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MARUTI SUZUKI Zen Supplementary Service Manual

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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special mean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for autho-
rized Maruti dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.

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  • Page 1 IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special mean- ings. Pay special attention to the messages high- lighted by these signal words. WARNING: Indicates a potential hazard that could result in death or injury.
  • Page 3 TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION GENERAL INFORMATION ENGINE General Information Engine Diagnosis Maintenance and Lubrication Engine Mechanical Engine Cooling HEATING AND AIR CONDI- Engine Fuel TIONING Engine and Emission Control Air Conditioning System (If Equipped) Ignition System STEERING, SUSPENSION, Cranking System WHEELS AND TIRES...
  • Page 4 GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL ..............0A- 2 PRECAUTIONS .
  • Page 5 0A-2 GENGERAL INFORMATION HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed.
  • Page 6 GENERAL INFORMATION 0A-3 PRECAUTIONS GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS”...
  • Page 7 0A-4 GENGERAL INFORMATION When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be re- installed in the proper order and position.
  • Page 8 GENERAL INFORMATION 0A-5 When disconnecting vacuum hoses, attach a tag describ- ing the correct installation positions so that the hoses can be reinstalled correctly. After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be...
  • Page 9 0A-6 GENGERAL INFORMATION PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S controller, etc.).
  • Page 10 GENERAL INFORMATION 0A-7 When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis.
  • Page 11 0A-8 GENGERAL INFORMATION 3) Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal. Check contact tension by inserting and removing just for Check each terminal visually for poor contact (possibly caused once by dirt, corrosion, rust, entry of foreign object, etc.).
  • Page 12 GENERAL INFORMATION 0A-9 If measurements were taken as shown in the figure at the left and results were as listed below, it means that the circuit is open be- tween terminals B-1 and A-1. Voltage Between: C-1 and body ground: Approx. 5V B-1 and body ground: Approx.
  • Page 13 0A-10 GENGERAL INFORMATION INTERMITTENT AND POOR CONNECTION Most intermittent are caused by faulty electrical connections or wir- ing, although a sticking relay or solenoid can occasionally be at fault. When checking it for proper connection, perform careful check of suspect circuits for: Poor mating of connector halves, or terminals not fully seated in the connector body (backed out).
  • Page 14 GENERAL INFORMATION 0A-11 PRECAUTION FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT When installing mobile communication equipment such as CB (Cit- izens-Band)-radio or cellular-telephone, be sure to observe the fol- lowing precautions. Failure to follow cautions may adversely affect electronic control system. Keep the antenna as far away as possible from the vehicle’s electronic control unit.
  • Page 15 0A-12 GENGERAL INFORMATION VEHICLE LIFTING POINTS WARNING: Before applying hoist to underbody, always take vehicle balance throughout service into consider- ation. Vehicle balance on hoist may change depending of what part to be removed. Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 16 GENERAL INFORMATION 0A-13 In raising front or rear vehicle end off the floor by jacking, be sure When using floor jack: to put the jack against the center portion of front cross member (1) or rear axle (2). WARNING: Never apply jack against suspension parts (i.e., stabi- lizer, etc.) or vehicle floor, or it may get deformed.
  • Page 17 0A-14 GENGERAL INFORMATION ABBREVIATIONS MAY BE USED IN THIS MANUAL : Anti-lock Brake System EBCM : Electronic Brake Control ATDC : After Top Dead Center Module, ABS Control : American Petroleum Institute Module : Automatic Transmission Fluid : Engine Control Module : Automatic Locking Retractor ECT Sensor : Engine Coolant Temperature...
  • Page 18 GENERAL INFORMATION 0A-15 : Left Hand : Throttle Body Fuel Injection LSPV : Load Sensing Proportioning (Single-Point Fuel Injection, Valve SPI) : Torque Converter Clutch : Transmission Control Module MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control (Air Flow Sensor, AFS, Air Module) Flow Meter, AFM)
  • Page 19 0A-16 GENGERAL INFORMATION METRIC INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric. When replac- ing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 4T, 7T and radial line with the class identification embossed on the head of each bolt.

  • Page 20: Table Of Contents

    MAINTENANCE AND LUBRICATION 0B-1 SECTION 0B MAINTENANCE AND LUBRICATION CONTENTS PERIODIC MAINTENANCE SCHEDULE ............0B- 2 MAINTENANCE SERVICE .

  • Page 21: 0B-2 Maintenance And Lubrication

    0B-2 MAINTENANCE AND LUBRICATION PERIODIC MAINTENANCE SCHEDULE This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.
  • Page 22 MAINTENANCE AND LUBRICATION 0B-3 This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.
  • Page 23 0B-4 MAINTENANCE AND LUBRICATION This table includes services as scheduled up to 80,000 km mileage. Beyond 80,000 km, carry out the same services at the same intervals Interval: respectively. This interval should be judged by odometer reading or months, which- Km (x 1,000) ever comes first.

  • Page 24: Maintenance Service

    MAINTENANCE AND LUBRICATION 0B-5 MAINTENANCE SERVICE ENGINE Drive Belt Inspection and Replacement WARNING: Disconnect negative cable at battery before checking and replacing belt. Water pump/generator belt inspection 1) Disconnect negative cable from battery. 2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. Replace if necessary.
  • Page 25 0B-6 MAINTENANCE AND LUBRICATION Camshaft Timing Belt Replacement Replace belt with new one. Refer to SECTION 6A1 for replacement procedure. CAUTION: D Do not bent or twist timing belt. D Do not allow timing belt to come into contact with oil, water, etc.
  • Page 26 MAINTENANCE AND LUBRICATION 0B-7 3) Loosen oil filter (1) by using oil filter wrench (Special tool). Special Tool (A): 09915-47330 4) Apply engine oil to new oil filter “O” ring. 5) Screw new filter on oil filter stand by hand until filter “O” ring con- tacts mounting surface.
  • Page 27 0B-8 MAINTENANCE AND LUBRICATION Engine Coolant Change WARNING: To help avoid danger of being burned, do not remove ra- diator cap while engine and radiator are still hot. Scald- ing fluid and steam can be blown out under pressure if cap is taken off too soon.
  • Page 28 MAINTENANCE AND LUBRICATION 0B-9 5) Slowly pour specified amount of coolant to the base of radiator filler neck, and run engine, with radiator cap removed, until ra- diator upper hose is hot. This drives out any air which may still be trapped within cooling system.

  • Page 29: Ignition System

    0B-10 MAINTENANCE AND LUBRICATION IGNITION SYSTEM Spark Plugs Replacement Replace spark plugs with new ones referring to Section 6F1. Distributor Cap and Rotor Inspection Check distributor cap and rubber caps for cracks. Clean dusty and stained parts using a dry, soft cloth. Check center electrode and terminals for wear.

  • Page 30: Emission Control System

    MAINTENANCE AND LUBRICATION 0B-11 Fuel Filter Replacement WARNING: This work must be performed in a well ventilated area and away from any open flames (such as gas hot water heaters). Fuel filter (1) is installed in front of fuel tank (2). Replace fuel filter with new one, referring to Section 6C for removal and installation.

  • Page 31: Brake

    0B-12 MAINTENANCE AND LUBRICATION BRAKE Brake Discs, Pads, Drums and Shoes Inspection Brake discs and pads 1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check front disc brake pads and discs for excessive wear, dam- age and deflection.

  • Page 32: Chassis And Body

    MAINTENANCE AND LUBRICATION 0B-13 Brake Fluid Change CAUTION: Since brake system of this vehicle is factory-filled with brake fluid indicated on reservoir cap, do not use or mix different type of fluid when refilling; otherwise serious damage will occur. Do not use old or used brake fluid, or any fluid from a un- sealed container.
  • Page 33 0B-14 MAINTENANCE AND LUBRICATION Tire and Wheel Disc Inspection Tire inspection 1) Check tire for uneven or excessive wear, or damage. If defec- tive, replace. 1. Wear indicator 2) Check inflating pressure of each tire and adjust pressure to specification as necessary. NOTE: Tire inflation pressure should be checked when tires are cool.
  • Page 34 MAINTENANCE AND LUBRICATION 0B-15 Suspension System Inspection Inspect front strut and rear shock absorber for evidence of oil leakage, dents or any other damage on sleeves; and inspect an- chor ends for deterioration. Replace defective parts, if any. Check front and rear suspension systems for damaged, loose or missing parts;...
  • Page 35 0B-16 MAINTENANCE AND LUBRICATION Manual Transmission Oil Inspection and Change Inspection 1) Inspect transmission case for evidence of oil leakage. Repair leaky point if any. 2) Make sure that vehicle is placed level for oil level check. 3) Remove oil filler/level plug (1) of transmission. 4) Check oil level.
  • Page 36 MAINTENANCE AND LUBRICATION 0B-17 Fluid change 1) Perform steps 1) and 2) of above Fluid Level inspection. 2) Change fluid with new specified fluid. For its procedure, refer to On-Vehicle Service in Section 7B. 1. Drain plug Fluid cooler hose change Replace inlet and outlet hoses (1) of cooler hose and their clamps.

  • Page 37: Final Inspection

    0B-18 MAINTENANCE AND LUBRICATION FINAL INSPECTION Exhaust System Check Check for leakage, cracks or loose supports. WARNING: Clutch (For Manual transmission) When carrying out road tests, select a safe Check for the following. place where no man or no running vehicle is Clutch is completely released when depressing seen so as to prevent any accident.

  • Page 38: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B-19 Steering Meters and Gauge D Check to ensure that steering wheel is free from in- Check that speedometer, odometer, fuel meter, tem- stability, or abnormally heavy feeling. perature gauge, etc. are operating accurately. D Check that the vehicle does not wander or pull to Lights one side.
  • Page 39 AIR CONDITIONING (OPTIONAL) 1B-1 SECTION 1B AIR CONDITIONING (OPTIONAL) CAUTION: The air conditioning system of this vehicle uses refrigerant CFC-12 (R-12). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a). Be sure to check which refrigerant is used before any service work including inspection and mainte- nance.

  • Page 40: General Description

    1B-2 AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Whether the A/C in the vehicle being serviced uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on LABEL on the compres- sor. Also, it can be checked by the shape of the service (charge) valve.

  • Page 41: Major Components And Location

    AIR CONDITIONING (OPTIONAL) 1B-3 MAJOR COMPONENTS AND LOCATION 1. Cooling unit 2. Compressor 3. Condenser assembly 4. Receiver/dryer 5. Discharge hose 6. Suction hose 7. Receiver/dryer outlet pipe 8. Condenser outlet pipe 9. Expansion valve 10. Ventilation air 11. Foot air 12.

  • Page 42: Diagnosis

    1B-4 AIR CONDITIONING (OPTIONAL) DIAGNOSIS GENERAL DIAGNOSIS TABLE Condition Possible Cause Correction Cool air won’t come out No refrigerant Recover, evacuation and charging. (A/C system won’t Fuse blown Check “HEATER” fuse, “A/C” fuse, operative) “Fusible Link” and check short circuit to ground.
  • Page 43 AIR CONDITIONING (OPTIONAL) 1B-5 Condition Possible Cause Correction Cool air won’t come out or Insufficient or excessive charge of Check charge of refrigerant. insufficient cooling (A/C refrigerant Check system for leaks. system normal operative) Condenser clogged Check condenser. A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator thermistor.

  • Page 44: Diagnosis Of Abnormal Noise

    1B-6 AIR CONDITIONING (OPTIONAL) DIAGNOSIS OF ABNORMAL NOISE There are various types of noise, ranging from those produced in the engine compartment to those from the pas- senger compartment, also from rumbling noises to whistling noises. ABNORMAL NOISE FROM COMPRESSOR Condition Possible Cause Correction...
  • Page 45 AIR CONDITIONING (OPTIONAL) 1B-7 ABNORMAL NOISE FROM CRANKSHAFT PULLEY Condition Possible Cause Correction A large rattling noise is heard at Loosen pulley mounting bolt. Retighten bolt. idle or sudden acceleration. Worn or broken bearings Replace bearings. ABNORMAL NOISE FROM TENSION PULLEY Condition Possible Cause Correction...

  • Page 46: Quickly Checking Of Refrigerant Charge

    1B-8 AIR CONDITIONING (OPTIONAL) QUICKLY CHECKING OF REFRIGERANT 3. Bubbles CHARGE CHARGE OF REFRIGERANT The following procedure can be used for quickly checking whether the A/C system has a proper charge of refrigerant or not. Run engine at fast idle, and operate A/C at its max. cooling capacity for a few minutes.

  • Page 47: Performance Diagnosis

    AIR CONDITIONING (OPTIONAL) 1B-9 PERFORMANCE DIAGNOSIS 1) Confirm that vehicle and environmental conditions are as fol- lows. – Vehicle is not exposed to direct sun. – Ambient temperature is within 15 C – 35 C. 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed.
  • Page 48 1B-10 AIR CONDITIONING (OPTIONAL) 9) Check for each pressure of low side and high side if it is within shaded range of left graph. NOTE: Pressure registered on gauge varies with ambient tem- perature. Therefore, use left graphs when determining if pressures are normal or not.
  • Page 49 AIR CONDITIONING (OPTIONAL) 1B-11 PERFORMANCE DIAGNOSIS TABLE TESTING RESULTS POSSIBLE CAUSE REMEDY D Refrigerant overcharged D Recharge Pressure high D Expansion valve frozen or clogged D Check expansion valve (“A” area of high side D Clogged refrigerant passage of high side D Clean or replace graph) D Condenser fan malfunction...
  • Page 50 1B-12 AIR CONDITIONING (OPTIONAL) DETAIL DIAGNOSIS TABLE (AT AMBIENT TEMPERATURE WITHIN 30 – 35 C) MANIFOLD kg/cm CONDITION POSSIBLE CAUSE CORRECTION GAUGE 0.2 – 0.3 1.18 – 1.47 2.0 – 3.0 12.0 – 15.0 Normal condition. 28.4 – 42.6 170 – 213 The low pressure side Dust particles or water Clean expansion valve.

  • Page 51: Wiring Circuit

    AIR CONDITIONING (OPTIONAL) 1B-13 WIRING CIRCUIT 1. Blower fan motor 10. Main fuse box 2. Blower fan motor resistor 11. Ignition switch 3. Blower fan motor switch 12. A/C evaporator thermistor 4. Dual pressure switch 13. ECT sensor 5. A/C Switch 14.

  • Page 52: A/C System Inspection Of Ecm And Its Circuits

    1B-14 AIR CONDITIONING (OPTIONAL) A/C SYSTEM INSPECTION OF ECM AND ITS Fig. A CIRCUITS ECM and its Circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from it.
  • Page 53 AIR CONDITIONING (OPTIONAL) 1B-15 ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL Measurement Terminal Wire Circuit Normal value Condition ground Ground to E03-01 ECM main ground –0.4 – 0 volt Engine running body (Fig A) Main power supply Ground to E03-02 10 –...

