Mitsubishi 1989-1993 GALANT Service Manual

Table of Contents

Quick Links

BACKUP

Service Manual

Volume 1

Chassis & Mechanical

FOREWORD

This Service Manual has been prepared with the

latest service information available at the time of

publication. It is subdivided into various group cate-

gories and each section contains diagnostic, dis-

assembly, repair, and installation procedures along

with complete specifications and tightening ref-

erences. Use of this manual will aid in properly per-

forming any servicing necessary to maintain or res-

tore the high levels of performance and reliability

designed into these outstanding vehicles.

This BACKUP DSM manual is to be used DNLY as a SACKUP.

WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed DWN

manual was lost or destroyed.)

VOLUNTARY

CERTIFICATION THROUGH

previously manufactured

Motors Corporation

WE SUPPORT

TECHNICIAN

EXCELLENCE

MITSUBISHI

MOTOR SALES OF

AMERICA. Inc.

GROUP INDEX

General .........................................................

Engine ...........................................................

Fuel ................................................................

Cooling .........................................................

Intake And Exhaust ..............................

Emission Control ....................................

Clutch ............................................................

Manual Transaxle ..................................

Automatic Transaxle ............................

Propeller Shaft ........................................

Front Axle ..................................................

Rear Axle ....................................................

Wheel And Tire .......................................

Power Plant Mount ..............................

Front Suspension ...................................

Active-Electronic

Control Suspension

Rear Suspension .................................... &

Service Brakes .........................................

Parking Brakes ........................................

Alphabetical Index .................................

NOTE: Electrical system Information is contained in

Volume 2 "Electrical" of this paired Service Manual.

For overhaul procedures of engines or transmissions,

refer to the separately issued Engine Service Manual

or Manual/Automatic Transmission Service Manual.

..............................

