TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION 0A 6

GENERAL INFORMATION ENGINE 0B 6A1

General Information 0A General Information and
Diagnosis 6 1A 6A2
Maintenance and Lubrication 0B
Engine Mechanical (G16) 6A1 1B 6A4
HEATING AND AIR
CONDITIONING Engine Mechanical (H25) 6A2
Engine Mechanical (J20) 3 6B
Heater and Ventilation 1A 6A4
Air Conditioning 1B Engine Cooling 6B 3A 6C
STEERING, SUSPENSION, Engine Fuel 6C
3 3B1 6E1
WHEELS AND TIRES Engine and Emission Control
System (SF1 for G16/J20) 6E1
Front End Alignment 3A 3C 6E2
Power Steering (P/S) System 3B1 Engine and Emission Control
System (SF1 for H25) 6E2 3C1 6F1
Steering Wheel and Column
3C Ignition System (G16) 6F1 3D 6F2
(Not Equipped with Air Bag)
Air Bag Steering Wheel Ignition System (J20/H25) 6F2
3C1 3E 6G
and Column Cranking System
6G
Front Suspension 3D (Reduction Type) 3F 6G1
Rear Suspension 3E Cranking System
(No-Reduction Type) 6G1 4A2 6H
Wheel and Tires 3F
Charging System 6H 4B 6K
DRIVE SHAFT/PROP. SHAFT
Exhaust System 6K
Front Drive Shaft/Shaft 5 7A
4A2 TRANSMISSION, CLUTCH
Bearing, Oil Seal
AND DIFFERENTIAL 5A 7A1
Propeller Shaft 4B
Manual Transmission (Type 1) 7A
BRAKES 5 5B 7B1
Manual Transmission (Type 2) 7A1
Brake Pipe/Hose /Master 5A Automatic Transmission 7B1 5C 7C1
Cylinder
Clutch (Hydraulic Type) 7C1 5E1 7D
Front Brakes 5B
Transfer 7D
Parking and Rear Brakes 5C
Differential (Front) 7E
Antilock Brake System 5E1 7E
Differential (Rear) 7F 7F
BODY ELECTRICAL SYSTEM 8
8
Wiring Diagram 8A
Lighting System 8B
8A
Instrumentation/Driver 8B
Information 8C

Windows, Mirrors, Security 8C

8D
and Lock
8D
Immobilizer Control System 8G
BODY SERVICE 9 8G
RESTRAINT SYSTEM 10 9
Seat Belt 10A
10
Air Bag System 10B
SERVICE BULLETIN 10A
Power Steering (P/S) System 3B1 10B
NOTE:
The screen toned Sections 0A – 5E1 and 7A – 10B are included in Volume 1 and section 3B1
8A is in Wiring Diagram Manual mentioned in Foreword of this manual.

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10) Remove exhaust No.1 pipe.

1. Stiffener
2. Exhaust No.1 pipe

11) For Type 2 exhaust system only:

Detach exhaust manifold stiffener from transmission case.
12) Remove exhaust manifolds and their gaskets from cylinder
heads.

1. Exhaust manifold stiffener

2. Exhaust No.1 pipe
3. Transmission

INSTALLATION
1) Install new manifold gaskets to cylinder heads and No.1 pipe
gasket to exhaust pipe No.1.
2) Install exhaust manifolds.
Always install new bolts with pre-coated adhesive to the loca-
tions with
mark.
Tighten manifold nuts and bolts to specified torque.

1. Left (No.1) exhaust manifold Tightening Torque

2. Right (No.2) exhaust manifold
(a): 30 N.m (3.0 kg-m, 21.5 lb-ft)

3) For Type 2 exhaust system only:

Attach exhaust manifold stiffener to transmission.

4) Install exhaust No.1 pipe and stiffener.

Tighten exhaust No.1 pipe bolts and nuts to specified torque.

Tightening Torque
(b): 50 N.m (5.0 kg-m, 36.5 lb-ft)

1. Exhaust No.1 pipe

2. Catalytic converter
3. Stiffener

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CLEAN
Clean sealing surface on timing chain cover, crankcase, cylinder block and
cylinder heads.
Remove oil, old sealant, and dust from sealing surface.

INSPECTION
Check oil seal lip for damages or deterioration.
Replace as necessary.

