J M O O B 1 0 3 t0 0
Mazda 121
CONTENTS Tirle
Workshop Manual Vofume 1 of 2 FOREWORD This workshopmanualis intendedfor use bv service technicians of AuthorizedMazda D-ealers to help them serviceMazdavehicles. It can also be uselulto ownersand operators of Mazda vehicles in diagnosing some problemsand performinglimitedrepairand maintenanceon Mazda vehicles.
Generallnformation Pre-DeliveryInspection and Scheduled MaintenanceService Engine Lubrication System Cooling System C,onttol SystemI EGI-S FuelandEmission Engine ElectricalSystem Clutch ManualTransaxle Automatic Transaxle Front and Rear Axles
For proper repair and maintenance,a withthismanualis imthoroughlamiliarization portant,and it shouldalwaysbe kept in a handy placefor quick and easy reterence. All the contentsof this manual,including arethe latestavaildrawingsand specifications, able at the time of printing. As modifications affectingrepairor maintenanceoccur,relevant to thisvolumewill informationsupplementary Mazda Authorized at be made available Dealers.This manual should be kept upto-date.
Steering System
Mazda Motor Corporationreservesthe right to alterthe specificationsand contentsof this manualwithoutobligationor advancenotice. All rightsreserved.No part of this book may be reproduced or used in any form or by any means,electronicor mechanical-including photocopying and recording and the use of any kind oJ informationstorage and retrieval system-without permissionin writing.
TechnicalData
Mazda Motor Corporation HIROSHIMA.JAPAN APPLICATION: Thismanualis applicableto vehiclesbeginning with the Vehicle ldentificationNumbers (VlN) shown on the following page.
Secti
Braking Syslem Wheels and Tires Suspension Body Body Electrical System Heater and Aar Conditioner Systems
Special Tools
wiringDiasram Sili:.|Tj|:'"''""'0"'' The section Z is published separatelrom this manual.
o 1990MazdaMotorCorporation ocT. '90 @) 1249-10-90J
(VlN) NUMBERS vEHlcLE IDENTIFICATION JMo D8103100 100001
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GENERALINFORMATION Gl- 2 TMPORTANT TNFORMATION ..................... BAS|CASSUMPT|ONS............................ Gl- 2 ... Gl- 2 sAFEryH1SK............... LOSSOFWARRANry.....,,...... GI- 2 POSSIBLE WARNING ON LUBRICANTS ............. Gl- 2 ANDGREASES. Gt- 3 HOWTO USETH|SMANUAL.................... PREPARATTON ................ Gl- 3 PROCEDURE............................. Gl- 3 REpAtR ............... Gl- 4 SYMBOLS........ GI4 NOTES. AND WARNINGS....... CAUTIONS. FUNDAMENTAL PROCEDURES................. GI- 4 ..,........... GI- 4 PROTECTION OFTHEVEHICLE Gl- 5 A WORDABOUTSAFETY....................... PREPARATION OFTOOLS EQUIPMENT............. GI_ 5 ANDMEASURING .. Gl- 5 SPEC|AL TOO1S............ Gl- s REMOVAL OF PARTS............................. ................ Gl- 5 DTSASSEMBLY REASSEMBLY ................. GI- 6 ..,....,..,,... GI- 7 ADJUSTMENTS ANDTUBING.............,.. GI_ 7 RUBBER PARTS GI- 8 JACKAND SAFETYSTANDPOSITIONS.... TYPE) VEHICLELIFT(2.SUPPORT postTtoNs..... ................. Gl- I ................... Gl- 9 TOW|NG......... NUMBERLOCATIONS.,... GI-10 IDENTIFICATION . . . . . . . . . . . . . . .G. .l .- l 0 uNtTs............. ..................................... Gl-l0 ABBREVTATTONS .... Gl-ll CAUT|ON INSTALLATION OFA MOBILE FAD|OSYSTEM.................... Gl-l1 TWO-WAY KEYON REMOVAL OF IGNITION TRANSAXLE MODE1.......... GI-11 AUTOMATIC TOOLSGI-12 ELECTRICAL TROUBLESHOOTING PARTS........ WITHELECTRICAL GI-13 CAUTION 03uGtx-001
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IMPORTANTINFORMATION
IMPORTANTINFORMATION BASICASSUMPTIONS for the safeandetfiThisworkshopmanualassumesthatyou havecertainspecialtoolsthatarenecessary on Mazdavehiclesandthatyou knowhowto usethemproperly. cientperlormance of serviceoperations You systemsandbasicserviceand repairprocedures. It alsoassumes thatyouarefamiliarwithautomobile you and understand the conseare correcl shouldnotattemptto usethismanualunlesstheseassumptions quencesdescribed below. SAFETYRISK thatyoushouldcarefully information Thismanualcontainscertainnotes,warnings,andotherprecautionary readand iollowto reducethe riskof personalinjuryto yourselfor othersandthe riskof improperservice in regardto anyspectfic thatmay damagethe vehicleor renderit unsafe.lf thereis no suchinformation that personalsafetyor vehiclesafetywill be servicemethod,this does not meanthereis no possibility jeopardized by the use oJincorrectmethodsor tools. POSSIBLELOSSOF WARRANTY Themanufacturer's warrantyon Mazdavehiclesand enginescan be voidedif improperserviceor repairs performed persons by otherthan thoseat an AuthorizedMazdaDealer. are AND GREASES WARNING ON LUBRICANTS Avoidall prolongedand repeatedcontactwith mineraloils,especiallyusedoils.Usedoilscontaminated including effects, (e.g.,enginesumpoils)aremoreirritating andmorelikelyto causeserious duringservice skincancer,in the eventof grossand prolongedskincontact. Washskinthoroughlyafterwork involvingoil. handcleanersmaybe of valueprovidedtheycan be removedfromthe skinwithwater.Do not Protective paraffin,or othersolventslo removeoil fromthe skin. gasoline, use Lubricants and greasesmay be slightlyirritatingto the eyes. Particuclothingif necessary. Bepeated or prolongedskincontactshouldbe avoidedby wearingprotective lead.Do notallowworkclothingto be conlarcareshouldbe takenwithusedoilsand greasescontaining taminatedwithoil. Dry cleanor laundersuchclothingat regularintervals. sMuGrx_oo
Gl-z
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HOWTO USETHISMANUAL
HOWTO USETHISMANUAL matit pro-E operation service Tool(ssT)fortheservice F[rtFf#rtifiirointsouttheneeded speciat
ceeds.Gatherall necessarySST beforebeginningwork. Example: MANUALSTEERING PREPARATION
SST NUMBER
ssT
49 0118850C Pullef,balljoinl
SST NAME
SST ILLUSTRATION 03uGtx-@6
REPAIBPROCEDURE lt identifies the components, showshowthe 1. Mostrepairoperations beginwithan overviewillustration. partsfit together,and visualpartslnspections. lf a damagedor wornpart is found,repairor replaceit as necessary. parts,tightening andsealant areshownin theoverview torques, andsymbols foroil,grease, 2. Expendable illustration. whenserBeferto thisinformation 3. Pagesrelatedto serviceproceduresareshownunderthe illustration. part. vicingthe related Example:
SHOWS TIGHTENING TOROUE UNIT
sHows
RELATED PAGEFOR SERVICE
"1:
17 Spacer 18 Drive pinion page M-2'l Bemoval rpecl splines and leelh fot weat or damage
9MUGIX.O34
(ex.@)showsserviceprocedure. Thenumbering specified. Unitsshownin Nm (m-kg,ftJb)unlessotherwise
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PROCEDURES HOWTO USE THIS MANUAL/FUNDAMENTAL
SYMBOLS Thesesymbolsshowthe pointsof applyingsuch if,er" uresi* symbolsindicatingoil,grease,and sealant. service. during materials Kind
Meaning
Symbol
g
Apply oil
New engine oil or gear oil as appropriate
@
Apply brake fluid
Only brake fluid
E
Apply automatictransmissionfluid
OnlyATF
Applygrease
Appropriategrease
Apply sealant
Appropriatesealant
Apply petroleumjelly
AppropriatepetroleumjellY
€
(@[
e
osuctx005
Note . Whenspecial oil or grease is needed,this is shown in the illustration. AND WARNINGS NOTES,CAUTIONS, Each andWARNINGS. CAUTIONS, youwillcomeacrossNOTES, As you ieadthroughihe procedures, oneis thereforea ipecific purpose.NOTESgiveyou added informationthatwill helpyou to complete procedrire. GAUTIbNSaregivento pri:ventyoufrommakingan errorthatcoulddamagethe a particular cancausePer' carefulinthoseareaswherecarelessness remindyouto beespecially vdhicle.WARNINGS youworkon you when follow general should WARNINGS some lilt contains sonatiniury.Thefollowing a vehicle
olA.,x-oo2
PROCEDURES FUNDAMENTAL OF THEVEHICLE PROTECTION Alwaysbe sureto coverfenders,seats,and floorareasbefore startinowork.
Gt-4
9MUGIX.O37
PROCEDURES FUNDAMENTAL
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A WORDABOUTSAFETY mustbefollowedwhenjackingup Thefollowingprecautions the vehicle. 1. Blockthe wheels. jackingpositions. 2. Useonlythe specified 3. Supportthe vehiclewith safetystands. Starttheengineonlyaftermakingcertaintheenginecompartmentis clearof toolsand people. 9MUGtX-003
9[,{UGtX-038
47UOGX-005
47U0GX-006
SMUGIX,O39
OF TOOLSANDMEASURING PREPARATION EOUTPMENT are equipment toolsandmeasuring Besurethatallnecessary availablebeforestartingany work.
SPECIALTOOLS Use specialtoolswhen they are required.
REMOVAL OF PARTS Whilecorrectinga problem,try alsoto determineits cause. Beginworkonly afterfirstlearningwhichpartsand subassemb es mustbe removedand disassembledfor replacementor repair.
DISASSEMBLY procedureis complex,requiringmanyparts lf the disassembly in a way all partsshouldbe disassembled to be disassembled, that will not affecttheir performanceor externalappearance and identifiedso that reassemblycan be performedeasilyand efficiently.
Gr-5
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PROCEDURES FUNDAMENTAL 1. lnsoectlonof Parts for inspected partshouldbecarefully Whbnremoved,-each problems' other and damage, detormation, malfunctioning,
9MUGtX-040
9MUGIX.O41
2. Arrangementof Parts arrangedior reAlldisJssembled oartsshouldbecarefully assembly. Be sureio separateor otherwiseidentifythe partsto be reolacedfromthosethat will be reused
3. Cleaningparts tor reuse All oarts'iobe reusedshouldbe carefullyand thoroughly method. cleanedin the appropriate
REASSEMBLY Standardvalues,suchas torquesand certainad.iustments' of all parts' mustbe strictlvobservedin the reassembly TORQUE TIGHTENING NUT AND BOLT NEIEr tOSTNUONRD in themain torqueshotmentioned in SectionTDfortightening text. lf removed,thesepartsshouldbe replacedwithnewones: '1. Oil seals 2. Gaskets 4. Lockwashers 3. O-rings 6. Nylonnuts 5. Cotterpins 9MUGIX-OM
)ffi
9MUGIX{42
Gt-6
Dependingon location: 1. Sealantshouldbe appliedto gaskets. of parts' 2. Oil shouldbe appliedto the movingcomponents prescribed the at be applied giease should oilor 3. Specified locations(suchas oil seals)beforereassembly'
PROCEDURES FUNDAMENTAL
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ADJUSTMENTS gaugesand/ortesterswhenmakingadiustments. Usesuitable E
57UoGX-002
RUBBERPARTSANDTUBING or oilfromgettingon rubberpartsortubing. Preventgasoline
9MUGIX.OOs
Gt-7
TYPE)FosmoNs Gl ,oo ANDsAFEw srANDFosmoNsyvEHplEUFT(25UPP6RT
JACKAND SAFETYSTANDPOSITIONS FRONTEND Jack positioni At the frontcrossmember
Satetystand positions: Sidesills
REAREND Jack position: At the centerof the rearcrossmember
Safetystand positions: Sidesills
03uGlx'oog
TYPE)POSITIONS vEHlcLE LIFT (2-SUPPORT REAREND Frame Sidesills
FRONTEND Frame Sidesills
Gt-8
9ltlUGlX-010
TOWING
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TOWING
WHEEL DOLLIES
03uGlx002
is necessary to preventdamageto p Propertowingequipment the vehicle. to vehiclesin tow mustal Lawsand regulations applicable waysbe observed. shouldbe pulledwiththe As a generalrule,towedvehicles damageor other drivingwheels offtheground.lf excessive prevent withthedrivingwheels towingthevehicle conditions offthe ground.usewheeldollies. Witheitherautomaticor manualtransaxle: switchin the ACCposition: 1. Setthe ignition 2. Placethe selectorleveror shiftleverin N (Neutral); the parkingbrake. 3. Release Caution . Do not tow the vehiclebackwardwith drivingwheels on the ground.This may causeinternaldamageto the transaxles. . Do not usethe hookloops underlhe front and rear ol the vehicle tor towing purposes. These hook loops aredesignedONLYtor transporttie-down.It tie.down hook loops are used for towing, the front/rear bumperwill be damaged.
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NUMBER LocATroNs/uNtrs/ABBREVtATtoNS rDENTIFrcATroN
NUMBERLOCATIONS IDENTIFICATION VEHICLE IDENTIFICATIONNUMBER (VIN)
AUTOMATICTRANSAXLEiIODEL AND NUMBER
,'% r(g ' /tYl
.,,/Pk
ENGINEMODELAND NUMBER
UNITS N.m (m-kg or cm-kg, ......Torque ftlb or in-lb).. per minute rpm......... ... . ........Revolutions A . . . . . . . . . . . . . . . . . . . . . . . . .A. m p e r e ( s ) V . . . . . . . . . . . . . . . . . . . . . .V o l t ( s ) Ohm(s)(resistance) . ....... ........... o. . kPa (kg/cm2,psi)..... .. Pressure (usuallyPositive) Pressure mmHg(inHg).... (usuallYnegative) . . . . . .W . att W.......... .... liters (US qt, lmp qt) . . Volume mm (in) ...... ....... .. Length 89U0GX.006
ABBREVIATIONS Atterbottomdead center A / C . . . . . . . . . . . . . . . . . .. A i r c o n d i t i o n e r . ccessories A C C . . . . . . . . . . . . . . . . . . . .A Automatictransaxle ATX. ...... After top dead center ATDC ..... Automatrctransmrssion ATF fluid Bypassair control BAC......... Beforebottomdead BBDC... center BTDC... .... ...... ....Beforetop deadcenter Centralprocessingunit CPU........ ABDC.......
........Electronically-controlled automatictransmission . .n g i n ec o n t r oul n i t E C U. . . . . . . . . . . . .. . . . . . .E gasoline ... Electronic EGI . .............. injection E I L . . . . . . . . . . . . . . . . . . . .E l e c t r i c laol a d .. . Exhaust EX.. circuit Integrated lC........ ....... .. l G N .. . . . . . . . . . . . l g n i t i o n l N . . . . . . . . . . . . . . . . . . . . .I .n. t. a . .k. e . rmftent 1 N T . . . . . . . . . . . . . . . . . . . . .I .n. t. e ldle speedcontrol ISC ............. . .f.th a n d L H . . . . . . . . . . . . . . . . . . . .L. e M....................... tvlotor M I L . . . . . . . . . . . . . . . . . . . . .l .\ .r a l f u n c t i o n i n d i c a t o r lamp Manualtransaxle MTX.......... . Overdrive OD ....... O F F . . . . . . . . .... . . . . . . . . . .S. .w. .i t c ho f f . .i t c ho n O N . .. . . . . . . . . . . . . . . . . .S. .w Positivecrankcase PCV........ ventilatlon PRC.................. Pressureregulator control Powersteering . P/S.-.... .............. P / ! V . . . . . . . . . . . .......... . . . P o w e rw i n d o w . . i g h th a n d R H . . . .... . . . . . . . . .. . . . . . .R Specialservicetool SST.,... . . . t. a r t S T . . . . . ..... . . . . . . . . . . . S . .w . .i t c h S W . . . . . . . . . . . . . . . . .S TDC.......... ............ Top dead center EC-AT.........
03uGtx.004
Gt-l0
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CAUTION
CAUTION INSTALLATIONOF MOBILETWO.WAYRADIOSYSTEM typeis used,the EGIsystem improperly or if a high-powered lf a mobiletwo-wayradiosystemis installed and othersystemsmay be affected. Whenthe vehicleis to be equippedwitha mobiletwo-wayradio,observethe followlngprecaulions: pointlromcontrolunits. 1. lnstallthe antennaal theJarthest (at least30 cm [11.8in]). fromthecontrolunitharnesses feederas far as possible 2. lnstalltheantenna 3. Ensurethat the antennaand feederare properlyadjusted. mobiletwo-wayradiosystem. 4. Do not installa high-powered MOBILETWO.WAYRADIO
EGAT CONTFOL UNIT ENGINECONTROLUNIT
"'o'"*'*J Ll lZ'""-rRoLUN,r
r/rl
AT LEAST 30 cm (11.8 in)
FARTHESTPOINT
05uGlx'013
KEY ON AUTOMATIC REMOVAL OF IGNITION TRANSAXLEMODEL to turntheignitionkey Theselectorlevermustbe in P (PARK) position. to be off butthekey lf the switch seems to the OFF cannotbe removed,the switchmaystillbe in the ACCposilevermaynot be in P (PARK). Shiftthe tion,or the selector and turnthe ignitionkeyto the leverto P (PARK), selector Thekeyshouldnowbe lreefor removal. LOCKposition.
R N D
s L
03UGIX.OOs
Gl-11
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CAUTION TOOLS TROUBLESHOOTING ELECTRICAL Test Light as shownin thefigure,usesa 12Vbulb.The Thetest-light, two leadwiresshouldbe connectedto probes. Thetestlightis usedforsimplevoltagechecksandfor checkingfor shortcircuits. Caution . Whencheckingthe control unit, never use a bulb over 3,4W. 9MUGIX.O19
JumperWire Thelumperwireis usedtortestingby shortingacrossswitch and groundconnections. terminals Caution . Do not connecta iumperwirefromthe powersource line to a body ground; this may cause burning or other damage to harnesses or electronic com' ponents.
9MUGIXO2O
VOLTMETER
Voltmeter is usedto measureof circuitvoltage.A voltTheDCvoltmeter the meterwitha rangeof 15Vor moreis usedby connecting positive(+) probe(redleadwire)to the pointwherevoltage is to be mi;asuredand the negative(-) probe(blacklead wire)to a bodyground.
GFOUNO 9MUGIX.O21
DiagnosisConnector a jumholewhenconnecting theprobeintotheservice Insert per wireto the diagnosisconnector. Caution . Do not insert the jumper wire probe lnto the diag' nosis connectorterminal, which may damagethe terminal.
05uGtx-021
Ohmmeter two between theresistance isusedto measure Theohmmeter anddiagnooointsina circuitandalsoto checkforcontinuity sis of shortcircuits. Caution . Do not attemptto connectthe ohmmeterto any circuit to which voltage is applied;this may burn or otherwisedamagethe ohmmeter.
9MUGIX045
Gl-12
CAUTION
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PARTS CAUTIONWITHELECTRICAL Battery Cable parts, electrical connectors or replacing Beforedisconnecting disconnectthe negativebatterycable.
9MUGIX-022
connectors Removalof connector
conNever pull on the wiringharnesswhen disconnecting nectors.
9MUGIX.O23
9MUGIX.O24
9MUGIX-025
03uGtx,011
Connectorscan be removedby pressingor pullingthe lock leveras shown.
Lockingof connector makesureto listenfor a clickthat Whenlockingconnectors, locked. theyaresecurely willindicate
lnspection orto measure 1. Whena testerisusedto checkforcontinuity side. insertthetesterprobefromthewireharness voltage,
Gr-l3
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CAUTION fromtheconconnectors of waterproof 2. Checktheterminals from thewireharbe accessed cannot nectorside,asthey nessside. Caution . Use fine wire to prevent damageto the terminal. . Do not damageihe terminal when inserting the tester lead.
Terminals lnsoection putitigntly wiresto checkthattheyaresecured on individual in the terminal.
9MUGIX.O27
ReDlacementof terminals as shown' toolsto removetheterminal Us6theappropriate it locks insert it until to be sure theterminal, Wheninstailind securery.
9MUGIX-028
Sameas the temaletYPe.
Sensors,Switches,and RelaYs and relayscarefully.Do not drop Handlesensors,switches, themor strikethemagainstotherparts.
Gt-l4
9MUGIX-O3O
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CAUTION
Fuse Replacement 1. Whenreplacinga fuse,be sureto replaceit withone of specifiedcapacity. lf a fuseagainfailsafterit has beenreplaced,the circuit probablyhas a short circuitand the wiringshouldbe checked. be2. Be surethe negativebatteryterminalis disconnected fore replacinga mainfuse(80A). 9MUGIX.O31
M*m
fuse,usethefusepullersupplied 3. Whenreplacing a pullout in thefuseboxcover.
ffifi,.".
9MUGIX,O32
BR/Y
olAGtX-001
Wiring Harness Wiring color codes Two-color wiresare indicatedby a two-colorcode symbol. Thefirstcodeindicates thebasecolorofthewireandthesecond the colorof the strioe. CODE
COLOR
CODE
COLOF
B
Black
o
Orange
BR
Brown
P
Pink
LJ
Green
R
Red
GY
Gray
Violet
L
Blue
White
LB
LightBlue
LG
Light Green
Y
Yellow
Gl-15
A
! PRE-DELIVERY INSPECTION AND MAINTENANCE SCHEDULED SERVICES A- 2 ..........,.......... PRE-DEL|VERY TNSPECTION A- 2 PRE-DELIVERY INSPECTION TA81E.......... A- 3 MAINTENANCE SERVICES..... SCHEDULED
INSPECTION PRE.DELIVEBY
INSPECTIONTABLE PFE-DELIVERY the tolowingilemslo INSPECTandADJUST,I necessary, ! Glass€xterorbight melaland paintlor damage . Wheellug nuls ps ior darnageor detachrnenl C Al weathelslf ol bonnelreleaseand lock ! Operation ol tiJnk id and fue lid open€r D Operalion (l equipped) and ahgnmenl tr Dooroperaiion tr Headlghlaimlng INSTALLlhe lo lowrngParls ! Wheelcapsor ngs(f equPPed) ! outsidemrro(s) - Frontllap(il equrppeo)
OFF UNDERBONNET.ENGINE INSPECTand ADJUST. ir necessary.the lolowlng itemslo ! Fuel,coolantand hydraulc lines,ill ngs,connecnonsand componentsior leaks ! Englneol evel ! Brake mastercylnder lluid evels ! ClutchmastercyLnderiluid levels(if equrpped) - Windshiedwasher reservor lluid evel ! Radiatorcoolanl leveland speciic graviiy tr Tlghtnessoi waler hose clamps ! Tghhessol balierylelminals,e ectrol,'leleveland specillc graviry I l l a n u a l l r a n s a x eo l e v e ! Dflv€ belt(s)tenson tr Acceeratorcable and linkagelor iree movemeni tl Headlght ceaner and lluld level(if equipped) CLEAN lhe spark plugs
INSTALL the lo lowing parls C Fubber slopperior nside rear vew mifror (ii equ pped) tr Fuseior accessones CHECKihe operationoi lhe lolowing tems - Seatconlrols(slidng and reclning)and head rest I Seal belts I lgntion switchand steerng lock ! Power window(it equipp€d) ! Door locks includingchid prool door locks ! nhibitorswllch (ATXonly) n A l l , g l L s T l u o , n g w a r 1 1 9a l d . n dL a l o rl g h t s ! lgfiton key rem nder buzzer(f equlpped)
A-2
! Headishtcleaner{il equipped) ! Horn,wipersand washer tr Antenna ii equipped) tr cigarenelighterandclock(if equLpp€d) tr Heaterand defrosteral variousmode seleclions D Canvaslop (il equipped) CHECKihe lolowng items: ! Presenceol sparetuse finish and interlor ! upholslery lhe lollowingtems CHECKandADJUST,il necessary, andtit ol windows ! Operallon I Pedalheighland ireeplayol blakeandclutchpedal I Parklngbrake
RUNNINGAT UNDERBONNET-ENGINE TEMPEBATUBE OPEFATTNG CHECKthe lollowingilems: C Operaton ol idle_ups)€temior air cond toner or powerseer' ing (it equ pped) D Aulornalc transaxlelluid level I lnitiallgnton tmrng - ldle speed ! Operallonol ihroltlesensor ! Operatonof dashpot
CHECKlhetollowingtems. ! u ndersdelue, coolarlandhydralliclineslitlings'connec' 1orleaks tons andcomponents ! Tireslor clts or bruises syslem andalrunder exhausl suspension, D Sleeinginkage, or oamage lor looseness sde hardware
ROADTEST CHECKlhe followingenrs: ! Brakeoperalon ! Clulchoperauon contro ! Steering tr op€mtionol metersandgauges raltesor unusuanoses tr Squeaks, ! EnginegeneralPeriormance ockingreiiaclors ! Emerge^cy
AFTERROADTEST REMOVE the seat and lloor mat proled ve covers CHECKfor the necessaryowner nformallonmaterias lools and spare tire n vehicle
SERVICES SCHEDULEDMAINTENANCE
SERVICES MAINTENANCE SCHEDULED -\.\_{e!:Inc€
inrerval
llaintenance item------\
llonths x 1000km
ilumber ot months or km. whlchever comcs lla3l 42 48 54 60 6€ 1 2 1 8 24 30 42.5 {5 60 67.5 t.5 1 5 22.5 30
so
ENGINE Enoinevalveclearance Ex. manifoldbolls and nuls
I
T
T T Replacoevery105,000kilometels
T
Enoineliminq bell" Dfive belts'"
I
R
Enoineoil' Oil lille'"
R R
R R
B
R R
B B
B
R R
R
R R
COOLINGSYSTEM I
Cooiingsystem Enqinecoolanl(Withreservon)
R
F
R
R B
R
FUELSYSTEM Arrcleanerelemsnt"
R
R
I
R I
IGNITIONSYSTEM I I
I
Initiallqnitionliminq
Sparkplugs
EMISSIONCONTROLSYSTET' EVAPOFATIVE EXHAUSTEMISSIONCONTROLSYSTEM I I
oashpot
SYSTEM ELECTRICAL level and sp€crllc qravfy
CHASSISAND BODY I I
Clulchpeda Brake llnes. hoses and connections
B
Brakefl'rid"
I
I
llud and lines(ll oquippeo Powersreenng Sleerng oporalionand gear housing
rackqude and lie rodends Steerina linkaoes
I
Automatictransaxlefluid level Frontsuspension ballioir(s Fronlwheelbearlnggreases Driveshaftdust boots 8olls, nuls on chassis and body
Exhaugsystemheal shields
R
I
I I
R I
1
T
T
T
T
T
T I
A-3
SERVICES SCHEDULEDMAINTENANCE Chart symbols: of system'soperation(performance) |: lsoecl : V|sua|exam|nalonoI iunclona|measurement A: ,ljust R: aedace or change T: Tighten L: Lubricate Note: . f!-the resuhot visual examinationol tunctlonalmeasurementol a system'soperation(perlolmance),correct, clgan or leplace as required' Remarks: itemsandintermaintenance . After90,OOO kmor 72 months,conllnueto followthedescribedscheduled valsperiodically. to the followingpollts - chart'pleasepay attention . n"lJ-- maite'oitemsin this maintenance ii' iiin" ".tri"i" i" op"ratedunderthsiollowing thattheengineoilandoilfilter itis suggested conditions' intervals' OeCnangedmoie oftenthan at usualrecommended a) Drivingin duslyconditions Oi extenaeOperiodsof idlingor low speedoperation' or drivingonlyshortdistanceregularly' ij Oriuinglor'"prolongedplrrod in coldtemoerature .2: ieolacerientof ihe timingbeltis Auned;t;very 1o5,oookm' Failureto replacetimingbeltmay resultin damageto the engine. replacemoreoften 's, ir-fr;u.hi"l! i;;p;rated in-verydustyor sandyareas,inspectand' if necessary' intervals. thanat usualrecommended drive 'a, AJlustoiinip""t alternator andwaGi pumpdrivebelt'andpowersteeringandair conditioner beft,if equipped. '5: - Replaceeverytwo Years or iiiti"i! ta" o6en"ontinuousharddflving,mountaindrivrng,or it the brakesare usedextensively annually' be changed fluid should brake the huriid climates, the vehicleis operatedin extremely EmlsgionConirol and RelaledSystems: controlandrelated ottheemission properoperation impottanttothe "i"temJ"* uitdrrv t;Jl; il;;;;" as wellas tor etflcientengineoperations' svste-ms,
ift;;;'g[,"r;;;;JtnJ
A-4
""oi,?"*fl. bedonebvvourauthorized svstems tothese reraed dt se"rvicing
SERVICES SCHEDULEDMAINTENANCE ADJUSTIIENTOF ENGINEVALVECLEARANCE Note . Whenvalveclearanceinspectionand cylindefiead r bolts retightening service are ai the same interval, E I tlEhtenthe cylinder head bolts tlrst. temperature. 1. Warmup the engineto normaloperating TDCofcompression, 2. WiththepistonoftheNo.1cylinderat illustrated. adjustthe valveclearances
ADJUSTING SCFEW LOCKNUT
valve clearance (at valve) lntake : 0.30mm(0.012in) Exhaust:0.30mm(0.012in) onefull turnso thatthe pistonof the 3. Turnthe crankshaft andadjusltheclearNo.4cylinderis atTDCol compression, valves. ancesof the remaining
INTAKEMANIFOLDBOLTSAND NUTS TIGHTENING Tighteningtorque: 19-25 N.m(1,9-2.6 m-kg, 14-19 ttlb)
EXHAUSTMANIFOLDNUTS TIGHTENING Tighteninglorque: 16-23 Nm (1.6-2.3 m-kg, 12-17 ftlb)
TIMINGBELT REPLACEMENT Manualfor the replaceReferto SectionI ot theWorkshop mentprocedureof the timingbelt.
A-5
SERVICES SCHEDULEDMAINTENANCE ANDADJUSTI'ENTOF DRIVEBELTS INSPECTION aAlternalotand water pump drive bell' Powersteering iump and alr condilionel compressordrive belt) i cfieck the belttor cracksor any otherdamage. il necessary. 2. Adiustor rePlace, of about tensionwiththumbpressure belt drive Ch;ckthe 3. 98 N (10 kg, 22 lb) at eacharrowpoints
Belt detlection Altemator drive belt New belt : 5'5-7.0mm (0.21-0.27 in) Usedbell: 6.0-7.5mm (0.23-0'29 in)
ALTEFINATOR
P/S
Air conditionerdrive belt (if eqipped) New bell : 8-9mm (0.31-0.35 in) Used belt: 9-l0mm (0.35-0.39 in)
COMPFESSOFI
Power steeringoil pumPdrive belt (if equipped) Newbelt: 8-9mm (0.31-0'35in) Usedbelt: 9-1omm (0.35-0.39 in)
)X \euuevi j
,a'z
\
\\
CFANKSHAFT/ \ P U T L E Y| 1",^ |
\
A-6
-zcoMPREssoF
Air condltionel compressorand powel steedng oil pump drive belt (it equiPPed) New belt : 8-9mm (0'31-0.35 in) Usedbelt: 9-10mm (0.35-0.39 in)
SERVICES SCHEDULEDMAINTENANCE REPLACEMENT OF ENGINEOIL 'l.Warmup theengine. the drainplugand oilfillercap. 2. Drainthe oilby removing Warning . Walt a while fo. the engine is too hot, And be caretulto drain. 3. Reinstall the drainplugsecurely. Tighteningtorque: 29-41 Nm (3.0-4.2 m-kg,22-30 ft-lb) oiltothe"F" levelmarked 4. Refillthe enginewiththespecified on the levelgauge. 5. Refitthe oil iillercap securely. Oil pan capacity:3.0liters (3.2 US qt, 2.6 lmp qt) RecommendedSAE viscosily numbers
(.c) eF)
-30
-m
-10
0
v
5W.30
5w-rd->
10
20
30
40
50
'
30 :
Engineoil
10w-30
Typicalspecitication:API service SD, SE or SF REPLACEMENT OF ENGINEOIL FILTER 1. Removetheoil filterwiththe SST a suitablewrench. 2. lJsea cleanrag to wipeoff the mountingsudaceon the engine. 3. Applya smallamountof cleanengineoilio therubberseal ol the newfilter. 4. Installthe oilfilterandtightenit by handuntilthe rubber sealcontactsthe base. 5. Tightenthe fllter1 and 1/6turnswitha filterwrench. 6. Startthe engineand checkfor leaks. 7. Checkthe oil levelandadd oil if necessary. Oil filler capaclty 83: 0.17liter(0.18US ql, 0.15lmp qt)
A-7
SERVICES MAINTENANCE SCHEDULED OF COOLINGSYSTEiI INSPECTION Warning . Nevei removethe radialorcap while the engineis hot. . Wraoa thick cloth aroundlhe cap when removingit. . Whdn removingthe radiatorcap, loosen it slowly to the fitst stop until the pressurein the radialoris released.and then removeit. CoolantLevel (Enginecold) 1.Verifvthatthecoolanllevelis nearthe ladiatorf llel neck is be' 2. Verilvthatlhe coolantlevelin the coolantreservior tweenthe FULLand LOWmarks 3. Add coolantif necessary. CoolantOuallty 1.Verffythattheieis no buildupof rustor scalearoundthe radiatorcao or radiatorfillerneck 2. Verilythat coolantis free of oi! Replacethe coolantif necessarv,
CoolantLeakage andthe available) tester(commercially 1. Connecta radiator filler neck. radiator to the SST to the 2. Applyt03 kPa(1.05kg/cmz.15 psi) pressure system. 3. Verifythatthe pressureis held. It not,checkior coolanileakage
?_---z'- .- l,'1,/
' CoolanlProtection Caution . Do not use alcohol-or methanol-basedcoolant' water in the coolant . Useonly soft (deminerallzed) mixlure. andspecificgravitywith temperature thecoolant 1. Measure and a hydrometer' a thermometer to thegraph by referring thecoolantprotection 2. Determine is notproper'addwaterorcoolant lrthecoolantprotectaon Antitreezesolution mixture percentage Gravilyai
Above -16"C (3oF) Above 26oC (-1soF)
Above-a0'C (-40"D COOLANTIEMPEFATUFE'C (.F)
A-8
65 55
coolant 20"c (68"F) 1.054 35 55
1.078
SERVICES SCHEDULEDMAINTENANCE REPLACEi'ENTOF ENGINECOOLANT Warning . Neveropenthe radiatorcapwhilethe engineis hot. . Wrapa thick cloth aroundthe cap whenloosening. . Use caution when draininghqt coolanl.
E
THEDFAINHOSE
Caution . Do nol use alcghol.or methanol-based coolant. . Useonly soft (demineralized) water in the coolanl mixture. '1.Removethe radiatorcapand loosenthe drainplug. 2. Drainthe coolantintoa suitablecontarner. 3. Flushthecoolingsystemwithwateruntilalltracesof color are gone;lhen letthe systemdraincompletely. 4. Installthe drainplug. glycol 5. Fillwiththe properamountand mixtureof ethylene to the tableabove. basedcoolantby referring Coolanlcapacity MTX:5.0 liters (5.3 US qt, 4.4 lmp qt) ATX: 6.0 liters (6.3 US qt, 5.3 lmp qt) 6. Runtheenginewiththeradiatorcapremoveduntiltheupper radiatorhoseis hot. 7. Withthe engineidling,add coolantto the radiatoruntilit reachesthe bottomol the fillerneck. 8. Installthe radialorcap.
A-9
SERVICES SCHEDULEDMAINTENANCE OF IDLE SPEED ADJUSTMENT Preparalion '1.Warmup the engineto normaloperatlngtemperaure. 2. Verityihatthe wat rod e)dendsoutwardiullyandthe idle fromthe roller' cam separates 3. Turnall electricloadsOFF. . BlowerFan . Headlight . RearWindowDelroster 4. Makesurethatthe enginespeeddoesnotchangewnen valve@ connector. lhealr btpasssolenoid disconnecting Note . lf lhe enginesPeeddecleases.the engineis still under the warm-upcondition' waittillthefanslops 5. lftheelectficcoolingfan isoperating, idle in goodcondition6. Verifythatthe engineis runningat connector' 7. Connectthe SSTto the diagnosis lG- terconnector io thediagnosis 8. Connecta tachometer minalas shown.
L Sel switch6) to Position1. 10 SetTESTSW10SELF-TEST. Note . lf the SSTis not used, iump acrossthe TENtelmi' nal and the GND telminal ot the diagnosiscon' nector.
t-\*l
ldle Speed 1. Check the idle speed with a tachometer.
ldle speed:MTX(Neutral) 750 jT rpm ATX(P range)|,100 :'t rpm
adjustthe idlebylurningthe 2. lf notwithinthe specifacalion, throttleadjustingscrewOAS).
A-10
SCHEDULEDMAINTENANCE SERVICES REPLACEMENT OF AIF CLEANEFELEMENT Visually checktheaircleaner elementfor excessive dirt,dam, age or oil, replacelf necessary.
REPLACEMENT OF FUELFILTER Warning . Keepsparksand open flamesaway trom lhe tuel area. . After replacinglhe tuel filter, check ihat the filler ioints are nol leaking. To reolacethe fuelfilter,oroceedas follows: 1. Disconnect the fuelhoses. lheluelli/terwirhrhebrackel 2. Remove 3. lnstalla newfilterin the reverseorderol removal. Note . Wheninstallinglhe fillter makesurelhe hosesare pushedgn as tal as possiblg.Securethe hoseswith clips. INSPECTION OF FUELLINESANOHOSES Checktheiuellinefittings,connections andcomponents for |eaKs, Thereshouldbe no wetness or stalnedareasthatmiohtindicateleaksReplaceany detectivehosesor clips.
A-1 1
SERVICES SCHEDULEDMAINTENANCE OF IGNITIONTIMING ATUUSTMENT Preparation 1. Warmup the engineto normaloperatingtemperature. 2. Verilythatthewaxrod extendsoutwardfullyandthe idle fromthe roller. cam separates loadsOFF. electric 3. Turnall . BlowerFan . Headlight . RearWindowDefroster 4. lvlakesurethatthe enginespeeddoesnotchangewhen valve@ connector' theairbypasssolenoid disconnecting Note . I the enginespeeddecreases,the engineis still u]} der the warm-upcondition. ACHOMETEF
waittillthetanstops. 5. lf theelectriccoolingfanisoperating, in goodcondition. at idle is running 6. Verifythalthe engine connector. the diagnosis to 7. Connectthe SST 8. Connecta timinglight. connector lG- ter' to thediagnosis 9. Connecta tachometer minalas shown.
.--
|N
re
IG-
_--\
GNO
10.Setswitch@ to Position1. 11.SetTESTSWto SELFTEST. Note . lf the SSTis not used,iump acrossthe TENlermi' nal and the GNDterminal gl the diagnosiscon' nector.
GND
.?-.:f-=\,('__',
\r:1.\
lgnition Timing Inspeclion/ Adiustment 1. Checkthatthe idlespeedis withinthe specification. ldle speed: MTX(Neutral) ?50 :l! rPm ATX (P range)1,100 i'! rpm
2. Checkthe ignjtiontimingwitha timinglight lgnition timing: BTDC16 + | "
/1.,"_(V
.:TS r ,<--
loosen 3. lf the ignitiontimingis notwithinthe specification, to make lockboltsandturnthe distributor the distributor the adiustmentlockboltsto the speciliedtorque. 4. Tiqhtenthe distributor Tiohteninqtoloue: ie-zsI{m (i.6-2.3 m-kg,12-16 ftlb) lock bolt 5. Puta sealon the distributor
A-12
SCHEDULEDMAINTENANCE SEFVICES INSPECTION OF SPARKPLUGS '1.Checkthe plugstor burnedor erodedelectrodes, fouling or crackedporcelain. gap.lf necessary, 2. lvleasure theelectrode adjustthegapto specifications or replacethe sparkplugs. Pluggap: 1.0-l.1mm (0.039-0.043in) (0.75-0.85mm10.029-0.033inl) -Bl Carburetor ENGINE
B1
B3
NGK BPBsES, BPBoES BKRsE.11, BKN6E.] ] W2OEXR.U K16PR-U11, K2OPR-IJ11 NIPPONDENSO W16EXF.U,
Cauiion . when inslallinga newplug or reinstallingold plugs, use a small amount of anti-seizecgmDoundor Bolybdenum-bas€dlhread lubricar on the filst few threads. . Do not pull the spark plug cables lo remove them, pull on the spark plug boots.
USECONNECTOR A
INSPECTION OF THROTTLESENSOR 1. Warmup the engineto normaloperalingtemperature. 2. Verifythatthewaxrodexpandsoutwardlullyandthecam fromthe roller. separates 3. Stopthe engineand turnthe ignitionswitchON. SSTS(EngineSignalMonilorand Adapter 4. Connectthe Harness)to the ECUas shown. 5. Setlhe SST (EnglneSignelMonitor)to terminal2M.
6. Rotate the throttlelinkby handand verifythatthe voltage is withinthe specification. Speciticalion ECUTerminal 2M
Throtle valvecondilion
0.41-062V
7. It nol as specilied,a4ust the throttlesensor.
A-13
SCHEDULEDI'AINTENANCESERVICES OF DASHPOT INSPECTION Inapection 1. ODenthethrottlevalvelully.Pushthe dashpotrod witha fingerandveritythatit goesintothe dashpotslowly. 2. Release the rod and checkthat it comesout quickly 3. Replacethe dashpotif notas specified.
4. Warmup the engineand run it at idle. to the diagnosisconnectorlG5. Connecta tachometer enginespeed. terminaland increase the enginespeedandcheckthatthe le6. Slowlydecrease ver touchesthe dashpotrod at the specifiedspeed. Specitication:2,500 + 100 rpm loosenthelocknutandturnthedashpot 7. if notasspecilied, to adjust.
ADJUSTING SCFEW
A-14
MAINTENANCE SERVICES SCHEDULED SYSTEM INSPECTION OF EVAPORATIVE temperature and 1 Warmup theengineto normaloperatang .un it at idle. 2. Disconnecl the vacuumhosefromthe solenoidvalveas showninthefigure,andveritythatnovacuumisfeltatthe solenoidvalve. checkthe solenoidvalve. 3. lf notas specified,
INSPECTION OF BATTERY level. Checkthe electrolyte Thelevelshould be between theupperandlowerlines.ll the levelis low.add distilledwater. Checkthe specificgravity. Speciticgravity: 1.27-1.29
SYSTEM INSPECTION OF ALL ELECTRICAL systems. Checkthe all electrical Tor wiringdiagrams isfound,reierto Section lf he mulfuncton tor reparr.
A-15
SERVICES MATNTENANCE SCHEDULED OF CLUTCHPEDAL INSPECTION '1.Checkthe pedallor smoothoperation adjudthepedalheight 2. Checkthepedalheight.lf necessary' locknut@ andturningtheclutchswltch(q). by loosening the locknut(4). retighlen adiustthe pedal 3. Ch;ck the pedalfree play.lf necessary, free play.Referto H-4. Pedalheiqht: 196-207mm (7.72-8.15 in) PedalfreC play: 0.7-3.3mm (0.03-0.13 In) height: Diaenqagement 4lmm (1.61 in) mlnimum(With carPet)
OF BFAKELINES,HOSESAND INSPECTION CONNECTIONS Checkthe pointsbelow,replacepartsif necessary. 1. Crackind,damageor corrosionol the brakehose 2. Damaoeto the brakehosethreads. 3. Scars.lracksor swellingof the flexiblehose. 4. All linesfor fluidleakage.
OF BRAKEFLUID INSPECTION the bebetween Thelevelshould Checklluidlevelin reservoir. lvax.and Min.lineson the reservoir. low,checkthe brakesystemfor lf thefluidlevelis extremelv €aKs.
A-16
SERVICES MAINTENANCE SCHEDULED OF BRAKEFLUID REPLACEMENT AIR BLEEDING by usinga suc1. Removethe brakefluidkom the reservoir lon pump. withnewbrakefluid. 2. Fillthe reservoir Fluid apecllication:FMVSS116: DOT-3 SAE: J1703 3. Attacha vinyltubetothebleederscrewandplacetheother end ol the vinyltubein a containel. eachbleeder 4. Pumpout the old brakefluidby loosening screw(oneby one)and pumpingthe brakepedal. 5. Bleedair as describedbelow. Cautlon . The tluid in the reservolr must be maintalnedal the Z4 l€vel or higherdurlng air bleeding. . Be caretul nol to spill brake lluid onto Painted surtaces.
'1.Jackup the vehicleand supportit withsaletystands 2. Removelhe bleedercap and attacha vinylhoseto the bleederplug. 3. Placethe otherendof the vinyltube in a container. 4. Slowlypumpthe brakepedalseveraltimes. screw loosenthe bleeder 5. Whilethebrakepedalis pressed, escape. to letfluidand a'r 6. Repeatsteps4 and5 untilthereare no air bubblesin the fluid. 7. Checkfor cotrectbrakeoperation. Besureto 8. Checkto be surethatthereis no fluidleakage. cleanawayany spilledfluidwithrags. up 9. Afterbleedingthe air,add brakefluidto the reservoir level. to the sDeciiied OF PARKINGBRAKE INSPECTION 1. Pullthebrakeleverwith98 N (10 kg, 22 lb) ol forceand measurethe leverstroke. adjustthe leverstrokeby turningtheadjust2. lf necessary, Ingnut. Stroke: 6-8 noiches
@ @
OF POWERBRAKEUNITAND HOSES INSPECTION for andcheck-valve 1. Checkthe vacuumhose,connectors etc. cracks,chafing,deterioration 2. Withthe enginestopped,depressthe pedala fewtimes startthe engine. 3. Withthe pedaldepressed, aftertheenginestarts,thepedalmovesdown 4. lf, immediately slightly,the unitis good.
ww
A-17
SCHEDULEDi'AINTENANCESERVICES OF DISCBRAKE INSPECTION Checkthe lollowingdiscbrakecomponents. and inspectfor leaks 1. Checkthe caliperoperation 2. Checkthe Padslot wear. ol the discplate 3 Checkthe conditionand thickness Minimum:BrakePad2.0mm (0.08 in) Dlsc plate thicknesa l6.0mm (0.63in) ATX models lomm (0.39in) MTXmod€ls OF DRUMBBAKE INSPECTION '1. Checkthe wheelcylinderoperation and inspecttor leaks. 2. Checkthe lin'ngsfor wearor damage of the innersurfaceandthe innerdl3. Checkthe condition ameterof the drum. Limli: l.omm (0.04in) Brake1in1n9........... (7.15in) l81.smm '..'.,.... lnnerdlamaterof drum
ANDFRONTSUSPENSION OFSTEERING INSPECTION play free wheel steering 1. Checkthe Free play: 0-30mm (0-1.18 in) andfor looseness for properoperation 2. Checkthesteering of the steeringhouslng. 3. Checkthe steeringgear housingfor lluid leakageor seepage.
playonthetie rodendsandrackguide 4. Checktor exoessive 5. Checkfor damageol the dust boots. ofthetierodends or greaseleakage 6. Checklorlooseness
FLUIDAND LINES OF POWERSTEERING INSPECTION (if equipped) lor cracks, i- Checkthe fluidhoses,linesand connections etc. chafing,deterioration, 2. Checkthe fluidlevelon the reservolr. "F" and "L" level Add Thelevelshouldbe betweenthe fluidif necessary. Fluld soecificalion: ATF Dexronoll or M-m
A-18
SERVICES SCHEDULEDMAINTENANCE OF MANUALTRANSAXLEOIL REPLACEi'ENT lor oil leakage. 1.Visuallycheckthe manualtransaxle lf leakagejs found,checkfor the cause,and repair. cableand drivengear. 2. Removethe speedometer plug drainthe oil. and 3. Removethe drain plug securely. the drain 4. Reinstall Tlghteningtorque: 24-35 Nm (2.4-3.6 m-kg, 17-26 ftJb) drivengear oillromthespeedometer 5. Fillwiththespecified drivengear. hoieto the F markon the speedometer Specilledoil Grade:API serviceGL-4 ol M2C33F Viscoslly:All-seasonDexron@tr -l8cc (0"F) 75W'80 SAE Above Capacity: 2.5 litets (2.64US qt, 2.2 lmp qt)
TMNSAXLE FLUIDLEVEL OFAUTOMATIC INSPECTION Caulion . Placethe vehlcleon a flat, level surtace. 1. Applythe parkingbrakeand positionwheelchockssecurely lo preventthe vehiclefrom rolling. 2. Warm-uplhe engineuntil the ATF .eaches60-70oC (140-rs8oq.
HOTBANGE
the brakepedal,shiftthe selectorlever 3. Whiledepressing to eachrange(P-L)and leaveit a iew secondsin each range. 4. Shiftback to P. Nole . Only use the COOL (20oC) range as a rough tetetence. 5. EnsurethattheATFlevelis intheHOT(65oC)range.Add if necessary. ATFto soecffication, ATF type: oexron@tror M-Itr Capacity:6.3 literc (6.7 US qt, 5'5 lmp qt) GREASES OF FRONTWHEELBEARING BEPLACEMENT withlithi' in the ligure shown lilltheshadedarea Completely grease. um Note . Reler to page M-8 for disassembly/ assembly procedure.
A-19
SERVICES SCHEDULEDMAINTENANCE INSPECTION OF DRIVESHAFTDUSTBOOTS Checkthe dustbooton the driveshaftfor cracks,damage, greaseleakage,and a loosebootband.
TIGHTENING OF BOLTSAND NUTSON CHASSISAND BODY '1.Tightenall seatmountingbolts. body 2. Retighten anyloosenutsandboftsonthechassisand torque.(Referto SectionTD.) to the specified
TNSPECTION OF EXHAUSTSYSTEMHEATSHIELD Checktheclearancebetweenthe insulatorand bodyandalso and the exhaustsystem. betweenthe insulator
A-20
ENGINE B-2 B-3 .... B-3 SPECTFTCATIONS B-3 TROUBLESHOOTING GUIDE..,........, ENGINE TUNE-UP PROCEDURE ......,B - 5 PtrFPAHATI.)I\I B-5 E N G T NOEr 1 . . . . . - . . . . . B-5 B-5 ENGINECOOLANT . B-5 B-7 VALVECLEARANCE IGNITION TIIVIING, IDLESPEED ......B - 8 coMPRESStON...... B-10 TNSPECTTON .......... 9-10 ON.VEHICLE MAINTENANCE............ B-11 PREPARATION B-l1 T||VltNG 8E1T......... B-12 HEADGASKET.....,....... B-17 CYLINDEH FRON'T OILSEAL.... B-21 trFAA AII qFAI B-23 REMOVAL ............. 8-26 8-26 ENGINE STANOMOUNTING............. B-33 PREPARATION B-33 B-34 DrsAssEMBLY....... B-36 PREPARAIION ....... B-36 AUX|LIARY PARTS........................ a-37 TIMING 8E1T......... B-38 ...-.-. c Y L t N D EH RE A D . . . . . . . . . . . . . . . . . . .B-40 BLOCK CYLINDER (EXTERNAL PARTS)..................... B'42 BLOCK CYLINDER {tNTERNAL PARTS)...................... B-45 tNDEX.............,.....
ourLrNE...............
e-48 tNSPECT|ON / REPA|R..................... pREpARATtON ......,...................,.. B-48 HEAD.......................... B-48 cYLtNDER g-49 ..................... VALVEtVIECHANtSM B-52 cAt\,4sHAFT.................................. 81OCK........................ B-54 cYLtNDEB PISTON, PISTON RING,AND 8-56 PtsToNPrN................................ ROD....................... B-57 coNNECT|NG B-s8 CRANKSHAFT .............................. B-58 BEARlNG.........-.-......................... B-59 TTMtNG 8E1T......,........................ rDLER....................... B-sg TENSTONER, B-sg TENSTONEB SPRrNG..................... pu11EY.................-..-..-............... B-59 8-60 ASSEI'BLY..................................... pREPARATTON 8-60 ..........,.................. BLOCK CYLINDER 8-61 flNTERNAL PARTS)...................... CYLINDEH BLOCK (EXTERNAL PARTS)........-............ 8-67 HEAD.......................... B-72 cYLtNDER TIMING 8 E 1 T . . . . , . . . . . . . . . . . . . . . . . .9. .-.7. .6. . . B-79 AUXtLtARY PARTS........................ B-82 ENGINE STANDDISMOUNTING........ pRocEDURE B-42 ............................... B-84 rNST4LLAT|ON............................... pRocEDURE............................... B-84 01a08x.001
INDEX INDEX INTAKEMANIFOLO 19-25 rktr (1,$-2,6 n-*t, la-19ll-rb) lN: 0.3omm(0.012in) E* 0.30mm(0.012in) / ADJUSTMENT INSPECTION
ENGINE @OIAMI, SEFIVICE SECTION E
ENGINEOIL FIEPLACEMENT, INSPECTION D SECTION
EXHAUSTMANIFOLD rr-23
DEFLECTION AT {98 N, 10 kg, 22 lb)
5.0-7-0 (o.1
l&n {r.9-2.3 f-*9,
MPRESSIONINSPECTIONPAGE B-12
6.0-7.5 {0.23-0.29}
1412(14.4,2O4l30O
5. Engine 1.Timingbelt pageB-12 R e m o v a | . . . . . . . . . . . . . . . . . . . . .p. .a. g . .e.P. . -26 ........ / Insta||ation.................. Removal page B-33 .............. mounung Engine stand 2. Cylinderheadgasket D i s a s s e m b | y . . . . . . . . . . . . . . . .p.a. .g. .eB-36 .......... . .e.B. .-.1.7 B e p | a c e m .e.n. .t. . . . . . . . . . . . . . . .p. .a. g page 8,48 / F]epair................-..... InspecUon 3. Frontoil seal A s s e m b | y . . . . . . . . . . . . . . . . . . . .p. -a-g. .e.B-60 .......... R e p l a c e m e n t . . . . . . . . . . . . . . -p . .a. .g. .eB . . .2. .1. . . . page 8,82 ......... dismounting Engine stand Rear oil seal 41 n s t a | I a t i o n . . . . . . . . . . . . . . . . .p. a. .g. .e.8. .8. .4. . . . . . R e p l a c e m e n t . . . . . . . . . . - . . . .p . .a. .g. .eB . . -. 2 . .3. . . .