  • Page 54: A/C Compressor Drive Belt Inspection

    1B-16 AIR CONDITIONING (OPTIONAL) A/C COMPRESSOR DRIVE BELT INSPEC- TION 1) Check belt for wear and cracks, and replace as required. 2) Check belt tension by measuring how much it deflects when pushed at intermediate point between compressor pulley (1) and crankshaft pulley (2) with about 100 N (10 kg) force.

  • Page 55: Refrigerant Recovery, Evacuation And Charging

    AIR CONDITIONING (OPTIONAL) 1B-17 REFRIGERANT RECOVERY, EVACUATION AND CHARGING WARNING: Your eyes should not be exposed to refrigerant (liquid). Any liquid Refrigerant-12 escaping by accident shows a temperature as low as approx. –6 C below freezing point. Should liquid CFC-12 (R-12) get into your eyes, it may cause a serious injury. To protect your eyes against such accident, it is necessary to always wear goggles.

  • Page 56: Recovery

    1B-18 AIR CONDITIONING (OPTIONAL) RECOVERY NOTE: When discharging refrigerant out of A/C system, always re- cover it by using refrigerant recovery and recycling equip- ment (1). Discharging it into atmosphere would cause adverse effect to environments. When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.

  • Page 57: Charging

    AIR CONDITIONING (OPTIONAL) 1B-19 CHARGING CAUTION: D ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A/C system at after the initial charging is performed from the high-pressure side with the engine stopped. D NEVER CHARGE TO HIGH PRESSURE-SIDE of A/C system with engine running. D Do not charge while compressor is hot.
  • Page 58 1B-20 AIR CONDITIONING (OPTIONAL) 7) When refrigerant container (3) is emptied, use following proce- dure to replace it with a new refrigerant container (3). a. Close low pressure valve. b. Replace empty container (3) with a refrigerant container which has been charged with refrigerant. When using refrig- erant container tap valve (4), use following procedure for re- placement.

  • Page 59: Removing Manifold Gauge Set

    AIR CONDITIONING (OPTIONAL) 1B-21 REMOVING MANIFOLD GAUGE SET When A/C system has been charged with a specified amount of re- frigerant, remove manifold gauge set as follows: 1) Close low pressure-side valve of manifold gauge set, (The high pressure-side valve is closed continuously during the process of charging.) 2) Close refrigerant container valve.

  • Page 60: On-Vehicle Service

    1B-22 AIR CONDITIONING (OPTIONAL) ON-VEHICLE SERVICE WARNING: Should refrigerant CFC-12 (R-12) strike your eye(s), consult a doctor immediately. DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S). Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
  • Page 61 AIR CONDITIONING (OPTIONAL) 1B-23 Tighten flared nuts according to Table of Tightening Torque as shown below: Tightening Torque (Flared Nut Used for) 8mm pipe: 13 N·m (1.3 kg-m, 9.5 lb-ft) 14.5 mm pipe: 23 N·m (2.3 kg-m, 16.6 Ib-ft) 16 mm pipe: 33 N·m (3.3 kg-m, 23.8 Ib-ft) Route drain hose so that drained water does not make any contact to vehicle components.

  • Page 62: A/C Condenser Assembly

    1B-24 AIR CONDITIONING (OPTIONAL) A/C CONDENSER ASSEMBLY 1. A/C condenser 2. A/C condenser fan assembly 3. Pipe clamp 4. Condenser packing INSPECTION Check the following. Condenser tins tor leakage, blockage and damage Condenser fittings tor leakage Clogged condenser tins should be washed with water, and should be dried with compressed air.

  • Page 63: Condenser Cooling Fan Motor

    AIR CONDITIONING (OPTIONAL) 1B-25 5) Remove front bumper mounting bracket (1). 6) Remove discharge hose (2) from condenser inlet fittings. 7) Disconnect condenser outlet pipe (3) from condenser outlet fit- tings. 8) Disconnect suction hose (4) from suction pipe (5). NOTE: As soon as the above hose and pipe disconnected, cap opened fittings so that moisture and dust do not enter...

  • Page 64: Receiver/Dryer

    1B-26 AIR CONDITIONING (OPTIONAL) Connect battery to condenser cooling fan motor (1) as shown in fig- ure, then check that the condenser cooling fan motor operates smoothly. Reference current : approx. 6 – 9 A at 12 V REMOVAL AND INSTALLATION Refer to A/C CONDENSER ASSEMBLY in this section.
  • Page 65 AIR CONDITIONING (OPTIONAL) 1B-27 Installation 1) Reverse removal sequence to install receiver/dryer noting the follows. Tighten specified torque to flared nut for receiver/dryer. NOTE: When replacing receiver/dryer, add 20 cc of refrigerating oil from compressor suction-side. Blind plugs of receiver/dryer should not be removed un- til just before receiver/dryer is installed.

  • Page 66: Cooling Unit

    1B-28 AIR CONDITIONING (OPTIONAL) COOLING UNIT (EVAPORATOR) 1. Evaporator 2. A/C Evaporator thermistor (Evaporator temperature sensor) 3. Expansion valve 4. Evaporator case Removal 1) Disconnect the negative (–) cable at battery. 2) Recover refrigerant by using recovery and recycling equipment (1).
  • Page 67 AIR CONDITIONING (OPTIONAL) 1B-29 9) Disconnect compressor suction pipe (1) and receiver dryer outlet pipe (2) from evaporator unit (cooling unit) fittings at en- gine room. NOTE: As soon as above hose and pipe are disconnected, be sure to cap opened fittings so that moisture and dust do not enter cooling unit.

  • Page 68: Expansion Valve

    1B-30 AIR CONDITIONING (OPTIONAL) INSPECTION Check the following. Evaporator tins for leakage, blockage and damage. Evaporator fittings for leakage. Clogged evaporator tins should be washed with water, and should be dried with compressed air. NOTE: Be careful not to damage evaporator fins. If evaporator fin is bent, straighten it by using a screwdriver or pair of pliers, If any leakage is found from fitting or tube, repair or replace evaporator.
  • Page 69 AIR CONDITIONING (OPTIONAL) 1B-31 Removal Refer to REMOVAL and DISASSEMBLY in the previous section COOLING UNIT (EVAPORATOR). Inspection 1) Connect manifold gauge set (1) to expansion valve (2) and its charging hose to refrigerant container (3). 2) Soak remote bulb of expansion valve in water contained in a water pan (4).

  • Page 70: A/C Evaporator Thermistor

    1B-32 AIR CONDITIONING (OPTIONAL) Installation 1) Reverse removal sequence to install expansion valve noting the follows. Tighten specified torque to flared nut for expansion valve. Tightening Torque for flared nut Evaporator pipe : 33 N·m (3.3 kg-m) Evaporator joint pipe : 13 N·m (1.3 kg-m). 2) Evacuate and charge system according to previously-de- scribed procedure.

  • Page 71: Refrigerant Pipes And Hoses

    AIR CONDITIONING (OPTIONAL) 1B-33 REFRIGERANT PIPES AND HOSES Inspection 1) Use a leak tester to check hoses and pipes for any gas leakage. 2) Check each hose or pipe clamp for tightness. Retighten or replace loose clamp as required, if any. Removal 1) Recover refrigerant by using recovery and recycling equipment (1).

  • Page 72: Dual Pressure Switch

    1B-34 AIR CONDITIONING (OPTIONAL) DUAL PRESSURE SWITCH INSPECTION 1) Check dual pressure switch (1) on liquid pipe for continuity at normal temperature (approx. 25 C) when A/C system has a proper charge of refrigerant and when A/C system (compres- sor) is under operation. In each of these cases, switch should show proper continuity.

  • Page 73: A/C Condenser Cooling Fan Motor Relay And A/C Compressor Relay

    AIR CONDITIONING (OPTIONAL) 1B-35 A/C CONDENSER COOLING FAN MOTOR RELAY AND A/C COMPRESSOR RELAY INSPECTION 1) Disconnect negative (–) cable at battery. 2) Remove condenser cooling fan motor relay (2) or compressor relay (1) from vehicle. 3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
  • Page 74 1B-36 AIR CONDITIONING (OPTIONAL) 7) Loosen compressor drive belt, then remove compressor mounting bolts (2). 8) Remove compressor assembly (1) from its mounts. 9) Remove compressor mount by removing its mounting bolt (3) from engine if necessary. INSTALLATION Reverse removal procedure noting the following points. Tighten compressor mounting bolts and nut to specified torque.
  • Page 75 AIR CONDITIONING (OPTIONAL) 1B-37 Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION” in this Section. CAUTION: Be sure to use CFC-12 (R-12) compressor oil. NOTE: Compressor assembly supplied from factory is filled up with the following amount of oil. Oil amount in compressor: 60 –...

  • Page 76: Magnet Clutch

    1B-38 AIR CONDITIONING (OPTIONAL) MAGNET CLUTCH 1. Pressure plate 2. Shim 3. Circlip 4. Drive clutch 5. Magnetic clutch coil 6. Compressor 7. Pressure plate nut INSPECTION D Inspect clutch plate and clutch pulley for leaks of compressor oil. D Check clutch pulley bearings for noise and grease leakage. D Using ohmmeter, measure resistance of clutch coil between clutch lead wire and compressor body ground.
  • Page 77 AIR CONDITIONING (OPTIONAL) 1B-39 3) Remove shims from shaft. 4) Remove circlip by using special tool (C). Special Tool (C): 09900-06107 5) With special tool (D) in place, remove drive clutch (3) from com- pressor (2) with puller (1). Special Tool (D): 09951-65510 6) Disconnect coil lead wire from compressor housing.
  • Page 78 1B-40 AIR CONDITIONING (OPTIONAL) ASSEMBLY 1) Install magnetic clutch coil (5). 2) Install drive clutch (4). i) Install drive clutch (4) to compressor (6) shaft. ii) Using snap ring pliers, install snap ring (3). 1. Pressure plate 2. Shim 3) Install pressure plate. i) Adjust clearance between pressure plate (1) and drive clutch (2) by putting shims on compressor shaft.

  • Page 79: Compressor

    AIR CONDITIONING (OPTIONAL) 1B-41 COMPRESSOR 10. Cylinder seal 11. Compressor cylinder 12. Cylinder seal 13. Suction valve 14. Valve front plate 15. Reed valve 1. Joint service connector 16. Front gasket 2. Diffuser seal 17. Cylinder front head 3. “O” ring 18.
  • Page 80 1B-42 AIR CONDITIONING (OPTIONAL) DISASSEMBLY 1) Remove magnet clutch, refer to MAGNET CLUTCH in this sec- tion. 2) Pry out oil ring (1) by using like a screwdriver, and then remove oil felt (2). 3) Remove key (1) from shaft by using a hammer and punch. 4) Remove circlip (1) by using special tool (E).
  • Page 81 AIR CONDITIONING (OPTIONAL) 1B-43 ii) Turn special tool (F) unit its protrusion (1) engages with the groove (3) provided on lip seal (2). iii) Check that special tool (F) goes down slightly when the protru- sion (1) and groove (3) are engaged. iv) Turn special tool (F) by 30 –...
  • Page 82 1B-44 AIR CONDITIONING (OPTIONAL) 11) Remove front housing (2) by prying its protrusion (1). NOTE: Be careful not to scratch sealing surface of front housing. 12) Remove front valve plate (2). Remove two pins (1) from cylinder block. 13) Remove the rear housing (2) by prying its protrusion (1). NOTE: Be careful not to scratch sealing surface of rear housing.
  • Page 83 AIR CONDITIONING (OPTIONAL) 1B-45 CHECKING COMPONENTS Clean all parts with cleaning solvent and apply compressor oil to them. PARTS NAME CHECK POINT REMEDY 1. Check sealing surface for scratches and corro- Replace Lip seal sion. 1. Check both surfaces for scratches and corro- Replace or polish with Valve plate sion.
  • Page 84 1B-46 AIR CONDITIONING (OPTIONAL) ASSEMBLY NOTE: Do not re-use gasket shaft seal, O-rings, or washers. Use overhaul gasket kit. Before starting assembly, make sure all parts and work- bench are clean. 1) Install rear valve plate (2) on rear cylinder. i) Install two pins in rear cylinder.
  • Page 85 AIR CONDITIONING (OPTIONAL) 1B-47 2) Install rear housing (2) on rear cylinder. Housing protrusion (1) is positioned at the top. 3) Install front valve plate (2) on front cylinder. i) Install two pins in front cylinder. ii) Lubricate new O-ring with compressor oil. Install O-ring in front cylinder.
  • Page 86 1B-48 AIR CONDITIONING (OPTIONAL) 5) Install lip seal. i) Coat special tool (G) surface with oil and install it to the shaft (1). Special Tool (G): 09990-58230 ii) Apply oil lip seal O-ring and install it over special tool (E). When fitting lip seal over the special tool, care should be taken so as not to confuse its designated direction.
  • Page 87 AIR CONDITIONING (OPTIONAL) 1B-49 8) Install new oil felt (1) to inside the bore, and then install ring (2) to inside the bore. 2. Ring 9) Pour compressor oil into compressor. NOTE: Compressor assembly supplied from factory is filled up with 60 –...