NOTE:
When installing new oil seal, top it in until its surface is flash with
edge of timing chain cover.
To install oil seal, use special tool (bearing installer).

1. Timing chain cover Special Tool

2. Oil seal (D): 09913-75510

INSTALLATION
Reverse removal sequence to install timing chain cover noting following
points.
1) Apply sealant “A” and “B” to timing chain cover sealing surface area as
shown in figure.

“A”: Sealant 99000-31150

“B”: Sealant 99000-31140

2) Apply engine oil to oil seal lip and water pump O-ring, then install timing
chain cover.

Tightening torque
1. Timing chain
cover Timing chain cover bolt: 11 N.m (1.1 kg-m, 7.5 lb-ft)
2. Sealant “A”
3. Cylinder head
4. Cylinder block
5. Cylinder head
gasket
6. Rub into
7. Jig
“a”: 7 mm (0.28 in.)
“b”: 67 mm (2.64 in.)
“c”: 17 mm (0.67 in.)
“d”: 18 mm (0.71 in.)
“e”: 10 mm (0.39 in.)

(a) 3) Install crankshaft pulley.

To lock crankshaft pulley, use special tool (camshaft pulley holder) with
it at shown in figure.
Special Tool
(A): 09917-68221
CAUTION:
Be sure to use the following bolt for fixing special tool to crank
pulley.
Bolt size: M8, P1.25 ȏ = 45 mm
Strength: 7T
1. Crankshaft pulley
2. Bolt Tightening Torque
3. Wrench
(a): 150 N.m (15 kg-m, 108.5 lb-ft)
 ENGINE MECHANICAL (H25 ENGINE) 6A2-43

4) Apply oil to sliding surface of each camshafts and camshaft jour-

nals.

5) Install RH bank 2nd timing chain on camshaft sprockets by align-

ing match marks with the plates in silver or yellow color.

1. Yellow or silver colored plate

2. Match mark of RH bank 2nd timing chain exhaust
camshaft sprocket
3. Match mark of RH bank 2nd timing chain intake
camshaft sprocket

6) Install camshaft housing pins as shown in figure.

1. RH bank intake camshaft

2. RH bank exhaust camshaft
3. Pin

7) Check position of camshaft housings.

I: Intake side
Embossed marks are provided on each camshaft housing, indi-
E: Exhaust side cating position and direction for installation. Install housings as
indicated by these marks.
Position from timing chain side

Timing chain side

8) After applying oil to housing bolts, tighten them temporarily first.

Then tighten them by following sequence as indicated in figure.
Tighten a little at a time and evenly among bolts and repeat tight-
ening sequence two or three times before they are tightened to
specified torque below.

Tightening Torque
12 N.m (1.2 kg-m, 8.5 lb-ft)

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COMPONENTS
TYPE-II
RESISTER SHAPE AND LOCATION
(Located in the engine room)

1. Ignition coil assembly for No.1 and No.4 cylinders

2. Ignition coil assembly for No.2 and No.3 cylinders
3. Monitor coupler (*)
4. CMP sensor
5. ECM (or PCM) (*)
6. High-tension cord
NOTE: 7. Spark plug
8. Noise suppressor
Above figure shows left hand steering vehicle. For right hand 9. Ignition resistor (*) ... Type-I
steering vehicle, parts with (*) are installed at the other side. 9-1. Ignition resister (*) ... Type-II
10. Ignition Label

Condition
Engine cranks, but will not
start or hard to start
Poor fuel economy or engine
performance
DIAGNOSIS
Possible Cause Correction
No spark

Blown fuse for ignition coil Replace.

Loose connection or disconnection of lead Connect securely.
wire or high-tension cord(s)

Faulty high-tension cord(s) Replace.

Faulty spark plug(s) Adjust, clean or replace.

Faulty ignition coil assembly (s) Replace.

Faulty CMP sensor Clean, tighten or replace.

Faulty ECM (or PCM) Replace.

Incorrect ignition timing Adjust.

Faulty high-tension cord(s) Replace.

Faulty spark plug(s) Adjust, clean or replace.

Faulty ignition coil assembly (s) Replace.

Faulty CMP sensor Clean, tighten or replace.

Faulty ECM (or PCM) Replace.

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Overseas Service Department

1st Ed. Jan., 1998

3rd Ed. Oct., 2001

Printed in Japan

Printing: 610

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