RM38N0EC _51 Engine / Hybrid System _111786 M20C-FKS, M20D-FKS ENGINE MECHANICAL _0499716 ENGINE G

M20C-FKS, M20D-FKS ENGINE MECHANICAL ENGINE ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:: ·

When working near the engine room while the engine has started or the ignition switch ON, do not touch the V-ribbed belt or rotating components such as the fan, etc.

·

Touching the V-ribbed belt or rotating components such as the fan, etc. could result in your hand or clothing getting caught and pulled in.

NOTICE:: This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.; Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY,

PROCEDURE

Hide Display 1.INSPECT ENGINE COOLANT

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0022,

Hide Display 2.INSPECT ENGINE OIL

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0023,

Hide Display 3.INSPECT BATTERY CONDITION

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0024,

Hide Display 19100P 4.INSPECT SPARK PLUG

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0025,

Hide Display 17801 5.INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click hereGeneral>MAINTENANCE>M20D-FKS AIR CLEANER FILTER ELEMENT>REMOVAL202111,999999,_V1,_112220,_0504043,RM100000001ZGXV_02_0003,

Hide Display 16361A 6.INSPECT V-RIBBED BELT

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>DRIVE BELT>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499717,RM100000001YZI2_01_0001,

Hide Display 16620D 7.INSPECT V-RIBBED BELT TENSIONER ASSEMBLY

Remove the V-ribbed belt.

Click hereGeneral>MAINTENANCE>M20D-FKS AIR CLEANER FILTER ELEMENT>REMOVAL202111,999999,_V1,_112220,_0504043,RM100000001ZGXV,

Turn the V-ribbed belt tensioner assembly clockwise and counterclockwise and check that it turns smoothly and does not catch.

HINT:: If the V-ribbed belt tensioner assembly does not turn smoothly or catches, replace the V-ribbed belt tensioner assembly.

Install the V-ribbed belt.

Click hereGeneral>MAINTENANCE>M20D-FKS AIR CLEANER FILTER ELEMENT>INSTALLATION202111,999999,_V1,_112220,_0504043,RM100000001ZGXW,

Hide Display 13750 8.INSPECT VALVE LASH ADJUSTER ASSEMBLY NOISE

Rev up the engine several times. Check that the engine does not emit unusual noises.

If tappet noise is heard, perform the following procedure.

Idle the engine for at least 10 minutes and then stop the engine.

ii.

Remove the fuel (engine room side) pump assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL PUMP (for High Pressure)>REMOVAL202111,202203,_51,_111793,_0504182,RM100000001ZHEB,202203,202303,_51,_111793,_0504182,RM1000000022KC5,202303,202406,_51,_111793,_0504182,RM100000002AK25,202406,999999,_51,_111793,_0504182,RM100000002MUMD,

iii.

Remove the ignition coil assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>IGNITION COIL AND SPARK PLUG>REMOVAL202111,999999,_51,_111785,_0503276,RM100000001ZE1Y,

iv.

Remove the camshaft position sensor (for Intake Side).

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>CAMSHAFT POSITION SENSOR>REMOVAL202111,999999,_51,_111785,_0503274,RM100000001ZE1T_02_0008,

Remove the camshaft position sensor (for Exhaust Side).

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>CAMSHAFT POSITION SENSOR>REMOVAL202111,999999,_51,_111785,_0503274,RM100000001ZE1T_02_0005,

vi.

Disconnect the air fuel ratio sensor connector.

vii.

Disengage the 3 clamps.

viii.

Remove the cylinder head cover sub-assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE UNIT>DISASSEMBLY202111,202303,_51,_111786,_0499723,RM100000001YZIL_01_0048,202303,999999,_51,_111786,_0499723,RM100000002B6T6_01_0048,

ix.

0.948,0.292 1.073,0.292 1.073,0.292 1.469,0.438 false 2.563,1.292 2.771,1.292 false 0.823,0.813 1.031,0.813 false 2.51,0.604 2.719,0.604 false 0.771,0.24 1.083,0.438 0.313,0.198 10 false *1 2.802,1.177 3.115,1.375 0.313,0.198 10 false *2 0.646,0.75 0.958,0.948 0.313,0.198 10 false *3 2.75,0.521 3.063,0.719 0.313,0.198 10 false *a

*1	No. 1 Valve Rocker Arm Sub-assembly
*2	Valve Lash Adjuster Assembly
*3	Valve Stem Cap
*a	Pivot
	Push

Push the pivot of the No. 1 valve rocker arm sub-assembly.

OK:: The plunger is very difficult to move.

If the plunger is easy to move, replace the valve lash adjuster assembly.

xi.