Table of Contents

Troubleshooting

Summary of Contents for Mitsubishi 1989-1993 GALANT

Page 1: Rear Suspension
Alphabetical Index ......... WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH EXCELLENCE MITSUBISHI MOTOR SALES OF AMERICA. Inc. NOTE: Electrical system Information is contained in Volume 2 “Electrical” of this paired Service Manual. For overhaul procedures of engines or transmissions, refer to the separately issued Engine Service Manual or Manual/Automatic Transmission Service Manual.
Page 3: Table Of Contents
CONTENTS Rear Axle ............GENERAL DATA AND SPECIFICATIONS ..23 Rear Drum Brake Linings and HOW TO USE THIS MANUAL ...... Rear Wheel Cylinders ........Definition of Terms ........Spark Plugs ........... Explanation of Circuit Diagrams ....Timing Belt ........... 40 Explanation of Manual Contents ....
Page 4 NOTES...
Page 5: How To Use This Manual Definition Of Terms
GENERAL - How to Use This Manual SCOPE OF MAINTENANCE, REPAIR AND DEFINITION OF TERMS SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspectian or the and servicing of the subject model.
Page 6: Explanation Of Manual Contents
GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Maintenance and Servicing Procedures Removal steps: The part designation number corres- ponds to the number in the illustration...
Page 7 GENERAL - How to Use This Manual Denotes non-re- 3 Connectm for pressure hose cotter P!” 10. Center member rear mouniing bou Repair kit or set parts are shown. (Only very frequently used parts . . 13. Mounting rubber Operating procedures, cautions, etc.
Page 8: Explanation Of The Troubleshooting Guide
GENERAL - How to Use This Manual EXPLANATION OF THE TROUBLESHOOTING GUIDE 3. Checking Indicates Indicates con- circuit diagram nector’s termi- nal number. (including the interface of air conditioning control unit). number. Num- bers are used i n t h e o p e r a - tion descrip- tions only as...
Page 9: Explanation Of Circuit Diagrams
GENERAL EXPLANATION OF CIRCUIT DIAGRAMS The symbols used in circuit diagrams are used as NOTE described below. For detailed information concerning the reading of , circuit diagrams, refer to GROUP 54lCircuit Dia- grams. The input/output (direr of current flow) relativ Indicates a the electronic control is indicated by sym...
Page 10: Vehicle Identification Number List
“Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number. VEHICLE IDENTIFICATION NUMBER LIST VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine Displacement Models Code Mitsubishi Galant 2.0 dm3 (122 cu.in.) [SOHC-MFI] 2.0 dm3 ( 7 22 cu.in.) TSB Revision...
Page 11 GENERAL - Vehicle Identification VEHICLES FOR CALIFORNIA V.I.N. (except sequence number) Brand Engine Displacement Models Code Mitsubishi Galant 2.0 dm3 (122 cu.in.1 [SOHC-MFI] 2.0 dm3 (122 cu.in.) [DOHC-MFI] VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine Displacement Models Code Mitsubishi 2.0 dm3 (122 cu.in.1...
Page 12 GENERAL VEHICLES FOR CALIFORNIA Engine Displacement Models Code V.I.N. (except sequence number) Brand Mitsubishi 2.0 dm3 (122 cuin.) [SOHC-MFI] 2.0 dm3 (122 cuin.) [DOHC-MFI] VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine Displacement Mitsubishi 2.0 dm3 (122 cu.in.) [SOHC-MFI] 2.0 dm3 (122 cu.in.)
Page 13 Engine Displacement Models Code V.I.N. (except sequence number) Brand 2.0 dm3 (122 cu.in.) Mitsubishi 2.0 dm3 (122 cu.in.) VEHICLE INFORMATION CODE PLATE Vehicle information code plate is riveted onto the bulkhead in the engine compartment. The plate shows model code, engine model, transaxle model, and body color code.
Page 14: Engine Model Stamping
GENERAL VEHICLE SAFETY CERTIFICATION LABEL 1. The vehicle safety certification label is attached to face of left door pillar. 2. This label indicates Gross Vehicle Weight Rating (G.V. W.R.), Gross Axle Weight Rating (G.A.W.R.) front, rear and Vehicle Identification Number (V.I.N.). ENGINE MODEL STAMPING 1.
Page 15 GENERAL - Vehicle Identification LOCATIONS Part Target area Engine SOHC-Up to 1992 models SOHC-l 993 models DOHC Manual transaxle Automatic transaxle...
Page 16 GENERAL inner side of the parts shown The illustration indicates left hand side, outer. Right hand side is symmetrically opposite. inner side of the parts shown in the figure. The illustration indicates left hand side, outer. TSB Revision...
Page 17: Precautions Before Service
GENERAL - Vehicle Identification/Precautions before Service inner side of the parts shown SERVICING ELECTRICAL SYSTEM Note the before proceeding with work on the following electrical system. Note that the following must never be done: Unauthorized modifications of any electrical device or wiring, because such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle.
Page 18 GENERAL Caution 1. Before connecting or disconnecting the negative cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.) 2. For MFI-equipped models, after completion of the work steps [when the battery’s negative (-) termi- nal is connected], warm up the engine and allow it to idle for approximately five minutes under the...
Page 19: Towing And Hoisting
GENERAL - Towina and Hoisting TOWING AND HOISTING Sling type WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using sling-type equipment to prevent the bumper from deformation. Wheel lift type If this vehicle is towed, use wheel lift or flat bed equipment.
Page 20 GENERAL SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle. 1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts of damaged vehicle such as hoods, doors, fenders, trim, etc., should be secured prior to moving the vehicle.
Page 21 GENERAL - Towing and Hoisting LIFTING, JACKING SUPPORT LOCATION Approximate center of gravity Floor jack locations EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack supplied with the vehicle for emergency road service. Always block opposite wheels and jack on level surface.
Page 22 GENERAL - Special Handling Instructions for AWD Models TOWING Remarks Towing methods For AWD models, the basic principle is that If a tow truck is used all four wheels are to be raised before Lifting method for 4 wheels-Good towing. The shift lever should be set to 1 st gear and the parking brake should be applied.
Page 23 GENERAL - Special Handling Instructions for AWD Models SPEEDOMETER TEST IF A FREE ROLLER IS USED 1. Set the free roller on the floor (at the rear wheels) so that it is aligned with the vehicle’s wheelbase and the rear tread. 2.
Page 24 GENERAL REAR WHEEL MEASUREMENTS After placing the rear wheels on the brake tester, follow the same procedures as for the front wheel measurements. WHEEL BALANCE FRONT WHEEL MEASUREMENTS 1. Jack up the rear wheels, and place an axle stand at the designated part of the side sill.
Page 25: General Data And Specifications
GENERAL - General Data and Specifications GENERAL SPECIFICATIONS <Up to 1992 models> DOHC Engine DOHC Engine DOHC Engine SOHC Engine (Non-Turbo) (Turbo) Vehicle dimensions mm (in.) Overall length 4,670 (183.9) 4,670 (183.9) 4,670 (183.9) 4,670 (183.9) Overall width 1,695 (66.7) 1,695 (66.7) 1,695 (66.7) 1,695 (66.7)
Page 26 GENERAL - General Data and Specifications Items DOHC Engine DOHC Engine DOHC Engine SOHC Engine (Non-Turbo) (Turbo) Vehicle weight kg (Ibs.) Curb weights 1.2 10 (2.668) 1,495 (3.296) 1.3 10 (2.8881e2 1,230 (2.7 12) or 1,425 (3.142) 1,300 (2,866) 1,270 (2.800)” Gross vehicle weight rating 1,700 (3,747) 1,780 (3,923)
Page 27 GENERAL Items SOHC Engine DOHC Engine Vehicle dimensions mm (in.) Overall length 4,670 (183.9) 4,670 (183.9) Overall width 1,695 (66.7) 1,695 (66.7) Overall height 1,425 (56.1) 1,425 (56.1) Wheel base 2,600 (102.4) 2,600 (102.4) Tread Front 1,460 (57.5) 1,460 (57.5) Rear 1,450 (57.1) 1,450 (57.1)
Page 28: Engine Specifications
GENERAL - General Data and Specifications DOHC Engine SOHC Engine Tire Front suspension independent strut Independent strut Rear suspension Brake Front Disc Disc Disc Rear Drum Steering Rack and pinion Rack and pinion Gear type Gear ratio Fuel tank 60 (16) 60 (16) Capacity ENGINE SPECIFICATIONS...
Page 29: Tightening Torque
GENERAL Each torque value in the table is a standard value for tightening under the following conditions. (1) Bolts, nuts and washers are all mode of steel and plated with zinc. (2) The threads and bearing surface of bolts and nuts are all in dry condition. The values in the table are not applicable: (2) If plastic parts are fastened.
Page 30 GENERAL Taper thread tightening torque Torque Nm (ftlbs.) Thread size Female thread material: Steel Female thread material: Light alloy 1- NPTF II6 5 - 8 (3.6-5.8) PT 118 PT 114, NPTF 114 35-45 (25-33) PT 318 NOTE: NPTF dry seat pope thread, while PT is pipe thread. ENGINE OVERHEATS Reference page Probable cause...
Page 31 GENERAL - Master Troubleshooting ROUGH IDLE OR ENGINE STALL Reference page or remedy Symptom Probable cause 17-3 Rough idle or engine stalls Vacuum leaks Purge control valve hose Vacuum hoses Intake manifold Intake manifold plenum Throttle body EGR valve Ignition system problems 16-32 Check idle speed control sys- Idle mixture too lean or too rich...
Page 32 GENERAL - Master Troubleshooting EXCESSIVE OIL CONSUMPTION Reference page or remedy Probable cause Symptom Repair as necessary. Oil leak Excessive Repair as necessary. Repair as necessary. Valve stem worn. Repair as necessary. Piston ring worn or damaged. POOR FUEL MILEAGE Reference page or remedy Probable cause Symptom...
Page 33 GENERAL - Master Troubleshooting POOR RETURN OF STEERING WHEEL TO CENTER Symptom Probable cause Reference page Poor return of steering wheel to Improper front wheel alignment center 31-3 Improper tire pressure Excessive tightened rack support cover Damaged front wheel bearing 26-9 POOR RIDING Reference page or remedy...
Page 34: Vehicle Pulls To One Side
GENERAL ROAD WANDER Reference page Probable cause Symptom Improper front or rear wheel alignment Road wander 34-5, 23 Excessive play of steering wheel Poor turning resistance of lower arm ball joint 31-3 Improper tire pressure Loose or worn lower arm bushing 26-9 Loose or worn wheel bearings Loose rack support cover in steering gear box...
Page 35 GENERAL - Master Troubleshootinn BOTTOMING Symptom Probable cause Bottoming Malfunctioning shock absorber WHEEL BEARING TROUBLESHOOTING Trouble Sympton Probable cause Pitting Pitting occurs because of uneven rotation of race Excessive bearing preload and bearing surfaces Flaking The surface peels because of uneven rotation of End of bearing life , the race and bearing surfaces Improper bearing assembly...
Page 36: Lubrication And Maintenance
GENERAL when available, should be used. These oils contain sufficient chemical additives to provide maximum engine protection. Both the SAE grade and the designation can be found on the container. Maintenance and lubrication service recommenda- tions have been compiled to provide maximum Caution protection for the vehicle owner’s investment Test results submitted to EPA have shown that...
Page 37: Automatic Transaxle
GENERAL - If premium unleaded gasoltne not available, MATERIALS ADDED TO FUEL unleaded gasoline having a octane rating of 87 or Indiscriminate use of fuel system cleaning agents 91 RON (Research Octane Number) may be used. should be avoided. Many of these materials in- In this case, the performance and fuel consumption tended for gum and varnish removal may contain highly active solvents or similar ingredients that can...
Page 38: Recommended Lubricants And Lubricant Capacities Table
GENERAL - Recommended Lubricants and Lubricant Capacities Table LUBRICANT CAPACITIES TABLE U.S. measure Crankcase Models built up to April 1992 3.7 qts. 3.5 dm3 < S O H C > 4.0 dm3 4.2 qts. < D O H C > 4.0 dm3 4.2 qts.
Page 39 GENERAL Oil Identification Symbol A standard .symbol appears on the top of oil containers and has three district areas for identifying various aspects of the oil. The top polqion will indicate the quality of the oil. The center portion will show the SAE viscosity grade, such as SAE indicates that the oil has fuel-saving capabilities.
Page 40 GENERAL SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE Inspection and Services should be performed any time a malfunction is observed or suspected. Retain Kilometers in Thousands 24 48 72 80 96 Intervals Service Mileage in Thousands 15 30 45 50 60 Check Fuel System (Tank, Line and Connections and Fuel Tank Filler Tube Cap) for Leaks Every 5 Years Check Fuel Hoses Every 2 Years for leaks or damage...
Page 41: Fuel Hoses
GENERAL - Scheduled Maintenance Table/Maintenance Service SCHEDULED MAINTENANCE UNDER SEVEiRE USAGE CONDITIONS The maintenance items should be performed according to the following table: Mileage Intervals Kilometers in Thousands Severe Usage Conditions (Miles in Thousands) Service to be Maintenance Item Performed More Frequently Engine Oil C h a n g e E v e r y or...
Page 42: Spark Plugs
GENERAL Caution The air cleaner cover should be removed carefully, because it includes the volume air flow sensor. (5) Remove the air cleaner element. (6) Set a new air cleaner element and install the air cleaner cover. <Turbo> (1) Disconnect the volume air flow sensor connector. (2) Disconnect the breather hose, purge hose, by-pass air hose hose and boost hose connections.
Page 43: Drive Belt (For Water Pump And Generator)
The quality of replacement filters varies considerably. Only high quatlity filters should be used to assure most efficient service. Genuine oil filters require that the filter is capable of and are recommended as follows: Oil Filter Part No. Mitsubishi Genuine Parts: MD135737, MD136466 TSB Revision...
Page 44: Manual Transaxle
256 psi (manufacturer’s specifications) to avoid filter and engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle : Mitsubishi Engine No. MD1 35737 Oil Filter Part Any replacement oil filter should be installed in accordance with the oil filter manufacturer’s installation instructions.
Page 45 GENERAL Inspect fluid level 1. Drive until the fluid temperature reaches the usual ternperature [70-80°C (160- 18O”F)I. 2. Plaice vehicle on level floor. 3. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 46: Engine Coolant
GENERAL - Maintenance Service Then, with parking brake on, move selector fever momentarily to each position, ending in “N” Neutral position. Operating Recheck fluid level after transaxle is at normal temperature. Fluid level should be between upper and lower marks of “HOT”...
Page 47: Brake Hoses
GENERAL Inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears or heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly.) Checking the Brake Shoes for Wear.
Page 48 Engine coolant temperature switch Engine coolant temperature sensor Thermal vacuum valve Engine coolant temperature gauge unit Joint MITSUBISHI GENUINE Part No.MD997110 or (4) Oil pan equivalent 2. Sealing for weatherstrip Sealing of tempered glass and weatherstrip (2) Sealing of laminated glass and weatherstrip 3.
Page 49 GENERAL Application Recommended brand 4. Interior adhesive equivalent Gluing of headlining, interior materials Gluing of fuel tank and pad equivalent equivalent Sealing of sheet metal joints such as sheet metal, drip rail, floor, body side panel, trunk, front panel, etc. Sealing of tailgate hinge Chassis sealant Sealing of flanges and screws...
Page 50 GENERAL - Table of Main Sealants and Adhesives brand Recommended Application cylinder 7. Instant super-strong adhesive Gluing of all kinds of material <Exceptions are plyethylene, polypropylene, fluororesin and other surface absorbent materials> 3. Anaerobic super-strong adhesive Tightening parts for drive gear and differential case Tilt steering upper, lower column joint bolt (2) Fixing of joints of bearings, fan, pulley, gear, etc.
Page 51 CONTENTS ENGINE < D O H C > ......CAMSHAFT AND CAMSHAFT OIL CAMSHAFT AND CAMSHAFT OIL SEAL .....*..... . 19 SEALS ..........
Page 52: General Specifications
ENGINE <SOHC> - Specifications GENERAL SPECIFICATIONS Specifications Items In-line Single Over Head Camshaft Number of cylinders mm (in.) 85 (3.35) Bore Stroke mm (in.) 88 (3.46) Piston drsplacement 8.5 <8 VALVE>, 9.5 < 16 VALVE> Compression ratio Firing order Silent shaft Valve timing Intake valve Opens (BTDC)
Page 53 ENGINE <SOHC> - Specifications Standard Value Limit Drive belt For generator Deflection mm (in.) Inspection New belt 10 (.394) Used belt Tension Inspection New belt Used belt 400 (88) For air conditioning compressor Deflection mm (in.) Inspection New belt Used belt Tension Inspection New belt...
Page 54 ENGINE <SOHC> - Specifications TORQUE SPECIFICATIONS Engine mount insulator nut (large) 43-58 22-29 Engine mount bracket nut and bolt 36-47 Front roll stopper insulator nut 36-47 Front roll stopper bracket to center member 29-36 Rear roll stopper insulator nut 29-36 Rear roll stopper bracket to crossmember 29-36 Transaxle mount insulator nut...
Page 55: Special Tools
ENGINE <SOHC> - Specifications/Special Tools SEALANTS AND ADHESIVES Items Specified sealant Engine support bracket bolt <I 6 VALVE> MITSUBISHI GENUINE PART No.MD970389 or equivalent SPECIAL TOOLS Number Name INSTALLER, Installation of camshaft oil seal camshaft oil seal Use with GUIDE, camshaft oil...
Page 56 ENGINE <SOHC> - Special Tools/Troubleshooting Number Name Tool Supporting of lash adjuster to prevent it HOLDER, lash from falling when rocker shaft assembly adjuster removed or installed Adjustment of timing belt tension Tension pulley wrench Remedy Symptom Probable cause Replace gasket Compression too low Cylinder head gasket blown Replace rings...
Page 57: Engine Oil Check
ENGINE <SOHC> - Service Adjustment Procedures ENGINE OIL CHECK range indicated on the oil dip stick. (2) Check to ensure that the oil is not noticeably dirty or mixed with coolant or gasoline, and that it has the proper viscosity. NOTE Soon after the engine is started or while it is running, abnormal noise (clattering) which may be attributed to the...
Page 58 ENGINE <SOHC> - Service Adjustment Procedures (3) If any abnormal not eliminated by racing, check the noise 8 VALVE lash adjuster. the top dead centre of the compression. arrow mark to check whether the rocker arm is lowered or not. arm at the area indicated by the 0 arrow mark.
Page 59 ENGINE <SOHC> (5) Cover the spark plug holes with a cloth, etc., and crank the engine. Then verify that no foreign material sticks to the cloth, etc. Caution 1. During cranking, be especially careful of the spark plug installing hole. 2.
Page 60 ENGINE <SOHC> - Service Adjustment Procedures hose from the PCV valve and attach a Remove the PCV vacuum gauge. (4) Check that the negative pressure at the intake manifold during idle revolution is normal. Standard value: Approx. 500 mmHg (20 Approx.
Page 61 ENGINE <SOHC> - Servioe Adjustment Procedures (9) Remove the air conditioning drive belt and the generator drive belt. inserting a screwdriver into the slots indicated by the raised arrows in the timing belt cover and twisting. Access cover access hole and loosen the tension spacer (with a tensioner lock nut on it) 1 to 2 turn.
Page 62 ENGINE <SOHC> - Service Adjustment Procedures TENSION ADJUSTMENT DRIVE BELTS (2) Apply IOON (22 Ibs.) force to the belt back midway between the pulleys as shown in the figure, measure the deflection or, by using a belt-tension gauge, check the Power belt’s tension.
Page 63 ENGINE <SOHC> TENSION ADJUSTMENT OF THE GENERATOR DRIVE BELT Caution 1. Before checking, turn the engine one time or more. 2. If the belt tension is too strong, it is possible that the generator or water pump bearing is damaged. slipping will be heard, and the belt’s service life will be reduced.
Page 64: Removal And Installation
ENGINE <SOHC> - Ennine Assemblv REMOVAL AND INSTALLATION Pre-removal Operation Eliminating fuel pressure in fuel line (Refer to GROUP 13-On-Vehicle Inspection of MFI Components.) *Removal of the Hood (Refer to GROUP 42-Hood.) *Draining of the Coolant (Refer to GROUP OO-Maintenance Service.) *Removal of the Transaxle Assembly (Refer to GROUP 22, 23-Transaxle.) *Removal of the Radiator...
Page 65 ENGINE <SOHC> - Engine Assembly 3 5 - 4 5 2 5 - 3 3 3 5 - 4 5 N m 2 5 - 3 3 ft.lbs. 3 5 - 4 5 N m 2 5 - 3 3 ft.lbs. 2 3 - 2 7 3 6 - 4 7 ft.lbs.
Page 66 ENGINE <SOHC> - Engine Assembly SERVICE POINTS OF REMOVAL Ml 1SBBC 24. REMOVAL OF POWER STEERING OIL PUMP Remove the oil pump (with the hose attached). NOTE Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal/installation of the engine assembly.
Page 67: Engine Assembly
<SOHC> ENGINE -- Engine Assembly ENGINE ASSEMBLY <I6 VALVE> REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Installation of the Radiator @Eliminating Fuel Pressure in Fuel Line (Refer (Refer to GROUP 14-Radiator.) to GROUP 13-Service Adjustment Proce- Installation of the Transaxle dures.) (Refer to GROUP 22, 23-Transaxle.) Removal of the Hood...
Page 68 ENGINE <SOHC> - Engine Assembly 35-45 Nm 35-45 Nm 25-33 ft.lbs. 35-45 Nm 23-27 36-47 ft.lbs. 43-58 ft.lbs. 29-36 ft.lbs. Removal steps 19. Connection for generator P.l 1-16.) 23. Self-locking nuts 2 4 . G a s k e t - 25.
Page 69 ENGINE <SOHC> CAMSHAFT AND CAMSHAFT OIL SEAL <8 REMOVAL AND INSTALLATION 5-7 Nm 4-5 ft.lbs. Sealant: 3M ATD Part No. 8660 or eauivalent 5 8 - 7 2 ftlbs. 1. Connection for spark plug cables and hioh tension cable 3. timing belt (Refer to P.l I-34.) 4.
Page 70 ENGINE <SOHC> SERVICE POINTS OF REMOVAL 11. REMOVAL OF ROCKER ARM AND SHAFr ASSEMBLY Before removing the rocker arm and shaft assembly, use the special tool to ensure that the auto-lash adjuster doesn’t fall out. Caution Do not disassemble the rocker arm and shaft assembly. SERVICE POINTS OF INSTALLATION 12.
Page 71 1 I-21 ENGINE <SOHC> CAMSHAFT AND CAMSHAFT OIL SEAL <I6 VALVE> Post-installation Operation Installation of Distributor (Refer to GRPUP 16-Distnbutor) (Refer to GROUP 16-Distributor) Installation of Timing Belt Cover (Refer to P.l l-42.) Service Adjustment Procedures (Refer to P.l l-7.) Lip section 01 NO042 Cam section and...
Page 72 Seal ENGINE <SOHC> - Camshaft and Camshaft Oil SERVICE POINTS OF REMOVAL 6. REMOVAL OF CAMSHAFT SPROCKET Using the special tool, remove the camshaft sprocket. 8. REMOVAL OF ROCKER ARMS AND ROCKER ARM SHAFT ASSEMBLY (INTAKE SIDE)/S. ROCKER ARMS AND ROCKER ARM SHAFT ASSEMBLY (EXHAUST SIDE) Before removing the rocker arm and shaft assembly, use the special tool to ensure that the auto-lash adjuster...
Page 73 ENGINE <SOHC> REMOVAL AND INSTALLATION Pre-removal and Post-installation Bolt hole portion Sealant: MITSUBISHI GENUINE P A R T No.MD970389 or equivalent 15-22 11-16 Removal steps 3 5 - 4 5 Nm a 1. Drain plug 25- -33 Oil screen Oil screen gasket SERVICE POINTS OF REMOVAL 2.
Page 74 ENGINE <SOHC> - Oil Pan and Oil Screen SERVICE POINTS OF INSTALLATION 2. INSTALLATION OF OIL PAN surfaces of the cylinder block and oil pan so that all loose material is removed. (2) Gasket surfaces must be free of oil and dirt. the specified sealant around the surface of oil pan as specified in illustration.
Page 75 ENGINE <SOHC> 4-6 Nm REMOVAL AND INSTALLATION 3-4 ft.lbs. Pre-removal ODeration Post-installation Operation (Refer to GROUP 00-Maintenance Service.) (Refer to P.ll-7.) 36-47 ftlbs. 4-6 Nm 3-4 ftlbs.
Page 76 5-7 Nm 4-5 ft.lbs head Sealant: 3M ATD Part No.8660 or equivalent 65-72 ftlbs. 29 - 36 ft.lbs. Removal steps 18. Connection for EGR temperature sensor (California vehicles only) 2. Connection for accelerator cable or 19. Connection for ignition power transistor throttle cable (Refer to GROUP 13- Procedures.) 20.
Page 77 ENGINE <SOHC> SERVICE POINTS OF REMOVAL 3. DISCONNECTION OF FUEL HIGH PRESSURE HOSE Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. For information concerning the bleeding of the residual pressure, refer to GROUP 13-On-Vehicle Inspection of 5.
Page 78 ENGINE <SOHC> - Cylinder Head Gasket 35. REMOVAL OF CYLINDER HEAD ASSEMBLY (1) Using the special tool, remove cylinder head bolts in OPTIONAL sequence shown in figure. (2) Remove the cylinder head assembly. Front of engine + Intake side Exhaust side SERVICE POINTS OF INSTALLATION 36.
Page 79 ENGINE <SOHC> (2) Using the special tool, tighten the bolts in the order shown in two or three steps. Front of engine I) Intake side Exhaust side 5. INSTALLATION OF RADIATOR UPPER HOSE Align the mating marks (of the radiator hose and hose clamp), and then, while applying force in the direction of the arrow in the illustration, seat the hose clamp to the trace marks (on the hose) remaining from the prior...
Page 80 ENGINE <SOHC> Ml IJA-C REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Supplying of the Engine Coolant Releasing of Fuel Line Pressure (Refer to GROUP 14-Service Adjust- (Refer to GROUP 13-Service Adjust- ment Procedures.) ment Procedures.) Supplying of the Engine Oil Draining of the Engine Coolant Accelerator Cable Adjustment (Refer to GROUP 14-Service Adjust-...
Page 81 ENGINE <SOHC> Gasket 3-3.5 Nm Cold Engine 2 . 2 - 2 . 5 ft.lbs. 80 Nm + 0 Nm - 20 Nm - +1/4 turn + +I/4 turn 58 ft.lbs. - 0 ftlbs. -+ 14fWbs. - +I/4 turn - +1/4 turn ‘...
Page 82 < S O H C > ENGINE SERVICE POINTS OF REMOVAL 27. REMOVAL OF CAMSHAFT SPROCKET (1) Rotate the crankshaft in the forward (right) direction and align the timing mark. Caution The crankshaft must always be rotated in the for- ward direction only.
Page 83 (2) Apply specified sealant to the thermostat case assem- bly as shown in the illustration. Specified sealant: MITSUBISHI GENUINE PART (3) Apply a small amount of water to the O-ring of the water inlet pipe, and press the thermostat case assem- bly onto the water inlet pipe.
Page 84 ENGINE <SOHC> - Timina Belt REMOVAL AND INSTALLATION Pre-removal Operation 36-47 ftlbs. 7-9 ft.lbs. 6-7 ft.lbs. 1 4 - 2 2 ft.lbs. \ 23-27 Nm Removal steps 16. Tensioner spacer 17. Tensioner spring and high pressure hose (air conditioning) 2. Engine mount bracket 18.
Page 85 ENGINE <SOHC> Post-installation Operation installation of under cover (Refer to P.ll-7.) 15-22 Nm 1 1 - 1 6 ft.lbs. 24 36-43 ftlbs. Installation steps 13. Access cover 12. Gasket 30. Key + 11. Timing belt front lower cover * 29. Crankshaft sprocket “B” 28.
Page 86 ENGINE <SOHC> - Timinn Belt SERVICE POINTS OF REMOVAL 2. REMOVAL OF ENGINE MOUNT BRACKET between the jack and the engine’s oil pan. Caution Jack up carefully so as not to apply an excessive load to the various parts. 20. REMOVAL OF TIMING BELT (1) Turn the crankshaft clockwise and align the timing Timing mark marks.
Page 87 ENGINE <SOHC> - Timing Belt 22. REMOVAL OF OIL PUMP SPROCKET (2) Insert a Phillips screwdriver [shank diameter 8 mm (.31 in.)] to block the left silent shaft. (3) Remove the oil pump sprocket nut. (4) Remove the oil pump sprocket. 26.
Page 88 ENGINE <SOHC> - Timing Belt (7) Abnormal wear on teeth. Initial stage: Rubber canvas Canvas on load side tooth flank worn (Fluffy exposed fibers, rubber gone and color changed to white, and unclear canvas texture) Tooth missing and Final stage: canvas fiber exposed Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced)
Page 89 ENGINE <SOHC> - Timing Belt . ADJUSTMENT OF TIMING BELT “B” TENSION (1) Temporarily fix the timing belt “B” tensioner such that left and the centre of the tensioner pulley is to the above the centre of the installation bolt, and temporari- ly attach the tensioner pulley so that the flange is toward the front of the engine.
Page 90 ENGINE <SOHC> rarily secure tensioner. 20. INSTALLATION OF TIMING BELT Timing mark Timing mark (on cylinder head) et, the crankshaft sprocket, and the oil pump sprocket are all aligned. T i m i n g m a r k “1 (2) When aligning the timing mark of the oil pump sprocket, remove the plug of the cylinder block;...
Page 91 ENGINE <SOHC> - Timina Belt (3) Turn the crankshaft clockwise by two teeth of the camshaft sprocket. Caution As the purpose of this procedure is to apply the proper amount of tension on the timing belt, be sure not to rotate the crankshaft counter-clockwise or place pressure on the belt to check the amount of tension.
Page 92 ENGINE <SOHC> REMOVAL AND INSTALLATION Pre-removal Operation Removal of under cover 36-47 ft.lbs. 7-9 ftlbs. 6-7 ftlbs. 23-27 Nm Removal steps idle pulley Clamp for pressure hose (power steering) Camshaft sprocket and high pressure hose (air conditioning) Oil pump sprocket Engine mount bracket Crankshaft sprocket bolt Drive belt (generator)
Page 93 ENGINE <SOHC> 36-43 ft.lbs. Installation steps +I 2. Timing belt 29. Timing belt under cover Adjustment of timing belt tension +28. Engine support bracket bolt 41 0. Timing belt front lower cover 8. Crankshaft pulley +25. Spacer 7. Water pump pulley 24.
Page 94 ENGINE <SOHC> SERVICE POINTS OF REMOVAL 2. REMOVAL OF ENGINE MOUNT BRACKET (1) With a wooden block placed against the oil pan part of the engine, jack up the vehicle. Caution Jack up gently, so as not to apply a load to the va- rious parts.
Page 95 E N G I N E < S O H C > (2) Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will not move with respect to the timing belt. sprocket (3) Use the special tool to remove the camshaft sprocket with the timing belt attached.
Page 96 ENGINE <SOHC> (2) Cracked back surface rubber. (3) Cracked or separated canvas. (4) Cracked tooth bottom. (5) Cracked side. Separation Crack ’ (6) Abnormal wear on side. NOTE Normal belt should have clear-cut sides as if cut by a sharp knife.
Page 97 ENGINE <SOHC> (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value: 12 mm (.47 in.) (4) Using a vise with soft jaws push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner.
Page 98 ENGINE <SOHC> - Timing Belt 25. INSTALLATION OF SPACER (1) Apply a thin coat of engine oil to the outer circumfer- ence of the spacer. (2) Install the spacer with the chamfered end facing the oil seal. NOTE If the spacer is installed adversely, the oil seal may be damaged, resulting in the oil leaks.
Page 99 ENGINE <SOHC> - Timing Belt 21. INSTALLATION OF FLANGE Crankshaft sprocket “B” Install the flange in correct direction as shown. Caution Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken timing belt could result.
Page 100 ENGINE <SOHC> - Timing Belt (2) Install the auto tensioner. Caution Leave the wire installed in the auto tensioner. 13. INSTALLATION OF TENSIONER PULLEY Center bolt i (1) Install the tensioner pulley onto the tensioner arm. (2) Locate the pinhole in the tensioner pulley shaft to the left of the center bolt.
Page 101 ENGINE <SOHC> - Timing Belt (3) Install the timing belt around sprockets as follows. Camshaft sprocket and crankshaft sprocket and secure the timing belt onto the tensioner pulley with your left hand. the oil pump sprocket. align its timing mark with the cylinder head top sur- face (see illustration in step 0).
Page 102 ENGINE <SOHC> (7) If the clearance between the tensioner arm and the auto tensioner body cannot be measured (when the engine is being mounted, etc.), the following proce- dures can be used to substitute for the ordinary method of measurement. screwing it in until the push rod of the auto ten- sioner body is caused to move backward and the tensioner arm contacts the auto tensioner body.
Page 103: Specifications
E N G I N E < D O H C > - S p e c i f i c a t i o n s ENGINE <DOHC> SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items In-line Double, Over Head Camshaft Number of cylinders mm (in.) 85 (3.35) Bore mm (in.) 88 (3.46)
Page 104 ENGINE <DOHC> - Specifications Standard Value Limit Items For air conditioning compressor mm (in.) Deflection Approx. 8 (.315) Inspection New belt Used belt Tension Inspection New belt Used belt For power steering pump mm (in.) Deflection Inspection Timing belt Amount of projection of auto tensioner rod mm (in.) 12 (.47) Timing belt “B”...
Page 105 ENGINE <DOHC> - SDecifications Items Transfer assembly 44-57 Front exhaust pipe to engine 22-29 Center bearing bracket 36-46 26-33 Timing belt cover 7 - 9 Cylinder head bolt (Cold engine) <Up to 1992 models> 65-72 <From 1993 models> 20 -t l/4 turn Camshaft sprocket 58-72 Water pump pulley bolt...
Page 106: Troubleshooting
SEALANTS AND ADHESIVES Specified sealant Items Semi-circular packing Rocker cover Oil pressure switch Engine support bracket bolt <From 1993 models> Oil pan MITSUBISHI GENUINE PART No.MD970389 or equivalent SPECIAL TOOLS Tool Number Name INSTALLER, camshaft oil seal Use with GUIDE, camshaft oil...
Page 107 ENGINE <DOHC> SERVICE ADJUSTMENT PROCEDUBFzo ENGINE OIL CHECK (1) Check to ensure that the engine oil level is within the level range indicated on the oil dip stick. (2) Check to ensure that the oil is not noticeably dirty or mixed with coolant or gasoline, and that it has the proper NOTE Soon after the engine...
Page 108 ENGINE <DOHC> - Service Adjustment Procedures (3) lf any abnormal noise lash adjuster so that cylinder No. 1 positioned at the top dead centre of the compression. arrow mark to check whether the rocker arm is lowered or not. the crankshaft 360 degrees clockwise. turn at the area indicated by the 4 arrow mark.
Page 109: Compression Pressure Check
<DOHC> ENGINE position switch terminal and body. NOTE When there is continuity, a clearance will be created between the throttle lever and dash pot rod when the dash pot rod is pressed lightly. switch (12) When there is no continuity, lower the engine speed when the dash pot begins operation to within the standard value tolerance.
Page 110 ENGINE <DOHC> - Service Adjustment Procedures (9) If a cylinder’s compression pressure or pressure difference is outside the limit, fill a small amount of engine oil through the spark plug hole and repeat Items (7) and (8) above. the piston and/or cylinder wall may be worn or damaged.
Page 111 ENGINE <DOHC> DRIVE BELTS TENSION ADJUSTMENT (1) Check that the belts are not damaged. (2) Apply 100N (22 Ibs.) force to the belt back midway between the pulleys as shown in the figure, measure the deflection or, by using a belt-tension gauge, check the belt’s tension.
Page 112 ENGINE <DOHC> TENSION ADJUSTMENT OF THE GENERATOR DRIVE BELT Caution 1. Before checking, turn the engine one time or more. 2. If the belt tension is too strong, it is possible that the generator or water pump bearing is damaged. If the belt tension is too weak, however, sounds of its slip- ping will be heard, and the belt’s service life will be reduced.
Page 113 ENGINE <DOHC> ENGINE ASSEMBLY Post-installation Operation Pre-removal Operation installation of radiator assembly Eliminating fuel pressure in fuel lines (Refer to GROUP 14-Radiator.) (Refer to GROUP 13-On-Vehicle lnspectior Installation of transaxle assembly of MFI Components.) (Refer to GROUP 42-Hood.) (Refer to GROUP 00-Maintenance Service.: (Refer to GROUP 22, 23-Transaxle.) *Removal of radiator assembly (Refer to GROUP 14-Radiator.)
Page 114 ENGINE <DOHC> 4-6 Nm 3-4 ftlbs.. 3-4 ftlbs. 7-9 ft.lbs. 4-6 Nm 3 - 4 ftlbs. \ 4 - 6 Nm 3-4 ftlbs. 7-9 ftlbs. TSB Revision...
Page 115 ENGINE <DOHC> <From 1991 models> 4-6 Nm 4-6 Nm 3-4 ftlbs. 12. Connection for engine coolant 19. Connection for fuel injectors temperature switch 13. Connection for oxygen sensor (California vehicles only) 14. Connection for engine coolant 21. Connection for knock sensor (Turbo) temperature sensor 22.
Page 116 ENGINE <DOHC> 35-45 Nm 25-33 ftlbs. 36-47 ft.lbs. 29-36 ftlbs. 43-56 ft.lbs. 28. z;tFhction for power steering pressure 29. Connection for generator 30. Generator wiring harness clamps compressor 34. Self-locking nut 35. Gasket 36. Bracket NOTE 37. Engine mount bracket For tightening locations indicated by the , symbol, first 38.
Page 117 ENGINE <DOHC> - Engine Assembly SERVICE POINTS OF REMOVAL 32. DISCONNECTION OF POWER STEERING OIL PUMP Disconnect the oil pump with hoses from the bracket. NOTE The removed power steering oil pump should be fastened (by using rope, etc.) in a position that will not interfere with the removal/installation of the engine assembly.
Page 118 ENGINE <DOHC> - Camshaft and Camshaft Oil Seals CAMSHAFT AND CAMSHAFT OIL SEALS REMOVAL AND INSTALLATION l Servtce Adjustment Procedures 2.5-3.5 Nm 2.5-3.5 Nm 19-21 Nm 14-15 ft.lbs. 19-21 Nm 14-15 ft.lbs. 58-72 ft.lbs. Removal steps Connection for accelerator cable or throttle cable (Refer to GROUP 13- Service Adjustment Procedures.) 2.
Page 119 ENGINE <DOHC> SERVICE POINTS OF REMOVAL 11. REMOVAL OF EXHAUST CAMSHAFT SPROCKET/ 12. INTAKE CAMSHAFT SPROCKET (1) Using a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning), loosen the cramshaft sprocket bolt. (2) Remove the camshaft sprokets. 13.
Page 120 ENGINE <DOHC> Install new camshafts using the following procedure. (2) Lay the camshafts on the cylinder head and install the bearing caps. (3) Check that the camshaft can be easily turned by hand. (4) After checking, remove the bearing caps and the camshafts, and install the rocker arms.
Page 121: Oil Pan And Oil Screen
ENGINE <DOHC> - Oil Pan and Oil Screen OIL PAN AND OIL SCREEN REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation (Refer to GROUP OO-Mamtenance Service.) Sealant: MITSUBISHI GENUINE PART No. MD970389or equivalent 11-16 ft.lbs. 35-45 Nm <Non-Turbo> 25-33 ft.lbs. Removal steps 1.
Page 122 (2) Gasket surfaces must be free of oil and dirt. (3) Apply the specified sealant around the surface of the oil pan as specified in illustration. Specified sealant: MITSUBISHI GENUINE PART 4 m m Sealant Groove...
Page 123: Cylinder Head Gasket
ENGINE <DOHC> - Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION <Turbo> 9-14 Nm 6-7 ft.lbs. Connection for water by-pass hose - 1 1 ‘ 4 Connection for heater hose - 1 6 4 - 6 PCV hose Connection for vacuum hose (Turbo) Connection for high- **421.
Page 124 ENGINE <DOHC> ‘ 3 6 4-6 Nm 3-4 ftlbs. 4 - 6 Nm 3 - 4 ftlbs. 2.5-3.5 Nm TSB Revision...
Page 125 ENGINE <DOHC> <From 1991 models> 4-6 Nm 7-9 ft.lbs. 4-6 ‘Nm 3-4 ftlbs. Removal steps 30. Connection for engine coolant 37. Connection for knock sensor (Turbo) temperature switch 38. Connection for ianition coil 31. Connection for oxygen sensor 39. Connection for ignition power transistor 32.
Page 126 ENGINE <DOHC> 2.5-3.5 (Refer to GROUP OO-Maintenance 2 - 3 l Service ‘Adjustment Procedures (Refer to 12-15 Nm . - 0 ftlbs. - 14 ft.lbs. - <Turbo> <Non-Turbo> 29 ftlbs. <ID- , L I 48. Timing belt (Refer to P.l I-80.) 49.
Page 127 ENGINE <DOHC> SERVICE POINTS OF REMOVAL 21. DISCONNECTION OF HIGH-PRESSURE FUEL HOSE Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. For information concerning the bleeding of the residual pressure, refer to GROUP 13-On-vehicle Inspection of 56.
Page 128 ENGINE <DOHC> - Cylinder Head Gasket SERVICE POINTS OF INSTALLATION 57. INSTALLATION OF CYLINDER HEAD GASKET cylinder block. Caution Take care that no foreign material gets into the cylinder, or into coolant passages or oil passages. (2) Make sure that the gasket has the proper identification mark for the engine.
Page 129 ENGINE <DOHC> (1) Use a scraper to clean the gasket surface of the cylin- der head assembly. Caution Take care that no foreign material gets into the coolant passages or oil passages. (2) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit.
Page 130: Timing Belt
ENGINE <DOHC> - Timing Belt TIMING BELT REMOVAL AND INSTALLATION 36-47 ft.lbs. 36-47 ftlbs. Pre-removal Operation Removal of under cover 7-9 ft.lbs. 7-9 ft.lbs. Rocker cover 7. Semi-circular packing 18. Plug rubber 19. Auto tensioner 20. Timing belt Removal steps 22.
Page 131 ENGINE <DOHC> - Timing Belt ‘ 3 6 Installation steps 38. Timing belt rear left cover (lower) 36. Timing belt rear left cover (upper) 35. Timing belt rear right cover Service Adjustment Procedures * 33. Spacer 32. Silent shaft sprocket 12.
Page 132 ENGINE <DOHC> - Timing Belt SEALING POINTS 0 1 A0583 Sealant: 3M ATD Part No.8660 or equivalent SERVICE POINTS OF REMOVAL 3. REMOVAL OF ENGINE MOUNT BRACKET (1) With a wooden block placed against the oil pan part of jack up the vehicle. engine, Caution Jack up gently, so as not to apply a load to the...
Page 133 ENGINE <DOHC> 20. REMOVAL OF TIMING BELT Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. Caution Water or oil on the belt shorten its life drastically, so the removed timing belt, sprocket, and tensioner must be free from oil and water.
Page 134 ENGINE <DOHC> - Timing Belt INSPECTION TIMING BELTS The timing belts must be checked closely. Should the following defects be evident, replace the belt with a new one. Glossy, non-elastic, and so hard that no mark is produced even when scratched by a fingernail. (3) Cracked or separated canvas Crack rack...
Page 135 ENGINE <DOHC> - Timing Belt AUTO TENSIONER (1) Check the auto tensioner for possible leaks and replace as necessary. (2) Check the rod end for wear or damage and replace as necessary. (3) Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Page 136 ENGINE <DOHC> 34. INSTALLATION OF CRANKSHAFT SPROCKET “B” Crankshaft sprocket “B” Install the crankshaft sprocket “B” as shown while paying attention to its direction. Crankshaft 33. INSTALLATION OF SPACER Spacer (1) Apply a thin coat of engine oil to the outer circumfer- ence of the spacer.
Page 137 E N G I N E < D O H C > - Timing Belt (3) To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust. Standard value: 5-7 mm (.20-.28 in.) 29.
Page 138 ENGINE <DOHC> TENSIONER 19. INSTALLATION OF AUTO (1) If the auto tensioner rod is in its fully extended position, reset it as follows. clamp it in the vise with soft jaws. If the plug at the bottom of the auto tensioner protrudes, surround it with a plain washer as illustrated to prevent the plug from being in direct contact with the vise.
Page 139 E N G I N E < D O H C > - Timing Belt 20. INSTALLATION OF TIMING BELT Camshaft sprocket (1) Turn the two sprockets so that their dowel pins are located on top. Then, align the timing marks facing each other with the top surface of the cylinder head.
Page 140 E N G I N E < D O H C > - Timing Belt (5) Install the timing belt around the intake side camshaft sprocket and fix it at indicated position by a spring type paper clip (binder clip). (6) Install the timing belt around the exhaust side sprocket, aligning the timing marks with the cylinder head top surface using two wrenches.
Page 141 ENGINE <DOHC> . ADJUSTMENT OF TIMING BELT TENSION (1) After turning the crankshaft l/4 turn counterclockwise, turn it clockwise to move the No. 1 cylinder to top dead center. (2) Loosen the center bolt, and then, as shown in the illustration, attach the special tool and a torque wrench and apply a torque of 2.6-2.8 Nm (1.88-2.03 ft.lbs.).
Page 142 ENGINE <DOHC> 11. INSTALLATION OF TIMING BELT LOWER COVER/ 10. TIMING BELT UPPER COVER The dimensions of the installation bolts for the timing covers differ according to the installation location, so be sure not to install the bolts in the incorrect locations. Thread diameter A: 6x 16 1.24x.63) D: 6x28 (.24x1.10) mm (in.)
Page 143: Table Of Contents
FUEL CONTENTS AUTO-CRUISE CONTROL SYSTEM ....EGR Solenord <California> ....AUTO-CRUISE CONTROL .
Page 144 FUEL SYSTEM <SOHC-8 VALVE> ..FUEL SYSTEM <SOHC-16 VALVE> ... FUEL FILTER ........FUEL FILTER .
Page 145: General Information
FUEL SYSTEM <SOHC-8 VALVE> FUEL SYSTEM <SOHC-8 VALVE> GENERAL INFORMATION <Federal> sensor Ignition switch-ST purge solenoid sensor Power supply Fuel pump control Vehicle-speed sensor Air conditioning switch ture sensor injection relay Park/neutral position A/C compresser clutch switch relay switch Power steering Ignition timing control pressure switch On-board diagnostic...
Page 146 13-4 FUEL SYSTEM <SOHC-8 VALVE> <California> sensor ‘11 EGR temperature sensor purge solenoid Ignition switch-ST sensor Power supply Fuel pump control ture sensor (Multiport fuel Air conditioning switch control module injection relay) Park/neutral position switch switch relay Power steering pressure switch On-board diagnostic output Check engine/muj-...
Page 147 FUEL SYSTEM <SOHC-8 VALVE> SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Fuel Tank capacity Equipped Return system High pressure type Filter Fuel pump Electrical, in-tank type Electric motor Driven by Throttle body mm (in.) 50 (1.9691 Throttle bore Variable resistor type Throttle position sensor Electric motor Contact type, within idle speed control motor Closed throttle position switch...
Page 148: Torque Specifications
13-6 FUEL SYSTEM <SOHC-8 VALVE> - Specifications SERVICE SPECIFICATIONS Specifications Basic ignition timing Curb idle speed r p m 7502 100 850 at neutral position 700 at D range r p m 750+50 Basic idle speed Throttle position sensor adjusting voltage Throttle position sensor resistance Intake air temperature sensor resistance Engine coolant temperature sensor resistance...
Page 149 FUEL SYSTEM <SOHC-8 VALVE> Tools SEALANT Items Specified sealant Engine coolant temperature sensor threaded portion SPECIAL TOOLS Ml JDA- Number Name I Use OPTIONAL: AVAI OPTIONAL: AVAILABLE FROM O.T.C. NOTE *: <From 1990 models> Revision...
Page 150 13-8 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting TROUBLESHOOTING EXPLANATION OF TROUBLESHOOTING PROCEDURES Effective troubleshooting procedures related to problems of the MFI system are described below. START Cause the malfunction to reoccur and check the details of the malfunction and the conditions (engine condition, 1.
Page 151 13-9 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting EXPLANATION AND PRECAUTION RELATED TO I Connector HARNESS CHECKING Connector symbols are described as seen from the end of the terminal for the connector. The abbreviation “B+” used for the normal judgment value when checking the voltage is the abbreviation for battery positive voltage.
Page 152 FUEL SYSTEM <SOHC-8 VALVE> If the voltage (power-supply voltage) supplied to a sensor is not normal, repair the harness. at sensor side If the voltage to the sensor is still not normal after the har- ness has been repaired, repalce the engine control module and check again.
Page 153 FUEL SYSTEM <SOHC-8 VALVE> ON-BOARD DIAGNOSTIC- module monitors the input/out- disconnected. In addition, beginning with the engine The engine control put signals (some signals at all times and the others control module of 1990 and later models, the diag- under specified conditions) of the engine control nostic trouble codes are erased by turning on the module.
Page 154 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting Diagnostic trouble code On-board Memory Check item (Remedy) diagnostic Output signal pattern item Harness and connector Retained Throttle Throttle position sensor position Closed throttle position switch sensor Retained Harness and connector control position sensor motor Throttle position sensor position...
Page 155 FUEL SYSTEM <SOHC-8 VALVE> Diagnostic trouble code On-board diagnostic Check item (Remedy) Memory Output signal pattern item Harness and connector Retained EGR temperature sensor EGR valve EGR solenoid EGR valve control vacuum Normal state NOTE Replace the engine control module if a diagnostic trouble code is output although the inspection reveals that there is no TROUBLESHOOTING TABLE NOTE The failsafe back-up function is in operation.
Page 156 13-14 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting Remarks (trouble Major cause Diagnostic content trouble diagnostic phenomenon, etc.) item code No. Slightly improper (1) The throttle position sensor is Throttle (1) The signal voltage of the acceleration troubled or improperly throttle position sensor is position <...
Page 157 FUEL SYSTEM <SOHC-8 VALVE> Diagnosti On-board Remarks (trouble Diagnostic content Major cause trouble diagnostic phenomenon, etc.) code No. item (1) The vehicle speed sensor is The engine Vehicle During acceleration of engine sometimes cuts off troubled. speed revolution speed of 3,000 rpm when stopping afte or more, the signal voltage of (2) Open-circuit, short-circuit or...
Page 158 FUEL SYSTEM <SOHC-8 VALVE> FAILSAFE/BACK-UP FUNCTIONS LIST If trouble with any major sensor is detected by the on-board diagnostic, the vehicle will be kept in the safe driving conditions according to the preset control logic. Control content for trouble Trouble item Volume air flow Fuel injection timing and ignition timing are determined according to the throttle position sensor (TPS) and engine revolution speed signal (crankshaft position sensor signal).
Page 159 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting Using Voltmeter (1) Connect an analog-type voltmeter between the ground/ terminal and the on-board diagnostic output terminal of the data link connector. (2) Set the ignition switch to the “ON” position. (3) Make a note of the pattern of the on-board diagnostic out- put indicated by the voltmenter’s indicator.
Page 160 13-18 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS GR solenoid <California> indicate the checking sequence.)
Page 161 FUEL SYSTEM <SOHC-8 VALVE> PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Symptom Items - - -... __----. -~- The starter used to crank the engine, but there no combustron wrthrn the cylinders. (no rnrtral combustron) and the engine won’t start There (Initial combustion, then stall) Engine speed doesn’t remain constant;...
Page 162 FUEL SYSTEM <SOHC-8 VALVE> CIRCUIT DIAGRAM...
Page 163 13-21 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting ON: 235kPa TSB Revision...
Page 164 13-22 FUEL SYSTEM <SOHC-8 VALVE> CIRCUIT DIAGRAM (CONTINUED) “, - e - * - e -...
Page 165 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting ‘OR FRONT SIDE DATA LINK CONNECTOR TSB Revision...
Page 166: Circuit Diagram
FUEL SYSTEM CIRCUIT DIAGRAM...
Page 167 13-25 FUEL SYSTEM <SOHC-8 VALVE> - - - - - a - - O N : 235kPa T E R Y B A C K UP TSB Revision...
Page 168 13-26 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) “4 “6 Revision...
Page 169 FUEL SYSTEM (SOHC-8 VALVE> - Troubleshooting - I - IDLE SPEED CONTROL MOTOR TSB Revision...
Page 170 13-28 FUEL SYSTEM <SOHC-8 VALVE> CIRCUIT DIAGRAM I ____------- FF - ON OFF - ON TSB Revision...
Page 171 13-29 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting - - - - 1 2 C-23 54 -.-----------. TSB Revision...
Page 172 FUEL SYSTEM <SOHC-8 VALVE> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) TSB Revision...
Page 173 FUEL SYSTEM <SOHC-8 VALVE> - - - - - - - 0 3 CONTROL MOTOR...
Page 174 FUEL SYSTEM <SOHC-8 VALVE> FUEL TANK AND FUEL LINE Remedy Symptom Probable cause Repair or replace Bent or kinked fuel pipe or hose Clean or replace Clogged fuel pipe or hose Replace Clogged fuel filter or in-tank fuel filter Replace the fuel filter or clean the fuel tank Water in fuel filter and fuel line Clean or replace...
Page 175 FUEL SYSTEM <SOHC-8 VALVE> - Service Adjustment Procedures 13-33 CHART CLASSIFIED BY PROBLEM SYMPTOMS and check the MFI component. BASIC IDLE SPEED ADJUSTMENT inspection and adjustment. Engine coolant temperature: 85-95°C (185-205°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P for vehicles with an automatic transaxle) (2) Slacken the accelerator cable enough.
Page 176 FUEL SYSTEM <SOHC-8 VALVE> - Service Adjustment Procedures (5) Switch ON the ignition switch (but do not start the engine) and leave as if for 15 seconds or longer. NOTE When the ignition switch is switched ON, the idle speed control plunger extends to the fast-idle opening degree, and, after 15 seconds have passed, contracts to the initial position and stops there.
Page 177 FUEL SYSTEM <SOHC-8 VALVE> - Service Adjustment Procedures 13-35 329.) ten minutes; check to be sure that the idling condition is normal. THROTTLE BODY (THROTTLE VALVE AREA) CLEANING engine coolant reaches 80°C (176°F) or higher; then stop the engine. (2) Disconnect the air intake hose at the throttle body side. (3) Spray cleaning liquid (from the intake port of the throttle body) onto the valve, and then leave as is for about five minutes.
Page 178 13-36 FUEL SYSTEM <SOHC-8 VALVE> - Service Adjustment Procedures (blue clip, sensor output) of the throttle position sensor and terminal @I (red clip, sensor ground). <From 1990 models> use the special tool (test harness set) between the disconnected connector. Sensor connector <From 1990 models>...
Page 179 FUEL SYSTEM (SOHC-8 VALVE> - Service Adjustment Procedures 13-37 (5) If there is a deviation from the standard value, loosen the throttle-position sensor installation bolt and then turn the throttle-position sensor itself to make the adjustment. Be sure to securely retighten the bolt after making the adjustment.
Page 180 13-38 FUEL SYSTEM <SOHC-8 VALVE> ON-VEHICLE INSPECTION OF MFI COMPONENTS COMPONENT LOCATION Symbol Name Name Symbol Ignition coil (ignition power transistor) Air conditioning compressor clutch relay Ignition timing adjustment terminal Air conditioning switch Injector Crankshaft position sensor and camshaft posi- tion sensor Data link connector EGR solenoid <California>...
Page 181 FUEL SYSTEM <SOHC-8 VALVE> Oxygen sensor motor (closed throttle or Dosition sensor) sensor TSB Revision...
Page 182 FUEL SYSTEM <SOHC-8 VALVE> switch...
Page 183 FUEL SYSTEM <SOHC-8 VALVE> COMPONENTS INSPECTION PROCEDURE- USING THE SCAN TOOL (1) Switch OFF the ignition switch. cigarette lighter socket. engine, use the battery harness to take power directly from the battery. (4) Switch ON the ignition switch. (5) Select the vehicle model and the system. Select by pressing the m key.
Page 184 FUEL SYSTEM <SOHC-8 VALVE> (9) Switch OFF the ignition switch. confirm that the malfunction has been corrected. POWER SUPPLY relay ’ “ 2 “3 “6 Harness side connector Engine control module Engine control module connector OPERATION While the ignition switch is ON, battery power As a result, the MFI relay switch is switched ON, and power is supplied, by way of the MFI relay supply is supplied to the engine control module,...
Page 185 FUEL SYSTEM <SOHC-8 VALVE> HARNESS INSPECTION Measure the power supply voltage of the multiport fuel injection relay. Harness side . Multiport fuel injection relay con- connector nector: Disconnected . Ignition switch: ON Repair the harness. (Ignition Check for continuity of the ground circuit.
Page 186 FUEL SYSTEM <SOHC-8 VALVE> Caution When applying battery voltage directly, make sure that it is applied to correct terminal. Otherwise, the relay could be damaged. (1) Check continuity of the multiport fuel injection relay coil. Measuring terminals Continuity Conductive (approx. 35 52) Conductive in one direction only (2) Check the continuity of the multiport fuel injection relay...
Page 187 FUEL .SYSTEM <SOHC-8 VALVE> - ENGINE CONTROL MODULE POWER GROUND Engine control module control module Engine control module connector TROUBLESHOOTING HINTS OPERATION If there is incorrect or incomplete contact of the en- Grounding of the engine control module. aine control module’s ground line, the engine con- HARNESS INSPECTION Engine control module Check for continuity of the ground...
Page 188: Fuel System
13-46 FUEL SYSTEM FUEL PUMP connector fuel injection Component side relay connector 2 ’ Fuel pump I T - - - - - - check terminal - connector connector Engine control module Engine control module connector TSB Revision...
Page 189 FUEL SYSTEM <SOHC-8 VALVE> OPERATION control Activates the fuel pump during engine cranking While the engine is running, the engine while the engine is running. module switches ON the power transistor, after switch is set to the START When the ignition which current flows to the multiport fuel injec- position, current flows, by way of the multiport tion relay coil, and the power for activation of...
Page 190 FUEL SYSTEM <SOHC-8 VALVE> Check for continuity between the checking terminal and the engine control module, and between the nals. . Multiport fuel injection relay con- nector: Disconnected Repair the . Engine control module connec- harness. tor: Disconnected . F u e l p u m p c o n n e c t o r : Discon- connector 01 A0579 Measure the power supply voltage of...
Page 191 FUEL SYSTEM <SOHC-8 VALVE> - VOLUME AIR FLOW SENSOR injection relay Volume air flow sensor connector Engine control module Intake air amount Harness side connector OPERATION The volume air flow sensor is incorporated The power for the volume air flow sensor is within the air cleaner;...
Page 192 FUEL SYSTEM <SOHC-8 VALVE> INSPECTION Using Scan Tool Inspection conditions Data display Item No. . Engine coolant Sensor de- temperature: 85-95°C tection air volume (fre- . Lights, cooling fan, elec- quency) trical accessories: OFF . Transaxle: neutral (iVT Frequency in- models: “P”...
Page 193: Intake Air Temperature Sensor
FUEL SYSTEM <SOHC-8 VALVE> Check for continuity of the ground circuit. Harness side . Connector: Disconnected Repair the harness. INTAKE AIR TEMPERATURE SENSOR Volume air flow s e n s o r ) \ Temperature Temperature 1621008 sensor connector Intake air temperature sensor Harness side connector OPERATION...
Page 194 FUEL SYSTEM <SOHC-8 VALVE> TROUBLESHOOTING HINTS Consequently, the intake air temperature sensor terminal voltage varies in accordance with the sensor detects Because the intake air temperature temperature of the intake air, becoming lower the air cleaner, it the temperature of the intake air in when the temperature of the intake air in- indicates a temperature different than the tempera- creases.
Page 195 FUEL SYSTEM <SOHC-8 VALVE> (3) Measure resistance while heating the sensor using a hair drier. Resistance T e m p e r a t u r e Smaller (4) If the value deviates from the standard value or the resist- ance remains unchanged, replace the volume air flow sen- sor assembly.
Page 196 FUEL SYSTEM <SOHC-8 VALVE> TROUBLESHOOTING HINTS Hint 2: Hint 1: If, during high-speed driving, there is a noticeable If there is a malfunction of the barometric-pressure s h a r p d r o p o f t h e d i s p l a y e d p r e s s u r e o f t h e the vehicle will become worse sensor, driveability of the air cleaner.
Page 197: Engine Coolant Temperature Sensor
FUEL SYSTEM <SOHC-8 VALVE> - ENGINE COOLANT TEMPERATURE SENSOR Coolant temperature Engine coolant temperature sensor Harness side Component side connector connector Engine control module OPERATION The engine coolant temperature sensor func- Note that the resistance of the engine coolant tions to convert the barometric pressure to vol- temperature sensor decreases when the tem- tage, and to input that voltage (as signals) to the perature of the coolant increases.
Page 198 FUEL SYSTEM <SOHC-8 VALVE> INSPECTION Using Scan tool Coolant temperature Standard value Check conditions Function Item No. Data display At -20°C (-4°F) Sensor de- Ignition switch: ON Data reading -* Or, engine running tection temperature At 0°C (32°F) At 20°C (68°F) At 40°C (104°F) At 80°C (176°F) HARNESS INSPECTION...
Page 199 13-57 FUEL SYSTEM <SOHC-8 VALVE> INSTALLATION (1) Apply sealant 3M NUT locking No.41 71 or equivalent to threaded portion. (2) Install engine coolant temperature sensor and tighten it to specified torque. Sensor tightening torque: 20-40 Nm (15-29 ft.lbs.1 (3) Fasten harness connectors securely THROTTLE POSITION SENSOR <I989 models>...
Page 200 FUEL SYSTEM <SOHC-8 VALVE> - TROUBLESHOOTING HINTS Hint 1: Hint 2: If the voltage of the throttle-position sensor deviates The signals of the throttle-position sensor are more from the standard value, check once again after important for control of the automatic transaxle than making the throttle-position sensor adjustment.
Page 201 FUEL SYSTEM <SOHC-8 VALVE> - SENSOR INSPECTION (1) Disconnect the throttle position sensor connector, and connect the special tool (Test harness) between the disconnected connectors. (2) Measure the resistance between terminal @ (black clip of special tool) and terminal @ (red clip) of the connector on throttle position sensor side.
Page 202 FUEL SYSTEM <SOHC-8 VALVE> - OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool Refer to P.13-57. HARNESS INSPECTION Measure the power supply voltage of the throttle positlon sensor. . Connector: Disconnected . Ignition switch: ON . Connector: Disconnected Check for an open-circuit, or a short- circuit to ground between the engine side connector control module and the throttle posi-...
Page 203 FUEL SYSTEM <SOHC-8 VALVE> CLOSED THROTTLE POSITION SWITCH <I989 models> Engine control module c o n t r o l - motor connector connector Closed throttle connector Throttle shaft turning angle 0 1 2 0 9 2 OPERATION Voltage within the engine control module is ap- The closed throttle position switch functions to plied, by way of the resistance, to the closed convert (to HIGH/LOW-level voltage) data as to...
Page 204 F U E L S Y S T E M <SOHC-8 VALVE> - INSPECTION Using Scan tool Function Normal indication Item No. Data display Inspection conditions Throttle valve Data reading 26 To idle position (Check after pumping accelerator several times.) Slightly opened HARNESS INSPECTION Measure the power supply voltage of...
Page 205 13-63 FUEL SYSTEM <SOHC-8 VALVE> - CLOSED THROTTLE POSITION SWITCH <From 1990 models> Engine control module motor (Closed throttle position switch and idle speed control motor cosition sensor) Idle speed control Closed throttle Idle speed control motor position switch position sensor connector Throttle shaft -x-ring angle - 0 1 2 0 9 2 OPERATION...
Page 206 FUEL SYSTEM <SOHC-8 VALVE> - IDLE SPEED CONTROL MOTOR POSITION SENSOR <I989 models> position sensor connector @ Harness side I-- connector Engine control module Plunger stroke OPERATION The idle speed control motor position sensor When the plunger located within the idle-speed functions to convert the data concerning the control motor extends from its contracted con- position of the plunger (located within the idle-...
Page 207 FUEL SYSTEM <SOHC-8 VALVE> (4) Improper seating of the EGR valve seat. (2) Deposits adhering to the ttirottle valve. (5) lmcomplete combustion within a cylinder. (Mal- (3) Air being taken into the intake manifold due to a function of spark plugs, ignition coil, injectors, gasket leak, etc.
Page 208 13-66 FUEL SYSTEM <SOHC-8 VALVE> - ground Check for continuity of the . Connector: Disconnected Repair the Harness harness. connector Engine control Check for an open-circuit, or a short- module harness circuit to ground between the engine side connector control module and the idle speed control motor position sensor.
Page 209 FUEL SYSTEM <SOHC-8 VALVE> - m o d e l s > connector connector Engine control module connector Voltage between Plunger stroke 01 LO838 OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool Refer to HARNESS INSPECTION Measure the power supply voltage of the idle speed control motor position sensor.
Page 210 FUEL SYSTEM <SOHC-8 VALVE> - Engine control Check for an open-circuit, or a short- module harness circuit to ground, between the engine side connector control module and the idle speed control motor position sensor. STOP . Engine control module connec- tor: Disconnected .
Page 211 FUEL SYSTEM <SOHC-8 VALVE> CAMSHAFT POSITION SENSOR <Up to 1990 models> Ignition switch (IG,) Camshaft position sensor Distributor connector connector Engine control module Out put characteristic One rotation of distributor OPERATION The power for the camshaft position sensor is The camshaft position sensor functions to de- supplied from the ignition switch-IG and is tect the top dead center position of the No.
Page 212 FUEL SYSTEM <SOHC-8 VALVE> - (1) Run the engine at the idle speed. (2) Connect the probe to the oscilloscope pick-up point in the circuit diagram, and check the waveform. ov - Normal waveform HARNESS INSPECTION Measure the power supply voltage. .
Page 213 FUEL SYSTEM <SOHC-8 VALVE> - CAMSHAFT POSITION SENSOR <From 1991 models> Ignition switch (IG,) connector sensor Engine control module Out put charactenstic > Time One rotatton of distributor 01 R0102 OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Oscilloscope Refer to P.13-69. HARNESS INSPECTION Measure the power supply voltage.
Page 214 FUEL SYSTEM <SOHC-8 VALVE> - Check for continuity of the ground Harness stde circuit. Connector: Disconnected Repair the harness. Ground) . Connector: Disconnected . Ignition switch: ON TSB Revision...
Page 215 FUEL SYSTEM <SOHC-8 VALVE> - CRANKSHAFT POSITION SENSOR <Up to 1990 models> Ignition switch (IG,) Distributor connector Distributor connector connector One rotation of distributor OPERATION The power for the crankshaft position sensor is The crankshaft position sensor functions to de- supplied from the ignition switch-IG and is tect the crank angle (position) of each cylinder, grounded to the vehicle body.
Page 216 13-74 FUEL SYSTEM <SOHC-8 VALVE> - Examples: Hint 4: (1) Malfunction of the coolant-temperature sensor. If idling is possible even though the crankshaft posi- (2) Malfunction of the idling-speed control motor. tion sensor indicated rpm is a deviation from the (3) Improper adjustment of the standard idling standard value, the cause is usually a malfunction of speed.
Page 217 FUEL SYSTEM <SOHC-8 VALVE> - Check for continuity of the ground circuit. . Connector: Disconnected connector Ground) Check the voltage of the output cir- cuit. . Connector: Disconnected . ignition switch: ON STOP Repair the connector harness. CRANKSHAFT POSITION SENSOR <From 1991 models> Ignition switch (IG1) connector Engine control module ,( 21...
Page 218 13-76 FUEL SYSTEM <SOHC-8 VALVE> - OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool INSPECTION-Using Oscilloscope Refer to P.13-73. HARNESS INSPECTION Measure the power supply voltage. . Connector: Disconnected . Ignition switch: ON Voltage (VI Repair the harness. Battery positive voltage Ignition switch) Check for continuity of the ground circuit,...
Page 219 FUEL SYSTEM <SOHC-8 VALVE> - I G N I T I O N S W I T C H - S T < M / T > Ignition switch (ST) Engine control module connector Engine control module 01 LO838 OPERATION The ignition switch-ST inputs HIGH-level signals When the ignition switch is set to START, the to the engine control module during engine...
Page 220 FUEL SYSTEM <SOHC-8 VALVE> - IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH <A/T> Component Harness side Park/neutral position s Engine ’ control module Engine control module connector OPERATION The ignition switch-ST inputs HIGH-level signals depending upon whether the selector lever is at to the engine control module during engine the “P”...
Page 221 VALVE> FUEL SYSTEM <SOHC-8 INSPECTION Using Scan tool Ignition switch-ST Normal display Check conditions Engine Data display Function Item No. . Ignition switch: ON Stopped Switch status Data reading 18 Cranking Park/neutral position switch Selector lever position Normal display Data display Check conditions Function Item No.
Page 222 FUEL SYSTEM <SOHC-8 VALVE> - Engine control VEHICLE SPEED SENSOR module Vehicle speed sensor Component side Vehicle speed sensor Component side Engine control module connector 1 6 2 4 5 1 OPERATION The vehicle-speed sensor is incorporated within The vehicle-speed sensor, by intermitting by the the speedometer;...
Page 223 13-81 FUEL SYSTEM <SOHC-8 VALVE> Measure the power supply voltage of the vehicle speed sensor. connector . Connector: Disconnected . Ignition switch: ON Voltage (V) Repair the harness. 4.5-4.9 Check for continuity of the ground Connector: Disconnected 1 7 1 6 1 5 1 4 1 3 1 2 ~ 1 ~ 1 0 Repair the harness.
Page 224 FUEL SYSTEM <SOHC-8 VALVE> - OPERATION The power-steering pressure switch functions The battery voltage within the engine control to convert data as to whether there is or is not a module is applied, by way of the resistance, to power steering load to LOW-or HIGH-level vol- the power-steering pressure switch.
Page 225 FUEL SYSTEM <SOHC-8 VALVE> - AIR CONDITIONING SWITCH AND A/C COMPRESSOR CLUTCH RELAY Sub fl Auto compressor Air conditioning switch ‘1 Air conditic clutch relal Magnetic clutch Engine control 65 module Engine control module connector OPERATION When the air conditioning signals are input, the The air conditioning switch applies battery vol- engine control module activates the idle-speed tage to the engine control module when the air...
Page 226 FUEL SYSTEM <SOHC-8 VALVE> INSPECTION Using Scan tool Air conditioning switch Air conditioning switch Normal display Check conditions Data display Function Switch status . Engine idling (The air Data reading 28 conditioning com- pressor should be ac- tivated when the air conditioning switch is switched ON.) Air conditioning compressor clutch relay...
Page 227 FUEL SYSTEn rll (SOHC-8 V A L V E > - EGR TEMPERATURE SENSOR <Calif.> Component side EGR Harness side Temperature OPERATION The EGR temperature sensor functions to con- sensor decreases when the EGR gas volume vert the data regarding the temperature of the increases and the temperature of the EGR gas EGR gas downstream from the EGR valve to increases.
Page 228 FUEL SYSTEM <SOHC-8 VALVE> Using Scan tool Function Item No. Engine condition Standard value Data display Inspection conditions Data reading 43 . Engine: warm up 750 rpm (Idling) Sensor . Engine is maintained in a temperature 3,500 rpm constant state for 2 minutes or more .
Page 229 FUEL SYSTEM <SOHC-8 VALVE> OXYGEN SENSOR Component side Component side connector Oxygen sensor connector In case of FED case of CALIF Oxygen sensor Engine control module Theoretical A/F 01 Lo836 NOTE 1 : <I989 models> OPERATION if the air/fuel mixture ratio in leaner than the d e t e c t t h e T h e o x y g e n s e n s o r f u n c t i o n s t o air/fuel mixture ratio (Le., if the...
Page 230 FUEL SYSTEM TROUBLESHOOTING HINTS Examples: Hint I’ The exhaust gas purification performance will (2) Air leakage into the intake manifold from a worsen if there is a malfunction of the oxygen leaking gasket. sensor. (3) Malfunction of the volume air flow sensor, the Hint 2: intake air temperature sensor, the barometric- If the oxygen sensor output voltage deviates from...
Page 231 FUEL SYSTEM <SOHC-8 VALVE> SENSOR INSPECTION Caution 1. Before checking, warm up the engine until engine coolant temperature reaches 85 to 95°C (185 to 205°F). 2. Use an accurate digital voltmeter. (1) Disconnect the oxygen sensor connector and connect a voltmeter to the oxygen sensor connector.
Page 232 INJECTORS Fuel Filter Connector Plunger Needle valve -----I Injection 0 1 LO636 OPERATION injectors length of time that the needle valve is open, or, equipped injection nozzles that function to inject in other words, by the length of time of current fuel based upon injection signals from the flow to the solenoid coil.
Page 233 FUEL SYSTEM <SOHC-8 VALVE> - INSPECTION Using Scan tool Function Item No. Data display Inspection conditions Engine coolant temperature Standard value Data reading 41 Engine cranking At 0°C (3~2°F)“~ Approx. 21 ms At 20°C (68°F) Approx. 43 ms At 80°C (176°F) Approx.
Page 234 Check for an open-circuit, or a short- circuit to ground between the engine Harness control module and the injector. . Engine control module connector: connector Disconnected STOP . Injector connector: Disconnected Repair the harness. module harness side connector ACTUATOR INSPECTION CHECKING OPERATION SOUND Using a sound scope, check the operation sound (“chi-chi-chi”) of injectors during idling or during cranking.
Page 235 IDLE SPEED CONTROL MOTOR (DC MOTOR) Enoine control module m o t o r /---T- Harness side Component side connector control speed control motor Engine control module connector OPERATION The volume of intake air during idling is reg- The DC motor is driven in either the forward or reverse direction according to the direction of ulated by the opening and closing of the throttle switching of the current flow of the motor-...
Page 236 ACTUATOR INSPECTION (1) Disconnect the idle speed control motor connector. (2) Check continuity of the idle speed control motor coil. Continuity Measuring terminals 5 to 359 resistance at 20°C (68°F) Idle speed control motor connector (3) Connect 6V DC between terminal @I and terminal @ of the Idle speed control idle speed control motor connector, and check to be sure motor connector...
Page 237 FUEL SYSTEM <SOHC-8 VALVE> - HARNESS INSPECTION Engine control Check for an open-circuit, or a short- module harness circuit to ground between the engine control module and the idle speed control motor. Repair the side connector ACTUATOR INSPECTION (1) Disconnect the idle speed control motor connector. (2) Check continuity of the idle speed control motor coil.
Page 238: Ignition Coil And Ignition Power Transistor
FUEL SYSTEM <SOHC-8 VALVE> IGNITION COIL AND IGNITION POWER TRANSISTOR Harness side connector Component side Harness side Distributor timing Tachc Imeter adjustment OPERATION the power transistor within the unit, the battery When the ignition power transistor unit is voltage within the unit is applied to the ignition switched ON by the signals from the engine power transistor unit, and the ignition power control module, the primary current of the igni-...
Page 239 FUEL SYSTEM (SOHC-8 VALVE> - Using Oscilloscope 1. Primary signal of ignition coil (2) Connect the probe to oscilloscope pick-up point 1 as shown in the circuit diagram, and check the primary signal of the ignition coil. N o r m a l w a v e f o r m 6Fu,28, 2.
Page 240 S Y S T E M <SOHC-8 VALVE> - Check for continuity of the ground circuit. Repair the harness. Ground) Measure the voltage of the ‘control Harness connector Repair the ACTUATOR INSPECTION Refer to GROUP 16-Ignition System. TSB Revision...
Page 241 FUEL SYSTEM <SOHC-8 VALVE> EVAPORATIVE EMISSION PURGE SOLENOID Evaporative emission Component side connector connector Engine control module Engine control module connector OPERATION The evaporative emission purge solenoid is an Battery power supply is supplied, by way of the ON/OFF type of solenoid valve; it functions to regulate the introduction of purge air from the module switches ON the power transistor evaporative emission canister to the intake...
Page 242 FUEL SYSTEM <SOHC-8 V A L V E > HARNESS INSPECTION Measure the power supply voltage. Connector: Disconnected Ignition switch: ON Voltage (V) Repair the harness. fuel injec- tion relay- connector Check for an open-circuit, or a short- circuit to ground between the evapo- Engine rative emission purge solenoid and /-A control...
Page 243 FUEL SYSTEM <SOHC-8 VALVE> Components EGR SOLENOID <Calif.> Component EGR solenoid Engine control module 01 LO838 OPERATION Battery power supply is supplied, by way of the The EGR solenoid is a duty-control type of sole- noid valve; it performs its control function by When the engine control module switches OFF leaking the EGR valve-activation vacuum to the the power transistor within the unit, current...
Page 244 FUEL SYSTEM <SOHC-8 V A L V E > HARNESS INSPECTION voltage. Measure the power supply . Connector: Disconnected . Ignition switch: ON Harness side connector Check for an open-circuit, or a short- Engine circuit to ground between the EGR control solenoid and the engine control mod- Harness side...
Page 245 FUEL SYSTEM <SOHC-8 VALVE> - (2) Lift up the chassis, and disconnect the connector from the fuel pump which is mounted on the rear area of the fuel tank. (3) Check the terminals, wiring, etc., for damage. (4) Using an ohmmeter, check the motor continuity. FUEL PRESSURE TEST (Refer to P.13-1 OZ.) (2) Disconnect the fuel high pressure hose at the fuel rail...
Page 246 FUEL SYSTEM <SOHC-8 VALVE> regulator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: 330-370 kPa (47-53 psi) at curb idle speed not decrease even after the engine is raced a few times. repeatedly racing the engine, and check to be sure that there is fuel pressure in the return hose also.
Page 247 FUEL SYSTEM <SOHC-8 VALVE> - (15) Reduce the internal pressure of the fuel pipes and hoses. (Refer to P.13-102.) (16) Disconnect the fuel pressure gauge and the special tools from the fuel rail. Caution Because there will be some residual pressure in the fuel pipe line, use a shop towel to cover so that fuel doesn’t splatter.
Page 248 FUEL SYSTEM <SOHC-8 VALVE> TERMINAL VOLTAGE CHECK CHART Terminal arrangement of engine control module connector 01 LO838 Standard Remarks Check item Check condition (Engine state) value Backup power Power supply ignition switch: ON Fuel pump Engine: Cranking Engine: Idling Ignition switch: ON injection relay Engine: ldlrng (Fuel pump)
Page 249 SYSTEM <SOHC-8 VALVE> - Standard Check Item Check condition (Engine state) Remarks value Camshaft position Engine: Cranking 0.2 - 3.ov sensor 0.2 - 3.ov Crankshaft position Engine: Cranking sensor Engine: Idling Ignition Set the selector lever to P or N. Park/neutral s w i t c h : position switch...
Page 250 FUEL SYSTEM <SOHC-8 VALVE> Standard Check condrtron (Engrne state) Check Item value Check engine/ malfunction Indicator lamp (After several minutes have elapsed) EGR solenoid drops slightly accelerator pedal from the rdlrng state. from B+. EGR temperature Sensor temperature of 50°C (122°F) sensor Sensor temperature of 100°C (2 12°F) Ignition swatch:...
Page 251: Fuel Tank
FUEL SYSTEM <SOHC-8 VALVE> - Fuel Tank FUEL TANK 2 - 3 N m 2 - 3 N m 1 7 - 2 6 N m 19 ft.lbs. Removal steps 1. Fuel tank filler tube cap 2. Drain plug + 3. Return hose + 4.
Page 252 FUEL SYSTEM <SOHC-8 VALVE> - Fuel Tank INSPECTION Check the hoses and the pipes for crack or damage. Check the fuel tank filler tube cap for malfunction. Check the fuel tank for deformation, corrosion or crack. Check the fuel tank for dust or foreign material. NOTE If the inside of the fuel tank is to be cleaned, use any one of the following:...
Page 253: Fuel Pump Replacement
FUEL SYSTEM <SOHC-8 VALVE> - Fuel Tank 9. CONNECTION OF VAPOR HOSE/8. FILLER HOSE (1) The vapor hose should be connected all the way at the tank, and approximately 40 mm (1.6 in.) at the fuel tank filler tube. (2) The end of the filler hose with the shorter straight pipe part should be connected at the tank side.
Page 254 FUEL SYSTEM <SOHC-8 VALVE> - Fuel Tank the fuel screws and the bolt for Remove pump installation holding the fuel pump (at the lower side of the fuel tank), and then remove the fuel pump from the fuel tank. (9) Align the three positioning projections of the packing with the holes in the fuel pump.
Page 255 FUEL SYSTEM (SOHC-8 VALVE> REMOVAL AND INSTALLATION Pre-removal Operation Removal of the Battery Tray (Refer to GROUP 54-Starter Motor) *Release of Residual Pressure from High Pressure Fuel Hose (Refer to P.13-102.) Post-installation Operation *Measurement of Fuel Pressure (Refer to P.13-103.) Installation of the Battery Tray (Refer to GROUP 54-Starter Motor) 4-6 N m...
Page 256 FUEL SYSTEM <SOHC-8 VALVE> - Fuel Line and Vapor Line SERVICE POINTS OF REMOVAL 1. REMOVAL OF EYE BOLT Remove the eye bolt while holding the fuel filter nut securely. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure pipe line.
Page 257 FUEL SYSTEM <SOHC-8 VALVE> - Fuel Line and Vapor Line/Fuel Filter 2. INSTALLATION OF HIGH PRESSURE FUEL HOSE Apply engine oil to the hose union. Insert the hose, being careful not to damage the O-ring, and tighten securely. Caution Because there is high pressure applied between the fuel fuel pump and the injection mixer, be especially sure that there is no fuel leakage in this area.
Page 258 FUEL SYSTEM (SOHC-16 VALVE> - General Information GENERAL INFORMATION < F e d e r a l > TSB Revision...
Page 259 FUEL SYSTEM <SOHC-16 VALVE> <California> TSB Revision...
Page 260 FUEL SYSTEM (SOHC-16 VALVE> - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Fuel 60 (15.9) Tank capacity Equipped Return system High pressure type Filter Fuel pump Electrical, in-tank type Electric motor Driven by Throttle body mm (in.) 50 (1.969) Throttle bore Variable resistor type Throttle position sensor DC motor type...
Page 261: Explanation Of Troubleshooting Procedures
Specifications/Special Tools/ FUEL SYSTEM <SOHC-16 VALVE> SERVICE SPECIFICATIONS Specifications Basic ignition timing r p m 700-C 100 Curb idle speed 850 at neutral position < M / T > 650 at D range < A / T > r p m 700+50 Basic idle speed Throttle position sensor adjusting voltage Throttle position sensor resistance...
Page 262 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting Among the on-board diagnostic items, a check engine/mal- function indicator lamp comes on to notify the driver of the emission control items when an irregurality is detected. However, when an irregular signal returns to normal and the engine control module judges that it has returned to normal, the check engine/malfunction indicator lamp goes out.
Page 263 FUEL SYSTEM <SOHC-16 VALVE> ON-BOARD DIAGNOSTIC The engine control module monitors the input/out- control module. put signals (some signals at all times and the others Caution under specified conditions) of the engine control If the sensor connector is disconnected with module.
Page 264 FUEL SYSTEM <SOHC-l6 VALVE> - Troubleshooting Diagnostic trouble code On-board Check item (Remedy) Memory diagnostic Output signal pattern item Harness and connector Retained Throttle position Throttle position sensor Closed throttle position switch sensor Harness and connector Retained Engine Engine coolant temperature coolant temperature sensor...
Page 265 FUEL SYSTEM <SOHC-l6 VALVE> - Troubleshooting Check item (Remedy) EGR valve control vacuum NOTE Replace the engine control module if a diagnostic trouble code is output although the inspection reveals that there is no problem with the check items. The code numbers will be displayed in order, starting from the lowest. TROUBLESHOOTING TABLE NOTE failsafe/back-up function is in operation.
Page 266 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting Diagnostic On-board Remarks (trouble Diagnostic content Major cause trouble diagnostic phenomenon, etc.) code No. item (1) The intake air temperature Slightly improper Intake air (1) The signal voltage of the intake air temperature sensor is troubled. At high sensor is 4.5V or higher.
Page 267 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshootinn Remarks (trouble Diagnostic content Major cause diagnostic phenomenon, etc.) code No. item Vehicle During acceleration of engine (1) The vehicle speed sensor is The engine speed revolution speed of 3,000 rpm troubled. sometimes cuts off sensor or more, the signal voltage of (2) Open-circuit, short-circuit or...
Page 268 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting FAILSAFE/BACK-UP FUNCTIONS LIST If trouble with any major sensor is detected by the on-board diagnostic, the vehicle will be kept in the safe driving conditions according to the preset control logic. Trouble item Control content for trouble position Volume air flow (1) Fuel injection timing and ignition timing are determined according to the throttle...
Page 269 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshootins CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS Problem Starting Idling stability Driving symptoms ntake air temperature sensor ingine coolant temperature sensor ‘hrottle position sensor osition switch <A/T> ower steering pressure switch motor) ansistor EGR solenoid <California> Fuel pressure 0 : Warm engine (number inside indicates check order) PROBLEM SYMPTOMS TABLE (FOR YOUR INFOMATION)
Page 270 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting CIRCUIT DIAGRAM IGNITION SUB F'JI LINK @ 3 .____ ------------ --q-w- NEUTRAL FUEL PUMP RELAY...
Page 271 13-129 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting AUTO COMPRESSOR CONTROL UNIT METER CONDENSER COMBINATION...
Page 272 FUEL SYSTEM <SOHC-l6 VALVE> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) IGNITION SWITCH (IGl) RELAY VOLUME AIR FLOW EXNSOR “3 ENGINE TSB Revision...
Page 273 FUEL SYSTEM <SOHC-16 VALVE> - Troubleshooting IDLE SPEED "6 “2 "4"3 “1 37 5 TIMING CONNECTOR DATA LINK CONNECTOR...
Page 274 NOTE...
Page 275 FUEL SYSTEM <SOHC-l 6 VALVE> FUEL TANK AND FUEL LINE Remedy Symptom Probable cause Engine malfunctions Repair or replace Bent or kinked fuel pipe or hose due to insufficient Clean or replace fuel supply Clogged fuel pipe or hose Replace Clogged fuel filter or in-tank fuel filter Water in fuel filter Replace the fuel filter or clean the...
Page 276: Basic Idle Speed Adjustment
FUEL SYSTEM (SOHC-16 VALVE> - Service Adjustment Procedures BASIC IDLE SPEED ADJUSTMENT NOTE 1. The standard idling speed has been adjusted, by the en- gine speed adjusting screw, by the manufacturer, and there should usually be no need for readjustment. 2.
Page 277 FUEL SYSTEM <SOHC-16 VALVE> - Service Adjustment Procedures Diagnostic test mode control terminal of the data link connector. (4) Remove the waterproof female connector from the ignition timing adjustment connector. (5) Use a jumper wire to ground the ignition timing adjustment terminal.
Page 278 FUEL SYSTEM <SOHC-16 VALVE> THROTTLE BODY (THROTTLE VALVE AREA) CLEANING Start the engine and warm it up until the engine coolant is heated to 80°C (176°F) or higher and then stop the engine. Remove the air intake hose from the throttle body. Plug the bypass passage inlet of the throttle body.
Page 279 FUEL SYSTEM <SOHC-16 VALVE> - Service Adjustment Procedures Insert a feeler gauge with a thickness of 0.65 mm (.0256 in.) between the fixed SAS and the throttle lever. (4) Loosen the throttle position sensor mounting bolt; then turn the throttle position sensor body fully counter clock- wise.
Page 280 FUEL SYSTEM (SOHC-16 VALVE> FIXED SAS ADJUSTMENT NOTE been precisely adjusted by the manufacturer. If the adjustment for any reason is disturbed, readjust as follows. Loosen the tension of the accelerator cable sufficiently. (2) Back out the fixed SAS lock nut. (3) Turn the fixed SAS anti-clockwise until it is sufficiently backed out, and fully close the throttle valve.
Page 281: Component Location
FUEL SYSTEM <SOHC-l 6 VALVE> - ON-VEHICLE INSPECTION OF MFI COMPONENTS COMPONENT LOCATION Symbol Name Symbol Name Ignition coil (ignition power transistor) Air conditioning compressor clutch relay Ignition timing adjustment terminal Air conditioning switch Injector Camshaft position sensor and crankshaft posi- tion sensor Check engine/malfunction indicator lamp Data link connector...
Page 282 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE>...
Page 283 13-141 FUEL SYSTEM <SOHC-l 6 VALVE> - ::ii,,k:t~pection Of MF’ Crankshaft position sensor Air conditioning I ~ Check engine/malfunction indicator lamp TSB Revision...
Page 284 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> COMPONENTS INSPECTION PROCEDURE- USING THE SCAN TOOL Refer to P.13-41. TSB Revision...
Page 285: Power Supply
On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> POWER SUPPLY connector injection relay connector - - - " 2 "6 Engine control module Enaine control module connector OPERATION Using San Tool Refer to P.13-42. TSB Revision...
Page 286 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> HARNESS INSPECTION Measure the power supply voltage of the multiport fuel injection relay. connector Repair the nector: Disconnected harness. Measure the power- supply voltage of the multiport fuel injection relay. connector Check for continuity of the ground connector Engine control Check for open circuit, or short circuit...
Page 287 ‘On-Vehicle Inspection of MFI 13-145 FUEL SYSTEM (SOHC-16 VALVE> (1) Remove the multiport fuel injection relay. (2) Check the continuity between the multiport fuel injection relay terminals. (3) Use jumper leads to connect multiport fuel terminal 0 to the battery (+) terminal and battery (-) terminal.
Page 288 FUEL SYSTEM <SOHC-16 VALVE> - ENGINE CONTROL MODULE POWER GROUND Engine control module Engine control module connector OPERATION TROUBLESHOOTING HINTS Refer to P.13-45. HARNESS INSPECTION Check for continuity of the ground circuit. Connector: Disconnected harness. side connector , @ - G r o u n d ) TSB Revision...
Page 289 FUEL SYSTEM (SOHC-16 VALVE> - :::;::tt?ction Of MF’ FUEL PUMP Ignition switch (IG) connector connector Fuel pump connector connector Engine module A 8 OPERATION fuel relay coil. This causes injection fuel injection relay switch to turn the multiport cranking and while the is running.
Page 290 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> HARNESS INSPECTION Check for continuity of the fuel pump grounding line. Fuel pump connector: Discon- R e p a i r t h e Ground) connector Check for open-circuit or short circuit between the fuel pump and the fuel pump drive terminal.
Page 291 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> Check for continuity between the fuel pump checking terminal and between the multiport fuel injection relay ter- nector: Disconnected t h e connector Fuel pump connector: Discon- nected Check for an open circuit, or short-cir- cuit to ground between the multiport fuel injection relay and the fuel pump.
Page 292 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> VOLUME AIR FLOW SENSOR injection relay Intake air amount 1 6 2 4 5 1 Harness side OPERATION TROUBLESHOOTING HINTS Refer to P.13-49. INSPECTION Using Scan Tool Standard value Engine condition Inspection conditions Data display Item No.
Page 293 On-Vehicle Inspection of MFI Using Oscilloscope shown in the circuit diagram, and check the wave form. Regular waveform HARNESS INSPECTION Check for continuity between volume air flow sensor and multiport fuel in- jection relay. nector: Disconnected Volume air flow sensor connec- tor: Disconnected connector NOTE...
Page 294: Intake Air Temperature Sensor
FUEL SYSTEM (SOHC-16 VALVE> - INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor Volume air flow sensor (built in intake air (built in intake air Temperature Temperature 1621006 s e n s o r c o n n e c t o r [ Intake air temoerature sensor Harness side connector k...
Page 295 FUEL SYSTEM <SOHC-16 VALVE> - ::ii$%tt=pection Of MF’ Check for open circuit or short circuit to ground, between intake air tempera- ture sensor and engine control mod- tor: Disconnected Engine control module connec- tor: Disconnected connector Measure the impressed voltage. tor: Disconnected Engine control module connec- tor: Disconnected...
Page 296 On-Vehicle Inspection of MFI 13-154 FUEL SYSTEM <SOHC-16 VALVE> - BAROMETRIC PRESSURE SENSOR Barometric pressure sensor sensor conneclur connector pressure sensor Engine control module connector Barometric pressure mmHg 760 OPERATION TROUBLESHOOTING HINTS INSPECTION Using Scan Tool Refer to P.13-53. HARNESS INSPECTION tor: Disconnected TSB Revision...
Page 297 FUEL SYSTEM <SOHC-l 6 VALVE> - ::~,%~t~pection Of MF’ Engine control Check for an open circuit, or a short- module harness circuit to ground between the engine side connector control module and the barometric pressure sensor. Volume air flow sensor connec- tor: Disconnected Engine control module connec- tor: Disconnected...
Page 298 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> OPERATION TROUBLESHOOTING HINTS INSPECTION Using Scan Tool Refer to HARNESS INSPECTION Check for continuity of the ground circuit. Harness side Engine coolant temperature connector sensor connector: Drsconnected module harness Check for open circuit or short-circuit side connector to ground, between engine coolant temperature and engine control mod-...
Page 299 FUEL SYSTEM (SOHC-16 VALVE> - ::ii,,k%ti=pec*ion Of MF’ perature sensor immersed in hot water, check resistance Resistance (k!S) Temperature PC (“F)l 0 (32) 20 (68) 80 (I 76) replace the sensor. INSTALLATION Specified sealant: 3M NUT locking Part No. 4171 or equivalent specified torque.
Page 300 On-Vehicle Inspection of FUEL SYSTEM (SOHC-16 VALVE> TROUBLESHOOTING HINTS OPERATION Hint 1: The throttle position sensor signal is more The throttle position sensor converts the throttle important in the control of automatic trans- position opening into a voltage and inputs it to the axle than in the engine control.
Page 301 FUEL SYSTEM <SOHC-16 VALVE> - ~:~t%~t~pection Of MF’ Measure the impressed voltage of the throttle position sensor. Throttle position sensor connector: Disconnected connector Engine control module connec- tor: Connected SENSOR INSPECTION side connector terminal @ and terminal @. Standard value: 3.5 - 6.5 kQ side connector terminal @ and terminal @.
Page 302: Closed Throttle Position Switch
On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> CLOSED THROTTLE POSITION SWITCH Engine control module connector throttle position switch connector Throttle shaft turning angle 0,z092 TROUBLESHOOTING HINTS OPERATION If the closed throttle position switch harness and in- The closed throttle position switch senses results are normal but the closed dividual check whether the accelerator pedal is depressed or...
Page 303 FUEL SYSTEM <SOHC-l 6 VALVE> - :::;k%l;nspection Of MF’ HARNESS INSPECTION Check for open-circuit, or short-circuit to ground, between closed throttle position switch and engine control module. Engine control module connec- tor: Disconnected Closed throttle position switch connector: Disconnected Check for continuitv of the ground connector: Disconnected Measure the impressed voltage of the closed throttle position switch.
Page 304 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> connector Engine control module TROUBLESHOOTING HINTS OPERATION Hint 1: The IAC valve position sensor is the most The IAC valve position sensor converts the changes (increase or decrease) in the valve important sensor for controlling the idle speed.
Page 305 FUEL SYSTEM <SOHC-16 VALVE> - :::,:k:t?=tiion Of MF’ INSPECTION Using Scan Tool Function Data display Check condition Load state Engine coolant tem- D a t a r e a d i n g / 5 5 Air conditioning switch: perature: 85 to 95°C position step (185 to 203’F) Lights, electric cool-...
Page 306 On-Vehicle Inspection of MFI 13-164 FUEL SYSTEM (SOHC-16 VALVE> - Measure the impressed voltage. tor: Disconnected control module connec- Engine tor: Connected Measure the impressed voltage. tor: Disconnected connector control module connec- tor: Connected Ignition switch: ON TSB Revision...
Page 307: Camshaft Position Sensor
FUEL SYSTEM (SOHC-16 VALVE> - %$k%lnspectio” Of MF’ CAMSHAFT POSITION SENSOR Distributor Camshaft @ Equipment side position connector connector Output characteristic PJ) ‘One rotation of distributor Engine control Engine control module connector TROUBLESHOOTING HINTS OPERATION Hint 1: If the camshaft position sensor is defective, The camshaft position sensor detects the top proper sequential injection will not occur, so the engine will stall, or unstable idling and...
Page 308 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> INSPECTION Using Oscilloscope HARNESS INSPECTION switch Check for continuity of the ground circuit. tor: Disconnected Ground) Check for open circuit or short circuit to ground, between camshaft position sensor and engine control module. Engine control module connec- Engine control tor: Disconnected...
Page 309: Crankshaft Position Sensor
FUEL SYSTEM <SOHC-16 VALVE> - ::ii,,:::ti=pection Of MF’ CRANKSHAFT POSITION SENSOR Ignition switch Distributor Crankshaft position sensor side connector Output characteristic (V) connector Time One rotation of distributor Engine control module Engine control module connector...
Page 310 13-168 FUEL SYSTEM <SOHC-16 VALVE> - TROUBLESHOOTING HINTS OPERATION Hint 1: If unexpected shocks are felt during driving The crankshaft position sensor detects the or the engine stalls suddenly during idling, crank angle (piston position) of each cylinder, shake the crankshaft position sensor har- converts it to a pulse signal and inputs it to the engine control module.
Page 311 FUEL SYSTEM (SOHC-16 VALVE> - :::%%t:nspection Of MF’ INSPECTION Using Scan Tool Normal state Check content Function Item No. i Data display Check condition D a t a r e a d i n g ) 22 Engine cranking agree speed Tachometer con- and scan tool reading...
Page 312 FUEL SYSTEM <SOHC-16 VALVE> - ::$%:ti=pection Of MF’ HARNESS INSPECTION Measure the power supply voltage. Crankshaft position sensor connec- tor: Disconnected Ignition switch: ON Repair the hahrness Voltage (VI tion switch) or check the ignition switch Check for continuity of the ground circuit.
Page 313 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> IGNITION SWITCH-ST <M/T> Ignition switch (ST) Engine control module connector Engine control module OPERATION INSPECTION Using Scan Tool Refer to P.13-77. HARNESS INSPECTION Engine control Measure the input voltage to the module harness side connector engine control module.
Page 314 On-Vehicle inspection of MFI 13-172 FUEL SYSTEM <SOHC-16 VALVE> IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH <A/T> Ignition switch (ST) Starter S terminal Engine control module connector Engine control module 0~~~2~5 OPERATION TROUBLESHOOTING HINTS INSPECTION Using Scan Tool Refer to P.13-78. HARNESS INSPECTION Measure the power supply voltage of...
Page 315 FUEL SYSTEM <SOHC-l6 VALVE> - ::i%%?ction Of MF’ Ignition switch: ON PARK/NEUTRAL POSITION SWITCH INSPECTION Refer to GROUP 23-Troubleshooting. VEHICLE SPEED SENSOR Vehicle speed sensor Vehicle speed sensor Component side Frequency Engine control module connector Vehicle speed [km/h (mph)] 1 6 2 4 5 1 OPERATION TROUBLESHOOTING HINTS Refer to P.13-80.
Page 316 13-174 FUEL SYSTEM <SOHC-16 VALVE> - :::;:%t~pection Of MF’ HARNESS INSPECTION Engine control module Check the vehicle speed sensor harness side connector output circuit for continuity. Engine control module connec- Move the vehicle. Engine control Check for open circuit or short-circuit module harness to ground, between engine control side connector...
Page 317: Power Steering Pressure Switch
On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> POWER STEERING PRESSURE SWITCH Engine control module side connector Power steering 700 - 2,000 pressure switch Pressure fkPa (kg/on?*. psi11 Enaine control module connector OPERATION INSPECTION Using Scan Tool HARNESS INSPECTION Engine control module harness Check for open circuit or short-circuit side connector...
Page 318 FUEL SYSTEM <SOHC-16 VALVE> - Measure the impressed voltage. Power steering pressure switch connector: Disconnected Engine control module connec- tor: Connected Ignition switch: Voltage 04 AIR CONDITIONING SWITCH AND A/C COMPRESSOR CLUTCH RELAY Sub fusible link Auto compressor Air conditionino control unit ‘...
Page 319: Egr Temperature Sensor
On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> HARNESS INSPECTION Measure the power supply voltage of the air conditioning circuit. Air conditioning switch: ON Engine control module connec- tor: Disconnected Ignition switch: ON Check the Engine control air condi- module harness tioning side connector circuit...

