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Mazda
626
MX-6
1988
Workshop Manu

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Troubleshooting

   Summary of Contents for Mazda 626 MX-6

  • Page 1

    Mazda MX-6 1988 Workshop Manu...

  • Page 2

    B ody service or repairs are performed by persons ther than those at an Authorized Mazda Dealer. B ody E lectrical Mazda M o to r C o rp o rta tio n Technical Data HIROSHIMA, JAPAN APPLICATION: Special Tools...

  • Page 3: Scheduled Maintenance

    PRE-DELIVERY INSPECTION SCHEDULED MAINTENANCE SERVICES PRE-DELIVERY INSPECTION......0— 2 PRE-DELIVERY INSPECTION TABLE... 0— 2 SCHEDULED MAINTENANCE SERVICES ..0— 3 MAINTENANCE TABLE (SCHEDULE 1)..0— 3 MAINTENANCE TABLE (SCHEDULE 2 )..0— 7 86U00X-001...

  • Page 4: Pre-delivery Inspection

    0 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE EXTERIOR INSPECT and ADJUST, if necessary, the following items □ Cigarette lighter and clock to the specifications: □ Remote control outside rear view mirrors (if equipped) □ Power windows (if equipped) □ Glass, exterior bright metal and paint for damage □...

  • Page 5

    *1 Replacement of the timing belt is required at every 60,000 miles (96,000km). Failure to replace the timing belt may result in damage to the engine. *2 This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability.

  • Page 6

    Interval Number of months or km (miles) whichever comes first Months 22.5 37.5 52.5 Service data and inspection point Page Miles 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 Procedure & item Kilometers 12,000 24,000 36,000 48,000 60,000 72,000 84,000 96,000 Steering operations and linkage •...

  • Page 7

    /•> Interval Number of months or km (miles) whichever comes first > Months 22.5 37.5 52.5 Service data and inspection point Page Miles 7,500 *5,000 22,500 30,000 37,500 45,000 52,500 60,000 Procedure & item Kilometers 12,000 24,000 36,000 48,000 72,000 84,000 96,000 >...

  • Page 8

    *1 Replacement of the timing belt is required at every 60,000 miles (96,000km). Failure to replace the timing belt may result in damage to the engine. *2 This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty-coverage or manufacturer recall liability.

  • Page 9

    Interval Number of months or km (miles) whichever comes first Months Miles Service data and inspection point Page (x1,000) Kilometers Procedure & item (x1,000) > Steering operations and linkage • Free play: 0—30 mm (0—1.18 in) 1 0 -1 0 •...

  • Page 10

    Interval Number of months or km (miles) whichever comes first Months </> Miles Page Service data and inspection point (x1,000) > Kilometers Procedure & item (x1,000) • Damage, looseness and grease 13-17 Front suspension ball joints leakage J> Drive shaft dust boots •...

  • Page 11: Table Of Contents

    ENGINE OUTLINE............1 — 2 STRUCTURAL VIEW ........1— 2 SPECIFICATIONS .......... 1— 3 TROUBLESHOOTING GUIDE......1— 3 TUNE-UP PROCEDURE........1— 5 ON-VEHICLE INSPECTION......1— 9 COMPRESSION ........... 1— 9 ON-VEHICLE MAINTENANCE......1—10 TIMING BELT ..........1—10 CYLINDER HEAD .........1—16 VALVE SEAL ..........1—22 REMOVAL............

  • Page 12: Outline

    1 OUTLINE OUTLINE STRUCTURAL VIEW 4BG01A-002 1 - 2...

  • Page 13: Troubleshooting Guide

    TROUBLESHOOTING GUIDE SPECIFICATIONS model Engine Turbo Non-Turbo Type Gasoline, 4 cycle Cylinder arangement and number In line, 4 cylinders Combustion chamber Pentroof Valve system OHC, belt driven 12 valves Displacement cc (cu in) 2,184 (133.2) Bore and stroke mm (in) 8 6 .0 x 94.0 ^3.39 x 3.70) Compression ratio 7.8 : 1...

  • Page 14

    TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Insufficient power Insufficient compression Malfunction of HLA Replace 1 -6 9 Compression leakage from valve seat Repair 1 -4 5 Seized valve stem Replace 1—43 Weak or broken valve spring Replace 1—46 Failed cylinder head gasket Replace 1 -1 6 Cracked or distorted cylinder head...

  • Page 15: Tune-up Procedure

    i " • 1 1 "•'* V • ' " TUNE-UP PROCEDURE TUNE-UP PROCEDURE Tune the engine according to the procedures de­ scribed below. Battery 1. Check the indicator sign on the top of the battery. If the indicator sign is blue, the battery is normal. 2.

  • Page 16

    TUNE-UP PROCEDURE Coolant Level (Cold engine) 1. Check that the coolant level is near the radiator inlet port. 2. Check that the level in the coolant reservoir is be­ tween the FULL and LOW marks. Add coolant if necessary. Warning a) Never remove the radiator cap while the en­...

  • Page 17

    TUNE-UP PROCEDURE Spark Plug Check the following points. Clean or replace if necessary. 1. Damaged insulation 2. Worn electrodes 3. Carbon deposits 4. Damaged gasket 5. Burnt spark insulator 6. Plug gap Plug gap: 1.0—1.1 mm (0.039—0.043 in) Distributor Cap Check the following points.

  • Page 18

    TUNE-UP PROCEDURE 2. If the noise does not stop, check for movement of each HLA by pushing down each rocker arm by hand while at TDC of compression stroke. 3. If the rocker arm moves down, replace the HLA. (Refer to page 1—69.) 86U01X-016 Ignition Timing 1.

  • Page 19: On-vehicle Inspection

    ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION If the engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to Section 5) 2. Compression 3. Fuel system (Refer to Section 4) COMPRESSION 1. Check that the battery is fully charged. Recharge it if necessary.

  • Page 20: On-vehicle Maintenance

    ON-VEHICLE MAINTENANCE (TIMING BELT) ON-VEHICLE MAINTENANCE TIMING BELT Removal 1. Disconnect the negative battery cable. 2. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. 6. Lower timing belt cover 1. High-tension lead and spark plug 7.

  • Page 21

    ON-VEHICLE MAINTENANCE (TIMING BELT) Removal note Timing belt tensioner 1. Turn the crankshaft to align the “ f 1 ” mark of the camshaft pulley with the front housing timing mark. 2. Remove the tensioner. 86U01X-211 Timing belt Mark the timing belt rotation for proper reinstallation if it is reused.

  • Page 22

    ON-VEHICLE MAINTENANCE (TIMING BELT) Installation Install in the reverse order of removal, referring to installation note. Torque Specifications 86U01X-026 Installation note Timing belt 1. Check that the mark on the timing belt pulley is aligned with the mating mark. 86U01X-220 1 -1 2...

  • Page 23

    ON-VEHICLE MAINTENANCE (TIMING BELT) 2. Check that the “ f 1 ” mark of the camshaft pulley is aligned with the timing mark. If it is not aligned, turn the camshaft to align. 69G01B-025 3. Install the timing belt tensioner and spring. Tem­ porarily secure it with the spring fully extended.

  • Page 24

    ON-VEHICLE MAINTENANCE (TIMING BELT) 8. Tighten the timing belt tensioner lock bolt. Tightening torque: 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) 69G01B-028 9. Check the timing belt deflection. If the deflection is not correct, repeat the adjustment from step 5 above.

  • Page 25

    ON-VEHICLE MAINTENANCE (TIMING BELT) Spark plug 1. Apply anti-seize compound or molybdenum-based lubricant to the spark plug threads. 2. Install the spark plugs. Tightening torque: 15—23 Nm (1.5—2.3 m-kg, 11—17 ft-lb) Steps After Installation Perform the necessary engine adjustment. (Refer to TUNE-UP PROCEDURE.) 1—15...

  • Page 26: Cylinder Head

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) CYLINDER HEAD Removal Warning: Release the fuel pressure. (Refer to Section 4.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. 86U01X-030 86U01X-031 19.

  • Page 27

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) Removal note Fuel hose Warning a) Cover the hose with a rag because fuel will spray out when disconnecting. b) Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid fuel leakage. 86U01X-032 Timing belt 1.

  • Page 28

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) Cylinder head bolt Loosen the cylinder head bolts in two or three steps, and in the order shown in the figure. 69G01A-031 Disassembly of Cylinder Head Refer to page 1 —36. Inspection of Cylinder Head Refer to page 1—42. Assembly of Cylinder Head Refer to page 1—67.

  • Page 29

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) Installation Install in the reverse order of removal, referring to the installation note. Note a) Position the hose clamp in the original location on the hose. b) Squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications (1.6—2.4 m-kg, (2.2—2.8 m-kg,...

  • Page 30

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) Installation note Cylinder head 1. Thoroughly remove all dirt and oil from the top of the cylinder block with a rag. 2. Place a new cylinder head gasket in position. 3. Set the cylinder head in place. 4.

  • Page 31

    ON-VEHICLE MAINTENANCE (CYLINDER HEAD) Distributor 1. Apply engine oil to the O-ring, and position it on the distributor. 2. Apply engine oil to the blade. 3. Install the distributor into the rear housing. 4. Loosely tighten the distributor mounting bolt. 86U01X-039 Engine harness connector Install the engine harness connectors.

  • Page 32: Valve Seal

    ON-VEHICLE MAINTENANCE (VALVE SEAL) VALVE SEAL Removal 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. 86U01X-042 86U01X-043 10. Rocker arm and shaft assembly 1.

  • Page 33

    ON-VEHICLE MAINTENANCE (VALVE SEAL) Removal note Timing belt Remove the timing belt. (Refer to page 1—10.) Rocker arm and shaft assembly Loosen the rocker arm shaft bolts in two or three steps in the order shown in the figure. 86U01X-044 Valve seal 1.

  • Page 34

    ON-VEHICLE MAINTENANCE (VALVE SEAL) Installation Install in the reverse order of removal, referring to installation note. Torque Specifications 19—25 N m (1.9—2.6 m-kg, 1 4 -1 9 ft-lb) 15—23 N m (1.5—2.3 m-kg, 11—17 ft-lb) 7 - 1 0 Nm (70—100 cm-kg, 61—87 in-lb) 86U01X-048 Installation note...

  • Page 35

    ON-VEHICLE MAINTENANCE (VALVE SEAL) Valve spring Valve spring 1. Install the valve spring with the narrower pitch to­ ward the cylinder head side. 2. Install the valve keepers, and tap the end of the valve stem lightly two or three times with a plastic hammer to confirm that the keepers are all fully seated.

  • Page 36

    ON-VEHICLE MAINTENANCE (VALVE SEAL) 6. Install the camshaft caps. 7. Install the rocker arm and shaft assemblies on the cylinder head, and tighten them in three steps in the order shown in the figure. Tightening torque: 18—26 N m (1.8—2.7 m-kg, 13—20 ft-lb) Front 86U01X-051 Caution...

  • Page 37

    ON-VEHICLE MAINTENANCE (VALVE SEAL) Timing belt Install the timing belt. (Refer to TIMING BELT of ON- VEHICLE MAINTENANCE.) 86U01X-053 Cylinder head cover and gasket 1 . Clean out used silicon sealant from the gasket and gasket groove. ' 2. Apply new silicon sealant to the back of the gasket. 3.

  • Page 38: Removal

    REMOVAL REMOVAL Warning: Release the fuel pressure. (Refer to Section 4.) 1. Disconnect the negative battery cable. 2. Drain the engine oil and coolant. 3. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. TURBO 86U01X-056...

  • Page 39

    REMOVAL 86U01X-057 26. A/C compressor and 1. Battery and battery carrier 14. EG I harness 15. Engine harness bracket 2. Air-cleaner assembly 27. P/S oil pump 16. Brake vacuum hose 3. High-tension lead 28. Engine side cover 4. Accelerator cable 17.

  • Page 40

    REMOVAL Removal note Fuel hose Warning a) Cover the hose with a rag because fuel will be splashed out when disconnecting the hose. b) Keep sparks and open flames away from the fuel area. After disconnecting the fuel hoses, plug them to avoid fuel leakage.

  • Page 41

    v REMOVAL Driveshaft Remove the driveshafts. (Refer to Section 9.) Slide the SST into the transaxle. £ MTX (Turbo): 49 H027 003 MTX (Non-Turbo), ATX: 49 G030 455 86U01X-060 T ransaxle Separate the transaxle from the engine. 86U01X-213 626, MX-6 Revised 10/87 1 -3 1...

  • Page 42: Disassembly

    DISASSEMBLY (AUXILIARY PARTS) DISASSEMBLY 1. Remove in the sequence shown in the figure, for the specially marked parts referring to disassem­ bly note. 2. Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed.

  • Page 43

    DISASSEMBLY (AUXILIARY PARTS) 1. Oil level gauge 12. Engine mount bracket 2. P/S oil pump bracket 13. Distributor and high-tension lead 3. Exhaust manifold insulator 14. Spark plug 4. EGR pipe 15. Thermostat and thermostat cover 5. Turbocharger oil pipe (turbo) 16.

  • Page 44: Timing Belt

    DISASSEMBLY (TIMING BELT) TIMING BELT 69G01B-072 1. Crankshaft pulley 6. Tinning belt idler pulley 2. Upper timing belt cover 7. Timing belt 3. Lower timing belt cover 8. Camshaft pulley 4. Baffle plate 9. Timing belt pulley 5. Timing belt tensioner and spring 1 -3 4...

  • Page 45

    DISASSEMBLY (TIMING BELT) Disassembly note Crankshaft pulley 1. Set the SST against the flywheel. 2. Remove the crankshaft pulley. 86U01X-222 Timing belt 1. Loosen the tensioner lock bolt, and remove the ten­ sioner spring after. 2. Mark the timing belt rotation for proper reinstalla­ tion if it is reused.

  • Page 46

    DISASSEMBLY (CYLINDER HEAD) CYLINDER HEAD 86U01X-065 1. Cylinder head cover 8. Cylinder head 2. Front housing 9. Cylinder head gasket 3. Rear housing 10. Valve keeper 4. Rocker arm and shaft assembly 11. Upper spring seat 5. Camshaft cap 12. Valve spring 6.

  • Page 47

    DISASSEMBLY (CYLINDER HEAD) Disassembly note Camshaft Before removing the rocker arm and shaft assembly, clean the bearings and journals, and measure the fol­ lowing: 1. Camshaft end play. (Refer to page 1—48.) 2. Camshaft journals oil clearance. (Refer to page 1 -4 8 .) 86U01X-066 Rocker arm and shaft assembly...

  • Page 48

    DISASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK—I 86U01X-070 6. Oil strainer 1. Clutch cover (MTX), Backing plate (ATX) 7. Stiffener 2. Clutch disc (MTX), Drive plate (ATX) 8. Rear cover 3. Flywheel (MTX), Adaptor (ATX) 9. Water pump assembly 4. End plate 10.

  • Page 49

    DISASSEMBLY (CYLINDER BLOCK) Disassembly note Clutch cover, flywheel (MTX) or drive plate (ATX) Remove the clutch cover and flywheel (MTX), or drive plate (ATX) with the SST. 86U01X-071 Oil pan 1. Remove the oil pan mounting bolts. 2. Insert a scraper or a suitable tool between the oil pan and the stiffener to separate them.

  • Page 50

    DISASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK—II 86U01X-073 6. Crankshaft 1. Connecting rod cap 7. Pilot bearing (MTX) 2. Connecting rod bearing 3. Connecting rod and piston 8. Main bearing 9. Cylinder block 4. Piston ring 5. Main bearing cap Disassembly note Connecting rod and cap Before removing the connecting rod, clean the bear­...

  • Page 51

    DISASSEMBLY (CYLINDER BLOCK) Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the following: 1. Crankshaft end play. (Refer to page 1—60.) 2. Main journal oil clearance. (Refer to page 1—59.) 86U01X-075 Pilot bearing (MTX) Remove the pilot bearing from the crankshaft with the...

  • Page 52: Inspection And Repair

    INSPECTION AND REPAIR INSPECTION AND REPAIR 1. Clean all parts, taking care to remove any gasket fragments, dirt, oil or grease, carbon, moisture residue, or other foreign materials. 2. Inspect and repair must be performed in the order specified. Caution Be careful not to damage the joints or friction surfaces of aluminum alloy components (such as the cylinder head or pistons).

  • Page 53

    INSPECTION AND REPAIR Valve and Valve Guide 1. Inspect each valve for the following. Replace or resurface if necessary. (1) Damaged or bent stem (2) Roughness or damage to face (3) Damage or uneven wear of stem tip 2. Check the valve head margin thickness. Replace if necessary Margin thickness IN : 0.5 mm (0.020 in) min.

  • Page 54

    INSPECTION AND REPAIR (2) Method No. 2 Measure the valve stem play at a point close to the valve guide with the valve lifted slightly off the valve seat. Clearance IN : 0.025—0.060 mm (0.0010—0.0024 in) EX: 0.030—0.065 mm (0.0012—0.0026 in) Maximum: 0.20 mm (0.0079 in) 7.

  • Page 55

    INSPECTION AND REPAIR 2. Remove the valve guide from the side opposite the combustion chamber with the SST. 86U01X-084 Installation 1. Gradually heat the cylinder head in water to ap­ prox. 90°C (190°F). 2. Tap the valve guide in from the side opposite the combustion chamber with the SST until the pro­...

  • Page 56

    INSPECTION AND REPAIR 5. Check the seat contact width. Width: 1.2—1.6 mm (0.047—0.063 in) 79G01C-062 6. Check that the valve seating position is at the cen­ ter of the valve face. (1) If the seating position is too high, correct the valve seat with a 60°...

  • Page 57

    INSPECTION AND REPAIR Angle: 1.7 mm (0.067 in) max. 86U01X-091 Camshaft 1. Set the front and rear journals on V-blocks. Check the camshaft runout. Replace if necessary. Runout: 0.03 mm (0.0012 in) max. 86U01X-092 2. Check the cam for wear or damage. Replace if necessary.

  • Page 58

    INSPECTION AND REPAIR 5. Measure the oil clearance of the camshaft and camshaft caps. (1) Remove any oil, or dirt from the journals and bearing surface. (2) Set the camshaft onto the cylinder head. (3) Position plasti-gauge on top of the journals in the axial direction.

  • Page 59

    INSPECTION AND REPAIR (2) Measure the rocker arm shaft diameter. Diameter: 18.959—18.980 mm (0.7464—0.7472 in) (3) Subtract the shaft diameter from the rocker arm diameter. Oil clearance: 0.020—0.074 mm (0.0008—0.0029 in) Maxim um : 0 .1 0 mm (0 .00 3 9 in) Hydraulic Lash Adjuster (HLA) Check the HLA face for wear or damage.

  • Page 60

    INSPECTION AND REPAIR Measure the cylinder bore in directions X and Y at three levels in each cylinder as shown. Cylinder bore mm (in) Bore Size Standard 86.000-86.019 (3.3858-3.3866) 0.25 (0.010) oversize 86.250-86.269 (3.3957-3.3964) 0.50 (0.020) oversize 86.500—86.519 (3.4055-3.4063) (1) If the difference between the measurement A and C exceeds the maximum taper, rebore the cylinder to oversize.

  • Page 61

    INSPECTION AND REPAIR Piston 1. Inspect the outer circumferences of all pistons for seizure or scoring. Replace if necessary. 2. Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 18 mm (0.709 in) below the oil ring land lower edge.

