ENGINE SECTION E M ENGINE MECHANICAL CONTENTS HR16DE Removal and Installation 18 SYMPTOM DIAGNOSIS ... SPARK PLUG .. Exploded View .. sn ot NOISE, VIBRATION AND HARSHNESS Removal and Installation .eon.omeone ar) (NVH) TROUBLESHOOTING .. NVH Troubleshooting - Engine Noise & CAMSHAFT VALVE CLEARANCE sss 2t Use the Chart Below to Help You Find the Cause Inspection and Adjustment .. core A onihsisimeten s ® COMPRESSION PRESSURE . 24 PRECAUTION Inspection - dt PRECAUTIONS viesinsssnnnnnnnannunnnnnet? ON-VEHICLE REPAIR 25 Precaution for Supplemental Restraint System Hee eee eer oeese, DRIVE BELTIDLER PULLEY enon SIONER 7 Precaution for Procedure without Cowl Top Cover....7___ Removal nd installation %8 Precaution Necessary for Steering Wheel Rota- AIR CLEANER AND AIR DUCT 27 tion After Battery Disconnect 7” Exploded View 27 Precaution for Drain Coolant 8 Removal and instalation 27 Precaution for Disconnecting Fuel Piping 8 Inspection 28 Precaution for Removal and Disassembly 8 Precaution for Inspection, Repair and Replace- INTAKE MANIFOLD .. 29 ment 8 Exploded View 29 Precaution for Assembly and Installation .. 8 Removal and Installation 29 Parts Requiring Angular Tightening 8 Precaution for Liquid Gasket, 9 EXHAUST MANIFOLD .srsssssnrnnnnnnnnnnS2 Exploded View 32 PREPARATION Removal and Installation 32 PREPARATION vsssssnutannnaninannennaunntt FUEL INJECTOR AND FUEL TUBE 35 Special Service Tools 11 Exploded View 238 Commercial Service Tools 12 Removal and Installation 38 Inspection 39 ON-VEHICLE MAINTENANCE, OIL PAN (LOWER) dO DRIVE BELTS .. Exploded View 40 Checking 18 Removal and Installation 40 Tension Adjustment 18 Inspection 4 Removal and Installation OIL PAN (UPPER) AND OIL STRAINER .......42 AIR CLEANER FILTER . Component a2 EM-1Removal and Installation 2 IGNITION COIL, SPARK PLUG AND ROCK- ER COVER Exploded View 47 Removal and Installation 47 TIMING CHAIN Exploded View Removal and Installation 50 Inspection CAMSHAFT Exploded Vi Removal and installation 59 Inspection n OIL SEAL sssssstssesenen VALVE OIL SEAL VALVE OIL SEAL : Removal and Installation ...... 77 FRONT OIL SEAL FRONT OIL SEAL : Removal and Installation ...... 78 REAR OIL SEAL . REAR OIL SEAL : Removal and Installation 78 CYLINDER HEAD sss sivissarisiess 80 Removal and Installation 20 Disassembly and Assembly 2 REMOVAL AND INSTALLATION . ENGINE ASSEMBLY .. Exploded View Removal and Installation Inspection DISASSEMBLY AND ASSEMBLY ENGINE STAND SETTING Setting ENGINE UNIT Disassembly .. Assembly OIL PAN (UPPER) ss. Exploded View Removal and installation Inspection CYLINDER BLOCK 100 Exploded View 100 Disassembly and Assembly 101 Inspection 108 HOW TO SELECT PISTON AND BEARING ...117 Description... - 417 Connecting Rod Bearing 117 Main Bearing 119 ‘SERVICE DATA AND SPECIFICATIONS (SDS) .. SERVICE DATA AND SPECIFICATIONS (sps) 122 General Specification 122 Drive Belts 122 Spark Plug 123 Exhaust Manifold 123 Camshaft 123 Cylinder Head 125 Cylinder Block 127 Connecting Rod Bearing 130 Main Bearing 131 MR18DE SYMPTOM DIAGNOSIS NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ... NVH Troubleshooting - Engine Noise Use the Chart Below to Help You Find the Cause of the Symptom 133 PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- SIONER" Precaution for Procedure without Cowl Top Cover. 134 Precaution Necessary for Steering Wheel Rota- tion After Battery Disconnect 134 Precaution for Drain Coolant 135 Precaution for Disconnacting Fuel Piping... 135 Precaution for Removal and Disassembly 135 Precaution for Inspection, Repair and Replace- ment. 135 Precaution for Assembly and Installation v.00 135, Parts Requiring Angular Tightening 135 Precaution for Liquid Gasket 136 PREPARATION ......sssssssssseessessssnneeseenee PREPARATION Special Service Tool Commercial Service Tool ON-VEHICLE MAINTENANCE .. DRIVE BELTS .. ‘Component... Checking Drive Belts Tension Adjustment Removal and Installation AIR CLEANER FILTER Removal and installation SPARK PLUG EM-2‘Component 145 Removal and Installation 145 CAMSHAFT VALVE CLEARANCE, ne 148, Valve Clearance 148 COMPRESSION PRESSURE .. 181 ‘Checking Compression Pressure 181 ON-VEHICLE REPAIR .. 183 DRIVE BELT AUTO TENSIONER «.essssosenes 153 ‘Component 183 Removal and Installation of Drive Belt Auto Ten- sioner AIR CLEANER AND AIR DUCT ‘Component .. si Removal and Installation .... INTAKE MANIFOLD Component Removal and Installation EXHAUST MANIFOLD ‘Component Removal and Installation FUEL INJECTOR AND FUEL TUBE ‘Component Removal and Installation OIL PAN ‘Component 168 Removal and Installation 168 IGNITION COIL, Component .. Removal and Installation ROCKER COVER ‘Component Removal and Installation... TIMING CHAIN ‘Component Removal and Installation CAMSHAFT Component Removal and Installation OIL SEAL . Removal and Installation of Valve Removal and Installation of Front Oil Seal Removal and Installation of Rear Oil Seal CYLINDER HEAD .. ‘Component 8 Removal and Installation .... 198 ‘Component .. 200 Disassembly and Assembly 200 Inspection After Disassembly 202 REMOVAL AND INSTALLATION ENGINE ASSEMBLY 207 207 Component 207 Removal and Installation 207 DISASSEMBLY AND ASSEMBLY an ENGINE UNIT ... 214 Component 2 Disassembly and Assembly 212 Inspection After Disassembly 219 HOW TO SELECT PISTON AND BEARING .. 230 How to Select Piston and Bearing 200 SERVICE DATA AND SPECIFICATIONS (SDS) scircaravennonminnenconneunennsen 238 SERVICE DATA AND SPECIFICATIONS (SDS) .. Standard and Limit 238 238 K9K SYMPTOM DIAGNOSIS NOISE, VIBRATION AND HARSHNESS: (NVH) TROUBLESHOOTING. 249 249 NVH Troubleshooting - Engine Noise 249 Use the Chart Below to Help You Find the Cause of the Symptom 250 PRECAUTION 251 PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- SIONER" 251 Precaution for Procedure without Cowl Top Cover. 