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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.)
1
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.
..............................

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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, Fuel Pump

    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< i