EM-170
< SERVICE INFORMATION >[VK45DE]
DRIVE BELTS
DRIVE BELTS
ComponentINFOID:0000000001325765
Checking Drive BeltsINFOID:0000000001325766
WARNING:
Be sure to perform when engine is stopped.
Remove air duct (inlet) when inspecting drive belt for alternator, water pump and A/C compressor.
Remove front engine undercover with power tool when inspecting power steering oil pump belt.
Make sure that indicator (single line notch) of eac
h auto tensioner is within the allowable working range
(between three line notches).
NOTE:
Check auto tensioner indication when engine is cold.
When new drive belt is installed, the range should be “A”.
The indicator notch is located on the moving side of auto tensioner for alternator, water pump and A/C
compressor belt, while it is found on the fixed side for power steering oil pump belt.
Visually check entire belt for wear, damage or cracks.
If the indicator is out of allowable wo rking range or belt is damaged, replace belt.
Tension AdjustmentINFOID:0000000001325767
Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner.
Removal and InstallationINFOID:0000000001325768
REMOVAL
Alternator, Water Pump and A/C Compressor Belt
1. Remove air duct (inlet). Refer to EM-173, "Component".
2. With box wrench, and while securely holding the hexagonal part in pulley center of auto tensioner, move wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not tu rn it clockwise). If turned
clockwise, the complete dri ve belt auto-tensioner must be
replaced as a unit, including the pulley.
PBIC2331E
PBIC2976E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
DRIVE BELTSEM-171
< SERVICE INFORMATION > [VK45DE]
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3. Under the above condition, insert a metallic bar of
approximately 6 mm (0.24 in) in diameter (hexagonal
bar wrench shown as example in the figure) through the holding boss to lock auto tensioner pulley arm.
Leave auto tensioner pulley arm locked until belt is installed again.
4. Remove alternator, water pump and A/C compressor belt.
Power Steering Oil Pump Belt
1. Remove air duct (inlet). Refer to EM-173, "Component".
2. Remove front engine undercover with power tool.
3. Remove alternator, water pump and A/C compressor belt. Refer to "Alternator, Water Pump and A/C Compressor Belt".
4. While securely holding the hexagonal protrusion part of auto tensioner pulley with box wrench, move wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a locat ion where pinching may occur
if holding tool accidentally comes off.
5. Under the above condition, insert a metallic bar of approximately 6 mm (0.24 in) in diameter (hexagonal bar wrench shown as
example in the figure) through the holding boss to lock auto ten-
sioner pulley arm.
Leave auto tensioner pulley arm locked until belt is installed
again.
6. Remove power steering oil pump belt.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Make sure belt is securely installed around all pulleys.
Make sure belt is correctly engaged with the pulley groove.
Check for engine oil and engine coolan t are not adhered belt and pulley groove.
Check that belt tension is within the allowable working range, using indicator notch on auto ten-
sioner. Refer to EM-170, "
Checking Drive Belts".
ComponentINFOID:0000000001325769
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
PBIC1543E
1.Auto tensioner ( Us
ed for alternator,
water pump and A/C compressor) 2. Idler pulley 3. Auto tensioner (Use
d for power steer-
ing oil pump belt)
PBIC2788E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-176
< SERVICE INFORMATION >[VK45DE]
INTAKE MANIFOLD
Refer to
GI-8, "Component" for symbols in the figure.
Removal and InstallationINFOID:0000000001325775
REMOVAL
WARNING:
To avoid the danger of being scalded, never drai n the engine coolant when the engine is hot.
1. Remove engine cover with power tool.
2. Release fuel pressure. Refer to EC-665, "
Fuel Pressure Check".
3. Remove air duct (inlet), power duct, air cleaner case and air duct and resonator assembly. Refer to EM-
173, "Component".
4. Drain engine coolant from radiator. Refer to CO-37, "
Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
Do not spill engine coolant on drive belts.
7. EVAP service port 8. EVAP tube 9. Vacuum hose
10. Vacuum hose 11. PCV hose 12. PCV tube
13. PCV hose 14. PCV hose 15. Water hose
16. EVAP hose 17. Water hose 18. Intake manifold adapter
19. Gasket 20. Electric throttle control actuator 21. Gasket
22. Gasket 23. Intake manifold (lower) 24. Vacuum hose
25. VIAS control solenoid valve 26. Vacuum hose 27. Vacuum hose
28. Vacuum tank 29. Vacuum hose 30. Engine cover bracket (LH)
31. Vacuum hose 32. Water hose 33. Gasket
34. Intake manifold (upper)
A. To centralized under-floor piping B. To rocker cover (right bank) C. To rocker cover (left bank)
D. To thermostat housing E. To air duct and resonator assembly F. To heater pipe
PBIC4553E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-178
< SERVICE INFORMATION >[VK45DE]
INTAKE MANIFOLD
Check the surface distortion of both the intake manifold (upper and
lower) mating surfaces with straightedge and feeler gauge.
If it exceeds the limit, replac e intake manifolds (lower and/or
upper).
