SERVICE MANUAL

PERODUA

D18D(D29G)
FOREWORD

This service manual has been prepared to provide information covering general service repairs for the
model D18D(D29G) series manufactured in May, 2007 afterward.
All information used in this service manual was in effect at time when the manual was printed. However,
the specifications and procedures may be revised owing to continuing improvements in design without
advance notice and without incurring any obligation to us.

Published in May, 2007

PERODUA SALES SDN. BHD.

© 2007 PERODUA SALES SDN. BHD. SM-D18D-0507

All rights reserved. This material may not be reproduced or copied, in whole or in part, without the
written permission of PERODUA SALES SDN. BHD.
 SECTION INDEX
SECTION NAME INDEX
PERODUA GENERAL INFORMATION A1
ENGINE B1
ENGINE MECHANICAL B2
INTAKE SYSTEM B3
EXHAUST SYSTEM B4
LUBRICATION SYSTEM B5
COOLING SYSTEM B6
FUEL SYSTEM B7
B8

Service
ENGINE CONTROL COMPUTER
EMISSION CONTROL SYSTEM B9
IGNITION SYSTEM B10

manual STARTING SYSTEM/CHARGING SYSTEM

ENGINE MOUNTING
B11
B12
C1
FRONT SUSPENSION
REAR SUSPENSION C2
WHEEL & TYRE C3
DRIVE SHAFT D1
BRAKE E1
PARKING BRAKE E2
BRAKE CONTROL (ABS) E3
CLUCTH F1
MANUAL TRANSMISSION F2
AUTOMATIC TRANSMISSION F3
STEERING G1
POWER STEERING G2
SRS AIRBAG SYSTEM H1
BODY I1
EXTERIOR/INTERIOR I2
WINDSHIELD WINDOW GLASS/MIRROR I3
DOOR LOCK & THEFT DETERRENT I4
LIGHTING J1
WIPER & WASHER J2
METER J3
AUDIO & VISUAL SYSTEM J4
FUSIBLE LINK J5
AIR CONDITIONER J6
WIRING DIAGRAM K1
A1 E3 A1 F3 A1 E3 A1 E3
B1 F1 B1 G1 B1 F1 B1 F1
B2 F2 B2 G2
B3 H1
B2 F2 B2 F2
B3 F3 B3 F3 B3 F3
B4 I1
B4 G1 B5 I2 B4 G1 B4 G1
B5 G2 B6 I3 B5 G2 B5 G2
B6 H1 B7 I4
B8 J1
B6 H1 B6 H1
B7 I1
B9 J2 B7 I1 B7 I1
B8 I2
B10 J3 B8 I2 B8 I2
B9 I3
B11 J4 B9 I3 B9 I3
B10 I4 B12 J5
B11 J1 C1 J6
B10 I4 B10 I4
B12 J2 C2 K1 B11 J1 B11 J1
C1 J3 C3 B12 J2 B12 J2
C2 J4 D1 C1 J3 C1 J3
E1
C3 J5 C2 J4 C2 J4
E2
D1 J6 E3 C3 J5 C3 J5
E1 K1 F1 D1 J6 D1 J6
E2 F2 E1 K1 E1 K1
E2 E2
Helvetica 20 pt Helvetica 20 pt 90% Helvetica 22 pt 90% Helvetica 22 pt
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
GENERAL INFORMATION B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
IMPORTANT SAFETY NOTICE ....................................A1–1 INSTRUCTIONS FOR SYSTEM C3
GENERAL DESCRIPTION ....................................A1–1 INSPECTION ..............................................................A1–17
WARNINGS, CAUTIONS AND NOTES .................A1–1 HANDLING INSTRUCTION OF D1
GENERAL WARNINGS .........................................A1–2 CONNECTOR.....................................................A1–17
HOW TO USE THIS MANUAL .......................................A1–3 CHECK PROCEDURE OF WIRE
E1
ARTICLE TO BE PREPARED ................................A1–3 HARNESS AND CONNECTOR ..........................A1–18 E2
REMOVAL AND INSTALLATION CIRCUIT INSPECTION OF
PROCEDURES ...................................................A1–3 COMPUTER UNIT ..............................................A1–19 E3
DESCRIPTION OF SERVICE HANDLING INSTRUCTION OF
STANDARD VALUE ............................................A1–4 F1
SYSTEM .............................................................A1–19
CONTENTS NOT DESCRIBED IN INSTRUCTIONS FOR RADIO
THIS MANUAL ...................................................A1–5 F2
INSTALLATION...........................................................A1–20
DEFINITIONS OF TERMS .....................................A1–5 HANDLING INSTRUCTIONS ON
ABBREVIATION CODES ..............................................A1–6 CATALYTIC CONVERTER-EQUIPPED
F3
UNIT ..............................................................................A1–7 G1
VEHICLES ................................................................A1–21
NEW UNIT BECAUSE OF THE PRECAUTION FOR VEHICLES
INTRODUCTION OF THE SI UNIT .....................A1–7 EQUIPPED WITH SRS AIRBAG.................................A1–22 G2
GENERAL SERVICE INSTRUCTION ...........................A1–8 INSTRUCTIONS FOR SERVICE
SUPPORTING POINTS FOR JACKS AND OPERATION .......................................................A1–22H1
SAFETY STANDS ....................................................A1–10 VEHICLE IDENTIFICATION .........................................A1–24
JACKING POINTS ................................................A1–10 BODY COLOR CODE ...........................................A1–24 I1
SUPPORTING POINTS OF SAFETY CHASSIS SERIAL NUMBER .................................A1–24
STANDS..............................................................A1–10 ENGINE TYPE AND ENGINE
I2
SUPPORTING POINTS OF LIFTS ...............................A1–11 I3
NUMBER ............................................................A1–24
TOWING INSTRUCTIONS ............................................A1–13 MANUFACTURER’S PLATE
TOWING WITH ROPE (ONLY FOR I4
POSITION...........................................................A1–24
EMERGENCY) ....................................................A1–13
USING FLAT BED TRUCK ....................................A1–13 J1
DIAGNOSTICS INSTRUCTIONS ..................................A1–14
DIAGNOSIS ..........................................................A1–14 J2
DATA LINK CONNECTOR ............................................A1–16
DATA LINK CONNECTOR
J3
TERMINAL ARRANGEMENT..............................A1–16 J4
CONNECTION METHOD OF DATA
LINK CONNECTOR............................................A1–16 J5
CONNECTION METHOD OF EACH
SYSTEM .............................................................A1–16 J6
K1
 A1–1
1 IMPORTANT SAFETY
1-1 GENERAL DESCRIPTION
1. The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially
hazard. However, one can handle it safely if he has the required knowledge.
2. Correct service methods and repair procedures are very vital for assuring not only the safety and reliability
of a vehicle, but also the safety of service personnel concerned.
3. The methods and procedures contained in this manual describe in a general way the techniques which the
manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the products.
The contents of the servicing operations come in a wide variety of ways. Moreover, techniques, tools and
parts necessary for each operation are different widely from each other.
4. This manual does not cover all details of techniques, procedures, parts, tools and handling instructions
which are necessary for these operations, for such coverage is impossible. Hence, any one who obtains
this manual is expected first to make his responsible selection as to techniques, tools and parts which are
necessary for servicing the vehicle concerned properly. Furthermore, he must assume responsibility for his
actions in connection with his own safety.
5. Therefore, one should not perform any service if he is not capable of making responsible selection and/or if
he can not understand the contents herein described, for this manual has been prepared for experienced
service personnel.
1-2 WARNINGS, CAUTIONS AND NOTES
1. All these symbols have their specific purposes, respectively.
WARNING
• This symbol means that there is the possibility of personal injury of the operator himself or the nearby workers
if the operator fails to follow the operating procedure prescribed in this manual.

CAUTION
• This symbol means that there is the possibility of damage to the component being repaired if the operator fails
to follow the operating procedure prescribed in this manual.

NOTE
• To accomplish the operation in an efficient manner, additional instructions concerning the operation are given
in this section.
A1–2
1-3 GENERAL WARNINGS
1-3-1 WARNING OVER THE WHOLE SERVICE OPERATIONS
1. Always wear safety glasses for eye protection.
2. Use safety stands whenever a procedure requires you to be under the vehicle.
3. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
4. Set the parking brake when working on the vehicle.
5. Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide.
6. Keep yourself and your clothing away from moving parts, when the engine is running, especially from the fan
and belts.
7. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe,
catalytic converter and muffler.
8. Do not smoke while working on a vehicle.
9. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to
work on a vehicle.
10. Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted on the
radiator and can start to operate anytime by a rise in coolant temperature or turning ON of the air conditioner
switch in the case of vehicles equipped with an air conditioner. The electric cooling fan is also mounted on
the condenser for air conditioner and starts to operate anytime when the air conditioner switch is turned ON.
For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected
when working under the hood.
 A1–3
2 HOW TO USE THIS MANUAL
2-1 ITEMS TO BE PREPARED
When SST, tool, measuring instrument, lubricant and oil to be prepared before operation are necessary, those are
described by compiling in the table as preparation tools at the beginning of each item.
However, the general tools, jacks, fixtures as considered being equipped always at the service shop are usually
omitted.
2-2 REMOVAL AND INSTALLATION PROCEDURES
1. Block diagrams are posted so as to show the installed state of each part.
2. The application of a sort of fat and oil and sealer are instructed in the figure with arrow. And the indication
of a tightening torque and non–reusable parts are also described. The explanation of each code is posted
below the block diagram concerned.
3. The removal and installation( disassembling and assembling ) procedure list is shown just beneath of
components figure.
The removal (disassembling) procedure, the installation (assembling) procedure and parts name are
described in the sequence from left side of list. And the alphabet written before a part name links with
alphabet in the figure.
4. In principle, the reverse of the removal (or disassembly) procedure is the installation (or assemble) procedure
of the parts.
NOTE
• Only in cases where the installation (or assembly) can not be carried out by reversing the removal (or
disassembly) procedure, the installation (or assembly) procedure is provided.
5. In cases where a special procedure is required for the operation, a marking 8j/8 is provided in front of
the removal (or disassembly) procedure. Furthermore, explanation is given in the 8Main points of Removal
(Disassembly)8 or the 8Main points of Installation (Assembly).8 The marking 8j8 shows that there are the
8Main points of Removal (Disassembly),8 whereas 8/8 shows that there are the 8Main points of Installation
(Assembly).8
A1–4
2-2-1 ENTRY EXAMPLE
(1) COMPONENTS

W13C5006S24

k : Rubber grease
~: Non(reusable part
Unit:N;m{kgf;cm}
(2) DISASSEMBLY AND ASSEMBLY PROCEDURES

2-3 DESCRIPTION OF SERVICE STANDARD VALUE

The necessary service standard value for inspection and service operation are described with bold letter in the text
as standard and allowable limit. The details of terms are described in the section for definition of terms.
2-4 CONTENTS NOT DESCRIBED IN THIS MANUAL
The description of the next elemental operation may be omitted in this service manual, but please perform them in
an actual operation.
1. Jacking operation and lifting operation
2. Cleaning and cleansing of removed parts to be performed when needed.
(Not sure if this is the right sentence)
3. Visual inspection
 A1–5
2-5 DEFINITIONS OF TERMS
A1–6
3 ABBREVIATION CODES
The abbreviation codes that appear in this manual stand for the following, respectively.

ABBREVIATION CODE ORIGINAL WORD ABBREVIATION CODE ORIGINAL WORD

2WD Two Wheel Drive LSPV Load Sensing Proportioning Valve
ABS Anti-lock Brake System MP Multipurpose
A/C Air Conditioner MT Manual Transmission
API American Petroleum Institute N/A Natural Aspiration
A/T Automatic Transmission NOx Nitrogen Oxides
ATDC After Top Dead Center OPT Option
ATF Automatic Transmission Fluid O/S Over Size
Ay Assembly PCV Positive Crankcase Ventilation
BTDC Before Top Dead Center PR Ply Rating
DLC Data Link Connector PTO Power Take Off
DLI Distributor Less Ignition RH Right Hand
DVVT Dynamic Variable Valve Timing RHD Right Hand Drive
ECU Electronic Control Unit RR Rear
EFI Electronic Fuel Injection S/A Sub-Assembly
EGR Exhaust Gas Recirculation System SST Special Service Tools
ESA Electronic Spark Advance STD Standard
EX Exhaust SW Switch
F/L Fusible Link TDC Top Dead Center
FR Front U/S Under Size
GND Ground VSV Vacuum Switching Valve
HC Hydrocarbon VTV Vacuum Transmitting Valve
IG Ignition W/ With
IN Intake B Bolt
ISC Idle Speed Control S Screw
LED Light Emitting Diode N Washer
LH Left Hand C Clip
 A1–7
4 UNIT
As for the units, the SI units (international unit system) have been posted. (The hitherto – employed units, too, are
posted.)
Example: 33.25&13.25N;m{340&135kgf;cm}
4-1 NEW UNIT BECAUSE OF THE INTRODUCTION OF THE SI UNIT
1. SI unit is the international unit system established by aiming to proceed the communication in technology
smoothly by unifying the former unit system which were different internationally each other into one value by
one unit. The specification value is described in accordance with SI unit system in this service manual.
A1–8
5 GENERAL SERVICE INSTRUCTION
1. Use fender covers, seat covers, and floor sheets so that the vehicle may not get dirty or be scratched.
2. Jacking up
(1) When only front section or rear section of a vehicle is jacked up, be sure to place chocks at the wheels
so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using the
safety stands.
(3) When the vehicle has been lifted up, be sure to set the cradle of the lift at the specified location, and lift
it up. And after the jacking up, ensure to apply the protective safety device.
3. Installation and removal of battery terminal
(1) Before you start performing the electrical works, make certain to disconnect the battery ground cable
terminal from the negative terminal of the battery.
(2) Before disconnecting the battery ground cable terminal from the negative terminal of the battery, be sure
to read out the diagnosis code of the EFI systems if it is equipped.
(3) After reconnecting the battery ground cable terminal to the negative terminal of the battery, be sure to
reset the watch or radio, if the vehicle is equipped with such equipment.
(4) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out
checks or repairs, always disconnect the negative terminal of the battery ground cable from the negative
terminal of the battery first.
(5) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery ground
cable terminal straight upward, rather than turning or prying the terminal.
(6) Be sure to employ a battery terminal puller (commercially available) to remove battery ground cable
terminal from the negative terminal of the battery, if any difficulty is encountered.
(7) Clean the battery terminal posts or battery ground cable terminals, using a cloth. Never use a file or other
abrasive agents.
(8) Install the battery cable terminals to the battery posts after loosing the nuts, and tighten the nuts after
installation. Never tap the terminals on the battery posts using a hammer or the like.
(9) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.
4. Repairing of fuel system
(1) Do not work near open flames.
(2) Be certain to place a suitable container, a cloth, etc. under the connected section of the fuel line before
disconnecting the fuel line.
(3) Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by detaching
the fuel filler cap.
(4) Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other connected
section of the fuel line is loosened or slackened.
(5) Tighten each connecting section to the specified torque.
(6) Attach the specified clips to each connecting section.
5. For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special Service Tools)
effectively.
 A1–9
6. Removal, Disassembly
(1) In case for the operation at the complicate place, the stamping and mating mark shall be put at the place
where there is no influence to the function, so that the assembling operation becomes easy.
(2) At every time when each parts are removed, check the condition when it was assembled , deformation,
breakage, roughness and existence of scratch .
(3) Arrange the removed parts in order, and divide them to the parts to replace and parts to reuse .
(4) Proper cleaning and cleansing operation should be performed for parts to be used again.
7. Check and measurement of parts
(1) Perform thorough checks and measurements as required for parts according to the correct procedure
following the specified standard.
8. Installation, Assembling
(1) Assemble the good parts according to the correct procedure following the specified standard.
(2) When replacing parts use genuine parts only.
(3) Ensure that seal packing and grease are applied at the appropriate place.
(4) Ensure to use new packing, gasket or the like, cotter pin etc.
(5) When using a seal bolt, apply the specified liquid gasket and seal lock agent on the bolt.
(6) Use specified bolts and nuts only.
9. Adjustment should be carried out to the specified service standard value by using gauge and tester.
(1) Adjust with the specified service standard value by using the gauge and the tester.
10. Handling of hose or the like
(1) Ensure to insert fuel hose, water hose or the like properly to present them from coming out or leaking.
(2) Be careful fuel does not splash on the parts near by removing the fuel hose. (Deep care should be paid to
engine mounting rubber or the like, as there may be a possibility of material deterioration from the liquid
gasoline.
11. Touch up
(1) When removing a bolt or the like during body fitting operations and others, the scratch of the paint finish
surface on the body or bolt shall be repaired according to the same body color.
A1–10
6 SUPPORTING POINTS FOR JACKS AND SAFETY STANDS
6-1 JACKING POINTS
CAUTION
• The jack–up operation must be carried out only on a level, flat place.
• Never jack up the vehicle at the front and rear sides at the same time.
• Be sure to set the jack in such a way that jack may not interfere with the bumper.

L21S5101ES33
 A1–11
6-2 SUPPORTING POINTS OF SAFETY STANDS
CAUTION
• Never support the vehicle at points other than the specified points.

Safety stand support

L21S5102ES33
A1–12
7 SUPPORTING POINTS OF LIFTS
CAUTION
• Front side: Align the supporting pad of a two-post lift with the supporting points of safety stands, as indicated
in the figure of previous page.
Rear side: Align the supporting pad of a two-post lift with the rear spring as indicated in the figure below.

L21S5103ES33
 A1–13
8 TOWING INSTRUCTIONS
8-1 TOWING WITH ROPE (ONLY FOR EMERGENCY)
Release parking brake, and turn IG switch to ACC position,
and then put the shift lever into neutral range.
CAUTION
• Never tow with the rope when the running system and/or
driving system seems to be abnormal.
• When driving with the engine stopped, brake efficiency
become less due to no function of the brake servo system.
Depress the brake pedal more powerfully than the usual. L21S5016ET10
• For automatic transmission vehicle, be sure to always use a
flat bed truck.
8-2 USING FLAT BED TRUCK
Transfer the vehicle with applying parking brake and fixing
the vehicle firmly.
CAUTION
• Be certain to transfer the vehicle by using the flat deck truck
when the running system and/or driving system seems to
be abnormal.

L21S5017ET10
A1–14
9 DIAGNOSTICS INSTRUCTIONS
9-1 DIAGNOSIS
9-1-1 HOW TO PROCEED DIAGNOSIS
1. Each electronic control system equipped on the vehicle is an important clue at performing trouble shooting.
Also this system has self(diagnosis function to inspect the malfunction portion which occurred in
corresponding system, and battery back up (the function that power source for diagnosis code memory is
supplied even if IG switch is OFF) is equipped for self(diagnosis function of electronic control system with,
and is designed so that diagnosis code is memorized to each system. As the function of diagnosis code
memory is different by each system, perform the confirmation / elimination of code memory according to the
right operation procedure after confirming equipped diagnosis code memory function.

L11E7008ES35
 A1–15
9-1-2 SYMPTOM CONFIRMATION
1. When conducting a trouble shooting, the operator cannot pinpoint the cause for the malfunction, unless he
actually confirms the phenomenon. For this purpose, it is indispensable to reproduce the malfunctioning
phenomenon by creating conditions and environments that are similar to those where the malfunction actually
took place, based on the information obtained through the inquiry with the customer. As for phenomena
which cannot be reproduced easily, it is necessary to produce running conditions that are close to those
when the malfunction took place (road surface condition, weather condition, and driving condition), based
on the information obtained through the inquiry with the customer. To this end, it is of great importance to
try to reproduce the malfunction persistently by applying external factors, such as vibration (moving wire
harnesses and relays by hand), heat (applying hot air), and water (applying moisture). Furthermore, while the
malfunction phenomenon is being reproduced, it is essential to check diagnosis codes indicated before and
after the confirmation of the malfunction phenomenon. Checking whether the code that was indicated before
the confirmation is outputted or not is also an important step for confirming the malfunction phenomenon.
9-1-3 CUSTOMER PROBLEM ANALYSIS
1. For the vehicle which malfunctions occurred, confirm first the malfunction phenomenon, and study the cause
and then eliminate the cause. There is possibility that the vehicle does not return to normal condition even if
perform many operation without study of cause. An asking about problems is to gather the information from
the customer before confirming the malfunction phenomenon, and become an important clue when attempt
to reproduce the malfunction. When perform the asking about problem, it is necessary to focus to the items
relating to said malfunctions so that information attained with an asking about problems becomes useful
reference of trouble shooting.
A1–16
10 DATA LINK CONNECTOR
10-1DATA LINK CONNECTOR TERMINAL ARRANGEMENT

L21S5020ES16

10-2 CONNECTION METHOD OF DATA LINK CONNECTOR

Perform it by connecting the engine control system inspection wire (SST) with the data link connector.
Perform the system check of each system by using the terminal for short circuit (SST), the terminal for detecting
engine speed and the terminal for VF output monitoring (SST).
10-3 CONNECTION METHOD OF EACH SYSTEM
1. Diagnosis code output of engine control system
: Short circuit between T(EFI) ( E
2. Functioning check of O2 sensor for engine control system
: Measure between VF ( E
3. Engine speed check of engine control system
: Measure between REV ( Body earth
4. Diagnosis code output of ABS system
: Short circuit between T(ECU) ( E
5. Diagnosis code output of airbag system
: Short circuit between T(ECU) ( E
 A1–17
11 INSTRUCTIONS FOR SYSTEM
INSPECTION
11-1 HANDLING INSTRUCTION OF CONNECTOR
1. Connection or disconnection of the connector and each
terminal shall be performed after removing the negative
terminal of the battery.
However, there may be the case where the diagnosis code
is erased when the battery negative terminal is removed
confirm the diagnosis code first before the removing the G07E5017T10
battery negative terminal.
2. When disconnecting connectors, be sure to hold the
connector itself and pulling connectors to unlock them.
Never pull harnesses. When connecting connectors, be
sure to insert the connectors positively, until you hear a
clicking sound and the lock is engaged.
3. When inserting tester probes into a connector, insert them
from the rear side of the connector.

