ENGINE ASSEMBLY
EM-75
< REMOVAL AND INSTALLATION >
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a. Tighten the bolt No. 2 as shown in the figure. (temporarily)
b. Tighten the bolts in numerical order as shown in the figure.
(specified torque)
InspectionINFOID:0000000003802274
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leak, lubricates leak and exhaust gases 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-11, "
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 check there is no leakage of fuel, exhaust gases, 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.: Vehicle front
JPBIA1743ZZ
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 —
CAMSHAFT
EM-91
< DISASSEMBLY AND ASSEMBLY >
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Check if surface of valve lifter has any wear or cracks.
If anything above is found, replace valve lifter. Refer to EM-136,
"Camshaft".
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER Measure the outer diameter at 1/2 height of valve lifter with a
micrometer (A) since valve lifter is in barrel shape.
VALVE LIFTER HOLE DIAMETER Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer.
VALVE LIFTER CLEARANCE (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
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-137, "
Diagnosis Pro-
cedure".
Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-7, "
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-411, "
Inspection".
KBIA0182E
Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
JPBIA0125ZZ
Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
SEM867E
Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
EM-92
< DISASSEMBLY AND ASSEMBLY >
CAMSHAFT
b. Disconnect ignition coil and injector harness connectors. Refer to EM-49, "Exploded View" and EM-44,
"Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-79, "
Exploded View".
4. Crank engine, and then check 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 belt, 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 no to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
Remove oil filter, and then clean it. Refer to LU-10, "
Removal and Installation".
Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2,
"EngineLubricationSystem".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
Clean oil groove if necessary. Refer to LU-2, "
EngineLubricationSystem".
7. After inspection, install removed parts in the reverse order.
Inspection for Leakage
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-11, "
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 check 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.1 : Valve timing control cover (bank 2)
: Engine front
JPBIA1783ZZ
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
EM-104
< DISASSEMBLY AND ASSEMBLY >
CYLINDER HEAD
c. Using a drift, press-fit spark plug tube so that its height (A) is as
specified in the figure.
CAUTION:
When press-fitting, take care not to deform spark plug
tube.
After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
11. Install spark plug with the spark plug wrench (commercial service tool).
InspectionINFOID:0000000003802292
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (C) and (B)
exceeds the limit, replace them with new one.
If reduction of outer diameter appears in a position other than (B),
use it as (B) point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-143,
"CylinderBlock".
1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions (A), (B), (C), (D), (E) and
(F).
If it exceeds the limit, replace cylinder head.
INSPECTION AFTER DISASSEMBLY
Valve Dimensions
Check the dimensions of each valve. For the dimensions, refer to EM-139, "CylinderHead".
If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "Valve Seat Con-
tact".
Valve Guide Clearance
Valve Stem Diameter
B : High strength thread locking sealant application area
Standard press-fit height: 37.7 - 38.7 mm (1.484 - 1.524 in)
JPBIA0181ZZ
Limit [(C) - (B)] : 0.11 mm (0.0043 in)
A : Measuring point
d : 11 mm (0.43 in)
e : 48 mm (1.89 in)
JPBIA0173ZZ
Limit : Refer to EM-139, "CylinderHead".
JPBIA0176ZZ
EM-106
< DISASSEMBLY AND ASSEMBLY >
CYLINDER HEAD
Check the valve spring pressure at specified spring height.
If the installation load or load with valve open is out of the stan-
dard, replace valve spring.
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leak, lubricates leak and exhaust gases 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-11, "
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 check there is no leakage of fuel, exhaust gases, 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.
Standard (Intake and exhaust)
: Refer to EM-139,
"CylinderHead". Free height
Installation height
Installation load
Height during valve open
Load with valve open
SEM113
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 —
FSU-16
< REMOVAL AND INSTALLATION >
FRONT SUSPENSION MEMBER
REMOVAL AND INSTALLATION
FRONT SUSPENSION MEMBER
Exploded ViewINFOID:0000000003811126
Removal and InstallationINFOID:0000000003811127
REMOVAL
1. Remove tires.
2. Remove under cover.
3. Remove wheel sensor. Refer to BRC-57, "
FRONT WHEEL SENSOR : Exploded View" (without VDC),
BRC-151, "
FRONT WHEEL SENSOR : Exploded View" (with VDC).
4. Remove lock plate of brake hose. Refer to BR-19, "
FRONT : Exploded View".
5. Remove caliper assembly. Hang caliper assembly not to interfere with work. Refer to BR-34, "
BRAKE
CALIPER ASSEMBLY : Exploded View".
6. Remove stabilizer connecting rod (upper side). Refer to FSU-14, "
Exploded View".
7. Remove exhaust front tube. Refer to EX-5, "
Exploded View".
8. Remove power steering solenoid valve harness connector and harness clip. Refer to ST-18, "
Exploded
View".
9. Remove heat insulator from suspension member.
10. Remove drive shaft. Refer to FAX-18, "
LEFT SIDE : Removal and Installation" (left side), FAX-19, "RIGHT
SIDE : Removal and Installation" (right side).
11. Separate lower shaft and steering gear assembly. Refer to ST-16, "
Exploded View".
12. Remove power steering oil pump and then separate suction hose and high pressure piping. Refer to ST-
28, "Exploded View", ST-34, "Exploded View".
13. Separate engine mount insulator from engine assembly. Refer to EM-67, "
Exploded View".
14. Set suitable jack to front suspension member.
15. Remove front suspension member stay.
16. Remove front suspension member mounting bolts.
17. Gradually lower the jack placed at the front suspension member.
CAUTION:
Perform the work while checking that the jack is stable.
1. Front suspension member 2. Rebound stopper 3. Front suspension member stay
Refer to GI-4, "
Components" for symbols in the figure.
JPEIA0102GB
GI-1
GENERAL INFORMATION
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CONTENTS
GENERAL INFORMATION
HOW TO USE THIS MANUAL ......................3
HOW TO USE THIS MANUAL ............................3
Description ................................................................3
Terms ........................................................................3
Units ..........................................................................3
Contents ....................................................................3
Relation between Illustrations and Descriptions .......4
Components ..............................................................4
HOW TO FOLLOW TROUBLE DIAGNOSES .....6
Description ................................................................6
How to Follow Test Groups in Trouble Diagnosis ......6
Key to Symbols Signifying Measurements or Pro-
cedures .....................................................................
7
HOW TO READ WIRING DIAGRAMS ................9
Connector Symbols ...................................................9
Sample/Wiring Diagram -Example- .........................10
Description ..............................................................11
ABBREVIATIONS ..............................................13
Abbreviation List ......................................................13
TIGHTENING TORQUE OF STANDARD
BOLTS ................................................................
14
Description ..............................................................14
Tightening Torque Table (New Standard Includ-
ed) ...........................................................................
14
TERMINOLOGY .................................................17
SAE J1930 Terminology List ...................................17
FEATURES OF NEW MODEL .....................21
IDENTIFICATION INFORMATION .....................21
Model Variation .......................................................21
Information About Identification or Model Code ......21
Dimensions .............................................................23
Wheels & Tires ........................................................23
PRECAUTION ..............................................24
PRECAUTIONS .................................................24
Description ...............................................................24
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
24
Precautions For Xenon Headlamp Service .............24
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ...................................
24
Precaution for Procedure without Cowl Top Cover ....25
General Precautions ................................................25
Three Way Catalyst .................................................27
Multiport Fuel Injection System or Engine Control
System .....................................................................
27
Hoses ......................................................................27
Engine Oils ..............................................................28
Air Conditioning .......................................................28
Fuel ..........................................................................29
LIFTING POINT .................................................30
Commercial Service Tools .......................................30
Garage Jack and Safety Stand and 2-Pole Lift .......30
Board-On Lift ...........................................................31
TOW TRUCK TOWING .....................................32
Tow Truck Towing ...................................................32
Vehicle Recovery (Freeing a Stuck Vehicle) ...........32
BASIC INSPECTION ...................................34
SERVICE INFORMATION FOR ELECTRICAL
INCIDENT ..........................................................
34
Work Flow ................................................................34
Control Units and Electrical Parts ............................34
Intermittent Incident .................................................35
Circuit Inspection .....................................................37
CONSULT-III/GST CHECKING SYSTEM .........43
Description ...............................................................43
CONSULT-III Function and System Application*1 ....43
CONSULT-III/GST Data Link Connector (DLC)
Circuit ......................................................................
43
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
GI-35
< BASIC INSPECTION >
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Do not apply excessive shock to the control unit by dropping or hit-
ting it.
Be careful to prevent condensation in the control unit due to rapid
temperature changes and do not let water or rain get on it. If water
is found in the control unit, dry it fully and then install it in the vehi-
cle.
Be careful not to let oil to get on the control unit connector.
Avoid cleaning the control unit with volatile oil.
Do not disassemble the control unit, and do not remove the upper
and lower covers.
When using a DMM, be careful not to let test probes get close to
each other to prevent the power transistor in the control unit from
damaging battery voltage because of short circuiting.
When checking input and output signals of the control unit, use the
specified check adapter.
Intermittent IncidentINFOID:0000000003852795
DESCRIPTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-
lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics: Vehicle vibration
Heat sensitive
Freezing
Water intrusion
Electrical load
Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
Connector & Harness
SAIA0255E
SEF348N