Daihatsu Terios II J200, J210, J211 2006-2014 Engine Mechanical Part 2

ENGINE MECHANICAL - CHAIN (3SZ-VE)
EM–105
CHAIN (3SZ-VE)
ENGINE MECHANICAL
COMPONENTS
AIR CLEANER ASSEMBLY
T=3.5{36}
BATTERY
BATTERY CLAMP T=7.5{76}
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
AIR CLEANER HOSE NO. 1 ACCELERATOR CONTROL CABLE ASSEMBLY
RADIATOR HOSE NO. 1
FAN AND ALTERNATOR V BELT
ENGINE UNDER COVER
T=5.4{55} ×11
..... TIGHTENING TORQUE [N*m{kgf*cm}]

A136903J01
EM–106 ENGINE MECHANICAL - CHAIN (3SZ-VE)
VENTILATION HOSE IGNITION COIL ASSEMBLY
EM VENTILATION HOSE NO. 2 SPARK PLUG

T=20{204}
T=7.5{76}
×4
CAMSHAFT TIMING OIL T=7.5{76}

CONTROL VALVE ASSEMBLY ×4
×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}
CRANKSHAFT PULLEY VANE PUMP ASSEMBLY
CRANKSHAFT POSITION SENSOR
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART

A136904J02
EM–107
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11
CHAIN TENSIONER PLUNGER

EM
CYLINDER HEAD COVER GASKET
TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
TIMING CHAIN (BELT) COVER OIL SEAL
TIMING CHAIN GUIDE NO. 2
CRANKSHAFT ANGLE SENSOR PLATE NO. 1
APPLY MP GREASE
..... TIGHTENING TORQUE [N*m{kgf*cm} NON-REUSEABLE PART A136905J03
REMOVAL
1. DISCONNECT NEGATIVE BATTERY TERMINAL
(See page SS-10.)
2. REMOVE BATTERY CARRIER (See page EM-146)
3. REMOVE ENGINE UNDER COVER
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT (See page CO-15)
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-146)
7. REMOVE RADIATOR HOSE NO. 1 (See page CO-15)
EM 8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-147)
9. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)
10. REMOVE FAN PULLEY (See page CO-29)
11. REMOVE VANE PUMP ASSEMBLY (See page EM-44)
12. REMOVE IDLER PULLEY NO. 1 (See page EM-150)
13. DISCONNECT VENTILATION HOSE (See page EM-147)
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147)
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM-147)
16. REMOVE RADIATOR PIPE (See page EM-147)
17. REMOVE IGNITION COIL ASSEMBLY (See page EM-150)
18. REMOVE CYLINDER HEAD COVER (See page EM-151)
19. REMOVE CRANKSHAFT PULLEY (See page EM-151)
20. REMOVE CAM POSITION SENSOR (See page EM-152)
21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(See page EM-152)
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-152)
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-153)
24. REMOVE CRANK ANGLE SENSOR PLATE NO. 1
(a) Remove the crank angle sensor plate No. 1.
D-MARK
25. REMOVE CHAIN TENSIONER PLUNGER
(a) Move the stopper plate downward and hold it with the lock
released.[*1]
HINT:
If it is difficult to release the stopper plate lock, use the hexagon
head portion of the camshaft and rotate the camshaft a little to
the right and left.
A135998
EM–109
(b) Under the conditions noted at [*1], use the hexagon head por-
tion of the camshaft to rotate the camshaft a little to the right
and hold.[*2]
HINT:
Rotating the camshaft to the right will press the tensioner
plunger.
A108005
(c) Under the conditions noted at [*2], align the stopper plate and
the chain tensioner plunger hole.[*3]
HINT: EM
If the stopper plate and the chain tensioner plunger hole are dif-
ficult to align, rotate the camshaft a little to the left and then
back a little to the right again to align them.
Stopper Plate Plunger

A108555J02
(d) Under the conditions noted at [*3], insert a bar of 3 mm in diam-

eter into the stopper plate and the chain tensioner plunger hole.
(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
A108556
26. REMOVE TIMING CHAIN TENSION ARM

(a) Remove the bolt and the timing chain tensioner arm.
A108557
27. REMOVE TIMING CHAIN GUIDE

(a) Remove the 2 bolts and the timing chain guide.
A108558
28. REMOVE TIMING CHAIN GUIDE NO. 2

(a) Remove the 2 bolts and the timing chain guide No. 2.
29. REMOVE CHAIN
INSTALLATION
A108559
1. INSTALL CHAIN
(a) Align the mark plate (yellow) and the timing mark as shown in
EM Mark Plate Mark Plate
the illustration and install the chain.
Timing Mark Timing Mark
Mark Plates
Timing Mark
A137742
2. INSTALL TIMING CHAIN GUIDE NO. 2

(a) Install the timing chain guide No. 2 with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm)
A108559
EM–111
3. INSTALL TIMING CHAIN GUIDE

(a) Install the timing chain guide with the 2 bolts.
A108558
4. INSTALL TIMING CHAIN TENSION ARM

(a) Install the timing chain tension arm with the bolt.
Torque: 19 N*m (195 kgf*cm) EM
A108557
5. INSTALL CHAIN TENSIONER PLUNGER

(a) Install the chain tensioner plunger with the bolt and nut.
HINT:
Using the hexagon wrench head portion of the camshaft, rotate
the camshaft a little to the left, and with the chain slightly slack
on the chain tensioner plunger side, attach the chain tensioner
plunger.
(b) Pull the 3 mm diameter bar out from the chain tensioner
A108556 plunger.
6. INSTALL CRANK ANGLE SENSOR PLATE NO. 1

(a) Install the crank angle sensor plate No. 1 so that the D mark is
D-MARK
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-160)
8. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
200)
9. INSTALL CRANK POSITION SENSOR (See page EM-57)
A135998
10. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(See page EM-162)
11. INSTALL CRANKSHAFT PULLEY (See page EM-161)
12. INSTALL CYLINDER HEAD COVER (See page EM-162)
13. INSTALL SPARK PLUG (See page EM-162)
14. INSTALL IGNITION COIL ASSEMBLY (See page EM-162)
15. INSTALL RADIATOR PIPE (See page EM-166)
16. INSTALL ENGINE ROOM MAIN WIRE (See page EM-165)
17. INSTALL VENTILATION HOSE (See page EM-166)

18. INSTALL VENTILATION HOSE NO. 2 (See page EM-166)
19. INSTALL IDLER PULLEY NO. 1 (See page EM-163)
20. INSTALL VANE PUMP ASSEMBLY (See page EM-68)
21. INSTALL FAN PULLEY (See page CO-29)
22. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)
23. ADJUST FAN AND ALTERNATOR V BELT (See page EM-9)
24. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)
25. INSTALL ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-165)
EM 26. INSTALL RADIATOR HOSE NO. 1 (See page CO-18)
27. INSTALL AIR CLEANER ASSEMBLY (See page EM-167)
28. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-18)
29. INSTALL BATTERY CARRIER (See page EM-167)
30. INSTALL BATTERY
31. CONNECT NEGATIVE BATTERY TERMINAL

32. ADD ENGINE COOLANT (See page CO-9)
33. ADD ENGINE OIL
34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10)
35. INSPECT ENGINE OIL LEAKS
36. CHECK ENGINE OIL LEVEL (See page EM-167)
37. CHECK IGNITION TIMING (See page EM-1)
38. CHECK IDLE SPEED (See page EM-2)
39. INSTALL ENGINE UNDER COVER (See page EM-69)

ENGINE MECHANICAL - CHAIN (K3-VE)
EM–113
CHAIN (K3-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
EM–114 ENGINE MECHANICAL - CHAIN (K3-VE)

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
EM–115
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM
TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
MP GREASE
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART A136905J05
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-173 )
4. DRAIN ENGINE OIL
5. DRAIN ENGINE COOLANT (See page CO-11 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-173 )
7. REMOVE RADIATOR HOSE NO. 1 (See page CO-22 )
EM 8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

page EM-175 )
9. REMOVE FAN AND ALTERNATOR V BELT (See page EM-12 )
10. REMOVE VANE PUMP WITH BRACKET (See page EM-79 )
11. REMOVE FAN PULLEY (See page CO-33 )
12. REMOVE IDLER PULLEY NO. 1 (See page EM-177 )
13. DISCONNECT VENTILATION HOSE (See page EM-174 )
14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174 )
15. REMOVE ENGINE ROOM MAIN WIRE (See page EM-175 )
16. REMOVE RADIATOR PIPE (See page EM-174 )
17. REMOVE IGNITION COIL ASSEMBLY (See page EM-178 )
18. REMOVE CYLINDER HEAD COVER (See page EM-178 )
19. REMOVE CRANKSHAFT PULLEY (See page EM-179 )
20. REMOVE CAM POSITION SENSOR (See page EM-179 )

(See page EM-180 )
22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-180 )
23. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL (See page
EM-180 )
D-MARK
released.[*1]
HINT:
the right and left.
A135998
EM–117
and hold.[*2]
HINT:
plunger.
A108005
HINT: EM
Stopper Plate Plunger A108555J02

(e) Remove the bolt and nut and then remove the chain tensioner
plunger.
A108556

A108557

A108558

29. REMOVE CHAIN
INSTALLATION
A108559
1. INSTALL CHAIN
(a) Align the mark plate (yellow) and the timing mark as shown in
EM Mark Plate Mark Plate
Mark Plates
Timing Mark
A137742

A108559
EM–119

A108558

Torque: 19 N*m (195 kgf*cm) EM
A108557

HINT:
plunger.
A108556 plunger.

