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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HOW TO SELECT PISTON AND BEARINGEM-113
< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]
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In grinding crankshaft pin to
use undersize bearings, keep the
fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].
Main BearingINFOID:0000000012431741
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft Are Used
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on left side of cylinder block.
• If there is a corrected stamp mark (B) on cylinder block, use itas a correct reference.
2. Apply main journal diameter grade stamped on crankshaft front side to column in the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
4. Apply the symbol obtained to the “Main B earing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft Are Reused
1. Measure the dimensions of the cylinder block ma in bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-102, "
Inspection".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
4. Apply the symbol obtained to the “Main B earing Grade Table” to select main bearing.
Bearing undersize table:
Refer to EM-125, "
Connecting Rod Bearing".
PBIC3263J
(A) : Basic stamp mark
: Engine front
PBIC3760E
(A) : Main journal diameter grade (No. 1 to 5 from left)
(B) : Crankshaft pin journal diameter grade (No. 1 to 4 from left)
PBIC3757E
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EM-116
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000012431742
GENERAL SPECIFICATIONS
Va l v e Ti m i n g
Unit: degree
( ): Valve timing control “ON”
Drive BeltINFOID:0000000012431743
DRIVE BELT
Belt Deflection
*: When engine is cold.Engine type
HR16DE
Cylinder arrangement In-line 4
Displacement cm
3 (cu in)1,598 (97.51)
Bore and stro ke mm (in)78.0× 83.6 (3.071 × 3.291)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings Compression
2
Oil 1
Compression ratio 9.8:1
Compression pressure
kPa (kg/cm
2, psi) / 200 rpm Standard 1,510 (15.4, 219)
Minimum
1,270 (12.95, 184)
Differential limit between cylinders 100 (1.0, 14.5)
Va l v e t i m i n g
: Intake valve
: Exhaust valve
ab c d e f
216 228 11 (
−27)
AT D C 59 (-21)
ABDC -1 (49)
AT D C 37 (-13)
BBDC
JPBIA4228ZZ
Location Deflection adjustment *
Unit: mm (in)
Used belt New belt
Limit After adjusted
Drive belt With A/C
10.0 (0.39) 4.9 - 5.2 (0.19 - 0.20) 4.1 - 4.4 (0.16 - 0.17)
Without A/C 9.1 (0.36)4.3 - 4.7 (0.17 - 0.19) 3.7 - 3.9 (0.146 - 0.154)
Applied pushing force 98.1 N (10.0 kg-f, 22.0 lb-f)
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SERVICE DATA AND SPECIFICATIONS (SDS)EM-117
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]
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Belt Tension and Frequency
*: When engine is cold.
Spark PlugINFOID:0000000012431744
SPARK PLUG (PLATINUM-TIPPED TYPE)
*: Always check with the Parts Department for the latest parts information.
Exhaust ManifoldINFOID:0000000012431745
EXHAUST MANIFOLD
Unit: mm (in)
CamshaftINFOID:0000000012431746
CAMSHAFT
Unit: mm (in)
Location
Tension adjustment *
Unit: N (kg-f,
lb-f) Frequency adjustment * Unit: Hz
Used belt New beltUsed belt
New belt
Limit After adjusted Limit After adjusted
Drive belt With A/C
350 (35.7, 78.7)881 - 951
(89.9 - 97.0,
198.0 - 213.8)
1070 - 1138
(109.1 - 116.1, 240.5 - 255.8) 145.5 230.5 - 239.5 254 - 262
Without A/C 876 - 964
(89.4 - 98.3,
196.9 - 216.7)1064 - 1152
(108.5 - 117.5,
239.2 - 259.0)
162 256.5 - 268.5 282.5 - 293.5
Make
NGK
Standard type* PLZKAR6A-11
Gap (nominal) 1.1 mm (0.043 in)
Items Limit
Surface distortion 0.3 (0.012)
ItemsStandardLimit
Camshaft runout [TIR*] 0.02 (0.0008)0.1 (0.0039)
Camshaft cam height “A” Intake
41.705 - 41.895 (1.6419 - 1.6494) 41.505 (1.6341)
Exhaust 40.915 - 41.105 (1.6108 - 1.6183) 40.715 (1.6029)
Camshaft journal outer diameter No. 1
27.935 - 27.955 (1.0998 - 1.1006) —
No. 2, 3, 4, 5 24.950 - 24.970 (0.9822 - 0.9830) —
Camshaft bracket inner diameter No. 1
28.000 - 28.021 (1.1024 - 1.1032) —
No. 2, 3, 4, 5 25.000 - 25.021 (0.9842 - 0.9850) —
SEM671
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EC-1
ENGINE
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SECTION EC
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CONTENTS
ENGINE CONTROL SYSTEM
HR16DE
PRECAUTION ....... ........................................
