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1994 Mazda 626/MX-6 Workshop Manual FOREWORD A thorough familiarization with this manual is important for proper repair and maintenance. It should always be kept in a handy place for quick and easy reference. The contents of this manual, including draw­ ings and specifications, are the latest availa­ ble at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the righ: to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical— "eluding photocopying and recording and the use of any kind of information storage and retrieval system—without permission in writing. WARRANTY The manufacturer’s warranty on Mazda ve­ hicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer. CONTENTS Title General Information Pre-Delivery Inspection and Scheduled Maintenance FS Engine KL Lubrication System FS Cooling System FS KL KL FS (MTX) Fuel and Emission Control Systems KL FS (ATX) Engine Electrical System Clutch Manual Transaxle G25M-R Automatic Transaxle GF4A-EL LA4A-EL Front and Rear Axles Steering System Braking System Wheels and Tires Suspension Body *Body Electrical System * Heater and Air Conditioner Systems Technical Data Special Tools Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page. Wiring Diagram (Form No.5266-10-93G) y y (Part No.9999-95-021G-94) * Refer to the 1994 626/MX-6 Body Electrical Troubl shooting Manual (Form No.1359-10-93G , Pa No.9999-95-084F-94) for servicing of the body electric components. © 1993 Mazda Motor Corporatior Printed in the U.S.A. (6/93) Form No. 1355-10-93G Part No. 9999-95-019B-94 VEHICLE IDENTIFICATION NUMBERS (VIN) 626 1YV GE22C*R5 1 0 0 0 0 1 1YV GE22D*R5 100001 — MX-6 1YV GE31C*R5 100001 — 1YV GE31D*R5 100001 — 1994 Mazda 626/MX-6 Workshop Manual WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury and property damage increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience w I be at less risk when performing servicing operations. However, all users ofThis manual are expected to know general safety procedures. This manual contains "Warnings” and “ Cautions" applicable to risks not normally encountered in a general technician’s experience. They should be followed to reduce the risk of injury and the risk that improper se^. ce or repair may damage the vehicle or render it unsafe. It s a so "iportant to understand that the “ Warnings” and Cautors are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procec^es recommended and described in this manual are effective methods of performing service and repair. Some require tools specif ca resigned for a specific purpose. Nonrecommended procedures arc :ools should include consideration for safety of the technician a^c continued safe operation of the vehicle. Parts shou;d be replaced with genuine Mazda replacement parts, not parts of lesser quality. Use of a nonrecommended replacement part should nclude consideration for safety of the technician and continued safe operation of the vehicle. © 1993 Mazda Motor Corporation Printed in the U.S.A. (6/93) Form No. 1355-10-93G Part No. 9999-95-019B-94 A PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE PRE-DELIVERY INSPECTION..............A - 2 PRE-DELIVERY INSPECTION TABLE............................................... A - 2 SCHEDULED MAINTENANCE.............A - 3 MAINTENANCE TABLE (USA).......... A - 3 MAINTENANCE TABLE (CANADA)... A - 6 INSPECTION AND ADJUSTMENT OF DRIVE BELTS...................................A - 8 ENGINE OIL REPLACEMENT........... A-11 ENGINE TIMING BELT REPLACEMENT............................... A-11 ENGINE OIL FILTER REPLACEMENT............................... A-12 INSPECTION OF COOLING SYSTEM.............................................A—13 ENGINE COOLANT REPLACEMENT............................... A -14 ADJUSTMENT OF IDLE SPEED........A -15 FUEL FILTER REPLACEMENT.........A -16 INSPECTION OF FUEL LINES.......... A -17 INSPECTION OF EMISSION HOSES AND TUBES..................................... A -17 SPARK PLUG REPLACEMENT.........A -17 INSPECTION OF BRAKE LINES, HOSES AND CONNECTIONS.........A -17 INSPECTION OF DISC BRAKE.........A -17 INSPECTION OF DRUM BRAKE...... A -17 INSPECTION OF STEERING OPERATIONS AND LINKAGES...... A -18 BRAKE FLUID REPLACEMENT........A -18 INSPECTION OF FRONT SUSPENSION BALL JOINTS..........A -18 INSPECTION OF DRIVE SHAFT DUST BOOTS...................................A -19 INSPECTION OF PCV VALVE........... A -19 INSPECTION OF BRAKE AND CLUTCH FLUID...............................A -19 INSPECTION OF POWER STEERING FLUID LEVEL.................................. A -20 INSPECTION OF TIRES..................... A -20 TIRE ROTATION................................. A -20 MANUAL TRANSAXLE OIL REPLACEMENT...............................A -20 INSPECTION OF AUTOMATIC TRANSAXLE FLUID LEVEL............ A-21 INSPECTION OF EXHAUST SYSTEM HEAT SHIELD.................................. A -22 INSPECTION OF REFRIGERANT AND A/C COMPRESSOR................ A -22 AIR CLEANER ELEMENT REPLACEMENT...............................A -23 TIGHTENING OF BOLTS AND NUTS ON CHASSIS AND BODY...............A -23 46U0AX-001 A PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE The following items may be done at any time prior to delivery to your customer. EXTERIOR INSPECT and ADJUST, if necessary, the following items to specification: □ Glass, exterior bright metal and paint for damage □ Wheel lug nuts, and locks (if equipped) 8 8 -1 1 8 N-m ( 9 - 1 2 kgf-m, 6 5 -8 7 ft-lbf) □ All weatherstrips for damage or detachment □ Operation of hood release and lock □ Operation of trunk lid, and fuel lid opener □ Door operation and alignment □ Headlight aim INSTALL the following parts: □ Wheel caps □ Power windows (if equipped) □ Heater, defroster and air conditioner at various mode selections (if equipped) CHECK the following items: □ Presence of spare fuse □ Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: □ Pedal height and free play of brake and clutch pedal Clutch pedal Brake pedal UNDER HOOD—ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification: □ Fuel, coolant and hydraulic lines, fittings, connections, and components for leaks □ Engine oil level □ Power steering fluid level □ Brake (clutch) fluid level □ Windshield washer reservoir fluid level □ Radiator coolant level □ Tightness of battery terminals □ Manual transaxle oil level INTERIOR CHECK operations of the following items: □ Seat controls (sliding and reclining) and head restraints □ Folding rear seat □ Door locks, including childproof door locks (if equipped) □ Seat belts and warning system □ Ignition switch and steering lock □ Air bag system using warning light □ Shift-lock system and transmission range sensor switch (ATX only) □ Starter interlock switch (clutch pedal, MTX only) □ All lights including warning, and indicator lights □ Sound warning system □ Horn, wipers, and washers □ Audio system (if equipped) □ Cigarette lighter and clock □ Sunroof (if equipped) □ Power outside mirrors (if equipped) Pedal height mm (in) 186-211 (7.3 2-8 .31 ) (with carpet) 191.5-196.5 (7.54-7.74) (with carpet) Free play mm (in) 5 -1 4 (0.2 0-0 .55 ) 4 -1 2 (0.16—0.47) □ Parking brake 5—7 notches/98 N (10 kgf, 22 Ibf) UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE_________ CHECK the following items: □ Automatic transaxle fluid level ON HOIST CHECK the following items: □ Underside fuel, coolant, and hydraulic lines, fittings, con­ nections, and components for leaks □ Tires for cuts or bruises □ Steering linkage, suspension, exhaust system, and all un­ derside hardware for looseness or damage ROAD TESf~ CHECK the following items: □ Brake operation □ Clutch operation □ Steering control □ Operation of gauge □ Squeaks, rattles or unusual noises □ Emergency locking retractors □ Cruise control system (if equipped) AFTER ROAD TEST CHECK for necessary owner information materials, tools and spare tire in vehicle The following items must be done just before the delivery to your customer. □ Load test battery and charge if necessary □ Adjust tire pressure to specification (Refer to section Q) □ Clean outside of vehicle Volts Load test result □ Install fuses for accessories □ Remove seat and cabin carpet protective covers □ Vacuum inside of vehicle 46 U0AX-041 A—2 SCHEDULED MAINTENANCE A SCHEDULED MAINTENANCE MAINTENANCE TABLE (USA) Schedule 1 (Normal driving conditions) If the vehicle is mainly operated where none of the “ unique driving conditions” apply. Schedule 2 (Unique driving conditions) • Repeated short-distance driving. • Driving in dusty conditions. • Driving with extended use of brakes. • Driving in areas where road salt or other corrosives are used. • Driving on rough or muddy roads. • Extended periods of idling or low-speed operation. • Driving for long periods in cold temperatures or extremely humid climates. 46U0AX-002 o A -3 A SCHEDULED MAINTENANCE Schedule 1 (Normal Driving Conditions) Maintenance Interval Maintenance l t e m ^ \ Number of months or kilometers (miles), whichever comes first 12 24 6 18 30 42 Months 36 12 24 36 kilometers 48 60 84 72 x 1000 Miles 7.5 15 22.5 30 37.5 52.5 45 48 96 60 Engine Engine oil Oil filter Tension of all drive belts Engine timing belt R R Engine timing belt (California) R R R R R R R R R R R R I Replace every 96,000 km (60,000 miles) *2 Inspect at 96,000 km (60,000 miles), and again at 144,000 km (90,000 miles) Replace every 168,000 km (105,000 miles) R R I I Hose and tube for emission Air cleaner Air cleaner element Ignition system Spark plugs Fuel system I*1 R*1 r i I*2 Idle speed *2 Fuel filter Fuel lines and hose Fuel hose (California) I*2 Inspect every 168,000 km (105,000 miles) Cooling system Cooling system Engine coolant 1 R 1 R 1 1 1 1 1 1 1 1 L 1 1 1 1 1 1 1 1 L Chassis and body Brake lines, hoses and connections Disc brakes Drum brakes Steering operation and linkage Front suspension ball joints Driveshaft dust boots Bolts and nuts on chassis and body Exhaust system heat shield All locks and hinges L L L L L L Air conditioner system (if equipped) Refrigerant A/C compressor Inspect the refrigerant amount annually Inspect the operation annually Chart symbols: I : Inspect, and repair, clean, or replace if necessary R : Replace L: Lubricate Remarks: • After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom­ mended intervals. ‘ ‘ This a maintenance is required for all states except California. However we recommend that it also be performed on California vehicles. *2This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover­ age or manufacturer recall liability. 46U0AX-003 A SCHEDULED MAINTENANCE Schedule 2 (Unique Driving Conditions) Maintenance Interval Maintenance l t e m ^ \ Number of months or kilometers Months 4 8 12 16 kilometers 8 16 24 32 x 1000 Miles 5 10 15 20 miles), whichever comes first 20 24 28 32 36 40 40 48 56 64 72 80 25 30 35 40 45 50 44 88 55 48 96 60 R R R R R R R R R R Replace every 4,800 km (3,000 miles (or 3 months) R R R R R R R R R R I Replace every 96,000 km 60,000 miles) *2 Inspect at 96,000 km (60,000 miles), and again at 144,000 km (90,000 miles) Replace every 168,000 km (105,000 miles) R Engine Engine oil Engine oil Oil filter Tension of all drive belts Engine timing belt R (For Puerto Rico) R Engine timing belt (California) Hose and tube for emission R I I*2 Air cleaner I *2 I Air cleaner element R I*2 R Ignition system I Spark plugs R R I I R I R Cooling system Cooling system Engine cooling Fuel system R.i Fuel filter Fuel lines and hoses Idle speed Fuel hoses (California) I*2 r i I* 1 I*1 Inspect every 168,000 km 105,000 miles) Chassis and body Brake lines hoses and connections Drum brakes Disc brakes Steering operation and linkage Front suspension ball joints Driveshaft dust boots Bolts and nuts on chassis and body Exhaust system heat shield All lock and hings 1 1 L L L L L 1 1 1 1 1 1 1 1 L 1 1 L L L L L 1 1 1 1 1 1 1 1 L Air conditioner system (if equipped) Refrigerant A/C compressor Inspect the refrigerant amount annually Inspect the operation annually Chart symbols: I : Inspect, and repair, clean, or replace if necessary. (Inspect, and replace if necessary.... Air cleaner ele­ ment only) R: Replace L: Lubricate Remarks: • After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom­ mended intervals. This a maintenance is required for all states except California. However we recommend that it also be performed on California vehicles. , . *2This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover­ age or manufacturer recall liability. a 46U0AX-004 A—5 A SCHEDULED MAINTENANCE MAINTENANCE TABLE (CANADA) Maintenance Interval Maintenance I t e m " ^ ^ Number of months or kilometers 5 15 20 Months 10 16 24 32 kilometers 8 x 1000 Miles 5 10 15 20 miles), whichever comes first 25 30 35 40 45 50 40 48 56 64 72 80 25 30 35 40 45 50 55 88 55 60 96 60 Engine Engine oil Oil filter Tension of all drive belts Engine timing belt * 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R R 1 R 1 1 1 1 1 1 1 1 R 1 1 1 1 1 1 1 1 R Air cleaner Air cleaner element Ignition system Spark plugs Cooling system Engine coolant level and strength Cooling system for leaks Engine coolant Fuel system 1 Idle speed Fuel lines and hoses Fuel filter PCV valve *2 Emission hoses and tubes 1 1 *2 R 1 1 1 R 1 1 Chassis and body Automatic transaxle fluid level Transaxle oil (MTX and ATX) Driveshaft dust boots Brake lines and hoses Brake and clutch fluid level Brake fluid *3 Disc brakes (front and rear) Rear drum brakes Tire inflation pressure and tire wear Rotate tires Power steering fluid level Steering operation and linkage (Includes four wheel alignment) Suspension components front and rear All chassis and body nuts and bolts Exhaust system heat shield All locks and hinges Washer fluid level Function of all lights 1 1 I I I I I 1 I I I I I I I I R I I I I I I I I I I R I I I I I I I I I I I every 24,000 kilometers or every 15 months I I I I I I I I I I Rotate I I I I I L I I L I I L I I L I I L I I I I I L I I A—6 I I I I I I I I I I I I L I I L I I L I I Air conditioner system (if equipped) Refrigerant A/C compressor I Inspect the refrigerant amount annually Inspect the operation annually L I I L I I I I SCHEDULED MAINTENANCE A Chart Symbols: I : Inspect, and repair, clean, or replace if necessary, and replace if necessary... Air cleaner element only R : Replace or change L : Lubricate Remarks: After 60 months or 96,000 km {60,000 miles), continue to follow the described maintenance and intervals. As for * marked items in this maintenance chart, please pay attention to the following points. *1: Replacement of the timing belt is required every 96,000 km {60,000 miles). Failure to replace this belt may result in damage to the engine. *2: This maintenance operation is recommended by Mazda. However this maintenance is not necessary for emission warranty coverage or manufacturer recall liability. *3: This maintenance operation is recommended by Mazda. 46U0AX-005 A SCHEDULED MAINTENANCE INSPECTION AND ADJUSTMENT OF DRIVE BELTS Inspection (FS) 1. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 2. Verify that the drive belts are correctly mounted on the pulleys. V-RIBBED BELT x o x 46U0AX-006 3. Check the drive belt deflection when the engine is cold, or at least 30 minutes after engine has stopped. Apply moder­ ate pressure 98 N {10 kgf, 22 Ibf} midway between speci­ fied pulleys. Deflection mm (in) /p /s oilN / XPULLEY/ / [ PUMP Limit Used *New 10 7.0--9.0 6.5—7.0 Alternator (0.39) (0.26-0.27) (0.28--0.35) 11 8.0- -9.5 7.5—9.0 P/S, P/S + A/C (0.43) (0.30-0.35) (0.32- -0.37) *A belt that has been on a running engine for less than five minutes. Drive belt y f ---'N '' s '--/CRANK-\ //( A/C ^ SHAFT I'/ COMPRESSOR \ pulley/ ^PULLEY/ 4. If the deflection is not within specification, adjust it. 46U0AX-008 Drive belt tension check Belt tension can be checked in place of belt deflection. 1. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. Tension N (kgf, Ibf) ’ New Used Limit 740-830 500-680 390 Alternator (75-85,170-180) (50-70, 110-150) (40, 88) 590-780 500-680 390 P/S, P/S + A/C (60-80, 140-170) (50-70,110-150) (40, 88) *A belt that has been on a running engine for less than five minutes. 2. If the tension is not within specified, adjust it. A—8 A SCHEDULED MAINTENANCE Adjustment Alternator belt 1. Loosen the alternator mounting bolts A and B and adjust the belt deflection by turning the adjusting bolt C. 2. Tighten the mounting bolts A and B and recheck the defleciton. t m Tightening torque A: 16—22 N m [1.6—2.3 kgf m, 12—16 ft Ibf) B: 32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf) m 46U0AX-010 <8r y p/s o il N A y P/S belt, P/S + A/C belt 1. Loosen the bolt ® and (§) and adjust the belt deflection by turning the adjusting bolt (5). 2. Tighten the mounting bolts ® and (D and recheck the deflection. PUM P \P U L LE Y v r"© y f/ / crank- \ SHAFT I VPULLEY I A/C COMPRESSOR PULLEY Tightening torque ® : 44—60 N m {4.4—6.2 kgf m, 32—44 ft Ibf) (§): 32—46 N m {3.2—4.7 kgf-m, 24—33 ft-lbf) 46U0AX-Q42 (KL) 1. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 2. Verify that the drive belts are correctly mounted on the pulleys. V-RIBBED BELT A A A X A Im s m J O X 16E0AX-013 3. Check the drive belt deflection by applying moderate pres­ sure 98 N {10 kgf, 22 Ibf) midway between the pulleys. Note • A belt is considered “ New” if it has been used on a run­ ning engine for less than five minutes. Set the deflection as specified below. • Check the belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. 46U0AX-043 A -9 A SCHEDULED MAINTENANCE Deflection mm (in) Drive belt Alternator + A/C P/S Used -8.0 -0.31) 6.5--7.5 (0.26--0.29) 7.0--8.0 (0.28--0.31) I I O 00 o Alternator New 6.0—7.0 (0.24-0.27) 5.5—6.5 (0.22-0.25) 6.0—7.0 (0.24-0.27) Limit 9.0 (0.35) 8.0 (0.31) 9.0 (0.35) 4. If the deflection is not within specifications, adjust it. Drive belt tension check Note • Belt tension can be checked in place of belt deflection. • Belt tension can be measured between any two pulleys. 1. Using the SST, check the belt tension. 16E0AX-016 Tension N {kgf, Ibf) Drive belt Alternator Alternator + A1C P/S New Used 690-880 500-680 {70-90, 160-190) (50-70, 110-150) 690-880 500-680 (70-90, 160-190) (50-70, 110-150) 540-680 400-530 (55-70, 130-150) (40-55, 88-120) Limit 440 (45, 99) 440 (45, 99) 340 (35, 77) 2. If the tension is not within specification, adjust it. Adjustment Note • A belt is considered “ New” if it has been used on a run­ ning engine for less than five minutes. Alternator + A/C belt 1. Loosen the idler pulley locknut. 2. Adjust the belt deflection by turning the adjusting bolt. Deflection New: 5.5—6.5mm {0.22—0.25 in) Used: 6.5—7.5mm {0.26—0.29 in) Limit: 8.0mm {0.32 in) 3. Tighten the pulley. Tightening torque: 32—46 N m {3.2—4.7 kgf m, 24—33 ft-lbf) 46U0AX-045 A—10 A SCHEDULED MAINTENANCE Alternator, P/S 1. Loosen the idler pulley locknut. 2. Adjust the belt deflection by turning the adjusting bolt. Deflection New : 6—7mm {0.24—0.27 in) Used: 7—8mm {0.28—0.31 in) Limit: 9.0mm {0.35 in) 3. Tighten the pulley. 46U0AX-046 Tightening torque: 32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf} ENGINE OIL REPLACEMENT 1. Remove the oil filler cap and the oil pan drain plug. 2. Drain the oil into a container. 3. Install a new gasket and the drain plug. Tightening torque: 30—41 N-m {3.0—4.2 kgf-m, 22—30 ft-lbf} 4. Refill the engine with the specified type and amount of en­ gine oil. 46U0AX-011 Oil capacity L (US qt, Imp qt) Engine type Total (dry engine) Engine oil replacement Engine oil replacement (with oil filter) FS 3.7 [3.9, 3.3) 3.3 {3.5, 2.9) 3.5 (3.7, 3.1) KL 4.9 (5.2, 4.3) 3.7 (3.9, 3.3) 4.0 (4.2, 3.5) 5. Refit the oil filler cap. 6. Run the engine and check for leaks. 7. Check the oil level and add oil if necessary. ENGINE TIMING BELT REPLACEMENT Refer to sectios B1, B2. 46U0AX-013 A -11 A SCHEDULED MAINTENANCE ENGINE OIL FILTER REPLACEMENT (FS) 1. Remove the oil filter with the SST. 2. Use a clean rag to wipe off the mounting surface on the engine. 3. Apply a small amount of clean engine oil to the O-ring of the new filter. 46U0AX-014 4. Install the oil filter and hand tighten it until the O-ring con­ tacts the cylinder block. 5. Tighten the filter 1 and 1/6 turns with the SST. Tightening torque: 13.8—17.6 N m {140—180 kgf cm, 122—156 in lb f} 6. Start the engine and check for leaks. 7. Check the oil level and add oil if necessary. Oil filter capacity: 0.2 L {0.21 US qt, 0.18 Imp qt} 46U0AX-015 (KL) 1. Remove the oil filter with the SST. 2. Use a clean rag to wipe off the mounting surface on the oil cooler base. 3. Apply a small amount of clean engine oil to the O-ring of the new filter. 36UOAX-O11 4. Install the oil filter and tighten it by hand until the O-ring con­ tacts the oil cooler base. 5. Tighten the filter 1 and 1/6 turns with the SST. Tightening torque: 13.8—17.6 N m {140—180 kgf cm, 122—156 in lbf) 36U0F2-012 6. Start the engine and check for leaks. 7. Check the oil level and add oil if necessary. Oil filter capacity: 0.3 L {0.3 US qt, 0.3 Imp qt} 46U0AX-016 A—12 SCHEDULED MAINTENANCE INSPECTION OF COOLING SYSTEM Warning • Removing the radiator cap or radiator drain plug while the engine is running or when the en­ gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. Turn off the engine and wait until it is cool. Wrap a thick cloth around the cap and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. After all the pressure is gone, press down on the cap with the cloth and turn the cap to re­ move it. 46U0AX-017 Coolant Level (Engine cold) 1. Verify that the coolant level is near the filler neck of the radiator. 2. Remove the coolant level dipstick from the coolant reser­ voir and verify that the coolant level is between the F and L marks. Add coolant if necessary. Coolant Quality 1. Verify that there is no buildup of rust or scale around the radiator cap, and filler neck. 2. Verify that coolant is free of oil. Replace the coolant if necessary. 49 9 2 0 0 146 Coolant Leakage 1. Connect a radiator tester (commercially available) and the SST to the radiator filler neck. 2. Apply 123 kPa {1.25 kgf/cm2, 17.8 psi) (FS)or103 kPa {1.05 kgf/cm2, 15.0 psi} (KL) pressure to the system. 3. Verify that the pressure is held. If not, check for coolant leakage. 36U0AX-014 A—13 A SCHEDULED MAINTENANCE Coolant Protection Caution • Do not use alcohol or methanol in the cooling sys­ tem. The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Use only ethylene-glycol-based coolant. Caution • Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. 1. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2. Determine the coolant protection by referring to the graph shown. 3. If the coolant protection is not proper, add water or coolant as necessary. Antifreeze solution mixture percentage Coolant protection Above -16 °C (3°F) Above -2 6 °C {—15°FJ Above - 4 0 °C |-4 0 °F ) Volume percentage Water Coolant 65 35 55 45 45 55 Cravity at 20°C (68°F) 1.054 1.066 1.078 ENGINE COOLANT REPLACEMENT Warning • Removing the radiator cap or radiator drain plug while the engine is running or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. Turn off the engine and wait until it is cool. Wrap a thick cloth around the cap and slowly turn it coun­ terclockwise to the first stop. Step back while the pressure escapes. After all the pressure is gone, press down on the cap with the cloth and turn the cap to remove it. Caution • Do not use alcohol or methanol in the cooling sys­ tem. The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Use only ethylene-glycol-based coolant. Caution • Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. A—14 A SCHEDULED MAINTENANCE 1. 2. 3. 4. Remove the radiator cap and loosen the drain plug. Disconnect the oil cooler hoses. (KL) Drain the coolant into a suitable container. Flush the cooling system with water until all traces of color are gone; then, let the system drain completely. 5. Install the drain plug. 6. Fill with the proper amount and mixture of ethylene glycol based coolant by referring to the table above. Coolant capacity FS: 7.0 L {7.4 US qt, 6.2 Imp qt} KL: 7.5 L {7.9 US qt, 6.6 Imp qt} 7. Run the engine with the radiator cap removed until the up­ per radiator hose is hot. 8. With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck. 9. Install the radiator cap. ADJUSTMENT OF IDLE SPEED 1. Warm up the engine to normal operating temperature. 2. Shift the selector lever to P range (ATX) or Neutral (MTX). 3. Turn off all electric loads. • Headlight • Blower • Rear window defroster • Power steering 4. Wait until the coolant fan is stopped. 5. Connect a tachometer to the data link connector terminal IG - as shown. 6. Verify that the idle speed is within the specification. Idle speed (Neutral): 600—700 (650 ± 50) rpm 7. If not within the specification, connect the SST to the data link connector. 8. Set switch A to position 1. 9. Set test switch to SELF TEST. 10. If the SST is not used, connect a jumper wire between the TEN terminal and the GND terminal of the data link con­ nector. 46U0AX-022 11. Adjust the idle speed by turning the air adjusting screw. AIR ADJUSTING SCREW ' Idle speed (TEN terminal grounded): 600—700 (650 ± 50) rpm 12. Disconnect the SST. 46U0AX-023 A—15 A SCHEDULED MAINTENANCE FUEL FILTER REPLACEMENT FUEL PUMP (GREEN) 46U0AX-024 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury. Keep sparks and flames away from fuel. Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the following “ Fuel Line Safe­ ty Procedures.” Fuel Line Safety Procedures Fuel in the fuel system is under high pressure when the en­ gine is not running. A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakage. 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removel. High-pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule. 1. Disconnect and plug the fuel hoses from the fuel filter. 2. Remove the fuel filter and bracket. 3. Install in the reverse order of removal. Tightening torque: 7.9—10.7 N m [80—110 kgf cm, 70—95.4 in Ibf) 4. Verify that the fuel hoses are pushed fully onto the fuel filter nipples. 5. Secure the fuel hoses with clips. 6. Start the engine and verify that the fuel line joints do not leak. A—16 A SCHEDULED MAINTENANCE INSPECTION OF FUEL LINES 1. Check the fuel line fittings, connections and components for leaks. 2. There should be no wetness or stained areas that might in­ dicate leaks. 3. Replace any defective hoses or clips. INSPECTION OF EMISSION HOSES AND TUBES 1. Check the emission hoses and tubes fitings, connections and components for leaks. 2. There should be no wetness or stained areas that might in­ dicate leaks. 3. Replace any defective hoses, tubes or clips. 36U0AX-O29 SPARK PLUG REPLACEMENT Caution • Pulling on the wire part of the spark plug lead may break the wire. To remove the lead, pull only on the boot. 1. Remove and install the high-tension leads carefully. 2. Remove and install the spark plug with a plug socket. 3. Apply anti-seize compound or molybdenum-based lubricant to the spark plug threads. 4. Tighten the spark plug to the specified torque. Tightening torque: 15—22 N-m {1.5—2.3 kgf m, 11—16 ft-lbf) 46U0AX-047 INSPECTION OF BRAKE LINES, HOSES AND CONNECTIONS Check the points below; replace parts if necessary. 1. Cracking, damage or corrosion of the brake hose. 2. Damage to the brake hose threads. 3. Scars, cracks or swelling of the flexible hose. 4. All lines for fluid leakage. 16E0AX-108 INSPECTION OF DISC BRAKE Check the following disc brake components. 1. Check the caliper operation and inspect for leaks. 2. Check the pads for wear. 3. Check the condition and thickness of the disc plate. 46U0AX-048 Limit Brake pad thickness Front: 2.0mm {0.08 in) Rear: 1.0mm {0.04 in) Disc plate thickness Front: 22.0mm {0.87 in) Rear: 8.0mm {0.31 in) A -1 7 A SCHEDULED MAINTENANCE INSPECTION OF DRUM BRAKE 1. Check the wheel cylinder operation and inspect for leaks. 2. Check the linings for wear or damage. 3. Check the condition of the inner surface and the inner di­ ameter of the drum. Limit: Brake lining.................................. 1.0mm (0.04 in) Inner diameter of drum ....... 230.1mm (9.059 in j INSPECTION OF STEERING OPERATIONS AND LINKAGES 1. Check the steering wheel free play. Free play: 0—30mm (0—1.18 in} 2. Check the steering for proper operation and for looseness of the steering housing. 3. Check the steering gear housing and hoses for fluid leak­ age or seepage. 36U0AX-020 BRAKE FLUID REPLACEMENT 1. Remove the brake fluid from the reservoir by using a suc­ tion pump. 2. Fill the reservoir with new brake fluid. Fluid specification FMVSS 116: DOT-3 46U0AX-028 3. Attach a vinyl tube to the bleeder screw and place the oth­ er end of the vinyl tube in a container. 4. Remove all the old brake fluid from the brake lines by loosen­ ing each bleeder screw (one by one) and pumping the brake pedal. 5. Bleed air as described below. Caution • Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off im­ mediately. (1) Jack up the vehicle and support it with safety stands. (2) Remove the bleeder cap and attach a vinyl hose to the bleeder plug. (3) Place the other end of the vinyl tube in a container. (4) Slowly pump the brake pedal several times. (5) While the brake pedal is pressed, loosen the bleeder screw to let fluid and air escape. (6) Repeat steps 4 and 5 until there are no air bubbles in the fluid. (7) Check for correct brake operation. (8) Check to be sure that there is no fluid leakage. Be sure to clean away any spilled fluid with rags. (9) After bleeding the air, add brake fluid to the reservoir up to the specified level. A -1 8 SCHEDULED MAINTENANCE INSPECTION OF FRONT SUSPENSION BALL JOINTS Inspect the front suspension ball joints. INSPECTION OF DRIVE SHAFT DUST BOOTS Check the dust boot on the drive shaft for cracks, damage, grease leakage, and a loose boot band. INSPECTION OF PCV VALVE 1. Verify that the engine coolant temperature is below 20°C {68°FJ. 2. Start the engine and let it idle. 3. Disconnect the PCV valve with the ventilation hose from the cylinder head cover. 4. Block the PCV valve opening. 5. Verify that vacuum is felt. 46U0AX-031 jin J® 46U0AX-032 6. Remove the PCV valve. 7. Blow through the valve from port A and verify that air comes out of port B. 8. Blow through the valve from port B and verify that no air comes out of port A. 9. Replace the PCV valve if not as specified. A -1 9 A SCHEDULED MAINTENANCE SERVICES INSPECTION OF BRAKE AND CLUTCH FLUID Check fluid level in reservoir.The level should be between the Max. and Min. lines on the reservoir. If the fluid level is extremely low, check the brake system for leaks. 16E0AX-110 INSPECTION OF POWER STEERING FLUID LEVEL Check the fluid level on the reservoir. The level should be between the “ HIGH” and “ LOW” lev­ el. Add fluid if necessary. Fluid specification: ATF Dexron®n or M-m 36U0AX-032 INSPECTION OF TIRES Inspection and Adjustments Check the following and adjust or replace as necessary. 1. Air pressure Check the air pressure of all tires, including the spare tire, with an air pressure gauge. (Refer to section Q.) Measure the pressure when the tires are cold. 46U0AX-049 2. Tire wear Remaining tread Ordinary tires: 1.6mm {0.063 in) min. Snow tires: 50% of tread (Tire should be replaced if wear indicators are exposed.) WEAR INDICATOR vvcam INDICATOR 3. Check damage, cracks or foreign matter (metal pieces, nails, stone, etc) in the tire and cracks or damage to the wheel. 4. Air leakage from the valve. 16E0AX-127 TIRE ROTATION To prolong tire life and assure uniform tire wear, rotate the tires as specified below. After rotating the tires, adjust each tire to the specified air pressure. (Refer to page Q-2.) USA: Every 6,000 km {3,750 miles) Canada: Every 24,000 km {15,000 miles) or 15 months (whichever comes first) 46U0AX-033 A -2 0 A SCHEDULED MAINTENANCE SERVICES MANUAL TRANSAXLE OIL REPLACEMENT 1. Visually check the manual transaxle for oil leakage. If leak­ age is found, check for the cause, and repair. 2. Remove the drain plug with washer. 3. Drain the oil into a suitable container. 4. Install a new washer and the drain plug. Tightening torque: 40—58 N m {4.0—6.0 kgf m, 29—43 ft-lbf] 5. Remove the oil level plug with washer add the specified amount and type of oil through the oil level plug hole until the level reaches the bottom of the oil level plug hole. Specified oil Grade: API Service GL-4 or GL-5 Viscosity: All-season SAE 75W-90 Above 10°C {50°F} SAE 80W-90 Capacity: 2.7 liters (2.9 US qt, 2.4 Imp qt) 6. Install a new washer and the oil level plug. Tightening torque: 40—58 N m {4.0—6.0 kgf-m, 29—43 ft-lbf} INSPECTION OF AUTOMATIC TRANSAXLE FLUID LEVEL 1. Place the vehicle on a flat, level surface. 2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling. 3. Warm up the engine until the ATF reaches one of the fol­ lowing temperatures. 60—70°C (140—1 5 8 °F )...............................GF4A-EL 66—77°C (150—1 7 0 °F )...............................LA4A-EL 4. While depressing the brake pedal, shift the selector lever to each range (P—L), pausing momentarily in each range. 5. Shift back to P. 16E0KX-052 6. Ensure that the ATF level is between MAX. and MIN., if necessary. RANGE ATF type: Dexron®n or M -m ...................... GF4A-EL COOL 46U0AX-036 A—21 A SCHEDULED MAINTENANCE ATF type: MERCON®H or M -m .................. LA4A-EL DO NOT DRIVE MARK MIN. MIX. I I !> r DON’T ADD IN THIS AREA '-T_l FLUD LEVEL AT NORMAL OPERATING TEMPERATURE 6 6 °C — 77°C (1 5 0 °F — 170°F) 46U0AX-050 INSPECTION OF EXHAUST SYSTEM HEAT SHIELD 1. Visually check the exhaust system insulator for damage. 2. Replace it if necessary. 36U0AX-025 INSPECTION OF REFRIGERANT AND A/C COMPRESSOR Checking Refrigerant Amount 1. Close the front windows. 2. Start the engine and run it at 1,500 rpm. 3. Follow the procedures in the table to determine the refriger­ ant amount condition. Sl(3 H T GL/ASS w 46U0AX-037 1 1. Turn ACS to ON and blower switch to fourth position. 2. Press REC switch and VENT switch to ON. 3. Set TEMP lever to MAX COLD. 4. Verify that A/C compressor is operating and observe refrigerant condition in sight glass. Turn off A/C compressor by us­ ing ACS and observe refriger­ ant condition in sight glass. 2 Sight glass /ffv K *— \ \ ° ° / .— Is. / S f r © i— N y— v / °o aJ °CD Q) i Procedure © Step Action Too much or proper amount of refrigerant Go to step 2 Bubbles present Insufficient refrigerant Check refrigerant pressure Cloudy Insufficient refrigerant Check refrigerant pressure ^ Iear immediately after A/C compressor turned off; bubbles appear and then disappear Too much refrigerant Check refrigerant pressure Bubbles appear and then disappear Proper amount of refrigerant Check refrigerant pressure Clear No refrigerant Check refrigerant pressure 46U0AX-038 A -2 2 SCHEDULED MAINTENANCE Checking Refrigerant Pressure 1. Close the front windows. 2. Install the manifold gauge set. 3. Start the engine and run it at 1,500 rpm. 4. Turn the ACS to ON and set the blower switch to the fourth position. 5. Press the REC switch and VENT switch to ON. 6. Set the TEMP lever to MAX COLD. 7. Verify that the pressure readings of the manifold gauge are in the shaded zones. 8. If the pressures are not as specified, refer to the table and repair the system. (Refer to the 1994 626/MX-6 Body Elec­ trical Troubleshooting Manual, section G.) 9. If the pressures are normal, inspect the control system. REFRIGERANT PRESSURE kPa (kgf/cm2) 20 (1,961) jf 18 (1,765) HIGH-PRESSURE SIDE V • , s ' 16 (1,569) X s ' 14 (1,373) 12 (1,177) 10 (98 1 ) . jis r ■ 2.5 (24 5 ) A LOW-PRESSURE SIDE 2.0 (19 6 ) 1.5 (147) 1.0 (9 8 ) ( °F ) 68 77 86 95 104 °C 20 25 30 35 40 AMBIENT TEMPERATURE 46U0AX-039 AIR CLEANER ELEMENT REPLACEMENT 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution • Cleaning the element with compressed air will re­ duce the element’s ability to filter air. Don’t use compressed air to clean the element. 2. Replace the element if necessary. TIGHTENING OF BOLTS AND NUTS ON CHASSIS AND BODY 1. Tighten all seat mounting bolts. 2. Retighten any loose nuts and bolts on the chassis and body to the specified torque. 36U0AX-024 B1 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. \ ENGINE (FS) INDEX................................................. B 1- 2 OUTLINE........................................... B 1- 3 SPECIFICATIONS........................... B 1 - 3 TROUBLESHOOTING GUIDE.......... B 1- 3 ENGINE TUNE-UP.............................B 1 - 5 PREPARATION............................... B 1- 5 ENGINE O IL...................................B 1- 5 ENGINE COOLANT........................B 1- 5 DRIVE BELT...................................B 1- 6 HLA TROUBLESHOOTING GUIDE.......................................... B 1- 7 COMPRESSION................................ B 1 - 8 INSPECTION...................................B1— 8 ON-VEHICLE MAINTENANCE.........B 1- 9 PREPARATION............................... B 1- 9 TIMING BELT................................. B 1- 10 CYLINDER HEAD GASKET........... B 1 - 16 HLA................................................. B 1 - 22 FRONT OIL SEAL.......................... B 1 - 24 REAR OIL SEAL............................ B 1- 26 REMOVAL.......................................... B 1- 29 PROCEDURE................................. B 1- 29 ENGINE STAND MOUNTING.......... B 1- 37 PREPARATION............................... B 1- 37 PROCEDURE................................. B 1- 38 DISASSEMBLY................................. B 1- 40 PREPARATION............................... B 1- 40 AUXILIARY PARTS.........................B 1- 42 TIMING BELT................................. B 1- 43 CYLINDER HEAD.......................... B 1- 46 CYLINDER BLOCK (EXTERNAL PARTS)....................B 1- 49 CYLINDER BLOCK (INTERNAL PARTS)..................... B 1- 52 INSPECTION / REPAIR....................B 1 - 57 PREPARATION...............................B 1 - 57 CYLINDER HEAD..........................B 1- 57 VALVE MECHANISM.....................B 1- 58 CAMSHAFT....................................B 1- 61 HLA................................................. B 1- 63 CYLINDER BLOCK.........................B 1- 64 PISTON, PISTON RING, AND PISTON PIN................................. B 1- 66 CONNECTING ROD...................... B 1- 67 CONNECTING ROD BOLT........... B 1- 68 MAIN BEARING CAP BOLT.......... B 1 - 68 CRANKSHAFT................................B 1- 68 BEARING....................................... B 1- 69 TIMING BELT................................. B 1- 69 TENSIONER....................................B 1- 69 IDLER............................................. B1— 70 TENSIONER SPRING..................... B 1- 70 PULLEY..........................................B 1- 70 ASSEMBLY....................................... B 1 - 71 PREPARATION...............................B 1- 71 CYLINDER BLOCK (INTERNAL PARTS).....................B 1- 73 CYLINDER BLOCK (EXTERNAL PARTS)....................B 1 - 79 CYLINDER HEAD..........................B 1 - 84 TIMING BELT................................. B 1- 89 AUXILIARY PARTS.........................B 1- 94 ENGINE STAND DISMOUNTING .... B 1- 98 PROCEDURE................................. B 1 - 98 INSTALLATION................................B1-101 PROCEDURE................................. B1-101 46U0B1-103 B1 INDEX INDEX (3 ) HLA INSPECTION, PAGE B 1 -23 COMPRESSION INSPECTION, PAGE B 1 -1 0 STANDARD: 1,177 kPa {12.0 kgf/cm2, 171 psi}-300 rpm MINIMUM: 824 kPa (8.4 kgf/cm2, 119 psi)-300 rpm INTAKE MANIFOLD TIGHTENING TORQUE 1 9 - 2 5 N-m (1.9—2.6 kgf-m, 1 4 - 1 6 ft-lbf} COOLANT, SECTION E1 ENGINE OIL, EXHAUST MANIFOLD TIGHTENING TORQUE NUT: 20—28 N-m (2.0—2.9 kgf-m, 15—20 ft-lbf) BOLT: 16—22 N-m [1.6—2.3 kgf-m, 12— 16 ft-lbf) mm (in) DEFLECTION AT 98 N (10 kgf, 22 Ibf) DRIVE BELT ALTERNATOR P/S, P/S + A/C LIMIT NEW USED 6.5— 7.0 (0.26— 0.27) 7.0— 9.0 ( 0.28— 0.35) 10 (0.39) 7.5—9.0 (0.30—0.35) 8.0— 9.5 (0.32—0.37) 11 (0.43) 46U0B1-104 1. Timing belt Removal / Installation............... page 2. Cylinder head gasket Replacement............................page 3. HLA Removal / Installation............... page 4. Front oil seal Replacement....... .................... page 5. Rear oil seal Replacement............................page B 1 -2 B1-10 B1-16 B1-22 B1-24 B1-26 6. Engine Removal................................ page Engine stand mounting......... page Disassembly.......................... page Inspection / Repair................. page Assembly............................... page Engine stand dismounting....page Installation.............................. page B1- 29 B1- 37 B1- 40 B1- 57 B1- 71 B1- 98 B1-101 B1 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS ------ ------------------------------------Engine Type Item ------------------- - Gasoline, 4-cycle Cylinder arrangement and number In-line, 4-cylinders Combustion chamber Pentroof Valve system DOHC, belt-driven Displacement ml [cm 3, cu in) Bore and stroke mm (in } Compression ratio 1,991 (1,991 121.5) 83.0x92.0 (3.27x3.62) 9.0 Compression pressure kPa (kgf/cm2, psi)-rpm IN Valve timing EX Valve clearance FS mm (in) 1,177 (12.0, 171)-300 Open BTDC 8° Close ABDC 50° Open BBDC 54° Close ATDC 8° IN 0: Maintenance-free EX 0: Maintenance-free 46U0B1-001 TROUBLESHOOTING GUIDE Problem Difficult starting Poor Idling Excessive oil consumption Possible Cause Action Page Malfunction of engine-related components Burnt valve Worn piston, piston rings, or cylinder Damaged cylinder head gasket Replace Replace or repair Replace Malfunction of fuel system Refer to sections F1, F3 Malfunction of ignition system Refer to section G Malfunction of engine-related components Malfunction of HLA* Poor valve-to-valve seat contact Damaged cylinder head gasket Replace Replace or repair Replace Malfunction of fuel system Refer to sections F1, F3 Malfunction of ignition system Refer to section G Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Replace Replace or repair B1-66 B1-64, 66 Oil working down Worn valve seal Worn valve stem or guide Replace Replace B1-48, 84 B1-58 Oil leakage Refer to section D1 B1-58 B1-64, 66 B1-16 B1-22 B1-60 B1-16 * Tappet noise may occur if the engine has set idle for an extended period. The noise should stop after the engine has reached normal operating temperature. (HLA troubleshooting: Refer to page B1-7.) B 1-3 B1 TROUBLESHOOTING GUIDE Possible Cause Problem Insufficient power Abnormal combustion Engine noise Action Insufficient compression Malfunction of HLA* Compression leakage from valve seat Seized valve stem Weak or broken valve spring Damaged cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston Replace Repair Replace Replace Replace Replace Replace Replace Malfunction of fuel system Refer to sections F1, F3 Malfunction of ignition system Refer to section G Others Slipping clutch Dragging brakes Incorrect tire size Refer to section H Refer to section P Refer to section Q Malfunction of engine-related components Malfunction of HLA* Sticking or burnt valve Weak or broken valve spring Carbon accumulation in combustion chamber Replace Replace Replace Eliminate carbon Malfunction of fuel system Refer to sections F1, F3 Page B1-22 B1-60 B1-58 B1-61 B1-16 B1-57 B1-66 B1-66 B1-22 B1-58 B1-61 Malfunction of ignition system Refer to section G Crankshaft- or bearing-related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged Replace or repair Replace Replace of repair Replace or repair Replace B1-74 B1-69 B1-75 B1-78 B1-69 Piston-related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod Replace or repair Replace Replace Replace Replace B1-64 B1-66 B1-66 B1-66 B1-67 Valves or timing-related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Replace Replace Replace B1-22 B1-61 B1-59 Malfunction of cooling system Refer to section E1 Malfunction of fuel system Refer to sections F1, F3 Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage Malfunction of timing belt tensioner Refer to section E1 Adjust Refer to section G Refer to sections F1, F3 Replace B1- 6 B1-10 46U0B1-105 * Tappet noise may occur if the engine has set idle for an extended period. The noise should stop after the engine has reached normal operating temperature. (HLA troubleshooting: Refer to page B1-7.) B 1 -4 ENGINE TUNE-UP B1 ENGINE TUNE-UP PREPARATION SST 49 9200 020 Tension gauge, V-ribbed belt For inspection of drive belt tension 46U0B1-106 ENGINE OIL Inspection 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condition. 5. Add or replace oil if necessary. Note • The distance between the L and F marks on the dipstick represents 1.0 L {1.1 US qt, 0.9 Imp qt). ENGINE COOLANT Inspection Coolant level (Engine cold) Warning • Removing the radiator cap or the coolant drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam can shoot out and cause serious injury. It can also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth - turn it, and remove it. 1. Verify that the coolant level is near the filler neck of the radiator. 2. Remove the dipstick from the coolant reservoir and verify that the coolant level is between the F and L marks. Add coolant if necessary. Coolant quality 1. Verify that there is no buildup of rust or scale around the radiator cap and radiator filler neck. 2. Verify that the coolant is free of oil. 3. Replace the coolant if necessary. 16E0B1-009 B1—5 B1 ENGINE TUNE-UP DRIVE BELT Inspection 1. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 2. Verify that the drive belts are correctly mounted on the pulleys. V-RIBBED BELT a I 16E0B1-010 3. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply moderate pressure98 N {10 kgf, 22 Ibf} midway between the specified pulleys. .M OUNTING BOLT 3 WATER PUMP CRANK­ SHAFT PULLEY MOUNTING BOLT 46L30B1-004 Deflection mm (in) *New Limit Used 10 6.5—7.0 7.0—9.0 Alternator (0.26-0.27) (0.39) (0.28-0.35) 11 7.5—9.0 8.0—9.5 P/S, P/S + A/C (0.43) (0.30-0.35) (0.32-0.37) * A belt that has been on a running engine for less than five minutes. / 3/s oii_N /\ PUMP Drive belt / VPULLEYy V s /X '/'t \ '''s '— /CRANK-\ ,'/ { A/C SHAFT Y' COMPRESSOR ^PULLEY/ ^PULLEY/ 4. If the deflection is not within specifications, adjust it. 46U0B1-005 Drive belt tension check Belt tension can be checked in place of belt deflection. 1. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. N (kgf, ibf) Limit *New Used 390 740-830 500-680 Alternator (40, 88) (75-85, 170-180) (50-70, 110-150) 390 590-780 500-680 P/S, P/S+A/C (60-80, 140-170) [50-70, 110-150) (40, 88) * A belt that has been on a running engine for less than five minutes. 2. If the tension is not within specifications, adjust it. B 1 -6 B1 ENGINE TUNE-UP Adjustment Alternator belt 1. Loosen alternator mounting bolts A and B and adjust the belt deflection/tension by turning adjusting bolt C. 2. Tighten mounting bolts A and B and recheck the deflec­ tion/tension. Tightening torque A: 16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf} B: 32—46 N-m {3.2—4.7 kgf m, 24—33 ft-lbf} P/S belt, P/S + A/C belt 1. Loosen bolts A and B and adjust the belt deflection/tension by turning adjusting bolt C. 2. Tighten mounting bolts A and B and recheck the deflec­ tion/tension. Tightening torque A: 44—60 N m {4.4—6.2 kgf m, 32—44 ft-lbf} B: 32—46 N-m {3 .2 -4 .7 kgf m, 24—33 ft Ib f} HLA TROUBLESHOOTING GUIDE Problem Possible Cause 1. Noise when engine is started immediately after oil is changed. 2. Noise when engine is started after setting approx. one day. Oil leakage in oil passage 3. Noise when engine is started after crank­ ing for 3 seconds or more. 4. Noise when engine is started after new HLA is installed. Oil leakage in HLA 5. Noise continues more than 10 minutes. Insufficient oil pressure Check oil pressure. If lower than specification, check for cause. Oil pressure: 400—490 kPa (4.0—5.0 kgf/cm2, 57—71 psi)-3,000 rpm Damaged HLA (Refer to page B1-22) Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. Action Run engine at 2,000—3,000 rpm. If noise stops after 2 seconds—10 minutes*, HLA is normal. If not, replace HLA. *Time required for engine oil to circulate within engine includes tolerance for engine oil condition and ambient temperature. Measure valve clearance. If more than 0mm (0 in), replace HLA. 6. Noise during idle after high-speed running. Incorrect oil amount Check oil level. Drain or add oil as necessary. Deteriorated oil condition Check oil quality. If deteriorated, replace with specified type and amount of oil. 36U0B1-007 B 1 -7 B1 COMPRESSION COMPRESSION If the engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to section G.) 2. Compression (Refer to below.) 3. Fuel system (Refer to sections F1, F3.) 46U0B1-108 INSPECTION 1. Verify that the battery is fully charged. Recharge it if neces­ sary. (Refer to section G.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool for about 10 minutes. 4. Remove the spark plugs. 5. Disconnect the primary wire connector from the ignition coil as shown. 16E0B1-020 6. 7. 8. 9. Connect a compression gauge to No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Record the maximum gauge reading. Check each cylinder as above. Compression: 1,177 kPa (12.0 kgf/cm2, 171 psi}-300 rpm Minimum: 824 kPa {8.4 kgf/cm2, 119 psi)-300 rpm 10. If the compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, piston rings, or cylinder wall may be worn. (2) If the compression stays low, the valve may be stuck or seated improperly. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 11. Connect the ignition coil connector. 46U0B1-110 12. Install the spark plugs. Tightening torque: 15—22 N m {1.5—2.3 kgf-m, 11—16 ft-lbf} 16E0B1-023 B 1 -8 B1 ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE PREPARATION SST 49 S120 710 Holder, coupling flange 49E011 101 Holder (Part of 49 E0111A1) 49G011 103 Bolts 49 G017 501 Bar (Part of 49 G017 5A0) 49 G017 503 Hook (Part of 49G017 5A0) 49E011 103 Shaft (Part of 49E011 1A0) 49E011 105 Stopper (Part of For prevention of crankshaft rotation 49E011 1A1 For prevention of crankshaft rotation 49 E011 102 Set, holder For prevention of crankshaft rotation Bolts (Part of 49 E011 1A1) For prevention of crankshaft rotation 49 G017 5A0 For support of engine 49 G017 502 For support of engine Support, engine For support of engine Support (Part of 49 G017 5A0) For support of engine 49E011 1A0 For prevention of crankshaft rotation 49E011 104 For prevention of crankshaft rotation For prevention of crankshaft rotation For prevention of crankshaft rotation Brake set, ring gear Collar (Part of 49E011 1A0) 49 0118 850C Puller, ball joint a For prevention of crankshaft rotation For removal of tie rod end 4 9 E 0 1 1 1 AO) 36U0B1-100 B 1 -9 B1 ON-VEHICLE MAINTENANCE TIMING BELT Removal / Installation 1. Disconnect the negative battery cable. 2. Remove the right front wheel. 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to Installation Note. 5.9—7.8 N-m (60—80 kgf-cm, (9) 53—69 ln-lbf) 7.9—10.7 N-m 180—110 kgf-cm, 70—95 ln-lbf I 15—22 (1.5—2.3, 1 1 -1 6 ) 5.9—7.8 N-m 160—80 kgf-cm, 53—69 ln-lbf | ©' 74—102 ( 7.5—10.5, 55—75} 86—116 (8.7—11.9 63—86 7.9—10.7 N-m (80—110 kgf-cm, 70—95 in lbf I 7.9—10.7 N-m (80—110 kgf-cm, 7 0 -9 5 ln-lbf) 3 2 -4 6 (3.2—4.7, 24—33 (4) 6.9—9.8 N-m (70—100 kgf-cm, 61—86 ln-lbf | N-m (kgf-m, ft-lbf) 46U0B1-111 1. Undercover 2. P/S and/or A/C drive belt Inspection.................................page Adjustment...............................page 3. Alternator drive belt Inspection.................................page Adjustment...............................page 4. Pulley shield 5. P/S oil pump and hose Removal Note.......................... page 6. Water pump pulley 7. Crankshaft pulley Removal Note.......................... page Installation Note....................... page 8. Guide plate 9. High-tension lead 10. Spark plug B 1 -1 0 B1- 5 B1 - 6 B1- 5 B1- 6 B1-11 B1-11 B1-15 11. Cylinder head cover Removal Note.................. page B1-11 Installation Note............... page B1-14 12. Dipstick and pipe 13. Timing belt cover, upper 14. Timing belt cover, lower 15. Engine mount No.3 rubber Removal Note.................. page B1-11 Installation Note............... page B1-14 16. Timing belt Removal Note.................. page B1-12 Installation Note............... page B1-12 Inspection........................ page B1-70 17. Tensioner and tensioner spring Inspection........................ pages B1-70, 71 18. Idler Inspection........................ page B1-71 -f ON-VEHICLE MAINTENANCE B1 Removal Note P/S oil pump and hose 1. Remove the P/S oil pump with the hoses still connected. 2. Position the pump away from the engine and affix it with wire. 36U0B1-014 Crankshaft pulley 1. Hold the crankshaft pulley by using the SST. 2. Loosen the crankshaft pulley lock bolt. 3. Remove the crankshaft pulley lock bolt and the crankshaft pulley. 36U0B1-015 1© © (D (D (D (D Cylinder head cover 1. Loosen the cylinder head cover bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head cover bolts. 3. Remove the cylinder head cover. ®= Engine mount No.3 rubber 1. Suspend the engine by using the SST. 16A0B1-096 2. Remove the ground harness. 3. Remove the engine mount No.3 rubber. SiA ? B1—11 B1 ON-VEHICLE MAINTENANCE Timing belt 1. Install the crankshaft pulley lock bolt. 2. Turn the crankshaft to align the matching marks of the pul­ leys as shown. 3. Turn the tensioner clockwise by using an Allen wrench. 4. Disconnect the tensioner spring from the hook pin. 46U0B1-013 Caution • The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bend­ ing it, or allowing oil or grease on it. MARK DIRECTION OF ROTATION 5. When the belt will be reused, mark its rotation for proper reinstallation. 6. Remove the timing belt. 46U0B1-014 7. Check the timing belt for damage, wear, peeling, cracks and hardening. Replace the timing belt if necessary. DAMAGE, WEAR PEELING CRACK 46U0B1-015 Installation Note Timing belt 1. Turn the crankshaft clockwise and align the timing marks as shown. ON-VEHICLE MAINTENANCE B1 Note • The timing marks (grooves) can also be used to align the pulleys. 46U0B1-O16 2. Verify that the camshaft pulley I and E marks are aligned with the cylinder head upper line. 16E0B1-038 3. Install the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys. 16E0B1-379 4. Turn the crankshaft clockwise two turns, and align the tim­ ing marks. 5. Verify that all timing marks are correctly aligned. If not aligned, remove the timing belt and repeat from step 1. 16E0B1-040 6. Turn the tensioner clockwise by using an Allen wrench and connect the tensioner spring to the hook pin. Verify that ten­ sion is applied to the timing belt. 16E0B1-041 B 1-13 B1 ON-VEHICLE MAINTENANCE 7. Turn the crankshaft clockwise two turns, and verify that all timing marks are aligned. If not aligned, repeat from step 1. 16E0B1-042 Engine mount No.3 rubber 1. Install the engine mount No.3 rubber. Tightening torque Bolt: 86—116 N-m {8 .7 -1 1 .9 kgf m, 63—86 ft Ibf} Nut: 74—102 N-m {7.5—10.5 kgf m, 55—75 ft-lbf) 36U0B1-1Q1 2. Install the ground harness. Tightening torque: 64—89 N m {6.5—9.1 kgf m, 48—65 ft-lbf) HARNESS 16A0B1-003 3. Remove the SST from the engine. 49 G 0 1 7 5 A 0 16A0B1-004 Cylinder head cover 1. Apply a bead of silicone sealant as shown in the figure. 2. Install a new cylinder head cover gasket. 16E0B1-364 B 1-1 4 B1 ON-VEHICLE MAINTENANCE 3. Apply silicone sealant to the shaded areas of the cylinder head as shown in the figure. 16E0B1-365 4. Set the cylinder head cover on the cylinder head. 5. Tighten the cylinder head cover bolts in two or three steps in the order shown in the figure. Tightening torque: 5.9—7.8 N m {60—80 kgf cm, 53—69 in Ibf} 16E0B1-046 Crankshaft pulley 1. Install the crankshaft pulley lock bolt. 2. Tighten the crankshaft pulley lock bolt by using the SST. 49 G011 103 49 E 0 1 1 1A 1 Tightening torque: 157—166 N-m {16.0—17.0 kgf m, 116—122 ft-lbf} 49 S 1 2 0 710 16A0B1-005 Steps After Installation 1. Install the right front wheel. 2. Connect the negative battery cable. 3. Perform the necessary engine adjustments. (Refer to sections F1, F3.) 46U0B1-112 B 1-15 B1 ON-VEHICLE MAINTENANCE CYLINDER HEAD GASKET Replacement Warning • Release the fuel pressure. (Refer to Section F1.) • Keep sparks and open flame away from the fuel area. 1. 2. 3. 4. 5. Disconnect the negative battery cable. Drain the engine coolant. Remove the hood. Remove in the order shown in the figure, referring to Removal Note. Install in the reverse order of removal, referring to Installation Note. N-m (kgf-m, ft-lbf j 46U0B1-118 B 1-1 6 ON-VEHICLE MAINTENANCE 1. Undercover 2. Resonance chamber No.1 3. Fresh-air duct 4. Mass airflow sensor connector 5. Intake air temperature sensor connector 6. Air cleaner housing and resonance chamber No.2 7. Accelerator cable Installation Note..................... page B1-21 8. Hose Removal Note........................ ............ below Installation Note..................... .. page B1-21 9. Harness connectors 10. Timing belt Removal / Installation............. .. page B1-10 B1 11. Distributor Installation Note............... ....... 12. Camshaft pulley Removal Note.................. ....... Installation Note............... ....... 13. Camshaft Removal Note.................. ....... Installation Note....................... 14. Intake manifold bracket 15. Cylinder head bolt Removal Note................... ....... Installation Note................ ....... 16. Cylinder head 17. Cylinder head gasket page B1-20 page B1-18 page B1-20 page B1-18 page B1-19 page B1-18 page B1-18 46U0B1-114 Removal Note Hose Disconnect the hoses shown in the figure. HEATER HOSE / I BRAKE VACUUM HOSE 16E0B1-050 B1-17 B1 ON-VEHICLE MAINTENANCE Fuel hose Warning • Cover the hose with a rag because fuel will spray out when disconnected. • Keep sparks and open flames away from the fuel area. Plug the disconnected hoses to prevent fuel leakage. 36U0B1-019 Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lock bolt. 2. Remove the camshaft pulley. 46U0B1-115 X - © ________________ © A y Camshaft 1. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. 2. Remove the camshaft caps. 3. Remove the camshafts. 4. Remove the camshaft oil seals from the camshafts. M 8 r ----16E0B1-054 Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. ^ o ® n o r o ® o © o r © 16E0B1-055 Installation Note Cylinder head bolt 1. Measure the length of each cylinder head bolt below its head. Length Standard: 104.2—104.8mm {4.103—4.125 in) Maximum: 105.5mm (4.154 in) 36U0B1-074 B 1-1 8 ON-VEHICLE MAINTENANCE B1 2. If the length is not within specifications replace the bolt. 3. Apply clean engine oil to the bolt threads and head seat. 4. Install and tighten the cylinder head bolts. (1) Tighten the bolts to the specified torque in the order shown. Caution • Bolts must be tightened fully to prevent leaks and poor compression. 46U0B1-116 Tightening torque: 17.2—22.0 N-m {1.75—2.25 kgf m, 12.7— 16.2 ft-lbf} (2) Make paint marks on the bolt heads, as shown. (3) With the paint marks as a reference point, tighten each cylinder head bolt 85 °—95° in order. (4) Tighten them another 85°—95° in the tightening order 46UOB1-O17 Camshaft mehhbsb^ •' No. 3 C Y L IN D E R S 46UQB1-018 Q ® g ® g© g ® n5® 0® 0 ® £5® 16E0B1-Q60 Revised 2/96 Caution • Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiv­ ing area of the cylinder head journal. To avoid this, the following procedure must be observed. 1. Assemble camshaft onto the cylinder head, facing the cam noses at No.1 and No.3 cylinders as shown. 2. Apply silicone sealant to the areas shown. Keep the cam­ shaft sliding surface free of sealant to prevent engine damage. 3. Apply engine oil to the camshaft and the cylinder head journals. 4. Install the camshaft caps to the positions from which they were removed. 5. Tighten the camshaft cap bolts in two or three steps in the order shown. Tightening torque: 11.3—14.2 N-m {115— 145 kgf-cm, 100—125 in lbf) 6. Verify that the camshaft settles horizontally when two bear­ ing cap bolts at No.3 journal .are tightened. (1994 6 26/M X-6) B1-19 B1 ON-VEHICLE MAINTENANCE 7. Apply a small amount of clean engine oil to the lip of each new camshaft oil seal. 8. Push the oil seal slightly in by hand. 9. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge the camshaft cap. Oil seal outer diameter: 48.0mm (1.89 in) Oil seal inner diameter: 34.0mm {1.34 in } 46UOB1-O19 Camshaft Pulley 1. Install the camshaft pulleys, positioning the dowel pins as shown. DOW EL PIN 16E0B1-Q62 2. Apply engine oil to the lock bolt threads and temporarily tighten the lock bolts. 3. Hold the camshaft by using a wrench on the cast hexagon as shown, and tighten each lock bolt. Tightening torque: 50—60 N-m {5.0—6.2 kgf m, 37—44 ft-lbf} 4 6 7 0 B - 1 17 Distributor 1. Apply clean engine oil to a new O-ring and position it on the distributor. 2. Apply clean engine oil to the drive gear. 3. Align the matching marks as shown. 1 6 E 0B 1 - 06 4 4. Install the distributor and hand tighten the mounting bolts. R e v is ed 2/96 ON-VEHICLE MAINTENANCE B1 Hose Connect the hoses as shown in the figure. 16E0B1-067 Accelerator cable 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.0mm {0.06—0.16 in) 3. If not as specified, adjust the cable free play by turning stop­ per B while pressing lock button A with the throttle valve fully closed. 4. Reset the cable lock. 46UOB1-020 Steps After Installation 1. Install the hood. 2. Connect the negative battery cable. 3. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E1.) 4. Start the engine and check as follows: (1) Engine oil and engine coolant leakage (2) Ignition timing, idle speed (Refer to sections F1, F3.) (3) Operation of emission control system 46U0B1-119 B1-21 B1 ON-VEHICLE MAINTENANCE HLA Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. 46U0B1-120 1. Timing belt Removal / Installation............... page 2. Distributor Installation Note....................... page 3. Camshaft pulley Removal Note.......................... page Installation Note....................... page B 1-2 2 B1-10 B1-20 B1-18 B1-20 4. Camshaft Removal Note.......................... page Installation Note....................... page 5. HLA Removal Note.......................... page Inspection................................ page Installation Note....................... page B1-18 B1-19 B1-23 B1-23 B1-23 B1 ON-VEHICLE MAINTENANCE Removal Note HLA Caution • The HLA must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear. Note • Mark the HLA to show their original positions. 46U0B1-021 1. Remove the HLA from the cylinder head. 2. Store the HLA upside down in an oil-filled container. Inspection 1. Inspect the HLA friction surfaces for wear and damage. Re­ place the HLA if necessary. 2. Hold the bucket body and press the plunger by hand. If the plunger moves, it is defective. Replace the HLA — do not attempt to repair it. 46U0B1-022 Installation Note HLA 1. Apply clean engine oil to the friction surfaces. 2. If the HLA are being reused, install them in the positions from which they were removed. 3. Verify that the HLA move smoothly in their bores. 16E0B1-073 Step After Installation 1. Connect the negative battery cable. 2. Start the engine and check as follows: (1) Engine oil leakage (2) Ignition timing, idle speed (Refer to sections F1, F3.) (3) Operation of emission control system (Refer to section F1.) (4) HLA tappet noise (Refer to page B1-7.) 46U0B1-121 B 1-23 B1 ON-VEHICLE MAINTENANCE FRONT OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. 46U0B1-122 1. Timing belt Removal / Installation............... page B1-10 2. Timing belt pulley Removal Note.....................................below Installation.................................page B1-25 3. Oil seal Removal Note.......................... page B1-25 Installation Note....................... page B1-25 Removal Note Timing belt pulley Note • If necessary, remove the pulley with a steering wheel puller. 1. Remove the timing belt pulley. 2. Remove the pulley key. 46U0B1-023 B1—24 ON-VEHICLE MAINTENANCE B1 Oil seal 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag. Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of the new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the oil pump body. Oil seal outer diameter: 54.5mm (2.15 in] Oil seal inner diameter: 42.5mm (1.67 in) Timing belt pulley 1. Install the timing belt pulley. 2. Install the pulley key. Step After Installation 1. Connect the negative battery cable. 2. Start the engine and check the ignition timing. (Refer to sections F1, F3.) 46U0B1-123 B 1-25 B1 ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. ATX N-m I kgf-m, ft-lbf) 46U0B1-124 1. Transaxle MTX Removal / Installation............... ....section J ATX Removal / Installation............... ... section K2 2. Clutch cover, clutch disc (MTX) Removal / Installation............... .... section H 3. Flywheel (MTX) Removal Note............. Installation Note........... 4. Drive plate (ATX) Removal Note.............. Installation Note........... 5. Oil seal Removal Note.............. Installation Note........... Removal Note Flywheel (MTX) 1. Hold the flywheel by using the SST. 2. Remove the flywheel bolts. 3. Remove the flywheel. 16EQB1-082 B 1 -2 6 ..................... below .......... page B1-27 .......... page B1-27 .......... page B1-28 .......... page B1-27 .......... page B1-27 B1 ON-VEHICLE MAINTENANCE Drive plate (ATX) 1. Hold the drive plate by using the SST. 2. Remove the drive plate bolts. 3. Remove the backing plate, drive plate, and adapter. 16E0B1-083 Oil seal 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag. OIL SEAL LIP 16E0B1-084 Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of the new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the rear cover. Oil seal outer diameter: 109mm (4.29 in) Oil seal inner diameter: 89.0mm (3.50 in) Flywheel (MTX) 1. Remove the sealant from the flywheel bolt holes in the crank­ shaft and from the flywheel bolts. Caution • If all of the old thread sealant cannot be removed from the bolt, it will not torque properly. Replace the bolt. Note • If a new bolt is used, do not apply thread locking seal­ ant. New Mazda bolts have sealant on them. 2. 3. 4. 5. Set the flywheel onto the crankshaft. Apply sealant to the flywheel bolts and install them. Hold the flywheel by using the SST. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 97—102 N m (9.8—10.5 kgf m, 71—75 ft-lbf) 36U0B1-102 B1—27 B1 ON-VEHICLE MAINTENANCE Drive plate (ATX) 1. Remove the sealant from the drive plate bolt holes in the crankshaft and from the drive plate bolts. Caution • If all of the old thread sealant cannot be removed from the bolt, it will not torque properly. Replace the bolt. Note • If a new bolt is used, do not apply thread locking seal­ ant. New Mazda bolts have sealant on them. 2. Install the adapter, drive plate, and backing plate onto the crankshaft. 3. Apply sealant to the drive plate bolts and install them. 4. Hold the drive plate by using the SST. 5. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 97—102 N m (9.8—10.5 kgf m, 71—75 ft-lbf} Steps After Installation 1. Connect the negative battery cable. 2. Start the engine and perform engine adjustments as necessary. 3. Check the oil level. 46U0B1-126 REMOVAL B1 REMOVAL Warning • Release the fuel pressure. (Refer to section F1.) PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant and transaxle oil. 3. Remove the hood and front wheels. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 46U0B1-027 1. Undercover 2. Resonance chamber No.1 3. Fresh-air duct 4. Mass airflow sensor connector 5. Intake air temperature sensor connector 6. Air cleaner housing assembly 7. Air hose 8. Resonance chamber No.2 9. Battery and carrier 10. Accelerator cable 11. Fuel filter 12. 13. 14. 15. 16. 17. 18. Radiator hose ATF cooler hose (ATX) Coolant fan motor connector Coolant reservoir pipe Radiator bracket Radiator and coolant fan assembly P/S oil pump and adjuster Removal Note.......................... page B 1 -3 0 19. A/C compressor (if equipped) Removal Note.......................... page B 1 -3 0 B 1-29 B1 REMOVAL Removal Note P/S oil pump 1. Remove the P/S oil pump with the hoses still connected. 2. Position the pump away from the engine and affix it with wire. 46U0B1-028 A/C compressor 1. Remove the A/C compressor with the hoses still connected. 2. Position the compressor away from the engine and affix it with wire. 46U0B1-029 Step 2 Disconnect the harness connectors. 46U0B1-127 B 1 -3 0 REMOVAL B1 Step 3 Disconnect the hoses shown in the figure. 16A0B1-050 1. Fuel hose Removal Note.....................................below 2. Heater hose 3. Brake vacuum hose 4. Vacuum hose (Purge) Removal Note Fuel hose Warning • Fuel vapor is hazardous. If can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Disconnect the fuel hoses. 46U0B1-128 B1 REMOVAL Step 4 GASKET, NUT, 46U0B1-129 1. Clutch release cylinder (MTX) Removal Note.................... 2. Shift control cable (ATX) 3. Transverse member 4. Engine mount No.5 rubber 5. Engine mount No.2 nuts 6. Engine mount member Removal Note...................... below page B1-33 7. Exhaust pipe 8. Shift control rod (MTX) 9. Extension bar (MTX) 10. Stabilizer control link 11. Tie rod end Removal Note.......... 12. Drive shaft Removal Note.......... page B1-33 page B1-33 Removal Note Clutch release cylinder (MTX) 1. Remove the bolts and clips shown in the figure. Caution • Bending the pipe can cause kinks or cracks. 2. Remove the release cylinder with the hose still connected and position it away from the transaxle. 46U0B1-030 B 1 -3 2 REMOVAL B1 Engine mount member Caution • Support the engine before removing the member. 1. Suspend the engine by using a chain block. 2. Remove the engine mount No.2 nuts. 3. Remove the engine mount member bolts and nuts and re­ move the engine mount member. Tie rod end 1. Remove the cotter pin and loosen the nut so that it is flush with the end of the ball joint stud. Caution • The ball-joint dust boots and oil seals are damaged easily if this procedure is not done correctly. 2. Separate the knuckle arm and ball joint by using the SST. Drive shaft 1. Remove the bolts and nuts from the lower arm ball joints. 2. Pry the lower arm downward to separate it from the knuckles. 3. Separate the drive shafts from the transaxle by prying with a bar inserted between the shaft and the case. (Left side) 46UQB1-033 4. As shown in the figure, insert a pry bar between the drive shaft and the joint shaft and tap on the bar to uncouple them. (Right side) B 1-33 B1 REMOVAL 5. Remove the joint shaft. REMOVAL B1 Step 5 46U0B1-130 1. 2. 3. 4. Engine Engine Engine Engine mount mount mount mount No.1 No.3 No.1 No.1 stay bracket rubber bolts (MTX) (ATX) 5. Engine mount No.4 rubber 6. Engine mount No.4 bracket 7. Engine and transaxle assembly Removal Note.................................... below Removal Note Engine and transaxle assembly Slowly lift the engine and transaxle assembly a unit. Keep the engine from swinging or bumping into compo­ nents in the engine compartment. 46U0B1-034 B 1-35 B1 REMOVAL Step 6 D ATX 46U0B1-131 1. Intake manifold bracket 2. Starter 3. Engine mount No.2 rubber B 1 -3 6 4. Manual transaxle 5. Automatic transaxle 6. Engine assembly B1 ENGINE STAND MOUNTING ENGINE STAND MOUNTING PREPARATION SST 49 0107 680A 1 For disassembly / assembly of engine 49 L010 1A0 For disassembly / assembly of engine 49 L010 102 For disassembly / assembly of engine engine stand i t = 4 49 L010 101 » Plate (Part of 49 L010 1A0) n N? * * y \fi_ . ft / 49 L010 103 Hooks (Part of 49 L010 1A0) O ^ For disassembly / assembly of engine 49 L010 105 49 L010 1A0) For disassembly / assembly of engine S . Arms (Part of 49 L010 1A0) ) I- u 49 L010 104 Nuts (Part of 49 L010 1A0) 49 L010 106 For disassembly / assembly of engine (0 !} For disassembly / assembly of engine For disassembly / assembly of engine ^ L o t o 1A0) ..................... i|ip[i 16E0B1-108 B1 ENGINE STAND MOUNTING PROCEDURE Step 1 Remove in the order shown in the figure. 16E0B1-109 1. P/S oil pump bracket 2. Exhaust manifold insulator 3. EGR pipe 4. Exhaust manifold 5. A/C compressor bracket (if equipped) 6. Thermostat cover 7. Thermostat 8. Water bypass pipes 9. Thermostat housing Step 2 Engine stand Mounting procedure 1. Use the holes shown in the figure. 46U0B1-035 B 1 -3 8 ENGINE STAND MOUNTING B1 2. Install the SST (arms) to the holes as shown in the figure, and hand tighten the SST (bolts). 49 L 0 1 0 106 46U0B1-036 3. Assemble the SST (bolts and plate) in the specified po­ sition. 49 L 0 1 0 105 4. Assemble the SST (nuts, hooks, and bolts). 5. Install the SST to the respective arms. I 49 L 0 1 0 103 fQ i O i * 49 L 0 1 0 104 49 L01 0 101 46U0B1-038 6. Adjust the SST (bolts) so that less than 20mm {0.79 in } of thread is exposed. 7. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 8. Tighten the SST (bolts and nuts) to affix the SST firmly. 9. Mount the engine on the SST (engine stand). 49 0 1 0 7 6 8 0A 46U0B1-040 B 1-39 B1 DISASSEMBLY DISASSEMBLY PREPARATION SST For prevention of crankshaft rotation 49 E011 1A0 Brake set, ring gear rsjapy® 49 E011 104 C0llar (Part of 49 E011 1A0) C ^> ) 49 B012 0A2 49 B012 013 Foot (Part of 49 B012 0A2) X Shaft (Part of 49 E011 1A0) For prevention of crankshaft rotation 6 For prevention of crankshaft rotation 49 E011 105 ^ Stopper (Part of 49 E011 1A0) (a ) \ / \ / W For removal / installation of valves 49 B012 012 For removal / installation of valves 49 B012 014 Body (Part of 49 B012 0A2) For prevention of crankshaft rotation For removal / installation of valves < For removal / installation of valves Locknut 4SHB012 0A2) 49 0636 100A Arm, valve spring lifter 49 E011 103 ....... .. 11// I For removal / installation of valves For removal / installation of piston pins 49 L011 0A0B Tool set, piston pin setting 0 For removal / installation of piston pins 49 L011 001 Body, support block (Part of 49 L011 0A0A) 49 E011 002 Screw 49 E011 001 Guide, piston pin B 1 -4 0 r II Installer, piston jJ . For removal / installation of piston pins (Part of 49 L011 0A0A) J r. <3 N . 49 L011 006 For removal / installation of piston pins 49 H011 001B For removal / installation of piston pins 49 G014 001 Head, support Wrench, oil filter For removal / installation of piston pins For removal / installation of oil filter B1 DISASSEMBLY 49 S120 170 Remover, valve seal — For removal of valve seals — — 46U0B1-041 1. Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed. 2. Clean the parts by using a steam cleaner. Blow dry with compressed air. B1 DISASSEMBLY AUXILIARY PARTS 1. Drain the engine oil. 2. Disassemble in the order shown in the figure. 46U0B1 -042 1. Engine hanger 2. Distributor and high-tension lead 3. Spark plug 4. Intake manifold assembly 5. Drive belt 6. Alternator stay (MTX) 7. Alternator strap B 1-4 2 8. Alternator 9. Alternator bracket 10. Engine coolant temperature sensor 11. Heat gauge sender unit 12. Water outlet 13. Oil filter Removal........................................section D DISASSEMBLY B1 TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B1-132 1. Cylinder head cover Disassembly N ote................... page B1-44 2. Crankshaft pulley Disassembly N ote................... page B1-44 3. Water pump pulley 4. Oil level dipstick and pipe 5. Timing belt cover, upper 6. Timing belt cover, lower 7. Engine mount No.3 bracket 8. Timing belt guide plate 9. Timing belt Disassembly Note.......... . page Inspection....................... • page 10. Tensioner, tensioner spring Inspection....................... . pages 11. Idler Inspection....................... . page 12. Timing belt pulley Disassembly Note.......... • page B1-44 B1-69 B1-69, 70 B1-70 B1-45 B1 DISASSEMBLY Disassembly Note Cylinder head cover 1. Loosen the cylinder head cover bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head cover bolts. 3. Remove the cylinder head cover. 36U0B1-120 Crankshaft pulley 1. Hold the flywheel (MTX) or the drive plate (ATX) by using the SST. 16A0B1-057 2. Remove the crankshaft pulley lock bolt. 3. Remove the crankshaft pully. 36U0B1-121 Timing belt 1. Install the crankshaft pulley bolt. 2. Turn the crankshaft to align the matching marks as shown in the figure. CRANKSHAFT PULLEY LOCK 46U0B1-043 3. Turn the tensioner clockwise by using an Allen wrench. 4. Disconnect the tensioner spring from the hook pin. 46U0B1-044 B 1 -4 4 DISASSEMBLY B1 Note • Mark the timing belt rotation for proper reinstallation. 5. Remove the timing belt. Caution • The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bend­ ing it, or allowing oil or grease on it. 46U0B1 -045 Timing belt pulley 1. Remove the timing belt pulley. 2. Remove the timing belt pulley key. Note • If necessary, remove the pulley by using a steering wheel puller. 46U0B1-046 B1—45 B1 DISASSEMBLY CYLINDER HEAD Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B1-133 1. Camshaft pulley Disassembly Note..... ..... page Inspection.................. ..... page 2. Camshaft Disassembly Note..... ..... page Inspection.................. ..... page 3. HLA Disassembly Note..... ..... page Inspection.................. ..... pages 4. Cylinder head bolt Disassembly Note..... ..... page Inspection.................. ..... page 5. Cylinder head Inspection.................. ..... page B1-47 B1-70 B1-47 B1-61 B1-47 B1-23, 63 B1-47 B1-58 B1-57 6. Cylinder head gasket 7. Valve keeper Disassembly Note............ ...... 8. Valve spring seat, upper 9. Valve spring Inspection......................... ...... 10. Valve Inspection......................... ...... 11. Valve seal Disassembly Note............ ...... 12. Valve spring seat, lower 13. Valve guide Inspection.......................... ...... Replacement..................... ...... page B1-47 page B1-61 page B1-58 page B1-48 page B1-59 page B1-59 B1 DISASSEMBLY Disassembly Note Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley bolt. 2. Remove the camshaft pulley. 46U0B1-134 Camshaft 1. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. 2. Remove the camshaft caps. 3. Remove the camshafts. 4. Remove the camshaft oil seals from the camshafts. 16E0B1-130 HLA Caution • The HLA must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear. Note • Mark the HLA to show their original positions. 46U0B1 -047 1. Remove the HLA from the cylinder head. 2. Store the HLA upside down in an oil-filled container. Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. 16E0B1-132 4 9 0 6 3 6 10 0 A Valve keeper 1. Set the SST against the upper valve spring seat as shown in the figure. 2. Compress the spring and remove the valve keepers. 49 B 012 0A 2 16E0B1-133 B 1-4 7 B1 DISASSEMBLY Valve seal Remove the valve seal by using the SST. 16E0B1-134 B 1 -4 8 B1 DISASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B1-135 1. Water pump 2. Rubber seal 3. Oil pump Disassembly / Assembly............. section D1 4. Front oil seal Disassembly N ote................... page B1-51 5. Clutch cover and clutch disc (MTX) Disassembly N ote................... page B1-50 6. Flywheel (MTX) Disassembly N ote................... page B1-50 7. Backing plate, drive plate, and adapter (ATX) Disassembly N ote................... page B1-50 8. End plate 9. Oil pan Disassembly Note................... page Inspect for damage 10. Oil strainer Disassembly Note................... page Inspect for damage 11. Oil pan upper block Disassembly Note................... page 12. Rear cover 13. Rear oil seal Disassembly Note................... page B1-50 B1-51 B1-51 B1-51 B1 DISASSEMBLY Disassembly Note Clutch cover and Clutch disc (MTX) 1. Hold the flywheel by using the SST. 2. Loosen the clutch cover bolts evenly and gradually. 3. Remove the clutch cover bolts. 4. Remove the clutch cover and clutch disc. 46U0B1-048 Flywheel (MTX) 1. Hold the fly wheel by using the SST. 2. Loosen the flywheel bolts evenly and gradually. 3. Remove the flywheel bolts. 4. Remove the flywheel. Backing plate, drive plate, and adapter (ATX) 1. Hold the drive plate by using the SST. 2. Loosen the drive plate bolts evenly and gradually. 3. Remove the drive plate bolts. 