Toyota 3VZ–FE Troubleshooting Manual

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EG–1

ENGINE

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Troubleshooting

Summary of Contents for Toyota 3VZ–FE

Page 1 EG–1 ENGINE...
Page 2 EG–2 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION EG0EF–01 The 3VZ–FE engine is a V–6, 3.0 liter, DOHC 24–valve engine.
Page 3 EG–3 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL The 3VZ–FE engine has 6 cylinder in a V arrangement at a bank angle of 60 . From the front of the RH bank cylinders are numbered 1–3–5, and from the front of the LH bank cylinders are numbered 2–4–6. The crankshaft is supported by 4 bearings inside the crankcase.
Page 4 EG–4 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) EG0EG–01...
Page 5 EG–5 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 6 EG–6 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL RECOMMENDED TOOLS EG0EH–01 EQUIPMENT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ EG0EJ–01 Battery specific gravity gauge Ñ...
Page 7 EG–7 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Steel square Valve spring Ñ...
Page 8 EG–8 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TROUBLESHOOTING EG0EL–01 When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still cannot be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbers in the order given in the table below.
Page 9 EG–9 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 10 EG–10 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 11 EG–11 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TUNE–UP ENGINE COOLANT INSPECTION EG0EM–01 CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the ”LOW” and ”FULL” lines at low temperature. If low, check for leaks and add engine coolant up to the ”FULL”...
Page 12 EG–12 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Standard specific gravity at 20 C (68 F): 1.25–1.27 (55D23L Battery) 1.27–1.29 (80D26L Battery) If not within specifications, charge the battery. HINT: Check the indicator as shown. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded.
Page 13 EG–13 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL GENERATOR DRIVE BELT INSPECTION EG0ES–01 (See CH section) Drive belt tension: New belt 5 lbf Use belt 20 lbf VALVE CLEARANCE INSPECTION AND ADJUSTMENT EG0ET–02 HINT: Inspect and adjust the valve clearance when the en- gine is cold.
Page 14 EG–14 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL REMOVE EMISSION CONTROL VALVE SET (a) (Calif. only) Disconnect the EGR gas temp. sensor connector clamp from the emission control valve set. (b) Disconnect the two vacuum hoses of the fuel pressure control VSV. (c) Disconnect the two vacuum hoses of the IACV VSV.
Page 15 EG–15 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (d) Disconnect the throttle position sensor connector. (e) Disconnect the IAC valve connector. Disconnect the IAC valve air hose. (g) Disconnect the PS air hose. (h) Using 8 mm hexagon wrench, remove the two bolts, nuts air intake chamber and gasket.
Page 16 EG–16 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 18. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS 19. REMOVE CYLINDER HEAD COVERS Remove the six nuts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers. 20. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark ”0”...
Page 17 EG–17 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Turn the crankshaft further 2/3 of a revolution (2405), and check only the valves indicated in the illustration. Measure the valve clearance. (See procedure step (a)) (d) Remove the adjusting shim. Turn the crankshaft so that the cam lobe for the valve to be adusted faces up.
Page 18 EG–18 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Place a new adjusting shim on the valve lifter. Press down the valve lifter with SST (A), and remove SST (B). SST 09248–55020(09248–05011, 09248–05021) (g) Recheck the valve clearance. 22. REINSTALL CYLINDER HEAD COVERS (a) Apply seal packing to the cylinder heads as shown in the illustration.
Page 19 EG–19 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 25. RECONNECT LH ENGINE WIRE HARNESS (a) Connect the three clamps of the LH engine wire harness and install the wire harness with the two bolts. (b) Connect the following connectors: (1) Three injector connectors (2) Engine oil level sensor connector (3) Oil pressure switch connector (4) A/C compressor and wire...
Page 20 EG–20 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (5) Vacuum hose (from throttle body) to TVV (for EVAP) 27. RECONNECT HYDRAULIC MOTOR PRESSURE PIPE Connect the hydraulic pressure pipe to the air intake cham- ber with the bolt. 28. REINSTALL EGR PIPE Install a new gasket, sleeve ball and the EGR pipe with the two bolts and union nut.
Page 21 EG–21 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 34. REINSTALL EMISSION CONTROL VALVE SET (a) Install the emission control valve set with the two bolts. (b) Connect the two VSV connectors. (c) Connect the two vacuum hoses of the IACV VSV. (d) Connect the two vacuum hoses of the fuel pressure control VSV.
Page 22 EG–22 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 23 EG–23 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 24 EG–24 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL IGNITION TIMING INSPECTION AND ADJUSTMENT EG0EU–01 (See IG section) Ignition timing: 10 BTDC @ idle (w/ Terminals TE1 and E1 connected) IDLE SPEED INSPECTION EG0EV–01 Idle speed: 700 50 rpm...
Page 25 EG–25 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL IDLE AND/OR 2,500 RPM CO/HC CHECK EG0EW–02 HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All operating accessories switched OFF (e) All vacuum lines properly connected...
Page 26 EG–26 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Troubleshooting EG0EX–01 If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (a) Check oxygen sensor operation. (See page EG–228) (b) See the table below for possible causes, and then inspect and correct the applicable causes if necessary.
Page 27 EG–27 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL COMPRESSION CHECK EG0EY–01 HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating tempera- ture.
Page 28 EG–28 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,226 kPa (12.5 kgf/cm , 178 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm , 142 psi) Difference between each cylinder:...
Page 29 EG–29 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TIMING BELT COMPONENTS EG0EZ–02...
Page 30 EG–30 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TIMING BELT REMOVAL EG0F0–02 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 31 EG–31 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL REMOVE GENERATOR DRIVE BELT Loosen the pivot bolt and adjusting lock bolt, and remove the drive belt. REMOVE RH FRONT WHEEL REMOVE RH FENDER APRON SEAL REMOVE PS DRIVE BELT Loosen the bolts, and remove the drive belt. 10.
Page 32 EG–32 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 13. REMOVE RH ENGINE MOUNTING STAY AND NO.2 RH ENGINE MOUNTING BRACKET Remove the bolt, nut, mounting stay and mounting bracket. 14. REMOVE PS OIL RESERVOIR TANK WITHOUT DISCONNECTING HOSES 15. REMOVE SPARK PLUGS 16.
Page 33 EG–33 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 19. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with the timing mark ”O” of the No.1 timing belt cover. (b) Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
Page 34 EG–34 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Remove the timing belt from the camshaft timing pulleys. HINT (Re–using timing belt): If the installation marks have disappeared, after removing the timing belt from the cam- shaft timing pulleys, place new installation mark on the timing belt to match the end of the No.1 timing belt cover.
Page 35 EG–35 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 24. REMOVE CRANKSHAFT PULLEY (a) Using SST, remove the pulley bolt. SST 09213–54015, 09213–70010 (90105–08076) 09330–00021 HINT (Re–using timing belt): When the crankshaft pulley bolt is loosened, the position of the timing mark of the crankshaft pulley and also the installation mark may slip, so check and align them again.
Page 36 EG–36 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 27. REMOVE TIMING BELT HINT (Re–using timing belt): If the installation marks have disappeared, place a new installation mark on the timing belt to match the drilled mark of the crankshaft timing pulley. 28. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer.
Page 37 EG–37 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TIMING BELT INSPECTION EG0F1–01 INSPECT TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.
Page 38 EG–38 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check to correct gasket installation and for foreign material on the pulley teeth. If necessary, replace the timing belt. INSPECT IDLER PULLEYS Check that the idler pulley turns smoothly.
Page 39 EG–39 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL TIMING BELT INSTALLATION EG0F2–01 (See page EG–29) INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the timing pulley. (b) Slide on the timing pulley, facing the flange side inward. INSTALL NO.1 IDLER PULLEY (a) Apply adhesive to two or three threads of the mount bolt end.
Page 40 EG–40 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide the pulley. (b) Using SST, install and torque the bolt. SST 09213–54015, 09213–70010 (90105–08076) 09330–00021 Torque: 245 N m (2,500 kgf cm, 181 ft lbf) INSTALL NO.2 IDLER PULLEY (a) Install the idler pulley with the bolt.
Page 41 EG–41 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) (RH Camshaft Pulley Position) Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No.3 timing belt cover. (c) (LH Camshaft Pulley Position) Turn the camshaft timing pulley, align the timing marks of the camshaft timing pulley and No.3 timing belt cover.
Page 42 EG–42 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 11. INSTALL RH CAMSHAFT TIMING PULLEY AND TIMING BELT (a) Remove any oil or water on the RH camshaft timing and No.2 idler pulleys, and keep them clean. (b) Align the installation mark on the timing belt with the timing mark of the RH camshaft timing pulley as shown.
Page 43 EG–43 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 12. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using 981–9,807 N (100–1,000 kgf, 200–2,205 lbf) of pressure. (b) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
Page 44 EG–44 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) CHeck that each pulley aligns with the timing marks as shown in the illustration. If the marks do not align, remove the timing belt and reinstall 15. INSTALL ENGINE RH MOUNTING BRACKET Install the mounting bracket with the three bolt. Torque: 39 N m (410 kgf cm, 30 ft lbf) 16.
Page 45 EG–45 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Torque the three bolts in the sequence shown. Torque: 64 N m (650 kgf cm, 47 ft lbf) 20. INSTALL RH ENGINE MOUNTING STAY Install the mounting stay with the bolt and nut. Torque: 31 N m (320 kgf cm, 23 ft lbf) 21.
Page 46 EG–46 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 26. INSTALL NO.2 AND NO.3 RH ENGINE MOUNTING STAYS (a) Install the No.2 RH engine mounting stay with the bolt and nut. Bolt Torque: 75 N m (760 kgf cm, 55 ft lbf) Torque: 62 N m (630 kgf cm, 46 ft lbf) (b) Install the No.3 RH engine mounting stay with the two bolts.
Page 47 EG–47 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER HEADS COMPONENTS EG0F3–01...
Page 48 EG–48 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL COMPONENTS (Cont’d)
Page 49 EG–49 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER HEADS REMOVAL EG0F4–02 (See page EG–47) DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 50 EG–50 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the two nuts and V– bank cover. REMOVE IAC VALVE (a) Disconnect the following hoses: (1) PS idle–up air hose (2) Water by–pass hoses (3) No.5 air hose (b) Disconnect the IAC valve connector.
Page 51 EG–51 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 14. REMOVE EMISSION CONTROL VALVE SET (a) Disconnect the two vacuum hoses of the fuel pressure control VSV. (b) Disconnect the two vacuum hoses of the IACV VSV. (c) Disconnect the two VSV connectors. (d) Remove the two bolts and emission control valve set.
Page 52 EG–52 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 20. REMOVE NO.2 FUEL PIPE (a) Remove the union bolt and two gaskets, and disconnect the No.2 fuel pipe from the cold start injector. (b) Disconnect the IACV vacuum hose. (c) Remove the two union bolts, four gaskets and No.2 fuel pipe. 21.
Page 53 EG–53 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 23. DISCONNECT RH ENGINE WIRE HARNESS (a) Disconnect the following connectors: (1) Three injector connectors (2) Engine coolant temp. sender gauge connector (3) Oxygen sensor connector (4) PS pump connector (5) Oil pressure switch connector (6) Engine oil level sensor connector (7) A/C compressor connector (8) Engine coolant temp.
Page 54 EG–54 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 28. REMOVE INTAKE MANIFOLD (a) Remove the two bolts and No.2 idler pulley bracket stay and disconnect the ground strap. (b) Remove the eight bolts, four nuts, intake manifold and gasket. 29. REMOVE RH EXHAUST MANIFOLD (a) Remove the three nuts and heat insulator.
Page 55 EG–55 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Remove the six nuts, exhaust manifold and gasket. 31. REMOVE OIL DIPSTICK ASSEMBLY Remove the bolt and oil dipstick assembly. 32. REMOVE SPARK PLUGS 33. REMOVE TIMING BELT, CAMSHAFT TIMING PULLEYS AND NO.2 IDLER PULLEY (See page EG–29) 34.
Page 56 EG–56 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Remove exhaust camshaft of RH cylinder head (a) Align the timing marks (two pointed marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub–gear to the driven gear with a service bolt.
Page 57 EG–57 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Secure the exhaust camshaft sub–gear to the driven gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16–20 mm HINT: When removing the camshaft, make certain that the torsional spring force of the sub–gear has been eliminated by the above operation.
Page 58 EG–58 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Insert a service bolt (A) into the service hole of the camshaft sub–gear. (c) Using a screwdriver, turn the sub–gear clockwise, and remove the service bolt (B). NOTICE: Be careful not to damage the camshaft. (d) Using snap ring pliers, remove the snap ring.
Page 59 EG–59 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 40. REMOVE CYLINDER HEADS (a) Using a 8 mm hexagon wrench, remove the cylinder head (recessed head) bolts. (b) Uniformly loosen and remove the cylinder head (12 pointed head) bolts in several passes, in the sequence shown. NOTICE: Head warpage or cracking could result from re- moving bolts in an incorrect order.
Page 60 EG–60 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER HEADS DISASSEMBLY EG0F5–01 (See page EG–47) REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. REMOVE VALVES (a) Using SST, compress the valve spring and remove the two keepers.
Page 61 EG–61 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER HEAD COMPONENTS INSPECTION, CLEANING AND REPAIR EG0F6–01 CLEAN TOP OF PISTONS AND TOP OF BLOCK (a) Turn the crankshaft and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surfaces.
Page 62 EG–62 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL INSPECT CYLINDER HEADS FOR FLATNESS Using precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and manifolds for war- page. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head.
Page 63 EG–63 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.970–5.985 mm (0.2350–0.2356 in.) Exhaust 5.965–5.980 mm (0.2348–0.2354 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025–0.060 mm (0.0010–0.0024 in.)
Page 64 EG–64 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Using SST and a hammer, tap out the guide bushing. SST 09201–70010 (d) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Both intake and exhaust (e) Select a new guide bushing (STD size or O/S 0.05). Ñ...
Page 65 EG–65 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 11. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pins and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness:...
Page 66 EG–66 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Check the valve face and seat for the following: If blue appears 360 around the face, the valve is concentric. If not, replace the valve. If blue appears 360 around the valve seat, the guide and face are concentric.
Page 67 EG–67 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using a vernier caliper, measure the free length of the valve spring. Free length: 41.4 mm (1.630 in.) If the free length is not as specified, replace the valve spring. (c) Using a spring tester, measure the tension of the valve spring at the specified installed length.
Page 68 EG–68 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Inspect camshaft journals Using micrometer, measure the journal diameter. Journal diameter: 26.949–26.965 mm (1.0610–1.0616 in.) If the journal diameter is not as specified, check the oil clear- ance. Inspect camshaft bearings Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
Page 69 EG–69 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (e) Remove the bearing caps. Measure the Plastigage at its widest point. Standard oil clearance: 0.035–0.072 mm (0.0014–0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the cam- shaft.
Page 70 EG–70 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.2191 – 1.2195 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurements. Standard oil clearance: 0.024 – 0.052 mm (0.0009 – 0.0020 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the lifter.
Page 71 EG–71 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 17. IF NECESSARY, REPLACE SPARK PLUG TUBE GASKETS (a) Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out. NOTICE: Do not deform the baffle plate gasket. (b) Push in part of the outer circumference of the plug tube gasket and use needle–nose pliers to remove the plug gasket.
Page 72 EG–72 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL HINT: Different oil seals are used for the intake and exhaust. (b) Install the following parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer (c) Using SST, compress the valve spring and place the two keepers around the valve stem.
Page 73 EG–73 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER HEADS INSTALLATION (See page EG–47) INSTALL CYLINDER HEADS Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be sure to install the gasket correctly. (b) Place the cylinder head in position on the cylinder head gasket.
Page 74 EG–74 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Install cylinder head (recessed head) bolts (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Using a 8 mm hexagon wrench, install the cylinder head bolts.
Page 75 EG–75 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using snap ring pliers, install the snap ring. (c) Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (d) Insert a service bolt (A) into the service hole of the camshaft sub–gear.
