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Toyota 3F-E Repair Manual Supplement

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  • Page 2 FOREWORD This supplement has been prepared to provide information covering general service repairs for the 3F-E engine equipped on the TOYOTA LAND CRUISER. Application models: FJ62 series For basic engine service repair, refer to the following repair manual 3F Engine Repair Manual (Pub. No. 36253E)
  • Page 3 CHARGING SYSTEM SERVICE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS SST AND SSM ©1993 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation.
  • Page 4 I N-1 INTRODUCTION Page HOW TO USE THIS MANUAL ..........IN-2 I DENTIFICATION INFORMATION ......... IN-4 GENERAL REPAIR INSTRUCTIONS ........IN-4 PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER ........IN-7 ABBREVIATIONS USED IN THIS MANUAL ....IN-8...
  • Page 5 I N-2 I NTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through this manual, the section title and major heading are given at the top of every page. An INDEX is provided on the 1st page of each section to guide you to the item to be repaired.
  • Page 6 IN-3 How to Use This Manual I NTRODUCTION — The procedures are presented in a step-by-step format: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information, such as specifications and warnings.
  • Page 7 INTRODUCTION — IN -4 Identification Information, General Repair Instructions I DENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the right side of the cylinder block. GENERAL REPAIR INSTRUCTIONS Use fender, seat and floor covers to keep the vehicle clean and prevent damage.
  • Page 8 INTRODUCTION — General Repair Instructions IN-5 Precoated Parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adheasive at the factory. (a) If a precoated part is tightened, loosened or caused to move in any way, if must be recoated with the specified adhesive.
  • Page 9 General Repair Instructions I N-6 I NTRODUCTION — (d) When steam cleaning an engine, protect the distrib- utor, coil, air filter, and VCV from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.
  • Page 10 INTRODUCTION - Precautions for Vehicles Equipped with a Catalytic Converter IN -7 PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and ex- plain them to your customer.
  • Page 11 Idle Speed Control Over Head Valve Oversize Positive Crankcase Ventilation Power Steering Special Service Materials Special Service Tools Standard Switch TCCS TOYOTA Computer Controlled System Top Dead Center Undersize Vacuum Control Valve Vacuum Switching Valve Vacuum Transmitting Valve With Without...
  • Page 12 EM-1 ENGINE MECHANICAL REFER TO 3F ENGINE REPAIR MANUAL (Pub. No. 36253E) NOTE: The following pages contain only the points which differ from the above listed manual. Page EM-2 DESCRIPTION ............TROUBLESHOOTING EM-4 ..........ENGINETUNE-UP EM-8 ............. I DLE HC/CO CONCENTRATION CHECK METHOD EM-13 ..............
  • Page 13 Description ENGINE MECHANICAL – EM-2 DESCRIPTION The 3F-E engine is an in-line 6-cylinder 4.0 liter OHV 12-valve engine.
  • Page 14 Description ENGINE MECHANICAL — EM-3 The 3F-E engines are an in-line 6-cylinder engine The oil pan is bolted onto the bottom of the cylin- with the cylinders numbered 1 -2-3-4-5-6 from the der block. The oil pan is an oil reservoir made of front.
  • Page 15 Troubleshooting EM-4 ENGINE MECHANICAL — TROUBLESHOOTING ENGINE OVERHEATING Problem Possible cause Remedy Page Engine overheats Cooling system faulty Troubleshoot cooling system Incorrect ignition timing Reset timing EM-11 HARD STARTING Page Problem Possible cause Remedy Engine will not crank Starting system faulty Troubleshoot starting system or cranks slowly Engine will not start/...
  • Page 16 ENGINE MECHANICAL — Troubleshooting EM-5 ROUGH IDLING (Cont'd) Problem Possible cause Remedy Page Rough idle, stalls or • Throttle body misses (Cont'd) • ISC valve • Brake booster line Pulling in air between air flow meter and throttle body Incorrect idle speed Check ISC system FI-40,67...
  • Page 17 Troubleshooting ENGINE MECHANICAL — EM-6 ENGINE DIESELING Page Remedy Possible cause Problem Repair as necessary EFI system problems Engine diesels (runs after ignition switch turned off) AFTER FIRE, BACKFIRE Page Remedy Possible cause Problem Check EFI (fuel cut) system Deceleration fuel cut system always off Muffler explosion (after fire) on deceleration only...
  • Page 18 ENGINE MECHANICAL —Troubleshooting EM-7 POOR GASOLINE MILEAGE Problem Possible cause Remedy Page Poor gasoline Fuel leak Repair as necessary mileage Air cleaner clogged Check air cleaner EM-8 Incorrect ignition timing Reset timing EM-11 EFI system problems Repair as necessary • Injector faulty •...
  • Page 19 Engine Tune-up ENGINE MECHANICAL — EM-8 ENGINE TUNE-UP I NSPECTION OF ENGINE COOLANT 1. CHECK ENGINE COOLANT LEVEL AT RESERVE TANK The coolant level should be between the "LOW" and "FULL" lines. If low, check for leaks and add coolant up to the "FULL" li ne.
  • Page 20 Engine Tune-up EM-9 ENGINE MECHANICAL — I NSPECTION OF BATTERY 1.26 1. CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity When fully charged at 20°C (68°F): 1 .25 — 1.27 If not within specification, charge the battery. Upper Level Check the electrolyte quantity of each cell.
  • Page 21 EM-10 ENGINE MECHANICAL — Engine Tune-up I NSPECTION OF ALTERNATOR DRIVE BELT ( See page CH-4) Drive belt deflection: New belt 7.0 — 9.0 mm (0.278 — 0.354 in.) Used belt 9.0 — 12.0 mm (0.354 — 0.472 in.) Drive belt tension: New belt 55 —...
  • Page 22 ENGINE MECHANICAL — Engine Tune-up EM-11 (b) Turn the crankshaft pulley one revolution (360 Front 4- Second and align the mark as above. Adjust only the valves indicated by arrows. ® o ^ oo ®o l^^ o^ ^^ o ^ 1^ 0 1 INSTALL CYLINDER HEAD COVER II of...
  • Page 23 EM-12 Engine Tune-up ENGINE MECHANICAL — If necessary, loosen the distributor bolts and turn the distributor until the timing on the drive plate is aligned with the 7° mark. Tighten the distributor bolt and recheck the ignition ti ming, Torque: 175 kg-cm (13 ft-lb, 17 N•m) Remove the service wire.
  • Page 24 ENGINE MECHANICAL — Idle HC/CO Concentration Check Method EM-13 I DLE HC/CO CONCENTRATION CHECK METHOD HINT: This check is used only to determine whether or not the idle NC/CO complies with regulations. 1. INITIAL CONDITIONS Engine at normal operating temperature (b) Air cleaner installed All pipes and hoses of air induction system con- nected...
  • Page 25 Idle HC/CO Concentration Check Method ENGINE MECHANICAL — EM-14 4. RACE ENGINE AT 2,500 RPM FOR APPROX. 2 MINUTES I NSERT HC/CO METER TESTING PROBE INTO TAIL PIPE AT LEAST 40 cm (1.3 ft) MEASURE HC/CO CONCENTRATION AT IDLE Wait at least one minute before measuring to allow the concentration to stabilize.
  • Page 26 ENGINE MECHANICAL — Inspection and Adjustment of Dash Pot (DP) Setting Speed EM-15 I NSPECTION AND ADJUSTMENT OF DASH POT (DP) SETTING SPEED WARM UP ENGINE CHECK IDLE SPEED DISCONNECT ISC CONNECTOR REMOVE CAP, FILTER AND SEPARATER FROM DP CHECK DP SETTING SPEED Maintain engine speed at 2,500 rpm.
  • Page 27 Compression Check ENGINE MECHANICAL — EM-16 COMPRESSION CHECK HINT: If there is lack of power, excessive oil consump- tion or poor fuel economy, measure the cylinder com- pression pressure. WARM UP AND STOP ENGINE DISCONNECT DISTRIBUTOR CONNECTOR DISCONNECT COLD START INJECTOR CONNECTOR REMOVE SPARK PLUGS CHECK CYLINDER COMPRESSION PRESSURE...