251 Precaution Necessary for Steering Wheel Rota- 251 tion After Battery Disconnect 254 Precaution for Drain Coolant oe DBZ Precaution for Disconnecting Fuel Piping vv....--252 Precaution for Removal and Disassembly «...0..«.252 Precaution for Inspection, Repair and Replace- ment 252 Precaution for Assembly and installation 252 Parts Requiring Angular Tightening 252 Precaution for Liquid Gasket 253 Precaution for Diesel Equipment 253 Installation of Thread Inserts PREPARATION PREPARATION Special Service Tools... Commercial Service Tools, ON-VEHICLE MAINTENANCE ............ 287 258 258 258 260 263 EM-3 eyDRIVE BELTS ... Exploded View 263 Inspection and Adjustment 263 Removal and installation 263 AIR CLEANER FILTER .. 265 Removal and Installation 265 CAMSHAFT VALVE CLEARANCE Inspection and Adjustment COMPRESSION PRESSURE Inspection ON-VEHICLE REPAIR 266 DRIVE BELT AUTO-TENSIONER 268 Exploded View 268 Removal and Installation 268 AIR CLEANER AND AIR DUCT .. 269 Exploded View Removal and installation CHARGE AIR COOLER Exploded View Removal and installation Inspection EGR SYSTEM .. Exploded View 272 Removal and Installation 272 CATALYST 208 Exploded View 274 Removal and installation 274 Inspection 274 TURBOCHARGER ss. Exploded View Removal and Installation Inspection EXHAUST MANIFOLD Exploded View Removal and Installation 277 Inspection 278 GLOW PLUG Exploded View 279 Removal and installation 279 VACUUM PUMP .. essenenee 280 Exploded View 280 Removal and Installation 280 Inspection 280 INJECTION TUBE AND FUEL INJECTOR .... 281 Exploded View 281 Removal and Installation ...... seen 84 OIL PAN ... Exploded View .. Removal and installation 284 284 Inspection. 286 HIGH PRESSURE SUPPLY PUMP 287 Exploded View 287 Removal and Installation 287 ROCKER COVER 289 Exploded View .. 289 Removal and installation 289 TIMING BELT .. 201 Exploded View 291 Removal and installation 291 CAMSHAFT onnscssstsstnnstnsnntnessnnninsnseee 298, Exploded View .. 298 Removal and Installation 298 Inspection. 300 REMOVAL AND INSTALLATION 302 ENGINE ASSEMBLY 302 Exploded View .. 302 Removal and Installation “302 Inspection “304 DISASSEMBLY AND ASSEMBLY 305 ENGINE STAND SETTING ... 305 Setting 308 ‘CYLINDER HEAD 306 Exploded View .. 306 Removal and installation... 306 Disassembly and Assembly 307 Cleaning 310 Inspection “310 CYLINDER BLOCK 314 Exploded View .. w 314 Disassembly and Assombiy a "314 Inspection 330 SERVICE DATA AND SPECIFICATIONS (SDS) vesssisnnsnininnnsennsennnsnnnee S88 SERVICE DATA AND SPECIFICATIONS (sDs) 333, General Specification 333, Drive Belt 333, Camshaft . 333 Cylinder Head .. - 335 Cylinder Block . 337 Turbocharger . 339NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS > [HR16DE] SYMPTOM DIAGNOSIS NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting - Engine Noise Ns 2 CCamshat beating noise Tappet noise ‘connecting 108 eae Dave bal noise (stiNslppng) EM-5NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS > [HR16DE] Use the Chart Below to Help You Find the Cause of the Symptom 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source If necessary, repair or replace these parts. ‘Operating condition of engine Location | Type ot | Before | Ater | When] | | qa] Soureot sek tem Refer. cetnoise | noise | warm | ware stare | When | When While | “noise neck ence page iaing racing | arving uw | wing rater meager! co | «| — | a | 8 | — | RR | vane tearnce uaz Rocker oer Gamshat | Camshat journal | ay 25 Cynder | Rate cA | =) A&B |G | bearng clearance ca nose | Camshat runout ees Piston o piston pin ot ‘tap or ke s | s Piston pin clearance ewet27 knock - - — | noise | Connecting od smal | EM-190 end clearance Piston to eylinder bare crank clearance EMAZ7 shaft pu- | ap or a | — | | w]e) on [Paton | Beton siete | ET cae 2eptese | engencgan | BN block Comecing rod bend | E180 Gide of and torsion engine) Connect. | Gonecing roa sai i pan Ingrod end clearance eM127 Kook A) Bf |B | BB | bearing | Connecting od bearing | EML130 noise ollclearance some ale nw | Matar Hai Baring a ear 7 ee 7 ingnoise | GS EMLIZ7 a Crankshaft runout Front Tina | ming an cracks engine | Tappingor chain and | ang wear Front cow | scking AK = BB) 8 | crainer- Timing chain tensioner | FMST e sioner operation Dive bat Squeaks ie ingot] A | 8 | — | B | — | c | GAERTE | prve vet detection = ping) LE Front of Dive belt Idler puley bearing op- engine | creasng | A | 8 | A |B | A |B | Rive bel | Ider puley bearing om Saul Water teak A B | — | 8 | A | B | pump | Waterpump operaton | coz ReCloselyrelated 6: Related : Sometimes related —: Notrelated EM-6PRECAUTIONS < PRECAUTION > [HR16DE] PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT Em PRE-TENSIONER" eo counoonotaee The Supplemental Restraint System such as “AIR BAG" and “SEAT BELT PRE-TENSIONER’, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SR and SB section of this Service Manual. WARNING: + To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. + Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SR section. + Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this ‘Service Manual. SRS wiring harnesses can be Identified by yellow and/or orange harnesses or har- hess connectors. Precaution for Procedure without Cowl Top Cover ‘When performing the procedure after removing cowl top cover, cover the lower end of windshield NOTE: + This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS- TEM). + Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. + Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results, For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- anism is adopted on the key cylinder. For this reason, if the battery Is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation. OPERATION PROCEDURE 1. Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. 