G07E5018ET10

4. For water(proof connectors which cannot be accessed

from behind, take good care not to deform the connector
terminals.
5. Never touch the terminal of connector directly by hand.
6. When a tester probe is applied to a terminal to which
voltage is applied, care must be exercised so that two
tester probes may not come in contact with each other so
that short circuit may not take place.

G07E5024ET10
A1–18
11-2 CHECK PROCEDURE OF WIRE HARNESS AND CONNECTOR
Perform the inspection of the wire harness and connector portion of the respective system inspection according to
the following points.
11-2-1 CONTINUITY INSPECTION
1. Remove the connector of corresponding harness on both
ends.
2. Measure the electrical resistance between corresponding
terminals of connector on both end.
SPECIFIED VALUE: Not more than 1Ω
CAUTION
• Measure the electrical resistance while shaking wire harness
in top and down and right and left lightly.
NOTE
• In case of open circuit, as it is seldom that open circuit G07E5020ET10

happen in central part of wiring harness, and most of part

the open circuit happen are connector area.
Particularly, check the connector of the sensor portion
carefully.
11-2-2 SHORT CIRCUIT INSPECTION
1. Remove the connector of corresponding harness on both
end.
2. Measure the electrical resistance between corresponding
terminal of connector and body earth connecting. In addition
to above, perform the inspection with the connector of each
side.
SPECIFIED VALUE: Not less than 1MΩ
CAUTION
• Measure the electrical resistance while shaking wire harness
in top and down, and right and left lightly. G07E5019ET10

3. Measure electrical resistance between terminals in same

connector with the connector of corresponding terminal
(except between each power supply lines or earth lines).
In addition to above, perform the inspection at the connector
of both sides.
SPECIFIED VALUE: Not less than 1MΩ
CAUTION
• There may be short circuits due to wiring in the vehicle
compartment which is pinched by the body or faulty
clamps.
G07E5021ET10

11-2-3 VISUAL INSPECTION, CONTACT FORCE INSPECTION

1. Remove the connector of corresponding harness on both
end.
2. Check visually the rust generation or mixing of the foreign
material at connector terminal portion.
3. Check whether there are looseness, damage at the staking
portion and check coming out from the coupler by pulling
the wire harness lightly .

G07E5022ET10
 A1–19
4. Prepare the same male terminal as that of the connector
terminal. Insert it into the female terminal and check the
pulling force.
The terminal having a smaller pulling force, compared with
other terminals, may cause poor contact.
CAUTION
• If the terminal section has rust formation, admission of
foreign matters or poor contact pressure between the male
terminal and the female terminal, the contact condition may
change by disconnecting and reconnecting the connector
once, thus resulting in No malfunction. G07E5023ET10

Therefore, if the check of the wire harness and connector

reveals that there is no malfunction, confirm the malfunction
phenomenon. At this time, if no malfunction phenomenon
is reproduced, most likely the poor contact between the
male terminal and the female terminal was causing the
malfunction.
11-3 CIRCUIT INSPECTION OF COMPUTER UNIT
Perform computer unit circuit inspection. If malfunction exists, repair the corresponding connector, circuit,and if
normal, change the computer unit.
1. VISUAL CHECK OF CONNECTOR PORTION, CONTACT FORCE INSPECTION
Check the connector of computer unit according to visual check and the contact force check point described
in previous page.
2. COMPUTER UNIT EARTH CONNECTING INSPECTION
Remove the connector of computer unit, and then measure the applied voltage between each power source
terminal, each earth connector and body earth connecting.
SPECIFIED VALUE: VOLTAGE OF EACH POWER SUPPLY TERMINAL

CAUTION
• When carrying out the computer unit circuit check, there may be cases when the malfunction disappears by
removing and installing the connectors, due to change of contact condition. Accordingly, when the result of
computer unit circuit check is normal, judge that computer unit is malfunctioned after confirming the malfunction
again by connecting the computer unit connector.

11-4 HANDLING INSTRUCTION OF SYSTEM

1. The computer unit, sensors, etc. are precision parts. Be very careful not to apply strong impacts to those
parts during the installation and removal. Never use those parts which impacts have been given (for example,
in case where the parts were dropped on the floor).
2. When the test is carried out on rainy day or the vehicle is washed, care must be exercised so that no water
may be admitted and ensure that the computer unit, connectors, sensors, actuators, etc. do not get wet.
3. In cases where the computer unit was judged to be malfunctioning and the vehicle has been remedied by
replacing it, install the removed computer unit (which has been judged to be malfunctioning) again to confirm
that the original malfunction is reproduced. Then the computer unit can be finally judged to have been
malfunctioning.
A1–20
12 INSTRUCTIONS FOR RADIO INSTALLATION
CAUTION
• For those motor vehicles equipped with a mobile communication system, such as a bidirectional wireless
telephone and cellular phone, be sure to observe the following precautionary measures.

1. Install the antenna as far away as possible from electronic control system.
2. As the electromagnetic wave is radiated from antenna feeder, set the antenna feeder within the distance at
least not less than 300 mm apart from computer unit and ECU harness. Do not arrange both line in parallel
for long distance.
3. Never bind the antenna feeder together with the engine harness with binding tape.
4. Regulate the antenna and the feeder to get rid of radio interference.
5. Never install a strong mobile communication system (exceeding 10 kW).
 A1–21
13 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER EQUIPPED
VEHICLES
WARNING
• When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to occur,
resulting in a fire hazard.
• To avoid such trouble in advance, be certain to observe the following precautions. Also be sure to explain such
precautions to your customers.

1. Use only unleaded gasoline to catalytic converter equipped vehicles.

2. Be sure to observe following points when performing the spark jump test.
(1) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure to
finish the test in the shortest possible time.
(2) Never race the engine during the test.
(3) Be sure to shut off the fuel supply in advance when performing the spark jump test.
3. Do not run the engine when the fuel tank becomes nearly empty.
Failure to observe this caution will cause misfiring. Also it will apply excessive load to the catalytic converter,
even leading to catalyst damage.
4. Do not dispose the waste catalyst along with parts contaminated with gasoline or oil.
A1–22
14 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG

14-1 INSTRUCTIONS FOR SERVICE OPERATION

Be sure to perform the service operation for the vehicle equipped with the airbag according to the correct procedure
and method, otherwise it may result in malfunction and lead to serious accidents during the service operation.Be
sure to perform the service operation according to the correct procedure and method described in this manual.
14-1-1 PRECAUTION PRIOR TO SERVICE OPERATION
1. Before servicing the airbag components device, perform the following procedures.
(1) Check the status of airbag warning lamp.
(2) Read the diagnosis codes and put it on record
(3) Turn OFF the ignition switch and detach the negative terminal of the battery cable.
(4) Then, wait for at least 60 seconds to prevent the airbag from the deployment.
WARNING
• If the operation is carried out within 60 seconds from disconnecting the negative terminal of the battery cable,
the airbag may be deployed.

NOTE
• As the airbag system is provided with a the back up capacitor (for ignition purpose), about 60 seconds is
necessary as discharging time even though the battery negative terminal cable is disconnected. (natural
discharge)

CAUTION
• Be careful that the memory of the computer of other system (such as engine control) may be erased
simultaneously when the battery negative terminal cable is disconnected.

2. Ensure to use the digital circuit tester for the electric inspection of the vehicle equipped with the airbag and
use a circuit tester which satisfies the following standard.
WARNING
• Ensure before satisfies to measure the electric current value of circuit tester to be used for an operation, and
confirm if it satisfy the following specified value. When the circuit tester exceeding specified value is used,
there may be possibility that malfunction or deterioration of airbag occur. In addition to the above, measure the
electric current of the circuit tester with minimal resistance (Ω) range.

SPECIFIED VALUE: Not more than 50 mA (0.05A)

14-1-2 PRECAUTION TO PREVENT MISS OPERATION

1. Be sure not to drop the airbag system component parts during removal and installation.
2. Be sure not to apply impact or cause damage when removing the airbag system component parts.
3. Be sure to put the pad Ay and assistant driver seat airbag unit with deployment surface upward during the
operation though it is temporary operations. And never stack the pad Ay. (It may lead to serious accidents if
metal surface is facing upward at an emergency)
4. Keep the airbag system component parts in the place where the effect of electricity noise, the high(temperature
(not less than atmosphere temperature 85°C), and high humidity can be avoided.
5. Do not expose the airbag system component parts directly to high(temperature or flames.
6. Considering the case an airbag is actuated at an emergency, perform the service operation with posture as
not to get your body close to deploying portion as much as possible.
In view that an airbag is actuated during an emergancy, perform the service operation. So as not to get your body
close to the deploying portion as much as possible.
 A1–23
14-1-3 GENERAL SERVICE INSTRUCTION
1. Follow the indication of the caution plate affixed on the airbag system related parts.
2. Be sure to mate the center when the steering roll connector is installed.
3. Be sure to perform the mating of the center for steering roll connector and marking to the separating portion
when repair the related parts described below.If the relation of mutual position of parts are changed, the
harness of roll connector may be snapped when the steering wheel is operated.
(1) STEERING CONCERNED
1. Steering wheel, steering column, steering gear or the like
(2) VEHICLE BODY CONCERNED
1. Instrument panel or the like
2. Body electrical malfunctioned
3. Multi–use lever switch or the like
(3) POWER TRAIN CONCERNED
1. The case when separate the connection of steering gear at the removal and installation of the engine and
transmission and so on.
14-1-4 PRECAUTION PRIOR TO BODY AND PAINT OPERATION
1. As an inflator or the like are installed in the steering wheel central part, the upper part of instrument panel,
the root of A pillar, the root of B pillar, the front seat back. Be sure not to give strong impact with hammer or
the like, and high temperature during repairing.
2. Perform the operation after removing airbag system component parts when use of electric welding machine
is needed.
3. Perform the operation after removing the airbag system component parts when use of impact and the high
temperature is needed.
4. Do not expose the painting surface near the airbag related parts to high temperature ( 85$C or more) during
drying it.
5. Be sure to change with new parts when an airbag related parts have the external scratch, deformation.
A1–24
15 VEHICLE IDENTIFICATION
15-1 BODY COLOUR CODE
Body colour name Color code
Ivory White W09
Ebony Black 209
Passion Red R57
Saphire Blue B66
Glittering Silver S28
Pearl Jade G47
Tropical Green G45

15-2 CHASSIS SERIAL NUMBER Chassis serial number

1. The chassis serial number is stamped on the position as
shown in the illustration.

15-3 ENGINE TYPE AND ENGINE NUMBER EJ-VE engine

1. The engine type and engine number are given on the
places as shown in the illustration.

Engine type Engine number

L21S1104ET10

ED-VE engine

Engine type Engine number

L21S1105ET10

EF-VE engine

Engine type Engine number

L21S1105bET10
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
ENGINE B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
C3
ENGINE ................................................................B1– 1
ITEMS TO BE PREPARED ....................................B1– 1 D1
BASIC CHECK AND ADJUSTMENT.....................B1– 2
E1
E2
E3
F1
F2
F3
G1
G2
H1
I1
I2
I3
I4
J1
J2
J3
J4
J5
J6
K1
 B1–1
1 ENGINE
1-1-1 ITEMS TO BE PREPARED
SST

Instrument
B1–2
1-2 BASIC CHECK AND ADJUSTMENT
1-2-1 CHECK OF COOLING WATER LEVEL AND WATER LEAKAGE
(1) Water level
Check that the cooling water level is between the upper limit (FULL) and the lower limit (LOW) of the
reservoir tank.
(2) WATER LEAKAGE
With the engine idling, visually check that there is no water leakage
from the radiator, radiator hose, heater hose, water pump, heater
hose, etc.
Moreover, apply pressure, using a radiator cap tester. Under this
condition, check that no water leakage is present.
SPECIFIED VALUE: Specified value for check
122.7kPa {1.25kgf/cm2}

M21E5001ET10

(3) FUNCTION CHECK OF RADIATOR CAP

1. Remove the radiator cap. Then, visually check the valve seat
Seal surface
surface for smear and damage. Also, move the negative
pressure valve by your hand and check that it opens and
closes.

L11E5002ET10

2. Check the valve opening pressure of the cap, using a

radiator cap tester.
SPECIFIED VALUE: Specified value for check
108.0&14.7kPa{1.1&0.15kgf/cm2}
CAUTION
• Liberally apply water to the cap seal surface before the
installation to the tester.

L11E5003T10

1-2-2 CHECK OF ENGINE OIL LEVEL

1. Stop the engine. Perform the check on a level place.
2. Pull out the oil level gauge. Wipe out the oil adhered to the gauge and insert it again.
3. Check that the oil level is between the lower limit (L) and the upper limit (F).
1-2-3 CHECK OF SPARK PLUG
WARNING
• Be very careful not to get scalded, for the spark plug is very hot.

1. Ensure that the designated plugs are used. Also, check that the plug exhibits no smoldering and the plug is
not burnt excessively. Check to see if the gap between the electric poles is normal.
Spark plug specifications
EJ-VE ED-VE EF-VE
Type BKR5E BKR6E
Electrode gap (mm) 1.0 - 1.1 0.8 - 0.9
 B1–3
1-2-4 CHECK AND ADJUSTMENT OF TENSION (DEFLECTION AMOUNT) OF V-BELT FOR ALTERNATOR
(1) CHECK
1. Check the V-ribbed belt for cracks, deterioration and significant wear.
2. Check the tension of the V-ribbed belt, using a belt tension gauge.
NOTE
• The check can be performed by measuring the deflection amount of the V-belt.
Specified value
When a new part is installed During inspection
Tension value (N {kgf}) vibration method 490 - 690 {50-70} 340 - 440 {34-44}
Deflection amount (mm) (pushing force 98N {10kgf})
4-5 6-7

CAUTION
• When checking the deflection amount of the belt, push a
point between the alternator and the water pump pulley (the
section A in the figure on the right) with a force of 98 N (10
kgf). Under this condition, measure the deflection amount.
• In cases where the tension is measured after the belt has
been assembled, the measurement should be performed
after cranking two turns.
• When the belt is replaced with a new one, the belt tension
should be adjusted to the mid-value of the specified value
for “When a new part is installed.”
• As regards the belt that has been used for more than
five minutes, ensure that the belt tension conforms to the
specified value for “During inspection.”
• When the belt that has been used for more than five minutes
is assembled, the belt tension should be adjusted to the
mid-value of the specified value for
“During inspection.” M21E5002ET16

(2) ADJUSTMENT
1. Loosen the bolts A and B.

M21E5003T10
B1–4
2. Install the SST and a washer. Turn the adjusting nut to adjust
the tension.
SST: 09286-87701-000
3. Tighten the bolt
TIGHTENING TORQUE: Bolt A
29.0&5.8N·m
{300&60kgf·cm}
Bolt B
52.0&5.2N·m
{530&53kgf·cm} M21E5004T10

4. Confirm the belt tension.

1-2-5 CHECK AND ADJUSTMENT OF VALVE CLEARANCE

(1) Specified value
Valve clearance (mm)
IN During cold 0.18 ± 0.05 During hot 0.25 ± 0.05
EJ - VE/ED-VE/EF-VE
EX condition 0.25 ± 0.05 condition 0.30 ± 0.05

(2) CHECK
CAUTION
• For the removal and installation procedures of each part, refer to the section under “Removal and Installation
of Camshaft.”
<Refer to section B2>

1. Remove the cylinder head cover.

2. Turn the crankshaft in the normal direction, until the timing mark of the crankshaft pulley is aligned with
the indicator of the timing belt cover (Compression Top Dead Center position).
3. Ensure that the mating marks at the top of the drive gear and driven gear of the camshaft are aligned
with each other. If they are not aligned, make one more turn
so that the mating marks are aligned.

4. Using a thickness gauge, check the valve clearances M21E5005ET10

shown in the right figure.

Cylinder No. 1 Cylinder No. 2 Cylinder No. 3
IN EX IN EX IN EX
O O _ O O _

L11E5010T10
 B1–5
5. Turn the crankshaft once so that the cylinder No.1 comes
to the exhaust top dead center. Then, check the valve
clearance at a position indicated in the figure on the right.
Cylinder No. 1 Cylinder No. 2 Cylinder No. 3
IN EX IN EX IN EX

6. If the clearance deviates from the specified value, replace

the valve lifter in the following procedure and adjust it to the
specified value.
L11E5010T10

CAUTION
• Record the position of the valve where the clearance
deviates from the specification, as well as their measurement ± 0.01
results.
Valve lifter thickness

(1) Remove the camshafts No.1 and No.2.

Selection code
Refer to Page B2-12.
marking

(2) Using a micrometer, measure the thickness of the lifter that

Back side of lifter
has been removed.
L11E5011T10

(3) Select the lifter, using the following formula given below, so
that the valve clearance becomes the specified value.
Intake Valve
(Thickness of valve lifter to be selected)
= (Thickness of removed lifter) + [(Measured clearance) - ( 0.18 mm)]
Exhaust Valve
(Thickness of valve lifter to be selected)
= (Thickness of removed lifter) + [(Measured clearance) - ( 0.25 mm)]
Valve lifter thickness (mm)
Valve lifter thickness Valve lifter thickness Valve lifter thickness Valve lifter thickness
No. No. No. No.
(mm) (mm) (mm) (mm)
12 5.120 28 5.280 44 5.440 60 5.600
14 5.140 30 5.300 46 5.460 62 5.620
16 5.160 32 5.320 48 5.480 64 5.640
18 5.180 34 5.340 50 5.500 66 5.660
20 5.200 36 5.360 52 5.520 68 5.680
22 5.220 38 5.380 54 5.540  
24 5.240 40 5.400 56 5.560  
26 5.260 42 5.420 58 5.580  
(4) Apply engine oil to the circumference of the selected valve lifter. Insert it into the lifter hole.
LUBRICANT: Engine oil

CAUTION
• After insertion, ensure that the valve lifter turns smoothly.

(5) Assemble the camshafts No.1 and No.2.

Refer to Page B2-12

7. Install the cylinder head cover.

B1–6
1-2-6 COMPRESSION CHECK
1. Warm up the engine thoroughly.
2. Turn OFF the ignition key switch.
3. Remove all of the IG coils and spark plugs.
4. Remove the fuel pump relay.
5. Install the compression gauge.
6. Fully open the throttle valve and turn the starter. At this time,
measure the compression pressure.

Type Compression Pressure Difference between cylinder

M21E5012ET10
EF 1078 - 1373 Kpa 147 Kpa at 400 rpm
ED 1590 - 1650 Kpa 147 Kpa at 400 rpm
EJ 1579 - 1755 Kpa 147 Kpa at 400 rpm

CAUTION
• Be sure to use a fully-charged battery. The measurement
should be carried out in the shortest possible time.

1-2-7 CHECK OF IGNITION TIMING

1. Connect an engine tachometer to the terminal REV(8),
using the SST.
SST: 09991-87402-000
09991-87404-000
NOTE M21E5013ET10

• The SST 09991-87404-000 is a harness for extension use.

This does not have to be used.
2. Warm up the engine (until the fan motor makes one turn).

3. Install the clip of a timing light at a position indicated in the

figure.

M21E5014ET10

4. Short the terminals EFI T and E of the check connector,

using the SST.
SST: 09991-87403-000
09991-87404-000
CAUTION
• Be sure to short the correct terminals. If wrong terminals are
shorted, it will lead to malfunction.
NOTE
• The SST 09991-87404-000 is a harness for extension use.
This does not have to be used. M21E5016ET10
 B1–7
5. Check the ignition timing.
SPECIFIED VALUE: 5$&2$(BTDC)

CAUTION
• The specified value is given as a guide for the inspection.
No adjustment is required. L11E5031ET10
NOTE
• Engine revolution speed
Type EJ-VE, ED-VE & EF-VE engine
M/T vehicles 850 +100
-50 rpm
A/T vehicles 850 +100
-50 rpm

L11E5033ET10

NOTE
• It is recommended to check the ignition timing by observing
the indicator through between the engine
mount bracket and the timing belt cover.
6. Release the short of the check connector.
7. Raise the engine revolution speed. At this time, ensure that
the ignition timing advances.

