Mazda 121 Workshop Manual

J M O O B 1 0 3 t0 0
Mazda
121
CONTENTS
Tirle
Workshop
Manual
Vofume 1 of 2
FOREWORD
This workshopmanualis intendedfor use
bv service technicians of AuthorizedMazda
D-ealers
to help them serviceMazdavehicles.
It can also be uselulto ownersand operators
of Mazda vehicles in diagnosing some
problemsand performinglimitedrepairand
maintenanceon Mazda vehicles.
Generallnformation
Pre-DeliveryInspection and
Scheduled MaintenanceService
Engine
Lubrication System
Cooling System
C,onttol
SystemI EGI-S
FuelandEmission
Engine ElectricalSystem
Clutch
ManualTransaxle
Automatic Transaxle
Front and Rear Axles
For proper repair and maintenance,a
withthismanualis imthoroughlamiliarization
portant,and it shouldalwaysbe kept in a handy placefor quick and easy reterence.
All the contentsof this manual,including
arethe latestavaildrawingsand specifications,
able at the time of printing. As modifications
affectingrepairor maintenanceoccur,relevant
to thisvolumewill
informationsupplementary
be made available at Authorized Mazda
Dealers.This manual should be kept upto-date.
Steering System
Mazda Motor Corporationreservesthe right
to alterthe specificationsand contentsof this
manualwithoutobligationor advancenotice.
All rightsreserved.No part of this book may
be reproduced or used in any form or by any
means,electronicor mechanical-including
photocopying and recording and the use of
any kind oJ informationstorage and retrieval
system-without permissionin writing.
TechnicalData
Mazda Motor Corporation
HIROSHIMA.JAPAN
APPLICATION:
Thismanualis applicableto vehiclesbeginning
with the Vehicle ldentificationNumbers (VlN)
shown on the following page.
Secti
Braking Syslem
Wheels and Tires
Suspension
Body
Body Electrical System
Heater and Aar Conditioner Systems
Special Tools
wiringDiasram Sili:.|Tj|:'"''""'0"''
The section Z is published separatelrom this manual.
o 1990MazdaMotorCorporation
ocT. '90 @)
1249-10-90J
(VlN)
NUMBERS
vEHlcLE IDENTIFICATION
JMo D8103100 100001
GI
GENERALINFORMATION
Gl- 2
TMPORTANT
TNFORMATION
.....................
BAS|CASSUMPT|ONS............................
Gl- 2
... Gl- 2
sAFEryH1SK...............
LOSSOFWARRANry.....,,......
GI- 2
POSSIBLE
WARNING
ON LUBRICANTS
.............
Gl- 2
ANDGREASES.
Gt- 3
HOWTO USETH|SMANUAL....................
PREPARATTON
................
Gl- 3
PROCEDURE.............................
Gl- 3
REpAtR
...............
Gl- 4
SYMBOLS........
GI- 4
NOTES.
ANDWARNINGS.......
CAUTIONS.
FUNDAMENTAL
PROCEDURES.................
GI- 4
..,...........
GI- 4
PROTECTION
OFTHEVEHICLE
Gl- 5
A WORDABOUTSAFETY.......................
PREPARATION
OFTOOLS
EQUIPMENT.............
GI_ 5
ANDMEASURING
.. Gl- 5
SPEC|AL
TOO1S............
Gl- s
REMOVAL
OF PARTS.............................
................
Gl- 5
DTSASSEMBLY
REASSEMBLY
.................
GI- 6
..,....,..,,...
GI- 7
ADJUSTMENTS
ANDTUBING.............,..
GI_ 7
RUBBER
PARTS
GI- 8
JACKAND SAFETYSTANDPOSITIONS....
TYPE)
VEHICLELIFT(2.SUPPORT
postTtoNs.....
.................
Gl- I
...................
Gl- 9
TOW|NG.........
NUMBERLOCATIONS.,...
GI-10
IDENTIFICATION
. . . . . . . . . . . . . . .G. .l .- l 0
uNtTs.............
.....................................
Gl-l0
ABBREVTATTONS
.... Gl-ll
CAUT|ON
INSTALLATION
OFA MOBILE
FAD|OSYSTEM....................
Gl-l1
TWO-WAY
KEYON
REMOVAL
OF IGNITION
TRANSAXLE
MODE1..........
GI-11
AUTOMATIC
TOOLSGI-12
ELECTRICAL
TROUBLESHOOTING
PARTS........
WITHELECTRICAL
GI-13
CAUTION
03uGtx-001
GI
IMPORTANTINFORMATION
IMPORTANTINFORMATION
BASICASSUMPTIONS
for the safeandetfiThisworkshopmanualassumesthatyou havecertainspecialtoolsthatarenecessary
on Mazdavehiclesandthatyou knowhowto usethemproperly.
cientperlormance
of serviceoperations
You
systemsandbasicserviceand repairprocedures.
It alsoassumes
thatyouarefamiliarwithautomobile
theconsearecorreclandyou understand
shouldnotattemptto usethismanualunlesstheseassumptions
quencesdescribed
below.
SAFETYRISK
thatyoushouldcarefully
information
Thismanualcontainscertainnotes,warnings,andotherprecautionary
readand iollowto reducethe riskof personalinjuryto yourselfor othersandthe riskof improperservice
in regardto anyspectfic
thatmay damagethe vehicleor renderit unsafe.lf thereis no suchinformation
that personalsafetyor vehiclesafetywill be
servicemethod,this does not meanthereis no possibility
jeopardized
by the use oJincorrectmethodsor tools.
POSSIBLELOSSOF WARRANTY
Themanufacturer's
warrantyon Mazdavehiclesand enginescan be voidedif improperserviceor repairs
are performedby personsotherthan thoseat an AuthorizedMazdaDealer.
AND GREASES
WARNING
ON LUBRICANTS
Avoidall prolongedand repeatedcontactwith mineraloils,especiallyusedoils.Usedoilscontaminated
including
effects,
(e.g.,enginesumpoils)aremoreirritating
andmorelikelyto causeserious
duringservice
skincancer,in the eventof grossand prolongedskincontact.
Washskinthoroughlyafterwork involvingoil.
handcleanersmaybe of valueprovidedtheycan be removedfromthe skinwithwater.Do not
Protective
usegasoline,paraffin,or othersolventslo removeoil fromthe skin.
Lubricants
and greasesmay be slightlyirritatingto the eyes.
Particuclothingif necessary.
Bepeated
or prolongedskincontactshouldbe avoidedby wearingprotective
lead.Do notallowworkclothingto be conlarcareshouldbe takenwithusedoilsand greasescontaining
taminatedwithoil. Dry cleanor laundersuchclothingat regularintervals.
sMuGrx_oo2
Gl-z
GI
HOWTO USETHISMANUAL
HOWTO USETHISMANUAL
matit pro-E
operation
service
Tool(ssT)fortheservice
F[rtFf#rtifiirointsouttheneeded
speciat
ceeds.Gatherall necessarySST beforebeginningwork.
Example:
MANUALSTEERING
SST NUMBER
PREPARATION
ssT
49 0118850C
Pullef,balljoinl
SST NAME
SST ILLUSTRATION
03uGtx-@6
REPAIBPROCEDURE
lt identifies
the components,
showshowthe
1. Mostrepairoperations
beginwithan overviewillustration.
partsfit together,and visualpartslnspections.
lf a damagedor wornpart is found,repairor replaceit
as necessary.
parts,tightening
andsealant
areshownin theoverview
torques,
andsymbols
foroil,grease,
2. Expendable
illustration.
whenserBeferto thisinformation
3. Pagesrelatedto serviceproceduresareshownunderthe illustration.
vicingthe relatedpart.
Example:
SHOWS TIGHTENING
TOROUE UNIT
sHows
RELATED
PAGEFOR
SERVICE
17 Spacer
18 Drive pinion
page M-2'l
Bemoval
rpecl splines and leelh fot weat or damage
" 1 : Thenumbering
(ex.@)showsserviceprocedure.
9MUGIX.O34
specified.
Unitsshownin Nm (m-kg,ftJb)unlessotherwise
Gt-3
GI
PROCEDURES
HOWTO USE THIS MANUAL/FUNDAMENTAL
SYMBOLS
Thesesymbolsshowthe pointsof applyingsuch
if,er" uresi* symbolsindicatingoil,grease,and sealant.
duringservice.
materials
Kind
Meaning
Symbol
g
Apply oil
New engine oil or gear oil as appropriate
@
Apply brake fluid
Only brake fluid
E
Apply automatictransmissionfluid
OnlyATF
Applygrease
Appropriategrease
Apply sealant
Appropriatesealant
Apply petroleumjelly
AppropriatepetroleumjellY
€
(@[
e
osuctx005
Note
. Whenspecial oil or grease is needed,this is shown in the illustration.
AND WARNINGS
NOTES,CAUTIONS,
Each
andWARNINGS.
CAUTIONS,
youwillcomeacrossNOTES,
As you ieadthroughihe procedures,
you
to
complete
will
help
that
give
you
information
purpose.
added
NOTES
oneis thereforea ipecific
procedrire.
GAUTIbNSaregivento pri:ventyoufrommakingan errorthatcoulddamagethe
a particular
cancausePer'
carefulinthoseareaswherecarelessness
remindyouto beespecially
vdhicle.WARNINGS
youshouldfollowwhenyouworkon
somegeneralWARNINGS
lilt contains
sonatiniury.Thefollowing
a vehicle
olA.,x-oo2
PROCEDURES
FUNDAMENTAL
OF THEVEHICLE
PROTECTION
Alwaysbe sureto coverfenders,seats,and floorareasbefore startinowork.
Gt-4
9MUGIX.O37
PROCEDURES
FUNDAMENTAL
GI
A WORDABOUTSAFETY
mustbefollowedwhenjackingup
Thefollowingprecautions
the vehicle.
1. Blockthe wheels.
jackingpositions.
2. Useonlythe specified
3. Supportthe vehiclewith safetystands.
Starttheengineonlyaftermakingcertaintheenginecompartmentis clearof toolsand people.
9MUGtX-003
9[,{UGtX-038
47UOGX-005
47U0GX-006
SMUGIX,O39
OF TOOLSANDMEASURING
PREPARATION
EOUTPMENT
are
equipment
toolsandmeasuring
Besurethatallnecessary
availablebeforestartingany work.
SPECIALTOOLS
Use specialtoolswhen they are required.
REMOVAL OF PARTS
Whilecorrectinga problem,try alsoto determineits cause.
Beginworkonly afterfirstlearningwhichpartsand subassemb es mustbe removedand disassembledfor replacementor
repair.
DISASSEMBLY
procedureis complex,requiringmanyparts
lf the disassembly
in a way
all partsshouldbe disassembled
to be disassembled,
performance
appearance
or
external
that will not affecttheir
and identifiedso that reassemblycan be performedeasilyand
efficiently.
Gr-5
GI
PROCEDURES
FUNDAMENTAL
1. lnsoectlonof Parts
for
inspected
partshouldbecarefully
Whbnremoved,-each
problems'
other
damage,and
detormation,
malfunctioning,
9MUGtX-040
9MUGIX.O41
2. Arrangementof Parts
arrangedior reAlldisJssembled
oartsshouldbecarefully
assembly.
Be sureio separateor otherwiseidentifythe partsto be
reolacedfromthosethat will be reused
3. Cleaningparts tor reuse
All oarts'iobe reusedshouldbe carefullyand thoroughly
method.
cleanedin the appropriate
REASSEMBLY
Standardvalues,suchas torquesand certainad.iustments'
of all parts'
mustbe strictlvobservedin the reassembly
TORQUE
TIGHTENING
BOLTANDNUT
NEIEr
tOSTNUONRD
in
themain
mentioned
hot
torques
in SectionTDfortightening
text.
lf removed,thesepartsshouldbe replacedwithnewones:
'1. Oil seals
2. Gaskets
4. Lockwashers
3. O-rings
6. Nylonnuts
5. Cotterpins
9MUGIX-OM
)ffi
9MUGIX{42
Gt-6
Dependingon location:
1. Sealantshouldbe appliedto gaskets.
of parts'
2. Oil shouldbe appliedto the movingcomponents
prescribed
oilor gieaseshouldbeappliedatthe
3. Specified
locations(suchas oil seals)beforereassembly'
PROCEDURES
FUNDAMENTAL
GI
ADJUSTMENTS
gaugesand/ortesterswhenmakingadiustments.
Usesuitable
E
57UoGX-002
RUBBERPARTSANDTUBING
or oilfromgettingon rubberpartsortubing.
Preventgasoline
9MUGIX.OOs
Gt-7
TYPE)FosmoNs
Gl ,oo ANDsAFEw srANDFosmoNsyvEHplEUFT(25UPP6RT
JACKAND SAFETYSTANDPOSITIONS
FRONTEND
Jack positioni
At the frontcrossmember
Satetystand positions:
Sidesills
REAREND
Jack position:
At the centerof the rearcrossmember
Safetystand positions:
Sidesills
03uGlx'oog
TYPE)POSITIONS
vEHlcLE LIFT (2-SUPPORT
REAREND
Frame
Sidesills
FRONTEND
Frame
Sidesills
Gt-8
9ltlUGlX-010
TOWING
GI
TOWING
WHEEL DOLLIES
03uGlx002
is necessary
to preventdamageto p
Propertowingequipment
the vehicle.
to vehiclesin tow mustal
Lawsand regulations
applicable
waysbe observed.
shouldbe pulledwiththe
As a generalrule,towedvehicles
damageor other
drivingwheels
offtheground.lf excessive
prevent
withthedrivingwheels
towingthevehicle
conditions
offthe ground.usewheeldollies.
Witheitherautomaticor manualtransaxle:
switchin the ACCposition:
1. Setthe ignition
2. Placethe selectorleveror shiftleverin N (Neutral);
the parkingbrake.
3. Release
Caution
. Do not tow the vehiclebackwardwith drivingwheels
on the ground.This may causeinternaldamageto
the transaxles.
. Do not usethe hookloops underlhe front and rear
ol the vehicle tor towing purposes. These hook
loops aredesignedONLYtor transporttie-down.It
tie.down hook loops are used for towing, the
front/rear bumperwill be damaged.
Gt-9
Gl
NUMBER
LocATroNs/uNtrs/ABBREVtATtoNS
rDENTIFrcATroN
NUMBERLOCATIONS
IDENTIFICATION
VEHICLE IDENTIFICATIONNUMBER (VIN)
AUTOMATICTRANSAXLEiIODEL AND NUMBER
,'%
r(g
' /tYl
.,,/Pk
ENGINEMODELAND NUMBER
UNITS
N.m (m-kg or cm-kg,
......Torque
ftlb or in-lb)..
per minute
rpm......... ... . ........Revolutions
A . . . . . . . . . . . . . . . . . . . . . . . . .A. m p e r e ( s )
V . . . . . . . . . . . . . . . . . . . . . .V o l t ( s )
Ohm(s)(resistance)
. ....... ...........
o. .
kPa (kg/cm2,psi)..... .. Pressure
(usuallyPositive)
Pressure
mmHg(inHg)....
(usuallYnegative)
. . . . . .W
. att
W.......... ....
liters (US qt, lmp qt) . . Volume
mm (in) ...... ....... .. Length
89U0GX.006
ABBREVIATIONS
Atterbottomdead
center
A / C . . . . . . . . . . . . . . . . . .. A i r c o n d i t i o n e r
. ccessories
A C C . . . . . . . . . . . . . . . . . . . .A
Automatictransaxle
ATX. ......
After top dead center
ATDC .....
Automatrctransmrssion
ATF
fluid
Bypassair control
BAC.........
Beforebottomdead
BBDC...
center
BTDC... .... ...... ....Beforetop deadcenter
Centralprocessingunit
CPU........
ABDC.......
........Electronically-controlled
automatictransmission
. .n g i n ec o n t r oul n i t
E C U. . . . . . . . . . . . .. . . . . . .E
gasoline
... Electronic
EGI . ..............
injection
E I L . . . . . . . . . . . . . . . . . . . .E l e c t r i c laol a d
.. . Exhaust
EX..
circuit
Integrated
lC........ ....... ..
l G N .. . . . . . . . . . . . l g n i t i o n
l N . . . . . . . . . . . . . . . . . . . . .I .n. t. a
. .k. e
. rmftent
1 N T . . . . . . . . . . . . . . . . . . . . .I .n. t. e
ldle speedcontrol
ISC .............
. .f.th a n d
L H . . . . . . . . . . . . . . . . . . . .L. e
M....................... tvlotor
M I L . . . . . . . . . . . . . . . . . . . . .l .\ .r a l f u n c t i o n i n d i c a t o r
lamp
Manualtransaxle
MTX..........
. Overdrive
OD .......
O F F . . . . . . . . .... . . . . . . . . . .S. .w. .i t c ho f f
. .i t c ho n
O N . .. . . . . . . . . . . . . . . . . .S. .w
Positivecrankcase
PCV........
ventilatlon
PRC.................. Pressureregulator
control
Powersteering
.
P/S.-....
..............
P / ! V . . . . . . . . . . . .......... . . . P o w e rw i n d o w
. . i g h th a n d
R H . . . .... . . . . . . . . .. . . . . . .R
Specialservicetool
SST.,... .
. . t. a r t
S T . . . . . ..... . . . . . . . . . . . S
. .w
. .i t c h
S W . . . . . . . . . . . . . . . . .S
TDC.......... ............ Top dead center
EC-AT.........
03uGtx.004
Gt-l0
GI
CAUTION
CAUTION
INSTALLATIONOF MOBILETWO.WAYRADIOSYSTEM
typeis used,the EGIsystem
improperly
or if a high-powered
lf a mobiletwo-wayradiosystemis installed
and othersystemsmay be affected.
Whenthe vehicleis to be equippedwitha mobiletwo-wayradio,observethe followlngprecaulions:
pointlromcontrolunits.
1. lnstallthe antennaal theJarthest
(at least30 cm [11.8in]).
fromthecontrolunitharnesses
feederas far as possible
2. lnstalltheantenna
3. Ensurethat the antennaand feederare properlyadjusted.
mobiletwo-wayradiosystem.
4. Do not installa high-powered
MOBILETWO.WAYRADIO
EGAT CONTFOL UNIT
ENGINECONTROLUNIT
"'o'"*'*J
Ll lZ'""-rRoLUN,r
r/rl
AT LEAST 30 cm (11.8 in)
FARTHESTPOINT
05uGlx'013
KEY ON AUTOMATIC
REMOVAL
OF IGNITION
TRANSAXLEMODEL
to turntheignitionkey
Theselectorlevermustbe in P (PARK)
to the OFFposition.lf the switchseemsto be off butthekey
cannotbe removed,the switchmaystillbe in the ACCposilevermaynot be in P (PARK).
Shiftthe
tion,or the selector
and turnthe ignitionkeyto the
leverto P (PARK),
selector
Thekeyshouldnowbe lreefor removal.
LOCKposition.
R
N
D
s
L
03UGIX.OOs
Gl-11
GI
CAUTION
TOOLS
TROUBLESHOOTING
ELECTRICAL
Test Light
as shownin thefigure,usesa 12Vbulb.The
Thetest-light,
wires
shouldbe connectedto probes.
two lead
Thetestlightis usedforsimplevoltagechecksandfor checkingfor shortcircuits.
Caution
. Whencheckingthe control unit, never use a bulb
over 3,4W.
9MUGIX.O19
JumperWire
Thelumperwireis usedtortestingby shortingacrossswitch
and groundconnections.
terminals
Caution
. Do not connecta iumperwirefromthe powersource
line to a body ground; this may cause burning or
other damage to harnesses or electronic com'
ponents.
9MUGIXO2O
VOLTMETER
Voltmeter
is usedto measureof circuitvoltage.A voltTheDCvoltmeter
the
of 15Vor moreis usedby connecting
with
a
range
meter
positive(+) probe(redleadwire)to the pointwherevoltage
is to be mi;asuredand the negative(-) probe(blacklead
wire)to a bodyground.
GFOUNO
9MUGIX.O21
DiagnosisConnector
a jumholewhenconnecting
theprobeintotheservice
Insert
connector.
per wireto the diagnosis
Caution
. Do not insert the jumper wire probe lnto the diag'
nosis connectorterminal, which may damagethe
terminal.
05uGtx-021
Ohmmeter
two
between
theresistance
isusedto measure
Theohmmeter
anddiagnooointsina circuitandalsoto checkforcontinuity
sis of shortcircuits.
Caution
. Do not attemptto connectthe ohmmeterto any circuit to which voltage is applied;this may burn or
otherwisedamagethe ohmmeter.
9MUGIX045
Gl-12
CAUTION
GI
PARTS
CAUTIONWITHELECTRICAL
Battery Cable
parts,
electrical
connectors
or replacing
Beforedisconnecting
cable.
the
negative
battery
disconnect
9MUGIX-022
connectors
Removalof connector
conNever pull on the wiringharnesswhen disconnecting
nectors.
9MUGIX.O23
9MUGIX.O24
9MUGIX-025
03uGtx,011
Connectorscan be removedby pressingor pullingthe lock
leveras shown.
Lockingof connector
makesureto listenfor a clickthat
Whenlockingconnectors,
locked.
theyaresecurely
willindicate
lnspection
orto measure
1. Whena testerisusedto checkforcontinuity
side.
insertthetesterprobefromthewireharness
voltage,
Gr-l3
GI
CAUTION
fromtheconconnectors
of waterproof
2. Checktheterminals
fromthewireharnectorside,astheycannotbe accessed
nessside.
Caution
. Use fine wire to prevent damageto the terminal.
. Do not damageihe terminal when inserting the
tester lead.
Terminals
lnsoection
putitigntly
wiresto checkthattheyaresecured
on individual
in the terminal.
9MUGIX.O27
ReDlacementof terminals
as shown'
toolsto removetheterminal
Us6theappropriate
it locks
insert
it
until
to
be sure
theterminal,
Wheninstailind
securery.
<Female)
lnserta thin pieceof metaiirom theterminalsideof the connector,andthen,withtheterminallockingtab presseddown,
pullthe terminal
outfromthe connector.
9MUGIX-028
<Male>
Sameas the temaletYPe.
Sensors,Switches,and RelaYs
and relayscarefully.Do not drop
Handlesensors,switches,
otherparts.
against
themor strikethem
Gt-l4
9MUGIX-O3O
GI
CAUTION
Fuse
Replacement
1. Whenreplacinga fuse,be sureto replaceit withone of
specifiedcapacity.
lf a fuseagainfailsafterit has beenreplaced,the circuit
probablyhas a short circuitand the wiringshouldbe
checked.
be2. Be surethe negativebatteryterminalis disconnected
fore replacinga mainfuse(80A).
9MUGIX.O31
M*m
fuse,usethefusepullersupplied
3. Whenreplacing
a pullout
in thefuseboxcover.
ffifi,.".
9MUGIX,O32
BR/Y
olAGtX-001
Wiring Harness
Wiring color codes
Two-color
wiresare indicatedby a two-colorcode symbol.
Thefirstcodeindicates
thebasecolorofthewireandthesecond the colorof the strioe.
CODE
COLOR
CODE
COLOF
B
Black
o
Orange
BR
Brown
P
Pink
LJ
Green
R
Red
GY
Gray
Violet
L
Blue
White
LB
LightBlue
LG
Light Green
Y
Yellow
Gl-15
A
!
PRE-DELIVERY
INSPECTION
AND
MAINTENANCE
SCHEDULED
SERVICES
A- 2
..........,..........
PRE-DEL|VERY
TNSPECTION
A- 2
PRE-DELIVERY
INSPECTION
TA81E..........
A- 3
MAINTENANCE
SERVICES.....
SCHEDULED
INSPECTION
PRE.DELIVEBY
INSPECTIONTABLE
PFE-DELIVERY
the tolowingilemslo
INSPECTandADJUST,I necessary,
! Glass€xterorbight melaland paintlor damage
. Wheellug nuls
ps ior darnageor detachrnenl
C Al weathelslf
ol bonnelreleaseand lock
! Operation
ol tiJnk id and fue lid open€r
D Operalion
(l equipped)
and ahgnmenl
tr Dooroperaiion
tr Headlghlaimlng
INSTALLlhe lo lowrngParls
! Wheelcapsor ngs(f equPPed)
! outsidemrro(s)
- Frontllap(il equrppeo)
OFF
UNDERBONNET.ENGINE
INSPECTand ADJUST. ir necessary.the lolowlng itemslo
! Fuel,coolantand hydraulc lines,ill ngs,connecnonsand
componentsior leaks
! Englneol evel
! Brake mastercylnder lluid evels
! ClutchmastercyLnderiluid levels(if equrpped)
- Windshiedwasher reservor lluid evel
! Radiatorcoolanl leveland speciic graviiy
tr Tlghtnessoi waler hose clamps
! Tghhessol balierylelminals,e ectrol,'leleveland specillc
graviry
I l l a n u a l l r a n s a x eo l e v e
! Dflv€ belt(s)tenson
tr Acceeratorcable and linkagelor iree movemeni
tl Headlght ceaner and lluld level(if equipped)
CLEAN lhe spark plugs
INSTALL the lo lowing parls
C Fubber slopperior nside rear vew mifror (ii equ pped)
tr Fuseior accessones
CHECKihe operationoi lhe lolowing tems
- Seatconlrols(slidng and reclning)and head rest
I Seal belts
I lgntion switchand steerng lock
! Power window(it equipp€d)
! Door locks includingchid prool door locks
! nhibitorswllch (ATXonly)
n A l l , g l L s T l u o , n g w a r 1 1 9a l d . n dL a l o rl g h t s
! lgfiton key rem nder buzzer(f equlpped)
A-2
! Headishtcleaner{il equipped)
! Horn,wipersand washer
tr Antenna
ii equipped)
tr cigarenelighterandclock(if equLpp€d)
tr Heaterand defrosteral variousmode seleclions
D Canvaslop (il equipped)
CHECKihe lolowng items:
! Presenceol sparetuse
finish
and interlor
! upholslery
lhe lollowingtems
CHECKandADJUST,il necessary,
tit
ol
windows
and
! Operallon
I Pedalheighland ireeplayol blakeandclutchpedal
I Parklngbrake
RUNNINGAT
UNDERBONNET-ENGINE
TEMPEBATUBE
OPEFATTNG
CHECKthe lollowingilems:
C Operaton ol idle_ups)€temior air cond toner or powerseer'
ing (it equ pped)
D Aulornalc transaxlelluid level
I lnitiallgnton tmrng
- ldle speed
! Operallonol ihroltlesensor
! Operatonof dashpot
CHECKlhetollowingtems.
! u ndersdelue, coolarlandhydralliclineslitlings'connec'
1orleaks
tons andcomponents
! Tireslor clts or bruises
syslem
andalrunder
exhausl
suspension,
D Sleeinginkage,
or oamage
lor looseness
sde hardware
ROADTEST
CHECKlhe followingenrs:
! Brakeoperalon
! Clulchoperauon
contro
! Steering
tr op€mtionol metersandgauges
raltesor unusuanoses
tr Squeaks,
! EnginegeneralPeriormance
ockingreiiaclors
! Emerge^cy
AFTERROADTEST
REMOVE the seat and lloor mat proled ve covers
CHECKfor the necessaryowner nformallonmaterias lools
and spare tire n vehicle
SERVICES
SCHEDULEDMAINTENANCE
SERVICES
MAINTENANCE
SCHEDULED
-\.\_{e!:Inc€
inrerval
llaintenance item------\
llonths
x 1000km
ilumber ot months or km. whlchever comcs lla3l
42 48 54 60 6€
1 2 1 8 24 30
42.5 so
{5
60 67.5
t.5
1 5 22.5 30
ENGINE
Enoinevalveclearance
Ex. manifoldbolls and nuls
I
T
T
T
Replacoevery105,000kilometels
T
Enoineliminq bell"
Dfive belts'"
I
R
Enoineoil'
Oil lille'"
R
R
R
R
B
R
R
B
B
B
R
R
R
R
R
COOLINGSYSTEM
I
Cooiingsystem
Enqinecoolanl(Withreservon)
R
F
R
R
B
R
FUELSYSTEM
Arrcleanerelemsnt"
R
R
I
R
I
IGNITIONSYSTEM
I
I
I
Initiallqnitionliminq
Sparkplugs
EMISSIONCONTROLSYSTET'
EVAPOFATIVE
EXHAUSTEMISSIONCONTROLSYSTEM
I
I
oashpot
SYSTEM
ELECTRICAL
level and sp€crllc qravfy
CHASSISAND BODY
I
I
Clulchpeda
Brake llnes. hoses and connections
B
Brakefl'rid"
I
I
llud and lines(ll oquippeo
Powersreenng
Sleerng oporalionand gear housing
rackqude and lie rodends
Steerina
linkaoes
I
Automatictransaxlefluid level
Frontsuspension
ballioir(s
Fronlwheelbearlnggreases
Driveshaftdust boots
8olls, nuls on chassis and body
Exhaugsystemheal shields
R
I
I
I
R
I
1
T
T
T
T
T
T
I
A-3
SERVICES
SCHEDULEDMAINTENANCE
Chart symbols:
of system'soperation(performance)
|: lsoecl : V|sua|exam|nalonoI iunclona|measurement
A: ,ljust
R: aedace or change
T: Tighten
L: Lubricate
Note:
. f!-the resuhot visual examinationol tunctlonalmeasurementol a system'soperation(perlolmance),correct, clgan or leplace as required'
Remarks:
itemsandintermaintenance
. After90,OOO
kmor 72 months,conllnueto followthedescribedscheduled
valsperiodically.
to the followingpollts - chart'pleasepay attention
. n"lJ-- maite'oitemsin this maintenance
ii' iiin" ".tri"i" i" op"ratedunderthsiollowing
thattheengineoilandoilfilter
it
is
suggested
conditions'
intervals'
recommended
OeCnangedmoie oftenthan at usual
a) Drivingin duslyconditions
Oi extenaeOperiodsof idlingor low speedoperation'
or drivingonlyshortdistanceregularly'
ij Oriuinglor'"prolongedplrrod in coldtemoerature
.2: ieolacerientof ihe timingbeltis Auned;t;very 1o5,oookm' Failureto replacetimingbeltmay
resultin damageto the engine.
replacemoreoften
's, ir-fr;u.hi"l! i;;p;rated in-verydustyor sandyareas,inspectand' if necessary'
intervals.
thanat usualrecommended
drive
'a, AJlustoiinip""t alternator
andwaGi pumpdrivebelt'andpowersteeringandair conditioner
beft,if equipped.
'5:
- Replaceeverytwo Years
or
iiiti"i! ta" o6en"ontinuousharddflving,mountaindrivrng,or it the brakesare usedextensively
annually'
be
changed
fluid
should
brake
the
huriid climates,
the vehicleis operatedin extremely
EmlsgionConirol and RelaledSystems:
controlandrelated
ottheemission
properoperation
impottanttothe
"i"temJ"* uitdrrv
t;Jl;
il;;;;"
as wellas tor etflcientengineoperations'
svste-ms,
""oi,?"*fl.
ift;;;'g[,"r;;;;JtnJ
A-4
bedonebvvourauthorized
svstems
tothese
reraed
dt se"rvicing
SERVICES
SCHEDULEDMAINTENANCE
ADJUSTIIENTOF ENGINEVALVECLEARANCE
Note
. Whenvalveclearanceinspectionand cylindefiead r
bolts retightening service are ai the same interval, E
I
tlEhtenthe cylinder head bolts tlrst.
temperature.
1. Warmup the engineto normaloperating
TDC
ofcompression,
piston
No.1
cylinderat
ofthe
2. Withthe
illustrated.
adjustthe valveclearances
ADJUSTING
SCFEW
LOCKNUT
valve clearance (at valve)
lntake : 0.30mm(0.012in)
Exhaust:0.30mm(0.012in)
onefull turnso thatthe pistonof the
3. Turnthe crankshaft
andadjusltheclearis
at
TDC
ol compression,
No.4cylinder
valves.
ancesof the remaining
INTAKEMANIFOLDBOLTSAND NUTS
TIGHTENING
Tighteningtorque:
19-25 N.m(1,9-2.6 m-kg, 14-19 ttlb)
EXHAUSTMANIFOLDNUTS
TIGHTENING
Tighteninglorque:
16-23 Nm (1.6-2.3 m-kg, 12-17 ftlb)
TIMINGBELT
REPLACEMENT
Manualfor the replaceReferto SectionI ot theWorkshop
mentprocedureof the timingbelt.
A-5
SERVICES
SCHEDULEDMAINTENANCE
ANDADJUSTI'ENTOF DRIVEBELTS
INSPECTION
aAlternalotand water pump drive bell' Powersteering
iump and alr condilionel compressordrive belt)
i cfieck the belttor cracksor any otherdamage.
il necessary.
2. Adiustor rePlace,
of about
3. Ch;ckthedrivebelttensionwiththumbpressure
points
each
arrow
lb)
at
(10
kg,
22
98 N
Belt detlection
Altemator drive belt
New belt : 5'5-7.0mm (0.21-0.27 in)
Usedbell: 6.0-7.5mm (0.23-0'29 in)
ALTEFINATOR
P/S
Air conditionerdrive belt (if eqipped)
New bell : 8-9mm (0.31-0.35 in)
Used belt: 9-l0mm (0.35-0.39 in)
COMPFESSOFI
Power steeringoil pumPdrive belt (if equipped)
Newbelt: 8-9mm (0.31-0'35in)
Usedbelt: 9-1omm (0.35-0.39 in)
)X \euuevi
j
,a'z
\
\\
CFANKSHAFT/
\
P U T L E Y|
1",^
|
\
A-6
-zcoMPREssoF
Air condltionel compressorand powel steedng oil
pump
drive belt (it equiPPed)
New belt : 8-9mm (0'31-0.35 in)
Usedbelt: 9-10mm (0.35-0.39 in)
SERVICES
SCHEDULEDMAINTENANCE
REPLACEMENT
OF ENGINEOIL
'l.Warmup theengine.
the drainplugand oilfillercap.
2. Drainthe oilby removing
Warning
. Walt a while fo. the engine is too hot,
And be caretulto drain.
3. Reinstall
the drainplugsecurely.
Tighteningtorque:
29-41 Nm (3.0-4.2 m-kg,22-30 ft-lb)
oiltothe"F" levelmarked
4. Refillthe
enginewiththespecified
on the levelgauge.
5. Refitthe oil iillercap securely.
Oil pan capacity:3.0liters (3.2 US qt, 2.6 lmp qt)
RecommendedSAE viscosily numbers
(.c) -30
eF)
-m
-10
0
v
5W.30
5w-rd->
10
20
30
40
50
'
30
:
Engineoil
10w-30
Typicalspecitication:API service SD, SE or SF
REPLACEMENT
OF ENGINEOIL FILTER
1. Removetheoil filterwiththe SST a suitablewrench.
2. lJsea cleanrag to wipeoff the mountingsudaceon the
engine.
3. Applya smallamountof cleanengineoilio therubberseal
ol the newfilter.
4. Installthe oilfilterandtightenit by handuntilthe rubber
sealcontactsthe base.
5. Tightenthe fllter1 and 1/6turnswitha filterwrench.
6. Startthe engineand checkfor leaks.
7. Checkthe oil levelandadd oil if necessary.
Oil filler capaclty
83: 0.17liter(0.18US ql, 0.15lmp qt)
A-7
SERVICES
MAINTENANCE
SCHEDULED
OF COOLINGSYSTEiI
INSPECTION
Warning
. Nevei removethe radialorcap while the engineis
hot.
. Wraoa thick cloth aroundlhe cap when removingit.
. Whdn removingthe radiatorcap, loosen it slowly
to the fitst stop until the pressurein the radialoris
released.and then removeit.
CoolantLevel (Enginecold)
1.Verifvthatthecoolanllevelis nearthe ladiatorf llel neck
is be'
2. Verilvthatlhe coolantlevelin the coolantreservior
tweenthe FULLand LOWmarks
3. Add coolantif necessary.
CoolantOuallty
1.Verffythattheieis no buildupof rustor scalearoundthe
radiatorcao or radiatorfillerneck
Verily
that coolantis free of oi! Replacethe coolantif
2.
necessarv,
CoolantLeakage
andthe
available)
tester(commercially
1. Connecta radiator
filler
neck.
radiator
SST to the
to the
2. Applyt03 kPa(1.05kg/cmz.15 psi) pressure
system.
3. Verifythatthe pressureis held.
It not,checkior coolanileakage
?_---z'- .- l,'1,/
'
CoolanlProtection
Caution
. Do not use alcohol-or methanol-basedcoolant'
water in the coolant
. Useonly soft (deminerallzed)
mixlure.
andspecificgravitywith
temperature
thecoolant
1. Measure
and a hydrometer'
a thermometer
to thegraph
by referring
thecoolantprotection
2. Determine
is notproper'addwaterorcoolant
lrthecoolantprotectaon
Antitreezesolution mixture percentage
Gravilyai
Above -16"C (3oF)
Above 26oC (-1soF)
Above-a0'C (-40"D
COOLANTIEMPEFATUFE'C (.F)
A-8
65
55
coolant 20"c (68"F)
1.054
35
55
1.078
SERVICES
SCHEDULEDMAINTENANCE
REPLACEi'ENTOF ENGINECOOLANT
Warning
. Neveropenthe radiatorcapwhilethe engineis hot.
. Wrapa thick cloth aroundthe cap whenloosening.
. Use caution when draininghqt coolanl.
E
THEDFAINHOSE
Caution
. Do nol use alcghol.or methanol-based
coolant.
. Useonly soft (demineralized)
water in the coolanl
mixture.
'1.Removethe radiatorcapand loosenthe drainplug.
2. Drainthe coolantintoa suitablecontarner.
3. Flushthecoolingsystemwithwateruntilalltracesof color
are gone;lhen letthe systemdraincompletely.
4. Installthe drainplug.
glycol
5. Fillwiththe properamountand mixtureof ethylene
to the tableabove.
basedcoolantby referring
Coolanlcapacity
MTX:5.0 liters (5.3 US qt, 4.4 lmp qt)
ATX: 6.0 liters (6.3 US qt, 5.3 lmp qt)
6. Runtheenginewiththeradiatorcapremoveduntiltheupper radiatorhoseis hot.
7. Withthe engineidling,add coolantto the radiatoruntilit
reachesthe bottomol the fillerneck.
8. Installthe radialorcap.
A-9
SERVICES
SCHEDULEDMAINTENANCE
OF IDLE SPEED
ADJUSTMENT
Preparalion
'1.Warmup the engineto normaloperatlngtemperaure.
2. Verityihatthe wat rod e)dendsoutwardiullyandthe idle
fromthe roller'
cam separates
3. Turnall electricloadsOFF.
. BlowerFan
. Headlight
. RearWindowDelroster
4. Makesurethatthe enginespeeddoesnotchangewnen
valve@ connector.
lhealr btpasssolenoid
disconnecting
Note
. lf lhe enginesPeeddecleases.the engineis still under the warm-upcondition'
waittillthefanslops
5. lftheelectficcoolingfan isoperating,
idle
in goodconditionat
is
running
engine
6. Verifythatthe
connector'
the
diagnosis
to
the
SST
7. Connect
lG- terconnector
io thediagnosis
8. Connecta tachometer
minalas shown.
L Sel switch6) to Position1.
10 SetTESTSW10SELF-TEST.
Note
. lf the SSTis not used, iump acrossthe TENtelmi'
nal and the GND telminal ot the diagnosiscon'
nector.
t-\*l
ldle Speed
1. Check the idle speed with a tachometer.
ldle speed:MTX(Neutral) 750 jT rpm
ATX(P range)|,100 :'t rpm
adjustthe idlebylurningthe
2. lf notwithinthe specifacalion,
throttleadjustingscrewOAS).
A-10
SCHEDULEDMAINTENANCE
SERVICES
REPLACEMENT
OF AIF CLEANEFELEMENT
Visually
checktheaircleaner
elementfor
excessive
dirt,dam,
age or oil, replacelf necessary.
REPLACEMENT
OF FUELFILTER
Warning
. Keepsparksand open flamesaway trom lhe tuel
area.
. After replacinglhe tuel filter, check ihat the filler
ioints are nol leaking.
To reolacethe fuelfilter,oroceedas follows:
1. Disconnect
the fuelhoses.
lheluelli/terwirhrhebrackel
2. Remove
3. lnstalla newfilterin the reverseorderol removal.
Note
. Wheninstallinglhe fillter makesurelhe hosesare
pushedgn as tal as possiblg.Securethe hoseswith
clips.
INSPECTION
OF FUELLINESANOHOSES
Checktheiuellinefittings,connections
andcomponents
for
|eaKs,
Thereshouldbe no wetness
or stalnedareasthatmiohtindicateleaksReplaceany detectivehosesor clips.
A-1 1
SERVICES
SCHEDULEDMAINTENANCE
OF IGNITIONTIMING
ATUUSTMENT
Preparation
1. Warmup the engineto normaloperatingtemperature.
2. Verilythatthewaxrod extendsoutwardfullyandthe idle
fromthe roller.
cam separates
3. Turnall electricloadsOFF.
. BlowerFan
. Headlight
. RearWindowDefroster
4. lvlakesurethatthe enginespeeddoesnotchangewhen
valve@ connector'
theairbypasssolenoid
disconnecting
Note
. I the enginespeeddecreases,the engineis still u]}
der the warm-upcondition.
ACHOMETEF
waittillthetanstops.
5. lf theelectriccoolingfanisoperating,
6. Verifythalthe engineis runningat idlein goodcondition.
connector.
7. Connectthe SSTto the diagnosis
8. Connecta timinglight.
connector
lG- ter'
to thediagnosis
9. Connecta tachometer
minalas shown.
.--
|N
re
IG-
_--\
GNO
10.Setswitch@ to Position1.
11.SetTESTSWto SELFTEST.
Note
. lf the SSTis not used,iump acrossthe TENlermi'
nal and the GNDterminal gl the diagnosiscon'
nector.
GND
.?-.:f-=\,('__',
\r:1.\
lgnition Timing
Inspeclion/ Adiustment
1. Checkthatthe idlespeedis withinthe specification.
ldle speed: MTX(Neutral) ?50 :l! rPm
ATX (P range)1,100 i'! rpm
2. Checkthe ignjtiontimingwitha timinglight
lgnition timing: BTDC16 + | "
/1.,"_(V
.:TS
r ,<--
loosen
3. lf the ignitiontimingis notwithinthe specification,
to
make
distributor
and
turn
the
lock
bolts
the distributor
the adiustmentlockboltsto the speciliedtorque.
4. Tiqhtenthe distributor
Tiohteninqtoloue:
ie-zsI{m (i.6-2.3 m-kg,12-16 ftlb)
lock bolt
5. Puta sealon the distributor
A-12
SCHEDULEDMAINTENANCE
SEFVICES
INSPECTION
OF SPARKPLUGS
'1.Checkthe plugstor burnedor erodedelectrodes,
fouling
or crackedporcelain.
gap.lf necessary,
2. lvleasure
theelectrode
adjustthegapto
specifications
or replacethe sparkplugs.
Pluggap: 1.0-l.1mm (0.039-0.043in)
(0.75-0.85mm10.029-0.033inl)
-Bl Carburetor
ENGINE
B1
B3
NGK
BPBsES,
BPBoES BKRsE.11,
BKN6E.]
]
W2OEXR.U
K16PR-U11,
K2OPR-IJ11
NIPPONDENSO W16EXF.U,
Cauiion
. when inslallinga newplug or reinstallingold plugs,
use a small amount of anti-seizecgmDoundor
Bolybdenum-bas€dlhread lubricar on the filst few
threads.
. Do not pull the spark plug cables lo remove them,
pull on the spark plug boots.
USECONNECTOR
A
INSPECTION
OF THROTTLESENSOR
1. Warmup the engineto normaloperalingtemperature.
2. Verifythatthewaxrodexpandsoutwardlullyandthecam
fromthe roller.
separates
3. Stopthe engineand turnthe ignitionswitchON.
SSTS(EngineSignalMonilorand Adapter
4. Connectthe
Harness)to the ECUas shown.
5. Setlhe SST (EnglneSignelMonitor)to terminal2M.
6. Rotate
the throttlelinkby handand verifythatthe voltage
is withinthe specification.
Speciticalion
ECUTerminal
2M
Throtle valvecondilion
0.41-062V
7. It nol as specilied,a4ust the throttlesensor.
A-13
SCHEDULEDI'AINTENANCESERVICES
OF DASHPOT
INSPECTION
Inapection
1. ODenthethrottlevalvelully.Pushthe dashpotrod witha
fingerandveritythatit goesintothe dashpotslowly.
2. Release
the rod and checkthat it comesout quickly
3. Replacethe dashpotif notas specified.
4. Warmup the engineand run it at idle.
to the diagnosisconnectorlG5. Connecta tachometer
enginespeed.
terminaland increase
the enginespeedandcheckthatthe le6. Slowlydecrease
ver touchesthe dashpotrod at the specifiedspeed.
Specitication:2,500 + 100 rpm
loosenthelocknutandturnthedashpot
7. if notasspecilied,
to adjust.
ADJUSTING
SCFEW
A-14
MAINTENANCE
SERVICES
SCHEDULED
SYSTEM
INSPECTION
OF EVAPORATIVE
temperature
and
1 Warmup theengineto normaloperatang
.un it at idle.
2. Disconnecl
the vacuumhosefromthe solenoidvalveas
showninthefigure,andveritythatnovacuumisfeltatthe
solenoidvalve.
checkthe solenoidvalve.
3. lf notas specified,
INSPECTION
OF BATTERY
level.
Checkthe electrolyte
Thelevelshould
be between
theupperandlowerlines.ll the
levelis low.add distilledwater.
Checkthe specificgravity.
Speciticgravity: 1.27-1.29
SYSTEM
INSPECTION
OF ALL ELECTRICAL
systems.
Checkthe all electrical
Tor wiringdiagrams
isfound,reierto Section
lf he mulfuncton
tor reparr.
A-15
SERVICES
MATNTENANCE
SCHEDULED
OF CLUTCHPEDAL
INSPECTION
'1.Checkthe pedallor smoothoperation
adjudthepedalheight
2. Checkthepedalheight.lf necessary'
theclutchswltch(q).
turning
and
locknut
by loosening
@
(4).
the
locknut
retighlen
adiustthe pedal
3. Ch;ck the pedalfree play.lf necessary,
free play.Referto H-4.
Pedalheiqht: 196-207mm (7.72-8.15 in)
PedalfreC play: 0.7-3.3mm (0.03-0.13 In)
height:
Diaenqagement
(1.61
mlnimum(With carPet)
in)
4lmm
OF BFAKELINES,HOSESAND
INSPECTION
CONNECTIONS
Checkthe pointsbelow,replacepartsif necessary.
1. Crackind,damageor corrosionol the brakehose
2. Damaoeto the brakehosethreads.
3. Scars.lracksor swellingof the flexiblehose.
4. All linesfor fluidleakage.
OF BRAKEFLUID
INSPECTION
the
bebetween
Thelevelshould
Checklluidlevelin reservoir.
reservoir.
lvax.and Min.lineson the
low,checkthe brakesystemfor
lf thefluidlevelis extremelv
€aKs.
A-16
SERVICES
MAINTENANCE
SCHEDULED
OF BRAKEFLUID
REPLACEMENT
AIR BLEEDING
by usinga suc1. Removethe brakefluidkom the reservoir
pump.
lon
withnewbrakefluid.
2. Fillthe reservoir
Fluid apecllication:FMVSS116: DOT-3
SAE: J1703
3. Attacha vinyltubetothebleederscrewandplacetheother end ol the vinyltubein a containel.
eachbleeder
4. Pumpout the old brakefluidby loosening
screw(oneby one)and pumpingthe brakepedal.
5. Bleedair as describedbelow.
Cautlon
. The tluid in the reservolr must be maintalnedal the
Z4 l€vel or higherdurlng air bleeding.
. Be caretul nol to spill brake lluid onto Painted
surtaces.
'1.Jackup the vehicleand supportit withsaletystands
2. Removelhe bleedercap and attacha vinylhoseto the
bleederplug.
3. Placethe otherendof the vinyltube in a container.
4. Slowlypumpthe brakepedalseveraltimes.
screw
loosenthe
bleeder
5. Whilethebrakepedalis pressed,
escape.
to letfluidand a'r
6. Repeatsteps4 and5 untilthereare no air bubblesin the
fluid.
7. Checkfor cotrectbrakeoperation.
Besureto
8. Checkto be surethatthereis no fluidleakage.
cleanawayany spilledfluidwithrags.
up
9. Afterbleedingthe air,add brakefluidto the reservoir
level.
sDeciiied
to the
OF PARKINGBRAKE
INSPECTION
1. Pullthebrakeleverwith98 N (10 kg, 22 lb) ol forceand
measurethe leverstroke.
adjustthe leverstrokeby turningtheadjust2. lf necessary,
Ingnut.
Stroke: 6-8 noiches
@ @
OF POWERBRAKEUNITAND HOSES
INSPECTION
for
andcheck-valve
1. Checkthe vacuumhose,connectors
etc.
cracks,chafing,deterioration
2. Withthe enginestopped,depressthe pedala fewtimes
startthe engine.
3. Withthe pedaldepressed,
aftertheenginestarts,thepedalmovesdown
4. lf, immediately
slightly,the unitis good.
ww
A-17
SCHEDULEDi'AINTENANCESERVICES
OF DISCBRAKE
INSPECTION
Checkthe lollowingdiscbrakecomponents.
and inspectfor leaks
1. Checkthe caliperoperation
lot
wear.
2. Checkthe Pads
ol the discplate
3 Checkthe conditionand thickness
Minimum:BrakePad2.0mm (0.08 in)
Dlsc plate thicknesa
l6.0mm (0.63in) ATX models
lomm (0.39in) MTXmod€ls
OF DRUMBBAKE
INSPECTION
'1. Checkthe wheelcylinderoperation
and inspecttor leaks.
2. Checkthe lin'ngsfor wearor damage
of the innersurfaceandthe innerdl3. Checkthe condition
ameterof the drum.
Limli:
l.omm (0.04in)
Brake1in1n9...........
lnnerdlamaterof drum'..'.,....l81.smm(7.15in)
ANDFRONTSUSPENSION
OFSTEERING
INSPECTION
play
free
1. Checkthe steeringwheel
Free play: 0-30mm (0-1.18 in)
andfor looseness
for properoperation
2. Checkthesteering
of the steeringhouslng.
3. Checkthe steeringgear housingfor lluid leakageor
seepage.
playonthetie rodendsandrackguide
4. Checktor exoessive
5. Checkfor damageol the dust boots.
ofthetierodends
or greaseleakage
6. Checklorlooseness
FLUIDAND LINES
OF POWERSTEERING
INSPECTION
(if equipped)
lor cracks,
i- Checkthe fluidhoses,linesand connections
etc.
chafing,deterioration,
2. Checkthe fluidlevelon the reservolr.
"F" and "L" level Add
Thelevelshouldbe betweenthe
fluidif necessary.
Fluld soecificalion:
ATF Dexronoll or M-m
A-18
SERVICES
SCHEDULEDMAINTENANCE
OF MANUALTRANSAXLEOIL
REPLACEi'ENT
lor oil leakage.
the
1.Visuallycheck manualtransaxle
lf leakagejs found,checkfor the cause,and repair.
cableand drivengear.
2. Removethe speedometer
3. Removethe drainplugand drainthe oil.
the drainplugsecurely.
4. Reinstall
Tlghteningtorque:
24-35 Nm (2.4-3.6 m-kg, 17-26 ftJb)
drivengear
oillromthespeedometer
5. Fillwiththespecified
drivengear.
hoieto the F markon the speedometer
Specilledoil
Grade:API serviceGL-4
ol M2C33F
Viscoslly:All-seasonDexron@tr
Above -l8cc (0"F) SAE 75W'80
Capacity:
2.5 litets (2.64US qt, 2.2 lmp qt)
TMNSAXLE FLUIDLEVEL
OFAUTOMATIC
INSPECTION
Caulion
. Placethe vehlcleon a flat, level surtace.
1. Applythe parkingbrakeand positionwheelchockssecurely
lo preventthe vehiclefrom rolling.
2. Warm-uplhe engineuntil the ATF .eaches60-70oC
(140-rs8oq.
HOTBANGE
the brakepedal,shiftthe selectorlever
3. Whiledepressing
(P-L)
and leaveit a iew secondsin each
to eachrange
range.
4. Shiftback to P.
Nole
. Only use the COOL (20oC) range as a rough
tetetence.
5. EnsurethattheATFlevelis intheHOT(65oC)range.Add
if necessary.
ATFto soecffication,
ATF type: oexron@tror M-Itr
Capacity:6.3 literc (6.7 US qt, 5'5 lmp qt)
GREASES
OF FRONTWHEELBEARING
BEPLACEMENT
lilltheshadedareashownin theligurewithlithi'
Completely
um grease.
Note
. Reler to page M-8 for disassembly/ assembly
procedure.
A-19
SERVICES
SCHEDULEDMAINTENANCE
INSPECTION
OF DRIVESHAFTDUSTBOOTS
Checkthe dustbooton the driveshaftfor cracks,damage,
greaseleakage,and a loosebootband.
TIGHTENING
OF BOLTSAND NUTSON CHASSISAND
BODY
'1.Tightenall seatmountingbolts.
body
2. Retighten
anyloosenutsandboftsonthechassisand
(Refer
TD.)
to
Section
torque.
to the specified
TNSPECTION
OF EXHAUSTSYSTEMHEATSHIELD
betweenthe insulatorand bodyandalso
the
clearance
Check
and the exhaustsystem.
betweenthe insulator
A-20
ENGINE
B-2
B-3
....
B-3
SPECTFTCATIONS
B-3
TROUBLESHOOTING
GUIDE..,........,
ENGINE
TUNE-UP
PROCEDURE
......,B - 5
PtrFPAHATI.)I\I
B-5
E N G T NOEr 1 . . . . . - . . . . .
B-5
B-5
ENGINECOOLANT
.
B-5
B-7
VALVECLEARANCE
IGNITION
TIIVIING,
IDLESPEED
......B - 8
coMPRESStON......
B-10
TNSPECTTON
..........
9-10
ON.VEHICLE
MAINTENANCE............
B-11
PREPARATION
B-l1
T||VltNG
8E1T.........
B-12
HEADGASKET.....,.......
B-17
CYLINDEH
FRON'T
OILSEAL....
B-21
trFAA AII qFAI
B-23
REMOVAL
.............
8-26
8-26
ENGINE
STANOMOUNTING.............
B-33
PREPARATION
B-33
B-34
DrsAssEMBLY.......
B-36
PREPARAIION
.......
B-36
AUX|LIARY
PARTS........................
a-37
TIMING
8E1T.........
B-38
...-.-.
c Y L t N D EH
RE A D . . . . . . . . . . . . . . . . . . .B-40
BLOCK
CYLINDER
(EXTERNAL
PARTS).....................
B'42
BLOCK
CYLINDER
{tNTERNAL
PARTS)......................
B-45
tNDEX.............,.....
ourLrNE...............
e-48
tNSPECT|ON
/ REPA|R.....................
pREpARATtON
......,...................,..
B-48
HEAD..........................
B-48
cYLtNDER
g-49
.....................
VALVEtVIECHANtSM
B-52
cAt\,4sHAFT..................................
81OCK........................
B-54
cYLtNDEB
PISTON,
PISTON
RING,AND
8-56
PtsToNPrN................................
ROD.......................
B-57
coNNECT|NG
B-s8
CRANKSHAFT
..............................
B-58
BEARlNG.........-.-.........................
B-59
TTMtNG
8E1T......,........................
rDLER.......................
B-sg
TENSTONER,
B-sg
TENSTONEB
SPRrNG.....................
pu11EY.................-..-..-...............
B-59
8-60
ASSEI'BLY.....................................
pREPARATTON
8-60
..........,..................
BLOCK
CYLINDER
8-61
flNTERNAL
PARTS)......................
CYLINDEH
BLOCK
(EXTERNAL
PARTS)........-............
8-67
HEAD..........................
B-72
cYLtNDER
TIMING
8 E 1 T . . . . , . . . . . . . . . . . . . . . . . .9. .-.7. .6. . .
B-79
AUXtLtARY
PARTS........................
B-82
ENGINE
STANDDISMOUNTING........
pRocEDURE
B-42
...............................
B-84
rNST4LLAT|ON...............................
pRocEDURE...............................
B-84
01a08x.001
INDEX
INDEX
INTAKEMANIFOLO
19-25 rktr (1,$-2,6 n-*t, la-19ll-rb)
lN: 0.3omm(0.012in)
E* 0.30mm(0.012in)
/ ADJUSTMENT
INSPECTION
ENGINE @OIAMI,
SEFIVICE SECTION E
ENGINEOIL
FIEPLACEMENT,
INSPECTION
D
SECTION
EXHAUSTMANIFOLD
rr-23
DEFLECTION AT {98 N, 10 kg, 22 lb)
5.0-7-0 (o.1
l&n {r.9-2.3 f-*9,
MPRESSIONINSPECTIONPAGE B-12
6.0-7.5 {0.23-0.29}
1412(14.4,2O4l30O
5. Engine
1.Timingbelt
page
R e m o v a | . . . . . . . . . . . . . . . . . . . . .p. .a. g
. .e.P. . -26
........
B-1
2
/ Insta||ation..................
Removal
page
B-33
..............
mounung
Engine
stand
gasket
head
2. Cylinder
D i s a s s e m b | y . . . . . . . . . . . . . . . .p.a. .g. .eB-36
..........
. .e.B. .-.1.7
B e p | a c e m .e.n. .t. . . . . . . . . . . . . . . .p. .a. g
page8,48
/ F]epair................-.....
InspecUon
3. Frontoil seal
A s s e m b | y . . . . . . . . . . . . . . . . . . . .p. -a-g. .e.B-60
..........
R e p l a c e m e n t . . . . . . . . . . . . . . -p
. .a. .g. .eB
. . .2. .1. . . .
page8,82
.........
Enginestanddismounting
4- Rearoil seal
1 n s t a | I a t i o n . . . . . . . . . . . . . . . . .p. a. .g. .e.8. .8. .4. . . . . . . .
R e p l a c e m e n t . . . . . . . . . . - . . . .p
. .a. .g. .eB
. . -. 2
. .3. . . .
