Motor Nissan Hr16de
Motor Nissan Hr16de
Motor Nissan Hr16de
SECTION
EM
ENGINE MECHANICAL
EM
CONTENTS
HR16DE
PRECAUTION ............................................... 3
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 3
Precaution for Procedure without Cowl Top Cover...... 3
Draining Engine Coolant ........................................... 3
Disconnecting Fuel Piping ......................................... 3
Removal and Disassembly ........................................ 4
Inspection, Repair and Replacement ........................ 4
Assembly and Installation ......................................... 4
Parts Requiring Angle Tightening ............................. 4
Precaution for Liquid Gasket ..................................... 4
PREPARATION ............................................ 6
Inspection ................................................................17
Adjustment ...............................................................18
Inspection ................................................................ 13
PREPARATION ................................................... 6
Special Service Tools ................................................ 6
Commercial Service Tools ........................................ 7
EM-1
CAMSHAFT ....................................................... 56
Setting .................................................................... 86
EM-2
PRECAUTIONS
[HR16DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
EM
INFOID:0000000007732304
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
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 harness connectors.
INFOID:0000000007575573
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
N
PIIB3706J
INFOID:0000000007575576
Drain engine coolant and engine oil when the engine is cooled.
INFOID:0000000007575577
Before starting work, check no fire or spark producing items are in the work area.
Release fuel pressure before disconnecting and disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
EM-3
PRECAUTIONS
[HR16DE]
INFOID:0000000007575578
When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
Use care to avoid damage to mating or sliding surfaces.
Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
When loosening nuts and bolts, 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 in the step.
INFOID:0000000007575579
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
INFOID:0000000007575580
INFOID:0000000007575581
For the final tightening of the following engine parts use Tool:
Tool number
: KV10112100 (BT-8653-A)
INFOID:0000000007732305
: KV10111100 (J-37228)
CAUTION:
Do not damage mating surfaces.
Tap the seal cutter to insert it (1).
In areas where the Tool is difficult to use, lightly tap to slide it (2).
WBIA0566E
EM-4
PRECAUTIONS
< PRECAUTION >
LIQUID GASKET APPLICATION PROCEDURE
1. Remove the old liquid gasket adhering to the gasket application
surface and the mating surface using suitable tool.
Remove the liquid gasket completely from the groove of the
liquid gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign material.
[HR16DE]
A
EM
PBIC0003E
3.
4.
G
WBIA0567E
EM-5
PREPARATION
[HR16DE]
PREPARATION
PREPARATION
Special Service Tools
INFOID:0000000007732317
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
KV10111100
(J-37228)
Seal cutter
S-NT046
KV10116200
(J-26336-B)
Valve spring compressor
1. KV10115900
(J-26336-20)
Attachment
2. KV10109220
( )
Adapter
PBIC1650E
KV10112100
(BT-8653-A)
Angle wrench
S-NT014
KV10117100
( )
Heated oxygen sensor wrench
NT379
KV10107902
(J-38959)
Valve oil seal puller
NT011
KV10115600
(J-38958)
Valve oil seal drift
EM-6
PREPARATION
[HR16DE]
Description
EM03470000
(J-8037)
Piston ring compressor
EM
C
S-NT044
ST16610001
(J-23907)
Pulley puller
S-NT045
KV11103000
( )
Pulley puller
H
NT676
KV11105210
(J-44716)
Stopper plate
ZZA0009D
INFOID:0000000007732318
L
Tool name
Description
Power tool
N
PIIB1407E
PBIC0198E
EM-7
PREPARATION
[HR16DE]
Description
JPBIA0399ZZ
Pulley holder
NT035
S-NT048
S-NT030
PBIC4012E
PBIC4013E
(J-43897-18)
(J-43897-12)
Oxygen sensor thread cleaner
JPBIA0238ZZ
EM-8
PREPARATION
[HR16DE]
Description
EM
PBIC3881E
E
AEM489
ZZA1210D
1. Compression gauge
2. Adapter
J
ZZA0008D
WS39930000
( )
Tube presser
L
S-NT052
EM-9
BASIC INSPECTION
CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment
INFOID:0000000007575585
INSPECTION
Perform inspection as follows after removal, replacement or installation of camshaft or valve-related parts, or if
there are unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-44, "Removal and Installation".
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 (no
paint) (A) to timing indicator (1) on front cover.
B : White paint mark (Not used for service)
PBIC3673E
At the same time, check that both intake and exhaust cam
lobes of No. 1 cylinder face inside ( ) as shown in the figure.
1
: Camshaft (INT)
: Camshaft (EXH)
: Engine front
If the lobes do not face inside, rotate the crankshaft pulley 360
degrees to align as shown in the figure.
JPBIA4738ZZ
b.
JPBIA4116ZZ
EM-10
: No. 1 cylinder
: No. 2 cylinder
: No. 3 cylinder
: No. 4 cylinder
EM
C
JPBIA4117ZZ
D
Measuring position
No. 1 CYL.
c.
EXH
INT
No. 2 CYL.
No. 3 CYL.
No. 4 CYL.
I
PBIC3673E
: No. 1 cylinder
: No. 2 cylinder
: No. 3 cylinder
: No. 4 cylinder
JPBIA4118ZZ
Measuring position
No. 4 cylinder at compression TDC
No. 1 CYL.
No. 2 CYL.
No. 3 CYL.
EXH
INT
No. 4 CYL.
3.
ADJUSTMENT
NOTE:
Proper valve clearance is obtained by selecting the correct valve lifter head thickness.
1. Remove camshaft. Refer to EM-56, "Exploded View".
2. Remove valve lifters from the locations that are out of specification.
EM-11
[HR16DE]
PBIC3195J
4.
Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation:
t = t1 + (C1 C2)
t
= Valve lifter thickness to be replaced
= Removed valve lifter thickness
t1
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake
: 0.30 mm (0.012 in)
Exhaust
: 0.33 mm (0.013 in)
Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the under side of the lifter.
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50
mm (0.1181 to 0.1378 in) in increments of 0.02 mm (0.0008 in)
when manufactured at factory. Refer to EM-118, "Camshaft".
Stamp mark 302 indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
5.
6.
7.
8.
9.
10.
11.
EM-12
COMPRESSION PRESSURE
[HR16DE]
COMPRESSION PRESSURE
Inspection
1.
2.
3.
4.
5.
INFOID:0000000007575586
EM
F
JPBIA4119ZZ
J
JPBIA0171ZZ
6.
With accelerator pedal fully depressed, turn 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
7.
8.
9.
CAUTION:
Always use a fully charged battery to obtain the specified engine speed.
If the engine speed is out of the specified range, check the battery. Check the engine speed again with a
fully charged battery.
If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug
hole to recheck the compression.
- If the added engine oil improves the compression, the piston rings may be worn or damaged. Check the
piston rings and replace if necessary.
- If the compression pressure remains low despite the addition of engine oil, the valves may be malfunctioning. Check the valves for damage. Replace the valve or valve seat as necessary.
If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil the head gasket may be leaking, or valves in adjacent cylinders
may be damaged. Inspect and repair as required.
If the compression pressure is below the minimum value, check the valve clearances and parts associated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head,
cylinder head gasket). After repairing, measure the compression pressure again.
After inspection is completed, install removed parts.
Start the engine, and ensure that the engine runs smoothly.
Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-111, "Work Flow".
EM-13
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH troubleshooting Chart
INFOID:0000000007575587
JPBIA4739GB
1.
2.
3.
EM-14
Type of
noise
Front of
engine
front cover
Front of
engine
Reference page
EM
After
warmup
When
starting
When
idling
When
racing
While
driving
Ticking or
clicking
Tappet
noise
Valve clearance
EM-10
Rattle
Camshaft
bearing
noise
EM-118
Piston pin
noise
EM-122
Piston
slap noise
EM-122
EM-122
EM-126
Slap or
knock
Crankshaft pulley
cylinder
block (side
of engine)
oil pan
Source of
noise
Before
warmup
Slap or
rap
Check item
Knock
Connecting rod
bearing
noise
Knock
EM-125
EM-122
Timing
chain and
chain tensioner
noise
EM-47
EM-47
Drive belt
(Sticking
or slipping)
Tapping or
ticking
Squeaking or fizzing
Creaking
Drive belt
(Slipping)
Squall
Creak
Water
pump
noise
C: Sometimes related
EM-117
M
CO-19
: Not related
EM-15
DRIVE BELT
[HR16DE]
PERIODIC MAINTENANCE
DRIVE BELT
Exploded View
INFOID:0000000007575588
JSBIA1053ZZ
1.
Generator
2.
Water pump
3.
Crankshaft pulley
4.
5.
Idler pulley
6.
Drive belt
INFOID:0000000007575589
REMOVAL
1.
2.
3.
4.
: Generator
(2)
: Water pump
(3)
: Crankshaft pulley
(4)
(5)
: Idler pulley
(6)
: Drive belt
PBIC3643E
INSTALLATION
EM-16
DRIVE BELT
[HR16DE]
2.
3.
4.
(1)
: Generator
(2)
: Water pump
(3)
: Crankshaft pulley
(4)
(5)
: Idler pulley
(6)
: Drive belt
(B)
: Adjusting bolt
EM
C
PBIC3643E
NOTE:
Do not move the lock nut from the temporary tightened position. Go to step 2.
Install the drive belt on each pulley.
CAUTION:
Check that there is no oil, grease, or coolant, etc. in pulley grooves.
Check that the belt seats securely inside the groove on each pulley.
Adjust drive belt tension by turning the adjusting bolt. Refer to EM-18, "Adjustment".
CAUTION:
Perform the belt tension adjustment with the lock nut temporarily tightened to the torque specification listed in step 1 which prevents the idler pulley from tilting.