  • Page 88: Required Service Materials

    1B-50 AIR CONDITIONING (OPTIONAL) REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS PRODUCT Compressor oil O-ring DENSO COMPRESSOR OIL : ND-OIL6 (Refrigerant oil) Each component REFRIGERANT DRUM Refrigerant Refrigerant charge 95793-60D00-000 SPECIAL TOOLS 09900-06108 09900-06107 Snap ring pliers 09990-28210 Snap ring pliers 09990-48220 (Closing type) Key presser (Opening type)
  • Page 89 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-1 SECTION 3B1 ELECTRICAL POWER STEERING (EPS) SYSTEM CONTENTS GENERAL DESCRIPTION ............... 3B1- 2 Components .
  • Page 90 3B1-2 ELECTRICAL POWER STEERING (EPS) SYSTEM GENERAL DESCRIPTION COMPONENTS This electrical power steering (EPS) system consists of a P/S control module, a torque sensor, a motor assembly (with clutch incorporated) installed to the steering column. In this system, the P/S control module determines the level and direction of the assist force for the steering wheel according to the signals from the torque sensor and the vehicle speed, runs the motor so as to assist operation of the steering wheel.
  • Page 91 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-3 SYSTEM CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT E41-1 P/S control module power supply from battery X01-1 Motor output 1 E41-2 Ground X01-2 Motor output 2 E41-3 X01-3 Clutch output 1 E41-4 X01-4 Clutch output 2 E41-5 Diagnosis switch terminal X02-1...
  • Page 92 3B1-4 ELECTRICAL POWER STEERING (EPS) SYSTEM DIAGNOSIS The EPS system in this vehicle is controlled by P/S control module. P/S control module has an on-board diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of “ON-BOARD DIAGNOSTIC SYS- TEM”...
  • Page 93 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-5 SYSTEM CHECK FLOW TABLE STEP ACTION 1) Record details of the problem (failure, complaint) and Go to Step 2. Go to Step 3. how it occurred as described by the customer. For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 94 3B1-6 ELECTRICAL POWER STEERING (EPS) SYSTEM CUSTOMER QUESTIONNAIRE (EXAMPLE) Customer’s name: Model: VIN: Date of issue: Date Reg: Date of problem: Mileage: D Steering wheel feels heavy D Vehicle pulls to one side during straight driving D Poor recovery from turns D Too much play in steering Problem Symptoms D Abnormal noise while vehicle is running:...
  • Page 95 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-7 DTC CHECK 1) Apply chocks to wheels, set shift lever to neutral position and pull parking brake fully. 2) Start engine. 3) Connect positive probe of analog type voltmeter (1) to diagnosis output terminal (2) and negative probe to ground terminal (3) of monitor coupler (4).
  • Page 96 3B1-8 ELECTRICAL POWER STEERING (EPS) SYSTEM DTC TABLE CAUTION: Be sure to perform “SYSTEM CHECK FLOW TABLE” before starting diagnosis according to flow table of each DTC. Example: When VSS circuit fail (DTC 21) is set High Voltage between diag- nosis switch ter- minal and ground terminal...
  • Page 97 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-9 DTC 11 TORQUE SENSOR MAIN SENSOR CIRCUIT FAILURE DTC 13 TORQUE SENSOR MAIN AND SUB SENSOR CIRCUIT FAILURE DTC 15 TORQUE SENSOR SUB SENSOR CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2.
  • Page 98 3B1-10 ELECTRICAL POWER STEERING (EPS) SYSTEM DTC 14 TORQUE SENSOR 5V POWER SUPPLY CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Torque sensor 3. “P/S” fuse (30A) in fuse box 7. Connector “E41” 4. “IG. COIL METER” fuse (15A) in fuse box 8.
  • Page 99 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-11 DTC 21/23/24 VSS CIRCUIT FAILURE 1. To main fuse 2. Ignition switch 3. “P/S” fuse (30A) in fuse box 4. “IG. COIL METER” fuse (15A) in fuse box 5. Speedometer 6. Combination meter 7. To VSS 8.
  • Page 100 3B1-12 ELECTRICAL POWER STEERING (EPS) SYSTEM DTC 22 ENGINE SPEED SIGNAL CIRCUIT FAILURE 1. To main fuse 5. ECM/PCM 2. Ignition switch 6. P/S control module 3. “P/S” fuse (30A) in fuse box 7. Connector “E41” 4. “IG. COIL METER” fuse (15A) in fuse box STEP ACTION Was “SYSTEM CHECK FLOW TABLE”...
  • Page 101 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-13 DTC 41/42/43/44/45 MOTOR CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor assembly (with clutch incorporated) 3. “P/S” fuse (30A) in fuse box 7. Connector “E41” 4. “IG. COIL METER” fuse (15A) in fuse box 8.
  • Page 102 3B1-14 ELECTRICAL POWER STEERING (EPS) SYSTEM DTC 51 CLUTCH CIRCUIT FAILURE 1. To main fuse 5. P/S control module 2. Ignition switch 6. Motor assembly (with clutch incorporated) 3. “P/S” fuse (30A) in fuse box 7. Connector “E41” 4. “IG. COIL METER” fuse (15A) in fuse box 8.
  • Page 103 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-15 DTC 53 P/S CONTROL MODULE POWER SUPPLY CIRCUIT FAILURE 1. To main fuse 4. “IG. COIL METER” fuse (15A) in fuse box 2. Ignition switch 5. P/S control module 3. “P/S” fuse (30A) in fuse box 6.
  • Page 104 3B1-16 ELECTRICAL POWER STEERING (EPS) SYSTEM INSPECTION OF P/S CONTROL MODULE CIRCUIT P/S control module (1) and its circuits can be checked at P/S con- trol module wiring couplers (2) by measuring voltage and resis- tance. CAUTION: P/S control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to P/S control module with coupler disconnected from it.
  • Page 105 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-17 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E41-1 P/S control module power supply 10 – 14V – from battery E41-2 Ground – – E41-3 – – – E41-4 – – – E41-5 Diagnosis switch terminal Voltage deflection re- Engine idling peated between 0 –...
  • Page 106 3B1-18 ELECTRICAL POWER STEERING (EPS) SYSTEM TROUBLE DIAGNOSIS (FOR TROUBLE NOT INDICATED BY ON BOARD DIAGNOSTIC SYSTEM) This section describes trouble diagnosis of P/S system parts whose trouble is not indicated by the on-board diag- nostic system (self-diagnostic function). When DTC No.12 is indicated by the on-board diagnostic system (self-diagnosis function) and assuredly those steering basic parts as described in “DIAGNOSIS CHART”...
  • Page 107 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-19 STEERING WHEEL PLAY INSPECTION Check steering wheel for looseness or rattle by trying to move it in its shaft direction and lateral direction. If found defective, repair or replace. Check steering wheel play, holding vehicle in straight forward condition on the ground and with engine stopped.
  • Page 108 3B1-20 ELECTRICAL POWER STEERING (EPS) SYSTEM ON-VEHICLE SERVICE STEERING COLUMN ASSEMBLY Refer to “STEERING WHEEL AND COLUMN” section for removal and installation of steering column assembly but perform the fol- lowing step beforehand. Remove steering hole cover. Disconnect all couplers from P/S control module. CAUTION Never disassemble steering column assembly, remove torque sensor or motor assembly (with clutch incorpo-...
  • Page 109 ELECTRICAL POWER STEERING (EPS) SYSTEM 3B1-21 TORQUE SENSOR ON-VEHICLE INSPECTION 1) Remove steering column hole cover. 2) Turn ignition switch to ON position. 3) Check voltage between terminals of torque sensor connector with connecting it to P/S control module and not running engine. Steering Steering Steering...
  • Page 110 3B1-22 ELECTRICAL POWER STEERING (EPS) SYSTEM 5) Connect battery (1) between “X01-1” and “X01-2”. Check that motor rotates smoothly, then measure current between “X01-1” and “X01-2” using ammeter (2) as shown in left figure. Standard current (reference value) : About 0.65 A If check result is not satisfactory, replace steering column as- sembly.
  • Page 111 STEERING WHEEL AND COLUMN 3C-1 SECTION 3C STEERING WHEEL AND COLUMN NOTE: For the descriptions (items) not found in this section, refer to the same section of Service Manual mentioned in Forward of this manual. CONTENTS CHECKING STEERING COLUMN ASSEMBLY AND LOWER SHAFT FOR ACCIDENT DAMAGE (FOR EPS MODEL) .
  • Page 112 3C-2 STEERING WHEEL AND COLUMN CHECKING STEERING COLUMN AS- SEMBLY AND LOWER SHAFT FOR AC- CIDENT DAMAGE (FOR EPS MODEL) NOTE: Vehicles involved in accidents resulting in body damage, where steering column has been impacted may have a dam- aged or misaligned steering column. CHECKING PROCEDURE 1) Check that each capsule (1) is attached to steering column bracket (2) securely.
  • Page 113 ENGINE 6-1 SECTION 6 ENGINE CONTENTS GENERAL INFORMATION ..............6- 1 ENGINE DIAGNOSIS .
  • Page 114 6-2 ENGINE Throughout this manual, the four cylinders of the engine are identified by numbers: No.1, No.2, No.3 and No.4 as counted from crankshaft pulley side to flywheel side. 1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder 4. No.4 cylinder GENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON ENGINE SERVICE...
  • Page 115 ENGINE 6-3 PRECAUTION ON FUEL SYSTEM SERVICE Work must be done with no smoking, in a well-ventilated area and away from any open flames. As fuel feed line (between fuel pump and fuel pressure regula- tor) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or dis- connected.
  • Page 116 6-4 ENGINE FUEL PRESSURE RELIEF PROCEDURE CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. After making sure that engine is cold, relief fuel pressure as follows. 1) Place transmission gear shift lever in “Neutral” (shift selector le- ver to “P”...
  • Page 117 ENGINE 6-5 ENGINE DIAGNOSIS This vehicle is equipped with an engine and emission control system, which controls the A/F mixture, ignition tim- ing, emission, etc. suitably to engine conditions by ECM. ECM has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing a trouble in the engine including this system, be sure to have understanding of the outline of “On- Board Diagnostic system”...
  • Page 118 6-6 ENGINE ENGINE DIAGNOSTIC FLOW TABLE Refer to the following pages for the details of each step. STEP ACTION Customer Complaint Analysis Go to Step 2. Perform customer 1) Perform customer complaint analysis. complaint analysis. Was customer complaint analysis performed? Diagnostic Trouble Code (DTC) Check, Record and 1) Print DTC or Go to Step 4.
  • Page 119 ENGINE 6-7 1. CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal- ysis and diagnosis.
  • Page 120 6-8 ENGINE 2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE First, check DTC referring to “DTC Check” in Section 6E1. If DTC is indicated, print it or write it down and then clear it by referring to “DTC Clearance” in Section 6E1. DTC indicates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and the normal condition has been restored now.
  • Page 121 ENGINE 6-9 5. TROUBLE SYMPTOM CONFIRMATION Based on information obtained in Step 1 customer complaint analysis and Step 2 DTC check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” in Section 6E1. 6. and 7. RECHECKING AND RECORD OF DTC Refer to “DTC Check”...
  • Page 122 6-10 ENGINE 9. TROUBLESHOOTING FOR DTC Based on the DTC indicated in Step 6 or 7 and referring to the applicable DTC diag. flow table in Section 6E1, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and repair or replace faulty parts.
  • Page 123 ENGINE 6-11 Condition Possible Cause Reference Item Engine has no power Engine overheating. Refer to “Overheating” Section. Ignition system out of order. Defective spark plug Spark plugs in Section 6F. Faulty ignition coil Ignition coil in Section 6F. Fuel system out of order. Fuel pressure out of specification Diag.
  • Page 124 6-12 ENGINE Condition Possible Cause Reference Item Engine hesitates Ignition system out of order. (Momentary lack of Spark plug faulty or plug gap as out Spark plugs in Section 6F. response as the of adjustment accelerator is depressed. Fuel system out of order. Can occur at all Fuel pressure out of specification Diag.
  • Page 125 ENGINE 6-13 Condition Possible Cause Reference Item Excessive detonation Engine overheating Refer to “Overheating” Section. (The engine makes Ignition system out of order. sharp metallic knocks Faulty spark plug Spark plugs in Section 6F. that change with Improper ignition timing Ignition timing in Section 6F.
  • Page 126 6-14 ENGINE Condition Possible Cause Reference Item Excessive engine oil Oil entering combustion chamber consumption Sticky piston ring Piston cleaning in Section 6A. Worn piston and cylinder Cylinders, pistons and piston rings inspection in Section 6A. Worn piston ring groove and ring Pistons and piston rings inspection in Section 6A.
  • Page 127 ENGINE 6-15 Condition Possible Cause Referring Item Excessive Ignition system out of order hydrocarbon (HC) Defective spark plug emission or Excessive carbon Fuel system out of order monoxide (CO) Fuel pressure out of specification Fuel pressure check in Section 6E1. emission Engine and Emission control system out of order.
  • Page 128 ENGINE MECHANICAL 6A1-1 SECTION 6A1 ENGINE MECHANICAL CONTENTS GENERAL DESCRIPTION ... . . 6A1- 2 Oil Pan and Oil Pump Strainer ..6A1-22 Engine .
  • Page 129 6A1-2 ENGINE MECHANICAL GENERAL DESCRIPTION ENGINE The engine is a water-cooled, in line 4 cylinders, 4 The single overhead camshaft is mounted over the stroke cycle gasoline unit with its S.O.H.C. (Single cylinder head; it is driven from crankshaft through tim- Overhead Camshaft) valve mechanism arranged for ing belt, and no push rods are provided in the valve “V”-type valve configuration and 16 valves (IN2 and...
  • Page 130 ENGINE MECHANICAL 6A1-3 ENGINE LUBRICATION The oil pump is of a trochoid type, and mounted on In another path, oil goes up to cylinder head and lubri- crankshaft at crankshaft pulley side. cates camshaft journals, rocker arms, camshaft, etc., Oil is drawn up through oil pump strainer and passed after passing through the internal oilway of rocker arm through pump to oil filter.
  • Page 131 6A1-4 ENGINE MECHANICAL ON-VEHICLE SERVICE COMPRESSION CHECK Check compression pressure on all four cylinders as follows: 1) Warm up engine. 2) Stop engine after warming up. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral” (shift selector lever to “P” range for A/T model), and set parking brake and block drive wheels.
  • Page 132 ENGINE MECHANICAL 6A1-5 ENGINE VACUUM CHECK The engine vacuum that develops in the intake line is a good indi- cator of the condition of the engine. The vacuum checking proce- dure is as follows: 1) Warm up engine to normal operating temperature. NOTE: After warming up engine, place transmission gear shift le- ver in “Neutral”...
  • Page 133 6A1-6 ENGINE MECHANICAL 2) Install special tool (Oil pressure gauge) to vacated threaded hole. Special Tool (A): 09915-77310 3) Start engine and warm it up to normal operating temperature. NOTE: Be sure to place transmission gear shift lever in “Neutral” (shift selector lever to “P”...
  • Page 134 ENGINE MECHANICAL 6A1-7 4) Remove air cleaner assembly to observe “V” mark (2) on crank- shaft pulley (1). 5) Using 17 mm socket, turn crankshaft pulley clockwise until “V” mark (in white paint) on pulley aligns with “0” (zero) calibrated on timing belt cover.
  • Page 135 6A1-8 ENGINE MECHANICAL 8) After checking and adjusting valve lashes at valves (1), (2), (5) and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full turn (360 ) and check the same at valves (3), (4), (6) and (8) (or (1), (2), (5), and (7)).
  • Page 136 ENGINE MECHANICAL 6A1-9 AIR CLEANER ASSEMBLY REMOVAL 1) Disconnect air cleaner outlet hose (1) from air cleaner assembly (2). 2) Remove air cleaner assembly by removing bolts (3) shown in figure. INSTALLATION Reverse removal procedure for installation. AIR CLEANER OUTLET HOSE REMOVAL 1) Disconnect negative cable at battery.
  • Page 137 6A1-10 ENGINE MECHANICAL CYLINDER HEAD COVER REMOVAL 1) Disconnect negative cable at battery. 2) Disconnect breather hose and PCV valve from head cover. 3) Remove high-tension cords. 4) Remove cylinder head cover (1) with cylinder head cover gas- ket (2) and O-rings (3). INSTALLATION 1) Install O-rings (2) and cylinder head cover gasket (1) to cylinder head cover (3), after applying sealant to part “A”...
  • Page 138 ENGINE MECHANICAL 6A1-11 THROTTLE BODY AND INTAKE MANIFOLD 1. Intake manifold 2. Throttle body 3. Gasket 4. Fuel delivery pipe 5. Fuel injector 6. EVAP canister purge valve 7. MAP sensor : Do not reuse REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6.
  • Page 139 6A1-12 ENGINE MECHANICAL 4) Disconnect accelerator cable (1) from throttle body. 5) Remove air cleaner outlet hose (2) as previously outlined. 6) Disconnect following electric lead wires and release clamps. EVAP canister purge valve (1) Ground wire (2) from intake manifold Fuel injectors (3) TP sensor (4) IAC valve (5)
  • Page 140 ENGINE MECHANICAL 6A1-13 9) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 10) Remove intake manifold with throttle body from cylinder head, and then its gasket. INSTALLATION Reverse removal procedure for installation noting the followings. Use new intake manifold gasket.
  • Page 141 6A1-14 ENGINE MECHANICAL EXHAUST MANIFOLD 1. Exhaust manifold 2. Engine hook 3. Exhaust manifold cover 4. Oxygen sensor 5. Exhaust manifold gasket 6. Exhaust pipe seal ring 7. Exhaust pipe 8. Exhaust manifold cover bolt 9. Stud bolt 10. Catalytic converter case gasket 11.
  • Page 142 ENGINE MECHANICAL 6A1-15 6) Remove exhaust manifold (1) and its gasket from cylinder head. 7) Remove exhaust pipe seal ring from exhaust manifold. INSTALLATION 1) Install new exhaust manifold gasket to cylinder head and ex- haust pipe new seal ring to exhaust manifold. 2) Install exhaust manifold.
  • Page 143 6A1-16 ENGINE MECHANICAL TIMING BELT AND BELT TENSIONER 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 11. Outside cover seal 12.
  • Page 144 ENGINE MECHANICAL 6A1-17 7) Lock crankshaft inserting flat end rod or the like (2) between flywheel ring gear (drive plate ring gear for A/T) and transmis- sion case, after removing clutch housing (torque converter housing for A/T) lower plate. With crankshaft locked, remove crankshaft timing belt pulley bolt (3).
  • Page 145 6A1-18 ENGINE MECHANICAL CAUTION: After timing belt is removed, never turn camshaft and crankshaft independently more than such an extent as shown in figure. If turned, interference may occur among piston and valves, and parts related to piston and valves may be damaged. Never bend twist timing belt.
  • Page 146 ENGINE MECHANICAL 6A1-19 2) Install tensioner (2) and tensioner plate (3): Do not tighten tensioner bolt (1) with wrench yet. Hand tighten only at this time. Check to ensure that plate movement in arrow direction as shown in figure causes tensioner to move in the same direction. If no associated movement between plate and tensioner oc- curs, remove tensioner and plate again and reinsert plate lug into tensioner hole.
