Mazda Protege 1996 Workshop ManualWARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury and property damage increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda- trained technicians in mind. This manual may be useful to non- Mazda trained technicians, but a technician with our service-re- lated training and experience will be at less risk when performing servicing operations. However, all users of this manual are ‘expected to know general safety procedures. This manual contains “Wamings” and “Cautions” applicable to risks not normally encountered in a general technician's experi- ‘ence. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the “Warnings” and “Cautions” are not exhaustive. Itis impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. ‘The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Nonre- commended procedures and tools should include consideration for safety of the technician and continued safe operation of the vehicle. Parts should be replaced with genuine Mazda replacement parts, not parts of lesser quality. Use of a nonrecommended replacement part should include consideration for safety of the technician and continued safe operation of the vehicle.1996 Mazda Protegé Workshop Manual FOREWORD A thorough familiarization with this, manual is important for proper repair and maintenance. It should always be kept in a handy place for quick and easy refer- ence. The contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifi- cations affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and con- tents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechani- cal—ineluding photocopying and record- ing, and the use of any kind of information storage and retrieval system—without per- mission in writing WARRANTY The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Autho- rized Mazda Dealer. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual ‘is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page. CONTENTS Section jeneral Information Engine brication System joling System Fuel and Emission Control Systems F25M-R Automatic Transaxle FASA-EL |Front and Rear Axles tering System [Braking System [Wheels and Tires| jody Body Electrics System [Heater and Air Conditioner Systems © 1995 Mazda Motor Corporation PRINTED IN U.S.A., JULY '95 Form No, 1495-10-95G Part No. 9999-95-017B-96VEHICLE IDENTIFICATION NUMBERS (VIN) JM1 BB141#TO 300001— JM1 BB142+TO 300001— JM1 BB143%TO 300001— JM1 BB144*TO 300001— RELATED MATERIALS. 1995 323/Protegé Service Highlights ........... 9999-95-064F-95 1996 Protegé, MX-3, MX-5, 626/MX-6, 929, MPV, Millenia Service Highlights ......- 9999-95-MODL-96 Engine Workshop Manual Z5-DOHC 9999-95-EWZ5-95 Engine Workshop Manual B6, BP-DOHC 9999-95-EWBP-95, Manual Transaxle Workshop Manual F25M- 9999-95-F25M-95 Automatic Transaxle Workshop Manual FA4A-E1 9999-95-FA4A-95 1996 Protegé Wiring Diagram .. 9999-95-019G-96GENERAL INFORMATION ‘SAFETY INFORMATION LUBRICANTS. JACKING POSITION AND POSITION: DYNAMOMETER .. . ‘COMPRESSED AIR PREPARATION OF TOOLS AND MEASURING EQUIPMENT Git )JUSTMENTS. ~GH13 [RUBBER PARTS AND TUBING... -..--2. G13) HOSE CLAMPS .. TEST LIGHT . JUMPER WIRE VOLTMETER, [OHMMETER ECTRICAL PARTS . (El N a WIRING HARNESS . FUSE... STALLATION OF RADIO SYSTEM . TOWING . Vi : ELIVERY INSPECTION TABLE. NANCE... SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) ... aoe SCHEDULED MAINTENANCE TABLE (CANADA) ....sesssceseenseeeee PRED . G20, . G23 Gl caGl SAFETY INFORMATION SAFETY INFORMATION LUBRICANTS ‘Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, ard can ‘cause skin cancer and other skin disorders. Wash thoroughly after working with oil. We recommend water-soluble hand cleaners. Do not use kero- sene, gasoline, or any other solvent to remove oil from your skin. If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu- larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals, JACKING POSITIONS Warning ‘+ Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. Front Rear At the front of the engine mount member At the center of the crossmember_ ‘SAFETY STAND POSITIONS Front Rear Both sides of the si Both sides of the side sill G2SAFETY INFORMATION Gl VEHICLE LIFT POSITIONS Front Rear Both sides of the side sill Both sides of the side DYNAMOMETER When test-running a vehicle on a dynamometer: ‘Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle unoluttered. Watch the water temperature gauge. COMPRESSED AIR When using compressed air to clean or remove parts: + Wear protective eye wear. ‘Hold a rag over the opening to prevent parts trom shooting out. ‘Take precautions so that people around you are not struck by flying debris. GI-3Gl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL ADVISORY MESSAGES You'll ind several Warnings, Cautions, and Notes in this manual. Warning * A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution * A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note ‘+ ANote provides added information that will help you to complete a particular procedure. PREPARATION This points out the needed SSTs for the service operation. Itis best to gather all necessary SSTs before beginning work. Example: FRONT AXLE PREPARATION SST NUMBER USAGE Sst L I t Bore esoc For ; ee Fao of i od Pte, bat oe ’ ee T T SST NAME ‘SST ILLUSTRATION REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows hew the parts fit together, and describes visual part inspection. If a damaged or wotn part is found, repair or replace it as necessary. 