Мануал по мурано 2003

SECTION EM

ENGINE MECHANICAL

CONTENTS

PRECAUTIONS

●Before starting work, make sure no fire or spark producing items are in the work area.

●Release fuel pressure before disassembly.

●After disconnecting pipes, plug openings to stop fuel leakage.

●When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.

● Exercise maximum care to avoid damage to mating or sliding surfaces.

● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. ● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

● When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precautions for Inspection, Repair and Replacement ABS004RM

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

●Use torque wrench to tighten bolts or nuts to specification.

●When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.

●Replace with new gasket, packing, oil seal or O-ring.

●Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.

●Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. K Before assembly, oil sliding surfaces well.

●Release air within route when refilling after draining engine coolant.

● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and L exhaust systems for leakage.

●Use an angle wrench for the final tightening of the following engine parts:

–Cylinder head bolts

–Main bearing cap bolts

–Connecting rod cap nuts

–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening)

●Do not use a torque value for final tightening.

●The torque value for these parts are for a preliminary step.

●Ensure thread and seat surfaces are clean and coated with engine oil.

NT014

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SEM706G

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

1.Locate the area where noise occurs.

2.Confirm the type of noise.

3.Specify the operating condition of engine.

4.Check specified noise source.

If necessary, repair or replace these parts.

Belt Deflection and Tension

*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at different location on the belt.

CAUTION:

●When belt is replaced with a new one, adjust it to value for “New belt” to accommodate for insufficient adaptability with pulley grooves.

DRIVE BELTS

●When deflection or tension of belt being used exceeds “Used belt limit”, adjust it to value for “After adjustment of used belt”.

●When checking belt deflection or tension immediately after installation, first adjust it to the specified value. Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys.

●When installing belt, make sure that it is correctly engaged with pulley groove.

●Keep oil and water away from belt.

●Do not twist or bend belt excessively.

ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT

1.Remove splash guard (RH).

2.Loosen idler pulley lock nut (A) and adjust tension by turning adjusting bolt (B).

●For specified belt tension, refer to EM-11, «Checking Drive Belts» .

3.Tighten lock nut (A).

: 30.4 — 39.2 N·m (3.1 — 3.9 kg-m, 23 — 28 ft-lb)

4.Tighten adjusting bolt (B).

: 3.9 — 6.9 N·m (0.4 — 0.7 kg-m, 35 — 61 in-lb)

PBIC1163E

POWER STEERING OIL PUMP BELT

1.Remove splash guard (RH).

2.Loosen adjusting bolt (C).

3.Loosen power steering oil pump mounting bolt (D).

●Bolt head (D) is engine rear side.

4.Adjust by turning adjusting bolt (E).

●For specified belt tension, refer to EM-11, «Checking Drive Belts» .

NOTE:

Adjusting bolt (E) is loosened with counter-clockwise rotation.

5.Tighten bolt (C), then bolt (D).

Tightening torque:

Bolt (C) : 24.5 — 31.4 N·m (2.5 — 3.2 kg-m, 18 — 23 ft-lb)

Bolt (D) : 36.3 — 50.0 N·m (3.7 — 5.1 kg-m, 27 — 36 ft-lb)

REMOVAL

1.Remove splash guard (RH).

2.Fully loosen each belt by following the guidelines in EM-11, «Tension Adjustment» . Remove alternator and air conditioner compressor belt and then power steering oil pump belt.

CAUTION:

Grease is applied to idler pulley adjusting bolt. Be careful to keep grease away from the belt.

DRIVE BELTS

INSTALLATION

D

E

F

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L

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AIR CLEANER AND AIR DUCT

AIR CLEANER AND AIR DUCT

Removal and Installation

REMOVAL

1.Remove RH and LH both side radiator cover grills.

2.Remove air duct (inlet).

3.Disconnect harness connector from the mass air flow sensor.

4.Disconnect the tube clamp at the electric throttle control actuator and at the mass air flow sensor.

5.Remove PCV hose, air cleaner case (upper) with the mass air flow sensor attached.

6.Remove mass air flow sensor from air cleaner case (upper), as necessary.

CAUTION:

Handle mass air flow sensor with care.