B-2
B
GUIDE OUTLINE.TROUBLESHOOTING
OUTLINE SPECIFICATIONS Engine
Item
a3
and number Cylinderanangement chamber Combusrion OHC, belt-driven16 va ves cc (c'r in)
Displacemenl
mm (in)
Boreandstroke
1323(80.7) 71.0x83.6(2.80x3.29) 9.4
pressure Compression IN
kPa(kg/cm'.psi)'rpm Open BTDC ABDC
EX Vaiv€clearance ldle sp€ed
mm (in)
Open Close N
BBDC ATDC
1373(14.4,199)300
404
0.30(0.012) 0.30(0.012)
EX [/TX rpm ATX
750ri 1100r"3
lgnitiontiming
BTDC
16 1-3-4-2
TBOUBLESHOOTING GUIDE Posslble Cause Difiiculi startlng
eemedy
Page
Mallunction ol enginerelaied componenls B-49 8,54,56 B-17
Wom piston,pislon ring or cylinder Faled cylinderhead gasket
Mallunclion ol tuol system Mallunclion ol igrltion system Pooridling
Referro SectionG
uallunclion of engine-rslated components Poorvalvelo-valveseatconlact Failedcylinderheadgasket
B-49 B-17
Maltunction ol tuel system Mallunctlonol ign[ion system
Reler to Section G
Oil workingup Wornpjstonringgrooveor stickingpiston ng Wornpisionor cylinder
856 B 54,56
Oil workingdown
8-61,72 B-50
Wornvalvestemor guide Oll leakage
Reterio SectionD
B-3
B
GUIDE TROUBLESHOOTING Remedy Insulticient compaession Compressonleakagelrom valve seat
B-51 B -49 B-52 B-17 B-48 B-56 B-56
Weak or broken valvespfing Faiiedcylinderhead gasket Crackedor d'slorredcylinderheao Sticking damaged,or wom plslon Ing Crackedor wofi pislon
Mallunction ot luel system Mallunction ot ignition system
Ps9e
G Relerlo Secnon
Othera Slippingclutch Draggng brakes
lklfunction of enginerelaled components Siickingor burnedvalve weak or brokenvalvespnng ln combustion chamb€r Carbonaccumulalon
B-49 B-52
itallunclion ol tuel system lraltunctionof lgnllionsystem Enginsnois€
Crsnkshaft- or bearing-rolated p.tls Excessivernainbearingoil clearance Main bearingseizedor healdamag€d Excessivecrankshaitend Dlav Excessiveconnectingrod bearingoii clearance Connectingrod bearingseizedor heat_damaged
B-64 B-58 B-65 B-65 B-58
PBton-related parls
Damagedp stonrrng
8 8 8 8
valves or timing-related Parls Brokenvalvesping Excessvevalvegude clearance
B-52 B -49
Wompistonor pislonPn
Malfunctlonof coolingsystem llralluncllon of tuel sFtem
others
lvlaLfunction ol waterpumpbearing lmproperdrivebeLltenslon Malfunction oi aternalorbeanng Exhaustgasleakage N,4afunction oi I mingbelitensioner
B-4
5 5 5 5
5 6 6 6
Reforto Secton E
Befer to seci on E Relerlo SectionG
B-13
ENGINETUNE-UPPROCEDURE
ENGINETUNE.UPPROCEDURE PBEPARATION
ssr
49 8019 9A0
49 9200 020 Tensiongauge,
ignilionliming
ENGINEOIL Inspection 1. Be surethe vehicleis on levelground. temperature 2. Warmup theenginetonormaloperating and stop rI. 3. Waitfor fiveminutes. condition. theoildipstick andchecktheoilleveland 4. Remove replace oil if necessary. 5. Add or Note . The dislancebelweenthe Land F markson lhe dip. stick repressnts0.8 liter (0.85US qt, 0.70lmp qt). ENGINECOOLANT Inspectign Coolantlevel (englnecold) Warning . Neverremovethe radiatorcap whlle the engineis hot. . Wlapa thlckclotharoundthe capwhenremovingil. 1. Verilythatthecoolantlevelis nearthe radiatorfillerneck. is be' 2. Checkthatthecoolantlevelin thecoolantreservoir tweenthe FULLand LOWmarks. 3. Add coolanlil necessary. Coolanlquality 1. Verifythatthereis no buildupoi rustor scalearoundthe radiatorcap or radiatorfillerneck. 2. Verifythatthe coolantis freeof oil. 3. Fleplace the coolanlii necessary.
V.RIBEED 6ELT
MtwJtM o x x
ORIVEBELT Inspection Replace 1. Checkthedrivebeltsforwear,cracks,andfraying. if necessary. 2. Veritythatthe drivebeltsare correctlymountedon the puleys.
B-5
ENGINETUNE-UPPROCEDURE
!.t-q/lotL 2",.r puMp \
Y/
\ cutteY
" fi.i .sp,an'//
presby applyingmoderate 3. Checkthedrivebeltdeflection pulleys, the as lb) midway between (98 l0 kg, 22 sure N, il necessary. Adjust shown. Dellection Drive bet
l,.PULrEV
P/S, P/S + A/C
ALTERNATOF
pJc \,
'.-agy'
PULLEY CO
50 70 (019 0.27) 80 9.0 (0.31-035) 80-90 (0.31-035)
6.0-7.5 (o.23-O.29)
9.0-100 (0.35-0.39) 9.0-10.0 (0.3s 0.39)
- P/s\
r^A ,/orr pui,rp Y \"ut""\ '-- '/
CAANKSHAFI /.A/C\
trnn( n/
.4.' CFANKSHAFT/
\\ \
" y . . .J" \ " " J
withtheSST(tensiongauge). 4. Checkthedrivebelttension Note . Belt tension can be measuredbetweenany two pulleys, Tension
N (kg,rb)
Drive bell 451-785 (46 80. 101-176)
392 588 (40-60, 88 132)
P/S, PiS + A/C
491 589 (50-60, 110 132)
422-491 (43-50,95-110)
A/C
491-589 (50-60, 1r0-132)
422-491 (43 50,95-110)
5. lnstallthe alr intakePiPe.
Adiusiment Caution . It a new bett is used, adiusi the bell dellectionat the midpointot new belt specification. Alternator belt mountingbolts@and loosenthe alternator 1. lf necessary, boltG) . adruslrno z Leverth-ealternitoroutwaldandapplytensionlo thebeh Tighteninglorque i& : 37-51 N.m(3.8-5.3 m-kg, 27-38 ft-lb) \t: 18-25 N.m(l'9-2'6 m-kg,13-18 ft'lb) 3. Becheckthe belttensionor deflection. P/Sbelt.P/S + tuC belt It necessary, loosenthe P/Soil pumpmounting@, @ and bolt by tutningtheadjusting adjust thebeltdeflection and O @) Tighleningtorque @: 19-25 Nfl (1.9-2.6 m-kg' l4-19 ft-lb) !E,: 36-54 Nm (3.7-5.5 m'kg' 27-40 ft-lb) G : 36-54 N.m(3.7-5'5 m-kg, 27-40 flnb)
B-6
ENGINETUNE-UPPROCEDURE AJCbelt lf necessary, loosenthelocknut@ andadjustthe beltdeflection by turningthe adjustingbolt@. Tlghleningtorque: 37-51 Ntn (3.8-5.3 m-kg, 27-38 fl-lb)
:i\\
a.\.\
VALVECLEARANCE Inspecilon/ Adiustment 1. Warmup the engineto normaloperatingtemperature. 2. Removethe air cleaner. cable3. Removethe accelerator 4. Removethe cylinderheadcover. andalignthetimingmarksothatthe 5. Turnthe crankshaft piston isatTDCofcompressionNo.1 or No.4 cylinder ofthe
6. Measure thevalveclearances O withtheNo.'lcylinderat TDCof compression, andthoseof @ withthe No.4cylinder at TDCof compression. Valveclearanae(valveslde) lN : 0.30mm(0.012in) EX: 0.30mm(0.012in)
adjustand recheckthevalve 7. lf il is not withinspecification, clearance. B. Turnthe crankshaftone fLrllturn and measurethe remaining valve clearances.Adiust if necessary.
9. Installthe cylinderheadcover. Tighteninglorque Bolt @: 4.9-9.8 Nm (50-90 cm-lq, 43-78 In-lb) Bolt @r 7.8-11 Nm (80-110 cm-l€, 69-95 inlb) Caution . It the headcover gasketis reused,applysealantin the grooveas shown. cable. 10.lnstallthe accelerator '11.lnstallthe air cleaner. tappetnoise. 12.Startthe engineand checkfor excessive
B-7
ENGINETUNE-UPPROCEDURE IGNITIONTIMING,IDLESPEED Prsparalion 1.Warmup the engineto normaloperatingtemperature 2. Veritythatthe waxrod extendsoutwardfullyandthe idle fromthe roller' cam separates 3. Turnall electricloadsOFF. . BlowerFan . Headlight . RearWindowDefroster thatthe enginespeeddoesnotchangewhen 4. MakesLrre valve@ connector' theairbypasssolenoid disconnecting waittillthelanstops 5. ll theeleckiccoolingfanis operating, 6. Verifythatthe engineis runningat idlein goodcondition connector' 7. Connectthe ssT to the diagnosis 8. Connecta tlminglight. 9. Connecta tachoheterto the diagnosisconnectorlG- terminalas shown. Note . ll the engine speeddecreases,ths englne la atlll under the warm-upcondition. '10.Setswitch to position1. @ 1'1.SetTESTSWto SELF-TEST. Note . It the SSTis not used,iump acrossthe TENterminal and the GND ierminal ol the diagnoalsconnedor.
lgnition Timing Inspection/ Adius|ment 1.Checklhat tne idlespeedis wiihrnthe specification ldle speed: MTX(Neutral) 750 i:! rym ATx (P range)I,100 :1 rpm 2. Checkthe ignitiontimingwitha timinglight lgnitiontiming:BTDC16 + l" loosen 3. lt the ionitiontr|ninois not withinthe specilication. to make the disiflbutorlocLbohsand lurn the distributor the adiustment. torque lockboftsto the specified 4. Tighte;the distributor
A) B-8
Tiohteninqtorque: is-zs-Nm (i.9-2.6 m-ks, 14-19 ftlb) lockbolt. 5. Puta sealon the distributor
ENGINETUNE-UPPROCEDUFE ldle Speed '1.Perform"Preparaljon"(Referto pageB-8.) 2. Checkthe idlespeedwitha tachometer. ldle speed:MTx (Neutral) 750 it rpm ATX (P range)1,100:1 rpm
oree ^os'6"o"G66alj adjusttheidlebyturningthethrottle 3. lf notwithinspecification, adjustingscrew.
B-9
COMPRESSION
COMPRESSION ll rhe enoineexnibitslow power.poorluel economyor poor ldle checkthe lollowing: 1. lgnrtro;system(Belerto SectronG.) 2. Compressron 3. Fuelsvstem(Feferto SectionF.)
INSPECTION it if neces1. VerifvthatthebatteryistullychargedRecharge sarv.(Referto SectionG.) 2. Warmup the engineto normaloperatinglemperature' 3. Turnthe engineOFF. 4. Bemoveall sparkplugs. the ignitioncoilconnector' 5. Disconnect
gaugetotheNo l sparkplughole acompression 6. Connect pedalandcrankthe engine' depresslhe acceleiator 7. Fr.rlly gaugereaolng 8. Recordthe maxrmum 9. Checkeachcylinder. Compression Siandard
kPa(kg/cm',psilrpm B3 14121t4.4,2O4!3OO 103000.5, 149)-300 't96 (2.O,26)
s rcw'poura in oneor morecyllnders 10.lf thecompression and recheck cylinder into the oil of engine smallamount compressrcn. the the piston,pistonrings' (1) lt thecompression increases, or cvlinderwallmav be worn (2) lf the compression stayslow,the valvemaybe stuck or seatingimProperly. stayslow,the in adjacentcylinders {3) ' ' lt thecomoression the cylinder or gaskel delective maybe cvlinderhead head distorted. 11. Connectthe ignitioncoil connector.
lubricant or molybdenum-based compound 12.Applyantiseize threads. to the sparkPlug sparkPlugs. 13.Insiallthe Tidhleninotoroue: is-zsi{.m (i.5-2.3 m'ks' 11-17 finb)
B-10
ON-VEHICLEMAINTENANCE
MAINTENANCE ON-VEHICLE PREPARATION
ssT
49 G0175A0
4 9 D 0 1 11 0 2
Enginesuppod
inslallationof timing belt puley
49 E301060
49 E301061
Brake,ringgear
Sody (Panof 49 E301060)
49 E301062
43 SE01310
Collar (Partof 49 E301060)
Centeinglool,
installationot
B-11
ON.VEHICLEil|AINTENANCE TIMINGBELT / lnstallalign Femoval '1.Drsconnect the negativebatterycable. 2. Lilt up the vehicle. 3. Removein the ordershownin the figure,referringto RemovalNole. 4. Installin the reverseorderof removal,relerringto InstallalionNote
1r-25 O,r-2.6, 1a-19)
7€-rr
rlo (30-110 .eks,
6e-e5 In{b)
p0-rr0 *rs, ca-esr.-rb)
12-17 (1,2s-1.75,r09-rs2) 1s6-r65 05-17, 115-122)
L Timingbeltcover,upper 1.Splash shield L Timingbeltcover,lower 2. P/Sand/orA,/Cdrivebelt leads 10. p a g e I n s p € c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-tensron plugs 11. Spark drivebelt 3- Alternator I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. -e.B. .-. .5. . . . .12. . Timingbelt . .e.B. - 1 4 p a g e R e m o vN a ol t e . . . .......... . . . . . . . . .p. .a. g 8 , 6 Adjustment................................. I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .' 1. .4. . . . . . 4. Waterpump pulley pageB-14 -..................... Note.... Installalion 5. Plate '13. Tensioner RemovN a lo t e . . . . . . . . . . . . . . . . . .p. a. .g. .e. . . . . . pageB - 1 6 I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .- .1. 4. . . . . . Note.......................... Installation pageB-15 Note.......................... Installation 6. Pulleylock bolt spring RemovN a lo t e . . . . . . . . . . . . . . . . . .p.a. .g. .e8 . .,.1. .3. 14.Tensioner pageB 1 5 I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .- .1. 4. . . . . . -...............-. Note........ lnstallation pageB-'15 Note.......................... Installation pulleyand pulleyboss 7. Crankshatt
B-12
MAINTENANCE ON-VEHICLE Removalnote Plate mountingbolts. 1. Removelhe rightstabilizer
2. Suspendthe enginewiththe SST.
3 RemovetheenginemounlNo.3mountingboltsandturn overthe enginemountNo.3. 4 Lowertheengineapproximately 50mm(1.97In)gradually.
i.- i\\ z 5. Removethe platemountingbolts,and thenthe plate.
Pulley lock bolt 1. Holdthe oullevbosswiththe SST. 2. Usingthe SST,loosenthe pulleylock bolt. 3. Removethe pulleylockboltand pulley.
B-13
ON-VEHICLEiIAINTENANCE Tlming belt i. lnstiiltneouttevtoct bollandturnthecrankshaft(thepin on the oullevbossiacesup-right) Caution . Do not turn the crankshaftwhile removingthe pul' ley lock bolt.
2. Removethe timingbelt. Note . Ma* the liming belt rotallon lor proper leinslallatlon.
PEELIN6
lnsoeclion to pageB 69, inspectthe lollowingparts: Refb.ring 1.Timingbelt 2. Timingbelttengonerand spnng 3. Timingbeltpulley 4. Camshaft PLrlleY
lnslallationnole Tensioner,tensionersP.ing and the tensionerspring 1. lnstallthe tensioner withthe springfullyexsecllrethe tensioner 2. Temoorarilv tenoeo.
Timinq belt 1.Verii lhalthelrmingbellpulleymarkls alQnedwiththetimIng marK.
B-14
ON.VEHICLEMAINTENANCE 2. Installthe timingbeltso thatthereis no looseness at the tensionside. Caution . Do not tum the crankahaftcounterqlockwbe.
3. Installthe pulleybossand pulleylockbolt. two turnsclockwise, andfacethe pin 4. Turnthe crankshaft on the pulleybossuPright. 5. Verifythatthecamshaftpulleymarksare alignedwiththe cylinderheadcovermarks. lf notaligned,removethetimingbeltand repeatfromten' sionerinstallation.
6. Loosenlhetensioner lockboltto applytensionto thetiming belt. Caution . Be sure not to applytensionother than that of the ienslonerspring. lookbolt. 7. Tightenthe tensioner Tighleningtorque: 19-25 N.m(1.9-2,6 m-kg, 14-19 ft-lb)
9aN (10 kg, 22 lb)
8. Turnthe crankshaft 2 turnsclockwiseand verifythatthe marksare correctlyaligned. pree by applying moderate 9. Checkthetiming beltdeflection thecrankshaft sure(98 N, l0 kg, 22 lb) midwaybetween pulleyandthe camshaftpulley. ll the timingbeltdellection is notcorrect,temporarily se lockboltsothespringis fullyextended and curetensioner spring. repeatsteps4-8 aboveor replacethe tensioner Deflection: 11.0-13.0mm(0.43-0.st In) at 98 N (10kg, 22 lb) pulleylockboftandpulleybossusingtheSST. 10.Removethe Pulley lock bolt pulleyand tightenthe pulleylockboll lnstallthe crankshaft the SST. using Tighteningtorque: 157-167 N.m(16-17 m-kg,116-123 lt-lb)
B-15
ON.VEHICLEMAINTENANCE Plate 1. Installthe plate. Tlghteninglorque: iz-tz Nrn (1.25-1.7s m-kE,109-152 in'lb)
2. Littthe engineand installthe enginemountNo3. Tiohtenino torque: -ss-r li H.. (g.s-t1.9 m-kg,8.2-10.3in-lb)
@ 3. lnstallthe stabilizer. Tiohteninqlorque: !l-sz itm (5.s-5.9 m-ks, 4.7-5.9 innb)
Steps After Installation 1. Lowerthe vehicle. 2. Connectthe negativebatterycable. 3. Startthe engineand checkas follows: . lgnitiontiming(Referto pageB-8.)
B-16
MAINTENANCE ON-VEHICLE CYLINDERHEADGASKET Replacement Caulion . Positionlhe hose clamp in the orlginal locationon the hose, and squeezethe clamp lighlly with large pliers to ensure a good fit. 1. Disconnect the negativebatterycable. 2. Drainthe englnecoolantintoa container. 3. Removein the ordershownin the figure,referringlo RemovalNote. 4. Installin the reverseorderof removal,referringto InstallationNole.
(30-110 orl(gi 3r-95 h.tb) firs-11o cn-&, 6s-95 in.lb)
FEPLACE
r9-2s11.e-2.6,r4-r9)
1. Air cleanerassembly cable 2. Accelerator page B-20 Installation Note........-..... -........... 3. Throttlecable 4. Hoses page B-18 Flemoval / Installation Note.--...... 5. Harnesses page B-19 Flemoval / lnstallation Note......... 6. Waierbypasspipe nutsand bolts 7. Alternator drivebelt 8. Waterpumppulley 9. Timingbeltcover,upper
10.Timingbell pageB 12 Removal / Insta||ation.................. pipe 11.Frontexhaust 12.lntakemaniioldstay 13.Cylinderheadcover 14.Cylinderheadbolt RemovN a lo t e . . . . . . . . . . . . . . . . .p. .a. g . .e.B. . .1. .9. pageB 20 Note.......................... lnstallation 15.Cylinder head pageB-40 Disassembly ............................... 1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.B. .-.4. .8. . . . . A s s e m b 1 y . . . . . . . . . . . . . . . . . . .p. .a. g . .e.B. .-.7. .2. . . . . . 16.Cylinderheadgasket
B-17
ON.VEHICLEMAINTENANCE Removal/ Installationngte Hoses the hosesshownin the figure. Disconnect
'1.Brakevacuumhose 2. Fuelhose
B-18
valve) 3. Vacuumhose(solenoid 4. Heaterhose
MAINTENANCE ON-VEHICLE Hatnesses the harnessconnectorsshownin the figure. Disconnect
01EOBr162
Cylinderhead bolt 1. Loosenthecylinderheadbol{sintwoor threestepsinthe ordershownin the figure. 2. Removethe cylinderheadbolts.
B-19
MAINTENANCE ON-VEHICLE lnstallationnote Cvlinderhead bolt 1. Applycleanengineoilto the boltthreadsand seatfaces 2. Installthe cylinderheadbolts. 3. Tightenthecylinderheadboltsin twoor threestepsinthe ordershownin thefigure. Tiohtenlnq toroue: -N.n is-gr 1z.z-a.l m-rg, s6-60 ft-lb)
Acceleralorcable cable. 1. Installthe accelerator cabledeflectior 2. Checkthe accelerator is not correct,adjustby turningnut @. lf the deflection Delleciion:1-3mm (0,04-0'12 in)
Steps alter installation 1. Fillthe radiatorwiththe specifiedamountand typeof enginecoolant(Referto SectionE.) 2. Conneclthe negativebatterycable. 3. Startthe engineand checkas tollows: (1) Engineoil and enginecoolantleakage (2) lgnitiontiming,idle speed(Referto pageB-8.) (3) Operation of emissioncontrolsystem 4. Recheckthe enginecoolantlevel.
B-20
ON.VEHICLEMAINTENANCE FRONTOIL SEAL Replacement 1.Disconnect the negalivebaherycable. 2. Removein the ordershownin the figlre, retefiingto RemovalNole. 3. lnstallin the reverseorderof removal.referrinoto lnstallationNole.
I ../
-
---'r@\! (a l-.i €., $
43) aieurce
-na
Io 1.Timingbelt pageB-12 Removal/ Inslallation.................. pulley 2. Timing belt page B-22 lnstallation Note..........................
3. Oil seal RemovalNote...........-...-............... pageB-22 ................ lnstallation Note..........
Removalnote Oil seal 1. Cutthe oil seallip witha razorknife. protecled wilha rag. 2. Remove theoilsealwilha screwdriver
B-21
ON.VEHICLEIAINTENANCE lnslallationnote Oil seal '1.Apply of cleanengineoiltothelapol a new a smallamount oil seal. 2. Pushthe oil sealslightlyin by hand. Cautlon . The oilseal must be tapPedin until it is flush with the edge ot the oil PumPbody' pipeanda hammer' 3. Taptheoilsealinevenlywitha suitable Oil seal outer dlametet:50.5mm(1.98 in) Timing belt pulley 1. lnstallthetimingbeltpulley. pulleyWoodruff keywiththetaperedsidetoward 2. lnstallthe the oil pumpbody. \ ALIGN KEY GFIOOVE
B-22
ON.VEHICLEi,|AINTENANCE REAFOIL SEAL Beplacement 1.Disconnect the negativebatterycable. 2. Removein the ordershownin the ligure,referringto RemovalNote. 3. Installin the reverseorderot removal,referringto lnstallationNote.
@E
gs ; a\&h
ffi
(MTX) 1.Transaxle 3. Flywheel RemovN a lo t e . . . . . . . . . . . . . . . . . . . . - - b. .e. .l .o. w ..... MTX i oont e . . . . . . . . . . . . . . . p S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . . .S . .e. .c. t. i.o.J.n. . . . . . . . . l n s t a l l a t N . .a. .g. .eB . . -. 2 . .4 ATX 4. Driveplare(ATX) pageB-24 -........................ Removal Note.... S e r v i c e . . . . . . . . .............- . . . . . . . . .S. .e. .c.t.i.oKn pageB 25 2. Clutchcover,clutchdisc (MTX) Installation Note...-...................... S e r v i c e . - . . . . . . - . - . . - . . . . . . . . - . . . - - . . . . . . . . . . 5. -..O . Si les cetai ol n H pageB-24 ................ Removal Note............. pageB 24 Installation Note......-................... Removalnote Flywheel(MTx) Caution . Add approx13mm(0,51In)ol spacers(@) to space the SST away lrom the cylinder block, (MTX) 1. Holdthe flywheelwiththe SST. 2. Removethe flywheelbolts. 3. Removethe flywheel.
B-23
ON.VEHICLEMAINTENANCE Diive plate (ATX) 1. Holdthe driveplatewiththe SST. 2. Removethe driveplatelockbolts. 3. Removethe backingplate,driveplate,and adapter
Oil seal '1.Cut the oil seallip witha razorknife 2. Removethe oilsealwitha screwdtiverprotectedwitha rag.
OIL SEAL LIP
1h}'.
w
_
lnstallationnote Oll aeal of cleanengineoiltothelip ota new 1. Applya smallamount oil seal2. Pushthe oil sealslightlyin by hand Caution . The oil seal must be tappedin until it is llush wllh the edEeof the rear qover.
ffi'rl
)
pipeanda hammer. 3. Taptheoilsealinevenlywithasuitable Oil seal oute, dlameter:100mm(3'94 in)
@
H
EM
Flvwheel(MTxl s;ahntftomthellwheelbohholesinthecrank1. Femoveihe shattand lromthe llywheelbolts. Caution . ll all the previoussealantcannotbe removedtrom a bolt, replacethe bolt' . Do not apPlysealantIt a new bolt is used. 2. Setthe flywheelontothe crankshaft. 3. Applysealantto the flywheelboltsand installthem. Caulion . Add aporox13mm(0.51in) ot space6 (O) to space the SSi away from the cylinder block. (MTX) 4. Holdthe llvwheelwnhthe SST 5. Trohtenthe bohsin twoor lhreestepsIn lheordershown inlhe figure. Tiohteninq -ge-lOg=lorquei 1.lm ig.g-ro.s m-kg,7l-76 filb)
B-24
ON.VEHICLEMAINTENANCE Drive plate (ATX) fromthe driveplateboltholesin the 1. Removethe sealant andfromthe driveplatebolts. crankshaft Caulion . It all the prevloussealantcannotbe removedtrom a bolt, replacelhe bolt. . Do not apply new sealantif a new bolt is used.
@s
2. Installtheadapier,driveplate,andbackingplateontothe crankshatt. to the driveplateboltsand installthem. 3. Applysealant 4. Holdthe driveplatewiththe SST. 5. Tightenthebohsin tlvoor threestepsin the ordershown in the figure. Tightenlngtorque: 96-103 Nm (9.8-10.5 m-kg, 71-76 ftlb)
StepsAfter lnstallation 1. Connectthe negativebatterycable. 2. Startthe engineand performengineadjustmenis as necessary. 072 osuoBx
B-25
REMOVAL
REMOVAL PROCEDURE the negativebatterycable 1. Disconnect coolanland transaxleoil n the enorne 2. Dra 3 Removern tlie ordetshownrn ihe trgurerefernnglo RemovalNote Slep t
1. Air cleanerassembly 2. Batteryclamp 3. Battery 4. Batterycarrier cable 5. Accelerator 6. Badiatorhose 7. Oilcoolerhose(ATX) 8. Coolingfan connector
B-26
9. Radiaiorbracket and coolingfan assembly 10.Radiator 11.Drivebelt 12.P/Soil pumpand bracket(if equipped) ......pageB-27 Note..................... Removal (if 13.AJCcompressor equipped) ...... . .. ... pa1eB-27 Note..... Rernoval
REMOVAL Removalnote P/S oil pump (il equlpped) Cautlon . Do not damagethe hoaes,
i-
1. Removethe P/Soil pumpwiththe hosesstillconnectedlhe pumpawaytromtheengineandaifixit withwire. 2. Positjon
A 01E08X.062
A,/Ccompressor (it equippeo Caution . Do noi damagelhe hoaes, withthehosesslillconnected. 1. Removethe AJCcompressor thecompressor awayfromtheengineandaflixit 2. Position withwrre.
Steo 2 shownin thefioure. Disconnect the harnessconnectors
B,-27
REMOVAL Steo 3 Disionnectthe hosesshownin the ligure
valve) 3. Vacuumhose(solenoid 1- Brakevacuumhose hose 4. Heater 2. Fuelhose Nlo t e . . . . . . . . . . . . - . . . . . . . . . .b. .e. l.o. .w. . . . . . . . Remova Removalnote Fuel hose Wamlng . Keep sparks and open flame away lrom the tuel area, Cautlon . Coverthe hose wlth a rag becausefuel will spray oul when disconnectlng. . Plugthe disconnectedhosesto avoidfuel leakage.
B-24
.,**d
the fuelhoses. Disconnect
REMOVAL Step 4
GASKET,
B
1.Speedometer cable 2. Shiftcontrolrod (MTX) 3. Extension bar (MTX) 4. Shittcontrolcable(ATX) 5. Frontexhaustpipe 6. Clutchcable
7. Lowerarm R e m o vN a lo t e . . . . . . . . . . ..............p.. a . g eB - 2 9 Driveshatt 8. pageB-30 Removal Note....-........................ L Enginemountmember pageB-30 Fiemoval Note............................. Removalnote Lowet arm 1. Removethe boltsand nutsat the leftandrightlowerarm balljoints.
B-29
REMOVAL themfromthe 2. Pullthe lowerarm downwardto separate knuckles. Caution . Do not damagethe ball-iointdusl boots.
Driveehafi by pryingwitha fromthetransaxle the driveshafts Separate bar inserledbetweenthe shaftand the case. Caution . Do not damagethe oil sgal.
Enoinemount member 1. Suspendthe enoinewrtha chainblock 2. Removethe No.1and No.2enginemountnuts. enginemountmemberboltsandnutsandthe 3. Removethe enginemountmember. Caution . Be caretul so that the engine does not fall when removlngthe member'
ro, J"o,^. ]F "o , 1"n,", MOUMI
B-30
MOUNT
B
REUOVAL Step 5
01EOBX070
1. No.3enginemount
assembiy 2. Engjneand transaxle Removal note...................................... below Removalnote Engineand transaxleassembly Caution . Do not damageanycomponenlsln the enginecompartment, assembiy out as a unrt. Liftthe engineandtransaxle
B-31
REMOVAL Step 6 the engineand kansaxlein the ordershownin the ligure' Sep'arate MTX
ATX
1.Starterand bracket 2. Throttlecable(ATX) 3. No.'1enginemount stitfener 4. Integrated
B-32
and driveplatenuts(ATX) 5. Torqueconverter bolts installatian 6. Transaxle assy. 7.Transaxle
B
ENGINESTANDIiIOUNTING
ENGINESTANDMOUNTING PFEPAFATION
ssT
49 0107 6804
49 L0l0 1A0
Enginestand
Hangerset,
49 1010101
49 1010102 engrne
engrne
4910101A0)
49 LO101Ao)
49 L0t0 103
49 1010104
Hooks
(Pad ol 49 1010 1AO)
lOl
=l
engine
l[$" 49 Lolo 1A0)
4 9 1 0 1 01 0 5
49 10101m
Bolts (Part ol 491010 1A0)
Bolls iParroJ 49 L0t0 1A0)
g
engine
engrne
B-33
ENGINESTANDMOUNTING PROCEDURE Step I Removein the older shownIn lne lgure
GASKET.qEPLACE
C.V'G \\,
6*
n \Jl a o
,'-g-\ SKET,REPLACE
a)5
oi,tuo, @ REPLACE
bracketand idler 4. fuC compressor 5.WaterinletPiPe 6- ExhaustPiPebracket
1. Exhaustmanifoldinsulator 2. Exhaustmanifold 3. Waterbypasspipe L-..:
1-
l-
-) ao- -oj -o)
u l
Frl 1ll1 fi ltr Fr
B-34
Siep 2 Caution . Wheninsrallingthe SST (enginehanger)'use the holes shown in lhe ligure.
ENGINESTANDMOUNTING ji,--\ -
\\J,
,.=r
ie
1. lnstalltheSST(arms)to theholesas shownin thefigure, and looselytightenthe SST (bolts).
l-' ui
2. Assemble the SST (bottsand plale) in the speciliedposition.
-
F
AO
O
I
3. Assemble the SST (nuls, hooks, and bolts) arms. 4. Installthe SST to the respective
Note . Adiust the SST Oolts) so that lea€than 20mm(0.79 in) ol thread is exposed. . Makethe SsT (plateand arms)parallelby adiustIng the SST (bolts and nuis). 5. TightentheSST (boltsand nuts)to atfixthe SSTfirmly.
20mm(0.79 i
6. Mountthe engineon the SST (englnestand).
B-35
DISASSEit!BLY
DISASSEMBLY PREPARATION
ssT
49 E301060
49 E301061
Brake,fing gear
Body (Partof 49 E301060)
49 E301062
49 06361008
Collar
of instalation iller
49 E301060)
49 BO12042
49 BO12012 Body
springlitler
49 80120A2)
4 9 8 0 1 20 1 3
49 8012014
49 BO12OA2)
(Partol 49 8012oA2)
4 9 S 1 2 01 7 0
49 D01l 001
insiallalion ol
Supportblock
4 9 H 0 1 10 0 1 8
49 DO11003 inslallation ot
49 8t 34 045 Pistonpin guide
rods'and valvesprings)so thatthey 1. Codeall identicalparts(suchas piston,pistonrlngs connectrng, removeo trom were whichltley in fie cylinder can be rernslalled alr' waterwithcompressed z. Cf"untn" plrts witha steim cleaner'Blowotf any remaining Note . 6-uring disassemolyof any part or system,be sure to sludy its order of assembly'Also' note any delormation,wear, or damage. 04o $coBr
B-36
DISASSEMBLY AUXILIARYPARTS '1.Draintheengineoil. 2. Disassemble in the ordershownin the fioure.
o o
ro
l
g @
6P
z,
\
N,)
'1.Alternator drivebelt 2. Alternator 3. Intakemanifoldstay 4. lntakemanifoldassembly 5. Intakemanifoldgasket 6. Distributor and highlensionlead
7. No.3enginemountbracket 8. Oil pressure switch L Enginehanger '10.Oil dipstick 11.Sparkplug 12.Oilfilter
B-37
DISASSEMBLY TIMINGBELT in the ordersnownin the figure,referringto DisassemblyNote Disassemble
@
1.WaterPumPPUlleY 2. Crankshait Pulleybolt 3. Plate 4. Crankshaft Pulley 5. Pulleylock bolt Note ...... Dlsassembly 6. Pulleyboss
B-38
7.Timingbeltcover,upper 8. Timingbeltcover'lower 9. " Timinobelt
oirZ.!"totvNote . .
.. page g-47
paseq-99
r n J p " i t i o n . - . . . . .............. . . . p a g e B - 5 9 spring tensioner 1o. '-' Tensioner, -inipeition................. .. .. .. pageB-59
DISASSEMBLY DisassemblyNole Pulley lock boll Caution . Add approxt3mm (0,51in) ot spacers(@)to space lhe SSTawaytrom the cylinder block. (MTX) (IVTX) 1. Holdtheflywheel or driveplaie(ATX)wlththeSST. 2. tlemovethe pulleylockbolt.
Timing belt 1.Turnthe crankshalt and allgnthe marks.
- p\o'9ecrto
2. Markthetimingbeltrotationfor properreinsialiation.
- ' g r -\;-,/\.t
\\-zz
W:
S== "G
Caution . Neverforcetullytwist the timing belt. Do not lurn it insideout or bend it. . Be carelul not to allow oil or greaseon the belt,
W*ff.,f B-39
DISASSEMBLY CYLINDERHEAD in the ordershownin the figure,referrinqto DisassemblyNoie. Disassemble
@\
1. Cylinderheadcoverand gasket coverano gasKel 2. Thermostal 3. Thermostal 4. Thermosensor 5. Rockerarm and shattassembly note..... . .- . . pageB-41 Disassembly 6. Rockerarm 7. Rockerarm spring 8. Rockershafi 9. Camshaft PulleY Note..... .. . . .. .. pugeg-11 Disassembly pageB-59 Inspeclion......... plate 10.Thrust '11. Camshatt page - B-52 inspection......... head bolts 12.Cylinder ... page Note .. ... - B-41 Disassembly
B-40
head 13 Cylinder 'lnspection pageB-48 ." 'l4 Cylinderheadgasket l5 Valvekeeper pageB-41 Note Disassembly 16 Valvespringseat'upper lT ValvesPrrng ' pageB-52 " " Inspdction lS Valvespringseat'lower 19 - Valve pageB-49 " .. lnspeclion 20 valveseal . paqeB 41 Note Disassembly Jorweal and damage Inspect Valve,g-urde 21 " pageB-49 " " Inspection pageB 50 " Replacement 22.Oil seal
DISASSEMBLY DlsassemblyNote Rocker arm and rocker shaft assembly 1. Removethe rockerarm and rockershaftassembly. 2. Codeallrockerarmsandspringssothattheycanbe rein" stalledinthesameplacesfromwhichtheywereremoved.
Camshafipulley 1. Holdthe camshaftusinga suitablewrenchon the casl hexaoon. 2. Remdvethe camshaftpulleybolt. 3. Removethe camshaftoullev.
Cyllnderhead bolts 1. Loosenthecylinderheadboltsintwoorthreeslepsin the ordershownanthe figure. 2. Removethe cylinderheadbolts.
Valve keeper 1.SettheSSTagainsttheuppervalvespringseatasshown in the figure. 2. Flemove the valvekeepers.
Valveseal Removelhe valvesealwiththe SST
B-41
DISASSEMBLY
f lSJ'"'"'""'nn'oo'"'"".'0''*ot" i.tn",f, 3*:*1T"11?f"-"[TI"tff
, FEPLACE
E
Hr."*".
7. Oil pan diassemblyNote . .... .. .. . pageB-43 lnspectfor damage -2. Timrngbelt Pulley slrainer Oil 8. B-59 Page insie"tion.......... bearingsupportplate(M6sl') 9. Main (MTX) 3 Clutchcover,clutchdisc Ndte..... . ... . .. pageB-44 S e r v i c e . . . . . _ . . . . . . . . . . . . . . . . . .S. .e. .c.t.i.o.H .n. . . . . . . . . Disassem6ly for damage Inspect (MTX) 4 Flvwheel 'Disassembly - Oil - pump .. paqeB-43 10. Note. . i e r v i i e . . . . . . . . . . . . . . . . . . . . . . . . . .S . . e. .c. .t .i o .D .n. . . . Inspeclfor wearand damage seal oil 1. Front (ATX) 1 5 Backi;g pbte. dnveplate and adapter Note ...... ... ... pageB-44 bisassembly Note......... . . . pageB-43 Disaisbmbly 12.Rearcover 6. End Plate 13.Rearoil seal Note ..... .. .... pageB-44 Disassembly
1. ' Water ''i"rv]"".. PumP " "
B-42
E " section
DISASSEMBLY DbaaaemblyNote Flywheel Cautlon . Add approx l3mm (0.51In) ot spacets (@) lo space the SSTaway trom lhe cylinder block. (MTX) 1. Holdtheflywheelwiththe SST. 2. Loosentheclutchcoverboltsin two or threestepsin the ordershownin the figure. 3. Removethe clutchcove.. 4. Removethe flywheelbolts. 5. Bemovetheflywheel. 6. Removethe SST. Backingplate, drive plate, and adapter(ATX) '1.Holdthe driveplatewiththe SST. 2. Removethe driveplatebotts. 3. Removethe backingplate,driveplate,and adapter. 4. Removethe SST.
@ Oll pan '1.Removethe oil pan mountingbolts. toolbetweenthe IVIBSP or a suitable 2. lnsena screwdriver and oil pan,and Prythemapart. Caution . Do not insert the prying tool betweenthe MBSPand cylinder block. . Do not damageor sc6tch the contactsurfaces.
B-43
DISASSEMBLY ain beadngsupport plate (MBSP) '1.Removethe MBSPmountingboltsfromthe mainbearing cao. the MBSP tool between or a suitable 2. Indena screwdriver pry themapart. and cylinderblock,and Cautlon . Do not damage or scratch the contact surlaceg when removlngold sealant.
Front oll seal protected witha rag. Removetheoil sealwitha screwdriver THEPUMP PFOTECT
THEEEAACOVEFI PFOTECT
B-44
Rsar oil seal protected witha rag. Removetheoil sealwitha screwdriver
DISASSEMBLY CYLINDEFBLOCKONTERNALPAFTSI D,sassemble in rhe ordershown,n the tigure,refefiinglo DisassemblyNote.
tr/:r
v
ry n
I
1.Connecting rod cap 6. Piston page8-46 pageB-56 Disassembly Note...................... Inspection..................-................ 2. Connecting rod 7. [/ain bearingcap pageB-47 page8-46 Disassembly Note.......-............. Disassembly Note...................... pageB-57 Inspection....-.......-...................... 8. Crankshaft pageB-47 rod bearing Note.......-.............. 3. Connecting Disassembly I n s p e c t i o n . . . . . . . . . . . . . - . . . . p. .a- .g. e.B . .-.5. .8. . - . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. .g. e.B . .-.5. .8. . . . . 4. Pislonring 9. Mainbearing pageB-58 pageB-46 Disassembly Note...................... Inspection......................-....-....... page8-56 10.Thrustbearing Inspection......................-............ 5. Pistonpin 11.Oilfilterjoint page8-46 12. Cylinder Note...................... Disassembly block I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .eB . . -. .5.4. . . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g . .e.B. .-.5. .7. . . . .
B-45
DISASSEI'BLY DisassemblyNote Connectingrod caP theconrodcaps'measure d-torJie.dving tne'connecting page B 66 (Reler to ) ieciino roo sid6clearance
Connectlnqrod theconnect re;ovrnglneconnecingrods'measure 1. Before B-57 page (Refer to ) ino roo oil clea'rance-
fromthe crankpiniournals' 2. Removeihe Plastigage Caulion l-do-not ""rar"tt ttt" clankshaftiournalor the cylinder wall. to removethepl$onandcon3. - Usethehandleot a hammer thetopofthecylinderblock through uo".uly t; i*tlng
Pision ring Caution . oJ not apptyexcessivetension,which may cause the rings to anapoul. Removethe pistonringswitha pistonringexpander(comavailable) merciallv
Plston oin Caution . Ma* lhe connectingrod directionfol proPerreassembly. '1.Beforedisassembling rod'check thepistonandconnecting shown. as torque the oscillation iiin"luioe Lno aoe" notdrop by itsownweight,replace the pistonor the PistonPin
B-46
DISASSEMBLY the SST as shown. 2. Assemble
rodintheSSTasshown. 3. l\rountthepistonandconnecting piston the 4- Pressout Pin. the oistonpin,checkthe pressurelf iI is Whileremovino lowerthan4905N (500 kg, 1100lb)' replacethe piston pin or connectrng rod.
@TEE ltlaln bearingcap lhecrankcaps measure theman beanng 1 Belorerem6ving page 8-65 play. (Reter to shaftend )
2. Loosenthe mainbearingcap boltsin two or threesteps in the ordershownin the figure. Remove the mainbearingcaps 3.
Crankshaft measurethe mainbearing the crankshaft, Beforeremovino (Refer page B-74.) to clearances. oil
B-47
/ REPAIR INSPECTION
/ REPAIR INSPECTION PREPARATION
ssr
49 BO12005
gulde(83)
and restdue' dirt,oil'grease'carbonmoisture 1. Cleanallparts,beingsureto removeallgasketfragments, olherloreignmaterlals repairsmustbe pertormedIn the orderspecified' Z. tnsoection"anO
Caution (suchas the cy'fuiJt a"t"s" rne ioints orlrlction surtacesol alumlnumalloycomponents Inder head or pistons). orEoBx.oe3
CYLINDERHEAD headfordamage,cracks,andleakage i. lnspectthecyhnder ot walerand oll. Replacethe cylinderheadif necessary in the six directions Z. i,reaiuielni cvtinaerheaddistortion shownin the figure. Distortion:0.l5mm (0.006in) max. Caution -selole qrinalns the cylinder head,checkth€ tollow' . ing ani repair or rePlacethe cylinder head as necesaary. Sinklngol valve seals Damagl ot manifgldcgntacl sudace cams6aftoil clearancesand end play
grind exceedsspecification' 3. lf thecylinderheaddislortion the cvlindelheadsurface redace ii tnetvtinoerneaonerghlis notwithinspecilrcation it. Heiohl: 107.4-107.6mm(4,228-4'236 In) Gri;ding: o.20mm(0.008in) max.
B-48
INSPECTION / REPAIR the manifoldcontactsurfacedistortion in the six 4. l\4easure shownin the figure. directions oistorllon: 0.t5mm (0.006in) max. grindthe surfaceor reexceedsspecification, 5. lf distortion olacethe cvlinderhead.
4.. -sreure fJ
VALVEMECHANISM Valveand ValveGulde Replaceor resurlace 1. Inspecteachvalvefor thefollowing. the valveil necessary. (1) Damagedor bentstem (2) Roughor damagedface (3) Darnagedor unevenlywornstemtip 2. Measurethe valveheadmarginlhickness01eachvalve. Replacethe valveif necessary. Marginthicknesamin. mm {in) B3 1.1(0.043) 1.2(O.O47)
IN
THICKNESS
EX
3. Measurethe lengthof eachvalve. Length Standard
IN
Standa.d
EX
Minimum
B3 108.2414.261't 107.74 14.241 109.34{4.304) 108.84(4.?85)
4. Measurethe stemdiameterof each valveal the points Dlameter B3 IN
EX
5.970-5_985i0.2350-0.2356) 5.965-5.980 {0.2348-0.23541
5. Measurethe innerdiameterof eachvalveguideat the points shown. lnner diameter IN, EX
B3 6.01-6.03(0.2366-02374)
6. Calculate the valvestemto guideclearanceSubtracttheouterdiameterof the valvestemfromthe invalveguide. ner diameterof the corresponding
|h"::
Clearance In) lN r 0.025-0.060mm (0.0010--1t.0024 EX: 0.030-0.065mm (0.0012-0.0026in) Maximum:0.20mm(0.008In)
replacethe valve 7. lf the clearanceexceedssp€cification, and/orvalveguide.
B-49
/ BEPAIR INSPECTION 8. Measurethe protrusionheightof eachvalveguide Replace the valveguideil necessary. Height
mm{in)
CYLINDEF HEAD
Replacementol valve guide
of the intakeand exhaustvalve lll? tte strapes installcorrectly' guidesarealitferent,
EX
IN
thecombus' u"ru"srioelromthesideopposite B:fio9Jilh.
tion chamberwiththe SST
rlH
Installation 1. Fitthe clip ontothe valveguide'
\]H ffi IN
combustion 2. - UsinqlheSST.tapthevalveguideiniromthe A (dimension herghl protrusion "n"ril"i "io" to inat the In the figure)is withrnspecilication
:a;l?h
sft|kehardarterthecllPcontactsthecvlin-
der head, the cliP will be damaged'
B-s0
INSPECTION / REPAIR ValveSeat 1. Inspectthe contactsurtaceof eachvalveseatand valve facefor thefollowing: (1) Roughness (2) Damage valveseatwitha45" valveseat resurfacethe 2. lf necessary, the valveface. cutterand/orresurface
db
blueto the valvelace. 3. Applya thincoatol Prussian thevalveagainstthe valveseatingby pressing 4. Inspectthe seat. (1) li bluedoesnotappear3600aroundthevalveface,replacethe valve. (2) lf bluedoesnotappear3600aroundthe valveseat, resurlace the seat.
v..vl \ \€=:.,
5. Measurethe seatcontactwidth. width EAT CONTACTWIDTH
mm (in) IN,EX
B3 0.8-1.4 (0.031-0.0s5)
if IN
E"'il
6. Verifvthatthevalveseatingposiiionis at thecenterof the vave Tace. (1) lf theseatingposition istoohigh,correctthevalveseat witha 70o cutterand a 45" cutter (2) lf the seatingposition is too low correctthevalveseat witha 40' cutterand a 45o cutter 7. Seatthe valveto the valveseatwithlappingcompound.
8. Inspectthe sinkingol the valveseat. length{djmension L) of the valve Measuretheprotruding stem. DIMENSION!
DimensionL: 41.05-41.95mm(1.616-1.652in)
B-51
/ REPAIR INSPECTION mm (n) 41.5-420 {r.634 1.654) 42.0-43.0 (1.654-1.693)
[4orethana3 0 (1.693)
No correctonn€€ded Adjuslwithwasheron sping seal areaof cylinderhead Beplacecylinderhead
ValveSpring 1. Inspecteachvalvespringlor cracksand damage 2. Measurethe freelengthand out oi squareReplacethe valvespringif necessary. Frge length
IN EX
(kg lb)/mm(in) (in),Mit]imum...N standard...mm B3 (1.602) 40 7 Slandard 0 (1417) 2988-3381!36 7 (r358 1s.37. Minimum 133.2-r50 40.70.602) Slandard 4.88-338l)860 (1414 L4inimum 133.2-150.i 0358-15.3/
Out-ol-square IN
EX
1.42(0.055) 1.42(0055)
CAMSHAFT 1. Setthe frontand reariournalson V-blocks2. Measurethe camshaftrunout Replacethe camshaftif necessarv. Runout:0.03mm(0'00'12in) max.
3. Inspectthe camshaftfor wearand damageReplacethe camshafiiJnecessary. thecamlobeheightsatthetwo pointsasshown 4. Measure
#@ B-52
Height
IN
mm {rnl Slandard
lVlnimum Slandard [,'linrm!m
B3 36.5270.4380) (1.4301) 36.327 36.333(1.4304) 36.133i'1.422s)
INSPECTION / REPAIR X andY directions atthetwo 5. Measurethe iournaldiameters points(@ and @) shown. Diameter No.l & No.s No-2& No.4 No.3
B3 (1.7102-17.1 10) 43.440*43.460 (1.7096-1.7106) 43.425-43.450 43.41O 43.43511.7O9 1, 1.71OO)
Out of round: 0.05mm(0.002in) max, lhecamshaft andcyl 6. Measure theoilclearances between inderhead. and allioreignmaterial andoilfromthejournals {1) Remove the camshaftbore. (2) lvleasure the camshaftborediameter. 03u081105
Diameler No.1& No.5 N o . 2 ,N o 3 , N o 4
mm(in) B3 43.500-43.525 0.7r26-1.7135) (1.7126-1.7135) 43.500-43.525
(3) Subtract the journaldiameterlromthe borediameter.
Oil clealance No.1& No.5 No2&No4 No-3
0.040 0.085(0.0016 0_0033) 0.050 0.100(0.0019 0.0039) 0.065-0.115 (0.0a25-0.0045) 0.15(0.006)
(4) li theclearanceexceedsthemaximum,replacethecamshaftor cylinderhead themaximum, thecamshaft endplay.lf itexceeds 7. Measure reolacethe thrustolateor camshaft. End play : 0.060-0.200mm (0.0023-0.0078in) Maxlmumr0.2mm(0.007in)
B-53
/ REPAIR INSPECTION RockerArm and BockerArm Shaft 1. Checkfor wearor damageto thecontactsurfaceof therocker arm shattor the rockerarm-Replaceif necessary the rockerarmandshalt between 2. Checktheoilclearance Replaceif necessary. (1) Measurethe rockerarm innerdiameter' Diameter
G
IN EX
B3 (0.7480-0.7493) 9.033 19.000-l
(2) Measurethe rockerarm shattdiameler' Diameter l N , EX
B3 1&959-18.980(0.7464-0.7472)
(3) Subt.actthe shaftdiameterfrom the rocke' arm di' ameler.
Oil clearance tN, EX
mm (in) B3 0o20-o 074(00008-0.0029) 010 (0.004)
BLOCK CYLINOER 1. Checkthecylinderblocklorthefollowingand'epalror replacethe cylinderblockas necessary (1) Leakagedamage (2) Cracks. (3) Sconngol wall block oflhetopsLriaceoi lhecvlinder Z. Miasurethi distonion shownin figure in the slx directions (0.006in) max. Distortion:0.15mm exceedsthe maximum.repairby grinding 3. lf thedistortion or replacethe cylinderbiock Height:22l.smm(8'720in) Grinding:0.20mm(0'008in) max.
B-54
INSPECTION / REPAIR
___n_ o c2 So z/-I\"
r"$\1-l^
o\ 4o -L__-r-
H
4. Measurethe cylinderboresin X and Y directionsat ihree levels(A, B, and C) in each cylinderas shown. Cylinder bore
mm(rnl B3
Slandard
0-25(0.010)oversize 0.s0(0.020)overcize 0.75 (0 030) oversize 1.00 (0.04)oversEe
71.006-71.013 (2.7955-2.7958)
7 1.256-71.26312.8053,2.4056) 71.506-71.51312.81522.8155) 7 t.756-71.763(2.8250 2.8253) 72.046 72.013 12.8349-2.4352)
Caution . The boring size should be basedon the sizeof an overslzepislon and be the sametor all cylinders. (1) lf thecylinderboreexceedsthe maximum, reborethe cylinderto oversize(2) If the difference betweenmeasu.ements A and C exceeds the maximumtaper, reborethe cylinderto overslze. (0.0007in) max. Taper:0,01gmm
o7
so
71"1--\v
(3) lf the difierencebetweenmeasurements X and Y ex' ceedsthe maximumoutof-round,feboreihe cy{inder to oversrze. Out-ol-round:0.01gmm(0.0007in) max.
Os-to 5. lftheupperpartof a cylinderwallshowsunevenwear, rnovethe ridgewitha ridgereamer.
ry B-55
INSPECTION / REPAIR PIN PISTON.PISTONRING,AND PTSTON Plston Caution . lf the piston is reptaced,the pistonrings mustalso be replaced.
o - R|NG
GnoovE lo.7min) OIAMETER
of all pistonsfor seizure 1. Inspectthe outercircumferences piston f necessary or scoring.Replacethe of eachpistonat a rightangle outerdiameter 2. Measureihe (90o)to the pistonp n, 16.5mm(0'650in) belowthe oil ring landloweredge. Piston diameter
mm{in) 70.961-7 0.967 \2.7937 2.7939)
0.25 (0.010)ove6ze
71.211 71.217I2.AO36-2.aO2A)
0.50(0.020)oversze 0.75(0.030)oversrze ] 00 (004)oversize
71.461 71.46712A134-2.8137) 7 t .711-71 .717 Q.A2$-2.A235)
(2.83312.8333) 71.961-7r.967
clearance 3. Measurethe piston{o-cylinder Clearance:0.039-0,052mm (0.0015-0.0020in) Maximum:0.15mm(0.006in) replacethepiston exceedsthe maximum, 4. lf theclearance pistons fit oversize to the cylinders or rebore
Pision and Piston Rings aroundthe the pistonringto ringlandclearance 1. Iveasure plslon nng. usrnga new enlirecircumference Clearance(Top and Second) B3 0.030-0.070(0.0012-00028) 015 {0.006)
replacethepiston. the maximum, exceeds 2 . lf theclearance 3 . Inspectthe pistonringsfor damage,abnormalwear,and breakage.Replacethe pistonringsii necessary
4. Inserttlie pistonring intothe cylinderby handand usethe Distonto oush it to the bottom of the ring travel
FING
B-56
INSPECTION / REPAIR 5. Measure eachpislonringendgapwitha feelergauge.Replacethe pistonringif necessary. Erd gap Top : 0.15-0.30mm(0.006-0.012in) Second: 0.30-0.45mm(0,011-0,017in) Oil rail : 0.20-0.70mm (0.008-0.028 in) Maximum: 1.omm(0.039in)
Pistonand PistonPin 1. Measureeachpistonpin holediameterin X andY directionsat lour points. Diameier:19.988-20.000mm(0-7869-0.7874in) f-6t'1
L'----\-v in X andY directions 2. Measure eachoistonoindiameler ai four points. Diameter:19.974-19.980mm(0.7864-0.7866in) the oistonDin{eoistonclearance. 3. Caiculate Clearance:0,008-0.026mm(0.0003-0.0010in) 4. Il the clearance exceedsspecification, replacethe piston and/ofoistonoin. ROD CONNECTING rod bushinginnerdiameter. 1. Measureeachconnecting Diameter:19.943-19.96lmm (0.7852-0.7859in) c/earance theconnectino rodbush2. Calculatethe between ingandpistonpin. Interterence:0.013-0.037mm(0.0005-0.0015in)
rod for bending.Repairor re 3. Measureeachconnecting placethe connecting rod if necessary. Bending.'0.075mm(0.0030in) max./somm(1.97 in)
B-57
/ REPAIR INSPECTION CRANKSHAFT andpinsfor damage,scoring,and oil 1. Checkthe iournals holeclogging. on V'blocks. 2. Setthe crankshaft runoutat the centerlournal. 3. Measurethe crankshaft if necessary. Replacethe crankshaft Runout:0.04mm(0.0016in) max'
attwo in X andY directions 4. Measure eachiournaldiameter points.
t
t
f----T----i
\
\i_,i
Main iournal Diameter:49.938-49.956mm(1.9661-1.9668in) Out-of-round:0.05mm(0.0020in) max. Crankpiniournal Diameter:39.940-39.956mm(1.5724-1.5731in) Out-ol-round:0,05mm(0,0020in) 6ax. grindthelournals is lessthantheminimum, 5. lfthediameter bearing. to matchan undersize Undersizebea ng: 0.25mm(0.010in), 0.50mm(0.020in), 0.75mm(0.030In) Main iournal diameterundelsize Bearinosize 0.25(0.010)undersze 0.50(0.020)undersze 0.75 (0.030)undelsEe
mm (in)
49.688-49.706 0.9562 1.9569) 49.438-49.456 (1.9463-1.9470)
49 188-49.206(1.9365-1.9372)
Crankpiniournal diamelerundersize 0.25 {0.010)unde6ize
irndersize 0.5010.020) 0.7510.030) Lrndersize
EB E
$drE BB B-58
39.690-39.706 {1.5626-1.5632)
(1.5528-1.5534) 39.440-39.456 (1 39 190-39.206 5429-1 5435)
BEARING Maln Beadngand ConnectingFod Bea ng rod bearings and the connecting Checkthe mainbearings for peeling,scoring,and otherdamage.