2. Expendable parts, tightening torques, and symbols for cil, grease, and sealant are shown in the over- view illustration 8. Pages related to service procedures are shown under the illustration. Refer to this information when servicing the related part. Gl-4Gl HOW TO USE THIS MANUAL. Example: sHows SPECIAL, SERVICE TOOL as z (SST) FOR SER- \ ‘ewscrnl a VICE OPERATION) \ x " a shows EXPENDABLE PARTS shows ‘APPLICATION POINT OF OIL, atesene Ere. eam avowe — wa RELATED mens a PAGE FOR pong = ‘SERVICE, ON. page M_2+ — ¥ vee oan pace ee ae Sete ae “1: The numbers (©, etc.) refer to part identification and servicing procedures. ‘SYMBOLS sHOWS TIGHTENING TORQUE SPECIFICATIONS. shows TIGHTENING ‘TORQUE UNITS, ‘SHOWS VISUAL Met INSPECTION INFORMATION There are seven symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. ‘Symbol Meaning Kind Wo wwe now eng oor ge spp Apply brake tid FMVSsi16: DOT-3 Apply groase Appropriate grease Apply seatant Appropriate sealant FB srtrautomaticransante tui Mull oF Dexron®It causes leaks. > 2, Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the pre- scribed locations (such as oil seals) before reassembly. GH12FUNDAMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and testers when meking adjust- ments, RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rutber parts or tubing. HOSE CLAMPS ‘When reinstalling, position the hose clamp in the original Y location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. TORQUE FORMULAS When using a torque wrench-SST combination, the writ- ten torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the * torque by using the following formulas. Choose the for- mula that applies to you. Torgue Unt Fomua Nm Wimx(V-Al a o—— igh gmx (UILAAIT igtem gem (LILA ‘tr feBPTUTAN) int im [LA] ne length of the SST past the torque wrench drive. he length of the torque wrench. VISE ‘When usinga vise, put protective plates in the jaws of the vise to prevent damage to parts. G-13Gl ELECTRICAL TROUBLESHOOTING TOOLS saWors4w GROUND POWER SOURCE LINE OnWMETER, G14 ELECTRICAL TROUBLESHOOTING TOOLS TEST LIGHT The test light, as shown in the figure, uses a 12 V bulb. The two lead wires should be connected to probes. The test light is used for simple voltage checks and for check- ing for short circuits. Caution + Using a bulb over 3.4 W when chec! trol unit may damage the control unit. g the con- JUMPER WIRE ‘A jumper wire is used to create a temporary circuit. Con- neet the jumper wire between the terminals of a circuit to bypass a switch. Caution ‘+ Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components. VOLTMETER The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by con- necting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (—) probe (black lead wire) to a body ground, OHMMETER The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continu- ity and short circuits. Caution * Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ‘ohmmeter.ELECTRICAL PARTS Gl — ELECTRICAL PARTS BATTERY CABLE Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. CONNECTORS Data Link Connector Insert the probe into the service hole when connecting ‘a jumper wire to the data link connector. Caution © Inserting a jumper wire probe into the data link connector terminal may damage the terminal. Disconnecting Connectors When disconnecting two connectors, grasp the connec tors, not the wires. Connectors can be disconnected by pressing or pulling the lock lever as shown, Locking Connector When locking connectors, listen for a click that will indi- ot cate they are securely locked. GI-5ELECTRICAL PARTS Inspection 1, When a tester is used to check for continuity or te mea- sure voltage, insert the tester probe from the wiring har- ness side. 2. Check the terminals of waterproof connectors frem the connector side, as they cannot be accessed from the wiring hamess side. Caution * To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal. ‘TERMINALS Inspection Pull lightly on individual wires to check that they are secured in the terminal. Replacement Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it Until it locks securely. Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the conrector. ‘SENSORS, SWITCHES, AND RELAYS Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.ELECTRICAL PARTS, INSTALLATION OF RADIO SYSTEM Gl S| ame eae am un cies ea as Inealedby @ two-coler code sym- The first letter indicates the base color of the wire and the feo yewow second the color of the stripe. cope | _coLoR cone | coLoR 8 sack | | 0 Orange leas G Green R Red oy Gray v Violet iy Light Blue es Yellow ts | tight Green p= E ee FUSE Replacement ‘When replacing a fuse, be sure to replace it with one of the specified capacity. Ifa fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse. 3. When replacing a pullout fuse, use the fuse puller sup- PULLER plied in the fuse box cover. t INSTALLATION OF RADIO SYSTEM If radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions: 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control module hamesses (at least 30 cm { 11.8 in », 3. Ensure that the antenna and feeder are properly adjusted. 4. Do not install a high-powered radio system. GI-17TOWING TOWING Precautions ‘+ Proper towing equipment is necessary to prevent dam- age to the vehicle. ‘+ Laws and regulations applicable to vehicles in tow must always be observed. + Asa general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies, ‘+ Ifall four wheels are on the ground, the vehicle may be towed only forward. Remember that power assist for the brakes and steering are not available when the engine is not running. Procedure With either automatic or manual transaxle: 1. Set the ignition switch in the ACC position. 2. Place the selector lever or shift lever in N (Neutral). 3. Release the parking brake. Caution + Do not tow the vehicle backward with driving wheels on the ground. This may cause internal, damage to the transaxle. Caution + Don't use the tiedown hooks under the front and rear for towing. They are designed ONLY fortying down the vehicle when it’s being transported. Using them for towing will damage the bumper.PRE-DELIVERY INSPECTION GI PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE EXTERIOR INSPECT and ADJUST, if necessary, the following items to specification: Glass, exterior bright metal, and paint for damage Wheel lug nuts (Tire pressure D Allweathorstrips for damage or detachment Operation of hood release and lock [Operation of fuo! lid and trunk lid opener (f equipped) [DiBoor operation and alignment (D)Headight aiming INSTALL the following parts: CoWheet caps (it equipped) UNDER HOOD—ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification: 1 Fuel, coolant, and hydraulic lines, fitings, connections, and ‘components for leaks Engine cil level [Power steering ud level (if equipped) [DiBrake and clutch fluid level Windshield washer reservoir fluid level DiRadiator coolant level and specific gravity Tightness of water hose clamps [DiTightness of battery