cylinder baad
ci

temperature lee than 100° SEC)

1. Remove the elder headcover eee page 6.22)

2. Sue No, ono dente ac Tim

I mark (Al onthe arabe vale mig conto
Ie) aewator ang e punch mark 6) onthe
exhaust comes sprocket shouldbe athe op.
lg in TDC mans (0) on he VIC actuator and
faust cama sprocket

fonts)

6-9

Cylinder Head

Valve Clearance Adjustment (cont'd)

3. Select he orrect thickness ewer gauge forthe
valves you're going to check

Intake: 021-026 mm (0008-0010
Exhaust: 028 042mm (011 DO13In)

‘Adjusting setew locations

gaupe ar betwoentheasusting
se Band tn nd fe valve les nd lie it
Back and fr: you should oe asi mou of
pr

6-10

5. you too much oto ine drag, loosen ne
Tosen Al an tn the adjusting orem 8) un
tha rag onthe alr gauge ie ones!

ESSE 2

6. Tobin the oca, andrecneck th ieranco
Repeat readjustment necessary

7. Rotate th cranesnalt 180" cocoa amant
pulley tre 9°

8. Check and necessary aust the vale cenrance
en No Sevlindoe

a

10. Check and, noces asst new
on No Leida

11, Rotate the crank 180° coche teamarat
pulley tne"

12, Chock and nacosary acs! the vale clearance

13. tral eager hxc cover

son 6

Crankshaft Pulley Removal and
Install:

150 mm OINAB 0010404
{AN ODIG20A ors commen

1. Remove ron trosinhnes,
2. Remove he slash sel (se ste 23 on page.

3. Hold the play with har handle A aná holder
cm

Songooeon

N

4, Remove th bat witha 18 mm socket Ci nd
broker bar

6-11

Cylinder Head

Installation

1. Clan the crnkshaf pulley IA). crankehat (8), bolt
(Cl andwosner (DI. Lubvcae ss sho blow,

Cam Chain Removal

NOTE: Keep the cam chain away om magnetic Flas.

Y. Turntho eranshaf play e te op dese comer
{TCI mack tA Ines up vet the porter,

2 Tin

the bot to 245 Nam 125 049m. 181 1)

th atoraue wrench and 9 mm sache Do rot
se an impactaron

state splash sel ise stop 20 on page 512.

$. Insta tro cents

6-12

A Remove the deve belt ese page 425.
5. Remove the einer wad cover (on page 6-22)

$. Remove ha crankshaft puley ece page 9-1

o

VEC ol onto! stencil 106
ge 1-120,

In with ik and wood sock

poor racer

11, Remove he ido engine mount bracket

12. Romove th

eons)

6-13

Cylinder Head

Cam Chain Removal (cont'd)

13 Loco instal ne erarkshat pty

14. Turn no craft eounerlocknis to compres
co

"5 Mines onthe oo arene ate
nto he holes. Turn the crankshaft

6-14

8. Remove te cam chain guide A AI and tensioner
seme

19, Remove th cam chan

Cam Chain Installation

NOTE: Keapne cam chan away tom magnetic fle

1. Satin crantahof to top dead comer TOC) Align
{the TOC mor A on th rankshat srasket ith
‘he pointer Bion he vlinder beck

2 Sethe caminata to TOC. The punch mat Aron
{he tab valve ting contr! (VTC actuator and
the guncn mark} onthe exhaust camshaft
sprocket shoul
(on ma VTC x

Cylinder Head

Cam Chain Installation (cont'd)

3, neal the cam chain on ho crankshaft prete
‘ath ha coreo piace Av aligned he punch
kB 09 ha crankshaft orocket

+. natal he carn chain on me TC actuator and
‘oust amalaft sprocket wih the punch mar
‘avaignsdwin seo colored pieces I.

6-16

$ Insta he cam chain guise À (A) on tensioner arm
e

Ei ata

y

in guide.

ER Gi 16 tu
I |

ai

8. Check he chain ease ol sea for damage.
seals mages replace he chain case 0
(eae page 6211

10, Remove liquid gasket om the chain ose
mating surfaces, bls, and bl holes.

11, Clean and cry och caso mating uraces
12. App quid gust, PN 08718-0008, oven tothe

finder Bock mating surco ofthe chain caso ano
the inerte atthe hoes

12. Apply qua gaa othe cyinder ick per
‘ilove contact reo (Alon the I 068.

14 Apply guid gast PIN 08718:009, overly tthe
fl pan mating surscnofihechain case andthe
inner re fe hoes.

NOTE: Do not instal he persis minus oF more
hve wanted since app ing qui sie Intend
repo hauls gasket ater removing rex,

PETER

(eon)

6-17

Cylinder Head

Cam Chain Installation (cont'd)

15. Install she new Oui (onthe chain cas. Sot me

NOTE: When instaling the enan cae, donot lise
the bottom surface on In ci pan mourting uriac

16. nea side engine mount back.

18 rata the grountcabi (1

timing cono! WTC) ot
vege eo 191 page 1 127

nat postion (CP) sensor
VTC ol ental slenoi valve

2). neta tn rarshat pully (no pogo 612.
22. Insta o vlindsr headcover see page 6-41
ZU Inst tn rive a

24 natal the slash

Auto-Tensioner Removal/
Installation

Removal:

Aemovethe coin case cover.

6-19

Cylinder Head

Auto-Tensioner Removal/Installation (cont'd)

3. Align the holes on the ook A} arte aro.
tensioner hen insert a 15 mm (008
nto the hole, Turathecrankshat
9 eacurathe pin.

Installation:

1. rsa the autostersioner

6-20

MN age ex mt

2 Remove he pin fem the auto tersloner

NS

2 Remove old aud gasket from a chain case cover
mating surfaces, bls ar el holes

Can and dry the chain ese cover mating surtacs

Apply liquid goste AN 087182008, evenly othe
Rain ate mating race ofthe chain cara cover
their trad ofthe hor

NOTE: Do mot intl he ons iS minutes or mor
ave elapsed since appiyin aud goskot Instead,
reapply liquid greet sar removing eld reside

6 aa the chin case cover.

Chain Case Oil Seal Installation

Seil Tools Required
= Driver 07749 0010020
Aootment, 5205 mm 07745 0010400

square he chain ase 1 the
ina height.

