Table of Contents
Part I Engine ...........................................................................1
Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA)...................1
Section 1 Routine Inspection.........................................................................................1
Section 2 Drive Belt Replacement ...............................................................................5
Section 3 Valve Clearance Adjustment ...........................................................................6
Chapter 2 Engine Components Replacement
(MR479Q, MR479QA, MR481QA) ................................................................10
Section 1 Engine Components ....................................................................................10
Section 2 Engine Components Replacement ............................................................13
Section 3 Timing Belt Replacement .........................................................................17
Section 4 Camshaft Replacement ............................................................................22
Section 5 Cylinder Head Gasket Replacement .........................................................28
Section 6 Oil Pump Oil Seal Replacement ................................................................33
Section 7 Engine Rear Oil Seal Replacement ............................................................34
Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA) ...............35
Section 1 Oil Pressure Gage Sensor Replacement ....................................................35
Section 2 Oil Pump Assembly Replacement ..............................................................36
Section 3 Oil Filter Replacement ................................................................................38
Section 4 Starter Replacement .................................................................................39
Section 5 Generator Replacement ............................................................................40
Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A) ........................41
Section 1 Check Fuel System Pressure .....................................................................41
Section 2 Fuel Pump Inspection ...................................................................................42
Section 3 Fuel Injector Replacement .........................................................................43
Section 4 Fuel Pump Replacement ............................................................................45
Section 5 Fuel Emission Control System ....................................................................47
Section 6 Carbon Canister Replacement ....................................................................48
Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A) .................50
Chapter 6 Cooling System Inspection
(MR7131A, MR7151A, MR7161A) .................................................................52
Section 1 System Check
Section 2 Water Pump, Thermostat and Radiator Replacement.................................... 54
Chapter 7 Clutch (MR7131A, MR7151A, MR7161A) ....................................56
Section 1 Clutch Replacement ...................................................................................57
Chapter 8 Maunal Transaxle Assembly
(MR7131A, MR7151A, MR7161A) ................................................................59
Section 1 Manual T ransaxle Replacement ..................................................................60
Section 2 Vehicle Speed Sensor Replacement
Section 3 Transmission Case Oil Seal ..........................................................................62
Section 4 Transaxle Case Oil Seal Replacement ........................................................63
Chapter 9 General Engine Troubles and Their Troubleshooting ....................64
Section 1 Overview ........................................................................................................64
Section 2 General Engine Fault and T roubleshooting .......................................................64
Section 3 Engine Noise Diagnosis and T roubleshooting ................................................77
Chapter 10 Engine Management Unit..............................................................81
Section 1 System Description .........................................................................................81
Section 2 System Component and W orking Principle ......................................................82
Part II Chassis............................................................................85
Chapter 1 Transmission Control Device .........................................................85
Section 1 Transmission Control Device .........................................................................85
Section 2 Lever Type Transmission Control Device ......................................................85
Section 3 Cable T ype Transmissi on Control Module ......................................................87
Chapter 2 Accelerator Pedal............................................................................90
Section 1 Accelerator Pedal ..........................................................................................90
Chapter 3 Clutch Control System ....................................................................91
Section 1 Clutch Control System ....................................................................................91
Section 2 Clutch Cable Control Mechanism .....................................................................91
Section 3 Clutch hydraulic Control Device .......................................................................94
Chapter 4 Propeller Shaft ...............................................................................97
...............................................................................................52
..............................................................61
Section 1 Propeller Shaft .................................................................................................. 97
Chapter 5 Front Suspension System ............................................................... 103
Section 1 Front Suspension System ................................................................................ 103
Section 2 Front Suspension ............................................................................................105
Section 3 Front Wheel Alignment .......................................................................................106
Section 4 Front Strut Assembly ....................................................................................... 107
Section 5 Lower Swing Arm Assembly ............................................................................ 110
Section 6 Front Stabilizer Bar and Link Rod Assembly .....................................................113
Chapter 6 Rear Suspension System ................................................................116
Section 1 Rear Suspension System
Section 2 Rear Suspension ............................................................................................117
Section 3 Rear Wheel Alignment .................................................................................... 118