/ REPAIR INSPECTION TIMINGBELT
sry6
f,*f^^y
Caution . Neverforcelullylwist, turn insideout, or bendthe timing beh. . Do nol allow oil or greaseon the belt,
1. Replacethe timingbeltif thereis any oil or greaseon it 2. Checkthetimingbeltfor damage,wear,peeling,cracks, Replacethe timingbeltil necessary. and hardening.
IDLER TENSIONER,
G
Caution . Do not clean the lensioneror idler with cleanlng fluids. ll necessary, use a solt lag to wiPe them clean,and avoid scratchingthem. andabnorandidlerforsmoothrotation Checkthetensioner idler il necessary or Fleplace the tensioner mal noise.
SPRING TENSIONER spring.Replace the Measure thelreelengthof thetensioner tensionerspring'f necessary. Free length: 54.0mm(2.520in)
r-'E
T{7\\E sry
lilll-1LlE
-5*\
reF.rsr- ZilF\ Vg
PULLEY Timing Belt Pulley,CamshaltPulley Cautlon . Do not clean the pulleys with cleaninglluids' ll necessary,use a soft rag to wipe them clean,and avoid scralchingthem. andotherdampulleyteethforwear,deformation, Inspectthe pulley if necessary. the Beplace age.
B-59
ASSEII/IBLY
ASSEMBLY PREPARATION
ssT
49 D011001
49 H0110018
supponblock
Supportblock
49 D011003
49 8134 044 Pistonpin quide
installer
insiallationol
inslalatLon
pislonpins
49 E301060
49 E301061
Brak€,rng gear
Body
ean oi
49 E3o1060)
49 AO12oPe
49 E301062 Collat (Parl oi 49 E301060)
enginerotation
498012013
49 B0l2 012 Body (Parloi 49 BO120A2)
installalion sping lilier
of inslallation
inslallation of
(Partor 49Bo120A2)
49 06361008
49 8012014 installationof
installationof lilter
49 80120A2)
4 9 S E 0 13 1 0
installationof
Centellngtool,
1. Cleanall partsbeforereinstallation. 2. Aoplvnew engineoil to all slidingand rotatilgparts. 3. R;phce plainbearingsif theyare peelingburned'or otherwseoamageo 4 Tidhrenall boltsand nuls1othe specifiedtorques
cluton
. Do not reuse Easketsor oil seals.
B-60
ASSEMBLY CYLINDERBLOCK(INTERNALPARTS) Torque Specifications
CYUNOEF WALLS PAOTBUSTON 19mm(0.75in)
JOUFNALS
T
8-61
ASSEMBLY ConnectingRod the SST as shown. 1. Assemble
2. Applyengineoil to the pistonpln
3. Setthe oistonon theSSTwiththe F markfacingupward rod in the dlrec' 4 Assemtjle the oistonandthe connecting disassembled were they which tionfrom Pressure torce: 4905-14715 N (500-1s00 kg' I100-3300 lb)
MABK INOENTIFICATION
torce lf fie plstonpin.checkthe pressure 5. Whirernserting pin piston the conor the replace it rslessthanaoecified, neclnoroq. rodun6- Pressihepistonoinintothepistonandconnecting til the SST contactsthe stopperbolt roo torqueof the connectlng 7. Checkthe oscillation (Referto Page8-46.)
Piston Ring oil ringson the pistons 1. lnstallthe three-piece (1) Applvcleanengineoirlo theotlringspacerand rails i2) lnslallthe oil rinOspacerwithlhe endsupwaro Note . ihe upperand lowertails a.e the sameand maybe lnstalied with elther lace upward. (3) Installthe upperrailand lowe' rail
8,-62
ASSEMBLY as 2. Verifythatbothrailsareexpandedbythespacertangs therailsturn smoothly showninthefigurebymakingcertain in bothdiections. -,.--'-) sEcoNo
-/D
Caution . The rings must be installed wlth the R marks upward. . The secondring musl be installedwith the sclaper face downward.
3. Applycleanengineoilto thetop andsecondpistonrangs thetopring. theninstall 4. Install thesecondringto thepiston; available). Usea pistonringexpander(commercially
O I LF I N G SPACEF ENOS PISTON
the end gapsof the ringsas shownin thefigure 5. Position OIL RING
OIL FING
PISTON
SECOND RING
Oil Filter Jolnl as specified. Installthe oil filteriointso that il protrudes Prolrusion:19mm(0.75in)
PLASTIGAGE
Crankshaft inspectthe mainbearing thecrankshaft, 1- Beioreinstalling as follows. oil clearances Oil clearanceinspection and andoilfromthejournals (1) Remove alltoreignmaterjal Deallngs.
Caution . Installthe gtooveduppermain bearingsin the cyF inder block. . lnstall the thrust bearingswith the oil groovefac' Ing the crankshaft.
B-63
ASSEMBLY THFUSI METAL
(2) lnstallthe uppermainbeanngsand thrustbearings in the cyl'nderblock i3t Setthe crankshatt Caution lio not totate rtte crankshaftwhen measutinglhe oil clealances. (4) PositionPlastigageatop the journalsin the axal directton.
mainbearing (5) '-' Installthe lowermainbeanngsand the € mark and number cap to tne iaos according steps (6) - Tnh€n themainbearingcapbollsIntlvoor thre€ in'theordershownin the figure.
t'?l':!'Jt*.ii'irT-".0 40-43n'rb) m-ks,
lhePlaslF caps.aFdmeasure themainbearing '17) ' Remove poini for the smallest purnal wldest the at oaoeat each largest point for lhe narrowest lhe al and ileirance clearance. grind lhe fgr ' ' lt lhe oil clearanceexceedsspecilicalion bearings and useunderszemain crankshaft (Referto PageB-58.) Oil clearance:0.018-O,O36mm(0'0007--'{''0014in) Maximum:O.lomm(0.004in) 2. Applya |beralamountol cleanengineoilto themainbea' bearingsano mainlournals inqs,'thrusr andthe marnbean'rgcapsaccordcrarkst'Jtl s. inidr thi and e mark. number the cap to ing
4. Tiohtenthe mainbearingcap boltsin two or threesteps in the ordershownin the figure torque: Tiqhteninq -Hm !r-sg 15.s-o'o m-rg, 40-43 ft'lb)
B-64
ASSEII'BLY 5. l\4easure the crankshaft end play. Endplay: 0.080-0.282mm(0.0031-0.0111 In) Maximum:0.30mm(0.012in)
(_. :/:\
,.-
y oe,l rl |Qro. grindthecrankshaft 6. lf theendplayexceedsthe maximum, andinstallanoveasize thrustbearingor replacethecrankshaftand thrustbearing. Thrust beadngwidth Standard: 2.500-2.550mm(0.0984-0.1004 in) 0.25mm(0.0t0 ln) overaize: 2.625-2.675mm(0.1033-0.1053in) 0.50mm(0.020in) ove6ize: 2.750-2.800mm(0.1083-0.1102 tn) 0.75mm(0.030in) oversize: 2.875-2.925mm(0,1132-0.1152 in) Pision and ConneciingRod Assembly Cautlon . Prolectthe connectingrod bolts with rubbersleeves to prevenldamageto the crankpiniournals.
t'r
\'rinl|* Rod Cap Connectlng '1.[/easufetheconnecting rod bearingoil clearances usang thesameprocedure asfor themainbearingoilclearance. Caution . Align lhe matchingmarksgn lhe cap and the connectingrod wheninstallingthe connectingrod cap. Tighleningtorque: 29-34 N.m(3.0-3.5 m-kg, 22-25 ft-lbl
MATCHINGMAFKS
Oil clearance:0.028-0.068mm(0.0011-0.0027 in) Maximum:0.lomm (0.004in) grindthecrank2. lftheoilclearance maximum, exceedsthe (Referto pageB-58.) shaftand useundersize bearings.
B-65
ASSEMBLY rod sideclearances' the connecting 3. lvleasure IOCATION MEASURTNG
Sideclearance:0.110-0.262mm(0.0043-0.0103in) Maximum:0.30m8 (0.012ln) exceedsthe maximum'replacethe con4. lf lheclearance nectingrod and cap.
5. Apprya liberalamountof cleanengineoilto the crankpin roo Deanngs iournalsand connectlng rod capswiththe matchingmarks 6. installthe connecting alioned. rodcap nutsin twoor threesteps theconnecting 7. Tig-hten Tiohteninolorque: is-31-Nm {ir.o-e.s m-t
8-66
'll
ll
I
L))=r
-
ASSEMBLY CYLINDERBLOCK(EXTERNALPARTS) TorqueSpecilications re-25 {1.r-2.6, 14-1r)
GAS(ET,NEW
g r l
v7h
".*$ E
NEW GASKET,
7i-r!
Nn (30-1r0 cm-kq,59-95 in-lb)
GASKET,NEW
(30-1 ro cD-ks, 6s-95 inrb)
GASKET.
--..-t* EEi 13-25 O.3-2.7, r3-20) 03uoB1.133
Fear Cover oiltothelipofa new of cleanengine 1.Applya sma,larnount o seat, 2. Pushthe oil sealslightlyin by hand. Cauiion . The oil sealmust be pressedin until it is flush wilh the edge ot the rear cover. 3. Pressthe oll sealin evenlywitha suitabiepipe. Oil seal outer diameter:100mm(3.94in) 4. Applysiliconesealantto the shadedareashownin the ngure.
8-67
ASSEIIIIBLY ..'i \,
! ILL- -l-
\o /l
5. lnstallthe rearcover. Tiohleninqtoroue: ?.s-t t-N.ma8o-l1O cm'kg,69-95 in-lb)
Oll PumD 1. Applya smallamounlol cleanergineorllo thelipof a new oil seal. 2. Pushthe oil sealslightlyin by hand Caution . The oilseal musl be pressedin until it is llush with the edge of the oil PumPbody. 3. Presslhe oil seal:n evenrywill' a sutablepipe Oil seal outer diametef:44mm(1.73 in) a newgasketand installthe oil pump 4. l\y'ount iorque: Tiohteninq js-zs -N.m{i.s-z.o m-tg, 14-19 tt-lb)
Caulion . Do not sqratchihe oil Pump. 5. Cutawaythe portionof the gasketthatprojectsfromthe bodytowardthe oil Panside
Oil Strainer Mourt a newgaskeland nslalltf'e oil strainer' Tiohteninqtoroue: ?.a-tt-l'lm igo-lto
B-68
cm-kg, 69-95 in-lb)
ASSEi'BLY Oil Pan 1. Removeall foreignmaterial fromthecontactsurfaces. 2. Applysiliconesealantto the shadedareasshownin the figure.
3. Installnewgasketsontothe oil pumpbodyand the rear coverwiththe proiections in the notchesas shownin ihe figure.
l
-/-= {. I
Qr)
4. Applya continuous beadof siliconesealant to the oil pan alongthe insideof lhe boltholesandoverlapthe ends. 5. Installthe oil pan. Tighteningtorque: 7.8-ti N.m(80-110 cm-kg, 69-95 in-lb)
End Plale Installthe end plate. Tighteningtorque: 7.8-ll N.m(80-ll0 sm-kg,69-95 inlb)
@
BM
Flywheel(MTX) 1- Removethesealantfromthetlwheel boltholesinthecrankshaftandtromthe flywheelbolts. Cautlon . lf all the previoussealantcannotbe removedlrom a bolt, replacethe bolt, . Do not apply sealantif a new bolt is used. 2. Setthe flywheelonlothe crankshaft. 3. Applysealantto the flywheelboltsand installthem.
B-69
ASSEMBLY 4. Hold the flywheelwith the SST
Caution . Addapprox13mm(0.51in)ol spacers(O) to space the S5i awaytrom the cylinderblock'(MTX) lhe oollsInn/voor h'ee stepsin tneoldershow4 5. Trghten Tiohtenino -go-roJ torque:
H.mis.s-r0.s m-ks,71-76 tt'lb)
Clutch Disc and Clutch Cover(MTX) Caution . Add aporox13mm(0.51in) of spacers(@) lo space the SSi ayyayfrom the cyllnder block. (MTX) lnstallthe clutchdiscand clutchcoverusingthe SST. (Referto SectionH.) Tiohtenino -t'ttorque: i a-zo m ti.e-z.t
m-xl,13-20 ft'lb)
Drive Plate (ATX) 1.Removelh-esealant{romthe oriveplateboll holesIn the andfromthe driveplatebolts. crankshaft Caution . ll all the previoussealantcannot be removedfrom a bolt. replacethe bolt' . Do nor aiply sealantIt a new bolt is used,
i@el B-70
theaoapter.d've plale,andback|.gplateontolhe 2. Insrall crankshaft. 3 Aoolvsealantto lhe driveplalebolrcand ;nstallthem +. ttbio tne driveplatewiththe SST. 5- Tiohtenlhe bo{sinlwo or lhreestepsin theordershown Tlohtenlnqtolque: !s-rod tt.mig.s-t0.5 m-ks,7l-76 ft-lb)
ASSEMBLY Timlng Belt Pulley 1. Installthetimingbeltpulley. pulleyWoodrutf 2. Installthe keywiththetaperedsidetoward the oil pumpbody.
WaterPump 1. Removeall foreignmaterialfromthe waterpumpmountino surface. 2. PEcea new waterpumpgasketin position. 3. Installthe watefpumo. Tightenlngtolque: 19-25 Nm (1.9-2.6 m-kg, 14-19 ft-lb)
B-71
ASSEMBLY CYLINDEBHEAD TorqueSpecitlcalions
{50-90 cn-kg, 43-73 In'lb}
12,2-2.9, 16-211
e-__u
Pe
(65-e5 cd-&, 56-t2 rFlb)
valve Seal 1. Installthe newvalvesealontothe valveguideby hand adjustthe protrusion @ to specitication 2. Afterinstallation, Proltusion:18.1-18.7mm(0.713-0.736in)
B-72
93GOBr 0S0
ASSEMBLY Valveand ValveSpring 1. Installthe lowerspringseat. 2. lnstallthe valve. @GBEATEFTHAN@
Caution . Installthe spring wlth lhe closer pitch toward the cylinder head. 3. ,nslalllhe valvespnngand the upoerspringseat.
H E A OS I D E
4. Compress tne valvespringw[h the SST.and inslallthe varveKeepers_ 5. Removethe SST. 6. Taptheendofthevalvesternlightlylwoor threetimeswith verifythalthekeepers a plastichammerto arefullyseated.
CylinderHeadGasket 1. Removeall foreignmaterialirom the top of the cylinder block. 2. Placethe newcylinderheadgasketin position. CylinderHead head. 1. Install thecylinder 2. Applycleanenglneoil to the boltthreadsand seatfaces. 3. Tightenthecylinderheadboltsin twoor threestepsin the oroersnown. Tighteninqtorque: 76-81 N.m(7.7-8.3 m-kg, 56-60 tt-lb) CamshattOil Seal 1. Applya thincoatof engineoilto thecamshaft oilsealand cylinderhead. cylinderheadwitha suitaoilsealintothe 2. Tapthecamshaft ble pjpe. Cautlon . The oil seal must be tappedin unlil it is llush with the cylinder head, Oil seal outer diameter:40mm (1.57in) Camshall 1.Applyengineo,lro theJournals andbearing withthethrust 2. Insenandmountthecamshaltintoposition plate.
B-73
ASSEUBLY CamshaftPulley OOWEL PIN ANO PIN GFOOVE
.t'i
Note . Be certainthat the dowel pin ot the camshaftalso laces straighl upward. 1. Insiallthecamshaftpulleyontothe dowelpinwiththepin groovefacingstraightupward
pulleybolt Holdthecamshaflusing the camshatt 2. Trohlen a ;uitablewrenchon Ihe casthexagonas showr. Tiohteninq -ls-ot'itmloroue: (6.0-o.z m-tg, 36-45 ft'lb)
RockerArm and RockerShalt Assembly Cautlon . Facethe rockershalt ldentilicationmark upward' . The installationbolt holes are dlfterentfor the exhausi and intakesides. ldentilication mark Yellowgreen lN ........,.,.... E X . . . . . . . . . . . .P. i. n. k '1. Assemble as the rockerarm and rockershaftassembly shownin the figure2. lnstallthe rockerarmand rockershaftassemblyCaution . Thebolts musl be tightenedgraduallyand in lhe or' der shown. Tidhteninq -zz-za torque:
il.m (tz.z-z.sm-xg,16-21ttlb)
ValveClearanceAdiustment Referto pageB-7.
B-74
ASSEMBLY Temperaturegaugeunit gaugeunitintothecylinderheadwith Installthe temperature sealtape on the threads.
;nY\v
w"ffi
Tlghtenlnglolque: 6.4-9.3 Nm (65-95 cm-kg,56-82 in-lb)
Thermostat and Thermostal Cover cover 1. Removeall foreignmateriallrom the thermostat mountingsurface. 2. Installthe thermostat withthe jigglepinfacingupward. cover. 3. Installa newgasketand the thermostat Tighleningtorque: l9-25 N{n (1.9-2.6 m-kg, 14-19 ft-lb)
Caution . Thg pdnted side ol the gasketmust face lhe thermgstat.
PBINT€O SIOE
a _-/-$ ,1
?\+
C:lrlinderHead Cover lnstallthe cylinderheadcover. Tightenlnglorque: 4.9-8.8 N.m(50-90 cm-kg, 43-78 in-lb) Caution . lf the headcovergasketis reused,applysealantin the groove as shown. OlEOBXJS3
B-75
ASSEIIBLY TIIIIINGBELT Torque Specificallons
t9-25 O.9-2.5, r/Frg)
7.t-ll
r*o (30-110 cr*1,
6!l-95 i.'lb)
12-17 fl .25-r.75, r09-r52) r!i6-106 {16-17, 1r5-122)
Timing Belt Tensionel spring andthe tensioner 1.lnstellthe tensioner springtullyexwith the the tensioner Temporarily secure 2. tended.
Timino Belt wilhthetim1.Verii thatthetmingbeltpulleymarkrsaligned Ing marK.
o3uoB11s4
B-76
ASSEMBLY pulleymarksare alignedwiththe 2. Verifythatthecamshaft cylinderheadcovermarks.
3-Install thetimingbeltsothalthereis no looseness at the lension side. '/-\ caution . Do not turn the crankshaft counierclockwiscd
andalignthetim4. Turnthecrankshaft twoturnsclockwise, ing beltpulleymarkwiththe timingmark. 5. Verifythatthecamshaftpulleymarksarealignedwiththe cylinderheadcovermark. lf notaligned, removethetimingb€liandrepeatfromtensionerinstallation.
to thetimingbelt. 6. Loosen lhetensioner boltto applytension Caulion . Be sure not lo applytensionother than thal ot the tensionerspring, 7. Tlghtenthetensioner bolt. Tighteningtorque: '19-25 N.m {1.9-2.6 m-kg, 14-19 ft-lb) andveritythatthe 8. Turnthecrankshaft bro turnsclockwise timingmarksare correctlyaligned.
9aN (10 kg. 22 lb)
thetimingbeltdeflection by applyingmoderate 9. Measure pressure thecrank{98 N, l0 kg, 22 lb) midwaybetween shaftpulleyand the camshaftpulley. is notcorrect,temporarily se' lf the timingbeltdeflection boltsothespringis fullyextendedand curethetensioner spring. repeatsleps4-8 aboveor replacethe tensioner Deflectlon: '|1.0-13.0mm(0.43---0.51 in) at 98 N ('10kg, 22 lb)
B-77
ASSEMBLY Timlng Belt Covet lnsta[the loweranduppertimingbeltcoversandnewgaskets TIMING BELT
Tlqhteninqtolque: ?.4-t t-Hm igo-tro cm-kg,69-95 in-lb)
covEa
CrankshaftPulley 1. Installthe pulleyboss.
Caution . Add approx13mm(0,51in) ol spacers(rt) to space the SSi awayfron the cylinder block. (MTX) 2. Mountthe SSTand tightenthe pulleylock bolt Tiohteninqtoroue: iso-ro1 *m oe-t7 m-kg,115-122 finb) 3. Removethe SST. 4. Installthe crankshatt PUlleY. 5. Installthe plate.
waler Pump Pulley Installthe waterpumpPulley. Tiohteninqtotoue: ?.9-rr-N.. a8o-1lO cm-kg, 69-95 Inlb)
0rEoBx'3c
B-78
ASSEMBLY AUXILIARYPABTS Torque Specilicalions
15-27 (r,5-2i,
r1-20)
e3-1 13{e.5-tt.s, 3s-€3)
GASKET, NEW
19-25 0,9-2.5, r.-11)
@w
r I
1e-30 (1,e-3,r, 13r2)
EngineHangel Instailthe frontand rearenginehangers. Tlghtenlngtorque Front 37-63 N.m(3.8-5.4 m-kg, 27-46 ft-lb) Real: 19-25 N{n (1.9-2.6 m-kg, 14-19 ft-lb)
B-79
ASSEMBLY Spa* Plug lubdcant or molybdenum-based compound 1. Applyanitserze threads. to the sparkPlug 2. lnstallthe sparkPlugs. loroue: Tiohteninq 'is-zs'il.m 1t.s-z.s m-rg, 11-17 ftlb) Oil Dlpstick Installthe oil dipstick. Oil PressureSwilch switch. lnstallthe oil Dressure Tiohteninqtorque: lz-re-tt.m ti.z-r.8 m-kg,104-156 in-lb)
Oil Filter 1. Removeall toreignmaterialfrom the oil iiltermounting surlace. 2. Applya smallamountoi cleanengineoiltotherubberseal of the oil filter. 3. Installthe oil filterand tightenit by handuntilthe rubber sealcontactsthe base. 4. Tightenthe filter1 and 1/6turn witha filterwrench
No.3 EngineMountBrackel Installthe No.3enginemountbracket totoue: Tiohteninq -ss-t t3- Hln ig.s-i1.5 m-kg. 69-83 ttlb)
Allernator strap. 1. Installthe alternator Tiahtenino torque: -t't.m iz-sz 1s.e-s.o m-t
B-80
ASSEi'BLY Intake ManltoldAssembly 'l. Removeallforeignmaterial tromtheintakemanifoldcontact surtace. 2. Installa newgasketand the intakemanifoldassembly. Tighleningtorque: t9-25 Nm (1.9-2.6 m-kg, 14-19 fub)
Distrlbutorand High-tensionLead 1.Applyengineoil to the O-ring,and positionit on the distributor. 2. Applyengineoil to the blade. 3. Installthe distributor withthe bladefit intothe camshaft groove.
\=.\-6FY--.J \ \ \ . t . u -
//t \
\
4. Temporarily, looselytightenthe dist.ibutor installing boll. 5. Connectthe high-tension leads. 6. Adjuslthe ignitiontimingafterengineinstallation. (Referto SectionG.)
B-81
ENGINESTANDDISMOUNTING
ENGINESTANDDISMOUNTING PROCEDURE 1. Removethe enginefromthe SST (enginestand) 2. Removethe SST (englnehanger)flom the englne. 3. lnstallthe partsshownin the figure TorqueSpecitications
37-52 (3,3-5,3, 27-34)
(fr----- --\
ts=;\
|5fi
37-52 {3.H.3,
27--33)
1e-25 0,9-2.3, 14-r9) {8O-iio m-rq, 69-t5 in'lb)
O.FIING,NEW APPLY ENGINECOOLANT
16-2311.5-2,3, 12-1n
waler lnlet Pioe '1. Remove fromthewaterinletpipemoun! dlfdreignmaterial ino surface. 2. Inatalla newgaskelandthe waierinletpipe toroue: Tiohteninq 'is-zs -Nm (i.s-z.e m-kg' 14-19 ft-lb)
B-82
ENGINESTANDDISMOUNTING 3. Applya smallamountof enginecoolanttothe newO-ring. 4. lnstallthe waterbypasspipe.
ExhaustPioe Bracket lnstallthe exhaustoioebracket. Tighteningtorque: 37-52 N{n (3.8-5.3 m-kg, 27-38 fi-lb)
A/C ComDressorBrackel Installthe tuC comoressor bracketTighleningtorque @: 19-25 N.m(1.9-2.6 m-kg, t4-19 ftJb) @: 37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)
ExhaustManitold 1. Remove fromtheexhaust manifold conallforeignmaterial tact surface. 2. Insiaila newgasketand the exhaustmanifold. Tighteningtorque: 16-23 Nm (1.6-2.3 m-kg, t2-17 ft-lb)
ExhaustManitoldlnsulalor Installthe exhaustmanitoldinsulator. Tighteningtorque: 7.8-11 N.m(80-110 cm-kg, 69-95 In-lb)
B-83
INSTALLATION
INSTALLATION PROCEDURE Tightenall boltsand nutslo the specifiedtorques. Step I Jointhe engineand transmission. Torque Specilications TX
6!-a9 {6.5-r.r, 47-16) 37-52 (3.3-s.3, 27-33)
37-52 (3.3-5.3, 2?-33)
3?-s2 (3.3-5.3, 27--33)
ATX
37-52 (3,3-5.3, 27Ja)
37-52 e.a-5.3, 27--33)
B-84
INSTALLATION Step 2 Warning . Be sure lhe vehicle is securelysuppgrtedon safety stands. Torque Speqifications
Engineand transaxleassembly 1. Suspendthe engineand transaxle assembly. Caution . Do nol damaEeanycomponentsin lhe enginecompartment. 2. AligntheNo.3enginemountboltswiththe enginemounl mountingholes.
B-85
INSTALLATION Enginemouni the l\o.1enginemounlnutandtrghten 1. Inslall Tiohteninq -gz-sr lorque:
1m 1il.a-s.sm-rg,27-38lr-tbl
IffiI
2. Installthe No.2enginemounlnut and tighten.
No.2 ENGINE I,IOUNT
No.1 ENGINE MOUNT
torque: Tiohteninq -tr.m (g.g-s.g m-tg, 27-38 ft-lb) iz-st Enginemount member Installthe enginemountmember. torque: Tiohteninq -ea-es -Nm 16.s-S.l m-t
Step 3 TorqueSpecificalions
15-22 0.6-23, 1r-16) 31,-46{3.2-4.7,23-33)
40-s4 {4.r-s,5, 2s--r0)
nr-.",J *-"",u.u-",,
B-86
37-51 (3.3-5.3. 27-33)
&..-..-..-------'n*.,".*, ', o,*"
INSTALLATION Drlveshaft 1. Applygreaseto the end ot the driveshaft. Caulion . When installingthe drlveshaft,be caretul not to damagelhe oil seal. . After Installation,pull the front huboulwardto conlirm that the driveshaltis sequrelyheld bythe clip. 2 Fil a newclip and installthe driveshaft. 3. Installthe lowerarm ball-joint 1othe knuckle,andtighten the clinchbolt. Tighteningtorque: 43-53 N.m(4.4-5.5 m-kg, 32-39 fl-lb)
Clutch cable lnstallthe clutchcableand checkdiffrection. (Referto SectionH.)
Shlft control cable (ATx) Installthe shittcontrolcableto the transaxle. Tighteningtorque: 6.9-11 N m (70-110 qm.kg,6l-95 inlb)
Shift control rod (MTX) Installthe shiftcontrolrod to the transaxle. Tighteningtorque: '16-22 Nm (1.6-2.3 m-kg,12-16 in-lb) Extensionbar (MTX) Installthe extension barto the transaxle. Tighteninglorque: 3l-46 N.m(3.2-4.7 m-kg, 23-34 in-lb)
B-87
INSTALLATION Speedometercable cable lnstallthe sDeedometer Tldhtenlnqtoroue:
?.s-rfN.m iao-rzo cm-ks,69-96 In'lb)
Li,
B-88
Exhausipipe '1 lnstallthe exhaustoipeanda gasketithenlooselytighten the locknuts. 2. Looselytightenthe bracketbohs 3. Tightenthe locknuts. Tiohteninq toroue: -lo-sl -t'l.m tl.t-s.6
m-kq, 29-40 ft'lb)
INSTALLATION Srep 4 Connectthe hosesshownin the figure. Cautlon . Posltionthe hose clamp in the original locationon lhe hose, and squeezethe clamp llghtly with large pliers to ensure a good fit.
Siep 5 Connectthe harnessconnectorsshown in the fioure.
B-89
INSTALLATION Siep 6 Torque Specificationa
(30-110 .n-ts, 6e-ss lFlb)
B-90
INSTALLATION A/C compressor (it equipped) Installthe fuC compressor.
E
Tighteningtorque: 37-s2 N.m(3.8-s.3 m-kg, 27-38 ft-lb)
01EoBXI5a
P/S oil pump and bracket lnstallthe P/Soil oumpand bracket. Tightenlngtorque: 37-52 N.m(3.8-5.3 m-kg, 27-38 ftlb)
I J
.DLEF
Drivebell 1. lnstallthe P/Sand/orA/C drivebelt. (Referto pageB-5.) 2. Adjustthe drivebelldeflections.
IJLLEY COMPFI
Radiatorand cooling fan assembly 1. Installthe radiatorand coolinglan assembly. Tighleningtorque: 7.8-11 N.m(80-il0
cm-kg, 69-95 in-lb)
2. Tightenthe AJCpipebracketto the radiator. Tighteningtorqle: 6.4-9.3 Nm (65-95 cm-kg, 56-82 in-lb) 3. Connectthe uooerand lowerradiatorhoses.
&6
Caution . Poaltionthe hoseclampin the orlginallocationon ihe hose,and aqueezethe claBp lightly wlth large pllers tg ensurea good fit. hose. 4. Connectthe coolantreservoir 5. Connectthe coolingian connector. 6. Connectthe oil coolerhose.(Al'X)
B-91
INSTALLATION Accelerator cable cable 1. lnstallthe accelerator by turningnut @ oetlection caUte tne z. AOiust Deflection:l-3mm (0.04--'0.12In)
Battery duct, battery car er, and battery 1. Installthe batteryduct. 2. Installthe batterycarrier.
-YA
Tlohtenlnqtorque: ig-zs l.m (i.9-2.5 m-kg, l4-19 fl-|b) 3. Installthe batteryand the batterybracket. Tiohtgninotorque: i.s-s.5 N.m'(so-60 cm-kg, 26-52 inlb) Air cleaner assembly lnstallthe air cleanerassembly Undercover and slde cover and sidecover. lnstallthe undercover
steDs After Installatlon i. ii'tn" 6"si"J o-'l*i" drarned,lill withthe specifiedamountandtype of engineoil (Referto SectionD.) 2. Fillthe radiatorwiththe specifiedamountand typeof enginecoolant' {Reterto SectionE.) amountandtypeof transaxleoil s..ii iil" to^""*|. oil;.s drained,fill withthe specified (Reterto SectionsJ, K ) 4. aonnectthe negativebatterycable 5. Startthe engineand checkthelollowing {1) Enaineoil,transaxleoil and enginecoolantleakage izi tgnitiontiming.idle speed(Referto pageB-8) (3) Operation ot emissioncontrolsyslem 6. Performa roadtest. 7. Recheckthe engineoil and enginecoolantlevels.
B-92
LUBRICATION SYSTEM tL 2 1NDEX.......,.,...,..,.......................,,.,.......... ...,.,tL 3 ouTLtNE.,............, D- 3 sPECtFtCAT|ONS.................................... IL 3 TnoUBLESHOOT|NG GU|DE.,......,...,.,..,.... D- 4 otL PRESSURE.........,.,........................,.,.. D- 4 PREPARAT|ON,,...,...............................,. D- 4 TNSPECTTON ....................,..................,.. D- 5 ENGTNE OtL,.,.....................,..,................. D- s tNSPECT|ON...........,..,..................,.,.,.... D- 5 REPLACEMENT,,.,....................,............. D- 6 otl F|LTER...,....,..,.,.,.,........................,... lL 6 REP1ACEMENT.......,.............................. D7 otl PAN..................,,.............................. D- 7 REMOVAL / |NSTALLAT|ON......,.,..,.,........ IL I otl PUMP..,.,...,..,.........................,......,... ....................,. D- I REMOVAL / TNSTALLATION D-ll D|SASSEt\4BLY / ASSEMBLY ..................... D-12 TNSPECTTON ......................,.,.,,..............
INDEX INDEX
ENGINEOILSPECIFICATION SD,SE OB SF API SEBVTCE 3.4 lir6.s(3-6us qr, 3.0 hp q0
l. Oil pressure . pageD- 4 Inspectron...........-.................... 2. Engineoil pageD- 5 l"nspection.......--...-...................... . . ... Rep1acement................ pi6e O- s 3. Oillilter R e p 1 a c e m e n t . . . . . . . . . . . ..... p . .a. .g. .eD . . -. . 6
D-2
4 Oil-Pan Installation " - Removal/ 5 OilPumP Installation " Removal/ / Assembly Disassembly
pageD- 7 pageq- I pageD-1'1
OUTLINE,TROUBLESHOOTING GUIDE
OUTLINE SPECIFICATIONS B:]
IemHmodel
Oil pump
Tvpe Regulaledpressure
kPa(kg/cmz,psi)
343 441 (3.5-4.5, 50-64)
Type Oil llter
Full.iow, pap€relement
Felief pres€ureditferenlial kPa (kg/cmz,psl)
Oilwarnng p€sslre
Oil capacily
98 (1.0,1 4)
, kPa(kg/cm' psi)
4.9-44 (0.05-0.45, 0.7-6.4)
Tolal(dryensine)
lilerc(USqt, lmp qt)
3.4 (3.6,3.0)
Oll pan
llers (USqt, lmp qt)
3.0 (3.2,2.6J
Oiltlter
liters(USqt, lmp qi)
0 . 1 7( 0 . 1 8 , 0 . r 5 )
Englneoil (APl servce)
SD.SE,or SF
RecommendedSAEViscosity
fc) ('D
-30
-20
,--20
-10 0
0 20
10 40
v
5w'30
5EA----\
30
20 60
80
Engineoil
100
50 720
\
30
20w.20 'l0w-30
40
:
@ ffi Anticipated rangebeforesucceeding ambienttemperature oil change,"C ("D
TROUBLESHOOTING GUIDE Possible Cause
Remedy
D-5 D-5
Enginehardstarting Insuflicieniengine oil
Exceasiveoil Oll pressurc drop
Warnlnglamp lllumlnrteswhlle engineb running
Oilworkngup o. down Oil leakage Oil eakage Womand/ofdamag€doil pumpgear Wornplunger(insideoil pump)or weaksprins Clossedoil strain€r Excessive ma,nbeanngo, .orneq ng rod oea rc Oil prcssure drop Maltunction oJoil pressure swnch Mallunctionof electical srstenr
Page
Reier to Section B
o_o Clean Reler to Seclion B
Feferto SectionT
D-3
OIL PRESSURE
OIL PRESSURE PNEPARATION
ssT
49 0187 2AO Gauge,
INSPECTION swltch 1. Removethe oil Pressure
2. Screwthe SST intothe oil pressureswitchhole. 3. Warmup the engineto normaloperatngtemperalure 4. Runthe engineai 10Oorpmand3000rpm,and notethe gaugereaorng. Oll pressure: 99-196 kPa (1.0-2.0 kg/cm' ,15-28 psi)'1000rpm 294-392 kPa (3.0-4.0 kg/cmi, 43-57 psi)'3000rpm is nolasspecitiedchecklor thecauseand 5. lt rheDressure (Refer Guide.) to Troubleshooting reoaii.
D-4
ENGINEOIL
ENGINEOIL INSPECTION 1. Be surethe vehicleis on levelground. temperature 2. Warmuptheengineto normaloperating and stop it. 3. Waitfor fiveminutes.
o','"u"' und conditio 3.IET?,1",f;r","'i"t'3il"1i*ffitn" E Note . The distancebetweenthe L and F marl6 on the dip stick represents0.8 llter {0.85USql, 0.70lmp ql}. REPLACEi'ENT warning . Be carelul when drainlng;the oil is hot. 1. Warmuptheengineto normaloperating temperature and stop rt. 2. Removethe oil lillercap and the oil pan drainplug. 3. Drainthe oil intoa suitablecontainer. 4. Installa newgasketand the drainplug. Tighteningtorque: 29-41 N.m(3.0-4.2 m-kg, 22-30 flnb) o5u00x.011
typeandamountof en5. Relilltheenginewiththe specified gineoil.(Relerto pageD-3.) 6. Retitthe oil fillercap.
7. Flunthe engineandchecklor leaks. L Checkthe oil leveland add oil if necessarv. Oil pan capaclty: 3.0 liters (3.2 US qt, 2.6 lmp ql)
D-5
OIL FILTER
OIL FILTER REPLACEI'ENT 1. Removethe oil filterwitha suitablewrench. 2. Usea cleanrag to wipeotf the mountingsurfaceon the enoine. cleanengineoiltotherubberseal a smallamountof 3. Ap-ply of the newfilter. 4.Installtheoil filterandtightenit by handuntilthe rubber sealcontactsthe base.
,',,\
Y r)+
e
tvpe(Numbersprintedon lilter) 5. Handtiohtenrnq 3i4 of a turnbv handafterit contactslhe liltei Tiohtenihe block. cvliinder lf tighteningby handis difficult,use a suitablewrench Example: . Wh;n the oil filter contaclsthe cylinder block at " l " ' "4." turn il 3/4 of a turn fulther to type(Nonumbersprintedon filter) tightening Filterwrench wrenchat1/6 1 Tiohtenthefifter and turnswitha suitable block. the cylinder tei it contacts 6. Startthe engineandcheckfor leaks 7. Checkfie oil leveland add oil if necessary Oll fllter capacity: 0.17 liter (0.18 US qt, 0.15 lmP qt)
D-6
OIL PAN
OIL PAN RE!'OVAL/ INSTALLATION 1. Disconnect the negativebatterycable. 2. Drainthe engineoil. 3. Removethe undercover and sidecover. 4. Removein the ordershownin the figure,referringto RemovalNote. 5. Installin the reverseorderof removal,referring to InstallationNote.
GASKET, BEPLAC€
REPLACE
REPIACE
'@
3r-52 (4.3-5.3, 27-36)
REPlACE {3!-110 cfrkg, 69-95 tn.tb)
1. Frontexhaustpipe and bracket ,
lhr6^r.rorl
di1l6n6r
3. Oil pan bolts 4. Oil pan B e m o v aNl o t e . . . . . . . . . . . . . . . . . p. .a. .g. e .D . . -. .8. Installation pageD- 8 Note..........................
5. Gaskets 6. Oilstrainer
D-7
OIL PAN Rgmoval Noie 1. Removethe oil pan mountingbolts. 2. lnserta screwdriveror a suitabletool betweenthe MBSP and oil pan to pry them apart. Cautlon . Do nol Insed the prylng tool betweenlhs iIBSP ard cylindel block. . Do not damage or scratch the conlact surlacea. 3. Removethe oil pan. lnatallation Note Oil pan
\ ^ Akit*
ffi"::+
Cauilon . lf the bolts al€ to be reused, remove ihe old aaalant from the bolt thr€ada. Tlghtenlng a boll with old sealant on lt may cause cracklngInaldethe bolt hole.
1. Removeall loreignmaterialfromthe contactsurfaces. 2. Applysiliconesealantto the endsof a newoil pangaskets. 3. Installngwgasketsontothe oil pumpbodyandlhe rear cover withthe proiectionsin the noichesas shownin the figure.
beadof siliconesealantto the oil pan 4. Applya continuous alongthe insideol the boltholesand overlapthe ends. 5. lnstallthe oil pan. Tightenlngtorque: 7.8-ll N.m(80-ll0
cm-kg, 69-95 in-lb)
Steps Atter Inslallallon and sidecover. 1. lnstallthe undercover 2. Fillwiththe speciliedamountand type of engineoil. (Referto page D-5.) 3. Connectthe negativebatterycable. 4. Startthe engineand checkfor leaks. 5- checkthe oil leveland add oil if nec€ssary. o1aoDxo11
D-8
OIL PUMP
OIL PUMP REMOVAL/ INSTALLATION 1. Disconnect the negativebatterycable. 2. Drainthe engineoil. 3. Removethe timingbelt.(Referto SectionB.) (Reterto pageD-7.) 4. Removethe oil pan and integrated stittener. 5. Removein the ordershownin the figure,relerringto RemovalNote. 6. Installin the reverseordefof removal,referringto InstallationNote.
o I
i
REPLACE
19-2s (1.9-2,6,14-rs)
_
2ir-35 e,r-_3.6i1
1.Timingbeltassembly 5. Timingbeltpulley S e r v i c e . . . . . . . - . . . . . . . . . . . . . . . . .S. .e.c. .t.i .o.Bn. . - . . . . . . S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . .S . .e. .c. U . . .oB .n. . . . . . 2. Oil pan 6. Oilpump pageD-11 / Assembly........... Disassembly RemovN a lo t e . . . . . . . . . . . . . . . . . p . .a. .g. e .D . . . . 8. pageD- B Installation Note.......................... 7. Frontoil seal 3. Aiternator S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . .S . .e. .c. t. i. o. B .n. . . . . . . (withA/C) 4. tuC compressor R e m o vN a lo t e . . . . . . . . . . . . . . . . . .p.a. .g. .eD . . .1. 0 .
D-9
OIL PUMP RemovalNote A/C compressor (with A/C) Caution . Do not damagethe hoses. withthe hosesstillconnected. 1. Removethe A,/Ccompressor awaytromihe engineandafiixit 2. Position the compressor withwire.
Sleps After Insiallation 1. Installthe oil panand mainbearingsupportplate (Relerto pageD-8.) 2. Installthe timingbelt.(Referto SectionB.) amountandtype of engineoil. 3. Fillwiththe specified (Referto pageD-5.) 4. Connectthe negativebatterycable. 5. Startthe engineand checklor leaks. 6. Checkthe oil leveland add oil if necessary. orAooxol3
D-10
OIL PUMP DISASSEMALY / ASSEMBLY 1.Disassemble in the ordqrshownin the figure,reierringto DisassemblyNoie. 2. Assemblein the reverseorderof disassembly, referring to AssemblyNote.
5.9-3.3 Nm (60-00.m.kg, 52-73 i.-lb)
o
e-@E. l
t
^
s_@
1.Oilseal Disassembly Note............................... below pageD-12 Assembly Note... 2. Pumpcover Inspectfor distortion and damage 3. Outerrotor 4. lnnerrotor 5. Bollpin
6. Springseat 7. Pressure spring pageD 12 Inspeciion..............................-.... B.Controlplunger lnspeclfor wearand damage L Pumpbody /nspectfor distortion and damage
DisassemblyNote Oil seal protected witha rag. Removetheoil sealwitha screwdriver
D-11
OIL PUMP INSPECTION Pressure Spring or breaKage. 1- lnspectthe springfor weakness the springif necessary' Replace treelength. the 2. [/'leasure Free lengih: 45,5mm(1.791In)
Rotor Clearance Beplacethe rotorif necessary' the iollowingclearances. Measure
93G0DX{30
Tooth tlp clearance: 0.20mm(0.0079in) max.
Outerrotorto PumPbody: 0.22mm(0.0087in) max.
Side clearance: 0.l4mm (0.0055in) max.
A€semblyNole Oll seal ofcleanengineoiltothelip ol a new 1. Applya smallamount oil seal. 2. Pushthe oil sealslightlyin by hand.
r\>:>'\
;LS
Caution . The oil sealmust be Pteesedin until it is flush wlth the edge ol the oll PumPbody. 3. Pressthe oil sealin evenlywitha suitablepipe. Oil seal outel dlameler:50.5mm(1.98 in)
D-12
E
COOLINGSYSTEM ..,'.'E- 2 fNDEX................... ...... E- 3 ouTLlNE,.............. E- 3 spEctFtcATloNS....,......-....................... E- 3 GU|DE....................,. TROUBLESHOOTING ...... E- 4 ENGINECOOLANT. pREPARAT|ON....................................... E- 4
E- 4 rNspEcTtoN............-.........-..................
E- 5 REP1ACEMENT..........,........................... E6 ...... CAP..... RADTATOR E- 6 PREPARAT|ON....................................... E- 6 rNSPECTrON...................,...........,.......... ......E- 7 RADfATOR ............ E- 7 .............,........ REMOVAL / TNSTALLATION E- 7 rNSPECT|ON............,............................. ..'... E- 8 THERMOSTAT....... E- 8 .......,............'. / INSTALLATION REMOVAL 9 EtNSPECTrON..........,............................... ...... E-10 WATERPUMP....... E-i0 ...................... REMOVAL / rNSTAI1AT|ON t E-l ....'....... SYSTEM FAN COOLING ELECTRIC c|Rcu1r..................""""""""" E-1I SYSTEM E-l I sysrEM tNSPECT|ON.......................,...... ...'.' E-12 FAN MOTOR.......,.. E-12 .......................................... tNSpECT|ON E-l2 REPLACEI,|ENT...................................... E-l3 .......................... warER THEBMOSWITCH E-i3 ...........-,......... REMOVAL / TNSTALLATION E-13 """""" lNSPEcrloN ......E-i4 FAN RELAY........... E-l4 .....-................ REMOVAL / lNSTALLAT|ON E-l4 lNSPEcrloN..."""""""""""""""""""'
E
INDEX
INDEX
CONNECTOF
ENGINECOOLANTTOTALCAPACITY:
5.0(5.3,4..r)
6.0 (6,3,5,3)
6. Electriccoolingfan system 1. Enginecoolant c i r c u i t . . . . . . . . . . . . ... . . .p a g eE - 1 1 System I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e .E . .-. .4. . . . . . S y s t e m i n s p e c r i o n . . . . . . . . .p. .a.g. .e. .E. - 1 1 R e p | a c e m e n t . . . . . . . . . . . . . . . .p.a. .g. eE - 5 7. Fanmotor 2. Radiatorcap l n s p e c i i o n . . . . . . . . . . . . . . . . . . .p. .a. .S. .eE. .-.1. .?. . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e .E . .-. .6. . . . . . 8 e p 1 a c e m e n t . . . . . . . . . . . . . . .p. .a.g. .e.E. .-.1. 2 .. 3. Radiator thermoswitch B. Water page E7 Removal / Insla|ation.................. pageE - 13 / Insta||atron.................. Removal 4. Thermostat 9. Fanrelay pageE- 8 / Instal|ation.................. Removal . pageE-14 / Installation............... Removal pump 5. Water pageE-10 / Instaj|ation.................. Removal
E-2
E
OUTLINE.TBOUBLESHOOTING GUIDE
OUTLINE SPECIFICATIONS Enginemodel
|rem
B3 iorcedc rculation Waier<,ooled,
Coolingsyslem lite6 (US qt, lmp qt)
Coolanlcapacily
[4IX 5.0(s.3 4.4) ATX.6O(6.3.s.3) Centnrugal bell-driven Unlliedmechanicalseal
Tvpe
Full-open temperature
'C fD 'C fR
Fifopen ltt
mm (in)
Openinglemperature
86.5 89.5 (187-193) 1OO\212)
8.5 (0.335)or more corugatediin
Radiator Cap valveopeningpressJre
hPa (kg/cm?.ps,
l4olorcurrenl
74-103(0.75-r.05. 1r-r5)
A
6.6+1
Coolinglan
Outerd ameterol blade
300(rr.9)
mm (in)
TROUBLESHOOTING GUIDE Problem Overhealin9
Coro€lon
Possible Cau3e Coolantlevel insuiticient Coolantleakage Radlator finsclogged Badialorcap malfunction Cooiingfan malfunclion Thermogalmalfunction Walerpassageclogg€d Waterpumpmalfunction
Remedy
Page E-4
Clean
Clean
E-6 E-11 E-8 E-5 E-10 E-5
E-3
ENGINECOOLANT
ENGINECOOLANT PREPABATION
ssT
49 DO150A0
49 D015002
49 DO15040)
INSPECTION Waming . Nevei removethe radiatorcap while lhe enginei6 hot, . W;D a thick clolh aroundthe cap when removinglt' . wh;n removingthe radiatorcap, loosen ltslowly to the tirst stotuntllthe Pressureln the radlalorls released, and then remove il. muoEx.oo6 CoolantLevel (Enginecold) levelis nearthe radiatorirllerneck 1. Venlythatthe'coolant is be 2. Veritvthatthe coolantlevelIn lhe coolantreservior weeh the FULLand LoW marks 3. Add coolantit necessary
CoolantOuality 1 Verffvthatthie is no buildupof rustor scalearoundthe radiatorcap or radiatorfillerneck 2. Veritvthat coolantis lree of oil Replacethe coolantif necessary.
CoglantLeakage availade)andthe 1.connecta radlalortester(commercially neck, filler SSTto the radiator z. AppV tO3 kPa (1.05 kg/cm' , 15 psi) pressureto the svstem. thatthe pressureis held 3. V'erifv checklor coolantleakage 4. lt noi as specified,
E-4
E
ENGINECOOLANT CoolantProtection
Caution . Do not uae alcohol- or methanol-basedcoolant. . Use only soft (demineralized)water In the coolant mixture. 1. Measure thecoolant temperature andspecfiicgravitywith a thermometer anda hydrometer. 2. Determine thecoolantproreclion by referring to thegraphI s. iili" loor"n, prot""tionis norproper,add w"te, o, "oolanl.E Antlfreeze solutlon mlxture percentage Coobrn pdeclion
Coolant
Above -16oC ( 3oR Above -26oC {-1soR
65
Above-4ooo i-40on
Gravityat 2o.c (68.0
35 45
45
1054
1066 '1o78
CCfF) COOL^NTTEMPERATUFE
REPLACEMENT ol EoEx@7
Warnlng . Neveropen lhe radialor cap while the engine ls hot. . Wrapa thlckclolh aroundthccap when loosening. . Whenremovinglhe radiatorcap, loosen it slowly to the tirst stop unlll the presaure in the radiator is released. and then remove it. . Use cautlonwhen draininghol coolant. Cautlon . Do nol use alcohol-or methanol-based coolant. . Useonly sotl (demineralized) water ln the coolant mixture. . Befors looseningthe radlalor draln plug, verity thal lhe radlatgrdrain hose taces slraight down. 1. Bemovethe radiatorcapandloosen$e drainplugby hand (MTE or by a wrench(ATX). 2. Drainthe coolanlinloa suilablecontaner. 3. Flushthecoolingsystemwithwateruntilalltracesof color are goneithenletthe systemdraincompletely. 4. Insiallthe drainplug. glycol 5. Fillwiththe properamountandmixtureof ethylene basedcoolantby referring to the tableabove. Coolanicapaclty
lilers(USqi, lmpql) B3
i\,ITX (5.3, 4.4) 5.0
AIX
6.016.3, s.3)
6. Runtheenginewiththeradiator capremoveduntiltheup per radiatorhoseis hot. 7. Withthe engineidling,add coolantto the radiatoruntilit reachesthe bottomot the filler neck. 8. Installthe radiatorcap.
E-5
E
RADIATORCAP
RADIATORCAP PREPARATION
ssT
49 D015003
49 DO150A0
AdaplerB 49 D0150A0)
INSPECTION Radiato. Cap Valve frombe (suchas waterresidue) 1. Removeforeignmaterial valve seat. the valve and tweenthe radiatorcap 2. Attachthe radiatorcapto a radiatorcaptester(commer' gradually to withtheSST.Applypressure ciallvavailable) 74-103 kPa (0.?5-1.05 kg/cm" 11-'15 psl) 3. WaitaboutlO aecgnds.Veritythatthe pressurehasnot decreased. 4. Feplacethe radiatorcap il necessary
kk=fiK"DlN" \{ ,l\\\//rIA\
'
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E-6
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N€gative Pressurc valve 1. Pullthe negativepressurevalve10openI VerifyIhat it whenreleased closescomDletelv andforcracked 2. Checkior damag;onthecontactsurfaces or deformedsealPacking. the radiator€p if necessary' 3. ReDlace
RADIATOR
RADIATOR REMOVAL/ INSTALLATION Caution . Eetore loosening the radiator drain plug, verlty lhat the radiator d.ain hose tac€s straight down, . Poallionthe hose damp in the originallocalionon the hose, and squeezethe clamp lightly with large pliers to ensure a good tit. 1 Disconnecl lhe negatrvebatterycable. 2. Drainthe enginecoolant. 3. Removein the ordershownin the figure. 4. lnstallin the reverseoroerol removal r*n {3o-1 ro cfrrg, 6F95 hrb)
1.Cooling fan connector 2. Coolantreservoirhose 3. Radialorhose 4. Oilcoolerhose(ATX)
5. Radiatorbracket 6. Radiator I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .p. .a. g . .e.E. . .7. . . . . . . 7-Coolingfan and radiatorcowlingassembly INSPECTION Checkfor thetollowing and repairor replaceas necessary. 1. Cracks,damage,and waterleakage. 2. Bentlins(repairwitha screwdriver). 3. Distoned or bentradiatorinlet. Sleps Atter Installation 1. Fillthe radiator withthe specifiedamountandtypeof enginecoolant.(Referto pageE-4.) 2. Connectthe negativebatterycable. 3. Startthe engineand checkfor leaks.
E-7
THERMOSTAT
THERMOSTAT REi'OVAL/ INSTALLATION Caution . Betore loosening the radlator drain ptug, verlty that the radiatordrain ho€elace€ slraighl {oll. . Positionthe hose clamp In the originil locatlonon the hose' and squeezethe clamp lightly with large pliers to ensure a good tll. L Disconnect the negatlvebatterycable 2. Drainthe enginecoolant3. Removein the ordershownin the figure. 4. Installin the reverseorderof removal.
(r.9-2.6 n-kg, ra-rg ftlb,
connector 1.Waterthermoswitch 2. Upperradiatorhose cover 3. Thermostat gasket 4. Thermostat pageE-g Note............................ Installation
E-8
5. Thermostat pageE-9 Inspection..................................... pageE-g Note........................,... Installation
THERMOSTAT INSPECTION '1.Visuallycheckthat the thermostat valveis airtaght. 2. Placethe thermostatand a thermometerin water. 3. Heatthe waterand checkthe following: B3 "C Openinglempe.ature (.D FuI'opentemperalure oC (oD Full-openlilt
mm (in)
86.5-89.5 (187-193)
lOO1212) (0.335) 8.5 or more
Installation Note Thermostat Installthe thermostat intothecylinderheadwiththejigglepin at the top.