2. Use the Intelligent Key or mechanical key to turn the ignition switch to the “ACC” position. At this time, the steering lock will be released. —EM-7PRECAUTIONS < PRECAUTION > [HR16DE] 3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. 4. Perform the necessary repair operation. 5. When the repair work is completed, return the ignition switch to the “LOCK” position before connecting the battery cables. (At this time, the steering lock mechanism will engage.) 6. Perform a self-diagnosis check of all control units using CONSULT-II Precaution for Drain Coolant + Drain coolant when engine is cooled. Precaution for Disconnecting Fuel Piping + Before starting work, make sure no fire or spark producing items are in the work area + Release fuel pressure before disassembly. + After disconnecting pipes, plug openings to stop fuel leakage. Precaution for Removal and Disassembly + When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. + Exercise maximum care to avoid damage to mating or sliding surfaces, + Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. + Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. + When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally ‘opposite, and so on. if the order of loosening is Specified, do exactly as specified. Power tools may be used where noted in the step. Precaution for Inspection, Repair and Replacement + Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary. Precaution for Assembly and Installation + Use torque wrench to tighten bolts or nuts to specification + When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. Ifthe order of tightening is specified, do exactly as specified + Replace with new gasket, packing, oil seal or O-ring + Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. + Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, il sliding surfaces well + Release air within route after draining coolant. + Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). ‘Then make sure that there are no leaks at fuel line connections. + After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage. Parts Requiring Angular Tightening + Use an angle wrench for the final tightening of the following engine parts: = Cylinder head bolts = Camshaft sprocket (INT) = Main bearing cap bolts - Connecting rod cap nuts ~ Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) Tool number —_: KV10112100 (BT-8653-A) + Do not use a torque value for final tightening EM-8PRECAUTIONS < PRECAUTION > [HR16DE] ~ The torque value for these parts are for a preliminary step. + Ensure thread and seat surfaces are clean and coated with engine oil Precaution for Liquid Gasket REMOVAL OF LIQUID GASKET SEALING + After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool Tool number — : KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surfaces. + In areas where the cutter is dificult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied Use a plastic hammer to slide the cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as a flat-bladed ass screwdriver Is used, be careful not to damage the mating sur- faces. LIQUID GASKET APPLICATION PROCEDURE 1. Using a scraper, remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface. + Remove the sealant completely from the groove of the gasket application surface, bolts, and bolt holes. 2. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign materials. 3. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Re ‘GI-27, “Recommended Chemical Products and Sealants". 4, Apply the sealant without breaks to the specified location using Tool Tool number ~WS39930000( - ) + If there is @ groove for the sealant application, apply the seal- ant to the groove. + As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make 7 = sure to read the text of this manual + Within five minutes of the sealant application, install the mat- ing component. anc + Ifthe sealant protrudes, wipe it off immediately. + Do not retighten after the installation. + After 30 minutes or more have passed from the installation, fil Bhar the engine with the specified oil and coolant. Refer to MA-19, side “Fluids and Lubricants”. CAUTION: —EM-9PRECAUTIONS < PRECAUTION > [HR16DE] Follow all specific instructions in this manual. EM-10< PREPARATION > PREPARATION [HR16DE] PREPARATION PREPARATION Special Service Tools —_ Tool number oli Description KV07T1100 Removing ol pan (lower and upper) etc. ‘Seal cuter v10776200 Disassembling and assembling valve mecha- Valve spring compressor 4. KV10115800 Aitachment 2. Kv10709220 Adapter Kv10112100 ‘Angie wrench Kv10117100 Heated oxygen sensor wrench Kv10107002 Valve oll seal puller 4. KV10116100 Valve ol seal puller adapter Kv10718600 Valve oll seal art nism Pat (1) is a component of KV10116200, but Part (2) snot so. Tightening bolts for bearing cap, cylinder head, et. In angle Loosening or tightening heated oxygen sen- sort For 22 mm (0.87 in) width hexagon nut Removing valve ol seal Instaling vaive oll seal Use side A. 20(0.79) dia. «8 (0.31) dia, b: 13 (0.51) dia. fe: 10.7 (0.421) ©: 10.3 (0.406) dia, 1:5 (0.20) ‘Unit: mm (in) EM-11PREPARATION < PREPARATION > [HR16DE] Tool number Too! name Desarpion #E§03470000 Instaling piston assemby into oyinder bore Piston ring compressor qv11103000 Puley puller Removing crankshat pulley Quick connector release 1. Prese stand: ST13030020 2. Center shaft: KV10114120 3, Deft: KV10109730 4, Spring: ST13030030 5. Genter cap: KV10110310 Kv11105210 ‘Stopper plate Removing fuel ube quick connectors in en- gine room (Avallable in SEC. 164 of PARTS CATALOG: Patt No, 16441 8N210) Inataling and removing piston pin Fhing drive plate and fywheel Commercial Service Tools EM-12PREPARATION < PREPARATION > [HR16DE] Teotname Deserpton ‘Spark plug wrench Removing and insialing spark plug Valve seat