(a) Install the crank angle sensor plate No. 1 so that the D mark is
D-MARK
visible.
7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-188 )
8. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
206 )
9. INSTALL CRANK POSITION SENSOR (See page EM-92 )
A135998
(See page EM-189 )
11. INSTALL CRANKSHAFT PULLEY (See page EM-189 )
12. INSTALL CYLINDER HEAD COVER (See page EM-190 )
13. INSTALL SPARK PLUG (See page EM-190 )
14. INSTALL IGNITION COIL ASSEMBLY (See page EM-190 )
15. INSTALL RADIATOR PIPE (See page EM-194 )
17. INSTALL VENTILATION HOSE (See page EM-193 )

18. INSTALL VENTILATION HOSE NO. 2 (See page EM-193 )
19. INSTALL IDLER PULLEY NO. 1 (See page EM-191 )
20. INSTALL FAN PULLEY (See page CO-33 )
21. INSTALL VANE PUMP WITH BRACKET (See page EM-103 )
22. INSTALL FAN AND ALTERNATOR V BELT (See page EM-12 )
23. ADJUST FAN AND ALTERNATOR V BELT (See page EM-13 )
24. CHECK FAN AND ALTERNATOR V BELT (See page EM-13 )

page EM-193 )
EM 26. INSTALL RADIATOR HOSE NO. 1 (See page CO-25 )
27. INSTALL AIR CLEANER ASSEMBLY (See page EM-194 )
28. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-26 )
29. INSTALL BATTERY CARRIER (See page EM-194 )
30. INSTALL BATTERY

32. ADD ENGINE COOLANT (See page CO-11 )
33. ADD ENGINE OIL
34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-12 )
35. CHECK FOR ENGINE OIL LEAKS
36. CHECK ENGINE OIL LEVEL (See page EM-195 )
37. CHECK IGNITION TIMING (See page EM-4 )
38. CHECK IDLE SPEED (See page EM-5 )
39. INSTALL ENGINE UNDER COVER (See page EM-104 )

ENGINE MECHANICAL - CAMSHAFT (3SZ-VE)
EM–121
CAMSHAFT (3SZ-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
EM–122 ENGINE MECHANICAL - CAMSHAFT (3SZ-VE)
VENTILATION HOSE VENTILATION HOSE NO. 2

IGNITION COIL ASSEMBLY
T=11{112}
×4
×2 T=7.5{76}
×4
CYLINDER HEAD COVER T=7.5{76}
T=9.0{92} ×11
EM
CYLINDER HEAD COVER
GASKET
RADIATOR PIPE
CAMSHAFT BEARING CAP NO. 1 T=12.5{130}
×16
CAMSHAFT BEARING CAP NO. 2
T=12.5{130}
×4
×8
CAMSHAFT
CAMSHAFT TIMING CAMSHAFT NO. 2
SPROCKET
T=47{480}
TIMING CHAIN (BELT) COVER NO. 2
T=8.5{87}
T=17{173}
CHAIN COVER SERVICE HOLE

SCREW PLUG
TIGHTENING TORQUE [N*m{kgf*cm}]

A137081J01
EM–123
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-146 )
4. DRAIN ENGINE COOLANT (See page CO-9 )
5. REMOVE RADIATOR HOSE NO. 1 (See page CO-15 )
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-146 )
7. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15 )
8. DISCONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(See page EM-147 )
EM
9. DISCONNECT VENTILATION HOSE (See page EM-147 )
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147 )
12. REMOVE RADIATOR PIPE (See page EM-147 )
13. REMOVE IGNITION COIL ASSEMBLY (See page EM-150 )
14. REMOVE CYLINDER HEAD COVER (See page EM-151 )
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2

(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
(a) Rotate the crankshaft pulley clockwise to align the timing mark
(groove) so it is at 0°.Make sure that each timing mark is posi-
tioned as shown in the illustration.
HINT:
If the timing marks are not aligned, turn the crankshaft pulley
Timing Marks
clockwise again and align the marks.
Notch
A137746
(b) Place a paint mark on each plate of the chains at the points
where the camshaft timing gear and the timing mark of the cam-
shaft timing sprocket are aligned.
Paint Mark Paint Mark
EM Timing Marks
A107964J01
(c) Using the hexagon head portion of the camshaft, loosen the
camshaft timing sprocket installation bolt.
A133812
(d) Using a 10 mm socket hexagon wrench, remove the chain

cover service hole screw plug.
A137724
(e) Using a screwdriver, access the tensioner stopper plate through

the chain tensioner service hole, move it downward and hold it
with the lock released.[*1]
HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A133813
EM–125
(g) Under the conditions noted at [*2], remove the screwdriver from
the chain tensioner service hole, align the stopper plate and the
tensioner holes, and insert a bar of 3 mm in diameter.
NOTICE:
• If the 3 mm diameter bar is difficult to insert, rotate the
camshaft a little to the left and then back a little to the
right and insert the bar again.
• Hold the camshaft in the position using the hexagon
head portion.
A133879 • Fix the 3 mm diameter bar using tape or similar so it
does not come out.
(h) Remove the chain from the camshaft timing sprocket.
17. REMOVE CAMSHAFT TIMING SPROCKET

(a) Remove the bolt and the camshaft timing sprocket.
EM
A133815
18. REMOVE CAMSHAFT BEARING CAP NO. 1

NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90° clockwise with the valve fully open and check that the
90°
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
A137743
(a) Remove the camshaft bearing cap No. 1 in the order indicated
in the illustration.
2
A133124

2 10 14 6
NOTICE:
Uniformly loosen the bolts keeping the camshaft level.
4 12 16 8
HINT:
3 11 15 7
Be sure to keep the removed parts separate according to the
installation areas.
1 9 13 5
20. REMOVE CAMSHAFT
A133125
(a) Remove the camshaft.
21. REMOVE CAMSHAFT NO. 2

(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
Do not allow any foreign matter to enter the timing chain
cover.
A133818
EM Advance Angle Port

22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Retard Angle Port • Do not damage the camshaft.
• Do not tighten the vise too firmly.
A033448J02 • Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
• Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
Torque: 47 N*m (479 kgf*cm)
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm2) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
A033449J01 by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
• Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
• Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
EM–127
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30°.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
1. INSTALL CAMSHAFT NO. 2
Camshaft NO. 1 Camshaft NO. 2 (a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
(In Side) (Ex Side) angle) in the direction that the engine rotates from cylinder No. EM
NO. 3 NO. 4 NO. 4 NO. 2 1 TDC/compression so the lifted valve does not interfere with
the piston.
(b) Apply engine oil to the cam part of camshaft No. 2 and the jour-
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
Position it so the cam nose of cylinders No. 2 and 4 of the
A137596 camshaft No. 2 push down the lifter valve.
2. INSTALL CAMSHAFT
Camshaft NO. 1 Camshaft NO. 2 (a) Apply engine oil to the cam of the camshaft and the journal part
(In Side) (Ex Side) of the cylinder head, and then install the camshaft.
NO. 3 NO. 4 NO. 4 NO. 2 NOTICE:
camshaft push down the lifter valve.
3. INSTALL CAMSHAFT BEARING CAP NO. 2

(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
A137596
(b) Tighten the camshaft bearing cap No. 2 in the order shown in
the illustration.
I2
I3
I4
I5

NOTICE:
• Position the cap so the arrows on it face toward the
front of the engine, and install it so the punched num-
15 7 3 11
bers are positioned as shown in the illustration.
• Uniformly tighten the bolts, keeping the camshaft level.
13 5 1 9
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
1
NOTICE:
Tighten it after checking that the thrust part of the camshaft
2 is aligned with the groove on camshaft bearing cap No. 1.
4
5. INSTALL CAMSHAFT TIMING SPROCKET
(a) Apply engine oil to the installation surface to the camshaft.
A133071
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
Knock Pin
EM Pin Hole • If the knock pin and pin hole do not align, use the hexa-
gon head portion of the camshaft and rotate the cam-
shaft a little to the right and left so they align.Do not
press too firmly on the camshaft timing sprocket as the
seal surface can be easily damaged by the end of the
Do Not Remove knock pin which may cause the seal to fail.
• Do not remove the 3 bolts.If the bolts are removed,
A136098 replace the camshaft timing sprocket.
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
and the chain are aligned.
Timing Marks
A133561
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
Using the hexagon head portion of the camshaft, rotate the
camshaft a little to the left with the chain slightly slack on
the tensioner side, and pull out the 3 mm diameter bar.
A109220
EM–129
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
Clean and degrease the bolt and bolt hole.
Timing Marks
EM
Notch
A137746
(e) Using a 10 mm socket hexagon wrench, install the chain cover

service hole screw plug.
A137724
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2

Apply Liquid Gasket (a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
• Clean and degrease the installation surfaces.
• Install within 3 minutes of applying Three Bond
TB1207B.
• Do not start the engine within 2 hours of installation.
A139347
(b) Install the timing chain cover No. 2 with the 2 bolts.
8. INSTALL CYLINDER HEAD COVER (See page EM-162 )
9. INSTALL IGNITION COIL ASSEMBLY (See page EM-162 )
10. INSTALL RADIATOR PIPE (See page EM-166 )
11. INSTALL RADIATOR HOSE NO. 1 (See page CO-18 )

A107960
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-166 )
14. CONNECT VENTILATION HOSE (See page EM-166 )

page EM-165 )
16. INSTALL AIR CLEANER ASSEMBLY (See page EM-167 )
17. INSTALL AIR CLEANER HOSE NO. 1 (See page CO-19 )
18. ADD ENGINE COOLANT (See page CO-9 )
20. CHECK FOR ENGINE COOLANT LEAKS (See page CO-10 )
21. CHECK COOLANT LEVEL (See page CO-10 )
EM 22. INSTALL ENGINE UNDER COVER (See page EM-69 )

24. CHECK IGNITION TIMING (See page EM-1 )
25. CHECK ENGINE IDLE SPEED (See page EM-2 )
26. CHECK DENSITY OF CO AND HC (See page EM-3 )

ENGINE MECHANICAL - CAMSHAFT (K3-VE)
EM–131
CAMSHAFT (K3-VE)
ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
EM–132 ENGINE MECHANICAL - CAMSHAFT (K3-VE)
VENTILATION HOSE VENTILATION HOSE NO. 2

IGNITION COIL ASSEMBLY
T=11{112}
×4
×2 T=7.5{76}
×4
CYLINDER HEAD COVER T=7.5{76}
T=9.0{92} ×11
EM
CYLINDER HEAD COVER
GASKET
RADIATOR PIPE
CAMSHAFT BEARING CAP NO. 1 T=12.5{130}
×16
T=12.5{130}
×4
×8
CAMSHAFT
CAMSHAFT TIMING CAMSHAFT NO. 2
SPROCKET
T=47{480}
TIMING CHAIN (BELT) COVER NO. 2
T=8.5{87}
T=17{173}
CHAIN COVER SERVICE HOLE

SCREW PLUG

A137081J01
EM–133
REMOVAL
(See page RS-164.)
2. REMOVE BATTERY CARRIER (See page EM-173)
6. REMOVE AIR CLEANER ASSEMBLY (See page EM-173)
7. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-22)

(See page EM-175)
EM
9. DISCONNECT VENTILATION HOSE (See page EM-174)
10. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-174)
11. REMOVE ENGINE ROOM MAIN WIRE (See page EM-175)
12. REMOVE RADIATOR PIPE (See page EM-174)
13. REMOVE IGNITION COIL ASSEMBLY (See page EM-178)
14. REMOVE CYLINDER HEAD COVER (See page EM-178)
15. REMOVE TIMING CHAIN (BELT) COVER NO. 2

(a) Remove the 2 bolts and the timing chain (belt) cover No. 2.
16. REMOVE CHAIN
HINT:
Timing Marks If the timing marks are not aligned, turn the crankshaft pulley
Notch
A140612
(b) Place a paint mark on each plate of the chains at the points
where the camshaft timing gear and the timing mark of the cam-
shaft timing sprocket are aligned.
Paint Mark Paint Mark
EM Timing Marks
A107964J01
(c) Using the hexagon head portion of the camshaft, loosen the
A133812
(d) Using a 10 mm socket hexagon wrench, remove the chain

cover service hole screw plug.
A137724
(e) Using a screwdriver, access the tensioner stopper plate through

the chain tensioner service hole, move it downward and hold it
with the lock released.[*1]
HINT:
the right and left.
(f) Under the conditions noted at [*1], use the hexagon head por-
and hold.[*2]
HINT:
plunger.
A133813
EM–135
(g) Under the conditions noted at [*2], remove the screwdriver from
the chain tensioner service hole, align the stopper plate and the
tensioner holes, and insert a bar of 3 mm in diameter.
NOTICE:
• If the 3 mm diameter bar is difficult to insert, rotate the
camshaft a little to the left and then back a little to the
right and insert the bar again.
• Hold the camshaft in the position using the hexagonal
head portion.
A133879 • Fix the 3 mm diameter bar using tape or similar so it
does not come out.
(h) Remove the chain from the camshaft timing sprocket.