4. Remove the backing plate, drive plate, and adapter. 46U0B1-136 Oil pan 1. Remove the oil pan mounting bolts. Caution • Pry tools can easily scratch the oil pan stiffener and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange. Refer to the fol­ lowing instructions before removing the oil pan. 46U0B1-137 2. Remove the sealant from the bolt threads. 3. Screw an oil pan bolt into the weld nut to make a small gap between the oil pan upper block and the oil pan. 4. Using a screwdriver, pry apart the oil pan and oil pan up­ per block. 5. Remove the oil pan. 46U0B1-138 B 1-5 0 DISASSEMBLY B1 Oil strainer 1. Remove bolt A. 2. Remove bolts B. 3. Remove the oil strainer. Oil pan upper block 1. Remove the two nuts at the rear of the cylinder block. 2. Loosen the oil pan upper block bolts in two or three steps in the order shown in the figure. 3. Remove the bolts. 4. Insert a screwdriver as shown in the figure and pry loose the oil pan upper block. & 46U0B1-049 Front oil seal Remove the front oil seal by using a screwdriver protected with a rag. Rear oil seal Remove the rear oil seal by using a screwdriver protected with a rag. 16E0B1-145 B1-51 B1 DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B1-139 1. Connecting rod bolt Inspection......................... 2. Connecting rod cap Disassembly Note........... 3. Connecting rod Disassembly N ote........... Inspection......................... 4. Connecting rod bearing Inspection......................... 5. Piston ring Disassembly N ote........... Inspection......................... 6. Piston pin Disassembly N ote........... Inspection......................... B1—52 ...... page B1-68 ...... page B1-53 ...... page B1-53 ...... page B1-67 ...... page B1-69 ...... page B1-53 ...... page B1-66 ...... page B1-53 ...... page B1-66 7. Piston Inspection....................... 8. Main bearing cap bolt Inspection....................... 9. Main bearing cap Disassembly Note.......... 10. Crankshaft Disassembly Note.......... Inspection....................... 11. Main bearing Inspection....................... 12. Thrust bearing 13. Cylinder block Inspection....................... Oil je t.............................. ....... page B1-66 ....... page B1-68 ....... page B1-54 ....... page B1-55 ....... page B1-68 ....... page B1-69 ....... page B1-64 ....... page B1-55 DISASSEMBLY MEASURING LOCATION B1 Disassembly Note Connecting rod cap Before removing the connecting rod caps, measure the con­ necting rod side clearance. (Refer to page B1-78.) 46U0B1-140 Connecting rod 1. Before removing the connecting rods, measure the connect­ ing rod bearing oil clearance. (Refer to page B1-78.) 2. Remove the Plastigage from the crankpin journals. 3. Use the handle of a hammer to remove the piston and con­ necting rod assembly through the top of the cylinder block. Piston ring Remove the piston rings by using a piston ring expander (commercially available). Piston pin Caution • The connecting rods must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear. 1. Before disassembling the piston and connecting rod, check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston and/or the piston pin. B 1-53 B1 DISASSEMBLY 2. Use the following SSTs and a press. • Support block body (49 L011 001) • Support block head (49 H011 001B) • Piston pin installer (49 L011 006) • Piston pin guide (49 E011 001) • Screw (49 E011 002) 46U0B1-051 3. Insert the SST into the piston pin as shown. / 16E0B1-153 4. Verify that the SST fits squarely into the piston before pressing. 46U0B1-052 5. Set the piston and connecting rod on the SST as shown. 6. Press out the piston pin. While removing the piston pin, check the pressure. If it is lower than 4,903 N {500 kgf, 1,100 Ibf), replace the pis­ ton pin and/or connecting rod. 46U0B1-053 Main bearing cap 1. Before removing the main bearing caps, measure the crank­ shaft end play. (Refer to page B1-75.) 46U0B1-144 B 1-5 4 DISASSEMBLY B1 2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure. 3. Remove the main bearing caps. 16E0B1-157 Crankshaft Before removing the crankshaft, measure the main bear­ ing oil clearances. (Refer to page B1-73.) 46U0B1-145 Oil Jet Removal / Installation Removal 1. Drill a hole into the center of the oil jet head with a 7mm drill bit. 2. Remove the spring and ball through the hole. 3. Tap the hole with a M 8x 1.25 tap to 8mm (0.31 in} deep. 4. Screw a M 8x 1.25 bolt into the tapped hole. 5. Attach the sliding hammer to the bolt. 46U0B1-146 Caution • Twisting or turning the sliding hammer while remov­ ing the oil jet can damage the cylinder block. 6. Pull the sliding hammer straight upward and discard the oil jet. Installation 1. Temporarily install the crankshaft, connecting rod, and pis­ ton to the cylinder block. 2. Coat the oil jet installation hole with a small amount of clean engine oil. 3. Fit the oil jet into the hole and align the nozzle with the piston’s notch. 4. Remove the crankshaft, connecting rod and piston. 5. Remove the cylinder block from the SST (engine stand). 6. Put the cylinder block on the press stand. 7. Verify that the oil jet nozzle is properly aligned. Caution • If the oil jet nozzle is not properly aligned after be­ ing pressed in, it can damage the oil jet, cylinder block, and the piston. 46U0B1-147 B 1-55 B1 DISASSEMBLY M INIMUM “■------PRESSURE 3.2 kN 330 kgf, 726 Ibf) 8. Press-fit the oil jet into the cylinder block. Depth: 11.0—10.5mm (0.44—0.41 in} Pressure: 3.2 kN (330 kgf, 726 Ibf} minimum Caution • Depth over specification can damage the oil jet nozzle. • Pressure below specification indicates loose fit. Re­ place the cylinder block and oil jet. STANDARD 11.0— 10.5mm 10.44— 0.41 in) 46U0B1-148 9. Mount the cylinder block on the SST (engine stand). 10. Install the crankshaft, connecting rod, and piston to the cyl­ inder block. 11. Turn the crankshaft clockwise and check that the crankshaft and piston do not contact the oil jet. INSPECTION / REPAIR B1 INSPECTION / REPAIR PREPARATION SST 1. Clean all parts, being sure to remove all foreign materials. 2. Inspection and repairs must be performed in the order specified. 46U0B1-054 CYLINDER HEAD 1. Inspect the cylinder head for damage, cracks, and leakage of water and oil. Replace if necessary. 2. Using a straightedge, measure the cylinder head for dis­ tortion in the six directions shown in the figure. Distortion: 0.10mm (0.004 in] max. 46U0B1-055 3. Inspect for the following and repair or replace. (1) Sunken valve seats (2) Damaged intake and exhaust manifold contact surfaces (3) Excessive camshaft oil clearances and end play 4. If the cylinder head distortion exceeds the specification, grind the cylinder head surface. 5. If the cylinder head height is not within the specification, replace it. Height: 124.45—124.55mm (4.8996—4.9035 in) Grinding: 0.15mm (0.0059 in} max. 46U0B1-Q56 B 1-5 7 B1 INSPECTION / REPAIR 6. Using a straightedge, measure the manifold contact sur­ faces for distortion in the six directions shown in the figure. Distortion: 0.10mm (0.004 in) max. 7. If distortion exceeds the specification, grind the surface or replace the cylinder head. 46U0B1-Q57 Cylinder Head Bolt Measure the length of each bolt. Replace if necessary. Length : 104.2—104.8mm (4.103—4.125 in) Maximum: 105.5mm (4.154 in) 36U0B1-076 VALVE MECHANISM Valve and Valve Guide 1. Inspect each valve for the following. Replace or resurface the valves as necessary. (1) Damaged or bent stem (2) Rough or damaged face (3) Damaged or unevenly worn stem tip 2. Measure the head margin thickness of each valve. Replace the valves as necessary. Margin thickness IN : 1.10mm (0.0433 in] EX: 1.20mm (0.0472 in) 3. Measure the length of each valve and replace the valves as necessary. Length Standard IN : 89.68mm EX: 89.78mm Minimum IN : 89.28mm EX: 89.38mm (3.5307 (3.5346 (3.5150 (3.5189 in) in) in) in) 16A0B1-067 4. Measure the diameter of each valve stem and replace the valves as necessary. Diameter Standard IN : 5.970—5.985mm (0.2351—0.2356 in) EX: 5.965—5.980mm (0.2349—0.2354 in) Minimum IN : 5.940mm (0.2339 in) EX: 5.935mm (0.2337 in) 36U0B1-077 B 1-5 8 B1 INSPECTION / REPAIR 5. Measure the inner diameter of each valve guide at the points shown. Inner diameter IN : 6.01—6.03mm (0.2367—0.2374 in) EX: 6.01—6.03mm (0.2367—0.2374 in) 6. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. Clearance IN : 0.025—0.060mm (0.0010—0.0023 in) EX: 0.030—0.065mm (0.0012-0.0025 in) Maximum: 0.10mm (0.004 in) 7. If the clearance exceeds specifications, replace the valve and/or valve guide. 8. Measure each valve guides projection height A. Replace the guides as necessary. Height A IN : 13.5—14.1mm (0.532—0.555 in) EX: 13.5—14.1mm (0.532—0.555 in) Replacement of valve guide Note The intake and exhaust valve guides are the same. Removal Remove the valve guide from the side opposite the com­ bustion chamber by using the SST. B 1-59 B1 INSPECTION / REPAIR Installation 1. Assemble the SST so that depth L is as specified. Depth L: 13.5—14.1mm (0.532—0.555 in) 2. Tighten the locknut. 36UQB1-080 3. Tap the valve guide in from the side opposite the combus­ tion chamber until the SST contacts the cylinder head. 4. Verify that the valve guide height is within specifications. (Refer to page B1-59.) 5. If not within specifications, repeat steps 1—4. 46U0B1-149 Valve Seat 1. Inspect the contact surface of each valve seat and valve face for the following: (1) Roughness (2) Damage 2. If necessary, resurface the valve seat with a 45° valve seat cutter and/or resurface the valve face. 16E0B1-176 3. Apply a thin coat of Prussian blue to the valve face. 4. Check the valve seating by pressing the valve against the seat. (1) If blue does not appear 360° around the valve face, re­ place the valve. (2) If blue does not appear 360° around the valve seat, resurface the seat. 16E0B1-177 5. Measure the seat contact width. Width: 0.9—1.3mm (0.036—0.051 in) 36U0B1-081 B 1-6 0 INSPECTION / REPAIR B1 6. Verify that the valve seating position is at the center of the valve face. (1) If the seating position is too high, correct the valve seat using 65° (IN) or 75° (EX) cutter, and a 45° cutter. (2) If the seating position is too low, correct the valve seat using a 35° cutter and a 45° cutter. 7. Seat the valve to the valve seat by using a lapping compound. 8. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Dimension L: 39.0mm {1.535 in) (1) If L is 39.0—39.5mm {1.536— 1.555 in ), no correc­ tion needed. (2) If L is 40.6mm {1.598 in } or more, replace cylin­ der head. 36U0B1-082 Valve Spring 1. Inspect each valve spring for cracks or damage. 2. Measure the free length and out-of-square. Replace the valve springs as necessary. Free length Standard: 44.0mm {1.732 in) Minimum: 36.5mm {1.437 in }/177.1—200.2 N {18.05—20.42 kgf, 39.71—44.92 Ibf} 36U0B1-083 Out-of-square: 1.54mm {0.061 in) max. 16E0B1-182 CAMSHAFT 1. Set the front and rear journals on V-blocks. 2. Measure the camshaft runout. Replace the camshaft if necessary. Runout: 0.03mm {0.0012 in) max. 16E0B1-183 B 1-61 B1 INSPECTION / REPAIR 3. Inspect the camshaft for wear and damage. Replace the camshaft if necessary. 4. Measure each camshaft lobe height at the point as shown. Height mm {in} IN EX Standard Minimum Standard Minimum 42.973 42.823 43.338 43.188 {1-6918} {1.6859} {1.7062} {1.7003 J 36U0B1-049 5. Measure the journal diameters in X and Y directions at the two points (A and B) shown. Diameter: 25.940—25.965mm {1.0213—1.0222 in } Minimum: 25.910mm {1.0201 in} Out-of-round: 0.03mm {0.001 in} max. / 16A0B1-101 6. Measure the camshaft journal oil clearances with the HLA removed. (1) Remove all foreign material and oil from the journals and bearing surfaces. (2) Set the camshaft onto the cylinder head. (3) Position Plastigage atop the journals in the axial direction. (4) Install the camshaft caps according to the cap numbers as shown in the figure. 46U0B1-058 (5) Tighten the camshaft cap bolt in two or three steps. (Refer to page B1-86.) f l® 0 ® B® 0 ® 0© 0® 9® ^ B® s ®— 0 ® ..... 16E0B1-188 B 1 -6 9 M QQA R O R /M Y .W B1 INSPECTION / REPAIR (6) Loosen the camshaft cap bolts in two or three steps in the order shown in the figure. (7) Remove the camshaft caps. 16E0B1-189 (8) Measure the oil clearances. Oil rlPflrflnrP' 0.035—0.081mm (0.0014—0.0031 in} Maximum: 0.15mm {0.006 in) (9) If the oil clearance exceeds specifications, replace the cylinder head. 36U0B1-051 7. Measure the camshaft end play. If it exceeds specifica­ tions, replace the camshaft and/or the cylinder head. End play: 0.08—0.20mm {0.0032—0.0078 in) Maximum: 0.21mm {0.008 in} 36U0B1-052 HLA 1. Measure the diameter of each HLA bore. Diameter: 30.000—30.025mm {1.1811—1.1820 in} 36U0B1-053 2. Measure the diameter of each HLA . Diameter: 29.959—29.975mm {1.1795—1.1801 in) 3. Calculate the clearance between the HLA and the related HLA bore. Clearance* 0 .0 2 5 -0 .066mm {0.00099—0.00259 in} Maximum: 0.180mm {0.0071 in} 36U0B1-084 B 1-6 3 B1 INSPECTION / REPAIR 4. Inspect the HLA friction surfaces for wear and damage. Re­ place the HLA if necessary. 5. Hold the housing body and press the plunger by hand. If the plunger moves, it is defective. Replace the HLA — do not attempt to repair it. 46U0B1-15C) CYLINDER BLOCK 1. Inspect the cylinder block for the following. Repair or re­ place the cylinder block as necessary. (1) Leak damage (2) Cracks (3) Scoring of wall 2. Using a straightedge, measure the top deck of the cylin­ der block for distortion in the six directions shown in the figure. Distortion: 0.05mm (0.002 in) max. 46U0B1-151 3. If the distortion exceeds the specification, replace it. Height: 271.0mm (10.67 in] 36U0B1-054 4. Measure the cylinder bore in X and Y directions at three levels (A, B, and C) in each cylinder as shown. Cylinder bore Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter. mm (in) Bore size Standard 0.25 (0.010) oversize 0.50 (0.020) oversize Diameter 83.000-83.019 (3.2678-3.2684) 83.250-83.269 (3.2776-3.2783) 83.500-83.519 (3.2874-3.2881) 46U0B1-059 tH W m |y » :3 g 1 r T-------- A --------- !i I 1 1 1 1 1— : B — i, -- -"s; f ■ IS i! i cH t 46U0B1-06C) B 1 -6 4 (1) If the cylinder bore exceeds the maximum, rebore it to oversize. (2) If the difference between measurements A and C ex­ ceeds the maximum taper, rebore the cylinder to oversize. Taper: 0.010mm (0.0004 in) max. INSPECTION / REPAIR B1 (3) If the difference between measurements X and Y ex­ ceeds the maximum out-of-round, rebore the cylinder to oversize. Out-of-round: 0.010mm (0.0004 in) max. 5. If the upper part of a cylinder wall shows uneven wear, remove the ridge with a ridge reamer. 16E0B1-200 B1 INSPECTION / REPAIR PISTON, PISTON RING, AND PISTON PIN Piston If the piston is replaced, the piston rings must also be replaced. 1. Inspect the outer circumferences of all pistons for seizing and scoring. Replace as necessary. 2. Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 16.5mm {0.650 in } below the oil ring groove lower edge. Piston diameter mm (in) Piston size Standard 0.25 (0.010) oversize 0.50 (0.020) oversize Diameter 82.954-82.974 (3.2659-3.2666) 83.204-83.224 (3.2758-3.2765) 83.454-83.474 (3.2856-3.2863) 3. Measure the piston-to-cylinder clearance. Clearance: 0.039—0.052mm {0.0016—0.0020 in) Maximum: 0.15mm (0.006 in) 4. If the clearance exceeds the maximum, replace the piston or rebore the cylinders to accept oversize pistons. C LEARAN C E 36U0B1-087 Piston and Piston Rings 1. Measure the piston ring-to-ring land clearance around the entire circumference of the piston by using a new piston ring. Clearance Top: 0.035—0.065mm (0.0014—0.0025 in) Second: 0.030—0.065mm (0.0012—0.0025 in) Maximum: 0.085mm (0.0033 in) 2. If the clearance exceeds the maximum, replace the piston. 3. Inspect the piston rings for damage and abnormal wear. Replace the piston rings if necessary. 4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 46U0B1-152 B 1-6 6 B1 INSPECTION / REPAIR 5. Measure the end gap of each piston ring by using a feeler gauge. Replace the piston rings as necessary. End gap Top: 0.15—0.30mm (0.006—0.011 in) Second: 0.15—0.30mm (0.006—0.011 in) Oil rail: 0.20—0.70mm (0.008—0.027 in) Maximum Top, Second: 0.50mm (0.020 in) Oil rail: 0.90mm (0.035 in) 36UQB1-089 Piston and Piston Pin 1. Measure each piston pin bore diameter in X and Y direc­ tions at four points. Diameter: 18.988—19.000mm (0.7476—0.7480 in) 2. Measure each piston pin diameter in X and Y directions at four points. Diameter: 18.974—18.980mm (0.7470—0.7472 in) 3. Calculate the related piston pin to piston clearance. Clearance: 0.008—0.026mm (0.0003—0.0010 in) 4. If the clearance exceeds specifications, replace the piston and/or piston pin. CONNECTING ROD 1. Measure the small end inner diameter of each connecting rod. Diameter: 18.943—18.961mm (0.7458—0.7465 in) 2. Calculate the interference between the connecting rod small end bore and the related piston pin. Interference: 0.013—0.037mm (0.0005—0.0015 in) If the connecting rod is replaced, the connecting rod cap, bolts, and nuts must also be replaced because they are a matched set. 3. Measure each connecting rod for bending. Repair or re­ place connecting rods as necessary. Bending: 0.05mm (0.002 in) max./50mm (1.97 in) Length (Center to Center): 135.15—135.25mm (5.3209—5.3248 in) B 1-67 B1 INSPECTION / REPAIR CONNECTING ROD BOLT Measure the length of each connecting rod bolt. Replace as necessary. Length: 46.7—47.3mm (1.839—1.862 in) Maximum: 48.0mm (1.890 in) 16E0B1-210 MAIN BEARING CAP BOLT Measure the length of each main bearing cap bolt. Re­ place as necessary. Length: 67.7—68.3mm (2.665—2.689 in} Maximum: 69.0mm (2.717 in] 16E0B1-211 CRANKSHAFT 1. Check the journals and pins for damage, scoring, and oil hole clogging. 2. Set the crankshaft on V-blocks. 3. Measure the crankshaft runout at the center journal. Replace the crankshaft if necessary. Runout: 0.03mm (0.0012 in) max. 16E0B1-212 4. Measure each journal diameter in X and Y directions at two points. Main journal Diameter: 55.937—55.955mm (2.2022—2.2029 in) Out-of-round: 0.003mm (0.0001 in) max. Crankpin journal Diameter: 47.940—47.955mm (1.8874—1.8880 in) Out-of-round: 0.003mm (0.0001 in) max. 5. If the diameter is less than the minimum, grind the jour­ nals to accept undersize bearings. Undersize bearing: 0.25mm (0.010 in) (MAIN JOURNAL AND CRANK­ PIN), 0.50mm (0.020 in) (CRANKPIN) Caution • Do not remove the fillet roll area when grinding. 16E0B1-214 B 1-68 B1 INSPECTION / REPAIR Main journal diameter undersize mm (in) Bearing size 0.25 (0.010) undersize Journal diameter 55.687-55.705 (2.1924-2.1931) Crankpin journal diameter undersize mm (in) Bearing size 0.25 (0.010) undersize 0.50 (0.020) undersize Journal diameter 47.690-47.705 [ 1.8776-1.8781) 47.440-47.455 (1.8677-1.8683) BEARING Main Bearing and Connecting Rod Bearing Check the main bearings and the connecting rod bearings for peeling, scoring, and other damage. TIMING BELT Caution • The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bend­ ing it, or allowing oil or grease on it. 1. Replace the timing belt if there is any oil or grease on it. 2. Check the timing belt for damage, wear, peeling, cracks, and hardening. Replace if necessary. TENSIONER Caution • Using cleaning fluids or a steam cleaner to clean the tensioner can dissolve the grease in its sealed bearing. 1. Use a clean, soft rag to wipe the tensioner contact surface. 2. If the tensioner does not rotate smoothly, replace it. 3. If there are silicone oil leaks, scratches or abnormal noise when turning the tensioner, replace it. 4. If the spring bracket and grommet are loose or damaged, replace the tensioner. B1—69 B1 INSPECTION / REPAIR IDLER Caution • Using cleaning fluids or a steam cleaner to clean the idler can dissolve the grease in its sealed bearing. 1. Use a clean, soft rag to wipe the idler contact surface. 2. If the idler does not rotate smoothly, replace it. 3. If there are silicone oil leaks, scratches or abnormal noise when turning the idler, replace it. TENSIONER SPRING Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length: 36.6mm (1.441 in} PULLEY Timing Belt Pulley, Camshaft Pulley Inspect the pulley teeth for wear, deformation, and other damage. Replace the pulley if necessary. B 1-7 0 B1 ASSEMBLY ASSEMBLY PREPARATION SST For prevention of engine rotation 49 E011 1AO Brake set, ring gear 49 E011 104 Collar (Part of 49 E011 1AO) 49 SE01 310A Centering tool, clutch disc 49 L012 005 Spacer (Part of 49 L012 0A0) 49 L012 002 Body (Part of 49 L012 0A0) 49 L011 001 Body, support block (Part of 49 L011 0A0A) 49 L011 006 Installer, piston pin (Part of 49 L011 0A0A) 49 E011 002 Screw a For prevention of engine rotation For installation of clutch disc For installation of valve seals For installation of valve seal For removal / installation of piston pin For removal / installation of piston pin For removal / installation of piston pin For prevention of engine rotation 49 E011 103 Shaft (Part of 49 E011 1A0) For prevention of engine rotation 49 E011 105 Stopper (Part of 49 E011 1A0) For installation of valve seal 49 L012 0A0 Installer set, valve seal & valve guide 49 L012 001 Installer (Part of 49 L012 0A0) 49 L011 0A0B Tool set, piston pin setting' 49 L011 005 Bolt, stopper (Part of 49 L011 0A0A) 49 E011 001 Guide, piston pin (Part of 49 L011 0A0A) 49 H011 001B Head, Support block a m For installation of valve seal For removal / installation of piston pin For removal / installation of piston pin For removal / installation of piston pin For removal / installation of piston pin B1-71 B1 49 0636 100A Arm, valve spring lifter 49 B012 012 Body (Part of 49 B012 0A2) 49 B012 014 Locknut (Part of 49 B012 0A2) ASSEMBLY For removal / installation of valve 49 B012 0A2 For removal / installation of valve 49 B012 013 For removal / installation of valve Pivot Foot (Part of 49 B012 0A2) 49 G014 001 Wrench, oil filter For removal / installation of valve For removal / installation of valve For removal / installation of oil filter 46U0B1 -066 1. Do not reuse gaskets or oil seals. 2. Clean all parts before reinstallation. 3. Apply clean engine oil to all sliding and rotating parts. 4. Replace plain bearings if they are peeling, burned, or otherwise damaged. 5. Tighten all bolts and nuts to the specified torque. 46U0B1-155 B1 ASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Torque Specifications ___________ 850-95° N-m (kgf-m, ft-lbf) 16E0B1-225 Crankshaft 1. Before installing the crankshaft, inspect the main bearing oil clearances as follows. Oil clearance inspection (1) Remove all foreign material and oil from the journals and bearings. 46U0B1-067 B 1-73 B1 ASSEMBLY (2) Install the grooved upper main bearings in the cylinder block. (3) Install the thrust bearings with the oil groove facing the crankshaft. (4) Set the crankshaft in the cylinder block. (5) Position Plastigage atop the journals in the axial direction. (6) Do not rotate the crankshaft when measuring the oil clearances. 46U0B1-068 (7) Install the lower main bearings and the main bearing caps according to the cap number, facing the □ mark forward. (8) Tighten the main bearing cap bolts in two or three steps in the order shown in the figure. Tightening torque: 17.2—22.0 N-m {1.75—2.25 kgf-m, 12.7—16.2 ft Ibf} 46U0B1-069 PAINT MARK 85° (9) Put a paint mark on each bolt head. (10) Using the mark as a reference, tighten the bolts by turn­ ing each 85°—95° in the sequence shown. 17.2—22.0 N-m (1.75—2.25 kgf-m, 12.7—16.2 ft-lbf) 46U0B1-070 (11) Remove the main bearing caps, and measure the Plasti­ gage at each journal at the widest point for the smallest clearance, and at the narrowest point for the largest clearance. (12) If the oil clearance exceeds specifications, grind the crankshaft and install undersize main bearings. (Refer to page B1-68.) mm (in) Oil c le a ra n c e M a xim u m N o .1 , 2, 4, 5 N o .3 0.024-0.050 (0.0009-0.002] 0.030-0.056 (0.001-0.002) 0 .0 6 7 (0 .0 0 2 6 ) 46U0B1-071 2. Apply a liberal amount of clean engine oil to the main bear­ ings, thrust bearings and main journals. 3. Install the main bearing caps according to the cap num­ ber, facing the □ mark toward the front. FRONT 16E0B1-232 B 1-7 4 B1 ASSEMBLY 4. Tighten the main bearing cap bolts in two or three steps in the order shown in the figure. Tightening torque: 17.2—22.0 N-m {1.75—2.25 kgf-m, 12.7—16.2 ft Ibf} + 8 5 °—95° 5. Measure the crankshaft end play. End play: 0.080—0.282mm {0.0031—0.0111 in) Maximum: 0.30mm {0.0118 in] 6. If the end play exceeds the maximum, grind the crankshaft and install oversize thrust bearings, or replace the crank­ shaft and thrust bearings. Thrust bearing width Standard: 2.500—2.550mm {0.0984—0.1004 0.25mm {0.010 in) oversize: 2.625—2.675mm {0.1033—0.1053 0.50mm {0.020 in] oversize: 2.750—2.800mm {0.1083—0.1102 0.75mm {0.030 in] oversize: 2.875—2.925mm {0.1132—0.1152 49 E011 001 49 L011 006 in) in] in] in] Connecting Rod 1. Assemble the SST and piston pin as shown. 2. Apply clean engine oil to the piston pin. PISTON PIN 49 E 0 1 1 002 16E0B1-236 49 H 0 1 1 0 0 1 B DIMENSION 3. Adjust the SST (stopper bolt) so that the depth L is as specified. Depth L: 59.1mm {2.33 in] 4. Tighten the locknut. 49 L011 001 -LOCKNUT w 49 L 0 1 1 005 16E0B1-237 B 1-75 B1 ASSEMBLY 5. Set the piston on the SST with the F mark facing upward. 6. Assemble the piston and the connecting rod in the direc­ tion from which they were disassembled. 7. Verify that the SST is set squarely into the piston. 46U0B1-072 8. Set the piston and connecting rod on the SST as shown and press the piston pin through the piston and connect­ ing rod until the SST contacts the stopper bolt. 9. While inserting the piston pin, check the pressing force. If it is less than specified, replace the piston pin and/or the connecting rod. Pressing force: 4,903—14,710 N {500—1,500 kgf, 1,100—3,300 Ibf) 10. Check the oscillation torque of the connecting rod. If the large end does not drop by its own weight, replace the pis­ ton and/or piston pin. 46U0B1-074 Piston Ring 1. Install the three-piece oil rings on the pistons. (1) Apply clean engine oil to the oil ring spacer and rails. (2) Install the oil ring spacer with the ends upward. Note • The upper and lower rails are the same. They can be in­ stalled with either face upward. (3) Install the upper and lower rails. 2. Verify that the spacer tang separates the rails, and that the rails turn smoothly in both directions. SPACER TANG fV - / y UPPER RAIL -y u f\, OIL RING SPACER ENDS ■£Z LOWER RAIL PISTON 46U0B1-158 B 1 -7 6 B1 ASSEMBLY 3. 4. 5. 6. Install the rings with the R marks upward. Install the second ring with the scraper face downward. Apply clean engine oil to the top and second piston rings. Install the second ring to the piston; then install the top ring. Use a piston ring expander (commercially available). 7. Position the end gaps of the rings as shown in the figure. OIL RING LOWER RAIL OIL RING TOP RING PISTON SPACER OIL RING UPPER RAIL SECOND RING 46U0B1-076 Piston and connecting rod assembly The piston and cylinder block have matching marks on them to ensure correct installation. Note these marks when in­ stalling the pistons. Mark Standard Piston a b c Cylinder block A B C Oversize (piston) 25 50 0.25 O.S. 0.50 O.S. 1. Apply a liberal amount of clean engine oil to the cylinder walls, pistons, and piston rings. 2. Check the piston rings for correct end gap alignment. 3. Using a piston ring compressor (commercially available), insert each piston assembly into the cylinder block with the F mark facing the front of the engine. 16E0B1-247 B 1-7 7 B1 ASSEMBLY Connecting Rod Cap 1. Measure the connecting rod bearing oil clearances using the same procedure as for the main bearing oil clearance. KNOCK PIN ALIGNMENT MARK Tightening torque: 22.1—26.9 N-m {2.25—2.75 kgf-m, 16.3—19.8 ft-lbf} + 85°—95° Oil clearance: 0.024—0.061mm {0.0009—0.0024 in) Maximum: 0.067mm {0.0026 in) 46U0B1-078 2. If the oil clearance exceeds the maximum, grind the crank­ shaft to accept undersize bearings. (Refer to page B1-68.) 46U0B1-159 3. Measure the connecting rod side clearances. MEASURING LOCATION Side clearance: 0.110—0.262mm {0.0043—0.0103 in) Maximum: 0.30mm {0.012 in) 4. If the clearance exceeds the maximum, replace the con­ necting rod and cap. 16E0B1-250 5. Apply a liberal amount of clean engine oil to the crankpin journals and connecting rod bearings. 6. Install the connecting rod caps with the knock pins and the alignment marks aligned. 7. Tighten the connecting rod cap bolts. Tightening torque: 22.1—26.9 N-m {2.25—2.75 kgf-m, 16.3—19.8 ft Ibf) + 85°—95° 46U0B1-160 B1 ASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Torque Specifications 19—25 (1.9—2.6, 14—18) GASKET, NEW O-RING, NEW jiQgggl 7.9—10.7 Nm (80—110 kgf-cm 70—95.4 ln-lbf) GASKET, NEW 7 .9 -1 0 .7 N m (80—110 kgf-cm, 70—95.4 In Ibf) 7.9—10.7 N m (80—110 kgf-cm, 70—95.4 in lbf) 16E0B1-252 Rear Cover 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a press, tap the oil seal in evenly until it is flush with the edge of the rear cover. Oil seal outer diameter: 109mm (4.29 in) Oil seal inner diameter: 89.0mm {3.50 in) 46U0B1-079 B 1-79 B1 ASSEMBLY 4. Apply a continuous bead of silicone sealant to the rear cover as shown in the figure. 16E0B1-254 5. Install the rear cover. Tightening torque: 7.9—10.7 N-m (80—110 kgf cm, 70—95.4 in lbf ] 46U0B1-161 Oil Pump 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a press, tap the oil seal in evenly until it is flush with the edge of the oil pump body. Oil seal outer diameter: 54.5mm {2.15 in] Oil seal inner diameter: 42.5mm {1.67 in) 46U0B1-080 4. Apply a continuous bead of silicone sealant to the oil pump housing as shown in the figure. 16E0B1-257 5. Install the oil pump. Tightening torque: 19—25 N-m {1.9—2.6 kgf-m, 14—18 ft-lbf) B1 ASSEMBLY 6. Remove any sealant that is pushed out at the oil pan side. 46U0B1-162 RUBBER SEAL Water Pump Install the water pump along with a new gasket and new rubber seals. Verify that the rubber seals stay in place when installing the pump. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} RUBBER SEAL 46U0B1-163 Oil Pan Upper Block 1. Remove all foreign material from the contact surfaces. 2. Apply a continuous bead of silicone sealant to the oil pan upper block as shown in the figure. 46U0B1-081 3. Install the oil pan upper block. 4. Tighten the two nuts. Tightening torque: 7.9—10.7 N m (80—110 kgf cm, 70—95.4 in lbf) 46U0B1-082 5. Tighten the oil pan upper block bolts in two or three steps in the order shown in the figure. Tightening torque: 19—25 N m (1.9—2.6 kgf m, 14—18 ft-lbf} 46U0B1-083 B1—81 B1 ASSEMBLY Oil Strainer 1. Install the oil strainer along with a new gasket. 2. Tighten the bolts marked A first. Tightening torque: 7.9—10.7 N m [80—110 kgf cm, 70—95.4 in lbf} 46U0B1-164 Oil Pan 1. Remove all foreign material from the contact surfaces. 2. Apply a continuous bead of silicone sealant to the oil pan as shown in the figure. 46U0B1-165 3. Install the oil pan within five minutes of applying the sealant. 4. Tighten the oil pan bolts. Tightening torque: 19—25 N-m(1.9—2.6 kgf-m, 14—18 ft-lbf} 46U0B1-166 End Plate Install the end plate. Tightening torque: 7.9—10.7 N-m [80—110 kgf cm, 70—95.4 in lbf} 46U0B1-167 Flywheel (MTX) 1. Remove the sealant from the flywheel bolt holes in the crank­ shaft and from the flywheel bolts. Caution • If all of the old thread locking sealant cannot be re­ moved from the bolt, it will not torque properly. Re­ place the bolt. Note • If a new bolt is used, do not apply thread locking seal­ ant. New Mazda bolts have sealant on them. 2. Set the flywheel onto the crankshaft. 3. Apply sealant to the flywheel bolts and install them. B1—82 B1 ASSEMBLY 4. Hold the flywheel by using the SST. 5. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 97—102 N m [9.8—10.5 kgf m, 71—75 ft-lbf) Clutch Disc and Clutch Cover (MTX) 1. Install the clutch disc and the clutch cover by using the SST. 2. Tighten the clutch cover bolts in two or three steps in the order shown in the figure. Tightening torque: 1 8 -2 6 N-m [1 .8 -2 .7 kgf m, 1 4 -1 9 ft-lbf) 16E0B1-270 Drive Plate (ATX) 1. Remove the sealant from the drive plate bolt holes in the crankshaft and from the drive plate bolts. Caution • If all of the old thread locking sealant cannot be re­ moved from the bolt, it will not torque properly. Re­ place the bolt. Note • If a new bolt is used do not apply thread locking sealant. New Mazda bolts have sealant on them. 2. Set the adapter, drive plate, and backing plate onto the crankshaft. 3. Apply sealant to the drive plate bolts and install them. 4. Hold the drive plate by using the SST. 5. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 97—102 Nm [9.8—10.5 kgf m, 71—75 ft-lbf) B 1-83 B1 ASSEMBLY CYLINDER HEAD Torque Specifications r BOLT THREADS 5 0 — 60 ( SEAL, N m [kgf-m, ft-lbt| 16E0B1-273 Valve Seal The intake and exhaust valve seals are different. The exhaust valve seal has ridges on the top for identifi­ cation. 46U0B1-085 B 1-84 ASSEMBLY B1 1. Assemble the SST so that depth L is as specified. 4 9 L 0 1 2 00 5 Depth L: 17.7— 18.3mm {0.697—0.720 in) 4 9 L 0 1 2 001 49 L012 002 4 9 L 0 1 2 00 5 16E0B1-275 2. Slide the valve seal onto the valve guide. 3. Set the SST against the valve seal. 49 L 0 1 2 0 0 5 16E0B1-276 Caution • Using a hammer will damage the valve seal. 4. Using the SST, press the valve seal on by hand until the SST touches the cylinder head. 49 L012 002 46U0B1 -086 Valve and Valve Spring 1. Install the lower spring seat. 2. Install the valve. 3. Install the valve spring with the closer pitch toward the cyl­ inder head. 4. Install the upper spring seat. 46U0B1-087 5. Com press the valve spring by using the SST, and install the valve keepers. 6. Remove the SST. 7. Tap the end of the vaive stem lightly two or three times with a plastic hammer to verify that the keepers are fully seated. 46U0B1 -088 B1 ASSEMBLY Cylinder Head Gasket 1. Remove all foreign material from the top of the cylinder block. 2. Place the new cylinder head gasket in position. 16E0B1-280 Cylinder Head 1. Install the cylinder head. 2. Tighten the cylinder head bolts. (1) Apply clean engine oil to the bolt threads and seat faces. (2) Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 17.2—22.0 N-m [1.75—2.25 kgf-m, 12.7—16.2 ft-lbf} (3) Put a paint mark on each bolt head. (4) Use this mark as a reference, tighten the bolts 85°—95° in the order shown. (5) Further tighten each bolt another 8 5 °—95°. 46U0B1-169 HLA 1. Apply clean engine oil to the friction surfaces of the HLA. 2. If the HLA are being reused, install them in the position from which they were removed. 3. Verify that the HLA move smoothly in their bores. 36U0B1-062 Camshaft Caution • Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiv­ ing area of the cylinder head journal. To avoid this, the following procedure must be observed. No. 3 _ CYLINDER 1. Assemble camshaft onto the cylinder head, facing the cam noses at No.1 and No.3 cylinders as shown. MQQA B1 ASSEMBLY 2. Apply silicone sealant to the areas shown. Keep the cam­ shaft sliding surface free of sealant to prevent engine damage. 46U0B1-089 3. Apply engine oil to the camshaft and the cylinder head journals. 4. Install the camshaft caps to the positions from which they were removed. 16E0B1-286 5. Tighten the camshaft cap bolts in two or three steps in the order shown. Tightening torque: 11.3— 14.2 N m {115—145 kgf cm, 100—125 in Ib f} 6. Verify that the camshaft settles horizontally when two bear­ ing cap bolts at No.3 journal are tightened. 7. Apply a small amount of clean engine oil to the lip of each new camshaft oil seal. 8. Push the oil seals slightly in by hand. 9. Using a pipe and hammer, tap the oil seal in evenly until it is flush with the edge of the camshaft cap. Oil seal outer diameter: 48.0mm {1.89 in] Oil seal inner diameter: 34.0mm {1.34 in) Camshaft Pulley 1. Install the camshaft pulleys, positioning the dowel pins as shown. 16E0B1-289 Revised 2/96 (1994 626/M X-6) B 1 -8 7 bl ASSEMBLY 2. Apply clean engine oil to the camshaft bolt threads and hand tighten the bolts. 3. Hold the camshafts by using a wrench on the cast hexa­ gon as shown, and tighten the bolts. Tightening toque: 50—60 N m {5.0—6.2 kgf-m, 37—44 ft-lbf} B1 ASSEMBLY TIMING BELT Torque Specifications 5.9—7.8 N-m (80—80 kgf-cm, 53—68 ln-lbf | 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 Inlbf) GASKET, NEW O-RING, NEW 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 in lbf) 157—166 (16.0—17.0, 118—122) j g_-10,7 N*m ^ (80—110 kgf cm, 70—95.4 In Ibf) BOLT THREADS ft-lbf) 16E0B1-291 Timing belt 1. Install the timing belt pulley and key. 16E0B1-292 B 1-89 B1 ASSEMBLY 2. Install the tensioner spring to the tensioner. 3. Install the tensioner and the idler. Tightening torque A: 38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf) B: 38—51 N-m {3.8—5.3 kgfm, 28—38 ft-lbf) 16E0B1-293 4. Using a torque wrench, rotate the tensioner right and left to measure the resistance. Replace the tensioner if the tor­ que (resistance) is not as specified. Resistance: 0.49—2.25 N-m {5.0—23.0 kgf-cm, 4.4—19.9 inlbf) AT 10—30°C {50—86°F) 36U0B1-091 5. Temporarily install the crankshaft pulley bolt. 6. Turn the crankshaft clockwise and align the timing marks. 36U0B1-063 7. Verify that the camshaft pulley marks are aligned with the cylinder head parting line. 16E0B1-296 8. Install the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys. IDLER 16E0B1-297 B 1-9 0 ASSEMBLY B1 9. Turn the crankshaft two turns clockwise, and align the tim­ ing belt pulley marks. 10. Verify that all timing marks are correctly aligned. If not aligned, remove the timing belt and repeat from ten­ sioner installation. 16E0B1-298 11. Turn the tensioner clockwise by using an Allen wrench. 12. Connect the tensioner to the hook pin. 16E0B1-299 13. Turn the crankshaft two turns clockwise and again verify that the timing marks are correctly aligned. 16E0B1-30Q 14. Hold the flywheel (MTX) or the drive plate (ATX) by using the SST. 16E0B1-301 15. Remove the crankshaft pulley bolt. 16E0B1-302 B1-91 B1 ASSEMBLY Engine Mount No.3 bracket Install the engine mount No.3 bracket. Tightening torque: 44—60 N m {4.4—6.2 kgf m, 32—44 ft-lbf} 46U0B1-171 Timing Belt Cover 1. Install the lower, then upper covers. 2. Install the oil level dipstick and pipe. Tightening torque: 7.9—10.7 N-m {80—110 kgf-cm, 70—95.4 in lbf} 46U0B1-172 Water Pump Pulley Install the water pump pulley, facing the “ F” marks outward. Tightening torque: 7.9—10.7 N-m {80—110 kgf-cm, 70—95.4 in lbf) 46U0B1-091 2. Hold the flywheel (MTX) or the drive plate (ATX) by using the SST. 16E0B1-307 B 1-92 B1 ASSEMBLY 3. Install the crankshaft pulley. 4. Tighten the crankshaft pulley bolt. Tightening torque: 157—166 N-m {16.0—17.0 kgf-m, 116—122 ft-lbf) 16E0B1-308 Cylinder head cover 1. Apply silicone sealant as shown in the figure. 2. Install a new cylinder head cover gasket. 16E0B1-366 3. Apply silicone sealant to the shaded areas of the cylinder head as shown in the figure. 16E0B1-309 4. Install the cylinder head cover. 5. Install the cylinder head cover bolts and tighten them in two or three steps in the order shown in the figure. Tightening torque: 5.9—7.8 Nm {60—80 kgfcm, 53—69 inlbf) 16E0B1-31Q B 1-93 B1 ASSEMBLY AUXILIARY PARTS Torque Specifications 19—25 (1 .9—2.6, 14— 18) 1 9 - 2 5 (1.9—2.6, 14— 18) 1 9 - 2 5 (1.9—2.6, 1 4 - 1 8 ) 38—51 (3.8—5 .3 ,2 8 —38 38—51 (3.8—5 .3 ,2 8 —38 .C T T W I 1 9 - 2 5 (1.9—2.6, 14— 18) WASHER NEW 15—22 (1 .5—2.3, 11— 16 - 2 3 (1 .6—2.4, 1 2 - 1 7 ) GASKET, NEW 19—25 (1.9—2.6, 14—18 O-RING, NEW I f N-m (kgf-m, ft-lbf) 16E0B1-311 B 1-94 B1 ASSEMBLY Oil Filter 1. Remove all foreign material from the oil filter mounting surface. 2. Apply a small amount of clean engine oil to the rubber seal of the oil filter. 3. Install the oil filter and tighten it by hand until the rubber seal contacts the mounting surface. 4. Tighten the filter 1-1/6 turns by using the SST. Tightening torque: 13.8—17.6 N m (140—180 kgf cm, 122—156 in Ibf} Water Outlet 1. Hand tighten bolt ® . 