Professional Documents
Culture Documents
~3-103~
3-104 Engine control system - control system
P0351/0352/0353/0354
DTC P0351 No.1 ignition coil fault Type of fault code:A
DTC P0352 No.2 ignition coil fault Type of fault code:A
Ignition coil
Shielded
wire
Note
DTC Test starting conditions Fault criteria Emergency control scheme Possible causes to faults
P0351 • The ignition control
circuit between ignition
P0352
coil and ECU is short-
The ignition circuit of circuited or broken.
P0353 • The engine is running. • Stop the injection of
corresponding cylinder
• The battery voltage is corresponding cylinder • The contact between
is broken or short to
greater than 10V. • No fuel closed-loop control ignition coil connectors
power supply or ground.
P0354 is poor.
• The ignition coil breaks
down.
Wiring diagram
Ignition coil
Double-core
shielded wire
Double-core
shielded wire
Check procedure:
1. Check harness and connectors (ignition coil-ECU)
Ignition coil
Definition of ignition coil plug-in connector terminal
Positive power supply of ignition
A
switch
B Ground wire
C Ignition signal
~3-105~
3-106 Engine control system - control system
~3-106~
Engine control system - control system 3-107
~3-107~
3-108 Engine control system - control system
P0420
The conversion efficiency of catalytic
DTC P0420 Trouble code type: A
converter is lower than threshold.
Instructions to functions:
The converter is used to convert such noxious gases as carbon
monoxide, hydrocarbon, NOX in exhaust gases to carbon dioxide,
nitrogen, and water. The rear oxygen sensor behind the converter is
used to detect oxygen amount. If the converter is degraded, the rear
oxygen sensor will send over-rich/over-thin signals repeatedly like
the front oxygen sensor in a short period. Therefore, calculate the
voltage timing based on the rich/lean signal sent out by the rear
oxygen sensor, and compare it with the rich/lean signal sent out by
the front oxygen sensor. If the voltage exceeds the preset value and
the rear oxygen sensor responds to signals from the front oxygen
sensor much faster than the preset value, it indicates that the catalyst
has been deteriorated.
Note
DTC Test starting conditions Fault criteria Emergency control scheme Possible causes to faults
Check procedure:
1. Replace catalyst.
B Check the intermittent fault
A > Check and replace ECU.
~3-108~
Engine control system - control system 3-109
P0458/0459
DTC P0458 Short circuit of valve EGR to low voltage Type of fault code:E
or circuit disconnection
DTC P0459 Short circuit of valve EGR to high voltage Type of fault code:E
Instructions to functions:
Flow curve
~3-109~
3-110 Engine control system - control system
Wiring diagram
Valve EGR
Main
relay
Battery
Check procedure:
1. Check canister solenoid valve
(a) Dismantle down canister solenoid valve.
(b) Check canister solenoid valve resistance.
Measure the resistance between terminals with an ohmmeter.
Standard resistance
Connection of tester Regulatory conditions
A–B 19Ω-22Ω (at temperature of 20°C)
~3-110~
Engine control system - control system 3-111
~3-111~
3-112 Engine control system - control system
Standard resistance
Connection of tester Regulatory conditions
3-5 10kΩ or higher (before powering on)
~3-112~
Engine control system - control system 3-113
P0480
DTC P0480 Fan faul Trouble code type: A
Instructions to functions:
When the engine coolant temperature exceeds a certain value, the
low-speed fan will be on to accelerate cooling; when the temperature
further rises to another calibration value, the high-speed fan will be
on.
Note
DTC Test starting conditions Fault criteria Emergency control scheme Possible causes to faults
• The control circuit
ECU detects that control circuit • When the coolant between fans and
P0480 • The engine is running. is broken or short to power temperature is excessive, ECU is broken or
supply or ground. high-speed fan is opened. short to power supply
or ground.
Wiring diagram
Battery
Fan relay Single speed fan
Check procedure:
1. Check ECU (FANLO terminal voltage)
(a) Turn igniting switch ON.
(b) Measure the voltage between ECU connector terminals.