cutter set Piston ring expander Valve guide ert Valve guide reamer ‘Oxygen sensor tread cleaner ‘Acoustic tension gauge Finishing valve seat dimensions Removing and instaling piston ring Removing and insialing valve guide 1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide Reconditioning the exhaust system threads before insialing a new heated oxygen sensor (Use with ant-seize lubicant shown below) ‘a= 18 mm (0.71 in) dia. for zirconia heated. oxygen sensor b= 12mm (0.47 In) dia. for titania heated oxygen sensor CGhecking dive bet tension EM-13< PREPARATION > PREPARATION [HR16DE] Teal name ‘Description ‘Ant-seize lubricant (Permatex 133AR ‘or equivalent meeting MIL speciica- tion MIL-A-907) Manual it table caddy Tube presser “Lubricating axygen sensor thread cleaning tool when reconditioning exhaust system teads Removing and instaling engine Pressing the tube of quid gasket EM-14DRIVE BELTS < ON-VEHICLE MAINTENANCE > [HR16DE] ON-VEHICLE MAINTENANCE DRIVE BELTS Checking + Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped “ Generator Wate pump Crarkshan puley +3 INC compressor (wth VC models eo lar ple thou A/C moses) ler pulley Dive bet + Visually check belts for wear, damage, and cracks on inside and edges. + Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the test + When measuring deflection, apply 98 N (10 kg, 22 Ib) at the (¥) marked point. + Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the (¥) marked point. CAUTION: + When the tension and frequency are measured, the acoustic tension gauge should be used. + When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation In deflection between pulleys. Belt Deflection / Belt Tension and Frequency: Refer to EM-122, "Drive Belts” Tension Adjustment Tocation Location of adjuster and lightening method Drive belt ‘Agjusting bolton ler pulley CAUTION: + When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new belt will not fully seat in the pulley groove. + When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”. + When installing a belt, make sure it is correctly engaged with the pulley groove. + Never allow oil or engine coolant to get on the belt. + Never twist or bend the belt strongly. 1. Loosen the idler pulley lock nut (A) from the tightening position with the spacified torque by 45 degrees. Generator 2: Water pump Cranksnat pulley AIC compressor (with AIC mode!s) Idler pulley (without A/G models) Idler pulley Drive bett Idler pulley lock rut Adjusting bot wroe EM-15DRIVE BELTS < ON-VEHICLE MAINTENANCE > THR16DE] CAUTION + When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjust- ment cannot be performed. Never loosen it excessively (more than 45 degrees). + Put a matching mark on the lock nut, and check turning angle with a protractor. Never visually check the tightening angle. 2. Adjust the belt tension by turning the adjusting bolt. CAUTION: + When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflec- tion between pulleys. + When the tension adjustment is performed, the lock nut should be in the condition at step"2”. If the tension adjustment is performed when the lock nut Is loosened more than the standard, the Idler pulley tilts and the correct tension adjustment cannot be performed. 3. Tighten the idler pulley lock nut. Idler pulley lock nut: 34.8 Nem (3.5 kg-m, 26 ft-lb) Removal and Installation REMOVAL 1. Loosen the idler pulley lock nut (A), and then adjust the belt ten- sion by turing the adjusting bolt (B). >-o 4: Generator 2: Water pump 3: Crankshaft pulley Oo ‘AIC compressor (with AIC models) Ider pulley (without A'C models) 5 :ldler pulley 6: Drive bett 4 2. Remove drive belt INSTALLATION 1. Pull the idler pulley in the loosening direction, and then tempo- ° rarily tighten the idler pulley lock nut (A) to the following torque. 1 Generator 1g. 1A%G compressor (with AIG models) Ider pulley (wthout AIC models) _\L@ 5: Idler pulley 6: Drive bet B: Adjusting bok Idler pulley lock nut: 4.4 N-m (0.45 kg-m, 39 in-Ib) NOTE: Do not move the lock nut from the tightened position. Proceed to step “2 2. Install the drive belt to each pulley. CAUTION: + Make sure that there Is no oll, grease, or coolant, etc. in pulley grooves. + Make sure that the belt is securely inside the groove on each pulley. 3. Adjust drive belt tension by turing the adjusting bolt. Refer to EM-15, "Tension Adjustment’. CAUTION: EM-16DRIVE BELTS < ON-VEHICLE MAINTENANCE > THR16DE] + Perform the belt tension adjustment with the lock nut temporarily tightened at the step “1” so as not to tilt the idler pulle + When checking immediately after installation, first adjust It to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflec- tion between pulleys. 4, Tighten the idler pulley lock nut Idler pulley lock nut: 34.8 Nem (3.5 kg-m, 26 ft-lb) 5. Make sure that belt tension of each belt within the standard. EM-17AIR CLEANER FILTE! < ON-VEHICLE MAINTENANCE > AIR CLEANER FILTER Removal and Installation REMOVAL 1. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B). 