  • Page 62

    INSPECTION AND REPAIR 5. Measure each piston ring end gap with a feeler gauge. Replace if necessary. End gap : 0.20—0.35 mm (0.008—0.014 in) Second: 0.15—0.30 mm (0.006—0.012 in) Oil rail Turbo : 0.20—0.70 mm : (0.008—0.028 in) Non-Turbo: 0.30—0.90 mm : (0.012—0.035 in) Maximum: 1.0 mm (0.039 in) 86U01X-105...

  • Page 63

    INSPECTION AND REPAIR 3. Check each connecting rod for bending or twist­ ing. Repair or replace if necessary. B end: 0.06 mm (0.0024 in) max. Twist: 0.06 mm (0.0024 in) max. 86U01X-108 Crankshaft 1. Check the journals and pins for damage, scoring, or oil hole clogging.

  • Page 64

    INSPECTION AND REPAIR Crank pin journal diameter undersize mm (in) Bearing size Journal diameter 0.25 undersize 50.690—50.705 (1.9957-1.9963) 0.50 undersize 50.440-50.455 (1.9858-1.9864) 0.75 undersize 50.190—50.205 (1.9760-1.9766) Caution Do not grind the rolled fillet area. 86U01X-112 Main Bearing and Connecting Rod Bearing Check the main bearings and the connecting rod bearings for peeling, scoring, or other damage.

  • Page 65

    INSPECTION AND REPAIR Timing Belt Tensioner and Idler Pulley Check the timing belt tensioner and idler pulley for smooth rotation and abnormal noise. Replace if necessary. Caution Do not clean the tensioner with cleaning fluids. If necessary, use a soft rag to wipe it clean, and avoid scratching it.

  • Page 66: Assembly

    ASSEMBLY (CYLINDER BLOCK) ASSEMBLY 1. Clean all parts before reinstallation. 2. Apply new engine oil to all sliding and rotating parts. 3. Replace plain bearings if they are peeling, burned, or otherwise damaged. 4. Tighten all bolts and nuts to the specified torques. Caution Do not reuse gaskets or oil seals.

  • Page 67

    ASSEMBLY (CYLINDER BLOCK) Connecting Rod 1. Assemble the SST to the piston pin. 2. Apply engine oil to the piston pin. 86U01X-118 3. Set the piston on the SST with the “ F” mark fac­ ing upward. 4. Set the connecting rod in piston with the oil hole in the large end opposite the “...

  • Page 68

    ASSEMBLY (CYLINDER BLOCK) 2. Check that both rails are expanded by the spacer tangs as shown in the figure by checking that both Spacer tang rails turn smoothly in both directions. Upper rail Oil ring spacer ends Lower rail Piston 69G01A-145 3.

  • Page 69

    ASSEMBLY (CYLINDER BLOCK) Oil clearance inspection (1) Remove any foreign material and oil from the journals and bearings. (2) Install the upper main bearings in the cylinder block. (3) Set the crankshaft into the cylinder block. (4) Position the plasti-gauge on top of the journals in the axial direction.

  • Page 70

    ASSEMBLY (CYLINDER BLOCK) 4. Inspect the crankshaft end play. End play: 0.08—0.18 mm (0.0031—0.0071 mm) Maximum: 0.30 mm (0.012 in) 5. If the end play exceeds the maximum, grind the crankshaft (Refer to page 1 —53) and install an un­ dersize center main bearing.

  • Page 71

    ASSEMBLY (CYLINDER BLOCK) Connecting Rod Cap 1. Check the connecting rod bearing clearances us­ ing the same procedure as used for the main bear­ ing oil clearance. Connecting rod cap tightening torque: 65—69 N m (6.6—7.0 m-kg, 48—51 ft-lb) Oil clearance: 0.027—0.067 mm (0.0011—0.0026 in) Maximum: 0.10 mm (0.0039 in) 69G01B-137...

  • Page 72

    ASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK—II Torque Specifications (70—120 cm-kg, 61—104 in-lb) 69G01A-166 Rear Cover 1. Apply engine oil to the rear cover, oil seal and oil seal lip. 2. Press the oil seal into the rear cover. 4BG01A-158 1 -6 2...

  • Page 73

    ASSEMBLY (CYLINDER BLOCK) 3. Install the rear cover and a new gasket. Tightening torque: 8—12 Nm (80—120 cm-kg, 69—104 in-ib) 86U01X-131 4. Cut away the portion of the gasket that projects out from the rear cover assembly toward the oil pan side.

  • Page 74

    ASSEMBLY (CYLINDER BLOCK) 3. Apply engine oil to the oil seal lip. 4. Remove any dirt or other material from the con­ tact surfaces. 5. Apply a continuos bead of silicon sealant to the contact surface of the oil pump. Caution Do not allow any sealant to get into the oil hole.

  • Page 75

    ASSEMBLY (CYLINDER BLOCK) Oil Pan 1. Apply a continuous bead of silicon sealant to the oil pan along the inside of the bolt holes, and over­ lap the ends. 2. Install the oil pan. Tightening torque: 7—12 Nm (70—120 cm-kg, 61—104 in-lb) 86U01X-137 Flywheel (MTX), Drive Plate (ATX) 1.

  • Page 76

    ASSEMBLY (CYLINDER BLOCK) Clutch Disc and Clutch Cover (MTX) Install the clutch disc and clutch cover using the SST. (Refer to Section 6.) Tightening torque: 22—32 Nm (2.2—3.3 m-kg, 16—24 ft-lb) 86U01X-141 Water Pump 1. Remove all dirt, grease, and other material from the water pump mounting surface.

  • Page 77

    ASSEMBLY (CYLINDER HEAD) CYLINDER HEAD Torque Specifications 6—8 Nm (60—80 cm-kg, 52—69 In-lb) 19—25 N m (1.9—2.6 m-kg, 1 4 -1 9 ft-lb) 18—26 N-m 80—86 N-m (8.2—8.8 m-kg, 59—64 ft-lb) 19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 69G01B-152 Valve Seal 1.

  • Page 78

    ASSEMBLY (CYLINDER HEAD) Valve and Valve Spring 1. Install the lower spring seat. 2. Install the valve. 3. Install the valve springs and the upper spring seat. Note Install the valve spring with the closer pitch toward the cylinder head. 86U01X-144 4.

  • Page 79

    ASSEMBLY (CYLINDER HEAD) Camshaft 1. Apply a liberal amount of engine oil to the journals and bearings. 2. Place the camshaft in position with the dowel pin facing straight up. Hydraulic Lash Adjuster (HLA) 1. Pour engine oil into the oil reservoir in the rocker arm.

  • Page 80

    ASSEMBLY (CYLINDER HEAD) 3. Apply liberal amount of clean engine oil to the cam lobes and journals. 4. Position the camshaft caps according to the *■ mark. Note The No. 3 camshaft cap has an oil passage from the cylinder head, be certain it is in­ stalled correctly.

  • Page 81

    ASSEMBLY (CYLINDER HEAD) 1 3. Apply engine oil to the oil seal lip. 4. Install the front housing and a new gasket. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 86U01X-156 Rear Housing Install the rear housing and a new gasket. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 86U01X-157...

  • Page 82

    ASSEMBLY (TIMING BELT) TIMING BELT Torque Specifications (1.25— 1.75 m-kg, 109— 152 in-lb) 69G01B-160 1 -7 2...

  • Page 83

    ASSEMBLY (TIMING BELT) Camshaft Pulley 1. Install the camshaft pulley on the camshaft with the dowel pin fit into the hole at the “ f i ” mark. 2. Tighten the camshaft pulley bolt. Tightening torque: 47—65 Nm (4.8—6.6 m-kg, 35—48 ft-lb) 3.

  • Page 84

    ASSEMBLY (TIMING BELT) Timing Belt Idler Pulley Install the tinning belt idler pulley. Tightening torque: 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) Tensioner Timing Belt Tensioner 1. Install the timing belt tensioner and tensioner spring. 2. Tentatively secure the tensioner with the spring fully extended.

  • Page 85

    ASSEMBLY (TIMING BELT) 6. Measure the belt tension between the crankshaft pulley and the camshaft pulley. If the timing belt tension is not correct, loosen the tensioner lock bolt and repeat steps 3—5 above. Replace the tensioner spring if necessary. kg, 22 lb) Belt deflection: 7.5—8.5 mm (0.30—0.33 In)

  • Page 86: Auxiliary Parts

    ASSEMBLY (AUXILIARY PARTS) AUXILIARY PARTS Torque Specifications 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) 19— 30 N-m 37—63 N-m (1.9—3.1 m-kg, 1 4 -2 2 ft-lb) (3.8—6.4 27—4( 85—117 N-m (8.7—11.9 63—86 19—30 N m (3.5—4.5 m-kg, (1.9—3.1 m-kg, 25—33 ft-lb) 14—22 ft-lb) 22—27 N-m (2.2—2.8 m-kg, 16—20...

  • Page 87

    ASSEMBLY (AUXILIARY PARTS) Knock Sensor (Turbo) Install the knock sensor. Tightening torque: 20—34 N m (2.0—3.5 m-kg, 14—25 ft-lb) Oil Pressure Switch Install the oil pressure switch. Tightening torque: 12—18 N-m (1.2—1.8 m-kg, 104—156 in-lb) Oil Cooler (Turbo) Install the oil cooler. Tightening torque: 29—39 N m (3.0—4.0 m-kg, 22—29 ft-lb) Oil Filter...

  • Page 88

    ASSEMBLY (AUXILIARY PARTS) Thermostat and Thermostat Cover 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Position a new gasket with the printed side facing the cylinder head. 3. Install the thermostat cover. Tightening torque: 19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb) Spark Plug...

  • Page 89

    ASSEMBLY (AUXILIARY PARTS) Alternator 1. Install the alternator strap and bracket. Tightening torque: 37—63 N m (3.8—6.4 m-kg, 27—46 ft-lb) 86U01X-171 2. Install the alternator. Tightening torque (§): 31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb) (§): 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) 3.

  • Page 90

    ASSEMBLY (AUXILIARY PARTS) Exhaust Manifold Assembly 1. Place the new gaskets in position with the ridge facing the cylinder head. 2. Install the exhaust manifold assembly. 3. Tighten the nuts in two or three steps. Tightening torque: 22—28 Nm (2.2—2.9 m-kg, 16—21 ft-lb) 4.

  • Page 91: Installation

    INSTALLATION INSTALLATION TRANSAXLE ASSEMBLY Assemble the transaxle to the engine in the sequence shown in the figure, referring to installation note. 86U01X-179 1. Transaxle 3. Gusset plate 2. Clutch under cover 4. Starter Installation note Clutch under cover Before installation, fill the notches with silicon as shown in the figure.

  • Page 92: Engine Installation

    INSTALLATION ENGINE INSTALLATION Install the engine and transaxle assembly. Warning: Be sure the vehicle is securely supported. Torque Specifications_______________________________ TURBO 8—11 N-m 86U01X-180 1 -8 2...

  • Page 93

    INSTALLATION NON-TURBO 86U01X-218 1-83...

  • Page 94

    INSTALLATION Engine Mount Install the engine mount. 85—117 N-m ft-lb) Non-Turbo: Turbo: 86U01X-181 Exhaust Pipe 1. Install the exhaust pipe. Tightening torque: ® : 31 —46 N-m (3.2—4.7 m-kg, 23—34 ft-lb) (§): 64—89 N-m (6.5—9.1 m-kg, 47—66 ft-lb) 2. Tighten the bracket bolt. Tightening torque: 19—25 N m (1.9—2.6 m-kg, 14—19 ft-lb) Extension Bar (MTX)

  • Page 95

    INSTALLATION Driveshaft 1. Apply grease to the end of the driveshaft. 2. Install the driveshaft and a new clip. Caution a) When installing the driveshaft, be careful not to damage the oil seal. b) After installation, pull the front hub outward to confirm that the driveshaft is securely held by the clip.

  • Page 96

    INSTALLATION P/S Oil Pump 1. Install the P/S oil pump. Tightening torque: 31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb) 2. Tighten the pulley lock nut. Tightening torque: 39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb) A/C Compressor 1. Install the A/C compressor strap to the P/S oil pump bracket.

  • Page 97

    INSTALLATION Clutch Release Cylinder (MTX) 1. Set the pipe bracket in position. Tightening torque: 8—11 N m (80—110 cm-kg, 69—95 in-lb) 2. Install the clutch release cylinder. Tightening torque: 19—25 N m (1.9—2.6 m-kg, 14—19 ft-lb) Control Cable (ATX) Install the control cable and adjust the shift selector position.

  • Page 98

    INSTALLATION Turbocharger Oil Pipe and Hose (Turbo) 1. Install the turbocharger pipe. Tightening torque ® : 64—89 N m (6.5—9.1 m-kg, 47—66 ft-lb) (§): 8—11 N m (80—110 cm-kg, 69—95 in-lb) 2. Connect the turbocharger hoses. 76F01C-043 Radiator 1. Install the radiator and cooling fan. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-lb) 2.

  • Page 99

    INSTALLATION High-Tension Lead Connect the high-tension lead to the ignition coil. Accelerator Cable and Throttle Cable (ATX) 1. Install the accelerator cable and the throttle cable (ATX). 2. Check the deflection of the cable. Deflection: 1—3mm (0.04—0.12 in) Battery and Battery Carrier 1.

  • Page 100: Lubrication System

    LUBRICATION SYSTEM OUTLINE............2— 2 LUBRICATION CIRCUIT........2— 2 SPECIFICATIONS..........2— 3 TROUBLESHOOTING GUIDE ......2— 3 INSPECTION........... 2— 4 ENGINE O IL ............. 2— 4 OIL PRESSURE..........2— 4 ENGINE OIL.............2— 4 2— 4 REPLACEMENT..........OIL FILTER............2— 5 REPLACEMENT..........

  • Page 101

    2 OUTLINE OUTLINE LUBRICATION CIRCUIT 86U02X-003 1. Oil pump 5. Oil cooler (only Turbo) 2. Pressure regulator valve 6. Oil filter 3. Main gallery 7. Oil control plug 4. Oil pressure switch 2 - 2...

  • Page 102

    TROUBLESHOOTING GUIDE 2 SPECIFICATIONS — - — _________ Model Lubrication system Fore 3-fed Type Trochoid gear Oil pump Regulated pressure kPa (kg/cm2, psi) 392 (4.0, 57) Full-flow, paper element Type Oil filter 98 (1.0, 14) Relief pressure differential kPa (kg/cm2, psi) Water-cooled, 4 layer Type Oil cooler...

  • Page 103: Engine Oil

    2 INSPECTION, ENGINE OIL INSPECTION ENGINE OIL 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temper­ ature and stop it. 3. Wait for five minutes. 4. Remove the oil level gauge and check the oil lev­ el and condition.

  • Page 104: Oil Filter

    OIL FILTER, OIL COOLER 2 3. Install the drain plug and a new gasket. 4. Refill the engine with the specified type and amount of oil. 5. Refit the oil filler cap. Oil pan capacity: 3.9 liters (4.1 US qt, 3.4 Imp qt) 6.

  • Page 105: Oil Pan

    OIL PAN OIL PAN REMOVAL 1. Disconnect the negative battery cable. 2. Drain the engine oil. 3. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. 86U02X-011 1. Exhaust pipe 5. Oil pan 6.

  • Page 106

    OIL PAN 2 INSPECTION Check the following points. Repair or replace if necessary. 1. Cracks, deformation, damage 2. Damaged drain plug threads 4BG02X-037 INSTALLATION Install in the reverse order of removal referring to the installation note. Installation Note Stiffener, oil strainer, and oil pan 1.

  • Page 107: Oil Pump

    2 OIL PUMP OIL PUMP REMOVAL 1. Disconnect the negative battery cable. 2. Drain the engine oil. 3. Remove in the sequence shown in the figure, for the specially marked parts referring to removal note. 86U02X-017 86U02X-018 1. Timing belt (Refer to Section 1) 4.

  • Page 108

    OIL PUMP 2 DISASSEMBLY Disassemble in the sequence shown in the figure. 69G02B-012 1. Pump cover 2. Outer rotor 3. Inner rotor 4. Pressure relief valve 5. Oil seal 6. Oil pump body 69G02B-013 INSPECTION 1. Check the following and replace any faulty parts. (1) Distorted or damaged oil pump body or cover (2) Worn or damaged plunger (3) Weak or broken plunger spring...

  • Page 109

    2 OIL PUMP 4. Measure the outer gear to pump body clearance. Clearance: 0.20 mm (0.008 in) max. 86U02X-021 ASSEMBLY Assemble the pump as follows. Oil Seal 1. Apply engine oil to the pump body and the out­ side of the new oil seal. 2.

  • Page 110: Cooling System

    COOLING SYSTEM OUTLINE............3— 2 COOLANT FLOW CHART......3— 2 SPECIFICATIONS..........3— 3 TROUBLESHOOTING GUIDE......3— 3 COOLANT............3— 4 INSPECTION............ 3— 4 REPLACEMENT..........3— 4 RADIATOR CAP..........3— 5 INSPECTION............ 3— 5 RADIATOR............3— 6 REMOVAL AND INSTALLATION....3— 6 INSPECTION............

  • Page 111

    3 OUTLINE OUTLINE 86U03X-027 1. Water pump 5. Oil cooler (only Turbo) 2. Thermostat 6. Electric fan 3. Radiator 7. No.1 water thermo switch 4. Coolant reservoir 8. No.2 water thermo switch...

  • Page 112

    TROUBLESHOOTING GUIDE 3 SPECIFICATIONS Cooling system Water-cooled, forced circulation With heater 7.5 (7.9, 6.6) Coolant capacity liters (US qt, Imp qt) Without heater 6.9 (7.3, 6.1) Type C entrifugal, tim in g belt driven Water pump Water seal Unified seal Type 86.5-89.5 (188-193) Opening temperature...

  • Page 113

    COOLANT COOLANT INSPECTION Coolant Level (Engine cold) 1. Check that the coolant level is near the radiator inlet port. 2. Check that the coolant level in the coolant reser­ voir is between the marks. F U L L Lo w Add coolant if necessary.

  • Page 114: Radiator Cap

    RADIATOR CAP 3 3. Set the heater control switch to the maximum heat position. 4. Flush the cooling system with water until all traces of color are gone, then let the system drain com­ pletely. 5. Fill with the proper mixture and amount of ethy­ lene glycol-based coolant.

  • Page 115

    3 RADIATOR RADIATOR REMOVAL AND INSTALLATION 1. Drain the engine coolant. 2. Remove in the sequence shown in the figure. 3. Install in the reverse order of removal. Note a) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit.

  • Page 116

    RADIATOR RADIATOR REMOVAL / INSTALLATION 1. Drain the engine coolant. 2. Remove in the sequence shown in the figure. 3. Install in the reverse order of removal. Note • Position the hose clamp in the original location on the hose. •...

  • Page 117

    RADIATOR Installation Notes The damper bush on the bracket and the stud on the radiator should be centered as illustrated. Align the center by moving the radiator and/or brackets. 16U0EX-050 INSPECTION Check the following points. Repair or replace if necessary. 1.

  • Page 118: Water Pump

    WATER PUMP WATER PUMP REMOVAL 1. Disconnect the negative battery cable. 2. Turn the crankshaft so that the No.1 cylinder is at TDC of compression. 3. Drain the engine coolant. 4. Remove in the order shown in the figure. 16U0EX-004 N-m (m-kg, ft-lb) UOEX-OO 1.