Install the cylinder head cover sub-assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE UNIT>REASSEMBLY202111,202303,_51,_111786,_0499723,RM100000001YZIM_01_0020,202303,999999,_51,_111786,_0499723,RM100000002B6TA_01_0020,

xii.

Engage the 3 clamps.

xiii.

Connect the air fuel ratio sensor connector.

xiv.

Connect the camshaft position sensor (for Exhaust Side) connector.

xv.

Connect the camshaft position sensor (for Intake Side) connector.

xvi.

Install the ignition coil assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>IGNITION COIL AND SPARK PLUG>INSTALLATION202111,999999,_51,_111785,_0503276,RM100000001ZE1Z,

xvii.

Install the fuel (engine room side) pump assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL PUMP (for High Pressure)>INSTALLATION202111,202303,_51,_111793,_0504182,RM100000001ZHEA,202303,999999,_51,_111793,_0504182,RM100000002AK29,

Hide Display 9.INSPECT IGNITION TIMING

NOTICE:: ·

Check the ignition timing with the cooling fan off.

·

Turn off all electrical systems and the A/C.

·

When checking the ignition timing, the transaxle should be in neutral or park.

Start the engine and warm it up.

Read the value displayed on the GTS.

Powertrain > Engine > Data List

Tester Display
Ignition Timing Cylinder #1

50003 372 213

Standard Ignition Timing:: 0 to 15° BTDC at idle

Check that the ignition timing advances immediately when the engine speed is increased.

Read the value displayed on the GTS.

Powertrain > Engine > Active Test

Active Test Display
Activate the TC Terminal

Data List Display
Ignition Timing Cylinder #1

50004 372 22 213

Standard Ignition Timing:: 8 to 12° BTDC at idle

Hide Display 10.INSPECT ENGINE IDLE SPEED

NOTICE:: ·

Check the engine idle speed with the cooling fan off.

·

Turn off all electrical systems and the A/C.

·

When checking the engine idle speed, the transaxle should be in neutral or park.

Start the engine and warm it up.

Read the value displayed on the GTS.

Powertrain > Engine > Data List

Tester Display
Engine Speed

50003 372 211

Standard Idle Speed:: 750 to 850 rpm

Hide Display 11.INSPECT COMPRESSION

NOTICE:: Keep the spark plug holes free of foreign matter when measuring the compression pressure.

Warm up and stop the engine.

Check for DTCs.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR202111,202303,_51,_111785,_0504416,RM100000001ZNYW,202303,999999,_51,_111785,_0504416,RM1000000029K26,

Remove the 4 spark plugs.

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS SPARK PLUG>REMOVAL202111,999999,_V1,_112220,_0503246,RM100000001ZDYI,

Disconnect the fuel injector connector (for Port Injection).

Remove the front fender front splash shield LH.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL202111,202203,_51,_111786,_0499722,RM100000001YZIH_01_0304,202203,202303,_51,_111786,_0499722,RM1000000022F78_01_0304,202303,202406,_51,_111786,_0499722,RM100000002A0JY_01_0304,202406,202409,_51,_111786,_0499722,RM100000002MXOE_01_0304,202409,999999,_51,_111786,_0499722,RM100000002OLFC_01_0304,

Remove the front fender front splash shield RH.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL202111,202203,_51,_111786,_0499722,RM100000001YZIH_01_0303,202203,202303,_51,_111786,_0499722,RM1000000022F78_01_0303,202303,202406,_51,_111786,_0499722,RM100000002A0JY_01_0303,202406,202409,_51,_111786,_0499722,RM100000002MXOE_01_0303,202409,999999,_51,_111786,_0499722,RM100000002OLFC_01_0303,

Remove the No. 1 engine under cover.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL202111,202203,_51,_111786,_0499722,RM100000001YZIH_01_0003,202203,202303,_51,_111786,_0499722,RM1000000022F78_01_0003,202303,202406,_51,_111786,_0499722,RM100000002A0JY_01_0003,202406,202409,_51,_111786,_0499722,RM100000002MXOE_01_0003,202409,999999,_51,_111786,_0499722,RM100000002OLFC_01_0003,

0.458,0.542 0.5,0.219 0.5,0.219 0.708,0.219 false 0.74,0.104 1.052,0.26 0.313,0.156 10 false *a

*a	Lock Lever

Disengage the claw and raise the lock lever to disconnect the fuel injector connector (for Direct Injection) as shown in the illustration.

Remove the inlet air cleaner assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202111,999999,_51,_111785,_0503267,RM100000001ZE11_01_0028,

Remove the air cleaner assembly with air cleaner hose.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202111,999999,_51,_111785,_0503267,RM100000001ZE11_01_0027,

Using an 8 mm socket wrench, remove the 3 bolts to separate the throttle body with motor assembly from the intake manifold.