Standard voltage
Connection of tester Regulatory conditions
~3-113~
3-114 Engine control system - control system
3. Check harness and connectors (ECU-fan relay)
~3-114~
Engine control system - control system 3-115
Electronic fan
~3-115~
3-116 Engine control system - control system
P0502
DTC P0502 No vehicle speed signal Trouble code type: E
Instructions to functions:
The ECU vehicle speed sensor signals are from instrument cluster
and transmitted to ECU in collector open type. ECU determines
vehicle speed based on the frequency of pulse signals.
Note
DTC Test starting conditions Fault criteria Emergency control scheme Possible causes to faults
Instrument cluster
Check procedure:
1. Check instrument cluster (speedometer)
(a) Drive the car to check the speedometer in instrument cluster
for normal running.
OK: The speedometer operates normally.
Result Into
OK A
NG B
~3-116~
Engine control system - control system 3-117
~3-117~
3-118 Engine control system - control system
P0506/0507
DTC P0506 Idling control system fault-the rotate Type of fault code:E
speed is too low.
DTC P0507 Idling control system fault-the rotate Type of fault code:E
speed is too high.
Note
Emergency control
DTC Test starting conditions Fault criteria Possible causes to faults
scheme
• No trouble codes related to MAP The duration of the idle • Idling control circuit
sensor, coolant temperature sensor, speed which is lower than trouble
P0506 No idling adjustment.
TPS sensor, cooling system, the target speed (100RPM) • ETC trouble
oxygen sensor, fuel correction, car set by the system is over 10s. • Ignition system fault
speed sensor, injector, misfire,
• Circuit trouble
crankshaft position sensor,
The duration of the idle between ETC and
camshaft position sensor, ignition
speed which is greater than ECU
P0507 system, etc. No idling adjustment.
the target speed (200RPM) • ETC trouble
• The engine is running.
set by the system is over 10s. • Ignition system fault
• The coolant temperature is over
• Vacuum leak
60°C.
~3-118~
Engine control system - control system 3-119
P0011/0012/0016/0026/0076/0077
DTC P0011 Lagging response of air intake VCP phase Type of fault code:A
DTC P0012 Big error to phase of air intake VCP camshaft Type of fault code:A
~3-119~
3-120 Engine control system - control system
~3-120~
Engine control system - ECU power circuit 3-121
Ignition switch
Main relay
Battery
~3-121~
3-122 Engine control system - ECU power circuit
On-board check
1. Check ECU (VBATPRO voltage)
Continue to check the next circuit shown by trouble symptoms.
(d)
Reconnect ECU connector.
(e)
Reconnect cable of negative power supply.
NG Repair or replace harness or connectors.
OK > To the 3rd step
3. Check ECU (IGN voltage)
(a) Turn igniting switch ON.
(b) Measure the voltage between ECU connector terminals.
Standard voltage
Connection of tester Regulatory conditions
68–02 or 03 11-14V
Schematic diagram of connector pins
(seeing from the harness side)
NG Repair or replace harness or connectors.
OK > To the 4th step
4. Check fuse (ECU fuse)
(a) Dismantle down ECU fuse from fuse box.
(b) Check ECU fuse resistance.
Standard resistance:
Lower than 1Ω
(c) Reinstall ECU fuse.
NG Check all harness and connectors connected to fuse for
short circuit, and replace fuse.
ECU fuse OK > To the 5th step
~3-122~
Engine control system - ECU power circuit 3-123
1–2–3
ON
5-6 Lower than 1Ω
1-2
START
4+ -5×-6
(c) Reconnect ignition switch connector.
NG Replace ignition or engine switch assembly
OK > To the 6th step
6. Check ECU (MPR voltage)
(a) Turn igniting switch ON.
(b) Measure the voltage between ECU connector terminals.
Standard voltage
Connection of tester Regulatory conditions
44–02 or 03 11-14V
NG Replace ECU.
OK > To the 7th step
Schematic diagram of connector pins
(seeing from the harness side)
7. Check fuse (main relay fuse)
(a) Dismantle down main relay fuse from fuse box.
(b) Check main relay fuse resistance.
Standard resistance:
Lower than 1Ω
(c) Reinstall main relay fuse.
NG Check all harness and connectors connected to fuse for
short circuit, and replace fuse.
OK > To the 8th step
8. Check main relay.
Main relay
fuse
~3-123~
3-124 Engine control system - ECU power circuit
Main relay
(a) Dismantle down main relay from fuse box.
(b) Check main relay resistance.