(a) Remove the bolt and the camshaft timing sprocket.
EM
A133815

NOTICE:
When rotating the camshaft with the chain disconnected, rotate
it 90° clockwise with the valve fully open and check that the
90°
crankshaft pulley groove is located in the position shown in the
illustration so that it does not interfere with the piston.
A137743
2
A133124

2 10 14 6
NOTICE:
4 12 16 8
HINT:
3 11 15 7
Be sure to keep the removed parts separate according to the
installation areas.
1 9 13 5
20. REMOVE CAMSHAFT
A133125
(a) Remove the camshaft.
21. REMOVE CAMSHAFT NO. 2

(a) Remove the camshaft No. 2.
(b) After removing the camshaft, hold the chain using a bar or rope
so that it does not drop.
NOTICE:
Do not allow any foreign matter to enter the timing chain
cover.
A133818
EM Advance Angle Port

22. INSPECT CAMSHAFT TIMING SPROCKET
(a) Cover all the ports except one advance port shown in the illus-
tration with plastic tape.
(b) Secure the service hexagon wrench head portion of the cam-
shaft in a vise using an aluminum or other metal cap, and then
install the camshaft timing sprocket with the bolt.
NOTICE:
Retard Angle Port • Do not damage the camshaft.
• Do not tighten the vise too firmly.
A033448J02 • Do not press too firmly on the camshaft timing gear
assembly as the seal surface can be easily damaged by
the end of the camshaft knock pin which may cause the
seal to fail.
• Do not remove the other 3 bolts.If the bolts are
removed, replace the camshaft timing gear assembly.
(c) Using an air gun, apply an air pressure of approximately 100
kPa (1 kgf/cm2) to the advance port shown in the illustration.
NOTICE:
Cover the ports with a piece of cloth to prevent oil from
splattering when the air pressure is applied.
HINT:
Air pressure is applied to release the lock pin for the most
retarded angle.
(d) Under the above conditions, rotate the camshaft timing sprocket
A033449J01 by hand in the advance direction (direction indicated by the
arrow in the illustration).
Standard:
Must rotate
HINT:
• Applying air pressure will rotate the camshaft timing
sprocket in the advance direction without applying manual
force.Air leaking out from the ports will make it difficult to
apply air pressure, which may also make it difficult to
release the lock pin.
• Attempting to rotate the camshaft timing sprocket will make
it difficult to release the lock pin due to pressure applied
from the side.
EM–137
(e) Unless it is in the most retarded position where the lock pin
engages, rotate the camshaft timing sprocket fully 2 to 3 times
and check the movable range and slide.
Standard:
Movable in a range of approximately 30°.
(f) Rotate the camshaft timing sprocket by hand and lock it in the
most retarded position.
(g) Remove the bolt and the camshaft timing sprocket.
INSTALLATION
Camshaft NO. 1 Camshaft NO. 2 (a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
(In Side) (Ex Side) angle) in the direction that the engine rotates from cylinder No. EM
NO. 3 NO. 4 NO. 4 NO. 2 1 TDC/compression so the lifted valve does not interfere with
the piston.
nal part of the cylinder head, and then install camshaft No. 2.
NOTICE:
A137596 camshaft No. 2 push down the lifter valve.
2. INSTALL CAMSHAFT

(a) Confirm the front mark and number of the camshaft bearing cap
No. 2 and install it.
A137596
(b) Tighten the camshaft bearing cap No. 2 in the order indicated in
the illustration.
I2
I3
I4
I5

NOTICE:
• Position the cap so the arrows on it face toward the
front of the engine, and install it so the punched num-
15 7 3 11
13 5 1 9
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order shown in
the illustration.
3
1
NOTICE:
Tighten it after checking that the thrust part of the camshaft
2 is aligned with the groove on camshaft bearing cap No. 1.
4
A133071
(b) Install the camshaft knock pin and the camshaft timing sprocket.
NOTICE:
Knock Pin
EM Pin Hole • If the knock pin and pin hole do not align, use the hex-
agonal head portion of the camshaft and rotate the cam-
press too firmly on the camshaft timing sprocket as the
Do Not Remove knock pin which may cause the seal to fail.
A136098 replace the camshaft timing sprocket.
6. INSTALL CHAIN
(a) Install the chain so the matchmarks of the camshaft timing gear
and the chain are aligned.
Timing Marks
A133561
(b) Pull the 3 mm diameter bar out from the chain tensioner.
NOTICE:
Using the hexagon head portion of the camshaft, rotate the
camshaft a little to the left with the chain slightly slack on
the tensioner side, and pull out the 3 mm diameter bar.
A109220
EM–139
(c) Make sure that each timing mark is positioned as shown in the
illustration.
(d) Apply TB1324 to the first 2 to 3 threads of the chain cover ser-
vice hole screw plug bolt.
NOTICE:
Timing Marks Clean and degrease the bolt and bolt hole.
EM
Notch
A140612
(e) Using a 10 mm socket hexagon wrench, install the chain cover

service hole screw plug.
A137724
7. INSTALL TIMING CHAIN (BELT) COVER NO. 2

Apply Liquid Gasket (a) Apply Three Bond TB1207B to the position shown in the illustra-
tion.
CAUTION:
TB1207B.
A139347
(b) Install the timing chain cover No. 2 with the 2 bolts.
8. INSTALL CYLINDER HEAD COVER (See page EM-190)
9. INSTALL IGNITION COIL ASSEMBLY (See page EM-190)
10. INSTALL RADIATOR PIPE (See page EM-194)
11. INSTALL RADIATOR HOSE NO. 1 (See page CO-18)
12. INSTALL ENGINE ROOM MAIN WIRE (See page EM-193)

A107960
13. CONNECT VENTILATION HOSE NO. 2 (See page EM-193)
14. CONNECT VENTILATION HOSE (See page EM-193)

page EM-193)
16. INSTALL AIR CLEANER ASSEMBLY (See page EM-194)
21. CHECK COOLANT LEVEL (See page CO-10)
EM 22. INSTALL ENGINE UNDER COVER (See page EM-104)

25. CHECK ENGINE IDLE SPEED (See page EM-5)
26. CHECK DENSITY OF CO AND HC (See page EM-6)

ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE)
EM–141
CYLINDER HEAD GASKET (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
EM–142 ENGINE MECHANICAL - CYLINDER HEAD GASKET (3SZ-VE)

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
EM–143
COOLANT BYPASS HOSE NO. 2

T=7.5{76}
COOLANT BYPASS HOSE
THROTTLE BODY ASSEMBLY ×2

T=21{214} EM
T=7.5{76}
×2
OIL LEVEL GAUGE GUIDE

O-RING THROTTLE BODY
T=19{194} T=21{214}
BRACKET NO. 2
T=19{194} ×2
×2 ×3
THROTTLE BODY
T=8.5{87}
BRACKET
O-RING
GASKET EXHAUST MANIFOLD
INTAKE MANIFOLD
INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=19{194} GASKET
T=10{102}
T=32{326}
T=44{449}
T=35{357}
×2
ALTERNATOR ASSEMBLY
×3
EXHAUST
T=9.3{95} MANIFOLD
T=35{357}
..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PARTA140623J01

OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM

TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
APPLY MP GREASE
EM–145

T=12.5{130}
×16
T=12.5{130}
×4
×8 CAMSHAFT
CAMSHAFT TIMING SPROCKET
EM
T=47{480}
×10
CYLINDER HEAD BOLT

CAMSHAFT NO. 2
WASHER
×10
CYLINDER HEAD
CYLINDER HEAD GASKET
PLASTIC REGION TIGHTENING METHOD

TIGHTENING TORQUE A137085J01
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
Instrument Panel J/B (3) Start up the engine.
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
DTC P0171/25 lean malfunction may be detected.
(5) Crank the engine again, then check that the engine does
F/P Relay not start.
EM (6) Remove the fuel tank cap to discharge pressure from the
A135986J01 fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.

(See page RS-164.)
3. REMOVE BATTERY CARRIER

(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-43)
7. REMOVE RADIATOR RESERVE TANK ASSEMBLY (See page CO-

15)
8. REMOVE CHARCOAL CANISTER ASSEMBLY (See page CO-16)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-17)
12. REMOVE AIR CLEANER ASSEMBLY

(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
13. DISCONNECT HEATER INLET WATER HOSE
(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
A136001
EM–147
14. DISCONNECT HEATER OUTLET WATER HOSE

(a) Loosen the clip, then disconnect the heater outlet water hose.
A136002
15. REMOVE RADIATOR PIPE

(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe. EM
A133397
16. REMOVE VENTILATION HOSE

(a) Loosen the clip and remove the ventilation hose.
A134307
17. REMOVE VENTILATION HOSE NO. 2

(a) Loosen the clip and remove ventilation hose No. 2.
A134308

(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE

(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
A131808
(d) Remove the 2 bolts and disconnect the ground wire.
A133250
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR

(a) Remove the 2 bolts and 2 springs, then disconnect the exhaust
EM pipe assembly FR from the exhaust manifold.
A134989
21. REMOVE FUEL HOSE NO. 2

(a) Loosen the clip, then disconnect fuel hose No. 2.
A133396
22. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.
23. DISCONNECT VACUUM HOSE ASSEMBLY

(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
A136065
24. REMOVE THROTTLE BODY ASSEMBLY

(a) Remove the 2 bolts and bracket.
(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
A131805
EM–149
(c) Loosen the clamp, then disconnect the water hose.

