INSPECTION AND ADJUSTMENT
EC-1047
< BASIC INSPECTION >[K9K]
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4. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
6.CHECK ENGINE CONDITION
Start engine.
Is the engine start?
YES >> GO TO 7.
NO >> GO TO 9.
7.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation temperature
60°C (140°F)
Engine running at idle speed.
- Select “HIGH PRES CIRCUIT LEAK TEST” in “ACTIVE TEST” mode with CONSULT-III.
- Engine will perform 4 acceleration cycles.
- Select “DATA MONITOR” mode with CONSULT-III.
- Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
- Does “RAIL PRESSURER” follow “RAIL PRES SET” at ± 5000 kPa(50 bar, 51 kg/cm
2, 725 psi) during the
phase of the 4 acceleration cycles?
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 8.
8.CHECK RAIL HIGH PRESSURE CONTROL CIRCUIT
Carry out TEST 5.
>> GO TO 11.
9.CHECK ENGINE CONDITION
Check that the oil level is correct.
Select “DATA MONITOR” mode with CONSULT-III.
Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
Does “RAIL PRESSURER” follow “RAIL PRES SET” when the cranking engine.
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 10.
10.CHECK MAJOR LEAK IN FUEL INJECTOR/FUEL INJECTORS OPEN
Carry out TEST 6.
>> GO TO 11.
11 .INSPECTION END
High pressure supply pump (volumetric control valve) OK.
High pressure supply pump
(volumetric control valve)ECM
Continuity
Connector Terminal Connector Terminal
F54 2 F11 50 Existed
INSPECTION AND ADJUSTMENT
EC-1049
< BASIC INSPECTION >[K9K]
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>> INSPECTION END
6.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation tempera-
ture.60°C (140°F)
Engine running at idle speed.
- Select “HIGH PRES CIRCUIT LEAK TEST” in “ACTIVE TEST” mode with CONSULT-III.
- Engine will perform 4 acceleration cycles.
- Select “DATA MONITOR” mode with CONSULT-III.
- Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
- Does “RAIL PRESSURE” follow “RAIL PRES SET” at during the phase of 4 acceleration cycles?
Is the inspection result normal?
YES >> GO TO 22.
NO >> GO TO 7.
7.CHECK ENGINE COOLANT TEMPERATURE AND FUEL TEMPERATURE
1. Select “DATA MONITOR” mode with CONSULT-III.
2. Check that the “FUEL TEMP” indication when operating at idle speed is between 60 - 80°C (140 - 176°F)
3. Check that the “WATER TEMP” indication is between 80 - 90°C (176 - 194°F)
NOTE:
When the fuel temperature is above 136°C (277°F), the maximum rail pressure is reduced to protect the
plastic pipes.
When the coolant temperature is above 100°C (212°F), the maximum rail pressure is reduced to protect the
engine.
Are the
“FUEL TEMP” and “WATER TEMP” within the reference value range?
YES >> GO TO 8.
NO >> Check the fuel pump temperature sensor (Refer to EC-1137, "
Component Inspection") or engine
coolant temperature sensor (Refer to EC-1133, "
Component Inspection").
8.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) POWER SUPPLY
1. Turn ignition switch OFF.
2. Disconnect high pressure supply pump (volumetric control valve) harness connector.
3. Turn ignition switch ON.
4. Check the voltage between high pressure supply pump (volumetric control valve) harness connector and
ground.
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 9.
9.DETECT MALFUNCTIONING PART
Check the following.
