CYLINDER BLOCKEM-107
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• Measure the dimensions at four different points as shown on each
main journal and pin journal using suitable tool.
• Out-of-round is indicated by the difference in dimensions between
(a) and (b) at (c) and (d).
• Taper is indicated by the diff erence in dimension between (c) and
(d) at (a) and (b).
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing. Refer to EM-125, "
Connecting Rod Bearing" and/or EM-124,
"Main Bearing".
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.
• Place a suitable tool (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
suitable tool. (Total indicator reading)
• If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
• Install connecting rod bearings (2) to connecting rod (3) and con- necting rod cap (1), and tighten connecting rod cap bolts to the
specified torque. Refer to EM-94, "
Disassembly and Assembly".
• Measure the inner diameter of connecting rod bearing using suit- able tool.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-125,
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and c ap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-94, "
Disassembly and Assembly".
CAUTION:
Do not rotate crankshaft. Limit:
Out-of-round [Difference between (a) and (b)]
Taper [Difference between (c) and (d)] : Refer to EM-121, "
Cylinder Block".JPBIA0229ZZ
Standard and Limit : Refer to EM-121, "Cylinder
Block".
PBIC3458J
(A) : Example
(B) : Inner diameter measuring direction
Standard and Limit : Refer to EM-125, "Connecting Rod Bearing".
PBIC3275J
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EM-108
< UNIT DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-94, "
Disassembly and Assembly".
• Measure the inner diameter (B) of main bearing (3) using suitable tool.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-124, "
Main Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec- ified torque. Refer to EM-94, "
Disassembly and Assembly".
CAUTION:
Do not rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
PBIC3276J
(A) : Example
(B) : Inner diameter measuring direction
Standard and Limit : Refer to EM-124, "Main Bearing".
PBIC3277J
PBIC3278J
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SERVICE DATA AND SPECIFICATIONS (SDS)EM-121
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
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*1: Diameter made by intersection point of conic angles
α1 and α2
*
2: Diameter made by intersection point of conic angles α2 and α3
*
3: Machining data
VALVE SPRING
Cylinder BlockINFOID:0000000012431748
CYLINDER BLOCK
Unit: mm (in)
Angle “ α2” Intake 88
°45 ′ - 90 °15 ′
Exhaust 88°45 ′ - 90 °15 ′
Angle “ α3” Intake
120°
Exhaust 120°
Contacting width “W”*
3Intake 1.44 - 2.1 (0.0567 - .0827)
Exhaust 1.1 - 1.9 (.0433 - .0748) or 0.9 - 2.1 (.0354 - .0827)
Height “h” Intake
4.7 (0.185) 4.15 (0.163)
Exhaust 6.0 (0.236) 5.43 (0.213)
Depth “H” Intake
4.7 (0.185)
Exhaust 6.0 (0.236)
Free height 46.73 mm (1.8398 in)
Installation height 32.40 mm (1.2756 in)
Installation load 136 - 154 N (13.9 - 15.7 kg, 30.6 - 34.6 lb)
Height during valve open 23.96 mm (0.9433 in)
Load with valve open 242 - 272 N (24.7 - 27.7 kg, 54.4 - 61.1 lb)
Surface distortionLimit 0.1 (0.004)
Cylinder bore Inner diameter Standard 78.000 - 78.015 (3.0709 - 3.0715)
Wear limit —
Out-of-round (Difference between “X” and “Y”) Limit 0.015 (0.0006)
Taper (Difference between “A” and “C”) 0.010 (0.0004)
PBIC3924E
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COMPONENT PARTSEC-23
< SYSTEM DESCRIPTION > [HR16DE]
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Exhaust Valve Timing Control Solenoid ValveINFOID:0000000012431286
Exhaust valve timing control solenoi
d valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The exhaust valve timing control solenoid valve changes the oil
amount and direction of flow through exhaust valve timing control
unit or stops oil flow.
The longer pulse width retards valve angle.
The shorter pulse width advances valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the exhaust valve angle at the control
position.
Fuel InjectorINFOID:0000000012431287
The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injec-
tor is energized. The energized coil pulls the ball valve back and
allows fuel to flow through the fuel injector into the intake manifold.
The amount of fuel injected depends upon the injection pulse dura-
tion. Pulse duration is the length of time the fuel injector remains
open. The ECM controls the injection pulse duration based on
engine fuel needs.
Fuel PumpINFOID:0000000012431288
*: ECM determines the start signal status by the signals of engine speed and battery voltage.
The ECM activates the fuel pump for a few seconds after the ignition switch is turned ON to improve engine
start ability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and cam-
shaft position sensor (PHASE), it knows that the engi ne is rotating, and causes the pump to operate. If the
engine speed signal is not received when the ignition s witch is ON, the engine stalls. The ECM stops pump
operation and prevents battery discharging, thereby improving safety. The EC M does not directly drive the fuel
pump. It controls the ON/OFF fuel pump rela y, which in turn controls the fuel pump.
JSBIA0652ZZ
JSBIA0742ZZ
SensorInput signal to ECMECM functionActuator
Crankshaft position sensor (POS)
Camshaft position sensor (PHASE) Engine speed*
Fuel pump controlFuel pump relay
↓
Fuel pump
Battery Battery voltage*
Condition Fuel pump operation
Ignition switch is turned to ON. Operates for 1 second.
Engine running and cranking Operates.
When engine is stopped Stops in 1.5 seconds.
Except as shown above Sto ps .
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COMPONENT PARTSEC-25
< SYSTEM DESCRIPTION > [HR16DE]
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*: These data are reference values and are measured between ECM terminals.
Intake Valve Timing Control Solenoid ValveINFOID:0000000012431293
Intake valve timing control solenoid valve is activated by ON/OFF
pulse duty (ratio) signals from the ECM.