Blue Paint (d) Remove the 3 bolts and the throttle body assembly.
(e) Remove the 2 bolts and the throttle body assembly.
A131806
25. REMOVE FUEL DELIVERY PIPE

BOLT
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove. EM
A134311
26. REMOVE THROTTLE BODY BRACKET

(a) Remove the 2 bolts and the throttle body bracket.
27. REMOVE FUEL INJECTOR ASSEMBLY

(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
• The O-ring may be stuck, but even if it is, do not apply
sideways force to the fuel injector assembly.
• If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
A109106
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
O-ring 28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
Insulator
A107004J02
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
29. REMOVE FAN AND ALTERNATOR V BELT (See page EM-8)
31. REMOVE ALTERNATOR ASSEMBLY (See page CH-10)
32. REMOVE VANE PUMP WITH BRACKET (See page EM-44)

A109108
33. REMOVE IDLER PULLEY NO. 1

(a) Remove the nut, then remove idler pulley No. 1.
A137714
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
EM 1.
A133399
35. REMOVE MANIFOLD STAY

(a) Remove the 2 bolts and the manifold stay.
A136071
36. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.
37. REMOVE IGNITION COIL ASSEMBLY

(a) Disconnect the ignition coil connector.
A133400
EM–151
(b) Remove the bolt and the ignition coil assembly.
A133310
38. REMOVE CYLINDER HEAD COVER

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover. EM
A132251
39. REMOVE CRANKSHAFT PULLEY

HINT:
If the timing marks are not aligned, turn the crankshaft pulley
Timing Marks
Notch
A137746
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST
Install the SST to the crankshaft pulley so that the fixing
bolts for the SST do not contact with the chain cover.
A137589
40. REMOVE CRANK POSITION SENSOR

(a) Remove the bolt and the crank position sensor.
EM
A137713

(a) Remove the bolt and the camshaft timing oil control valve
assembly.
A136191
42. REMOVE TIMING CHAIN (BELT) COVER

(a) Remove the 13 bolts and 2 nuts.
A133402
EM–153
(b) Using a screwdriver wrapped with protective tape, lever off and
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
A133404
43. REMOVE TIMING CHAIN (BELT) COVER OIL SEAL

(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal. EM
Wooden
Protective Tape Block
A033132J01

D-MARK
A135998

released.[*1]
HINT:
the right and left.
A108005 and hold.[*2]
HINT:
plunger.
HINT:

A108555J01

EM (e) Remove the bolt and nut and then remove the water inlet.
A108556

A108557

A108558

49. REMOVE CHAIN
A108559
EM–155

Hold (a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90° (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
A136076

2
in the illustration. EM
4
A133124

2 10 14 6
NOTICE:
4 12 16 8
3 11 15 7
1 9 13 5
A133125
53. REMOVE CYLINDER HEAD

4 6 9 7 1 (a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra-
tion, then remove the cylinder head bolt and washer.
NOTICE:
• When removing the bolt, do not drop the washer into
the head.
• Failure to remove the bolts in the specified order may
damage the cylinder head.
2 8 10 5 3 (b) Remove the cylinder head.
A132854
54. REMOVE CYLINDER HEAD GASKET

INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
A within the range indicated by A in the illustration.
Maximum limit:
25mm 20mm 8.75 mm
HINT:
• Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
A108575J01 • If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
EM 2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Cylinder Head • Install the cylinder head gasket within 3 minutes and tighten
0-4 mm
21-27 mm the cylinder head bolts within 15 minutes after applying
2.5 mm Three Bond TB1207B.
(a) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
Cylinder Head
Gasket
17-23 mm Cylinder Block
2.0 mm
A083197J02
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
• Check that it is installed in the correct direction.
• Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD

NOTICE:
Front • Clean and degrease the installation surfaces.
• Inspect and clean the cylinder head and installation hole.
A033157J01
• Tighten the cylinder head using the plastic area tightening
method.
• Do not allow oil to get on the lower surface of the cylinder
head.
(a) Install the cylinder head.
NOTICE:
• Take care not to damage the cylinder head gasket when
installing it.
• Install the cylinder head bolt to the same place it was
removed from.
EM–157
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
Apply Engine Oil

A133007
(c) Using an 8 mm double hexagon wrench, temporarily install the

7 5 2 4 10 cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec- EM
ified torque.
9 3 1 6 8
A133008
(d) Put paints mark on the engine front side of heads of the cylinder
head bolts.
Paint Mark (e) Using the paint mark as a reference, tighten the cylinder head
bolts 180° in the specified order.
(f) Check all the paint marks are now moved 180°.
180° Tighten
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the seal packing black, do not allow it to
A140645 enter the bolt hole or knock pin hole.

(a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
angle) in the direction that the engine rotates from cylinder No.
1 TDC/compression so the lifted valve does not interfere with
the piston.
Camshaft NO. 1 Camshaft NO. 2 nal part of the cylinder head, and then install the camshaft No.
(In Side) (Ex Side) 2.
camshaft No. 2 push down the lifter valve.
A137596
5. INSTALL CAMSHAFT
A137596

(a) Confirm the front mark and number of camshaft bearing cap No.
EM
I2
I3
I4
I5
2 and install it.

the illustration.
15 7 3 11
NOTICE:
• Position the cap so the arrow on it faces toward the
13 5 1 9 front of the engine, and install it so the punched num-
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
3
1
NOTICE:
Tighten the bolts after checking that the thrust part of the
2 camshaft is aligned with the groove on camshaft bearing
4 cap No. 1.

A133071
(b) Align the camshaft knock pin and the camshaft timing sprocket
pin hole, and install the camshaft timing sprocket to the cam-
Pin Hole Knock Pin
shaft.
NOTICE:
• If the knock pin and pin hole do not align, use the hexa-
Do Not Remove press too firmly on the camshaft timing sprocket as the
A136098 knock pin which may cause the seal to fail.
replace the camshaft timing sprocket.
EM–159
(c) Apply a small amount of engine oil to the camshaft timing

Hold sprocket installation bolt thread and seating surface to tempo-
rarily install them.
(d) Using the hexagon head portion of the camshaft, tighten the
A136076
9. INSTALL CHAIN
Mark Plate Mark Plate (a) Align the mark plate (yellow) and the timing mark as shown in
the illustration and install the chain. EM
HINT:
Install so that the mark plate is on the engine front side.
Mark Plates
Timing Mark
A137742

A108559

A108558

A108557

EM Torque: 9 N*m (92 kgf*cm)
HINT:
plunger.
A108556 plunger.

D Mark (a) Install the crank angle sensor plate No. 1 so that the D mark is
visible.
A133073
15. INSTALL TIMING CHAIN (BELT) COVER

(a) Install a new gasket to the timing chain (belt) cover.
A108562
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
NOTICE:
• Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
• Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
• Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
Apply Liquid Gasket A108563J02 TB1207B.
EM–161
• Do not add engine oil within 2 hours of installation.

B B 6 mm Diameter
EM
6 mm Diameter
3-4 mm Diameter 3 mm Diameter

A A
Apply Liquid Gasket

3-4 mm 3-4 mm A139363
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
10 44 N*m (449 kgf*cm) (Bolts 13 to 15)
3
2 16. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
200)
4 12
15
11 13
14
5
1
9
6
7 8
A136081
17. INSTALL CRANKSHAFT PULLEY

(a) Using the SST, hold the crankshaft pulley and tighten the bolt.
SST 09278-87201
SST
18. INSTALL CRANK POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring.
A137588
(b) Install the crank position sensor with the bolt.

NOTICE:
Install the sensor so that the O-ring is not cut or pinched.
A137713

EM (b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
A136191
20. INSTALL CYLINDER HEAD COVER

(a) Apply seal packing black to the position shown in the illustra-
tion.
NOTICE:
TB1207B.
• Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
Apply Liquid Gasket
A079650J02 • Do not start the engine within 2 hours of installation.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
8 2 4 6
several passes in the order shown in the illustration.
Torque: 11 N*m (112 kgf*cm) (Nut)
12 13 9.0 N*m (92 kgf*cm) (Bolt)
9
21. INSTALL SPARK PLUG
10 11
5 3 1 7
A133409
22. INSTALL IGNITION COIL ASSEMBLY

(a) Install the ignition coil assembly with the bolt.
23. INSTALL EXHAUST MANIFOLD

(a) Install the exhaust manifold using a new gasket.
A133310
EM–163
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
EM
A133400
24. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (Bolt)
A136071
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
26. INSTALL ALTERNATOR ASSEMBLY (See page CH-10)
A133399
28. INSTALL IDLER PULLEY NO. 1

(a) Install the idler pulley No. 1 with the nut.
29. INSTALL VANE PUMP WITH BRACKET (See page EM-68)

A137714
33. INSTALL INTAKE MANIFOLD

(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
A109108
(b) Tighten the bolts and nuts in the order shown in the illustration.
EM
A079976J02
34. INSTALL THROTTLE BODY ASSEMBLY

(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
A109106 Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
(f) Connect the engine wire harness.
35. INSTALL FUEL INJECTOR ASSEMBLY
(a) Install a new injector vibration insulator.
O-ring (b) Apply gasoline to the new fuel injector assembly O-ring.
Insulator
A107004J01
EM–165
(c) Install the fuel delivery pipe while rotating the fuel injector
assembly to the left and right.
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
A107005
36. INSTALL FUEL DELIVERY PIPE
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
EM
• Do not drop the fuel injector when installing the fuel
delivery pipe.
• If the tip of the sensor is hit or dropped, replace it with a
new one.
• Make sure there is no foreign matter in or damage to the
insertion part of the injector assembly (cylinder head).
A136082 (c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
37. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the brake booster
assembly.
38. INSTALL OIL LEVEL GAUGE GUIDE
39. CONNECT FUEL HOSE NO. 2

(a) Connect the fuel hose No. 2.
NOTICE:
• Before proceeding, check that there is no damage to or
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-66)

41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
A133250
(c) Adjust the wire cable and tighten the nut.
43. INSTALL VENTILATION HOSE

(a) Install the ventilation hose.
Yellow Paint A131812
44. INSTALL VENTILATION HOSE NO. 2

White Paint
Yellow Paint (a) Install ventilation hose No. 2.
EM
A131807
45. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with the 2 bolts and connect the hose.
A133397
46. CONNECT HEATER OUTLET WATER HOSE

(a) Connect the heater outlet water hose.
A136002
47. CONNECT HEATER INLET WATER HOSE

(a) Connect the heater inlet water hose.
48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-29)
49. CONNECT RADIATOR HOSE NO. 1 (See page CO-18)
50. INSTALL CHARCOAL CANISTER ASSEMBLY (See page CO-18)
51. INSTALL RADIATOR RESERVE TANK ASSEMBLY (See page CO-