Page 320 FUEL SYSTEM <SOHC-16 VALVE> - HARNESS INSPECTION Check for continuity of the ground circuit. Harness stde EGR temperature sensor connec- connector tor: Disconnected Check for an open circuit, or a short circuit to ground between the engine control module and the EGR tempera- Harness side connector ture sensor.
Page 321 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> OXYGEN SENSOR connector Oxygen sensor connector Theoretical A/F Engine control module Engine control module connector OPERATION TROUBLESHOOTING HINTS INSPECTION Using Scan Tool Refer to P.13-87. HARNESS INSPECTION Engine control module harness Check for an open circuit, or a short ide connector engine circuit to ground, between the...
Page 322 FUEL SYSTEM <SOHC-16 VALVE> - Check for continuity of the ground connector Repair the harness SENSOR INSPECTION and check to be sure that the engine coolant temperature is 85-95°C (185-203°F). digital voltmeter. Caution When disconnecting the oxygen sensor connector, do not pull the connector or lead wire too strongly.
Page 323 FUEL SYSTEM <SOHC-l 6 VALVE> - :::,:%?pection Of MF’ INJECTORS connector Fuel Plunger Engine control module Needle valve Engine control module connector OPERATION TROUBLESHOOTING HINTS Refer to P.13-90. TSB Revision...
Page 324 FUEL SYSTEM <SOHC-16 VALVE> - ~~~;~~~t~pection Of MF’ INSPECTION Using Scan Tool Standard value Check condition Function Data display 1 Approx. 20 ms D r i v e trme *’ 1 Engine: Cranking Data reading / 41 Approx. 40 ms Standard value C h e c k c o n d i t i o n I Data display 1...
Page 325 FUEL SYSTEM <SOHC-16 VALVE> - ~:$%:t?on Of MF’ HARNESS INSPECTION Harness Check for continuity between injector side connector and multiport fuel injection relay. lniector connector: Disconnected nector: Disconnected Repair the NOTE harness injection relay Touch the circuit tester probes to both harness side ends of the harness.
Page 326 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> IDLE AIR CONTROL MOTOR (DC MOTOR) Engine control module connector connector Idle air control motor Engine control module connector TROUBLESHOOTING HINTS OPERATION Hint 1: While the engine is idling, if the idle speed The volume of intake air during engine idling is and IAC valve position (step) change when controlled by the opening and closing of the IAC...
Page 327 FUEL SYSTEM <SOHC-16 VALVE> - :,%,,k%$spection Of MF’ HARNESS INSPECTION Engine control ) module harness Check for open circuit, or short-circuit side connector to ground, between idle air control motor and engine control module. STOP connector tor: Disconnected Engine control module connec- Repair the tor: Disconnected harness...
Page 328 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> IGNITION COIL AND IGNITION POWER TRANSISTOR Distributor (built in ignition coil and Ignition power transistor) Distributor connector adjustment connector Spark connector Engine control module connector Engine control module OPERATION Refer to P.13-96. INSPECTION Function C h e c k c o n d i t i o n j...
Page 329 FUEL SYSTEM <SOHC-l6 VALVE> - :::;:it,t*?pec*ion Of MF’ Using Oscilloscope 1. Primary signal of ignition coil (2) Connect the probe to oscilloscope pick-up point 1 as shown in the circuit diagram, and check the primary signal of the ignition coil. Normal waveform 2.
Page 330 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> Check to be sure that there is no continuity between the ignition coil and the earth. Harness side connector Ignition coil connector: Discon- short in the ignition coil primary circuit of the control Measure the voltage signal circuit of the ignition power transistor.
Page 331 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> EVAPORATIVE EMISSION PURGE SOLENOID Evaporative emission / injection relay Evaporative emission purge solenoid connector Engine !!!I module ki Engine control module connector OPERATION INSPECTION Using Scan Tool Refer to P.13-99. TSB Revision...
Page 332 On-Vehicle Inspection of MFI FUEL SYSTEM <SOHC-16 VALVE> HARNESS INSPECTION Check for continuity between evapo- Harness side rative emission purge solenoid and connector Evaporative emission purge sole- noid connector: Disconnected nector: Disconnected Touch the circuit tester probes to connector both ends of the harness. Check for an open circuit, or a short- circuit to ground, between the evapo- rative emission purge solenoid and...
Page 333 FUEL SYSTEM <SOHC-l 6 VALVE> - EGR SOLENOID <California> injection relay connector EGR solenoid “ Engine Engine control module connector control module OPERATION TROUBLESHOOTING HINTS INSPECTION Using Scan Tool Refer to P.13-101. HARNESS INSPECTION Check for continuity between EGR solenoid and multiport fuel injection relay.
Page 334 On-Vehicle Inspection of MFI FUEL SYSTEM (SOHC-16 VALVE> Engine control module a short- Check for an open circuit, or harness circuit to ground, between the solenoid and the engine control mod- connector STOP ule. EGR solenoid connector: Discon- nected Repair the Engine control module connec- harness tor: Disconnected...
Page 335 FUEL SYSTEM <SOHC-16 VALVE> - i%$-%~pection Of MF’ Check Item Check Condition (Engrne Condrtron) value Volume air flow sensor reset signal Engine rpm: 3,000 rpm Ignition switch: ON When Intake atr temperature Intake air tempera- ture sensor When intake air temperature When intake air temperature is 80°C (176°F) sensor When altitude is 1,200 m (3,937 ft.)
Page 336 13-194 FUEL SYSTEM <SOHC-16 VALVE> - ::~;:%~specion Of MF’ Standard C h e c k I t e m Check Condrtion (Engine Condition) No. , value 56 1 Oxygen sensor (Changes repeatedly) From 1 l- No. 1 Injector accelerator pedal. momen- No.
Page 337: Fuel Filter
Fuel Tank/Fuel Line and Vapor Line/ FUEL SYSTEM (SOHC-16 VALVE> Refer to P.13-109. Refer to P.13-113. FUEL FILTER Refer to P.13-115. TSB Revision...
Page 338 FUEL SYSTEM <DOHC> - General Information GENERAL INFORMATION <Federal-Non-Turbo Up to 1991 models> Fuel pump control ‘10 perature sensor tion relay) voltage power-drs- Air conditioning corm- tribution type) Power supply sensor Vehicle-speed sen- sion purge solenoid . Arr conditioning output switch Power steering function indicator...
Page 339 FUEL SYSTEM <DOHC> <Federal-Non-Turbo From 1992 models> Fuel pump control tion relay) perature sensor voltage power-dis- sensor Ignition switch ST tribution type) Air conditioning com- Power supply pressor clutch relay Vehicle-speed sen- Ignition timing control purge switch sion solenoid On-board diagnostic output Air conditioning switch...
Page 340 FUEL SYSTEM <DOHC> <California-Non-Turbo Up To 1991 models> tion relay) Engien coolant tem- tribution type) perature sensor sensor pressor clutch relay . Ignition switch ST Power supply sion purge solenoid Vehicle-speed sen- switch output Air conditioning function indicator switch lamp pressure switch sensor ‘9 Engine coolant temper-...
Page 341 FUEL SYSTEM <DOHC> - General Information <California-Non-Turbo From 1992 models> Fuel pump control s e n s o r ‘11 EGR temperature sen tion relay) voltage power-dis- sensor ‘12 Engien coolant tem- tribution type) Air conditioning com- perature sensor Ignition switch ST l 4 Evaporative emis- Ignition timing control switch...
Page 342 FUEL SYSTEM <DOHC> - General Information < F e d e r a l - T u r b o > . Fuel pump Control Engien coolant tem- tion relay) voltage perature sensor Air conditioning com- tribution type) sensor Power supply control .
Page 343 FUEL SYSTEM <DOHC> - General Information/Specifications <California-Turbo> Fuel pump control ‘11 EGR temperature sen- voltage power-dis- tion relay) sensor ‘12 Engien coolant tem- tribution type) Air conditioning com- ‘4 Throttle position sensor perature sensor pressor clutch relay “5 Closed throttle position Ignition switch ST Ignition timing control switch...
Page 344 FUEL SYSTEM <DOHC> - Specifications Specifications Throttle body mm (in.) 60 (2.362) Throttle bore Variable resistor type Throttle position sensor Stepper motor type The stepper motor type by-pass air system with the Fast Idle Air Valve (FIAV) Contact switch type Closed throttle position switch Engine control module Identification model No.
Page 345 FUEL SYSTEM <DOHC> Specifications Items 5” f 2”BTDC at curb idle Basic ignition timing 750 + 100: Non-Turbo Curb idle speed Idling rpm when air conditioning ON 850 at neutral position 700 at D range 750 & 50: Non-Turbo Basic idle speed 800 + 50: Turbo Throttle position sensor adjustment voltage 3.5-6.5...
Page 346 FUEL SYSTEM <DOHC> - Specifications/Special Tools 9 - 1 4 Fuel filter mounting bolts 9 - 1 4 Fuel pipes clip attaching bolt SEALANT Engine coolant temperature sensor threaded portion Fuel tank hole cover <AWD> equivalent SPECIAL TOOLS (For the number, refer to GROUP OO- Precautions before service.
Page 347 FUEL SYSTEM <DOHC> - Troubleshootina TROUBLESHOOTING TROUBLESHOOTING E X P L A N A T I O N O F PROCEDURES Refer to P.13-8. EXPLANATION AND PRECAUTION RELATED TO HARNESS CHECKING Refer to P.13-9. Among the on-board diagnostic items, a check engine/mal- function indicator lamp comes on to notify the driver of the emission control items when an irregurality is detected.
Page 348 FUEL SYSTEM <DOHC> - Troubleshooting ON-BOARD DIAGNOSTIC disconnected. In addition, beginning with the engine The engine control module monitors the input/out- control module of 1990 and later models, the diag- put signals (some signals at all times and the others nostic trouble code are erased by turning on the ig- under specified conditions) of the engine control nition switch and sending the diagnostic trouble...
Page 349 FUEL SYSTEM <DOHC> - Troubleshooting Diagnostic trouble code On-board diagnostic Check item (Remedy) Memory Output signal pattern item Throttle Harness and connector Retained position Throttle position sensor sensor Closed throttle position switch Engine Harness and connector Retained coolant Engine coolant temperature sensor temperature sensor...
Page 350 FUEL SYSTEM <DOHC> Diagnostic trouble code On-board Memory Check item (Remedy) diagnostic Output signal pattern item Retained Harness and connector EGR temperature sensor EGR valve EGR solenoid EGR valve control vacuum Retained Ignition coil, Harness and connector Ignition coil Ignition Ignition power transistor power transistor...
Page 351 FUEL SYSTEM <DOHC> - Troubleshootina agnostic On-board Remarks (trouble trouble diagnostic Diagnostic content Major cause phenomenon, etc.) ode No. item Intake air (1) The signal voltage of the (1) The intake air temperature Slightly improper intake air temperature sensor is troubled. sensor is 4.5V or higher.
Page 352 FUEL SYSTEM <DOHC> - Troubleshooting Remarks (trouble Major cause diagnostic Diagnostic content phenomenon, etc code No. item (1) The barometric pressure sensor Unstable idling* Barometric (1) The signal voltage of the is troubled. Improper pressure barometric pressure (2) Open-circuit, short-circuit or acceleration* sensor sensor is 4.5V or higher.
Page 353: Clear Memory Of Diagnostic Trouble Code
FUEL SYSTEM <DOHC> - Troubleshooting FAILSAFE/BACK-UP FUNCTIONS LIST If trouble with any major sensor is detected by the on-board diagnostic, the vehicle will be kept in the safe driving conditions-accdrding to the preset control logic. Trouble item Control content for trouble Volume air flow (1) Fuel injection timing and ignition timing are determined according to the throttle positior sensor...
Page 354 13-212 FUEL SYSTEM <DOHC> - Troubleshooting CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS 270.27 274.27 <A/T>...
Page 355 FUEL SYSTEM <DOHC> - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Symptom Won’t start The starter used to crank the engine, but there is no combustron withrn tht (no inrtial combustion) cylinders, and the engine won’t start. There is combustion within the cylinders, but then the engine soon stalls. (Starting takes a long Engine won’t start quickly.
Page 356 13-214 FUEL SYSTEM <DOHC> - Troublesh’ooting CIRCUIT DIAGRAM SUB I LINK 8 _______________--___---------------- ----- CONNECTOR K X 35AC-H0528-NY TSB Revision...
Page 357 FUEL SYSTEM <DOHC> - Troubleshooting ------ IGNITION COIL CIRCUIT TO SPARK PLUG Revision...
Page 358 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) IGNITION POWER RELAY TRANSISTOR UNIT . POSITION SENSOR “3 "5 ENGINE OXYGEN SENSOR TSB Revision...
Page 359 FUEL SYSTEM <DOHC> - Troubleshooting 11 58 5E --- -. 2 $kl CONNECTOR $flI;,S 9MENT POWER STEERING FRONT SIDE (VEHICLES FOR CALIFORNIA) TSB Revision...
Page 360 13-218 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) AUTO COMPRESSOR DUAL RELAY SOLENOID CALIFORNIA) A-OS TSB Revision...
Page 361 FUEL SYSTEM <DOHC> - Troubleshooting 13-219 CIRCUIT DIAGRAM TSB Revision...
Page 362 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) GNITION COIL ENGINE SPEED DETECTION IGNITION CONNECTOR TSB Revision...
Page 363 13-221 FUEL SYSTEM <DOHC> - Troubleshooting UNIT RELAY VOLUME AIR FLOW SENSOR CRANKSHAFT POSITION 21 t%TROL UNIT TSB Revision...
Page 364 FUEL SYSTEM <DOHC> - Troubleshooting 13-222 CIRCUIT DIAGRAM (CONTINUED) COMBINATION ONNECTOR POWER STEERING (VEHICLES FOR CALIFORNIA) TSB Revision...
Page 365 13-223 FUEL SYSTEM <DOHC> - Troubleshooting AUTO COMPRESSOR DUAL OF;- RELAY CALIFORNIA) ENGINE COOLANT BATTERY BACK MAGNETIC CLUTCH MFI CONTROL UNIT' Revision...
Page 366 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM IGNITION 3 C-24 FWD !AWD NEUTRAL g FUEL PUMP AND GAUGE " 2 TSB Revision...
Page 367 FUEL SYSTEM <DOHC> GNITION COIL CONDENSER COMBINATION METER IGNITION POWER TRANSISTOR z+ TSB Revision...
Page 368 FUEL SYSTEM <DOHC> - Troubleshooting 13-226 CIRCUIT DIAGRAM (CONTINUED) RELAY CRANKSHAFT POSITION "4 "6 "1 "3 TSB Revision...
Page 369 FUEL SYSTEM <DOHC> - Troubleshootina IDLE AIR ,,2 CONTROL MOTOR IGNITION TIMING DATA LINK ADJUSTMENT CONNECTOR CONNECTOR EGR TEMERATURE SENSOR FRONT SIDE (VEHICLES FOR CALIFORNIA)
Page 370 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) F U S I B L E L I N K AUTO COMPRESSOR CONTROL UNIT CONNECTOR 1 9 3 4 RELAY C A L I F O R N I A ) MFI CONTROL UNIT...
Page 371 FUEL SYSTEM <DOHC> - Troubleshootina CIRCUIT DIAGRAM IGNITION 3 C-24 IBLE NEUTRAL CONNECTOR -------- --- "7 "2 ---------------...
Page 372 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) IGNITION COIL CONDENSER ENGINE 6PEED "7 3 CONNECTOR IGNITION POWER XL----- TSB Revision...
Page 373 FUEL SYSTEM <DOHC> - Troubleshooting U N I T THROTTLE = ENGINE COOLANT SENSOR HEATED OXYGEN SENSOR OXYGEN SENSOR CHECK CONNECTOR...
Page 374 13-232 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) IGNITION TIMING DATA LINK ADJUSTMENT CONNECTOR CONNECTOR POWER STEERING (VEHICLES FOR CALIFORNIA) TSB Revision...
Page 375 FUEL SYSTEM <DOHC> - Troubleshootina SUB FUSIBLE LIh AUTO COMPRESSOR CONTROL UNIT SOLENOID CALIFORNIA) CONDITIONING ENGINE COOLANT MAGNETIC CLUTCH MFI CONTROL UNIT TSB Revision...
Page 376 FUEL SYSTEM <DOHC> - Troubleshootinca CIRCUIT DIAGRAM <From 1991 models (Turbo)> IBLE “ 7 "2 TSB Revision...
Page 377 FUEL SYSTEM <DOHC> - Troubleshooting GNITION CO ENGINE SPEED DETECTION "2 CONNECTOR TSB Revision...
Page 378 13-236 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) RELAY SENSOR OXYGEN GENSOR CHECK CONNECTOR TSB Revision...
Page 379 13-237 FUEL SYSTEM <DOHC> - Troubleshooting EMISSION IDLE AIR 5~~ CONTROL IGNITION CONNECTOR (VEHICLES FOR CALIFORNIA)
Page 380 13-238 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <From 1991 models (Turbo)> FUSIBLE LINF UNIT CONTROL IOD OR RELAY CONDITIONING ENGINE COOLANT TURE CLUTCH MAGNETIC TSB Revision...
Page 381 FUEL SYSTEM <DOHC> - Troubleshootina CIRCUIT DIAGRAM IGNITION 3 C-24 FWD AWD A-OS FUEL PUMP "2...
Page 382 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) ------- IGNITION COIL CONDENSER ENGINE SPEED DETECT I ON IGNITION CONNECTOR Irl -------- TSB Revision...
Page 383 13-241 FUEL SYSTEM <DOHC> - Troubleshooting CONTROL UNIT CONTROL KNOCK CTOR TSB Revision...
Page 384 13-242 FUEL SYSTEM <DOHC> - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) IGNITION TIMING ADJUSTMENT CONNECTOR C- 18 POWER STEERING FRONT SIDE CALIFORNIA)
Page 385 13-243 FUEL SYSTEM <DOHC> - Troubleshooting I FUSIBLE LINb AUTO COMPRESSOR CONTROL UNIT CONNECTOR RELAY 1 x B S L H E N O I D CALIFORNIA) , BAWL”‘, UNIT TSB Revision...
Page 386 FUEL SYSTEM <DOHC> - Troubleshooting FUEL TANK AND FUEL LINE Remedy Symptom Probable cause Repair or replace Bent or kinked fuel pipe or hose Engine malfunctions due to insufficient fuel Clean or replace Clogged fuel pipe or hose Clogged fuel filter or in-tank fuel filter Replace Replace the fuel filter or clean the fuel tank Water in fuel filter...
Page 387 13-245 FUEL SYSTEM <DOHC> - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES CURB IDLE SPEED INSPECTION inspection. Engine coolant temperature: 85-95°C (185-205°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P for vehicles with an automatic transaxle) (2) Connect a tachometer. NOTE tion of a tachometer.
Page 388 13-246 FUEL SYSTEM <DOHC> inspection and adjustment. Engine coolant temperature: 85-95°C (185-205°F) Lights, electric cooling fan and accessories: OFF Transaxle: Neutral (P for vehicles with an automatic transaxle) Connect the scan tool to the data link connector (white). NOTE When the scan tool is connected, the diagnostic test mode control terminal is grounded.
Page 389 FUEL SYSTEM <DOHC> - Service Adjustment Procedures NOTE For rpm, one-half of the actual engine rpm is indicated, so the actual engine rpm in two times the indicated value shown by the tachometer. <From 1990 models> control terminal of the data link connector. (4) Use a jumper wire to ground the terminal for adjustment of ignition timing.
Page 390 FUEL SYSTEM <DOHC> - Adjustment Procedures Service (8) Switch OFF the ignition switch. (9) If the scan tool was not used, disconnect the jumper wire from the diagnostic test mode control terminal. ment of ignition timing, and return the connector to its original condition.
Page 391 13-249 FUEL SYSTEM <DOHC> - Service Adjustment Procedures (2) If a scan tool is not used, perform the following operation. and connect the special tool (test harness) between the disconnected connectors. al (red clip, sensor ground) and the @I terminal (blue clip, sensor output) of the throttle-position sensor connec- tor.
Page 392 FUEL SYSTEM <DOHC> - Service Adjustment Procedures (5) If there is a deviation from the standard value, loosen the T V = = = - - throttle-position sensor installation bolt and then turn the throttle-position sensor itself to make the adjustment after the throttle body was removed.
Page 393 13-251 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components ON VEHICLE INSPECTION OF MFI COMPONENTS COMPONENT LOCATION Name Symbol Name Symbol Air conditioning compressor clutch relay idle air control motor (stepper motor) Air conditioning switch Ignition coil (ignition power transistor) Closed throttle position switch (fixed SAS) Ignition timing adjustment terminal Crankshaft position sensor and camshaft posi-...
Page 394 FUEL SYSTEM <DOHC> Heated oxygen sensor Dower transistor).\...
Page 395 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components switch ___..
Page 396 FUEL SYSTEM <DOHC> control module adjustment terminal - - - - Turbocharger waste gate...
Page 397 FUEL SYSTEM <DOHC> COMPONENTS INSPECTION PROCEDURE- Using Scan Tool Refer to P.13-41. POWER SUPPLY AND IGNITION SWITCH-IG Ignition switch [IG,] Component Harness side connect< injection relay ‘OWE OPERATION the multiport fuel injection relay While the ignition switch is ON, battery power a result, switch is switched ON, and power is supplied, supply is supplied to the engine control module,...
Page 398 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components HARNESS INSPECTION Engine control Measure the ignition switch terminal module harness input voltage. . Engine control module connector: Disconnected . Ignition swatch: ON Repair the harness. (Ignition switch - Measure the power supply voltage of the multioort fuel iniection relav.
Page 399 FUEL SYSTEM <DOHC> - On-Vehicle inspection of MFI Components (1) Remove the multiport fuel injection relay. (2) Use jumper wires and connect multiport fuel injection relay terminal @I to the battery 0 terminal and terminal @I to the battery 0 terminal. Caution Be very careful when connecting the jumper wires because the relay will be damaged if a mistake is made...
Page 400 FUEL SYSTEM <DOHC> FUEL PUMP Fuel pump check terminal Fuel pump connector Ignition switch [IGI Component side I g n i t i o n s w i t c h [r connector Component side connector c o n n e c t o r connector Fuel pump check Engine control module...
Page 401 FUEL SYSTEM <DOHC> - On-Vehicle lnwection of MFI Components INSPECTION Using Scan tool Item No. Actuation Actuator test Actuates fuel . Engine cranking Hold the return hose Pulsation can be felt. pump, circu- . Fuel pump forced between two fingers lating fuel.
Page 402 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components Measure the power supply voltage of connector the multiport fuel injection relay ignition switch. Connector: Disconnected . Ignition switch: START (@a when checked) . Ignition switch: ON (@@ when Check for an open-circuit, or a short- circuit, to ground between the multi- Harness srdc port fuel injection relay and the en-...
Page 403 FUEL SYSTEM <DOHC> - On-Vehicle inspection of MFI Components VOLUME AIR FLOW SENSOR The area enclosed with :I: is injection relay applicable only for Turbo vehicle. (Filter reset circuit) <Turbo> side connector Engine control module @Harness side connector connector Fnnine control module connector Intake air amount OPERATION The power for the volume air flow sensor is...
Page 404 FUEL SYSTEM <DOHC> INSPECTION Using Scan tool Standard value Engine condition Inspection conditions Data display Idling . Engine coolant Data Sensor de- temperature: 85-95°C reading volume (fre- 2,000 rpm . Lights, cooling fan, elec- . Transaxle: neutral (PJT Frequency increases as models: “P”...
Page 405 FUEL SYSTEM <DOHC> < N o n - T u r b o > Check for continuity of the ground circuit of the VAF sensor. . Connector: Disconnected connector Check for continuity between the en- 3 air gine control moduie and volumt UII flow sensor.
Page 406 FUEL SYSTEM <DOHC> OPERATION Note that the resistance of the intake air The intake air temperature sensor functions to temperature sensor decreases when the convert the temperature of the air (intaken to the temperature of the intake air increases. engine) to voltage, and to input that voltage (as * The intake air temperature sensor terminal signals) to the eingine control module.
Page 407 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components < N o n - T u r b o > SENSOR INSPECTION Volume air flow sensor (2) Measure resistance between terminals @ and @. <Non- side connector (3) Er$%e resistance between terminals @ and 0,. <Turbo>...
Page 408 FUEL SYSTEM <DOHC> BAROMETRIC PRESSURE SENSOR <Non-Turbo> <Turbo> air flow sensor connector sensor connector Barometric pressure sensor pressure @Harness side sensor connector control module Output Voltage Engine control module connector 0 Lz Barometric pressure mmHg 760 OPERATION The 5V power supply within the engine control The barometric-pressure sensor functions to module is supplied to the barometric-pressure convert the barometric pressure to voltage, and...
Page 409 FUEL SYSTEM <DOHC> - On-Vehicle inspection of MFI Components INSPECTION Using Scan tool Check conditions Item No. Data display Sensor detec- Data reading tion pressure 710 mmHg At 600 m (1,969 ft.) 660 mmHg At 1,200 m (3,937 ft.) 610 mmHg At I:800 m (5,906 ft.) HARNESS INSPECTION...
Page 410 FUEL SYSTEM <DOHC> - FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components On-Vehicle Inspection of MFI Components ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR Coolant temperature Coolant temperature Coolant temperature Coolant temperature s e n s o r t side Engine coolant temperature o m p o n connector...
Page 411 INSPECTION Using Scan tool Function Coolant temperature Data display Check conditions Standard value Data reading Sensor de- Ignition switch: ON At -20°C (-4°F) Or, engine running At 0°C (32°F) temperature At 20°C (68°F) At 40°C (104°F) At 80°C (176°F) HARNESS INSPECTION Check for continuity of the ground circuit.
Page 412 FUEL SYSTEM <DOHC> INSTALLATION Sensor tightening torque: equivalent to threaded portion. (2) Install engine coolant temperature sensor and (3) Fasten harness connectors securely. tighten it to specified torque. Throttle position sensor connector Engine control module Terminal voltage Throttle shaft turning angle OPERATION The throttle-position sensor functions to convert When the throttle valve shaft is rotated all the...
Page 413 FUEL SYSTEM <DOHC> TROUBLESHOOTING HINTS Hint 1: Hint 2: the voltage of the throttle-position sensor deviates of the signals throttle-position sensor are more important for control of the automatic transaxle than from the standard value, check once again after making the throttle-position sensor adjustment. in for control of the engine;...
Page 414 FUEL SYSTEM <DOHC> SENSOR INSPECTION (1) Disconnect the throttle position sensor connector. Throttle position (2) Measure resistance between terminal @ (sensor ground) sensor connector and terminal @ (sensor power). Standard value: 3.5-6.5 kR (3) Connect a pointer type ohmmeter between terminal @ (sensor ground) and terminal @ (sensor .output).
Page 415 FUEL SYSTEM <DOHC> - On-Vehicle inspection of MFI Components HARNESS INSPECTION Measure the power supply voltage of the throttle position sensor. . Connector: Disconnected . Ignition switch: ON connector Check for continuity of the ground circuit. . Connector: Disconnected Repair the Engine control Check for an open-circuit, or a short- module harness...
Page 416 13-274 FUEL SYSTEM <DOHC> CLOSED THROTTLE POSITION SWITCH <IS89 models> Engine control module Throttle position sensor connector Component side connector Harness side connector Terminal voltage Throttle shaft turning angle OPERATION Voltage within the engine control module is ap- The closed throttle position switch functions to plied, by way of the resistance, to the closed convert (to HIGH/LOW-level voltage) data as to throttle position switch.
Page 417 13-275 FUEL SYSTEM <DOHC> INSPECTION Using Scan tool Throttle valve Normal indication Data display Inspection conditions Function Item No. Data reading 26 Switch status To idle position pumping (Check after accelerator several times.) Slightly opened HARNESS INSPECTION Measure the power supply voltage of the closed throttle position switch.
Page 418 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components CLOSED THROTTLE POSITION SWITCH <From 1990 models> Engine control module voltage Closed throttle Closed throttle position switch position switch terminal Throttle shaft 012092 turning angle OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool Refer to P.13-274.
Page 419 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components CAMSHAFT POSITION SENSOR <Up to 1990 models> injection relay Component side Crankshaft position sensor connector Camshatt posItIon sensor Crankshaft position sensor connector connector Engine control module Time One rotation of crankshaft position sensor OPERATION The power for the camshaft position sensor is The camshaft position sensor functions to de-...
Page 420 13-278 FUEL SYSTEM <DOHC> HARNESS INSPECTION Measure the power supply voltage. Harness side connector Check for continuity of the ground circuit. Connector: Disconnected Repair the harness. Harness connector Ground) Check the output circuit voltage. . Connector: Disconnected Harness side connector TSB Revision...
Page 421 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components CAMSHAFT POSITION SENSOR <From 1991 models> injection relay Crankshaft position sensor I 3 connector Engine control module Output characteristic Time One rotation of crankshaft position sensor OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Oscilloscope Refer to P.13-277.
Page 422 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components C h e c k f o r c o n t i n u i t y o f t h e g r o u n d Harness side circuit.
Page 423 FUEL SYSTEM <DOHC> OPERATION The power for the crankshaft position sensor is The crankshaft position sensor functions to de- supplied from the ignition switch-IG and is tect the crank angle (position) of each cylinder, grounded to the vehicle body. The crankshaft and to convert those data to pulse signals, position sensor, by intermitting the flow (to which are then input to the engine control mod-...
Page 424 FUEL SYSTEM <DOHC> the engine at an idle speed. (2) Connect the probe to the oscilloscope pick-up point as and check the waveform. shown in the circuit diagram, Normal waveform 0310202 HARNESS INSPECTION Measure the power supply voltage. . Connector: Disconnected .
Page 425 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components CRANKSHAFT POSITION SENSOR <From 1991 models> injection relay connector Engine control One rotation of crankshaft position sensor OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool INSPECTION-Using Oscilloscope Refer to P.13-281. HARNESS INSPECTION Measure the power supply voltage. Disconnected .
Page 426: Ignition Switch-St
FUEL SYSTEM <DOHC> Check for continuity of the ground circuit. . Connector: Disconnected Repair the harness. Ground) Check the voltage of the output cir- . Connector: Disconnected . Ignition switch: ON IGNITION SWITCH-ST Refer to P.13-77. IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH Refer to P.13-78.
Page 427 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components AIR CONDITIONING SWITCH AND A/C COMPRESSOR CLUTCH RELAY Sub fusible link 2 Dual pressure switch Air conditioning Engine control module ,(65 1\7 Engine control module connector OPERATION The air conditioning switch applies battery vol- When the air conditioning signals are input, the tage to the engine control module when the engine control module activates the idle air con-...
Page 428 FUEL SYSTEM <DOHC> INSPECTION Using Scan tool Air conditioning switch Normal display Air conditioning switch Check conditions Data display Item No. Function Switch status . Engine idling Data reading 28 (The air conditioning compressor should be activated when the air conditioning switch is switched ON.) Air conditioning compressor clutch relay...
Page 429 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components KNOCK SENSOR <Turbo, Non-Turbo From 1992 models> Engine control module connector I it’ s e n s o r ! T connector OPERATION control module. The knock sensor converts cylinder block vibrations The engine control module controls the delay in due to knocking into voltage according to the spark timing according to this signal.
Page 430 On-Vehicle Measure the terminal voltage. . Connector: Disconnected connector 1 FU0513 C h e c k f o r c o n t i n u i t y o f t h e g r o u n d circuit.
Page 431 13-289 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components OPERATION The EGR temperature sensor functions to con- ture sensor decreases when the EGR gas vol- vert the data regarding the temperature of the ume increases and the temperature of the EGR gas downstream from the EGR valve to gas increases.
Page 432 FUEL SYSTEM <DOHC> to 1990.5 model-Non-Turbo, Turbo> HEATED OXYGEN SENSOR <Up Heated oxygen . sensor Component side injection relay sensor connector Engine control module x4H106 connector Theoretical A/F OPERATION The heated oxygen sensor functions to detect The engine control module, based upon those the concentration of oxygen in the exhaust gas;...
Page 433 FUEL SYSTEM <DOHC> - On-Vehicle inspection of MFI Components INSPECTION Using Scan tool Item No. Data display Inspection conditions Engine condition Standard value Function Data reading Engine: warm up When sudden decel- 250 mV or lower Sensor de- tection vol- (Make the mixture lean eration from 4,000 rpm tage...
Page 434 FUEL SYSTEM <DOHC> SENSOR INSPECTION (1) Disconnect the heated oxygen sensor connector, and con- nect the special tool (harness connector) to the heated ox- ygen sensor side. (2) Check that there is continuity [approx. 1252 at 20°C (68”F)] oxygen sensor between heated oxygen sensor connector terminal @ (red side connec clip of special tool) and terminal @ (blue clip).
Page 435 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components HEATED OXYGEN SENSOR <From 1991 model-Non-Turbo> Heated oxygen sensor injection relay sensor connector Engine control module connector Engine control module connector OPERATION TROUBLESHOOTING HINTS INSPECTION-Using Scan tool Refer to P.1.3-290. HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor.
Page 436 FUEL SYSTEM <DOHC> - On-Vehicle Inspection of MFI Components Engine Check for an open-circuit or a short- control mod& circuit to ground, between the engine harness side connector control module and the heated oxy- gen sensor. . Heated oxygen sensor connec- tor: Disconnected .
Page 437 13-295 FUEL SYSTEM <DOHC> - The area enclosed with ~~~~ is applicable onlv for Turbo. connector Filter Connector Engine Solenoid coil module Plunger Engine control module connector Needle valve -&$ OPERATION injection of the injectors is cut off in sequence, injectors length of time that the needle valve is open, or, equipped injection nozzles that function to inject...
Page 438 13-296 INSPECTION Using Scan tool Inspection conditions Engine coolant temperature Standard value Function Item No. Data display Approx. 17 ms <Non-Turbo> At 0°C (32”F)*2 Data Approx. 40 ms <Turbo> reading At 20°C (68°F) Approx. 38 ms <Non-Turbo> Approx. 19 ms <Turbo> At 80°C (176°F) Approx.
Page 439 FUEL SYSTEM <DOHC> - Measure the power supply voltage of the injector. . Resistor connector: Connected connector <Turbo> . Injector connector: Disconnected . Ignition switch: ON module harness side connecror ACTUATOR INSPECTION INJECTOR CHECKING OPERATION SOUND Using a sound scope, check the operation sound (“chi-chi-chi”) of injectors during idling or during cranking.
Page 440: Resistor
FUEL SYSTEM <DOHC> RESISTOR <Turbo> MEASURING RESISTANCE BETWEEN TERMINALS (1) Disconnect the resistor connector. (2) Measure the resistance between the terminals. Standard value: Resistance (52) Measurement terminals t %$%&)I (3) If the resistance deviates from the standard value, replace the resistor. IDLE AIR CONTROL MOTOR (STEPPER MOTOR) injection relay motor)