8
PRECAUTIONS .............................................. .....8
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
8
On Board Diagnostic (OBD) System of Engine
and CVT ....................................................................
8
General Precautions .................................................9
PREPARATION ...........................................12
PREPARATION .............................................. ....12
Special Service Tools .......................................... ....12
Commercial Service Tools ......................................12
SYSTEM DESCRIPTION .............................14
COMPONENT PARTS ................................... ....14
ENGINE CONTROL SYSTEM ............................... ....14
ENGINE CONTROL SYSTEM :
Component Parts Location ....................................
14
ENGINE CONTROL SYSTEM : Component De-
scription ............................................................... ....
17
Accelerator Pedal Position Sensor ..........................18
Air Fuel Ratio Sensor 1 ...........................................19
Air Fuel Ratio Sensor 1 Heater ...............................19
Camshaft Position Sensor .......................................19
Clutch Pedal Position Switch ..................................20
Cooling Fan .............................................................20
Crankshaft Position Sensor .....................................20
ECM .................................................................... ....20
Electric Throttle Control Actuator ............................21
Engine Coolant Temperature Sensor ......................21
Engine Oil Pressure Sensor ....................................21
Engine Oil Temperature Sensor ..............................21
EVAP Canister Purge Volume Control Solenoid
Valve ................................................................... ....
22
EVAP Canister Vent Control Valve .........................22
EVAP Control System Pressure Sensor ..................22
Exhaust Valve Timing Cont rol Solenoid Valve ........23
Fuel Injector ......................................................... ....23
Fuel Pump ...............................................................23
Heated Oxygen Sensor 2 ........................................24
Heated Oxygen Sensor 2 Heater ............................24
Ignition Coil With Power Transistor .........................24
Intake Air Temperature Sensor ...............................24
Intake Valve Timing Control Solenoid Valve ...........25
Knock Sensor ...................................................... ....25
Battery Current Sensor (With Battery Tempera-
ture Sensor) .............................................................
25
Malfunction Indicator Lamp (MIL) ............................26
Mass Air Flow Sensor ..............................................26
Oil Pressure Warning Lamp ....................................26
Refrigerant Pressure Sensor ............................... ....27
Stop Lamp Switch & ASCD Brake Switch ...............27
Throttle Control Motor .......................................... ....27
Throttle Control Motor Relay ...................................27
Throttle Position Sensor ..........................................27
ASCD Steering Switch .............................................27
STRUCTURE AND OPERATION .....................28
Positive Crankcase Ventilation ................................28
On Board Refueling Vapor Recovery (ORVR) ........29
SYSTEM ............................................................30
ENGINE CONTROL SYSTEM ........................ ...........30
ENGINE CONTROL SYSTEM : System Diagram ....30
ENGINE CONTROL SYSTEM : System Descrip-
tion ...........................................................................
31
MULTIPORT FUEL INJECTION SYSTEM ................31
MULTIPORT FUEL INJECTION SYSTEM :
System Diagram ................................................. ....
32
MULTIPORT FUEL INJECTION SYSTEM : Sys-
tem Description ........................................................
32
ELECTRIC IGNITION SYSTEM .................................35
ELECTRIC IGNITION SYSTEM :
System Diagram ................................................. ....
35
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EC-2
ELECTRIC IGNITION SYSTEM : System De-
scription ............................................................... ...
35
AIR CONDITIONING CUT CONTROL ................... ...36
AIR CONDITIONING CUT CONTROL : System
Diagram ..................................................................
37
AIR CONDITIONING CUT CONTROL : System
Description ..............................................................
