OIL PAN AND OIL STRAINEREM-27
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4. Install the oil pan drain plug.
5. Install engine assembly. Refer to
EM-74, "
Removal and Installation".
• Do not fill the engine oil for at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil if necessary. Refer to LU-8, "Inspection".
2. Start the engine, and check for leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.
EM-34
< SERVICE INFORMATION >
FUEL INJECTOR AND FUEL TUBE
6. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
After installing the fuel tubes, make sure there are no fuel leaks at the connections using the following steps.
1. Apply fuel pressure to the fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at the connections.
NOTE:
Use mirrors for checking on hidden points.
2. Start the engine and rev it up and check for fuel leaks at the connections. CAUTION:
Do not touch the engine immediately after stopping, as engine becomes extremely hot.
EM-40
< SERVICE INFORMATION >
TIMING CHAIN
8. Remove the oil pump drive spacer.• Hold and remove the flat space of the oil pump drive spacer bypulling it forward.
9. Remove the oil pump. Refer to LU-14, "
Removal and Installation".
10. Remove the chain tensioner on the LH bank using the following steps. NOTE:
To remove the timing chain and associated parts, start with those on the LH bank. The procedure for
removing parts on the RH bank is omitted because it is the same as that for the LH bank.
a. Squeeze the return-proof clip ends using suitable tool and push the plunger into the tensioner body.
b. Secure the plunger using stopper pin. • Stopper pin is made from hard wire approximately 1 mm (0.04
in) in diameter.
c. Remove the bolts and chain tensioner.
WARNING:
Plunger, spring, and spring seat pop out when (squeezing)
return-proof clip without holding plunger head. It may
cause serious injuries. Alw ays hold plunger head when
removing.
NOTE:
• Stop the plunger in the fully extended position by using the return-proof clip 1 if the stopper pin is removed.
• Push the plunger 2 into the tensioner body while squeezing
the return-proof clip 1. Secure it using stopper pin 3.
11. Remove the timing chain tension guide and timing chain slack guide.
12. Remove the timing chain and crankshaft sprocket.
13. Loosen the camshaft sprocket bolts as shown and remove the camshaft sprocket.
CAUTION:
To avoid interference between valves and pistons, do not
turn crankshaft or camshaft wh en timing chain is discon-
nected.
14. Repeat the same procedure to remove the RH timing chain and associated parts.
INSPECTION AFTER REMOVAL
KBIA2512E
KBIA2479E
KBIA2483E
WBIA0799E
EM-56
< SERVICE INFORMATION >
CAMSHAFT
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-80, "
Fuel Pressure Check".
b. Disconnect ignition coil and injector harness connectors if practical.
3. Remove IVT control solenoid valve.
4. Crank engine, and then make sure that engine oil comes out from IVT control cover oil hole. End cranking
after checking.
WARNING:
Be careful not to touch rotating parts (drive be lts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
• Engine oil may squirt from IVT control soleno id valve installation hole during cranking. Use a
shop cloth to prevent engine oil from splashin g on worker, engine components and vehicle.
• Do not allow engine oil to get on rubber compon ents such as drive belts or engine mount insula-
tors. Immediately wipe off any splashed engine oil.
5. Clean oil groove between oil strainer and IVT control solenoid valve if engine oil does not come out from IVT control valve cover oil hole. Refer to LU-7, "
Schematic".
6. Remove components between IVT control solenoid va lve and camshaft sprocket (INT), and then check
each oil groove for clogging.
• Clean oil groove if necessary.
7. After inspection, installation of the remaining components is in the reverse order of removal.
Valve ClearanceINFOID:0000000003531536
INSPECTION
NOTE:
Perform the following inspection after removal, installation or replacement of camshaft or valve-related parts,
or if there are unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or
noise).
1. Warm up the engine. Then stop the engine.
2. Remove the engine cover and. Refer to EM-12, "
Removal and Installation".
3. Remove the battery cover. Refer to SC-8, "
Removal and Installation".
4. Remove the air cleaner and air duct assembly EM-15, "
Removal and Installation".
5. Remove the RH bank and LH bank rocker covers using power tool. Refer to EM-35, "
Removal and Instal-
lation".
6. Turn the crankshaft pulley in the normal direction (clockwise when viewed from engine front) to align TDC identification notch
(without paint mark) with timing indicator.
KBIA2476E
EM-64
< SERVICE INFORMATION >
CYLINDER HEAD
CYLINDER HEAD
On-Vehicle ServiceINFOID:0000000003531540
CHECKING COMPRESSION PRESSURE
1. Warm up the engine thoroughly. Then stop the engine.
2. Release the fuel pressure. Refer to EC-80, "
Fuel Pressure Check".
