Engine mechanical

Engine mechanical

1NZ-FE ENGINE MECHANICAL – ENGINE EM–1 EM ENGINE ON-VEHICLE INSPECTION 1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page LU-1) 3. INSPECT BATTERY (See page CH-4) 4. INSPECT AIR CLEANER FILTER ELEMENT SUB- ASSEMBLY (a) Remove the air cleaner filter element sub-assembly. (b) Visually check that there is no dirt, blockage, or damage to the air cleaner filter element. HINT: • If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. • If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it. 5. INSPECT SPARK PLUG (See page IG-5) 6. INSPECT IGNITION TIMING (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / TC (TE1) / ON. HINT: Refer to the intelligent tester operator's manual for further details. (5) Inspect the ignition timing during idling. Ignition timing: 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (6) Select the following menu items: TC (TE1) / OFF. (7) Turn the ignition switch OFF. (8) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester: (1) Remove cylinder head cover No. 2 (see page IG-9). DLC3 Intelligent Tester CAN VIM A125658E01 EM–2 1NZ-FE ENGINE MECHANICAL – ENGINE EM (2) Pull out the wire harness (brown) shown in the illustration. NOTICE: After checking, wrap the wire harness with tape. (3) Warm up and stop the engine. (4) Connect the clip of the timing light to the wire harness. NOTICE: Use a timing light that detects the first signal. (5) Turn the ignition switch ON. (6) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE: Examine the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine. (7) Inspect the ignition timing during idling. Ignition timing: 8 to 12 degrees BTDC NOTICE: • Turn all the electrical systems and the A/ C off. • Inspect the ignition timing with the cooling fan off. • When checking the ignition timing, shift the transmission to the neutral position. (8) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (9) Turn the ignition switch OFF. (10) Remove the timing light. (11) Install cylinder head cover No. 2 (see page IG- 10). 7. INSPECT ENGINE IDLING SPEED (a) When using an intelligent tester: (1) Warm up and stop the engine. (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II/ DATA LIST / PRIMARY / ENGINE SPD. HINT: Refer to the intelligent tester operator's manual for further details. (5) Inspect the engine idling speed. Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle NOTICE: • Turn all the electrical systems and the A/ C off. A116196 1 2 34 5 6 7 8 910111213141516 DLC3 CG TC A082779E23 DLC3 Intelligent Tester CAN VIM A125658E01 1NZ-FE ENGINE MECHANICAL – ENGINE EM–3 EM • Inspect the idling speed with the cooling fan off. • When checking the idling speed, shift the transmission to either the neutral position or the parking position. (6) Turn the ignition switch OFF. (7) Disconnect the intelligent tester from the DLC3. (b) When not using an intelligent tester. (1) Warm up and stop the engine. (2) Install SST to terminal 9 (TAC) of the DLC3, then connect a tachometer. SST 09843-18040 NOTICE: Examine the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine. (3) Turn the ignition switch ON. (4) Inspect the engine idling speed. Idling speed: 550 to 650 rpm for manual transaxle 650 to 750 rpm for automatic transaxle (5) Turn the ignition switch OFF. (6) Disconnect the tachometer. (7) Remove SST from terminal 9 (TAC). 8. INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Remove cylinder head cover No. 2 (see page IG-9). (c) Remove the 4 ignition coils (see page IG-9). (d) Remove the 4 spark plugs. (e) Disconnect the 4 fuel injector connectors. (f) Inspect the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression: 1,471kPa (15.0 kgf/cm 2 , 213 psi) Minimum pressure: 1,079 kPa (11.0 kgf/cm 2 , 156 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm 2 , 14 psi) or less NOTICE: • Use a fully-charged battery so the engine speed can be increased to 250 rpm or more. • Inspect the other cylinders in the same way. • Measure the compression in as short a time as possible. 910111213141516 DLC3 TAC 12 34 567 8 A082779E24 A116195 EM–4 1NZ-FE ENGINE MECHANICAL – ENGINE EM (4) If the cylinder compression is low, pour a light coat of engine oil into the cylinder through the spark plug hole, then inspect it again. HINT: • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. • If the pressure stays low, the valve may be stuck or seated improperly, or there may be leakage from the gasket. (g) Connect the 4 fuel injector connectors. (h) Install the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (i) Install the 4 ignition coils (see page IG-9). (j) Install cylinder head cover No. 2 (see page IG-10). 