Standard resistance
Connection of tester Regulatory conditions
(a) Dismantle the main relay from the main fuse box.
(b) Disconnect the ECU connector.
(c) Check the resistance.
Main relay
~3-124~
Engine control system - Camshaft Timing Oil Control Valve 3-125
~3-125~
3-126 Engine Control System - Camshaft Timing Oil Control Valve
On-board check
OCV valve check:
1. Check appearance
Example:
(a) If OCV is not started, the spring lets the valve core return to
normal position.
2. Apply force on valve core
(a) OCV valve core shall be free of blocking at any positions,
and it shall be able to return to its normal position in the
case of hand release.
~3-126~
Engine control system - Camshaft Timing Oil Control Valve 3-127
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down camshaft timing oil control valve assembly
(a) Disconnect camshaft timing oil control valve connector.
(b) Dismantle down bolts, and then dismantle down camshaft
timing oil control valve.
Installation
1. Install camshaft timing oil control valve assembly
(a) Apply a thin layer of engine oil on O-ring.
(b) Install camshaft timing oil control valve with bolts.
Torque:7~9N.m
Note:
Do not twist O-ring.
(c) Connect up camshaft timing oil control valve connector.
2. Connect cable to battery negative terminal
Torque :8~12N.m
3. Check engine oil for leakage.
~3-127~
3-128 Engine control system - Camshaft position sensor
~3-128~
E
Engine control system - Camshaft position sensor 3-129
n
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down camshaft position sensor.
(a) Disconnect camshaft position sensor connector.
(b) Dismantle down bolts and camshaft position sensor.
~3-129~
3-130 Engine control system - Camshaft position sensor
On-board check
1. Check the sensor output voltage wave form.
(a) The oscilloscope probe is connected with corresponding
ECU terminal.
(b) Check the waveform when the engine is at idle speed or at a
speed.
ECU terminal name Tester Range Regulatory conditions
OK:
Different waveforms for different engine speed
Prompt:
• Shown in the diagram is the wave form when the engine
is at idle.
• Take the oscilloscope wave forms as an example,
excluding those of noise or vibration.
• The wave amplitude sees nuances based on the difference
between cars.
• In case of grounding of shielded wires, the wave forms
will produce noises.
Installation
1. Install camshaft position sensor.
(a) Apply a thin layer of engine oil on O-ring, and then use
bolts to install camshaft position sensor.
Torque:7~9N.m
Note:
Confirm that the O-ring is free of cracks or
extruding before installation.
(b) Connect up camshaft position sensor connector.
2. Connect cable to battery negative terminal
Torque :8~12N.m
3. Check engine oil for leakage.
~3-130~
Engine control system – Crankshaft position sensor 3-131
Transmission assy
Crankshaft position
sensor
~3-131~
3-132 Engine control system - Crankshaft position sensor
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down crankshaft position sensor.
(a) Disconnect crankshaft position sensor connector.
(b) Dismantle down bolts and crankshaft position
sensor.
~3-132~
Engine control system -Crankshaft position sensor 3-133
On-board check
1. Check ECU output voltage.
(a) Connect the oscilloscope probe with the ECU connector
terminals 30 and 11.
(b) Check waveform when the engine is at idle speed or others.
ECU terminal name Tester Range Operating conditions
Terminals 30 and 11 2V/DIV,20msec/DIV Idle speed or others
OK:
Different waveforms for different engine speeds.
Prompt:
• Shown in the diagram is the wave form when the engine
is at idle.
• Take the oscilloscope wave forms as an example,
excluding those of noise or vibration.
• The wave amplitude sees nuances based on the difference
between cars.
• In case of grounding of shielded wires, the wave forms
will produce noises.
2. Check crankshaft position sensor.
Crankshaft position sensor
(a) Disconnect crankshaft position sensor connector.
Definitions of crankshaft position sensor connector terminals
A Positive signal output terminal
B Negative signal output terminal
C System shield ground
~3-133~
3-134 Engine control system - coolant temperature sensor
~3-134~
Engine Control System - coolant temperature sensor 3-135
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down engine coolant temperature sensor.
(a) Disconnect engine coolant temperature sensor connector.
(b) Dismantle down hex nuts and engine coolant temperature
sensor.