Page 76 EG–76 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No.08826–00080 or equivalent (d) Install the five bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
Page 77 EG–77 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the eight bearing cap bolts in several passes, in the sequence shown. Torque: 16 N m (160 kgf cm, 12 ft lbf) (g) Remove the service bolt (B).
Page 78 EG–78 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Install exhaust camshaft of LH cylinder head (a) Apply MP grease to the thrust portion of the camshaft. (b) Align the timing marks (one pointed mark) of the camshaft drive and driven gears. (c) Place the intake camshaft on the cylinder head. (d) Install the four bearing caps in their proper locations.
Page 79 EG–79 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using SST, tap in the oil seals. SST 09223–46011 INSTALL CYLINDER HEAD COVERS (a) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No.08826–00080 or equivalent (b) Install the gasket to the cylinder head cover. (c) Install the cylinder head cover with the eight seal washers and nuts.
Page 80 EG–80 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 12. INSTALL RH EXHAUST MANIFOLD (a) Install a new gasket and the exhaust manifold with new six nuts. Uniformly tighten the nuts in several passes. Torque: 39 N m (400 kgf cm, 29 ft lbf) (b) Install the heat insulator with the three nuts.
Page 81 EG–81 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 15. INSTALL INTAKE MANIFOLD (a) Install two new gaskets and the intake manifold with the eight bolts and four nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 18 N m (180 kgf cm, 13 ft lbf) (b) Install the No.2 idler pulley bracket stay and ground strap with the two bolts.
Page 82 EG–82 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (e) Install the three bolts. Torque: 13 N m (130 kgf cm, 9 ft lbf) 18. INSTALL AIR PIPE (a) Install the air pipe with the two bolts. Torque: 8.3 N m (85 kgf cm, 73 in. lbf) 19.
Page 83 EG–83 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 20. CONNECT RH ENGINE WIRE HARNESS (a) Connect the two clamps, and install the engine wire harness with the four bolts. (b) Connect the following connectors: (1) Three injector connectors (2) Engine coolant temp. sender gauge connector (3) Oxygen sensor connector (4) PS pump connector (5) Oil pressure switch connector...
Page 84 EG–84 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 23. INSTALL NO.2 FUEL PIPE (a) Install the No.2 fuel pipe with four new gaskets and the union boots. Torque: 34 N m (350 kgf cm, 25 ft lbf) (b) Connect the IACV vacuum hose. (c) Connect the No.2 fuel pipe with two new gaskets and the union bolt.
Page 85 EG–85 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 28. CONNECT LH ENGINE WIRE HARNESS (a) Connect the three clamps of the LH engine wire harness and install the wire harness with the two bolts. (b) Connect the following connectors: (1) Three injector connectors (2) Cold start injector time switch connector (3) Engine coolant temperature sensor connector (4) Oxygen sensor connector...
Page 86 EG–86 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 34. INSTALL IAC VALVE (a) Install a new gasket with the two bolts. Torque: 13 N m (130 kgf cm, 9 ft lbf) (b) Connect the IAC valve connector. (c) Connect the following connectors: (1) PS idle–up air hose (2) Water by–pass hoses (3) No.5 air hose...
Page 87 EG–87 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 39. (A/T) CONNECT THROTTLE CABLE, AND ADJUST IT 40. INSTALL ACCELERATOR CABLE, AND ADJUST IT 41. FILL WITH ENGINE COOLANT 42. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 43. START ENGINE AND CHECK FOR LEAKS 44.
Page 88 EG–88 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER BLOCK ENGINE REMOVAL EG0F8–02...
Page 89 EG–89 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL...
Page 90 EG–90 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 91 EG–91 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 13. DISCONNECT ENGINE COOLANT RESERVOIR HOSE Remove the bolt and disconnect the reservoir hose. 14. REMOVE WASHER TANK (a) Remove the three washer tank mounting bolts. (b) Disconnect the connector and hose, and remove the washer tank.
Page 92 EG–92 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (h) Data link connector 1 Ground strap from RH fender apron (M/T) Back–up light switch connector (k) (M/T) Speed sensor connector 17. DISCONNECT HEATER HOSES 18. DISCONNECT FUEL RETURN HOSE CAUTION: Catch leaking fuel in a container. 19.
Page 93 EG–93 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 21. (M/T) REMOVE CLUTCH RELEASE CYLINDER WITHOUT DIS- CONNECTING TUBE Remove the four bolts, release cylinder and tube from the transaxle. 22. DISCONNECT TRANSAXLE CONTROL CABLE (S) FROM TRANSAXLE 23. DISCONNECT VACUUM HOSES (a) Brake booster vacuum hose from air intake chamber. (b) Charcoal canister vacuum hose (c) IACV vacuum tank vacuum hoses 24.
Page 94 EG–94 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Remove the two nuts, and pull out the engine wire from the cowl panel. 25. REMOVE COMPRESSOR WITHOUT DISCONNECTING HOSES (a) Disconnect the A/C compressor connector. (b) Remove the drive belt. (c) Remove the five bolts, compressor stay and disconnect the A/C compressor.
Page 95 EG–95 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 28. DISCONNECT PS ACV (a) Disconnect the two PS air hoses. (b) Remove the nut and disconnect the PS ACV 29. DISCONNECT HYDRAULIC COOLING FAN PRESSURE HOSE Using SST, disconnect the pressure hose. SST 09631–22020 30.
Page 96 EG–96 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 32. DISCONNECT RR ENGINE MOUNTING INSULATOR (a) Remove the hole plugs. (b) Remove the four nuts, and disconnect the mounting insulator. 33. REMOVE ENGINE MOUNTING ABSORBER Remove the four bolts and engine mounting absorber. 34.
Page 97 EG–97 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 37. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE: Be careful not to hit the PS gear housing or park/neutral position switch (A/T). (b) Make sure the engine is clear of all wiring, hoses and cables.
Page 98 EG–98 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL COMPONENTS EG0F9–01...
Page 99 EG–99 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL PREPARATION FOR DISASSEMBLY EG0FA–01 (M/T) REMOVE CLUTCH COVER AND DISC (M/T) REMOVE FLYWHEEL (A/T) REMOVE DRIVE PLATE REMOVE REAR END PLATE Remove the bolt and end plate. INSTALL ENGINE ENGINE STAND DISASSEMBLY REMOVE DISTRIBUTOR (See IG section) REMOVE TIMING BELT AND PULLEYS (See page EG–29) REMOVE CYLINDER HEADS...
Page 100 EG–100 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 14. REMOVE WATER BY–PASS PIPE (a) Disconnect the two knock sensor connectors. (b) Remove the two bolts, nut and water by–pass pipe. 15. REMOVE KNOCK SENSORS Using SST, remove the two knock sensors. SST 09816–30010 16.
Page 101 EG–101 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY EG0FB–01 (See page EG–98) REMOVE REAR OIL SEAL RETAINER Remove the six bolts and retainer. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.150–0.330 mm (0.0059–0.0130 in.) Maximum thrust clearance:...
Page 102 EG–102 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings.
Page 103 EG–103 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Measure the Plastigage at its widest point. Standard oil clearance: 0.028–0.065 mm (0.0011–0.0026 in.) U/S 0.25 0.027–0.080 mm (0.0011–0.0031 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings.
Page 104 EG–104 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in correct order. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while pry- ing the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020–0.220 mm (0.0008–0.0087 in.) Maximum thrust clearance:...
Page 105 EG–105 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. Place the crankshaft on the cylinder block.
Page 106 EG–106 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL HINT: If replacing the cylinder block subassembly, the bear- ing standard clearance will be: 0.031–0.067 mm (0.0012–0.0026 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace with one having the same number.
Page 107 EG–107 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Mark ”5” 2.001–2.004 mm (0.0788–0.0789 in.) (k) Completely remove the Plastigage. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the upper main bearings and upper thrust washers from cylinder block. HINT: Arrange the main bearings and thrust washers in cor- rect order.
Page 108 EG–108 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the six cylinders or replace the cylinder block. INSPECT CYLINDER BORE DIAMETER HINT: There are three sizes of the standard cylinder bore di- ameter, marked ”1”, ”2”...
Page 109 EG–109 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL PISTON AND CONNECTING ROD ASSY DISASSEMBLY EG0FD–01 CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the two compression rings.
Page 110 EG–110 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Using a plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order.
Page 111 EG–111 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL INSPECT PISTON Inspect piston oil clearance HINT: There are three sizes of the standard diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top of the piston. (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 26 mm (1.02 in.) from the piston head.
Page 112 EG–112 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Inspect piston ring groove clearance Using a thickness gauge, measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearance: No.1 0.010–0.080 mm (0.0004–0.0031 in.) No.2 0.030–0.070 mm (0.0012–0.0028 in.) If the clearance is greater than maximum, replace the piston.
Page 113 EG–113 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Inspect piston pin fit At 60 C (140 F), you should be able to push the piston pin into the piston pin hole with your thumb. INSPECT CONNECTING ROD Inspect connecting rod alignment Using a rod aligner and thickness gauge, check the connect- ing rod alignment.
Page 114 EG–114 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL If necessary, replace connecting rod bushing (a) Using SST and a press, press out the bushing. SST 09222–30010 (b) Align the oil holes of a new bushing and the connecting rod. (c) Using SST and a press, press in the bushing. SST 09222–30010 (d) Using a pin hone grinder, hone the bushing to obtain the standard specified clearance (see step B above) between...
Page 115 EG–115 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Inspect connecting rod bolts (a) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. (b) If the cap nut cannot be turned easily, measure the outer diameter of the compressed thread with a vernier caliper.
Page 116 EG–116 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL BORING OF CYLINDER EG0FF–01 HINT: Bore all the six cylinders for the oversized piston outside diameter. Replace the piston rings with ones to match the oversized pistons. KEEP OVERSIZED PISTONS Oversized piston diameter: O/S 0.50 87.945–87.975 mm (3.4624–3.4636 in.) CALCULATE AMOUNT TO BORE CYLINDER (a) Using a micrometer, measure the piston diameter at right...
Page 117 EG–117 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CRANKSHAFT INSPECTION AND REPAIR EGOFG–01 INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V–blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft.
Page 118 EG–118 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CRANKSHAFT OIL SEALS REPLACEMENT EG0FH–01 HINT: There are two methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL If oil pump is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal.
Page 119 EG–119 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal retainer is removed from cylinder block: (a) Using screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge.
Page 120 EG–120 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL PISTON AND CONNECTING ROD ASSEMBLY EG0FJ–01 ASSEMBLE PISTON AND CONNECTING ROD (a) Install a new snap ring on one side of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.
Page 121 EG–121 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using a piston ring expander, install the two compression rings with the code mark facing upward. Code mark: No.1 T or 1R No.2 T2 or 2R (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends.
Page 122 EG–122 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CYLINDER BLOCK ASSEMBLY EG0FK–01 (See page EG–98) HINT: Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O–rings and oil seals with new parts. INSTALL MAIN BEARINGS HINT: Main bearings come in widths of 20 mm (0.79 in.) and 22 mm...
Page 123 EG–123 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Install the main bearing cap with the front mark facing forward. Install main bearing cap bolts HINT: The main bearing cap bolts are tightened in two progressive steps (steps (b) and (d)). If any main bearing cap bolt is broken or deformed, replace (a) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts.
Page 124 EG–124 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. INSTALL CONNECTING ROD CAPS Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod.
Page 125 EG–125 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (d) Retighten the connecting rod cap nuts 905 as shown. (e) Check that the painted mark is now at a 905 angle to the front. Check that the crankshaft turns smoothly. (g) Check the connecting rod thrust clearance. (See step 2 on page EG–101) INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be careful not...
Page 126 EG–126 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL POST ASSEMBLY EG0FL–01 INSTALL NO.2 IDLER PULLEY BRACKET Install the pulley bracket with the three bolts. Torque the bolts. Torque: 37 N m (380 kgf cm, 27 ft lbf) INSTALL KNOCK SENSORS Using SST, install the two knock sensors. SST 09816–30010 Torque: 44 N m (450 kgf cm, 33 ft lbf) INSTALL WATER BY–PASS PIPE...
Page 127 EG–127 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (c) Install the by–pass pipe with the two bolts and nut. Torque: 8.3 N m (85 kgf cm, 74 ft lbf) (d) Connect the two knock sensor connectors. INSTALL ENGINE COOLANT DRAIN COCK (a) Install a new drain cock as shown. Torque: 39 N m (400 kgf cm, 29 ft lbf) (b) Install the drain hose clamp with the bolt.
Page 128 EG–128 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 11. INSTALL DISTRIBUTOR (See IG section) 12. REMOVE ENGINE STAND 13. INSTALL REAR END PLATE Install the end plate with the bolt. Torque: 8.3 N m (85 kgf cm, 74 in. lbf) 14. (M/T) INSTALL FLYWHEEL (a) Apply adhesive to two or three threads of the mount bolt end.
Page 129 EG–129 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL ENGINE INSTALLATION EG0FM–02 (See page EG–88) INSTALL RR ENGINE MOUNTING INSULATOR Install the mounting insulator with the four bolts. Torque: 77 N m (790 kgf cm, 57 ft lbf) INSTALL FR ENGINE MOUNTING INSULATOR Install the mounting insulator with the three bolts.
Page 130 EG–130 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL INSTALL NO.2 ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD (a) Temporarily install the engine moving control rod and No.2 engine mounting bracket with the three bolts in the sequence shown. (b) Tighten the three bolts in the sequence shown. Torque: 64 N m (650 kgf cm, 47 ft lbf) (c) Install the RH mounting stays with the three bolts and nut.
Page 131 EG–131 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL CONNECT RR ENGINE MOUNTING INSULATOR (a) Connect the mounting insulator with the four nuts. Torque: 66 N m (670 kgf cm, 48 ft lbf) (b) Install the hole plugs. 10. CONNECT LH ENGINE MOUNTING INSULATOR (M/T) Connect the mounting insulator with the three bolts.
Page 132 EG–132 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 15. CONNECT PS ACV (a) Connect the PS ACV with the nut. (b) Connect the two PS air hoses. 16. INSTALL FRONT EXHAUST PIPE (a) Place three new gaskets on the front exhaust pipe. (b) Install the front exhaust pipe with the bolts and six nuts.
Page 133 EG–133 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 19. CONNECT VACUUM HOSES (a) Brake booster vacuum hose to air intake chamber (b) Charcoal canister vacuum hose (c) IACV vacuum tank vacuum hose 20. CONNECT TRANSAXLE CONTROL CABLE (S) TO TRANSAXLE...
Page 134 EG–134 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 21. (M/T) INSTALL CLUTCH RELEASE CYLINDER Install the release cylinder and tube with the four bolts. 22. (M/T) INSTALL STARTER 23. CONNECT FUEL INLET HOSE Torque: 29 N m (300 kgf cm, 22 ft lbf) 24.
Page 135 EG–135 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Data link connector 1 Ground strap from RH fender apron (k) (M/T) Back–up light switch connector (M/T) Speed sensor connector 27. INSTALL ENGINE COOLANT RESERVOIR TANK 28. INSTALL WASHER TANK (a) Connect the connector and vinyl hose to the washer tank. (b) Install the washer tank with the three bolts.
Page 136 EG–136 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL 33. INSTALL AIR CLEANER ASSEMBLY, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Install the air cleaner case with three bolts. (b) Install the air filter. (c) Connect the air cleaner hose to the throttle body. (d) Install the air cleaner cap together with the volume air flow meter and air cleaner hose.
Page 137 EG–137 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL (b) Adjust the PS drive belt. (See SR section) Drive belt tension: New belt 150–185 lb Used belt 115 20 lb (c) Adjust the ignition timing. (See IG section) Ignition timing: BTDC @ idle (w/ Terminals TE1 and E1 connected) 41.
Page 138 EG–138 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL EXHAUST SYSTEM COMPONENTS EG0FN–01...