  • Page 28 ENGINE MECHANICAL — Cylinder Head EM-17 CYLINDER HEAD COMPONENTS Air Intake Chamber Stay Seal Washer Air Intake Chamber Cylinder Head Cover • Gasket Cold Start See page EM-28 Injector Pipe Valve Rocker Shaft Air Injection Manifold Assembly ®^ Keeper 911. EGR Pipe g Retainer (IN) Valve Spring...
  • Page 29 Cylinder Head ENGINE MECHANICAL — EM-18 REMOVAL OF CYLINDER HEAD (See page EM-17) DRAIN ENGINE COOLANT REMOVE PS PUMP BRACKETS DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS AND IGNITION COIL 4. REMOVE AIR PUMP Disconnect the air hose. Remove the bolt, nut and air pump stay. Remove the through bolt, nut and air pump.
  • Page 30 ENGINE MECHANICAL — Cylinder Head EM-19 8. REMOVE WATER OUTLET ASSEMBLY Disconnect the water by-pass hose from the water outlet. Remove the two bolts holding the water outlet housing to the cylinder head, and remove the water outlet assembly and gasket. 9.
  • Page 31 Cylinder Head ENGINE MECHANICAL — EM-20 13. REMOVE CYLINDER HEAD Uniformly loosen and remove the fifteen head bolts in several passes, in the sequence shown. NOTICE: Head warpage or cracking could result from removing the bolts in incorrect order. Remove the air pump bracket with engine hanger. (c) Lift the cylinder head from the dowels on the cylin- der block and place it on wooden blocks on a bench.
  • Page 32 ENGINE MECHANICAL — Cylinder Head EM-21 DISASSEMBLY OF CYLINDER HEAD (See page EM-17) 1. REMOVE AIR INJECTION MANIFOLD UNIONS EM4359 2. REMOVE VALVES Using SST, press the valve springs and remove the two keepers. SST 09202-43013 Remove the spring retainer (or valve rotator), valve springs and valve.
  • Page 33 EM-22 ENGINE MECHANICAL — Cylinder Head I NSPECTION, CLEANING AND REPAIR OF CYLINDER HEAD COMPONENTS 10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS (a) Using SST and a hammer, drive out the valve guide bushing. SST 09201 -6001 1 Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
  • Page 34 ENGINE MECHANICAL — Cylinder Head EM-23 11. INSPECT AND GRIND VALVES Grind the valve only enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check the valve head margin thickness. Standard margin thickness: Intake 1.5 —...
  • Page 35 Cylinder Head ENGINE MECHANICAL — EM-24 Check the valve seating position. Apply a thin coat of prussian blue (or white lead) to the valve face. Install the valve. While applying light pressure to the valve, rotate the valve against the seat.
  • Page 36 ENGINE MECHANICAL — Cylinder Head EM-25 16. INSPECT INTAKE AND EXHAUST MANIFOLDS Intake (Cylinder Head Side) Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder head and air intake chamber for warpage. Maximum warpage: 0.50 mm (0.0197 in.) If the warpage is greater than maximum, replace the manifold.
  • Page 37 EM-26 ENGINE MECHANICAL — Cylinder Head ASSEMBLY OF CYLINDER HEAD (See page EM-17) 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 and oil seals with new ones. 1.
  • Page 38 Cylinder Head EM-27 ENGINE MECHANICAL — (d) Using SST, compress the valve spring and place the t wo keepers around the valve stem. SST 09202-43013 HINT: Different keepers are used for the spring retainer w/ Spring Retainer and valve rotator. w/ Valve Rotator EM1540 EM1541...
  • Page 39 EM-28 ENGINE MECHANICAL — Cylinder Head INSTALLATION OF CYLINDER HEAD (See page EM-17) 1. INSTALL CYLINDER HEAD Place a new cylinder head gasket on the cylinder block. NOTICE: Be careful of the installation direction. Place the cylinder head on the cylinder head gasket. Apply a light coat of engine oil on the threads and under the cylinder head bolts.
  • Page 40 ENGINE MECHANICAL — Cylinder Head EM-29 4. ADJUST VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. • Align the TDC mark of the drive plate with the ti ming pointer by turning the crankshaft clock- wise with a wrench. •...
  • Page 41 EM-30 ENGINE MECHANICAL — Cylinder Head 7. INSTALL WATER OUTLET ASSEMBLY Install a new gasket and the water outlet assembly with the two bolts. Torque: 250 kg-cm (18 ft-lb, 25 N•m) Connect the water by-pass hose. 8. INSTALL INTAKE AND EXHAUST MANIFOLDS (a) Place a new gasket so that the front mark is toward the front side.
  • Page 42 ENGINE MECHANICAL — Cylinder Head EM-31 11. INSTALL AIR PUMP Install the air pump with the through bolt and nut. Install the air pump stay with the bolt and nut. Connect the air hose. CONNECT HIGH-TENSION CORDS TO SPARK PLUGS AND IGNITION COIL INSTALL PS PUMP BRACKETS REFILL WITH ENGINE COOLANT Capacity:...
  • Page 43 Timing Gears and Camshaft ENGINE MECHANICAL — TIMING GEARS AND CAMSHAFT COMPONENTS Push Rod Cover Power Steering Pulley ♦ Gasket Timing Gear Cover ♦ Oil Seal Crankshaft Pulley 3,500 (253, 343) : Specified torque EM4521...
  • Page 44 ENGINE MECHANICAL — Timing Gears and Camshaft EM-33 REMOVAL OF TIMING GEARS AND CAMSHAFT (See page EM -32) DRAIN ENGINE COOLANT REMOVE FLUID COUPLING WITH FAN AND WATER PUMP PULLEY REMOVE PS BRACKETS REMOVE DISTRIBUTOR REMOVE VALVE ROCKER SHAFT ASSEMBLY (See steps 10 to 12 on pages EM-19) 6.
  • Page 45 EM-34 ENGINE MECHANICAL — Timing Gears and Camshaft 8. REMOVE PS PULLEY FROM CRANKSHAFT PULLEY Remove the six bolts and PS pulley. 9. REMOVE CRANKSHAFT PULLEY (a) Using SST and a 46 mm socket wrench, remove the pulley mount bolt. SST 09213-58011 and 09330-00021 (b) Using SST, remove the pulley.
  • Page 46 ENGINE MECHANICAL — Timing Gears and Camshaft EM-35 13. REMOVE CAMSHAFT TIMING GEAR AND CAMSHAFT ASSEMBLY (a) Remove the two bolts mounting the thrust plate to the cylinder block. EM4505 (b) Carefully pull out the camshaft and timing gear as- sembly.
  • Page 47 ENGINE MECHANICAL — Timing Gears and Camshaft EM-36 INSTALLATION OF TIMING GEARS AND CAMSHAFT (See page EM-32) 1. INSTALL CRANKSHAFT TIMING GEAR Put the timing gear on the crankshaft with timing mark facing forward. (b) Align the timing gear set key with the key groove of the timing gear.
  • Page 48 ENGINE MECHANICAL — Timing Gears and Camshaft EM-37 (d) Install the two bolts mounting the thrust washer to the cylinder block. Torque the bolts. Torque: 120 kg-cm (9 ft-lb, 12 N•m) 3. CHECK TIMING GEAR BACKLASH Using a dial indicator, measure the backlash at several places while turning the camshaft clockwise and coun- terclockwise.
  • Page 49 Timing Gears and Camshaft EM-38 ENGINE MECHANICAL — Align the pulley set key with the key groove of the pulley. Using SST and a hammer, tap in the pulley. SST 09214-60010 (e) After installing the pulley, torque the cover bolts. Torque: Bolts A 250 kg-cm (18 ft-lb, 25 N•m)
  • Page 50 ENGINE MECHANICAL — Timing Gears and Camshaft ( Reference) Using SST, check the drive belt tension. SST A 09216-00020 SST B 09216-00030 Drive belt tension: Alternator to water pump - New belt 55 — 65 kg Used belt 30 — 45 PS pump to crankshaft - New belt 45 —...