terminals, electrolyte level, and specific gravity [1Manual transaxle of level 5 Drive bet(s) tension (1Accelerator cable and linkage for tree movement TERIOR INSTALL the following pats: {1 Fuse for accessories CHECK the operation of he following tems: 11 Seat controls (Sing and rectnng) and headrest (Dir bag system using warring ight {2 Cruge set using indicator ight (f equipped) {anion switch and steering lock (Power window (if equipped) Power dor lack (i equipped) {2 Door locks including chil proot door lacks 1 Transaxle range switch (ATX only) Aight including waming and incicatorghts Ci lgnition key reminder buzzer (if equipped) DHom, wipes, and washers (ron and rer, equipped) Antenna Cigarette lighter and clock DiPower outside mirrors (f equipped) Heater, defogger, and air conditioner at various mode selec- tions (it equipped) Sliding suntoot (if equipped) CHECK the folowing items: [DiPresence of spare fuse [Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: Operation and fit of windows, C)Pedal height and free play of brake and clutch pedal CiParking brake UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE ‘CHECK the folowing items: 7 Operation of idle-up system or electrcalload, air conditioner ‘or power steering (if equipped) Automatic transaxle fluid level ignition timing Dildle speed ON HOIST CHECK the following tems: [CJ.Underside fuel, coolant and hydraulic ines, tings, connec- tions, and components (ur eaks. (Tires for cuts or bruises Steering linkage, suspension, exhaust system, and all ‘underside hardware for laoseness or damage ROAD TEST | ‘CHECK the following items: Brake operation BiCutch operation D Steering contro! Operation of meters and gauges Squeaks, ratios, or unusual noises. DiEngine general performance Emergency locking tractors AFTER ROAD TEST REMOVE the seat and floor mat protective cavers CHECK for the necessary owner information materials, tools, and spare tie in vehicle GH19Gl SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) ‘Schedule 1 (Normal driving conditions) The vehicle is mainly operated where none of the “unique driving conditions” apply. ‘Schedule 2 (Unique driving conditions) Repeated short-distance driving, Driving in dusty conditions. Driving with extended use of brakes. Driving in areas where road salt or other corrosive materials are used. Driving on rough or muddy roads. Extended periods of idling or low-speed operation. Driving for long prolonged periods in cold temperatures or extremely humid climates. GI-20SCHEDULED MAINTENANCE GI ‘Schedule 1 (Normal driving conditions) Wiaintenance Interval “Number af month or miles ( ilometers), whichever comes first] Months 6 | 12 | | 2 | 90 | 3 | | Too | Kitmaters | 12_[24 | a6 | 48 | 6072 | @4 | 96 Maintenance tem ae Miles [75 | 16) 225 | 30] 375 | 45 | 525 | 60 Engine Engine valve Gearance (25 engine) 7 Engine oil aya [ALA|A|A,A[A Oil titer Apa ,A|A|A|A|A]A Tension of all dive bets _ 1 i “Engine timing bel (except Calforna) Replace every 60,000 miles (96,000 Km] inspect at 60,000 miles {$6,000 km ), and Engine timing bet (California) ‘gain at 90,000 mils {144,000 km’) place every 106,000 miles 168,000 kn} Flos and tube or emission [eee |e] Air cleaner [Rirsioaner element Lore tt] Ignition system [Spans a F Fuel system Tale speed FE Fuel iter a 7 a | Fuct ines and hoses —__ re Fust hose (Calfornia) inspect every 105,000 ries (168,000 Wi} Cooling system Gooting system 7 ae place at fst 45,000 mils (72,000 km or 36 months Engine coolant after that, every 30,000 miles ( 48,000 km | or 24 months Chassis and body Brake fines, hoses, and connections Dise brakes Drum brakes: Steering operation and linkages: Front suspension bal joints Drive shaft dust boots Bolts and nuts on chassis and body Exhaust system heat shield ‘Alllocks and hinges (ajaGeee Air conditioner system (if equipped) Fefigerant amount 7 7 T 7 Compressor operation es T i T 1 Chart symbols: 1: Inspect and repair, clean, or replace if necessary. R : Replace L: Lubricate Remarks: ‘Alter 48 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ommended intervals. “This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. a I-21Gl SCHEDULED MAINTENANCE ‘Schedule 2 (Unique driving conditions) Maintenance interval ‘Number of months or miles { kilometers }, whichever comes first Months: 4 [8] 12] 16) 20 | 24 | 28 | s2[ 36 [| 40| 44 46 vao00 | Kilometers |e | 16 [24 [32 | 40 | 48 | 56 [64 | 72 | 00 | 08 96 Maintenance Item Miles [5 | 10. 18 | 20) 25 | 30] a5 | 40 | 45 | 50_| 5560 Engine Engine valve clearance (25 engine) Engine ol R[A[;ALA|A|A[A|A|A [Ala Engine oil (Puerto Rico) Replace every 3,000 miles {4,800 ke } (or S months) Oifiter A[A[R[A[A|A[R[A[A[A[R “Tension ofall dive bats i T Engine timing bet (except Calfornia) Feplace every 60,000 miles {96,000 km inspect at 60,000 miles {96,000 km J, and Engine timing bet (California) ‘again at 90,000 miles {144,000 km’) place every 105,000 mies {168,000 ki. Toss and ibe or emission [es ee Jee eee Air cleaner [Aircleener element [ee ee fee re [ee | oe] Ignition system [Spancpiuge [ee er ee eee] Cooling system Cooling system Ty tT 7 {'] { T 7 7 I aay Replace at rt 45,000 miles (72,000 kn) oF 36 montis ‘a ater that, every 30,000 miles (48,000 km oF 24 months Fuel system Fost iter wy Fuel tines and hoses: r rT Tale speed e re 7 Fuel hose (Galforia) Trspect every 105,000 miles (168,000 Chassis and body ‘Brake lines, hoses, and connections ‘Drum brakes Disc brakes ‘Steering operation and linkages Front suspension ball joints Drive shaft dust Bools Boils and nus on chassis and body. i Exhaust system heat shield ‘Allocks and hinges. Air conditioner system (if equipped) Refrigerant amount T T T ia T ‘Compressor operation t 1 7 el 1 Chart symbols: 1: Inspect and repair, clean, or replace if necessary. (Inspect, and if necessary replace element only) Air cleaner R : Replace L : Lubricate Remarks: + After 48 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ‘ommended intervals. “1” This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. Gl-22SCHEDULED MAINTENANCE Gl ‘SCHEDULED MAINTENANCE TABLE (CANADA) ‘Maintenance Interval ‘Number of months or miles { ki whichever comes first ] Months 3 [10 | 1 | 20 | 25 | 30 | 38 | 40 | 45 | 50 | 55] 60 Trang | Kilometers | 8 [16 [24 | 32] a0 | 48 | 56 | 6 | 72 | 00.