When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, readjust to the specified value to avoid variation in deflection between pulleys.
Tighten the lock nut to final tightening specification.
Lock nut (Final tightening)
5.
Check that belt tension is within the specification. Refer to EM-117, "Drive Belt".
Inspection
INFOID:0000000007575590
: Generator
(2)
: Water pump
(3)
: Crankshaft pulley
(4)
(5)
: Idler pulley
(6)
: Drive belt
N
PBIC3642E
Visually check belt for wear, damage, and cracks on inside and
edges.
Turn crankshaft pulley clockwise twice, and check that the tension on all pulleys equalizes before testing.
When measuring deflection, apply 98.1 N (10 kg, 22 lb) at the ( ) marked point.
Measure the belt tension and frequency with acoustic tension gauge 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, readjust to the specified value to avoid variation in deflection between
pulleys.
Belt deflection/belt tension and frequency
Revision: March 2013
EM-17
DRIVE BELT
[HR16DE]
Adjustment
INFOID:0000000007575591
Location
Drive belt
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, check 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. Remove the fender protector (RH) front side clip. Refer to EXT-26, "Removal and Installation".
2. Tighten lock nut (A) temporarily to the following torque.
Lock nut (A)
(Temporary tightening)
(1)
3.
4.
: Generator
(2)
: Water pump
(3)
: Crankshaft pulley
(4)
(5)
: Idler pulley
(6)
: Drive belt
(B)
: Adjusting bolt
PBIC3643E
Adjust the belt tension by turning the adjusting bolt. Refer to EM-117, "Drive Belt".
CAUTION:
When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, readjust to the specified value to avoid variation in deflection 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 temporary
tightening, the idler pulley tilts and the correct tension adjustment cannot be performed.
Tighten the lock nut to final tightening specification.
Lock nut (Final tightening)
EM-18
Exploded View
INFOID:0000000007575686
EM
I
AWBIA1126ZZ
1.
Clamp
2.
PCV hose
3.
Clamp
4.
Mount rubber
5.
6.
7.
Grommet
8.
9.
A.
B.
12. Clamp
To rocker cover
INFOID:0000000007575687
REMOVAL
1.
Unhook clips (A) and pull the air cleaner cover upward (1).
JSBIA1092ZZ
EM-19
[HR16DE]
JSBIA1093ZZ
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Check that the air cleaner filter is securely placed in the air cleaner body.
EM-20
SPARK PLUG
[HR16DE]
SPARK PLUG
Exploded View
INFOID:0000000007733081
EM
G
PBIC3662E
1.
Ignition coil
2.
Spark plug
H
INFOID:0000000007575596
REMOVAL
1.
2.
: 14 mm (0.55 in)
CAUTION:
Never drop or shock spark plug.
L
M
JPBIA0030ZZ
SMA773C
If the spark plug tip is covered with carbon, a spark plug cleaner may be used.
Revision: March 2013
EM-21
SPARK PLUG
[HR16DE]
SMA806CA
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Do not drop or shock the spark plug.
Make
NGK
Standard type*
PLZKAR6A-11
Gap (nominal)
*: Always check with the Parts Department for the latest parts information.
EM-22
: Generator bracket
: Center shaft
: Spacer
: Adjusting bolt
: Washer
: Idler pulley
: Plate
INFOID:0000000007733082
EM
PBIC3644E
INFOID:0000000007733083
REMOVAL
1.
2.
3.
4.
5.
INSTALLATION
M
EM-23
[HR16DE]
PBIC3885E
3.
EM-24
Exploded View
INFOID:0000000007733084
EM
I
AWBIA1126ZZ
1.
Clamp
2.
PCV hose
3.
Clamp
4.
Mount rubber
5.
6.
7.
Grommet
8.
9.
A.
B.
12. Clamp
To rocker cover
INFOID:0000000007575699
REMOVAL
NOTE:
Mass air flow sensor is removable as an assembly with the air cleaner cover.
1. Remove air duct (inlet) from the air cleaner body.
2. Disconnect PCV hose from the air duct.
3. Remove the air duct (between air cleaner case and electric throttle control actuator).
Add matching marks if necessary for easier installation.
4. Remove air cleaner assembly with the following steps:
a. Disconnect mass air flow sensor harness connector.
b. Remove the two air cleaner body bolts.
c. Pull up on the air cleaner assembly to disengage it from the grommet and remove the air cleaner assembly.
CAUTION:
Never shock the mass air flow sensor.
Never disassemble the mass air flow sensor.
Never touch the sensor of the mass air flow sensor.
EM-25
[HR16DE]
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Align marks, attach each joint and screw clamps firmly.
EM-26
INTAKE MANIFOLD
[HR16DE]
INTAKE MANIFOLD
Exploded View
INFOID:0000000007575602
EM
I
AWBIA1127GB
1.
2.
Hose clamp
3.
Vacuum hose
4.
PCV hose
5.
Hose clamp
6.
7.
Gasket
8.
Intake manifold
9.
C.
To brake booster
10. Gasket
A.
To air duct
B.
D.
To air duct
E.
To rocker cover
L
INFOID:0000000007575603
REMOVAL
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
1. Remove air duct (inlet), air duct and air cleaner assembly. Refer to EM-25, "Removal and Installation".
2. Disconnect water hoses from electric throttle control actuator.
CAUTION:
Perform this step when the engine is cold.
Never spill engine coolant on drive belt.
3. Remove electric throttle control actuator.
CAUTION:
Handle carefully to avoid any shock to electric throttle control actuator.
Never disassemble electric throttle control actuator.
4. Disconnect harness connector and vacuum hose from EVAP purge control solenoid valve.
CAUTION:
Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
5. Disconnect vacuum hose for brake booster from intake manifold.
Revision: March 2013
EM-27
INTAKE MANIFOLD
< REMOVAL AND INSTALLATION >
6. Remove intake manifold mounting bolts at the rocker cover.
[HR16DE]
AWBIA1128GB
7.
JSBIA1219ZZ
8.
9.
JPBIA4741ZZ
INSTALLATION
Installation is in the reverse order of removal.
Intake Manifold
1.
JSBIA1220ZZ
2.
EM-28
INTAKE MANIFOLD
[HR16DE]
< REMOVAL AND INSTALLATION >
Check that the oil level gauge guide is not detached from the securing clip of the water inlet due to
interference of intake manifold.
3. Tighten the bolts to specification in the numerical order as
shown.
EM
D
JSBIA1219ZZ
4.
AWBIA1128GB
EM-29
EXHAUST MANIFOLD
[HR16DE]
EXHAUST MANIFOLD
Exploded View
INFOID:0000000007575604
JPBIA4091GB
1.
2.
Harness bracket
3.
4.
5.
Heat insulator
6.
Exhaust manifold
7.
8.
Gasket
: Engine front
INFOID:0000000007575605
REMOVAL
1.
2.
3.
4.
5.
6.
7.
Remove air duct (inlet), air duct and air cleaner assembly. Refer to EM-25, "Exploded View".
Remove exhaust center tube and front tube. Refer to EX-5, "Exploded View".
Remove the air-fuel ratio sensor harness bracket from the cylinder head on the right rear side.
Remove exhaust manifold cover.
Disconnect the harness from air-fuel ratio sensor 1.
Remove exhaust manifold side mounting bolt of exhaust manifold stay.
Remove exhaust manifold.
-3 0
EXHAUST MANIFOLD
< REMOVAL AND INSTALLATION >
Loosen nuts in reverse order as shown in the figure.
[HR16DE]
A
EM
C
JPBIA4127ZZ
8.
Use Tool (A) to remove the air-fuel ratio sensor 1 (if necessary).
Tool number
: KV10117100 ( )
CAUTION:
Handle the air-fuel ratio sensor carefully and avoid
impacts.
Before installing a new air-fuel ratio sensor 1, clean the
exhaust tube threads using suitable tool and approved
anti-seize lubricant.
If air-fuel ratio sensor is dropped onto a hard surface,
such as a concrete floor, from a height of 0.5 m or more,
discard the sensor and use a new one.
G
JPBIA4126ZZ
:
:
(J-43897-12)
(J-43897-18)
Limit
PBIC3530J
INSTALLATION
EM-31
EXHAUST MANIFOLD
[HR16DE]
JPBIA4127ZZ
2.
Tool number
: KV10117100 ( )
CAUTION:
Handle it carefully and avoid impacts.
Before installing a new air-fuel ratio sensor 1, clean the
exhaust tube threads using suitable tool and approved antiseize lubricant.
Do not over-tighten the air-fuel ratio sensor 1. Doing so may
damage the air-fuel ratio sensor 1, resulting in the MIL coming on.
Oxygen sensor thread cleaner
Oxygen sensor thread cleaner
:
:
JPBIA4126ZZ
(J-43897-12)
(J-43897-18)
EM-32
Exploded View
INFOID:0000000007575607
EM
L
AWBIA1569ZZ
1.
2.
O-ring
3.
4.
5.
6.
Crankshaft key
7.
Crankshaft sprocket
8.
9.
Oil pump
10. O-ring
11. O-ring
18. O-ring
A.
B.
C.
Refer to EM-47
Refer to LU-11
INFOID:0000000007575608
REMOVAL
WARNING:
Be careful not to get burned, engine coolant and engine oil may be hot.
Revision: March 2013
EM-33
JSBIA1126ZZ
3.
Insert Tool (A) between oil pan (upper) and oil pan (lower).
Tool number
4.
5.
: KV10111100 (J-37228)
CAUTION:
Do not damage mating surfaces.
Never insert a screwdriver. This damages the mating surfaces.
Slide the Tool (A) by tapping on the side of tool with a suitable
tool to loosen the oil pan (lower).