The intake valve timing control solenoid valve changes the oil
amount and direction of flow through intake valve timing control unit
or stops oil flow.
The longer pulse width advances valve angle.
The shorter pulse width retards valve angle.
When ON and OFF pulse widths become equal, the solenoid valve
stops oil pressure flow to fix the intake valve angle at the control
position.
Knock SensorINFOID:0000000012431294
The knock sensor is attached to t
he cylinder block. It senses engine
knocking using a piezoelectric el ement. A knocking vibration from
the cylinder block is sensed as vibrational pressure. This pressure is
converted into a voltage signal and sent to the ECM.
Battery Current Sensor (With Battery Temperature Sensor)INFOID:0000000012431295
OUTLINE
The power generation voltage variable control enables fuel con-
sumption to be decreased by reducing the engine load which is
caused by the power generation of the generator.
Based on sensor signals, ECM judges whether or not the power
generation voltage variable contro l is performed. When performing
the power generation voltage variable control, ECM calculates the
target power generation voltage based on the sensor signal. And
ECM sends the calculated value as the power generation command
value to IPDM E/R. For the details of the power generation voltage
variable control, refer to CHG-8, "
System Description".
CAUTION:
Never connect the electrical co mponent or the ground wire
directly to the battery terminal. The connection cau ses the malfunction of the power generation volt-
age variable control, and then the battery discharge may occur.
BATTERY CURRENT SENSOR
The battery current sensor is installed to the battery negative cable. The sensor measures the charging/dis-
charging current of the battery.
Intake air temperature [ °C ( °F)] Voltage* (V) Resistance (k Ω)
25 (77) 3.31.800 - 2.200
80 (176) 1.20.283 - 0.359
SEF012P
PBIB1842E
JSBIA0284ZZ
JPBIA3262ZZ
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EC-34
< SYSTEM DESCRIPTION >[HR16DE]
SYSTEM
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
The mixture ratio feedback sys
tem provides the best air-fuel mixture ra tio for drivability and emission control.
The three way catalyst (manifold) can better reduce CO, HC and NOx emissions. This system uses A/F sen-
sor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The ECM adjusts the
injection pulse width according to the sensor voltage signal. For more information about A/F sensor 1, refer to
EC-19, "
Air Fuel Ratio Sensor 1". This maintains the mixture ratio within the range of stoichiometric (ideal air-
fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the th ree way catalyst (manifold). Even if the switching
characteristics of A/F sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from heated
oxygen sensor 2.
• Open Loop Control The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
- Deceleration and acceleration
- High-load, high-speed operation
- Malfunction of A/F sensor 1 or its circuit
- Insufficient activation of heated sensor 1 at low engine coolant temperature
- High engine coolant temperature
- During warm-up
- After shifting from N to D (CVT models)
- When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors t he mixture ratio signal transmitted from A/F sensor 1.
This feedback signal is then sent to the ECM. The ECM c ontrols the basic mixture ratio as close to the theoret-
ical mixture ratio as possible. However, the basic mi xture ratio is not necessarily controlled as originally
designed. Both manufacturing differences (i.e., mass ai r flow sensor hot wire) and characteristic changes dur-
ing operation (i.e., fuel injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value co mpared against the basic injection duration. Fuel trim
includes “short-term fuel trim” and “long-term fuel trim”.
“Short-term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from A/F sensor 1 indicates whether the mixture ratio is RICH or LEAN compared to the the-
oretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in
fuel volume if it is lean.
“Long-term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the “short-term fuel trim” from the central value. Such deviation will occur due to individual engine differ-
ences, wear over time and changes in the usage environment.
PBIB2793E
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SYSTEMEC-35
< SYSTEM DESCRIPTION > [HR16DE]
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FUEL INJECTION TIMING
Two types of systems are used.
• Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycl e according to the firing order. This system is used
when the engine is running.
• Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals
of the same width are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail safe system (CPU) is operating.
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration, operation of the engine at excessively high speeds or oper-
ation of the vehicle at excessively high speeds.
ELECTRIC IGNITION SYSTEM
ELECTRIC IGNITION SYSTEM : System DiagramINFOID:0000000012431311
ELECTRIC IGNITION SYSTEM : System DescriptionINFOID:0000000012431312
INPUT/OUTPUT SIGNAL CHART
SEF337W
JPBIA4883GB
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EC-36
< SYSTEM DESCRIPTION >[HR16DE]
SYSTEM
*1: M/T models
*2: CVT models
*3: ECM determines the start signal status
by the signals of engine speed and battery voltage.
*4: This signal is sent to the ECM through CAN communication line.
SYSTEM DESCRIPTION
Firing order: 1 - 3 - 4 - 2
The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the
engine. The ignition timing data is stored in the ECM.
The ECM receives information such as the injection pulse width and camshaft position sensor signal. Comput-
ing this information, ignition signals are transmitted to the power transistor.
During the following conditions, the ignition timing is re vised by the ECM according to the other data stored in
the ECM.
• At starting
• During warm-up
• At idle
• At low battery voltage
• During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the \
knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.
AIR CONDITIONING CUT CONTROL
SensorInput signal to ECM ECM function Actuator
Crankshaft position sensor (POS) Engine speed
*3
Piston position
Ignition timing control Ignition coil (with power transistor)
Camshaft position sensor (PHASE)
Mass air flow sensor
Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Throttle position sensor Throttle position
Accelerator pedal position sensor Accelerator pedal position
Park/neutral position (PNP) switch
*1
PNP signal
Transmission range switch*2
Battery Battery voltage*3
Knock sensorEngine knocking
Combination meter Vehicle speed
*4
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