ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS 11-1

SECTION 11

ENGINE
CONTENTS

General .......................................................1 Camshaft, valve stem seals .....................4

Servicing standards .................................1 Cylinder head gaskets.............................14
Sealants .....................................................1 Timing belt, timing belt B........................20
Special tools ..............................................2 Engine ASSY ............................................28
Engine tuning .............................................4
1. Checking of revolutions when idling ................4
2. Checking compression pressure.......................4

General

The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.

Servicing standards

Sealants

Note
The code inside the brackets ( ) is the actual product number.
11-2 ENGINE – SPECIAL TOOLS

Special tools

Tool Number Name Function

MB991502 MUT-II Sub Checking and adjusting the tension in
ASSY timing belt B

Note
If a MUT-III main harness A is
connected to a vehicle not fitted with
CAN, there is a chance that a pulse
signal will be entered in the simulated
vehicle speed line, when the MUT-III is
MB991955 MUT-III Sub ASSY activated. Therefore, use a MUT-III main
A: MB991824 A: Vehicle harness B with vehicles not fitted with
B: MB991827 Communication CAN.
C: MB991910 Interface (VCI)
D: MB991911 B: USB cable
E: MB991825 C: MUT-III Main
F: MB991826 harness A
(For vehicles
fitted with CAN)
D: MUT-III Main
harness B
(For vehicles
not fitted with
CAN)
E: Adaptor
DO NOT USE F: Trigger harness

MB991668 Belt tension meter • Checking the tension in the drive belt.
A: MB991969 set (Use in conjunction with VCI)
B: MB991670 A: Tension meter • Checking the tension in the balancer
cartridge timing belt.
B: Mic ASSY Adjusting (Use in conjunction with VCI)

MD998772 Valve spring Compression of the valve spring.

compressor
 ENGINE – SPECIAL TOOLS 11-3

Tool Number Name Function

MD998737 Valve stem seal Valve stem seal installation
installer

MD998713 Camshaft oil seal Camshaft oil seal installation

installer

MB991654 Cylinder head bolt Cylinder head bolt removal, installation

wrench

MB991367 Special spanner Holding the crankshaft sprocket

MB991385 Pins

MB991704 Battery harness Checking and adjustment of the tension in the

balancer timing belt (Use in conjunction with VCI
or MUT-II)

MD998738 Adjusting bolt Holding the tensioner arm or the auto-tensioner

adjuster

MD998767 Tensioner pulley Adjusting the tension of the timing belt

socket wrench
11-4 ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL

Tool Number Name Function

MB991454 Engine hanger Holding the engine assembly while the
balancer transmission assembly is removed/installed

Recommended Mechanical engine

tools MZ203830 hanger
panzai or
MZ203831 safe
vehicle handling

MB991928 Engine hanger

Slide bracket (HI)
A: MB991929 A: joint (50) x2
B: MB991930 B: joint (90) x2
C: MB991931 C: joint (140) x2
D: MB991932 D: Foot (standard) x4
E: MB991933 E: Foot (short) x4
F: MB991934 F: Chain and hook
ASSY

Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min

Camshaft, valve stem seal

Removal and fitting
Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools
because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it
should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.

Jobs to be completed before removal and after fitting

• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-5

Removal procedure
1. Oil feeder control valve connector 8. Connection of the control harness

O
 2. Oil feeder control valve 9. Vacuum hose

O
 3. O-ring 10. PCV hose
4. Breather hose  A



N 11. Connection of the radiator upper hose
• Secondary air control valve 12. Camshaft position sensor connector
(refer to Section 15-2: Secondary Air (exhaust side)
Control System) 13. Camshaft position sensor connector
5. Centre cover (inlet side)
• Ignition coil 14. Connection of the earth cable
6. O2 sensor connector
M
 15. Rocker cover ASSY
7. Crank angle sensor connector 16. Spark plug hole gasket
17. Rocker cover gasket
11-6 ENGINE – CAMSHAFT, VALVE STEM SEAL

During assembly, apply

engine oil to all sliding
parts.