  • Page 119

    THERMOSTAT THERMOSTAT REMOVAL 1. Drain the engine coolant. 2. Remove the thermostat cover. 3. Remove the thermostat. INSPECTION Check the thermostat. Replace if necessary. 1. Visually check that the valve is airtight. 2. Place the thermostat and a thermometer in water. 3.

  • Page 120

    3 ELECTRIC FAN ELECTRIC FAN SYSTEM CIRCUIT 3 -1 0 626, MX-6 Revised 10/87...

  • Page 121

    ELECTRIC FAN 3 CIRCUIT INSPECTION Check the cooling fan operation. Operating fan With A/C Without A/C Condition Turbo Non-Turbo Coolant temp, over 97°C (177°F) Main (Lo) Main Main Main (Lo) Main Main (Hi), Main, Coolant temp, over 108°C (226°F) Main (Hi) —...

  • Page 122

    3 ELECTRIC FAN ■ i n Inspection . Connect an ammeter and battery to the fan motor connectors. 2. Check that the fan motor operates smoothly at the specified current or less. Current 5.6—7.6 Turbo 10.6—16.6 Non-Turbo 86U03X-023 3. Replace the fan motor if necessary. WATER THERMO SWITCH 1.

  • Page 123

    FUEL AND EMISSION CONTROL SYSTEM (NON-TURBO) DECELERATION CONTROL OUTLINE.........4A— SYSTEM........4A— 66 SYSTEM DIAGRAM....... 4A— COMPONENT LOCATION... 4A— COMPONENT DESCRIPTIONS..4A— 67 TROUBLESHOOTING....4A— 68 VACUUM HOSE ROUTING DIAGRAM........4A — EXHAUST GAS RECIRCULATION SPECIFICATIONS......4A— (EGR) SYSTEM ......4A— 70 COMPONENT DESCRIPTIONS..

  • Page 124

    -P * (/> > -< > Solenoid valve Fuel filter Check and cut valve (Pressure regulator) (high pressure Vacuum switch valve > Three-way > check valve\ohfice Fuel filter (Low pressure side) Fuel pump Atmospheric pressure sensor Air flow meter Throttle sensor and idle switch Idle switch Intake air thermo EGR control valve...

  • Page 125

    OUTLINE COMPONENT LOCATION Input Devices Throttle sensor Test connector: Yellow 2 pin Test connector: Green 1 p Idle switch Water thermo valve Air flow meter, E/L control unit Engine control unit EC-AT control unit Atmospheric pressure sensor Circuit opening Clutch switch Brake light switch Water thermo Neutral switch...

  • Page 126

    OUTLINE Fuel and Output Devices Pressure regulator Delivery pipe Solenoid valve /(Idle speed control) Injector Check connector Green (for Self-Diagnosis checker) « * > ! / EGR control_____ valve Solenoid valve (EGR) Shift indicator light Separator Three-way check valve Check and cut valve 86U04A-004 4A—4...

  • Page 127

    Exhaust System 86U04A-005 4A—5...

  • Page 128

    > B : Black W: White L : Blue O : Orange G : Green Br: Brown R : Red Y : Yellow Vacuum delay valve Pressure regulator Solenoid valve (Purge) Solenoid valve (Pressure regulator) Solenoid valve (EGR) Charcoal canister >...

  • Page 129

    OUTLINE SPECIFICATIONS Engine type Non-Turbo Engine Item Idle speed 750 ± 25 (ATX: P range)* Throttle body Horizontal draft (2-barrel) Type No. 1 MTX: 40 (1.6), ATX: 46 (1.8) mm (in) Throat diameter MTX: 46 (1.8), ATX: 40 (1.6) No. 2 Air flow meter E2-VS Fully closed: 20—400 Fully open: 20—1,000...

  • Page 130

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE This troubleshooting guide shows the malfunction numbers and the symptoms of various failures. Perform troubleshooting as described below. Output solenoid valves Possible cause Input sensors and switches J B O £ 4 > > £ 3 &...

  • Page 131

    TROUBLESHOOTING GUIDE The Troubleshooting Guide lists the systems most likely to cause a given symptom. After finding sys­ tems to check, refer to the pages shown for detailed guides for each system. Fuel and Emission Control Systems 4A—74 4A—68 4 A -8 3 4A—81 4A—45 4A—56...

  • Page 132

    TROUBLESHOOTING WITH SST 4 A INSPECTION PROCEDURE Check connector: Green . Connect the SST to the check connector. (Green, -pin) and the negative battery terminal. 2. Set the select switch to position A. Note The check connector is located at the rear of the left side wheel housing.

  • Page 133

    TROUBLESHOOTING WITH SST 2. Connect the SST to the check connector. 3. Ground the test connector (Green, 1-pin) with a 4 9 H 0 1 8 9A1 jumper wire. Test connector: Green (1 pin) 86U04A-015 4. Turn the ignition switch ON, but do not start the engine for six seconds.

  • Page 134

    TROUBLESHOOTING WITH SST 4 A PRINCIPLE OF CODE CYCLE Malfunction codes are determined as shown below 86U04A-017 1. Code cycle break The time between warning code cycles is 4.0 sec (the time the light is off). Malfunction code cycle cycle break 4.0 sec.

  • Page 135

    TROUBLESHOOTING WITH SST CODE NUMBER Malfunction display Self-diagnosis Fail-safe Code MIL output sign, subsystem pattern Ignition pulse No ignition signal ° N | | Air flow meter Open or short circuit Maintains basic sig­ nal at preset value “ J i m Water thermo sensor Open or short circuit Maintains constant...

  • Page 136

    TROUBLESHOOTING WITH SST If a malfunction code number is shown on the SST, check the following chart along with the wiring diagram. Code No. 01 (Ignition pulse) PC: Possible Cause 86U04A-021 4 A—15...

  • Page 137

    TROUBLESHOOTING WITH SST PC: Possible Cause Code No. 08 (Air flow meter) Are there poor connections in air flow meter circuit? Repair or replace connector Is there continuity between air flow meter and engine control unit? Air flow meter Control unit PC: Open circuit in wiring harness from air flow (RB wire) meter to engine control unit...

  • Page 138

    TROUBLESHOOTING WITH SST Code No. 09 (Water thermo sensor) PC: Possible Cause Are there poor connections at water thermo Repair or replace connector sensor circuit? Is there continuity between water thermo sensor and control unit? PC: Open circuit in wiring harness from water thermo Water thermo sensor Control unit sensor to engine control unit...

  • Page 139

    TROUBLESHOOTING WITH SST PC: Possible Cause Code No. 10 (Intake air thermo sensor) Are there poor connections in air flow meter circuit? Repair or replace connector Is there continuity between intake air thermo sensor (in air flow meter) and engine control unit? Intake air temperature sensor PC: Open circuit in wiring harness from intake air thermo Control unit...

  • Page 140

    TROUBLESHOOTING WITH SST Code No. 12 (Throttle sensor) PC: Possible cause 86U04A-025 « r 4A—19...

  • Page 141

    TROUBLESHOOTING WITH SST Code No. 14 (Atmospheric pressure sensor) PC: Possible cause Are there poor connections in atmospheric pressure Repair or replace connector sensor circuit? PC: Open or short circuit in wiring harness from Is there Vref at (LgR) wire of atmospheric pressure (LgR) wire to engine control unit sensor connector? •...

  • Page 142

    TROUBLESHOOTING WITH SST 4 A Code No. 15 (Oxygen sensor) PC: Possible Cause Note When the Code No.15 and 17 are present at the same time, first preform the checking proce­ dure for the Code No.17. (Refer to page 4A—22.) 86U04A-027 4 A—21...

  • Page 143

    TROUBLESHOOTING WITH SST PC: Possible Cause Code No. 17 (Feedback system) 86U04A-028 4A-22...

  • Page 144: Table Of Contents

    TROUBLESHOOTING WITH SST Code No. 25 (Solenoid valve-Pressure regulator) PC: Possible Cause 86U04A-029 Code No. 26 (Solenoid valve-Purge) 86U04A-030 4A-23...

  • Page 145

    TROUBLESHOOTING WITH SST Code No. 28 (Solenoid valve—EGR) 86U04A-031 Code No. 34 (Solenoid valve—Idle speed control valve (ISC)) 86U04A-032 4A—24...

  • Page 146

    SWITCH MONITOR FUNCTION SWITCH MONITOR FUNCTION Individual switches can be monitored by the SST. Note The test connector must be grounded and the ignition switch ON (engine stopped). Self-Diagnosis Checker (Monitor lamp) Remarks Switch Light ON Light OFF Gear: IN Pedal released Pedal depressed Clutch switch...

  • Page 147

    SWITCH MONITOR FUNCTION INSPECTION PROCEDURE Check connector: Green pin) 1. Warm up the engine to normal operating temper­ ature and stop it. 2. Connect the SST to the check connector (Green, -pin) and the negative battery terminal. 86U04A-034 3. Connect a jumper wire between the test connec­ tor (Green, 1-pin) and a ground.

  • Page 148

    SWITCH MONITOR FUNCTION Idle switch 86U04A-037 Brake light switch 86U04A-038 Blower switch 86U04A-039 A/C switch 86U04A-040 4A -27...

  • Page 149

    SWITCH MONITOR FUNCTION Headlight switch 86U04A-041 Rear defroster switch 86U04A-042 Inhibitor switch 86U04A-043 Water thermo switch circuit (not included in switch inspection) Warning The electrical fan operates when the 4A-28...

  • Page 150

    IDLE ADJUSTMENT IDLE ADJUSTMENT IDLE SPEED Because the idle speed is controlled automati­ Idle speed cally by the engine control unit through the idle speed control (ISC) solenoid valve, usually it is Automatic not necessary to check and adjust the idle Control speed.

  • Page 151

    IDLE ADJUSTMENT IDLE MIXTURE Because an automatic compensation function for air/fuel mixture is built into the engine con­ trol unit, it is not necessary to check and adjust Idle mixture the idle mixture. Automatic Control Function Engine Control Unit 86U04A-049...

  • Page 152

    INTAKE AIR SYSTEM INTAKE AIR SYSTEM 86U04A-050 This system controls the air required by the engine for operation. The system consists of the air duct, air cleaner, air flow meter, throttle body, dynamic chamber, and intake manifold. This system also has a resonance chamber to improve mid-range torque characteristics. COMPONENT DESCRIPTIONS Application Prevous...

  • Page 153

    INTAKE AIR SYSTEM REMOVAL Caution Before removing the following parts, release the fuel pressure from fuel system to reduce the possibility of injury or fire. (Refer to page 4A—46.) Remove in the sequence shown in the figure. 86U04A-047 1. Air flow meter connector 9.

  • Page 154

    INTAKE AIR SYSTEM PARTS INSPECTION Air Cleaner Element 1. Check the condition of the air cleaner element. 2. Replace, if necessary. Caution Do not use the compressed air to clean the air cleaner element. 69G04A-059 Accelerator Cable 1. Inspect the deflection of the cable. If the deflec­ tion is not within 1—3 mm (0.04—0.12 in.), ad­...

  • Page 155

    INTAKE AIR SYSTEM Dynamic Chamber 1. Visually check the dynamic chamber for damage. 2. Replace, if necessary. Intake Manifold 1. Visually check the intake manifold for damage. 2. Replace, if necessary. 69G04A-064 Resonance Chamber 1. Visually check the resonance chamber for damage.

  • Page 156

    INTAKE AIR SYSTEM REPLACEMENT Throttle Lever Removal Caution When loosening the throttle lever nut, hold the throttle valves fully open to prevent damag­ ing the idle switch. Remove the throttle lever in the sequence shown in the figure. 69G04C-130 Installation 1.

  • Page 157

    INTAKE AIR SYSTEM INSTALLATION Install in the reverse order of removal, referring to the installation note. Torque Specification 86U04A-055 4A-36...

  • Page 158

    INTAKE AIR SYSTEM Installation Note Water hose spring clamps Face the clamp end as shown in the figure. Gasket Use new gaskets at the intake manifold, dynamic chamber, and throttle body. 86U04A-056...

  • Page 159

    ISC SYSTEM IDLE SPEED CONTROL (ISC) SYSTEM Throttle sensor Air valve BAC valve (ISC valve + air valve) ISC valve To engine R > Air passage Coolant passage Idle switch Coolant temperature 86U04A-057 To improve idle smoothness, the ISC system controls the intake air amount by regulating the bypass air amount that passes through the'throttle body.

  • Page 160

    ISC SYSTEM COMPONENT DESCRIPTIONS Application Component Function Remarks Previous model model • Air valve When cold, supplies bypass air into dy­ Engine speed increased to namic chamber shorten warm-up period • Thermo wax type • Installed in BAC valve Detects in-gear condition; Switch ON when clutch pedal Clutch switch sends signal to control unit...

  • Page 161

    ISC SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switch. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) Possible cause Solenoid...

  • Page 162

    ISC SYSTEM BAC Valve Air valve . Remove the BAC valve from the throttle body. 2. Blow air throgh the valve from port A and check that air comes out of port B when the BAC valve is cold. 3. If not correct, replace the BAC valve. Note Refer to “...

  • Page 163: Fuel System

    FUEL SYSTEM FUEL SYSTEM 86U04A-065 This system supplies the fuel necessary for combustion at a constant pressure to the injectors. Fuel is metered and injected into the intake manifold according to the injection control signals from the en­ gine control unit. It consists of the fuel pump, fuel filters, delivery pipe, pulsation damper, pressure regulator, injectors, fuel pump switch (incorporated in the air flow meter), and the circuit opening relay.

  • Page 164

    FUEL SYSTEM COMPONENT DESCRIPTIONS Application Component Function Remarks Previous model model Air flow meter Detects amount of intake air; Intake air temp sensor and fuel pump switch are in­ sends signal to control unit tegrated Atmospheric pres­ Detects atmospheric pressure; sends sig­ sure sensor nal to control unit Circuit opening relay...

  • Page 165

    FUEL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches. Possible cause Engine con­ trol unit terminal \ Page 3C 3E 4A-96 4A-103 4A-102 4A-97 4A-101 4A-101 4A-50 4A-52 4A-49 4A-92 4A-92 Symptom Hard start or won’t start (Cranks OK) While warming up...

  • Page 166

    FUEL SYSTEM FUEL PRESSURE RELEASE AND SERVICING FUEL SYSTEM Fuel in the fuel system remains under high pressure even when the engine is not running. a) Before disconnecting any fuel line, release the fuel pressure from the fuel system to reduce the pos­ sibility of injury or fire.

  • Page 167

    FUEL SYSTEM MULTI-PRESSURE TESTER (49 9200 750A) 49 9200 750A 69G04A-099 The MULTI-PRESSURE TESTER (49 9200 750A) has been developed to check the fuel pressure and intake manifold vacuum. These can easily be inspected by setting the buttons on the tester.

  • Page 168

    FUEL SYSTEM How to Connect Multi-Pressure Tester Warning Before connecting the SST, release the fuel pressure from the fuel system to reduce the possibility of injury or fire. (Refer to page 4A—46.) 1. Disconnect the negative battery terminal. 2. Disconnect the fuel main hose from the fuel filter. 3.

  • Page 169

    FUEL SYSTEM FUEL PRESSURE Note a) When inspecting fuel pressure, use the SST. (Refer to page 4A—48). b)Warm up the engine to normal operating temperature. Injection Pressure 1. Set the lever on the adapter as shown in the figure. 86U04A-073 2.

  • Page 170

    FUEL SYSTEM Fuel Line Pressure 1. Start the engine and run it idle. 2. Set the lever on the adapter as shown in the figure. 3. Check the fuel line pressure. Fuel line pressure: Approx. 186—226 kPa (1.9—2.3 kg/cm2, 27—33 psi) 4.

  • Page 171

    FUEL SYSTEM Volume Test Warning connector (Yellow) Before performing following procedures, re­ lease the fuel pressure to reduce the possi­ bility of injury or fire. (Refer to page 4A—46) 1. Connect a jumper wire to test connector (Yellow). 2. Disconnect the fuel return hose from fuel return pipe.

  • Page 172

    FUEL SYSTEM INJECTOR On-vehicle Inspection Engine does not start Perform "Quick Inspection for Electrical Signal” below. Engine runs 1. Warm up the engine and run it at idle. 2. Listen for operational sound of the injector with a screwdriver or a sound scope. 86U04A-084 3.

  • Page 173

    FUEL SYSTEM Inspection There are 3 inspections which must be performed for the injectors. Resistance . Remove the injectors from the engine. (Refer to page 4A—59.) 2. Check the resistance of each injector with an ohmmeter. 3. If not correct, replace the injector. Resistance: 12—16 Q Fuel leakage test and volume test 1.

  • Page 174

    FUEL SYSTEM PRESSURE REGULATOR CONTROL SYSTEM Water therm o sensor Fuel (To fuel tank) 86U04A-092 To prevent percolation of the fuel during idle after the engine is restarted, vacuum is cut to the pres­ sure regulator, increasing the fuel pressure. Specified time: Approx.

  • Page 175

    FUEL SYSTEM COMPONENT DESCRIPTIONS Application Previous Component Function Remarks model model Detects signals from input sensors and Engine control unit switches; controls solenoid valve (Pres­ sure regulator control) Ignition coil (-) Detects engine speed; sends signal to control unit terminal Ignition switch Sends engine cranking signal to control (ST position)

  • Page 176

    FUED SYSTEM 7. Restart the engine. Fuel line pressure kPa Operating time . Check the fuel line pressure and operating times (kg/cm2, psi) as shown in the chart. After starting: for 120 235-275 sec. (2.4—2.8, 3 4-40) 186-226 After 120 sec. (1.9-2.3, 27-33) 86U04A-097 Solenoid Valve (Pressure Regulator Control)

  • Page 177

    FUEL SYSTEM REPLACEMENT Caution A)Before performing the following procedure, release the fuel pressure from the fuel sys­ tem to reduce the possibility of injury or fire (Refer to page 4A—46). b)When servicing the fuel system, keep sparks, cigarettes, and open flames away from the fuel.

  • Page 178

    FUEL SYSTEM Injector . Remove the wiring harness bracket. 2. Remove the EGR modulator valve bracket. 3. Disconnect the vacuum pipe mounting bolts. 86U04A-103 4. Disconnect the air hose from the throttle body. 86U04A-104 5. Remove the engine hanger. Engine .

  • Page 179

    FUEL SYSTEM 11. Remove the grommets, injectors, and insulators. 12. Install in the reverse order of removal, referring to installation note. Tightening torque: ,19—25 N m Delivery pipe Dynamic chamber (1.9—2.6 m-kg, Engine hanger 14—19 ft-lb) Installation note Injector 1. Use new O-rings. 2.

  • Page 180

    FUEL SYSTEM Delivery Pipe 1. Perform steps 1 to 7 of removal procedure for in­ jectors. (Refer to page 4A—59.) 2. Remove the pulsation damper, pressure regula­ tor, and injectors. 3. Replace the delivery pipe. 4. Install in the reverse order of removal, referring to installation note.

  • Page 181

    FUEL SYSTEM Pressure Regulator 1. Perform steps 1 to 8 of removal procedure for the injector. (Refer to page 4A—59.) 2. Disconnect the vacuum hose and fuel return hose. 3. Remove the pressure regulator. 4. Install in the reverse order of removal. Tightening torque: 8—11 Nm (0.8—1.1 m-kg, 69—95 in-lb) Pulsation Damper...

  • Page 182

    FUEL SYSTEM FUEL TANK Removal Caution a) Before performing the following procedure, release the fuel pressure from the fuel sys­ tem to reduce the possibility of injury or fire. (Refer to page 4A—46) b) When removing the fuel tank, keep sparks, cigarettes, and open flames away from the fuel tank.