B-2
B
GUIDE
OUTLINE.TROUBLESHOOTING
OUTLINE
SPECIFICATIONS
Engine
Item
a3
and number
Cylinderanangement
chamber
Combusrion
OHC, belt-driven16 va ves
Displacemenl
cc (c'r in)
Boreandstroke
mm (in)
1323(80.7)
71.0x83.6(2.80x3.29)
9.4
pressure
Compression
IN
kPa(kg/cm'.psi)'rpm
Open
BTDC
ABDC
EX
Vaiv€clearance
ldle sp€ed
mm (in)
Open
Close
N
BBDC
ATDC
1373(14.4,199)300
404
0.30(0.012)
0.30(0.012)
EX
[/TX
rpm
ATX
750ri
1100r"3
lgnitiontiming
BTDC
16
1-3-4-2
TBOUBLESHOOTING
GUIDE
Posslble Cause
Difiiculi startlng
eemedy
Page
Mallunction ol enginerelaied componenls
B-49
8,54,56
B-17
Wom piston,pislon ring or cylinder
Faled cylinderhead gasket
Mallunclion ol tuol system
Mallunclion ol igrltion system
Pooridling
Referro SectionG
uallunclion of engine-rslated components
Poorvalvelo-valveseatconlact
Failedcylinderheadgasket
B-49
B-17
Maltunction ol tuel system
Mallunctlonol ign[ion system
Reler to Section G
Oil workingup
Wornpjstonringgrooveor stickingpiston ng
Wornpisionor cylinder
856
B 54,56
Oil workingdown
8-61,72
B-50
Wornvalvestemor guide
Oll leakage
Reterio SectionD
B-3
B
GUIDE
TROUBLESHOOTING
Remedy
Insulticient compaession
Compressonleakagelrom valve seat
B-51
B -49
B-52
B-17
B-48
B-56
B-56
Weak or broken valvespfing
Faiiedcylinderhead gasket
Crackedor d'slorredcylinderheao
Sticking damaged,or wom plslon Ing
Crackedor wofi pislon
Mallunction ot luel system
Mallunction ot ignition system
Ps9e
G
Relerlo Secnon
Othera
Slippingclutch
Draggng brakes
lklfunction of enginerelaled components
Siickingor burnedvalve
weak or brokenvalvespnng
ln combustion
chamb€r
Carbonaccumulalon
B-49
B-52
itallunclion ol tuel system
lraltunctionof lgnllionsystem
Enginsnois€
Crsnkshaft- or bearing-rolated p.tls
Excessivernainbearingoil clearance
Main bearingseizedor healdamag€d
Excessivecrankshaitend Dlav
Excessiveconnectingrod bearingoii clearance
Connectingrod bearingseizedor heat_damaged
B-64
B-58
B-65
B-65
B-58
PBton-related parls
855
856
856
856
Wompistonor pislonPn
Damagedp stonrrng
valves or timing-related Parls
Brokenvalvesping
Excessvevalvegude clearance
Malfunctlonof coolingsystem
B-52
B -49
Reforto Secton E
llralluncllon of tuel sFtem
others
lvlaLfunction
ol waterpumpbearing
lmproperdrivebeLltenslon
Malfunction
oi aternalorbeanng
Exhaustgasleakage
N,4afunction
oi I mingbelitensioner
B-4
Befer to seci on E
Relerlo SectionG
B-13
ENGINETUNE-UPPROCEDURE
ENGINETUNE.UPPROCEDURE
PBEPARATION
ssr
49 8019 9A0
49 9200 020
Tensiongauge,
ignilionliming
ENGINEOIL
Inspection
1. Be surethe vehicleis on levelground.
temperature
2. Warmup theenginetonormaloperating
and
stop rI.
3. Waitfor fiveminutes.
condition.
theoildipstick
andchecktheoilleveland
4. Remove
5. Add or replaceoil if necessary.
Note
. The dislancebelweenthe Land F markson lhe dip.
stick repressnts0.8 liter (0.85US qt, 0.70lmp qt).
ENGINECOOLANT
Inspectign
Coolantlevel (englnecold)
Warning
. Neverremovethe radiatorcap whlle the engineis
hot.
. Wlapa thlckclotharoundthe capwhenremovingil.
1. Verilythatthecoolantlevelis nearthe radiatorfillerneck.
is be'
2. Checkthatthecoolantlevelin thecoolantreservoir
tweenthe FULLand LOWmarks.
3. Add coolanlil necessary.
Coolanlquality
1. Verifythatthereis no buildupoi rustor scalearoundthe
radiatorcap or radiatorfillerneck.
2. Verifythatthe coolantis freeof oil.
3. Fleplace
the coolanlii necessary.
V.RIBEED
6ELT
MtwJtM
o
x
x
ORIVEBELT
Inspection
Replace
1. Checkthedrivebeltsforwear,cracks,andfraying.
if necessary.
2. Veritythatthe drivebeltsare correctlymountedon the
puleys.
B-5
ENGINETUNE-UPPROCEDURE
!.t-q/lotL
2",.r
puMp
\
Y/
\ cutteY
" fi.i .sp,an'//
presby applyingmoderate
3. Checkthedrivebeltdeflection
the pulleys,
as
sure(98 N, l0 kg, 22 lb) midwaybetween
shown.Adjustil necessary.
Dellection
Drive bet
l,.PULrEV
P/S, P/S + A/C
ALTERNATOF
pJc
\,
'.-agy'
PULLEY CO
50 70
(019 0.27)
80 9.0
(0.31-035)
80-90
(0.31-035)
6.0-7.5
(o.23-O.29)
9.0-100
(0.35-0.39)
9.0-10.0
(0.3s 0.39)
- P/s\
r^A ,/orr pui,rp
Y \"ut""\
'-- '/
CAANKSHAFI /.A/C\
trnn( n/
.4.'
CFANKSHAFT/
\\
\
" y . . .J" \ " " J
withtheSST(tensiongauge).
4. Checkthedrivebelttension
Note
. Belt tension can be measuredbetweenany two
pulleys,
Tension
N (kg,rb)
Drive bell
451-785
(46 80. 101-176)
392 588
(40-60, 88 132)
P/S, PiS + A/C
491 589
(50-60, 110 132)
422-491
(43-50,95-110)
A/C
491-589
(50-60, 1r0-132)
422-491
(43 50,95-110)
5. lnstallthe alr intakePiPe.
Adiusiment
Caution
. It a new bett is used, adiusi the bell dellectionat
the midpointot new belt specification.
Alternator
belt
mountingbolts@and
loosenthe alternator
1. lf necessary,
.
bolt
adruslrno G)
z Leverth-ealternitoroutwaldandapplytensionlo thebeh
Tighteninglorque
i& : 37-51 N.m(3.8-5.3 m-kg, 27-38 ft-lb)
\t: 18-25 N.m(l'9-2'6 m-kg,13-18 ft'lb)
3. Becheckthe belttensionor deflection.
P/Sbelt.P/S + tuC belt
It necessary,
loosenthe P/Soil pumpmounting@, @ and
bolt
by tutningtheadjusting
adjust
thebeltdeflection
and
O
@)
Tighleningtorque
@: 19-25 Nfl (1.9-2.6 m-kg' l4-19 ft-lb)
!E,: 36-54 Nm (3.7-5.5 m'kg' 27-40 ft-lb)
G : 36-54 N.m(3.7-5'5 m-kg, 27-40 flnb)
B-6
ENGINETUNE-UPPROCEDURE
AJCbelt
lf necessary,
loosenthelocknut@ andadjustthe beltdeflection by turningthe adjustingbolt@.
Tlghleningtorque:
37-51 Ntn (3.8-5.3 m-kg, 27-38 fl-lb)
:i\\
a.\.\
VALVECLEARANCE
Inspecilon/ Adiustment
1. Warmup the engineto normaloperatingtemperature.
2. Removethe air cleaner.
cable3. Removethe accelerator
4. Removethe cylinderheadcover.
andalignthetimingmarksothatthe
5. Turnthe crankshaft
piston
isatTDCofcompressionoftheNo.1or No.4cylinder
6. Measure
thevalveclearances
O withtheNo.'lcylinderat
TDCof compression,
andthoseof @ withthe No.4cylinder at TDCof compression.
Valveclearanae(valveslde)
lN : 0.30mm(0.012in)
EX: 0.30mm(0.012in)
adjustand recheckthevalve
7. lf il is not withinspecification,
clearance.
B. Turnthe crankshaftone fLrllturn and measurethe remaining valve clearances.Adiust if necessary.
9. Installthe cylinderheadcover.
Tighteninglorque
Bolt @: 4.9-9.8 Nm (50-90 cm-lq, 43-78 In-lb)
Bolt @r 7.8-11 Nm (80-110 cm-l€, 69-95 inlb)
Caution
. It the headcover gasketis reused,applysealantin
the grooveas shown.
cable.
10.lnstallthe accelerator
'11.lnstallthe air cleaner.
tappetnoise.
12.Startthe engineand checkfor excessive
B-7
ENGINETUNE-UPPROCEDURE
IGNITIONTIMING,IDLESPEED
Prsparalion
1.Warmup the engineto normaloperatingtemperature
2. Veritythatthe waxrod extendsoutwardfullyandthe idle
fromthe roller'
cam separates
3. Turnall electricloadsOFF.
. BlowerFan
. Headlight
. RearWindowDefroster
thatthe enginespeeddoesnotchangewhen
4. MakesLrre
valve@ connector'
theairbypasssolenoid
disconnecting
waittillthelanstops
5. ll theeleckiccoolingfanis operating,
6. Verifythatthe engineis runningat idlein goodcondition
connector'
7. Connectthe ssT to the diagnosis
8. Connecta tlminglight.
9. Connecta tachoheterto the diagnosisconnectorlG- terminalas shown.
Note
. ll the engine speeddecreases,ths englne la atlll under the warm-upcondition.
'10.Setswitch to position1.
@
1'1.SetTESTSWto SELF-TEST.
Note
. It the SSTis not used,iump acrossthe TENterminal and the GND ierminal ol the diagnoalsconnedor.
lgnition Timing
Inspection/ Adius|ment
1.Checklhat tne idlespeedis wiihrnthe specification
ldle speed: MTX(Neutral) 750 i:! rym
ATx (P range)I,100 :1 rpm
2. Checkthe ignitiontimingwitha timinglight
lgnitiontiming:BTDC16 + l"
loosen
3. lt the ionitiontr|ninois not withinthe specilication.
to make
the disiflbutorlocLbohsand lurn the distributor
the adiustment.
torque
lockboftsto the specified
4. Tighte;the distributor
A)
B-8
Tiohteninqtorque:
is-zs-Nm (i.9-2.6 m-ks, 14-19 ftlb)
lockbolt.
5. Puta sealon the distributor
ENGINETUNE-UPPROCEDUFE
ldle Speed
'1.Perform"Preparaljon"(Referto pageB-8.)
2. Checkthe idlespeedwitha tachometer.
ldle speed:MTx (Neutral) 750 it rpm
ATX (P range)1,100:1 rpm
oree
^os'6"o"G66alj
adjusttheidlebyturningthethrottle
3. lf notwithinspecification,
adjustingscrew.
B-9
COMPRESSION
COMPRESSION
ll rhe enoineexnibitslow power.poorluel economyor poor ldle checkthe lollowing:
1. lgnrtro;system(Belerto SectronG.)
2. Compressron
3. Fuelsvstem(Feferto SectionF.)
INSPECTION
it if neces1. VerifvthatthebatteryistullychargedRecharge
sarv.(Referto SectionG.)
2. Warmup the engineto normaloperatinglemperature'
3. Turnthe engineOFF.
4. Bemoveall sparkplugs.
the ignitioncoilconnector'
5. Disconnect
gaugetotheNo l sparkplughole
acompression
6. Connect
pedalandcrankthe engine'
lhe
acceleiator
depress
7. Fr.rlly
gaugereaolng
8. Recordthe maxrmum
9. Checkeachcylinder.
Compression
Siandard
kPa(kg/cm',psilrpm
B3
14121t4.4,2O4!3OO
103000.5, 149)-300
't96 (2.O,26)
s rcw'poura
in oneor morecyllnders
10.lf thecompression
smallamountof engineoil intothe cylinderand recheck
the compressrcn.
the piston,pistonrings'
(1) lt thecompression
increases,
worn
mav
be
wall
or cvlinder
(2) lf the compression
stayslow,the valvemaybe stuck
or seatingimProperly.
stayslow,the
in adjacentcylinders
{3)
' ' lt thecomoression
or
cvlinderheadgaskelmaybe delective the cylinder
head distorted.
11. Connectthe ignitioncoil connector.
lubricant
or molybdenum-based
compound
12.Applyantiseize
threads.
the
spark
to
Plug
sparkPlugs.
13.Insiallthe
Tidhleninotoroue:
is-zsi{.m (i.5-2.3 m'ks' 11-17 finb)
B-10
ON-VEHICLEMAINTENANCE
MAINTENANCE
ON-VEHICLE
PREPARATION
ssT
49 G0175A0
4 9 D 0 1 11 0 2
Enginesuppod
inslallationof
timing belt puley
49 E301060
49 E301061
Brake,ringgear
Sody
(Panof
49 E301060)
49 E301062
43 SE01310
Collar
(Partof
49 E301060)
Centeinglool,
installationot
B-11
ON.VEHICLEil|AINTENANCE
TIMINGBELT
/ lnstallalign
Femoval
'1.Drsconnect
the negativebatterycable.
2. Lilt up the vehicle.
3. Removein the ordershownin the figure,referringto RemovalNole.
4. Installin the reverseorderof removal,relerringto InstallalionNote
1r-25 O,r-2.6, 1a-19)
7€-rr
rlo (30-110 .eks,
6e-e5 In{b)
p0-rr0 *rs, ca-esr.-rb)
12-17 (1,2s-1.75,r09-rs2)
1s6-r65 05-17, 115-122)
L Timingbeltcover,upper
1.Splash
shield
L Timingbeltcover,lower
2. P/Sand/orA,/Cdrivebelt
leads
10.
p
a
g
e
I n s p € c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-tensron
plugs
11.
Spark
drivebelt
3- Alternator
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. -e.B. .-. .5. . . . .12.
. Timingbelt
. .e.B. - 1 4
R e m o vN
a ol t e . . . .......... . . . . . . . . .p. .a. g
A d j u s t m e n t . . . . . . . . . . . . . . . . . .p. .a. g
. .e.8. .,. .6. . . . .
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .' 1. .4. . . . . .
4. Waterpump pulley
pageB-14
-.....................
Note....
Installalion
5. Plate
'13.Tensioner
p
a
g
e
RemovN
a lo t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pageB - 1 6
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .- .1. 4. . . . . .
Note..........................
Installation
pageB-15
Note..........................
Installation
Pulley
lock
bolt
6.
spring
RemovN
a lo t e . . . . . . . . . . . . . . . . . .p.a. .g. .e8
. .,.1. .3. 14.Tensioner
pageB 1 5
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .e.B. .- .1. 4. . . . . .
-...............-.
Note........
lnstallation
pageB-'15
Note..........................
Installation
pulleyand pulleyboss
7. Crankshatt
B-12
MAINTENANCE
ON-VEHICLE
Removalnote
Plate
mountingbolts.
1. Removelhe rightstabilizer
2. Suspendthe enginewiththe SST.
3 RemovetheenginemounlNo.3mountingboltsandturn
overthe enginemountNo.3.
4 Lowertheengineapproximately
50mm(1.97In)gradually.
i.- i\\ z
5. Removethe platemountingbolts,and thenthe plate.
Pulley lock bolt
1. Holdthe oullevbosswiththe SST.
2. Usingthe SST,loosenthe pulleylock bolt.
3. Removethe pulleylockboltand pulley.
B-13
ON-VEHICLEiIAINTENANCE
Tlming belt
i. lnstiiltneouttevtoct bollandturnthecrankshaft(thepin
on the oullevbossiacesup-right)
Caution
. Do not turn the crankshaftwhile removingthe pul'
ley lock bolt.
2. Removethe timingbelt.
Note
. Ma* the liming belt rotallon lor proper leinslallatlon.
PEELIN6
lnsoeclion
to pageB 69, inspectthe lollowingparts:
Refb.ring
1.Timingbelt
2. Timingbelttengonerand spnng
3. Timingbeltpulley
4. Camshaft
PLrlleY
lnslallationnole
Tensioner,tensionersP.ing
and the tensionerspring
1. lnstallthe tensioner
withthe springfullyexsecllrethe tensioner
2. Temoorarilv
tenoeo.
Timinq belt
1.Verii lhalthelrmingbellpulleymarkls alQnedwiththetimIng marK.
B-14
ON.VEHICLEMAINTENANCE
2. Installthe timingbeltso thatthereis no looseness
at the
tensionside.
Caution
. Do not tum the crankahaftcounterqlockwbe.
3. Installthe pulleybossand pulleylockbolt.
two turnsclockwise,
andfacethe pin
4. Turnthe crankshaft
pulley
on the
bossuPright.
5. Verifythatthecamshaftpulleymarksare alignedwiththe
cylinderheadcovermarks.
lf notaligned,removethetimingbeltand repeatfromten'
sionerinstallation.
6. Loosenlhetensioner
lockboltto applytensionto thetiming belt.
Caution
. Be sure not to applytensionother than that of the
ienslonerspring.
lookbolt.
7. Tightenthe tensioner
Tighleningtorque:
19-25 N.m(1.9-2,6 m-kg, 14-19 ft-lb)
9aN
(10 kg, 22 lb)
8. Turnthe crankshaft
2 turnsclockwiseand verifythatthe
marksare correctlyaligned.
pree
by applying
moderate
9. Checkthetiming
beltdeflection
thecrankshaft
sure(98 N, l0 kg, 22 lb) midwaybetween
pulleyandthe camshaftpulley.
ll the timingbeltdellection
is notcorrect,temporarily
se
lockboltsothespringis fullyextended
and
curetensioner
spring.
repeatsteps4-8 aboveor replacethe tensioner
Deflection:
11.0-13.0mm(0.43-0.st In) at 98 N (10kg, 22 lb)
pulleylockboftandpulleybossusingtheSST.
10.Removethe
Pulley lock bolt
pulleyand tightenthe pulleylockboll
lnstallthe crankshaft
usingthe SST.
Tighteningtorque:
157-167 N.m(16-17 m-kg,116-123 lt-lb)
B-15
ON.VEHICLEMAINTENANCE
Plate
1. Installthe plate.
Tlghteninglorque:
iz-tz Nrn (1.25-1.7s m-kE,109-152 in'lb)
2. Littthe engineand installthe enginemountNo3.
Tiohtenino
torque:
-ss-r
li H.. (g.s-t1.9 m-kg,8.2-10.3in-lb)
@
3. lnstallthe stabilizer.
Tiohteninqlorque:
!l-sz itm (5.s-5.9 m-ks, 4.7-5.9 innb)
Steps After Installation
1. Lowerthe vehicle.
2. Connectthe negativebatterycable.
3. Startthe engineand checkas follows:
. lgnitiontiming(Referto pageB-8.)
B-16
MAINTENANCE
ON-VEHICLE
CYLINDERHEADGASKET
Replacement
Caulion
. Positionlhe hose clamp in the orlginal locationon the hose, and squeezethe clamp lighlly
with large pliers to ensure a good fit.
1. Disconnect
the negativebatterycable.
2. Drainthe englnecoolantintoa container.
3. Removein the ordershownin the figure,referringlo RemovalNote.
4. Installin the reverseorderof removal,referringto InstallationNole.
(30-110 orl(gi 3r-95 h.tb)
firs-11o cn-&, 6s-95 in.lb)
FEPLACE
r9-2s11.e-2.6,r4-r9)
1. Air cleanerassembly
cable
2. Accelerator
page B-20
Installation
Note........-.....
-...........
3. Throttlecable
4. Hoses
page B-18
Flemoval
/ Installation
Note.--......
5. Harnesses
page B-19
Flemoval
/ lnstallation
Note.........
6. Waierbypasspipe nutsand bolts
7. Alternator
drivebelt
8. Waterpumppulley
9. Timingbeltcover,upper
10.Timingbell
pageB 12
Removal
/ Insta||ation..................
pipe
11.Frontexhaust
12.lntakemaniioldstay
13.Cylinderheadcover
14.Cylinderheadbolt
RemovN
a lo t e . . . . . . . . . . . . . . . . .p. .a. g
. .e.B. . .1. .9.
pageB 20
Note..........................
lnstallation
15.Cylinder
head
pageB-40
Disassembly
...............................
1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.B. .-.4. .8. . . . . .
A s s e m b 1 y . . . . . . . . . . . . . . . . . . .p. .a. g
. .e.B. .-.7. .2. . . . . .
16.Cylinderheadgasket
B-17
ON.VEHICLEMAINTENANCE
Removal/ Installationngte
Hoses
the hosesshownin the figure.
Disconnect
'1.Brakevacuumhose
2. Fuelhose
B-18
valve)
3. Vacuumhose(solenoid
4. Heaterhose
MAINTENANCE
ON-VEHICLE
Hatnesses
the harnessconnectorsshownin the figure.
Disconnect
01EOBr162
Cylinderhead bolt
1. Loosenthecylinderheadbol{sintwoor threestepsinthe
ordershownin the figure.
2. Removethe cylinderheadbolts.
B-19
MAINTENANCE
ON-VEHICLE
lnstallationnote
Cvlinderhead bolt
1. Applycleanengineoilto the boltthreadsand seatfaces
2. Installthe cylinderheadbolts.
3. Tightenthecylinderheadboltsin twoor threestepsinthe
ordershownin thefigure.
Tiohtenlnq
toroue:
-N.n
is-gr
1z.z-a.l m-rg, s6-60 ft-lb)
Acceleralorcable
cable.
1. Installthe accelerator
cabledeflectior
2. Checkthe accelerator
is not correct,adjustby turningnut @.
lf the deflection
Delleciion:1-3mm (0,04-0'12 in)
Steps alter installation
1. Fillthe radiatorwiththe specifiedamountand typeof enginecoolant(Referto SectionE.)
2. Conneclthe negativebatterycable.
3. Startthe engineand checkas tollows:
(1) Engineoil and enginecoolantleakage
(2) lgnitiontiming,idle speed(Referto pageB-8.)
(3) Operation
of emissioncontrolsystem
4. Recheckthe enginecoolantlevel.
B-20
ON.VEHICLEMAINTENANCE
FRONTOIL SEAL
Replacement
1.Disconnect
the negalivebaherycable.
2. Removein the ordershownin the figlre, retefiingto RemovalNole.
3. lnstallin the reverseorderof removal.referrinoto lnstallationNole.
I ../
-
---'r@\!
(a
l-.i
43)
€., $
aieurce
-na
Io
1.Timingbelt
pageB-12
Removal/ Inslallation..................
2. Timing belt pulley
page B-22
lnstallation
Note..........................
3. Oil seal
RemovalNote...........-...-.....................
pageB-22
................
lnstallation
Note..........
Removalnote
Oil seal
1. Cutthe oil seallip witha razorknife.
protecled
wilha rag.
2. Remove
theoilsealwilha screwdriver
B-21
ON.VEHICLEIAINTENANCE
lnslallationnote
Oil
seal
'1.Apply
of cleanengineoiltothelapol a new
a smallamount
oil seal.
2. Pushthe oil sealslightlyin by hand.
Cautlon
. The oilseal must be tapPedin until it is flush with
the edge ot the oil PumPbody'
pipeanda hammer'
3. Taptheoilsealinevenlywitha suitable
Oil seal outer dlametet:50.5mm(1.98 in)
Timing belt pulley
1. lnstallthetimingbeltpulley.
pulleyWoodruff
keywiththetaperedsidetoward
2. lnstallthe
pump
the oil
body.
\
ALIGN KEY GFIOOVE
B-22
ON.VEHICLEi,|AINTENANCE
REAFOIL SEAL
Beplacement
1.Disconnect
the negativebatterycable.
2. Removein the ordershownin the ligure,referringto RemovalNote.
3. Installin the reverseorderot removal,referringto lnstallationNote.
@E
gs
; a\&h
ffi
(MTX)
1.Transaxle
3. Flywheel
R
e
m
o
vN
a lo t e . . . . . . . . . . . . . . . . . . . . - - b. .e. .l .o. w
........MTX
i oont e . . . . . . . . . . . . . . . p
S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . . .S
. .e. .c. t. i.o.J.n. . . . . . . . . l n s t a l l a t N
. .a. .g. .eB
. . -. 2
. .4
ATX
4. Driveplare(ATX)
pageB-24
-........................
Removal
Note....
S e r v i c e . . . . . . . . .............- . . . . . . . . .S. .e. .c.t.i.oKn
pageB 25
2. Clutchcover,clutchdisc (MTX)
Installation
Note...-......................
S e r v i c e . - . . . . . . - . - . . - . . . . . . . . - . . . - - . . . . . . . . . . 5. -..O
. Si les cetai ol n H
pageB-24
................
Removal
Note.............
pageB 24
Installation
Note......-...................
Removalnote
Flywheel(MTx)
Caution
. Add approx13mm(0,51In)ol spacers(@) to space
the SST away lrom the cylinder block, (MTX)
1. Holdthe flywheelwiththe SST.
2. Removethe flywheelbolts.
3. Removethe flywheel.
B-23
ON.VEHICLEMAINTENANCE
Diive plate (ATX)
1. Holdthe driveplatewiththe SST.
2. Removethe driveplatelockbolts.
3. Removethe backingplate,driveplate,and adapter
Oil
seal
'1.Cut
the oil seallip witha razorknife
2. Removethe oilsealwitha screwdtiverprotectedwitha rag.
OIL SEAL LIP
1h}'.
w
_
lnstallationnote
Oll aeal
of cleanengineoiltothelip ota new
1. Applya smallamount
oil seal2. Pushthe oil sealslightlyin by hand
Caution
. The oil seal must be tappedin until it is llush wllh
the edEeof the rear qover.
ffi'rl
)
pipeanda hammer.
3. Taptheoilsealinevenlywithasuitable
Oil seal oute, dlameter:100mm(3'94 in)
@
H
EM
Flvwheel(MTxl
s;ahntftomthellwheelbohholesinthecrank1. Femoveihe
the llywheelbolts.
and
lrom
shatt
Caution
. ll all the previoussealantcannotbe removedtrom
a bolt, replacethe bolt'
. Do not apPlysealantIt a new bolt is used.
2. Setthe flywheelontothe crankshaft.
3. Applysealantto the flywheelboltsand installthem.
Caulion
. Add aporox13mm(0.51in) ot space6 (O) to space
the SSi away from the cylinder block. (MTX)
4. Holdthe llvwheelwnhthe SST
5. Trohtenthe bohsin twoor lhreestepsIn lheordershown
inlhe figure.
Tiohteninq
-ge-lOg=lorquei
1.lm ig.g-ro.s m-kg,7l-76 filb)
B-24
ON.VEHICLEMAINTENANCE
Drive plate (ATX)
fromthe driveplateboltholesin the
1. Removethe sealant
andfromthe driveplatebolts.
crankshaft
Caulion
. It all the prevloussealantcannotbe removedtrom
a bolt, replacelhe bolt.
. Do not apply new sealantif a new bolt is used.
@s
2. Installtheadapier,driveplate,andbackingplateontothe
crankshatt.
to the driveplateboltsand installthem.
3. Applysealant
4. Holdthe driveplatewiththe SST.
5. Tightenthebohsin tlvoor threestepsin the ordershown
in the figure.
Tightenlngtorque:
96-103 Nm (9.8-10.5 m-kg, 71-76 ftlb)
StepsAfter lnstallation
1. Connectthe negativebatterycable.
2. Startthe engineand performengineadjustmenis
as necessary.
072
osuoBx
B-25
REMOVAL
REMOVAL
PROCEDURE
the negativebatterycable
1. Disconnect
2. Dran the enornecoolanland transaxleoil
3 Removern tlie ordetshownrn ihe trgurerefernnglo RemovalNote
Slep t
1. Air cleanerassembly
2. Batteryclamp
3. Battery
4. Batterycarrier
cable
5. Accelerator
6. Badiatorhose
7. Oilcoolerhose(ATX)
8. Coolingfan connector
B-26
9. Radiaiorbracket
and coolingfan assembly
10.Radiator
11.Drivebelt
12.P/Soil pumpand bracket(if equipped)
......pageB-27
Note.....................
Removal
(if equipped)
13.AJCcompressor
...... . .. ... pa1eB-27
Note.....
Rernoval
REMOVAL
Removalnote
P/S oil pump (il equlpped)
Cautlon
. Do not damagethe hoaes,
i-
1. Removethe P/Soil pumpwiththe hosesstillconnectedlhe pumpawaytromtheengineandaifixit withwire.
2. Positjon
A
01E08X.062
A,/Ccompressor (it equippeo
Caution
. Do noi damagelhe hoaes,
withthehosesslillconnected.
1. Removethe
AJCcompressor
thecompressor
awayfromtheengineandaflixit
2. Position
withwrre.
Steo 2
shownin thefioure.
Disconnect
the harnessconnectors
B,-27
REMOVAL
Steo 3
Disionnectthe hosesshownin the ligure
valve)
3. Vacuumhose(solenoid
1- Brakevacuumhose
hose
4.
Heater
2. Fuelhose
Nlo t e . . . . . . . . . . . . - . . . . . . . . . .b. .e. l.o. .w. . . . . . . .
Remova
Removalnote
Fuel hose
Wamlng
. Keep sparks and open flame away lrom the tuel
area,
Cautlon
. Coverthe hose wlth a rag becausefuel will spray
oul when disconnectlng.
. Plugthe disconnectedhosesto avoidfuel leakage.
B-24
.,**d
the fuelhoses.
Disconnect
REMOVAL
Step 4
GASKET,
B
1.Speedometer
cable
2. Shiftcontrolrod (MTX)
3. Extension
bar (MTX)
4. Shittcontrolcable(ATX)
5. Frontexhaustpipe
6. Clutchcable
7. Lowerarm
R e m o vN
a lo t e . . . . . . . . . . ..............p.. a
. g eB - 2 9
8. Driveshatt
pageB-30
Removal
Note....-........................
L Enginemountmember
pageB-30
Fiemoval
Note.............................
Removalnote
Lowet arm
1. Removethe boltsand nutsat the leftandrightlowerarm
balljoints.
B-29
REMOVAL
themfromthe
2. Pullthe lowerarm downwardto separate
knuckles.
Caution
. Do not damagethe ball-iointdusl boots.
Driveehafi
by pryingwitha
fromthetransaxle
the driveshafts
Separate
bar inserledbetweenthe shaftand the case.
Caution
. Do not damagethe oil sgal.
Enoinemount member
1. Suspendthe enoinewrtha chainblock
2. Removethe No.1and No.2enginemountnuts.
enginemountmemberboltsandnutsandthe
3. Removethe
enginemountmember.
Caution
. Be caretul so that the engine does not fall when
removlngthe member'
ro, J"o,^. ]F "o , 1"n,",
MOUMI
B-30
MOUNT
B
REUOVAL
Step 5
01EOBX070
1. No.3enginemount
assembiy
2. Engjneand transaxle
Removal
note......................................
below
Removalnote
Engineand transaxleassembly
Caution
. Do not damageanycomponenlsln the enginecompartment,
assembiy
out as a unrt.
Liftthe engineandtransaxle
B-31
REMOVAL
Step 6
the engineand kansaxlein the ordershownin the ligure'
Sep'arate
MTX
ATX
1.Starterand bracket
2. Throttlecable(ATX)
3. No.'1enginemount
stitfener
4. Integrated
B-32
and driveplatenuts(ATX)
5. Torqueconverter
bolts
installatian
6. Transaxle
assy.
7.Transaxle
B
ENGINESTANDIiIOUNTING
ENGINESTANDMOUNTING
PFEPAFATION
ssT
49 0107 6804
49 L0l0 1A0
Enginestand
Hangerset,
49 1010101
49 1010102
engrne
engrne
4910101A0)
49 LO101Ao)
49 L0t0 103
49 1010104
Hooks
(Pad ol
49 1010 1AO)
lOl
=l
engine
l[$"
49 Lolo 1A0)
4 9 1 0 1 01 0 5
49 10101m
Bolts
(Part ol
491010 1A0)
Bolls
iParroJ
49 L0t0 1A0)
g
engine
engrne
B-33
ENGINESTANDMOUNTING
PROCEDURE
Step I
Removein the older shownIn lne lgure
GASKET.qEPLACE
C.V'G
\\,
6* n \Jl
a o
,'-g-\
SKET,REPLACE
a)5
oi,tuo, @
REPLACE
bracketand idler
4. fuC compressor
5.WaterinletPiPe
6- ExhaustPiPebracket
1. Exhaustmanifoldinsulator
2. Exhaustmanifold
3. Waterbypasspipe
L-..:
1-
l-
-) ao- -oj -o)
u l
Frl
1ll1
fi ltr
Fr
B-34
Siep 2
Caution
. Wheninsrallingthe SST (enginehanger)'use the
holes shown in lhe ligure.
ENGINESTANDMOUNTING
ji,--\
-
\\J,
,.=r
ie
1. lnstalltheSST(arms)to theholesas shownin thefigure,
and looselytightenthe SST (bolts).
l-'
ui
2. Assemble
the SST (bottsand plale) in the speciliedposition.
-
F
AO
O
I
3. Assemble
the SST (nuls, hooks, and bolts)
arms.
4. Installthe SST to the respective
Note
. Adiust the SST Oolts) so that lea€than 20mm(0.79
in) ol thread is exposed.
. Makethe SsT (plateand arms)parallelby adiustIng the SST (bolts and nuis).
5. TightentheSST (boltsand nuts)to atfixthe SSTfirmly.
20mm(0.79 i
6. Mountthe engineon the SST (englnestand).
B-35
DISASSEit!BLY
DISASSEMBLY
PREPARATION
ssT
49 E301060
49 E301061
Brake,fing gear
Body
(Partof
49 E301060)
49 E301062
49 06361008
Collar
of
instalation
iller
49 E301060)
49 BO12042
49 BO12012
Body
springlitler
49 80120A2)
4 9 8 0 1 20 1 3
49 8012014
49 BO12OA2)
(Partol
49 8012oA2)
4 9 S 1 2 01 7 0
49 D01l 001
insiallalion ol
Supportblock
4 9 H 0 1 10 0 1 8
49 DO11003
inslallation
ot
49 8t 34 045
Pistonpin guide
rods'and valvesprings)so thatthey
1. Codeall identicalparts(suchas piston,pistonrlngs connectrng,
in fie cylindertromwhichltley wereremoveo
can be rernslalled
alr'
waterwithcompressed
plrts
with
a steim cleaner'Blowotf any remaining
z. Cf"untn"
Note
. 6-uring disassemolyof any part or system,be sure to sludy its order of assembly'Also' note
any delormation,wear, or damage.
04o
$coBr
B-36
DISASSEMBLY
AUXILIARYPARTS
'1.Draintheengineoil.
2. Disassemble
in the ordershownin the fioure.
o o
ro
l
g
@
6P
z,
\
N,)
'1.Alternator
drivebelt
2. Alternator
3. Intakemanifoldstay
4. lntakemanifoldassembly
5. Intakemanifoldgasket
6. Distributor
and highlensionlead
7. No.3enginemountbracket
8. Oil pressure
switch
L Enginehanger
'10.Oil dipstick
11.Sparkplug
12.Oilfilter
B-37
DISASSEMBLY
TIMINGBELT
in the ordersnownin the figure,referringto DisassemblyNote
Disassemble
@
1.WaterPumPPUlleY
2. Crankshait
Pulleybolt
3. Plate
4. Crankshaft
Pulley
5. Pulleylock bolt
Note ......
Dlsassembly
6. Pulleyboss
B-38
7.Timingbeltcover,upper
8. Timingbeltcover'lower
9.
" Timinobelt
oirZ.!"totvNote . .
.. page g-47
paseq-99
r n J p " i t i o n . - . . . . .............. . . . p a g e B - 5 9
spring
tensioner
1o.
'-' Tensioner,
-inipeition.................
.. .. .. pageB-59
DISASSEMBLY
DisassemblyNole
Pulley lock boll
Caution
. Add approxt3mm (0,51in) ot spacers(@)to space
lhe SSTawaytrom the cylinder block. (MTX)
(IVTX)
1. Holdtheflywheel
or driveplaie(ATX)wlththeSST.
2. tlemovethe pulleylockbolt.
Timing belt
1.Turnthe crankshalt
and allgnthe marks.
- p\o'9ecrto
2. Markthetimingbeltrotationfor properreinsialiation.
- ' g r
-\;-,/\.t
\\-zz
W:
S== "G
Caution
. Neverforcetullytwist the timing belt. Do not lurn
it insideout or bend it.
. Be carelul not to allow oil or greaseon the belt,
W*ff.,f
B-39
DISASSEMBLY
CYLINDERHEAD
in the ordershownin the figure,referrinqto DisassemblyNoie.
Disassemble
@\
1. Cylinderheadcoverand gasket
coverano gasKel
2. Thermostal
3. Thermostal
4. Thermosensor
5. Rockerarm and shattassembly
note..... . .- . . pageB-41
Disassembly
6. Rockerarm
7. Rockerarm spring
8. Rockershafi
9. Camshaft
PulleY
Note..... .. . . .. .. pugeg-11
Disassembly
pageB-59
Inspeclion.........
10.Thrustplate
'11. Camshatt
page
- B-52
inspection.........
12.Cylinderheadbolts
... page
Note .. ...
- B-41
Disassembly
B-40
head
13 Cylinder
'lnspection
pageB-48
."
'l4 Cylinderheadgasket
l5 Valvekeeper
pageB-41
Note
Disassembly
upper
seat'
spring
16 Valve
lT ValvesPrrng
' pageB-52
"
"
Inspdction
lS Valvespringseat'lower
19
- Valve
pageB-49
"
.. lnspeclion
20 valveseal
.
paqeB 41
Note
Disassembly
Jorweal and damage
Inspect
21 Valve,g-urde
" pageB-49
" "
Inspection
pageB 50
"
Replacement
22.Oil seal
DISASSEMBLY
DlsassemblyNote
Rocker arm and rocker shaft assembly
1. Removethe rockerarm and rockershaftassembly.
2. Codeallrockerarmsandspringssothattheycanbe rein"
stalledinthesameplacesfromwhichtheywereremoved.
Camshafipulley
1. Holdthe camshaftusinga suitablewrenchon the casl
hexaoon.
2. Remdvethe camshaftpulleybolt.
3. Removethe camshaftoullev.
Cyllnderhead bolts
1. Loosenthecylinderheadboltsintwoorthreeslepsin the
ordershownanthe figure.
2. Removethe cylinderheadbolts.
Valve keeper
1.SettheSSTagainsttheuppervalvespringseatasshown
in the figure.
2. Flemove
the valvekeepers.
Valveseal
Removelhe valvesealwiththe SST
B-41
DISASSEMBLY
f lSJ'"'"'""'nn'oo'"'"".'0''*ot"
i.tn",f,
3*:*1T"11?f"-"[TI"tff
, FEPLACE
E
Hr."*".
7. Oil pan
diassemblyNote . .... .. .. . pageB-43
lnspectfor damage
-2. Timrngbelt Pulley
slrainer
Oil
8.
B-59
Page
insie"tion..........
bearingsupportplate(M6sl')
9.
Main
(MTX)
disc
3 Clutchcover,clutch
Ndte..... . ... . .. pageB-44
S e r v i c e . . . . . _ . . . . . . . . . . . . . . . . . .S. .e. .c.t.i.o.H
.n. . . . . . . . . Disassem6ly
Inspectfor damage
(MTX)
4 Flvwheel
'Disassembly
pump
paqe
10.
Oil
B-43
..
Note. .
i
e
r v i i e . . . . . . . . . . . . . . . . . . . . . . . . . .S
. . e. .c. .t .i o
.D
.n. . . . . . .
Inspeclfor wearand damage
oil seal
5 Backi;g pbte. dnveplate and adapter(ATX) 11. Front
Note ...... ... ... pageB-44
bisassembly
page
B-43
.
.
.
..
Note.......
Disaisbmbly
12.Rearcover
6. End Plate
13.Rearoil seal
Note ..... .. .... pageB-44
Disassembly
1.
' Water
''i"rv]""..
PumP
" "
B-42
E
" section
DISASSEMBLY
DbaaaemblyNote
Flywheel
Cautlon
. Add approx l3mm (0.51In) ot spacets (@) lo space
the SSTaway trom lhe cylinder block. (MTX)
1. Holdtheflywheelwiththe SST.
2. Loosentheclutchcoverboltsin two or threestepsin the
ordershownin the figure.
3. Removethe clutchcove..
4. Removethe flywheelbolts.
5. Bemovetheflywheel.
6. Removethe SST.
Backingplate, drive plate, and adapter(ATX)
'1.Holdthe driveplatewiththe SST.
2. Removethe driveplatebotts.
3. Removethe backingplate,driveplate,and adapter.
4. Removethe SST.
@
Oll pan
'1.Removethe oil pan mountingbolts.
toolbetweenthe IVIBSP
or a suitable
2. lnsena screwdriver
and oil pan,and Prythemapart.
Caution
. Do not insert the prying tool betweenthe MBSPand
cylinder block.
. Do not damageor sc6tch the contactsurfaces.
B-43
DISASSEMBLY
ain beadngsupport plate (MBSP)
'1.Removethe MBSPmountingboltsfromthe mainbearing
cao.
the MBSP
tool between
or a suitable
2. Indena screwdriver
and cylinderblock,and pry themapart.
Cautlon
. Do not damage or scratch the contact surlaceg
when removlngold sealant.
Front oll seal
protected
witha rag.
Removetheoil sealwitha screwdriver
THEPUMP
PFOTECT
THEEEAACOVEFI
PFOTECT
B-44
Rsar oil seal
protected
witha rag.
Removetheoil sealwitha screwdriver
DISASSEMBLY
CYLINDEFBLOCKONTERNALPAFTSI
D,sassemble
in rhe ordershown,n the tigure,refefiinglo DisassemblyNote.
tr/:r
v
ry
n
I
1.Connecting
rod cap
6. Piston
page8-46
pageB-56
Disassembly
Note......................
Inspection..................-................
2. Connecting
rod
7. [/ain bearingcap
pageB-47
page8-46
Disassembly
Note.......-.............
Disassembly
Note......................
page
Inspection....-.......-......................
B-57
8. Crankshaft
pageB-47
rod bearing
Note.......-..............
3. Connecting
Disassembly
I n s p e c t i o n . . . . . . . . . . . . . - . . . . p. .a- .g. e.B
. .-.5. .8. . - . . .
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. .g. e.B
. .-.5. .8. . . . .
4. Pislonring
9. Mainbearing
pageB-58
pageB-46
Disassembly
Note......................
Inspection......................-....-.......
page8-56 10.Thrustbearing
Inspection......................-............
5. Pistonpin
11.Oilfilterjoint
page
Note
Disassembly ...................... 8-46 12. Cylinder
block
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a. .g. .eB
. . -. .5.4. . . . . .
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g
. .e.B. .-.5. .7. . . . .
B-45
DISASSEI'BLY
DisassemblyNote
Connectingrod caP
theconrodcaps'measure
d-torJie.dving tne'connecting
page
B
66
)
ieciino roo sid6clearance(Relerto
Connectlnqrod
theconnect
re;ovrnglneconnecingrods'measure
1. Before
B-57
page
(Refer
to
)
ino roo oil clea'rance-
fromthe crankpiniournals'
2. Removeihe Plastigage
Caulion
l-do-not ""rar"tt ttt" clankshaftiournalor the cylinder wall.
to removethepl$onandcon3.
- Usethehandleot a hammer
i*tlng t; uo".uly throughthetopofthecylinderblock
Pision ring
Caution
. oJ not apptyexcessivetension,which may cause
the rings to anapoul.
Removethe pistonringswitha pistonringexpander(comavailable)
merciallv
Plston oin
Caution
. Ma* lhe connectingrod directionfol proPerreassembly.
'1.Beforedisassembling
rod'check
thepistonandconnecting
torqueas shown.
the oscillation
iiin"luioe Lno aoe" notdrop by itsownweight,replace
the pistonor the PistonPin
B-46
DISASSEMBLY
the SST as shown.
2. Assemble
rodintheSSTasshown.
3. l\rountthepistonandconnecting
piston
the
Press
out
4Pin.
the oistonpin,checkthe pressurelf iI is
Whileremovino
lowerthan4905N (500 kg, 1100lb)' replacethe piston
pin or connectrng
rod.
@TEE
ltlaln bearingcap
lhecrankcaps measure
theman beanng
1 Belorerem6ving
page
8-65
play.
(Reter
to
shaftend
)
2. Loosenthe mainbearingcap boltsin two or threesteps
in the ordershownin the figure.
3. Removethe mainbearingcaps
Crankshaft
measurethe mainbearing
the crankshaft,
Beforeremovino
(Referto pageB-74.)
oil clearances.
B-47
/ REPAIR
INSPECTION
/ REPAIR
INSPECTION
PREPARATION
ssr
49 BO12005
gulde(83)
and
restdue'
dirt,oil'grease'carbonmoisture
1. Cleanallparts,beingsureto removeallgasketfragments,
olherloreignmaterlals
repairsmustbe pertormedIn the orderspecified'
Z. tnsoection"anO
Caution
(suchas the cy'fuiJt
a"t"s" rne ioints orlrlction surtacesol alumlnumalloycomponents
Inder head or pistons).
orEoBx.oe3
CYLINDERHEAD
headfordamage,cracks,andleakage
i. lnspectthecyhnder
ot walerand oll. Replacethe cylinderheadif necessary
in the six directions
Z. i,reaiuielni cvtinaerheaddistortion
shownin the figure.
Distortion:0.l5mm (0.006in) max.
Caution
-selole
qrinalns the cylinder head,checkth€ tollow'
.
ing ani repair or rePlacethe cylinder head as
necesaary.
Sinklngol valve seals
Damagl ot manifgldcgntacl sudace
cams6aftoil clearancesand end play
grind
exceedsspecification'
3. lf thecylinderheaddislortion
the cvlindelheadsurface
redace
ii tnetvtinoerneaonerghlis notwithinspecilrcation
it.
Heiohl: 107.4-107.6mm(4,228-4'236 In)
Gri;ding: o.20mm(0.008in) max.
B-48
INSPECTION
/ REPAIR
the manifoldcontactsurfacedistortion
in the six
4. l\4easure
shownin the figure.
directions
oistorllon: 0.t5mm (0.006in) max.
grindthe surfaceor reexceedsspecification,
5. lf distortion
olacethe cvlinderhead.
4.. -sreure
fJ
VALVEMECHANISM
Valveand ValveGulde
Replaceor resurlace
1. Inspecteachvalvefor thefollowing.
the valveil necessary.
(1) Damagedor bentstem
(2) Roughor damagedface
(3) Darnagedor unevenlywornstemtip
2. Measurethe valveheadmarginlhickness01eachvalve.
Replacethe valveif necessary.
Marginthicknesamin.
mm {in)
B3
1.1(0.043)
1.2(O.O47)
IN
THICKNESS
EX
3. Measurethe lengthof eachvalve.
Length
Standard
IN
Standa.d
EX
Minimum
B3
108.2414.261't
107.74 14.241
109.34{4.304)
108.84(4.?85)
4. Measurethe stemdiameterof each valveal the points
Dlameter
B3
IN
EX
5.970-5_985i0.2350-0.2356)
5.965-5.980 {0.2348-0.23541
5. Measurethe innerdiameterof eachvalveguideat the points
shown.
lnner diameter
IN, EX
B3
6.01-6.03(0.2366-02374)
6. Calculate
the valvestemto guideclearanceSubtracttheouterdiameterof the valvestemfromthe invalveguide.
ner diameterof the corresponding
|h"::
Clearance
In)
lN r 0.025-0.060mm (0.0010--1t.0024
EX: 0.030-0.065mm (0.0012-0.0026in)
Maximum:0.20mm(0.008In)
replacethe valve
7. lf the clearanceexceedssp€cification,
and/orvalveguide.
B-49
/ BEPAIR
INSPECTION
8. Measurethe protrusionheightof eachvalveguide Replace
the valveguideil necessary.
Height
mm{in)
CYLINDEF HEAD
Replacementol valve guide
of the intakeand exhaustvalve
lll? tte strapes
installcorrectly'
guidesarealitferent,
EX
IN
thecombus'
u"ru"srioelromthesideopposite
B:fio9Jilh.
tion chamberwiththe SST
rlH
Installation
1. Fitthe clip ontothe valveguide'
\]H
ffi
IN
combustion
2.
- UsinqlheSST.tapthevalveguideiniromthe
A
(dimension
herghl
protrusion
the
"n"ril"i "io" to inat
In the figure)is withrnspecilication
:a;l?h
sft|kehardarterthecllPcontactsthecvlin-
der head, the cliP will be damaged'
B-s0
INSPECTION
/ REPAIR
ValveSeat
1. Inspectthe contactsurtaceof eachvalveseatand valve
facefor thefollowing:
(1) Roughness
(2) Damage
valveseatwitha45" valveseat
resurfacethe
2. lf necessary,
the valveface.
cutterand/orresurface
db
blueto the valvelace.
3. Applya thincoatol Prussian
thevalveagainstthe
valveseatingby pressing
4. Inspectthe
seat.
(1) li bluedoesnotappear3600aroundthevalveface,replacethe valve.
(2) lf bluedoesnotappear3600aroundthe valveseat,
resurlace
the seat.
v..vl
\ \€=:.,
5. Measurethe seatcontactwidth.
width
EAT CONTACTWIDTH
mm (in)
IN,EX
B3
0.8-1.4 (0.031-0.0s5)
if
IN
E"'il
6. Verifvthatthevalveseatingposiiionis at thecenterof the
vave Tace.
(1) lf theseatingposition
istoohigh,correctthevalveseat
witha 70o cutterand a 45" cutter
(2) lf the seatingposition
is too low correctthevalveseat
witha 40' cutterand a 45o cutter
7. Seatthe valveto the valveseatwithlappingcompound.
8. Inspectthe sinkingol the valveseat.
length{djmension
L) of the valve
Measuretheprotruding
stem.
DIMENSION!
DimensionL: 41.05-41.95mm(1.616-1.652in)
B-51
/ REPAIR
INSPECTION
mm (n)
41.5-420 {r.634 1.654)
42.0-43.0 (1.654-1.693)
[4orethana3 0 (1.693)
No correctonn€€ded
Adjuslwithwasheron sping
seal areaof cylinderhead
Beplacecylinderhead
ValveSpring
1. Inspecteachvalvespringlor cracksand damage
2. Measurethe freelengthand out oi squareReplacethe
valvespringif necessary.
Frge length
IN
EX
(kg lb)/mm(in)
(in),Mit]imum...N
standard...mm
B3
40 7 (1.602)
Slandard
0 (1417)
2988-3381!36
7 (r358 1s.37.
Minimum 133.2-r50
40.70.602)
Slandard
4.88-338l)860 (1414
L4inimum 133.2-150.i
0358-15.3/
Out-ol-square
IN
EX
1.42(0.055)
1.42(0055)
CAMSHAFT
1. Setthe frontand reariournalson V-blocks2. Measurethe camshaftrunout Replacethe camshaftif
necessarv.
Runout:0.03mm(0'00'12in) max.
3. Inspectthe camshaftfor wearand damageReplacethe
camshafiiJnecessary.
thecamlobeheightsatthetwo pointsasshown
4. Measure
#@
B-52
Height
IN
mm {rnl
Slandard
lVlnimum
Slandard
[,'linrm!m
B3
36.5270.4380)
(1.4301)
36.327
36.333(1.4304)
36.133i'1.422s)
INSPECTION
/ REPAIR
X andY directions
atthetwo
5. Measurethe
iournaldiameters
points(@ and @) shown.
Diameter
No.l & No.s
No-2& No.4
No.3
B3
(1.7102-17.1
10)
43.440*43.460
(1.7096-1.7106)
43.425-43.450
43.41O 43.43511.7O9
1, 1.71OO)
Out of round: 0.05mm(0.002in) max,
lhecamshaft
andcyl
6. Measure
theoilclearances
between
inderhead.
and
allioreignmaterial
andoilfromthejournals
{1) Remove
the camshaftbore.
(2) lvleasure
the camshaftborediameter.
03u081105
Diameler
No.1& No.5
N o . 2 ,N o 3 , N o 4
mm(in)
B3
43.500-43.525
0.7r26-1.7135)
(1.7126-1.7135)
43.500-43.525
(3) Subtract
the journaldiameterlromthe borediameter.
Oil clealance
No.1& No.5
No2&No4
No-3
0.040 0.085(0.0016 0_0033)
0.050 0.100(0.0019 0.0039)
0.065-0.115 (0.0a25-0.0045)
0.15(0.006)
(4) li theclearanceexceedsthemaximum,replacethecamshaftor cylinderhead
themaximum,
thecamshaft
endplay.lf itexceeds
7. Measure
reolacethe thrustolateor camshaft.
End play : 0.060-0.200mm (0.0023-0.0078in)
Maxlmumr0.2mm(0.007in)
B-53
/ REPAIR
INSPECTION
RockerArm and BockerArm Shaft
1. Checkfor wearor damageto thecontactsurfaceof therocker arm shattor the rockerarm-Replaceif necessary
the rockerarmandshalt
between
2. Checktheoilclearance
Replaceif necessary.
(1) Measurethe rockerarm innerdiameter'
Diameter
G
IN EX
B3
19.000-l 9.033(0.7480-0.7493)
(2) Measurethe rockerarm shattdiameler'
Diameter
l N , EX
B3
1&959-18.980(0.7464-0.7472)
(3) Subt.actthe shaftdiameterfrom the rocke' arm di'
ameler.
Oil clearance
tN, EX
mm (in)
B3
0o20-o 074(00008-0.0029)
010 (0.004)
BLOCK
CYLINOER
1. Checkthecylinderblocklorthefollowingand'epalror replacethe cylinderblockas necessary
(1) Leakagedamage
(2) Cracks.
(3) Sconngol wall
block
oflhetopsLriaceoi lhecvlinder
Z. Miasurethi distonion
shownin figure
in the slx directions
(0.006in) max.
Distortion:0.15mm
exceedsthe maximum.repairby grinding
3. lf thedistortion
biock
cylinder
or replacethe
Height:22l.smm(8'720in)
Grinding:0.20mm(0'008in) max.
B-54
INSPECTION
/ REPAIR
___n_
o c2 So
z/-I\"
r"$\1-l^
o\ 4o
-L__-r-
H
4. Measurethe cylinderboresin X and Y directionsat ihree
levels(A, B, and C) in each cylinderas shown.
Cylinder bore
mm(rnl
B3
Slandard
71.006-71.013 (2.7955-2.7958)
0-25(0.010)oversize
0.s0(0.020)overcize
0.75 (0 030) oversize
7 1.256-71.26312.8053,2.4056)
71.506-71.51312.81522.8155)
7 t.756-71.763(2.8250 2.8253)
72.046 72.013 12.8349-2.4352)
1.00 (0.04)oversEe
Caution
. The boring size should be basedon the sizeof an
overslzepislon and be the sametor all cylinders.
(1) lf thecylinderboreexceedsthe maximum,
reborethe
cylinderto oversize(2) If the difference
betweenmeasu.ements
A and C exceeds the maximumtaper, reborethe cylinderto
overslze.
(0.0007in) max.
Taper:0,01gmm
o7
so
71"1--\v
(3) lf the difierencebetweenmeasurements
X and Y ex'
ceedsthe maximumoutof-round,feboreihe cy{inder
to oversrze.
Out-ol-round:0.01gmm(0.0007in) max.
Os-to
5. lftheupperpartof a cylinderwallshowsunevenwear,
rnovethe ridgewitha ridgereamer.
ry
B-55
INSPECTION
/ REPAIR
PIN
PISTON.PISTONRING,AND PTSTON
Plston
Caution
. lf the piston is reptaced,the pistonrings mustalso
be replaced.
o - R|NG
GnoovE
lo.7min)
OIAMETER
of all pistonsfor seizure
1. Inspectthe outercircumferences
or scoring.Replacethe pistonf necessary
of eachpistonat a rightangle
outerdiameter
2. Measureihe
p
(90o)to the piston n, 16.5mm(0'650in) belowthe oil
ring landloweredge.
Piston diameter
mm{in)
70.961-7 0.967 \2.7937 2.7939)
0.25 (0.010)ove6ze
71.211 71.217I2.AO36-2.aO2A)
0.50(0.020)oversze
0.75(0.030)oversrze
] 00 (004)oversize
71.461 71.46712A134-2.8137)
7 t .711-71 .717 Q.A2$-2.A235)
(2.83312.8333)
71.961-7r.967
clearance
3. Measurethe piston{o-cylinder
Clearance:0.039-0,052mm (0.0015-0.0020in)
Maximum:0.15mm(0.006in)
replacethepiston
exceedsthe maximum,
4. lf theclearance
or reborethe cylindersto fit oversizepistons
Pision and Piston Rings
aroundthe
the pistonringto ringlandclearance
1. Iveasure
usrnga new plslonnng.
enlirecircumference
Clearance(Top and Second)
B3
0.030-0.070(0.0012-00028)
015 {0.006)
replacethepiston.
the maximum,
exceeds
2 . lf theclearance
3 . Inspectthe pistonringsfor damage,abnormalwear,and
breakage.Replacethe pistonringsii necessary
4. Inserttlie pistonring intothe cylinderby handand usethe
Distonto oush it to the bottom of the ring travel
FING
B-56
INSPECTION
/ REPAIR
5. Measure
eachpislonringendgapwitha feelergauge.Replacethe pistonringif necessary.
Erd gap
Top : 0.15-0.30mm(0.006-0.012in)
Second: 0.30-0.45mm(0,011-0,017in)
Oil rail : 0.20-0.70mm (0.008-0.028 in)
Maximum: 1.omm(0.039in)
Pistonand PistonPin
1. Measureeachpistonpin holediameterin X andY directionsat lour points.
Diameier:19.988-20.000mm(0-7869-0.7874in)
f-6t'1
L'----\-v
in X andY directions
2. Measure
eachoistonoindiameler
ai
four points.
Diameter:19.974-19.980mm(0.7864-0.7866in)
the oistonDin{eoistonclearance.
3. Caiculate
Clearance:0,008-0.026mm(0.0003-0.0010in)
4. Il the clearance
exceedsspecification,
replacethe piston
and/ofoistonoin.
ROD
CONNECTING
rod bushinginnerdiameter.
1. Measureeachconnecting
Diameter:19.943-19.96lmm (0.7852-0.7859in)
c/earance
theconnectino
rodbush2. Calculatethe
between
ingandpistonpin.
Interterence:0.013-0.037mm(0.0005-0.0015in)
rod for bending.Repairor re
3. Measureeachconnecting
placethe connecting
rod if necessary.