IPDM E/R
Harness for open or short between ECM and high pressure supply pump (volumetric control valve)
Harness for open or short between IPDM E/R and high pressure supply pump (volumetric control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
10.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) OUTPUT SIGNAL CIR-
CUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
High pressure supply pump
(volumetric control valve)
Ground Voltage
Connector Terminal
F54 1 Ground Battery voltage
EC-1094
< FUNCTION DIAGNOSIS >[K9K]
GLOW CONTROL
1. Turbocharger boost control solenoid
valve2. Fuel pump 3. Turbocharger boost sensor
4. Refrigerant pressure sensor 5. EGR volume control valve 6. Engine oil filler cap
7. Accelerator pedal position sensor 8. Accelerator pedal
: Vehicle front
ALBIA0301ZZ
STARTING DIFFICULT WITH COLD ENGINE
EC-1259
< SYMPTOM DIAGNOSIS >[K9K]
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STARTING DIFFICULT WITH COLD ENGINE
DescriptionINFOID:0000000001162703
CHART 3: STARTING DIFFICULT WITH COLD ENGINE
Diagnosis ProcedureINFOID:0000000001162704
1.CHECK ENGINE OIL LEVEL
Is the engine oil level correct?
Ye s o r N o
Yes >> GO TO 2.
No >> Top up the oil.
2.CHECK ENGINE OIL
Check the grade of engine oil. Refer to LU-26, "
Inspection".
Is the inspection result normal?
YES >> GO TO 3.
NO >> Replace engine oil. Refer to LU-27, "
Refilling"
3.CHECK BATTERY
Check the battery. Refer to PG-6, "
Removal and Installation".
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace battery. Refer to PG-6, "
Removal and Installation"
4.CHECK STARTER MOTOR
Check the starter motor. Refer to STR-35, "
Removal and Installation".
Is the inspection result normal?
YES >> GO TO 5.
NO >> Repair or replace starter motor. Refer to STR-35, "
Removal and Installation"
5.CHECK COMPONENT PART
Check the following.
Engine coolant temperature sensor. Refer to EC-1133, "
Component Inspection".
Fuel pump temperature sensor. Refer to EC-1137, "
Component Inspection".
Intake air temperature sensor. Refer to EC-1131, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 6.
NO >> Repair or replace.
6.CHECK GLOW SYSTEM
Check the glow system. Refer to EC-1156, "
Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 7.
NO >> Repair or replace glow system. Refer to EM-279, "
Removal and Installation"
7.CHECK LOW PRESSURE CIRCUIT
Perform the TEST 1: LOW PRESSURE CIRCUIT CHECK. Refer to EC-1043, "
BASIC INSPECTION : Special
Repair Requirement (TEST 1: Low Pressure Fuel Supply System Check)".
>> GO TO 8.
8.CHECK INTERNAL FUEL TRANSFER PUMP
Perform the TEST 2: INTERNAL FUEL TRANSFER PUMP CHECK. Refer to EC-1044, "
BASIC INSPECTION
: Special Repair Requirement (TEST 2: Internal Fuel Transfer Pump Check)".
ENGINE KNOCK
EC-1283
< SYMPTOM DIAGNOSIS >[K9K]
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ENGINE KNOCK
DescriptionINFOID:0000000001162729
CHART 16: ENGINE KNOCK
Diagnosis ProcedureINFOID:0000000001162730
1.CHECK ENGINE OIL
Check the grade of engine oil. Refer to LU-26, "
Inspection".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Replace engine oil. Refer to LU-27, "
Refilling"
2.CHECK ENGINE OIL LEVEL
Is the engine oil level correct?
Ye s o r N o
Yes >> GO TO 3.
No >> Top up the oil.
3.CHECK ECM POWER SUPPLY AND GROUND CIRCUIT
Check ECM power supply and ground circuit. Refer to EC-1106, "
Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace harness or connector.
4.CHECK WIRING HARNESS
Visually check the condition of the engine wiring harness.
Is the inspection result normal?
YES >> GO TO 5.
NO >> Repair or replace harness or connector.
5.CHECK AIR INTAKE SYSTEM
Check air intake system. Refer to EM-269, "
Removal and Installation".
Is the inspection result normal?
YES >> GO TO 6.
NO >> Repair or replace air intake system.