Page 139 EG–139 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL SERVICE SPECIFICATIONS SERVICE DATA EG0FP–01 Ñ Ñ Ñ Ñ Ñ Ñ Idle speed Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ –– Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ 50 rpm Intake at Idle speed...
Page 140 EG–140 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Camshaft Thrust clearance–STD 0.033–0.080 mm (0.0013–0.0031 in.)
Page 141 EG–141 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Connecting Thrust clearance–STD 0.150–0.330 mm (0.0059–0.0130 in.)
Page 142 EG–142 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ No.
Page 143 EG–143 ENGINE TROUBLESHOOTING – ENGINE MECHANICAL Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ RR engine mounting insulator X Cylinder block FR engine mounting insulator X Cylinder block Ñ...
Page 144 EG–144 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS SYSTEM PURPOSE EG08A–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ System Abbreviation Purpose...
Page 145 EG–144 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS SYSTEM PURPOSE EG08A–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ System Abbreviation Purpose...
Page 146 EG–145 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS LAYOUT AND SCHEMATIC DRAWING EG08E–01...
Page 147 EG–146 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EG08F–01 To reduce HC emission, crankcase blow–by gas (HC) is routed through the PCV valve to the air intake chamber for combustion in the cylinders.
Page 148 EG–147 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS PCV VALVE INSPECTION EG08G–01 REMOVE PCV VALVE INSTALL CLEAN HOSE TO PCV VALVE BLOW AIR FROM CYLINDER HEAD SIDE Check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful.
Page 149 EG–148 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM EG08J–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ To reduce HC emissions, evaporated fuel from the fuel tank is routed through the charcoal canister to the intake manifold for combustion in the cylinders.
Page 150 EG–149 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS FUEL VAPOR LINES, FUEL TANK AND TANK CAP INSPECTION EG08K–01 VISUALLY INSPECT LINES AND CONNECTIONS Look for loose connections, sharp bends or damage. VISUALLY INSPECT FUEL TANK Look for deformation, cracks or fuel leakage. VISUALLY INSPECT FUEL TANK CAP Check if the cap and / or gasket are deformed or damaged.
Page 151 EG–150 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS TVV INSPECTION EG08M–01 CHECK TVV BY BLOWING AIR INTO PIPE (a) Drain the engine coolant from the radiator into a suitable container. (b) Remove the TVV from the water by–pass outlet. (c) Cool the TVV to below 35C (95F) with cool water. (d) Blow air into a port and check that the TVV is closed.
Page 152 EG–151 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS EXHAUST GAS RECIRCULATION(EGR) SYSTEM EG08P–01 To reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature.
Page 153 EG–152 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS EGR SYSTEM INSPECTION EG08Q–01 CHECK AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Check the filter for contamination or damage. (b) Using compressed air, clean the filter. HINT: Install the filter with the coarser surface facing the at- mospheric side (outward).
Page 154 EG–153 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS CHECK EGR VALVE (a) Apply vacuum directly to the EGr valve with the engine idling. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to the proper locations. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, SYSTEM IS NORMAL;...
Page 155 EG–154 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS TVV INSPECTION EG08T–01 CHECK TVV BY BLOWING AIR INTO PIPE (a) Drain the engine coolant from the radiator into a suitable container. (b) Remove the TVV from the water by–pass outlet. (c) Cool the TVV to below 35C (95F) with cool water. (d) Blow air into the pipe, and check that the TVV is closed.
Page 156 EG–155 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EG08U–01 EXHAUST PIPE ASSEMBLY INSPECTION EG08V–01 CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE...
Page 157 EG–156 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEMS THREE–WAY CATALYTIC CONVERTER INSPECTION EG08W–01 CHECK FOR DENTS OR DAMAGE If any part of protector is damaged or dented to the extent that it contacts the three–way catalytic converter, repair or re- place it. HEAT INSULATOR INSPECTION EG08X–01 CHECK HEAT INSULATOR FOR DAMAGE...
Page 158 EG–157 ENGINE TROUBLESHOOTING – EMISSION CONTROL SYSTEM SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS EG08Z–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Part tightened Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 159 EG–158 ENGINE TROUBLESHOOTING – SFI SYSTEM SFI SYSTEM DESCRIPTION SYSTEM CIRCUIT EG0FR–01...
Page 160 The air induction system provides sufficient air for engine operation. ELECTRONIC CONTROL SYSTEM EG0FV–01 The CAMRY 3VZ–FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which cen- trally controls the SFI, EI, IAC, Diagnosis systems etc. by means of an ECM (ECM–formerly SFI computer) employing a microcomputer.
Page 161 EG–160 ENGINE TROUBLESHOOTING – SFI SYSTEM OPERATION FUEL SYSTEM EG0FW–02 Fuel is pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector and cold start injector at a set pressure maintained by the pressure regulator. The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side) to a pres- sure 284 kPa (2.9 kgf/cm , 41 psi) higher than the pressure inside the intake manifold, and excess fuel is...
Page 162 EG–161 ENGINE TROUBLESHOOTING – SFI SYSTEM AIR INDUCTION SYSTEM EG0FX–02 Air filtered through the air cleaner passes through the volume air flow meter and the amount flowing to the air intake chamber is determined according to the throttle valve opening in the throttle body and the engine rpm.
Page 163 EG–162 ENGINE TROUBLESHOOTING – SFI SYSTEM ELECTRONIC CONTROL SYSTEM EG0FY–02 The control system consists of sensors which detect various engine conditions, and a ECM which deter- mines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air volume, engine rpm, oxygen density in the exhaust gas, engine coolant temperature, intake air temperature and atmospheric pressure etc.
Page 164 EG–163 ENGINE TROUBLESHOOTING – SFI SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) EG0FZ–01 RECOMMENDED TOOLS EG0G0–01...
Page 165 EG–164 ENGINE TROUBLESHOOTING – SFI SYSTEM EQUIPMENT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ EG0G1–01 Graduated cylinder Injector...
Page 166 EG–165 ENGINE TROUBLESHOOTING – SFI SYSTEM PRECAUTIONS EG0G2–01 Before working on the fuel system, disconnect the cable from negative (–) terminal of the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. There- fore, if necessary, read the diagnosis before removing the battery terminal.
Page 167 EG–166 ENGINE TROUBLESHOOTING – SFI SYSTEM IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) EG0G4–02 The ECM has been designed so that it will not be affected by outside interference. However, if your vehicle is equipped with a CB radio trans- ceiver, etc.
Page 168 EG–167 ENGINE TROUBLESHOOTING – SFI SYSTEM ELECTRONIC CONTROL SYSTEM EG0G6–01 Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. HINT: Always check the diagnostic trouble code before dis- connecting the battery terminal.
Page 169 EG–168 ENGINE TROUBLESHOOTING – SFI SYSTEM When inspecting a connector with a volt/ohmmeter. (a) Carefully take out the water–proofing rubber if it is a water–proof type connector. (b) Insert the test probe into the connector from wiring side when checking the continuity, amperage or voltage. (c) Do not apply unnecessary force to the terminal.
Page 170 EG–169 ENGINE TROUBLESHOOTING – SFI SYSTEM Observe the following precautions when removing and installing the injectors. (a) Never reuse the O–ring. (b) When placing a new O–ring on the injector, take care not to damage it in any way. (c) Coat a new O–ring with spindle oil or gasoline before installing–never use engine, gear or brake oil.
Page 171 EG–170 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL PUMP SYSTEM CIRCUIT EG0GD–01 ON–VEHICLE INSPECTION EG0GE–01 CHECK FUEL PUMP OPERATION (a) Using SST, connect terminals +B and FP of the data link connector 1. SST 09843–18020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine.
Page 172 EG–171 ENGINE TROUBLESHOOTING – SFI SYSTEM (d) Remove SST. SST 09843–18020 (e) Turn the ignition switch OFF. If there is no pressure, check the following parts: Fusible link Fuses (AM2 30A, EFI 15A, IGN 7.5A) SFI main relay Fuel pump Wiring connections CHECK FUEL PRESSURE (a) Check that the battery voltage is above 12 volts.
Page 173 EG–172 ENGINE TROUBLESHOOTING – SFI SYSTEM (h) Using SST, connect terminals +B and FP of the data link connector 1. SST 09843–18020 Reconnect the battery negative (–) cable. Turn the ignition switch ON. (k) Measure the fuel pressure. Fuel pressure: 265–304 kPa (2.7–3.1 kgf/cm , 38–44 psi) If pressure is high, replace the fuel pressure regulator.
Page 174 EG–173 ENGINE TROUBLESHOOTING – SFI SYSTEM Stop the engine. Check that the fuel pressure remains 147 kPa (1.5 kgf/cm , 21 psi) or more for 5 minutes after the engine is turned off. If pressure is not as specified, check the fuel pump, pressure regulator and/or injector.
Page 175 EG–174 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL PUMP REMOVAL AND INSPECTION EG0GF–01 CAUTION: Do not smoke or work near an open flame when working on the fuel pump. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Air bag): Work must be started after approx.
Page 176 EG–175 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE: These tests must be performed quickly (within 10 seconds) to prevent the coil burning out.
Page 177 EG–176 ENGINE TROUBLESHOOTING – SFI SYSTEM COMPONENTS EG0GG–01 FUEL PUMP DISASSEMBLY EG0GH–01 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET (a) Remove the fuel pump lead wire. (b) Pull off the lower side of the fuel pump from the pump bracket. (c) Disconnect the fuel hose from the fuel pump, and remove the fuel pump.
Page 178 EG–177 ENGINE TROUBLESHOOTING – SFI SYSTEM REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. REMOVE CONNECTOR Remove the two screws, connector support, connector and gasket. FUEL PUMP ASSEMBLY EG0GJ–01 (See page EG–176) INSTALL CONNECTOR...
Page 179 EG–178 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL PUMP INSTALLATION EG0GK–01 (See page EG–174) INSTALL FUEL PUMP BRACKET ASSEMBLY TO FUEL TANK (a) Install a new gasket to the pump bracket. (b) Insert the pump bracket assembly into the fuel tank. (c) Install the pump bracket with the eight screws.
Page 180 EG–179 ENGINE TROUBLESHOOTING – SFI SYSTEM COLD START INJECTOR ON–VEHICLE INSPECTION EG0GL–01 INSPECT RESISTANCE OF COLD START INJECTOR (a) Disconnect the cold start injector connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 2–4 W If the resistance is not as specified, replace the cold start in- jector.
Page 181 EG–180 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 182 EG–181 ENGINE TROUBLESHOOTING – SFI SYSTEM COLD START INJECTOR INSPECTION EG0GN–01 INSPECT INJECTION OF COLD START INJECTOR CAUTION: Keep injector clear of sparks during the test. (a) Put a suitable container or shop towel under the fuel filter. (b) Remove the union bolt and two gaskets, and disconnect the fuel inlet hose from the fuel filter outlet.
Page 183 EG–182 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT LEAKAGE (a) In the condition above, disconnect the test probes of SST (wire) from the battery and check fuel leakage from the injector. SST 09842–30050 Fuel drop: One drop or less per minute (b) Disconnect the battery negative (–) cable.
Page 184 EG–183 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL PRESSURE REGULATOR ON–VEHICLE INSPECTION EG0GQ–01 INSPECT FUEL PRESSURE (See page EG–171) FUEL PRESSURE REGULATOR REMOVAL EG0GR–01 REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the two nuts and V– bank cover.
Page 185 EG–184 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT VACUUM SENSING HOSE DISCONNECT FUEL RETURN HOSE (a) Put a suitable container or shop towel under the pressure regulator. (b) Disconnect the return hose from the pressure regulator. REMOVE FUEL PRESSURE REGULATOR Loosen the lock nut, and remove the pressure regulator. FUEL PRESSURE REGULATOR INSTALLATION EG0GS–01...
Page 186 EG–185 ENGINE TROUBLESHOOTING – SFI SYSTEM CONNECT FUEL RETURN HOSE CONNECT VACUUM SENSING HOSE CHECK FOR FUEL LEAKAGE (See page EG–160) INSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the two nuts.
Page 187 EG–186 ENGINE TROUBLESHOOTING – SFI SYSTEM INJECTORS ON–VEHICLE INSPECTION EG0GT–01 INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm.
Page 188 EG–187 ENGINE TROUBLESHOOTING – SFI SYSTEM INJECTORS REMOVAL EG0GU–01...
Page 189 EG–188 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 190 EG–189 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT HOSES (a) Brake booster vacuum hose (b) PS air hose (c) PCV hose (d) IACV vacuum hose DISCONNECT GROUND STRAPS Remove the nut and disconnect the two ground straps. 10. DISCONNECT COLD START INJECTOR CONNECTOR 11.
Page 191 EG–190 ENGINE TROUBLESHOOTING – SFI SYSTEM (h) Using 8 mm hexagon wrench, remove the two bolts, nuts, air intake chamber and gasket. 16. DISCONNECT FUEL INLET AND RETURN HOSES (a) Disconnect the fuel return hoses from the No.1 fuel pipe. (b) Disconnect the fuel inlet hose from the fuel filter.
Page 192 EG–191 ENGINE TROUBLESHOOTING – SFI SYSTEM 20. REMOVE AIR PIPE WITH HOSES (a) Disconnect the two air hoses. (b) Remove the bolts and air pipe with hoses. 21. REMOVE RH DELIVERY PIPE AND INJECTORS (a) Remove three bolts and RH delivery pipe together with the three injectors.
Page 193 EG–192 ENGINE TROUBLESHOOTING – SFI SYSTEM (e) Install a new O–ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41045 (g) Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.
Page 194 EG–193 ENGINE TROUBLESHOOTING – SFI SYSTEM INJECTORS INSTALLATION EG0GW–02 (See page EG–187) INSTALL INJECTORS TO DELIVERY PIPES (a) Install two new grommets to the injector. (b) Apply a light coat of gasoline to two new O–rings and install them to the injector. (c) When turning the injector left and right, install it to the delivery pipes.
Page 195 EG–194 ENGINE TROUBLESHOOTING – SFI SYSTEM INSTALL AIR PIPE WITH HOSES (a) Install the air pipe with the two bolts. Torque: 8.3 N m (85 kgf cm, 74 in. lbf) (b) Connect the two air hoses. INSTALL LH DELIVERY PIPE AND INJECTORS (a) Place the two spacers in position on the intake manifold.
Page 196 EG–195 ENGINE TROUBLESHOOTING – SFI SYSTEM CONNECT FUEL INLET AND RETURN HOSES (a) Connect the inlet hose to the fuel filter with two new gaskets and union bolt. Torque: 29 N m (300 kgf cm, 22 ft lbf) (b) Connect the return hose to the No.1 fuel pipe. INSTALL AIR INTAKE CHAMBER (a) Using 8 mm hexagon wrench, install a new gasket and the air intake number with the two bolts and nuts.
Page 197 EG–196 ENGINE TROUBLESHOOTING – SFI SYSTEM CONNECT HYDRAULIC MOTOR PRESSURE PIPE Connect the hydraulic pressure pipe to the air intake cham- ber with the bolt. 10. INSTALL EGR PIPE Install a new gasket, sleeve ball and the EGR pipe with the two bolts and union nut.
Page 198 EG–197 ENGINE TROUBLESHOOTING – SFI SYSTEM 17. INSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the two nuts. 18. INSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Connect the air cleaner hose, and install the air cleaner cap and volume air flow meter with the four clips.
Page 199 EG–198 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL TANK AND LINES COMPONENTS EG0GX–01...
Page 200 EG–199 ENGINE TROUBLESHOOTING – SFI SYSTEM PRECAUTIONS EG0GY–01 Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened. FUEL LINES AND CONNECTIONS INSPECTION EG0GZ–01 (a) Check the fuel lines for cracks or leakage, and all connections for deformation.
Page 201 EG–200 ENGINE TROUBLESHOOTING – SFI SYSTEM VOLUME AIR FLOW METER ON–VEHICLE INSPECTION EG0H0–01 INSPECT RESISTANCE OF VOLUME AIR FLOW METER (a) Disconnect the volume air flow meter connector. (b) Using an ohmmeter, measure the resistance between each terminal. Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 202 EG–201 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable disconnected from the battery.