2. Pullup the air cleaner cover (1) and remove it (C), 3. Remove air cleaner filter (1) and holder (2) assembly from the air cleaner case. 4, Remove the air cleaner filter (1) from the holder (2) INSPECTION AFTER REMOVAL It is necessary to clean air cleaner filter or replace it at the recomm: conditions. Refer to MA-7, "Periodic Maintenance’. + Blow air into the back side of air cleaner filter until no objects spray out INSTALLATION Installation is in the reverse order of removal. + Install the air cleaner cover (1) in the direction shown. ner filter EM-18 R [HR16DE] fended intervals, more often under dustySPARK PLUG < ON-VEHICLE MAINTENANCE > [HR16DE] SPARK PLUG Exploded View ‘SEC. 220, BB: 0 a: inte) = Nem em te) 4. Ignition cot 2. Spark plug Removal and Installation REMOVAL 1, Remove intake manifold. Refer to EM-29. " ion’ 2, Remove ignition coil. Refer to EM-47," " 3, Remove spark plug with a spark plug wrench (commercial ser- vice tool), Wrench with a magnet to hold sparkplug (osstm INSPECTION AFTER REMOVAL Use the standard type spark plug for normal condition. ‘Spark plug (Standard type): Refer to MA-29, "SPARK PLUG : In- spection". CAUTION: EM-19SPARK PLUG < ON-VEHICLE MAINTENANCE > [HR16DE] + Never drop or shock spark plug. + Never use a wire brush for cleaning. + If plug tip Is covered with carbon, spark plug cleaner may be Less than 588 kPa (6 kgicm?, 85 psi) Cleaning time: Less than 20 seconds + Checking and adjusting plug gap is not required between change intervals. INSTALLATION Installation is the reverse order of removal Plug type : Platinum tipped Make :NGK Part number : PLZKARGAP-11 Gap (nominal) —_: 4.1 mm (0.043 in) EM-20CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > CAMSHAFT VALVE CLEARANCE Inspection and Adjustment INSPECTION there is unusual engine conditions regarding valve clearance. 1, Remove rocker cover. Refer to EM-47, "Exploded View" 2, Measure the valve clearance with the following procedure: a, Set No. 1 cylinder at TDC of its compression stroke. + Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. 1B: White paint mark (Not use for service) + Atthe same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face outside as shown +: Camshaft (INT) 2: Camshaft (EXH) <1: Engine front + If they do not face outside, rotate crankshaft pulley once more (360 degrees) and align as shown. b. Use a feeler gauge, measure the clearance between valve lifter and camshaft Valve Clearance: Refer to EM-123, "Camshi + By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below [locations indicated with black arrow (#8) shown] with a feeler gauge. ‘A: No. 1 cylinder compression TDC [HR16DE] ©. Rotate crankshaft pulley (2) one revolution (360 degrees) and align TOC mark (without paint mark) (A) to timing indicator (1) on front cover. B_: White paint mark (Not use for service) + By referring to the figure, measure the valve clearance at loca- tions marked "x" as shown in the table below [locations indi- cated with black arrow (8) shown] with a feeler gauge. A :No.4 oylinder compression TOC <3: Engine tront Measuring postion | No.1 GYL. | No.2GYL, | No SGYL.| No.4 OYL Measurement | EXH x x Point INT x x 3. If out of standard, perform adjustment procedure, ADJUSTMENT + Perform adjustment depending on selected head thickness of valve 1. Remove camshaft. Refer to EM-59. "Exploded View". 2. Remove valve lifters at the locations that are out of the standard, 3. Measure the center thickness of the removed valve lifters with a micrometer (A). Valve lifter thickness calculation: t=t1 + (C1~C2) t =Valve lifter thickness to be replaced ti = Removed valve lifter thickness C1 = Measured valve clearance C2 = Standard valve clearance: Intake 0.30 mm (0.012 in) Exhaust — : 0,33 mm (0.013 in) EM-22 lifter. Use the equation below to calculate valve lifter thickness for replacementCAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > [HR16DE] 9 + Thickness of new valve lifter (B) can be identified by stamp mark (A) on the reverse side (inside the cylinder), + Stamp mark "300" indicates 3.00 mm (0.118 in) in thickness. 3 e| Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-123, "Camshaft". Install the selected valve lifter. Install camshaft. Refer to EM-59. "Exploded View". Manually rotate crankshaft pulley a few rotations. Make sure that valve clearances for cold engine are within specifications by referring to the specified val- ues, Install all removed parts in the reverse order of removal 10. Warm up the engine, and check for unusual noise and vibration. EM-23COMPRESSION PRESSURE < ON-VEHICLE MAINTENANCE > [HR16DE] COMPRESSION PRESSURE Inspection 1. Warm up engine thoroughly. Then, stop it. 2. Release fuel pressure. Refer to EC-377. "Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT EURO-OBD). 3. Remove ignition coil and spark plug from each cylinder. Refer to EM-47, "Exploded View" Connect an engine tachometer (not required in use of CONSULT-I). 5. Install a compression tester (B) with an adapter (commercial service tool) (A) onto spark plug hole. + Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal 20 mm (0.79 in) dia, 6. With accelerator pedal fully depressed, tum ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression Pressure: _Refer to EM-122, "General Specification. CAUTION: Always use fully a changed battery to obtain the specified engine speed. + If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. + If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again + If'some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. ~ Ifthe added engine oll improves the compression, piston rings may be worn out or damaged. Check pis- ton rings and replace if necessary. - If the compression pressure remains at low level despite the addition of engine oil, valves may be mal- functioning. Check valves for damage. Replace valve or valve seat accordingly. + If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gasket is leaking, In such a case, replace cylinder head gasket 7. After inspection is completed, install removed parts. Start the engine, and confirm that the engine runs smoothly. 9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-469, "Descriotion’. EM-24DRIVE BELT IDLER PULLEY < ON-VEHICLE REPAIR > [HR16DE] ON-VEHICLE REPAIR DRIVE BELT IDLER PULLEY Exploded View Generator bracket Center shaft Spacer ‘Adjusting bok Washer Ider pulley Piate Si Phs19.a5,20) 9 Ss nem (ag, 0) Removal and Installation REMOVAL 1. Remove drive belt. Refer to EM-16, "Removal and Installation’. 2, Remove the lock nut, and then remove the plate, idler pulley, and washer. 