Bending.'0.075mm(0.0030in) max./somm(1.97 in)
B-57
/ REPAIR
INSPECTION
CRANKSHAFT
andpinsfor damage,scoring,and oil
1. Checkthe iournals
holeclogging.
on V'blocks.
2. Setthe crankshaft
runoutat the centerlournal.
3. Measurethe crankshaft
if necessary.
Replacethe crankshaft
Runout:0.04mm(0.0016in) max'
attwo
in X andY directions
4. Measure
eachiournaldiameter
points.
t
t
f----T----i
\
\i_,i
Main iournal
Diameter:49.938-49.956mm(1.9661-1.9668in)
Out-of-round:0.05mm(0.0020in) max.
Crankpiniournal
Diameter:39.940-39.956mm(1.5724-1.5731in)
Out-ol-round:0,05mm(0,0020in) 6ax.
grindthelournals
is lessthantheminimum,
5. lfthediameter
undersize
bearing.
to matchan
Undersizebea ng:
0.25mm(0.010in), 0.50mm(0.020in),
0.75mm(0.030In)
Main iournal diameterundelsize
Bearinosize
0.25(0.010)undersze
0.50(0.020)undersze
0.75 (0.030)undelsEe
mm (in)
49.688-49.706
0.9562 1.9569)
49.438-49.456 (1.9463-1.9470)
49 188-49.206(1.9365-1.9372)
Crankpiniournal diamelerundersize
0.25 {0.010)unde6ize
irndersize
0.5010.020)
0.7510.030)
Lrndersize
EB E
$drE BB
B-58
39.690-39.706 {1.5626-1.5632)
(1.5528-1.5534)
39.440-39.456
39 190-39.206(1 5429-1 5435)
BEARING
Maln Beadngand ConnectingFod Bea ng
rod bearings
and the connecting
Checkthe mainbearings
for peeling,scoring,and otherdamage.
/ REPAIR
INSPECTION
TIMINGBELT
sry6
f,*f^^y
Caution
. Neverforcelullylwist, turn insideout, or bendthe
timing beh.
. Do nol allow oil or greaseon the belt,
1. Replacethe timingbeltif thereis any oil or greaseon it
2. Checkthetimingbeltfor damage,wear,peeling,cracks,
Replacethe timingbeltil necessary.
and hardening.
IDLER
TENSIONER,
G
Caution
. Do not clean the lensioneror idler with cleanlng
fluids. ll necessary, use a solt lag to wiPe them
clean,and avoid scratchingthem.
andabnorandidlerforsmoothrotation
Checkthetensioner
or idleril necessary
the tensioner
mal noise.Fleplace
SPRING
TENSIONER
spring.Replace
the
Measure
thelreelengthof thetensioner
tensionerspring'f necessary.
Free length: 54.0mm(2.520in)
r-'E
T{7\\E
sry
lilll-1LlE
-5*\
reF.rsr- ZilF\
Vg
PULLEY
Timing Belt Pulley,CamshaltPulley
Cautlon
. Do not clean the pulleys with cleaninglluids' ll
necessary,use a soft rag to wipe them clean,and
avoid scralchingthem.
andotherdampulleyteethforwear,deformation,
Inspectthe
pulley
if necessary.
age.Beplacethe
B-59
ASSEII/IBLY
ASSEMBLY
PREPARATION
ssT
49 D011001
49 H0110018
supponblock
Supportblock
49 D011003
49 8134 044
Pistonpin quide
installer
insiallationol
inslalatLon
pislonpins
49 E301060
49 E301061
Brak€,rng gear
Body
ean oi
49 E3o1060)
49 AO12oPe
49 E301062
Collat
(Parl oi
49 E301060)
enginerotation
498012013
49 B0l2 012
Body
(Parloi
49 BO120A2)
installalion
sping lilier
of
inslallation
inslallation
of
(Partor
49Bo120A2)
49 06361008
49 8012014
installationof
installationof
lilter
49 80120A2)
4 9 S E 0 13 1 0
installationof
Centellngtool,
1. Cleanall partsbeforereinstallation.
2. Aoplvnew engineoil to all slidingand rotatilgparts.
3. R;phce plainbearingsif theyare peelingburned'or otherwseoamageo
4 Tidhrenall boltsand nuls1othe specifiedtorques
cluton
. Do not reuse Easketsor oil seals.
B-60
ASSEMBLY
CYLINDERBLOCK(INTERNALPARTS)
Torque Specifications
CYUNOEF
WALLS
PAOTBUSTON
19mm(0.75in)
JOUFNALS
T
8-61
ASSEMBLY
ConnectingRod
the SST as shown.
1. Assemble
2. Applyengineoil to the pistonpln
3. Setthe oistonon theSSTwiththe F markfacingupward
rod in the dlrec'
4 Assemtjle
the oistonandthe connecting
disassembled
were
tionfromwhichthey
Pressure torce:
4905-14715 N (500-1s00 kg' I100-3300 lb)
MABK
INOENTIFICATION
torce lf
fie plstonpin.checkthe pressure
5. Whirernserting
pin
piston
the
conor
replacethe
it rslessthanaoecified,
neclnoroq.
rodun6- Pressihepistonoinintothepistonandconnecting
bolt
the
stopper
til the SST contacts
roo
torqueof the connectlng
7. Checkthe oscillation
(Referto Page8-46.)
Piston Ring
oil ringson the pistons
1. lnstallthe three-piece
(1) Applvcleanengineoirlo theotlringspacerand rails
i2) lnslallthe oil rinOspacerwithlhe endsupwaro
Note
. ihe upperand lowertails a.e the sameand maybe
lnstalied with elther lace upward.
(3) Installthe upperrailand lowe' rail
8,-62
ASSEMBLY
as
2. Verifythatbothrailsareexpandedbythespacertangs
therailsturn
smoothly
showninthefigurebymakingcertain
in bothdiections.
-,.--'-)
sEcoNo
-/D
Caution
. The rings must be installed wlth the R marks
upward.
. The secondring musl be installedwith the sclaper
face downward.
3. Applycleanengineoilto thetop andsecondpistonrangs
thetopring.
theninstall
4. Install
thesecondringto thepiston;
available).
Usea pistonringexpander(commercially
O I LF I N G
SPACEF ENOS
PISTON
the end gapsof the ringsas shownin thefigure
5. Position
OIL RING
OIL FING
PISTON
SECOND
RING
Oil Filter Jolnl
as specified.
Installthe oil filteriointso that il protrudes
Prolrusion:19mm(0.75in)
PLASTIGAGE
Crankshaft
inspectthe mainbearing
thecrankshaft,
1- Beioreinstalling
as follows.
oil clearances
Oil clearanceinspection
and
andoilfromthejournals
(1) Remove
alltoreignmaterjal
Deallngs.
Caution
. Installthe gtooveduppermain bearingsin the cyF
inder block.
. lnstall the thrust bearingswith the oil groovefac'
Ing the crankshaft.
B-63
ASSEMBLY
THFUSI METAL
(2) lnstallthe uppermainbeanngsand thrustbearings
in the cyl'nderblock
i3t Setthe crankshatt
Caution
lio not totate rtte crankshaftwhen measutinglhe
oil clealances.
(4) PositionPlastigageatop the journalsin the axal
directton.
mainbearing
(5)
'-' Installthe lowermainbeanngsand the
€ mark
and
number
cap
to
tne
iaos according
steps
(6)
- Tnh€n themainbearingcapbollsIntlvoor thre€
in'theordershownin the figure.
t'?l':!'Jt*.ii'irT-".0
40-43n'rb)
m-ks,
lhePlaslF
caps.aFdmeasure
themainbearing
'17)
' Remove
poini
for
the
smallest
purnal
wldest
the
at
oaoeat each
largest
point
for
lhe
narrowest
lhe
al
ileirance and
clearance.
grind lhe
fgr
' ' lt lhe oil clearanceexceedsspecilicalion
bearings
and useunderszemain
crankshaft
(Referto PageB-58.)
Oil clearance:0.018-O,O36mm(0'0007--'{''0014in)
Maximum:O.lomm(0.004in)
2. Applya |beralamountol cleanengineoilto themainbea'
bearingsano mainlournals
inqs,'thrusr
s. inidr thi crarkst'Jtlandthe marnbean'rgcapsaccording to the cap numberand e mark.
4. Tiohtenthe mainbearingcap boltsin two or threesteps
in the ordershownin the figure
torque:
Tiqhteninq
-Hm
!r-sg
15.s-o'o m-rg, 40-43 ft'lb)
B-64
ASSEII'BLY
5. l\4easure
the crankshaft
end play.
Endplay: 0.080-0.282mm(0.0031-0.0111
In)
Maximum:0.30mm(0.012in)
(_. :/:\
,.-
y oe,l rl
|Qro.
grindthecrankshaft
6. lf theendplayexceedsthe
maximum,
andinstallanoveasize
thrustbearingor replacethecrankshaftand thrustbearing.
Thrust beadngwidth
Standard:
2.500-2.550mm(0.0984-0.1004 in)
0.25mm(0.0t0 ln) overaize:
2.625-2.675mm(0.1033-0.1053in)
0.50mm(0.020in) ove6ize:
2.750-2.800mm(0.1083-0.1102 tn)
0.75mm(0.030in) oversize:
2.875-2.925mm(0,1132-0.1152 in)
Pision and ConneciingRod Assembly
Cautlon
. Prolectthe connectingrod bolts with rubbersleeves
to prevenldamageto the crankpiniournals.
t'r
\'rinl|*
Rod Cap
Connectlng
'1.[/easufetheconnecting
rod bearingoil clearances
usang
thesameprocedure
asfor themainbearingoilclearance.
Caution
. Align lhe matchingmarksgn lhe cap and the connectingrod wheninstallingthe connectingrod cap.
Tighleningtorque:
29-34 N.m(3.0-3.5 m-kg, 22-25 ft-lbl
MATCHINGMAFKS
Oil clearance:0.028-0.068mm(0.0011-0.0027 in)
Maximum:0.lomm (0.004in)
grindthecrank2. lftheoilclearance
maximum,
exceedsthe
(Referto pageB-58.)
shaftand useundersize
bearings.
B-65
ASSEMBLY
rod sideclearances'
the connecting
3. lvleasure
IOCATION
MEASURTNG
Sideclearance:0.110-0.262mm(0.0043-0.0103in)
Maximum:0.30m8 (0.012ln)
exceedsthe maximum'replacethe con4. lf lheclearance
nectingrod and cap.
5. Apprya liberalamountof cleanengineoilto the crankpin
roo Deanngs
iournalsand connectlng
rod capswiththe matchingmarks
6. installthe connecting
alioned.
rodcap nutsin twoor threesteps
theconnecting
7. Tig-hten
Tiohteninolorque:
is-31-Nm {ir.o-e.s m-t<g,22-25 lr'tb)
'
8-66
'll
ll
I
L))=r
-
ASSEMBLY
CYLINDERBLOCK(EXTERNALPARTS)
TorqueSpecilications
re-25 {1.r-2.6, 14-1r)
GAS(ET,NEW
g r l
v7h
".*$
E
NEW
GASKET,
7i-r!
Nn (30-1r0 cm-kq,59-95 in-lb)
GASKET,NEW
(30-1 ro cD-ks, 6s-95 inrb)
GASKET.
--..-t* EEi
13-25 O.3-2.7, r3-20)
03uoB1.133
Fear Cover
oiltothelipofa new
of cleanengine
1.Applya sma,larnount
o seat,
2. Pushthe oil sealslightlyin by hand.
Cauiion
. The oil sealmust be pressedin until it is flush wilh
the edge ot the rear cover.
3. Pressthe oll sealin evenlywitha suitabiepipe.
Oil seal outer diameter:100mm(3.94in)
4. Applysiliconesealantto the shadedareashownin the
ngure.
8-67
ASSEIIIIBLY
..'i
\,
!
ILL- -l-
\o
/l
5. lnstallthe rearcover.
Tiohleninqtoroue:
?.s-t t-N.ma8o-l1O cm'kg,69-95 in-lb)
Oll PumD
1. Applya smallamounlol cleanergineorllo thelipof a new
oil seal.
2. Pushthe oil sealslightlyin by hand
Caution
. The oilseal musl be pressedin until it is llush with
the edge of the oil PumPbody.
3. Presslhe oil seal:n evenrywill' a sutablepipe
Oil seal outer diametef:44mm(1.73 in)
a newgasketand installthe oil pump
4. l\y'ount
iorque:
Tiohteninq
js-zs -N.m{i.s-z.o m-tg, 14-19 tt-lb)
Caulion
. Do not sqratchihe oil Pump.
5. Cutawaythe portionof the gasketthatprojectsfromthe
bodytowardthe oil Panside
Oil Strainer
Mourt a newgaskeland nslalltf'e oil strainer'
Tiohteninqtoroue:
?.a-tt-l'lm igo-lto
B-68
cm-kg, 69-95 in-lb)
ASSEi'BLY
Oil Pan
1. Removeall foreignmaterial
fromthecontactsurfaces.
2. Applysiliconesealantto the shadedareasshownin the
figure.
3. Installnewgasketsontothe oil pumpbodyand the rear
coverwiththe proiections
in the notchesas shownin ihe
figure.
l
-/-= {. I
Qr)
4. Applya continuous
beadof siliconesealant
to the oil pan
alongthe insideof lhe boltholesandoverlapthe ends.
5. Installthe oil pan.
Tighteningtorque:
7.8-ti N.m(80-110 cm-kg, 69-95 in-lb)
End Plale
Installthe end plate.
Tighteningtorque:
7.8-ll N.m(80-ll0 sm-kg,69-95 inlb)
@
BM
Flywheel(MTX)
1- Removethesealantfromthetlwheel boltholesinthecrankshaftandtromthe flywheelbolts.
Cautlon
. lf all the previoussealantcannotbe removedlrom
a bolt, replacethe bolt,
. Do not apply sealantif a new bolt is used.
2. Setthe flywheelonlothe crankshaft.
3. Applysealantto the flywheelboltsand installthem.
B-69
ASSEMBLY
4. Hold the flywheelwith the SST
Caution
. Addapprox13mm(0.51in)ol spacers(O) to space
the S5i awaytrom the cylinderblock'(MTX)
lhe oollsInn/voor h'ee stepsin tneoldershow4
5. Trghten
Tiohtenino
-go-roJ torque:
H.mis.s-r0.s m-ks,71-76 tt'lb)
Clutch Disc and Clutch Cover(MTX)
Caution
. Add aporox13mm(0.51in) of spacers(@) lo space
the SSi ayyayfrom the cyllnder block. (MTX)
lnstallthe clutchdiscand clutchcoverusingthe SST.
(Referto SectionH.)
Tiohtenino
-t'ttorque:
i a-zo m ti.e-z.t
m-xl,13-20 ft'lb)
Drive Plate (ATX)
1.Removelh-esealant{romthe oriveplateboll holesIn the
andfromthe driveplatebolts.
crankshaft
Caution
. ll all the previoussealantcannot be removedfrom
a bolt. replacethe bolt'
. Do nor aiply sealantIt a new bolt is used,
i@el
B-70
theaoapter.d've plale,andback|.gplateontolhe
2. Insrall
crankshaft.
3 Aoolvsealantto lhe driveplalebolrcand ;nstallthem
+. ttbio tne driveplatewiththe SST.
5- Tiohtenlhe bo{sinlwo or lhreestepsin theordershown
Tlohtenlnqtolque:
!s-rod tt.mig.s-t0.5 m-ks,7l-76 ft-lb)
ASSEMBLY
Timlng Belt Pulley
1. Installthetimingbeltpulley.
pulleyWoodrutf
2. Installthe
keywiththetaperedsidetoward
the oil pumpbody.
WaterPump
1. Removeall foreignmaterialfromthe waterpumpmountino surface.
2. PEcea new waterpumpgasketin position.
3. Installthe watefpumo.
Tightenlngtolque:
19-25 Nm (1.9-2.6 m-kg, 14-19 ft-lb)
B-71
ASSEMBLY
CYLINDEBHEAD
TorqueSpecitlcalions
{50-90 cn-kg, 43-73 In'lb}
12,2-2.9, 16-211
e-__u
Pe
(65-e5 cd-&, 56-t2 rFlb)
valve Seal
1. Installthe newvalvesealontothe valveguideby hand
adjustthe protrusion
@ to specitication
2. Afterinstallation,
Proltusion:18.1-18.7mm(0.713-0.736in)
B-72
93GOBr
0S0
ASSEMBLY
Valveand ValveSpring
1. Installthe lowerspringseat.
2. lnstallthe valve.
@GBEATEFTHAN@
Caution
. Installthe spring wlth lhe closer pitch toward the
cylinder head.
3. ,nslalllhe valvespnngand the upoerspringseat.
H E A OS I D E
4. Compress
tne valvespringw[h the SST.and inslallthe
varveKeepers_
5. Removethe SST.
6. Taptheendofthevalvesternlightlylwoor threetimeswith
verifythalthekeepers
a plastichammerto
arefullyseated.
CylinderHeadGasket
1. Removeall foreignmaterialirom the top of the cylinder
block.
2. Placethe newcylinderheadgasketin position.
CylinderHead
head.
1. Install
thecylinder
2. Applycleanenglneoil to the boltthreadsand seatfaces.
3. Tightenthecylinderheadboltsin twoor threestepsin the
oroersnown.
Tighteninqtorque:
76-81 N.m(7.7-8.3 m-kg, 56-60 tt-lb)
CamshattOil Seal
1. Applya thincoatof engineoilto thecamshaft
oilsealand
cylinderhead.
cylinderheadwitha suitaoilsealintothe
2. Tapthecamshaft
ble pjpe.
Cautlon
. The oil seal must be tappedin unlil it is llush with
the cylinder head,
Oil seal outer diameter:40mm (1.57in)
Camshall
1.Applyengineo,lro theJournals
andbearing
withthethrust
2. Insenandmountthecamshaltintoposition
plate.
B-73
ASSEUBLY
CamshaftPulley
OOWEL PIN ANO PIN GFOOVE
.t'i
Note
. Be certainthat the dowel pin ot the camshaftalso
laces straighl upward.
1. Insiallthecamshaftpulleyontothe dowelpinwiththepin
groovefacingstraightupward
pulleybolt Holdthecamshaflusing
the camshatt
2. Trohlen
a ;uitablewrenchon Ihe casthexagonas showr.
Tiohteninq
-ls-ot'itmloroue:
(6.0-o.z m-tg, 36-45 ft'lb)
RockerArm and RockerShalt Assembly
Cautlon
. Facethe rockershalt ldentilicationmark upward'
. The installationbolt holes are dlfterentfor the exhausi and intakesides.
ldentilication mark
Yellowgreen
lN ........,.,....
E X . . . . . . . . . . . .P. i. n. k
'1. Assemble
as
the rockerarm and rockershaftassembly
figurein
the
shown
2. lnstallthe rockerarmand rockershaftassemblyCaution
. Thebolts musl be tightenedgraduallyand in lhe or'
der shown.
Tidhteninq
-zz-za torque:
il.m (tz.z-z.sm-xg,16-21ttlb)
ValveClearanceAdiustment
Referto pageB-7.
B-74
ASSEMBLY
Temperaturegaugeunit
gaugeunitintothecylinderheadwith
Installthe
temperature
sealtape on the threads.
;nY\v
w"ffi
Tlghtenlnglolque:
6.4-9.3 Nm (65-95 cm-kg,56-82 in-lb)
Thermostat and Thermostal Cover
cover
1. Removeall foreignmateriallrom the thermostat
mountingsurface.
2. Installthe thermostat
withthe jigglepinfacingupward.
gasket
and the thermostat
cover.
3. Installa new
Tighleningtorque:
l9-25 N{n (1.9-2.6 m-kg, 14-19 ft-lb)
Caution
. Thg pdnted side ol the gasketmust face lhe thermgstat.
PBINT€O SIOE
a _-/-$ ,1
?\+
C:lrlinderHead Cover
lnstallthe cylinderheadcover.
Tightenlnglorque:
4.9-8.8 N.m(50-90 cm-kg, 43-78 in-lb)
Caution
. lf the headcovergasketis reused,applysealantin
the groove as shown.
OlEOBXJS3
B-75
ASSEIIBLY
TIIIIINGBELT
Torque Specificallons
t9-25 O.9-2.5, r/Frg)
7.t-ll
r*o (30-110 cr*1,
6!l-95 i.'lb)
12-17 fl .25-r.75, r09-r52)
r!i6-106 {16-17, 1r5-122)
Timing Belt Tensionel
spring
andthe tensioner
1.lnstellthe tensioner
withthe springtullyexsecurethetensioner
2. Temporarily
tended.
Timino Belt
wilhthetim1.Verii thatthetmingbeltpulleymarkrsaligned
Ing marK.
o3uoB11s4
B-76
ASSEMBLY
pulleymarksare alignedwiththe
2. Verifythatthecamshaft
cylinderheadcovermarks.
3-Install
thetimingbeltsothalthereis no looseness
at the
lension
side.
'/-\
caution
. Do not turn the crankshaft
counierclockwiscd
andalignthetim4. Turnthecrankshaft
twoturnsclockwise,
ing beltpulleymarkwiththe timingmark.
5. Verifythatthecamshaftpulleymarksarealignedwiththe
cylinderheadcovermark.
lf notaligned,
removethetimingb€liandrepeatfromtensionerinstallation.
to thetimingbelt.
6. Loosen
lhetensioner
boltto applytension
Caulion
. Be sure not lo applytensionother than thal ot the
tensionerspring,
7. Tlghtenthetensioner
bolt.
Tighteningtorque:
'19-25 N.m
{1.9-2.6 m-kg, 14-19 ft-lb)
andveritythatthe
8. Turnthecrankshaft
bro turnsclockwise
timingmarksare correctlyaligned.
9aN
(10 kg. 22 lb)
thetimingbeltdeflection
by applyingmoderate
9. Measure
pressure
thecrank{98 N, l0 kg, 22 lb) midwaybetween
shaftpulleyand the camshaftpulley.
is notcorrect,temporarily
se'
lf the timingbeltdeflection
boltsothespringis fullyextendedand
curethetensioner
spring.
repeatsleps4-8 aboveor replacethe tensioner
Deflectlon:
'|1.0-13.0mm(0.43---0.51
in) at 98 N ('10kg, 22 lb)
B-77
ASSEMBLY
Timlng Belt Covet
lnsta[the loweranduppertimingbeltcoversandnewgaskets
TIMING BELT
Tlqhteninqtolque:
?.4-t t-Hm igo-tro cm-kg,69-95 in-lb)
covEa
CrankshaftPulley
1. Installthe pulleyboss.
Caution
. Add approx13mm(0,51in) ol spacers(rt) to space
the SSi awayfron the cylinder block. (MTX)
2. Mountthe SSTand tightenthe pulleylock bolt
Tiohteninqtoroue:
iso-ro1 *m oe-t7 m-kg,115-122 finb)
3. Removethe SST.
4. Installthe crankshatt
PUlleY.
5. Installthe plate.
waler Pump Pulley
Installthe waterpumpPulley.
Tiohteninqtotoue:
?.9-rr-N.. a8o-1lO cm-kg, 69-95 Inlb)
0rEoBx'3c
B-78
ASSEMBLY
AUXILIARYPABTS
Torque Specilicalions
15-27 (r,5-2i,
r1-20)
e3-1 13{e.5-tt.s, 3s-€3)
GASKET,
NEW
19-25 0,9-2.5, r.-11)
@w
r
I
1e-30 (1,e-3,r, 13r2)
EngineHangel
Instailthe frontand rearenginehangers.
Tlghtenlngtorque
Front 37-63 N.m(3.8-5.4 m-kg, 27-46 ft-lb)
Real: 19-25 N{n (1.9-2.6 m-kg, 14-19 ft-lb)
B-79
ASSEMBLY
Spa* Plug
lubdcant
or molybdenum-based
compound
1. Applyanitserze
to the sparkPlugthreads.
2. lnstallthe sparkPlugs.
loroue:
Tiohteninq
'is-zs'il.m
1t.s-z.s m-rg, 11-17 ftlb)
Oil Dlpstick
Installthe oil dipstick.
Oil PressureSwilch
switch.
lnstallthe oil Dressure
Tiohteninqtorque:
lz-re-tt.m ti.z-r.8 m-kg,104-156 in-lb)
Oil Filter
1. Removeall toreignmaterialfrom the oil iiltermounting
surlace.
2. Applya smallamountoi cleanengineoiltotherubberseal
of the oil filter.
3. Installthe oil filterand tightenit by handuntilthe rubber
sealcontactsthe base.
4. Tightenthe filter1 and 1/6turn witha filterwrench
No.3 EngineMountBrackel
Installthe No.3enginemountbracket
totoue:
Tiohteninq
-ss-t
t3- Hln ig.s-i1.5 m-kg. 69-83 ttlb)
Allernator
strap.
1. Installthe alternator
Tiahtenino
torque:
-t't.m
iz-sz
1s.e-s.o m-t<g,2?-38 ft'lb)
drivebeft Looselytight'
andalternator
alternator
2. lnstallthe
installation
bolt.
en the alternator
(Referto pageB-5.)
3. Adjustthe drivebeltdeflection.
Tighteningtorque
Alternatorinslallationbolt (D :
37-52 N.m(3.8-5.3 m-kg, 27_38 ftnb)
Belt-adiustlngboll @ :
'19-25 N.m(1.9-2.6 m-kg, 14-19 tt-lb)
B-80
ASSEi'BLY
Intake ManltoldAssembly
'l. Removeallforeignmaterial
tromtheintakemanifoldcontact surtace.
2. Installa newgasketand the intakemanifoldassembly.
Tighleningtorque:
t9-25 Nm (1.9-2.6 m-kg, 14-19 fub)
Distrlbutorand High-tensionLead
1.Applyengineoil to the O-ring,and positionit on the distributor.
2. Applyengineoil to the blade.
3. Installthe distributor
withthe bladefit intothe camshaft
groove.
\=.\-6FY--.J \ \ \
. t . u
-
//t \
\
4. Temporarily,
looselytightenthe dist.ibutor
installing
boll.
5. Connectthe high-tension
leads.
6. Adjuslthe ignitiontimingafterengineinstallation.
(Referto SectionG.)
B-81
ENGINESTANDDISMOUNTING
ENGINESTANDDISMOUNTING
PROCEDURE
1. Removethe enginefromthe SST (enginestand)
2. Removethe SST (englnehanger)flom the englne.
3. lnstallthe partsshownin the figure
TorqueSpecitications
37-52 (3,3-5,3, 27-34)
(fr----- --\
ts=;\
|5fi
37-52 {3.H.3,
27--33)
1e-25 0,9-2.3, 14-r9)
{8O-iio m-rq, 69-t5 in'lb)
O.FIING,NEW
APPLY ENGINECOOLANT
16-2311.5-2,3, 12-1n
waler lnlet Pioe
'1. Remove
fromthewaterinletpipemoun!
dlfdreignmaterial
ino surface.
2. Inatalla newgaskelandthe waierinletpipe
toroue:
Tiohteninq
'is-zs -Nm
(i.s-z.e m-kg' 14-19 ft-lb)
B-82
ENGINESTANDDISMOUNTING
3. Applya smallamountof enginecoolanttothe newO-ring.
4. lnstallthe waterbypasspipe.
ExhaustPioe Bracket
lnstallthe exhaustoioebracket.
Tighteningtorque:
37-52 N{n (3.8-5.3 m-kg, 27-38 fi-lb)
A/C ComDressorBrackel
Installthe tuC comoressor
bracketTighleningtorque
@: 19-25 N.m(1.9-2.6 m-kg, t4-19 ftJb)
@: 37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)
ExhaustManitold
1. Remove
fromtheexhaust
manifold
conallforeignmaterial
tact surface.
2. Insiaila newgasketand the exhaustmanifold.
Tighteningtorque:
16-23 Nm (1.6-2.3 m-kg, t2-17 ft-lb)
ExhaustManitoldlnsulalor
Installthe exhaustmanitoldinsulator.
Tighteningtorque:
7.8-11 N.m(80-110 cm-kg, 69-95 In-lb)
B-83
INSTALLATION
INSTALLATION
PROCEDURE
Tightenall boltsand nutslo the specifiedtorques.
Step I
Jointhe engineand transmission.
Torque Specilications
TX
6!-a9 {6.5-r.r, 47-16)
37-52 (3.3-s.3, 27-33)
37-52 (3.3-5.3, 2?-33)
3?-s2 (3.3-5.3, 27--33)
ATX
37-52 (3,3-5.3, 27Ja)
37-52 e.a-5.3, 27--33)
B-84
INSTALLATION
Step 2
Warning
. Be sure lhe vehicle is securelysuppgrtedon safety stands.
Torque Speqifications
Engineand transaxleassembly
1. Suspendthe engineand transaxle
assembly.
Caution
. Do nol damaEeanycomponentsin lhe enginecompartment.
2. AligntheNo.3enginemountboltswiththe enginemounl
mountingholes.
B-85
INSTALLATION
Enginemouni
the l\o.1enginemounlnutandtrghten
1. Inslall
Tiohteninq
-gz-sr lorque:
1m 1il.a-s.sm-rg,27-38lr-tbl
IffiI
2. Installthe No.2enginemounlnut and tighten.
No.2 ENGINE
I,IOUNT
No.1 ENGINE
MOUNT
torque:
Tiohteninq
-tr.m
(g.g-s.g m-tg, 27-38 ft-lb)
iz-st
Enginemount member
Installthe enginemountmember.
torque:
Tiohteninq
-ea-es -Nm
16.s-S.l m-t<g,47-66 ft-lb)
Step 3
TorqueSpecificalions
15-22 0.6-23, 1r-16)
31,-46{3.2-4.7,23-33)
40-s4 {4.r-s,5, 2s--r0)
nr-.",J
*-"",u.u-",,
B-86
37-51 (3.3-5.3. 27-33)
&..-..-..-------'n*.,".*,
', o,*"
INSTALLATION
Drlveshaft
1. Applygreaseto the end ot the driveshaft.
Caulion
. When installingthe drlveshaft,be caretul not to
damagelhe oil seal.
. After Installation,pull the front huboulwardto conlirm that the driveshaltis sequrelyheld bythe clip.
2 Fil a newclip and installthe driveshaft.
3. Installthe lowerarm ball-joint
1othe knuckle,andtighten
the clinchbolt.
Tighteningtorque:
43-53 N.m(4.4-5.5 m-kg, 32-39 fl-lb)
Clutch cable
lnstallthe clutchcableand checkdiffrection.
(Referto SectionH.)
Shlft control cable (ATx)
Installthe shittcontrolcableto the transaxle.
Tighteningtorque:
6.9-11 N m (70-110 qm.kg,6l-95 inlb)
Shift control rod (MTX)
Installthe shiftcontrolrod to the transaxle.
Tighteningtorque:
'16-22 Nm (1.6-2.3 m-kg,12-16 in-lb)
Extensionbar (MTX)
Installthe extension
barto the transaxle.
Tighteninglorque:
3l-46 N.m(3.2-4.7 m-kg, 23-34 in-lb)
B-87
INSTALLATION
Speedometercable
cable
lnstallthe sDeedometer
Tldhtenlnqtoroue:
?.s-rfN.m iao-rzo cm-ks,69-96 In'lb)
Li,
B-88
Exhausipipe
'1 lnstallthe exhaustoipeanda gasketithenlooselytighten
the locknuts.
2. Looselytightenthe bracketbohs
3. Tightenthe locknuts.
Tiohteninq
toroue:
-lo-sl -t'l.m
tl.t-s.6
m-kq, 29-40 ft'lb)
INSTALLATION
Srep 4
Connectthe hosesshownin the figure.
Cautlon
. Posltionthe hose clamp in the original locationon lhe hose, and squeezethe clamp llghtly
with large pliers to ensure a good fit.
Siep 5
Connectthe harnessconnectorsshown in the fioure.
B-89
INSTALLATION
Siep 6
Torque Specificationa
(30-110 .n-ts, 6e-ss lFlb)
B-90
INSTALLATION
A/C compressor (it equipped)
Installthe fuC compressor.
E
Tighteningtorque:
37-s2 N.m(3.8-s.3 m-kg, 27-38 ft-lb)
01EoBXI5a
P/S oil pump and bracket
lnstallthe P/Soil oumpand bracket.
Tightenlngtorque:
37-52 N.m(3.8-5.3 m-kg, 27-38 ftlb)
I J
.DLEF
Drivebell
1. lnstallthe P/Sand/orA/C drivebelt.
(Referto pageB-5.)
2. Adjustthe drivebelldeflections.
IJLLEY COMPFI
Radiatorand cooling fan assembly
1. Installthe radiatorand coolinglan assembly.
Tighleningtorque:
7.8-11 N.m(80-il0
cm-kg, 69-95 in-lb)
2. Tightenthe AJCpipebracketto the radiator.
Tighteningtorqle:
6.4-9.3 Nm (65-95 cm-kg, 56-82 in-lb)
3. Connectthe uooerand lowerradiatorhoses.
&6
Caution
. Poaltionthe hoseclampin the orlginallocationon
ihe hose,and aqueezethe claBp lightly wlth large
pllers tg ensurea good fit.
hose.
4. Connectthe coolantreservoir
5. Connectthe coolingian connector.
6. Connectthe oil coolerhose.(Al'X)
B-91
INSTALLATION
Accelerator cable
cable
1. lnstallthe accelerator
by turningnut @
z. AOiusttne caUteoetlection
Deflection:l-3mm (0.04--'0.12In)
Battery duct, battery car er, and battery
1. Installthe batteryduct.
2. Installthe batterycarrier.
-YA
Tlohtenlnqtorque:
ig-zs l.m (i.9-2.5 m-kg, l4-19 fl-|b)
3. Installthe batteryand the batterybracket.
Tiohtgninotorque:
i.s-s.5 N.m'(so-60 cm-kg, 26-52 inlb)
Air cleaner assembly
lnstallthe air cleanerassembly
Undercover and slde cover
and sidecover.
lnstallthe undercover
steDs After Installatlon
i. ii'tn" 6"si"J o-'l*i" drarned,lill withthe specifiedamountandtype of engineoil
(Referto SectionD.)
2. Fillthe radiatorwiththe specifiedamountand typeof enginecoolant'
{Reterto SectionE.)
amountandtypeof transaxleoil
s..ii iil" to^""*|. oil;.s drained,fill withthe specified
(Reterto SectionsJ, K )
4. aonnectthe negativebatterycable
5. Startthe engineand checkthelollowing
{1) Enaineoil,transaxleoil and enginecoolantleakage
izi tgnitiontiming.idle speed(Referto pageB-8)
(3) Operation
ot emissioncontrolsyslem
road
test.
6. Performa
7. Recheckthe engineoil and enginecoolantlevels.
B-92
LUBRICATION
SYSTEM
tL 2
1NDEX.......,.,...,..,.......................,,.,..........
...,.,tL 3
ouTLtNE.,............,
D- 3
sPECtFtCAT|ONS....................................
IL 3
TnoUBLESHOOT|NG
GU|DE.,......,...,.,..,....
D- 4
otL PRESSURE.........,.,........................,.,..
D- 4
PREPARAT|ON,,...,...............................,.
D- 4
TNSPECTTON
....................,..................,..
D- 5
ENGTNE
OtL,.,.....................,..,.................
D- s
tNSPECT|ON...........,..,..................,.,.,....
D- 5
REPLACEMENT,,.,....................,.............
D- 6
otl F|LTER...,....,..,.,.,.,........................,...
lL 6
REP1ACEMENT.......,..............................
D- 7
otl PAN..................,,..............................
D- 7
REMOVAL
/ |NSTALLAT|ON......,.,..,.,........
IL
I
PUMP..,.,...,..,.........................,......,...
otl
....................,.
D- I
REMOVAL
/ TNSTALLATION
D-ll
D|SASSEt\4BLY
/ ASSEMBLY
.....................
D-12
TNSPECTTON
......................,.,.,,..............
INDEX
INDEX
ENGINEOILSPECIFICATION
SD,SE OB SF
API SEBVTCE
3.4 lir6.s(3-6us qr, 3.0 hp q0
l. Oil pressure
. pageD- 4
Inspectron...........-....................
2. Engineoil
pageD- 5
l"nspection.......--...-......................
... . . pi6e O- s
Rep1acement................
3. Oillilter
R e p 1 a c e m e n t . . . . . . . . . . . ..... p
. .a. .g. .eD
. . -. . 6
D-2
4 Oil-Pan
Installation "
- Removal/
5 OilPumP
Installation "
Removal/
/ Assembly
Disassembly
pageD- 7
pageq- I
pageD-1'1
OUTLINE,TROUBLESHOOTING
GUIDE
OUTLINE
SPECIFICATIONS
B:]
IemHmodel
Oil pump
Tvpe
Regulaledpressure
kPa(kg/cmz,psi)
343 441 (3.5-4.5, 50-64)
Type
Oil llter
Full.iow, pap€relement
Felief pres€ureditferenlial kPa (kg/cmz,psl)
Oilwarnng p€sslre
Oil capacily
98 (1.0,1 4)
,
kPa(kg/cm' psi)
4.9-44 (0.05-0.45, 0.7-6.4)
Tolal(dryensine)
lilerc(USqt, lmp qt)
3.4 (3.6,3.0)
Oll pan
llers (USqt, lmp qt)
3.0 (3.2,2.6J
Oiltlter
liters(USqt, lmp qi)
0 . 1 7( 0 . 1 8 , 0 . r 5 )
Englneoil (APl servce)
SD.SE,or SF
RecommendedSAEViscosity
fc)
('D
-30
-20
,--20
-10
0
0
20
10
40
v
5w'30
5EA----\
30
20
60
80
Engineoil
50
100
720
\
30
20w.20
'l0w-30
40
:
@
ffi
Anticipated
rangebeforesucceeding
ambienttemperature
oil change,"C ("D
TROUBLESHOOTING
GUIDE
Possible Cause
Remedy
D-5
D-5
Enginehardstarting
Insuflicieniengine oil
Exceasiveoil
Oll pressurc drop
Warnlnglamp
lllumlnrteswhlle
engineb running
Oilworkngup o. down
Oil leakage
Oil eakage
Womand/ofdamag€doil pumpgear
Wornplunger(insideoil pump)or weaksprins
Clossedoil strain€r
Excessive
ma,nbeanngo, .orneq ng rod oea rc
Oil prcssure
drop
Maltunction
oJoil pressure
swnch
Mallunctionof electical srstenr
Page
Reier to Section B
o_o
Clean
Reler to Seclion B
Feferto SectionT
D-3
OIL PRESSURE
OIL PRESSURE
PNEPARATION
ssT
49 0187 2AO
Gauge,
INSPECTION
swltch
1. Removethe oil Pressure
2. Screwthe SST intothe oil pressureswitchhole.
3. Warmup the engineto normaloperatngtemperalure
4. Runthe engineai 10Oorpmand3000rpm,and notethe
gaugereaorng.
Oll pressure:
99-196 kPa
(1.0-2.0 kg/cm' ,15-28 psi)'1000rpm
294-392 kPa
(3.0-4.0 kg/cmi, 43-57 psi)'3000rpm
is nolasspecitiedchecklor thecauseand
5. lt rheDressure
Guide.)
reoaii.(Referto Troubleshooting
D-4
ENGINEOIL
ENGINEOIL
INSPECTION
1. Be surethe vehicleis on levelground.
temperature
2. Warmuptheengineto normaloperating
and
stop it.
3. Waitfor fiveminutes.
o','"u"'
und
condition
3.IET?,1",f;r","'i"t'3il"1i*ffitn"
E
Note
. The distancebetweenthe L and F marl6 on the dip
stick represents0.8 llter {0.85USql, 0.70lmp ql}.
REPLACEi'ENT
warning
. Be carelul when drainlng;the oil is hot.
1. Warmuptheengineto normaloperating
temperature
and
stop rt.
2. Removethe oil lillercap and the oil pan drainplug.
3. Drainthe oil intoa suitablecontainer.
4. Installa newgasketand the drainplug.
Tighteningtorque:
29-41 N.m(3.0-4.2 m-kg, 22-30 flnb)
o5u00x.011
typeandamountof en5. Relilltheenginewiththe specified
gineoil.(Relerto pageD-3.)
6. Retitthe oil fillercap.
7. Flunthe engineandchecklor leaks.
L Checkthe oil leveland add oil if necessarv.
Oil pan capaclty:
3.0 liters (3.2 US qt, 2.6 lmp ql)
D-5
OIL FILTER
OIL FILTER
REPLACEI'ENT
1. Removethe oil filterwitha suitablewrench.
2. Usea cleanrag to wipeotf the mountingsurfaceon the
enoine.
cleanengineoiltotherubberseal
a smallamountof
3. Ap-ply
of the newfilter.
4.Installtheoil filterandtightenit by handuntilthe rubber
sealcontactsthe base.
,',,\
Y
r)+
e
tvpe(Numbersprintedon lilter)
5. Handtiohtenrnq
3i4
of a turnbv handafterit contactslhe
liltei
Tiohtenihe
block.
cvliinder
lf tighteningby handis difficult,use a suitablewrench
Example:
. Wh;n the oil filter contaclsthe cylinder block at " l " '
"4."
turn il 3/4 of a turn fulther to
type(Nonumbersprintedon filter)
tightening
Filterwrench
wrenchatTiohtenthefifter1 and1/6turnswitha suitable
tei it contactsthe cylinderblock.
6. Startthe engineandcheckfor leaks
7. Checkfie oil leveland add oil if necessary
Oll fllter capacity:
0.17 liter (0.18 US qt, 0.15 lmP qt)
D-6
OIL PAN
OIL PAN
RE!'OVAL/ INSTALLATION
1. Disconnect
the negativebatterycable.
2. Drainthe engineoil.
3. Removethe undercover
and sidecover.
4. Removein the ordershownin the figure,referringto RemovalNote.
5. Installin the reverseorderof removal,referring
to InstallationNote.
GASKET,
BEPLAC€
REPLACE
REPIACE
'@
3r-52 (4.3-5.3, 27-36)
REPlACE
{3!-110 cfrkg, 69-95 tn.tb)
1. Frontexhaustpipe and bracket
,
lhr6^r.rorl
di1l6n6r
3. Oil pan bolts
4. Oil pan
B e m o v aNl o t e . . . . . . . . . . . . . . . . . p. .a. .g. e
.D
. . -. .8.
Installation
pageD- 8
Note..........................
5. Gaskets
6. Oilstrainer
D-7
OIL PAN
Rgmoval Noie
1. Removethe oil pan mountingbolts.
2. lnserta screwdriveror a suitabletool betweenthe MBSP
and oil pan to pry them apart.
Cautlon
. Do nol Insed the prylng tool betweenlhs iIBSP ard
cylindel block.
. Do not damage or scratch the conlact surlacea.
3. Removethe oil pan.
lnatallation Note
Oil pan
\ ^ Akit*
ffi"::+
Cauilon
. lf the bolts al€ to be reused, remove ihe old aaalant from the bolt thr€ada.
Tlghtenlng a boll with old sealant on lt may cause
cracklngInaldethe bolt hole.
1. Removeall loreignmaterialfromthe contactsurfaces.
2. Applysiliconesealantto the endsof a newoil pangaskets.
3. Installngwgasketsontothe oil pumpbodyandlhe rear
cover withthe proiectionsin the noichesas shownin the
figure.
beadof siliconesealantto the oil pan
4. Applya continuous
alongthe insideol the boltholesand overlapthe ends.
5. lnstallthe oil pan.
Tightenlngtorque:
7.8-ll N.m(80-ll0
cm-kg, 69-95 in-lb)
Steps Atter Inslallallon
and sidecover.
1. lnstallthe undercover
2. Fillwiththe speciliedamountand type of engineoil.
(Referto page D-5.)
3. Connectthe negativebatterycable.
4. Startthe engineand checkfor leaks.
5- checkthe oil leveland add oil if nec€ssary.
o1aoDxo11
D-8
OIL PUMP
OIL PUMP
REMOVAL/ INSTALLATION
1. Disconnect
the negativebatterycable.
2. Drainthe engineoil.
3. Removethe timingbelt.(Referto SectionB.)
(Reterto pageD-7.)
4. Removethe oil pan and integrated
stittener.
5. Removein the ordershownin the figure,relerringto RemovalNote.
6. Installin the reverseordefof removal,referringto InstallationNote.
o
I
i
REPLACE
19-2s
(1.9-2,6,14-rs)
_
2ir-35
e,r-_3.6i1
1.Timingbeltassembly
5. Timingbeltpulley
S e r v i c e . . . . . . . - . . . . . . . . . . . . . . . . .S. .e.c. .t.i .o.Bn. . - . . . . . . S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . .S
. .e. .c. U
. . .oB
.n. . . . . . . . .
2. Oil pan
6. Oilpump
pageD-11
/ Assembly...........
Disassembly
RemovN
a lo t e . . . . . . . . . . . . . . . . . p
. .a. .g. e
.D
. . . . 8.
pageD- B
Installation
Note..........................
7. Frontoil seal
3. Aiternator
S e r v i c e . . . . . . . . . . . . . . . . . . . . . . . .S
. .e. .c. t. i. o. B
.n. . . . . . . . .
(withA/C)
4. tuC compressor
R e m o vN
a lo t e . . . . . . . . . . . . . . . . . .p.a. .g. .eD
. . .1. 0
.
D-9
OIL PUMP
RemovalNote
A/C compressor (with A/C)
Caution
. Do not damagethe hoses.
withthe hosesstillconnected.
1. Removethe A,/Ccompressor
awaytromihe engineandafiixit
2. Position
the compressor
withwire.
Sleps After Insiallation
1. Installthe oil panand mainbearingsupportplate
(Relerto pageD-8.)
2. Installthe timingbelt.(Referto SectionB.)
amountandtype of engineoil.
3. Fillwiththe specified
(Referto pageD-5.)
4. Connectthe negativebatterycable.
5. Startthe engineand checklor leaks.
6. Checkthe oil leveland add oil if necessary.
orAooxol3
D-10
OIL PUMP
DISASSEMALY
/ ASSEMBLY
1.Disassemble
in the ordqrshownin the figure,reierringto DisassemblyNoie.
2. Assemblein the reverseorderof disassembly,
referring
to AssemblyNote.
5.9-3.3 Nm (60-00.m.kg, 52-73 i.-lb)
o
e-@E.
l
t
^
s_@
1.Oilseal
Disassembly
Note...............................
below
pageD-12
Assembly
Note...
2. Pumpcover
Inspectfor distortion
and damage
3. Outerrotor
4. lnnerrotor
5. Bollpin
6. Springseat
7. Pressure
spring
pageD 12
Inspeciion..............................-....
B.Controlplunger
lnspeclfor wearand damage
L Pumpbody
/nspectfor distortion
and damage
DisassemblyNote
Oil seal
protected
witha rag.
Removetheoil sealwitha screwdriver
D-11
OIL PUMP
INSPECTION
Pressure Spring
or breaKage.
1- lnspectthe springfor weakness
the springif necessary'
thetreelength.Replace
2. [/'leasure
Free lengih: 45,5mm(1.791In)
Rotor Clearance
Beplacethe rotorif necessary'
the iollowingclearances.
Measure
93G0DX{30
Tooth tlp clearance:
0.20mm(0.0079in) max.
Outerrotorto PumPbody:
0.22mm(0.0087in) max.
Side clearance:
0.l4mm (0.0055in) max.
A€semblyNole
Oll seal
ofcleanengineoiltothelip ol a new
1. Applya smallamount
oil seal.
2. Pushthe oil sealslightlyin by hand.
r\>:>'\
;LS
Caution
. The oil sealmust be Pteesedin until it is flush wlth
the edge ol the oll PumPbody.
3. Pressthe oil sealin evenlywitha suitablepipe.
Oil seal outel dlameler:50.5mm(1.98 in)
D-12
E
COOLINGSYSTEM
..,'.'E- 2
fNDEX...................
...... E- 3
ouTLlNE,..............
E- 3
spEctFtcATloNS....,......-.......................
E- 3
GU|DE....................,.
TROUBLESHOOTING
......
E- 4
ENGINECOOLANT.
pREPARAT|ON.......................................
E- 4
E- 4
rNspEcTtoN............-.........-..................
E- 5
REP1ACEMENT..........,...........................
...... E- 6
CAP.....
RADTATOR
E- 6
PREPARAT|ON.......................................
E- 6
rNSPECTrON...................,...........,..........
7
......
ERADfATOR
............
E- 7
.............,........
REMOVAL
/ TNSTALLATION
E- 7
rNSPECT|ON............,.............................
..'... E- 8
THERMOSTAT.......
E- 8
.......,............'.
/ INSTALLATION
REMOVAL
9
EtNSPECTrON..........,...............................
......
E-10
WATERPUMP.......
E-i0
......................
REMOVAL
/ rNSTAI1AT|ON
ELECTRICCOOLINGFAN SYSTEM....'....... E-l t
c|Rcu1r..................""""""""" E-1I
SYSTEM
E-l I
sysrEM tNSPECT|ON.......................,......
E-12
...'.'
FAN MOTOR.......,..
E-12
..........................................
tNSpECT|ON
E-l2
REPLACEI,|ENT......................................
E-l3
..........................
warER THEBMOSWITCH
E-i3
...........-,.........
REMOVAL
/ TNSTALLATION
"""""" E-13
lNSPEcrloN
......E-i4
FAN RELAY...........
E-l4
.....-................
lNSTALLAT|ON
REMOVAL
/
E-l4
..."""""""""""""""""""'
lNSPEcrloN
E
INDEX
INDEX
CONNECTOF
ENGINECOOLANTTOTALCAPACITY:
5.0(5.3,4..r)
6.0 (6,3,5,3)
6. Electriccoolingfan system
1. Enginecoolant
c i r c u i t . . . . . . . . . . . . ... . . .p a g eE - 1 1
System
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e
.E
. .-. .4. . . . . .
S y s t e m i n s p e c r i o n . . . . . . . . .p. .a.g. .e. .E. - 1 1
R e p | a c e m e n t . . . . . . . . . . . . . . . .p.a. .g. eE - 5
motor
7.
Fan
2. Radiatorcap
l
n
s p e c i i o n . . . . . . . . . . . . . . . . . . .p. .a. .S. .eE. .-.1. .?. . . . .
p
a
g
e
E
6
Inspection...................................
8 e p 1 a c e m e n t . . . . . . . . . . . . . . .p. .a.g. .e.E. .-.1. 2
..
3. Radiator
B.Waterthermoswitch
pageE- 7
Removal
/ Insla|ation..................
pageE - 13
/ Insta||atron..................
Removal
4. Thermostat
9. Fanrelay
pageE- 8
/ Instal|ation..................
Removal
. pageE-14
/ Installation...............
Removal
5. Waterpump
page
E-10
/ Instaj|ation..................
Removal
E-2
E
OUTLINE.TBOUBLESHOOTING
GUIDE
OUTLINE
SPECIFICATIONS
Enginemodel
|rem
B3
iorcedc rculation
Waier<,ooled,
Coolingsyslem
lite6 (US qt, lmp qt)
Coolanlcapacily
[4IX 5.0(s.3 4.4) ATX.6O(6.3.s.3)
Centnrugal
bell-driven
Unlliedmechanicalseal
Tvpe
Openinglemperature
'C fD
86.5 89.5 (187-193)
Full-open
temperature
'C fR
1OO\212)
Fifopen ltt
mm (in)
8.5 (0.335)or more
corugatediin
Radiator
Cap valveopeningpressJre
hPa (kg/cm?.ps,
l4olorcurrenl
74-103(0.75-r.05.
1r-r5)
A
6.6+1
mm (in)
300(rr.9)
Coolinglan
Outerd ameterol blade
TROUBLESHOOTING
GUIDE
Problem
Overhealin9
Coro€lon
Possible Cau3e
Coolantlevel insuiticient
Coolantleakage
Radlator
finsclogged
Badialorcap malfunction
Cooiingfan malfunclion
Thermogalmalfunction
Walerpassageclogg€d
Waterpumpmalfunction
Remedy
Page
E-4
Clean
Clean
E-6
E-11
E-8
E-5
E-10
E-5
E-3
ENGINECOOLANT
ENGINECOOLANT
PREPABATION
ssT
49 DO150A0
49 D015002
49 DO15040)
INSPECTION
Waming
. Nevei removethe radiatorcap while lhe enginei6
hot,
. W;D a thick clolh aroundthe cap when removinglt'
. wh;n removingthe radiatorcap, loosen ltslowly
to the tirst stotuntllthe Pressureln the radlalorls
released, and then remove il.
muoEx.oo6
CoolantLevel (Enginecold)
levelis nearthe radiatorirllerneck
1. Venlythatthe'coolant
is be
2. Veritvthatthe coolantlevelIn lhe coolantreservior
marks
LoW
and
weeh the FULL
3. Add coolantit necessary
CoolantOuality
1 Verffvthatthie is no buildupof rustor scalearoundthe
radiatorcap or radiatorfillerneck
2. Veritvthat coolantis lree of oil Replacethe coolantif
necessary.
CoglantLeakage
availade)andthe
1.connecta radlalortester(commercially
neck,
filler
radiator
to
the
SST
z. AppV tO3 kPa (1.05 kg/cm' , 15 psi) pressureto the
svstem.
thatthe pressureis held
3. V'erifv
checklor coolantleakage
4. lt noi as specified,
E-4
E
ENGINECOOLANT
CoolantProtection
Caution
. Do not uae alcohol- or methanol-basedcoolant.
. Use only soft (demineralized)water In the coolant
mixture.
1. Measure
thecoolant
temperature
andspecfiicgravitywith
a thermometer
anda hydrometer.
2. Determine
thecoolantproreclion
by referring
to thegraphI
s. iili" loor"n, prot""tionis norproper,add w"te, o, "oolanl.E
Antlfreeze solutlon mlxture percentage
Coobrn pdeclion
Coolant
Above -16oC ( 3oR
Above -26oC {-1soR
65
Above-4ooo i-40on
Gravityat
2o.c (68.0
35
45
45
1054
1066
'1o78
CCfF)
COOL^NTTEMPERATUFE
REPLACEMENT
ol EoEx@7
Warnlng
. Neveropen lhe radialor cap while the engine ls hot.
. Wrapa thlckclolh aroundthccap when loosening.
. Whenremovinglhe radiatorcap, loosen it slowly
to the tirst stop unlll the presaure in the radiator is
released. and then remove it.
. Use cautlonwhen draininghol coolant.
Cautlon
. Do nol use alcohol-or methanol-based
coolant.
. Useonly sotl (demineralized)
water ln the coolant
mixture.
. Befors looseningthe radlalor draln plug, verity thal
lhe radlatgrdrain hose taces slraight down.
1. Bemovethe radiatorcapandloosen$e drainplugby hand
(MTE or by a wrench(ATX).
2. Drainthe coolanlinloa suilablecontaner.
3. Flushthecoolingsystemwithwateruntilalltracesof color
are goneithenletthe systemdraincompletely.
4. Insiallthe drainplug.
glycol
5. Fillwiththe properamountandmixtureof ethylene
basedcoolantby referring
to the tableabove.
Coolanicapaclty
lilers(USqi, lmpql)
B3
i\,ITX
5.0 (5.3,4.4)
AIX
6.016.3,
s.3)
6. Runtheenginewiththeradiator
capremoveduntiltheup
per radiatorhoseis hot.
7. Withthe engineidling,add coolantto the radiatoruntilit
reachesthe bottomot the filler neck.
8. Installthe radiatorcap.
E-5
E
RADIATORCAP
RADIATORCAP
PREPARATION
ssT
49 D015003
49 DO150A0
AdaplerB
49 D0150A0)
INSPECTION
Radiato. Cap Valve
frombe
(suchas waterresidue)
1. Removeforeignmaterial
valve
seat.
the
valve
and
cap
the
radiator
tween
2. Attachthe radiatorcapto a radiatorcaptester(commer'
gradually
to
withtheSST.Applypressure
ciallvavailable)
74-103 kPa (0.?5-1.05 kg/cm" 11-'15 psl)
3. WaitaboutlO aecgnds.Veritythatthe pressurehasnot
decreased.
4. Feplacethe radiatorcap il necessary
kk=fiK"DlN"
\{ ,l\\\//rIA\
'
\lt\v2liK\
'ii::\!@=-
E-6
-,-'-_
\\
,--A\,\
f/\\\\}1
-/ \,\
N€gative Pressurc valve
1. Pullthe negativepressurevalve10openI VerifyIhat it
whenreleased
closescomDletelv
andforcracked
2. Checkior damag;onthecontactsurfaces
or deformedsealPacking.
the radiator€p if necessary'
3. ReDlace
RADIATOR
RADIATOR
REMOVAL/ INSTALLATION
Caution
. Eetore loosening the radiator drain plug, verlty lhat the radiator d.ain hose tac€s straight down,
. Poallionthe hose damp in the originallocalionon the hose, and squeezethe clamp lightly
with large pliers to ensure a good tit.
1 Disconnecl
lhe negatrvebatterycable.
2. Drainthe enginecoolant.
3. Removein the ordershownin the figure.
4. lnstallin the reverseoroerol removal
r*n {3o-1 ro cfrrg, 6F95 hrb)
1.Cooling
fan connector
2. Coolantreservoirhose
3. Radialorhose
4. Oilcoolerhose(ATX)
5. Radiatorbracket
6. Radiator
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . .p. .a. g
. .e.E. . .7. . . . . . . .
7-Coolingfan and radiatorcowlingassembly
INSPECTION
Checkfor thetollowing
and repairor replaceas necessary.
1. Cracks,damage,and waterleakage.
2. Bentlins(repairwitha screwdriver).
3. Distoned
or bentradiatorinlet.
Sleps Atter Installation
1. Fillthe radiator
withthe specifiedamountandtypeof enginecoolant.(Referto pageE-4.)
2. Connectthe negativebatterycable.
3. Startthe engineand checkfor leaks.
E-7
THERMOSTAT
THERMOSTAT
REi'OVAL/ INSTALLATION
Caution
. Betore loosening the radlator drain ptug, verlty that the radiatordrain ho€elace€ slraighl {oll.
. Positionthe hose clamp In the originil locatlonon the hose' and squeezethe clamp lightly
with large pliers to ensure a good tll.
L Disconnect
the negatlvebatterycable
2. Drainthe enginecoolant3. Removein the ordershownin the figure.
4. Installin the reverseorderof removal.
(r.9-2.6 n-kg, ra-rg ftlb,
connector
1.Waterthermoswitch
hose
Upper
radiator
2.
cover
3. Thermostat
gasket
4. Thermostat
pageE-g
Note............................
Installation
E-8
5. Thermostat
pageE-9
Inspection.....................................
pageE-g
Note........................,...