Page 203 EG–202 ENGINE TROUBLESHOOTING – SFI SYSTEM VOLUME AIR FLOW METER INSTALLATION EG0H3–01 (See page EG–200) INSTALL VOLUME AIR FLOW METER TO AIR CLEANER (a) Install the volume air flow meter with the gasket, lock plate, four plate washers, four nuts and bolt. Pry the lock plate on the nut.
Page 204 EG–203 ENGINE TROUBLESHOOTING – SFI SYSTEM THROTTLE BODY ON–VEHICLE INSPECTION EG0H4–01 INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. Start the engine. Check the vacuum with your finger. Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 205 EG–204 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT AND ADJUST DASH POT (DP) Warm up engine Allow the engine to warm up to normal operating tempera- ture. Check idle speed Idle speed: 50 rpm Remove cap, filter and separator from DP Check and adjust DP setting speed (a) Maintain the engine at 3,000 rpm.
Page 206 EG–205 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT THROTTLE OPENER Warm up engine Allow the engine to warm up to normal operating tempera- ture. Check idle speed Idle speed: 50 rpm Check throttle opener setting speed (a) Disconnect the vacuum hose from the throttle opener, and plug the hose end.
Page 207 EG–206 ENGINE TROUBLESHOOTING – SFI SYSTEM THROTTLE BODY REMOVAL EG0H5–01 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 208 EG–207 ENGINE TROUBLESHOOTING – SFI SYSTEM REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the volume air flow meter connector. (b) Disconnect the coil cord clamp. (c) Disconnect the air hoses. (d) Loosen the air cleaner hose clamp bolt. (e) Disconnect the air cleaner cap clips.
Page 209 EG–208 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Insert a thickness gauge between the throttle stop screw and stop lever. (c) Using an ohmmeter, measure the resistance between each terminal. Ñ...
Page 210 EG–209 ENGINE TROUBLESHOOTING – SFI SYSTEM THROTTLE BODY INSTALLATION EG0H7–01 (See page EG–206) INSTALL THROTTLE BODY Install a new gasket and the throttle body with the two bolts and two nuts. Torque: 13 N m (130 kgf cm, 9 ft lbf) CONNECT HOSES TO THROTTLE BODY (a) Water by–pass hose (b) Emission control vacuum hoses...
Page 211 EG–210 ENGINE TROUBLESHOOTING – SFI SYSTEM IAC VALVE EG0H8–01 ON–VEHICLE INSPECTION EG0H9–01 CHECK FOR OPERATING SOUND FROM IAC VALVE Check that there is a clicking sound immediately stopping the engine. INSPECT IAC VALVE RESISTANCE (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminals B1–S1 or S3, and B2–S2 or S4.
Page 212 EG–211 ENGINE TROUBLESHOOTING – SFI SYSTEM If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. INSPECT AIR ASSIST SYSTEM (a) Start and wame up the engine. (b) Disconnect the No.5 air hose from the IAC valve and plug the hose end with your finger.
Page 213 EG–212 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 214 EG–213 ENGINE TROUBLESHOOTING – SFI SYSTEM IAC VALVE INSTALLATION EG0HC–01 (See page EG–210) INSTALL IAC VALVE (a) Install a new gasket and the IAC valve with the two bolts. Torque: 13 N m (130 kgf cm, 9 ft lbf) CONNECT PS IDLE UP VACUUM HOSE CONNECT TWO WATER BY–PASS HOSES CONNECT TWO AIR HOSES CONNECT IAC VALVE CONNECTOR...
Page 215 EG–214 ENGINE TROUBLESHOOTING – SFI SYSTEM INTAKE AIR CONTROL VALVE (IACV) ON–VEHICLE INSPECTION EG0HD–01 INSPECT IACV (a) Using a 3–way connector, connect vacuum gauge to the actuator hose. (b) Start the engine. (c) While the engine is idling, check that the vacuum gauge needle does not move.
Page 216 EG–215 ENGINE TROUBLESHOOTING – SFI SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 217 EG–216 ENGINE TROUBLESHOOTING – SFI SYSTEM IACV AND COMPONENTS INSPECTION EG0HF–01 INSPECT IACV (a) With 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum in (a), check that the actuator rod does not return.
Page 218 EG–217 ENGINE TROUBLESHOOTING – SFI SYSTEM Inspect VSV operation (a) Check that air flows from pipe E to the filter. (b) Apply battery voltage across the terminals. (c) Check that air flows from pipe E to pipe F. If operation is not as specified, replace the VSV. IACV INSTALLATION EG0HG–01 (See page EG–214)
Page 219 EG–218 ENGINE TROUBLESHOOTING – SFI SYSTEM INSTALL COLD START INJECTOR Install a new gasket and the injector with the two nuts. Torque: 8.3 N m (85 kgf cm, 74 in. lbf) CONNECT COLD START INJECTOR (NO.2 FUEL PIPE) Connect the injector pipe with two new gaskets and the union bolt.
Page 220 EG–219 ENGINE TROUBLESHOOTING – SFI SYSTEM ELECTRONIC PARTS LOCATION EG0HH–04...
Page 221 EG–220 ENGINE TROUBLESHOOTING – SFI SYSTEM SFI MAIN RELAY EG0HJ–01 SFI MAIN RELAY INSPECTION EG0HK–01 INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is no continuity between terminals 2 and 4. If continuity is not as specified, replace the relay.
Page 222 EG–221 ENGINE TROUBLESHOOTING – SFI SYSTEM CIRCUIT OPENING RELAY EGOHL–01 CIRCUIT OPENING RELAY REMOVAL AND INSTALLATION EG0HM–02...
Page 223 EG–222 ENGINE TROUBLESHOOTING – SFI SYSTEM CIRCUIT OPENING RELAY INSPECTION EG0HN–01 INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals ST and E1. (b) Check that there is continuity between terminals IG and FC. (c) Check that there is no continuity between terminals B and FP. If continuity is not as specified, replace the relay.
Page 224 EG–223 ENGINE TROUBLESHOOTING – SFI SYSTEM COLD START INJECTOR TIME SWITCH EGOHP–01 COLD START INJECTOR TIME SWITCH INSPECTION EGOHQ–01 INSPECT RESISTANCE OF COLD START INJECTOR TIME SWITCH Using an ohmmeter, measure the resistance between each terminal. Resistance: STA–STJ 25–45 W below 15 C (59 F) 65–85 W above 30 C (86 F) STA–Ground 25–85 W...
Page 225 EG–224 ENGINE TROUBLESHOOTING – SFI SYSTEM ENGINE COOLANT TEMPERATURE SENSOR EGOHR–01 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION EGOHS–01 INSPECT RESISTANCE OF ENGINE COOLANT TEMPERA- TURE SENSOR Using an ohmmeter, measure the resistance between the ter- minals. Resistance: Refer to the chart above If the resistance is not as specified, replace the sensor.
Page 226 EG–225 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL PRESSURE VSV EGOHT–01 FUEL PRESSURE VSV INSPECTION EGOHU–01 CHECK VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39 W If there is no continuity, replace the VSV. CHECK VSV FOR GROUND Using an ohmmeter, check that there is no continuity be- tween each terminal and the body.
Page 227 EG–226 ENGINE TROUBLESHOOTING – SFI SYSTEM CHECK VSV OPERATION (a) Check that the air flows from port E to port G. (b) Apply battery voltage across the terminals. (c) Check that the air flows from port E to the filter. If operation is not as specified, replace the VSV.
Page 228 EG–227 ENGINE TROUBLESHOOTING – SFI SYSTEM EGR GAS TEMPERATURE SENSOR (CALIFORNIA ONLY) EGOHV–01 EGR GAS TEMPERATURE SENSOR INSPECTION EG0HW–01 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the ter- minals. Resistance: 69–89 kW at 50 C (112 F) 11 –15 kW at 100C (212F) 2 –...
Page 229 EG–227 ENGINE TROUBLESHOOTING – SFI SYSTEM EGR GAS TEMPERATURE SENSOR (CALIFORNIA ONLY) EGOHV–01 EGR GAS TEMPERATURE SENSOR INSPECTION EG0HW–01 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the ter- minals. Resistance: 69–89 kW at 50 C (112 F) 11 –15 kW at 100C (212F) 2 –...
Page 230 EG–228 ENGINE TROUBLESHOOTING – SFI SYSTEM OXYGEN SENSOR OXYGEN SENSOR INSPECTION EG0HX–01 WARM UP ENGINE Allow the engine to warm up to normal operating tempera- ture. INSPECT FEEDBACK VOLTAGE Connect the position (+) probe of a voltmeter to terminal VF1 (for LH bank) or VF2 (for RH bank) of the data link connector 1, and negative (–) probe to terminal E1.
Page 231 EG–229 ENGINE TROUBLESHOOTING – SFI SYSTEM...
Page 232 EG–230 ENGINE TROUBLESHOOTING – SFI SYSTEM SUB–OXYGEN SENSOR (CALIFORNIA ONLY) SUB–OXYGEN SENSOR INSPECTION EG0HY–01 INSPECT SUB–OXYGEN SENSOR HINT: Inspect only when code No.27 is displayed. (a) Cancel the diagnostic trouble code. (See TR section) (b) Warm up the engine until it reaches normal operating temperature.
Page 233 EG–230 ENGINE TROUBLESHOOTING – SFI SYSTEM SUB–OXYGEN SENSOR (CALIFORNIA ONLY) SUB–OXYGEN SENSOR INSPECTION EG0HY–01 INSPECT SUB–OXYGEN SENSOR HINT: Inspect only when code No.27 is displayed. (a) Cancel the diagnostic trouble code. (See TR section) (b) Warm up the engine until it reaches normal operating temperature.
Page 234 EG–231 ENGINE TROUBLESHOOTING – SFI SYSTEM ENGINE CONTROL MODULE (ECM) Engine Control Module (ECM) Terminals EG0GB–01...
Page 235 EG–232 ENGINE TROUBLESHOOTING – SFI SYSTEM ECM REMOVAL AND INSTALLATION EG0HZ–01 ECM INSPECTION EG0J0–01 HINT: The SFI circuit can be checked by measuring the resis- tance and voltage at the wiring connectors of the ECM. PREPARATION (a) Disconnect the connectors from the ECM. (b) Remove the locks as shown in the illustration so that the tester probe(s) can easily come in.
Page 236 EG–233 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT VOLTAGE OF ECM Check the voltage between each terminal of the wiring con- nectors. Turn the ignition switch ON. Measure the voltage at each terminal. HINT: Perform all voltage measurements with the connectors connected.
Page 237 EG–234 ENGINE TROUBLESHOOTING – SFI SYSTEM ECM Wiring Connectors Voltage...
Page 238 EG–235 ENGINE TROUBLESHOOTING – SFI SYSTEM INSPECT RESISTANCE OF ECM NOTICE: Do not touch the ECM terminals. The tester probe should be inserted in the wiring connector from the wiring side. Check the resistance between each of the terminals of the wiring connector.
Page 239 EG–236 ENGINE TROUBLESHOOTING – SFI SYSTEM FUEL CUT RPM FUEL CUT RPM INSPECTION EG0J1–01 REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the two nuts and V– bank cover. WARM UP ENGINE Allow the engine to warm up to normal operating tempera- ture.
Page 240 EG–237 ENGINE TROUBLESHOOTING – SFI SYSTEM SERVICE SPECIFICATIONS SERVICE DATA EG0J2–01 Fuel pressure Fuel pressure at no vacuum 26–304 kPa Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 241 EG–238 ENGINE TROUBLESHOOTING – SFI SYSTEM SERVICE DATA (Cont’d) Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ HINT: Ñ...
Page 242 EG–239 ENGINE TROUBLESHOOTING – SFI SYSTEM SERVICE DATA (Cont’d) Ñ Ñ Ñ Ñ Ñ Ñ ECM (cont’d) Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 243 EG–240 ENGINE TROUBLESHOOTING – COOLING SYSTEM COOLING SYSTEM DESCRIPTION EG09K–01 This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by–pass valve mounted on the inlet side. The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electronically controlled hydraulic cooling fan, hoses and other components.
Page 244 EG–241 ENGINE TROUBLESHOOTING – COOLING SYSTEM RADIATOR The radiator performs function of cooling the engine coolant which has passed through the water jacket and become hot, and it is, mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank, and a core which connects the two tanks.
Page 245 EG–242 ENGINE TROUBLESHOOTING – COOLING SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) EG09L–01 RECOMMENDED TOOLS EG09M–01 EQUIPMENT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 246 EG–243 ENGINE TROUBLESHOOTING – COOLING SYSTEM LUBRICANT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ EG09P–01 Item Capacity...
Page 247 EG–244 ENGINE TROUBLESHOOTING – COOLING SYSTEM COOLANT CHECK AND REPLACEMENT EG09S–01 CHECK ENGINE COOLANT LEVEL AT RESERVE TANK The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add engine coolant up to the ”FULL”...
Page 248 EG–245 ENGINE TROUBLESHOOTING – COOLING SYSTEM NOTICE: Do not use alcohol type coolant. The engine coolant should be mixed with demineralized water or distilled water. Capacity (w / Heater): 8.5 liters (9.0 US qts, 7.5 lmp. qts) 8.4 liters (8.9 US qts, 7.4 lmp. qts) 9.0 liters (9.5 US qts, 7.9 lmp.
Page 249 EG–246 ENGINE TROUBLESHOOTING – COOLING SYSTEM WATER PUMP COMPONENTS EG09T–01 WATER PUMP REMOVAL EG09U–01 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK”...
Page 250 EG–247 ENGINE TROUBLESHOOTING – COOLING SYSTEM REMOVE WATER INLET AND THERMOSTAT (a) Disconnect the engine coolant temperature sensor connector. (b) Remove the three nuts and water inlet from the water pump. (c) Remove the thermostat and gasket. REMOVE WATER PUMP (a) Remove the seven bolts.
Page 251 EG–248 ENGINE TROUBLESHOOTING – COOLING SYSTEM WATER PUMP INSTALLATION EG09W–01 (See page EG–246) INSTALL WATER PUMP (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block.
Page 252 EG–249 ENGINE TROUBLESHOOTING – COOLING SYSTEM (c) Install the water inlet with the three nuts. Torque: 20 N m (200 kgf cm, 14 ft lbf) INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe. (b) Apply soapy water to the O–ring. (c) Connect the water inlet pipe to the water inlet.
Page 253 EG–250 ENGINE TROUBLESHOOTING – COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL EG09X–01 HINT: Removal of the thermostat would have an adverse ef- fect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx.
Page 254 EG–251 ENGINE TROUBLESHOOTING – COOLING SYSTEM REMOVE WATER INLET PIPE (a) Remove the bolt holding the water inlet pipe to the generator belt adjusting bar. (b) Remove the water inlet pipe and O–ring. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR REMOVE WATER INLET Remove the three nuts and water inlet from water pump.
Page 255 EG–252 ENGINE TROUBLESHOOTING – COOLING SYSTEM THERMOSTAT INSTALLATION EG09Z–01 (See page EG–250) PLACE THERMOSTAT IN WATER PUMP (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with stud bolt (A), and insert the thermostat in the water pump. INSTALL WATER INLET Install the water inlet with the three nuts.
Page 256 EG–253 ENGINE TROUBLESHOOTING – COOLING SYSTEM RADIATOR RADIATOR CLEANING EG0A0–01 Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,942–3,432 kPa (30–35 kgf/cm 427–498 psi), keep a distance at least 40–50 cm (15.75 –19.69 in.) between the radiator core and cleaner nozzle.
Page 257 EG–254 ENGINE TROUBLESHOOTING – COOLING SYSTEM Water outlet side 83–113 kPa (0.85–1.15 kgf/cm , 12.1–16.4 psi) Minimum opening pressure: Radiator side 78 kPa (0.8 kgf/cm , 11.4 psi) Water outlet side 69 kPa (0.7 kgf/cm , 10.0 psi) If the opening pressure is less than minimum, replace the ra- diator cap.