3. Remove the center shaff together with the spacer with inserting the adjusting bolt. INSTALLATION EM-25DRIVE BELT IDLER PULLEY < ON-VEHICLE REPAIR > THR16DE] 7__ Insert the center shaft (1) into the slide groove of the spacer (2) Fully screw in the adjusting bolt (3) in the belt loosening direc- tion (<3) + At that time, place the flange (a) of the adjusting bolt and the seat (b) of the center shaft on the spacer. 2. Place each surface (c, d) of the spacer on the generator bracket, Install the washer, idler pulley, and plate, and then temporarily tighten the lock nut |: 4.4.N-m (0.45 kg-m, 39 in-Ib) 3. Installation is in the reverse order of removal. EM-26AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR > [HR16DE] AIR CLEANER AND AIR DUCT Exploded View — SEC. 116-165 5(0.35.19) 4. Alrcleaner titer 2. Mass alr flow sensor 3. Oxting 4. Holder 5. Aircleaner cover 6 Aleduct 7. Pov hose 8 Clip 8. Alrduct (inlet) 10. Grommet 11. Aleduct 12, Grommet 18, Air cleaner case A. Toetecttonic trate control actuator B, To rocker cover, Removal and Installation REMOVAL Remove the battery. Refer to PG-6, "Removal and Installation”. Remove the air duct (inlet), Remove the air cleaner fitter from the air cleaner case. Refer to EM-18, "Removal and Installation”, Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case. Remove the PCV hose, Remove the air duct (between air cleaner case and electronic throttle control actuator) + Add marks as necessary for easier installation. Disconnect harness connector from mass air flow sensor. Remove air cleaner case. 9, Remove the mass air flow sensor from the air cleaner case, if necessary. CAUTION: + Handle mass air flow sensor carefully and avoid impacts. + Never touch sensor part. INSTALLATION Installation is in the reverse order of removal. OP okeNs EM-27AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR > (HR16DE] * Align marks. Attach each joint. Screw clamps firmly. Inspection INSPECTION AFTER REMOVAL Inspect air ducts and air cleaner assembly for crack or tear. + Ianything found, replace air ducts and air cleaner assembly as necessary. EM-28INTAKE MANIFOLD < ON-VEHICLE REPAIR > [HR16DE] INTAKE MANIFOLD Exploded View neocon Bison. Pn00s.8 x PBI 100 (19,20 Broo y0.09 << Bt (gem i) ye Pte thom. ti) WB 1001.0, 00) 4. EVAP hose 2 Vacuum tan 3. EVAPhose 4 xing 5. EVAP canister Purge voume cont! erect trot contol actuator 7. Water hose (Northern Europe models) 8. Waterhose (Northern Europe medels) 8. Gasket 10. tntoke manifold support (rer) 11. Intake manitotd 12, Intake manitold support (trot) 13, nfake manifold suppor (center) 4. Cylinder nead 48. Vacuum hose 16. Gasket A. Tocentvalzed under-toor piping «BL To bake booster ©. Towater outet Removal and Installation REMOVAL 1. Remove the air duct (inlet) and air duct (between air cleaner case and electronic throttle control actuator). Refer to EM-27. "Exploded View". 2, Remove the reservoir tank. Refer to CO-16, "Component". 3. Remove the oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials. 4, Remove electronic throttle control actuator and position aside. CAUTION: + Handle electric throttle control actuator carefully and avoid impacts. + Never disassemble or adjust electric throttle control actuator. 5. Disconnect the hamess connector and EVAP hose from the EVAP canister purge volume control solenoid valve 6. Disconnect vacuum hose for brake booster from intake manifold. EM-29INTAKE MANIFOLD < ON-VEHICLE REPAIR > [HR16DE] 7. Remove intake manifold support front (1) and bolt from rear (2). + Bracket (2) is not removed. Remove bolt from intake manifold 8. Remove intake manifold + Loosen bolts in the reverse of the order shown, <>: Engine tront 9. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. CAUTION: Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts. 10. Remove intake manifold support (center) from cylinder head, if necessary, NOTE: The intake manifold support (center) functions as the guide when the intake manifold is installed. INSTALLATION Installation is in the reverse order of removal. Intake Manifold 1. Install the gasket to the intake manifold. + Align the protrusion (A) of gasket to the groove of intake mani- fold. 2. Place the intake manifold into the installation position. CAUTION: Make sure that the oll level gauge guide is not disconnected from the fixing clip of water inlet due to interference with intake manifold. EM-30INTAKE MANIFOLD < ON-VEHICLE REPAIR > [HR16DE] 3. Tighten bolts in the numerical order shown. <2: Englne front 4, Install intake manifold support (front and reer). Electronic Throttle Control Actuator + Tighten bolts of electronic throttle control actuator equally and diagonally in several steps. + Perform “Throttle Valve Closed Position Learning’ after repair when removing harness connector of the elec- trie throttle control actuator, Refer to EC-27. "THROTTLE VALVE CLOSED POSITION LEARNING : Description" (EURO-OBD), EC-390, "THROTTLE VALVE CLOSED POSITION LEARNING = Description® (WITHOUT EURO-OBD). + Perform “Throttle Valve Closed Position Learning’ and “Idle Air Volume Learning” after repair when replacing electric throttie control actuator. Refer to EC-27. "THROTTLE VALVE CLOSED POSITION LEARNING : Description" (EURO-OBD), EC-390. "THROTTLE VALVE CLOSED POSITION LEARNING Description" (WITHOUT EURO-OBD), EC-27, "IDLE AIR VOLUME LEARNING = Description (EURO-OBD), EC-390. “IDLE AIR VOLUME LEARNING = Descriotion” (WITHOUT EURO-OBD). EM-31EXHAUST MANIFOLD < ON-VEHICLE REPAIR > [HR16DE] EXHAUST MANIFOLD Exploded View SEC. 1111402226 100 (10,89) paeensy Oy 200.88. 