  • Page 51 Cylinder Block EM-40 ENGINE MECHANICAL — CYLINDER BLOCK COMPONENTS Piston Ring (No. 1 Compression Piston Ring (No. 2 Compression) Piston Ring (Side Rail) Piston Ring (Expander) Piston Snap Ring Connection Rod ♦ Camshaft Bearing ♦ Expansion Plug Connecting Rod Bearing 890 (64, 87) Connecting Rod Cap 600 (43, 59)
  • Page 52 ENGINE MECHANICAL - Cylinder Block EM-41 PREPARATION FOR DISASSEMBLY REMOVE DRIVE PLATE REMOVE TRANSMISSION HOUSING ADAPTOR INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE CYLINDER HEAD (See page EM-18) REMOVE ALTERNATOR REMOVE WATER PUMP REMOVE TIMING GEAR AND CAMSHAFT ( See page EM-32) REMOVE OIL COOLER AND OIL FILTER BRACKET REMOVE OIL PAN AND OIL PUMP DISASSEMBLY OF CYLINDER BLOCK...
  • Page 53 EM-42 ENGINE MECHANICAL - Cylinder Block Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Install the main caps. Torque: 19 mm bolt head 1,375 kg-cm (99 ft-lb, 135 N•m) 17 mm bolt head 1,175 kg-cm (85 ft-lb, 115 N•m) HINT: Do not turn the crankshaft.
  • Page 54 ENGINE MECHANICAL - Cylinder Block EM-43 ( Reference) Crankshaft journal diameter: Mark "3" No.1 66.972 - 66.980 mm (2.6367 - 2.6370 in.) No.2 68.472 - 68.480 mm (2.6957 - 2.6961 in.) No.3 69.972 - 69.980 mm (2.7548 - 2.7551 in.) No.4 71 .472 - 71 .480 mm (2.8139 - 2.8142 in.)
  • Page 55 EM-44 ENGINE MECHANICAL — Cylinder Block Standard bearing thickness (at center wall): Mark "Ti" 2.493 — 2.497 mm (0.0981 — 0.0983 in.) Mark "T2" 2.497 — 2.501 mm (0.0983 — 0.0985 in.) Mark "T3" 2.501 — 2.505 mm (0.0985 — 0.0986 in.) Mark "T4"...
  • Page 56 ENGINE MECHANICAL — Cylinder Block E M -45 I NSPECTION OF PISTON AND CONNECTING ROD ASSEMBLIES 2. INSPECT PISTON DIAMETER AND OIL CLEARANCE (a) Using a micrometer, measure the piston diameter at a right angle to the piston pin hole center line, 16 mm (0.63 in.) below the skirt bottom edge.
  • Page 57 Cylinder Block ENGINE MECHANICAL — EM-46 (c) Using a thickness gauge, measure the end gap. Standard end gap: No. 1 0.200 — 0.420 mm (0.0079 — 0.0165 in.) No. 2 0.500 — 0.720 mm (0.0197 — 0.0283 in.) Oil (side rail) 0.200 — 0.820 mm (0.0079 —...
  • Page 58 ENGINE MECHANICAL — Cylinder Block EM-47 Using a micrometer, measure the piston pin diame- ter. Piston pin diameter: 22.004 — 22.019 mm (0.8663 — 0.8669 in.) Subtract the piston pin diameter measurement from the busing inside diameter measurement. Standard oil clearance: 0.005 —...
  • Page 59 ENGINE MECHANICAL — Cylinder Block EM-48 POST ASSEMBLY INSTALL OIL PUMP AND OIL PAN INSTALL OIL COOLER AND OIL FILTER BRACKET INSTALL TIMING GEARS AND CAMSHAFT (See page EM-36) INSTALL WATER PUMP INSTALL CYLINDER HEAD (See page EM-28) REMOVE ENGINE STAND INSTALL TRANSMISSION HOUSING ADAPTOR 8.
  • Page 60 FI-1 EFI SYSTEM Page SYSTEMDESCRIPTION ....... FI-2 PRECAUTIONS........... FI-4 INSPECTION PRECAUTIONS ....FI-4 TROUBLESHOOTING......FI-9 DIAGNOSISSYSTEM ......FI-21 TROUBLESHOOTING WITH VOLT/OHMMETER ......FI-27 FUELSYSTEM .......... FI-44 FuelPump ..........FI-44 ColdStart Injector ......FI-50 FuelPressure Regulator ..... FI-53 Injectors..........FI-55 AIRINDUCTION SYSTEM .....
  • Page 61 FI-2 EFI SYSTEM — System Description SYSTEM DESCRIPTION Pressure Regulator (For Pressure Regulator) Fuel Pulsation Damper Fuel Tank Fuel Filter • Throttle VSV (For EGR) Position Sensor Air Flow Meter Valve Vacuum Modulator " \• EGR Valve Air Temp. Sensor <...
  • Page 62 ENGINE MECHANICAL — Troubleshooting EM -6 ENGINE DIESELING Page Remedy Possible cause Problem Repair as necessary EFI system problems Engine diesels (runs after ignition switch turned off) AFTER FIRE, BACKFIRE Page Remedy Possible cause Problem Check EFI (fuel cut) system Deceleration fuel cut system always off Muffler explosion (after fire) on...
  • Page 63 FI-4 EFI SYSTEM — Precautions, Inspection Precautions PRECAUTIONS 1. Before working on the fuel system, disconnect the cable from the negative (—) terminal of the battery. HINT: Any diagnostic code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before remov- ing the battery terminal.
  • Page 64 Inspection Precautions EFI SYSTEM — Fl-5 IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) The ECU has been designed so that it will not be affected by outside interference. However, if your vehicle is equipped with a CB radio transceiver, etc.
  • Page 65 Inspection Precautions FI-6 EFI SYSTEM — Care is required when pulling out and inserting wiring connectors. Release the lock and pull out the connector. Fully insert the connector and check that it is locked. 8. When inspecting a connector with a volt/ohmmeter. (a) Carefully take out the water-proofing rubber if it is a water-proof type connector.
  • Page 66 Inspection Precautions EFI SYSTEM — FI-7 FUEL SYSTEM 1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the follow- ing procedure: (a) Put a container under the connection. Plug Slowly loosen the connection. Disconnect the connection.
  • Page 67 Inspection Precautions FI-8 EFI SYSTEM — Check that there are no fuel leaks after performing any Check Connector maintenance on the fuel system. With engine stopped, turn the ignition switch ON. Using a service wire, short terminals + B and FP of the check connector.
  • Page 68 Troubleshooting EFI SYSTEM — FI-9 TROUBLESHOOTING TROUBLESHOOTING HINTS Engine troubles are usually not caused by the EFI system. When troubleshooting, always first check the condition of the other systems. Electronic source • Battery • Fusible links • Fuses Body ground Fuel supply •...
  • Page 69 FI-10 Troubleshooting EFI SYSTEM — 4. Use a volt/ohmmeter with high impedance (10 k1 /V minimum) for troubleshooting of the electrical circuit. (See page FI-27) TROUBLESHOOTING PROCEDURES - DIFFICULT SYMPTOM TO START OR NO START (ENGINE WILL NOT CRANK OR CRANKS SLOWLY) CHECK ELECTRIC SOURCE 1.
  • Page 70 EFI SYSTEM — Troubleshooting FI-11 OK CONTINUED FROM PAGE FI-10 CHECK SPARK PLUGS 1. Spark plugs Standard: 0.8 mm (0.031 in.) 2. Compression pressure HINT: Check compression pressure and Minimum: 8.0 kg/cm2 valve clearance if necessary. (114 psi, 785 kPa) at 200 rpm 3.
  • Page 71 SYMPTOM - ENGINE OFTEN STALLS CHECK DIAGNOSIS SYSTEM Diagnostic code(s) (See pages FI-24, 25) Check for output of diagnostic code. Malfunction (See page FI-21) code(s) Normal code CHECK FOR VACUUM LEAKS IN AIR 1. Oil filler cap INTAKE LINE 2. Oil dipstick 3.
