Chapter 2 Engine Assembly

Section 1 3-cylinder engine assembly 18

Section 2 4-cylinder engine assembly 28

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 Chapter2 Engine Assembly

Section 1 3-cylinder Engine Assembly

Engine removal and installation

Removal
1) Remove engine hood (4 bolts).
［ NOTE ］ Due to the high weight of engine
hood, do this work by at least two operators, and
never scratch engine hood or body.
2) Remove fuel pipes （ Release pressure of
fuel first）。
3) Recollect air-conditioner refrigerant,
drain lubrication oil and coolant fully.
4) Remove battery terminal post connection,
and remove battery fixed clip, then take out
battery.
5) Remove battery support bracket (4 bolts).

6) Remove air cleaner Ay.

7) Remove all hoses connecting engine.
8) Remove plugs connecting engine wires
and ECU, and draw wires from cab to engine-
room.
9) Remove the starter motor plug.
10) Remove plugs connecting engine
wires with other wires.
11) Remove the generator earth wire.
12) Remove the starter motor earth wire
and the front cross-arm earth wire.
13) Remove high-pressure pipe and low-
pressure pipe of air-conditioner.
14) Remove air-conditioner belt.
15) Remove the compressor (4 bolts).

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 16) Remove the clutch cable.

17) Lift car, support it by safety bracket

and remove wheels.
18) Drain lubricating oil in
transmission case.

19) Remove the shifter S/A (3 bolts).

20) Remove 2 bolts connecting the

exhaust pipe with the exhaust manifold, and
take it from the exhaust manifold.

21) Remove under-protection cover

(2bolts and a clip).

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 22) Remove the stabilizer bar (4 bolts and 2 nuts).

23) Remove the suspension lower cross-arm

bracket S/A (3 bolts in right, and 3 bolts in left).

24) Remove the front drive shaft.

［ NOTE ］ Inside of drive shaft, there is no
retainer for universal joint, so hold this part when
removing.
Specified service tool:
09648-87201-000

25) Remove the engine rear mounting

bracket sub-plate. Remove 3 bolts only of
transmission side.
26) Remove the engine right mounting
bracket (4 bolts).
Remove fixed bolts between lower engine
mounting beam S/A and engine right mounting
bracket.

27) Hang up engine by specified hoist

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equipment.

28) Remove engine Ay.

① Remove left engine fixed insulator
② Remove the front fixed insulator(one
bolt)
③ Hang up engine by specified hoist
equipment.
［ NOTE ］ Before drop engine, make final
check for disassembly parts as demanded.

29) Remove the starter motor Ay from the

transmission.
30) Remove the transmission Ay from the
engine Ay.
31) Put the engine Ay on the specified
bracket.

Installation

1) Remove the engine from the specified

bracket.
2) Install the transmission Ay on the engine
Ay.
Tighten Torque：
49～68.6N·m(5.0～7.0kgf·m)

3) Install the starter motor on the

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transmission.
4) Install engine Ay.
① Hang up the engine with specified hoist.
②Install the front insulator to the engine(one
bolt).
Tighten Torque ： 73.5 ～ 102.9N·m(7.5 ～
10.5kgf·m)
③Install the left insulator to the engine.
Tighten Torque ： 73.5 ～ 102.9N·m(7.5 ～
10.5kgf·m)

5) Install the engine right mounting bracket.

Tighten Torque：
73.5～102.9N·m(7.5～10.5kgf·m)

6) Install the rear mounting bracket sub-

plate on the engine (3 bolts).
Tighten Torque ： 29.4 ～ 44.1N·m(3.0 ～
4.5kgf·m)

7) Remove the specified hoist from the

engine
Ay.

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 8) Install the front drive shaft.
［NOTE］Install the front drive shaft on the differential carrier carefully and slowly so as not to
damage the oil seal.

9) Install the suspension lower cross-arm

bracket S/A (3 bolts in the right, and 3 bolts in the
left).
Tighten Torque：
73.5～102.9N·m(7.5～10.5kgf·m)

10) Install the stabilizer bar.

