EM-16
< ON-VEHICLE MAINTENANCE >[HR16DE]
DRIVE BELTS
CAUTION:
When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjust-
ment cannot be performed. Never loosen it excessively (more than 45 degrees).
Put a matching mark on the lock nut, and check turning angle with a protractor. Never visually
check the tightening angle.
2. Adjust the belt tension by turning the adjusting bolt.
CAUTION:
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 deflec-
tion between pulleys.
When the tension adjustment is performed, the lock nut should be in the condition at step“2”. If
the tension adjustment is performed when the lock nut is loosened more than the standard, the
idler pulley tilts and the correct tension adjustment cannot be performed.
3. Tighten the idler pulley lock nut.
Removal and InstallationINFOID:0000000001381386
REMOVAL
1. Loosen the idler pulley lock nut (A), and then adjust the belt ten-
sion by turning the adjusting bolt (B).
2. Remove drive belt.
INSTALLATION
1. Pull the idler pulley in the loosening direction, and then tempo-
rarily tighten the idler pulley lock nut (A) to the following torque.
NOTE:
Do not move the lock nut from the tightened position. Proceed to step “2”.
2. Install the drive belt to each pulley.
CAUTION:
Make sure that there is no oil, grease, or coolant, etc. in pulley grooves.
Make sure that the belt is securely inside the groove on each pulley.
3. Adjust drive belt tension by turning the adjusting bolt. Refer to EM-15, "
Tension Adjustment".
CAUTION:Idler pulley lock nut : 34.8 N·m (3.5 kg-m, 26 ft-lb)
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
PBIC3643E
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
B : Adjusting bolt
Idler pulley lock nut : 4.4 N·m (0.45 kg-m, 39 in-lb)
PBIC3643E
SPARK PLUG
EM-19
< ON-VEHICLE MAINTENANCE >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
SPARK PLUG
Exploded ViewINFOID:0000000001381388
Removal and InstallationINFOID:0000000001381389
REMOVAL
1. Remove intake manifold. Refer to EM-29, "Removal and Installation".
2. Remove ignition coil. Refer to EM-47, "
Removal and Installation".
3. Remove spark plug with a spark plug wrench (commercial ser-
vice tool).
INSPECTION AFTER REMOVAL
Use the standard type spark plug for normal condition.
CAUTION:
1. Ignition coil 2. Spark plug
PBIC3662E
PBIC3871E
Spark plug (Standard type): Refer to MA-29, "SPARK PLUG : In-
spection".
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".
INTAKE MANIFOLD
EM-29
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
INTAKE MANIFOLD
Exploded ViewINFOID:0000000001381398
Removal and InstallationINFOID:0000000001381399
REMOVAL
1. Remove the air duct (inlet) and air duct (between air cleaner case and electronic throttle control actuator).
Refer to EM-27, "
Exploded View".
2. Remove the reservoir tank. Refer to CO-16, "
Component".
3. Remove the oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
4. Remove electronic throttle control actuator and position aside.
CAUTION:
Handle electric throttle control actuator carefully and avoid impacts.
Never disassemble or adjust electric throttle control actuator.
5. Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid
valve.
6. Disconnect vacuum hose for brake booster from intake manifold.
PBIC4737E
1. EVAP hose 2. Vacuum tank 3. EVAP hose
4. O-ring 5.EVAP canister purge volume control
solenoid valve6. Electric throttle control actuator
7. Water hose (Northern Europe models) 8. Water hose (Northern Europe models) 9. Gasket
10. Intake manifold support (rear) 11. Intake manifold 12. Intake manifold support (front)
13. Intake manifold support (center) 14. Cylinder head 15. Vacuum hose
16. Gasket
A. To centralized under-floor piping B. To brake booster C. To water outlet
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