IGNITION SIGNAL
EC-539
< SERVICE INFORMATION >
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1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
4. If NG, replace ignition coil with power transistor.
If OK, go to next step.
5. Turn ignition switch OFF.
6. Reconnect all harness connectors disconnected.
7. Remove fuel pump fuse (1) in IPDM E/R (2) to release fuel pres-
sure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pres-
sure applies again during the following procedure.
- : Vehicle front
8. Start engine.
9. After engine stalls, crank it two or three times to release all fuel
pressure.
10. Turn ignition switch OFF.
11. Remove all ignition coil harness connectors to avoid the electri-
cal discharge from the ignition coils.
12. Remove ignition coil and spark plug of the cylinder to be checked.
13. Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
14. Connect spark plug and harness connector to ignition coil.
15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
16. Crank engine for about 3 seconds, and check whether spark is
generated between the spark plug and the grounded metal por-
tion.
CAUTION:
• Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the electrical discharge voltage
becomes 20kV or more.
• It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.
CONDENSER-2
1. Turn ignition switch OFF.
2. Disconnect condenser-2 harness connector.
Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)]
1 and 2 Except 0 or ∞
1 and 3
Except 0
2 and 3
Spark should be generated.
PBIB0847E
PBIB2958E
PBIB2325E
EC-540
< SERVICE INFORMATION >
IGNITION SIGNAL
3. Check resistance between condenser-2 terminals 1 and 2.
4. If NG, replace condenser-2.
Removal and InstallationINFOID:0000000001703075
IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-30. Resistance: Above 1 MΩ [at 25°C (77°F)]
PBIB0794E
EM-1
ENGINE
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SECTION EM
A
EM
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CONTENTS
ENGINE MECHANICAL
SERVICE INFORMATION ............................3
PRECAUTIONS ...................................................3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
3
Precaution for Procedure without Cowl Top Cover ......3
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .....................................
3
Precaution for Drain Coolant .....................................4
Precaution for Disconnecting Fuel Piping .................4
Precaution for Removal and Disassembly ................4
Precaution for Inspection, Repair and Replace-
ment ..........................................................................
4
Precaution for Assembly and Installation ..................4
Parts Requiring Angular Tightening ..........................4
Precaution for Liquid Gasket .....................................5
PREPARATION ...................................................7
Special Service Tool .................................................7
Commercial Service Tool ..........................................9
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................
11
NVH Troubleshooting - Engine Noise .....................11
Use the Chart Below to Help You Find the Cause
of the Symptom .......................................................
12
DRIVE BELTS ....................................................13
Component ..............................................................13
Checking Drive Belts ...............................................13
Tension Adjustment ................................................13
Removal and Installation .........................................13
Component ..............................................................14
Removal and Installation of Drive Belt Auto Ten-
sioner ......................................................................
14
AIR CLEANER AND AIR DUCT ........................16
Component ..............................................................16
Removal and Installation .........................................16
Changing Air Cleaner Filter .....................................17
INTAKE MANIFOLD .........................................18
Component ..............................................................18
Removal and Installation .........................................18
EXHAUST MANIFOLD ......................................21
Component ..............................................................21
Removal and Installation .........................................21
OIL PAN ............................................................24
Component ..............................................................24
Removal and Installation .........................................24
IGNITION COIL, SPARK PLUG AND ROCK-
ER COVER ........................................................
30
Component ..............................................................30
Removal and Installation .........................................30
FUEL INJECTOR AND FUEL TUBE ................33
Component ..............................................................33
Removal and Installation .........................................33
TIMING CHAIN ..................................................37
Component ..............................................................37
Removal and Installation .........................................38
CAMSHAFT .......................................................47
Component ..............................................................47
Removal and Installation .........................................47
Valve Clearance ......................................................55
OIL SEAL ..........................................................59
Removal and Installation of Valve Oil Seal ..............59
Removal and Installation of Front Oil Seal ..............59
Removal and Installation of Rear Oil Seal ...............60
CYLINDER HEAD .............................................62
On-Vehicle Service ..................................................62
Component ..............................................................63
Removal and Installation .........................................63
Component ..............................................................65
Disassembly and Assembly .....................................66
Inspection After Disassembly ..................................67
EM-4
< SERVICE INFORMATION >
PRECAUTIONS
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
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-III.
Precaution for Drain CoolantINFOID:0000000001702463
• Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000001702464
• 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:0000000001702465
• 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:0000000001702466
• Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000001702467
• 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:0000000001702468
• 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)
EM-12
< SERVICE INFORMATION >
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom
INFOID:0000000001702473
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 relatedD. Drive belt E. Crankshaft pulley F. A/C compressor
G. Water pump H. Generator I. Tension pulley
J. Valve mechanism K. Valves
Location
of noiseTyp e 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-104
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-47EM-47
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-93
EM-93
Slap or
rapA——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-93EM-93
EM-93
EM-93
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bushing
oil clearance
Connecting rod bearing
oil clearanceEM-93EM-93
Knock A B — A B CMain bear-
ing noiseMain bearing oil clear-
ance
Crankshaft runoutEM-93EM-93
Front of
engine
Front cov-
erTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-38
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing op-
eration
Squall
CreakAB—BABWater
pump
noiseWater pump operationCO-16
EM-14
< SERVICE INFORMATION >
DRIVE BELTS
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a box wrench securely. Then move the wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6
mm (0.24 in) in diameter into the hole (B) of retaining boss to fix
drive belt auto-tensioner.
3. Install drive belt.
CAUTION:
• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-13, "
Checking Drive Belts".
ComponentINFOID:0000000001702478
Removal and Installation of Drive Belt Auto TensionerINFOID:0000000001702479
REMOVAL
1. Remove drive belt. Refer to EM-13, "Removal and Installation".
2. Release the fixed drive belt auto-tensioner pulley.
3. Loosen bolt and remove drive belt auto-tensioner.
NOTE:
PBIC3936E
1. Front cover 2. Drive belt auto–tensioner 3. Idler pulley (models without A/C)
4. Bracket (models without A/C) 5. Shaft (models without A/C)
PBIC4698E
IGNITION COIL, SPARK PLUG AND ROCKER COVER
EM-31
< SERVICE INFORMATION >
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3. Remove spark plug using suitable tool.
CAUTION:
Never drop or shock it.
4. Remove rocker cover.
• Loosen bolts in reverse order as shown.
• Engine front
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 rocker cover gasket to rocker cover.
PBIC3871E
PBIC3151J
SMA806CA
Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
SMA773C
EM-32
< SERVICE INFORMATION >
IGNITION COIL, SPARK PLUG AND ROCKER COVER
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as
shown.
• Engine front
CAUTION:
Check if rocker cover gasket is not dropped from the instal-
lation groove of rocker cover.
3. Install spark plug using suitable tool.
CAUTION:
Never drop or shock it.
4. Install ignition coil.
CAUTION:
• Handle it carefully and avoid impacts.
• Never disassemble.
5. Install intake manifold. Refer to EM-18
. 1st step : 1.96 N·m (0.20 kg-m, 17 in-lb)
2nd step : 8.33 N·m (0.85 kg-m, 73 in-lb)
PBIC3151J
Plug type : Iridium tipped
Make : DENSO
Part number : FXE20HR11
Gap (nominal) : 1.1 mm (0.043 in)
PBIC3871E