37
CAN COMMUNICATION ........................................ ...38
CAN COMMUNICATION : System Description ......38
COOLING FAN CONTROL .................................... ...38
COOLING FAN CONTROL : System Diagram .......38
COOLING FAN CONTROL : System Description ...38
EVAPORATIVE EMISSION SYSTEM .................... ...40
EVAPORATIVE EMISSION SYSTEM : System
Diagram ............................................................... ...
40
EVAPORATIVE EMISSION SYSTEM : System
Description ........................................................... ...
40
INTAKE VALVE TIMING CONTROL ..................... ...41
INTAKE VALVE TIMING CONTROL : System Di-
agram .................................................................. ...
41
INTAKE VALVE TIMING CONTROL : System De-
scription ............................................................... ...
41
EXHAUST VALVE TIMING CONTROL ................. ...42
EXHAUST VALVE TIMING CONTROL : System
Diagram ............................................................... ...
42
EXHAUST VALVE TIMING CONTROL : System
Description ........................................................... ...
42
ENGINE PROTECTION CONTROL AT LOW EN-
GINE OIL PRESSURE ..............................................
43
ENGINE PROTECTION CONTROL AT LOW EN-
GINE OIL PRESSURE : S ystem Diagram ..............
43
ENGINE PROTECTION CONTROL AT LOW EN-
GINE OIL PRESSURE : S ystem Description .........
43
FUEL FILLER CAP WARNING SYSTEM .............. ...44
FUEL FILLER CAP WARNING SYSTEM :
System Diagram ....................................................
44
FUEL FILLER CAP WARNING SYSTEM : System
Description ........................................................... ...
44
AUTOMATIC SPEED CONTROL DEVICE (ASCD) ...45
AUTOMATIC SPEED CONTROL DEVICE (AS-
CD) : System Diagram ............................................
45
AUTOMATIC SPEED CONTROL DEVICE (AS-
CD) : System Description .......................................
45
OPERATION ......................................................47
AUTOMATIC SPEED CONTROL DEVICE (ASCD) ...47
AUTOMATIC SPEED CONTROL DEVICE (AS-
CD) : Switch Name and Function ...........................
47
ON BOARD DIAGNOSTIC (OBD) SYSTEM .....49
Diagnosis Description .......................................... ...49
GST (Generic Scan Tool) .......................................49
DIAGNOSIS SYSTEM (ECM) ............................50
DIAGNOSIS DESCRIPTION .................................. ...50
DIAGNOSIS DESCRIPTION : 1st Trip Detection
Logic and Two Trip Detection Logic ........................
50
DIAGNOSIS DESCRIPTION : DTC and Freeze
Frame Data .......................................................... ...
50
DIAGNOSIS DESCRIPTION : Counter System ......51
DIAGNOSIS DESCRIPTION : Driving Pattern ..... ...54
DIAGNOSIS DESCRIPTION : System Readiness
Test (SRT) Code .................................................. ...
55
DIAGNOSIS DESCRIPTION : Permanent Diag-
nostic Trouble Code (Permanent DTC) ..................
56
DIAGNOSIS DESCRIPTION : Malfunction Indica-
tor Lamp (MIL) ..................................................... ...
57
On Board Diagnosis Function .................................57
CONSULT Function ................................................60
ECU DIAGNOSIS INFORMATION .............71
ECM ...................................................................71
Reference Value .................................................. ...71
Fail Safe .................................................................83
DTC Inspection Priority Chart ...............................85
DTC Index ..............................................................87
Test Value and Test Limit .......................................90
WIRING DIAGRAM ....................................99
ENGINE CONTROL SYSTEM ........................ ...99
Wiring Diagram .................................................... ...99
BASIC INSPECTION .................................120
DIAGNOSIS AND REPAIR WORKFLOW ...... ..120
Work Flow ............................................................ .120
Diagnostic Work Sheet .........................................123
ADDITIONAL SERVICE WHEN REPLACING
ECM ..................................................................
125
Description ........................................................... .125
Work Procedure ....................................................125
VIN REGISTRATION ........................................127
Description ........................................................... .127
Work Procedure ....................................................127
ACCELERATOR PEDAL RELEASED POSI-
TION LEARNING ............................................ ..
