Page 68 of 1463

1A3-10 GENERAL ENGINE INFORMATION
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following
procedures may help you in locating and repairing
most leaks.
Finding the Leak
1. Identify the fluid. Determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be
necessary to clean the suspected area with a
degreaser, steam or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at
normal operating temperature and varying
speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white
powder surface to the source.
Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.1. Pour the specified amount of dye into the engine
oil fill tube.
2. Operate the vehicle normal operating conditions
as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must
be determined n order for it to be repaired properly. If
a gasket is replaced, but the sealing flange is bent,
the new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check for the following conditions and correct
them as they may cause a leak.
Gaskets
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe fasteners are tightened improperly or the
threads are dirty or damaged.
lThe flanges or the sealing surface is warped.
lThere are scratches, burrs or other damage to the
sealing surface.
lThe gasket is damaged or worn.
lThere is cracking or porosity of the component.
lAn improper seal was used (where applicable).
Seals
lThe fluid level/pressure is too high.
lThe crankcase ventilation system is malfunctioning.
lThe seal bore is damaged (scratched, burred or
nicked).
lThe seal is damaged or worn.
lImproper installation is evident.
lThere are cracks in the components.
lThe shaft surface is scratched, nicked or damaged.
lA loose or worn bearing is causing excess seal
wear.
DIAGNOSIS
Page 72 of 1463

1A3-14 GENERAL ENGINE INFORMATION
Leakage Test
1. Run the engine to be the coolant temperature 80°C.
2. Remove the fuel injection nozzle.
3. Open the coolant subtank cap.
4. Check the coolant level and replenish if necessary.
5. Open the oil filler cap.
6. Remove the air cleaner cover and element.
7. Position the piston at TDC.
8. Install the connector (1) and connection piece (2).
9. Calibrate the tester and connect the connection hose
(3)
10. Pressurize with compressed air and compare the
pressure changes with permissible pressure leakage.
11. If permissible pressure leakage is out of standard, check
followings :
- Intake and exhaust lines.
- Sounds in oil filler area.
- Air bubbles in radiator coolant.
12. Do pressure leakage test for the remaining cylinders
according to the firing order.
lOM 662LA Engine : 1-2-4-5-3
lOM 661LA Engine : 1-3-4-2
13. Remove the tester.
14. Close the coolant pressure cap and oil filler cap.
15. Install the air cleaner element and cover.
16. Install the fuel injection nozzle.
Page 94 of 1463
M162 ENGINE MECHANICAL 1B1-21
5. Disconnect the vent hose from the A/C bracket.
6. Unscrew all the mounting bolts (arrows) and remove the
A/C bracket and the gasket.
Installation Notice
7. Clean the sealing surface.
8. Replace the gasket with new one.
9. Installation should follow the removal procedure in the
reverse order.
10. Check the oil leakage by operating the engine after
installation.
Tightening Torque 22.5 - 27.5 Nm
Page 98 of 1463
M162 ENGINE MECHANICAL 1B1-25
POLY V - BELT
Preceding Work : Removal of cooling fan
1 Poly V-belt
Removal & Installation Procedure
1. Release the belt tension by turning the belt tensioning pulley
nut clockwise.
2. Remove the poly v-belt.
Notice
Check the belt for damage and tensioning pulley bearing
point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley
clockwise.
2 Belt Tensioning Pulley
Page 102 of 1463
M162 ENGINE MECHANICAL 1B1-29
3. Pointed rib.
4. Belt cord visible in the base of rib.
POLY V - BELT INSPECTION
lMake marks on the belt with chalk.
lRotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found, replace
the belt.
1. Rubber lumps in the base of rib.
2. Dirt or grit ingrained.
5. Cord torn out at the side.
6. Outer cords frayed.
Page 105 of 1463
1B1-32 M162 ENGINE MECHANICAL
Removal & Installation Procedure
1. Remove the intake air duct.
Installation Notice
2. Remove the ignition cable cover.
Installation Notice
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2,3) and remove the head cover and
the gasket.
Installation Notice Notice
Unscrew the seven (M6 x 60) bolts and remove the ignition
cable cover.
Notice
Replace the gasket with a new one if necessary.
5. Installation should follow the removal procedure in the
reverse order.
6. Check for oil leaks by operating the engine.
Tightening Torque 8 - 9 Nm
Tightening Torque 9 - 10 Nm
Tightening Torque 9 - 10 Nm
Page 110 of 1463
M162 ENGINE MECHANICAL 1B1-37
7. Remove the cylinder head bolts in numerical order.
Installation Notice
8. Check the length of the cylinder head bolt.
Installation Notice
Box Wrench Insert 000 589 01 10 00
lReplace the bolt if the measured length exceed the
max. length.
lApply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating
surface.
10. Installation should follow the removal procedure in the
reverse order. 6. Remove the guide rail fixing pin from the cylinder head using
the sliding hammer (01) and the threaded pin (02).
Sliding Hammer 116 589 20 33 00
Threaded Pin 116 589 02 34 00
Tightening Torque1st step 55 Nm
2nd step 9 0 °
3rd step 9 0 °
Length (L)New 160 ± 0.8 mm
Max. 162 ± 0.7 mm
Page 112 of 1463
M162 ENGINE MECHANICAL 1B1-39
3. Remove the cooling fan and the viscous clutch. Unscrew
the three bolts from the cooling fan bracket and remove the
bracket (arrows).
Installation Notice
4. Remove the timing gear case cover after unscrewing the
bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
lApply the sealant after cleaning the timing gear case
cover surface.
lBe careful not to stain the oil chamber of chain tensioner
with the sealant.
5. Installation should follow the removal procedure in the
reverse order.
6. Warm up the engine and check for oil leaks.
Tightening Torque 22.5 - 27.5 Nm
Tightening TorqueBolt (3,4) 22.5 - 27.5 Nm
Bolt (9) 9 - 11 Nm