●Do not shock it.

●Do not disassemble it.

●Do not touch its sensor.

7.Remove resonator in the fender, lifting left fender protector, as necessary.

AIR CLEANER AND AIR DUCT

INSTALLATION

Installation is in the reverse order of removal. A

CHANGING AIR CLEANER FILTER

1. Unhook the air cleaner case (lower) side clips and lift up the air cleaner case (upper).

EM

2. Remove the air cleaner filter.

C

D

E

PBIC1165E

F

G

H

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L

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INTAKE MANIFOLD COLLECTOR

INTAKE MANIFOLD COLLECTOR

Removal and Installation

REMOVAL

WARNING:

To avoid the danger of being scalded, never drain the coolant when the engine is hot.

1.Remove engine cover.

2.Drain engine coolant, or when water hose is disconnected, attach plug to prevent engine coolant leakage. Refer to CO-8, «Changing Engine Coolant» .

CAUTION:

Perform when engine is cold.

3.Remove air duct. Refer to EM-14, «AIR CLEANER AND AIR DUCT» .

PBIC1167E

4.Remove electric throttle control actuator.

● Loosen bolts in the reverse order of that shown in the figure.

CAUTION:

●Handle carefully to avoid any shock to the electric throttle control actuator.

●Do not disassemble.

SEM711G

5.Disconnect vacuum hose and water hose from intake manifold collector (upper and lower).

6.Disconnect EVAP canister purge volume control solenoid valve mounting bolt from intake manifold collec-

7.Remove VIAS control solenoid valve and vacuum tank.

8.Remove the RH windshield wiper arm and RH front cowl top cover. Refer to EI-21, «COWL TOP» .

9.Disconnect the power steering hose bracket.

10.Remove intake manifold collector support bracket.

11.Remove PCV hose [between intake manifold collector (upper) and RH rocker cover].

12.Loosen bolts in reverse order of illustration with power tool, and remove intake manifold collector (upper and lower) assembly with power tool.

SEM713G

INTAKE MANIFOLD COLLECTOR

13.Loosen bolts in reverse order of illustration to remove intake manifold collector (upper) with power tool.

SEM712G

14. Remove power valve in reverse order of illustration.

SEM714G

INSPECTION AFTER REMOVAL

Surface Distortion

●Using straightedge and feeler gauge, inspect the surface distortion of intake manifold collector (lower).

Limit : 0.1 mm (0.004 in)

●If it exceeds the limit, replace the intake manifold collector.

PBIC1168E

INSTALLATION

●Install in the reverse order of removal paying attention to the following.

Installation of Power Valve

●Tighten in numerical order as shown in the figure.

: 17.6 — 21.6 N·m (1.8 — 2.2 kg-m, 13 — 15 ft-lb)

SEM714G

Installation of Intake Manifold Collector (Upper)

●Tighten in numerical order as shown in the figure.

: 17.6 — 21.6 N·m (1.8 — 2.2 kg-m, 13 — 15 ft-lb)

Installation of Intake Manifold Collector (Lower)

●Tighten in numerical order as shown in the figure.

: 17.6 — 21.6 N·m (1.8 — 2.2 kg-m, 13 — 15 ft-lb)

NOTE:

Tighten mounting bolts to secure gasket (lower), intake manifold collector (lower), gasket (upper).

Installation of Electric Throttle Control Actuator

●Install gasket with three protrusions for installation check facing any direction other than upward or down-

●Tighten in numerical order as shown in the figure.

●Perform the “Throttle Valve Closed Position Learning” when harness connector of the electric throttle control actuator is discon-

●Perform the “Idle Air Volume Learning” and “Throttle Valve

INTAKE MANIFOLD

INTAKE MANIFOLD

Removal and Installation

PBIC1169E

REMOVAL

1.Release fuel pressure. Refer to EC-66, «FUEL PRESSURE RELEASE» .

2.Remove intake manifold collector (upper and lower). Refer to EM-16, «INTAKE MANIFOLD COLLECTOR»

.

3.Remove fuel tube and fuel injector assembly. Refer to EM-38, «FUEL INJECTOR AND FUEL TUBE»

4.Loosen bolts and nuts in reverse order of illustration to remove intake manifold assembly with power tool.

