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SECTION EM
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CONTENTS
ENGINE MECHANICAL
HR16DE
PRECAUTION ....... ........................................
3
PRECAUTIONS .............................................. .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
Precaution for Procedure without Cowl Top Cover ......3
Draining Engine Coolant ...........................................3
Disconnecting Fuel Piping .........................................3
Removal and Disassembly ........................................3
Inspection, Repair and Replacement ........................4
Assembly and Installation .........................................4
Parts Requiring Angle Tightening ....................... ......4
Precaution for Liquid Gasket .....................................4
PREPARATION ............................................6
PREPARATION .............................................. .....6
Special Service Tools .......................................... ......6
Commercial Service Tools ........................................7
BASIC INSPECTION ...................................10
CAMSHAFT VALVE CLEARANCE ............... ....10
Inspection and Adjustment .................................. ....10
COMPRESSION PRESSURE ............................13
Inspection ............................................................ ....13
SYMPTOM DIAGNOSIS ..............................14
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ ....
14
NVH troubleshooting Chart ................................. ....14
PERIODIC MAINTENANCE .........................16
DRIVE BELT ................................................... ....16
Exploded View .................................................... ....16
Removal and Installation .........................................16
Inspection ............................................................ ....17
Adjustment ...............................................................17
AIR CLEANER FILTER .....................................19
Exploded View .........................................................19
Removal and Installation .........................................19
SPARK PLUG ...................................................21
Exploded View .........................................................21
Removal and Installation .........................................21
REMOVAL AND INSTALLATION ...............24
DRIVE BELT IDLER PULLEY ..........................24
Exploded View ..................................................... ....24
Removal and Installation .........................................24
AIR CLEANER AND AIR DUCT .......................26
Exploded View .........................................................26
Removal and Installation .........................................26
INTAKE MANIFOLD .........................................28
Exploded View .........................................................28
Removal and Installation .........................................28
EXHAUST MANIFOLD ......................................31
Exploded View .........................................................31
Removal and Installation .........................................31
OIL PAN AND OIL STRAINER .........................34
Exploded View .........................................................34
Removal and Installation (Lower Oil Pan) ...............34
Removal and Installation (Upper Oil Pan) ........... ....37
FUEL INJECTOR AND FUEL TUBE ................40
Exploded View .........................................................40
Removal and Installation .........................................40
IGNITION COIL .................................................47
Exploded View .........................................................47
Removal and Installation .........................................47
ROCKER COVER .............................................48
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OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER
Exploded ViewINFOID:0000000012431709
Removal and Installation (Lower Oil Pan)INFOID:0000000012431710
REMOVAL
WARNING:
• Be careful not to get bu
rned, engine coolant and engine oil may be hot.
• Prolonged and repeated contact with used engi ne oil may cause skin cancer; avoid direct skin con-
tact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as
possible.
1. Drain engine oil. Refer to LU-8, "
Draining".
1. Rear oil seal 2. O-ring 3. Oil pan (upper)
4. Oil pump chain tensioner (for oil pump drive chain) 5. Oil pump drive chain
6. Crankshaft key
7. Crankshaft sprocket 8. Oil pump sprocket9. Oil pump
10. O-ring 11. O-ring 12. Oil pan drain plug
13. Drain plug washer 14. Oil pan (lower) 15. Oil filter
16. Connector bolt 17. Oil cooler 18. O-ring
19. Relief valve A. Refer to EM-37, "
Removal and In-
stallation (Upper Oil Pan)"
B. Refer to LU-10, "Removal and Instal-
lation"
C. Oil pan (lower) side
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CAMSHAFT
CAMSHAFT
Exploded ViewINFOID:0000000012431720
Removal and InstallationINFOID:0000000012431721
CAUTION:
The rotation direction
indicated in the procedure is as viewed from the engine front.