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold (Lower)
Tighten in numerical order as shown in the figure.
There are two types of mounting bolts. Refer to the following for locating bolts.
Intake Manifold (Upper)
Tighten in numerical order as shown in the figure.
Electric Throttle Control Actuator
Install gasket with its directional protrusion set up/downward.
Tighten mounting bolts of electric throttle cont rol actuator equally and diagonally in several steps.
After installation perform procedure in "INSPECTION AFTER INSTALLATION".
Water Hose
Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
Va c u u m H o s e
Refer to EC-684, "Vacuum Hose Drawing".
INSPECTION AFTER INSTALLATION
Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control
actuator is disconnected. Refer to EC-663, "
Throttle Valve Closed Position Learning".
Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle
control actuator is replaced. Refer to EC-663, "
Idle Air Volume Learning".
Limit : 0.1 mm (0.004 in)
PBIC0016E
: Engine front
M8
× 90 mm (3.54 in) : 7, 8
M8 × 35 mm (1.38 in) : Except the above
PBIC3298E
: Engine front
PBIC3297E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-181
< SERVICE INFORMATION > [VK45DE]
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16. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifold.
NOTE:
Disregard the numerical order No. 9 to 12 in removal.
17. Remove exhaust manifold gaskets. CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion
Check the surface distortion of the each exhaust manifold flange
mating surface with straightedge and feeler gauge.
If it exceeds the limit, replace exhaust manifold.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
Install exhaust manifold gasket with its directional protrusion set upward.
Refer to the figure of components on former page. Refer to "Removal and Installation".
Exhaust Manifold
A : Left bank
B : Right bank : Engine front
PBIC3300E
Limit : 0.3 mm (0.012 in)
PBIC1550E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-186
< SERVICE INFORMATION >[VK45DE]
OIL PAN AND OIL STRAINER
Refer to the figure of components of former page for
installation direction of drain plug washer. Refer to
"Removal and Installation".
5. Install in the reverse order of removal after this step. NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-23, "Inspection".
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 15 minutes.
4. Check engine oil level again. Refer to LU-23, "
Inspection".
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-190
< SERVICE INFORMATION >[VK45DE]
FUEL INJECTOR AND FUEL TUBE
FUEL INJECTOR AND FUEL TUBE
ComponentINFOID:0000000001325784
Refer to
GI-8, "Component" for symbols in the figure.
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
Removal and InstallationINFOID:0000000001325785
REMOVAL
WARNING:
Put a “CAUTION: FLAMMABLE” sign in the workshop.
Be sure to work in a well ventilate d area and furnish workshop with a CO
2 fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
To avoid the danger of being scalded, do no t drain engine coolant when engine is hot.
1. Remove engine cover with power tool. Refer to EM-175, "
Component".
2. Release fuel pressure. Refer to EC-665, "
Fuel Pressure Check".
1. Fuel feed hose 2. Fuel feed hose bracket 3. Centralized under-floor piping
4. Quick connector cap 5. O-ring 6. Fuel tube (RH)
7. Spacer 8. Fuel feed damper 9. Fuel damper and fuel hose assembly
10. Clip 11. O-ring (Green) 12. Fuel injector
13. O-ring (Black) 14. Fuel tube (LH)
A. Refer to EM-190
PBIC4554E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
FUEL INJECTOR AND FUEL TUBEEM-193
< SERVICE INFORMATION > [VK45DE]
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When handling new O-rings, be careful of the following caution.
CAUTION:
Handle O-ring with bare hands. Do not wear gloves.
Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring an d its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not
to twist or stretch O-ring. If O-ring was stretc hed while it was being attached, do not insert it
quickly into fuel tube.
Insert new O-ring strai ght into fuel tube. Do not decenter or twist it.
Insert fuel feed damper straight into fuel tube (RH).
Tighten mounting bolts evenly in turn.
After tightening mounting bolts, make sure that there is no gap between flange and fuel tube (RH).
2. Install new O-rings to fuel injector paying attention to the following caution. CAUTION:
Upper and lower O-ring are different . Be careful not to confuse them.
Handle O-ring with bare hands. Never wear gloves.
Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretche d while it was being attached, do not insert it
quickly into fuel tube.
Insert O-ring straight into fuel in jector. Do not decenter or twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip into clip mounting groove on fuel injector. Insert clip so that “protrusion A” of fuel injector matches “cut-
out A” of clip.
CAUTION:
Do not reuse clip. Replace it with a new one.
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached. Insert it while matching it to the axial center.
Insert fuel injector so that “p rotrusion B” of fuel tube matches
“cutout B” of clip.
Make sure that fuel tube flange is securely fixed in flange fixing
groove on clip.
c. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
Make sure that protrusions of fuel injectors are aligned with
cutouts of clips after installation.
4. Install spacers on intake manifold (lower).
5. Install fuel tube and fuel injector assembly to intake manifold (lower). CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
Fuel tube side : Black
Nozzle side : Green
PBIC2545E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C