| 68 | 96 Maintenance item Miles [5 [10] 18/20 | 25 | 90 | a5 [a0 | 45 | 50 | 55 | 60 Engine Engine valve clearance (75 engine) 7 Engine of wlatata ATA yAlAlaAyAyAlA Oil filter = R/R/A[A/ARI/A|A[A/R[A[AL[R [Tension of ail drive bats CC Engine timing belt"? RB Air cleaner [Aireleaner element ere san] [needs Jee eee [ee] Ignition system [Seampios a a Ee dL Cooling system Engine cocant vel an avongth ete) te] aa) ate ete | ete [ata atie| a [Cooling system for leaks z 7 T 7 i ee place a ret 45,000 miles (73,000 km’ or 45 mons Sore after that, every 30,000 miles { 48,000 km } or 30 months Fuel system Tale speed Fuel lines and hoses Fuel fiter PCV valve Emission hoses and tubes Chassis and body Tatomatio waneane Hid Tevel | Transaxte oll (MTX and ATX) Drive shaft dust boots Brake lines and hoses Brake and clutch fuid level Brake fic Disc brakes (front and rear) Rear drum brakes Tire inflation pressure and tire wear Tires Power steering Td evel ‘Steering operation and linkages (includes four whee! alignment) ‘Suspension components (front and rear) Al chasse and body nuts and bols Exhaust system heat shields [Alllocks and hinges Washer fuid level Function of all ights Air conditioner system (if equipped) Refrigerant amount ‘Compressor operationGl SCHEDULED MAINTENANCE Chart symbols: 1: Inspect and repair, clean, or replace it necessary. (Inspect, and if necessary replace ... Air cleaner ele- ment only) R : Replace L : Lubricate Rt: Rotation (tires) Remarks: ‘After 60 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ‘ommended intervals. “1” Replacement of the timing belt is required every 60,000 miles { 96,000 km }. Failure to replace this belt may result in damage to the engine. “2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability *3 This maintenance operation is recommended by Mazda. Gl-24B1 Before beginning any service procedure, refer to section T1 of this manual for air bag system service warnings. ENGINE (25) ONT OIL SEAL PREPARATION fa PREPARATION REPLACEMENT ENGINE, PREPAI [DISASSEMBLY ASSEMBLY... -.2...2.... 81-28)B1 DRIVE BELT DRIVE BELT PREPARATION SST 49 9200 0208 For inspection of ‘Tension ‘rive belt tension gauge, belt GENERATOR WATER INSPECTION / ADJUSTMENT PUMP Inspection GeNeRaTor PULLEY PULLEY CRANK: SHAFT PULLEY CCAANKSHAFT PULLEY Bi-2 WHEN MEASURED —/ wren ser 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. ‘Apply moderate pressure 98 N { 10 kgf , 22 Ibf } midway between the specified pulleys. Deflection mom {in} Drive belt "New Used Limit ae 55-70 | 60-75 | 80 a {022-027} | (0.24029) | (031) PS, 80-90 | 90-100 | 15 PIS!AC (0.32-0.35} | (0.36—0:39) | (045) "A balt that has been on a running engine for less than five minutos, 2. Ifthe deflection is not within the specification, adjust it Drive belt tension check 1. Belt tension can be checked in place of belt deflection ‘Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two puleys. Tension N (kgf, tot) Drive " [ oe New Used Limit eee [sees oo r00 500700 340 | Senerator| (50-76 , 110160} | (50—72, 10—150} |{ 95.77) PAS, 500680 420490 250) PIS+ AIC |{ 50-60, 110-190) | (43-50, e5—110) | 25.55) *Abelt that has been on a running engine for less than five minutos, 2. If the tension is not within the specification, adjust it,DRIVE BELT B1 GENERATOR Adjustment _ Generator drive belt 1, Loosen bolts @ and ®), 2. Adjust the belt deflection by turning adjusting bolt ©) Deflection (At 98N { 10 kgf , 22 Ibf}) New: 5.5—7.0 mm { 0.22—0.27 in } GenehaTor Used: 6.0—7.5 mm { 0.24—0.29 in } PULLEY Hee SHAFT sieerad 3. Tighten bolts ® and®. Tightening torque 98-51 Nem { 3.85.3 kgf-m , 28-38 ft-bf } 19—25 Nem { 1.9—2.6 kgf-m , 14—18 ft-lbt } PIS, PIS + A/C drive belt 1. Loosen the bolts and nuts marked @, ® and ©. 2. Adjust the belt deflection by turning adjusting bolt ©). Deflection (At 98 N { 10 kaf , 22 Ibf }) ‘New: 8.0—9.0 mm { 0.32—0.35 in } Used: 9.0—10.0 mm { 0.36—0.39 in } IS OIL PUMP PULLEY 3. Tighten the bolts and nuts marked ®, ® and ©. ‘CRANKSHAFT PULLEY Tightening torque 44—60 Nem { 4.4—6.2 kgf-m , 32—44 ftbt } 38—51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } 38—51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } P+ AC PISO PUMP. PULLEY CRANKSHAFT PULLEY ‘NC COMPRESSOR PULLEY B1-3Bi VALVE CLEARANCE VALVE CLEARANCE PREPARATION ssT soTo12080 ror s9T012001 ror rSocorent of Tplocomontot ter apet Seamer sin | Body eset in ate Sate oy ssTo12002 ror oro12008 = ‘placoment ot rStaconentot Shan Meamonstin | Cine, shat EES Shamront stn Parte are St ono Shs ono re Foe TSlcementt ot Seon sn _ Oanot INSPECTION / ADJUSTMENT Inspection 4. Remove the cylinder head cover. B1-4 Standard (Engine cold) .25—0.31 mm { 0.010—0.012 in } EX: 0.25—0.31 mm { 0.010—0.012 in } 2. Verify that the engine is in cold condition. 3. Measure the valve clearance (1) Tum the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke. (2) Measure the valve clearance at @) in the figure. (8) Ifthe valve clearance exceeds the standard, replace the adjustment shim.[{Refer to page B1-5. ® ® ® © (4) Turn the crankshaft 360 ° clockwise so that the No.4 = = piston is at TDC of the compression stroke. (6) Measure the valve clearance at @ in the figure. wf ogo ogo ago of) ‘Standard (Engine cold) Not No2 No3 Nos 1.25—0.31 mm { 0.010—0.012 in } ex ei fl EX: 0.25—0.31 mm { 0.010—0.012 in } 7 (6) If the valve clearance exceeds the standard, replace x the adjustment shim [[Befer fo page BT-5.31 ® oo 4. Install the cylinder head cover.VALVE CLEARANCE B1 Adjustment Perform this same procedure for all camshafts requiting valve clearance adjustment. cy 1. Tum the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are posi- tioned straight up. 2. Remove the camshaft cap bolts as necessary. @: For EX side No.1, 2, 3 cylinder adjustment shim removal. ®: For IN side No.1, 2, 3 cylinder adjustment shim removal. ©: For EX side No.2, 3, 4 cylinder adjustment shim removal. For IN side No.2, 3, 4 cylinder adjustment shim removal. Note * For EX side No.2, 3 cylinder adjustment shim removal, remove bolts either @ or ©. + For IN side No.2, 3 cylinder adjustment shim removal, remove bolts either ©) or ©). 