PRECAUTIONS
EM-5
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2
When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ
Use torque wrench to tighten bolts or nuts to specification.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Dowel pins are used for several parts alignment. When replacing and reassembling with dowel pins, make
sure that dowel pins are installed in the original portion.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route when refilling after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00KN5
Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
–Balancer unit
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
EM-8
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PREPARATION
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
ST16610001
Pilot bushing pullerRemoving pilot converter
WS39930000
Tube presserPressing the tube of liquid gasket
KV11103000
Pulley pullerRemoving crankshaft pulley
Quick connector release Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210) Tool number
Tool nameDescription
S-NT605
S-NT603
S-NT044
S-NT045
S-NT052
NT676
PBIC0198E
PREPARATION
EM-9
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Commercial Service ToolsEBS00L7O
Tool nameDescription
Spark plug wrench Removing and installing spark plug
Pulley holderCrankshaft pulley removing and installing
Valve seat cutter set Finishing valve seat dimensions
TORX socketRemoving and installing flywheel
Size: T55
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT047
ZZA1010D
S-NT048
PBIC1113E
S-NT030
S-NT015
S-NT016
EM-12
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom.EBS00L7Q
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-64
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-59EM-58
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-107
EM-109
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-112EM-108
EM-108
EM-109
Knock A B CBBBConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-109EM-113
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-114EM-113
Front of
engine
Front
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-50
EM-46
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-21,
"WATER
PUMP"
DRIVE BELTS
EM-13
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DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00KN7
WARNING:
Be sure to perform this step when the engine is stopped.
Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use
range (between three line notches on moving side).
NOTE:
Check the drive belt auto-tensioner indication when the engine is cold.
When new drive belt is installed, the indicator (notch on fixed side) should be within the range “a” in the
figure.
Visually check entire drive belt for wear, damage or cracks.
If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension AdjustmentEBS00KN8
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationEBS00KN9
REMOVAL
1. Remove splash guard on RH undercover.
2. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Do not loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pul-
ley.
3. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of the retaining boss to fix drive belt auto-tensioner pulley.
4. Loosen drive belt from water pump pulley in sequence, and remove it.
PBIC2622E
PBIC2169E
EM-14
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DRIVE BELTS
INSTALLATION
1. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Do not loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Do not turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pul-
ley.
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole of retaining boss to fix drive belt auto-tensioner pulley.
3. Hook drive belt onto all pulleys except for water pump, and then onto water pump pulley finally.
CAUTION:
Confirm drive belt is completely set to pulleys.
Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-13, "
Checking Drive Belts" .
Removal and Installation of Drive Belt Auto-TensionerEBS00KNA
REMOVAL
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
1. Remove splash guard on RH undercover.
2. Remove drive belt. Refer to EM-13, "
Removal and Installation" .
3. Release the fixed drive belt auto-tensioner pulley.
4. Remove drive belt auto-tensioner.
PBIC2627E
1. Drive belt auto-tensioner 2. Water pump pulley
PBIC2170E
DRIVE BELTS
EM-15
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CAUTION:
Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it counter-
clockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a
unit, including the pulley.
INSTALLATION
Note the following, and install in the reverse order of removal.
When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.
Do not swap the pulley between new and old drive belt auto-tensioner.
EM-46
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TIMING CHAIN
TIMING CHAINPFP:13028
Removal and InstallationEBS00KNL
REMOVAL
1. Remove the following parts.
1. O-ring 2. Camshaft sprocket (INT) 3. Camshaft sprocket (EXH)
4. Chain tensioner 5. Spring 6. Chain tensioner plunger
7. Timing chain slack guide 8. Timing chain 9. Front cover
10. Chain guide 11.Intake valve timing control solenoid
valve12. Intake valve timing control cover
13. RH engine mounting bracket 14. Crankshaft pulley bolt 15. Crankshaft pulley
16. Front oil seal 17. Balancer unit timing chain tensioner 18. Oil pump drive spacer
19. Crankshaft sprocket 20. Timing chain tension guide 21. Balancer unit timing chain
22. Balancer unit 23. Oil ring
PBIC2181E