Thermoslal gasket Installa newgasketwiththe sealingringfacingthe cylinder neao.
0rEoE(.o16
Steps Atter Installation 1. Fillthe radiatorwiththe specifred amountandtype of enginecoolant.(Referto pageE-5.) z. Uonnectthe negatrve batterycable. 3. Startthe engineand checkfor leaks. 01EOEX017
E-9
WATERPUMP
WATERPUMP REMOVAL/ INSTALLATION Cautlon l-adfore toosenin' the radlator drain ptug, verity that the radlatordrain hose taces stralght do{vn. . oJnoi aisasseiule the water purilp.-tta probtemis found, replacethe pumPas a unit' the negativebatterycable. 1. Disconnect 2. Drainthe enginecoolant. in the ordershownin the figure. 3. Flemove orderof removal. 4. lnstallin the revease
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aOREPLAoE
^
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FEPLACE
re-2s 0,9-2.6, t4-re)
1.Timingbelt B ..... .... Section Service.........-........ gasket pipe and 2. Waterintet 3. Waterbypasspipeand O'ring
4 Waterpumpassembly mounting damaged tor cracks, Inspect surface,bearingcondition,and leakage 5. Waterpumpgasket
Steps Aller lnstallaiion i. Fi|ltn" iio"ioi ritn the spec redamountandtype ot enginecoolant(Referto pageE-5 ) 2. Connectthe negativebatterycable. 3. Startthe engineand checkfor leaks.
E-l0
ELECTRICCOOLINGFAN SYSTEM
ELECTBICCOOLINGFAN SYSTEM SYSTEMCIRCUIT
COOLING
TAGNOSTS CONNECTOF PBESSUFIE ADDITIONAL SWITCH
MAGNETIC CLUTCH
t-](-%,re 0r EoEX.021
THEFIMOSWITCH ABOVE91"C (196'F): ON
SYSTEMINSPECTION 1.Jump acrossthe ian testOFA)terminaland the ground (GND)terminalof the diagnosis connector. 2. Turntheignition switchONandverifythatthefanoperateslithe fandoesnotoperate,inspectthecoolingfansystem components and wiringharness.
3. Removethe radiator cao andplacea thermometer in the radiatorfillerneck. 4. Startthe engine. 5. Veritythatthefanoperates whenthecoolanttemperature is as specified. Operationtemperalure:above91'C (196'D lf thefan doesnot operate,checkthe waterthermoswitch. (Referto pageE-13.)
E-11
E
FAN IIOTOR
FAN MOTOR INSPECTION 1. Checkthatthe batteryis fullycharged. the fan motorconnector. 2. Disconnect to thelanmotorconbatteryandan ammeter 3. Connectthe neqor. 4. Verifythatcurrentis as specilied. Current(A) ATX
It4TX 6.6+1
B3
and/orthetandoesnot 5. ll currentis notwithinspeciiication replacethe lan motor' turn smoothly, REPLACEMENT Cautlon ; Posiiionthe hose clamp in the orlginal locationon the hose, and squeezethe clamp llghtly with large plierato ensu.e a good llt. 1. Disconnecl the negativebatterycable. 2. Drainthe enginecoolant. 3. Removein the ordershownin the figure. 4. lnstallin the reverseorderof removal. 7,3-ll
x{
(30-110
d*q,
30-95
lDlD)
0,01-o.oit f (0.ra--a.22ciFtg, 015-o 1l lFlb) 0.oa'0,06 Nfl (0JHr,56
1. Coolingfan connector 2. Fiadiator cowling
E-12
crF*!,0.3!H.5o
3. Coolingfan 4. Fanmotor
lFlb)
E
WATERTHERMOSWITCH
WATERTHERMOSWITCH NE OVAL/ INSTALLATION 1. Disconnect the negativebatterycable 2. Removein the ordershownin the ligure 3. Installin the reverseorderoi removal,referring to InstallatlonNote.
GFING FEPLACE
1.Waterthermoswitch connector
2. Waterthermoswitch 1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g . .e.E. .-.l.3. . . . . . pageE-13 Insialiation Note.......................... INSPECTION 1. Placethe switchand a thermometer in water. oftheswitch 2. Heatthewatergradually andcheckcontinuity wilh an ohmmeter. Coolantlemperalure [4orethan91 (196)
'C fD
Continuity
Lessthan 84 {183)
replacethe waterthermoswitch. 3. lt not as specified, lnstallationNote Waterthermoswitch 1. Applya smallamountof enginecoolantto thenewGring. Caution . Do not use an impact wrench tor Installatlon. 2. lnstallthe waterthermoswitch. Tighieninglorque: 5.9-4.8 N.m(60-90 cm-kg, 52-78 innb)
E-13
FAN RELAY
FAN RELAY REMOVAL/ INSTALLATION the negativebatterycable 1. Disconnect the 2. Remove fan relay. 3. Installin the reverseorderof removal.
:-\_
-=-=l
24 INSPECTION as shownwithan ohmmeter. 1. Checkcontinuity Contlnuity @
@
NO
o @ 2. Apply12v betweenlerm,rals6 an{ @; betweentermlnals(, ano (9) Checklor contrnuiry the fan relay. replace 3. lf notas specified,
E-14
F FUELAND EMISSION CONTROLSYSTEMS
(EGr-S) F- 2 POSITIVE CRANKCASE tNDEX....,....,,...,...,,.......,..-...,......"....-.. (PCV)SYSTEM..,.......... F- 99 FVENTTLATTON ouTLtNE.....,...,,....,...,...,......,.......,..,... SYSTEMD|ACR4M..,...............,......... FVACUUI\IHOSE BOUTING DIAGRAI\,1........,,......................,,...,. FwtRtNGD|AGBAM...,...-..........,.....,..,. F-
spEctFtcATtoNs.........................,..... F- a DESCRIPT|ONS............. F- 9 coMPoNENT F- 1 1 TROUBLESHOOTTNG GU|DE...........,..,.. F- 1 1 FELATTONSHTP CHART......................
ustNG THlssEcTtoN.....,....,.,...,,,..,,. F-
DIAGNOSTIC TNDEX .....,.,.........,.,...,.. F- 't4 F- 1 6 PRECAUTTON .,....,,.......,,...,,.....,....... F- 1 7 SYMPTOM TROUBLESHOOTING.......... ENGTNE TUNE-UP...,..,,...,.,,.......,,..,..,., F- 61 PREP4RAT|ON.....,..................,,....,... F- 61 tNSPECT|ON.......-...............,... F- 61 BASTC ADJUSTi\4ENT,..,,,..,...,,....,,.,...,........, F- 62 F- 66 SELF-D|AGNOS|S FUNCT|ON,..,..........., DESCRtPTION....,...,.........,...,.,........,. F- 66 PREPABATtON....,,.,,...............,......... F- 67 MALFUNCTION CODENUMBEF .........F- 67 swtTcHMoNtToRFUNCT|ON.......,.... F- 80 TNTAKE AtR SYSTEM.,....................,.... F- 83 F- 83 coMPoNENTPABTS.........,..........,.... F- 84 tNJECTtON BODY,.....,....,,............,.... I\4ANIFOLD..........,..... F- 86 BAFFLE/INTAKE ACCELERATOR PEDAL.,,,,,..,........-.,.. F- 86 F- 86 ACCELEFATOR CABLE.,,.......,....-...... F- 87 FUELSYSTEM,...,,..,..,.,.,,,.,..........-...... PRECAUTION .,,....,.......,......,,.,,,......, F- 88 F- 88 SYSTET\4 OPERATION...,.....,.-............. FUELTANK,...,,...,,..,..,,,....,..,.,.,......, F- 90 FUELPUMP...,,...........-................,... F- 9 l FUELFtLTER.,,................................. FRE1AY..........,...,.., F- 93 crRcutTOPENING PRESSURE BEGULATOR..........-......... F- 94 F- 94 iNJECTOR...............................-........ F- s7 EXHAUST SYSTEM.......,...................... coMPONENT PARTS............,..,...,,,.,. F- 97 OUTLINEOF EMISSION F- 9a CoNTROLSYSTEi,............................ V|EW....,.....,................ FSTRUCTUEAL
F- 99 DESCBtPTtON................-...,.............. F- 99 PCVVALVE..........,....................,.,.... CONTROL EMISSION EVAPORATIVE F-l00 sYsTEM....-........,.,.......................,.... F-r00 DESCRtPTION,...,....,....................,...F-l01 SYSTEN,i OPERAT|ON.,..,.......,,.....,..,,. SOLENOID VALVE (PURGE F-101 CONTHOL)..,,................,..--. VALVE .,.....,,..,..,....,.,,,. F-l01 FUELVAPOR F-102 cHECKVALVEai'WO-WAn..............,.. F-102 cHAFCOAL CANrSTER....................... SYSTEM....... F-'IO3 CATALYTICCONVERTER F-103 DESCRtPTtON.,,..............................-. F-l03 oATALyTtC CONVERTER................-... DECELERATION CONTROLSYSTEM.....F-104 F-l04 DESCRtPT1ON.......,.,.,...,.......,......,..,, F-ltX DASHPOT.,................,..,..,,,..,..,...,..., F-l05 A/C CUT-OFF SYSTEM.........,.............,, F-105 DESCR1PTrON................................... F-l0s SYSTEM OPERAT|ON............,..,.,....... F-l06 DECHOKE CONTROLSYSTEM.............F-106 DESCFtPTtON....,,,,.......,.......-........... F-106 SYSTE|\4 oPERAT|ON............,.........,.. AtR BYPASSCONTROLSYSTET,.,.,..,.,F-107 F-107 DESCRrpION..,,-............,................. F-108 sYsTEt\4 oPEFAT|ON............-............ AIRBYPASS SOLENOID F-10e VALVE@, @, @............................. F-110 CONTROL SYSTEI,|..........................,... F-110 PREPARA'IrON...................,.....,......., VtEW,...,..,...,...,..,...,..,, F-l1 1 STRUCTURAL UNtr{ECU..,........ F-112 ENGTNE CONTFOL CBANKANGLESENSOR F-r20 itN D|STRtBUTOR),........................... AIRFLOW SENSOR (BYPASS ryPq..........,.,,,. F-l21 HOT-W|RE wATERTHEB[,4OSENSOR...,..,,.,.,.,..,.. F-121 F-l22 TfIBoTTLE SENSOR,....,..,,,.,,.,....,..,.. F-123 oxyGENSENSOR............,........,.,..,.. F-124 t\4AtN RELAY ...,,....,.......................-.. F-l24 cLUTCHSWTTCH fi,,4Tn,..,...,.........,-.. (L4TX).,....,.,,.....,.... F-l25 NEUTRAL SWTTCH PFESSUFE SWITCH F-125 POWER STEEFING o1a0Fx.001
F
INDEX
INDEX
STOPLIGHTSWITCH SERVICE,SECTIONT
IDLESPEED PAGEF-€3
TIMING IGNITION
swrrcH(Arx)
K SECTION SERVICE,
F-2
INDEX
F
1. Fueltank 14.Air bypasssolenoidvalve@ Removal pageF-109 / lnspection / Inspection....-............................ Insta||ation............................... pageF- 90 15.Air bypasssolenoidvalve@ 2. Fuelpump Inspection.................p . .a. .g. .eF . . .1. .0. .9. . . pageF- 91 16.Enginecontrolunit(ECU) Inspectjon........................-........ pageF-112 R e p | a c e m e n t . . . . . . . . . . . . . .p. .a. g . .e.F. .-. .9. 2 .... Rep1acement............................. 3. Fuelfiher(low-pressure I n s p e c t i o n . . . . . . . . . . . . . . . . .p . .a. .g. e .F . .-. 1.1. .2. . . . side) R e p | a c e m e n l . . . . . . . . . . . . . . p. .a. .g. e .F. . . .9. .3. . . 17.Airflowsensor 4. Fuelfilter(high-pressure side) fn s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .- .1. 2 . .1. . . pageF- 85 Replacement.-........................... pageF- 93 Rep1acement............................. 5. Circuitopeningrelay 18.Waterthermosensor R e p l a c e m e n l . . . . . . . . . . . . . .p . .a. .g. e .F. .-. .9. .3. . . I n s p e c t i o n . . . . . . . . . . . . . . . - . .p. a. .g. .e.F. -. . 9. .3. . . . 6. Pressure regulator 19.Throttlesensor Inspection................................. pageF- 94 I n s p e c t i o n . . . . . . . . . . . . . . . . .p . .a. .g. e .F . . .1. .2. .2. . . pageF- 94 Rep|acement............................. A d i u s t m e n i . . . . . . . . . . . . . . . . .p. a. .g. .eF . .-.12 2 pageF- 122 7. lnjectol Removal / lnstallation................ (on-vehjcle).............. pageF- 94 20.Oxygensensor lnspection pageF- 95 Removal/ Installation I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. a. .g. .eF . . -. 1 . .2. .3. . . ................ I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-. .9. 6 .... pageF-124 Rep1acement............................. 8. PCVvalve 21.Mainrelay I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a . .g. .e.F. -. . 9 . .9. . . . pageF-124 Rep1acement............................. 9. Solenoidvalve(purgecontrol) l n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a. .g. .eF . . .1. .2. .4. . . Inspection................................. pageF-10'| 22.Clutchswilch(MTX) pageF-101 Removal / Installation................ 1 n s p e c t i o n . . . . . . . . . . . . . . . . .p. a . .g. .e.F. . 1. .2. .4. . . . 10.Fuelvaporvalve pageF 124 Repiacemeni............................. I n s p e c t i o n . . . . . . . . . . . . . . . - . .p. a. .g. .eF . . -. 1 . .0. .1. . . 23. Neutralswitch(N,,|TX) 11.Checkvalve(two-way) pageF-125 Inspection................................. I n s p e c t a o n . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. .0.2. . . . pageF-125 Rep|acement..........................-.. 12-Charcoalcanister 24.Powersteeringpfessureswitch I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a . .g. .e.l .- .-.1. .0.2. . . pageF-125 Inspection................................. 13.Air bypasssolenoidvalve@ 25.Crankanglesensor 1 n s p e c t i o n . . . . . . . . . . . . . . . ...p. .a. .g. e.F. .-.1. .0. 9 .. Inspection .................. *t".,H.r_:
flil"'.Y,fl;......:.'' ..... .....833: i-:,31
F-3
F
INDEX
1.Aircleaner I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-. .6. 2. . . . 2. Dashpot I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. .0. 4. . . pageF- 85 ................ Installation Removal/ 3. lnjectionbody . .. .. ... pageF- 84 Inspection................. pageF- 85 / Assembly........... Disassembly 4. Bafile I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a . .g. .e.F. .-. .8. 6. . . .
F-4
5. lntakemanifold .. .........pageF 86 Inspection.................... 6. Intakemanifoldstay 7. Exhaustsystem / Removal/InsDectlon I n s t a | l a t i o n . . . . . . . . . . . . . . . . p. .a. .g. e . .F. 9 / L Catalyticconverter I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e.F. -. 9 7
F
OUTLINE
OUTLINE SYSTEMDIAGRAM
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F-5
F
OUTLINE
VACUUMHOSEROUTINGDIAGRAM
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OUTLINE WIRING DIAGRAM
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F-7
F
OUTLINE
SPECIFICATIONS 1 , 1 0 0 1 5(3P r a n g e )
7501"3(Neutral)
Bfqq
limino' lsnlrion rtrui-,-
, kPa(ks/cm' psi)
ortprip,""*,"
Below638 (6.5,92) Nylonelement(in tuelPumP)
kPa(rCcm),Ps)
FeSrl"rrSp'e."r'"
235 275 12.4-2.A,34-40)
Air bypass solenold valve @ Alr byp.ss solenold valve @ Alr bypass solenoid wlve @ Solenold valve (purge conlrol) 't4.6-17.8
Resistance
ko
40oc 004oR
o"c (176'D Bypasstype ol hol_wre ko
Besistance {HWN-HWP)
rpr
'tv'vt"'ry
40 00.6,8.8)
(RON90 or hgheo Unieaded 'TEN termnal of diagnoslsconnectorgrounded
F-8
F
OUTLINE DESCRIPTIONS COMPONENT Component
Rems]k
Air bypasssolenoid SLrpplies bypassair intointakemanilold by valve @ openrngbypassarr passageat eitheriollowng ilj€e1\otj a) Ensinecrankins b) El€ctricload $oe'i c) P/SpressureswitchON d) A,/CswitchON e) BangechangelN-D) f) Deceleralionconlrol Air bypass solenold valve @
. Electricaload a) coolingfan b) Blowermolor swltch c) Headlighl switch d) Rearwindowdehosler switch
Supplies bypassair anlolnlakemanifodby openingbypassair passageal eiiherlollowing a) Enginecranking b) P/SpressureswilchON c) Deceeralon conlrol
Air bypass solenoid valve O
S'rpplies bypass air inlo nlake manifold by opedng bypas arf passage with A/C swltch ON Filiersair enleing injectionbody
Oil p€rmeated
Detects anrounl of inlake air; sends signal to ECU
UsesVref(5v) as powersource
Batlle
Drrectsluel/ai. mixtureinto intakemanilold
Cat.lytic convener
ReduceHC, CO and NOx by chemcal Storesluel tank llmes whie enginestopped
Controlspressureln iuel tank Circuit opening retay Vollagefor {uel pump while enEne runnrnq clutch $viich (MTx) Delectsclutchcondlioni sendssignalto ECU Crank angle sensor Ne.signal
SwilchOFFwhen cl'rlch pedal released
Detects crankangleat iaoo inlervalsi sends signalto ECU
Diagnoslsconneclor ConcentraledseMce connectorTerminals: 1. 2. 3. 4. 5. 6.
2l pin (locatednear leti struttoweo
EGI self.diagnostclerminal EC-ATself-diagnostctermifal Inilia set lerminal Fuel pLrmpcheck lerminal Coollngian ch€ck terminal Enginerpm oulput telm nal
Oashpor
Preventsalter burn when throtllevaivecloses
Ehglneconlrol unil (ECU)
Conkolsoperalon ol the following. a) Fuelinjectionconlrol system b) Elecironicspafkadvance(ESA)control c) AJCcur-otisysrem d) Deceleralionconlrol syslem e) Fuelp'rmp controlsystem D Evaporativeemissionconlrolsyslem g) Falsaleconkolsystem h) Secondary air injeclionsystem
Fuel lllie.
Filterspanicleslrom luel
Fuelpump
ProvrdeslLielto nleclor
whaleenginerunnng Operates
Supply only evaporativeemissioninto charcoa can sler lo prevent charcoai canisler from lue
F-9
F
OUTLINE Remart
Componsnt lghlllon swilch (STABT posilion)
Enginecrankingsignalsent1oECU
lnhlbllor swilch (ATX)
sendssignalto ECU Detectsin-gearconditioni
S w i c hO N n N o r P r a n g e s
Inleclion body
a) lniectsiuel intoinlakemanilold b) Adiuslsinlakealr amounlby throttlevalve vave @ ct ldl;-upby air bypasssolenoid d) Deteclsamountol intakesalr by airlow
Conssts ol throtlle vaive dashpot, throtlle sen' sor, last idle cam, airflowsensor,inieclor,pres' sure fegulator,and ar bypasssolenod valve
Ini6ctor
to englneneeds lniecrsfue in relatlon
by signalslfom ECU Conrrolled lnjector High-ohmic Installedon injecton body
Main relay (FUELINJ relay)
ECU,elc Supplieselectriccurrenlto injector,
t{eurralswnch(t TD
sendssignalto ECU Detectsin-gearcondiLon; sendssignallo Deiectsoxygenconcenlrationi ECU
Orygen sensoa
@
SwitchON in neulral
coatng cetamicand platrnum Zrrconia
Contros blowby gas IntroducedInlo engine
P/S pressure 3witch Prelsure regulrtor
P/Soperatonisendssignallo ECU Derecrs AdjustsJue pressuresuppliedto injector
P/SrON when sleeing wheellum€d
Specd s€nsor stopllglrr swllch
Detects speed: sends signal to ECU
cluster Insialled on instrumenl
Solenoid valve (purg. conltoD
sends Delectsbrakingoperalion(deceleranon)i signalto ECU Conlrolsevaporativelumesfrom canister10in_
Throltle sercof
Deiectslhrottlevalveop€nlnganglelsends sg_ nal to ECU
body on injecuon Installed
Wat.r thetmos€nsor
Delectscoolanttemperature;sendssignalto ECU
lnsraledon iniakemanlfod
F-l0
F
GUIDE TROUBLESHOOTING
GUIDE TROUBLESHOOTING CHART RELATIONSHIP OUTPUTOEVICE .,1
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tcNtTtol{sw|rcH (STARTPOSII|ON)
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E/L SIGNAL'
o
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P/S PRESSURE SWITCH
o
o
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a/c swlTcH
o
INHIBITORSWITCH(ATX}
o
o
o
o
o
o
o
o
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EUTRALAND CLUTCHSWTTCHES GITX)
o o
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sToPltGHT SWITCH SPEEOSENSON
o
THROTTLESENSOA
o
o
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AINFLOIY SENSOR
o
o
o
OXYGENSENSOR
o
o
WATERTHER OSENSON
o
o
o
CRANK ANGLE SENSON O{6'SIGNAL)
o
o
o
o
o
o
o
o
o
o
o
o
o
o o
o
o
o
o
o
o
o
o
o
' E/L 3lgnal ls headlighls, rear window dalroster, blow€r 3witch and cooling lan.
F-11
F
GUIDE TROUBLESHOOTING
USINGTHIS SECTION lntroduction oftenmakjngit ditficultto diagnose controlled, Mostol the fuelandemissioncontrolsystemis electrically problems. actualchecks,takea few minutes Before undertaking oroblemsintho system,especiallyintermittent is oftena goodsource customer complaint The with a drivability who approaches io talkwitha customer onecanfind with the customer, problems, Through talks intermittent ones. especially on such of inlormation occur. condjtions they are and under what symptoms out whatthe work tlow CHECK IN
I
I
TO CUSTOMEB COIVPLAINTS LISTEN
I
I
_ DIAGNOSTICINOEX (Belerto PageF 14)
TO TROUBLESHOOIING PAGETHAT REFEB TO ACTUALSYMPIOIV COBRESPONDS
_ -
CHECKFORWHATIS BAD IN SYSTEM CHECKFORWHATPARTIS BAD
_ _
I
i RTOAIB/FEPLACEMENT J
INSPECTION
ACTION i
I
HASBEENELIMINATED IF TROUBLE DETEBI\4INE I Yes CHECKOUT
Diagnosticindex DESCRIPTION: Describes eachtroubleshooting ilem. No.: itemis Eachtroubleshooting assigneda number-
ITEM: TROUBLESHOOTING Thereare26 troubleshooting items.Choosethe itemthat to mostcloselycorresponds the actualsvmDtom.
F-12
F
TROUBLESHOOTING GUIDE Troubleshootingchart
. E n 0 i e . u n s n o m a y a ' r d e t rd r e
F o u s hd r e ( N o s3 , r 2 ) l
FROUALESHOOTIIG HIf,ISI (cotr*lo^ 'or coorad rehpe'aruE)
*rnund|onc*No'ck'l.y.d checkro' cau* (Ferer'ospsr'd ch&ks4uercel Che.NEcLrrem'^a lFvorase (rernion
d ox) 3Cat.F2_rle
EC! andsenDaqDss ch4ker
05u0Fx.015
OESCRIPTION: Furtherdescribes the symptom.Confirmthatthechartaddresses theactualsymptombeforebeginning troubleshooting. TROUBLESHOOTING HINTS: fhis describes the possibleDointof maltunction. STEP: Thisshowsthe orderol troubleshooting. Proceedwithtroubleshooting as indicated. INSPECTION: Thisdescribes aninspection procedure to quicklydeterminethe malfunction of parts.lf a detailed isnecessary to performthe INSPECTION, referto ihe pageshownby the "F" mark. ACTION: Thisrecommends theappropriate actionto takeasa result(YeVNo) of theINSPECTION. Howto perform the actionis describedon the reference pageshownby ihe "t?" mark. 0su0F1.016
F-13
F
GUIDE TROUBLESHOOTING
INDEX DIAGNOSTIC ITEI TROUBLESHOOTING Willnol crankor cranksslowly 2
7
8 9
Enginestallsai dle
10 11
E/L ON Rough idle/Enginestallsjust atier sta(ng
13 14
High idle speed atterwam-up ldle moves up and down/ldlehunting Engrneslallson deceieralion
(lntemiten0 Eng,nesrallssuddenly
OESCRIPTION Reierto EngineElecticalSystem Engnecranksal normalspg€dbul showsno signot lring Enginecrank€at normalspeedbut showsonlypar_ andwillnolconlinueto run tialcombuslion Enginesladsnomallywhencold,but will notslana, ter runningandhoisoaked
PAGE G--4 F-17
F- r9 F-21
Eng,necranhsal rormal speed bul reqJies eices sive cranking time belore staring
F-23
as No.swhenenginecold Samecondition Reslansnormallyafterwa|m_up as No.5aflerrunningano hot Samecondltion
F-25 F-27
Startsnoimallywhencold Enginestallsor vibratesexcessivelyat |dle
F-29
Enginestallsor vlblatesexcessivelyal idle dlrng
F-31
Enginerunsnomallyat idleduringwatm'upbul or stallsaft€rwarmlp vibates excessively Enginestallsor v bralesexcessivelyal idle wrcn }JC, P/S,or E/LON onlylustaner Enginestallsof v bralesexcessively Jromidle) staning(acceleralion ldle speedexcessveafterwam_up Enginespeedsup and down pe.iodicallyat dle E^grneune^pecledlvsloos run'nng\th le dFcele'ar ing or atler decelefallo.' Engineintemiltenty slops runnhg
F-35 F-36 FJE F-39 F41
F42 F-43
16 17
Hesitates/Siumbles on acceleration
Flatsoot occursiustalier acceleralordepressedor mlldjerkingoccursduing acceleranon
18
Surges
Unexpectedchangein engne sp€€d which ls lsually rep€lilive
F--45
poorunderlmd whenthroltlevalve Pedo.mance
F-17
19
lvlaximumspeedr€duced 20 21
Runsroughon deceleralion/Backlire
22 23 24 25 26
F-l4
Highoil consumpnon
Pedormancepoot whileacceleral,ng Enq,le runs roughwhiledeceeraing 3nd abrornal combustion occurs in exhaust sYstem Abnomal combustionaccompaniedby audible ''pinging" nois€ Gasoine odor in cabin Exhaustgas smellslike rotteneggs
ercessNe Oilconsumplion Fueleconomyunsalislactory
F-50
F-55 F-57
F-58 F-58 F-59
F
TROUBLESHOOTING GUIDE Doscription ol Drivablllty STUMBLE : Mib jerkingduringacceleration. pedalis depressed HESITATION: Flatspotoccurringjustafterthe accelerator jerking : SURGE Continuous soft duringcruise.
03u0Fx233
ENGINESPEED
WNo.laSURGE No.17STUMaLE
-12'1no
" """o'on No.21 RUI{SFOUGHON OECELEBATION
F-l5
F
22-30 12.2-3.1 , 16-22t r+m (n-kg, n$)
GUIDE TROUBLESHOOTING
PUMP CONNFCTOB
PRECAUTION Fuel PreasureReleaseand ServicingFuel System evenwhen remalns underhighpressure Fuelinthefuelsystem the enoineis not runnrno. anytuelline,releaselhe fuelpres_ a) Beto'redrsconnecltng ol iniury surekom thefue syslemto reducelhe possibihtv or fire. 1. Stanthe engine. 2. Removethe rearseatcushlon. the iuel oumoconnector. 3. Disconnect 4. Afterthe engineslalls,turn otf the ignitionswitch. rearseat andinstallthe fuelpumpconnector 5. Reconnect cushron. fromluelspraywhendisconnecf b) Usea ragas protection ino the hoses. Pluothe hosesatterremoval. fuelpresthefuelsystem,usea suitable c) Wheninspecting suregauge. Cautlon . Install hose clamps lo secure lhe tuel pressule gaugetothe tuelfilterandthe tuel mainhoaeto pre' vent luel leakage, PinchinoHose Whenp;ching an air hoseor a fuelhosewithpliers,wrap the hosewitha rag to preventdamage
F-16
F
GUIDE TFOUBLESHOOTING SYMPTOMTFOUBLESHOOTING CAANKSNORMALLY BUT WILL]{OT STARTfiO COMBUSTION} .Enginecranksat normalspeedbut showsno signol "fting . DESCRIP. Bane.yIn normalcondrtion .Throttlevalvenoi heldiullyopenwhiiecranking(Oechoke syslemnot operale) Ttotl HINTSI ITROUBLESHOOTING possiblyn o Because ol no combustDn, O No spark . lgntioncontrolmalfunction
r u e i s n F L l e d l o e n g r n . o r o € 1 l i o n a l d r lc / l - d a r '
€) Lowruellinepressure @ Lowens,necompressioi @ ECUpowersupplycrrcuitopen @ ECUgroundc rcui open
.lgnition sysiemcomponentmafunction @ No iuel inlection . Fuelpump inopefalive .Injector inoperative INSPECTTON l
acTtor,l
hgh. ls svongbluesparkvsibe at disconnecled
/
>. 2
PerformSlep 2 4 a
/)
ll OK, check rgnton system (Referto lroubleshooiing ''Misfke") (r Page G-17 ff not OK, relerio speciJiedcheck seqlence lor displayedcode No. F Page F-?0
ls 00" displayedon SellDiagnosisChecker wlth lgnilLonswilchON? ri page F-67 Maltunctlon code No. displayed Check lor cause(Belerlo specited check sequenceior displayedcode No.) "88" flashes Check ECUlerm nal lF vo tag€
17 Page F-7o r? page F-114
voltage: Approx. 12v (lgnillon switch ON) 4 +
3
Rer.oveair c eanercoveri is fuei iniecledfrom injeclorwhie crankingengine?
1.5-2.0 Nn {15-20 crks,13-17
in-rb)
ll OK. replaceECU ll not OK. check wl.ing belween ECU and SelfDbgnosisChecker and ECUlerm nal 18 vollage Ch€ckiollowng poinls .Spark ptugs . tgnjtionrmrng .Engine compressiof .Warer thermosensor (ECU 20 tem nal vollase) .Fuel pressure (lr njectediuel is smallariounl) .Inlecror (li njecledfuel is smallamounl) Checkfor lnjectoroperatingsound whllecrankng engrne
+ +
ri page F-112
r page c-19 E? pag€ F-63 c? page B-lO -r page F-118 c7 page F-89 17 page F-97
li OK, So lo nexl siep l{ not OK, go ro Slep 6
F-17
F
GUIDE TROUBLESHOOTING ACTION
tNsPECT|Oll F/P.and terminals connector dlagnosis Connect GNDwithiumperwireiis fuelpumpoperarng solnd evidedwilh isnilionswitchON? -7 pege F-92
Check if iuel is iniecledwhib crankng englne n this condftion +
lf injected,check circultopening
4
ll not injecred,check inieclorlof cloggingand if lue is in tank
;)).
GND
5
ls there conllnuilybelweenlLlelpump connecior @ and @?
relay Checkcncuitopenrng
6
at ECU2Vler_ ls thercapprox.12Vmomenlariy m naLwhib crankingengine? (Engrne signalmonitorgreenand red amps ilash)
Try io replace njector(lniectorstuck)
No
F-l8
Checkinjeclorlor continuity +
lf OK,checkwlfinSrelatedto 2Y,2V,2U,and ECUterrninals
+
ll notOK, repaceinjeclor
c7 page F-93
F
TROUBLESHOOTING GUIDE CRANKSNOF ALLY BUT W|LL r,rOTSTART(PART|ALCOtitBUSTtOt{)- U,HENEI{G[{E COLD .Engine at normalsp€edbutshowsonlyparlialcombustion and willnot conlinuelo run DESCN|P.. Batlerycranks in nomal condilion Tto
HtNTsl rrFouBLEsHooTrilc
O Lowensinecompressron
mixtureloo rich O Air/Fuel . Waterlhermosensor malluncllon loo lean O AidFuelrnixture .Fuel njecton controlmallunction (Corectionror coolanltemperature) .Low iuellinepressure .An leakageof inlakeair system INSPECTION 1
ACTION
ls 0O displayedon SellDiagnosisChecker wlth ignilion switch ON?
MallunctionCodeNo. displayed Checklor cause(Reierlo soeciiied checksequence)
17 pageF-m
"88" llashes CheckECUlelmlnal1F voliage
F pageF-114
Voltage:Appror. 12V (lgnltlon switch oN) TESTSWiSELFTEST
a 4
ll OK,replaceECIJ c7 pageF-112 I nol OK.checkwiringbelween ECUand S€lf-Diagnosis Checker
?
/\^\_
/
Checf d sr ouror cdp ard rolor
c:i page G-23
d\<<=F 3
=I)'b B\
Connectdiagnosis connecror letminals F/Pand GNDwilhjumperwne; s lherecorrectluelline pressure withlgnitionswitchON? e page F-49 Fuelllne prossuae: 235-275 kPa (2.4-2.a kg/cm', 34-40 psD
Check luel line pressurewhile p nch + -:
PFFSSUREGAIIGE
' l
ll tuel line pressurcquickly increases,check pressureregulalor il luel line pressufegraduallyin. creases,check lor clogging belween tuel pump and pressure lf not clogged,check luei pump max mum pressure
t""
otAGNOStS CONNECTOF
e
page F-91
High pre$ure ls llel relurnhosecloggedor res, lricled? + .)
ll OK,replacepressure regulalor c? pageF-94 ll not OK,repa.or replace
F-19
F
GUIDE TROUBLESHOOTING ACTION
INSPECTION
AreECUteminalvoltagesOK? 1C,1K,20 and 20) lEsDeciallv c7 PageF-112
5
ls lhere air leakageol intakeai svstemcom-
6
is Doesenginestartswhenwalerthemos€nsor
7
A'e spark plugs OK?
Checkior cause
-
Page F-114 F-l16
Chbck waterthermosensor
!7 page F-121
Clean,or rep ace
tr- Page G-19
F Page G-19
WEAFANDCAFBONBUILDUP BUBNS (0.039-0.o4i, AND DETERIOFAIION
a
No
correct? comorcssion ls enoine s PageB-10
Try knowngood EcU andcheckaf
EnoinecomDression:Morethan 1,030kPa (t-o.srglcr;'. 149psi)-300rPm
Check enginecondition .wofn pston, pislonrings or cylinder .Defectivecylinderhead gasket . Distorled cylindff head .lmproper valve s€atng . Valveslickinsin Suide
F-20
.? Page B-10
F
GUIDE TROUBLESHOOTING CNANKSNORMALLYBUT WILL OT START(PARTIALCO AUSTIOII)- AFTERWARM.UP .Enginecranksat nomalspeedandshowspartialcombustion but willnotcontinue lo runaflerrLrnning and
DESCBIP. .8atteryin normalcondition Tt0ll . Engne slartsnormallywhencold
Ht{Tsl rrRouaLEsHooTtNG
@ Vapoflock .Fuel pressu.e not heldin luelIne afierensinestopped .Hish RVP(winler) luelusedin warmweather
O Ar/Fu6l nixture too ch .lnsuftcienttuellnjection conlrol (Corr€ct on lor coolanltemperalue) .lnjeclortuelleakase INSPECTION to normal operaling lempera-
1
ACTION Changeluel io anolherbrand
;is conneclorterminalsF/P and Connecldiasnor GNDwithjump€r wire ior 3 minrres with ignilion swilchON,then
,'
JUMPEFwlFE l# ---t I 64\ @t),x.
,/,1{Q
2
Jl l^
\
\
ts
lermlnals F/Pand Connectdiagnosis connector cor GNDwithjumperwireiis tueillnepressure r€ct wilh ignitionswilchON? rr page F-89 235-275 kPa (2.4-2.a kg/cln', 3/t-40 psi)
Check fueLline pressurewhile pinch' .+
PRESSUFE a
FUELFILTEFi
.riupin wrne
High piossure ls iuel returnhosecloggedor res + +
3
ln samecondilionas Slep2, is tuel ine pressure heldafterignitionswitchls lurnedOFF? e p.ge F-88
lf luel llne pressurequicklyincreases, check presslre reguiator I luel line prcssuregladuallyln cr€ases,check luel line and filter for clogging li not clogged,check fuel purnp maxirnum pressure r7 page F-91
li OK, replacepressure regulator s pageF-94 li nol OK, repairor replace
Go to Step 5
Fuel llne pressure: Morc than 147 kPa ('1.5kg/cm',2t psi) for 5 min. is fuelIne Plugoutleiof prcsslreregulator: pressure heldatlergnilionswilchis lurnedOFF? 17 page F-88 Fuelllno prc3surq Morethan !47 kPa (1.5 kg/cm' ,21 psOfor 5 min.
BeplacepressLrre regulatof
r- page F-94
Check fuel pump hold pressure
c7 page F-84
4 4
lf OK, check inlectorior fuel leakage lf nof OK, rcplace iue pump
F page F-96 .r page F-92
F-21
F 5
GUIDE TROUBLESHOOTING ACTION Ch€ckwaterlhermo€ensot
TNSPECTtOt{ O:sconneclwaterthermosemorconnectoridoes
c7 gage F-121
+
It OK, checkconn€clionsot waler and ECU20 themosensot
4
ll not OK, feplacewaterther mosensor
(j PaSeF-121
Mallunction code l{o. disPlayed Checkior cause{Belel lo specined checksequerce)
f? Page F_70
"88" llasheg CheckECUteminal1F vollage
c7 page F-114
No
6
Checker on S€lt_Diagnosis ls 00" displayed switchON? wnh ionition t7 Page F-'67
vollage: appror, 12v (lgnltionswitch oN) 4 +
7
8
!1'PageF-112 ECU li OK,replace li nol OK,checkwirng between Checker ECUand Seli'Diagnosis
OK? Are ECUterminalvoltag€s (Especrallv 1C,20 and 20) c7 PageF-i12
Checklor cause
-
Try knowngoodECUand checkii condilion
ReplaceECU
F Page F-l 12
Changetuelto anotherbrand
F-22
PageF-115 F-l17 F-lt9
F
TROUBLESHOOTING GUIDE CRANKSNORMALLYBUT HARDTO START- ALWAYS .Englne al nomal speedbut req'rnesexcessivecranklngllme berorestarling DESCRIP.. Batlervcranks ln norrnaconclition Ttol{ .Enginerunsnomallyat ldlefll idlecondllionnotOK,referto "Boughidle"(Nos.8 l2)l G HTNTSI FnoUBLESHOOTtfl rnixture too lean @ Air/Fuelm nure ioo ich O Air/Fuel .Fuel injeclion .Fuel injection controlmalfunclion controlmalluncion (Correclionlor coolanttemperalure) (Correclion tor coolanltemperaiurd .Calbondeposilin hot-wire passaSe .Low luellin€pressure @ Poo'isnitionspafk ACTIO tNSPECTtOl{ ls 00" dsplayed on Selloiagnos'sChecker wth iqnitionswilch oN? F page F-57
ma[unciion Code l{o, dlspl.yed Checkior cause{Referio soeciiied checksequence)
? p.ge F-70
"88" tl.shes CheckECUtermlnal1F voltage
c7 page F-114
Vo[.g€: Appror. l2V (lgnitionsvritchO ) + 4
2
ls there a r leakage ol intake air syslem com-
3
s ar cleanerelementclsan?
-
page F-62 No
Doesenginesla( easllywhen lhrofle valve
5
t:" p.ge F-172 lf OK, replaceECU ll nol OK,checkwiringbelween ECUandSsll-Diagnosis Checkef
Repaceair c eanerelemenl Ch€ck throtle valvetor carbon depost and lhen go to Siep 6
ls iuelIne prcs$rrecofieclal idle? F page F-94 235-275 XPa 12.4-2.A kg/cm" 34-40 psD
whilepinchCheckluellinepressure + +
quicklyinll fuelllnepfessure regulalor creases, checkpressure gradually ll fuelllnepressure in' creases, checkfor cloggingbelweentuel pumpand pressure ll notclogg€d,ch€ckiuelpump maimum prcssurc F page F-91
FUEL FILTER
F-23
F
GUIDE TROUBLESHOOTING ACTION
INSPECTION 6
ls ar bypasssolenordvalve@OX?
r' p.g€ F-104
No SOLENOID VALVE@\\\
r)
o 7
8
9
Replacesolenoidvalve
INJECTIONBODY
k!
Are ECUterminalvoltagesOK? (Esoec,aly 1C,th and20) c? Page F-lOg
Go lo nexl slep
Connect cliagnoss conneclor tetminals F/P and GND with iumperwirei does engrnestan
Eneckcircultopeningrelay
Cn""f io, "uuse
a
ff rclayOK, repairor teplacewi€
+
li r€laynoi OK, repiacerelay
r' PageF-115 F-117 F-l19 c7 PageF-93
connector ConnectSystemS€lectorto diagnosis 'i and setT€st Switchto SELFTEST is lhere lmng €t dle aiterwarm_up? corecl |gnrtion e PageF-63 lgniliontiming: aTDC16 + 1c
,-JE"
1 0 ls enginecompressioncorreci? c7 page B-lo Englnecompres€lon(ilinimum): 1.030kPa (10.5ksr'cn', r49 Fel)-300rPm
1 1 Try knowngoodECUIdoescondilionimprove?
F-24
Adjust lgntion iiminq
!? Page F-63
c? PageB-1o Checkenglnecondition .Wornpislon,pLston nngsor cy lnoer . Delecuve cylinderheadgaskei . Dlsroded cylinderhead . lmpropetvalveseating .valvestckinsin guide
F
TROUBLESHOOTING GUIDE CRANKSNORMALLY AUTHAROTO START- WHE E GINECOLD .Englne crank al nofmal speed but rcquires excossive cranking lime before slarl ng
DESCRIP.. Baltery n nofmal condition . Festarc OK after wam-uo TION
.Engrne runs no.mallyat idle [f idle cond]tionis not OK, r€terio 'Roughldle' (Nos.8-12)l
HtNTsl rrnouBLEsHoollt{G
O Air/Fuelm)duretoo rich .Fuel injeclion convolmal,unction (Correction tor coolantlemperature) .Thermowax mallunclion INSPECTION ls "o0 displayed on SellDiagnosis Ch€cker wlthignitionswitchON? 17 page F-67 SYSTEMSELECT:r
m xiureroo ean @A1r/Fuel .Carbon deposltln hol wire passage . Fu€linj€ction conlrolmalfunction (Coffeclionior coolantlemperalure) @ Pooratomzation . LowRVP(summer) fuelb€rngused ACTION
MalfunctlonCode No, displayed Checklor causeFeler 10soeciti€d checksequencei
E? page F-7O
"88" llashes CheckECUterminal1F voltage
c7 pageF-'l 14
Voltage:Approx.12V (lgnition switch ON) d 4 2
3
rr page F-112 ll OK,replaceECU ll not OK,checkwiing betlveen ECUandSelfDiagnosis Checbr
Are ECU leminal vollagesOK? (Especiaiy1C. 2D, and 20) -:r page F-112
Checkfor caus€
Does engineslart easilywhen throtllevalve
Check lhemowar 4 4
c7 page F-115 F-117 F-lt9 c7 page F-85
f OK, go to Srep 5 ll nol OK, replaceinjeclionbody
ls there air leakageol inlakear systemcom'
5
ls arr cleanerelementclean? cr page F-62 Beplaceair cleanerelement
6
Are sparkplugsOK?
e page G-19 AND WEAB CAqBON AUILOUP BUFNS
(0.039-0.043 in)
E AND DETEFIORATION
F-25
F
GUIDE TROUBLESHOOTING
correctal idle? ls iu6llin€pressure
t7 Plge F-94
Fuel line pre$uaa: 235-275 kPa (2.4-2.8 kgL/cm"3{-40 p6i)
Checkluel line pressurewhil€pinch_ ing iuel r€lum hose quicklyin_ lf fuellinepressurc creases,checkpressureregulator in_ + ll fuellinepres$rregradually ch€ckluellinelo. clog_ crcases, ging betwe€nfuel PUmPand pr€€sureregulalor ll nol clogged,checktu61PumP c? PageF-91 pressure maximum High prcs3ure ls tuel rettim hosecloggedor fes +
lmprove? Iry knowngoodECU;doescondition
+ ll OK, replacepressureregulator - Page F94 4 ll nol oK, reparor replacehose c7 PageF-112 Replace ECL, Changefuel lo anotherbrand
F-26
F
TROUBLESHOOTING GUIDE CRAI{KSI{ORI{ALLY zuT HARDTO START - AFTERWABi&UP .Engine cranksat normalspeedbut requiresexcessivecrankingtme beiorestadingaller runninoand hol
DESCRIP.. Baiteryin normalcondition . Enginestarlsno|mallyvlhencoLd .Ensinerunsnormally nol OK,referto Roughidle"(Nos.8-12)l al idlelll idlecondltion HI TSI ITBOUALESHOOTING @ Vaporlock O Ai/Fud rni(ureloo rich .Fuel pressufenot heldin luellineafterengineslopped . Fuelinjecton conlrol malfunclion .HiSh RVP(wider)fuelusedin warmwealher .hieclor luel leakage
n0
acTrol{
r{sPEcTtot{ 1
ls "00" displayedon S€llDiagnosisChecker with igniiion switch ON? NO
allunc{lon Code No. dlsplayed Checkior causeSeler to soectied checks€quence) "88" tlashas CheckECUrermlnal1Fvoltage
c7 pag€ F-70 s pag€F-114
Voll.ge Approx. 12V (lgnition switch oN) =) lf OK, r€placeECU E' pag€F-112 + lf not OK, ch€ckwiringbelween ECU and SellDiagnosisCh€cker 2
3
Go to nextstep
Are ECUterminalvoltages OK? (Especlally 1C,20, and 2T) c7 PageF-l12 is held Runengineal idleiis luellin6prossure afterignilionswitchturnedOFF? .7 p.ge F-88 Fu€t llne oreaaure: More then 147 kPa (t.5 kg/cmz,21 psl) tor 5 fiin.
Checktor cause
NO
F pag€ F-115 F-|17 F-l19
Plugou.tlelof pressureregllalor and is heldafier checkil Juellinepressure ignilionswitchlurnedOFF .+ lf OK, replacepressureregulalor 17 page F-94 + lf nol OK,ch€ckluelpumphold pressure .7 pago F-88 lf luel pump is OK, ch€ckintector r? page F-96 lor iuel leak€ge
F-27
F JTEP
GUIDE TROUALESHOOTING ACNON Changefuel to anotherbrand
|l{SPECT|O}l op€ratngtemFera_ lo normal engine Warm-up lureand slopil F/Pand conneclorterminals Connectdraonosis GNDMh iumos wirator 3 minule6wilhignition switchON; do€s if englne$ans easili/?
Go to nexts|ep
5
Heptace ECU
Try knowngood ECU;do€s condilionimprcves? NO
F-24
ChangeJuello anolherbrand
E? l,d,ge F-112
F
TBOUBLESHOOTING GUIDE ROUGHIDLE/EXGINESTALLSAT IDLE _ ALWAYS
a
DESCBP- .Engrne sads normalv bul stallsor v,braresexcessvey al idle in everyco']d ion |
HtitTSl FROUALESHOOTTNG mixlureloo lean O Air/Fuel
rn r^^^-4r
. Fuelinjeciion conlrolmalluncUon .Low luellinepressure @ Lowintakeair amount INSPECTION
1
ls "0O drsplayed on SeJi-Diagnosis Checker wilh ignitionswltchON?
iira clEAd
. ldlespeedmisadiust'nent @ Oneor moresparkplugsnol firlng O Lowenginecompression @ Carbondepositin injectonbody ACTION
Mallunclion Code No. dlsplayed Checkfor caus€lRete.to soecilied checksequence)
.? page F-70
"8a" tlaEhes CheckECI.J lerminal1F voltag€
c? pageF-114
Voltage Appro!. 12v (lgnltion€wltchO ) + + 2
3
AreECUteminalvoltages OK? (Esp€cially 1K,2M,20 and20) -r page F-112
Disconn€€leach hightensionlead al idlei does enginespeed decreaseequallyat each cylinde?
o p.ge F-112 ll OK,replaceECU ll nol OK,checkwlringbetw€en Check€r ECUandSellDiagnosis
Checktor cause
F pageF-115 F-117 F-l19
Go to Step 5
ls slrong blue spark visibleat disconnectedhigh-
Ch€ck hrghlensionlead
/
+ +
5
Arc sparkplugsOK?
c7 page G-19
WE1AFAND CARBONBUTLDUP
ll OK, check distrbuto. cap and rotor It nol OK, replacehighlenson
F psge G-23 c7 p.ge G-23
Checktof corect enginecompression rt'page 8-10 + +
lf OK, replace injeclor lf not OK, checktor cause
c? Page F-96 F psge B-10
AURNS (0.039-0.0,*l
Cean or replace
F page G-19
DETERIOFAIION
F-29
F STEP 6
GUIDE TROUBLESHOOTING
lgnitiontlming: BI
16
t
-tfi" INOICATOF /
7
.- /fEN
GNo
Adtust gniton timing
,
Dtl.r9*
corrcclal idle? ls luelIne oressure c7 Page F-94
""'*Y"'-94u9:-lwlllK;/ -\-,aJ.6V.]Ly.V /
9
17 Page F_52
//
Fuel line pressure: 235-275 kPa 12.4-2.A rg/ctn', 34-40 psi) {vacuum hos€ to pte*3ure regulstor dlsconnected) ., .ih, (\ )
I
ACTION
INSPECTION Sel ector to diagnossconn€ctor ConnectSyslem to 'SELF'IEST"|is coffecl ri at idle aiter walm up? ignitiontimingcorrer .7 page F-62
Checkfuel line ptessurewhileprnch_ + +
ll fuel line pressurequicklyin_ creases,check Pres$re regulalor I fuel line prcssll|esraduallyIn_ creases,check lor cloggingbe tweenfue punrp and pressure regulatot It not clogged,check fuel PUmP I maximum pressure
Page F-91
FUETFIITEF ls thero an bakage ai intake air syslem com
correcl? ls eno - ne cornpression e paEeB-10
Try knowngoodECUanddoescon
Ensinecompression(r !nimum): t,o3o tPa Oo.5 kg/cm'. 149Psi)-300rPm
Checklor cause
F-30
F Page B-lO
F
GUIDE TROUBLESHOOTING WARM.UP ROUGHIDLE./EI{GINE STALLSAT IDLE_ BEFORE excessvely al idledurlngwarm_up OESCRIPI .Enginespeedlow or enginestallsor vibrates Ttolt l 9
HTNTSI frRouBLESHOOT|i,rG ar amount O Lowlntake
O Low fue njectiof control .Fuel njectioncontrolmaifunclion (Coiiectionfor coolanltemperalure) @ Poor alornization .Low BvP (summe0fuel used in cold wealher
.Carbon deposilln injectionbody .Aif cleanerelementc ogged . Thefiowax unil sluck
ACTION
INSPECTION 1
ls "00 ' displayedon SelfDiagnosisChecker wilh igniton switchON? F page F-67
Malfunction Code No. displayed Check tor cause(Felerto specilied check sequence)
r? Page F-70
"68" tleshes CheckECUt€ffninal]F voltage
(7 gage F-114
Voltage:Approx.12v (lgnitionswitchON)
TESTSW:SELFTESI
2
ls there ar leakageo{ intakeair syslemcom-
3
ls air cleanerelemeniclean?
+ lf OK,replace rpageF-ll2 ECU €. It nor OK,checkwkins belween ECUandSef-OagnosisChecker
17 page F-62 Aeplaceair cleanerelement
Are ECU lelm nal voltagesOK? (EspecialylK, 2M, 20, 2T and 20) r. page F-112
5
Checkior cause
F Page F-115 F-117 F-119
Beplacesoenoidvaive
r7 Page F-109
rs a r bypasssoenold valve @ OK? r? page F-!09
a i : SOLENOID
INJECTIONBOOY
varvE(A\\'
r)
o'
,(4) F-31
F
GUIDE TROUBLESHOOTING
ls waterihermosensorresslancecorrec?
Beplacewaterlhemosensor
r- page F-121
Reolaceinieclionbodv
F Page F-84
Adjust€ntion limlng
G Page F-62
lo dlagnosisconneclor ConneclSyslemSeleclor 'SELFTEST when en_ and set Test Swtch lo g i n el s c o d Does enqine speed decr€aseas engrnewarms
to diagnoss connector ConnectSystemSeector "SELF TEST and sel Tesi Swllchto ls rqnlrontrmng corect al tdb aner warm upt ci page F-62 lgnilion tlming: BTDG 16 * 1"
GND INDICATOFI
TESTSW G oaae F-112
Try known good ECU; does conditon improves? Changetue to anoiherbland
F-32
F
TROUBLESHOOTING GUIDE ROUGHIDLE/ENGINE STALLSAT IDLE- AFTERWARII.UP
10
DESCRIP. .Enginerunsnormally al idleduringwam-upbutenginestallsor vibralesexcessively aflerwarm-up TION
HINTSI ITROUaLESHOOTTNG O) rdlespeedcontrorsvslemmallunction @ Air/Fuelmixtureloo lean
@ ArlFuelmi(ure too nch .Fuel injeclon controlmal,unclion (Corectionior coolanltemperature) @ Poorignilion on O Lowenginecompress
.Low fuellinepressure . PCVvatvestuck(open) INSPECT|oiT 1
ACTION
ls 00" displayedon Self-Diagnosis Checker with ignilionswitchON? e page F-67
llalluncfion Code ilo. displ.yed Checklor causeGeler lo so€cilied ch€cksequence)
(? page F-m
"8a" tlashes CheckECUterminalF vollage
c7 page F-114
Volreg€: Approx. r2V (lgnition switch ON) + + 2
3
Are ECU lerminalvoltagesOK? (Especially 1K,2M, 20 and 20) F page F-112
li OK,replaceECU rz page F-112 ll noiOK,checkwiringbolween ECUand SellDiasnosis Checker
Checkior caus€
c7 page F-115 F-117 F-r9
Disconnecthighlensionlead at dle; does englne speed d€creaseequallyal al cylinders? Go to Slep 10 ls ihere air leakageol intakearr systemcom-
5
ls air cleanerelementcl€an?
e page F-62 No
6
lurn thronleadjuslingscrewc, doesidlecondilionimprove?