PBIC0778E

INSPECTION AFTER REMOVAL

Surface Distortion

●Using straightedge and feeler gauge, inspect the surface distortion of each surface on intake manifold.

Limit : 0.1 mm (0.04 in)

●If it exceeds the limit, replace the intake manifold.

PBIC0870E

EXHAUST MANIFOLD AND THREE WAY CATALYST

Removal and Installation

REMOVAL

WARNING:

●Perform the work when the exhaust and cooling system have completely cooled down.

●When removing the engine mounting through bolts and nuts, lift the engine up slightly for safety with a transmission jack. Refer to EM-95, «ENGINE ASSEMBLY» .

1.Remove the exhaust front tube. Refer to EX-3, «Removal and Installation» .

2.Remove rear engine mount insulator (2WD models) (when RH exhaust manifold and three way catalyst is removed). Refer to EM-95, «ENGINE ASSEMBLY» .

3.Remove the RH windshield wiper arm and RH front cowl top cover (when RH exhaust manifold and three way catalyst is removed). Refer to EI-21, «COWL TOP» .

EXHAUST MANIFOLD AND THREE WAY CATALYST

INSPECTION AFTER REMOVAL

Surface Distortion

●Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces.

Limit : 0.3 mm (0.012 in)

●If it exceeds the limit, replace the exhaust manifold.

PBIC1173E

INSTALLATION

Installation is in the reverse order of removal paying attention to the following.

CAUTION:

●When using the heated oxygen sensor wrench [special service tool: KV10117200 (J38365)], tighten to the middle of specified torque range, because the length of the tool may increase the actual tightness. Do not tighten to the maximum specified torque range.

●Before installing a heated oxygen sensor, clean the threads on the exhaust manifold using the oxygen sensor thread cleaner tool (commercial service tool), and apply anti-seize lubricant.

●Do not over-torque the heated oxygen sensors. Doing so may cause damage to the heated oxygen sensors.

Exhaust Manifold

●Install the exhaust manifold nuts in the numerical order as shown.

PBIC1171E

PBIC1172E

EXHAUST MANIFOLD AND THREE WAY CATALYST

Three Way Catalyst Supports

: 19 — 25 N·m (2.0 — 2.5 kg-m, 14 — 18 ft-lb)

EM

C

D

PBIC1174E

E

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OIL PAN AND OIL STRAINER

OIL PAN AND OIL STRAINER

Removal and Installation

PBIC1175E

REMOVAL

2WD Model

WARNING:

Do not remove the oil pan until the exhaust system and cooling system have completely cooled off.

CAUTION:

When removing the upper oil pan from the engine, first remove the crankshaft position sensor (POS). Be careful not to damage sensor edges or signal plate teeth.

1.Remove splash guard (RH).

2.Remove the front RH road wheel and tire with power tool.

3.Drain engine oil. Refer to LU-8, «Changing Engine Oil» .

4.Drain engine coolant. Refer to CO-8, «Changing Engine Coolant» .

CAUTION:

●Perform when engine is cold.

●Do not spill engine coolant on the drive belts.

5.Remove oil filter. Refer to LU-9, «OIL FILTER» .

CAUTION:

Do not spill engine oil on the drive belts.

OIL PAN AND OIL STRAINER

CAUTION:

●Handle carefully to avoid dropping and shocks.

●Do not disassemble.

●Do not allow metal powder to adhere to magnetic part at sensor tip.

●Do not place sensors in a location where they are exposed to magnetism.

17.Remove the four engine-to-transaxle bolts.

SEM949G

18.Remove upper oil pan.

● Loosen bolts in reverse order as shown with power tool.

PBIC1636E

19.Insert an appropriate size tool into the notch of the upper oil pan as shown (1).

Pry off the upper oil pan by moving the tool up and down as shown (2).

SEM155F

20.Remove O-rings from the bottom of the cylinder block and oil pump body.

PBIC1144E

3.Install oil pan drain plug.

● Refer to illustration of components of former page for installation direction of washer.

4.Install in the reverse order of removal after this step.