18. Camshaft position sensor support cover
F

 30. Camshaft bearing cap No. 2
19. Camshaft position sensor support cover
F
 31. Camshaft bearing cap No. 5
gasket
F
 32. Camshaft bearing cap No. 3

L
 20. Camshaft position sensing cylinder
F
 33. Camshaft bearing cap No. 4
(exhaust side)
E
 34. Exhaust camshaft

J
 21. Camshaft position sensor support 35. Camshaft sprocket cap
22. Camshaft position sensor support cover 36. Washer
23. Camshaft position sensor support cover  B



H 37. Camshaft sprocket (inlet side)
gasket
G
 38. Camshaft oil seal

K
 24. Camshaft position sensing cylinder (inlet
F
 39. Camshaft bearing cap front
side)
F
 40. Camshaft bearing cap rear right

J
 25. Camshaft position sensor support
F
 41. Camshaft bearing cap No. 2
 B



I 26. Camshaft sprocket (exhaust side)
F
 42. Camshaft bearing cap No. 5

G
 27. Camshaft oil seal
F
 43. Camshaft bearing cap No. 3

F
 28. Camshaft bearing cap front
F
 44. Camshaft bearing cap No. 4

F
 29. Camshaft bearing cap rear left
E
 45. Inlet camshaft
 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-7

46. Rocker arm 51. Valve spring retainer

D
 47. Rush adjuster
B
 52. Valve spring
48. Oil delivery body
A
 53. Inlet valve stem seal
49. Spark plug
A
 54. Exhaust valve stem seal
 C



C 50. Valve spring retainer lock
11A-8 ENGINE – CAMSHAFT, VALVE STEM SEAL

Locations for the application of lubricant and seals

<View from A>

Semi-dry sealant: Three bond 1207F

Semi-dry sealant:
Three bond 1207D

(around the lip):

Engine oil
Semi-dry sealant: Three bond 1207F

<Viewed looking down onto the cylinder head>

Semi-dry sealant: Three bond 1207D

 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-9

Removal guidelines
 A

Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.

Indicator marks

 B

Removing the camshaft sprockets

Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.

 C

Removing the valve spring retainer lock

Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.

Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.

Colour of main Colour of main Fitting guidelines

body: grey body: grey/green

A Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Inlet side Exhaust side
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Valve

Valve stem
seal

Valve guide
11-10 ENGINE – CAMSHAFT, VALVE STEM SEAL

B  Fitting the valve spring
Rocker arm side
Fit the valve spring so that the end of the valve spring which has
the smaller radius is on the rocker arm side.

C  Fitting the valve spring retainer lock

In the same way as when the valve spring retainer lock was
removed, compress the valve spring using the special tool for
compressing valve springs (MD998772), and fit the valve spring
retainer lock.

D  Fitting the rush adjuster

Caution
If a rush adjuster is being reused, it must be washed and
inspected before fitting.
(Ref: Engine Service Manual)

E
 Fitting the camshaft
Front of engine
<inlet side> 1. Remove any sealant from the cylinder head.
2. Apply engine oil to the camshaft cams and journals.
slit 3. Fit the camshaft to the cylinder head.

Caution
Ensure that the inlet and exhaust sides are not the wrong way
<exhaust side>
round.

slit

F
 Fitting the camshaft bearing cap No.4, the camshaft
Approx. 4° bearing cap No.3, the camshaft bearing cap No.5, the
dowel pins
camshaft bearing cap No.2, the rear camshaft bearing
cap, and the front camshaft bearing cap
1. Set the camshaft dowel pins in the position shown in the
diagram.

inlet side exhaust side

 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-11
2. Because camshaft bearing caps Nos. 2~5 are the same shape,
check the identification marks on them so that the bearing cap
number and the inlet and exhaust sides are not mistaken. Then
fit them in the direction shown in the diagram.
bearing cap No.
Front of Identification marks (stamped on the front bearing cap, and on
engine bearing cap Nos. 2~5).
I: inlet side
mark indicating
E: exhaust side
inlet side or
exhaust side

3. Apply sealant at the 8 places shown in the diagram of the top

view of the cylinder head.
Front of engine

Semi-dry sealant: Three bond 1207D

4. Fit the rear camshaft bearing cap in the direction indicated by

<Inlet side>
the front mark.
5. In just the same way as for bearing caps Nos. 2~5, check the
front mark
identification marks on the front camshaft bearing cap so that
the exhaust side and the inlet side are not mistaken.
Front 6. Tighten the bearing cap mounting bolts gradually, 2~3 turns at a
of
time, to the specified torque.
engine
Tightening torque: 20 ± 1 N•m
7. Check that the rocker arm has been fitted correctly.
Note
Completely wipe away any sealant that has been squeezed out.