① Install the stabilizer bar on the lower
cross-arm (2 nuts).
Tighten Torque：
73.5～107.8N·m(7.5～11.0kgf·m)
② Tighten the stabilizer bar bracket (4
bolts).
Tighten Torque：
39.2～58.8N·m(4.0～6.0kgf·m)

11) Install the under-protection cover for

the engine (2 bolts and a clip) .

12) Install the exhaust pipe Ay.

Tighten Torque：
29.4～49N·m(3.0～5.0kgf·m)

13) Install the shifter S/A.

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 Tighten Torque：
9.8～15.68N·m(1.0～1.6kgf·m)
［NOTE］After installing, make sure that the shifter can be released and shifted smoothly at
each speed position.

14) Pour the oil fully into the transmission.

15) Tighten the wheels slightly. After

removing the backstop of the car, tighten the
wheels thoroughly.
Tighten torque:
88.2～117.6N·m(9.0～12.0kgf·m)

16) Install the clutch cable.

［ NOTE ］ Apply all-purpose grease lubricant to
the place where the clutch release lever and the
clutch cable are joint.

17) Install the compressor and the belt of the

compressor.
18) Install the high and low-pressure pipes
for the air condition.

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 19) Join all the cable plugs and earth
wires, including the starter motor and ECU,
etc.
20) Install all the hoses connecting the
engine, including the gasoline pipe.
21) Install the air cleaner Ay.

22) Install the battery bracket

23) Install the battery clip.
Install the connection on the
terminal post.

24) Fill engine oil into the engine.

Engine oil capacity: 3.2L
Check the engine oil level.

25) Pour the coolant into the radiator and

the fluid reservoir.
［NOTE］ After finished, check the leakage.

26) Fill the air condition with refrigerant.

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 27) Install the engine hood.
［NOTE］Apply rust-proof grease on the bolts.

Section 2 4-cylinder Engine Assembly

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Engine removal and installation
Removal
1) Remove the engine hood (four bolts).
[NOTE] Due to the high weight of engine hood, do
this work by at least two operators, and never
scratch engine hood or body.
2) Remove the fuel pipes（Release pressure of
fuel first）.

3) Recollect the air-condition refrigerant.

4) Drain the engine oil and coolant fully and

remove the radiator Ay.

5) Remove the battery terminal post connection,

remove the fixed clip of battery, and remove the
battery.
6) Remove the battery bracket.

7) Remove the clutch cable.

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 8) Remove the accelerator cable.

9) Remove the air cleaner Ay.

10) Drain the power steering oil fully and

remove the power steering pump and partial
pipes.

11) Remove all hoses connecting the engine,

Including water pipes and power brake hoses.
12) Remove the plug connecting the engine
wire and ECU, and draw the wire from cab to
engine-room.
13) Remove the plugs connecting engine
wires and other wires.
14) Remove the wire connecting the engine
gearbox Ay and other parts.

15) Remove the high and low pressure pipes of

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the air-conditioner.
16) Remove the air-conditioner belt.
17) Remove the compressor.

18) Lift the car and remove the wheels.

19) Remove the under-protection cover (6 bolts
and 1 clip).
20) Drain the lubrication oil from the
transmission.

21) Remove the shifter S/A(3 blots).

22) Remove the stabilizer bar and the

strengthening beams (6 bolts and 2 nuts).

23) Remove the stabilizer bar support plate (4

bolts in the right, and 4 bolts in the left).

24) Remove the suspension lower cross-arm

S/A (3 bolts in the right, and 3 bolts in the left).

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 25) Remove the engine lower protecting beam (3 bolts).
26) Remove the exhaust pipe, take it from the exhaust manifold.（2 bolts and 2 nuts）

27) Remove the front drive shaft.

［NOTE ］ Inside of the drive shaft, there is no
retainer for universal joint, so hold this part when
removing.
SST：09648-87201-000

28) Hang up the engine by specified hoist

equipment.
Place the specified bracket under the engine
and may replace it by available bracket or desk.

29) Remove engine Ay.

① Remove the mounting bracket of the
transmission（4 bolts）.

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 ② Remove the rear insulator of the
engine (1 bolt).

