ENGINE MECHANICAL

CO (w/o TWC) . . . . . . . . . . . . . . . . . . . . . . . . . . . EM–1

CO/HC (w/ TWC) . . . . . . . . . . . . . . . . . . . . . . . . . EM–3
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . EM–5
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM–7
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM–8
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . EM–9
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . EM–13

REFER TO FOLLOWING REPAIR MANUALS:

Manual Name Pub. No.
3S–FE Engine Repair Manual RM395E
3S–FE Engine Repair Manual Supplement RM495E
NOTE: The above pages contain only the points which differ
from the above listed manuals.
 EM–1
ENGINE MECHANICAL – CO (w/o TWC)

CO (w/o TWC) EM0IB–01

INSPECTION
HINT:
This check is used only to determine whether or not the idle CO
complies with specifications.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) EFI system wiring connectors fully plugged
(g) Ignition timing checked correctly
(h) Transmission in neutral position
(i) Air conditioning switched OFF
(j) Tachometer and CO meter calibrated by hand
2. CHECK AND ADJUST CO CONCENTRATION AT IDLE
NOTICE:
Always use a CO meter when adjusting the idle mixture. It is not
necessary to adjust with the idle mixture screw in most vehicles
if they are in good condition. If a CO meter is not available, DO
NOT ATTEMPT TO ADJUST IDLE MIXTURE.

(a) Using SST, connect terminals 13 (TC) and 4 (CG) of the

DLC3
DLC3.
4 (CG) SST 09843–18040
(b) Race the engine at 2,500 rpm for approx. 180 seconds.

SST 13 (TC)

A00987

(c) Insert a CO meter testing probe into the tailpipe at least

CO Meter
40 cm (1.3 ft).
(d) Wait at least 1 minute before measuring to allow the con-
centration to stabilize. Complete the measuring within 3
minutes.
Idle CO concentration: 1.0 - 2.0 %

A02622
EM–2
ENGINE MECHANICAL – CO (w/o TWC)

If the CO concentration does not conform to regulations, adjust

by turning the idle mixture adjusting screw in the variable resis-
tor with SST.
SST 09243–00020
Idle Mixture
Adjusting
Screw
SST

B03543

HINT:
The idle mixture adjusting screw can be tightened through on
angle of 180°.
S If the CO concentration is within specification, this
adjustment is complete.
S If the CO concentration cannot be corrected by idle
mixture adjustment, see the table on page EM–3 for
180° other possible causes.
A01322 (e) Remove the SST.
SST 09843–18040
 EM–3
ENGINE MECHANICAL – CO/HC (w/ TWC)

CO/HC (w/ TWC) EM0IC–01

INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with specifications.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) EFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPOROX. 180 SE-
CONDS

4. INSERT CO/HC METER TESTING PROBE INTO TAIL-

CO/HC Meter
PIPE AT LEAST 40 cm (1.3 ft) DURING IDLING
5. CHECK CO/HC CONCENTRATION AT IDLE
Idle CO concentration: 0 – 0.5 %
Idle HC concentration: Applicable local regulation
If the CO/HC concentration does not conform to specifications,
perform troubleshooting in the order given below.
(1) Check the oxygen sensor operation.
A02622 (2) See the table next page for possible causes, and
then inspect and correct the applicable causes if
necessary.
EM–4
ENGINE MECHANICAL – CO/HC (w/ TWC)

HC CO Problems Causes
Normal High Rough idle 1. Faulty ignition:
S Incorrect timing
S Fouled, shorted or improperly gapped plugs
S Open or crossed high–tension cords
2. Incorrect valve clearance
3. Leaky EGR valve
4. Leaky intake and exhaust valves
5. Leaky cylinders
Low High Rough idle 1. Vacuum leaks:
(Fluctuating HC reading) S PCV hoses
S EGR valve
S Intake manifold
S Throttle body
S Brake booster line
2. Lean mixture causing misfire
High High Rough idle 1. Restricted air filter
(Black smoke from exhaust) 2. Plugged PCV valve
3. Faulty EFI systems:
S Faulty pressure regulator
S Defective water temperature sensor
S Faulty engine ECU
S Faulty injectors
S Faulty throttle position sensor
S Faulty vacuum sensor
 EM–5
ENGINE MECHANICAL – IGNITION TIMING

IGNITION TIMING EM0ID–01

INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.

Hand–Held Tester 2. CONNECT HAND–HELD TESTER TO DLC3

(a) Connect a hand–held tester to the DLC3.
(b) Please refer to the hand–held tester operator’s manual
for further details.