<Exhaust side>

front mark

Front
of
engine

camshaft oil seal
G Fitting the camshaft oil seal

1. Apply engine oil around the entire circumference of the oil seal
lip.
2. Insert the oil seal using the special tool for installing the
camshaft oil seal (MD998713), as shown in the diagram.

(engine oil)
11-12 ENGINE – CAMSHAFT, VALVE STEM SEAL

H Fitting the camshaft sprocket (inlet side)
1. Apply engine oil to the edges of the camshaft, and to the parts
Front of of the camshaft sprocket which will make contact with the
(engine oil)
engine camshaft.
2. Match up the camshaft dowel pins with the dowel pin holes in
the camshaft sprocket, and fit the camshaft into the camshaft
sprocket.
3. Hold the hexagonal part of the camshaft with a wrench, and
check that the camshaft sprocket cannot be twisted.
camshaft Note
sprocket This operation is necessary because it is impossible to check by
looking whether the camshaft dowel pins are inserted into the
dowel pin holes in the camshaft sprocket.
4. Apply engine oil to the screw thread and the underside of the
camshaft sprocket mounting bolt, and in the same way as when
Front of the camshaft sprocket was removed, hold the camshaft in place
(engine oil) using a wrench and tighten the bolt to the specified torque.
engine

Tightening torque: 65 ± 5 N•m

camshaft
sprocket

I
 Fitting the camshaft sprocket (exhaust side)
In the same way as when the camshaft sprocket was removed,
hold the hexagonal part of the camshaft with a wrench and
tighten the bolt to the specified torque.

Tightening torque: 89 ± 9 N•m

<Exhaust side>
J
 Fitting the camshaft position sensor support
1. Remove any sealant from the camshaft position sensor support.
2. As shown in the diagram, apply sealant to the flange of the
camshaft position sensor support, and then fit it to the cylinder
head.
Semi-dry sealant: Three bond 1207F
3. Tighten the mounting bolts for the camshaft position sensor
support to the specified torque.

Tightening torque: 14 ± 1 N•m

<Inlet side>
 ENGINE – CAMSHAFT, VALVE STEM SEAL 11-13

<Intake side>

K
 Fitting the camshaft position sensing cylinder (inlet
dowel pin side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.

Tightening torque: 22 ± 4 N•m

pane

approx. 45º dowel pin
L Fitting the camshaft position sensing cylinder (exhaust
pane (small) side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
Note
Under pressure from the exhaust valve spring, it will turn slightly
in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position
approximately 45° to the exhaust camshaft dowel pin.
pane (large) 3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.

Tightening torque: 22 ± 4 N•m

M Fitting the locker cover assembly

Front of engine
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.

Semi-dry sealant: Three bond 1207D

2. Fit the rocker cover assembly onto the cylinder head.

N Connecting the radiator upper hose

Protrusion 1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose.

water outlet indicator marks

fitting
11-14 ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET

O Fitting the O-ring/oil feeder control valve

Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
Tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.

1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.

Tightening torque: 11 ± 1 N•m

Cylinder head gasket

Removal and fitting
Jobs to be completed before removal and after fitting
• Measures to prevent fuel leaking. <Only before removal>
• Check for fuel dripping. <Only after fitting>
• Removal and refitting of the strut tower bar.
• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Check the tension of the drive belt. <Only after fitting>
• Adjustment of the axle letter cable. <Only after fitting>
• Draining and replacing the engine oil.
• Draining and replacing the coolant.
• Removal and refitting of the air cleaner.
• Removal and refitting of air pipe C.
• Removal and refitting of the battery and the battery tray.
• Removal and refitting of the centre cover. (Ref P11-5)
• Removal and refitting of the axle letter cable.
• Removal and refitting of the radiator.
• Removal and refitting of the front exhaust pipe.
• Removal and refitting of the timing belt. (Ref P11-20)
 ENGINE – CYLINDER HEAD GASKET 11-15

(engine oil)