2. Install the water outlet. Tightening torque: 19—25 N m {1.9—2.6 kgf-m, 14—18 ft Ibf} 46U0B1-092 Heat Gauge Sender Unit and Engine Coolant Tempera­ ture Sensor 1. Apply silicone sealant to the top two-thirds of the threads. 2. Install the heat gauge sender unit. Tightening torque: 6.4—9.3 Nm (65—95 kgf cm, 57—82 in lbf} 3. Install the engine coolant temperature sensors. Tightening torque: 16—23 N m (1.6—2.4 kgf m, 12—17 ft-lbf} 36U0B1-093 Alternator 1. Install the alternator bracket. Tightening torque: 38—51 N m (3.8—5.3 kgf-m, 28—38 ft-lbf} B 1-95 B1 ASSEMBLY 2. Install the alternator and strap. Tightening torque A: 38—51 Nm {3.8—5.3 kgfm, 28—38 ft-lbf} B: 38—51 Nm [3.8—5.3 kgfm, 28—38 ft-lbf} C: 19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf} 16E0B1-320 3. Install the alternator stay. (MTX) Tightening torque: 19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf) 16A0B1-012 Intake Manifold Assembly 1. Remove all foreign material from the intake manifold con­ tact surface. 2. Install a new gasket and the intake manifold assembly. Tightening torque: 19—25 N-m [1.9—2.6 kgfm, 14—18 ft-lbf) 16E0B1-314 Spark Plug Install the spark plugs. Tightening torque: 15—22 N-m [1.5—2.3 kgfm, 11—16 ft-lbf) 16E0B1-316 Distributor and High-tension Lead 1. Apply clean engine oil to a new O-ring and position it on the distributor. 2. Apply clean engine oil to the drive gear. 3. Verify that the No.1 cylinder is at top dead center and align the distributor matching marks. 36U0B1-066 B 1-96 B1 ASSEMBLY 4. Install the distributor and hand tighten the installation bolts. 5. Connect the high-tension leads. Engine Hanger Install the front and rear engine hangers. Tightening torque: 38—51 Nm [3.8—5.3 kgf m, 28—38 ft-lbf} B 1-9 7 B1 ENGINE STAND DISMOUNTING ENGINE STAND DISMOUNTING PROCEDURE 1. Remove the engine from the SST (engine stand). 2. Remove the SST (engine hanger) from the engine. 3. Install the parts shown in the figure. Torque Specifications N-m jkgt-m, ft-lbf) 16E0B1-323 Thermostat Housing Install a new gasket and the thermostat housing. Tightening torque: 19—25 Nm (1.9—2.6 kgfm, 14—18 ft-lbf} 16E0B1-324 B1—98 B1 ENGINE STAND DISMOUNTING Water Bypass Pipe 1. Apply a small amount of clean engine coolant to new O-rings. 2. Install the water bypass pipes. Note • Bolt A is at the water outlet. (Refer to page B1-95.) Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} 46U0B1-175 JIGGLE PIN 3. Connect the water hose. Thermostat, Thermostat Cover 1. Remove all foreign material from the thermostat cover mounting surface. 2. Verify that the jiggle pins are aligned with the tab of the ther­ mostat gasket as shown. 46U0B1-176 3. Install the thermostat and gasket into the thermostat hous­ ing, aligning the tab to the housing as shown in the figure. 16E0B1-327 4. Install the thermostat cover. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} 16E0B1-328 A/C Compressor Bracket (if equipped) Install the A/C compressor bracket. Tightening torque: 38—51 Nm {3.8—5.3 kgf-m, 28—38 ft-lbf} 16E0B1-329 B 1-99 B1 ENGINE STAND DISMOUNTING Exhaust Manifold 1. Remove all foreign material from the exhaust manifold con­ tact surface. 2. Install the new gasket and the exhaust manifold. Tightening torque Nut: 20—28 N-m {2.0—2.9 kgf-m, 15—20 ft-lbf} Bolt: 16—22 N-m {1.6—2.3 kgf-m, 12—16 ft-lbf} 16E0B1-330 EGR Pipe Install the EGR pipe. Tightening torque A: 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf} B: 32—47 N-m {3.2—4.8 kgf m, 24—34 ft Ibf) 46U0B1-177 Exhaust Manifold Insulator Install the exhaust manifold insulator. Tightening torque: 7.9—10.7 N-m {80—110 kgf cm, 70—95.4 inlbf) 46U0B1-178 P/S oil pump bracket Install the P/S oil pump bracket. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf) 16E0B1-368 B 1-100 B1 INSTALLATION INSTALLATION PROCEDURE Tighten all bolts and nuts to the specified torques. Step 1 Torque Specifications INSTALLATION, REFER TO SECTION J 86— 116 ( 8.7— 11.9, 63—86) INSTALLATION, REFER TO SECTION K2 N-m (kgfm , ft-lbf) 16E0B1-333 Engine mount No.2 bracket Install the mount bracket. Tightening torque: 44—60 Nm [4.4—6.2 kgfm, 32—44 ft-lbf) 16A0B1-103 B1-101 B1 INSTALLATION Engine mount No.2 rubber Install the engine mount No.2 rubber and hand tighten the through bolt. 46U0B1-179 Starter Install the starter to the transaxle housing. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf} 16E0B1-335 Intake manifold bracket Install the intake manifold bracket. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf} 16E0B1-336 INSTALLATION B1 Step 2 Warning • Be sure the vehicle is securely supported on safety stands. Torque Specifications Engine and transaxle assembly 1. Suspend the engine and transaxle assembly. Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into compo­ nents in the engine compartment. 2. Position the engine and transaxle assembly in the engine compartment. 3. Align the engine mounts with the engine mount member mounting holes. 46U0B1-180 B 1-103 B1 INSTALLATION Engine mount 1. Hand tighten the nuts marked B. (Engine mount No.2) 2. Install the bolts and nuts as shown. Tightening torque A: 67—93 N m [6.8—9.5 kgf m, 50—68 ft-lbf) 46U0B1-093 3. Install the engine mount No.1 mounting bolts. Tightening torque MTX: 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf) ATX ® : 75—104 N m {7.6—10.7 kgf m, 59—82.2 ft-lbf) (§): 86—116 N-m {8.7—11.9 kgf m, 63—86.0 ft Ibf) © : 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf) 46U0B1-094 4. Install the engine mount No.3 rubber. Tightening torque Nut: 74—102 N-m {7.5—10.5 kgf m, 54.3—75.9 ft-lbf) Bolt: 86—116 N-m {8.7—11.9 kgf m, 63—86.0 ft-lbf) 46U0B1-095 5. 6. 7. 8. Install the engine mount No.4 bracket. Hand tighten bolts B. Tighten bolts B. Tighten bolts A. Tightening torque A: 59—80 N-m {6.0—8.2 kgf m, 44—59 ft-lbf) B: 59—80 N m {6.0—8.2 kgf m, 44—59 ft-lbf) 9. Install the engine mount No.4 rubber. 46U0B1-096 Tightening torque MTX ® : 67—93 N m {6.8—9.5 kgf m, 50—68 ft-lbf) (§): 86—116 N m {8.7—11.9 kgf-m, 63—86 ft-lbf) ATX (§): 38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf) 10. Remove the chain from the engine hangers. 11. Tighten the engine mount No.2 nuts. (Refer to Step 1.) Tightening torque: 75—104 N-m {7.6—10.7 kgf m, 55—77.3 ft-lbf) 46U0B1-097 B 1-104 B1 INSTALLATION 12. Tighten the engine mount No.2 rubber through bolt. (Refer to page B1-102.) Tightening torque: 86—116 Nm {8.7—11.9 kgf m, 63—86 ft-lbf) 13. Install the engine mount No.5 rubber as shown. Tightening torque A: 67—93 Nm (6.8—9.5 kgfm, 50—68 ft-lbf) B: 44—60 Nm (4.4—6.2 kgfm, 32—44 ft-lbf) 46U0B1-098 14. Install the engine mount No.1 stay bracket and ground har­ ness (MTX). Tightening torque: 10.8—14.7 Nm (110—150 kgf cm, 96—130 in Ibf) 46U0B1-099 Step 3 Torque Specifications 16E0B1-343 B 1-105 B1 INSTALLATION Joint shaft 1. Install the new clip. 2. Install the joint shaft. 3. Tighten the bolts in the order shown. Tightening torque: 43—61 N m (4.3—6.3 kgf m, 32—45 ft-lbf} 4. Apply grease to the end of joint shaft. 16A0B1-Q88 Drive shaft 1. Apply grease to the end of the drive shafts. Caution • The oil seals are damaged easily if this procedure is not done correctly. 2. 3. 4. 5. Install the drive shaft. Install the new clip with the end gap facing upward. Push the drive shaft into the joint shaft. After installation, pull the front hub outward to confirm that the drive shaft is securely held by the clip. 6. Install the lower arm ball joint to the knuckle and tighten the through bolt. Tightening torque: 35—56 N m {3.5—5.8 kgf m, 26—41 ft-lbf} Tie rod end 1. Install the tie rod end to the knuckle. Tightening torque: 32—44 N m {3.2—4.5 kgf m, 24—32 ft-lbf} 2. Install a new cotter pin. 16E0B1-347 Stabilizer control link Install the stabilizer control link. Tightening torque: 37—53 Nm {3.7—5.5 kgf-m, 27—39 ft-lbf} 36U0B1-115 B 1-106 B1 INSTALLATION Extension bar (MTX) Install the extension bar to the transaxle. Tightening torque: 3 8 -5 1 N m {3.8—5.3 kgf m, 28—38 ft Ib f} Shift control rod (MTX) Install the shift control rod to the transaxle. Tightening torque: 16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf} Front exhaust pipe 1. Install a new gasket and connect the front exhaust pipe to the exhaust pipe. Hand tighten the new nuts. 2. Connect the exhaust pipe to the vehicle body by the mount rubbers. 3. Tighten the exhaust pipe mounting nuts. Tightening torque: 38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf} Exhaust pipe 1. Install a new gasket and the exhaust pipe. Hand tighten the new nuts. 2. Hand tighten the bracket bolts. 3. Tighten the exhaust pipe mounting nuts. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf} 4. Tighten the bracket bolts. Tightening torque: 38—51 N m {3.8—5.3 kgf m, 28—38 ft-lbf} Transverse member Install the transverse member. Tightening torque: 94—131 Nm {9.5—13.4 kgf m, 69—96 ft-lbf} 36U0B1-116 Clutch release cylinder Install the clutch release cylinder. Tightening torque: 16—22 Nm {1.6—2.3 kgf m, 12—16 ft-lbf} 16E0B1-350 B1—107 B1 INSTALLATION Step 4 Connect the hoses shown in the figure. HEATER HOSE BRAKE VACUUM HOSE VACUUM HOSE /(PURGE) FUEL HOSE Step 5 Connect the harness connectors. 46U0B1-185 B 1-108 B1 INSTALLATION Step 6 Torque Specifications 19—25 (1.9—2.6, 14—18' 7.9—10.7 N m (80—110 kgf cm, 70—95.4 in Ibf) 7.9—10.7 N-m (80—110 kgf cm, 70—95.4 ln-lbf) 19—25 (1.9—2.6, 14—18) 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 ln-lbf) 44—60 ( 4.4—6.2, 32—44 32—46 (3.2—4.7, 2 4 -3 3 ) 6.9—9.8 N-m (70—100 kgf-cm, 70—86 ln-lbf) 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 ln-lbf) 16—22 (1 .6 -2 .3 , 12—16) 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 ln-lbf) 24—35 12.4—3.6, 1 8 -2 6 ) N-m |kgf-m, ft-lbf) 16E0B1-355 A/C compressor (if equipped) Install the A/C compressor to the bracket. Tightening torque: 24—35 N m {2.4—3.6 kgf-m, 18—26 ft-lbf} 16E0B1-356 P/S oil pump and adjuster 1. Install the P/S oil pump adjuster. Tightening torque: 16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf} 2. Install the P/S oil pump. Tightening torque A: 44—60 N-m {4.4—6.2 kgfm, 32—44 ft-lbf] B: 32—46 Nm {3.2—4.7 kgfm, 24—33 ft-lbf} 3. Connect the P/S oil pump pressure switch connector. 16A0B1-Q94 B 1-109 B1 INSTALLATION 4. Install the P/S pipe brackets to the cylinder head cover. Tightening torque: 7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf} 46U0B1-186 Drive belt 1. Install the drive belt. 2. Adjust the drive belt deflections. (Refer to page B1-6.) 16E0B1-358 Radiator and coolant fan assembly 1. Install the radiator and coolant fan assembly. Verify that the radiator is centerd in the radiator upper brackets. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} 46U0B1-187 2. 3. 4. 5. Connect Connect Connect Connect the the the the upper and lower radiator hoses. coolant reservoir hose. coolant fan motor connector. ATF cooler hoses. (ATX) Accelerator cable 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.0mm (0.06—0.16 in} 3. If not as specified, adjust the cable free play by turning stop­ per (D while pressing lock button ® with the throttle valve fully closed. 4. Reset the cable lock. 46U0B1-101 B1 INSTALLATION Battery 1. Install the battery. Tightening torque: 7.9—10.7 Nm (80—110 kgf-cm, 70—95.4 in lbf) 2. Connect the positive battery terminal. 46U0B1-188 Resonance chamber No.2 1. Slide the hose clamp onto the hose and push it onto reso­ nance chamber No.2. 16E0B1-380 2. Rotate the hose and hook it securely onto the locating knob. 16E0B1-381 3. Tighten the hose clamp. 16E0B1-382 Air cleaner assembly 1. Install the air cleaner assembly. Tightening torque: 19—25 N m (1.9—2.6 kgf m, 14—18 ft Ibf) 2. Connect the mass airflow sensor connector. 3. Connect the intake air thermosensor connector. 46U0B1-189 B1-111 B1 INSTALLATION Fresh air duct Install the fresh air duct. Tightening torque: 7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf) 46U0B1-190 Resonance chamber No.1 Install resonance chamber No.1. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf} Undercover Install the undercover. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf) 46U0B1-191 Steps After Installation 1. Fill with the specified amount and type of engine oil. (Refer to section D1.) 2. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E1.) 3. Fill with the specified amount and type of transaxle oil. (Refer to sections J, K2.) 4. Install the hood and front wheels. 5. Start the engine and: (1) Check the engine oil, transaxle oil, and engine coolant leakage (2) Check the ignition timing, idle speed (Refer to sections F1, F3.) (3) Check the operation of emission control system 6. Turn off the engine and check drive belt deflection. (Refer to page B1-6.) 7. Perform a road test. 8. Recheck the engine oil and coolant levels. 46U0B1-102 B1—112 B2 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warning and section J for audio antitheft system alarm conditions._________ ENGINE (KL) INDEX......................................... .... B 2- 2 OUTLINE...................................... .... B2— 3 SPECIFICATIONS...................... .... B 2- 3 TROUBLESHOOTING GUIDE..... .... B 2- 3 ENGINE TUNE-UP ...................... .... B 2- 5 PREPARATION........................ .... B 2 - 5 ENGINE O IL .............................. .... B 2- 5 ENGINE COOLANT................... .... B 2- 5 DRIVE BELT.............................. .... B 2- 5 HLA TROUBLESHOOTING GUIDE..................................... .... B 2- 7 COMPRESSION........................... .... B 2- 8 INSPECTION........................... .... B 2- 8 ON-VEHICLE MAINTENANCE.... .... B 2- 9 PREPARATION.......................... .... B 2- 9 TIMING BELT............................ .... B 2- 10 CYLINDER HEAD GASKET...... .... B 2- 20 HLA............................................. .... B 2- 34 FRONT OIL SEAL ................... .... B 2- 37 REAR OIL SEAL ...................... .... B2— 39 REMOVAL..................................... .... B 2- 42 PROCEDURE............................ .... B 2- 42 ENGINE STAND MOUNTING..... .... B 2- 51 PREPARATION.......................... .... B2— 51 PROCEDURE............................ .... B2— 52 DISASSEMBLY .......................... .... B 2- 55 PREPARATION.......................... .... B 2- 55 AUXILIARY PARTS.................. .... B2— 57 TIMING BELT.......................... .... B2— 59 CYLINDER HEAD..................... .... B2— 61 CYLINDER BLOCK (EXTERNAL PARTS)............... .... B 2- 65 CYLINDER BLOCK (INTERNAL PARTS)................ ..... B2— 68 INSPECTION / REPAIR.................... PREPARATION............................... CYLINDER HEAD.......................... VALVE MECHANISM................... CAMSHAFT................................. HLA............................................. CYLINDER BLOCK......................... PISTON, PISTON RING, AND PISTON PIN................................. CONNECTING ROD...................... CRANKSHAFT............................. BEARING .................................... OIL JE T .......................................... TIMING BELT................................. TIMING BELT AUTO TENSIONER. PULLEY.......................................... TIMING BELT COVER.................... ASSEMBLY .................................... PREPARATION............................... CYLINDER BLOCK (INTERNAL PARTS)..................... CYLINDER BLOCK (EXTERNAL PARTS).................... CYLINDER HEAD.......................... TIMING BELT................................. AUXILIARY PARTS....................... ENGINE STAND DISMOUNTING .... PROCEDURE.............................. INSTALLATION................................ PROCEDURE................................. B?-■ 72 B2-- 72 B2-■ 72 B2-■ 73 B2-■ 76 B2-■ 79 B2-■ 79 B2- 80 B2- ■ 82 B2- 82 B2- 83 B2- 83 B2- 83 B2- 84 B2- 84 B2- 84 B2- 85 B2- 85 B2- 87 B 2- 95 B 2- 99 B 2- 106 B 2- 111 B 2- 115 B 2- 115 B 2- 116 B 2- 116 46U0B2-001 B2 INDEX INDEX HLA INSPECTION PAGE B 2 -7 INTAKE MANIFOLD TIGHTENING TORQUE 19—25 N m (1.9—2.6 kgf-m 14—18 ft-lbf ENGINE COOLANT, SECTION E2 ENGINE OIL, SECTION D2 COMPRESSION INSPECTION, PAGE B 2 -8 EXHAUST MANIFOLD TIGHTENING TORQUE 19—25 N-m [1.9—2.6 kgf-m, 14— 18 ft-lbf) DRIVE BELT DEFLECTION AT 98 N (10 kgf, 22 Ibf) mm (in) DRIVE BELT NEW USED LIMIT ALTERNATOR 6.0—7.0 (0.24-0.27) 7.0—8.0 (0.28-0.31) 9.0 (0.35) ALTERNATOR + A/C 5.5—6.5 (0.22-0.25) 6.5—7.5 (0.26-0.29) P/S 6.0—7.0 [0.24-0.27] 7.0—8.0 (0.28-0.31) COMPRESSION STANDARD MINIMUM kPa (kgf/cm2, psi)-rpm 1,402 (14.3, 203)-250 981 (10.0, 142)-250 8.0 (0.32) 9.0 (0.35) 46U0B2-002 1. Timing belt Removal / Inspection / Installation...............................page 2. Cylinder head gasket Replacement............................page 3. HLA Removal / Installation............... page 4. Front oil seal Replacement............................page B2—2 B2-10 B2-20 B2-34 B2-37 5. Rear oil seal Replacement......................... page 6. Engine Removal................................ page Engine stand mounting......... page Disassembly.......................... page Inspection / Repair................. page Assembly............................... page Engine stand dismounting....page Installation.............................. page B2- 39 B2- 42 B2- 51 B2- 55 B2- 72 B2- 85 B2-115 B2-116 B2 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Engine KL Item Gasoline, 4-cycle Type 60°-V configuration, 6 cylinders Cylinder arrangement and number Pentroof Combustion chamber B2 DOHC, belt-driven, 24 valves Valve system ml (cm3, cu in) Displacement 2,496 (2,496, 152.3) 84.5x74.2 (3.33x2.92) mm (in) Bore and stroke 9.2 Compression ratio kPa (kgf/cm2, psi)-rpm Compression pressure IN Valve timing EX Valve clearance 1,402 (14.3, 203)-250 Open BTDC 8° Close ABDC 47° Open BBDC 50° Close ATDC 5° IN mm (in) 0: Maintenance-free EX mm (in) 0: Maintenance-free 46U0B2-003 Cylinder Arrangement RH "\ LH TROUBLESHOOTING GUIDE Problem Hard starting Poor idling Possible Cause Action Malfunction of engine-related components Burned valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Replace Replace or repair Replace Malfunction of fuel system Refer to section F2 Malfunction of electrical system Refer to section G Malfunction of engine-related components Malfunction of HLA* Poor valve-to-valve seat contact Damaged cylinder head gasket Replace Repair or replace Replace Malfunction of fuel system Refer to section F2 Page B2-73 B2-80, 81 B2-20 B2-34 B2-75 B2-20 ‘ Tappet noise may occur if the engine has not been started for an extended period of time. The noise should stop after the engine reaches normal operating temperature. (HLA troubleshooting: Refer to page B2-7.) B 2-3 B2 TROUBLESHOOTING GUIDE Insufficient power Abnormal combustion Excessive oil consumption Engine noise Action Possible Cause Problem Page Insufficient compression Malfunction of HLA* Compression leakage from valve seat Sticking valve Weak or broken valve spring Damaged cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston Replace Repair Replace Replace Replace Replace Replace Replace Malfunction of fuel system Refer to Section F2 Others Dragging brake Incorrect tire size Refer to Section P Refer to Section Q Malfunction of engine-related components Malfunction of HLA* Sticking or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Replace Replace Replace Eliminate carbon Malfunction of fuel system Refer to Section F2 Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Replace Replace or repair B2-81 B2-80, 81 Oil working down Worn valve seal Worn valve stem or guide Replace Replace B2-64 B2-73, 74 Oil leakage Refer to Section D2 Crankshaft or bearing-related parts Excessive main bearing oil clearance Main bearing heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing heat-damaged Replace or repair Replace Replace or repair Replace or repair Replace B2-89 B2-83 B2-92 B2-93 B2-83 Piston-related parts Worn cylinder Worn piston or piston pin Damaged piston ring Bent connecting rod Replace or repair Replace Replace Replace B2-79 B2-80, 81 B2-81 B2-82 Valve train-related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Malfunction of timing belt auto tensioner Malfunction of friction gear Replace Replace Replace Replace Replace Malfunction of cooling system Refer to section E2 Malfunction of fuel system Refer to section F2 Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage Refer to section E2 Adjust Refer to section G Refer to section F2 B2-34 B2-75 B2-73 B2-76 B2-20 B2-72 B2-81 B2-80 B2-34 B2-73 B2-76 B2-79 B2-76 B2-73 B2-84 B2-76 B2- 5 46U0B2-125 * Tappet noise may occur if the engine has not been started for an extended period of time. The noise should stop after the engine reaches normal operating temperature. (HLA troubleshooting: Refer to page B2-7.) B 2 -4 ENGINE TUNE-UP B2 ENGINE TUNE-UP PREPARATION SST For inspection of drive belt tension 49 9200 020 Tension gauge, belt * 46U0B2-126 ENGINE OIL Inspection 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condition. 5. Add or replace oil if necessary. Note • The distance between the L and F marks on the dipstick represents 1.0 L (1.1 US qt, 0.9 Imp qt}. ENGINE COOLANT Inspection Coolant level (Engine cold) Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam can shoot out and cause serious injury. It can also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap—still using a cloth—turn it, and remove it. 1. Verify that the coolant level is at the filler neck. 2. Verify that the coolant level on the dipstick is between the F and L marks. 3. Add coolant if necessary. Note • The distance between the L and F marks on the dipstick represents 0.5 L {0.5 US qt, 0.4 Imp qt). Coolant quality 1. Verify that there is no buildup of rust or scale around the radiator cap, filler cap, and filler neck. 2. Verify that the coolant is free of oil. 3. Replace the coolant if necessary. B2—5 B2 ENGINE TUNE-UP DRIVE BELT Inspection 1. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 2. Verify that the drive belts are correctly mounted on the pulleys. V-RIBBED BELT 46U0B2-127 3. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply moderate pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys. 46U0B2-007 Deflection mm (in) *New Used 6.0—7.0 7.0—8.0 Alternator (0.24-0.27) (0.2 8-0 .31 ) Alternator + 5.5—6.5 6.5—7.5 (0.22-0.25) (0.26—0.29) A1C 6.0—7.0 7.0—8.0 P/S (0.24-0.27) (0.28-0.31) * A belt that has been on a running engine for less than five Drive belt Limit 9.0 (0.35) 8.0 (0.32) 9.0 (0.35) minutes. 4. If the deflection is not within specifications, adjust it. Drive belt tension check Belt tension can be checked in place of belt deflection. 1. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys. Tension N (kgf, Ibf) ’ New Limit Used 690-880 5 00 -6 80 440 Alternator (7 0 -9 0 , 160-190) (5 0 -7 0 , 110-150) (45, 99) 440 Alternator + 690-880 5 00 -6 80 A/C (70—90, 160—190) (50—70, 110—150) (45, 99) 340 5 40 -6 80 4 00 -5 30 P/S (35, 77) (5 5 -7 0 , 130-150) (40—55, 8 8 -1 2 0 ) * A belt that has been on a running engine for less than five minutes. Drive belt 2. If the tension is not within specifications, adjust it. 46U0B2-010 B 2 -6 B2 ENGINE TUNE-UP Adjustment Alternator+ A/C belt 1. Loosen the idler pulley locknut ® . 2. Adjust the belt deflection by turning the adjusting bolt (§). ^>51 spgr (to / (D 1 46U0B2-Q11 Deflection (Alternator + A/C) New: 5.5—6.5mm [0.22—0.25 in) Used: 6.5—7.5mm (0.26—0.29 in) (Alternator) New: 6.0—7.0mm (0.24—0.27 in) Used: 7.0—8.0mm (0.28—0.31 in) 3. Tighten the pulley. Tightening torque: 32—46 N-m (3.2—4.7 kgf m, 24—33 ft-lbf} P/S 1. Loosen the idler pulley locknut ® . 2. Adjust the belt deflection by turning the adjusting bolt (§). tfr I/M® 46U0B2-128 Deflection New: 6.0—7.0mm (0.24—0.27 in) Used: 7.0—8.0mm (0.28—0.31 in) 3. Tighten the pulley locknut. Tightening torque: 32—46 N-m (3.2—4.7 kgf-m, 24—33 ft-lbf} HLA TROUBLESHOOTING GUIDE Problem Possible Cause Action Run engine at 2,000—3,000 rpm. If noise stops after 2 seconds—10 minutes,* HLA is normal. If not, replace HLA. *Time required for engine oil to circulate within engine includes tolerance for engine oil condition and ambient temperature. 1. Noise when engine is first started after oil is changed. 2. Noise when engine is started after setting apporox. one day. Insufficient oil in system Oil leakage from HLA 3. Noise when engine is started after crank­ ing for 3 seconds or more. 4. Noise when engine is started after new HLA is installed. Insufficient oil in HLA Oil leakage from HLA 5. Noise continues more than 10 minutes. Insufficient oil pressure Check oil pressure. If lower than the specification, check for cause. Oil pressure: 340—490 kPa (3.4—5.0 kgf/cm2, 49—71 psi)-3,000 rpm Faulty HLA (Refer to page B2-36) Press down HLA by hand. If it moves, replace HLA. If it does not move, HLA is normal. Measure valve clearance. If more than 0mm (0 in), replace HLA. Incorrect oil amount Check oil level. Drain or add oil as necessary. Deteriorated oil Check oil quality. If deteriorated, replace with specified type and amount of oil. 6. Noise during idle after high speed running. 36U0B2-005 B 2 -7 B2 COMPRESSION COMPRESSION If the engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to section G.) 2. Compression (Refer to below) 3. Fuel system (Refer to section F2.) INSPECTION 1. Verify that the battery is fully charged. Recharge it if necessary. 2. Warm up the engine to the normal operating temperature. 3. Remove the spark plugs. 4. Disconnect the primary wire connector from the ignition coil. 16E0B2-024 5. 6. 7. 8. Insert a compression gauge into the No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Record the maximum gauge reading. Check each cylinder as above. Compression: 1,402 kPa {14.3 kgf/cm2, 203 psi}-250 rpm Minimum: 981 kPa {10.0 kgf/cm2, 142 psi)-250 rpm 9. If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, piston rings, or cylinder wall may be worn. (2) If the compression stays low, a valve may be stuck or improperly seating. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 10. Connect the ignition coil connector. 11. Install the spark plugs. Tightening torque: 15—22 Nm {1.5—2.3 kgf m, 11—16 ft-lbf} 16E0B2-026 B 2 -8 B2 ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE PREPARATION SST 49 S120 710 Holder, coupling flange 49 E011 101 Holder (Part of 49 E011 1A1) 49 G017 5A0 Support, engine 49 G017 502 Support (Part of 49 G017 5A0) 49 E011 1A0 Brake set, ring gear 49 E011 104 Collar (Part of 49 E011 1A0) For prevention of crankshaft rotation For prevention of crankshaft rotation 49 E011 1A1 Set, holder 49 E011 102 Bolts (Part of 49 E011 1A1) For support of engine 49 G017 501 For support of engine 49 G017 503 For prevention of crankshaft rotation 49 E011 103 For prevention of crankshaft rotation 49 E011 105 Bar (Part of 49 G017 5A0) Hook (Part of 49 G017 5A0) Shaft (Part of 49 E011 1A0) Stopper (Part of 49 E011 1A0) s i For prevention of crankshaft rotation For prevention of crankshaft rotation For support of engine For support of engine For prevention of crankshaft rotation For prevention of crankshaft rotation 46U0B2-131 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Pro­ tect your skin by washing with soap and water immediately after this work. B2 ON-VEHICLE MAINTENANCE TIMING BELT Removal / Inspection / Installation 1. Disconnect the negative battery cable. 2. Remove the sprash shield and right front wheel. 3. Remove the drive belts. 4. Remove in the order shown in the figure, referring to Removal Note. 5. Install in the reverse order of removal, referring to Installation Note. I N m {kgfm, ft-lbf) 46U0B2-132 1. Water pump pulley 2. Idler pulley bracket 3. P/S oil pump Removal Note..............................page B2-11 Installation Note........................page B2-18 4. Crankshaft pulley Removal Note.......................... page B2-12 Installation Note....................... page B2-18 5. Timing belt pulley Removal Note...........................page B2-12 6. Dipstick and pipe Removal Note...........................page B2-12 Installation Note........................page B2-17 7. Crankshaft position sensor harness bracket B 2 -1 0 8. Engine harness bracket 9. Timing belt cover Removal Note.......................... page Installation Note....................... page 10. Timing belt Removal Note.......................... page Inspection................................ page Installation Note....................... page 11. Timing belt auto tensioner Inspection................................ page Installation Note....................... page 12. Tensioner pulley 13. No.2 idler pulley 14. No.1 idler pulley B2-13 B2-16 B2-13 B2-83 B2-15 B2-84 B2-14 ON-VEHICLE MAINTENANCE B2 Removal Note P/S oil pump 1. Remove the bolts shown in the figure and secure the P/S oil reservoir away from the engine. 16E0B2-029 2. Loosen the pulley nut as shown. 3. Remove the pulley. 16E0B2-030 4. Remove the bolt shown in the figure. 16EQB2-031 5. Remove the bolts shown in the figure and remove the P/S oil pump. 16E0B2-032 6. Position the P/S oil pump away from the engine and secure it with wire. 16E0B2-033 B 2-11 B2 ON-VEHICLE MAINTENANCE Crankshaft pulley Caution • The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily. 46U0B2-015 1. Install the SST with bolts (M1 Ox 1.25) to the crankshaft pulley. Caution • Install the bolts fully. 2. Remove the crankshaft pulley bolt and the pulley. 46U0B2-133 Timing belt pulley Note • If necessary, remove the pulley with a steering wheel puller. 46U0B2-016 Dipstick and pipe 1. Disconnect the crankshaft position sensor connector. 2. Remove the clip from the dipstick pipe. 46U0B2-134 3. Remove the dipstick and pipe. 4. Plug the hole in the engine after removing the pipe. 46U0B2-017 B 2-12 ON-VEHICLE MAINTENANCE B2 Timing belt cover 1. Support the engine by using the SST (engine support). 2. Remove the engine mount No.3. 16A0B2-077 3. Remove the right and left timing belt covers. 16E0B2-041 Timing belt 1. Install the crankshaft pulley bolt into the crankshaft. 2. Turn the crankshaft so that the No.1 piston is at TDC of the compression stroke. 3. Mark the timing belt rotation on the belt for proper reinstal­ lation. 16A0B2-078 4. Loosen the auto tensioner bolts and remove the lower bolt. Caution • When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged. 46U0B2-018 B2—13 B2 ON-VEHICLE MAINTENANCE 5. Remove the No.1 idler pulley and remove the timing belt. Caution • When removing the pulley bolt, hold the pulley so that the bolt holes are aligned, otherwise the threads can be damaged. • The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bend­ ing it, or allowing oil or grease on it. No.1 IDLER PULLEY 46U0B2-019 Inspection Inspect the following and repair or replace as necessary. (1) Timing belt (Refer to page B2-83.) (2) Timing belt auto tensioner (Refer to page B2-84.) (3) Timing belt pulley (Refer to page B2-84.) (4) Camshaft pulleys (Refer to page B2-84.) I*I f &) Y I v - • .’ • q ) 46U0B2-135 I ALIGN THE HOLES WASHER Installation Note Timing belt auto tensioner 1. Set a flat washer under the tensioner body to prevent dam­ age to the body plug. 2. Slowly press in the tensioner rod by using a press or a vise. • Do not press the tensioner rod to more than 9,807 N {1,000 kgf, 2,200 Ibf). It will damage the ten­ sioner. 46U0B2-136 3. Insert a pin into the second hole in the body as shown to hold the tensioner rod. Pin diameter: 1.6mm {0.063 in] 46U0B2-137 4. Set the tensioner in place and snugly tighten the tensioner upper bolt. Note • This must be done to reduce the timing belt resistance when the idler pulley is installed. 46U0B2-020 B 2-1 4 B2 ON-VEHICLE MAINTENANCE Timing belt 1. Turn the camshaft pulleys and align the timing marks of the camshaft pulleys with those of the cylinder heads. 16E0B2-049 2. Using the crankshaft bolt, turn the crankshaft and align the timing marks of the timing belt pulley and the oil pump. 3. Install the timing belt on the pulleys in the order shown below. Timing belt pulley Idler pulley No.2 (3) LH camshaft pulley @ Tensioner pulley © RH camshaft pulley S / ■ '•'* ■ 4. Verify that the belt has no looseness at the tension side. 5. Install the No.1 idler pulley while applying pressure on the timing belt. Tightening torque: 38—51 N-m {3.8—5.3 kgf m, 28—38 ft Ibf) 46U0B2-021 6. Push the auto tensioner in the direction of the arrow and tighten the bolts. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf J 46U0B2-138 B 2-15 B2 ON-VEHICLE MAINTENANCE 7. Remove the pin from the auto tensioner to apply tension to the belt. 8. Turn the crankshaft twice in the direction of rotation, and align the timing marks. 9. Verify that all timing marks are correctly aligned. If neces­ sary, repeat the procedure beginning from installation of the timing belt auto tensioner. 10. Check the timing belt deflection by applying moderate pres­ sure 98 N {10 kgf, 22 Ibf) midway between the crank­ shaft pulley and the auto tensioner. If not correct, replace the auto tensioner. Deflection: 6.0—8.0mm {0.24—0.31 in) Timing belt cover 1. Install the right timing belt cover. Tightening torque: 7.9—10.7 N m {80—110 kgf-cm, 70—95.4 in Ibf) 2. Install the left timing belt cover. Tightening torque: 7.9—10.7 N-m {80—110 kgf cm, 70—95.4 in lbf} 46U0B2-143 B 2-1 6 ON-VEHICLE MAINTENANCE B2 3. Install the crankshaft position sensor connector bracket on the left timing belt cover. Tightening torque: 7.9—10.7 N m {8 0 -1 1 0 kgf cm, 70—95.4 in lbf) 46U0B2-144 4. Install the harness bracket on the right timing belt cover. Tightening torque: 7.9—10.7 N m {80—110 kgf cm, 70—95.4 in Ibf) 46U0B2-145 5. Install the engine mount No.3. Tightening torque A: 74—102 Nm {7.5—10.5 kgf m, 55—75 ft-lbf) B: 86—116 N-m {8.7—11.9 kgf m, 63—86.0 ft Ibf) 6. Remove the SST (engine support). 16E0B2-446 Dipstick and pipe 1. Apply clean engine oil to a new O-ring and install it on the pipe. 2. Remove the plug from the engine and install the pipe. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in lbf) 3. Install the dipstick. 46U0B2-147 B 2-17 B2 ON-VEHICLE MAINTENANCE 4. Install the crankshaft position sensor harness and clip to the dipstick pipe. 5. Connect the connector. 36U0B2-081 Crankshaft pulley 1. Remove the crankshaft pulley bolt. 2. Install the crankshaft pulley and hand tighten the bolt. 3. Mount the SST on the crankshaft pulley to hold the crankshaft. 4. Tighten the crankshaft pulley bolt. Tightening torque: 157—166 Nm {16.0—17.0 kgf m, 116—122 ft-lbf) 46U0B2-148 P/S oil pump 1. Install the P/S oil pump. Tightening torque A: 32—46 N m {3.2—4.7 kgf m, 24—33 ft Ibf) B: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf) 16E0B2-065 2. Install the P/S oil pump pulley and hand tighten the pulley nut. 3. Tighten the pulley nut by using a 12mm {0.47 in) socket on one of the P/S oil pump mount bolts. Tightening torque: 63—93 Nm {6.4—9.5 kgf m, 47—68 ft-lbf) 46U0B2-149 B2 ON-VEHICLE MAINTENANCE 4. Install the P/S oil reservoir and the engine ground. Tightening torque: 6.9—9.8 N-m {70—100 kgf-cm, 61—86 in-ibf) 36U0B2-155 Steps After Installation 1. Install the drive belts. (Refer to page B2-7.) 2. Install the sprash shield and right front wheel. 3. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant. 4. Perform the necessary engine adjustments. (Refer to section F2.) 46U0B2-15Q B2 ON-VEHICLE MAINTENANCE CYLINDER HEAD GASKET Replacement Warning • Release the fuel pressure. (Refer to Section F2.) • Keep sparks and open flames away from the fuel area. • Do not support the engine by using a jack under the oil pan. It will damage the oil pan. Rein' stall the engine mount No.3 to support the engine after removing the timing belt. 1. 2. 3. 4. 5. Disconnect the negative battery cable. Piain the engine coolant. (Refer to section E2.) Romove the timing belt. (Refer to page B2-10.) Romove in the order shown in the figure, referring to Removal Note. Install in the reverse order of removal, referring to Installation Note. 19—25 (1.9—2.6, 14—18) (2 ) 11.3—14.2 N m 1115-145 kgf-cm, 100—125 In lbf) 5.0—8.8 N m 150—90 kgfcm, 44—78 Inlbf) GASKET, REPLACE Ir i r BOLT THREADS 123—140 12.5—14.3, 91—103) (1.9—2.6, 14—18) —10.7 N m -110 kgf-cm, 95.4 Inlbf) .65, 17.0—19.1) 95° + 85°—95° 1 9 -2 5 (1.9—2.6, 14—18 GASKET, REPLACE 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 ln-lbf | 44—60 14.4—6.2, 32 7.9—10.7 Nm (80—110 kgfcm, 70—95.4 Inlbf) N-m (kgf-m, ft-lbf) 46U0B2-151 B 2 -2 0 ON-VEHICLE MAINTENANCE 1. Fresh air duct 2. Air cleaner housing assembly 3. Accelerator cable Installation Note.................... ... 4. High-tention leads 5. Harness Removal Note........................ ... Installation Note.................... ... 6. Intake manifold assembly Removal Note........................ ... Installation Note.................... ... 7. Distributor Installation Note.................... ... 8. Cylinder head cover Removal Note........................ ... Installation Note.................... ... 9. Camshaft pulley Removal Note........................ ... Installation Note.................... ... page B2-33 page B2-22 page B2-33 page B2-22 page B2-22 page B2-31 page B2-24 page B2-30 page B2-24 page B2-29 10. Radiator hose, upper 11. No.3 engine mount bracket Removal Note.......................... Installation Note....................... 12. Seal plate 13. Water outlet 14. Exhaust pipe 15. Engine hanger 16. Camshaft cap, blind cap, and oil Removal Note.......................... Installation Note....................... 17. Camshaft Installation Note....................... 18. Cylinder head bolt Removal Note.......................... 19. Alternator strap 20. Cylinder head Installation Note....................... 21. Cylinder head gasket and O-ring B2 page B2-24 page B2-29 seal page B2-24 page B2-28 page B2-27 page B2-25 page B2-26 46U0B2-152 B2-21 B2 ON-VEHICLE MAINTENANCE Removal Note Harness Disconnect the harness connectors shown in the figure. 16E0B2-076 Intake manifold assembly Warning • Cover the hose with a rag because fuel will spray out when disconnecting. • Keep sparks and open flames away from the fuel area. 1. Plug the disconnected hoses to avoid fuel leakage. 36U0B2-017 2. Temporarily install the engine mount No.3 bracket to sup­ port the engine. 16A0B2-082 B 2-22 B2 ON-VEHICLE MAINTENANCE 3. Remove the SST installed for timing belt removal. 4. Remove the stays, bracket, fuel pipe, and hoses as shown in the figure. 5. Loosen the mounting bolts and nuts in two or three steps. MOUNTING BOLTS AND NUTS INTAKE MANIFOLD STAY FUEL PIPE AND HOSE W ASHER,REPLACE AIR CLEANER HOUSING BRACKET 16E0B2-448 B 2-23 B2 ON-VEHICLE MAINTENANCE Cylinder head cover 1. Remove the bolts shown in the figure. 2. Disconnect the ventilation pipe (left cylinder head). 3. Remove the cylinder head cover. 16E0B2-082 Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lockbolt. 2. Remove the camshaft pulley. 46U0B2-153 Engine mount No.3 bracket 1. Install the SST and support the engine. 16A0B2-083 2. Disconnect the engine mount No.3 bracket from the engine mount rubber. 3. Remove the engine mount No.3 bracket from the engine. 16A0B2-084 Camshaft cap, blind cap, and oil seal Caution • When the camshaft lobe is pressing on the HLA, removing the camshaft caps can damage the cylin­ der head thrust journal support. 46U0B2-022 B 2 -2 4 ON-VEHICLE MAINTENANCE B2 1. Loosen the front camshaft cap bolts in five or six steps in the order shown. 2. Remove the front camshaft cap. Note • Perform this same procedure for the right and left cylin­ der head. • Bolt © fits only the right cylinder head. 3. Loosen the camshaft cap bolts in five or six steps in the or­ der shown. 4. Remove the camshaft caps. Caution • Remove the thrust cap only after removing all cam­ shaft caps. Otherwise, the thrust cap can be damaged. Note • Before removing the camshaft caps, note their locations. They are identified as follows; Right head: numbers Left head: letters 46U0B2-025 Cylinder head bolt 1. Temporarily install the engine mount No.3 bracket to sup­ port the engine. 2. Remove the SST. B 2-25 B2 ON-VEHICLE MAINTENANCE 3. Loosen the cylinder head bolts in two or three steps in the order shown. 