M21E5017T10

1-2-8 CHECK OF IDLE SPEED

CAUTION
• Be sure to mount an air cleaner.
• Warm up the engine.
• Do not apply electric load (headlamp, etc.).
• In the case of A/T vehicles, the inspection should be performed with the shift lever placed in the P range.
• The inspection should be carried out under a condition where each vacuum pipe is not disconnected and
exhibits no rupture, etc.
1. Connect an engine tachometer to the terminal REV(8),
using the SST.
SST: 09991-87402-000
09991-87404-000
NOTE
• The SST 09991-87404-000 is a harness for extension use.
This does not have to be used.
2. Check the idle speed.
SPECIFIED VALUE: Type EJ-VE, ED-VE & EF-VE engine
M/T vehicles 850+100
-50 rpm
M21E5013ET10
A/T vehicles 850 +100
-50 rpm
CAUTION
• It is not necessary to adjust the idle speed because of
the ISC.
B1–8
1-2-9 CHECK OF CO AND HC CONCENTRATIONS
1. Keep the engine speed at more than 2,500 rpm for two minutes, thus warming up the O2 sensor.
2. Short the terminals EFI T and E (5–$) of the check
connector, using the SST.
SST: 09991-87402-000
09991-87403-000
09991-87404-000
CAUTION
• Be sure to short the correct terminals. If wrong terminals
are shorted, it will lead to malfunction.
NOTE
• The SST 09991-87404-000 is a harness for extension use.
M21E5018ET10
This does not have to be used.
3. Connect the positive (+) terminal of the tester to the terminal
VF ' of the check connector and the negative (-) terminal
to the body earth.
4. Keep the engine revolution speed at 3,000 rpm. At this
time, measure the indicated voltage (VF output) of the
tester.
SPECIFIED VALUE: 0#5V (Repeating)
(Confirmation of O2 feedback)
5. Release the short between the terminals EFI T and E
(5–$).
6. With the engine idling, measure the VF voltage.
SPECIFIED VALUE: 2.5V (Confirmation of A/F learning
value)
7. With the engine idling, measure the CO and HC
concentrations.
SPECIFIED VALUE: 0.2% or less (CO concentration)
200 ppm or less (HC concentration)
CAUTION
• The specified values above are given as a guide for
the inspection. No adjustment is required.

1-2-10 CHECK OF AIR CONDITIONER IDLE-UP

1. Warm up the engine.
2. Turn ON the air conditioner switch while the engine is running at the idle speed. At this time, ensure that the
engine revolution speed conforms to the specified value.
50
SPECIFIED VALUE: 950 -150 (M/T vehicles)
50
900 -150 (A/T vehicles)
CAUTION
• The engine revolution speed above is given as a guide for the inspection. No adjustment is
required.
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
ENGINE MECHANICAL B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
CYLINDER HEAD GASKET .........................................B2 - 1
C3
REMOVAL AND INSTALLATION ...........................B2 - 1 D1
TIMING BELT ................................................................B2 - 5
REMOVAL AND INSTALLATION ...........................B2 - 5 E1
CAM SHAFT .................................................................B2 - 15
REMOVAL AND INSTALLATION ...........................B2 - 15 E2
ENGINE ASSY ..............................................................B2 - 25
REMOVAL AND INSTALLATION ...........................B2 - 25 E3
CYLINDER BLOCK ......................................................B2 - 34
COMPONENTS .............................................................B2 - 34
F1
DISASSEMBLY .....................................................B2 - 35 F2
INSPECTION ........................................................B2 - 42
INSPECTION OF PISTONS ..........................................B2 - 45 F3
ASSEMBLY OF CYLINDER BLOCK ............................B2 - 51
REPLACEMENT OF CYLINDER BLOCK ....................B2 - 51 G1
ENGINE TUNE-UP ........................................................B2 - 61
COMPRESSION CHECK ..............................................B2 - 61 G2
CHECKING OF A/F (Air/Fuel)
CONTROL SYSTEM ...........................................B2 - 63
H1
Ä ED-VE/EF-VE ..........................................................B2 - 64 I1
SERVICE SPECIFICATIONS .................................B2 - 64
Ä EJ-VE.......................................................................B2 - 67 I2
SERVICE SPECIFICATIONS .................................B2 - 67
SSTs ......................................................................B2 - 70 I3
I4
J1
J2
J3
J4
J5
J6
K1
 B2–1
1 CYLINDER HEAD GASKET
1-1 REMOVAL AND INSTALLATION
WARNING
• No fire should be brought near when servicing the fuel system.
• Never open the drain plug, radiator cap or water hose when engine is hot. Failure to observe this instruction
may result in your getting burnt.

1-1-1 ITEMS TO BE PREPARED

Tool

Instrument

Lubricant,adhesive,others

1-1-2 OPERATION BEFORE REMOVAL

1. Release the fuel pressure.
Refer to Page B7 - 1.

2. Remove the negative _ terminal of the battery.

CAUTION
• It must be noted that, when the negative _ terminal of the battery is removed, memories for the
diagnosis, radio setting, etc. will be erased at the same time.

3. Drain the coolant.

4. Remove the front exhaust pipe.
Refer to Page B4 - 3.

5. Remove the timing belt.

Refer to Page B2 - 5.

6. Remove the camshaft.

Refer to Page B2 - 15.
B2–2
1-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

"
d b

f ENGINE DISCRIMINATION DISCRIMINATION

MODEL SHAPE HOLE

EF-VE 1 piece
e

ED-VE WITHOUT
c

" . EJ-VE WITHOUT

L21E8501S30

~Non-reusable parts
Unit:N;m{kgf;cm}

(2) REMOVAL AND INSTALLATION PROCEDURES

Hose, radiator No.1
Hose, radiator outlet No.2
Stay, exhaust manifold
Head assy, cylinder
Gasket, cylinder head
 B2–3
1-1-4 POINTS OF REMOVAL
(1) Head Assy, cylinder
   
1. Remove the connectors, hoses, earth wire, etc.
2. Remove the eight bolts of the cylinder head in the
sequence shown at the right figure by loosening them
evenly over several stages.
3. Remove the cylinder head assembly together with
the intake manifold assembly and exhaust manifold
assembly.
   
M21E8053T10

1-1-5 POINTS OF INSTALLATION

WARNING
• Never use fire during the work.
• Wear safety goggles during the cleaning so as to protect your eyes.

(1) O RING
1. Install a new O-ring on the water pump. Confirm that the O-ring is not protruding out of the groove by pushing
the upper surface of the O-ring over the entire circumference.

(2) CYLINDER HEAD GASKET

1. Using a scraper, clean the gasket installation surfaces of the cylinder block and cylinder head. Then, install
a new cylinder head gasket.
CAUTION
• Never drop the gasket swarf into the cylinder block.
• Completely remove foreign matters, oil, etc. from the cylinder head gasket installation surface.

(3) CYLINDER HEAD ASSY

1. Install the cylinder head assembly into the cylinder block    
together with the intake manifold assembly and exhaust
manifold assembly.
2. After installing the plate washer, apply oil to the threaded
portion and seating surface of the bolts. Tighten the bolts
to the specified torque over two or three stages in the
sequence shown at the right figure.
3. Install the connectors, earth wire, etc.
   
L11E5036T10

(4) Evaporative emission purge hose

1. Install the evaporative emission purge hose to the
evaporative emission purge control VSV, as shown at the
right figure.

L21E8502T10
B2–4
1-1-6 OPERATION AFTER INSTALLATION
1. Install the camshaft.
Refer to Page B2 - 15.

2. Install the timing belt.

Refer to Page B2 - 5.

3. Install the front exhaust pipe.

Refer to Page B4 - 3.

4. Replenish the coolant.

5. Install the negative _ terminal of the battery.
6. Perform the checks and tune-up of the engine.
Refer to Page B1 - 1.
 B2–5
2 TIMING BELT
2-1 REMOVAL AND INSTALLATION
2-1-1 ITEMS TO BE PREPARED
SST

Instrument

2-1-2 OPERATION BEFORE REMOVAL

1. Remove the negative _ terminal of the battery.
CAUTION
• It must be noted that, when the negative _ terminal of the battery is removed, memories for the diagnosis,
radio setting, etc. will be erased at the same time.

2. Remove the front bumper.

Refer to Page I2 - 1.

3. Remove the headlamp assembly.

Refer to Page J1 - 7.

4. Remove the engine mounting right insulator subassembly.

Refer to Page B12 - 1.
B2–6 (Revision 0607)
2-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

"

"

" "

" "

"
"
"
"
"

T:1146.0 {116361}

L21E8503S40

Unit:N;m{kgf;cm}
(2) REMOVAL AND INSTALLATION PROCEDURES

RH

Tensioner Sub-assy, timing belt

 B2–7
2-1-4 POINTS OF REMOVAL 
(1) AIR CLEANER HOSE No.1
1. Remove the pivot section from the grommet by lifting it
about 20 mm.
2. Remove the air cleaner hose No.1 by turning it 15$(30$
around the connecting section with the air cleaner case.
CAUTION
• If the air cleaner hose No.1 is removed by pulling it, the 
pawl will get worn severely, resulting in excessive play at the
fitting section. 
M21E6033T10

(2) WATER PUMP PULLEY

1. Remove the water pump pulley by preventing it from turning
with a screwdriver, as shown at the right figure.

L11E5187T10

(3) CRANKSHAFT PULLEY

1. Using the SST, remove the crankshaft pulley.
SST: 09213-87211-000
2. Adjust the diameter of the SST belt section indicated at the

right figure to approximately the same size as the crankshaft
pulley.
CAUTION

• It must be noted that, if the diameter indicated at the right
figure is too large, the pulley will not be secured, resulting in
slippage of the belt. Then, the handle section may damage
TONE1006T10
the ignition timing checking indicator provided at the timing
belt cover.
NOTE
• The adjustment can be done easily if the belt edge section
is pulled (2 at the right figure) with the belt section drawn to
the handle side (1 at the right figure).
3. Apply the belt section of the SST to the second stage (at the
air conditioner compressor driving side) of the crankshaft
pulley, as shown at the right figure.
CAUTION
• If the SST is applied to the first stage (alternator driving
side), the ignition timing checking indicator provided at the
timing belt cover will be broken. Therefore, never apply the
SST to the first stage.
4. Secure the handle section of the SST, and remove the bolt,
ensuring that the belt is not twisted.
L11E5039T10
B2–8
NOTE
• Removing the engine under cover in advance will facilitate
the operation.

M21E8022T10

(4) TIMING BELT TENSIONER

1. Set the No.1 cylinder to the top dead center under the Mating mark
compression stroke.
(1) Temporarily attach the attaching bolts of the crankshaft
pulley. Turn the engine in the normal rotating direction
(clockwise), until the punch mark of the camshaft timing
pulley aligns with the mark of the cap camshaft bearing
no.1.

MYD00004-00003

(2) At this time, ensure that the punch mark of the crankshaft
timing belt pulley aligns with the mating mark of the oil
pump.

Mating mark
MYD00005-00004

(3) If the timing belt is reused, ensure that the printed line
white is matched with the mating mark.
(4) Remove the timing belt tensioner subassembly.

M21E8007ET10

Mating mark
MYD00005-00004
 B2–9
(5) TIMING BELT
1. Remove the timing belt.
CAUTION
• When removing the belt, never pry it with a screwdriver
or the like.
• When the timing belt is reused, draw an arrow which
shows the normal direction on the back of the timing
belt.

MYD00019

2-1-5 INSPECTION
(1) TIMING BELT
1. The following precaution must be paid as to handling of the timing belt.
CAUTION
• Do not bend or twist the timing belt at a sharp angle lest that the belt cord is cut.
• Do not allow grease or water to get to the belt lest that the life of the belt gets short.
• When applying the belt, never pry it with a screwdriver or the like.
• When turning the engine by applying the belt, turn the engine only at the crankshaft side.
• When the belt is reused, install the belt in the correct turning direction (by aligning the arrows of the belt and
the belt back put at the time of the removal).

2. Check each section of the timing belt. If there are damages given below, replace the timing belt with a new
one. Then, perform the check in parentheses.
(1) Cracks on the back rubber (Lock check of the timing belt idler)
(2) Cracks on the tooth bottom, peel off or cracks on the canvas (improper sealing, camshaft lock check)
(3) Wear of canvas, missing teeth (improper seating, camshaft lobe check)
(4) Abnormal side wear (guide check of the crankshaft timing pulley)
3. Check that no water, grease or dirt has got to the belt. Replace the timing belt with a new one, as required.
If the belt is not contaminated severely, wipe the belt clean with a cloth or cleaning paper.
CAUTION
• Do not wash the timing belt with gasoline or kerosene.

(2) TIMING BELT TENSIONER

1. Turn the tensioner. Check to see if there is bearing lock, binding or abnormal sound. Also check the belt
contact surface for scratches.

(3) TIMING BELT PULLEY

1. Check the timing belt pulley for damage or deformation. Mating mark

2-1-6 POINTS OF INSTALLATION Punched mark

(1) TIMING BELT
1. Set the No.1 cylinder to the top dead center under the
compression stroke.
2. Ensure that the punch mark of the camshaft timing pulley
is aligned with the mating mark of the cap camshaft bearing MYD00017

no.1.
B2–10
3. Ensure that the punch mark of the crankshaft timing pulley
is aligned with the mating mark of the oil pump.

L18E8009ET10

4. Install the timing belt, while aligning the mating marks on

the timing belt back with the punch mark of the camshaft
timing pulley and the punch mark of the crankshaft timing
pulley, respectively.

M21E8007ET10

Mating mark
MYD00005-00004

TIMING BELT TENSIONER SUB-ASSY

1. Install the timing belt tensioner sub-assy. Adjust the timing
belt tension. With the timing belt tensioner sub-assy
assembled, temporarily tighten the retaining bolt until the
tensioner exhibits no slackness.
NOTE:
• The operation above should be carried out by ensuring that
the engine is in a cold state.
• Ensure that the tensioner exhibits no slackness. If the
tensioner is loose, the tension can not be adjusted
properly.

REFERENCE:
• This can be accomplished when the retaining bolt is tightened
until its flange section is seated and then the retaining bolt is
backed off about an 1/8 turn. Spring installing hole

(1) Install the SST spring to the stay section of the tensioner.
Insert the shaft section to the oil pump hole.

REFERENCE: Shaft inserting hole

• The right figure shows the assembled state.
SST: 09223-97203-000 MYD00021
 B2–11
Temporarily install the crankshaft pulley retaining bolt with the collar
interposed. Turn the engine two turns in the clockwise (normal)
direction so that the No.1 cylinder becomes the top dead center
under the compression stroke.
NOTE:
• Never turn the crankshaft reversely while it is being turned.
If the crankshaft should be turned reversely, repeat the Be sure to
operations from the step of Paragraph 2 above. interpose
the collar.
• If the crankshaft pulley retaining bolt should be installed
temporarily without the collar, the bolt could bottom, resulting
in damaged threads. Hence, this temporary installation of
the crankshaft pulley retaining bolt must be made with the MYD00023
collar interposed.

Tighten the timing belt tensioner retaining bolt to the specified

torque.
Tighening Torque: 39&7.8 N.m
B2–12
2. Ensure that the pushing load necessary to lower the timing
belt 5 mm is the following specified value.
3. If the specified value is not obtained, perform the adjustment
again by loosening the tensioner securing bolt.
SPECIFIED VALUE: Pushing load
EJ -VE & ED -VE 11.8 ~ 16.7N {1.2 ~ 1.7kgf}
EF -VE 19.6 ~ 29.4N {2.0 ~ 3.0kgf}

4. Tighten the timing belt tensioner attaching bolts to the

specified torque. L18E8010ET10

(3) CRANKSHAFT TIMING BELT PULLEY FLANGE

1. Install the crankshaft timing belt pulley flange.
CAUTION Crankshaft
timing pulley
• When installing the flange, face the protruding surface to the
side
crankshaft timing belt pulley side.

L11E5050ET10

(4) TIMING BELT COVER

1. Remove the old gasket.
2. Install the new gasket to the groove of the timing belt
cover.
3. Attach the timing belt cover and tighten the bolts to the
specified torque.

L11E5051ET10

(5) CRANKSHAFT PULLEY

1. Install the crankshaft pulley, using the SST.
SST: 09213-87211-000
2. Adjust the diameter of the SST belt section indicated at the 
right figure to approximately the same size as the crankshaft
pulley.
CAUTION 
• It must be noted that, if the diameter indicated at the right
figure is too large, the pulley will not be secured, resulting in
slippage of the belt. Then, the handle section may damage
TONE1006T10
the ignition timing checking indicator provided at the timing
belt cover.
NOTE
• The adjustment can be done easily if the belt edge section
is pulled (2 at the right figure) with the belt section drawn to
the handle side (1 at the right figure).
 B2–13
3. Apply the belt section of the SST to the second stage (at the
air conditioner compressor driving side) of the crankshaft
pulley, as shown at the right figure.
CAUTION
• If the SST is applied to the first stage (alternator driving
side), the ignition timing checking indicator provided at the
timing belt cover will be broken. Therefore, never apply the
SST to the first stage.
4. Secure the handle section of the SST, and install the bolt,
ensuring that the belt is not twisted.
L11E5039T10

NOTE
• Removing the engine under cover in advance will facilitate
the operation.

M21E8022T10

(6) WATER PUMP PULLEY

Install the water pump pulley, while preventing it from turning with a
screwdriver or the like, as shown at the right figure.

L11E5187T10

(7) V RIBBED BELT (ALTERNATOR)

1. Adjust the V-ribbed belt tension.
Reffer to Page B1 - 3.

(8) V BELT (AIR CONDITIONER)

1. Adjust the belt tension.
Refer to Page J6 - 5.
B2–14
(9) ENGINE MOUNTING RIGHT BRACKET No.2
1. Install the engine mounting right bracket No.2 to the engine
assembly.
(1) Temporarily tighten the bolt 1.
(2) Tighten the bolt 4 to the specified torque.
CAUTION
• Before tightening to the specified torque, be sure to confirm 
that the bolt 1 surface of the engine mounting RH bracket  
No.2 is in close contact with the cylinder head surface 

without clearance. 
(3) Tighten the bolts 1, 2 and 3 to the specified torque.
(There is no specific tightening sequence for these
bolts.)
(4) Temporarily install the engine mounting RH stay No.2 
with the bolt 7.
(5) Tighten the bolts 5 and 6 to the specified torque.
(There is no specific tightening sequence for these
bolts.) L21E8504T16

CAUTION
• Before tightening to the specified torque, be sure to confirm
that the engine mounting RH stay No.2 is in close contact
with the unit side stay seating surface or cylinder head
surface.
(6) Tighten the bolt 7 to the specified torque.

2-1-7 OPERATION AFTER INSTALLATION

1. Install the engine mounting right insulator subassembly.
Reffer to Page B12 - 1.

2. Install the headlamp assembly.

Reffer to Page J1 - 6 .

3. Install the front bumper.

Reffer to Page I2 - 1.

4. Install the negative _ terminal of the battery.

 B2–15
3 CAM SHAFT
3-1 REMOVAL AND INSTALLATION
3-1-1 ITEMS TO BE PREPARED
SST

Tool

Instrument

Lubricant,adhesive,others

3-1-2 OPERATION BEFORE REMOVAL

1. Remove the air cleaner cap and air cleaner element.
Refer to Page B3 - 1.

2. Remove the throttle body bracket and throttle body.

Refer to Page B3 - 3.

3. Remove the ignition coil.

Refer to Page B10 - 2.

4. Remove the timing belt.

Refer to Page B2 - 5.
B2–16
3-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

T:5.541.1 {56411}

"
c

d
T:8.042.4 {82424} "
a
T:8.341.3 {85413}

T:8.341.3 {85413}

f g

" T:21.046.3 {214464}

T:52.045.0 {510449}

b
T:39.045.0 {382449}
T:2046 {204461} "

k
n o
l m
i

e
T:98.0410.0 {10004100}

L21E8505S36

~Non-reusable parts
Unit:N;m{kgf;cm}

(2) REMOVAL PROCEDURES

9 i Plug
Pipe Sub-assy, oil 10 j Camshaft assy, no.2 (The VVT controller is install
on Type VE engine only.
11 k Camshaft assy, No.1
5 e Pulley, camshaft timing 12 l Ring, shaft snap
6 f Cap, camshaft bearing, No.1 13 m Washer, wave
7 g Cap, camshaft bearing, No.2 14 n Gear Sub-assy, camshaft sub
8 h Seal, type T oil 15 o Spring, camshaft gear
 B2–17
(3) INSTALLATION PROCEDURES
Spring, camshaft gear
Gear, Sub-assy, camshaft sub

12
Camshaft assy, No. 1 13
Camshaft assy, No. 2 (The VVT controller 14 Pipe Sub-assy, oil
is installed on Type VE engine only) 15

3-1-4 POINTS OF REMOVAL

(1) CAMSHAFT TIMING BELT PULLEY
1. Hold the sub-gear by setting the SST to two 06 holes of
the camshaft sub-gear subassembly.
SST: 09504-87501-000
CAUTION
• It should be noted that the oil flows out from the camshaft
when the bolt is removed.
• Do not use the hexagonal section of the camshaft to prevent
turning.
• It should be noted that the pulley and pin are not supplied as L11E5054T10

the assembly.
(2) NO.1 CAMSHAFT BEARING CAP, NO.2 CAMSHAFT
BEARING CAP
1. Using the hexagonal section of the No.2 camshaft (EX
side), turn the camshaft until the configuration becomes as
shown at the right figure.

