OIL PAN AND OIL STRAINEREM-39
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c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in).
• Press-fit to the specified dimensions as shown.
CAUTION:
• Do not touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting partof oil pan (upper) and cylinder block or the crankshaft.
• Press-fit straight and check that oil seal does not curl or tilt.
d. After press-fitting the rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side.
3. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels, includi ng 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 and 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, exhaust gas, or any oils/fluids including engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*Power steering fluid, brake fluid, etc.
PBIC3660E
(1) : Rear oil seal
(A) : Rear end surface of cylinder block
PBIC3149J
Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeakage Level
Engine oil LevelLeakage Level
Transmission/
transaxle fluid A/T and CVT Models
LeakageLevel/Leakage Leakage
M/T Models Level/Leakage LeakageLevel/Leakage
Other oils and fluids* LevelLeakage Level
Fuel LeakageLeakageLeakage
Exhaust gas —Leakage —
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EM-40
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FUEL INJECTOR AND FUEL TUBE
FUEL INJECTOR AND FUEL TUBE
Exploded ViewINFOID:0000000012431712
Removal and InstallationINFOID:0000000012431713
WARNING:
• Put a “CAUTION: FLAMMABLE”
sign in the workshop.
• Be sure to work in a well-ventila ted 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.
CAUTION:
Do not remove or disassemble parts unless instructed.
NOTE:
When removing components such as hoses, tubes/lines, etc. , cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Release the fuel pressure. Refer to EC-137, "Work Procedure".
2. Remove intake manifold. Refer to EM-28, "
Removal and Installation".
1. Stud bolt 2. O-ring (green) 3. Fuel injector (front)
4. Clip 5. Fuel injector (rear) 6. O-ring (black)
7. Fuel tube protector 8. Fuel tube9. Clamp
10. Quick connector cap (engine side) 11. Fuel feed hose 12. Quick connector cap (floor piping-side)
13. Fuel connector protector 14. Fuel pipeA. To centralized under-floor piping
Front
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FUEL INJECTOR AND FUEL TUBEEM-41
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3. Disconnect fuel feed hose from
fuel tube. Disconnect quick con-
nector:
NOTE:
There is no fuel return path.
a. Remove quick connector cap (engine side) (1) from quick con- nector connection.
b. Disconnect fuel feed hose from hose clamp.
c. With the sleeve (B) side of quick connector release (A) facing quick connector (2), install quick connector release (A) onto fuel
tube (1) as shown.
d. Insert quick connector release (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold quick connector
release (A) in that position (D).
CAUTION:
Inserting quick connector re lease hard will not disconnect
quick connector. Hold qui ck connector release where it
contacts and goes no further.
e. Draw and pull out quick connector (E) straight up from fuel tube (1).
CAUTION:
• Pull quick connector up (E) from holding position (C) as shown.
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth be forehand as fuel will leak out.
• Discard O-ring, do not reuse.
• Avoid fire and sparks.
• Keep parts away from heat source. Be especi ally careful when welding is performed.
• Do not expose parts to battery electrolyte or other acids.
• Do not bend or twist connection between quick connector and fuel feed tube during installation
or removal.
• Be sure to cover openings of disconnected fuel feed hose
(A) and fuel tube (C) with plug or plastic bag (B) to avoid
fuel leaks and entry of foreign material.
4. Disconnect fuel feed hose from fuel pipe as follows:
(1) : Quick connector cap (engine side)
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• Be sure to cover openings of disconnected pipes with
plug or plastic bag (B) to avoid fuel leaks and entry of for-
eign material.
5. Disconnect harness connectors from fuel injectors.
6. Disconnect harness connectors from intake and exhaust valve timing control solenoid valves.
7. Remove fuel tube protector. • Loosen bolts in reverse order as shown.
8. Remove fuel injector and fuel tube assembly:
a. Loosen two nuts in reverse order as shown.
b. Pull the fuel tube straight out until injector lower O-rings are clear.
c. Remove the nuts and the fuel tube.
CAUTION:
• When removing, be careful to avoid interference with fuel injectors.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
9. Remove fuel injector from fuel tube:
a. Open and remove clip.
b. Remove fuel injectors and from fuel tube by pulling straight out.
CAUTION:
• Be careful with remaining fuel that may leak from fuel tube.
• Be careful not to damage fuel injector nozzle during removal.
• Do not bump or drop fuel injector.
• Do not disassemble fuel injector.
• Do not reuse O-rings.
INSTALLATION
CAUTION:
Do not reuse O-rings.
1. Install O-rings on the fuel injector. CAUTION:
• Upper and lower O-rings are different. Be careful not to interchange them.