  • Page 183

    FUEL SYSTEM Inspection 1. Check the fuel tank for cracks and corrosion. 2. If any defect is found, repair or replace the tank. Warning Before repairing, clean the fuel tank thorough­ ly with steam to sufficiently remove all explo­ sive gas. 86U04A-118 Installation Install in the reverse order of removal, referring to the installation note.

  • Page 184

    FUEL SYSTEM Installation note 1. Push the hose ends of the main fuel hose, fuel re­ turn hose and evaporation hoses onto the fuel tank fittings at least 25 mm (1.0 in). 2. Push the fuel filler hose ends onto the fuel tank pipe and filler pipe at least 35 mm (1.4 in).

  • Page 185

    DECELERATION CONTROL SYSTEM DECELERATION CONTROL SYSTEM The fuel cut system is provided as a deceleration control system. This system is to improve fuel economy. 4A—66 626, MX-6 Revised 10/87...

  • Page 186

    DECELERATION CONTROL SYSTEM COMPONENT DESCRIPTIONS Application Component Function Previous Remarks model model Brake light switch Detects braking operation (deceleration); sends signal to control unit Detects in-gear condition; Switch ON when clutch pedal Clutch switch sends signal to control unit released Detects N or P range;...

  • Page 187

    DECELERATION CONTROL SYSTEM 4. Increase the engine speed to 4,000 rpm, then sud­ denly decrease the engine speed. 0-8* 0-20* 5. Check that the red indicator lamp stays illuminat­ ed during deceleration.

  • Page 188

    EGR SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM This system introduces exhaust gas into the intake manifold to reduce NOx in the exhaust gas. It oper­ ates depending on the engine load, engine speed (above 1,500 rpm), engine coolant temperature (above 70°C, 158°F), and radiator coolant temperature (above 17°C, 63°F). COMPONENT DESCRIPTIONS Application Previous...

  • Page 189: Egr System

    EGR SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) System Water Water...

  • Page 190

    EGR SYSTEM 4. Disconnect the solenoid valve connector. 5. Connect 12V and a ground to the terminals of the solenoid valve. 6. Blow through the solenoid valve from vacuum hose 7. Check that air flows from the valve air filter. EGR Modulator Valve 1.

  • Page 191

    EEC SYSTEM EVAPORATIVE EMISSION CONTROL (EEC) SYSTEM This system stores fuel vapor generated in the fuel tank in the canister when the engine is not running. The fuel vapor is stored in the canister until it is drawn into the dynamic chamber and burned when the engine is started.

  • Page 192

    EEC SYSTEM TROUBLESHOOTING Check the condition of the wiring harness or connectors, before checking the sensors or switches. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) Possible cause 4A-76 4A-77 4A-77 4A-78 4A-78 4A-76 4A-76 4A-77 4A-101 4A-92 4A-75 Page...

  • Page 193

    EEC SYSTEM System Inspection 1. Check the vacuum hose routing. 2. If there is a poor connection, clog, or leak, repair or replace as necessary. 3. Warm up the engine and run it at idle. 4. Disconnect vacuum hose A from No. 1 purge con­ 49 9200 750A trol valve and connect the SST to the hose.

  • Page 194

    EEC SYSTEM 14. Disconnect the evaporation hose from the evapo­ ration pipe. 15. Connect the vacuum pump to the evaporation pipe. 16. Operate the vacuum pump and verify that no vacu­ um is held. 17. If vacuum is held, check the evaporation pipe for clogging.

  • Page 195

    EEC SYSTEM Water Thermo Valve 1. Remove the water thermo valve. 2. Immerse the valve in a water-filled container. 3. Heat the water gradually and observe the tem­ perature. 4. Blow through the valve from one vacuum port and verify that air comes out of the other port at 46—54°C (115—129°F).

  • Page 196

    EEC SYSTEM 2. Connect vacuum hoses to the valve as shown in the figure. 3. Blow air through the valve from hose A and check that air comes out of the valve air filter. 4. Apply 12V and ground the solenoid valve with jum­ per wires.

  • Page 197

    PCV SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM valve 86U04A-155 The PCV valve is operated by the intake manifold vacuum. When the engine is running at idle, the PCV valve is opened slightly and a small amount of blow-by gas is drawn into the dynamic chamber. At high engine speeds, the PCV valve is further opened and a larger amount of blow-by gas is drawn into the dynamic chamber.

  • Page 198: Exhaust System

    EXHAUST SYSTEM EXHAUST SYSTEM Exhaust manifold ■ Only MTX Main silencer 86U04A-158 The catalytic converter is used to reduce CO, HC and NOx. The converter contains a compound of platinum and rhodium. It is a three-way catalyst type with a volume of 2,100 cc (128 cu in). 4A—80...

  • Page 199

    EXHAUST SYSTEM REMOVAL AND INSTALLATION 1. Remove in the sequence shown in the figure. 2. Install in the reverse order of removal. Torque Specifications 86U04A-159 1. Main silencer 4. Catalytic converter 2. Middle pipe 5. Bracket 3. Pre-silencer 6. Front pipe INSPECTION 1.

  • Page 200

    SHIFT INDICATOR LIGHT CONTROL SYSTEM SHIFT INDICATOR LIGHT CONTROL SYSTEM The shift indicator light warns the driver when the accelerator pedal is excessively depressed in view of optimum fuel economy. COMPONENT DESCRIPTIONS Application Remarks Previous Function Component model model Intake air temp sensor and Air flow meter Detects amount of intake air;...

  • Page 201

    SHIFT INDICATOR LIGHT CONTROL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensor or switches below. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) 86U04A-163 System Inspection 1.

  • Page 202: Control System

    CONTROL SYSTEM CONTROL SYSTEM sensor Idle switch Atmospheric pressure sensor E/L control unit Engine control unit Water thermo sensor Water thermo switch Circuit opening relay lutch switch Brake light switch Main relay Neutral switch 5th gear switch Inhibitor switch 86U04A-166 The control system consists of the input devices and the control unit.

  • Page 203

    CONTROL SYSTEM RELATIONSHIP CHART Output Devices and Input Devices TEST CONNECTOR 5TH GEAR SWITCH BRAKE LIGHT SWITCH VEHICLE SPEED SWITCH ELECTRICAL LOAD CONTROL UNIT P/S PRESSURE SWITCH A/C SWITCH IGNITION SWITCH (STA POSITION) INHIBITOR SWITCH and EC—AT CONTROL UNIT NEUTRAL AND CLUTCH SWITCH OXYGEN SENSOR WATER THERMO...

  • Page 204

    > e n g in e c o n d it io n s ■o > IDLE MEDIUM LOAD IGN: (THROT­ WARNING CRANKING < HEAVY DECEL­ ACCEL­ (ENGINE REMARKS (COLD VALVE ERATION LOAD ERATION (DURING ENGINE) FULLY IDLE) RUNNING) CLOSED) COLD WARM OUTPUT DEVICES...

  • Page 205

    CONTROL SYSTEM EGI MAIN FUSE Inspection Check the continuity of EGI main fuse. MAIN RELAY 1. Check that a “ clicking” sound is heard at the main relay when turning the ignition switch ON and OFF. 2. Apply 12V and a ground to (A) and (B) terminals of the main relay.

  • Page 206

    CONTROL SYSTEM ENGINE CONTROL UNIT Engine Signal Monitor (49 9200 162) and Adapter (49 9200 163). 49 9200 163 A d a p te r h a rn e s s Engine wiring harness' Selector switch Terminals (A and B) Monitor switch ENGINE SIGNAL MONITOR •...

  • Page 207

    CONTROL SYSTEM Wiring Diagram 86U04A-172 4A-89...

  • Page 208

    CONTROL SYSTEM Terminal Voltage If the input and output devices and related wiring are normal, but the engine control unit terminal volt­ age is incorrect, replace the engine control unit. Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Malfunction indicator For 3sec.

  • Page 209

    CONTROL SYSTEM Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle — — — — — — — — — — — — — — — — — — — — Battery voltage Shift indicator light il­ Shift indicator light luminates: below (MTX)

  • Page 210

    CONTROL SYSTEM Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Solenoid valve Below 3.5V • Cold engine: be­ (EGR) low 3.5V Radiator coolant temp.—below 17°C (63°F) or Engine coolant temp.—below 70°C (158°F) • Engine above ap­ prox.

  • Page 211

    CONTROL SYSTEM Replacement 1. Disconnect the negative battery cable. 2. Remove the front console covers (right and left). 3. Disconnect the connectors from the control unit. 4. Replace the control unit. 86U04A-174 NEUTRAL SWITCH Inspection 1. Disconnect the neutral switch connector. 2.

  • Page 212

    CONTROL SYSTEM P/S PRESSURE SWITCH Inspection 1. Disconnect the P/S pressure switch connector. 2. Connect an ohmmeter to the switch. 3. Start the engine. Check continuity of the switch while turning the steering wheel at idle. Continuity Turning Not-turning 4. Connect the switch connector after checking. Note Refer to section 10 for replacement of the P/S pressure switch.

  • Page 213

    CONTROL SYSTEM E/L CONTROL UNIT Inspection 1. Connect a voltmeter between the E/L control unit and ground. 2. Start the engine and check the terminal voltages as described below. 69G04A-174 Voltage (after warm-up) Connection to Terminal Input Output Remarks Ignition switch: ON Idle Ignition switch Battery voltage...

  • Page 214

    CONTROL SYSTEM AIR FLOW METER Potentiometer switch Measuring plate Intake air thermo sensor Fuel pump switch Connector- l o o 0 0 0 0 0 1 69G04C-100 Inspection 1. Remove the air flow meter. (Refer to page 4A—32) 2. Check the air flow meter body for cracks. 3.

  • Page 215

    CONTROL SYSTEM THROTTLE SENSOR Caution Use a precision voltmeter with a scale of 0.01V to inspect or adjust the throttle sensor. Inspection 1. Remove the air hose from the throttle body. 2. Disconnect the throttle sensor connector (3-pin). 3. Connect the SST between the throttle sensor and the wiring harness.

  • Page 216

    CONTROL SYSTEM 12 If not correct, replace the throttle sensor. 13 Turn the ignition OFF. 14 Disconnect the SST and reconnect the throttle sen­ sor connector. 15 Disconnect the negative battery terminal and de­ press the brake pedal for at least 5 seconds to elim­ inate the control unit malfunction memory.

  • Page 217

    CONTROL SYSTEM 9. Turn the throttle sensor to adjust BLUE wire volt­ age within the range specified for the recorded RED wire voltage. Specification: BLUE wire RED wire BLUE wire RED wire voltage (V) voltage (V) voltage (V) voltage (V) 4.50-4.59 0.37-0.54 5.10-5.19...

  • Page 218

    CONTROL SYSTEM Throttle valve fully closed position (Example) Throttle valve fully open position (Example) RED wire voltage: BLUE wire voltage: RED wire (V) x 0.78 —\ RED wire (V) x 0.94 Inspection Steps Step 1: Throttle valve fully closed position ©...

  • Page 219

    CONTROL SYSTEM IDLE SWITCH Inspection 1. Disconnect the idle switch connector (1-pin). 2. Check continuity between the switch and ground. Throttle valve condition Continuity Fully closed Open 3. If not correct, check condition of wiring harness of the idle switch. Replace the idle switch and throt­ tle body as an assembly, if necessary.

  • Page 220

    CONTROL SYSTEM OXYGEN SENSOR Inspection of Output Voltage 1. Warm up the engine and run it at idle. 2. Disconnect the oxygen sensor connector. 3. Connect a voltmeter between the oxygen sensor and ground. 4. Run the engine at 4,500 rpm until the voltmeter indicates approx.

  • Page 221

    CONTROL SYSTEM ATMOSPHERIC PRESSURE SENSOR Inspection 1. Connect a voltmeter to the atmospheric pressure Atmospheric sensor (D) terminal. pressure sensor 2. Turn the ignition switch on and take a voltage reading. Voltage: 3.5—4.5V at sea level 2.5—3.5V at high altitude [2,000m (6,500 ft)] 3.

  • Page 222

    FUEL AND EMISSION CONTROL SYSTEMS (TURBO) PULSATION DAMPER....4B— 65 O U TLIN E...........4B— 2 • INJECTOR........4B — 66 SYSTEM DIAGRAM.......4B— COMPONENT LOCATION... 4B— TRANSFER PUMP CONTROL SYSTEM (4 WHEEL STEERING). 4B— 68 VACUUM HOSE ROUTING DIAGRAM........4B— PRESSURE REGULATOR CONTROL SYSTEM....

  • Page 223

    i— Solenoid valve (Pressure regulalor) > Fuel filter Solenoid valve (purge) No.1 purge pressure r,e 5 = > u,e No.2 purge control valve control valve regulator Vacuum > switch Distributor Three-way check v a lve ' Fuel filter (Low pressure side) Fuel pump Atm ospheric pressure...

  • Page 224

    OUTLINE COMPONENT LOCATION Input Devices Throttle sensor Test connector: Yellow 2 pin Idle switch Test connector: Green 1 pin EGR position sensor Circuit opening relay Clutch switch Brake light switch W ater thermo switch Main relays Neutral switch W ater thermo sensor Inhibitor switch 86U04A-003 4 B -3...

  • Page 225

    OUTLINE Fuel and Output Devices Delivery pipe Pulsation damper Solenoid valve (Idle speed control) Pressure regulator Check connector Injector Green 6 pin (for Self-Diagnosis Vacuum chamber Checker) (with check valve) EGR control valve Solenoid valve (Pressure regulator) Transfer pump (4 wheel steering) Separator Three-way check valve Check and cut valve...

  • Page 226

    OUTLINE Exhaust System 86U04A-005 4 B -5...

  • Page 227

    ~*zZi' < > C T > c /> Air bypass valve Pressure regulator > C T > > rv > c r> § Vacuum chamber ~ s l Solenoid valve (Purge) Vacuum switch valve Black Solenoid valve (Pressure regulator) Yellow Water thermo Blue...

  • Page 228

    OUTLINE SPECIFICATIONS Engine type Turbo Engine Item Idle speed 750 ± 25 (ATX: P range)* Throttle body Type Horizontal draft (2-barrel) No. 1 MTX: 40 (1.6), ATX: 46 (1.8) Throat diameter mm (in) No. 2 MTX: 46 (1.8), ATX: 40 (1.6) A ir flow meter E2-VS Fully closed: 20—400 Fully open: 20—1,000...

  • Page 229

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE This troubleshooting guide shows the malfunction numbers and the symptoms of various failures. Perform troubleshooting as described below. Input sensors and switches Output solenoid valves Possible cause o > ' 3 5 a > > < o >...

  • Page 230

    Symptom ® • H o — I =3 CD Possible cause < =r — k — A . — L < m m k - ' J 3 - & ^ "o 3 Intake Air System CD CD 9. ® ° n- 7T Z T (Poor connection of components, throttle body) 03 CL C T w...

  • Page 231: Troubleshooting With Sst

    TROUBLESHOOTING WITH SST TROUBLESHOOTING WITH SST When troubles occur in the main input devices or output devices, check for the cause using the SST. Failures of each input and output device are indicated and retrieved from the control unit as malfunc­ tion code numbers.

  • Page 232

    TROUBLESHOOTING WITH SST 4 B INSPECTION PROCEDURE Check connector: Green 1. Connect the SST to the check connector. (Green, 6-pin) and the negative battery terminal. 2. Set the select switch to position A. Note The check connector is located at the rear of the left side wheel housing.

  • Page 233

    TROUBLESHOOTING WITH SST 4 B PRINCIPLE OF CODE CYCLE Malfunction codes are determined as shown below 86U04A-017 1. Code cycle break The time between malfunction code cycles is 4.0 sec (the time the light is off). Malfunction code cycle cycle break 4.0 sec.

  • Page 234

    TROUBLESHOOTING WITH SST CODE NUMBER Malfunction display Sensor or Malfunction MIL output signal Self-diagnosis Fail-safe subsystem code no. pattern Ignition pulse No ignition signal I I i ° fN f Ne signal No Ne signal from £ J L J J I L crank angle sensor ♦...

  • Page 235

    TROUBLESHOOTING WITH SST 4 B Malfunction display wCnsor or Self-diagnosis Fail-safe Malfunction MIL output signal subsystem code no. pattern Solenoid valve (pres­ ° J W « f n f sure regulator) Solenoid valve in n o (purge control) 0N nn Solenoid valve 1 1 1 1 n (EGR-vacuum)

  • Page 236

    TROUBLESHOOTING WITH SST Code No. 01 (Ignition pulse) PC: Possible Cause 86U04B-007...

  • Page 237

    TROUBLESHOOTING WITH SST 4 B Code No. 02 (Ne signal) PC: Possible Cause Is there continuity between distributor and engine control unit? Control unit Distributor Is same Code No. present after performing after­ repair procedure? (Refer to page 4B—11) Are control unit 1T and 1Q terminal voltages OK? PC: Engine control unit malfunction 86U04B-008 4B-17...

  • Page 238

    TROUBLESHOOTING WITH SST Code No. 03 (G1 signal) PC: Possible Cause Are there poor connections in distributor circuit? Repair or replace connector Is resistance between E and F terminal OK? Replace distributor (Refer to page 4B—88) Is there continuity between distributor and engine control unit? PC: Open circuit in wiring harness from distributor to Distributor...

  • Page 239

    TROUBLESHOOTING WITH SST 4 B Code No. 04 (G2 signal) PC: Possible Cause Are there poor connections in distributor circuit? Repair or replace connector Is resistance between C and D terminal OK? Replace distributor (Refer to page 4B—88) Is there continuity between distributor and engine control unit? PC: Open circuit in wiring harness from distributor to Distributor...

  • Page 240

    TROUBLESHOOTING WITH SST PC: Possible Cause Code No. 05 (Knock sensor and Knock control unit) Are there poor connections in relative circuit? Repair or replace connector (all Are knock control unit terminal voltages correct? PC: • Open or short circuit in wiring harness be­ wires) tween main relay and knock control unit Terminal...

  • Page 241

    TROUBLESHOOTING WITH SST 4 B Code No. 08 (Air flow meter) PC: Possible Cause Are there poor connections in air flow meter circuit? Repair or replace connector Is there continuity between air flow meter and engine control unit? Air flow meter Control unit PC: Open circuit in wiring harness from air flow (RB wire)

  • Page 242

    TROUBLESHOOTING WITH SST PC: Possible Cause Code No. 09 (Water thermo sensor) Are there poor connections at water thermo Repair or replace connector sensor circuit? Is there continuity between water thermo sensor and control unit? PC: Open circuit in wiring harness from water thermo Water thermo sensor Control unit sensor to engine control unit...

  • Page 243

    TROUBLESHOOTING WITH SST 4 B PC: Possible Cause Code No. 10 (Intake air thermo sensor) Are there poor connections in air flow meter circuit? Repair or replace connector Is there continuity between intake air thermo sensor (in air flow meter) and engine control unit? Intake air temperature sensor PC: Open circuit in wiring harness from intake air thermo Control unit...

  • Page 244

    TROUBLESHOOTING WITH SST Code No. 12 (Throttle sensor) PC: Possible cause 86U04B-015 4B—24...

  • Page 245

    TROUBLESHOOTING WITH SST 4 B Code No. 14 (Atmospheric pressure sensor) PC: Possible cause Are there poor connections in atmospheric pressure Repair or replace connector sensor circut? PC: Open or short circuit in wiring harness from Is there Vref at (LgR) wire of atmospheric pressure (LgR) wire to engine control unit sensor connector? •...