REMOVAL
1. Remove timing chain. Refer to EM-51, "Removal and Installation"
1. Camshaft bracket (No. 2 to 5) 2. Camshaft bracket (No. 1) 3. Camshaft sprocket (EXH)
4. Exhaust valve timing control sole-
noid valve 5. O-ring 6. Camshaft sprocket (INT)
7. Plug (EXH) 8. Washer (EXH) 9. Oil filter (for exhaust valve timing control solenoid valve)
10. Cylinder head 11. Oil filter (for intake valve timing
control solenoid valve) 12. Washer (INT)
13. Plug (INT) 14. O-ring15. Intake valve timing control solenoid
valve
16. Bracket 17. Valve lifter (INT)18. Valve lifter (EXH)
19. Camshaft (INT) 20. Camshaft (EXH)A. Refer to INSTALLATION
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CAMSHAFT
10. Remove the intake valve timing control solenoid valve (1) and
the plug (2) securing the oil filter for intake valve timing control
solenoid valve.
11. Remove the exhaust valve timing control solenoid valve.
12. Remove the plug on the exhaust valve timing control solenoid valve.
13. Remove the oil filter for exhaust valve timing control solenoid valve.
14. For component inspection after removal, refer to EM-68,
"Inspection".
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1. Install oil filter (1) for intake and exhaust valve timing control
solenoid valves.
CAUTION:
Do not reuse washers.
NOTE:
The intake side is shown as an example.
• The oil filter (1) and washer (2) are assembled to the plug (3),and then install them in to the cylinder head. Refer to EM-60,
"Exploded View".
2. Install intake and exhaust valve timing control solenoid valves. • Insert it straight into the cylinder head.
• Tighten bolts.CAUTION:
Do not reuse O-rings.
3. Install valve lifters. • If they are reused, install them in the original positions.
4. Put a matching mark for positioning the cams haft (INT) and the camshaft sprocket (INT):
NOTE:
This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft
(INT) and the camshaft sprocket (INT).
a. Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface.
• Put the marks on the visible position with the camshaft
sprocket installed as shown.
b. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2) as shown.
• Put the marks on the visible position with it installed to thecamshaft.
5. Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH): NOTE:
This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft
(INT) and the camshaft sprocket (EXH).
PBIC3692E
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PBIC3696E
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CAMSHAFT
• 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 leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
at connection points.
• Start engine. With engine speed increased, che ck again for fuel leaks 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 leak s 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.
InspectionINFOID:0000000012431722
INSPECTION AFTER REMOVAL
Oil Filter
• Check that there is no foreign material on the oil filter (1) and check it for clogging.
• Check the oil filter for damage.
• If there is some damage, replace the oil filter, the plug, and the washer as a set.
CAUTION:
Do not reuse the washer.
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour- nals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a differe nt diameter from the other
four locations.
2. Set a suitable tool vertically to No. 3 journal.
3. Turn camshaft to one direction, and measure the camshaft runout using suitable tool. (Total indicator reading)
Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeaks Level
Engine oil LevelLeaks Level
Transmission/
transaxle fluid CVT Models
LeaksLevel/Leaks Leaks
M/T Models Level/Leaks LeaksLevel/Leaks
Other oils and fluids* LevelLeaks Level
Fuel LeaksLeaksLeaks
Exhaust gas —Leaks —
PBIC3693E
PBIC2499E
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• Measure the outer diameter of valve lifter using suitable tool (A).
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head using suit-
able tool (A).
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
• If out of the standard, referring to the each standard of
valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 or P 0014 is detected in self-diagnostic results of CON-
SULT and it is directed according to insp ection procedure of EC section. Refer to EC-168, "
Diagnosis
Procedure" (P0011) or EC-172, "Diagnosis Procedure" (P0014).
• Check when engine is cold so as to pr event burns from the splashing engine oil.
NOTE:
This section provides the inspection method of oil passage of cam sprocket on the intake side. For oil passage
on the exhaust side, the inspection proc edure must be changed as instructed below:
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-137, "
Work Procedure".
b. Remove intake manifold. Refer to EM-28, "
Removal and Installation".
Standard : Refer to
EM-117, "
Camshaft".
PBIC3185J
Standard : Refer to EM-117, "Camshaft".
PBIC3184J
Standard : Refer to EM-117, "Camshaft".
· Step 3 : Remove exhaust valve timing control solenoid valve. Refer to EM-60, "Exploded View".
· Step 4 : Crank engine, and then check that engine oil comes out from exhaust valve timing control solenoid
valve hole (A). End crank after checking.
·Step 5 Perform the following inspection if engine oil does not come out from exhaust valve timing control
solenoid valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to
EM-60, "
Exploded View".
• Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to
EM-60, "
Exploded View".