Installation
THERMOSTAT
INSPECTION
'1.Visuallycheckthat
the thermostat
valveis airtaght.
2. Placethe thermostatand a thermometerin water.
3. Heatthe waterand checkthe following:
B3
Openinglempe.ature "C (.D
FuI'opentemperalure oC (oD
Full-openlilt
mm (in)
86.5-89.5 (187-193)
lOO1212)
8.5 (0.335)
or more
Installation Note
Thermostat
Installthe
thermostat
intothecylinderheadwiththejigglepin
at the top.
Thermoslal gasket
Installa newgasketwiththe sealingringfacingthe cylinder
neao.
0rEoE(.o16
Steps Atter Installation
1. Fillthe radiatorwiththe specifred
amountandtype of enginecoolant.(Referto pageE-5.)
z. Uonnectthe negatrve
batterycable.
3. Startthe engineand checkfor leaks.
01EOEX017
E-9
WATERPUMP
WATERPUMP
REMOVAL/ INSTALLATION
Cautlon
l-adfore toosenin' the radlator drain ptug, verity that the radlatordrain hose taces stralght do{vn.
. oJnoi aisasseiule the water purilp.-tta probtemis found, replacethe pumPas a unit'
the negativebatterycable.
1. Disconnect
2. Drainthe enginecoolant.
in the ordershownin the figure.
3. Flemove
orderof removal.
4. lnstallin the revease
f_o
@neeurce
E t
aOREPLAoE
^
_\6
FEPLACE
re-2s 0,9-2.6, t4-re)
1.Timingbelt
B
..... .... Section
Service.........-........
gasket
pipe
and
intet
Water
2.
3. Waterbypasspipeand O'ring
4 Waterpumpassembly
mounting
damaged
tor cracks,
Inspect
surface,bearingcondition,and leakage
5. Waterpumpgasket
Steps Aller lnstallaiion
i. Fi|ltn" iio"ioi ritn the spec redamountandtype ot enginecoolant(Referto pageE-5 )
2. Connectthe negativebatterycable.
3. Startthe engineand checkfor leaks.
E-l0
ELECTRICCOOLINGFAN SYSTEM
ELECTBICCOOLINGFAN SYSTEM
SYSTEMCIRCUIT
COOLING
TAGNOSTS
CONNECTOF
PBESSUFIE
ADDITIONAL
SWITCH
MAGNETIC
CLUTCH
t-](-%,re
0r EoEX.021
THEFIMOSWITCH
ABOVE91"C (196'F): ON
SYSTEMINSPECTION
1.Jump acrossthe ian testOFA)terminaland the ground
(GND)terminalof the diagnosis
connector.
2. Turntheignition
switchONandverifythatthefanoperateslithe fandoesnotoperate,inspectthecoolingfansystem
components
and wiringharness.
3. Removethe radiator
cao andplacea thermometer
in the
radiatorfillerneck.
4. Startthe engine.
5. Veritythatthefanoperates
whenthecoolanttemperature
is as specified.
Operationtemperalure:above91'C (196'D
lf thefan doesnot operate,checkthe waterthermoswitch.
(Referto pageE-13.)
E-11
E
FAN IIOTOR
FAN MOTOR
INSPECTION
1. Checkthatthe batteryis fullycharged.
the fan motorconnector.
2. Disconnect
to thelanmotorconbatteryandan ammeter
3. Connectthe
neqor.
4. Verifythatcurrentis as specilied.
Current(A)
ATX
It4TX
6.6+1
B3
and/orthetandoesnot
5. ll currentis notwithinspeciiication
replacethe lan motor'
turn smoothly,
REPLACEMENT
Cautlon
; Posiiionthe hose clamp in the orlginal locationon the hose, and squeezethe clamp llghtly
with large plierato ensu.e a good llt.
1. Disconnecl
the negativebatterycable.
2. Drainthe enginecoolant.
3. Removein the ordershownin the figure.
4. lnstallin the reverseorderof removal.
7,3-ll
x{
(30-110
d*q,
30-95
lDlD)
0,01-o.oit f (0.ra--a.22ciFtg, 015-o 1l lFlb)
0.oa'0,06 Nfl (0JHr,56
1. Coolingfan connector
2. Fiadiator
cowling
E-12
crF*!,0.3!H.5o
3. Coolingfan
4. Fanmotor
lFlb)
E
WATERTHERMOSWITCH
WATERTHERMOSWITCH
NE OVAL/ INSTALLATION
1. Disconnect
the negativebatterycable
2. Removein the ordershownin the ligure
3. Installin the reverseorderoi removal,referring
to InstallatlonNote.
GFING
FEPLACE
1.Waterthermoswitch
connector
2. Waterthermoswitch
1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g
. .e.E. .-.l.3. . . . . . .
page
Insialiation
Note..........................
E-13
INSPECTION
1. Placethe switchand a thermometer
in water.
oftheswitch
2. Heatthewatergradually
andcheckcontinuity
wilh an ohmmeter.
Coolantlemperalure
[4orethan91 (196)
'C fD
Continuity
Lessthan 84 {183)
replacethe waterthermoswitch.
3. lt not as specified,
lnstallationNote
Waterthermoswitch
1. Applya smallamountof enginecoolantto thenewGring.
Caution
. Do not use an impact wrench tor Installatlon.
2. lnstallthe waterthermoswitch.
Tighieninglorque:
5.9-4.8 N.m(60-90 cm-kg, 52-78 innb)
E-13
FAN RELAY
FAN RELAY
REMOVAL/ INSTALLATION
the negativebatterycable
1. Disconnect
2. Removethe fan relay.
3. Installin the reverseorderof removal.
:-\_
-=-=l
24
INSPECTION
as shownwithan ohmmeter.
1. Checkcontinuity
Contlnuity
@
@
NO
o @
2. Apply12v betweenlerm,rals6 an{ @;
betweentermlnals(, ano (9)
Checklor contrnuiry
replacethe fan relay.
3. lf notas specified,
E-14
F
FUELAND EMISSION
CONTROLSYSTEMS
(EGr-S)
F- 2
POSITIVE
CRANKCASE
tNDEX....,....,,...,...,,.......,..-...,......"....-..
(PCV)SYSTEM..,..........
F- 99
FVENTTLATTON
ouTLtNE.....,...,,....,...,...,......,.......,..,...
F- 99
DESCBtPTtON................-...,..............
F- 99
PCVVALVE..........,....................,.,....
CONTROL
EMISSION
EVAPORATIVE
F-l00
sYsTEM....-........,.,.......................,....
F-r00
DESCRtPTION,...,....,....................,...spEctFtcATtoNs.........................,.....
F- a
F-l01
DESCRIPT|ONS.............
F- 9
SYSTEN,i
OPERAT|ON.,..,.......,,.....,..,,.
coMPoNENT
SOLENOID
VALVE
F- 1 1
TROUBLESHOOTTNG
GU|DE...........,..,..
(PURGE
F-101
F- 1 1
CONTHOL)..,,................,..--.
FELATTONSHTP
CHART......................
VALVE
.,.....,,..,..,....,.,,,.
F-l01
FUELVAPOR
ustNG
THlssEcTtoN.....,....,.,...,,,..,,.
F- 't4
F-102
cHECKVALVEai'WO-WAn..............,..
DIAGNOSTIC
TNDEX
.....,.,.........,.,...,..
FF-102
F- 1 6
cHAFCOAL
CANrSTER.......................
PRECAUTTON
.,....,,.......,,...,,.....,.......
SYSTEM....... F-'IO3
F- 1 7
CATALYTICCONVERTER
SYMPTOM
TROUBLESHOOTING..........
F-103
DESCRtPTtON.,,..............................-.
ENGTNE
TUNE-UP...,..,,...,.,,.......,,..,..,.,
F- 61
F-l03
oATALyTtC
CONVERTER................-...
PREP4RAT|ON.....,..................,,....,...
F- 61
DECELERATION
CONTROLSYSTEM.....F-104
tNSPECT|ON.......-...............,...
F- 61
BASTC
F-l04
DESCRtPT1ON.......,.,.,...,.......,......,..,,
ADJUSTi\4ENT,..,,,..,...,,....,,.,...,........,
F- 62
F-ltX
F- 66
DASHPOT.,................,..,..,,,..,..,...,...,
SELF-D|AGNOS|S
FUNCT|ON,..,...........,
F-l05
A/C CUT-OFF
SYSTEM.........,.............,,
DESCRtPTION....,...,.........,...,.,........,.
F- 66
F-105
DESCR1PTrON...................................
PREPABATtON....,,.,,...............,.........
F- 67
F-l0s
SYSTEM
OPERAT|ON............,..,.,.......
MALFUNCTION
CODENUMBEF
.........F- 67
F-l06
DECHOKE
CONTROLSYSTEM.............swtTcHMoNtToRFUNCT|ON.......,....
F- 80
F-106
DESCFtPTtON....,,,,.......,.......-...........
TNTAKE
AtR SYSTEM.,....................,....
F- 83
F-106
SYSTE|\4
oPERAT|ON............,.........,..
F- 83
coMPoNENTPABTS.........,..........,....
F- 84
AtR BYPASSCONTROLSYSTET,.,.,..,.,F-107
tNJECTtON
BODY,.....,....,,............,....
F-107
I\4ANIFOLD..........,.....
F- 86
DESCRrpION..,,-............,.................
BAFFLE/INTAKE
F-108
sYsTEt\4
oPEFAT|ON............-............
ACCELERATOR
PEDAL.,,,,,..,........-.,..
F- 86
F- 86
AIRBYPASS
SOLENOID
ACCELEFATOR
CABLE.,,.......,....-......
F-10e
F- 87
VALVE@, @, @.............................
FUELSYSTEM,...,,..,..,.,.,,,.,..........-......
F-110
CONTROL
SYSTEI,|..........................,...
F-110
PREPARA'IrON...................,.....,.......,
PRECAUTION
.,,....,.......,......,,.,,,......,
F- 88
VtEW,...,..,...,...,..,...,..,,
F-l1 1
F- 88
STRUCTURAL
SYSTET\4
OPERATION...,.....,.-.............
UNtr{ECU..,........
F-112
ENGTNE
CONTFOL
FUELTANK,...,,...,,..,..,,,....,..,.,.,......,
F- 90
CBANKANGLESENSOR
FUELPUMP...,,...........-................,...
F- 9 l
F-r20
itN D|STRtBUTOR),...........................
FUELFtLTER.,,.................................
FAIRFLOW
SENSOR
RE1AY..........,...,..,
F- 93
crRcutTOPENING
(BYPASS
ryPq..........,.,,,. F-l21
HOT-W|RE
PRESSURE
BEGULATOR..........-.........
F- 94
wATERTHEB[,4OSENSOR...,..,,.,.,.,..,..
F-121
F- 94
iNJECTOR...............................-........
F-l22
F- s7
TfIBoTTLE
SENSOR,....,..,,,.,,.,....,..,..
EXHAUST
SYSTEM.......,......................
F-123
oxyGENSENSOR............,........,.,..,..
coMPONENT
PARTS............,..,...,,,.,.
F- 97
F-124
t\4AtN
RELAY
...,,....,.......................-..
OUTLINEOF EMISSION
F-l24
F- 9a
cLUTCHSWTTCH
fi,,4Tn,..,...,.........,-..
CoNTROLSYSTEi,............................
(L4TX).,....,.,,.....,....
F-l25
V|EW....,.....,................
FNEUTRAL
SWTTCH
STRUCTUEAL
PFESSUFE
SWITCH
F-125
POWER
STEEFING
SYSTEMD|ACR4M..,...............,.........
FVACUUI\IHOSE BOUTING
DIAGRAI\,1........,,......................,,...,.
FwtRtNGD|AGBAM...,...-..........,.....,..,.
F-
o1a0Fx.001
F
INDEX
INDEX
STOPLIGHTSWITCH
SERVICE,SECTIONT
IDLESPEED
PAGEF-€3
TIMING
IGNITION
swrrcH(Arx)
K
SECTION
SERVICE,
F-2
INDEX
F
1. Fueltank
14.Air bypasssolenoidvalve@
Removal
pageF-109
/ lnspection
/
Inspection....-............................
Insta||ation...............................
pageF- 90 15.Air bypasssolenoidvalve@
2. Fuelpump
Inspection.................p
. .a. .g. .eF
. . .1. .0. .9. . .
pageF- 91 16.Enginecontrolunit(ECU)
Inspectjon........................-........
pageF-112
R e p | a c e m e n t . . . . . . . . . . . . . .p. .a. g
. .e.F. .-. .9. 2
....
Rep1acement.............................
3. Fuelfiher(low-pressure
I n s p e c t i o n . . . . . . . . . . . . . . . . .p
. .a. .g. e
.F
. .-. 1.1. .2. . . .
side)
R e p | a c e m e n l . . . . . . . . . . . . . . p. .a. .g. e
.F. . . .9. .3. . . 17.Airflowsensor
4. Fuelfilter(high-pressure
side)
fn s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .- .1. 2
. .1. . .
pageF- 85
Replacement.-...........................
pageF- 93
Rep1acement.............................
5. Circuitopeningrelay
18.Waterthermosensor
R e p l a c e m e n l . . . . . . . . . . . . . .p
. .a. .g. e
.F. .-. .9. .3. . .
I n s p e c t i o n . . . . . . . . . . . . . . . - . .p. a. .g. .e.F. -. . 9. .3. . . .
6. Pressure
regulator
19.Throttlesensor
Inspection.................................
pageF- 94
I n s p e c t i o n . . . . . . . . . . . . . . . . .p
. .a. .g. e
.F
. . .1. .2. .2. . .
pageF- 94
Rep|acement.............................
A d i u s t m e n i . . . . . . . . . . . . . . . . .p. a. .g. .eF
. .-.12 2
pageF- 122
7. lnjectol
Removal
/ lnstallation................
(on-vehjcle)..............
pageF- 94 20.Oxygensensor
lnspection
pageF- 95
Removal/
Installation
I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. a. .g. .eF
. . -. 1
. .2. .3. . .
................
I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-. .9. 6
....
pageF-124
Rep1acement.............................
8. PCVvalve
21.Mainrelay
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a
. .g. .e.F. -. . 9
. .9. . . .
pageF-124
Rep1acement.............................
9. Solenoidvalve(purgecontrol)
l n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a. .g. .eF
. . .1. .2. .4. . .
Inspection.................................
pageF-10'| 22.Clutchswilch(MTX)
pageF-101
Removal
/ Installation................
1 n s p e c t i o n . . . . . . . . . . . . . . . . .p. a
. .g. .e.F. . 1. .2. .4. . . .
10.Fuelvaporvalve
pageF 124
Repiacemeni.............................
I n s p e c t i o n . . . . . . . . . . . . . . . - . .p. a. .g. .eF
. . -. 1
. .0. .1. . . 23. Neutralswitch(N,,|TX)
11.Checkvalve(two-way)
pageF-125
Inspection.................................
I n s p e c t a o n . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. .0.2. . . .
pageF-125
Rep|acement..........................-..
12-Charcoalcanister
24.Powersteeringpfessureswitch
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a
. .g. .e.l .- .-.1. .0.2. . .
pageF-125
Inspection.................................
13.Air bypasssolenoidvalve@
25.Crankanglesensor
1 n s p e c t i o n . . . . . . . . . . . . . . . ...p. .a. .g. e.F. .-.1. .0. 9
..
Inspection
.................. *t".,H.r_:
flil"'.Y,fl;......:.''
..... .....833:
i-:,31E
F-3
F
INDEX
5. lntakemanifold
1.Aircleaner
.. .........pageF 86
Inspection....................
p
a
g
e
F
6
2
Inspection.................................
6. Intakemanifoldstay
2. Dashpot
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. .0. 4. . . 7. Exhaustsystem
/
Removal/InsDectlon
pageF- 85
................
Installation
Removal/
I
n
s
t
a
|
l
a
t
i
o
n
.
.
.
.
. . . . . . . . . . . . p. .a. .g. e
. .F. 9 /
3. lnjectionbody
converter
Catalytic
L
page
84
F.
..
..
...
Inspection.................
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a
. .g. .e.F. -. 9 7
pageF- 85
/ Assembly...........
Disassembly
4. Bafile
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a
. .g. .e.F. .-. .8. 6. . . .
F-4
F
OUTLINE
OUTLINE
SYSTEMDIAGRAM
0
@
tr
o
E
6
I
I
s
o
,3
6
IE
tA
9*
F
o
{@
s
c<
a *
:t
?F
2=
3"
@
T-
i
E
*
9
F-5
F
OUTLINE
VACUUMHOSEROUTINGDIAGRAM
f
s
E
;
a
@
o
l
t i e
l^
O
M u {
i
6
n - A
c
F-6
e
q
q
e
F
OUTLINE
WIRING DIAGRAM
E3
2
9:
ea
€!
et
t;
E.
E;!
rt l:
l
F-7
F
OUTLINE
SPECIFICATIONS
1 , 1 0 0 1 5(3P r a n g e )
7501"3(Neutral)
Bfqq
limino'
lsnlrion
rtrui-,-
,
kPa(ks/cm' psi)
ortprip,""*,"
Below638 (6.5,92)
Nylonelement(in tuelPumP)
kPa(rCcm),Ps)
FeSrl"rrSp'e."r'"
235 275 12.4-2.A,34-40)
Air bypass solenold valve @
Alr byp.ss solenold valve @
Alr bypass solenoid wlve @
Solenold valve (purge conlrol)
't4.6-17.8
Resistance
ko
40oc 004oR
o"c (176'D
Bypasstype ol hol_wre
ko
Besistance
{HWN-HWP)
rpr<fl rs nrl lmp ga)
'tv'vt"'ry
40 00.6,8.8)
(RON90 or hgheo
Unieaded
'TEN termnal of diagnoslsconnectorgrounded
F-8
F
OUTLINE
DESCRIPTIONS
COMPONENT
Component
Rems]k
Air bypasssolenoid SLrpplies
bypassair intointakemanilold
by
valve @
openrngbypassarr passageat eitheriollowng
ilj€e1\otj
a) Ensinecrankins
b) El€ctricload
$oe'i
c) P/SpressureswitchON
d) A,/CswitchON
e) BangechangelN-D)
f) Deceleralionconlrol
Air bypass solenold
valve @
. Electricaload
a) coolingfan
b) Blowermolor swltch
c) Headlighl
switch
d) Rearwindowdehosler
switch
Supplies
bypassair anlolnlakemanifodby
openingbypassair passageal eiiherlollowing
a) Enginecranking
b) P/SpressureswilchON
c) Deceeralon conlrol
Air bypass solenoid
valve O
S'rpplies bypass air inlo nlake manifold by
opedng bypas arf passage with A/C swltch ON
Filiersair enleing injectionbody
Oil p€rmeated
Detects anrounl of inlake air; sends signal to
ECU
UsesVref(5v) as powersource
Batlle
Drrectsluel/ai. mixtureinto intakemanilold
Cat.lytic convener
ReduceHC, CO and NOx by chemcal
Storesluel tank llmes whie enginestopped
Controlspressureln iuel tank
Circuit opening retay Vollagefor {uel pump while enEne runnrnq
clutch $viich (MTx) Delectsclutchcondlioni sendssignalto ECU
Crank angle sensor
Ne.signal
SwilchOFFwhen cl'rlch pedal released
Detects
crankangleat iaoo inlervalsi
sends
signalto ECU
Diagnoslsconneclor ConcentraledseMce connectorTerminals:
1. EGI self.diagnostclerminal
2. EC-ATself-diagnostctermifal
3. Inilia set lerminal
4. Fuel pLrmpcheck lerminal
5. Coollngian ch€ck terminal
6. Enginerpm oulput telm nal
Oashpor
Preventsalter burn when throtllevaivecloses
Ehglneconlrol unil
(ECU)
Conkolsoperalon ol the following.
a) Fuelinjectionconlrol system
b) Elecironicspafkadvance(ESA)control
2l pin (locatednear leti struttoweo
c) AJCcur-otisysrem
d) Deceleralionconlrol syslem
e) Fuelp'rmp controlsystem
D Evaporativeemissionconlrolsyslem
g) Falsaleconkolsystem
h) Secondary
air injeclionsystem
Fuel lllie.
Filterspanicleslrom luel
Fuelpump
ProvrdeslLielto nleclor
whaleenginerunnng
Operates
Supply only evaporativeemissioninto charcoa
can sler lo prevent charcoai canisler from lue
F-9
F
OUTLINE
Remart
Componsnt
lghlllon swilch
(STABT posilion)
Enginecrankingsignalsent1oECU
lnhlbllor swilch
(ATX)
sendssignalto ECU
Detectsin-gearconditioni
S w i c hO N n N o r P r a n g e s
Inleclion body
a) lniectsiuel intoinlakemanilold
b) Adiuslsinlakealr amounlby throttlevalve
vave @
ct ldl;-upby air bypasssolenoid
d) Deteclsamountol intakesalr by airlow
Conssts ol throtlle vaive dashpot, throtlle sen'
sor, last idle cam, airflowsensor,inieclor,pres'
sure fegulator,and ar bypasssolenod valve
Ini6ctor
to englneneeds
lniecrsfue in relatlon
by signalslfom ECU
Conrrolled
lnjector
High-ohmic
Installedon injecton body
Main relay
(FUELINJ relay)
ECU,elc
Supplieselectriccurrenlto injector,
t{eurralswnch(t TD
sendssignalto ECU
Detectsin-gearcondiLon;
sendssignallo
Deiectsoxygenconcenlrationi
ECU
Orygen sensoa
@
SwitchON in neulral
coatng
cetamicand platrnum
Zrrconia
Contros blowby gas IntroducedInlo engine
P/S pressure 3witch
Prelsure regulrtor
P/Soperatonisendssignallo ECU
Derecrs
AdjustsJue pressuresuppliedto injector
P/SrON when sleeing wheellum€d
Specd s€nsor
stopllglrr swllch
Detects speed: sends signal to ECU
cluster
Insialled
on instrumenl
Solenoid valve
(purg. conltoD
sends
Delectsbrakingoperalion(deceleranon)i
signalto ECU
Conlrolsevaporativelumesfrom canister10in_
Throltle sercof
Deiectslhrottlevalveop€nlnganglelsends sg_
nal to ECU
body
on injecuon
Installed
Wat.r thetmos€nsor
Delectscoolanttemperature;sendssignalto
ECU
lnsraledon iniakemanlfod
F-l0
F
GUIDE
TROUBLESHOOTING
GUIDE
TROUBLESHOOTING
CHART
RELATIONSHIP
OUTPUTOEVICE
.,1
o
o
z
ts
=
=
z
F
z
z
o
o
z
=
z
o
(,
=
(,
F
@
L
z
@
o
-
9
z
zr)
e
t
=
UI
o
o
z
|r|
o
=
z
fi
I|rl
z
t5
EOAT @I{TFOL UI{IT
o
DIAGNOSISCO IECTOR CTENTEN INAL)
o
o
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(r^
to
oo
oa
>
g 9=9 . .
SO
lo
c
@
-
6? qE
n: JO
d=.u €
o
o
fi
Q . = ./Jo<
I
6-
E?
I PUT DEVICE
=
dd
9
.=
40
' J
o
z
o
o
z
o
o
o
tcNtTtol{sw|rcH (STARTPOSII|ON)
o
E/L SIGNAL'
o
o
o
P/S PRESSURE
SWITCH
o
o
o
a/c swlTcH
o
INHIBITORSWITCH(ATX}
o
o
o
o
o
EUTRALAND CLUTCHSWTTCHES
GITX)
o
o
o
o
o
o
o
o
o
o
o
sToPltGHT SWITCH
SPEEOSENSON
o
THROTTLESENSOA
o
o
o
AINFLOIY
SENSOR
o
o
o
OXYGENSENSOR
o
o
WATERTHER OSENSON
o
o
o
CRANK ANGLE SENSON O{6'SIGNAL)
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
' E/L 3lgnal ls headlighls, rear window dalroster, blow€r 3witch and cooling lan.
F-11
F
GUIDE
TROUBLESHOOTING
USINGTHIS SECTION
lntroduction
oftenmakjngit ditficultto diagnose
controlled,
Mostol the fuelandemissioncontrolsystemis electrically
problems.
actualchecks,takea few minutes
Before
undertaking
especially
intermittent
in
tho
system,
oroblems
complaintThecustomeris oftena goodsource
witha drivability
who approaches
io talkwitha customer
onecanfind
intermittent
ones.Throughtalkswiththecustomer,
especially
on suchproblems,
of inlormation
occur.
they
out whatthe symptomsare and underwhatcondjtions
work tlow
CHECK IN
I
I
TO CUSTOMEB
COIVPLAINTS
LISTEN
I
I
_ DIAGNOSTICINOEX
(Belerto PageF 14)
TO TROUBLESHOOIING
PAGETHAT
REFEB
TO ACTUALSYMPIOIV
COBRESPONDS
_ -
CHECKFORWHATIS BAD IN SYSTEM
CHECKFORWHATPARTIS BAD
_ _
I
i
RTOAIB/FEPLACEMENT
J
INSPECTION
ACTION
i
I
HASBEENELIMINATED
IF TROUBLE
DETEBI\4INE
I Yes
CHECKOUT
Diagnosticindex
DESCRIPTION:
Describes
eachtroubleshooting
ilem.
No.:
itemis
Eachtroubleshooting
assigneda number-
ITEM:
TROUBLESHOOTING
Thereare26 troubleshooting
items.Choosethe itemthat
to
mostcloselycorresponds
the actualsvmDtom.
F-12
F
TROUBLESHOOTING
GUIDE
Troubleshootingchart
. E n 0 i e . u n s n o m a y a ' r d e t rd r e
F o u s hd r e ( N o s3 , r 2 ) l
FROUALESHOOTIIG HIf,ISI
(cotr*lo^ 'or coorad rehpe'aruE)
*rnund|onc*No'ck'l.y.d
checkro' cau* (Ferer'ospsr'd
ch&ks4uercel
Che.NEcLrrem'^a lFvorase
(rernion
d ox)
3Cat.F2_rle
EC! andsenDaqDss ch4ker
05u0Fx.015
OESCRIPTION:
Furtherdescribes
the symptom.Confirmthatthechartaddresses
theactualsymptombeforebeginning
troubleshooting.
TROUBLESHOOTING
HINTS:
fhis describes
the possibleDointof maltunction.
STEP:
Thisshowsthe orderol troubleshooting.
Proceedwithtroubleshooting
as indicated.
INSPECTION:
Thisdescribes
aninspection
procedure
to quicklydeterminethe
malfunction
of parts.lf a detailed
isnecessary
to performthe INSPECTION,
referto ihe pageshownby the "F" mark.
ACTION:
Thisrecommends
theappropriate
actionto takeasa result(YeVNo)
of theINSPECTION.
Howto perform
the actionis describedon the reference
pageshownby ihe "t?" mark.
0su0F1.016
F-13
F
GUIDE
TROUBLESHOOTING
INDEX
DIAGNOSTIC
ITEI
TROUBLESHOOTING
Willnol crankor cranksslowly
2
7
8
9
Enginestallsai dle
10
11
E/L ON
Rough idle/Enginestallsjust atier sta(ng
13
14
High idle speed atterwam-up
ldle moves up and down/ldlehunting
Engrneslallson deceieralion
(lntemiten0
Eng,nesrallssuddenly
OESCRIPTION
Reierto EngineElecticalSystem
Engnecranksal normalspg€dbul showsno signot
lring
Enginecrank€at normalspeedbut showsonlypar_
andwillnolconlinueto run
tialcombuslion
Enginesladsnomallywhencold,but will notslana,
ter runningandhoisoaked
PAGE
G--4
F-17
F- r9
F-21
Eng,necranhsal rormal speed bul reqJies eices
sive cranking time belore staring
F-23
as No.swhenenginecold
Samecondition
Reslansnormallyafterwa|m_up
as No.5aflerrunningano hot
Samecondltion
F-25
F-27
Startsnoimallywhencold
Enginestallsor vibratesexcessivelyat |dle
F-29
Enginestallsor vlblatesexcessivelyal idle dlrng
F-31
Enginerunsnomallyat idleduringwatm'upbul
or stallsaft€rwarmlp
vibates excessively
Enginestallsor v bralesexcessivelyal idle wrcn
}JC, P/S,or E/LON
onlylustaner
Enginestallsof v bralesexcessively
Jromidle)
staning(acceleralion
ldle speedexcessveafterwam_up
Enginespeedsup and down pe.iodicallyat dle
E^grneune^pecledlvsloos run'nng\th le dFcele'ar
ing or atler decelefallo.'
Engineintemiltenty slops runnhg
F-35
F-36
FJE
F-39
F41
F42
F-43
16
17
Hesitates/Siumbles
on acceleration
Flatsoot occursiustalier acceleralordepressedor
mlldjerkingoccursduing acceleranon
18
Surges
Unexpectedchangein engne sp€€d which ls lsually
rep€lilive
F--45
poorunderlmd whenthroltlevalve
Pedo.mance
F-17
19
lvlaximumspeedr€duced
20
21
Runsroughon deceleralion/Backlire
22
23
24
25
26
F-l4
Highoil consumpnon
Pedormancepoot whileacceleral,ng
Enq,le runs roughwhiledeceeraing 3nd abrornal
combustion occurs in exhaust sYstem
Abnomal combustionaccompaniedby audible
''pinging" nois€
Gasoine odor in cabin
Exhaustgas smellslike rotteneggs
ercessNe
Oilconsumplion
Fueleconomyunsalislactory
F-50
F-55
F-57
F-58
F-58
F-59
F
TROUBLESHOOTING
GUIDE
Doscription ol Drivablllty
STUMBLE : Mib jerkingduringacceleration.
pedalis depressed
HESITATION:
Flatspotoccurringjustafterthe accelerator
SURGE : Continuous
softjerkingduringcruise.
03u0Fx233
ENGINESPEED
WNo.laSURGE
No.17STUMaLE
-12'1no
" """o'on
No.21
RUI{SFOUGHON
OECELEBATION
F-l5
F
22-30 12.2-3.1 , 16-22t
r+m (n-kg, n$)
GUIDE
TROUBLESHOOTING
PUMP CONNFCTOB
PRECAUTION
Fuel PreasureReleaseand ServicingFuel System
evenwhen
remalns
underhighpressure
Fuelinthefuelsystem
the enoineis not runnrno.
anytuelline,releaselhe fuelpres_
a) Beto'redrsconnecltng
ol iniury
surekom thefue syslemto reducelhe possibihtv
or fire.
1. Stanthe engine.
2. Removethe rearseatcushlon.
the iuel oumoconnector.
3. Disconnect
4. Afterthe engineslalls,turn otf the ignitionswitch.
rearseat
andinstallthe
fuelpumpconnector
5. Reconnect
cushron.
fromluelspraywhendisconnecf
b) Usea ragas protection
ino the hoses.
Pluothe hosesatterremoval.
fuelpresthefuelsystem,usea suitable
c) Wheninspecting
suregauge.
Cautlon
. Install hose clamps lo secure lhe tuel pressule
gaugetothe tuelfilterandthe tuel mainhoaeto pre'
vent luel leakage,
PinchinoHose
Whenp;ching an air hoseor a fuelhosewithpliers,wrap
the hosewitha rag to preventdamage
F-16
F
GUIDE
TFOUBLESHOOTING
SYMPTOMTFOUBLESHOOTING
CAANKSNORMALLY
BUT WILL]{OT STARTfiO COMBUSTION}
.Enginecranksat normalspeedbut showsno signol "fting
DESCRIP. . Bane.yIn normalcondrtion
.Throttlevalvenoi heldiullyopenwhiiecranking(Oechoke
syslemnot operale)
Ttotl
HINTSI
ITROUBLESHOOTING
possiblyn o r u e i s n F L l e d l o e n g r n . o r o € 1 l i o n a l d r l c / l - d a r '
Because
ol no combustDn,
€) Lowruellinepressure
O No spark
. lgntioncontrolmalfunction
@ Lowens,necompressioi
.lgnition sysiemcomponentmafunction
@ ECUpowersupplycrrcuitopen
@ ECUgroundc rcui open
@ No iuel inlection
. Fuelpump inopefalive
.Injector inoperative
INSPECTTON
l
acTtor,l
hgh.
ls svongbluesparkvsibe at disconnecled
/
>.
2
PerformSlep 2
4
a
/)
ll OK, check rgnton system
(Referto lroubleshooiing
''Misfke")
(r Page G-17
ff not OK, relerio speciJiedcheck
seqlence lor displayedcode No. F Page F-?0
ls 00" displayedon SellDiagnosisChecker
wlth lgnilLonswilchON?
ri page F-67
Maltunctlon code No. displayed
Check lor cause(Belerlo specited
check sequenceior displayedcode
No.)
"88" flashes
Check ECUlerm nal lF vo tag€
17 Page F-7o
r? page F-114
voltage: Approx. 12v
(lgnillon switch ON)
ri page F-112
ll OK. replaceECU
ll not OK. check wl.ing belween
ECU and SelfDbgnosisChecker
and ECUlerm nal 18 vollage
Ch€ckiollowng poinls
.Spark ptugs
r page c-19
. tgnjtionrmrng
E? pag€ F-63
.Engine compressiof
c? page B-lO
.Warer thermosensor
-r page F-118
(ECU 20 tem nal vollase)
.Fuel pressure
c7 page F-89
(lr njectediuel is smallariounl)
.Inlecror
17 page F-97
(li njecledfuel is smallamounl)
Checkfor lnjectoroperatingsound
whllecrankng engrne
4
+
3
Rer.oveair c eanercoveri is fuei iniecledfrom
injeclorwhie crankingengine?
1.5-2.0 Nn {15-20 crks,13-17
in-rb)
+
+
li OK, So lo nexl siep
l{ not OK, go ro Slep 6
F-17
F
GUIDE
TROUBLESHOOTING
ACTION
tNsPECT|Oll
F/P.and
terminals
connector
dlagnosis
Connect
GNDwithiumperwireiis fuelpumpoperarng
solnd evidedwilh isnilionswitchON?
-7 pege F-92
Check if iuel is iniecledwhib crankng
englne n this condftion
+
lf injected,check circultopening
4
ll not injecred,check inieclorlof
cloggingand if lue is in tank
;)).
GND
5
ls there conllnuilybelweenlLlelpump connecior
@ and @?
relay
Checkcncuitopenrng
6
at ECU2Vler_
ls thercapprox.12Vmomenlariy
m naLwhib crankingengine?
(Engrne
signalmonitorgreenand red amps
ilash)
Try io replace njector(lniectorstuck)
No
F-l8
Checkinjeclorlor continuity
+
lf OK,checkwlfinSrelatedto
2Y,2V,2U,and
ECUterrninals
+
ll notOK, repaceinjeclor
c7 page F-93
F
TROUBLESHOOTING
GUIDE
CRANKSNOF ALLY BUT W|LL r,rOTSTART(PART|ALCOtitBUSTtOt{)- U,HENEI{G[{E COLD
.Enginecranksat normalsp€edbutshowsonlyparlialcombustion
and willnot conlinuelo run
DESCN|P.. Batleryin nomal condilion
Tto
HtNTsl
rrFouBLEsHooTrilc
O Lowensinecompressron
mixtureloo rich
O Air/Fuel
. Waterlhermosensor
malluncllon
loo lean
O AidFuelrnixture
.Fuel njecton controlmallunction
(Corectionror coolanltemperature)
.Low iuellinepressure
.An leakageof inlakeair system
INSPECTION
1
ACTION
ls 0O displayedon SellDiagnosisChecker
wlth ignilion switch ON?
MallunctionCodeNo. displayed
Checklor cause(Reierlo soeciiied
checksequence)
17 pageF-m
"88" llashes
CheckECUlelmlnal1F voliage
F pageF-114
Voltage:Appror. 12V
(lgnltlon switch oN)
TESTSWiSELFTEST
a
4
ll OK,replaceECIJ
c7 pageF-112
I nol OK.checkwiringbelween
ECUand S€lf-Diagnosis
Checker
?
/\^\_
/
Checf d sr ouror cdp ard rolor
c:i page G-23
d\<<=F
3
=I)'b B\
Connectdiagnosis
connecror
letminals
F/Pand
GNDwilhjumperwne; s lherecorrectluelline
pressure
withlgnitionswitchON?
e page F-49
Fuelllne prossuae:
235-275 kPa (2.4-2.a kg/cm', 34-40 psD
Check luel line pressurewhile p nch
+
-:
PFFSSUREGAIIGE
' l
ll tuel line pressurcquickly increases,check pressureregulalor
il luel line pressufegraduallyin.
creases,check lor clogging belween tuel pump and pressure
lf not clogged,check luei pump
max mum pressure
t""
otAGNOStS
CONNECTOF
e
page F-91
High pre$ure
ls llel relurnhosecloggedor res,
lricled?
+
.)
ll OK,replacepressure
regulalor c? pageF-94
ll not OK,repa.or replace
F-19
F
GUIDE
TROUBLESHOOTING
ACTION
INSPECTION
AreECUteminalvoltagesOK?
1C,1K,20 and 20)
lEsDeciallv
c7 PageF-112
5
ls lhere air leakageol intakeai svstemcom-
6
is
Doesenginestartswhenwalerthemos€nsor
7
A'e spark plugs OK?
Checkior cause
-
Page F-114
F-l16
Chbck waterthermosensor
!7 page F-121
Clean,or rep ace
tr- Page G-19
F Page G-19
WEAFANDCAFBONBUILDUP
BUBNS
(0.039-0.o4i,
AND
DETERIOFAIION
a
No
correct?
comorcssion
ls enoine
s PageB-10
Try knowngood EcU andcheckaf
EnoinecomDression:Morethan 1,030kPa
(t-o.srglcr;'. 149psi)-300rPm
Check enginecondition
.wofn pston, pislonrings or cylinder
.Defectivecylinderhead gasket
. Distorled cylindff head
.lmproper valve s€atng
. Valveslickinsin Suide
F-20
.? Page B-10
F
GUIDE
TROUBLESHOOTING
CNANKSNORMALLYBUT WILL OT START(PARTIALCO AUSTIOII)- AFTERWARM.UP
.Enginecranksat nomalspeedandshowspartialcombustion
but willnotcontinue
lo runaflerrLrnning
and
DESCBIP.
.8atteryin normalcondition
Tt0ll
. Engne slartsnormallywhencold
Ht{Tsl
rrRouaLEsHooTtNG
@ Vapoflock
.Fuel pressu.e
not heldin luelIne afierensinestopped
.Hish RVP(winler)
luelusedin warmweather
O Ar/Fu6l nixture too ch
.lnsuftcienttuellnjection
conlrol
(Corr€ct
on lor coolanltemperalue)
.lnjeclortuelleakase
INSPECTION
to normal operaling lempera-
1
ACTION
Changeluel io anolherbrand
;is conneclorterminalsF/P and
Connecldiasnor
GNDwithjump€r wire ior 3 minrres with ignilion
swilchON,then
,'
JUMPEFwlFE
l#
---t I 64\
@t),x.
,/,1{Q
2
Jl l^
\
\
ts
lermlnals
F/Pand
Connectdiagnosis
connector
cor
GNDwithjumperwireiis tueillnepressure
r€ct wilh ignitionswilchON?
rr page F-89
Check fueLline pressurewhile pinch'
235-275 kPa (2.4-2.a kg/cln', 3/t-40 psi)
.+
PRESSUFE
a
FUELFILTEFi
.riupin wrne
High piossure
ls iuel returnhosecloggedor res
+
+
3
ln samecondilionas Slep2, is tuel ine pressure
heldafterignitionswitchls lurnedOFF?
e p.ge F-88
lf luel llne pressurequicklyincreases, check presslre reguiator
I luel line prcssuregladuallyln
cr€ases,check luel line and filter
for clogging
li not clogged,check fuel purnp
maxirnum pressure
r7 page F-91
li OK, replacepressure
regulator s pageF-94
li nol OK, repairor replace
Go to Step 5
Fuel llne pressure: Morc than 147 kPa
('1.5kg/cm',2t psi) for 5 min.
is fuelIne
Plugoutleiof prcsslreregulator:
pressure
heldatlergnilionswilchis lurnedOFF?
17 page F-88
Fuelllno prc3surq Morethan !47 kPa
(1.5 kg/cm' ,21 psOfor 5 min.
BeplacepressLrre
regulatof
r- page F-94
Check fuel pump hold pressure
c7 page F-84
4
4
lf OK, check inlectorior fuel
leakage
lf nof OK, rcplace iue pump
F page F-96
.r page F-92
F-21
F
5
GUIDE
TROUBLESHOOTING
ACTION
Ch€ckwaterlhermo€ensot
TNSPECTtOt{
O:sconneclwaterthermosemorconnectoridoes
c7 gage F-121
+
It OK, checkconn€clionsot waler
and ECU20
themosensot
4
ll not OK, feplacewaterther
mosensor
(j PaSeF-121
Mallunction code l{o. disPlayed
Checkior cause{Belel lo specined
checksequerce)
f? Page F_70
"88" llasheg
CheckECUteminal1F vollage
c7 page F-114
No
6
Checker
on S€lt_Diagnosis
ls 00" displayed
switchON?
wnh ionition
t7 Page F-'67
vollage: appror, 12v
(lgnltionswitch oN)
4
+
7
8
!1'PageF-112
ECU
li OK,replace
li nol OK,checkwirng between
Checker
ECUand Seli'Diagnosis
OK?
Are ECUterminalvoltag€s
(Especrallv
1C,20 and 20)
c7 PageF-i12
Checklor cause
-
Try knowngoodECUand checkii condilion
ReplaceECU
F Page F-l 12
Changetuelto anotherbrand
F-22
PageF-115
F-l17
F-lt9
F
TROUBLESHOOTING
GUIDE
CRANKSNORMALLYBUT HARDTO START- ALWAYS
.Englne cranksal nomal speedbut req'rnesexcessivecranklngllme berorestarling
DESCRIP.. Batlervln norrnaconclition
Ttol{
.Enginerunsnomallyat ldlefll idlecondllionnotOK,referto "Boughidle"(Nos.8 l2)l
G HTNTSI
FnoUBLESHOOTtfl
rnixture
too lean
@ Air/Fuelm nure ioo ich
O Air/Fuel
.Fuel injeclion
.Fuel injection
controlmalfunclion
controlmalluncion
(Correclionlor coolanttemperalure)
(Correclion
tor coolanltemperaiurd
.Calbondeposilin hot-wire
passaSe
.Low luellin€pressure
@ Poo'isnitionspafk
ACTIO
tNSPECTtOl{
ls 00" dsplayed on Selloiagnos'sChecker
wth iqnitionswilch oN?
F page F-57
ma[unciion Code l{o, dlspl.yed
Checkior cause{Referio soeciiied
checksequence)
? p.ge F-70
"88" tl.shes
CheckECUtermlnal1F voltage
c7 page F-114
Vo[.g€: Appror. l2V
(lgnitionsvritchO )
+
4
2
ls there a r leakage ol intake air syslem com-
3
s ar cleanerelementclsan?
-
page F-62
No
Doesenginesla( easllywhen lhrofle valve
5
t:" p.ge F-172
lf OK, replaceECU
ll nol OK,checkwiringbelween
ECUandSsll-Diagnosis
Checkef
Repaceair c eanerelemenl
Ch€ck throtle valvetor carbon depost and lhen go to Siep 6
ls iuelIne prcs$rrecofieclal idle?
F page F-94
235-275 XPa 12.4-2.A kg/cm" 34-40 psD
whilepinchCheckluellinepressure
+
+
quicklyinll fuelllnepfessure
regulalor
creases,
checkpressure
gradually
ll fuelllnepressure
in'
creases,
checkfor cloggingbelweentuel pumpand pressure
ll notclogg€d,ch€ckiuelpump
maimum prcssurc
F page F-91
FUEL FILTER
F-23
F
GUIDE
TROUBLESHOOTING
ACTION
INSPECTION
6
ls ar bypasssolenordvalve@OX?
r' p.g€ F-104
No
SOLENOID
VALVE@\\\
r)
o
7
8
9
Replacesolenoidvalve
INJECTIONBODY
k!
Are ECUterminalvoltagesOK?
(Esoec,aly
1C,th and20)
c? Page F-lOg
Go lo nexl slep
Connect cliagnoss conneclor tetminals F/P and
GND with iumperwirei does engrnestan
Eneckcircultopeningrelay
Cn""f io, "uuse
a
ff rclayOK, repairor teplacewi€
+
li r€laynoi OK, repiacerelay
r' PageF-115
F-117
F-l19
c7 PageF-93
connector
ConnectSystemS€lectorto diagnosis
'i
and setT€st Switchto SELFTEST is lhere
lmng €t dle aiterwarm_up?
corecl |gnrtion
e PageF-63
lgniliontiming: aTDC16 + 1c
,-JE"
1 0 ls enginecompressioncorreci?
c7 page B-lo
Englnecompres€lon(ilinimum):
1.030kPa (10.5ksr'cn', r49 Fel)-300rPm
1 1 Try knowngoodECUIdoescondilionimprove?
F-24
Adjust lgntion iiminq
!? Page F-63
c? PageB-1o
Checkenglnecondition
.Wornpislon,pLston
nngsor cy lnoer
. Delecuve
cylinderheadgaskei
. Dlsroded
cylinderhead
. lmpropetvalveseating
.valvestckinsin guide
F
TROUBLESHOOTING
GUIDE
CRANKSNORMALLY
AUTHAROTO START- WHE E GINECOLD
.Englne crank al nofmal speed but rcquires excossive cranking lime before slarl ng
DESCRIP.. Baltery n nofmal condition
. Festarc OK after wam-uo
TION
.Engrne runs no.mallyat idle [f idle cond]tionis not OK, r€terio 'Roughldle' (Nos.8-12)l
HtNTsl
rrnouBLEsHoollt{G
O Air/Fuelm)duretoo rich
.Fuel injeclion
convolmal,unction
(Correction
tor coolantlemperature)
.Thermowax
mallunclion
INSPECTION
ls "o0 displayed
on SellDiagnosis
Ch€cker
wlthignitionswitchON?
17 page F-67
SYSTEMSELECT:r
m xiureroo ean
@A1r/Fuel
.Carbon deposltln hol wire passage
. Fu€linj€ction
conlrolmalfunction
(Coffeclionior coolantlemperalure)
@ Pooratomzation
. LowRVP(summer)
fuelb€rngused
ACTION
MalfunctlonCode No, displayed
Checklor causeFeler 10soeciti€d
checksequencei
E? page F-7O
"88" llashes
CheckECUterminal1F voltage
c7 pageF-'l 14
Voltage:Approx.12V
(lgnition switch ON)
d
4
2
3
rr page F-112
ll OK,replaceECU
ll not OK,checkwiing betlveen
ECUandSelfDiagnosis
Checbr
Are ECU leminal vollagesOK?
(Especiaiy1C. 2D, and 20)
-:r page F-112
Checkfor caus€
Does engineslart easilywhen throtllevalve
Check lhemowar
4
4
c7 page F-115
F-117
F-lt9
c7 page F-85
f OK, go to Srep 5
ll nol OK, replaceinjeclionbody
ls there air leakageol inlakear systemcom'
5
ls arr cleanerelementclean?
cr page F-62
Beplaceair cleanerelement
6
Are sparkplugsOK?
e page G-19
WEABANDCAqBON
AUILOUP
BUFNS
(0.039-0.043 in)
E AND
DETEFIORATION
F-25
F
GUIDE
TROUBLESHOOTING
correctal idle?
ls iu6llin€pressure
t7 Plge F-94
Fuel line pre$uaa:
235-275 kPa (2.4-2.8 kgL/cm"3{-40 p6i)
Checkluel line pressurewhil€pinch_
ing iuel r€lum hose
quicklyin_
lf fuellinepressurc
creases,checkpressureregulator
in_
+ ll fuellinepres$rregradually
ch€ckluellinelo. clog_
crcases,
ging betwe€nfuel PUmPand
pr€€sureregulalor
ll nol clogged,checktu61PumP
c? PageF-91
pressure
maximum
High prcs3ure
ls tuel rettim hosecloggedor fes
+
lmprove?
Iry knowngoodECU;doescondition
+ ll OK, replacepressureregulator - Page F94
4 ll nol oK, reparor replacehose
c7 PageF-112
Replace
ECL,
Changefuel lo anotherbrand
F-26
F
TROUBLESHOOTING
GUIDE
CRAI{KSI{ORI{ALLY zuT HARDTO START - AFTERWABi&UP
.Engine cranksat normalspeedbut requiresexcessivecrankingtme beiorestadingaller runninoand hol
DESCRIP.. Baiteryin normalcondition
. Enginestarlsno|mallyvlhencoLd
.Ensinerunsnormally
nol OK,referto Roughidle"(Nos.8-12)l
al idlelll idlecondltion
TSI
HI
ITBOUALESHOOTING
@ Vaporlock
O Ai/Fud rni(ureloo rich
.Fuel pressufenot heldin luellineafterengineslopped
. Fuelinjecton conlrol malfunclion
.HiSh RVP(wider)fuelusedin warmwealher
.hieclor luel leakage
n0
acTrol{
r{sPEcTtot{
1
ls "00" displayedon S€llDiagnosisChecker
with igniiion switch ON?
NO
allunc{lon Code No. dlsplayed
Checkior causeSeler to soectied
checks€quence)
"88" tlashas
CheckECUrermlnal1Fvoltage
c7 pag€ F-70
s pag€F-114
Voll.ge Approx. 12V
(lgnition switch oN)
=) lf OK, r€placeECU
E' pag€F-112
+ lf not OK, ch€ckwiringbelween
ECU and SellDiagnosisCh€cker
2
3
Go to nextstep
Are ECUterminalvoltages
OK?
(Especlally
1C,20, and 2T)
c7 PageF-l12
is held
Runengineal idleiis luellin6prossure
afterignilionswitchturnedOFF?
.7 p.ge F-88
Fu€t llne oreaaure: More then 147 kPa
(t.5 kg/cmz,21 psl) tor 5 fiin.
Checktor cause
NO
F pag€ F-115
F-|17
F-l19
Plugou.tlelof pressureregllalor and
is heldafier
checkil Juellinepressure
ignilionswitchlurnedOFF
.+ lf OK, replacepressureregulalor 17 page F-94
+ lf nol OK,ch€ckluelpumphold
pressure
.7 pago F-88
lf luel pump is OK, ch€ckintector
r? page F-96
lor iuel leak€ge
F-27
F
JTEP
GUIDE
TROUALESHOOTING
ACNON
Changefuel to anotherbrand
|l{SPECT|O}l
Warm-upenginelo normalop€ratngtemFera_
lureand slopil
F/Pand
conneclorterminals
Connectdraonosis
GNDMh iumos wirator 3 minule6wilhignition
switchON; do€s if englne$ans easili/?
Go to nexts|ep
5
Heptace ECU
Try knowngood ECU;do€s condilionimprcves?
NO
F-24
ChangeJuello anolherbrand
E? l,d,ge F-112
F
TBOUBLESHOOTING
GUIDE
ROUGHIDLE/EXGINESTALLSAT IDLE _ ALWAYS
a
DESCBP- .Engrne sads normalv bul stallsor v,braresexcessvey al idle in everyco']d ion
|
HtitTSl
FROUALESHOOTTNG
mixlureloo lean
O Air/Fuel
rn r^^^-4r
. Fuelinjeciion
conlrolmalluncUon
.Low luellinepressure
@ Lowintakeair amount
INSPECTION
1
ls "0O drsplayed
on SeJi-Diagnosis
Checker
wilh ignitionswltchON?
iira clEAd
. ldlespeedmisadiust'nent
@ Oneor moresparkplugsnol firlng
O Lowenginecompression
@ Carbondepositin injectonbody
ACTION
Mallunclion Code No. dlsplayed
Checkfor caus€lRete.to soecilied
checksequence)
.? page F-70
"8a" tlaEhes
CheckECI.J
lerminal1F voltag€
c? pageF-114
Voltage Appro!. 12v
(lgnltion€wltchO )
+
+
2
3
AreECUteminalvoltages
OK?
(Esp€cially
1K,2M,20 and20)
-r page F-112
Disconn€€leach hightensionlead al idlei does
enginespeed decreaseequallyat each cylinde?
o p.ge F-112
ll OK,replaceECU
ll nol OK,checkwlringbetw€en
Check€r
ECUandSellDiagnosis
Checktor cause
F pageF-115
F-117
F-l19
Go to Step 5
ls slrong blue spark visibleat disconnectedhigh-
Ch€ck hrghlensionlead
/
+
+
5
Arc sparkplugsOK?
c7 page G-19
WE1AFAND CARBONBUTLDUP
ll OK, check distrbuto. cap and
rotor
It nol OK, replacehighlenson
F psge G-23
c7 p.ge G-23
Checktof corect enginecompression rt'page 8-10
+
+
lf OK, replace injeclor
lf not OK, checktor cause
c? Page F-96
F psge B-10
AURNS
(0.039-0.0,*l
Cean or replace
F page G-19
DETERIOFAIION
F-29
F
STEP
6
GUIDE
TROUBLESHOOTING
lgnitiontlming: BI
16
t
-tfi"
INOICATOF /
7
.- /fEN
GNo
Adtust gniton timing
,
Dtl.r9*
corrcclal idle?
ls luelIne oressure
c7 Page F-94
""'*Y"'-94u9:-lwlllK;/
-\-,aJ.6V.]Ly.V /
9
17 Page F_52
//
Fuel line pressure:
235-275 kPa 12.4-2.A rg/ctn', 34-40 psi)
{vacuum hos€ to pte*3ure regulstor dlsconnected)
., .ih, (\
)
I
ACTION
INSPECTION
to diagnossconn€ctor
ConnectSyslemSelector
to 'SELF'IEST"|is coffecl
ri at idle aiter walm up?
ignitiontimingcorrer
.7 page F-62
Checkfuel line ptessurewhileprnch_
+
+
ll fuel line pressurequicklyin_
creases,check Pres$re regulalor
I fuel line prcssll|esraduallyIn_
creases,check lor cloggingbe
tweenfue punrp and pressure
regulatot
It not clogged,check fuel PUmP
I
maximum pressure
Page F-91
FUETFIITEF
ls thero an bakage ai intake air syslem com
correcl?
ls eno
- ne cornpression
e paEeB-10
Try knowngoodECUanddoescon
Ensinecompression(r !nimum):
t,o3o tPa Oo.5 kg/cm'. 149Psi)-300rPm
Checklor cause
F-30
F Page B-lO
F
GUIDE
TROUBLESHOOTING
WARM.UP
ROUGHIDLE./EI{GINE
STALLSAT IDLE_ BEFORE
excessvely
al idledurlngwarm_up
OESCRIPI .Enginespeedlow or enginestallsor vibrates
Ttolt
l
9
HTNTSI
frRouBLESHOOT|i,rG
ar amount
O Lowlntake
O Low fue njectiof control
.Fuel njectioncontrolmaifunclion
(Coiiectionfor coolanltemperalure)
@ Poor alornization
.Low BvP (summe0fuel used in cold wealher
.Carbon deposilln injectionbody
.Aif cleanerelementc ogged
. Thefiowax unil sluck
ACTION
INSPECTION
1
ls "00 ' displayedon SelfDiagnosisChecker
wilh igniton switchON?
F page F-67
Malfunction Code No. displayed
Check tor cause(Felerto specilied
check sequence)
r? Page F-70
"68" tleshes
CheckECUt€ffninal]F voltage
(7 gage F-114
Voltage:Approx.12v
(lgnitionswitchON)
TESTSW:SELFTESI
2
ls there ar leakageo{ intakeair syslemcom-
3
ls air cleanerelemeniclean?
+ lf OK,replace
rpageF-ll2
ECU
€. It nor OK,checkwkins belween
ECUandSef-OagnosisChecker
17 page F-62
Aeplaceair cleanerelement
Are ECU lelm nal voltagesOK?
(EspecialylK, 2M, 20, 2T and 20)
r. page F-112
5
Checkior cause
F Page F-115
F-117
F-119
Beplacesoenoidvaive
r7 Page F-109
rs a r bypasssoenold valve @ OK?
r? page F-!09
ai
:
SOLENOID
INJECTIONBOOY
varvE(A\\'
r)
o'
,(4)
F-31
F
GUIDE
TROUBLESHOOTING
ls waterihermosensorresslancecorrec?
Beplacewaterlhemosensor
r- page F-121
Reolaceinieclionbodv
F Page F-84
Adjust€ntion limlng
G Page F-62
lo dlagnosisconneclor
ConneclSyslemSeleclor
'SELFTEST when en_
and set Test Swtch lo
g i n el s c o d
Does enqine speed decr€aseas engrnewarms
to diagnoss connector
ConnectSystemSeector
"SELF TEST
and sel Tesi Swllchto
ls rqnlrontrmng corect al tdb aner warm upt
ci page F-62
lgnilion tlming: BTDG 16 * 1"
GND
INDICATOFI
TESTSW
G oaae F-112
Try known good ECU; does conditon improves?
Changetue to anoiherbland
F-32
F
TROUBLESHOOTING
GUIDE
ROUGHIDLE/ENGINE
STALLSAT IDLE- AFTERWARII.UP
10
DESCRIP. .Enginerunsnormally
al idleduringwam-upbutenginestallsor vibralesexcessively
aflerwarm-up
TION
HINTSI
ITROUaLESHOOTTNG
O) rdlespeedcontrorsvslemmallunction
@ Air/Fuelmixtureloo lean
@ ArlFuelmi(ure too nch
.Fuel injeclon controlmal,unclion
(Corectionior coolanltemperature)
@ Poorignilion
on
O Lowenginecompress
.Low fuellinepressure
. PCVvatvestuck(open)
INSPECT|oiT
1
ACTION
ls 00" displayedon Self-Diagnosis
Checker
with ignilionswitchON?
e page F-67
llalluncfion Code ilo. displ.yed
Checklor causeGeler lo so€cilied
ch€cksequence)
(? page F-m
"8a" tlashes
CheckECUterminalF vollage
c7 page F-114
Volreg€: Approx. r2V
(lgnition switch ON)
+
+
2
3
Are ECU lerminalvoltagesOK?
(Especially
1K,2M, 20 and 20)
F page F-112
li OK,replaceECU
rz page F-112
ll noiOK,checkwiringbolween
ECUand SellDiasnosis
Checker
Checkior caus€
c7 page F-115
F-117
F-r9
Disconnecthighlensionlead at dle; does englne speed d€creaseequallyal al cylinders?
Go to Slep 10
ls ihere air leakageol intakearr systemcom-
5
ls air cleanerelementcl€an?
e page F-62
No
6
lurn thronleadjuslingscrewc,
doesidlecondilionimprove?