6.CHECK ELECTRIC THROTTLE CONTROL ACTUATOR
Check electric throttle control actuator. Refer to EC-1134, "
Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 7.
NO >> Repair or replace.
7.CHECK MASS AIR FLOW SENSOR
Check mass air flow sensor. Refer to EC-1125, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 8.
NO >> Repair or replace.
8.CHECK CATALYTIC CONVERTER
Is the catalytic converter clogged or deteriorated?
Is the inspection result normal?
YES >> GO TO 9.
NO >> Repair or replace.
9.CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE)
PRECAUTIONS
EC-1297
< PRECAUTION >[K9K]
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NOTE:
Before any work is carried out on the high pressure injection system, protect:
the accessories and timing belts,
the electrical accessories, (starter, alternator, electric power assisted steering pump),
the flywheel surface, to prevent any diesel from running onto the clutch friction plate.
Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department).
The plugs are single-use only. After use, they must be discarded (once used they are soiled and cleaning is
not sufficient to make them reusable). Unused plugs must be discarded.
Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags are to be used once only, and discarded after use.
Use lint-free cleaning cloths. Using normal cloth or paper is prohibited. They are not lint-free and could con-
taminate the fuel circuit. Each cloth should only be used once.
Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into an uncon-
taminated container.
For each operation, use a clean brush in good condition (the brush must not shed its bristles).
Use a brush and cleaning agent to clean the unions to be opened.
Blast compressed air over the cleaned parts (tools, workbench, the parts, unions and injection system
zones). Check that no bristles remain.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves cover them with latex gloves to prevent contamination.
INSTRUCTIONS TO BE FOLLOWED WHEN CARRYING OUT ANY WORK
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Department. The plugs must not be reused under any cir-
cumstances.
Seal the pouch shut, even if it has to be opened shortly afterwards. Ambient air carries contamination.
All components removed from the injection system must be stored in a hermetically sealed plastic bag once
they have been plugged.
Using a brush, cleaning agent, air gun, sponge or normal cloth is strictly prohibited once the circuit has been
opened. These items could allow contamination to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
EM-1
ENGINE
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SECTION EM
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CONTENTS
ENGINE MECHANICAL
HR16DE
SYMPTOM DIAGNOSIS ...............................
5
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .............................
5
NVH Troubleshooting - Engine Noise .......................5
Use the Chart Below to Help You Find the Cause
of the Symptom .........................................................
6
PRECAUTION ...............................................7
PRECAUTIONS ...................................................7
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
7
Precaution for Procedure without Cowl Top Cover ......7
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .....................................
7
Precaution for Drain Coolant .....................................8
Precaution for Disconnecting Fuel Piping .................8
Precaution for Removal and Disassembly ................8
Precaution for Inspection, Repair and Replace-
ment ..........................................................................
8
Precaution for Assembly and Installation ..................8
Parts Requiring Angular Tightening ..........................8
Precaution for Liquid Gasket .....................................9
PREPARATION ...........................................11
PREPARATION ..................................................11
Special Service Tools ..............................................11
Commercial Service Tools ......................................12
ON-VEHICLE MAINTENANCE ....................15
DRIVE BELTS ....................................................15
Checking .................................................................15
Tension Adjustment ................................................15
Removal and Installation .........................................16
AIR CLEANER FILTER ......................................18
Removal and Installation .........................................18
SPARK PLUG ...................................................19
Exploded View .........................................................19
Removal and Installation .........................................19
CAMSHAFT VALVE CLEARANCE ..................21
Inspection and Adjustment ......................................21
COMPRESSION PRESSURE ...........................24
Inspection ................................................................24
ON-VEHICLE REPAIR .................................25
DRIVE BELT IDLER PULLEY ..........................25
Exploded View .........................................................25
Removal and Installation .........................................25
AIR CLEANER AND AIR DUCT .......................27
Exploded View .........................................................27
Removal and Installation .........................................27
Inspection ................................................................28
INTAKE MANIFOLD .........................................29
Exploded View .........................................................29
Removal and Installation .........................................29
EXHAUST MANIFOLD ......................................32
Exploded View .........................................................32
Removal and Installation .........................................32
FUEL INJECTOR AND FUEL TUBE ................35
Exploded View .........................................................35
Removal and Installation .........................................35
Inspection ................................................................39
OIL PAN (LOWER) ...........................................40
Exploded View .........................................................40
Removal and Installation .........................................40
Inspection ................................................................41
OIL PAN (UPPER) AND OIL STRAINER .........42
Component ..............................................................42
EM-3
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145
Removal and Installation .......................................145
CAMSHAFT VALVE CLEARANCE .................148
Valve Clearance ....................................................148
COMPRESSION PRESSURE ..........................151
Checking Compression Pressure ..........................151
ON-VEHICLE REPAIR ...............................153
DRIVE BELT AUTO TENSIONER ...................153
Component ............................................................153
Removal and Installation of Drive Belt Auto Ten-
sioner ....................................................................
153
AIR CLEANER AND AIR DUCT ......................154
Component ............................................................154
Removal and Installation .......................................154
INTAKE MANIFOLD .........................................156
Component ............................................................156
Removal and Installation .......................................156
EXHAUST MANIFOLD .....................................159
Component ............................................................159
Removal and Installation .......................................159
FUEL INJECTOR AND FUEL TUBE ...............162
Component ............................................................162
Removal and Installation .......................................162
OIL PAN ...........................................................166
Component ............................................................166
Removal and Installation .......................................166
IGNITION COIL ................................................172
Component ............................................................172
Removal and Installation .......................................172
ROCKER COVER .............................................173
Component ............................................................173
Removal and Installation .......................................173
TIMING CHAIN .................................................176
Component ............................................................176
Removal and Installation .......................................177
CAMSHAFT ......................................................186
Component ............................................................186
Removal and Installation .......................................186
OIL SEAL .........................................................195
Removal and Installation of Valve Oil Seal ...........195
Removal and Installation of Front Oil Seal ............195
Removal and Installation of Rear Oil Seal ............196
CYLINDER HEAD ............................................198
Component ............................................................198
Removal and Installation .......................................198
Component ............................................................200
Disassembly and Assembly ..................................200
Inspection After Disassembly ................................202
REMOVAL AND INSTALLATION .............207
ENGINE ASSEMBLY ......................................207
Component ............................................................207
Removal and Installation .......................................207
DISASSEMBLY AND ASSEMBLY ............211
ENGINE UNIT ..................................................211
Component ............................................................211
Disassembly and Assembly ...................................212
Inspection After Disassembly ................................219
HOW TO SELECT PISTON AND BEARING ..230
How to Select Piston and Bearing .........................230
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
238
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
238
Standard and Limit ................................................238
K9K
SYMPTOM DIAGNOSIS ............................
249
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .........................
249
NVH Troubleshooting - Engine Noise ....................249
Use the Chart Below to Help You Find the Cause
of the Symptom .....................................................
250
PRECAUTION ............................................251
PRECAUTIONS ...............................................251
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
251
Precaution for Procedure without Cowl Top Cover ..251
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
251
Precaution for Drain Coolant .................................252
Precaution for Disconnecting Fuel Piping ..............252
Precaution for Removal and Disassembly .............252
Precaution for Inspection, Repair and Replace-
ment .......................................................................
252
Precaution for Assembly and Installation ..............252
Parts Requiring Angular Tightening .......................252
Precaution for Liquid Gasket .................................253
Precaution for Diesel Equipment ...........................253
Installation of Thread Inserts .................................257
PREPARATION .........................................258
PREPARATION ...............................................258
Special Service Tools ............................................258
Commercial Service Tools .....................................260
ON-VEHICLE MAINTENANCE ..................263