Remove oil pan (lower).
JPBIA0276ZZ
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1. Use a scraper (A) to remove old liquid gasket from mating surfaces.
Also remove old liquid gasket from mating surface of oil pan
(upper).
Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surface when cleaning
off old liquid gasket.
JSBIA1127ZZ
EM-34
[HR16DE]
A
EM
: Engine outside
G
JSBIA1128ZZ
3.
: Engine front
JSBIA1126ZZ
4.
5.
EM-35
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Transmission/
transaxle fluid
Other oils and fluids*
Fuel
Exhaust gas
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
EM-36
Exploded View
INFOID:0000000007575610
EM
I
JSBIA1222GB
1.
Stud bolt
2.
O-ring (green)
3.
4.
Clip
5.
6.
O-ring (black)
7.
8.
Fuel tube
9.
Clamp
A.
CAUTION:
Never remove or disassemble parts unless instructed.
L
INFOID:0000000007575611
WARNING:
Put a CAUTION: FLAMMABLE sign in the workshop.
Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
1.
2.
EM-37
[HR16DE]
NOTE:
There is no fuel return path.
JPBIA4130ZZ
a.
b.
Remove quick connector cap (engine side) (1) from quick connector connection.
Disconnect fuel feed hose from hose clamp.
JPBIA4131ZZ
c.
d.
e.
With the sleeve (B) side of quick connector release (A) facing
quick connector (2), install quick connector release (A) onto fuel
tube (1) as shown.
Insert quick connector release (A) into quick connector (2) until
sleeve (B) contacts and goes no further. Hold quick connector
release (A) in that position (D).
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
JPBIA2255ZZ
Draw and pull out quick connector (E) straight up from fuel tube
(1).
CAUTION:
Pull quick connector up (E) from holding position (C) as shown.
Never pull with lateral force applied. O-ring inside quick connector may be damaged.
Prepare container and cloth beforehand as fuel will leak out.
Discard O-ring, do not reuse.
Avoid fire and sparks.
Keep parts away from heat source. Be especially careful when welding is performed.
Never expose parts to battery electrolyte or other acids.
Never bend or twist connection between quick connector and fuel feed tube during installation
or removal.
Be sure to cover openings of disconnected fuel feed hose
(A) and fuel tube (C) with plug or plastic bag (B) to avoid
fuel leaks and entry of foreign material.
JSBIA1295ZZ
4.
EM-38
[HR16DE]
A
EM
D
JSBIA1291ZZ
b.
JSBIA1292ZZ
c.
Hold the quick connector (1) while pushing in tabs (F), and pull
out the hard tube (A).
2 : Retainer
B : Connection (cross-section)
C : Resin tube
D : To under floor fuel line
E : To fuel tank
G : Disconnection
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
The tube can be removed when the tabs are completely
depressed. Do not twist it more than necessary.
Do not use any tools to remove the quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid such as battery electrolyte etc. from getting
on the resin tube.
Do not bend or twist the tube during installation and
removal.
Remove the remaining retainer only when the tube is
replaced.
When the tube is replaced, also replace the retainer.
EM-39
JPBIA0130ZZ
:Fuel tube
[HR16DE]
JSBIA1295ZZ
5.
6.
JPBIA4132ZZ
7.
: Engine front
a.
b.
JPBIA4133ZZ
JPBIA4134ZZ
INSTALLATION
CAUTION:
Do not reuse O-rings.
1. Note the following, and install new O-rings on the fuel injector.
CAUTION:
Revision: March 2013
EM-40
[HR16DE]
A
: Black
: Green
2.
a.
b.
: O-ring (black)
: O-ring (green)
CAUTION:
Never reuse clip. Replace it with a new one.
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
Insert fuel injector (4) into fuel tube (1) with clip (2) attached.
Insert fuel injector (4) while matching it to the axial center.
Insert fuel injector (4) so that protrusion (B) of fuel tube
matches cut-out (C) of clip (2).
Check that fuel tube flange (A) is securely located in flange
groove (E) on clip (2).
JPBIA4530ZZ
c.
3.
EM
Check that installation is complete by checking that fuel injector (4) does not rotate or come off.
Set fuel tube and fuel injector assembly in position for installation on cylinder head.
CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
Tighten mounting bolts in numerical order as shown.
: Engine front
JPBIA4133ZZ
4.
EM-41
[HR16DE]
: Engine front
JPBIA4132ZZ
5.
6.
a.
b.
c.
d.
e.
f.
7.
a.
b.
: Upright insertion
: Correctly connected
CAUTION:
Hold in position (A) as shown when inserting fuel tube
into quick connector.
Carefully align center to avoid inclined insertion to preJPBIA2256ZZ
vent damage to O-ring inside quick connector.
Insert until you hear a click sound and actually feel
the engagement.
To avoid misidentification of engagement with a similar sound, pull quick connector hard by hand. Check it
is completely engaged (connected) so that it does not come out from fuel tube.
Install quick connector cap (engine side) (1) to quick connector
connection.
Install quick connector cap (engine side) (1) with the side
arrow facing quick connector side (fuel feed tube side) as
shown.
CAUTION:
Check that the quick connector and fuel tube are
securely engaged with the quick connector cap (engine
side) mounting groove.
If the quick connector cap (engine side) cannot be
installed easily the quick connector may not be conJPBIA4131ZZ
nected correctly. Remove and reconnect.
Install fuel feed hose to hose clamp.
Connect fuel feed tube (floor piping side):
Check the connection for damage or any foreign materials.
Align the quick connector with the tube, then insert the connector straight into the centralized under floor
piping until a click is heard.
EM-42
[HR16DE]
A
EM
C
PBIC3795E
1.
2.
Turn ignition switch ON with the engine stopped. Ensure there are no fuel leaks at fuel pipe connection
points.
NOTE:
Use mirrors for checking points out of clear sight.
Start the engine and increase engine speed. Check again that there are no fuel leaks.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
EM-43
INFOID:0000000007575613
JPBIA4094GB
1.
Ignition coil
2.
Spark plug
3.
4.
Hose cramp
5.
PCV hose
6.
PCV valve
7.
O-ring
8.
Gasket
9.
10.
O-ring
11.
12.
13.
Clip
A.
To intake manifold
Rocker cover
INFOID:0000000007575614
REMOVAL
1.
2.
3.
4.
5.
EM-44
: Engine front
EM
D
JPBIA4135ZZ
8.
9.
INSTALLATION
CAUTION:
Do not reuse O-ring.
1. Install the rocker cover:
a. Press gasket onto the bosses for the rocker cover bolt holes as
shown to prevent the gasket from dropping off.
: Engine front
J
JPBIA4136ZZ
b.
Apply liquid gasket to the cylinder head (1) and front cover (2) as
shown.
JPBIA4137ZZ
EM-45
[HR16DE]
: Engine front
JPBIA4135ZZ
2.
EM-46
TIMING CHAIN
[HR16DE]
TIMING CHAIN
Exploded View
INFOID:0000000007575615
EM
L
JPBIA4095GB
1.
2.
3.
4.
5.
Plug
6.
7.
Crankshaft pulley
8.
9.
Front cover
A.
O
INFOID:0000000007575616
CAUTION:
The rotation direction indicated in the text is as viewed from the engine front.
REMOVAL
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
1. Remove front road wheel (RH).
Revision: March 2013
EM-47
TIMING CHAIN
[HR16DE]
< REMOVAL AND INSTALLATION >
2. Remove front fender protector (RH). Refer to EXT-26, "Removal and Installation".
3. Drain engine oil. Refer to LU-9, "Draining".
CAUTION:
Perform this step when engine is cold.
Do not spill engine oil on drive belt.
4. Drain coolant. Refer to CO-8, "Draining Engine Coolant".
5. Remove the following parts.
Intake manifold. Refer to EM-27, "Removal and Installation".
Drive belt. Refer to EM-16, "Removal and Installation".
Rocker cover. Refer to EM-44, "Exploded View".
Water pump pulley. Refer to CO-19, "Removal and Installation".
6. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-82, "Exploded View".
7. Set No. 1 cylinder at TDC of its compression stroke:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
B
PBIC3673E
b.
Check the matching marks on each camshaft sprocket are positioned as shown.
1
: Timing chain
3.
: Pink link
JPBIA4138ZZ
PBIC3710E
EM-48
TIMING CHAIN
< REMOVAL AND INSTALLATION >
c. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and
remove crankshaft pulley.
B
[HR16DE]
A
: M6 bolt
EM
Tool number
: KV11123000 (
)
C
PBIC3711E
9.
a.
K
JPBIA4139ZZ
b.
JPBIA4140ZZ
10. Remove front oil seal from front cover using a suitable tool.
CAUTION:
Be careful not to damage the front cover.
EM-49
TIMING CHAIN
[HR16DE]
< REMOVAL AND INSTALLATION >
11. Remove chain tensioner (1):
a. Fully push down the chain tensioner lever (A), and then push the
plunger (C) into the inside of tensioner.
The tab (B) is released by fully pushing the lever down. Then
the plunger can be moved.
b. Pull up the lever to align its hole position with the body hole position.
When the lever hole is aligned with the body hole position, the
plunger is secured.
When the protrusion parts of the plunger ratchet and the tab
PBIC3713E
face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
slightly moving the plunger.
c. Insert the stopper pin (D) into the body hole through the lever hole, and then secure the lever at the upper
position.
NOTE:
A hexagonal wrench of 2.5 mm (0.098 in) is used as a stopper pin (D).
d. Remove chain tensioner.
12. Remove the timing chain tension guide (2) and the timing chain
slack guide (1).