Section 4 Left & Right Rear Strut Assembly .....................................................................119
Section 5 Rear stabilizer bar assembly, strut rod components ..........................................121
Section 6 Left & Right Trailing Rod Assembly .............................................................. 123
Section 7 No. 1 Transverse Arm Assembly .....................................................................124
Section 8 No. 2 Transverse Arm Assembly .....................................................................125
Chapter 7 Wheel ................................................................................................126
Section 1 Tire Inspection ................................................................................................. 126
Section 2 Wheel Replacement ......................................................................................... 127
Chapter 8 Power Steering System .................................................................. 128
Section 1 Power Steering System .................................................................................... 128
Section 2 Steering Drive and Control Mechanism ......................................................... 130
Section 3 Steering Pipeline Component .......................................................................... 133
Section 4 Power Steering Gear Retaining Device
Chapter 9 Brake System .................................................................................. 139
Section 1 Brake System................................................................................................... 139
Section 2 Brake Fluid ....................................................................................................... 140
Section 3 Brake Pedal...................................................................................................... 141
Section 4 Vacuum Booster with Brake Master Cylinder Assembly ....................................143
Section 5 Front Brake Assembly ..................................................................................... 144
Section 6 Rear Brake
Section 7 Brake Line ....................................................................................................... 151
..................................................................................116
.....................................................................................................147
..........................................................136
Section 8 Parking Brake System .....................................................................................155
........................................................157
Chapter 1 Survey................................................................................................157
Chapter 2 Starting and Charging System .........................................................161
Section 1 Starting System (MR479Q MR479QA MR481QA) ..........................................161
Section 2 Charging System (MR479Q, MR479QA, MR481QA) .......................................164
Chapter 3 Combination Meter System ..............................................................171
Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in
Terminal ............................................................................................................................ 171
Section 2 Malfunction Symptom T able and Solution Pr ocedure ...........................................174
Section 3 Combination Meter .......................................................................................... 187
Chapter 4 Wiper and Washer System ...............................................................193
Section 1 Wiper and W asher System Inspection ............................................................ 193
Section 2 Replacement and Adjustment ............................................................................196
Chapter 5 Light System ......................................................................................198
Section 1 Survey of Light System......................................................................................198
Section 2 Light System Symptom Inspection .................................................................. 202
Section 3 Headlamp Replacement ....................................................................................211
Section 4 Front Fog Lamp Replacement ............................................................................215
Section 5 Rear Combination Lamp Replacement ..............................................................217
Section 6 High Mounted Stop Lamp Replacement ............................................................218
Section 7 Interior Dome Lamp Replacement .....................................................................219
Section 8 Rear Row Reading Lamp Replacement ...........................................................220
Section 9 License Plate Lamp Replacement ...................................................................220
Chapter 6 Audio System......................................................................................221
Section 1 Audio System Description .................................................................................221
Section 2 Audio System Connector Terminal Layout ...........................................................224
Section 3 Audio System Inspection .................................................................................225
Section 4 Audio and V ideo System Replacement ........................................................... 238
Chapter 7 SRS (Supplemental Restraint System).............................................242
Section 1 SRS-General Information .................................................................................242
Section 2 Troubleshooting ................................................................................................ 251
Part III Electrical Equipment
Section 3 Removal & Installation ................................................................................... 262
Chapter 8 MK-20 ABS System ........................................................................ 272
Section 1 ABS Diagnosis ................................................................................................. 272
Section 2 ABS System Check.......................................................................................... 276
Section 3 Removal and Installation .................................................................................292
Part IV Air Conditioner and Inside & Outside Trim ......................297
Chapter 1 A/C System ...................................................................................... 297
Section 1 The Structure & W orking Principle of Refrigeration System ...............................297
Section 2 Heating System ................................................................................................299
Section 3 A/C contr olling system .................................................................................... 302
Section 4 Service Caution & Notice ................................................................................ 304
