EC-1298
< SERVICE DATA AND SPECIFICATIONS (SDS) [K9K]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Idle SpeedINFOID:0000000001162748
*: Under the following conditions
A/C switch: OFF
Electric load: OFF (Lights, glow plug, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead positionCondition Specification
No load* (in Neutral position) 800 ± 50 rpm
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
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
FUEL INJECTOR AND FUEL TUBE
EM-39
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
c. Align center to insert quick connector straightly into fuel tube.
Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the 2nd level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
Hold “A” position shown when inserting fuel tube into
quick connector.
Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
Insert until you hear a “click” sound and actually feel
the engagement.
To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position.
Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (1) to quick connector connection.
Install quick connector cap with the side arrow facing quick
connector side (fuel feed hose side).
CAUTION:
Make sure that the quick connector and fuel tube are
securely engaged with the quick connector cap mount-
ing groove.
Quick connector may not be connected correctly if
quick connector cap cannot be installed easily. Remove
the quick connector cap, and then check the connection
of quick connector again.
f. Install fuel feed hose to hose clamp.
7. Installation is in the reverse order of removal, for the remaining parts.
InspectionINFOID:0000000001381405
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, make sure
there are no fuel leaks at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
KBIA0272E
PBIC3664E
EM-44
< ON-VEHICLE REPAIR >[HR16DE]
OIL PAN (UPPER) AND OIL STRAINER
c. Apply a continuous bead of liquid gasket (C) with the tube
presser (SST: WS39930000) to areas shown.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Installation should be done within 5 minutes after coating.
d. Tighten bolts in the numerical order shown.
CAUTION:
Install avoiding misalignment of both oil pan gasket and O-
ring.
The bolts are different according to the installation position.
Follow the numbers shown.
2. Install rear oil seal with the following procedure:
CAUTION:
The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
Do not touch oil seal lip.
a. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a spatula.
b. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Liquid Gasket or equivalent.
c. Press-fit the rear oil seal using a drift with outer diameter 113
mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial
service tool) (A).
A : 2 mm (0.07 in) protruded to outside
B : 2 mm (0.07 in) protruded to rear oil seal mounting side
: Engine front
: Engine out side
PBIC4344E
: Engine front
M8 × 179 mm (7.09 in) : No. 9, 10
M8 × 25 mm (0.98 in) : No. 4, 7, 8
M8 × 90 mm (3.54 in) : No. 1, 2, 3, 5, 6 MBIB1374E
PBIC3660E
EM-52
< ON-VEHICLE REPAIR >[HR16DE]
TIMING CHAIN
9. Remove front cover with the following procedure:
a. Loosen bolts in the reverse of the order shown.
b. Cut liquid gasket by prying the position ( ) shown, and then
remove the front cover.
10. Remove front oil seal from front cover.
Remove by lifting it up using a suitable tool.
CAUTION:
Be careful not to damage the front cover.
11. Remove chain tensioner (1) with the following procedure.
a. Fully push down the chain tensioner lever (A), and then push the
plunger (C) into the inside of tensioner.
The tab (B) is released by fully pushing the lever down. As a
result, the plunger can be moved.
b. Pull up the lever to align its hole position with the body hole posi-
tion.
When the lever hole is aligned with the body hole position, the
plunger is fixed.
When the protrusion parts of the plunger ratchet and the tab
face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
slightly moving the plunger.
c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper
position.
The example that a hexagonal wrench for 2.5 mm (0.098 in) is used as shown.
d. Remove chain tensioner.
KBIA3429J
PBIC3712E
PBIC3713E
TIMING CHAIN
EM-55
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
c. Install chain tensioner (1).
Insert the body into the shaft (B) while inserting the spring into
the fixing hole (A) of cylinder block front surface.
Make sure that the tension is applied to the oil pump drive
chain after installing.
2. Install timing chain with the following procedure.
Install by aligning matching marks on each sprocket and tim-
ing chain.
If these matching marks are not aligned, rotate the camshaft
slightly to correct the position.
CAUTION:
Check matching mark position of each sprocket and tim-
ing chain again after installing the timing chain, keep
matching marks aligned by holding them with a hand.
To avoid skipped teeth, never rotate crankshaft and cam-
shaft until front cover is installed.
3. Install timing chain tension guide (2) and timing chain slack
guide (1).
4. Install chain tensioner (1).
Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
Securely pull out the stopper pin after installing the chain ten-
sioner.
PBIC3716E
A : Dark blue link
B : Matching mark (stamp)
C : Orange link
D : Matching mark (stamp)
E : Crankshaft key (point straight up)
F : Matching mark (peripheral stamp line)
G : Dark blue link
PBIC3721E
PBIC3714E
PBIC3722E
CAMSHAFT
EM-63
< ON-VEHICLE REPAIR >[HR16DE]
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
If the lock pin is not released by hands, tap the camshaft
sprocket (INT) lightly with a plastic hammer (A).
If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.
d. While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counter-
clockwise direction in the most advanced angle position.
Keep the air pressure on.
If there is no click, as soon as the vane-side (camshaft side)
starts moving independently of the sprocket, the lock pin has
become disengaged.
Make sure that it is in the most advanced angle position by
seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown.
e. Complete the applying procedure of air pressure and the holding procedure of camshaft (INT).
f. Insert the stopper pin (A) into the stopper pin holes in the cam-
shaft sprocket (INT) and lock in the most advanced angle posi-
tion.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent
it from coming out.
NOTE:
The stopper pin shows one example of a hexagonal wrench for
2.5 mm (0.098 in) [length of inserted section: approximately15
mm (0.59 in)].
13. Remove camshaft brackets (No. 2 to 5).
Loosen bolts in several steps in the reverse of the order
shown.
NOTE:
The camshaft bracket (No. 1) has been already removed.
14. Remove camshaft (EXH).
AWBIA0106ZZ
C : Most retarded angle (lock pin engaged)
D : Most advanced angle
PBIC3684E
AWBIA0107ZZ
A : EXH side
B : INT side
: Engine front
PBIC3686E