CAUTION:
If CONSULT-II is not used to release fuel pressure leave the fu el pump fuse disconnected until
step 7.
3. Remove the spark plug from each cylinder. Refer to EM-29, "
Removal and Installation".
4. Connect the engine tachometer (not required in use of CONSULT-II).
5. Install the compression tester with Tool into the spark plug hole.
6. With the accelerator pedal fully depressed, turn the ignition switch to “START” for cranking. When the gauge pointer stabi-
lizes, read the compression pressure and engine rpm. Perform
these steps to check each cylinder.
Unit: kPa (kg/cm2, psi) /rpm
CAUTION:
Always use a fully charged battery to obtain specified engine speed.
• If the engine speed is out of the specified range, che ck the battery liquid for proper gravity. Check the
engine speed again with normal battery gravity.
• If the compression pressure is below the minimum value, check the valve clearances and parts associ- ated with the combustion chamber (valve, valve seat , piston, piston ring, cylinder bore, cylinder head,
cylinder head gasket). After checking, measure the compression pressure again.
• If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, t he piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
- If the compression pressure remains at a low level despite the addition of engine oil, the valves may be
malfunctioning. Check the valves for damage. R eplace the valve or valve seat accordingly.
• If two adjacent cylinders have respectively low co mpression pressure and their compression remains
low even after the addition of engine oil, the gaskets may be leaking, or a valve in adjacent cylinders
may be damaged. Inspect and repair as required.
7. Install the components in the reverse order of removal.
8. Start the engine and confirm that it runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-32
.
Tool number : EG15050500 (J-45402)
Standard Minimum
Deference limit be-
tween cylinders
1,520 (15.5, 220) / 200 1,324 (13.5, 192) / 200 98 (1.0, 14) / 200WBIA0605E
EM-76
< SERVICE INFORMATION >
ENGINE ASSEMBLY
a. Before removing the drive plate, put a match mark (A) on the
crankshaft and drive plate for alignment during installation.
b. Remove the drive plate.
• Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
• Loosen the bolts diagonally.
CAUTION:
• Be careful not to damage the drive plate. Especially
avoid deforming and damaging of the signal plate teeth
(circumference position).
• Place the drive plate with the signal plate surface facing
other than downward.
• Keep magnetic materials away from the signal plate.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand.
- Remove the fuel tube and fuel injector assembly. Refer to EM-31, "
Removal and Installation".
- Remove the intake manifold. Refer to EM-17, "
Removal and Installation".
- Remove the ignition coil. Refer to EM-28, "
Removal and Installation".
- Remove the rocker cover. Refer to EM-35, "
Removal and Installation".
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
31. Remove the generator. Refer to SC-22, "
Removal and Installation".
32. Remove the engine mounting insulator and bracket using power tool.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.
• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-
etrain components.
INSPECTION AFTER INSTALLATION
• Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are
lower than required quantity, fill to the specified level. Refer to MA-10, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel
leakage at the connection points.
ALBIA0522ZZ
KBIA2491E
ENGINE ASSEMBLY
EM-77
< SERVICE INFORMATION >
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• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
specified level if necessary.
• Summary of the inspection items:
*Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
DIFFERENTIAL GEAR OIL
FFD-7
< SERVICE INFORMATION >
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DIFFERENTIAL GEAR OIL
Changing Differential Gear OilINFOID:0000000003532588
DRAINING
1. Stop the engine.
2. Remove the drain plug from the front final drive assembly to drain the differential gear oil.
3. Install the drain plug with sealant applied on the threads to the front final drive assembly. Tighten to the
specified torque. Refer to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to GI-45, "
Recommended Chemical Product
and Sealant".
FILLING
1. Remove the filler plug from the front final drive assembly.
2. Fill the front final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole.
3. Install the filler plug with sealant applied on the threads to the
front final drive assembly. Tighten to the specified torque. Refer
to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant".
Checking Differential Gear OilINFOID:0000000003532589
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL
1. Make sure that differential gear oil is not leaking from the front final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as
shown.
CAUTION:
Do not start engine while checking differential gear oil level.
3. Install the filler plug with sealant applied on the threads to the
front final drive assembly. Tighten to the specified torque. Refer
to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant". Differential gear oil
grade and capacity: Refer to MA-10, "
Fluids
and Lubricants".
LDIA0176E
LDIA0176E