At least 30 minutes after oil pan is installed, pour engine oil.

OIL PAN AND OIL STRAINER

INSPECTION AFTER INSTALLATION

●Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required quantity, fill to the specified level.

●Use procedure below to check for fuel leakage.

–Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.

–Start engine. With engine speed increased, check again for fuel leakage at connection points.

●Run engine to check for unusual noise and vibration.

●Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil and working fluid, fuel and exhaust gas.

●Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.

●After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.

1.Remove the engine cover. Refer to EM-16, «INTAKE MANIFOLD COLLECTOR» .

2.Disconnect the mass air flow sensor electrical connector and remove the air cleaner and air duct assem-

3.Remove the RH windshield wiper arm and the RH front cowl top cover. Refer to EI-21, «COWL TOP» .

4.Remove the intake manifold collector (upper and lower), gasket, and electric throttle control actuator.

L

M

SPARK PLUG (PLATINUM-TIPPED TYPE)

Removal and Installation

REMOVAL

1.Remove engine cover. Refer to EM-16, «INTAKE MANIFOLD COLLECTOR» .

2.Remove ignition coil. Refer to EM-35, «IGNITION COIL» .

3.Remove spark plug using spark plug wrench (commercial service tool).

SEM294A

INSPECTION AFTER REMOVAL

●Use standard type spark plug for normal condition.

The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as:

●Frequent engine starts

●Low ambient temperatures

The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug under conditions such as:

●Extended highway driving

●Frequent high engine revolution

CAUTION:

●Do not drop or shock spark plug.

●Do not use a wire brush for cleaning.

●If plug tip is covered with carbon, spark plug cleaner may be used.

Cleaner air pressure:

Less than 588 kPa (6 kg/cm2 , 85 psi)

Cleaning time:

Less than 20 seconds

SMA773C

SPARK PLUG (PLATINUM-TIPPED TYPE)

●Checking and adjusting plug gap is not required between

INSTALLATION

●Install in the reverse order of removal.

CAUTION:

Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL

WARNING:

To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.

1.Remove the engine cover. Refer to EM-16, «INTAKE MANIFOLD COLLECTOR» .

2.Release the fuel pressure. Refer to EC-66, «FUEL PRESSURE RELEASE» .

3.Remove the RH windshield wiper arm and the RH cowl top cover. Refer toEI-21, «Removal and Installation» .

4.Remove radiator cover grille, air duct (inlet), air cleaner case, air duct assembly and mass air flow sensor. Refer to EM-14, «AIR CLEANER AND AIR DUCT» .

5.Disconnect electric throttle control actuator and engine coolant hoses.

CAUTION:

Handle carefully to avoid any shock to the electric throttle control actuator.

6.Disconnect vacuum hose, fuel injectors electrical connectors, and PCV hose.

CAUTION:

Cover any engine openings to avoid the entry of any foreign material.

7.Remove the vacuum tank from intake manifold collector (lower).

8.Disconnect the power steering hose bracket.

FUEL INJECTOR AND FUEL TUBE

9.Remove the intake manifold collector (upper and lower). Refer to EM-16, «INTAKE MANIFOLD COLLEC-

●While hoses are disconnected, plug them to prevent fuel from draining.

●Do not separate fuel damper and fuel feed hose.

11. Disconnect fuel feed hose (with damper) quick connector at vehicle piping side. When separating fuel C feed hose and centralized under-floor piping connection, disconnect quick connector with the following procedure.

a.Remove quick connector cap from quick connector.

b.Disconnect quick connector from centralized under-floor piping as follows:

CAUTION:

Disconnect quick connector by using quick connector release (special service tool: J-45488), not by picking out retainer tabs.

i.With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.

ii.Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position.

CAUTION:

Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.

iii.Draw and pull out quick connector straight from centralized under-floor piping.

●Do not pull with lateral force applied. O-ring inside quick connector may be damaged.

●Prepare container and cloth beforehand as fuel will leak out.

●Avoid fire and sparks.

●Keep parts away from heat source. Especially, be careful when welding is performed around them.

●Do not expose parts to battery electrolyte or other acids.

●Do not bend or twist connection between quick connector and fuel hose (with damper) during installation/removal.