4. Remove the cylinder head bolts. 16E0B2-092 Installation Note Cylinder head 1. Apply dean engine oil to new O-rings and install them to the oil control plugs. 46U0B2-154 2. Thoroughly remove all dirt, oil, and other material from the decks of the cylinder block. 3. Turn the crankshaft clockwise and apply engine oil to the cylinder walls. 4. Place a new cylinder head gasket on the left bank with the L mark. 5. Place a new cylinder head gasket on the right bank with the R mark. 46U0B2-026 6. Install the cylinder head to the cylinder block. 7. Tighten the cylinder head bolts as described below. (1) Before installation, measure the length of each bolt. Re­ place a bolt if it exceeds the maximum length. 133.7— 134.3mm {5.264— 5.287 in } * Length: 133.7—134.3mm (5.264—5.287 in) Maximum: 135.0mm (5.315 in} 46U0B2-155 (2) Apply clean engine oil to the threads and the seat face of each bolt, and install them and the washers. (3) Tighten the bolts in two or three steps in the order shown. Tightening torque: 23.1—25.9 N-m (2.35—2.65 kgf m, 17.0—19.1 ft-lbf} 16E0B2-096 B 2-26 ON-VEHICLE MAINTENANCE B2 (4) Put a paint mark on each bolt head. (5) Using the marks as a reference, tighten the bolts by turning each 85°— 95° in the sequence shown. (6) Further tighten each bolt by turning another 85°— 95°. 8. Support the engine by using the SST. 9. Disconnect the engine mount No.3 bracket. 10. Remove the engine mount No.3 bracket from the en­ gine. Camshaft, camshaft cap, blind cap, and oil seal 1. Apply clean engine oil to the camshaft journals, cam­ shaft lobes, and camshaft gears. 2. Install the camshafts so that the intake camshaft gear mark and exhaust camshaft gear marie align. Adjust the friction gear position with a screwdriver so that the HLAs are not lifted by the cam lobes. {Intake Side cam lobes of the No.1 cylinder <RH) and No.2 cylinder (LH) face straight up.) B2 r tp p iie u ON-VEHICLE MAINTENANCE VMM. 1YVGE22D*R5100001— 1YVGE31D*R5100001— Caution • Install the thrust caps (RH is 5 mark, LH is B m ark) first. Otherwise, camshaft can be broken or dam­ aged. ....... 3. Install the thrust caps onto the cylinder head. Hand tight­ en the cap bolts gradually in five or six steps in the order shown, until the thrust caps fully seated on the cylinder head. B2 ON-VEHICLE MAINTENANCE 4. Apply silicone sealant to the shaded areas as shown. Caution • Because there is little camshaft thrust clearance, the camshaft m ust be held horizontally while it is installed. Otherwise, excessive force will be ap­ plied to the thrust area, causing burr on the thrust receiving area of the cylinder head Journal. To avoid this, the following procedure must be ob­ served. 5. Install the camshaft caps according to their identification marks, and hand tighten the bolts. Note • • RH: numbers LH: letters 6. Tighten the bolts in the order shown. Verify that t ie cam­ shaft remains horizontal as the camshaft cap bolts (marked (T) in the figure) tightened. Tightening torque: 11.3— 14.2 N m {115— 145 kgf-cm, 100— 125 in lbf) 7. Retighten the bolts in the order shown. Tightening torque: 11.3— 14.2 N m {115— 145 kgf-cm, 100— 125 in lbf} 8. Apply a light coat of clean engine oil to the new oil seal and the cylinder head. 9. Tap the camshaft oil seal into the cylinder head by using a pipe. Protrusion: 0— 0.5 mm {0— 0.02 in} Note • Oil seal outer diameter: 44.0 mm {1.73 in} • Oil seal inner diameter: 30.0 mm {1.18 in} 46U0B2-162 Revised 5/96 B2 ON-VEHICLE MAINTENANCE 10. Apply sealant to a new blind cap. 11. Tap in the blind cap by using a plastic hammer. 46U0B2-163 Engine mount No.3 bracket 1. Install the engine mount No.3 bracket to the engine. Tightening torque: 44—60 Nm {4.4—6.2 kgf m, 32—44 ft Ibf) 2. Temporarily install the engine mount No.3 bracket to the engine mount rubber. 3. Remove the SST (engine support). Camshaft pulley The right and left pulleys are different and must be installed on the same head that they were removed from. 1. Install the camshaft pulley so that the “ R” mark can be seen and the groove aligns with the camshaft knock pin. 46U0B2-028 B 2-29 B2 ON-VEHICLE MAINTENANCE 2. Install the camshaft pulley so that the “ L” mark can be seen and the groove aligns with the camshaft knock pin. 36U0B2-084 3. Apply engine oil to the lock bolt threads and hand tighten the lock bolt. 4. Hold the camshaft by using a suitable wrench on the cast hexagon as shown, and tighten the bolt. Tightening torque: 123—140 N m (12.5—14.3 kgf m, 91—103 ft-lbf) 46U0B2-164 Cylinder head cover 1. Remove all old silicone sealant from the cylinder head and cover. 2. Coat a new gasket with silicone sealant, and install onto the cylinder head cover. 16A0B2-017 3. Remove all dirt and other material from the cylinder head, and apply sealant to the shaded areas as shown. » & 1 < f l l r f i t B ■sassii | 16A0B2-018 4. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown. Note • Left cylinder head cover bolts are round. Tightening torque: 5.0—8.8 N m (50—90 kgf cm, 44—78 in lb f) 46U0B2-029 B 2-3 0 ON-VEHICLE MAINTENANCE B2 5. Recheck the torque of the bolts indicated, and tighten them if necessary. RH: © , © LH: © , ® 6. Install the ventilation pipe to the left cylinder head cover. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95 in lbf} 36U0B2-085 Distributor 1. Apply clean engine oil to a new O-ring and position it on the distributor. 2. Apply clean engine oil to the drive blade. 16AOB2-060 3. Install the distributor with the blade fit into the camshaft groove. 4. Hand tighten the distributor mounting bolts. 46U0B2-Q30 B2-31 B2 ON-VEHICLE MAINTENANCE Intake manifold assembly 1. Install a new gasket and the intake manifold. Hand tighten the bolts and nuts. 2. Connect the stays, bracket, fuel pipe, and hoses as shown in the figure. 3. Tighten the intake manifold bolts and nuts in two or three steps. 19—25 11.9—2.6, 14—18 19—25 {1.9—2.6, 14—18) 7.9—10.7 Nm (80—110 kgf-cm, 70—95 Inlbf) WASHER, NEW N-m{kgf.m, ft-lbf) 46U0B2-167 B 2-32 ON-VEHICLE MAINTENANCE B2 Harness Connect the harness connectors as shown in the figure. 16E0B2-124 Accelerator cable 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.5mm (0.06—0.17 in) 3. If not as specified, turn stopper © while pressing lock but­ ton (A) to release the lock. 4. Push the spring in direction (5) and adjust the cable free play. 5. Lock stopper ® after locking stopper (§). UNLOCK 46U0B2-168 Steps After Installation 1. Install the timing belt. (Refer to page B2-10.) 2. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant. (Refer to section E2.) 3. Start the engine and check as follows: (1) Engine oil and engine coolant leakage. (2) Ignition timing, idle speed. (Refer to section F2.) (3) Operation of emission control system. 4. Recheck the engine coolant and oil levels. 46U0B2-169 B 2-33 B2 ON-VEHICLE MAINTENANCE HLA Removal / Installation Warning • Release the fuel pressure. (Refer to section F2.) • Keep sparks and open flames away from the fuel area. 1. 2. 3. 4. Disconnect the negative battery cable. Remove the timing belt. (Refer to page B2-10.) Remove in the order shown in the figure, referring to Removal Note Install in the reverse order of removal, referring to Installation Note. 11.3—14.2 N-m (115—145 kgf-cm, 100—125 ln-lbf) 5.0—8.8 N-m (50—90 kgf-cm, 44—78 Inlbf) 11.3—14.2 N m (115—145 kgf-cm, 100—125 ln-lbf) GASKET, REPLACE 7.9—10.7 N m (80—110 kgf-cm, 70—95.4 in Ibf) BOLT THREADS 123—140 (12.5-14.3, 9 1 -1 0 3 ) N-m( kgf-m, ft-lbf) 46U0B2-170 B2 ON-VEHICLE MAINTENANCE 1. Accelerator cable Installation Note....................... page B2-33 2. High-tension leads 3. Harness Removal / Installation Note................. below 4. Intake manifold assembly Removal Note...........................page B2-22 Installation Note........................page B2-32 5. Cylinder head cover Installation Note....................... page B2-30 6. Distributor Installation Note....................... page B2-31 7. Camshaft pulley Removal Note.......................... page Installation Note....................... page 8. Camshaft cap, blind cap, and oil seal Removal Note.......................... page Installation Note....................... page 9. Camshaft Installation Note....................... page 10. HLA Inspection................................ page Removal / Installation note Harness Disconnect the harness connectors as shown in the figure. B2-24 B2-29 B2-24 B2-28 B2-27 B2-36 46U0B2-171 B2 ON-VEHICLE MAINTENANCE Inspection HLA Note • Refer to page B2-7 for HLA troubleshooting. 1. Inspect the HLA friction surfaces for wear and damage. Re­ place the HLA if necessary. 2. Hold the bucket body and press the plunger by hand. If the plunger moves, it is defective. Replace the HLA—do not attempt to repair it. Steps After Installation 1. Install the timing belt. (Refer to page B2-10.) 2. Fill the radiator and coolant reservoir with the specified amount and type or engine coolant. (Refer to Section E2.) 3. Start the engine and check the following. (1) Engine oil and engine coolant leakage. (2) Ignition timing, idle speed. (Refer to section F2.) (3) Operation of emission control system. 4. Recheck the engine coolant and oil levels. 46U0B2-172 ON-VEHICLE MAINTENANCE B2 FRONT OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. 46U0B2-173 1. Tinning belt Removal / Installation 2. Timing belt pulley Removal Note.......... Installation Note....... page B2-10 3. Oil seal Removal Note.......................... page B2-38 Installation Note....................... page B2-38 page B2-38 page B2-38 B 2-37 B2 ON-VEHICLE MAINTENANCE Removal Note Timing belt pulley Note • If necessary, remove the pulley with a steering wheel puller. 1. Remove the timing belt pulley. 2. Remove the crankshaft key. 46UOB2-032 Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag. 16E0B2-134 Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of the new oil seal. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly with a pipe and a hammer. Protrusion: 0—0.7mm {0—0.03 in) Oil seal outer diameter: 48.0mm {1.89 in) Oil seal inner diameter: 34.0mm {1.34 in) 46U0B2-174 Timing belt pulley 1. Install the timing belt pulley. 2. Install the crankshaft key with the tapered side toward the oil pump body. 16E0B2-136 Steps After Installation 1. Connect the negative battery cable. 2. Start the engine and check the following. • Ignition timing. (Refer to section F2.) 46U0B2-175 B2 ON-VEHICLE MAINTENANCE Removal Note Flywheel (MTX) 1. Mount the SST to hold the flywheel. 2. Remove the flywheel mounting bolts in two or three steps in the order shown in the figure. 3. Remove the flywheel. 16E0B2-139 Drive plate, backing plate, adapter (ATX) 1. Mount the SST to hold the drive plate. 2. Remove the drive plate mounting bolts. 3. Remove the backing plate, drive plate, and adapter. 16E0B2-140 Oil seal 1. Cut the oil seal lip with a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag. 16E0B2-141 Installation Note Oil seal 1. Apply a small amount of clean engine oil to the lip of the new oil seal. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly with a pipe and a hammer. Protrusion: 0—0.7mm {0—0.03 in) Oil seal outer diameter: 93.0mm {3.66 in} Oil seal inner diameter: 75.0mm (2.95 in) Flywheel (MTX) 1. Set the flywheel onto the crankshaft. 2. Hand tighten the mounting bolts. 3. Hold the flywheel by using the SST. 4. Tighten the bolts in two or three steps in the order shown in the figure. 49 E011 1A0 46U0B2-178 B 2-4 0 Tightening torque: 61—67 N m {6.2—6.9 kgf m, 45—49 ft-lbf} B2 ON-VEHICLE MAINTENANCE Drive plate (ATX) 1. Install the adapter, drive plate, and backing plate onto the crankshaft. (1) Adapter (2) Drive plate (3) Backing plate 2. Hand tighten the mounting bolts. 3. Hold the drive plate by using the SST. 4. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 61—67 N m {6.2—6.9 kgf m, 45—49 ft-lbf} 49 E 0 1 1 1 AO 16E0B2-146 Steps after installation 1. Connect the negative battery cable. 2. Start the engine and perform engine adjustments as necessary. 3. Check the oil level. 16E0B2-147 B2-41 B2 REMOVAL REMOVAL Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel cab also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on section F2. PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the engine coolant and transaxle oil. (Refer to section E2 and section J, K1.) 3. Remove the hood and front wheels. 4. Remove in the order shown in the figure, referring to Removal Note. Step 1 46U0B2-034 1. Splash shield 2. Fresh-air duct 3. Air cleaner housing assembly 4. Battery and carrier 5. Accelerator cable 6. Radiator hoses 7. ATF cooler hose (ATX) 8. Coolant fan motor connector 9. Radiator and coolant fan assembly 10. Drive belts Removal Note.......................... page B2- 5 11. P/S oil pump Removal Note.......................... page B2-43 12. A/C compressor (if equipped) Removal Note.......................... page B2-44 13. Cruise actuator Removal / Installation.................... section T 14. Control cable (ATX) REMOVAL B2 Removal Note P/S oil pump 1. Remove the bolts shown in the figure and secure the P/S oil reservoir away from the engine. 16E0B2-149 2. Loosen the pulley nut as shown. 3. Remove the pulley. 16E0B2-150 4. Remove the bolt shown in the figure. 16E0B2-151 5. Remove the bolts shown in the figure and remove the P/S oil pump. 16E0B2-152 6. Position the P/S oil pump away from the engine and se­ cure it with wire. 16E0B2-153 B 2-43 B2 REMOVAL A/C compressor (if equipped) 1. Remove the A/C compressor with the hoses still connected. 2. Position the compressor away from the engine and secure it with wire. 46U0B2-035 Step 2 Disconnect the harness connectors shown in the figure. REMOVAL B2 Step 3 Disconnect the hoses shown in the figure. 16E0B2-156 Removal note Fuel hose Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Disconnect the fuel hoses. 46U0B2-179 Heater hose Press the heater hose retainer tabs and remove the heater hoses. 46U0B2-036 B 2-45 B2 REMOVAL Step 4 46U0B2-180 1. Clutch release cylinder (MTX) Removal Note................... 2. Transverse member 3. Exhaust pipe 4. Shift control rod (MTX) 5. Extension bar (MTX) 6. Stabilizer control link below 7. Tie rod end Removal Note.......................... page B2-47 8. Drive shaft Removal Note.......................... page B2-47 9. Joint shaft Removal Note.......................... page B2-47 Removal Note Clutch release cylinder (MTX) 1. Remove the bolts and clips as shown. Caution • Bending the pipe can cause kinks or cracks. 2. Remove the release cylinder and position it away from the transaxle with the hose still connected. 46U0B2-181 B 2-4 6 REMOVAL B2 Tie rod end 1. Remove the cotter pin and loosen the nut so that it is flush with the end of the ball joint stud. 2. Separate the knuckle arm and ball-joint by using the SST. 46U0B2-182 Drive shaft 1. Remove the bolts and nuts at the left and right lower arm ball joints. Caution • The ball-joint dust boots and oil seals are damaged easily if this procedure is not done correctly. 2. Pry the lower arms downward to separate them from the knuckles. 3. Separate the drive shafts from the transaxle by prying with a bar inserted between the shaft and the case. 46U0B2-183 Joint shaft 1. Remove the joint shaft mounting bolts. 2. Remove the joint shaft. 16A0B2-024 B2 REMOVAL Step 5 46U0B2-184 1. Engine mount No.3 rubber 2. Engine mount No.4 rubber and bracket 3. Engine mount member Removal Note.....................................below 4. Engine and transaxle assembly Removal Note.......................... page B2-49 Removal Note Engine mount member Caution • Removing the member without first suspending the engine can cause the engine to tilt or fall and cause injury. Suspend the engine properly before remov­ ing the member. 46U0B2-038 B 2-4 8 1. Suspend the engine by using a chain block. 2. Remove the engine mount No.2 nuts. 3. Remove the engine mount No.5 rubber bolts and engine mount member bolts and nuts and remove the No.5 en­ gine mount rubber and engine mount member. REMOVAL B2 Engine and transaxle assembly Slowly lift the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into components in the engine compartment. 46U0B2-039 B2—49 B2 REMOVAL Step 6 (MTX) 46U0B2-185 1. Starter 2. Engine mount No.2 rubber 3. Engine mount No.2 bracket B 2-5 0 4. Torque converter mounting nuts (ATX) 5. Transaxle B2 ENGINE STAND MOUNTING ENGINE STAND MOUNTING PREPARATION SST 49 0107 680A Stand, engine 49 L010101 Plate (Part of 49 L0101A0) 49 L010103 Hooks (Part of 49 L0101A0) o 49 L010105 Bolts (Part of 49 L0101A0) 49 E0101A0 Hanger set, engine 49 E010102 Bolt (Part of 49 E0101A0) 49 E010103 Hanger (Part of 49 E010 1A1) 49 E010104 Bolt (Part of 49 E0101A1) (H i flMllilllllllllllllllllllllllllllll For disassembly / assembly of engine 4 9 L0101A0 For disassembly / assembly of engine 49 L010 102 For disassembly / assembly of engine For disassembly / assembly of engine a Hanger set, engine Arms (Part of 49 L0101A0) 49 L010104 Nuts (Part of 49 L0101A0) 49 L010106 Bolts (Part of 49 L0101A0) For disassembly / assembly of engine 4 9 E010101 For disassembly / assembly of engine 49 E0101A1 For disassembly / assembly of engine 49 E010102 Body (Part of 49E0101A0) Hanger set, engine Bolt (Part of 49 E0101A1) For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine For disassembly / assembly of engine 36U0B2-089 B2-51 B2 ENGINE STAND MOUNTING PROCEDURE When using SST (49 E010 1A0) 1. Remove the right exhaust manifold insulator. 2. Remove the EGR valve bolts. 16E0B2-170 3. Remove the right exhaust manifold and gasket together with the EGR valve and pipe. 16E0B2-171 4. Install the SST at the positions shown in the figure. 16E0B2-172 5. Mount the engine on the SST. 16E0B2-173 When using SST (49 E010 1A1 and 49 L010 1A0) 1. Remove the right exhaust manifold insulator. 2. Remove the right exhaust manifold and gasket. 3. Install the SST as shown in the figure. 16E0B2-174 B 2-52 ENGINE STAND MOUNTING B2 4. Install the SST (arms) to the holes as shown in the figure, and hand tighten the SST (bolts). 49 L 0 1 0 102 49 L 0 1 0 106 5. Assemble the SST (bolts, nuts and plate) as shown in the figure. 16E0B2-176 6. Install the SST assembled in Step 5 to the SST installed in Step 4. 7. Adjust the SST (bolts) so that less than 20mm {0.79 in) of thread is exposed. 8. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 9. Tighten the SST (bolts and nuts) to affix the SST firmly. 10. Mount the engine on the SST. 46U0B2-041 Coolant Draining 1. After installing the engine to the engine stand, disconnect the oil cooler hose (cylinder block side) to drain the coolant. 46U0B2-187 B2—53 B2 ENGINE STAND MOUNTING 2. Remove the blind cover and drain the engine coolant (cyl­ inder block, right side). 3. After draining the coolant, install a new O-ring and install the blind cover. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft lbf) 36U0B2-091 B2 DISASSEMBLY DISASSEMBLY PREPARATION SST For removal / installation of valves 49 0636 100A Arm, valve spring lifter For removal I installation of piston pins 49 L011 001 Body, support block (Part of 49 L011 0A0A) 49 E011 002 Screw 49 L011 007 Guide, piston pin (Part of 49 L011 0A0A) 49 H018 001 Wrench, knock sensor 49E011 1A0 Brake set, ring gear 49E011 104 Collar (Part of 49E011 1A0) 49 B012 0A2 Pivot u 49 L011 0A0B Tool set, piston pin setting 49 L011 006 Installer, piston pin (Part of 49 L011 0A0A) For removal / installation of piston pins 49 H011 001B For removal / installation of piston pins 49 G014 001 For removal of knock sensor 49 S120 170 For prevention of crankshaft rotation 49E011 103 For prevention of crankshaft rotation 49E011 105 For removal / installation of valves Head, support block Wrench, oil filter Remover, valve seal Shaft (Part of 49E011 1A0) Stopper (Part of 49E011 1A0) 49 B012 012 Body (Part of 49 B012 0A2) For removal / installation of piston pins For removal / installation of piston pins For removal / installation of piston pins For removal / installation of oil filter For removal of valve seals For prevention of crankshaft rotation For prevention of crankshaft rotation For removal / installation of valves B 2-55 B2 49 B012 013 F °°t (Part of 49 B012 0A2) DISASSEMBLY For removal / installation of valves 49 B012 014 Locknut (Part of 49 B012 0A2) VA/Q5VT''^^=s^'''Tft) For removal / installation of valves 46U0B2-042 1. Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed. 2. Clean the parts by using a steam cleaner. Blow dry with compressed air. Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Pro­ tect your skin by wasing with soap and water immediately after this work. 46U0B2-043 DISASSEMBLY B2 AUXILIARY PARTS 1. Drain the engine oil. 2. Disassemble in the order shown in the figure. R EPLACE 46U0B2-188 1. A/C compressor bracket (if equipped) 2. Alternator 3. Bracket and tensioner 4. Exhaust manifold insulator (LH) 5. Exhaust manifold (LH) 6. Distributor and high-tension lead 7. 8. 9. 10. Intake manifold assembly Engine hangers Spark plugs Oil filter Disassembly Note................... page B2-58 B 2 -5 7 B2 DISASSEMBLY Disassembly Note Oil filter Remove the oil filter by using the SST. 16E0B2-184 B 2-58 DISASSEMBLY B2 TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B2-189 1. Crankshaft pulley Disassembly N ote................... page B2-60 2. Water pump pulley 3. Dipstick and pipe 4. Crankshaft position sensor 5. Timing belt cover (LH) 6. Timing belt cover (RH) 7. Engine mount bracket 8. Timing belt Disassembly Note................... page B2-60 9. Timing belt auto tensioner Disassembly Note................... page B2-60 10. Tensioner pulley 11. No.2 idler pulley 12. No.1 idler pulley 13. Timing belt pulley Disassembly Note................... page B2-60 B 2-59 B2 DISASSEMBLY Disassembly Note Crankshaft pulley 1. Hold the flywheel (MTX) or driveplate (ATX) by using the SST Caution • The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily. 2. Remove the pulley bolt. 3. Remove the crankshaft pulley. 46U0B2-044 Timing belt 1. Temporarily install the crankshaft pulley bolt. 2. Turn the crankshaft to align the timing marks of the pulleys. 16E0B2-187 3. Mark the timing belt rotation for proper reinstallation. 16E0B2-188 Caution • When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged. 4. Remove the auto tensioner bolts in the order shown in the figure. 5. Remove the timing belt. 46U0B2-045 Timing belt pulley 1. Remove the timing belt pulley. 2. Remove the crankshaft key. Note • If necessary, remove the pulley with a steering wheel puller. 46U0B2-046 B 2-60 DISASSEMBLY B2 CYLINDER HEAD Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B2-190 1. Cylinder head cover 2. Camshaft pulley Disassembly N ote................... page Inspection.................................page 3. Seal plate 4. Water outlet 5. Camshaft cap Disassembly N ote................... page 6. Blind cap 7. Camshaft Inspection.................................page 8. Camshaft oil seal 9. HLA Disassembly Note................... page Inspection.................................page B2-62 B2-84 B2-62 B2-63 B2-63 B2-74 10. Cylinder head bolt Disassembly N ote............ ..... page B2-63 11. Cylinder head page B2-72 Inspection......................... 12. Cylinder head gasket 13. Valve keeper page B2-63 Disassembly Note............ 14. Valve spring seat, upper 15. Valve spring Inspection......................... 16. Valve spring seat, lower 17. Valve page B2-73 Inspection......................... 18. Valve seal Disassembly Note............ B2-61 B2 DISASSEMBLY Disassembly Note Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon of the camshaft. 2. Remove the camshaft pulley bolt. 3. Remove the camshaft pulley. 46U0B2-191 Camshaft cap Caution • When the camshaft lobe is pressing on the HLA, removing the camshaft caps can damage the cylin­ der head thrust journal support. 46U0B2-047 1. Loosen the front camshaft cap bolts in five or six steps in the order shown. 2. Remove the front camshaft caps. Caution • Remove the thrust cap only after removing all cam­ shaft caps. Otherwise, the thrust cap can be damaged. 46U0B2-192 3. Loosen the remaining camshaft cap bolts in five or six steps in the order shown. 4. Remove the camshaft caps. 46U0B2-193 46U0B2-048 B2—62 B2 DISASSEMBLY Camshaft Inspect the following when removing the camshaft. (1) Camshaft end play (Refer to page B2-79.) (2) Camshaft journal oil clearance (Refer to page B2-79.) 46U0B2-194 HLA Caution • The HLA must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear. Note • Mark the HLA to show their original positions. ADD Note-See Notes 1. Remove the HLA from the cylinder head. 2. Store the HLA upside down in an oil-filled container. 46U0B2-049 Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. 16E0B2-199 Valve keeper 1. Set the SST against the upper valve spring seat as shown in the figure. 2. Compress the spring and remove the valve keepers. 46U0B2-050 B 2-63 B2 DISASSEMBLY Valve seal Using the SST, remove and discard the valve seal. 46U0B2-051 DISASSEMBLY B2 CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B2-052 1. Clutch cover, clutch disc (MTX) Disassembly N ote................... page B2-66 2. Flywheel (MTX) Disassembly Note................... page B2-66 3. Drive plate, backing plate, adapter (ATX) Disassembly N ote................... page B2-66 4. Oil cooler 5. Water pipe and thermostat housing Disassembly Note................... page B2-66 6. Knock sensor Disassembly Note................... page B2-67 7. Oil pan Disassembly Note................... page B2-67 8. Oil strainer 9. Baffle 10. Water pump 11. Oil pump 12. Front oil seal Disassembly Note................... page B2-67 B 2-65 B2 DISASSEMBLY Disassembly Note Clutch cover, clutch disc (MTX) 1. Hold the flywheel by using the SST. 2. Loosen the clutch cover bolts in two or three steps. 3. Remove the clutch cover and disc. 16E0B2-203 Flywheel (MTX) 1. Hold the flywheel by using the SST. 2. Remove the flywheel mounting bolts in two or three steps in the order shown in the figure. 3. Remove the flywheel. 4. Remove the SST. 16E0B2-204 Drive plate, backing plate, adapter (ATX) 1. Hold the drive plate by using the SST. 2. Remove the drive plate mounting bolts. 3. Remove the backing plate, drive plate, and adapter. 16E0B2-205 Water pipe and thermostat housing 1. Disconnect the clip and separate the knock sensor har­ ness from the water pipe. 16E0B2-206 2. Remove the water pipe and thermostat housing as an assembly. 16E0B2-2Q7 B 2-66 DISASSEMBLY B2 Knock sensor Remove the knock sensor by using the SST. Oil pan 1. Remove the oil pan mounting bolts. 2. Remove the old sealant from the bolt threads. 3. Turn a bolt into the special bolt hole as shown to make a small gap between the oil pan and the lower cylinder block. 4. Separate the oil pan from the lower cylinder block by us­ ing a scraper or a separator tool (commercially available). Front oil seal Remove the oil seal by using a screwdriver protected with a rag. B2 DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note. 46U0B2-195 . Connecting rod cap Disassembly Note............ ....... . Connecting rod bearing Inspection................................. . Piston ring Disassembly N ote............ ...... Inspection.......................... ...... Piston pin Disassembly Note............ ...... Inspection......................... ...... Connecting rod Disassembly N ote............ ...... Inspection.......................... ...... B 2-68 page B2-69 page B2-83 page B2-69 page B2-81 page B2-69 page B2-81 page B2-69 page B2-82 6. Piston Inspection................................ 7. Lower cylinder block Disassembly Note................... 8. Main bearing and thrust bearing, 9. Crankshaft Inspection................................ 10. Rear oil seal 11. Main bearing and thrust bearing, 12. Oil jet Inspection................................ 13. Cylinder block Inspection................................ page B2-81 page B2-70 lower page B2-82 upper page B2-83 page B2-79 DISASSEMBLY B2 Disassembly Note Connecting rod cap Before removing the connecting rod caps, measure the con­ necting rod side clearance. (Refer to page B2-94.) 46U0B2-196 Connecting rod 1. Before removing the connecting rods, measure the connect­ ing rod bearing oil clearance by using Plastigage. (Refer to page B2-93.) 46U0B2-197 2. Remove the Plastigage from the journals and bearings. 3. Use the handle of a hammer to push the piston and con­ necting rod assembly through the top of the cylinder block. 46U0B2-053 Piston ring Remove the piston rings by using a piston ring expander. 46U0B2-054 Piston pin Caution • The connecting rods must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear. 1. Before disassembling the piston and connecting rod, check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin. 46U0B2-055 B 2-69 B2 DISASSEMBLY 2. Use the following SSTs and a press. • Support block body (49 L011 001) • Support block head (49 H011 001B) • Piston pin installer (49 L011 006) • Piston pin guide (49 E011 007) • Screw (49 E011 002) 46U0B2-056 3. Assemble the SST into the piston pin as shown. 4. Verify that the SST fits squarely into the piston before pressing. 46U0B2-057 5. Set the piston and connecting rod on the SST as shown. 6. Press out the piston pin. While removing the piston pin, note the pressing pressure. If it is less than 4,910 N {500 kgf, 1,100 Ibf}, replace the piston pin or connecting rod. PISTON PIN PISTON CONNECTING ROD CONNECTING ROD 4 9 L0 1 1 0 0 7 4 9 L011 001 46U0B2-058 Lower cylinder block 1. Before removing the lower cylinder block, measure the crankshaft end play. (Refer to page B2-92.) 46U0B2-198 B2—70 DISASSEMBLY B2 2. Loosen the cylinder block bolts and crankshaft cap bolts in two or three steps in the order shown in the figure. 3. Insert a screwdriver or a suitable tool only at the points shown in the figure. 4. Remove the lower cylinder block. B2-71 B2 INSPECTION / REPAIR INSPECTION / REPAIR PREPARATION SST 16E0B2-225 1. Clean all parts, being sure to remove all gasket fragments, dirt, oil, etc. 2. Perform the inspections and repairs in the order specified. 46UOB2-060 CYLINDER HEAD 1. Inspect the cylinder head for damage, cracks, and leakage of water and oil. Replace if necessary. 2. Using a straightedge, measure the cylinder head for dis­ tortion in the six directions shown in the figure. Distortion: 0.10mm (0.004 in) max. 16E0B2-227 B2 INSPECTION / REPAIR 3. If the distortion exceeds the specification, grind the cylin­ der head. If the cylinder head height is not within the specification, replace it. Grinding: 0.15mm (0.0059 in) max. Height: 133.4—133.6mm (5.252—5.259 in} 46U0B2-061 4. Using a straightedge, measure the intake and exhaust man­ ifold contact surfaces for distortion in the six directions shown in the figure. Distortion: 0.10mm (0.0039 in} max. 5. If distortion exceeds the specification, grind the surface or replace the cylinder head. VALVE MECHANISM Valve and Valve Guide 1. Inspect each valve for the following. Replace or resurface as necessary. (1) Damaged or bent stem (2) Rough or damaged face (3) Damaged or unevenly worn stem tip 2. Measure the valve head margin thickness. Replace the valve if necessary. Margin thickness IN: 0.9mm (0.0355 in} min. EX: 1.0mm (0.0394 in} min. 3. Measure the valve length and replace the valve if necessary. Length Standard Minimum mm IN EX IN EX 93.91 94.99 93.41 94.49 (3.697) (3.740) (3.678) (3.720) 4. Measure the valve stem diameter and replace the valve if necessary. 46U0B2-062 Diameter Standard IN: 5.970—5.985mm (0.2351—0.2356 in} EX: 5.965—5.980mm (0.2349—0.2354 in} Minimum IN: 5.920mm (0.2331 in} EX: 5.915mm (0.2329 in} 5. Measure the valve guide inner diameter and replace the guide if necessary. Inner diameter IN: 6.01—6.03mm (0.2367—0.2374 in} EX: 6.01—6.03mm (0.2367—0.2374 in} 16E0B2-232 B 2-73 B2 INSPECTION / REPAIR 6. Calculate the valve stem-to-guide clearance. Subtract the outer diameter of the valve stem from the in­ ner diameter of the corresponding valve guide. Clearance IN: 0.025—0.060mm (0.0010—0.0023 in) EX: 0.030—0.065mm (0.0012—0.0025 in] Maximum: 0.20mm (0.0078 in} 7. If the clearance exceeds the maximum, replace the valve and/or valve guide. 8. Measure the valve guide projection height (dimension A). Replace the guide if necessary. Height A IN: 14.7—15.3mm (0.579—0.602 in} EX: 12.2—12.8mm (0.481—0.503 in} Replacement of valve guide Note • The intake and exhaust valve guides are the same. 16E0B2-235 Remove the valve guide from the side opposite the com­ bustion chamber by using the SST. 16E0B2-236 2. Assemble the SST so that the depth L is as specified. Depth L IN: 14.7—15.3mm (0.579—0.602 in} EX: 12.2—12.8mm (0.481—0.503 in} 3. Tighten the locknut. 16E0B2-237 B 2-74 INSPECTION / REPAIR B2 4. Tap the valve guide in from the side opposite the combus­ tion chamber until the SST contacts the cylinder head. 5. Verify that the valve guide projection height is within the specification. (Refer to page B2-74.) 6. If not within the specification, repeat steps 2-4. 46U0B2-199 Valve Seat 1. Inspect the contact surface of the valve seat and valve face for the following. (1) Roughness (2) Damage 2. If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face. 16E0B2-239 3. Apply a thin coat of Prussian blue to the valve face. 4. Check the valve seating by pressing the valve against the seat. (1) If blue does not appear 360° around the valve face, re­ place the valve. (2) If blue does not appear 360° around the valve seat, resurface the seat. 16E0B2-240 5. Measure the seat contact width. Width: 0.8—1.4mm (0.031—0.055 in) 16E0B2-241 (1) If the valve seating position on the valve face is too high, correct the valve seat with a 75° cutter. (2) If the valve seating position of the valve face is too low, correct the valve seat with a 45° cutter. 6. Seat the valve to the valve seat by using a lapping compound. 16E0B2-242 B 2-75 B2 INSPECTION / REPAIR 7. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Dimension L: 41.5mm {1-634 in) (1) If L is as below, it can be used as it is. 41.5—42.0mm {1.634— 1.653 in) 16E0B2-243 (2) If L is as below, insert a washer onto the spring seat area so that L will be as specified. 42.1—43.0mm {1.658—1.692 in) (3) If L is more than below, replace the cylinder head. 43.1mm {1.697 in) 46U0B2-200 Valve Spring 1. Inspect the valve springs for cracks and damage. 2. Check the free length of each spring. Free length Standard: 46.92mm {1.847 in) Minimum length: 38.7mm {1.524 in) with a set load of 233.0—263.6 N {23.75—26.88 kgf, 52.25—59.14 Ibf) 3. If not within specification, measure spring pressure when the spring length is compressed to 35.5mm {1.398 in). Replace if necessary. 4. Check the out-of-square of the springs. Replace as necessary. Out-of-square: 1.63mm {0.0642 in) 46U0B2-202 CAMSHAFT 1. Visually inspect helical gears and the friction gear. Replace the camshaft assembly if a problem is found with the heli­ cal gear. Replace the friction gear if a problem is found with it. 2. Secure the camshaft cast hexagon in a vise protected with aluminum plates. 3. Loosen the locknut and remove the friction gear. 4. Assemble the friction gear so that the matching marks align. Tightening torque: 69—78 N m {7.0—8.0 kgf m, 51—57 ft-lbf) B 2-76 B2 INSPECTION/REPAIR 4. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary. Runout: 0.02 mm {0.0007 in} max. 5. Check the camshaft for wear and damage. Replace it if necessary. 6. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary. Height mm {in} IN EX Height 43.549 {1.7145} Minimum 43.349 {1.7067} Height 43.549 {1.7145} Minimum 43.349 {1.7067} 7. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the cam­ shaft if necessary. Journal diameter mm {in} Journals Standard Minimum No.1 (RH EX, LH IN) and No.5 25.940—25.960 {1.0213— 1.0220} 25.890 {1.0193} No.1 (RH IN, LH EX) 29.975—29.995 {1.1802— 1.1809} 29.925 {1.1782} No.2— No.4 25.910—25.930 {1.0201— 1.0208} 25.860 {1.0182} 8. Measure the camshaft oil clearances with the HLA removed. (1) Remove all oil, dirt, etc. from the journals and the camshaft saddles. (2) Install the camshafts so that the intake camshaft gear mark and exhaust camshaft gear mark align. Adjust the friction gear position with a screwdriver so that the HLAs are not lifted by the cam lobes. (Intake side cam lobes of the No.1 cylinder (RH) and No.2 cylinder (LH) face straight up.) (3) Position Plastigage atop each journal in the journal axial direction. (4) Do not rotate the camshaft when measuring the oil clearance. R e v ic p H fi/Q fi B2 INSPECTION /REPAIR Caution Install the thrust caps (RH is 5 mark, LH is B mark) first. Otherwise, camshaft can be broken or dam ­ aged. • (5) Install the thrust caps onto the cylinder head. Hand tighten the cap bolts gradually in five or six steps in the order shown, until the thrust caps fully seated on the cylinder head. THRUST CAPS (3 Caution • Because there is little camshaft thrust clearance, the camshaft m ust be held horizontally while it is installed. Otherwise, excessive force will be ap­ plied to the thrust area, causing burr on the thrust receiving area of the cylinder head Journal. To avoid this, the following procedure must be ob­ served. (6) Install the camshaft caps according to their identifi­ cation marks, and hand tighten the bolts. Note • • RH: numbers LH: letters (7) Tighten the bolts in the order shown. Verify that the camshaft remains horizontal as the camshaft cap bolts (marked (J) in the figure) tightened. Tightening torque: 11.3— 14.2 N*m {115— 145 kgf-cm, 100— 125 in-lbf} (8) Retighten the bolts in the order shown. Tightening torque: 11.3— 14.2 N-m (115— 145 kgf-cm, 100— 125 in-lbf} Caution • Remove the thrust cap only after removing all camshaft caps. Otherwise, the thrust cap can be damaged. (9) Loosen the camshaft cap bolts in five or six steps in the reverse order of installation. INSPECTION/REPAIR (10) Measure the oil clearance. Oil clearance No.1, No.5: 0.040—0.081 mm {0.0016—0.0031 in} No.2— No.4: 0.070—0.111 mm {0.0028—0.0043 in} Maximum No.1, No.5: 0.120 mm {0.0047 in} No.2— No.4: 0.150 mm {0.0059 in} (11) If the oil clearance exceeds the maximum, replace the camshaft or the cylinder head. 9. Measure the camshaft end play. If it exceeds the maxi­ mum, replace the camshaft or the cylinder head. End play: 0.05— 0.10 mm {0.0020—0.0039 in} Maximum: 0.14 mm {0.0056 in} HLA 1. Inspect the friction surfaces of each HLA for wear and damage. Replace the HLA if necessary—do not attempt to repair it. 2. Hold the bucket body and press the plunger by hand. If the plunger moves, it is defective. Replace the HLA—do not attempt to repair it. CYLINDER BLOCK 1. Check the cylinder block for the following and repair or replace as necessary. (1) Leakage damage (2) Cracks (3) Scoring of wall 2. Using a straightedge, measure the cylinder block decks for distortion in six directions as shown in the figure. Distortion: 0.15 mm {0.0059 in} max. 16E0B2-262 3. If distortion exceeds the maximum, replace the cylinder block. B2 INSPECTION / REPAIR 4. Measure the cylinder bores in X and Y directions at three levels (A,B and C) as shown. Cylinder bore Standard 0.25 [0.010J oversize 0.50 {0.020) oversize mm fin) 84.500—84.522 (3.3268—3.3276) 84.750-84.772 (3.3367-3.3374) 85.000—85.022 (3.3465-3.3473) 46U0B2-Q70 Cylinder bore Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter. (1) If the cylinder bore exceeds the maximum, rebore the cylinder to oversize. (2) If the difference between measurements A and C ex­ ceeds the maximum taper, rebore the cylinder to oversize. Taper: 0.022mm {0.0008 in} max. 46U0B2-071 (3) If the difference between measurements X and Y ex­ ceeds the maximum out-of-round, rebore the cylinder to oversize. Out-of-round: 0.020mm {0.0007 inj max. 5. If the upper part of a cylinder wall shows uneven wear, re­ move the ridge with a ridge reamer. o PISTON, PISTON RING, AND PISTON PIN Piston 46U0B2-205 1. Inspect the outer circumferences of all pistons for seizing and scoring. Replace as necessary. 2. Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 16.5mm {0.650 in) below the oil ring groove lower edge. Piston diameter Standard 0.25 (0.010) oversize 0.50 (0.020) oversize mm (in) 84.453—84.485 (3.3250—3.3261) 84.703-84.735 (3.3348-3.3360) 84.953-84.985 (3.3446-3.3458) 3. Measure the piston-to-cylinder clearance. Clearance: 0.028— 0.056mm {0.0012— 0.0022 in) Maximum: 0.13mm {0.0051 in) C LEARAN C E 46U0B2-073 B 2-80 4. If the clearance exceeds the maximum, replace the piston or rebore the cylinders to fit oversize pistons. If the piston is replaced, the piston rings must also be replaced. B2 INSPECTION / REPAIR Piston and Piston Rings 1. Measure the piston ring-to-ring land clearance around the entire circumference by using a new piston ring. Clearance Top: 0.020—0.065mm (0.0008—0.0025 in) Second: 0.030—0.065mm (0.0012—0.0025 in) Oil: 0.025—0.052mm (0.0010—0.0020 in] Maximum: 0.15mm (0.0059 in) 36U0B2-098 2. If the clearance exceeds the maximum, replace the piston. 3. Inspect the piston rings for damage, abnormal wear, and breakage. Replace as necessary. 4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. PISTON RING 36U0B2-099 5. Measure each piston ring end gap by using a feeler gauge. Replace if necessary. End gap Top: 0.15—0.30mm (0.0060—0.0118 in] Second: 0.25—0.40mm (0.010—0.015 in) Oil rail: 0.20—0.70mm (0.008—0.027 in) Maximum: 1.0mm (0.0393 in) Piston and Piston pin 1. Measure the piston pin bore diameter in X and Y directions at four points. Diameter: 19.988—20.000mm (0.7870—0.7874 in) 2. Measure the piston pin diameter in X and Y directions at four points. x Diameter: 19.974—19.980mm (0.7864—0.7866 in) 3. Calculate the related piston pin-to-piston clearance. Clearance: 0.008—0.026mm (0.0004—0.0010 in) 4. If the clearance exceeds the specification, replace the pis­ ton and/or piston pin 36U0B2-051 B2—81 B2 INSPECTION / REPAIR CONNECTING ROD 1. Measure the connecting rod small end bore. Diameter: 19.943—19.961mm {0.7852—0.7858 in) 2. Calculate the interference between the small end bore and piston pin. Interference: 0.013—0.037mm (0.0006—0.0014 in) If the connecting rod is replaced, the connecting rod cap and bolts must also be replaced because they are a matched set. 3. Check each connecting rod for bending. Repair or replace as necessary. Bend: 0.05mm (0.0019 in}/50mm (1.9685 in) Length (Center to Center): 137.80—137.90mm (5.426—5.429 in) CRANKSHAFT 1. Check the journals and pins for damage, scoring, and oil hole clogging. 2. Set the crankshaft No.1 and No.4 journals on V-blocks. 3. Measure the crankshaft runout at the No.2 and No.3 journals. Replace the crankshaft if necessary. Runout: 0.015mm (0.0005 in) max. 16E0B2-275 4. Measure each journal diameter in X and Y directions at two points. Main journal Diameter: 61.938—61.955mm (2.4385—2.4391 in) Out-of-round: 0.05mm (0.0019 in) max. Crankpin journal Diameter: 52.940—52.955mm (2.0843—2.0848 in) Out-of-round: 0.05mm (0.0019 in) max. B2 INSPECTION / REPAIR 5. If the diameter is less than the minimum, grind the journals to match undersize bearings. Undersize bearing: 0.25mm {0.010 in) Main journal diameter undersize Bearing size 0.25 (0.010) undersize Journal diameter 61.688-61.705 (2.4287-2.4293) Crankpin journal diameter undersize Bearing size 0.25 (0.010) undersize mm (in) mm (in) Journal diameter 52.690-52.705 (2.0745-2.0749) BEARING Main Bearing and Connecting Rod Bearing Check the main bearing and the connecting rod bearings for peeling, scoring, and other damage. OIL JET Check the oil jets for clogging by applying compressed air. Replace if necessary. TIMING BELT 1. Replace the timing belt if there is any oil or grease on it. 2. Check the timing belt for damage, wear, peeling, cracks, and hardening. Replace it if necessary. Caution • The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bend­ ing it, or allowing oil or grease on it. 25mm (1.0 in) MIN 46U0B2-Q76 B 2-83 B2 INSPECTION / REPAIR TIMING BELT AUTO TENSIONER Caution • Using cleaning fluids or a steam cleaner to clean the tensioner can dissolve the grease in its sealed bearing. M® fL 1 1. Use a clean, soft rag to wipe the idler contact surface. 2. If the idler does not rotate smoothly, replace it. 3. If there are oil leaks, or if there are scratches or abnormal noise when turning the idler, replace it. 4. Check the tensioner pulley for rough rotation and abnor­ mal noise. Replace it if necessary. 5. Check the auto tensioner for oil leakage. Replace it if necessary. 6. Check the tensioner rod projection ® . Replace the auto tensioner if necessary. f Projection A (free length): 14—16mm {0.56—0.62 in] ,* l> 46U0B2-078 PULLEY Timing Belt Pulley and Camshaft Pulley Inspect the teeth of each pulley for wear, deformation, and other damage. Replace as necessary. TIMING BELT COVER Inspect the timing belt covers for damage and cracks. Replace as necessary. 46U0B2-079 B 2 -8 4 B2 ASSEMBLY ASSEMBLY PREPARATION SST 49 L011 OAOB fv Tool set, piston pin setting \ k Cv For removal / installation of piston pins For removal / installation of piston pins 49 L011 005 Bolt, stopper 49 L011 0A0A) 49 L011 007 Guide (Part of 49 L011 OAOA) C 49 H011 001B Head, support block Brake set, ring gear js?R®\ ^ 49 H018 001 For prevention of engine rotation Collar (Part of 49E0111A0) ( V For removal / installation of piston pins Puller & installer (Part of 49 L011 OAOA) For removal / installation of piston pins \W Screw Installer set, valve seal & valve guide isr 49 L012 001 49 L012 0A0) <3*3^ ^ ® % For installation of valve seals For removal / installation of piston pins xx. For installation of knock sensor Wrench, knock sensor 49 E011 103 For prevention of engine rotation Shaft (Part of 49E0111A0) V ** 49 E011 105 For prevention of engine rotation Stopper (Part of 49 E011 1A0) f 49L012 0A0 For removal / installation of piston pins (-^ 49 L011 006 49 E011 002 v \ 49 E011 104 Body, support block (Part of 49 L011 OAOA) For removal / installation of piston pins For prevention of engine rotation 49E011 1AO ®) j) 49 L011 001 \ 49SE01 310A For installation of clutch disc Centering tool, clutch disc K ^i cup For installation of valve seals 4Q i m ? nn? B° dy (Part of 49 L012 0A0) 0 liii ^ J For installation of valve seals B2—85 B2 49 L012 005 Spacer (Part of 49 L012 0A0) 49 B012 0A2 Pivot 49 B012 013 Foot (Part of 49 B012 0A2) 49 G014 001 Wrench, oil filter ASSEMBLY For installation of valve seals 49 0636 100A For removal / installation of valves 49 B012 012 For removal / installation of valves Arm, valve spring lifter Body (Part of 49 B012 0A2) 49 B012 014 Locknut (Part of 49 B012 0A2) For removal / installation of valves For removal / installation of valves For removal / installation of valves For removal / installation of oil filter 46U0B2-080 1. Do not reuse gaskets or oil seals. 2. Clean all parts before reinstallation. 3. Apply clean engine oil to all sliding and rotating parts. 4. Replace plain bearings if they are peeling, burned, or otherwise damaged. 5. Tighten all bolts and nuts to the specified torque. 46U0B2-081 B2 ASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) Torque Specifications CYLINDER WALLS APPLY THREAD LOCKING COMPOUND 2.9—4.9 N m (30—50 kgf-cm, 27—43 Inlbf I JOURNALS AND CRANK PINS^ 16E0B2-286 Connecting Rod 1. Assemble the SST (tool set, piston pin setting) to the pis­ ton pin. 2. Apply clean engine oil to the piston pin. PISTON PIN - I ------ D 49 E011 002 49 L011 007 49 L01 1 006 16E0B2-287 B 2-87 B2 ASSEMBLY 3. Set the SST (stopper bolt) so that the depth L is as specified. 49 H011 0 0 1 B DIMENSION L t 49 L 0 11 001 1 Depth L: 61.5mm (2.421 in] 1 ------ 4. Tighten the locknut. == — I n B — i 36U0B2-055 5. Assemble the piston and the connecting rod. 6. Insert the SST (tool set, piston pin setting) assembled in step 1 into the piston pin hole. 7. Mount the piston and connecting rod onto the SST (sup­ port block). 36U0B2-056 8. Verify that the SST fits squarely into the piston before pressing. 9. Press the piston pin into the piston and connecting rod un­ til the SST (piston pin guide) contacts the SST (stopper bolt). 10. While inserting the piston pin, note the pressing force. If it is not within specification, replace the piston pin and/or the connecting rod. Pressing force: 3,923—12,748 N (400—1,300 kgf, 880—2,860 Ibf] 11. Check the connecting rod oscillation torque. (Refer to page B2-69.) Piston Ring Note • The upper and lower rails are the same. • Each rail can be installed with either face upward. • When reusing an oil ring, make sure that it is reinstalled in the same place and that it is facing in the same direc­ tion as it was before. 1. Install the three-piece oil rings on the pistons. (1) Apply clean engine oil to the oil ring spacer and rails. (2) Install the oil ring spacer so that the opening faces upward. (3) Install the upper rail and lower rail. 2. Verify that both rails are expanded by the spacer tangs, as shown in the figure, by verifying that they turn smoothly in both directions. 36U0B2-102 B 2-8 8 B2 ASSEMBLY 3. Using a piston ring expander, install the second ring with the scraper face downward. 4. Using a piston ring expander, install the top ring. 5. Apply a liberal amount of clean engine oil to the piston rings. 46U0B2-084 6. Position the end gap of each ring as shown in the figure. OIL RING UPPER RAIL OIL RING TOP RING / ( SPACER H ~ OIL RING LOWER RAIL 30° \ 30° T / \ ____ PISTON . P'N SECOND RING 46U0B2-085 Oil jet 1. Apply a thread locking compound to the oil jet threads. 2. Install the oil jets into the upper cylinder block. Tightening torque: 2.9—4.9 N m {30—50 kgf cm, 27—43 in-lbf] Crankshaft 1. Measure the main bearing oil clearances as described below. Oil clearance inspection 2. Install the upper main bearings (with oil groove) and the up­ per thrust bearings. (1) Remove any foreign material and oil from the journals and bearings. (2) Install the upper main bearings and upper thrust bearings. Note • No.4 bearing is wider than other bearings. 46U0B2-086 8.05—8.15mm (0.317—0.321 in) ® a t 135.7—136.3mm( 5.343—5.366 in 7.45—7.55mm (0.293—0.297 in) & u s * 1135.7—136.3mm (5.343—5.366 in)| 119.7—120.3mm (4.713—4.736 in) (3) Install the lower cylinder block along with the lower main bearings and lower thrust bearings. (4) Measure the length of each crankshaft cap bolt. Replace any that exceed the maximum length. Main cap bolt (A and B) Length: 135.7—136.3mm (5.343—5.366 in) Maximum: 138.5mm {5.452 in] Sub cap bolt (C) Length: 119.7—120.3mm {4.713—4.736 in] Maximum: 121.0mm {4.763 in) 46U0B2-206 B 2-89 B2 ASSEMBLY (5) Apply clean engine oil to the bolt threads and seat faces of the crankshaft cap bolts. (6) Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque Main bolt: 23.1—25.9 N m {2.35—2.65 kgf m, 17.0—19.1 ft-lbf) .......... A, B Sub bolt: 18.2—21.0 N-m {1.85—2.15 kgf m, 13.4—15.5 ft-lbf}................ C 16E0B2-298 Note • A bolts are marked “ 4” on the head. • B bolts are marked " I” on the head. 16E0B2-299 (7) Put a paint mark on the lower cylinder block next to the A, B, C bolts flange marks as shown. (8) Using the marks as a reference, further tighten the A, B, C bolts in the order shown. Main cap bolt A (No.4 journals): 75°—85° Main cap bolt B (No.1—No.3 journals): 65°—75° Sub cap bolt: 55°—65° PAINT (9) Tighten the bolts till the mark on each bolt flange aligns with the corresponding paint mark. 46U0B2-087 (10) Further tighten each bolt by performing Step (7), (8). PAINT MARKS 46U0B2-088 (11) After tightening, measure the cylinder block No. 1—No.4 journal bore diameter. (12) Subtract the crankshaft journal diameter from the bore diameter. (13) If the oil clearance exceeds the maximum, replace the bearing or grind the crankshaft and install undersize main bearings. (Refer to page B2-83.) Oil clearance: 0.037—0.057mm {0.0015—0.0022 in] Maximum: 0.064mm {0.0025 in] 46UQB2-089 B 2-9 0 B2 ASSEMBLY Main journal diameter Standard: 61.938—61.955mm {2.4385—2.4391 in) 0.25mm {0.0098 in} undersize: 61.688—61.705mm {2.4287—2.4293 in) CRANK PIN 16E0B2-303 (14) Remove the lower cylinder block in the reverse order of Step (6). 46U0B2-090 3. Install the lower cylinder block as follows: (1) Install the upper thrust bearings in the upper cylinder block. (2) Apply a liberal amount of clean engine oil to the main bearings, thrust bearings, and main journals. (3) Install the crankshaft in the upper cylinder block. (4) Remove any foreign material, oil, and sealant from the contact surfaces of the upper cylinder block and lower cylinder block. (5) Apply a continuous bead of silicone sealant to the con­ tact surface as shown. (6) Install the lower cylinder block, lower main bearings, and lower thrust bearings within five minutes of applying the sealant. (7) Install the lower cylinder block along with the lower main bearings and lower thrust bearings. (8) Apply clean engine oil to the threads and seat faces of the bearing cap bolts. (9) Tighten the main cap bolts A, B and sub cap bolts C as in Steps 1—(6)/1—(9). 46U0B2-092 (10) Tighten the lower cylinder block bolts in the order as shown. Tightening torque: 19—21 N m {1.9—2.2 kgf m, 14—15 ft-lbf} 46U0B2-093 B2-91 B2 ASSEMBLY 4. Inspect the crankshaft end play. End play: 0.08—0.282mm {0.0032—0.0111 in} Maximum: 0.32mm {0.0125 in} 5. If the end play exceeds the maximum, grind the crankshaft and install oversize thrust bearings or replace the crankshaft and thrust bearing. Thrust bearing width Standard: 2.000—2.050mm {0.0788—0.0807 in} 0.25mm {0.0098 in} oversize: 2.125—2.175mm {0.0837—0.0856 in} 0.50mm {0.020 in) oversize: 2.250—2.300mm {0.0886—0.0905 in} 6. Apply a small amount of clean engine oil to the lip of a new rear oil seal. 7. Push the rear oil seal slightly in by hand. 8. Tap the oil seal in evenly with a pipe and a hammer. Protrusion: 0—0.7mm {0—0.03 in} Oil seal outer diameter: 93.0mm {3.66 in} Oil seal inner diameter: 75.0mm {2.95 in} Piston and Connecting Rod Assembly 1. Rotate the engine on the engine stand as shown in the figure. Note • Assembly is easier if the pistons are installed with the crankpin at the BDC position. 46U0B2-096 2. Remove any foreign material and oil from the connecting rod journals and bearings. 3. Install the upper connecting rod bearings in the connect­ ing rods. 4. Apply a liberal amount of clean engine oil to the cylinder walls, pistons, piston rings and connecting rod cap bolts. 46U0B2-097 5. Check the piston rings for proper end gap positioning. 6. Insert the piston assemblies into the cylinder block with the L mark (left bank) and the R mark (right bank) facing the front of the engine. Use a piston installer tool to install. 46U0B2-207 B 2-92 ASSEMBLY B2 Connecting Rod Cap 1. Measure the connecting rod bearing oil clearances as follows. (1) Measure the oil clearance with the connecting rod in BDC position. (2) Do not rotate the crankshaft when measuring the oil clearances. 46U0B2-098 I I I 46.7— 47.3m m {1.84-- 1 .8 6 in ) 46U0B2-099 (3) Position Plastigage atop the journals in the axial direction. (4) Remove any foreign material and oil from the lower con­ necting rod bearing and connecting rod cap. (5) Install the connecting rod bearing in the cap. (6) Measure the length of connecting rod cap bolt. Replace it if the length exceeds the maximum. Length: 46.7—47.3mm (1.84—1.86 in) Maximum: 48.0mm (1.89 in) (7) Apply engine oil to the threads and seat faces of the connecting rod cap bolts. (8) Install the connecting rod cap. (9) Tighten the connecting rod cap bolts. Tightening torque: 22.1—26.9 N-m (2.25—2.75 kgf-m, 16.3—19.8 ft-lbf) (10) Put a paint mark on each bolt head. (11) Using this mark as a reference, tighten the bolts 83°—97°. (12) Remove the connecting rod cap. (13) Measure the Plastigage at each journal at the widest point for the smallest clearance, and the narrowest point for the largest clearance. Oil clearance: 0.023—0.043mm (0.0010—0.0016 in) Maximum: 0.08mm (0.0032 in) 46U0B2-101 (14) If the oil clearance exceeds the maximum, grind the crankshaft and install undersize bearings. (Refer to page B2-83.) CRANK PIN 46U0B2-102 B 2-93 B2 ASSEMBLY 2. Install the connecting rod caps as follows. (1) Remove the Plastigage from the journals and bearings. (2) Apply a liberal amount of clean engine oil to the con­ necting rod bearings. (3) Install the connecting rod bearings and caps. (4) Apply engine oil to the threads and seat faces of the cap bolts and tighten them as in step 1. (5) Verify that the crankshaft rotates smoothly by hand. 16E0B2-318 3. Measure the connecting rod side clearances. (1) Measure each connecting rod side clearance. Side clearance: 0.178—0.330mm (0.0071—0.0129 in) Maximum: 0.40mm (0.0157 in) (2) If the clearance exceeds the maximum, replace the con­ necting rod and cap assembly. 16E0B2-319 ASSEMBLY B2 CYLINDER BLOCK (EXTERNAL PARTS) Torque Specifications 16E0B2-320 Oil Pump 1. Apply clean engine oil to the oil pump body and a new oil seal. 2. Install the oil seal into the oil pump body by hand. 3. Press the oil seal into the oil pump body by using a pipe. Protrusion: 0—0.7mm {0—0.03 in) Oil seal outer diameter: 48.0mm {1.89 in) Oil seal inner diameter: 34.0mm (1.34 in) 46U0B2-208 B 2-95 B2 ASSEMBLY 4. Remove any dirt or other material from the contact surfaces. 5. Apply a continuous bead of silicone sealant to the contact surface of the oil pump. 6. Apply engine oil to a new O-ring and install it into the pump body. O-RING Caution • Keep the oil hole free of sealant to prevent engine damage. 46U0B2-103 7. Apply clean engine oil to the oil seal lip. 8. Install the oil pump within five minutes of applying the seal­ ant, making sure that the O-ring doesn’t come out. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} Bolt length A: 40mm (1.57 in) B: 25mm (0.98 in) 46U0B2-104 9. Cut away the portion of the gasket that projects toward the oil pan. Water Pump 1. Remove all dirt, grease, and other material from the water pump mounting surface. 2. Install a new rubber seal and the water pump. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft Ibf) 36UQB2-107 Baffle 1. Remove any dirt or other material from the baffle. 2. Install the baffle. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} 16E0B2-325 Oil Strainer Install a new gasket and the oil strainer onto the oil pump body. Tightening torque: 7.9—10.7 N-m {80—110 kgf cm, 70—95 in Ibf) Caution • Tighten bolts A first. 36U0B2-162 B 2-9 6 B2 ASSEMBLY (CRACKS Oil Pan 1. Remove the sealant from the oil pan bolts and bolt holes in the lower cylinder block. Caution • If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old seal­ ant on it can cause thread damage. OLD SEALANT 46U0B2-1Q5 2. Remove any dirt and oil from the contact surfaces. 3. Apply a continuous bead of silicone sealant to the oil pan along the inside of the bolt holes, and overlap the ends. 46U0B2-209 4. Install the oil pan, within five minutes of applying the sealant. Tightening torque A: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf) B: 7.9—10.7 Nm {80—110 kgf m, 70—95 in-lbf} 46U0B2-210 Knock Sensor Install the knock sensor by using the SST. 49 H018 001 Tightening torque: 20—34 N-m {2.0—3.5 kgf m, 15—25 ft-lbf} 16E0B2-330 Water Pipe and Thermostat Housing 1. Install a new gasket and install the water pipe and thermostat housing as an assembly. Tightening torque: 19—25 Nm {1.9—2.6 kgf-m, 14—18 ft-lbf) 2. Secure the knock sensor harness to the water pipe with the clip as shown. 16E0B2-332 B2—97 B2 ASSEMBLY Oil cooler 1. Install a new gasket and the oil cooler. Tightening torque: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf] 2. Connect the water hose. 46U0B2-211 Flywheel (MTX) 1. Set the flywheel onto the crankshaft. 2. Hold the flywheel by using the SST. 3. Tighten the bolts in two or three steps in the order shown. Tightening torque: 61—67 Nm {6.2—6.9 kgf-m, 45—49 ft-lbf] 16E0B2-334 Clutch Disc and Clutch Cover (MTX) Install the clutch disc and clutch cover by using the SST. (Refer to Section H.) Tightening torque: 18—26 Nm {1.8—2.7 kgf-m, 14—19 ft-lbf] 16E0B2-335 Drive Plate (ATX) Caution • Verify that the adapter and the backing plate are mounted in the directions shown. Incorrect mount­ ing can damage the engine and transmission. 1. Install the following parts to the crankshaft. (1) Adapter (2) Drive plate (3) Backing plate 2. Loosely tighten the lock bolts. 3. Hold the drive plate by using the SST. 4. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 61—67 Nm {6.2—6.9 kgf m, 45—49 ft-lbf] 46U0B2-107 B 2-9 8 B2 ASSEMBLY CYLINDER HEAD Torque Specifications 5.0—8.8 N-m 150—90 kgf-cm, 44—78 in-lbf | 5.0—8.8 N-m (50—90 kgf-cm, 44—78 in-lbf) 11.3— 14.2 N-m 1115— 145 kgf-cm, 100—125 In-lbf) 1 1 .3 -1 4 .2 N-m (115—145 kgf-cm, 100— 125 in-lbf 23.1—25.9 (2.35—2.65, 17.0— 19.1) + 85°—95° + SS'-SS0 HEAD COVER CONTACT SURFACES 11.3— 14.2 N-m 115— 145 kgf-cm 100— 125 in-lbf) 123—140 ( 1 2 .5 - 1 4 .3 ,9 1 — 103) r HEAD COVER CONTACT SURFACES CAMSHAFT CAP CONTACT SURFACES -x> BOLT THREADS CAMSHAFT CAP CONTACT SURFACES 7.9—10.7 N m (80—110 kgf-cm, 70—95 in-lbf) 19—25 (1 .9—2.6, 14—18) 7.9— 10.7 N m (80—110 kgf-cm, 70—95 in-lbf) 19—25 (1 N-m (kgf-m, ft-lbf) 16E0B2-338 Valve Seal The intake and exhaust valve seals are different. The exhaust valve seal has ridges on the top for identification. 1. Assemble the SST so that depth L is as specified. Depth L IN: 16.3mm (0.642 in) EX: 13.8mm (0.543 in] 46U0B2-212 B 2-99 B2 ASSEMBLY 2. Slide the valve seal onto the valve guide with the SST. 3. Set the SST against the valve seal. Caution • Using a hammer will damage the valve seal. 4. Using the SST, press the valve seal on by hand until the SST touches the cylinder head. 46U0B2-108 Valve and Valve Spring 1. Install the lower spring seat. 2. Install the valve. 3. Install the valve spring with the closer pitch toward the cyl­ inder head. 4. Install the upper spring seat. 46U0B2-109 5. Compress the valve spring with the SST, and install the valve keepers. 6. Remove the SST. 7. Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that the keepers are fully seated. 8. Using a flashlight, verify that all valve springs are fully seat­ ed in the cylinder head. 49 B012 0A2 46U0B2-110 Cylinder Head 1. Apply clean engine oil to new O-rings and install them to the oil control plugs. 46U0B2-213 2. Thoroughly remove all dirt, oil, and other material from the decks of the cylinder block. 3. Turn the crankshaft clockwise and apply engine oil to the cylinder walls. 4. Place a new cylinder head gasket on the left bank with the L mark. 5. Place a new cylinder head gasket on the right bank with the R mark. 46U0B2-214 B 2-100 B2 ASSEMBLY 6. Install the cylinder heads to the cylinder block. 7. Tighten the cylinder head bolts as described below. (1) Before installation, measure the length of each bolt. Length: 133.7— 134.3mm {5.264—5.287 in) Maximum: 135.0mm {5.315 in) 46U0B2-215 (2) Apply clean engine oil to the threads and the seat face of each bolt and install them and new washers. (3) Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque: 23.1—25.9 N m {2.35—2.65 kgf m, 17.0—19.1 ft-lbf) 36U0B2-108 (4) Put a paint mark on each bolt head. (5) Using the marks as a reference, tighten the bolts by turn­ ing each 85°—95° in the sequence shown. (6) Further tighten each bolt by turning another 85°—95°. 46U0B2-216 8. Connect the water pipe to the water pipe elbow and secure to the cylinder head. Tightening torque: 7.9—10.7 N-m {80—110 kgf cm, 70—95 in-lbf} O-RING 46U082-217 HLA 1. Apply clean engine oil to the friction surfaces. 2. If the HLA are being reused, install them in the positions from which they were removed. 3. Verify that the HLA move smoothly in their bores. 16E0B2-349 B2-101 B2 ASSEMBLY Camshaft 1. Apply clean engine oil to the camshaft journals, camshaft lobes, and camshaft gears. 2. Install the camshafts so that the intake camshaft gear mark and exhaust camshaft gear mark align. Adjust the friction gear position with a screwdriver so that the HLAs are not lifted by the cam lobes. (Intake side cam lobes of the No.1 cylinder (RH) and No.2 cylinder (LH) face straight up.) Caution • Install the thrust caps (RH is 5 mark, LH is B mark) first. Otherwise, camshaft can be broken or dam­ aged. 3. Install the thrust caps onto the cylinder head. Hand tight­ en the cap bolts gradually in five or six steps in the order shown, until the thrust caps fully seated on the cylinder head. 4. Apply silicone sealant to the shaded areas as shown. Caution * Because there is little camshaft thrust clearance, the camshaft m ust be held horizontally while it is instalied. Otherwise, excessive force will be ap­ plied to the thrust area, causing burr on the thrust receiving area of the cylinder head journal. To avoid this, the following procedure must be ob­ served. LH TH R U S T RH TH R U ST FRONT * * DawiraW R/QC Appuea v i i m . 1 Y V G E 2 2 D *R 5 100001 — 1YV GE31 D * R 5 1 0 0 0 0 1 - ASSEMBLY B2 5. Install the camshaft caps according to their identification marks, and hand tighten the bolts. Note • RH: numbers • LH: letters 6. Tighten the bolts in the order shown. Verify that the cam­ shaft remains horizontal as the camshaft cap bolts (marked © in the figure) tightened. Tightening torque: 11.3— 14.2 N-m {115— 145 kgf-cm, 100— 125 in lb f} 7. Retighten the bolts in the order shown. Tightening torque: 11.3— 14.2 N-m {115— 145 kgf-cm, 100— 125 in-lbf} B2 ASSEMBLY 9. Lightly apply clean engine oil to the new oil seal and the cylinder head. 10. Tap the camshaft oil seal into the cylinder head by using a pipe. Protrusion: 0—0.5mm (0—0.02 in) Note • Oil seal outer diameter: 44.0mm (1.73 in) • Oil seal inner diameter: 30.0mm (1.18 in) 11. Apply sealant to a new blind cap. 12. Tap in the blind cap by using a plastic hammer. Water Outlet Install the water outlet with new O-rings. Tightening torque: 19—25 N m (1.9—2.6 kgf m, 14—18 ft-lbf) 36U0B2-110 Seal Plate Install the seal plate. Tightening torque: 7.9—10.7 N m (80—110 kgf cm, 70—95 in lbf) B 2-103 B2 ASSEMBLY Camshaft Pulley The right and left pulleys are different and must be installed on the same head that they were removed from. 1. Install the camshaft pulley so that the "R" mark can be seen and the groove aligns with the camshaft knock pin. 46U0B2-112 2. Install the camshaft pulley so that the “ L” mark can be seen and the groove aligns with the camshaft knock pin. 46U0B2-113 Camshaft Pulley Lockbolt 1. Apply clean engine oil to the lock bolt threads. 2. Hold the camshaft by using a wrench on the cast hexagon as shown, and tighten the bolt. Tightening torque: 123—140 N m (12.5—14.3 kgf m, 91—103 ft-lbf} 46U0B2-222 LH f Cylinder Head Cover 1. Remove all dirt, old sealant and other material from the cyl­ inder head and cover. 2. Apply sealant to the shaded area as shown in the figure. RH ♦ 16A0B2-039 3. Coat a new gasket with silicone sealant. 4. Install the gasket onto the cylinder head cover. 16A0B2-040 B 2-104 B2 ASSEMBLY 5. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown. Note • Left cylinder head cover bolt heads are round. Tightening torque: 5.0—8.8 N m (50—90 kgf cm, 44—78 in-lbf} 6. Recheck the torque of the bolts indicated, and tighten then if necessary. 36U0B2-113 RH: © , © LH: © , (7) B 2-105 B2 ASSEMBLY TIMING BELT Torque Specification 44—60 14.4—6.2, 32—44) 19—25 11.9—2.6, 14—181 7.9—10.7 N-m (80—110 kgf-cm, 70—95 In-lbf) 7.9—10.7 N-m 80—110 kgf-cm, 7 0 -9 5 in-lbf) ~Mbi BOLT Tl THREADS W oO-RING, NEW 7.9—10.7 N-m (80—110 kgf-cm, 70—95 In-lbf) N-m (kgf-m, ft-lbf) 16E0B2-365 Timing Belt Pulley 1. Hold the flywheel by using the SST. 2. Install the crankshaft key and the timing belt pulley on the crankshaft. 3. Temporarily tighten the timing belt pulley bolt. 16E0B2-366 B 2-106 B2 ASSEMBLY No.2 Idler Pulley Install the No.2 idler pulley to the cylinder block. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf} 16A0B2-097 Timing Belt Auto Tensioner 1. Set a flat washer under the tensioner body to prevent dam­ age to the body plug. 16E0B2-368 2. Press in the tensioner rod slowly, using a press or vise. Caution • Do not press the tensioner rod to more than 9,807 N {1,000 kgf, 2,200 Ibf}. It will damage the ten­ sioner. 46U0B2-223 3. Insert a pin to hold the tensioner rod in the body. 16E0B2-370 4. Install the auto tensioner to the cylinder block and hand tight­ en the upper tensioner bolt so that the tensioner can move. Note • This must be done to reduce the timing belt resistance when the idler pulley is installed. 5. Temporarily install the tensioner pulley. 46U0B2-224 B 2-107 B2 ASSEMBLY Timing Belt 1. Align the matching marks of the pulleys. 16E0B2-372 2. Install the timing belt on the pulleys in the order described below. © Timing belt pulley © No.2 idler pulley © LH camshaft pulley @ Tensioner pulley © RH camshaft pulley 16A0B2-098 3. Verify that the belt has no looseness at the tension side. 4. Install the No.1 idler pulley while applying the pressure on the timing belt. Tightening torque: 38—51 N-m {3.8—5.3 kgf m, 28—38 ft Ibf) 46U0B2-114 5. Push the auto tensioner in the direction of the arrow and install the lower bolt. 6. Tighten the upper and lower tensioner bolts to the speci­ fied torque. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf) 46U0B2-115 7. Remove the pin from the auto tensioner, and apply tension to the belt. 8. Tighten the tensioner pulley. Tightening torque: 38—44 N-m {3.8—4.5 kgf m, 28—32 ft Ibf) 46U0B2-116 B 2-108 B2 ASSEMBLY 9. Turn the crankshaft twice in the direction of rotation, and align the timing marks. 10. Verify that the timing marks are correctly aligned. If not, re­ peat the procedure from Timing Belt Auto Tensioner. (Refer to page B2-108.) 46U0B2-117 11. Check the timing belt deflection. If it is incorrect, replace the auto tensioner. Deflection: 6.0—8.0mm [0.24—0.31 in) 98 22 46U0B2-118 Engine Mount Bracket Install the engine mount bracket. Tightening torque: 44—60 Nm {4.4—6.2 kgf m, 32—44 ft-lbf} 16E0B2-379 Timing Belt Cover 1. Install the right timing belt cover. Tightening torque: 7.9—10.7 N m {80—110 kgf-cm, 70—95 in-lbf} 36U0B2-166 2. Install the left timing belt cover. Tightening torque: 7.9—10.7 N-m {80—110 kgf cm, 70—95 in-lbf} 36U0B2-167 B 2-109 B2 ASSEMBLY Crankshaft Position Sensor Install the crankshaft position sensor. Tightening torque: 7.9—10.7 N m [80—110 kgf-cm, 70—95 in lbf} 36U0B2-114 Dipstick and Pipe Install the dipstick and pipe with the clip. Tightening torque: 7.9—10.7 N m [80—110 kgf cm, 70—95 in lbf} O-RING, NEW 46U0B2-225 Water Pump Pulley Install the water pump pulley. Tightening torque: 7.9—10.7 N m [80—110 kgf cm, 70—95 in-lbf) 36U0B2-169 1if EESBMEl frA ' 1 P Crankshaft Pulley 1. Hold the flywheel (MTX) or drive plate (ATX) by using the SST. 2. Remove the crankshaft pulley bolt. Caution • Install the crankshaft pulley carefully. The crank­ shaft position sensor rotor is on the rear of the pul­ ley, and can be damaged easily. 3. Install the crankshaft pulley onto the crankshaft. 4. Apply clean engine oil to the bolt threads. 5. Tighten the crankshaft pulley. Tightening torque: 1 5 7 -1 6 6 Nm [1 6 .0 -1 7 .0 kgf m, 116—122 ft Ibf) B 2-110 ASSEMBLY B2 AUXILIARY PARTS Torque Specifications 3 8 -5 1 [3.8—5 .3 ,2 8 —38) N-m |kgf-m, ft-lbf) 16E0B2-386 Oil Filter 1. Apply a small amount of clean engine oil to the rubber seal of the new oil filter. 2. Install the filter and tighten it by hand until the rubber seal contacts the mounting base. 3. Tighten the filter 1-1/6 turns by using the SST. 16E0B2-387 B2-111 B2 ASSEMBLY Spark Plug Install the spark plugs. Tightening torque: 15—22 N m (1.5—2.3 kgf m, 11—16 ft-lbf] A/C Compressor Bracket (If equipped) Install the A/C compressor bracket. Tightening torque: 38—51 N m {3.8—5.3 kgf m 28—38 ft-lbf} Engine Hanger 1. Install the front engine hanger and the ground harness. Tightening torque: 19—25 N-m {1.9—2.6 kgf m, 14—18 ft-lbf] 2. Install the rear engine hanger. Tightening torque: 38—51 Nm (3.8—5.3 kgfm, 28—38 ft-lbf] Intake Manifold Assembly 1. Install new gaskets and the intake manifold assembly. Hand tighten the bolts and nuts. 46U0B2-226 ASSEMBLY B2 2. Connect the stays, bracket, fuel pipe, and hoses in the order shown in the figure. 3. Tighten the intake manifold bolts and nuts in two or three steps. N-m (kgf-m, ft-lbf) 46U0B2-227 Distributor 1. Apply clean engine oil to a new O-ring and position it on the distributor. 2. Apply engine oil to the drive blade. 3. Align the groove of the distributor body and shaft gear mark as shown. 4. Install the distributor with the blade fit into the camshaft groove. 16A0B2-074 B 2-113 B2 ASSEMBLY 5. Hand tighten the distributor mounting bolts. 6. Connect the high-tension leads. Note • Adjust the ignition timing after engine installation. (Refer to section G.) 46U0B2-120 Exhaust Manifold Assembly (Left) 1. Place the new gasket in position. 2. Install the left exhaust manifold. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} 16E0B2-395 Exhaust Manifold Insulator (Left) Install the left exhaust manifold insulator. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95 in-lbf} 36U0B2-170 Bracket and Tensioner 1. Install the bracket and tensioner. 2. Hand tighten bolt 1, then bolt 2. 3. Tighten bolt 2, then bolt 1 to the specified torque. Tightening torque: 19—25 N-m {1.9—2.6 kgf-m, 14—18 ft-lbf} Alternator Install the alternator and the bracket. Tightening torque A: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf} B: 1 9 -2 5 Nm {1.9—2.6 kgf m, 14—18 ft Ibf} 16E0B2-398 B 2-114 B2 ENGINE STAND DISMOUNTING ENGINE STAND DISMOUNTING PROCEDURE 1. Remove the engine from the engine stand. 2. Remove the SST from the engine in the reverse order of installation. (Refer to page B2-52.) 46U0B2-229 3. Install the new gasket and the right exhaust manifold togeth­ er with the EGR valve and pipe. Tightening torque: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf} 4. Tighten the EGR valve bolts. Tightening torque: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf} 16E0B2-400 5. Install the right exhaust manifold insulator. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95 in lbf} 36U0B2-171 B 2-115 B2 INSTALLATION INSTALLATION PROCEDURE Tighten all bolts and nuts to the specified torques. Step 1 Torque Specifications N-m {kgf-m, ft-lbf) 16E0B2-402 No.2 Engine mount rubber and bracket 1. Install the mount rubber bracket. Tightening torque: 38—51 N m [3.8—5.3 kgf m, 28—38 ft-lbf) 16A0B2-099 B2—116 B2 INSTALLATION 2. Install the engine mount No.2 rubber and hand tighten the through bolt. Starter Install the starter to the transaxle housing. Tightening torque: 38—51 Nm {3.8—5.3 kgf m, 28—38 ft-lbf) B 2-117 B2 ASSEMBLY Step 2 Warning • A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands. Torque Specifications 67—93 I 67—93 67—93 [6.8—9.5, 50—68] N-m [kgf-m, ft-lbf) 46U0B2-121 Engine and transaxle assembly 1. Suspend the engine and transaxle assembly. 2. Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into compo­ nents in the engine compartment. 3. Install the engine and transaxle assembly in the engine com­ partment. 4. Align the engine mounts with the engine mount member mounting holes. 46U0B2-122 B 2-118 B2 INSTALLATION Engine mount member Install the bolts and nuts (A) as shown and hand tighten the nuts (§). Tightening torque: 67—93 N-m (6.8—9.5 kgf m, 50—68 ft-lbf} Engine mount 1. Install the engine mount No.1 mounting bolts. Tightening torque: 67—93 Nm {6.8—9.5 kgfm, 50—68 ft-lbf] 2. Install the engine mount No.3 rubber. Tightening torque ® : 74—102 Nm (7.5—10.5 kgf m, 55—75 ft-lbf} (§): 86—116 N m {8.7—11.9 kgf m, 63—86.0 ft-lbf} 3. 4. 5. 6. Install the engine mount No.4 bracket. Hand tighten bolts ® . Tighten bolts ® . Tighten bolts ® . Tightening torque ® : 59—80 Nm {6.0—8.2 kgf m, 44—59 ft-lbf} (§): 59—80 Nm {6.0—8.2 kgf m, 44—59 ft-lbf} 7. Install the engine mount No.4 rubber. (ATX) Tightening torque ® : 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf} (S): 86—116 Nm {8.7—11.9 kgf m, 63—86 ft-lbf} 8. Remove the chain block from the engine hangers. 9. Tighten the engine mount No.2 rubber mounting bolt. (Refer to page B2-120.) Tightening torque: 86—116 N m {8.7—11.9 kgf-m, 63—86 ft-lbf} 36U0B2-175 B 2-119 B2 INSTALLATION 10. Tighten the engine mount No.2 nuts B. (Refer to page B2-121.) Tightening torque: 75—104 Nm {7.6—10.7 kgf m, 55—77 ft-lbf) 11. Install the engine mount No.5 rubber. Tightening torque A: 67—93 N-m {6.8—9.5 kgf m, 50—68 ft-lbf) B: 44—60 Nm {4.4—6.2 kgf m, 3 2 - 4 4 ft Ibf) 36U0B2-176 Step 3 Torque specifications Drive shaft 1. Apply grease to the ends of the drive shafts. 46U0B2-234 B 2-120 16E0B2-413 B2 INSTALLATION 2. Install new clips with the end gap upward and install the drive shafts. 3. Install the joint shaft. 4. Tighten the bolts in the order shown. Tightening torque: 43—61 Nm [4.3—6.3 kgf m, 32—45 ft-lbf} 5. Coat the ball joints with grease. 6. Install the lower arm ball joints to the knuckles and tighten the through bolts. Tightening torque: 44—58 Nm {4.4—6.0 kgfm, 32—43 ft-lbf) 16A0B2-047 Tie rod end 1. Install the tie rod ends to the knuckles and tighten them. Tightening torque: 43—56 Nm {4.3—5.8 kgfm , 32—41 ft-lbf) 2. Install new cotter pins. 16E0B2-417 Stabilizer control link Install the stabilizer control link. Tightening torque: 44—60 Nm {4.4—6.2 kgfm, 32—44 ft-lbf) 36U0B2-177 Extension bar (MTX) Install the extension bar to the transaxle. Tightening torque: 32—46 Nm {3.2—4.7 kgfm, 24—33 ft-lbf) Shift control rod (MTX) Install the shift control rod to the transaxle. Tightening torque: 16—22 N m {1.6—2.3 kgfm, 12—16 ft-lbf) B2-121 B2 INSTALLATION Front exhaust pipe 1. Connect the front exhaust pipe to the exhaust pipe with a new gasket. Loosely tighten the new nuts. 2. Install the exhaust pipe to the vehicle body with mount rubbers. 3. Tighten the nuts. Tightening torque: 64—89 Nm {6.5—9.1 kgf m, 48—65 ft-lbf) 4. Install the front exhaust pipe with new gaskets. Tightening torque: 38—51 N m {3.8—5.3 kgfm, 28—38 ft-lbf) 46U0B2-248 Transverse member Install the transverse member. Tightening torque: 94—126 Nm {9.5—12.9 kgf m, 69—93 ft-lbf) 16E0B2-422 Clutch release cylinder (MTX) 1. Install the clutch release cylinder. Tightening torque: 16—22 N m {1.6—2.3 kgf m, 12—16 ft-lbf) 2. Mount the pipe in the brackets and install the clips. I J •M Fuel filter Install the harness bracket and the fuel filter. sS ' Tightening torque: 7.9—10.7 Nm {80—110 kgf-cm, 70—95.4 in-lbf) pv-J rl r( 46U0B2-235 INSTALLATION B2 Step 4 Connect the hoses shown in the figure. HEATER HOSES 46U0B2-236 B 2-123 B2 INSTALLATION Step 5 Connect the harness connectors shown in the figure. B 2-124 B2 INSTALLATION Step 6 Torque Specifications 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 In Ibf) 25 7.9—10.7 N-m 180—110 kgf-cm, 7 0 -9 5 .4 in Ibf) 7.9—10.7 N-m 180-110 kgf-cm, 70—95.4 In Ibf) 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in Ibf) CRUISE ACTUATOR SERVICE, REFER TO SECTION T N-m {kgf-m, ft-lbf) 16E0B2-427 B 2-125 B2 INSTALLATION A/C compressor Install the A/C compressor to the bracket. Tightening torque: 24—35 N-m {2.4—3.6 kgf-m, 18—26 ft-lbf] P/S oil pump and bracket 1. Install the P/S oil pump. Tightening torque A: 32—46 Nm {3.2—4.7 kgf m, 24—33 ft-lbf] B: 19—25 Nm (1.9—2.6 kgf-m, 14—18 ft-lbf] 2. Tighten the bolts shown in the figure. Tightening torque: 32—46 N m {3.2—4.7 kgf m, 24—33 ft-lbf] c 3. Connect the P/S pressure switch connector. 4. Install the P/S oil pump pulley to the pump body and hand tighten the nut. 5. Tighten the pulley nut by using a 12mm {0.47 in] socket through the pulley hole. Tightening torque: 63—93 N m {6.4—9.5 kgf m, 47—68 ft-lbf] 46U0B2-237 B 2-126 B2 INSTALLATION 6. Install the P/S oil reservoir and the engine ground. Tightening torque: 6.9—9.8 N-m {70—100 kgf-cm, 61—86 in-lbf) Drive belt 1. Install the P/S and/or A/C drive belt. 2. Adjust the drive belt deflection. (Refer to page B2-6.) Radiator and electric coolant fan assembly 1. Install the radiator. Tightening torque: 19—25 Nm {1.9—2.6 kgfm, 14—18 ft-lbf) 2. Connect the ATF cooler hoses. (ATX) 3. Connect the upper and lower radiator hoses. 