18)
A136001
EM–167
52. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY
54. CONNECT BATTERY NEGATIVE TERMINAL

55. INSTALL AIR CLEANER ASSEMBLY
A (a) Install the air cleaner assembly with the 3 bolts.
A
B
Torque: 7.5 N*m (75 kgf*cm) (Bolt A)
18 N*m (184 kgf*cm) (Bolt B)
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor. EM
A136084 57. ADD ENGINE OIL
61. CHECK ENGINE OIL LEVEL

(a) Warm up the engine, stop the engine and wait 5 minutes. Check
that the oil level is between the F mark and L marks. If low,
check for leakage and add oil up to the F mark.
63. CHECK FOR FUEL LEAKS

(a) Check the fuel pump operation.
(1) Connect the DS-II to the DLC.
(2) Follow the prompts on the screen to select ACTIVE TEST
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(b) Check for fuel leaks.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
64. CHECK FOR EXHAUST GAS LEAKS

EM–168 ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE)
CYLINDER HEAD GASKET (K3-VE)

ENGINE MECHANICAL
COMPONENTS
T=3.5{36}
BATTERY
×2
EM
T=8.5{87} ×3 T=18{184}
T=7.5{76} ×2
BATTERY CARRIER
RADIATOR HOSE NO. 1
ENGINE UNDER COVER
T=5.4{55} ×11

A136903J01
ENGINE MECHANICAL - CYLINDER HEAD GASKET (K3-VE)
EM–169
VENTILATION HOSE NO. 2 SPARK PLUG EM

T=20{204}
T=7.5{76}
×4

×4
O-RING
T=7.5{76}
IDLER PULLEY
IDLER PULLEY NO. 1

RADIATOR PIPE
×3
T=11.5{117}
T=44{449}
T=130{1326}
×3
T=20.6{210}
O-RING
T=7.5{76}

A136904J02
COOLANT BYPASS HOSE NO. 2

T=7.5{76}
COOLANT BYPASS HOSE
EM ×2
T=21{214}
THROTTLE BODY ASSEMBLY T=7.5{76}

×2
OIL LEVEL GAUGE GUIDE

O-RING
T=19{194}
T=21{214} THROTTLE BODY
T=19{194}
×2 ×3
BRACKET NO. 2
×2
THROTTLE BODY
T=8.5{87}
BRACKET
O-RING
GASKET
INTAKE MANIFOLD EXHAUST MANIFOLD HEAT
INSULATOR NO. 1
T=8.5{87}
T=8.5{87}
T=19{194} GASKET
T=10{102}
T=32{326}
T=44{449}
T=35{357}
×2
ALTERNATOR ASSEMBLY
×3
EXHAUST
T=9.3{95}
MANIFOLD
T=35{357}
TIGHTENING TORQUE NON-REUSEABLE PART A140623J02

EM–171
OIL FILLER CAP

T=11{112}
CYLINDER HEAD COVER
T=9.0{92}
×11

EM

TIMING CHAIN
TENSIONER ARM
TIMING GEAR (CHAIN)
COVER GASKET
TIMING CHAIN GUIDE
T=9.0{92}
CHAIN
T=23{235}
T=12{122}
×9
×2
T=44{449} ×3
T=19{195}
T=7.5{76}
T=7.5{76}
×2
APPLY MP GREASE

T=12.5{130}
×16
T=12.5{130}
×4
×8 CAMSHAFT
CAMSHAFT TIMING SPROCKET
EM
T=47{480}
×10
CYLINDER HEAD BOLT

CAMSHAFT NO. 2
WASHER
×10
CYLINDER HEAD
CYLINDER HEAD GASKET
PLASTIC REGION TIGHTENING METHOD

TIGHTENING TORQUE A137085J01
EM–173
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
NOTICE:
• Always discharge fuel system pressure before removing any
fuel system components.
• As some pressure will remain in the fuel line even after the
fuel system pressure has been discharged, cover the open-
ing with a shop rag or a similar to prevent fuel from splash-
ing.
(a) Procedure required when removing the F/P relay
(1) Turn the ignition switch to the LOCK position.
(2) Remove the F/P relay.
Instrument Panel J/B (3) Start up the engine. EM
(4) After the engine has stopped on its own, turn the ignition
switch off.
HINT:
DTC P0171/25 lean malfunction may be detected.
(5) Crank the engine again, then check that the engine does
F/P Relay not start.
(6) Remove the fuel tank cap to discharge pressure from the
A135986J01 fuel tank.
(7) Disconnect the negative terminal from the battery.
(8) Install the F/P relay.

(See page RS-164.)
3. REMOVE BATTERY CARRIER

(a) Remove the 3 bolts and battery carrier.
5. DRAIN ENGINE OIL (See page EM-78)

22)
10. REMOVE WITH WATER FAN ASSEMBLY (See page CO-24)
12. REMOVE AIR CLEANER ASSEMBLY

(a) Disconnect the VSV connector and 2 hoses.
(b) Disconnect the vacuum sensor connector and hose.
(c) Remove the inlet air temperature sensor.
(d) Remove the 3 bolts and the air cleaner assembly.
13. DISCONNECT HEATER INLET WATER HOSE

(a) Loosen the clip, then disconnect the heater inlet water hose
from the radiator pipe.
A136001
14. DISCONNECT HEATER OUTLET WATER HOSE

(a) Loosen the clip, then disconnect the heater outlet water hose.
EM
A136002
15. REMOVE RADIATOR PIPE

(a) Remove the 2 bolts, loosen the clip and then remove the radia-
tor pipe.
A133397
16. REMOVE VENTILATION HOSE

(a) Loosen the clip and remove the ventilation hose.
A134307
17. REMOVE VENTILATION HOSE NO. 2

(a) Loosen the clip and remove ventilation hose No. 2.
A134308
EM–175

(a) Loosen the nut and disconnect the accelerator control cable
assembly from the throttle body assembly.
(b) Remove the bolt and bracket.
19. DISCONNECT ENGINE ROOM MAIN WIRE

(a) Disconnect the engine wire clamp from the bracket.
(b) Disconnect the sensor connectors.
(c) Disconnect the ground connector of the cylinder head cover.
A131808
(d) Remove the 2 bolts and disconnect the ground wire.
EM
A133250
20. DISCONNECT EXHAUST PIPE ASSEMBLY FR

(a) Remove the 2 bolts and 2 springs, then disconnect the exhaust
pipe assembly FR from the exhaust manifold.
A134989
21. REMOVE FUEL HOSE NO. 2

(a) Loosen the clip, then disconnect fuel hose No. 2.
A133396
22. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and nut, then remove the oil level gauge guide
and O-ring.
23. DISCONNECT VACUUM HOSE ASSEMBLY

(a) Disconnect the vacuum hose assembly from the booster vac-
uum tube.
A136065
24. REMOVE THROTTLE BODY ASSEMBLY

(a) Remove the 2 bolts and bracket.
(b) Disconnect the throttle body assembly connector and wire har-
ness clamp.
A131805
(c) Loosen the clamp, then disconnect the water hose.

Blue Paint (d) Remove the 3 bolts and the throttle body assembly.
EM (e) Remove the 2 bolts and the throttle body assembly.
A131806
25. REMOVE FUEL DELIVERY PIPE

BOLT
(a) Remove the 2 bolts, then hold both sides of the fuel delivery
pipe and lift it straight up to remove.
A134311
26. REMOVE THROTTLE BODY BRACKET

(a) Remove the 2 bolts and the throttle body bracket.
27. REMOVE FUEL INJECTOR ASSEMBLY

(a) Remove the fuel injector assembly from the fuel delivery pipe.
NOTICE:
• The O-ring may be stuck, but even if it is, do not apply
sideways force to the fuel injector assembly.
• If re-installing the fuel injector assembly instead of
replacing it with a new one, note the cylinder number on
A109106
a tag or similar to distinguish it.
(b) Remove the O- ring and insulator from the fuel injector assem-
bly.
O-ring 28. REMOVE INTAKE MANIFOLD
(a) Disconnect the water by-pass hose from the cylinder head.
(b) Disconnect the wire harness from the intake manifold.
Insulator
A107004J02
EM–177
(c) Remove the 3 bolts and 2 nuts, then remove the intake mani-
fold.
(d) Remove the gasket from the intake manifold.
30. REMOVE VANE PUMP WITH BRACKET (See page EM-79)
32. REMOVE ALTERNATOR ASSEMBLY (See page CH-13)

A109108
33. REMOVE IDLER PULLEY NO. 1

(a) Remove the nut, then remove idler pulley No. 1.
EM
A137714
34. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Remove the 5 bolts and the exhaust manifold heat insulator No.
1.
A133399
35. REMOVE MANIFOLD STAY

(a) Remove the 2 bolts and the manifold stay.
A136071
36. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and 2 nuts, then remove the exhaust mani-
fold.
37. REMOVE IGNITION COIL ASSEMBLY

(a) Disconnect the ignition coil connector.
EM
A133400
(b) Remove the bolt and the ignition coil assembly.
A133310
38. REMOVE CYLINDER HEAD COVER

(a) Remove the 11 bolts and 2 nuts, then remove the cylinder head
cover.
A132251
EM–179

HINT:
Timing Marks If the timing marks are not aligned, turn the crankshaft pulley
EM
Notch
A140612
(b) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(c) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST
A137589
40. REMOVE CRANK POSITION SENSOR

(a) Remove the bolt and the crank position sensor.
A137713

(a) Remove the bolt and the camshaft timing oil control valve
assembly.
A136072
42. REMOVE TIMING CHAIN (BELT) COVER

EM
A133402
remove the timing chain (belt) cover.
NOTICE:
Do not damage the timing chain cover, cylinder block or
cylinder head.
A133404

(a) Using a screwdriver, pry out the timing chain (belt) cover oil
seal.
Wooden
Protective Tape Block
A033132J01
EM–181

D-MARK
A135998

released.[*1] EM
HINT:
the right and left.
A108005 and hold.[*2]
HINT:
plunger.
HINT:

A108555J01

(e) Remove the bolt and nut and then remove the water inlet.
A108556

A108557

EM
A108558

49. REMOVE CHAIN
A108559

Hold (a) Using the hexagon head portion of the camshaft, remove the
NOTICE:
When rotating the camshaft with the chain removed, rotate
the crankshaft 90° (crank angle) in the direction that the
engine rotates from cylinder No. 1 TDC / compression so
the valve does not interfere with the piston.
A136076

