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ENGINE MAINTENANCE (MR18DE)
MA-41
< ON-VEHICLE MAINTENANCE >
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INSPECTION AFTER REMOVAL
CAUTION:
Never drop or shock spark plug.
Checking and adjusting spark plug gap is not required
between change intervals.
If spark plug tip is covered with carbon, a spark plug cleaner may be used.
Never use wire brush for cleaning spark plug.
INSTALLATION
1. Install spark plug using suitable tool.
CAUTION:
Never drop or shock it.
2. Install ignition coil.
CAUTION:
Handle it carefully and avoid impacts.
Never disassemble.
3. Install intake manifold. Refer to EM-156, "
Removal and Installation".
EVAP VAPOR LINES
EVAP VAPOR LINES : InspectionINFOID:0000000001277636
Refer to FL-10, "Removal and Installation"
SMA806CA
Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
SMA773C
Plug type : Platinum tipped
Make : NGK
Part number : PLZKAR6A-11
Gap (nominal) : 1.1 mm (0.043 in)
PBIC3871E
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MA-42
< ON-VEHICLE MAINTENANCE >
ENGINE MAINTENANCE (K9K)
ENGINE MAINTENANCE (K9K)
DRIVE BELTS
DRIVE BELTS : Exploded ViewINFOID:0000000001730873
DRIVE BELTS : Inspection and AdjustmentINFOID:0000000001730874
INSPECTION
WARNING:
Be sure to perform when the engine is stopped.
1. Inspect drive belt for cracks, fraying, wear and oil. Replace drive belt if necessary.
2. Manually evaluate the drive belt tension (tension cannot be measured using frequency meter).
3. Replace drive belt when tension is beyond normal operating limit.
CAUTION:
Auto-tensioner must be replaced with a new one when the belt is replaced.
ADJUSTMENT
Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.
ENGINE COOLANT
ENGINE COOLANT : InspectionINFOID:0000000001730880
LEVEL CHECK
Check if the reservoir tank engine coolant level is within the “MIN”
to “MAX” range when engine is cool.
Adjust the engine coolant level as necessary.
CHECKING COOLING SYSTEM FOR LEAKS
E1BIA0021ZZ
1. Crankshaft pulley 2. A/C compressor 3. Drive belt
4. Generator 5. Drive belt auto-tensioner
SMA412B
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ENGINE MAINTENANCE (K9K)
MA-43
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To check for leaks, apply pressure to the cooling system using suit-
able tool.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
ENGINE COOLANT : DrainingINFOID:0000000001730881
WARNING:
To avoid being scalded, do not change engine coolant when engine is hot.
Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter of a
turn to release built-up pressure. Then turn the cap all the way.
Be careful not to allow engine coolant to contact drive belt.
1. Remove engine undercover using power tool.
2. Disconnect radiator hose (lower) from radiator and remove reservoir tank cap.
When draining all of engine coolant in the system, open water drain plug on cylinder block. Refer
to EM-314, "
Exploded View".
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belt.
3. Remove air relief plug from water outlet. Refer to EM-302, "
Exploded View".
4. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.
5. Check drained coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer to CO-59, "
Flushing".
ENGINE COOLANT : RefillingINFOID:0000000001730882
Before starting work, turn off the automatic air conditioner and the blower motor.
1. Install reservoir tank if removed, lower radiator hose and air relief plug.
If water drain plug on cylinder block is removed, install and tighten it. Refer to EM-314,
"Exploded View".
2. Fill reservoir tank slowly with coolant until coolant spills from the air relief hole.
Put a cloth under the air relief plug to prevent engine coolant from dampening the crankshaft
position sensor.
Pour coolant to the MAX level line of the reservoir tank at
a rate of 2 liter (1-3/4 lamp qt.)/min. or lower.
3. Close the air relief plug.
CAUTION:
If the filling rate is too fast, this could lead to air being
mixed in the coolant. Be sure to fill the coolant slowly
according to the rate indicated above.
