1995 Mazda MX-3 Workshop Manual 1994. Mazda Moto tor Corporation * Pr INTED IN USA AUG "6 PRET NO. , 9996-96-0080-95WARNING Servicing a vehicle can be dangerous. you have not veceived service- felted aling he rsks of fury ancl property damage noresae, The recommended servicing procedures for the veriole in this workshop ‘manual ware developed with Mazda-trained techricians in mind, This, manual may be useful to noreMazda trained technicians, but a techni- lan with our service elated vralning ang experience will bat less risk ‘when performing servicing operations, However, all users of his manu= al are expected to know general safety procedures, ‘This manual contains "Warnings" end "Cautions" applicable torisks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk thal improper sarvico oF repair may damage the vehio'a or render itansale, ILis 2180 importamtto understand that the “Warnings” and "Cautions? aré nat ex- bhaustive, itis impossible to warn of all the hazardous consequences ‘hat might result from failure to follow the procedures. ‘The procedures recommenced and described in this manual are effec- ‘ive mothods of performing service and repair. Some raquire tools specifically designed for a specific purpose. Nonvecarrmended prace- dures and tools should include consideration for safety of the techni- cian and continued safe operation of the vehicle. Parts should be replaced with genuine Mazda replacement parts, not aris of lesser qualily. Uso of a rionrecommended replacemant part Should inolude consideration far safely of the technician and continued safe operation of the vehicle,1995 Mazda MX-3 Workshop Manual General information Pre-Delivery inspection and Scheduled Maintenance Engine Bg DOHC Lubrication System Cooling System Fuel and Emission Control Systems: FOREWORD For proper repair and maintenance, a thor- ‘ough familiarization with this manual Ig im- portant, and it should always be kept ina handy place for quick and easy reference. All the contents of this manual, including Grawings and specications, ar the latest available at the time of printing. As modifica- tions affecting repair or maintenance occur, relevant information supplementary to this volume wil be made available at Mazda daalers. This manual should be kept up-to- date. K8 DOHC Engine Electrical System Clutch Manual ‘Transaxle ‘Automatic Transaxle G25M-R Electronically Controlled Mazda Motor Corporation raserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this boo may be reproduced of used In any form or by any means, olectronis ar machanical—in- cluding photocopying anc recording and the use of any kind ofinformation slorage and re- trieval system—without permission in writ- ing. WARRANTY The manufacturer's warranty on Mazda vehicles and engines can be voided if im- Proper service or repairs are performed by Persons other than those at an Authorized Mazda Dealer. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vahiclas begin- ning with the Vehicle Identification Numbers (VIN) shown en the following page. Front and Rear Axles Steering System “Body Electrical System “Heater and Alr Conditioner Systoms Technical Data Special Tools wiring Diagram Form No. 5330-10-94G Part No, 9999-95-034G-85 2% Refer to the 1995 MX-3 Body Electr Troubleshooting Manual {Form No, 1474=10-94H, Part No. 9999-95-086F-95} for servicing of the body electrical components. ‘© 1994 Mazda Motor Corporation PRINTED IN THE U.S.A AUG, 94 Form No. 1472~10-944 Part No. 9999-98-0565-95VEHICLE IDENTIFICATION NUMBERS (VIN) JM EC433 + SO. 400001 — JM EC434 « $0 400001 —PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE PRE-DELIVERY INSPECTIGN .. PRE-OELIVERY INSPECTION SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE DA)A PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE ‘The following items may be done at any time prior fo delivery to your customer. EXTERIOR, INSPECT and ADJUST, if necessary, the following tems, to spacitication: 1 Glass, exterlor bright metal, and paint for damage 1 Wheel lug nuts and locks ( equiopec} 89-117 Nem (9-12 kgf, 60-86 feibi} © All weatherstrips for damage or detachment 1D Operation of hoad release and lock 1D Operation of rear hatch, and fue! id opener With irunk open, check for spare jack, tr, toots, and fasteners securing these ilems in place. 1D Sliding sunroof (it equiped) © Power door lock (if equipped) 10 Power outside mirrors (i equipped) 1 Power windows {if equipped) 0 Heater, detroster, and air conditioner at various mode selections (if ecuipped) CHECK the Toflowing items: U Presence of speré fuss Upholstery and interior finish _ CHECK and ADJUST, if necessary, the following items: 1 Pedal hoight and trae play of brake and clutch pedal © Door operation and alignment esate img ee iy mm 1 Heaiight aim T9-204:7. 858.65) INSTALL the following parts: hutch pedal ‘vein carpet S018 063 1 Wheel caps of rings (it equioped) Bakopeta | 195-100 i760-77) | a7 (Ote-0H) UNDER HOOD-ENGINE OFF © Paving brake INSPECT and ADJUST.if necessary thefollowingitems _5-/ natchesAVBN {10 kot, 22 lot} te specincation: anes. UNDER HOOD-ENGINE RUNNING AT 1 Feel, cootant and hydraufetines, tings, connections, Sdoonnanents faeleaes OPERATING TEMPERATURE. 1D Engine oll level CHECK the folowing items: 1D Power staering fuid level U Autornatc transaxte id eve G Braks and clutch master cylinder fd tevel 10 Windshield washer reservolt Fuld level ONHOIST © Radiator coolant level CHECK tho folowing Rome: U Tigntness of battery terminals 1G Manual transaxle oll level INTERIOR: INSTALL the following parts: 1D Rubyer stopper for rearview mirror CHECK operation of the following iter: 1 Seat contro's {slide and recline) and headrests 1 Folding rear seat 1B Doer tacks: 1 Seat betts and warning system 1 Ignition switch and steoring lock © Transaxle range sulich {ATX only) O Starter interlock switch (clutch pedal, MTX only) All ights, including waming and indicator igits 1B Sound warning system 5 Hom, wipers, and washers (front and rear, ¥ equipped} 1D Audio system {if equipped) 1D Cigarette lighter and clack 15 Underside fuel, coclant and hydraulic lines, fitings, connections, ard components for leaks Gi Tites for cuts or bruises 1 Steering tinkage, suspension, exnaust system, andall undarside hardware for looseness or damage ROAD TEST, CHECK the following items: 1 Brake operation a ‘operation © Steoriag zontrol 5 Operation of gauges 1 Squeaks rates or unusual noes 1 Emergency iocking retractors, 1 Cruise control system (F equipped) ‘AFTER ROAD TEST CHECK for owner information materials. ‘The following items must be done just before dolivery to your customer. Load test battery and charge if necessary Zl G Adjust tite pressure to specification Gattexrent (Refer to door label} 1 Glean outside of vehicle Az Install fusas far accessories U Rerrove seat and cabin caret protective covers Vacuum and clean interior of vehicle 1 Inspect installation of optional parts:SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) Schedule 1 (Normal driving conditions) ‘The vehicie is mainly operated where none of the “unique driving conditions” apply. Schedule 2 (Unique driving conditions) © Repeated shori-disiance criving. * 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 idiing or low-speed operation. '* Driving for tong prolonges periods in cold temperatures or extremely humid climates. A3A SCHEDULED MAINTENANCE Schedule 4 (Normal driving conditions) atntonaros Number of manthe ar milea Wlomotany, wilchover somes fret Interval onthe [2 | « [= | 0 | o | «2 [ae sooo Kiometos | 1 | a [m0 | a | oo | me | a | 6 Maintenance om nas wows | 75 {13 | 25 | 20 [srs | os | es | 60 Engine Freire od - pF Te [es >a] | AA Otte: a |e [ep a la | aiata “Toneion of al eve BOBS 1 v Engwe tring bot op avery 6000 ils (98,000) Inept at 60.00 re (66000 on as Engine timing bat (Calfoia) gale at 90/00 rifles (C00 kn“ pions every 105200 ios (168,000 kn ‘Hose and ube fer emieion T ve Air cleaner ‘Ai lear lear a1 es ee Ignition system ‘Spark pga z A Fuel system 1a ar003 2 Fat ter Fuel knes and hoses ta Fusi hoses (Cellos) ingpec very 105,000 fs {768,000 4 Cooling system eta sytem iT 7 Ergie coolant at a Chassis and