Removal procedure 12. Inlet camshaft position sensor

1. Ignition coil connector connector
2. O2 sensor connector 13. Water temperature gauge unit
3. Oil feeder control valve connector connector
4. Crank angle sensor connector 14. Joint control harness and transmission
5. Manifold absolute pressure sensor harness
connector 15. Water temperature sensor connector
6. Fuel pressure solenoid valve connector 16. Secondary air control solenoid valve
7. Knock sensor connector connector
8. Purge control solenoid valve connector 17. Vacuum tank, solenoid valve, vacuum
9. Throttle position sensor connector pipe and hose assembly
10. Injector connector 18. Brake booster vacuum hose connection
11. Exhaust camshaft position sensor 19. Oil level gauge and guide assembly
connector 20. O-ring
21. Purge hose connection
11-16 ENGINE – CYLINDER HEAD GASKET

(engine oil)

(when
cool)

(engine oil)

22. Alternator bracket connection
D

 35. Oil return pipe gasket
23. Inlet manifold stay 36. Exhaust fitting bracket

E
 24. Eye bolt • Water outlet fitting and thermostat case
25. Gasket assembly (Refer to Section 14: Water hose
26. Eye bolt pipe)
27. Gasket 37. Water hose connection
28. Oil feeder control valve pipe 38. Heater hose connection
29. Filter 39. Fuel return hose connection
30. Oil pipe joint
C
 40. Fuel high pressure hose connection
31. Gasket
C
 41. O-ring
32. Oil return pipe gasket  A



B 42. Cylinder head bolt
33. Oil return pipe 43. Cylinder head assembly
34. Oil return pipe gasket
A
 44. Cylinder head gasket
 ENGINE – CYLINDER HEAD GASKET 11-17
Removal guidelines

A  Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn
the bolts 2~3 times in order to loosen them, before removing them
in the numerical order as shown in the diagram.

Front of engine

Fitting guidelines

A  Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of
the gasket.

Caution
Do not allow any foreign matter to get into the channels for
coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the
holes in the cylinder head gasket match up with the holes in the
cylinder head.

B Fitting the cylinder head bolts

1. Check that the length of the body of cylinder head bolts is less
than the maximum permitted. If the length is in excess of the
(engine oil) maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the
bolt, and to the washer.
11-18 ENGINE – CYLINDER HEAD GASKET
3. Use the special wrench for cylinder head bolts (MB991654) to
(loosely) tighten the bolts in the following order.
(1) In the order shown in the diagram, tighten the bolts to
78 ± 2 N•m.
(2) In reverse order to that shown in the diagram, completely loosen
the bolts.
(3) In the order shown in the diagram, tighten the bolts to
20 ± 2 N•m.

Front of engine

Procedure number (4) Procedure number (5) (4) Make a paint mark on the top of the cylinder head bolt, and on
the cylinder head, and tighten them to 90° as shown in the
diagram.
(5) Tighten the bolts to 90° as shown in the diagram, and check that
the paint mark on the top of the cylinder head bolt and the paint
mark on the cylinder head are in line.
Caution
1) If a bolt is tightened to an angle of less than 90° it has not
been tightened sufficiently.
paint mark
2) If the angle of tightening exceeds the regulation level,
paint mark
remove the bolt and start again from procedure number (1).

C Fitting the O-ring/fuel high pressure hose

1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that engine oil does not get inside the delivery pipe.
2. Without damaging the O-ring, twist the fuel high pressure hose
to fit it to the delivery pipe, making sure that it is twisted
smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose to the
specified torque.
Tightening torque: 5.0 ± 1.0 N•m.
 ENGINE – CYLINDER HEAD GASKET 11-19

D Fitting the oil return pipe gasket
Replace the gasket with a new one, and fit it to the protruded part
shown in the diagram.
Note:
For the oil return pipe gasket on the turbocharger side, there is no
direction for slotting it in.

Protrusion

E Fitting the eyebolts

Caution
When tightening the eyebolts, hold the oil pipe joint in place
with a spanner so that it does not turn round as the eyebolts
are tightened.
11-20 ENGINE – TIMING BELT, TIMING BELT B

TIMING BELT, TIMING BELT B

Removal and fitting

Caution
If Brembo brake callipers are being used take care that they are not scratched by other
components or tools because there is a chance that the paint might peel off. In
addition, if any brake fluid gets on the callipers, it should be wiped off immediately.