6-21

Cylinder Head

Cylinder Head Cover Removal

1. Remove the intake mario cover,

6-22

4. Remove the eylindar hand cover.

SL

Cylinder Head Removal

NOTE:
Use fonder cover to avoid damaging painted
+ Te void damage urplug the wing connectors

Var 19 and nases to avoid miscomcton
‘Also, ba sure ha they do not contac mr ring OF
hoses, interfere th other pats

1. Drain the angnecootat see page 106)

2. Remove the dive belt ace page 426

3. Remove th inte maniol soe

4. Remove the ireiner housing sen tan on page
2,

5, Remove tre water bypass hose

8: Remove the exhaust mani (ses page 97

7. Remove te com chain seepage 6-121

8. Remove the angine wir hamass connectors and
vir hores amp rom ta eyinger ed

+ Engine coolanttompernura (ECT) sansor

+ Esmenst position (CMP (op desd conter TOC)
ao Scennector

+ Camshat poston (CMP sensor A comactor

9. Remove tre upper radiator hose (A and heater
hose 181

10, Ramon the harass holder (A from he bracket,
‘hon remove the connecting pipe mourir bo (8)
tnd brake booster vacuumtine mounting ol LC.

11, Remove the water bypass hos (D)

eon)

6-23

Cylinder Head

Cylinder Head Removal (cont'd)

12. Remove th rocher am assembly (sos page 8 21.

13, Remove the sind hess bot, To prevent
‘warmege, ner ale in sequence Yuen at

‘CYLINDER HEAD BOLTS LOOSENING SEQUENCE:

14, Remove tha ender hon.

6-24

VTC Actuator, Exhaust Camshaft
Sprocket Replacement

Removal:
1. Remove the eam han ee page 612.
2 tld ma camara than oamend ren nen

ba valve iming control VTC)
aus carahat

3, Remove he VIC acustor and exhaust eamshaft
sprocket

Installation:

1. Install the VTC actuator and exaust amanafı

2. Anal engine oto het

‘uring bol and exhaust cams
then neal hem,

VTC actor

3 Hosdtnecamenat wth an open end wrench. then

‘Specie torque
‘VTC actuator mounting ott:

RSR TRS fm, 8

Esti camshaft sprocket mounting alt
Tann htm, Sale)

4 tsa the cam chan so page 6:16),

Cylinder Head Inspection for
Warpage

Remove the einer hese (eo pago 6 23

2. apache comal seepage 6-29)

(ind ad resuracing is nt requires.

+ Woarpage e benunan 9.95 mm (0.002 m) and
02 mm 0.008 n),resuiac the cylinder has

+ Maximum resurfoe limit 02 rm (0408)
bosedon a height of 104 rym (409 in),

Cylinder Head Haight:
Standard New! 10395 10405 mm
(4055 —4098in)

PRECIIONSTRAGNTEDGE >

6-25

Cylinder Head

Rocker Arm Assembly Removal

1. Ramov the eam chain (ae page 612.

2, Loosen the rotor arm adjusting ere (A

amshatsunserow ha bole o
atime, in eräseroe pate,

is

‘CAMSHAFT HOLDER BOLTS LOOSENING
SEQUENCE:

4. Remove ma cam chain guide 6, camshaf hades,
Andeamsnal

5. Insert bolts A) nto the rocker shaft older, non

roce arm assomaly (8

= \ +
9. À
Ñ = 4
Mer

@ Rocker Arms and Shafts Di

Cylinder Head

Rocker Arms and Shafts Inspection

1. Remove the rocker arm assembly (see page 6-28)

2. Maseurtha

meter ofthe shat ato frst rocker

6-28

4. Measute te side dismere of he rocker ar, and
co oran out a reurd cordon.

Racker Arm-o-Shat Crane

Standard (New!

Intake: 0025-0062 mm
oo 000201.)

Exhaust: 0018-0058 mm
(0000700022 in)

Service Limit: 0.08 mm (0003 I.

primary and secondary ae se

6, epost tne rocker am pistons (A Push nach
piston manuel
Ia docs not move smoothly replace the rocker

NOTE: Anplyol:0 tho pstonswhonroaesembing.

O camshatt inspection

NOTE: Do not ote tho camanat during inseeton

1. Remove the roc sembly ese page 628,
and isassembie (se page 521)

2. Putte rocker sat holdere cumshaf ana
camaheft holders on the eyindsr hos thon tigre
the bos tthe oscila torque

Spected torque
Emm bots:
222 kot, WEY
seth (1.2 gt. 8.2 EH
Gmm bo: dc

3. Seah camshaft by pushing tamy rom the
‘Samah pally end of he einer

gains: the ond of the
1 caminafe back and orth

Service imi roplace the camahet hea wrt
Foctock Mis si beyond the seven limi, replace

‘Camshaft End Poy
Standard Nev: 0 5-020 mm
{0.002-0.0081n)

Serica Limit; Damm (0021)

eons)

6-29

Cylinder Head

Camshaft Inspection (cont'd)

5. Uneerow camahaft hkdar nots wotums ata
time, in neriseros pattern. Than remove
Carnal Folders rom tr cyinder he

6. Litthecamshotis out of he cyinder head, wise
them ceso, men inspect the tramps Repisee ne
camahal any lobes are pitted scored, or

7. Clean the cant journal surtacos ito cyinder
hand, en aot the cams baci loc, Place
plostigege sip across each journal.

8 Intl th carahat holders then tighten th be

9. Romove the coma
potion plenas:

holders Measure the widest
‘onan journal

+ ine camshaft-holdrcesrane is within
limits, goo stp 0
ine Cjmahaft ha der lasrance is beyond the
erie leit end the comal has been place,
‘eplac the cylinderheas
+ ihe camshaft to holder clearance is beyond the
fence mit ane tna camahaı
replaced, goto te 10

CCamahat to Holder ON Cearance:

Standard New
No" douar 0000-0069 mm

(0001-0003
No.23.4,5.J0umals: 0.080-0.098 mm

Service Limit 0.15 mm (0.006103

6-30

10. Check ne oa unovtwih ma men suppotes
nao

+ ithe total rout ofthe cama is within he

19 Holder ol aaranc, the ol clearance ft
beyond the service tim replace to ylnder
head

‘Camshaft Total Runout
Standard (New 0.03 mm (0001 In) max.
Server Limi 004mm {0002in)

RL

11. Maasure cam tve eg.

‘abe ih Sed te

INTAKE EXPAUST
PAT [snm [3202
nassen) [sain
SE [sn
GG im
PAL Prima Sonde
(ic: Cam Cn

@ Vaives, Springs, and Valve Seals Removal

A. stato valve guide seal remover

Valve spring compresor atachment OIVAE.0010104

Identity the vas and valve sorge 38 hey are
so that aah tm canbe at nt

1. Remove to pinder head eee page 62.

2. Using an approprin-ine socket A) and pistic
malt 8 ight tap he valve rotin o oton.
the valve keepers.

3, nea the spring compressor. Compress the spring.