body rts Bren, hese, and connacions Brian brakes Disc brakes t t v ‘Sleering aperalon andineanee. v front suspension ball flnts U Drs sre cust baat L t t L Rov anchaits on crass ane bey Exhaust yarn eal nee Aloo and Fiages cpa er Air conditioner system (if equipped) Fotgrontamaure 1 T NG compressor operate 1 H f 1 Chart symbols: Inspect and repair, clean, or replace if necessary. R: Replace L: Lubricate Remarks: After 48 montis or 60,000 miles (96,000km}, continue to follow the described maintenance atthe recom- mended intervals. “1 This maintenance is required tor all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintonanco is rocommenciod by Mazda. However, itis not necessary for emission warranty coverage or manufacturer recall lability. A4SCHEDULED MAINTENANCE Schedule 2 (Unique conditions) Maintonance Tumber of onthe or Tales (elomeler), waichever Comes Mat tmtervel Wonihe ele «]o[a|mlelslelale ereee STS se [ae [oe [ao [foo] oo 2 | | os | we Mamtenance tem les 10 [as [20 [as Teo fos [0] 8 | oo | os Lo Engine Engine atalTaTayel@[alayalela Fngine ol (Puan Ris) Replace ore 9.000 nies 100m ord monte Oe aATeilayr[rl[ayalalalala Teasion a arva be 2 \ Ens ning bok Replace ey SRO es 65 G00 Trapeet a 69000 ies 85200 fo) an Engine tring bet (Calor saa at 90,000 ries {t= 00m Replace every 19,060 mies (158.000 Haro ard tbe fr emition = Air cleaner Leicceaner stemeat I 1 = a Ignition system Searcoes a ITT Fuel system Tale spose) Fost iter Fuct ines andes Fuat noses (Cater) Cooling system = ‘Coning S187 Endine coolant Chassis and body (Brave ins, hoses, and connectors Bombrakes Dive brakes ‘Steering oporetion and RRQ Front. eugpention bal joints (Drive Shafi dust boas Bots and nuts. on chassis and boa Exhaust syetern neat svokts ‘itbocke and hinges Air conditioner system (if equipped) Retigerartarount AIG comcreesor operation Chart symbole: T: Inspect and repair, clean, or replace if necessary. (inspect, and ifmecessary replace---Air cleaner element only) R: Replace Remarks: ‘After 48 months or 60,000 miles {96,000 kr}, continue to follow the described maintonance atthe recom- mended intervals. “1. This maintenance is required for all states except California, However, we recommend thatitalso be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, il Is not necassary for emission warranty coverage or manufacturer recall lability. ASA SCHEDULED MAINTENANCE ‘SCHEDULED MAINTENANCE TABLE (CANADA) ‘Humber of months OF miles (KIOTI¢ter), whichever comes Arst ‘Waimtenaneo ‘terval ‘Montho 5 [10 20 | 25 | 20 [48 1,000 Malntonance Hem 1s Kuemoters |e | 76 | o | 32 | 40 | we 6 % | ia |e|a| la |e] Milos | 3 | 10 20 | 25 [a0 [as Engine Engine of ‘Gi or “Tension of all crive bets Engine ling ett ‘cleaner Fireeaner element Ignition system Cooling system ‘Spak ghar 5 Enghe ecclart ovo! and etangih {Gooing system fortnaks Engine coolant Fuel system Ide pest Fuelinse and hoees Fuetarer POV wane Enso howes and bes Chassis and body ‘Automat Wanearis Fuld level Transeote oi @ANX and ATH) ‘rive shaft cust boats Brake tines and hoses Brake and circ tc ovat Broke fuid Divo brakes (Fort and ear) Rear drum brakes “Teg ilaon prewsure and Bre wear Tues Powor stoaing fudiovel ‘Steering operation ard inkage includes fou wheel alignment Front ard rear euaoeneian components ‘Altohaseis ang body nits and bole Eehaustsystern host shields Alllocks andinges ‘Wash fu Hoval ~|~|-|-|-|-] - (-|el-]-]-]al-[-/-[2]-] Funetin ofa lights Alr conditioner system (if equipped) Raivigarant amount ‘AIC cornpressex operation ASCHEDULED MAINTENANCE A Chart symbols: 1 inspect and repair, clean, or roplace if necessary, (Inspect, and if necessary replace.....Air cleaner element only} F: Replace L: Luoricate Rt: Rotation (tires) Remarks: ‘After 60 months or 60,000 miles {98,000 kia}, continue to follow the described maintenance at the recom- a mended intervals, “1 Replacement of the timing beltis required every 60,000 miles (28,000 km}. Fallure to replace this belt may result in damage to tie engine. *2 This maintenance is recommenced by Mazda. However, it is not necessary for emission warranty coveraga or manufacturer recall ability. “8 This maintenance is recommended by Mazda. ATBefore beginning any service procedu joting Mant B2 refer to the 1995 MX-3 see section § for ai TROUBLESHOOTING ENGINE TUNE-UP PREPARATION ENGINE OIL. ENGINE COOLANT DRIVE BELT . HLA TROUBLESHOOTING GUIDE. IGNITION TIMING, IDLE SPEED COMPRESSION PREPARATION INSPECTION . ON-VEHICLE MAI PREPARATION . TIMING BELT. CYLINDER HEAD GASKET FRONT OIL SEAL . REAR OIL SEAL, REMOVAL ... PROCEDURE, ENGINE STAND MOUNTING . PREPARATION PROCEDURE DISASSEMBLY . PREPARATION . AUXILIARY PARTS TIMING BELT... CYLINDER HEAD . CYLINDER BLOCK (EXTERNAL PARTS) «22. .0000+ CYLINDER BLOCK (INFERNAL PARTS) «0... .--eeeee ENGINE (K8) B2- B2- B2- Bl B2- B2- B2- B2- B2- B2- Ba B2. 40 B2- 10 B2- 10 Oe GAAADBOEN + BR it + Ba 11 - B2- 13 : B2 23 B2- 37 B2- 40 + B2~ 42 + B2- 44 + B2- 4d + B2- 62 + B2- 52 - B2- 63 + B2- 66 B2- 56 + B2~ 58 + B2- 60 + B2~ 62 INSPECTION / REPAIR PREPARATION . GYLINDER HEAD . VALVE MECHANIS! CAMSHAFT HLA .. CYLINDER BLOCK PISTON, PISTON RING, AND PISTON PIN. CONNECTING ROD CRANKSHAFT - BEARING . OILJET. TIMING BELT TIMING BELT TENSIONER, IDLER PULLEY .. TIMING BEL ASSEMBLY ... PREPARATION CYLINDER BLOCK (INTERNAL PARTS) . CYLINDER BLOCK (EXTERNAL PARTS) CYLINDER HEAD TIMING BELT. AUXILIARY PARTS ENGINE STAND DISMOl PROCEDURE . INSTALLATION PROCEDURE « B2-116 B26 B2-117 B27B2 INDEX INDEX INTAKE MABIFOLD ENING TOR COMPRESS ON INSPECTION, PABE_92-10 Teese m2 Seg STANDARD: 1998 KPa (‘O.glom?, 199 pa) 200 rpm 14-18 felt " MINIMUM: S87HPa (10.0 kagllom®, 142 pel)-$00 rpms ENGINE OIL INSPECTION’ SEAMIGE SECTION D2 pxnwwsrienaroun cereece ar Sgt 2) emi ENGST ES resem DRIVE BELT NEW USED LMT. GENERATOR |6.0-7.0024-027 { 7.0-3.0(.28-031}] 9,010.95) COMPRESSION. kPa {kgtiem?, pal}-rpm | [GENERATOR + AC /5.5-6.5 10.22-0.25 6.5-7.5 {0.26-0.29}] 8.04032}, STANDARD. 1,334 113.6, 193}-300 Ps [8.0-7.0 {0.24-0.273 7.0-8.0 {028-0.31}] 9.0 {0.35} SIRUIRAU 981 {10.0, 142} 4. Timing bolt 5. Rear oll seal Removal / Inspection / Replacement ... Installation -- pageB2-13 6, Engine 2. Cylinder head gasket Removal ............. 0 B2- 44 Replacement ......--.2. 20+ Engine stand mounting page 82- 52 3. HLA my... page B2- 56 Removal Installation .. Inspection ? Repair 4, Front oil seal Assembly Replacement ......-- Engine stand dismounting ... page B2-118 lnsiallation .. . B2-2OUTLINE ‘SPECIFICATIONS: OUTLINE, TROUBLESHOOTING GUIDE B2 Her Engine Ks DOHC Typo Gasctine, Faye ‘Gyno arangoroat and number GOV coniguaton, 6 ofiaders ‘Combustion chember Pentoot Valve system DOHC betven, Saves Displacement 0, cup Bae (804, 1924) Bere etre tom Gf 76 x 606 246 x 2.78) Compression alo a2 Compression pressure Pa feel irom 1384 (8.6, 165800 tN Span En e Close ‘ABDC ar ‘eotning Open e800 a tone arwe = 1N wa fe) Of} Maintenance bes Nae doarance & mann 0 (OF: atrtenance-ea Fimgerder 126-6 Cylinder Arrangement =H uk TROUBLESHOOTING GUIDE Problem Pasaible Cause: Action Page Dificult starting Malfuncion of engine-related components Burned valve Replace eos ern piston, piston rng, or oyinder Ropace orrenar | Boao Dameted oyinder head geskel place Boos Weattunetion of fue! system Fete to weston Fa Maitunetion of electrical system RelertosactonG Pooridling Mattunotion of enginerelated components Matfuncdon of HLA Retace 22-37 Pct valvevo-talve seat contact, Repairorvepiace | 22/6 Daaraged ayindoc hod gesket Replace Maifunetion of tue! systerm ofer to soclon F2 “Tappet noise may occur the engine tras not been started for an extended period of me. Tre noise should ston ater the engine reaches noimal operating temperature. (HLA troubleshooting: Refer le page B2~2.) B2-3B2 TROUBLESHOOTING GUIDE Problem Possible Cause ‘Action: Page Insufficient power fneutfiolent comprossion Molfunction of HLA Replace 82-37 Compression leakage from valve seat Repair 8-78 Stuck vaive Replace Ba-74 Weak or broken vaive spring Replace B77 Damaged cylinder head gasket Replace 82-25 Grackéd er cistorted oyinder head Replace B73 Stuck, damaged, or wern piston ring Replace 2-82 Cracked er worn pision