Page 258 EG–255 ENGINE TROUBLESHOOTING – COOLING SYSTEM RADIATOR REMOVAL EG0A2–01 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 259 EG–256 ENGINE TROUBLESHOOTING – COOLING SYSTEM DISCONNECT RADIATOR UPPER HOSE DISCONNECT ENGINE COOLANT RESERVOIR HOSE DISCONNECT HYDRAULIC MOTOR RETURN HOSE REMOVE ENGINE UNDER COVER DISCONNECT RADIATOR LOWER HOSE 10. (A/T) DISCONNECT OIL COOLER HOSE 11. REMOVE RADIATOR AND HYDRAULIC COOLING FAN (a) Remove the two bolts and two upper supports.
Page 260 EG–257 ENGINE TROUBLESHOOTING – COOLING SYSTEM COMPONENTS EG0A3–01 RADIATOR DISASSEMBLY EG0A4–01 ASSEMBLY OF SST SST 09230–01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B”...
Page 261 EG–258 ENGINE TROUBLESHOOTING – COOLING SYSTEM REMOVE TANKS AND O–RINGS (a) Lightly tap the radiator hose inlet (or outlet) with a soft–faced hammer and remove the tank. (b) Remove the O–ring. (A/T) REMOVE OIL COOLER FROM LOWER TANK (a) Remove the pipes. HINT: Make a note of the direction to face the pipes.
Page 262 EG–259 ENGINE TROUBLESHOOTING – COOLING SYSTEM Therefore, first correct any deformation with pliers or like object. Water leakage will result if the bottom of the lock plate groove is damaged or dented, Therefore, repair or replace if necessary. INSTALL NEW O–RINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new O–ring without twisting it.
Page 263 EG–260 ENGINE TROUBLESHOOTING – COOLING SYSTEM HINT: Do not stake the areas protruding around the pipes, brackets or tank ribs. The points shown in the illustration and oil cooler near here (A/T) cannot be staked with the SST. Use a plier or like object and be careful not to damage the core plates.
Page 264 EG–261 ENGINE TROUBLESHOOTING – COOLING SYSTEM HINT: On radiators with resin tanks, there is a clearance be- tween the tank and lock plate where a minute amount of air will remain, giving the appearance of an oil leak when the ra- diator is submerged in water.
Page 265 EG–262 ENGINE TROUBLESHOOTING – COOLING SYSTEM (A/T) CONNECT OIL COOLER HOSES CONNECT RADIATOR LOWER HOSE INSTALL ENGINE UNDER COVER CONNECT HYDRAULIC MOTOR RETURN HOSE CONNECT ENGINE COOLANT RESERVOIR HOSE CONNECT RADIATOR UPPER HOSE CONNECT PRESSURE HOSE TO HYDRAULIC MOTOR Connect the pressure hose with a new gasket and the union bolt.
Page 266 EG–263 ENGINE TROUBLESHOOTING – COOLING SYSTEM ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN SYSTEM DESCRIPTION EG0A7–01 In this system, the cooling fan ECU controls the hydraulic pressure acting on the hydraulic motor, thus con- trolling the speed of the cooling fan steplessly in response to the condition of the engine and air condition- ing.
Page 267 EG–264 ENGINE TROUBLESHOOTING – COOLING SYSTEM ON–VEHICLE INSPECTION FLUID LEVEL INSPECTION EG0A9–01 KEEP VEHICLE LEVEL INSPECT FLUID LEVEL (a) Using SST, connect terminals OP1 and E1 of the data link connector 1. SST 09843–18020 (b) Keep the engine speed at 2,000 rpm until the fluid temperature reaches the specified temperature.
Page 268 EG–265 ENGINE TROUBLESHOOTING – COOLING SYSTEM HYDRAULIC COOLING FAN SYSTEM BLEEDING EG0AA–01 CHECK FLUID LEVEL IN RESERVOIR TANK If low, add fluid. Fluid: ATF DEXRON HINT: Check that fluid level is within the ”HOT” level on reser- voir tank. If the fluid is cold, check that it is within the ”COLD” level on the tank.
Page 269 EG–266 ENGINE TROUBLESHOOTING – COOLING SYSTEM OIL PRESSURE INSPECTION EG0AB–01 CONNECT PRESSURE GAUGE (a) Remove the union bolt and gasket, and disconnect the pressure hose from the hydraulic motor. (b) Connect the gauge side of a pressure gauge to pressure hose, and the valve side to the hydraulic motor.
Page 270 EG–267 ENGINE TROUBLESHOOTING – COOLING SYSTEM (e) Measure the oil pressure at idling. Oil pressure: 981–1,961 kPa (10–20 kgf/cm , 142–284 psi) Remove the SST from the data link connector 1. SST 09843–18020 (g) Check that the oil pressure decreases.
Page 271 EG–268 ENGINE TROUBLESHOOTING – COOLING SYSTEM HYDRAULIC MOTOR HYDRAULIC MOTOR REMOVAL EG0AD–03...
Page 272 EG–269 ENGINE TROUBLESHOOTING – COOLING SYSTEM DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 273 EG–270 ENGINE TROUBLESHOOTING – COOLING SYSTEM 10. REMOVE HYDRAULIC MOTOR FROM FAN SHROUD Remove the three bolts and hydraulic motor. COMPONENTS EG0AE–01 HYDRAULIC MOTOR DISASSEMBLY EG0AF–01 MOUNT MOTOR HOUSING Slightly mount the motor housing in a vise. NOTICE: Be careful not to damage the motor housing. REMOVE MOTOR COVER (a) Remove the four bolts and motor cover.
Page 274 EG–271 ENGINE TROUBLESHOOTING – COOLING SYSTEM REMOVE REAR THRUST WASHER AND DRIVE SHAFT REMOVE DRIVE AND DRIVEN ROTORS REMOVE FRONT THRUST WASHER HYDRAULIC MOTOR INSPECTION EG0AG–01 INSPECT DRIVE AND DRIVEN ROTORS (a) Install the drive and driven rotor to the motor housing with the dot mark facing upward.
Page 275 EG–272 ENGINE TROUBLESHOOTING – COOLING SYSTEM INSPECT OIL CLEARANCE OF DRIVE SHAFT (a) Using a caliper gauge, measure the shaft hole inside diameter of the housing and cover. Shaft hole inside diameter: 14.000–14.011 mm (0.5512–0.5516 in.) (b) Using a micrometer, measure the drive shaft diameter. Shaft diameter: 13.973–13.984 mm (0.5501–0.5506 in.) (c) Subtract the drive shaft diameter measurement from the...
Page 276 EG–273 ENGINE TROUBLESHOOTING – COOLING SYSTEM OIL SEAL REPLACEMENT EG0AH–01 REMOVE OIL SEAL (a) Using snap ring pliers, remove the snap ring and plate washer. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the housing. INSTALL OIL SEAL (a) Using SST, and a hammer, tap in a new oil seal to a depth of 4.5–5.5 mm (0.177–0.217 in.) from the housing edge.
Page 277 EG–274 ENGINE TROUBLESHOOTING – COOLING SYSTEM HYDRAULIC MOTOR ASSEMBLY EG0AJ–01 (See page EG–270) HINT: Throughly clean all parts to be assembled. Before installing the parts, apply new fluid to all sliding and rotating surfaces. MOUNT MOTOR HOUSING Slightly mount the motor housing in a vise. NOTICE: Be careful not to damage the motor housing.
Page 278 EG–275 ENGINE TROUBLESHOOTING – COOLING SYSTEM INSPECT DRIVE SHAFT PRELOAD (a) Check that the drive shaft rotates smoothly without abnormal noise. (b) Temporarily install the pulley nut, and check the rotating torque. Rotating torque: 0.3 N m (3.0 kgf cm, 2.6 in. lbf) HYDRAULIC MOTOR INSTALLATION EG0AK–01 (See page EG–268)
Page 279 EG–276 ENGINE TROUBLESHOOTING – COOLING SYSTEM CONNECT PRESSURE HOSE TO HYDRAULIC MOTOR Connect the pressure hose with a new gasket and union bolt. Torque: 64 N m (650 kgf cm, 47 ft lbf) INSTALL CRUISE CONTROL ACTUATOR COVER FILL WITH ENGINE COOLANT (See page EG–244) 10.
Page 280 EG–277 ENGINE TROUBLESHOOTING – COOLING SYSTEM OIL COOLER OIL COOLER REMOVAL EG0AL–02 REMOVE UPPER RADIATOR SEAL Remove the ten clips and radiator seal. REMOVE RH HEADLIGHT ASSEMBLY (a) Remove the three bolts. (b) Disconnect the three connectors and remove the headlight assembly.
Page 281 EG–278 ENGINE TROUBLESHOOTING – COOLING SYSTEM DISCONNECT HOSES FROM OIL COOLER Disconnect the following hoses: (1) Outlet hose (to reservoir tank) (2) Inlet hose (from hydraulic motor) REMOVE UNDER COVER Remove the five bolts and under cover. REMOVE RH FOG LAMP ASSEMBLY (a) Remove the two bolts.
Page 282 EG–279 ENGINE TROUBLESHOOTING – COOLING SYSTEM OIL COOLER INSPECTION EG0AM–02 INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. OIL COOLER INSTALLATION EG0AN–02 (See page EG–277) INSTALL OIL COOLER (a) Install the oil cooler with the two nuts. Torque: 7.8 N m (80 kgf cm, 69 in lbf) (b) Install the bolt while pulling aside the shroud.
Page 283 EG–280 ENGINE TROUBLESHOOTING – COOLING SYSTEM CONNECT HOSES TO OIL COOLER Connect the following hoses: (1) Outlet hose (to reservoir) (2) Inlet hose (from hydraulic motor) INSTALL RH HEADLIGHT ASSEMBLY (a) Connect the three connectors. (b) Install the headlight assembly with the three bolts. INSTALL UPPER RADIATOR SUPPORT SEAL Install the support seal with the ten clips.
Page 284 EG–281 ENGINE TROUBLESHOOTING – COOLING SYSTEM ELECTRONIC CONTROL PARTS SYSTEM CIRCUIT EG0AP–01...
Page 285 EG–282 ENGINE TROUBLESHOOTING – COOLING SYSTEM COOLING FAN ECU COOLING FAN ECU REMOVAL AND INSTALLATION EG0AQ–01 COOLING FAN ECU INSPECTION EG0AR–01 INSPECT COOLING FAN ECU Check the connector on the wiring harness side as shown in the chart. Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 286 EG–283 ENGINE TROUBLESHOOTING – COOLING SYSTEM ENGINE COOLANT WATER TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR REMOVAL AND INSTALLATION EG0AS–02 INSPECT ENGINE COOLANT TEMPERATURE SENSOR EG0AT–01 Using an ohmmeter, measure the resistance between the ter- minals. Resistance: 1.48–1.58 kW at 80 C (176 F) If the resistance is not as specified, replace the sensor.
Page 287 EG–284 ENGINE TROUBLESHOOTING – COOLING SYSTEM SOLENOID VALVE SOLENOID VALVE INSPECTION EG0AU–01 INSPECT SOLENOID VALVE Using an ohmmeter, measure the resistance between the ter- minals Resistance: 7.6–8.0 W at 25 C (77 F) If the resistance is not as specified, replace the solenoid valve.
Page 288 EG–285 ENGINE TROUBLESHOOTING – COOLING SYSTEM SERVICE SPECIFICATIONS SERVICE DATA EG0AV–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Thermostat Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Valve opening pressure Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ 80–84 C (176–183 F) Valve lift at 95 C (203 F)
Page 289 EG–286 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM LUBRICATION SYSTEM DESCRIPTION EG090–01 A fully pressurized, fully filtered lubrication system has been adopted for this engine.
Page 290 EG–287 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block.
Page 291 EG–288 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) EG091–01 RECOMMENDED TOOLS EG092–01 EQUIPMENT Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 292 EG–289 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM SSM (SPECIAL SERVICE MATERIALS) Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ EG095–01 08826–00080 Seal packing or equivalent...
Page 293 EG–290 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL PRESSURE CHECK EG096–01 CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is poor, replace the oil. Oil grade: API grade SG Energy–Conserving II multigrade engine oil.
Page 294 EG–291 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM WARM UP ENGINE Allow the engine to warm up to normal operating tempera- ture. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm , 4.3 psi) or more At 3,000 rpm 294–539 kPa (3.0–5.5 kgf/cm , 43–78 psi) REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH...
Page 295 EG–292 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL AND FILTER REPLACEMENT EG097–01 CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Page 296 EG–293 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228–07500 FILL WITH ENGINE OIL (a) Clean the install the oil drain plug with a new gasket.
Page 297 EG–294 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL PUMP OIL PUMP REMOVAL EG098–02 HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx.
Page 298 EG–295 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM REMOVE FRONT EXHAUST PIPE (a) Loosen the two bolts, and disconnect the bracket. (b) Remove the two bolts and nuts holding the front exhaust pipe to the three–way catalyst converter. (c) Remove the four nuts holding the front exhaust pipe to the exhaust manifolds.
Page 299 EG–296 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM REMOVE OIL PAN BAFFLE PLATE Remove the four bolts, nut and baffle plate. 10. REMOVE WASHER TANK (a) Remove the three washer tank mounting bolts. (b) Disconnect the connector and hose, and remove the washer tank.
Page 300 EG–297 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM 16. REMOVE A/C COMPRESSOR BRACKET Remove the three bolts and A/C compressor bracket. 17. SUSPEND ENGINE WITH ENGINE SLING DEVICE 18. REMOVE TIMING BELT (See page EG–29) 19. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer.
Page 301 EG–298 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM COMPONENTS EG099–01 OIL PUMP DISASSEMBLY EG09A–01 REMOVE RELIEF VALVE Remove the plug, spring and relief valve. REMOVE DRIVE AND DRIVEN ROTORS Remove the eight screws, pump body cover, the drive and driven rotors.
Page 302 EG–299 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL PUMP INSPECTION EG09B–01 INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly.
Page 303 EG–300 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM Inspect rotor tip clearance Using thickness gauge, measure the clearance between the drive and driven rotors. Standard tip clearance: 0.110–0.240 mm (0.0043–0.0094 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the ro- tors as a set.
Page 304 EG–301 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge. SST 09309–37010 OIL PUMP ASSEMBLY EG09D–01 (See page EG–298)
Page 305 EG–302 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL PUMP INSTALLATION EG09E–02 (See page EG–294) INSTALL OIL PUMP (a) Remove any old packing (FIPG) material and be careful not to drop and oil on the contact surfaces of the oil pump and cylinder block.
Page 306 EG–303 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM (e) Install the oil pump with the nine bolts. 12 mm head bolt (C and D) Torque: 20 N m (200 kgf cm, 14 ft lbf) 14 mm head bolt (A and B) Torque: 41 N m (420 kgf cm, 30 ft lbf) HINT: On vehicles with A/C, tighten bolt A together with the A/C bracket.
Page 307 EG–304 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM INSTALL GENERATOR BRACKET Install the generator bracket with the two bolts. INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe. (b) Install the water inlet with the the bolt. INSTALL A/C COMPRESSOR (a) Install the A/C compressor and drive belt adjusting bar bracket with the five bolts.
Page 308 EG–305 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM 13. INSTALL OIL PAN BAFFLE PLATE Install the baffle plate with the four bolts and nut. Torque: 5.5 N m (75 kgf cm, 65 in. lbf) 14. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the three nuts. Torque: 5.5 N m (75 kgf cm, 65 in.
Page 309 EG–306 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM (c) Install the oil pan with the fifteen bolts and four nuts. Torque: 5.5 N m (75 kgf cm, 65 in. lbf) (d) Install the dipstick. 16. INSTALL STIFFENER PLATE (a) Install the dust seal to the stiffener plate. (b) Install the stiffener plate with the six bolts.
Page 310 EG–307 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL FILTER BRACKET OIL FILTER BRACKET REMOVAL EG09F–01 REMOVE OIL FILTER Using SST, remove the oil filter. SST 09228–07500 REMOVE OIL FILTER BRACKET (a) Remove the four nuts and oil filter bracket. (b) Remove the O–ring from the oil filter bracket.