4. Install the coolant fan assembly. Tightening torque: 7.9—10.7 Nm {80—110 kgf cm, 70—95.4 in-lbf) 5. Connect the coolant reservoir hose. 6. Connect the coolant fan motor connector. Accelerator cable Inspection / Adjustment 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.0mm {0.06—0.16 in) UN LOCK 46U0B2-123 3. If not as specified, turn stopper (§) while pressing lock but­ ton (A) to release the lock. 4. Push the spring in direction (5) and adjust the cable free play. 5. Lock stopper ® after locking stopper (§). Air cleaner housing assembly 1. Install the air cleaner housing assembly. 2. Connect the hoses. Tightening torque: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf) 3. Connect the mass airflow sensor connector. 46U0B2-246 B 2-127 B2 INSTALLATION Fresh air duct Install the fresh air duct. Tightening torque: 7.9—10.7 N m {80—110 kgf cm, 70—95.4 in lbf) 46U0B2-247 Steps After Installation 1. Fill the engine with the specified amount and type of engine oil. (Refer to section D2.) 2. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E2.) 3. If the transaxle was drained, fill it with the specified amount and type of transaxle oil. (MTX: Refer to section J, ATX: Refer to section K1.) 4. Install the front wheels. 5. Start the engine and (1) Check the engine oil, transaxle oil, and engine coolant leakage. (2) Check the ignition timing and idle speed (Refer to section F2.) (3) Check the operation of the emission control system. 6. Turn off the engine and check drive belt deflection. (Refer to page B2-6.) 7. Perform a road test. 8. Recheck the oil and coolant levels. 46U0B2-124 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. LUBRICATION SYSTEM (FS) INDEX...............................................................D 1 - 2 OUTLINE..........................................................D 1 - 3 SPECIFICATIONS........................................ D 1 - 3 TROUBLESHOOTING GUIDE....................... D 1 - 3 OIL PRESSURE...............................................D 1 - 4 PREPARATION............................................ D 1 - 4 INSPECTION................................................D 1- 4 ENGINE OIL.....................................................D 1- 6 INSPECTION................................................D 1 - 6 REPLACEMENT...........................................D 1 - 6 OIL FILTER...................................................... D 1 - 7 PREPARATION............................................ D 1- 7 REPLACEMENT........................................... D 1- 7 OIL PAN...........................................................D 1- 8 REMOVAL /INSTALLATION....................... D 1 - 8 OIL PUM P....................................................... D1-11 DISASSEMBLY/ASSEMBLY....................... D1-11 INSPECTION................................................ D1-12 36U0D1-001 D1 INDEX INDEX ENGINE OIL SPECIFICATION API SERVICE SG, SH (ECU) ILSAC TOTAL CAPACITY 3.7 L (3.9 US qt, 3.3 Imp qt) 36UOD1-002 1. Oil pressure Inspection............. .................... page D1-4 2. Engine oil Inspection.................................. page D1-6 Replacement.............................. page D1-6 3. Oil filter Replacement.............................. page D1-7 D 1 -2 4. Oil pan Removal / Installation.............. page D 1- 8 5. Oil pump Disassembly / Assembly......... page D 1-1 1 Inspection................................ page D1-12 D1 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS _ Engine FS Item Lubrication system Oil pump Force-fed type Trochoid gear Type Relief pressure 4 4 2 -5 3 9 (4 .5 -5 .5 , 6 4 -7 8 ) kPa (kgf/cm2, psi) Full-flow, paper element Type Oil filter Relief pressure differential kPa (kgf/cm2, psi) Oil pressure switch activation pressure Total (dry engine) 7 9 -1 1 7 (0 .8 -1 .2 , 1 2 -1 7 ) kPa {kgf/cm2, psi) 14.8—27.4 (0.15—0.28, 2.14-3.98) L [US qt, Imp qt) 3.7 (3.9, 3.3) Engine oil replacement 3.3 (3.5, 2.9) L (US qt, Imp qt) Oil capacity Engine oil replacement (with oil filter) L (US qt, Imp qt) 3.5 (3.7, 3.1) API Service SG, SH (EC II) ILSAC Engine oil 46U0D1-001 Recommended SAE Viscosity o _ 1 CM O_ 1 (°C ) ( °F) CO Temperature 1 -2 0 1 0 -1 0 I 5W-30 Engine oil 0 I I 20 I 40 10 i i 20 i 60 i 80 30 i 40 i i 100 50 I ! 120 > 10W-30 < Anticipated ambient temperature range before the succeeding oil change, °C (°F) TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Engine hard starting Improper engine oil Insufficient engine oil Replace Add oil Excessive oil consumption Oil working up or down in cylinder Oil leakage Refer to Section B1 Repair Oil pressure drop Insufficient oil Oil leakage Worn and/or damaged oil pump rotor Worn plunger (inside oil pump) or weak spring Clogged oil strainer Excessive main bearing or connecting rod bearing clearance Add oil Repair Replace Replace Clean Refer to Section B1 Oil pressure drop Malfunction of oil pressure switch Malfunction of electrical system As described above Refer to Section T Refer to Section T Warning lamp illuminates while engine is running Page D1— 6 D 1- 6 _ D 1- 6 D 1-12 D 1-12 36U0D1-004 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Pro­ tect your skin by washing with soap and water immediately after this work. 46U0D1-002 D1 OIL PRESSURE OIL PRESSURE PREPARATION SST INSPECTION 1. Remove the intake manifold bracket. 2. Remove the oil pressure switch. 3. Screw the SST into the oil pressure switch installation hole. 4. Warm up the engine to normal operating temperature. 5. Run the engine at 3,000 rpm and note the gauge readings Oil pressure: 400—490 kPa {4.0—5.0 kgf/cm2, 57—71 psi}-3,000 rpm 6. If the pressure is not as specified, check for the cause and repair. (Refer to Troubleshooting Guide p. D1-3.) 7. Apply sealant to the oil pressure switch threads as shown. 16E0D1-009 D1—4 OIL PRESSURE D1 8. Remove the SST and install the oil pressure switch. Tightening torque: 11.8— 17.6 N m {120— 180 kgf-cm, 105— 156 in-lbf} D1 9. Install the intake manifold bracket. Tightening torque: 38—51 N-m {3.8—5.3 kgf-m, 28—38 ft-lbf} 16EQD1-039 D 1 -5 D1 ENGINE OIL ENGINE OIL INSPECTION 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condition. 5. Add or replace oil as necessary. Note • The distance between the L and F marks on the dipstick represents 1.0 L {1.1 US qt, 0.9 Imp qt). REPLACEMENT Warning • When the engine and the oil are hot, they can bad­ ly burn. Don’t burn yourself with either. 46U0D1-005 1. Remove the oil filler cap and the oil pan drain plug. 2. Drain the oil into a container. 3. Install the drain plug. Tightening torque: 30—41 N m {3.0—4.2 kgf m, 22—30 ft Ibf} 4. Refill the engine with the specified type and amount of en­ gine oil. Oil capacity L (US qt, Imp qt) 46U0D1-006 Total (dry engine) 3.7 (3.9, 3.3) Engine oil replacement 3.3 (3.5, 2.9) Engine oil replacement (with oil filter) 3.5 (3.7, 3.1) 5. Refit the oil filler cap. 6. Run the engine and check for leaks. 7. Check the oil level and add oil if necessary. 6 46U0D1-014 D 1 -6 OIL FILTER D1 OIL FILTER PREPARATION SST 49 G014 001 Oil filter wrench For removal and installation of oil filter 16E0D1-015 REPLACEMENT 1. Remove the oil filter by using the SST. 2. Use a clean rag to wipe off the mounting surface on the engine. 3. Apply a small amount of clean engine oil to the O-ring of the new filter. 36U0D1-005 4. Install the oil filter and tighten it by hand until the O-ring con­ tacts the cylinder block 5. Tighten the filter 1 and 1/6 turns by using the SST. Tightening torque: 13.8— 17.6 N m (140— 180 kgf cm, 122— 156 in lb f) 6. Start the engine and check for leaks. 7. Check the oil level and add if necessary. Oil filter capacity: 0.2 L (0.21 US qt, 0.18 Imp qt) 46UQD1-007 D1 OIL PAN OIL PAN REMOVAL / INSTALLATION 1. 2. 3. 4. Disconnect the negative battery cable. Drain the engine oil. (Refer to page D1-6.) Remove in the order shown in the figure, referring to Removal Note. Install in the reverse order of removal, referring to Installation Note. GASKET, REPLACE 7.9— 10.7 N-m (80— 110 kgf cm, 70—95.4 in-lbf) 19—25 (1.9—2.8, 14— 18) 7.9— 10.7 N m (80— 110 kgf cm, 70—95.4 in-lbf) N m (kgf m, ft-lbf) 46UOD1-O15 1. Undercover 2. Heated oxygen sensor connector 3. Front exhaust pipe 4. Oil pan Removal Note............................page D1-9 Installation Note..........................page D1-9 D 1 -8 5. Oil strainer Removal Note... Installation Note. page D1-9 page D1-9 OIL PAN D1 Removal Note Oil pan 1. Remove the oil pan mounting bolts. Caution • Pry tools can easily scratch the oil pan stiffener and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange. Refer to the fol­ lowing instructions before removing the oil pan. D1 2. Remove the sealant on the bolt threads. 3. Screw in an oil pan bolt in the weld nut hole to make a small gap between the oil pan upper block and the oil pan. 4. Insert a screwdriver or suitable tool as shown in the figure. 5. Remove the oil pan. 36U0D1-008 Oil strainer 1. Remove bolt (§). 2. Remove bolts ® . 3. Remove the oil strainer and gasket. 36U0D1-0Q9 Installation Note Oil strainer 1. Install the oil strainer with a new gasket. 2. Tighten the bolts marked ® first. Tightening torque: 7.9— 10.7 N m [80— 110 kgf cm, 70—95 in lbf) 46UOD1-OQ9 Oil pan Caution • If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old seal­ ant on it can cause thread damage. 46U0D1-010 D 1 -9 D1 OIL PAN 1. Remove all foreign material from the contact surfaces. 2. Apply silicone sealant to the oil pan as shown in the figure. 3. Install the oil pan within five minutes of applying the sealant. 4. Install the oil pan. Tightening torque: 19—25 N m [1.9—2.6 kgf m, 14—18 ft-lbf) Steps After Installation 1. Fill with the specified amount and type of engine oil. (Refer to page D1-6.) 2. Connect the negative battery cable. 3. Start the engine and check for leaks. 4. Check the oil level and add oil if necessary. 46U0D1-016 OIL PUMP D1 OIL PUMP DISASSEMBLY / ASSEMBLY 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. 53—78 In-lbf) 36U0D1-012 1. Oil seal Disassembly Note, Assembly Note .... 2. Pump cover Disassembly Note Assembly Note.... 3. Outer rotor Assembly N ote.... 4. Inner rotor Assembly Note.... .......... below page D1-13 page D1-12 page D1-13 page D1-13 5. Snap ring 6. Spring seat 7. Pressure spring Inspection................................page D1-12 8. Control plunger Inspect for wear or damage 9. Pump body Inspect for distortion or damage page D1-13 Disassembly Note Oil seal Remove the oil seal with a screwdriver protected with a rag. 16E0D1-Q29 D1-11 D1 OIL PUMP Pump cover 1. Remove the pump cover mounting bolts with an impact screwdriver. 2. Remove the pump cover. 46U0D1-017 INSPECTION Pressure spring 1. Inspect the spring for weakness and damage. 2. Measure the free length. Replace the spring if necessary. Free length: 46.79mm [1.842 in) 46U0D1-018 Rotor Clearance Measure the following clearance. Replace the rotor if necessary. Tooth tip clearance: 0.02—0.18mm [0.0008—0.0071 in) Maximum: 0.200mm [0.0118 in) 46U0D1-020 Outer rotor to pump body clearance: 0.113—0.186mm [0.0044—0.0073 in) Maximum: 0.210mm [0.0083 in) 46U0D1-021 Side clearance: 0.035—0.095mm [0.0014—0.037 in) Maximum: 0.120mm [0.0047 in) 46U0D1-022 D 1 -1 2 OIL PUMP D1 Assembly Note Inner and outer rotor 1. Apply a small amount of clean engine oil to the contact sur­ face of the pump body. 2. Install the inner and outer rotors into the oil pump body with the marks aligned as shown. Pump cover 1. Install the pump cover. Tightening torque: 5.9—8.8 N m (60—90 kgf cm, 53—78 in Ibf) 2. Verify that the inner rotor turns smoothly when turned by hand. Oil seal 1. Apply a small amount of clean engine oil to the lip of a new oil seal. 2. Push the oil seal slightly in by hand. 3. Using a press, tap the oil seal in evenly until it is flush with the edge of the oil pump body. Note • Oil seal outer diameter: 54.5mm (2.15 in) • Oil seal inner diameter: 42.5mm (1.67 in) 46U0D1-013 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. LUBRICATION SYSTEM (KL) INDEX........................................................... D 2- 2 OUTLINE.......................................................D 2- 3 SPECIFICATIONS.......................................D2- 3 TROUBLESHOOTING GUIDE...................... D2- 3 OIL PRESSURE............................................ D 2- 4 PREPARATION.......................................... D2- 4 INSPECTION..............................................D2- 4 ENGINE OIL.................................................. D2— 5 INSPECTION............................................. D 2- 5 REPLACEMENT.........................................D2- 5 OIL FILTER................................................... D2- 6 PREPARATION.......................................... D2- 6 REPLACEMENT.........................................D2- 6 OIL COOLER................................................D2- 7 PREPARATION.......................................... D2- 7 REMOVAL/INSTALLATION...................... D 2- 7 OIL PAN........................................................ D2- 8 REMOVAL / INSTALLATION...................... D 2- 8 INSPECTION............................................. D2- 9 OIL PUMP.....................................................D2-11 DISASSEMBLY/ASSEMBLY...................... D2-11 INSPECTION............................................. D2-12 36U0D2-001 D2 INDEX INDEX ILSAC TOTAL CAPACITY 4.9 L (5.2 US qt, 4.3 Imp qt) 16A0D2-007 1. Oil pressure Inspection.................................. page 2. Engine oil Inspection.................................. page Replacement..............................page 3. Oil filter Replacement............................ page D 2 -2 D2-4 D2-5 D2-5 D2-6 4. Oil cooler Removal / Installation.............. page 5. Oil pan Removal / Installation.............. page Inspection.............................:.. page 6. Oil pump Disassembly / Assembly......... page Inspection................................ page D 2- 7 D2- 8 D 2- 9 D 2-11 D2-12 D2 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS ---------------------------Item Lubrication system Oil pump Engine ------------ ---------- KL Force-fed type Type Trochoid gear Relief pressure kPa (kgf/cm2, psi) 5 00 -5 80 (5.0—6.0, 7 2 -8 5 ) Type Oil filter Full-flow, paper element Relief pressure differential kPa |kgf/cm2,psi) Total (dry engine) 7 9 -1 1 0 (0.8—1.2, 1 1 -1 7 ) L (US qt, Imp qt) 4.9 (5.2, 4.3) Engine oil replacement Oil capacity 3.7 (3.9, 3.3) L (US qt, Imp qt) Engine oil replacement (with oil filter) L (US qt, Imp qt) 4.0 (4.2, 3.5) Engine oil API service SG, SH (EC H) ILSAC 46U002-001 Recommended SAE Viscosity I o CM I -1 0 _ _ (°F ) o (°C ) CO T e m p e ra tu re I -2 0 I 0 5W-30 E n g in e o il I 0 1 1 20 10 1 40 20 i 30 i i 60 40 i i 80 i 100 i 50 i i 120 " > 10W-30 < Anticipated ambient temperature range before the succeeding oil change, °C (°F) TROUBLESHOOTING GUIDE Problem Possible Cause Action Engine hard staring Incorrect oil viscosity Insufficient oil Replace Add oil Excessive oil consumption Oil working up or down in cylinder Oil leakage Refer to Section B2 Repair or replace Oil pressure drop Insufficient oil Oil leakage Worn and/or damaged oil pump Worn plunger (inside oil pump) or weak spring Clogged oil strainer Excessive main bearing or connecting rod bearing clearance Add oil Repair or replace Replace Replace Clean Refer to Section B2 Page D 2- 5 D 2- 5 _ D 2- 5 D2-11, 12 D 2 -1 1 ,12 36U0D2-006 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Pro­ tect your skin by washing with soap and water immediately after this work. 46U0D2-002 D2 OIL PRESSURE OIL PRESSURE PREPARATION SST 16E0D2-005 INSPECTION 1. Remove the oil pressure switch. 16E0D2-006 2. Screw the SST into the oil pressure switch installation hole. 3. Warm up the engine to normal operating temperature. 4. Run the engine at the specified, and note the gauge readings. Oil pressure 1.000 rpm:200 kPa (2.0 kgf/cm2, 28 psi) 3.000 rpm: 340—490 kPa {3.4—5.0 kgf/cm2, 49—71 psi) 46U0D2-003 5. If the pressure is not as specified, check for the cause and repair as necessary. (Refer to Troubleshooting Guide p. D2-3.) 6. Apply sealant to the oil pressure switch threads as shown. 16E0D2-008 7. Remove the SST and install the oil pressure switch. Tightening torque: 11.8—17.6 Nm {120—180 kgf-cm, 104—156 Inlbf) 36U0D2-101 D 2 -4 D2 ENGINE OIL ENGINE OIL INSPECTION 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condition. 5. Add or replace oil as necessary. Note • The distance between the L and F marks on the dipstick represents 1.0 L {1.1 US qt, 0.9 Imp qt). REPLACEMENT Warning • When the engine and the oil are hot, they can bad­ ly burn. Don’t burn yourself with either. 1. Remove the oil filler cap and the oil pan drain plug. 2. Drain the oil into a suitable container. 3. Install a new gasket and the drain plug. 46U0D2-005 Tightening torque: 30—41 N m {3.0—4.2 kgf m, 22—30 ft-lbf) 4. Refill the engine with the specified type and amount of en­ gine oil. Oil capacity L [U S qt, Im p q t) 46U0D2-006 T otal (d ry e n g in e) 4 .9 (5 .2 , 4 .3 ) E n g in e oil re p la c e m e n t 3 .7 [3 .9 , 3 .3 ) Engine oil replacement (with oil filter) 4 .0 (4 .2 , 3 .5 ) 5. Refit the oil filler cap. 6. Run the engine and check for leaks. 7. Check the oil level and add oil if necessary. D2 OIL FILTER OIL FILTER PREPARATION SST 4 9 G 0 1 4 001 W re n c h , oil filte r F or re m o va l / in sta lla tio n of oil filte r 16E0D2-012 REPLACEMENT 1. Remove the oil filter with the SST. 2. Use a clean rag to wipe off the mounting surface on the oil cooler base. 3. Apply a small amount of clean engine oil to the O-ring of the new filter. 16E0D2-013 4. Install the oil filter and tighten it by hand until the O-ring con­ tacts the oil cooler base. 5. Tighten the filter 1 and 1/6 turns with the SST. 49 GO 14 001 Tightening torque: 13.8—17.6 N m (140—180 kgf-cm, 122—156 in-lbf ] 6. Start the engine and check for leaks. 7. Check the oil level and add oil if necessary. Oil filter capacity: 0.3 L (0.3 US qt, 0.3 Imp qt) 46U0D2-0Q7 D2 OIL COOLER OIL COOLER PREPARATION SST D2 REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. REPLACE N-m (kgf-m, ft-lbf) 46U0D2-011 1. Oil filter Replacement........ ..................... page D2-6 2. Oil cooler hoses 3. Oil cooler 4. Oil pressure switch 5. Oil filter body 6. Gasket Steps After Installation 1. Fill with the specified amount and type of engine coolant. (Refer to Section E2-6.) 2. Check for leaks. D 2 -7 D2 OIL PAN OIL PAN REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to page D2-5.) 3. Remove in the order shown in the figure, referring to Removal Note. 4. Install in the reverse order of removal, referring to Installation Note. GASKET, REPLACE Short: 7.9— 10.7 N m (80— 110 kgf cm, 70—95.4 in-lbf) Long: 19—25[ 1.9—2.6, 14— 18) N m (kgf m, ft-lbf) 46U0D2-012 1. Undercover 2. Transverse member 3. Front exhaust pipe D2—8 4. Oil pan Removal Note........................... page D2-9 Inspection...................................page D2-9 Installation Note......................... page D2-9 5. Oil strainer OIL PAN D2 Removal Note Oil pan 1. Remove the oil pan mounting bolts. Caution • Pry tools can easily scratch the lower cylinder block and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange. Refer to the following instructions before removing the oil pan. 2. Remove the sealant from the bolt threads. Screw on oil pan bolt into the oil pan (arrow) to make a small gap between the block and oil pan. 3. Insert a screwdriver or suitable tool shown in the figure and pry loose the oil pan. 4. Remove the oil pan. INSPECTION Oil Pan Visually check for cracks, deformation and damage. Repair or replace if necessary. 16E0D2-020 Installation Note Oil pan Caution • If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old seal­ ant on it can cause thread damage. 46U0D2-009 1. Remove all foreign material from the contact surfaces. 16E0D2-022 D 2 -9 D2 OIL PAN 2. Apply a continuous bead of silicone sealant to the oil pan flange as shown in the figure. 3. Install the oil pan within five minutes of applying the sealant. 4. Install the oil pan. Tightening torque ® : 7.9—10.7 N m (80—110 kgf cm, 70—95.4 inlbf) (I): 1 9 -2 5 N m (1 .9 -2 .6 kgf m, 1 4 -1 8 ft-lbf) Steps After Installation 1. Fill with the specified amount and type of engine oil. (Refer to page D2-5.) 2. Connect the negative battery cable. 3. Start the engine and check for leaks. 4. Check the oil level and add oil if necessary. 16E0D2-025 _____________________________OIL PUMP________ ________________ D2 OIL PUMP DISASSEMBLY / ASSEMBLY 1. Disassemble in the order shown in the figure, referring to Disassembly Note. 2. Assemble in the reverse order of disassembly, referring to Assembly Note. 53—78 In-lbf) -----------0 57—68 15.8—7.0, 42—50) N m (kgf m, ft-lbf) 16E0D2-026 1. Pump cover Disassembly Note...............................below Assembly Note.........................page D2-13 2. Outer rotor Assembly Note.........................page D2-12 3. Inner rotor Assembly Note.........................page D2-12 4. Blind plug 5. Spring seat 6. Pressure spring Inspection.................................page D2-12 7. Control plunger Inspect for wear and damage 8. Pump body Inspect for distortion and damage Disassembly Note Pump cover 1. Remove the pump cover mounting bolts with an impact screwdriver. 2. Remove the pump cover. 46U0D2-013 D2-11 D2 OIL PUMP INSPECTION Pressure Spring 1. Inspect the spring for weakness and damage. 2. Measure the spring free length. Replace the spring if necessary. Free length: 46.79mm (1.842 in) 46U0D2-014 Rotor Clearance Measure the following clearances. Replace the rotor if necessary. Tooth tip clearance: 0.02—0.18mm (0.0008—0.0070 in} Maximum: 0.20mm (0.0079 in} 46U0D2-015 Outer rotor to pump body clearance: 0.113—0.186mm (0.0045—0.0073 in) Maximum: 0.22mm (0.0087 in) 46U0D2-016 Side clearance: 0.03—0.09mm (0.0012—0.0035 in) Maximum: 0.13mm (0.0051 in) 46U0D2-017 Assembly Note Inner and outer rotor 1. Apply a liberal amount of clean engine oil to the friction sur­ face of the pump body and the rotors. 2. Install the inner rotor and outer rotor with the markings fac­ ing upward. 16E0D2-032 D 2-1 2 D2 OIL PUMP Pump cover 1. Install the pump cover. Tightening torque: 5.9—8.8 N-m (60—90 kgf-cm, 53—78 in-lbf) 2. Verify that the oil pump rotates smoothly when turned by hand. 16E0D2-033 D 2-1 3 E1 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. COOLING SYSTEM (FS) INDEX........................................................... E1- 2 OUTLINE.......................................................E1- 3 SPECIFICATIONS.......................................E1- 3 TROUBLESHOOTING GUIDE...................... E1- 3 ENGINE COOLANT.......................................E1- 4 PREPARATION........................................... E1- 4 INSPECTION...............................................E1- 4 REPLACEMENT.........................................E1- 5 RADIATOR CAP........................................... E1- 7 PREPARATION........................................... E1- 7 INSPECTION...............................................E1- 7 RADIATOR.....................................................E1- 8 REMOVAL / INSTALLATION....................... E1- 8 INSPECTION...............................................E1- 8 THERMOSTAT............................................. E1- 9 REMOVAL / INSTALLATION....................... E1- 9 INSPECTION...............................................E1— 9 WATER PUMP...............................................E1-11 REMOVAL / INSTALLATION....................... E1-11 COOLANT FAN MOTOR.............................. E1-12 INSPECTION...............................................E1-12 REPLACEMENT.........................................E1-13 COOLANT FAN RELAY............................... E1-14 REMOVAL.................................................. E1-14 INSPECTION...............................................E1-14 46U0E1-001 E1 INDEX INDEX 1. Engine coolant Inspection.................................page Replacement.............................page 2. Radiator cap Inspection.................................page 3. Radiator Removal / Inspection / Installation...............................page 4 Thermostat Removal / Inspection / Installation...............................page E 1-2 E1- 4 E1- 5 E1- 7 E1- 8 E1- 9 5. Water pump Removal / Installation............... page E 1-11 6. Coolant fan motor Inspection................................ page E1-12 Replacement............................ page E1-13 7. Engine coolant temperature sensor Removal / Inspection / MTX: Section F1 Installation ..... ATX: Section F3 8. Coolant fan relay Removal................................... page E1—14 Inspection................................ page E1-14 E1 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE •* SPECIFICATIONS ' ------------------------ Item Cooling system Engine ~ MTX ATX Water-cooled, fcirced circulation Coolant capacity Water pump -------------- ~ FS L (US qt, Imp qt) 7.0 (7.4, 6.2) Centrifugal, V-ribbed belt-driven Type Water seal Unified mechanical seal Wax, bottom-bypass Type Thermostat Radiator Opening temperature °C (°F ) 8 0 -8 4 (1 7 6 -1 8 3 ) Full-open temperature °C (°F ) 95 (203) Full-open lift mm (in) 8.5 (0.33) min. Type Corrugated fin Cap valve opening pressure kPa (kgf/cm2, psi) 9 3 -1 2 3 (0.95-1.25, 13.5-17.8) Electric Type Coolant fan Blade Motor Outer diameter Current 340 (13.4) mm (in) Number A 4 5 5.6—7.6 8 .0-14 .0 (LOW) 11.5-17.5 (HIGH) 46U0E1-003 TROUBLESHOOTING GUIDE Overheating Corrosion Action Possible Cause Problem Page Coolant level insufficient Coolant leakage Radiator fins clogged Radiator cap malfunction Coolant fan malfunction Thermostat malfunction Water passage clogged Water pump malfunction Add Repair or replace Clean Replace Replace Replace Clean Replace E 1- 4 Impurities in coolant Replace E1- 5 E 1- 8 E1- 7 E1-12 E1- 9 E1- 5 E1-11 36U0E1-003 E 1 -3 E1 ENGINE COOLANT ENGINE COOLANT PREPARATION SST 49 9200 145 Adapter set, radiator cap tester Jjf /g v ^ ^ y For inspection of cooling system pressure 49 9200 146 Adapter A (Part of 49 9200 145) // iL \\ For inspection of cooling system pressure 16E0E1-005 INSPECTION Warning • Removing the radiator cap or the radiator drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 46U0E1-004 Coolant Level (Engine cold) 1. Verify that the coolant level is near the filler neck of the radiator. 2. Remove the coolant level dipstick from the coolant reser­ voir and verify that the coolant level is between the F and L marks. Add coolant if necessary. 46U0E1-0Q5 Note • The distance between the L and F mark on dipstick represents 0.55 L {0.55 US qt, 0.44 Imp qt). Coolant Quality 1. Verify that there is no buildup of rust or scale around the radiator cap and filler neck. 2. Verify that the coolant is free of oil. Replace the coolant if necessary. 36U0E1 -004 Coolant Leakage 1. Connect a radiator tester (commercially available) and the SST to the radiator filler neck. 2. Apply 123 kPa {1.25 kgf/cm2, 17.8 psi) pressure to the system. 3. Verify that the pressure is held. If not, check for coolant leakage. Caution • Applying more than 123 kPa (1.25 kgf/cm2, 17.8 psi) can damage the hoses, fittings and other compo­ nents, and cause leaks. 46U0E1-017 E1 ENGINE COOLANT Coolant Protection Caution • The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. • Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. COOLANT PROTECTION SPECIFIC GRAVITY 1. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2. Determine the coolant protection by referring to the graph shown. 3. If the coolant protection is not proper, add water or coolant as necessary. Antifreeze solution mixture percentage COOLANT TEMPERATURE °C |°F| 46U0E1-006 Coolant protection Volume percentage Gravity at 20°C |68°F) Water Coolant Above -16°C (3°F) 65 35 1.054 Above -26°C (—15°F) 55 45 1.066 Above -40°C {-40°F) 45 55 1.078 REPLACEMENT Draining Warning • Removing the radiator cap or the radiator drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 1. Remove the radiator cap and loosen the radiator drain plug. 3. Drain the coolant into a container. 4. Flush the cooling system with water until all traces of color are gone. 5. Let the system drain completely. 6. Tighten the drain plug. 46U0E1-008 E 1 -5 E1 ENGINE COOLANT Refilling Use the proper amount and mixture of ethylene-glycol based coolant. (Refer to Coolant Protection, page E1-5.) 1. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace: 1.0 L (1.1 US qt, 0.9 Imp qt}/min. max. 2. 3. 4. 5. Fill the coolant reservoir up to the F mark. Fully install the radiator cap. Start the engine and let it idle until it warms up. If the temperature increases beyond normal, there is exces­ sive air in the system. Stop the engine and allow it to cool; then repeat Step 1—3. 6. Run the engine at 2,200—2,800 rpm for five minutes. 7. Stop the engine and allow it to cool. 8. Repeat steps 1—7; then go to step 9. Warning • Removing the radiator cap while the engine is run­ ning, or when the engine and radiator are hot is dan­ gerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 9. Remove the radiator cap and verify that the engine coolant level is near the filler neck. If not, repeat steps 1—9. 10. Fill the reservoir up to the F mark. 46U0E1-009 -f E1 RADIATOR CAP RADIATOR CAP PREPARATION SST 49 9200 145 Adapter set, radiator cap tester ({ JL \ /y \ /X ,4 ^ For inspection of radiator cap valve 49 9200 147 Adapter B (Part of 49 9200 145) J ' wOAV' For inspection of radiator cap valve 16E0E1-014 INSPECTION Radiator Cap Valve 49 92 00 147 46U0E1-018 Warning • Removing the radiator cap while the engine is run­ ning, or when the engine and radiator are hot is dan­ gerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter clockwise to the first stop. Step back while the pressure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 1. Remove all foreign material (such as water residue) from between the radiator cap valve and the valve seat. 2. Attach the radiator cap to a radiator cap tester (commer­ cially available) with the SST. Apply pressure gradually to 93—123 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi). 3. Verify that the pressure is held for at least 10 seconds. Negative Pressure Valve 1. Pull the negative pressure valve to open it. Verify that it closes completely when released. 2. Check for damage of the contact surfaces and for cracked and deformed seal packing. 3. Replace the radiator cap if necessary. 16E0E1-016 E1 RADIATOR RADIATOR REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E1-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. N-m {kgf-m, ft-lbf) 46UOE1-010 1. Resonance chamber No.1 2. Fresh air duct 3. Coolant fan motor connector 4. Coolant reservoir pipe 5. Upper and lower, radiator hose 6. Oil cooler hose (ATX) 7. Radiator bracket 8. Radiator Inspection............................................below 9. Coolant fan and radiator cowling assembly INSPECTION Radiator Check for the following and repair or replace as necessary. 1. Cracks, damage, and water leakage 2. Bent fins (Repair with a screwdriver.) 3. Distorted and bent radiator inlet and outlet Steps After Installation 1. Fill the radiator with the specified amount and type of en­ gine coolant. (Refer to page E1-6.) 2. Check for leaks. 46U0E1-019 E 1 -8 E1 THERMOSTAT THERMOSTAT REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E1-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal, referring to Installation Note. E1 14—18) N-m {kgf m, ft-lbf) 46U0E1-020 3. Thermostat Inspection............................................below Installation Note....................... page E1-10 1. Radiator hose, lower 2. Thermostat cover INSPECTION Thermostat 1. Visually check that the thermostat valve is airtight. 2. Place the thermostat and a thermometer in water. 3. Heat the water and check the following. Initial-opening temperature: 80—84°C {176—183°F) Full-open temperature: 95°C {203°Fj Full-open lift: 8.5mm {0.33 in} min. 36U0E1-015 E 1 -9 E1 THERMOSTAT 4. If the gasket of the thermostat is damaged, replace the ther­ mostat assembly. 16E0E1-021 Installation Note Thermostat 1. Verify that the jiggle pin is aligned with the projection of the thermostat gasket as shown. 36U0E1-006 2. Install the thermostat and gasket into the thermostat hous­ ing, aligning the tab to the housing, as shown in the figure. 16E0E1-023 Steps After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E1-6.) 2. Check for leaks. 46UQE1-021 E1—10 E1 WATER PUMP WATER PUMP REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the coolant. (Refer to page E1-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. N-m (kgf-m, ft-lbf) 46U0E1-022 1. Timing belt Removal / Installation...... ............Section B1 2. P/S oil pump adjuster 3. Water pump assembly Inspect for cracks, damaged mounting sur­ face, bearing condition, and leakage 4. Water pump rubber seal Inspect for damage Steps After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E1-6.) 2. Check for leaks. E1 COOLANT FAN MOTOR COOLANT FAN MOTOR INSPECTION Single-Speed Type (MTX) 1. Verify that the battery is fully charged. 2. Disconnect the coolant fan motor connector. 3. Connect battery positive voltage and an ammeter to the cool­ ant fan motor connector. 4. Verify that current draw is as specified. Current: 5.6—7.6A 46U0E1-011 5. If current is not within the specification or the coolant fan does not turn smoothly, replace the coolant fan motor. Two-Speed Type (ATX) 1. Verify that the battery is fully charged. 2. Disconnect the coolant fan motor connector. 3. Connect battery positive voltage and an ammeter to the cool­ ant fan motor connector for low-speed inspection. 4. Verify that the coolant fan motor operates smoothly at the standard current draw. Current: 8.0—14.0A 46U0E1-Q12 5. Connect battery positive voltage and an ammeter to the cool­ ant fan motor connector for high-speed inspection. 6. Verify that the coolant fan motor operates smoothly at the standard current draw. Current: 11.5—17.5A 7. If not as specified, replace the coolant fan motor. 46U0E1-013 E1—12 w COOLANT FAN MOTOR E1 REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. 2.7—3.7 N-m (27—38 kgf-cm, 24—32 In-lbf) 46U0E1-014 1. Resonance chamber No.1 2. Fresh air duct 3. Coolant fan motor connector 4. Radiator cowling 5. Coolant fan blade 6. Coolant fan motor E 1 -13 E1 COOLANT FAN RELAY V COOLANT FAN RELAY REMOVAL 1. Disconnect the negative battery cable. 2. Remove the coolant fan relay as shown in the figure. 46U0E1-015 INSPECTION 1. Check continuity of the coolant fan relay as shown. Terminal Continuity A -C No B -D Yes 2. Apply battery positive voltage between terminals B and D. Check for continuity between terminals A and C. 3. If not as specified, replace the coolant fan relay. E1—14 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. COOLING SYSTEM (KL) INDEX............................................................E2- 2 OUTLINE.......................................................E2- 3 SPECIFICATIONS...................................... E2- 3 TROUBLESHOOTING GUIDE...................... E2- 3 ENGINE COOLANT.......................................E2- 4 PREPARATION........................................... E2- 4 INSPECTION...............................................E2— 4 REPLACEMENT.........................................E2- 5 RADIATOR CAP........................................... E2- 7 PREPARATION........................................... E2- 7 INSPECTION...............................................E2- 7 RADIATOR.....................................................E2— 8 REMOVAL / INSTALLATION....................... E2- 8 INSPECTION...............................................E2- 8 THERMOSTAT..............................................E2- 9 REMOVAL / INSTALLATION....................... E2- 9 INSPECTION...............................................E2-10 WATER PUMP...............................................E2-11 REMOVAL / INSTALLATION....................... E2-11 COOLANT FAN MOTOR.............................. E2-12 INSPECTION...............................................E2-12 REPLACEMENT.........................................E2-13 COOLANT FAN RELAY............................... E2-14 REMOVAL.................................................. E2-14 INSPECTION...............................................E2-14 46U0E2-001 E2 INDEX INDEX 1. Engine coolant Inspection......................... ....... page E2- 4 Replacement.................... ....... page E2- 5 2. Radiator cap Inspection......................... ....... page E2- 7 3. Radiator Removal / Installation....... ....... page E2- 8 Inspection......................... ....... page E2- 8 4. Thermostat Removal / Installation....... ....... page E2- 9 Inspection......................... ....... page E2-10 46U0E2-002 5. Water pump Removal / Installation...... ........ page E2-11 6. Coolant fan motor Inspection....................... .......page E2-12 Replacement................... ....... page E2-13 7. Engine coolant temperature sensor Removal / Inspection / Installation..................... .......... Section F2 8. Coolant fan relay Removal.......................... ....... page E2-14 Inspection....................... ....... page E2-14 E2 OUTLINE, TROUBLESHOOTING GUIDE OUTLINE SPECIFICATIONS Engine Item Cooling system Water-cooled, forced circulation Coolant capacity L (US qt, Imp qt) Type Unified mechanical seal Type Wax, bottom-bypass Opening temperature °C ( °F) Full-open temperature °C (°F) 95 (203) Full-open lift mm (in) 8.5 (0.33) min. Type Radiator Cap valve opening pressure kPa (kgf/cm2, psi) Blade Motor 8 0 -8 4 (1 7 6 -1 8 3 ) Corrugated fin E2 7 4 -1 0 2 (0.75-1.05, 10.7-14.9) Type Coolant fan 7.5 (7.9, 6.6) Centrifugal Water seal Thermostat KL Electric Outer diameter mm (in) Number Current 340 (13.4) 5 A MTX 11.5-17.5 (High) 8 .0-14 .0 (Low) ATX 13.7-19.7 (High) 9 .0 -1 5 .0 (Low) 46U0E2-003 TROUBLESHOOTING GUIDE Possible Cause Problem Overheating Corrosion Action Page Coolant level insufficient Coolant leakage Radiator fins clogged Radiator cap malfunction Coolant fan malfunction Thermostat malfunction Water passage clogged Water pump malfunction Add Repair or replace Clean Replace Repair or replace Replace Clean Replace E 2- 8 E2- 7 E2-12 E2-10 E 2- 4 E2-11 Impurities in coolant Replace coolant E2- 4 E2- 4 46U0E2-004 E2—3 E2 ENGINE COOLANT ENGINE COOLANT PREPARATION SST 49 9200 145 Adapter set, radiator cap tester // \\ For inspection of cooling system 49 9200 146 Adapter A (Part of 49 9200 145) _____ If X gQ \\ A For inspection of cooling system 46U0E2-005 INSPECTION Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 36U0E2-010 Coolant Level (Engine cold) 1. Verify that the coolant level is at the filler neck. 2. Verify that the coolant level on the coolant dipstick is be­ tween the F and L marks. 3. Add coolant if necessary. Note • The distance between the L and F mark on dipstick represents 0.5 L {0.5 US qt, 0.4 Imp qt). Coolant Quality 1. Verify that there is no buildup of rust or scale around the radiator cap, filler cap or filler neck. 2. Verify that coolant is free of oil. Replace the coolant if necessary. 16E0E2-008 Coolant Leakage 1. Connect a radiator tester (commercially available) and the SST to the radiator filler neck. 2. Apply 102 kPa {1.05 kgf/cm2, 14.9 psi) pressure to the system. 3. Verify that the pressure is held. If not, check the system for coolant leakage. Caution • Applying more than 102 kPa {1.05 kgf/cm2, 14.9 psi} can damage the hoses, fittings, and other compo­ nents, and cause leaks. 46U0E2-017 E 2 -4 E2 ENGINE COOLANT Coolant Protection Caution • The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. • Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. COOLANT PROTECTION SPECIFIC GRAVITY 1. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2. Determine the coolant protection by referring to the graph shown. 