③ Remove the front insulator of the

engine(2 bolts and 1 nut).
④Hang up the engine by specified hoist
equipment and place the engine to the specified
bracket slowly.
［ NOTE ］ Before drop the engine, make final
check for every disassembly parts as demanded.
Remove the engine from the lower side of the
engine compartment.

30) Remove the starter motor Ay from the

transmission.
31) Remove the transmission Ay from the
engine Ay.
32) Put the engine Ay on the specified bracket.

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Installation
1) Remove the engine from the specified
bracket.
2) Install the transmission Ay on the engine
Ay.
Tighten Torque:
49～68.6N·m(5.0～7.0kgf·m)
M10 Tighten Torque 46 N·m

3) Install the starter motor on the

transmission.
4) Install the engine Ay.
①Hang up the engine with specified hoist.
②Install the front insulator to the engine.(2
bolts and 1 nut)
Tighten Torque: 73.5 ～ 102.9N·m(7.5 ～
10.5kgf·m)
③ Install the rear insulator to the engine.
Tighten Torque: 98 ～ 117.6N·m(10 ～
12kgf·m)
④ Install the bracket for the transmission.
（4 bolts）
5) Remove the special hoist from the engine.

6) Install the front drive shaft.

［ NOTE ］ Install the front drive shaft on the
differential carrier carefully and slowly so as not
to damage the oil seal.

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 7) Install the exhaust muffler Ay.
Tighten Torque:
44～81N·m(4.5～8.2kgf·m)

8) Install the under-protection cover for the

engine. (3 bolts)
Tighten Torque:
73.5～107.8N·m(7.5～11.0kgf·m)

9) Install the suspension lower cross-arm

bracket S/A.
Tighten Torque:
73.5～102.9N·m(7.5～10.5kgf·m)

10) Install the stabilizer bar support plate.

(8 bolts)

11) Install the stabilizer bar and the

strengthening beam. (2 bolts)
①Install the stabilizer bar on the lower
cross-arm.
Tighten Torque:
73.5～107.8N·m (7.5～11.0kgf·m)
② Tighten the stabilizer bar bracket. (6
bolts)
Tighten Torque: 39.2 ～ 58.8N·m(4.0 ～
6.0kgf·m)
12) Install the shifter S/A.

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 Tighten Torque:
9.8～15.68N·m(1.0～1.6kgf·m)
［NOTE］After installing, make sure that the shifter can be released and shifted smoothly at
Bolt
each speed position.

13) Fill the lubrication oil into the

transmission.

14) Install the under-protection cover for

the engine. (6 bolts)

15) Tighten the wheels slightly. After

removing the backstop of the car, tighten the
wheels thoroughly.
Tighten torque:
88.2～117.6N·m(9.0～12.0kgf·m)

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 16) Install the compressor.
Tighten torque: 24.5~29.4 N·m
17) Install the compressor belt.
18) Install the high and low-pressure
pipes for the air condition.

19) Install the power steering pump and

hoses.
Tighten torque:
M10 bolt: 39.2 N·m
M8 bolt: 19.1 N·m

20) Connect all the cable plugs and earth

Hood
wires, including the starter motor and ECU, etc.
21) Install all the hoses connecting the
engine, including the gasoline pipe.
Clip
22) Install the air Cleaner Ay.

Battery

23) Install the clutch cable.

［ NOTE ］ Apply all-purpose grease to the
place where the clutch release lever and the
clutch cable are joint.

24) Install the accelerator cable.

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 25) Install the support bracket for the
battery.（4 bolts） Hood
26) Install the terminal clip for the battery
and the wires on the terminal post.
Clip

27) Pour the engine oil into the engine Battery

fully.
Engine oil capacity: 3.2L
Check the engine oil level.

28) Pour the coolant into the radiator and

the fluid reservoir.
［NOTE］ After finished, check the leakage.

29) Fill the air condition with the refrigerant.