Page 311 EG–308 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM OIL FILTER BRACKET INSTALLATION EG09G–01 (See page EG–307) INSTALL OIL FILTER BRACKET (a) Install a new O–ring to the oil filter bracket. (b) Apply a light coat of engine oil on the O–ring. (c) Install the oil filter bracket with the four nuts. Torque: 19 N m (195 kgf cm, 14 ft lbf) INSTALL OIL FILTER (a) Clean the filter contact surface on the filter mounting.
Page 312 EG–309 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM SERVICE SPECIFICATIONS SERVICE DATA EG09H–01 Ñ Ñ Ñ Ñ Ñ Ñ Oil pressure Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ At idle speed (normal operating temperature) Ñ...
Page 313 EG–310 ENGINE TROUBLESHOOTING – LUBRICATION SYSTEM –MEMO–...
Page 314 EG–311 ENGINE TROUBLESHOOTING...
Page 315 EG–312 ENGINE TROUBLESHOOTING – HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING The Engine Control System broadly consists of the sensors, ECM and actuators. The ECM receives signals from various sensors, judges the operating conditions and determines the optimum injection duration, tim- ing, ignition timing and idle speed.
Page 316 EG–313 ENGINE TROUBLESHOOTING – HOW TO PROCEED WITH TROUBLESHOOTING EG–318 EG–323 EG–321 EG–322 IN–20 EG–322 EG–334 EG–324 EG–344 EG–354 EG–333...
Page 317 EG–314 ENGINE TROUBLESHOOTING – HOW TO PROCEED WITH TROUBLESHOOTING [12]. CHECK FOR MOMENTARY INTERRUPTION By performing the check for momentary interruption, the place where momentary interruptions or momen- tary shorts are occurring due to poor contacts can be isolated. [13] ADJUSTMENT, REPAIR After the cause of the problem is located, perform adjustment or repairs by following the inspection and replacement procedures in this manual.
Page 318 EG–315 ENGINE TROUBLESHOOTING –MEMO–...
Page 319 EG–316 ENGINE TROUBLESHOOTING – HOW TO PROCEED WITH TROUBLESHOOTING How to Proceed with Troubleshooting Using Volt/Ohm Meter and TCCS Checker For the explanation of steps , and [16], see the explanation of steps with the same title on page EG–312.
Page 320 EG–317 ENGINE TROUBLESHOOTING – HOW TO PROCEED WITH TROUBLESHOOTING EG–318 EG–321 EG–323 EG–322 IN–20 EG–322 EG–324 EG–334 EG–344 EG–354 EG–333...
Page 321 EG–318 ENGINE TROUBLESHOOTING – CUSTOMER PROBLEM ANALYSIS CHECK SHEET CUSTOMER PROBLEM ANALYSIS CHECK SHEET...
Page 322 EG–319 ENGINE TROUBLESHOOTING –MEMO–...
Page 323 EG–320 ENGINE TROUBLESHOOTING – DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The ECM contains a built–in self–diagnosis system by which troubles with the engine signal network are detected and a Mal- function Indicator Lamp on the instrument panel lights up. By analyzing various signals as shown in the later table (See page EG–324) the ECM detects system malfunctions relating to the sensors or actuators.
Page 324 EG–321 ENGINE TROUBLESHOOTING – DIAGNOSIS SYSTEM Diagnosis Inspection (Normal Mode) MALFUNCTION INDICATOR LAMP CHECK The Malfunction Indicator Lamp will come on when the ignition switch is turned ON and the engine is not running. HINT: If the Malfunction Indicator Lamp does not light up, pro- ceed to troubleshooting of the combination meter (See page BE–144).
Page 325 EG–322 ENGINE TROUBLESHOOTING – DIAGNOSIS SYSTEM Diagnosis Inspection (Test Mode) Compared to the normal mode, the test mode has high sensing ability to detect malfunctions. It can also detect malfunctions in the starter signal circuit, the IDL contact signal of the throttle position sensor, air conditioning signal and park/neu- tral position switch signal.
Page 326 EG–323 ENGINE TROUBLESHOOTING – DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE CLEARANCE After repair of the trouble areas, the diagnostic trouble code retained in the ECM memory must be cleared out by removing the EFI fuse (15A) from J/B No.2 for 10 seconds or more, with the ignition switch OFF.
Page 327 EG–324 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly same as your reading due to type of the instruments or other factors. *4: See page EG–331.
Page 328 EG–325 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check in test mode, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). Ñ...
Page 329 EG–326 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) *3, 4: See page EG–330, 331.
Page 330 EG–327 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 331 EG–328 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d)
Page 332 EG–329 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 333 EG–330 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) *1: ”ON” displayed in the diagnosis mode column indicates that the Malfunction Indicator Lamp is lighted up when a malfunction is detected. ”OFF” indicates that the ”CHECK” does not light up during malfunction diagnosis, even if a malfunction is detected.
Page 334 EG–331 ENGINE TROUBLESHOOTING – DIAGNOSTIC TROUBLE CODE CHART Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 335 EG–332 ENGINE TROUBLESHOOTING – FAIL–SAFE CHART FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 336 EG–333 ENGINE TROUBLESHOOTING – CHECK FOR MOMENTARY INTERRUPTION CHECK FOR MOMENTARY INTERRUPTION As described in the preceding paragraph, abnormality detection ability in the test mode is increased compared to that in the normal mode, so that when momentary interruptions or momentary shorts occur in the ECM signal circuits (G1, G2, NE, THW, THA, VS, VTA) shown in the table below, the appropriate diagnostic trouble code is output.
Page 337 EG–334 ENGINE TROUBLESHOOTING – BASIC INSPECTION BASIC INSPECTION When the normal code is displayed in the diagnostic trouble code check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently.
Page 338 EG–335 ENGINE TROUBLESHOOTING – BASIC INSPECTION Check idle speed. Shift transmission into “N” position or neutral. Warm up engine at normal operating temperature. Switched off all accessories. Switched off air conditioning. Connect tachometer test probe to terminal IG data link connector 1. Check idle speed.
Page 339 EG–336 ENGINE TROUBLESHOOTING – BASIC INSPECTION Check fuel pressure. Be sure that fuel is enough in tank. Turn ignition switch on. Using SST, connect terminals FP and +B of data link connector 1. SST 09843–18020 Check that there is pressure in the hose from the fuel fil- ter.
Page 340 EG–337 ENGINE TROUBLESHOOTING – PARTS LOCATION PARTS LOCATION...
Page 341 EG–338 ENGINE TROUBLESHOOTING – WIRING DIAGRAM WIRING DIAGRAM...
Page 342 EG–339 ENGINE TROUBLESHOOTING – WIRING DIAGRAM...
Page 343 EG–340 ENGINE TROUBLESHOOTING – TERMINALS OF ECM TERMINALS OF ECM When measuring the voltage or resistance of the connector part of the ECM, remove the locks as required in the following procedure and always insert the test probe into the connector from the wire harness side.
Page 344 EG–341 ENGINE TROUBLESHOOTING – TERMINALS OF ECM Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Terminal Symbol Connection...
Page 345 EG–342 ENGINE TROUBLESHOOTING – STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF ECM TERMINALS...
Page 346 EG–343 ENGINE TROUBLESHOOTING – STANDARD VALUE OF ECM TERMINALS...
Page 347 EG–344 ENGINE TROUBLESHOOTING – MATRIX CHART OF PROBLEM SYMPTOMS MATRIX CHART OF PROBLEM SYMPTOMS When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below.
Page 348 EG–345 ENGINE TROUBLESHOOTING –MEMO–...
Page 349 EG–346 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS LOCATION OF CONNECTORS Location of Connectors in Engine Compartment...
Page 350 EG–347 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS...
Page 351 EG–348 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS Location of Connectors in Engine Compartment (Cont’d)
Page 352 EG–349 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS Location of Connectors in Body...
Page 353 EG–350 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel...
Page 354 EG–351 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS...
Page 355 EG–352 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel (Cont’d)
Page 356 EG–353 ENGINE TROUBLESHOOTING – LOCATION OF CONNECTORS...
Page 357 EG–354 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT INSPECTION RPM Signal Circuit (No. 1) CIRCUIT DESCRIPTION The distributor in the Engine Control System contains three pick–up coils (G1, G2 and NE). The G1, G2 signals inform the ECM of the standard crankshaft angle. The NE signals inform the ECM of the crankshaft angle and the engine speed.
Page 358 EG–355 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART WIRING DIAGRAM...
Page 359 EG–356 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check resistance of each pickup coils in distributor. Disconnect distributor connector. Measure resistance between each terminal shown. Replace distributor. Check for open and short in harness and connector between ECM and distributor (See page IN–27).
Page 360 EG–357 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION RPM Signal Circuit (No. 2) CIRCUIT DESCRIPTION Refer to RPM signal circuit (No. 1) on page EG–354. Code No. Diagnostic Trouble Code Detecting Condition Trouble Area No NE signal to ECM for 0.1 sec. or more at 1,000 rpm Open or short in NE circuit.
Page 361 EG–358 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Ignition Signal Circuit The ECM determines the ignition timing, turns on Tr at a predetermined angle (CA) before the desired ignition timing and outputs an ignition signal (IGT) “1” to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr turns on.
Page 362 EG–359 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART...
Page 363 EG–360 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check for spark. Disconnect the high–tension cord from the distributor, hold its end about 12.5 mm (1/2”) from the ground, see if spark occurs while the engine is being cranked. Spark should be generated. Hint To prevent excessive fuel injected from the injectors during this check, don’t crank the engine for more the 1 –...
Page 364 EG–361 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminal IGT of ECM connector and body ground. Remove glove compartment (See page BO–111). Measure voltage between terminal IGT of ECM connec- tor and body ground when engine is cranked. Voltage: 0.5 –...
Page 365 EG–362 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN–27). Repair or replace harness or connector. Check ignition coil. Disconnect ignition coil connector. Check primary coil.
Page 366 EG–363 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Disconnect igniter connector and check voltage between terminal IGT of ECM connector and body ground. Disconnect igniter connector. Measure voltage between terminal IGT of ECM connec- tor and body ground when engine is cranked. Voltage: 0.5 –...
Page 367 EG–364 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION ELECTRONIC CONTROLLED TRANSMISSION Control Signal Malfunction CIRCUIT DESCRIPTION The signal from the Electronic Controlled Transmission CPU retards the ignition timing of the engine during Elec- tronic Controlled Transmission gear shifting, thus momentarily reducing torque output of the engine for smooth clutch operation inside the transmission and reduced shift shock.
Page 368 EG–365 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 369 EG–366 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION 21, 28 Main Oxygen Sensor Circuit CIRCUIT DESCRIPTION Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ To obtain a high purification rate for the CO, HC and NO components of the exhaust gas, a Three–Way Ñ...
Page 370 EG–367 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern (a) To simulate diag. trouble code detecting condition after diag. trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diag. trouble code is no longer detected.
Page 371 EG–368 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART HINT: If diag. trouble code 21 is output, replace the left bank main oxygen sensor. If diag. trouble code 28 is output, replace the right bank main oxygen sensor. WIRING DIAGRAM...
Page 372 EG–369 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Reference: INSPECTION USING OSCIL- Ñ...
Page 373 EG–370 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Engine Coolant Temp. Sensor Circuit CIRCUIT DESCRIPTION The water temperature sensor senses the engine Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ coolant temperature.
Page 374 EG–371 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART HINT: If diagnostic trouble codes 22, 24, 32 and 41 are output simultaneously, E2 (Sensor ground) may be open. (See page EG–333). WIRING DIAGRAM...
Page 375 EG–372 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes 22, 24, 32 and 41 are output simultaneously, E2 (sensor ground) may be open. Check voltage between terminals THW and E2 of ECM connector. Remove glove compartment (See page BO–111). Turn ignition switch on.
Page 376 EG–373 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 377 EG–374 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Intake Air Temp. Sensor Circuit CIRCUIT DESCRIPTION The intake air temp. sensor is built into the volume air flow meter and senses the intake air temperature. The structure of the sensor and connection to the ECM is the same as the water temp. sensor shown on page EG–370.
Page 378 EG–375 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals THA and E2 of ECM connector. Remove glove compartment. (See page BO–111). Turn ignition switch on. Measure voltage between terminals THA and E2 of ECM connector. Check for momentary interruption (See page EG–333). Check intake air temp.
Page 379 EG–376 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Air–Fuel Ratio Lean Malfunction Air–Fuel Ratio Rich Malfunction CIRCUIT DESCRIPTION The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the concentrate of oxygen present in the exhaust gas.
Page 380 EG–377 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern (a) To simulate diag. trouble code detecting condition after diag. trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diag. trouble code is no longer detected.
Page 381 EG–378 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART WIRING DIAGRAM Refer to page EG–368 for the WIRING DIAGRAM.
Page 382 EG–379 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals VF1, VF2 and E1 of data link connector 1. Warm up engine at normal operating temperature. Connect terminals TE1 and E1 of data link connec- tor 1. Connect positive probe to terminal VF1, VF2 and negative probe to terminal E1 of data link connec- tor.
Page 383 EG–380 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open and short in harness and connector between ECM and main oxygen sensor, ECM and data link connector 1 (See page IN–27). Repair or replace harness or connector. Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in or .
Page 384 EG–381 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in . The num- bers in the table below show the order in which the checks should be performed. Ñ...
Page 385 EG–382 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Sub–Oxygen Sensor Circuit (only for California spec.) CIRCUIT DESCRIPTION The sub–oxygen sensor is installed on the exhaust pipe. Its construction and operation is the same as the man oxygen sensor on page EG–366. Code No. Diagnostic Trouble Code Detecting Condition Trouble Area Open or short in heater circuit of sub–oxygen...
Page 386 EG–383 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern (a) To simulate diag. trouble code detecting condition after diag. trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diag. trouble code is no longer detected.
Page 387 EG–384 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART HINT: When other codes are output in addition to 27 at the same time, check the circuits for other codes first. WIRING DIAGRAM...
Page 388 EG–385 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal HT of ECM connector and body ground. Remove glove compartment. (See page BO–111). Turn ignition switch on. Measure voltage between terminal HT of ECM connec- tor and body ground. Voltage: 10 –...
Page 389 EG–386 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminal HT of ECM connector and body ground Connect ECM connector. Warm up engine to normal operating temperature. Measure voltage between terminal HT of ECM connec- tor and body ground, when engine is idling and racing at 2,500 rpm.
Page 390 EG–387 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 391 EG–388 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Volume Air Flow Meter Circuit (No. 1) CIRCUIT DESCRIPTION The volume ar flow meter is located directly behind the air cleaner, and detects the intake air volume. It converts the intake air readings into a voltage signal by means of a potentiometer. Intake air volume signal is used to calculate the basic injection duration and basic ignition advance angle.
Page 392 EG–389 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals VC and E2 of ECM Remove glove compartment. (See page BO–111). Turn ignition switch ON. Measure voltage between terminals VC and E2 of ECM. Voltage: 4 – 6 V Check for momentary interruption (See page EG–333) Check resistance between terminals VC and E2 of volume air flow meter.
Page 393 EG–390 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Volume Air Flow Meter Circuit (No. 2) CIRCUIT DESCRIPTION The volume ar flow meter is located directly behind the air cleaner, and detects the intake air volume. It converts the intake air readings into a voltage signal by means of a potentiometer. Intake air volume signal is used to calculate the basic injection duration and basic ignition advance angle.
Page 394 EG–391 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals VS and E2 of ECM Remove air cleaner cap. Remove glove compartment. (See page BO–111). Turn ignition switch ON. Measure voltage between terminals VS and E2 of ECM. Check for momentary interruption (See page EG–333) Check resistance between terminals VS and E2 of volume air flow meter.
Page 395 EG–392 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Throttle Position Sensor Circuit CIRCUIT DESCRIPTION The throttle position sensor is mounted in the Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ throttle body and detects the throttle valve opening Ñ...
