EM-8
< PRECAUTION >[HR16DE]
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precaution for Drain CoolantINFOID:0000000001527635
Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001527636
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000001527637
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
where noted in the step.
Precaution for Inspection, Repair and ReplacementINFOID:0000000001527638
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001527639
Use torque wrench to tighten bolts or nuts to specification.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route after draining coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
Parts Requiring Angular TighteningINFOID:0000000001527640
Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Camshaft sprocket (INT)
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Do not use a torque value for final tightening. Tool number : KV10112100 (BT-8653-A)
PRECAUTIONS
EM-9
< PRECAUTION >[HR16DE]
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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]
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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 -58
< ON-VEHICLE REPAIR >[HR16DE]
TIMING CHAIN
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain as necessary.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-19, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.A: Crack
B: Wear
JPBIA0091ZZ
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
CAMSHAFT
EM-75
< ON-VEHICLE REPAIR >[HR16DE]
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The following are procedures for checking fluids leak, lubricates leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-19, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-131, "
Diagnosis Pro-
cedure" (EURO-OBD), EC-484, "Diagnosis Procedure" (WITHOUT EURO-OBD).
Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-6, "
Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-377, "
Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
b. Remove intake manifold. Refer to EM-29, "
Exploded View".
c. Disconnect ignition coil and injector harness connectors. Refer to EM-47, "
Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-50, "
Exploded View".
4. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End
crank after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
Prevent splashing by using a shop cloth so as to prevent
the worker from injury from engine oil and so as to prevent engine oil contamination.
Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
1: Plug
:Engine front
PBIC3706E
EM-80
< ON-VEHICLE REPAIR >[HR16DE]
CYLINDER HEAD
CYLINDER HEAD
Removal and InstallationINFOID:0000000001381421
REMOVAL
1. Release fuel pressure. Refer to EC-377, "Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
2. Drain engine coolant and engine oil. Refer to CO-11, "
Changing Engine Coolant" and LU-7, "Draining".
CAUTION:
Perform this step when the engine is cold.
Never spill engine coolant and engine oil on drive belt.
3. Remove the following components and related parts.
Front fender protector (RH): Refer to EXT-22, "
Removal and Installation".
Generator: Refer to CHG-15, "
Removal and Installation".
Exhaust front tube: Refer to EX-5, "
Component".
Exhaust manifold: Refer to EM-32, "
Exploded View".
Intake manifold: Refer to EM-29, "
Exploded View".
Fuel tube and fuel injector: Refer to EM-35, "
Exploded View".
Water outlet: Refer to CO-24, "
Removal and Installation".
Drive belt: Refer to EM-16, "
Removal and Installation".
Front cover: Refer to EM-50, "
Exploded View".
Camshaft: Refer to EM-59, "
Exploded View".
4. Remove cylinder head loosening bolts in reverse order as
shown with cylinder head wrench (commercial service tool).
1. Cylinder head assembly 2. Cylinder head bolt 3. Washer
4. Cylinder head gasket
A. Refer to EM-80
PBIC3731E
A : EXH side
B: INT side
: Engine front
PBIC3732E
CYLINDER HEAD
EM-81
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5. Remove cylinder head gasket.
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-127, "
Cylinder
Block".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
If it exceeds the limit, replace cylinder head.
INSTALLATION
1. Install new cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown with the
following procedure to install cylinder head.
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Follow the “Cylinder Head Bolts
Outer Diameter” measurement procedure.
a. Apply new engine oil to threads and seating surfaces of mount-
ing bolts.
b. Tighten all bolts.
c. Completely loosen.
CAUTION:Limit (“d1”–“d2”): 0.15 mm (0.0059 in)
PBIC3717E
A : Straightedge
B : Feeler gauge
Limit : Refer to EM-125, "Cylinder Head".
PBIC3207J
A : EXH side
B : INT side
: Engine front
: 66.7 N·m (6.8 kg-m, 49 ft-lb)
: 0 N·m (0 kg-m, 0 ft-lb)
PBIC3732E
EM-82
< ON-VEHICLE REPAIR >[HR16DE]
CYLINDER HEAD
In this step, loosen bolts in reverse order of that indicated.
d. Tighten all bolts.
e. Turn all bolts 75 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
ment by visual inspection without the tool.
f. Turn all bolts 75 degrees clockwise again (angle tightening).
3. Installation is in the reverse order of removal, for the remaining parts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-19, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- 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 gases, or any oil/fluids includ-
ing engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Disassembly and AssemblyINFOID:0000000001381422
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
PBIC3733E
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —