EC-1022< SERVICE INFOMATION >
[MR TYPE 2]
PRECAUTIONS
• Be sure to connect rubber tubes properly afte r work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the fuel injection system, etc.
• Be sure to erase the unnecessary malfunction info rmation (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
Precaution INFOID:0000000004499902
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is
running.
• Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative bat-
tery cable. Failure to do so may damage the ECM because
battery voltage is applied to ECM even if ignition switch is
turned OFF.
• Before removing parts, turn ig nition switch OFF and then dis-
connect negative battery cable.
• Do not disassemble ECM.
• If battery cable is disconnected, the memory will return to the
initial ECM values.
The ECM will now start to self-c ontrol at its initial values.
Engine operation can vary slight ly in this case. However, this
is not an indication of a malf unction. Do not replace parts
because of a slight variation.
• If the battery is disconnected, the following emission-related
diagnostic information will be lost within 24 hours.
- Diagnostic trouble codes
- 1st trip diagnostic trouble codes
- Freeze frame data
- 1st trip freeze frame data
- System readiness test (SRT) codes
- Test values
• When connecting ECM harness connector, fasten (B) it
securely with a lever (1) as far as it will go as shown in the fig-
ure.
- ECM (2)
- Loosen (A)
• When connecting or disconnect ing pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM pin
terminal, when connecting pin connectors.
• Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge) volt-
age to develop in coil and co ndenser, thus resulting in dam-
age to ICs.
• Keep engine control system harness at least 10 cm (4 in) away
from adjacent harness, to preven t engine control system mal-
functions due to receiving exter nal noise, degraded operation
of ICs, etc. SEF289H
PBIA9222J
PBIB2947E
PBIB0090E
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, che ck 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 make sure 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.
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is de tected in self-diagnostic results of CONSULT-III
and it is directed according to inspect ion procedure of EC section. Refer to EC-133, " Diagnosis Pro-
cedure " .
• Check when engine is cold so as to pr event 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-498, " Inspection " .
b. Remove intake manifold. Refer to EM-28, " Exploded View " .
c. Disconnect ignition coil and injector harness connectors. Refer to EM-46, " Exploded View " .
3. Remove intake valve timing control solenoid valve. Refer to EM-49, " Exploded View " .
4. Crank engine, and then make sure 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 belts, 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 an d 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 not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engi ne oil off immediately if it is splashed.
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 1 : Plug
:Engine front
" Removal and Installation " (ABS).
2. Remove brake caliper assembly with piping connected fr om steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-25, " Component " .
3. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-9, " Removal and Installation (Left
Side) " and
FAX-10, " Removal and Installation (Right Side) " .
4. Remove exhaust front tube. Refer to EX-5, " Component " .
5. Remove rear torque rod. NOTE:
A/T models shown.
6. Remove A/T cooler hoses from transmission (if equipped).
7. Preparation for the separation work of transaxle is as follows: • Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-42, " Compo-
nent " .
Removal
1. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine with a hoist.
2. Lift with a hoist and secure the engine in appropriate position.
3. Use a suitable tool (A) to securely support bottom of the engine and the transaxle assembly and simultaneously adjust hoist ten-
sion.
CAUTION:
Put a piece of wood or someth ing similar as the supporting
surface, secure a completely stable condition. PBIC3223J
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DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
Setting INFOID:0000000004784310
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-88, " Exploded View " .
2. Remove clutch cover and clutch disc (if equipped). Refer to CL-15, " Removal and Installation " .
3. Remove flywheel or driveplate. • Secure flywheel or driveplate with Tool, and remove bolts.
CAUTION:
• Never disassemble flywheel.
• Never place flywheel or driveplate with signal plate facing down.
• When handling signal plate, take car e not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
4. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-28, " Exploded View " .
- Exhaust manifold: Refer to EM-31, " Exploded View " .
- Rocker cover: Refer to EM-46, " Exploded View " .
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transaxle with flywheel or drive-
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to LU-8, " Draining " .
6. Drain engine coolant by removing water drain plug (1) from RH side of the engine. Tool number : KV11105210 (J-44716)
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Removal and Installation
INFOID:0000000004307143
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL 1. Remove front RH wheel. Refer to WT-7, " Rotation " .
2. Remove front fender protector (RH). Refer to EI-24, " Removal and Installation " .
3. Drain engine oil. Refer to LU-17, " Changing Engine Oil " .
CAUTION:
Perform this step when engine is cold.
4. Remove the following parts. • Rocker cover: Refer to EM-153, " Component " .
• Drive belt: Refer to EM-136, " Removal and Installation " .
• Water pump pulley: Refer to CO-43, " Component " .
• Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Refer to EM-195, " Component " .
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
b. At the same time, make sure that the cam noses of the No.1 cyl- inder are located ( ) as shown.
• If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
7. Hold crankshaft pulley (1) using suitable tool (A) loosen crank- shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39
in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as it will be used as
a supporting point for the pulley puller.
16. Oil pump drive chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Chain tensioner (for oil pump)
A. Refer to EM-161 B. Refer to
EM-170 C : White paint mark (Not use for service)
CAMSHAFT
EM-177
< SERVICE INFORMATION >
[MR18DE] C
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10. Install camshaft sprocket (EXH) (2).
NOTE:
Secure the hexagonal part (A) of camshaft (EXH) using wrench
to tighten bolt.
11. Install timing chain and related parts. Refer to EM-160 .
12. Inspect and adjust valve clearance. Refer to EM-178, " Valve Clearance " .
13. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION The following are procedures for chec king fluids leak, lubricates leak.
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to GI-42, " Recommended Chemical Product and Sealant " .
• 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 make sure there is no leak age 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.
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 inspect ion procedure of EC section. Refer to EC-638, " Diagnosis Pro-
cedure " (Type 1) or
EC-1153, " Diagnosis Procedure " (Type 2).
• Check when engine is cold so as to pr event burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-16, " Inspection " .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Remove intake manifold. Refer to EM-141, " Component " .
b. Disconnect ignition coil and in jector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-160, " Component " .
1 : Camshaft sprocket (INT)
Camshaft sprocket
bolt (EXH) : 88.2 N·m (9.0 kg-m, 65 ft-lb) PBIC3454J
Item 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 —
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24. Remove A/C compressor with piping connected from t
he engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to MTC-80, " Removal and Installation of Compressor -
MR18DE " .
25. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-141, " Compo-
nent " .
26. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a hoist.
27. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
28. Use a manual lift table caddy (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine
and the transaxle, and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or someth ing similar as the supporting
surface, secure a completely stable condition.
29. Remove torque rod (RH) (1), engine insulator (RH) (2) and engine bracket (RH) (3).
30. Remove engine through bolt-securing nut (C).
31. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating sup- porting tools.
CAUTION:
• During the operation, make sure that no part interferes with the vehicle side.
• Before and during this lifting, alw ays check if any harnesses are left connected.
• During the removal operation, alw ays be careful to prevent the vehicle from falling off the lift due
to changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
• During operation, securely suppor t the engine by placing a piece of wood under the engine oil
pan and transaxle oil pan. Securely sup port the engine slingers with a hoist.
32. Remove starter motor. Refer to SC-9 .
33. Separate the engine and the transaxle and mount the engine on a suitable engine stand. Refer to AT-232(A/T models),
CVT-182 or
CVT-354 (CVT models) or
MT-58 (M/T models).
INSTALLATION Note the following, and install in the reverse order of removal. : Engine front
Slinger bolts : 25.5 N·m (2.6 kg-m, 19 ft-lb) PBIC3223J
Com-
ponent " .
• Prior to installing the upper torque rod, apply a light coat of silicone lubricant (A) to the washer facing side of the bushing inner tube as
shown.
NOTE:
• Apply silicone lubricant (A) by dabbing the outward facing tube
surface with a sponge or suitable tool.
• Do not apply excess lubricant.
• Make sure that each mounting insulator is seated properly, and tighten nuts and bolts.
• Tighten engine mounting insulator (RH) bolts in the numerical order shown.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14 .
• 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, che ck again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gases, or any oil/fluids includ-
ing 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