2
A133124
EM–183

2 10 14 6
NOTICE:
4 12 16 8
3 11 15 7
1 9 13 5
A133125
53. REMOVE CYLINDER HEAD

4 6 9 7 1 (a) Using an 8 mm double hexagon wrench, loosen the cylinder
head bolts in several passes in the order shown in the illustra- EM
tion, then remove the cylinder head bolt and washer.
NOTICE:
• When removing the bolt, do not drop the washer into
the head.
• Failure to remove the bolts in the specified order may
damage the cylinder head.
2 8 10 5 3 (b) Remove the cylinder head.
A132854
54. REMOVE CYLINDER HEAD GASKET
INSTALLATION
1. INSPECT CYLINDER HEAD BOLT
(a) Using vernier calipers, measure the diameter of the thread
A within the range indicated by A in the illustration.
Maximum limit:
25mm 20mm 8.75 mm
HINT:
• Measure the diameter at several locations. If the smallest
measured value is above the limit, the engine may be dam-
aged. Replace the bolt with a new one.
A108575J01 • If there is any damage to the thread on the bolt, replace the
cylinder head bolt.
2. INSTALL CYLINDER HEAD GASKET
NOTICE:
Cylinder Head • Install the cylinder head gasket within 3 minutes and tighten
0-4 mm
21-27 mm the cylinder head bolts within 15 minutes after applying
2.5 mm Three Bond TB1207B.
tration.
Cylinder Head
Gasket
17-23 mm Cylinder Block
2.0 mm
A083197J02
(b) Install a new cylinder head gasket in the direction shown in the
illustration.
NOTICE:
• Check that it is installed in the correct direction.
• Do not damage the cylinder head gasket.
3. INSTALL CYLINDER HEAD

NOTICE:
Front • Clean and degrease the installation surfaces.
• Inspect and clean the cylinder head and installation hole.
A033157J01
• Tighten the cylinder head using the plastic area tightening
method.
• Do not allow oil to get on the lower surface of the cylinder
head.
EM (a) Install the cylinder head.
NOTICE:
• Take care not to damage the cylinder head gasket when
installing it.
• Install the cylinder head bolt to the same place it was
removed from.
(b) Apply a light coat of engine oil to the threads and bolt-seating
surface of the cylinder head bolts.
Apply Engine Oil

A133007
(c) Using an 8 mm double hexagon wrench, temporarily install the

7 5 2 4 10 cylinder head bolts and washers in several passes in the order
shown in the illustration and then tighten the bolts with the spec-
ified torque.
9 3 1 6 8
A133008
(d) Put paint marks on the engine front side of heads of the cylinder
head bolts.
Paint Mark (e) Using the paint mark as a reference, tighten the cylinder head
bolts 180° in the specified order.
(f) Check all the paint marks are now moved 180°.
180° Tighten
(g) When installing the cylinder head, wipe off any Three Bond
TB1207B that is squeezed out.
NOTICE:
When wiping off the Three Bond TB1207B, do not allow it
A140645 to enter the bolt hole or knock pin hole.
EM–185

(a) When installing camshaft No. 2, rotate the crankshaft 90° (crank
angle) in the direction that the engine rotates from cylinder No.
1 TDC/compression so the lifted valve does not interfere with
the piston.
Camshaft NO. 1 Camshaft NO. 2 nal part of the cylinder head, and then install the camshaft No.
(In Side) (Ex Side) 2.
camshaft No. 2 push down the lifter valve.
EM
A137596
5. INSTALL CAMSHAFT
A137596

(a) Confirm the front mark and number of camshaft bearing cap No.
I2
I3
I4
I5
2 and install it.

the illustration.
15 7 3 11
NOTICE:
• Position the cap so the arrow on it faces toward the
13 5 1 9 front of the engine, and install it so the punched num-
14 6 2 10
16 8 4 12
E2
E4
E5
E3
A133070

(a) Tighten the camshaft bearing cap No. 1 in the order indicated in
the illustration.
3
1
NOTICE:
Tighten the bolts after checking that the thrust part of the
2 camshaft is aligned with the groove on camshaft bearing
4 cap No. 1.

A133071
(b) Align the camshaft knock pin and the camshaft timing sprocket
pin hole, and install the camshaft timing sprocket to the cam-
Pin Hole Knock Pin
shaft.
NOTICE:
• If the knock pin and pin hole do not align, use the hexa-
Do Not Remove press too firmly on the camshaft timing sprocket as the
A136098 knock pin which may cause the seal to fail.
replace the camshaft timing sprocket.
(c) Apply a small amount of engine oil to the camshaft timing
EM Hold sprocket installation bolt thread and seating surface to tempo-
rarily install them.
(d) Using the hexagon head portion of the camshaft, tighten the
A136076
9. INSTALL CHAIN
Mark Plate Mark Plate (a) Align the mark plate (yellow) and the timing mark as shown in
HINT:
Install so that the mark plate is on the engine front side.
Mark Plates
Timing Mark
A137742
EM–187

A108559

Torque: 7.5 N*m (76 kgf*cm) EM
A108558

A108557

HINT:
plunger.
A108556 plunger.

D Mark (a) Install the crank angle sensor plate No. 1 so that the D mark is
visible.
A133073
15. INSTALL TIMING CHAIN (BELT) COVER

(a) Install a new gasket to the timing chain (belt) cover.
A108562
(b) Apply Three Bond TB1207B to the locations shown in the illus-
tration.
EM NOTICE:
• Clean and degrease the installation surfaces using
brake cleaner and white gasoline.
• Install the timing chain (belt) cover within 3 minutes of
applying Three Bond TB1207B.
• Tighten the timing chain (belt) cover to the specified
torque within 15 minutes of applying Three Bond
Apply Liquid Gasket A108563J02 TB1207B.
• Do not add engine oil within 2 hours of installation.
B B 6 mm Diameter
6 mm Diameter
3-4 mm Diameter 3 mm Diameter

A A
Apply Liquid Gasket

3-4 mm 3-4 mm A139363
EM–189
(c) Install the timing chain (belt) cover with the 13 bolts and 2 nuts.
Torque: 12 N*m (122 kgf*cm) (Bolts 1 to 9)
23 N*m (235 kgf*cm) (Nuts 11 to 12)
10 44 N*m (449 kgf*cm) (Bolts 13 to 15)
3
2 16. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL (See page EM-
206)
4 12
15
11 13
14
5
1
9
6
7 8 EM
A136081

SST 09278-87201
SST
18. INSTALL CRANK POSITION SENSOR
A137588
(b) Install the crank position sensor with the bolt.

NOTICE:
A137713

(b) Install the camshaft timing oil control valve assembly with the
bolt.
NOTICE:
A136072
20. INSTALL CYLINDER HEAD COVER

tration.
NOTICE:
TB1207B.
• Tighten the cylinder head cover to the specified torque
within 15 minutes of applying Three Bond TB1207B.
Apply Liquid Gasket
A079650J02 • Do not start the engine within 2 hours of installation.
(b) Install the cylinder head cover with the 11 bolts and 2 nuts in
8 2 4 6
several passes in the order shown in the illustration.
EM Torque: 11 N*m (112 kgf*cm)
12 13
9 21. INSTALL SPARK PLUG
10 11
5 3 1 7
A133409
22. INSTALL IGNITION COIL ASSEMBLY

(a) Install the ignition coil assembly with the bolt.
23. INSTALL EXHAUST MANIFOLD

(a) Install the exhaust manifold using a new gasket.
A133310
(b) Install the intake manifold with the 3 bolts and 2 nuts in the
order shown in the illustration.
A133400
EM–191
24. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt.
Torque: 9.3 N*m (95 kgf*cm) (bolt)
EM
A136071
25. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Install the exhaust manifold heat insulator No. 1 with the 5 bolts.
26. INSTALL ALTERNATOR ASSEMBLY (See page CH-13)
A133399
28. INSTALL IDLER PULLEY NO. 1

(a) Install the idler pulley No. 1 with the nut.
29. INSTALL VANE PUMP WITH BRACKET (See page EM-103)

A137714 33. INSTALL INTAKE MANIFOLD
(a) Temporarily install the intake manifold with the 3 bolts and 2
nuts using a new gasket.
(b) Tighten the bolts and nuts in the order shown in the illustration.
A079976J02
34. INSTALL THROTTLE BODY ASSEMBLY

(a) Temporarily install the throttle body bracket with the 2 bolts.
(b) Temporarily install the throttle body assembly with the 3 bolts
using a new gasket.
(c) Tighten the throttle body bracket with the 2 bolts.
(d) Using a new gasket, tighten the throttle body assembly on the
throttle body bracket side and then the intake manifold side with
the 3 bolts.
A109106 Torque: 21 N*m (214 kgf*cm) Bolt throttle body bracket
side
7.5 N*m (75 kgf*cm) Bolt intake manifold side
(e) Connect the 2 water by-pass hoses.
EM (f) Connect the engine wire harness.
35. INSTALL FUEL INJECTOR ASSEMBLY
(a) Install a new injector vibration insulator.
O-ring (b) Apply gasoline to the new fuel injector assembly O-ring.
Insulator
A107004J01
(c) Install the fuel delivery pipe while rotating the fuel injector
assembly to the left and right.
NOTICE:
Install the sensor so that the O-ring is not twisted or
pinched.
(d) Check that the fuel injector assembly rotates smoothly.
NOTICE:
If the fuel injector assembly does not rotate smoothly, rein-
stall it with a new O-ring.
A107005
36. INSTALL FUEL DELIVERY PIPE
(a) Install the fuel pipe insulator.
(b) Temporarily install the fuel delivery pipe and the fuel tube with
the 2 bolts.
NOTICE:
• Do not drop the fuel injector when installing the fuel
delivery pipe.
• If the tip of the sensor is hit or dropped, replace it with a
new one.
• Make sure there is no foreign matter in or damage to the
insertion part of the injector assembly (cylinder head).
A136082 (c) Check that the fuel injectors rotate smoothly.
NOTICE:
If a fuel injector does not rotate smoothly, reinstall it with a
new O-ring.
(d) Tighten the 2 bolts.
EM–193
37. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the brake booster
assembly.
38. INSTALL OIL LEVEL GAUGE GUIDE
39. CONNECT FUEL HOSE NO. 2

(a) Connect the fuel hose No. 2.
NOTICE:
• Before proceeding, check that there is no damage to or
foreign matter on the fuel hose No. 2 or the connection
of the pipe.
40. INSTALL EXHAUST PIPE ASSEMBLY FR (See page EM-101)

41. CONNECT ENGINE ROOM MAIN WIRE
(a) Install the ground wire with the 2 bolts.
EM
(b) Connect the cylinder head cover ground connector.
(c) Connect the connectors of the sensors.
(d) Connect the engine wire clamp to the bracket.
42. CONNECT ACCELERATOR CONTROL CABLE ASSEMBLY