  • Page 147 6A1-20 ENGINE MECHANICAL 6) To take up slack of timing belt, turn crankshaft two rotations clockwise after installing it. After making sure that belt is free from slack, tighten tensioner stud (1) first and then tensioner bolt (2) to each specified torque. Then confirm again that two sets of marks are aligned respec- tively.
  • Page 148 ENGINE MECHANICAL 6A1-21 12) Install water pump pulley (1) and drive belt (2). Tightening Torque (a): 11 N m (1.1 kg-m, 8.0 lb-ft) 13) Install A/C compressor belt (3) (if equipped). 14) Adjust drive belt tension, referring to Section 6B. 15) Adjust A/C compressor belt tension (if equipped).
  • Page 149 6A1-22 ENGINE MECHANICAL OIL PAN AND OIL PUMP STRAINER 1. Oil pan: Apply sealant 99000-31150 to oil pan mating surface. 2. Oil pump strainer 3. O-ring 4. Drain plug gasket 5. Drain plug 6. Oil pan bolt 7. Oil pan nut 8.
  • Page 150 ENGINE MECHANICAL 6A1-23 8) Remove oil pan (2) and then oil pump strainer (1). CLEANING Clean mating surface of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. Clean oil pump strainer screen. INSTALLATION 1) Apply sealant to oil pan mating surface continuously as shown in figure.
  • Page 151 6A1-24 ENGINE MECHANICAL 3) Install gasket and drain plug to oil pan. Tighten drain plug to specified torque. Tightening Torque (a): 50 N m (5.0 kg-m, 36.5 lb-ft) 4) Remove wood block (1) and then install engine mounting member bolts (2) and engine rear mounting nut (3). Tighten bolts and nut to specified torque.
  • Page 152 ENGINE MECHANICAL 6A1-25 OIL PUMP 1. Rotor plate 2. Inner rotor: Apply thin coat of engine oil. 3. Outer rotor: Apply thin coat of engine oil. 4. Gasket 5. Pin 6. Pin 7. Relief valve: Apply thin coat of engine oil. 8.
  • Page 153 6A1-26 ENGINE MECHANICAL 6) Remove oil pump (1) assembly. DISASSEMBLY 1) Remove oil level gauge guide bolt (3) and pull out guide (2) from oil pump (1). 2) Remove rotor plate (1). 3) Remove outer rotor (1) and inner rotor (2).
  • Page 154 ENGINE MECHANICAL 6A1-27 INSPECTION Check oil seal lip for fault or other damage. Replace as neces- sary. NOTE: When installing oil seal (1), press-fit it till its end face is flush with oil pump case (2) end face. Check outer and inner rotors, rotor plate, and oil pump case for excessive wear or damage.
  • Page 155 6A1-28 ENGINE MECHANICAL ASSEMBLY 1) Wash, clean and then dry all disassembled parts. 2) Apply thin coat of engine oil to inner rotor (2) and outer rotor (1), oil seal lip portion, and inside surfaces of oil pump case and plate.
  • Page 156 ENGINE MECHANICAL 6A1-29 4) Install rubber seal between oil pump and water pump. 5) Install key (2) and crank timing belt pulley (3). Refer to figure 1. Dowel pin for proper installation of these parts. (crankshaft pulley pin) With crankshaft locked using flat end rod or the like (5), tighten crank timing belt pulley bolt (4) to specified torque.
  • Page 157 6A1-30 ENGINE MECHANICAL ROCKER ARMS, ROCKER ARM SHAFT AND CAMSHAFT 1. Camshaft 2. Camshaft oil seal 3. Rocker arm shaft 4. O-ring 5. Rocker shaft bolt 6. Rocker arm (IN) 7. Rocker arm No.1 (EX) 8. Rocker arm No.2 (EX) 9.
  • Page 158 ENGINE MECHANICAL 6A1-31 5) After loosening all valve adjusting screw lock nuts (2), turn ad- justing screws (1) back all the way to allow all rocker arms (3) to move freely. 6) Remove camshaft housing, camshaft and distributor case with distributor, after disconnect CMP sensor connector.
  • Page 159 6A1-32 ENGINE MECHANICAL 10) Remove exhaust rocker arms (1) and rocker arm spring (2) by pulling rocker arm shaft to transmission side. 11) Remove O-ring from rocker arm shaft. INSPECTION Adjusting Screw and Rocker Arm If tip of adjusting screw (1) is badly worn, replace it. Rocker arm (2) must be replaced if its cam-riding face (3) is badly worn.
  • Page 160 ENGINE MECHANICAL 6A1-33 Rocker Arm-to-Rocker Arm Shaft Clearance Using a micrometer and a bore gauge, measure rocker shaft dia. and rocker arm I.D. Difference between two readings is arm-to-shaft clearance on which a limit is specified. If limit is exceeded, replace shaft or arm, or both. Item Standard Limit...
  • Page 161 6A1-34 ENGINE MECHANICAL Check clearance by using gaging plastic. The procedure is as follows. 1) Clean housings and camshaft journals. 2) Install camshaft to cylinder head. 3) Place a piece of gaging plastic the full width of journal of cam- shaft (parallel to camshaft).
  • Page 162 ENGINE MECHANICAL 6A1-35 INSTALLATION 1) Apply engine oil to rocker arm shaft and rocker arms. 2) Install rocker arm shaft (3) with shaft bolt holes (4) facing up, rocker arm (exhaust side) (2) and rocker arm spring (1). 3) Check O-ring for damage or deterioration. Install O-ring to rocker arm shaft.
  • Page 163 6A1-36 ENGINE MECHANICAL 6) Apply engine oil to cams and journals on camshaft and put cam- shaft on cylinder head. Install camshaft housing to camshaft and cylinder head. Apply engine oil to sliding surface of each housing against camshaft journal. Apply sealant to mating surface of No.1 (1) and No.6 (2) housings which will mate with cylinder head.
  • Page 164 ENGINE MECHANICAL 6A1-37 9) Install camshaft timing belt pulley (1) to camshaft while fitting pin (2) on camshaft into slot at “E” mark. 10) Using special tool, tighten pulley bolt to specified torque. Tightening Torque (a): 60 N m (6.0 kg-m, 43.5 lb-ft) Special Tool (A): 09917-68221 11) After place cylinder head cover on proper position, install belt...
  • Page 165 6A1-38 ENGINE MECHANICAL VALVES AND CYLINDER HEAD : Tightening Torque : Do not reuse : Apply engine oil to sliding surfaces of each part. 1. Valve cotters 4. Valve stem seal 10. Camshaft housing: 2. Valve spring retainer 5. Valve spring seat Apply sealant to mating surface of No.1 and No.6 3.
  • Page 166 ENGINE MECHANICAL 6A1-39 5) Remove intake manifold rear stiffener (1) and generator adjust arm reinforcement (2) from intake manifold (3). 6) Remove exhaust pipe (1). 7) Disconnect following electric wires: MAP sensor CMP sensor Engine oil pressure switch High-tension cords ECT sensor Ground wire from intake manifold and cylinder head Fuel injectors...
  • Page 167 6A1-40 ENGINE MECHANICAL 10) Disconnect fuel feed hose (1) from fuel delivery pipe. 11) Remove cylinder head cover as previously outlined. Loosen all valve lash adjusting screws fully. 12) Remove timing belt and camshaft as previously outlined. 13) Loosen cylinder head bolts in such order as indicated in figure and remove them.
  • Page 168 ENGINE MECHANICAL 6A1-41 DISASSEMBLY 1) For ease in servicing cylinder head, remove thermostat case, intake manifold with throttle body and exhaust manifold from cylinder head. 2) Remove rocker arms and springs by pulling its shaft out to transmission side. 3) Using special tool (Valve lifter), compress valve springs and then remove valve cotters (1) by using special tool (Forceps) as shown.
  • Page 169 6A1-42 ENGINE MECHANICAL INSPECTION Valve Guides Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each stem and guide. If clearance exceeds limit, replace valve and valve guide.
  • Page 170 ENGINE MECHANICAL 6A1-43 Inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve.
  • Page 171 6A1-44 ENGINE MECHANICAL 2. INTAKE VALVE SEAT: Cutting sequence is the same as for exhaust valve seats. Seat width for intake valve seat: 1.1 – 1.3 mm (0.0433 – 0.0512 in.) 3. VALVE LAPPING: Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the se- cond with fine-size compound, each time using valve lapper according to usual lapping method.
  • Page 172 ENGINE MECHANICAL 6A1-45 Distortion of manifold seating faces: Check seating faces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to determine wheth- er these faces should be corrected or cylinder head replaced. Limit of distortion: 0.10 mm (0.004 in.) Valve Springs Referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak-...
  • Page 173 6A1-46 ENGINE MECHANICAL ASSEMBLY 1) Before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special Tool (A): 09916-34542 (B): 09916-38210 2) Install valve guide to cylinder head. Heat cylinder head uniformly at a temperature of 80 to 100 C (176 to 212 F) so that head will not be distorted, and drive new valve guide into hole with special tools.
  • Page 174 ENGINE MECHANICAL 6A1-47 5) Install new valve stem seal (1) to valve guide. After applying engine oil to seal and spindle of special tool (Valve guide installer handle), fit oil seal to spindle, and then install seal to valve guide by pushing special tool by hand. After installing, check to be sure that seal is properly fixed to valve guide.
  • Page 175 6A1-48 ENGINE MECHANICAL 9) Install rocker arms, springs, rocker arm shaft as previously outlined. 10) Install thermostat case, intake manifold and exhaust manifold. INSTALLATION 1) Remove old gasket and oil on mating surfaces and install new head gasket (1) as shown in figure, that is, “TOP” mark provided on gasket comes to crankshaft pulley side, facing up (toward cylinder head side).
  • Page 176 ENGINE MECHANICAL 6A1-49 4) Reverse removal procedure for installation, noting the following points. Adjust drive belt tension, referring to Section 6B. Adjust A/C compressor belt tension (if equipped). Refer to Section 1B. Adjust intake and exhaust valve lashes as previously out- lined.
  • Page 177 6A1-50 ENGINE MECHANICAL PISTON, PISTON RINGS, CONNECTING RODS AND CYLINDERS 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10.
  • Page 178 ENGINE MECHANICAL 6A1-51 DISASSEMBLY 1) Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston. 2) Remove piston pin from connecting rod. Ease out piston pin circlips (1), as shown. Force piston pin out. CLEANING Clean carbon from piston head and ring grooves, using a suitable tool.
  • Page 179 6A1-52 ENGINE MECHANICAL INSPECTION Cylinders Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. Using a cylinder gauge, measure cylinder bore in thrust and ax- ial directions at two positions as shown in figure.
  • Page 180 ENGINE MECHANICAL 6A1-53 Piston clearance: Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it is out of specification, re- bore cylinder and use oversize piston. Piston clearance: 0.02 –...
  • Page 181 6A1-54 ENGINE MECHANICAL Piston Rings To measure end gap, insert piston ring (1) into cylinder bore and then measure the gap by using thickness gauge (2). If measured gap is out of specification, replace ring. NOTE: Decarbon and clean top of cylinder bore before inserting pis- ton ring.
  • Page 182 ENGINE MECHANICAL 6A1-55 Crank Pin and Connecting Rod Bearings Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damaged, or out-of-round or taper is out of limit, replace crank- shaft or regrind crank pin to undersize and use undersize bear- ing.
  • Page 183 6A1-56 ENGINE MECHANICAL 5) Remove cap and using a scale (2) on gaging plastic envelope, measure gaging plastic (1) width at the widest point (clearance). If clearance exceeds its limit, use a new standard size bearing and remeasure clearance. Item Standard Limit Bearing...
  • Page 184 ENGINE MECHANICAL 6A1-57 c) Stamped number on piston and that on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with number 2 and a number 1 piston to cylin- der with number 1. Unit: mm (in.) Piston Cylinder...
  • Page 185 6A1-58 ENGINE MECHANICAL INSTALLATION OR CONNECTION 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. NOTE: Do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) Install guide hoses (1) over connecting rod bolts. These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly.
  • Page 186 ENGINE MECHANICAL 6A1-59 6) Reverse removal procedure for installation, noting the following points. Adjust water pump drive belt tension, referring to Section 6B. Adjust A/C compressor belt tension (if equipped). Refer to Section 1B. Adjust accelerator cable play. Refer to Section 6E1. Check to ensure that all removed parts are back in place.
  • Page 187 6A1-60 ENGINE MECHANICAL UNIT REPAIR OVERHAUL ENGINE MOUNTING 1. Front lower cross member 13. Engine left mounting (A/T) 2. Engine mounting member 14. Engine left mounting bracket (A/T) 3. Engine front mounting 15. Front lower cross member bolt 4. Engine front mounting bracket (M/T) 16.
  • Page 188 ENGINE MECHANICAL 6A1-61 ENGINE ASSEMBLY REMOVAL 1) Relieve fuel pressure in fuel feed line by referring to Section 2) After disconnect negative and positive cables at battery, re- move battery and battery tray. 3) Remove engine hood. 4) Remove radiator outlet hose (1) to drain coolant. WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator...
  • Page 189 6A1-62 ENGINE MECHANICAL 11) Disconnect following vacuum hose. Brake booster hose (1) from intake manifold. Canister purge hose (2) from EVAP canister purge valve. 12) Disconnect following electric wires: High-tension cord from ignition coil Ground wire from intake manifold EVAP canister purge valve MAP sensor TP sensor IAC valve...
  • Page 190 ENGINE MECHANICAL 6A1-63 17) Remove stabilizer bar (1) referring to Section 3D. 18) Remove drive shaft joints from differential gear of transmis- sion. Refer to Section 4 (DRIVE SHAFT) for procedure to discon- nect drive shaft joint. For engine and transmission removal, it is not necessary to re- move left side of drive shaft from steering knuckle, but remove right side of drive shaft.
  • Page 191 6A1-64 ENGINE MECHANICAL 27) Before removing engine with transmission from body, recheck to make sure all hoses, electric wires and cables are discon- nected from engine and transmission. 28) Lower engine with transmission, front lower cross member and engine mounting member from body.
  • Page 192 ENGINE MECHANICAL 6A1-65 INSTALLATION 1) Lift engine with transmission, front lower cross member and engine mounting member into engine compartment, but do not remove support device. 2) Install engine right mounting bracket bolts (1). 3) Install engine left mounting bracket nuts (2). (For A/T model) 4) Install rear torque stopper bracket bolt (3) and nut (4).
  • Page 193 6A1-66 ENGINE MECHANICAL MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK 1. Cylinder block 6. Timing pulley key 10. Pin 2. Front oil seal: 7. Crankshaft: 11. Oil seal housing gasket Apply engine oil to contact part Apply engine oil to crankshaft 12.
  • Page 194 ENGINE MECHANICAL 6A1-67 REMOVAL 1) Remove engine assembly from body as previously outlined. 2) Remove clutch cover, clutch disc and flywheel (1) (drive plate for A/T). Special Tool (A): 09924-17810 3) Remove crankshaft pulley, timing belt and crankshaft timing pulley. 4) Remove cylinder head assembly.
  • Page 195 6A1-68 ENGINE MECHANICAL INSPECTION Crankshaft Crankshaft runout Using a dial gauge, measure runout at center journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) Crankshaft thrust play Measure this play with crankshaft set in cylinder block in the normal manner, that is, with thrust bearing (1) and journal bearing caps installed.
  • Page 196 ENGINE MECHANICAL 6A1-69 Main Bearings General information Service main bearings are available in standard size and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differing in tolerance. Upper half of bearing (2) has oil groove (3) as shown in figure. Install this half with oil groove to cylinder block (1).
  • Page 197 6A1-70 ENGINE MECHANICAL 5) Remove cap and using scale (2) on gaging plastic (1) envelope, measure gaging plastic width at its widest point. If clearance ex- ceeds its limit, replace bearing. Always replace both upper and lower inserts as a unit. A new standard bearing may produce proper clearance.
  • Page 198 ENGINE MECHANICAL 6A1-71 2) Next, check bearing cap bore diameter without bearing. On mating surface of cylinder block, five alphabets are stamped as shown in figure. Three kinds of alphabets (“A”, “B” and “C”) represent following cap bore diameters. Bearing cap bore diameter Alphabet stamped (without bearing) 49.000 –...
  • Page 199 6A1-72 ENGINE MECHANICAL 4) From numerals stamped on crank webs of No.2 and No.3 cylin- ders (1) and the alphabets stamped on mating surface of cylin- der block, determine new standard bearing to be installed to journal, by referring to table given below. For example, if numeral stamped on crank web is “1”...
  • Page 200 ENGINE MECHANICAL 6A1-73 If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. 1) Regrind journal to following finished diameter. Finished diameter: 44.732 – 44.750 mm (1.7611 – 1.7618 in.) 2) Using micrometer, measure reground journal diameter. Measurement should be taken in two directions perpendicular to each other in order to check for out-of-round.
  • Page 201 6A1-74 ENGINE MECHANICAL Flywheel If ring gear is damaged, cracked or worn, replace flywheel. If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. Check flywheel for face runout with dial gauge. If runout exceeds its limit, replace flywheel. Limit on runout: 0.2 mm (0.0078 in.) Cylinder Block Distortion of gasketed surface...
  • Page 202 ENGINE MECHANICAL 6A1-75 4) Calculate cylinder bore diameter to be rebored. D = A + B – C D: Cylinder bore diameter to be rebored. A: Piston diameter as measured. B: Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0015 in.) C: Allowance for honing = 0.02 mm (0.0008 in.) 5) Rebore and hone cylinder to calculated dimension.
  • Page 203 6A1-76 ENGINE MECHANICAL 3) Install crankshaft to cylinder block. 4) Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5, starting from pulley side.
  • Page 204 ENGINE MECHANICAL 6A1-77 8) Install pistons and connecting rods as previously outlined. 9) Install oil pump strainer and oil pan as previously outlined. 10) Install cylinder head assembly to cylinder block as previously A: Camshaft pulley side B: Distributor case side outlined.
  • Page 205 6A1-78 ENGINE MECHANICAL SPECIAL TOOLS 1. 09915-64510-001 Compression gauge 2. 09915-64510-002 Connector 3. 09915-64530 Hose 09915-77310 09915-67310 09918-08210 4. 09915-67010 Oil pressure gauge Vacuum gauge Vacuum gauge hose joint Attachment 1. 09916-14510 Valve lifter 09926-18210 09917-68221 2. 09916-14910 09917-18210 Oil seal guide (Vinyl resin) Camshaft pulley holder Valve lifter attachment Tappet adjuster wrench...
  • Page 206 ENGINE MECHANICAL 6A1-79 09916-77310 09924-17810 Piston ring compressor Flywheel holder REQUIRED SERVICE MATERIALS RECOMMENDED MATERIALS PRODUCT SUZUKI BOND NO. 1207C Sealant Mating surfaces of cylinder block and oil pan. (99000-31150) Mating surfaces of camshaft housing (No.1 and No.6). SUZUKI BOND NO. 1215 Sealant Mating surfaces of distributor case and cylinder head.
  • Page 207 ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS GENERAL DESCRIPTION ..............6B- 2 Cooling System Circulation .