Use Insane Genuine Engine Coolant or equivalent mixed
with water (distilled or demineralized). Refer to MA-21,
"Engine Coolant Mixture Ratio". Testing pressure
: 157 kPa (1.6 kg/cm
2, 23 psi)
WBIA0568E
JPBIA0306ZZ
Engine coolant capacity
(With reservoir tank at MAX): Refer to MA-19, "Fluids and Lubricants".
Reservoir tank capacity : Refer to MA-19, "
Fluids and Lubricants".
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MA-44
< ON-VEHICLE MAINTENANCE >
ENGINE MAINTENANCE (K9K)
4. Start engine without closing reservoir tank cap and keep engine racing at 1,500 rpm for about 2-3 minutes.
If necessary, pour engine coolant up to MAX level.
If coolant overflows reservoir tank hole, install filler cap.
Watch engine coolant temperature gauge so as not overheat the engine.
WARNING:
Be careful not to be scaled with hot engine coolant or vacuum pump when operating.
Radiator fan blade can start at any time and cause personal injuries.
5. Turn off the engine and loosen air relief plug until coolant spills from air relief hole.
6. Close the air relief plug and run the engine at 2,000 rpm until the upper hose becomes hot and radiator
fan operates. Leave the engine running approximately 5 minutes at idle speed and check for sound of
coolant flow while running engine from idle up to 3,000 rpm.
Sound may be noticeable at heater water cock.
7. If sound is heard, bleed air from cooling system by repeating steps 4 to 6 until coolant level no longer
drops.
Check the radiator lower hose for any signs of leakage.
8. Turn off the engine and let it cool down.
Cool down using a fan to reduce the time.
9. After cooling period, loosen the air relief plug and check if coolant spills from the air relief hole. if not,
remove the air relief plug until the coolant spills, and then close the relief air plug. Bleed air from cooling
system by repeating steps 6 to 10 until the coolant spills immediately.
10. Check the engine coolant level when engine is cool and refill to MAX level line if the level is lower.
Clean excess coolant from engine.
11. Check that the reservoir tank cap is tightened.
ENGINE COOLANT : FlushingINFOID:0000000001730883
1. Install reservoir tank if removed.
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-314, "
Exploded
View".
2. Fill reservoir tank with water until water spills from the air relief hole, then close air relief plug. Reinstall
reservoir tank cap.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from radiator.
8. Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water.
RADIATOR
RADIATOR : Checking Radiator CapINFOID:0000000001730884
Check valve seat of radiator cap.
- Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.
PBIC2816E
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ENGINE MAINTENANCE (K9K)
MA-45
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Pull negative-pressure valve to open it, and make sure that it is
completely closed when released.
- Make sure that there is no dirt or damage on the valve seat of radi-
ator cap negative-pressure valve.
- Make sure that the valve operates properly in the opening and
closing conditions.
Check radiator cap relief pressure using suitable tool.
- When connecting the radiator cap to the tester, apply water or
coolant to the cap seal surface.
- Replace the radiator cap if there is an abnormality in the negative-
pressure valve, or if the open-valve pressure is outside of the stan-
dard values.
Replace radiator cap if there it does not comply to specifications to the above three checks.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
RADIATOR : Checking RadiatorINFOID:0000000001730885
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud
and horns. Then tape harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2, 71 psi) and keep distance more than 30 cm
(11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
FUEL LINES
FUEL LINES : InspectionINFOID:0000000001277645
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.
SMA967B
Standard: 78 – 98 kPa (0.78 - 0.98 bar, 0.8 – 1.0 kg/cm2, 11
– 14 psi)
Limit: 59 kPa (0.59 bar, 0.6 kg/cm
2, 9 psi)
WBIA0570E
SMA803A
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MA-46
< ON-VEHICLE MAINTENANCE >
ENGINE MAINTENANCE (K9K)
AIR CLEANER FILTER
AIR CLEANER FILTER : Removal and InstallationINFOID:0000000001730875
REMOVAL
1. Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
2. Pull up the air cleaner cover (1) and remove it (C).
3. Remove air cleaner filter (1) and holder (2) assembly from the
air cleaner case.
4. Remove the air cleaner filter (1) from the holder (2).
INSPECTION AFTER REMOVAL
It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty
conditions. Refer to MA-7, "
Periodic Maintenance".