~3-135~
3-136 Engine control system - coolant temperature sensor
On-board check
1. Check engine coolant temperature sensor.
(a) Check resistance
(1) Measure the resistance between terminals with an
ohmmeter.
Ohm meter Standard resistance
Connection of tester Regulatory conditions
A–C It is between 2.29k and 2.60kΩ under 20°C.
B – shell It is between 0.302k and 0.327kΩ under 80°C.
~3-136~
Engine Control System – Intake pressure and temperature sensor 3-137
At 20±1°C 2308~2726Ω
At 80±1°C 309~350Ω
V5REF2(E1-Pin66)-V5RTN2(E1-
5.0±0.1V
Pin76)
~3-137~
3-138 Engine Control System - Intake pressure and temperature sensor
~3-138~
Engine control system – Electronic throttle body 3-139
~3-139~
3-140 Engine Control System - Electronic throttle body
Dismantle
1. Disconnect cable of battery negative terminal.
2. Disconnect crankcase vent pipe from the intake pipe on air
filter.
3. Disconnect the intake pipe on air filter connected to
electronic drive control throttle valve body.
4. Disconnect harness connector clip.
5. Dismantle down 4 assembling bolts.
6. Take down harness retaining bracket, and take out
electronic drive control throttle valve body assembly.
~3-140~
Engine control system – Electronic throttle body 3-141
On-board check
1. Check throttle valve assembly
(a) Check and confirm that the throttle valve axle will not
generate "cluck" noise.
2. Electronic throttle valve self-learning
Observe the following steps for electronic throttle valve self-
learning in case of electronic throttle valve or ECU replacement,
or reconnection of battery negative terminal.
(1) Turn ignition switch to "ON" position (no engine start) and
wait for 5s.
(2) Turn ignition switch to "OFF" position and wait for 15s.
(3) Turn ignition switch to "ON" position and start the engine.
Installation
1. Install 4 assembling bolts and fasten the harness retaining
bracket.
Torque:7~9N.m
2. Connect harness connector clip.
3. Connect up the intake pipe on air filter connected to
electronic drive control throttle valve body.
4. Connect crankcase vent pipe to the intake pipe on air filter.
5. Connect up cable of battery negative terminal.
Torque :8~12N.m
~3-141~
3-142 Engine control system - knock sensor
Knock sensor
Components
Knock sensor
Specified torque
~3-142~
Engine control system - knock sensor 3-143
Dismantle
1. Disconnect cable of battery negative terminal.
2. Dismantle down auxiliary instrument panel (refer to
related sections)
3. Dismantle down engine middle cover plate and disconnect
shift cable (refer to related sections).
4. Dismantle down intake manifold (refer to related sections)
5. Disconnect harness connector.
6. Dismantle down assembling bolts and take down knock
sensor.
~3-143~
3-144 Engine control system - knock sensor
On-board check
1. Check knock sensor.
(a) The oscilloscope probe is connected with corresponding
ECU terminal.
Knock sensor
(1) Check wave forms when the engine is idling or
at a certain speed.
ECU terminal Tester Range Regulatory
name conditions
ECU(36)-ECU(37) The engine is at idle
speed or at a certain
speed.
If the results are not satisfactory to related specification,
replace knock sensor.
2. Check knock sensor.
Schematic diagram of connector pins
(seeing from the harness side)
~3-144~
Engine Control System – Main relay 3-147
~3-145~
3-146 Engine Control System - Fuel Pump Relay
~3-146~
Engine Control System – Valve EGR 3-147
Valve EGR
On-board check
1. Dismantle down canister solenoid valve.
2. Check canister solenoid valve resistance.
Measure the resistance between terminals with an ohmmeter.
Standard resistance
Connection of tester Regulatory conditions
A–B 19Ω-22Ω (at temperature of 20°C)
~3-147~
3-148 Engine Control System - Heated Oxygen Sensor
Heated oxygen sensor
On-board check
1. Check the front and rear oxygen sensor output voltage
wave form.
(a) Connect the oscilloscope probe and ECU connector terminal
47 (front oxygen sensor) to car body and connect terminal
48 (rear oxygen sensor) to ground.
(b) Check waveform when the engine is at idle speed or others.
ECU terminal name Terminals 30 and 11
Tester Range 2V/DIV, 20msec/DIV
Operating conditions Idle speed or others
OK:
Different waveforms for different engine speeds.