Page 441 13-299 FUEL SYSTEM <DOHC> - OPERATION The amount of air taken in during idling is Battery power supply is supplied, by way of the regulated by the opening and closing of the stepper motor. The engine control module servo valve located in the air passage that switches ON the power transistors (located bypasses the throttle valve.
Page 442 FUEL SYSTEM <DOHC> HARNESS INSPECTION the power supply Measure the idle air control motor. . e Idle air control motor connec- tor: Disconnected . Ignition switch: ON connector Check for an open-circuit, or a short- circuit to ground, between the engine control module and idle air control motor.
Page 443 FUEL SYSTEM <DOHC> Operational Check models> d (1) Remove the throttle body. control motor (2) Remove the stepper motor (stepper motor) <From 1990 models> (3) Connect the special tool (Test harness) to the idle air con- trol motor connector. (4) Connect the positive (+) terminal of a power supply (approx.
Page 444 FUEL SYSTEM <DOHC> IGNITION COIL AND IGNITION POWER TRANSISTOR <I989 models> connector connector Ignition No 2 No.3 No 4 No 1 adjustment Engine control module connector 01 LO838 OPERATION When ignition power transistor unit A is When the engine control module switches OFF switched ON by signals from the engine control the power transistor inside the unit, battery vol- module, primary current flows to ignition coil A.
Page 445 FUEL SYSTEM <DOHC> - INSPECTION Using Scan tool Function Item No. Data display Inspection conditions Engine condition Standard value Data reading 44 Ignition . Engine: warm 750 rpm (idling) 5-15” BTDC advance . Timing light: set (Use the timing light to 32 - 4 1 “BTDC check the actual ignition 2,000 rpm...
Page 446 Check for an open-circuit, or a short- circuit to around, between the iani- c o i l . Harness side connector . Ignition power transistor connec- tor: Disconnected Check for continuity of the ground circuit. Harness side Repair the harness. Ground) Measure the voltage of the control signal circuit of the ignition power...
Page 447 IGNITION COIL AND IGNITION POWER TRANSISTOR <From 1990 models> Battery connector connector connector Spark control module Engine control module connector INSPECTION Using Scan tool Refer to P.13-302. Standard value Engine condition Data display Inspection conditions Item No. Function...
Page 448 FUEL SYSTEM <DOHC> HARNESS INSPECTION Measure the power supply voltage of the ignition coil. . Connector: Disconnected . Ignition switch: ON Measure the power supply voltage of the ignition coil. . Connector: Disconnected Harness side . ignition switch: ON Harness control module and the ignition power transistor.
Page 449: Fuel Pressure Solenoid
FUEL SYSTEM <DOHC> - Measure the voltage of the control signal circuit of the ignition power transistor. Harness side Measure the voltage of the ignition timing adjustment terminal. Ignition timrng . Ignition switch: ON adjustment connector ACTUATOR INSPECTION Refer to GROUP 16-Ignition System. EVAPORATIVE EMISSION PURGE SOLENCI!,D,,.

Page 450 FUEL SYSTEM <DOHC> OPERATION The fuel pressure solenoid is an ON-OFF type of solenoid valve and changes pressure fed into temperature (approximately 50°C (122°F) or the fuel pressure regulator to intake manifold more) are high when the engine is started, fuel pressure and barometric pressure.
Page 451: Turbocharger Waste Gate Solenoid
FUEL SYSTEM <DOHC> - ACTUATOR INSPECTION Operation inspection NOTE When removing the vacuum hose, make a mark so that it can later be installed in the original connecting position. solenoid valve. (3) Apply a negative pressure in the nipple to which the black vacuum hose is connected with a hand vacuum pump and check that it is airtight when voltage is applied to the solenoid valve terminal and when not applied.

Page 452 FUEL SYSTEM OPERATION module The turbocharger waste gate solenoid is an ON- the unit, turns on the power transistor inside OFF type solenoid valve and controls the leaking current flows to the coil and some overboost of overboost pressure that is fed to the turbo- pressure that is fed to the turbocharger waste charger waste gate actuator.
Page 453: Boost Meter
FUEL SYSTEM <DOHC> - 13-311 BOOST METER <Turbo> Ignition switch (IG,) meter Boost meter Engine control module connector HARNESS INSPECTION Measure the power supply voltage. connector . Connector: Disconnected . Ignition switch: ON Voltage (VI Repair the harness. Engine Check for an open-circuit or a short- control circuit to ground, between the engine module...

Page 454 13-312 FUEL SYSTEM <DOHC> FUEL PRESSURE TEST Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. (3) Remove the throttle body stay. (4) Place the MD998742-01 adapter on the end of the fuel rail, then attach the fuel high pressure hose to the adapter using the bolts supplied with the MIT210196 fuel pressure test assembly.
Page 455 13-313 FUEL SYSTEM <DOHC> - regulator, and then measure the fuel pressure while using a finger to plug the end of the hose. Standard value: not decrease even after the engine is raced a few times. repeatedly racing the engine, and check to be sure that there is fuel pressure in the return hose also.
Page 456 13-314 FUEL SYSTEM <DOHC> - indicated by the fuel pressure gauge. The condition is normal if there is no decrease of the indicated value within two minutes. If there is a decrease of the indicated value, monitor the speed of the decrease, and, referring to the table below, determine the cause of the problem and make the appropriate repair.
Page 457 13-315 FUEL SYSTEM <DOHC> - INSPECTION OF ENGINE CONTROL TERMINAL VOLTAGE Refer to P.13-105. TERMINAL VOLTAGE CHECK CHART Terminal arrangement of engine control module connector NOTE: Standard Terminal Remarks Check condition (Engine state) Check item v a l u e Ignition switch: OFF Backup power Ignition switch: ON...
Page 458 13-316 Terminal Standard Remarks Check item Check condition (Engine state) value Throttle positron Ignition switch: It Set the throttle valve to the sensor seconds or more Fully open the throttle valve. Set the throttle valve to the idling Closed throttle switch: position.
Page 459 FUEL SYSTEM <DOHC> - Terminal Check item Standard Check condition (Engine state) Remarks value Ignition power Engine speed: 3.000 rpm transistor unit Evaporative Ignition switch: ON emission purge solenoid Keep the engrne speed at 3.000 rpm after the warmed-up engine is started, Fuel pressure solenoid Engine: Cranking - Idling...
Page 460 13-318 FUEL TANK INSTALLATION Removal steps 2. Drain plug + 3. Return hose Vapor hose 5. Fuel gauge unit connector 6. Electrical fuel pump connector 4 7. High pressure hose to fuel pump connection 12. Tank band 13. Fuel tank Caution + 15.
Page 461 13-319 FUEL SYSTEM <DOHC> - Fuel Tank <MID> INSPECTION Check the hoses and the pipes for crack or damage. Check the fuel tank filler tube cap for malfunction. Check the fuel tank for deformation, corrosion or crack. Check the fuel tank for dust Qr foreign material. NOTE If the inside of the fuel tank is to be cleaned, use any one of the following:...
Page 462 FUEL SYSTEM <DOHC> - Fuel Tank HOSE VAPOR HOSE/8. FILLER CONNECTION OF tank, and approximately 40 mm (1.6 in.) at the fuel tank filler tube. (2) The end of the filler hose with the shorter straight pipe part should be connected at the tank side. hose in.) Filler...
Page 463 13-321 FUEL SYSTEM <DOHC> - Fuel Tank <FWD> (8) Remove the fuel pump installation screws and the bolt for holding the fuel pump (at the lower side of the fuel tank), and then remove the fuel pump from the fuel tank. (9) Align the three positioning projections of the packing with the holes in the fuel pump.
Page 464: Fuel Tank
13-322 FUEL SYSTEM <DOHC> - Fuel Tank FUEL TANK <AWD> REMOVAL AND INSTALLATION @Release of Residual Pressure from High Sealant: or equivalent 22-29 ftlbs. 22-29 ftlbs. 21-31 N/m 15-22 ftlbs. Removal steps 2. Drain plug 1 7 - 2 6 3.

Page 465 <DOHC> 13-323 FUEL SYSTEM FUEL PUMP AND GAUGE ASSEMBLY REPLACE- MENT (1) Remove the protectors. (2) Disconnect the fuel pump and gauge assembly harness connector, and then remove the hole cover. (3) Bleed the remaining pressure from the fuel pipe line to prevent fuel discharge.
Page 466: Fuel Line And Vapor Line
FUEL SYSTEM <DOHC> FUEL LINE AND VAPOR LINE <FWD> REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation *Measurement of Fuel Pressure @Removal of the Battery Tray (Refer to GROUP 54-Starter Motor) *Release of Residual Pressure from High *Installation of the Battery Tray Pressure Fuel Hose (Refer to GROUP 54-Starter Motor) (Refer to P.13-312.)

Page 467 13-325 FUEL SYSTEM <DOHC> SERVICE POINTS OF REMOVAL 1. REMOVAL OF EYE BOLT Remove the eye bolt while holding the fuel filter nut securely. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.
Page 468: Fuel Line And Vapor Line
FUEL SYSTEM <DOHC> - Fuel Line and Vapor tine <AWD> FUEL LINE AND VAPOR LINE <AWD> REMOVAL AND INSTALLATION Pre-removal Operation *Removal of the Battery Tray (Refer to GROUP 54-Starter Motor) *Release of Residual Pressure from High *Installation of the Battery Tray Pressure Fuel Hose (Refer to GROUP 54-Starter Motor.) (Refer to P.13-312.)