A00988

If you have no hand–held tester, connect a tachometer tester

DLC3 probe to terminal 9 (IG–) of the DLC3 with SST.
Tachometer SST 09843–18030
9 (IG–)
3. CONNECT TIMING LIGHT TO ENGINE
4. CHECK IDLE SPEED (See page EM–7)
5. DISCONNECT HAND–HELD TESTER FROM DLC3
SST
Battery
A00986

6. INSPECT IGNITION TIMING

DLC3
(a) Using SST, connect terminals 13 (TC) and 4 (CG) of the
4 (CG) DLC3.
SST 09843–18040

SST 13 (TC)

A00987

(b) Using a timing light, check the ignition timing.

Ignition timing:
8 – 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC3.
7. FURTHER CHECK IGNITION TIMING
Ignition timing:
10 – 20° BTDC @ idle
A04206 (Transmission in neutral position)
EM–6
ENGINE MECHANICAL – IGNITION TIMING

HINT:
The timing mark moves in a range between 10° and 20°.
8. DISCONNECT TIMING LIGHT FROM ENGINE

HINT:
Reference (w/o TWC):
When the fuel control connector is unplugged, use gasoline of
95 RON or higher.
When the fuel control connector is plugged together, use gaso-
line from 90 up to 94 RON.

Fuel Pump
Connector
B01386
 EM–7
ENGINE MECHANICAL – IDLE SPEED

IDLE SPEED
EM0IE–01

INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All vacuum lines properly connected
(e) EFI system wiring connectors fully plugged
(f) All operating accessories switched OFF
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Air conditioning switched OFF
2. CONNECT HAND–HELD TESTER TO DLC3 (See page EM–5)
3. INSPECT IDLE SPEED
(a) Race the engine at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed (w/ Cooling fan OFF):
w/ Day light 750 ± 50 rpm
w/o Day light 700 ± 50 rpm
If the idle speed is not as specified, check the air intake system.
4. DISCONNECT HAND–HELD TESTER FROM DLC3
EM–8
ENGINE MECHANICAL – TIMING BELT

TIMING BELT
EM0IF–01

COMPONENTS

No.2 Timing Belt *1 Gasket

Timing Belt
Cover

Wire
Clamp
RH Engine
Mounting
Bracket
Alternator

52 (530, 38)
Timing Belt
Guide
No.1 Timing Belt *1 Gasket
Cover
Crankshaft
Pulley High–Tension
Cord

108 (1,100, 80)

Spark Plug
18 (180,13)
Wire Clamp

Wire Clamp

Wire Clamp
Wire Clamp
Camshaft Timing
Pulley Tension Spring

54 (550, 40)
*2 37 (380, 27)

No.1 Idler Pulley

42 (425, 31)

No.2 Idler Pulley

42 (425, 31)

24 (245,18)

Oil Pump Pulley

Crankshaft Timing Pulley
N·m (kgf·cm, ft·lbf) : Specified torque
*1 Replace only if damaged
*2 For use with SST A04889
 EM–9
ENGINE MECHANICAL – CYLINDER HEAD

CYLINDER HEAD
EM0IG–01

COMPONENTS
Wire Clamp
Ignition Coil
Connector
Ignition Coil and No.2 Intake
Manifold Stay Assembly Throttle Position
(with High–Tension Cord) Sensor Connector
Air Hose
(Except Europe) 19 (195, 14)

Vacuum Hose
(w/ TWC)
Water
Temperature ISC Valve
Sensor Connector
Purge Hose
Alternator Connector
Throttle Body
Water Outlet

z Gasket
Oil Pressure
Switch w/ TWC
Connector

No.1 Exhaust Manifold

Heat Insulator

z Gasket

w/o TWC

x5

x6
No.1 Exhaust 49 (500, 36)
Manifold Heat
Insulator
Exhaust
Exhaust Manifold
Manifold
and No.2 Exhaust
49 (500, 36) Exhaust Manifold Stay
x6 Manifold Heat
Insulator and No.2 Exhaust
Exhaust Assembly Manifold Heat
Manifold Insulator
Stay Assembly

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part A04845
EM–10
ENGINE MECHANICAL – CYLINDER HEAD

EGR Valve and Vacuum

Modulator (w/ TWC)
Ground Wire

z Gasket

VSV Connector
for EGR

Intake
Manifold VSV for EGR

Fuel Inlet Hose

z Gasket
19 (195, 14)