Jobs to be completed before removal and after fitting

• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Removal and refitting of the LH side cover.
• Checking and adjustment of the tension of the drive belt. <Only after fitting>
• Removal and refitting of the crankshaft pulley.
• Removal and refitting of the cross member bar.
• Removal and refitting of the front exhaust pipe.

Removal procedure • Remove the engine mount bracket

1. Pressure hose connection
G
 • Adjust the tension of the timing belt
2. Timing belt front upper cover <Only after fitting>
3. Water pump pulley  A



F 7. Timing belt
4. Idler pulley
E
 8. Tensioner pulley
5. Drive belt auto-tensioner 9. Tensioner arm
6. Timing belt front lower cover
D
 10. Auto-tensioner
 ENGINE – TIMING BELT, TIMING BELT B 11-21

(engine oil)

10. Power steering oil pressure switch connector  C

C 16. Crankshaft sprocket
11. Heat protector
C
 17. Crankshaft sensing blade
 B


12. Power steering oil pump ASSY
B
 • Adjust the tension of the timing belt B
13. Power steering oil pump bracket <Only after fitting>
14. Idler pulley
A
 18. Timing belt B tensioner
15. Crank angle sensor  D



A 19. Timing belt B

Removal guidelines
Timing marks
 A

Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all
the timing marks until the No.1 cylinder is in the compressor top
dead centre position.

Caution
Turn the crankshaft in the normal way.

2. Remove the rubber plug from the rear cover of the timing belt,
and prepare the special tool for adjusting bolts (MD998738).

Timing belt
valence
11-22 ENGINE – TIMING BELT, TIMING BELT B
3. Twist the special tool for adjusting bolts (MD998738) by hand
timing belt tensioner until it touches the tensioner arm.
arm
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.

4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.

5. Insert a wire or a pin into the aligned holes.

bolt for fitting the timing belt 6. Remove the special tool for adjusting bolts (MD998738), and
tensioner then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.

Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
wire or pin direction (clockwise direction) on the back of the belt.

 B

Removing the power steering oil pump ASSY

Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.

 C

Removing the crankshaft sprocket

1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.

Crankshaft
sprocket
 ENGINE – TIMING BELT, TIMING BELT B 11-23
 D


Removing timing belt B

Caution
If planning to re-use a timing belt B, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.

timing marks Fitting guidelines

side of belt
A
 Fitting timing belt B and the timing belt B tensioner
under tension 1. Check that the timing marks for the crankshaft sprocket and the
balancer shaft sprocket are aligned.
timing 2. Fit timing belt B onto the crankshaft sprocket and the balancer
marks shaft sprocket. Ensure that the side of the belt under tension is
balancer shaft not slack.
sprocket

crankshaft sprocket

3. As a temporary step, fit the timing belt B tensioner pulley so that

its centre is to the upper left of the centre of the mounting bolt,
and so that the flange of the pulley is facing towards the front of
the engine.
centre of the
4. Adjust the tension of timing belt B.
pulley

centre of the
mounting bolt

B Adjusting the tension of timing belt B

1. Hold the timing belt B tensioner between fingertips and in the
direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to
timing belt B until the side of the belt under tension becomes
taught. In this condition, tighten the mounting bolt to the
specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m
Caution
When tightening the mounting bolt, ensure that the
tensioner does not turn round with it. If the tensioner turns
with the mounting bolt, it could cause the tension in the belt
to become too high.
11-24 ENGINE – TIMING BELT, TIMING BELT B
2. <Measuring the amount of give>
(1) As shown in the diagram, apply a force of about 100N to the
approx. 100 N middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
<when adjusted> 5~7mm
amount of <when replaced> 5~7mm
give (2) If the specified values are not met, readjust the tension of the
belt.

3. <When using MUT-II/III>

(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.

(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
pull lightly with fingertips between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.

(7) If the specified values are not met, readjust the tension of the
belt.
 ENGINE – TIMING BELT, TIMING BELT B 11-25

C Fitting the crankshaft sensing blade and the
Front of engine
crankshaft sprocket
1. Clean, and remove any grease from the crankshaft sensing
blade, the crankshaft sprocket, and the surface of the crankshaft
to which the crankshaft sprocket will be fitted.
2. Fit the crankshaft sensing blade and the crankshaft sprocket in
crankshaft
the direction shown in the diagram.
crankshaft sprocket 3. Clean the screw hole in the crankshaft.
clean 4. Place the washer with the larger surface side in the direction as
washer here shown in the diagram, and fit it to the crankshaft bolt.
5. Apply a small quantity of engine oil to the top and to the screw
thread parts of the crankshaft bolt.
6. In the same way as when it was removed, hold the crankshaft
sprocket using the special tool, and tighten the crankshaft bolt to
the specified torque.