JPBIA4141ZZ
JPBIA4142ZZ
14. Remove the crankshaft sprocket and the oil pump drive related parts:
a. Remove oil pump drive chain tensioner (1).
Pull out from the shaft (B) and spring attaching holes (A).
JPBIA4143ZZ
EM-50
TIMING CHAIN
< REMOVAL AND INSTALLATION >
b. Hold the top of the oil pump shaft using the socket (size: E8),
and then loosen the oil pump sprocket nut and remove it.
c. Remove the crankshaft sprocket (1), the oil pump drive chain
(2), and the oil pump sprocket (3) at the same time.
[HR16DE]
A
EM
C
JPBIA4230ZZ
INSTALLATION
NOTE:
For installation follow the relationship between the matching mark on
each timing chain and that of the corresponding sprocket, with the
components installed.
1
: Timing chain
: Chain tensioner
: Crankshaft sprocket
: Pink link
: Orange link
K
JPBIA4223ZZ
1.
a.
Install the crankshaft sprocket and the oil pump drive related parts:
Install the crankshaft sprocket (1), the oil pump drive chain (2),
and the oil pump sprocket (3) at the same time.
: Engine front
Install the crankshaft sprocket so that its invalid gear area (A)
is toward the back of the engine.
Install the oil pump sprocket so that its protrusion faces the
front of engine.
NOTE:
There is no matching mark in the oil pump drive related parts.
O
JPBIA5248ZZ
EM-51
TIMING CHAIN
< REMOVAL AND INSTALLATION >
b. Hold the top of the oil pump shaft using the socket (size: E8),
and then tighten the oil pump sprocket nut.
1
: Crankshaft sprocket
[HR16DE]
JPBIA4230ZZ
c.
JPBIA4143ZZ
2.
: Pink link
: Orange link
JPBIA4144ZZ
3.
Install timing chain tension guide (2) and timing chain slack
guide (1).
JPBIA4141ZZ
EM-52
TIMING CHAIN
< REMOVAL AND INSTALLATION >
4. Install chain tensioner (1).
Secure the plunger at the most compressed position using a
stopper pin (A), and then install it.
Pull out the stopper pin after installing the chain tensioner.
[HR16DE]
A
EM
C
PBIC3722E
5.
6.
7.
a.
Check matching mark position of timing chain and each sprocket again.
Install the front oil seal to the front cover. Refer to EM-71, "FRONT OIL SEAL : Removal and Installation".
Install front cover with the following procedure:
Apply a continuous bead of liquid gasket to the front cover as
shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-15, "Recommended Chemical Products and Sealants".
1
: Cylinder head
: Cylinder block
: Liquid gasket application area [3.0 - 4.0 mm (0.12 - 0.16 in) diameter]
Tool number
: WS39930000 (
JPBIA4145ZZ
EM-53
TIMING CHAIN
< REMOVAL AND INSTALLATION >
b. Apply a continuous bead of liquid gasket to front cover as
shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-15, "Recommended Chemical Products and Sealants".
1
: 4.0 - 5.6 mm
: Liquid gasket application area [3.0 - 4.0 mm (0.12 - 0.16 in) diameter]
[HR16DE]
JPBIA4146ZZ
c.
d.
JPBIA4139ZZ
8.
9.
a.
b.
EM-54
TIMING CHAIN
[HR16DE]
EM
C
PBIC3726E
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Transmission/
transaxle fluid
Other oils and fluids*
Fuel
Exhaust gas
EM-55
CAMSHAFT
[HR16DE]
CAMSHAFT
Exploded View
INFOID:0000000007575618
JPBIA4096GB
1.
2.
3.
4.
5.
O-ring
6.
7.
Plug (EXH)
8.
Washer (EXH)
9.
11.
14. O-ring
16. Bracket
A.
Refer to EM-56
INFOID:0000000007575619
CAUTION:
The rotation direction indicated in the procedure is as viewed from the engine front.
REMOVAL
1.
2.
3.
Hold the bottom surface of the engine with a jack to remove the right engine mount assembly and the
insulator. Refer to EM-82, "Exploded View".
Remove rocker cover. Refer to EM-44, "Exploded View".
Place cylinder No. 1 at TDC of its compression stroke:
EM-56
CAMSHAFT
< REMOVAL AND INSTALLATION >
a. Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
[HR16DE]
A
EM
C
PBIC3673E
b.
c.
4.
5.
6.
a.
Check that the matching marks on each of the camshaft sprockets are in the position as shown.
1.
: Timing chain
2.
3.
: Pink link
JPBIA4138ZZ
If not, rotate crankshaft pulley one more turn to align matching
marks to the positions as shown.
Paint matching marks (A) on the timing chain links.
Remove crankshaft pulley. Refer to EM-47, "Exploded View".
Remove front cover. Refer to EM-47, "Exploded View".
Secure the plunger of chain tensioner in the fully compressed position. Then, loosen the timing chain tension.
Fully push down the lever (B) of chain tensioner (2) from the
plug hole, and then insert the stopper pin (A) into the body side
hole and secure the lever at the lowest position.
L
PBIC3676E
Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) held. Apply the tension to the timing chain, and
then push the plunger into the inside of chain tensioner.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
PBIC3677E
EM-57
CAMSHAFT
< REMOVAL AND INSTALLATION >
c. Pull out the stopper pin (A) of chain tensioner (2) side from plug
hole. Lift the lever (B) up to align its hole position with the hole of
the body.
[HR16DE]
d.
7.
8.
9.
When the lever hole (C) is aligned with the body hole position,
the plunger (1) is secured.
When the protrusion parts of the plunger ratchet and the tab
face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
PBIC3772E
slightly moving the plunger.
Insert the stopper pin into the body hole through the lever hole, and then secure the lever at the upper
position.
Remove timing chain.
Remove camshaft sprocket (EXH) (1).
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
Never rotate crankshaft and camshaft separately, so as
not to contact valve with piston.
NOTE:
The timing chain with the front cover installed is not disengaged
from the crankshaft sprocket and it is not dropped into the front
cover. Therefore, the timing chain tension holding device is not
necessary.
JPBIA4160ZZ
Turn the camshaft sprocket (INT) to the most advanced position.
CAUTION:
Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position. Make sure to follow the procedure exactly.
The sprocket (C) and vane (camshaft coupling) (B) are
designed to spin and move within the range of a certain
angle.
With the engine stopped and the vane in the most
retarded angle, it will not spin because it is locked to the
sprocket side by the internal lock pin (A).
If the camshaft sprocket mounting bolts are turned in the
situation described above, the lock pin will become damaged and cause malfunctions because of the increased
horizontal load (cutting force) on the lock pin.
PBIC3679E
a.
PBIC3680E
EM-58
CAMSHAFT
< REMOVAL AND INSTALLATION >
b. Apply the following air pressure to the No. 1 journal oil hole (A)
of camshaft (INT) (1) shown using an air gun.
Air pressure
[HR16DE]
A
EM
Apply the air pressure into the oil hole on the second groove
from the front of camshaft thrust (B).
Proceed all the way through step e with the air pressure on.
Attach the rubber nozzle narrowed to the top of the air gun to
C
prevent air leakage from the oil hole (A). Securely apply the air
pressure to the oil hole.
JPBIA4150ZZ
WARNING:
D
Eye protection should be worn as needed.
CAUTION:
There are other oil holes in the side grooves. Never use the incorrect oil holes.
E
Be sure not to damage the oil path with the tip of the air gun.
Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the
area around the air gun should be wiped with a rag when applying air pressure. Eye protection
should be worn as needed.
F
NOTE:
The air pressure is used to move the lock pin into the disengage position.
c.
Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternately.
J
JPBIA4151ZZ
If the lock pin is not released, tap the camshaft sprocket (INT)
lightly with a plastic hammer (A).
If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.
N
JPBIA4152ZZ
d.
While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position.
C
EM-59
PBIC3684E
CAMSHAFT
[HR16DE]
< REMOVAL AND INSTALLATION >
Check that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown.
e. Stop applying air pressure and release the camshaft (INT).
f. Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent
it from falling out.
NOTE:
The stopper pin in the figure shows one example of a hexagonal
wrench for 2.5 mm (0.098 in) [length of inserted section:
approximately15 mm (0.59 in)].
JPBIA4153ZZ
Camshaft (INT)
JPBIA4154ZZ
CAUTION:
Never drop stopper pin.
Tape (C) the stopper pin (B) so it does not come out.
Never subject it to impact by dropping.
Never disassemble. [Never loosen the three mounting
bolts (A)].
NOTE:
While removing the camshaft sprocket (INT), if you have taken
out the stopper pin and the lock pin has been rejoined in the
most retarded angle, do the following to restore it.
i. Install the camshaft (INT) and tighten the mounting bolts enough
to prevent air from leaking out.
CAUTION:
PBIC3691E
The internal lock pin will get damaged, so keep the torque
on the mounting bolts to the minimum required to prevent air from escaping.
ii. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.
iii. Insert the stopper pin.
iv. Remove camshaft sprocket (INT) from the camshaft.
11. Remove camshaft brackets (No. 2 to 5).
EM-60
CAMSHAFT
< REMOVAL AND INSTALLATION >
Loosen bolts in several steps in the reverse order as shown in
the figure.
A
: EXH side
: INT side
[HR16DE]
A
EM
: Engine front
NOTE:
The camshaft bracket (No. 1) has been already removed.
C
PBIC3686E
H
PBIC3692E
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-56,
"Exploded View".
N
AWBIA1146GB
2.
3.
4.
EM-61
CAMSHAFT
< REMOVAL AND INSTALLATION >
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 the
camshaft.
[HR16DE]
PBIC3696E
5.
a.
b.
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).
Put the matching marks (A) on a line extending from the knock
pin position of camshaft (EXH) (1) front surface.