13 (130, 9)
Air Hose
(Except Europe)
34 (350, 25)
Fuel Pressure Regulator * 29 (300, 21)
(Except Europe)
z Gasket
Delivery Pipe
Spacer

Spacer
z O–Ring Injector
z Grommet Connector

Injector
z Insulator
Engine Wire
PCV Hose

Knock Sensor
Connector

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part
* For use with SST B03986
 EM–11
ENGINE MECHANICAL – CYLINDER HEAD

Spark Plug
18 (180, 13)
Adjusting
Shim
44 (450, 33)
Valve Lifter
Grommet
Keeper
Cylinder Head Cover Spring Retainer

Gasket Valve Spring

z Oil Seal
Exhaust Spring Seat
19 (190, 14)
Camshaft
Intake z Valve Guide
Camshaft Bushing

Camshaft Bearing Cap Valve

z Camshaft Oil Seal
1st 49 (500, 36)
2nd Turn 90°
Camshaft Timing Pulley Engine
Camshaft
Semi–Circular Hanger
Gear Spring
54 (550,40) Plug
*2 37 (380, 27) Camshaft Sub–Gear
Snap Ring Semi–Circular
Plug
Wave Washer
Camshaft Position Sensor Connector
Camshaft Position Sensor
Oil Pressure
Wire Clamp
Switch
No.3 Timing Belt Cover
42 (425, 31)
Cylinder
Head
Wire Clamp z Cylinder
Tension Spring Head
Gasket
No.1 Idler Pulley Timing Belt

*1 Gasket

No.2 Timing
Wire Belt Cover
Clamp
Wire
Clamp

52 (530, 38)

RH Engine
Mounting
Bracket
N·m (kgf·cm, ft·lbf) : Specified torque Alternator Bracket
z Non–reusable part and RH Engine Hanger
*1 Replace only if damaged Assembly
*2 For use with SST B03987
EM–12
ENGINE MECHANICAL – CYLINDER HEAD
EM0IH–01

INSPECTION
1. INSPECT VALVE SPRINGS
Using vernier calipers, measure the free length of the valve
spring.
Free length: 40.95 – 42.80 mm (1.6122 – 1.6850 in.)
If the free length is not as specified, replace the valve spring.

EM0801
 EM–13
ENGINE MECHANICAL – CYLINDER BLOCK

CYLINDER BLOCK
EM0II–01

COMPONENTS

No.2 Timing Belt

Cover Alternator
* Gasket

Wire
RH Engine Clamp
Mounting Timing Belt
Bracket

52 (530, 38)
No.1 Timing Timing Belt Guide
Belt Cover
* Gasket
Crankshaft
Pulley High–Tension Cord

108 (1,100, 80)

Spark Plug
L
18 (180, 13)
88 (900, 65)
Wire Clamp
Wire Clamp
No.1 Rear
Wire Clamp
Camshaft End Plate
Timing Wire Clamp
Pulley

54 (550, 40)

Flywheel
42 (425, 31) (M/T)

42 (425, 31)
A/T
L
No.2 Idler 83 (850, 61)
Pulley Tension Spring Drive Plate

No.1 Idler Pulley

Crankshaft Timing Pulley

Rear Spacer

N·m (kgf·cm, ft·lbf) : Specified torque Front Spacer

L Precoated part
* Replace only if damaged A00989
EM–14
ENGINE MECHANICAL – CYLINDER BLOCK

44 (450, 33)
PCV Hose
19 (190, 14) Intake Camshaft

Grommet Camshaft
Bearing Cap Exhaust
Camshaft
Cylinder Head
Cover

Gasket

x 10
z Camshaft Oil Seal 1st 49 (500, 36)
2nd Turn 90°

Cylinder Head Assembly

Accelerator Cable
Bracket
No.3 Timing Belt Cover

VSV for EGR (w/o TWC)

z Cylinder Head Gasket

ISC Valve Water Bypass Hose Water

Bypass
Knock Sensor Connector Hose

w/o TWC
Wire Clamp

Exhaust
Manifold Exhaust Manifold
Stay Stay (w/ TWC)

Crankshaft Position
Sensor Connector
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part
A04843
 EM–15
ENGINE MECHANICAL – CYLINDER BLOCK

Oil Filter
Water Pump, Water Bypass Pipe
and Oil Cooler Assembly

78.5 (800, 58)