Tightening torque: 167 N·m

remove
grease
crankshaft bolt crankshaft
sensing
blade

D Fitting the auto-tensioner

1. If the auto-tensioner rod remains in an extended state, install it
using the following procedure.
(1) Using a press or a vice, slowly compress the auto-
tensioner rod and align the rod with setting hole A and the
tensioner cylinder with setting hole B.

Caution
If the speed of compression is too fast, there is a
chance that the rod may break, so carry out this
operation slowly.

(2) Insert a wire or pin into the aligned holes.

wire or pin Note
If a brand new or a replacement auto-tensioner is being
used, use a pin to set the auto-tensioner in place.

2. Fit the auto-tensioner into the engine and tighten the mounting
bolt to the specified torque. Do not remove the wire or pin until
the tension of the timing belt has been adjusted.

Tightening torque: 23 ± 3 N·m

E Fitting the tensioner pulley

As a temporary step, fit the tensioner pulley as shown in the
diagram.

tensioner pulley holes

11-26 ENGINE – TIMING BELT, TIMING BELT B

F
 Fitting the timing belt
timing marks 1. Check that all the timing marks for the camshaft sprocket, the
crankshaft sprocket and the oil pump sprocket are aligned.

camshaft
camshaft sprocket
sprocket (inlet (exhaust
side) side)

timing
timing marks
marks

oil pump
crankshaft sprocket
sprocket

2. After the timing marks for the oil pump sprocket have been
more than
aligned, remove the plug from the cylinder block and insert a
60 mm
plug posidrive (+) with a diameter of 8 mm into the plug hole. Check
that more than 60 mm of the shaft of the screwdriver can be
inserted. If the screwdriver strikes the balancer shaft and can
only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one
screwdriver complete turn, realign the timing marks, and check that more
than 60 mm of the screwdriver can be inserted. Do not remove
the screwdriver until the timing belt has been fitted.
balancer shaft

3. Install the timing belt in accordance with the following guidelines

camshaft camshaft so that the side that is under tension does not get slack.
sprocket (inlet sprocket (1) Fit the timing belt around the crankshaft sprocket first, then
side) (exhaust side) the oil pump sprocket and then fit it around the idler pulley.

tensioner pulley idler

pulley

crankshaft oil pump

sprocket sprocket

paper (2) Fit the timing belt around the camshaft sprocket (exhaust
clip side) and hold it in place with a paper clip at the position
shown in the diagram.
 ENGINE – TIMING BELT, TIMING BELT B 11-27
(3) Use a wrench to align the timing marks on the rocker cover and
paper clips the camshaft sprocket, and whilst doing so, fit the timing belt
around the camshaft sprocket (inlet side) and hold it in place
with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley.
(5) Remove the two paper clips.

Caution
After the timing belt has been installed, apply some force in
an anti-clockwise direction to the camshaft sprocket and
check once more that all the timing marks are in the correct
position when the side of the belt under tension is taught.

4. Using the special wrench for the tensioner pulley socket

(MD998767), tense the timing belt by turning the tensioner
pulley in the direction shown in the diagram, and temporarily
tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.

G Adjusting the tension of the timing belt

1. Remove the rubber plug from the rear cover of the timing belt
and put the special adjusting bolt (MD998738) in position.
Slowly twist the adjusting bolt a little at a time, so that the wire
or pin inserted when fitting the auto-tensioner, only moves a
little.

Caution
There is a possibility that the wire or pin inserted in the
auto-tensioner may break if the adjusting bolt is twisted
with a spanner or a similar tool, so it must be twisted by
hand.

2. Turn the crankshaft a quarter turn in an anti-clockwise direction.

3. Turn the crankshaft in a clockwise direction, realign all the timing
marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had
been temporarily tightened.
11-28 ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.

Specified projection (A): 3.8 ~ 4.5 mm

10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11. Recheck that the timing marks on all of the sprockets are in line.

Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.

ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
• Measures to prevent fuel leaking. <Only before removal>
• Check for fuel dripping. <Only after fitting>
• Removal and refitting of the bonnet.
• Removal and refitting of the strut tower bar.
• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Checking the tension of the drive belt. <Only after fitting>
• Adjustment of the axle letter cable. <Only after fitting>
• Draining and replacing the engine oil.
• Draining and replacing the coolant.
• Removal and refitting of the air cleaner.
• Removal and refitting of air pipe C.
• Removal and refitting of the battery and the battery tray.
• Removal and refitting of the centre cover. (Ref P11-5)
• Removal and refitting of the axle letter cable.
• Removal and refitting of the radiator.
• Removal and refitting of the front exhaust pipe.
 ENGINE – ENGINE ASSY 11-29

Removal procedure
1. Ignition coil connector 11. Exhaust cam position sensor connector
2. O2 sensor connector 12. Inlet cam position sensor connector
3. Oil feeder control valve connector 13. Water temperature gauge unit connector
4. Crank angle sensor connector 14. Joint control harness and transmission
5. Manifold absolute pressure sensor harness
connector 15. Water temperature sensor connector
6. Fuel pressure solenoid valve connector 16. Alternator connector and terminal
7. Knock sensor connector 17. Secondary air control solenoid valve
8. Purge control solenoid valve connector connector
9. Throttle position connector 18. Engine oil pressure switch connector
10. Injector connector  A


19. Drive belt
11-30 ENGINE – ENGINE ASSY
Caution
Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is
being supported by the chassis.

(engine oil)

20. Vacuum tank, solenoid valve, vacuum 28. Heater hose connection
pipe and hose ASSY 29. Fuel return hose connection
21. Brake booster vacuum hose connection
D
 30. Fuel high pressure hose connection
22. Purge hose connection
D
 31. O-ring
23. Power steering oil pressure switch  C



C • Transfer ASSY, transmission ASSY
connector  D



B 32. Engine mount bracket & stopper ASSY
24. Heat protector  E



A 33. Engine ASSY
 B


25. Power steering oil pump
26. A/C compressor connector
<For cars fitted with A/C>
 B


27. A/C compressor <For cars fitted with
A/C>
 ENGINE – ENGINE ASSY 11-31

Removal guidelines
 A

Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, and remove the drive belt.
B hole
Caution
A hole If planning to re-use the drive belt, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.

L-shaped
hex-
agonal
Allen
wrench

 B

Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.

 C

Removing the transfer ASSY and the transmission

ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
11-32 ENGINE – ENGINE ASSY
 D


Removing the engine mount bracket & stopper ASSY
MZ203830 or MZ203831
1. Support the engine using a garage jack.
2. Remove the special mechanical engine hanger (MZ203830,
MZ203831 or MB991928).

slide bracket (HI)

3. Hold the engine ASSY using a chain block.

4. Support the engine oil pan component with the garage jack
through the engine block, so that the weight of the engine is not
taken by the engine mount bracket.
5. Loosen the nuts and bolts and remove the engine mount bracket
and stopper ASSY.

 E

Removing the engine ASSY

After checking that all of the cables, hoses and harness connectors
etc have been disconnected, slowly hoist the engine using a chain
block and remove the engine from the engine compartment.

Fitting guidelines

A Fitting the engine ASSY
Install the engine whilst checking that cables, hoses and harness
connectors etc will not be squashed beneath it.
 ENGINE – ENGINE ASSY 11-33

engine side engine side
B Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
engine mount stopper 4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
<viewed from <viewed from
rear of chassis> front of chassis>

MZ203830 or MZ203831 (1) <When using the special mechanical engine hanger
(MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).

slide bracket (HI) (2) <When using the special engine hanger (MB991928)>
Fit the following parts to the base hanger.
front of • Slide bracket (HI)
chassis
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)

joint (90)
(MB991930)

foot (standard) (MB991932)

slide bracket (HI)

C Fitting the transfer ASSY and the transmission ASSY

1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).
11-34 ENGINE – ENGINE ASSY
 D


Fitting the O-ring and the fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.

Caution
Ensure that no engine oil gets inside the deliver pipe.

2. Without damaging the O-ring, fit the fuel high pressure hose to
the delivery pipe by twisting it from left to right. Ensure that the
hose is twisted smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose, to
the specified torque.

Tightening torque: 5.0 ± 1.0 N•m.