6-31

Cylinder Head

Valve Inspection

1. Ramos ta valves (sae page 6:2,

2. Mensure th valve int

Intake Valve Dimensions

A Standard (New: 34.85. 3515 mm
Perser

B Standard New: 106.7 108. mm
(420-4311 a)

(GStandard iNew: 5475 5.45 mm
102186 02189m)

Service imite 544mm (214m)

Exhaust Valve Dimensions
A Standard (New): 23.85 30.18 mm
nr
B Standard ews: 10.3 108.1 mm
(200-205)
Standard New: 450 5480 mm
(02180215040)
Service Limit: S42mm (0213)

Valve Stem-to-Guide Clearance
Inspection

1. Remove e vavas (sea page 631,

2 Side ie volvo curo guide about 10 mm, on.
Mansure tr gu tam lanos win al
indicator whe rocking the tem in the leon of
normal hust wabbie eto,
time meaeurementexcned the serien rit,

recnack Fusiones

it esssemblo using a new valve

Intake Valve Stem to Guido Ciearance:

Standard Now D.OB 0.11 mm
19002 0.004in)

Service Limit: ME mm D 006 in)

Exhaust Valve Stemto Guide Cloro:

Standard New! 0.11 0.18 mm
1004-0006 in)

Service Limite 022mm (0009in)

6-32

3. Surat the 0.0 ofthe valve ser, mesure ith
a micramete om the LD. ofthe valve guido.
moss res wh an nsid mierometer o al gauge
Toke ths mass remonte in re places slong ne
valo stem and thee places ini o vato guido
‘The lence between to largest guido
‘Should not xcend ne save lint.

Intake Vale Stemto-Guide Clearance

‘Standard New © 600.85 mm
Lo 00022 in.

Service Limit: 008 mm (0.03 in)

Standard New: 0.058 0000 mm
(0002200051 in
Service Limit: 0:11 mm (0.04 ia

© Valve Guide Replacement

Special Tools Required
vide ie, 83 mm 07742 2010100
fide reer, 8 Simm GPA F70108

1. nspoct aie stem to guide clearance (sos page 6-
2

2. As lustre below, use a commercial
‘impact valve gue diver A moi
“meter othe vo vo guides. In most.
fama procadure cane dore usin the apes te!
and convenant harm.

TE

3. Sole tho proper replacement guides, and chil

nemin me azo saco la efngeraortor
tout hour
A. Uso aha plate or veto evenly heat the cylinder

1028105007 150°. Monitor he temperature
vit cooking trarmometar, Do not get the heed

5. Working fom the camahat id, use the river ana
anairhammerto dive he guide about 2 mm 103
in) towards ne combustion chamber. This AL
Knock of tome othe carbon and make removal
tates, Hold heat hammer deci inline with the
Yale guide to preven demeging the driver

{6 Turina naad over, and rive the guido ou toward
Aa came sige of th hese

LAS
EN
(RIGS
2. acaso vota, hm
na oe nn Dl o

‘onreme coses you could damage te inde
Pose the guide eae.

8. Remove tho new guides rom ho ever, one ato
time, se you noe them,

6-33

Cylinder Head

Valve Guide Replacement (cont'd)

8. Apps tin costo! lean engine ito the ouside

a
{ay tm guid (8 Hy have 116

Valve Guido installed Height:
Intake: 182-162 mn

6-34

10. Coat both reamar and valve guido with cutting ci

11, Rotate te reamerclockmis o long of he
valve gu bore.

12. Continue te rotna ma nares loci while

13, Thoroughly wash the que in detargent and water
toremove any cutingresicwe

14, Check the cosroncs sth a valve

© vano Seat Reconditioning

none av tm ao aus are we pa
page 638 before eating the valu seta

Renew the valve seats ia the cylinder hans ung

sera 0 ensures moat end concert se

Bevel ha upper and lower exes atthe angles
shown ine at

3. Moke one more very light pass win the 45 euer
{ocemove ory posse bus causa bythe rar

Valve Seat wa
Standard New) 125-153 mm (0049. 0.061 a)
Service Limit 200 mm (0791.

8. Aer rs rc to cat inspector even valve
‘eating: Apply Prusia Glue compoung Ab tothe
Vaio fe. ner to valve ns orga icon in
“ho nad, then lit end enapi coses agers the

The actu vaive seating surface
the Bum eompound, should e

+ tie high coser tote valve stem, you
must make à 262974 eu withthe 675 certo
‘move down. then one mor cut with he LE.

+ itis oo lon [coco tn valve edge, you must
side) or ine 30 cutter exhaust side} to move it up
‘then make one mor
restore soot wid

NOTE: Th ina ut shoul always ba made with
the a canas

6-35

Cylinder Head

Valve Seat Reconditioning (cont'd)

8. Inar ia ineke and exhaust valves in th ha,
and measure valve stem installed ght

Intake Valve Stem installed Height
Standard New! 408 61.0 mm
DER

exhaust Valve Stem Install Height:
Standard (New! S46. Stamm
Der

9. Itvalv stem installed height is ver the standard,

ies tn valve ane rock iti til over the
andara, oplaca the cido hoa In valve sat
inthe heeds too de

6-36

Valves, Springs, and Valve Seals Installation

Special Tools Required
Vale spring compressor altchmant @7VAE-GO1010A,

1. Coatthe valve sms wth engine ol. nstalthe
vavesin the vale guide

2. Check hate valves move up and down soci
3. stl spring cote onthe ylnder he

4. total the na valve sans A using ne valve quico
salina

NOTE: The exhaust vato seal) hos Black pring
(0), snd thin EI ne a white spring
{F1 Thay arent tron angeable

5. Insta valvo spring. Place the end of he valve
Spring nt clsaly wound eos toward the oidor
ass

6 install eval ruiner.

7. stone valve spring comprosso. Compress the
{and instal the alv sopas. Remove the
‘alee spring compresor

Se.

6-37

Cylinder Head

Rocker Arm Assembly Installation

aan ane ary tne No. rocker shat older mating

2 eassambie the ocho am assombly seepage &

qui geht FP 08718-0008, every tothe
er head main surfoce oo No. Stocker
this

OTE: De not instalo pari minutes or more
“sue elapsed since applying qua gasket. 11036,
“nat qui greet ate rmauing où rs due

4 raat the Dot (A ino the oko shat hor then,
{natal the rocker arm aseamiy IB on heey dee

$. Remove the bots rom he rocks

6: Mate sure the pureh marks on

7. Setthecamanst here (Mond cam chain quid
¿Cin pica

8. Tigenthe bolts tothe speifiedtorave,

‘Spacing torque:

Bmmblt 22 Nm (22 kg, 161)
Smmbolss 2m 112kgfm 87 BH
Smmbais: 2.8.8

wae

6-38

Instale cam chain co paga 6.151 and ast he
valve png 8S.