  • Page 72 EFI SYSTEM — Troubleshooting FI-13 OK CONTINUED FROM PAGE FI-12 CHECK COLD START INJECTOR 1. Cold start injector (See page FI-50) (See page FI-50) 2. Cold start injector time switch (See page FI-72) RECHECK FUEL PRESSURE 1. Fuel pump (See page FI-44) (See page FI-45) 2.
  • Page 73 Troubleshooting FI-14 EFI SYSTEM — SYMPTOM - ROUGH I DLING AND/OR MISSING Diagnostic code(s) (See pages FI-24, 25) CHECK DIAGNOSIS SYSTEM Check for output of diagnostic code. Malfunction (See page FI-21) code (s) Normal code 1. Oil filler cap CHECK FOR VACUUM LEAKS IN AIR 2.
  • Page 74 EFI SYSTEM — Troubleshooting FI-1 OK CONTINUED FROM PAGE FI-14 CHECK FUEL PRESSURE Fuel pump (See page FI-44) (See page FI-45) 2. Fuel filter 3. Fuel pressure regulator (See page FI-53) CHECK INJECTORS Injection condition (See page FI-55) CHECK EFI ELECTRONIC CIRCUIT 1.
  • Page 75 EFI SYSTEM — Troubleshooting FI-16 SYMPTOM - HIGH ENGINE IDLE SPEED (NO DROP) Linkage — Stuck ACCELERATOR LINKAGE CHECK ISC valve AIR CONDITIONER IDLE-UP CHECK CIRCUIT Diagnostic code(s) (See pages FI-24, 25) CHECK DIAGNOSIS SYSTEM Malfunction Check for output of diagnostic code. code(s) (See page FI-21) Normal code...
  • Page 76 EFI SYSTEM — Troubleshooting FI-17 SYMPTOM - ENGINE BACKFIRES-Lean Fuel Mixture CHECK DIAGNOSIS SYSTEM Diagnostic code(s) (See pages FI-24, 25) Check for output of diagnostic code. Malfunction (See page FI-21) code(s) Normal code CHECK FOR VACUUM LEAKS IN AIR • 1. Oil filler cap INTAKE LINE 2.
  • Page 77 FI-18 EFI SYSTEM - Troubleshooting SYMPTOM - MUFFLER EXPLOSION (AFTER FIRE) - Rich Fuel Mixture-Misfire CHECK DIAGNOSIS SYSTEM Diagnostic code(s) (See pages F1-24, 25) Check for output of diagnostic code. Malfunction (See page F1-21) code(s) Normal code CHECK IGNITION TIMING Ignition timing —...
  • Page 78 EFI SYSTEM — Troubleshooting FI-19 SYMPTOM - ENGINE HESITATES AND/OR POOR ACCELERATION CHECK BRAKES Brakes — Drag CHECK FOR VACUUM LEAKS IN AIR 1. Oil filler cap I NTAKE LINE 2. Oil dipstick 3. Hose connections 4. PCV hose(s) 5. EGR system —...
  • Page 79 FI-20 EFI SYSTEM — Troubleshooting OK CONTINUED FROM PAGE FI-19 CHECK SPARK PLUGS 1. Spark plugs Plug gap: 0.8 mm (0.031 in.) 2. Compression pressure HINT: Check compression pressure and Minimum: 8.0 kg/cm2 valve clearance if necessary. (114 psi, 785 kpa) at 200 rpm 3.
  • Page 80 EFI SYSTEM — Diagnosis System FI-21 DIAGNOSIS SYSTEM DESCRIPTION The ECU contains a built-in self-diagnosis system by which troubles with the engine signal network are detected and a "CHECK" engine warning light on the instrument panel flashes. By analyzing various signals as shown in the later tables (See pages FI-24, 25) the ECU detects system malfunctions which are related to the various operating parameter sensors or actu- ator.
  • Page 81 FI-22 Diagnosis System EFI SYSTEM — Read the diagnostic code as indicated by the number of flashes of the "CHECK" engine warning light. Diagnostic Codes (See pages FI-24, 25) No malfunction (a) Normal System Operation (no malfunction) Approx. 1 Second •...
  • Page 82 Diagnosis System EFI SYSTEM - FI-23 CANCELLING DIAGNOSTIC CODE After repair of the trouble area, the diagnostic code re- tained in memory by the ECU must be cancelled out by removing the EFI fuse (15A) for 30 seconds or more, depending on ambient temperature (the lower the tem- perature, the longer the fuse must be left out) with the ignition switch OFF.
  • Page 83 Diagnosis System FI-24 EFI SYSTEM — DIAGNOSTIC CODES Number of Code Check engine System Diagnosis Trouble area page blinks — — — — This appears when none of Normal — — — the other codes are identified. —— F11604 • Ignition switch circuit' •...
  • Page 84 FI-25 EFI SYSTEM — Diagnosis System DIAGNOSTIC CODES (Cont'd) Number of Trouble area Diagnosis Check engine System page Open circuit in VC signal or • Air flow meter circuit short circuit between VS and Air flow • Air flow meter FI-35 E2 when idle contacts are Meter Signal...
  • Page 85 FI-26 EFI SYSTEM — Diagnosis System I NSPECTION OF DIAGNOSIS CIRCUIT 0 BATT EFI Main Relay Fusible Link Fuse 0+ B MAIN 0.85R EFI 15A 0M-REL "CHECK" Engine — I gnition Switch Warning Light 0.5G Fuse I G1 GAUGE 7.5A I G SW 0.5G I GN 7.5A...
  • Page 86 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-27 TROUBLESHOOTING WITH VOLT/OHMMETER HINT: The following troubleshooting proce- The following troubleshooting procedures are dures are designed for inspection of each sepa- based on the supposition that the trouble lies in rate system, and therefore the actual procedure either a short or open circuit in a component out- may vary somewhat.
  • Page 87 FI-28 EFI SYSTEM — Troubleshooting with Volt/ Ohmmeter EFI SYSTEM CHECK PROCEDURE HINT: • Perform all voltage measurements with the connectors connected. • Verify that the battery voltage is 11 V or more when the ignition switch is "ON" position. Using a voltmeter with high impedance (10 kQ/V mini- mum), measure the voltage at each terminal of the wiring connectors.
  • Page 88 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-29 Voltage at ECU Wiring Connectors Terminals Condition STD Voltage See page BATT-E1 — 10-14 FI-30 IG SW - El FI-31 M-REL - El Ignition switch ON 10 - 14 +B (+B1) - E1 FI-32 IDL - E2 Throttle valve open...
  • Page 89 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-30 Condition STD Voltage Terminals Trouble 10 — 14 V BATT — El No voltage SW — 10 — 14 No voltage Ignition switch ON 10 — 14 V M-REL — El No voltage Ignition switch ON 10 —...
  • Page 90 EFI SYSTEM — Tr oub l eshooting with Volt/Ohmmeter FI-31 IG SW — • There is no voltage between ECU terminals IG SW and El. (IG SW ON) Check that there is voltage between ECU terminal IG SW ground. (IG SW ON) body Check wiring between ECU terminal El and body ground.
  • Page 91 ENGINE MECHANICAL — Cylinder Head EM-23 11. INSPECT AND GRIND VALVES Grind the valve only enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check the valve head margin thickness. Standard margin thickness: Intake 1.5 —...
  • Page 92 FI-33 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter Condition STD Voltage Terminals Trouble 4 - 6 V Throttle valve open IDL - E2 4 - 6 V VC - E2 — Ignition No voltage switch ON Throttle valve fully closed 0.1 - 1.0 V VTA - E2 Throttle valve fully open 4- 5 V...
  • Page 93 FI-34 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter VC — E2 • There is no voltage between ECU terminals VC and E2. (IG SW ON) U000 MOLDED MODODOEuD DOODOMMOD ADDDE =DOOM Voltmeter Check that there is voltage between ECU terminal ( + B1) and body ground. SW ON) F10325 Check throttle position sensor.