L11E5057ET10

2. Remove the No.1 camshaft bearing cap attaching bolts

in the sequence shown at the right figure. Remove the   
No.1camshaft bearing cap. 
CAUTION
• Cover the opening with an adhesive tap so that no dirt gets 
into the No.1camshaft bearing cap.

M21E8011T10
B2–18
3. Secure the driven gear of the No.1camshaft (IN side) and
the camshaft sub-gear assembly, using the bolts (size:
M5, pitch: 0.8 mm)

L11E5061ET10

4. Remove the No.2 camshaft bearing cap attaching bolts in

the sequence shown at the right figure. Remove the No.2
camshaft bearing cap.   

  

  

  

L11E5062T10

(3) NO.2 CAMSHAFT ASSEMBLY, NO.1 CAMSHAFT ASSEMBLY

1. Remove the No.2 camshaft assembly first, and then No.1 camshaft assembly.
CAUTION
• Since the camshaft thrust clearance is small, keep the camshaft horizontal during the removal.
(This should be observed lest that excessive force is applied to the thrust section, thus damaging it.)
(4) SHAFT SNAP RING, WAVE WASHER, CAMSHAFT SUB-GEAR SUBASSEMBLY, CAMSHAFT GEAR SPRING
1. Secure the hexagonal section of the No.1 camshaft assembly to a vice with protective metal sheets
interposed.
CAUTION
• Be very careful not to damage the cam section.
2. Remove the sub-gear securing bolt.
3. Hold the sub-gear by setting the SST to two 06 holes of
the camshaft sub-gear subassembly.
SST: 09504-87501-000

L11E5064T10
 B2–19
4. When the SST is not used, put a bolt (M6) at the position
shown at the right figure of the camshaft sub-gear
assembly.
Then, hold the sub-gear by inserting a screwdriver or the
like between the bolt and the camshaft journal.
CAUTION
• Be very careful not to scratch the cam journal by applying a
cloth or the like.
5. Remove the bolt securing the sub-gear, while keeping the
sub-gear teeth in mesh with the driven gear teeth.
6. Using snap ring pliers, remove the shaft snap ring. L11E5065ET10

Remove the wave washer, camshaft sub-gear subassembly,

and camshaft gear spring.

3-1-5 INSPECTION
(1) DVVT actuator inspection
1. Secure the hexagonal section provided for servicing the No.2 camshaft assembly to a vice.
2. Temporarily tighten the attaching bolt to the bolt hole for installing the timing pulley so as to close the oil
passage at the timing advance side.
3. Plug one of the two ports at the timing advance side of the
camshaft (see the right figure) with your finger.
4. Using an air tool, apply air pressure through another port
at the timing advance side.
CAUTION
• Care must be exercised as to splashing oil.
NOTE
• The most retarded locking is released.
5. At this time, ensure that the most retard lock of the
actuator is released, and you can move the actuator within
about 30$ without binding by hand. L11E5195ET10
NOTE
• The actuator is locked when it is turned to the most retard
timing position.
6. After the inspection, lock the actuator at the most retard
timing position. Remove the timing pulley attaching bolt.
CAUTION
• after removing the bolt, remove the sealing material
completely from the threaded hole of the camshaft.
(Failure to do this may cause malfunction of the DVVT
after it is installed.)
B2–20
3-1-6 POINTS OF INSTALLATION
(1) Camshaft gear spring, camshaft sub-gear subassembly,
wave washer, shaft snap ring
1. Secure the hexagonal section of the No.1 camshaft to a
vice with protective metal sheets interposed.
CAUTION
• Be very careful not to damage the cam section.
2. Set the camshaft gear spring, camshaft sub-gear sub
assembly and wave washer to the camshaft driven gear.
CAUTION
• As for the sub-gear, face the side where the stopper pin L11E5064T10

of the spring protrudes to the driven gear side.

3. Using snap ring pliers, install the shaft snap ring.

4. Set the SST to two 06 holes of the camshaft sub-gear subassembly. Turn the sub-gear clockwise, until the
sub-gear attaching auxiliary hole is aligned with the attaching auxiliary hole of the camshaft driven gear so
that the gear teeth are in mesh with each other.
SST: 09504-87501-000
5. When the SST is not used, put a bolt (M6) at the position shown at the right figure of the camshaft subgear
assembly. Then, turn the sub-gear clockwise by inserting a
screwdriver or the like between the bolt and the camshaft
journal, until the sub-gear attaching auxiliary hole is aligned
with the attaching auxiliary hole of the camshaft driven gear
so that the gear teeth are in mesh with each other.
CAUTION
• Be very careful not to scratch the cam journal by
applying a cloth or the like.
6. Install the bolt (size: M5, pitch: 0.8 mm) for securing the
sub-gear to the auxiliary hole above. (If no SST is used,
remove the M6 bolt.) L11E5065ET10

(2) NO.1 CAMSHAFT ASSEMBLY, NO.2 CAMSHAFT

ASSEMBLY
CAUTION
• Since the camshaft thrust clearance is small, keep the camshaft horizontal during the installation.
(This should be observed lest that excessive force is applied to the thrust section, thus damaging it.)

1. Apply engine oil to the cam section and gear section of the No.1 camshaft assembly, and to the journal
section of the cylinder head.
2. Set the No.1 camshaft assembly to the cylinder head in such a way that the bolt for securing the subgear
faces almost upward.
 B2–21
3. Turn the No.1 camshaft assembly, until, of the two mating
marks of the gear, the lower side mark may come within the
range about 10$(20$upward from the line which connects
the center of each camshaft, as shown at the right figure.
4. Apply engine oil to the cam section and gear section of the
No.2 camshaft assembly, and to the journal section of the
cylinder head.

L11E5067ET10

5. Of the two mating marks on the back of the camshaft driven

gear and camshaft drive gear, first align the upper mating
marks. Then, turn the camshaft drive gear on the driven
gear, until the lower mating marks are aligned with each
other.

L11E5066ET10

6. Ensure that the No.1 camshaft assembly and No.2 camshaft

assembly have been assembled as shown at the right
figure.

L11E5057ET10

7. At this time, ensure that there is no clearance between the

camshaft and the journal section of the cylinder head (the
camshaft is seating on the journal section, not floating).
CAUTION
• If the camshaft bearing cap is installed with the camshaft
floating, not seating on the journal section, the camshaft
may be broken.

L1ZE1017ET10
B2–22
(3) No.2 CAMSHAFT BEARING CAP
1. Set the No.2 camshaft bearing cap in such a way that its
stamped number faces to the engine front side.

L11E5170ET16

2. Tighten the attaching bolts to the specified torque in the

sequence shown at the right figure.
3. Remove the bolt securing the sub-gear of the No.1 camshaft   
assembly.   

  

  

L11E5069T10

(4) No.1 CAMSHAFT BEARING CAP

1. Apply liquid gasket to the No.1 camshaft bearing cap at the
positions shown at the right figure.
ADHESIVE: Three Bond1207F

M21E8012T10

2. Set the No.1 camshaft bearing cap. Tighten the attaching  

bolts to the specified torque in the sequence shown at the  
right figure.


M21E8013T10
 B2–23
(5) PLUG
1. Completely remove oil from the plug attaching surface of
the cylinder head and No.1 camshaft bearing cap. Then,
drive the plug using a 21 mm box wrench.
CAUTION
• Install the plug in the direction shown at the right figure.
• The plug shall be driven to a position 1&1mm to the
camshaft side from the cylinder head end surface.
(If the plug is driven excessively, it will come to contact with
the camshaft.)
L21E8010ET10

(6) TYPE T OIL SEAL

1. Apply engine oil to the lip surface of the type T oil seal.
Using the SST and an M10 bolt (nominal length: 50–60mm),
press fit the oil seal in the direction shown at the right figure
until it reaches the bottom.
SST: 09707-87302-000
CAUTION
• If the oil seal is reused, apply silicone bond to the rubber
section.
• After removing the bolt, lightly tap the SST with a hammer
L11E5074T10
or the like to check the press-fit condition.

2. When replacing the camshaft timing pulley, press fit the pin
into the camshaft timing pulley with a plastic hammer or the
like.
SPECIFIED VALUE: Protruding dimension from pulley
front side end surface
7&1mm

M21E8066ET10

(7) CAMSHAFT TIMING PULLEY

1. Install the camshaft timing pulley. While preventing it from
turning with the SST, tighten the new bolt to the specified
torque.
SST: 09504-87501-000
CAUTION
• Do not use the hexagonal section of the camshaft to prevent
turning.
• Be sure to use a new attaching bolt of the camshaft timing
pulley.
L11E5054T10
B2–24
(8) CYLINDER HEAD COVER, CYLINDER HEAD COVER
GASKET
1. Install the cylinder head cover gasket to the cylinder head
cover. Apply liquid gasket to the sections shown at the right
figure.
ADHESIVE: Three Bond1207F

M21E8014ET10

2. Install the cylinder head cover to the cylinder head. Tighten

the bolts to the specified torque in the sequence shown at
the right figure.
DEVIATION: When installing the cylinder head cover, be
careful that the harness of the O2 sensor
may not be caught in.
CAUTION
• The length of the bolt differs, depending upon the position
where the bolt is used. Use a bolt having the proper nominal
length, referring to the following information.
M21E8015T10
NOTE
• Bolt of tightening sequence number 1: Nominal length
16 mm
Bolts of tightening sequence number 2, 4, 7:
Nominal length 40 mm
Bolts of tightening sequence number 3, 5, 6:
Nominal length 25 mm

(9) OIL PIPE SUB-ASSY

1. When assembling the oil pipe subassembly at the No.1
camshaft bearing cap, place the connecting section of the
upper and lower gaskets at the left side (timing belt cover
side) of the oil pipe subassembly as shown at the right
figure.
CAUTION
• If the assembling is not made in the specified direction,
interference with the cylinder head cover may occur,
resulting in the damage of the gasket, which in turn may
cause oil leakage.
L21E8506T10

3-1-7 OPERATION AFTER INSTALLATION

1. Install the timing belt.
Refer to Page B2 - 5.

2. Install the ignition coil.

Refer to Page B10 - 2.

3. Install the throttle body bracket and throttle body.

Refer to Page B3 - 3.

4. Install the air cleaner cap and air cleaner element.

Refer to Page B3 - 1.
 B2–25
4 ENGINE ASSY
4-1 REMOVAL AND INSTALLATION
WARNING
• Never bring fire close during servicing the fuel system.
• When removing the fuel hose, prevent the fuel from splashing.
• When the coolant is hot, do not remove the radiator cap, drain plug or water hose.
• When the oil is hot, do not remove the drain plug or oil cooler hose.
4-1-1 ITEMS TO BE PREPARED
Instrument

Lubricant,adhesive,others
B2–26
4-1-2 OPERATION BEFORE REMOVAL
1. Release the fuel pressure.
Refer to Page B7 - 1.

2. Remove the battery and battery carrier.

CAUTION
• It must be noted that, when the negative _ terminal of the battery is removed, memories for the diagnosis,
radio setting, etc. will be erased at the same time.

3. Remove the relay block assembly.

4. In the case of manual transmission vehicles, disconnect the clutch release control cable.
Refer to Page F1 - 8.

5. Disconnect the vacuum hose for the brake booster.

6. In the case of automatic transmission vehicles, disconnect the throttle cable.
Refer to Page F3 - 42.

7. Remove the front bumper.

Refer to Page I2 - 1.

8. Remove the headlamp assembly.

Refer to Page J1 - 7.

9. Remove the air cleaner and air cleaner hose.

Refer to Page B3 - 1.

10.
Remove the front wheels.
11.
Remove the engine undercover.
12.
Drain the coolant.
13.
Disconnect the heater hose and radiator hose.
14.
Remove the drain plug and gasket. Drain the transmission oil (M/T vehicles) or automatic fluid (A/T
vehicles).
CAUTION
• The gasket is a non-reusable part.

15. In the case of automatic transmission vehicles, disconnect the oil cooler hose.
Refer to Page B6 - 9.

16. Remove the radiator.

Refer to Page B6 - 5.

CAUTION
• When the radiator is removed, the cooler condenser becomes free. Therefore, do not disconnect the pipes.
Rather suspend them with ropes or the like.

17. Remove the front crossmember.

18. Remove the performance rod.
19. Remove the front exhaust pipe assembly.
Refer to Page B4 - 3.

20. Remove the drive shaft.

Refer to Page D1 - 7.

21. Disconnect the shift lever assembly in the case of M/T vehicles.
Refer to Page F2 - 14.

22. Disconnect the control cable in the case of A/T vehicles.

Refer to Page F3 - 47.
 B2–27
4-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

d
i

"
a
k

p "
l
n

" "
h

" o

"
j " "

"
m

f
" q
"
s
"
e
" " r "
"
"

L21E8507S48
B2–28
~Non-reusable parts
Unit:N;m{kgf;cm}
(2) REMOVAL AND INSTALLATION PROCEDURES

k -
l
m
n

4-1-4 POINTS OF REMOVAL

(1) COMPRESSOR ASSY
1. Remove the compressor by removing the compressor
attaching bolts. At this time, do not remove the pipes.
Refer to Page J6 - 26.

NOTE
• Do not remove the compressor bracket. Use this
section when supporting the engine assembly with a
wooden piece during removal/installation of the engine
assembly.
2. Suspend the compressor with ropes or the like.
M21E8021T10

(2) ACCELERATOR CONTROL CABLE ASSY

1. Remove the throttle body side by loosening the nut at the bracket section.
CAUTION
• Be careful not to have the cable get curly when removing it.

(3) ENGINE ASSY

1. Remove the engine assembly together with the transmission assembly from the vehicle.
2. Disconnect the engine wire from the engine control computer, and pull it into the engine compartment.
3. Remove the connectors and clamps. Disconnect the engine wire from the vehicle.
4. Disconnect each harness, and the earth wires of the engine section and transmission case cover section.
5. Set the engine lifter at the position shown at the figure.
NOTE
• If no engine lifter is used, move the vehicle side up and
down (two-post lift, etc.) and perform the following work.

M21E8060T10
 B2–29
6. With wooden blocks or the like, support the engine assembly
and transaxle assembly in such a way that their balance
is well kept.
(1) As for the engine mounting right insulator side, apply
wooden blocks to the cooler compressor bracket and
exhaust manifold stay.
(2) As for the engine mounting left insulator side, apply
wooden blocks to the oil pan flange section (A/T
vehicles) or transaxle case (M/T vehicles).
CAUTION
• Do not apply wooden blocks to the crankshaft pulley. M21E8061T10

• Do not apply wooden blocks to the engine oil pan or the oil
pan of the automatic transaxle.
(3) As for the engine mounting rear insulator, apply wooden
blocks to the engine mounting rear bracket or engine
mounting rear bracket No.1.

M21E8062T10

7. If necessary, install the engine hanger to the position shown

at the right figure.

M21E8003T10

(1) Install the engine hanger No.1 and engine hanger

No.2.
NOTE
• The engine hangers No.1 and No.2 and bolts with washers
are supplied parts.
TIGHTENING TORQUE: 24.0&4.8 N;m
{245&49kgf;cm}

M21E8004T10
B2–30
(4) BOLT
1. Remove the connecting bolts of the engine mounting rear
bracket and engine mounting rear insulator.
CAUTION
• When the connecting bolts are removed, the engine
assembly will lean to the front of the vehicle.
Therefore, this operation should be done being sure
that the engine assembly is supported in a balanced way.
• Be careful that no interference occurs between the
front part of the engine compartment and the engine
assembly and transaxle assembly. M21E8064T10

(5) ENGINE MOUNTING RIGHT INSULATOR

1. Remove the engine mounting right insulator subassembly.
Refer to Page B12 - 1.

CAUTION
• Make sure that the engine assembly is supported in a well balanced way during the removal.
NOTE
• It is not necessary to remove the mounting right bracket No.2 tightened to the engine.

(6) ENGINE MOUNTING LEFT INSULATOR

1. Remove the engine mounting left insulator.
Refer to Page B12 - 4.

CAUTION
• Make sure that the engine assembly is supported in a well balanced way during the removal.
NOTE
• It is not necessary to remove the left mounting bracket tightened to the transaxle case.

(7) ENGINE MOUNTING LEFT INSULATOR BRACKET

1. Remove the engine mounting left insulator bracket from the engine mounting left bracket.
Refer to Page B12 - 4.

(8) ENGINE ASSY

1. By operating the engine lifter, remove the engine assembly with the transmission assembly installed to it.
CAUTION
• Slowly remove the engine assembly, making sure that no connectors or hoses are left not removed or that they
are not interfering with other parts.
• Do not allow the engine assembly to interfere with the suspension crossmember or lower arm during the
removal. Carefully avoid these parts.

(9) TRANSAXLE ASSY

1. Remove the automatic transmission assembly in the case of A/T vehicles.
Refer to Page F3 - 11.

2. Remove the manual transmission assembly in the case of M/T vehicles.

Refer to Page F2 - 2.
 B2–31
4-1-5 POINTS OF INSTALLATION
(1) TRANSAXLE ASSY
1. Install the automatic transmission assembly to the engine assembly in the case of A/T vehicles.
Refer to Page F3 - 11.

2. Install the manual transmission assembly to the engine assembly in the case of M/T vehicles.
Refer to Page F2 - 2.

(2) ENGINE MOUNTING REAR BRACKET NO.1,TRANSMISSION CASE STIFFENER PLATE, ENGINE MOUNTING
REAR BRACKET
1. Install the engine mounting rear bracket No.1, transmission case stiffener plate and engine mounting rear
bracket.
(1) AUTOMATIC TRANSMISSION ASSY
Refer to Page F3 - 11.

(2) MANUAL TRANSMISSION ASSY

Refer to Page F2 - 2.

(3) ENGINE ASSY

1. Install the engine assembly together with the transmission assembly to the vehicle.
2. Using wooden blocks or the like, set the engine assembly
and transmission assembly to the engine lifter in a well
balanced way.
(1) On the engine mounting right insulator side, apply
wooden blocks to the cooler compressor bracket and
exhaust manifold stay.
(2) On the engine mounting left insulator side, apply
wooden blocks to the flange section of the oil pan
(A/T vehicles) and transmission case (M/T vehicles).

M21E8061T10
CAUTION
• Do not apply wooden blocks to the crankshaft pulley.
• Do not apply wooden blocks to the engine oil pan or the oil pan of the automatic transmission.
(3) On the engine mounting rear insulator side, apply
wooden blocks or the like to the engine mounting
rear bracket or engine mounting rear bracket No.1.

M21E8062T10
B2–32
3. By operating the engine lifter, lift the engine assembly
together with the transmission assembly to the vehicle
mounting position.
NOTE
• When no engine lifter is used, move the vehicle side
(two-post lift, etc.) up and down to perform the following
operations.
CAUTION
• Be careful not to allow interference with parts in the
engine compartment to occur.
• Do not allow the engine assembly to interfere with the M21E8060T10

suspension crossmember or lower arm during the

operation. Carefully avoid these parts.

(4) ENGINE MOUNTING LEFT INSULATOR BRACKET

1. Install the engine mounting left insulator bracket to the engine mounting left bracket.
Refer to Page B12 - 4.

(5) ENGINE MOUNTING BRACKET LEFT INSULATOR

1. Install the attaching bolts of the engine mounting bracket left insulator.
Refer to Page B12 - 4.

(6) ENGINE MOUNTING BRACKET RIGHT INSULATOR

1. Install the engine mounting right insulator subassembly.
Refer to Page B12 - 1.

(7) BOLT
1. Install the connecting bolts of the engine mounting rear
bracket and engine mounting rear insulator.

M21E8064T10

(8) ENGINE ASSY

1. Install each harness, connector and clamp.
2. Route the engine wire in the vehicle interior to connect it to the engine control computer.
3. Install the earth wires of the engine section and transmission section.

(9) ACCELERATOR CONTROL CABLE ASSY

1. Install the accelerator control cable assembly to the throttle body. After adjusting the accelerator pedal
free play, tighten the nut to the specified torque.
SPECIFIED VALUE: 1–5mm (accelerator pedal free play)

(10) COMPRESSOR ASSY

1. Install the compressor assembly. Adjust the V-belt tension.
Refer to Page J6 - 26.
 B2–33
4-1-6 OPERATION AFTER INSTALLATION
1. On the A/T vehicles, install the control cable.
Refer to Page B12 - 4.