(A) :Fuel feed hose
(C) :Fuel tube
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: Engine front
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: Engine front
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< REMOVAL AND INSTALLATION >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
• Check that O-ring and its mating pa
rt are free of foreign material.
• When installing O-ring, be careful not to scratch it.
• Do not twist or stretch O-ring. If O-ring was st retched while it was being attached, allow it to
retract before inserting it into fuel tube.
• Insert O-ring straight into fuel tube. Do not angle or twist it.
2. Install fuel injector (4) to fuel tube (1):
a. Insert new clip (2) into clip groove (G) on fuel injector (4). • Insert new clip (2) so that protrusion (F) of fuel injector
matches cut-out (D) 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 (4) into fuel tube (1) with clip (2) attached. • Insert fuel injector (4) while matching it to the axial center.
• Insert fuel injector (4) so that protrusion (B) of fuel tubematches cut-out (C) of clip (2).
• Check that fuel tube flange (A) is securely located in flange groove (E) on clip (2).
c. Check that installation is complete by checking that fuel injector (4) does not rotate or come off.
3. Set fuel tube and fuel injector assembly in position for installation on cylinder head. CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
• Tighten bolts in numerical order as shown.
4. Install fuel tube protector. Fuel tube side
: Black
Nozzle side : Green
(3) : O-ring (black)
(5) : O-ring (green)
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: Engine front
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• Tighten bolts in numerical order as shown.
5. Connect harness connectors to fuel injectors.
6. Connect harness connectors to intake and ex haust valve timing control solenoid valves.
7. Connect fuel feed tube (engine side):
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straight into fuel tube. • Insert quick connector (1) to fuel tube until the top spool (C) on
fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end.
CAUTION:
• Hold in position (A) as sh own when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
• Insert until you hear a “click” sound and actually feel
the engagement.
d. To avoid misidentification of engagement with a simi lar sound, pull quick connector hard by hand. Check it
is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (engine side) (1) to quick connector connection.
• Install quick connector cap (engine side) (1) with the sidearrow facing quick connector side (fuel feed tube side) as
shown.
CAUTION:
• Check that the quick connector and fuel tube aresecurely engaged with the qu ick connector cap (engine
side) groove.
• If the quick connector cap (engine side) cannot be installed easily the quick connector may not be con-
nected correctly. Remove and reconnect.
f. Install fuel feed hose to hose clamp.
8. Connect fuel feed tube (floor piping side):
a. Check the connection for damage or any foreign materials.
b. Align the quick connector with the tube, then insert the connector straight into the centralized under floor piping until a click is heard.
: Engine front
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(B) : Upright insertion
(E) : Correctly connected
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< REMOVAL AND INSTALLATION >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
c. After connecting, check that the connection is secure:
• Visually confirm that the two retainer tabs are connected to theconnector.
• With the fuel feed hose not fix ed to the clamp, pull quick con-
nector (A) hard by hand to check that the quick connector (A)
is not disconnected from the centralized underfloor piping (1)
and that the quick connector (1) is securely connected.
9. Installation of remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check on Fuel Leaks
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there are no fuel leaks at connection points. Refer to.
NOTE:
Use mirrors for checking points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
• Perform procedures for “Throttle Valve Closed Posi tion Learning” after finishing repairs. Refer to EC-
129, "Description".
• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after
finishing repairs. Refer to EC-130, "
Description".
CAUTION:
Do not touch the engine immediately after stopping, as the engine becomes extremely hot.
PBIC3795E
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ROCKER COVEREM-49
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• Loosen bolts in reverse order as shown.
6. Remove rocker cover gasket from rocker cover.
7. Remove all traces of liquid gasket from cylinder head and front cover using suitable tool. CAUTION:
Do not scratch or damage the mating su rface when cleaning off old liquid gasket.
INSTALLATION
CAUTION:
Do not reuse O-ring.
1. Install the rocker cover:
a. Press gasket onto the bosses for the rocker cover bolt holes as
shown to prevent the gasket from dropping off.
b. Apply liquid gasket to the cylinder head (1) and front cover (2) as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-22, "
Recommended Chemical Products and Sealants".
CAUTION:
• The components must be inst alled within 5 minutes of the
liquid gasket application.
• Then allow 30 minutes for th e liquid gasket to set before
putting oil in the engine.
c. Install rocker cover to cylinder head. CAUTION:
Check that the gasket has no t slipped out of position.
• Tighten bolts in numerical order in at least three separate stages as shown.
: Engine front
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: Engine front
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(a) : 2.5 - 3.5 mm diameter
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: Engine front
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