(a) Connect the accelerator control cable assembly to the throttle
body assembly.
(b) Install the bracket with the bolt.
A133250
(c) Adjust the wire cable and tighten the nut.
43. INSTALL VENTILATION HOSE

(a) Install the ventilation hose.
Yellow Paint A131812
44. INSTALL VENTILATION HOSE NO. 2

White Paint (a) Install ventilation hose No. 2.
Yellow Paint
A131807
45. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with the 2 bolts and connect the hose.
A133397
46. CONNECT HEATER OUTLET WATER HOSE

(a) Connect the heater outlet water hose.
EM
A136002
47. CONNECT HEATER INLET WATER HOSE

(a) Connect the heater inlet water hose.
48. INSTALL WITH WATER FAN ASSEMBLY (See page CO-24)

25)
A136001 52. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 3 bolts.
53. INSTALL BATTERY
54. CONNECT BATTERY NEGATIVE TERMINAL

55. INSTALL AIR CLEANER ASSEMBLY
A (a) Install the air cleaner assembly with the 3 bolts.
A
B
NOTICE:
• Check that the O-ring is installed correctly to the throt-
tle body joint.
• Check that there is no foreign matter in the throttle
body opening.
• Check that there is no foreign matter on the clean side
part of the air cleaner.
A136084 Torque: 7.5 N*m (75 kgf*cm) (Bolt A)
18 N*m (184 kgf*cm) (Bolt B)
(b) Connect the VSV connector.
(c) Connect the inlet air temperature sensor.
(d) Connect the connector of the vacuum sensor.

EM–195
57. ADD ENGINE OIL
61. CHECK ENGINE OIL LEVEL

(a) Warm up the engine, stop the engine and wait 5 minutes. Check
that the oil level is between the F mark and L marks. If low,
check for leakage and add oil up to the F mark.
63. Check for fuel leaks.

(a) Check the fuel pump operation.
(1) Connect the DS-II to the DLC.
EM
(2) Follow the prompts on the screen to select ACTIVE TEST
/ CIRCUIT RELAY / ON, and check the fuel pump opera-
tion.
(b) Check for fuel leaks.
(1) Check that there are no leaks in the fuel system with fuel
pressure applied.
64. CHECK FOR EXHAUST GAS LEAKS

EM–196 ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
EM
AIR CLEANER HOSE NO. 1
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
FOG LIGHT ASSEMBLY RH
FOG LIGHT ASSEMBLY LH
T=5.4{55} ×11

A136654J01
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (3SZ-VE)
EM–197
CHARCOAL CANISTER NO. 1

RADIATOR RESERVE RADIATOR HOSE NO. 2
TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
T=7.5{76}
RADIATOR CAP EM
RADIATOR SUPPORT UPR
×2
×2
WITH WATER
×2 FAN ASSEMBLY
T=7.5{76}
RADIATOR SUPPORT CUSHION

×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
DRAIN COCK SUB-ASSEMBLY
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
OIL COOLER INLET HOSE NO. 1

A136655J01
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
EM–199
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page CO-15)
5. REMOVE FOG LIGHT ASSEMBLY RH
6. REMOVE FRONT BUMPER COVER (See page CO-15)
8. REMOVE SEAL PLATE (See page CO-15) EM

10. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

TRANSMISSION) (See page CO-15)
11. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC


15)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-16)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See

page CO-16)
17. REMOVE RADIATOR ASSEMBLY (See page CO-17)

(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST

(a) Using a cutter knife, cut off the lip of the oil seal.
A137589
remove the oil seal.
Protective Tape NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
A107954J01
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
EM • Keep the lip free of chips, sand and other foreign mat-
ter.
• Wipe off any grease on the crankshaft.
(b) Using the SST, drive in a new timing chain (belt) cover oil seal
to the position shown in the illustration.
SST 09223-87202
NOTICE:
• Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
SST
• After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
A137591 (c) Standard
(1) Press fit margin
• Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
• Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)

SST 5. CHECK FAN AND ALTERNATOR V BELT (See page EM-9)
A139349
6. INSTALL RADIATOR ASSEMBLY (See page CO-17)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page

CO-18)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-18)

18)
12. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC

TRANSMISSION)(See page CO-18)
EM–201
13. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

15. INSTALL SEAL PLATE (See page CO-19)
17. INSTALL ENGINE UNDER COVER (See page CO-19)
18. INSTALL FRONT BUMPER COVER (See page CO-19)
19. INSTALL FOG LIGHT ASSEMBLY LH
20. INSTALL FOG LIGHT ASSEMBLY RH
21. CONNECT NEGATIVE BATTERY TERMINAL (See page CO-19)

EM

EM–202 ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)

ENGINE MECHANICAL
COMPONENTS
EM
AIR CLEANER HOSE NO. 1
T=7.5{76}
×2
FRONT BUMPER COVER
ENGINE UNDER COVER
FOG LIGHT ASSEMBLY RH
FOG LIGHT ASSEMBLY LH
T=5.4{55} ×11

A136654J01
ENGINE MECHANICAL - TIMING CHAIN (BELT) COVER OIL SEAL (K3-VE)
EM–203
CHARCOAL CANISTER NO. 1

RADIATOR RESERVE RADIATOR HOSE NO. 2
TANK ASSEMBLY
T=7.5{76}
RADIATOR HOSE NO. 1
T=7.5{76}
CHARCOAL CANISTER
ASSEMBLY
T=7.5{76}
RADIATOR CAP EM
RADIATOR SUPPORT UPR
×2
×2
WITH WATER
×2 FAN ASSEMBLY
T=7.5{76}

×4
RADIATOR ASSEMBLY
T=5.0{51}
T=5.0{51}
DRAIN COCK SUB-ASSEMBLY
×2 OIL COOLER
OUTLET HOSE NO. 1
A/T
T=5.0{51}
T=5.0{51}
CONDENSER ASSEMBLY
(WITH RESERVOIR)
SEAL PLATE
OIL COOLER INLET HOSE NO. 1

A136655J01
EM
CRANKSHAFT PULLEY
T=130{1326}
APPLY MP GREASE
A137089J02
EM–205
REMOVAL
(See page RS-164.)
4. REMOVE FOG LIGHT ASSEMBLY LH (See page LI-33)
5. REMOVE FOG LIGHT ASSEMBLY RH
6. REMOVE FRONT BUMPER COVER (See page ET-2)
8. REMOVE SEAL PLATE (See page AC-57) EM

10. DISCONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

11. DISCONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC


22)
15. REMOVE RADIATOR SUPPORT UPPER (See page CO-23)
16. DISCONNECT CONDENSER ASSEMBLY (WITH RECEIVER) (See

page CO-23)
17. REMOVE RADIATOR ASSEMBLY (See page CO-24)

(a) Using the SST, hold the crankshaft pulley and loosen the bolt.
SST 09278-87201
SST
A139349
(b) Using the SST and the crankshaft pulley bolt, remove the crank-
shaft pulley.
SST 09306-87501
NOTICE:
SST

(a) Using a cutter knife, cut off the lip of the oil seal.
A137589
remove the oil seal.
Protective Tape NOTICE:
After removing the oil seal, check there are no scratches or
other damage to the crankshaft part.If there are any
scratches, remove them using sandpaper (No. 400).
INSTALLATION
1. INSTALL TIMING CHAIN (BELT) COVER OIL SEAL
A107954J01
(a) Apply a light coat of MP grease to the lip of a new timing chain
(belt) cover oil seal.
NOTICE:
EM • Keep the lip free of chips, sand and other foreign mat-
ter.
• Wipe off any grease on the crankshaft.
(b) Using the SST, pressure fit a new timing chain (belt) cover oil
seal vertically.
SST 09223-87202
NOTICE:
• Be careful not to tap the timing chain (belt) cover oil
seal at an angle.
SST
• After installing it, check that the timing chain (belt)
cover oil seal has been driven in right to the end face of
the timing gear (chain) case.
A137591 (c) Standard
(1) Press fit margin
• Amount of protrusion from the end face of the timing
chain (belt) cover: less than 0.5 mm
• Press fit depth from the end face of the timing chain
(belt) cover: less than 1 mm
SST 09278-87201
Torque: 130 N*m (1,326 kgf*cm)

SST 5. CHECK FAN AND ALTERNATOR V BELT (See page EM-13)
A139349
6. INSTALL RADIATOR ASSEMBLY (See page CO-24)
7. INSTALL CONDENSER ASSEMBLY (WITH RECEIVER) (See page

CO-25)
8. INSTALL RADIATOR SUPPORT UPPER (See page CO-25)

25)
12. CONNECT OIL COOLER OUTLET HOSE NO. 1 (AUTOMATIC

TRANSMISSION)(See page CO-25)
EM–207
13. CONNECT OIL COOLER INLET HOSE NO. 1 (AUTOMATIC

15. INSTALL SEAL PLATE (See page CO-26)
18. INSTALL FRONT BUMPER COVER (See page ET-5)
19. INSTALL FOG LIGHT ASSEMBLY LH (See page LI-34)
20. INSTALL FOG LIGHT ASSEMBLY RH
21. CONNECT NEGATIVE BATTERY TERMINAL (See page EM-103)

EM

EM–208 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
ENGINE REAR OIL SEAL (3SZ-VE)

ENGINE MECHANICAL
COMPONENTS
REAR END PLATE ENGINE REAR OIL SEAL
T=7.5{76}
EM
×7
T=10{102}
ENGINE REAR OIL SEAL RETAINER
T=68{693}
×4
T=8.5{86}
×10
FRONT SUSPENSION
T=8.5{86} ×4 CROSS MEMBER LWR
OIL PAN
M/T CLUTCH DISC ASSEMBLY

T=19.1{195}
A/T ×6
T=27.5{280} T=78{800}
×6
×6
T=78{800}
×6
FLYWHEEL RING GEAR FLYWHEEL CLUTCH COVER ASSEMBLY
APPLY MP GREASE
TIGHTENING TORQUE NON-REUSEABLE PART
A139030J01
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
EM–209
REMOVAL
1. REMOVE TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-
SION)
HINT:
See IP-8 for the procedure leading up to the removal of the transmis-
sion assembly.
2. REMOVE FLYWHEEL RING GEAR (AUTOMATIC TRANSMIS-

SION) (See page EM-49)
3. REMOVE TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
HINT:
sion assembly.
EM
4. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-
SION) (See page CL-20)
5. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