  • Page 94 EFI S Y STEM — Troubleshooting with Volt/Ohmmeter FI-35 Trouble Condition Terminals STD Voltage 4 - 6 V VC-E22 — Ignition Measuring plate fully closed 4 - 5 V VS - E22 SW ON No voltage VS - E22 Measuring plate fully open 0.02 - 0.08 V Idling —...
  • Page 95 Troubleshooting with Volt/Ohmmeter EFI SYSTEM — FI-36 Voltage Condition Terminals Trouble Ignition switch Intake air temperature 20°C 1 — 3 V THA — E22 No voltage (68°F) • ( +B1) Air Temp. Sensor ( Air Flow Meter) • Fll 272 There is no voltage between ECU terminals THA and E22.
  • Page 96 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-37 Terminals Trouble Condition STD Voltage Ignition switch Coolant temperature 80°C THW - E2 No voltage 0.1 - 1.0 V (176°F) F10487 There is no voltage between ECU terminals THW and E2. (IG SW ON) Check that there is voltage between ECU terminal + B ( + B1) and body ground.
  • Page 97 Troubleshooting with Volt/Ohmmeter EFI SYSTEM — FI-38 STD Voltage Condition Trouble Terminals No. 10 - E01 14 V 10 - Ignition switch ON No voltage No. 20 - E02 Ignition Switch Fusible 110.5G Link Injector No. 10 0 No. 20 Battery 0E01 0 E02...
  • Page 98 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-39 STD Voltage Terminals Trouble Condition No voltage Cranking 6 — 14 V STA — El Ignition Switch Neutral Start Switch Fusible 0.5G Link STA (Terminal 50) To Circuit Opening Relay Battery F12436 There is no voltage between ECU terminals STA and El. (IG SW START) Check starter Check wiring between ECU terminal...
  • Page 99 Troubleshooting with Volt/Ohmmeter FI-40 EFI SYSTEM - STD Voltage Terminals Trouble Condition ISC4 — El No voltage Ignition switch ON 10 — 14 ISC1 EFI Main Relay Fuse ISC1 ISC2 EFI 15A ISC3 ISC4 Fusible MAIN 0.85R Link M REL Battery F12437 There is no voltage between ECU terminals ISC1...
  • Page 100 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter FI-41 Terminals Trouble Condition STD Voltage IGT — El No voltage Idling 0.7 — 1.0 V Ignition Switch Tachometer Fusible Igniter w/ Link Ignition Coil Battery F12438 There is no voltage between ECU terminals IGT and El. (Idling) Check that there is voltage between ECU terminal IGT and body ground.
  • Page 101 FI-42 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter Terminals Trouble Condition STD Voltage No trouble ("CHECK" engine warning W — El No voltage 10 — 14 V light off) and engine running F10728 There is no voltage between ECU terminals W and El . (Idling) Check that there is voltage between ECU terminal W and body ground.
  • Page 102 FI-43 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter CHECK CONNECTOR Oxygen Sensor 1 Oxygen Sensor Heater 1 Oxygen Sensor 2 _--- — Oxygen Sensor FI2702 1 There is no voltage between ECU terminals VF1 or VF2 and El. Check that there is specified voltage between ECU terminal VF1 or VF2 and body ground.
  • Page 103 FI-44 EFI SYSTEM — Fuel System SYSTEM FUEL Fuel Pump OUTLET Relief Valve Check Valve Bearing INLET OUTLET ..*: • • • Armature • • • • • • 9 t. • • • Magnet • • •• Bearing Impeller t INLET EFI Main Relay Fuse...
  • Page 104 EFI SYSTEM - Fuel System FI-45 ON-VEHICLE INSPECTION 1. INSPECT FUEL PUMP OPERATION (a) Turn the ignition switch ON. ° nnnA HINT: Do not start the engine. Check Connector Using a service wire, connect terminals + B and FP Service Wire of the check connector.
  • Page 105 EFI SYSTEM — Fuel System FI-46 Install SST (pressure gauge) to the delivery pipe with new two gaskets and union bolt. SST 09268-45012 (09268-41080) Torque: 180 kg-cm (13 ft-lb, 18 N.m) (g) Wipe off any splattered gasoline. Reconnect the battery negative (—) cable. Using a service wire, connect terminals + B and FP of the check connector.
  • Page 106 EFI SYSTEM — Fuel System F I -47 Reconnect the vacuum sensing hose to the fuel pressure regulator. Measure the fuel pressure at idling. Reconnect Fuel pressure: 2.3 — 2.6 kg/cm2 (33 — 37 psi, 226 — 265 kPa) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator.
  • Page 107 EFI SYSTEM - Fuel System FI-48 REMOVAL OF FUEL PUMP 35 (30 in-lb, 3.4) Clip Fuel Hose Fuel Pump Fuel Pump Bracket Fuel Pump Filter ♦ Clip Rubber Cushion kg-cm (ft-lb, N•m) Specified torque ♦ Non-reusable part F12374 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DRAIN FUEL FROM FUEL TANK CAUTION: Do...
  • Page 108 EFI SYSTEM — Fuel System FI-49 6. REMOVE FUEL PUMP FILTER FROM FUEL PUMP Remove the rubber cushion. Using a small screwdriver, remove the clip. Pull out the pump filter. I NSTALLATION OF FUEL PUMP (See page FI-48) 1. INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip.
  • Page 109 EFI SYSTEM — Fuel System FI-50 Cold Start Injector Ignition Terminal Switch Solenoid Coil Spring FI2420 FI2482 ON-VEHICLE INSPECTION INSPECT RESISTANCE OF COLD START INJECTOR Disconnect the cold start injector connector. Using an ohmmeter, measure the resistance be- tween the terminals. Resistance: 2 —...
  • Page 110 EFI SYSTEM — Fuel System FI-51 I NSPECTION OF COLD START INJECTOR SST (Hose) Union Bolt 1. INSPECT INJECTION OF COLD START INJECTOR New Gasket CAUTION: Keep clear of sparks during the test. SST (Union) Install SST (two unions) to the injector and delivery pipe with new gaskets and the union bolts.
  • Page 111 FI-52 EFI SYSTEM - Fuel System I NSTALLATION OF COLD START I NJECTOR 1. INSTALL COLD START INJECTOR Install a new gasket and the injector with the two bolts. Torque: 50 kg-cm (43 in.-lb, 4.9 N•m) 2. INSTALL COLD START INJECTOR PIPE Install the cold injector pipe with new four gaskets, the two union bolts and pipe clamp bolt.
  • Page 112 EFI SYSTEM — Fuel System FI-53 Fuel Pressure Regulator Vacuum Sensing Hose Spring INTAKE VACUUM Diaphragm FROM DELIVERY PIPE Pressure Regulator Return Pipe TO RETURN PIPE FI2419 FI2554 ON-VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page FI-45) REMOVAL OF FUEL PRESSURE REGULATOR 1.
  • Page 113 EFI SYSTEM — Fuel System FI-54 I NSTALLATION OF FUEL PRESSURE REGULATOR 1. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new 0-ring, and install it to the pressure regulator. Install the pressure regulator with the two bolts. Torque: 50 kg-cm (43 in.-lb, 4.9 N•m) 2.
  • Page 114 EFI SYSTEM — Fuel System FI-55 Injectors Connector Terminal Needle Valve INLET INJECTION Coil F12478 I N-VEHICLE INSPECTION INSPECT INJECTOR OPERATION Check operation sound from each injector. With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm.
  • Page 115 EFI SYSTEM — Fuel System FI-56 REMOVAL OF INJECTOR 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. DISCONNECT ACCELERATOR AND THROTTLE CABLES 3. REMOVE AIR INTAKE HOSE 4. DISCONNECT FOLLOWING HOSES: (a) Emission control hoses HINT: Before disconnecting the emission control hoses, use tags to identify how they should be recon- nected.
  • Page 116 EFI SYSTEM — Fuel System FI-57 Disconnect the water hoses and remove the two bolts and water by-pass pipe. Remove the four bolts and two intake chamber stays. EM4517 Remove the seven bolts, two nuts and air intake chamber. Remove the bolt, manifold temperature sensor with stay and air intake chamber gasket.