71) FI i20 2.9) em ist) » Ts pg-m tiny Fs8008.26) 25.0 08.26 4. Exhaust manitowd cover 2. Exhaust manifold cover 3. Harness bracket 4. Heated oxygen sensor 1 5. Exhaust manifold stay 6. Exhaust manifold 7. Gasket 8. Stud bot 9. Heat insulator [HR16DE] = Using heated oxygen sensor wrench (SST: KV10117100] (A), remove heated oxygen sensor 1 CAUTION: Handle heated oxygen sensor 1 carefully and avoid impacts. NOTE: The exhaust manifold can be removed and installed without removing the heated oxygen sensor 1 (Disassembly of harness connector is necessary) 7. Remove exhaust manifold side mounting bolt of exhaust manifold stay. 8. Remove exhaust manifold + Loosen nuts in the reverse of the order shown. <1: Engine front 9. Remove gasket, CAUTION: Cover engine openings to avoid entry of foreign materials. 10. Remove exhaust manifold cover from back of exhaust manifold INSPECTION AFTER REMOVAL, Mounting Surface Distortion + Use suitable tools (A) and (B) to check distortion of exhaust mani- fold mounting surface as shown. Limit: 0.3 mm (0.012 in) + Replace exhaust manifold if outside the limit, INSTALLATION Installation is in the reverse order of removal. Exhaust Manifold EM-33EXHAUST MANIFOLD < ON-VEHICLE REPAIR > [HR16DE] 7_ Tighten nuts in numerical order shown. <2: Engine front 2. Tighten to the specified torque again EM-34FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > [HR16DE] FUEL INJECTOR AND FUEL TUBE Exploded View ‘SEC. 164 5012618) 25.0 (28, 18) Nem kg nto) BA}: Ner ag: tb) oe 1. Quick connector cap 2. Fuel feed hose 3. Fuel tube 4. Fuel tube protector 5. Oxting (diac) 6. Clip 7. Fuel injector 8, Outing (green) CAUTION: Never remove or disassemble parts unless instructed as shown. Removal and Installation WARNING: + Puta “CAUTION: FLAMMABLE" sign in the workshop. + Be sure to work in a well ventilated area and furnish workshop with a COz fire extinguisher. + Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. REMOVAL 1. Release the fuel pressure. Refer to EC-377. "Inspection" (EURO-OBD), EC-681. "Inspection (WITHOUT EURO-OBD). 2, Remove intake manifold. Refer to ElV-29, "Exploded View". EM-35FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > [HR16DE] 3. Disconnect quick connector with the following procedure. Dis- connect fuel feed hose from fuel tube. 41. : Quick connector cap NOTE: There is no fuel retum path. a. Remove quick connector cap (1) from quick connector connec- tion, b. Disconnect fuel feed hose from hose clamp. c. With the sleeve side of quick connector release (SST) facing quick connector, install quick connector release onto fuel tube d. Insert quick connector release into quick connector until sleeve [Gaex connecter contacts and goes no further. Hold quick connector release on | release that position fem Pull quick connector es CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where It ‘Qulek connector contacts and goes no further. * . Draw and pull out quick connector straight from fuel tube. + CAUTION: Insert and retain + Pull quick connector holding “A” position. Quick corecor al has + Never pull with lateral force applied. O-ring inside quick | ‘ss connector may be damaged. + Prepare container and cloth beforehand as fuel will leak out. + Avold fire and sparks. + Keep parts away from heat source. Especially, be careful when wel the + Never expose parts to battery electrolyte or other acids. + Never bend or twist connection between quick connector and fuel feed hose during installation’ removal. + To keep clean the connecting portion and to avoid dam- age and foreign materials, cover them completely with plastic bags or something similar. 9 is performed around Plastic bags, ate 4, Disconnect harness connector from fuel injector. EM-36FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > [HR16DE] %. Remove fuel tube protector. + Loosen bolts in the reverse of the order shown, <1: Engine front ey 6. Remove the fuel injector and fuel tube assembly. + Loosen bolts in the reverse of the order shown <2: Engine front CAUTION: + When removing, be careful to avoid any interference with fuel injector. + Use a shop cloth to absorb any fuel leaks from fuel tube. 7. Remove the fuel injector (3) from the fuel tube (1) with the fol- lowing procedure. a, Open and remove the clip (2) b. Remove fuel injector from the fuel tube by pulling straight. CAUTION: + Be careful about fuel leakage remaining in fuel tube. + Be careful not to damage the nozzle of fuel injector. + Never subject fuel injector to impact by dropping or hit- ting. + Never disassemble. INSTALLATION 1. Install new the O-ring to the fue! injector, paying attention to the following CAUTION: + The upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side : Black Nozzle side :Green * Handle O-ring with bare hands. (Never wear gloves.) + Lubricate O-ring with engine oil. + Never clean O-ring with solvent. Make sure that the O-ring and its mating part are free of foreign material. Be careful not to scratch O-ring with tool or fingernalls when installing it. Also be careful not to twist or stretch O-ring. If O-ring Is stretched while installing, never insert it into fuel tube immedi- ately. + Insert O-ring straight into fuel tube, Never decenter or twist it EM-37FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 2 gepoo Install the fuel injector (4) onto the fuel tube (1) with the following procedure: 3: Oxting (Black) 5: Oring (Green) Insert the clips (2) into the clip mounting grooves on the fuel injector. + Insert clip cut-out (D) into fuel injector protrusion (F). CAUTION: + Always replace olip with new one. + Make sure that the clip does not Interfere with the O- ring. If interference occurs, replace the O-ring. Insert the fuel injector into the fuel tube with clip attached. + Make sure that the axis is lined up when inserting, + Insert clip cut-out (C) into fuel tube protrusion (B). + Make sure that the flange (A) on the fuel tube fits securely in the clip flange fixing groove (E). Make sure that installation is