49)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for

4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.
9. SEPARATE FRONT SHOCK ABSORBER WITH COIL SPRING

(See page EM-47)
10. REMOVE REAR END PLATE (See page EM-50)
11. REMOVE OIL PAN

(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
• Be careful not to damage the oil pan and the cylinder
block.
• When removing, take care not to deform the oil pan
flange.
A139023
EM–210 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
12. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts and then the engine rear oil seal retainer.
A139034
13. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver, pry out the engine rear oil seal.
EM
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
A139035
(b) Using the SST, drive in a new engine rear oil seal to the position
shown in the illustration.
NOTICE:
• Be careful not to tap the engine rear oil seal at an angle.
• After installing it, check that the engine rear oil seal has
been driven in right to the end face.
SST -0.5-1 mm
Wooden Block A139032
2. INSTALL ENGINE REAR OIL SEAL RETAINER

(a) Apply Three Bond TB1207B to the engine rear oil seal retainer
3-4 mm
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
A139033
3. INSTALL OIL PAN

Liquid Gasket Thickness 3.0-4.0 mm
18 mm (a) Apply Three Bond TB1207B to the locations shown in the illus-
tration (3 to 4 mm diameter).
NOTICE:
• Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
• Tighten the oil pan to the specified torque within 15
17 mm Liquid Gasket Thickness 1.3-1.5 mm minutes of applying Three Bond TB1207B.
:Apply Liquid Gasket A139022 • Do not start the engine within 2 hours of installation.
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3SZ-VE)
EM–211
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-59)
5. INSTALL FRONT SUSPENSION CROSS MEMBER LWR (See page

PR-4)
6. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the installation of the front
differential carrier assembly.
7. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
drive shaft assembly.
EM
8. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-
59)
9. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-21)
10. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-

11. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
HINT:
See IP-8 for the procedure leading up to the installation of the trans-
mission assembly.
12. INSTALL FLYWHEEL RING GEAR (AUTOMATIC TRANSMISSION)

(See page EM-61)
13. INSTALL TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-

SION)
HINT:
mission assembly.
EM–212 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
ENGINE REAR OIL SEAL (K3-VE)

ENGINE MECHANICAL
COMPONENTS
REAR END PLATE ENGINE REAR OIL SEAL
T=7.5{76}
EM
×7
T=10{102}
ENGINE REAR OIL SEAL RETAINER
T=68{693}
×4
T=8.5{86}
×10
FRONT SUSPENSION
T=8.5{86} ×4 CROSS MEMBER LWR
OIL PAN
M/T CLUTCH DISC ASSEMBLY

T=19.1{195}
A/T ×6
T=27.5{280} T=78{800}
×6
×6
T=78{800}
×6
FLYWHEEL RING GEAR FLYWHEEL CLUTCH COVER ASSEMBLY
APPLY MP GREASE
TIGHTENING TORQUE NON-REUSEABLE PART
A139030J01
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
EM–213
REMOVAL
1. REMOVE TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-
SION)
HINT:
sion assembly.
2. REMOVE FLYWHEEL RING GEAR (AUTOMATIC TRANSMIS-

SION) (See page EM-84)
3. REMOVE TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
HINT:
sion assembly.
EM
4. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-
5. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)

(See page CL-20)
6. REMOVE FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

85)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
See IP-8 for the procedure leading up to the removal of the front drive
shaft assembly.
8. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for

4WD)
HINT:
See IP-8 for the procedure leading up to the removal of the front dif-
ferential carrier assembly.
9. REMOVE REAR END PLATE (See page EM-85)
10. REMOVE OIL PAN

(b) Using an oil pan seal cutter, remove the oil pan from the cylin-
der block.
NOTICE:
• Be careful not to damage the oil pan and the cylinder
block.
• When removing, take care not to deform the oil pan
flange.
A139023
EM–214 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
11. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 7 bolts and then the engine rear oil seal retainer.
A139034
12. REMOVE ENGINE REAR OIL SEAL

(a) Using a screwdriver, pry out the engine rear oil seal.
EM
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply a light coat of MP grease to the lip of a new engine rear
oil seal.
NOTICE:
Keep the lip free of chips, sand and other foreign matter.
A139035
(b) Using the SST, drive in a new engine rear oil seal to the position
shown in the illustration.
NOTICE:
• Be careful not to tap the engine rear oil seal at an angle.
• After installing it, check that the engine rear oil seal has
been driven in right to the end face.
SST -0.5-1 mm
Wooden Block A139032
2. INSTALL ENGINE REAR OIL SEAL RETAINER

3-4 mm (a) Apply Three Bond TB1207B to the engine rear oil seal retainer
as shown in the illustration (3 to 4 mm diameter).
(b) Install the engine rear oil seal retainer with the 7 bolts.
A139033
3. INSTALL OIL PAN

Liquid Gasket Thickness 3.0-4.0 mm
18 mm (a) Apply Three Bond TB1207B to the locations shown in the illus-
tration (3 to 4 mm diameter).
NOTICE:
• Install the oil pan within 3 minutes of applying Three
Bond TB1207B.
• Tighten the oil pan to the specified torque within 15
17 mm Liquid Gasket Thickness 1.3-1.5 mm minutes of applying Three Bond TB1207B.
:Apply Liquid Gasket A139022 • Do not start the engine within 2 hours of installation.
ENGINE MECHANICAL - ENGINE REAR OIL SEAL (K3-VE)
EM–215
(b) Install the oil pan with the 10 bolts and 4 nuts.
4. INSTALL REAR END PLATE (See page EM-94)
5. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

HINT:
differential carrier assembly.
6. INSTALL FRONT DRIVE SHAFT ASSEMBLY (for 4WD)

HINT:
drive shaft assembly.
7. INSTALL FLYWHEEL (MANUAL TRANSMISSION) (See page EM-

94)
EM
8. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
(See page CL-21)
9. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMIS-

10. INSTALL TRANSMISSION ASSEMBLY (MANUAL TRANSMIS-

SION)
HINT:
mission assembly.
11. INSTALL FLYWHEEL RING GEAR (AUTOMATIC TRANSMISSION)

(See page EM-96)
12. INSTALL TRANSMISSION ASSEMBLY (AUTOMATIC TRANSMIS-

SION)
HINT:
mission assembly.
TO INDEX TO NEXT SECTION

Daihatsu Terios II J200, J210, J211 2006-2014 Engine Mechanical Part 2

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Daihatsu Terios II J200, J210, J211 2006-2014 Engine Mechanical Part 2

Uploaded by

Copyright:

Available Formats

ENGINE MECHANICAL - CHAIN (3SZ-VE)

AIR CLEANER ASSEMBLY

AIR CLEANER HOSE NO. 1 ACCELERATOR CONTROL CABLE ASSEMBLY

RADIATOR HOSE NO. 1

FAN AND ALTERNATOR V BELT

ENGINE UNDER COVER

..... TIGHTENING TORQUE [N*m{kgf*cm}]

VENTILATION HOSE IGNITION COIL ASSEMBLY

EM VENTILATION HOSE NO. 2 SPARK PLUG

CAMSHAFT TIMING OIL T=7.5{76}

IDLER PULLEY NO. 1

CRANKSHAFT PULLEY VANE PUMP ASSEMBLY

CRANKSHAFT POSITION SENSOR

..... TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART

OIL FILLER CAP

CHAIN TENSIONER PLUNGER

CRANKSHAFT ANGLE SENSOR PLATE NO. 1

2. REMOVE BATTERY CARRIER (See page EM-146)

3. REMOVE ENGINE UNDER COVER

4. DRAIN ENGINE OIL

5. DRAIN ENGINE COOLANT (See page CO-15)

6. REMOVE AIR CLEANER ASSEMBLY (See page EM-146)

7. REMOVE RADIATOR HOSE NO. 1 (See page CO-15)

EM 8. REMOVE ACCELERATOR CONTROL CABLE ASSEMBLY (See

9. REMOVE FAN AND ALTERNATOR BELT (See page EM-8)

10. REMOVE FAN PULLEY (See page CO-29)

11. REMOVE VANE PUMP ASSEMBLY (See page EM-44)

12. REMOVE IDLER PULLEY NO. 1 (See page EM-150)

13. DISCONNECT VENTILATION HOSE (See page EM-147)

14. DISCONNECT VENTILATION HOSE NO. 2 (See page EM-147)

15. REMOVE ENGINE ROOM MAIN WIRE (See page EM-147)

16. REMOVE RADIATOR PIPE (See page EM-147)

17. REMOVE IGNITION COIL ASSEMBLY (See page EM-150)

18. REMOVE CYLINDER HEAD COVER (See page EM-151)

19. REMOVE CRANKSHAFT PULLEY (See page EM-151)

20. REMOVE CAM POSITION SENSOR (See page EM-152)

21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

22. REMOVE TIMING CHAIN (BELT) COVER (See page EM-152)

Stopper Plate Plunger

(d) Under the conditions noted at [*3], insert a bar of 3 mm in diam-

26. REMOVE TIMING CHAIN TENSION ARM

27. REMOVE TIMING CHAIN GUIDE

28. REMOVE TIMING CHAIN GUIDE NO. 2

29. REMOVE CHAIN

Timing Mark Timing Mark

2. INSTALL TIMING CHAIN GUIDE NO. 2

3. INSTALL TIMING CHAIN GUIDE

4. INSTALL TIMING CHAIN TENSION ARM

5. INSTALL CHAIN TENSIONER PLUNGER

6. INSTALL CRANK ANGLE SENSOR PLATE NO. 1

7. INSTALL TIMING CHAIN (BELT) COVER (See page EM-160)

9. INSTALL CRANK POSITION SENSOR (See page EM-57)

11. INSTALL CRANKSHAFT PULLEY (See page EM-161)

12. INSTALL CYLINDER HEAD COVER (See page EM-162)

13. INSTALL SPARK PLUG (See page EM-162)

14. INSTALL IGNITION COIL ASSEMBLY (See page EM-162)

15. INSTALL RADIATOR PIPE (See page EM-166)

16. INSTALL ENGINE ROOM MAIN WIRE (See page EM-165)

17. INSTALL VENTILATION HOSE (See page EM-166)

18. INSTALL VENTILATION HOSE NO. 2 (See page EM-166)

19. INSTALL IDLER PULLEY NO. 1 (See page EM-163)

20. INSTALL VANE PUMP ASSEMBLY (See page EM-68)

21. INSTALL FAN PULLEY (See page CO-29)

22. INSTALL FAN AND ALTERNATOR V BELT (See page EM-8)

..... TIGHTENING TORQUE [Nm{kgfcm}]

..... TIGHTENING TORQUE [Nm{kgfcm}] NON-REUSEABLE PART

..... TIGHTENING TORQUE [Nm{kgfcm}]

..... TIGHTENING TORQUE [Nm{kgfcm}] NON-REUSEABLE PART