Page 396 EG–393 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART HINT: If diagnostic trouble codes 22, 24, 32 and 41 are output simultaneously, E2 (sensor ground) may be open. WIRING DIAGRAM...
Page 397 EG–394 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes 22, 24, 32 an d41 are output simultaneously, E2 (sensor ground) may be open. Check voltage between terminals VC and E2 of ECM. Remove glove compartment. (See page BO–111). Turn ignition switch ON.
Page 398 EG–395 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminals VTA and E2 of ECM. Turn ignition switch ON. Measure voltage between terminals VTA and E2 of ECM. Check for momentary interruption (See page EG–333). Check resistance between terminals 3 and 1 of throttle position sensor. Disconnect the throttle position sensor connector.
Page 399 EG–396 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Vehicle Speed Sensor Signal Circuit CIRCUIT DESCRIPTION The No.1 speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular wave- form by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM.
Page 400 EG–397 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART (See page BE–125). (See page BE–125). WIRING DIAGRAM...
Page 401 EG–398 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check operation of speedometer. Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. The No. 1 speed sensor is operating normally if the speedometer display is normal. Hint Check speedometer circuit.
Page 402 EG–399 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 403 EG–400 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery voltage is applied to terminal STA of the ECM.
Page 404 EG–401 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diag. trouble code 43. Setting the test mode. Turn ignition switch OFF. Connect terminals TE2 and E1 of data link connec- tor 2. Turn ignition switch ON. (Don’t start the engine.) Connect terminals TE1 and E1 of data link connec- tor 2.
Page 405 EG–402 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION 52, 53, 55 Knock Sensor Circuit CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which oc- curs when the cylinder block vibrates due to knocking.
Page 406 EG–403 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diag. trouble code detecting condition after diag. trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diag. trouble code is no longer detected.
Page 407 EG–404 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART HINT: If diag. trouble code 52 is displayed, check No.2 knock sensor (for left bank) circuit. If diag. trouble code 55 is displayed, check No. 1 knock sensor (for right bank) circuit. If diag.
Page 408 EG–405 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check continuity between terminals KNK1, KNK2 of ECM connector and body ground. Remove glove compartment. (See page BO–111). Disconnect the ECM connector. Measure resistance between terminals KNK1, KNK2 of ECM connector and body ground. Resistance: 1 MW or higher Go to step Check knock sensor.
Page 409 EG–406 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open and short in harness and connectors between ECM and knock sensor (See page IN–27). Repair or replace harness or connector. Does malfunction disappear when a good knock sensor is intalled? Replace knock sensor (See page EG–100). Check and replace ECM Reference INSPECTION USING OSCILLOSCOPE With the engine racing (4,000 rpm) measure...
Page 410 EG–407 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 411 EG–408 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION EGR System Malfunction (Only for Califor- nia spec.) CIRCUIT DESCRIPTION The EGR system, recirculates exhaust gas, which is controlled to the proper quantity to suit the driving condi- tions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions.
Page 412 EG–409 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diag. trouble code detecting condition after diag. trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diag. trouble code is no longer detected.
Page 413 EG–410 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART WIRING DIAGRAM...
Page 414 EG–411 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check EGR system (See page EG–152). Repair EGR system. Check resistance of EGR gas temp. sensor. Remove EGR gas temp. sensor. Measure resistance between terminals of EGR gas temp. sensor connector. Resistance: 69 – 89 kW at 50C (122F) 12 –...
Page 415 EG–412 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Switch Condition Signal Circuit CIRCUIT DESCRIPTION Park/Neutral Position Switch Signal* The ECM uses the signals from the park/neutral position switch to determine whether the transmission is in park or neutral, or in some other position. Air Conditioning Switch Signal The ECM uses the output from the air conditioning switch to determine whether or not the air conditioning is operating so that it can increase the idling speed of the engine if necessary.
Page 416 EG–413 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART See page EG–416 (See page EG–344) (See page EG–207)
Page 417 EG–414 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diag. trouble code 51. Setting the test mode. Turn ignition switch OFF. Connect terminals TE2 and E1 of data link connector. Turn ignition switch ON. (For checking terminal A/C, start the engine.) Connect terminals TE1 and E1 of data link connector 2.
Page 418 EG–415 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Disconnect A/C control assembly connector, check voltage between terminal AC1 of A/C con- trol assembly connector and body ground. Remove air conditioning control assembly. Disconnect air conditioning control assembly con- nector. Turn ignition switch on. Measure voltage between terminal AC1 of air condition- ing control assembly connector and body ground.
Page 419 EG–416 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Park/Neutral Position Switch Circuit (Only vehicles with ELECTRONIC CONTROLLED TRANSMISSION) CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on the terminal PNP of the ECM is grounded to body ground via the starter relay and theft deterrent ECU, thus the terminal PNP voltage becomes O V.
Page 420 EG–417 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION WIRING DIAGRAM...
Page 421 EG–418 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diag. trouble code 51. Connect terminals TE2 and E1 of data link connec- tor 2. Turn ignition switch on. Crank the engine. Connect terminals TE1 and E1 of data link connec- tor 2.
Page 422 EG–419 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 423 EG–420 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION ECM Power Source Circuit CIRCUIT DESCRIPTION Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ When the ignition switch is turned on, battery volt- Ñ...
Page 424 EG–421 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART (See page EG–344).
Page 425 EG–422 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals +B, +B1 and E1 of ECM connector. Remove glove compartment. (See page BO–111). Turn ignition switch on Measure voltage between terminals +B, +B1 and E1 of ECM connector. Voltage: 10 –...
Page 426 EG–423 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check IGN fuse. Remove IGN fuse form J/B No. 1 Check continuity of IGN fuse. Continuity Check for short in all the harness and components con- nected to IGN fuse (See attached wiring diagram). Check ignition switch.
Page 427 EG–424 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminal M–REL of ECM connector and body ground. Turn ignition switch on. Measure voltage between terminal M–REL of ECM con- nector and body ground. Voltage: 10 – 14 V Check and replace ECM. Check EFI fuse.
Page 428 EG–425 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check SFI main relay. Remove SFI main relay from J/B No. 2. Check continuity between terminals of SFI main relay shown below. Apply battery voltage between terminals 1 and 3. Check continuity between terminals 2 and 4. Replace SFI main relay.
Page 429 EG–426 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Back Up Power Source Circuit CIRCUIT DESCRIPTION Battery voltage is supplied to terminal BATT of the ECM even when the ignition switch is off for use by the diag- nostic trouble code memory and air–fuel ratio adaptive control value memory, etc. DIAGNOSTIC CHART DIAGNOSTIC CHART (See page EG–344).
Page 430 EG–427 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check EFI fuse. Remove EFI fuse from J/B No. 2. Check continuity of EFI fuse. Continuity Check for short in all the harness and components con- nected to EFI fuse (See attached wiring diagram). Check voltage between terminal BATT of ECM connector and body ground.
Page 431 EG–428 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Injector Circuit CIRCUIT DESCRIPTION The injectors are provided to the intake manifold. They inject fuel into the cylinders based on the signals from the ECM. Reference INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM With the engine idling measure between terminals # 10 ~ # 60 and E01 of ECM. HINT: The correct waveform appears as shown in the illustration on the below.
Page 432 EG–429 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION WIRING DIAGRAM...
Page 433 EG–430 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals #10 60 of ECM and body ground. Remove glove compartment. (See page BO–111). Turn ignition switch on. Measure voltage between terminals #10 60 of ECM and body ground. Voltage: 10 –...
Page 434 EG–431 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open in harness and connector between terminal E01, E02 of ECM connector and body ground (See page IN–27). Repair or replace harness or connector. Check injectors. Disconnect injector connector (See page EG–187). Measure resistance of injector.
Page 435 EG–432 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Cold Start Injector Circuit CIRCUIT DESCRIPTION The cold start injector is used to maintain the engine startability when it is cold. The injection volume, i,e, the length of time the injector is energized, is controlled by the ECM and the cold start injector time switch. During a cold start, when the starter turns the contacts in the cold start injector time switch close.
Page 436 EG–433 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART (See page EG–344). WIRING DIAGRAM...
Page 437 EG–434 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal STJ of ECM connector and body ground. Remove glove compartment. (See page BO–111). Disconnect start injector time switch connector. Disconnect ECM connector. Measure voltage between terminal STJ of ECM connec- tor and body ground when ignition switch is turned to STA.
Page 438 EG–435 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check start injector time switch. Remove start injector time switch (See page EG–219). Measure resistance between terminals shown below. Replace start injector time switch. Check for open and short in harness and connector between cold start injector and start injec- tor time switch (See page IN–27).
Page 439 EG–436 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION IAC Valve Circuit CIRCUIT DESCRIPTION Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ The IAC valve is provided on the intake air chamber Ñ...
Page 440 EG–437 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART (See page EG–344). WIRING DIAGRAM...
Page 441 EG–438 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check IAC valve. Disconnect IAC valve connector. Measure resistance between terminals shown below. Remove IAC valve. Connect the battery positive lead to terminals B1 and B2, and the negative lead to terminals S1–S2–S3–S4 in that order.
Page 442 EG–439 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION –MEMO–...
Page 443 EG–440 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Fuel System Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil, the starter relay switches on and current flows to coil L1 of the circuit opening relay. Thus the circuit opening relay switches on, power is supplied to the fuel pump and the fuel pump operates.
Page 444 EG–441 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART DIAGNOSTIC CHART...
Page 445 EG–442 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION WIRING DIAGRAM...
Page 446 EG–443 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check STARTER fuse. Remove STARTER fuse from J/B No. 2. Check continuity of STARTER fuse. Continuity. Check for short in all the harness and components con- nected to STARTER fuse. Check circuit opening relay. Remove glove compartment (See page BO–111).
Page 447 EG–444 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open in harness and connector between STARTER fuse and circuit opening relay, relay and body ground (See page IN–27). Repair or replace harness or connector. Check IGN fuse. Remove IGN fuse from J/B No. 1. Check continuity of IGN fuse.
Page 448 EG–445 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check for open in harness and connector between IGN fuse and circuit opening relay, relay and body ground (See page IN–27). Repair or replace harness or connector. Check ECM power source circuit (See page EG–420). Repair or replace.
Page 449 EG–446 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Fuel Pressure Control VSV Circuit CIRCUIT DESCRIPTION Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ The ECM turns on a VSV (Vacuum Switching valve) Ñ...
Page 450 EG–447 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION WIRING DIAGRAM...
Page 451 EG–448 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check fuel pressure control VSV. Remove fuel pressure control VSV. Disconnect fuel pressure control VSV connector. Measure resistance between terminals. Measure resistance between each terminal and the body. Resistance: 30 – 50 W at 20C (68F) Resistance: 1 MW or higher Check operation of fuel pressure control VSV when bat- tery voltage is applied to the terminals of fuel pressure...
Page 452 EG–449 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminal FPU of ECM connector and body ground. Remove glove compartment. (See page BO–111). Turn ignition switch on. Measure voltage between terminal FPU of ECM con- nector and body ground. Hint Voltage: 10 –...
Page 453 EG–450 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Air Conditioning Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration perfor- mance. During acceleration with the vehicle speed at 25 km/h (16 mph) or less, engine speed at 1,600 rpm or less and throttle valve opening angle at 60 or more, the A/C magnet switch is turned OFF for several seconds.
Page 454 EG–451 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal ACT of ECM and body ground. Remove glove compartment. (See page BO–111). Disconnect ECM connector. Turn ignition switch ON. Measure voltage between terminal ACT of ECM and body ground when A/C switch is turned to ON. Voltage: 10 –...
Page 455 EG–452 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the IACV (Intake Air Control Valve) in response to the engine load in order to in- crease the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 3,900 rpm or less and the throttle valve opening angle is 60 or more, the ECM turns the VSV ON and closes the IACV.
Page 456 EG–453 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION WIRING DIAGRAM...
Page 457 EG–454 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check IACV control VSV. Remove IACV control VSV. Disconnect IACV control VSV connector. Measure resistance between terminals. Measure resistance between each terminal and the body. Resistance: 33 – 39 W at 20C (68F) Resistance: 1 MW or higher Check operation of IACV control VSV when battery volt- age is applied to the terminals of IACV control VSV con-...
Page 458 EG–455 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Check voltage between terminal ISAAC of ECM connector and body ground. Remove glove compartment. (See page BO–111). Turn ignition switch on. Measure voltage between terminals ISAAC of ECM connector and body ground. Voltage: 10 – 14 V Hint Check for vacuum tank.
Page 459 EG–456 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION TE1, TE2 Terminal Circuit CIRCUIT DESCRIPTION Terminals TE1 and TE2 are located in the data link connectors 1 and 2. The data link connector 1 located in the engine compartment and the data link connector 2 located in the cabin. When these terminals are connected with the E1 terminal, diagnostic trouble codes in normal mode or test mode can be read from the Malfunction Indicator Lamp on the combination meter.
Page 460 EG–457 ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals TE1, TE2 and E1 of data link connectors 1 and 2. Turn ignition switch on. Measure voltage between terminals TE1, TE2 and E1 of data link connectors 1 and 2. Voltage: 10 –...
Page 461 IG–1 IGNITION SYSTEM...
Page 462 IG–2 IGNITION SYSTEM – DESCRIPTION DESCRIPTION IG018–02 The ECM is programmed with data for optimum ignition timing under any and all operating conditions. Us- ing data provided by sensors which monitor various engine functions (rpm, intake air volume, eng, temper- ature, etc.), the microcomputer (ECM) triggers the spark at precisely the right instant.
Page 463 IG–3 IGNITION SYSTEM – PRECAUTIONS PRECAUTIONS IG019–01 Do not leave the ignition switch on for more than 10 minutes if the engine does not start. With a tachometer connected to the system. Connect the test probe of the tachometer to terminal IG of the DLC1.
Page 464 IG–4 IGNITION SYSTEM – OPERATION SYSTEM CIRCUIT IG01A–01 OPERATION IG01B–01 To maintain the most appropriate ignition timing, the ECM sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark.
Page 465 IG–4 IGNITION SYSTEM – OPERATION SYSTEM CIRCUIT IG01A–01 OPERATION IG01B–01 To maintain the most appropriate ignition timing, the ECM sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark.
Page 466 IG–5 IGNITION SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) IG01C–01 RECOMMENDED TOOLS IG01D–01 EQUIPMENT IG01E–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ...
Page 467 IG–6 IGNITION SYSTEM – ON–VEHICLE INSPECTION ON–VEHICLE INSPECTION SPARK TEST IG01R–02 CHECK THAT SPARK OCCURS (a) Disconnect the high–tension cord from the distributor. (See page IG–7) (b) Hold the end approx. 12.5 mm (0.50 in.) from the body of vehicle. (c) See if spark occurs while engine is being cranked.
Page 468 IG–7 IGNITION SYSTEM – ON–VEHICLE INSPECTION HIGH–TENSION CORDS INSPECTION IG01F–01 REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the two nuts and V– bank cover. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS Disconnect the high–tension cords at the rubber boot. DO NOT pull on the cords.
Page 469 IG–8 IGNITION SYSTEM – ON–VEHICLE INSPECTION RECONNECT HIGH–TENSION CORDS TO DISTRIBUTOR CAP AND IGNITION COIL (a) (Ex. Center Cord on the Distributor Side) Insert the grommet portion into the terminal hole of the distrib- utor cap (ignition coil). (b) (Ex. Center Cord on the Distributor Side) Align the spline of the distributor (ignition coil) with the spline of the holder, and slide on the holder.
Page 470 IG–9 IGNITION SYSTEM – ON–VEHICLE INSPECTION SPARK PLUGS INSPECTION IG01G–02 NOTICE: Never use a wire brush for cleaning. Never attempt to adjust the electrode gap on used spark plug. Spark plug should be replaced every 100,000 km (60,000 miles). REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the two nuts and V–...