  • Page 117 Fuel System FI-58 EFI SYSTEM — I NSPECTION OF INJECTORS 1. INSPECT INJECTOR INJECTION Keep clear of sparks during the test. CAUTION: ( Clamp) Fuel Filter ( On Vehicle) F 12556 Disconnect the fuel hose from the fuel filter outlet. Connect SST (union and hose) to the fuel filter outlet with new gaskets and the union bolt.
  • Page 118 EFI SYSTEM — Fuel System FI-59 (j) Connect SST (wire) to the injector and battery for 1 5 seconds, and measure the injection volume with a graduated cylinder. Test each injector two or three ti mes. SST 09842-30070 Volume: 47 — 59 cc (2.9 — 3.6 cu in.) per 15 sec. Difference between each injector: 5 cc (0.3 Cu in.) or less If the injection volume is not as specified, replace the...
  • Page 119 FI-60 EFI SYSTEM - Fuel System Place the injectors together with the delivery pipe in position on the intake manifold. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of 0-rings. Replace the 0-rings.
  • Page 120 EFI SYSTEM — Fuel System FI-61 Install the water by-pass pipe with the two bolts and connect the water hoses. Install the cold start injector pipe. (See page FI-52) EM4517 Install the EGR pipe with the two union nuts Torque: 800 kg-cm (58 ft-lb, 78 N•m) Install the two clamp mount bolts.
  • Page 121 Air Induction System EFI SYSTEM — FI-62 AIR INDUCTION SYSTEM Air Flow Meter • TO AIR INTAKE CHAMBER Return Spring INTAKE CLEANER CHAMBER SIDE SIDE Air By-pass Passage Air By-pass Passage FROM AIR Measuring Plate CLEANER Measuring Plate F11286 F10449 ON-VEHICLE INSPECTION JNSPECT RESISTANCE OF AIR FLOW METER Disconnect the air flow meter connector.
  • Page 122 EFI SYSTEM — Air Induction System FI-63 I NSPECTION OF AIR FLOW METER INSPECT RESISTANCE OF AIR FLOW METER Using an ohmmeter, measure the resistance between FC El E2 VS each terminal by'Pnoving the measuring plate. ®a=®®®®® Between Measuring plate Resistance (S2) Terminals opening...
  • Page 123 ER SYSTEM — Air Induction System FI-64 Throttle Body Throttle Position Sensor F12483 F11476 F11533 ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. Check the vacuum at each port. • Start the engine. • Check the vacuum with your finger. Other than idling At idling Port No.
  • Page 124 EFI SYSTEM — Air Induction System FI-65 Clearance between Between terminals Resistance lever and stop screw 0mm(0in.) VTA—E2 0.3-6.3kQ 0.77 mm (0.0303 in.) I DL — E2 Less than 2.3 kQ IIJ ^^ ^j_l—EDL 1.09 mm (0.0429 in.) IDL— E2 Infinity Throttle valve fully VTA—E2...
  • Page 125 EFI SYSTEM — Air Induction System FI-66 INSPECT THROTTLE POSITION SENSOR (See step 2 on page FI-64) IF NECESSARY, ADJUST THROTTLE POSITION SENSOR (a) Loosen the two set screws of the sensor. Insert a 0.93 mm (0.0366 in.) thickness gauge, be- t ween the throttle stop screw and stop lever.
  • Page 126 EFI SYSTEM — Air Induction System FI-67 Idle Speed Control (ISC) Valve Rotor Coil Rotor Valve F12372 F11692 ON-VEHICLE INSPECTION CHECK FOR OPERATING SOUND FROM ISC VALVE Check that there is a clicking sound immediately after stopping the engine. REMOVAL OF ISC VALVE DRAIN ENGINE COOLANT DISCONNECT ISC VALVE CONNECTOR DISCONNECT AIR AND TWO WATER BY-PASS...
  • Page 127 EFI SYSTEM — Air Induction System FI-68 I NSPECTION OF ISC VALVE INSPECT ISC VALVE RESISTANCE Using an ohmmeter, measure the resistance between ter- minal B1 — S1 or S3, and B2 — S2 or S4. Resistance: B1 - 51 or S3 10 - 30 B2 - S2 or S4 10 - 30 If resistance is not as specified, replace the ISC valve.
  • Page 128 EFI S Y S TEM — Electronic Control System FI-69 ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts "CHECK" Connector EGR Gas Temp. Sensor (Calif. only) Circuit Opening Relay Cold Start Injector Time Switch Water Temp. Switch EFI Main Relay Oxygen Sensor Water Temp.
  • Page 129 EFI SYSTEM — Electronic Control System FI-70 EFI Main Relay I NSPECTION OF EFI MAIN RELAY 1. INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 3. Check that there is no continuity between terminals 2 and 4.
  • Page 130 EFI SYSTEM — Electronic Control System FI-71 Circuit Opening Relay To Ignition Switch (ST1) To ECU (STA) ECU (+B) EFI Main Relay Circuit Opening Relay Check Connector Fuel Pump Switch (Air Flow Meter) Fuel Pump FI1274 I NSPECTION OF CIRCUIT OPENING Continuity RELAY 1.
  • Page 131 EFI SYSTEM — Electronic Control System FI-72 Cold Start Injector Time Switch To Ignition ECU (STA) Switch (ST1) ECU (STJ) Cold Start Injector Time Switch FI1374 I NSPECTION OF COLD START INJECTOR TIME SWITCH INSPECT RESISTANCE OF COLD START INJECTOR TIME SWITCH Using an ohmmeter, measure the resistance between each terminal.
  • Page 132 EFI SYSTEM — Electronic Control System FI-73 Water Temperature Sensor WATER TEMPERATURE SENSOR I/////7 Thermistor 20 0 20 40 60 80 100 120 (-4) (32) (68) (104) (1 40)(1 76)(21 2) (248) TEMPERATURE °C ('F) F10515 F10709 I NSPECTION OF WATER TEMPERATURE SENSOR INSPECT RESISTANCE OF WATER TEMPERATURE SENSOR...
  • Page 133 FI-74 EFI SYSTEM — Electronic Control System High Temperature Line Pressure Up System Fusible Main Relay Link Fuse MAIN EFI 15A 0.85R 0 M-REL Water Temperature Switch Battery 0 E1 F12462 I NSPECTION OF HIGH TEMPERATURE LINE UP SYSTEM 1. INSPECT WATER TEMPERATURE SWITCH Using an ohmmeter, check that there is no continu- ity between the terminal and body when the oil temperature is below 98°C (208°F).
  • Page 134 EFI SYSTEM — Electronic Control System FI-75 Oxygen Sensors I NSPECTION OF OXYGEN SENSOR ' .o'D WARM UP ENGINE Check Connector Allow the engine to reach normal operating temperature. Voltmeter INSPECT FEEDBACK VOLTAGE Connect the positive (+) probe of a voltmeter to terminal VF1 of the check connector, and negative (—) probe to F12409 terminal El.
  • Page 135 FI-76 Electronic Control System EFI SYSTEM — CONTINUED FROM PAGE FI-75 Repair the relevant diagnostic code. Malfunction code(s) (Ex. code Nos. 21, 25, 26 and 28) Read and record diagnostic codes. (See pages FI-24, 25) Normal code, code Nos. 21, 25, 26 and 28 Disconnect terminals TE1 and El of the check connector.
  • Page 136 EFI SYSTEM — Electronic Control System FI-77 3. INSPECT HEATER RESISTANCE OF OXYGEN Ohmmeter SENSOR Using an ohmmeter, measure the resistance between the terminal + B and HT. Resistance (Cold): 5.1 — 6.3 Q If the resistance is not as specified, replace the sensor. F12749 Electronic Controlled Unit (ECU) I NSPECTION OF ECU...
  • Page 137 Electronic Control System EFI SYSTEM — FI-78 Voltage at ECU Wiring Connectors (Cont'd) Condition STD Voltage Terminals Intake air temperature 20°C (68°F) 1 — 3 Ignition switch ON THA — E2 Ignition switch ON Coolant temperature 80°C (176°F) 0.1 — 1.0 THW —...