Prompt:
Plugin pin schematic diagram • Shown in the diagram is the wave form when the engine
(from harness terminal)
is at idle.
• Take the oscilloscope wave forms as an example,
excluding those of noise or vibration.
• The wave amplitude sees nuances based on the
difference between cars.
OK > Check intermittent trouble
NG > To the next step
2. Check heated oxygen sensor (the same to both front and
Oxygen sensor rear oxygen sensor).
Terminal Number Definition of terminal Colors of connecting wires
A Signal output low level Gray
B Signal output high level Black
C Cathode of heating element White
D Anode of heating element Purple
~3-148~
Engine Control System – Fuel Injector 3-149
Fuel injector
On-board check
1. Check resistance.
Measure the resistance between terminals with a universal meter.
(a) Disconnect injector connector.
M3.5 Injector (b) Measure the resistance of injector.
Standard resistance
Connection of tester Regulatory conditions
When the temperature is 20°C, the
A–B
resistance is 12.0±0.6Ω.
Schematic diagram of connector pins (c) Reconnect the fuel injector connector.
(seeing from the injector end)
Note:
Do this operation in a well-ventilated area for
fire prevention.
If the resistance value is not satisfactory to the requirements,
replace injector.
2. Check injection amount.
Note:
Carry out the test in an area with good ventilation
and keep away from fire.
(a) Disconnect fuel hose from No.1 fuel pipe.
(hose)
(b) Install a new O-ring on fuel injector.
(b) Install SST and ethylene tube on fuel injector.
(connector)
Clamp SST 09268-31012 (09268-41110, 09268-41300,
spring 95336-08070)
(d) Connect SST (one hose) to No.1 fuel pipe.
(e) Place fuel injector in measuring cylinder.
(clamp)
Ethylene tube
(f) Execute fuel pump operation.
(g) Install SST on fuel injector.
(h) Connect SST to battery and measure the injection amount
for 15s. Carry out twice or 3 times check and then calculate
the average.
Injection amount: 2.4g/s
Note:
Switching operation shall be carried out on the side of
battery.
Measuring If the results are not satisfactory to related specification,
Battery
cylinder replace fuel injector.
3. Check for leakage.
~3-149~
3-150 Engine Control System - Fule Injector
~3-150~
Engine Control System - Ignition Coil 3-151
Ignition coil
On-board check
1. Check DTC
Note:
If there are DTCs, analyze to discover the trouble based on the
detailed specification of corresponding DTC.
2. Dismantle down ignition coil
3. Dismantle down all ignition plugs.
4. Disconnect all injector connectors.
5. Check ignition plug.
Process ignition plugs accordingly.
6. Install the ignition plugs in ignition coil, and then connect
up ignition coil connector.
7. Check and confirm the correct connections between
connectors.
8. Have the ignition plugs grounded, use tester drive to
execute the test functions of ignition coil to check the
ignition sparks of ignition plugs.
Note:
If anything unusual happens to sparks, replace ignition plugs to
test again; if the ignition spark remains abnormal, connect
ignition coil to normal parts for conversion testing; and if the
ignition coil is confirmed as abnormal after comparison
validation, replace ignition coil.
~3-151~
~3-152~
Engine machinery
Engine 4-2
On-board check v 4-2
Transmission Belt 4-4
Component 4-4
Dismantle 4-5
Check 4-5
Installation 4-5
Valve clearance 4-7
Adjustment 4-7
Camshaft 4-19
Component 4-19
Dismantle 4-21
Check 4-24
Installation 4-25
Engine assembly 4-29
Component 4-29
Dismantle 4-37
Installation 4-44
Engine Unit 4-51
Component 4-51
Dismantle down 4-58
Check 4-70
Re-install 4-83
Repair 4-103
~4-1~
4-2 Engine Machinery - Engine
Engine
On-board check
1. Check coolant.
2. Check engine oil.
3. Check battery.
4. Check air filter filter-element subassembly.
(a) Dismantle down air filter filter-element subassembly.
(b) Visually check the air filter filter-element for dust, blocking,
or damages.
Prompt:
• If there is dust or blocking on air filter filter-element, clean
with compressed air.
• If there is still dust or blocking on air filter filter-element
after cleaning with compressed air, replace it.