Put the marks on the visible position with the camshaft
sprocket installed as shown.
Put the matching marks on a line extending from the knock pin
hole (B) position of camshaft sprocket (EXH) (2) as shown.
Put the marks on the visible position with it installed to the
camshaft.
JPBIA4155ZZ
6.
Install camshaft.
1
: Camshaft (EXH)
: Camshaft (INT)
: Identification mark
Note that the camshafts (INT and EXH) have different shapes
at the rear.
JPBIA4156ZZ
: Camshaft (EXH)
: Camshaft (INT)
: Upper side
NOTE:
Though camshaft does not stop at the portion as shown for the
placement of cam nose, it is generally accepted camshaft is
placed for the same direction as shown.
-6 2
JPBIA4157ZZ
CAMSHAFT
< REMOVAL AND INSTALLATION >
7. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown.
A
: EXH side
: INT side
[HR16DE]
A
EM
: Engine front
C
PBIC3703E
8.
: EXH side
: INT side
: Engine front
a.
b.
c.
9.
a.
Install the camshaft sprocket (INT and EXH) to the camshaft (INT and EXH):
Refer to the matching mark (A) added in step 4. Securely align
the knock pin and the pin hole, and then install them.
NOTE:
The intake side is shown as an example.
N
PBIC3700E
10. Tighten the camshaft sprocket mounting bolt (INT and EXH).
1
CAUTION:
Hold the camshaft hexagonal part (A), using a suitable tool
to secure the camshaft.
JPBIA4158ZZ
EM-63
CAMSHAFT
< REMOVAL AND INSTALLATION >
11. Install the camshaft (INT and EXH) to the camshaft sprocket
(INT and EXH) (2 and 3) while aligning the matching mark
(marked when timing chain is removed) (A) and the pink link (B)
of camshaft sprocket (INT and EXH).
1
: Timing chain
[HR16DE]
If the positions of knock pin and pin groove are not aligned,
move the camshaft (EXH) slightly to correct these positions.
JPBIA4159ZZ
12. Pull out the stopper pin (A), and then apply the tension to the
timing chain by rotating the crankshaft pulley clockwise slightly.
1
: Plunger
: Chain tensioner
: Lever
: Lever hole
PBIC3772E
13.
14.
15.
a.
: Tape
PBIC3685E
b.
Turn the crankshaft pulley (1) slowly clockwise (A) and return
the camshaft sprocket (INT) to the most retarded angle position.
PBIC3704E
EM-64
CAMSHAFT
[HR16DE]
EM
C
PBIC3705E
16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
Tighten bolts with it completely inserted.
17. Check and adjust valve clearance. Refer to EM-10, "Inspection and Adjustment".
18. Installation of the remaining components is in the reverse order of removal.
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Transmission/
transaxle fluid
Other oils and fluids*
Fuel
Exhaust gas
INFOID:0000000007575620
Inspection
EM-65
CAMSHAFT
< REMOVAL AND INSTALLATION >
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.
[HR16DE]
PBIC3693E
Camshaft Runout
1.
2.
3.
Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
Set a dial indicator vertically to No. 3 journal.
Turn camshaft to one direction, and measure the camshaft
runout on the dial indicator. (Total indicator reading)
Standard and Limit
: Refer to EM-118, "Camshaft".
4.
PBIC2499E
1.
2.
Standard:
PBIC3179J
EM-66
CAMSHAFT
< REMOVAL AND INSTALLATION >
Measure inner diameter (b) of camshaft bracket with a bore gauge
(A).
Standard
[HR16DE]
A
C
JPBIA4192ZZ
If it exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly.
1.
2.
Install camshaft in cylinder head. Refer to EM-56, "Removal and Installation" for tightening procedure.
Install a dial indicator (A) in thrust direction on front end of camshaft. Measure the camshaft end play on the dial indicator when
camshaft is moved forward/backward (in direction to axis).
K
PBIC3694E
1.
Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
EM-67
CAMSHAFT
< REMOVAL AND INSTALLATION >
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit
[HR16DE]
JPBIA4193ZZ
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
If anything above is found, replace valve lifter. Refer to EM-118,
"Camshaft".
KBIA0182E
Standard
PBIC3185J
PBIC3184J
If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.
EM-68
CAMSHAFT
[HR16DE]
1.
2.
a.
b.
c.
3.
4.
Step 3
: Remove exhaust valve timing control solenoid valve. Refer to EM-56, "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 .
Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to
EM-56, "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.
J
1
: Plug
:Engine front
5.
6.
7.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
JPBIA4194ZZ
Prevent splashing by using a shop cloth to prevent injury
from splashing engine oil and so as to prevent engine oil contamination.
Use a shop cloth to prevent engine oil from being 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 immediately if it is splashed.
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-11, "Removal and Installation".
Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-6,
"Engine Lubrication System".
Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
Clean oil groove if necessary. Refer to LU-6, "Engine Lubrication System".
After inspection, installation of components is in the reverse order of removal
EM-69
OIL SEAL
[HR16DE]
OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation
INFOID:0000000007575621
REMOVAL
1.
2.
3.
4.
: KV10116200 (J-26336-B)
: KV10115900 (J-26336-20)
: KV10109220 ( )
PBIC3727E
5.
6.
Remove valve spring retainer, valve spring and valve spring seat. Refer to EM-75, "Disassembly and
Assembly".
Remove valve oil seal with Tool (A).
Tool number
: KV10107902 (J-38959)
PBIC3728E
INSTALLATION
1.
2.
Apply new engine oil to valve oil seal joint surface and seal lip.
Press in valve oil seal to the height H shown with Tool (A).
Height H
Tool number
: KV10115600 (J-38958)
PBIC3211J
3.
EM-70
OIL SEAL
[HR16DE]
INFOID:0000000007575622
REMOVAL
1.
2.
EM
INSTALLATION
1.
2.
Apply new engine oil to new front oil seal joint surface and seal lip.
Install front oil seal so that each seal lip is oriented as shown.
A
: Engine outside
: Engine inside
H
PBIC3485J
Press-fit front oil seal using a suitable drift with outer diameter 50 mm (1.97 in) and inner diameter 44
mm (1.73 in).
CAUTION:
Be careful not to damage front cover and crankshaft.
Press-fit oil seal straight to avoid causing burrs or tilting.
3.
INFOID:0000000007575623
REMOVAL
1.
2.
3.
4.
Remove transaxle assembly. Refer to TM-23, "Removal and Installation" (M/T models), TM-249,
"Removal and Installation" (CVT models).
Remove clutch cover and clutch disk (M/T models). Refer to CL-18, "Removal and Installation".
Remove flywheel (M/T models) or drive plate (CVT models). Refer to EM-94, "Exploded View".
Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products
and Sealants".
INSTALLATION
1.
EM-71
OIL SEAL
< REMOVAL AND INSTALLATION >
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
A
[HR16DE]
: Engine outside
: Engine inside
PBIC3485J
Press-fit rear oil seal with a suitable drift (A) outer diameter
113 mm (4.45 in) and inner diameter 90 mm (3.54 in).
CAUTION:
Be careful not to damage crankshaft and cylinder block.
Press-fit oil seal straight to avoid causing burrs or tilting.
Never touch grease applied onto oil seal lip.
PBIC3660E
Press in rear oil seal (1) to the position as shown in the figure.
A
PBIC3149J
3.
EM-72
CYLINDER HEAD
[HR16DE]
CYLINDER HEAD
Exploded View
INFOID:0000000007575624
EM
G
JPBIA4097ZZ
1.
2.
4.
A.
Refer to EM-74
3.
Washer
Valve Components
J
JPBIA4098GB
1.
Spark plug
2.
Valve collet
3.
4.
Valve spring
5.
6.
EM-73
CYLINDER HEAD
[HR16DE]
8.
9.
Refer to EM-75
INFOID:0000000007575625
REMOVAL
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
1. Release fuel pressure. Refer to EC-126, "Work Procedure".
2. Remove the following components and related parts.
Air duct. Refer to EM-25, "Removal and Installation".
Fuel tube and fuel injector. Refer to EM-37, "Exploded View".
Water outlet. Refer to CO-25, "Removal and Installation".
Exhaust manifold. Refer to EM-30, "Exploded View".
Front cover and timing chain. Refer to EM-47, "Exploded View".
Camshaft. Refer to EM-56, "Exploded View".
3. Remove cylinder head loosening bolts in reverse order as
shown.
A
B
: EXH side
: INT side
: Engine front
PBIC3732E
4.
INSTALLATION
1.
2.
: EXH side
: INT side
: Engine front
a.
b.
CAUTION:
If cylinder head bolts are reused, check their outer diameters before installation. Refer to EM-76, "Inspection".
Apply new engine oil to threads and seating surfaces of mounting bolts.
Tighten all bolts.
Cylinder head bolts
PBIC3732E
EM-74
CYLINDER HEAD
< REMOVAL AND INSTALLATION >
c. Turn all bolts 60 degrees clockwise (angle tightening) using Tool
(A) in the specified order.
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Avoid judgment by visual inspection without the
tool.
Tool number
[HR16DE]
A
EM
: KV10112100 (BT-8653-A)
C
PBIC3733E
d.
e.
: 0 Nm (0 kg-m, 0 ft-lb)
CAUTION:
In this step, loosen bolts in reverse order of that indicated as shown.
Tighten all bolts.
Cylinder head bolts
f.
g.
3.
H
INFOID:0000000007575626
DISASSEMBLY
1.
2.
3.
: KV10116200 (J-26336-B)
: KV10115900 (J-26336-20)
: KV10109220 ( )
M
PBIC3727E
4.
5.
6.