R€placealr cleanerelement
Adjust idle speed
.? page F-62
AIFFLOW SENSORI
-ffiqf l";;I
No
=.\\\
Relurnlhrottleadiuslingscrewto its
originalpositlon,
andgo to nextslep
/
F-33
F
GUIDE
TROUBLESHOOTING
ACTION
INSPECTION
7
ls fuel line pressurecotrect at idle?
c? Page F-94
Frel lih6 pr$sure:
235-275 kPa (2.4-2.A
whilepinch_
Checkfuellinepressure
kg/cmz, 34-40 p3l)
+
+
quicklyIn.
ll fuellinepressure
regulator
checkpressure
creas€s,
g€duallyinll iuellinepressure
checktor cloggingbe_
creas€s,
tweenluel pumpand pr€ssure
lf notclogged,checkiuel pump
E7 Page F-91
maximumprsssure
I
to diagnossconnector
ConnectSystemSelector
"SELFTEST
and set TestSwitchto
ls ignitionlimingcorrectat idlealt€rwarm_up?
(7 gage F-€ 2
Go to nexl step
No
Adjuslignrtionsystem
r' Pag€ F-62
lgnitionllmlng: BIDC 16 + 1'
9
Replacewat€rthermosensor
Disconnectwaterlhermosensorconneclor
imprcve?
Doesenglnecondition
No
TryknowngoodECUandcheckil
correcP
comoression
1 0 ls enoine
.7 page 8-10
Enginecompression(llhlmum):
I,O3OkPa (10.5kgL/cm',149 psl)-3lx)rpm
11
Checkengine
r? Page &-10
Check high'tension lead
.7 page e-23
ls slrong blue spa visibleal each d sconnecled
hgh'tensionlead?
c-----,-- \-\
<72oNl #
4
/
+
/
12
Try knowngood ECUand check
AresparkplugsOK?
s pagoG-19
WEAFANOCAFiBON
BUILDUP
BUANS
(0.039-o.043
NO
DETEBIOBATION
F-34
lJ OK, check dislrlbulorcap and
rotor
ll not OK, replacehightensron
F page G-23
F
TROUBLESHOOTING
GUIDE
'tl
ROUGIIIDLE/E GI E STALLSAT IDLE - WHEI{ A./C.P/S, EIL OI{
.Enginestallsor vibratesexcessively
at idlewhenP/Sor E/LON
DESCRIP..AJC, P/S,
headlights,blowertan and e{eciriccoolingfan opelale normally
Ttol{
.ldle condilionis normalwhen!,/C. P/SandE/Lare OFF
rrRoualEsHooTtitcHtNTsl
O tdle spe€d control svslem malluncljon
;TEP
INSPECTION
ACTION
ls 'OO dlsplayed
on SeliDiagnosis
Checker
wilh ignitionswilchON?
F page F-€7
SYSTEMSELECII I
ll.ltuncllon Code l{o. displayod
Checktor caus€lReferlo soecilied
check sequenc€)
rr p.ge F-m
"88" llasha6
1F voltage
CheckECUterminal
c? page F-ll4
Vollage: Apprcx. l2V
0gnlrbn switch Ol{)
.'
+
2
UsingSellDiagnosis
Ch€cke.MonitorLampiare
switchesOK with ignilionswitchON?
F pege F-80
NO
k@tl
e page F-112
li OK,replaceECU
ll not OK, checkwiring belween
Check€r
ECUandSelf-Diagnosis
Lamp nol ON or OFF wllh speclfied swatch
Checkior causeFefer lo sDecifed
check sequence)
tr7 P.ge F-81
F-82
L.mp alwaF ON
Checkwringbeh{eenECUlemina
1D andSellDiagoosis
Check€r
3
ls air bypasssolenoidvalveOK?
Adjust dleup enginespeed
s page F-64
. A/C.....Solenoid
valve @ rr prge F-109
. E/L.....Solenoid
valve@ c7 p.te F109
. P/S.....Solenold
v.lve @ r? page F-109
NO
Replace solenoid valve
AtR AYPASSSOL.V.
rf .4
./ (o lF
//-!hV
q"l' ,&
AIF BYPASSSOL.V, @
l
t
l
'
F-35
F
GUIDE
TROUBLESHOOTING
NOUGHIDLE,/ENGIIIESTALLSJUST AFTEBSTATIING
DESC-RtP-.Enstr€ stansnormallybut vibratesexcessivelyor slallsj0st atler starting(acceleraliontlom idle)
.ldle conditonsar€ normalin olherconditons
Trotl
Hll{TSl
TTBoUBLESHOOTING
ml{ure loo lean
@ Throltlesensormailur'ction
O Air/Fuel
l2
.Fuel injeclion
controlmalfunction
. Lowluellinepressure
tNSPECT|OI{
}TE'
ACTION
ls OO"displayedon Self-DiagnossChecker
with ionition
swilchON?
c? page F-67
No
SYSTEM
SELECT:1
lr.ltunctlon Code No. d|sPlayed
Checklor cause{Referto specilied
checks€ouence)
c7 PzEeF-7O
"88" tlash€5
CheckECUierminallF vollage
ca p.go F-114
Volt.ge: Approx.12v
(lgnitlon 3witch ON)
+
+
2
c? PageF-112
It OK,redaceECU
ll nol OK,checkwirlngbetween
Checker
ECUandS€lf-Diagnosis
ls thereair leakageof intak€air systemcom_
No
3
conectal idle?
ls tuelIne prescure
e page F-94
295-275 kPa 12.4-2.a kg,fcmu,3l-40 psl)
while
Checifor fuelIne pressure
pinchingtuelfelumhose
quicklyin_
ll fuellinepressu.e
creases,checkpressureregulaior
gradually
In+ ll fuellinepressurc
creases,ch€ckfor cLoggingbe
Meen luel pumpand pressure
r€gulator
lf not clogged,checkluel PumP
.? PageF-91
maxmum p€ssure
Hlgh pre33t|re
ls fuel line clogged?
+
!o dlagnosi
ConnectSyslemSeleclor
and set TestSwitchto 'SELFTEST"
ls ignltiontimingcorreclal idleaiter
go F--{t3
4
+
,TEN
f::
GND
INOICATOFI
F-36
(
l
]/ TES
\tg-aL
+ ll OK, replacepressureregulalor rj' PageF-S4
+ lf not OK,rcplace
as StsP3 in_
In samecondilion
specIon
.? pag€ F-63
Check'o' conecl idle speed
ldle speed: 750 'l rPtn (tilTx)
1,t00 '1lpm (ATX)
6
ll OK, go io nexl step
ll not OK, adjustidle speed
17 page F-63
F
TROUBLESHOOTING
GUIDE
STEP
utsPEcTtoN
5 Are ECU lerminalvoltagesOK?
(Especially
18, 2M, 20, and2Q)
ACTION
Go lo neil step
Nole
When ch€cking voltagss, tap, moye, and
wlgglo harmss and connector to recreate
6
Arc sparkplugsOK?
WEAFANDCAFBON
BUILDUP
EUBNS
{0_03$-0.043
OETEFIIOFATION
7
ls enginecompression
correc?
F page E-10
Englnecompression(Minimum):
1,030kPa (10.5kg/cm', 1as psl)-3oo rpm
Try knowngood ECU and check il
NO
Check engine
c7 page B-lO
F-37
F
GUIDE
TROUBLESHOOTING
HIGHIOLESPEEDAFTENWANM"UP
.ldle spe€dexcessivealter warm_up
HI TSI
ITROUBLESIIOOTING
to engne
EicssJveinlaksan supph€d
O Throttlevalvenol lully clos€d
@ ldle spe€dcodrol mallunction
.Thermowax
malfuncton
.Air bypasssolenoid
valveON al idle
. 1,./C,P/Sor E/L sgnai senl lo ECU
ls lhfotle valvetullyclosed whenaccelerator
ls lhrottlelinkagecorrcc{y installed
+
+
Oo€s iast idle cam release throttle levs?
ls "oo" displayedon SellDiagnosrsChecker
switchON?
with lonition
-7 paq'eF-67
lf OK,go to Slep2
ll nol OK,clean,adjustor replace
linkage
Adjustidle sp€edby iumins throtlle
!7 page F_63
lltaltunction code tlo. dlspl.yed
Checklor cause(Beierto sp€cilied
check sequence)
t- Pzge F-7O
"a8" llashe3
CheckECUterminal1Fvoltage
e page F-114
voltaoe
- AoDrox.12v
0initlon switch oN)
+
+
2Q,2R,and
Are ECU1P, ]R, 15, 1T,lU, 2[,'1,
2T lerminalvoltagesOK?
(? P.ge F-112
ff OK,feplaceECU
wiing
belween
check
lf not OK,
Checker
ECU and Selt-Diagnocis
Adjustidla speedby lurningthrot s
'
Chechtor cause
F-38
r'. Pagc F-63
_7 pag. F-115
F-117
F-l19
F
TROUBLESHOOTING
GUIDE
HUNN G
IDLEMOVESUP AI{ODOWN/IDLE
t4
DESCRIP.
| .Engine spesds up and down periodicallyal idle
TroN
I
HrNrsr
5X?u68j*:SoorNG
@ Throfle sensormisadjusted
amounlnconstant
@ Fuelinjection
@ Poorignition
STEP
INSPECTION
1
ls rherea r leakaoear intakeair svstem?
2
acrtot{
Repajror replaceleak€gepoinl
ls PCV valve OK?
cz page F-99
NO
3
ls arrcl€anerelemenlclean?
4
Disconneclhighlensionlead at idle does en
gine speed decreaseequallyal each cylinder?
5
ls '00 displayed
on SefDlagnosis
Checker
wlh ignirionswtchoN?
e page F-57
No
Go1ostep9
NO
MaltunctionCodeNo. d|spl.ye.d
Checklor cause(Relerto speciied
checksequence)
cr PageF-m
"84" flashes
CheckECUl€rminallF voltage
17 PageF-114
vohage:Approx.12v
(lgnitionswilch ON)
TESi SWi SELF TEST
6
to diagnosis
ConneclSyslemSeleclor
connector
and setTeslSwilchto " SELFTEST'
+
+
F page F-112
lt OK,replaceECU
ll nol OK,checkwins b€tween
Checker
ECUandSell-Diagnosis
good
Try known
ECU
F-39
F
GUIDE
TROUBLESHOOTING
to diagnosisconn€cior
ConneclSystemSeteclor
"SELFTEST
and set TestSwitchto
ls rofttontrmrnocotted at Ldleatterwarmup?
7 P.ge F-62
BTDC16 + 1.
tNDtcAToB---l
tming
Adjustlgnition
e PageFl2
tor cause
CtrecX
e PageF-119
\,,1S\ \|!/ TEsr sw
OK?
AreECUleminalvollages
2[/)
lEsoeciallv
'
e PagoF-lla
ls strongblue sparkvisibleat €ach disconnected
high'tensionlead?_
:"''-t'
',-t'.--
_1-(_(d
Ar€sparkplugsOK?
lead
Check high-tension
ll OK, check dislribulorcap and
e
fi not OK, replacehigh'tension
!? pageB-10
Checklor correctengineconrpression
p 17 page G-19
BUFNS
in)
(0.039--o.043
Try known good ECU and check il condition
F-40
+
(Minimum):1,030kPa
Compression
(t0.5 kg/dn', 1r9 Psi)-300rPm
4
+
lf OK, go to nexi step
tJnotOK,checkfor cause
c7 pag€A-10
F
GUIDE
TROUBLESHOOTING
ENGII{ESTALLS ON OECELERATION
.Engine
unexpectedly
DESCATPstopsrunningwhle deceleraling
or aJterdecelerallon
. ldleconditionnor,ral
Tro
15
H|NTSI
rrRouBLEsHooTtNG
Engine
speeddropsloomuchwhenreleasing
d sconnected
by deceleralion
accelerator
or poorconneclor
connection
@ ldlespeedmisadjustment
O Dashpormisadjusted
@ Fuelcut controlmallunclion
ACTION
INSPECTION
ls rdle conditon normal?
ls dashpoi correclly adjustecl?
Adjustor perlormtroubleshootng
Nos.8-11 RoUGHIDLE"
,- pag"
Mallunclion Code No. dlsplayed
Checkror cause{Beferto sDecified
checksequence)
rj page F-7o
"88" tlashes
CheckECUteminal1F vollage
u pageF-111
l-?9
13 p.ge F-104
Dashpol set speed: 2,500 + 1O0 rpm
3
|s "00" dlspLayed
on SeliDiagnosis
Checker
with gnltionswitchON?
r:' page F-67
sYsTEM
SELECT:1
Voltage:Approx.t2V
(bnirion switch oN)
+
+
lr OK,replaceECU
F pageF-112
ll nol OK, checkwring between
ECUandSer'Diagnosis
Checker
Are air bypass sojenoid valves OK?
SOLENOI
voLut
-@-ll
5
6
AreECUterminal
voliagesOK?
(Especialy
1B,2lV,20and2\4
G pageF-112
Checklor cause
-
page F-115
F-117
F-l19
ls therepoorconnection
at eilherol lollowing?
. lgnilioncoil
. lsniter
. Dislribulor
. C rcuitopeningrelay
. ECU
Try known good ECU
Doescondilionimproves?
F-41
F
GUIDE
TROUBLESHOOTING
't6
E GDTESTALLSSUDDELY (INTERT|TTENT}
slopsrunning
0EscnlP. .EngrneintermitenUy
.Belorestallinq,
OK
ensrnecondition
Ttoil
G HINTSI
TTROUBLESHOOTI
O it'frtrnitt""tv "" "p"tl "t no luel Iniectioncausedby vehiclevibration,accelefaijon,or cleceloralion
.Poor conn€ctonin wiing harness
ACTION
tlrsPEcTtoN
3TE
"m"
ch€cker
on Self-Diagnoss
ls
displayed
switchON?
wilh ionition
r? page F-.67
Maltunction Cod€ No. d|3played
NO
Checklor caus€(Refefto sp€cified
F Pagd F-70
checksequence)
Note
.When checklngwiainghamcssand conneclol3,
tao. mov6, and wiggle guaFcl 3enaorand/or h.r'
ndsg to r€cGale Problem
"88" ll6ah€3
x7 p.ge F_114
CheckECUterminal1F voltage
Voltag€: App.ox. 12V
0gnition swilch ON)
4
+
TESTSW;SEIF TEST
2
c7 P3€eF-112
lf OK,replaceECU
li not OK, ch€ckwiringbetween
Checklt
tCU andSellDrag.osE
ls lhere poor connectionat eilhel of lollowing?
. lgnitioncoil
. Distribdor
. High-tensionlead
3
. Ckcuitopeninsrelay
. ECU
OK?
Are ECUtemina,voltages
and2\i)
18, 1G,11,2A,24,2C,2E
{Especially
.7 pege F-112
Note
.when checklng volteg€, lap, move, and
wlggle halne3s and conneclor to recneate
F-42
No.2
Go to Troubleshootjng
"CBANKSNOBMALLY
BUTWILL
NOTSTART(NOCOIVBUSTION) ? p.ge F-17
No
Check lor cause
c7 Pag€ F-115
F-117
F-l19
F
TROUBLESHOOTING
GUIDE
HESITATESFTUIIBLESON ACCELERATION
17
DESCND. .Flat spotoccurslug ater accelerator
depressed
or mrldjerlingoccursduringac.deraon
TION
G Ht]{TSl
ITROUBLESHOOTT
rean$nen dep.e€srng
mxlureoecom€s
accelerator
O Air/Fuel
.Fuel injeclloncontrolmalfunction(Corectionfor acceleratingcondition)
.Fuel line pressured€creases
.Sparkadvanceconlfolmalfunclion
INSPECTION
"00"
1
ls
display€d
on SellDiagnosis
Checker
wilhignilionsiwilch
ON?
ACTION
I.ltuncllon Code l{o, dhplay€d
Checklor cause(Refer1osoec'lied
checksequerce)
"88" fl.3hes
CheckECUterminal1Fvoliage
o page F-70
F page F-114
Vollag€: Approx, 12V
(lgnitlon sw[ch ON]
.> lf OK,rcplaceECU
ri pegeF-112
.+ lf not OK,checkwiing between
ECIJand Self-Diagnosis
Checker
2
ls thereair leakageat iniakeair sygem com-
3
ls arrcleanerelsmentcl€an?
Go to nen siep
tr- p.ge F-62
Replace
aircleanerelemenl
4
5
6
Arc ECUt€rminal1K, 2M, 20 and 20 voltages
OK?
.? p.ge F-l12
Go lo nexl step
No
Ch€ckior cause
c7 psge F-1r5
F-117
F-lt9
ls lhrotllelinl€ge coreclly inslalledand does
thrcttle valve open frcel',
ls iuellinepressure
correctat idle?
.? p.ge F-94
Fuelline preasure
235-275 kPa (2.4-2.8 tg/cm', 3'F/1() psD
Cl€anor replaceas requiredany
bindingor damagedlinkageandadlust cabl€ dell€ctional inieclionbody e pag€ F-86
decrease
Doesltrelllnepressure
qulcklf
whenacceleruting
.+
4
li decreases,checkluel lineand
lilteflor clogging
lf no decrease,go to next slep
whle pinchChecktuellinepressure
+
+
quicklyiG
lf luellinepressufe
creases,check pres$ire regulator
gradually
11luel
linepressure
in'
creases,checklor cloggingbe
tlve€niuel pump and pressurc
r€gulatot
ll not clogged,checktuel pump
17 page F-91
maximurnpressure
F-43
F
GUIDE
TROUBLESHOOTING
acfloll
t sPEcTto
7
tmingadvancewhen
Doesignltion
accelerating?
ConnectSysternSeleclorto diagnosisconnector
and set T€stSwilchto 'SELF TEST"
ls ignitiontimingconect at idle alt€r warm_up?
ri' p.ge F--62
+
+
ll advances,go lo ne)dstep
ll not advan6, replaceECU
lgnnlontlmlng: BTOC16 + l"
NO
INDICATOR
8
Go to nexl step
installed?
Are arrductand air hosescorrectly
NO
9
ls exhaustsystemrest cted?
(t p.ge F-1t7
NO
1 0 Try knowngood ECUand ch€ck if conditEn
F-44
R€pair
s pag€ F-112
F
TROUBLESHOOTING
GUIDE
ta
SUFGESWHILECRUISING
DESCRIP.. UnexpecledchanSein enginespeedwnich is usuallyrepetitive
TION
HTNTSI
TIROUaLESHOOTTNG
O Air/Fuelmixtureloo ean
@ Misfirc
in wiringharness
@ Poorconnection
STEP
tNSPECT|Ot{
ACTION
ls '0O displayed
Go 10nextslep
on SellDiagnos
s Checker
wth ignitionswltchON?
c? page F-€?
No
Malluncllon Code No. displ.yed
Checkfor cause{Belerlo soecilied
ch€cks€quenc€)
"88" llashes
Check ECUielminal 1F voltage
!? page F-70
e p.ge F-114
Vo[age: Approx. l2V
(lgnilion sMtch ON)
+
+
2
ls throttleseosorOK?
lf OK, replaceECU
r? page F-112
lf not OK, check wirins benxeen
ECU and Self-Diagnosis
Checker
Go ro ne( step
s
D4ge F-122
NO
3
Disconnectoxyg€nsensorconnector;does con'
Checkoxygensensor
(? eage F-123
Checktor cause
.7 pege F-115
F-117
F-It9
OXYGENSENSORCONNEC]
OFt
Are ECUterminalvoltagesOK?
t- page F-112
5
ls lh.ottle linkagecofrecly installedand does
thronde valve open op€raies lrcely?
Corfecl,clean,or replaceas requircd
anybindingor damagedlinkage,and
adiuslcalte dellectionat injeclion
F page F-{6
body
6
ls thereair leakageoi inlak€arrsystemcom-
7
ls arr cleanerelementclean?
o
page F-62
Beplaceair cl€anerelemenl
F-45
F
SIEF
a
GUIDE
TROUBLESHOOTING
INSPECTION
to diagnosisconnector
Conn€ctSyslemSelector
and sel Tesl Swltchto "SELFTEST"
ls Lgnll|onmrngcorredat rdleatlerwam up?
.j pagc F-42
ACTION
Does ignition timing advance \,rten
4
+
lf advances, go lo na)d step
tf not advance, replace ECU
rr p.g. F-112
lgnitlonliming: BTDC16 + r'
INDICATOF
9
correctal dle?
ls luellinepressure
E7 page F44
Doesfuel line pressuledecrease
whenaccaleatingquickly?
+
zgs-zzi
xpa (z.t-z.a
*g,fcm', 34-iu) p6i)
4
tf decreases,checklor tuel pump
!? PagGF-91
maximumpressure
li OK, checkfuel lineand lilter for
cbggrng
li no decrease,go to n€xt slep
ChecktueLlineprsssurcby pinchang
qulcklyinll iuel lineprcssure
creases,ch€ckpressufaregulalor
+ lf luel line pressureSraduallyln
creases,checkfor cloggingbe
lweeniuel pump and pressure
rcgu|alol
li not clogged,checkluelpump
c7 P.go F-91
maximumpressure
High prcas0ae
Checkit tuel ret'rrnline is clogged
+
4
+
1 0 Checklor poor connectionof lollowingparts
. lgnitef
. Distribuor
. Hishtensionlead
. Crrcuitopeningrelay
. ECU
tl
Try knowngood EcU and ch€ckil
F-46
ll OK, repiacepressurefegulalor e Pag. F-94
ll not OK, replace
F
TROUBLESHOOTING
GUIDE
LACK OF POWER
.Perforrnance
poorunderloadwhenthrotllevalvewideopen
DESCBIP- .
Beducedmaximumspeed
Ttot{
.ldle condilionnomal
TTROUBLESHOOTING
HINTSI
mlxtureloo ean
O Faclorsotherlhanenqrnem;runcrion
@ Air/Fuel
.Cturchstipping
.Fuel linepressure
decreases
.ATX stipping
. Fuellnjection
maltunclion
.Brakedragging
@ Poorigniton
.Low rre prcssure
@ Lowenginecompresson
.IncorrectI re size
@ Alcohobendedtuelused
19
@ Lowintakeair amount
.Throttlevalvenol openiully
.Cloggedintakeak system
STEP
INSPECTION
l
2
Check laclorsother than engine
. c urch slipping
l? page H-3
. ATX slpprng
.? page K-10
. Blake dragging
c7 page P-5
. Low tire pressure
F page O-2
ACTION
NO
ls throltlevalvelully openedwhen acceleralor
s acceleralor cab/e correctly insl,alled r'
4
4
3
page F-86
ll oK, check lhroltlevalve
ll nol OK, installacceleralorcable
r? page F-86
corecty
ls 00 dlsplayed
wilh gnitionswitch
Mallunclion Code tlo. displayed
Check ior cause{Referlo soecified
check sequence)
E7 page F-70
"88" llashes
Check ECU termnal lF voltage
-
page F-114
Voltag€: Appror. 12V
(lgniiion swiich ON)
4
€
TESI SW' SELFTEST
SETECTSW: A
ConnectSyslemSelectorlo diagnosrsconnl
and set Tesl Switch lo SELF TEST
ls gnitiontming corecl at dle afterwarm-!p?
- page F_ 62
lgnition laming: BTDC 16 * 1.
t\'k\\o\\\t\\t
\\.-\\ \\-*rtriff
\NN
-'fi"
INOICATOF ::
5
lf OK, replace ECU
r:7 page F-112
li no OK, check wiring betw€en
ECU and S€fDiagnoss Checker
Check I lgniliontimingadvances
4
a
ll advances,go !o next step
li nol advance,check ECU temi
nalvoliages
r? page F112
- '"
\
l.
cNo
(
o d
l
\S) a(r/ TES
A.e ECUleminalvoltages
OK?
(Especialy
1K,2M,2K,and25)
l? page F-112
Checkior cause
r:, page F-115
F-117
F-l19
F-47
F
;TEP
6
GUIDE
TROUBLESHOOTING
acTtor,l
INSPECTION
ls there air leakageoi intakeair systemcom_
ls air cleanerelemenlclean?
s page F-62
Beplacear cleanerelemenl
8
Doesiue Ine pressuredecrease
when accelefanng quickly
ls luel ine pressurecorect at idle?
c7 pag€ F-94
+
psD
,
zgs-zzi rpa (z.l-z.a rg/cm' 34-40
+
li decrcases,check tuel pump
17 Page F-91
maxlmumpressure
ll OK check fuel line and filtefior
cloggrng
ll not decr€ase, So to ne)d slep
whilepinch
Checktuellinepressure
+
+
ll fuellinepfessurcquicklyrn
creases,check pressureregulalor
gradually
ln'
lf luellinepressure
checktor cloggingbe
creases,
iweeniuelpumpandpressure
lf notcLogged,
checkluel pump
pressure
F PageF-91
maximum
prcssure
Hlgh
Checkaftuelreturnlineis clogged
+
4
I
Clean
Bemoveair cleaneri s there any carbon depost
or drn In njecton bo4,r/' { -l - \ -i r t
No
1 0 Are spa.k plugs OK?
17 page G-19
WEAFANDCAFBONBUILDUP
AURNS
(0.039-0.044|in)
DETERIOBATION
F-48
regllalor t7 pageF-95
ll oK, replacepressure
li not OK,replace
F
TROUBLESHOOTING
GUIOE
acTtofl
INSPECTION
?l
ls resistance
ol igntioncoilOK?
c7 page c-20
Resi6tance(et 20.C 168oFl):
Primarycoil winding........0.58--"0.a49
Secondarycoil whding.... 9.6-14.4 ko
SECONDAFIY
COIL
'12 ls enginecompfesson
co(ect?
c? page B-10
Engine clmpresslon:
1,030kPa{10.5kg/cm' ,149psl}-300rpm
No
t? page B-'10
Check enginecondition
.Worn piston,pislonrlngsor cylinder
. Deteclrvecyiinderhead gaskel
. Distorted cylinder head
.hproper valve seatng
.Valve stickinSin guide
1 3 Changeiuel; does conditionimproves?
Changetuel to anotherbrand
Try known good ECU and see il driv'
F-49
F
GUIDE
TROUBLESHOOTING
POORACCELEFATION
20
DESCRIP-| . Pe''omance poor whle acceleratng
Tlolil
| .ldle condilionnomd
HlllTSl
FROUBLESHOOTING
olherthanenginemalfrJnction
O Factors
.Clutchslipping
.ATX stippinS
. Brakedraggrng
.LOWnrc pressufe
.lncoffednre sze
@ An/Fuelmixtureloo lean
. Fuellinepressure
decreas€s
. Fuelinjection
malfuncl|on
@ Poorignilion
@ Low ensinecompreseon
@Alcoholblendediuelus€d
@ Lowintakeaif amount
.Throltlevalvenotopenlully
.Clogginsin intakearrsystem
INSPECTION
'I
enorne
factoG
other
than
check
. Clutchslippins
e P.ge H-3
. Brakedrassins
G page P-5
. Low fte pressurc
s Pageo-2
. lncor€ct tirc sze
3 Page O-2
. ATXslipplng
-F page K-10
2 Doesthrottlevalvetully open wtrencleprcssng
ACTION
Go to n€)dstep
No
Check il accelefator cable ls coreclly
ndaled
r+
+
3
Checker
is '00' displayedon Self-Diagnosis
with lgnitionswitchON?
!7 Page F-67
SYS'IEMsELEcTi1
F page F-86
lf oK, check throtllevalve
li nol OK, install accelerator cable
t7 Page F-E6
conecily
Go lo nexl step
llallunctlon Code l{o. dlsPlayed
Cheoklor cause{Reterto specifed
checksequence)
e PageF-70
"88" llash€s
Check ECIJterminal1F voltage
t7 page F-114
voltage Appror. 12v
(bnirion swilch ON)
4
4
TESTSwi SELFTEST
conn€ctor
ConnectSystemSelectorto dlagnosis
'
and setTest Swilchto SELFTEST
ls ignltonlimlngcorreclal ldlealterwarm_up?
!? Page F-62
lgnltionliming: ETDC16 + l'
\\\<\to\\\l\tll
\\.-\\ \\.igA'f
\M
-"fi"
\
-"-
-Page
ll OK, replaceECU
ll nol OK, check winnSbelween
Checker
ECU and Sell-Dlagnosis
F-112
Does ignitiontiming advancewhen
+
+
It advances, go to nexl st€P
ll not advance,check ECU lermi'
tr7 Page F-112
nal voltages
-'
INOICATOF--/
5
OK?
AreECUlermlnalvoltages
tr7 Pago F 112
{Especially2M)
F-50
'Check
Jorcause
t7 Page F-115
F-l17
F-lt9
F
GUIDE
TROUBLESHOOTING
6
ITSPECTION
is lhere alr leakageal inlakear systemcom-
7
ls thereanycarbondepositor did in injection
STEP
ACTION
Clean
\
8
ls lue linepressure
cofiectat dle?
c7 page F-94
CheckI' luellinepressure
decreases
whenaccel€ral
ng qulckly
+
235-275 kPa 12.4-2.a kg/cmz, 34-40 psi)
..)
ll decrease,
checkiuel pump
pressure
c? page F-91
rnaxmurn
ll OK,ch€ckllel lineandiiter lor
cloggng
go lo nexlstep
ll nol decrease,
Checklor luel line pressurewhle
pinchlngluel returnhose
4
4
lf luel line prcs$re quickly ncreases, check pressure r€gu alor
lf luel line pressrfegradually ncreases,checklor clogging be
tweenluel pump and Pressure
ll nol clogged,check l'rei pump
p.essure
ma-ximum
c7 Page F-91
Haghpressure
Checkil tuelllnes clogged
+
4
I
Ar€ spark plugs OK?
regualor s page F-95
ll OK rcplacepressure
ll notOK, replace
-. page c_lg
WEAFAND CAFIBONBUILDUP
EUFNS
{0.039-O.0,*t
OETEFIOFATION
F-51
F
GUIDE
TROUBLESHOOTING
ACTION
t sPEcflot{
1(
Change luel !o another brand
Changeluel and check if acc€leralionmproves
Go 10 nexlstep
11
Tfy known good ECU and check il
enginecondltionimproves
Chockfor corr€ctenginecomprcssion
e PageB-10
Enginecompr$3lon (ulnimum):
1.030kP. (t0.5 kgL/cm',149 p3lF30Orpn
NO
17 Pagea-10
Check€ngnecondition
.Wornpiston,pislooringsor cvlinder
.Defectivecylinderheadgasket
. Di$onedc''linderhead
.lmpropetvalveseatmg
.valve sticking
in guide
F-52
F
TFOUBLESHOOTING
GUIDE
21
RUIIS BOUGHON DECELERATION/BAC|(FIRE
DESCfitP. .Engine lirns rough w+)iledec€leratingand abnormalcombustionoccurcin exhauslsystem
.Transaxlein normaiconditon
noN
c HtNTsl
rrRoualEsHooTr
O Ar/Fue{mxluretoo rich
.Arr cleanerelementclogged
.Fuel inieclion
(Fuelcutcontrol)
cortro malJunclion
.Iniectorfuelleakage
.Throttle sensormalfunction
. Dashpolmalfunciion
t]tsPEcTtol{
1
ls OO"display€don SellDiagnosas
Checker
with ignitlonswilch ON?
u p'g'e F-6'7
ACTION
Go to next step
No
llallunctlon Codo No, dasplayed
Checklor causeGeter to soeciiied
checksequence)
rt page F-70
"88" tla3he€
CheckECUteminal1F voltage
cz page F-114
Volt.ge: Approx. 12V
(lgnition swilch Ol{)
+
4
IEST SW: SEIF TEST
2
ls there air eal.age at inlake air system com
3
ls air cleanerelementclean?
Go lo nexI step
F
page F-62
No
Are ECU terminalvoliagesOK?
(Especially 21v1and 20)
.:7 page F-112
5
lf OK,replaceECU
cz psge F-112
ll nol OK, checkwiringbeiween
Chsckar
ECUandSelf-Diagnos,s
Aeplaceair cleanerelement
Ch€cklof calse
.7 page F-1t5
F-117
F-119
ls lhere0V al ECU2V leminalabove3,000rpm
(Enginesignalmonilorgreenlampilluminates)
Try knowngood ECUand checkii
6
ls lhrotle sensorOK?
Ei pag6 F-122
Adjusl
(r page F-1ZI
F-53
F
GUIDE
TROUBLESHOOTING
ls dashpoicorrectlyadiusted?
c7 page F-lo4
Daahpot3et speed:
Approx.2,500 + 100 tPm
ls there nleclor luel leakage?
.? page F-96
Fuel leakage: Below I drop/s mln.
Try knowngood ECUand ch€ck ii condition
F-54
Check if lhrottle valve is cornamlnai€d
4
li contaminated, clean throllle
4
ll nol contaminaled, replace throt_
F
TROUBLESHOOTING
GUIDE
22
KN(rcKNG
DEsilcBlP..Aolormarcombust,on
accompalred
by audrbleprnsins no|se
|
H|NTSI
TIROUALESHOOTTNG
@ Ai/Fue mi(uretoo lean
O Incor€ctignilionlimingfloo advanced)
.Fuel injectonamountnotcorrect
in cylinder
@ Carbondeposlts
.Fuel linepressure
trhileacceleraling
decfeases
overhealing
@
ACTION
litsPEcTtoN
1
ConneclSyslemSelectorto diagnosisconnector
and set Tesl Swilch to "SELF TEST '
ls ignilion liming correct at idle after wa.rn'up?
E? page F-62
lgnilion liming: BTDC 16 + 1'
INDICATOF
2
ls '00" d splayedon Self'Diagnosis
Ch€cker
with ign'tionswitchON?
c:r page F-67
No
llaltunctlon Code ilo. displayed
Checklor cause(Belerio specilied
checkseqlence)
c7 page F-70
"88" flashes
Check ECU termlnal1F vollage
F page F-114
volrage: Approx. 12V
(lgnition swirch ON)
+
+
3
(? page F-112
lf OK, replaceECU
ll not OK. check wking between
ECU and S€f-DiagnosisChecksr
ls thereair leakageol intakeair systemcom
ls enginecompression
correcp
e page A-10
Englnecompression(Mlnhum):
1,030kPa (10.5kg/cm' ,t4s psiF30orpm
tligh compr$sion
Checkengne condition
c7 page B-10
F-55
F
GUIDE
TROUBLESHOOTING
ls fuel line presswecorrectal idle?
t? PaEeF-94
Doesif fuel lroep€ssure decrease
qulck\,
whenacceleraling
Fuel line pres3ure:
235-275 kPa 12.4-2-a Wlcm', 3!t-40 psl)
+
4
checklor clogging
ll decrcas€s,
b€trveenluel pump and pressure
regulator
ll not decrease,go to next step
whilepinch_
Checkfuellinepressurc
+
+
qulcklyn_
It fuellineprcssure
creases,checkpres€ureregulalot
gradually
inll fuellinepressure
checklor cloggrngbs
creases,
tweenluel PumPand Pressure
regulator
lf notclogged,checkluel PUmP
r? PageF_91
maximumpressure
ls coolingsystemOK?
Try knowngood ECIJand checkil conditon
.Themostat
. Et€ctic cooling lan
.Rad,ator
.7 Page E-8
.7 Page E-1 1
.? page E-7
ReplaceEcU
1:7 PegeF-112
Changetuel lo anotherbrandor use
F-56
F
TROUBLESHOOTING
GUIDE
23
FUELODOR
DESCRIP. .Gasolineodorin cabin
IION
HTNTSI
FROUBLESH(X)T|NG
o Poorconnecflono. oamaqedal lue sysler- o- evaporanveemsson cofrol sygem
ca,rslerovedowdue lo evaporatve
emEsoncont'olsl,slemma unct,on
@ Charcoar
INSPECTIOT
ls tirerefuel leakageor damageof fuel system
and evaooatve emissionconirol svstem?
2
|s 00" displayed
on SellDiagnosis
Checker
withignillonswilchON?
c? page F-67
ACT|Oir
Go to nexl step
L.lfunction Code No, dbplayed
Checklor caus€(Referto soecined
checkseqlence)
t7 pag. F-7O
CheckECUterminal1F voltage
6' p.ge F-114
Voltag€: Approx. l2V
(lgnltion swnch ON)
+
+
3
ls vacuumfell at solenoidvalve (purge conlrol)
with engine runn,ng and throltle valve open€d?
(Neutral switch connector disconnected)
ll OK,replaceECU
F p.ge F-112
li nol OK, checkwring between
ECUand SsltDiagnosisChecker
Go to Slep 5
No
Ch€cktor solenoid
valveoperaling
+' lf OK,checkvacuumhoseslor
clogsins
4 lf noi OK, go lo next step
Apply12Vand gro0ndt, solenoidvalve (purge
Check ECUieminai voltages
rt p.ge F-112
ls vacuumleltat solenol(
V
5
'r<a
No
Replacesolenoidvalve
TryknowngoodECUand checkif condition
F-57
F
GUIDE
TROUBLESHOOTING
.Exhauslgassmellsabnormally
HINTSI
TTROUALESIIOOT|NG
Highsulferconternfuel used
Change fuel to another bland
. Ol consumphon
excessve
HINTSI
ITRoUBLESHOOTING
O rcV sy$em mallunction
tO workingup workrngdown or leakage)
6 Enqr# malunction
Are there PCV hos€, venlilation hose or |hen al_
lach ng nipplesseparated.damaged, clogged,
e
P.ge F-99
ls thereair pressufeor oil at venulalionhos€?
Checkfor correciengnecompressionF page B-10
Comor€*ion ( inimum):1,030kPa
Oo.5 rgr'cm', 149 l,6il-300 rpm
+
4
ls vacuumlelt al PCVvalv€ at 'dle?
F-58
tf OK, go to next step
lf not Ok, checklor cause
Crreit engineconoltion
.wom pElonnnggroove
.Stuckprstonnngs
.Wornpistonor cylinder
e page B-10
F seclion a
F
GU'DE
TROUBLESHOOTING
POORFUELECONOTIY
26
DESCalP- . Fueleconomyunsatislaclory
fl0N
H|NTSI
ITRoUBLESHOOT|NG
slopand go driving,extended
winler
Whileluelconsumption
is drastically
incfeased
by citydriving,shorl-run
operalion,
warm-upp€riods,etc., as opposedto 'trip" mibage,an atlernplshouldbe madeto det€rmineth€selaclorswh€ncon
frontedwith "poor mileage condlrions.However,sincethe operatoris not alwaysat taull, lhe iollowingis oJfercd.
@ Air/Fuelrninur€loo rich
O Operatordep€sslng acceleratormorethan usualdue to
.Hlgh luellinepl€ssure
low enginepower
.Poor ignltion
Alcohol
blendedluelused
@
.Low intakeai amount
@ Highvehicleload
.Electronicsoarkadvanceconlrol svslemmalJunclion
.Clutchslipping/ATx
slipping
.Bake dragsing
. Exhaust
component
restricted
NSPECTTON
ACTION
1
factors
other
than
engine
Check
. Low tire pressufe
E7 page O-2
. Unrecommended
lire size € pag . ()-2
. Clutchslipping
s prge H.-3
NO
. Brakedragging
s pege P--5
. Exhauslcornponenlrestricreds page F-97
2 Are air hosesconnectedcorrcctly?
.7 page F-Eil
NO
3
ls '0O"displayed
on Self'Diagnosis
Checker
withignitionswilchON?
'' page F-67
Go lo next slep
NO
[alfunclion Code No, dbplay€d
Ch€cklor cause{Reterto soeclfied
checksequence)
G gage F-7o
"88" ll.3he3
CheckECUt€rminal1F voltage
F page F-114
Volage: Appror. t2V
{lgnltlonswltch ON)
4
+
TESTSW: SELF TEST
,t OK, feplaceECU
t7 page F-112
ll not OK, checkwiring between
ECUandSelt-Diagnosis
Checker
ls lhere air leakageal intakeair sl,stemcom'
5
6
ls ai cleanerelementclean?
r? page F-62
Are ECUleminalvoltages
OK?
(Especially
2M,2N, 2R and 2T)
.7 pageF-112
NO
Beplaceair cleanerelemer'1
No
Checktor cause
-
page F-115
F-l17
F-l19
F-59
F
GUIDE
TROUBLESHOOTING
acflo1{
It{SPECTTON
7
Go to nexl slep
Connect System Selecto! to diagnosjs connector
and ser Test Swnch to SELF TEST
ls ionitiontminq co(ect at idle ajt€r wafm_up?
.r gage F-t62
NO
INDICATOR
I
conect al idl€?
ls lu€] line oressurc
'
s P.ge F-94
23s-274 kPa 12.4-2.a xg/cm' , 3l-40 p€l)
Hlgh Pressu.€
check if vacuumhoselo pressure
rcgulaloris damagedot poorly con+
4
9
lf OK, replacepressureregulalor F page F-94
ll nol OK, repat or replacehos€
Runengin€at idleand lhenstopengme
hold?
ts fuellin€pressure
c7 Pege F-84
Fuel llnc Drcasure: More than 147 kPa
(1.s kgr'cn" 21 p3l)lof 5 min,
No
1 0 ChangeJuelto anotherbrand
F-60
Checkinjectofsfor tu€l leakage
e page F-96
ENGINETUNE-UP
F
ENGINETUNE.UP
PNEPARATION
ssT
49 8019 9A0
gniliontiming
BASICINSPECTION
EngineOil
1. Be surethe vehicleis on ievelground.
and
temperature
2. Warmup theengineto normaloperating
stop it.
3. Waittor five minutes.
condition.
andchecktheoilleveland
theoildipstick
4. Bemove
5. Add or replaceoil if necessary.
Note
. The distance betweenthe L and F markson lhe diF
sllck represents0,8 lirer (0,85US qt, 0.70 lmp qt).
EngineCoolant
Coolantlevel (enginecold)
Warning
. Neverremovethe radiatorcap while the engineis
hot.
. Wrapa thickclothaloundthecapwhenlemovlngit.
1. Pulloutthesubtankcap.
fillerneck.
2. Verifvthatthecoolantlevelis nearthe radiator
is be3. Verifythatthecoolantlevelin thecoolantreservoir
tweenthe FULLand LOWmarks.
4. Add coolantf necessary.
Batlery
to ensuregoodelectri
oftheterminals
1.Checkthetightness
cal connections.
2. Checkfor corrodedo. frayedbatterycables.
3. Washthetop olthe batterywithwaterto preventarcover'
the upperand
levelis between
4. Verifythatthe electrolyte
lowermarks.Add distilledwaterif necessary.
F-61
F
ENGINETUNE.UP
5. Disconnectthe negativebatterycable
6. Ooenthe cap.
i. Miasurethe ipecilic gravityof eachcellwitha hydrometer'
Specilfcatlon:1.27-1.29 (at 20oCl68oR)
Alr CleanetElement
dirt,damage'
1. Checktheair cleanerelementfor excessive
and oil.
2. Replacethe air cleanerelementil necessary'
ADJUSTUENT
PteDaralion
1.Warmup the englneto normaloperatingtemperalure
outwardtu y anonal
waxrodhasextended
2. Verilvthatthe
the fast idle cam has separatedtrom the roller'
loadsOFF.
3. Turnall electrical
. Blowerfan
. Headlisht
. Rearwindowdefroster
4. Makesurethatthe enginespeeddoesnotchangewnen
valve@ connector'
theairbypasssolenoid
Jiiconnecting
Note
. liine engine speeadecreasea,the engine is slill un'
der the warm-uPconditlon.
5. ll the electriccoollngtan is operatingwat untilit stops
6. Verifythattheenginais runningat idlein goodcondilion
connector'
7. con;ecl the SSTto the diagnosis
8. Connecta timinglight.
to the diagnosisconnectorlGs c."""ii a tacn6m-eter
lermlnal.
10.SetswitchG)to Position1
1'!.Sei TESTSWtOSELF-TEST'
Not€
. liitre ssr is not us€d,lump acrosslhe TENt€rminai and ttre GND termlnai ot the diagnosiaconnector.
F-62
ENGINETUNE.UP
F
lgnition Timlng
Inspection
/ Adjustment
'1.Perform"Preparation".
(Relerto pageF-62.)
2. Veritythatthe idlespeedis withinthe specification.
ldle speed: irTX (Neutral) 750 ::E rpm
ATX (P range)1,100 :'6 rpm
INDICATOF
3. Checkthe ignitiontimingwitha timinglight.
lgnition timing: BTDC16 + l"
fi -)
loosenthe
4. lf the ignitiontimingis notwithinspecification,
to makethe
distributor
lockboltsandturnthe distributor
adjustment.
torque.
lockboltsto the specified
5. Tightenthe distributor
Tighleningtorque:
l6-23 Nm (1.6-2.3 m-kg,l2-16 ftlb)
ldle Speed
(Referto pageF-62.)
1. Perform"Preparation".
2. Checkthe idlespeedwitha tachometer.
ldle speed;MTx (Neuttal) ?50 158rPm
ATX (P range)1,'100:"8 rPm
3. l, notwithinspecification,
adjusttheidlebytuningthethrottle
adjustingscrew.
F-63
F
ENGINETUNE-UP
ldle-up Speed
. (tlelerto pageF-62 )
1 Perfbrm Preparanon
2. Checkthe idlespeedwitha tachometer'
MTx (Neutral) 750 1fl rym
ldle sDeed:
'
ATX(P range)1'100:'3 rPm
/t
INS iAL
"o"".-ird"]i
oi'l
fhnlriL€
I
DISTRIBUTOFI
BoD'i
3. Adjuslthe air bypasssolenoidvalve@ by the following
orocedure.
iiCrouno rn. arl bypasssolenoidvalve@ terminal@
shownin the figure
screw'
2) Adiusttheidle-upspeedbyturningtheadjusting
MTX(Neulral)1,080 + 30 rpm
ldle speed:
'
ATX (P range)1,350 + 30 rPm
thejumperwire
3) Disconnect
4. Adjustthe air bypasssolenoidvalve @ by the following
orocedure.
i) Groundthe checkconnector(black)shownin ihefigure'
'fL
qHECKCON
0
ADJUSTSCREW
screw'
theidle-upspeedbyturningtheadjusting
2) AdiL.rst
MTX(Neutral)1,030 :53rpm
ldle speed:
'
l'6 rPm
ATX(P range)1,700
wrre
lhe lLlmPer
3) Disconnect
F-64
ENGINETUNE.UP
F
5. Adjustthe air bypasssolenoidvalve@ by the following
procedure.
1) Djsconnect
theconnectorof theair bypasssolenoidvalve
2)Applybatteryvoltageto air bypasssolenoidvalve@
terminal.
3)Adjusttheidle-upspeedbyturningtheadjusting
screw.
ldle sp6ed: MTX(Neutral) 1,250 + 25 rpm
ATX (P range)1,600 + 25.pm
4) Installthe connectorof air bypasssolenoidvalveO.
F-65
F
FUNCTION
SELF.DIAGNOSIS
FUNCTION
SELF.DIAGNOSIS
DESCRIPTION
checkforthecauseusingtheSST Failures
occurinthemaininputdevicesor outputdevices'
Whintroubles
lromtheenginecontrolunit(ECU)as malfuncandretrieved
oieacttinpuiina outputdeviceaie indicated
tioncode numbers.
Note
checkslormaF
. ihe EGuconstantlycheckstor maltunctionof the inputdevic€s.But'-the-ECU
switch
is turned
perlod
the
ignltion
after
dndion ot output?evbes only In a thtee seconds
grounded.
ls
ON when ihe fEN lerminal ol the diagnosisconneclor
ENGINECONTFOL UNIT
OUTPUT
oEvtcEs
SYSTEM
SELECTOR
F-66
SELF.DIAGNOSIS
CHECKER
FUNCTION
SELF-DIAGNOSIS
PREPAHATION
ssr
49 HO189A1
43 80199AO
diagnosis
SystemSelector
diagno6is
Self-Diagnosis
Checker
MALFUNCTION
CODENUMBEB
InspectlonPrccedurc
1. Connectthe SSTto the diagnosis
connector.
2. Set switch@ to position1.
3. SetTESTSWto SELFTEST.
and a ground.
4. Connectthe SSTto the SystemSelector
5. Setthe selectswitchto posilion
7 - )
aZWr
',6^
ir '"!
@@
6
.
lql.
6. Turnthe ignitionswitchON.
7. Verifythat"88" llasheson
thedigitaldisplay
andthebuzzer soundsfor 3 sec, afterturningthe ignitionswitchON.
8. ll "88" doesnotflash,checkthemainrelay(Feterto page
F-124),powersupplycircuit,and diagnosisconnector
wrflng.
for more
9. lf 88 flashesandlhe buzzersoundscontinuously
than20 sec., checkfor a shortcircuilbetweenthe ECU
connector.
Replacethe
ECU
terminal1Fandthediagnosis
if necessary
and performSteps3 and 7 again.
10.Noteanycodenumbers
andcheckforthecausesby referring to the check sequencesshownon pages F-70
throughF-78. Repairas necessary.
Note
. Cancel the code numbeB by performing the afterrepair procedurefollowing repairs.
(Referto page F-79.)
F-67
F
FUNCTION
SELF-DIAGNOSIS
Prlncipleof Code Cycle
as shownbelow
codesare determined
Malfunction
L Code cycle break
code cyclesis 4.0 seconds(lhetimethe buzzeris otD
ihe tim6 betweenmalfunction
MALFUNCTIONCODE
CYCLEBFEAK
2.
Seconddiqit of maltunctioncode (ones position)
-'i;;l;il
thenumberoi timesthe buzzersounds
codeiepresents
positn ot tne marrtr.,ncli6n
;i;;;;;i
0.4 secondduringone cycle
COOE
r cYcL€ MALFUNCTTON
MALFIJNCTION
COoE:03
sEc. sEc
3.
- Firsl diqit ol maltunctioncode (tens position)
the numberof timesthe buzer is on
c;de represents
in" O,giii" ine lenspositionot th; maffunction
1.2 secondsduringone cycle.
The buzzeris off for 1.6 secondsbetweenthe longand shortpulses
I CYCLE
MALFUNCTIONCOOE
CYCLE
1 2 SEC SEC
FIRST DIGIT
F-68
4 o sEc
SECOND
DIGIT
coDE 22
F
FUNCTION
SELF-DIAGNOSIS
code Numb€rs
Sensor or
Ne'sisnal
Maltuncllon dbplay
Condition
Fail'sate
No Ne-signalwhil-a
crankrng
Stops iu6l injection
llaltunctlon
CodeNo.
output slgnalpan.m
ON
02
Open or short of aif-
ON
08
Openor shod oi
20oc (68oF)
throlilesensorcircuil 33.degreecommand
Oxygensensor
llnuesunchanged
2
min.aflerengineexceeds2,000rpm
09
ON
12
Cancelsengine
ON
15
Cancels
engine
{purgecontrol)
vaive @
valve @
40 sec. atterengine
exceeds1,500lpm
Openor short of
;,ilffilrfljlli
ON
17
ON
26
ON
valve@circujt
34
valve @ ci/cr.tt
35
Noie
. The buzzersounds only tor the ones positionwhen using the DlgltalCodeChecker.
To iudge lhe corect maltunctioncode number,reler to lhe digital display.
Caulion
. lf ihere ls morc than one failure p.esent,the code numberswill be indicatedin numericalorder. lowesl nrmber ttst.
. Aller repairinga lailure, perform the afler-repalrprocedure.(Referto page F-79.)
F-69
F
FUNCTION
SELF.DIAGNOSIS
Troubleshootlng
c6denumberiSShownon the SST,checkfor thecauseby Usinglhe chartrelatedto the
lf a malfunction
codgnumbershown.
COOE o.
STEI
O:IID TRIBUTOR I{E.SIGNAL)
ACTION
NSPECNON
circui0
in distributor
ls lherea poorconn€ction
Repairor replacewnng
No
2
3
Go to nextgep
ls therecontinud b€tweendistributorterminal
wirc (B/LG)and grcund?
Checkfor opencircuit in wirng ifom distributorto ground
ls therebatteryvoltageat disltibutortetminal
Ch€cklor opencircutin wiing tromdislibutorto main
relay(fUEl INJrelay)
Go to nextslep
NO
ls lhere aoorox.5V at ECUtemlnal 2E?{Wilh
distributorconnectordisconnected)
neplaceECU
5
Feplacedist butor
ls thereapprox.5V dist bLrtorterminal_wre
(G/R)?(At harnesesideconnectorwith discon_
NO
Checklor snortor opencircuitin wringlrcm disldbutor
2E
ECUterminal
Circult Diagram
O|sTR|aUTOR
DIS]RIBUTOF
IGNITION BATTEFIY
swrTcH
TO IGNITION
swtTcH
TO TACHOMEIEFi
TO DIAGNOSIS
CONNECTOR
IGNITEF
G/B
F-70
F
FUNCTION
SELF-DIAGNOSIS
08 (ATRFLOW
SE SOR)
CODE t{o.
STEP
2
acTtot{
IISPECTTON
ls iherepoofconnection
in airilowsensorcircuiP
Repairor teplacewi ng
ls ECU lerminal20 vollageOK?
e page F-118
ls sameCodepresenlatter performing
alter'repalfprocedure?
ldle
No
3
e p.g€ F-79
+
+
lgnitionswilchON
lf YES,replaceECU
lf NO,r€checkairliowsensorand
ECUior poorconneclion
Go to nextstep
ls lhere batteryvollageat airtlowsensorconnec'
tor teminal C with airilows€nsorconnectordis.
Checktor shortor opencircuilin wirng trom aiflow sensorconneclortermnalC lo mainrelay.
+
+
lJOK,checkmainrealy
ll notOK,repairor rcplace
ls lhe.e conlinuiiy belween airilow sensor lerrnina B and sround?
R€panor rcplacewiing
5
ls thereconllnutybetweenECUterminal20 and aidlow
ls resislance between arrflow sensor teminals A
and B OK?
E7 page F-121
+
+
Resistance:
4 + 1 m eo"C t68.Fl)
No
lf OK,replac€aidlowsensor
lf notOK,repairor replace
Aeplaceairllowsensor
Circult Diagram
FFOM IGNITION
swtTcH
t
r
rl
l
l
rl
1l G/w ll
r
r
clv
l
,i
AIFFLOW SENSOR
F-71
F
FUNCTION
SELF-DIAGNOSIS
09 (WATERTHERI'OSENSOR}
CODENO.I
STEP
1
2
tNSPECTTOI{
ls therea poor conneciionin waler thermosen_
ACTION
wrnng
leplace
nepairor
ls therecontinuitybetweenwaler lhermosensor
and ECU?
Go lo nexl step
ECU
20 (R/L)
G)
2D CYi
A (R/L)
B C/iG)
3
ls resistanceof waterlhermosensorcorrecf
Coolant lemp.
,200c ( -40D
Fesislance(kO)
20.c ( 68'D
80.c 076'R
2.21-2.69
0.29-0.35
No
Beplacewalerthermosensor
14.6 17.A
ls sameCodeNo.prcsentiollowingafler_repair
F Pag€F-67
5
Arc ECUtermlnals2D and 20 voltagescorrcct?
c7 page F-l16
andcrcuitOK
Waterthemosensor
17 PsgeF_112
n"pru". tCu
Checkfor shotlcircuilin wiringtromwaterthemosensor
lo ECU
Circult DiaEram
ECU
THROTTIESENSOR
re
@
\lB
)i
IER THERMOSENOR
re
ll
@
WATEBfHEFTMOSENSOF
F-72
F
FUNCTION
SELF-DIAGNOSIS
CODENo.
r2 fTHRoTTLESEI{SOR)
SIEP
INSPECTION
ACTION
1
ls lhele a poor conneclionin throltlesensor
2
ls there conllnuitybehdeenthrotllesensorand
ECU?
B (LGMI
ECU
2K (LG/R)
2M (1G,4/)
D ff/B)
2D (v/G)
A (LG/R)
3
Bepairor replacewiing
ls resislancesbetweenterminalsB (LG/'14and C
(Y/B)correc"
Adlust or replace throttle sensor
o
page F-12.
ReplaceECU
17 page F-112
Below1 kA
Approx. 5 kO
ls ECU terminal 2lV vollage cofrccl?
.7 page F-116
Checklor shortcicuil in wirnglromthrcttlesensorio
ECU
Circuil Diagram
IHFOTTLESENSOF
re
@
ll
Y/B jl
TERTHERMOSENOR
re
@
Y/G
THFOTTLESENSON
F-73
F
FUNCTION
SELF-DIAGNOSIS
ffiYGEN
STEP
2
3
t]{sPECTlOt{
ls therea poor connectionn orygen sensor
ls oxygensensorodpul vollagecotrecr?
F PageF-123
ACTION
Repairor replacewing
Replaceoxygonsensor
ls therecontinuitybetlveenoxygensensorand
EclJ termlnal2N?
ls ECU terminal 2N voltage correcl?
F Page F-1lE
5
- tNAcrtvATtot{)
sENsoB
ls sensitivityof oxygensensorcorrecp
t7 PageF-123
Circuit Diagram
F-7 4
Checkior shodcircuitin wiringlromoxvgensensorto
ECU
aadro
Fa||
Try knowngoodotygensensorand
ch;ck It co;ditionimproves
s
oaoe F-t12
.? ptge F-124
F
FUNCTION
SELF-DIAGNOSIS
mDE No.
.I7 (FEEOBACKSYSTEi|)
ACTtOl{
STEP
I SPECTTON
ls s3meCodeNo, presentafter pedormingallerE7 eagc F--67
NO
Checkoxygensensorcircuitior poor
+
.)
Checkmonhorlamp ol Sef-DiaqnosisCheckeril
luminateat jdle alter warming.upengineand
runningit at 2,500-3,000 rpm lor I minutes?
li OK, p€rfom toLrbleshooling
CodeNo.15
lf not OK, repairor replacecon-
s PageF-74
Go 1o nod step
ilole
. A/F mixtui€ lB rich
Go to Slep5
3
Nole
. A./Fmlrtur! b le.n or mi8fire occuiing
Go to nextslep
ls tuellinepressurc
at idlecorrec0
e prge F-94
Hlgh prossuro
ls fuel relurnho€ecloggedor restricted?
Fuel llne Dr€65ure:
235-275 wa (2.1-2.A r.glcnf, 3,F40 p5l)
(Vacuum ho3. lo preasurc rcgulrlot
dbconncctcr0
ls lhereleak€geot fueljnjectot
c? page F-97
+t ll OK. replacepres$re regulalor + lf nol OK, rcpairor replacehose
NO
ls waler lhemossnsor OK?