2. On the M/T vehicles, install the shift lever assembly.

Refer to Page D1 - 7.

3. Install the drive shaft.

Refer to Page B4 - 3.

4. Install the front exhaust pipe assembly.

Refer to Page B4 - 3.

5. Install the performance rod.

6. Install the front crossmember.
7. Install the radiator.
Refer to Page B6 - 5.

8. On A/T vehicles, install the oil cooler hose.

Refer to Page B6 - 9.

9. Install the radiator hose.

10. Install a new gasket. Tighten the drain plug to the specified torque. Fill the transmission oil (M/T vehicles);
automatic fluid (A/T vehicles).
11. Fill the coolant.
12. Install the engine undercover.
13. Install the front wheels.
14. Install the air cleaner and air cleaner hose.
Refer to Page B3 - 1.

15. Install the headlamp light.

Refer to Page J1 - 7.

16. Install the front bumper.

Refer to Page I2 - 1.

17. On A/T vehicles, install the throttle cable and perform the automatic adjustment.
Refer to Page F3 - 42.

18. Install the vacuum hose for brake booster.

19. On M/T vehicles, install the clutch release cable.
Refer to Page F1 - 8.

20. Install the relay block assembly.

21. Install the battery carrier and battery.
22. Remove the engine hanger if it has been installed.
B2–34

CYLINDER BLOCK
COMPONENTS

MT
. T:21.04.2 {21043}

@
B :

> AT

=
T:12.542.5 {127425}
 T:36.046.0 {366461}
T:19.043.8 {193439} 
  T:39.0~49.0 {397~499}

 q Cylinder block
  w Cylinder head gasket
 e Rear end plate
 r Rear oil seal
2 8 t Rear oil seal retainer
y Water pump gasket
 u Water pump
T:19.043.8 {193439}  i Front oil seal
 o Oil pump
!0 Oil pump gasket
 !1 Piston ring No. 1

 !2 Piston ring No. 2

!3 Oil ring
 !4 Piston pin
!5 Piston
!6 Connecting rod
!7 Connecting rod bearing
!8 Spacer
T:59.046.0 {600461}
T:114.046.0 {1160461} !9 Flywheel
 @0 Crankshaft
@1 Key
T:8.041.6 {81416.3} @2 Crankshaft timing belt pulley
@3 Flange
 @4 Crankshaft pulley
T:8.041.6 {81416.3}
@5 Crankshaft bearing
@6 Crankshaft bearing cap
@7 Oil strainer
T:24.044.8 {244449} @8 Oil pan

DEM00119-00114
~Non-reusable parts
Unit:N;m{kgf;cm}
 B2–35
DISASSEMBLY
1. Drain the engine oil by removing the drain plug of the oil pan.
2. Drain the engine coolant by removing the drain plug of the
water pump.

DEM00120-00115

3. Remove the water pump.

4. Remove the timing belt. (For removal procedure, refer to the
“TIMING BELT” section.)
5. Remove the cylinder head. (For removal procedure, refer to the
“CYLINDER HEAD” section.)

DEM00122-00117

6. Check the drive plate for runout (A/T).

Check the flywheel for runout (M/T).
NOTE:
• If the runout does not conform to the specification, confirm
the tightening torque of the drive plate. Only in the case
where the tightening torque conforms to the specified value,
replace the drive plate.
Specified Runout Limit: Less than 0.25 mm (drive plate)
Less than 0.1 mm (flywheel)

DEM00123-00118

7. Loosen the attaching bolts of the drive plate (flywheel) in the

sequence as indicated in the right figure. Remove the drive
plate (flywheel).
NOTE:
• Prevent the drive plate from turning, using the following SST
=
SST. ;
:
SST: 09210-87701-000
. @
B

DEM00124-00119
B2–36
8. Remove the rear end plate.
9. Removal of oil pan
(1) Loosen the attaching bolts and nuts of the oil pan over two
or three stages. Pull out the bolts and nuts.
(2) Separate the oil pan from the cylinder block by driving the
following SST into between the cylinder block and the oil
pan.
SST: 09032-00100-000

DEM00125-00120

10. Remove the oil strainer.

11. Remove the oil strainer gasket from the oil pump.
12. Remove the oil pump from the cylinder block.
(For the disassembly and inspection of the oil pump, refer to
the LU section.)
13. Remove the oil pump gasket from the cylinder block.
14. Remove the rear oil seal retainer.

DEM00126-00121

15. Measurement of connecting rod thrust clearance

Measure the thrust clearance between the connecting rod and
the crankshaft, using a thickness gauge.
Thrust Clearance:
Specified Value: 0.15 - 0.25 mm
Maximum Limit: 0.3 mm

NOTE:
• The thrust clearance should be measured while the
connecting rod is being pushed against either side of
the crankshaft in the axial direction. Measure the thrust
DEM00126-00121
clearance at the opposite side.

If the clearance exceeds the specified value, replace the

connecting rod or the crankshaft, or both of them, referring
to the width of the big end of the connecting rod in the thrust
direction and the side width of the crankpin journal.

[Reference]

Width of big end of connecting rod in thrust direction Side width of crankpin journal
19.80 - 19.85 mm 20.00 - 20.05 mm
Connecting rod Crankshaft

LCO00017-00015
 B2–37
16. Loosen the connecting rod bearing cap nuts evenly over two or
three stages. Then, remove the nut.
17. Remove the connecting rod bearing cap.

18. Measure the oil clearance between the crankpin journal and DEM00129-00124

the connecting rod bearing cap.

(For the tightening method of the connecting rod cap nuts, refer
to page B2–53.)
Oil Clearance:
STD: 0.020 - 0.044 mm
Maximum Limit: 0.07 mm

NOTE:
• If the oil clearance does not conform to the specification,
measure the crankshaft pin journal and connecting rod
big end bore, following the procedure given. If both meet
DEM00130-00125
the specifications, replace the bearing according to the
classification. A B Y

Measurement of crankpin diameter X X

1. Measure the crankpin diameter of the crankshaft in four
directions for each crankshaft pin, 90 degrees spaced, at those
points indicated in the right figure. Y
2. The greatest value among the measured diameters is regarded 4 12 4 12 4 12
as the crankpin journal diameter.
Specified Crankpin Journal Diameter:

EF 037 mm
DEM00131-00126
ED,EJ 040 mm

Dimension Tolerence:

No. 1 - 0.024 min - 0.016 max

No. 2 - 0.016 over - 0.008 max A B
No. 3 - 0.008 over 0 max

4 4

Measurement of connecting rod big end bore diameter DEM00132-00127

1. Perform measurement at the two points indicated in the figure.
2. The smaller value among the measured diameters is regarded
as the connecting rod big end bore diameter.
Specified Connecting Rod Big End Bore:

EF 040
ED,EJ 043

DEM00133-00000
B2–38
CAUTION:
• If the classification that has been determined by the
measured value differs from the code attached to the part,
be sure to carefully select the bearing.
• Since undersized bearings are available, the crank pin
journals of a crankshaft which will not meet the specification
can be machined according to the undersized bearing.
In this case, perform machining of the crank pin journals,
referring to the table below.
• When some parts only are replaced, the replacement should
be done only when the classification matches with each
other.

Crankpin code No.

1 ED & EJ
Crankpin code No. Crankpin diameter (mm)
1 39.976 - 39.984
2 39.985 - 39.992 No. 1 crankpin code No.
No. 2 crankpin code No.
3 39.993 - 40.000
No. 3 crankpin code No.
2 EF
DEM00134-00128
Crankpin code No. Crankpin diameter (mm)
Connecting rod
1 36.976 - 36.984 Front mark
A
ED, EJ only
2 36.985 - 36.992
B
EF only
3 36.993 - 37.000 C
All models

Connecting rod big end bore code No. A B C

1 ED & EJ
Connecting rod big end
Connecting rod big Connecting rod big end bore diameter
bore code No.
end bore code No. (mm)
4 43.000 - 43.008 DEM00135-00129

5 43.009 - 43.016
6 43.017 - 43.024

2 EF
Connecting rod big Connecting rod big end bore diameter
end bore code No. (mm)
4 40.000 - 40.008
5 40.009 - 40.016
6 40.017 - 40.024

Connecting rod bearing Connecting rod bearing

code No. selection

Connecting rod Connecting rod Crankshaft Crankpin Identification color

bearing code No. bearing center code No.
(Identification color) thickness (mm) Connecting
rod 1 2 3
1 (Yellow) 1.486 - 1.490
Connecting 4 3 2 1
2 (Green) 1.491 - 1.494 rod big end 5 4 3 2
bore code No.
3 (Brown) 1.495 - 1.498
6 5 4 3
4 (Black) 1.499 - 1.502
5 (Blue) 1.503 - 1.506 DEM00136-00130
 B2–39
20. Removal of piston
(1) Cover each connecting rod bolt with a short piece of hose
to protect the crankpin journal from damage.
(2) Push out the piston and connecting rod assembly and the
upper bearing through the top of the cylinder block.
NOTE:
• Arrange the removed pistons and connecting rods so that
their installation positions may be identified readily.
• Care should be exercised so as not to damage the
bearings.

21. Checking procedure of crankshaft thrust clearance DEM00138-00131

NOTE:
• Measure the thrust clearance, using a dial gauge.
Thrust Clearance:
Specified Value: 0.02 - 0.22 mm
Maximum Limit: 0.30 mm

If the thrust clearance exceeds the specified value, measure

the width of the crankshaft thrust washer contact surface. If
the measure value is less than 22.63 mm, replace the thrust
washer with a standard thrust washer or a suitable oversize
thrust washer. If the measured value exceeds 22.63 mm,
DEM00139-00132
replace the crankshaft and thrust washer.

22. Removal of crankshaft

(1) Gradually loosen the main bearing cap bolts over three
stages in the numerical sequence shown in the figure.
Remove the bearing cap bolts.

DEM00141-00134

(2) With the main bearing cap bolts inserted into the bolt holes
of the main bearing cap, wiggle the bearing cap back
and forth. Remove the bearing cap together with the lower
bearing.
NOTE:
• Keep the lower bearing fitted to the main bearing cap.
Arrange the removed main bearing caps in order.

DEM00142-00135
B2–40
(3) Lift off the crankshaft.
(4) Remove the upper bearing.
NOTE:
• Be very careful not to allow the main bearings to be mixed
with the bearings of other cylinders.
• Remove the thrust washer.

DEM00142-00135

23. Measure the oil clearance between the crank journal and the
crankshaft bearing cap.
NOTE:
• For the tightening method of the crankshaft bearing cap,
refer to page B2–55.)
Oil Clearance:
STD: 0.004 - 0.028 mm
Maximum Limit: 0.06 mm

NOTE:
• If the oil clearance is greater than maximum limit, measure the
crank journals, cylinder block crank journal bore diameters DEM000143-00136

and crankshaft bearing center thickness, following the

procedure given below.
Replace any part which will not conform to the
specifications.
As an alternative method, when undersized bearings are
available as replacement parts, machine the crank journal
in such a way that the following formula given below may
be satisfied.
Measured cylinder block crank journal bore diameter –
(Measured crank journal diameter + Undersized bearing
center thickness to be used ✕ 2) = 0.004 - 0.028 mm

Measurement of crank journal diameter

1. Measure the crank journal diameter of the crankshaft in four
directions for each crank journal, 90 degrees spaced, at those Y
points indicated in the right figure. AB
2. The greatest value among the measured diameters is regarded X X
as the crank journal diameter.
Specified Crank Journal Diameter: Y
10 10 10 10
EF 41.976-42.000 mm 6 6 6 6

ED,EJ 45.976-46.000 mm

DEM00144-00137

Measurement of cylinder block crank journal bore diameter

1. Perform the measurement at the two points shown in the
figure.
2. The smaller value among the measured diameters is regarded 15˚
as the cylinder block crank journal bore diameter.
A B
Specified Cylinder Block Crank Journal Bore Diameter:

EF 46.000-46.024 mm
ED,EJ 50.000-50.024 mm
4 4 5 5 5 5 4 4

DEM00145-00138
 B2–41
CAUTION:
• If the classification that has been determined by the
measured value differs from the code attached to the part,
be sure to carefully select the bearing.
• Since undersized bearings are available, the crank journals
of a crankshaft which will not meet the specification can be
machined according to the undersized journals, referring to
the table below.
• When some parts only are replaced, the replacement
should be done only when the classification matches with
each other.

Crank journal code No.

ED & EJ
Crank journal code No. Crank journal diameter (mm)
1 45.976 - 45.984
2 45.985 - 45.992
3 45.993 - 46.000 No. 4 crank journal code No.
No. 3 crank journal code No.
No. 2 crank journal code No.
EF No. 1 crank journal code No.
Crankpin code No. Crankpin diameter (mm)
DEM00147-00139
1 41.976 - 41.984
No. 1 cylinder
2 41.985 -41.992 block crank journal
3 41.993 - 42.000 bore code No.
No. 2
No. 3
Cylinder block crank journal bore code No. No. 4
ED & EJ
Cylinder block crank Cylinder block crank journal bore
journal bore code No. diameter (mm)
4 50.000 - 50.008
DEM00148-00140
5 50.009 - 50.016
6 50.017 - 50.024

EF Identification color
Connecting rod big Connecting rod big end bore diameter
end bore code No. (mm)
4 46.000 - 46.008
5 46.009 - 46.016
6 46.017 - 46.024

DEM00149-00141

Crankshaft bearing selection code No.

Crankshaft bearing Crankshaft bearing Crankshaft Crank journal
code No. center thickness code No.
(Identification color) (mm)
Cylinder block 1 2 3
3 (Brown)
4 5 4 3
4 (Black) Cylinder block
crank journal 5 6 5 4
5 (Blue) bore code No.
6 7 6 5
6 (Pink)
7 (Purple)
B2–42
INSPECTION
Crank shaft
1. Check the main journals and bearings for pitting or scratches.
If the main journals exhibits damage, repair or replace the
crankshaft.
If the main journal bearings are damaged, replace the main
journal bearings.

DEM00150-00142

2. Support the both ends of the crankshaft with a V-block. Measure

the crankshaft runout with a dial gauge at No. 3 journal.
Allowable Limit of Runout: 0.06 mm

NOTE:
• The allowable limit of bend is 0.03 mm

If the runout exceeds the allowable limit, replace the

crankshaft.

DEM00151-00143

Crankshaft bearing & Connecting rod bearing

Check the bearings for pitting or scratches.
If the bearings exhibits damage, replace the bearing.

DEM00152-00144

Cylinder block
1. Inspection of top surface of cylinder block
Using a precision straightedge and a thickness gauge, check
the surface contacting the cylinder head gasket for warpage in
the six directions as shown in the figure.
Maximum Warpage: 0.08 mm

If the warpage exceeds the allowable limit, replace the cylinder

block or reface the upper gasket surface of the cylinder block,
referring to the following cylinder block height as a limit.
Cylinder Block Height:
DEM00153-00145
STD: EJ & ED : 236 mm
EF : 220 mm
Minimum Height:
STD: EJ & ED : 235.67 mm
EF : 219.67 mm

DEM00154-00146
 B2–43
2. Measurement of cylinder bores
(1) Measure the bore diameter of each cylinder at the six
points shown in the right figure. Ensure that the difference
between the maximum and minimum bore diameters of
each cylinder is within 0.03 mm.
Specified Cylinder Bore Diameter:

EF 068.000 - 68.030
ED 066.600 - 66.630
EJ 072.000 - 72.030
DEM00155-00147
If the difference between the maximum and minimum
values exceeds 0.03 mm, perform boring and/or honing for
the cylinder bore in accordance with the oversized piston.

3. Inspection of piston-to-cylinder bore clearance

(1) Calculate the piston-to-cylinder bore clearance based on h
the cylinder bore diameter and the piston outer diameter
that were measured in Step 2.
(2) Measurement of piston diameter
Measure the piston outer diameter horizontally at a point h
from the lower end of the piston at right angles to the piston
pin. DEM00156-00148
Specified Piston Outer Diameter:
Engine type Specified piston outer Diameter h specification

EF 067.975 - 68.005 mm 8.0 mm

ED 066.550 - 66.580 mm 13.5 mm
EJ 071.965 - 71.995 mm 13.0 mm

(3) Calculation of piston-to-cylinder bore clearance

Subtract the measured piston outer diameter from the
measured cylinder bore diameter.
Piston-to-Cylinder Bore Clearance:
EF : Specified Value: 0.015 ~ 0.035 mm
Allowable Limit: 0.10 mm
ED : Specified Value: 0.040 ~ 0.060 mm
Allowable Limit: 0.11 mm
EJ : Specified Value: 0.025 ~ 0.045 mm

If the piston-to-cylinder bore clearance exceeds the

allowable limit, perform boring and/or honing for the
cylinder bore in accordance with the oversized piston.
4. Boring and honing of cylinder bore
NOTE:
• When the cylinder is bored, all cylinders should be
bored at the same time.
• As for piston and piston rings, use oversized piston and
piston rings.

(1) Determining cylinder finishing diameter

1 Measure the diameter of the oversized piston to be used,
using a micrometer.
B2–44
(2) Hone the cylinder after the boring.
q Bore the cylinder, leaving a honing allowance of 0.02 mm.
w Hone the cylinder.
Honing Angle: 35° ± 5°
Surface Coarse Degree: 1 - 4Z

[Reference]
• The table below shows the cylinder bore diameter when
oversized pistons are used.
• However, after the diameter of the replacement piston
has been measured, perform the finishing in accordance
DEM00157-00149
with the piston diameter.
mm
EF Kind Piston outer diameter Cylinder bore
STD 67.965 - 67.995 68.000 - 68.030
0.25 68.215 - 68.245 68.250 - 68.280
0.50 68.465 - 68.495 68.500 - 68.530
mm
ED Kind Piston outer diameter Cylinder bore
STD 66.555 - 66.585 66.600 - 66.630
0.25 66.805 - 66.835 66.850 - 66.880
0.50 67.055 - 67.085 67.100 - 67.130
mm
EJ Kind Piston outer diameter Cylinder bore
STD 72.000 - 72.030 71.695 - 71.630
0.25 72.250 - 72.280 72.215 - 72.245
0.50 72.500 - 72.530 72.465 - 72.495

(3) Measure the bore diameter of each cylinder at a position

shown in the right figure. Record the measured values.
NOTE:
• This measurement should be conducted at point 45
mm measured from the upper surface of the cylinder
block. Also, the measurement should be performed in a
direction perpendicular to the crankshaft.

DEM00158-00150

5. Removal of cylinder ridges

If ridges are formed at the upper parts of the cylinder bores,
use a ridges reamer to remove the ridges.

DEM00159-00151
 B2–45
INSPECTION OF PISTONS
1. Inspection of fit between piston and piston pin
Try to move the piston back and forth on the piston pin. If any
movement is felt, inspect the piston and piston pin clearance.
NOTE
• When the piston is moved back and forth on the piston
pin, you may encounter hard movement. However, if the
piston moves smoothly without any binding, this fitting of
the piston is normal.

2. Removal of piston rings DEM00157-00149

NOTE
• Arrange the removed piston rings in order so that their
installation positions may be known readily.
• Do not expand the piston ring unnecessarily beyond the
required extent.

(1) Remove the piston rings No. 1 and No. 2 using a piston ring
expander.
(2) Remove the oil ring side rails by hand.
(3) Remove the oil ring expander by hand.

3. Cleaning of pistons DEM00157-00149

(1) Remove the carbon deposits from the piston top, using a
gasket scraper or the like.
NOTE
• Be very careful not to scratch the piston.

(2) Clean the piston grooves with a broken piston ring or a

groove cleaning tool.
NOTE
• Be very careful no to scratch the piston.

4. Inspection of pistons
Visually inspect the piston for cracks, damage or seizure.
DEM00157-00149
Replace the piston, if necessary.
5. Measurement of piston diameter
(1) Measure the piston outer diameter horizontally at a point
13.5 mm from the lower end of the piston at right angles to
the piston pin.
(2) Calculation of piston-to-cylinder bore clearance Subtract
the measured piston outer diameter from the measured h
cylinder bore diameter. Ensure that this piston-to-cylinder
bore clearance is less than 0.11 mm.
Piston-to-Cylinder Bore Clearance
Kind Specified Valve Allowable limit
EF 0.015~0.035 mm 0.10 mm
ED 0.040~0.060 mm 0.11 mm
h: EF 8.0mm
EJ 0.025-0.045 mm –
ED 13.5mm
If the piston-to-cylinder bore clearance exceeds the allowable EJ 13.0mm
limit, perform boring and honing on the cylinder bores so that
the cylinder bore diameter may match with the oversized DEM00157-00149

piston.
However, when the cylinder bore diameter exceeds below
diameter, replace the cylinder block.
EF 068.530 mm
ED 067.130 mm
EJ 072.530 mm
B2–46
6. Inspection of piston ring groove side clearance
Measure the side clearances of the piston rings No. 1 and No.
2 over the entire periphery of each groove, using a thickness
gauge.
The maximum measured value is regarded as the piston ring
side clearance.