Reeplaoe B82 Malfunction of fuel system Refer to section F2 ‘Others Dragging brake Refer to section F Wrong size tires Rotor o scction @ ‘Abnormal combustion | Malfunction of engine-related components Malfunction of HLA Reclace 6237 ‘Stuck or burned vaive Replace Bars Weak or brekn voive spring Replace BGT Carbon zocumulation in combustion chamber Eliminate caroon Malfunction of fuel system Rotor to section FO Excessive oll ‘Oil working wp ‘consumption ‘Worn piston ring groove or stuck piston ring Revlace 2B Worn piston of cylinder Replace o repair | B2-81,82 Oil working down Worn valve seal Ropizce 82-06 |Wemn valve stem or guide Roplcoo 62-76 ‘Olleakage Refer to section D2 Engine noise ‘Crankshaft or bearing-related parte Excussive main bearing ol loarancs Replace or repair B29 Main bearing hoatdamaged Replace Be 84 Excessive crankshaft end play Replace or repair 2-99 Excessive connecting 100 beating cil dearance Replace or repair eas Gonnecting red hearing heat-damaged Replace Bead Piston-rolatod parts Worn ojinder Replace oF repair e281 ‘Wom piston or piston pin Replace 2-82.83 Damaged piston ring Replace 82-62 Bent conrecting rod Replace 52-83 Valve train-retated parts Moifunesion of HLAY Replace B80 Broken valve spring Replace B77 Exaoosive valve guile oloeranoe Replace RO75 ‘Malfunction of timing belt auto tensioner Replace 52-25 Maltunction of trction gear Replace 8276 ‘Maifunction of cooting system efor io sostion ED Malfunction of fuel system eter 70 section F2 Others Malfunction of water pump bearing Replace — Improper ets belt tension Adjust B25 Maltunction of ganarator bearing Replace Exhaust gas leakage Repair = “Tappet noise may ooauritthe angine hes nathean startad iran evlended peri oftime. The nse should slop afar the engin reaoans ronmel operating emperate. (HLA taubseshooting: Re‘erto page E28) Warning * Continuous exposure with USED engine oll has caused skin cancer in laboratory mica. Protect your skin by washing with soap and water immediately after this work. B24ENGINE TUNE-UP B2 ENGINE TUNE-UP PREPARATION Sst 49.9200 0298 For 49 B019 940 For inspection of inspection of ‘ribbed belt drive belt tension | System selector ignition timing tension gauge and ide speed ENGINE OIL Inspection 1, Be sure the vehicle is on Isve! ground. 2, Warm up the engine te normal operating temperature and atop it, 8. Wait fer five minutes. 4, Remove the dipstick and check the oll level and condition. 5. Add or replace oil if necessary. 4 Note © Thedistanca batween tha Land F marks on the dipstick represents 1.0L (1.1 US at, 0.9 Imp qt}. ENGINE COOLANT Inspection Coolant level (engine cold) Warning © Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scaiding coolantand steam can shoot out and cause serious injury. It can also damage the engine and cooling system. ‘Turn off the engine and wait until It is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly tum it counter- clockwise to the first stop. Stop back while the Pressure escapes. When you're sure all the pressure Is gone, press down on the cap —still using a cloth —turn it, and remove it. 1. Verify that the coolant level is near the filler nec. 2. Verify that the coolant level in the coolant reservoir is be~ tween the FULL and LOW marks. 8. Add coolant i necessary. B2-5ENGINE TUNE-UP- doga! laanal Wrage x oO x [GENERATOR GENERATOR Coolant quality 1 Verity that there is no buildup of rust or soate around the radiator cap, fillar cap, or filler neck. 2, Verify that tha coolants free of cil. 3. Replace the coolant if necessary. DRIVE BELT Inspection 1. Cheok the crive belts for wear, cracks, and fraying. Replace if necessary, 2. Verify thatthe drive bells are correctly mounted on the pul leys, 8. Check the drive belt deflection when the engine is cold, or at ieasi 30 minules after the engine has stopped. Apply moderate pressure 98 N{ 10kgf, 22 Ibf} midway between DAS PULLEY the specified pulleys. Defleotion rman) Driva bolt New" Used Limit 30-79 70-80 $0 CRAMKSHAPT Generator | yozeozn | @2e051) (0.35) PULLEY Generator + 55-65 65-75 8.0 NG 22025) | 202) | 034 [GENERATOR PS 6070 7.086 30 wae GENERATOR pron | 2003n | oa9 RIVE PULLEY ©) CRANKSHAFT PULLEY. * A bet that has been cn a runing engine for less than five minutes. 4. Ifthe deflection is not within the specification, adjust it (Refer to page 22-7.)ENGINE TUNE-UP B2 Drive belt tension check Belt tension can be checked in place of belt deflection. 41. Check the drive be'! tension whan the engine Is cold, or at Jeast 30 minutes ater tne engine has stopped. Using the SST, check the belt tension between any two pulleys, ‘Tension IN af, tp Drive bert New" sed ‘Gimit Generator ‘peo, oo, rN ene 0, 8 180-196) ¥ig-180) ca Generator =| 90-600 500-860 40 AC {70-0,160-109) | 0-70,170-159} | £45.89) PS ‘540-860 90-660 340 195-70.196-150} | (40-65.90-120) | _ (35.7 ‘TBST nat has baer on a running ergine for less than Fve minutes, 2, | the tension is not within the spectfication, adjust it, (Refer to below) Adjustment Generator + A/C, Generator 1. Loosen idler pulley locknut @. 2, Adjust the belt deflection by turning adjusting bolt ®. Deflection (Generator + A/G) New : 6.5-8.5mm {0.22-0.25 in} Used: 6.5-7.5mm {0.26-0.29 in} (Generator) N 0 mm {0.24-0.27 in} Used: 7.0-8.0 mim {0.28-0.31 in} 3, Tighten pulley ocknut ©. Tightening torque: 32-46 Nom {3.2-4.7 kgf-m, 24-33 fbf} PIS 1. Loosen idler pulley locknut®. 2, Adjust the belt deflection by turing adjusting bolt &. Deflection New : 6.0-7.0mm {0.24-0.27 in} Used: 7.0-8.0mm {0.28-0.31in} 3. Tighten pulley locknut @. Tightening torque: 32-46 Nem (3.24.7 kgf, 24-89 fll B2-7B2 ENGINE TUNE-UP HLA TROUBLESHOOTING GUIDE { Problem Possible Cause ‘ation Tae aben angels atawiedatirorw | fgullwrtolin HA | Runengine 000-0000 cm, tarps i ta | Faget 3 : PMO ny secceemacang, | Stbsave tons [Pane aps eter 2 secenda-10 minutes approx. one day “3 Nalee whon engine lp sarod afer orang for ‘Sgeconds o move. 4. Nee whon engi is startod after now HLA is instal HLA is normal FEnot, replace HLA. “Time required for engine ollo crculste ‘within org’re inaludos folorance fer es ‘gine oil condition and ambient tempera ture. 5, Nese continues more than 10 minutes Inpuficient ok preseue | Ohock ol pressure Ir lower than epectficatio, check for eaucs, Oil pressure: 504490 kPa (8:4 0 kpliom?, 48-71 po) 2,000 rpm (Reler to page 8-73) Frees down fILA by nena. if toes not move, HLA is normal. Ititmoves. rapiana HLA, Faulty HA Measure valve oleararce. I more than Omm (Dir, replace HLA. 0, Nese daring ile ator high speed evry Thoarredt oll ameunt Check of level. Drain or add 3 ag necessary Deterfovated oil Check of quailty. IFeterterated, replace with specified type and atrount of oi IGNITION TIMING, Preparation 4. Warm up the engine to normal oporating temperature. 2, Tum all eiectric loads off © Headlight switch # Blowor switch © Rear window defroster switch 3. Connect the SST io the data link cannactor. 4. Connect a timing light. 5. Connect a tachometer to the data link connector terminal 1G-. IDLE SPEED GND Ignition timing 1. Perform “Preparation, * (Refer to above.) 2, Make sure the idle speedis within the specitication. Ifnot, adjust the idle speed. Idle speed (MTX in Neutral, ATX in P range) 3650-710 rpm 3. Set switch @ to position 1. 4, Set TEST SW to SELF-TEST. 5. ifthe SST is not used, jump across the TEN and GND ter- minals of the data link connector. B2-8 6. Make sure the timing mark (yellow) on the crankshatt pulley and the mark on the timing bell cover are aligned. Ignition timing: 9-11° BTDCENGINE TUNE-UP B2 7. Ifthe marks are not aligned, Icosen the distributor mount- ing bolts and turn the distibutor to make the adjustment. 8, Tighten the distributor bolts to the specified torque. Tightening torque: 19-25 Nim {1.9-2.6 kgm, 14-48 frlb} 9, Disconnect the jumper wire or the SST. Idle Speed 4. Apply parking breke. 2, Pertorm *Preparation.” (Refer to page B2-.) 8. With the coolant fan off, verify that the idle speed is within the specification. Idle speed {Neutral or P range) : 640-700 rpm 4.1 not, adjust the idle speed by turning the air acjusting screw (AAS) 6, Discorinect the jumper wira or the SST. B2-9B2 COMPRESSION COMPRESSION ifthe engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to section G.) 2. Compression (Refer to below.) 