Remove the throttle body gasket.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202111,999999,_51,_111785,_0503267,RM100000001ZE11_01_0026,

Check the cylinder compression pressure.

Insert a compression gauge into the spark plug hole.

ii.

While cranking the engine, measure the compression pressure.

Standard Compression Pressure:: 1400 kPa (14.3 kgf/cm², 203 psi)

Minimum Compression Pressure:: 1200 kPa (12.2 kgf/cm², 174 psi)

Pressure Difference between Each Cylinder:: 200 kPa (2.0 kgf/cm², 29 psi) or less

NOTICE:: ·

Always use a fully charged battery to obtain an engine speed of 250 rpm or more.

·

Measure the compression pressure as quickly as possible.

iii.

If the cylinder compression pressure is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect it again.

HINT:: ·

If adding engine oil increases the compression pressure, the piston rings and/or cylinder bore may be worn or damaged.

·

If the compression pressure stays low, a valve may be stuck or seated improperly, or there may be leaks in the cylinder head gasket.

Install the throttle body gasket.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0033,

Using an 8 mm socket wrench, install the throttle body with motor assembly to the intake manifold with the 3 bolts.

Torque:: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the air cleaner assembly with air cleaner hose.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0037,

Install the inlet air cleaner assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0036,

2.24,0.531 2.396,0.208 2.396,0.208 2.615,0.208 false 2.656,0.115 2.969,0.271 0.313,0.156 10 false *a

*a	Lock Lever

Connect the fuel injector connector (for Direct Injection) and push down the lock lever to engage the claw as shown in the illustration.

Install the No. 1 engine under cover.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202111,202203,_51,_111786,_0499722,RM100000001YZIF_01_0293,202203,202303,_51,_111786,_0499722,RM1000000022F79_01_0293,202303,202406,_51,_111786,_0499722,RM100000002A0JZ_01_0293,202406,202409,_51,_111786,_0499722,RM100000002MXOU_01_0293,202409,999999,_51,_111786,_0499722,RM100000002OLFD_01_0293,

Install the front fender front splash shield LH.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202111,202203,_51,_111786,_0499722,RM100000001YZIF_01_0350,202203,202303,_51,_111786,_0499722,RM1000000022F79_01_0350,202303,202406,_51,_111786,_0499722,RM100000002A0JZ_01_0350,202406,202409,_51,_111786,_0499722,RM100000002MXOU_01_0350,202409,999999,_51,_111786,_0499722,RM100000002OLFD_01_0350,

Install the front fender front splash shield RH.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202111,202203,_51,_111786,_0499722,RM100000001YZIF_01_0349,202203,202303,_51,_111786,_0499722,RM1000000022F79_01_0349,202303,202406,_51,_111786,_0499722,RM100000002A0JZ_01_0349,202406,202409,_51,_111786,_0499722,RM100000002MXOU_01_0349,202409,999999,_51,_111786,_0499722,RM100000002OLFD_01_0349,

Connect the fuel injector connector (for Port Injection).

Install the 4 spark plugs.

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS SPARK PLUG>INSTALLATION202111,999999,_V1,_112220,_0503246,RM100000001ZDYJ,

Clear the DTCs.

Powertrain > Engine > Trouble Codes: 50001 372

NOTICE:: After the inspection, clear the DTCs, check for DTCs again and make sure the normal system code is output.

Hide Display 12.INSPECT CO/HC

HINT:: This check determines whether or not the idle CO/HC complies with regulations.

Start the engine.

Run the engine at 2500 rpm for approximately 180 seconds.

Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idle.

Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

HINT:: When performing a 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.; If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below.

Check for DTCs.

Powertrain > Engine > Trouble Codes: 50001 372

ii.

See the following table for possible causes, then inspect the applicable parts and repair them if necessary.

CO	HC	Problem	Cause
Normal	High	Rough idle	1. Faulty ignition: - Incorrect valve timing - Fouled, shorted or improperly gapped spark plugs 2. Incorrect valve clearance (valve lash adjuster assembly) 3. Leaks in intake or exhaust valves 4. Leaks in cylinders 5. Faulty EGR
Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks: - PCV hoses - Intake manifold - Throttle body with motor assembly 2. Lean mixture causing misfire 3. Faulty EGR
High	High	Rough idle (Black smoke from exhaust)	1. Restricted air cleaner filter element sub-assembly 2. Plugged PCV valve 3. Faulty SFI systems: - Fuel pressure regulator assembly - Engine coolant temperature sensor - Mass air flow meter - ECM - Fuel injector assemblies - Throttle position sensor (built into throttle body with motor assembly) 4. Faulty EGR