Section 5 The Refrigeration System Operation Procedure ..............................................305
Section 6 Basic System.................................................................................................... 308
Section 7 A/C System Faults Check & Troubleshooting ................................................ 313
Chapter 2 Inside & outside Trim and Accessory................................................318
Section 1 Configuration Index ............................................................................................318
(I) Outside Trim And Front Accessory .................................................................................318
(II) Outside Trim and Rear Accessory .................................................................................319
(III) Front inside trim ..........................................................................................................320
(IV) Rear inside trim ............................................................................................................321
Section 2 Inside & Outside T rim and Accessories Removal and Installation .......................322
(I) Front Bumper ..................................................................................................................322
(II) Engine Hood .................................................................................................................324
(III) Outside Rear View Mirror
(IV) Rear trunk Lid ...............................................................................................................327
(V) Rear Bumper ...................................................................................................................329
(VI) Seat Removal, Installation and Adjustment ...................................................................331
(VII) Seat Belt .....................................................................................................................335
(VIII) Instrument panel and auxiliary console .....................................................................338
(IX) A pillar inside trim and front door sill ............................................................................343
(X) B pillar inside trim ........................................................................................................344
(XI) Cpillar inside trim and rear door sill .............................................................................345
(XII) Roof inside trim
(XIII) Carpet and Heat Insulator.............................................................................................347
...............................................................................................326
...........................................................................................................346
(XIV) Rear trunk Inside Trim ............................................................................348
(XV) Engine Hood Inside Trim ...........................................................................349
(XVI) Door ..............................................................................................................350
Part V Body............................................................................359
Chapter 1 General Information .....................................................................359
Section 1 Body Structure ..............................................................................................359
Chapter 2 Body Repair..................................................................................369
Section 1 Body Damage Forms and Requirements for Repair ....................................369
Section 2 T ypical Technology Of Body Panel Repair ..................................................372
Section 3 Repair after Body Damage ..........................................................................372
Section 4 Features and Composition of Automobile Body ............................................. 377
Section 5 Painting Technique after Body Repair............................................................383
Section 6 Service Data For Body ................................................................................385
1
Part I Engine
Chapter 1 Engine Assembly
(MR479Q, MR479QA, MR481QA)
Section 1 Routine Inspection
1. Check coolant
2. Check engine oil
3. Check battery
4. Check air cleaner element assembly
5. Check spark plug
6. Check drive belt
Figure 1
Notice:
z
Check the belt deflection at the specified point See (Figure 1).
z Set tension to specified value when installing new belt.
z Check the deflection to ensure it is below the specified value after the belt runs for over 5 minutes.
z Reinstall the belt which has been running for over 5 minutes. The deflection of the old belt is regarded as
the standard for inspection.
z Check V-belt for tension and distortion after the engine cranks for 2
turns.
7. Check ignition timing See (Figure 2)
a) Warm up the engine.
b) When using fault diagnosis tester
Connect fault diagnosis tester to fault diagnosis interface socket.
Ignition timing:
MR479Q: 10 ± 2° BTDC (before top dead center) at idle
MR479QA: 10 ± 2° BTDC at idle
MR481QA: 10 ± 2° BTDC at idle
Figure 2
New Belt mm Old Belt mm
Fan Belt 7
～
13.5
Power steering Belt 5～66
～
8
A/C Belt 6. 5～78
～
9
Belt deflection See (Table 1)
Belt pressure : 98N
Belt Looseness
Measuring Point
Water pump
Power steering
crankshaft
generator
Air condition
compressor
pump
11.5
～
9
2
c) When fault diagnosis tester is not used
(1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal.
Notice:
z Ensure correct connection, otherwise the engine will be damaged.
z Switch off all electrical appliance system.
z Check when disconnecting cooling fan motor.
(2) Using timing light to check ignition timing.
Ignition timing: 10 ± 2° BTDC at idle
Notice:
(1) Transmission shift lever should be in neutral position when checking ignition timing.
(2) Running engine at 1,000-1,300rpm for 5s and check at idle.
(3) Remove the tester on fault diagnosis socket.
(4) Ignition timing advance angle becomes larger when the engine roate speed is higher.
(5) Remove timing light.
8. Check engine idle See (Figure 3)
Notice:
z Check idle when cooling fan motor is disconnected.
z
Switch off all electrical accessories and A/C.
9. Check compression pressure See (Figure 4)
(a) Engine switched off.
(b) Detach high voltage cable.
(c) Detach spark plug.
(d) Check the compression pressure in the cylinder.
(1) Insert pressure gauge into the hole of the spark plug.
(2) Throttle valve full open.
(3) Crank the engine, measure the compression pressure.
MR479Q 800±50 (rpm)
MR479 QA 800±50 (rpm)
MR 4 81QA 800±50 (rpm)
Table 2
(a) Warm up the engine.
(b) Connect fault diagnosis tester to fault diagnosis interface socket.
(c) Connect tachometer testing pen to fault diagnosis socket terminal
9 when not using fault tester.
(d) Check idle See (Table 2).
Figure 4
Figure 3
Techometer
Battery
3
The Min. compression pressure: 980 kPa
The tolerance range of the cylinders pressure: 100 kPa
Notice:
z
Ensure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute).
z Check the compression pressure of other cylinders in the same way.
z Complete the measure as quick as possible.