3. Fuel system (Refer to section F2.) PREPARATION SST 48 HO10 103 For 49. HOTC 194 For cespen ERE fee Ce | emt gauge INSPECTION 1. Verify that the battery is fully charged. Recharge it ifnec- essary. 2. Warm up the engine to the normal operating temperature, 3. Stop the engine and allow i to coo! for about 10 munutes. 4. Remove the all spark plugs. 5. Disconnect the distributor connector. 6 Install $ST Into the No.1 spark plug hole. 7. Fully depress the accelerator pedal and crank the angina. 8, Note the maximum gauge reading, 9. Gheck each cylinder as above. Compression kPa kotor? psi, ‘Standard 1.384 (18,6,168} 900 Minin 84 (10.6, 142}-300 ‘Maximuen atference “ 198 (2.0, 28) 10. f the compression in one or more cylinders is low, pour a ‘small amount of clean engine oll inte the eylinder and re check the compression, (1) Ifthe compression increases, the piston, piston rings, ar cylinder wall may be worn. (2) Ifthe compression stays low, the vaive may be stuck or improperly seated. (@) Ifthe compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 11. Remove the SST, 12. Connect the distributor connector. 13.{nsta! all spark plugs. Tightening torque: 45-22 Non (1.52.3 kgf-m, 1116 Flbh} B2-10ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE B2 PREPARATION SST sewn ver seat iat Soerimot Holder. coupling eS | Santana Set, holder ts wan <9eonio1 er seo ste rer CIES prevention ot prevention of Holder corankehatt Bolts & crangshatt Pariot rotaton (Part of rotation BES ia cos BES an 49GOI7 BAO For 49017 501 For : a spor eae = Parl of 49 GO17 5AQ) 49 GO17 602 For 49. GOIT 603 For support of ‘support of eispet ae vexk oe (Partof (Part of Ses) SSS sam 49 E011 140 For 49 E011 103 For Sevan anton — see | sun sore gone anon | Bas wae Sa a) eon we fer sean 1 tr Senter (enton cover SEER | cee Eo Partof rotation (Part of rotation 49 BOTT 1A0} 49 E11 1A0) a> ores fer sacereot7 Fa q fehon at ‘Slatatonst Puller, ball joint tie rod end Installer, rear oil seal cake | SS 49 F401 3808 For 49 FA01 2378, For Flas of Fella or instar set Somtatee | stan c ee sane oa a Part of 49 F401 $308} B2-11B2 ON-VEHICLE MAINTENANCE Waming © Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work, B2-12ON-VEHICLE MAINTENANCE TIMING BELT Removal / inspection / Installation 1. Disconnect the negative battery cable, 2, Remove the right front wheel. B2 8. Remove in the order showa In the figure, referring to Removal Note. 4, Install in the reverse order of removal, referring to instaliation Note. 79-1027 Nan (20-4 katom, ‘o-05.ciny 94070 {90-210 rgtem, Tose em orate] 4. Splash shield (RH) 9. Engine hamess bracket 2, Drive bait 10. Timing belt cover Removal / Installation ....... page B2- 6 Femovei Note . - page B2-15, 3, Water pump pulloy Installation Note * page B2-19 4. Idler pulley and bracket 11. Timing belt 5. PIS oll pump Removal Note . - page B2-18 Removal Note. «page B24 Incpection ... page B2-85, Installation Note + page B2-21 Installation Note: page 82-17 8. Crankshaft pulley 12,Timing bett auto tensioner Removal Nota . page B2-15 Ingpeation 0. page B2-85, Installation Note « page B2-21 Installation Note . . . page B2-17 7. Dipstick and pipe 19. Tensioner pulley Removal Note. + page B2-1S 14. No.2 idler pulley Instattation Note page B2-20 15.No.1 idler pulley 8. Crankshafl position sensor hemess bracket B2-13B2 ON-VEHICLE MAINTENANCE B2-14 Removal Note P/S oll pump 1. Disconnect the P/S oi! pump hose from the engine. 2. Disconnec! the steering pressure sensor connector. 8. Remove the bots shawna in the figure and secure the P/S cil reservoir away from the engine. 4. Loosen the pulley nut as shown, 5. emove the pulley. 6. Remove the bolt shown, 7. Remove the bolts shown in the figure and remove the P/S cil pump. 8. Position ihe P/S oil pump away from the engine and se- cure it with wire,ON-VEHICLE MAINTENANCE B2 Grankshatt pulley a Caution # The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily. 1. Install the SST to the crankshaft pulley with bolts (M10 X 2. emve the crankshaft pulley bot and te pulley. Dipstick and pipe 1. Disconnect the crankshaft position sensor connecter. 2. Remove the cip from the dipstick pipe. 3. Remove the cipstick and pipe, 4: Plug the hofe in the engine after removing the pipe. Timing belt cover 1. Support the engine by using the SST {engine support}. B2-15B2 ON-VEHICLE MAINTENANCE 2. Remove the No.3 engine mount 3. Remove the right and leit timing belt covers. Timing belt 1. Install the crankshaft pulley bolt into the crankshaft. 2. Turmthe cranksha'? clockwise and afign the timing marks. (No.f piston is al TDC of the compression stroke.) 3. Mar the timing bolt rokaon on te bal for proper rela- stallation. 4, Loosen the auto tensicner bolts and remove the lower bott Caution * When removing the bolt, hald the tensioner so that the bolt holes are aligned, otherwise the threads. can be damaged. 5. Remove the No.1 idfer pulley and remove the timing bett. Caution © When removing the pulley bolt, hold the pulley so that the bolt hoies are aligned, otherwise the threads can be damaged. © The following will damage the belt and shorten tts life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.ALIGN THE HOLES ON-VEHICLE MAINTENANCE B2 Inspection Inspect the following and repair or replace as necessary. (1) Timing belt (Refar to paga B2-85.) 2) Timing belt auto tensioner (Reefer to page B2-85.) (8) Timing belt pulley (Refer to page 32-86.) (4) Camshaft pulleys (Refer to page B2-85.) Installation Note Timing belt auto tensioner 4. Slowly press the tensioner rad into the tansioner body by using @ press, Caution © Applying pressure of more than 9,807 N{1,000 kgf, 2,200 Ibf} can damage the tensioner. 2. insert a pin into the second hole in the body as shown to hold the tensioner rod. Note # Pin diameter: 1.6mm {0.063 in} 8. Set the tensioner in piace and snugly tighten the tensioner upper bolt. Note # This must be done to reduce the timing bett resistance when the idler pulley is inslalled. Timing belt 4. Turn the camshaft pullays clockwise and align the timing marks. B2-17B2-18 ON-VEHICLE MAINTENANCE 2. Using the crankshaft bolt, tum the crankshaft clockwise and align the timing marks of the timing balt pulley andthe oil pump. 2. Install the timing belt on the pulleys in the order shown be- , low. © Timing belt putey ® No? idler pulley © LH camshaft pulley ® Tensioner pulley © RH camshaft pulley 4. Verity that there is tens'on between pulleys ® and ©, and between pullays @ and ©. 5. Install the No. 1 idler pulley while applying pressure on the timing belt. Tightening torque: 38-51 Nem {(3.8-5.3 kgf-m, 28-38 ftlbf} 6. Push the auto tensioner in the direction of the arrow and lighten the bolts. Tightening torque: 19-25 Nem {1.9-2.6 kgtm, 14-18 ttf} 7. Remove the pin from the auto tensioner to apply tension to the belt.ON-VEHICLE MAINTENANCE B2 8. Turn the crankset cloclse twice, and align the timing 9 ony hat all timing marks are correctly aligned. lineces- sary, repeat the procedure beginning from installation of the timing belt auto tensioner. 10.Cheok the timing belt deflection by applying moderate pressure 98 N{10 kgf, 22 Ibf} micway between the crank shaft pulley and the auto tensioner. # not correct, replace the auto tensioner. Deflection: 6.0-8.0mm {0.24-0.31in) Timing belt cover 1 Install the right liming belt caver. htening torque: 910.7 Nem {80-110 kgf-om, 7095.4 in- Ib} 2. Install the left timing belt cover. Tightening torque: 7.9-10.7 N-m {80-110 kgf-cm, 70-95.4 in-tbh 3. Install the crankshaft position sensor connector bracket ‘on the left timing belt cover. Tightening torque: 79-1 10.7 New (80-110 kgf-cm, 70-95.4 in- tof B2-19B2-20 ON-VEHIGLE MAINTENANCE 4. Insiall the harness brackel on the right timing belt cover. Tightening torque: 7.9-10.7 Nem {80-110 kgf-om, 7095.4 in-Ibf} 6. Install the No.3 engine mount. Tightening torque & : 74-102 N-m (7.5-40.5 kyf'm, 55-769 it Ib} © : 86-116 N.m (8.7-11.9 kfm, 63-86.0 feb} 6. Remove the SST (engine support). Dipstick and pipe 1. Apply clean engine oiltoa new O-ring, and installiton the pipe. 2. Remove the plug irom the engine and install the pipe. Tightening torque: 7.9-10.7 N-m {80-110 kgt-om, 70-95.4 intbf} 3. Install the dipstick. 