0 Cylinder Head Installation

Inzane cylinder headin tha reverse order al

1. Clan the cyirderhoad an Bock surface.

2 nea he new einer hana gasket (A and dome
Inder Boch Always ue ano

‘he TDC mar A onthe rankana sprocket wth

@ “Shores
{he pointer} onthe cylinder lock

5. Measure the clameter et each eylinar hand bol at
point Aan point 8.

n'a

6 either ameter ie ees han 106 mm (042 in},
“pise the cylinder hee bt,

6-39

Cylinder Head

Cylinder Head Installation (cont'd)

7. Appl engine ot the bot read aro under the
Pot head of athe cine hand ola

8. Tiger cylinder hood bot in sequaront 29
Nim (40 gm, 291. Uso a Beam type torque

‘wrench. Vien using» prete toro wench,
Pa sue 1e gen sly and donot over. 1
ol mates any noice while you are rc,

Toosen the bl and ghten rem the it te,

3. Alter orqung,ghten ll eylinder head bats into
tops 10" por step youre ing» naw eye
eae Do, gene bat an extra 90"

JO

6-40

10. Insta rocker or em (os pape 64)

11. realite water bypnse Por (A

fige
esco arma

12. Tigentno concectig pipe mounting bo
brake booster vacuum ine mounting bol
natal te harness holder Dj onthe brace

13 inst ho upper rate hoe A) and heater hose
es

14 Install the water bypass ose.

16, Insta the nate mani see page 8 5.

7, ral ochaust mario seo pago 9),

8. Insiste cam chain (son page 5-15),

19. Aust me valve clsranse ses page 69)

20. instal ma diva at eve page 426,

2%. Clean te batay post and cable terminals min
Sandeaper, men sezamble hem snd apply gree

22, after installation, check that ster, Por ant
Connector are nel core.

22. Inspector fuel eos. Turn heigntionswitchON
te tre starr eo that fo

‘heck forfuelleaage at ary pontinte fue

2

Inne radiator vith en
ir om m ooling system wi
‘pan tece page 1081

olan, ana bees

25. napect tral speed ss page 11-138,

28. Inspect me ignition timing ses page 4:17,

Cylinder Head Cover Install

1. Thoroughly lean the headcover gasket ana to.
groove

2. Inst no nan cover gasket (i the groove of

2. Check nat the mating surfaces ar cloo ana ey.

4. Appui gasta, PIN 87184009, the chain
ten ante No.5 rocker hal olde rating ares.

NOTE: De notinsal the part minus or more
hve alapen snes appiymg quid gasket. instead,
PDP iid gone ater removing ld reside,

6-41

Cylinder Head

Cylinder Head Cover Installation (cont'd)

5. Sethe spar plug als A onthe spor lug tbs,

$. Inspoctinecovor washer (C Rio any washer
hate damaged or detente.

6-42

2. Tien the bols in no res saps th nal
top, gen al bots, in sequence. 0688 Nım [10
kat 22)

3. Is me ourigniton cols see page #18,

0. Check hat al tubes, hos, nd eomoctore are
Inatledeorsey.

14 sale intake manifold cover,

en

12, Afr assembly, wait at nat 30 minutes before
‘ing ne engi tl

6-43

Engine Mechanical

Engine Block
Special Tools a 72
Component Location index
Connecting Rod and Crankshaft End Play
Inspection
Crankshaft Main Bearing Replacement
Connecting Rod Bearing Replacement
Oil Pan Removal u
Crankshaft and Piston Removal
Crankshaft Inspection mm...
Block and Piston Inspection
Gylinder Honing E
Piston, Pin and Connecting Rod Replacament en. 7-18
ton Ring Replacement
Piston Installation
Connecting Rod Bait inspection
Grankshaftinstallation
Gil Pan Installation Ñ
Transmission End Crankahalt Seal
Installation In Car cos u 728

Engine Block

Special Tools
Fei Tool Number ‘aston
D [ODA

@ | 77480010700
cn | o77as.0010000

‘it seat Orivar tachment 95
Atlchment 26% 26mm

Eres

7-2

---B|

0 Component Location Index

73

Engine Block

Component Location Index (cont'd)

a

mane

7-4

Connecting Rod and Crankshaft End Play Inspection

1. Remove te oll pump seepage 39)

2, Remove the ball lotes soe step on page 7-12)

3. Measure the connocting os and play with afeler
huge Betaden the connecting rocanderankehnt

Connecting Rod End Play

Standard New! 018-030 mm
{0.006- 0.01210)

Serves Limit: 040mm 076 In)

pul he ernkshat fury backtoward ih Indienor
the dal reaing hould not exceed ne servia lim.

Crankshatt nd tay

StandndiNew:010-035 mm
(000400140)

Service Limit: 045 mm (0018 in}

6. Hine ena play is unto
mana and vacheck ie
re ne eronkrat

7-5

Engine Block

Crankshaft Main Bearing Replacement

Main Bearing Clearance Inspection

remove the lower bck and bearing halves see
Page
2 Clean en main journal and begin hat th a

Scan shop tam

3 Place one sip of plasigoge across each main

Reinsta tho bering an lower ok, tan torque
the bots 28 m3 0 kg, 22 BE) — 50",

NOTE: Do not ot
inapection,

rarkehat during

3. Remove te lower blocs ane bearings agai, und
macsurethe widen! part oft plas gag

‘Main Bearing t0-Journal Oi Clearance
‘No. 1,2, 46 Journals:

Standard (Nw 00% 004mm
100007 ~ oo0i6in)

Service Limit: 0050 mm 10.020

No 3 Journal

‘Standard New;0.025 — 0.048 mm
00010 — o.00%9in)

Service Limit: 0.058 mm 1.022 in)

6. tv pistigage messures too wide orto nar,
remove tha enteran, and remave he upper nal
‘tthe bearing Intl no, compet tearing with
‘he same color codes, and check the sra,
Do rat il, shim ot stage the Bring oF theo
to acute

2. tthe psa shows thn oaacanc i til
incorrect ty de net larger or eme basing
oor las above e below tat one an check

res cannot be obtained
gor or salar bearing,
cogio ne erankhaft and tart ove

Main Bearing Selection

Crankahat Bore Code Location

ne Jura
LEE)

Maia Journal Cod Location

2. The main ourna oder en stompad nt

7-7

Engine Block

Crankshaft Main Beari
Replacement (cont'd)

3. Urethe crank hore codes and eran jourel codes
Lo select appropriate reacement besiege

NOTE:

+ Color ode is onthe ge atthe bearing,

“When using bearing oleo of torent colors,
dogs not mater wnich color used nthe op or
ono

ee [AS [Bon Bm Bm

Bree ic

[Pot a Yalow Green

San
Voten Gren Sse!