Page 469 FUEL SYSTEM <DOHC> FUEL FILTER REMOVAL AND INSTALLATION 25-35 Nm 18-25 ft.lbs. Pre-removal Operation from High Pressure Fuel Hose (Refer to P.l3-312.) Post-installation Operation *Measurement of Fuel Pressure (Refer to P.13-312.) Fuel filter removal steps 2. O-ring 3. Connection for high pressure fuel hose 4.
Page 470: Engine Control
ENGINE CONTROL ENGINE CONTROL SPECIFICATIONS SERVICE SPECIFICATIONS Specifications Standard value Accelerator cable play mm (in.) 3 - 5 (.12-,201 Accelerator switch switching point mm (in.) 4 - 8 (.16-,311 TORQUE SPECIFICATIONS 6 - 9 Accelerator arm bracket to body 8-12 3 - 4 4 - 6 Throttle body side inner cable to intake manifold plenum...
Page 471 ENGINE CONTROL 13-329 SERVICE ADJUSTMENT PROCEDW,E,t& ACCELERATOR CABLE INSPECTION AND ADJUSTMENT For models equipped with the auto-cruise control system, refer to P. 13-398. (1) Confirm there are no sharp bends in accelerator cable. (2) On models with an SOHC engine, turn the ignition switch to the ON position (without starting the engine) and leave in that condition for approximately 15 seconds.
Page 472 ENGINE CONTROL - Engine Control ENGINE CONTROL REMOVAL AND INSTALLATION Post-installation Operation Adjustment *Accelerator Cable 4-6 Nm 4-6 Nm 3-4 ft.lbs.\ Sealant: or equivalent 6 - 9 ft.lbs. Removal steps l + 8. Accelerator arm bracket 2. Throttle body side inner cable 9.
Page 473 ENGINE CONTROL INSPECTION Check the inner and outer cable for damage. Check the cable for smooth movement. Check the accelerator arm for bending. Check the return spring for deterioration. Check the connection of bushing to end metal fitting. Check the accelerator switch for ON/OFF switching. SERVICE POINTS OF INSTALLATION 8.
Page 474 AUTO-CRUISE CONTROL SYSTEM - Specifications AUTO-CRUISE CONTROL SYSTEM GENERAL SPECIFICATIONS Specifications Items Auto-cruise control switch Rated load Main RESUME Voltage drop Stop light switch Rated load Voltage drop (at rated load) Clutch pedal position switch Rated load Voltage drop (at rated load) km/h (mph) Set error Range of speed control...
Page 475 AUTO-CRUISE CONTROL SYSTEM - Specifications/Special Tools 13-333 TORQUE SPECIFICATIONS Items Electrical type Auto-cruise control actuator protector 4 - 6 3 - 4 9-14 Actuator bracket 4 - 6 3 - 4 Accelerator cable plate Vacuum type 4 - 6 3 - 4 Link protector 9-14 Link assembly...
Page 476 AUTO-CRUISE CONTROL SYSTEM TROUBLESHOOTING <Electrical type: Up to 1990 models> The auto-cruise control system performs control functions for the setting or cancellation of the fixed-speed driving speed bas- ed upon the data provided by input signals. As a result, when the auto-cruise control system is canceled, the cause of the cancellation is memorized in a separate circuit by the ECU, regardless of whether or not the auto-cruise control system...
Page 477 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting NOTE If. after the occurrence of the problem, the ignition switch and Auto-cruise control system cannot be set. the main switch have not been switched OFF, it is possible to determine (by checking the on-board diagnostic output code) Prepare to conduct input check.
Page 478 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting Probable cause Malfunction of the ve- Repair the vehicle speec The set vehicle speed varies sensor system, or re- greatly upward or downward. place the part. “Hunching” (repeated alternating acceleration and deceleration) oc- Malfunction of the spee- curs after setting is made.
Page 479 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting Trouble symptom Probable cause Check chart No. Remedy Cannot decelerate by using the Repair the harness or Temporary damaged No. 2 SET switch or disconnected wir- replace the SET ing of SET switch switch. Actuator circuit poor No.
Page 480 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 13-338 Check chart No. Remedy Trouble symptom Probable cause Repair the harness or Malfunction of control function by Malfunction of circuit No. 7 replace the part. ON/OFF switching of ELC 4 A/T related to accelerator switch OFF function accelerator switch (Non-operation of torque converter...
Page 481 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CHECK CHART 1. CHECKING THE CONTROL UNIT POWER SUPPLY CIRCUIT Ignition switch Description of operation fuse no. (9) of the junction block, and to the cruise- When the “MAIN” switch (of the cruise-control’s control switch, the control unit, and to ground. switches) is switched ON while the ignition switch is ON, current flows to the ignition switch (IGl), to Troubleshooting hint...
Page 482 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 2. CHECKING THE SET SWITCH CIRCUIT Description of operation switch is pressed and held while the vehicle is SET switch is switched ON (at the W h e n t h e set constant speed, and, traveling at the previously vehicle speed desired to be maintained, and with when the SET switch is released, tne vehicle then...
Page 483 AUTO-CRUISE CONTROL SYSTEM 3. CHECKING THE RESUME SWITCH CIRCUIT RESUME Terminal Terminal voltage Conditions Signal RESUME switch When the RESUME switch is siitched ON When the RESUME switch switched Revision...
Page 484 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 4. CHECKING THE VEHICLE-SPEED SENSOR CIRCUIT Combination meter Description of operation type This vehicle-speed sensor is the reed switch The vehicle-speed sensor is installed within the of sensor; it generates four pulse signals for each speedometer;...
Page 485 AUTO-CRUISE CONTROL SYSTEM 5. CHECKING THE ACTUATOR CIRCUIT clutch coil Clutch @at’! To junction block fuse No. (9) Main Sun <ear Worm gear control To junction block switch fuse No. (9) Actuator (LG) Diode Actuator NOTE NC: ON at all times NO: OFF at all times TSB Revision...
Page 486 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting Description of operation DC motor reversing the direction of current flow to the motor, and this is automatically regulated by switches ON the SET switch when the pre- the control unit. scribed vehicle speed is reached, the control 4.
Page 487 AUTO-CRUISE CONTROL SYSTEM Battery NOTE (GO) : at all times NC: ON NO: OFF at all times stop Description of operation sending of the cancel signal to the control unit, so When the brake pedal is depressed during con- that the actuator’s electromagnetic clutch current stant-speed travel, the stop light switch’s ( N C ) is discontinued within the control unit, thereby contacts for the cruise-control system open, with...
Page 488 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 3 pry Park/neutral position switch Starter motor Description of operation to the control unit, park/neutral position switch, The park/neutral position switch also functions as starter motor, and to ground; the cancel signal is the switch for the starter. therefore input to the control unit, thus canceling If the selector handle is moved to the “N”...
Page 489 AUTO-CRUISE CONTROL SYSTEM 6-3. CHECKING THE CLUTCH PEDAL POSITION SWITCH CIRCUIT <M/T> Ignition switch Junction block NOTE NO: OFF at all time Description of operation the actuator is discontinued within the control If the clutch pedal is depressed during constant- unit, thereby canceling the constant-speed travel.
Page 490 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 7. CHECKING THE CIRCUITS RELATED TO THE ACCELERATOR SWITCH OFF FUNCTION <A/T> Ignition switch Junction block 4 A/T control module NOTE NC: ON at all time ground circuit (transistor Tr2) of the accelerator The accelerator switch is a switch that detect-s the switch is switched OFF only during constant-speed operational status of the accelerator pedal;...
Page 491 13-349 AUTO-CRUISE CONTROL SYSTEM 8. CHECKING THE CIRCUITS RELATED TO THE OVERDRIVE-CANCELLATION FUNCTlON <A/T> Ignition switch <IG2> 4 A/T control module Description of operation This is a function that cancels the overdrive Under either of the conditions described above, function for a certain fixed period of time, if during the overdrive-ON signals output from the micro- computer (within the control unit) are no longer constant-speed travel in overdrive, the actual vehi-...
Page 492 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting The auto-cruise control system performs control functions for the setting or cancellation of the fixed-speed driving speed based upon the data provided by input signals. As a result, when the auto-cruise control system is canceled by abnormal system operation, the cause of the cancellation is memorized in a separate circuit by the ECU, thus providing the ECU with the on-board diagnostic function by certain fixed patterns, as...
Page 493 AUTO-CRUISE CONTROL SYSTEM NOTE This chart is to be used, then, for troubleshooting if it is not Auto-cruise control system cannot be set. possible to use the on-board diagnostic for checking. Prepare to conduct input check. Where codes No.21, 22, 23, 25 and 26, Damaged or disconnected wiring of the ECU power-supply cir- displayed when, with the vehicle stationary, Damaged or disconnected wiring of the SET or RESUME...
Page 494 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting Trouble symptom Probable cause Check chart No. Remedy The set vehicle speed varies Malfunction of the ve- Repair the vehicle spee greatly upward or downward. sensor system, or re- “Hunching” (repeated alternating place the part. acceleration and deceleration) oc- curs after setting is made.
Page 495 AUTO-CRUISE CONTROL SYSTEM Trouble symptom Probable cause Check chart No. Remedy Cannot accelerate or resume speed Damaged or discon- Repair the harness or by using the RESUME switch. replace the RESUME circuit, of RESUME switch. switch input circuit No. 5 Auto-cruise vacuum Repair the harness or pump circuit poor con-...
Page 496 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CHECK CHART 1. CHECKING THE CONTROL UNIT POWER SUPPLY CIRCUIT Description of operation When the cruise control switch (CRUISE) is switched ON while Ignition the ignition switch is ON, current flows to the ignition swrtch switch (IG,), to fuse No.(ll) of the junction block, and to the cruise-control switch (MAIN switch), the control unit, and to...
Page 497 AUTO-CRUISE CONTROL SYSTEM 3. CHECKING THE RESUME SWITCH CIRCUIT Description of operation The set speed (before cancellation) resumes when the RE- SUME switch is swrtched ON, even if the constant-speed control has been cancelled. That speed will not resume, however, even if the RESUME switch is switched ON, if the CRUISE switch is switched OFF and if the vehicle speed decreases to 40 km/h (25 mph) or lower.
Page 498 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 5. CHECKING THE AUTO-CRUISE CONTROL VACUUM PUMP Description of operation Hold mode When the SET switch is turned ON by the driver turning the CRUISE switch ON when a determined speed is reached, the control unit receives a set signal, and turns the auto-cruise vacuum pump motor ON.
Page 499 AUTO-CRUISE CONTROL SYSTEM 6. CHECKING THE STOP LIGHT SWITCH CIRCUIT Description of operation When the brake pedal is depressed during constant-speed travel, the stop light swrtch’s (NC) contacts for the cruise- control system open, with the result that the current to the auto-cruise vacuum pump is interrupted, thus canceling the Sub fusible link @ constant-speed travel.
Page 500 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 8. CHECKING THE CLUTCH PEDAL POSITION SWITCH CIRCUIT <M/T> Description of operation If the clutch pedal is pressed when driving at a constant speed, the clutch pedal position switch is turned ON and a cancel signal is input to the control unit and the determined driving speed is canceled because current flows to the clutch pedal position switch junction block from the control unit and to ground.
Page 501: Auto-Cruise Control
AUTO-CRUISE CONTROL SYSTEM - Troubleshootina 10. CHECKING THE CIRCUITS RELATED TO THE OVERDRIVE-CANCELLATION FUNCTION <A/T> Description of operation This is a function that cancels the overdrive function for a certain fixed period of time, if during constant-speed travel in overdrive, the actual vehicle speed decreases to less than the time causes the vehicle speed to return to the vehicle speed retained in the memory.
Page 502 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 11. CHECKING THE THROTTLE POSITION SENSOR AND CLOSED THROTTLE POSITION SWITCH CIRCUIT Description of operation <DOHC Engine> The throttle position sensor and closed throttle position switch control unit in the idle speed control motor position sensor Or throttle body and are sensors in the MFI system.
Page 503 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting ON-BOARD DIAGNOSTIC CHECK On-board diagnostic checking is performed when there has been an automatic cancellation, without cancel switch opera- tion. diagnostic. Note that the data link connector is located under the driver’s side instrument panel. Connect the scan tool’s socket and connector to the cigarette lighter socket and the data link connector, and set the tester.
Page 504 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting DIAGNOSTIC DISPLAY PATTERNS AND TROUBLE CODES Code Display patterns (output codes) Probable cause Check chart No. (use with voltmeter) Abnormal condition of actuator drive system <Electrical type> Abnormal condition of auto-cruise vacuum pump drive system <Vacuum type> Abnormal condition of vehicle-speed signal No.
Page 505 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting After the diagnostic trouble codes in the memory are erased, if (when the power supply of the electronic control unit is switched ON once again) the power supply of the electronic control unit is normal, the on-board diagnostic output code display will be as below, regardless of whether the system condition is normal or not.
Page 506 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting INPUT CHECK TABLE Check results Display patterns (output codes) Input operation Code (use with voltmeter) SET switch ON RESUME switch circuit RESUME switch ON normal <Electrical type> <Electrical type> Each cancel circuit nor- Each cancel switch ON 1.
Page 507: Auto-Cruise Control Related Harnesses
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting AUTO-CRUISE CONTROL RELATED HARNESSES <ENGINE COMPARTMENT> <INSIDE THE CABIN> 7 - Clutch pedal position switch 14 - Overdrive switch 2 - Park/neutral position switch 8 - Column switch 15 - Control harness and body harness coupling 9 - lgnrtion switch 3 - Actuator <Up to 1990 models>, 16 - Control harness and body harness Coupling...
Page 508 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting <Engine> SOHC <Up to 1992 models> DOHC [Front side view1 19 - Throttle position sensor 20 - Idle speed control motor position sensor 21 - Closed throttle position switch 22 - Throttle position sensor (Closed throttle position switch) TSB Revision...
Page 509 AUTO-CRUISE CONTROL SYSTEM - Troubleshootinn LOCATION OF CONTROL UNIT GROUND POINT JUNCTION BLOCK p-;a Front harness Roof harness Instrument panel harness Body harness Heater fuses) TSB Revision...
Page 510 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting AUTO-CRUISE CONTROL COMPONENTS LOCATION NOTE The “Name” column is arranged in alphabetical order. <Engine compartment> SOHC DOHC <Interior> TSB Revision...
Page 511 AUTO-CRUISE CONTROL SYSTEM (Reed switch) < F r o m 1 9 9 0 models> ‘\ I 1. TSB Revision...
Page 512 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting 1750407 Accelerator pedal switch TSB Revision...
Page 513 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM IGNITION WITCH(IG1) SUB FUSIB LINK Q AUTO-CRUISE CONTROL UNIT COLUMN SWITCH TSB Revision...
Page 514 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <M/T (1989 models)> AUTO CRUISE CONTROL ACTUATOR AUTO-CRUISE CONTROL UNIT METER 9 c-50 OPEN CONNEC- STOP LIGHT SWITCH J/B-- " 4 STOP LIGHT I 2 I Revision...
Page 515 AUTO-CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM IGNITION SWITCH(IG1) SUB FUSIB CLUTCH PEDAL AUTO-CRUISE CONTROL UNIT' COLUMN SWITCH AUTO-CRUISE CONTROL SWITCH 16 17 - - - _--_-_ ACTUATOR...
Page 516: Control System
CONTROL SYSTEM AUTO-CRUISE CIRCUIT DIAGRAM (CONTINUED) <M/T (1990 models)> AUTO CRUISE CONTROL ACTUATOR AUTO-CRUISE CONTROL UNIT DIODE OPEN CONNEC STOP LIGHT SWITCH STOP LIGHT TSB Revision...
Page 517 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM <M/T (1991 models)> AUTO-CRUISE CONTROL UNIT COLUMN GWITCH CONTROL GWITCH ----- -_ I CRUISE CONTROL TSB Revision...
Page 518 AUTO-CRUISE CONTROL SYSTEM - Trotibleshooting CIRCUIT DIAGRAM (CONTINUED) <M/T (1991 models)> AUTO-CRUISE CONTROL UNIT STOP ' LIGHT SWITCH AUTO-CRUISE CONTROL UNIT STOP LIGHT FRONT 8JDE REVERSE SIDE TSB Revision...
Page 519 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting AUTO-CRUISE CONTROL UNIT IDLE SPEED CONTROL MOTOR POSITION SENSOR Revision...
Page 520 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM <M/T (1992 models)> IGNITION J/E! UTO-CRUISE ONTROL UNIT “12 CLUTCH COLUMN EWITCH CONTROL SWITCH 4 _---- TSB Revision...
Page 521 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting SWITCH AUTO-CRUISE CONTROL UNIT AUTO-CRUISE CONTROL UNIT STOP LIGHT FRONT BIDE...
Page 522 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <M/T (1992 models)> AUTO-CRUISE CONTROL UNIT IDLE SPEED CONTROL MOTOR POSITION SENSOR POSITION “1 CONTROL UNIT Revision...
Page 523 AUTO-CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM <M/T (1993 models)> SUB FUSIBI AUTO-CRUISE CONTROL UNIT TSB Revision...
Page 524 AUTO-CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM (CONTINUED) <M/T (1993 models)> COLUMN SWITCH AUTO-CRUISE CONTROL UNIT 14 "22 39 STOP - LIGHT SWITCH 06 0. 1 < AUTO-CRUISE CONTROL UNIT STOP LIGHT REVERSE SIDE Revision...
Page 525 AUTO-CRUISE CONTROL SYSTEM ------- J,7 c-07-1 "CLOSED c- 12 CONTROL UNIT Revision...
Page 526 13-384 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM <A/T (1989 models)> 3 10 OD OFF INDICATOR LIGHT AUTO-CRUISE CONTROL UNIT 1 B-19 DATA LINK CONNECTOR STARTER= MOTOR TSB Revision...
Page 527 AUTO-CRUISE CONTROL SYSTEM IGNITION SWITCH (1Gl) SUB FUSIf - 4 - 5 COLUMN SWITCH AUTO-CRUISE CONTROL SWITCH ) CRUISE CONTROL ACTUATOR DIODE OPEN CONNECTOR STOP I ,IGH TSB Revision...
Page 528 13-386 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM OVER DRIVE opj SWITCH OD OFF. INDICATOR LIGHT PARK/NEUTRAL AUTO-CRUISE CONTROL UNIT BATTERY c- 18 DATA LINK CONNECTOR STARTER MOTOR...
Page 529 13-387 AUTO-CRUISE CONTROL SYSTEM IGNITION SWITCH (IGl) SUB FUSII AUTO-CRUISE CONTROL UNIT OPEN CONNECTOR STOP TSB Revision...
Page 530 13-388 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM <A/T (1991 models)> I zc OD OFF INDICATOR LIGHT AUTO-CRUISE CONTROL UNIT 24 C-0';' DATA LINK CONNECTOR TSB Revision...
Page 531 AUTO-CRUISE CONTROL SYSTEM 13-389 IGNITION AUTO-CRUISE CONTROL UNIT CRUISE PUMP OPEN CONNECTOR AUTO-CRUISE CONTROL UNIT STOP LIGHT...
Page 532 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <A/T (1991 models)> AUTO-CRUISE CONTROL UNIT - _ _ _ _ _ _ _ - I - - - - - - - - - I - - CONTROL UNIT TSB Revisio,n...
Page 533 13-391 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM <A/T (1992 models)> IGNITION OD OFF INDICATOR LIGHT 'ARK/NEUTRAL AUTO-CRUISE CONTROL UNIT BATTERY 24 C-0; DATA LINK CONNECTOR REVERSE SIDE TSB Revision...
Page 534 13-392 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <A/T (1992 models)> SUB FUSIBI AUTO-CRUISE CONTROL UNIT AUTO-CRUISE CONTROL UNIT STOP LIGHT TSB Revision...
Page 535 AUTO-CRUISE CONTROL SYSTEM...
Page 536 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (A/T (1993 models)> OD OFF INDICATOR I el PARK/NEUTRAL LIGHT AUTO-CRUISE CONTROL UNIT BATTERY STARTER MOTOR Revision...
Page 537 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting IGNITION SUB FUSIB LE ~ LINK@ AUTO-CRUISE CONTROL UNIT 1 J/ B ;a LIGHT OPEN AUTO-CRUISE CONTROL UNIT STOP LIGHT TSB Revision...
Page 538 AUTO-CRUISE CONTROL SYSTEM - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <A/T (1993 models)> CLOSED THROTTLE 0 "4 CONTROL UNIT...
Page 539 AUTO-CRUISE CONTROL SYSTEM SERVICE ADJUSTMENT PROCEDU$$jF AUTO-CRUISE CONTROL SYSTEM INSPECTION AUTO-CRUISE CONTROL MAIN SWITCH CHECK (2) Check to be sure that the indicator light within the switch illuminates when the main switch is switched ON. AUTO-CRUISE CONTROL SETTING CHECK (1) Switch ON the main switch. (2) Drive at the desired speed within the range of approxi- mately 40-145 km/h (25-90 mph).
Page 540 13-398 AUTO-CRUISE CONTROL SYSTEM AUTO-CRUISE CONTROL CANCELLATION CHECK (1) Set the auto-cruise control. a return to ordinary driving, (2) Check to be sure that there is and that the illumination of the auto-cruise indicator stops, when either of the operations below is performed. C H E C K O F R E T U R N T O T H E S E T S P E E D B E F O R E CANCELLATION (1) Set the auto-cruise control.
Page 541 AUTO-CRUISE CONTROL SYSTEM Accelerator cable B loosening the adjustment bolts at the intake manifold plenum side and freeing the inner cable, use the adjust- Intake manifold plenum ment bolts to secure the plate so that the free play of the inner cable becomes the standard value. Standard value: l-2 mm (.04-.08 in.) NOTE If there is excessive play of the accelerator cable, the...
Page 542 AUTO-CRUISE CONTROL SYSTEM Adjusting nut B Throttle cable (1) Remove the link protector. (Refer to P.13-402.) (2) Check that there are. no sharp bends and breaks in the accelerator cable, throttle cable and auto-cruise control cable. (3) Turn the ignition switch to the ON position (without starting the engine) and leave in that condition for approximately 15 seconds.
Page 543 AUTO-CRUISE CONTROL SYSTEM INDIVIDUAL PARTS INSPEtiTION AUTO-CRUISE CONTROL SWITCH INSPECTION (1) Remove the instrument under cover and the lower column cover. (2) Disconnect the column switch connector and check the continuity between the terminals. C-O: continuity SET swttch ON RESUME switch ON <From 1990 models>...
Page 544 AUTO-CRUISE CONTROL SYSTEM PARK/NEUTRAL POSITION SWITCH (“N” AND “P” POSITIONS) INSPECTION (2) Check to be sure that there is continuity ,between connector terminals 8 and 9 when the shift lever moved to the “N” range. ACTUATOR INSPECTION <Electrical type: Up to 1990 models>...
Page 545 AUTO-CRUISE CONTROL SYSTEM ( 2 ) C h e c k i n g t h e m o t o r ( P U L L d i r e c t i o n ) a n d l i m i t s w i t c h operation In the condition described in (1).
Page 546 AUTO-CRUISE CONTROL SYSTEM ( 3 ) C h e c k i n g t h e m o t o r ( R E L . d i r e c t i o n ) a n d l i m i t s w i t c h operation Reverse the connections to terminal (4) and terminal from those described in (2).
Page 547 AUTO-CRUISE CONTROL SYSTEM CIRCUIT ELECTRONIC CONTROL UNIT (ECU) SIGNAL connector terminals CHECK <Electrical type: Up to 1990 models> Disconnect the connector of the ECU, and then check at the body side wiring harness according to the chart below. MAIN SW: Main switch OD SMI: Overdrive switch Tester con- Check conditions...
Page 548 AUTO-CRUISE CONTROL SYSTEM - Service Connection of mea- Check conditions Standard Termi- sured part ment item 1 connection Continuity Park/neutral position Continuity switch (P, N) Other than “P” or “N” range No continui- Stop light switch Voltage At all times power supply side Clutch pedal position Voltage...
Page 549 AUTO-CRUISE CONTROL SYSTEM AUTO-CRUISE CONTROL VACUUM PUMP INSPECTION <Vacuum type: From 1991 models> Inspection of solenoid valves (control valve, release valve) connector. (1) Remove the auto-cruise control vacuum pump terminals 0-0 (2) Measure the resistance value between and between 0-0. Standard value: 50-60 Q (3) Check that the solenoid valve makes an operating noise when batten/ voltage is impressed between terminals...
Page 550 AUTO-CRUISE CONTROL SYSTEM - Auto-cruise Control AUTO-CRUISE CONTROL 4 - 6 Nm 3-4 ft.lbs. REMOVAL AND INSTALLATION Post-installation Operation to P. 13-398.) Removal steps actuator 2. Accelerator cable B adjusting nut 3. Accelerator cable A adjusting nut 4. Actuator side inner cable 5.
Page 551 AUTO-CRUISE CONTROL SYSTEM <Vacuum type: From 1991 models> *Accelerator Cable Adjustment 9 - 1 4 Nm Removal steps of sensor and switches Removal steps of actuator 13. Accelerator switch <AfT> 2. Throttle cable 15. Clutch pedal position switch <M/T> 3. Accelerator cable 16.
Page 552 AUTO-CRUISE CONTROL SYSTEM - Auto-cruise Control INSPECTION Check the inner and outer cable for damage. Check the cable for smooth movement. Check the actuator cover for damage. CHECKING THE ACTUATOR Refer to P.13-397. SERVICE POINTS OF INSTALLATION 6. INSTALLATION OF VACUUM HOSE Align the marking end of the vacuum hose to the clamp position and install.
Page 553 CONTENTS Sealant ....__...’ ...._..ENGINE COOLANT TEMPERATURE GAUGE UNIT, ENGINE COOLANT Service Specifications .
Page 554 COOLING - Specifications 14-2 SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Items Water-cooled, pressurized, forced circulation Cooling method with electrical fan Radiator Pressurized corrugated fin type Radiator fan motor Direct current ferrite type Water pump Centrifugal impeller type Thermostat Wax pellet type with jiggle valve Identification mark 88 (Stamped on flange), *82 (Stamped on flange) Drive belt...
Page 555 14-3 COOLING - Specifications Items Specifications Engine coolant temperature gauge unit Resistance A t 70°C (158°F) Engine coolant temperature sensor (Engine control) Resistance 2.45 f 0.24 A t 20°C (68°F) A t 80°C (176°F) Air conditioning engine coolant temperature switch <always closed type>...
Page 556 COOLING - Specifications Items Exhaust manifold to cylinder head <SOHC> <Up to 1992 models> 18-22 27-33 < D O H C > 18-22 Engine hanger to engine bracket 12-15 9-11 Oxygen sensor 29-36 Water inlet pipe installation bolt Transaxle side 43-55 Engine block side <Up to 1992 models>...
Page 557: Special Tool
COOLING - Special TooVTroubleshooting SPECIAL TOOL Number Name Radiator cap test Radiator cap test TROUBLESHOOTING Remedy Symptom Probable cause Replenish Overheat Insufficient engine coolant Correct anti-freeze Too high an anti-freeze concentration concentration Replace Loose or broken drive belt Replace Faulty thermosensor Replace Faulty electrical motor Replace...
Page 558 COOLING - Troubleshooting CIRCUIT DIAGRAM < N o n - T u r b o (FWD, AWD-M/T)> CONDENSER FAN MOTOR RADIATOR RADIATOR CONDENSER FAN MOTOR + FAN MOTOR FAN MOTOR FAN MOTOR RELAY (HI) TSB Revision...
Page 559 14-7 COOLING - AUTO 'ION COMPRESSOR CONTROL UNIT 2 "1 'RADIATOR FAN MOTOR RESISTOR OFF -p OPERATION fan motor and the radiator fan motor relay When the engine coolant temperature reaches approximately 85°C (185°F) in the ignition switch (contact) to the ground to rotate the radiator fan motor.
Page 560 14-8 COOLING - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDUl$t& ENGINE COOLANT LEAK CHECK 1. Loosen radiator cap. neck. 3. Install a radiator cap tester to the radiator filler neck and apply 160 kPa (23 psi) pressure. Hold pressure for. two the radiator, minutes, while checking for leakage from hose or connections.
Page 561 14-9 COOLING - Radiator RADIATOR REMOVAL AND INSTALLATION Pre-removal and Post-installation @Draining and Supplying of the En- gine Coolant (Refer to GROUP 00-Maintenance 9-14 Nm braking system> 9-14 Nm 4 - 6 3-4 ftlbs. 2-4 ft.lbs. Removal steps 12. Condenser fan motor connector 1.
Page 562 COOLING - Radiator SERVICE POINTS OF REMOVAL 7. REMOVAL OF RADIATOR UPPER HOSE/& RADIATOR LOWER HOSE After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. 9. DISCONNECTION OF AUTOMATIC TRANSAXLE OIL COOLER HOSES Use a plug or otherwise cover the hose and nipple part of the radiator so that dust, dirt, foreign materials, etc.
Page 563 14-11 COOLING - Radiator RESISTOR INSPECTION <Non-Turbo (AWD-ATT), Turbo> (2) Measure the resistance between terminals 0 and @. (3) It can be judged OK if the resistance value is within the following range. Resistance value: 0.26-0.32 Q continuity Check for with the therm0 sensor in hot water.
Page 564 14-12 COOLING - Radiator/Radiator Fan Motor Assembly (2) Connect battery to terminal 2 and check continuity Circuit tester between terminals with terminal 1 grounded. SERVICE POINTS OF INSTALLATION 8. INSTALLATION OF RADIATOR LOWER HOSEI7. RADIA- TOR UPPER HOSE Align the mating marks on the radiator hose and hose clamp and then connect them;...
Page 565 COOLING THERMOSTAT AND INSTALLATION REMOVAL 12-14 ft.lbs. 12-14 ft.lbs. <DOHC> Removal steps 3. Water outlet fitting 4. Water inlet fitting 5. Gasket SERVICE POINTS OF REMOVAL RADIATOR LOWER HOSE After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. INSPECTION Check that valve closes tightly at room temperature.
Page 566 14-14 COOLING - Thermostat Standard value: Valve opening temperature DOHC, SOHC 8VALVE SOHC 1 GVALVE Full-open temperature DOHC, SOHC 8VALVE SOHC 16VALVE NOTE Measure valve height when fully closed. Calculate lift by measuring the height when fully open. SERVICE POINTS OF INSTALLATION <SOHC>...
Page 567 COOLING - Water Pump <SOHC> WATER PUMP <SOHC> REMOVAL AND INSTALLATION 36-47 ft.lbs. a (Refer to GROUP 00-Maintenance Post-installation Operation *Installation of the Under Cover *Supplying of the Engine Coolant (Refer to GROUP 00-Maintenance Service.) (Refer to GROUP 1 l-Service Adjustment Procedures.) 22-29 ft.lbs.
Page 568 COOLING 14-16 <Up to 1992 models> 5-7 N m 4-5 ftlbs. 22. Timing belt B (Referto GROUP ll- Timing Belt B.) 23. Generator brace Timing Belt) 424. Water pump 12. Rocker cover gasket 25. Water pump gasket GROUP 11 -Timing Belt) 15.
Page 569 COOLING 2.2-2.5 ftlbs. 12 Nm 7 - 9 20. Flange (Refer to GROUP 11 -Timing Belt 11. Rocker cover (Refer to GROUP 11 -Timing Belt.) 21. Timing belt B tensioner 12. Rocker cover gasket 22. Timing belt B (Refer to GROUP 14.
Page 570 14-18 COOLING SERVICE POINTS OF REMOVAL 2. REMOVAL OF ENGINE MOUNT BRACKET then jack up the vehicle. Caution Jack up carefully, so as not to apply a load to each part. 5. REMOVAL OF DRIVE BELT Before removing the V-ribbed belt, loosen the water pump pulley installation bolt.
Page 571 COOLING (1) Clean both gasket surfaces of water pump body and cylinder block. (2) Install water pump gasket and water pump assembly and tighten the bolts. Identification mark Torque Identification Bolt diameter (d) Nm (ftlbs.) mark 8 x 20 (31 x .79) <Up 1992 models>...
Page 572 COOLING - Water Pump <DOHC> WATER PUMP <DOHC> REMOVAL AND INSTALLATION (Refer to GROUP 00-Maintenance Post-installation Operation *Installation of the Under Cover *Supplying of the Engine Coolant (Refer to GROUP 00-Maintenance Service.) (Refer to GROUP 11-Service Adjustment Procedures.) 22-29 ft.lbs. 7 - 9 ft.lbs.
Page 573 COOLING 15. Crankshaft sprocket 15. Crankshaft sprocket 16. Flange (Refer to GROUP 11 -Timing Belt 16. Flange (Refer to GROUP 11 -Timing Belt 17. Timing belt B tensioner 17. Timing belt B tensioner Timing Belt B.) Timing Belt B.) 19. Generator brace 19.
Page 574 14-22 COOLING - Water Pump <DOHC> INSPECTION V-RIBBED BELT Refer to P.14-18. WATER PUMP Check each part for cracks, damage or wear, and replace the water pump assembly if necessary. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the water pump assembly if necessary.
Page 575 COOLING - Water Hose and Water Pipe <SOHC> WATER HOSE AND WATER PIPE <SOHC> <Up to 1992 models> REMOVAL AND INSTALLATION Pre-removal and Post-installation (Refer to GROUP 00-Maintenance 12-15 Nm 29 - 36 fths. 9-11 ft.lbs. Removal steps Oil level gauge 12.
Page 576 14-24 COOLING WATER HOSE AND WATER PIPE <SOHC> <I993 models> REMOVAL AND INSTALLATION Pre-removal and Post-installation *braining and Supplying of the Engine 12-15 Nm , ‘r- y’ ft”bs. 29-36 ftlbs. 22-29 ft.lbs. Removal steps 6. Self-locking nut 1. Condenser fan motor 7.
Page 577 COOLING 11. Connection for heater hose 12. Water by-pass hose 13. Water hose 14. Connection for thermostat case 15. Water inlet pipe 16. O-ring INSPECTION WATER PIPE AND HOSE INSPECTION Check the water pipe and hose for cracks, damage, clog and replace them if necessary.
Page 578 COOLING WATER HOSE AND WATER PIPE <DOHC (Non-Turbo)> REMOVAL AND INSTALLATION Operation (Refer to GROUP 00-Maintenance 12-15 Nm 9-11 ftlbs. 12-15 ‘Nm 9-11 ft.lbs. 18-22 ft.lbs. 40 50 Nm’&\ 9-11 ft.lbs. 22 - 29 ft.lbs. 2 2 - 2 9 ft.lbs. \ Removal steps 6.
Page 579 14-27 COOLING -55 Nm Removal steps 11. Connection for oxygen sensor and control harness 12. Water hose 13. Water by-pass hose 14. Connection for heater hose 15. Connection for radiator lower hose (Refer to P.14-10.) 16. Water inlet pipe (Refer to P.14-18.) 17.
Page 580 14-28 COOLING - Water Hose and Water Pipe <DOHC (Turbo)> WATER HOSE AND WATER PIPE <DOHC (Turbo)> <Up to 1992 models> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation 1 Coolant (Refer to GROUP 00-Maintenance Service.) *Draining and Filling of the Engine Oil 12-15 Nm (Refer to GROUP 11 -Service Adjustment Pro- cedures.)
Page 581 14-29 sensor harness connector 22. Oil return pipe 23. Gasket Eye bolt 26. Gasket 27. Water pipe B 6 - 7 ftlbs. Eye bolt 29. Gasket 30. Water pipe A 7 - 9 ft.lbs. 22-29 ft.lbs. 37. Water hose 38. Exhaust pipe support bracket 32.
Page 582 COOLING - Water Hose and Water Pipe <DOHC (Turbo)> SERVICE POINTS OF REMOVAL 24. REMOVAL OF TURBOCHARGER ASSEMBLY Remove the turbocharger assembly with the exhaust fitting, water pipe A, water pipe B and the oil pipe attached to it. INSPECTION WATER PIPE AND HOSE INSPECTION Refer to P.14-23.
Page 583 Engine Coolant Temperature Gauge Unit, Engine Coolant 14-31 COOLING - ENGINE COOLANT TEMPERATURE GAUGE UNIT, ENGINE COOLANT TEMPERATURE SENSOR AND ENGINE COOLANT TEMPERATURE SWITCH REMOVAL AND INSTALLATION <DOHC> gine Coolant (Refer to GROUP 00-Maintenance Service.) Sealant: 3M ATD Part No.8660 or equivalent <Up to 1992 models>...
Page 584 Engine Coolant Temperature Gauge Unit, Engine Coolant 14-32 COOLING - Temperature Sensor and Engine Coolant Temperature Switch INSPECTION ENGINE COOLANT TEMPERATURE GAUGE UNIT Raise the water temperature and measure the resistance if within the standard value. Standard value: 104k13.5 Q [at 70°C (158”F)] Sensor 0 4 6 0 0 3 3 ENGINE COOLANT TEMPERATURE SENSOR...
Page 585 Engine Coolant Temperature Gauge Unit, Engine Coolant COOLING - Temperature Sensor and Engine Coolant Temperature Switch ENGINE COOLANT TEMPERATURE SWITCH <Normal opened type> (Air conditioning or A/T control) water outlet fitting. (2) immerse the engine coolant temperature switch in oil and heat by a gas stove or similar method so as to increase the oil temperature.
Page 586 NOTES...
Page 587 EXHAUST CONTENTS SERVICE ADJUSTMENT PROCEDURES ..AIR CLEANER ... . . a..... Air Cleaner Element Inspection and CHARGE AIR COOLER .
Page 588: Exhaust System
15-2 INTAKE AND EXHAUST - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Air cleaner Element Unwoven cloth type Exhaust system Dual type Front exhaust pipe <Non-Turbo> Single type Front exhaust pipe <Turbo> Expansion resonance type Muffler Flat coupling Coupling Rubber hangers and O-rings Suspension system Turbocharger Exhaust gas turbine type...
Page 589 15-3 INTAKE AND EXHAUST - Specifications Items Intake manifold <SOHC> Accelerator cable to intake manifold plenum Fuel high pressure hose to fuel rail Fuel rail to intake manifold 7 - 9 Ignition coil <8 VALVE> 12-15 9-11 Intake manifold stay 18-25 13-18 Intake manifold to engine...
Page 590 15-4 INTAKE AND EXHAUST - Specifications Exhaust manifold <DOHC (turbo)> Front exhaust pipe to exhaust fitting 29-43 Front exhaust pipe to engine 22-29 Heat protector (A), (B) 12-15 9-11 Engine oil level gauge guide mounting bolt 12-15 9-11 Engine hanger to engine 12-15 9-11 Exhaust manifold to engine...
Page 591 15-5 INTAKE AND EXHAUST - Special Tool/Troubleshooting SPECIAL TOOL Tool Number Name Removal/Installation of oxygen sensor Oxygen sensor wrench Oxygen sensor wrench TROUBLESHOOTING Symptom Probable cause Retighten Loose joints Repair or replace Broken pipe or muffler Broken separator in muffler Replace Abnormal noise Broken rubber hangers...
Page 592 15-6 INTAKE AND EXHAUST - Adjustment Procedures Service SERVICE ADJUSTMENT PROCEDU&$ AIR CLEANER ELEMENT INSPECTION AND RE- PLACEMENT <Non-Turbo> (1) Disconnect the volume air flow sensor connector. (2) Disconnect the connection of the breather hose. (3) Remove the air intake hose. (4) Push the air intake hose backward, and remove the air cleaner cover.
Page 593: System Inspection
INTAKE AND EXHAUST - Adjustment Procedures Service SUPERCHARGING PRESSURE TURBOCHARGER INSPECTION Caution Perform running inspection with two passengers in tha made. The pressure gauge reading is taken by a front seat passenger. (1) Disconnect the supercharging pressure control hose at the Turbocharger waste solenoid valve (fixed to the air cleaner), and plug the nipple.
Page 594 15-8 INTAKE AND EXHAUST - Service Adjustment Procedures (6) Put a blind plug on the vacuum hose (black) end. (7) Apply negative pressure when idling. and check the negative pressure state when the knock sensor is con- nected and disconnected. Normal state Knock sensor connector...
Page 595: Air Cleaner
INTAKE AND EXHAUST - Air Cleaner AIR CLEANER REMOVAL AND INSTALLATION <Non-Turbo> 6 - 7 ft.lbs. Removal steps 2. Resonator 3. Branch tube 4. Connection for volume air flow sensor connector 5. EGR solenoid <Vehicles for California> 6. Breather hose 7.
Page 596 INTAKE AND EXHAUST - Air Cleaner <Turbo> 6 - 7 ft.lbs. Removal steps 17. Noise reduction filter 18. Cover 2. Connection for volume arr flow sensor 19. Grommet connector 20. Air cleaner body 3. Connection for boost hose 21. Insulator 4.
Page 597 INTAKE AND EXHAUST Check the air cleaner body, cover or packing for deforma- tion, corrosion or damage. Check the air duct for damage. Check the air cleaner element for clogging, contamination or damage. If element is slightly clogged, remove dust by blowing air from inside of element.
Page 598: Intake And Exhaust
INTAKE AND EXHAUST REMOVAL AND INSTALLATION 12-15 Nm 9-11 ft.lbs., 12-15 Nm 9-11 ftlbs. Removal steps 9. Air hose A Grille.) - 11. Air pipe A 12. Air hose B 13. Air pipe B 3. Headliaht 4. Front bumper face coupling clip 14.
Page 599 INTAKE AND EXHAUST INSPECTION Check the charge air cooler fins for bending, damage, or foreign matter. Check the charge air cooler hoses for cracking, damage, or wear. SERVICE POINTS OF INSTALLATlON 17. INSTALLATION OF CHARGE AIR COOLER Connect the air hoses and air pipes by aligning the paint marks on the hoses with the projections and indentations on the pipes.
Page 600 Intake Manifold <SOHC-8 VALVE> INTAKE AND EXHAUST - INTAKE MANIFOLD <SOHC-8 VALVE> <Up to 1992 models> 4-6 N m ‘Nm 3 - 4 3 - 4 Removal steps Pre-removal Operation Draining of Engine Coolant (Refer to GROUP 2. Connection for accelerator cable Service.) 4.
Page 601 INTAKE AND EXHAUST - Intake Manifold <SOHC-8 VALVE> 7 - 9 ftlbs. 7-9 ftlbs. 11-14 - - - - --I- 11-14 ftlbs. 7 - 9 ftlbs. 27. Intake manifold plenum stay 28. Intake manifold plenum regulator 29. Intake manifold plenum gasket 30.
Page 602 INTAKE AND EXHAUST SERVICE POINTS OF REMOVAL 3. DISCONNECTION OF RADIATOR UPPER HOSE Make mating marks on the radiator hose and the hose clamp, and then remove the radiator hose. 8. DISCONNECTION OF FUEL HIGH PRESSURE HOSE Relieve pressure in the fuel pipe line to prevent fuel outflow.
Page 603 INTAKE AND EXHAUST - Intake Manifold <SOHC-8 V A L V E > INTAKE MANIFOLD (1) Check for damage or cracking of any part. (2) Check load (negative pressure) of drain port. Check cooling water and jet air passages for clogging. Clean if required.
Page 604 INTAKE AND EXHAUST INTAKE MANIFOLD <SOHC-16 VALVE> REMOVAL AND INSTALLATION 3 - 4 6 - 8 Removal steps 1. Air intake hose (Refer to GROUP OO-Maintenance 2. Connection for accelerator cable 3. Connection for brake booster vacuum hose 4. Connection for vacuum pipe and hose Post-installation Operation assembly Filling of Engine Coolant...
Page 605 INTAKE AND EXHAUST - Intake Manifold <SOHC-l 6 VALVE> 7-9 ft.lbs. 13-18 ft.lbs. pressure regulator 11. Engine coolant temperature gauge unit connector assembly 12. Engine coolant temperature sensor 21. Insulator connector 22. Intake manifold stay 13. Oxygen sensor connector 23. Intake manifold 14.
Page 606 INTAKE AND EXHAUST POINTS OF REMOVAL SERVICE 6. DISCONNECTION OF FUEL HIGH PRESSURE HOSE Relieve pressure in the fuel pipe line to prevent fuel out- flow. (Refer to GROUP 13-Service Adjustment Proce- dures.) Caution Cover fuel pipe line with rag after relieving pressure as certain pressure may still remain.
Page 607 INTAKE AND EXHAUST - Intake Manifold <DOHC> REMOVAL AND INSTALLATION 3 - 4 <Turbo> 11-16 ft.lbs. 11-16 ft.lbs. Removal steps 1. Air intake hose <Non-Turbo> 2. Air hose D <Turbo> 3. Connection for control harness 4. Connection for accelerator cable Pre-removal Operation 5.
Page 608 INTAKE AND EXHAUST - Intake Manifold <DOHC> 11-16 ftlbs. 7 - 9 ft.lbs. 7-9 ftlbs. Fuel rail, fuel injector and pressure regulator 17. Insulator 18. Insulator 11-16 19. Intake manifold stay 22. Ignition coil 23. Power transistor unit EGR valve 25.
Page 609 INTAKE AND EXHAUST - Intake Manifold <DOHC> POINTS OF REMOVAL SERVICE 10. DISCONNECTION OF FUEL HIGH PRESSURE HOSE Relieve pressure in the fuel pipe line to prevent fuel outflow. (Refer to GROUP 13-MFI Components on Vehicle Inspection.) Caution Cover fuel pipe line with rag after relieving pressure as certain pressure may still remain.
Page 610 INTAKE AND EXHAUST - Turbocharger 12-15 Nm REMOVAL AND INSTALLATION 9-11 12-15 9-11 ftlbs. 29-36 ft.lbs. 22-29 ftlbs. (Refer to GROUP OO-Main- Service.) Engine steps Removal 13. Gasket (Refer to GROUP 14-Radiator.) 2. Connection for air intake hose 5. Connection for water pipe B 3.
Page 611 INTAKE AND EXHAUST - Turbocharger 28-34 Nm 55-65 25-36 ftlbs. 6 - 7 ft.lbs. 22. Oil return pipe 23. Gasket l I) l + 24. Turbocharger Eye bolt 26. Gasket 27. Water pipe B Eye bolt Flare nut 29. Gasket 30.
Page 612 INTAKE AND EXHAUST 24. REMOVAL OF TURBOCHARGER ASSEMBLY Remove the turbocharger assembly with the exhaust fitting, water pipe A, water pipe B and the oil pipe attached to it. 33. REMOVAL OF OIL PIPE Caution After disconnecting the oil pipe, take care that foreign material does not enter the oil passage hole of the turbocharger assembly.
Page 613 INTAKE AND EXHAUST - Exhaust Manifold EXHAUST MANIFOLD <SOHC-8 VALVE> <Up to 1992 9-11 ftlbs. 29 - 36 ft.lbs. Removal steps 1. Self locking nut 2. Gasket 3. Heat protector Oxygen sensor 5. Engine hanger 6. Exhaust manifold 7. Exhaust manifold gasket SERVICE POINTS OF REMOVAL 4.
Page 614 15-28 INTAKE AND EXHAUST EXHAUST MANIFOLD <SOHC-l6 VALVE> <I993 models> 1 ft.lbs. 29-36 ft.lbs. 22-29 ft.lbs. Removal steps Condenser fan motor (Vehicles with air conditioning) 2. Self locking 3. Gasket 4. Oxygen sensor 5. Exhaust manifold cover (A) 6. Self locking nut 7.
Page 615 INTAKE AND EXHAUST SERVICE POINTS OF REMOVAL 4. REMOVAL OF OXYGEN SENSOR Disconnect the connector of the oxygen sensor, and install the special tool to the oxygen sensor. Then, using an offset (box-end) wrench, remove the oxygen sensor. INSPECTION Check the following points; replace the part if a problem is found.
Page 616 Exhaust Manifold <DOHC-Non-Turbo> INTAKE AND EXHAUST - EXHAUST MANIFOLD <DOHC-Non-Turbo> REMOVAL AND INSTALLATION 12-15 Nm 27-33 Nm 40 50 Nm 12-15 1 9-11 ft. 22-29 ft.lbs Removal steps 1. Condenser fan motor (Vehicles AWD A/T) with air conditioning except 2. Self locking 3.
Page 617 Exhaust Manifold <DOHC-Turbo> INTAKE AND EXHAUST - EXHAUST MANIFOLD <DOHC-TURBO> REMOVAL AND INSTALLATION Operation Draining and Refilling Engine Coolant (Refer to GROUP 00-Maim (Refer to GROUP 00-Main. Removal steps 13. Gasket 1. Radiator (Referto GROUP 14-Radiator.) 14. Connection for water hose 2.
Page 618 15-32 INTAKE AND EXHAUST EXHAUST PIPE AND MAIN MUFFLER <SOHC> REMOVAL AND INSTALLATION 7-11 ft.lbs. 22-29 ft.lbs. 17 15lIl 22-29 ft.lbs. 22-29 ftlbs. 29-43 ft.lbs. 29 - 36 ftlbs. 29-36 ft.lbs. 22-29 ft.lbs. 29-43 ftlbs. Removal steps 9. Stopper 17. Catalytic converter Hanger bracket Gasket 2.
Page 619 Exhaust Pipe and Main Muffler <DOHC> INTAKE AND EXHAUST - EXHAUST PIPE AND MAIN MUFFLER <DOHC> REMOVAL AND INSTALLATION 7-11 ft.lbs. 22-29 ft.lbs. 22-29 ft.lbs. 29-43 ftlbs. 29 - 36 ft.lbs. Removal steps 13. Protector 2. Main muffler 14. Hanger bracket 3.
Page 620 Exhaust Pipe and Main Muffler <DOHC> 15-34 INTAKE AND EXHAUST - 3-4 ft.lbs. 29-43 ft.lb 22-29 ft.lbs. 29-43 ft.lbs. Removal steps 17. Catalytic converter 1. Hangers 18. Gasket 2. Main muffler 19. Self locking nut 3. Gasket 20. Hanger 4. Moulding 21.
Page 621: Table Of Contents
CONTENTS EGR Temperature Sensor <California> ... 28 CATALYTIC CONVERTER ..... EGR Valve ........EVAPORATIVE EMISSION CONTROL EGR Valve Control Vacuum ....SYSTEM .......... Thermal Vacuum Valve <Federal> ..27 Air Conditioning Switch ......21 Component Location ......15 MIXTURE CONTROL (MFI) SYSTEM ..29 Evaporative Emission Canister ....
Page 622: Emission Control Systems
EMISSION CONTROL SYSTEMS SPECIFICATIONS GENERAL SPECIFICATIONS Closed type with Positive Crankcase Ventilation valve Positive crankcase ventilation system Evaporative emission control system Evaporative emission canister storage type Evaporative emission canister Charcoal type Exhaust emission control system Exhaust gas recirculation system EGR valve Vacuum-actuated diaphragm type Thermal vacuum valve <Federal>...
Page 623 EMISSION CONTROL SYSTEMS - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Engine will not start or hard Vacuum hose disconnected or Repair or replace to start damaged The EGR valve is not closed. Repair or replace Malfunction of the evaporative Repair or replace emission purge solenoid Rough idle or engine stalls The EGR valve is not closed.
Page 624: Vacuum Hoses
17-4 EMISSION CONTROL SYSTEMS - Vacuum Hoses VACUUM HOSES VACUUM HOSES ROUTING <Federal-SOHC (1989 models)> Evaporative emission purge solenoid Evaporative emission cani*-- Throttle body Fuel pressure regulator Thermal vacuum valve G: Green EGR’ valve FRONT <California-SOHC (1989 models)> Evaporative emission Evaporative emission canister EGR solenoid...
Page 625 17-5 EMISSION CONTROL SYSTEMS - Vacuum Hoses <Federal-SOHC (From 1990 models)> Evaporative Evaporative emission emission canister purge solenoid Throttle body G: Green Thermal vacuum valve <California-SOHC (From 1990 models)> Evaporative emission Evaporative purge solenoid emission canister Fuel pressure regulator EGR valve FRONT G: Green...
Page 626 17-6 EMISSION CONTROL SYSTEMS <Federal-DOHC (1989 models)> Evaporative emission purge solenoid Evaporative Throttle body emission canister Fuel pressure regulator EGR valve/ Thermal vacuum valve G: Green FRONT <California-DOHC (1989 models)> Evaporative emission purge solenoid Evaporative emission canister Throttle body Fuel pressure regulator EGR sol EGR valve...
Page 627 17-7 EMISSION CONTROL SYSTEMS Hoses <Federal-DOHC (From 1990 models)> Evaporative emission purge solenoid Evaoorative emission canister Thermal vacuum valve G: Green FRONT <California-DOHC (From 1990 models)> Evaporative emission purge solenoid Evaoorative emission canister Fuel pressure regulator G: Green FRONT R: Red TSB Revision...
Page 628 EMISSION CONTROL SYSTEMS - Vacuum Hoses <Federal - DOHC T/C (From 1991 models)> purge solenoid Throttle body Purge control valve Fuel pressure , Fuel pressure regulator Thermal vacuum valve Air cleaner Turbocharger G: Green EGR valve Turbocharger FRONT gate solenoid W: White <California- DOHC T/C (From 1991 models)>...
Page 629: Vacuum Circuit Diagram
17-9 EMISSION CONTROL SYSTEMS VACUUM CIRCUIT DIAGRAM <Federal-SOHC (Up to 1992 models), Federal-DOHC (Up to 1991 models)> Intake manifold plenum Throttle body I r///////////// From air cleaner To combustion chamber G: Green L: Light blue B: Black <California-SOHC (Up to 1992 models), California-DOHC (Up to 1991 models)> Throttle body Intake manifold plenum From air cleaner...
Page 630 EMISSION, CONTROL SYSTEMS <Federal-SOHC (From 1993 models), Federal-DOHC (From 1992 models)> Intake manifold plenum Throttle body To combustion ch Fuel pressure regulator G: Green L: Light blue EGR valve B: Black EVAP canister <California-SOHC (From 1993 models), California-DOHC (From 1992 models)> Intake manifold plenum Throttle body From air cleaner...
Page 631 EMISSION CONTROL SYSTEMS Intake manifold plenum Throttle body From air cleaner To combustion chamber Purge control valve Turbocharger te gate , TC bypass valve EV ALi EVAP canister G: Green Y: Yellow L: Light blue B: Black W: White EGR valve Air cleaner TSB Revision...
Page 632 EMISSION CONTROL SYSTEMS Hoses <California-DOHC T/C> Throttle body From air cleaner To combustion chamber TC bypass valve urge (ON: EVAP canister G: Green L: Light blue R: Red B: Black Air cleaner W: White TSB Revision...
Page 633: Positive Crankcase Ventilation System
EMISSION CONTROL SYSTEMS - Vacuum Hoses/Positive Crankcase Ventilation System INSPECTION (1) Referring to the VACUUM HOSES ROUTING, confirm that the vacuum hoses are properly connected. (2) Check the hoses for irregularities (disconnection, loose- ness, etc.) and confirm that there is no breakage or damage.
Page 634: Positive Crankcase Ventilation (Pcv)
EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation System <DOHC> Symbol Name Positive crankcase ventilation valve CRANKCASE VENTILATION SYSTEM <SOHC-Up to 1992 models, DOHC> INSPECTION (1) Disconnect the ventilation hose from the positive crank- case ventilation (PCV) valve. Then, remove PCV valve from the rocker cover and reconnect it to the ventilation hose.
Page 635: Evaporative Emission Control System
Positive Crankcase Ventilation System/ EMISSION CONTROL SYSTEMS - Evaporative emission Control System EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENT LOCATION <SOHC-From 1993 models> Symbol Name Evaporative emission canister Evaporative emission purge solenoid...
Page 636 EMISSION CONTROL SYSTEMS - Evaporative Emission Control System <DOHC> Symbol Evaporative emission canister Evaporative emission purge solenoid Purge control valve <Turbo> Evaporative emission puige solenoid...
Page 637 EMISSION CONTROL SYSTEMS - Evaporative Emission Control Throttle body Intake air temperature Engine control module (1) Disconnect the vacuum hose (red stripes) from the throttle <SOHC (1999 models)> body and connect it to a hand vacuum pump. (2) Plug the nipple from which the vacuum hose was removed. (3) Under the engine conditions described below, provide a vacuum by using the hand vacuum pump, and then check.
Page 638 EMISSION CONTROL SYSTEMS - Evaporative Emission Control System PURGE CONTROL SYSTEM INSPECTION <Turbo> Evaporative emission canister Intake air temperature sensor Engine coolant temperature sensor Engine control module (1) Disconnect the purge air hose from the air intake hose, and plug the air intake hose. Then, connect the hand vacuum pump to the purge air hose.
Page 639: Purge Port Vacuum
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System When engine is hot-coolant temperature: Result Engine operating Applying vacuum condition Idling Vacuum is maintained Vacuum leaks 3,000 rpm within three minutes after vacuum starting engine 375 mmHg Vacuum will be main- 3,000 rpm after tained momentarily, three minutes...
Page 640: Purge Control Valve
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System (2) Start the engine and check to see that, after raising the engine speed by racing the engine, vacuum remains fairly constant. NOTE If there is no vacuum created, it is possible that the throttle body port may be clogged and require cleaning.