DEM00157-00149

Piston ring side clearance

ITEM Specified value (mm) Allowable limit (mm)
EF ED EJ
Compression ring No. 1 0.03 ~ 0.07 0.03 - 0.07 0.035 ~ 0.08 0.12
Compression ring No. 2 0.02 ~ 0.06 0.02 - 0.06 0.02 ~ 0.06 0.11

Replace the piston ring and/or piston so that the piston ring side
clearance may become less than the allowable limit.
NOTE:
• When replacing the piston rings, a set of piston rings for one
cylinder should be replaced.

7. Inspection of piston ring end gap

(1) Apply engine oil to the cylinder walls.
(2) Insert the piston rings into the cylinder bore.
(3) Using a piston, push down the piston ring to a point 45 mm
measured from the cylinder block upped surface.

DEM00158-00150

(4) Measure the piston ring end gap, using a thickness gauge
or a feeler gauge.

DEM00159-00151
 B2–47
Piston ring end gap
Engine Type EF ED EJ EF ED EJ

Item Specified value mm Allowable limit mm

Compression ring No. 1 0.20 ~ 0.30 0.20 ~ 0.35 0.20 ~ 0.30 0.65
Compression ring No. 2 0.30 ~ 0.45 0.40 ~ 0.55 0.50 ~ 0.65 0.65
Oil ring 0.20 - 0.60 0.15 - 0.50 1.0

If the piston ring end gap exceeds the allowable limit, a set of piston rings for one cylinder should be replaced.

8. Inspection of piston-to-piston pin oil clearance

Interpose the big end of the connecting rod between V-blocks
on a surface plate. Measure the play while moving the piston,
as indicated in the right figure.
Piston-to-Piston Pin Clearance
STD : 0.005 - 0.011 mm
Limit : 0.05 mm

If the oil clearance does not conform to the specification,

replace the piston and piston pin. (There are no replacement
parts for the piston only nor the piston pin only.)
DEM00161-00149

9. Disassembly of piston and connecting rod

Use the following SSTs for the disassembling operation.
SST: 09221-87202-000
09221-87207-000

(1) Set the SST to the piston as shown in the right figure.

DEM00166-00157

(2) When measuring oil clearance after disassembling

q Measure the diameter of the whole circumference at the
positions A and B indicated in the right figure. The minimum
dimension should be the piston pin hole diameter.
A B
Specified Value: 18.002 - 18.005 mm
w Measure the diameter of the whole circumference at
the positions A and B indicated in the right figure. The
maximum dimension should be the piston pin outer
diameter.
Specified Value: 17.994 - 17.997 mm 8 8
Unit: mm
DEM00161-00152
B2–48
e Calculate the oil clearance.
If the oil clearance does not conform to the specification,
replace the piston and piston pin. (There are no replacement
A B
parts for the piston only nor the piston pin only.)

8 8

Unit: mm

DEM00162-00153

NOTE:
• Prior to this operation, remove the spacer 09221-87202-000
in advance.

(3) Install the connecting rod in the following SST as shown in

the right figure.
NOTE:
• Be sure to insert the shorter SST into the base side
SST: 09221-87207-000

(4) Press off the piston pin, using a hydraulic press.

DEM00167-00158

10. Inspection of connecting rods

(1) Visually inspect the connecting rods for damage or
cracks.
(2) Check the connecting rod for bend and twist, using a
connecting rod aligner.
Maximum Bend: 0.05 mm
Maximum Twist: 0.05 mm

If the bend and/or twist is greater than the maxi-

mum limit, replace the connecting rod assembly.
DEM00168-00159

11. Inspection of piston pin-to-connecting rod interference fit

(1) Measure the outer diameter of the piston pin contacting
with the connecting rod, using a micrometer.
Specified Piston Pin Diameter: 17.994 - 17.997 mm

DEM00169-00160

(2) Measure the inner diameter of the connecting rod, using a

bore dial gauge.
Specified Connecting Rod Inner Diameter:
ED, EJ : 17.953 - 17.979 mm
EF : 17.960 ~ 17.980 mm

(3) Determine the interference fit by subtracting the outer

diameter of the piston pin from the inner diameter of the
connecting rod.
Interference Fit: ED, EJ : 0.015 ~ 0.044 mm
EF : 0.014 ~ 0.037 mm DEM00170-00161
 B2–49
If the interference fit does not conform to the specification,
replace the connecting rod or piston. (There are no
replacement parts for the piston pin only.)

12. Assembly of piston and connecting rod

Use the following SSTs for the assembling operation.
SST: 09221-87202-000
09221-87207-000

(1) Install the piston pin to the following SST in a way shown in
the right figure.
DEM00171-00162
SST: 09221-87202-000

(2) Install the piston and connecting rod in the SST in a way
shown in the right figure. Insert the SST with the piston pin Front mark
installed into the piston pin hole. (upper)
NOTE:
• The piston and connecting rod should be assembled in
such a way that the piston front mark and connecting
rod front mark come in the same direction.
• Prior to this operation, install the spacer 09221-87207-
000 in advance.
DEM00172-00163
(3) Press the piston pin into the piston and connecting rod,
using a hydraulic press.
(4) Remove the piston and connecting rod assembly
from the SST. Remove the SST from the piston pin.

Rear oil seal retainer

Replacement of rear oil seal
1. Removal of rear oil seal
Remove the rear oil seal from the rear oil seal retainer, using
a pin punch.
NOTE:
• Be very careful not to damage the oil seal retainer.

DEM00173-00164

DEM00174-00165
B2–50
Oil pan
Visually inspect the oil pan for damage or cracks.
Replace the oil pan, as required.

DEM00175-00166

Driveplate/Flywheel
Inspect the driveplate for cracks or damage.
Inspect the ring gear for damage.
Replace the driveplate if it exhibits defects.
CAUTION:
• Never use any bolt other than the specified bolts.

Oil pressure switch

For checking and replacement procedure, refer to the B8 section.
SST
Knocking sensor
For checking and replacement procedure, refer to the B8 section. DEM00176-00167

Oil filter
For checking and replacement procedure, refer to the B5 section.
 B2–51
ASSEMBLY OF CYLINDER BLOCK
NOTE:
• The cylinder block is furnished along with the pistons as a
set.
• Hence, make sure that each piston is installed in the mated
cylinder bore.
[Reference]
• Those numerals stamped at the positions as indicated in
the right figure are the piston selection code No. for each
cylinder.
DEM00179-00168
The table below indicates those sizes corresponding to each
selection code No.
Unit: mm
EF Code Cylinder bore diameter Piston outer diameter
Engine 1 68.000 - 68.010 67.975 - 67.985
2 68.011 - 68.020 67.986 - 67.995
3 68.021 - 68.030 67.996 - 68.005
Unit: mm
ED Code Cylinder bore diameter Piston outer diameter
Engine 1 66.600 - 66.610 66.550 - 66.560
2 66.611 - 66.620 66.561 - 66.570
3 66.621 - 66.630 66.571 - 66.580
Unit: mm
EJ Code Cylinder bore diameter Piston outer diameter
Engine 1 72.000 - 72.010 71.965 - 71.975
2 72.011 - 72.020 71.976 - 71.985
3 72.021 - 72.030 71.986 - 71.995

REPLACEMENT OF CYLINDER BLOCK

1. Wash the cylinder block, using cleaning solvent with a soft
brush.
2. Dry them using compressed air.
WARNING:
• When you use compressed air, be sure to protect your
eyes, wearing safety goggles.

3. Assembling Parts at Upper Surface of Cylinder Block

(1) Oil orifice
Press the oil orifice into the section A as indicated in Fig. 1,
unit it is recessed 1.2 to 2.0 mm from the upper surface of
the cylinder block.

NOTE:
• Never reuse the orifice.

DEM00179-00000
B2–52
(2) Pin ring
Press the pin ring into the section B as indicated in Fig. 1,
until the amount of protrusion becomes 4.5 to 5.5 mm.
NOTE:
• Never reuse the pin ring.

DEM00179-00168

(3) Plug tight (EF & ED only)

Press the plug tight into the Section C as indicated in fig.
1 until is recessed 1.0 to 2.0 mm from the upper surface of
the sylinder block.
NOTE: 1.0~2.0 mm
• Coating liquid gasket all around with Three Bond.
(TB 1386D)

DEM00179-00168

4. Assembly Parts at Front and Rear Sides

(1) Install the straight pin at the section A (two points) as indicated
in the right figure, until protrusion amount becomes 6.5 ~ 8.5
mm.
(2) Press the straight pin into the section B (four points) as
indicated in the right figure, until the amount of protrusion
becomes 6.5 to 8.5 mm.

DEM00179-00168
 B2–53
(3) Press the straight pin into section C (two points) as indicated
in the right figure, until the amount of protrusion becomes
5.5 to 7.5 mm.

(4) Press the ball into section D (two places) until it is recessed
0 ~ 1 mm from upper surface of cylinder block.
0~1mm

DEM00180-00000

5. Assembling Parts at Side

(1) Install the union bolt for installing oil filter.

Fr


DEM00180-00000

6. Assembling Part at Underside

Install the stud bolt at the asterisked (*) section (two points).

DEM00180-00000
B2–54
[Reference]
• Select the crankshaft bearing, connecting rod bearing
and piston, as required, referring to the table on page
B2–37, B2–40, B2–45, B2–48.

DEM00180-00000

1. Installation of crankshaft
(1) Install the crankshaft bearings to the cylinder block and
crankshaft bearing caps.
NOTE:
• Do not touch the front and back surfaces of each
bearing.
• Be sure to hold the bearing at its edge surfaces.

DEM00181-00169

(2) Lubricate the surface of each bearing with engine oil.

NOTE:
• Never apply engine oil to the crankshaft bearing caps.

DEM00182-00170

(3) Install the crankshaft in the cylinder block.

DEM00183-00171

(4) Apply engine oil to the thrust washers. With the side having
the oil groove facing toward the crankshaft side, insert
each thrust washer between the crankshaft main journal
No. 3 and the cylinder block.

DEM00184-00172
 B2–55
(5) Apply engine oil to the crankshaft main journal sections.
NOTE:
• Care must be exercised to ensure that no oil flows into
the bearing cap attaching bolt holes.

DEM00185-00173

(6) Install the crankshaft bearing caps with the arrow marks
facing toward the oil pump side and also in the numerical
sequence.
(7) Thinly apply engine oil to the crankshaft bearing cap bolts.
Tighten the bolts to the specified torque over two or three
stages in the sequence shown in the right figure.
Tightening Torque: 59.0 ± 6.0 N·m

DEM00186-00174

2. Assembly and installation of piston

Identification Color: EF ED EJ
Compression ring No. 1: Green Blue Orange
Compression ring No. 1: Green Blue Sky-Blue
Oil ring spacer: Green Blue Pink

DEM00187-00175

(1) Install the oil ring spacer expander in the oil ring groove.
Ensure that the expander end may not line up with the thrust
direction nor with the axial direction.
NOTE:
• Do not expand the spacer expander to an extent that is
more than necessary.

(2) Fit the upper rail into position in such a manner that it is
wound up while pushing the edge section of the oil ring
spacer expander with your thumb.

DEM00188-00176

NOTE:
• Ensure that the rail end is deviated 90 degrees to the left
from the end of the oil ring spacer expander.
• Do not expand the rail to an extent that is more than
necessary.

DEM00189-00177
B2–56
(3) Fit the lower rail into position in such a manner that it is
wound up.
NOTE:
• Ensure that the rail end is deviated 90 degrees to the right
from the end of the oil ring spacer expander.
• Do not expand the rail to an extent that is more than
necessary.
• Make sure that the oil ring can be rotated smoothly.

DEM00190-00178

(4) Install the compression ring No. 2 with the stamped mark
facing upward, using a piston ring expander.
NOTE:
• Do not expand the piston ring to an extent that is more than
necessary.

(5) Install the compression ring No. 1 with the stamped mark
facing upward, using a piston ring expander.

DEM00191-00179

(6) Position the piston rings so that each ring end may come at
the respective points as indicated in the right figure.
NOTE:
• It is not necessarily required to follow strictly the right figure.
However, be sure that the ring end is not lined up with the
thrust direction. Also, each ring should be deviated about
120 to 180 degrees from the adjacent ring.

DEM00192-00180

(7) Install the connecting rod bearings on the connecting rod

and connecting rod cap, making sure that your fingers will
not touch the front and back surfaces of the bearings.

DEM00193-00181

(8) Cut an appropriate vinyl hose to a suitable length. Fit the

vinyl hose to each connecting rod bolt sections.

DEM00194-00182
 B2–57
(9) Apply engine oil to the piston rings, piston pins, connecting
rod bearings, cylinder walls and crankpin journals.
NOTE:
• Apply a small amount of engine oil to each cylinder bore.
• Apply a small amount of engine oil to each piston ring
section.

DEM00196-00184

(10) Compress the piston rings by means of the piston ring

compressor SST, making sure that the piston ring ends will
not move during the installation.
SST: 09217-87001-000

(11) Push the piston by hand into the cylinder bore with the front
mark facing toward the oil pump side.
NOTE:
• Be very careful to avoid damaging the connecting rod
bearings during the installation.
• Care must be exercised to ensure that the crankpin journal
DEM00196-00184
is not scratched by the connecting rod.

(12) Push the piston with a suitable tool, until the connecting rod
reaches the crankpin journal.
(13) Apply engine oil to the bearing surface of each connecting
rod bearing.
NOTE:
• Do not touch the bearing front surface.

(14) Remove the vinyl hoses which were attached to the

connecting rod bolt sections.

(15) Install the connecting rod cap with the front mark facing DEM00197-00185

toward the oil pump side.

DEM00198-00186

(16) Thinly apply engine oil to the connecting rod cap

attaching nuts. Tighten the nuts to the specified torque
evenly over two or three stages.
Tightening Torque: 36.0 ± 6.0 N·m

NOTE:
• Prevent the crankshaft from turning, using the following
SST.
SST: 09210-87701-000

(17) Perform the operations described in the steps (1) through

DEM00199-00187
(16) for each cylinder.
B2–58
3. Installation of oil pump
(1) Turn the crankshaft, until the No. 1 cylinder is set to the top
dead center.
(2) Apply engine oil to the inner surface of the oil seal.
(3) Insert a new O-ring into the groove section of the pump
cover. Secure the O-ring by holding it at the three projection
sections at the cover side.
NOTE:
• Embossed marks having a 5 mm diameter have been
provided at the holding positions.

DEM00200-00188

(4) With the crankshaft’s two-flat sections for driving the oil
pump aligned with the oil pump, install the oil pump to the
cylinder block with a new gasket interposed.
(5) Tighten the oil pump attaching bolt to the specified torque.
Tightening Torque: 19.0 ± 3.8 N·m

DEM00201-00189

4. Installation of rear oil seal retainer

(1) Apply engine oil to the inner surface of the oil seal.
(2) Apply Three Bond 1207F or equivalent to the flange surface
in such a way that the sealing may be formed without any
discontinued spot, in a size equivalent to a 3 mm to 4 mm
diameter, following the procedure given in the right figure.

DEM00202-00190

(3) With the rear oil seal retainer aligned with the knock pin,
install the rear oil seal retainer to the cylinder block.
(4) Tighten the attaching bolt to the specified torque.
Tightening Torque: 12.5 ± 2.5 N·m

DEM00203-00203

5. Install the oil pump strainer with a new gasket interposed.

Tightening Torque: 8.0 ± 1.6 N·m

DEM00204-00192
 B2–59
6. Installation of oil pan
(1) Thoroughly remove any foreign matters (grease and water,
etc.) from both the oil pan attaching surface of the cylinder
block and the cylinder block attaching surface of the oil
pan.
(2) Apply Three Bond 1207F or equivalent to the flange surface
in such a way that the sealing may be formed without
any discontinued spot, in a size equivalent to a 3.5 ~ 4.5
diameter, following the procedure given in the right figure.

DEM00000-00193

7. Install the rear end plate.

Tightening Torque: 21 ± 4.2 N·m

DEM00221-00191

(3) Install the oil pan to the cylinder block.

(4) Tighten the oil pan attaching nuts and bolts to the specified
torque over two or three stages.
Tightening Torque: 8.0 ± 1.6 N·m

DEM00206-00194

8. Installation of drive plate

(1) Assemble the drive plate aligning it with the knock pin of
the crankshaft.
(2) Temporarily tighten the drive plate attaching bolts to the
following torque in the sequence indicated in the next t
step. q r
Tightening Torque: 25 - 34 N·m
e w
NOTE: y
• Prevent the crankshaft from turning at the ring gear section, SST
using the following SST.
DEM00207-00195
SST: 09210-87701-000
(3) Tighten the flywheel (drive plate) attaching bolts to the
specified torque in the sequence indicated in the right
figure.
Tightening Torque: 44.0 ± 5.0 N·m
t
q r
NOTE:
• Prevent the crankshaft from turning at the ring gear section,
e w
using the following SST.
SST: 09210-87701-000 y
SST

DEM00208-00196
B2–60
9. Check the flywheel runout. (For checking procedure, refer to
the page B2–35.)
10. Install the cylinder head. (For installation procedure, refer to the
“CYLINDER HEAD” section.)
11. Install the timing belt. (For installation procedure, refer to the
page B2–5.)

DEM00209-00197
 B2–61
ENGINE TUNE-UP
ENGINE COOLANT
Refer to the B6/B1 section.
RADIATOR CAP
Refer to the B1 section.
DRIVE BELT
Refer to the B1 section.
ENGINE OIL
Refer to the B1 section.
SPARK PLUG
Refer to the B1/B10 section.
VALVE CLEARANCE
Refer to the B1 section.
IGNITION TIMING
Refer to the B1 section.
BATTERY
Refer to the B11 section.
CHARCOAL CANISTER
Refer to the B1/B9 section.
FUEL LINE & CONNECTION
Refer to the B1 section.

LEM00210-00000

COMPRESSION CHECK
ST
NOTE:
• After completion of the engine tune-up, if the engine exhibits FLASHER
lack of power, excessive oil consumption or poor fuel
economy, measure the cylinder compression pressure.
IG

1. Warm up the engine thoroughly. EFI

2. Turn OFF the ignition key switch. HORN

3. Remove the fuel pump relay from the relay box.
F/P

Fuel pump relay position

LEM00211-00198

4. Remove the spark plug from the cylinder head. (For removal
procedure refer to the IG section.)
5. Measurement of cylinder compression pressure
NOTE:
• Perform the measurement in the shortest possible time.
• Crank the engine for the same duration for each cylinder.
• Always use a fully charged battery so that at least a revolution
speed of 400 rpm is attained.

LEM00246-00245
B2–62
(1) Insert a compression gauge into the spark plug hole.
(2) Depress the accelerator pedal fully.
(3) While cranking the engine, measure the compression
pressure.

TYPE Compression Pressure Difference between cylinder

EF 1078 - 1373 Kpa 147Kpa at 400 rpm
ED 1590 - 1650 Kpa 147Kpa at 400 rpm
EJ 1579 - 1755 Kpa 147Kpa at 400 rpm

MEM00213-00200

(4) Repeat the step (1) through (3) for each cylinder.
(5) If the compression of one or more cylinders is low, pour a
small amount of engine oil into that cylinder through the
spark plug hole and repeat the steps (1) through (3) for the
cylinder with low compression.
• If adding oil helps the compression to improve, chances
are that the piston rings and/or cylinder bores are worn
or damaged.
• If the pressure remains low after the operation described
in the step (5) has been performed, the valve may be
sticking or seated improperly, or there may be leakage
past the gasket. MEM00214-00201

6. Install the spark plug to the cylinder head, (Refer to the B10
section.)
7. Install the fuel pump relay to the relay box.

MEM00215-00000
 B2–63
CHECKING OF CO/HC CONCENTRATIONS
Preparation to be made prior to check of CO/HC concentrations.
• Apply the parking brake fully.
• Check the ignition timing.
• Check the idle speed.
• Warm up the engine thoroughly. (continue engine warm-up for another 10 minutes after the fan motor has started
its operation.)
• All accessory switches are turned OFF.
• The air cleaner element is installed.
• All pipes and vacuum hose are connected.
• Ensure that the intake system exhibits no air leakage.
• Ensure that the exhaust system exhibits no gas leakage.
• On the automatic transmission vehicle, the shift lever is placed in the [N] or [P] range.
• On the manual transmission vehicle, the shift lever is placed in the neutral position.
• Position the steering wheel to straight-ahead direction.
• Prior to the use, be sure to prepare the CO/HC meter, following the instructions of the manufacturer.
NOTE:
• This check is only for determining whether or not the idle HC/CO emission complies with the specified
values.
Specified Values:

TYPE CO less than: HC less than:

EF 0.2% 200 ppm
ED 0.2% 200 ppm
EJ 0.2% 200 ppm

If the CO/HC concentrations will not conform to the specified values, check the A/F control system and/or replace
the exhaust manifold.