(4) If the compression pressure in several cylinder is too low, fill some engine oil to the cylinder via the
hole of the spark plug. Check by repeating step 1-3.
Hint:
z If the compression pressure is improved after filling oil, the piston ring or the cylinder may be abrased
or damaged.
z If the pressure is still too low, the valve is stagnation or poor seal, or there is a leakage in gasket.
10. Check CO/HC
(a) Start engine.
(b) Running engine at 2500rpm for approximately 3 minutes.
(c) Insert CO/HC meter testing probe into tailpipe at least 40cm during idling.
(d) Check CO/HC concentration at idle and 2500rpm.
Hint:
z
Complete measurement within 3 minutes.
z Test the CO/HC emission concentration at idle and 2500 rpm on QC/T630-1999 standard.
(e) Take the following steps to diagnose the fault if the CO/HC concentration does not comply with standard .
(1) Check the oxygen sensor operation.
(2) See (Table 3) for the possible cause and check and repair.
4
Table 3
CO HC Problems Causes
1. F ault
. I ncorrect ignition timing
. Fouled, shorted or imprope r ly cle ara nce of spar k plug
2. Incorrect valve clearance
3. Leaky inta ke & exhaus t valves
4. Leaky cylinders
1. Air leaks
. PCV hoses, intake manifold
. Throttle body
. Brake booster circuit
2. L ean mixture gas caus ing misfire
1. Clogged air filter
2. C logged PCV valve
. Faulty ECU
. Faulty fuel pre ssure regula t or
. Faulty wa te r temperature sens or
. Faulty air compressor
. Faulty inje ctors
. Faulty throttle position sensor
Normal
Low High
High High
Rough idle
(Black smoke
from exhaust
pipe)
Rough idle
Rough idleHigh
5
Section 2 Drive Belt Replacement
1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine
compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section
Two, Chapter Two for detailed information)
2. Remove generator V-belt See (Figure 5)
3. Remove No. 1 V-belt A/C compressor to crankshaft pulley
4. Remove water pump belt See (Figure 6)
5. Install water pump V-belt
6. Adjust V-belt of steering assisting pump
(a) Adjust power steering belt tension, tighten bolt B.
(b) Tighten bolt A.
Torque : 39N. m
7. Install V-belt A/C compressor No. 1 to crankshaft pulley
8. Adjust V-belt A/C compressor No. 1 to crankshaft pulley
(a) Adjust A/C belt tension by tightening bolt B.
(b) Tighten nut A.
Torque : 39N. m
9. Install Generator V-belt See (Figure 7)
10. Adjust Generator V-belt.
Tighten bolt A and then bolt B.
Torque: Bolt A 18N. m Bolt B 58N. m
11. Check driving belt for distortion and tension
Figure 7
Figure 6Figure 5
6
Section 3 Valve Clearance Adjustment
1. Remove right camshaft timing gear
2. Remove ignition coil and high voltage cable
3. Remove cylinder head cover sub-assembly See (Figure 8)
(a) Disconnect generator wire joint..
(b) Disconnect generator circuit.
(c) Disconnect oil pressure switch connector.
(d) Disconnect A/C compressor switch connector.
(e) Open the wire harness clip.
(f) Remove wire harness from cylinder head cover.
(g) Separate 2 ventilation hoses from cylinder head cover.
(h) Remove 4 screw nuts, 4 oil seal gaskets, cylinder head and gasket.
4. Adjust piston of Cylinder 1 to the compression position
(a) Turn crankshaft pulley, align notch to timing mark "0" on Cylinder 1. See (Figure 9).
(b) Align mark "K" on camshaft timing pulley to the timing mark on bearing cap. See (Figure 10) Crank 360°
if it is not aligned.
5. Check valve clearance (cool). See (Table 5)
(a) Turn the crankshaft pulley for 360°. Align notch to timing mark "0" on timing belt cover No. 1.
(b) Only check the valve as shown in the figure. Valve clearance measurement. See (Figure 11).
Figure 8
Figure 10
Intake Valve mm Exha ust Valve mm
MR479Q 0.20 ± 0.05 0.30 ± 0.05
MR479Q A 0. 20 ± 0.05 0.30 ± 0.05
MR481Q A 0.20 ± 0.05 0.30 ± 0.05
Table
5
Figure 9
7
6. Adjust intake valve clearance
(a) Detach intake camshaft
Notice:
Because the camshaft end play is quite small, keep camshaft horizontal when removing it. If not, cylinder
head may be partially damaged by the thrust force£¬it may stuck or damage camshaft when turning crankshaft.