  • Page 246

    TROUBLESHOOTING WITH SST Code No. 15 (Oxygen sensor) PC: Possible Cause Note When the Code No. 15 and 17 are present at the same time, first perform the checking proce­ dure for the Code No. 17. (Refer to page 4B—28.) 86U04B-017 4B—26...

  • Page 247

    TROUBLESHOOTING WITH SST 4 B Code No. 16 (EGR position sensor) PC: Possible Cause Are there poor connections in sensor circuit? Repair or replace connector Is EGR control valve OK? (Refer to page 4B—94) Replace EGR control valve Is resistance of EGR position sensor OK? Replace EGR control valve (Refer to page 4B—94) Is there continuity between EGR position sensor and...

  • Page 248

    TROUBLESHOOTING WITH SST Code No. 17 (Feedback system) PC: Possible Cause 86U04B-019...

  • Page 249: Code No. 25 (solenoid Valve-pressure Regulator), Code No. 26 (solenoid Valve-purge)

    TROUBLESHOOTING WITH SST 4 B Code No. 25 (Solenoid valve-Pressure regulator) PC: Possible Cause PC: • Short circuit in wiring harness • Engine control unit malfunction 86U04A-029 Code No. 26 (Solenoid valve-Purge) Repair or replace connector Are there poor connections in solenoid valve circuit? Is there continuity of solenoid valve? Replace solenoid valve Is there battery voltage at (RB) wire of solenoid valve...

  • Page 250

    TROUBLESHOOTING WITH SST Code No. 28 (Solenoid valve—EGR, vacuum side) PC: Possible Cause Is there continuity between solenoid valve and en­ gine control unit? PC: Open circuit in wiring harness from solenoid Solenoid valve Control unit valve to engine control unit B (WL wire) YES PC: •...

  • Page 251

    TROUBLESHOOTING WITH SST 4 B Code No. 34 (Solenoid valve—Idle speed control valve (ISC)) PC: • Short circuit in wiring harness • Engine control unit malfunction 86U04A-032 Code No. 42 (Solenoid valve—Waste gate) Repair or replace connector Are there poor connections in solenoid valve circuit? Repair solenoid valve Is there continuity of solenoid valve? PC: Open circuit in wiring harness from RB wire to...

  • Page 252

    SWITCH MONITOR FUNCTION SWITCH MONITOR FUNCTION Individual switches can be monitored by the SST. Note The test connector must be grounded and the ignition switch ON (engine stopped). Control unit Clutch switch Neutral switch Idle switch Brake light switch A/C switch —...

  • Page 253

    SWITCH MONITOR FUNCTION 4 B INSPECTION PROCEDURE Check connector: Green (6 pin) 1. Warm up the engine to normal operating temper­ ature and stop it. 2. Connect the SST to the check connector (Green, 6-pin) and the negative battery terminal. 86U04A-034 3.

  • Page 254

    SWITCH MONITOR FUNCTION Idle switch 86U04B-026 Brake light switch 86U04B-026 Blower switch 86U04B-027 A/C switch 86U04B-028...

  • Page 255

    SWITCH MONITOR FUNCTION 4 B Headlight switch 86U04B-029 Rear defroster switch Inhibitor switch 86U04B-031 Water thermo switch circuit (not included in switch inspection) Warning The electrical fan operates when the connector is disconnected. Use caution. 86U04B-032 4B-35...

  • Page 256

    IDLE ADJUSTMENT IDLE ADJUSTMENT IDLE SPEED Because the idle speed is controlled automati­ Idle speed cally by the engine control unit through the idle Automatic speed control (ISC) solenoid valve, usually it is not necessary to check and adjust the idle Control speed.

  • Page 257

    IDLE ADJUSTMENT IDLE MIXTURE Because an automatic compensation function for air/fuel mixture is built into the engine con­ trol unit, it is not necessary to check and adjust Idle mixture the idle mixture. Automatic Control Function Engine Control Unit ---------- 86U04A-049 4B-37...

  • Page 258

    INTAKE AIR SYSTEM INTAKE AIR SYSTEM This system controls the air required by the engine for operation. The system consists of the air duct, air cleaner, air flow meter, throttle body, dynamic chamber, and intake manifold. COMPONENT DESCRIPTIONS Application Function Remarks Previous Component...

  • Page 259

    INTAKE AIR SYSTEM REMOVAL Caution Before removing the following parts, release the fuel pressure from fuel system to reduce the possibility of injury or fire. (Refer to page 4B— 60.) Remove in the sequence shown in the figure. 86U04B-033 17. Gasket 9.

  • Page 260

    INTAKE AIR SYSTEM PARTS INSPECTION Air Cleaner Element 1. Check the condition of the air cleaner element. 2. Replace, if necessary. Caution Do not use the compressed air to clean the air cleaner element. 69G04A-059 Accelerator Cable 1. Inspect the deflection of the cable.

  • Page 261

    INTAKE AIR SYSTEM Dynamic Chamber 1. Visually check the dynamic chamber for damage. 2. Replace, if necessary. Intake Manifold 1. Visually check the intake manifold for damage. 2. Replace, if necessary. 69G04A-064 4B—41...

  • Page 262

    INTAKE AIR SYSTEM REPLACEM ENT Throttle Lever Removal Caution When loosening the throttle lever nut, hold the throttle valves fully open to prevent damag­ ing the idle switch. Remove the throttle lever in the sequence shown in the figure. CDNut and spring (2) Throttle lever washer 69G04C-130...

  • Page 263

    INTAKE AIR SYSTEM IN STALLATIO N Install in the reverse order of removal, referring to the installation note. Torque Specification 86U04A-055 4 B -4 3...

  • Page 264

    INTAKE AIR SYSTEM Installation Note Water hose spring clamps Face the clamp end as shown in the figure. Gasket Use new gaskets at the intake manifold, dynamic chamber, and throttle body.. 4B—44...

  • Page 265

    ISC SYSTEM IDLE SPEED CONTROL (ISC) SYSTEM Throttle sensor Air valve BAC valve (ISC valve + air valve) Coolant temperature 86U04A-057 To improve idle smoothness, the ISC system controls the intake air amount by regulating the bypass air amount that passes through the throttle body. This system consists of the BAC valve and the control system.

  • Page 266

    ISC SYSTEM COM PONENT DESCRIPTIONS Application Component Function Remarks Previous model model A ir valve When cold, supplies bypass air into dy­ • Engine speed increased to namic chamber shorten warm-up period • Thermo wax type • Installed in BAC valve Clutch switch Detects in-gear condition;...

  • Page 267

    ISC SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4B—8 and 9.) Possible Solenoid Engine control unit...

  • Page 268

    ISC SYSTEM System Inspection (Air valve) 1. Disconnect the ISC valve connector when the en­ gine is cold and idling. 2. Note the engine speed and reconnect the con­ nector. 3. Warm up the engine to the normal operating tem­ perature and disconnect the connector again.

  • Page 269

    ISC SYSTEM BAC Valve Air valve 1. Remove the BAC valve from the throttle body. 2. Blow air through the valve from port A and check that air comes out of port B when the BAC valve is cold. 3. If not correct, replace the BAC valve. Note Refer to “...

  • Page 270

    TURBOCHARGING SYSTEM TURBOCHARGING SYSTEM This system utilizes the energy of the exhaust gas to pressurize the intake air. It therefore supplies more than the normal amount of air into the combustion chamber. As a result of the more fully charged combustion chamber, higher output and higher torque can be obtained by a turbocharged engine than that of a comparable non-turbocharged engine.

  • Page 271

    TURBOCHARGING SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking sensors or switches. 86U04B-040 OPERATION NOTE 1. Do not accelerate suddenly or operate at full throttle immediately after starting a cold engine. Allow the engine to reach normal operating temperature before using full power. 2.

  • Page 272

    TURBOCHARGING SYSTEM TURBOCHARGER BOOST PRESSURE 1. Be sure the engine is cool. 2. Disconnect hose A from the solenoid valve and connect the SST as shown. 3. Warm up the engine to normal operating tem­ perature. 4. Increase the engine speed to 4,000 rpm and check that the boost pressure is within specification.

  • Page 273

    TURBOCHARGING SYSTEM OVERBOOST WARNING 1. Start the engine and run it at 2,000 rpm. 2. Lift the air cleaner upper case, and push the meas­ uring plate open fully. 3. Check that the warning buzzer sounds and the en­ gine speed drops or engine stalls. 86U04B-047 TURBOCHARGER Inspection of Compressor Wheel Assembly...

  • Page 274

    TURBOCHARGING SYSTEM Inspection of Solenoid Valve 1. Disconnect the small air tube from the air hose. 2. Disconnect the solenoid valve connector. 3. Blow through the air tube and check that the air does not flow. 4. If not correct, replace the solenoid valve and tur­ bocharger as an assembly.

  • Page 275

    TURBOCHARGING SYSTEM 3. When reinstalling the turbocharger, perform the fol­ lowing: (1) Remove all the gaskets and sealant. (2) Use new gaskets. (3) Supply 25 cc (1.5 cu in) of oil in the oil pas­ sage of the turbocharger. 86U04B-055 4.

  • Page 276

    TURBOCHARGING SYSTEM Removal of turbocharger. 1. Cool the engine and drain the engine coolant. 2. Remove the parts in the order below. 1) Air hoses and air bypass valve 2) Insulators 3) Oil pipe and oil return hose from turbocharger 4) Water hoses from water pipe 5) EGR pipe from exhaust manifold 6) Oxygen sensor...

  • Page 277

    FUEL' SYSTEM FUEL SYSTEM 86U04B-061 This system supplies the fuel necessary for combustion at a constant pressure to the injectors. Fuel is metered and injected into the intake manifold according to the injection control signals from the en­ gine control unit. It consists of the fuel pump, fuel filters, delivery pipe, pulsation damper, pressure regulator, injectors, fuel pump switch (incorporated in the air flow meter), and the circuit opening relay.

  • Page 278

    FUEL SYSTEM COMPONENT DESCRIPTIONS Application Component Function Remarks Previous model model Air flow meter Detects amount of intake air; Intake air temp sensor and sends signal to control unit fuel pump switch are in­ tegrated Atmospheric pres­ Detects atmospheric pressure; sends sig­ sure sensor nal to control unit Voltage for fuel pump while engine running...

  • Page 279

    FUEL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches. 86U04B-063...

  • Page 280

    FUEL SYSTEM FUEL PRESSURE RELEASE AND SERVICING FUEL SYSTEM Fuel in the fuel system remains under high pressure even when the engine is not running. a) Before disconnecting any fuel line, release the fuel pressure from the fuel system to reduce the pos­ sibility of injury or fire.

  • Page 281

    FUEL SYSTEM MULTI-PRESSURE TESTER (49 9200 750A) Fuel filter 49 9200 750A 49 9200 750A 69G04A-099 The MULTI-PRESSURE TESTER (49 9200 750A) has been developed to check the fuel pressure and intake manifold vacuum. These can easily be inspected by setting the buttons on the tester. 4B—61...

  • Page 282

    FUEL SYSTEM How to Connect Multi-Pressure Tester iT o pulsation Warning J dam per Before connecting the SST, release the fuel pressure from the fuel system to reduce the To fuel pump possibility of injury or fire. (Refer to page 4B—60.) 1.

  • Page 283

    FUEL SYSTEM FUEL PRESSURE Note a) When inspecting fuel pressure, use the SST. (Refer to page 4B—62). b)Warm up the engine to normal operating temperature. Injection Pressure 1. Set the lever on the adapter as shown in the figure. 86U04B-066 2.

  • Page 284

    FUEL SYSTEM Fuel Line Pressure 1. Start the engine and run it idle. 2. Set the lever on the adapter as shown in the figure. 3. Check the fuel line pressure. Fuel line pressure: Approx- 186—226 kPa (1.9—2.3 kg/cm2, 27—33 psi) 4.

  • Page 285

    FUEL SYSTEM Volume Test Warning connector (Yellow) Before performing following procedures, re­ lease the fuel pressure to reduce the possi­ bility of injury or fire. (Refer to page 4B—60) 1. Connect a jumper wire to test connector (Yellow). 2. Disconnect the fuel return hose from fuel return pipe.

  • Page 286

    FUEL SYSTEM INJECTOR On-vehicle Inspection Engine does not start Perform “ Quick Inspection for Electrical Signal” below. Engine runs 1. Warm up the engine and run it at idle. 2. Listen for operational sound of the injector with a screwdriver or a sound scope. 3.

  • Page 287

    FUEL SYSTEM Inspection There are 3 inspections which must be performed for the injectors. Resistance 1. Remove the injectors from the engine. (Refer to page 4B—75.) 2. Check the resistance of each injector with an ohmmeter. 3. If not correct, replace the injector. Resistance: 11—15 86U04B-071 Fuel leakage test and volume test...

  • Page 288

    FUEL SYSTEM TRANSFER PUMP CONTROL SYSTEM (4 WHEEL STEERING) 1. Remove the rear seat. 2. Remove the fuel filler cap. 3. Turn the ignition switch ON. Note a) The tank should be more than 1/3 full. b) Due to the delay timer, transfer pump oper­ ation begins approx.

  • Page 289

    FUEL SYSTEM PRESSURE REGULATOR CONTROL SYSTEM W a te r th e rm o s e n s o r F u e l (T o fu el ta n k ) 86U04A-092 To prevent percolation of the fuel during idle after the engine is restarted, vacuum is cut to the pres­ sure regulator, increasing the fuel pressure.

  • Page 290

    FUEL SYSTEM COMPONENT DESCRIPTIONS Application Component Function Remarks Previous model model Engine control unit Detects signals from input sensors and switches;-controls solenoid valve (Pres­ sure regulator control) Ignition switch Sends engine cranking signal to control (ST position) unit Intake air thermo Detects intake air temperature;...

  • Page 291

    FUEL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connections before checking the sensors or switches below. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4B—8 and 9.) Possible Solenoid Water ther­...

  • Page 292

    FUEL SYSTEM 7. Restart the engine. Fuel line pressure kPa O perating tim e 8. Check the fuel line pressure and operating times (kg/cm 2, psi) as shown in the chart. After starting: for 120 2 3 5 - 2 7 5 sec.

  • Page 293

    FUEL SYSTEM REPLACEMENT Caution A)Before performing the following procedure, release the fuel pressure from the fuel sys­ tem to reduce the possibility of injury or fire (Refer to page 4B—60). b)When servicing the fuel system, keep sparks, cigarettes, and open flames away from the fuel.

  • Page 294

    FUEL SYSTEM Transfer Pump 1. Remove the fuel tank. (Refer to page 4B—79.) 2. Disconnect the fuel hoses from the transfer pump. 86U04B-082 3. Remove the transfer pump. 4. Install in the reverse order of removal. 4B—74...

  • Page 295

    FUEL SYSTEM Injector Dynamic chamber 1. Remove the wiring harness bracket. 2. Disconnect the vacuum pipe mounting bolts. Front 86U04B-084 3. Disconnect the air hose from the throttle body. 86U04B-085 4. Remove the engine hanger. 5. Remove the dynamic chamber mounting bolts and Engine nuts.

  • Page 296

    FUEL SYSTEM 10. Remove the grommets, injectors, and insulators. 11. Install in the reverse order of removal, referring to installation note. Tightening torque: 19—25 N m Delivery pipe Dynamic chamber (1.9—2.6 m-kg, 14—19 ft-lb) Engine hanger Installation note Injector 1. Use new O-rings. 2.

  • Page 297

    FUEL SYSTEM Delivery Pipe 1. Perform steps 1 to 7 of removal procedure for in­ jectors. (Refer to page 4B—75.) regulator 2. Remove the pulsation damper, pressure regula­ tor, and injectors. 86U04B-089 3. Replace the delivery pipe. 4. Install in the reverse order of removal, referring to installation note.

  • Page 298

    FUEL SYSTEM Pressure Regulator 1. Perform steps 1 to 8 of removal procedure for the injector. (Refer to page 4B—75.) 2. Disconnect the vacuum hose and fuel return hose. 3. Remove the pressure regulator. 4. Install in the reverse order of removal. Tightening torque: 8—11 N m (0.8—1.1 m-kg, 69—95 in-ib) Pulsation Damper...

  • Page 299

    FUEL SYSTEM FUEL TANK Removal Caution a) Before performing the following procedure, release the fuel pressure from the fuel sys­ tem to reduce the possibility of injury or fire. (Refer to page 4B—60) b) When removing the fuel tank, keep sparks, cigarettes, and open flames away from the fuel tank.

  • Page 300

    FUEL SYSTEM Inspection 1. Check the fuel tank for cracks and corrosion. 2. If any defect is found, repair or replace the tank, Warning Before repairing, clean the fuel tank thorough­ ly with steam to sufficiently remove all explo­ sive gas. Installation Install in the reverse order of removal, referring to the installation note.

  • Page 301

    FUEL SYSTEM Installation note Hoses 1. Push the hose ends of the main fuel hose, fuel re­ turn hose and evaporation hoses onto the fuel tank fittings at least 25 mm (1.0 in). 2. Push the fuel filler hose ends onto the fuel tank pipe and filler pipe at least 35 mm (1.4 in).

  • Page 302

    DECELERATION CONTROL SYSTEM DECELERATION CONTROL SYSTEM The fuel cut system is provided as a deceleration control system. This system is to improve fuel economy. 4B-82 626, MX-6 Revised 10/87...

  • Page 303

    DECELERATION CONTROL SYSTEM 4 B COM PONENT DESCRIPTIONS Application Component Function Remarks Previous model model Brake light switch Detects braking operation (deceleration); sends signal to control unit Clutch switch Detects in-gear condition; Switch ON when clutch pedal sends signal to control unit released EC-AT control unit Detects N or P range;...

  • Page 304

    DECELERATION CONTROL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensor or switches below. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to page 4B—8 and 9.) Possible cause Water thermo sensor System inspection...

  • Page 305

    DECELERATION CONTROL SYSTEM 4 B 4. Increase the engine speed to 4,000 rpm, then sud­ denly decrease the engine speed. 5. Check that the red indicator lamp stays illuminat­ ed during deceleration. 4B-85...

  • Page 306

    ESA CONTROL SYSTEM ELECTRONIC SPARK ADVANCE (ESA) CONTROL SYSTEM Igniter Engine control unit In p u t sig n a ls Ignition switch Air flow meter Idle switch | — Neutral/Clutch switch EGR position sensor Knock sensor Throttle sensor W ater thermo sensor Water therm o switch Inhibitor switch and EC-AT control unit...

  • Page 307

    ESA CONTRODSYSTEM COMPONENT DESCRIPTIONS Application Component Function Remarks Previous model model Air flow meter Detects amount of intake air; Intake air temp sensor and sends signal to control unit fuel pump switch are in­ tegrated Clutch switch Detects in-gear condition; Switch ON when clutch pedal sends signal to control unit depressed...

  • Page 308

    ESA CONTROL SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking sensors or switches. 86U04B-100 Distributor 1. Disconnect the distributor connector. 2. Connect an ohmmeter to the terminals of the dis­ tributor connector. 3. Check the resistance of the following, Resistance (at 20°C, 68°F) Terminal A - B...

  • Page 309

    ESA CONTROL SYSTEM 4. Tap the right engine hanger (drive belt side) and check that the monitor lamp on the SST flashes. 5. If not correct, connect a good knock sensor to the vehicle wiring harness and ground it. 6. Perform step 4 again and judge the malfunction­ ing part as follows: Malfunction Monitor lamp flashes...