3. Install the SSTs on the camshaft using the camshaft cap bolt holes. jhtening torque: 11.3—14.2 Nam {115—145 kgf-cm , 99.9128 inlbf } 4, Align the marks on the SSTs (shaft and shaft clamp). ®| _§. Tighten bolts @ to secure the SST (shaft). EE 6. Face the SST (body) toward the center of the cylinder head, and mount it on the SST (shaft) at the point of adjustment shim to be replaced. B1-5VALVE CLEARANCE 10. 12. 13, B1-6 14. 15, 16. 7. 7. 1. Face the notch of the tappet so that a fine screwdriver can be inserted, Set the SST on the tappet by its notch. . Tighten bolt ©) to secure the SST (body). Caution + Cylinder head can be damaged when the tappet is pressed down. Tighten bolt ©, and press down the tappet. Using a fine screwdriver, pry up the adjustment shim through the notch on the tappet. Remove the shim by using a magnet, Select proper adjustment shim. New adjustment st = Removed shim thickness + Measured valve clearance — Standard valve clearance (0.28 mm {0.011 in}) Push the selected shim into the tappet. Loosen bolt ©) to allow the tappet to move up. Loosen bolt ®) and remove the SST (body). Remove the SSTs and tighten the camshaft cap bolts, Tightening torque: 11.3—14.2 Nm {(115—145 kgf.cm , 99.9—125 in-Ibf} ‘Check the valve clearance.((Refer to page BI=4.)COMPRESSION B1 COMPRESSION INSPECTION Ga Verify that the battery is fully charged. Recharge it if necessary. [(Refer to section G.)] Warm up the engine to the normal operating temperature. ‘Stop the engine and allow it to cool for about 10 minutes. Remove the spark plugs. Disconnect the distributor connectors. Install a compression gauge into the No.1 spark plug hole. Measure compression in the following procedure. (1) Fully depress the accelerator pedal or fully open the throttle valve. (2) Crank the engine and note the maximum gauge reading. NeaseNs Compression ea (kgtlen® psi) rpm Standard 1344 (197, 105) -900 Minimum 1010 (10:8, 146) 200 ‘Maximum dference between oyinders ——~—~S~idCSCSCSCS*~«R KP ZO eM, ZORI) (3) Check each cylinder as above. (4) If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. @ Ifthe compression increases, the piston, piston rings, or cylinder wall may be wom, @® Ifthe compression stays low, a valve may be stuck or improperly seated. @& If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 8. Remove the compression gauge. 9. Connect the distributor connectors. 10. Install the spark plugs. Tightening torque: 15—22 N-m { 1.5—2.3 kgf-m , 11—16 ftlbf } B1-7B1 TIMING BELT TIMING BELT PREPARATION SST 490011 102 For 49 GO17 5A0 For Prevention of support of ongine Lock tool, ‘rankshat Support, crankshaft rotation ‘engine 49G017 501 For 49 G017 502 For support of engine ‘support of ongine Bar ‘Support (Pan of (Part of 49 GO17 5A0) 49 GO17 5A0) 49.G017 503 For ‘support of engine Hook 2 = (Part of 49 GO17 5A0) REMOVAL / INSTALLATION Caution ‘= The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be dam- aged ea Remove the right front wheel. . Install the right front wheel. Nogsepe Start the engine and Disconnect the negative battery cable. Connect the negative battery cable. . Remove in the order shown in the figure, referring tfRemoval Note] Install in the reverse order of removal, referring tolInstallation Note. | (1) check the pulleys and the timing belt for runout and contact. (2) check the ignition timing. B1-8TIMING BELT B1 69-107m Tomassinibt) (ro-NoKgtem, Sieaeainiy (7e—107, ss-773) © {20110 kgtem, 70-98.4inibt 2 a (19-23, 14-16) (S0-Nokgtem ,70-95.4insbt) or Nm (gmt) 1. Splash shield (RH) 9. No.3 engine mount bracket 2. Drive belt (Renaal Not pa =a] [Adjustment page Bi= 3] Installation Note page B1=1: 3. Water pump pulley 10. Timing belt cover, middle 4. Crankshaft pulley 11. Timing belt cover, lower 5. High-tension lead 12. Pulley boss, timing belt 6. Cylinder head cover Removal Note page B1-10 installation Note page Bina E 7. Dipstick and pipe stay 13, Idler pulley 8. Timing belt cover, upper 14. Tensioner pulley, tensioner spring Installation Note page BI-t B1-9 ae GaBi CE ROTATION ARROW Lock BOLT B1-10 TIMING BELT Removal Note No.3 engine mount bracket 1. Support the engine by using the SST. 2. Remove the No.3 engine mount bracket. Pulley boss, timing belt Note * Mark the timing belt rotation on the belt for proper reinstallation. 1. By using the SST, remove the pulley lock bolt 2. Remove the pulley boss. Caution © The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it. 3. Loosen the tensioner pulley lock bolt. 4. Pull the tensioner pulley in the direction of the arrow to reduce tension of the timing belt, and remove the belt.TIMING BELT B1 Installation Note Tensioner pulley, tensioner spring Pa 1. Measure the tensioner spring free length. Ifnot within the Sly) |) “enero Free length: 71.0 mm { 2.80 in} 2. Install the tensioner and the tensioner spring. 3. Temporarily secure the tensioner with the spring fully extended. Pulley boss, timing belt MARK 2) — ZTIMING MARKS. 1. Verify that all timing marks are correctly aligned. 2. Install the timing belt on the pulleys in the order shown, below. @ Timing bett pulley @ No.2 idler pulley @) No.1 idler pulley @ Camshaft pulley ® Tensioner pulley 3. Install the pulley boss and pulley lock bolt. Turn the crankshaft clockwise 1 and 5/6 times, and verify that the timing mark on the timing belt pulley is aligned with tim- ing mark @ (tensioner set mark). PULLEY BOSS: Bi-11B1 TIMING BELT Lock Bor 4, Loosen the tensioner lock bolt to apply tension to the tim ing belt. Do not apply tension other than that of the ten- sioner spring. 5. Tighten the tensioner pulley lock bolt. Tightening torque: 38—51 Nem { 3.85.3 kgf-m , 28—38 ft-lbf} 6. Tum the crankshaft and 1/6 times clockwise, and verity that all timing marks are correctly aligned. Note ‘* The pin on the pulley boss and the “Z” mark on the camshaft pulley must face upward. 7. Check the belt deflection at the point indicated by epply- ing moderate pressure 98 N {10 kgf , 22 Ibf }. Deflection: 7.0—9.0 mm { 0.28—0.35 in} 8, Ifthe timing belt deflection is not correct, remove the tim- ing belt and repeat from step 1 9, Mount the SST on the pulley boss to hold the crankshaft. Tighten the lock bolt Tightening torqui 157—166 Nm { 16.0—17.0 kgf-m , 116—122 ftlbf } 10. Remove the SST. No.3 engine mount bracket 1. Install the No.3 engine mount bracket Tightening torque: @ 19-22 Nem { 1.92.3 kgf-m , 14—16 ftbt } @ 67—93 N-m { 6.8—9.5 kgf-m , 50—68 ft-bt } @ 75—104 Nem { 7.6—10.7 kgf-m , 55—77.3 ft-lbf } 2. Remove the SST (Support, engine).TIMING BELT B1 Cylinder head cover 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. install the new cylinder head cover gasket into the cylin- der head cover. Caution * Silicone sealant hardens and causes oil leakage when it is left for an extended period. Therefore, install parts before sealant hardens. 