Take the following steps to avoid the damage:
(1) Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed. See
(Figure 12).
Hint:
The above condition allows the cylinders No. 1 and No. 3 of the intake camshaft to push up the valve tappet.
(2) Remove bolt and bearing cap No. 1.
(3) Install camshaft counter gear to drive gear with service bolt. See (Figure 13).
(4) Uniformly loose and remove 8 bearing cap bolts in several passes as
shown in the figure. See (Figure 14).
(5) Remove 4 bearing caps and camshafts.
Figure 11
Figure 14
Figure 12
Figure 13
8
Notice:
Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removing
it, it may stuck or damage camshaft. Take the following steps to avoid damage:
(1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See
(Figure 15).
(2) Align the matchmark on each gear to engage intake camshaft gear and exhaust camshaft gear. See
(Figure 16).
(3) When the gears are engaged, install the intake camshaft bearing onto bearing journal.
Hint:
The intake camshaft lobe of cylinder 1 and 3 can jack up their own valve tappet.
(5) Install 4 bearing caps to the right position.
(6) Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(7) Uniformly install and tighten 8 bearing cap bolts in several times, in the sequence shown in the figure.
Torque: 13N. m
(8) Remove service screw.
(9) Install the bearing cap No. 1. in the direction of the forward arrow mark.
(10)Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(11)Alternatively tighten and install 2 bearing bolts.
Torque: 13N. m
7. Adjust exhaust valve clearance. See (Figure 17)
Remove adjust gasket.
(1) Crank to keep the camshaft head upward.
(2) Face valve tappet nick to vehicle front.
(3) Press valve tappet, put special tool between camshaft and valve tappet.
Hint:
z Lean the end with mark "9" into the position in (Figure 18).
Figure 15
Install Mark
Timing Mark
March Mark
Cam Lobe
Upward
Nick
Front
Figure 17
Figure 18
Figure 16
9
(4) Alternatively press valve tappet with the special tool (A) (B). Check
valve clearance. See (Figure 19).
8. Install cylinder head sub-assembly
(a) Remove all old gasket material.
(b) Apply the seal glue to the cylinder head.
(c) Connect wire harness and clip.
(d) Install gasket under of cylinder head.
(e) Install the cylinder head cover with 4 seal gaskets and 4 screw caps.
T orque: 7.8N. m
(f) Install 2 ventilation hoses to cylinder head cover.
(g) Connect generator wire joint.
(h) Connect generator wires.
(i) Connect oil pressure switch connector.
(j) Install wire clip.
(k) Connect A/C compressor switch connector.
9. Install electronic ignition coil and high voltage cable
10. Check engine oil for leakage
Figure 19
10
Chapter 2 Engine Components Replacement
(MR479Q, MR479QA, MR481QA)
Section 1 Engine Components
Component 1
Air Filter Assembly W/ Hose
Accelerator Control
Cable Assembly
Heater Inlet Hose
Heater Outlet Hose
Fuel Sub-Assembly
Efi Fuel Pipe Clamp
MT:
Transmission
Control Cable
Assembly
AT:
Transmission Control Cable Assembly
MT:
Clutch Release
Cylinder Assembly
Radiator Outlet Pipe
Radiator Inlet Pipe
Starter Assembly
AT: Oil Cooler
Outlet
Pipe
AT: Oil Cooler
Inlet
Pipe
Radiator Assembly
Battery
Front Exhaust
Pipe Assy.
3-way catalytic
converter
Muffler
Tail Pipe
Figure 20
11
Component 2
Figure 21
Fan & Generator V-Belt
Vane-Type Pump V-Belt (V/ Power Steering)
V-Belt No.1
Right Engine
Mounting Insulator
Door Assembly
Steering Column
Assembly
Front Shaft Hub Left Nut
Left Front Speed Sensor
Left Engine Mounting Bracket
Steering Column Hole Cover
Hole Cover
Steering Column
Glove Compartment
Front exhauxt pipe assembly
Gasket
Gasket
One-off accessory
12
Component 3
Figure 22
Flywheel
Clutch Disc
Clutch Cover
Clutch Release Bearing
Clutch Release Fork
Release Fork Support
Release Fork Boot
13
Section 2 Engine Components Replacement
1. Avoid gasoline ejection when work.
2. Drain the coolant to empty.
3. Remove air filter assembly with hose. See (Figure 23)
4. Remove battery
5. Remove fuel delivery pipe sub-assembly
6. Disconnect water hoses, disconnect heater outlet hose
from A/C hose.