  • Page 138 EFI SYSTEM — Electronic Control System FI-79 2. INSPECT RESISTANCE OF ECU NOTICE: • Do not touch the ECU terminals. • The tester probe should be inserted into the wiring o ^ ao connector from the wiring side. Ohmmeter Check the resistance between each terminal of the wiring connectors.
  • Page 139 EFI SYSTEM — Electronic Control System FI-80 Fuel Cut RPM I NSPECTION OF FUEL CUT RPM WARM UP ENGINE Allow the engine to reach normal operating temperature. I NSPECT FUEL CUT RPM Disconnect the connector from the throttle position sensor. Connect terminals I DL and E2 of the wiring connec- tor.
  • Page 140 CO-1 COOLING SYSTEM REFER TO 3F ENGINE REPAIR MANUAL (Pub. No. 36253E) NOTE: The following pages contain only the points which differ from the above listed manual. Page ENGINE COMPARTMENT COOLING FAN ....CO-2...
  • Page 141 Engine Compartment Cooling Fan COOLING SYSTEM — CO-2 ENGINE COMPARTMENT COOLING FAN ENGINE COMPARTMENT COOLING FAN CIRCUIT F12430 I NSPECTION OF ENGINE COMPARTMENT COOLING FAN COMPONENTS Cooling Fan Relay I NSPECT COOLING FAN RELAY CIRCUIT Remove the driver's cowl side trim. Disconnect the relay connector and inspect the connector on wire harness side as shown in the chart below.
  • Page 142 COOLING SYSTEM — Engine C om partment Cooling Fan CO-3 Cooling Fan Motor Relay LOCATION: Inside of the driver's cowl side trim. BE0005 INSPECT COOLING FAN MOTOR RELAY A. Inspect relay continuity Check that there is continuity between terminals 1 and 3.
  • Page 143 COOLING SYSTEM — Engine Compartment Cooling Fan CO-4 Manifold Temperature Sensor LOCATION: Near the intake chamber. INSPECT MANIFOLD TEMPERATURE SENSOR Using an ohmmeter, measure the resistance of the tem- perature sensor terminals. Resistance (Q) Oil temperature °C (°F) Approx. 4 kQ 90°C (194°F) Approx.
  • Page 144 I G-1 I GNITION SYSTEM Page ........PRECAUTIONS I G-2 ......TROUBLESHOOTING I G-3 IGNITION SYSTEM CIRCUIT ..... I G-4 ON-VEHICLE INSPECTION ....I G-5 ........DISTRIBUTOR I G-8...
  • Page 145 Precautions I G-2 I GNITION SYSTEM — PRECAUTIONS Do not leave the ignition switch on for more than 10 minutesif the engine will not start. 2. When a tachometer is connected to the system, con- nect the tachometer test probe to terminal IG of the check connector.
  • Page 146 IGNITION SYSTEM — Troubleshooting IG-3 TROUBLESHOOTING Problem Possible cause Remedy Page Engine will not start/ Incorrect ignition timing Reset timing EM-1 1 hard to start Ignition problems (cranks ok) • Ignition coil Inspect coil IG-7 • Igniter Inspect igniter IG-7 •...
  • Page 147 IGNITION SYSTEM — Ignition System Circuit IG-4 I GNITION SYSTEM CIRCUIT Ignition Switch Ignition Coil Distributor Spark Plug Fusible C 0.5G Link Igniter To Tachometer Firing Order 1 5 3 6 2 4 Battery 0 0 0 GC NE G IGT IGF IG0831 ELECTRONIC SPARK ADVANCE (ESA)
  • Page 148 IGNITION SYSTEM — On-Vehicle Inspection IG-5 ON-VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS Disconnect high-tension cord from distributor. Hold the end approx. 12.5 mm (0.50 in.) from body of vehicle. See if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 -2 seconds at a time.
  • Page 149 ENGINE MECHANICAL — Timing Gears and Camshaft EM-37 (d) Install the two bolts mounting the thrust washer to the cylinder block. Torque the bolts. Torque: 120 kg-cm (9 ft-lb, 12 N•m) 3. CHECK TIMING GEAR BACKLASH Using a dial indicator, measure the backlash at several places while turning the camshaft clockwise and coun- terclockwise.
  • Page 150 IGNITION SYSTEM — On-Vehicle Inspection IG-7 I NSPECTION OF IGNITION COIL 1. DISCONNECT HIGH-TENSION CORD 2. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (—) terminals. Primary coil resistance (cold): 0.52 — 0.64 Q If the resistance is not as specified, replace the ignition coil.
  • Page 151 IG-8 IGNITION SYSTEM — Distributor DISTRIBUTOR COMPONENTS Distributor Packing Rotor ♦ 0-Ring ♦ Straight Pin ♦ Gear ♦ Non-reusable part IG0839 REMOVAL OF DISTRIBUTOR REMOVE AIR CLEANER HOSE DISCONNECT DISTRIBUTOR CONNECTOR DISCONNECT VENTILATION HOSES DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS AND IGNITION COIL 5.
  • Page 152 IGNITION SYSTEM — Distributor IG-9 REPLACEMENT OF DISTRIBUTOR DRIVEN GEAR 1. REMOVE DRIVEN GEAR Using a grinder, grind the driven gear and straight pin. NOTICE: Be careful not to damage the governor shaft. Mount the driven gear in a vise. Using a pin punch and hammer, tap out the straight pin.
  • Page 153 IGNITION SYSTEM — Distributor I NSTALLATION OF DISTRIBUTOR 1. SET NO. 1 CYLINDER TO TDC/COMPRESSION Set to TDC /compression in the following manner. • Remove the No. 1 spark plug. • Place your finger over the hole of the No. 1 spark plug and turn the crankshaft clockwise to TDC/ compression.
  • Page 154 IGNITION SYSTEM - Distributor IG-11 INSTALL DISTRIBUTOR CAP WITH HIGH-TENSION CORDS CONNECT HIGH-TENSION CORDS TO SPARK PLUGS Firing order: 1-5-3-6-2-4 CONNECT VENTILATION HOSES CONNECT DISTRIBUTOR CONNECTOR INSTALL AIR CLEANER HOSE 10. ADJUST IGNITION TIMING (See page EM-11) Ignition timing: 7 BTDC @ idle ( w/ connected TE1 - E1, Transmission in N position)
  • Page 155 CH-1 CHARGING SYSTEM Page PRECAUTIONS ............CH-2 TROUBLESHOOTING ..........CH-2 CHARGING SYSTEM CIRCUIT ........ CH-3 ON-VEHICLE INSPECTION ........CH-3 ALTERNATOR ............. CH-7 IGNITION MAIN RELAY ..........CH-15 CHARGE LIGHT RELAY ..........CH-16...
  • Page 156 CHARGING SYSTEM — Precautions, Troubleshooting CH-2 PRECAUTIONS Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is run- ning.
  • Page 157 CHARGING SYSTEM — Charging System Circuit, On-Vehicle Inspection CH-3 CHARGING SYSTEM CIRCUIT Alternator 0°4 Rectifier Fusible 6:40 "Wiln Link •m • I NI • <6 Stator Coil 0 . 0 efi • Battery Charge Light Ignition Relay Main Relay CH0625 ON-VEHICLE INSPECTION 1.
  • Page 158 CHARGING SYSTEM — On-Vehicle Inspection CH-4 3. INSPECT DRIVE BELT (a) Visually check the drive belt for cracks, oiliness or WRONG CORRECT wear. Check that the belt does not touch the bottom Clearance of the pulley groove. If necessary, replace the drive belt. I^^^i l l ^ ^ I I 'll...
  • Page 159 CHARGING SYSTEM — On-Vehicle Inspection CH-5 5. CHECK DISCHARGE WARNING LIGHT CIRCUIT Warm up the engine and turn it off. Turn off all accessories. Turn the ignition switch to "ON". Check that the charge light is lit. Start the engine. Check that the light goes out. If the light does come on and go off as specified, trou- bleshoot the discharge light circuit.