  • Page 208: Cooling System Circulation

    6B-2 ENGINE COOLING GENERAL DESCRIPTION The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type. COOLING SYSTEM CIRCULATION 1) While the engine is warmed up (thermostat closed), coolant circulates as follows. Thermostat case Heater core Throttle body...

  • Page 209: Cooling Fan

    ENGINE COOLING 6B-3 COOLING FAN The cooling fan is driven by electric motor (1), and the motor is acti- vated by ECM/PCM (and ECT sensor). For its details, refer to SEC- TION 6. WARNING: Keep hands, tools, and clothing away from engine cool- ing fan to help prevent personal injury.

  • Page 210: Diagnosis

    6B-4 ENGINE COOLING DIAGNOSIS Condition Possible Cause Correction D Loose or broken water pump belt Engine overheats Adjust or replace. D Not enough coolant Check coolant level and add as necessary. D Faulty thermostat Replace. D Faulty water pump Replace. D Dirty or bent radiator fins Clean or remedy.

  • Page 211: Coolant Level 6B

    ENGINE COOLING 6B-5 COOLANT LEVEL Coolant Level To check level, lift hood and look at “see-through” coolant reservoir (1). It is not necessary to remove radiator cap to check coolant level. WARNING: To help avoid danger of being burned: do not remove reservoir cap while coolant is “boiling”, do not remove radiator cap while engine and radiator are still hot.

  • Page 212: Cooling System Flush And Refill

    6B-6 ENGINE COOLING 4) Using a radiator cap tester, check system and radiator cap (1) for proper pressure holding capacity. If replacement of cap is re- quired, use proper cap specified torque for this vehicle. Pressure holding capacity: 90 kPa (0.9 kg/cm , 12.8 psi) .

  • Page 213: Water Pump Belt Tension

    ENGINE COOLING 6B-7 3) Stop engine and open radiator drain plug (1) or disconnect ra- diator outlet hose (2) from radiator to drain coolant. 4) Close drain plug or connect hose. Add water until system is filled and run engine until upper radiator hose is hot again. 5) Repeat steps 3) and 4) several times until drained liquid is nearly colorless.

  • Page 214: On-Vehicle Service

    6B-8 ENGINE COOLING ON-VEHICLE SERVICE WARNING: Check to make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative cord from battery terminal before removing any part. COOLING SYSTEM DRAINING 1) Remove radiator cap.

  • Page 215: Thermostat

    ENGINE COOLING 6B-9 REMOVAL 1) Drain cooling system. 2) To remove these pipes or hoses, loosen hose clip and pull hose end off. INSTALLATION Install removed parts in reverse order of removal procedure, noting the following. Tighten each clamp securely. Refill cooling system with proper coolant, referring to description on COOLANT of MAINTENANCE.

  • Page 216: Water Pump Belt

    6B-10 ENGINE COOLING 4) Check thermostatic movement of wax pellet as follows: a) Immerse thermostat (1) in water, and heat water gradually. b) Check that valve starts to open at specific temperature. c) If valve starts to open at a temperature substantially below or above specific temperature, thermostat unit should be re- placed with a new one.

  • Page 217: Radiator

    ENGINE COOLING 6B-11 RADIATOR REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system by loosening drain plug (1) of radiator or disconnecting outlet hose (2) from radiator. 3) Disconnect cooling fan motor lead wire at connector. 4) Disconnect radiator inlet and reservoir hose from radiator. 5) Disconnect A/T fluid hoses (1) from A/T fluid pipes (2) (for A/T vehicle).

  • Page 218: Water Pump

    6B-12 ENGINE COOLING CLEANING Clean frontal area of radiator cores. INSTALLATION Reverse removal procedures. NOTE: Refill cooling system with proper coolant referring to COOLANT item of MAINTENANCE. After installation, check each joint for leakage. WATER PUMP REMOVAL 1) Disconnect negative cable at battery. 2) Drain cooling system.

  • Page 219: Required Service Materials

    ENGINE COOLING 6B-13 INSTALLATION 1) Install new pump gasket to cylinder block. 2) Install water pump (1) to cylinder block. 3) After installing water pump, install rubber seal (2) between wa- ter pump and oil pump. 4) Install generator adjusting arm (1). 5) With engine oil applied to O-ring, install oil level gauge guide (2).
  • Page 220 ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS GENERAL DESCRIPTION ....6C-1 Fuel Filler Cap ......6G-4 Fuel System .
  • Page 221 6C-2 ENGINE FUEL ON-VEHICLE SERVICE With short pipe, fit hose as far as it reaches pipe joint as shown. Pipe Hose WARNING: Before attempting service of any type on fuel system, fol- lowing cautions should be always observed. Disconnect negative cable at battery. Clamp DO NOT smoke, and place “NO SMOKING”...
  • Page 222 ENGINE FUEL 6C-3 FUEL PIPE REMOVAL WARNING: A small amount of fuel may be released after fuel hose is disconnected. In order to reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved con- tainer when disconnection is completed.
  • Page 223 6C-4 ENGINE FUEL 3) Install pipe cover to body. Be sure to use new nuts. 4) Connect fuel hoses to fuel pipes. 5) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL FILLER CAP Remove cap (1), and check gasket (2) for even filler neck imprint, and deterioration or any damage.

  • Page 224: Fuel Tank

    ENGINE FUEL 6C-5 INSTALLATION 1) Install filter bracket to filter. 2) Connect outlet hose to fuel filter outlet pipe. 3) Install filter with outlet hose to body. 4) Connect outlet and inlet hoses. Clamp hoses securely. 5) Connect negative cable to battery. 6) With engine “OFF”...
  • Page 225 6C-6 ENGINE FUEL 7) As fuel tank has no drain plug, drain fuel tank by pumping fuel not through fuel tank filler. Use hand operated pump device to drain fuel tank. CAUTION: Never drain or store fuel in an open container to avoid possibility of fire or explosion.
  • Page 226 ENGINE FUEL 6C-7 5) Install fuel to vehicle. 6) Connect fuel filler hose (3) to tank and breather hose (2) to filler neck (1) as shown in figure and clamp them securely. 7) Connect fuel hoses to filter and pipes as shown in figure and clamp them securely.

  • Page 227: Fuel Pump

    6C-8 ENGINE FUEL FUEL PUMP WARNING: Refer to the WARNING at the beginning of ON-VEHICLE SERVICE in this section. REMOVAL 1) Remove fuel tank from vehicle. Refer to FUEL TANK RE- MOVAL in this section. 2) Remove fuel pump assembly from fuel tank. INSPECTION Check fuel pump assembly for damage.
  • Page 228 ENGINE AND EMISSION CONTROL SYSTEM 6E1-1 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM CONTENTS GENERAL DESCRIPTION ....6E1- 2 Resistance Check ....6E1-44 AIR INTAKE SYSTEM .
  • Page 229 6E1-2 ENGINE AND EMISSION CONTROL SYSTEM GENERAL DESCRIPTION The engine and emission control system has 4 major Fuel delivery system includes fuel pump, delivery sub-systems: air intake system, fuel delivery system, pipe, fuel pressure regulator, fuel injectors, etc. electronic control system and emission control sys- Electronic control system includes ECM (PCM), vari- tem.