R€placealr cleanerelement Adjust idle speed
.? page F-62
AIFFLOW SENSORI
-ffiqf l";;I No
=.\\\
Relurnlhrottleadiuslingscrewto its originalpositlon, andgo to nextslep
/
F-33
F
GUIDE TROUBLESHOOTING ACTION
INSPECTION 7
ls fuel line pressurecotrect at idle? c? Page F-94 Frel lih6 pr$sure: 235-275 kPa (2.4-2.A
whilepinch_ Checkfuellinepressure kg/cmz, 34-40 p3l)
+ +
quicklyIn. ll fuellinepressure regulator checkpressure creas€s, g€duallyinll iuellinepressure checktor cloggingbe_ creas€s, tweenluel pumpand pr€ssure lf notclogged,checkiuel pump E7 Page F-91 maximumprsssure
I
to diagnossconnector ConnectSystemSelector "SELFTEST and set TestSwitchto ls ignitionlimingcorrectat idlealt€rwarm_up? (7 gage F-€ 2
Go to nexl step
No
Adjuslignrtionsystem
r' Pag€ F-62
lgnitionllmlng: BIDC 16 + 1' 9
Replacewat€rthermosensor
Disconnectwaterlhermosensorconneclor imprcve? Doesenglnecondition No
TryknowngoodECUandcheckil
correcP comoression 1 0 ls enoine .7 page 8-10 Enginecompression(llhlmum): I,O3OkPa (10.5kgL/cm',149 psl)-3lx)rpm 11
Checkengine
r? Page &-10
Check high'tension lead
.7 page e-23
ls slrong blue spa visibleal each d sconnecled hgh'tensionlead?
c-----,-- \-\
<72oNl #
4
/
+
/ 12
Try knowngood ECUand check
AresparkplugsOK?
s pagoG-19 WEAFANOCAFiBON BUILDUP BUANS
(0.039-o.043
NO
DETEBIOBATION
F-34
lJ OK, check dislrlbulorcap and rotor ll not OK, replacehightensron
F page G-23
F
TROUBLESHOOTING GUIDE 'tl
ROUGIIIDLE/E GI E STALLSAT IDLE - WHEI{ A./C.P/S, EIL OI{ .Enginestallsor vibratesexcessively at idlewhenP/Sor E/LON DESCRIP..AJC, P/S, headlights,blowertan and e{eciriccoolingfan opelale normally Ttol{ .ldle condilionis normalwhen!,/C. P/SandE/Lare OFF
rrRoualEsHooTtitcHtNTsl
O tdle spe€d control svslem malluncljon ;TEP INSPECTION
ACTION
ls 'OO dlsplayed on SeliDiagnosis Checker wilh ignitionswilchON? F page F-€7 SYSTEMSELECII I
ll.ltuncllon Code l{o. displayod Checktor caus€lReferlo soecilied check sequenc€)
rr p.ge F-m
"88" llasha6 1F voltage CheckECUterminal
c? page F-ll4
Vollage: Apprcx. l2V 0gnlrbn switch Ol{) .' + 2
UsingSellDiagnosis Ch€cke.MonitorLampiare switchesOK with ignilionswitchON? F pege F-80
NO
k@tl
e page F-112 li OK,replaceECU ll not OK, checkwiring belween Check€r ECUandSelf-Diagnosis
Lamp nol ON or OFF wllh speclfied swatch Checkior causeFefer lo sDecifed check sequence)
tr7 P.ge F-81 F-82
L.mp alwaF ON Checkwringbeh{eenECUlemina 1D andSellDiagoosis Check€r
3
ls air bypasssolenoidvalveOK?
Adjust dleup enginespeed
s page F-64
. A/C.....Solenoid valve @ rr prge F-109 . E/L.....Solenoid valve@ c7 p.te F109 . P/S.....Solenold v.lve @ r? page F-109
NO
Replace solenoid valve
AtR AYPASSSOL.V.
rf .4
./ (o lF
//-!hV q"l' ,& AIF BYPASSSOL.V, @ l
t
l
'
F-35
F
GUIDE TROUBLESHOOTING
NOUGHIDLE,/ENGIIIESTALLSJUST AFTEBSTATIING DESC-RtP-.Enstr€ stansnormallybut vibratesexcessivelyor slallsj0st atler starting(acceleraliontlom idle) .ldle conditonsar€ normalin olherconditons Trotl Hll{TSl TTBoUBLESHOOTING ml{ure loo lean @ Throltlesensormailur'ction O Air/Fuel l2
.Fuel injeclion controlmalfunction . Lowluellinepressure tNSPECT|OI{ }TE'
ACTION
ls OO"displayedon Self-DiagnossChecker with ionition swilchON? c? page F-67
No
SYSTEM SELECT:1
lr.ltunctlon Code No. d|sPlayed Checklor cause{Referto specilied checks€ouence)
c7 PzEeF-7O
"88" tlash€5 CheckECUierminallF vollage
ca p.go F-114
Volt.ge: Approx.12v (lgnitlon 3witch ON) + + 2
c? PageF-112 It OK,redaceECU ll nol OK,checkwirlngbetween Checker ECUandS€lf-Diagnosis
ls thereair leakageof intak€air systemcom_ No
3
conectal idle? ls tuelIne prescure e page F-94 295-275 kPa 12.4-2.a kg,fcmu,3l-40 psl)
while Checifor fuelIne pressure pinchingtuelfelumhose quicklyin_ ll fuellinepressu.e creases,checkpressureregulaior gradually In+ ll fuellinepressurc creases,ch€ckfor cLoggingbe Meen luel pumpand pressure r€gulator lf not clogged,checkluel PumP .? PageF-91 maxmum p€ssure Hlgh pre33t|re ls fuel line clogged? +
!o dlagnosi ConnectSyslemSeleclor and set TestSwitchto 'SELFTEST" ls ignltiontimingcorreclal idleaiter go F--{t3
4 +
,TEN
f:: GND INOICATOFI
F-36
(
l ]/ TES \tg-aL
+ ll OK, replacepressureregulalor rj' PageF-S4 + lf not OK,rcplace as StsP3 in_ In samecondilion specIon .? pag€ F-63 Check'o' conecl idle speed ldle speed: 750 'l rPtn (tilTx) 1,t00 '1lpm (ATX)
6
ll OK, go io nexl step ll not OK, adjustidle speed
17 page F-63
F
TROUBLESHOOTING GUIDE STEP utsPEcTtoN 5 Are ECU lerminalvoltagesOK? (Especially 18, 2M, 20, and2Q)
ACTION Go lo neil step
Nole When ch€cking voltagss, tap, moye, and wlgglo harmss and connector to recreate
6
Arc sparkplugsOK? WEAFANDCAFBON BUILDUP EUBNS {0_03$-0.043 OETEFIIOFATION
7
ls enginecompression correc? F page E-10 Englnecompression(Minimum): 1,030kPa (10.5kg/cm', 1as psl)-3oo rpm
Try knowngood ECU and check il
NO
Check engine
c7 page B-lO
F-37
F
GUIDE TROUBLESHOOTING HIGHIOLESPEEDAFTENWANM"UP .ldle spe€dexcessivealter warm_up
HI TSI ITROUBLESIIOOTING to engne EicssJveinlaksan supph€d O Throttlevalvenol lully clos€d @ ldle spe€dcodrol mallunction .Thermowax malfuncton .Air bypasssolenoid valveON al idle
. 1,./C,P/Sor E/L sgnai senl lo ECU
ls lhfotle valvetullyclosed whenaccelerator ls lhrottlelinkagecorrcc{y installed + +
Oo€s iast idle cam release throttle levs?
ls "oo" displayedon SellDiagnosrsChecker switchON? with lonition -7 paq'eF-67
lf OK,go to Slep2 ll nol OK,clean,adjustor replace linkage
Adjustidle sp€edby iumins throtlle
!7 page F_63
lltaltunction code tlo. dlspl.yed Checklor cause(Beierto sp€cilied check sequence)
t- Pzge F-7O
"a8" llashe3 CheckECUterminal1Fvoltage
e page F-114
voltaoe - AoDrox.12v 0initlon switch oN) + + 2Q,2R,and Are ECU1P, ]R, 15, 1T,lU, 2[,'1, 2T lerminalvoltagesOK?
(? P.ge F-112 ff OK,feplaceECU lf not OK,checkwiing belween Checker ECU and Selt-Diagnocis
Adjustidla speedby lurningthrot s ' Chechtor cause
F-38
r'. Pagc F-63
_7 pag. F-115 F-117 F-l19
F
TROUBLESHOOTING GUIDE HUNN G IDLEMOVESUP AI{ODOWN/IDLE
t4
DESCRIP. | .Engine spesds up and down periodicallyal idle
TroN
I
HrNrsr 5X?u68j*:SoorNG
@ Throfle sensormisadjusted amounlnconstant @ Fuelinjection @ Poorignition STEP INSPECTION 1 ls rherea r leakaoear intakeair svstem?
2
acrtot{ Repajror replaceleak€gepoinl
ls PCV valve OK? cz page F-99 NO
3
ls arrcl€anerelemenlclean?
4
Disconneclhighlensionlead at idle does en gine speed decreaseequallyal each cylinder?
5
ls '00 displayed on SefDlagnosis Checker wlh ignirionswtchoN? e page F-57
No
Go1ostep9
NO
MaltunctionCodeNo. d|spl.ye.d Checklor cause(Relerto speciied checksequence)
cr PageF-m
"84" flashes CheckECUl€rminallF voltage
17 PageF-114
vohage:Approx.12v (lgnitionswilch ON) TESi SWi SELF TEST
6
to diagnosis ConneclSyslemSeleclor connector and setTeslSwilchto " SELFTEST'
+ +
F page F-112 lt OK,replaceECU ll nol OK,checkwins b€tween Checker ECUandSell-Diagnosis Try knowngoodECU
F-39
F
GUIDE TROUBLESHOOTING
to diagnosisconn€cior ConneclSystemSeteclor "SELFTEST and set TestSwitchto ls rofttontrmrnocotted at Ldleatterwarmup? 7 P.ge F-62 BTDC16 + 1.
tNDtcAToB---l
tming Adjustlgnition
e PageFl2
tor cause CtrecX
e PageF-119
\,,1S\ \|!/ TEsr sw
OK? AreECUleminalvollages 2[/) lEsoeciallv ' e PagoF-lla ls strongblue sparkvisibleat €ach disconnected high'tensionlead?_
:"''-t' ',-t'.--
_1-(_(d Ar€sparkplugsOK?
lead Check high-tension ll OK, check dislribulorcap and
e
fi not OK, replacehigh'tension
!? pageB-10 Checklor correctengineconrpression p 17 page G-19 BUFNS
in) (0.039--o.043
Try known good ECU and check il condition
F-40
+
(Minimum):1,030kPa Compression (t0.5 kg/dn', 1r9 Psi)-300rPm 4 +
lf OK, go to nexi step tJnotOK,checkfor cause
c7 pag€A-10
F
GUIDE TROUBLESHOOTING 15 ENGII{ESTALLS ON OECELERATION DESCATP-.Engineunexpectedly stopsrunningwhle deceleraling or aJterdecelerallon . ldleconditionnor,ral Tro
H|NTSI rrRouBLEsHooTtNG Engine speeddropsloomuchwhenreleasing d sconnected by deceleralion accelerator or poorconneclor connection @ ldlespeedmisadjustment
O Dashpormisadjusted @ Fuelcut controlmallunclion
ACTION
INSPECTION ls rdle conditon normal?
ls dashpoi correclly adjustecl?
Adjustor perlormtroubleshootng Nos.8-11 RoUGHIDLE"
,- pag"
Mallunclion Code No. dlsplayed Checkror cause{Beferto sDecified checksequence)
rj page F-7o
"88" tlashes CheckECUteminal1F vollage
u pageF-111
l-?9
13 p.ge F-104
Dashpol set speed: 2,500 + 1O0 rpm
3
|s "00" dlspLayed on SeliDiagnosis Checker with gnltionswitchON? r:' page F-67 sYsTEM SELECT:1
Voltage:Approx.t2V (bnirion switch oN) + +
lr OK,replaceECU F pageF-112 ll nol OK, checkwring between ECUandSer'Diagnosis Checker
Are air bypass sojenoid valves OK?
SOLENOI
voLut -@-ll
5
6
AreECUterminal voliagesOK? (Especialy 1B,2lV,20and2\4 G pageF-112
Checklor cause
-
page F-115 F-117 F-l19
ls therepoorconnection at eilherol lollowing? . lgnilioncoil . lsniter . Dislribulor . C rcuitopeningrelay . ECU
Try known good ECU Doescondilionimproves?
F-41
F
GUIDE TROUBLESHOOTING
't6
E GDTESTALLSSUDDELY (INTERT|TTENT} slopsrunning 0EscnlP. .EngrneintermitenUy .Belorestallinq, OK ensrnecondition Ttoil G HINTSI TTROUBLESHOOTI O it'frtrnitt""tv "" "p"tl "t no luel Iniectioncausedby vehiclevibration,accelefaijon,or cleceloralion .Poor conn€ctonin wiing harness ACTION tlrsPEcTtoN 3TE ch€cker on Self-Diagnoss ls "m" displayed switchON? wilh ionition r? page F-.67 Maltunction Cod€ No. d|3played NO Checklor caus€(Refefto sp€cified F Pagd F-70 checksequence) Note .When checklngwiainghamcssand conneclol3, tao. mov6, and wiggle guaFcl 3enaorand/or h.r' ndsg to r€cGale Problem "88" ll6ah€3 x7 p.ge F_114 CheckECUterminal1F voltage Voltag€: App.ox. 12V 0gnition swilch ON) 4 +
TESTSW;SEIF TEST
2
c7 P3€eF-112 lf OK,replaceECU li not OK, ch€ckwiringbetween Checklt tCU andSellDrag.osE
ls lhere poor connectionat eilhel of lollowing? . lgnitioncoil . Distribdor . High-tensionlead
3
. Ckcuitopeninsrelay . ECU OK? Are ECUtemina,voltages and2\i) 18, 1G,11,2A,24,2C,2E {Especially .7 pege F-112 Note .when checklng volteg€, lap, move, and wlggle halne3s and conneclor to recneate
F-42
No.2 Go to Troubleshootjng "CBANKSNOBMALLY BUTWILL NOTSTART(NOCOIVBUSTION) ? p.ge F-17 No
Check lor cause
c7 Pag€ F-115 F-117 F-l19
F
TROUBLESHOOTING GUIDE HESITATESFTUIIBLESON ACCELERATION .Flat DESCND. spotoccurslug ater accelerator depressed or mrldjerlingoccursduringac.deraon 17
TION
G Ht]{TSl ITROUBLESHOOTT rean$nen dep.e€srng mxlureoecom€s accelerator O Air/Fuel .Fuel injeclloncontrolmalfunction(Corectionfor acceleratingcondition) .Fuel line pressured€creases .Sparkadvanceconlfolmalfunclion INSPECTION "00" 1 ls display€d on SellDiagnosis Checker wilhignilionsiwilch ON?
ACTION
I.ltuncllon Code l{o, dhplay€d Checklor cause(Refer1osoec'lied checksequerce) "88" fl.3hes CheckECUterminal1Fvoliage
o page F-70 F page F-114
Vollag€: Approx, 12V (lgnitlon sw[ch ON] .> lf OK,rcplaceECU ri pegeF-112 .+ lf not OK,checkwiing between ECIJand Self-Diagnosis Checker 2
ls thereair leakageat iniakeair sygem com-
3
ls arrcleanerelsmentcl€an?
Go to nen siep
tr- p.ge F-62
Replace aircleanerelemenl 4
5
6
Arc ECUt€rminal1K, 2M, 20 and 20 voltages OK? .? p.ge F-l12
Go lo nexl step No
Ch€ckior cause
c7 psge F-1r5 F-117 F-lt9
ls lhrotllelinl€ge coreclly inslalledand does thrcttle valve open frcel',
ls iuellinepressure correctat idle? .? p.ge F-94 Fuelline preasure 235-275 kPa (2.4-2.8 tg/cm', 3'F/1() psD
Cl€anor replaceas requiredany bindingor damagedlinkageandadlust cabl€ dell€ctional inieclionbody e pag€ F-86 decrease Doesltrelllnepressure qulcklf whenacceleruting .+ 4
li decreases,checkluel lineand lilteflor clogging lf no decrease,go to next slep
whle pinchChecktuellinepressure + +
quicklyiG lf luellinepressufe creases,check pres$ire regulator gradually 11luel linepressure in' creases,checklor cloggingbe tlve€niuel pump and pressurc r€gulatot ll not clogged,checktuel pump 17 page F-91 maximurnpressure
F-43
F
GUIDE TROUBLESHOOTING acfloll
t sPEcTto 7
tmingadvancewhen Doesignltion accelerating?
ConnectSysternSeleclorto diagnosisconnector and set T€stSwilchto 'SELF TEST" ls ignitiontimingconect at idle alt€r warm_up? ri' p.ge F--62
+ +
ll advances,go lo ne)dstep ll not advan6, replaceECU
lgnnlontlmlng: BTOC16 + l"
NO
INDICATOR
8
Go to nexl step
installed? Are arrductand air hosescorrectly NO
9
ls exhaustsystemrest cted?
(t p.ge F-1t7 NO
1 0 Try knowngood ECUand ch€ck if conditEn
F-44
R€pair
s pag€ F-112
F
TROUBLESHOOTING GUIDE ta
SUFGESWHILECRUISING
DESCRIP.. UnexpecledchanSein enginespeedwnich is usuallyrepetitive TION HTNTSI TIROUaLESHOOTTNG O Air/Fuelmixtureloo ean @ Misfirc in wiringharness @ Poorconnection STEP tNSPECT|Ot{ ACTION ls '0O displayed Go 10nextslep on SellDiagnos s Checker wth ignitionswltchON? c? page F-€? No Malluncllon Code No. displ.yed Checkfor cause{Belerlo soecilied ch€cks€quenc€) "88" llashes Check ECUielminal 1F voltage
!? page F-70 e p.ge F-114
Vo[age: Approx. l2V (lgnilion sMtch ON) + +
2
ls throttleseosorOK?
lf OK, replaceECU r? page F-112 lf not OK, check wirins benxeen ECU and Self-Diagnosis Checker
Go ro ne( step s
D4ge F-122 NO
3
Disconnectoxyg€nsensorconnector;does con'
Checkoxygensensor
(? eage F-123
Checktor cause
.7 pege F-115 F-117 F-It9
OXYGENSENSORCONNEC] OFt
Are ECUterminalvoltagesOK? t- page F-112
5
ls lh.ottle linkagecofrecly installedand does thronde valve open op€raies lrcely?
Corfecl,clean,or replaceas requircd anybindingor damagedlinkage,and adiuslcalte dellectionat injeclion F page F-{6 body 6
ls thereair leakageoi inlak€arrsystemcom-
7
ls arr cleanerelementclean? o
page F-62
Beplaceair cl€anerelemenl
F-45
F SIEF
a
GUIDE TROUBLESHOOTING INSPECTION to diagnosisconnector Conn€ctSyslemSelector and sel Tesl Swltchto "SELFTEST" ls Lgnll|onmrngcorredat rdleatlerwam up? .j pagc F-42
ACTION Does ignition timing advance \,rten 4 +
lf advances, go lo na)d step tf not advance, replace ECU
rr p.g. F-112
lgnitlonliming: BTDC16 + r'
INDICATOF
9
correctal dle? ls luellinepressure E7 page F44
Doesfuel line pressuledecrease whenaccaleatingquickly? +
zgs-zzi
xpa (z.t-z.a
*g,fcm', 34-iu) p6i) 4
tf decreases,checklor tuel pump !? PagGF-91 maximumpressure li OK, checkfuel lineand lilter for cbggrng li no decrease,go to n€xt slep
ChecktueLlineprsssurcby pinchang qulcklyinll iuel lineprcssure creases,ch€ckpressufaregulalor + lf luel line pressureSraduallyln creases,checkfor cloggingbe lweeniuel pump and pressure rcgu|alol li not clogged,checkluelpump c7 P.go F-91 maximumpressure High prcas0ae Checkit tuel ret'rrnline is clogged
+
4 + 1 0 Checklor poor connectionof lollowingparts . lgnitef . Distribuor . Hishtensionlead . Crrcuitopeningrelay . ECU tl
Try knowngood EcU and ch€ckil
F-46
ll OK, repiacepressurefegulalor e Pag. F-94 ll not OK, replace
F
TROUBLESHOOTING GUIDE LACK OF POWER .Perforrnance poorunderloadwhenthrotllevalvewideopen DESCBIP- . Beducedmaximumspeed Ttot{ .ldle condilionnomal TTROUBLESHOOTING HINTSI mlxtureloo ean O Faclorsotherlhanenqrnem;runcrion @ Air/Fuel .Cturchstipping .Fuel linepressure decreases .ATX stipping . Fuellnjection maltunclion .Brakedragging @ Poorigniton .Low rre prcssure @ Lowenginecompresson .IncorrectI re size @ Alcohobendedtuelused 19
@ Lowintakeair amount .Throttlevalvenol openiully .Cloggedintakeak system STEP INSPECTION l
2
Check laclorsother than engine . c urch slipping l? . ATX slpprng .? . Blake dragging c7 . Low tire pressure F
page H-3 page K-10 page P-5 page O-2
ACTION
NO
ls throltlevalvelully openedwhen acceleralor s acceleralor cab/e correctly insl,alled r' 4 4
3
page F-86
ll oK, check lhroltlevalve ll nol OK, installacceleralorcable r? page F-86 corecty
ls 00 dlsplayed wilh gnitionswitch Mallunclion Code tlo. displayed Check ior cause{Referlo soecified check sequence)
E7 page F-70
"88" llashes Check ECU termnal lF voltage
-
page F-114
Voltag€: Appror. 12V (lgniiion swiich ON) 4 € TESI SW' SELFTEST
SETECTSW: A
ConnectSyslemSelectorlo diagnosrsconnl and set Tesl Switch lo SELF TEST ls gnitiontming corecl at dle afterwarm-!p? - page F_ 62 lgnition laming: BTDC 16 * 1.
t\'k\\o\\\t\\t \\.-\\ \\-*rtriff
\NN -'fi" INOICATOF ::
5
lf OK, replace ECU r:7 page F-112 li no OK, check wiring betw€en ECU and S€fDiagnoss Checker
Check I lgniliontimingadvances 4 a
ll advances,go !o next step li nol advance,check ECU temi nalvoliages
r? page F112
- '"
\ l.
cNo
(
o d
l \S) a(r/ TES
A.e ECUleminalvoltages OK? (Especialy 1K,2M,2K,and25) l? page F-112
Checkior cause
r:, page F-115 F-117 F-l19
F-47
F ;TEP 6
GUIDE TROUBLESHOOTING acTtor,l
INSPECTION intakeair systemcom_ leakage oi ls there air
ls air cleanerelemenlclean?
s page F-62 Beplacear cleanerelemenl
8
Doesiue Ine pressuredecrease when accelefanng quickly
ls luel ine pressurecorect at idle? c7 pag€ F-94
+
psD , zgs-zzi rpa (z.l-z.a rg/cm' 34-40 +
li decrcases,check tuel pump 17 Page F-91 maxlmumpressure ll OK check fuel line and filtefior cloggrng ll not decr€ase, So to ne)d slep
whilepinch Checktuellinepressure + +
ll fuellinepfessurcquicklyrn creases,check pressureregulalor gradually ln' lf luellinepressure checktor cloggingbe creases, iweeniuelpumpandpressure
lf notcLogged, checkluel pump pressure F PageF-91 maximum prcssure Hlgh Checkaftuelreturnlineis clogged + 4 I
Clean
Bemoveair cleaneri s there any carbon depost or drn In njecton bo4,r/' { -l - \ -i r t
No
1 0 Are spa.k plugs OK?
17 page G-19
WEAFANDCAFBONBUILDUP AURNS
(0.039-0.044|in) DETERIOBATION
F-48
regllalor t7 pageF-95 ll oK, replacepressure li not OK,replace
F
TROUBLESHOOTING GUIOE acTtofl
INSPECTION ?l
ls resistance ol igntioncoilOK? c7 page c-20 Resi6tance(et 20.C 168oFl): Primarycoil winding........0.58--"0.a49 Secondarycoil whding.... 9.6-14.4 ko
SECONDAFIY COIL
'12 ls enginecompfesson co(ect? c? page B-10 Engine clmpresslon: 1,030kPa{10.5kg/cm' ,149psl}-300rpm
No
t? page B-'10 Check enginecondition .Worn piston,pislonrlngsor cylinder . Deteclrvecyiinderhead gaskel . Distorted cylinder head .hproper valve seatng .Valve stickinSin guide
1 3 Changeiuel; does conditionimproves?
Changetuel to anotherbrand Try known good ECU and see il driv'
F-49
F
GUIDE TROUBLESHOOTING POORACCELEFATION
20 DESCRIP-| . Pe''omance poor whle acceleratng Tlolil | .ldle condilionnomd
HlllTSl FROUBLESHOOTING olherthanenginemalfrJnction O Factors .Clutchslipping .ATX stippinS . Brakedraggrng .LOWnrc pressufe .lncoffednre sze
@ An/Fuelmixtureloo lean . Fuellinepressure decreas€s . Fuelinjection malfuncl|on @ Poorignilion @ Low ensinecompreseon @Alcoholblendediuelus€d
@ Lowintakeaif amount .Throltlevalvenotopenlully .Clogginsin intakearrsystem INSPECTION 'I checkfactoGotherthanenorne . Clutchslippins e P.ge H-3 . Brakedrassins G page P-5 . Low fte pressurc s Pageo-2 . lncor€ct tirc sze 3 Page O-2 . ATXslipplng -F page K-10 2 Doesthrottlevalvetully open wtrencleprcssng
ACTION
Go to n€)dstep No
Check il accelefator cable ls coreclly ndaled r+ +
3
Checker is '00' displayedon Self-Diagnosis with lgnitionswitchON? !7 Page F-67 SYS'IEMsELEcTi1
F page F-86
lf oK, check throtllevalve li nol OK, install accelerator cable t7 Page F-E6 conecily
Go lo nexl step llallunctlon Code l{o. dlsPlayed Cheoklor cause{Reterto specifed checksequence)
e PageF-70
"88" llash€s Check ECIJterminal1F voltage
t7 page F-114
voltage Appror. 12v (bnirion swilch ON) 4 4 TESTSwi SELFTEST
conn€ctor ConnectSystemSelectorto dlagnosis ' and setTest Swilchto SELFTEST ls ignltonlimlngcorreclal ldlealterwarm_up? !? Page F-62 lgnltionliming: ETDC16 + l'
\\\<\to\\\l\tll \\.-\\ \\.igA'f
\M -"fi"
\
-"-
-Page ll OK, replaceECU ll nol OK, check winnSbelween Checker ECU and Sell-Dlagnosis
F-112
Does ignitiontiming advancewhen + +
It advances, go to nexl st€P ll not advance,check ECU lermi' tr7 Page F-112 nal voltages
-'
INOICATOF--/
5
OK? AreECUlermlnalvoltages tr7 Pago F 112 2M) {Especially
F-50
'Check
Jorcause
t7 Page F-115 F-l17 F-lt9
F
GUIDE TROUBLESHOOTING
6
ITSPECTION is lhere alr leakageal inlakear systemcom-
7
ls thereanycarbondepositor did in injection
STEP
ACTION
Clean
\
8
ls lue linepressure cofiectat dle? c7 page F-94
CheckI' luellinepressure decreases whenaccel€ral ng qulckly +
235-275 kPa 12.4-2.a kg/cmz, 34-40 psi) ..)
ll decrease, checkiuel pump pressure c? page F-91 rnaxmurn ll OK,ch€ckllel lineandiiter lor cloggng go lo nexlstep ll nol decrease,
Checklor luel line pressurewhle pinchlngluel returnhose 4 4
lf luel line prcs$re quickly ncreases, check pressure r€gu alor lf luel line pressrfegradually ncreases,checklor clogging be tweenluel pump and Pressure ll nol clogged,check l'rei pump p.essure ma-ximum
c7 Page F-91
Haghpressure Checkil tuelllnes clogged + 4 I
Ar€ spark plugs OK?
regualor s page F-95 ll OK rcplacepressure ll notOK, replace
-. page c_lg
WEAFAND CAFIBONBUILDUP EUFNS {0.039-O.0,*t OETEFIOFATION
F-51
F
GUIDE TROUBLESHOOTING ACTION
t sPEcflot{ 1(
Change luel !o another brand
Changeluel and check if acc€leralionmproves
Go 10 nexlstep 11
Tfy known good ECU and check il enginecondltionimproves
Chockfor corr€ctenginecomprcssion e PageB-10 Enginecompr$3lon (ulnimum): 1.030kP. (t0.5 kgL/cm',149 p3lF30Orpn
NO
17 Pagea-10 Check€ngnecondition .Wornpiston,pislooringsor cvlinder .Defectivecylinderheadgasket . Di$onedc''linderhead .lmpropetvalveseatmg .valve sticking in guide
F-52
F
TFOUBLESHOOTING GUIDE 21
RUIIS BOUGHON DECELERATION/BAC|(FIRE .Engine DESCfitP. lirns rough w+)iledec€leratingand abnormalcombustionoccurcin exhauslsystem .Transaxlein normaiconditon noN
c HtNTsl rrRoualEsHooTr
O Ar/Fue{mxluretoo rich .Arr cleanerelementclogged .Fuel inieclion (Fuelcutcontrol) cortro malJunclion .Iniectorfuelleakage .Throttle sensormalfunction . Dashpolmalfunciion
t]tsPEcTtol{ 1
ls OO"display€don SellDiagnosas Checker with ignitlonswilch ON? u p'g'e F-6'7
ACTION Go to next step No
llallunctlon Codo No, dasplayed Checklor causeGeter to soeciiied checksequence)
rt page F-70
"88" tla3he€ CheckECUteminal1F voltage
cz page F-114
Volt.ge: Approx. 12V (lgnition swilch Ol{) + 4 IEST SW: SEIF TEST
2
ls there air eal.age at inlake air system com
3
ls air cleanerelementclean?
Go lo nexI step F
page F-62 No
Are ECU terminalvoliagesOK? (Especially 21v1and 20) .:7 page F-112
5
lf OK,replaceECU cz psge F-112 ll nol OK, checkwiringbeiween Chsckar ECUandSelf-Diagnos,s
Aeplaceair cleanerelement
Ch€cklof calse
.7 page F-1t5 F-117 F-119
ls lhere0V al ECU2V leminalabove3,000rpm (Enginesignalmonilorgreenlampilluminates) Try knowngood ECUand checkii
6
ls lhrotle sensorOK? Ei pag6 F-122
Adjusl
(r page F-1ZI
F-53
F
GUIDE TROUBLESHOOTING
ls dashpoicorrectlyadiusted? c7 page F-lo4 Daahpot3et speed: Approx.2,500 + 100 tPm
ls there nleclor luel leakage?
.? page F-96
Fuel leakage: Below I drop/s mln.
Try knowngood ECUand ch€ck ii condition
F-54
Check if lhrottle valve is cornamlnai€d 4
li contaminated, clean throllle
4
ll nol contaminaled, replace throt_
F
TROUBLESHOOTING GUIDE KN(rcKNG
22
DEsilcBlP..Aolormarcombust,on accompalred by audrbleprnsins no|se | H|NTSI TIROUALESHOOTTNG @ Ai/Fue mi(uretoo lean O Incor€ctignilionlimingfloo advanced) .Fuel injectonamountnotcorrect in cylinder @ Carbondeposlts .Fuel linepressure trhileacceleraling decfeases @ overhealing ACTION litsPEcTtoN 1
ConneclSyslemSelectorto diagnosisconnector and set Tesl Swilch to "SELF TEST ' ls ignilion liming correct at idle after wa.rn'up? E? page F-62 lgnilion liming: BTDC 16 + 1'
INDICATOF
2
ls '00" d splayedon Self'Diagnosis Ch€cker with ign'tionswitchON? c:r page F-67
No
llaltunctlon Code ilo. displayed Checklor cause(Belerio specilied checkseqlence)
c7 page F-70
"88" flashes Check ECU termlnal1F vollage
F page F-114
volrage: Approx. 12V (lgnition swirch ON) + +
3
(? page F-112 lf OK, replaceECU ll not OK. check wking between ECU and S€f-DiagnosisChecksr
ls thereair leakageol intakeair systemcom
ls enginecompression correcp e page A-10 Englnecompression(Mlnhum): 1,030kPa (10.5kg/cm' ,t4s psiF30orpm
tligh compr$sion Checkengne condition
c7 page B-10
F-55
F
GUIDE TROUBLESHOOTING ls fuel line presswecorrectal idle? t? PaEeF-94
Doesif fuel lroep€ssure decrease qulck\, whenacceleraling
Fuel line pres3ure: 235-275 kPa 12.4-2-a Wlcm', 3!t-40 psl)
+ 4
checklor clogging ll decrcas€s, b€trveenluel pump and pressure regulator ll not decrease,go to next step
whilepinch_ Checkfuellinepressurc + +
qulcklyn_ It fuellineprcssure creases,checkpres€ureregulalot gradually inll fuellinepressure checklor cloggrngbs creases, tweenluel PumPand Pressure regulator lf notclogged,checkluel PUmP r? PageF_91 maximumpressure
ls coolingsystemOK?
Try knowngood ECIJand checkil conditon
.Themostat . Et€ctic cooling lan .Rad,ator
.7 Page E-8 .7 Page E-1 1 .? page E-7
ReplaceEcU
1:7 PegeF-112
Changetuel lo anotherbrandor use
F-56
F
TROUBLESHOOTING GUIDE 23
FUELODOR
DESCRIP. .Gasolineodorin cabin IION
HTNTSI FROUBLESH(X)T|NG o Poorconnecflono. oamaqedal lue sysler- o- evaporanveemsson cofrol sygem ca,rslerovedowdue lo evaporatve emEsoncont'olsl,slemma unct,on @ Charcoar INSPECTIOT ls tirerefuel leakageor damageof fuel system and evaooatve emissionconirol svstem?
2
|s 00" displayed on SellDiagnosis Checker withignillonswilchON? c? page F-67
ACT|Oir
Go to nexl step
L.lfunction Code No, dbplayed Checklor caus€(Referto soecined checkseqlence)
t7 pag. F-7O
CheckECUterminal1F voltage
6' p.ge F-114
Voltag€: Approx. l2V (lgnltion swnch ON) + + 3
ls vacuumfell at solenoidvalve (purge conlrol) with engine runn,ng and throltle valve open€d? (Neutral switch connector disconnected)
ll OK,replaceECU F p.ge F-112 li nol OK, checkwring between ECUand SsltDiagnosisChecker
Go to Slep 5
No
Ch€cktor solenoid valveoperaling +' lf OK,checkvacuumhoseslor clogsins 4 lf noi OK, go lo next step
Apply12Vand gro0ndt, solenoidvalve (purge
Check ECUieminai voltages
rt p.ge F-112
ls vacuumleltat solenol(
V
5
'r
No
Replacesolenoidvalve
TryknowngoodECUand checkif condition
F-57
F
GUIDE TROUBLESHOOTING
.Exhauslgassmellsabnormally HINTSI TTROUALESIIOOT|NG Highsulferconternfuel used Change fuel to another bland
. Ol consumphon excessve HINTSI ITRoUBLESHOOTING O rcV sy$em mallunction tO workingup workrngdown or leakage) 6 Enqr# malunction Are there PCV hos€, venlilation hose or |hen al_ lach ng nipplesseparated.damaged, clogged, e
P.ge F-99
ls thereair pressufeor oil at venulalionhos€?
Checkfor correciengnecompressionF page B-10 Comor€*ion ( inimum):1,030kPa Oo.5 rgr'cm', 149 l,6il-300 rpm + 4
ls vacuumlelt al PCVvalv€ at 'dle?
F-58
tf OK, go to next step lf not Ok, checklor cause
Crreit engineconoltion .wom pElonnnggroove .Stuckprstonnngs .Wornpistonor cylinder
e page B-10
F seclion a
F
GU'DE TROUBLESHOOTING POORFUELECONOTIY 26 DESCalP- . Fueleconomyunsatislaclory fl0N H|NTSI ITRoUBLESHOOT|NG slopand go driving,extended winler Whileluelconsumption is drastically incfeased by citydriving,shorl-run operalion, warm-upp€riods,etc., as opposedto 'trip" mibage,an atlernplshouldbe madeto det€rmineth€selaclorswh€ncon "poor frontedwith mileage condlrions.However,sincethe operatoris not alwaysat taull, lhe iollowingis oJfercd. @ Air/Fuelrninur€loo rich O Operatordep€sslng acceleratormorethan usualdue to .Hlgh luellinepl€ssure low enginepower .Poor ignltion @ Alcoholblendedluelused .Low intakeai amount @ Highvehicleload .Electronicsoarkadvanceconlrol svslemmalJunclion .Clutchslipping/ATx slipping .Bake dragsing . Exhaust component restricted NSPECTTON ACTION 1 Checkfactorsotherthan engine . Low tire pressufe E7 page O-2 . Unrecommended lire size € pag . ()-2 . Clutchslipping s prge H.-3 NO . Brakedragging s pege P--5 . Exhauslcornponenlrestricreds page F-97 2 Are air hosesconnectedcorrcctly? .7 page F-Eil NO
3
ls '0O"displayed on Self'Diagnosis Checker withignitionswilchON? '' page F-67
Go lo next slep NO
[alfunclion Code No, dbplay€d Ch€cklor cause{Reterto soeclfied checksequence)
G gage F-7o
"88" ll.3he3 CheckECUt€rminal1F voltage
F page F-114
Volage: Appror. t2V {lgnltlonswltch ON) 4 + TESTSW: SELF TEST
,t OK, feplaceECU t7 page F-112 ll not OK, checkwiring between ECUandSelt-Diagnosis Checker
ls lhere air leakageal intakeair sl,stemcom'
5
6
ls ai cleanerelementclean?
r? page F-62
Are ECUleminalvoltages OK? (Especially 2M,2N, 2R and 2T) .7 pageF-112
NO
Beplaceair cleanerelemer'1
No
Checktor cause
-
page F-115 F-l17 F-l19
F-59
F
GUIDE TROUBLESHOOTING acflo1{
It{SPECTTON 7
Go to nexl slep
Connect System Selecto! to diagnosjs connector and ser Test Swnch to SELF TEST ls ionitiontminq co(ect at idle ajt€r wafm_up? .r gage F-t62
NO
INDICATOR I
conect al idl€? ls lu€] line oressurc ' s P.ge F-94 23s-274 kPa 12.4-2.a xg/cm' , 3l-40 p€l)
Hlgh Pressu.€ check if vacuumhoselo pressure rcgulaloris damagedot poorly con+ 4
9
lf OK, replacepressureregulalor F page F-94 ll nol OK, repat or replacehos€
Runengin€at idleand lhenstopengme hold? ts fuellin€pressure c7 Pege F-84 Fuel llnc Drcasure: More than 147 kPa (1.s kgr'cn" 21 p3l)lof 5 min,
No
1 0 ChangeJuelto anotherbrand
F-60
Checkinjectofsfor tu€l leakage
e page F-96
ENGINETUNE-UP
F
ENGINETUNE.UP PNEPARATION
ssT
49 8019 9A0 gniliontiming
BASICINSPECTION EngineOil 1. Be surethe vehicleis on ievelground. and temperature 2. Warmup theengineto normaloperating stop it. 3. Waittor five minutes. condition. andchecktheoilleveland theoildipstick 4. Bemove 5. Add or replaceoil if necessary. Note . The distance betweenthe L and F markson lhe diF sllck represents0,8 lirer (0,85US qt, 0.70 lmp qt). EngineCoolant Coolantlevel (enginecold) Warning . Neverremovethe radiatorcap while the engineis hot. . Wrapa thickclothaloundthecapwhenlemovlngit. 1. Pulloutthesubtankcap. fillerneck. 2. Verifvthatthecoolantlevelis nearthe radiator is be3. Verifythatthecoolantlevelin thecoolantreservoir tweenthe FULLand LOWmarks. 4. Add coolantf necessary.
Batlery to ensuregoodelectri oftheterminals 1.Checkthetightness cal connections. 2. Checkfor corrodedo. frayedbatterycables. 3. Washthetop olthe batterywithwaterto preventarcover' the upperand levelis between 4. Verifythatthe electrolyte if necessary. lowermarks.Add distilledwater
F-61
F
ENGINETUNE.UP 5. Disconnectthe negativebatterycable 6. Ooenthe cap. i. Miasurethe ipecilic gravityof eachcellwitha hydrometer' Specilfcatlon:1.27-1.29 (at 20oCl68oR)
Alr CleanetElement dirt,damage' 1. Checktheair cleanerelementfor excessive and oil. 2. Replacethe air cleanerelementil necessary'
ADJUSTUENT PteDaralion 1.Warmup the englneto normaloperatingtemperalure outwardtu y anonal waxrodhasextended 2. Verilvthatthe trom the roller' the fast idle cam has separated loadsOFF. 3. Turnall electrical . Blowerfan . Headlisht . Rearwindowdefroster 4. Makesurethatthe enginespeeddoesnotchangewnen valve@ connector' theairbypasssolenoid Jiiconnecting Note . liine engine speeadecreasea,the engine is slill un' der the warm-uPconditlon. 5. ll the electriccoollngtan is operatingwat untilit stops 6. Verifythattheenginais runningat idlein goodcondilion connector' 7. con;ecl the SSTto the diagnosis 8. Connecta timinglight. to the diagnosisconnectorlGs c."""ii a tacn6m-eter lermlnal. 10.SetswitchG)to Position1 1'!.Sei TESTSWtOSELF-TEST' Not€ . liitre ssr is not us€d,lump acrosslhe TENt€rminai and ttre GND termlnai ot the diagnosiaconnector.
F-62
ENGINETUNE.UP
F
lgnition Timlng Inspection / Adjustment '1.Perform"Preparation". (Relerto pageF-62.) 2. Veritythatthe idlespeedis withinthe specification. ldle speed: irTX (Neutral) 750 ::E rpm ATX (P range)1,100 :'6 rpm
INDICATOF
3. Checkthe ignitiontimingwitha timinglight. lgnition timing: BTDC16 + l"
fi -)
loosenthe 4. lf the ignitiontimingis notwithinspecification, to makethe distributor lockboltsandturnthe distributor adjustment. torque. lockboltsto the specified 5. Tightenthe distributor Tighleningtorque: l6-23 Nm (1.6-2.3 m-kg,l2-16 ftlb) ldle Speed (Referto pageF-62.) 1. Perform"Preparation". 2. Checkthe idlespeedwitha tachometer. ldle speed;MTx (Neuttal) ?50 158rPm ATX (P range)1,'100:"8 rPm
3. l, notwithinspecification, adjusttheidlebytuningthethrottle adjustingscrew.
F-63
F
ENGINETUNE-UP ldle-up Speed . (tlelerto pageF-62 ) 1 Perfbrm Preparanon with a tachometer' idle speed the 2. Check MTx (Neutral) 750 1fl rym ldle sDeed: ' ATX(P range)1'100:'3 rPm
/t
INS iAL
"o"".-ird"]i
oi'l
fhnlriL€
I
DISTRIBUTOFI
BoD'i
3. Adjuslthe air bypasssolenoidvalve@ by the following orocedure. iiCrouno rn. arl bypasssolenoidvalve@ terminal@ shownin the figure
screw' 2) Adiusttheidle-upspeedbyturningtheadjusting MTX(Neulral)1,080 + 30 rpm ldle speed: ' ATX (P range)1,350 + 30 rPm thejumperwire 3) Disconnect
4. Adjustthe air bypasssolenoidvalve @ by the following orocedure. i) Groundthe checkconnector(black)shownin ihefigure'
'fL
qHECKCON
0
ADJUSTSCREW
screw' theidle-upspeedbyturningtheadjusting 2) AdiL.rst MTX(Neutral)1,030 :53rpm ldle speed: ' l'6 rPm ATX(P range)1,700 wrre lhe lLlmPer 3) Disconnect
F-64
ENGINETUNE.UP
F
5. Adjustthe air bypasssolenoidvalve@ by the following procedure. 1) Djsconnect theconnectorof theair bypasssolenoidvalve 2)Applybatteryvoltageto air bypasssolenoidvalve@ terminal. 3)Adjusttheidle-upspeedbyturningtheadjusting screw. ldle sp6ed: MTX(Neutral) 1,250 + 25 rpm ATX (P range)1,600 + 25.pm 4) Installthe connectorof air bypasssolenoidvalveO.
F-65
F
FUNCTION SELF.DIAGNOSIS
FUNCTION SELF.DIAGNOSIS DESCRIPTION checkforthecauseusingtheSST Failures occurinthemaininputdevicesor outputdevices' Whintroubles theenginecontrolunit(ECU)as malfunclrom and retrieved aie indicated output device oieacttinpuiina tioncode numbers. Note checkslormaF . ihe EGuconstantlycheckstor maltunctionof the inputdevic€s.But'-the-ECU switch is turned perlod the ignltion after dndion ot output?evbes only In a thtee seconds grounded. ls conneclor ON when ihe fEN lerminal ol the diagnosis
ENGINECONTFOL UNIT
OUTPUT
oEvtcEs
SYSTEM SELECTOR
F-66
SELF.DIAGNOSIS CHECKER
FUNCTION SELF-DIAGNOSIS PREPAHATION
ssr
49 HO189A1
43 80199AO diagnosis
SystemSelector
diagno6is
Self-Diagnosis Checker
MALFUNCTION CODENUMBEB InspectlonPrccedurc 1. Connectthe SSTto the diagnosis connector. 2. Set switch@ to position1. 3. SetTESTSWto SELFTEST.
and a ground. 4. Connectthe SSTto the SystemSelector posilion 5. Setthe selectswitchto
7 - )
aZWr ',6^
ir '"!
@@
6
.
lql.
6. Turnthe ignitionswitchON. 7. Verifythat"88" llasheson thedigitaldisplay andthebuzzer soundsfor 3 sec, afterturningthe ignitionswitchON. 8. ll "88" doesnotflash,checkthemainrelay(Feterto page F-124),powersupplycircuit,and diagnosisconnector wrflng. for more 9. lf 88 flashesandlhe buzzersoundscontinuously than20 sec., checkfor a shortcircuilbetweenthe ECU connector. Replacethe ECU terminal1Fandthediagnosis if necessary and performSteps3 and 7 again. 10.Noteanycodenumbers andcheckforthecausesby referring to the check sequencesshownon pages F-70 throughF-78. Repairas necessary. Note . Cancel the code numbeB by performing the afterrepair procedurefollowing repairs. (Referto page F-79.)
F-67
F
FUNCTION SELF-DIAGNOSIS
Prlncipleof Code Cycle as shownbelow codesare determined Malfunction
L Code cycle break code cyclesis 4.0 seconds(lhetimethe buzzeris otD ihe tim6 betweenmalfunction MALFUNCTIONCODE
CYCLEBFEAK
2. Seconddiqit of maltunctioncode (ones position) -'i;;l;il thenumberoi timesthe buzzersounds codeiepresents positn ot tne marrtr.,ncli6n ;i;;;;;i 0.4 secondduringone cycle COOE r cYcL€ MALFUNCTTON
MALFIJNCTION COoE:03
sEc. sEc
3. - Firsl diqit ol maltunctioncode (tens position) the numberof timesthe buzer is on c;de represents in" O,giii" ine lenspositionot th; maffunction one cycle. 1.2 secondsduring The buzzeris off for 1.6 secondsbetweenthe longand shortpulses I CYCLE
MALFUNCTIONCOOE CYCLE
1 2 SEC SEC FIRST DIGIT
F-68
4 o sEc SECOND DIGIT
coDE 22
F
FUNCTION SELF-DIAGNOSIS code Numb€rs Sensor or Ne'sisnal
Maltuncllon dbplay Condition No Ne-signalwhil-a crankrng
Fail'sate
llaltunctlon CodeNo.
Stops iu6l injection
output slgnalpan.m ON
02
Open or short of aif-
ON
08 Openor shod oi 20oc (68oF)
throlilesensorcircuil 33.degreecommand Oxygensensor
llnuesunchanged 2 min.aflerengineexceeds2,000rpm
09
ON
12
Cancelsengine
ON 15
Cancels engine
{purgecontrol)
vaive @
valve @
40 sec. atterengine exceeds1,500lpm Openor short of
;,ilffilrfljlli ON
17 ON
26 ON
valve@circujt
34
valve @ ci/cr.tt
35
Noie . The buzzersounds only tor the ones positionwhen using the DlgltalCodeChecker. To iudge lhe corect maltunctioncode number,reler to lhe digital display. Caulion . lf ihere ls morc than one failure p.esent,the code numberswill be indicatedin numericalorder. lowesl nrmber ttst. . Aller repairinga lailure, perform the afler-repalrprocedure.(Referto page F-79.)
F-69
F
FUNCTION SELF.DIAGNOSIS
Troubleshootlng c6denumberiSShownon the SST,checkfor thecauseby Usinglhe chartrelatedto the lf a malfunction codgnumbershown. COOE o. STEI
O:IID TRIBUTOR I{E.SIGNAL) ACTION
NSPECNON circui0 in distributor ls lherea poorconn€ction
Repairor replacewnng No
2
3
Go to nextgep
ls therecontinud b€tweendistributorterminal wirc (B/LG)and grcund?
Checkfor opencircuit in wirng ifom distributorto ground
ls therebatteryvoltageat disltibutortetminal Ch€cklor opencircutin wiing tromdislibutorto main relay(fUEl INJrelay) Go to nextslep
NO
ls lhere aoorox.5V at ECUtemlnal 2E?{Wilh distributorconnectordisconnected)
neplaceECU 5
Feplacedist butor
ls thereapprox.5V dist bLrtorterminal_wre (G/R)?(At harnesesideconnectorwith discon_ NO
Checklor snortor opencircuitin wringlrcm disldbutor 2E ECUterminal
Circult Diagram O|sTR|aUTOR
DIS]RIBUTOF IGNITION BATTEFIY
swrTcH
TO IGNITION
swtTcH
TO TACHOMEIEFi
TO DIAGNOSIS CONNECTOR IGNITEF
G/B
F-70
F
FUNCTION SELF-DIAGNOSIS 08 (ATRFLOW SE SOR)
CODE t{o. STEP
2
acTtot{
IISPECTTON poof ls ihere in airilowsensorcircuiP connection
Repairor teplacewi ng
ls ECU lerminal20 vollageOK? e page F-118
ls sameCodepresenlatter performing alter'repalfprocedure?
ldle No
3
e p.g€ F-79
+ +
lgnitionswilchON
lf YES,replaceECU lf NO,r€checkairliowsensorand ECUior poorconneclion Go to nextstep
ls lhere batteryvollageat airtlowsensorconnec' tor teminal C with airilows€nsorconnectordis. Checktor shortor opencircuilin wirng trom aiflow sensorconneclortermnalC lo mainrelay. + +
lJOK,checkmainrealy ll notOK,repairor rcplace
ls lhe.e conlinuiiy belween airilow sensor lerrnina B and sround?
R€panor rcplacewiing 5
ls thereconllnutybetweenECUterminal20 and aidlow
ls resislance between arrflow sensor teminals A and B OK? E7 page F-121
+ +
Resistance: 4 + 1 m eo"C t68.Fl) No
lf OK,replac€aidlowsensor lf notOK,repairor replace
Aeplaceairllowsensor
Circult Diagram
FFOM IGNITION
swtTcH
t r rl
l
l rl
1l G/w ll
r
r
clv
l
,i
AIFFLOW SENSOR
F-71
F
FUNCTION SELF-DIAGNOSIS 09 (WATERTHERI'OSENSOR}
CODENO.I STEP 1
2
tNSPECTTOI{ poor conneciionin waler thermosen_ ls therea
ACTION nepairor leplacewrnng
ls therecontinuitybetweenwaler lhermosensor and ECU?
Go lo nexl step
ECU 20 (R/L) G) 2D CYi
A (R/L) B C/iG) 3
ls resistanceof waterlhermosensorcorrecf Coolant lemp. ,200c ( -40D
20.c ( 68'D 80.c 076'R
Fesislance(kO)
No
Beplacewalerthermosensor
14.6 17.A
2.21-2.69 0.29-0.35
ls sameCodeNo.prcsentiollowingafler_repair F Pag€F-67 5
Arc ECUtermlnals2D and 20 voltagescorrcct? c7 page F-l16
andcrcuitOK Waterthemosensor 17 PsgeF_112
n"pru". tCu
Checkfor shotlcircuilin wiringtromwaterthemosensor lo ECU
Circult DiaEram ECU
THROTTIESENSOR
re
@ \lB
)i
IER THERMOSENOR
re
ll
@ WATEBfHEFTMOSENSOF
F-72
F
FUNCTION SELF-DIAGNOSIS CODENo.
r2 fTHRoTTLESEI{SOR)
SIEP
INSPECTION
ACTION
1
ls lhele a poor conneclionin throltlesensor
2
ls there conllnuitybehdeenthrotllesensorand ECU?
B (LGMI
ECU 2K (LG/R) 2M (1G,4/)
D ff/B)
2D (v/G)
A (LG/R)
3
Bepairor replacewiing
ls resislancesbetweenterminalsB (LG/'14and C (Y/B)correc" Adlust or replace throttle sensor
o
page F-12.
ReplaceECU
17 page F-112
Below1 kA Approx. 5 kO ls ECU terminal 2lV vollage cofrccl? .7 page F-116
Checklor shortcicuil in wirnglromthrcttlesensorio ECU
Circuil Diagram
IHFOTTLESENSOF
re
@
ll
Y/B jl
TERTHERMOSENOR
re @
Y/G
THFOTTLESENSON
F-73
F
FUNCTION SELF-DIAGNOSIS
ffiYGEN STEP
2
3
t]{sPECTlOt{ poor connectionn orygen sensor ls therea
ls oxygensensorodpul vollagecotrecr? F PageF-123
ACTION Repairor replacewing
Replaceoxygonsensor
ls therecontinuitybetlveenoxygensensorand EclJ termlnal2N?
ls ECU terminal 2N voltage correcl? F Page F-1lE
5
- tNAcrtvATtot{) sENsoB
ls sensitivityof oxygensensorcorrecp t7 PageF-123
Circuit Diagram
F-7 4
Checkior shodcircuitin wiringlromoxvgensensorto ECU aadro
Fa||
Try knowngoodotygensensorand ch;ck It co;ditionimproves
s
oaoe F-t12
.? ptge F-124
F
FUNCTION SELF-DIAGNOSIS mDE No.
.I7 (FEEOBACKSYSTEi|) ACTtOl{
STEP I SPECTTON ls s3meCodeNo, presentafter pedormingallerE7 eagc F--67
NO
Checkoxygensensorcircuitior poor + .)
Checkmonhorlamp ol Sef-DiaqnosisCheckeril luminateat jdle alter warming.upengineand runningit at 2,500-3,000 rpm lor I minutes?
li OK, p€rfom toLrbleshooling CodeNo.15 lf not OK, repairor replacecon-
s PageF-74
Go 1o nod step ilole . A/F mixtui€ lB rich
Go to Slep5
3
Nole . A./Fmlrtur! b le.n or mi8fire occuiing Go to nextslep
ls tuellinepressurc at idlecorrec0 e prge F-94
Hlgh prossuro ls fuel relurnho€ecloggedor restricted?