128
Description ........................................................... .128
Work Procedure ....................................................128
THROTTLE VALVE CLOSED POSITION
LEARNING .......................................................
129
Description ........................................................... .129
Work Procedure ....................................................129
IDLE AIR VOLUME LEARNING .......................130
Description ........................................................... .130
Work Procedure ....................................................130
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EC-5
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P0444, P0445 EVAP CANISTER PURGE
VOLUME CONTROL SOLENOID VALVE ..... ..
300
DTC Logic ........................................................... ..300
Diagnosis Procedure .............................................300
Component Inspection ..........................................301
P0447 EVAP CANISTER VENT CONTROL
VALVE ..............................................................
303
DTC Logic ........................................................... ..303
Diagnosis Procedure .............................................303
Component Inspection ..........................................304
P0448 EVAP CANISTER VENT CONTROL
VALVE ..............................................................
307
DTC Logic ........................................................... ..307
Diagnosis Procedure .............................................307
Component Inspection ..........................................309
P0451 EVAP CONTROL SYSTEM PRES-
SURE SENSOR ................................................
311
DTC Logic ........................................................... ..311
Diagnosis Procedure .............................................312
Component Inspection ..........................................313
P0452 EVAP CONTROL SYSTEM PRES-
SURE SENSOR ................................................
315
DTC Logic ........................................................... ..315
Diagnosis Procedure .............................................315
Component Inspection ..........................................317
P0453 EVAP CONTROL SYSTEM PRES-
SURE SENSOR ................................................
318
DTC Logic ........................................................... ..318
Diagnosis Procedure .............................................318
Component Inspection ..........................................321
P0456 EVAP CONTROL SYSTEM ..................322
DTC Logic ........................................................... ..322
Diagnosis Procedure .............................................323
Component Inspection ..........................................327
P0460 FUEL LEVEL SENSOR ........................328
DTC Logic ........................................................... ..328
Diagnosis Procedure .............................................328
P0461 FUEL LEVEL SENSOR ........................329
DTC Logic ........................................................... ..329
Component Function Check ..................................329
Diagnosis Procedure .............................................330
P0462, P0463 FUEL LEVEL SENSOR ............331
DTC Logic ........................................................... ..331
Diagnosis Procedure .............................................331
P0500 VSS .......................................................332
Description .......................................................... ..332
DTC Logic .............................................................332
Component Function Check ..................................333
Diagnosis Procedure .............................................333
P0506 ISC SYSTEM .........................................334
Description ........................................................... ..334
DTC Logic ..............................................................334
Diagnosis Procedure .............................................334
P0507 ISC SYSTEM ........................................335
Description .............................................................335
DTC Logic ..............................................................335
Diagnosis Procedure .............................................335
P050A, P050B, P050E COLD START CON-
TROL ...............................................................
337
Description .............................................................337
DTC Logic ..............................................................337
Diagnosis Procedure .............................................338
P0520 EOP SENSOR ......................................339
DTC Logic ..............................................................339
Diagnosis Procedure .............................................339
Component Inspection ...........................................340
P0524 ENGINE OIL PRESSURE ....................341
DTC Logic ..............................................................341
Diagnosis Procedure .............................................342
Component Inspection ...........................................343
P059F ACTIVE GRILLE SHUTTER ................344
DTC Logic ..............................................................344
Diagnosis Procedure .............................................344
Component Inspection (Active Grille Shutter) .......347
Component Inspection (Active Grille Shutter Re-
lay) ....................................................................... ..