  • Page 230: Fuel Filter

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-3 1. Air Cleaner 12. PCV valve 2. EVAP canister purge valve 13. Fuel injector 3. IAT sensor 14. Oxygen sensor 4. TP sensor 15. Fuel pump 5. IAC valve 16. Main fuse 6. MAP sensor 17.

  • Page 231: Fuel Return Line

    6E1-4 ENGINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM The main components of the air intake system are air uted by the intake manifold and finally drawn into each cleaner, air cleaner outlet hose, throttle body, IAC combustion chamber. valve and intake manifold. When the IAC valve is opened according to the signal The air (by the amount corresponding to the throttle from ECM (PCM), the air bypasses the throttle valve...

  • Page 232: Electronic Control System

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-5 ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1) various Idle speed control system sensors which detect the state of engine and driving Fuel pump control system conditions, 2) ECM (PCM) which controls various de- Ignition control system vices according to the signals from the sensors and 3) Radiator fan control system...
  • Page 233 6E1-6 ENGINE AND EMISSION CONTROL SYSTEM...
  • Page 234 ENGINE AND EMISSION CONTROL SYSTEM 6E1-7 TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE) 1. Fuel injector No.1 CIRCUIT TERMINAL TERMINAL CIRCUIT 2. Fuel injector No.2 E01-1 E03-1 Blank Ground 3. Fuel injector No.3 4. Fuel injector No.4 E01-2 E03-2 IAC valve...
  • Page 235 6E1-8 ENGINE AND EMISSION CONTROL SYSTEM SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULE INPUT OUTPUT FUEL PUMP RELAY FUEL INJECTOR A/C COMPRESSOR CONTROL RELAY/ CONDENSER FAN CONTROL RELAY IAC VALVE IGNITER EVAP CANISTER PURGE VALVE RADIATOR FAN CONTROL RELAY...

  • Page 236: Diagnosis

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-9 DIAGNOSIS The engine and emission control system in this vehicle are con- trolled by ECM (PCM). ECM (PCM) has an On-Board Diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full understanding of the outline of ON-BOARD DIAGNOSTIC SYSTEM and each item in PRECAUTION IN DIAGNOSING TROUBLE and execute diag- nosis according to ENGINE DIAGNOSTIC FLOW TABLE in SEC-...
  • Page 237 6E1-10 ENGINE AND EMISSION CONTROL SYSTEM MALFUNCTION INDICATOR LAMP (MIL) CHECK 1) Turn ON ignition switch (but engine at stop) and check that mal- function indicator lamp lights up. If lamp does not light up, go to DIAGNOSTIC FLOW TABLE A-1 in this section.
  • Page 238 ENGINE AND EMISSION CONTROL SYSTEM 6E1-11 [Not using SUZUKI scan tool] 1) Check malfunction indicator lamp referring to MALFUNCTION INDICATOR LAMP (MIL) CHECK in this section. 2) Using service wire (1), ground diagnosis switch terminal in mon- itor connector. 3) Read DTC from flashing pattern of malfunction indicator lamp. Refer to DTC TABLE.
  • Page 239 6E1-12 ENGINE AND EMISSION CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE [Using SUZUKI scan tool] 1) Turn ignition switch OFF. 2) Connect SUZUKI scan tool to data link connector (DLC) in the same manner as when making this connection for DTC check. 3) Turn ignition switch ON.
  • Page 240 ENGINE AND EMISSION CONTROL SYSTEM 6E1-13 DIAGNOSTIC TROUBLE CODE (DTC) TABLE DIAGNOSTIC TROUBLE CODE NO. MALFUNCTION INDICATOR DIAGNOSTIC ITEM DIAGNOSTIC ITEM DIAGNOSIS DIAGNOSIS LAMP FLASHING PATTERN SUZUKI SCAN TOOL Manifold absolute pressure P0105 sensor P0120 Throttle position sensor P0130 Oxygen sensor Diagnose trouble according to DIAG- P0340 Camshaft position sensor...
  • Page 241 6E1-14 ENGINE AND EMISSION CONTROL SYSTEM A-1 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK (MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON.) 1. Battery positive voltage 2. Main fuse 3. Ignition switch 4. “IG-COIL METER” fuse 5. Malfunction indicator lamp 6.

  • Page 242: Mil Check

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-15 A-2 MALFUNCTION INDICATOR LAMP CIRCUIT CHECK (MALFUNCTION INDICATOR LAMP FLASHES AT IGNITION SWITCH ON.) STEP ACTION MIL Flashing Pattern Check Go to Step 2. Substitute a known-good 1) Turn ignition switch ON. ECM (PCM) and recheck. Does lamp flashing pattern indicate diagnostic trouble code? Diagnosis Switch Circuit Check...

  • Page 243: Ecm (Pcm) Power And Ground Circuit Check

    6E1-16 ENGINE AND EMISSION CONTROL SYSTEM A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 1 of 2) (MALFUNCTION INDICATOR LAMP DOES NOT LIGHT AT IGNITION SWITCH ON AND ENGINE DOES NOT START THOUGH IT IS CRANKED UP.) 1. Battery positive voltage 2.
  • Page 244 ENGINE AND EMISSION CONTROL SYSTEM 6E1-17 A-4 ECM (PCM) POWER AND GROUND CIRCUIT CHECK (Page 2 of 2) STEP ACTION ECM (PCM) Power Circuit Check Check ground circuits “B/ Go to Step 6. 1) Using service wire, ground terminal E03-19 and Bl”...

  • Page 245: Code No.11 (P0105) Map Sensor Circuit 6E1-18

    6E1-18 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.11 (P0105) MAP SENSOR CIRCUIT (SIGNAL VOLTAGE LOW, HIGH OR PERFORMANCE PROBLEM) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/ Or” wire is open or “E02-9” terminal connections are poor.
  • Page 246 ENGINE AND EMISSION CONTROL SYSTEM 6E1-19 Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3 NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.
  • Page 247 6E1-20 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.13 (P0120) TP SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/ Or” wire is open or “E02-9” terminal connection are poor.
  • Page 248 ENGINE AND EMISSION CONTROL SYSTEM 6E1-21 Fig. for STEP 1 Fig. for STEP 2 Fig. for STEP 3 NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.
  • Page 249 6E1-22 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.14 (P0130) OXYGEN SENSOR CIRCUIT (SIGNAL VOLTAGE DOESN’T CHANGE) NOTE: Before diagnosing trouble according to flow table given below, check to make sure that following sys- tem and parts other than Electronic Fuel Injection system are in good condition.
  • Page 250 ENGINE AND EMISSION CONTROL SYSTEM 6E1-23 Fig. for STEP 1 1. ECM (PCM) connector connected 2. Body ground NOTE: Upon completion of inspection and repair work, perform DTC Confirmation Procedure, referring to page 6E1-33 to confirm that the trouble has been corrected.
  • Page 251 6E1-24 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.15 (P0340) CMP SENSOR CIRCUIT (SENSOR SIGNAL NOT INPUTTED FOR 2 SECONDS AT ENGINE CRANKING) 1. ECM (PCM) 2. CMP sensor 3. Rotor 4. CMP sensor connector NOTE: If starter circuit is open (i.e., start signal circuit is OK but starter fails to run), this DTC is stored in memory at starter switch ON, even through CMP sensor is in good condition.

  • Page 252: Code No.16 (P0500) Vss Circuit

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-25 CODE NO.16 (P0500) VSS CIRCUIT (M/T VEHICLE) (VSS SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN 4000 R/MIN. FOR LONGER THAN 4 SECONDS) M / T Vehicle 1. ECM 2. Speedometer STEP ACTION Does speedometer indicate vehicle...
  • Page 253 6E1-26 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.16 (P0500) VSS CIRCUIT (A/T VEHICLE) (VSS SIGNAL NOT INPUTTED ALTHOUGH FUEL IS KEPT CUT AT LOWER THAN 4000 R/MIN. FOR LONGER THAN 4 SECONDS) A / T Vehicle 1. PCM 2. VSS 3.

  • Page 254: Code No.19 (P0115) Ect Sensor Circuit 6E1-28

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-27 CODE NO.18 (P0110) IAT SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/ Or” wire is open or “E02-9” terminal connections are poor.
  • Page 255 6E1-28 ENGINE AND EMISSION CONTROL SYSTEM CODE NO.19 (P0115) ECT SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH OR LOW) NOTE: When Code No.11 (P0105), 13 (P0120), 18 (P0110) and 19 (P0115) are indicated together, it is possible that “B/ Or” wire is open or “E02-9” terminal connection is poor.
  • Page 256 ENGINE AND EMISSION CONTROL SYSTEM 6E1-29 DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE WARNING: When performing a road test, select a safe place where there is not traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. Road test should be carried out with 2 persons, a driver and a tester, on a level road.

  • Page 257: B-1 Fuel Pump And Its Circuit Check

    6E1-30 ENGINE AND EMISSION CONTROL SYSTEM B-1 FUEL PUMP AND ITS CIRCUIT CHECK 1. ECM (PCM) 2. Fuel pump relay 3. Fuel pump 4. Main relay STEP ACTION Is fuel pump heard to operate 2 se- Fuel pump and its circuit are in good Go to Step 2.

  • Page 258: B-2 Fuel Injector And Its Circuit Check

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-31 B-2 FUEL INJECTOR AND ITS CIRCUIT CHECK 1. Battery positive voltage 2. Main fuse box 3. “IG-COIL METER” fuse 4. Main relay 5. ECM (PCM) 6. No.1 injector 7. No.2 injector 8. No.3 injector 9.

  • Page 259: Fuel Pressure Check

    6E1-32 ENGINE AND EMISSION CONTROL SYSTEM B-3 FUEL PRESSURE CHECK (Page 1 of 2) 1. Fuel Injector 2. Delivery pipe 3. Fuel regulator 4. Fuel filter 5. Fuel pump Special Tool (A) Gauge (09912-58441) (B) Hose (09912-58431) (C) 3-way joint (09912-58490) STEP ACTION 1) Release fuel pressure from fuel feed line.
  • Page 260 ENGINE AND EMISSION CONTROL SYSTEM 6E1-33 B-3 FUEL PRESSURE CHECK (Page 2 of 2) STEP ACTION Was no fuel pressure applied in step 1? Go to Step 8. Go to Step 9. With fuel pump operated and fuel return hose blocked Faulty fuel pressure Shortage of fuel or fuel by pinching it, is fuel pressure applied?

  • Page 261: B-4 Idle Air Control System Check

    6E1-34 ENGINE AND EMISSION CONTROL SYSTEM B-4 IDLE AIR CONTROL SYSTEM CHECK 1. Battery positive voltage 2. Main fuse box 3. “IG-COIL METER” fuse 4. Main relay 5. ECM (PCM) 6. IAC valve 7. Throttle body 8. Engine coolant 9. Bypass air STEP ACTION Check engine idle speed and IAC duty referring to...

  • Page 262: B-5 Evaporative Emission Control System Check

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-35 B-5 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK 1. To throttle body 6. EVAP canister purge valve 2. To fuel tank 7. Main relay 3. EVAP canister 8. Sensed information 4. Air 9. ECM (PCM) 5. Air and vapor 10.

  • Page 263: B-6 Engine Start Signal Check

    6E1-36 ENGINE AND EMISSION CONTROL SYSTEM B-6 ENGINE START SIGNAL CHECK 1. ECM (PCM) 2. ECM (PCM) connector 3. Main switch 4. To starting motor STEP ACTION 1) With ignition switch OFF, disconnect connectors from Engine starter “B/Y” wire open or ECM (PCM).
  • Page 264 ENGINE AND EMISSION CONTROL SYSTEM 6E1-37 B-7 RADIATOR FAN CONTROL SYSTEM CHECK 1. Radiator fan motor 2. Radiator fan control (RFC) relay 3. ECM (PCM) 4. Main relay 5. Engine coolant temp. (ECT) sensor 6. Vehicle speed sensor STEP ACTION Check radiator fan control system referring to p.

  • Page 265: A/C Control Signal Check (If Equipped)

    6E1-38 ENGINE AND EMISSION CONTROL SYSTEM B-8 A/C CONTROL SIGNAL CHECK (IF EQUIPPED) 1. Battery 2. Main fuse box 3. Ignition switch 4. Circuit fuse 5. Blower fan motor 6. Blower fan switch 7. A/C switch 8. Dual pressure switch 9.

  • Page 266: B-9 Electric Load Signal Circuits Check

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-39 B-9 ELECTRIC LOAD SIGNAL CIRCUITS CHECK 1. ECM (PCM) 2. ECM (PCM) connector 3. From lighting switch (small)/Rear defogger 4. From heater blower switch STEP ACTION Check voltage at E01-18 terminal under each condition given Go to Step 2.

  • Page 267: B-10 Fuel Cut Operation Check

    6E1-40 ENGINE AND EMISSION CONTROL SYSTEM B-10 FUEL CUT OPERATION CHECK 1. ECM 2. ECM connector 3. TP sensor STEP ACTION Check fuel cut operation referring FUEL CUT OPERA- Fuel cut operation is Go to step 2. TION INSPECTION in this section. in good condition.

  • Page 268: Inspection Of Ecm (Pcm) And Its Circuits

    ENGINE AND EMISSION CONTROL SYSTEM 6E1-41 INSPECTION OF ECM (PCM) AND ITS CIRCUITS ECM (PCM) and its circuits can be checked at ECM (PCM) wiring connectors by measuring voltage and resistance. CAUTION: ECM (PCM) cannot be checked by itself. It is strictly pro- hibited to connect voltmeter or ohmmeter to ECM (PCM) with couplers disconnected from it.
  • Page 269 6E1-42 ENGINE AND EMISSION CONTROL SYSTEM TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION E01-1 Blank — — E01-2 IAC valve — — 10 – 14 V Ignition switch ON, selector lever: “2” range Transmission range switch E01-3 E01-3 “2” 1 V or less Ignition switch ON, selector lever: Other than “2”...
  • Page 270 ENGINE AND EMISSION CONTROL SYSTEM 6E1-43 TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION 0.78 – 0.83 V Throttle valve at idle position E02-6 E02-6 TP sensor TP sensor 3.7 – 4.7 V Throttle valve at full open position A/C evaporator temp. sen- E02-7 2.0 –...

  • Page 271: Resistance Check

    6E1-44 ENGINE AND EMISSION CONTROL SYSTEM Resistance Check 1) Disconnect ECM (PCM) couplers from ECM (PCM) with ignition switch OFF. CAUTION: Never touch terminals of ECM (PCM) itself or connect voltmeter or ohmmeter. 2) Check resistance between each pair of terminals of discon- nected couplers as listed in following table.