+
+
pag€ ru4
c? pege F-121
ll OK, Go lo Step7
ll not OK, replace water lhermc
(z page F-121
5
Disconn€ct each high-iension lesd at idle; does
enganespeed decrease equally at each cyinde|?
NO
Go to St€pI
Clrcult Dlagram
F-75
F
FUNCTION
SELF.DIAGNOSIS
acTtolr
INSPECTION
STEP
ls tuel line pressureat idle conecf
6
r7 P.ge F-94
Fuel line Dressure:
235-274 kPa 12.4-2,a kg/cm', 34-40 psD
(vacuum hose lo pr€*sune regulalor
No
whil€pinch
Checkiuellinepressr.rre
a
.t
qucklyinI luellinepressurc
creases,checkpressureregulator t7 Page F-95
gradually
in
lf iuellinepressure
creases.checkior cloggingbe_
tweeniuel pumpandpressure
lf notclogged,checkluelPUmP
F Peg€ F-91
maximumpressure
7
ls ihe.e air leal€ge in intake a I system com_
Go ro Step10
8
9
system
Repairor replaceignitlon
Wasmisfirelound in Slep 5 oJinspection?
b ;me CodeNo.presertiollowingpedorming
atter-rcpairprocedurc?
c7 Pege F--67
1 0 Try knowngoodECUIdoes conditionimprcve?
o page F-112
F-76
Go to noxl slep
NO
F
SELF-DIAGNOSIS
FUNCTION
26 (SOLENOID
VALVE- PURGECONTROL)
STEP
INSPECTION
ACTtOl{
Disconnectconn€ctorfrom ECIJ
CheckECUterminalconneclorlo. poor connecrion
ls lherc balteryvoltageat ECUterminal2X wire
+ lI OK,replaceECU
hamess(R/B)wnh ignilionswltchON?
- page F-112
+ ,l notOK,repairor replacewiring
CODENo.
2
Keep condilionStep 1
ls there bafleryvdrage al soleloid valveconnector terminal-wire (A/8)?
3
ls solenoidvalve OK?
(R/B)
Checkfor shod or open circuitin wiing lrom main relay
(FUELINJ relay)lo solenoidvalve
Beplace solenoid valve
F pago F-101
34 (AIRBYPASSSOLENOID
VALVEO)
STEP
INSPECTION
ACTION
1
Disconneclconneclortrorn ECU
Ch€ckECUterminalconnectorlor poorconneclion
CODEllo.
ls there baneryvotage al ECU leminal 2T wire
harness(BM) with lgnitionswtch ON?
.) ll OK, rcplaceECU
o page F-112
.> lf notOK,fepairor replacewiins
2
Keep condilionas Step 1
ls there baltery voltage at solenojd valve conneclor lerminalW.e (R/!9?
Repairwiring(R/Vr)
3
ls solenoid valve OK?
Ch€cklor shortor opencircuilin wiringfrommainrelay
(FUELINJ relay)to sol€noid
valve
F page F-109
NO
Replacesolenod valve
Clrcuit Diagram
VALVE€),
SoLENOID
FFIOMBATTERY
FROMIGNITION
SWITCH
VALVE
SOLENOIO
(PUNGE
CONTROL)
SOLENOIDVAIVE
soLENolovAtvE i
(PUFGE
COMIFOL)ii
F-77
F
FUNCTION
SELF-DIAGNOSIS
35 {An AYPASSSOLEI{OIDVALVE@)
Dsconneclconnectorfrom ECU
ls lhere batleryvoLtageal ECU le|minal2R wrre
(F/B)wilh ignilionswilchON?
Ke€ocondilionas StePI
ls th;re batteryvoltageat solenoidvalveconnec'
tor termina-wie (B/Bf
CheckECUtetminalconneclorlor poor connecron
+
.t
ll OK,replaceECU
lf noi OK,reparror replacewrrrng
PageF-112
Repairwi ng (R/B)
Ct ect tot "lon ot op.n "ircul in wiing fiom malnrelav
c? page F-109
Replace soLenod valve
Cllcuit Dlagram
i
AIF BYPASS
i
VALVEG)i
SOLENOID
FFOMBATTERY
FFOMIGNITION
SWITCH
VALVE
SOLENOIO
CONTFOL)
{PURGE
AIFIBYPASS
SOLENOID
valvE €)
z---F-----rr
ufjl-lJ
F-74
FUNCTION
SELF-DIAGNOSIS
Procedure
After-repair
'1.Cancelthememoryof mallunctions
fromthe ECu by disthe
thenegative
batterycableanddepressing
connecting
the
brakeoedalfor al least three seconds.Reconnect
negativebatterycable.
SST(SystemSeleclor)tothediagnosiscon2. Connectthe
nector.
3. Setswitch@ to position1.
4. SetTESTSWto SELF-TEST.
Ff
Checker)to the Sys5. Connectthe SST (Selt-Dlagnosis
tem Selectorand a ground.
Checkerto posi6. Settheselectswitchof theSelf-Diagnosis
tionA.
7. Turnthe ignitionswitchON.
8. Startandwarmup theengine,thenrunitat 2,000tpm tor
three minules.
9. Veritythat no code numbersare displayed.
"
lEJ.
F-79
F
FUNCTION
SELF-DIAGNOSIS
SWITCHiIONITORFUNCTION
Checker).
switchescan be inspectedby the SST (Selt-Diagnosis
Individual
Note
. itre TEN terminatol the diagnosisconneclormust be groundedand the ignltionswitch oN
(enginestopped),
. ti e-ntrerof i6e switches remainaclivated,the monilot lamp wlll be illuminated.
ENGINECONTFIOL
UNIT
NEUTRAL
SwlTCH
I
CLUTCHSWTTCH
I
STOPLIGHT
SWITCH
SWIICH
HEADIIGHT
SYSIEM
SELECTOB
OEFFOS1EFSWITCH
BLOWEFCONTFOL
SwlTCH
INHIBITOB
Self.DiagnoslsChecker(Monitor lamp)
Swilch
Clutch switch
Neutral swilch
Sloplight swilch
Headlighlswnch
Lighl Ol{
([4TX)
([/1X)
Inhibltorswitch
In gear
Clulch p€dal released
In gear
lights ON
Headlighls/small
ON
Rearwndow defrostersw ch
(ATX)
R€mark
Llght OFF
ON
ON
ON
L, S, D or F range
OFF
InspeclionProcedure
1.ionnecllheSST(SystemSelector)to theoiagnosrsconnector.
2 Setsw{ch@ to posttion1.
to SELF.TEST,
3 SeITESTSWITCH
F-80
F
FUNCTION
SELF.DIAGNOSIS
4. Connectthe SST(Sell-DiagnosisChecker)to the System Selectorand a ground.
Checkerto posi5. SettheselectswitchoftheSelf-Diagnosis
tion A.
6. Turnthe ignitionswitchON.
lampilluminateswhen
eachswitchismade
7. Checkif monitor
to tunctionas describedbelow.
Caution
. ll eitherot the switchesremainaclivated.the monitor lamp will be illuminated.
. Do not start the engine,
Procedure
Set conditionsto deactivateeach switch
.Ail accessor
es OFF
.Transmission
in neutral
Veity lhal monltorlarnpdoesnot illuminate
Checkeach swirchand relaledwting harness
.Clurch and Neurralswitch .Felerto pages F 124. 125
.Stoplightswitch
:Relerto SeclionT
.Headlight swlch
Relerto SectionT
.Water thefmoswilch
Feierto SectionE
.Rear delrosler switch
:Befer to Section T
. Blower swilch
Befer lo Section T
.lnh brtorswltch
:Belerto secfon K
Check each switch as describ€d
Neuiraland Clulch Switches(MTX)
Shifltransmissioninto gear
ls monilorbmp illurninated
wilhclulchpedalreleased?
PC .Neutralor clLrtch
switchmallunction
{Relerlo pagesF-124, 125)
.Openckcuilin relatedwirinSharness
. ECUiermlna(1\/)maitunciion
(Relerlo pageF-116)
Depress clutch pedal
Doesmonitorlamp go out?
B€tu.n transmission to neutral
PC . Clulchswitchmalunclion
(Relerto page F-124)
Stopllghtswllch
Depressbrakepedal
ls monitorlampillumlnaled?
Sloplightswilch OK
PC .Sloplight switchmalunction
(Beter to Section T)
.Open circut in w rlng harnesslrom sloplighl
switch to ECU
.ECU terminal(1O)maliuncllon
(F€ferto pase F 114)
F-81
FUNCTION
SELF-DIAGNOSIS
Blower switch
'Iun blowerswitchto ON position
ls monitorlampilluminated?
PC:.Blowerswitchmalfunclion
GeJerto SeclionT)
.dpen ctrcurlin ||e wrr'nghanesskom blower
swtchlo ECUterm,na(1S)
.ECU teminal(1S)maltunciion
(Reierto PageF 114)
Headlightswitch
Tum ON headllghtswitch
ls monrlorlamp illominated?
Headllghlsw(ch oK
Tum OFF headlighlswdch
PC:.Headlishtswitchmalfunclion
(Reierio SedionT)
lromheadlighr
.Open crrcuilIn w n19harness
swichlo Ecu ieminal(1u)
.ECU termrnal
(1U)mallunction
(Felerto PageF-l16)
Waterthermoswiichcircult (not included in switch insPeclion)
Warninq
I'iie c'ootinsr"n operateswhenthe diagnoslsconnectortermlnalsTFAtnd GNDare connected with a iumper ttrire' Use caution.
ConnectdiagnosisconnectortelminalsTFA and GND
V€ritylhat monilorlamp ill'rmlnates
PC. . Felay malfuncton
{Beler lo Section E)
.Open circlit ln wire harnessfrom watef thermo_
swrlchlo enginecontrolLinrl
.Enqrns controlunt lelminal 1R malluncliof
Waterthemoswitchckcuit is OK
a jumperwrrc
Dlsconnecl
Rea.defrosterswilch
Tum ON rear deffoslerswitch
ls monitorlampilluminated?
BeardeirosierswitchOK
TurnOFF rear deliosterswlch
swichmalfunclion
rc: .Fear delroster
(Beferto SeclionT)
fromfeardefroster
.bpen circuitin wldnsharness
switchto ECUteminal(1T)
.ECU terminal
(1T)maliuncton
(Reierto pageF-114)
Inhlbitorswitch (ATx)
Shitilransmissioninlo gear
ls monitorlamplluminated?
lnhilitor swilchOK
"P or "N
Shlflinto
F-42
range
PC:.hhlbiior switchmalllnct|on
iReterto SectionK)
.Open ot shol crrcuiln relaledwnng harness
(1V)maLfuncton
.ECU terminal
(Beterlo pageF 116)
F
INTAKEAIR SYSTEM
INTAKEAIR SYSTEM
PARTS
COMPONENT
Removal/ Inspectlon/ Installatlon
1. Removein the ordershownin the figure,referringto RemovalNote.
2. Visuallyinspectthe intakeair systemcomponents
and repairor replaceas necessary.
3. Installin the reverseorderol removal
19-25 (1.9-2.5. 1.-r9)
19-25 0,9-2,6, r/r-r9)
7.6-11 nn (40-t10 cn.tg,
6H5In-lb)
REPLACE
11 25 i,9-2.6, 1a-191-
/a :;;s
(3,3-s.3. 27-33)
1.Aircleaner
Inspectfor excessive
dirt or damage
2. Injectionbody
pageF-84
Inspection...................................
pageF-85
Disassembly
/ Assemb1y.............
page F-86
Inspection...................................
4. Intakemanifoldstay
5. Intakemanifold
pageF 86
Inspection...................................
RemovalNote
Coolant
container
beforeremovino
1. Drainthecoolantintoa suitable
the injectionbody.
2. Retillwilhcoolanlafterinstallation.
Cautlon
. Belorelooseningthe radialordrainplug verify thai
the radiatordraln hose taces stralghl down.
F-83
F
INTAKEAIF SYSTEI'
FUELPUMPCOVER
Fuel Pressure Releaae
thefuelpressure
anyluelhne,release
Beloredisconnecting
possibility
of Injuryor fire.
tromthetuelsvstemlo reducethe
|. Sladthe en-gine.
2. Removethe rearseatcushton.
the fuelpumpconnector'
3. Disconnect
4. Afterthe enoinestalls,turnofi the ignitionswitch
rearseat
andinstallthe
theluelpumpconnector
5. Reconnect
cush|on.
PUMPCONNECTOF
BODY
INJECTION
Inspeclion
1.Checkthe iniectionbodylol wearand deposils
withthethrot'
2. Verifythatthethrottlevalvemovessmoothly
tle valveleverfromfullyclosedto fullyopen.
Fastldle (On-vehicleInspection)
1.Turnall electricloadsOFF.
. Blowerfan
. Headlight
. Rearwindowdelroster
andthatthefastidle
2. Verifythatthe waxrod is contracted
cam asin contactwiththe roller.
4-?-2:
3. Connecta tachometer.
4. Starttheengineandverifythattheenginespeedis below
2,500nm.
and
temperature
5. Warmup theengine1onormaloperating
gradually
decreases.
speeo
the
engine
verfy that
6. AftertheenginewarmsLlp,verifythatthewaxrodextends
fromthe roller.
fullvand thatthe camsepartes
7. Vdity thatthe idlespeedis withinspecification.
ldle speed:MTX (Neutral) 750 :53rpm
:1 rpm
ATX (P range)1,100
Note
. Air bypass solenoid valve @ opens lrom hsll
ryanhedup condilion to wamed up condition.
. Walertempelaturewhen cam iust separatesis 6l
:3"C (142 1!l.R @TX),55 + 8oC (l3l + 46oF)
(ATD.
F-A4
F
INTAKEAIR SYSTEM
bodyif necessary.
8. Fieplace
theinjection
Caution
. Do not disasasmble
ihe iniectionbody.
. Do not turn the acrewgshownin lhc ligure.
01E0Faog1
Disassembly/ Aaaembly
in the ordershownin the figure.
1. Disassemble
2. Assemblein the reverseorderof disassemblv.
GASKET,
FEPLACE
3,4-a.S (35-50, 3O---4:r)
3.4-5.e (35-s0i 30-4t)
;?iil:"ts
7.4-12 t@-12O, 69-1U)
r.2-r.3(12-13, t0-r6)
O8ING,FEPLACE
2.0-2.s (20-30, r7_2G)
rl-22 lln (r.a-2.2 n.l(g,
4. Airflowsensor
valve@
1. Air bypasssotenoid
1 n s p e c t , o n . . . . . . . . . . . . . . . . .page
. . . . . .F-121
..........
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0
. .9. . .
regulator
5. Pressure
2. Dashpot
l n s p e c t i o n . . . . . . . . . . . . . . - . . .page
. . . . . F. . . .94
......
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0
. .4. . .
R e p | a c e m e n t . . . . . . . . . . . . . .page
. . . . . .F. . . 94
......
3. Throttlesensor
pageF-122 6. Injector
1nspection.................................
pageF- 95
(on-vehicle)..............
Inspection
A d j u s t m e n t . . . . . . . . . . . . . . . . .p. .a.g. .e.F. .-.1. 2
. .2. . .
pageF 96
pageF-I22
Bemoval
/ lnstallation................
Removal
/ fnstallation................
F-85
F
INTAKEAIR SYSTEM
MANIFOLD
BAFFLE/INTAKE
Inspection
1 Visuallvcheck for cracks or damageand reolaceif
INTAKEMANIFOLD
z. 8i"ff#
if
andreplace
oftheintakemanffold
ai"tonion
necessary-
PEDAL
ACCELERATOR
Removal/ Inspection / Installation
'1.Removein the ordershownin the fagure
pedaland retainerfor cracksor damage'
checkthe accelerator
2. Visually
3. Installin the reverseorderof removal.
9!-r5
{100-150, t7-r3o)
cable
1.Accelerator
... .. pageF-86
/ Adjustment....
lnspection
2. Retainer
3 cliP
4 Fletumspring ..
5 Accelerator
Pedal
CABLE
ACCELER,ATOR
InsD€ction/ Adiustment
pedalfully Verifythatthe throttle
1. deoressthe accelerator
valveis fullyopenedby tirrningthe throttleleverby hand
cable.
2. lnspectthe playol the accelerator
Play: 1-3mm (0.04-0.12 In)
3. Loosennuts@ to adjustthe play if necessary.
F-86
F
FUELSYSTEII/I
FUELSYSTEM
DESCRIPTION
Thissystemsuppliesthe necessary
fuelat a constantpressure
to the injector.
Fuelis meteredandinjectedintotheintakemanifold
according
to theinjection
conkolsignalkom theECU.
Thissystemconsistsof the fuel pump,fuelfilters,pressureregulator,
and injector.
PRESSUFE
FIEGUFATOB
vFUELFILIER(HIGH.PBESSURE
SIDE)
SIOE}
FUELFILTER(IOW.PRESSUFE
s
@
\
F-87
F
FUELSYSTEM
22-30 (2.2-3.r, 16-22)
PUMPCONNECTOFI
PRECAUTION
Fuel PressuleReleaseand ServicingFuel System
whenthe
underhighpressure
Fuelinthefuelsystemremains
is
not
running.
engine
anyfuelline'releasethetuel presa) 6eforedisconnecting
ot Iniury
surelromthetuelsystemto reducethepossrbrlity
or ire.
1. Startthe engine.
2. Removethe rearseatcushlon
the fuelpumpconnedor'
3. Disconnect
stalls,turn otf the ignitionswitch.
engine
After
the
4.
the rear
and install
thetuelpumpconnecior
5. Reconnect
seatcushion.
tromtuelspraywhendisconnecf
b) Usea rag as protection
ing the hoses.
Pluothe hosesatterremoval.
fuelpresthefuelsystem,usea suitable
c) Wh;n inspecting
gauge.
sure
Caution
. Instatl hose clamPsto secure lhe fuel pre$sure
gaugeto the fuel lllter and the tuel main hoseto prevent luel leakage.
SYSTEMOPERATION
Fuel PressureHold lnspection
Waming
. Beloreperformlngthe followlngoperation,release
the tueipEssure tlam the tud systemto .educe the
posslbilityot inlury or lire. (Relerlo above')
the negativebatterycable
1. Disconnect
2. Installa fuel pressuregauge.
3. Connectthe negativebatterycable-
. /4,-<'-\\. \
\
X.. \
oteelosts\
CONNECTOF
F/Pand GNq
terminals
connector
4. Connectthe diagnosis
witha jumperwire.
5. Turnthe ignitionswitchONlor l0 sec' to operatethefuel
oumo.
thejumperwire
switchOFFanddisconnect
6. iurn ihe ignition
pressure
min..
alter
5
7. Observethe fuel
Fuel pressure:
Morethan l4T kPa (1.5kg/cm',21 psi)
F-88
F
FUELSYSTEM
Fuel Line PressureInsoestion
Warning
. Belorc performlng the tollowing operatlon, release
the fuel p]gs$re lrcm the tuel syslem to leduce the
possibllltyot iniury or tire. (Reterto page F-88,)
1. Disconnect
the negatNebatterycable.
2. Connecta fuelpressuregauge.
3. Connectthe negativebatterycable.
F/PandGNDwith
terminals
4. Connectdiagnosis
connector
a umoerwtre.
5. Trjrnthe ignitionswitchON.
6. Measurethe fuelline pressure.
Fuel line pressure:
235-275 kPa (2,4-2.4 kglcm" 34-40 p8l)
F-89
F
FUELSYSTEM
FUELTANK
Removal/ Inspection/ Installalion
Warning
trom the fuel systemto
i'-diiJie pertormlnsihe following operalion,releasethe fuel-Pressure
page
F-88J
(Reler
lo
reduceihe pGstblllty ot iniury or fire.
. Wrrentitoilns tlte fuel ia;rk,'k;t spalrrs'cigaiett-cs,and open llames away |tom it'
gas.
. i'iiiij
iepiirin-g the fuet tanti, ctein ir ttrr6ug6ty with steam to lemove all exploslve
1. Removein the orde.shownin the tigure.
necessary
2. Visuallyinspectthe fueltank componentsand repairor replace-asNote
Installation
3. lnstall;n th; reverseorderof removal,relerringto
-
r.r-r.7 {r1-17, 9.5-15)
,."-, , ,*-r ,0,*rr, Q
SEALRUBBEF,FEPLACE
@
. \
43--6r r+m ({.4-4.2 n.kg, 3a--{6 tt lb)
Note
. Drainthe tuet lrom the tuel tank before removingthe tank.
1. Rearseatcushlon
2. Fuelpumpcover
3. Fuelpumpconnector
4. Fuelhoses
hoses
5. Evaporative
6. Fueltankstraps
F-90
7. Fueltank
Inspeclfor cracksand corrosion
8. Checkvalve(twoway)
L Fueltankunit
10.Fuelvaporvalve
valve
11.Non-return
FUELSYSTEiI
F
lnstallationNote
1. Pushtheendsof themainfuelhose,fuelreturnhose,and
ai least25mm
hosesontothefueltankfittings
evaporative
(r.0in).
hoseontothetueltankpipeandtillerpipe
2. Pushthefuelfiller
(1.4
In).
al least 35mm
FUELPUMP
Inspection
ltlaximum pressure
Warnlng
. Setore performingthe lollowlng operalion, release
the tuel prcssu|elrom the fuel system to r€ducethe
po$lbllily ol Inlury or lire. (Reterlo page F-{8.}
. When inspecting luel system palts, keep sparks,
cigarettes,and open tlames awayfrom the fuel,
'1.Disconnect
the negativebafterycable.
gaugeto the luelmainpipeand
2. Connecta fuelpressure
plugtheoutletofthefuelpressure
gaugeasshown.(lnstall
clamosas shown.)
3. Connectthe negativebatterycable.
F/PandGNDwith
4. Connectdiagnosis
connector
terminals
a lumperwre.
5. Turnthe ignitionswitchONtor l0 sec. to operatetheluel
pumpand measurethe fuel pressure.
Fuel pressure:
491-658 kPa (5.0-6.5 kg/cm', 7l.l-92.4
FUELPUMPCOVER
REANSEATCIJSHION
p6i)
tttejumperwire.
switchOFFanddisconnect
6. Turnhe ignition
pump.
replacethe fuel
7. lf not as specified,
Conlinully
1. Removethe rearsealcushion.
2. Disconnect
thefueloumDconnector.
22--.3012.2-3, 1, 1G-2'
Nfl (Gks, n.D) |
CONNECTOB
3. Checklor continuity
betweenthe terminals@ and @ of
the connector
at the fuelpumpshownin the figure.
4. lf thereis no continuity,
replacethe fuelpump.
(Referto page F-92.)
F-91
F
FUELSYSTEM
Fuel pump oPerationsound
1.Turnthe ignrtionswtch ON
connectortermtnalF/P to GND
2. connectdlaonosis
operg Remove
capandveritythatthefuelpump
their.relfilter
ationsoundis heard.
-.:-n
@Y...
&
s:'5
4;/
GNO
Replacement
Warning
-riltreri
lrom
ireplacins ttte tuel sysiem parts, keep sParks, cigarettes' and open flames away
the tuel.
. ieioie oerfotmfnsthe tollowlng operalion,releasethe tuel pressurefrom the fuel systemto
reduceihe possibilityol iniury or tire. (Referto page F-Ear'
1. Removein the ordershownin the tigure.
2. lnstallin the reverseorderof removal.
r.r-r.7 (1r-17,s.s-rs)
*k/
FUE! HOSE,
{30-rro, 69---eq
a
WASHEF,BEPIACE
2.7-4.1 123-42, 2a---36t
1. RearseatcushDn
2. Fuelpumpcover
3. Fuelpumpgaugeunltconneqor
4. Checkvalve
5. Fuelhoses
6. Fuelpumpgaugeunit
F-92
7. Fuelpumpconnector
8. Bracket
9. Rubbermounl
10.Fuellilter
'11.FLrel
pump
F
FUELSYSTEM
FUELFILTER
Replacement
Low-pressure side
Referto pageF-92.
.F\
7,a-lr {a0-r1o, 6r-95)
Hlgh-plessureside
the fuelfiltermustbe replacedattheintervals
outlinedinthe
maintenance
schedLrle.
Warnlng
. Belore pertorming the tollowing operation, release
the tuel pressurefrom the luel systemto rduce the
posslbilityot iniury or fire. (Referto page F-88.)
. When replacing the tuel filter, keep sparks,
cigarettesand open tlamesawayflom it.
'1.Disconnect
the fuelhosesfromthe tuelfilter.
2. Removethe fuelfilterand bracket.
3. Installin the reverseorderof removal.
CIRCUITOPENINGRELAY
Replacement
'|. Disaonnect
the negativebatteryterminal.
2. Removethe ECU.(Referto pageF-112.)
3. Removethe relaybrackel
4. Removethe circuitopeningrelaylromthe relaybracket.
CIRCUITOPENNINGFELAY
Inapectionot Continuity
1. Checkcontinuity
between
terinals@ and@ in thefollow
ing condition.
f--_-1
r*{ry
Gl'.
L.ora\€)
I
Te.minals
Aoolv 12V
@ * @
NO
T , _-ir
@ " @
No
(b_oorqA
Continultv {aA- G))
2. Replacethe relay if not as specified.
F-93
F
FUELSYSTEM
REGULATOF
PRESSURE
Irsp€ction
Fuel llne pressure
WarninE
. BebA oerforminqthe lollowingoperatlon,releaae
the fuel'presaurellom the fuel system to lsduce the
possibllity ot Iniury or tlre. (Reter lo page F-88.)
. When inipecting the pressure regulator' keep
sparks,ciiaretl$, and open llames awayfrom it'
FIEGULATOFI
PRESSUFIE
vAcuuM HosE ^
\
NJECTTON
BOOY
1. Disconneqthe negatNebatterycable
gauge.
2. Connecta fuelPressure
cable.
battery
the
negative
3. Connect
4. Startthe engineand run it at idle
5. Measurethe luel linePressure.
Fuel line Pressure:
235-2i5 kPa (2.4-2.a kglcm'' 34-40 psi)
Noie
. The tuel line pressurcwlll mt change when removIng the vacuum hose lrom the Plessule regulator
at ldle.
nepbcement
Warning
. Betoie oedormlng the following operatlon, lelease
the fueipressure from the luel system lo lsduce ihe
possibllityof iniury or tire. (Reler to page F-88.)
. iivhen replaclng tuel system componenta' keep
sparks,cigareties,and openflamesawayfrom the
lusl.
3.a--{.a {35-50, 3O--a3)
Cautlon
. Aller removlngthe air cleaner,coverlhe lntakeah
pagsag€ with a ctean rag to Protect the alrtlow
3enaor.
1. Removethe air cleaner.
the negativebatterycable
2. Disconnect
as shownin the figure
3. Removethe pressureregulator
4. lnstallin the reverseorderol removal
OAING,FEPIACE
INJECTOR
Inspection (On-vehlcle)
1. Removethe air cleanercover.
Caulion
. Performthe tollowing insPectioncarelullyto Protect the alrflow sensorttom damage.
2. Startthe enoineand run it at idle.
sounds
3. Usingasoundscope,verifythatinjectoroperaling
are nearo.
F-94
FUELSYSTEM
Removal/ lnstallation
Warning
. Betoreperformingthe following operalion,relgasethe luel pressurelrom the tuel system ot
reduqethe possibilityof injury or tire, (Reterto page F-88.)
. Whenremovingthe fuel syslem parts, keep sparks,cigarettes,and open tlamesaway trom
the tuel.
1.Loosenthe radiatordrainplug and drainthe coolant.
2. Removein the ordershownin the figure,referringto RemovalNote. (Refer10pageF-95-)
3. Installin the reverseorderot removal,referring
to InstallationNote. (Referto pageF-96.)
7,3-11 (30-110,69-9s)
GASKET,SEPLAC€
CIFINGS,FIEPLACE
CUSHION
RUBBEF,
ad
rQ-25O,e-2.6,r.-t9)
-e
re-25 0.e-2.6,r.-19)
GASKETS.
REPLACE
1.Air cleaner
2. Waterhose
3. Fuelhose
4. Air bypasshose
5. Injecuon
body
6. lnjectorcover
7. lnjector
Removd Note
. Whenreplacing
the injector,pushthe injectornozzleout
wjtha plasticor woodstick.
F-95
F
FUELSYSTEM
REPLACE
HION
lnslgllationNote
. UsenewGrings,cushionrubber,and gaskets
greaseto lhe O'ringsbe
. Applya smallahountof silicone
lore installation.
. Installtheiniectorsquarelyintoinjectionbodyanddo not
twistit whileinstalling.
F/P and
connector,
. Afterinstallation,
thediagnosis
connect
witha iumperwire,andcheckforfuelleak'
GNDterminals
age withthe ignitionswitchON.(Referto pageF-96.)
Inspection
Warning
. whe; inspecting the iniector, keep sparks,
cigarettes,and open tlames awaytrom the tuelIniectorresistance
the iniectorconnector.
1. Disconnect
ol the iniectorwithan ohmmeter.
2. Measureresistance
Resistance:1-20 (20'C l68oFl)
Fuel ldakagetest
Caution
. Perlormthe followlng inspectioncarefullyto pro'
iect the air bypasspassageof the airflow sensol
lrom the enllance of dust or dirt.
1. Removeihe air cleaneras shownin the fagure.
F/P andGND
terminals
connector
2. Connectthediagnosis
witha ilmper wire.
3. TurntheignitionswitchON andcheckfor tuelleakslrom
the injector.
Fuel leakage:Lesslhan I drop/s minutes
F-96
t
F
EXHAUSTSYSTEM
EXHAUSTSYSTEM
COMPONENT
PARTS
Inepection(On-vehicle)
Startthe engineand verifythatthereis no exhaustgasleakagefromthe exhaustsystemcomponents.
Removal/ lnspection/ Installation
1. Removein the ordershownin the figure.
2. Vlsuallyinspectthe exhaustsystemcomponents
and repairor replaceas necessary.
3. Installin the reverseorderof removal.
7.3-rt xn {3o-rt0 cn*g!
GASKET,FEPLACE
GASKET.
FEPLACE
re-23 fi,9-2.3, r{-r4
GASKET, FIEPIACE
;:;::: ",_.-1
:"
7.3-11 N.n (8c-rro cn{q,
SPFING,
"'_",.'"_""1".".:€
E
40-55 (4.r-5,6,30-41)
rL3
0.9-23, rr_14
crRrNG,
{o-55 (.r.1_5.6,3O__-4r)
a1aoFx47a
1-lnsulator
2 .F r o npt i p e
lnspectfor deterioration
and cracks
3. Exhaustmanifold
Inspectior cracks
pipe
4 .M i d d l e
lnspect
for deterioration
andcracks
5. Calalytic
converter
l n s p e c t i o n . . . . . . . . . . . . . . . . . .p. a
. .g. .e.F. . 1
. .0. .3. . .
6. N.4aln
silencer
lnspectfor delerioration
and cracks
7. Oxygensensor
Inspection.................p
. .a. .g. .eF
. .-. 1
. .2. .3. . .
pageF 124
Replacement.............................
B.lnsulalor
F-97
F
OUTLINEOF EMISSIONCONTROLSYSTEM
OUTLINEOF EMISSIONCONTROLSYSTEM
VIEW
STRUCTURAL
Thelollowingsystemsare employedto reduceCO, HC, and NOxemissions.
(PCV)syslem
crankcaseventilation
1. Positive
emissioncontrolsystem
2, Evaporative
conve(er
3. Catalytic
W
VALVE
SOLENOID
(PURGECONTFOI)
AR
-til
CANISTEF
GHECK VALVE (TWO_WA
F-98
(PCV)SYSTEM
VENTILATION
POStrtvEGRANKCASE
F
posrilvE GRANKCASE
(PCU SYSTEM
VENTILATION
DESCNIPTION
The PCVvalveis operatedby the intakemanifoldvacuum.
Whenthe engineis runningat idle,the PCVvalveis openedslightlyand a smallamountof blowbygas
is drawnintothe intakemanifoldto be burned.
largeramountot
blowAstheenginespeed
risesthePCVvalveis openedfurther,allowinga proportionately
by gasto be drawnintothe intakemanifold.
PCV VALVE
Inspectlon
lemperature
and
1.Warmup theengineto normaloperatlng
run it at idle.
hosefromthe
2. Disconnect
thePCVvalveandtheventilation
cylinderheadcover.
3. Blockthe PCVvalveopening.
4. Verifythatvacuumis telt.
5. Removethe PCVvalve.
6. Blowthroughthe valvefrom port @ andverifythatairflows
lromot gort 6).
7. Blowthrbughl-he
valveflom port@ andveritythatno airflows kom of port @.
8. Reolacethe PCVvalveif not as specified.
F-99
F
E]IIISSIONCONTROLSYSTEi'
EVAPORATIVE
EVAPORATIVEEM]SSIONCONTROLSYSTEM
DESCRIPTION
(ATX)
SWITCH
INHIBITOH
THFoTTLESENSoF
)\M
\lh-
s!q.t
OXYGENSENSOB
WATEF TH€RMOSE
q_l
rnrrori sersoa
CANISTEF
@
CHECKVALVE
FIJELVAPOFIVALVE
the
emissioncontrolsystemconsistsof the fuelvaporvalve'the-ch€ckvalve(two'way)'
Theevaporative
input
devices'
(ECU)'
the
and
unit
control
the engine
the solenoidvalva(purgecontrol),
chircoaicanister,
valveThe
by purgecontrolsolenoid
lumesdrawnintotheengineandburnedis controlled
Theevaporative
valve
solenoid
controlsthe
devices
and
input
by
the
various
coniitions
ibU a.G"is fne enqine'soperating
values.
to
these
according
signals
operationby electrical
Operation
by signalsfromthe ECUto periormpurgingof thecharcoal
ilie solenoidvalvelpurgecontrol)is controlled
are met:
canister.Purgingis donewhentheseconditions
(1) Afterwarm-up
(2) Drivingin gear
(3) Acceleratorpedal depressed
normally
(4) Oxygensensorfunctioning
F-l00
EMISSIONCONTROLSYSTEM
EVAPORATIVE
SYSTE" OPEFATION
temperature
and
1 Wam up theengineto normaloperating
at
idle.
run I
the vacuumhoselromthe solenoidvalveas
2. Disconnecl
showninthefigure,andverifythatno vacuumis teltatthe
solenoidvalve.
checkthe solenoidvalve
3. lf not as specified,
SoLENO|DVALVE(PURGECONTBOL)
Inspection
1. Drsconnect
lhe vacuumhoseskom lhe solenoidvalve
2. Veritythatno air flowsthroughthe valvefrom port @ to
pon @.
the solenoidvalveconectorand apply12V.
3. Disconnect
4. Verifythatairflowsthroughthevalvefrompgrt @ t9 pgt!
ol the solenoid
the resistance
CD.li no air is felt,measure
valve.
Reslstance:32 + 20
replacethe solenoldvaNe5. lf not as specified,
'-?j-r1
(30-110,6e-9q
Removal/ Inslallation
'1.Disconnectthe
valve
thesolenoid
hosesirom
evaporative
connector.
valve
the
solenoid
Disconnect
2.
nut andthe solenoidvalve.
3. RemoveJhe
4. lnstallin the reverseorderof removal.
Tlohteninotorque:
?.4-t r-Nfl 480-1 lO cm-kg, 69-95 in-lb)
FUELVAPOBVALVE
Inspectlon
thevalvefromport@ asshown
1. Verifuthatairilowsthrough
in thefioure.
F-10t
F
EVAPORATIVEEMISSIONCONTROLSYSTEM
2. Verifythat no airflowsthroughthe valvelromport @ as
shownin the fgure.
3. Replacethe fuelvaporvalveif necessary.
CHECKVALVE GWO-WAY)
Inspecilon
1. Removethe valve.
of the valvewitha vacuumpump.
2. Checkthe operation
Blow f,lroughvalvelrcm Pon @
Applyapprox.37 mmHg(1.46inHg)
vacuumat port @
Applyapprox.44 mmHg(1.73inHg)
vacuumat port @
3. Replacethe checkvalveif not as specified.
CHARCOALCANISTER
Inspectlon
1. Visuallycheckfor damageand cracks
2. Blowair intoeachportandverifythattheyarenotclogged.
the charcoalcanisterif not as specified
3. ReDlace
F-l02
CATALYTICCONVERTER
SYSTEM
F
CATALYTICCONVERTERSYSTEM
DESCNIPTION
ThecatalyticconverterreducesCO,HC,and NOxby chemicalreaction.
Theconverter
containsplatinum
and rhodiumcompounds.
01E0F2.1{s
CATALYTICCONVERTER
Inspection
Ngte
. The insulatorcannoi be removed.
checkfor deteriRemove
thecatal!4ic
converter
andvisually
orationand cracks.
F-l03
F
CONTROLSYSTEM
DECELERATION
CONTROLSYSTEM
DECELERATION
DESCRIPTION
Thedashpotis usedto preventthe throttlevalvetromsuddenlyclosing
osuoFx
rss
DASHPOT
lnsgeclion
1. Openthethrottlevalvefully.Pushthedashpol.od witha
fingerand veritythatit goesintothe dashpotslowly
2. Release
the rod and verifythatit comesout quickly.
3. Replacethe dashpotif notas specified
4. Warmup the engineand run it at idle
5. Connecta tachometelto the diagnosisconnectorlGterminaland increaseenginespeed.
DIAGNOSIS
CONNECTOB
theenginespeedandverifythatthelever
6. Slowlydecrease
touchesthe dashpotrod at the specifiedspeed.
Specification:2,500 + 100 rPm
loosenthe locknutandturnthe adjust7. lf notasspecified,
ing screwto adjust.
F-l04
F
A./CCUT.OFFSYSTEM
A/C CUT.OFFSYSTEM
DEsihrPrtoN
performance,
To improveidlesmoothness
afterjuststarting
theengineandto improveacceleration
an AJC
cut-offsvstemis used to controlA,/Coperation.
THFOTTLESENSOR
DETEFMINATION
u'o"""o*'1=:9J-1
MAGNEITC
CLUTCH
IGNITIONSWITCH
fr" .*,r""
I
Operation
TheA,/Cis cut off underthe conditionsbelow.
Cui-otl pcriod
E glne condlllon
Thrcttlevalvefully open
Accelerationfrom stop
:. ;.!9-
rHRorrLEL'NK
lmpfoveddravabilily
SYSTEiIOPERATION
andA,/CswitchON.
1. Turntheignitionswitch,blowerswitch,
stops
2. Openthethrottlevalveandveritythattheadditionalfan
for approximately 1 second.
F-l05
DECHOKECONTBOLSYSTEM
DECHOKECONTROLSYSTEM
OESCRIPTION
iJtacifitatestartinqtne engineit thesparkplugsbecomefouled,suchas whenthe engineis flooded,fuel
tempera
rscut it th; thronlevalveis heldwideopenwhi'ecrankingtheengineif theenginecoolant
injection
frorn
the
cylinders
purges
plugs
fuel
and
excess
to
dry
tu'rJisO"Ctiz"n or uelow.Thisallowsthe spark
CFANKANGIESENSOE
INJECTOF
DEIEFMI.
NATION
cur
THFIOTTLE
SENSOF
WATEFT
THEFMOSENSOR
SYSTEMOPERATION
is below ooc (32oF)
1.Ve4futhatthe enqrnecoolanttemperaiure
2. Verii that the enainewill not slartwhencrankedat normalspeedwiththe throttlevalvefullyopen.
3. lf theenginestarta,inspectthethrottlesensor.(Reierto pageF-122) andthe ECUterminal1Uvoltage.
(Relerto pageF-116.)
F-l06
F
AIR BYPASSCONTROLSYSTEM
AIR BYPASSCONTROLSYSTEM
DESCFIPTION
Theair bypasssystemoperatesto improveidlestabilityand vehicledrivability.
Thissystemsupplies
throttlevalvebypassair intointakemaniloldaccordingto engineloadcondition
and
drivingconditions.
Thissystemconsistsot two solenoidvalvescontrolledby the ECU.
AA AYPASSSOLENOIOVALVE@
AIF BYPASSSOLENOIDVALVE@
ArF BYPASSSOLENOTO
VALVE@
THAOTTLEVALVE
Operationot Ai. BypassSolenoidValve
Air bypa$ aolenold wlve
Englno condltlon
Duing cranking
lgnitionswilch OFFrON
'Acc€ssoryON
P/Spressuresw{ch ON
@
To improve$anability
To prcvenllrorn slickng
Dunng d€celelation {d€celelation conlrol)
@
o
o
To improvesrartability
,dJCswilch ON
Wam up (asoc-8ooc)
SeleclleverN-D (ATX)
o
To alleviats sudden engine speed drop
To improvedivabilty
'Accessoryis headlights,rear windowdefrosler,blowerswilchand coolingJan.
o
o
o
o
o
o
o
o
o
F-107
AIR BYPASSCONTBOLSYSTEM
SYSTEMOPERATION
1. Warmup the engineto normaloperatingtemperalure
2. Veritythatthethermowaxunitrode)dendsoutwardtullyand
fromthe roller.
thatthe cam separates
waituntilit stops.
lan
is operating,
cooling
3. lf lhe electric
4. Verifythatthe engineis idlingsmoothl,
FASTIDLECAM
valve
5. Verifuthatclickis heardfromtheail bypasssolenoid
and
OFF
ON
following
electficalload
the
when
turning
@
soLENoto
vALvEO
\
/ry
load
Electrical
. Blowerfan
. Headlight
. Rearwindowdetroster
6. Veritythat clickis fromthe air bypasssolenoidvalve@
whenthe enoinestans.
7. Turntheignitionswitch,blowerswitch,andAJCswitchON.
8. Rotatethe throttlelink by hand.
valve
is heardfromtheairbypasssolenoid
L Verirythatclick
@.
F-108
AIR BYPASSCONTROLSYSTEM
AIF SYPASSSOLENOID AIF BYPASSSOLENOID
F
AIB aYPASSSOLENOTD
VALVE@, @, @
Inspeclionlor contlnuhy
1. Disconnect
eachair bypasssolenoidvalveconnector.
2. Inspectfor continuity
between
the solenoidvalveconnector terminals.
3. Replace
the air bypasssolenoidvalveif not as speciiied.
AIR BYPASSSOLENOID
VALVE@
Inspectiontor Airllow
1. Inspectair bypasssolenoidvalve@.
1)Removethe air cleaner.
2) Closethe bypassair passagewithtape.
\
r-i
',:,,%rc,!
3) Disconnect
the bypassair hoselromtheair bypasssole
noidvalve@ as shownin the figure.
4) Verifythat
noairflowsthrough
airbypasssolenoid
valve
@ whenblowingair lightyintothe air bypasshose.
sotENotoVALVE
@
DISTFIBUTOR
d
r-:\*
trtlW
\__-,/'
PATTEFY
5)Turnthe ignitionswitchON.
6) Groundthe termlnal@ as shownin the flgure.
valve@
4 Verifythatairflowsthroughairbypasssolenoid
whenblowingair intothe air bypasshose.
2. Inspectair bypasssolenoidvaive@, O
1) Bemoveair bypasssolenoid
vdve @ or @.
2) Blowthroughthevalveffom port@ and verifythatno
air comesout of port @.
3) Apply12Vto the solenoidvalveconnector.
4) Blowthroughthevalvefromport@ and verifythatair
comesout oi port@.
Adiustment(idle-upspeed)
Relerto pageF-64.
F-l09
F
CONTROLSYSTEM
CONTROLSYSTETI'
PREPARATION
ssT
49 GO18903
49 9200162
EngineSignal
49 D015001
49 GO18904
Sheet
ECU
49 80199AO
Syslem
Seiector
F-l10
ECU
ECU
ignitiontiming
CONTROLSYSTEM
F
VIEW
STRUCTURAL
6. Oxygensensor
1 .E C U
I n s p e c n o n . . . . . . . . . . . . . . . . . .page
. . . . . .F. . 123
.......
R e p l a c e m e n t . . . . . . . . . . . - . .p. .a. .g. e. . . . . . . . . .
page
p
a
g
e
R
e
p
l
a
c
e
m
e
n
t
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . .F. . 124
.......
Inspection............................-....
7. lvlainrelay
2. Crankanglesensor
R e p l a c e m e n t . . . . . . . . . . . . . -page
..-..F
. . .124
.......
I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g
. .e.F-120
........I n s p e c i r o n . . . . . . . . . - . . . . , , . page
. , . . . ,F-124
,,,-......
3. Airflowsensor
8. Clutchswitch(MTX)
I n s p e c l i o n .. . . . . . . . . . . . p a g e
page
. . . . . .F-124
......
I n s p e c t i-o. .n. . . . . . . . . . . . . . - . . . page
Removal
/ Installation................
page
F-124
R
e
p
|
a
c
e
m
e
n
t
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.......-.
4. Waterthermosensor
R e m o v a | . . . . . . . . . . . . . . . . . . . . p. .a. .g. e
. . . . . . . . . . . 9. Neutralswitch(MTX)
I n s p e c n o n . . . . . . . . . . . . . . . . . .page
. . . . . .F-125
.........
I n s p e c t i o n . . . . . . . . . ... . ..-.... . .p a g e
R e p l a c e m e n t . . . . . . . . . . . . . .page
. . . . . .F-125
.........
5. Throttlesensor
10.P/Spressureswitch
/ Adjustme.t.
....... page
InspecLion
I n s p e c n o n . . . . . . . . . . . . . . . . . .page
. . . - . F-l25
..........
F-111
F
CONTROLSYSTEM
ENGINECONTROLUNIT(ECU)
Reolacement
'1.Removein the ordershownin the tigure.
2. Installin the reverseorderof removal
(
7.3-rr (60-rr0,69-es)
3. ECUconnector
1. Negativebatterycable
2. ECU
I n s p e c l i o n . . . . . . . . . . . . . . . . . .p. .a. .g.e.F. .-.1.1. .2. . .
Inspection
the ECUconnectors.
1. Disconnect
SSTS(EngineSignalMonitorand AdaPter
2. Connectthe
Harness)to the ECUas shown.
a1EAF2210
F-112
CONTROLSYSTEM
6 ' d
ffi
3. Placethe SST (Sheet)on the EngineSlgnalMonitor.
4. Measurethe voftageat eachterminal.
(Refer
to pagesF 114to F-119.)
5. lf anyECUtermjnal
voltageis incorfect,
checktherelated
inpuior outputdevicesandwiring.lf no problemisiound,
replacethe ECU.(Referto above.)
o .
Caulion
. Neverapply voltageto SSTterminalsA and g.
6
-d'
ffi
F-l13
F
CONTROLSYSTEM
Terminalvoltage (reterencedata)
f6r|rrlntl Input Ouipul Connecilonto
Batlery
]B
1c
o
iFUELINJ reay)
o
lgnltionswich
(STABI)
o
1D
Self-Diagnosis
Checker
(Monilorlamp)
Te€tcondillon
Constani
lgniljonswitch
SellD agnosis
Checker
(Cod€Number)
ON
vohage
Batlery
gnitionswitchON
WithSelt
Tesrswitchal "SELF-TEST"
Diagnosis
Checklor 3 sec aflerignilion
Lampilluminated
switchOFF*ON
Baneryvollage Seleclor
atter3 sec.
Lampnotilluminaled
Buzzersoundedlor 3 sec.aflergnitDn
swltchOFF*ON
Buzer notsoundedatter3 sec.
Batleryvo[age
Below2.5v
Banerylotage
Below2.5V
Batieryvoltage
o
lgniter
(ind strlbutoo
lgn,ronswtch ON
Apprcx.0.5V
ldle
1H
o
C rc'ritopenlng
lgnitionswilch
o
]J
IJC relay
Dlagnosis
(TENtermnal)
ON
STABT
ON idle)
lgnitionswilch ON
ldle
o
A/C ON
Sysiem Selector lest swilch at
"02 MONITOR"
System Se ector iest swltch al
,,SELF.TEST''
Bateryvolage
Below 1.0V
Batieryvollage
Below2.5V
Bateryvoltage
Balteryvoltage
Belowl.0v
]L
l lvl
o
lgnlion swilch ON
1N
10
o
o
Stopllghtswilch
Brakepedal r€eased
Brake pedal depressed
lgnilon switchoN
P/SoN ar idle
P/S OFF at dle
F-l 14
Rsmatt
OFF
"O2 MONITOF aI idle
Tesrswilch at
Monltorlamp illuminated
Test switchat "O2 MONITOF aI idle
Montor lamp nol iluminaled
o
Canpctvolrge
Bateryvollage
Bslow1.0V
Bateryvolage
Batteryvotage
Below1.0V
Bateryvo[age
Diagnosis
SystemS€leclor
F
CONTBOLSYSTEM
Inco]r€ct Yolt.ge
ROOtvl10,Allse burned
Op€nc rcuiiin wi ng kom ROO|0A fuseto ECUleminal14
Main relay mallunclion(Rel6rto page F-124)
Op€n or shortcircuitin wiringlrorn main relaylo ECU terminal18
Always0V ($anerturns)
Always battery voltage
2.5V
No displayon SelfoiagnosisChecker
''SA displayedand
. Openor shoricircuitin wiringlrcm ignitonswitch(MTX),
or inhlbitor
switch
iAlx) to ECUterminallC
(Relerto pageF-124)
Mainrelay(FUELINJ retay)mallunclion
conneclor
terminal+B
Op€ncircuitin wiing ,rommainrelayto diagnosls
termlnalMENlo
conn€clor
Openor shodcircuitin wiringtromdiagnosrs
ECUterminal1D
Poorconnection
at ECIJconnector
ECUmallunclion
ECUmallunclion
(Relerlo paseF-124)
Mainrelay(FUELINJ relay)malfuncllon
connector
teminal +B
Opencirclitin wirlnglrommainrelaylo diagnosis
. Open or shorlcircuil in wiing from diagnosisconneclorterminalFEN to
ECUtermlnal1F
Poorconnectional ECu connector
ECUmallunction
Always Baliery voltage
.
Shoncircuitin wirinSfiorn gniterio ECU teminal 1G
(Beferto paseF-124)
t.4aln
relay{FUELINJ relay)malrunclion
Poorconnection
at ECUconnector
Openckcuilin wkinglromcncuitopeningfelayto ECUlerminal1l
1J
. Opencircuitin wiing lromAC reay lo ECLJterminal
. Shoncncoitln wirngtromdiagnosis
lo ECUlerminallK
connector
ierminalTEN
Alwaysbatleryvonage
. Opencncuitin wiins tromdiagnosis
termnalTENlo ECUtem|
conneclor
. Opencicuil in wirinslfomdiagnosis
lerminal
GNDto ground
conneclor
AIways0V or Approx.5V
I)to ECUlemi
. Openor shoncircoiiin wiringfrcrnspeedswitch(Seclion
na 1[,1
Alwaysbelow1.ov(sloplights
OK)
. Opencircuitin wiringlroms1opllght
swilchto ECUtem nal10
Always battery vollage
P/Spressurcswitchmalluncllon
Geierto pageF-125)
switchECUterminal1P
Shortcircuitin wninglromP/Spressure
ECUmatlunction
(Refer
to pageF 125)
P/Spressure
swilchmaltunclion
'1P
Openctcuil in wkinglromPA presslfeswilchlo ECUte|nrinal
grcund
prcssure
swilchto
Op€ncircuilin wiringlromP/S
F-l 15
F
CONTROLSYSTEM
Test condition
TenninJInput Oulprd
10
o
1R
lgniton switchON
Below 1 0V
o
o
o
l-leadliq
o
Neutral/Clutch
swilches (MTX)
swnch
Rear windowdeiloslerswilch OFF
Rear w ndow de'roslerswlch ON
Below 1 0V lgnlion switch
Batleryvollage O N
HeadlighlsON
HeadlighlsOFF
Nedral posllionor clutch Pedal
Batery voltage
Olhers
Bateryvoltage
Below1.ov
Below1.0v
Below1.0V
(ATX)
Others
28
2C
2D
2E
Ground(lnieclor)
Ground(Oulpul)
Ground(cPU)
Ground(lnput)
o
(indisrributoo
(Ne'sisnal)
BaneryvoLlage
OV
OV
Constani
OV
Constanl
OV
lgnitionswitchON
or 5V
2G
2H
2l
2J
2K
o
Ground
Open
Throttlesenso/Ec
(ATX)
?t
F-116
Remark
Batleryvollage
A/C SWOFF
(engne coolant
Below1.0V
Coolingian operaung
temperature
over97'C (207'D of das
noslsconnector
temina TFAgtounded)
Batrery
volage
Fan nol operatinq(idle)
Batery
votage
BlowercontrolswitchOFF
Below1.0v ON
ElowercontrolswitchON
o
1T
PJCSW0N and
Cor'ecl Yolage
TITX
ATX
Below 1.0V
Batleryvolage
F
CONTBOLSYSTEM
. Opencircuitin wiing lromAJCswitchto ECuterminal10
. A/C sulch maliunclion(Relerto SectionlJ)
Always baltery vollage
Openor shorlcircuitln wirngtromlan retaylo ECUteffnina1B
ECUmallunction
(elect c cool ns tan OK)
Alwalsbelow1.0V(blowerlan OK)
Shoncircut n wiringfromblowerconlrolswilchto ECLJterminal15
Poorconneclion
at ECUconneclor
ECUmaltunclion
. Openc rcuitin wirinsircm blowercontrolswilchlo ECUlerminallS
Alwaysbatleryvoltage(blowerfan OK)
llluminalion
lampON
Op€nor shorlcncuirin wirlngtromrearwindowdstrosl€r
swtchro ECU
t.0v
lenninal1T
never ON
Alwaysbelow 1.0V(HeadlighlsOK)
Opencircuitin wirng lromignitionswitchto rearwindowdelroster
swilch
(Belerto SectionT)
Fearwndowdefroster
switchmalfunction
. Openor shoncircuitin wiringtromheadlighlrelaylo ECIJterminal1U
(Referto pageF-125)
Neulfalswilchmalluncton
Clutchswitchmaliunction
{Belerro pageF-124)
Shoncircuitln wninolromECUterminallV to neukalor ciltch switch
Neutraiswilch mallunclion(Felerto page F-125)
Clulchswlch malfunction(Rererto page F-124)
Opencrcut n widng from ECU tenninal1V lo neutralor clurchswitch
Poorconneclionat ECU connector
Inhbilor swltchmallunction{Relerto SectionK)
Shortcircuitwiringlromlnhibitor
switchlo ECUlerminal1V
nhibitorswilchmallunclion(Referlo SectlonK)
Openorcult in wiring frorninhibitorswrtchto ECU rerminal1V
Poorcontaclal groundterminal
Opencircuitin wirng lromECUto ground
Alwaysapprox0V or approx.2V
.
Referto Troubleshooting,
Code No.02(Relerto page F-70)
A ways battery vollage
.
Opencircuil wiringfrom lo ground
Beow 4.5V of above 5.5V
Shoncircultn wiringfromECUtenninal2K lo thrctllesensorECAT convol
unil(ATX),or ln aidowsensor
Poorconnection
at ECUconneclor
ECUmallunclion
. ECUmailuncton
F-117
F
CONTROLSYSTEM
-
-:.
Inpui Oulput
Consctvontgg
Rcmark
ThrcttlesensorEc_ Accelerator Pedal releas€d
o
(ATx)
2N
Teal condition
connection lo
Accelelalor pedal lully depressed
lgnron switchON
o
OV
ldle (coldengine)
0-0.1v
lncreasngengrnespeed{altefwarmup)
0.5 1-0v
0-0.4v
20
o
2S
2T
2V
(negatve)
o
2R
2U
(positive)
o
2P
2A
lqn,lon sw{ch ON
o
o
o
o
Appfox. 1.2V
OV
ldle
20oC(68oD
Enginecoolanttemperature
aiter
Enginecrankingandlew seconds
Below0.5v
Appox 2.3V
Other conditon
Batteryvdlage
AccessoryON
Oth€rscondition
Constant
Batleryvonage
noid valve @
nold valve@
hjector (negative)
Inieclor(positive)
EngineSignal
lgniton swtch ON
Below 1.0V
I ash
o
o
2\
o
22
o
OFF
noid valve @
Solenoidvalve
(purge conlroD
ON
EC'ATconlrol'rnrl
(ATX)
Balteryvoltage
Batteryvohge
lgnitionswitchON
ldle
switch
lgniUon
OFF
OV
ON
Enginecoolanttempelalurcbelow70'C
(15860 at rdre
above7o'C
coolanttemperaLrre
Engine-
F-l18
Batleryvdlage
Bateryvofiage
CONTROLSYSTEM
F
Incorrect voltage
Opencircuilin wkingfromECUlermnal 2[,1to throtte sensor
Openc rcuitin wiringfromECUlermnal 2K to thrct e sensot
Openclrcuitin w1ring
frcmECUlermnal 2D to lhrclile sensor
. Throtflesensormrs3dtushent
. Belerlo Troubleshooting
CodeNo.15(Reierlo pageF 74)
AlwaysapproxlV aflerwamr-up
.
Alwaysapprox.oV or approx.5V
. Referto Troubleshooting,
Code No.O8(8eferto page F-71)
Referto Troubleshooting,
Code No.17 (Refeflo page F 75)
. Opencircuilin wirinStromECUterminal
2Pto airllowsensor
Always approx. 0V or approx. 5V
.
Reierlo Troubleshootns,Code No.09 {Reierto page F 72)
.
Fererro ftoJblesnoor,ng.
Code No.35 (Felerro page F-78)
. Feler lo T ouble.hoorng,Code No 34 (Belerlo pagF F-781
. Openor shortcircuitin wing irominjector
to ECUtenrinal2v
. Opencircuilin wiins lrominjeclorto ECUt€minal2V
. Open or shortcrcu't in wking frcm ECU terminal2W 10air bypasssolenold
valve O
Alwaysapprox.0V or approx.12V
. Reterto TroubeshoolinS,
Code No.26 (Relerto page F 77)
. Oper crcLrr ,1 wrflnglrom man relayto ECU r€lmrnal2Y
Alwaysapprox.oV or appfox. 12V
. Openor shoncircuilin wr ng lromECUlerminal22 to EC'ATconlrolunit
termlnal1N
F-119
F
CONTROLSYSTEM
CRANKANGLESENSOR{lN OISTRIBUTOR)
Inspection
(Beferlo SeclionG.)
1. Bemovethe drslnbutor.
connecloras shownin the ligure.
2. Connectthe distributor
lead.
3. Connectthe high-tension
4. Turnthe ionitionswitchON.
A
USECONNECTOFI
5. Connectthe SSTS(EnglneSignalMonitorand Adaptel) to the ECUas shown.
6. SettheSSTS(EngineSignalMonitorand Adapler)terminal2E.
the ou!