9. INSPECT CO/HC (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe while idling. (d) Check the CO/HC concentration during idling and when running at 2,500 rpm. HINT: When doing the 2 mode (with the engine idling/ running at 2,500 rpm) test, the measuring procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (see page ES-276). (2) See the table below for possible causes, then inspect the applicable parts and repair them if necessary. CO HC Problems Possible Causes Normal High Rough idling 1. Faulty ignition: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leakage from intake and exhaust valves 4. Leakage from cylinders Low High Rough idling (Fluctuating HC reading) 1. Vacuum leaks: – PCV hoses – Intake manifold – Throttle body – Brake booster line 2. Lean mixture causing misfire High High Rough idling (Black smoke from exhaust) 1. Restricted air cleaner filter element 2. Plugged PCV valve 3. Faulty EFI systems: – Faulty pressure regulator – Faulty engine coolant temperature sensor – Faulty mass air flow meter –Faulty ECM – Faulty injectors – Throttle body 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–5 EM ENGINE1NZ-FE ENGINE MECHANICAL DRIVE BELT COMPONENTS 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER RH A115143E01 EM–6 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque 54 (551, 40) 19 (189, 14) A116199E01 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–7 EM REMOVAL 1. REMOVE ENGINE UNDER COVER RH 2. REMOVE FAN AND GENERATOR V BELT (a) Loosen bolts A and B. (b) Release the fan and generator V belt tension and remove the fan and generator V belt. INSPECTION 1. INSPECT FAN AND GENERATOR V BELT (a) Visually check the belt for excessive wear, frayed cords etc. If any defects are found, replace the belt. HINT: • If any defects are found, replace the belt. • Cracks on the rib side of a belt are considered acceptable. If the belt has pieces missing from the ribs, it should be replaced. A B A116197E01 B000543 EM–8 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM INSTALLATION 1. INSTALL FAN AND GENERATOR V BELT (a) Provisionally install the fan and generator V belt onto each pulley. NOTICE: Make sure that the V-belt is securely fitted into the rib groove of the pulley. 2. ADJUST FAN AND GENERATOR V BELT (a) Insert an adjusting bar between the engine mounting bracket and generator assembly. Push the adjusting bar toward the vehicle front to adjust the generator V belt tension. NOTICE: Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the camshaft timing oil control valve assembly. (b) First tighten bolt A, then tighten bolt B. Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf) for bolt A 54 N*m (551 kgf*cm, 40 ft.*lbf) for bolt B 3. INSPECT FAN AND GENERATOR V BELT (a) Check the V belt deflection and tension. Deflection Tension If the belt deflection is not as specified, adjust it. HINT: • Check the V belt deflection at the specified point. • Check the drive belt deflection at the specified point. • When installing a new belt, set its tension to the specified value. • When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications. NG OK A116198E01 A B A116197E01 w/o Air Conditioner w/ Air Conditioner A116200E01 Item Specified Condition New belt 7.0 to 8.5 mm (0.28 to 0.33 in) Used belt 11 to 13 mm (0.43 to 0.51 in) Item Specified Condition New belt 539 to 637 N (55 to 65 kg, 121 to 143 ld) Used belt 245 to 392 N (25 to 40 kg, 55 to 88 ld) 1NZ-FE ENGINE MECHANICAL – DRIVE BELT EM–9 EM • When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each used belt specification. • V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking. • When using a belt tension gauge, confirm its accuracy by using a master gauge first. 4. INSTALL ENGINE UNDER COVER RH 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–9 EM VALVE CLEARANCE ADJUSTMENT 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CYLINDER HEAD COVER NO. 2 (See page IG-9) 4. REMOVE IGNITION COIL NO. 1 (See page IG-9) 5. DISCONNECT VENTILATION HOSE (See page FU-13) 6. DISCONNECT VENTILATION HOSE NO. 2 (See page FU-13) 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See page FU-13) 8. INSPECT VALVE CLEARANCE HINT: Inspect the valve clearance when the engine is cold. (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft damper and align its timing notch with the timing mark "0" of the oil pump. (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward, as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (cold): for intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) for exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) Timing Notch A116203E01 Timing Marks A116204E01 A116201 [...]