78

Connecting Rod Bearing
Replacement

Rod 8

ring Clesrance inspection
1. Remove ie oi pump (se page 99)

2. Remove meat platos seo step Son page 7 121
3. Remove the connecting rod cap and bearing bat

4. Cieantrecrantanat rod joumat and bearing hall

Place platigoge across th os journal.

6. install the bearing ha a cop, ara torque he
Bolste 20m (20m, Tel 80"

NOTE: De not rot ho crankshaft ring
inspacton

7. Remove hero.
the widest par he plastigogo.

Connecting Red Bawring-to-Joumal Oi

Glsrance:

Standard New 0020-0050 mm
100008. 0002011

SeriseLimit 0.060 mm manzein]

ithe plasigage mesures 100 wide oe 10 nor
remove the upper half of the bearing insta ao,
complete bearing with he same color code) aná
recnackine clanance Do not is, shim, oreerape

ithe plotiage show the clearance’ sit
incor ry te nest larger or anale bearing te
color tee above or below hat one), andcnesk
Etearance soin the proper clearance cannot be
Sbained by using the appropriate loge or smaller
boaring, rte he crankshaft and tar over

Rod Bearing Selection

1. Inspect ch conneting od for cracks and heat
damage.

‘Connecting Rod Big End Bore Code Locations

2. Each rodhasatelerance range rer ©0024 mm
00008 in 006 mm (0.0002 incremente,
(Seponeing on no sina its bg en ot ra an.
sampad sn a number or dur 12,207 41,1. or
inh ireening the range. os may find any
combiraton of numbers and bar in ay angine.
{iat he cure orbar is taped o ha being

Ut youcontresd he code because an
accumulation fi ang vamo, do notserubit
Stn ie true or sraper, Clean ony wth
Solvent or detergent

‘Normal Bore Size: 48.0mm (180)

7-9

Engine Block

Connecting Rod Bearing Replacement (cont'd)

‘Connecting Rod Journal Code Location

3. The connsting rod journal codes are stomped on
cra

¡Connecting Rod Journal Code Location Letters or
Bar

7-10

ce tro big end bore codes and rod journal codes
to ele: appropriate replacement basing rom
Po ollowing table

Note:
2 Color ode is onthe geo the bowing

+ Vian sing bearing halves of ren coors, it
does nat mare which colo is used inthe top or
bee,

En ses vos ma
A Pink | Eh Ete ren |
. vin ten rl rom
. EEES
B sown oar Pr ou

ot veto

© citPan Removal

Drain tne engine lees page 2)

{the ong i sit in vacia, remove the
sublime

1 Attach the chain est tothe engin (se step
35 on page 581

-2 Dsconrect the suspension lower sm al
joins (ee step 3on page 1819.

-3 Remove ne eat mount mounting Bots aoe
stop 38 on page 5-7).

lion mount mounting bot ane

ped on page 871.

3 Uco.a markorts make algnment marks onthe
teren nee rat align with me centers of
{hoveersbirame mounting bot. Remove ne
{tone stram aon step 43 on page 5,

3. Remove te bouts securing the ar.

4. Deve anit pan
estirar Dick

cuter between ho ol pa and

N
BER

=

C=

5. Cut the oi pan eat by striking thes ofthe cuter
Loi ho eur ang the pan,

6. Ramove the ol pan,

7-11

Engine Block

Crankshaft and Piston Removal

1. Pavone ange seem esas.
2. Mere vario ne page 1.
3: Renove vean p87 1,
«Remove pump ep 88.
5. Paavo ne cvnderhed eo ge 629.
6: Romo ata ps.
$ 8
LE

8
Pa

di. To prevent nr nage
ca tum at a tine
sara loosened

8 Remove he lower ick and hasrngs Koop al
bearings in order

10. Remove the rod copstoarings. Keopallaps!
bearings inerce,

1 Lite cena out of ho angine, Doing careful
notte camage te journals

12, Remove te uppar bearing naves tom tho
cometng 1003, and ether aside wih thei
respective caps

12, you canta pe ot mata har earbon

4. Uso ho wooden handle oa hammer Alto drive
outthe pistons IM

15. Raisin lower block and bearings an me
engin in te proper order.

the connecting ed boating and cap

assembly.

17. To avoid mixup on reassembly, mark ech pito
connecting rod acsemaly with it pide number

NOTE: Tho exiting number an the connocting rod
ons nat inate pos om int angie
dales the rod bore size

Engine Block

Crankshaft Inspection

Out Round and Taper

1. Remove rant trom the cylinder black (os
page? 12

2. Clean tn crank oi partage with pipa
sanar ora sutble or.

3. Clean te heyway aná tesos.

4. Mensur out of rund at the mda of wach ro and
main jeurral in two places. The difference bewson
rement on asen una! must not BE more
te servico ma

Journal Out-of Round
Standard New! 0.005 mm (0.0021) max.

Servicii 0 10m om)
chy
>
Nas

NE
CAN
Li

3. Mesure par ano gos lese redane main

ara Sha dan buen assarmans o

urn muro mor an saree

m

oun agar

‘Standard Rew 005 mm 1002 In man.

Serie Un” mm (004

7-14

Straighiess

6. Pino the ovina bi on th ur pto.

7. Clean and instal ne beargns onthe No. and No

8. Lower the rarkahaft io he Bock.

shaft wo complete revolt ons. The
‘ference bereuen messurementa on euen fours!
‘mutt cot bo mare man ne cones i?

Crankahaf Total Ranout
Standard (New): 0.05 mm (0.0012. max
Servia Limit 0.04 mm (0 0016in}

© Block and Piston inspection

1. Remove he erankehaft and pistons (ae page 7-2)

2. Check he piston fo distortion or race

2 Moasure te piston sme
om ne oto ft

Piston Diamar:

‘Standard Neve

Nota or A: 85.390 65,590 mm
(2.2860 2:3864im)

8: 85570-85990 mm
(32046 236501)

Sordos Lim:
"Wo Letter or A: 85380 mm (33631 in)
ES 15320 mm (22627 in)

verte son amater:
We

“tere aro tuo.
Palo (No Lamar or À and Te

drectanX ard at
Mas eroan It

mess rements in any einer are bovord to
Dock iste rborec, ef step after reborn

Cylinder Bor Size

Standard Now!
‘orl 96010-86020 mm

(a3es2—3:3966in)
Bort 16000. 26010 mm

5058-3 38621)
Servico Limit: 86.070 mm (3.3885 In}

Oversize:
025: 86.250-06.200 mm (3.3957 23961 in}

Reboring mi: 025 mm 1.09 int max
Bore Taper

mi: Diferenoe between rat and third
‘measurement 0.05 mm (0002in)