5. Check ignition plug.
6. Check ignition timing
(a) Check and confirm that the ignition timing is subject to the
specified value range.
Ignition timing: 4-8 BTDC
Note:
During the check of ignition timing, the transmission
gear shall be on Park/Neutral position.
Prompt:
After the engine runs for 5s at the speed of 1,000 to 1,300,
release the accelerator and check whether the engine speed
returns to idle speed.
7. Check engine idle speed.
Idle speed: 750rpm
Note:
During the check of idle speed, the transmission gear shall be
on Park/Neutral position.
Turn all electrical systems and A/C to OFF position.
For the check of engine idle speed, the cooling fan shall be
turned to OFF position.
8. Check pressure
(a) Warm up the engine and then stop it.
(b) Dismantle down air filter assembly.
(c) Dismantle down ignition coil.
(d) Dismantle down ignition plug.
(e) Disconnect fuel injector connector.
~4-2~
Engine machinery - Engine 4-3
~4-
4-4 Engine machinery - transmission belt
Transmission Belt
Components
~4-4~
Engine machinery - transmission belt 4-5
Dismantle
1. Dismantle down fan and generator V belt.
(a) Loosen fixed bolt A and B.
(b) Loosen adjusting bolt C, and then dismantle down V belt.
Check
1. Check fan and generator V belt.
(a) Visually check the belt for excessive wear or absence of
cord thread wear. In case any flaws are found, replace the
belt.
Prompt:
It is allowed to have some cracks on the shoulder side of the
belt. If the teeth on the belt break down in pieces, the belt
shall be replaced.
Installation
1. Install fan and generator V belt.
(a) Install V belt on various belt pulleys temporarily.
2. Adjust fan and generator V belt.
(a) Turn the adjusting bolt C and adjust the tension of the V
belt.
(b) Tighten fixed bolt A and B.
Torque
19N.m for bolt A
44N.m for bolt B
~4-5~
4-6 Engine machinery - transmission belt
3. Check fan and generator V belt.
(a) Check the belt for deformation by pressing the position
indicated by the arrows in the diagram.
Deformation
Item Regulatory conditions
New belt 5.0-6.0mm
Old belt 8.0-9.0mm
Tension
Item Regulatory conditions
New belt 785-981N
Old belt 441N to 539N
~4-6~
Engine machinery - valve clearance 4-7
~4-7~
4-8 Engine machinery - valve clearance
Positioning mark
~4-8~
Engine machinery - valve clearance 4-9
Timing mark
Positioning mark
Positioning mark (f) Loosen the bolts for the fastening of camshaft timing chain
wheel at the same time of camshaft hexagonal top fastening.
Note:
All that is needed to loosen the bolts, do
not dismantle down bolts and chain wheel.
Prompt:
Loosen the bolts in advance. If the bolts are loosened after
the chain wheel is dismantled, the chain wheel might be
disturbed by the chain.
~4-9~
4-10 Engine machinery - valve clearance
(g) Use an 8mm sleeve hex wrench to dismantle down chain
cover service hatch screw plug.
(h) Insert a screwdriver into chain cover service hatch, and then
move downwards the lock plate of the tensioner and keep it
at unlocked state.
Prompt:
• The operation will open the plunger of the tensioner.
• If it is not easy to open the lock plate, use the hexagonal
top of the camshaft to rotate the camshaft right and left.
(i) Rotate the camshaft to the right with the hexagonal top of
the camshaft in order to make the chain push the tensioner
plunger.
(k) Dismantle down the rest bolts, and then dismantle down
camshaft timing chain wheel.
~4-10~
Engine machinery - valve clearance 4-11
~4-11~
4-12 Engine machinery - valve clearance
Measured
clearancea
~4-12~
Engine machinery - valve clearance 4-13
~4-13~
4-14 Engine machinery - valve clearance
Measured clearance
~4-14~
Engine machinery - valve clearance 4-15
~4-15~
4-16 Engine machinery - valve clearance
(z) Install No.2 camshaft with 1 bolt temporarily.
(aa) Install chain, and make the mating mark of the camshaft
Paint mark
timing chain wheel align to the paint mark made before the
dismantlement of the chain.
Prompt:
Firstly, install the chain on any one camshaft. Rotate the
camshaft left and right with the hexagonal top of the
camshaft to make the mating mark of the chain wheel align
to the paint mark of the chain.