  • Page 310

    EGR SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM Vent side Solenoid valves Vacuum Engine control unit V a c u u m side chamber Water ) thermo switch EGR position sensor Water thermo sensor control valve Throttle sensor Distributor (Ne signal) Air flow meter Engine coolant temperature 86U04B-105...

  • Page 311

    EGR SYSTEM COMPONENT DESCRIPTION Application Component Function Remarks Previous model model A ir flow meter Detects amount of intake air; Intake air temp sensor and fuel pump switch are in­ sends signal to control unit tegrated Distributor Has Ne and G rotors EGR control valve Recirculates portion of exhaust gas EGR position sensor...

  • Page 312

    EGR SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking sensors or switches. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4B—8 and 9.) Water EGR po­...

  • Page 313

    EGR SYSTEM System Inspection 1. Start the engine 2. Accelerate the engine and verify that the di­ aphragm of the EGR control valve does not move while the engine is still cold. 3. Warm up the engine to normal operating temper­ ature and run it at idle.

  • Page 314

    EGR SYSTEM 3. Disconnect the vacuum hose from the EGR con­ trol valve and connect the vacuum pump. 4. Turn the ignition switch ON. 5. Check voltage of each terminal in the conditions shown in the table. Vacuum SST wire Terminal color 120 mmHg (4.7 inHg)

  • Page 315

    EGR SYSTEM 3. Warm up the engine and run it at idle. 4. Connect a vacuum pump to the valve and apply vacuum. 5. Check that the engine runs roughly or stalls at more than the specified vacuum. Specification: 40—60 mmHg (1.6—2.4 inHg) 6.

  • Page 316

    EEC SYSTEM EVAPORATIVE EMISSION CONTROL (EEC) SYSTEM Engine control unit No.1 purge control valve From water From fuel 1 thermo valve' Solenoid valve To dynam ic No.2 purge (Purge) control val\ cham ber Water themo valve Vacuum sw itch' valve T h re e -w a y^ chech valve Check and...

  • Page 317

    PCV SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM 86U04B-121 This system is the same as that of the non-turbo engine. Refer to page 4A—79 page for servicing the system. 4B-97...

  • Page 318

    EXHAUST SYSTEM EXHAUST SYSTEM Exhaust manifold Catalytic converter Turbocharger Pre silencer § Main silencer Middle pipe 86U04B-122 The catalytic converter is used to reduce CO, HC and NOx. The converter contains a compound of platinum and rhodium. It is a three-way catalyst type with a volume of 2,300 cc (140 cu in). This system is the same as that of the non-turbo engine.

  • Page 319

    CONTROL SYSTEM CONTROL SYSTEM Throttle sensor 4dle switch Air flow meter Atmospheric pressure sensor Circuit opening relay -Clutch switch Brake light switch Main relay Water thermo switch eutral switch Water thermo sensor Inhibitor switch 86U04B-123 The control system consists of the input devices and the control unit. The control unit controls the fuel injection amount (EGI), fuel injection pressure, bypass air amount, ignition timing, switch monitor func­...

  • Page 320

    CONTROL SYSTEM RELATIONSHIP CHART Output Devices and Input Devices TEST CONNECTOR KNOCK SENSOR BRAKE LIGHT SWITCH EGR POSITION SENSOR ELECTRICAL LOAD CONTROL UNIT P/S PRESSURE SWITCH A/C SWITCH IGNITION SWITCH (STA POSITION) INHIBITOR SWITCH and EC—AT CONTROL UNIT NEUTRAL AND CLUTCH SWITCH OXYGEN SENSOR WATER THERMO...

  • Page 321

    e n g in e c o n d it io n s IDLE MEDIUM LOAD IGN: (THROT­ WARMING CRANKING < HEAVY DECEL­ ACCEL­ REMARKS (ENGINE (COLD LOAD ERATION VALVE (DURING ERATION ENGINE) FULLY IDLE) RUNNING) CLOSED) COLD WARM OUTPUT DEVICES Rich and Rich and Rich...

  • Page 322

    CONTROL SYSTEM EGI MAIN FUSE Inspection Check the continuity of EGI main fuse. 69G04A-161 MAIN RELAY 1. Check that a "clicking” sound is heard at the main relay when turning the ignition switch ON and OFF. 2. Apply 12V and a ground to (A) and (B) terminals of the main relay.

  • Page 323

    CONTROL SYSTEM ENGINE CONTROL UNIT Engine Signal Monitor (49 9200 162) and Adapter (49 9200 163). Adapter harness 49 9200 163 Engine wiring harness' Selector switch Term inals (A and B) . I n ... Monitor switch ENGINE SIGNAL MONITOR - * V ©...

  • Page 324: Wiring Diagram

    CONTROL SYSTEM Wiring Diagram (S ) (x )(m ) (m ) (a ) (w ) ® ® © ® © ® ir i f i r t i| i rf (EM | «*|EM| W W IEM J B R |EM | W Y |EM | Lg|EM| LflB |EM |...

  • Page 325

    CONTROL-SYSTEM Terminal Voltage If the input and output devices and related wiring are normal, but the engine control unit terminal volt­ age is incorrect, replace the engine control unit. Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Malfunction indicator For 3 sec.

  • Page 326: B Ody E Lectrical

    CONTROL SYSTEM Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Distributor (G2 © Approx. 0.6—0.8V signal) Distributor (G1, G2 © Approx. 0.6—0.8V signal) Distributor (Ne © Approx. 0.6—0.8V signal) Knock control unit 3.3—5.0V Knocking: 1.3—2.6V Warning buzzer TypeA*1: Approx.

  • Page 327

    CONTROL SYSTEM Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Solenoid valve Battery voltage • Voltages change (EGR-Vent side) depending on driving condition Solenoid valve Battery voltage (EGR amount) (EGR-vacuum side) • Cold engine: bat­ tery voltage Radiator coolant temp-below 17°C (63°F) or...

  • Page 328

    CONTROL SYSTEM Replacement 1. Disconnect the negative battery cable. 2. Remove the front console covers (right and left). 3. Disconnect the connectors from the control unit. 4. Replace the control unit. NEUTRAL SWITCH Inspection 1. Disconnect the neutral switch connector. 2.

  • Page 329

    CONTROL SYSTEM P/S PRESSURE SWITCH Inspection 1. Disconnect the P/S pressure switch connector. 2. Connect an ohmmeter to the switch. 3. Start the engine. Check continuity of the switch while turning the steering wheel at idle. Continuity Turning Not turning 4.

  • Page 330

    CONTROL SYSTEM E/L CONTROL UNIT Inspection 1. Connect a voltmeter between the E/L control unit and ground. 2. Start the engine and check the terminal voltages as described below. 69G04A-174 Voltage (after warm-up) Terminal Input Output Connection to Remarks Ignition switch: ON Idle —...

  • Page 331

    CONTROL SYSTEM AIR FLOW METER Potentiometer switch Measuring plate Intake air sensor Fuel pump switch 69G04C-100 Inspection 1. Remove the air flow meter. (Refer to page 4B—39) 2. Check the air flow meter body for cracks. 3. Verify that the measuring plate moves smoothly. 4.

  • Page 332

    CONTROL SYSTEM — THROTTLE SENSOR Caution Use a precision voltmeter with a scale of 0.01V to inspect or adjust the throttle sensor. Inspection 1. Remove the air hose from the throttle body. 2. Disconnect the throttle sensor connector (3-pin). 3. Connect the SST between the throttle sensor and the wiring harness.

  • Page 333

    CONTROL SYSTEM 12. If not correct, replace the throttle sensor. 13. Turn the ignition OFF. 14. Disconnect the SST and reconnect the throttle sen­ sor connector. 15. Disconnect the negative battery terminal and de­ press the brake pedal for at least 5 seconds to elim­ inate the control unit malfunction memory.

  • Page 334

    CONTROL SYSTEM 9. Turn the throttle sensor to adjust BLUE wire volt­ age within the range specified for the recorded RED wire voltage. Specification: RED wire BLUE wire RED wire BLUE wire voltage (V) voltage (V) voltage (V) voltage (V) 4.50-4.59 0.37-0.54 5.10-5.19...

  • Page 335

    CONTROL SYSTEM Throttle valve fully closed position (Example) RED wire voltage: BLUE wire voltage: RED wire (V) x 0.08 RED wire (V) x 0.12 Throttle valve fully open position (Example) RED wire voltage: BLUE wire voltage: / RED wire (V) x 0.78 ' RED wire (V) x 0.94 Inspection Steps Step 1: Throttle valve fully closed position...

  • Page 336

    CONTROL SYSTEM IDLE SWITCH Inspection 1. Disconnect the idle switch connector (1-pin). 2. Check continuity between the switch and ground. Throttle valve condition Continuity Fully closed Open 3. If not correct, check condition of wiring harness of the idle switch. Replace the idle switch and throt­ tle body as an assembly, if necessary.

  • Page 337

    CONTROL SYSTEM OXYGEN SENSOR Inspection of Output Voltage 1. Warm up the engine and run it at idle. 2. Disconnect the oxygen sensor connector. 3. Connect a voltmeter between the oxygen sensor and ground. 4. Run the engine at 4,500 rpm until the voltmeter indicates approx.

  • Page 338

    CONTROL SYSTEM ATMOSPHERIC PRESSURE SENSOR Inspection 1. Connect a voltmeter to the atmospheric pressure sensor (D) terminal. 2. Turn the ignition switch on and take a voltage reading. Voltage: 3.5—4.5V at sea level 2.5—3.5V at high altitude [2,000m (6,500 ft)] 3.

  • Page 339

    ENGINE ELECTRICAL SYSTEM OUTLINE......j ........5— 2 STRUCTURAL VIEW........5— 2 SPECIFICATIONS..........5— 3 TROUBLESHOOTING GUIDE......5— 4 BATTERY............5— 5 INSPECTION............ 5— 5 RECHARGE............. 5— 5 ALTERNATOR..........5— 6 CHARGING SYSTEM........5— 6 TROUBLESHOOTING........5— 7 REMOVAL............5—12 DISASSEMBLY..........5—12 INSPECTION...........

  • Page 340

    5 OUTLINE OUTLINE STRUCTURAL VIEW Non-Turbo High-tension lead Starter inter-lock switch (Only M/T) Ignition coil Alternator Turbo High-tension lead Starter inter-lock switch (Only M/T) Ignition coil Distributor Battery/ itarter 86U05X-002 5 - 2...

  • Page 341

    OUTLINE 5 SPECIFICATIONS — ------— ______ Model Non-Turbo Turbo Item ~~----- ------ Battery Voltage 12, Negative ground Type and capacity 50D20L (50Ah), 55D23L (60Ah) (20 hour rate) 26RCCA410, 85CCA550 Alternator Type A.C. Output V—A 1 2 -7 0 Regulator type Transistorized (built-in IC regulator) Regulated voltage 14.1-14.7...

  • Page 342

    5 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Problem Probable Cause Remedy Page Starter does not Battery and related parts turn at all, or turns Poor contact of battery terminal(s) Clean and tighten 5 - 5 too slow to start Poor grounding of negative cable Clean and repair 5 - 5 engine...

  • Page 343

    BATTERY 5 BATTERY Indicator INSPECTION Terminal and Cable 1. Check the tightness of the terminals to ensure good Upper line electrical connections. Clean the terminals and coat them with grease after tightening the terminal. 2. Inspect for corroded or frayed battery cables. 3.

  • Page 344

    5 ALTERNATOR ALTERNATOR CHARGING SYSTEM [__j 1C regulator 86U05X-007 Caution L Terminal a) Be sure the battery connections are not S Terminal reversed, because this will damage the rec­ tifier. b) Do not use high-voltage testers such as a megger, because they w ill damage the rec­ tifier.

  • Page 345

    ALTERNATOR 5 TROUBLESHOOTING Preliminary Check 1. Check the indicator on the top of the battery. If the indicator is blue, the battery is normal. 2. If the indicator is not blue, the electrolyte level of the battery is low, or capacity is insuffi­ cient, or both.

  • Page 346

    5 ALTERNATOR 3. Alternator warning light operates properly, but battery discharged 86U05X-070 4. Battery overcharged Less than 14.1V More than 14.7V (At 20°C, 68°F) (At 20°C,68°F) 86U05X-071 5 - 8...

  • Page 347

    ALTERNATOR 5 Warning Disconnect the nagative battery terminal when disconnect or reconnect B terminal. TEST 1 1. Disconnect the alternator connector (2-pin). 2. Connect the SST. 4. Connect the red clip of the adapter harness to the battery (+), and check that the red lamp and green lamp illuminate.

  • Page 348

    5 ALTERNATOR TEST 3 1. Turn all electric loads off and release the brake pedal. 2. Check that output current is 5A or more at 2,500—3,000 rpm of the engine speed. B terminal 86U05X-013 TEST 4 1. Turn all electric loads off and release the brake pedal. 2.

  • Page 349

    ALTERNATOR 5 TEST 6 1. Turn the ignition switch ON. 2. Turn all electric loads off and release the brake pedal. 3. Check that voltage between S terminal and ground is battery voltage. terminal 86U05X-074...

  • Page 350

    5 ALTERNATOR REMOVAL Remove in the sequence shown in the figure. 1. Disconnect the negative battery terminal. 2. Disconnect the wire and connector from the al­ ternator. 3. Remove the bolts. 4. Remove the V-belt. 5. Remove the alternator to upper side. 86U05X-018 DISASSEMBLY Disassemble in the sequence shown in the figure.

  • Page 351

    ALTERNATOR 5 1. Place a soldering iron (200W) on the bearing box for 3 or 4 minutes to heat it to about 50—60°C (122—140°F). Pull out the three bolts, and then insert a screw­ driver between the stator and front bracket and separate them.

  • Page 352

    5 ALTERNATOR 4. Replace the front bearing Using a socket which exactly fits on the outer race of the bearing, carefully press in the bearing. Use a hand press or a vise. 86U05X-076 5. Replace the rear bearing The bearing can be pulled off by using a bearing puller.

  • Page 353

    ALTERNATOR 5 Replace the brushes Remove the solder from the pigtail, and then re­ move the brush. When soldering the brush, solder the pigtail so that the wear limit line of the brush projects 2 — 3 mm (0.079—0.118 in) out from the end of the brush holder.

  • Page 354

    ■< 5 ALTERNATOR INSPECTION Rotor 1. Wiring damage (1) Check the resistance between the slip rings us­ ing an ohmmeter. Specification: 2—6 Q (2) If it is not within specification, replace the rotor 86U05X-078 2. Ground of the field coil (1) Check for continuity between the slip ring and the core using an ohmmeter.

  • Page 355

    ALTERNATOR 5 Brush If the brushes are worn almost to or beyond the limit, replace them. Standard: 16.5 mm (0.650 in) Minimum: 8 mm (0.315 in) Wear limit line 86U05X-022 Brush Spring 1. Measure the force of the brush spring using a spring pressure gauge.

  • Page 356

    5 ALTERNATOR Rectifier 1. Check for continuity of the diodes using an ohmmeter. Negative (Black) Positive (Red) Continuity Pi, P2, P3 P i, 2. Replace the rectifier. 86U05X-025 5—18...

  • Page 357

    ALTERNATOR 5 ASSEMBLY Stopper spring Assemble in the reverse order of disassembly, refer­ ring to assembly note. Assembly Note Stopper spring installation 1. Fit the stopper spring into the eccentric groove of the rear bearing circumference. 2. Check that the protruding part of the spring is fitted into the deepest part of the groove.

  • Page 358

    5 ALTERNATOR INSTALLATION Note When installing the alternator, tighten the bolts to the specified torque. Install in the reverse order of removal. Tightening torque: Bolt (1)..37.3—52 N m (3.8—5.3 m-kg, 27.5—38.3 ft-lb) Bolt (2)..18.6—25.5 Nm (1.9—2.6 m-kg, 13.7—18.8 ft-lb) 69G05X-018 V-BELT TENSION Adjustment Adjusting bar bolt...

  • Page 359

    STARTER 5 STARTER STARTING SYSTEM ON-VEHICLE INSPECTION Charge the battery fully before starting the following inspection. 1. Turn the ignition switch to the start position. 2. Check that the starter motor operates. 3. If the starter does not operate, check the voltage between S terminal and ground using a voltmeter.

  • Page 360

    5 STARTER REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the wiring from the starter. 3. Raise the front of the vehicle and support it with safety stands. 4. Remove the intake manifold bracket. 5. Remove the starter bolts. 6.

  • Page 361

    STARTER 5 Magnetic Switch Remove the following parts: M terminal nut Wire Switch installation screws Magnetic switch Plunger and plunger spring 86U05X-33 Rear Bracket and Brush Holder Remove the following parts: Brush holder installation screws Through bolts Rear cover Wave washer Brush holder assembly Note Put an aligning mark on the yoke and rear...

  • Page 362

    5 STARTER Overrunning Clutch Stopper 1. Remove the overrunning clutch stopper using a pipe. 2. Disassemble the drive pinion, internal gear and washer from the gear shaft. Brush and Brush Holder Remove the brush from the brush holder using a flat- tip screwdriver.

  • Page 363

    STARTER 5 INSPECTION Armature 1. Ground of armature coil Check for continuity between the commutator and the core using a circuit tester. Replace the arma­ ture if there is continuity. 67U05X-048 2. Insulation of armature coil Check for continuity between the commutator and the shaft using a circuit tester.

  • Page 364

    5 STARTER 6. Segments groove depth If the depth of the groove is less than standard, undercut the grooves to the standard depth. Standard depth: 0.5—0.8 mm (0.02—0.03 in) Minimum depth: 0.2 mm (0.008 in). 7BU05X-041 Magnetic Switch 1. Wiring damage (©term inal — ©terminal). Check for continuity between the ©terminal and the ©terminal using a circuit tester.

  • Page 365

    STARTER 5 Overrunning Clutch Turn the pinion shaft by hand and hold the overrun­ ning clutch. Replace the overrunning clutch if the pinion turns in both directions or in neither direction. Note Do not wash the overrunning clutch with sol­ vent;...

  • Page 366

    5 STARTER Brush and Brush Holder 1. Insulation of brush holder Check for continuity between the insulated brush and the plate using a circuit tester. Replace the brush holder if there is continuity. 67U05X-060 2. Brush Replace the brushes if they are worn beyond the wear limit, or if the wear is near the limit.

  • Page 367

    ■ V STARTER 5 ASSEMBLY Assemble in the reverse order of disassembly, refer­ ring to the assembly note. Assembly Note Lubricate During assembly lubricate the following points: 1. Gear of armature shaft 2. Internal gear and planetary gears 3. Plunger circumference 4.

  • Page 368

    5 STARTER Installation of Brush Holder Install the brush holder assembly and rear cover and align the through bolts. 7BU05X-048 CHECKING OPERATION Magnetic Switch Make the following tests: Pull-out test 1. Check that the pinion is pulled out when 12V is con­ nected to the S terminal and the body is grounded.

  • Page 369

    STARTER 5 No-Load Test 1. After adjusting the pinion gap, form a test circuit with a voltmeter and an ammeter. Note Use heavy gauge wires and tighten each ter­ minal fully. 2. Close switch K to run the starter. 3. Check for the following: Voltage 11.0 90 max.