“O E
JA mnt

cont

7-15

Engine Block

Block and Piston Inspection (cont'd)

5. Seoted or seratched cylinder bares mast be honed.

8. Cheek he op of he Block for warpage. ensure
along the edges and across the coma 9 shown.

Worpage
Mew 007 mm 0003} max.
Service Limit 0.10 mm (0.004in}

7-16

2. use terne inerte xin one
and en gamer ra cance
ston and

back lor excusas ver,

Piston to-Clinder Clearance

Standara ew! 0020-0040 mm
100008 00016in)

ServieeLimit: 005% (1002 n)

ee r2.cvunoen

Cylinder Honing

{niv soared or sertche cylinder bore shouldbe
honed,

1. Messut the cyindor bores see page 7-19,
Ihe blac tobe reused, hon Ie evinces and

2. Hone the yde bores wit Honing al and fine
{400 get stone in 60 degree cose math ptr
VAL Use on a ii hong with 200 grito ner
‘tone sen ae Sumen Ammeo, or aquvsert Do
ots tones hat are ern or race

Von honig ie complet, troroughly lean the

none lock seta paces. Wash he
finder bores vith ho: soupy water, then yan
them immediately oprovont runing, Never use
short tul nly ed aire the gto o
Spied was

lazoring or stones ae il present inte
Erin bare machine event,
coring and scratching le accetablo snot deen
{enough to eaten younger arc cogs not un
the engin ofthe pore.

7-17

Engine Block

Piston, Pin, and Connecting Rod Replacement

Disassembly

1. Romove he piston from the cylinder block coo
pago7-12

2. Reg ange ote piston in ese ina,
min re ring gtoover uni the and
nad ap vn actos ath pan in

bores

NOTE: Tae eve not to damage o ring groove

|
ft
ir|

3. Rumove both srap rings (A) Start at the cutost in
ta piston ola Bor. Remove to ap rings
array so ay co not go ying or gat ost. Wear
oye protection.

7-18

a. Hoatthe piston and conaetng od assembly o
about 189° 70°), den remove te piston pr.

AE

x

Inspection

red ion they

on. piston pin, nd concerts

1. Moasuro ho iometer ofthe piton pin.

Piston Pin Diameter

Standard (New! 21.961 -21965 mm
(08000-080481)

Service Limit: 21362 mm (03643 In)

(OF
Ss

Check ha foren besweon the piston in
meta” and piston sin ole diameter in he ion

Piston Pinto Piston Clearance
Standard Now! 0.08 0 "0002 mm

1 0007010 + 000008 m1
Service Limit: 0.008 mm 1.000}

Moasuro the pisto pinto-connecting rs clearance

Piston into Connecting Rod Clearance

Standard New! 0.005 0.015 mm
(00002 0000611

Service Limit: 002 mm (0.0008 in)

7-19

Engine Block

Piston, Pin, and Connecting Rod Replacement (cont'd)

Rosssembly

4 rsa the piston pin (Al Assomate the piston 8)
and connecting rod withthe ser DF andthe
anse mark (on he same ed.

2. Cootthe piston pin bar in na piston, ne boro in
"cometo ean ta Plon pi engine
on

3. Heatthe piston to about 158% (70°C)

CA À
a

7-20

$, Italic ing sap ing

6, Turnthe enopeing in toring grooves un he
nd gaps ae poston ata orion 3 the pion.

@ Piston Ring Replacement

1. Romove the piston from the ind lo ise
pageT 12,

2 Using ng expander (A, remove theo piston
ring ta,

2. Clan al ring grooves thorough with square
M okan rng or ring groove cleaner win lode
to tne piston grooves. The op and 2nd ing
‘tooves aro 12mm 10.08) Theo ng
{ro0vefs20 mm (Bin. wide Fla don y blade
npeessany. Do rat uso a wire brush 1 clean the
fing qreowes o tna ng grogves sopor with
the leaning tok.

NOTE: piston it be separate fromthe
Eanneting fod do at nal en ings yet

4 Using 9 piston, push anew ring Aint the
ylinder bore 19-20 mm (06 08 in ham the
bottom

>
/
OT:

F

ee,

5. Mesure th piston sing end a 18»
gauge:

= ithe gap is too small, hack to sa ¡you have
tho rope rings or your engine

+ ithe gap sto argo, recheck ne cylinder bore
citer aganetihe wear limits eee sep on
page 718.
Fre bore is over te servic iit, the cylinder
block must be revered

Piston RingEndGap

Top

‘Standard New 020-035 mm
(0008-0018in

Service Limit: 0160 mm (0.024in)

‘Second Ring

Standar New 040 055mm
(0016-00210)

Service Limit: 070 mm 10.028 in)

Ou Ring

REKEN manufactured ing

Standard New! 0250.68 mm
(0010-00261)
Servi Limit: 076 mm (0301.

FEDERAL MOGUL manufactured rng
Standard New) 020-070 mm

10200 002814
Service Limit: O10 mm (2.031 int

¿contar

7-21

Engine Block

Piston Ring Replacement (cont'd)

6 Intl he top ing ne secon rng ash
tpi Ay es a IR mark or no mark sd
cond ing (Bas a 28 mak or 2ND mark Te
marke most be acing ours

Heat

RTS

7. Rate Ihe ing in thee grooves 1e make au they
donot bina

7-22

|

Pet
ine cae stone

9, Alter iataling a nee set of rings, measure the
fing o gioove dearances

Top Ring Clearance
Standard New!

0.098.0.060 mm D 0014:0.024 in
Servi Limit 0.13 mm 0.005 in)

‘cond Ring Clearance

‘Standard Newt
REKEN manufactured ring
(030-0055 mm (.0012.00022in.
FEDERAL MOGUL manufstured ing
0025..060 mm (00010-09024 in}.