·Step 6 : Remove components between exhaust valve timing control solenoid valve and camshaft sprocket
(EXH), and then check each oil groove for clogging.
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CAMSHAFT
c. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to
EM-60, "
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 belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
• Prevent splashing by using a shop cloth to prevent injuryfrom splashing engine oil and so as to prevent engine oil contamination.
• Use a shop cloth to prevent engine oil from bein g splashed to engine and vehicle. Especially be
careful not to spill engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe
engine oil off immediatel y 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-5,
"Engine Lubrication System".
6. Remove components between intake valve timing c ontrol solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-5, "
Engine Lubrication System".
7. After inspection, installation of components is in the reverse order of removal
(1) : Plug
:Engine front
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EC-7
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DTC Logic ...........................................................
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416
Diagnosis Procedure .............................................416
Component Inspection ..........................................418
P2135 TP SENSOR ..........................................419
DTC Logic ........................................................... ..419
Diagnosis Procedure .............................................419
Component Inspection ..........................................420
P2138 APP SENSOR .......................................422
DTC Logic .............................................................422
Diagnosis Procedure .............................................422
Component Inspection ..........................................424
P219A AIR FUEL RATIO .................................426
DTC Logic ........................................................... ..426
Diagnosis Procedure .............................................427
P219C, P219D, P219E, P219F AIR FUEL RA-
TIO ....................................................................
431
DTC Logic ........................................................... ..431
Diagnosis Procedure .............................................433
ASCD BRAKE SWITCH ...................................437
Component Function Check ................................ ..437
Diagnosis Procedure .............................................437
Component Inspection (ASCD Brake Switch) .......438
CLUTCH PEDAL POSITION SWITCH .............439
Component Function Check ................................ ..439
Diagnosis Procedure .............................................439
Component Inspection (Clutch Pedal Position
Switch) ..................................................................
440
COOLING FAN .................................................441
Component Function Check ................................ ..441
Diagnosis Procedure .............................................441
Component Inspection (Cooling Fan Motor) .........443
Component Inspection (Cooling Fan Relay) .........443
ELECTRICAL LOAD SIGNAL .........................444
Description .......................................................... ..444
Component Function Check ..................................444
Diagnosis Procedure .............................................444
FUEL INJECTOR .............................................446
Component Function Check ................................ ..446
Diagnosis Procedure .............................................446
Component Inspection ..........................................447
FUEL PUMP .....................................................448
Component Function Check ................................ ..448
Diagnosis Procedure .............................................448
Component Inspection ..........................................450
IGNITION SIGNAL ...........................................451
Component Function Check ................................ ..451
Diagnosis Procedure .............................................451
Component Inspection (Ignition Coil with Power
Transistor) ........................................................... ..
454
Component Inspection (Condenser) ......................455
MALFUNCTION INDICATOR LAMP ..............456
Component Function Check ..................................456
Diagnosis Procedure .............................................456
ON BOARD REFUELING VAPOR RECOV-
ERY (ORVR) ....................................................
457
Component Function Check ..................................457
Diagnosis Procedure .............................................457
Component Inspection (Refueling EVAP vapor cut
valve) ................................................................... ..
459
Component Inspection (Drain filter) .......................461
REFRIGERANT PRESSURE SENSOR ..........462
Component Function Check ..................................462
Diagnosis Procedure .............................................462
SYMPTOM DIAGNOSIS ............................464
ENGINE CONTROL SYSTEM SYMPTOMS ...464
Symptom Table ................................................... ..464
NORMAL OPERATING CONDITION .............470
Description .............................................................470
PERIODIC MAINTENANCE ......................471
IDLE SPEED .... ...............................................471
Inspection ............................................................ ..471
IGNITION TIMING ...........................................472
Inspection ..............................................................472
EVAPORATIVE EMISSION SYSTEM .............473
Inspection ..............................................................473
EVAP LEAK CHECK ......................................474
Inspection ..............................................................474
POSITIVE CRANKCASE VENTILATION .......476
Inspection ..............................................................476
REMOVAL AND INSTALLATION .............477
ECM .................................................................477
Exploded View ..................................................... ..477
Removal and Installation .......................................477
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .......................................... .
478
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
478
Idle Speed ........................................................... ..478
Ignition Timing .......................................................478
Calculated Load Value ..........................................478
Mass Air Flow Sensor ............................................478
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