Page 641: Air Conditioning Switch
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System EVAPORATIVE EMlS$lON PURGE SOLENOID INSPECTION NOTE When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to the original posi- tion. (1) Disconnect the vacuum hoses (non stripe and red stripe hoses) from the solenoid valve (2) Disconnect the harness connector from solenoid valve.
Page 642 17-22 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EXHAUST GAS RECIRCULATION (EGR) SYSTEM COMPONENT LOCATION <SOHC-Up to 1992 models> Symbol Name EGR solenoid <California> EGR valve EGR temperature sensor <California> Thermal vacuum valve <Federal>...
Page 643 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System <SOHC-From 1993 models> Name Symbol EGR solenoid <California> EGR valve EGR temperature sensor <California>...
Page 644 17-24 EMISSION CONTROL SYSTEMS <DOHC> Symbol Name EGR solenoid <California> EGR valve EGR temperature sensor <California> Thermal vacuum valve <Federal> TSB Revision...
Page 645: Egr System Inspection
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EGR SYSTEM INSPECTION <Federal> hose (green stripe) from the (1) Disconnect the vacuum throttle body, and connect a hand vacuum pump to the vacuum hose. (2) Under the engine conditions described below, provide a vacuum by using the hand vacuum pump, and then check.

Page 646: Egr Valve Control Vacuum
EMISSION CONTROL SYSTEMS <When the engine is cold> <When the engine is warm> (3) Disconnect the three-way terminal and connect the manual vacuum pump directly to the exhaust gas recirculation (4) Check whether the engine stalls or the idling is unstable when a vacuum of 155 mmHg (5.9 in.Hg) or higher is applied during idling.
Page 647: Thermal Vacuum Valve
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (2) Start the engine and check to see that, after raising the engine speed by racing the engine, vacuum raises prop- ortionately with the rise in engine speed. NOTE if there is a problem with the change in vacuum, it is possible that the throttle body port may be clogged and require cleaning.