7. Loose nut, remove accelerator control cable
8. Remove throttle body assembly
9. Remove power steering pump reservoir assembly
10. Remove front exhaust pipe assembly
11. Remove steering gear boot
12. Seperate steering column assembly. See (Figure 24)
13. Remove front wheel hub nut
14. Disconnect front wheel vehicle speed sensor (with ABS)
15. Detach steering tie rod ball stud pin assembly
16. Detach front lower swing arm sub-assembly
17. Detach front propeller assembly. See (Figure 25)
Detach front propeller from the shaft hub with plastic hammer.
18. Disconnect transmission shift cable or gear shift level assembly
19. Disconnect clutch cylinder assembly or disconnect clutch cable
20. Detach engine assembly and transaxle
(a) Hoisting engine ;
(b) Remove 3 bolts. Detach the right engine mounting bracket. See (Figure 26) ;
(c) Remove 1 bolt. Detach the left engine mounting bracket;
(d) Remove 1 bolt. Detach the rear engine mounting bracket;
(e) Remove engine and transaxle and put them on the pallet;
(f) Jack up the boday.
Figure 23
Figure 24
Figure 25 Figure 26
14
21. Remove radiator assembly
22. Remove engine V-belt
23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley)
24. Remove generator assembly
25. Remove A/C compressor
26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No.
1 bracket.
27. Remove starter assembly
28. Remove power steering pump V- belt
29. Detach power steering pump assembly
30. Remove power steering pump, adjust the bracket
31. Detach manual transaxle assembly (Separate automatic transaxle assembly)
32. Detach clutch cover panel assembly.
33. Detach clutch pressure plate assembly.
34. Detach flywheel sub-assembly.
35. Remove engine rear end cover.
36. Remove injector assembly and remove intake manifold.
Remove 2 bolts and intake manifold support and remove 7 bolts,
2 nuts, intake manifold and gasket. See (Figure 27).
37. Remove knock sensor
38. Remove water temperature gauge sensor
39. Remove crankshaft position sensor
40. Remove engine oil pressure switch
41. Remove water inlet hose housing
42. Remove water outlet hose joint
43. Detach exhaust manifold. See (Figure 28)
44. Remove engion oil filter sub-assembly
45. Remove ignition coil and high voltage cable
46. Install engine sub-assembly
47. Install ignition coil and high voltage cable
48. Install engine oil filter sub-assembly
49. Install exhaust manifold
(a) Install new gasket and exhaust manifold stay with
5 nuts, Torque: 34N. m
(b) Install exhaust manifold stay with two bolts.
Torque: 59N. m
(c) Install upper heat shield with 4 bolts.
Torque: 17N. m
Figure 27
Figure 28
15
50. Install water outlet hose joint. See (Figure 29, 30)
Figure 29
51. Install water inlet hose housing. See (Figure 31, 32)
Figure 31 Figure 32
52. Install engine oil pressure switch
53. Install crankshaft position sensor
T orque: 9, 3N. m
54. Install water temperature gauge and water temperature sensor
T orque: 15N. m
55. Install knock sensor
Torque: 44N. M
56. Install intake manifold. See (Figure 33)
Install the intake manifold with new gasket with 7 bolts and 2
nuts. Uniformly tighten bolts and nuts in several time.
57. Install injector assembly
58. Install rear end cover
59. Install flywheel sub-assembly. See (Figure 34)
(a) Install flywheel to crankshaft.
(b)Install and uniformly tighten and connect bolt as shown in the
figure. Torque: 78N. m
60. Install clutch assembly
61. Install flywheel and ring gear. See (Figure 35)
(a)Install the oil thrower, it’s chamfer side on crankshaft in
the axie direction.
(b) Install flywheel and ring gear on crankshaft.
Figure 33
Figure 34
Figure 30
16
(c) Install and uniformly tighten connecting bolt in the sequence shown in
the figure.