MEM00216-00000

CHECKING OF A/F (Air/Fuel) CONTROL SYSTEM

NOTE:
• Since the A/F adjustment is performed by a computer, you are not able to perform this adjustment. Your
check ensures that the computer control is being properly performed. Your check is not for performing the
adjustment.

1. Connect the test terminal and the ground terminal with a jumper wire of the diagnosis connector.
2. While keeping the engine revolution speed at a speed in excess of 1200 rpm (aiming at a speed of around 3000
rpm), measure the voltage between the terminal VF of the diagnosis connector and the body.
3. Check that the measured value changes between 0 V and 5 V.
4. If the voltage described in Step 3 above is not obtained, it means that the computer control is not functioning
properly. Perform the check of EFI ECU, referring to the EF section.

MEM00217-00000
B2–64
Ä ED-VE/EF-VE
SERVICE SPECIFICATIONS
Engine type ED-VE EF-VE
Type Petrol, 4 cycle
Cylinder No. 3-cylinder-in-line
Combustion chamber type Pent roof type
Valve mechanism DOHC, Directly driven by camshaft
Bore × stroke 66.6 mm × 81.0 mm 68 × 60.5 mm
Total displacement 847 cc 659 cc
Compression ratio 10.0
Compression pressure (at 400 rpm) 1363 - 1538 kPa 1275 ~ 1538 kPa
2
(13.9 - 15.7 kg/cm ) (13.0 ~15.7)
Maximum power (kW/rpm) 39 / 6000 rpm 35 / 7200 rpm
Maximum torque (Nm/rpm) 76 / 4000 rpm 58 / 4400 rpm
Number of piston ring Compression ring 2
Oil ring 1
Valve timing Intake Open BTDC 41– -4°
Close A.B.D.C 9 – 54°
Exhaust Open B.B.D.C 44°
Close ATDC 6°
Valve clearance Intake (Cold) 0.18 ± 0.05 mm
Exhaust (Cold) 0.25 ± 0.05 mm
100
Idling speed STD 850 - 50

Blow-by gas recirculating system Closed type

MEM00218-00000
 B2–65
ED-VE EF-VE
Timing belt Belt tension (When the midpoint of
the belt at the tension side is pushed 5 mm) 198 ± 100 (N)
Camshaft Camshaft journal outer dia. (IN) No. 1 25.979 - 25.995 mm
No. 2, No.3, No. 4 22.979 - 22.995 mm
(EX) No. 1 28.979 - 28.995 mm
Camshaft bearing cap inner dia. (IN) No. 1 26.032 - 26.052 mm
No. 2, No. 3, No. 4 23.032 - 23.052 mm
(EX) No. 1 29.020 - 29.041 mm
Oil clearance No. 1 (IN) 0.037 - 0.073 mm
(EX) 0.025 - 0.062 mm
No. 2, No. 3, No. 4 (IN, EX) 0.037 - 0.073 mm
Camshaft thrust clearance (IN, EX) 0.04 - 0.10 mm
Cam lobe height IN 38.25 mm
EX 38.1 mm
Camshaft for runout 0.03 mm
Cylinder Warpage Cylinder block side 0.1 mm
head Intake manifold side 0.1 mm
Exhaust manifold side 0.1 mm
Cylinder head height 103.0 mm
Valve seat angle IN 45°
EX 45°
Valve lifter outer dia. 27.965 - 27.975 mm
Inner dia. of the cylinder head valve lifter bore 28.000 - 28.021 mm
Valve lifter oil clearance 0.025 - 0.056 mm
Valve Valve stem dia. IN 4.965 - 4.980 mm
EX 4.955 - 4.980 mm
Inner dia. of valve guide bush 5.000 - 5.012 mm
Valve stem oil clearance IN 0.020 - 0.047 mm
EX 0.030 - 0.057 mm
Valve length IN 79.15 mm
EX 79.8 mm
Valve face angle (IN, EX) 45.5°
Valve stock thickness (IN, EX) 1.0 ± 0.2 mm
Valve recession IN 4.0 mm
EX 4.0 mm
Width of the contact surface of valve seat 1.4 ± 0.5 mm
Valve stem oil seal installed position IN 14.2 ± 0.8 mm
EX 11.2 ± 0.8 mm

Valve Free length 37.9 mm

spring Valve spring for squareness 1.3 mm
Minimum fension/installation height 143.2 ± 8.63 N/32.0 mm
DEM00219-00000
B2–66
ED-VE EF-VE
Cylinder block Surface contacting the cylinder head gasket for warpage 0.08 mm
Cylinder block height 235.67 ~ 236.33 mm 219.67 ~ 220.03 mm
Cylinder bore dia. 66.600 ~ 66.630 mm 68.000 ~ 68.030 mm
Piston outer dia. 66.550 ~ 66.580 mm 67.975 ~ 66.005 mm
Piston-to-cylinder bore oil clearance 0.040 ~ 0.060 mm 0.015 ~ 0.035 mm
Crankshaft thrust clearance 0.02 - 0.22 mm
Connecting rod thrust clearance 0.15 - 0.25 mm
Width of big end of connecting rod in thrust direction 19.80 - 19.85 mm
Side width of crankpin journal 20.00 - 20.05 mm
Connecting Connecting rod big end bore dia. 43.000 - 43.024 40.0 ~ 40.02
rod
Crankpin dia. 39.976 - 40.000 36.976 ~ 37
Oil clearance between the crankpin journal and the 0.020 - 0.044 mm
connecting rod cap
Connecting rod for bend 0.05 mm
Crankshaft Crankshaft main journal dia. 45.976 - 46.000 41.976 ~ 42
Cylinder block main journal dia. 50.000 - 50.024 46.0 ~ 46.024
Oil clearance between the crankshaft main journal and 0.004 ~ 0.028
crankshaft bearing cap
Crankshaft for runout 0.05
Piston Piston pin outer dia. 17.994 ~ 17.997
Piston pin hole of piston dia. 18.002 ~ 18.005
Piston-to-piston pin oil clearance 0.005 ~ 0.011 mm
Connecting rod small end bore dia. 17.953 - 17.979 17.96 ~ 17.98
Connecting rod-to-piston pin interference fit 0.015 - 0.044 0.014 ~ 0.037
Piston ring groove side clearance No. 1 0.03 - 0.08 0.030 - 0.07
No. 2 0.02 - 0.06
Piston ring end gap No. 1 0.25 ~ 0.35 0.20 ~ 0.3
No. 2 0.40 ~ 0.55 0.30 ~ 0.45
Oil ring 0.15 ~ 0.50 0.20 ~ 0.60
Flywheel Flywheel for runout 0.10
DEM00220-00000
 B2–67
Ä EJ-VE
SERVICE SPECIFICATIONS
Engine type EJ-VE
Type Petrol, 4 cycle
Cylinder No. 3-cylinder-in-line
Combustion chamber type Pent roof type
Valve mechanism DOHC, DVVT
Bore × stroke 72 mm × 81.0 mm
Total displacement 989 cc
Compression ratio 10.0
Compression pressure 1363 - 1538 kPa (13.9 - 15.7 kg/cm2) at 400 rpm
Maximum output (kW/rpm) 45 / 6000
Maximum torque (Nm/rpm) 90 / 3600
Number of piston ring Compression ring 2
Oil ring 1
Valve timing Intake Open BTDC 43– -2°
Close A.B.D.C 17 – -62°
Exhaust Open B.B.D.C 44°
Close ATDC 6°
Valve clearance Intake (Cold) 0.18 ± 0.05 mm
Exhaust (Cold) 0.25 ± 0.05 mm
100
Idling speed STD 850 - 50

Blow-by gas recirculating system Closed type

MEM00115-00000
B2–68
Timing belt Belt tension (When the midpoint of the belt at the tension side is pushed 5 mm) 198 ± 100 N
Camshaft Camshaft journal outer dia. (IN) No. 1 25.979 - 25.995 mm
No. 2, No.3, No. 4 22.979 - 22.995 mm
(EX) No. 1 28.979 - 28.995 mm
Camshaft bearing cap inner dia. (IN) No. 1 26.032 - 26.052 mm
No. 2, No. 3, No. 4 23.032 - 23.052 mm
(EX) No. 1 29.020 - 29.041 mm
Oil clearance No. 1 (IN) 0.037 - 0.073 mm
(EX) 0.025 ~ 0.062 mm
No. 2, No. 3, No. 4 (IN, EX) 0.037 - 0.073 mm
Camshaft thrust clearance (IN, EX) 0.04 - 0.10 mm
Cam lobe height IN 39.25 mm
EX 38.1 mm
Camshaft for runout 0.03 mm
Cylinder head Warpage Cylinder block side 0.1 mm
Intake manifold side 0.1 mm
Exhaust manifold side 0.1 mm
Cylinder head height 103.0 mm
Valve seat angle IN 45°
EX 45°
Valve lifter outer dia. 27.965 - 27.975 mm
Inner dia. of the cylinder head valve lifter bore 28.000 - 28.021 mm
Valve lifter oil clearance 0.025 - 0.056 mm
Valve Valve stem dia. IN 4.965 - 4.98 mm
EX 4.955 - 4.970 mm
Inner dia. of valve guide bush 5.000 - 5.012 mm
Valve stem oil clearance IN 0.020 - 0.047 mm
EX 0.030 - 0.057 mm
Valve length IN 79.15 mm
EX 79.8 mm
Valve face angle (IN, EX) 45.5°
Valve stock thickness (IN, EX) 1.0 ± 0.2 mm
Valve recession IN 4.0 mm
EX 4.0 mm
Width of the contact surface of valve seat 1.4 ± 0.5 mm
Valve stem oil seal installed position IN 14.2 ± 0.8 mm
EX 11.2 ± 0.8 mm
Valve spring Free length 44.68 mm
Valve spring for squareness 1.6 mm
Minimum fension/installation height 143.2 ± 8.6 N/32.0 mm
DEM00116-00000
 B2–69
Component Item EJ-VE
Cylinder block Surface contacting the cylinder head gasket for warpage 0.08 mm
Cylinder block height 235.67 - 236.33 mm
Cylinder bore dia. 72.000 - 72.030 mm
Piston outer dia. 71.965 - 71.995 mm
Piston-to-cylinder bore oil clearance 0.025 - 0.045 mm
Crankshaft thrust clearance 0.02 - 0.22 mm
Connecting rod thrust clearance 0.15 - 0.25 mm
Width of big end of connecting rod in thrust direction 19.80 - 19.85 mm
Side width of crankpin journal 20.00 - 20.05 mm
Connecting Connecting rod big end bore dia. 43.000 - 43.024 mm
rod
Crankpin dia. 39.976 - 40.000 mm
Oil clearance between the crankpin journal and the connecting rod cap 0.020 - 0.044 mm
Connecting rod for bend 0.05 mm
Crankshaft Crankshaft main journal dia. 45.976 - 46.000 mm
Cylinder block main journal dia. 50.000 - 50.024 mm
Oil clearance between the crankshaft main journal and crankshaft bearing cap 0.004 - 0.028 mm
Crankshaft for runout 0.05 mm
Piston Piston pin outer dia. 17.994 - 17.997 mm
Piston pin hole of piston dia. 18.002 - 18.005 mm
Piston-to-piston pin oil clearance 0.005 - 0.011 mm
Connecting rod small end bore dia. 17.953 - 17.979 mm
Connecting rod-to-piston pin interference fit 0.015 - 0.044 mm
Piston ring groove side clearance No. 1 0.035 - 0.08 mm
No. 2 0.02 - 0.06 mm
Piston ring end gap No. 1 0.20 - 0.30 mm
No. 2 0.50 - 0.65 mm
Oil ring 0.15 - 0.50 mm
Flywheel Flywheel for runout 0.1 mm
DEM00117-00000
B2–70
SSTs
Shape Part number Part name Remarks

09210-87701-000 Fly wheel holder

09504-87501-000 Differential side bearing adjusting nut wrench

09202-87002-000 Valve cotter remover & replacer

09202-87002-0A0 Valve cotter attachment

09202-87702-000 Valve spring replacer

09202-87202-000 Valve sprig replacer body

09202-87201-000 Valve spring replacer pivot

09237-87201-000 Replacer

09707-87302-000 Spring bush remover & replacer

09221-87208-000 Exchange attachment shim

09032-00100-000 Oil pan seal cutter

09221-87207-000 Piston pin body remover & replacer

09221-87206-000 Piston pin remover & replacer

09608-87302-000 Axle hub & drive pinion bearing tool set

09217-87001-000 Piston replacing guide

MEM00220-00202
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
INTAKE SYSTEM B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
AIR CLEANER ..............................................................B3 - 1
C3
REMOVAL AND INSTALLATION ...........................B3 - 1 D1
THROTTLE BODY ........................................................B3 - 3
REMOVAL AND INSTALLATION ...........................B3 - 3 E1
INTAKE MANIFOLD GASKET......................................B3 - 5
REMOVAL AND INSTALLATION ...........................B3 - 5 E2
E3
F1
F2
F3
G1
G2
H1
I1
I2
I3
I4
J1
J2
J3
J4
J5
J6
K1
 B3–1
1 AIR CLEANER
1-1 REMOVAL AND INSTALLATION
NOTE
• The cylinder head cover is integral with the air cleaner case. The air cleaner element is directly assembled to
the air cleaner case integral type cylinder head cover.

1-1-1 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENT

M21E6019S20

(2) REMOVAL AND INSTALLATION PROCEDURES

Cap Sub-assy, air cleaner
Element Sub-assy, air filter

1-1-2 POINTS OF REMOVAL

(1) AIR CLEANER HOSE No.1
1. Remove the pivot from the grommet.
2. Turn the air cleaner connecting section 15$(30$.
3. Pull out the air cleaner hose.
CAUTION
• If the air cleaner hose is removed by pulling it, the pawl will
be worn severely, resulting in excessive play at the fitting
section.

M21E6033T10
B3–2
1-1-3 POINTS OF INSTALLATION
(1) AIR CLEANER ELEMENT SUB-ASSY
1. Install the cap to the air cleaner element.
CAUTION
• Care must be exercised that the element is not installed upside down.

(2) AIR CLEANER CAP SUB-ASSY

1. Place the air cleaner cap horizontally at the cylinder head cover side.
2. Insert the air cleaner cap into the throttle body side (until you feel a clonking).
3. Secure four clips.
 B3–3
2 THROTTLE BODY
2-1 REMOVAL AND INSTALLATION
WARNING
• Do not disconnect the water hose when the coolant is hot lest that you get scalded.

2-1-1 OPERATION BEFORE REMOVAL

1. Drain the coolant.
2. Remove the negative (-) terminal of the battery.
CAUTION
• It should be noted that the memory of the diagnosis, radio setting, etc. will be erased at the same time when
the negative (-) terminal of the battery is removed.

3. Disconnect the throttle cable (engine side). (A/T vehicles)

4. Remove the air cleaner cap subassembly.

Refer to Page B3 - 1.

2-1-2 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

a
g
h

f "
b "
e

c
27 d
"
" .

L21E6102S20

~:Non-reusable parts
Unit:N;m{kgf;cm}
(2) REMOVAL AND INSTALLATION PROCEDURES
Cable assy, acceleator, control

Hose Sub-assy, vacuum

B3–4
2-1-3 POINTS OF REMOVAL
(1) THROTTLE BODY
1. Remove the bolts of the throttle body.
2. Remove the throttle body upward. Make a space for removing the water hose clip and disconnect the water
hose.
(2) WATER HOSE
1. Apply cloth or the like during the operation, for the coolant will be leaking when the water hose is
disconnected.
2-1-4 INSPECTION
(1) THROTTLE BODY
1. There shall be no excessive play at the throttle shaft.
2. There shall be no restriction at each port.
3. The throttle valve should open or close smoothly.
4. There shall be no gap between the stop screw and lever when the throttle valve is fully closed.
2-1-5 POINTS OF INSTALLATION
(1) THROTTLE BODY GASKET
1. Clean the gasket installing surface of the throttle body and intake manifold. Install a new throttle body
gasket.
(2) THROTTLE BODY BRACKET
1. Install the throttle body bracket. Temporarily tighten the bolt (at the cylinder head side). Tighten the nut (at
the throttle body side) first, and then the bolt to the specified torque.
2. Install the earth wire to the throttle body bracket.
(3) ACCELERATOR CONTROL CABLE
1. Install the accelerator control cable. Adjust the play.
SPECIFIED VALUE: 1(5mm (Accelerator pedal play)

2-1-6 OPERATION AFTER INSTALLATION

1. Install the air cleaner cap sub-assy.
Refer to Page B3 - 1.

2. Install the throttle cable (at the engine side). (A/T vehicles)
3. Install the negative (-) terminal of the battery.
4. Fill the coolant.
5. Check if there is coolant leakage.
Refer to Page B3 - 1.
 B3–5
3 INTAKE MANIFOLD GASKET
3-1 REMOVAL AND INSTALLATION
WARNING
• Do not remove the radiator cap or drain plug when the coolant is hot.

3-1-1 OPERATION BEFORE REMOVAL

1. Drain the coolant.
2. Remove the negative (-) terminal of the battery.
CAUTION
• It should be noted that the memories of the diagnosis, radio setting, etc. will be erased at the same time when
the negative (-) terminal of the battery is removed.

3. Remove the air cleaner.

Refer to Page B3 - 1.

4. Remove the throttle body.

Refer to Page B3 - 3.

3-1-2 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

L21E6103S20

~:Non-reusable parts
Unit:N;m{kgf;cm}
(2) REMOVAL AND INSTALLATION PROCEDURES
B3–6
3-1-3 POINTS OF REMOVAL
(1) INTAKE MANIFOLD ASSY
1. Remove the intake manifold assy.
(1) Remove connectors, vacuum hoses, earth wire, etc.
(2) Remove the intake manifold assembly by removing the nuts.
CAUTION
• It must be noted that the coolant which remains inside the coolant passages of the cylinder head will flow out
when the intake manifold is removed.

3-1-4 POINTS OF INSTALLATION

(1) INTAKE MANIFOLD GASKET
1. Clean the gasket installing surface of the cylinder head and intake manifold.
2. Install a new intake manifold gasket.
(2) INTAKE MANIFOLD ASSY
1. Install the intake manifold assembly.
(1) Install the intake manifold assembly and tighten the nuts to the specified torque.
(2) Install the harness and connect the pressure sensor connector.
(3) VACUUM HOSE (To brake booster)
1. Install the vacuum hose.
CAUTION
• When installing the vacuum hose, care must be exercised
so that the hose is installed in the correct direction.
The “ENGINE " paint mark should face the engine
intake manifold side. If the paint has been erased, install
the hose in such a way that continuity exists from
the booster side to the intake manifold side by checking
the continuity.
• The installation should be performed in such a way that
the ENGINE " paint mark may face the vehicle upward.
• Connection at the booster side should be performed in
such a way that the paint line faces the vehicle upward. A11C5021ET10

• The vacuum hose should be inserted firmly to the

stopper surface. The clip should be installed in such a
way that the dimension A at the figure may become
2–5.5mm.

M21C7031ET10

A11C5022T10
 B3–7
3-1-5 OPERATION AFTER INSTALLATION
1. Install the throttle body.
Refer to Page B3 - 3.

2. Install the air cleaner.

Refer to Page B3 - 1.

3. Install the negative (-) terminal of the battery.

4. Fill the coolant.
5. Install the throttle cable (at the engine side). (mechanical A/T vehicles)
6. Check if there is coolant leakage.
Refer to Page B1 - 2.
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
EXHAUST SYSTEM B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
EXHAUST MANIFOLD GASKET..................................B4 - 1
C3
REMOVAL AND INSTALLATION ...........................B4 - 1 D1
EXHAUST PIPE ............................................................B4 - 3
REMOVAL AND INSTALLATION ...........................B4 - 3 E1
E2
E3
F1
F2
F3
G1
G2
H1
I1
I2
I3
I4
J1
J2
J3
J4
J5
J6
K1
 B4–1
1 EXHAUST MANIFOLD GASKET
1-1 REMOVAL AND INSTALLATION
WARNING
• Do not carry out operations while the exhaust manifold is still hot.

1-1-1 ITEMS TO BE PREPARED

Instrument

1-1-2 OPERATION BEFORE REMOVAL

1. Remove the front exhaust pipe.
Refer to Page B4 - 3.

1-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

"
. "
"
T: 13.03.9 {1354.0}

M21E6003S16

~:Non-reusable parts
Unit:N·m {kgf.cm}
(2) REMOVAL AND INSTALLATION PROCEDURES

Insulator Sub-assy, exhaust manifold heat

B4–2
1-1-4 POINTS OF REMOVAL
(1) Insulator Sub-assy, exhaust manifold
1. Remove the exhaust manifold insulator.
NOTE
• If it is difficult to remove, disconnect the clamp for the air conditioner hose or pipe to provide enough space for
the insulator removal.