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 30) Install the engine hood.
[NOTE] Apply the rust-proof grease on the bolts.

bolts bolts

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CHAPTER 3 CLUTCH & CLUTCH CONTROL MECHANISM

SECTION 1 MECHANISM & SPECIFICATION 41

CLUTCH 41
CLUTCH RELEASE LEVER & CLUTCH RELEASE LEVER YOKE 42
CLUTCH DISC 42
CLUTCH COVER 43
CLUTCH CABLE 43
CLUTCH PEDAL 43

SECTION 2 MAINTENANCE 44
CLUTCH 44
CLUTCH PEDAL & CLUTCH CABLE 49
CLUTCH PEDAL ADJUSTMENT 52
TROUBLESHOOTING 53

CHAPTER 3 CLUTCH & CLUTCH

CONTROL MECHANISM
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 SECTION 1 MECHANISM & SPECIFICATIONS

CLUTCH

The clutch mechanism employs a dry, single-disc, diaphragm spring type. As for its operating
way, a cable method is adopted.

Clutch

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Clutch Specifications
Item Specifications

Outer diameter × inner diameter 170×110mm

Clutch Disc Thickness 3.1±0.1mm

Material Without asbestos

Clutch Cover Diaphragm spring load as assembled 2205N（225kgf）

Clutch release lever & clutch release lever yoke

The clutch release leaver yoke is attached to the clutch release lever with a bolt.

Clutch release mechanism

Clutch disc

Clutch disc

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Clutch cover

Clutch cover

CLUTCH CABLE

The structure of Clutch pedal is as shown in

figure.
The free travel of clutch pedal can be adjusted by
adjusting the end of clutch cable connecting to
the gearbox.

clutch cable
CLUTCH PEDAL
The installation height of clutch pedal can be adjusted
by adjusting the bolt.

The installation height:

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clutch pedal

SECTION 2 MAINTENANCE

CLUTCH

COMPONENTS

REMOVAL
1. Remove the transmission assembly from the
vehicle.
2. Release the lock plate. Proceed to remove
the lock plate along with the bolt.

3. Pull out the clutch release fork lever. Remove the

bush, release lever yoke, spring, release bearing clip
and release bearing hub.

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4. Remove the clutch cover from the flywheel.
Take out the clutch disc.

INSPECTION
1. Check the pressure plate and flywheel
surface for scores, cracks and discoloration.

2. Check the diaphragm spring tips for wear, rust

and breakage

3. Check the clutch disc for wear and

runout.
Allowable Wear Limit (Rivet Depth):
0.3 mm

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Allowable Limit of Lateral Runout:
1.34 mm
NOTE:
Measure the lateral runout with the clutch disc
assembled onto a new input shaft.

4. Check to see if the release bearing

rotates smoothly.
Rotate the release bearing by your hand, while
applying a pressure to the bearing in a thrust
direction. Check to see if the bearing rotates
without any abnormal feeling or binding.

5. Check the release bearing hub, clip-

contacting surface and hub-to-housing sliding
section for damage and wear.

6. Check to see if the clip has the configuration

as shown in the figure in its horizontal plane.

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INSTALLATION
1. Install the clutch disc and clutch cover,
using the following SST.
SST: 09301-87202-000
Tightening Torque: 1.5 - 2.2 kg·m (14.7 -
21.56N·m)

NOTE:
①Assemble the clutch disc in the
direction as shown in the figure.
②Tighten the bolts evenly, starting with
those bolts provided near the locating pin.
③Apply lithium-based grease to the clutch disc
spline.

2. Check the clutch cover diaphragm spring

tips for variation in height. Adjust the
diaphragm spring tips, if it is necessary.
Check
Allowable Limit of Variation in
Height:
0.7 mm
SST: 09302-87701-000

3. Assemble the clutch release bearing

hub and release bearing clip to the
clutch release lever yoke.
(1) Bring the cut-out section of the
release lever yoke in contact with the
clip.
(2) Under the condition described in (1), assemble the
lever yoke by turning it 180 degrees.

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NOTE:
Apply lithium-based grease to the yoke-to-hub sliding
section and bearing-to-housing case sliding section.

4. Assemble the bush, dust seal, torsion spring and

clutch release lever in position.

5. Assemble the bolt with washer, with

the lock plate interposed.
Tightening Torque: 3.0 - 4.0 kg-m (29.4 - 39.2 N·m )

6. Check the release hub and yoke for

proper operation.
Operate the clutch release lever about
50 times. Check the section A of the
clip. If the clip exhibits excessive
spread and there is a likelihood that the
clip may be detached, replace it with a
new clip.
7. Install the transmission assembly to the vehicle.