3. Apply silicone sealant to the shaded areas as shown. Thickness: @ 3—4 mm { 0.12—0.15 in } 4, Install the cylinder head cover and tighten the bolts in five or six steps in the order shown. Tightening torque: 6.9—10.7 N-m { 70—110 kaf-cm , 61—95.4 in-tbf } 5, Retighten the bolts in the order shown. Tightening torque: 6.9—10.7 Nm { 70—110 kgf-cm , 61—95.4 in-Ibf } B1-13B1 CYLINDER HEAD GASKET CYLINDER HEAD GASKET PREPARATION Sst 49.6017 SAO For 496017501 For support of engine Support of engine Support, Bar engine (Part 49 6017 5A0) 49.6017 502 For 49.6017 508 For {support of engine Support of engine Support Hook (anol (Part of 49 6017 5A0) 49.6017 5A0) REPLACEMENT Warning «Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. + Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” on! 1. Disconnect the negative battery cable 2. Drain the engine coolant.(Heler to secton ED] 3. Remove the timing belt. [Refer to page BT-8.)) 4, Remove the alr leaner and front 5. Remove the exhaust manifold.[(Refer to section F7.)] 6. Remove in the order shown in the figure, referring to[ Removal Note.) 7. Instal\in the reverse order of removal, referring tollnstallaion Note:] 8: Install the exhaust manifold 9. Install the front pipe and air cleaner.| pater secion FU 10. Install the timing belt. (Refer to page B1-8.) 11. Fill the radiator and radiator reservoir Fee oe a ‘specified amount and type of engine coolant. 12. Connect the negative battery cable. 13, Start the engine and (1) check the engine oil and engine coolant leakage. (2) check the ignition timing and idle speed. [Refer to section FT.)] 14, Check the compression. (Refer to page B1-7.)] Bi-14CYLINDER HEAD GASKET Bi na-M2Nm CHE Aas aghem 988125 not) ate? EN meen Ch eg eye AN % 13-42Nm Cis =tWs gem ,98.6—125n or) om (agen 81) 1. Accelerator cable 6. Camshaft [Agiusiment scion FT] [Removal Note = page BI=T6, 2. Throttle cable (ATX) lation Not age BI=17 Adjustment. ection K] 7. Cylinder head bolt 3. Distributor [Removal Note one page B16 4. Intake manifold stay 5. Camshaft pull 8. Cylinder head assembly [BamovalNote-—------.-DaGeBT=16] 9. Cylinder head gasket installation Note page B1=18, B1-15B1 CYLINDER HEAD GASKET q DISTRIBUTOR CAP. © cransnrt]@ D @ © PULLEY (OROMOMOMO} ‘SIDE B1-16 Removal Note Camshaft pulley 1. Temporarily install the No.3 engine mount bracket to support the engine. 2, Remove the SST (Support, engine), 3. Hold the camshaft by using a wrench on the cast hexa- gon as shown, and loosen the camshaft pulley lock bolt 4, Remove the camshaft pulley. Camshaft 1. Tum the camshaft clockwise so that cams do not press- ing on the tappets. 2. Loosen the front camshaft cap bolts in five or six steps in the order shown 3. Remove the front camshaft cap bolts and the front cam- shaft cap. 4. Loosen the camshatt cap bolts in five or six steps in the order shown. Remove the camshaft cap bolts and camshaft caps. Remove the camshaft Remove the camshaft oil seals Noo Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown. 2. Remove the cylinder head bolts.CYLINDER HEAD GASKET B1 cranksHart| @) @ ® crasunrr] ® ® OD ® © cee ®D®OOOw CHAIN ADJUSTER 205 m{ 0.1 in) Installation Note Cylinder head bol Before installation, measure the length of each bolt. Replace any that exceed the maximum length. Length: 99.2—99.8 mm { 3.91—3.92 in} Maximum: 100.5 mm {3.957 in } 2. Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 17.2—22.0 N-m {1,752.25 kgf-m , 12.7—16.2 ft-lbf } 3. Puta paint mark on each bolt head. 4. Using the marks as a reference, tighten the bolts by tum- ing each 85°—95° in the sequence shown. 5, Further tighten each bolt by turning another 85°—95° in the sequence shown. Camshaft 1. Before installation, insert the chain adjuster betweon camshafts. 2, Install the camshafts onto the cylinder head, aligning marks on the camshaft gear and the timing chain. 3. Apply silicone sealant to the shaded areas shown, Thickness: $1 mm {0.04 in} 4, Install the camshaft caps to the positions from which they were removed. B1-17‘CYLINDER HEAD GASKET 5. Hand tighten the camshatt cap bolts marked ©), @, @, and ®. 6. Tighten the camshaft cap bolts in five or six steps in the order shown, Tightening torque: 11.3—14.2 Nem {115-145 kgf-cm , 99.9125 in-Ibf } 7. Apply clean engine oil to the lip of the new camshaft oil seal. Paneer 8. Push the oil seal slightly in by hand. 9. Tap the oil seal in evenly by using a pipe and a hammer. HAMMER, “a PPE ‘CYLINDER HEAD Note * Oil seal outer diameter : 48.0 mm { 1.89 in} * Oil seal inner diameter : 34.2 mm { 1.35 in } er IN: 0—0.7 mm { 0—0.02 in } 1—1.7 mm { 0.04—0.06 in } OW SEAL Camshaft pulley 1. Align the “2” mark with the camshaft knock pin and install the camshaft pulley. 2. Hold the camshaft by using a wrench on the cast hexa- gon, and tighten the lock bolt. Tightening torque: ‘50—60 Nem { 5.0—6.2 kgf.-m , 37—44 ft-lbf } B1-18 3. Support the engine by using the SST. 4, Remove the No.3 engine mount bracket.FRONT OIL SEAL B1 FRONT OIL SEAL PREPARATION ‘ssT _ oe s980t400t For fnatatono tate ol into sal ‘2 HAMMER, REPLACEMENT 1. Disconnect the negative battery cabl 2, Remove the timing belt 3. Remove the timing belt pulley. 4, Remove the key. 5. Cut the oil seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. Apply clean engine oil to the new oil seal. Push the oil seal slightly in by hand. Tap the oil seal in evenly by using the SST and a ham- mer. O@N 10. Install the timing belt pulley, aligning the key groove. 11. Insert the key with the tapered side toward the oil pump body. 12. Install the timing belt [(Refer to page B1-8)] 13. Connect the negative battery cable. 