EM-120
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
HOW TO SELECT PISTON AND BEARING
Main Bearing Selection Table
Main Bearing Grade Table
Use Undersize Bearing Usage Guide
When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
PBIC3759E
Main Bearing Grade Table : Refer to EM-131, "Main Bearing".
EM-122
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000001381439
GENERAL SPECIFICATIONS
Drive BeltsINFOID:0000000001381440
BELT DEFLECTION:
*: When engine is cold.
BELT TENSION AND FREQUENCY:
Engine typeHR16DE
Cylinder arrangementIn-line 4
Displacement cm
3 (cu in)1,598 (97.51)
Bore and stroke mm (in)78.0 x 83.6 (3.071 x 3.291)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio10.7
Compression pressure
kPa (bar, kg/cm
2, psi)/200 rpmStandard 1,510 (15.1, 15.4, 219)
Minimum 1,265 (12.65, 12.9, 183)
Differential limit between cylinders 6.2 (0.06, 0.06, 0.9)
Valve timing
(Intake valve timing control - “ON”)
Unit: degree
abcde f
208 228 -11 (24) 59 (24) 4 24
JPBIA0552ZZ
LocationDeflection adjustment * Unit: mm (in)
Used belt
New belt
Limit After adjusted
Drive beltWith A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18)
Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15)
Applied pushing force 98 N (10 kg, 22 lb)
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-123
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
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*: When engine is cold.
Spark PlugINFOID:0000000001381441
SPARK PLUG (PLATINUM-TIPPED TYPE)
Unit: mm (in)
Exhaust ManifoldINFOID:0000000001381442
EXHAUST MANIFOLD
Unit: mm (in)
CamshaftINFOID:0000000001381443
CAMSHAFT
Unit: mm (in)
Location Tension adjustment * Unit: N (kg, lb) Frequency adjustment * Unit: Hz
Used belt
New beltUsed belt
New belt
Limit After adjusted Limit After adjusted
Drive beltWith A/C models 500 (51.0, 112)876 - 964
(89.4 - 98.3,
197 - 217)1064 - 1152
(108.5 - 117.5,
239 - 259)163 216 - 225 238 - 246
Without A/C models 500 (51.0, 112)876 - 964
(89.4 - 98.3,
197 - 217)1064 - 1152
(108.5 - 117.5,
239 - 259)183 242 - 252 266 - 276
MakeNGK
Standard typePLZKAR6A-11
Gap (Nominal)1.1 (0.043)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012)
Items Standard Limit
Camshaft runout [TIR*] 0.02 (0.0008) 0.1 (0.004)
Camshaft cam height “A”Intake 41.705 - 41.895 (1.6419 - 1.6494) —
Exhaust 40.175 - 40.365 (1.5817 - 1.5892) —
Camshaft journal diameterNo. 1 27.935 - 27.955 (1.0998 - 1.1006) —
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) —
Camshaft bracket inner diameterNo. 1 28.000 - 28.021 (1.1024 - 1.1032) —
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
Camshaft journal oil clearanceNo. 1 0.045 - 0.086 (0.0018 - 0.0034)
0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
SEM671
EM-128
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
AVAILABLE PISTON
Unit: mm (in)
PISTON RING
Unit: mm (in)
PISTON PIN
Cylinder bore inner diameter Standard 78.000 - 78.015 (3.0709 - 3.0715)
Out-of-round
Limit0.015 (0.0006)
Taper0.010 (0.0004)
Cylinder block main bearing housing inner diameter gradeGrade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W51.997 - 51.998 (2.0471 - 2.0472)
51.998 - 51.999 (2.0472 - 2.0472)
51.999 - 52.000 (2.0472 - 2.0472)
52.000 - 52.001 (2.0472 - 2.0473)
52.001 - 52.002 (2.0473 - 2.0473)
52.002 - 52.003 (2.0473 - 2.0474)
52.003 - 52.004 (2.0474 - 2.0474)
52.004 - 52.005 (2.0474 - 2.0474)
52.005 - 52.006 (2.0474 - 2.0475)
52.006 - 52.007 (2.0475 - 2.0475)
52.007 - 52.008 (2.0475 - 2.0476)
52.008 - 52.009 (2.0476 - 2.0476)
52.009 - 52.010 (2.0476 - 2.0476)
52.010 - 52.011 (2.0476 - 2.0477)
52.011 - 52.012 (2.0477 - 2.0477)
52.012 - 52.013 (2.0477 - 2.0478)
52.013 - 52.014 (2.0478 - 2.0478)
52.014 - 52.015 (2.0478 - 2.0478)
52.015 - 52.016 (2.0478 - 2.0479)
52.016 - 52.017 (2.0479 - 2.0479)
Difference in inner diameter between cylinders Standard Less than 0.015 (0.0006)
Item Standard Limit
Piston skirt diameter “A” 77.965 - 77.980 (3.0695 - 3.0701) —
Measure point “H” 37.1 (1.461) —
Piston pin hole diameter 19.006 - 19.012 (0.7483 - 0.7485) —
Piston to cylinder bore clearance 0.020 - 0.050 (0.0008 - 0.0020) 0.09 (0.0035)
PBIC0188E
Items Standard Limit
Piston ring side clearanceTop 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil (rail ring) 0.045 - 0.125 (0.0018 - 0.0049) —
Piston ring end gapTop 0.20- 0.30 (0.0079 - 0.0118) 0.50 (0.0197)
2nd 0.35 - 0.50 (0.0138 - 0.0197) 0.66 (0.0260)
Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.92 (0.0362)
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-129
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