Fuel llne Dr€65ure: 235-275 wa (2.1-2.A r.glcnf, 3,F40 p5l) (Vacuum ho3. lo preasurc rcgulrlot dbconncctcr0 ls lhereleak€geot fueljnjectot c? page F-97
+t ll OK. replacepres$re regulalor + lf nol OK, rcpairor replacehose
NO
ls waler lhemossnsor OK? + +
pag€ ru4
c? pege F-121
ll OK, Go lo Step7 ll not OK, replace water lhermc (z page F-121
5
Disconn€ct each high-iension lesd at idle; does enganespeed decrease equally at each cyinde|? NO
Go to St€pI
Clrcult Dlagram
F-75
F
FUNCTION SELF.DIAGNOSIS acTtolr
INSPECTION STEP ls tuel line pressureat idle conecf 6
r7 P.ge F-94
Fuel line Dressure: 235-274 kPa 12.4-2,a kg/cm', 34-40 psD (vacuum hose lo pr€*sune regulalor
No
whil€pinch Checkiuellinepressr.rre a .t
qucklyinI luellinepressurc creases,checkpressureregulator t7 Page F-95 gradually in lf iuellinepressure creases.checkior cloggingbe_ tweeniuel pumpandpressure lf notclogged,checkluelPUmP F Peg€ F-91 maximumpressure
7
ls ihe.e air leal€ge in intake a I system com_
Go ro Step10 8
9
system Repairor replaceignitlon
Wasmisfirelound in Slep 5 oJinspection?
b ;me CodeNo.presertiollowingpedorming atter-rcpairprocedurc? c7 Pege F--67
1 0 Try knowngoodECUIdoes conditionimprcve? o page F-112
F-76
Go to noxl slep NO
F
SELF-DIAGNOSIS FUNCTION
26 (SOLENOID VALVE- PURGECONTROL) STEP INSPECTION ACTtOl{ Disconnectconn€ctorfrom ECIJ CheckECUterminalconneclorlo. poor connecrion ls lherc balteryvoltageat ECUterminal2X wire + lI OK,replaceECU hamess(R/B)wnh ignilionswltchON? - page F-112 + ,l notOK,repairor replacewiring CODENo.
2
Keep condilionStep 1 ls there bafleryvdrage al soleloid valveconnector terminal-wire (A/8)?
3
ls solenoidvalve OK?
(R/B)
Checkfor shod or open circuitin wiing lrom main relay (FUELINJ relay)lo solenoidvalve Beplace solenoid valve
F pago F-101
34 (AIRBYPASSSOLENOID VALVEO) STEP INSPECTION ACTION 1 Disconneclconneclortrorn ECU Ch€ckECUterminalconnectorlor poorconneclion CODEllo.
ls there baneryvotage al ECU leminal 2T wire harness(BM) with lgnitionswtch ON?
.) ll OK, rcplaceECU o page F-112 .> lf notOK,fepairor replacewiins
2
Keep condilionas Step 1 ls there baltery voltage at solenojd valve conneclor lerminalW.e (R/!9?
Repairwiring(R/Vr)
3
ls solenoid valve OK?
Ch€cklor shortor opencircuilin wiringfrommainrelay (FUELINJ relay)to sol€noid valve
F page F-109 NO
Replacesolenod valve
Clrcuit Diagram
VALVE€), SoLENOID FFIOMBATTERY FROMIGNITION SWITCH
VALVE SOLENOIO (PUNGE CONTROL)
SOLENOIDVAIVE
soLENolovAtvE i (PUFGE COMIFOL)ii
F-77
F
FUNCTION SELF-DIAGNOSIS 35 {An AYPASSSOLEI{OIDVALVE@) Dsconneclconnectorfrom ECU ls lhere batleryvoLtageal ECU le|minal2R wrre (F/B)wilh ignilionswilchON?
Ke€ocondilionas StePI ls th;re batteryvoltageat solenoidvalveconnec' tor termina-wie (B/Bf
CheckECUtetminalconneclorlor poor connecron + .t
ll OK,replaceECU lf noi OK,reparror replacewrrrng
PageF-112
Repairwi ng (R/B)
Ct ect tot "lon ot op.n "ircul in wiing fiom malnrelav c? page F-109 Replace soLenod valve
Cllcuit Dlagram
i
AIF BYPASS i VALVEG)i SOLENOID FFOMBATTERY FFOMIGNITION SWITCH
VALVE SOLENOIO CONTFOL) {PURGE
AIFIBYPASS SOLENOID valvE €)
z---F-----rr
ufjl-lJ F-74
FUNCTION SELF-DIAGNOSIS Procedure After-repair '1.Cancelthememoryof mallunctions fromthe ECu by disthe thenegative batterycableanddepressing connecting the brakeoedalfor al least three seconds.Reconnect negativebatterycable.
SST(SystemSeleclor)tothediagnosiscon2. Connectthe nector. 3. Setswitch@ to position1. 4. SetTESTSWto SELF-TEST.
Ff
Checker)to the Sys5. Connectthe SST (Selt-Dlagnosis tem Selectorand a ground. Checkerto posi6. Settheselectswitchof theSelf-Diagnosis tionA. 7. Turnthe ignitionswitchON. 8. Startandwarmup theengine,thenrunitat 2,000tpm tor three minules. 9. Veritythat no code numbersare displayed. "
lEJ.
F-79
F
FUNCTION SELF-DIAGNOSIS
SWITCHiIONITORFUNCTION Checker). switchescan be inspectedby the SST (Selt-Diagnosis Individual Note . itre TEN terminatol the diagnosisconneclormust be groundedand the ignltionswitch oN (enginestopped), . ti e-ntrerof i6e switches remainaclivated,the monilot lamp wlll be illuminated.
ENGINECONTFIOL UNIT NEUTRAL SwlTCH
I
CLUTCHSWTTCH
I
STOPLIGHT SWITCH SWIICH HEADIIGHT
SYSIEM SELECTOB
OEFFOS1EFSWITCH
BLOWEFCONTFOL SwlTCH
INHIBITOB
Self.DiagnoslsChecker(Monitor lamp)
Swilch Clutch switch Neutral swilch Sloplight swilch Headlighlswnch
Lighl Ol{ ([4TX) ([/1X)
Inhibltorswitch
In gear Clulch p€dal released
In gear
lights ON Headlighls/small
ON
Rearwndow defrostersw ch (ATX)
R€mark
Llght OFF
ON ON ON D L, S, or F range
OFF
InspeclionProcedure 1.ionnecllheSST(SystemSelector)to theoiagnosrsconnector. 2 Setsw{ch@ to posttion1. to SELF.TEST, 3 SeITESTSWITCH
F-80
F
FUNCTION SELF.DIAGNOSIS
4. Connectthe SST(Sell-DiagnosisChecker)to the System Selectorand a ground. Checkerto posi5. SettheselectswitchoftheSelf-Diagnosis tion A. 6. Turnthe ignitionswitchON. lampilluminateswhen eachswitchismade 7. Checkif monitor to tunctionas describedbelow. Caution . ll eitherot the switchesremainaclivated.the monitor lamp will be illuminated. . Do not start the engine, Procedure Set conditionsto deactivateeach switch .Ail accessor es OFF .Transmission in neutral Veity lhal monltorlarnpdoesnot illuminate
Checkeach swirchand relaledwting harness .Clurch and Neurralswitch .Felerto pages F 124. 125 .Stoplightswitch :Relerto SeclionT .Headlight swlch Relerto SectionT .Water thefmoswilch Feierto SectionE .Rear delrosler switch :Befer to Section T . Blower swilch Befer lo Section T .lnh brtorswltch :Belerto secfon K
Check each switch as describ€d
Neuiraland Clulch Switches(MTX) Shifltransmissioninto gear ls monilorbmp illurninated wilhclulchpedalreleased?
PC .Neutralor clLrtch switchmallunction {Relerlo pagesF-124, 125) .Openckcuilin relatedwirinSharness . ECUiermlna(1\/)maitunciion (Relerlo pageF-116)
Depress clutch pedal Doesmonitorlamp go out? B€tu.n transmission to neutral
PC . Clulchswitchmalunclion (Relerto page F-124)
Stopllghtswllch Depressbrakepedal ls monitorlampillumlnaled?
Sloplightswilch OK
PC .Sloplight switchmalunction (Beter to Section T) .Open circut in w rlng harnesslrom sloplighl switch to ECU .ECU terminal(1O)maliuncllon (F€ferto pase F 114)
F-81
FUNCTION SELF-DIAGNOSIS Blower switch 'Iun blowerswitchto ON position ls monitorlampilluminated?
PC:.Blowerswitchmalfunclion GeJerto SeclionT) .dpen ctrcurlin ||e wrr'nghanesskom blower swtchlo ECUterm,na(1S) .ECU teminal(1S)maltunciion (Reierto PageF 114)
Headlightswitch Tum ON headllghtswitch ls monrlorlamp illominated?
Headllghlsw(ch oK Tum OFF headlighlswdch
PC:.Headlishtswitchmalfunclion (Reierio SedionT) lromheadlighr .Open crrcuilIn w n19harness swichlo Ecu ieminal(1u) .ECU termrnal (1U)mallunction (Felerto PageF-l16)
Waterthermoswiichcircult (not included in switch insPeclion) Warninq I'iie c'ootinsr"n operateswhenthe diagnoslsconnectortermlnalsTFAtnd GNDare connected with a iumper ttrire' Use caution. ConnectdiagnosisconnectortelminalsTFA and GND V€ritylhat monilorlamp ill'rmlnates
PC. . Felay malfuncton {Beler lo Section E) .Open circlit ln wire harnessfrom watef thermo_ swrlchlo enginecontrolLinrl .Enqrns controlunt lelminal 1R malluncliof
Waterthemoswitchckcuit is OK a jumperwrrc Dlsconnecl
Rea.defrosterswilch Tum ON rear deffoslerswitch ls monitorlampilluminated?
BeardeirosierswitchOK TurnOFF rear deliosterswlch
swichmalfunclion rc: .Fear delroster (Beferto SeclionT) fromfeardefroster .bpen circuitin wldnsharness switchto ECUteminal(1T) .ECU terminal (1T)maliuncton (Reierto pageF-114)
Inhlbitorswitch (ATx) Shitilransmissioninlo gear ls monitorlamplluminated?
lnhilitor swilchOK "P or "N Shlflinto
F-42
range
PC:.hhlbiior switchmalllnct|on iReterto SectionK) .Open ot shol crrcuiln relaledwnng harness (1V)maLfuncton .ECU terminal (Beterlo pageF 116)
F
INTAKEAIR SYSTEM
INTAKEAIR SYSTEM PARTS COMPONENT Removal/ Inspectlon/ Installatlon 1. Removein the ordershownin the figure,referringto RemovalNote. 2. Visuallyinspectthe intakeair systemcomponents and repairor replaceas necessary. 3. Installin the reverseorderol removal 19-25 (1.9-2.5. 1.-r9)
19-25 0,9-2,6, r/r-r9) 7.6-11 nn (40-t10 cn.tg, 6H5In-lb)
REPLACE
11 25 i,9-2.6, 1a-191-
/a :;;s
(3,3-s.3. 27-33)
1.Aircleaner Inspectfor excessive dirt or damage 2. Injectionbody pageF-84 Inspection................................... pageF-85 Disassembly / Assemb1y.............
page F-86 Inspection................................... 4. Intakemanifoldstay
5. Intakemanifold pageF 86 Inspection...................................
RemovalNote Coolant container beforeremovino 1. Drainthecoolantintoa suitable the injectionbody. 2. Retillwilhcoolanlafterinstallation. Cautlon . Belorelooseningthe radialordrainplug verify thai the radiatordraln hose taces stralghl down.
F-83
F
INTAKEAIF SYSTEI' FUELPUMPCOVER
Fuel Pressure Releaae thefuelpressure anyluelhne,release Beloredisconnecting of Injuryor fire. tromthetuelsvstemlo reducethepossibility |. Sladthe en-gine. 2. Removethe rearseatcushton. the fuelpumpconnector' 3. Disconnect 4. Afterthe enoinestalls,turnofi the ignitionswitch rearseat andinstallthe theluelpumpconnector 5. Reconnect cush|on.
PUMPCONNECTOF
BODY INJECTION Inspeclion 1.Checkthe iniectionbodylol wearand deposils withthethrot' 2. Verifythatthethrottlevalvemovessmoothly tle valveleverfromfullyclosedto fullyopen.
Fastldle (On-vehicleInspection) 1.Turnall electricloadsOFF. . Blowerfan . Headlight . Rearwindowdelroster andthatthefastidle 2. Verifythatthe waxrod is contracted cam asin contactwiththe roller.
4-?-2:
3. Connecta tachometer. 4. Starttheengineandverifythattheenginespeedis below 2,500nm. and temperature 5. Warmup theengine1onormaloperating verfy thatthe enginespeeograduallydecreases.
6. AftertheenginewarmsLlp,verifythatthewaxrodextends fromthe roller. fullvand thatthe camsepartes 7. Vdity thatthe idlespeedis withinspecification. ldle speed:MTX (Neutral) 750 :53rpm :1 rpm ATX (P range)1,100 Note . Air bypass solenoid valve @ opens lrom hsll ryanhedup condilion to wamed up condition. . Walertempelaturewhen cam iust separatesis 6l :3"C (142 1!l.R @TX),55 + 8oC (l3l + 46oF) (ATD.
F-A4
F
INTAKEAIR SYSTEM bodyif necessary. 8. Fieplace theinjection Caution . Do not disasasmble ihe iniectionbody. . Do not turn the acrewgshownin lhc ligure.
01E0Faog1
Disassembly/ Aaaembly in the ordershownin the figure. 1. Disassemble 2. Assemblein the reverseorderof disassemblv.
GASKET, FEPLACE 3,4-a.S (35-50, 3O---4:r)
3.4-5.e (35-s0i 30-4t)
;?iil:"ts
7.4-12 t@-12O, 69-1U)
r.2-r.3(12-13, t0-r6)
O8ING,FEPLACE 2.0-2.s (20-30, r7_2G)
rl-22 lln (r.a-2.2 n.l(g,
4. Airflowsensor valve@ 1. Air bypasssotenoid 1 n s p e c t , o n . . . . . . . . . . . . . . . . .page . . . . . .F-121 .......... I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0 . .9. . . regulator 5. Pressure 2. Dashpot l n s p e c t i o n . . . . . . . . . . . . . . - . . .page . . . . . F. . . .94 ...... I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0 . .4. . . R e p | a c e m e n t . . . . . . . . . . . . . .page . . . . . .F. . . 94 ...... 3. Throttlesensor pageF-122 6. Injector 1nspection................................. pageF- 95 (on-vehicle).............. p Inspection A d j u s t m e n t . . . . . . . . . . . . . . . . . . .a.g. .e.F. .-.1. 2 . .2. . . pageF 96 pageF-I22 Bemoval / lnstallation................ Removal / fnstallation................
F-85
F
INTAKEAIR SYSTEM MANIFOLD BAFFLE/INTAKE Inspection 1 Visuallvcheck for cracks or damageand reolaceif
INTAKEMANIFOLD
z. 8i"ff#
if andreplace oftheintakemanffold ai"tonion
necessary-
PEDAL ACCELERATOR Removal/ Inspection / Installation '1.Removein the ordershownin the fagure pedaland retainerfor cracksor damage' checkthe accelerator 2. Visually of removal. reverse order in the 3. Install
9!-r5
{100-150, t7-r3o)
cable 1.Accelerator ... .. pageF-86 / Adjustment.... lnspection 2. Retainer
3 cliP 4 Fletumspring .. 5 Accelerator Pedal
CABLE ACCELER,ATOR InsD€ction/ Adiustment pedalfully Verifythatthe throttle 1. deoressthe accelerator the throttleleverby hand tirrning by valveis fullyopened cable. play ol the accelerator the 2. lnspect Play: 1-3mm (0.04-0.12 In) 3. Loosennuts@ to adjustthe play if necessary.
F-86
F
FUELSYSTEII/I
FUELSYSTEM DESCRIPTION Thissystemsuppliesthe necessary fuelat a constantpressure to the injector. Fuelis meteredandinjectedintotheintakemanifold according to theinjection conkolsignalkom theECU. Thissystemconsistsof the fuel pump,fuelfilters,pressureregulator, and injector.
PRESSUFE FIEGUFATOB
vFUELFILIER(HIGH.PBESSURE SIDE)
SIOE} FUELFILTER(IOW.PRESSUFE
s
@ \
F-87
F
FUELSYSTEM
22-30 (2.2-3.r, 16-22)
PUMPCONNECTOFI
PRECAUTION Fuel PressuleReleaseand ServicingFuel System whenthe underhighpressure Fuelinthefuelsystemremains engineis not running. anyfuelline'releasethetuel presa) 6eforedisconnecting ot Iniury surelromthetuelsystemto reducethepossrbrlity or ire. 1. Startthe engine. 2. Removethe rearseatcushlon the fuelpumpconnedor' 3. Disconnect 4. Afterthe enginestalls,turn otf the ignitionswitch. the rear and install thetuelpumpconnecior 5. Reconnect seatcushion. tromtuelspraywhendisconnecf b) Usea rag as protection ing the hoses. Pluothe hosesatterremoval. fuelpresthefuelsystem,usea suitable c) Wh;n inspecting suregauge. Caution . Instatl hose clamPsto secure lhe fuel pre$sure gaugeto the fuel lllter and the tuel main hoseto prevent luel leakage. SYSTEMOPERATION Fuel PressureHold lnspection Waming . Beloreperformlngthe followlngoperation,release the tueipEssure tlam the tud systemto .educe the posslbilityot inlury or lire. (Relerlo above')
the negativebatterycable 1. Disconnect pressuregauge. a fuel 2. Install 3. Connectthe negativebatterycable-
. /4,-<'-\\. \
\
X.. \ oteelosts\
CONNECTOF
F/Pand GNq terminals connector 4. Connectthe diagnosis jumper wire. witha 5. Turnthe ignitionswitchONlor l0 sec' to operatethefuel oumo. thejumperwire switchOFFanddisconnect 6. iurn ihe ignition alter 5 min.. 7. Observethe fuelpressure Fuel pressure: Morethan l4T kPa (1.5kg/cm',21 psi)
F-88
F
FUELSYSTEM Fuel Line PressureInsoestion
Warning . Belorc performlng the tollowing operatlon, release the fuel p]gs$re lrcm the tuel syslem to leduce the possibllltyot iniury or tire. (Reterto page F-88,) 1. Disconnect the negatNebatterycable. 2. Connecta fuelpressuregauge. 3. Connectthe negativebatterycable. F/PandGNDwith terminals 4. Connectdiagnosis connector a umoerwtre. 5. Trjrnthe ignitionswitchON. 6. Measurethe fuelline pressure. Fuel line pressure: 235-275 kPa (2,4-2.4 kglcm" 34-40 p8l)
F-89
F
FUELSYSTEM
FUELTANK Removal/ Inspection/ Installalion Warning trom the fuel systemto i'-diiJie pertormlnsihe following operalion,releasethe fuel-Pressure reduceihe pGstblllty ot iniury or fire. (Relerlo page F-88J . Wrrentitoilns tlte fuel ia;rk,'k;t spalrrs'cigaiett-cs,and open llames away |tom it' gas. . i'iiiij iepiirin-g the fuet tanti, ctein ir ttrr6ug6ty with steam to lemove all exploslve 1. Removein the orde.shownin the tigure. necessary 2. Visuallyinspectthe fueltank componentsand repairor replace-asNote Installation to 3. lnstall;n th; reverseorderof removal,relerring -
r.r-r.7 {r1-17, 9.5-15)
,."-, , ,*-r ,0,*rr, Q
SEALRUBBEF,FEPLACE
@ . \
43--6r r+m ({.4-4.2 n.kg, 3a--{6 tt lb)
Note . Drainthe tuet lrom the tuel tank before removingthe tank. 1. Rearseatcushlon 2. Fuelpumpcover 3. Fuelpumpconnector 4. Fuelhoses hoses 5. Evaporative 6. Fueltankstraps
F-90
7. Fueltank Inspeclfor cracksand corrosion 8. Checkvalve(twoway) L Fueltankunit 10.Fuelvaporvalve valve 11.Non-return
FUELSYSTEiI
F
lnstallationNote 1. Pushtheendsof themainfuelhose,fuelreturnhose,and ai least25mm hosesontothefueltankfittings evaporative
(r.0in).
hoseontothetueltankpipeandtillerpipe 2. Pushthefuelfiller al least 35mm(1.4 In).
FUELPUMP Inspection ltlaximum pressure Warnlng . Setore performingthe lollowlng operalion, release the tuel prcssu|elrom the fuel system to r€ducethe po$lbllily ol Inlury or lire. (Reterlo page F-{8.} . When inspecting luel system palts, keep sparks, cigarettes,and open tlames awayfrom the fuel, '1.Disconnect the negativebafterycable. gaugeto the luelmainpipeand 2. Connecta fuelpressure plugtheoutletofthefuelpressure gaugeasshown.(lnstall clamosas shown.) 3. Connectthe negativebatterycable. F/PandGNDwith 4. Connectdiagnosis connector terminals a lumperwre. 5. Turnthe ignitionswitchONtor l0 sec. to operatetheluel pumpand measurethe fuel pressure. Fuel pressure: 491-658 kPa (5.0-6.5 kg/cm', 7l.l-92.4 FUELPUMPCOVER REANSEATCIJSHION
p6i)
tttejumperwire. switchOFFanddisconnect 6. Turnhe ignition replacethe fuelpump. 7. lf not as specified, Conlinully 1. Removethe rearsealcushion. 2. Disconnect thefueloumDconnector.
22--.3012.2-3, 1, 1G-2' Nfl (Gks, n.D) |
CONNECTOB
3. Checklor continuity betweenthe terminals@ and @ of the connector at the fuelpumpshownin the figure. 4. lf thereis no continuity, replacethe fuelpump. (Referto page F-92.)
F-91
F
FUELSYSTEM Fuel pump oPerationsound 1.Turnthe ignrtionswtch ON connectortermtnalF/P to GND 2. connectdlaonosis operg Remove capandveritythatthefuelpump their.relfilter ationsoundis heard.
-.:-n @Y...
& s:'5 4;/
GNO
Replacement Warning -riltreri lrom ireplacins ttte tuel sysiem parts, keep sParks, cigarettes' and open flames away the tuel. . ieioie oerfotmfnsthe tollowlng operalion,releasethe tuel pressurefrom the fuel systemto reduceihe possibilityol iniury or tire. (Referto page F-Ear' 1. Removein the ordershownin the tigure. 2. lnstallin the reverseorderof removal.
r.r-r.7 (1r-17,s.s-rs)
*k/
FUE! HOSE,
{30-rro, 69---eq a
WASHEF,BEPIACE
2.7-4.1 123-42, 2a---36t
1. RearseatcushDn 2. Fuelpumpcover 3. Fuelpumpgaugeunltconneqor 4. Checkvalve 5. Fuelhoses 6. Fuelpumpgaugeunit
F-92
7. Fuelpumpconnector 8. Bracket 9. Rubbermounl 10.Fuellilter '11.FLrel pump
F
FUELSYSTEM FUELFILTER Replacement Low-pressure side Referto pageF-92.
.F\ 7,a-lr {a0-r1o, 6r-95)
Hlgh-plessureside the fuelfiltermustbe replacedattheintervals outlinedinthe maintenance schedLrle. Warnlng . Belore pertorming the tollowing operation, release the tuel pressurefrom the luel systemto rduce the posslbilityot iniury or fire. (Referto page F-88.) . When replacing the tuel filter, keep sparks, cigarettesand open tlamesawayflom it. '1.Disconnect the fuelhosesfromthe tuelfilter. 2. Removethe fuelfilterand bracket. 3. Installin the reverseorderof removal. CIRCUITOPENINGRELAY Replacement '|. Disaonnect the negativebatteryterminal. 2. Removethe ECU.(Referto pageF-112.) 3. Removethe relaybrackel 4. Removethe circuitopeningrelaylromthe relaybracket.
CIRCUITOPENNINGFELAY
Inapectionot Continuity 1. Checkcontinuity between terinals@ and@ in thefollow ing condition.
f--_-1
r*{ry Gl'. L.ora\€) I
(b_oorqA T , _-ir
Te.minals
Aoolv 12V
@ * @
NO
@ " @
No
Continultv {aA- G))
2. Replacethe relay if not as specified.
F-93
F
FUELSYSTEM REGULATOF PRESSURE Irsp€ction Fuel llne pressure WarninE . BebA oerforminqthe lollowingoperatlon,releaae the fuel'presaurellom the fuel system to lsduce the possibllity ot Iniury or tlre. (Reter lo page F-88.) . When inipecting the pressure regulator' keep sparks,ciiaretl$, and open llames awayfrom it'
FIEGULATOFI PRESSUFIE
vAcuuM HosE ^
\
NJECTTON BOOY
1. Disconneqthe negatNebatterycable gauge. 2. Connecta fuelPressure cable. battery the negative 3. Connect 4. Startthe engineand run it at idle 5. Measurethe luel linePressure. Fuel line Pressure: 235-2i5 kPa (2.4-2.a kglcm'' 34-40 psi) Noie . The tuel line pressurcwlll mt change when removIng the vacuum hose lrom the Plessule regulator at ldle. nepbcement Warning . Betoie oedormlng the following operatlon, lelease the fueipressure from the luel system lo lsduce ihe possibllityof iniury or tire. (Reler to page F-88.) . iivhen replaclng tuel system componenta' keep sparks,cigareties,and openflamesawayfrom the lusl.
3.a--{.a {35-50, 3O--a3)
Cautlon . Aller removlngthe air cleaner,coverlhe lntakeah pagsag€ with a ctean rag to Protect the alrtlow 3enaor. 1. Removethe air cleaner. the negativebatterycable 2. Disconnect as shownin the figure 3. Removethe pressureregulator 4. lnstallin the reverseorderol removal
OAING,FEPIACE
INJECTOR Inspection (On-vehlcle) 1. Removethe air cleanercover. Caulion . Performthe tollowing insPectioncarelullyto Protect the alrflow sensorttom damage. 2. Startthe enoineand run it at idle. sounds 3. Usingasoundscope,verifythatinjectoroperaling are nearo.
F-94
FUELSYSTEM Removal/ lnstallation Warning . Betoreperformingthe following operalion,relgasethe luel pressurelrom the tuel system ot reduqethe possibilityof injury or tire, (Reterto page F-88.) . Whenremovingthe fuel syslem parts, keep sparks,cigarettes,and open tlamesaway trom the tuel. 1.Loosenthe radiatordrainplug and drainthe coolant. 2. Removein the ordershownin the figure,referringto RemovalNote. (Refer10pageF-95-) 3. Installin the reverseorderot removal,referring to InstallationNote. (Referto pageF-96.) 7,3-11 (30-110,69-9s)
GASKET,SEPLAC€
CIFINGS,FIEPLACE
CUSHION RUBBEF,
ad
rQ-25O,e-2.6,r.-t9)
-e
re-25 0.e-2.6,r.-19)
GASKETS. REPLACE
1.Air cleaner 2. Waterhose 3. Fuelhose 4. Air bypasshose
5. Injecuon body 6. lnjectorcover 7. lnjector Removd Note . Whenreplacing the injector,pushthe injectornozzleout wjtha plasticor woodstick.
F-95
F
FUELSYSTEM
REPLACE HION
lnslgllationNote . UsenewGrings,cushionrubber,and gaskets greaseto lhe O'ringsbe . Applya smallahountof silicone lore installation. . Installtheiniectorsquarelyintoinjectionbodyanddo not twistit whileinstalling. F/P and connector, . Afterinstallation, thediagnosis connect for fuel leak' check wire, and witha iumper GNDterminals page (Refer F-96.) to ON. age withthe ignitionswitch
Inspection Warning . whe; inspecting the iniector, keep sparks, cigarettes,and open tlames awaytrom the tuelIniectorresistance the iniectorconnector. 1. Disconnect ol the iniectorwithan ohmmeter. 2. Measureresistance Resistance:1-20 (20'C l68oFl) Fuel ldakagetest Caution . Perlormthe followlng inspectioncarefullyto pro' iect the air bypasspassageof the airflow sensol lrom the enllance of dust or dirt. 1. Removeihe air cleaneras shownin the fagure.
F/P andGND terminals connector 2. Connectthediagnosis wire. witha ilmper 3. TurntheignitionswitchON andcheckfor tuelleakslrom the injector. Fuel leakage:Lesslhan I drop/s minutes
F-96 t
F
EXHAUSTSYSTEM
EXHAUSTSYSTEM COMPONENT PARTS Inepection(On-vehicle) Startthe engineand verifythatthereis no exhaustgasleakagefromthe exhaustsystemcomponents. Removal/ lnspection/ Installation 1. Removein the ordershownin the figure. 2. Vlsuallyinspectthe exhaustsystemcomponents and repairor replaceas necessary. 3. Installin the reverseorderof removal. 7.3-rt xn {3o-rt0 cn*g!
GASKET,FEPLACE
GASKET. FEPLACE
re-23 fi,9-2.3, r{-r4
GASKET, FIEPIACE
;:;::: ",_.-1 :"
7.3-11 N.n (8c-rro cn{q,
SPFING,
"'_",.'"_""1".".:€ E 40-55 (4.r-5,6,30-41)
rL3
0.9-23, rr_14
crRrNG,
{o-55 (.r.1_5.6,3O__-4r)
a1aoFx47a
1-lnsulator 2 .F r o npt i p e lnspectfor deterioration and cracks 3. Exhaustmanifold Inspectior cracks pipe 4 .M i d d l e lnspect for deterioration andcracks
5. Calalytic converter l n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a . .g. .e.F. . 1 . .0. .3. . . 6. N.4aln silencer lnspectfor delerioration and cracks 7. Oxygensensor Inspection.................p . .a. .g. .eF . .-. 1 . .2. .3. . . pageF 124 Replacement............................. B.lnsulalor
F-97
F
OUTLINEOF EMISSIONCONTROLSYSTEM
OUTLINEOF EMISSIONCONTROLSYSTEM VIEW STRUCTURAL Thelollowingsystemsare employedto reduceCO, HC, and NOxemissions. (PCV)syslem crankcaseventilation 1. Positive emissioncontrolsystem 2, Evaporative conve(er 3. Catalytic
W
VALVE SOLENOID (PURGECONTFOI)
AR -til CANISTEF
GHECK VALVE (TWO_WA
F-98
(PCV)SYSTEM VENTILATION POStrtvEGRANKCASE
F
posrilvE GRANKCASE (PCU SYSTEM VENTILATION DESCNIPTION The PCVvalveis operatedby the intakemanifoldvacuum. Whenthe engineis runningat idle,the PCVvalveis openedslightlyand a smallamountof blowbygas is drawnintothe intakemanifoldto be burned. largeramountot blowAstheenginespeed risesthePCVvalveis openedfurther,allowinga proportionately gas manifold. to be drawn into the intake by
PCV VALVE Inspectlon lemperature and 1.Warmup theengineto normaloperatlng run it at idle. hosefromthe 2. Disconnect thePCVvalveandtheventilation head cover. cylinder 3. Blockthe PCVvalveopening. 4. Verifythatvacuumis telt.
5. Removethe PCVvalve. 6. Blowthroughthe valvefrom port @ andverifythatairflows lromot gort 6). 7. Blowthrbughl-he valveflom port@ andveritythatno airport flows kom of @. 8. Reolacethe PCVvalveif not as specified.
F-99
F
E]IIISSIONCONTROLSYSTEi' EVAPORATIVE
EVAPORATIVEEM]SSIONCONTROLSYSTEM DESCRIPTION (ATX) SWITCH INHIBITOH
THFoTTLESENSoF
)\M \lh-
s!q.t
OXYGENSENSOB
WATEF TH€RMOSE
q_l
rnrrori sersoa
CANISTEF
@
CHECKVALVE
FIJELVAPOFIVALVE
the emissioncontrolsystemconsistsof the fuelvaporvalve'the-ch€ckvalve(two'way)' Theevaporative input devices' (ECU)' the and unit the enginecontrol the solenoidvalva(purgecontrol), chircoaicanister, valveThe by purgecontrolsolenoid lumesdrawnintotheengineandburnedis controlled Theevaporative valve solenoid controlsthe devices and input ibU a.G"is fne enqine'soperatingconiitionsby thevarious values. signalsaccordingto these operationby electrical Operation by signalsfromthe ECUto periormpurgingof thecharcoal ilie solenoidvalvelpurgecontrol)is controlled are met: canister.Purgingis donewhentheseconditions (1) Afterwarm-up (2) Drivingin gear (3) Acceleratorpedal depressed normally (4) Oxygensensorfunctioning
F-l00
EMISSIONCONTROLSYSTEM EVAPORATIVE SYSTE" OPEFATION temperature and 1 Wam up theengineto normaloperating run I at idle. the vacuumhoselromthe solenoidvalveas 2. Disconnecl showninthefigure,andverifythatno vacuumis teltatthe solenoidvalve. checkthe solenoidvalve 3. lf not as specified,
SoLENO|DVALVE(PURGECONTBOL) Inspection 1. Drsconnect lhe vacuumhoseskom lhe solenoidvalve 2. Veritythatno air flowsthroughthe valvefrom port @ to pon @.
the solenoidvalveconectorand apply12V. 3. Disconnect 4. Verifythatairflowsthroughthevalvefrompgrt @ t9 pgt! ol the solenoid the resistance CD.li no air is felt,measure valve. Reslstance:32 + 20 replacethe solenoldvaNe5. lf not as specified,
'-?j-r1
(30-110,6e-9q
Removal/ Inslallation '1.Disconnectthe valve thesolenoid hosesirom evaporative the solenoidvalveconnector. 2. Disconnect nut andthe solenoidvalve. 3. RemoveJhe 4. lnstallin the reverseorderof removal. Tlohteninotorque: ?.4-t r-Nfl 480-1 lO cm-kg, 69-95 in-lb)
FUELVAPOBVALVE Inspectlon thevalvefromport@ asshown 1. Verifuthatairilowsthrough in thefioure.
F-10t
F
EVAPORATIVEEMISSIONCONTROLSYSTEM 2. Verifythat no airflowsthroughthe valvelromport @ as shownin the fgure. 3. Replacethe fuelvaporvalveif necessary.
CHECKVALVE GWO-WAY) Inspecilon 1. Removethe valve. of the valvewitha vacuumpump. 2. Checkthe operation Blow f,lroughvalvelrcm Pon @ Applyapprox.37 mmHg(1.46inHg) vacuumat port @ Applyapprox.44 mmHg(1.73inHg) vacuumat port @
3. Replacethe checkvalveif not as specified. CHARCOALCANISTER Inspectlon 1. Visuallycheckfor damageand cracks 2. Blowair intoeachportandverifythattheyarenotclogged. the charcoalcanisterif not as specified 3. ReDlace
F-l02
CATALYTICCONVERTER SYSTEM
F
CATALYTICCONVERTERSYSTEM DESCNIPTION ThecatalyticconverterreducesCO,HC,and NOxby chemicalreaction. Theconverter containsplatinum and rhodiumcompounds.
01E0F2.1{s
CATALYTICCONVERTER Inspection Ngte . The insulatorcannoi be removed. checkfor deteriRemove thecatal!4ic converter andvisually orationand cracks.
F-l03
F
CONTROLSYSTEM DECELERATION
CONTROLSYSTEM DECELERATION DESCRIPTION Thedashpotis usedto preventthe throttlevalvetromsuddenlyclosing
osuoFx rss
DASHPOT lnsgeclion 1. Openthethrottlevalvefully.Pushthedashpol.od witha fingerand veritythatit goesintothe dashpotslowly 2. Release the rod and verifythatit comesout quickly. 3. Replacethe dashpotif notas specified
4. Warmup the engineand run it at idle 5. Connecta tachometelto the diagnosisconnectorlGterminaland increaseenginespeed.
DIAGNOSIS CONNECTOB
theenginespeedandverifythatthelever 6. Slowlydecrease touchesthe dashpotrod at the specifiedspeed. Specification:2,500 + 100 rPm loosenthe locknutandturnthe adjust7. lf notasspecified, ing screwto adjust.
F-l04
F
A./CCUT.OFFSYSTEM
A/C CUT.OFFSYSTEM DEsihrPrtoN
performance, To improveidlesmoothness afterjuststarting theengineandto improveacceleration an AJC is used to control A,/C operation. cut-offsvstem
THFOTTLESENSOR
DETEFMINATION
u'o"""o*'1=:9J-1
MAGNEITC CLUTCH
IGNITIONSWITCH
fr" .*,r""
I
Operation TheA,/Cis cut off underthe conditionsbelow. Cui-otl pcriod
E glne condlllon
Thrcttlevalvefully open Accelerationfrom stop
:. ;.!9-
rHRorrLEL'NK
lmpfoveddravabilily
SYSTEiIOPERATION andA,/CswitchON. 1. Turntheignitionswitch,blowerswitch, stops 2. Openthethrottlevalveandveritythattheadditionalfan for approximately 1 second.
F-l05
DECHOKECONTBOLSYSTEM
DECHOKECONTROLSYSTEM OESCRIPTION iJtacifitatestartinqtne engineit thesparkplugsbecomefouled,suchas whenthe engineis flooded,fuel tempera rscut it th; thronlevalveis heldwideopenwhi'ecrankingtheengineif theenginecoolant injection frorn the cylinders purges plugs fuel and excess to dry the spark This allows uelow. tu'rJisO"Ctiz"n or
CFANKANGIESENSOE
INJECTOF DEIEFMI. NATION
cur THFIOTTLE SENSOF
WATEFT THEFMOSENSOR
SYSTEMOPERATION is below ooc (32oF) 1.Ve4futhatthe enqrnecoolanttemperaiure at normalspeedwiththe throttlevalvefullyopen. when cranked will not slart that the enaine 2. Verii 3. lf theenginestarta,inspectthethrottlesensor.(Reierto pageF-122) andthe ECUterminal1Uvoltage. (Relerto pageF-116.)
F-l06
F
AIR BYPASSCONTROLSYSTEM
AIR BYPASSCONTROLSYSTEM DESCFIPTION Theair bypasssystemoperatesto improveidlestabilityand vehicledrivability. Thissystemsupplies throttlevalvebypassair intointakemaniloldaccordingto engineloadcondition and drivingconditions. Thissystemconsistsot two solenoidvalvescontrolledby the ECU.
AA AYPASSSOLENOIOVALVE@ AIF BYPASSSOLENOIDVALVE@
ArF BYPASSSOLENOTO VALVE@
THAOTTLEVALVE
Operationot Ai. BypassSolenoidValve Air bypa$ aolenold wlve
Englno condltlon Duing cranking lgnitionswilch OFFrON
'Acc€ssoryON P/Spressuresw{ch ON
@ To improve$anability To prcvenllrorn slickng
Dunng d€celelation {d€celelation conlrol)
@
o
o To improvesrartability
,dJCswilch ON
Wam up (asoc-8ooc) SeleclleverN-D (ATX)
o
To alleviats sudden engine speed drop To improvedivabilty
'Accessoryis headlights,rear windowdefrosler,blowerswilchand coolingJan.
o o o
o o
o
o
o o
F-107
AIR BYPASSCONTBOLSYSTEM SYSTEMOPERATION 1. Warmup the engineto normaloperatingtemperalure 2. Veritythatthethermowaxunitrode)dendsoutwardtullyand fromthe roller. thatthe cam separates waituntilit stops. 3. lf lhe electriccoolinglan is operating, 4. Verifythatthe engineis idlingsmoothl,
FASTIDLECAM
valve 5. Verifuthatclickis heardfromtheail bypasssolenoid and OFF ON following electficalload the when turning @
soLENoto vALvEO \
/ry
load Electrical . Blowerfan . Headlight . Rearwindowdetroster
6. Veritythat clickis fromthe air bypasssolenoidvalve@ whenthe enoinestans.
7. Turntheignitionswitch,blowerswitch,andAJCswitchON. 8. Rotatethe throttlelink by hand.
valve is heardfromtheairbypasssolenoid L Verirythatclick @.
F-108
AIR BYPASSCONTROLSYSTEM AIF SYPASSSOLENOID AIF BYPASSSOLENOID
F
AIB aYPASSSOLENOTD VALVE@, @, @ Inspeclionlor contlnuhy 1. Disconnect eachair bypasssolenoidvalveconnector. 2. Inspectfor continuity between the solenoidvalveconnector terminals. 3. Replace the air bypasssolenoidvalveif not as speciiied.
AIR BYPASSSOLENOID VALVE@
Inspectiontor Airllow 1. Inspectair bypasssolenoidvalve@. 1)Removethe air cleaner. 2) Closethe bypassair passagewithtape. \
r-i
',:,,%rc,!
3) Disconnect the bypassair hoselromtheair bypasssole noidvalve@ as shownin the figure. 4) Verifythat noairflowsthrough airbypasssolenoid valve when blowing air lighty into the air bypasshose. @
sotENotoVALVE @
DISTFIBUTOR
d r-:\*
trtlW \__-,/' PATTEFY
5)Turnthe ignitionswitchON. 6) Groundthe termlnal@ as shownin the flgure. valve@ 4 Verifythatairflowsthroughairbypasssolenoid whenblowingair intothe air bypasshose.
2. Inspectair bypasssolenoidvaive@, O
1) Bemoveair bypasssolenoid vdve @ or @.
2) Blowthroughthevalveffom port@ and verifythatno air comesout of port @. 3) Apply12Vto the solenoidvalveconnector. 4) Blowthroughthevalvefromport@ and verifythatair comesout oi port@. Adiustment(idle-upspeed) Relerto pageF-64.
F-l09
F
CONTROLSYSTEM
CONTROLSYSTETI' PREPARATION
ssT
49 GO18903
49 9200162 EngineSignal
49 D015001
49 GO18904 Sheet
ECU
49 80199AO Syslem Seiector
F-l10
ECU
ECU
ignitiontiming
CONTROLSYSTEM
F
VIEW STRUCTURAL
6. Oxygensensor 1 .E C U I n s p e c n o n . . . . . . . . . . . . . . . . . .page . . . . . .F. . 123 ....... R e p l a c e m e n t . . . . . . . . . . . - . .p. .a. .g. e. . . . . . . . . . page p a g e R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . .F. . 124 ....... Inspection............................-.... 7. lvlainrelay 2. Crankanglesensor R e p l a c e m e n t . . . . . . . . . . . . . -page ..-..F . . .124 ....... I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g . .e.F-120 ........I n s p e c i r o n . . . . . . . . . - . . . . , , . page . , . . . ,F-124 ,,,-...... 3. Airflowsensor 8. Clutchswitch(MTX) I n s p e c l i o n .. . . . . . . . . . . . p a g e page . . . . . .F-124 ...... I n s p e c t i-o. .n. . . . . . . . . . . . . . - . . . page Removal / Installation................ R e p | a c e m e n t . . . . . . . . . . . . . .page . . . . . .F-124 .......-. 4. Waterthermosensor R e m o v a | . . . . . . . . . . . . . . . . . . . . p. .a. .g. e . . . . . . . . . . . 9. Neutralswitch(MTX) I n s p e c n o n . . . . . . . . . . . . . . . . . .page . . . . . .F-125 ......... I n s p e c t i o n . . . . . . . . . ... . ..-.... . .p a g e page R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . .F-125 ......... 5. Throttlesensor 10.P/Spressureswitch / Adjustme.t. ....... page InspecLion I n s p e c n o n . . . . . . . . . . . . . . . . . .page . . . - . F-l25 ..........
F-111
F
CONTROLSYSTEM
ENGINECONTROLUNIT(ECU) Reolacement '1.Removein the ordershownin the tigure. 2. Installin the reverseorderof removal
(
7.3-rr (60-rr0,69-es)
3. ECUconnector 1. Negativebatterycable 2. ECU I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. .a. .g.e.F. .-.1.1. .2. . . Inspection the ECUconnectors. 1. Disconnect SSTS(EngineSignalMonitorand AdaPter 2. Connectthe Harness)to the ECUas shown.
a1EAF2210
F-112
CONTROLSYSTEM
6 ' d
ffi
3. Placethe SST (Sheet)on the EngineSlgnalMonitor. 4. Measurethe voftageat eachterminal. (Refer to pagesF 114to F-119.) 5. lf anyECUtermjnal voltageis incorfect, checktherelated inpuior outputdevicesandwiring.lf no problemisiound, replacethe ECU.(Referto above.)
o . Caulion . Neverapply voltageto SSTterminalsA and g. 6
-d'
ffi
F-l13
F
CONTROLSYSTEM
Terminalvoltage (reterencedata) f6r|rrlntl Input Ouipul Connecilonto Batlery ]B
1c
o
iFUELINJ reay)
o
lgnltionswich (STABI)
o
1D
Self-Diagnosis Checker (Monilorlamp)
Te€tcondillon Constani lgniljonswitch
SellD agnosis Checker (Cod€Number)
ON
vohage Batlery
gnitionswitchON
WithSelt Tesrswitchal "SELF-TEST" Diagnosis Checklor 3 sec aflerignilion Lampilluminated switchOFF*ON Baneryvollage Seleclor atter3 sec. Lampnotilluminaled
Buzzersoundedlor 3 sec.aflergnitDn swltchOFF*ON Buzer notsoundedatter3 sec.
Batleryvo[age
Below2.5v Banerylotage Below2.5V Batieryvoltage
o
lgniter (ind strlbutoo
lgn,ronswtch ON Apprcx.0.5V
ldle
1H
o
C rc'ritopenlng lgnitionswilch
o
]J
IJC relay
o
(TENtermnal)
ON STABT ON idle)
lgnitionswilch ON ldle
Dlagnosis
A/C ON
Sysiem Selector lest swilch at "02 MONITOR" System Se ector iest swltch al ,,SELF.TEST''
Bateryvolage Below 1.0V Batieryvollage Below2.5V
Bateryvoltage Balteryvoltage
Belowl.0v
]L
l lvl
o
lgnlion swilch ON
1N
10
o o
Stopllghtswilch
Brakepedal r€eased Brake pedal depressed lgnilon switchoN
P/SoN ar idle P/S OFF at dle
F-l 14
Rsmatt
OFF
"O2 MONITOF aI idle Tesrswilch at illuminated Monltorlamp Test switchat "O2 MONITOF aI idle Montor lamp nol iluminaled
o
Canpctvolrge Bateryvollage
Bslow1.0V Bateryvolage Batteryvotage
Below1.0V Bateryvo[age
Diagnosis SystemS€leclor
F
CONTBOLSYSTEM
Inco]r€ct Yolt.ge
ROOtvl10,Allse burned Op€nc rcuiiin wi ng kom ROO|0A fuseto ECUleminal14 Main relay mallunclion(Rel6rto page F-124) Op€n or shortcircuitin wiringlrorn main relaylo ECU terminal18
Always0V ($anerturns)
Always battery voltage
2.5V
No displayon SelfoiagnosisChecker ''SA displayedand
. Openor shoricircuitin wiringlrcm ignitonswitch(MTX), or inhlbitor switch iAlx) to ECUterminallC (Relerto pageF-124) Mainrelay(FUELINJ retay)mallunclion conneclor terminal+B Op€ncircuitin wiing ,rommainrelayto diagnosls termlnalMENlo conn€clor Openor shodcircuitin wiringtromdiagnosrs ECUterminal1D Poorconnection at ECIJconnector ECUmallunclion ECUmallunclion
(Relerlo paseF-124) Mainrelay(FUELINJ relay)malfuncllon connector teminal +B Opencirclitin wirlnglrommainrelaylo diagnosis . Open or shorlcircuil in wiing from diagnosisconneclorterminalFEN to ECUtermlnal1F
Poorconnectional ECu connector ECUmallunction
Always Baliery voltage .
Shoncircuitin wirinSfiorn gniterio ECU teminal 1G
(Beferto paseF-124) t.4aln relay{FUELINJ relay)malrunclion Poorconnection at ECUconnector Openckcuilin wkinglromcncuitopeningfelayto ECUlerminal1l 1J . Opencircuitin wiing lromAC reay lo ECLJterminal
. Shoncncoitln wirngtromdiagnosis lo ECUlerminallK connector ierminalTEN
Alwaysbatleryvonage
. Opencncuitin wiins tromdiagnosis termnalTENlo ECUtem| conneclor . Opencicuil in wirinslfomdiagnosis lerminal GNDto ground conneclor
AIways0V or Approx.5V
I)to ECUlemi . Openor shoncircoiiin wiringfrcrnspeedswitch(Seclion na 1[,1
OK) Alwaysbelow1.ov(sloplights
. Opencircuitin wiringlroms1opllght swilchto ECUtem nal10
Always battery vollage
P/Spressurcswitchmalluncllon Geierto pageF-125) switchECUterminal1P Shortcircuitin wninglromP/Spressure ECUmatlunction (Refer to pageF 125) P/Spressure swilchmaltunclion '1P Openctcuil in wkinglromPA presslfeswilchlo ECUte|nrinal swilchto grcund Op€ncircuilin wiringlromP/Sprcssure
F-l 15
F
CONTROLSYSTEM Test condition
TenninJInput Oulprd 10 o
1R
lgniton switchON
o
o
o
l-leadliq
o
Neutral/Clutch swilches (MTX)
swnch
Rear windowdeiloslerswilch OFF Rear w ndow de'roslerswlch ON
Below 1 0V lgnlion switch Batleryvollage O N
HeadlighlsON HeadlighlsOFF Nedral posllionor clutch Pedal
Batery voltage
Olhers
Bateryvoltage
Below1.ov Below1.0v
Below1.0V (ATX) Others
28 2C 2D 2E
Ground(lnieclor) Ground(Oulpul) Ground(cPU) Ground(lnput)
o
(indisrributoo (Ne'sisnal)
BaneryvoLlage OV OV
Constani
OV
Constanl
OV
lgnitionswitchON
or 5V
2G 2H
2l 2J
2K
o
Ground Open Throttlesenso/Ec (ATX)
?t
F-116
Remark
Below 1 0V
Batleryvollage A/C SWOFF (engne coolant Below1.0V Coolingian operaung temperature over97'C (207'D of das noslsconnector temina TFAgtounded) Batrery volage Fan nol operatinq(idle) Batery votage BlowercontrolswitchOFF Below1.0v ON ElowercontrolswitchON
o
1T
PJCSW0N and
Cor'ecl Yolage
TITX ATX
Below 1.0V Batleryvolage
F
CONTBOLSYSTEM
. Opencircuitin wiing lromAJCswitchto ECuterminal10 . A/C sulch maliunclion(Relerto SectionlJ)
Always baltery vollage
Openor shorlcircuitln wirngtromlan retaylo ECUteffnina1B ECUmallunction
(elect c cool ns tan OK)
Alwalsbelow1.0V(blowerlan OK)
Shoncircut n wiringfromblowerconlrolswilchto ECLJterminal15 Poorconneclion at ECUconneclor ECUmaltunclion . Openc rcuitin wirinsircm blowercontrolswilchlo ECUlerminallS Alwaysbatleryvoltage(blowerfan OK) llluminalion lampON Op€nor shorlcncuirin wirlngtromrearwindowdstrosl€r swtchro ECU t.0v lenninal1T never ON (Headlighls 1.0V Alwaysbelow OK)
Opencircuitin wirng lromignitionswitchto rearwindowdelroster swilch (Belerto SectionT) Fearwndowdefroster switchmalfunction . Openor shoncircuitin wiringtromheadlighlrelaylo ECIJterminal1U (Referto pageF-125) Neulfalswilchmalluncton Clutchswitchmaliunction {Belerro pageF-124) Shoncircuitln wninolromECUterminallV to neukalor ciltch switch Neutraiswilch mallunclion(Felerto page F-125) Clulchswlch malfunction(Rererto page F-124) Opencrcut n widng from ECU tenninal1V lo neutralor clurchswitch Poorconneclionat ECU connector
Inhbilor swltchmallunction{Relerto SectionK) Shortcircuitwiringlromlnhibitor switchlo ECUlerminal1V nhibitorswilchmallunclion(Referlo SectlonK) Openorcult in wiring frorninhibitorswrtchto ECU rerminal1V
Poorcontaclal groundterminal Opencircuitin wirng lromECUto ground
Alwaysapprox0V or approx.2V
.
Referto Troubleshooting, Code No.02(Relerto page F-70)
A ways battery vollage
.
Opencircuil wiringfrom lo ground
Beow 4.5V of above 5.5V
Shoncircultn wiringfromECUtenninal2K lo thrctllesensorECAT convol unil(ATX),or ln aidowsensor Poorconnection at ECUconneclor ECUmallunclion . ECUmailuncton
F-117
F
CONTROLSYSTEM
-
-:.
Inpui Oulput
Consctvontgg
Rcmark
ThrcttlesensorEc_ Accelerator Pedal releas€d
o
(ATx) 2N
Teal condition
connection lo
Accelelalor pedal lully depressed
lgnron switchON
o
OV
ldle (coldengine)
0-0.1v lncreasngengrnespeed{altefwarmup)
0.5 1-0v
0-0.4v 20
o
2S 2T
2V
(negatve)
o
2R
2U
(positive)
o
2P 2A
lqn,lon sw{ch ON
o
o
o
o
Appfox. 1.2V OV
ldle
20oC(68oD Enginecoolanttemperature aiter Enginecrankingandlew seconds
Below0.5v Appox 2.3V
Other conditon
Batteryvdlage
AccessoryON Oth€rscondition Constant
Batleryvonage
noid valve @
nold valve@ hjector (negative) Inieclor(positive)
EngineSignal
lgniton swtch ON Below 1.0V
I ash
o o 2\ 22
OFF noid valve @ Solenoidvalve (purge conlroD
o o
ON
EC'ATconlrol'rnrl (ATX)
Balteryvoltage Batteryvohge
lgnitionswitchON ldle
switch lgniUon
OFF
OV
ON
Enginecoolanttempelalurcbelow70'C (15860 at rdre
above7o'C coolanttemperaLrre Engine-
F-l18
Batleryvdlage
Bateryvofiage
CONTROLSYSTEM
F
Incorrect voltage Opencircuilin wkingfromECUlermnal 2[,1to throtte sensor Openc rcuitin wiringfromECUlermnal 2K to thrct e sensot Openclrcuitin w1ring frcmECUlermnal 2D to lhrclile sensor . Throtflesensormrs3dtushent
. Belerlo Troubleshooting CodeNo.15(Reierlo pageF 74) AlwaysapproxlV aflerwamr-up
.
Alwaysapprox.oV or approx.5V
. Referto Troubleshooting, Code No.O8(8eferto page F-71)
Referto Troubleshooting, Code No.17 (Refeflo page F 75)
. Opencircuilin wirinStromECUterminal 2Pto airllowsensor Always approx. 0V or approx. 5V
.
Reierlo Troubleshootns,Code No.09 {Reierto page F 72)
.
Fererro ftoJblesnoor,ng. Code No.35 (Felerro page F-78)
. Feler lo T ouble.hoorng,Code No 34 (Belerlo pagF F-781
. Openor shortcircuitin wing irominjector to ECUtenrinal2v . Opencircuilin wiins lrominjeclorto ECUt€minal2V
. Open or shortcrcu't in wking frcm ECU terminal2W 10air bypasssolenold valve O
Alwaysapprox.0V or approx.12V
. Reterto TroubeshoolinS, Code No.26 (Relerto page F 77) . Oper crcLrr ,1 wrflnglrom man relayto ECU r€lmrnal2Y
Alwaysapprox.oV or appfox. 12V
. Openor shoncircuilin wr ng lromECUlerminal22 to EC'ATconlrolunit termlnal1N
F-119
F
CONTROLSYSTEM CRANKANGLESENSOR{lN OISTRIBUTOR) Inspection (Beferlo SeclionG.) 1. Bemovethe drslnbutor. as shownin the ligure. conneclor 2. Connectthe distributor lead. the high-tension 3. Connect 4. Turnthe ionitionswitchON.
A USECONNECTOFI
5. Connectthe SSTS(EnglneSignalMonitorand Adaptel) to the ECUas shown. 6. SettheSSTS(EngineSignalMonitorand Adapler)terminal2E.
the ou! 7. Botatethe distributor driveby handandmeasure put voltage. Speclflcation ferminal 2E
Tesl condition onelull lurn Roratedistributor
Voltago
Apprcx.5V i4 pulses)
installthe distributor. 8. Afterthe inspection, (Referto SectionG.) 9. Starithe engineand adjustthe ignitiontimlng. (Reierio pageF-63.)
^- t:,?\ l;-\' l,!,-,:
lgnitioniimlngrBTDC16 + 10 torque lockboltsto the specified 0. Tightenthe distributor Tighleningtorque: t6-23 N.m(1.6-2.3 m-kg, 12-16 tt'lb)
F-120
F
CONTROLSYSTEM
TYPE) SENSOR(BYPASSHOT-WIRE ATRFLOW lnapoction 1. Removethe air cleaner. checkfor an opencircuitof theairflowsensorhot 2. Visually
INJECIION BODY
3. Checkthe airflowsensorbodyfor cracks.
4. Disconnect the airflowsensorconnector. theterbetween measureresistance 5. Usingan ohmmeter, mrnals.
@; lffi-fl
Speciticaiion Terminal A - B A - C
F$islance (20'C I68"Fl)
B - C
Femoval/ Installalion Relerto page F-84.
INTAXE FIEPLACE WATERIHENMO SENSOR
WATERTHERMOSENSOR Removal connector. the waterthermosensor 1. Disconnect usingthe SST. 2. Removethe waterthermosensor
lnboeclion andheatthe 1. Placethesensorinwaterwithathermometer watergraduallY. of the sensor. measureresistance 2. Usingan ohmmeter, Coolant -206C |-4aF)
o.c ( 32.D 2o.c ( 68.R 40oc (10!oR 60oc (140oR 80oc {176oR
(kO) Fesisance 1 4 . 6- 1 7 . A
2.211 . 0050, 0.29-
6.5 2.69 1.3 0.65 0.354
3 , 0
n i (ko) 2
WAIEFTEMPEMIUFIE {"C I"FD
F-121
E a
CONTROLUNIT THROTTLESENSOR Inspection 1. Warmup the engineto normaloperatingtemperature. 2. Verifythatthethermowaxunitrod extendsoutwardfullyand lromthe roller. the cam separates 3. Stopthe engineand turnthe ignitionswilchto ON. (EngineSignalMonitorandAdaptet 4. ConnecttheSSTS Harness)to the ECUas shown. 5. Setthe SST (EngineSignal Monitor)to terminal2M.
6. Rotatethethrottlelinkby handandveriiythatthe voltage is withinspecifications. Speclflcallon ECUTerminal 2M
Throtlle valv€ conditon
0.30 0.80v
adiustthe throttlesensor. 7. ll not as specified, Adiustment connector. 1. Connectthe SST to the diagnosis position 1. 2. Setswitch@to 3. SetTESI SWto SELF-TEST. Note . lf the SSTis not used,iump acrossthe TENterminat and the GNDterminalsol the diagnosiaconneglor.
THFOTTLE SENSOB
4. Loosenthe throttlesensorscrews. and untilthatthe volt' 5. Rotatethe throttlesensorgradually age is withjnspecification. tightenthe throttlesensorscrews 6. Afleradiustmenl, 7. Removethe SST.
Removal/ Inslallation '1.Turnthe ignitionswitchOFF. the throttlesensorconnector. 2. Disconnect 3. Removethe throttlesensor. Cautlon . Do not drop the thloule aensor. 4. Adjustthe throttlesensorafterinstallation (Referto pageF-122.) fNJECTfON BODY Ztt n l.trtg,
F-122
tFbl
CONTROLSYSTEM OXYGENSENSOR Inapectlon ol Termlnal Voltage 1. Warmup theengineto normaloperating temperature and run it at idle. 2. Disconnect the oxygensensorconnector. 3. Connecta voltmeterbetweenthe oxygensensorand a oround.
OXYGENSENSON CONNECTOF
".+try'",,' -\1
anddecreasing 4. Measure thevoltagewhileincreasing the enginespeedsuddenlyseveraltimes. Specitication Enginecondilron
@
o
VoltageM Below0.4 Above 0.5
o
5. Replacethe oxygensensorif notas specified. Inspectlonot Sensitivity 1.Warmup the engineto normaloperatingtemperature. 2. ConnecttheSSTS(SystemSelector and Self-Diagnosls Checker)to the diagnosis connectoras shown. 3. Set switch@ to position1. 4. SetTESTSWto Oz MONITOR.
5. Increase the enginespeedto between2,000and 3,000 rpm, andverilylhatthemonitorlampflasheslor l0 sec.. lf not as specified, replacethe oxygensensor. (Referto pageF-124.) 5AF-m6|$S6 o€OGR
Monltorlamp:Flasheamorethan Slimes/l0 seconds 6. Replacethe oxygensensorit not as specified.
MONITOF
/
;O-. 1r\
ooo o
tl_l r:] I
lnspectionot Heatel 1. Measureresistance betweenterminals@ and @. Realstance:60 (20"C l68oFl) 2. Reolacethe heaterif not as soecified.
F-123
F
CONTROLSYSTEM Replacement the oxygensensorconnector' 1. Disconnect 2. Removethe boltsand removethe exhaustmanifoldinsulator. 3. Removethe oxygensensor. 4. lnstallin the reverseorderof removal
i--1t lrFJtl /
OXYGENSENSON'
torque: Tiohteninq -N.m (it-s m-t
MAINRELAY neolacemeni the negativebatteryterminal 1. Disconnect 2. Removethe ECU. 3. Removethe relavbracket. 4. Removethe mainrelayfromthe relaybracket 5. Insiallin the reverseorderof removal.
RELAYBRACKET
Inspectionof Continuily '1.iheck conlinuity betweenlermrnals @ and @ TerminaLs
r--:7(cF-l-{d) Y
@-@
Y
faloouYD -r_-____J
Continuity
Apply12V No
the mainrelayif necessary. 2. ReDlace
cLuTcHswrTcH(MTX)
InsDectlon '1.Disconnect the clutchswitchconnector' to the switch 2. Connectan ohmmeter of the switch. 3. Checkcontinuity ContinuLiy No
replacethe clutchswitch 4. lf not as specified, Replacement '1 ioosen the nutsand removethe clutchswltch 2. lnstallthe clutchswitch. 3. Adiusttheclutchpedalheightreferringto the aboveand (Referto SectionH ) the heightspec lcalrons. torque 4. Trohtenthe nutsto the specified to.que, Ti-ohfeninq -t*m (2.0-z.s m-kg, l4-18 ft-lb) io-zs
CLUTCHPEDAL
F-124
o1aoFr103
F
CONTROLSYSTEM
NEUTRALSWITCH(MTX) Inspection 1. Disconnect theneutralswitchconnectorshownin thefiqure. 2. Connectan ohmmeter to the switch. 3. Checkcontinuity ol the switch. Contnuilv Otherranqss
4. lf not as soecified. reolacethe neutralswrtch. Replacemenl 1. Disconnect the neutralswitchconnector. 2. Removethe bracket. 3. Removethe neutralswitch. 4. Installin the reverseorderof rcmoval. Tighteningtorque: 20-29 N.m(2.0-3.0 m-kg, 14-22 ft-lb)
POWERSTEERING PRESSURE SWITCH In€pectlon 1. Disconnect the P/Spressureswitchconneclor. 2. Connectan ohmmeter to the switch. 3. Staritheengineandletitidle.Checkcontinuity oftheswitch whileturningthe steeringwheel. P/S Turnrng Nol turning
Continuily
4. lf not as specjfied,replacethe P/S pressureswitch.
F-125
ENGINEELECTRICAL t N D E X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G . . .- . .2. . . . . . . . . .
o u T L r N E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G . . -. .3. . . . . . . . . . . . . . . SPECrF|CAT|ONS.....,...........................-.. G- 3 TROUBLESHOOTTNG G- 4 GU|DE...................... DTAGNOSTTC rNDEX.........................,...... G- 4 TROUBLESHOOTING......,...,.... G- 4 SYMPTOIV G- 6 GHARG|NG SYSTEM................................. PREPARAT|ON....................................... G- 6 ctRculTD|AGRAM................................. G- 6 TROU81ESHOOT|NG.............................. G- 7 8ATTERY............................................... G- 8 A1TERNATOR........................................ G-r0 DRTVE 8E1T........................................... G-l4
rGNrTtoN G-r6 sYsTEM,...................................
P R E P 4 R A T | O N . . . . . . . . . . . . . . . . . . . . . . . . .G . .-.r. 6. . . . . . . . . . ctRcutTDIAGRAM................................. G-16 T 8 O U 8 1 E S H O O T I N G . . . . . . . . . . . . . . . . .G . .-. 1. .7. . . . . . . . l G N r T t oTNt M t N G . . . . . . . . . . . . . . . . . . . . . . . . .G. .-.l.8. . . . . . sPARKp1UGS....................................... G-l9 tGNtTloN co11....................................... G-20 DtSTRtBUTOR .......-....-.....-......-.....-........ G-20 t G N l T E R . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . .G, .-.2, .3. . . . . . . . . HrGH-TENSTON 1EA0.............................. G-23 START|NG SYSTEM.................................. G-24 P R E P A R A T I O N . . . . . . . . . . . . . . . . . . . . . . . . .G. .-.2. .4. . . . . . . . . CIRCUI'l DIAGRANiI ................................. G-24 sTARTER............................................... G-25
l
INDEX
INDEX
YTE LEVEL
7Y \'t coil (inthe distributor) 6. Ignition 1. Battery .- . . pageG 20 Inspection..................-... paSe 8 .. ...... . Inspectron...... 9 Distributor page 9 7. G............. Recl'argrng S p a r tke s t . . . . . .......... . . . . . . . . . . .p. .a.g. .e.G. .- 2 0 2. Alternator ...pageG-20 advanceinspeclion Eiectronrc pageG-l 0 / Installataon..........-....... Removal pageG 21 Inslarlation.......... Removal/ pageG-11 / Assemb|y............. Disassembly paqeG-22 / Assemb'y........ Disassembry I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e. G . . .1. 2. . . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . .p . .a. .g. e .G . . -. .2-3. 3. Drivebelt (in the distrlbutoo 8. lgniter I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e.G. .-.1.4. I n s p e c t i o n . . . . . . . . . ..................p .. .u. s. "9 - ? 9 A d j u s t m e n t . . . . . . . . . . . . . . . . . .p. a . .g. .e.G. .-.1. .4. . . . p R e p l a c e r n e n t . . . . . . . . . . . . . . . .a. .g. e .G . . .2. .3. . . . . p a g e 8 e p 1 a c e m e n l . . . . . . . . . . . . . . . . . . . . .G. .-.1.5. . . . . L Slarter lead 4. High-tension . .. pageG 25 Installation.......... Flemoval/ i n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. .e.G. . .2. 3 ...... .....pageG-27 Inspection...... Performance 5. Sparkplugs / Assembly . .....pageG-28 Disassembly pageG-19 / Insta|ation.................. Removal ... PageG-29 inspecron..... I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e.G. .--1. .9. . . . .
G-2
OUTLINE
OUTLINE SPECIFICATIONS Engine
Batlery
V
Volrage
(2o-houffale)
Type and capaciry
Mal. 20
Dafl' current
12-65
Outout
(bulr-n lC requlato4 rransrsronzed V
Fequlatedvo tage
Brushlength
mm(n)
6 (O.24)
V.kW
outpur Brush lenglh
rnm (rn)
14.1 14.7
25 (0.98)
Slandard
Drive bell detleclion mm (inY98N, 10 ks, 22 lb
Starter
83 '12 gL-S (334H) 34Br
Slandard
lVinimum
Dsrriburor BTDC
lgnilrontiming (IEN iermina oi dagnosis connectorgro'rnd)
5 5-7 .Al0 21-O.27) 6 0-7.5 (023-0.29) Oirect 12-0.85.1MTX) 12-0.95(Ar-4 17 (0 65) 1 15 (0 45) ESA
t6 0.68-0.840
Fesslance(20oC [68"F]]
9.6,14.4k0 NGK
Spark pllg
Tvpe NIPPONDENSO
Plussap
mm(rn)
BKRsE-11 BKR6E11 K16PR.UI1 K2OPR.U11 1 0-t 1 (0.039-0043) 1-3,4-2
G-3
GUIDE TROUBLESHOOTING
GUIDE TFOUBLESHOOTING INDEX DIAGNOSTIC o. -1
2
a
Page
Troubl6hooting llems will noi crank-starter motor do€s not operare will not crank slartermolor sp ns
5 6
G-4 cF4 G-5 G-5 G-5
Ale 1alorwah 1q laarp rlu-inares whrc enSLrerunnrng
banery Discharged Mislire
SYMPTOMTROUBLESHOOTING wlll not crank-starter motor do€s not oPerate ACTION INSPECTION
1
]TEP 1
Doesenginecrankwithlullychargedbanerv?
2
ls baneryvollagepr€6ernat terminal8?
17 Page G-7
Check charging syslem
TERMINALB
Check wiringharness
3
js batteryvoltagepresental lerminajS with lgni lion switchin STARTPosltion?
TERMINALS
. Check maSnetcswitch . Check lleld col . Check armalure
- Page G-29 F Page G-30 .? Page G-31
. Check nhibtor switch(ATX) . Check sntof swtch . Check wring harness
F Section K r7 Section T
will not crank-statler motor spins JTEP 1
INSPECTION ls drve p n on pushedoul while crankrng (clck is heard when pushed oul)?
ACTION Removeslarterand check llywheelrng gear teelh and slarier d ve pin|on teeth
Check magneticswilch
G-4
e Page G-29
GUIDE TROUBLESHOOTING Cranks alowly
3 STEiP l
Does enginecrank normallywilh lully charged
ACTION Checkcm'girg syslem
2
Are $aner cable connectionslooseor corroded?
Bepairor repace connecton
INSPECTION
s PageG-7
CHECK HECK Ch€ck stadff lor binding{suchas bruslrand armature.)
4 1
Altemalorwaaninglamplllumlnateswhileenginerunnlng ACTION INSPECTION arcrnahaness benreen Ch€ckwring ls baneryvoltageconect al idle? lor L teminal and alternatorwarnlng Specificalion:14.'l-14.7v Check chaelng system
c? Page G-7
Dischargedbsttery 1
INSPECTION system; is it OK? chaelng Check l? page G-7
ACTION TumigniuonswilchON and measurc darkcurrcnlas shown
Dafkcunenr:Below20mA Repairor replacepartsas necessary
G-5
CHARGINGSYSTEM
CHARGINGSYSTEM PREPARATION
ssT
49 9200020 gauge, Tension
CINCUITDIAGRAM
LAMP CHAFTGE T BATIEFY
II I
lunctionto warnof the followingproblemsin the chargingsystemhasa self-diagnostic Thealternator warninglampalluminates lf a problemarises,the alternator 1.TerminalS circuitopen 2. No voltageoutput 3. Fieldcoil circuitopen 4. TerminalB circuitopen 5. Voltageoutputtoo high
G-6
CHARGINGSYSTEM TROUBLESHOOTING
acno
INSPECTION 1
2
Check battery voltaget is il cofiecP Spocltlcatlon: Above 12.4V
Chec( batlery
SrarlenEnei does allernarorwarn^g lamp go
Go to ne,( slep
rt_ page e-a
Go io Slep 4
3
ls voltage al alternalor term nals coffect?
Checkwiring harnessbetweenterminal
SpeclllcElion:
lon.ONM 14.1-14.7 14.1-14.7 14.1 14.7
L S
1. Conneclan ammeler(70Amin)between terminaiB and haness 2. Starlengine 3. Turnall electricaloadsON anddepress
. Checkwiring harness . Replacealtefnator
F page G-10
Charging syslemnorna
4. ls outputcurrenl65Aor moreal 2,500-3,000rpm? Caution . Do not grolnd terminal a
5
Replacealternator
is drive belt tensionOh?
e pag€ G-10
N iks, lb) Drive belt 451-745 (46-80, 101-176)
491 589 (50 60. 110 132)
392-588 (40-60, 88 132) 422 491 (43,50, 95 110)
. Adjustdrive belt t€nsion
G-7
CHABGINGSYSTEiI BATTERY Inapecllon Electrolytelevel levelliesbetweenlhe upperand 1.Chec{ the electrol}4e lowerlines. 2. lf low' add distilledwater;do not overfill.
Speclfic gravily ol electrolyte Measurelhe specificgravitywltha hydromeler' Specilication:1.27-1.29 (at 20"C 168'Fl)
Voliage leat
Check battery voltage
tr 1-3 hours ouick-charse
ano tol ls minutes Ouick-charge
I l Below 12.0V
l Above 12 0V
tor Ouick-charge 3-4 hours
"*o*Cu
-----*J',ou
I
Quickchargefor 30 minutesancl rccheckvollage
rf=r
Below l2.4V
G-8
Above 12-4V
CHARGINGSYSTEM Te]mlnaland cable oftheterminals to ensuregoodeli?ctri1. Checkthetightness cal connections. 2. Checkfor corrodedor lrayedbatterycables. 3. Checkthe rubberprotectoronthe positiveteminalfor proP er coverage. andcoatthemwithgrease. 4. Cleantheterminalsif necessary,
Recharging Battery 3itB19L€
Slowcharge(4 Under3
Ouickcharge (A) lvlax. 20
Slow{harging to removethe ventcaps. It is not necessary 40 (164) 0O076) TEMPEFATURE CCTFD
Ouick-charging Removethebaneryfromlhevehicleandremovetheventcaps. Warning . Beto.epertormingmalntenanceor rechatgingthe banery,lurn ofl all a@essoriesand stop the €ngine. . The negativecablemusl be removedlirsl and installedlast. . Sel the battery in water when quick{harging to prevent overhealingthe battery.
G-9
CHARGINGSYSTEIIiI ALTERNATOR Removal/ Installation Cautlon . Be sqre the battery connectionsare not reversedbecausethis will damagethe reclifier' . Do not use high-v6hagetestefs such as a meggerbecausethey will damagethe rectitier' . Rememberth;t battet vottage ls alwayspresentat the alternatorterminal B' . Do not ground terminal L $rhilethe engine is running. . D,onot;tart the engine while the connlctor is disqonnectedfrom terminalsL and S' to RemovalNole. 1. Removein the ordershownin the figure,referring 2. Installin the reverseorderof removal,referringto lnstallationNote
7,r-11 |}n {3o-r r0 cGrs, 69-95 h.lh}
19-25O,e-2,6r.-r9)
37-52 (3.5-5.3,27-33)
5. N4ouniingbolt 1. Negativebatterycable 6. Alternator 2. Connector page G-1 1 / Assembly............. Disassembly 3. Mountingbolt,adjlst nut I n s p e c t i o n . . . . - . . . . . . . . . . . . . . .p . .a. .g. e . .G. .-.1. .2. . 4. Drivebelt I n s p e d r o n . . . . . . . . . . . . . . . . . . . page . . . . - .G-'14 .........A d J u s t m e n t . . . . - . . . . . . . . . . . .page . . . . . .G-14 .......... . . . . . G-15 R e p l a c e m e n t . .-....-... . . . . . . . . .page
G-l0
CHARGING SYSTEM Removal/ lnstallationNote Thealternator is femoved andinstalled lromunderthevehicle. 0rEoGx 094
Disassembly/ Assembly in the ordershownin the figure. 1. Disassemble 2. Assemblein the reverseorderof disassembly.
3,2J.s ($--ne, 2e-3E
46J3
bN
Nm (4,7-5,4 ckg,
#9_,5.$-?.3 3.2-3.9
(60-30, 53-70) (33-39!
2S-33)
3.r-4G fi-lbl
r.6-2.0 (i6-20. 14-13)
orEoGX015
L Stator 1. Nut set pageG 12 Inspection..........-........................ 2. Pulley set 3. Frontcover 9. Regulator 10.Rectifier 4. Bearing l n s p e c t i o n . . . . - - . . . . . . . . . . . . p. .a. .g. e .G . . . 1. .3. . . . . . 1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g . .e.G . .-.1. .2. . . . . . 11.Brushholderassembly 5. Retainer Inspection 6. Spacer pageG-13 (Brush andbrushspring)......... 7. Rotor . e a rb r a c k e t I n s p e c t i o n . . . . - . . . . - . . . . . . . .p . .a. .g. .eG . . .- -1.2. . . . .1.2 R
G-11
CHARGINGSYSTEM Inspectlon Rolor between the the resistance to measure 1. Usean ohmmeter sliprings. Specilicatlon:2.4-2.90 (at 20"C [68cq) replacethe rotor. 2. ll not withinspecilication,
3. (1) Usean ohmmeterto checkcontinuitybetweeneachslip rinoand the core. (2) Replacethe rotorif thereis continuity on the slip to smoothanyroughness 4. Ule tinesandpaper nng sunace.
Stator betweenthe stator io checkcontinuity 1. Usean ohmmeter coil leads. 2. Replacethe statorif there is no continuity.
betweenthe stator to checkcontinuity 3. Usean ohmmeter coilleadsand the core. the statorif thereis continuity. 4. Replace
Bearlng6 and sticking. 1. Checkfor abnormalnoise,looseness, il necessary. the bearing(s) 2. Replace
01E0GX.020
G-l2
CHAFGINGSYSTEM Rectiller Cautlon . Don't uae meggerlester to p€vent lhe reclifier trom breaklngdown. 1. Useananalogohmmeterto checkcontinuity of he diodes. Conlinurty E B E B
NO NO
2. Replacethe rectifierif necessary.
Bruah lf a brushis wornalmostto the limitor beyond,redaceall the brushes. Siandad: 25.0mm(0.984In) ilinimum: 6.0mm(0.236In)
Brush apring gaugeto measure theforceof the 1. Usea springpressure brushspring. 2. Replacethe springif not within. Standard lorce: 2.9-3.9 N (300-400 g, 10.6-14.1 oz) Minimum: 0.8-1.2 N (80-120 g, 2.8-4.2 o2) Note . Readlhe spring pressurewlth the brushtip proiectIng 2mm (0.079in).
G-13
CHARGINGSYSTEM DRIVEBELT Inspection forwea.,cracks,andllay1.Checkthedrivebeltsandpulleys ing. Replaceas necessary. drivebelttensionwitha tenslongauge 2. Nleasure Tension
N {ks,rb)
Dfive belt
A/C and P€
451 745 (46-80, 101-176)
392-588 (40-60,88 132)
49t-589 (50-60 110 132)
422-491 (43,50, 95-110)
(98 pressure byapplyingmoderale 3. lreasurethedeflection pulleys. if Adjust the between lb) midway N, lO kg, 22 necessary. Detlection
rnm(rn)
Dflve bell
5.5 7.0 {0.21 0.28) AJC and P/S
8-9 (0.31-0.35)
6.0-7.5 (0.23-O.30) 9-t 0 (0.35-0.39)
Adiustment 1. ioosen bolls(A)and @. by turningadin or outas necessary 2. Movethe alternator iustinonur (O. s. iignt6n ootd@ and @ and recheckthe beltdeflection Tidhtenino torquea -Boh !E;19-26 N.m(1.9-2.6 m-kg, 14-18 ft'lb) Bolt @: 38-51 Nm (3.8-5.3 m-kg, 28-38 ft'lb)
G-l4
CHARGINGSYSTEM Replacement 1. Bemovethe fuC and P/Sdrivebelt.it equipped Note . Retel to B Section, botts@ and @. 2. Loosenalternator afternator beli. Remove the 3. beltandadjustitto specifications newalternator 4. Installthe torques. 5. Tightenall boltsto the specified Tighlening torques Mounlingbolt: 38-51 Nm (3.8-5.3 m-kg,28-38 fi-lb) Adlustingbolt: l9-26 Nm (1.9-2.6 m-kg, 14-18 ft-lb) 6. Installthe AJCand P/Sdrivebehii equipped,and adjust it to specificataon. Note . Reterto B Seclion,
G-15
IGNITIONSYSTEi/I
IGNITIONSYSTEM PREPARATION
ssT
49 80199A0 SystemS€l€clor
and self-diagno€is ignitonliming
49 HO189A1
sell-diagnosis
Self-Diagnosis Checker
CIRCUITDIAGRA''
GFOUND TACHOMEIEFi DTAGNOSTS CONNECTOF IGNITION SWTCH
G-16
IGNITIONSYSTEM TNOUBLESHOOTING fi6tire
6
JTEF
|lrsPEcTtoN
' Checker ls "00 displayedon Self-Diagnosis with igniton swilch ON? .? p.ge F-67
ACTION
llallunctioncode no. displayed Checklor cause(Belerto specified E7 PageF-67 checksequence) "8a" tlash€s CheckECU leminal lF voltage
t7 psge F-114
Vollag6: Approl l2v (lgnilioh switch ON) 4 +
2
Bemovesparkplugiis therea slrongbluespark whie engineis cranking?
(j li OK, replace ECU lf nol OK, check wiringharness belweenECU and SelfDiagnosis
page F-112
lgn tion syslemis normal
Checksparkpug
r? gage G-2O
lf OK, Go lo next step lf notOK,cleanor .eplacesparkplug 3
ls resistanceot high-tensionleadsOK? specification:16 m per lm (3.28tl) c? page G-23
Repac€ high tensionleads
Afe therecorroslon, damageor crackson lhe disrribulor cap and rotof 17 page c-23 5
ls ignitroncoil nomal,
6
Aredisrributor connector and ECUconnector
(7 page G-2O
Measurevoltageot @ termlnal (dislibutorrop connector); is il coffec? Voltage:Apprcr. l2v Check mainluse, ignitionswitch,wiflng harness,and ECU
I
ls ECUnormal?
l? page F-r12 ReplaceECU
G-l7
IGNITIONSYSTEM TIMING IGNITION Adiustment
and lenoeralure operaling 1.Warmup theerg'neto normal neLtrdl (P or rdle ranqe i at [L4TX]) run [ATX] loadsOFF. 2. Turnall electrical 3. Turnthe tuC switchOFF. lGconnector to thediagnosis 4. Connecta testlachometer terminal.
---.--.-
_e\,t-
tc_
5. Connectthe SST to the diagnosisconneclor.
to position1 andTEST Selector 6- SetswitchA ontheSystem to SELFTEST. SWITCH Note . To createthe test conditionwithout usingthe Sys' tem Selector,connectterminalsTEN and GNOof the diagnosisconnectorwiih a iumper wiae. 7. Checkthe idlespeedand set it to the specitiedspeedit necessary. ldle speed:600-650 rpm (MTX) 810-860 rPm (Arx) 8. Checkthe igniiiontiming. Specification: BTDC 16 + 1'
9. ll the ignrtrontim ng is nol as specilied loose'lIhe dislribL tor |oc: boftsand turnI le dlsllibttol Io makelheadiugment 1O-Tighlenihe dlstributorlock boltsto speciliedtorque.
15."u-t'\ -,€=4
,N. G-l8
torque: Tiohteninq -H.m
ie-za
{i.s-z.s m-tg,12-16ltlb)
IGNITIONSYSTEM SPARKPLUGS Removal/ Installation leadscarefully. 1. Removeand installthe high-iension Caution . Whenthe spark plug lead is to be pulled ofi, pull on the boot itself, not the wire.
2. Removeand instailthe sparkp ug witha plug socket. Caution . Be sure the socket must be tit squarelyover lhe spark plug. lubricant 3. Applyantiseize compound or molybdenum-based to the sparkplugthreads. torque. 4. Tightenthe sparkplugto the specified Tighteninglorque: 15-23 N.m(1.5-2.3 m-kg,11-17 ftlb) Inspection 1. Removethe sparkplug. lead. 2. Connectlhe sparkplug10a high-tension pliers5-1omm 3. Holdthe highiensionleadwth insulated (0,20-0,39 in) froma ground. 4. Cranktheengineandverifythatthereisa strongbluespark.
)x
Note . It there is no spark,replacethe sparkplug or high" tension lead as necessary.
CAFBON BURNED
thespark following. lf a problemisfound,replace 5. Checkthe plug. . Damagedinsulation . Wornelectrodes . Carbondeposits ll cleaningis necessary, usea plugcleaneror a wtre brush.Cleanthe upperinsulatoralso . Damagedgasket . Burnedcondition Pluggap: 1,0-1,lmm (0.039-0.043in)
G-19
IGNITIONSYSTEIIi| IGNITIONCOIL Inspection Primarycoil rvindlng to ineasureres$anceol lhe pIimarycoll use an'ohmmeler replacethe ignitioncoil. winding.lf notwithinspeciflcation, Specification:0.68---0.840(al 20oC[68"F1)
Secondarycoil windlng of the primarycoil to measureresistance Usean ohinmeter the ignitioncoil. replace within specification, windlng.lf not Soeciflcalion:9.6-14.4 ko (at 20"C [680Fl)
Reolacement (Referto pageG-21.) 1. Replacethe distributor. 2. Adiustthe lgnltiontiming (Referto pageG-18 )
/
01aoGXo40
DISTRIBUTOR Spark Test leadtrom a sparKplug. the hiqh-tension 1. Disconnect in) froma ground. (0.20-0.39 5-iomm 2. Holdthe lead blue sparkls strong that a verify engine and 3. Cfankthe visible.
ElecironicAdvanceInspectlon Verifythat the ignitiontimingadvanceswith engineacceleralon.
G-20
IGNITIONSYSTEM Removal/ Installalion 1. Removein the ordershownin the figure. 2. lnstallin the reverseorderof removal.
{r.c-2.3 Gtg, 12-16 ft-tb)
2
,:t,
a''
'1.Negativebatterycable 2. High-tension lead pageG-23 lnspection...-............................... 3. Connector
o140cx.019
4. Mountingbolt 5. Distributor pageG-22 Disassembly / Assembly............. pageG-23 1nspec1ion..................................-
G-21
IGNITIONSYSTEM Disassembly/ Assembly '1.Disassemble in the ordershownIn the rigure to AssemblyNote. referring 2. Assemblein the reverseorderof disassembly,
ef ' ^ )
,
r,o-2,0o0-20, 0.7-1n
1. Cap pageG-23 Inspec1ron................................... 2. Rotor pageG 23 Inspection................................... 3. Cover
G-22
4 Crankanglesensorand igniter lnspection ..... coil 5. lgnition InspecUon ..
pageG-23 pageG-20
IGNITIONSYSTEM Inspectlon Capand rotor damage, andcracks. 1.Checkforcorrosion, 2. Replaceil necessary.
01E0GX.055
IGNITER lmpqction 1. Checkthe ECU.(Referto pageF-| 12.) distributor cap, ro2. Checkthecondition of the connector, leads. tor, ignitioncoil,and high-tension 3. ll allare normalbutmisfirestilloccurs,replacetheigniter. 01a0GX.021
Feplacemert (Referto pageG-21.) 1. Replacethe distributor. 2. Adjustthe ignitiontiming.(Referto pageG-18.) OlAOGX€2
HIGH-TENSION LEAO Insp€ciion lead. 1. Measureresislance of high'tension Spscification:16 m per I n (3.28ff) leadset. replacethe high-tension 2. lf notas specified,
G-23
STARTINGSYSTEM
STARTINGSYSTEM PREPAFATIOI{
ssr
49 E301 1'14
---)
installaltonol
.-\J--6-) \--=---
CIRCUITDIAGRAI'
PULL]N COIL
FIELDCOI!
G-24
STABTINGSYSTEM STAFTEN Inspection(on vehicle) 1. Measurethe batteryvoltage. Specitication:Above 12.4v turnssmoothly. 2. Cranktheengine,andverifythatthestarter 3. lfthestaderdoesnotturn,checkthevoltageofterminalS. 4. lf thevoltageis above8V,removeandinspectthestaner. ignill thevoltageis below8V,checkthewiringharness, tionswitch,and inhibitorsMich(ATX). 01E0GX.O60
Rgmoval/ Installation '1.Removein the ordershownin the figure,reterring to RemovalNote. to InstallationNgte. 2. Installin the revers€orderof removal,referring ATX
a7-5r l+n (3.&-5-3 m.kg, 2H3
n |b)
(t.3-5.3 rkg, 2a-33 fi.rb)
1. Negativebatterycable
2. S terminal,B terminal connector
bolt 3. l\.4ounting
G-25
STARTINGSYSTEM
'a;^ 37-51
1. Negativebatterycable
G-26
n (3,3-s.3 rl(g, 23-$
rl-25
l+n O.9-2.3 rlq,
n.|b)
S and B 2 Terminalconnectors
3 lvountingbolt
STARTINGSYSTEM Removal/ Insiallation Note ATX Thestarteris removedandinstalled frombelowthe vehicle. MTX fromabove. Thestarteris removedandinstalled 01A0GX{25
Pe.tormance Inspection i,lagnetic awltch theterminall\,4wire,and perlormthelollowingtests. Disconn€ct Pull-lntest whenthebatTheswitchis normaliftheoinioneiectsoutward tery is connected as shownin the figure. Caution . Do not applypowercontinuouslytor mote than 10 aeconqs. Hold-lntesl Aftercompletingthe pullin test,disconnectthe wirefromter' Theholdincoilis funcminalM (withthe pinionleftejected). tioningproperlyif the piniondoesnot return.
Adiuahent of pinion gap 1. Disconnect the wiringfromterminalM terminal S andthe 2. Whenthebatteryis c;nnectedbetween starter body,thepinionwillbeejectedandthenstop.Meas(piniongap)betlveen thepinionandthe uretheclearance stoooer. Note . Do not applypowercontinuouslyfor morethan 10 aeconds. Pinlongap: 0.5-2.omm (0.020-0.078 in) makeadjustmenl 3. lf thepiniongapis notwithinspecficaton. the numberofwashersbetween by increasing or decreasing the magnetic Switchandthe drivehousing.fihe gap be' comessmalleras the numberoi washersis increased.)
G-27
STARTINGSYSTEM Disassembly/ Assembly Note i.'-o-iJiJi.6r" in the ord;r shownin the figure'relerringto Disessembly.
i. iiGii,r.ln
referringto AssemblyNote *" ,""erie oroerof disasse-mblv,
o-r2 (so-l30, 79-ii2)
1. Magneticswitch l;spection...... PageG 29 2. Rearcover 3. Brushholderassembly .. pageG-30 Inspection............................... 4. Fieldcoil pageG-30 Inspection.................................
G-28
5- Frontcover 9 !eYe' . . T DrivePinion B Armature Inspection""
"
" pageG-31
STARTINGSYSTEM DisaasemblyNote Drlvs plnlon Removethe stopperfor the overrunning clutchwitha pipe as snown.
Assembly Note Drivepinlon 1. Setthedrivepinionontothearmature andinstallthe ring. 2. Installthe stopperwiththe SST and pressit, as shown.
Inspoctlon agnetic awilch 1. Usean ohmmeter to checkcontinuity betweentheS and switchifthereis noconM terminals. Replace themagnetic tinuity.
2. Useanohmmeter to checkcontinuity between theSterminalandthe body.Replace the magneticswitchif thereis no continuity.
to checkcontinuity between the M and 3. Usean ohmmeter Replace the magneticswitchil thereis conB termanals. tinuity.
G-29
STARTINGSYSTEM Brush and brush holder betweeneachinsu' to checkcontinuity 1. Usean ohmmeter lated brushand the 9late. Replacethe brushholderil thereis continuity.
2. Usea springbalanceto measurethe forceol the brush spring. Standard: 18.9-23.1N (1.89-2.31k9, 4.18-5'12 lb) BAUSHSPFING
the springif notas specified 3. Replace
Brush It a brushiswornalmostto thewearlimitor b€yond'replace all the brushes.
WEAB LIMIT
Standard:17mm(0.67 in) Minimum:I l.smm (0.453in) STANDARD
Field coll betweenthe M terto checkcontinuity 1. Usean ohmmeter if Replacetheyokeassembly minalwireandthebrushes. thereis no contnuity.
betweenthe M ter: to checkcontinuity 2. Usean ohmmeter minalwireandtheyoke.Replacetheyokeassemblyif there is continuity. theyokeassembly 3. Checkil thefieldcoilis loose.Replace if it is.
G-30
01EOG)!O73
STARTINGSYSTEI Armatur€ betweenthe comto checkcontinuity 1. Usean ohmmeter itthereisconarmature mutatorandthecore.Beplacethe tinurty.
betweenthe comto checkcontinuity 2. Usean ohmmeter ilthereisconarmature mutatorandtheshaft.ReDlacethe tinuity.
andmeasurethe runout on V-blocks, 3. Placethe armature witha dialindicator. repairit witha lathe lftherunoutis notwithinspecification, or replacethe armature. Runout:0.05mm(0.002in)
it theouteldiamele'of lhecomrru' thearmature 4. Replace tatoris almos(at or lessthanthe rnlnlmum surfaceis dirty,wipeit witha cloth;if it 5. lt thecommutator is rough,repairit witha latheor tinesandpaper' Gdndllmlt:31.4mm(1.23in)
is almostat or 6. ll thedepthof themoldbetweensegments grooves to the stanthe undercut than the minimum, less dard depth. Depth : 0.5-0.8mm (0.02-0.03 in) Minimum:0.2mm(0.008in)
G-31
CLUTCH H- 2 rNDEX.............................................,.,...... H- 3 ouTL|NE..,,,....,.,...,........,......................... H- 3 spEctFtcATtoNs.................................... H- 3 GU|DE...........,....,..... TROUBLESHOOTTNG H- 4 cLuTcH PEDAL.....................................,. H- 4 ADJUSTMENT...............................,..,.,... H- 5 REMOVAL / INSPECTION / INSTALLATION., H- 6 CLUTCHCABLE,..............................,....... H- 6 REMOVAL / INSPECTION / INSTALLATION.. H- 7 GLUTCHUNtT.....,..........-........................ H- 7 PREPARAT|ON..,.................................... H- I REMOVAL / TNSTALLATTON ...................... H-l 1 CLUTCHCOVER,........-............................ H-11 tNSPECTtON......,...................................
H-r1 cLuTcHDtsc....................,.....................
H-r1 tNSPECTrON.,.....................,.,.,,............. H-i2 RELEASE COLLAR...........................,....,.,. H-12 tNSPECTtON.......................................... H-'2 PTLOT BEAR|NG ........-.............................. 1 N S P E C T t O N . . . . . . . . . . . . . . . . . . . - . . . . . . .H. .-.1. .2. . . . . . . . . H-l2 FLYWHEEL........................-..................... H-12 rNSPECTtON................,.........................
INDEX
INDEX
TFANSAXLESERVICE, J SECTION
SEFVICE. CLUTCHSWITCH SECTIONF
'|. Clutchpedal ..... ..pageH- 4 / Adjustment Inspection / / Inspection Bemoval . .e.H . . . .5. I n s t a | | a t.i.o. .n. . . . . . . . . . . . . . . . .p. .a. g 2. Clutchcable / Removal/Inspection .... .. ...... ....pageH- 6 Installation Collar 3. Release . ..... pageH- 8 Installation...... Removal/ I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e.H. .-.1. .2. . . fork 4. Release . .-.- . .. pageH- 8 Removal/Installation...
H-2
5. Clutchcover .. pageH- 8 Installatron..... Removal/ I n s p e c t i o n . . . . . . . . . . . . . . . . . . p. .a. .g. e . .H - 1 1 6. Clutchdisc pageH- I .. .......... Installation Removal/ page H-11 .. ..---.. Inspection....................... 7. Pilotbearing pageH- 8 7 Installalion . . Removal PageH-12 lnspectron.. 8. Flwheel pageH- I Removal/Installalion .. page H-12 . .. Inspection..................
H
GUIDE OUTLINE.TROUBLESHOOTING
OUTLINE SPECIFICATIONS Enghe/Transarle Itodel
Clutchdisc
mm (in)
Diaphragm sprng 2 943 (300,660) 180(O 12514.92) 3.2(0.126) 3.0(0.118)
mm (in)
5.83 138(s.433)
N (kg, lb)
S€t load
mm tn) Oulerdameler lnnerdiameter rnm(jn) plate mm (ln) Pressure Rywheelside
B3 B5Mfi
Type Clutch pedal
Fullsvoke Helsht(Wlh carpet)
196,207 \7.72-8.15)
GUTDE TBOUBLESHOOTING Problem
Page
Poaslble Cause
Slipping
Culch disclacingwornexcessiveiy Cbbn disclacingsurfacehardened or oiled platedamaged Pr€ssure Diaphfaqm sprang damagedor weakened Insuflcient clurchpedalplay cturchpedatslicking
Faulty db€ngagoment
Excessiverunoul or damagedclulch disc Cldch discsplnesrusledoi worn
H- 8, 1t H 8 H-8 H-8 H-4 H-5 H-8
Rernoverust or repace
Diaphragm springweakened Excessiveclutch pedalplay Clulch vibraies
Clutch pedal 3licking
Clutchdisc oiled Torsionrubbersweakened Clutchdisc tacing hardenedor damagod Clutch disc lacing ivels oose Diaph€gm spring weakened Pressureplale damagedor excessiverunout Flwheel surfacehardenedor damaged loose or worn engrnemoum Pedalshan nor prop€rlylubricated
CLutch releasecoilff damaged Poorlubricalonof r€lease collarsleeve Torsonrubbercwsakened Excessivecrankshaltend play Pilorbearingworn or damaged Wornpivot pointsoi reeaselork
Tighlenor replace
H- 8, 11 H-8 H 8 H-8 H-4 H-8 H-8 H 8 H-8 H-8 H-8 H,8 Felerlo Secuons B, J
H- 8, 11 H-8 H-8 neier to Section B H- A, 12 H 8
H-3
CLUTCHPEDAL
CLUTCHPEDAL ADJUSTT'ENT clurch Pedal Height Insp€cilon lromlhe uppersurlaceof the podal 1 Measure thedistance pad to the carpet. Pedal hetght (Wlth carPet) 196-207mm (7.72-8.15 in) adjustthe pedalheight 2. lf necessary, I
Adiustment the clutchswitchconnector. 1. Disconnect 2. Loosenlocknut@ andturnclutchswitch@ untiltheheight |s Correq. 3. Tightenlocknut@. Tlohtenlnq loroue: -Nfl il-rg {i.l-t.a
m-kg, 1o-13 ft-lb)
measurethe pedalfreeplay. 4. Afteradjustment, Clutch Pedal Free PlaY lnsoection 1. Depressthe clutchpedalby handuntilclutchresistance is felt. Pedallree play: 9-l5mm (0.35-0.59 in) adiustthe pedalfreepla,. 2. lf necessary, height(fromthe uppersur3. Verifythatthe disengagement pedal to thecarpet)is correctwhenthe pedal faceof the is fullydepressed. Minimumdisengagementhelght: 85mm (3.35in) (Wlth caryet)
Adiuslmenl i.-iili t'f'"i"r"."" r"""r asshowninlhe figureThenturnthe clearance nut@ untiltherecommended @ be adjusting h^/;enthe oin andthe releaseleveris obtained. Slandardclearance:1,95-2'05mm (0.02-0.081 in)
6ye -7\\ H-4
2. Measurethe clutchPedalPlaY.
CLUTCHPEDAL REIIOVAL/ INSPECTION / INSTALLATION 1. Removein the ordershownin the ligure. 2. Inspectall pads and repair or replaceas necessary. Note . Apply lilhium bas€d greaas to the bushlng and pins b€tore installation. 3. lnsiallin the revers€order of removal. 4. After installation,verifythe clutch pedalfree play. (Referto page H-4.)
\q u'€
1.Adjustingnut 2. Clutchcable 3. Pedalpad 4. Nut 5. Lockwasher
6. Bolt 7. Bushing L Spring 10.Clutchpedal
H-5
CLUTCHCABLE
CLUTCHCABLE REIIOVAL / INSPECTION/ INSTALLATION 1. Removein the ordershownin the figur€. 2. lnspectall parts and repair or replaceas necessary. Note ; Apply firhlum based gtease lo lhe pln and lhe release leve] bslore installation' 3. lnstallin the reverseorderol removal 4. Alter installation,veritythe clutch pedal free play.(Referto page H-4.)
\-,\\
1.Adiustingnut 2. Pin 3. Clip
H-6
4. Clutchcable Inspectlor damage pageH-4 Adjustment................................
H
CLUTCHUNIT
CLUTCHUNIT PREPAFATION
ssT
49 E3010€0
49 E301061
Brake,.ing gear
enginerolation
Body 49 E301060)
49 E301062
49 SE01310A
Collal (Parlol 49 E301060)
enginerotation
49 1285071 Pu er,Jle€dle
Cente ng lool,
49 1285073 -G:
b€aring
Chuck ead ol 49 1285071)
beanng
H-7
CLUTCHUNIT REI'OVAL/ INSTALLATION Note . Dq not rcmove the pilor bealing It not necesaary, 1.Removein the ordershownin the figure,referringto RemovalNote 2. Installin the reverseorderof removal,referringto InstallationNote.
t5-r03 p.a-r0.5, 7r-761
ra-2a o
V
1.Transaxle " section J " service 2. Returnspring collar 3. Release pageH-12 Inspection................................... 4. Reamerbolt 5. Releaselever fork 6. Release 7. Clutchcover Note..... .. . ..... .. pageH- 9 Removal pageH-11 Inspection................................... pageH-11 Note.......................... Installation
H-8
8. Clutchdisc . ....pageH- 9 Note.................... Removal paSe!-1-1 lnspection................................... 1 pageH-10 Note.......................... Insiallation 9. Pilotbearing .. .... pageH- 9 Note....-............. Removal . .. .. ...pageH-1? Inspection...................... pageH-10 Note.......................... Installation 10.Flywheel paqeH- 9 Note.. ............. Removal pageH-12 Inspection................................... page H-10 Note.......................... Installaiion
CLUTCHUNIT Rgmoval Note Outch cover and disc 1. lnstallthe ssT. Caution . Put 8pacs6 betweenthe (49E30l 060)andlhecylinder block, setling dimeaion@ as shown in the figure io l3mm (0.51in). (Except83 ATX) 2. Looseneachboltoneturnat a timein a crisscross Dattern untilspringtensionis released. Thenremovetheclutchcover and disc. Pilot bearing Removethe pilotbearingwiththe SST if necessary.
Flywheel Note . After removlngthe lly'rvheel,Inspeci lor oil leakage pasl the crankshatt rear oil seal, lf ngcess€ry,replacethe oil seal. (Rete.lo Seclion B.) 1. Holdthe flywheelwiththe SST. 2. Removethe boltsin thesequenceshownin the figurein steos. 3. Removethe tlywheel.
H-9
CLUTCHUNIT lnstallationNote Flvwheel 1-hemovethe sealantlromtheilwheel bohholesin thecrank' bolts shattand fromtheflYwheel Caution . ll all the previous sealant cannot be removed flom a bolt, replace the bolt. . Do not apply sealant lf a new bolt is used. 2. Setthe flywheelontothe crankshatt 3. Apply sealantto the tlywheelboltsand installthem 4. Holdthe tlvwheelwiththeSST. 5 Tiohtenthe boltsin twoor threestepsin theordershown ti"otrt.nino to*r", -gHos'l*tn ig.a-to.s m'kg' 7l-?6 ftJb)
Pllot bearing Note . Insiall the pilol beafng flush with the tlywheel. Instailthe new bearingwitha plastichammer.
Clutch disc '1.Cleanthe clutchdiscsplinesand maindrivegearsplines grease. 2- Lightlygreasethe splineswithmolybdenum
3. Setthe clotchdiscontothe flywheelwiihthe SST.
@E@
H-l0
01EoHX{]7
CLUTCHUNIT.CLUTCHCOVER,CLUTCHDISC Clutch cgver 'l. Install the SST. 2. Alignthe dowelholeswiththe llywheeldowels. inthepattern shown. theboltsevenlyandgradually 3. Tighten Tlghteningtorque: 18-26 Nm (1.8-2.7 m-kg, l3-20 ft-lb)
CLUTCHCOVER INSPECTION Note . trlinorscoringor burningshould be removedwlth emerypaper. '1.Inspectlhe contactsurfaceof the clutchdiscfor scoring, cracks,and burning.Repairor replaceas necessary. 2. lnspectthe contactsurfaceof the clutchreleasebearing for wearandcracks. Replacethe clutchcoverif crackedor worn.
CLUTCHDISC INSPECTION Note . Use sandpaperil the trouble 15mlnor, liningsuriace for burningandoilcontamination. 1. Inspectthe theclutchdiscif it is badlyburnedor oil soaked. Replace 2. Inspectlor loosefacingrivetsand rubbers. Replacethe clutchdiscif eitheris loose. thethickness of theliningat a rivetheadon both 3. Measure sideswithverniercalipers. islessthanminimum. theclutchdiscif itsthickness ReDlace Minimumthickneaa:0.3mm(0.012in)
4. Measurethe clutchdiscrunoutwitha dialindicator. Replacetheclutchdiscif runoutis excessive. Runout:0.7nm (0.027in) max.
H-l1
RELEASECOLLAR,PILOTBEARING'FLYWHEEL
RELEASECOLLAR INSPECTION Note . The clutch Eleaae collar is a sealedbearlngand musl not be washed in solvent. Turnthe bearingwhileapplyingforcein the axialdirection It the bearinqsticksor has excessiveresislance,replaceit.
PILOTBEARING INSPECTION Turnthe bearingwhileapplyingtorcein the axialdirection replaceit resistance, lf the bearingsticksor hasexcessive
t FLYWHEEL INSPECTION Note . Minorscoringor burningshould be removedwith emery paPer. 1. Inspectthe contactsurfaceof the clutchdiscfor scorang, cracks,and burning.Flepairor replaceas necessary. the ringgearteethfo. wearanddamagell neces' 2. Inspect theflwheel. sarv.reDlace runoutwitha dialindicator'Replace 3. l'/easure lhetlvwheel is excessveif runout the flywheel Runout:0,2mm(0.008in) max,
H-12
J
MANUALTRANSAXLE tNDEX..................................................,,.. J- 2 ouTLtNE........,..........,..,....,...,.................. J- 3 J- 3 spEctFtcATroNS,...................,........,...... VtEW,.........,....,..,.............. J- 4 STRUcTUFAL powERF1OW,...........,..........,..,...,.......... J- s TROUBLESHOOTTNG GUTDE .......,.............. J- 6 J- 7 TRANSAXLE OtL,,,,.,.................,.....,.,.,..... tNSPECTtON......................-......,,,,......... J- 7 REPLACEMENT........-.....-.,.................., J- 7 J- I TRANSAXLE....,............................,........... PREPARATtON................................,..,.,.. J- 9 REMOVA1.................-...---.............,.... J-r r J-r4 DtSASSEMB1Y..................................,..... tNSPECTtON.................--..................,... J-27 ASSEM81Y..................,......,,.................. J-30 |NSTALLAT|ON ......,..,J-56 DtFFERENT|AL................,.,...,................... J-59 PREPARAT|ON.,.,....,.........,....,..,............. J-59 DISASSEMBLY / INSPECIION / ASSEI\,lBLY.. J-50 SHIFTMECHANlStrl...--...-.................,..... J-64 J-64 ovERHAU1...........,....,.,........................,
J
INOEX
INDEX
BACK.UPUGHT SWTTCH SEFIVICE,SECTIONT
NEUTRAL$AIITCH SEBVICE,SECTIONF
GFADE : API SEFVICEGI-4 VISCOSIIY:ALL SEASON D€xrend'[or M2C3ilF
aBovE-r8.c (ocD saE75W-80
cAPAclry: 2.5lllsls(2.6us qt, 2.2 lmp
2. Differential 1.Transaxle / / Insp€ction R e m o v a 1 . . . . . . . . . . . . . . . . . . . . .p. .a.g. .e.J.-.l. .1. . . . . . . Disassembly ..-.................:............. pageJ-60 Assembly D i s a s s e m b 1 y . . . . . . . . . . . . . . .p. .a. .g.e.J. -. .1. 4. . . . . . . i n s p e c l i o n . . . . . . . . . . . . . . . . . . .p . .a. .g. e .J. .- .2. 7. . . . . .3. . Shiftmechanism p a g e O v e r h a u | . . . . . . . . . . . . . . . . . . . . .p. a . .g. .eJ. .-.6. .4. . . . . . A s s e m b | y . . . . . . . . . . . . . . . . . . . . . . . . . .J. .- .3. 0 ...... p a g e oil 4. Transaxle I n s t a | I a t i o n . . . . . . . . . . . . . . . . . . . . . . . J. .-.5. .6. . . . . . . pageJ- 7 Inspection..--................................ R e p | a c e m e l t . . . . . . . . . . . . . . . .p. .a. g . .e.J. -. . .7. . . . .
J-2
J
OUTLINE
OUTLINE SPECIFICATIONS ----__ Item
____
-------
Engine
B3 85M-B Forward:Synchromesh Bev€rse:S€leclivesliding 3 454
mechanism Synchronlzation
Gearratio
2nd
1.944
3rd
1.392 1.030 0.810 3.583
5lh
4.058
gearratio Speedomeler gearnumber) (Driv€ngearnumber/Drlve
o.9112123)
Grade
Dexrono]I or M2C3&F
ol
Above -18oC (0"F)
Capaclty
liters(USqt, lmp qt)
SAE 75WAO
2.5 12.6,2.2:)
J-3
J
OUTLINE
VIEW STRUCTURAL
'lst 1. Primary gear 2. Pdmary2nd geat 3. Primary3rd g;ar a. Primaryatn gear 5. Primary5th gear
J-4
6- Primaryreversegear 7. Secondarylst gear B.Secoloary2nd gear 9. Secondary3rd gear 4th gear 10.Secondary
'11.Secondarysth gear reversegear 12.Secondary 13 FleveIse'dlergear 14 Ditferedial
J
OUTLINE POWEBFLOW
rsT
3RD
2ND
4TH
5TH
J-5
J
GUIDE TROUBLESHOOTING
GUIDE TROUBLESHOOTING Page shilt lever won't shlfi smoothly or is hatd ro shlfi Too much play in shilt lever Difficull to shltl
sllcking shiit lever ball Stcking changeconllol rod ioinl Benl change conlrol rod
J-€4 J-64 J-64
Wornchangeconlrclrod bushing Weakshiftleverballsprlng Worn shitt lever ball seat
J64 J64 J-64 J64 J64 J 7
conlrol No Oreas€n transaxle lnsuificieni oil Deteiorationof oil quality We or play ot shlft fork or shlft rod Wornsynchronizerng coneor gear Womsynchrcnizer ringandconeol gea' Bao conlacrol syrchro_i7Fr pay ol gears longiludinsl Excessive
J,21,24 J 21,24 J 21,24 J 21,24 J 21,24 J-21. 24 J-38
keysping Womsynchronlzer Excessiv€prirnaryshalt gear bearlngpreload lmpropeiyadjusledchangeguLdeplate Won't stay h gear
Benl change conlrol rod Wom change conlrol rod bushing W€ak shit lever balLspring
Tishten
Wofn clutch hub sleeve Worn slidingsudaceol gear or shait Worn steelslldinggrooveol conlroLend
J-64 J-64 J-64 J-64
J 21,24 J 1 4 J-14
Excessivethrusl clearance Loos€ engrnemounl
Deierloralion oi oil qualty Womslidingsurlaceoi gearor shafl Danrageclgearteeth Foregn materlaln gears gearor excessvebacklash DamagedditferentiaL
J-6
Tghten
J-56 J-7 J-7 J 21,24 J 21,24 J-21.24 J-21. 24 J-60
J
TRANSAXLEOIL
TRANSAXLEOIL INSPECTION Note . Park the vehicleon level ground. 1. Disconnect thespeedometer cableandremovethespeedo meterdrivengear. 2. Verifythatlhe oil levelis betweenthe F and L. drivengear. 3. Installthe speedometer Tighteninglorque: 7.8-12 Nm (0.8-t.2 m-kg, 5.8-8.7 tt-lb) cable. 4. Connectlhe speedometer
o
l-----.--
REPLACEMENT '1.Disconnect thespeedometer cableandremove thespeedometerdrivengear. 2. Removethedraanplugandwasher.Draintheoilintoa suitable container. 3. lnstalla newwasherand the drainplug. Tightenlngtorque: 24-35 N.m(2.4-3.5 m-kg, l7-26 finb)
4. Addthenecessary amountof thespecilied oilthroughthe drivengear hole. speedometer Specifiedoil Grade:API service GL-4 Viscosity:AlFseasonDexron@n or M2C33-F Above -t8"C (0"D SAE 75W-80 Capacity:2.5 liters (2.6 US qr, 2.2 lmp qt) 5. Veritvthe oil level. 6. Installthe speedometer driven gear and connectthe speedometer cable. Oil seal Replacement(On-vehicle) 1.Jack up the vehicleand supportit withsafetystands. 2. Drainthe transaxle oil. 3. Removethefrontwheel. 4. Femovelhe splashshield. the frontstabilizer lromthe lowerarm. 5. Separate
J-7
J
TRANSAXLEOIL Cautlon . Do noi damagethe dust boots. 6. Removetheclinchboltand pullthe lowerarmdownward lhe knucklelromlhe lowe.arm balljoint. to seDarate endwilhtheSST thetie-rod 7 Loosen thenutando6connect
Caution . Ilo not subiectthe tdPodlolnl to shockwhen remov' ing lhe driveshaft. by pryingwith fromthetransaxle thedriveshaft 8. Disconnect a bar insenedbetweenthe outerringandthe transaxle. witha rope 9. Suspendthe driveshaft
10.Removethe oil sealwitha screwdriver.