347
P0603 ECM .....................................................349
DTC Logic ..............................................................349
Diagnosis Procedure .............................................349
P0604 ECM .....................................................350
DTC Logic ..............................................................350
Diagnosis Procedure .............................................350
P0605 ECM .....................................................351
DTC Logic ..............................................................351
Diagnosis Procedure .............................................351
P0606 ECM .....................................................352
DTC Logic ..............................................................352
Diagnosis Procedure .............................................352
P0607 ECM .....................................................353
DTC Logic ..............................................................353
Diagnosis Procedure .............................................353
P060A ECM .....................................................354
DTC Logic ..............................................................354
Diagnosis Procedure .............................................354
P060B ECM .....................................................355
DTC Logic ..............................................................355
Diagnosis Procedure .............................................355
P0643 SENSOR POWER SUPPLY ................356
DTC Logic ..............................................................356
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EC-6
Diagnosis Procedure .............................................356
P0850 PNP SWITCH .......................................358
Description ........................................................... ..358
DTC Logic ..............................................................358
Component Function Check ..................................359
Diagnosis Procedure .............................................359
P1078 EVT CONTROL POSITION SENSOR ..361
DTC Logic ............................................................ ..361
Diagnosis Procedure .............................................361
Component Inspection ...........................................363
P1148 CLOSED LOOP CONTROL .................364
DTC Logic ............................................................ ..364
Diagnosis Procedure .............................................364
P1212 TCS COMMUNICATION LINE .............365
Description ........................................................... ..365
DTC Logic ..............................................................365
Diagnosis Procedure .............................................365
P1217 ENGINE OVER TEMPERATURE .........366
DTC Logic ............................................................ ..366
Component Function Check ..................................366
Diagnosis Procedure .............................................367
P1225 TP SENSOR .........................................369
DTC Logic ............................................................ ..369
Diagnosis Procedure .............................................369
P1226 TP SENSOR .........................................370
DTC Logic ............................................................ ..370
Diagnosis Procedure .............................................370
P1550 BATTERY CURRENT SENSOR ..........371
DTC Logic ............................................................ ..371
Diagnosis Procedure .............................................371
Component Inspection ...........................................372
P1551, P1552 BATTERY CURRENT SEN-
SOR ..................................................................
373
DTC Logic ............................................................ ..373
Diagnosis Procedure .............................................373
Component Inspection ...........................................374
P1553 BATTERY CURRENT SENSOR ..........375
DTC Logic ............................................................ ..375
Diagnosis Procedure .............................................375
Component Inspection ...........................................376
P1554 BATTERY CURRENT SENSOR ..........377
DTC Logic ............................................................ ..377
Component Function Check ..................................377
Diagnosis Procedure .............................................378
Component Inspection ...........................................379
P1564 ASCD STEERING SWITCH .................380
DTC Logic ............................................................ ..380
Diagnosis Procedure .............................................380
Component Inspection ...........................................382
P1572 ASCD BRAKE SWITCH ........................383
DTC Logic ............................................................ .383
Diagnosis Procedure .............................................384
Component Inspection (ASCD Brake Switch) .......386
Component Inspection (Stop Lamp Switch) ..........386
P1574 ASCD VEHICLE SPEED SENSOR .......388
Description ........................................................... .388
DTC Logic .............................................................388
Diagnosis Procedure .............................................388
P159F ACTIVE GRILLE SHUTTER .................390
DTC Logic .............................................................390
Diagnosis Procedure .............................................391
P1715 INPUT SPEED SENSOR .......................392
Description ........................................................... .392
DTC Logic .............................................................392
Diagnosis Procedure .............................................392
P1720 VSS ........................................................394
Description ........................................................... .394
DTC Logic .............................................................394
Diagnosis Procedure .............................................394
P1805 BRAKE SWITCH ................................. ..396
DTC Logic ............................................................ .396
Diagnosis Procedure .............................................396
Component Inspection ..........................................397
P2096, P2097 A/F SENSOR 1 .........................398
DTC Logic ............................................................ .398
Diagnosis Procedure .............................................398
P2100, P2103 THROTTLE CONTROL MO-
TOR RELAY .....................................................
402
DTC Logic ............................................................ .402
Diagnosis Procedure .............................................402
P2101 ELECTRIC THROTTLE CONTROL
FUNCTION ........................................................
405
DTC Logic ............................................................ .405
Diagnosis Procedure .............................................405
Component Inspection ..........................................408
P2118 THROTTLE CONTROL MOTOR ..........409
DTC Logic ............................................................ .409
Diagnosis Procedure .............................................409
Component Inspection ..........................................410
P2119 ELECTRIC THROTTLE CONTROL
ACTUATOR ......................................................
411
DTC Logic ............................................................ .411
Diagnosis Procedure .............................................411
P2122, P2123 APP SENSOR ...........................413
DTC Logic ............................................................ .413
Diagnosis Procedure .............................................413
Component Inspection ..........................................414
P2127, P2128 APP SENSOR ...........................416
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