Torque: 64N. m
62. Install manual transaxle assembly
63. Install starter assembly
64. Install power steering pump bracket
65. Install power steering pump adjusting bracket with 2 bolts.
66. Connect power steering pump assembly
67. Install engine assembly and transaxle
68. Connect left, right, front and rear lower suspension arm sub-assembly
69. Connect left and right tie rod ball stud pin assembly
70. Connect left, right and front vehicle speed sensor (with ABS)
71. Install left & right nuts on the front shaft hub
72. Install front exhaust pipe assembly
73. Connect steering shaft assembly and steering column hole cover. See (Figure 36)
74. Connect wire harness
75. Install belt adjusting bracket of A/C compressor
76. Connect A/C compressor
77. Install generator assembly
78. Install A/C compressor to crankshaft pulleyV-belt
79. Install generator belt
80. Install engine assembly with transaxle
81. Install radiator assembly
82. Install throttle body assembly
83. Install fuel delivery pipe sub-assembly
84. Install battery
85. Install air filter assembly with hose
86. Install front wheel
87. Fill engine oil
88. Fill coolant
89. Check engine oil for leakage
90. Check engine coolant for leakage
91. Check fuel for leakage
92. Check idle and ignition timing
93. Check CO/HC
94. Check and adjust front wheel alignment
95. Check ABS vehicle speed sensor signal
Figure 35
Figure 36
17
Section 3 Timing Belt Replacement
Figure 37
Air Filter Assembly W/ Hose
High Pressure Cable
Ventilation Pipe
Seal
Cylinder Head
Right Engine Mounting
Fan & Generator V-Belt
V-Belt No.1
Cylinder Head Gasket
Gasket
Timing Chain Or Timing Belt Cover Assembly No. 2
Crankshaft Or Pulley
Cover Sub-Assembly
Crankshaft Pulley
Timing Belt Guide
Timing Chain Timing Belt
Cover Sub-Assembly
Generator Assembly
Timing Belt
Fan Pulley
Vane-Type Pump V-Belt V/ Power Steering
18
1. Disconnect engine from all the wire harnesses and cables connected to body.
2. Remove air filter assembly with hose. See (Figure 38)
3. Disconnect oil pipe and water hoses
4. Loose positive and negative cables on battery
5. Detach propeller shaft
6. Loose engine left & right rear brackets after hoisting engine
7. Disconnect all the connectors of engine and the body
8. Remove engine per "Provision 20, Section 2, Chapter 2"
9. Remove A/C compressor to crankshaft pulley V-belt
10. Remove power steering pump V-belt
11. Remove water pump fan pulley
12. Remove high pressure cable.
13. Remove cylinder head cover sub-assembly
14. Remove generator assembly. See (Figure 39)
15. Put the piston in Cylinder 1 to TDC compression position
(a)Turn crankshaft pulley to align its notch to the timing mark "0"
on the timing belt cover. See (Figure 40).
(b) Check if the "K" mark on camshaft timing pulley and the timing mark
on the bearing cap are aligned. Crank the crankshaft for 360 degrees
if not. See (Figure 41).
16. Remove crankshaft pulley
17. Remove timing belt cover
18. Remove crankshaft gear or pulley cover sub-assembly
19. Remove timing belt cover sub-assembly
Figure 40
Figure 39
Figure 38
Figure 41
19
20. Remove timing belt guide wheel
Hint:
(a) Mark on pulley and belt (in engine turning direction) if re-using timing belt (See Figure 42).
(b) Install bolt to the idler pulley. Move pulley to its far left and tighten it temperarily (See Figure 43).
21. Remove spark plug and gasket
Figure 42
22. Install spark plug and gasket
23. Put the piston in Cylinder 1 to TDC compression position.
See (Figure 44)
(a) Turn camshaft hexagon part. Align the mark "K" on the camshaft
timing pulley to the mark on the bearing cap.
(b) Using the crankshaft pulley bolt, turn the crankshaft, align the mark
on crankshaft timing pulley to the oil pump.
24. Install timing belt. See (Figure 45)
Notice: The engine must be cool.
(a) Install timing belt. Check the tension force between crankshaft timing
pulley and camshaft timing pulley.
Hint: Align the marks if re-using the timing belt when removing. The
engine's rotating direction should be the same with the arrow's when
installing belt.
(b) Check valve timing. Loose idler bolt.
(1) Turn crankshaft from TDC to BDC slowly.
Notice: Crank always in clockwise.
(2) Align each pulley to timing mark as shown in the figure. If the timing mark is not aligned,
remove timing belt and reinstall it.
(3) Tighten idler bolt.
T orque: 37N. m
(4) Remove crankshaft pulley bolt.
Figure 44
Figure 45
Figure 43
20
(c) Check timing belt for deflection
Check the belt distorn as shown in the figure.