4, Install the crankshaft position sensor harness and clip to the dipstick pipe. 5. Connact the connector.ON-VEHICLE MAINTENANCE B2 Crankshaft pulley 1. Remove the crankshatt pulley bolt. 2. Install the crankshaft pulley and hand tighten the bolt, 3. Mount the SST on the crankshatt pulley to hold the crank shaft 4. Tighten the crankshatt pulley Delt Tightening torque: 157-166 N-m {16.0-17.0 kgfm, 116-122 flbf} P/S oil pump 1. Install the P/S oil pump, Tightening torque @ : 32-46 N-m {9.2-4.7 kgf-m, 24-93 ftibh Gf 19-25 N-m {1.9-2.6 kgtm, 14-78 ftlbf) 2. Install the P/S oit pump pulley and hand tighten the pulley HL rut. 3, Tighten the pulley nut by using a 12mm {0.47 In} socket on the P/S oil pump mount belts, Tightening torque: 3-03 Nim (6.4-9.8 kgfm, 46-69 fbf} 4. Install the P/S oil reservoir. Tightening torque: 6.9-9.8 N-m {70-100 kgf-om, 61-86.8 In-Ibf B2-21ON-VEHICLE MAINTENANCE Drive belt 1 Jnstall the water pump pulley and hand lighten the bolts. 2. install he P/S oil pump and water purnp drive belt on the ileys. 3. Siac the drive belt dettection. (Refer to page 82-6.) 4, Tighten the weter pump pulley, Tightening torque: 7.9-10.7 Nem {80-110 kgf-cm, 70-95.4 in-IbA} GENERATOR z 5. Install the A/C compressor drive bett on the pulleys, and +c é ‘GENERATOR adjust the belt deflection. (Refer to page 82-6.) cannon say Senay ‘Steps After Installation 1. Install the right front wheel. 2.Fill the radiator and coolant reservoir with the specified amount and type of engine coofant. . Perform the necessary engine adjustments. (Refer to ENGINE TUNE-U®, page B2-5.) B2-22ON-VEHICLE MAINTENANCE B2 CYLINDER HEAD GASKET Roplacement ‘Warning * Fuel line spills and leaks aro dangerous. Fuel can ignite and cause serious injuries or death ‘and damage. Fuel can also irritate skin and eyes, To prevent this, alvays complete the “Fuel Line Safety Procedures” on section F2. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to soction E2.) 3. Remove the timing belt. (Refer to page 22-12) 4, Remove in the order shown in the figure, referring to Removal Note. 5, Install in the reverse order of removal, referring 10 Installation Note. POO igrer tease ‘9-26 (281m, (ore 29-107 ¥en oot geen, baer) (eens ay a (sat B2-23B2 ON-VEHICLE MAINTENANCE 1. Fresh-air duct 8. Intake manifold assembly _15. Seal plate 2. Air cleaner assembly Removal Note page B2-26 16. Water outlet 3. Battery and cartier Installation Note 17-Exhaust pipe 4, Accelerator cable seseeeeeee page B2-84 18.Engino hanger installation Note 10. Distributor 19. Camshaft cap and oil seal ange B2-86 Installation Note Removal Note page 82-27 eTrotieabieIX nan page B2-83 installation Note (nstatiation 11. Cylinder head cover coos page B2-80 Agjustment ...... section k " Removel Note page B2-26 20.Camshatt” 6. High-tension lead Installation Note installation Note 7. Hamess page B2-33 --.- page B2-30 Removal Note page 82-25 12. Camshaft pulley 21.Cylinder head batt Installation Note Flemoval Note page 82-27 Rlemoval Note page B2-28 . +++ Page 82-36 Installation Note 22. Generator strap 8. Hoses page 82-2 28. Cylinder head Removal Note page 82-25 13. Rac Installation Note Installation Note 1. Ho, 3 engine mount bracket page 82-20 secssseeses page 82-35 Removal Note page 82-27 24.Gyinder head gasket and O- Installation Note ting toveestenes page B2-31 B2-24ON-VEHICLE MAINTENANCE B2 Removal Note Harness: Disconnect the harness connectors shown. Lore WATER TERIPERATURE SENDERUNTT 7 o IS OIL PRESSURE SWITCH VAIS. SOLENOID VALVE = HEATED GXY@EN SENSOR, EGR SOLENOID VALVE (VENT) FOR SOLENOID VALVE (VACUULA, (RGTTLE POSITION SENSOR, \ ENGINE COOL FURLINECTOR TePenaTORE Sense x (PCM) Sea Top aR OORTRON VALVE HEATEG OXYGEN SENSOR UPPER. RADIATOR HOSE B2-25B2 ON-VEHICLE MAINTENANCE B2-26 Fuel hose Warning * Fuel lino spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam- age. Fuel can also irritate skin and eyes. To prevent ‘this, always complete the “Fuel Line Safety Proce- dures” on section F2. Plug the disconnected hoses to avoid fuel leakage. Intake manifold assembly 4, Temporarily install the No.3 engine mount bracket to sup- port the engine. 2. Remove the SST installed for the timing belt removal. 3. Remove the intake manifo'd stay. 4, Loosen tie mounting bolts in two or thrae steps. Cylinder head cover 1. Remove the cylinder head cover bolts. 2: Disconnect the ventilation pipe (left cylinder head) 3, Remove the cylinder head cover.ON-VEHICLE MAINTENANCE B2 Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon ‘as shown, and loosen the camshaft pulley lock bolts. 2. Remove the camshatt pulleys. No.3 engine mount bracket 1, Install he SST and support the engine, 2. Disconnect the No.3 engine mount bracket from the en- gine mount rubber. 3. Ramove the No.3 engina mount bracket from the engine. Camshaft cap and oil seal Caution © When the front camshaft lobe is pressing on the HLA, removing the camshaft caps can damage the cylinder head thrust journal support. Perlorm this same procedure for the right and left oylinder heads. 4 Tum the camshatt clockwise by using a wrench on the cast hexagon and align the camshaft Knock pin and cylin der head marks as shown. 2, Loosen the front camshait cap bolls in five or six steps in the order shown. 3. Remove tha front camshaft cap. Note Bott © fits only for right cylinder head. B2-27ON-VEHICLE MAINTENANCE Note * Belore removing the camshaft caps, note their loca ions. 4, Loosen the camshaft cap boils in five or six steps in the order shown, 5, Remove the camshait caps. Caution # Remove the thrust cap only after removing all cam- shalt caps. Otherwise, the thrust cap can be dam- aged, Cylinder head bolt 1. Temporarily install the No.3 engine mount bracket to sup- port the engine. 2. Remove the SST. ‘3. Loosen the cylinder head bolts in two or three stepsin the order shown, 4, Remove the cylinder head bolts.ON-VEHICLE MAINTENANCE B2 1387-1943 mm (6.284 5.287 in} Installation Note Cylinder head 1, Measure the amount of oil contro! plug projection from the eck of the cylinder black, Projection: 8.0-9.0 mm {0.315-0.354 in} 2. Apply clean engine oll to new O-rings and install them to the cil control ge 9. Thoroughly remove all dirt oil, and other material from the decks of the cylinder block. 4, Turn the crankshaft clockwise and appiy engine oll to the cylinder walls, 5, Place a new cylinder head gasket (marked L) on the left bank. 6. Place anew cylinder head gasket (marked ®} on the right bank, 7. Instail the cylinder heads to the cylinder lock. 8, Tighten the cylinder head bolts as described below. (1) Before installation, measure the length of each batt. Replace the boit if it exceeds the maximum length. Length: 183.7—134.3 mm {6.264-6.287 in} Maximum: 135.0 mm {5.315 in} (2) Apply clan engine ollto the threads and the seat face: of each bolt, and instell them and the washers. (8) Tighten the bolts in two or three steps in the order shown. Tightening torque: 23.1-26.9 Nun {2.35-2.65 kgt-m, 17.0-19.4ft bf} (4) Puta paini mark on each bolt head. {8} Using the marks as a reference, tighten the bolts by turning each 85° 95° in the sequence shown. (6) Further tighten each bolt by tuming anather 85°-95°. B2-29B2 ON-VEHICLE MAINTENANCE 2. Support the engine by using ihe SST. 10. Disconnegl the No.3 engine mount bracket. 11. Remove the No.3 engine mountbracket from the engine. Camshaft Caution * Camshafts must be assembled in the following procedure, Otherwise, camshaft can be broken or damaged because there is little camshaft thrust clearance. 1. Apply a liberal amount of clean engine oil to the journals, cam lobes, and camshatt gears. 2.Align the timing mars of intake camshaft and exhaust ‘camshaft, 3. Install the camshafts on the eyfinder head. Note © The thrust plate positions for the right! and laft cylinder head camshafts are different, Camshaft cap and oil soal 1. Remove the oil, dt and other foreign material from the mating surfaces between the tront camshaft cap and the ‘oylinder head, and degrease. 