Page 648 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) Svstem REMOVAL (1) When removing the thermal vacuum valve, do not use wrenches or other tools on the resin part. (2) When disconnecting the vacuum hose, put a mark on the hose so that it may be reconnected at original position. INSTALLATION (1) Apply specified sealant to the threads of thermal vacuum valve and tighten to specified torque.
Page 649: Catalytic Converter
Exhaust Gas Recirculation (EGR) System/ EMISSION CONTROL SYSTEMS (4) Apply a vacuum and check for air-tightness when voltage applied directly to the EGR solenoid when the voltage is discontinued. (5) Measure the resistance between the terminals of the sole- noid valve. Standard value: 36-44 Q [at 20°C (68”F)] CATALYTIC CONVERTER INSPECTION...
Page 650 NOTE...
Page 651 CLUTCH CONTENTS SPECIFICATIONS ....*......CLUTCH CONTROL ......... CLUTCH MASTER CYLINDER .
Page 652 21-2 CLUTCH - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Specifications Non-Turbo Turbo Clutch operattng method Hydraulic type Hydraulic type Clutch disc” Single dry disc type Single dry disc type O.D. x I.D. mm (In.) 215 x 140 (8.5 x 5.5) 225 x 150 (8.9 x 5.9) 225 x 150 (8.9 x 5.9)‘2 Clutch cover assembly Diaphragm spring...
Page 653 15-21 11-15 NOTE LUBRICANTS Specified lubricants Items MITSUBISHI genuine grease inner surface of’ clutch release bearing Part No.010101 1 or equivalent Inner surface of clutch disc spline Input shaft spline Contact portion of release fork to release cylinder push rod...
Page 654 CLUTCH - Troubleshootinn TROUBLESHOOTING Symptom Probable cause Remedy Clutch slips Insufficient clutch pedal play Adjust Excessive wear of clutch disc facing Replace Hardening of clutch disc facing, or adhesion of oil Replace Clutch release fork catching Repair or replace parts Weak or damaged diaphragm spring Replace Clogging of hydraulic system...
Page 655 21-5 CLUTCH Clutch pedal height Clutch pedal clevis SERVICE ADJUSTMENT PROCEDURES pin play CLUTCH PEDAL INSPECTION AND ADJUSTM&‘+d+d 1. Measure the clutch pedal height (from the face of the pedal pad to the firewall) and the clutch pedal clevis pin play (measured at the face of the pedal pad.) Standard value (A): 176-181 mm (6.9-7.1 in.) Standard value (B): l-3 mm (.04-.12 in.)
Page 656 21-6 CLUTCH - Service Adjustment Procedures 5. If the clutch pedal free play and the distance between the clutch pedal and the firewall when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch.
Page 657 <Non-Turbo> Adjustment eration Adjustment of Brake Pedal (Refer tc *Removal and Installation of Instrument GROUP 35-Service Adjustment Proce Under Cover (Refer to GROUP 52-Instrument Panel.) l Removal and Installation of Steering Col- (Refer to P.21-5.) umn Assembly (Refer to GROUP 37A- Steering Wheel and Shaft.) 8-12 Nm 6-9 ft.lbs.
Page 658 CLUTCH - Clutch Pedal <Turbo> Adjustment Pre-removal and Post-installation Op- Adjustment of Brake Pedal (Refer to eration GROUP 35-Service Adjustment Proce- dures.) Under Cover *Adjustment of Clutch Pedal (Refer to GROUP 52-Instrument Panel.) (Refer to P.21-5.1 umn Assembly (Refer to GROUP 37A- Steering Wheel and Shaft.) Removal steps 14.
Page 659 Check the pedal shaft and bushing for wear. Check the clutch pedal for bend or torsion. Check the return spring for damage or deterioration. Check the pedal pad for damage or wear. INTERLOCK SWITCH INSPECTION Ohmmeter (2) Check to be sure that there is continuity between connector terminals 1 and 2 when the clutch pedal is depressed fully.
Page 660 Pre-removal Operation Draining of the Clutch Fluid 7-11 ft.lbs. 13-17 Nm 9-12 ft.lbs. 9-12 ft.lbs. 13-17 Nm 9-12 ft.lbs. Removal steps 2. Washer 3. Clevis pin a 4. Clutch tube + 5. Clutch tube Hose clips 8. Bracket 9. Clutch master cylinder 10.
Page 661 6. DISCONNECTION OF HOSE CLIPSI7. CLUTCH To disconnect clutch hose from the clutch tube, proceed. as follows: (1) Secure the nut on the clutch hose and loosen the flare nut on the clutch tube. (2) Remove the clip from the clutch hose to remove clutch hose from bracket.
Page 662 Disassembly steps 1. ‘Piston stop ring 2. Push rod Boot 4. Piston assembly 5. Reservoir cap Brake Fluid: Conforming to DOT3 6. Reservoir band or DOT4 7. Reservoir 8. Master cylinder body 4. REMOVAL OF PISTON ASSEMBLY Caution 1. Do not damage the master cylinder body and piston assembly.
Page 663 Pre-removal Operation Draining of the clutch fluid Bleeding of the clutch line (Refer Release cylinder O(Ivl,, push rod Removal steas 1. Clutch tube 2. Union 3. Clutch release cylinder Check the clutch release cylinder for fluid leakage. Check the clutch release cylinder boots for damage. TSB Revision...
Page 664 NOTES...
Page 665 MANUAL SERVICE ADJUSTMENT SERVICE ADJUSTMENT PROCEDURES ..........PROCEDURES ..........Drive Shaft Oil Seals Replacement ..Drive Shaft Oil Seals Replacement ..18 Speedometer Cable Replacement ... Speedometer Cable Replacement ... 19 Transaxle Oil Level Inspection ....Transaxle Oil Level Inspection ....17 Transaxle Oil Replacement ......
Page 666 Specifications Items Model 1993 models> models> 199 1 models> Gear ratio 1 St 3.363 2.846 1.947 1.947 1.833 1.285 1.285 1.217 Reverse 3.166 4.02 1 4.592 4.913 Speedometer gear ratio (driven/drive) NOTE Only the model code for KM206 and F5M22 is different. Items Shift lever to lever (A) 19-28...
Page 667 Items 1.8 dma <KM206, F5M22> Hypoid gear oil SAE 75W-85W Manual transaxle oil conforming to API classification (1.9 qts.) 2.3 dma <F5M3 l> (2.4 qts.) As required Shift lever bushing Front Wheel Bearing Grease Part Number 3837794 or eauivalent Tool Number Name Steering linkage...
Page 668 Refer to GROUP 00-Maintenance Service. (1) Position vehicle on a flat level. (2) Remove filler and drain plugs and allow the transaxle oil to drain. (3) Refill the transaxle to the proper level with specified transaxle oil. The oil level should be the bottom of the oil filler hole.
Page 669 1. Correctly insert the adapter into the instrument panel, and fasten the new speedometer cable. Adapter 2. Install the grommet so that, as shown in the illustration, the’ cable attachment part is positioned upward. Caution 1. The cable arrangement should be made so that the radius of cable bends is 150 mm (5.9 in.) or more.
Page 670 Pre-removal and Post-installation 1 Operation *Removal and Installation of Console I <From 1991 models> steps Removal Retainer 3. Retainer 4. Cotter pin * 5. Shift cable + 6. Select cable 7. Shift lever assembly Check the select cable for function and for damage. Check the shift cable for function and for damage.
Page 671 6. INSTALLATION OF SELECT CABLE (1) Move the transaxle shift lever to the neutral position. NOTE The select lever will be set to the neutral position when the transaxle shift lever is moved to the neutral position. (2) Move lever (B) to the neutral position. (3) Adjust, by using the adjuster, so that the end of the select cable is positioned as shown in the illustration relative to lever (B).
Page 672 (2) Move the shift lever (at the vehicle interior side) downward, in the direction (4th gear position) shown in the illustration until it contacts the stopper. (3) Adjust, by using the adjuster, so that the end of the shift cable is positioned as shown in the illustration relative Shift to the shift lever (interior side).
Page 673 19-28 Nm <From 1991 models> 19-28 Disassembly steps 1. Shift lever 2. Bushing l + 3. Return spring 4. Bushing 5. Lever (A) 6. Bushing 7. Collar <From 1991 models> 8. Bushing 9. Snap ring 11. Bushing 12. Bracket assembly 3.
Page 674 27-34 Nm 43-58 ft.lbs.* 11-16 ft.lbs. 11-16 ftlbs. Pre-removal Operation l Removal of the Air Cleaner Assembly (Refer to GROUP 15-Air Cleaner.) Removal steps Post-installation Operation 2. Cotter pin l Installation of the Air Cleaner Assembly 3. Connection for select cable (Refer to GROUP 15-Air Cleaner.) 4.
Page 675 43-52 ftfbs. 2 2 - 2 5 ft.lbs. / ( 43-52 ftlbs. 12. Cotter pin 13. Connection for tie rod end 14. Self-locking nut 4 15. Front height sensor rod <ACTIVE-ECS=i 16. Connection for lower arm ball joint 18. Circiip 19.
Page 676 1. DISCONNECTION OF COMPRESSOR ASSEMBLY FROM TRANSAXLE ASSEMBLY <ACTIVE-ECS> Remove the compressor assembly from the bracket, and then secure at the body side without disconnecting the air hose coupling. 5. DISCONNECTION OF CLUTCH RELEASE CYLINDER FROM TRANSAXLE ASSEMBLY Remove the clutch release cylinder and clutch oil line bracket installation bolt, and then secure at the body side without disconnecting the oil line coupling.
Page 677 (2) Keep the removed drive shaft as far away from the transaxle case as possible, and secure (by using rope, etc.) the joints to the body so that it does not fall. 21. REMOVAL OF TRANSAXLE ASSEMBLY Support the transaxle assembly by using a transaxle jack; then, after moving the transaxle assembly to the right, lower it.
Page 678 8. INSTALLATION OF STARTER Tighten with the lower starter installation the wiring harness clip bolt.
Page 679 Specifications Model Applicable engine Gear ratio 1 St 2.846 2.846 1.684 1.684 1.115 1.115 0.690 Reverse 3.166 3.166 Reduction ratio Primary 1.275 Secondary 3.866 Transfer Speedometer gear ratio (driven/drive) NOTE: The AWD vehicles have been discontinued from 1993 models. TRANSAXLE Items Bell housing cover mounting bolt 7 - 9...
Page 680 Transfer Hypoid gear oil, SAE 75W/8OW conforming to API classification GL-4 or higher 0.6 t.6) Transaxle Items Faying surfaces of transaxle case and clutch housing sealant Mitsubishi genuine Part No. MD997740 or equivalent Faying surfaces of clutch housing and adapter...
Page 681 Tool Number Name I Use Plug Prevention of entry of foreign objects into the transaxle and transfer Differential 011 seal Installation of differential oil seal installer Oil seal installer Installation of front output shaft bearing seal transfer extention housing oil Refer to P.22-3.
Page 682 plugs to drain transaxle oil. (2) Pour in fresh transaxle oil through filler port until it reaches the bottom of filler port. Transaxle oil: Hypoid gear oil SAE 75W-85W conform- ing to API classification GL-4 or higher Transaxle: 2.3 dm3 (2.4 qts.) Transfer: 0.6 dm3 (.6 qt.) (Refer to GROUP 26-Drive Shaft.)
Page 683 Service Adjustment Procedures/ L.H. side GROUP 25-Propeller Shaft.) (2) Using a fiat-tip (-) screwdriver, remove the oil seal. the special tool, tap the drive shaft oil seal into the Using transaxle. (4) Apply a coating of the transaxle. Transaxle oil: Hypoid gear oil SAE 75W-85W conform- ing to API classification GL-4 or higher Refer to P.22-5.
Page 684 Post-installation Operation @Supplying of Transaxle Oil (Refer to P.22-18.) l Installation of the Air Cleaner Assembly l Removal of the Battery and Battery Tray (Refer to GROUP 15-Air Cleaner.) *Removal of the Air Cleaner Assembly *Installation of the Battery and Battery (Refer to GROUP 15-Air Cleaner.) Tray *Checking the Operation of the Shift...
Page 685 7-9 ft.lbs. 1 36-46 -_ -- Nm _ _. 22-28 ft.lbs. <Non-Turbo> 22-29 ftlbs. <Turbo> 29-43 ft.lbs. 17. Circlip 18. Front exhaust pipe 11. Speed sensor <Vehicles with Anti-lock 19. Transfer assembly (Refer to P.22-23.1 Braking System> 20. Bell housing cover 12.
Page 686 16. DISCONNECTION OF DRIVE SHAFT insert a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the transaxle. Caution 1. Do not pull on the drive shaft; doing so will damage the inboard joint; be sure to use the pry bar. 2.
Page 687 AND INSTALLATION <Non-Turbo> Removal steps 1. Front exhaust pipe (Refer to GROUP 2. Transfer assembly 2. REMOVAL OF TRANSFER ASSEMBLY After moving the transfer assembly to the left and lowenng the front side, then remove it from the propeller shaft. Caution 1.
Page 688 NOTES...
Page 689: Table Of Contents
AUTOMATIC TRANSAXLE GENERAL INFORMATION ......TRANSAXLE ASSEMBLY <AWD> ... . . 105 SERVICE ADJUSTMENT PROCEDURES..
Page 691 2 3 - 2 AUTOMATIC TRANSAXLE - General Information , cari I TSB Revision...
Page 693 23-3 AUTOMATIC TRANSAXLE - General Information...
Page 695 AUTOMATIC TRANSAXLE - General Information Drive (FW...
Page 697 AUTOMATIC TRANSAXLE - General Information...
Page 699 AUTOMATIC TRANSAXLE - General Information...
Page 701 AUTOMATIC TRANSAXLE - General Information TSB Revision...
Page 703 AUTOMATIC TRANSAXLE - General Information Revision...
Page 705 AUTOMATIC TRANSAXLE - General Information...
Page 707 AUTOMATIC TRANSAXLE - General Information Hydraulic Circuit-Neutral for 1990.5, 1991, 1992 and 1993 model...
Page 709 2 3 - 1 1 AUTOMATIC TRANSAXLE - General Information and 1993 model 1’...
Page 711 23-12 AUTOMATIC TRANSAXLE - General Information Stopping for 1990.5, 1991, 1992 and 1993 model...
Page 713 23-13 AUTOMATIC TRANSAXLE - General Information Hydraulic Circuit-Drive First for 1990.5, 1991, 1992 and 1993 model T S B R e v i s i o n...
Page 715 23-14 AUTOMATIC TRANSAXLE - General Information for 1990.5, 1991, 1992 and 1993 model Hydraulic Circuit-Drive Second T S B R e v i s i o n...
Page 717 23-15 AUTOMATIC TRANSAXLE - General Information Hydraulic Circuit-Drive Third for 1990.5, 1991, 1992 and 1993 model...
Page 719 23-16 AUTOMATIC TRANSAXLE - General Information Hydraulic Circuit-Drive Fourth for 1990.5, 1991, 1992 and 1993 model Revision...
Page 721 23-17 [ L o c k - u p T S R Revision...
Page 723 23-18...
Page 725 AUTOMATIC TRANSAXLE SPECIFICATIONS GENERAL SPECIFICATIONS Specifications (1989 model) (1990 model) (1991, 1992 model) (1993 model) (1991 model) (1992 model) Torque converter torque conver- torque conver- torque conver- torque conver- torque conver- torque conver- ter clutch ter clutch ter clutch ter clutch ter clutch ter clutch speed...
Page 726 Items Oil pan bolts 7 - 9 Tie rod end to knuckle 24-35 17-25 43-52 Lower arm ball joint to knuckle Transaxle mounting bracket to transaxle 43-58 Special bolts 46-53 33-38 Selector lever assembly mounting bolts 9 - 1 4 Starter motor mounting bolt 27-34 Oil cooler hose clamp...
Page 727 AUTOMATIC TRANSAXLE SPECIAL TOOLS OPTIONAL: AVAILABLE FROM O.T.C. (For the number, refer to Precautions before service.) Oil pressure gauge easurement 0 Outlet sleeve Inner sleeve SERVICE TOOL TSB Revision...
Page 728 23-22 Based upon use of the troubleshooting guide, the probable location of the prob- lem should be estimated. F u n c t i o n a l m a l f u n c t i o n s (2) Malfunctions of the electronic control functions Checks should be made of fluid levels (3) Malfunctions of mechanical functions...
Page 730: Troubleshooting Guide
AUTOMATIC TRANSAXLE TROUBLESHOOTING GUIDE off) Problem Presumed cause Damaged or worn gear or other rotating part. or rnproper adjustment of the preload f parklng mechamsm 9 Cracked drive plate. or loose bolt L o w flutd level adjustment, etc ) of front clutch or poston of rear clutch or piston 1 6 Malfunction of klckdown b a n d o r piston...
Page 731 PSCV = Pressure control solenoid valve TCC = Torque converter clutch...
Page 732: Data Link And Test
AUTOMATIC TRANSAXLE DATA LINK AND TEST FLUID LEVEL AND CONDITION A W D CONTROL CABLE TSB Revision...
Page 733 READ OUT OF FAULT CODES <Scan tool> Data link lighter connector socket ROM back TSB Revision...
Page 734 23-28 AUTOMATIC TRANSAXLE - Troubleshooting ’ Fault Code Description for 1989 and 1990 model Fault Remedy Fault code (for voltmeter) Cause code Check the throttle position sen- Abnormal increase of TPS output sor connector. Check the throttle position sen- sor itself. Adjust the throttle position sen- sor.
Page 735 AUTOMATIC TRANSAXLE Fault Remedy Fault code (for voltmeter) Cause code Check the solenoid valve con- Damaged or disconnected wiring of the shift control solenoid valve A system Check shift control solenoid valve A itself. Check the shift control solenoid Short circuit of the shift-control valve A drive circuit harness solenoid valve A system Check the solenoid valve con-...
Page 736 AUTOMATIC TRANSAXLE - Troubleshooting Fault code I Fault code (for voltmeter) Cause Remedy Third gear non-synchronous Check the pulse generator A output circuit harness. Check pulse generator A and pulse generator B themselves. * Front clutch slippage. Rear clutch slippage. Fourth gear non-synchronous Check the pulse generator A output circuit harness.
Page 737 AUTOMATIC TRANSAXLE - Troubleshooting Remedy Description Output pattern Check the ignition sig- Damaged or disconnected wir- nal line. ing of the ignition pulse pick-up cable Check the accelerator switch Short circuit of the accelerator connector. switch or improper adjustment Check the accelerator switch itself.
Page 738 Remedy Description Output pattern ‘WC Check the pulse generator A First gear non-synchronous and pulse generator B con- nectors Check pulse generator A and pulse generator B them- selves. Rear clutch slippage. Check the pulse generator A Second gear non-synchronous and pulse generator B (AWD only) connectors.
Page 739 23-33 Output code Note Description Fail-safe (relation to Output pattern (for voltmeter) fault code) Damaged or discon- When code No. 41 or nected wiring, or 42 is generated 4th short circuit, of shift time. control solenoid valve Damaged or discon- When code No.
Page 740 AUTOMATIC TRANSAXLE C H E C K I N G T H E C O N T R O L S Y S T E M (WHEN A SCAN TOOL IS USED) FOR 1989 AND 1990 MODEL Possible cause (or remedy) for the abnormalrty Criterion value Inspection condition...
Page 741 AUTOMATIC TRANSAXLE l TPS system is defective. CHECKING THE CONTROL SYSTEM (WHEN A SCAN TOOL IS USED) FOR 1990.5, 1991, 1992 AND 1993 MODEL Inspection content Inspection item for the abnormality Inspection condition If voltage is high at the full opening 01 Accelerator is fullv closed.
Page 742 Possible cause (or remedy) for the abnormality Defective pulse generator A or harness 0 rpm Pulse generator A (FWD) *Defective shield cable of pulse gene item No.31 Defective pulse generator A or harness Pulse generator A 0 rpm External noise rnvasron Item No.
Page 743: Shift Patterns
AUTOMATIC TRANSAXLE - Troubleshooting ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER SHIFT PATTERNS TSB Revision...
Page 744 AUTOMATIC TRANSAXLE 1989 and 1990 Model (Vehicles with SOHC Engine) Transfer drive gear rpm (81) (87) (93) (99) 1750457 I I/ 1 1,000 2,000 3,000 4,000 5,000 6,000 Transfer drive gear rpm (81) (87) (99) Vehicle speed km/h (mph) 1750458 TSB Revision...
Page 745 AUTOMATIC TRANSAXLE 1990.5, 1991 and 1992 Model (Vehicles with SOHC Engine) range Transfer drive gear rpm Vehicle speed km/h (mph) range Transfer drive aear rpm Vehicle speed km/h (mph) Revision...
Page 746 AUTOMATIC TRANSAXLE - Troubleshooting 1990.5 Model (Vehicles with DOHC Engine) 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Transfer drive gearrpm 160 170 180 190 (62) (68) (75) (81) (87) (93) Vehicle speed km/h (mph) 2,000 3,000 4,000 5,000 1 , 0 0 0 6,000 Transferdrivegearrpm (19)
Page 747 AUTOMATIC TRANSAXLE 1991 and 1992 Model (Vehicles with DOHC Engine) Transfer drive gear rpm Vehicle speed km/h 1 oo- ‘I Idle Transfer drive gear rpm Vehicle speed km/h (mph) TSB Revision...
Page 748 23-42 AUTOMATIC TRANSAXLE - Troubleshooting 1991 and 1992 Model (AWD Vehicles with DOHC Engine) 3.000 4,000 5,000 6,000 Transfer drive gear rpm (49) Transfer drive gear rpm Vehicle speed km/h (mph) TSB Revision...
Page 749 AUTOMATIC TRANSAXLE - Troubleshootina 1993 model 1,000 2,000 7,000 3,000 4,000 5,000 6,000 Transferdrive gearrpm 90 100 110 120 130 140 150 160 170 180 1 9 0 (31) (37) (43) (49) (56) (62) (68) (75) (81) (87) (93) (99) (106)(111)(118) 6,000 7,000 5,000...
Page 750 AUTOMATIC TRANSAXLE - Troubleshooting INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS improper connection of Based on the wiring diagram, connector, damaged or check whether the continuity and 1. Wiring disconnected harness, grounding of each harness or incorrect wiring con- nection. Continuity Reconnect the connec- tor;...
Page 751 Damaged or discon- 3. Throttle- position sensor TPS terminal 3.5-6.5 kQ/20”C (68°F) SOHC Engine (1989 model)( terminals 2 and 3 (SOHC Engine 1989 model) 4 and 2 (SOHC Improper adjustment Engine _. _ From 1990 model, DOHC Engine) with the engine idling after throttle-valve open- Readjust the TPS in- SOHC Engine...
Page 752 AUTOMATIC TRANSAXLE - Troubleshootincl Connect the pulse generator and 5. Pulse generator body harness, and connect an A or B (checking oscilloscope. Check with the by an oscillo- chassis on a dynamo or with the scope) front wheels raised. With the selector lever at the “L” incorrect installation of position and the engine running at the pulse generator, or...
Page 753 AUTOMATIC TRANSAXLE - Troubleshooting Short-circuit, or dam- Check the resistance between aged or disconnected terminal 1 of the solenoid valve wiring connector and the transaxle case. 2.9 + 0.3Q/20°C (68°F) Replace the PCSV. Connect 12V between the trans- axle case and terminal 1; switch ON and OFF and check for Solenoid valve operation noise.
Page 754 W i t h t h e e n g i n e idliqg, de- Let the engine continue idling. Readjust the ,idling. TSB Revision...
Page 755 AUTOMATIC TRANSAXLE Check the resistance between 9. Torque conver- Short-circuit, or dam- terminal 2 of the solenoid valve too low or too aged or disconnected ter clutch connector and the transaxle solenoid wiring case. Replace the TCC solenoid Standard value: 3 Q/2O”C Solenoid valve connector terminals Connect 12V between the trans-...
Page 756 AUTOMATIC TRANSAXLE - Troubleshooting In the “P” range, check for con- tinuity between terminals 3 and 4, and terminals 8 and 9 ___ Up to 11. Park/Neutral 1992 model or terminals 1 and position switch 4, and terminals 5 and 8 _. _ 1993 Up to 1992 model Continuitv exists In the “R”...
Page 757 AUTOMATIC TRANSAXLE - Troubleshooting Check for continuity between the 1989 and 1990 model 1750447 check for continuity between the Poor contact (sticking) 1990.5, 1991 and and the transaxle case. 1992 model NOTE: Be sure the brakes are No continuity 1993 model Normal Disconnect the 13.
Page 758: Oil Pressure Tests
AUTOMATIC TRANSAXLE - Troubleshooting OIL PRESSURE TESTS I AWU brake pressure pressure (Release)
Page 759 AUTOMATIC TRANSAXLE STANDARD OIL PRESSURE TABLE Conditions Standard oil pressure kPa (psi) Engine speed position position pressure brake clutch pressure p r e s s u r e ) pressure pressure Neutral Idling Approx. (118-128) 2,500 Approx. Approx. 2,500 Approx. 1,000 Reverse Approx.
Page 760 AUTOMATIC TRANSAXLE - Troubleshooting Conditions Standard oil pressure kPa (Psi) Reducing Kickdown Front Rear Select Shift clutch clutch clutch reverse converter lever pressure brake brake position brake pressure position pressure pressure pressure pressure pressure pressure (Release) Neutral Idling (51-68) (51-68) Approx.
Page 761 AUTOMATIC TRANSAXLE - Troubleshooting Remedial Steps If Oil Pressure Is Not Normal FWD A/T Trouble symptom Probable cause Remedy Clogging of oil filter Visually inspect the oil filter; replace the oil filte are all low (or high). if it is cl,ogged. Improper adjustment of oil press- Measure line pressure @ (kickdown brake NOTE...
Page 762 23-56 AUTOMATIC TRANSAXLE - Troubleshooting Remedy Probable cause Trouble symptom O-ring between valve body and Remove the valve body assembly and check to 6. Improper low- be sure that the O-ring at the upper surface of reverse brake transaxle damaged or missing the upper valve body is not missing or dam- pressure aged;...
Page 763 AUTOMATIC TRANSAXLE - Troubleshootinn AWD A/T Problem Probable cause(s) Remedy a. Clogged oil filter. a. Visually check the oil filter; replace it if it is low (or high). b. Improper adjustment of the oil clogged. pressure (line pressure) of the b.
Page 764 23-58 AUTOMATIC TRANSAXLE - Troubleshooting Remedy Probable cause(s) Problem a. Remove the valve body assembly and check 8. Inappropriate low- a. Damage of the O-ring located whether or not there is an O-ring at the upper between the valve body and the reverse brake press- surface of the upper valve body, and if so transaxle.
Page 765: Converter Stall Test
AUTOMATIC TRANSAXLE - Troubleshooting ring brake CONVERTER STALL TEST neutral for 2 minutes to cool transaxle fluid Stall test consist of determining maximum engine speed obtained at full throttle in “D” and “R” between tests. positions. This test checks torque converter stator Stall speed: 1,800-3,200 rpm overrunning clutch operation, and holding ability of 7.
Page 766 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM IGNITION 2 -s/R BACK-UP LIGHT STARTER MOTOR...
Page 767 AUTOMATIC TRANSAXLE - Troubleshooting TAILLIGHT RELAY 2 c-43 POWER/ ECONOMY CHANGE OVER SWITCH (TAIL) AUTO-CRUISE BY 12, BW 1::s AUTOMATIC MODULE REMARK HARNESS FOR AUTO-CRUISE CONTROL SYSTEM.
Page 768 23-62 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) AUTO COMPRESSOR CONTROL UNIT FRONT SIDE COIL 18 ______ -------- CONTROL MODULE CONTROL ELC 4-SPEED AUTOMATIC TRANSAXLE SOLENOID VALVE CONTROL UNIT TSB Revision...
Page 769 AUTOMATIC TRANSAXLE - Troubleshooting THROTTLE (GROUND) 3 C-42 4 c-38 w REMARK HARNESS FOR AUTO-CRUISE CONTROL SYSTEM. TSB Revision...
Page 770 AUTOMATIC TRANSAXLE CIRCUIT DIAGRAM IGNITION 2 -o,-wdR COMBINATION METER BACK-UP LIGHT STARTER MOTOR TSB Revision...
Page 771 AUTOMATIC TRANSAXLE - Troubleshooting IGNITION I GHT a c-37 I234 POWER/ VE ( ECONOMY CHANGE OVER SWITCH (TAIL) AUTO-CRUISE AUTOMATIC MODULE REMARK HARNESS FOR AUTO-CRUISE CONTROL SYSTEM. TSB Revision...
Page 772 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) AUTO COMPRESSOR CONTROL UNIT 8 C-57 8 7 o ~~011s IGNITION POWER TRANSISTOR MODULE JUMPER ELC 4-SPEED AUTOMATIC TRANSAXLE SOLENOID VALVE UNIT...
Page 773 AUTOMATIC TRANSAXLE - Troubleshooting PULSE GENERATOR SERVO SWITCH REMARK TSB Revision...
Page 774 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM IGNITION IGNITION LB a I ,Prl\ COMBINATION BACK-UP LIGHT TSB Revision...
Page 775 23-69 AUTOMATIC TRANSAXLE - Troubleshooting AU’ I ~lc!
Page 776 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) AUTO COMPRESSOR FRONT 61DE r----- MODULE WITHOUT AUTO- CONTROL UNIT TSB Revision...
Page 777 AUTOMATIC TRANSAXLE - Troubleshooting RHEOSTAT SUB FU IBLE LINK 1 d IGNITION THROTTLE ELC 4-SPEED AUTOMATIC TRANSAXLE SOLENOID VALVE REMARK HARNESS FOR AUTO-CRUISE CONTROL SYSTEM.
Page 778 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM IGNITION e-m---- TSB Revision...
Page 779 AUTOMATIC TRANSAXLE - Troubleshootina I GHT 6 C-37 POWER/ SWITCH BY 101 4 RL 102:~ BY 103ka AUTOMATIC MODULE Remark harness for AUTO-CRUISE CONTROL SYSTEM.
Page 780 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) AUTO UNIT ON: 235kPa (33.4~a I I OFF: 2lOkPa C22. BPS I) OFF: 2TOOkPa V384Ps I ) DATA LINK I -I SERVO SWITCH TSB Revision...
Page 781 AUTOMATIC TRANSAXLE - Troubleshooting IGNITION (GROUND) GENERATOR ELC 4-SPEED AUTOtdATIC TRANSAXLE SOLENOID VAL TSB Revision...
Page 782 AUTOMATIC TRANSAXLE CIRCUIT DIAGRAM <From 1993 models> IGNITION ---- STARTER MOTOR TSB Revision...
Page 783 AUTOMATIC TRANSAXLE - Troubleshootina DEDICATED FUSE 6 C-37 ECONOMY AUTOMATIC MODULE ------- w-v---- Remark h a r n e s s f o r a u t o c r u i s e c o n t r o l system...
Page 784 AUTOMATIC TRANSAXLE - Troubleshooting CIRCUIT DIAGRAM (CONTINUED) <From 1993 models> AUTO COMPRESSOR CONTROL UNIT IOD OR STORAGE CONNECTOR SERVO SWITCH TSB Revision...
Page 785 AUTOMATIC TRANSAXLE - Troubleshooting J/C ’ P’L) !%flg RHEOSTAT IGNITION 66 C-60 -- , - - - ELC 4-SPEED AUTOMATIC TRANSAXLE SOLENOID VALVE TSB Revision...
Page 786 AUTOMATIC TRANSAXLE - Troubleshooting E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL COMPONENT LAYOUT Symbol Name Symbol Name Pulse generator A Data link connector Pulse generator 6 4 A/T control module Solenoid valve Throttle position sensor Oil temperature sensor Vehicle-speed sensor Power (PWR)/Economy (ECO) switch NOTE The “Name”...
Page 787 23-81 AUTOMATIC TRANSAXLE - Troubleshooting switch Power (PWR)/ switch control module TSB Revision...
Page 788: Transaxle Fluid Replacement
AUTOMATIC TRANSAXLE - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDUR&g TRANSAXLE FLUID LEVEL INSPECTION 1. Drive until the fluid temperature reaches the usual tem- perature [70-80°C (160- 18O”F)I. 2. Place vehicle on level floor. 3. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in “N”...
Page 789: Selector Lever Operation Check
23-83 AUTOMATIC TRANSAXLE - Service Adjustment Procedures SELECTOR LEVER OPERATION CHECK 1. Shift selector lever to each range and check that lever moves smoothly and is controled. Check that position indicator is correct. 2. Check to be sure the selector lever can be shifted to each position (by button operation as shown in the illustration).
Page 790: Shift Lock Mechanism Check
AUTOMATIC TRANSAXLE - Service Adiustment Procedures SHIFT LOCK MECHANISM CHECK Check to be sure that, under the following conditions, the Brake pedal selector lever cannot be moved from the “P” position to any other position. Ignition key position: “ACC” Brake pedal: Not depressed Button: Pressed Check to be sure that, under the following conditions, the selector lever can be moved smoothly from the “P”...
Page 791 AUTOMATIC TRANSAXLE - Service Adjustment Procedures 6. Loosen adjusting nuts A and B and keep them apart from the adjuster, and then gently pull the end of the cable in the direction of F. 7. Gently tighten adjusting nut A until there is contact with the adjuster.
Page 792 23-86 AUTOMATIC TRANSAXLE - Service Adjustment Procedures <From 1991 models> 1. Place selector lever in “N” (Neutral) position. 2. Place manual control lever in “N” (Neutral) position. 3. To adjust, rotate the switch body so that the manual control lever 5 mm (.2 in.) hole and the switch body 5 mm (.2 in.) hole are aligned.
Page 793 AUTOMATIC TRANSAXLE - Service Adjustment Procedures 23-87 5. Loosen the locking nut to before the V groove of the adjusting rod, and tighten ‘the special tool (inner) until it contacts the locking nut. 6. Engage the special tool (outer) on the lock nut. Rotating the outer cylinder counterclockwise and the inner cylinder clockwise, lock the locking nut and special tool (inner).
Page 794 23-88 AUTOMATIC TRANSAXLE 8. Engage the special tool (outer) on the locking nut. Rotating the outer cyliner clockwise and the inner cylinder counterclockwise, unlock the locking nut and special tool (inner). Caution When unlocking the lock, apply equal force to both tools.
Page 795 AUTOMATIC TRANSAXLE - Service Adjustment Procedures erature sensor 5. Remove the solenoid valve connector holding clip, and press in the connector. 6. Press the tabs of the solenoid valve harness grommet, and FWD . . . From MODEL 1990.5 then push into the case and remove.
Page 796 AUTOMATIC TRANSAXLE - Service Adjustment Procedures 7. Remove the valve body assembly. The manual valve can come out, so be careful not to drop it. 8. Turn the adjustment screw of the regulator valve and adjust so that the pressure (kickdown brake pressure) line becomes the standard value.
Page 797: Reducing Pressure Adjustment
AUTOMATIC TRANSAXLE - Service Adjustment Procedures 15. Tighten valve body assembly mounting. Valve body assembly mounting bolts: 11 Nm (8.0 ftlbs.) A: 18 mm (.709 in.) long B: 25 mm (.984 in.) long C: 40 mm (1.575 in.) long Caution (AWD) Fix the solenoid valve and oil temperature sensor harness securely in the position shown.
Page 798 23-92 AUTOMATIC TRANSAXLE - Service Adjustment Procedures NOTE When adjusting the reducing pressure, aim for the center value (425 kPa, 60 psi) of the standard value allowance. Standard value: 415-435 kPa (59-62 psi) Oil pressure change for each turn of adjustment screw: 22 kPa (3.1 psi) .
Page 799: Speedometer Cable Replacement
23-93 AUTOMATIC TRANSAXLE (3) Using the special tool, tap the drive shaft oil seal into the transaxle. (4) Apply a coating of the transaxle fluid to the lip of the oil seal. Transaxle fluid: DIAMOND ATF SP or equivalent 1 6 0 0 2 4 SPEEDOMETER CABLE REPLACEMENT fasten the new speedometer cable.
Page 800 23-94 AUTOMATIC TRANSAXLE - Transaxle Control TRANSAXLE CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation Removal and Installation of Console Box Assembly (Refer to GROUP 52-Floor Console.) *Removal and Installation of Air Cleaner (Refer to GROUP 15-Air Cleaner.) <From 1990 models> 2.
Page 801 AUTOMATIC TRANSAXLE - Transaxle Control Pre-removal and Post-installation Operation (Refer to GROUP 52-Floor Console.) bly, Column Cover, Lap Shower Duct and Foot Shower (Refer to GROUP 5’2-Instrument Panel.) <From 1990 models> 9-14 Nm 4-6 N m 3-4 ftlbs. 3 - 4 ftlbs. Key-interlock cable removal steps 3.
Page 802 AUTOMATIC TRANSAXLE - Transaxle Control INSPECTION Check the control cable for function and for damage. Check the bushing for wear or damage. POWER (PWR)/ECONOMY (ECO) SWITCH the console box. (2) Check for continuity between terminals when the switch is OFF and when ON. switch NOTE O-O indicates that there is continuity between the terminals.
Page 803 AUTOMATIC TRANSAXLE - Transaxle Control 14. INSTALLATION OF CLIP When connecting the control cable to the transaxle mount bracket, install the clip until it contacts the control cable, in the position shown in the figure. . ADJUSTMENT OF TRANSAXLE CONTROL CABLE Refer to the section concerning adjustment of the park/ neutral position switch.
Page 804 AUTOMATIC TRANSAXLE - Transaxle Control DISASSEMBLY AND REASSEMBLY (SELECTOR LEVER ASSEMBLY) 2.0 Nm or more 1.4 ft.lbs. or more 2.0 Nm or more Disassembly steps 1. Overdrive control switch connector Cover 3. Selector knob 4. Overdrive control switch button 5. Overdrive control switch 6.
Page 805 AUTOMATIC TRANSAXLE SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF OVERDRIVE CONTROL SWITCH CON- NECTOR Disconnect the overdrive control switch connector and then remove the terminal from the overdrive control switch connector. Screwdriver 4. REMOVAL OF OVERDRIVE CONTROL SWITCH (1) Using the flat-tip screwdriver, remove the overdrive control switch button.
Page 806 AUTOMATIC TRANSAXLE - Transaxle Oil Cooler Hoses REMOVAL AND INSTALLATION <Up to 1992 models> Pre-removal and Post-installation 3 - 5 Nm Operation 4 - 6 Nm Drainage and Filling of Automatic Trans- 3 - 4 ft.lbs. axle Fluid (Refer to GROUP 00 - Maintenance Service.) 3 - 4 ft.lbs.
Page 807 AUTOMATIC TRANSAXLE - Transaxle Assembly <FWD> REMOVAL AND INSTALLATION Pre-removal and Post-installation Op- eration @Draining and Supplying of the Transaxle Fluid (Refer to GROUP 00-Maintenance Ser- vice.) *Removal and Installation of the Battery and Battery Tray *Removal and Installation of the Air Com- pressor (Refer to GROUP 33B-Air Compressor.) 27-34 Nm...
Page 808 AUTOMATIC TRANSAXLE - Transaxle Assemblv <FliVD> <From 1990 models> 27-34 Nm 43-58 ftlbs. 43-58 ftlbs. 43-55 Nm 22-25 ftlbs. 22-25 ft.lbs. 2. Adjusting nut 3. Connection for transaxle control cable (Refer to P.23-85.) 4. Solenoid connector 5. Park/neutral position switch connector 6.
Page 809 AUTOMATIC TRANSAXLE - Transaxle Assembly dVVD> 43-52 ft.lbs. 4 6 - 5 3 24-35 Nm 33-38 ftlbs. 17-25 ftlbs. 7 - 9 ftlbs. - - -- Nm 43-52 ftlbs. 14. Under guard 15. Cotter pin 16. Connection for tie rod end 17.
Page 810 AUTOMATIC TRANSAXLE SERVICE POINTS OF REMOVAL 16. DISCONNECTION OF TIE ROD END Using the special tool, disconnect the tie rod end from the knuckle. Caution 1. Be sure to tie the cord of the special tool to the nearby part. 2.
Page 811 AUTOMATIC TRANSAXLE - Transaxle Assembly <AWD> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation axle Fluid (Refer to GROUP 00-Maintenance Removal and Installation of the Bat- tery and Battery Tray Cleaner (Refer to GROUP 15-Air Cleaner.) 14.5-19 ft.lbs. 27-34 Nm 22-25 ft.lbs. 22-25 ft.lbs.
Page 812 AUTOMATIC TRANSAXLE - Transaxle Assembly <AWD> 44-57 ftlbs. 44-57 ftlbs. 46-53 Nm 34-38 ftlbs. 18-24 ftlbs. 30-40 12. Under cover 13. Connection for tie rod end (Refer to 14. Connection for lower arm ball joint (Refer to P.23-104.) 17. Front exhaust pipe 18.
Page 813 AUTOMATIC TRANSAXLE SERVICE POINTS OF REMOVAL 15. REMOVAL OF DRIVE SHAFT (R.H.) from the front hub. drive shaft (R.H.) from the transaxle. Caution Do not pull out the drive shaft; doing so will damage the T.J.; be sure to use the pry bar. 16.
Page 814 AUTOMATIC TRANSAXLE - Transfer REMOVAL AND INSTALLATION 22-29 ftlbs. 44-57 ftlbs. Removal steps 1. Front exhaust pipe 2. Transfer assembly (Refer to P.23-105.) TSB Revision...
Page 815 PROPELLER SHAFT CONTENTS PROPELLER SHAFT ........Lubricants .
Page 816 PROPELLER SHAFT - Specifications The AWD vehicles have been discontinued from 1993 models. GENERAL SPECIFICATIONS Specifications Items Propeller shaft 4 joint propeller shaft 4 joint propeller shaft Length x O.D. mm (in.) Front 707 x 50.8 (27.8 x 2.00) 707 x 50.8 (27.8 x 2.00) 764.4 x 65 (30.1 x 2.56) Center 777.5 x 65 (30.8 x 2.56)
Page 817 PROPELLER SHAFT - Specifications/Special Tools/T;oubleshooting LUBRICANTS Items Specified lubricant Quantity Sleeve yoke surface Hypoid gear oil API classification GL-4 or As required higher, SAE 75W-85W Lobro joint Outer and inner races Repair kit grease As required assembly ball grooves Rubber packing Lobro joint assembly Repair kit grease 4 5 - 5 5 g...
Page 818 PROPELLER SHAFT - Propeller Shaft REMOVAL AND INSTALLATION Removal steps Propeller shaft Gear oil: Hypoid gear oil API classification GL-4 or higher, SAE 75W-85W SERVICE POINTS OF REMOVAL 3. REMOVAL OF SPACER The number of spacers used on each vehicle differs. Check the number of spacers used and write it down for reference during reassembly.
Page 819 PROPELLER SHAFT - Propeller Shaft Do not lower rear end of the vehicle as the oil will flow out of the transfer. avoid Be cautious to damage to the oil seal lip of the transfer. Use the special tool provided as a cover to prevent the entry of foreign objects into the transfer.
Page 820 PROPELLER SHAFT - Propeller Shaft DISASSEMBLY AND REASSEMBLY 116-159 ft.lbs. Universal joint kit 19 17 18 16 15 11 Disassembly steps * I, Snap ring 1010015 4. Flange yoke 5. Sleeve yoke 6. Front propeller shaft e +4 7. Lobro joint assembly <MTT> or D.O.J. 18 16 11 14 assembly <AA>...
Page 821 PROPELLER SHAFT - Propeller Shaft Grease points Rubber mount Dust seal I n n e r r a c e ioxoow Grease: Repair kii grease Grease: ‘Repair kit grease 45-55 g (1.59-1.94 oz.] D.O.J. assembly:...
Page 822 PROPELLER SHAFT - Propeller Shaft SERVICE POINTS OF DISASSEMBLY 1. REMOVAL OF SNAP RING (1) Make mating marks on the yoke and universal joint that is to be disassembled. 2. REMOVAL OF JOURNAL BEARING Journal Force out the journal bearings from the yoke with a general service tool by the following procedures.
Page 823 PROPELLER SHAFT - Propeller Shaft (2) After placing mating marks on the center bearing assembly (front) bracket and center propeller shaft, and the center bearing assembly (rear) bracket and rear propeller shaft, remove the center bearing bracket. Caution The mounting rubber cannot be removed from the center bearing bracket.
Page 824 PROPELLER SHAFT Shaft (3) If the outer race cannot be removed, remove the complete Lobro joint assembly from the center prop- / a s s e m b l y eller shaft by using a commercially available puller. 15. REMOVAL OF D.O.J. ASSEMBLY <A/T> (1) Remove the D.O.J.
Page 825 PROPELLER SHAFT - Propeller Shaft SERVICE POINTS OF REASSEMBLY 19. INSTALLATION OF WASHER/18. LOBRO JOINT BOOT OR D.O.J. BOOT/17. BOOT BAND/lG. R U B B E R ASSEMBLY / 14. SNAP RING shaft. (2) Wrap the splined end of center propeller shaft with adhesive tape.
Page 826 PROPELLER SHAFT - Propeller Shaft (5) Apply specified grease to the Lobro joint assembly. Specified grease: Repair kit grease (6) Apply a thin and even coat of the specified grease to the Rubber king rubber packing and fit the packing in the boot side end of the Lobro joint assembly.
Page 827: Propeller Shaft
PROPELLER SHAFT 19. INSTALLATION OF WASHER/18. D.O.J. JOINT BOOT/ 17. BOOT BAND/lG. RUBBER PACKING/15 D.O.J. ASSEMBLY <A/T>/14. SNAP RING (1) Put the washer and boot band on t.he center propeller shaft. adhesive tape. Washer Tape then remove the adhesive tape on the splined end of the propeller shaft.
Page 828 PROPELLER SHAFT - Propeller Shaft Apply a thin and even coat of the specified grease to the rubber packing and fit the packing in the boot king side end of the D.O.J. assembly. Specified grease: Repair kit grease Caution For the D.O.J. assembly, the side that has the concave part (for the rubber packing) in the outer race is the D.O.J.
Page 829 PROPELLER SHAFT - Propeller Shaft NOTE Face the side onto which the center bearing bracket mating mark is placed and the dust seal is installed to the side of the center propeller shaft and rear propeller shaft. 11. INSTALLATION OF RUBBER PACKING/lo. COMPAN- ION FLANGE/S.
Page 830 PROPELLER SHAFT - Propeller Shaft (2) Press fit the journal bearings to the yoke by using the general service tool according to the following proce- fit them by using the general service tool. Mating marks 1. INSTALLATION OF SNAP RING (1) Install snap rings of the same thickness onto both sides of each yoke.
Page 831: Front Axle
FRONT AXLE CONTENTS DRIVE SHAFT ..........12 SPECIFICATIONS ..........General Specifications ........HUB AND KNUCKLE ........Lubricants ............SERVICE ADJUSTMENT PROCEDURES..Service Specifications ........Hub End Play Inspection Torque Specifications ..............SPECIAL TOOLS ..........TROUBLESHOOTING ........
Page 832 FRONT AXLE - Specifications GENERAL SPECIFICATIONS Items Wheel bearing Double-row angular-contact ball bearing mm (in.) O.D. x I.D. 80 x 40 (3.15 x 1.57) Drive shaft <Up to 1992 models> Joint type <From 1993 models> Outer R.J. or B.J.* B.J. B.J.
Page 833 FRONT AXLE - Specifications/Special Tools LUBRICANTS Specified lubricants Quantity Items T.J. boot grease <SOHC> Repair kit grease B.J. boot grease 110 g (3.9 oz.) Repair kit grease 90 g (3.2 oz.) R.J. boot grease <SOHC> Repair kit grease inner dust seal Multipurpose grease 4 - 6 (.14-.21 o z .
Page 834 Tools FRONT AXLE I Use Number Press-fitting of the wheel bearing and oil seal Rear suspension bushing base OPTIONAL: AVAILABLE FROM O.T.C. Rear suspension arbor OPTIONAL: AVAILABLE FROM O.T.C. Axle puller Removal of the drive shaft GENERAL SERVICE TOOL Inner shaft remover Removal of the inner shaft Bearing and oil seal Removal of wheel bearing...
Page 835 FRONT AXLE - Troubleshooting/Service Adjustment Procedures Remedy Symptom Probable cause Vehicle pulls to one side Seizure of drive shaft ball joint Replace Replace Abnormal wear, play or seizure of wheel bear- Adjust or replace Malfunction of front suspension or steering Replace Vibration Bend, damage or abnormal wear of drive shaft...
Page 836 FRONT AXLE - Hub and Knuckle REMOVAL AND INSTALLATION Vehicles with ACTIVE-ECS*’ 65-76 ft.lbs. 58-72 ftlbs. 43-52 ft.lbs. Removal steps 1. Cotter pin l + 3. Washer 4. Front speed sensor connection 12. Drive shaft 13. Front strut mounting bolt GROUP 35-Speed sensor) 14.
Page 837 FRONT AXLE - Hub and Knuckle SERVICE POINTS OF REMOVAL REMOVAL OF DRIVE SHAFT NUT Loosen the drive shaft nut while the vehicle is on the floor with the brakes applied. DISCONNECTION OF FRONT SPEED SENSOR Remove the mounting bolts which hold the speed sensor bracket to the knuckle, and then remove the speed sensor.
Page 838 FRONT AXLE - Hub and Knuckle (2) Insert a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the transaxle. Caution 1. Do not pull on the drive shaft; doing so will damage the T.J.;...
Page 839 FRONT AXLE - Hub and Knuckle DISASSEMBLY AND REASSEMBLY 9-14 Reassembly steps Disassembly steps 8. Front toothed rotor (Refer to GROUP 35-Wheel Speed 2. Oil seal (drive shaft side) Sensor.) 3. Snap ring 7. Knuckle. 4. Oil seal (hub side) 6.
Page 840 FRONT AXLE - Hub and Knuckle 2. REMOVAL OF OIL SEAL (DRIVE SHAFT SIDE) Remove the oil seal (drive shaft side) from the knuckle. 5. REMOVAL OF WHEEL BEARING (1) Crush the oil seal in two places so that the tabs of the special tool will be caught on the wheel bearing inner race.
Page 841 FRONT AXLE SERVICE POINTS OF REASSEMBLY 5. INSTALLATION OF WHEEL BEARING (1) Fill the wheel bearing with multipurpose grease. (2) Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces. (3) With the wheel bearing inner removed, press-in the bearing by using the special tools.
Page 842 FRONT AXLE (2) Measure to determine whether the end play of the hub is within the specified limit or not. Limit: 0.2 mm (.008 in.) or less (3) If the starting torque and hub end play are not within the limit range while the nut is tightened to 200-260 Nm probably not been installed correctly.
Page 843 FRONT AXLE - Drive Shaft REMOVAL AND INSTALLATION 24-34 Nm 17-26 Nm 12-19 ft.lbs. Removal steps 1. Front height sensor connection <Vehicles with ACTIVE-ECS> (Refer to 7. Cotter pin l + 2. Cotter pin 8. Tie rod end connection 9. Drive shaft l * 4.
Page 844 FRONT AXLE 26-14 9. REMOVAL OF DRIVE SHAFT (1) Use the general service tool to push out the drive shaft from the front hub. (2) Insert a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the transaxle.
Page 845 Drive Shaft FRONT AXLE - DISASSEMBLY AND REASSEMBLY (T.J.-R.J. TYPE) T.J. Joint kit R.J. Boot kit R.J. Joint and shaft kit Disassembly steps l + 1. T.J. boot band l + 2. Boot band (small) T.J. case 4. Snap ring 5.
Page 846 FRONT AXLE - Drive Shaft (T.J.-R.J. Type) 26-16 Lubrication points Grease: Repair kit grease 120 g (4.2 oz.) NOTE The grease in the repalr kit should be divided in half for use, respectively, at the joint and inslde the boot. Grease: Repair kit grease 120 g (4.2 oz.) NOTE...
Page 847 FRONT AXLE - Drive Shaft (T.J.-R.J. Type) INSPECTION Check the drive shaft for damage, bending or corrosion. Check the drive shaft splines for wear or damage. Check for entry of water and/or foreign material into R.J. Check the spider assembly for roller rotation, wear or corrosion.
Page 848 FRONT AXLE - Drive Shaft (T.J.-R.J. Type) (7) For the boot band (small), cut away so that the length of the band width remains, and then bend it over the crimped band fitting. For the boot band (large), cut away so that the length until the clip holder position remains, and then secure by the clip.
Page 849 FRONT AXLE - Drive Shaft ‘(T.J.-B.J. Type) DISASSEMBLY AND REASSEMBLY (T.J.-B.J. TYPE) Disassembly steps l 1. T.J. boot band 3. T.J. case 4. Snap ring (Refer to P.26-16.) 5. Spider assembly (Refer to P.26-16.) 7. B.J. boot band 8. Boot band (small) 11.
Page 850 FRONT AXLE Lubrication points NOTE The grease in the repair kit should be divided in half for use. respectively, at the ioint and inside the boot. Grease: Repair kit grease 120 g (4.2 oz.) <SOHC> 130 g (4.5 oz.) <DOHC> NOTE The grease in the repair kit should be divided in half for use, respectively, at...
Page 851 26-21 FRONT AXLE - Drive Shaft (T.J.-B.J. Type) SERVICE POINTS OF REASSEMBLY 9. INSTALLATION OF B.J. BOOT/6. T.J. BOOT and then install the R.J. boot and T.J. boot, in that order. order. Caution Distinguish between B.J. boot and T.J. boot parts according to the section “Parts Distinction”, and be sure to assemble them correctly.
Page 852 FRONT AXLE DRIVE SHAFT <AWD-UP TO 1992 MODELS> shaft has an inner shaft and center bearing so that the left and right side drive shafts are same length. PARTS DISTINCTION Boots and boot bands can be distinguished by the indicated part numbers shown below. TSB Revision...
Page 853 26-23 FRONT AXLE - Drive Shaft REMOVAL AND INSTALLATION Pm-removal and Post-installation Operation l Removal and installation of the Under Cover 43-52 ftlbs. 43-52 ft.lbs. 24-34 Nm 17-25 ft.lbs. 145-188 ft.lbs. 26-33 ft.lbs. Removal steps 2. Drive shaft nut (Refer to P.26-13, 14.) 6.
Page 854 26-24 FRONT AXLE - Drive Shaft (2) Remove the drive shaft and inner shaft assembly (L.H.) from the transaxle by lightly tapping the T.J. case with a plastic hammer, etc. (3) Remove the drive shaft (R.H.) as described below. drive shaft, and then pry the drive shaft from the transaxle.
Page 855 26-25 FRONT AXLE - Drive Shaft DISASSEMBLY AND REASSEMBLY T.J. boot repair kit T.J. kit Bearing dust seal kii B.J. kii B.J. boot repair kit Disassembly steps l + 1. T.J. boot band l + 2. Boot band (small) l + 3. T.J. case and inner shaft assembly Bracket assembly kii T.J.
Page 856 26-26 FRONT AXLE - Drive Shaft irease Points Grease: Multipurpose grease Inner dust seal 7-10 g (.25-.35 oz.) Grease: Repair kit grease NOTE The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. Grease: Repair kit grease NOTE The grease in the repair kit should be...
Page 857 26-27 FRONT AXLE SERVICE POINTS OF DISASSEMBLY 6. REMOVAL OF INNER SHAFT (1) Using the special tool, remove the inner shaft assem- bly, together with the seal plate, from the T.J. case. NOTE Press the tool directly against the seal plate. The tool under pressure will puncture and deform the seal plate, and push out the inner shaft underneath.
Page 858 FRONT AXLE - Drive Shaft SERVICE POINTS OF REASSEMBLY 10. INSTALLATION OF CENTER BEARING (1) Apply multipurpose grease to the center bearing and inside the center bearing bracket. (2) Use the special tools to press-fit the center bearing into the center bearing bracket. 11 LOO10 Outer dust seal (1) Apply multipurpose grease to the rear surfaces of all...