Belt deflection:
20N: 5~6mm
Re-adjust the idler if the deflection does not comply with the regulation.
25. Install timing belt guide wheel. See (Figure 46)
Install guide, place the cup side outward.
26. Install timing belt cover sub-assembly
Torque: 9.3N. m
27. Install crankshaft gear or pulley cover sub-assembly
Torque: 9.3N. m
28. Install timing belt cover
Torque: 9.3N. m
29. Install crankshaft pulley. See (Figure 47)
(a) Align pulley lock key and pulley key groove. Install pulley .
(b) Install pulley bolt T orque: 127N. M
30. Install generator assembly
31. Install water pump pulley
32. Install power steering pump V-belt
33. Install A/C compressor fan to crankshaft pulleyV-belt
34. Install cylinder head cover sub-assembly.
(a) Wipe off all seal packing material.
(b) Apply the seal glue on cylinder head cover as shown in Figure 48.
(c) Install gasket onto cylinder head cover.
(d) Install cylinder head cover with 4 seal gaskets and 4 nuts.
Torque: 7.8N. M
(e) Install 2 ventilation hoses onto cylinder head cover.
(f) Install engine wire harness onto cylinder head cover.
(g) Connect generator wire joint.
(h) Connect generator wire.
(i) Connect oil pressure switch connector.
(j) Install wire clip.
(k) Connect A/C compressor switch connector.
35. Hoist the engine back into the compartment
36. Install left & right rear engine mounting brackets
37. Install ignition coil and high pressure cable
38. Install air filter assembly with hose
Figure 48
Figure 46
Figure 47
21
39. Install oil pipe and water hose
40. Install left & right propeller shaft
41. Install left & right front wheel
42. Check engine oil for leakage
43. Install all connected wire harnesses and the cables on engine and vehicle body
22
Section 4 Camshaft Replacement
Figure 49
Vane-Type Pump V-Belt
V/ Power Steering
Fan & Generator V-Belt
High Pressure Cable
Ventilation Pipe
V-Belt No.1
Cylinder Head
Cylinder
Head Gasket
Crankshaft Bearing Cap
Crankshaft Timing Belt Washer
Crankshaft Counter Gear
Wave Gasket
Snap Ring
Camshaft
Camshaft No. 2
Oil Seal
Camshaft Timing Pulley
Fan Pulley
Generator Assembly
Crankshaft Or Pulley
Cover Sub-Assembly
Timing Belt
Cover No. 2
Air Filter Assembly W/ Hose
Right Engine Mounting
Seal
23
1. Disconnect all connected wire harnesses and the cable on the engine and the vehicle body
2. Remove air filter assembly with hose
3. Disconnect oil pipe and water hose
4. Loose positive and negative cables of the battery
5. Detach propeller shaft
6. Loose left & right rear engine mounting bracket after hoisting the engine.
7. Disconnect all other connectors between the engine and the vehicle body.
8. Remove engine per "Provison 20, Section 2, Chapter 2"
9. Remove A/C compressor to crankshaft pulleyV-belt
10. Remove power steering pump V- belt
11. Remove water pump fan pulley
12. Disconnect ignition coil and high voltage cables
13. Remove cylinder head cover sub-assembly
14. Remove generator assembly
15. Remove cylinder head cover sub-assembly
(a) Disconnect generator wire joint.
(b) Disconnect generator circuit
(c) Disconnect A/C compressor switch connector.
(e) Open wires clips.
(f) Disconnect wire harness from the cylinder head cover.
(g) Disconnect 2 ventilation PCV hoses from cylinder head cover.
(h) Remove 4 screws, 4 seal gaskets, cylinder head and gasket.
16. Remove generator assembly. See (Figure 50)
17. Remove timing belt cover
18. Remove crankshaft gear or pulley cover sub-assembly
19. Put the piston on Cylinder 1 to TDC compression position.
(a) Turn crankshaft pulley. Align its notch to the timing mark "O" on the
timing belt cover.
(b) Check if the mark "K" on camshaft timing pulley is aligned to the
timing mark on the bearing cap. Turn crankshaft 360° if not.
20. Remove ignition coil assembly
21. Remove timing belt. See (Figure 51)
(a) Mark on the timing belt and the camshaft pulley. The mark on the
timing belt to the timing belt cover No. 1 should match.
(b) Remove rubber gasket from timing belt cover.
Figure 50
Figure 51
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