2. Apply silicone sealant to the shaded areas shown. Caution © Install the thrust caps first. Otherwise, camshaft can be broken or damaged. 3. Instaii the thrust cans onto the cylinder heads. Hand light- ‘en the bolts in five or six steps in the order shown, until the camshafl caps fully seated on the cylinder head.ON-VEHICLE MAINTENANCE B2 4. Install the camshatt caps, and hand tighten the camshatt cap batts. 5. Tighten the camshaft cep bolts gradually in five or six steps in the order shown. Tightening torque: 11.3142 Nm {115-146 kgf-om, 100-126 intbh} 6, Retighten the bolts in the order shown. Tightening torque: 11.3-14.2 N.m {118-445 kgf-cm, 100-128 in-Ibf} 7. Install the distributor cap. (LH cylinder head} Tightening torque: 41.3-44.2 Nm (118-145 kgf-cm, 100-128 in-Ibf 8. Apply alight coat of clean engine illo the new oll seal and the cylinder read. the cartshatt oll seal into the cylinder head by using a IT and a hammer. EOGOES Protrusion: 0-0.5mm {0-0.019 ing 10. Tap in the new blind cap by using a plastic hammer. No.3 engine mount bracket 1. Install the No.3 engine mount bracket to the engine. Tightening torque: 44-60 Nem (4.4-6.2 kgf m, 92-44 fbf) B2-31B2 ON-VEHICLE MAINTENANCE B2-32 2. Temporarily install the No.3 engine mount bracket to the engine mount ruber. 3. Remove the SST. Camshaft pulley 4. Install the RH camshaft pulley so that the “R” mark can be Been anche iming mark ago wih the camshaft knock ia. 2. Install the LH camshatt pulley so that the “L” mark can be seen and the timing mark aligns with the camshaft knock pin, 3. Apply clean engine oil to the look bolt threads and tempo- rarly tighten the camshaft pulley lock bol, 4. Hold the camshaft by using a wranch on the cast hexagon as shown, and tighten the camshaft pulley lack bolts. Tightening torque: {23-140 Nem {12.5-14.9 kgm, 91-109 ftbf}ON-VEHICLE MAINTENANCE B2 Cylinder head cover 1, Remove all old silicone sealant from the cylinder head and cover. 2.Apply silicone sealant to the cylinder head cover as shown. 3. Remove all dirtand other material from the cylinder head, and apply sealant as shown. 4. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown. Tightening torque: 5,0-8.8 Nan (50-90 kgt-om, 44-78 in, thf} 5. Ratighten the bolts. (RH @ ©, LH © @) Tightening torque: 5.0-8.8 N-m {50-90 kgt-cm, 44-78 in-Ibf} 6. install the ventilation pipe to the let! cylinder head cover. Tightening torque: 7.9-10.7 Nem {80-110 kgf-om, 70-95.4 in-Ibf} Distributor 1-Aply clean engine ol to sew O-ring and pasion it on the distributer 2. Apply clean engine cil othe dive blade. 3. Align the matching marks on the distributor body and the camshaft gear. B2-33B2 ON-VEHICLE MAINTENANCE B2-34 4. Instat! the distributor with the blade fit into the camshaft ‘groove. §. Fland tighten the distributor mounting bolt. Intake manifold assembly 1. Install a new gasket and the intake manifold. Hand tighten the bolts and nuts. 2. Install the intake manifold stay. Tightening torque: 19-25 Nem {1.9-2.6 kgt-m, 14-18 ft-lof} 3. Tighten the boits and nuts in two or three steps. Tightening torque: 19-28 N-m (1.9-2.8 kgf-m, 14-18 feibf}ON-VEHICLE MAINTENANCE B2 Hoses Connect the hases shown, i - ws & »y VENTILATION HOSES Le \ BRAKE VACUUM KOBE FUEL HOSES: LOWER RADIATOR HOSE: B2-35B2 ON-VEHIGLE MAINTENANCE Hamess: ‘Connect the hamness connectors shown, YP piso Fogasune sare Accelerator cable 1. Install the accelerator cable, 2. Adjust the cable deflection by tuning nuts @. Free play: 13mm {0.04-0.11in} Steps After Installation 1. Install the timing belt, (Refer fo page B213.) 2. Fill the radiator with the specified amount and type of engine coolant. (Refer to section £2.) 3. Start the engine and (1) check the engine oil and engine coolant leakage. (2) check the ignition timing and idle speed. (Ftefer to pages B2-6,9.) (8) check the operation of ihe omission control system, (Reler to section F2.) 4. Recheck the engine coolant and off levels. B2-36ON-VEHICLE MAINTENANCE B2 HLA Removal / installation 1. Disconnect the negative battery cable. 2. Remove the timing belt. (Refer to page B2-12.) 3, Remove in the order shown in the figure, referring to Removat Note. 4. Install in the reverse order of removal, referring to Installation Note. 10-25(1.002.6, 14018) so-aenm 450-20 kgf-em, 44-78 int 1925 (1.92.5, 14-48), 508th 90 torn, 44-76 into 113-442Nm 25-148 Kerem 190-426 19-25(1.0008, 1418) 123-140 (126-14.3, 81-106) Nem flgtm, fb) B2-37B2 1. Accelerator cable installation Note 2. Throttle cable (ATX) Adjustment . .. 3. High-tension leads 4, Hamess and hoses » page B2-36 Removal f installation Note ........ below 5, Intake manifold assembly Ramoval Note .. « page 82-28 installation Note + page 82-34 6. Cylinder head cover Fismaval Note ... page 32-28 installation Note page 82-23 Removal / Installation Note Harness and hoses ON-VEHICLE MAINTENANCE 7. Distributor Installation Note 8, Camshe#t pulley Removal Note Installation Note $, Gamshait cap and oil seal Removal Note Installation Note 10. Camshatt installation Note 11. HLA Inspection ... page B2-33 page B2-27 page B22 » page B2-30 page B2-80 1. Disconnect the hamess connectors and hoses shown. 2. Connect the harness connectors and hoses in the reverse order of disconnection. HARNESS waTeR TEMPERATURE, SENDER UNIT ENGINE COOLANT. TEMPERATURE SENSOR (ELECTRIC COOLANT Fan -VRIS SOLENOIO VALVE ~ HEATED OXYGEN SENSOR EGR SOLENOID VALVE (VENT) EGR SOLENCIO VALVE (VACUUM) THROTTLE FOSITION SENSOR B2-38ON-VEHICLE MAINTENANCE B2 or seb HOSES ‘Steps After Installation 1. install the timing belt, (Refer to page 82-13.) 2. Fillthe radiator witn the specified amount and type of engine coolant. (Refer to section E?.) 3. Start the engine and (1) check the engine oil and engine coolant feakage. {2} check the ignition timing and idle speed. (Refer to pages B2-8, 2.) (8) check the operation of the emission contre! system. (Refer to section F2.) 4. Recheck the engine coolant and cil levels. B2-39B2 FRONT OIL SEAL Roplacement 1. Disconnect the negative batiery cable. ON-VEHICLE MAINTENANCE 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, reterring to Instaitation Note. 1. Timing belt Removal / Installation . 2. Timing belt pulley Removal Noi Installation Note page B2-13 page 82-41 page B41 B2-40 3.Ollseal Removal Note page 52-41 Installation Note. page B2-41ON-VEHICLE MAINTENANCE B2 ‘Steps After Installation ‘Start the engine and check the following. © Ignition timing (Refer to page B2-8.) Removat Note Timing belt pulley Note © If necessary, remove the pulley with a steering wheal puller. 1. Remove the timing batt pulley. 2, Remove the crankshaft key. Oil seal 4. Cut the oil seal lip with a razor knife, 2. Remove the olf seal by using a screwdriver protected with arag. Installation Note Oil seal 1. Apply clean engine cil to the lip of a new oil seal 2. Push the oil seal slightly In by band. 3, Tap the oil seal in evenly with a pipe and a hammer. Protrusion: 0-0.8mm {0-0.019 in} Note # Oil seal outer diameter: 48.0 mm {1.89 in} © Oil seal inner diameter: 34.0 mm {1.34 in} Timing belt pulley 4. Install the timing belt pulley. 2. Install the crankshalt key with the tapered side toward the oll pump booy. B21B2 ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove In the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note, MIX 18-281.8-27,14-19) Nom thgtem, fa 1. Transaxle 4. Drive plate, bagking plate, adapter (ATX) MD Removal Note below + Section J2 Installation Note - B23 x Removal /instafation . AIX 5. Gil seal Femovel / Installation section K Removal Note. page 82-43 2. Clutch cover, clutch disc installation Note . age B2-43 Service . section H 3. Flywheel Removal Nate :balow Installation Not B2~43 Removal Note Flywheel (MEX) 1. Hold the fiywheel by using the SST. 2, Remove the flywhee| mounting bots. 3. Remove the fywhee!. Drive plate (ATX) 1. Hold the drive plate by using the SST. 2. Remove the lock bolts. 3. Remove the backing plate, drive plate, and adapter. CETTE B2-42ON-VEHICLE MAINTENANCE B2 ADAPTE DRIVE FLATE BACKING PLATE Oil soal 1, Cut the oil seal lio with a razor knife. 