Mating mark
(ab) Dismantle down the hex wrench with diameter of 2.5mm
from the tensioner.
Prompt:
Rotate the camshaft to the left slightly with the hexagonal
top of the camshaft, and then dismantle down the hex
wrench with diameter of 2.5mm when the tensioner side
chain is loosened.
(ac ) Tighten the bolts to specified torque for the installation of
camshaft timing chain wheel at the same time of camshaft
hexagonal top fastening.
Torque: 63~77N.m
(ad) Apply adhesive on 2 or 3 threads at the end of the chain
cover service hatch screw plug bolt.
Warning:
Wipe off the engine oil from the bolts and bolt holes.
(ae) Rotate crankshaft belt pulley clock-wise, and install the rest
2 bolts on No.2 camshaft chain wheel. And then tighten the
3 bolts to the specified torque.
Torque:8.0N.m
~4-16~
Engine machinery - valve clearance 4-17
Sealing material:
~4-17~
4-18 Engine machinery - valve clearance
~4-18~
Engine machinery - camshaft 4-19
Camshaft
Components
PVC valve
breather pipe
Cylinder cover
subassembly
Cylinder cover
sealing strip
Specified torque
~4-19~
4-20 Engine machinery - camshaft
Exhaust camshaft
Specified torque
~4-20~
Engine machinery - camshaft 4-21
Dismantle
1. Disconnect cable from battery negative terminal.
2. Dismantle down ignition coil assembly (refer to related
sections)
3. Disconnect vent hose (refer to related sections)
4. Dismantle down engine harness
5. Dismantle down cylinder head cover assembly
(a) Dismantle down 11 bolts and 2 nuts according to the
sequence shown in the diagram, and then dismantle cylinder
head cover.
~4-21~
4-22 Engine machinery - camshaft
Positioning mark
Paint mark
(d) Make 2 paint marks on timing chain disc to make them
align to the positioning marks on camshaft timing chain
wheel and camshaft timing gear.
Positioning mark
(e) Loosen the bolts for the fastening of camshaft timing chain
wheel at the same time of camshaft hexagonal top fastening.
Note:
All that is needed to loosen the bolts, do
not dismantle down bolts and chain wheel.
Prompt:
Loosen the bolts in advance. If the bolts are loosened after
the chain wheel is dismantled, the chain wheel might be
disturbed by the chain.
(g) Insert a screwdriver into chain cover service hatch, and then
move downwards the lock plate of the tensioner and keep it
at unlocked state.
Prompt:
• The operation will open the plunger of the tensioner.
• If it is not easy to open the lock plate, use the hexagonal
top of the camshaft to rotate the camshaft right and left.
~4-22~
Engine machinery - camshaft 4-23
(h) Rotate the camshaft to the right with the hexagonal top of
the camshaft in order to make the chain push the tensioner
plunger.
(j) Dismantle down the fixed bolts of the camshaft timing gear
or chain wheel, and dismantle down chain wheel from the
exhaust camshaft.
~4-23~
4-24 Engine machinery - camshaft
Check
1. Check camshaft timing chain wheel assembly.
Note:
Do not Dismantle down camshaft
timing chain wheel assembly.
(a) Clamp camshaft with a bench vise.
Note:
Do not damage the camshaft.
(b) Tighten the timing chain wheel temporarily with bolts.
Advance interface
~4-24~
Engine machinery - camshaft 4-25
(e) Check lock pins for loosening with hands, and check the
chain wheel for stable moving within 30°.
Note:
The timing chain wheel is locked at the maximum
delay position.
(f) Lock the timing chain wheel at the maximum delay position,
and then dismantle down bolts and timing chain wheel.
Installation
1. Install camshaft.
Note:
For the installation of camshaft, in order to avoid the
interference from the valves with pistons, rotate the crankshaft
about 90° from No.1 cylinder TDC/compression position in the
direction of engine running.
(a) Apply engine oil on cam, cylinder cover journal and the top
of valve tappet.
(b) Place camshaft to make the cam top of No.3 and No.4
cylinder on the side of intake (camshaft) to push the valve
tappet, and make the cam top of No.2 and No.4 cylinder on
the side of exhaust (No.2 camshaft) to push the valve tappet.