  • Page 160 CHARGING SYSTEM — On-Vehicle Inspection CH-6 • If the voltage reading is more than standard g 10 voltage, replace the IC regulator. 12 14 • If the voltage reading is less than standard voltage, check the alternator. CH0067 7. INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "HI".
  • Page 161 CHARGING SYSTEM — Alternator CH-7 ALTERNATOR COMPONENTS Terminal Insulator Rectifier End Frame Insulator Washer IC Regulator Rectifier Holder CH0586 DISASSEMBLY OF ALTERNATOR 1. REMOVE DRIVE END FRAME AND ROTOR ASSEMBLY FROM STATOR Remove the three through screws. Using a screwdriver, pry the end frame and remove it together with the rotor.
  • Page 162 CHARGING SYSTEM — Alternator CH-8 2. REMOVE PULLEY, FAN AND DRIVE END FRAME FROM ROTOR Mount the rotor in a soft jaw vise. Remove the pulley nut, spring washer, pulley and fan. Remove the spacer collar and drive end frame. Remove the spacer ring and snap ring.
  • Page 163 CHARGING SYSTEM - Alternator CH-9 I NSPECTION AND REPAIR OF ALTERNATOR Rotor INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity be- tween the slip rings. Standard resistance: 2.8 - 3.0 0 If there is no continuity, replace the rotor. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and the rotor.
  • Page 164 CH-10 CHARGING SYSTEM — Alternator Brushes 1. INSPECT EXPOSED BRUSH LENGTH Using a scale, measure the exposed brush length. Standard exposed length: 20.0 mm (0.787 in.) Minimum exposed length: 5.5 mm (0.217 in.) If the length is less than minimum, replace the brushes. 2.
  • Page 165 CHARGING SYSTEM — Alternator CH-11 2. INSPECT NEGATIVE SIDE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the negative (—) terminal and the other to each rectifier terminal. Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity.
  • Page 166 CH-12 CHARGING SYSTEM — Alternator 4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing from the rotor shaft. SST 09286-46011 (b) Using a press, press in a new rear bearing onto the rotor shaft. CH0182...
  • Page 167 CHARGING SYSTEM — Alternator CH-13 ASSEMBLY OF ALTERNATOR (See page CH-7) INSTALL RECTIFIER HOLDER TO STATOR Hold the stator coil lead with needle-nose pliers while soldering the leads. NOTICE: Protect the rectifiers from heat. INSTALL IC REGULATOR Hold the IC regulator terminal with needle-nose pliers while soldering the terminals.
  • Page 168 CHARGING SYSTEM — Alternator CH-14 4. INSTALL DRIVE END FRAME, FAN AND PULLEY TO ROTOR (a) Slide the snap ring and spacer ring onto the rotor shaft. Mount the rotor in a soft jaw vise. Slide the drive end frame and spacer collar CH0570 Slide the fan, pulley and spring washer onto the rotor shaft.
  • Page 169 Alternator, Ignition Main Relay CHARGING SYSTEM — CH-15 Install the three through screws. Remove the stiff wire from the access hole. Check that the rotor rotates smoothly. Seal the access hole. I GNITION MAIN RELAY I NSPECTION OF IGNITION MAIN RELAY 1.
  • Page 170 CHARGING SYSTEM — Charge Light Relay CH-16 CHARGE LIGHT RELAY I NSPECTION OF CHARGE LIGHT RELAY LOCATION: Inside of the passenger's cowl side trim. BE0016 1. INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is no continu- ity between terminals 1 and 2. Continuity O D D C H 0581...
  • Page 171 SERVICE SPECIFICATIONS Page ENGINE MECHANICAL ..........A-2 EFI SYSTEM ..............A-7 IGNITION SYSTEM ............A-10 CHARGING SYSTEM ............ A-10...
  • Page 172 SERVICE SPECIFICATIONS - Engine Mechanical ENGINE MECHANICAL Specifications Engine coolant capacity w/ Front heater 17.5 liters 18.5 US qts 1 5.4 Imp. qts w/ Front and rear heaters 1 9.5 liters 20.6 US qts 1 7.2 Imp. qts Engine oil capacity Drain and refill w/o Oil filter change 7.0 liters...
  • Page 173 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Cylinder head Cylinder block surface warpage Limit 0.15 mm 0.0059 in. Manifold surface warpage Limit 0.10 mm 0.0039 in. Valve seat Refacing angle Intake 25°, 45°, 70° Exhaust 45°, 65° Contacting angle 45° Contacting width Intake 1.1 - 1.7 mm...
  • Page 174 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Camshaft Circle runout Limit 0.30 mm 0.0118 in. and bearing Cam lobe height 38.36 - 38.46 mm 1.5102 - 1 .5142 in. 38.25 - 38.35 mm 1.5059 - 1.5098 in. Limit 38.0 mm 1.496 in.
  • Page 175 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Cylinder block Warpage Limit 0.15 mm 0.0059 in. Cylinder bore diameter STD Mark "1" 94.000 - 94.010 3.7008 - 3.7012 in. Mark "2" 94.010 - 94.020 3.7012 - 3.7016 in. ark "3" 94.020 - 94.030 3.7016 - 3.7020 in.
  • Page 176 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Crankshaft Main journal diameter STD No. 1 66.972 - 66.996 mm 2.6367 - 2.6376 in. and bearing No. 2 68.472 - 68.496 mm 2.6957 - 2.6967 in. (cont'd) No. 3 69.972 - 69.996 mm 2.7548 - 2.7557 in.
  • Page 177 SERVICE SPECIFICATIONS — Engine Mechanical, EFI System Torque Specifications (Cont'd) Part tightened kg-cm ft-lb N•m PS pulley x Crankshaft pulley 1 85 Push rod cover x Cylinder block 35 in.-lb Main bearing cap x Cylinder block 1 9 mm bolt head 1,375 1 35 1 7 mm bolt head...
  • Page 178 SERVICE SPECIFICATIONS — EFI System Specifications (Cont'd) Air flow meter E2 – THA Resistance at –20°C (-4°F) 1 0 – 20 kQ (cont'd) (cont'd) at 0°C (32°F) 4 – 7 kS2 at 20°C (68°F) 2 – 3 kQ at 40°C (1 04°F) 0.9 –...
  • Page 179 EFI System SERVICE SPECIFICATIONS — Specifications (Cont'd) ECU (cont'd) Terminals Condition STD voltage (V) Check connector TE1 — El not connect 4 — 6 T — El Ignition switch ON Check connector TE1 — El connect Shift position P or N range NSW —...
  • Page 180 1" A-10 SERVICE SPECIFICATIONS — Ignition System, Charging System I GNITION SYSTEM Ignition timing 7° BTDC @ idle (Check connector TE1 and El connected) Firing order 1 —5-3-6-2-4 High-tension Resistance Limit 25 kQ per cord cord Spark plug Type W16EXR-U BPR5EY Correct electrode gap 0.8 mm...
  • Page 181 STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS...
  • Page 182 STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Mark Class Mark Class Hexagon Stud bolt Bolt Head bolt No mark head No. 5 - No mark Hexagon flange bolt '/ Grooved No mark w/washer hexagon bolt Hexagon head bolt protruding...
  • Page 183 STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt kg-cm ft-lb N•m kg-cm ft-lb N•m 48 in.-lb 52 in.-lb 1.25 1 30 1 45 1.25 1.25 1,150 — 56 in.-lb —...
  • Page 184 SERVICE SPECIFICATIONS — Engine Mechanical, EFI System Torque Specifications (Cont'd) Part tightened kg-cm ft-lb N•m PS pulley x Crankshaft pulley 1 85 Push rod cover x Cylinder block 35 in.-lb Main bearing cap x Cylinder block 1 9 mm bolt head 1,375 1 35 1 7 mm bolt head...
  • Page 185 SST AND SSM — SST (Special Service Tools), SSM (Special Service Materials) SST (SPECIAL SERVICE TOOLS) (Cont'd) Section Classification Part Name Note Part No . Illustration (09268-41080) (No. 6 Union) • (09268-41090) (No.7 Union) 04,j • • (No. 1 Union) (90405-09015) , (A,, i - I EFI Fuel Pressure)

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