2, Remove the oil seal by using a screwdriver protected with arag installation Note Oil seal 1. Apply clean engine oil fo the lip of the new oil seal. 2. Push the off seal slightly in by hand. 3. Tap the oil soal in evenly with the SST and a hammer. Protrusion: 0-0.7mm {0-0.03 in} Flywheet (MTX) 1. Set the flywhzel onto the crankshaft. 2. Hand tighten the lock bolts. 3, Hold the fiywheel by using the SST. 4. Tighten the bolts In two or three steps in the order shown. Tightening torque: 81-87 Num (6.2-89 kof-m, 45-49 tb} Drive plate (ATX) 4. Install the adapter, drive plate and backing plateas shown and hand tighten the lock bolts. 2. Hold the drive plate by using the SST. 3. Tighten the bolts in two or three steps in the order shown. Tightening torque: ster Nim (2°89 kaf.m, 45-49 fb Steps After Installation Siarl the engine and perform engine adjustments as nec essary. B2-43B2 REMOVAL REMOVAL Warniny + Fut line spitis and leaks are dangerous. Fuel can ignite andi cause serious injuries or death and damage. Fue! can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Satety Procedures” on section F2, PROCEDURE 1, Disconnect the negative battery cabie. 2. Drain the engine coolant and transaxle oil. 3. Remove the hood and front wieals. 4, Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Splash shield 41. Shroud upper panel 2. Fresh-air duct 12. Radiator and coolant fan assembly 8. Air cleaner assombly 18. Drive belt 4. Coolant reservoir Romoval 2.2... page B2- 7 5.Battery duct 14S ol pune 6. Battery and carrier Removal Note .............. page B2-45 7. Accelerator cable 15. A/C compressor {if equipped) 8. Radiator hose Removal Note ... «+ page B2-46 9. Oil cooler hose (AEX) 16.Contro! cabte (ATX) 10. Cootant fan motor connector B2-44REMOVAL B2 Removal Note PIS oil pump 1. Disconnect the P/S oil pump hose from the engine. 2 Disconnect the steering pressure sensor connector. 8. Remove the bolts shown and secure the P/S oil reservoir away from the engine. 4. Loosen the pulley nut as shown, 5. Remove the pulley. 6. Remove the bolt shown, 7. Remove the bolts shown and remove the P/S ail pump. 8. Position the P/S oll pump away fram the engine and se- cure it with wire, B2-45B2 REMOVAL AIC compressor L 1. Reeve the A/C compresor with the hoses still con- Hi \ 2, Bostton the cocpressor away ftom the engine end 9¢- ure with wire, Step 2 Disconnect the hamess connectors shown. ENGINE COOLANT, TEMPERATURE SENSOR (ECM) VAIS SOLENOID VALVE WATER TEMPERATURE os ‘SENDER UNTT EATED OXYGEN SENSOR THROTTLE POSITON SENSOR CBANKEHAFTPQSITION ‘SENSOR SR SOLENOID VALVE (VENT) GROUND GR SOLENOID YALVE (VACUUM) FUBLINJECTOR GeNeRaZOR " y ue Aockyag.vave OWL PRESSURE SwITgH DISTAL ete — - — ee} B2-46Step 3 Disconnect the hoses shown, REMOVAL B2 HEATER HOSES: Ge MUSE Removal Note Fuel hose ‘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 dam- age. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Proce- dures” on section F2. Disconnect the fuel hoses. Heater hose Press the heater hose retainer tabs and remove the heal- er hoses, B2-47B2 REMOVAL Step 4 REPLACE SELF LOK OT, REPLACE 2 ® 1. Clutch ralease cylinder (MTX) 7. Tié-tod end ball joint Removal Note .. Removal Note ....eeec0+2++ page B2-49 2. Transverse member 8, Engine mount member 3. Exhaust front pipe Removal Noto .....6..0202+ page B2~49 4. Shift control rod (MTX) 9. Drive shaft Removal Note .........-2-+ page B2-49 5. Extension bar (MTX) 6. Stabilizer control link Removal Note ‘Clutch release cylinder (MTX) "-Unbot the release cyinder pls brackets trom the trans le. ‘Caution © Bending the pipe can cause kinks or cracks. 2. Remove the release oylinder and position itaway from the transaxle with the hose still connected.REMOVAL B2 Tie-rod end ball joint 1, Remove the cotter pin and toosen the nut so that itis flusn with the end of the bali joint stud. 2, Separate the knuckle arm and ball joint by using the SST. Engine mount member Warning # Removing the member without first suspending the engine can cause the engine to tift or fall and cause injury. Suspend the engine properly before removing the member. 1. Suspend the engine by using a chain block, 2. Remove the No.1 and No.2 engine mount nuts. 3. Remove the engine mount member bolts and nuts and re- move the engine mount member. Drive shaft Remove the bolts and nuts atthe left and tight lower arm ball joint, Caution © The ball joint dust boots and oil seals are damaged easily If this procedure Is not done correctly. Remove the joint shatt. 2. Pry the lower arms downward to separate them from the knuckles. 4. Separate the drive shafts from the transaxle by prying with @ bar inserted between the shaft and the case. B249B2 REMOVAL Step 5 1.. No.3 engine mount rubber 3. Engine and transaxle essembly 2. No.4 engine mount rubber and bracket Removal Note ....2.0eeseseeeeeee below Removal Note Engine and transaxle assembly Mt the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into compo- nents in the éngine compartment. Lift the engine and transaxle assembly out as a unit.B2 REMOVAL Step 6 8. Transaxle mounting bolts 1. Starter 2. Throtiia cable (ATX) 7, Manual iransaxto (MTX) 3.No.2 engine mount rubber and bracket 8, Automatic transaxle (ATX) 4. Seal plate 9, Engine assembly 5, Torque converter nuts (ATX) B2-51B2 ENGINE STAND MOUNTING ENGINE STAND MOUNTING PREPARATION SsT ‘80107 680A For ‘@Lo10 140 For oe PO | Eosen a Engine stand assembly of Hanger so, Bry | 2semaly ot eare mrave cad B | Sone spvott 01 Fr apto%o 102 For Easserly and oy Emassemby ara te sseeribal | Arm scoorny Pate ogre Poet orgie 49 L010 tA0) 43.L010 140) 291010708, ie souotoros fer = disassembly and cisascembly anc oa lf scone 2" | sue coonsyal Partor ogre Part crane 49 L010 1A0) 49 L010 1A0), so1010 105 fer «91010105 For disassembly and disassembly and Bolt assemaly oF Bott assembly of (Pato enging. (Part of engine 49 LOI 1A0) 49 L010 10) sn eor0 tad For 49 £010 101 for ‘eosomtiy ond ascenyane Haagor ct eon | Body Soon engine engine (Part of engine 49 E010 1A0) 49 €010 102 For 49 ECI0 IAT For disassembly and re disassembly and Batt assombly of Hanger sel, ongine ESS oe | asses ot Patt ngine && | crane SSE DTO x40 COS oes, 49 E010 108 fer 48£010 102 ter disassembly ard &h, © | Sossortiy are Hanger ascenbiyol | Bolt © | sssenisvot (Par ot engine iPartof engine G83 san Cuan © 29 E010 108 fer disassembly and Bot soontiyol acat came SSEetosan B2-52ENGINE STAND MOUNTING B2 PROCEDURE ‘When using 49 E010 1A0 1, Remove the right exhaust manifold insulator, 2. Remove the EGR vaive bolts. 3. Remove the right exhaust manifold and gasket together with the EGR valve and pipe. 4. trstall the SST al tha positions shown. 5. Mount the engine on the SST. When using 49 E010 141 and 49 L010 1A0 1. Remove the right exhaust manifold insulator. 2. Remove the right exhaust manifold and gasket, 3. Install the SST as shown. pai B2-53B2 ENGINE STAND MOUNTING ENGWNE wasien NUT LESS THAN nur eA LESS TaN B2-54 4. Install the SST (arms) to the holes as shown, and hand tighten the 8ST (Bolts). 5. Assemble the SST (bolts, nuts and plate) as shown inthe figure. 6. Install the SST assembled in step 5 to the SST installed in step 4. 7. Adjust the SST (bolts) so that loss than 20mm {0.79 in} of ‘thread is: eposed. 8. Make the S§T (plale and arms} peralie! by adjusting the SST (bolts and nuts). 9. Tighten the SST {bolts and nuts) to affix the SST firmly. 10. Mount the engine on the SST. Coolant Draining 1. Attar installing the engine to the engine stand, disconnect ‘he oil cooler hoses as shown in the figure (left cylinder head).ENGINE STAND MOUNTING B2 2. Remove the blind cover and drain the engine coolant. 