CLUTCH PEDAL AND CLUTCH RELEASE CABLE

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COMPONENTS

REMOVAL
1. Remove the brake pedal.
2. Remove the nut located at the clutch
pedal installation section. Separate
the end section of the clutch release
cable.

3. Remove the adjusting bolt.

4. Remove the bolt.

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5. Remove the cable bracket-attaching
bolt. Remove the clutch cable.

6. Remove the clutch pedal assembly.

Remove the spring, bush and spacer.

INSPECTION
Inspect the following parts.
1. Bush for wear or damage.
2. Pedal spacer for wear or damage.
3. Pedal for damage or deformation.
4. Pedal pad for wear or damage.
5. Spring for flattened condition.

6. Each section of clutch cable

INSTALLATION
14.7~21.56N· m
1. Apply grease to the following points. (1.5~ 2.2 kgf·m)
(1) inside of bush and spacer

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 (2) Connecting section of clutch pedal and release cable.

2. Install the spring, bush and spacer to the clutch pedal

assembly. Then, install the assembly to the pedal bracket.

3. Install the bolt.

4. Install both ends of the clutch cable. Tighten the bracket on

the body with the bolts.
Tightening Torque: 3.92 - 6.86N·m(0.4 - 0.7 kgf·m)

5. Install the stopping and adjusting bolt.

6. Tighten the nut.

Tightening Torque: 14.7 -
21.56N·m (1.5- 2.2 kgf·m)

7. Depress the clutch pedal 2～3 times.

Then adjust the stroke of clutch
pedal, following the procedure.
8. Install the brake pedal assembly.

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CLUTCH PEDAL
ADJUSTMENT
1. Check the clutch pedal for the
installation height.
Pedal installation height (Distance
between pedal pad upper surface’s
center and dash panel) ： 181.5-
186.5mm.

2. Adjust the pedal installation height, as

required.
(1) Slacken the lock nut. Turn the
stopper bolt until the Installation
height conforms to specification.
(2) Tighten the lock nut.

15 ～ 30mm

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3. Clutch cable adjustment
(1) Pull the over of cable lightly with a
force of 2 - 2.5 kgf. Check the
clearance.
(2) Ensure that the stopper (protruding
portion) is fitted securely in the
adjusting groove.
(3) Adjusting position of clutch outer
cable：3 - 6 mm

4. Adjust the clutch pedal free travel.

Depress the clutch pedal gradually
until you feel a resistance from the
clutch. Measure the depressing
distance up to this point.
Pedal Free Travel: 15 - 30 mm

5. Adjust the clearance between the

clutch pedal and the floor when the
pedal fully depressed. (Minimum
clearance between the dash panel
and the pedal arm)
This clearance value：≥ 25mm

Troubleshooting
Malfunction Possible causes Remedies
Hard to or could  Excessive free travel of clutch pedal  Adjust the free travel
not engage the  Excessive clutch disc runout, or  Check the clutch disc

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gear damaged disc line
 Contaminated or adhered Input shaft or
disc spline
 Faulty clutch cover
Slipping clutch  Improper clutch pedal free travel
 Worn or oily clutch disc linings
 Faulty clutch cover
 Flattened diaphragm spring
Grabbing and  Worn or oily clutch disc linings
chattering clutch
 Faulty clutch cover
 Failed disc torsion spring
 Bent diaphragm spring
Clutch noises  Loose fastenings
 Worn or contaminated release bearings
 Seized release yoke or linkage
Dragging clutch  Improper clutch pedal free travel
 Failed diaphragm spring or worn spring
tips
 Repair
 Replace clutch cover
 Adjust the free travel
 Replace the clutch disc
 Replace the clutch cover
 Replace the clutch cover
 Repair or replace clutch disc
 Replace the clutch cover
 Replace the clutch disc
 Replace the clutch cover
 Repair
 Replace the release bearing
 Repair
 Adjust the free travel
 Replace the clutch cover
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