complete by checking that fuel injector does not rotate or come off. Install fuel tube and injector assembly onto cylinder head, + Tighten bolts in the numerical order shown. <2: Engine ront CAUTION: Be careful not to let tip of injector nozzle interfere with other parts. Install fuel tube protector. + Tighten bolts in the numerical order shown, <2: Engine front Connect hamess connector to fuel injector. Connect fuel feed hose with the following procedure, [HR16DE] tr a 2 4 a ow ep Check for damage or foreign material on the fuel tube and quick connector. Apply new engine oil lightly to area around the top of fuel tube. EM-38FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > THR16DE] . Align center to insert quick connector straightly into fuel tube. + Insert quick connector to fuel tube until the top spool on fuel ‘Whennusa tube Is inserted completely and the 2nd level spool is posi- | auick tioned slightly below quick connector bottom end, conpector CAUTION: + Hold “A” position shown when inserting fuel tube into A quick connector. ’ + Carefully align center to avoid inclined insertion to pre- | tT Hage and vent damage to O-ring inside quick connector. sooot{) erton level poo! + Insert until you hear a “click” sound and actually fee! ont the engagement. il _—_ + To avoid misidentification of engagement with a similar sound, be sure to perform the next step. 4. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position. Make sure itis completely engaged (connected) so that it does not come out from fuel tube. €. Install quick connector cap (1) to quick connector connection + Install quick connector cap with the side arrow facing quick connector side (fuel feed hose side) CAUTION: + Make sure that the quick connector and fuel tube are securely engaged with the quick connector cap mount- ing groove. + Quick connector may not be connected correctly if quick connector cap cannot be installed easily. Remove the quick connector cap, and then check the connection of quick connector again. f. Install fuel feed hose to hose clamp, 7. Installation is in the reverse order of removal, for the remaining parts. Inspection INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, make sure there are no fuel leaks at connection points. NOTE: Use mirrors for checking at points out of clear sight 2. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection points. ‘CAUTION: Never touch the engine immediately after stopped, as the engine becomes extremely hot. EM-39OIL PAN (LOWER) < ON-VEHICLE REPAIR > [HR16DE] OIL PAN (LOWER) Exploded View SEC. 110-130-150 7 © a Ss Beoes.7 <= A isos Tl: bem tom) BB 10.0 (1.0 007 7 4. Rear ol sea 2 o-ring 3. Ollpan (upper) 4. Chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket 7. ll pump sprocket 8. Ollpan drain plug 8. Washer 10. Oilpan dower) 11. Oilfiter stud bot 12. oitfiter 13. Oilevel sensor AL Referto EM50 BL RefertoLus ©. Ollpan side Removal and Installation REMOVAL 1. Drain engine oil, Refer to LU-7, "Draining", 2, Remove the oil pan (lower) with the following procedure. a. Loosen bolts in the reverse of the order shown, <2: Engine front b. Insert the seal cutter [SST KV10111100] between oil pan (upper) and cil pan (lower) CAUTION: + Be careful not to damage the mating surface. + Amore adhesive liquid gasket is applied compared to pre- vious types when shipped, so It should not be forced off using a flat- bladed screwdriver, etc. EM-40OIL PAN (LOWER) < ON-VEHICLE REPAIR > THR16DE] INSTALLATION 41. Install oil pan (lower) with the following procedure. a. Use scraper to remove old liquid gasket from mating surfaces. + Also remove the old liquid gasket from mating surface of oil pan (upper). + Remove old liquid gasket from the bolt holes and threads, C CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. b. Apply @ continuous bead of liquid gasket (A) with the tube presser (commercial service tool) to areas shown, Engine out side Use Genuine Liquid Gasket or equivalent. CAUTION: Attaching should be done within 5 minutes after coating. je—7.5-25 mm (0.205 - 0.374 in) #4.0-5.0mm (0.187 = 0.196 in) zz ¢. Tighten bolts in the numerical order shown in the figure. <2: Engine front 2. Install oil pan drain plug. + For installation direction of washer. Refer to EM-40, "Exploded View". 3, Install in the reverse order of removal, for the rest of parts. CAUTION: Pour engine oll at least 30 minutes after oll pan Is installed. Inspection INSPECTION AFTER INSTALLATION Check the engine oil level and adjust engine oil. Refer to LU-6. “inspection’. Start engine, and check there is no leak of engine oi Stop engine and wait for 10 minutes. Check the engine oil level again. Refer to LU-6, "Inspection" Sere EM-41OIL PAN (UPPER) AND OIL STRAINER < ON-VEHICLE REPAIR > [HR16DE] OIL PAN (UPPER) AND OIL STRAINER Component ‘SEC, 170-130-150 Fscesin | ou Ny a Mh25.0(26, 18) 0") _S Ae BA maemo) boon ef Tl: bem tom) Brow oe Blenoeo.m 7 4. Rear ll seal 2 oxng 3. Ollpan (upper) 4. Chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket 7. Oil pump sprocket 8. _Olipan rain plug 8. Washer 10, Oil pan ower) ‘11, Ol iter stud bot 12, Ol fier 13. Ollevel sensor AL Referto EM50 8. RefertoLu.s ©. Ollpan side Removal and Installation ad NOTE: The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited REMOVAL NOTE: When removing oil pan (lower) only, steps *2” and ter completing step “4”, 1. Remove engine undercover using power tool 2. Remove engine and transaxle assembly from the vehicle, and then separate engine and transaxle. Refer to EIV-89, "Removal and Installation". are not necessary. Perform step 3. Install engine assembly to widely use engine stand, Refer to EM-94, "Setting. 4. Drain engine oil, Refer to LU-7, "Draining". 5. Remove the oil pan (lower) using the following procedure. EM-42