PRECAUTIONS
EM-9
< PRECAUTION >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid GasketINFOID:0000000001527641
REMOVAL OF LIQUID GASKET SEALING
After removing the bolts and nuts, separate the mating surface and
remove the sealant using Tool.
CAUTION:
Be careful not to damage the mating surfaces.
In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap (1) the cutter where the RTV Silicone Sealant is applied.
Use a plastic hammer to slide the cutter (2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old Silicone RTV Sealant adhering
to the gasket application surface and the mating surface.
Remove the sealant completely from the groove of the gasket
application surface, bolts, and bolt holes.
2. Thoroughly clean the gasket application surface and the mating
surface and remove adhering moisture, grease and foreign
materials.
3. Attach the sealant tube to the tube presser.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-27, "
Recommended Chemical Products and Sealants".
4. Apply the sealant without breaks to the specified location using
Tool.
If there is a groove for the sealant application, apply the seal-
ant to the groove.
As for the bolt holes, normally apply the sealant inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the text of this manual.
Within five minutes of the sealant application, install the mat-
ing component.
If the sealant protrudes, wipe it off immediately.
Do not retighten after the installation.
After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-19,
"Fluids and Lubricants".
CAUTION:Tool number : KV10111100 (J-37228)
WBIA0566E
PBIC0003E
Tool number WS39930000 ( – )
WBIA0567E
SEM159F
DRIVE BELTS
EM-15
< ON-VEHICLE MAINTENANCE >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
ON-VEHICLE MAINTENANCE
DRIVE BELTS
CheckingINFOID:0000000001381384
Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
Visually check belts for wear, damage, and cracks on inside and
edges.
Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the
test.
When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point.
Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( )
marked point.
CAUTION:
When the tension and frequency are measured, the acoustic tension gauge should be used.
When checking immediately after installation, first adjust it to the specified value. Then, after turning
crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection
between pulleys.
Tension AdjustmentINFOID:0000000001381385
CAUTION:
When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new belt
will not fully seat in the pulley groove.
When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”.
When installing a belt, make sure it is correctly engaged with the pulley groove.
Never allow oil or engine coolant to get on the belt.
Never twist or bend the belt strongly.
1. Loosen the idler pulley lock nut (A) from the tightening position
with the specified torque by 45 degrees.
1 : Generator
2 : Water pump
3 : Crankshaft pulley
4: A/C compressor (with A/C models)
: Idler pulley (without A/C models)
5 : Idler pulley
6: Drive belt
Belt Deflection / Belt Tension and Frequency : Refer to EM-122, "Drive Belts".
PBIC3642E
Location Location of adjuster and tightening method
Drive belt Adjusting bolt on idler pulley
1 : Generator
2: Water pump
3 : Crankshaft pulley
4: A/C compressor (with A/C models)
: Idler pulley (without A/C models)
5 : Idler pulley
6: Drive belt
A : Idler pulley lock nut
B : Adjusting bolt
PBIC3643E
EM-24
< ON-VEHICLE MAINTENANCE >[HR16DE]
COMPRESSION PRESSURE
COMPRESSION PRESSURE
InspectionINFOID:0000000001381392
1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to EC-377, "
Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-47, "
Exploded View".
4. Connect an engine tachometer (not required in use of CONSULT-III).
5. Install a compression tester (B) with an adapter (commercial
service tool) (A) onto spark plug hole.
Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
CAUTION:
Always use fully a changed battery to obtain the specified engine speed.
If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
If some cylinder has low compression pressure, pour 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, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder
head gasket.
7. After inspection is completed, install removed parts.
8. Start the engine, and confirm that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-469, "
Description".
PBIC3730E
SBIA0533E
Compression Pressure: Refer to EM-122, "General Specification".
EM-30
< ON-VEHICLE REPAIR >[HR16DE]
INTAKE MANIFOLD
7. Remove intake manifold support front (1) and bolt from rear (2).
Bracket (2) is not removed. Remove bolt from intake manifold.
8. Remove intake manifold.
Loosen bolts in the reverse of the order shown.
9. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
CAUTION:
Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
10. Remove intake manifold support (center) from cylinder head, if necessary.
NOTE:
The intake manifold support (center) functions as the guide when the intake manifold is installed.
INSTALLATION
Installation is in the reverse order of removal.
Intake Manifold
1. Install the gasket to the intake manifold.
Align the protrusion (A) of gasket to the groove of intake mani-
fold.
2. Place the intake manifold into the installation position.
CAUTION:
Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due
to interference with intake manifold.