(c) Check the forward marks and number on the bearing cap as
the sequence shown in the figure. And then tighten the bolts
by steps as the sequence shown in the figure.
Torque: 13N.m
~4-25~
4-26 Engine machinery - camshaft
(e) Install exhaust camshaft with 1 bolt temporarily.
Paint mark (f) Install chain, and make the mating mark of the camshaft
timing chain wheel align to the paint mark made before the
dismantlement of the chain.
(g) Dismantle down the hex wrench with diameter of 2.5mm
from the tensioner.
Prompt:
Rotate the camshaft to the left slightly with the hexagonal
top of the camshaft, and then dismantle down the hex
Mating mark wrench with diameter of 2.5mm when the tensioner side
chain is loosened.
(i) Rotate crankshaft belt pulley clock-wise, and install the rest 2
bolts on exhaust camshaft chain wheel. And then tighten the 3
bolts to the specified torque.
Torque:8.0N.m
~4-26~
Engine machinery - camshaft 4-27
Sealing material
~4-27~
4-28 Engine machinery - camshaft
9. Connect cable to battery negative terminal
Torque :8~12N.m
10. Check engine oil for leakage.
~4-28~
Engine machinery - engine assembly 4-29
Engine assembly
Components
Radiator assembly
V-ribbed belt
Specified torque
~4-29~
4-30 Engine machinery - engine assembly
Seal ring
Gasket assembly
Non-reusable parts
~4-30~
Engine machinery - engine assembly 4-31
Water pump
sealing gasket
Specified torque
Non-reusable parts
~4-31~
4-32 Engine machinery - engine assembly
Exhaust pipe
Specified torque
Non-reusable parts
~4-32~
Engine machinery - engine assembly 4-33
O-ring
Specified torque
Non-reusable parts
~4-33~
4-34 Engine machinery - engine assembly
Specified torque
~4-34~
Engine machinery - engine assembly 4-35
Ignition coil
Knock sensor
Specified torque
Non-reusable parts
~4-35~
4-36 Engine machinery - engine assembly
Flywheel baffle
Specified torque
~4-36~
Engine machinery - engine assembly 4-37
Dismantle
1. Disconnect battery negative terminal.
2. Discharge engine coolant, engine oil, and transmission oil
(refer to related sections)
3. Dismantle down driver's and co-driver's seat assembly
(refer to related sections)
4. Dismantle down engine intake hose and crankcase vent
pipe (refer to related sections)
5. Disconnect engine harness.
6. Disconnect all connectors of engine control system actuator
and sensor harness (refer to related sections).
7. Disconnect engine water inlet/discharging pipe (refer to
related sections).
8. Disconnect the discharging tube connected to the engine
and radiator (refer to related sections).
~4-37~
4-38 Engine machinery - engine assembly
12. Disconnect the fuel pipe on fuel guide rail from the engine.
Note:
Release fuel pressure before fuel pipe disconnection. Wrap up
the oil rail with clean rags to avoid oil-way blocking caused by
the entrance of foreign bodies. (refer to related sections)
~4-38~
Engine machinery - engine assembly 4-39
~4-39~
4-40 Engine machinery - engine assembly
~4-40~
Engine machinery - engine assembly 4-41
~4-41~
4-42 Engine machinery - engine assembly
~4-42~
Engine machinery - engine assembly 4-43
~4-43~
4-44 Engine machinery - engine assembly
37. Dismantle down seal water cover plate and seal water cover
plate gasket.
Installation
1. Install seal water cover plate and seal water cover plate
gasket.
~4-44~
Engine machinery - engine assembly 4-45
6. Install thermostat.
(a) Place the thermostat and install the 2 spring clamps, 2 bolts
shown in the figure.
~4-45~
4-46 Engine machinery - engine assembly
8. Install alternator.
(a) Install generator with generator mounting bolts.
Bolt torque: 44N.m
~4-46~
Engine machinery - engine assembly 4-47
~4-47~
4-48 Engine machinery - engine assembly
~4-48~
Engine machinery - engine assembly 4-49
(b) Apply little thread sealant to the front of the flywheel bolt.
adhesive Sealant: 262 Thread-locking Adhesives
(c) Install flywheel ring gear assembly.
~4-49~
4-50 Engine machinery - engine assembly
~4-50~