1-1-5 POINTS OF INSTALLATION

(1) EXHAUST MANIFOLD GASKET
1. Clean the gasket installation surfaces of the cylinder head and exhaust manifold.
2. Install a new exhaust manifold gasket.
(2) EXHAUST MANIFOLD INSULATOR
1. Install the exhaust manifold insulator
NOTE
• If it is difficult to install, disconnect the clamp for the air conditioner hose or pipe to provide enough space for
the insulator installation.

CAUTION
• After the installation of the insulator, connect the clamp that has been disconnected.

1-1-6 OPERATION AFTER INSTALLATION

1. Install the front exhaust pipe.
Refer to Page B4 - 3.
 B4–3
2 EXHAUST PIPE
2-1 REMOVAL AND INSTALLATION
WARNING
• Do not carry out operations while the exhaust manifold is still hot.

2-1-1 ITEMS TO BE PREPARED

Instrument

2-1-2 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

L21E6101S20

~:Non-reusable parts
Unit:N·m {kgf.cm}
Bolt, exhaust pipe support
Spring, exhaust manifold
Support, muffler
Pipe assy, exhaust, front
Gasket, exhaust pipe
Pipe assy, exhaust tail
7 g Gasket, exhaust pipe
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
LUBRICATION SYSTEM B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
LUBRICATION SYSTEM ..............................................B5 - 1
C3
FUNCTION CHECK ..............................................B5 - 1 D1
OIL PUMP .....................................................................B5 - 3
REMOVAL AND INSTALLATION.........................B5 - 3 E1
CRANKSHAFT FRONT OIL SEAL ...............................B5 - 5
REMOVAL AND INSTALLATION.........................B5 - 5 E2
OIL PAN ........................................................................B5 - 7
REMOVAL AND INSTALLATION.........................B5 - 7 E3
CHECK & CHANGE OF ENGINE OIL ..........................B5 - 9
OIL QUALITY & LEVEL CHECK .........................B5 - 9
F1
CHANGE OF ENGINE OIL AND F2
REPLACEMENT OF OIL FILTER.........................B5 - 9
OIL PRESSURE WARNING ................................B5 -10 F3
G1
G2
H1
I1
I2
I3
I4
J1
J2
J3
J4
J5
J6
K1
 B5–1
1 LUBRICATION SYSTEM
1-1 FUNCTION CHECK
WARNING
• Never carry out the operation while the engine and engine oil are still hot, for there are hazard potentials for
getting scald.

1-1-1 ITEMS TO BE PREPARED

SST

Instrument

Lubricant,adhesive,others
Three Bond 1207F

1-1-2 Oil pressure

1. Attach an engine tachometer to the terminal REV8 , using
the SST.
SST: 09991-87402-000
09991-87404-000
NOTE
• The 09991-87404-000 is a harness for extension use.
Hence, you may not use it.

M21E5013ET10
B5–2
2. Remove the oil pressure switch and install an oil pressure
gauge (thread diameter PT1/8).
3. Warm up the engine (until the radiator fan starts rotating).
4. Measure the pressure at each revolution speed.
SPECIFIED VALUE: At time of 1,000rpm
147kPa(1.5kgf/cm2)
At time of 4,000rpm
343kPa(3.5kgf/cm2)
5. Attach the oil pressure switch.
(1) Clean the threaded section of the oil pressure switch M21E5029ET10
and the switch attaching section of the cylinder block.
(2) Apply bond to the threaded section of the oil pressure
switch. Then, after a short length of time, install the oil
pressure switch.
ADHESIVE: Three Bond1207F
TIGHTENING TORQUE: 13.5&4.05{138&41}
 B5–3
2 OIL PUMP
2-1 REMOVAL AND INSTALLATION
WARNING
• Never carry out the operation while the engine and engine oil are still hot, for there are hazard potentials for
getting scald.

2-1-1 ITEMS TO BE PREPARED

Instrument

Lubricant,adhesive,others
Engine oil, SAE 5W30 or 10W30 API SJ or Higher

2-1-2 OPERATION BEFORE REMOVAL

1. Remove the oil pan.
Refer to Page B5 - 7.

2. Remove the timing belt.

Refer to Page B2 - 5.

2-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

"
"

" "

"

M21E5030ES16

~Non-reusable parts
Unit:N;m{kgf;cm}
(2) REMOVAL AND INSTALLATION PROCEDURES

Oil pump, assy

Oil strainer, Sub-assy
Oil strainer, Sub-assy, gasket
B5–4
2-1-4 POINTS OF INSTALLATION
(1) O-RING
1. Insert a new O-ring into the grooved section of the oil pump
cover. Retain and secure the O-ring at the three projected
sections provided at the cover side.

L11E5086T10

2-1-5 OPERATION AFTER INSTALLATION

1. Install the timing belt.
Refer to Page B2 - 5.

2. Install the oil pan.

Refer to Page B5 - 7.
 B5–5
3 CRANKSHAFT FRONT OIL SEAL
3-1 REMOVAL AND INSTALLATION
3-1-1 ITEMS TO BE PREPARED
SST

3-1-2 OPERATION BEFORE REMOVAL

1. Remove the timing belt.
Refer to Page B2 - 5.

3-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

L18E5003S16

~: Non-reusable parts
(2) REMOVAL AND INSTALLATION PROCEDURES

3-1-4 POINTS OF REMOVAL

(1) TYPE T OIL SEAL
1. Cut the lip-section of the type T oil seal, using a cutter or the
like. Pry off the oil seal, using a screwdriver or the like.
CAUTION
• Wind tape etc. around the screwdriver so as not to scratch
the surrounding area.
• After the oil seal has been removed, check that the chamfer
section of the crankshaft exhibits no scores.
(if scores are present, remedy them by means of an
adhesive paper (#400). L11E5184ET10
B5–6
3-1-5 POINTS OF INSTALLATION
(1) TYPE T OIL SEAL
1. Apply engine oil to the lip-section of the type T oil seal,
Then, press the oil seal until it becomes flush with the edge
surface, using the SST.
SST: 09223-87202-000
SPECIFIED VALUE: Protruding dimension: 0.5&0.5mm

R11E5056T10

3-1-6 OPERATION AFTER INSTALLATION

1. Install the timing belt.
Refer to Page B2 - 5.
 B5–7
4 OIL PAN
4-1 REMOVAL AND INSTALLATION
4-1-1 ITEMS TO BE PREPARED
SST

Instrument

Lubricant,adhesive,others
Three Bond 1207F

4-1-2 OPERATION BEFORE REMOVAL

WARNING
• Never remove the drain plug while the engine oil is still hot.

1.Drain the engine oil by removing the drain plug and gasket.
CAUTION
• The gasket is a non-reusable part.
2.Remove the front exhaust pipe.
Refer to Page B4 - 3.

4-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

"

" "

"

M21E5045S20

~: Non-reusable parts
Unit:N;m{kgf;cm}
B5–8
(2) REMOVAL AND INSTALLATION PROCEDURES

Pan Sub-assy, oil

4-1-4 POINTS OF REMOVAL

(1) OIL PAN SUB-ASSY
1. Remove the oil pan retaining bolts and nuts.
2. Drive the SST into between the oil pan and the cylinder
block.
CAUTION
• Slowly perform the operation so that the oil pan flange
section may not be deformed.
SST: 09032-00100-000
3. Remove the oil pan subassembly while turing it around
90° so that the baffle plate may not interfere with the oil
L11E5087T10
strainer.

4-1-5 POINTS OF INSTALLATION

CAUTION
• If the oil pan is deformed, flatten it by tapping it lightly, using a hammer.
• If it is difficult to flatten the oil pan due to being badly deformed, replace it with a new part.
(1) OIL PAN SUB-ASSY
1. Clean the gasket that may be stuck to the oil pan attaching surface and the oil pan flange section of the
cylinder block, using a scraper or a wire brush etc.
2. Apply a liquid gasket to the oil pan subassembly, as indicated in the right figure. Attach the oil pan subassembly
to the cylinder block.
ADHESIVE: Three Bond1207F
CAUTION
• Apply a liquid gasket without any missing portion with
a gauge of 03–4.
• The assembling should be made within 15 minutes after the
application of the gasket.
3. Tighten the bolts and nuts to the specified torque.

4-1-6 OPERATION AFTER INSTALLATION D11E5010ET10

1. Install the front exhaust pipe.
Refer to Page B4 - 3.

2. Tighten the drain plug to the specified torque with a new gasket interposed. Fill engine oil.
 B5–9
5 CHECK & CHANGE OF ENGINE OIL
5-1 OIL QUALITY & LEVEL CHECK

WARNING:
• Be sure to perform this inspection when the engine oil is not
hot, to prevent you from getting scalded.

1. Park the vehicle on a level surface.

2. Pull out the oil level gauge.
3. Check the engine oil for deterioration, ingress of water, LLU00037-00011
discoloring or dilution.
If oil quality is poor, change the engine oil.
(As for the procedure, see “CHANGE OF ENGINE OIL AND
REPLACEMENT OF OIL FILTER” section.)
4. Wipe off the engine oil from the oil level gauge.
5. Reinsert the oil level gauge as far as it will go.
6. Pull out the oil level gauge again.
7. Ensure that the engine oil level is between the “L” level and
“F” level on the oil level gauge.
If the engine oil level is below the “L” level, replenish the
specified engine oil to the “F” level after the checking of the
oil quality and leakage.
CAUTION:
• Use API grade SJ or higher (SAE 5W(30 or 10W(30).
(As for the procedure, see “CHANGE OF ENGINE OIL AND
REPLACEMENT OF OIL FILTER” section.)

NOTE:
• The amount of oil whose level is between “L” level and “F”
level equals to 0.8 liter.
Level “L” : 1.4 liter
Level “F” : 2.2 liter

5-2 CHANGE OF ENGINE OIL & REPLACEMENT OF

OIL FILTER

WARNING:
• Protect your eyes by wearing safety goggles.
• Be very careful not to burn yourself with hot engine oil or hot
engine compenents.

1. Park the vehicle on a level surface.

2. Place a suitable container under the oil drain plug. N11E5010ET10

3. Remove the drain pug and gasket, and drain the engine oil
into the placed container completely.
4. Remove the oil filler cap.
5. Place a suitable container under the oil filter.
6. Slacken the oil filter with a siutable oil filter wrench or the
following SST. Loosen
SST: 09228-87201-000

CAUTION:
• Be careful at this time, for the oil may flow out.

7. Remove the oil filter by hand. LLU00039-00013

B5–10
8. Wipe off the engine oil from the oil filter attaching part of the
engine.
9. Thinly apply engine oil to the O-ring of the new oil filter.
10. Screw in the oil filter by hand, until the O-ring of the oil filter
contacts the oil filter installing surface.

LLU00040-00014

11. Tighten the oil filter three fourths to one complete turn,
using a suitable oil filter wrench or the following SST.
SST: 09228-87201-000

CAUTION:
• Do not overtighten the oil filter. Failure to obcaution will
cause oil leakage or damage of the oil pump or oil filter.

N11E5010ET10

12. Clean the drain plug. Tighten the drain plug to the specified
torque with a new gasket interposed.
Tightening Torque: 24.0&4.8 N.m

13. Pour engine oil to the engine.

NOTE:
• Use API grade SJ or higher (SAE 5W(30 or 10W(30).
• The amount of oil whose level is between “L” level and the
“F” level equals to one liter.
Oil Capacity
LLU00042-00016
With oil filter : 2.3 liter
Without oil filter : 2.1 liter

14. Close the oil filler cap.

WARNING:
• Securely install the oil filler cap. Failure to observe this
warning will cause a fire.

15. Check the oil level. (refer to the “ ENGINE OIL QUALITY &
LEVEL CHECK”.)

5-3 OIL PRESSURE WARNING

Check to see if the oil pressure warning lamp will be illuminated
when the ignition switch is turned on.
NOTE:
• If the warning lamp will not illuminate, check to see if the
bulb in the combination meter is burnt out.
• If the warning lamp is illuminated when the engine has
started, perform the oil pressure check.
(In advance, be sure to check that the engine oil is at a
sufficient level.)
LLU00043-00017
 A1
PERODUA B1
B2
B3
B4
B5
B6
B7
COOLING SYSTEM B8
B9
EF-VE, ED-VE & EJ-VE B10
B11
B12
C1
C2
THERMOSTAT ..............................................................B6 - 1
C3
REMOVAL AND INSTALLATION ...........................B6 - 1 D1
WATER PUMP ..............................................................B6 - 3
REMOVAL AND INSTALLATION ...........................B6 - 3 E1
RADIATOR ....................................................................B6 - 5
REMOVAL AND INSTALLATION ...........................B6 - 5 E2
E3
F1
F2
F3
G1
G2
H1
I1
I2
I3
I4
J1
J2
J3
J4
J5
J6
K1
 B6–1
1 THERMOSTAT
1-1 REMOVAL AND INSTALLATION
1-1-1 ITEMS TO BE PREPARED
1-1 REMOVAL AND INSTALLATION
WARNING
• Do not remove the radiator cap or drain plug when the coolant is hot.

1-1-1 ITEMS TO BE PREPARED

Instrument

1-1-2 OPERATION BEFORE REMOVAL

1.Drain the coolant.
1-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

"

L21E6011S20

Unit:N;m
(2) REMOVAL AND INSTALLATION PROCEDURES
B6–2
1-1-4 INSPECTION
(1) Visual inspection
1. Ensure that the valve is completely closed at the room temperature of 20°C, and that the spring is free.
2. Check to see if the rubber ring is not damaged.
3. Ensure that the bypass valve and jiggle pin move smoothly.

M11E5060ET10

(2) Check of valve opening temperature

1. Immerse the thermostat in water. Raise the temperature
gradually and measure the temperature when the bypass
valve begins to open.
SPECIFIED VALUE: 84&1.5$C

M11E5061T10

2. Further raise the temperature. Measure the lift amount when

the temperature is 97$C
SPECIFIED VALUE: 8.5 mm or more

M11E5059ET10

1-1-5 POINTS OF INSTALLATION

(1) THERMOSTAT, WATER INLET
1. Assemble the thermostat to the water inlet, as shown at the right figure.
CAUTION
• Assemble the water inlet to the cylinder head in such a way that the jiggle pin of the thermostat
faces upward.

1-1-6 OPERATION AFTER INSTALLATION L11E5092ET10

1. Fill the coolant.
 B6–3
2 WATER PUMP
2-1 REMOVAL AND INSTALLATION
Instrument

2-1-1 OPERATION BEFORE REMOVAL

1. Drain the coolant.
2-1-2 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

"

"

"

"

"

L21E6804S20

~:Non-reusable parts
Unit:N;m

Cover Sub-assy, water pump

2-1-3 POINTS OF REMOVAL

(1) WATER PUMP PULLEY
1. Remove the water pump pulley, while preventing it from
turning by using a screwdriver or the like as shown at the
right figure.

L11E5187T10
B6–4
(2) TIMING BELT COVER No.2
1. Remove the timing belt cover No.2 by applying a flat
screwdriver to the cutout section of the timing belt cover.

L11E5180ET10

(3) WATER PUMP COVER

1. Remove the water pump cover.
CAUTION
• When removing, apply cloth so that no water remaining inside the pump may splash to the timing belt.
2-1-4 INSPECTION
1. Check to see if the rotor can turn smoothly by turning it by hand.
2-1-5 POINTS OF INSTALLATION
(1) WATER PUMP COVER
1. Clean the water pump installing section.
2. Install the water pump cover with a new O-ring interposed.
(2) TIMING BELT COVER No.2
1. Install the timing belt cover No.2.
(1) Install a part of the cover by aligning the pawl to the installing section of the timing belt cover.
(2) Ensure that the cover has been attached firmly to the collar.
(3) WATER PUMP PULLEY
1. Install the water pump pulley, while preventing it from turning
with a screwdriver or the like as shown at right figure.

L11E5187T10

(4) V BELT (for alternator)

1. Install the V belt (for alternator).
Refer to Page B1 - 3.

(5) V BELT (for air conditioner)

1. Install the V belt (for air conditioner). Adjust the belt tension.
Refer to Page J6 - 5.

2-1-6 OPERATION AFTER INSTALLATION

1. Fill the coolant.
 B6–5
3 RADIATOR
3-1 REMOVAL AND INSTALLATION
3-1-1 ITEMS TO BE PREPARED
Instrument

3-1-2 OPERATION BEFORE REMOVAL

WARNING
• Do not remove the radiator cap or drain plug when the coolant is hot.

1. Drain the coolant.

2. Remove the negative _ terminal of the battery.
CAUTION
• It must be noted that the memories of the diagnosis, radio settingetc. will be erased at the same time when the
negative _ terminal of the battery is removed.

3. Remove the front bumper.

Refer to Page I2 - 1.

4. Remove the attaching bolts with the air conditioner condenser.

B6–6
3-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

T:5.01.5 {5015}

"

"

"

T:123.6 {12237}

"
T:8.02.4 {8024}

"

T:8.01.6 {8215}

L21E6104S33

~:Non-reusable parts
Unit:N;m

Radiator assy

3-1-4 POINTS OF REMOVAL

(1) RADIATOR ASSY
1. Disconnect the connector for the fan motor.
2. Remove the radiator assy.
CAUTION
• Be careful not to damage or deform the fin when removing the radiator.
 B6–7
3-1-5 POINTS OF INSTALLATION
(1) FAN MOTOR ASSY
1. Install the fan motor assembly to the radiator assembly.
Temporarily tighten the reference hole first. Then, tighten
the attaching bolts to the specified torque.

M21E6027ET10

(2) HOSE, RADIATOR No.2

1. Connect the hose to the radiator in such a way that the identification paint mark faces downward of the
vehicle.
2. After installing the radiator assembly, assemble the hose to the engine assembly in such a way that the
identification paint is aligned with inlet water’s stopper.
(3) OIL COOLER HOSE
1. Install a new oil cooler inlet hose and oil cooler outlet hose
to the radiator assembly. (A/T vehicles)
CAUTION
• The oil cooler inlet hose and oil cooler outlet hose are
non-reusable parts.
(1) Clean the oil cooler pipe of the radiator assembly with
white gasoline.
(2) Insert the oil cooler inlet hose and oil cooler outlet
hose up to the second spool of the oil cooler pipe of
the radiator assembly, referring to the right figure. Align M21K5042ET10

them with the marking and attach the clips.

CAUTION
• Be careful not to allow the hose to ride over the second
spool.
• Install in such a way that the marking faces downward of the
vehicle.
• Install the clip in such a way that the protrusion faces
downward of the vehicle.
(4) OIL COOLER TUBE CLAMP
1. Pinch the oil cooler hose to the oil cooler tube clamp.
Referring to the right figure, align the marking position and
install the hose to the back of the fan motor assembly.
(A/T vehicles)
CAUTION
• The oil cooler hose should be pinched in such a way that the
oil cooler inlet hose comes at the right side of the vehicle.
• The section A should be installed with the clamp turn
preventive section applied to the recessed section of
the fan shroud. M21K5041ET10

• Care must be exercised so that the hose may not be

twisted.
B6–8
(5) RADIATOR ASSY
1. Install the radiator assembly.
CAUTION
• Never allow the vehicle harness to contact with the core (including the tank staked section). (If the contact
occurs, water will leak due to galvanic corrosion.)
• When installing the radiator, be careful not to damage or deform the fins.

(6) HOSE, RADIATOR No.1

1. Install the hose to the radiator in such a way that the identification paint may come at the upward direction of
the vehicle.
2. When installing to the engine assembly, make sure that the identification paint comes at the upward direction
of the engine.
 B6–9
(7) OIL COOLER HOSE
Install the oil cooler inlet hose and oil cooler outlet hose to the union of the transaxle side.
1. Type A4L automatic transaxle mounted vehicles
(1) Clean the union at the transaxle side with white
gasoline.
(2) Referring to the right figure, insert the oil cooler inlet
hose up to the second spool of the union at the
transaxle side and align it to the marking. Then,
attach the clip.
CAUTION
• Be careful not to allow the hose to ride over the second
spool.
• The white paint of the union should be aligned with the
marking position of the hose.
• Install the clip in such a way that the protrusion faces
upward. M21K5043ET10

(3) Insert the oil cooler outlet hose up to the second spool
of the oil cooler outlet tube of the transaxle and align
it with the marking. Then, attach the clip.
CAUTION
• Be careful not to allow the hose to ride over the second
spool.
• Be careful not to twist the hose.
• Install the clip in such a way that the protrusion comes
at the upward of the vehicle.
(4) Ensure that each hose is not twisting or not interfering
with other parts. Also ensure that the clearance with
other parts is not extremely small. M21K5044ET10

3-1-6 OPERATION AFTER INSTALLATION

1. Fill the coolant.
2. Install the front bumper.
Refer to Page I2 - 1

3. Install the attaching bolt with the air conditioner condenser.

4. Install the negative _ terminal of the battery.
5. On the A/T vehicles, replenish the automatic fluid. After warming up the engine, check the fluid level.
6. Check the coolant leakage.
Refer to Page B1 - 2