: KV10107902 (J-38959)
PBIC3728E
EM-75
CYLINDER HEAD
[HR16DE]
ASSEMBLY
1.
2.
3.
Tool number
: KV10115600 (J-38958)
PBIC3211J
4.
5.
6.
7.
8.
: KV10116200 (J-26336-B)
: KV10115900 (J-26336-20)
: KV10109220 ( )
PBIC3727E
Inspection
INFOID:0000000007575627
PBIC3717E
EM-76
CYLINDER HEAD
[HR16DE]
Limit
: Straightedge
: Feeler gauge
L
PBIC3213J
If the calculated value exceeds the limit, replace valve and/or valve guide. Refer to EM-75, "Disassembly
and Assembly".
N
SEM008A
EM-77
CYLINDER HEAD
< REMOVAL AND INSTALLATION >
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US
ton, 2.0 lmp ton) force] or suitable tool.
WARNING:
Cylinder head contains heat; when working, wear protective
equipment to avoid getting burned.
[HR16DE]
SEM931C
3.
SEM932C
4.
SEM008A
5.
Using a suitable tool, press valve guide (1) from camshaft side
to dimensions as shown.
Projection H: : 11.4 - 11.8 mm (0.448 - 0.464 in)
WARNING:
Cylinder head contains heat; when working, wear protective
equipment to avoid getting burned.
PBIC3217J
6.
SEM932C
EM-78
CYLINDER HEAD
[HR16DE]
: OK
If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions (B) even after the recheck,
replace valve seat. Refer to EM-75, "Disassembly and Assembly".
E
JPBIA0187ZZ
3.
SEM008A
4.
Provide valve seats cooled well with dry ice. Press-fit valve seats into cylinder head.
WARNING:
Cylinder head contains heat; when working, wear protective equipment to avoid getting burned.
CAUTION:
Avoid directly touching cold valve seats.
EM-79
CYLINDER HEAD
< REMOVAL AND INSTALLATION >
5. Using a suitable tool a valve seat grinder, finish valve seat to the
specified dimensions. For dimensions, refer to MA-12, "Fluids
and Lubricants".
CAUTION:
When using a valve seat cutter, firmly grip the cutter handle
with both hands. Then, press the contacting surface evenly
around the valve seat to cut in a single attempt. Improper
pressure or cutting several times may result in wavy valve
seat.
[HR16DE]
SEM934C
6.
7.
: Contact
Limit
Standard
If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).
SEM113
EM-80
CYLINDER HEAD
[HR16DE]
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Transmission/
transaxle fluid
Other oils and fluids*
Fuel
Exhaust gas
EM
EM-81
ENGINE ASSEMBLY
[HR16DE]
INFOID:0000000007576008
JSBIA1095GB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Mass damper
A.
Front mark
B.
Transaxle (upper)
C.
Transaxle (lower)
D.
M/T models
CAUTION:
Check that the stud bolt (*2) is tight at the specified torque before tightening the mounting nut (*1)
shown in the figure. [Stud bolt (*2) may be loosened after loosening the mounting nut (*1)]
INFOID:0000000007576009
WARNING:
Position the vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
Attach proper slingers and bolts described in PARTS CATALOG if engine is not already equipped.
CAUTION:
Always be careful to work safely.
Never start working until exhaust system and coolant are cool enough.
If items or work required are not covered by the engine section, refer to the applicable sections.
Always use the support point specified for lifting.
EM-82
ENGINE ASSEMBLY
[HR16DE]
< UNIT REMOVAL AND INSTALLATION >
Use either 2-pole lift type or separate type lift. If board-on type must be used, support the rear axle
jacking point with a transmission jack or similar tool before starting work, in preparation for the A
backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-30, "2-Pole Lift".
NOTE:
EM
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.
REMOVAL
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.
Preparation
1.
2.
3.
Engine Room LH
1.
2.
3.
4.
5.
Disconnect all connections of engine harness around the battery, and then temporarily secure the engine
harness into the engine side.
CAUTION:
Protect connectors against foreign materials during the operation by wrapping in a plastic bag.
Disconnect heater hoses. Refer to CO-14, "Exploded View".
Disconnect fuel feed hose at engine side. Refer to EM-37, "Removal and Installation".
Disconnect control linkage cable from transaxle. Refer to TM-19, "Removal and Installation" (M/T models), TM-229, "Removal and Installation" (CVT models).
Disconnect clutch tube on transaxle side from clutch damper. Refer to CL-14, "Exploded View".
Engine Room RH
1.
2.
3.
4.
Vehicle Underbody
1.
2.
EM-83
ENGINE ASSEMBLY
[HR16DE]
JSBIA0643ZZ
4.
Removal
1.
2.
PBIC3223J
3.
4.
: Transaxle side
JSBIA1223ZZ
5.
Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. Observe the following
cautions:
CAUTION:
Check that no part interferes with the vehicle side.
Before and during lifting, always check if any harnesses are left connected.
During removal, always be careful to prevent the vehicle from falling off the lift due to changes in
the center of gravity.
EM-84
ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
If necessary, support the vehicle by setting jack or suitable tool at the rear.
[HR16DE]
A
Separation
1.
2.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator.
Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
When installation directions are specified, install parts according to the direction marks on them,
referring to the figure of components. Refer to EM-82, "Exploded View".
: Vehicle front
H
JPBIA2809ZZ
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Level
Leakage
Level
Leakage
Leakage
Leakage
Leakage
Transmission/
transaxle fluid
Other oils and fluids*
Fuel
Exhaust gas
EM-85
INFOID:0000000007575631
NOTE:
The following procedures explain how to disassemble the engine with the engine stand fastened to the bell
housing. Some steps may be different if using a different type of engine stand.
1. Install engine to engine stand:
a. Remove flywheel or drive plate.
Secure flywheel (1) or drive plate using tool (A), and remove
mounting bolts (M/T models).
Tool number
: KV11105210 (J-44716)
CAUTION:
Never disassemble flywheel.
Never place flywheel or drive plate with signal plate facing down.
When handling signal plate, take care not to damage or
scratch it.
Handle signal plate in a manner that prevents it from
becoming magnetized.
b.
MBIB1382E
PBIC3227J
2.
EM-86
[HR16DE]
A
: Engine front
EM
EM-87
ENGINE UNIT
[HR16DE]
ENGINE UNIT
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
INFOID:0000000007575632
Assembly
INFOID:0000000007575633
EM-88
Exploded View
INFOID:0000000007575634
EM
L
AWBIA1569ZZ
1.
2.
O-ring
3.
4.
5.
6.
Crankshaft key
7.
Crankshaft sprocket
8.
9.
Oil pump
10. O-ring
11. O-ring
18. O-ring
A.
B.
C.
Refer to EM-47
Refer to LU-11
INFOID:0000000007575635
NOTE:
The oil strainer is included in the oil pan (upper) and cannot be removed.
REMOVAL
1.
EM-89
JPBIA4199ZZ
b.
c.
Insert the Tool between the oil pan (upper) and cylinder block.
Slide Tool by tapping on the side of Tool with a hammer.
Tool number
4.
: KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surface.
The liquid gasket used at the factory is very strong. Pry only in the areas shown.
Never remove oil pump and oil strainer from oil pan (upper).
Remove rear oil seal from crankshaft.
JPBIA4200ZZ
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.
1. Install the oil pan (upper):
a. Use scraper to remove old liquid gasket from mating surfaces.
Also remove the old liquid gasket from mating surface of cylinder block.
Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Install O-ring to the cylinder block.
EM-90
[HR16DE]
A
EM
: Cylinder block
G
JSBIA1301ZZ
d.
CAUTION:
Attaching should be done within 5 minutes after coating.
Tighten bolts in the numerical order as shown.
: Engine front
CAUTION:
Install avoiding misalignment of both oil pan gasket and Oring.
The bolts are different according to the installation position.
Refer to the numbers as shown.
M8180 mm (7.09 in)
M825 mm (0.98 in)
M890 mm (3.54 in)
2.
a.
b.
: No. 9, 10
: No. 4, 7, 8
: No. 1, 2, 3, 5, 6
K
JPBIA4199ZZ
EM-91
PBIC3660E
d.
3.
4.
CAUTION:
Never touch the grease applied to the oil seal lip.
Be careful not to damage the rear oil seal mounting part
of oil pan (upper) and cylinder block or the crankshaft.
Press-fit straight and check that oil seal does not curl or
tilt.
PBIC3149J
After press-fitting the rear oil seal, completely wipe off any liquid
gasket protruding to rear end surface side.
Installation of the remaining components is in the reverse order of removal.
Add the specified oil after waiting for at least 30 minutes. Refer to MA-12, "Fluids and Lubricants".
CAUTION:
The components must be installed within 5 minutes of the liquid gasket application.
Allow 30 minutes for the liquid gasket to set before adding oil to the engine.
Engine running
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Leakage
Level/Leakage
Leakage
M/T Models
Level/Leakage
Leakage
Level/Leakage
Level
Leakage
Level
Transmission/
transaxle fluid
Other oils and fluids*
EM-92
Engine running
Leakage
Leakage
Leakage
Leakage
EM
EM-93
CYLINDER BLOCK
[HR16DE]
CYLINDER BLOCK
Exploded View
INFOID:0000000007575637
JPBIA4749GB
1.
2.
3.
O-ring
4.
Drain plug
5.
Cylinder block
6.
7.
8.
O-ring
9.
Knock sensor
EM-94
CYLINDER BLOCK
[HR16DE]
11.
16. Piston
27. Crankshaft
A.
B.
EM
Refer to EM-95
: Crankshaft side
Chamfered
D
INFOID:0000000007575638
DISASSEMBLY
NOTE:
The following procedures explain how to disassemble the engine with the engine stand fastened to the bell
housing. Some steps may be different if using a different type of engine stand.