7. Botatethe distributor
driveby handandmeasure
put voltage.
Speclflcation
ferminal
2E
Tesl condition
onelull lurn
Roratedistributor
Voltago
Apprcx.5V i4 pulses)
installthe distributor.
8. Afterthe inspection,
(Referto SectionG.)
9. Starithe engineand adjustthe ignitiontimlng.
(Reierio pageF-63.)
^- t:,?\
l;-\'
l,!,-,:
lgnitioniimlngrBTDC16 + 10
torque
lockboltsto the specified
0. Tightenthe distributor
Tighleningtorque:
t6-23 N.m(1.6-2.3 m-kg, 12-16 tt'lb)
F-120
F
CONTROLSYSTEM
TYPE)
SENSOR(BYPASSHOT-WIRE
ATRFLOW
lnapoction
1. Removethe air cleaner.
checkfor an opencircuitof theairflowsensorhot
2. Visually
INJECIION BODY
3. Checkthe airflowsensorbodyfor cracks.
4. Disconnect
the airflowsensorconnector.
theterbetween
measureresistance
5. Usingan ohmmeter,
mrnals.
@;
lffi-fl
Speciticaiion
Terminal
A - B
A - C
F$islance (20'C I68"Fl)
B - C
Femoval/ Installalion
Relerto page F-84.
INTAXE
FIEPLACE
WATERIHENMO
SENSOR
WATERTHERMOSENSOR
Removal
connector.
the waterthermosensor
1. Disconnect
usingthe SST.
2. Removethe waterthermosensor
lnboeclion
andheatthe
1. Placethesensorinwaterwithathermometer
watergraduallY.
of the sensor.
measureresistance
2. Usingan ohmmeter,
Coolant
(kO)
Fesisance
-206C |-4aF)
1 4 . 6- 1 7 . A
40oc (10!oR
60oc (140oR
80oc {176oR
6.5
2.21- 2.69
1 . 0- 1 . 3
050, 0.65
0.29- 0.354
o.c ( 32.D
2o.c ( 68.R
3 , 0
n i
(ko) 2
WAIEFTEMPEMIUFIE {"C I"FD
F-121
E
a
CONTROLUNIT
THROTTLESENSOR
Inspection
1. Warmup the engineto normaloperatingtemperature.
2. Verifythatthethermowaxunitrod extendsoutwardfullyand
lromthe roller.
the cam separates
3. Stopthe engineand turnthe ignitionswilchto ON.
(EngineSignalMonitorandAdaptet
4. ConnecttheSSTS
Harness)to the ECUas shown.
5. Setthe SST (EngineSignal Monitor)to terminal2M.
6. Rotatethethrottlelinkby handandveriiythatthe voltage
is withinspecifications.
Speclflcallon
ECUTerminal
2M
Throtlle valv€ conditon
0.30 0.80v
adiustthe throttlesensor.
7. ll not as specified,
Adiustment
connector.
1. Connectthe SST to the diagnosis
2. Setswitch@to position1.
3. SetTESI SWto SELF-TEST.
Note
. lf the SSTis not used,iump acrossthe TENterminat and the GNDterminalsol the diagnosiaconneglor.
THFOTTLE
SENSOB
4. Loosenthe throttlesensorscrews.
and untilthatthe volt'
5. Rotatethe throttlesensorgradually
age is withjnspecification.
tightenthe throttlesensorscrews
6. Afleradiustmenl,
7. Removethe SST.
Removal/ Inslallation
'1.Turnthe ignitionswitchOFF.
the throttlesensorconnector.
2. Disconnect
3. Removethe throttlesensor.
Cautlon
. Do not drop the thloule aensor.
4. Adjustthe throttlesensorafterinstallation
(Referto pageF-122.)
fNJECTfON BODY Ztt n l.trtg,
F-122
tFbl
CONTROLSYSTEM
OXYGENSENSOR
Inapectlon ol Termlnal Voltage
1. Warmup theengineto normaloperating
temperature
and
run it at idle.
2. Disconnect
the oxygensensorconnector.
3. Connecta voltmeterbetweenthe oxygensensorand a
oround.
OXYGENSENSON
CONNECTOF
".+try'",,'
-\1
anddecreasing
4. Measure
thevoltagewhileincreasing
the
enginespeedsuddenlyseveraltimes.
Specitication
Enginecondilron
o
@ o
VoltageM
Below0.4
Above 0.5
5. Replacethe oxygensensorif notas specified.
Inspectlonot Sensitivity
1.Warmup the engineto normaloperatingtemperature.
2. ConnecttheSSTS(SystemSelector and Self-Diagnosls
Checker)to the diagnosis
connectoras shown.
3. Set switch@ to position1.
4. SetTESTSWto Oz MONITOR.
5. Increase
the enginespeedto between2,000and 3,000
rpm, andverilylhatthemonitorlampflasheslor l0 sec..
lf not as specified,
replacethe oxygensensor.
(Referto pageF-124.)
5AF-m6|$S6 o€OGR
Monltorlamp:Flasheamorethan Slimes/l0 seconds
6. Replacethe oxygensensorit not as specified.
MONITOF
;O-.
/ 1r\
ooo
o
tl_l
r:] I
lnspectionot Heatel
1. Measureresistance
betweenterminals@ and @.
Realstance:60 (20"C l68oFl)
2. Reolacethe heaterif not as soecified.
F-123
F
CONTROLSYSTEM
Replacement
the oxygensensorconnector'
1. Disconnect
2. Removethe boltsand removethe exhaustmanifoldinsulator.
3. Removethe oxygensensor.
4. lnstallin the reverseorderof removal
i--1t lrFJtl /
OXYGENSENSON'
torque:
Tiohteninq
-N.m
(it-s m-t<g,22-36 ft'lb)
is-lg
MAINRELAY
neolacemeni
the negativebatteryterminal
1. Disconnect
2. Removethe ECU.
3. Removethe relavbracket.
4. Removethe mainrelayfromthe relaybracket
5. Insiallin the reverseorderof removal.
RELAYBRACKET
Inspectionof Continuily
'1.iheck conlinuity
betweenlermrnals
@ and @
r--:7(cF-l-{d)
Y
Y
faloouYD
-r_-____J
TerminaLs
Apply12V
@-@
No
Continuity
the mainrelayif necessary.
2. ReDlace
cLuTcHswrTcH(MTX)
InsDectlon
'1.Disconnect
the clutchswitchconnector'
to the switch
2. Connectan ohmmeter
of
the
switch.
3. Checkcontinuity
ContinuLiy
No
replacethe clutchswitch
4. lf not as specified,
Replacement
'1 ioosen the nutsand removethe clutchswltch
2. lnstallthe clutchswitch.
3. Adiusttheclutchpedalheightreferringto the aboveand
(Referto SectionH )
the heightspec lcalrons.
torque
specified
4. Trohtenthe nutsto the
to.que,
Ti-ohfeninq
-t*m
(2.0-z.s m-kg, l4-18 ft-lb)
io-zs
CLUTCHPEDAL
F-124
o1aoFr103
F
CONTROLSYSTEM
NEUTRALSWITCH(MTX)
Inspection
1. Disconnect
theneutralswitchconnectorshownin thefiqure.
2. Connectan ohmmeter
to the switch.
3. Checkcontinuity
ol the switch.
Contnuilv
Otherranqss
4. lf not as soecified.
reolacethe neutralswrtch.
Replacemenl
1. Disconnect
the neutralswitchconnector.
2. Removethe bracket.
3. Removethe neutralswitch.
4. Installin the reverseorderof rcmoval.
Tighteningtorque:
20-29 N.m(2.0-3.0 m-kg, 14-22 ft-lb)
POWERSTEERING
PRESSURE
SWITCH
In€pectlon
1. Disconnect
the P/Spressureswitchconneclor.
2. Connectan ohmmeter
to the switch.
3. Staritheengineandletitidle.Checkcontinuity
oftheswitch
whileturningthe steeringwheel.
P/S
Turnrng
Nol turning
Continuily
4. lf not as specjfied,replacethe P/S pressureswitch.
F-125
ENGINEELECTRICAL
t N D E X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G
. . .- . .2. . . . . . . . . .
o u T L r N E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G
. . -. .3. . . . . . . . . . . . . . .
SPECrF|CAT|ONS.....,...........................-..
G- 3
TROUBLESHOOTTNG
G- 4
GU|DE......................
DTAGNOSTTC
rNDEX.........................,......
G- 4
TROUBLESHOOTING......,...,....
G- 4
SYMPTOIV
G- 6
GHARG|NG
SYSTEM.................................
PREPARAT|ON.......................................
G- 6
ctRculTD|AGRAM.................................
G- 6
TROU81ESHOOT|NG..............................
G- 7
8ATTERY...............................................
G- 8
A1TERNATOR........................................
G-r0
DRTVE
8E1T...........................................
G-l4
rGNrTtoN
G-r6
sYsTEM,...................................
P R E P 4 R A T | O N . . . . . . . . . . . . . . . . . . . . . . . . .G
. .-.r. 6. . . . . . . . . .
ctRcutTDIAGRAM.................................
G-16
T 8 O U 8 1 E S H O O T I N G . . . . . . . . . . . . . . . . .G
. .-. 1. .7. . . . . . . .
l G N r T t oTNt M t N G . . . . . . . . . . . . . . . . . . . . . . . . .G. .-.l.8. . . . . .
sPARKp1UGS.......................................
G-l9
tGNtTloN
co11.......................................
G-20
DtSTRtBUTOR
.......-....-.....-......-.....-........
G-20
t G N l T E R . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . .G, .-.2, .3. . . . . . . . .
HrGH-TENSTON
1EA0..............................
G-23
START|NG
SYSTEM..................................
G-24
P R E P A R A T I O N . . . . . . . . . . . . . . . . . . . . . . . . .G. .-.2. .4. . . . . . . . .
CIRCUI'l
DIAGRANiI
.................................
G-24
sTARTER...............................................
G-25
l
INDEX
INDEX
YTE LEVEL
7Y
\'t
coil (inthe distributor)
6. Ignition
1. Battery
.- . . pageG 20
Inspection..................-...
paSe
........
.
Inspectron......
9 8
Distributor
page
9
7.
G.............
Recl'argrng
S p a r tke s t . . . . . .......... . . . . . . . . . . .p. .a.g. .e.G. .- 2 0
2. Alternator
...pageG-20
advanceinspeclion
Eiectronrc
pageG-l 0
/ Installataon..........-.......
Removal
pageG 21
Inslarlation..........
Removal/
pageG-11
/ Assemb|y.............
Disassembly
paqeG-22
/
Assemb'y........
Disassembry
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a
. .g. .e. G
. . .1. 2. . .
p
.
.
.
I
n
s
p
e
c
t
i
o
n
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. .a. .g. e
.G
. . -. .2-3.
3. Drivebelt
(in
the
distrlbutoo
lgniter
p
a
g
e
8.
G
1
4
Inspection..............................
I n s p e c t i o n . . . . . . . . . ..................p
.. .u. s. "9 - ? 9
A d j u s t m e n t . . . . . . . . . . . . . . . . . .p. a
. .g. .e.G. .-.1. .4. . . .
p
R e p l a c e r n e n t . . . . . . . . . . . . . . . .a. .g. e
.G
. . .2. .3. . . . .
8 e p 1 a c e m e n l . . . . . . . . . . . . . . .p. a
. .g. .e.G. .-.1.5. . . . .
L Slarter
lead
4. High-tension
. .. pageG 25
Installation..........
Flemoval/
i n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. .e.G. . .2. 3
......
.....pageG-27
Inspection......
Performance
5. Sparkplugs
pageG-28
.
.....
/
Assembly
Disassembly
page
/ Insta|ation..................G-19
Removal
...
G-29
inspecron.....
Page
p
a
g
e
G
1
9
Inspection...........................-.......
G-2
OUTLINE
OUTLINE
SPECIFICATIONS
Engine
Batlery
V
Volrage
(2o-houffale)
Type and capaciry
Mal. 20
Dafl' current
12-65
Outout
(bulr-n lC requlato4
rransrsronzed
V
Fequlatedvo tage
Brushlength
mm(n)
6 (O.24)
V.kW
outpur
Brush lenglh
rnm (rn)
14.1 14.7
25 (0.98)
Slandard
Drive bell detleclion
mm (inY98N, 10 ks, 22 lb
Starter
83
'12
gL-S
(334H)
34Br
Slandard
lVinimum
Dsrriburor
BTDC
lgnilrontiming
(IEN iermina oi dagnosis connectorgro'rnd)
5 5-7 .Al0 21-O.27)
6 0-7.5 (023-0.29)
Oirect
12-0.85.1MTX)
12-0.95(Ar-4
17 (0 65)
1 15 (0 45)
ESA
t6
0.68-0.840
Fesslance(20oC [68"F]]
9.6,14.4k0
NGK
Spark pllg
Tvpe
NIPPONDENSO
Plussap
mm(rn)
BKRsE-11
BKR6E11
K16PR.UI1
K2OPR.U11
1 0-t 1 (0.039-0043)
1-3,4-2
G-3
GUIDE
TROUBLESHOOTING
GUIDE
TFOUBLESHOOTING
INDEX
DIAGNOSTIC
o.
-1
2
a
Page
Troubl6hooting llems
not
operare
will noi crank-starter motor do€s
will not crank slartermolor sp ns
5
6
G-4
cF4
G-5
G-5
G-5
Ale 1alorwah 1q laarp rlu-inares whrc enSLrerunnrng
banery
Discharged
Mislire
SYMPTOMTROUBLESHOOTING
wlll not crank-starter motor do€s not oPerate
ACTION
INSPECTION
1
]TEP
1
Doesenginecrankwithlullychargedbanerv?
2
ls baneryvollagepr€6ernat terminal8?
17 Page G-7
Check charging syslem
TERMINALB
Check wiringharness
3
js batteryvoltagepresental lerminajS with lgni
lion switchin STARTPosltion?
. Check maSnetcswitch
. Check lleld col
. Check armalure
- Page G-29
F Page G-30
.? Page G-31
TERMINALS
. Check nhibtor switch(ATX)
. Check sntof swtch
. Check wring harness
F Section K
r7 Section T
will not crank-statler motor spins
JTEP
1
INSPECTION
ls drve p n on pushedoul while crankrng
(clck is heard when pushed oul)?
ACTION
Removeslarterand check llywheelrng
gear teelh and slarier d ve pin|on teeth
Check magneticswilch
G-4
e Page G-29
GUIDE
TROUBLESHOOTING
Cranks alowly
3
STEiP
l
Does enginecrank normallywilh lully charged
ACTION
Checkcm'girg syslem
2
Are $aner cable connectionslooseor corroded?
Bepairor repace connecton
INSPECTION
s PageG-7
CHECK
HECK
Ch€ck stadff lor binding{suchas
bruslrand armature.)
4
1
Altemalorwaaninglamplllumlnateswhileenginerunnlng
ACTION
INSPECTION
Ch€ckwring haness benreenarcrnals baneryvoltageconect al idle?
lor L teminal and alternatorwarnlng
Specificalion:14.'l-14.7v
Check chaelng system
c? Page G-7
Dischargedbsttery
1
INSPECTION
Checkchaelngsystem;is it OK?
l? page G-7
ACTION
TumigniuonswilchON and measurc
darkcurrcnlas shown
Dafkcunenr:Below20mA
Repairor replacepartsas necessary
G-5
CHARGINGSYSTEM
CHARGINGSYSTEM
PREPARATION
ssT
49 9200020
gauge,
Tension
CINCUITDIAGRAM
LAMP
CHAFTGE
T BATIEFY
II
I
lunctionto warnof the followingproblemsin the chargingsystemhasa self-diagnostic
Thealternator
warninglampalluminates
lf a problemarises,the alternator
1.TerminalS circuitopen
2. No voltageoutput
3. Fieldcoil circuitopen
4. TerminalB circuitopen
5. Voltageoutputtoo high
G-6
CHARGINGSYSTEM
TROUBLESHOOTING
acno
INSPECTION
1
2
Check battery voltaget is il cofiecP
Spocltlcatlon: Above 12.4V
Chec( batlery
SrarlenEnei does allernarorwarn^g lamp go
Go to ne,( slep
rt_ page e-a
Go io Slep 4
3
ls voltage al alternalor term nals coffect?
Checkwiring harnessbetweenterminal
SpeclllcElion:
lon.ONM
14.1-14.7
14.1-14.7
14.1 14.7
L
S
1. Conneclan ammeler(70Amin)between
terminaiB and haness
2. Starlengine
3. Turnall electricaloadsON anddepress
. Checkwiring harness
. Replacealtefnator
F page G-10
Charging
syslemnorna
4. ls outputcurrenl65Aor moreal
2,500-3,000rpm?
Caution
. Do not grolnd terminal a
5
Replacealternator
is drive belt tensionOh?
e pag€ G-10
N iks, lb)
Drive belt
451-745
(46-80,
101-176)
491 589
(50 60.
110 132)
392-588
(40-60,
88 132)
422 491
(43,50,
95 110)
. Adjustdrive belt t€nsion
G-7
CHABGINGSYSTEiI
BATTERY
Inapecllon
Electrolytelevel
levelliesbetweenlhe upperand
1.Chec{ the electrol}4e
lowerlines.
2. lf low' add distilledwater;do not overfill.
Speclfic gravily ol electrolyte
Measurelhe specificgravitywltha hydromeler'
Specilication:1.27-1.29 (at 20"C 168'Fl)
Voliage leat
Check battery voltage
tr 1-3 hours
ouick-charse
ano
tol ls minutes
Ouick-charge
I
l
Below 12.0V
l
Above 12 0V
tor
Ouick-charge
3-4 hours
"*o*Cu
-----*J',ou
I
Quickchargefor 30 minutesancl
rccheckvollage
rf=r
Below l2.4V
G-8
Above 12-4V
CHARGINGSYSTEM
Te]mlnaland cable
oftheterminals
to ensuregoodeli?ctri1. Checkthetightness
cal connections.
2. Checkfor corrodedor lrayedbatterycables.
3. Checkthe rubberprotectoronthe positiveteminalfor proP
er coverage.
andcoatthemwithgrease.
4. Cleantheterminalsif necessary,
Recharging
Battery
3itB19L€
Slowcharge(4
Under3
Ouickcharge (A)
lvlax. 20
Slow{harging
to removethe ventcaps.
It is not necessary
40 (164)
0O076)
TEMPEFATURE
CCTFD
Ouick-charging
Removethebaneryfromlhevehicleandremovetheventcaps.
Warning
. Beto.epertormingmalntenanceor rechatgingthe
banery,lurn ofl all a@essoriesand stop the €ngine.
. The negativecablemusl be removedlirsl and installedlast.
. Sel the battery in water when quick{harging to prevent overhealingthe battery.
G-9
CHARGINGSYSTEIIiI
ALTERNATOR
Removal/ Installation
Cautlon
. Be sqre the battery connectionsare not reversedbecausethis will damagethe reclifier'
. Do not use high-v6hagetestefs such as a meggerbecausethey will damagethe rectitier'
. Rememberth;t battet vottage ls alwayspresentat the alternatorterminal B'
. Do not ground terminal L $rhilethe engine is running.
. D,onot;tart the engine while the connlctor is disqonnectedfrom terminalsL and S'
to RemovalNole.
1. Removein the ordershownin the figure,referring
2. Installin the reverseorderof removal,referringto lnstallationNote
7,r-11 |}n {3o-r r0 cGrs, 69-95 h.lh}
19-25O,e-2,6r.-r9)
37-52 (3.5-5.3,27-33)
5. N4ouniingbolt
1. Negativebatterycable
6. Alternator
2. Connector
page G-1 1
/ Assembly.............
Disassembly
3. Mountingbolt,adjlst nut
p
I
n
s
p
e
c
t
i
o
n
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. .a. .g. e
. .G. .-.1. .2. . 4. Drivebelt
I n s p e d r o n . . . . . . . . . . . . . . . . . . . page
. . . . - .G-'14
.........A d J u s t m e n t . . . . - . . . . . . . . . . . .page
. . . . . .G-14
..........
. . . . . G-15
R e p l a c e m e n t . .-....-... . . . . . . . . .page
G-l0
CHARGING
SYSTEM
Removal/ lnstallationNote
Thealternator
is femoved
andinstalled
lromunderthevehicle.
0rEoGx
094
Disassembly/ Assembly
in the ordershownin the figure.
1. Disassemble
2. Assemblein the reverseorderof disassembly.
3,2J.s ($--ne, 2e-3E
46J3
bN
Nm (4,7-5,4 ckg,
#9_,5.$-?.3
3.2-3.9
(60-30, 53-70)
(33-39!
2S-33)
3.r-4G fi-lbl
r.6-2.0 (i6-20. 14-13)
orEoGX015
L Stator
1. Nut set
pageG 12
Inspection..........-........................
2. Pulley
set
3. Frontcover
9. Regulator
10.Rectifier
4. Bearing
l n s p e c t i o n . . . . - - . . . . . . . . . . . . p. .a. .g. e
.G
. . . 1. .3. . . . . .
1 n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g
. .e.G
. .-.1. .2. . . . . .
Brush
holder
assembly
11.
5. Retainer
Inspection
6. Spacer
pageG-13
(Brush
andbrushspring).........
7. Rotor
. e a rb r a c k e t
I n s p e c t i o n . . . . - . . . . - . . . . . . . .p
. .a. .g. .eG
. . .- -1.2. . . . .1.2 R
G-11
CHARGINGSYSTEM
Inspectlon
Rolor
between
the
the resistance
to measure
1. Usean ohmmeter
sliprings.
Specilicatlon:2.4-2.90 (at 20"C [68cq)
replacethe rotor.
2. ll not withinspecilication,
3. (1) Usean ohmmeterto checkcontinuitybetweeneachslip
rinoand the core.
(2) Replacethe rotorif thereis continuity
on the slip
to smoothanyroughness
4. Ule tinesandpaper
nng sunace.
Stator
betweenthe stator
io checkcontinuity
1. Usean ohmmeter
coil leads.
2. Replacethe statorif there is no continuity.
betweenthe stator
to checkcontinuity
3. Usean ohmmeter
coilleadsand the core.
the statorif thereis continuity.
4. Replace
Bearlng6
and sticking.
1. Checkfor abnormalnoise,looseness,
il necessary.
the bearing(s)
2. Replace
01E0GX.020
G-l2
CHAFGINGSYSTEM
Rectiller
Cautlon
. Don't uae meggerlester to p€vent lhe reclifier trom
breaklngdown.
1. Useananalogohmmeterto
checkcontinuity
of he diodes.
Conlinurty
E
B
E
B
NO
NO
2. Replacethe rectifierif necessary.
Bruah
lf a brushis wornalmostto the limitor beyond,redaceall
the brushes.
Siandad: 25.0mm(0.984In)
ilinimum: 6.0mm(0.236In)
Brush apring
gaugeto measure
theforceof the
1. Usea springpressure
brushspring.
2. Replacethe springif not within.
Standard lorce:
2.9-3.9 N (300-400 g, 10.6-14.1 oz)
Minimum:
0.8-1.2 N (80-120 g, 2.8-4.2 o2)
Note
. Readlhe spring pressurewlth the brushtip proiectIng 2mm (0.079in).
G-13
CHARGINGSYSTEM
DRIVEBELT
Inspection
forwea.,cracks,andllay1.Checkthedrivebeltsandpulleys
ing. Replaceas necessary.
drivebelttensionwitha tenslongauge
2. Nleasure
Tension
N {ks,rb)
Dfive belt
A/C and P€
451 745
(46-80, 101-176)
392-588
(40-60,88 132)
49t-589
(50-60 110 132)
422-491
(43,50, 95-110)
(98
pressure
byapplyingmoderale
3. lreasurethedeflection
N, lO kg, 22 lb) midwaybetweenthe pulleys.Adjustif
necessary.
Detlection
rnm(rn)
Dflve bell
5.5 7.0
{0.21 0.28)
AJC and P/S
8-9
(0.31-0.35)
6.0-7.5
(0.23-O.30)
9-t 0
(0.35-0.39)
Adiustment
1. ioosen bolls(A)and @.
by turningadin or outas necessary
2. Movethe alternator
iustinonur (O.
s. iignt6n ootd@ and @ and recheckthe beltdeflection
Tidhtenino
torquea
-Boh
!E;19-26 N.m(1.9-2.6 m-kg, 14-18 ft'lb)
Bolt @: 38-51 Nm (3.8-5.3 m-kg, 28-38 ft'lb)
G-l4
CHARGINGSYSTEM
Replacement
1. Bemovethe fuC and P/Sdrivebelt.it equipped
Note
. Retel to B Section,
botts@ and @.
2. Loosenalternator
beli.
3. Removethe afternator
beltandadjustitto specifications
newalternator
4. Installthe
torques.
to
the
specified
Tighten
all
bolts
5.
Tighlening torques
Mounlingbolt:
38-51 Nm (3.8-5.3 m-kg,28-38 fi-lb)
Adlustingbolt:
l9-26 Nm (1.9-2.6 m-kg, 14-18 ft-lb)
6. Installthe AJCand P/Sdrivebehii equipped,and adjust
it to specificataon.
Note
. Reterto B Seclion,
G-15
IGNITIONSYSTEi/I
IGNITIONSYSTEM
PREPARATION
ssT
49 80199A0
SystemS€l€clor
and
self-diagno€is
ignitonliming
49 HO189A1
sell-diagnosis
Self-Diagnosis
Checker
CIRCUITDIAGRA''
GFOUND
TACHOMEIEFi
DTAGNOSTS
CONNECTOF
IGNITION
SWTCH
G-16
IGNITIONSYSTEM
TNOUBLESHOOTING
fi6tire
6
JTEF
|lrsPEcTtoN
'
Checker
ls "00 displayedon Self-Diagnosis
with igniton swilch ON?
.? p.ge F-67
ACTION
llallunctioncode no. displayed
Checklor cause(Belerto specified
E7 PageF-67
checksequence)
"8a" tlash€s
CheckECU leminal lF voltage
t7 psge F-114
Vollag6: Approl l2v
(lgnilioh switch ON)
4
+
2
Bemovesparkplugiis therea slrongbluespark
whie engineis cranking?
(j
li OK, replace ECU
lf nol OK, check wiringharness
belweenECU and SelfDiagnosis
page F-112
lgn tion syslemis normal
Checksparkpug
r? gage G-2O
lf OK, Go lo next step
lf notOK,cleanor .eplacesparkplug
3
ls resistanceot high-tensionleadsOK?
specification:16 m per lm (3.28tl)
c? page G-23
Repac€ high tensionleads
Afe therecorroslon,
damageor crackson lhe
disrribulor
cap and rotof
17 page c-23
5
ls ignitroncoil nomal,
6
Aredisrributor
connector
and ECUconnector
(7 page G-2O
Measurevoltageot @ termlnal
(dislibutorrop connector);
is il coffec?
Voltage:Apprcr. l2v
Check mainluse, ignitionswitch,wiflng
harness,and ECU
I
ls ECUnormal?
l? page F-r12
ReplaceECU
G-l7
IGNITIONSYSTEM
TIMING
IGNITION
Adiustment
and
lenoeralure
operaling
1.Warmup theerg'neto normal
run i at rdle(P ranqe[ATX]or neLtrdl[L4TX])
loadsOFF.
2. Turnall electrical
3. Turnthe tuC switchOFF.
lGconnector
to thediagnosis
4. Connecta testlachometer
terminal.
---.--.-
_e\,t-
tc_
5. Connectthe SST to the diagnosisconneclor.
to position1 andTEST
Selector
6- SetswitchA ontheSystem
to SELFTEST.
SWITCH
Note
. To createthe test conditionwithout usingthe Sys'
tem Selector,connectterminalsTEN and GNOof
the diagnosisconnectorwiih a iumper wiae.
7. Checkthe idlespeedand set it to the specitiedspeedit
necessary.
ldle speed:600-650 rpm (MTX)
810-860 rPm (Arx)
8. Checkthe igniiiontiming.
Specification: BTDC 16 + 1'
9. ll the ignrtrontim ng is nol as specilied loose'lIhe dislribL
tor |oc: boftsand turnI le dlsllibttol Io makelheadiugment
1O-Tighlenihe dlstributorlock boltsto speciliedtorque.
15."u-t'\
-,€=4
,N.
G-l8
torque:
Tiohteninq
-H.m
ie-za
{i.s-z.s m-tg,12-16ltlb)
IGNITIONSYSTEM
SPARKPLUGS
Removal/ Installation
leadscarefully.
1. Removeand installthe high-iension
Caution
. Whenthe spark plug lead is to be pulled ofi, pull
on the boot itself, not the wire.
2. Removeand instailthe sparkp ug witha plug socket.
Caution
. Be sure the socket must be tit squarelyover lhe
spark plug.
lubricant
3. Applyantiseize
compound
or molybdenum-based
to the sparkplugthreads.
torque.
4. Tightenthe sparkplugto the specified
Tighteninglorque:
15-23 N.m(1.5-2.3 m-kg,11-17 ftlb)
Inspection
1. Removethe sparkplug.
lead.
2. Connectlhe sparkplug10a high-tension
pliers5-1omm
3. Holdthe highiensionleadwth insulated
(0,20-0,39 in) froma ground.
4. Cranktheengineandverifythatthereisa strongbluespark.
)x
Note
. It there is no spark,replacethe sparkplug or high"
tension lead as necessary.
CAFBON
BURNED
thespark
following.
lf a problemisfound,replace
5. Checkthe
plug.
. Damagedinsulation
. Wornelectrodes
. Carbondeposits
ll cleaningis necessary,
usea plugcleaneror a wtre
insulator
also
brush.Cleanthe upper
. Damagedgasket
. Burnedcondition
Pluggap: 1,0-1,lmm (0.039-0.043in)
G-19
IGNITIONSYSTEIIi|
IGNITIONCOIL
Inspection
Primarycoil rvindlng
to ineasureres$anceol lhe pIimarycoll
use an'ohmmeler
replacethe ignitioncoil.
winding.lf notwithinspeciflcation,
Specification:0.68---0.840(al 20oC[68"F1)
Secondarycoil windlng
of the primarycoil
to measureresistance
Usean ohinmeter
the ignitioncoil.
replace
within
specification,
lf
not
windlng.
Soeciflcalion:9.6-14.4 ko (at 20"C [680Fl)
Reolacement
(Referto pageG-21.)
1. Replacethe distributor.
2. Adiustthe lgnltiontiming (Referto pageG-18 )
/
01aoGXo40
DISTRIBUTOR
Spark Test
leadtrom a sparKplug.
the hiqh-tension
1. Disconnect
2. Holdthe lead5-iomm (0.20-0.39 in) froma ground.
3. Cfankthe engineand verifythat a strongblue sparkls
visible.
ElecironicAdvanceInspectlon
Verifythat the ignitiontimingadvanceswith engineacceleralon.
G-20
IGNITIONSYSTEM
Removal/ Installalion
1. Removein the ordershownin the figure.
2. lnstallin the reverseorderof removal.
{r.c-2.3 Gtg, 12-16 ft-tb)
2
,:t,
a''
'1.Negativebatterycable
2. High-tension
lead
pageG-23
lnspection...-...............................
3. Connector
o140cx.019
4. Mountingbolt
5. Distributor
pageG-22
Disassembly
/ Assembly.............
pageG-23
1nspec1ion..................................-
G-21
IGNITIONSYSTEM
Disassembly/ Assembly
'1.Disassemble
in the ordershownIn the rigure
to AssemblyNote.
referring
2. Assemblein the reverseorderof disassembly,
ef
' ^ )
,
r,o-2,0o0-20, 0.7-1n
1. Cap
pageG-23
Inspec1ron...................................
2. Rotor
pageG 23
Inspection...................................
3. Cover
G-22
4 Crankanglesensorand igniter
lnspection .....
coil
5. lgnition
InspecUon ..
pageG-23
pageG-20
IGNITIONSYSTEM
Inspectlon
Capand rotor
damage,
andcracks.
1.Checkforcorrosion,
2. Replaceil necessary.
01E0GX.055
IGNITER
lmpqction
1. Checkthe ECU.(Referto pageF-| 12.)
distributor
cap, ro2. Checkthecondition
of the connector,
leads.
tor, ignitioncoil,and high-tension
3. ll allare normalbutmisfirestilloccurs,replacetheigniter.
01a0GX.021
Feplacemert
(Referto pageG-21.)
1. Replacethe distributor.
2. Adjustthe ignitiontiming.(Referto pageG-18.)
OlAOGX€2
HIGH-TENSION
LEAO
Insp€ciion
lead.
1. Measureresislance
of high'tension
Spscification:16 m per I n (3.28ff)
leadset.
replacethe high-tension
2. lf notas specified,
G-23
STARTINGSYSTEM
STARTINGSYSTEM
PREPAFATIOI{
ssr
49 E301 1'14
---)
installaltonol
.-\J--6-)
\--=---
CIRCUITDIAGRAI'
PULL]N COIL
FIELDCOI!
G-24
STABTINGSYSTEM
STAFTEN
Inspection(on vehicle)
1. Measurethe batteryvoltage.
Specitication:Above 12.4v
turnssmoothly.
2. Cranktheengine,andverifythatthestarter
checkthe
voltage
ofterminalS.
stader
does
not
turn,
3. lfthe
4. lf thevoltageis above8V,removeandinspectthestaner.
ignill thevoltageis below8V,checkthewiringharness,
tionswitch,and inhibitorsMich(ATX).
01E0GX.O60
Rgmoval/ Installation
'1.Removein the ordershownin the figure,reterring
to RemovalNote.
to InstallationNgte.
2. Installin the revers€orderof removal,referring
ATX
a7-5r l+n (3.&-5-3 m.kg, 2H3
n |b)
(t.3-5.3 rkg, 2a-33 fi.rb)
1. Negativebatterycable
2. S terminal,B terminal
connector
bolt
3. l\.4ounting
G-25
STARTINGSYSTEM
'a;^
37-51
1. Negativebatterycable
G-26
n (3,3-s.3 rl(g, 23-$
rl-25
l+n O.9-2.3 rlq,
n.|b)
S and B
2 Terminalconnectors
3 lvountingbolt
STARTINGSYSTEM
Removal/ Insiallation Note
ATX
Thestarteris removedandinstalled
frombelowthe vehicle.
MTX
fromabove.
Thestarteris removedandinstalled
01A0GX{25
Pe.tormance Inspection
i,lagnetic awltch
theterminall\,4wire,and perlormthelollowingtests.
Disconn€ct
Pull-lntest
whenthebatTheswitchis normaliftheoinioneiectsoutward
tery is connected
as shownin the figure.
Caution
. Do not applypowercontinuouslytor mote than 10
aeconqs.
Hold-lntesl
Aftercompletingthe pullin test,disconnectthe wirefromter'
Theholdincoilis funcminalM (withthe pinionleftejected).
tioningproperlyif the piniondoesnot return.
Adiuahent of pinion gap
1. Disconnect
the wiringfromterminalM
terminal
S andthe
2. Whenthebatteryis c;nnectedbetween
starter
body,thepinionwillbeejectedandthenstop.Meas(piniongap)betlveen
thepinionandthe
uretheclearance
stoooer.
Note
. Do not applypowercontinuouslyfor morethan 10
aeconds.
Pinlongap: 0.5-2.omm (0.020-0.078 in)
makeadjustmenl
3. lf thepiniongapis notwithinspecficaton.
the numberofwashersbetween
by increasing
or decreasing
the magnetic
Switchandthe drivehousing.fihe gap be'
comessmalleras the numberoi washersis increased.)
G-27
STARTINGSYSTEM
Disassembly/ Assembly
Note
i.'-o-iJiJi.6r" in the ord;r shownin the figure'relerringto Disessembly.
i. iiGii,r.ln
referringto AssemblyNote
*" ,""erie oroerof disasse-mblv,
o-r2 (so-l30, 79-ii2)
1. Magneticswitch
l;spection......
PageG 29
2. Rearcover
3. Brushholderassembly
.. pageG-30
Inspection...............................
4. Fieldcoil
pageG-30
Inspection.................................
G-28
5- Frontcover
9 !eYe' . .
T DrivePinion
B Armature
Inspection""
"
" pageG-31
STARTINGSYSTEM
DisaasemblyNote
Drlvs plnlon
Removethe stopperfor the overrunning
clutchwitha pipe
as snown.
Assembly Note
Drivepinlon
1. Setthedrivepinionontothearmature
andinstallthe ring.
2. Installthe stopperwiththe SST and pressit, as shown.
Inspoctlon
agnetic awilch
1. Usean ohmmeter
to checkcontinuity
betweentheS and
switchifthereis noconM terminals.
Replace
themagnetic
tinuity.
2. Useanohmmeter
to checkcontinuity
between
theSterminalandthe body.Replace
the magneticswitchif thereis
no continuity.
to checkcontinuity
between
the M and
3. Usean ohmmeter
Replace
the magneticswitchil thereis conB termanals.
tinuity.
G-29
STARTINGSYSTEM
Brush and brush holder
betweeneachinsu'
to checkcontinuity
1. Usean ohmmeter
the
and
lated brush
9late.
Replacethe brushholderil thereis continuity.
2. Usea springbalanceto measurethe forceol the brush
spring.
Standard:
18.9-23.1N (1.89-2.31k9, 4.18-5'12 lb)
BAUSHSPFING
the springif notas specified
3. Replace
Brush
It a brushiswornalmostto thewearlimitor b€yond'replace
all the brushes.
WEAB LIMIT
Standard:17mm(0.67 in)
Minimum:I l.smm (0.453in)
STANDARD
Field coll
betweenthe M terto checkcontinuity
1. Usean ohmmeter
yokeassembly
if
Replace
the
minalwireandthebrushes.
thereis no contnuity.
betweenthe M ter:
to checkcontinuity
2. Usean ohmmeter
minalwireandtheyoke.Replacetheyokeassemblyif there
is continuity.
theyokeassembly
3. Checkil thefieldcoilis loose.Replace
if it is.
G-30
01EOG)!O73
STARTINGSYSTEI
Armatur€
betweenthe comto checkcontinuity
1. Usean ohmmeter
itthereisconarmature
mutatorandthecore.Beplacethe
tinurty.
betweenthe comto checkcontinuity
2. Usean ohmmeter
ilthereisconarmature
mutatorandtheshaft.ReDlacethe
tinuity.
andmeasurethe runout
on V-blocks,
3. Placethe armature
witha dialindicator.
repairit witha lathe
lftherunoutis notwithinspecification,
or replacethe armature.
Runout:0.05mm(0.002in)
it theouteldiamele'of lhecomrru'
thearmature
4. Replace
tatoris almos(at or lessthanthe rnlnlmum
surfaceis dirty,wipeit witha cloth;if it
5. lt thecommutator
it
with
a latheor tinesandpaper'
is rough,repair
Gdndllmlt:31.4mm(1.23in)
is almostat or
6. ll thedepthof themoldbetweensegments
undercutthe groovesto the stanlessthanthe minimum,
dard depth.
Depth : 0.5-0.8mm (0.02-0.03 in)
Minimum:0.2mm(0.008in)
G-31
CLUTCH
H- 2
rNDEX.............................................,.,......
H- 3
ouTL|NE..,,,....,.,...,........,.........................
H- 3
spEctFtcATtoNs....................................
H- 3
GU|DE...........,....,.....
TROUBLESHOOTTNG
H- 4
cLuTcH PEDAL.....................................,.
H- 4
ADJUSTMENT...............................,..,.,...
H- 5
REMOVAL
/ INSPECTION
/ INSTALLATION.,
H- 6
CLUTCHCABLE,..............................,.......
H- 6
REMOVAL
/ INSPECTION
/ INSTALLATION..
H- 7
GLUTCHUNtT.....,..........-........................
H- 7
PREPARAT|ON..,....................................
H- I
REMOVAL
/ TNSTALLATTON
......................
H-l 1
CLUTCHCOVER,........-............................
H-11
tNSPECTtON......,...................................
H-r1
cLuTcHDtsc....................,.....................
H-r1
tNSPECTrON.,.....................,.,.,,.............
H-i2
RELEASE
COLLAR...........................,....,.,.
H-12
tNSPECTtON..........................................
H-'2
PTLOT
BEAR|NG
........-..............................
1 N S P E C T t O N . . . . . . . . . . . . . . . . . . . - . . . . . . .H. .-.1. .2. . . . . . . . .
H-l2
FLYWHEEL........................-.....................
H-12
rNSPECTtON................,.........................
INDEX
INDEX
TFANSAXLESERVICE,
J
SECTION
SEFVICE.
CLUTCHSWITCH
SECTIONF
'|. Clutchpedal
5. Clutchcover
.. pageH- 8
Installatron.....
Removal/
4
..pageH.....
Adjustment
/
Inspection
I n s p e c t i o n . . . . . . . . . . . . . . . . . . p. .a. .g. e
. .H - 1 1
/
Bemoval/ Inspection
disc
6. Clutch
. .e.H
. . . .5.
I n s t a | | a t.i.o. .n. . . . . . . . . . . . . . . . .p. .a. g
pageH- I
.. ..........
Installation
Removal/
2. Clutchcable
page
H-11
..
..---..
Inspection.......................
/
Removal/Inspection
7. Pilotbearing
.... .. ...... ....pageH- 6
Installation
pageH- 8
7 Installalion . .
Removal
Collar
3. Release
PageH-12
lnspectron..
. ..... pageH- 8
Installation......
Removal/
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. a
. .g. .e.H. .-.1. .2. . . 8. Flwheel
pageH- I
Removal/Installalion ..
fork
4. Release
page
H-12
.
..
Inspection..................
page
H8
. .-.- . ..
Removal/Installation...
H-2
H
GUIDE
OUTLINE.TROUBLESHOOTING
OUTLINE
SPECIFICATIONS
Enghe/Transarle Itodel
Clutchdisc
mm (in)
Diaphragm
sprng
2 943 (300,660)
180(O
12514.92)
3.2(0.126)
3.0(0.118)
mm (in)
5.83
138(s.433)
N (kg, lb)
S€t load
mm tn)
Oulerdameler
lnnerdiameter
rnm(jn)
plate mm (ln)
Pressure
Rywheelside
B3
B5Mfi
Type
Clutch pedal
Fullsvoke
Helsht(Wlh carpet)
196,207 \7.72-8.15)
GUTDE
TBOUBLESHOOTING
Problem
Page
Poaslble Cause
Slipping
Culch disclacingwornexcessiveiy
Cbbn disclacingsurfacehardened
or oiled
platedamaged
Pr€ssure
Diaphfaqm
sprang
damagedor weakened
Insuflcient
clurchpedalplay
cturchpedatslicking
Faulty db€ngagoment
Excessiverunoul or damagedclulch disc
Cldch discsplnesrusledoi worn
H- 8, 1t
H 8
H-8
H-8
H-4
H-5
H-8
Rernoverust or repace
Diaphragm
springweakened
Excessiveclutch pedalplay
Clulch vibraies
Clutchdisc oiled
Torsionrubbersweakened
Clutchdisc tacing hardenedor damagod
Clutch disc lacing ivels oose
Diaph€gm spring weakened
Pressureplale damagedor excessiverunout
Flwheel surfacehardenedor damaged
loose or worn engrnemoum
Clutch pedal
3licking
Pedalshan nor prop€rlylubricated
CLutch
releasecoilff damaged
Poorlubricalonof r€lease
collarsleeve
Torsonrubbercwsakened
Excessivecrankshaltend play
Pilorbearingworn or damaged
Wornpivot pointsoi reeaselork
Tighlenor replace
H- 8, 11
H-8
H 8
H-8
H-4
H-8
H-8
H 8
H-8
H-8
H-8
H,8
Felerlo Secuons
B, J
H- 8, 11
H-8
H-8
neier to Section B
H- A, 12
H 8
H-3
CLUTCHPEDAL
CLUTCHPEDAL
ADJUSTT'ENT
clurch Pedal Height
Insp€cilon
lromlhe uppersurlaceof the podal
1 Measure
thedistance
pad to the carpet.
Pedal hetght (Wlth carPet)
196-207mm (7.72-8.15 in)
adjustthe pedalheight
2. lf necessary,
I
Adiustment
the clutchswitchconnector.
1. Disconnect
locknut
2. Loosen
@ andturnclutchswitch@ untiltheheight
|s Correq.
3. Tightenlocknut@.
Tlohtenlnq
loroue:
-Nfl
il-rg
{i.l-t.a
m-kg, 1o-13 ft-lb)
measurethe pedalfreeplay.
4. Afteradjustment,
Clutch Pedal Free PlaY
lnsoection
1. Depressthe clutchpedalby handuntilclutchresistance
is felt.
Pedallree play: 9-l5mm (0.35-0.59 in)
adiustthe pedalfreepla,.
2. lf necessary,
height(fromthe uppersur3. Verifythatthe disengagement
pedal
to thecarpet)is correctwhenthe pedal
faceof the
is fullydepressed.
Minimumdisengagementhelght: 85mm (3.35in)
(Wlth caryet)
Adiuslmenl
i.-iili t'f'"i"r"."" r"""r asshowninlhe figureThenturnthe
clearance
nut@ untiltherecommended
@ be
adjusting
obtained.
lever
is
h^/;enthe oin andthe release
Slandardclearance:1,95-2'05mm (0.02-0.081 in)
6ye
-7\\
H-4
2. Measurethe clutchPedalPlaY.
CLUTCHPEDAL
REIIOVAL/ INSPECTION
/ INSTALLATION
1. Removein the ordershownin the ligure.
2. Inspectall pads and repair or replaceas necessary.
Note
. Apply lilhium bas€d greaas to the bushlng and pins b€tore installation.
3. lnsiallin the revers€order of removal.
4. After installation,verifythe clutch pedalfree play. (Referto page H-4.)
\q
u'€
1.Adjustingnut
2. Clutchcable
3. Pedalpad
4. Nut
5. Lockwasher
6. Bolt
7. Bushing
L Spring
10.Clutchpedal
H-5
CLUTCHCABLE
CLUTCHCABLE
REIIOVAL / INSPECTION/ INSTALLATION
1. Removein the ordershownin the figur€.
2. lnspectall parts and repair or replaceas necessary.
Note
; Apply firhlum based gtease lo lhe pln and lhe release leve] bslore installation'
3. lnstallin the reverseorderol removal
4. Alter installation,veritythe clutch pedal free play.(Referto page H-4.)
\-,\\
1.Adiustingnut
2. Pin
3. Clip
H-6
4. Clutchcable
Inspectlor damage
pageH-4
Adjustment................................
H
CLUTCHUNIT
CLUTCHUNIT
PREPAFATION
ssT
49 E3010€0
49 E301061
Brake,.ing gear
enginerolation
Body
49 E301060)
49 E301062
49 SE01310A
Collal
(Parlol
49 E301060)
enginerotation
49 1285071
Pu er,Jle€dle
Cente ng lool,
49 1285073
-G:
b€aring
Chuck
ead ol
49 1285071)
beanng
H-7
CLUTCHUNIT
REI'OVAL/ INSTALLATION
Note
. Dq not rcmove the pilor bealing It not necesaary,
1.Removein the ordershownin the figure,referringto RemovalNote
2. Installin the reverseorderof removal,referringto InstallationNote.
t5-r03 p.a-r0.5, 7r-761
ra-2a o
V
1.Transaxle
"
section J
"
service
2. Returnspring
collar
3. Release
pageH-12
Inspection...................................
Reamer
bolt
4.
5. Releaselever
fork
6. Release
7. Clutchcover
Note..... .. . ..... .. pageH- 9
Removal
pageH-11
Inspection...................................
page
H-11
Note..........................
Installation
H-8
8. Clutchdisc
. ....pageH- 9
Note....................
Removal
paSe!-1-1
lnspection...................................
1
pageH-10
Note..........................
Insiallation
9. Pilotbearing
.. .... pageH- 9
Note....-.............
Removal
.
.. .. ...pageH-1?
Inspection......................
pageH-10
Note..........................
Installation
10.Flywheel
paqeH- 9
Note.. .............
Removal
pageH-12
Inspection...................................
pageH-10
Note..........................
Installaiion
CLUTCHUNIT
Rgmoval Note
Outch cover and disc
1. lnstallthe ssT.
Caution
. Put 8pacs6 betweenthe (49E30l 060)andlhecylinder block, setling dimeaion@ as shown in the
figure io l3mm (0.51in). (Except83 ATX)
2. Looseneachboltoneturnat a timein a crisscross
Dattern
untilspringtensionis released.
Thenremovetheclutchcover and disc.
Pilot bearing
Removethe pilotbearingwiththe SST if necessary.
Flywheel
Note
. After removlngthe lly'rvheel,Inspeci lor oil leakage
pasl the crankshatt rear oil seal,
lf ngcess€ry,replacethe oil seal.
(Rete.lo Seclion B.)
1. Holdthe flywheelwiththe SST.
2. Removethe boltsin thesequenceshownin the figurein
steos.
3. Removethe tlywheel.
H-9
CLUTCHUNIT
lnstallationNote
Flvwheel
1-hemovethe sealantlromtheilwheel bohholesin thecrank'
bolts
shattand fromtheflYwheel
Caution
. ll all the previous sealant cannot be removed flom
a bolt, replace the bolt.
. Do not apply sealant lf a new bolt is used.
2. Setthe flywheelontothe crankshatt
3. Apply sealantto the tlywheelboltsand installthem
4. Holdthe tlvwheelwiththeSST.
5 Tiohtenthe boltsin twoor threestepsin theordershown
ti"otrt.nino
to*r",
-gHos'l*tn
ig.a-to.s m'kg' 7l-?6 ftJb)
Pllot bearing
Note
. Insiall the pilol beafng flush with the tlywheel.
Instailthe new bearingwitha plastichammer.
Clutch disc
'1.Cleanthe clutchdiscsplinesand maindrivegearsplines
grease.
2- Lightlygreasethe splineswithmolybdenum
3. Setthe clotchdiscontothe flywheelwiihthe SST.
@E@
H-l0
01EoHX{]7
CLUTCHUNIT.CLUTCHCOVER,CLUTCHDISC
Clutch
cgver
'l. Install
the SST.
2. Alignthe dowelholeswiththe llywheeldowels.
inthepattern
shown.
theboltsevenlyandgradually
3. Tighten
Tlghteningtorque:
18-26 Nm (1.8-2.7 m-kg, l3-20 ft-lb)
CLUTCHCOVER
INSPECTION
Note
. trlinorscoringor burningshould be removedwlth
emerypaper.
'1.Inspectlhe contactsurfaceof the clutchdiscfor scoring,
cracks,and burning.Repairor replaceas necessary.
2. lnspectthe contactsurfaceof the clutchreleasebearing
for wearandcracks.
Replacethe clutchcoverif crackedor worn.
CLUTCHDISC
INSPECTION
Note
. Use sandpaperil the trouble 15mlnor,
liningsuriace
for burningandoilcontamination.
1. Inspectthe
theclutchdiscif it is badlyburnedor oil soaked.
Replace
2. Inspectlor loosefacingrivetsand rubbers.
Replacethe clutchdiscif eitheris loose.
thethickness
of theliningat a rivetheadon both
3. Measure
sideswithverniercalipers.
islessthanminimum.
theclutchdiscif itsthickness
ReDlace
Minimumthickneaa:0.3mm(0.012in)
4. Measurethe clutchdiscrunoutwitha dialindicator.
Replacetheclutchdiscif runoutis excessive.
Runout:0.7nm (0.027in) max.
H-l1
RELEASECOLLAR,PILOTBEARING'FLYWHEEL
RELEASECOLLAR
INSPECTION
Note
. The clutch Eleaae collar is a sealedbearlngand
musl not be washed in solvent.
Turnthe bearingwhileapplyingforcein the axialdirection
It the bearinqsticksor has excessiveresislance,replaceit.
PILOTBEARING
INSPECTION
Turnthe bearingwhileapplyingtorcein the axialdirection
replaceit
resistance,
lf the bearingsticksor hasexcessive
t
FLYWHEEL
INSPECTION
Note
. Minorscoringor burningshould be removedwith
emery paPer.
1. Inspectthe contactsurfaceof the clutchdiscfor scorang,
cracks,and burning.Flepairor replaceas necessary.
the ringgearteethfo. wearanddamagell neces'
2. Inspect
theflwheel.
sarv.reDlace
runoutwitha dialindicator'Replace
3. l'/easure
lhetlvwheel
the flywheelif runoutis excessveRunout:0,2mm(0.008in) max,
H-12
J
MANUALTRANSAXLE
tNDEX..................................................,,..
J- 2
ouTLtNE........,..........,..,....,...,..................
J- 3
J- 3
spEctFtcATroNS,...................,........,......
VtEW,.........,....,..,..............
J- 4
STRUcTUFAL
powERF1OW,...........,..........,..,...,..........
J- s
TROUBLESHOOTTNG
GUTDE
.......,..............
J- 6
J- 7
TRANSAXLE
OtL,,,,.,.................,.....,.,.,.....
tNSPECTtON......................-......,,,,.........
J- 7
REPLACEMENT........-.....-.,..................,
J- 7
J- I
TRANSAXLE....,............................,...........
PREPARATtON................................,..,.,..
J- 9
REMOVA1.................-...---.............,....
J-r r
J-r4
DtSASSEMB1Y..................................,.....
tNSPECTtON.................--..................,...
J-27
ASSEM81Y..................,......,,..................
J-30
|NSTALLAT|ON
......,..,J-56
DtFFERENT|AL................,.,...,...................
J-59
PREPARAT|ON.,.,....,.........,....,..,.............
J-59
DISASSEMBLY
/ INSPECIION
/ ASSEI\,lBLY..
J-50
SHIFTMECHANlStrl...--...-.................,.....
J-64
J-64
ovERHAU1...........,....,.,........................,
J
INOEX
INDEX
BACK.UPUGHT SWTTCH
SEFIVICE,SECTIONT
NEUTRAL$AIITCH
SEBVICE,SECTIONF
GFADE : API SEFVICEGI-4
VISCOSIIY:ALL SEASON
D€xrend'[or M2C3ilF
aBovE-r8.c (ocD
saE75W-80
cAPAclry: 2.5lllsls(2.6us qt, 2.2 lmp
2. Differential
1.Transaxle
/
/ Insp€ction
R e m o v a 1 . . . . . . . . . . . . . . . . . . . . .p. .a.g. .e.J.-.l. .1. . . . . . . Disassembly
.
.
.
.
:.
............ pageJ-60
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.
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.
.
Assembly
p
a
g
e
D i s a s s e m b 1 y . . . . . . . . . . . . . . . . . . . . .J. -. .1. 4. . . . . . .
i n s p e c l i o n . . . . . . . . . . . . . . . . . . .p
. .a. .g. e
.J. .- .2. 7. . . . . .3.
. Shiftmechanism
O v e r h a u | . . . . . . . . . . . . . . . . . . . . .p. a
. .g. .eJ. .-.6. .4. . . . . .
A s s e m b | y . . . . . . . . . . . . . . . . . . . .p. .a. .g.e.J. .- .3. 0
......
oil
I n s t a | I a t i o n . . . . . . . . . . . . . . . . . .p. a. .g. .eJ. .-.5. .6. . . . . 4.
. . Transaxle
pageJ- 7
Inspection..--................................
R e p | a c e m e l t . . . . . . . . . . . . . . . .p. .a. g
. .e.J. -. . .7. . . . .
J-2
J
OUTLINE
OUTLINE
SPECIFICATIONS
----__
Item
____
-------
Engine
B3
85M-B
Forward:Synchromesh Bev€rse:S€leclivesliding
3 454
mechanism
Synchronlzation
Gearratio
2nd
1.944
3rd
1.392
1.030
0.810
3.583
5lh
4.058
gearratio
Speedomeler
gearnumber)
(Driv€ngearnumber/Drlve
o.9112123)
Grade
Dexrono]I
or M2C3&F
ol
Capaclty
Above -18oC (0"F)
SAE 75WAO
liters(USqt, lmp qt)
2.5 12.6,2.2:)
J-3
J
OUTLINE
VIEW
STRUCTURAL
'lst
1. Primary gear
2. Pdmary2nd geat
3. Primary3rd g;ar
a. Primaryatn gear
5. Primary5th gear
J-4
6- Primaryreversegear
7. Secondarylst gear
B.Secoloary2nd gear
9. Secondary3rd gear
4th gear
10.Secondary
'11.Secondarysth gear
reversegear
12.Secondary
13 FleveIse'dlergear
14 Ditferedial
J
OUTLINE
POWEBFLOW
rsT
2ND
3RD
4TH
5TH
J-5
J
GUIDE
TROUBLESHOOTING
GUIDE
TROUBLESHOOTING
Page
shilt lever won't shlfi
smoothly or is hatd
ro shlfi
Too much play in
shilt lever
Difficull to shltl
sllcking shiit lever ball
Stcking changeconllol rod ioinl
Benl change conlrol rod
J-€4
J-64
J-64
Wornchangeconlrclrod bushing
Weakshiftleverballsprlng
Worn shitt lever ball seat
J64
J64
J-64
J64
J64
J 7
conlrol
No Oreas€n transaxle
lnsuificieni
oil
Deteiorationof oil quality
We or play ot shlft fork or shlft rod
Wornsynchronizerng
coneor gear
Womsynchrcnizer
ringandconeol gea'
Bao conlacrol syrchro_i7Fr
pay ol gears
longiludinsl
Excessive
J,21,24
J 21,24
J 21,24
J 21,24
J 21,24
J-21. 24
J-38
keysping
Womsynchronlzer
Excessiv€prirnaryshalt gear bearlngpreload
lmpropeiyadjusledchangeguLdeplate
Won't stay h gear
Benl change conlrol rod
Wom change conlrol rod bushing
W€ak shit lever balLspring
Tishten
Wofn clutch hub sleeve
Worn slidingsudaceol gear or shait
Worn steelslldinggrooveol conlroLend
J-64
J-64
J-64
J-64
J 21,24
J 1 4
J-14
Excessivethrusl clearance
Loos€ engrnemounl
Deierloralion
oi oil qualty
Womslidingsurlaceoi gearor shafl
Danrageclgearteeth
Foregn materlaln gears
gearor excessvebacklash
DamagedditferentiaL
J-6
Tghten
J-56
J-7
J-7
J 21,24
J 21,24
J-21.24
J-21. 24
J-60
J
TRANSAXLEOIL
TRANSAXLEOIL
INSPECTION
Note
. Park the vehicleon level ground.
1. Disconnect
thespeedometer
cableandremovethespeedo
meterdrivengear.
2. Verifythatlhe oil levelis betweenthe F and L.
drivengear.
3. Installthe speedometer
Tighteninglorque:
7.8-12 Nm (0.8-t.2 m-kg, 5.8-8.7 tt-lb)
cable.