  • Page 370: Spark Plugs

    SPARK PLUGS SPARK PLUGS REMOVAL AND INSTALLATION Note the following points: 1. When the spark plug lead, is to be pulled off, be sure to pull the boot itself, not the wire. 2. Tighten the spark plugs to the specified torque. Tightening torque: 15—23 N m (1.5—2.3 m-kg, 10.8—16.6 ft-lb)

  • Page 371: Ignition Coil

    IGNITION COIL, HIGH-TENSION LEAD 5 IGNITION COIL INSPECTION Primary Coil Use an ohmmeter and check for resistance in the pri­ mary coil. If it is not within the specification, replace the coil. Primary coil resistance: (at 20°C 68°F) Turbo....0.72— 0.88 fl Non-Turbo...1.04—...

  • Page 372

    5 DISTRIBUTOR DISTRIBUTOR SPARK T E S T 1. Disconnect the distributor lead from the distributor. 2. Hold it with insulated pliers approx. 5—10 mm (0.20—0.39 in) from a ground. 3. Crank the engine and check that a strong blue spark is visible.

  • Page 373

    DISTRIBUTOR 5 8. If the mark is not aligned, loosen the distributor lock bolt, and turn the distributor housing to make the adjustment. 9. Reconnect the vacuum hoses, or disconnect the jumper wire from the test connector. 10. Tighten the distributor lock bolt to specified torque. Tightening torque: 18.6—...

  • Page 374

    5 DISTRIBUTOR 5. Apply vacuum and check the advance with the tim­ ing light. Crank angle (°) A cham ber Vacuum [mm Hg (in Hg)] (4.33) (1 0.83) B chamber 86U05X-055 REMOVAL 1. Remove the high-tension leads. 2. Disconnect the vacuum hoses and wiring. (Non-Turbo) 3.

  • Page 375

    DISTRIBUTOR 5 DISASSEMBLY Disassemble in the order shown in the figure. Turbo Engine 86U05X-057 3. Coupling set 1. Cap 4. Distributor set 2. Distributor rotor Caution Do not disassemble the distributor set. Non-Turbo Engine 9. Coupling set 5. Signal rotor and pin 1.

  • Page 376

    5 DISTRIBUTOR INSPECTION Pick-up Coil with Igniter (Non-Turbo) 1. Connect an ohmmeter to the pick-up coil. 2. Measure the resistance. Resistance: 900— 1,200 fl 3. If it is not within specification, replace it. Pick-up Coil (Turbo) Refer to page 4B—88. 86U05X-059 Cap and Rotor 1.

  • Page 377

    DISTRIBUTOR 5 ASSEM BLY Assemble in the reverse order of disassembly, refer­ ring to the assembly note. 86U05X-062 Assembly Note Align the coupling set blade with the alignment mark and check that the rotor is aligned as shown in the illustration.

  • Page 378

    5 DISTRIBUTOR H.E.I. TROUBLESHOOTING (Non-Turbo) 7BU05X-089...

  • Page 379

    IGNITER 5 IGNITER (Turbo) INSPECTION Warning While checking the igniter, disconnect the connector from the ignition coil. 86U05X-065 1. Disconnect the igniter connector. 2. Connect the SST between the igniter and igniter connector. Caution Do not misconnect the ohmmeter leads. Connect as follows: + lead to ground - lead to SST...

  • Page 380

    5 STARTER INTER-LOCK SYSTEM (ONLY M/T) STARTER INTER-LOCK SYSTEM (ONLY M/T) Ignition switch 86U05X-085 This system is similar to that of the inhibitor switch on an A/T vehicle. If the clutch pedal is not depressed during starting, battery power will not be supplied to the starter and it will not operate.

  • Page 381

    CLUTCH OUTLINE............6— 2 STRUCTURAL VIEW........6— 2 SPECIFICATIONS..........6— 3 TROUBLESHOOTING GUIDE......6— 3 ON-VEHICLE MAINTENANCE......6— 4 FLUID LEVEL..........6— 4 PEDAL HEIGHT..........6— 4 PEDAL FREEPLAY.......... 6— 4 CLUTCH PEDAL..........6— 5 REMOVAL AND INSTALLATION....6— 5 INSPECTION............

  • Page 382

    6 OUTLINE OUTLINE STRUCTURAL VIEW 1. Clutch pedal 4. Clutch pipe 7. Clutch release bearing 2. Assist spring 5. Clutch release cylinder 8. Clutch cover 3. Clutch master cylinder 6. Clutch release fork 9. Clutch disc 6 - 2...

  • Page 383

    TROUBLESHOOTING GUIDE 6 SPECIFICATIONS ------------ — ___ Enqine Non-Turbo Turbo Item ---------------------- -------- ----- Hydr Clutch control type aulic Clutch cover Type Diaphragm spring 5494 (560, 1232) Set load N (kg, lb) 4316 (440, 968) Outer diameter mm (in) 225 (8.858) 240 (9.449) 150 (5.906) 160 (6.299)

  • Page 384

    6 ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE FLUID LEVEL 1. Clean the area around the reservoir and the reser­ voir cap. 2. Check the fluid level. If the level is near or below the “ MIN” mark, add brake fluid to the “ MAX” mark.

  • Page 385: Clutch Pedal

    CLUTCH PEDAL 6 CLUTCH PEDAL REMOVAL AND INSTALLATION Remove the clutch pedal in the sequence shown in the figure. Install in the reverse order of removal. Apply a coat of grease (lithium base, N.L.G.I. No. 2) to the pedal bushing. 86U06X-006 1.

  • Page 386: Clutch Master Cylinder

    6 CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER 1. Clutch pipe 2. Nuts 3. Clutch master cylinder REMOVAL 1. Remove the ABS relay box. 2. Disconnect the clutch pipe with the SST. 3. Remove the mounting nuts. 4. Remove the clutch master cylinder. 86U06X-009 Caution Clutch fluid will damage painted surfaces.

  • Page 387

    CLUTCH MASTER CYLINDER 6 DISASSEMBLY 86U06X-011 1. Snap ring 6. Tank cap and baffle 2. Piston and secondary cup assembly 7. Reserve tank 3. Spacer 8. Bushing 4. Primary cup 9. Cylinder body 5. Return spring Caution When disassembling or assembling the clutch master cylinder, do so in a clean space free from dirt and dust.

  • Page 388

    6 CLUTCH MASTER CYLINDER 2. Remove the piston and secondary cup assembly by blowing compressed air through the clutch pipe installation hole. Caution When doing so, use a rag to prevent the pis­ ton and secondary cup assembly from project­ ing out.

  • Page 389: Clutch Release Cylinder

    CLUTCH RELEASE CYLINDER 6 4. While pressing the piston with a screwdriver, in­ stall the snap ring. INSTALLATION 1. Install the clutch master cylinder. 2. Tighten the mounting nuts. Tightening torque: 19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 3. Tighten the clutch pipe flare nut securely with the 4.

  • Page 390

    6 CLUTCH RELEASE CYLINDER REMOVAL 1. Disconnect the clutch pipe, with the SST. 49 0259 770B Note Plug the pipe in order to prevent fluid from leaking. 86U06X-020 2. Remove the installation bolts. 3. Remove the release cylinder. 86U06X-021 DISASSEMBLY 1.

  • Page 391

    CLUTCH RELEASE CYLINDER 6 1. Pull out the push rod and boot. 2. Remove the piston and piston cup by blowing com­ pressed air through the clutch pipe installation hole. Caution When doing so, use a rag to prevent the pis­ ton and piston cup assembly from projecting out.

  • Page 392: Air Bleeding

    6 AIR BLEEDING 4. Install the following parts: (1) Push rod (2) Boot 76U06X-031 INSTALLATION 1. Install the release cylinder. 49 0259 770B 2. Tighten the installation bolts. Tightening torque: 19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 3. Tighten the clutch pipe flare nut securely with the After installation 1.

  • Page 393

    CLUTCH AND FLYWHEEL 6 CLUTCH AND FLYWHEEL REMOVAL © 86U06X-029 1. Clutch release bearing 4. Clutch disc 2. Clutch release fork 5. Pilot bearing 3. Clutch cover 6. Flywheel 7. Ring gear 1. Remove the transaxle. (Refer to Section 7). 2.

  • Page 394

    6 CLUTCH AND FLYWHEEL 3. Remove the pilot bearing from the crankshaft with the SST. Note Do not remove the bearing if it is not necessary. 86U06X-031 4. Remove the flywheel. 86U06X-032 5. Remove the release bearing. 6. Remove the release fork. 86U06X-033 INSPECTION Check the following and repair or replace any faulty...

  • Page 395

    CLUTCH AND FLYWHEEL 6 Clutch Disc 1. Facing surface for hardening or presence of oil. Note Use sandpaper if the trouble is minor. 2. Loose facing rivets. 3. Worn clutch disc. Measure the depth to the rivet heads with a slide caliper.

  • Page 396

    6 CLUTCH AND FLYWHEEL Clutch Release Fork Cracked or bent clutch release fork. 67U06X-035 Flywheel 1. Surface marks, scoring or discoloration of clutch contact surface. Note If the problem is minor, repairs can be made by cleaning with sandpaper. 4BG06X-028 2.

  • Page 397

    CLUTCH AND FLYWHEEL 6 INSTALLATION 1. Apply clutch grease (Mori While TA No.2 or equivalent organic molybdenum grease) to the clutch release bearing and fork, indicated by the shaded lines in the figure. 2. Install the clutch release fork and release bearing. 3.

  • Page 398

    6 CLUTCH AND FLYWHEEL 5. Clean the clutch disc splines and primary shaft splines, then apply clutch grease (Mori White TA No. 2 or equivalent organic molybdenum grease) 6. Install the clutch disc with the SST. Note Install the clutch so that it faces in the direc­ tion shown in the figure.

  • Page 399: Manual Transaxle

    MANUAL TRANSAXLE New G-type (Non-Turbo) H-type (Turbo) OUTLINE........... 7A— 2 OUTLINE........... 7A— 3 ......7A— 2 STRUCTURAL V IE W STRUCTURAL VIEW ......7A— 3 ..... 7A— 4 CROSS-SECTIONAL VIEW CROSS-SECTIONAL VIEW ..... 7A— 5 ......7A— 6 SPECIFICATIO N S SPECIFICATIONS ......7 A - 6 TROUBLESHOOTING GUIDE..7A—...

  • Page 400

    OUTLINE OUTLINE STRUCTURAL VIEW (Non-Turbo) 86U07A-002 5. Primary reverse synchronizer gear 1. Primary shaft gear assembly 6. Secondary reverse synchronizer gear 2. Secondary shaft gear assembly 7. Reverse idle gear 3. Differential assembly 8. Transaxle case 4. Clutch housing 7 A—2...

  • Page 401

    OUTLINE OUTLINE STRUCTURAL VIEW (Turbo) 86U07A-003 6. Secondary reverse synchronizer gear 1. Primary shaft gear assembly 7. Reverse idle gear 2. Secondary shaft gear assembly 8. Transaxle case 3. Differential assembly 9. Interlock plate 4. Clutch housing 5. Primary reverse synchronizer gear 7 A—3...

  • Page 402

    OUTLINE CROSS-SECTIONAL VIEW (Non-Turbo) 86U07A-004 7 A—4...

  • Page 403

    OUTLINE CROSS-SECTIONAL VIEW (Turbo) 85U07A-005 7 A -5...

  • Page 404

    OUTLINE SPECIFICATIONS -— Engi ne model Non-Turbo (G-type) Turbo (H-type) Item Transaxle control Floor shift Synch romesh system Forward..synchromesh, Reverse..selective sliding and synchromesh 3.307 3.250 1.833 1.772 1.233 1.194 Gear ratio 0.914 0.926 0.711 0.717 Reverse 3.166 3.461 Final gear ratio 4.105 ATF: DEXRON-II Above 0°F:...

  • Page 405

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Problem Possible cause Remedy Page Change lever won’t Seized change lever ball Replace 7 A—84 shift smoothly, or is Seized change control rod joint Replace 7A—84 hard to shift Bent change control rod Replace 7A—84 Too much play in Worn change control rod bushing Replace 7A—84...

  • Page 406

    ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE TRANSAXLE OIL Inspection 1. Park the vehicle on level ground. 2. Remove the speedometer cable dust cover, and disconnect the cable from the speedometer driv­ en gear. 3. After removing the bolt, pull the gear case to re­ move it from the housing.

  • Page 407

    ON-VEHICLE MAINTENANCE DRIVESHAFT OIL SEALS Replacement Jack up the vehicle, support it on safety stands, and then drain the transaxle oil. Next, use the following procedure to replace the driveshaft oil seals: 1. Remove the front wheel(s). 2. Remove the splash shield(s). 3.

  • Page 408

    ON-VEHICLE MAINTENANCE Tap the new oil seal into the transaxle case with the SST. Note a) Tap in until the oil seal installer contacts the case. b)Coat the oil seal lip with transaxle oil. Replace the driveshaft end clip with a new one. Insert the clip with the gap at the top of the groove.

  • Page 409

    ON-VEHICLE MAINTENANCE 13. Adjust and tighten the stabilizer. Tightening torque: 16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb) Dimension: 20.1 mm (0.79 in) 86U07A-016 14. Install the drain plug. Tightening torque: 39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb) 15. Install the wheel. Tightening torque: 88—118 N-m (9.0—12.0 m-kg, 65—87 ft-lb) 16.

  • Page 410

    REMOVAL REMOVAL 86U07A-018 20. Under cover 10. Wheel(s) 1. Battery 11. Splash shield(s) 21. Extension bar 2. Main fuse block 22. Control rod 12. Clutch release cylinder 3. Distributor lead 23. Surge tank bracket 4. Air flow meter connector 13. Tie-rod end 24.

  • Page 411

    REMOVAL REMOVAL 1. Remove the battery and battery carrier. 2. Disconnect the main fuse block. 3. Disconnect the distributor lead. 4. Disconnect the air flow meter connector and re­ move the air cleaner assembly. 86U07A-019 [Turbo] 5. Remove the inter cooler hoses as follows. (1) Inter cooler hose to throttle body (2) Air cleaner to turbocharger [Non-Turbo]...

  • Page 412

    REMOVAL 11. Remove the clutch release cylinder. 12. Disconnect the tie-rod ends using SST. 86U07A-023 13. Remove the stabilizer bar control links. 14. Remove the bolts and nuts at the left and right low­ er arm bolt joints. 15. Pull the lower arms downward to separate them from the knuckles.

  • Page 413

    REMOVAL 19. Install the SST to the differential side gear. Non-turbo Note Failure to install the SST may cause the differential side gears to become misposi- tioned. 86U07A-027 20. Remove the gusset plates. 21. Remove the under cover. 22. Remove the extension bar and the control rod. 23.

  • Page 414

    REMOVAL 26. Remove the engine mount No. 4 and bracket. 27. Remove the engine mount No. 2. 28. Disconnect the hanger rubber then remove the crossmember and the left side lower arm as an as­ sembly. 29. Lean the engine toward the transaxle. 30.

  • Page 415

    DISASSEMBLY New G-type MTX (Non-Turbo) DISASSEMBLY STEP 1 Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked parts. seuo/A-oss 86U07A-036 Secondary 5th gear 23. Pin 1. Rear cover Lock bolt 24. Crank lever shaft 2.

  • Page 416

    DISASSEMBLY Disassembly Note Transaxle Mount the transaxle on the SST. 49 0107 680A 49 G019 0A0 86U07A-037 Lock nut 1. Lock the primary shaft with the SST. 2. Shift to 1st or 2nd gear. 3. Remove the lock nut. 86U07A-038 Shift fork and shift rod assembly 1.

  • Page 417

    DISASSEMBLY STEP 2 Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked parts. 86U07A-040 76U07A-229 15. Selector 28. Spring pin 1. Bearing outer race 16. Oil seal 29. Reverse lever shaft 2. Oil seal 3.

  • Page 418

    DISASSEMBLY Disassembly Note Bearing outer race (primary shaft) Remove the bearing outer race with the SST. Bearing outer race (secondary shaft) Remove the bearing outer race by lifting out the fun­ nel and race together. Spring pin Align the groove for removal of the clutch housing pin with the position of the spring pin, then tap the pin out using a pin punch.

  • Page 419

    DISASSEMBLY STEP 3 Disassemble in the sequence shown in the figure, referring to the disassembly note for the specially marked parts. Note a) Replace the bearings with new ones whenever they are disassembled. b) Before disassembly, check the thrust clearance of all gears. (Refer to page 7A—32.) 86U07A-045 26.

  • Page 420

    DISASSEMBLY Disassembly Note Bearing inner race (secondary 4th gear end) Remove the bearing inner race and secondary 2nd gear with the SST. Caution Hold the shaft with one hand so that it does not fail. 86U07A-046 Secondary 3rd gear and 2nd gear 1.

  • Page 421

    DISASSEMBLY Bearing inner race (4th gear end) 1. Remove the retaining ring. 2. Remove the bearing inner race with the SST. Caution Hold the shaft with one hand so that it does not fall. Clutch hub assembly (3rd/4th) 1. Remove the retaining ring. 2.

  • Page 422

    DISASSEMBLY STEP 4 (DIFFERENTIAL) Disassemble in the sequence shown in the figure referring to disassembly note for the specially marked parts. Note a) If the bearing inner races are removed replace them with new ones. b) Before disassembly, check the backlash of the side gears and pinion gears. (Refer to page 7A—29) 1.

  • Page 423

    INSPECTION INSPECTION Check the following parts, and replace if necessary. 1st, 2nd, 3rd, 4th, and 5th gears 1. Worn or damaged synchronizer cone. 2. Worn or damaged hub sleeve coupling. 3. Worn or damaged teeth. 4. Worn or damaged inner surface or end surface of gears.

  • Page 424

    INSPECTION Synchronizer Ring 1. Engagement with gear 2. Worn or damaged teeth 3. Worn or damaged tapered surface 4. Clearance from side of gear Clearance: 1.5 mm (0.059 in) Minimum: 0.8 mm (0.031 in) Note a) Press the synchronizer ring uniformly against the gear and measure around the circumference.

  • Page 425

    INSPECTION Reverse idle Gear 1. Worn or damaged bushing. 2. Worn or damaged teeth. 3. Worn or damaged release lever coupling groove. 4. Clearance between sleeve and reverse lever. Standard: 0.095—0.318 mm (0.004—0.013 in) Maximum: 0.5 mm (0.020 in) 86U07A-058 Clutch Housing, Transaxle Case, Rear Cover, and Differential Gear Case Cracks or damage.

  • Page 426

    ASSEMBLY ASSEMBLY Note a) Wash all parts. b) Apply oil to all friction surfaces. c) Use new roll pins and retaining rings. STEP 1 (DIFFERENTIAL) 86U07A-059 Assembly 1. Install the speedometer drive gear and the new bearing inner race with the SST. 49 G030 338 Note Press to 19,620 N (2,000 kg, 4,400 lb).

  • Page 427

    ASSEMBLY 3. Install the thrust washers and pinion gears. 4. Install the pinion shaft. 86U07A-062 5. Install the knock pin, then crimp it so that it cannot come out of the gear case. 6. Install the thrust washers and the side gears. 86U07A-063 Check and adjust using the following procedure.

  • Page 428

    ASSEMBLY STEP 2 Note During assembly, check the thrust clearance of each gear. (Refer to page 7A—32) 86U07A-066 Assembly Install the synchronizer key spring in the clutch hub with the hook in the groove. This holds the three syn­ chronizer keys in place. Note a) The sizes of the synchronizer keys are different.