... IG-9) 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–21 14 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 15 CHECK FOR ENGINE OIL LEAKAGE 16 INSTALL CYLINDER HEAD COVER NO 2 (See page IG-10) 17 INSTALL ENGINE UNDER COVER RH EM EM–22 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN TIMING CHAIN 1NZ-FE ENGINEENGINE MECHANICAL COMPONENTS EM 5.0 (51, 44 in.*lbf) ENGINE UNDER COVER... Specified torque A115143E01 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–23 7.0 (71, 62 in.*lbf) CYLINDER HEAD COVER NO 2 7.0 (71, 62 in.*lbf) EM N*m (kgf*cm, ft.*lbf) : Specified torque A115136E01 EM–24 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM 19 (189, 14) 54 (551, 40) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A116199E01 EM–25 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN for Hatchback:... 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN CHAIN TENSIONER ASSEMBLY NO 1 9.0 (92, 80 in.*lbf) EM CHAIN SUB-ASSEMBLY CHAIN TENSIONER SLIPPER 9.0 (92, 80 in.*lbf) CHAIN VIBRATION DAMPER NO 1 N*m (kgf*cm, ft.*lbf) : Specified torque A116579E01 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–33 REMOVAL 1 DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2 REMOVE FRONT WHEEL RH 3 REMOVE ENGINE UNDER COVER RH 4 DRAIN ENGINE. .. 5.700(0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–17 EM A117458 EM–18 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Exhaust valve clearance (Cold): 0.25 to 0.35 mm (0.010 to 0.014 in.) EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and the measured... ASSEMBLY 45 (459, 33) 52 (530, 38) EM x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft.*lbf) : Specified torque A116193E06 EM–26 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN for Sedan: 11 (112, 8.1) FAN BELT ADJUSTING BAR 19 (189, 14) 54 (551, 40) 52 (530, 38) EM x2 GENERATOR ASSEMBLY 52 (530, 38) x3 9.8 (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38)... (100, 7.2) ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 52 (530, 38) N*m (kgf*cm, ft*lbf) : Specified torque A133594E01 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–27 9.0 (92, 80 in.*lbf) EM IGNITION COIL NO 1 N*m (kgf*cm, ft.*lbf) : Specified torque A115486E01 EM–28 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN 13 (133, 9.6) WIRE HARNESS BRACKET 10 (102, 7.0) SEAL WASHER EM x7 10 (102, 7.0) 10 (102, 7.0) 10... HOSE CYLINDER HEAD COVER GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A115504E01 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–29 EM GASKET 11 (112, 8.1) x2 x3 x3 15 (153, 11) WATER PUMP ASSEMBLY 11 (112, 8.1) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116194E01 EM–30 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN O-RING CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY EM 7.5 (76,... CONTROL VALVE ASSEMBLY EM 7.5 (76, 66 in.*lbf) 11 (112, 8.1) 19 (189, 14) FAN BELT ADJUSTING BAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116180E01 1NZ-FE ENGINE MECHANICAL – TIMING CHAIN EM–31 TRANSVERSE ENGINE ENGINE MOUNTING BRACKET 55 (561, 41) x4 EM 24 (245, 18) x2 32 (326, 24) 24 (245, 18) x11 11 (112, 8.1) OIL PUMP ASSEMBLY 7.5 (76, 66 in.*lbf) 11 (112, 8.1) CRANKSHAFT POSITION... EM EM–14 1NZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Valve clearance: Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (s) Select a new lifter with a thickness as close to the calculated values as possible HINT: Lifters are available in 35 sizes in increments of 0.020mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.) EM 1NZ-FE ENGINE MECHANICAL – VALVE... TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page LU-18) 20 REMOVE OIL PUMP ASSEMBLY (See page LU-19) 21 REMOVE OIL PUMP SEAL (See page LU-21) 22 REMOVE CHAIN TENSIONER ASSEMBLY NO 1 NOTICE: • Do not rotate the crankshaft with the chain tensioner removed • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first EM EM–34 1NZ-FE ENGINE MECHANICAL . 1NZ-FE ENGINE MECHANICAL – ENGINE EM–1 EM ENGINE ON-VEHICLE INSPECTION 1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page. 567 8 A082779E24 A116195 EM–4 1NZ-FE ENGINE MECHANICAL – ENGINE EM (4) If the cylinder compression is low, pour a light coat of engine oil into the cylinder through