4. Connectlhe speedometer
o
l-----.--
REPLACEMENT
'1.Disconnect
thespeedometer
cableandremove
thespeedometerdrivengear.
2. Removethedraanplugandwasher.Draintheoilintoa suitable container.
3. lnstalla newwasherand the drainplug.
Tightenlngtorque:
24-35 N.m(2.4-3.5 m-kg, l7-26 finb)
4. Addthenecessary
amountof thespecilied
oilthroughthe
drivengear hole.
speedometer
Specifiedoil
Grade:API service GL-4
Viscosity:AlFseasonDexron@n
or M2C33-F
Above -t8"C (0"D SAE 75W-80
Capacity:2.5 liters (2.6 US qr, 2.2 lmp qt)
5. Veritvthe oil level.
6. Installthe speedometer
driven gear and connectthe
speedometer
cable.
Oil seal
Replacement(On-vehicle)
1.Jack up the vehicleand supportit withsafetystands.
2. Drainthe transaxle
oil.
3. Removethefrontwheel.
4. Femovelhe splashshield.
the frontstabilizer
lromthe lowerarm.
5. Separate
J-7
J
TRANSAXLEOIL
Cautlon
. Do noi damagethe dust boots.
6. Removetheclinchboltand pullthe lowerarmdownward
lhe knucklelromlhe lowe.arm balljoint.
to seDarate
endwilhtheSST
thetie-rod
7 Loosen
thenutando6connect
Caution
. Ilo not subiectthe tdPodlolnl to shockwhen remov'
ing lhe driveshaft.
by pryingwith
fromthetransaxle
thedriveshaft
8. Disconnect
a bar insenedbetweenthe outerringandthe transaxle.
witha rope
9. Suspendthe driveshaft
10.Removethe oil sealwitha screwdriver.
Note
. Tap in until lhe oil seal Installercontactsthe case.
. Coat the gil seal lip wilh ttanaaxleoil.
casewiththeSST
11. Tapthe newoilsealintothetransaxle
endclipwitha newone-Insertthe
12.Replace
thedriveshaft
withthe splitol the ciip facingupward
driveshaft
to veritvthatit isheldfirmlyinplace.
on
the
driveshatt
13.Pullout
J-8
J
TRANSAXLE
TRANSAXLE
PBEPARATION
ssT
49 GO175AO
49 G017501
Suppon,englne
Bar
(Parlof
49 GO175A0)
49 G017
49 G017503
Suppod
49 G017 5A0)
Hook
{Pan of
49 G0175AO)
49 0107 6804
49 DO172A2A
Enginestand
sh,ms€ecro,se,
B,fffiililp
_g
adiuslmenlof
bearingPreload
../-t
49 G019 0A0
49 F401384
adjuslrnentof
Collar
(Panof
49 DOIT2A2A)
49 G019001
49 F401385
Body
(Panol
49 G0190A0)
Bar
49 G019002
49 F4013818
Siay
{Parrol
49 GOrg0A0)
SelectorC6o
(Padof
49 F4013814)
49 G019 003
49 G019019
F:'"Tr888
R-
49 Do172MA)
adjustrnentot
bearng preload
Bolt set
49 Gor9 0A0)
49 Do172A2A)
4 9 D O 1 71 0 1
49 8001 795
J-9
J
TRANSAXLE
49 BO270024
49 FTot 361
beanngpreload
(Partot
49 DO172A2A)
4 9 0 1 8 05 1 0 8
49 G030 795
beaing prcload
measuing
49 G030797
49 DOIT 241
beanng
Body
(Partol
49 G030 795)
49 F401331
49 G030 796
beaflng
b€aring
Body
(Partol
49 D0172A1)
49 DO17201
Attachmenl
(Padof
49 D0172A1)
49 0710 520
Body
(Pad of
49 G030 795)
49 0839 425C
/A\
w|,
gezl
bearng
beanng
49 0A62 428
bearlngpullef
(Pan oi
49 0839 425C)
49 0636 145
49 0a39 426
beaflng
(Partol
49 0839425C)
J-10
J
TRANSAXLE
REMOVAL
1. Disconnect
the negativebatterycable.
2. Raisethe vehicleon a vehiclehoist.
3. Drainthe transaxleoil intoa suitablecontainer.
4. Removein the ordershownln the figure,referring
to RemovalNole.
{!e
CLIP,
01A0JX{02
1.Wheeland tire
2.Splashshield
3. Battery,batterycarrier
4. Speedometer
cable
5.Clutchcable
6. Back-uplightswitchconnector
7. Neutralswitchconnector
8. Extension
bar
rod
L Control
10.Driveshafts
pageJ-12
Bemoval
Note.............................
11. Starter
12.Enginemountingmember
pageJ-12
Bemoval
Note.............................
13.Exhaustpapebracket
'14.Stifiner
15.Transaxle
pageJ-13
Removal
Note.............................
16.Engine
mountNo.2
J-1 1
J
TRANSAXLE
- 1 .
Removd Note
DrlvEhaft
1. Removethe balljointclinchbolt.
Caution
. Wrap a rag around the ball ioint dusi boot to pro'
lect h trom damage.
2. Prythe lowerarmfromthe knucklewitha pry bar.
Cautlon
. Do not shock the tripod ioint when removing the
dtiveshaft.
by pryingwilh
fromthe transaxle
the driveshaft
3. Seoarate
a bar insertedbetweenlhe outernng and thetransaxle.
witha rope.
4. Suspendthe driveshaft
EnginemountinEmember
1. Suspendthe enginewiththe SST
theboltsandnutsshown,andremovetheenglne
2. Remove
mountingmember.
J-12
TBANSAXLE
J
Tranaaxle
1. LoosentheSST(€nginesuppon)andleantheengineto
ward the transaxle.
2. Supportthe transaxlewith a jack.
mountingbolts.
3. Removethe transaxle
4. Removethe transaxle.
J-l3
J
TRANSAXLE
DISASSEi'BLY
Precaution
beforedisassembly'
solvent
wilha steamcleane.or cleaning
thoroughly
i. 6t""n tn" ttuna""f.exterior
anddry
solvent,
with
cleaning
sudaces
seating
a
Oearings)and
s"-ateb
i.
- di;;; il";,.d;"J pirti (except
are
check
that
there
and
air,
plsiages
with
a
compressed
and
iitiilii,irr""llO iii Cteinouiatttrotes
no obskuctions.
airto cleancomponefis
whenusingcompressed
3.Weareyeprotection
HousingParls
to DisassemblyNote'
ijGo"inOt" in the ordershownin ll"eiigure'referring
BEPIACE
"-/Wr
./
F-u
\-,.,@
a'.
\
t ] af
\
xqrqk'
/(t
@
\
FEPLACE
REPLACE
@
g
o
BEPLACE
BEPLACE
J-l4
TRANSAXLE
J
26.Rollpin
1.Transaxle
pageJ-16 27.Rollpin
Disassembly
Note.......................
28.Shifttork(sth/Rev)
2. Returnspring
pageJ-27
1nspeciion....................................
3. Clutchlever
29.Shiftrod (sth/Rev)
4. Clutchreleasetork
pageJ-16
Disassembly
Note.......................
5. Clutchreleasecollar
pageJ-27 30. Inlerlockpin
fnspection.............-......................
31.Shiftrod end (sth/Rev)
6.EnginemountNo.1
plug
32.
Ueverseidlergear
7. Drain
33.
Feverseidlershaft
Plug,
steel
ball
8.
spring,
34.Follpin
9. Back-uplightswitch
J5. l.tn
10.Neutralswitch
36.Leversetspring
drivengearassembly
11.Speedometer
37.Reverselevershaft
caseassembly
12.Transaxle
'13.Retaining
ring
38. O'ring
shittlever
39. Reverse
14.Cranklevershatt
40. Interlockpin
15.Crankleverassembly
pageJ-16
Disassembly
Note.......................
16.Baseplateunit
4'1. Interlockpin
17.Plug,spring,steelball
pageJ- 16
Note.......................
Disassembly
18.Rollpin
gear
pin
42. Primaryshaft
assembly
19.Roll
43.Secondary
shaftgearassembly
20.Shiftfork (3rd/4th)
pageJ-27 44.Difierentialassembly
fnspection....................................
45.Clutchhousingassembly
21.Shiftrod (3rd/4th)
pageJ-16 46.Follpin
Disassembly
Note.......................
gearsleeve
47.Speedometer
22.Shiftrod end (3rd/4th)
48.O-rin9
23.Rollpin
49.Oil seal
24.Shifllork (1sv2nd)
pageJ-16
pageJ-27
Disassembly
Note.......................
1nspection....................................
50.Drivengear
25.Shiftrod (1st/2nd)
pageJ-16 51.Magnet
Disassembly
Note.......................
J-15
J
TRANSAXLE
Disaasembly Note
Transaxle
on the SST.
Mountthe transaxle
Shlft rod
WiaptheshiftroOwitha ragandturnit withplierswhilepull
ing it out.
lnterlock pln
Removethe interlockpinwitha magnet.
Oll seal
drivengearoil sealasshowninthe
iem-dvettre speeaometer
figure.
J-16
J
TRANSAXLE
Clulch Housingand TaansaxleCaseComponents
Caution
. Do not remove an oil seal lf not necessary,
1. Disassemble
in the ordershownin the figure,referring
to DisassemblyNote.
2. Inspectall partsand repairor replaceas necessary.
REPLACE
BEPLACE
SELECNVE
AEPLACE
1. Batfleplate
2. Bleeder
3. Rollpin
4. Changearm
5. Changerod assembly
7. Oilseal(changerod)
Disassembly
pageJ-18
Note.......................
8. Oilseal(primaryshaft)
Disassembly
Note.......................
pageJ-18
9. Bearingouterrace(secondary
shaft)
Disassembly
Note....................
pageJ-18
10.Funnel
Disassembly
pageJ-18
Note.......................
11.Oilseal(ditferential)
Disassembly
pageJ-18
Note.......................
12.Bearingouterrace(differential)
Disassembly
pageJ-19
Note.......................
13.Oilseal
'14.Bushing
15.Clutchhousing
16.Oil passage
17.Adjustment
shim
18.Funnel
pageJ-19
Disassembly
Note.......................
lO
Ra./i^^
^' d6r /r^6
pageJ-20
Disassembly
Note.......................
20.Adjustment
shim(secondary
shaft)
pageJ-20
Disassembly
Note.......................
21.Bearingouterrace(ditferential)
pageJ-19
Disassembly
Note.......................
22.Adjustment
shim
23.Oil seal(differential)
pageJ-18
Note.......................
Disassembly
24.Transaxle
case
J*17
J
TRANSAXLE
DisassemblyNote
Oil seal (changerod)
Caution
. Do not damagethe cluich housing'
Removethe oil sealwitha screwdriver.
Oil seal (dlfterential)
\r
l<,
Caution
. Do ngt damagethe clutch housing.
Removethe oil sealwith a screwdrver'
Oil seal (p mary shafl)
Cautlon
. Do noi damagethe clutch housing.
Removethe oil sealwitha screwdriver'
Funneland bearingouter race (secondaryshatt)
Noie
. Removethe bearingouter racewith a acrewdriver
it neces-sary.
I ) lnaerta screwdrive.betweenthe clutch housing
and bearlngouter race.
2)Pry the bearlngouter race flee.
Removethe bearingouterraceby liftingoutthefunneland
race together.
J-l8
J
TRANSAXLE
Funnel
Removethe funnelwithpliers.
Bearlngouter race (differential)
1. Installthe SSTto the bearingouterrace.
2. Turnoverthe clutchhousing.
3. Removethe bearingouterracewitha su,tableprpe.
Bearingouler raaeand adiustmentshim (difierential)
1. Installthe SSTto the bearingouterrace.
.'-/l
l\).r.< ' -t,'.-,t
)-P
2.Turnovertheclutchhousing.
holeto re3. TaptheSSTwitha pipethroughthe driveshatt
movethe bearinoouterrace.
J-19
J
TRANSAXLE
Bearing outel race and adluslment shin
(seqondary shalt)
i. puttoutitre beaiingouterraceas shownin the figure.
shim
2. Removethe adiustment
J-20
J
TRANSAXLE
PrlmaryShaft Assembly
referring
to Preinspection.
1. Measurethe thrustclearances
ot all gearsbetoredisassembly,
2. Disassemble
in the ordershownin the figure,reterringto DisassemblyNote.
FEPLACE
E
FEPLACE
ring
1. Retaining
ring
10.Synchronizer
pageJ-22
Note.......................
2. Bearing(sth)
Disassembly
pageJ 27
pageJ-22
Disassembly
Note.......................
Inspection....-...............................
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. .g. e.J. -. .2. 8. . . . .1.1.
. 3rd gear
pageJ-22
Note.......................
Disassembly
3. Spacer
pageJ-28
Inspection....................................
4. Steelball
gear
12.Bearing
5. sth
pageJ-22
pageJ-22
Note.......................
Disassembly
Note.......................
Disassembly
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p. .a. g. .e.J. .2. .8. . . . . . .
Inspectgearteethfor damage,wear,and
13.Primaryshaft
cracKs
pageJ 28
Inspection....................................
6. 4th gear
pageJ-22 14.Synchronizer
spring
Disassembly
Note.......................
pageJ-28 '15.Clutchhub sleeve(3rd/4th)
Inspection....................................
pageJ-27
1nspection....................................
7. Synchronizer
ring
key
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e
.J. -. .2. 7. . . . .16.
. . Synchronizer
ring
17.Clutchhub (3rd/4th)
8. Retaining
9. Clutchhub assembly(3rd/4th)
pageJ-22
Disassembly
Note.......................
pageJ-29
Inspection....................................
J-21
J
TBANSAXLE
Preinspection
3rd qear thrusl clearance
between3rd qearand 2nd gear'
1 M;-asure
the clearance
Clearance:0.06-0.41mm (0.002-0.016 in)
llaximum : 0.46mm(0.0'18in)
checkthecontact
the maximum,
exceeds
2. lf theclearance
ofthe3rdgear,2ndgear,andclutchhub(3rd/4th).
surfaces
Replacewornor damagedParts
4th qear thrust clearance
t. MEasurethe clearancebetween4th gearand the ball
bearing.
Clearance:0.22-0.52mm (0.009-0.020 lr)
Maxlmum:0,57mm(0.022in)
checkthecontact
exceedsthemaximum,
2. lf theclearance
and clutchhub
gear,
bearing,
ball
4th
surfacesof the
(3rd/4th).Replacewornor damagedparts
Disassembly Noie
Bealing (sth)
1. Placethe primaryshaflgearin a vrse
Noie
. Use protectfuePlatesin the iaws ot lhe vlse'
2. Removethe bearingwiththe SST.
4ih gear and 5th geat
1 lnsrallthe 4th oearwrththe SST.
Cauilon
. Holdthe shaftwith one handso that lt does not fall'
the 4th gearand sth gearwiththe SST
2. Flemove
Clutch hub assembly(3rd/4lh),synchronizerring (3td)
and 3rd gear
Caution
. Holdthe shaftwith one handso that it does nottall.
ring.
1. Bemovethe retaining
(3rd/4th)'
synchronizer
2. Removethe clutchhubassembly
gear
SST
with
the
(3rd)
and
3rd
ring
J-22
J
TRANSAXLE
Bea ng
Note
. Use protectlve plalea In ihe laws ol the v|se.
Removethe bearingwiththe SST.
J-23
J
TRANSAXLE
Secondary Shaft Assembly
to Preinspectlon.
1. Measutethe thrustclearanceof 1st gear,2nd gear,and sth gear,relerring
in the ordershownin the figure,referringto DisassemblyNote.
2. Disassemble
NEPLACE
N€PLACE
ring
12.Synchronizer
1. Bearinginne. race(5th)
pageJ-26
Note.......................
pageJ-25
Disassembly
Note.......................
Disassembly
page
J-27
1nspection....................................
Inspectfor damageand roughrotation
(1sv2nd)
hub
assembly
13.
Clutch
ring
2. Retaining
pageJ-26
Note.......................
Disassembly
3. Washer
pageJ 29
(5th)
Inspection.......-............................
4. Clutchhub assembly
ring
.......pageJ-26 14.Synchronizer
Note................
Disassembly
pageJ-26
I n s p e c t i o n . . . . . . . . . . . . . . . . . . . p. .a. .g. e
.J. .-.2. .9. . . - . . Disassemb|y................................
pageJ-27
1nspection....................................
ring
5. Synchronizer
gear
p
a
g
e
15.
2nd
J
2
7
fn s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pageJ-29
Inspection.....................-..............
6. sth gear
spring
I n s p e c t i o n . . . . . . . . . . . . . . . . . . .p
. .a. .g. e
.J. . .2. 9. . . . .16.
. . Synchronizer
17.Clutchhub sleeve(sth)
ring
7. Retaining
pa]e J 27
Inspection..................................
8. Bearinginnerrace(1st)
key
page
Note....................... J-26 18.Synchronizer
Disassembly
19.Clutchhub (sth)
lnspectfor damageand roughrotatpn
spring
20.
Synchronizer
gear
L Pinion
pageJ-26 21.Clutchhub sleeve(1st/2nd)
Note.......................
Disassembly
pageJ-27
fnspection....::...............................
Inspectgearteethfor damage,wear,and
key
22.Synchronizer
cracks
23.Clutchhub (1sv2nd)
10.1stgear
shaft
page
24.Secondary
J-26
Note.......................
Disassembly
p
a
g
e
I
n
s
p
e
c
t i o n . . . . . . . . . . . . . . . . . . .p. a
. .g. .e.J. .2. .9. . . . . . .
J
2
9
Inspection....................................
ring
11.Retaining
J-24
J
TRANSAXLE
Prelnspectlon
lsi gear thrust clearance
1. Measurethe clearancebetween1stgearand the pinion
gear.
Clearance:0.22-0.62mm (0.008-0.024 In)
Itaximum: 0.67mm(0.026in)
2. lf theclearance
exceedsthemaximum,
checkthecontact
surfaces
olthe lstgear,piniongearofthesecondary
shaft
gear,andclutchhubassembly
(1sv2nd).
Replace
wornor
damagedparts.
2nd gear lhrusi clearance
1. Measure
theclearance
between2nd gearandsecondary
3rd gear.
Clearance:0.06-0.2lmm (0.002-0.008 in)
Maximum:0.26mm(0.010in)
2. lf theclearance
exceedsthemaximum,
checkthecontact
surtaces
ol the2nd gear,secondary
3rd gear,andclutch
(1sy2nd).
hubassembly
Replace
wornor damagedparls.
slh gear lhru9t clearance
1. Measure
the clearance
betweensth gearand secondary
4th gear.
Clearance:0.06-0.2lmm (0,002-0.008 in)
Maximum:0.26mm(0.010in)
2. lf theclearance
exceeds
themaximum,
checkthecontact
surfacesof the sth gear,secondary
4th gear,and clutch
(sth).Replacewornor damagedparts.
hub assembly
Disassembly Note
Bearinginner race (5th)
Caution
. Holdthe shaftwith one handso that it doesnot tall.
1. Setthe SST to the sth gear.
2. Removethe bearingouterracewitha suitablepipe.
Pipe diameter:20mm(0.79 in)
J-25
J
TRANSAXLE
Clutch hub assembly (sth)
Nole
. Removethe clulch hub assembly(sth) as lollows
ll necessary.
1-lnstallthe SST as shownin the figure.
(sth)usinga press
2. Removethe clutchhub assembly
Bearlnginner race (lsl), pinion gear' l3l gear
Caullon
. Hold the shaft with one hand so that lt does not tall.
'1. Setthe SST to the 1stgear'
2. Removethe b€aringinnerracewitha suiiablepipe
Plpe diameter:20mm(0'79 in)
Clutch hub assembly(lsu2nd), synchronizerring
Note
. Removethe cluich hub assembly(15u2nd)as tollows if necessary.
1.lnstallthe SST as shownin the figure
(1s 2nd)usinga press
the clutchhubassembly
2. Remove
J-26
J
TBANSAXLE
INSPECTION
Inspectall partsand repairor replaceas necessary.
Clutch releasecollar
Inspecttheclutchrelease
collarfor roughness
or noisewhile
turning.
Synchronizerring
Note
. Setthe synchronizerring squarelyin lhe geanthen
measurearoundthe clrcumlerence,
1. l\,leasurethe
ringand
clearance
between
thesynchronizer
lianksurfaceof the gear.
Standardclearance:1.5mm(0.059in)
Minimum:0.8mm(0.015In)
2. Inspectthe
ringteethfor damage,wear,and
synchronizer
cracks.
3. lnsoectthe taoersurfacefor wearor cracks.
Shift tork, clulch hub sleeve
1. Measurethe clearance
betweenthe shiftfork andclutch
hub sleevegroove.
Standardclealance
(1st/2nd):0.100-0,358mm(0.004-0.014 in)
(3rd/4th): 0.150-0.458mm(0.006-0.018 in)
(5th)
: 0.150-0.458mm(0.006-0.018 In)
Maximum(1st/2nd):0.408mm(0.0i6 in)
(3rd/4th):0.508mm(0.020in)
(sth)
:0.508mm (0.020In)
J-27
J
TRANSAXLE
Pdmary Shatl
3FD GEAB
Note
. ll the prlmary shaft is replaced, adiust the bearing
pretoad.(Relerio PageJ-39.)
1. Inspectthe primaryshaftrunout
Maximumrunout: 0.0lsmm (0.0005in)
2. Inspectthe splinestor damageand wear.
3. Insbectthe gearteethfor damage'wear,and cracks
4. Inspectthe oil passagefor blockage.
3rd gear, 4th gear
'1.l\,leasure
the clearancebetweenthe shaftand gears
mm(.n)
B
A
3rd gearsideA
4th geff side B
Shaftsrde
(outerdiameleo
32.945-32.970
(1.297- 1.298)
2A.545-28.570
0 .123-1.125)
Ge side
(innerdiamelet
33.000-33.025
(1.299-1.30O)
[email protected]
l1.126-1.127)
coneslor weat.
2. Inspectthe synchronizer
3. Inspectthe gearteethfor damage,wear'andcracKs.
ringand
of the synchronizer
surfaces
4. Insbectthe Contact
gear
and
cracks
for wear
the 3rd/4th
Bearing
Insoectthe bearingior damageor roughrotation.
J-28
0rFoJx063
J
TRANSAXLE
SeaondaryShafl
Nole
. ll the secondaryshatt is replaced, adiust the bearing preload.(Reterio pageJ-39.)
1. Inspectthe secondary
shaftrunout.
Maximumrunout: 0.015mm(0.001in)
2. Inspectthe splinesfor damageand wear.
3. Inspectthe gearteethfor damage,wear,and cracks.
4. Inspectthe oil passagefor blockage.
1st gear, 2nd gear, sth geal
betweenthe shaftand the qear.
1. Measurethe clearance
mm (in)
2nd gearsideB
39.945-39.970
(1.573-1 .574)
Gearside
(nnerdiameter)
33.000-33.025
(1.299-1 .30O)
40.000-40.025
(1.575-1.576)
sth seff side C
28.545 28.570
11.124- t .125J
24.604-24.62-l
lt.126-1.127)
Shaltside
(olter diameled
32.945-32.970
11.297-1 .294)
2. Inspectthe synchronizer
conesfor wear.
3- Inspectthe gearteethfor damage,wear,and cracks.
ol the synchronizer
ringand
4. Inspectthe contactsurfaces
the l st/2ndand sth oearfor wearand cracks.
Clutch hub aaaembly
1. Inspectthe clutchhubsleeveand hub operation.
2. Inspectthe gearteethfor damage,wear,and cracks.
keyfor damage,wear,andcracks.
3. Inspeclthe synchronizer
J-29
J
TRANSAXLE
ASSEIIIBLY
Precaution
i. lil-O;i;a. and gasketsmustbe replacedwiththe newonesincludedin the overhaulkit'
cleanbeforeassembly
2. Veritythatall pansare completely
applyingsealant
minutes
after
10
within
"3. Assehbboans
wnhoil'
be{oretillingthe lransaxle
at leastgo minuiesaftErassembrv
"A;;ti;cure
;ffi;il
assemDly
an
replaced
as
4. A bearingouterraceand bearinginnerracemuslbe
olEoJx.o6s
Clutch hub assembly
Note
. Synchlonizerring diametelsare as follows.
mm (ln,
--_=_-
@
1st
55.7(2.r93)
?nd
3rd and 4lh
5th
55.7 {2.193)
49.7(r.954
4 3 . 7\ 1 7 2 O )
. Synchronizerkey dlmensionsare as tollows.
o
1sv2nd
17.00(0.669)
3tdl4th
14.00(0.551)
1 4 . 0 0( 0 . 5 5 1 )
@
4 25 (0.r67)
4.25(0.164
4 25\0.16n
5.00(0.r 97)
5.00(0.197)
5.00(0194
keyspringsin theclutchhubwith
1. lnstallthe svnchronizer
keys
to holdthethreesynchronizer
thehooksinthegrooves
In p|ace.
SYNCHRONBEB RING
KEY
SYNCHRONIZEF
J-30
ringgrooveswiththesynchronlzer
2. Alignthe synchronizer
key duringassembly.
J
TRANSAXLE
secondaryShaft Assembly
Assemble
in the ordershownin the figure,reierringto AssemblyNote.
BEAFINQINNEFRACE,
YI
@
RETAINING
FIING,NEW
'1-Secondary
shaft
2. Clutchhub (1sv2nd)
key
3- Synchronizer
4. Clutchhub sleeve
5. Synchronizer
keyspring
6. Clutchhub
7. Synchronizer
key
8. Clutchhub sleeve(5th)
key spring
9. Synchronizer
10.2ndgear
pageJ-32
Note............................
Assembly
11.Synchronizer
ring
pageJ-32
Assembly
Note............................
12.Clutchhub assembly(1sl2nd)
pageJ-32
Assembly
Note............................
13.Synchronizer
ring
pageJ-32
Assembly
Note............................
@E
AEAFINGINNER
ring
14.Relaining
15.1stgear
pageJ-32
Note............................
Assembly
gear
16.Pinion
pageJ-32
Note............................
Assembly
17.Bearinginnerrace(1st)
..... pageJ-32
Assembly
Note...............
ring
18.Retaining
pageJ-33
Note............................
Assembly
gear
19.5th
ring
20.Synchronizer
(sth)
21.Clutchhub assembly
-..- pageJ-33
Assembly
Note........................
22.Washer
23.Retaining
ring
24.Bearinginnerrace(sth)
pageJ-33
Note............................
Assembly
J-31
J
TRANSAXLE
Assembly note
2nd gear, synchronlzerrino
shaftas shown
the2nd gearto the secondary
1.Asaemble
in thefigure.
ring.
the synchronizer
2. Assemble
I
&
Y
Clutch hub as€embly(lsu2nd), synchronizerfng
shaft
to thesecondary
1.Assemble
theclutchhubassembly
as shownin the{igure.
ring.
the synchronizer
2. Assemble
Caution
.lnstall the clutch hub assembly(lsi/2nd) wlth a
presa It necessary.
. Align the synchlonizerdrg gloove and leverse gear
key groove when installing.
1st gear
shaftasshowninthe
Assemble
the 1stgearto thesecondary
figure.
Caulion
. Alignthe synchronizerring grooveand clutch hub
assemblykey when Installing.
Piniongear, bearinginner race (lst)
Caution
. Replacethe bearing inner race lf removed.
shatt.
1.Supportthe 4th gearof the secondary
2. Inslallthe olainend ol piniongearwiththe bonomup.
3. SetlheSSTto thenewbearinginnerraceasshowninthe
fagure.
J-32
J
TRANSAXLE
Rstainingrlng
Cautlon
. Roplacethe retalning ng ll removed.
1. Installthe retainingring.
2. Measurethe clearancebetweenthe retaininoring and
secondary
shaftgroove.
Clearance:0-0.1mm (0-0.004 in)
3. ll notasspecilied,
selecttheproperretaining
ringfromthe
chartbelowand installit.
Retainingring thickness:
mm (in)
2.0 (0.079)| 2.1 {0.082)| 2.2 (0.086)| 2.3(O.O9O)
| 24 (0.094)
Clutch hub assembly(5th)
Installthe clutchhub assembly
ontothe secondary
shaft.
Note
. Installthe clutch hub assembly(sth) wilh a press
it necessary.
Bearlng Inner race (5th)
Cautlon
. Replace the bearlng Inner race it removed.
1.Supportthe lst gearof thesecondary
shaftandpressthe
bearinginnerraceon.
2. Installthe
newbearinginnerraceusingtheSSTandpress,
as shownin the figure.
3. lvleasure
the clearancebetween1stgearandthe pinion
gear.
in)
Clearance:0.22-0.62mm (0.008---{t.024
Maximum:0.57mm(0.025in)
J-33
TBANSAXLE
between2nd gearandtheseconthe clearance
4. Measure
dary3rd gear.
Clearance:0.06---0.2lmm(0.002-0.008 In)
Itaxlmum: 0.26mm(0.010in)
betweensth gearandthe secon'
the clearance
5. Measure
dary4th gear.
Clearance:0.06-0.21mm (0.002-0.008 in)
Itaxlmum: 0.26mm(0.010In)
J-34
TRANSAXLE
J
PrlmaryShaft Assembly
As.semble
in the ordershownin the figure,referringto AasemblyNote.
RETAINING
FIN6, NEW
1.Clutchhub (3rd/4th)
2. Synchronizer
key
3. Clutchhub sleeve
4. Synchronizer
keyspring
5. Primaryshaft
6. Bearing('1st)
pageJ-36
Assembly
Note............................
7. 3rd gear
8. Synchronizer
ring
(3rd/4th)
9. Clutchhub assembly
pageJ-36
Assembly
Note............................
10.Retaining
ring
11.Synchronizer
ring
pageJ-36
Assembly
Nole............................
12.4th gear
pageJ-36
Assembly
Note............................
13.sth gear
pageJ-36
Assembly
Note............................
'14.Sleelball
pageJ-37
Assembly
Note............................
15.Spacer
pageJ-37
Assembly
Note............................
16.Bearing(sth)
pageJ-37
Assembly
Note............................
ring
17.Retaining
pageJ-37
Assembly
Note............................
J-35
J
TRANSAXLE
Asssmblytlote
Bearing(lst)
wth a Press
Install
thebearing
---
t-
Clutch hub assembly(3rd/4th)
ontothe primaryshaft
i. Fressthe clutchhu6 assembly
il!,1\
OILGFOOVE
Caution
. lliqn the svnchronlzerring grooveand clutch hub
assiemblylieys (3rd,/4th)when Installing'
2. Alignhe clutchhubandshaltgearsplineandtheninstalling'
*re@69
Synchronizerring, 4th gear
nng and clutchhub assembly
1. Installthe synchronEer
(3rd/4th).
2. Installthe 4th gear.
5th gear
Caution
. ltion tne svnctrronizelring grooveand clutch hub
ass;embly*eys (3rd/4th)whsn installlng'
'1.Alignthe clutchhub and primaryshaftsplines'
2. Pressthe sth gearon
J-36
TRANSAXLE
J
Steel ball, spacer
Holdthe steelballwitha finger,and installthe spacer.
Bearing(sth)
C€ution
. Replacethe ball bearingif removed,
Installthe ballbearingwiththe SST and a press.
Retainingring
Caution
. Replacethe relainingring it removed,
1. lnstallthe retaining
ring.
2. Measure
theclearance
betweenretaining
ringandtheprimaryshatt.
Clearance:0-0.1mm (0-0,004 in)
3. lf notasspecified,
ringfromthe
selecttheproperretaining
chartbelowand installit.
Fetainingring
mm (in)
2.0 (0.079)I 2 r (0082 | 22 (0.086)| 2.3 (0.090)| 2.! (0094)
Note
. Thelollowing Inspectlonis to verity properassem.
bly ol lhe primaryshatt.
. ileasure the clearancebetweenthe 3rd gear and
2nd geal. (Reterto page J-22.)
. Measurethe clearancebetweenthe 4th gear and ball
bearing.(Referto page J-22.)
J-37
J
TRANSAXLE
Clutch Housinqand Tlansaxle CaseComponents
lo BearlngPreloadAdiustmenl
shim(s).reterrrng
L selectthe adiusiment
to AssemblyNote
frgule
reterring
in
the
in
shown
2. Assemble ihe order
case
1-Transaxle
shrm
2. Adjustment
. .5.
A s s e m bN
l yo i e . . . . . . . . . . . . . . . . .p. .a. .g. e.J. .' 4
(differential)
race
Bearing
outer
3.
- .e.J. .4. .5.
A s s e m bN
l yo t e . . . . . . . . . . . . . . . . .p. .a. g
4. Oil seal(difierential)
pageJ-45
-.......
Note....................
Assembly
shim
5. Adjustment
pageJ 45
Assembly
Note............................
shaft)
6. Bearingouterrace(secondary
pageJ-45
Note............................
Assembly
/ FUnnel
pageJ-46
.............
AssemblyNote...............
8. Adjustmenishrm
. AssemblyNote.........................-..
page J-46
passage
9. Oil
10.Clutchhousing
11.Bushang
12.Oil seal
J-38
13.Bearingouterrace(dilterential)
pageJ-46
Note............................
Assembly
14.Oil seal(ditferential)
pageJ-46
Note.........................
Assembly
15.Funnel
pageJ-47
Note............................
Assembly
shatt)
16.Bearingouterrace(secondary
pageJ-47
Note............................
Assembly
'17.Oil seal(primaryshaft)
. ....pageJ-47
Note.....................
Assembly
(change
rod)
18.Oil seal
pageJ-47
Note.............-..............
Assembly
19.Boot
-. pageJ-47
Note..........................
Assembly
20.Changerod
arm
21.Change
22.Rollpin
pageJ-48
Note............................
Assembly
23.Bleeder
24.Batfleplate
J
TRANSAXLE
Adiustmenishim selection
Selectthe shim(s)as follows.
Primaryshaft assembly
1. Setthe primaryshaftassemblyintothe clutchhousing.
2. Installthe
transaxle
caseto theclutchhousingandtighten
the boltsio the soecified
torque.
Tighteningtorque;
19-26 N.m(1.9-2.6 m-kg, 14-19 ftlb)
hanoerandmeas'
3. l\4ount
a dialindicalorto the transaxle
urethe primaryshatlthrustclearance.
Clearance:0-0.lmm (0-0.004 In)
Caution
. Do nol use more than three (3) shims.
4. Selectthecloseslshimon thethinsidefromthetabletor
of the primaryshatt.
adiustment
Adiustmenlshim thickness:
0 30 (0.012)
I
0 40 (0.016)
|
0 50 100r9)
Secondaryshalt assembly
Caution
. Do nol install lhe secondaryshafl shim.
. Applypetroleumielly to preventthe shimllom falling when installinEii.
1- Removethe transaxle
caseand installthe properadjust'
mentshimfor the orimarvshafi.
2. lnstalltheprimaryshaftgearassembly
andthesecondary
shaftgearassembly.
Do not installthe secondaryshaftshlmat thistime.
3. Shiflthe gearsto 4th gear.
J-39
J
TRANSAXLE
caseto theclutchhousingandtighten
4. lnstallthetransaxle
torque
the bohsto the specified
Tiohteninqiorque:
d.F
ig-zs-Hm {i.s-z.s m-rs,14-19tt'lb)
\ic
thestad5. SettheSSTontotheprimaryshaftandmeasure
wrench
torque
with
a
ing torque
Sta inq torque:
o-ra7 N.m(o-15 m-kg, o-1oB fi-lb)
I
rA
\
caseand the bearingouterrace'
6. Removethe transaxle
andthebear'
duringdisassembly
shimremoved
7. lnstallthe
ino outerrace.
6
,1-
Caution
. Verifvthal the primaryshatt canbe turnedby hand
atteriightenina lhe transaxlecase bolts'
the startingtorquewitha torque
8. Usinothe SST measure
proper
shimif thestadingtorqueis
the
select
wren;hand
greaterthanin SteP4.
Caulion
. oo not use mote than two (2) shims.
Adlustmentshim lhickness:
0.30(0.011)
0.50(0.020)
J-40
0.35(0.013)
0.55(0.021)
0.40(0.016)
0.60 {0.023)
mm (in)
0.45(0.0r8)
TRANSAXLE
J
Dltterenllal
'1.Removethe bearingouterracestromthe transaxle
case
and removethe adjustment
shims.
Note
. Turn A and B untilthe gap (anow)in lhe tigu.e is
eliminated,
2. Installthe differential
sidebearingouterraceto the SST
(selector).
3. Setthe bearingouterraceanddiiferential
assemblyintothe
clutchhousino.
4. Setthe bearingouterraceandSSTontothe differentialassemblyas shownin the fagure.
5. Slidethe transaxle
caseoverthe ditferential
assemblv
J-41
J
TRANSAXLE
6. SettheSST(collals) betweenthetransaxlecaseandclutch
shownin the figure.
housingin the positions
torque
7. Tightenthe SST (bolt set) io the specjfied
Tiqhtenlnqtorque:
ls-ze-Nm (i.9-2.6 m-kg,14-19 fi'lb)
Note
. Turn the bars until the SST (seleclor)no longer
iurns,
andturn
8. Mountthebarson parts@ and@ oftheselector,
the selsctorso the gap is widened.
9. Turnin the reversedirectionuntilthe gap is eliminated.
pinionshaftthroughthe
10.Installthe SSTto the difterential
case.
transaxle
01EoJX,115
J-42
J
TRANSAXLE
@t@
Note
. Procedurework with a pull scale.
. Procedure12 work wilh a torque wnench.
11.Turnthe SSTwitha pullscale.Adjusithe SST(preload
adapter)untilthe specifiedpreload.
@
Preload:0.5--0.7 N.m(5-7.6 cm-kg, 4.3-6.6 inlb)
Puffscafe:500-760 g (17.7-26.8 ozl
12.TurntheSSTwithatorquewrench.
AdjusttheSST(seleclor) withthe barsuntilthe specifiedpreloadis obtained.
Preload:0.5-0.7 N.m(5-7.6 cm-kg, 4.3-6.6 In-lb)
13.BemovetheSST.
14.Measurethegap aroundthe entirecircumference
of the
SST (seleqtor).
15.Selectthe properadjustment
shim(s)to be usedfor the
ditferential
by referring
to thetableand selecting
theshim
(onthethickside)to thelargestmeasured
whichis nearest
in the selector.
clearance
Adiustmentshim lhickness:
0.10(0.004)
0.35(0.014)
0-25(0.010)
0.80(0.031)
16.RemovetheSST (bolts).
17.Removethetransaxle
caseandthe SST (collars).
'18.
RemovethebearingouterracefromtheSST(selector).
't9 Installthe selectedshim(s)and bearingouterraceto the
case.
transaxle
J-43
J
TRANSAXLE
20. Measurethe preloadasfollows.Setthe differentialassembly intothe clutchhousing.
01E0JX-121
21. lnstallthe kansaxlecaseontothe clutchhousing
Tlght€ningtorque:
t9-26 N.m(1.9-2.6 m-kg, 14-19 ft-lb)
sidegearthroughthetrans22. InstalltheSSTto thedifferential
axle case.
Note
. Procadurc 23 work wilh a pull scale'
. Prccedure24 work with a iorque wrsnch.
23.Turnthe SST (preloadanachmet ) witha pullscale
Readjustthe SST (prsload adaptor) until the specified
preloadwhennotapply.
Preload:0,5-0.7 Nm (5-7.6 cm-kg, 4'3-6.6 innb)
Pull scale: 500-760 g (17.7-26'8 oz)
!:1
t/
@
J-44
24.Turnthe SST witha torquewrench.
Readjustlhe SST (Preload adaptor) until the specified
preloadwhen not aPPlY.
Pleload:0.5-0.7 l,l'rn(5-7.6 cm-kg, 4.3-6'6 in'lb)
25.Removethe SST.
26. Removethe transaxlecase and then the ditferentialassemory.
TRANSAXLE
J
Assembly Noie
Adiustmer shlm and bearing outer racc (dltferential)
shimand newbearingouterraceinto
1. Setthe adjustment
the lransaxlecase.
2. Aftermountingthe
clutchhousingontolhetransaxle
hanger, tap in the diffe.entialbearingouter raceswith a hammer untilit is llushwiththe end of thetransaxle
case.
Pipe diametsr:59mm(2,32 ln)
Oll seal (ditterential)
Caution
. Apply transaxleoil to the outet circumfercnceol the
oil seal,
lnstallthe newoil sealwiththe SST.
\
Adiustment shim, bearlng ouier race (secondaryshaft)
shimandbearingouterraceintothe
1. Installthe
adjustment
clutchhousing.
2. Aftermounting
theclutchhousingontothetransaxle
hanger, tap in the difterentialbearingouterraceswith a hammeruntilit is flushwiththe end ol the clutchhousinq.
Plpe dlametel:47mm(1.85 in)
J-45
J
TRANSAXLE
Adlustmentshim and tunnel (Primaryshaft)
1. lnstailthe tunnelintothe transaxecase
Pipe diameter:40mm (1.57 in)
shim(s).
2. Installthe adjustment
Oll seal (ditlerential)
-4
r-J
Caution
. Apply transaxleoil to lhe outer clrcumGl€nce of the
oll seal.
lr_:
lnstallthe newoil sealwiththe SST.
Bearlng outer race (differential)
1. Instaithe bearingouterraceintothe clutchhousing-
--\R
$,\o,-
hang'
theclutchhousingontothetransaxle
2. Aftermounting
with
a
hamraces
bearingouter
er, tap in the differential
housing
clutch
end
of
the
flush
with
the
meruntilit is
\m#
4PY
\
J-46
Pipe diameter:59mm(2.32 in)
J
TRANSAXLE
Funneland bea.ing outer race (secondaryshafl)
Note
. lnstall the tunnel which has the extra hole.
1.Setthefunneland
bearing
outerraceintotheclutchhousing.
pipeuntilitisful
2. Tapthebearingouterracewitha suitable
ly seatedin the clutchhousing.
Plpe diameter:50mm ('1,97in)
Oil seal (primaryshalt gear)
Caution
. Apply transaxleoil to lhe outer qircutnlerencaol lhe
oil seal.
lnstallthe newoil sealwitha suitablepipe.
Pipe diameter:38mm(1.50 in)
Oil seal (changerod)
Cautlon
. Apply transaxleoil to ihe outer circumferenceol the
oil seal.
Tapthe newoil sealin untilit is lullyseated.
e\\r
\
\
u
<-,2
.\--
l\
t -
-J,,-
Change rod and boot
1. lnsEllthe changerod and bootintothetransaxle.
2. Fitthe bootoverthe seal.
Cautlon
. lnstall the boot wlth the air bleed downwardas
shown in the ligure.
J-47
,J
TRANSAXLE
Roll pln
lnsialithe new rollpin as shownin the tigure.
J-48
TRANSAXLE
J
i,EMO
J-49
J
TRANSAXLE
HousingParts
to AsaemblyNote
ljsemo-tein theordershownin theiigurereferring
r20-29
(2.oJ,0,1s-22)
t i
(3.6-5.3,
q
(2.0-3.0,
fl e-^
q02.-r5
{\\
(2..--3.€r
\
@
NEW
J-50
17__61
TRANSAXLE
1.Clutchhousingassembly
2. Differentialassembly
3. Primaryshaftgearassembly
pageJ-52
Note............................
Assembly
gear
assembly
shaft
4. Secondary
A s s e m bN
l yo t e . . . . . . . . . . . . . . . . .p. a
. .g. .eJ. .-.5. .2.
5. Reverseshittlever
pageJ 52
Note..........
Assembly
6. Oring
7. Reverselevershalt
pageJ 52
Assembly
Note..........
tJ Htn
9. Rollpin
10.Reverseidlershaff
'11.Reverseidlergear
pageJ-52
Assembly
Note............................
12.Leverset sprrng
13.Shiftfork(1sv2nd)
pageJ-52
-......................
Assembly
Note.....
14.Shiftrod (1st/2nd)
pageJ-52
Assembly
Note............................
15.Bollpin
Note..........
Assembly
PageJ-52
pin
16.interlock
pageJ-52
Assembly
Note..........
17.Shiftfork (sth/Rev)
pageJ 53
Assembly
Note..........
18.Shiftrod end (sth/Rev)
Note..........
Assembly
PageJ-53
pin
19.Interlock
pageJ-53
Assembly
Note..........
20.Shiftrod (sth/Rev)
pageJ-53
Assembly
Note..........
21.Follpin
pageJ 53
Assembly
Note..........
pin
22.Roll
pageJ-53
Note..........
Assembly
pin
23.lnterlock
pageJ-53
Note..........
Assembly
24.Shittfork (3rdi4th)
Note..........
Assembly
PageJ-53
J
25.Shitirod end (3rd/41h)
pageJ 53
Assembly
Note............................
(3rd/4th)
26.Shiftrod
pageJ 53
Assembly
Note............................
27.Rollpin
pageJ-53
Assembly
Note............................
28.Rollpin
pageJ-53
Assembly
Note............................
29.Plug,spring(3rd/4th),
steelball
30.Baseplateunit
31.Crankleverassembly
32.Cranklevershaft
33. Retalning
ring
pageJ-54
Assembly
Note............................
34. N4agnet
35.Transaxle
caseassembly
pageJ-54
Assembly
Note............................
36-EnginemountNo.1
37. Plug,spring('lsv2nd,sth/Bev),steelball
pageJ-54
Assembly
Note............................
38.Drainplug
39.Back-uplightswitch
40. Neutraiswitch
41.Oilseal
pageJ 55
Note............................
Assembly
gearsleeve
42.Speedometer
43.OJing
44.Drivengear
45.Rollpin
pageJ-55
Assembly
Note..........
..................
46.Speedometer
drivengear assembly
47.Clutchreleasecollar
pageJ-55
Assembly
Note............................
release
tork
48.Clutch
pageJ-55
Note..........
..................
Assembly
49.Clutchlever
pageJ-55
Assembly
Note............................
50.Returnspring
51.Transaxle
J-51
J
TRANSAXLE
Assembly Note
Primary ahalt gear assembly and secondary shatt gear
assembly
shaft
andthesecondary
Inslallthebdmaryshattgearassembly
gearassembly
together.
Reverse shift lever, reverse lever shalt
oil to the newO-ringandtheninslallthe
1. Applytransaxle
reverselevershalt.
reverselereverseshiftleverandtheninstallthe
2. Installthe
ver shaft.
3. Inslallthe newpin.
Reverse idler gaar
Installthe reverseidlergearand the reverseidlershalt.
Shift rod (l sU2nd),shift fork (l su2nd), roll pin, interlock
pin
Caution
. The mark 0ndicated by the atrow in the llgure) and
theshin rod end mountlngbolt hole must be in the
aamedirection.
'l. ,nstallthe shittiork and the shiftrod.
Caution
. WhenInstallingthe roll pin, be caretulnot to dam'
age the shlft rod.
2. Installthe newrollpin.
3. Installthe interlockpin.
J-52
J
TRANSAXLE
Shift rod (slvRev), shitt fork (sth/Rev),
shltt rod end (5th/Fev),roll pin, inte ock pin
Caution
. lnstalllhe intedockpln into the holeof clutchhousing as shown in the flgure.
shiflrod.
1. lnstallthe
interlock
Dintotheshiftrodandinstallthe
Cautlon
. Wheninstallinglhe roll pin, becaretul not to damage the shift rod.
Note
Shifl lork {sth/Rev)
Shifl rod end (slh/Rev)
Diameter
Length
s.0(0.20)
s.0(0.20)
22l9.8n
20 (0.79)
2. Installthe new rollpin.
3. lnstallthe interlockpin.
Shift rod (3rd/4th), shift lork (3rd/4th),
shift rod end (3rd/4th),roll pin
Caution
. Installthe interlockpin inlo the holeot clutchhou&
ing as shown in lhe llgure.
pintofte shiftrodandinstallthe
shiftrod.
1. Installthe
interlock
Caution
. WhenInstallinglhe roll pin, be caletul not to damage the shift rod.
2. Installthe new rollpin.
J-s3
J
TRANSAXLE
Retainingring
1. lnstallthe crankleverand installthe cranklevershaft.
Caution
. Verify the in3tallinga retalningring 6urely.
. lnstal the groove of crank lever shalt to the diftereF
tlal end.
2. Installthe newretainingring.
3. Shiftthe gearsto 3rd gearand holdthe shiftrod withone
handso thatit doesnol fall.
Transaxlecase assembly
Note
. Tightenlhe bolts to the specifiedtorque.
1. Applysealantand installthe lransaxlecase.
ENGINEMOUNT No.l
Caution
. When installingthe transaxlecase,install the englnemountNo.l.
caseto the clutchhousing.
2. lnstallthe transaxle
Tlghteningtorque:
i9-26 N.m(1.9-2.6 m-kg, 14-19 ft-lb)
Plug, spring, steel ball
'1. Applysealantto the
Plugs.
2. Installthe geel balls,springsand plugs
torque:
Tiqhtenlnq
-20-2tN.m
i2.O-3.0 m-kg, 14-22 ftlb)
sp ng
@
o
Oiametermm {in) Lensh mm (n)
22.5 (0.89)
7.2 lO.2A)
33.2(r.31)
7.2 10.28)
22.5(0.89)
7.2 /{0.28)
whenshitted.
smoothly
operates
thatthetransaxle
3. Contirm
transaxle.
the
If not,reassembly
J-54
TRANSAXLE
J
Oil seal
gearsleevein a vice.
1. Placethe speodometer
gearsleeveus2. Tap the newoil sealintothe speedometer
ing a suitablepipe.
Pipe diameter:15mm{0,59 in)
Folt pln
Installthe newrollpin as shownin the figure.
1-
Clulch releasefork, clutch releaaecolol
Applygreaseas shownin the figure.
"=
Clutch lever
1. Applygreaseto the bushing.
fork.
2. lnstallthe clutchleverto the clutchrelease
Tighteningtorque:
35-41 Nm (3.6-4.2 m-kg, 26-30 fi-lb)
J-55
J
TRANSAXLE
INSTALLATION
1. Raisethe vehicleand supportwithsaletystands
2. Installin the ordershownin the lighre.reflerringto InstallationNole
3. Ado the specitiedamountol the specitiedlransaxleojl (Referto pageJ-7 )
a. Warmup ihe engineand transaxle,and inspectfor oil leakageand trasaxleoperation
3r --45 (4.2-4,7, 23--.34)
€!t
huz
32-56
(3.4-s.7,
6a--a,---:6
J-56
&-trif"l',.'-."
J
TRANSAXLE
1. EnginemountNo.2
2. Iransaxle
pageJ-57
Note........
lnstallation
3. Stittner
4. Exhaustpipe bracket
5. Enginemountmember
pageJ-57
installationNote........
6. Staner
7. Driveshatt
pageJ-58
Installation
Note..........................
8. Controlrod
pageJ-58
lnstallation
Note..........................
bar
9. Extension
pageJ-58
lnstallation
Note..........................
10.Neutralswitchconnector
11.Back-uplightswitchconnector
'12.Clutchcable
pageJ-58
lnstallatlon
Note..........................
11
qno6.l^mal6r
^.h16
pageJ-58
lnstallation
Note..........................
14. Battery,batterycarrier
15.Splashshied
16.Wheeland trre
Installation Note
Transaxle
on a jackand lift it intoplace.
1. Setthe transaxle
2. lnstalllhe transaxlebolts.
@rj&{r@
Tighteninglorque
A: 64-89 N.m(6.5-9.1 m-kg, 47-66 ft-lb)
Bt 7.3-11 N.m(0.8-l.l n-kg, 5.8-8.0 ft-lb)
Enginemount member
1. Installthe boltsand nutsas shown.
Tightenlngtorque
@: 64-89 N.m(6.5-9.1 m-kg,47-66 ft-lb)
@: 37-52 N.m(3.8-5.3 m-kg,28-38 ft-lb)
Caution
. BetoF installthe enginemountmember,pul engine
mount No.1and No.2studs in the installlnghole.
2. Removethe SST (Eqine support).
J-57
J
TRANSAXLE
Ddveshaft
f\rt")
Cautlon
. Verlty that the oil seal is not damaged.
. Do not damagethe oil seal.
'1. Insertthe newclipwiththeend-gapat thetop otthegroove
2. Apply transaxleoil aroundthe oil seal lip lnstallthe
driveshaft.
is correctlyseatedby pullingon
3. Veritythatthedriveshaft
the shaft.
4. Connect
thelowerarmto theknuckleandtightentheclinch
bolt.
<\
*
Tighteningtorque:
43-54 N.m(4.4-5.5 m-kg, 32-40 tt-lb)
Extenslon bar and conlrol rod
barto the transaxle.
1. lnstallthe extension
Tightenin9torque:
31-46 Nfl (3.2-4.7 m-kg, 23-34 fr'b)
2. Installthe changecontrolrod to the transaxle.
Tighteningtorque:
16-23 N.m(1.6-2.3 m-kg, l2-17 ft'lb)
Clulch cable
Installthe clutchcable.(Referto SectionH.)
Speedometercable
amountoi the specifiedkansaxleoil
1. Add the sDecified
hole
drivengearinsiallation
thoughtthe speedometer
drivengear.
2. lnstallthe speedometer
Tighteningtorque:
7.8-12 Nm (0.8-1.2 m-kg, 5.8-8.7 ft-lb)
driv'
cableto the speedometer
3. Connectthespeedometer
en gear.
J-58
J
DIFFERENTIAL
DIFFERENTIAL
PNEPARATION
SST
49 8017 2A0
@
49 DO27002
@@@
@@@
(Partof
49 80172A0)
49 F40l 366A
bearins
49 0839 425C
oeafrng
49 80172A0)
beanng
49 0439 428
49 0862 426
bearingpuller
bearingpuller
49 0839 425C)
49 0839425C)
49 D017 241
49 F401 3374
4 9 D 0 1 72 A l )
J-59
J
DIFFERENTIAL
/ ASSEMBLY
/ INSPECTION
DISASSEMBLY
Caqtion
. Do not remove the inner race il not neoessary'
'1.Beforedisassembly,
inspectthe backlashol sidegears'referflngto Preln6P€ctlon
in the ordershownin the figure.rete(ingto Disa$embly Note'
2. Disassemble
parts
and repairor replaceas necessary
3. Inspectall
referring
to Backlashol Pinlon Geara
afterassembly,
the
backlash
Me;sure
4.
'wa
..-'4b,
Tffi.
'1.Sidegear
lnspectfor wearand cracks
2. Washer
3. Rolipin
pageJ-61
Note.......................
Disassembly
4. Pinionshaft
5. Thrustwasher
J-60
6. Piniongear
Inspecttor wearand cracks
7. Sidebearingannerrace
..........pageJ-61
Note...........
Disassembly
Inspectfor wearand cracls
drivegear
8. Speedometer
gear
and gearcase
9. Ring
Inspecttor wear and cracl$
J
DIFFERENTIAL
Preinspection
Backlash ol pinion geals
Measurethe backlash
as follows.
intothe ditferential
1. Installthe leftand rightdriveshafts
assemDly.
the backlash
ol bothpiniongears.
2. lMeasure
Backlash: 0-0,1mm (0-0.004 in)
Maximum:0.5mm(0,020In)
is notas soeciiied,
replacethedifierential
3. lf the backlash
as an assemoty.
v€LocK
DisassemblyNote
Roll oin
Caution
. use prolectiveplatesin the vbe.
. Insenlhe punchinto the roll pin holellom the rlng
gear slde.
Securethe gearcasein a viceand tap outthe rollpin.
Slde bearinginner race
Cautlon
. Whenreplacinga bearing,replac€the innerand outer taces as a set,
drivegear
1. Removethe bearinginnerrace(speedometer
side)withthe SST.
01EoJXj75
2. Removethebearinginnerrace(ringgearside)wilhtheSSI.
BEABINGINNER
J-61
J
OIFFERENTIAL
Assembly
drivegearas shownintheligure
1. Installthespeedometer
Cautlon
. Wtlen replacinga bearing,replacelhe inner and outer races as a set.
2. Installthe newbeannglnnerrace.
drive
(1) Installthenewbearinginnerrace(speedometer
SST
gearsjde)witha Pressandthe
(2) Installthenewbearinginnerrace (ringgearside)with
a pressand the SST.
3. Setthe piniongearsandthrustwasherintothegearcase
4. Insertthe pinionshaft.
J-62
DIFFERENTIAL
J
5. Installa new roll pin and stakethe caseto preventit from
workinoout.
6. Installthe sideoearsand washers.
Backlashof PinionGears
Recheckthe backlashol the piniongears.
(Referto pageJ-61.)
J-63
J
SHIFTIIECHANISM
SHIFTMECHANISM
OVERHAUL
in the ordershownin the figure.
1. Disassemble
2. Inspectall partsand repairor replaceas necessary.
referringto AssemblyNote
in the reverseorderof disassembly,
3. Assemble
16-26 0.6-2.3, t2-t4
J-64
SHIFTMECHANIS]II
1.Shiftleverknob
2. Ashtray
3. Frontconsole
4. Boot
5. Nut
6. Washer
7. Bolt
8. Nut
9. Bolt
10.Controlrod
Inspectfor bending
AssemblyNote............................
pageJ-66
11.Bushing
Inspectfor wear and damage
12.Nut
13.Washer
14.Washer
15. Nut
'16.Washer
17.Extension
bar
Inspectfor bending
pageJ-66
Assembly
Note............................
J
18.Washer
19.Pipe
20.Bushing
Insp€ctfor wearand damage.
21.Insulator
Inspectfor damageandcracks
22. Bushing
Inspecttor wearand damage
23. Boot
Insp€ctfor damage
24.Spring
Inspectfor damageand weakness
pageJ-66
Assembly
Note............................
(upper)
25. Ball seat
26. Boot
Inspectfor wearand damage
27. Holdel
28. Ball seat bwer)
29.Shiftlever
olEoJxr86
J-65
J
SHIFTiIECHANISM
Asso|nbly Note
Sprlng
'1.Applygreaseto the spnng.
2. Aisemblethe springas shownin the ligure
Extensionbar
the insulator
to the bracketol theexensionbar
1. Assemble
and installthe nutsand washers.
thento ihe body.
barto thetransaxle,
2. Connecltheextension
Tighteninglorque
Tranaaxle:
5.9-8.8 N{n (0.6-0.9 m-kg, 4.3-6.5 ft-lb)
Shlft lever:
31-45 Nm (3.2-4.7 m-kg, 23-34 finb)
Control rod
1. Installthe controlrod.
2. Verifysmoothoperalionof the shiftmechanlsm
01E0JX-149
J-66
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