14. Start the engine and check the ignition timing. B1-19B1 REAR OIL SEAL REAR OIL SEAL PREPARATION SST 49 oss 105 Installer, oll seal For installation of, installation of ‘ear il seal Installer, rear oil seal «il seal 49 G090 795 For 49 G030 797 Handle (Part of 49 GO30 795) For Installation of, rear ol soal Olt SEAL LIP RAG. B1-20 REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the transaxle assembly. 3. Rameve the duich gover and clutch disc (MTX) 4, Remove the Aye (MTX) or drive plate (ATX). [(Refer to section JIK)] 5. Cut the oil seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. ‘Apply clean engine oil to the new oil seal. Push the oil seal slightly in by hand. Tap the cil seal in evenly by using the SST and a ham- mer. 10. Install the flywheel (MTX) or drive plate (ATX). [{Refer to section J]K)) 11. Install the clutch disc and clutch cover (MTX). (Refer to section HJ] 12, Install the transaxle assembly. 13, Connect the negative battery cable. oonENGINE Bi ENGINE PREPARATION Sst 49 G017 5A0 For 49 G017 501 For support engine | ‘suppor of engine Support, 7 engine ~ (Part of 49 GO17 5A0) 49 G017 502 For 49.6017 503 For support of engine ‘support of engine ‘Support Hook: (Part of (Part of 49 GO17 5A0) 49 O17 5A0) REMOVAL / INSTALLATION Procedure Warnin: 2 Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” ot + Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Caution © Cover the fuel hoses with a rag because fuel will spray out when disconnected. Note * Plug the disconnected fuel hoses to prevent fuel leakage. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the hood and front wheels. 4. Drain the transaxle oi {(Refer to section JK] 5, Remove the radiator. 6. Remove the three way catalytic converter and front pipe.((Refer to section FT.]] 7. Remove the exhaust manifold {(efer to section F')] 8, Remove in the order shown in the figure, referring tol Removal 9. Install in the reverse order of removal, referring tolinstallation Note.] 10. Install the exhaust manifold, 11. Install the front pipe and three way catalytic converter. {Haferto section FT] 12. install the radiator [(Refer to section E.)] 18. Fill the transaxle with the specified amount and type of transaxle oil (Refer to section JIK] 14. Install the hood and front wheels. 15. Fill the radiator and radiator reservoir with the specified amount and type of engine coolant. (Refer to section E)] 16. Connect the negative battery cable. 17. Start the engine and (1) check the engine oil, transaxle oil, and engine coolant leakage. {2) check the ignition timing and idle speed {(Fefer to section F1,) 18. Tum off the engine and check the drive belt deflection. [Refer fo p: 19. Perform a road test. 20. Recheck the engine oil, transaxle oil, and engine coolant levels. B1-21B1 ENGINE Step 1 75-107 Wm (ao—tiakgtem, jovasainty 20-S8Nm (Somsolgtem . saint) 79107 ¥m (soto kgrem, 6s-S20Nm (7o—100Kgrem, Simeeniniiy Nem (gn 01) 1. Air cleaner 9. Throttle cable (ATX) 2. Battery clamp A = 3. Battery 10. Splash shield 4. Battery carrier 11. Drive belt 5. Radiator reservoir Adjusiment a page BT 6. Battery duct, bracket 12. AC compressor (if equipped) 7. Resonance chamber No.2 8. Accelerator cable 13. P/S oil pump [Adjustment ~ section F1] [Removal Note... below] Removal Note AIC compressor (if equipped) 1. Remove the A/C compressor with the hoses still connected (Refer to section U, 2. Position the compressor away from the engine and affix it with wire. PIS oil pump 1. Remove the P/S oil pump with the hoses still connected. 2. Position the pump away from the ongine and affix it with wire B1-22ENGINE B1 Step 2 3851 (38-53,28-38) rema(1s23,2-16) 280%m 70100 kgf om, Saat) 19-25(19-26 14-18} se60(44-62, 52-48) sa 55(44-60,92-43) So Gs se(ess0,s1) Nov (agen 181) Control rod (MTX) Extension bar (MTX) Selector cable (ATX) Clutch release oylinder (MTX) pepe EF IZ 8. Drive shaft Lin Stabilizer control link 9Bi Step 3 ENGINE 75104 (74-107 65-773) (30-53, 20-98) 6700 (68-0.7,60-65) 351 (38-62, 28-20) 7 ATX ay (88-85, 50-60) Non (kgm ft) 4. No.4 engine mount bracket 1. No.1 engine mount bracket Removal Note _. page B1=25 Removal Note page Bi Installation Note. page B1-27 Installation Note ............ page Bt 5. No.3 engine mount bracket 2. Engine mount member Removal Note age BI=27 Removal Note installation Note Installation Note 3. No.2 engine mount bracket 6. Engine and transaxi Removal Note _. page B1-25 jemoval Note... mo page B1-26 Installation Note Installation Note B1-24ENGINE B1 wrx AIX Removal Note No.1 engine mount bracket 4. Support the engine by using the SST. 2. Remove the No.1 engine mount bracket. Engine mount member 1, Remove the No.2 engine mount nuts @). 2. Remove the engine mount member bolts and nuts. 3. Remove the engine mount member. No.2 engine mount bracket 1. Remove the No.2 engine mount bracket batts ®) 2. Remove the No.2 engine mount bracket. No.4 engine mount bracket 1. Remove the engine and transaxle assemoly from the SST (Support, engine) and securely support it with the chain block, 2. Remove the No.4 engine mount bracket bolts and nuts, marked ©. 3. Remove the No.4 engine mount bracket. No.3 engine mount bracket Remove the No.3 engine mount bracket nuts. B1-25B1 ENGINE En e and transaxle assembly Slowly lift up the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into ‘components in the engine compartment. Installation Note Engine and transaxle assembly Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into components in the engine compartment. No.3 engine mount bracket Hand tighten No.3 engine mount bracket nuts (1). No.4 engine mount bracket 1. Hand tighten No.4 engine mount bracket bolts and nuts @. @. 2. Hand tighten No.4 engine mount bracket nuts @). No.2 engine mount bracket MTX ATX Install No.2 engine mount bracket. 38—51 N-m {3.85.3 kgf-m , 28-38 ft.lbf } B1-26ENGINE B1 Engine mount member 1. Install the engine mount member. Tightening torque: 67—89 N.m { 6.8—9.1 kgf-m , 50—65 ft-Ibf } 2, Hand tighten No.2 engine mount nuts @). No.1 engine mount bracket 1. Tighten No.1 engine mount bracket bolts ©), ®. Tightening torque ©): 64—89 N-m { 6.5—9.1 kgf-m , 48—65 ftbf } ©: 67-93 Nm { 6.8—9.5 kgt-m , 50—68 ft-Ibf } 2. Remove the chain block. 