1. Remove cylinder head. Refer to EM-73, "Exploded View".
2. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
3. Remove the crankshaft position sensor cover (3), and then
crankshaft position sensor (POS) (2).
1.
O-ring
4.
Cylinder block
a.
b.
c.
: Engine front
4.
5.
CAUTION:
Avoid impacts such as a dropping.
Never disassemble.
Keep sensor away from metal particles.
JPBIA4202ZZ
Never place the sensor in a location where it is exposed to
magnetism.
Do not reuse O-ring.
Remove oil pan (upper and lower). Refer to EM-89, "Exploded View".
Remove piston and connecting rod assembly:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-103, "Inspection".
Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
Remove connecting rod cap.
Using a hammer handle or similar tool, push piston and connecting rod assembly out through the cylinder head side.
CAUTION:
Be careful not to damage mating surface with connecting
rod cap.
Be careful not to damage the cylinder wall or crankshaft
pin.
KBIA3365J
6.
EM-95
CYLINDER BLOCK
[HR16DE]
< UNIT DISASSEMBLY AND ASSEMBLY >
7. Remove piston rings from piston.
Before removing piston rings, check the piston ring side clearance. Refer to EM-103, "Inspection".
Use a suitable tool) (A) as shown.
CAUTION:
When removing piston rings, be careful not to damage
the piston.
Be careful not to damage piston rings by expanding
them excessively.
PBIC3233J
8.
: KV10109730
: KV10110310
: ST13030020
CAUTION:
Do not damage the piston and connecting rod.
Do not reuse piston and piston pin after removing piston
pin from connecting rod.
The connecting rod is reusable.
NOTE:
The joint between the connecting rod and the piston pin is a press fit.
9.
a.
PBIC5270J
NOTE:
When removing or installing signal plate, use socket (size T40).
JPBIA4203ZZ
b.
Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.
EM-96
CYLINDER BLOCK
[HR16DE]
< UNIT DISASSEMBLY AND ASSEMBLY >
Identify original installation positions, and store the bearings without mixing them up.
13. Remove oil jets.
CAUTION:
Insert the dowel pin of oil jet into the cylinder block dowel pin hole to loosen the mounting bolt.
EM
ASSEMBLY
CAUTION:
Do not reuse O-rings.
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
WARNING:
Use goggles to protect your eyes.
2. Install oil jets.
3. Install main bearings and thrust bearings:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.
b. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.
: Engine front
Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).
H
PBIC3258J
c.
M
PBIC3746E
4.
a.
b.
c.
5.
EM-97
JPBIA4231ZZ
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
While turning crankshaft by hand, check that it turns smoothly.
CAUTION:
Do not install rear oil seal at this time.
6. Install main bearing caps.
Install the main bearing cap while referring to the front mark
(B) and the journal number stamp (A).
[HR16DE]
: Engine front
NOTE:
Main bearing cap cannot be replaced as a single part,
because it is machined together with cylinder block.
JPBIA4204ZZ
7.
a.
b.
Apply new engine oil to threads and seat surfaces of the mounting bolts.
Tighten main bearing cap bolts in numerical order.
Main bearing cap bolts
c.
Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order as shown in the figure.
CAUTION:
Check and confirm the tightening angle by using the Tool
(A) or protractor. Avoid judgment by visual inspection without the Tool.
Tool number
: KV10112100 (BT-8653-A)
PBIC3750E
After installing the main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.
Check crankshaft end play. Refer to EM-103, "Inspection".
8. Install piston to connecting rod with the following procedure:
a. Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position as shown.
B
: Oil hole
NOTE:
The symbols without notes are for manufacturing.
PBIC3766E
EM-98
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
b. Press-fit the piston pin using the Tools (A, B, C, D, E).
[HR16DE]
A
Tool number A
B
C
D
E
F
: KV10109730
: KV10110310
: ST13030020
: KV10114120
: ST13030030
: Detail
EM
CAUTION:
Press-fit the piston so as not to damage it.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.
G
PBIC5271J
Press-fit the piston pin (2) from piston surface (A) to the depth
of 2.35 mm (0.092 in) (b).
1
: Connecting rod
: Press-fit direction
After finishing work, check that the piston (3) moves freely.
J
JPBIA2058ZZ
9.
N
PBIC3233J
Position each ring with the gap as shown referring to the piston front mark (B).
A
Install second ring with the stamped mark (E) facing upward.
PBIC3752E
EM-99
CYLINDER BLOCK
[HR16DE]
: 1R
: 2R
10. Install connecting rod bearings to connecting rod and connecting rod cap.
When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it.
Install the bearing in the center position.
NOTE:
There is no stopper tab.
Check that the oil holes on connecting rod and connecting rod bearing are aligned.
Install the connecting rod in the dimension (A) as shown.
1
: Connecting rod
NOTE:
Install the connecting rod bearing in the center position with
the dimension as shown. For service operation, the center
position can be checked visually.
PBIC4169E
: EM03470000
PBIC3765E
: Front mark
: Oil hole
PBIC3766E
13. Inspect outer diameter of connecting rod bolts. Refer to EM-103, "Inspection".
14. Tighten connecting rod bolt:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
Revision: March 2013
EM-100
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
b. Tighten connecting rod bolts in several steps.
[HR16DE]
A
d.
EM
: 0 Nm (0 kg-m, 0 ft-lb)
e.
Then turn all connecting rod bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the Tool (A) or protractor. Avoid judgement by
visual inspection without the Tool.
Tool number
: KV10112100 (BT-8653-A)
F
H
PBIC3753E
After tightening connecting rod bolt, check that crankshaft rotates smoothly.
Check the connecting rod side clearance. Refer to EM-103, "Inspection".
15. Install oil pan (upper). Refer to EM-89, "Exploded View".
NOTE:
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Refer to EM-71, "REAR OIL SEAL : Removal and Installation".
17. Install flywheel (M/T models) or drive plate (CVT models).
M/T models
Secure crankshaft with a stopper plate (A) and tighten mounting bolts crosswise over several times.
1
Tool number
:Flywheel
: KV11105210 (J-44716)
N
MBIB1382E
O
CVT models
EM-101
CYLINDER BLOCK
[HR16DE]
:Drive plate
Tool number
: KV11105210 (J-44716)
PBIC3226J
CAUTION:
Be careful not to damage or scratch and contact surface for clutch disc of flywheel.
18. Install knock sensor (1).
: Engine front
PBIC3754E
: Engine front
CAUTION:
Avoid impacts such as a dropping.
Never disassemble.
Keep sensor away from metal particles.
Never place the sensor in a location where it is exposed to
magnetism.
Do not reuse O-ring.
JPBIA4202ZZ
20. For the oil level gauge guide (1), secure in position (B) shown in
the figure to the water inlet clip (A) after inserting to the cylinder
block side.
PBIC3755E
EM-102
CYLINDER BLOCK
[HR16DE]
Inspection
INFOID:0000000007575639
EM
D
PBIC3762E
H
PBIC3763E
Standard
PBIC3265J
Standard
P
PBIC3266J
Standard
EM-103
CYLINDER BLOCK
[HR16DE]
< UNIT DISASSEMBLY AND ASSEMBLY >
If oil clearance is out of the standard, replace piston and piston pin assembly.
When replacing piston and piston pin assembly. Refer to EM-95, "Disassembly and Assembly".
NOTE:
Piston is available together with piston pin as assembly.
Piston pin (piston pin hole) grade is provided only for the parts installed at the factory. For service parts, no
grades can be selected. Only grade 0 is available.
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PBIC3280J
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace cylinder block.
PBIC3267J
: Bend
: Torsion
: Feeler gauge
Limit
PBIC3268J
EM-104
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified
torque. Refer to EM-94, "Exploded View".
2
: Connecting rod
: Example
[HR16DE]
A
EM
Measure the inner diameter (B) of connecting rod big end with a
suitable tool.
Standard
C
PBIC3269J
Inner diameter
(Standard)
H
JPBIA0223ZZ
Outer diameter
(Standard)
L
JPBIA0218ZZ
Oil clearance
(Standard and Limit)
If the measured value is out of the standard range, replace connecting rod assembly and/or piston and piston pin assembly.
If replacing piston and piston pin assembly. Refer to EM-122, "Cylinder Block".
If replacing connecting rod assembly. Refer to EM-126, "Connecting Rod Bearing".
EM-105
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
Measure the distortion on the cylinder block upper face at different
points in six directions with a suitable tool (A) and (B).
Limit
[HR16DE]
JPBIA0224ZZ
: Cylinder block
Standard
PBIC4005E
If out of the standard, replace cylinder block and main bearing
caps assembly.
NOTE:
Main bearing caps cannot be replaced individually, because they are machined together with cylinder block.
: 10 mm (0.39 in)
: 60 mm (2.36 in)
NOTE:
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) position.
JPBIA2059ZZ
Standard:
Cylinder bore inner diameter
: Refer to EM-122, "Cylinder Block".
Limit:
Out-of-round [Difference between (A) and (B)]
Taper [Difference between (C) and (E)]
: Refer to EM-122, "Cylinder Block".
If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
Oversize piston is not available.
Revision: March 2013
EM-106
CYLINDER BLOCK
[HR16DE]
Standard
PBIC3272J
: Direction A
: Position C
: Position E
: 10 mm (0.39 in)
: 60 mm (2.36 in)
JPBIA2059ZZ
If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-122, "Cylinder Block".
Measure the outer diameter of crankshaft main journals with a suitable tool (A).
Standard
M
PBIC3457J
If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-126, "Connecting Rod Bearing".
EM-107
CYLINDER BLOCK
[HR16DE]
JPBIA0229ZZ
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.