3. After draining the coolant, install a new O-ring to the blind ‘cover. Tightening torque: 19-25 Nim (1.9-2.6 kgfm, 14-18 fib B2-55B2 DISASSEMBLY DISASSEMBLY PREPARATION Sst 1 #9 censt006 ree 461011 9908 fer Ar ounce of in ite of rm, veh Tuliténat [Totes A. gfe | eehaton ‘pring iter valves piaton pin eating! & 2s piston pina wee sso sot foe ao.on 008 rer reo! foo Body support instafiation of Installer, piston installation of Dh piston pine pin. piston pins Bator Part foot 9908 SStbtt ono sseon oe fee 490011 0028 For ronal Fear Sorow installation of | Head, support installation of piston pins: block piston pins: (Patof Gost os soeonan foe soaoissat Fer Popova ‘ror Gato, pte Fedataten ot | Wien, tiation of oe feet | Siete ier AQ HOGS 001 For 499120 170 For fool Kerovalof Wrench, instaltation of Remover, valve seals: Bo ene eckson | wave sel soe0H1 10 For s9011 408, rer prevention of prevention of Brake se, Santon | at Benoret iragear rton thatot ace ES s10y w@ sse0rt 104 fer 98017105, rer Prevention of prevent of Cota Berean | stopper Serer Patet cmon eae roan 49 £017 1A0) 49 E011 1A0) 49 6012 CAR For 498012 012 For fonoud/ renova Pht fractiainet | Bey Ielaton of anes trator wee 49 BO12 042) B2-5649 BO12 013 Foot instalation of anot valves 49 B02 OA2) 49 B12 014 Lockmut ant of 498072 942) 1.Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs) so thai they ean be reinstaitad in the cylinder from which they were removed. 2. Clean the parts by using a steam cleaner. Blow dry with compressed air. ‘Wamins + Continuous exposure with USED engine ol has caused skin cancarn faboratory mice. Protect your skin by wasing with soap and water immediately after this work. B2-57B2 DISASSEMBLY AUXILIARY PARTS: 1. Remove the oil drain plug and drain the engine oil. After draining the engine cil, install the oil drain plug. Tightening torque: $0-41 N-m {3.0-4.2 kgm, 22-30 ftbh, 2, Disassemble in the order shown in the figure, referring to Disassembly Note. 1. AC compressor bracket 7. Intake manifold assembly 2. Genarator 8. Engine hanger 8: Braoket ard tensioner $. Spark plug 4, Extiaust manifold insulator(LH) 10.011 fitter 5. Exhaust manifold(LH) Disassembly Note ........... page B2-69 6. Distributor and high-tension lead B2-58ETT DISASSEMBLY Disassembly Note Remave the oil filter by using the SST. B2 B2-59B2 DISASSEMBLY TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Crankshaft pulley 8. Timing belt Disassembly Note .......... page B2-81 Disassembly Note .......... page B2-61 2. Water pump pulley 9. Timing bet: auto tensioner 9. Dipstick and pipe 10. Tensioner pulley 4, Crankshaft position sensor 11. No.2 idler pulley 5, Timing belt cover (LH) 42.No.1 idler pulley 6. Timing belt cover (RH) 18, Timing belt pulley 7. No.3 engine mount bracket Disassembly Note = page 32-64 B2-60DISASSEMBLY B2 Disassembly Note Crankshatt pulley ‘Hold the Rye! (ATX) or dive plate (ATX) By using the 2. Remove the pulley bolt. 8. Remove the crankshaft pultey. Timing belt 1. Temporarily install the crankshalt pulley dott, 2.Turn the crankshaft clockwise to align the timing marks of ‘the pulleys. 3, Mark the timing belt rotation for proper reinstaltation, Caution © When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged. 4, Remove the auto tensioner bolts gradually in five or six steps in the order shown, Caution * The following will damage the belt and shorten its life; Forcefully twisting it, turning It inside out, bending it, oF allowing ofl or grease on it, 5. Remove the timing bell, Timing belt pulley 1. Remove the timing belt pulley. 2. Remove the crankshaft key. Note ® If necessary, ramave the pulley with a steering wheel puller. B2-61B2 ISASSEMBLY CYLINDER HEAD Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Cylinder head cover 2 Camshaft pulley Disassembly Note Inspection ......4.4 3. Seal plate 4. Water outlet 5, Camshaft cap Disassombly Note .. 6.Blind cap 7. Camshaft Inspection 8, Camshaft oil seal 9 HLA Disassembly Note Inspection B2-62 . page B2-63 * page B2-85 ++ page 22-63 .. page B2-64 » page B2-64 + page B2-80 10. Cylinder head bolt Disassembly Noto... +6 page B2-64 11, Cylinder head Inspection ... 12. Cylinder head gasicet 18. Valve keeper Disassembly Note .......... page B2-64 14. Upper valve spring seat 16. VeWve spring Inspection -... 16. Lower valve spring se 47. Nalve Ingpection 18. Valve seal Disassembly Note .......--- page B2-65DISASSEMBLY B2 Disassembly Note ‘Camshaft pulley 1. Hold the camshaft by using a wrench on the cast haxa- gon. 2. Remove the camshaft pulley bolts. 3, Remove the camshaft pullays, Camshaft cap 1. Align the camshaftknockpinas shownto reduce the pres- sure of the HLA, Caution © When the front camshaft tobe is pressing an the HLA, removing the camshaft caps can damage the cylirider head thrust journal support, 2. Loosen the front camshatt cap bolis in five or six steps in the order shown. 3. Remove the front camshatt cap. 4, Loosen the camshaft cap bolts in five or six steps in the order shown. Caution © Remove the thrust oap only after removing all cam- shaft caps. Othernise, the thrust cap can be dam- aged. 5, Remove the camshaft caps. B2-63B2-64 DISASSEMBLY Note * Before removing the camshaft caps, note their loca tions, They are identified as follows; Right head: numbers Left heed: letters. Camshaft Inspect the following when removing the camshatt. 1. Camshatt end play (Refer to page B2-79,) 2, Camshatt journal ail clearance (Refer to page -79,) HLA Caution © The HLA must bo reinstalled in the same positions from which they were removed. ff they are not, it can cause premature and uneven wear. Note © Mark the HLA to show their original positions. J. Remove the HLA from the cylinder head. 2. Store the HLA upside down in an oililled container. Cylinder head bolt 1, Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. Valve keeper 1. Set the SST against the upper valve spring seat as shown. 2. Compress the spring and remove the valve keepers.DISASSEMBLY B2 Vatve seal Using the SST, remove and discard the valve seal. B2-65B2 DISASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note, 1. Cluich cover, clutch disc (MTX) 7. Oil pan Disassenbiy Note . Disassembly Note .......4++ page 82-68 2. Flywheel (MTX) 8. Oilstrainer Disassembly Note . 8. Oil baffle 3. Backing plate, drive plate, fapter 10, Water pump Disassembly Note . 11.08 pump 4, Oilcooler and of fier body 12, Front oil seat Disassembly Note ...-..-..- page B2-68 5. Water pipe and thermostat housing Disassembly Note ss» page B2-67 6. Knock sensor Disassembly Note .......... page B2-68 B2-66DISASSEMBLY B2 Disassembly Note Clutch cover, clutch disc (MTX) 1. Hold the flywheel by using the SST. 2. Remove the clutch cover bolts in two or three steps. 3. Remove the clutch cover. 4, Remove the olutch caver and disc. Flywheel (MTX) 3. Hold tho flywheel by using the SST, 2. Remove the flywheel bolts in two or three steps in the or- dar shown. 3, Remove the flywheel. 4. Remove the SST. Backing plate, drive plate, and adapter (ATX) 1. Hold the drive plate by using the SST. 2. Remove the drive plate bolts in two or three steps. (Refer to above.) 8. Remove the backing plate, drive plate, and adapter. 4, Remove the SST. Water pipe and thermostat housing 1. Disconnect the clip and separate the knock sensor har- ness from the water pipe. 2. Remove the waterpipe and thermostat housing as an as sembly. B2-67DISASSEMBLY Knock sensor Remove the knock sensor by using the SST. Oil pan 7. Remove the oil pan mounting volts. 9. Remove the old sealant from the bot threads. 3. Turn aboltinto the boll beie as shown to make 2 sali gap: between the oli pan and the lower cylinder block, 4. Separate the oil pan trom the lower cylinder block by using a sorew driver or suitable tool. Front oll seat Remove the cil seal by using a screwdriver protected with, arag. B2-68DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) B2 Disassemble in the order shown in the figure, referring to Disassembly Note, 1. Connecting rad cap Disassomoly Note ........... page B2-70 2. Lower connecting rod bearing Inspection ...............--. page B2-84 8. Piston and connecting rod assembly Disassembly Note ........... page B2-70 4, Piston ring Disassembly Note . - page 82-70 Inspection + page B2-82 5, Piston pin Disassembly Note . = page B2-70 Ingpection 2.) * page B2-82 8. Connecting rod Disassembly Note - ses page B2-70 Inapection .... “page B2-83 Inspection .........2....+2.- page B2-8t 8. Lower cylinder block Disassembly Note .. -- page B&-71 9, Lower main bearing and thrust bearing 10.Crankshaft ingpection page .... -- B28, 11. Rear oil soa 12.Upper main bearing and thrust bearing 18.0 jet Inspection «+ page B2-84 14. Gylinder block Inspection... eee e cee page B2-81 B2-69