Page 471 IG–10 IGNITION SYSTEM – ON–VEHICLE INSPECTION VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator dam- age. If abnormal, replace the spark plug. Recommended spark plug: ND PQ20R NGK BCPR6EP–11 INSPECT ELECTRODE GAP Maximum electrode gap: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug.
Page 472 IG–11 IGNITION SYSTEM – ON–VEHICLE INSPECTION IGNITION COIL INSPECTION IG02G–01 DISCONNECT IGNITION COIL CONNECTOR DISCONNECT HIGH–TENSION CORD INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (–) terminals. Primary coil resistance (Cold): 0.3–0.6 W If the resistance is not as specified, replace the ignition coil.
Page 473 IG–12 IGNITION SYSTEM – ON–VEHICLE INSPECTION INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, measure the resistance between termi- nals. Pickup coil resistance (Cold): G1 and G 125–190 W at–10~40 C (14~104 F) G2 and G 125–190 W at–10~40 C (14~104 F) NE and G 155–240 W at–10~40 C (14~104 F) If the resistance is not as specified, replace the distributor...
Page 474 IG–13 IGNITION SYSTEM – DISTRIBUTOR DISTRIBUTOR DISTRIBUTOR REMOVAL IG01T–01 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 475 IG–14 IGNITION SYSTEM – DISTRIBUTOR DISCONNECT HIGH–TENSION CORDS FROM DISTRIBUTOR CAP AND IGNITION COIL (a) Using a screwdriver, lift up the lock claw and disconnect the holder from the distributor cap (ignition coil). (b) Disconnect the high–tension cord at the grommet. DO NOT pull on the cord.
Page 476 IG–15 IGNITION SYSTEM – DISTRIBUTOR COMPONENTS IG01K–01 DISTRIBUTOR DISASSEMBLY IG01L–01 REMOVE WIRE HARNESS CLAMP CLIP Remove the screw and clip. REMOVE DISTRIBUTOR CAP Remove the three bolts and distributor cap.
Page 477 IG–16 IGNITION SYSTEM – DISTRIBUTOR REMOVE ROTOR Remove the two screws and rotor. DISTRIBUTOR ASSEMBLY IG01M–02 (See page IG–15) INSTALL ROTOR (a) Align the hollow of the signal rotor with the protrusion of the rotor. (b) Install the rotor with the two screws. INSTALL DISTRIBUTOR CAP Install the distributor cap with the three screws.
Page 478 IG–17 IGNITION SYSTEM – DISTRIBUTOR DISTRIBUTOR INSTALLATION IG01N–02 (See page IG–13) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft clockwise, and position the slit of the in- take camshaft (RH cylinder head) as shown. Look at the distributor attachment hole to set. INSTALL DISTRIBUTOR (a) Install a new O–ring to the housing.
Page 479 IG–18 IGNITION SYSTEM – DISTRIBUTOR (b) (Ex. Center Cord) Align the spline of the distributor cap with the spline groove of the holder, and slide the holder. NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustra- tion.
Page 480 IG–19 IGNITION SYSTEM – DISTRIBUTOR CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the tachometer test probe to terminal IG of the DCL1. NOTICE: NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil.
Page 481 IG–20 IGNITION SYSTEM – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA IG01P–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ignition timing w/ Terminals TE1 and E1 connected 10 BTDC @ idle...
Page 482 ST–1 STARTING SYSTEM...
Page 483 ST–2 STARTING SYSTEM – DESCRIPTION DESCRIPTION ST018–02 The starter is a reduction type with a small, high–speed motor used to drive the pinion gear.
Page 484 ST–3 STARTING SYSTEM – OPERATION SYSTEM CIRCUIT ST017–01 OPERATION ST019–01 When the ignition switch is turned to START position, current flows from terminal 50 to the coil of the sole- noid and the plunger is pulled by the magnetic force of the coil. When the plunger is pulled to the left as shown above, the contact plate of the plunger allows current from the battery to flow directly from terminal 30 to the motor, and the starter rotates.
Page 485 ST–3 STARTING SYSTEM – OPERATION SYSTEM CIRCUIT ST017–01 OPERATION ST019–01 When the ignition switch is turned to START position, current flows from terminal 50 to the coil of the sole- noid and the plunger is pulled by the magnetic force of the coil. When the plunger is pulled to the left as shown above, the contact plate of the plunger allows current from the battery to flow directly from terminal 30 to the motor, and the starter rotates.
Page 486 ST–4 STARTING SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) ST01A–01 RECOMMENDED TOOLS ST01C–01 EQUIPMENT ST01E–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Dial indicator Ñ...
Page 487 ST–5 STARTING SYSTEM – STARTER STARTER STARTER REMOVAL ST01B–02 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) termi- nal cable is disconnected from the battery.
Page 488 ST–6 STARTING SYSTEM – STARTER REMOVE STARTER (a) Disconnect the starter connector. (b) Remove the nut, and disconnect the starter wire. (c) Remove the two bolts and starter. COMPONENTS ST01D–01 STARTER DISASSEMBLY ST01F–01 REMOVE FIELD FRAME AND ARMATURE (a) Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
Page 489 ST–7 STARTING SYSTEM – STARTER (b) Remove the two through bolts. (c) Pull out the field frame with the armature from the magnetic switch assembly. (d) Remove the O–ring. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR (a) Remove the two screws. (b) Remove the following parts from the magnetic switch assembly: (1) Starter housing and clutch assembly...
Page 490 ST–8 STARTING SYSTEM – STARTER (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the four brushes and remove the brush holder. REMOVE ARMATURE FROM FIELD FRAME STARTER INSPECTION AND REPAIR ST01G–01 Armature Coil INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between...
Page 491 ST–9 STARTING SYSTEM – STARTER INSPECT COMMUTATOR DIAMETER Using a vernier caliper, measure the commutator diameter. Standard diameter: 30 mm (1.18 in.) Minimum diameter: 29 mm (1.14 in.) If the diameter is less than minimum, replace the armature. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials.
Page 492 ST–10 STARTING SYSTEM – STARTER If the length is less than minimum, replace the brush holder and field frame. Brush Springs INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring sepa- rates from the brush. Spring installed load: 18–24 N (1.79–2.41 kgf, 3.9–5.3 lbf) If the installed load is not within specification, replace the...
Page 493 ST–11 STARTING SYSTEM – STARTER IF NECESSARY, REPLACE CLUTCH ASSEMBLY A. Disassembly of starter housing and clutch assembly (a) Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar. (b) Push down the pinion gear (c) Using a plastic–faced hammer, tap down the stop collar.
Page 494 ST–12 STARTING SYSTEM – STARTER (g) Disassemble the following parts: (1) Starter housing (2) Starter clutch (3) Compression spring (4) Clutch shaft B. Assemble starter housing and clutch assembly (a) Assemble the following parts: (1) Starter housing (2) Starter clutch (3) Compression spring (4) Clutch shaft (b) Mount a brass bar in a vise, install the starter housing and...
Page 495 ST–13 STARTING SYSTEM – STARTER Using pliers, compress the snap ring. (g) Check that the snap ring fits correctly. (h) Remove the starter housing and clutch assembly from the brass bar. Using a plastic–faced hammer, tap the clutch shaft and install the stop collar onto the snap ring.
Page 496 ST–14 STARTING SYSTEM – STARTER Magnetic Switch PERFORM PULL–IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch. PERFORM HOLD–IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
Page 497 ST–15 STARTING SYSTEM – STARTER (d) Install a new O–ring to the end cover screw. (e) Install the end cover to the field frame with the two screws. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE (a) Apply grease to the steel ball. (b) Insert the steel ball into the clutch shaft hole.
Page 498 ST–16 STARTING SYSTEM – STARTER INSTALL FIELD FRAME AND ARMATURE ASSEMBLY (a) Place a new O–ring in position on the field frame. (b) Align the protrusion of the field frame with the cutout of the magnetic switch. (c) Install the field frame and armature assembly with the two through bolts.
Page 499 ST–17 STARTING SYSTEM – STARTER STARTER PERFORMANCE TEST ST01L–01 NOTICE: These tests must be performed within 3 to 5 se- conds to avoid burning out the coil. PERFORM PULL–IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown.
Page 500 ST–18 STARTING SYSTEM – STARTER STARTER INSTALLATION ST01M–02 (See page ST–5) INSTALL STARTER (a) Install the starter with the two bolts. Torque: 39 N m (400 kgf cm, 29 ft lbf) (b) Connect the starter wire with the nut. (c) Connect the starter connector. INSTALL CRUISE CONTROL ACTUATOR (a) Install the cruise control actuator with the three bolts.
Page 501 ST–19 STARTING SYSTEM – NEUTRAL START SWITCH STARTER RELAY STARTER RELAY INSPECTION ST01H–02 LOCATION: (See page ST–2) INSPECTION RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is no continuity between terminals 2 and 4. If continuity is not as specified, replace the relay.
Page 502 ST–19 STARTING SYSTEM – NEUTRAL START SWITCH STARTER RELAY STARTER RELAY INSPECTION ST01H–02 LOCATION: (See page ST–2) INSPECTION RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is no continuity between terminals 2 and 4. If continuity is not as specified, replace the relay.
Page 503 ST–19 STARTING SYSTEM – NEUTRAL START SWITCH STARTER RELAY STARTER RELAY INSPECTION ST01H–02 LOCATION: (See page ST–2) INSPECTION RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is no continuity between terminals 2 and 4. If continuity is not as specified, replace the relay.
Page 504 ST–20 STARTING SYSTEM – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA ST01P–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Starter Rated voltage and output power 12 V 1.4 kW...
Page 505 CH–1 CHARGING SYSTEM...
Page 506 CH–2 CHARGING SYSTEM – PRECAUTIONS DESCRIPTION CH00H–02 The generator is a small, high rpm, high performance type with an IC regulator incorporated. The IC regulator uses integrated circuits and controls the voltage produced by the generator. PRECAUTIONS CH00K–01 Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge.
Page 507 CH–2 CHARGING SYSTEM – PRECAUTIONS DESCRIPTION CH00H–02 The generator is a small, high rpm, high performance type with an IC regulator incorporated. The IC regulator uses integrated circuits and controls the voltage produced by the generator. PRECAUTIONS CH00K–01 Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge.
Page 508 CH–3 CHARGING SYSTEM – OPERATION SYSTEM CIRCUIT CH00M–01 OPERATION CH00P–01 When the ignition switch is turned ON, current from the battery flows from terminal L of the generator through the IC regulator to terminal E, causing the discharge warning light to light up. Then when the engine is started, the voltage output increases as the generator rpm increases.
Page 509 CH–3 CHARGING SYSTEM – OPERATION SYSTEM CIRCUIT CH00M–01 OPERATION CH00P–01 When the ignition switch is turned ON, current from the battery flows from terminal L of the generator through the IC regulator to terminal E, causing the discharge warning light to light up. Then when the engine is started, the voltage output increases as the generator rpm increases.
Page 510 CH–4 CHARGING SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) CH00R–01 RECOMMENDED TOOLS CH00T–01 EQUIPMENT CH00V–01 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ammeter(A) Ñ...
Page 511 CH–5 CHARGING SYSTEM – ON–VEHICLE INSPECTION ON–VEHICLE INSPECTION CH00X–01 CHECK BATTERY SPECIFIC GRAVITY ELECTROLYTE LEVEL (a) Check the electrolyte level of each cell. If insufficient, refill with distilled (or purified) water. (b) Check the specific gravity of each cell. Standard specific gravity at 20 C (68 F): 1.25–1.27 (55D23L Battery) 1.27–1.29 (80D26L Battery) If not within specifications, charge the battery.
Page 512 CH–6 CHARGING SYSTEM – ON–VEHICLE INSPECTION (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: New belt 175 5 lb Used belt 115 20 lb If the belt tension is not as specified, adjust it. HINT: “New belt”...
Page 513 CH–7 CHARGING SYSTEM – ON–VEHICLE INSPECTION INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer’s instruc- tions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: Disconnect the wire from terminal B of the generator and connect it to the negative (–) lead of the ammeter.
Page 514 CH–8 CHARGING SYSTEM – ON–VEHICLE INSPECTION If the ammeter reading is less than the standard amperage, repair the generator. (See page CH–9) HINT: If the battery is fully charged, the indication will some- times be less than standard amperage.
Page 515 CH–9 CHARGING SYSTEM – GENERATOR GENERATOR GENERATOR REMOVAL CH00Z–02 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY CAUTION (w / Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 516 CH–10 CHARGING SYSTEM – GENERATOR REMOVE DRIVE BELT Loosen the pivot bolt and adjusting lock bolt, and remove the drive belt. REMOVE GENERATOR (a) Disconnect the generator connector. (b) Remove the nut, and disconnect the generator wire. (c) Disconnect the wire harness from the clip. (d) Remove the pivot bolt, adjusting lock bolt and generator.
Page 517 CH–11 CHARGING SYSTEM – GENERATOR GENERATOR DISASSEMBLY CH013–01 REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the three nuts and end cover. REMOVE BRUSH HOLDER AND IC REGULATOR (a) Remove the brush holder cover from the brush holder. (b) Remove the five screws, brush holder and IC regulator.
Page 518 CH–12 CHARGING SYSTEM – GENERATOR (b) Remove the four rubber insulators. (c) Remove the seal plate. REMOVE PULLEY (a) Hold SST (a) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N m (400 kgf cm, 29 ft lbf) (b) Check that SST (A) is secured to the rotor shaft.
Page 519 CH–13 CHARGING SYSTEM – GENERATOR (b) Using SST, remove the rectifier end frame. SST 09286–46011 (c) Remove the thrust washer. REMOVE ROTOR FROM DRIVE END FRAME GENERATOR INSPECTION AND REPAIR CH015–01 Rotor INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings.
Page 520 CH–14 CHARGING SYSTEM – GENERATOR INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 4.2–14.4 mm (0.559–0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor.
Page 521 CH–15 CHARGING SYSTEM – GENERATOR Rectifiers (Rectifier Holder) INSPECT POSITIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity.
Page 522 CH–16 CHARGING SYSTEM – GENERATOR (b) Using a socket wrench and press, press out the bearing. (c) Using SST and a press, press in a new bearing. SST 09608–20012(09608–00030) (d) Install the bearing retainer with the four screws. INSPECT REAR BEARING Check that the bearing is not rough or worn.
Page 523 CH–17 CHARGING SYSTEM – GENERATOR (c) Using SST and a press, press in a new bearing. SST 09820–00030 (d) Using SST, push in the bearing cover. SST 09285–76010 GENERATOR ASSEMBLY CH017–02 (See page CH–10) INSTALL ROTOR TO DRIVE END FRAME (a) Place the rectifier end frame on the pulley.
Page 524 CH–18 CHARGING SYSTEM – GENERATOR (c) Install the cord clip and four nuts. INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (b) clockwise to the specified torque.
Page 525 CH–19 CHARGING SYSTEM – GENERATOR (c) Install the rectifier holder with the four screws. INSTALL IC REGULATOR AND BRUSH HOLDER (a) Place the IC regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder installation direction. (b) Install the five screws until there is a clearance of approx.
Page 526 CH–20 CHARGING SYSTEM – GENERATOR CHECK THAT ROTOR ROTATES SMOOTHLY GENERATOR INSTALLATION CH019–02 (See page CH–9) INSTALL GENERATOR (a) Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet. (b) Connect the generator connector. (c) Connect the generator wire with the nut.
Page 527 CH–21 CHARGING SYSTEM – GENERATOR INSTALL NO.2 AND NO.3 RH ENGINE MOUNTING STAYS (a) Install the No.2 RH engine mounting stay with the bolt and nut. Bolt Torque: 75 N m (760 kgf cm, 55 ft lbf) Torque: 62 N m (630 kgf cm, 46 ft lbf) (b) Install the No.3 RH engine mounting stay with the two bolts.
Page 528 CH–22 CHARGING SYSTEM – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA CH01B–02 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Battery Specific gravity (When full charged at 20 C Ñ...

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