3, Tighten the engine mount bolts and nuts as follows. (1) No.2 engine mount. Tightening torque @: 38—51 Nem (3.85.3 kgf-m , 28—38 ft-lbf } (2) No.3 engine mount bracket. Tightening torque (D: 75—104 Nem { 7.6—10.7 kgf-m , 55—77.3 ft-lbf } (3) No.4 engine mount bracket. Tightening torque @: 44—60 N-m { 4.46.2 kgf-m , 32—44 ftlbf } @: 67—93 N-m { 6.8—9.5 kgf-m , 50—68 ftlbf } B1-27B1 ENGINE DISASSEMBLY / ASSEMBLY . Disconnect the engine and transaxle. [(Refer to section JIK.)] . Remove the clutch cover and clutch disc (MTX).|(Refer to section H.)) . Remove the intake-air system and crankshaft position sensor. Disassemble in the order shown in the figure. ‘Assemble in the reverse order of disassembly. . Install the intake-air system and crankshaft position sensor. . Install the clutch disc and clutch cover (MT). [Refer to section H.)] }. Connect the engine and transaxle. (Refer to section JJK.)] PNOMaEDS aw (218,713) sone {85119 69-050) —— (32552, 20-30) 1925 (1826, 14¢18) Nm {kgm bt) 1. Water bypass pipe 2. Water inlet pipe 3. AIC compressor bracket (if equipped) 7. No.3 engine mount 4. Oil fitter 8. Distributor 5. Oil pressure switch B1-28B2 jing any service procedure, refer to section T1 of this manual for air bag system service warnings. ENGINE (BP)B2 DRIVE BELT inspection of ‘ive belt tension DRIVE BELT PREPARATION SST 49.9200 020A For Tension ‘gauge, belt GENERATOR WATER PUMP PULLEY GENERATOR PULLEY CRANK SHAFT 4 PULLEY (CRANKSHAFT PULLEY B2-2 INSPECTION / ADJUSTMENT Inspection 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. ‘Apply moderate pressure 98 N{ 10 kaf , 22 Ibf } midway between the specified pulleys. Deflection mm (in} Drive belt "New Used Limit fees 55-70 | 60-75 | 60 {0.22027} | (024-029) | (031) 60-90 | 90-100 | 115 oe {0.32035} | (0.36038) | (045) “Abelt that has been on a running engine for less than five minutes 2. If the deflection is not within the specification, adjust it. Refer to page B2-3. Drive belt tension check 1, Belt tension can be checked in place of belt deflection ‘Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two puleys. Tension N {kgf, bf} Drive oa "New Used Limit Gees |e 00700) ‘500700 340 {50-76 , 110—160} | (50-72, 110150} |{ 95,77), PS, 500—880 +420—400 250 prs+ ac |{50—60, 110—130} | (49-50, 95—110) | 125,55) “Abelt that has been on a running engine for less than five minutes. 2. Ifthe tension is not within the specification, adjust it. (Refer tGENERATOR PULLEY ure PULLEY 7”pI8 OL PUMP. PULLEY PISOIL PUMP. PULLEY ® AIC COMPRESSOR PULLEY DRIVE BELT B2 Adjustment Generator drive belt 1. Loosen bolts ® and ®). 2. Adjust the belt deflection by turning adjusting bolt ©) Pee | Deflection (At 98 N { 10 kgf , 22 Ibf }) New : 5.5—7.0 mm { 0.20.27 in} Used: 6.0—7.5 mm { 0.24—0.29 in } 3. Tighten bolts ® and ®. Tightening torque @: 3851 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } ©: 19-25 Nem { 1.92.6 kgf-m , 14—18 ft-ibf } PIS, PIS + AIC drive belt 1. Loosen the bolts and nuts marked ®, @ and ©) 2. Adjust the belt deflection by turning adjusting bolt ©) Deflection (At 98 N { 10 kof , 22 Ibf }) New: 8.0—9.0 mm { 0.32—0.35 in } Used: 9.0—10.0 mm { 0.36—0.39 in } 3, Tighten the bolts and nuts marked @), ® end ©. Tightening torque @): 44-60 Nem { 4.46.2 kgf-m , 32—44 ftlbf } ©: 38-51 Nem {3.8—5.3 kgf-m , 28—38 ft-lbf } ©: 38-51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } B2-3B2 COMPRESSION COMPRESSION INSPECTION Warm up the engine to the normal operating temperature. Stop the engine and allow ito cool for about 10 minutes. Remove the spark plugs. Disconnect the distributor connectors. Connect a compression gauge into the No.1 spark plug hole. Measure compression in the following procedure. Negsens Verify that the battery is fully charged. Recharge it if necessary. (1) Fully depress the accelerator pedal or fully open the throttle valve, (2) Crank the engine and note the maximum gauge reading. ‘Compression kPa { kgtlem?, psi }-rpm Standard 1275 (180, 185}-200 Minimum 961 (98, 180)-300 Maximum diference between cylinders 196 kPa (2.0 katlom?, 28 psi) (8) Check each cylinder as above. (4) If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the ‘oylinder and recheck the compression @ Ifthe compression increases, the piston, piston rings, or cylinder wall may be worn. @ If the compression stays low, a valve may be stuck or improperly seated, If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 8. Disconnect the compression gauge. 9. Connect the distributor connectors. 10. Install the spark plugs. Tightening torque: 15—22 N-m { 1.5—2.3 kgf-m , 11—16 ft-lbf } B24TIMING BELT B2 TIMING BELT PREPARATION — ca 49 0011 102 For 49.6017 5A0 For prevention of Supsot of engine Lock too, Grankshatt Support, crankshalt Ge ‘otation cngme 49.6017 501 For 49 G17 502 For Suppor of engine Support of engine bar Support (Part of @arot 0.6017 5A0) {9.6017 5a0) 49.6017 503 For Suppor of engine Hook . (Part ot 49 GO17 5A0) REMOVAL / INSTALLATION Caution + The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be dam- aged easily. B25B2 TIMING BELT Disconnect the negative battery cable. Remove the right front wheel. Remove in the order shown in the figure, referring td Removal Note. Install in the reverse order of removal, referring tc Install the right front wheel. Connect the negative battery cable. Start the engine and (1) check the pulleys and the belt for runout and contact. (2) check the ignition timing. (Refer to section F2.) Novseps {020 Kgten, se 7ainibn) (soto agtem Soresainbt) 73-107 Nm {e010 kgtem, 719-107 D {0110 kgtem, 70-95.) 187166 160—17.0, 116122), 123-174 (1254175,905-126) Nem (gn 061) B2-6TIMING BELT B2 1. Splash shield (RH) 9. No.3 engine mount bracket 2. Drive belt Sorc): ee Unstallation Note _............page B2-10] 3. Water pump pulley 10. Timing belt cover, middle 4. Crankshaft pulley 11. Timing belt cover, lower Ell 5, High-tonsion lead 12, Pulley boss, timing belt 6. Cylinder head cover (Homoval Noie <= ESTO] tallation Note... ~page B2-10) age Bo 7. Dipstick and pipe stay 13. Idler pulley 8, Timing belt cover, upper 14 Tensioner pully, tensioner spring Removal Note No.3 engine mount bracket 1. Support the engine by using the SST. 2. Remove the No.3 engine mount bracket. Pulley boss, timing belt Note + Mark the timing belt rotation on the belt for proper reinstallation, 1. By using the SST, remove the pulley lock bolt. 2. Remove the pulley boss. Caution The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it. 25 mm (4.01) MIN B2-7