Place a suitable tool (A) straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on the
suitable tool. (Total indicator reading)
Standard and Limit
PBIC3458J
: Example
Measure the inner diameter of connecting rod bearing with a suitable tool.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
(Crankshaft pin journal diameter)
PBIC3275J
If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-126,
"Connecting Rod Bearing".
Method of Using Plastigage
Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the specified torque. Refer to EM-95, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
EM-108
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
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.
[HR16DE]
A
EM
C
PBIC3276J
: Example
Measure the inner diameter (B) of main bearing (3) with a suitable
tool.
(Bearing oil clearance) = (Main bearing inner diameter) (Crankshaft main journal diameter)
PBIC3277J
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-125, "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 mounting bolts to
the specified torque. Refer to EM-95, "Disassembly and Assembly".
CAUTION:
Never 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.
PBIC3278J
EM-109
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-95, "Disassembly and
Assembly".
A
[HR16DE]
: Example
Standard
: Example
Standard
PBIC4015E
PBIC4016E
EM-110
CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
Measure the deflection of flywheel contact surface to torque with a
suitable tool (A).
Measure the deflection at 210 mm (8.27 in) diameter.
Limit
[HR16DE]
A
EM
C
PBIC4006E
EM-111
INFOID:0000000007575640
Selection points
Selection parts
Selection items
Selection methods
Main bearing
The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text for the appropriate part.
INFOID:0000000007575641
: Oil hole
: Cylinder number
: Front mark
PBIC3756E
2.
Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the Connecting Rod Bearing
Selection Table.
A
PBIC3757E
3.
4.
Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection
Table.
Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing.
Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-103, "Inspection".
EM-112
EM
JPBIA4823GB
EM-113
[HR16DE]
PBIC3263J
Main Bearing
INFOID:0000000007575642
1.
PBIC3760E
2.
PBIC3757E
3.
4.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table.
Apply the symbol obtained to the Main Bearing Grade Table to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
1.
2.
3.
4.
Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-103, "Inspection".
Apply the measured dimension to the Main Bearing Selection Table.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table.
Apply the symbol obtained to the Main Bearing Grade Table to select main bearing.
EM-114
EM
L
PBIC3759E
EM-115
[HR16DE]
PBIC3263J
EM-116
INFOID:0000000007575643
EM
GENERAL SPECIFICATIONS
Engine type
HR16DE
Cylinder arrangement
In-line 4
cm3 (cu in)
Displacement
Bore and stroke
1,598 (97.51)
78.0 83.6 (3.071 3.291)
mm (in)
Valve arrangement
DOHC
Firing order
1-3-4-2
Compression
Oil
Compression ratio
9.8
Compression pressure
kPa (kg/cm2, psi) / 200 rpm
Standard
Minimum
Valve Timing
Unit: degree
J
Valve timing
: Intake valve
: Exhaust valve
JPBIA4228ZZ
216
228
11 (27)
ATDC
59 (-21)
ABDC
-1 (49)
ATDC
37 (-13)
BBDC
INFOID:0000000007575644
Drive Belt
DRIVE BELT
Belt Deflection
Deflection adjustment *
Location
Drive belt
Used belt
Unit: mm (in)
New belt
Limit
After adjusted
With A/C
10 (0.39)
Without A/C
9.1 (0.36)
EM-117
Tension adjustment *
Location
Unit: N (kg-f,
lb-f)
Used belt
Limit
With A/C
Drive belt
New belt
After adjusted
Frequency adjustment *
Unit: Hz
Used belt
Limit
After adjusted
New belt
881 - 951
(89.8 - 97.0,
198.1 - 213.8)
1070 - 1138
(109.1 - 116.0,
240.6 - 255.8)
145.5
230.5 - 239.5
254 - 262
876 - 964
(89.3 - 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
Spark Plug
INFOID:0000000007575645
NGK
Standard type*
PLZKAR6A-11
Gap (nominal)
*: Always check with the Parts Department for the latest parts information.
Exhaust Manifold
INFOID:0000000007575646
EXHAUST MANIFOLD
Unit: mm (in)
Items
Limit
Surface distortion
0.3 (0.012)
Camshaft
INFOID:0000000007575647
CAMSHAFT
Unit: mm (in)
Items
Camshaft runout [TIR*]
Standard
Limit
0.02 (0.0008)
0.1 (0.0039)
SEM671
Intake
41.505 (1.6341)
Exhaust
40.715 (1.6029)
No. 1
No. 2, 3, 4, 5
No. 1
No. 2, 3, 4, 5
EM-118
Standard
Limit
No. 1
No. 2, 3, 4, 5
0.2 (0.0078)
0.1 (0.0039)
EM
VALVE LIFTER
Unit: mm (in)
Items
Standard
VALVE CLEARANCE
Unit: mm (in)
Cold1
Hot 2
Intake
Exhaust
1:Approximately
20C (68F)
2:Approximately
80C (176F)
Thickness (B)
JPBIA0170ZZ
300
3.00 (0.1181)
302
3.02 (0.1188)
304
3.04 (0.1196)
306
3.06 (0.1204)
308
3.08 (0.1212)
310
3.10 (0.1220)
312
3.12 (0.1228)
314
3.14 (0.1236)
316
3.16 (0.1244)
318
3.18 (0.1251)
320
3.20 (0.1259)
322
3.22 (0.1267)
324
3.24 (0.1275)
EM-119
Thickness (B)
326
3.26 (0.1283)
328
3.28 (0.1291)
330
3.30 (0.1299)
332
3.32 (0.1307)
334
3.34 (0.1314)
336
3.36 (0.1322)
338
3.38 (0.1330)
340
3.40 (0.1338)
342
3.42 (0.1346)
344
3.44 (0.1354)
346
3.46 (0.1362)
348
3.48 (0.1370)
350
3.50 (0.1377)
Cylinder head
INFOID:0000000007575648
CYLINDER HEAD
Unit: mm (in)
Items
Limit
0.1 (0.004)
VALVE DIMENSIONS
Unit: mm (in)
PBIC3878E
Valve length a
Intake
Exhaust
Intake
101.73 (4.01)
Exhaust
102.49 (4.04)
Intake
1.0 (0.0393)
Exhaust
1.0 (0.0393)
Intake
Exhaust
Intake
3.0 (0.1181)
Exhaust
Intake
Exhaust
Intake
4515 - 4545
Exhaust
EM-120
Unit: mm (in)
EM
D
PBIC0184E
Items
Outer diameter
Valve guide
Standard part
Service part
Items
Valve guide clearance
Standard
Limit
Intake
0.1 (0.004)
Exhaust
0.1 (0.004)
Projection length L
VALVE SEAT
Unit: mm (in)
L
PBIC2745E
Items
Cylinder head seat recess diameter D
Standard
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Intake
29.6 (1.165)
Exhaust
23.0 (0.905)
Intake
Exhaust
Intake
60
Exhaust
45
EM-121
Angle 3
Contacting width W*3
Height h
Depth H
Intake
8845 - 9015
Exhaust
8845 - 9015
Intake
120
Exhaust
120
Intake
Exhaust
Intake
4.7 (0.185)
4.15 (0.163)
Exhaust
6.0 (0.236)
5.43 (0.213)
Intake
4.7 (0.185)
Exhaust
6.0 (0.236)
VALVE SPRING
Free height
Installation height
Installation load
Cylinder Block
INFOID:0000000007575649
CYLINDER BLOCK
Unit: mm (in)
PBIC3924E
Surface distortion
Cylinder bore
Limit
Inner diameter
0.1 (0.004)
Standard
Wear limit
0.015 (0.0006)
Limit
0.010 (0.0004)
EM-122
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
Standard
EM
* : Always check with the Parts Department for the latest parts information.
AVAILABLE PISTON
Unit: mm (in)
PBIC0188E
37.1 (1.460)
PISTON RING
Unit: mm (in)
Items
Side clearance
End gap
Standard
Limit
Top
0.11 (0.0043)
2nd
0.10 (0.0039)
Top
0.50 (0.0196)
2nd
0.66 (0.0259)
0.77 (0.0303)
PISTON PIN
Unit: mm (in)
Standard
Standard
EM-123
Unit: mm (in)
Center distance
Limit
0.15 (0.0059)
Limit
0.30 (0.0118)
Side clearance
Standard
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
CRANKSHAFT
Unit: mm (in)
PBIC3459J
SEM645
Center distance r
Out-of-round
Limit
0.003 (0.0001)
Taper
Limit
0.004 (0.0002)
Runout [TIR*1]
Limit
0.10 (0.0039)
Standard
Limit
0.35 (0.0138)
EM-124
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
EM
Main Bearing
INFOID:0000000007575650
MAIN BEARING
M
EM-125
Unit: mm (in)
SEM685D
Grade number
Thickness
Identification color
Black
Brown
Green
Yellow
Blue
Pink
Black
UPR
01
12
23
34
45
LWR
Brown
UPR
Brown
LWR
Green
UPR
Green
LWR
Yellow
UPR
Yellow
LWR
Blue
UPR
Blue
LWR
Pink
Remarks
Undersize
Unit: mm (in)
Items
Thickness
US 0.25 (0.0098)
Standard
INFOID:0000000007575651
Grade number
Thickness
Identification color
Brown
Green
Yellow
Blue
Pink
EM-126
Remarks
23
34
56
UPR
Brown
LWR
Green
UPR
Green
LWR
Yellow
UPR
Yellow
LWR
Blue
UPR
Pink
LWR
Purple
A
Grade and color are different
between upper and lower bearings.
EM
Undersize
D
Unit: mm (in)
Items
Thickness
US 0.25 (0.0098)
Standard
Limit
0.10 (0.0039)
EM-127