Note . Tap in until lhe oil seal Installercontactsthe case. . Coat the gil seal lip wilh ttanaaxleoil. casewiththeSST 11. Tapthe newoilsealintothetransaxle
endclipwitha newone-Insertthe 12.Replace thedriveshaft withthe splitol the ciip facingupward driveshaft to veritvthatit isheldfirmlyinplace. 13.Pulloutonthedriveshatt
J-8
J
TRANSAXLE
TRANSAXLE PBEPARATION
ssT
49 GO175AO
49 G017501
Suppon,englne
Bar (Parlof 49 GO175A0)
49 G017
49 G017503
Suppod 49 G017 5A0)
Hook {Pan of 49 G0175AO)
49 0107 6804
49 DO172A2A
Enginestand
sh,ms€ecro,se, B,fffiililp
_g
adiuslmenlof bearingPreload
../-t
49 G019 0A0
49 F401384
adjuslrnentof
Collar (Panof 49 DOIT2A2A)
49 G019001
49 F401385
Body (Panol 49 G0190A0)
Bar
49 G019002
49 F4013818
Siay {Parrol 49 GOrg0A0)
SelectorC6o (Padof 49 F4013814)
49 G019 003
49 G019019
F:'"Tr888 R-
49 Do172MA)
adjustrnentot bearng preload
Bolt set
49 Gor9 0A0)
49 Do172A2A)
4 9 D O 1 71 0 1
49 8001 795
J-9
J
TRANSAXLE 49 BO270024
49 FTot 361
beanngpreload (Partot 49 DO172A2A)
4 9 0 1 8 05 1 0 8
49 G030 795
beaing prcload measuing
49 G030797
49 DOIT 241 beanng
Body (Partol 49 G030 795)
49 F401331
49 G030 796
beaflng
b€aring
Body (Partol 49 D0172A1)
49 DO17201
Attachmenl (Padof 49 D0172A1)
49 0710 520
Body (Pad of 49 G030 795)
49 0839 425C
/A\ w|,
gezl
bearng
beanng
49 0A62 428 bearlngpullef (Pan oi 49 0839 425C)
49 0636 145
49 0a39 426 beaflng
(Partol 49 0839425C)
J-10
J
TRANSAXLE REMOVAL 1. Disconnect the negativebatterycable. 2. Raisethe vehicleon a vehiclehoist. 3. Drainthe transaxleoil intoa suitablecontainer. 4. Removein the ordershownln the figure,referring to RemovalNole.
{!e
CLIP,
01A0JX{02
1.Wheeland tire 2.Splashshield 3. Battery,batterycarrier 4. Speedometer cable 5.Clutchcable 6. Back-uplightswitchconnector 7. Neutralswitchconnector 8. Extension bar rod L Control
10.Driveshafts pageJ-12 Bemoval Note............................. 11. Starter 12.Enginemountingmember pageJ-12 Bemoval Note............................. 13.Exhaustpapebracket '14.Stifiner 15.Transaxle pageJ-13 Removal Note............................. 16.Engine mountNo.2
J-1 1
J
TRANSAXLE
- 1 .
Removd Note DrlvEhaft 1. Removethe balljointclinchbolt.
Caution . Wrap a rag around the ball ioint dusi boot to pro' lect h trom damage. 2. Prythe lowerarmfromthe knucklewitha pry bar.
Cautlon . Do not shock the tripod ioint when removing the dtiveshaft. by pryingwilh fromthe transaxle the driveshaft 3. Seoarate a bar insertedbetweenlhe outernng and thetransaxle. witha rope. 4. Suspendthe driveshaft
EnginemountinEmember 1. Suspendthe enginewiththe SST
theboltsandnutsshown,andremovetheenglne 2. Remove mountingmember.
J-12
TBANSAXLE
J
Tranaaxle 1. LoosentheSST(€nginesuppon)andleantheengineto ward the transaxle. 2. Supportthe transaxlewith a jack.
mountingbolts. 3. Removethe transaxle 4. Removethe transaxle.
J-l3
J
TRANSAXLE
DISASSEi'BLY Precaution beforedisassembly' solvent wilha steamcleane.or cleaning thoroughly i. 6t""n tn" ttuna""f.exterior anddry solvent, with cleaning sudaces seating a (except Oearings)and pirti s"-ateb i. - di;;; il";,.d;"J are check that there air,and andplsiageswitha compressed iitiilii,irr""llO iii Cteinouiatttrotes no obskuctions. airto cleancomponefis whenusingcompressed 3.Weareyeprotection HousingParls to DisassemblyNote' ijGo"inOt" in the ordershownin ll"eiigure'referring
BEPIACE
"-/Wr ./
F-u
\-,.,@
a'.
\ t ] af
\
xqrqk'
/(t @
\
FEPLACE
REPLACE
@
g
o BEPLACE BEPLACE
J-l4
TRANSAXLE 1.Transaxle pageJ-16 Disassembly Note....................... 2. Returnspring 3. Clutchlever 4. Clutchreleasetork 5. Clutchreleasecollar pageJ-27 fnspection.............-...................... Engine mount No.1 6. 7. Drainplug 8. Plug,spring,steelball 9. Back-uplightswitch 10.Neutralswitch drivengearassembly 11.Speedometer caseassembly 12.Transaxle '13.Retaining ring 14.Cranklevershatt 15.Crankleverassembly 16.Baseplateunit 17.Plug,spring,steelball 18.Rollpin 19.Rollpin 20.Shiftfork (3rd/4th) pageJ-27 fnspection.................................... 21.Shiftrod (3rd/4th) pageJ-16 Disassembly Note....................... (3rd/4th) 22.Shiftrod end 23.Rollpin 24.Shifllork (1sv2nd) pageJ-27 1nspection.................................... 25.Shiftrod (1st/2nd) pageJ-16 Disassembly Note.......................
J
26.Rollpin 27.Rollpin 28.Shifttork(sth/Rev) pageJ-27 1nspeciion.................................... 29.Shiftrod (sth/Rev) pageJ-16 Disassembly Note....................... pin 30. Inlerlock 31.Shiftrod end (sth/Rev) 32.Ueverseidlergear 33.Feverseidlershaft 34.Follpin J5. l.tn
36.Leversetspring 37.Reverselevershaft 38. O'ring shittlever 39. Reverse 40. Interlockpin pageJ-16 Disassembly Note....................... 4'1. Interlockpin pageJ- 16 Note....................... Disassembly 42. Primaryshaftgearassembly 43.Secondary shaftgearassembly 44.Difierentialassembly 45.Clutchhousingassembly 46.Follpin gearsleeve 47.Speedometer 48.O-rin9 49.Oil seal pageJ-16 Disassembly Note....................... 50.Drivengear 51.Magnet
J-15
J
TRANSAXLE Disaasembly Note Transaxle on the SST. Mountthe transaxle
Shlft rod WiaptheshiftroOwitha ragandturnit withplierswhilepull ing it out.
lnterlock pln Removethe interlockpinwitha magnet.
Oll seal drivengearoil sealasshowninthe iem-dvettre speeaometer figure.
J-16
J
TRANSAXLE Clulch Housingand TaansaxleCaseComponents Caution . Do not remove an oil seal lf not necessary, 1. Disassemble in the ordershownin the figure,referring to DisassemblyNote. 2. Inspectall partsand repairor replaceas necessary.
REPLACE BEPLACE
SELECNVE
AEPLACE
1. Batfleplate 2. Bleeder 3. Rollpin 4. Changearm 5. Changerod assembly 7. Oilseal(changerod) Disassembly pageJ-18 Note....................... 8. Oilseal(primaryshaft) Disassembly Note....................... pageJ-18 9. Bearingouterrace(secondary shaft) Disassembly Note.................... pageJ-18 10.Funnel Disassembly pageJ-18 Note....................... 11.Oilseal(ditferential) Disassembly pageJ-18 Note....................... 12.Bearingouterrace(differential) Disassembly pageJ-19 Note.......................
13.Oilseal '14.Bushing 15.Clutchhousing 16.Oil passage 17.Adjustment shim 18.Funnel pageJ-19 Disassembly Note....................... lO
Ra./i^^
^' d6r /r^6
pageJ-20 Disassembly Note....................... (secondary 20.Adjustment shim shaft) pageJ-20 Disassembly Note....................... 21.Bearingouterrace(ditferential) pageJ-19 Disassembly Note....................... 22.Adjustment shim 23.Oil seal(differential) pageJ-18 Note....................... Disassembly 24.Transaxle case
J*17
J
TRANSAXLE DisassemblyNote Oil seal (changerod) Caution . Do not damagethe cluich housing' Removethe oil sealwitha screwdriver.
Oil seal (dlfterential)
\r l<,
Caution . Do ngt damagethe clutch housing. Removethe oil sealwith a screwdrver'
Oil seal (p mary shafl) Cautlon . Do noi damagethe clutch housing. Removethe oil sealwitha screwdriver'
Funneland bearingouter race (secondaryshatt) Noie . Removethe bearingouter racewith a acrewdriver it neces-sary. I ) lnaerta screwdrive.betweenthe clutch housing and bearlngouter race. 2)Pry the bearlngouter race flee. Removethe bearingouterraceby liftingoutthefunneland race together.
J-l8
J
TRANSAXLE Funnel Removethe funnelwithpliers.
Bearlngouter race (differential) 1. Installthe SSTto the bearingouterrace.
2. Turnoverthe clutchhousing. 3. Removethe bearingouterracewitha su,tableprpe.
Bearingouler raaeand adiustmentshim (difierential) 1. Installthe SSTto the bearingouterrace.
.'-/l
l\).r.< ' -t,'.-,t )-P
2.Turnovertheclutchhousing. holeto re3. TaptheSSTwitha pipethroughthe driveshatt movethe bearinoouterrace.
J-19
J
TRANSAXLE Bearing outel race and adluslment shin (seqondary shalt) i. puttoutitre beaiingouterraceas shownin the figure. shim 2. Removethe adiustment
J-20
J
TRANSAXLE PrlmaryShaft Assembly referring to Preinspection. 1. Measurethe thrustclearances ot all gearsbetoredisassembly, 2. Disassemble in the ordershownin the figure,reterringto DisassemblyNote.
FEPLACE
E
FEPLACE
ring 1. Retaining ring 10.Synchronizer pageJ-22 Note....................... 2. Bearing(sth) Disassembly pageJ 27 pageJ-22 Disassembly Note....................... Inspection....-............................... I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. .g. e.J. -. .2. 8. . . . .1.1. . 3rd gear pageJ-22 Note....................... Disassembly 3. Spacer pageJ-28 Inspection.................................... 4. Steelball gear 12.Bearing 5. sth pageJ-22 pageJ-22 Note....................... Disassembly Note....................... Disassembly I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. .e.J. .2. .8. . . . . . Inspectgearteethfor damage,wear,and 13.Primaryshaft cracKs pageJ 28 Inspection.................................... 6. 4th gear pageJ-22 14.Synchronizer spring Disassembly Note....................... pageJ-28 '15.Clutchhub sleeve(3rd/4th) Inspection.................................... pageJ-27 1nspection.................................... 7. Synchronizer ring p a g e key I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . .J. -. .2. 7. . . . .16. . . Synchronizer ring 17.Clutchhub (3rd/4th) 8. Retaining 9. Clutchhub assembly(3rd/4th) pageJ-22 Disassembly Note....................... pageJ-29 Inspection....................................
J-21
J
TBANSAXLE Preinspection 3rd qear thrusl clearance between3rd qearand 2nd gear' 1 M;-asure the clearance Clearance:0.06-0.41mm (0.002-0.016 in) llaximum : 0.46mm(0.0'18in) checkthecontact the maximum, exceeds 2. lf theclearance gear, andclutchhub(3rd/4th). ofthe3rdgear,2nd surfaces Replacewornor damagedParts 4th qear thrust clearance t. MEasurethe clearancebetween4th gearand the ball bearing. Clearance:0.22-0.52mm (0.009-0.020 lr) Maxlmum:0,57mm(0.022in) checkthecontact exceedsthemaximum, 2. lf theclearance surfacesof the 4th gear, ball bearing,and clutchhub (3rd/4th).Replacewornor damagedparts Disassembly Noie Bealing (sth) 1. Placethe primaryshaflgearin a vrse Noie . Use protectfuePlatesin the iaws ot lhe vlse' 2. Removethe bearingwiththe SST.
4ih gear and 5th geat 1 lnsrallthe 4th oearwrththe SST. Cauilon . Holdthe shaftwith one handso that lt does not fall' the 4th gearand sth gearwiththe SST 2. Flemove
Clutch hub assembly(3rd/4lh),synchronizerring (3td) and 3rd gear Caution . Holdthe shaftwith one handso that it does nottall. ring. 1. Bemovethe retaining (3rd/4th)' synchronizer 2. Removethe clutchhubassembly ring(3rd)and 3rd gearwiththe SST
J-22
J
TRANSAXLE Bea ng Note . Use protectlve plalea In ihe laws ol the v|se. Removethe bearingwiththe SST.
J-23
J
TRANSAXLE
Secondary Shaft Assembly to Preinspectlon. 1. Measutethe thrustclearanceof 1st gear,2nd gear,and sth gear,relerring Note. referring to Disassembly in the figure, in the ordershown 2. Disassemble NEPLACE
N€PLACE
ring 12.Synchronizer 1. Bearinginne. race(5th) pageJ-26 Note....................... pageJ-25 Disassembly Note....................... Disassembly page J-27 1nspection.................................... Inspectfor damageand roughrotation (1sv2nd) 13.Clutchhub assembly ring 2. Retaining pageJ-26 Note....................... Disassembly 3. Washer page J 29 (5th) Inspection.......-............................ 4. Clutchhub assembly ring page 14. Synchronizer ....... J-26 Note................ Disassembly pageJ-26 I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e .J. .-.2. .9. . . - . . Disassemb|y................................ pageJ-27 1nspection.................................... ring 5. Synchronizer gear p a g e 15. 2nd J 2 7 fn s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pageJ-29 Inspection.....................-.............. 6. sth gear spring I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p . .a. .g. e .J. . .2. 9. . . . .16. . . Synchronizer 17.Clutchhub sleeve(sth) ring 7. Retaining pa]e J 27 Inspection.................................. 8. Bearinginnerrace(1st) key pageJ-26 18.Synchronizer Note....................... Disassembly 19.Clutchhub (sth) lnspectfor damageand roughrotatpn spring 20.Synchronizer L Piniongear (1st/2nd) page hub sleeve 21. Clutch Note.......................J-26 Disassembly pageJ-27 f nspection....::............................... gear for wear, and teeth damage, Inspect key 22. Synchronizer cracks 23.Clutchhub (1sv2nd) 10.1stgear shaft pageJ-26 24.Secondary Note....................... Disassembly I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a . .g. .e.J. .2. .9. . . . . . I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e .J. .-.2. .9. . . . . . ring 11.Retaining
J-24
J
TRANSAXLE
Prelnspectlon lsi gear thrust clearance 1. Measurethe clearancebetween1stgearand the pinion gear. Clearance:0.22-0.62mm (0.008-0.024 In) Itaximum: 0.67mm(0.026in) 2. lf theclearance exceedsthemaximum, checkthecontact surfaces olthe lstgear,piniongearofthesecondary shaft gear,andclutchhubassembly (1sv2nd). Replace wornor damagedparts. 2nd gear lhrusi clearance 1. Measure theclearance between2nd gearandsecondary 3rd gear. Clearance:0.06-0.2lmm (0.002-0.008 in) Maximum:0.26mm(0.010in) 2. lf theclearance exceedsthemaximum, checkthecontact surtaces ol the2nd gear,secondary 3rd gear,andclutch (1sy2nd). hubassembly Replace wornor damagedparls. slh gear lhru9t clearance 1. Measure the clearance betweensth gearand secondary 4th gear. Clearance:0.06-0.2lmm (0,002-0.008 in) Maximum:0.26mm(0.010in) 2. lf theclearance exceeds themaximum, checkthecontact surfacesof the sth gear,secondary 4th gear,and clutch (sth).Replacewornor damagedparts. hub assembly Disassembly Note Bearinginner race (5th) Caution . Holdthe shaftwith one handso that it doesnot tall. 1. Setthe SST to the sth gear.
2. Removethe bearingouterracewitha suitablepipe. Pipe diameter:20mm(0.79 in)
J-25
J
TRANSAXLE Clutch hub assembly (sth) Nole . Removethe clulch hub assembly(sth) as lollows ll necessary. 1-lnstallthe SST as shownin the figure. (sth)usinga press 2. Removethe clutchhub assembly
Bearlnginner race (lsl), pinion gear' l3l gear Caullon . Hold the shaft with one hand so that lt does not tall. '1. Setthe SST to the 1stgear'
2. Removethe b€aringinnerracewitha suiiablepipe Plpe diameter:20mm(0'79 in)
Clutch hub assembly(lsu2nd), synchronizerring Note . Removethe cluich hub assembly(15u2nd)as tollows if necessary. 1.lnstallthe SST as shownin the figure (1s 2nd)usinga press the clutchhubassembly 2. Remove
J-26
J
TBANSAXLE INSPECTION Inspectall partsand repairor replaceas necessary.
Clutch releasecollar Inspecttheclutchrelease collarfor roughness or noisewhile turning.
Synchronizerring Note . Setthe synchronizerring squarelyin lhe geanthen measurearoundthe clrcumlerence, 1. l\,leasurethe ringand clearance between thesynchronizer lianksurfaceof the gear. Standardclearance:1.5mm(0.059in) Minimum:0.8mm(0.015In) 2. Inspectthe ringteethfor damage,wear,and synchronizer cracks. 3. lnsoectthe taoersurfacefor wearor cracks.
Shift tork, clulch hub sleeve 1. Measurethe clearance betweenthe shiftfork andclutch hub sleevegroove. Standardclealance (1st/2nd):0.100-0,358mm(0.004-0.014 in) (3rd/4th): 0.150-0.458mm(0.006-0.018 in) (5th) : 0.150-0.458mm(0.006-0.018 In) Maximum(1st/2nd):0.408mm(0.0i6 in) (3rd/4th):0.508mm(0.020in) (sth) :0.508mm (0.020In)
J-27
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TRANSAXLE Pdmary Shatl 3FD GEAB
Note . ll the prlmary shaft is replaced, adiust the bearing pretoad.(Relerio PageJ-39.) 1. Inspectthe primaryshaftrunout Maximumrunout: 0.0lsmm (0.0005in) 2. Inspectthe splinestor damageand wear. 3. Insbectthe gearteethfor damage'wear,and cracks 4. Inspectthe oil passagefor blockage.
3rd gear, 4th gear '1.l\,leasure the clearancebetweenthe shaftand gears
mm(.n)
B
A
3rd gearsideA 4th geff side B
Shaftsrde (outerdiameleo 32.945-32.970 (1.297- 1.298) 2A.545-28.570 0 .123-1.125)
Ge side (innerdiamelet 33.000-33.025 (1.299-1.30O) [email protected] l1.126-1.127)
coneslor weat. 2. Inspectthe synchronizer gear for damage,wear'andcracKs. teeth 3. Inspectthe ringand of the synchronizer Contact surfaces Insbect the 4. the 3rd/4thgearfor wearand cracks
Bearing Insoectthe bearingior damageor roughrotation.
J-28
0rFoJx063
J
TRANSAXLE SeaondaryShafl
Nole . ll the secondaryshatt is replaced, adiust the bearing preload.(Reterio pageJ-39.) 1. Inspectthe secondary shaftrunout. Maximumrunout: 0.015mm(0.001in) 2. Inspectthe splinesfor damageand wear. 3. Inspectthe gearteethfor damage,wear,and cracks. 4. Inspectthe oil passagefor blockage.
1st gear, 2nd gear, sth geal betweenthe shaftand the qear. 1. Measurethe clearance mm (in)
2nd gearsideB
39.945-39.970 (1.573-1 .574)
Gearside (nnerdiameter) 33.000-33.025 (1.299-1 .30O) 40.000-40.025 (1.575-1.576)
sth seff side C
28.545 28.570 11.124- t .125J
24.604-24.62-l lt.126-1.127)
Shaltside (olter diameled 32.945-32.970 11.297-1 .294)
2. Inspectthe synchronizer conesfor wear. 3- Inspectthe gearteethfor damage,wear,and cracks. ol the synchronizer ringand 4. Inspectthe contactsurfaces the l st/2ndand sth oearfor wearand cracks.
Clutch hub aaaembly 1. Inspectthe clutchhubsleeveand hub operation. 2. Inspectthe gearteethfor damage,wear,and cracks. keyfor damage,wear,andcracks. 3. Inspeclthe synchronizer
J-29
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TRANSAXLE
ASSEIIIBLY Precaution i. lil-O;i;a. and gasketsmustbe replacedwiththe newonesincludedin the overhaulkit' cleanbeforeassembly 2. Veritythatall pansare completely "3. Assehbboanswithin10 minutesafterapplyingsealant wnhoil' be{oretillingthe lransaxle at leastgo minuiesaftErassembrv "A;;ti;cure ;ffi;il assemDly an replaced as be race musl inner 4. A bearingouterraceand bearing
olEoJx.o6s
Clutch hub assembly Note . Synchlonizerring diametelsare as follows.
mm (ln,
--_=_-
@ 1st
55.7(2.r93)
?nd 3rd and 4lh 5th
55.7 {2.193)
49.7(r.954 4 3 . 7\ 1 7 2 O )
. Synchronizerkey dlmensionsare as tollows.
o 1sv2nd
17.00(0.669)
3tdl4th
14.00(0.551) 1 4 . 0 0( 0 . 5 5 1 )
@ 4 25 (0.r67) 4.25(0.164
4 25\0.16n
5.00(0.r 97) 5.00(0.197) 5.00(0194
keyspringsin theclutchhubwith 1. lnstallthe svnchronizer keys grooves to holdthethreesynchronizer thehooksinthe In p|ace.
SYNCHRONBEB RING
KEY SYNCHRONIZEF
J-30
ringgrooveswiththesynchronlzer 2. Alignthe synchronizer key duringassembly.
J
TRANSAXLE secondaryShaft Assembly Assemble in the ordershownin the figure,reierringto AssemblyNote.
BEAFINQINNEFRACE,
YI
@
RETAINING FIING,NEW
'1-Secondary shaft 2. Clutchhub (1sv2nd) key 3- Synchronizer 4. Clutchhub sleeve 5. Synchronizer keyspring 6. Clutchhub 7. Synchronizer key 8. Clutchhub sleeve(5th) key spring 9. Synchronizer 10.2ndgear pageJ-32 Note............................ Assembly 11.Synchronizer ring pageJ-32 Assembly Note............................ (1sl2nd) hub 12.Clutch assembly pageJ-32 Assembly Note............................ 13.Synchronizer ring pageJ-32 Assembly Note............................
@E
AEAFINGINNER
ring 14.Relaining 15.1stgear pageJ-32 Note............................ Assembly gear 16.Pinion pageJ-32 Note............................ Assembly 17.Bearinginnerrace(1st) ..... pageJ-32 Assembly Note............... ring 18.Retaining pageJ-33 Note............................ Assembly 19.5thgear ring 20.Synchronizer (sth) 21.Clutchhub assembly -..- pageJ-33 Assembly Note........................ 22.Washer 23.Retaining ring 24.Bearinginnerrace(sth) pageJ-33 Note............................ Assembly
J-31
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TRANSAXLE Assembly note 2nd gear, synchronlzerrino shaftas shown the2nd gearto the secondary 1.Asaemble in thefigure. ring. the synchronizer 2. Assemble
I
& Y
Clutch hub as€embly(lsu2nd), synchronizerfng shaft to thesecondary 1.Assemble theclutchhubassembly as shownin the{igure. ring. the synchronizer 2. Assemble Caution .lnstall the clutch hub assembly(lsi/2nd) wlth a presa It necessary. . Align the synchlonizerdrg gloove and leverse gear key groove when installing. 1st gear shaftasshowninthe Assemble the 1stgearto thesecondary figure. Caulion . Alignthe synchronizerring grooveand clutch hub assemblykey when Installing.
Piniongear, bearinginner race (lst) Caution . Replacethe bearing inner race lf removed. shatt. 1.Supportthe 4th gearof the secondary pinion gear with the bonomup. end ol Inslall the 2. olain
3. SetlheSSTto thenewbearinginnerraceasshowninthe fagure.
J-32
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TRANSAXLE Rstainingrlng Cautlon . Roplacethe retalning ng ll removed.
1. Installthe retainingring. 2. Measurethe clearancebetweenthe retaininoring and secondary shaftgroove. Clearance:0-0.1mm (0-0.004 in) 3. ll notasspecilied, selecttheproperretaining ringfromthe chartbelowand installit. Retainingring thickness:
mm (in) 2.0 (0.079)| 2.1 {0.082)| 2.2 (0.086)| 2.3(O.O9O) | 24 (0.094)
Clutch hub assembly(5th) Installthe clutchhub assembly ontothe secondary shaft. Note . Installthe clutch hub assembly(sth) wilh a press it necessary.
Bearlng Inner race (5th) Cautlon . Replace the bearlng Inner race it removed. 1.Supportthe lst gearof thesecondary shaftandpressthe bearinginnerraceon. 2. Installthe newbearinginnerraceusingtheSSTandpress, as shownin the figure.
3. lvleasure the clearancebetween1stgearandthe pinion gear. in) Clearance:0.22-0.62mm (0.008---{t.024 Maximum:0.57mm(0.025in)
J-33
TBANSAXLE between2nd gearandtheseconthe clearance 4. Measure dary3rd gear. Clearance:0.06---0.2lmm(0.002-0.008 In) Itaxlmum: 0.26mm(0.010in)
betweensth gearandthe secon' the clearance 5. Measure dary4th gear. Clearance:0.06-0.21mm (0.002-0.008 in) Itaxlmum: 0.26mm(0.010In)
J-34
TRANSAXLE
J
PrlmaryShaft Assembly As.semble in the ordershownin the figure,referringto AasemblyNote.
RETAINING FIN6, NEW
1.Clutchhub (3rd/4th) 2. Synchronizer key 3. Clutchhub sleeve 4. Synchronizer keyspring 5. Primaryshaft 6. Bearing('1st) pageJ-36 Assembly Note............................ 7. 3rd gear 8. Synchronizer ring (3rd/4th) 9. Clutchhub assembly pageJ-36 Assembly Note............................ 10.Retaining ring 11.Synchronizer ring pageJ-36 Assembly Nole............................
12.4th gear pageJ-36 Assembly Note............................ 13.sth gear pageJ-36 Assembly Note............................ '14.Sleelball pageJ-37 Assembly Note............................ 15.Spacer pageJ-37 Assembly Note............................ 16.Bearing(sth) pageJ-37 Assembly Note............................ Retaining ring 17. pageJ-37 Assembly Note............................
J-35
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TRANSAXLE Asssmblytlote Bearing(lst) wth a Press Install thebearing
---
t-
Clutch hub assembly(3rd/4th) ontothe primaryshaft i. Fressthe clutchhu6 assembly
il!,1\ OILGFOOVE
Caution . lliqn the svnchronlzerring grooveand clutch hub assiemblylieys (3rd,/4th)when Installing' 2. Alignhe clutchhubandshaltgearsplineandtheninstalling'
*re@69
Synchronizerring, 4th gear nng and clutchhub assembly 1. Installthe synchronEer (3rd/4th). 2. Installthe 4th gear.
5th gear Caution . ltion tne svnctrronizelring grooveand clutch hub ass;embly*eys (3rd/4th)whsn installlng' '1.Alignthe clutchhub and primaryshaftsplines' 2. Pressthe sth gearon
J-36
TRANSAXLE
J
Steel ball, spacer Holdthe steelballwitha finger,and installthe spacer.
Bearing(sth) C€ution . Replacethe ball bearingif removed, Installthe ballbearingwiththe SST and a press.
Retainingring Caution . Replacethe relainingring it removed, 1. lnstallthe retaining ring. 2. Measure theclearance betweenretaining ringandtheprimaryshatt. Clearance:0-0.1mm (0-0,004 in) 3. lf notasspecified, ringfromthe selecttheproperretaining chartbelowand installit. Fetainingring
mm (in)
2.0 (0.079)I 2 r (0082 | 22 (0.086)| 2.3 (0.090)| 2.! (0094)
Note . Thelollowing Inspectlonis to verity properassem. bly ol lhe primaryshatt. . ileasure the clearancebetweenthe 3rd gear and 2nd geal. (Reterto page J-22.) . Measurethe clearancebetweenthe 4th gear and ball bearing.(Referto page J-22.)
J-37
J
TRANSAXLE
Clutch Housinqand Tlansaxle CaseComponents lo BearlngPreloadAdiustmenl shim(s).reterrrng L selectthe adiusiment to AssemblyNote in ihe ordershownin the frgule reterring 2. Assemble
case 1-Transaxle shrm 2. Adjustment . .5. A s s e m bN l yo i e . . . . . . . . . . . . . . . . .p. .a. .g. e.J. .' 4 3. Bearingouterrace(differential) - .e.J. .4. .5. A s s e m bN l yo t e . . . . . . . . . . . . . . . . .p. .a. g 4. Oil seal(difierential) pageJ-45 -....... Note.................... Assembly shim 5. Adjustment pageJ 45 Assembly Note............................ (secondary shaft) outer race 6. Bearing pageJ-45 Note............................ Assembly / FUnnel
pageJ-46 ............. AssemblyNote............... 8. Adjustmenishrm . AssemblyNote.........................-.. page J-46 9. Oil passage 10.Clutchhousing 11.Bushang 12.Oil seal
J-38
13.Bearingouterrace(dilterential) pageJ-46 Note............................ Assembly (ditferential) 14.Oil seal pageJ-46 Note......................... Assembly 15.Funnel pageJ-47 Note............................ Assembly shatt) 16.Bearingouterrace(secondary pageJ-47 Note............................ Assembly '17.Oil seal(primaryshaft) . ....pageJ-47 Note..................... Assembly (change rod) 18.Oil seal pageJ-47 Note.............-.............. Assembly 19.Boot -. pageJ-47 Note.......................... Assembly 20.Changerod arm 21.Change 22.Rollpin pageJ-48 Note............................ Assembly 23.Bleeder 24.Batfleplate
J
TRANSAXLE Adiustmenishim selection Selectthe shim(s)as follows.
Primaryshaft assembly 1. Setthe primaryshaftassemblyintothe clutchhousing. 2. Installthe transaxle caseto theclutchhousingandtighten the boltsio the soecified torque. Tighteningtorque; 19-26 N.m(1.9-2.6 m-kg, 14-19 ftlb) hanoerandmeas' 3. l\4ount a dialindicalorto the transaxle urethe primaryshatlthrustclearance. Clearance:0-0.lmm (0-0.004 In) Caution . Do nol use more than three (3) shims. 4. Selectthecloseslshimon thethinsidefromthetabletor of the primaryshatt. adiustment Adiustmenlshim thickness: 0 30 (0.012)
I
0 40 (0.016)
|
0 50 100r9)
Secondaryshalt assembly Caution . Do nol install lhe secondaryshafl shim. . Applypetroleumielly to preventthe shimllom falling when installinEii. 1- Removethe transaxle caseand installthe properadjust' mentshimfor the orimarvshafi.
2. lnstalltheprimaryshaftgearassembly andthesecondary shaftgearassembly. Do not installthe secondaryshaftshlmat thistime. 3. Shiflthe gearsto 4th gear.
J-39
J
TRANSAXLE caseto theclutchhousingandtighten 4. lnstallthetransaxle torque to the specified the bohs Tiohteninqiorque:
d.F
ig-zs-Hm {i.s-z.s m-rs,14-19tt'lb)
\ic
thestad5. SettheSSTontotheprimaryshaftandmeasure wrench torque with a ing torque Sta inq torque: o-ra7 N.m(o-15 m-kg, o-1oB fi-lb)
I
rA \
caseand the bearingouterrace' 6. Removethe transaxle andthebear' duringdisassembly removed shim 7. lnstallthe race. ino outer
6 ,1-
Caution . Verifvthal the primaryshatt canbe turnedby hand atteriightenina lhe transaxlecase bolts' the startingtorquewitha torque 8. Usinothe SST measure wren;handselectthe propershimif thestadingtorqueis greaterthanin SteP4. Caulion . oo not use mote than two (2) shims. Adlustmentshim lhickness: 0.30(0.011) 0.50(0.020)
J-40
0.35(0.013) 0.55(0.021)
0.40(0.016) 0.60 {0.023)
mm (in) 0.45(0.0r8)
TRANSAXLE
J
Dltterenllal '1.Removethe bearingouterracestromthe transaxle case and removethe adjustment shims.
Note . Turn A and B untilthe gap (anow)in lhe tigu.e is eliminated, 2. Installthe differential sidebearingouterraceto the SST (selector).
3. Setthe bearingouterraceanddiiferential assemblyintothe clutchhousino.
4. Setthe bearingouterraceandSSTontothe differentialassemblyas shownin the fagure.
5. Slidethe transaxle caseoverthe ditferential assemblv
J-41
J
TRANSAXLE 6. SettheSST(collals) betweenthetransaxlecaseandclutch shownin the figure. housingin the positions
torque 7. Tightenthe SST (bolt set) io the specjfied Tiqhtenlnqtorque: ls-ze-Nm (i.9-2.6 m-kg,14-19 fi'lb)
Note . Turn the bars until the SST (seleclor)no longer iurns, andturn 8. Mountthebarson parts@ and@ oftheselector, the selsctorso the gap is widened. 9. Turnin the reversedirectionuntilthe gap is eliminated.
pinionshaftthroughthe 10.Installthe SSTto the difterential transaxlecase.
01EoJX,115
J-42
J
TRANSAXLE @t@
Note . Procedurework with a pull scale. . Procedure12 work wilh a torque wnench. 11.Turnthe SSTwitha pullscale.Adjusithe SST(preload adapter)untilthe specifiedpreload.
@
Preload:0.5--0.7 N.m(5-7.6 cm-kg, 4.3-6.6 inlb) Puffscafe:500-760 g (17.7-26.8 ozl
12.TurntheSSTwithatorquewrench. AdjusttheSST(seleclor) withthe barsuntilthe specifiedpreloadis obtained. Preload:0.5-0.7 N.m(5-7.6 cm-kg, 4.3-6.6 In-lb) 13.BemovetheSST.
14.Measurethegap aroundthe entirecircumference of the SST (seleqtor). 15.Selectthe properadjustment shim(s)to be usedfor the ditferential by referring to thetableand selecting theshim (onthethickside)to thelargestmeasured whichis nearest in the selector. clearance Adiustmentshim lhickness: 0.10(0.004) 0.35(0.014)
0-25(0.010) 0.80(0.031)
16.RemovetheSST (bolts). 17.Removethetransaxle caseandthe SST (collars). '18. RemovethebearingouterracefromtheSST(selector).
't9 Installthe selectedshim(s)and bearingouterraceto the case. transaxle
J-43
J
TRANSAXLE 20. Measurethe preloadasfollows.Setthe differentialassembly intothe clutchhousing.
01E0JX-121
21. lnstallthe kansaxlecaseontothe clutchhousing Tlght€ningtorque: t9-26 N.m(1.9-2.6 m-kg, 14-19 ft-lb)
sidegearthroughthetrans22. InstalltheSSTto thedifferential axle case.
Note . Procadurc 23 work wilh a pull scale' . Prccedure24 work with a iorque wrsnch. 23.Turnthe SST (preloadanachmet ) witha pullscale Readjustthe SST (prsload adaptor) until the specified preloadwhennotapply. Preload:0,5-0.7 Nm (5-7.6 cm-kg, 4'3-6.6 innb) Pull scale: 500-760 g (17.7-26'8 oz)
!:1 t/
@
J-44
24.Turnthe SST witha torquewrench. Readjustlhe SST (Preload adaptor) until the specified preloadwhen not aPPlY. Pleload:0.5-0.7 l,l'rn(5-7.6 cm-kg, 4.3-6'6 in'lb) 25.Removethe SST. 26. Removethe transaxlecase and then the ditferentialassemory.
TRANSAXLE
J
Assembly Noie Adiustmer shlm and bearing outer racc (dltferential) shimand newbearingouterraceinto 1. Setthe adjustment the lransaxlecase.
2. Aftermountingthe clutchhousingontolhetransaxle hanger, tap in the diffe.entialbearingouter raceswith a hammer untilit is llushwiththe end of thetransaxle case. Pipe diametsr:59mm(2,32 ln)
Oll seal (ditterential) Caution . Apply transaxleoil to the outet circumfercnceol the oil seal, lnstallthe newoil sealwiththe SST.
\
Adiustment shim, bearlng ouier race (secondaryshaft) shimandbearingouterraceintothe 1. Installthe adjustment clutchhousing.
2. Aftermounting theclutchhousingontothetransaxle hanger, tap in the difterentialbearingouterraceswith a hammeruntilit is flushwiththe end ol the clutchhousinq. Plpe dlametel:47mm(1.85 in)
J-45
J
TRANSAXLE Adlustmentshim and tunnel (Primaryshaft) 1. lnstailthe tunnelintothe transaxecase Pipe diameter:40mm (1.57 in)
shim(s). 2. Installthe adjustment
Oll seal (ditlerential)
-4
r-J
Caution . Apply transaxleoil to lhe outer clrcumGl€nce of the oll seal.
lr_:
lnstallthe newoil sealwiththe SST.
Bearlng outer race (differential) 1. Instaithe bearingouterraceintothe clutchhousing-
--\R $,\o,-
hang' theclutchhousingontothetransaxle 2. Aftermounting with a hambearingouterraces er, tap in the differential housing clutch meruntilit is flushwiththe end of the
\m# 4PY \
J-46
Pipe diameter:59mm(2.32 in)
J
TRANSAXLE Funneland bea.ing outer race (secondaryshafl) Note . lnstall the tunnel which has the extra hole.
1.Setthefunneland bearing outerraceintotheclutchhousing. pipeuntilitisful 2. Tapthebearingouterracewitha suitable ly seatedin the clutchhousing. Plpe diameter:50mm ('1,97in)
Oil seal (primaryshalt gear) Caution . Apply transaxleoil to lhe outer qircutnlerencaol lhe oil seal. lnstallthe newoil sealwitha suitablepipe. Pipe diameter:38mm(1.50 in)
Oil seal (changerod) Cautlon . Apply transaxleoil to ihe outer circumferenceol the oil seal. Tapthe newoil sealin untilit is lullyseated.
e\\r \ \
u
<-,2
.\--
l\ t -
-J,,-
Change rod and boot 1. lnsEllthe changerod and bootintothetransaxle. 2. Fitthe bootoverthe seal. Cautlon . lnstall the boot wlth the air bleed downwardas shown in the ligure.
J-47
,J
TRANSAXLE Roll pln lnsialithe new rollpin as shownin the tigure.
J-48
TRANSAXLE
J
i,EMO
J-49
J
TRANSAXLE
HousingParts to AsaemblyNote ljsemo-tein theordershownin theiigurereferring
r20-29 (2.oJ,0,1s-22)
t i
(3.6-5.3,
q (2.0-3.0,
fl e-^ q02.-r5
{\\
(2..--3.€r
\
@
NEW
J-50
17__61
TRANSAXLE 1.Clutchhousingassembly 2. Differentialassembly 3. Primaryshaftgearassembly pageJ-52 Note............................ Assembly shaftgearassembly 4. Secondary A s s e m bN l yo t e . . . . . . . . . . . . . . . . .p. a . .g. .eJ. .-.5. .2. 5. Reverseshittlever pageJ 52 Note.......... Assembly 6. Oring 7. Reverselevershalt pageJ 52 Assembly Note.......... tJ Htn
9. Rollpin 10.Reverseidlershaff '11.Reverseidlergear pageJ-52 Assembly Note............................ 12.Leverset sprrng 13.Shiftfork(1sv2nd) pageJ-52 -...................... Assembly Note..... (1st/2nd) rod 14.Shift pageJ-52 Assembly Note............................ 15.Bollpin Note.......... Assembly PageJ-52 pin 16.interlock pageJ-52 Assembly Note.......... 17.Shiftfork (sth/Rev) pageJ 53 Assembly Note.......... (sth/Rev) 18.Shiftrod end Note.......... Assembly PageJ-53 pin 19.Interlock pageJ-53 Assembly Note.......... 20.Shiftrod (sth/Rev) pageJ-53 Assembly Note.......... 21.Follpin pageJ 53 Assembly Note.......... 22.Rollpin pageJ-53 Note.......... Assembly pin 23.lnterlock pageJ-53 Note.......... Assembly 24.Shittfork (3rdi4th) Note.......... Assembly PageJ-53
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25.Shitirod end (3rd/41h) pageJ 53 Assembly Note............................ 26.Shiftrod (3rd/4th) pageJ 53 Assembly Note............................ 27.Rollpin pageJ-53 Assembly Note............................ pin 28.Roll pageJ-53 Assembly Note............................ 29.Plug,spring(3rd/4th), steelball 30.Baseplateunit 31.Crankleverassembly 32.Cranklevershaft 33. Retalning ring pageJ-54 Assembly Note............................ 34. N4agnet 35.Transaxle caseassembly pageJ-54 Assembly Note............................ 36-EnginemountNo.1 37. Plug,spring('lsv2nd,sth/Bev),steelball pageJ-54 Assembly Note............................ 38.Drainplug 39.Back-uplightswitch 40. Neutraiswitch 41.Oilseal pageJ 55 Note............................ Assembly gear sleeve 42.Speedometer 43.OJing 44.Drivengear 45.Rollpin pageJ-55 Assembly Note.......... .................. 46.Speedometer drivengear assembly 47.Clutchreleasecollar pageJ-55 Assembly Note............................ 48.Clutchreleasetork pageJ-55 Note.......... .................. Assembly 49.Clutchlever pageJ-55 Assembly Note............................ 50.Returnspring 51.Transaxle
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TRANSAXLE Assembly Note Primary ahalt gear assembly and secondary shatt gear assembly shaft andthesecondary Inslallthebdmaryshattgearassembly gearassembly together.
Reverse shift lever, reverse lever shalt oil to the newO-ringandtheninslallthe 1. Applytransaxle reverselevershalt. reverselereverseshiftleverandtheninstallthe 2. Installthe ver shaft. 3. Inslallthe newpin.
Reverse idler gaar Installthe reverseidlergearand the reverseidlershalt.
Shift rod (l sU2nd),shift fork (l su2nd), roll pin, interlock pin Caution . The mark 0ndicated by the atrow in the llgure) and theshin rod end mountlngbolt hole must be in the aamedirection. 'l. ,nstallthe shittiork and the shiftrod. Caution . WhenInstallingthe roll pin, be caretulnot to dam' age the shlft rod. 2. Installthe newrollpin. 3. Installthe interlockpin.
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TRANSAXLE Shift rod (slvRev), shitt fork (sth/Rev), shltt rod end (5th/Fev),roll pin, inte ock pin
Caution . lnstalllhe intedockpln into the holeof clutchhousing as shown in the flgure. shiflrod. 1. lnstallthe interlock Dintotheshiftrodandinstallthe Cautlon . Wheninstallinglhe roll pin, becaretul not to damage the shift rod. Note Shifl lork {sth/Rev) Shifl rod end (slh/Rev)
Diameter
Length
s.0(0.20) s.0(0.20)
22l9.8n 20 (0.79)
2. Installthe new rollpin.
3. lnstallthe interlockpin.
Shift rod (3rd/4th), shift lork (3rd/4th), shift rod end (3rd/4th),roll pin Caution . Installthe interlockpin inlo the holeot clutchhou& ing as shown in lhe llgure. pintofte shiftrodandinstallthe shiftrod. 1. Installthe interlock
Caution . WhenInstallinglhe roll pin, be caletul not to damage the shift rod. 2. Installthe new rollpin.
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TRANSAXLE Retainingring 1. lnstallthe crankleverand installthe cranklevershaft. Caution . Verify the in3tallinga retalningring 6urely. . lnstal the groove of crank lever shalt to the diftereF tlal end. 2. Installthe newretainingring.
3. Shiftthe gearsto 3rd gearand holdthe shiftrod withone handso thatit doesnol fall.
Transaxlecase assembly Note . Tightenlhe bolts to the specifiedtorque. 1. Applysealantand installthe lransaxlecase.
ENGINEMOUNT No.l
Caution . When installingthe transaxlecase,install the englnemountNo.l. caseto the clutchhousing. 2. lnstallthe transaxle Tlghteningtorque: i9-26 N.m(1.9-2.6 m-kg, 14-19 ft-lb) Plug, spring, steel ball '1. Applysealantto the Plugs. 2. Installthe geel balls,springsand plugs torque: Tiqhtenlnq -20-2tN.m i2.O-3.0 m-kg, 14-22 ftlb) sp ng @
o
Oiametermm {in) Lensh mm (n) 22.5 (0.89) 7.2 lO.2A) 33.2(r.31) 7.2 10.28) 22.5(0.89) 7.2 /{0.28)
whenshitted. smoothly operates thatthetransaxle 3. Contirm the transaxle. If not,reassembly
J-54
TRANSAXLE
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Oil seal gearsleevein a vice. 1. Placethe speodometer gearsleeveus2. Tap the newoil sealintothe speedometer pipe. ing a suitable Pipe diameter:15mm{0,59 in)
Folt pln Installthe newrollpin as shownin the figure.
1-
Clulch releasefork, clutch releaaecolol Applygreaseas shownin the figure.
"=
Clutch lever 1. Applygreaseto the bushing. fork. 2. lnstallthe clutchleverto the clutchrelease Tighteningtorque: 35-41 Nm (3.6-4.2 m-kg, 26-30 fi-lb)
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TRANSAXLE
INSTALLATION 1. Raisethe vehicleand supportwithsaletystands 2. Installin the ordershownin the lighre.reflerringto InstallationNole 3. Ado the specitiedamountol the specitiedlransaxleojl (Referto pageJ-7 ) a. Warmup ihe engineand transaxle,and inspectfor oil leakageand trasaxleoperation
3r --45 (4.2-4,7, 23--.34)
€!t
huz 32-56 (3.4-s.7,
6a--a,---:6
J-56
&-trif"l',.'-."
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TRANSAXLE 1. EnginemountNo.2 2. Iransaxle pageJ-57 Note........ lnstallation 3. Stittner 4. Exhaustpipe bracket 5. Enginemountmember pageJ-57 installationNote........ 6. Staner 7. Driveshatt pageJ-58 Installation Note.......................... 8. Controlrod pageJ-58 lnstallation Note..........................
bar 9. Extension pageJ-58 lnstallation Note.......................... 10.Neutralswitchconnector 11.Back-uplightswitchconnector '12.Clutchcable pageJ-58 lnstallatlon Note.......................... 11
qno6.l^mal6r
^.h16
pageJ-58 lnstallation Note.......................... 14. Battery,batterycarrier 15.Splashshied 16.Wheeland trre
Installation Note Transaxle on a jackand lift it intoplace. 1. Setthe transaxle
2. lnstalllhe transaxlebolts.
@rj&{r@
Tighteninglorque A: 64-89 N.m(6.5-9.1 m-kg, 47-66 ft-lb) Bt 7.3-11 N.m(0.8-l.l n-kg, 5.8-8.0 ft-lb)
Enginemount member 1. Installthe boltsand nutsas shown. Tightenlngtorque @: 64-89 N.m(6.5-9.1 m-kg,47-66 ft-lb) @: 37-52 N.m(3.8-5.3 m-kg,28-38 ft-lb) Caution . BetoF installthe enginemountmember,pul engine mount No.1and No.2studs in the installlnghole. 2. Removethe SST (Eqine support).
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TRANSAXLE Ddveshaft
f\rt")
Cautlon . Verlty that the oil seal is not damaged. . Do not damagethe oil seal. '1. Insertthe newclipwiththeend-gapat thetop otthegroove 2. Apply transaxleoil aroundthe oil seal lip lnstallthe driveshaft. is correctlyseatedby pullingon 3. Veritythatthedriveshaft the shaft. 4. Connect thelowerarmto theknuckleandtightentheclinch bolt.
<\ *
Tighteningtorque: 43-54 N.m(4.4-5.5 m-kg, 32-40 tt-lb)
Extenslon bar and conlrol rod barto the transaxle. 1. lnstallthe extension Tightenin9torque: 31-46 Nfl (3.2-4.7 m-kg, 23-34 fr'b) 2. Installthe changecontrolrod to the transaxle. Tighteningtorque: 16-23 N.m(1.6-2.3 m-kg, l2-17 ft'lb) Clulch cable Installthe clutchcable.(Referto SectionH.)
Speedometercable amountoi the specifiedkansaxleoil 1. Add the sDecified hole drivengearinsiallation thoughtthe speedometer drivengear. 2. lnstallthe speedometer Tighteningtorque: 7.8-12 Nm (0.8-1.2 m-kg, 5.8-8.7 ft-lb) driv' cableto the speedometer 3. Connectthespeedometer gear. en
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DIFFERENTIAL
DIFFERENTIAL PNEPARATION SST 49 8017 2A0
@
49 DO27002
@@@ @@@
(Partof 49 80172A0)
49 F40l 366A
bearins
49 0839 425C oeafrng
49 80172A0)
beanng
49 0439 428
49 0862 426
bearingpuller
bearingpuller
49 0839 425C)
49 0839425C)
49 D017 241
49 F401 3374
4 9 D 0 1 72 A l )
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DIFFERENTIAL
/ ASSEMBLY / INSPECTION DISASSEMBLY Caqtion . Do not remove the inner race il not neoessary' '1.Beforedisassembly, inspectthe backlashol sidegears'referflngto Preln6P€ctlon in shownin the figure.rete(ingto Disa$embly Note' the order Disassemble 2. 3. Inspectall partsand repairor replaceas necessary referring to Backlashol Pinlon Geara 4. Me;surethe backlashafterassembly,
'wa ..-'4b,
Tffi. '1.Sidegear lnspectfor wearand cracks 2. Washer 3. Rolipin pageJ-61 Note....................... Disassembly 4. Pinionshaft 5. Thrustwasher
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6. Piniongear Inspecttor wearand cracks 7. Sidebearingannerrace ..........pageJ-61 Note........... Disassembly Inspectfor wearand cracls drivegear 8. Speedometer 9. Ringgearand gearcase Inspecttor wear and cracl$
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DIFFERENTIAL
Preinspection Backlash ol pinion geals Measurethe backlash as follows. intothe ditferential 1. Installthe leftand rightdriveshafts assemDly. the backlash ol bothpiniongears. 2. lMeasure Backlash: 0-0,1mm (0-0.004 in) Maximum:0.5mm(0,020In) is notas soeciiied, replacethedifierential 3. lf the backlash as an assemoty.
v€LocK
DisassemblyNote Roll oin Caution . use prolectiveplatesin the vbe. . Insenlhe punchinto the roll pin holellom the rlng gear slde. Securethe gearcasein a viceand tap outthe rollpin.
Slde bearinginner race Cautlon . Whenreplacinga bearing,replac€the innerand outer taces as a set, drivegear 1. Removethe bearinginnerrace(speedometer side)withthe SST.
01EoJXj75
2. Removethebearinginnerrace(ringgearside)wilhtheSSI.
BEABINGINNER
J-61
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OIFFERENTIAL Assembly drivegearas shownintheligure 1. Installthespeedometer Cautlon . Wtlen replacinga bearing,replacelhe inner and outer races as a set.
2. Installthe newbeannglnnerrace. drive (1) Installthenewbearinginnerrace(speedometer gearsjde)witha Pressandthe SST
(2) Installthenewbearinginnerrace (ringgearside)with a pressand the SST.
3. Setthe piniongearsandthrustwasherintothegearcase
4. Insertthe pinionshaft.
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DIFFERENTIAL
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5. Installa new roll pin and stakethe caseto preventit from workinoout.
6. Installthe sideoearsand washers.
Backlashof PinionGears Recheckthe backlashol the piniongears. (Referto pageJ-61.)
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SHIFTIIECHANISM
SHIFTMECHANISM OVERHAUL in the ordershownin the figure. 1. Disassemble 2. Inspectall partsand repairor replaceas necessary. referringto AssemblyNote in the reverseorderof disassembly, 3. Assemble
16-26 0.6-2.3, t2-t4
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SHIFTMECHANIS]II 1.Shiftleverknob 2. Ashtray 3. Frontconsole 4. Boot 5. Nut 6. Washer 7. Bolt 8. Nut 9. Bolt 10.Controlrod Inspectfor bending AssemblyNote............................ pageJ-66 11.Bushing Inspectfor wear and damage 12.Nut 13.Washer 14.Washer 15. Nut '16.Washer 17.Extension bar Inspectfor bending pageJ-66 Assembly Note............................
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18.Washer 19.Pipe 20.Bushing Insp€ctfor wearand damage. 21.Insulator Inspectfor damageandcracks 22. Bushing Inspecttor wearand damage 23. Boot Insp€ctfor damage 24.Spring Inspectfor damageand weakness pageJ-66 Assembly Note............................ (upper) 25. Ball seat 26. Boot Inspectfor wearand damage 27. Holdel 28. Ball seat bwer) 29.Shiftlever olEoJxr86
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SHIFTiIECHANISM Asso|nbly Note Sprlng '1.Applygreaseto the spnng. 2. Aisemblethe springas shownin the ligure
Extensionbar the insulator to the bracketol theexensionbar 1. Assemble and installthe nutsand washers. thento ihe body. barto thetransaxle, 2. Connecltheextension Tighteninglorque Tranaaxle: 5.9-8.8 N{n (0.6-0.9 m-kg, 4.3-6.5 ft-lb) Shlft lever: 31-45 Nm (3.2-4.7 m-kg, 23-34 finb) Control rod 1. Installthe controlrod. 2. Verifysmoothoperalionof the shiftmechanlsm 01E0JX-149
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