Page 859 26-29 FRONT AXLE - Drive Shaft 6. INSTALLATION OF INNER SHAFT Use the pipe to hold the inner race of the center bearing Inner shaft and force the inner shaft into place. 3. INSTALLATION OF T.J. CASE AND INNER SHAFT ASSEMBLY (1) Apply multipurpose grease to the inner shaft spline, then press fit it into the T.J.
Page 860 NOTES...
Page 861: Rear Axle
REAR AXLE HUB AXLE SHAFT ........... 17 <VEHICLES WITH REAR DISC BRAKES> ............DIFFERENTIAL CARRIER ........
Page 862 27-2 REAR AXLE <FWD> - Specifications/Troubleshooting REAR AXLE <FWD> SPECIFICATIONS GENERAL SPECIFICATIONS DOHC SOHC Wheel bearing Unit ball bearing Tapered roller bearing mm (in.) Outer 39.9 x 17.5 (1.57 x ,691 inner 50.3 x 27.0 (1.98 x 1.06) SERVICE SPECIFICATIONS SOHC DOHC Standard value...
Page 863 27-3 REAR AXLE <FWD> SPECIAL TOOLS Tool Number Name Bearing and oil seal GENERAL Installation of outer bearing outer race installer set Installation of inner bearing outer race SERVICE TOOL Installation of oil seal Handle Installation of the drive gear Bushing remover and installer base OPTIONAL: AVAIlABLE FROM O.T.C.
Page 864 27-4 REAR AXLE <FWD> - Service Adjustment Procedures rope to the hub bolt, and, pulling at a 90” angle from the hub bolt, measure to determine whether or not the rotary- sliding resistance of the rear hub is the standard value. Standard value: Rear hub rotary-sliding resistance When a new bearing is used...
Page 865 27-5 REAR AXLE <FWD> REAR HUB ROTARY-SLIDING !RESlSTANCE (TORQUE) ADJUSTMENT Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. Release the parking brake. Remove the caliper assembly and the brake disc. After turning the hub a few times to seat the bearing, attach a spring balance and rope to the hub bolt, and, pull- ing at a 90”...
Page 866 REAR AXLE <FWD> REAR AXLE HUB <VEHICLES WITH REAR DRUM BRAKES> REMOVAL AND INSTALLATION Removal steps 2. Split pin 3. Lock cap 4. Lock nut Adjustment of wheel bearing end play (Refer to P.27-3.) 5. Tongued washer 6. Outer bearing inner race 7.
Page 867 27-7 REAR AXLE <FWD> DISASSEMBLY AND REASSEMBLY Disassembly steps * 1. Oil seal 2. Inner bearing c 4. Inner bearing outer race 5. Rear hub SERVICE POINTS OF DISASSEMBLY Inner bearing Outer bearing outer race outer race and outer bearing outer races by driving Remove inner Brass rod...
Page 868 27-8 REAR AXLE -4WD> REAR AXLE HUB <VEHICLES WITH REAR DISC BRAKES> REMOVAL AND INSTALLATION 36-43 ftlbs. 9-14 Nm Removal steps 1. Rear speed sensor <Vehicles with 2. Caliper assembly 3. Brake disc 4. Hub cap l 4 5. 6. Tongued washer 7.
Page 869 27-9 REAR AXLE <FWD> 2. REMOVAL OF CALIPER ASSEMBLY Remove the caliper assembly and suspend it with a piece of wire. 8. REMOVAL OF REAR ROTOR Caution Care must be taken not to scratch or otherwise damage the teeth of the rotor. The rotor must never be dropped. If the teeth of the rotor are chipped, resulting in a deformation of the rotor, it will not be able to accurate- ly detect the wheel rotation speed, and the system will...
Page 870 REAR AXLE <AWD> - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Specifications Axle shaft Semi-floating type Shaft dimensions Outer bearing portion dia. mm (in.) 35 (1.38) Inner bearing portion dia. mm (in.) 28 (1.10) Center portion dia. mm (in.) 34.5 (1.36) Overall length mm (in.) 214.9 (8.46) Bearing O.D.
Page 871 REAR AXLE <AWD> - SDecifications Items Specifications Differential gear backlash mm (in.) O-0.076 (O-.003) Drive pinion rotation starting torque with oil seal Nm (in.lbs.) New part New part/reusable part without oil seal Nm (in.lbs.1 New part New part/reusable part Rear axle total backlash mm (in.) 5 (2) Drive gear runout mm (in.) 0.05 (.002)
Page 872 REAR AXLE <AWD> - Specifications/Special Tools SEALANTS AND ADHESIVES Specified sealants and adhesives Items Vent plug Differential cover Drive gear threaded hole SPECIAL TOOLS Number Name I Use ide hammer with Removal of the drive pinion rear bearing inner TSB Revision...
Page 873 REAR AXLE <AWD> - Special Tools Tool Number Name I Use Driving-out and installation of differential Lower arm bushing installer and remover support member bushing llation of drive pinion front bearing outer oval of axle shaft inner bearing Removal of drive pinion rear bearing inner race TSB Revision...
Page 874 REAR AXLE <AWD> Remedy Probable cause Symptom AXLE SHAFT Replace Noise while wheels are Brake drag rotating Bent axle shaft Worn or scarred axle shaft bearing Replace Worn or damaged oil seal Grease leakage Malfunction of bearing seal Replace Wear, play or seizure of ball joint Noise Excessive drive shaft spline looseness Correct or replace...
Page 875 REAR AXLE <AWD> - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system, measure the rear axle total backlash by the following procedures to see if the differential carrier assembly requires removal.
Page 876 REAR AXLE <AWD> REAR WHEEL ROTATION SLIDING RE- BEARING SISTANCE CHECK (1) Remove the drive shaft from the companion flange. (2) Remove the brake pad or caliper assembly. (3) Attach a spring balance and rope to the hub bolt, then, pull- ing the balance at a right angle to the hub bolt, measure the rotation sliding resistance to see whether it is within the standard value.
Page 877: Axle Shaft
REAR AXLE <AWD> - Axle Shaft AXLE SHAFT Post-installation Operation Stroke (Refer to GROUP 36-Service Adjustment Procedures.) 55-65 Nm 116-159 36-43 50-60 ft.lbs. Nm 9-14 Nm Removal steps 1. ifsa.yyed sensor <Vehicles with 2. Brake caliper assembly 3. Brake disc 4.
Page 878 REAR AXLE <AWD> - Shaft Axle 5. REMOVAL OF SELF LOCKING NUT With the special tool, secure the axle shaft and remove the companion flange self-locking nut. 8. REMOVAL OF AXLE SHAFT ASSEMBLY With the special tool, remove the axle shaft from the trailing arm.
Page 879 REAR AXLE <AWD> - Axle Shaft SERVICE POINTS OF INSTALLATION Trailing arm 15. INSTALLATION OF INNER BEARING With the special tool, press fit the inner bearing onto the trailing arm. 14. INSTALLATION OF OIL SEAL With the special tool, press fit the oil seal onto the trailing Trailing arm arm with the depression in the oil seal facing upward, and until it contacts the shoulder on the inside of the inner arm.
Page 880: Drive Shaft
REAR AXLE <AWD> - Axle Shaft/Drive Shaft 9. INSTALLATION OF REAR ROTOR <VEHICLES WITH Press fit the rear rot,or to the axle shaft with the rear rotor groove surface toward the axle shaft flange. 5. INSTALLATION OF SELF LOCKING NUT With the special tool, secure the axle shaft and tighten the companion flange self locking nut.
Page 881 27-21 REAR AXLE <AWD> Shaft REMOVAL AND INSTALLATION Removal steps 1. Bolt + 2. Drive shaft 3. Circlip 4 4. Oil seal SERVICE POINTS OF REMOVAL 2. REMOVAL OF DRIVE SHAFT Using a tire lever, etc. remove the drive shaft from the differential carrier.
Page 882 27-22 REAR AXLE <AWD> DISASSEMBLY AND REASSEMBLY 1 lAOO69 D.O.J. kit B.J. boot repair kit D.O.J. boot repair kit Disassembly steps Reassembly steps 1. Circlip 16. Drive shaft and B.J. 2. Boot band (B) 15. Dust cover 3. Boot band (C) 4 14.
Page 883 27-23 REAR AXLE <AWD> LUBRICATION POINTS Grease: Repair kit grease 90 g (3.20 oz.) Caution The orease in the repair kit should be divided in half for use, respectively, at the joint and in ide the boot. A soecial tvoe of grease is allowd to come in contact with the joint.
Page 884 REAR AXLE <AWD> - Drive Shaft 27-24 SERVICE POINTS OF DISASSEMBLY 8. REMOVAL OF SNAP RING/8. BALLS/S. D.O.J. INNER the D.O.J. inner race, the D.O.J. cage, and the remove balls as a unit. (2) Clean the D.O.J. inner race, the D.O.J. cage, and the balls, without dismantling them.
Page 885 REAR AXLE <AWD> 27-25 (4) Secure the B.J. boot with boot bands (A) and (C) to the drive shaft and B.J. Caution Snap Ensure that the B.J. is at a zero angle with the drive shaft to ensure the boot contains the specified amount of air.
Page 886 27-26 DIFFERENTIAL CARRIER REMOVAL AND INSTALLATION and Post-installation Operation Gear Draining and Refilling of Differential Oil (Refer to P.27-15.) Removai and installation of Centf haust Pipe (Refer to GROUP Exhaust PiDe and Main Muffler.) 19-28 Nm 72-87 ft.lbs. 14-21 Nm 9-14 Nm 72-87 ft.lbs.
Page 887 REAR AXLE <AWD> - Differential Carrier 27-27 DIFFERENTIAL SUPPORT MEMBER BUSHING RE- Beveled place PLACEMENT Use the special tool to pull out and press in the differential support member bushing. NOTE Press in the bushing from the beveled part of the differential support member;...
Page 888 27-28 REAR AXLE <AWD> - Differential Carrier FINAL DRIVE GEAR TOOTH CONTACT Check the final drive gear tooth contact by following the steps of the drive gear teeth. (2) Insert a brass rod between the differential carrier and the differential case, and then rotate the companion flange by hand (once in the normal direction, and then once in the reverse direction) while applying a load to the drive gear, so that the revolution torque [approximately 2.5-3.0 Nm...
Page 889 REAR AXLE <AWD> contact Standard tooth pattern 1 Narrow tooth side during forward movement) 3 Wide tooth side 4 Coast-side tooth surface (the side applying pow- er during reverse movement) Problem Solution Tooth contact pattern resulting from exces- sive pinion height The drive pinion is positioned too far from the shim, and position the drive pinion closer to the center of the drive gear.
Page 890 REAR AXLE <AWD> DISASSEMBLY Inspection Before Disassembly *Differential Gear Backlash <Conventional type> (Refer to P.27-27.) *Final Drive Gear Tooth Contact (Refer to Disassembly steps 2. Vent plug Bearing cap Differential case assembly 5. Side bearing spacer 20. Drive pinion assembly Side bearing inner race 21.
Page 891 27-31 REAR AXLE <AWD> SERVICE POINTS OF DISASSEMBLY 4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY Prize out the differential case assembly using hammer shafts. NOTE When removing the differential case assembly, the remov- al should be accomplished slowly and carefully and caution paid to ensure that the side bearing outer race is not dropped.
Page 892 27-32 REAR AXLE <AWD> - Differential Carrier 20. REMOVAL OF DRIVE PINION Mating marks companion flange. NOTE Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. spacer and drive pinion front shims. 0161 24.
Page 893 27-33 REAR AXLE <AWD> - Differential Carrier REASSEMBLY 116-159 ft.lbs. Final drive Differential gear set gear set Reassembly steps 1. Gear carrier Adjustment of differential gear backlash + 4. Drive pinion front bearing outer race 19. Side gear spacer Adjustment of pinion height 20.
Page 894 27-34 REAR AXLE <AWD> Lubrication, sealing and adhesion points Sealant: 3M ATD Part No.6661, 6663 or equivalent Part No. 4170 or equivalent TSB Revision...
Page 895 27-35 REAR AXLE <AWD> SERVICE POINTS OF REASSEMBLY 2. PRESS FITTING OF OIL SEAL (1) With the special tool, press fit the oil seal until it is flush with the end of the gear carrier. (2) Apply multipurpose grease to the oil seal lip. 3.
Page 896 REAR AXLE <AWD> (4) Position the special tool in the side bearing seat of the gear carrier, and then select a drive pinion rear shim of a thickness which corresponds to the gap between the special tools. NOTE Clean the side bearing seat thoroughly. Confirm that the special tool is in close contact with the side bearing When selectina the drive oinion rear shims.
Page 897 REAR AXLE <AWD> (6) Install the drive pinion assembly and companion flange with mating marks properly aligned, and tighten the companion flange self-locking nut to the specified torque by using the special tools. verify that the drive pinion turning torque complies with the standard value.
Page 898 27-38 REAR AXLE <AWD> - Differential Carrier adjust the backlash by installing thicker side gear spacers. and confirm that it is within the limit. NOTE (1) After adjustment, check that the backlash is the less than the limit and differential gear rotates smoothly.
Page 899 REAR AXLE <AWD> - Differential Carrier 26. PRESS-FITTING OF SIDE BEARING INNER RACE Press-fit the side bearing inner races to the differential case by using the special tool. ADJUSTMENT OF FINAL DRIVE GEAR BACKLASH Adjust the final drive gear backlash by the following procedures: those removed, to the side bearing outer races, and then mount the differential case assembly into the gear...
Page 900 WHEEL CONTENTS SERVICE ADJUSTMENT PROCEDURES ..TROUBLESHOOTING ....*..... Tire Inflation Pressure Check ..... . Bald Spots Tire Wear Check .
Page 901 31-2 WHEEL AND TIRE - Specifications GENERAL SPECIFICATIONS DOHC-FWD DOHC-AWD Items SOHC Wheel <Up to 1992 models> Tire size Steel type or Wheel type Steel type or Steel type or Aluminium type Aluminium type Aluminium type 14 x 5% JJ 14 x 5’/2 JJ or Wheel size Amount of wheel offset...
Page 902 31-3 WHEEL AND TIRE - Troubleshooting TROUBLESHOOTING Symptom Probable cause Remedy Rapid wear Under-inflation or Adjust the tire pressure at shoulders lack of rotation Rapid wear Over-inflation or at center lack of rotation Cracked Under-inflation treads Near on Excessive oe-in Adjust the imbalanced wheels vheel ack of rotation of tyres or worn or...
Page 903 31-4 WHEEL AND TIRE - Service Adjustment Procedures SERVICE ADJUSTMENT PROCEDURES TIRE INFLATION PRESSURE CHECK Check the inflation pressure of the tires. If it is not within the standard value, make the necessary adjustment. TIRE WEAR CHECK Measure the tread depth of tires. Limit: 1.6 mm (.06 in.) If the remaining tread depth is less than the limit, replace the W ear indicator...
Page 904: Wheel And Tire
WHEEL AND TIRE WHEEL AND TIRE REMOVAL AND INSTALLATION Steel wheel <SOHC> < D O H C > <up to 1 mode 1110396 Aluminium type wheel <Up to 1992 models> Removal steps <From 1993 models> 1. Wheel cover <Vehicles with wheel cover>...
Page 905 WHEEL AND TIRE INSTRUCTIONS FOR ALUMINUM TYPE WHk&g detergent has been used, or salt from sea water or road chemicals has adhered, wash the vehicle as soon as possible. After washing the vehicle, apply body or wheel wax to the aluminum type wheels to prevent corrosion. 2.
Page 906: Table Of Contents
POWER PLANT CONTENTS SPECIFICATIONS ..........CENTERMEMBER AND CROSSMEMBER..8 Service Specifications ........ENGINE MOUNTING ........4 Torque Specifications ........ENGINE ROLL STOPPER ......... 6 TRANSAXLE MOUNTING ........ SPECIAL TOOL ..........3 TROUBLESHOOTING ........
Page 907 32-2 POWER PLANT MOUNT - Specifications SPECIFICATIONS SERVICE SPECIFICATIONS Specifications Standard value Crossmember bushing (A) projection m m ( i n . ) 7.2-10.2 (.28-.40) Crossmember bushing (B) projection m m ( i n . ) 6 . 5 - 9 . 5 (.26-.37) TORQUE SPECIFICATIONS Engine mounting Engine mount insulator nut (large)
Page 908 32-3 POWER PLANT MOUNT Items Centermember and crossmember <AWD> 29-36 Front roll stopper to No. 1 crossmember 36-47 Front roll stopper insulator nut 58-72 No. 1 crossmember installation nut Gusset installation bolt 58-72 Right member installation bolt (front) Right member installation bolt (rear) 58-72 Left member installation bolt (front) 51-58...
Page 909: Engine Mounting
POWER PLANT MOUNT - Troubleshooting/Engine Mounting 32-4 TROUBLESHOOTING Remedy Probable cause Symptom Replace Cracked rubber parts of insulator Excessive engine wob- Retighten gine rn normal condition) Insufficiently tightened parts Retighten Insufficiently tightened parts Abnormal noise ENGINE MOUNTING REMOVAL AND INSTALLATION Post-installation Operation 36-47 ftlbs.
Page 910: Power Plant Mount
32-5 POWER PLANT MOUNT SERVICE POINTS OF INSTALLATION Engine side Mounting stopper 5. INSTALLATION OF MOUNTING STOPPER Install the mounting stopper of the engine mount bracket so that the arrow faces the center part of the engine. Arrow TRANSAXLE MOUNTING REMOVAL AND INSTALLATION Post-installation Operation...
Page 911: Engine Roll Stopper
32-6 POWER PLANT MOUNT - Engine Roll Stopper ENGINE ROLL STOPPER REMOVAL AND INSTALLATION 29-36 ft.lbs. Pre-removal Operation Extent Force not applied to the Engrne Mount Post-installation Operation Lower the Engine 29-36 ft.lbs. 36-47 ft.lbs.* 29-36 ft.lbs. 29-36 ftlbs. 36-47 ft.lbs. Front roll stopper bracket removal steps 1.
Page 912 POWER PLANT MOUNT - Engine Roll Stopper SERVICE POINTS OF INSTALLATION 6. INSTALLATION OF REAR ROLL STOPPER BRACKET in.) <Vehicles with FWD-A/T> After temporarily tightening the rear roll stopper bracket, Rear roll tighten so that, in the unladen vehicle condition, the dimension of the clearance of the insulator is the specified dimension.
Page 913 32-8 POWER PLANT MOUNT - Centermember and Crossmember CENTERMEMBER AND CROSSMEMBER <FWD> REMOVAL AND INSTALLATION Post-installation Operation Pre-removal Operation Lower the Engine Disconnection of the Front Exhaust Pipe when removing the Crossmember (Re- fer to GROUP 15-Exhaust Pipe and fer to GROUP 15-Exhaust Pipe and Main Muffler.) Main Muffler.) Air bleeding of the Power-steering Fluid...
Page 914 32-9 POWER PLANT MOUNT 35-45 25-33 11-14 ftlbs. 43-58 ft.lbs. 10. Stabilizer link installation nut 16. Cotter pin (Refer to GROUP 33A-Stabilizer Bar.) 17. Tie-rod end connection nut 11. Stabilizer link 18. Joint assembly connection bolt 12. Stabilizer bar bracket installation bolt 19.
Page 915: Power Plant
MOUNT - Centermember and Crossmember POWER PLANT 72-87 ft.lbs.*’ ------@ 58-72 ftlbs. 58-72 ft.lbs. 23. Self locking nut 24. Clamp 25. Lower arm mounting bolt 26. Stopper 27. Rear roll stopper bracket mounting bolt NOTE 28. Self locking nut parts which should be temporarily tightened, 29.
Page 916 POWER PLANT MOUNT - Centermember and Crossmember INSPECTION Check the crossmember for cracks or deformation. Check the bushings for cracks or deterioration. Check the centermember for cracks or deformation. Press out Press fit BUSHING REPLACEMENT and B. (2) Press in bushings A and B so that the projecting amount of the inner sleeve agrees with the standard value.
Page 917 POWER PLANT MOUNT - Centermember and Crossmember REMOVAL AND INSTALLATION 29-36 ft.lbs. 36-47 58-72 ftlbs. - - --_ ’ 58-72 Removal steps Pre-removal Operation 1. Cover installation screw (Refer to GROUP 37A-Service Adjust- 2. Left member ment Procedures.) 3. Right member 4.
Page 918 POWER PLANT MOUNT - Centermember and Crossmember 29-43 ft.lbs. 11 \ 22-29 ftlbs. 22-29 ftlbs. <Turbo> 40-60 Nm 29-43 ftlbs. Front exhaust pipe rear installation bolt Gasket Self locking nut Front exhaust pipe Gasket 35-45 25-33 16. Stabilizer link installation nut (Refer to GROUP 33A-Stabilizer Bar.) 17.
Page 919 Centermember and Crossmember POWER PLANT MOUNT - 11-14 ftlbs. 9-13 ftlbs. 4 0 - 4 3 ftlbs. 22 44-57 ft.lbs. 0110473 42-58 ft.lbs. 22. Transfer assembly 23. Cotter pin 24. Tie-rod end connection nut 25. Joint assembly connection bolt 26. Return tube connection 27.
Page 920 Centermember and Crossmember POWER PLANT MOUNT - 29-36 ftlbs. 72-87 ft.lbs.* 30. Self locking nut 31. Clamp 58-72 ft.lbs.* 32. Lower arm mountino bolt 33. Stopper 34. Rear roll stopper bracket mounting bolt 35. Self locking nut 36. Lower plate 37.
Page 921 NOTES...
Page 922 FRONT SUSPENSION CONTENTS LOWER ARM ........... STABILIZER BAR .
Page 923 FRONT SUSPENSION - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS McPherson strut with coil spring McPherson strut with coil spring Suspension system and compression rod type and compression rod type Coil spring Wire dia. x O.D. x free length mm (in.) Coil spring identification color Blue x 2 Pink x 2”...
Page 924: Front Suspension
FRONT SUSPENSION SERVICE SPECIFICATIONS Items Standard value Camber 22’ k 30’ Caster 2” + 30’ Toe-in m m ( i n . ) Ok3 (Of.12) Protruding length of stabilizer bar mounting bolt m m ( i n . ) 1 6 - 1 8 (.63-.70)* - Lower arm ball joint starting torque m (in.lbs.1 3-10 (26-87) Stabilizer link ball joint starting torque...
Page 925 Special Tools/Troubleshooting FRONT SUSPENSION - SPECIAL TOOLS I Use Number OPTIONAL: AVAILABLE FROM O.T.C. TROUBLESHOOTING Remedy Probable cause Symptom Adjust or replace Suspension malfunction wheel is heavy, vibrates or Ball joint pulls to one side Coil spring Wheel alignment Unbalanced or worn tires Adjust or replace Excessive vehicle rolling Broken or deteriorated stabilizer...
Page 926 FRONT SUSPENSION - Service Adiustment Procedures SERVICE ADJUSTMENT PROCEDURES FRONT WHEEL ALIGNMENT NOTE The front suspension assembly must be free of worn, loose or damaged parts prior to measurement of front wheel align- ments. Measure wheel alignment by using the tool. CAMBER AND CASTER Standard value: Camber 22’...
Page 927 FRONT SUSPENSION - Strut Assembly STRUT ASSEMBLY REMOVAL AND INSTALLATION Removal steps 1. Brake hose and tube bracket 2. Strut lower mounting bolt 3. Strut upper mounting nut SERVICE POINTS OF REMOVAL 1. REMOVAL OF BRAKE HOSE AND TUBE BRACKET Do not pry and tube clamp away when the brake hose...
Page 928 FRONT SUSPENSION SERVICE POINTS OF INSTALLATION Strut 4. INSTALLATION OF STRUT ASSEMBLY insulator Install the strut assembly so that the strut insulator faces in the direction indicated in the illustration. NOTE Be sure to confirm that the direction is correct, because there will be a deviation of the wheel alignment if it is not.
Page 929 FRONT SUSPENSION SERVICE POINTS OF DISASSEMBLY 2. REMOVAL OF SELF-LOCKING NUT (1) Holding the spring upper seat with the special tool, loosen the self-locking nut. Caution The self-locking nut should be loosened only, not removed. (2) Using the special tools, compress the coil spring, and then remove the self-locking nut.
Page 930 FRONT SUSPENSION SERVICE POINTS OF REASSEMBLY 7. INSTALLATION OF DUST COVER/G. BUMP RUBBER Join the dust cover and bump rubber. Bump rubber Dust iover 4. INSTALLATION OF SPRING UPPER SEAT ASSEMBLY (1) Assemble the sprivg upper seat to the piston rod, fitting the notch in rod to the shaped hole in spring seat.
Page 931 FRONT SUSPENSION - Lower Arm LOWER ARM REMOVAL AND INSTALLATION 43-52 72-87 35-47 <From 1990 models> o n b o l t h e a d 43-52 58-72 Bolt embossed @ on bolt head 72-87 2-87 35-47 58-72 on bolt head Removal step 58-72 Bolt embossed @...
Page 932 FRONT SUSPENSION - Lower Arm SERVICE POINTS OF REMOVAL 5. REMOVAL OF STABlLlZEk LINK MOUNTING NUTS Using a wrench or similar tool to secure the ball studs at both ends of the stabilizer link, remove the mounting nuts. 7. REMOVAL OF SELF-LOCKING NUT Using the special tool, disconnect the lower arm ball joint from the knuckle.
Page 933 FRONT SUSPENSION - Lower Arm BALL JOINT DUST COVER REPLACEMENTM~~NEAF (1) Remove the dust cover. (2) Apply multipurpose grease to the lip and inside of the dust cover. (3) Drive in the dust cover with special tool until it is fully seated.
Page 934 FRONT SUSPENSION - Stabilizer Bar STABILIZER BAR <FW REMOVAL AND INSTALLAT ON 58-72 ft.lbs. 22-29 ftlbs. <From 1990 models> Removal steps 35-45 2. Front exhaust pipe 25-33 3. Gasket 4. Stay 5. Centermember rear installation bolt 7. Stabilizer bar mounting bolt 8.
Page 935 FRONT SUSPENSION SERVICE POINTS OF REMOVAL 2. REMOVAL OF FRONT EXHAUST PIPE After disconnection of the front exhaust pipe assembly and the exhaust manifold, use wire, etc. to hang the front Wire ’ exhaust pipe down. Caution There is danger of damage to the interior if the flexible joint is bent very much.
Page 936 FRONT SUSPENSION INSPECTION Check the bushing for wear and deterioration. Check the stabilizer bar for deterioration or damage. Check the stabilizer link ball joint dust cover for cracks. Check all bolts for condition and straightness. CHECKING OF STABILIZER LINK BALL JOINT FOR START- ING TORQUE (1) If a crack is noted in the dust cover, replace it, adding (2) !%% side to side the stabilizer link ball joint stud several...
Page 937 FRONT SUSPENSION - Stabilizer Bar SERVICE POINTS OF INSTALLATION 13. INSTALLATlON OF STABILIZER BAR BRACKET (1) Temporarily tighten the stabilizer bar bracket. (2) Align the bushing end with the marked part of the stabilizer bar, and then fully tighten the stabilizer bar bracket.
Page 938 FRONT SUSPENSION STABILIZER BAR <AWD-UP TO 1992 MODELS> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation @Removal of Front Exhaust Pipe (Refer to GROUP 15-Exhaust Pipe and Main 44-57 ft.lbs. * 58-72 ftlbs. -42 Nm Left member 35-45 Gusset 25-33 Transfer Stabilizer link mounting nut to P.33A-14, 16.) Stabilizer link...
Page 939 FRONT SUSPENSION - Stabilizer Bar SERVICE POINTS OF REMOVAL 9. REMOVAL OF STABILIZER BAR (1) Disconnect the coupling of the knuckle and lower arm at the right side. (2) Pull out the left side stabilizer bar edge, pulling it out between the drive shaft and lower arm.
Page 940 CONTROL ACTIVE-ECS RELAY ........141 Low-pressure Switch (Low-pressure Tank Side) ACTIVE-ECS SENSOR ........138 Actuation Pressure Check ......Normal Vehicle Height Check and AIR COMPRESSOR ........
Page 941 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Front suspension Rear suspension Suspension system McPherson strut with coil spring and compression rod type spring type Coil spring Front Wire dia. x upper end O.D. L.H. side L.H. side 13.0 x 173 x 193 x 391 9.5 x 119.5 x 119.5 x 428 mm (in.) (51 x 6.81 x 7.59 x 1 5 .
Page 942 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Specifications SERVICE SPECIFICATIONS Items Specifications Standard value Toe-in mm (in.) 20’ t 30’ Camber Caster 2” t 30’ Rear height 314-316 (12.36-12.44) sensor rod Installation location dimension mm (in.) Wheel arch height to center of wheel mm (in.) Front Rear...
Page 943 CONTROL SUSPENSION - Specifications TORQUE SPECIFICATIONS Items Strut assembly 29-36 Front strut upper mounting nut Air tube to strut 17-26 12-19 Front height sensor rod mounting bolt 16-76 Front strut lower mounting nut 29-43 Actuator bracket to strut 58-72 Strut insulator installation nut Lower arm 43-52 Lower arm ball joint to knuckle...
Page 944 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Specifications Items Shock absorber assembly Air tube to shock absorber 6 - 7 Shock absorber upper mounting nut 29-36 Shock absorber lower mounting nut 58-72 Rear height sensor mounting bolt 17-26 12-19 Actuator bracket mounting nut 45-55 Piston rod tightening nut 45-55...
Page 945 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Specifications Items Air compressor Air compressor mounting bolt 4 - 6 3 - 4 6 - 7 Compressor mounting bracket to transaxle 9 - 1 4 Solenoid valve and dryer Front solenoid valve bracket to body 5 - 8 Front solenoid valve to bracket 7-11...
Page 946 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Special Tools Number Name I Use djustment Procedures For the number, refer to OPTIONAL. AVAILA OPTIONAL: AVAILABLE FROM O.T.C. TSB Revision...
Page 947 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Special Tools Tool Number Name Compression of the rear coil spring TSB Revision...
Page 948 NOTES...
Page 949 ACTIVE-ELECTRONIC CONTROL SUSPENSION TROUBLESHOOTING TROUBLESHOOTING POINTS REGARDING THE DIAGNOSTIC FUNCTION For the ACTIVE-Electronic Control Suspension (ACTIVE-ECS), control unit has been provided with the following electronic functions in order to make checking of the electronic-control (1) Diagnostic trouble code output (2) Service data output (3) Actuator test Note that all of the above can be checked by using the scan tool.
Page 950 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting CHECKING BY USING THE SCAN TOOL 1. DIAGNOSTIC TROUBLE CODE OUTPUT TROUBLESHOOTING CHART Diagnostic trouble Malfunction Vehicle condition Probable cause Action code No. Normal Damaged or disconnected Alarm light illuminates; wiring or short-circuit of G among attitude-control of G sensor.
Page 951 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic Action Malfunction Vehicle condition Probable cause trouble code No. Front height sensor Troubleshoot An abnormal signal (a signal The alarm light illuminates, and the attitude-control malfunction. ing hints unlike any normal srgnal function and the vehicle- Damaged or disconnected classified by such as an error code, etc.) wiring, or a short-circuit, of circuit [IO]...
Page 952 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic trouble Malfunction Vehicle condition Probable cause Action Damaged or disconnected The alarm light illuminates, Troubleshoot All connectors of the wiring of the damping force ing hints and the attitude-control damping-force switching switching actuator (step function and the damping- classified by actuator (step motor...
Page 953 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic Action Malfunction Vehicle condition Probable cause trouble code No. Damaged or disconnected Damaged or disconnect- Troubleshoot The alarm light illuminates, ing hints wiring, or a short-circuit, of ed wiring, or a short and the attitude-control -circuit, of the exhaust classified by the exhaust valve actuation...
Page 954 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshootina Diagnostic trouble Malfunction Vehicle condition Action Probable cause code No Damaged or disconnected Damaged or disconnected Troubleshoo The alarm light illuminates, wiring of the left front or wiring of the left front or ing hints and the attitude-control right front valve actuation right front valve coil.
Page 955 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting terminal) or for air leakage (code No.56) within the front or rear valves. For malfunctions represented by a code number with the * symbol, if the malfunction is of a temporary nature (such as improper contact of a connector, etc.), the warning lamp’s illumination will stop when the malfunction stops, and the function will return to normal.
Page 956 ACTIVE-ELECTRONIC CONTROL SUSPENSION CHECKING ACCORDING TO CHARTS CLASSIFIED BY THE MALFUNCTION SYMPTOM [A] DIAGNOSTIC TROUBLE CODE NO.54 Unload the vehicle and turn justment time (due (overload) overload). restart the engine and check whether or not the system functions normally. Improper setting of the height Correct the installation position of the height sen- the height sensor correct?
Page 957 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting 2. SERlflCE DATA OUTPUT Conditions for checking Standard Item No. Service data item Vehicle horizontal condition After checking the above, shake the body to the The indication fluctuate! above and below 2.5V. left and right. Ignition switch at ON;...
Page 958 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshootina Item No. I Service data item Conditions for checking Standard Front vehicle-height sensor Switch ON the “HIGH” switch to set to the high vehicle height. Switch ON the “AUTO” switch to set to the norma vehicle height.
Page 959 ACTIVE-ELECTRONIC CONTROL SUSPENSION Revision...
Page 960 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting TROUBLESHOOTING HINTS CLASSIFIED ACCORDING TO CIRCUITS Contents Item G-sensor circuit Generator “L” terminal circuit Low-pressure switch circuit Throttle-position sensor circuit High-pressure switch circuit ACTIVE-ECS indicators circuit Headlight switch circuit Front-height sensor circuit Rear-height sensor circuit Vehicle-speed sensor circuit Rear-pressure sensor circuit Stop light switch circuit...
Page 961 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting G-sensor output characteristic Output voltage (VI Right - Left Direction of acceleration Accelera- tion (G) Angle (D) -48.6" -30" [(A) surface LH - standard surface (A) F-l 8 TSB Revision...
Page 962 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The G-sensor detects the amount of acceleration response to acceleration, and these changes are that is generated (to the left or right) when the vehi- taken out as changes of voltage. Within the coil, silicon oil is enclosed in order to suppress the vibra- ferential transformer, the magnetic field changes tion of the movable iron core.
Page 963 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Battery Main Relay fusible (From 1990 models) G E N E R A T O R % NOTE...
Page 964 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The generator ‘I-” terminal signal is used to deter- mine whether or not the engine is operating. system is possible while the engine is operating, or This is in order to reduce the frequency of com- at a vehicle speed of 3 km/h (2 mph) or higher.
Page 965 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting pressure switch 70 (10) 140 (20) Pressure kPa (psi) Low-pressure tank pressure detectlon Low-pressure switch Revision...
Page 966 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The low-pressure switch is switched ON and OFF becomes 140 kPa (20 psi) or higher, it is switched * by the pressure in the low-pressure tank, and as a OFF, and as a result the ECU sends the drive signal result the ECU functions to control the activation to the return pump.
Page 967 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting SENSOR CIRCUIT Throttle-position sensor output characteristic (1989 models) 80 82 Throttle opening Fully open (degrees) c l o s e d (From 1990 models) (From 1990 models) (1989 models) Throttle-position sensor NOTE TSB Revision...
Page 968 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The throttle-position sensor is the same for the ECM of engine and transaxle. The ECM estimates the acceleration status of the vehicle according to the sensor output. Service data indication Display I l 4 1 The output voltage of the throttle 1 4 : T P S 549mV indicated.
Page 969 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Shield plate pressure switch 760 (108) 950 (135) Pressure kPa (psi) Lo&pressure switch High-pressure switch Detection of high-pressure tank pressure High-pressure switch TSB Revision...
Page 970 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The high-pressure switch is switched ON and OFF Conversely, when the pressure of the high-pressure by the pressure in the high-pressure tank, and as a tank becomes 950 kPa (135 psi) or higher, the result the ECU functions to control the activation high-pressure switch is switched OFF, and the and stop of the compressor.
Page 971 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Solenoid : Relay box valve . 1 2 3 4 5 control circuit Solenoid valve power source Revision...
Page 972 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation When the ignition is switched ON, the ECS power When the ignition switch is switched OFF after driv- relay is also switched ON, and power is supplied to ing, the three-minute OFF delay timer makes the system.
Page 973 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Battery Column switch (From 1990 models) Power source, I’ ACTIVE-ECS 1 indicator I’ NOTE * mark is applicable for 1991, 1992, 1993 models. TSB Revision...
Page 974 ACTIVE-ELECTRONIC CONTROL SUSPENSION Service data indication Code No Indication Standard value Indication example ECU input voltage indications when When switches are open 17: MANUAL CNG. SW SPORT, AUTO, SOFT, HIGH switches are pressed. When SPORT switch is ON When AUTO switch is ON When SOFT switch is ON When HIGH swrtch is ON ACTIVE-ECS indicators check chart...
Page 975 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting 2. Checking the individual ACTIVE-ECS indicators After disconnecting the control unit’s connector, turn the nition kev to ON All items shown in the tables on the next page are satisfied indicator when each terminal of the ACTIVE-ECS indicator’s connector F and the connector terminal.
Page 976 ACTIVE-ELECTRONIC CONTROL SUSPENSION Control unit wiring ACTIVE-ECS indicator harness connector Normal connector terminal No terminal No All termrnals are not earthed vehicle-height indicator illuminate. In addition to the “SOFT” and “NORM” indicators, the “MEDIUM” damping In addition to the “SOFT” and “NORM” indicators, the “SOFT”*’ switch indicator also illuminates.
Page 977 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Battery Ignition F-l 6 ‘89 switch (From 1991 models) To meter (upper beam indicator light) (From 1990 models) Head- light To column switch TL headlight NOTE TSB Revision...
Page 978 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The ACTIVE-ECS system functions, in order to During the nighttime, however, in order to prevent improve the “air drag” characteristic, to adjust the deviation of the headlight beams from the required vehicle height to the LOW setting at the front end directional path, the vehicle height is adjusted to the only during the daytime when the vehicle speed LOW setting for both the front end and the rear end...
Page 979 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Steering angular-veloclty sensor- m0439 heel ii -- Steering angular- velocity sensor TSB Revision...
Page 980 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The slitted disc installed to the steering shaft inter- ty of the steering wheel movement are detected rupts, or allows light to pass with the result that and passed to the ECU. electric signals corresponding to the angular-veloci- Diagnostic described in the table below.
Page 981 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting IO] FRONT-HEIGHT SENSOR CIRCUIT Relationship between N (normal vehicle height) and other vehicle-height levels High EH (highest) 50 (1.97) 40 (1.57) HH (higher than HIGH) 30 (1.18) NH (higher than NORM) Normal EL (lowest) [Unit: mm (in.11 Operation The front-height sensor detects (by detecting the sistors, and the slits in the disc thus interrupt, or let...
Page 982 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic When a signal (error code) indicating an abnormal photo-transistor, etc.) is input, the alarm light illu- condition (resulting from damage or disconnection minates and control is as described in the table of the heavy-line circuit, or a malfunction of a below.
Page 983 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting 1989 models High 50 (1.97) 40 (1.57) HH (higher than HIGH) 30 (1.18) NH (higher than NORM) Normal NL (lower than NORM) LL (lower than LOW) [Unit: mm F-l 9 sensor Rear-height Operation and the slits in the disc thus interrupt, or let pass. The rear-height sensor detects (by detecting the the light beams between the light-emitting diodes relative position of the body and the rear axle) the...
Page 984 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshootina Diagnostic When a signal (error code) indicating an abnormal photo-transistor, etc.) is input, the alarm light illu- condition (resulting from damage or disconnection minates and control is as described in the table of the heavy-line circuit, or a malfunction of a below.
Page 985 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting controlled F-l 9 - - - - - J C-Oi Meter assembly TSB Revision...
Page 986 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The vehicle-speed sensor is a reed switch type with pulse signals being sent four times for each rotation of the transaxle output gear. Diagnostic If there is damage or disconnection of the heavy-line the alarm light illuminates and control is as de- circuit, or a malfunction of the vehicle-speed sensor, scribed in the table below.
Page 987 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Rear-pressure sensor output voltage characteristic Rear air springs internal pressure kPa (psi) Rear-pressure sensor F-l 8 Sensor power source 5 V Operation The rear-pressure sensor detects the internal pressure of to a predetermined “map”, the supplying and exhaust the rear air springs.
Page 988 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic If, because of damage or disconnection of the heavy-line below. Note, however, this diagnostic signal is given if circuit, or a malfunction of the rear-pressure sensor, etc., there is an overload. a htgher than normal value of the internal pressure of the 1989 models...
Page 989 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting F-l 6 Target vehicle height order of priority To stop lights Revision...
Page 990 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation When the brake pedal is depressed, the stop light switch is switched ON and 1% is sent to the ECU, thus resulting in the detection that braking is in progress. Service data indication Indication Display Code No.
Page 991 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Ignition switch (IG,) Junction 1989 block models From 1990 models Back-up light switch From 1990 models 1989 models To back-up light Checking the back-up light switch circuit (with the connector disconnected) Terminal Connection destination or ,v,easurement Tester Standard Check condition measured Dart...
Page 992 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Batten/ Dome light ETACS unit E l - - - - g - l - - - Front door swatch Rear door switch Service data indication Code No Indication Display Indicates the ON or OFF status of 33: DOOR SW.
Page 993 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting (Rear, L.H.) Actuator...
Page 994 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The damping force switching actuator is the step at one of four levels (HARD, MEDIUM, AUTO-SOFT motor. That allows the control rod of each shock or SOFT). absorber to rotate, thus selecting the damping force Diagnostic If there is damage or disconnection of the heavy-line tuators are connected in parallel, there can be no...
Page 995 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Compressor relay---- Exhaust valve for vehicle-height link...
Page 996 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The compressor is activated when the pressure the return pump is operating. A thermal switch is within the high-pressure tank decreases to 760 kPa provided at the motor circuit. This thermal switch (108 psi) or lower, and then stops two seconds after functions to interrupt the power to the motor (in the pressure reaches 950 kPa (135 psi).
Page 997 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting R e t u r n p u m p r e l a y - assembly Reserve tank “ 2 Operation A thermal switch is provided at the motor circuit. The return pump is activated when the pressure within the low-pressure pressure tank increases to This thermal switch functions to interrupt the power 140 kPa (20 psi) or higher, and then stops two...
Page 998 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Diagnostic If there is damage or disconnection of the heavy-line illuminates and ‘control is as described in the table circuit, or a short-circuit, or a malfunction of the out- below. (Note that the diagnostic is only applicable p u t t r a n s i s t o r w i t h i n t h e E C U , t h e a l a r m l i g h t up to the compressor relay.) Switch acceptance...
Page 999 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Exhaust valve [for vehicle-height adjustment) Usually OFF; ON Air cleaner vehicle-height downward Exhaust valve f o r vehicle-height A-l 1 adjustment TSB Revision...
Page 1000 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The exhaust valve for adjustment of the vehicle adjustment of the vehicle height is being made; it height is installed at the compressor assembly. functions to discharge air (from the air springs) into This valve is switched ON only when a downward the atmosphere.
Page 1001 Flow-rate switchovpr \J~I\~P -low-control valve assembly Front air supply Rear air sLpply valve Rear air-suppl) Front air-suppi) valve TSB Revision...
Page 1002 S U S P E N S I O N Operation The flow-rate switchover valve switches, in two is supplied to each of the air springs with the flow stages, the intake air flow volume supplied to each volume restricted by the orifice. of the air springs.
Page 1003 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Flow-control valve assembly Rear exhaust valve (Right sidemember front part) To dryer valve Right front - o r r i g h t rear valve Left front valve Front exhaust...
Page 1004 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation These valves switch the air exhausted (from the through the dryer, is discharged (from the exhaust front and rear left and right strut air springs) to either valves for vehicle-height adjustment) into the at- internal recirculation or discharge to the at- mosphere.
Page 1005 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Front solenoid valve assembly , Front valve (right) Front air-supply (Cowl top panel center) Usually OFF (closed). (open) during front air SUpplY Left front valve Right valve TSB Revision...
Page 1006 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation Usually, and during air exhaust, these valves are The front air-supply valves are switched ON (open- OFF (closed). during attitude control and during vehicle-height ad- Note that a check valve is provided in these valves in justment upward.
Page 1007 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Rear solenoid valve assembly Rear valve (right) Rear air-supply valve [Luggage compartment right front surface) Rear valve (left) Air-supply y (Flow-rate switchover valve) Usually OFF (closed). ON (open) during rear air-supply Flow-rate A switchover valve Rear ‘(right) Relar (left) valve valve...
Page 1008 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation Usually, and during air exhaust, these valves are The rear air-supply valves are switched ON (opened) OFF (closed). Note that the rear-pressure sensors, for air supply to the left and right air springs during attitude control and during vehicle-height adjust- for detection of the internal pressure of the rear ment upward.
Page 1009 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Front solenoid valve assembly Riaht front Left front valve (Cowl top panel center) Fron air-supply valve exhaust air springs valve Usually. and during exhaust. Front OFF (closed) Left front Front and right - f r o n t a i r exhaust - springs valve...
Page 1010 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The left front and right front valves are for switching and during air intake, OFF (closed), and are ON the air intake and exhaust for the left front and right (open) during exhaust. front strut air springs. These valves are usually, Diagnostic If there is damage or disconnection of the heavy-line...
Page 1011 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Rear (riaht) Rear (left) Luggage compartment right front surface) valve Rear air-supply valve Rear exhaust valve springs Usually, and during exhaust, Rear OFF (closed) valve Left rear/right Rear exhaust - valve Relay box TSB Revision...
Page 1012 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Operation The left rear and right rear valves are for switching usually, and during air supply, OFF (closed), and are the air supply and exhaust for the left rear and right ON (open) during exhaust. rear shock absorber air springs.
Page 1013 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting models) Vehicle-speed sensor (meter) Serial/on-board diagnostic output connector C-l 8 Simulated speed input TSB Revision...
Page 1014 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting ECU terminal voltages (when connector is connected) Terminal Terminal Condition voltage Diagnostic/service data When scan tool is connected switching signal Usual Diagnostic/service data Constantly switching signal Battery posi- tive voltage ACTIVE-ECS related diagnostic/service data output circuit (with the connector disconnected) Terminal Connection destination or Measurement Check condition Standard...
Page 1015 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting CONFIGURATION DIAGRAMS ENGINE ROOM A-l 1 A-l 1 ACTIVE-ECS exhaust solenoid valve A-l 2 ACTIVE-ECS air compressor cable combination TSB Revision...
Page 1016 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting Ground point (detailed view)
Page 1017 Concentrated junction Dedicated fuses @I-@ A-01X Headlight relay valve power source relay Sub fusible link 0-a ENGINE AND TRANSAXLE B-l 5 Alternator Ground point (detailed view) TSB Revision...
Page 1018 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting DASHBOARD PANEL Junction block Front harness and junction block coupling Body harness and junction block coupling TSB Revision...
Page 1019 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshooting DASHBOARD PANEL Control wiring harness and ACTIVE-ECS wiring harness combination Front wiring harness and ACTIVE-ECS wiring harness combination Body wiring harness and ACTIVE-ECS wiring harness combination Engine control module ACTIVE-ECS wiring harness and instrument wirina harness combination C-l 8 Data link connect&...
Page 1020 ACTIVE-ELECTRONIC CONTROL SUSPENSION - Troubleshootina Junction block Rear side Front side Revision...

This manual is also suitable for:

1989 galant 1990 galant 1991 galant 1992 galant 1993 galant

Mitsubishi 1989-1993 GALANT Service Manual

Quick Links

GROUP INDEX

Troubleshooting

Related Manuals for Mitsubishi 1989-1993 GALANT

Summary of Contents for Mitsubishi 1989-1993 GALANT

This manual is also suitable for:

Table of Contents