‘Servlet. 0.3 mm (0005 in]

the crankshaft i

Remove the connocting rod cps, thon itl the
Fing compressor an check hat ine Bearing ie
Securely in placa,

Poston the arrow facing the cam en side of
the engin

(Bo prauert th ge rom expanding Biere
Enter he eylinder bore.

ours

lgomant Deore pushing te piston Ina pase

{Crack ane connecting rod bowringelaranen vtr
platgnge is pape? 8.

le 35%

ing red toto ive page 724

th bol tea, th neal the
98 Torque te bolts o 0 Ni
wo

Ifthe erankshaft is not installed

1. Remove the connecting rod
fing compressor and chock
My piece

eng

2. Posiionth arrow A) acing tha cam chain i of
the engine.

using the wooden handle a hammer
aint downward force on tha ting comerssor
{to praventthe ring rom oxpanding pato

7-23

Engine Block

Connecting Rod Bolt Inspection

1. Wescure the diameter ofeach connacting rod bolt
point nnd point 8

Fam

Colculate te iron in diameter baume oe
‘Rana pon

Point A~Polnt B=Difrance in Diameter

Diterance in Diameter
Specifestion: 0-0. mm (D D004in)

2. Mine ditranca in lamater out oftoarane,
‘placa a connecting rod ol

7-24

Crankshaft Installation

‘Space Tools Required
river 07749-0070000

cm, 24% 26 mm 077400010700
Li set cr ver ansehman 85 07ZADPNAAIOO

1. natal th rankahat end bushing with the spi
tools wher replacing th crantchat Drive ino
{rankahot are bushing um te sei cele
bottom ag mate rantenst

A

o,

2. Chock the connecting rod bring clearance win
plowigege tens page?

3. Check he main beeing lerance with plaigoge
Iseepage 78,

x

5 etal he bearing halves inthe

$. Any coat of engine ito the main args an
rod near.

7. Hold se crankshaft o ta journal No.2 androd
Journal No.3 ee sight up, and lower the
Srankshaftimehe block.

Int ne hut waters A inthe No 4journa of
the eyindar Doc.

8. Apply engine ot tre treads of the connecting

10. Seat the rd journal nto connecting od No. nd
‘oaneting rod No. Lineup the mark onthe
Sonnen od nd cap, thn instal the cape and
Bons tinge ugh

11. Rotate the crak cine, and sat ne
¡outrasinto connecting rod No. 2 and zonmactng
redNo.3 Lin up he mot on th connecting 100
fd eap, men instale care and ts gor gmt

‘Tighten he connecting rod bots to 20 Nm
2osgtm. rat

Tighten he connecting red ons an editions 90

Remove old aud asie rom the lower block
‘mating surfaces, os and bot hole,

‘lean and y th lowe block mating surfaces.
Appi lid gasket, AN 087980000, evenly tothe

plnder Dock mating surco of he lower Bock
nato me Inner hrasds of ie el holes.

NOTE: Do not instal he parts i
have elapsed since apalying uid gas
“ep qui geste removing résidu,

‘cones

7-25

Engine Block

Crankshaft Installation (cont'd)

17, Putthelower bock on tha elindar lock 21, Use ho special tole to drive anew ol eat
nuarey let ro block tothe species installed
18. Tignanthe bearing cap bolt in sequence to eh

25m OA 2216

22. Measure he distance benwcen the rankahat A)
and al en.

Oisuthetadhaght 55 dE nn

8. Tighon the bearing cap bot on addtional Se, pr 7 Er
20. Tighten the 8 mm bois in sequence 1022 Nm (22

NS

x =

uy;

7-26

23. Inline bate pats.

24 instal ai pump ese page 8-18.
25. natal he pan (ee nage 7:77.

28. instal re cylinder he see page 6 39.
2. oat me tronamision (se page 139.

28. natale angi assembly (ss paga 6.)

Oil Pan Installation

1. Remove oi gud gaskat rom he oil pan mating
faces, bli are beh holes.

2. Clean any te ol pan ming suraces

3. App liquid guste, PIN 08716 0009 evenly othe
Giner beck mating sure ofthe pan anto
{hina mad fhe bot naar

NOTE: Do not instal the ars minutes or more
have elapsed since applying Nui gasket. Instead
respi utd ont ater roving lá mel.

io
4 total eo pan
5. Tight the boss inte of thre stas. ln

tap, er al bl, in enuenen o 17
Karma oth

7-27

Engine Block

Oil Pan Installation (cont'd)

6 the engi i ai in the vehicle instal he
suba.

=) In he subforo. Align the reference lines
‘nthe sueno eh ra ol head ente, then
foto ie bals fave step Son page 510)

-2 Tigton the romtmourting bolt ee step Bon
page,

a Tighten tne ear mount mounting bole ss
step Ton page sn,

4 Connect the suspension lower arm ballin
(wea step on page 18 1,

7. Aer assembly, wah atea 30 minutes toro
fing te engine wi a

7-28

‘Transmission End Crankshaft Seal
Installation - In Car

‘paca Tools Required
“Driver 07480012000
+ Oi ea river taime 96 07ZAD-PNAATOO

1. Dry the crankshaft ol sea housing

2, Us the special 100110 dv new
no he blk he specie

3. Measuothe distance between the crankahaft A)
Andeison

\

LV

Engine Mechanical

Engine Lubrication
Special TOOLS enn
Component Location index
Git Pressure Switch Test ..
Oil Pressure Test
Engine Oil Replacement
Engine Oil Filter Replacement
il Filter Feed Pipe Replacement
Oil Pump Overhaul
e Oil Pressure Switch Replacement

Engine Lubrication

Special Tools

“Faia. | Tool Number

T
GIF

Description

5 Tome

8-2

Engine Lubrication

Oil Pressure Switch Test

1. Remove the VEL/AED wre (A om ne argin ot
reich

2. Checkfor cominuty Between the postive terminal
{Clanaine eng ne orouns). There shouldbe
ontnuty with the angine stopped. There should
bs n continuity with he engine runing

4. Hane gite at operat, check the engine il
laval the angine iva OF. enact angie
Ol aressure be ol pressure OX reparo thr ll
sure switch

8-4

Oil Pressure Test

fun a pressure indicator toy on with the engine
running, crec ne engine aleve the i eva ie

1. Connect tachometer,

2. Remove te engine où pressure surte, net intl
an ol pressure gouge (A

3. Stenthe engine, Shut itt immediately the

Salts conning

Allow the engine to each operating temperature
(Han comes on test rio. The pressure should

Engine Oil Temperature: 178° 80°C)
Engine ilPressre:

Atle: 7O4Pa 0.7 kale pa
83,0 pm: 300 KPa 2 hem’ 4 pal
minima

3. fine oil pressure NOT within specications,
Inspect hee
"Greek tne ol eorean for cogging.
* Chock the oil pump (see pogo 2,
* Check crankshaft and connecting od bearing

x

Engine Oil Replacement

1. Warm up tne engine

2. Ramove the sain Bot, an dain the engine i

2 Raine the oran atin eve wosner
4, Ref with he recommended lise page 32.
capacity
(42 US ato change.

422144 US q atoll change including tte.
532158 US qu ater engine overhaul

5 Bunche engine for more thon 3 minuts, han check
foro shape,

85

Engine Lubrication

Engine Oi

‘Special Toot Required
(hier ranch OTHAA P370100

Engine Oil Filter (3/4-turn type)

1. Remove tn cl iter wit the spi! 20.

2. Inspect the ihrends (A) and rubber sea (8) nthe
now fio. Wipe off ne soa on te engine bc,

‘hen apply light coat ofa tothe er aber ses.
son ter win

instal hoo ft by hand

4. Atar robber sent eats, oh na her

Tight 3/4:ur clockwise
Tightening torque: 12m 2Kgtm- 871)

8-6

5. dé numbers or marke (110400 Vio WWW) are
printed round the outset Aa, ut he
ling procedure to sho the fito

by tuning ice
number?