  • Page 272: On-Vehicle Service

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-45 ON-VEHICLE SERVICE GENERAL When hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of hoses. ACCELERATOR CABLE ADJUSTMENT 1) With throttle valve closed, check accelerator pedal play which should be within the following specification.
  • Page 273 6E1-46 ENGIINE AND EMISSION CONTROL SYSTEM IDLE SPEED/IAC DUTY INSPECTION Before idle speed/IAC duty check, make sure of the following. Lead wires and hoses of Electronic Fuel Injection system is con- nected securely. Accelerator cable has some play, that is, it is not tight. Valve lash is checked and adjusted according to maintenance schedule.
  • Page 274 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-47 [Not using SUZUKI scan tool] 1) Using service wire (1), ground diagnosis switch terminal in mon- itor connector. 2) Connect duty meter between duty output terminal (2) and ground terminal (3) of monitor connector. 3) Set tachometer.

  • Page 275: Air Intake System

    6E1-48 ENGIINE AND EMISSION CONTROL SYSTEM AIR INTAKE SYSTEM THROTTLE BODY CAUTION: Do not remove or adjust throttle stop screw as it is factory adjusted precisely CAUTION: Do not disassemble IAC valve. Disassembly spoils its original performance 1. Throttle body 2.
  • Page 276 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-49 5) Disconnect connectors from TP sensor (1) and IAC valve (2). 6) Remove throttle body from intake manifold. 7) Disconnect engine coolant hoses (3) and EVAP canister purge valve hose from throttle body. DISASSEMBLY NOTE: While disassembling and assembling throttle body, use spe- cial care not to deform levers on throttle valve shaft or cause...
  • Page 277 6E1-50 ENGIINE AND EMISSION CONTROL SYSTEM INSTALLATION 1) Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket. 2) Install throttle body to intake manifold. 3) Connect engine coolant hoses (1) and EVAP canister purge valve hose.
  • Page 278 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-51 IAC VALVE REMOVAL 1) Remove throttle body from intake manifold referring to THROTTLE BODY REMOVAL. 2) Remove IAC valve from throttle body. INSPECTION 1) Remove IAC valve from throttle body. 2) Connect each connector to IAC valve and TP sensor. 3) Check that rotary valve (2) of lAC valve (1) opens and closes once and then stops in about 60 ms as soon as ignition switch is turned ON.

  • Page 279: Fuel Delivery System

    6E1-52 ENGIINE AND EMISSION CONTROL SYSTEM FUEL DELIVERY SYSTEM FUEL PRESSURE INSPECTION WARNING: Be sure to perform work in a well-ventilated area and away from any open flames, or there is a risk of a fire breaking out. 1) Relieve fuel pressure in fuel feed line referring to FUEL PRES- SURE RELIEF PROCEDURE in SECTION 6.

  • Page 280: Fuel Pump

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-53 9) Remove special tools from fuel delivery pipe. 10) Connect fuel feed hose to fuel delivery pipe and clamp it se- curely. 11) With engine “OFF” and ignition switch “ON”, check for fuel leaks. FUEL PUMP ON-VEHICLE INSPECTION CAUTION:...

  • Page 281: Fuel Pressure Regulator

    6E1-54 ENGIINE AND EMISSION CONTROL SYSTEM FUEL PRESSURE REGULATOR ON-VEHICLE INSPECTION Perform fuel pressure inspection according to procedure de- scribed in FUEL PRESSURE INSPECTION in this section. REMOVAL 1) Relieve fuel pressure according to procedure described in Sec- tion 6. 2) Disconnect battery negative cable at battery.

  • Page 282: Fuel Injector

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-55 FUEL INJECTOR ON-VEHICLE INSPECTION 1) Using sound scope (1) or such, check operating sound of injec- tor (2) when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unusual sound is heard, preform B-2 FUEL IN- JECTOR AND ITS CIRCUIT CHECK in this section.
  • Page 283 6E1-56 ENGIINE AND EMISSION CONTROL SYSTEM 1) Install injector (1) and fuel pressure regulator (2) to special tool (injector checking tool). Connect fuel return hose (3) to fuel pressure regulator and clamp hose securely. Special Tool (A): 09912-58421 2) Connect special tools (hoses and attachment) to fuel feed hose (4).
  • Page 284 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-57 INSTALLATION For installation, reverse removal procedure and note following pre- cautions. Replace injector O-ring (1) with new one using care not to dam- age it. Check if cushion (3) is scored or damaged. If it is, replace with new one.

  • Page 285: Electronic Control System

    6E1-58 ENGIINE AND EMISSION CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM ECM (PCM) CAUTION: As ECM (PCM) consists of precision parts, be careful not to expose it to excessive shock. REMOVAL 1) Disconnect battery negative cable at battery. 2) Remove glove box upper cover and dash side trim (2). 3) Disconnect connector from ECM (PCM) (1).

  • Page 286: Tp Sensor

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-59 INSTALLATION 1) Arrange 3 new 1.5V batteries in series (2) (check that total volt- age is 4.5 – 5.0 V) and connect its positive terminal to “a” termi- nal of sensor (1) and negative terminal to “c” terminal. Then check voltage between “b”...
  • Page 287 6E1-60 ENGIINE AND EMISSION CONTROL SYSTEM REMOVAL 1) Disconnect battery negative cable at battery. 2) Disconnect coupler from TP sensor. 3) Remove TP sensor from throttle body. INSTALLATION 1) Install TP sensor (1) to throttle body. Fit TP sensor to throttle body in such way that its holes (2) are a little away from TP sensor screw holes (3) as shown and turn TP sensor counter clockwise so that those holes align.

  • Page 288: Iat Sensor

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-61 3) Turn TP sensor (1) clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified below is obtained. TP sensor output voltage when throttle is fully close: 0.805 0.025 V 4) Tighten TP sensor screw to specified torque.

  • Page 289: Ect Sensor

    6E1-62 ENGIINE AND EMISSION CONTROL SYSTEM INSTALLATION Reverse removal procedure noting the following. Clean mating surfaces of IAT sensor (1) and air cleaner outlet hose (2). Connect IAT sensor coupler securely. ECT SENSOR REMOVAL 1) Disconnect battery negative cable at battery. 2) Drain coolant referring to Section 6B.

  • Page 290: Main Relay

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-63 INSTALLATION Reverse removal procedure noting the following. Clean mating surfaces of ECT sensor and water outlet pipe. Check O-ring for damage and replace if necessary. Tighten ECT sensor to specified torque. Tightening Torque (a): 12 N·m (1.2 kg-m, 9.0 lb-ft) Connect connect to ECT sensor securely.

  • Page 291: Oxygen Sensor

    6E1-64 ENGIINE AND EMISSION CONTROL SYSTEM OXYGEN SENSOR INSPECTION Inspect oxygen sensor referring to flow table of diagnostic trouble code No. 14 (P0130). REMOVAL WARNING: To avoid danger of being burned, do not touch exhaust system when system is hot. Oxygen sensor removal should be performed when system is cool.

  • Page 292: Fuel Pump Relay

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-65 FUEL PUMP RELAY INSPECTION 1) Disconnect negative cable at battery. 2) Remove fuel pump relay (1) from its connector. 3) Structure of fuel pump relay is the same as that of main relay. Check its resistance and operation using the same procedure as that for main relay.

  • Page 293: Radiator Fan Control System

    6E1-66 ENGIINE AND EMISSION CONTROL SYSTEM RADIATOR FAN CONTROL SYSTEM System Inspection WARNING: Keep hands, tools and clothing away from engine cool- ing fan to help prevent personal injury. This fan is electric and can come on whether or not the engine is running. The fan can start automatically in response to the ECT sensor with the ignition switch in the “ON”...
  • Page 294 ENGIINE AND EMISSION CONTROL SYSTEM 6E1-67 4) Check that there is continuity between terminals “A” and “B” when battery is connected to terminals “C” and “D”. If found defective, replace. 5) Install relay and connect its coupler securely. VEHICLE SPEED SENSOR (VSS) INSPECTION M/T VEHICLE 1) Remove combination meter from instrument panel.

  • Page 295: Evap Emission Control System

    6E1-68 ENGIINE AND EMISSION CONTROL SYSTEM EVAP EMISSION CONTROL SYSTEM EVAP CANISTER PURGE INSPECTION NOTE: Before inspection, check to make sure that gear shift lever is in neutral position (with A/T model, selector lever in “P” range) and that parking brake lever is pulled all the way up. 1) Warn up engine to normal operating temperature.

  • Page 296: Evap Canister Purge Valve

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-69 EVAP CANISTER PURGE VALVE INSPECTION [Using SUZUKI scan tool] 1) With ignition switch OFF, disconnect coupler from EVAP canis- ter purge valve. 2) Check resistance between two terminals of EVAP canister purge valve. Resistance of EVAP canister purge valve: 30 –...

  • Page 297: Evap Canister

    6E1-70 ENGIINE AND EMISSION CONTROL SYSTEM [Not using SUZUKI scan tool] 1) With ignition switch OFF, disconnect connector from EVAP can- ister purge valve. 2) Check resistance between two terminals of EVAP canister purge valve. Resistance of EVAP canister purge valve: 30 –...

  • Page 298: Tank Pressure Control Valve

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-71 2) When air is blown into tank pipe, there should be no restriction of flow through purge pipe and air pipe. 1. Tank pipe 2. Purge pipe 3. Air pipe 4. Blow air 3) If operation differs from above description, EVAP canister must be replaced.

  • Page 299: Pcv System

    6E1-72 ENGIINE AND EMISSION CONTROL SYSTEM PCV SYSTEM NOTE: Be sure to check that there is no obstruction in PCV valve or its hoses before checking engine idle speed/IAC duty, for ob- structed PCV valve or hose hampers its accurate checking. PCV HOSE Inspection Check hoses for connection, leakage, clog and deterioration.

  • Page 300: Special Tools

    ENGIINE AND EMISSION CONTROL SYSTEM 6E1-73 SPECIAL TOOLS 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment 4-4. Holder 4-5.
  • Page 301 IGNITION SYSTEM 6F-1 SECTION 6F IGNITION SYSTEM CONTENTS GENERAL DESCRIPTION ....6F- 2 Spark Plugs ......6F- 7 Components .

  • Page 302: General Description

    6F-2 IGNITION SYSTEM GENERAL DESCRIPTION The ignition system used for this vehicle has an electronic ignition control system and consists of the following parts. ECM (or PCM) It detects the engine condition through the signals from the sensors, determines the most suitable ignition timing and time for electricity to flow to the primary coil and sends a signal to the igniter.

  • Page 303: System Wiring

    IGNITION SYSTEM 6F-3 SYSTEM WIRING 1. Battery 11. CMP sensor 2. Main fuse box 12. Spark plug 3. Ignition switch 13. Noise suppressor 4. Main relay 14. ECT sensor 5. Ignition coil 15. MAP sensor 6. Igniter 16. VSS 7. ECM (PCM) 17.

  • Page 304: Diagnosis

    6F-4 IGNITION SYSTEM DIAGNOSIS Condition Possible Cause Correction Engine cranks, but will Blown fuse for ignition coil Replace not start or hard to start Loose connection or disconnection of lead wire or Connect securely high-tension cord(s) Faulty high-tension cord(s) Replace Faulty spark plug(s) Adjust, clean or replace Cracked rotor or cap...
  • Page 305 IGNITION SYSTEM 6F-5 STEP ACTION Ignition Coil Power Supply And Ground Circuit Check Go to Step 7. Repair or replace. 1) Check ignition coil power supply (“B/W” wire) circuit for open and short. Are circuits in good condition? Ignition Coil Check Go to Step 8.

  • Page 306: On-Vehicle Service

    6F-6 IGNITION SYSTEM ON-VEHICLE SERVICE IGNITION SPARK TEST 1) Disconnect all injector connectors (1) from injectors (2). WARNING: Without disconnection of injector coupler, combus- tible gas may come out from spark plug holes during this test and may get ignited in engine room. 2) Disconnect all high-tension cords from spark plugs.

  • Page 307: Spark Plugs

    IGNITION SYSTEM 6F-7 INSTALLATION 1) Reverse removal procedure for installation. CAUTION: Never attempt to use metal conductor high-tension cords as replacing parts. Insert each cap portion fully when installing high- tension cords. SPARK PLUGS REMOVAL 1) Remove high-tension cords, referring to HIGH-TENSION CORDS in this section.

  • Page 308: Noise Suppressor

    6F-8 IGNITION SYSTEM NOISE SUPPRESSOR REMOVAL 1) Unwrap tape from noise suppressor. 2) Disconnect connector of noise suppressor (1). 3) Remove noise suppressor. INSTALLATION Reverse removal procedure for installation. INSPECTION Using an ohmmeter (1) to check continuity as the following. “a”...

  • Page 309: Ignition Coil

    IGNITION SYSTEM 6F-9 IGNITION COIL INSPECTION 1) Pull out high-tension cord by gripping its cap. 2) Disconnect ignition coil connector (1). 3) Measure primary and secondary coil resistances. Ignition coil resistance (at 20 C, 68 F) : 1.33 – 1.63 W Primary Secondary: 10.7 –...

  • Page 310: Ignition Timing

    6F-10 IGNITION SYSTEM CMP Sensor Resistance 1) Disconnect distributor lead wire connector (1). 2) Measure resistance of CMP sensor by using ohmmeter. CMP sensor resistance: 185 – 275 W (at –10 – 50 C/14 – 122 F) 240 – 325 W (at 50 – 100 C/122 – 212 F) 3) If resistance is out of specification, replace CMP sensor as fol- lows.
  • Page 311 IGNITION SYSTEM 6F-11 5) Fix ignition timing to initial one as follows: When using SUZUKI scan tool: Select “MISC” mode on SUZUKI scan tool and fix ignition tim- ing to initial one. When not using SUZUKI scan tool: Disconnect scan tool from DLC, and connect D and E termi- nals of monitor connector (1) or E to body ground by using ser- vice wire so that ignition timing is fixed on initial one.

  • Page 312: Distributor Unit

    6F-12 IGNITION SYSTEM DISTRIBUTOR UNIT 1. Cap 2. Cap seal 3. Cap screw 4. Rotor 5. CMP sensor 6. CMP sensor screw 7. Housing 8. O-ring DISMOUNTING 1) Disconnect distributor lead wire connector (1). 2) Disconnect high tension cords from distributor cap (2). NOTE: Always grip the cap of high tension cord when disconnect- ing it.
  • Page 313 IGNITION SYSTEM 6F-13 REMOUNTING NOTE: Before installing distributor, check to make sure that its O- ring (1) is in good condition. If new O-ring (1) is to be installed, apply oil. 1) Install distributor without cap (2) to camshaft. Fit the dogs of distributor coupling into the slots of camshaft (3), when installing.