  • Page 429

    ASSEMBLY Primary Shaft 1. Install the new bearing inner race with the SST. Note Press to 19,620 N (2,000 kg, 4,400 lb). 86U07A-069 2. Install the 3rd gear, synchronizer ring, and clutch hub assembly with the SST. Note a) Press to 19,620 N (2,000 kg, 4,400 lb). b) Align the synchronizer ring groove and clutch housing hub key when installing.

  • Page 430

    ASSEMBLY 6. Measure the clearance between the 3rd gear and 2nd gear. Clearance: 0.05—0.20 mm (0.0020—0.0079 in) Maximum: 0.25 mm (0.0098 in) 86U07A-073 7. Measure the clearance between the 4th gear and bearing inner race. Clearance: 0.165—0.365 mm (0.0064—0.0144 in) Maximum: 0.415 mm (0.0163 in) 86U07A-074 8.

  • Page 431

    ASSEMBLY Secondary Shaft 1. Assemble the 1st gear, synchronizer ring, and clutch hub assembly (reverse gear), as shown in the figure. Oil groove Note Align the synchronizer ring, groove and clutch housing hub key when installing. 86U07A-077 2. Press on the clutch hub assembly (reverse gear) ■...

  • Page 432

    8. Measure the clearance between the 1 st gear and differential drive gear. Clearance: 0.05—0.28 mm (0.0020—0.0110 in) Maximum: 0.33 mm (0.0199 in) 86U07A-081 9. Measure the clearance between the 2nd gear and secondary 3rd gear. Clearance: 0.175—0.455 mm (0.0069—0.0179 in) Maximum: 0.505 mm (0.0199 in) 86U07A-082...

  • Page 433

    ASSEMBLY STEP 3 20—29 N m (2—3 m-kg, 86U07A-083 7A—35 626, MX-6 Revised 10/87...

  • Page 434

    ASSEMBLY Bearing Preload Adjust the bearing preload by selecting adjust shim(s). 49 G030 380C 49 F401 3 8 2 A 49 G 0 3 0 381 4 9 F401 38 4 4 9 F401 3 8 5 49 G019 021 49 FT01 5 1 5A 83U07A-099 -Transaxle case...

  • Page 435

    ASSEMBLY 1. Install the primary and secondary shaft bearing out­ O uter race er races into the transaxle case (diaphragm springs and shims removed). 2. After mounting the clutch housing onto the trans­ axle hanger, and set the differential bearing outer race into the clutch housing.

  • Page 436

    ASSEMBLY 6. To seat the bearings, mount the SST (bars) on parts ® a n d (§)of the selector, and then turn the selector so the gap is widened. Then turn it in the reverse direction until the gap is eliminated. 86U07A-255 7.

  • Page 437

    ASSEMBLY 10. Install the SST. 11. Adjust the selector with the SST until the specified preload is obtained. Preload: 0.5 N-m (5 cm-kg, 4.3 in-lb) 12. Use a feeler gauge to measure the gap in the selec­ tor for the differential. Note Measure the gap around the entire circumfer­...

  • Page 438

    ASSEMBLY Assembly 1. Install the neutral switch. 2. Install the drain plug. 3. Install the back-up lamp switch. 4. Install the new oil seals with the SST. 86U07A-102 5. Install the differential adjust shim(s) and the bear­ ing outer race with a suitable pipe. 86U07A-103 6.

  • Page 439

    ASSEMBLY 8. Install the new breather. 9. Install the new change rod oil seal. 86U07A-106 10. Install the change rod (1), the boot (2), the spring (3), the reverse gate (4), and selector (5), as shown. 11. Install the new roll pin. 86U07A-107 12.

  • Page 440

    ASSEMBLY Bearing Preload Check the shaft gears and the differential bearing preload. Note a) Check that the correct adjust shims were selected. b) If the bearing preload is not within specifi­ cation, adjust again. 1. Set the primary shaft gear and the differential into the clutch housing.

  • Page 441

    ASSEMBLY STEP 4 Torque Specifications 86U07A-110 626, MX-6 Revised 10/87 7A-43...

  • Page 442

    ASSEMBLY 1. Install the magnet and the differential assembly. 2. Install the primary shaft gear assembly and the secondary shaft gear assembly together. 86U07A-111 3. Shift to 2nd gear and position the shift fork and shift rod assembly as shown. 4.

  • Page 443

    ASSEMBLY 8. Fit the crank lever in between the change arm and the control end, and connect the crank lever shaft to the crank lever. 9. Align the pin holes of the crank lever shaft and the clutch housing, and insert the pin. Note Use a new O-ring for the crank lever shaft.

  • Page 444

    ASSEMBLY 16. Install the lock bolt (1), the guide bolt (2). 17. Install the ball, spring and lock bolt (3). Tightening torque: (1) 18— 26 N m (184— 264 cm-kg, 159— 228 in-lb) (2) 9— 14 N m (90— 140 cm-kg, 78— 121 in-lb) (3) 15—...

  • Page 445

    ASSEMBLY 22. Shift to 1st gear. 23. Lock the primary shaft with the SST. 24. Tighten new lock nuts. Tightening torque: 128— 196 N-m (13.0— 20.0 m-kg, 94— 145 ft-lb) 25. Stake the lock nuts. 49 G030 440 86U07A-119 26. Clean and coat the both surfaces and install the rear cover.

  • Page 446

    DISASSEMBLY H-type MTX (Turbo) DISASSEMBLY STEP 1 Disassemble in the sequence shown in the figure referring to the disassemble note for the specially marked parts. 86U07A-121 1. Rear cover Ball 31. Roll pin 2. Roll pin Interlock plate 32. Shift rod (3rd/4th) 3.

  • Page 447

    ------------------------------- - - -------- DISASSEMBLY Disassembly Note Roll pin(s) Remove the roll pin(s) with pin punch. 86U07A-122 Lock nut 1. After removing the roll pin, shift the gears to 5th gear. 2. Shift the gears to 1st gear. 3. Remove the lock nuts. Caution Uncrimp the tab of the locknuts.

  • Page 448

    DISASSEMBLY Disassembly Note Bearing outer race (differential) Remove the bearing outer races with the SST. 86U07A-126 Bearing outer race and funnel (secondary shaft gear; clutch housing) Remove the bearing outer race by lifting the funnel and the race out together. 86U07A-127 Bearing outer race (secondary shaft gear;...

  • Page 449

    DISASSEMBLY STEP 3 Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked part. Note a) Replace the bearings with new ones whenever they are disassembled. b) Before disassembly, check the thrust clearance of all gears. (Refer to page 7A—65) 86U07A-130 21.

  • Page 450

    DISASSEMBLY Disassembly Note Primary shaft gear Bearing (4th gear end) Remove the bearing inner race with the SST. Caution Hold the shaft with one hand so that it does not fall. Clutch hub assembly (3rd/4th) Remove the 3rd gear, clutch hub assembly with the 86U07A-132 Bearing Remove the bearing inner race with the SST.

  • Page 451

    DISASSEMBLY Secondary shaft gear Bearing (secondary 4th gear end) Remove the bearing and secondary 4th gear with the Caution Hold the shaft with one hand so that it does not fall. 1st gear Remove the clutch hub assembly (1st/2nd) and 1st gear with the SST.

  • Page 452

    DISASSEMBLY STEP 4 (Differential) Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked parts. Note If any of the bearings are removed, replace with new ones. 8 6 U 0 7 M 3 8 61G07X-067 1.

  • Page 453

    DISASSEMBLY Knock-pin To remove the knock-pin from the pinion shaft, place the gear case in a vise and knock the pin out. Note Insert the rod into the knock-pin hole from the ring gear mounting surface side. 61G07X-181 Side bearing inner race (side opposite ring gear) Remove the bearing inner race with the SST.

  • Page 454

    INSPECTION INSPECTION Check the following parts, replace if necessary. 1st, 2nd, 3rd, 4th, and 5th gears 1. Worn or damaged synchronizer cone. 2. Worn or damaged hub sleeve coupling. 3. Worn or damaged teeth. 4. Worn or damaged inner surface or end surface of gears.

  • Page 455

    DISASSEMBLY Secondary Shaft Gear 1. Worn or damaged gear contact surface. 2. Worn or damaged splines. 3. Worn teeth. 4. Clogged oil passage. 5. Secondary shaft gear run-out. Run-out: 0.03 mm (0.0012 in) max. Note If the shaft gear is replaced, adjust the bear­ ing preload.

  • Page 456

    INSPECTION Synchronizer Ring 1. Engagement with gear. 2. Worn or damaged teeth. 3. Worn or damaged tapered surface. 4. Clearance from the side of gear. Clearance: 1.5 mm (0.059 in) Minimum: 0.8 mm (0.031 in) Note a) Place the synchronizer ring on the gear cone and rotate until it stops (approx.

  • Page 457

    INSPECTION Clutch Housing and Transaxle Case Cracks or damage. Note If the clutch housing or transaxle case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings. (Refer to page 7A—67) 76G07A-636 Speedometer Driven Gear Assembly 1.

  • Page 458

    ASSEMBLY ASSEMBLY Note a) Wash all parts. b) Apply oil to all friction surface. c) Use new roll pins and retaining rings. 86U07A-151 1. Install the speedometer drive gear. 2. Install the side bearing inner race with the SST. 86U07A-152 3.

  • Page 459

    ASSEMBLY 4. Install the pinion gears and washers. 5. Install the pinion shaft. 6. After installing the knock pin, make a crimp so that the pin cannot come out of the gear case. 7. Install the side gears and washers. Backlash of Side Gear and Pinion Gear Check and adjust by the following procedure.

  • Page 460

    ASSEMBLY STEP 2 86U07A-156 Synchronizer key Note There are two (2) types of synchronizer key. Standard dimension: © © 22.0 (0.87) 14.2 (0.56) 1 st/2nd 3rd/4th, 5th/Rev. 17.0 (0.67) 12.2 (0.48) 86U07A-157 Synchronizer ring Note The size of the 1st, 2nd, and 3rd/4th syn­ chronizer rings is the same.

  • Page 461

    ASSEMBLY Synchronizer ring and clutch hub assembly Note Align the synchronizer ring groove and clutch hub key when installing. . linn u h T iiiiT = iiiiiiiiiiiii --------------------- ^ ----------------;------------ — — — 86U07A-159 Primary Shaft Gear 1. Install the needle bearing and the 3rd gear. Note Apply transaxle oil to the needle bearing.

  • Page 462

    ASSEMBLY 8. Measure the clearance between the 3rd gear and primary shaft gear. If clearance is not within specification, replace any part which is worn or damaged. Clearance: 0.150—0.262 mm (0.059—0.0103 in) 86U07A-163 9. Measure the clearance between the 4th gear and bearing inner race.

  • Page 463

    ASSEMBLY 6. Install the 3rd gear, the secondary 3rd gear, spacer and the secondary 4th gear. 7. Install the new bearing inner race with the SST. Note Check that the spacer does not rotate. 86U07A-167 8. Install the new bearing inner race with the SST. 86U07A-168 9.

  • Page 464

    ASSEMBLY STEP 3 Torque Specifications 86U07A-171 Transaxle Case 1. Install the oil passage. Tightening torque: 8—11 N-m (80—115 cm-kg, 69—100 in-lb) 2. Install the new oil seal with the SST. 76G07A-638 3. Tap the primary and secondary shaft bearing out­ er races in until they are fully seated with a suit­...

  • Page 465

    ASSEMBLY Clutch Housing 1. Install the new oil seal (change rod) to clutch housing. 2. Install the change arm. boot and change rod. Note The boot should be installed as shown in the figure. 86U07A-174 3. Install the new roll pin as shown in the figure. Note Roll pin length is 28 mm (1.10 in) 4.

  • Page 466

    ASSEMBLY Bearing Preload Adjustment When any of following parts are replaced, the bearing preload should be checked and adjusted. 49 F401 382A 49 FT01 51 5A 49 F401 385 49 G019 021 86U07A-178 -Transaxle case 49 G027 001 O uter races Outer race Differential Primary shaft assembly...

  • Page 467

    ASSEMBLY 1. Put the outer race into the SST. 2. Mount the secondary shaft gear assembly as shown. Note The secondary shaft selector touches the 49 G030 381 differential gear, so the secondary shaft bear­ ing preload adjustment should be done separately from for the primary shaft and differential assembly.

  • Page 468

    ASSEMBLY 6. Use a thickness gauge to measure the gap of the selector. Note Measure the gap around the entire circumfer­ ence of the selector. 76G07A-643 7. Select the shim for the shaft gear by referring to Thickness (Primary and Secondary) the table and selecting the shim which is nearest (on the thick or thin side as shown) to the value 0.25 mm (0.010 in)

  • Page 469

    ASSEMBLY 11. Move the bars and expand the SST until it can no longer be turned, then turn it in the reverse direc­ tion until the gap is eliminated. 86U07A-189 12. Set the SST. 13. Expand the selector with the bar until preload specification is obtained.

  • Page 470

    ASSEMBLY Rechecking of Bearing Preload 1. Remove the SST and transaxle. 2. Remove the bearing outer races from the trans­ axle case. 3. Install the primary and secondary adjust shims, di­ aphragm springs and bearing outer races to the case as shown in the figure. 4.

  • Page 471

    ASSEMBLY STEP 4 Torque Specification 8—11 N-m (80—115 cm-kg, 69—100 In-lb) 86U07A-197 Assembly 1. Install the lever set spring and the reverse shift lever. Tightening torque: 8—11 Nm (80—110 cm-kg, 69—95 in-lb) 2. Install the differential assembly, the secondary shaft gear assembly and the primary shaft gear as­...

  • Page 472

    ASSEMBLY 5. Install the shift rod and the shift fork (1st/2nd). 6. Shift to the 2nd gear. 7. Install the roll pin. 8. Install the interlock pin to shift rod (5th/Rev.) 9. Install the shift rod end the shift rod (5th/Rev.). 10.

  • Page 473

    ASSEMBLY 13. Install the magnet. 14. Coat both surfaces with sealant and install the trans­ axle case and the engine mount bracket. Note Before coating with sealant, clean the contact surfaces. Tightening torque: 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) 15. Install the engine mounting bracket. Tightening torque: 78—117 N-m (8.0—11.9 m-kg, 58—86 ft-lb) 16.

  • Page 474

    ASSEMBLY 26. Install the synchronizer ring, gear the primary re­ verse synchronizer gear, sleeve and the secondary reverse synchronizer gear. 27. Shift to the 5th gear and the 1st gear. 28. Tighten the lock nuts and stake it. Tightening torque: 128—196 N-m (13.0—20.0 m-kg, 94—145 ft-lb) 29.

  • Page 475: Torque Specifications

    INSTALLATION INSTALLATION Torque Specifications 10—12 N-m (100—120 cm-kg, 42—62 N-m (4.3—6.3 m-kg, 31—46 ft-lb) 64—89 N-m (6.5—9.1 m-kg, 42—66 ft-lb) 8—11 N-m (80—110 cm-kg, 65—95 In-lb) 36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb) 29—44 N-m (3.0—4.5 m-kg, 22—33 ft-lb) 43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb) 89—117 N m...

  • Page 476

    INSTALLATION 1. Attach rope at 2 places on the transaxle and place a board on the jack and position the transaxle on it. Caution The transaxle is not well balanced; be care­ ful when positioning on the jack. 2. Move the transaxle into the place and attach the rope (attached to the transaxle in step 1) to the 86U07A-210 3.

  • Page 477

    INSTALLATION 6. Install the crossmember and the left side lower arm as an assembly. Tightening torque: Bolts, 36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb) Nut, 75—93 Nm (7.6—9.5 kg, 55—69 ft-lb) 7. Remove the jack and take of the rope. 8. Remove the SST. 86U07A-214 9.

  • Page 478

    INSTALLATION 14. Replace the clips at the end of the driveshafts and joint shaft with new ones. 15. Install the joint shaft and right driveshaft as follows: (1) Install and tighten the reamer bolts ® ; then in­ stall and tighten the standard bolts (§). Tightening torque: (£) :7—10 N-m (70—100 cm-kg, 61—87 in-ib)

  • Page 479

    INSTALLATION 19. Install the stabilizer bar control links as follows. (1) Install the stabilizer bar control link. (2) Adjust protrusion to 20.1 mm (0.79 in) (3) Tighten bolt to specified torque. Tightening torque: 16—23 N-m (1.6—2.3 m-kg , 12—17 ft-lb) 20.

  • Page 480

    INSTALLATION 25. Install the intercooler hoses as follows. (1) Air cleaner to turbocharger. (2) Inter cooler to throttle body. 86U07A-226 26. Install the air cleaner assembly and connect the air flow meter connector. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-ib) 27.

  • Page 481

    INSTALLATION TRANSAXLE CONTROL REMOVAL AND INSTALLATION 1. Jack up the vehicle and support it with safety stands. 2. Remove in the sequence shown in the figure. 3. Install in the reverse order of removal. 6iG07x-i65 86U07A-230 12. Spring 7. Nut and washer 1.

  • Page 482

    TRANSAXLE CONTROL Spring Remove the spring by prying on the hooked part of the spring with a screwdriver. INSPECTION Check the following, and replace if necessary: 1. Bent control rod. 2. Wear, damage, or malfunction of any joint. 3. Damaged gear shift lever ball. 4.

  • Page 483

    TRANSAXLE CONTROL Gear Shift Lever Ball Apply grease to the ball seat surface, and install the upper and lower ball seat, holder, and boot. Note Apply grease to all joints. Spring Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure.

  • Page 484: Automatic Transaxle

    AUTOMATIC TRANSAXLE (Electronically Controlled) OUTLINE.........7B— OIL STRAINER......7B— 55 SPECIFICATIONS......7B— ADJUSTMENT OF 2-4 BRAKE COMPONENT LOCATION...7B— BAND......... 7B — 56 STRUCTURAL VIEW....7B— REPLACEMENT OF DRIVESHAFT OPERATION OF COMPONENTS . 7B— OIL SEAL........7B — 56 FLUID PASSAGE LOCATION..7 B - OIL COOLER.........

  • Page 485

    OUTLINE OUTLINE SPECIFICATIONS EC-AT (G4A-EL) Model Turbo Non-Turbo Torque converter stall torque ratio 1.600-1.800 : 1 1.700-1.900 : 1 First 2.800 Second 1.540 Gear ratio Third 1.000 Fourth (OD) 0.700 Reverse 2.333 Final gear ratio 3.700 Forward clutch Coasting clutch Number of drive plates/ 3-4 clutch driven plates...

  • Page 486

    OUTLINE COMPONENT LOCATION 86U07B-003 Cruise control switch 11. Idle switch 1. Hold indicator light 12. Fluid temperature switch Mode switch 2. EC-AT control unit 13. EC-AT Hold switch 3. Vehicle speed sensor 14. Pulse genelator Water temperature switch 4. Mode indicator light 15.

  • Page 487

    OUTLINE STRUCTUAL VIEW 86U07B-004 1. Coasting clutch 7. Low and reverse brake 13. Control body 14. Oil pump 8. Output gear 2. Forward clutch 15. Inhibitor switch 9. Idle gear 3. Reverse clutch 16. Pulse generator 4. Reverse and forward drum 10.

  • Page 488

    OUTLINE OPERATION OF COMPONENTS Low and reverse brake Forward clutch Torque convertor Reverse Coasting clutch One-way clutch 1 Long pinion Damper piston One-way clutch 2 Internal gear 76U07B-508 Operation elements Engine Gear braking 2-4 brake Range Coasting Reverse L o w & re v e rs e One-way One-way Forward...

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