‘the number à

Markumen a
wer rre

onen,

5. Aor ine, th ong
Specie lol run the
mines than che or

th il up tothe
mare an à
one.

© "on riner Feed Pipe Replacement

3. aa the 50020 X 15 men uns LA) onto ho nese
bi Vitoria pipe le the nu wth sarc then
Monte the ther ut

4: Tighon ho i ter food pipe o na block 0 49 Ne
‘mi. kgm, Bi, then remove the cut tomy
the titer ond pipe

8-7

Engine Lubrication

Oil Pump Overhaul
Exploded View

Examen
Sein
nm

Lbrreneauancer
LEP

8-8

Oil Pump Removal

1. Seti No. giston ot top dead coto TOC) ess
step Ton page 812

2. Remove tell pan (sen page 7-12.

3. Remove and dace the ol pumpchaintenianer

4. To old he rer balancer shaft. inst 96 mm pin
liver (A) tothe maintenance ola in the lower
Palancar sna older and through tra rar nlancer

5. Remove the opamp sprocket (A thon remove the
pump,

8-9

Engine Lubrication

Oil Pump Overhaul (cont'd)

(Oil Pump Inspection

+. Rama the pump housing

A

2. Check heinnerto-outer rotor ro easrance
beten ne inner rotor A and tr rotor).
the nner to.ovter ofr ral elearance exceeds
{he sonen ma, epica tr o Dom.

Inner Rotor to Outer Rotor
Standard New): 0.02-0.16mm 0 001-0006 in}
Servia Lime 020 mm (008 in

a Clearance

8-10

3. Check he housing o-eter xi ierancs Between
‘tho et (A) and pump housing (81 he housing”
replace the ol pump. “

Housingto-Rotor Aa lerance
Standard New| 0.02 9.0 mm (0.001 0.003 in}
Service Limit 012mm (0.005in)

4 Check e housing to cuter rotor radial learance
between me outer ator (Al ang pumphoveng BL
Ifthe nousingto-outor rotor rail ciendo
xeceds tha service it apace the oi pura.

Howing-to-Outer Rotor Raa Clearance
‘Standard Nev: 0.15" 0.21 mm 0.006 0.008 in}
‘Servic Limit 023 mm (0.003 a.)

5. Inspact both rtors and ho pump housing fr
Storing or ina damage. Rapa ptt
coo

Balancer Shaft Inspection

1. Seat the balancr shat by pushing it away fom he

Zero tn dal inaiestor against the endothe
san shat then path tha balancer sha bee
‘nd orth and ead the and pay

‘SatancerShat End Ploy:
From Blanca‘
Standard ew: 0070-0136 mm
10002300053 in)
Serie Limit: 0:18 mm 0.06 In)
Rear Balances Sat
‘Standard eo 070 0.126 mm
100028 0.9083'im]
105 mm 000m}

Sersie Limit

shat holder wi oor ogs) (then
rent lancer af (C) and 00, algacr aD

8-11

Engine Lubrication

Oil Pump Overhaul (cont'd)

4 Measure he inner mar ofthe No bearing for

the fro
roten.

the rear balances

‘Bearing Inner Diematar

Front

Standard News: 20.000-20.020 men
(07874 07682

Service Limit: 2003 mm (7801)

Rear

Standard New! 24000-24020 mm
jonas ous im

Service Lime 2403 mm (0848in}

8-12

5. Measure te iametrs oftne No. journals on the
Iron alar nat andrea alancr ent

NO: Journal Diameter:

Front

Standard [Newt 1.328 18.960 mm
3000-0704)

ServiceLimit: 1982 mm 10784 in.

Standard Now: 22 28-23 950 mm
Wozu 00a)

Service Limit. 2332 mm 10842 ia)

6, Clean both balancer shaft No, 2 journals and
bearing halves witha clean thon owe

7. Ps one svi of pastigage across each No.2

8 Reinsa the Bearings and upper balancer shat
holder, than torque tha bois

NOTE: Do notrotte the balancer shaft during

a the upger balancer shalt holder and

replace the balancer shat.

No.2 Journal Oi Clearance:

Standard New! 0.080 0.120 mm
{o.0024~ 0004710)

Servi Limit: rm (0.006 n

10. ign he purch mot on the ear balancer shat
‘tno anar of he two punch marks on no rent
Planer shaft than insta e hala shat in
A or halarcar shaft older,

12. Insta the upper balancer shaft holder (8) and
Este aie (Cr

8-13

Engine Lubrication

Oil Pump Overhaul (cont'd)

18. natal he pump housing Oil Pump Installation

a 1. Mate sur the No, son at TDC tae sep on
e a Pe

2. Aignthe dow in A on ie rear balancer ha

io
‘withthe mark (8) onthe où pum,

Î
ke
man

3. Told a rear balance shat Isarta 6mm pin
ver Ao the maintenance hole nthe lamer
Ealancer shat older an trough he xr Entancar

Anh engine ol tothe teats of the o pump
sprocket mooring bot

5 Loose instal theo pump El, hen nat
pump sprocket

6, Remove the pn ive 1).

7. Tighten th oi pump mounting bolts

8. Squeere the new ol pump chain tonsioner iA. an

{Sion ites shown

3. Instit ol pump chain tens one

SEGA ate,
Be

voran

8-15

Engine Lubrication

Oil Pump Overhaul (cont'd) Oil Pressure Switch Replacement \ 4
10, Remove the set lip ram tec pump chain 1. Disconnects ei pressure sich connector, an

2. Apply quid gosko tothe al pressure switch
1 raie ip Iso page 7:27 “roads, then nel the ol pressu euren

Engine Mechanical

Intake Manifold and Exhaust System
Intake Manifold Removal and Installation. 92
Exhaust Manifold Removal and installation "9-7
Exhaust Pipe and Muffler Replacoment ss

Intake Manifold and Exhaust System

Intake Manifold Removal and Installation

exploded View:

om

9-2

1. Ramona the intake manitol cover

4 Fu pon the tor lnk and envie conta ln
boy aná, then move tho roe cade Aland
tui control cti 9) rm the inks Loosen the
Teoknuts (land remove ne cables fam ne
bracket,

e y

J

9-3

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