  • Page 314: Special Tools

    6F-14 IGNITION SYSTEM SPECIAL TOOLS 1. Storage case 2. Operator’s manual 3. Tech. 1A 4. DLC cable (14/26 pin, 09931-76040) 5. Test lead/probe 6. Power source cable 7. DLC cable adaptor 8. Self-test adaptor 09931-76030 09913-76011 16/14 pin DLC cable SUZUKI scan tool (Tech.
  • Page 315 CRANKING SYSTEM 6G-1 SECTION 6G CRANKING SYSTEM CONTENTS GENERAL DESCRIPTION ....6G-2 Performance Test ..... . 6G-11 Cranking Circuit .

  • Page 316: General Description

    6G-2 CRANKING SYSTEM GENERAL DESCRIPTION CRANKING CIRCUIT The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These com- ponents are connected electrically. Only the starting motor will be covered in this section. STARTING MOTOR CIRCUIT The magnetic switch coils are magnetized when the starter switch is closed.

  • Page 317: Starting Motor

    CRANKING SYSTEM 6G-3 STARTING MOTOR Both of them consist of yoke assembly, armature assembly, over-running clutch assembly, magnetic switch assem- bly, front housing, rear housing, brush holder and drive lever. The magnetic switch assembly and parts in the starting motor are enclosed in the housings so that they will be protected against possible dirt and water splash.

  • Page 318: Diagnosis

    6G-4 CRANKING SYSTEM DIAGNOSIS Possible symptoms due to starting system trouble would be as follows: Starting motor does not run (or runs slowly) Starting motor runs but fails to crank engine Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies ..in battery, wiring harness, (including starting motor switch), starting motor or engine.
  • Page 319 CRANKING SYSTEM 6G-5 Condition Possible Cause Correction Starting motor If battery and wiring are satisfactory, inspect running but too starting motor slow (small torque) Insufficient contact of magnetic switch main contacts Replace magnetic switch. Layer short-circuit of armature Replace. Disconnected, burnt or worn commutator Repair commutator or replace armature.

  • Page 320: Unit Repair Overhaul

    6G-6 CRANKING SYSTEM UNIT REPAIR OVERHAUL DISMOUNTING AND REMOUNTING 1) Disconnect negative cable at battery. 2) Disconnect magnetic switch lead wire (1) and battery cable (2) from starting motor terminals. 3) Remove 2 mounting bolts (3). 4) Remove generator cover, if necessary. 5) Remove starting motor (4).

  • Page 321: Reassembly

    CRANKING SYSTEM 6G-7 REASSEMBLY 1) Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary. 2) Before installing over-running clutch (2) to armature (1), apply grease as shown in figure and then fasten stop ring (3) with snap ring (4).

  • Page 322: Inspection

    6G-8 CRANKING SYSTEM 7) Hook magnetic switch plunger (3) with drive lever and then fas- ten magnetic switch assembly (1) with nuts (4). 8) Connect lead wire (5) as it was and then check magnetic switch for operation. NOTE: Before installing nuts, make sure that plunger hook is connected with drive lever without fail.
  • Page 323 CRANKING SYSTEM 6G-9 Hold-In Coil Open Circuit Test Check for continuity across magnetic switch ‘S’ terminal (1) and coil case. If no continuity exists, coil is open and should be re- placed. BRUSH Measure length of brushes and replace them as necessary. Brush length Limit : 6.0 mm (0.236 in.)
  • Page 324 6G-10 CRANKING SYSTEM Check commutator for run-out with armature (1) supported on V-blocks (2). Correct it by using lathe, if required. Commutator out of round Limit (maximum value): 0.4 mm (0.015 in.) Check for wear and replace armature if diameter is below limit. Commutator outside diameter Limit (minimum value): 27 mm (1.063 in.) Correct and clean surface by using #400 emery cloth.

  • Page 325: Performance Test

    CRANKING SYSTEM 6G-11 PERFORMANCE TEST CAUTION: Each test must be performed within 3 – 5 seconds to avoid coil from burning. PULL-IN TEST Connect test leads as shown in figure and check that pinion (over- running clutch) move outward. If it does not, replace magnetic switch.

  • Page 326: Pinion Return Test

    6G-12 CRANKING SYSTEM PINION (PLUNGER) RETURN TEST As a next step to the above, disconnect negative lead and check to make sure that pinion returns inward quickly. NO-LOAD PERFORMANCE TEST Connect test leads as shown in left figure and check that motor runs without fail with pinion moved out.

  • Page 327: Specifications

    CRANKING SYSTEM 6G-13 SPECIFICATIONS Rated output 0.7 kW at 12 volts Rated operating time 30 seconds Direction of rotation Clockwise as viewed from pinion side Number of pinion teeth 50 A maximum No load characteristic at 11.5 volts 6,000 rpm minimum 2.84 N m minimum Performance Load characteristic at 9 volts, 150 A...
  • Page 328 CHARGING SYSTEM 6H-1 SECTION 6H CHARGING SYSTEM CONTENTS GENERAL DESCRIPTION ..............6H- 2 Battery .

  • Page 329: General Description

    Since freezing may ruin a battery, it should be protected against freezing by keeping it in a fully charged condition. If a battery is fro- zen accidentally, it should not be charged until it is warmed. SULFATION If the battery is allowed to stand for a long period in discharged...
  • Page 330 CHARGING SYSTEM 6H-3 CARE OF BATTERY WARNING: Never expose battery to open flame or electric spark because of battery generate gas which is flammable and explosive. Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush any contacted area with water immediately and thor- oughly.

  • Page 331: Generator

    6H-4 CHARGING SYSTEM GENERATOR The generator is a small and high performance type with an IC regulator incorporated. The internal components are connected electrically as shown below figure. The generator features are as follows: Solid state regulator is mounted inside the generator. All regulator components are enclosed into a solid mold.
  • Page 332 CHARGING SYSTEM 6H-5 1. Pulley 2. Pulley nut 3. Rotor fan 4. Stator coil B : Generator output (Battery terminal) 5. Stator core 6. Field coil D : Dummy terminal 7. Regulator E : Ground 8. Brush F : Field coil terminal IG : Ignition terminal 9.

  • Page 333: Diagnosis

    6H-6 CHARGING SYSTEM DIAGNOSIS BATTERY VISUAL INSPECTION Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious damage is noted, replace battery. Determine cause of damage and correct as needed. HYDROMETER TEST The direct method of checking the battery for state of charge is to carry out a high rate discharge test, which involves a special pre-...

  • Page 334: Generator

    CHARGING SYSTEM 6H-7 GENERATOR CAUTION: Do not mistake polarities of IG terminal and L terminal. Do not create a short circuit between IG and L termi- nals. Always connect these terminals through a lamp. Do not connect any load between L and E. When connecting a charger or a booster battery to ve- hicle battery, refer to this section describing battery charging.
  • Page 335 6H-8 CHARGING SYSTEM UNDERCHARGED BATTERY This condition, as evidenced by slow cranking can be caused by one or more of the following conditions even though indicator lamp may be operating normal. Following procedure also applies to cars with voltmeter and amme- ter.
  • Page 336 CHARGING SYSTEM 6H-9 Higher Voltage If voltage is higher than standard value, check ground of brush. If brush ground is correct, replace IC regulator. Lower Voltage If voltage is lower than standard value, proceed to following check. 2) Ground F terminal and start engine, then measure voltage at B terminal as shown in figure.

  • Page 337: On-Vehicle Service Battery

    6H-10 CHARGING SYSTEM ON-VEHICLE SERVICE BATTERY JUMP STARTING IN CASE OF EMERGENCY WITH AUXILIARY (BOOSTER) BATTERY Both booster and discharged battery should be treated carefully when using jumper cables. Follow procedure outlined below, being careful not to cause sparks. WARNING: Departure from these conditions or procedure de- scribed below could result in: 1) Serious personal injury (particularly to eyes) or...

  • Page 338: Removal

    CHARGING SYSTEM 6H-11 With Charging Equipment CAUTION: When jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipment. Using such equip- ment can cause serious damage to electrical system or electronic parts.

  • Page 339: Generator

    6H-12 CHARGING SYSTEM GENERATOR 1. Adjusting bolt 2. Generator 3. Pivot bolt 4. “B” terminal wire 5. Coupler 6. Nut 7. Generator cover 8. Generator cover bolt 9. Generator bracket 10. Generator bracket bolt 11. Generator bracket nut : Tightening Torque REMOVAL 1) Disconnect negative cable (1) at battery (2).

  • Page 340: Generator/Water Pump Drive Belt

    CHARGING SYSTEM 6H-13 GENERATOR/WATER PUMP DRIVE BELT BELT TENSION INSPECTION 1) Inspect belt cracks, cuts, deformation, wear and cleanliness. 2) Check belt for tension. Belt is in proper tension when it deflects 6 to 8 mm (0.24 – 0.31 in.) under thumb pressure (1) (about 10 kg or 22 lb.).

  • Page 341: Unit Repair Overhaul

    6H-14 CHARGING SYSTEM UNIT REPAIR OVERHAUL GENERATOR 1. Pulley nut 11. Spacer 21. Rectifier 2. Pulley 12. End housing bearing 22. Regulator 3. Spacer 13. Bearing cover 23. Regulator screw 4. Drive end frame 14. Wave washer 24. Regulator screw (long) 5.

  • Page 342: Disassembly

    CHARGING SYSTEM 6H-15 DISASSEMBLY 1) Remove B terminal inner nut (1) and insulator (2). 2) Remove 3 screws (3) and remove rear end cover (4). 3) Remove brush holder screws (1) and pull out brush holder as- sembly (2). 4) Remove regulator screws (3) and IC regulator (4). 5) Remove brush holder cover from brush holder.
  • Page 343 6H-16 CHARGING SYSTEM 12) If required, use bearing puller (1) to remove end housing bear- ing (2) and bearing cover (3). CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller. 13) If required, remove 4 screws, retainer plate (1) and then drive out drive end bearing (2).

  • Page 344: Inspection

    CHARGING SYSTEM 6H-17 INSPECTION Rotor Open Circuit Using ohmmeter, check for continuity between slip rings of rotor (1). If there is no continuity, replace rotor. Standard resistance: About 2.9 Ground Using ohmmeter, check that there is no continuity between slip ring and rotor (1).
  • Page 345 6H-18 CHARGING SYSTEM Brush Exposed Brush Length Check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Refer to “Replace Brush” in this section. Exposed brush length “a” Standard : 10.5 mm (0.413 in.) Limit : 1.5 mm (0.059 in.)

  • Page 346: Replace Brush

    CHARGING SYSTEM 6H-19 Bearing Drive End Bearing Check that bearing is not rough or worn. End Housing Bearing Check that bearing is not rough or worn. When removal is necessary, refer to disassembly of UNIT REPAIR OVERHAUL. REPLACE BRUSH 1) Unsolder and remove brush and spring. 2) Run wire of new brush through the hole in the brush holder, and insert spring and brush into brush holder.

  • Page 347: Assembly

    6H-20 CHARGING SYSTEM ASSEMBLY 1) If end housing bearing (1) is removed, install it. 2) Check end housing bearing turns smoothly. 3) If stator (2) is removed, install stator and tighten stud bolts (1). 4) If drive end bearing (3) is removed, install it. 5) Check drive end bearing turns smoothly.
  • Page 348 CHARGING SYSTEM 6H-21 9) Install pulley (1) and tighten pulley nut (2) with holding shaft us- ing hexagonal box wrench to specified torque. Tightening Torque (a): 113 N m (11.3 kg-m, 81.5 lb-ft) 10) Install rectifier (1). Curl stator leads (2) as shown in figure. CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan...

  • Page 349: Specifications

    6H-22 CHARGING SYSTEM 16) Make sure that rotor turns smoothly. SPECIFICATIONS BATTERY Rated capacity 28 AH / 5 HR, 12 Volts EXCIDE : 2.4 L (5.07 / 4.22 US / lmp pt) Electrolyte STANDARD : 2.2 L (4.65 / 3.87 US / lmp pt) AMCO : 2.4 L (5.07 / 4.22 US / lmp pt) Electrolyte S.G.
  • Page 350 EXHAUST SYSTEM 6K-1 SECTION 6K EXHAUST SYSTEM CONTENTS GENERAL DESCRIPTION ............... . . 6K-2 MAINTENANCE .
  • Page 351 6K-2 EXHAUST SYSTEM GENERAL DESCRIPTION The exhaust system consists of an exhaust manifold, exhaust pipes, a muffler and seals, gasket and etc., and ex- haust pipe has the three-way catalytic converter (TWC). The three-way catalytic converter is an emission control device added to the exhaust system to lower the levels of Hydrocarbon (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx) pollutants in the exhaust gas.
  • Page 352 EXHAUST SYSTEM 6K-3 MAINTENANCE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. At every interval of periodic maintenance service, and when ve- hicle is raised for other service, check exhaust system as follows: Check rubber mountings for damage, deterioration, and out of position.
  • Page 353 6K-4 EXHAUST SYSTEM ON-VEHICLE SERVICE WARNING: To avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. EXHAUST MANIFOLD Refer to Section 6A1 for removal and installation procedures of ex- haust manifold.
  • Page 354 BODY ELECTRICAL SYSTEM 8-1 SECTION 8 BODY ELECTRICAL SYSTEM NOTE: For the descriptions (items) not found in this section of this manual, refer to the same section of Service Manual mentioned in Forward of this manual. CONTENTS GENERAL DESCRIPTION ............... . . 8- 1 Combination Meter .
  • Page 355 8-2 BODY ELECTRICAL SYSTEM ON-VEHICLE SERVICE HEADLIGHT ROUND TYPE HEADLIGHT REMOVAL 1) Disconnect negative cable at battery. 2) Remove front bumper. 3) Disconnect couplers. 4) Rotate headlight assembly (1), and then detach it as shown. 5) If necessary, remove mounting nuts of headlight housing (2) and remove it.
  • Page 356 BODY ELECTRICAL SYSTEM 8-3 POWER WINDOW CONTROL SYSTEM (IF TYPE 1 EQUIPPED) POWER WINDOW MAIN SWITCH INSPECTION Inspect switch for continuity between the following terminals. Driver Side Passenger Side Window Switch Window Switch Terminal Switch DU DD PU PD Position DOWN TYPE 2 DOWN...
  • Page 357 8-4 BODY ELECTRICAL SYSTEM POWER WINDOW SUB SWITCH TYPE 1 INSPECTION Inspect switch for continuity between the following terminals. Terminal Switch Position DOWN TYPE 2...
  • Page 358 Prepared by Overseas Service Department 1st Ed. January, 2000 Printing: January, 2000...

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