Blow air into the back side of air cleaner filter until no objects spray
out.
INSTALLATION
Installation is in the reverse order of removal.
Install the air cleaner cover (1) in the direction shown.
ENGINE OIL
PBIC3557J
PBIC3558J
SMA384C
2 : Air cleaner filter
3 : Holder
PBIC3559J
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ENGINE MAINTENANCE (K9K)
MA-47
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ENGINE OIL : InspectionINFOID:0000000001730878
OIL LEVEL AND MUDDINESS
Before starting the engine, check the oil level placing the vehicle
on a level surface. If the engine is already started, stop it and allow
10 minutes before checking.
Make sure the oil level is within the range shown.
If it is out of range, adjust it.
Check the oil for white turbidity or remarkable contamination.
If the oil becomes turbid and white, it is highly probable that it is
contaminated with coolant. Find the cause and repair.
OIL LEAKAGE
Check for oil leakage around the following area.
Oil pan
Oil pan drain plug
Oil pressure switch
Oil filter bracket
Vacuum pump
Oil pump housing
Mating surface between cylinder block and cylinder head
Mating surface between cylinder head and rocker cover
Oil cooler
Crankshaft oil seals
OIL PRESSURE CHECK
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
Oil pressure check should be done in Neutral “N” position.
1. Check the engine oil level.
2. Remove engine undercover using power tool.
3. Disconnect the electrical connector (A) and remove the oil pres-
sure switch (1) to connect the oil pressure gauge [SST:
KV113E0020 (Mot. 836-05)].
4. After warming up the engine, make sure oil pressure corre-
sponding to the engine speed is produced.
5. After checking, install the oil pressure switch (1) as follows.
a. Remove old sealant adhering to the oil pressure switch (1) and
engine.
b. Apply thread sealant.
Use Genuine Liquid Gasket or equivalent.
6. Start engine and check for oil leakage.
ENGINE OIL : DrainingINFOID:0000000001730876
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
MBIB0548E
Idle speed : Refer to LU-33, "EngineOilPressure".
3000 rpm : Refer to LU-33, "
EngineOilPressure".
Oil pressure switch:
: 25 N·m (2.55 kg-m, 18.4 ft-lb)
ALBIA0418ZZ
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MA-48
< ON-VEHICLE MAINTENANCE >
ENGINE MAINTENANCE (K9K)
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct skin
contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as
possible.
1. Put the vehicle on a level surface.
2. Warm up engine, and check for oil leakage from engine components.
3. Stop engine and wait for 10 minutes.
4. Loosen oil filler cap.
5. Remove drain plug and then drain engine oil.
ENGINE OIL : RefillingINFOID:0000000001730877
1. Refill with new engine oil.
The refill capacity depends on the oil temperature and drain time.
Use these specifications for reference only.
Always use the dipstick to determine when the proper amount of oil
is in the engine.
CAUTION:
Be sure to clean drain plug and install with new washer.
The refill capacity depends on the oil temperature and drain
time. Use these specifications for reference only.
Always use the dipstick to determine when the proper amount of oil is in the engine.
2. Warm up engine and check area around drain plug and oil filter for oil leakage.
3. Stop engine and wait for 10 minutes.
4. Check oil level and add engine oil as necessary. Refer to LU-26, "
Inspection".
OIL FILTER
OIL FILTER : ReplacementINFOID:0000000001730879
1. Remove engine undercover using power tool.
2. Using an oil filter wrench [SST: KV113C0010 (Mot. 1329)],
remove oil filter.
CAUTION:
Be careful not to get burned when the engine and engine
oil are hot.
When removing, prepare a shop cloth to absorb any oil
leakage or spillage.
Do not allow engine oil to adhere to the drive belts.
Completely wipe off any oil that adhere to the engine and
the vehicle.
3. Remove foreign materials adhering to the oil filter installation
surface.
4. Install oil filter bracket to oil cooler.
CAUTION:
Install oil filter bracket, positioning lug in the hole of oil cooler. Oil capacity
(Approximate): Refer to MA-19, "
Fluids and
Lubricants".
MBIB0548E
MBIB0551E