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Unit: mm (in)
CONNECTING ROD
Unit: mm (in)
CRANKSHAFT
Unit: mm (in)
Piston pin outer diameter 18.996 - 19.002 (0.7479 - 0.7481)
Piston to piston pin oil clearance Standard 0.008 - 0.012 (0.0003 - 0.0005)
Center distance129.84 - 129.94 (5.11 - 5.12)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod small end clearance Standard –0.018 - –0.044 (–0.0007 - –0.0017)
Connecting rod small end inner diameter Standard 18.958 - 18.978 (0.7464 - 0.7472)
Connecting rod side clearance Standard 0.200 - 0.352 (0.0079 - 0.0139)
Connecting rod big end diameterGrade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N43.000 - 43.001 (1.6929 - 1.6929)
43.001 - 43.002 (1.6929 - 1.6930)
43.002 - 43.003 (1.6930 - 1.6930)
43.003 - 43.004 (1 6930 - 1.6931)
43.004 - 43.005 (1.6931 - 1.6931)
43.005 - 43.006 (1.6931 - 1.6931)
43.006 - 43.007 (1.6931 - 1.6932)
43.007 - 43.008 (1.6932 - 1.6932)
43.008 - 43.009 (1.6932 - 1.6933)
43.009 - 43.010 (1.6933 - 1.6933)
43.010 - 43.011 (1.6933 - 1.6933)
43.011 - 43.012 (1.6933 - 1.6934)
43.012 - 43.013 (1.6934 - 1.6934)
Center distance “r” 41.68 - 41.76 (1.6409 - 1.6441)
Out-of-round Limit 0.003 (0.0001)
Taper Limit 0.004 (0.0002)
Runout [TIR*] Limit 0.10 (0.0039)
Crankshaft end playStandard 0.098 - 0.260 (0.0039 - 0.0102)
Limit 0.35 (0.0138)
SEM645PBIC3459J
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-131
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
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UNDERSIZE TABLE
Unit: mm (in)
CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in)
Main BearingINFOID:0000000001381447
MAIN BEARING GRADE TABLE
Unit: mm (in)
UNDERSIZE TABLE
Unit: mm (in)
MAIN BEARING OIL CLEARANCE
Unit: mm (in)
Item Thickness Crankshaft pin journal diameter
US 0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644) Grind so that bearing clearance is the specified value.
Connecting rod bearing oil clearanceStandard 0.029 - 0.039 (0.0011 - 0.0015)
Limit 0.10 (0.0039)
Grade number Thickness Identification color Remarks
0 1.996 - 1.999 (0.0786 - 0.0787) Black
Grade and color are the same
for upper and lower bearings. 1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow
4 2.008 - 2.011 (0.0791 - 0.0792) Blue
5 2.011 - 2.014 (0.0792 - 0.0793) Pink
01UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
Grade and color are different
for upper and lower bearings. LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green
23UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
34UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
SEM685D
Items Thickness Main journal diameter
0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.
Main bearing oil clearance Standard 0.024 - 0.034 (0.0009 - 0.0013)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-133
< SYMPTOM DIAGNOSIS >[MR18DE]
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Use the Chart Below to Help You Find the Cause of the SymptomINFOID:0000000001337775
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedA. Rotational mechanism B. Water pump C. Timing chain
D. Drive belt E. Crankshaft pulley F. A/C compressor
G. Water pump H. Generator I. Tension pulley
J. Valve mechanism K. Valves
Location
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
Top of en-
gine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-238
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-186EM-186
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bushing
oil clearanceEM-219
EM-219
Slap or
rapA——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-219EM-219
EM-219
EM-219
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bushing
oil clearance
Connecting rod bearing
oil clearanceEM-219EM-219
Knock A B — A B CMain bear-
ing noiseMain bearing oil clear-
ance
Crankshaft runoutEM-219EM-219
Front of
engine
Front cov-
erTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-177
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-142
CreakingA B ABABDrive belt
(Slipping)Idler pulley bearing op-
eration
Squall
CreakAB—BABWater
pump
noiseWater pump operationCO-44
PRECAUTIONS
EM-135
< PRECAUTION >[MR18DE]
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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:0000000001337765
Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001337766
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:0000000001337767
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:0000000001337768
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001337769
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:0000000001337770
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)