JPBIA0278ZZ
: Engine front
PBIC3652E
PBIC3651E
FUEL INJECTOR AND FUEL TUBE
EM-37
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
5. Remove fuel tube protector.
Loosen bolts in the reverse of the order shown.
6. Remove the fuel injector and fuel tube assembly.
Loosen bolts in the reverse of the order shown.
CAUTION:
When removing, be careful to avoid any interference with
fuel injector.
Use a shop cloth to absorb any fuel leaks from fuel tube.
7. Remove the fuel injector (3) from the fuel tube (1) with the fol-
lowing procedure.
a. Open and remove the clip (2).
b. Remove fuel injector from the fuel tube by pulling straight.
CAUTION:
Be careful about fuel leakage remaining in fuel tube.
Be careful not to damage the nozzle of fuel injector.
Never subject fuel injector to impact by dropping or hit-
ting.
Never disassemble.
INSTALLATION
1. Install new the O-ring to the fuel injector, paying attention to the following.
CAUTION:
The upper and lower O-rings are different. Be careful not to confuse them.
Handle O-ring with bare hands. (Never wear gloves.)
Lubricate O-ring with engine oil.
Never clean O-ring with solvent.
Make sure that the O-ring and its mating part are free of foreign material.
Be careful not to scratch O-ring with tool or fingernails when installing it. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, never insert it into fuel tube immedi-
ately.
Insert O-ring straight into fuel tube. Never decenter or twist it.
: Engine front
PBIC3665E
: Engine front
PBIC3666E
PBIC3667E
Fuel tube side : Black
Nozzle side : Green
EM-38
< ON-VEHICLE REPAIR >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
2. Install the fuel injector (4) onto the fuel tube (1) with the following
procedure:
a. Insert the clips (2) into the clip mounting grooves on the fuel
injector.
Insert clip cut-out (D) into fuel injector protrusion (F).
CAUTION:
Always replace clip with new one.
Make sure that the clip does not interfere with the O-
ring. If interference occurs, replace the O-ring.
b. Insert the fuel injector into the fuel tube with clip attached.
Make sure that the axis is lined up when inserting.
Insert clip cut-out (C) into fuel tube protrusion (B).
Make sure that the flange (A) on the fuel tube fits securely in
the clip flange fixing groove (E).
c. Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
3. Install fuel tube and injector assembly onto cylinder head.
Tighten bolts in the numerical order shown.
CAUTION:
Be careful not to let tip of injector nozzle interfere with
other parts.
4. Install fuel tube protector.
Tighten bolts in the numerical order shown.
5. Connect harness connector to fuel injector.
6. Connect fuel feed hose with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
3 : O-ring (Black)
5 : O-ring (Green)
PBIC3668E
: Engine front
PBIC3666E
: Engine front
PBIC3665E
EM-40
< ON-VEHICLE REPAIR >[HR16DE]
OIL PAN (LOWER)
OIL PAN (LOWER)
Exploded ViewINFOID:0000000001381406
Removal and InstallationINFOID:0000000001381407
REMOVAL
1. Drain engine oil. Refer to LU-7, "Draining".
2. Remove the oil pan (lower) with the following procedure.
a. Loosen bolts in the reverse of the order shown.
b. Insert the seal cutter [SST: KV10111100] between oil pan
(upper) and oil pan (lower).
CAUTION:
Be careful not to damage the mating surface.
A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
using a flat- bladed screwdriver, etc.
1. Rear oil seal 2. O-ring 3. Oil pan (upper)
4. Chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket
7. Oil pump sprocket 8. Oil pan drain plug 9. Washer
10. Oil pan (lower) 11. Oil filter stud bolt 12. Oil filter
13. Oil level sensor
A. Refer to EM-50
B. Refer to LU-9C. Oil pan side
JPBIA0553GB
: Engine front
PBIC4345E
OIL PAN (LOWER)
EM-41
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
INSTALLATION
1. Install oil pan (lower) with the following procedure.
a. Use scraper to remove old liquid gasket from mating surfaces.
Also remove the old liquid gasket from mating surface of oil pan (upper).
Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Apply a continuous bead of liquid gasket (A) with the tube
presser (commercial service tool) to areas shown.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating.
c. Tighten bolts in the numerical order shown in the figure.
2. Install oil pan drain plug.
For installation direction of washer. Refer to EM-40, "
Exploded View".
3. Install in the reverse order of removal, for the rest of parts.
CAUTION:
Pour engine oil at least 30 minutes after oil pan is installed.
InspectionINFOID:0000000001381408
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "
Inspection".
: Engine out side
PBIC5006E
: Engine front
PBIC4345E