Alternator Drive Belt

Adjusting Bar
Plate Washer
z O–Ring

Oil Dipstick
PS Pump Bracket

Knock Sensor

Crankshaft
z O–Ring
Position Sensor
Connector
Oil Pump

x 10 Oil Pan Baffle Plate

z Gasket

5.4 (55, 48 in.·lbf)

8.8 (90, 78 in.·lbf)

z Gasket
z Crankshaft
Front Oil Seal
Oil Strainer
x 17

5.4 (55, 48 in.·lbf)

z Gasket
Drain Plug
Oil Pan
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part A04844
EM–16
ENGINE MECHANICAL – CYLINDER BLOCK

No.1 Piston Ring

No.2 Piston Ring
Side Rail
Expander Oil Ring
Side Rail

Piston Pin
Piston

Connecting Rod

Connecting Rod Bearing

z Crankshaft
Connecting Rod Cap Rear Oil Seal
1st 25 (250, 18)
2nd Turn 90°
z Gasket

Cylinder Block x6

Rear Oil Seal

Retainer

Upper Crankshaft Thrust Washer

Upper Main Bearing

Lower Main Bearing

Lower Crankshaft Thrust Washer

Main Bearing Cap

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part 59 (600, 43)
A04842
 EM–17
ENGINE MECHANICAL – CYLINDER BLOCK
EM0IJ–01

Mark Mark INSPECTION

1, 2 or 3 Z (w/ TWC) 1. INSPECT PISTON
or
Y (w/o TWC) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked ”1”,
”2” and ”3” accordingly. The mark is stamped on the piston top.
Front Mark
(Cavity)
A00966

(1) Using a micrometer, measure the piston diameter at

right angles to the piston pin center line, 23 mm
(0.91 in.) from the piston head.
Piston diameter:
w/ TWC
STD Mark ”1” 85.837 – 85.847 mm (3.3794 – 3.3798 in.)
Mark ”2” 85.847 – 85.857 mm (3.3798 – 3.3802 in.)
23 mm Mark ”3” 85.857 – 85.867 mm (3.3802 – 3.3806 in.)
O/S 0.50 86.337 – 86.367 mm (3.3991 – 3.4003 in.)
A00967
w/o TWC
STD Mark ”1” 85.847 – 85.857 mm (3.3798 – 3.3802 in.)
Mark ”2” 85.857 – 85.867 mm (3.3802 – 3.3806 in.)
Mark ”3” 85.867 – 85.877 mm (3.3806 – 3.3810 in.)
O/S 0.50 86.347 – 86.377 mm (3.3995 – 3.4007 in.)

(2) Measure the cylinder bore diameter in the thrust

directions.
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
w/ TWC 0.153 – 0.173 mm (0.0060 – 0.0068 in.)
w/o TWC 0.143 – 0.163 mm (0.0056 – 0.0064 in.)

Maximum oil clearance:

w/ TWC 0.193 mm (0.0076 in.)
w/o TWC 0.183 mm (0.0072 in.)

If the oil clearance is greater than maximum, replace all the 4

pistons and rebore all the 4 cylinders. If necessary, replace the
cylinder block.
EM–18
ENGINE MECHANICAL – CYLINDER BLOCK

HINT:
Mark 1, 2 or 3 Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.

No.1 No.2 No.3 No.4

Mark Mark
1, 2 or 3 Z (w/ TWC)
or
Y (w/o TWC)

Front Mark
(Cavity)
A04891
A00966 A04890
 EM–19
ENGINE MECHANICAL – CYLINDER BLOCK
EM0IK–01

REPLACEMENT
REPLACE OVERSIZED (O/S) PISTONS FOR CYLINDER
BORING
HINT:
S Bore all the 4 cylinders to the oversized piston outside di-
ameter.
S Replace all the piston rings with ones to match the over-
sized pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
w/ TWC 86.337 – 86.367 mm (3.3991 – 3.4003 in.)
w/o TWC 86.347 – 86.377 mm (3.3995 – 3.4007 in.)

(b) Using a micrometer, measure the piston diameter at right

angles to the piston pin center line, 23 mm (0.91 in.) from
the piston head.
(c) Calculate the amount each cylinder is to be rebored as fol-
lows:
Size to be rebored = P + C – H
P = Piston diameter
23 mm C = Piston clearance:
A00967 w/ TWC 0.153 – 0.173 mm (0.0060 – 0.0068 in.)
w/o TWC 0.143 – 0.163 mm (0.0056 – 0.0064 in.)

H = Allowance for honing: 0.02 mm (0.0008 in.) or less

(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.