3. If the coolant protection is not proper, add water or coolant as necessary. Antifreeze solution mixture percentage |6 8 ) |8 6 J 1 1 0 4 )11 2 2 )(1 4 0 )11 5 8 1 (1 7 6 )1194) COOLANT TEMPERATURE Coolant protection °C ( " F | 46U0E2-007 Volume percentage Water Coolant Gravity at 20°C (68°Fj Above -16°C (3°F) 65 35 1.054 Above -26°C (-15°F) 55 45 1.066 Above -40°C (-40°F) 45 55 1.078 16E0E2-011 REPLACEMENT Draining o Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 46U0E2-008 1. 2. 3. 4. Remove the filler cap and loosen the radiator drain plug. Disconnect the oil cooler hose. Drain the coolant into a container. Flush the cooling system with water until all traces of color are gone. 5. Let the system drain completely. 6. Tighten the drain plug and connect the oil cooler hose. Caution • Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. E 2 -5 E2 ENGINE COOLANT, RADIATOR CAP Refilling Use the proper amount and mixture of ethylene-glycol based coolant. (Refer to Coolant Protection, page E2-5.) 1. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace: 1.0 L (1.1 US qt, 0.9 Imp qt]/min. max. 2. 3. 4. 5. Fill the coolant reservoir up to the F mark. Fully install the filler cap. Start the engine and let it idle until it warms up. If the temperature increases beyond normal, there is exces­ sive air in the system. Stop the engine and allow it to cool; then repeat Step 1—3. 6. Run the engine at 2,200—2,800 rpm for five minutes. 7. Stop the engine and allow it to cool. 8. Repeat steps 1—7; then go to step 9. Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 9. Remove the filler cap and verify that the engine coolant level is near the filler neck. If not, repeat step 1—9. 10. Fill the reservoir to the F mark. 46U0E2-010 ____________________________RADIATOR CAP________ _______________ E2 RADIATOR CAP PREPARATION 49 9200 145 Adapter set, radiator cap tester If rw l ^ .ii. Z \ For inspection of radiator cap 49 9200 147 Adapter B j) For inspection of radiator cap (Part °f 49 9200 145) 16E0E2-015 INSPECTION Radiator Cap Valve 46U0E2-018 Warning • Removing the radiator cap while the engine is run­ ning, or when the engine and radiator are hot is dan­ gerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth-turn it, and re­ move it. 1. Remove all foreign material (such as water residue) from between the radiator cap valve and the valve seat. 2. Attach the radiator cap to a radiator cap tester (commer­ cially available) with the SST. Apply pressure gradually to 74—102 kPa [0.75—1.05 kgf/cm2, 10.7—14.9 psi). 3. Verify that the pressure is held for at least 10 seconds. Negative Pressure Valve 1. Pull the negative pressure valve to open it. Verify that it closes completely when released. 2. Check for damage on the contact surfaces and for cracked or deformed seal packing. 3. Replace the radiator cap if necessary. 16E0E2-017 E2—7 E2 RADIATOR RADIATOR REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E2-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 1. 2. 3. 4. Fresh air duct Coolant fan motor connector Coolant reservoir hose Radiator hose (upper and lower) 5. Radiator bracket 6. Radiator Inspection............................................below 7. Condenser fan and radiator cowling assembly INSPECTION Check for the following and repair or replace as necessary. 1. Cracks, damage, and water leakage. 2. Bent fins, (repair with a screwdriver.) 3. Distorted and bent radiator inlet and outlet. Steps After Installation 1. Fill the radiator with the specified amount and type of en­ gine coolant. (Refer to page E2-6.) 2. Check for leaks. 46U0E2-019 E2—8 E2 THERMOSTAT THERMOSTAT REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E2-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal, referring to Installation Note. 19—25 (1.9—: O-RING, REPLACE 19—25 11.9—2.6, 14— 18) N m (kgfm , ft-lbf| 46U0E2-020 1. Water inlet pipe 2. Engine harness bracket 3. Thermostat cover 4. Thermostat Inspection................................ page E2-10 Installation Note....................... page E2-10 E 2 -9 E2 THERMOSTAT INSPECTION 1. Visually check that the thermostat valve is airtight. 2. Place the thermostat and a thermometer in water. 3. Heat the water and check the following. Initial-opening temperature: 80—84°C (176—183°F} Full-open temperature: 95°C (203°F) Full-open lift: 8.5mm (0.33 in) min. 4. If the gasket of the thermostat is damaged, replace the ther­ mostat assembly. Installation Note Thermostat Install the thermostat into the cylinder head with the left jig­ gle pin and projection at the top. 16E0E2-022 Steps After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E2-5.) 2. Check for leaks. 46UQE2-021 WATER PUMP E2 WATER PUMP REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. _______________________________________________________________________________________________________________________ N m (kgf-m, ft-lbf t 46U0E2-022 1. Timing belt Removal / Installation.................. Section B2 2. No.3 Engine mount bracket 3. Water pump assembly Inspect for cracks, damages mounting surface, bearing condition, and leakage 4. Water pump rubber seal Steps After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E2-6.) 2. Check for leak. E2—11 E2 COOLANT FAN MOTOR COOLANT FAN MOTOR INSPECTION 1. Verify that the battery is fully charged. 2. Disconnect the coolant fan motor connector. 3. Connect battery positive voltage and an ammeter to the cool­ ant fan motor connector for low-speed inspection. 4. Verify that the coolant fan motor operates smoothly at the standard current draw. 46U0E2-012 Current MTX: 8.0—14.0A ATX: 9.0—15.0A 5. Connect battery positive voltage and an ammeter to the cool­ ant fan motor connector for high-speed inspection. 6. Verify that the coolant fan motor operates smoothly at the standard current draw. Current MTX: 11.5—17.5A ATX: 13.7—19.7A 46U0E2-Q13 7. If not as specified, replace the coolant fan motor. E2 COOLANT FAN MOTOR REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to page E2-5.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 7.9—10.7 N m {BO— 110 kgf-cm, 70—95.4 in Ib f) (8 0 -1 1 0 kgf cm, 7 0 -9 5 .4 In Ibf) 19—25 (1.9—2.6, 14— 18). 1.5—2.4 N m (15—25 kgf cm, 14—21 In Ib f) APPLY LOCKING COMPOUND 1.8—2.1 N m (18—22 kgf cm, 16— 19 In lbf) 4.0—4.9 (40—50 kgf cm, 35—43 In lbf) APPLY LOCKING COMPOUND 4.3—5.1 N m (43—53 kgf cm, 38—46 in Ibf) N m (kgf m, ft-lbf) 46U0E2-014 1. Fresh air duct 2. Radiator bracket 3. Coolant reservoir hose 4. Radiator hose (upper and lower) 5. Radiator 6. Coolant fan motor connector 7. Condenser fan motor connector 8. Radiator cowling 9. Condenser fan 10. Coolant fan 11. Condenser fan motor 12. Coolant fan motor Steps After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E2-6.) 2. Check for leak. E2—13 E2 COOLANT FAN RELAY COOLANT FAN RELAY REMOVAL 1. Disconnect the negative battery cable. 2. Remove the coolant fan relay from the place shown in the figure. 46U0E2-015 INSPECTION 1. Check continuity of the coolant relay as shown. Terminal Continuity A -C No B -D Yes 2. Apply battery positive voltage between terminals B and D. Check for continuity between terminals A and C. 3. If not as specified, replace the coolant fan relay. 46U0E2-016 F1 Before beginning any service procedure, refer to the Body Electrical Troubleshooting Manual; see section S for air bag system precautions and J1 for audio antitheft system precautions. FUEL AND EMISSION CONTROL SYSTEMS (FS MTX) IN D EX.................................................................. F 1 - 2 OUTLINE............................................................. F 1 - 5 SYSTEM DIAGRAM........................................ F 1 - 5 VACUUM HOSE ROUTING DIAGRAM......... F 1 - 7 WIRING DIAGRAM......................................... F 1 - 8 SPECIFICATIONS............................................ F 1 - 10 COMPONENT DESCRIPTIONS..................... F 1 - 11 ENGINE TUNE-UP.............................................. F 1 - 14 PREPARATION................................................F 1 - 14 BASIC INSPECTION.......................................F 1 - 14 ADJUSTMENT.................................................F 1 - 15 ON-BOARD DIAGNOSIS SYSTEM...................F 1 - 17 DESCRIPTION.................................................F 1 - 17 PREPARATION................................................F 1 - 18 DIAGNOSTIC TROUBLE CODE NUMBER... F 1 - 18 SWITCH MONITOR FUNCTION.................... F 1 - 38 HEATED OXYGEN SENSOR MONITOR FUNCTION.....................................................F1— 39 INTAKE AIR SYSTEM .......................................F 1 - 42 COMPONENT PARTS.................................... F 1 - 42 THROTTLE BODY...........................................F 1 - 43 INTAKE MANIFOLD.......................................F 1 - 43 RESONANCE CHAMBER No.2..................... F 1 - 43 ACCELERATOR PEDAL.................................F 1 - 44 ACCELERATOR CABLE.................................F 1 - 44 IDLE-SPEED CONTROL SYSTEM................... F 1 - 45 DESCRIPTION.................................................F 1 - 45 PREPARATION................................................F 1 - 46 SYSTEM OPERATION.................................... F 1 - 46 IDLE AIR CONTROL VALVE......................... F 1 - 46 AIR VALVE...................................................... F 1 - 46 FUEL SYSTEM ................................................... F 1 - 47 DESCRIPTION.................................................F 1 - 47 SYSTEM OPERATION.................................... F 1 - 48 FUEL TANK.....................................................F 1 - 50 FUEL FILTER.................................................. F 1 - 51 FUEL PUMP................................................... F 1 - 52 FUEL PUMP RELAY.......................................F 1 - 55 PRESSURE REGULATOR.............................. F 1 - 55 INJECTOR....................................................... F 1 - 57 PRESSURE REGULATOR CONTROL SYSTEM ............................................................ F1— 60 PRESSURE REGULATOR CONTROL SOLENOID VALVE............................................................ F 1 - 61 EXHAUST SYSTEM............................................F 1 - 62 COMPONENT PARTS.................................... F 1 - 62 OUTLINE OF EMISSION CONTROL SYSTEM ............................................................ F 1 - 63 STRUCTURAL VIEW.......................................F 1 - 63 EXHAUST GAS RECIRCULATION (EXCEPT CALIFORNIA)..................................F 1 - 64 DESCRIPTION.................................................F1— 64 SYSTEM OPERATION.................................... F 1 - 64 SYSTEM INSPECTION................................... F 1 - 64 EGR CONTROL VALVE..................................F 1 - 65 EGR FUNCTION CONTROL.......................... F 1 - 65 EGR SOLENOID VALVE................................ F 1 - 65 EGR FUNCTION SENSOR.............................F 1 - 65 EXHAUST GAS RECIRCULATION (CALIFORNIA)..................................................F 1 - 66 DESCRIPTION................................................ F 1 - 66 SYSTEM OPERATION.................................... F 1 - 66 SYSTEM INSPECTION...................................F 1 - 67 EGR SOLENOID VALVE (VACUUM).............F 1 - 67 EGR SOLENOID VALVE (VENT)...................F 1 - 67 EGR CONTROL VALVE..................................F 1 - 67 EGR FUNCTION SENSOR.............................F 1 - 68 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM................................................ F 1 - 69 DESCRIPTION................................................ F 1 - 69 PCV VALVE.................................................... F 1 - 69 FUEL EVAPORATIVE SYSTEM...................... F 1 - 70 DESCRIPTION................................................ F1— 70 SYSTEM OPERATION.................................... F 1 - 71 PURGE CONTROL SOLENOID VALVE........F 1 - 71 FUEL VAPOR VALVE.................................... F 1 - 71 CHECK VALVE (TWO-WAY).......................... F 1 - 72 CHARCOAL CANISTER................................ F 1 - 72 FUEL-CUT CONTROL SYSTEM...................... F 1 - 73 DESCRIPTION................................................ F 1 - 73 PREPARATION............................................... F 1 - 74 SYSTEM OPERATION.................................... F 1 - 75 A/C CUTOFF SYSTEM..................................... F 1 - 76 DESCRIPTION................................................ F 1 - 76 SYSTEM OPERATION.................................... F 1 - 76 DECHOKE CONTROL SYSTEM...................... F 1 - 77 SYSTEM OPERATION.................................... F 1 - 77 COOLANT FAN CONTROL SYSTEM..............F 1 - 77 DESCRIPTION................................................ F 1 - 77 SYSTEM OPERATION.................................... F 1 - 78 CONTROL SYSTEM.......................................... F 1 - 79 PREPARATION............................................... F 1 - 79 STRUCTURAL VIEW.......................................F 1 - 80 POWERTRAIN CONTROL MODULE (ENGINE)...................................................... F 1 - 81 MASS AIRFLOW SENSOR.............................F 1 - 90 CRANKSHAFT POSITION SENSOR..............F 1 - 90 ENGINE COOLANT TEMPERATURE SENSOR........................................................F 1 - 91 INTAKE AIR TEMPERATURE SENSOR........F 1 - 92 THROTTLE POSITION SENSOR.................... F 1 - 92 HEATED OXYGEN SENSOR......................... F 1 - 93 IDLE SWITCH..................................................F 1 - 94 MAIN RELAY..................................................F 1 - 94 COOLANT FAN RELAY.................................. F 1 - 94 CLUTCH SWITCH.......................................... F 1 - 94 NEUTRAL SWITCH........................................F 1 - 95 STEERING PRESSURE SENSOR................. F 1 - 95 TROUBLESHOOTING GUIDE.......................... F 1 - 96 QUICK DIAGNOSIS CHART.......................... F 1 - 96 RELATIONSHIP CHART................................ F 1-1 00 USING THIS SECTION...................................F1-102 DIAGNOSTIC INDEX..................................... F 1-1 04 SYMPTOM TROUBLESHOOTING................. F 1 -1 07 SERVICE POINTS.............................................. F1-142 OUTLINE......................................................... F 1-142 WIRING DIAGRAM......................................... F 1-146 ELECTRICAL DIAGNOSIS SUPPORT........... F 1-1 48 46U0F1-001 F1 INDEX CALIFORNIA INDEX F1 INDEX 1. Fresh air duct Inspection / Replacement......... page F1-42 2. Air cleaner element Inspection.................................page F1-15 Replacement.............................page F1-42 3. Resonance chamber No.1, No.2 Inspection / Replacement......... page F1-42 4. Throttle body Inspection.................................page F1-43 Replacement.............................page F1-42 5. Idle air control valve Inspection.................................page F1-46 Replacement.............................page F1-42 6. Air valve (In BAC valve) Inspection.................................page F1-46 Replacement.............................page F1-42 7. Intake manifold Removal / Installation............... page F1-42 8. Accelerator cable Inspection / Adjustment............ page F1-44 9. Fuel filter (High-pressure side) Replacement.............................page F1-51 10. Fuel pump relay Inspection.................................page F1-55 Replacement.............................page F1-55 11. Pressure regulator Inspection.................................page F1-55 Replacement.............................page F1-56 12. Injector Inspection.................................page F1-57 Removal....................................page F1-57 Installation.................................page F1-57 13. Pressure regulator control solenoid valve Inspection.................................page F1-61 14. EGR control valve Inspection / Replacement......... page F1-65 15. EGR function sensor Inspection / Replacement......... page F1-65 16. EGR function control (Except California) Inspection.................................page F1-65 17. PCV valve Inspection.................................page F1-69 18. EGR solenoid valve (Except California) Inspection.................................page F1-65 19. EGR solenoid valve (Vacuum-California) Inspection............................. ... page 20. EGR solenoid valve (Vent-California) Inspection............................. ... page 21 . Purge control solenoid valve Inspection............................. ... page 22. Charcoal canister Inspection............................. ... page 23. Powertrain control module (Engine) Removal / Installation............ ... page Inspection............................. ... page 24. Mass airflow sensor Inspection............................. ... page Replacement......................... ... page 25. Crankshaft position sensor Inspection............................. ... page 26. Engine coolant temperature sensor Removal................................ ... page Inspection............................... ... page Installation............................. ... page 27. Intake air temperature sensor Inspection............................. ... page Replacement......................... ... page 28. Throttle position sensor Inspection............................. ... page Adjustment............................ ... page Replacement......................... ... page 29. Heated oxygen sensor Inspection............................. ... page Replacement......................... ... page 30. Idle switch Inspection............................. ... page 31. Main relay Inspection............................. ... page 32. Coolant fan relay Inspection............................. ... page 33. Clutch switch Inspection............................. ... page Replacement......................... ... page 34. Neutral switch Inspection............................. ... page Replacement......................... ... page 35. Steering pressure sensor Inspection............................. ... page page Replacement......................... 1-67 1-67 1-71 1-72 1-81 1-81 1-90 1-42 1-90 1-91 1-91 1-92 1-92 1-92 1-92 1-92 1-93 1-93 1-93 1-94 1-94 1-94 1-94 1-95 1-95 1-95 1-95 F1-95 46U0F1-002 F 1 -3 F1 INDEX ja> CALIFORNIA © c© 46U0F1 -003 1. Fuel tank Removal / Inspection / Installation...............................page 2. Fuel filter Replacement.............................page 3. Fuel pump Inspection.................................page Removal / Installation............... page 4. Fuel vapor valve Inspection.................................page F1—4 F1-50 F1-51 F1-52 F1-54 F1-71 5. Check valve (Two-way) Inspection................................ page F1-72 6. Exhaust system Removal / Inspection / Installation.............................. page F1-62 7. Three-way catalyst Removal / Inspection I Installation.............................. page F1-62 8. Warm-up three-way catalyst Removal / Inspection I Installation.............................. page F1-62 CO CHARCOAL CANISTER PRESSURE REGULATOR CONTROL SOLENOID VALVE •< w H m o > o 3) > m x o m TJ H O > *—TO PCME o c z m SYSTEM CHARCOAL CANISTER PRESSURE REGULATOR CONTROL SOLENOID VALVE DIAGRAM PRESSURE REGULATOR PURGE CONTROL SOLENOID VALVE FUEL VAPOR VALVE THROTTLE POSITION SENSOR PCV VALVE / PCME IDLE SWITCH = = * MASS AIRFLOW SENSOR INTAKE AIR TEMPERATURE SENSOR INJECTOR FUEL FILTER (LOW-PRESSURE SIDE) FUEL ru M r WARM-UP THREE-WAY CATALYST BAC VALVE ENGINE COOLANT TEMPERATURE SENSOR EGR FUNCTION SENSOR VALvI°<(VENT) vI n t !D VALVE EGR SOLENOID VALVE (VACUUM) EGR CONTROL VALVE THREE-WAY CATALYST HEATED OXYGEN SENSOR 46U0F1-005 *—TO PCME Al” CLEANER FILTER (CALIFORNIA) CRANKSHAFT POSITION SENSOR (IN DISTRIBUTOR) F1 OUTLINE VACUUM HOSE ROUTING DIAGRAM EXCEPT CALIFORNIA EGR MODULATOR VALVE SOLENOID VALVE (PURGE CONTROL) R SOLENOID VALVE (PRESSURE REGULATOR) SOLENOID VALVE (EGR) VACUUM HOSE COLOR B: BLACK G: GREEN L: BLUE O: ORANGE R: RED W: WHITE Y: YELLOW CHARCOAL CANISTER EGR CONTROL VALVE PRESSURE REGULATOR 16E0F1-006 F 1 -7 FI_________________ _________ OUTLINE WIRING DIAGRAM 46U0F1-006 F1—8 OUTLINE F1 0© F 1 -9 FI________________ OUTLINE SPECIFICATIONS Engine Item rpm Idle speed*1 BTDC Ignition timing*1 Throttle body Type mm [in) Throat diameter Fuel pump kPa (kgf/cm2, psi) Maximum output pressure Fuel filter Low-pressure side Type High-pressure side Pressure regulator kPa (kgf/cm2, psi) Regulating pressure Injector Type Type of drive 12 [20°C [ 68°F)] Resistance m (cc, fl oz)/15 sec. Volume Idle air control valve Q [23°C (73°F)] Resistance Purge control solenoid valve n [20°C {68°F) ] Resistance Pressure regulator control solenoid valve J2 [20°C (68°F)] Resistance EGR solenoid valve (Except California) n [20°C (68°F)] Resistance EGR solenoid valve (Vent and vacuum) (California) n [20°C (68°F)] Resistance Crankshaft position sensor Type Mass airflow sensor Type Engine coolant temperature sensor -2 0 °C { -4 °F ) 20°C ( 68°F) 80°C (176°F) kfl 91°C ( 196°F) Resistance 97°C (207°F) 108°C (226°F) 110°C (230°F) Fuel tank L (US gal, Imp gal) Capacity Air cleaner element Element type Fuel Specification * x TEN te rm in a l o f data lin k c o n n e c to r g ro u n d e d F 1 -1 0 FS 6 50 -7 50 (700 ± 50) 11—13° (12 ± 1°) Horizontal draft 55 (2.2) 640 (6.5, 92) Nylon element (in fuel pump) Paper element 2 60 -3 20 (2.6—3.3, 3 7 -4 6 ) High-ohmic Voltage 1 2 -1 6 4 7 -6 8 (4 7 -6 8 , 1 .4 -2 .0 ) 7.7—9.3 30—34 3 6 -4 3 3 3 -3 9 3 0 -4 5 Hall sensor Heat resistor 13.5—16.5 2.20-2.70 0.29-0.35 0.226—0.241 0.193-0.205 0.145-0.153 0.137-0.146 58.5 (15.5, 12.9) Oil permeated Unleaded—(R + M)/2 method 87 or higher 46U0F1-007 F1 OUTLINE COMPONENT DESCRIPTIONS Remark Function Component A/C relay Controls A/C compressor magnetic clutch Air cleaner housing Filters air entering throttle body • Intake air temperature sensor mounted in housing Air valve Supplies bypass air into intake manifold (engine cold) • Engine speed increased to shorten warm-up period • Thermowax type • Installed in BAC valve Bypass air control (BAC) valve Supplies bypass air into intake manifold • Consist of air valve and idle air control valve Charcoal canister Stores fuel tank fumes (engine stopped) — Check valve (two-way) Controls pressure in fuel tank Clutch switch Detects clutch condition; sends signal to PCME • Switch OFF when clutch pedal released Crankshaft position sensor [G signal, NE signal] Detects No. 1 cylinder TDC;sends signal to PCME (G signal) Detects crank angle at 180° intervals; sends signal to PCME (NE signal) • Installed in distributor Data link connector Concentrated service connector terminals for serviceability • 25-pin (located near battery) 1. 2. 3. 4. 5. 6. 7. CIS self-diagnosis Initial set Fuel pump check Engine speed output Switch and heated oxygen sensor monitor Supply battery positive voltage Ground — — 1. 2. 3. 4. 5. 6. 7. FEN terminal TEN terminal FIP terminal IG - terminal MEN terminal + B terminal GND terminal EGR control valve Recirculates portion of exhaust gas EGR function control (Except California) Controls vacuum acting on EGR control valve EGR solenoid valve Controls vacuum to EGR control valve EGR function sensor (California) Detects EGR control valve position • Installed in EGR control valve EGR function sensor (Except California) Detects EGR gas temperature to detect EGR control valve open condition; sends signal to PCME • Installed in EGR control valve Engine coolant temperature sensor Detects coolant temperature;sends signals to PCME • Installed in engine F u e l filter Filters particles from fuel Fuel pump Provides fuel to injectors Fuel pump relay Voltage for fuel pump while engine is running, controlled by PCME — — — — • Operates while engine is running • Installed in fuel tank — F1 —11 F1 OUTLINE Function Component Remark Fuel vapor valve Prevents fuel from flowing into charcoal canister Heated oxygen sensor Detects oxygen concentration;sends signal to PCME • Zirconic and platinum coating • With heater Idle air control valve Supplies bypass air to intake manifold • Controlled by duty signal from PCME • Installed in BAC valve Idle switch Detects idle condition;sends signal to PCME • Installed in throttle body Igniter Receives spark signal from PCME and gener­ ates high voltage in ignition coil • Installed in distributor Ignition switch (START position) Sends engine cranking signal to PCME Injector Injects fuel into intake port Intake manifold Supplies intake air to all cylinders Intake air temperature senser Detects intake air temperature;sends signal to PCME • Installed in air cleaner housing Idle air control valve Controls bypass air amount • Controlled by duty signal from PCME Main relay Supplies current to output devices and PCME Mass airflow sensor Detects amount of intake air;sends signal to PCME • Heat resistor type Neutral switch Detects in-gear condition;sends signal to PCME • Switch ON in neutral PCV valve Controls blowby gas introduced into engine Powertrain control module (Engine) Detects the following: 1. A/C operation 2. Air/fuel ratio (oxygen concentration) 3. Braking signal 4. Cranking signal 5. E/L operation 6. 7. 8. 9. 10. 11. 12. 13. 14. Engine coolant temperature Engine speed Ignition ON signal In-gear condition Intake air amount Intake air temperature No.1 piston TDC (compression stroke) P/S operation Diagnostic test mode signal (ignition tim­ ing, idle speed, diagnostic trouble code no.) 15. Throttle valve opening angle 16. Throttle valve fully closed 17. Vehicle speed F 1 -1 2 — — • Controlled by signals from PCME — — — 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Air conditioning sensor Heated oxygen sensor Stoplight switch Ignition switch (START position) Blower motor switch, coolant fan relay, headlight switch, and rear window defroster switch Engine coolant temperature sensor Crankshaft position sensor (NE signal) Ignition switch Neutral and clutch switch Mass airflow sensor Intake air temperature sensor Crankshaft position sensor (G signal) Steering pressure sensor Data link connector (TEN terminal) 15. Throttle position sensor 16. Idle switch 17. Vehicle speed sensor F1 OUTLINE Component Remark Function Powertrain control module (Engine) -cont’d Controls operation of following; 1. A/C (cut-off) 2. On-board diagnosis system 3. Fuel injection system 4. Idle speed control 5. Ignition system 6. Monitor function 7. Purge control system 8. Exhaust gas recirculation 9. PRCV control system 10. Coolant fan control 11. Fuel pump control Pressure regulator Adjusts fuel pressure supply to injectors — Pressure regulator control solenoid valve Controls vacuum to pressure regulator control valve — Purge solenoid valve Controls evaporative fumes from charcoal canister to intake manifold Resonance chamber Reduces intake air suction noise and increases engine torque Steering pressure sensor Detects P/S operation;sends signal to PCME Stoplight switch Detects braking;sends signal to PCME Three way catalyst Reduces HC, CO, NOx by chemical reaction Throttle body Controls intake air amount Throttle position sensor Detects throttle valve opening angle;sends signal to PCME • Installed on throttle body Vehicle speed sensor Detects vehicle speed;sends signal to PCME • Installed in instrument cluster 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. A/C relay Self-Diagnosis Checker Injector Idle air control valve Igniter Monitor lamp Purge solenoid valve EGR solenoid valve PRC solenoid valve Coolant fan relay Fuel pump relay • Controlled by duty signal from PCME — • Steering pressure sensor ON when steering wheel turned — • Monolith type — 46UOF1-008 F 1-1 3 F1 ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST 16E0F1 -011 BASIC INSPECTION Engine Oil 1. Remove the engine oil dipstick and check the engine oil level and oil-condition. 2. Add or change oil as necessary. Note • The distance between the L and F marks on the dipstick represents 1.0 L (1.1 US qt, 0.9 Imp qt). Coolant (Engine cold) Warning • Removing the radiator cap or the coolant drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth - turn it, and remove it. 1. Verify that the coolant level is near the radiator filler neck. 2. Remove the coolant level dipstick from the coolant reser­ voir and verify that the coolant level is between the F and L marks. 3. Add coolant if necessary. Battery Removing the label on the top of the battery or removing the vent caps will void the battery’s warranty. 1. Remove any corrosion on the clamps or battery posts. 2. Verify that the battery top is clean. If necessary, clean with baking soda and water. 3. Verify that cables are in good condition and not frayed or corroded. Repair or replace if necessary. 4. Verify that cable clamps are tight. Note • Because this is a maintenance free battery, it is not neces­ sary to check the fluid level. F 1 -1 4 ENGINE TUNE-UP F1 Air Cleaner Element Inspection 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution • Cleaning the element with compressed air will re­ duce the element’s ability to filter the air. Don’t use compressed air to clean the element. 2. Replace the element if necessary. 46UQF1-012 ADJUSTMENT Preparation 1. Warm up the engine to normal operating temperature. 2. Shift the selector lever to Neutral. 3. Turn off all electric loads. • Headlight • Blower • Rear window defroster • Power steering 4. Wait until the coolant fan is stopped. 46U0F1-013 Ignition Timing 1. Perform Preparation. (Refer to above.) 2. Connect a tachometer to the data link connector terminal IG - as shown. 3. Verify that the idle speed is within the specification. Idle speed: 650—750 (700 ± 50) rpm 4. If not within the specification, adjust the idle speed. (Refer to page F1 -16.) 5. 6. 7. 8. Connect the SST to the data link connector. Set switch A to position 1. Set test switch to SELF TEST. If the SST is not used, connect a jumper wire between the TEN terminal and GND terminal of the data link connector. 9. Verify that the idle speed is within the specification. Idle speed (Ground the terminal TEN): 500—800 rpm 46U0F1-015 10. Connect a timing light to the engine. 11. Verify that the timing mark (yellow) on the crankshaft pully and the mark on the timing belt cover are aligned. Ignition timing: BTDC 11—13° (12 ± 1°) 46U0F1-016 F 1-1 5 F1 ENGINE TUNE-UP 12. If the marks are not aligned, loosen the distributor lock bolts and turn the distributor to make the adjustment. 13. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 N m [1.9—2.6 kgf m, 14—18 ft-lbf} 46U0F1-017 14. Disconnect the SST. 15. Verify that the ignition timing is within the specification. Ignition timing: BTDC 6—18° 46U0F1-018 Idle Speed 1. Perform Preparation. (Refer to page F1-15.) 2. Connect a tachometer to the data link connector terminal IG - as shown. 3. Verify that the idle speed is within the specification. Idle speed (Neutral): 650—750 (700 ± 50) rpm 46U0F1-019 4. If not within specification, connect the SST to the data link connector. 5. Set switch A to position 1. 6. Set test switch to SELF TEST. 7. If the SST is not used, connect a jumper wire between the TEN terminal and the GND terminal of the data link con­ nector. 46U0F1-020 8. Adjust the idle speed by turning the air adjusting screw. Idle speed (Groud the terminal TEN): 650—750 (700 ± 50) rpm 9. Disconnect the SST. 46U0F1-021 F 1 -1 6 ON-BOARD DIAGNOSIS SYSTEM F1 ON-BOARD DIAGNOSIS SYSTEM DESCRIPTION When trouble occurs in the main input or output devices, check for the cause by using the SST. Malfunc­ tions of each input and output device are indicated and retrieved from the PCME as diagnostic trouble code numbers. For input devices, the PCME continuously checks for malfunctions. For output devices, it checks for mal­ functions only in a three-second period after the ignition switch is turned to ON, or the TEN terminal of the data link connector is grounded. 46U0F1-022 F 1 -1 7 F 1 ON-BOARD DIAGNOSIS SYSTEM PREPARATION SST DIAGNOSTIC TROUBLE CODE NUMBER Inspection Procedure 1. Connect the SST (System Selector) to the data link con­ nector. 2. Set switch A to position 1. 3. Set the test switch to SELF TEST. 4. Connect the SST (Self-Diagnosis Checker) to the System Selector and a ground. 5. Set the select switch to position A. 6. Turn the ignition switch ON. 7. Verify that 88 flashes on the digital display and the buzzer sounds for 3 seconds after turning the ignition switch ON. 8. If 88 does not flash, check the main relay (refer to page F1-94), power supply circuit, and data link connector wiring. 9. If 88 flashes and the buzzer sounds continuously for more than 20 seconds, check for a short circuit between the PCME terminal 1F and the data link connector. Replace the PCME if necessary and perform Steps 3 through 7 again. 10. Note any code numbers and check for the causes by refer­ ring to the check sequences shown on pages F 1-22 through F1-37, Repair as necessary. 11. After repairs, cancel the code numbers by performing the “ After-repair procedure” (Refer to page F1-38.) 8B 46U0F1-025 ON-BOARD DIAGNOSIS SYSTEM F 1 Principle of Code Cycle Diagnostic trouble codes are determined as shown below. 1. Code cycle break The time between diagnostic trouble code cycles is 4.0 seconds. DIAGNOSTIC TROUBLE CODE 1 C YCLE CYCLE BREAK ON OFF 4.0 SEC. 36U0F1-018 2. Second digit of diagnostic trouble code (ones position) The digit in the ones position of the diagnostic trouble code represents the number of times the checker buzzer sounds 0.4 second during one cycle. DIAGNOSTIC TROUBLE CODE 1 CYCLE ON 1 2 3 DIAGNOSTIC TROUBLE CODE: 03 CYCLE BREAK OFF 0.4 SEC. 0.4 SEC. 4.0 SEC. 36U0F1-019 3. First digit of diagnostic trouble code (tens position) The digit in the tens position of the diagnostic trouble code represents the number of times the checker buzzer sounds 1.2 seconds during one cycle. The buzzer remains off for 1.6 seconds between the long and short pulses. 1 CYCLE 1 2 nr 1 2 C YCLE BREAK | i 0.4 •1.2 S EC . SEC 1.6 h ---------------- S FC F IR S T D IG IT 4.0 S EC . n DIAGNOSTIC TROUBLE CODE. 22 SECOND D IG IT 36U0F1-020 F1—19 FI___________________ SELF-DIAGNOSIS FUNCTION Diagnostic Trouble Code Number No. Indicator flashing pattern 02 03 Diagnosted circuit Condition Memorized Page Yes F1-22 Yes F1-23 Measures intake air amount by throttle valve opening angle Yes F1-24 Maintains con­ stant 34°C (93°F) command Yes F1-25 Intake air tempera­ ture sensor Maintains con­ stant 20°C (68°F) command Yes F1-26 Throttle position sensor Maintains con­ stant command of throttle valve fully open Yes F1-27 Yes F1-28 Yes F1-29 Yes F1-30 No F1-31 No F1-32 No F1-33 F1-34 Ne signal (Crankshaft position sensor) No Ne signal while de­ tecting 12 G signals G signal (Crankshaft position sensor) No G signal for 1.5 sec. Mass airflow sensor 08 09 Engine coolant tem­ perature sensor Fail-safe Cancels sequen­ tial injection Open or short circuit 11 12 15 Heated oxygen sensor (Inactivation) Sensor output con­ tinues less than 0.55V 75 sec. after engine ex­ ceeds 1,500 rpm EGR function sensor Open or short circuit EGR valve stuck 16 17 25 26 Heated oxygen sensor (Inversion) Sensor output con­ tinues unchanged 40 sec. after engine ex­ ceeds 1,500 rpm Pressure regulator control solenoid valve Purge control sole­ noid valve Cancels engine closed loop operation Cancels engine closed loop operation Open or short circuit 28 • EGR solenoid valve (Except California) • EGR solenoid valve (vacuum) (California) F1—20 F1 ON-BOARD DIAGNOSIS SYSTEM No. 29 Indicator flashing pattern Diagnosted circuit Condition EGR solenoid valve (vent) (California) Fail-safe Memorized Page No F1-35 No F1-36 No F1-37 Idle air control valve Open or short circuit 34 Coolant fan relay 67 46U0F1-026 F1 ON-BOARD DIAGNOSIS SYSTEM Troubleshooting If a diagnostic trouble code number is shown on the SST, check for the cause by using the chart related to the code number shown. 02 (DISTRIBUTOR NE-SIGNAL) CODE No. 1 2 3 4 5 6 Are there any poor connections in distributor circuit? Is Code No. 03 also present? Does wire between distributor terminal 2A and ground have continuity? Does battery positive voltage exist at distributor terminal 2B with ignition switch ON? Does wire between distributor terminal 2C and PCME terminal 2E have continuity? Is PCME terminal 2E voltage OK? c r 7 8 ACTION INSPECTION STEP Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Go to Step 5 Yes Go to next step No Repair or replace Yes Go to next step No Check for open circuit in wiring (Distributor—Main relay) Yes Go to next step No Repair or replace Yes Replace PCME No Go to next step Yes Replace distributor No Go to next step Yes Check for short circuit in wiring (Distributor—PCME) No Replace PCME c r page F1-81 page F1-81 Does approx. 0V or approx. 5V exist at distribu­ tor terminal 2C? Does approx. 5V exist at PCME terminal 2E? (with distributor connector disconnected) c r page F1-81 c r page F1-81 46U0F1-Q27 Circuit Diagram F1—22 16E0F1-034 ON-BOARD DIAGNOSIS SYSTEM 03 (DISTRIBUTOR G SIGNAL) CODE No. INSPECTION STEP 1 2 3 4 5 6 7 8 F1 Are there any poor connections in distributor circuit? Is Code No. 02 also present? Does wire between distributor terminal 2A and ground have continuity? Does battery positive voltage exist at distributor terminal 2B with ignition switch ON? Does wire between distributor terminal 2D and PCME terminal 2G have continuity? Is PCME terminal 2G voltage OK? c r page F1-81 Does approx. 0V or approx. 5V exist at distribu­ tor terminal 2D? Does approx. 5V exist at PCME terminal 2G? (with distributor connector disconnected) c r page F1-81 ACTION Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Go to Step 5 Yes Go to next step No Repair or replace Yes Go to next step No Check for open circuit in wiring (Distributor—main relay) Yes Go to next step No Repair or replace Yes Replace PCME No Go to next step Yes Replace distributor No Go to next step Yes Check for short circuit in wiring (Distributor—PCME) No Replace PCME c r page F1-81 c r page F1-81 46U0F1-028 Circuit Diagram DISTRIBUTOR 1C 1B 1A 2F 2E 2D 2C 2B 2A 16E0F1-036 F1—23 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 08 (MASS AIRFLOW SENSOR) 1 2 3 4 ACTION INSPECTION STEP Are there any poor connections in mass airflow sensor circuit? Is voltage of mass airflow sensor OK? c r page F1-90 Does wire harness between mass airflow sensor and PCME have continuity? Mass airflow sensor PCME B 20 C 2C Are PCME 1B, 2C, and 2 0 terminals voltages OK? c r page F1-81 Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Replace mass airflow sensor Yes Go to next step No Repair wire harness Yes Replace PCME No Check for short circuit in wiring (Mass airflow sensor—PCME) c r page F1-81 46U0F1-029 Circuit Diagram MASS AIRFLOW SENSOR F 1-2 4 16E0F1-040 ON-BOARD DIAGNOSIS SYSTEM CODE No. 09 (ENGINE COOLANT TEMPERATURE SENSOR) STEP 1 2 3 4 5 F1 INSPECTION Are there any poor connections in engine cool­ ant temperature sensor circuit? Does wire harness between engine coolant tem­ perature sensor and PCME have continuity? Engine coolant temperature sensor PCME A 2Q B 2D Is resistance of engine coolant temperature sen­ sor OK? Coolant temp. Resistance (k0) 20°C ( 68°F) 2.2—2.7 80°C ( 176°F) 0.29-0.35 ACTION Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Repair wiring Yes Go to next step No R e p la ce e n g in e c o o la n t te m p e ra tu re sensor Is same Code No. present following after-repair procedure? c r page F1-38 Yes Go to next step No Engine coolant temperature sensor and circuit OK Are PCME terminals 2D and 2Q voltages OK? c r page F1-81 Yes Replace PCME No Check for short circuit in wiring (Engine coolant temperature sensor—PCME) c r page F1-81 46UOF1-030 Circuit Diagram IGNITION SWITCH ENGINE COOLANT € B TEMPERATURE SENSOR A 16E0F1-042 F1—25 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 11 (INTAKE AIR TEMPERATURE SENSOR) STEP 1 2 INSPECTION Are there any poor connections in intake air tem­ perature sensor circuit? Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Repair wiring Yes Go to next step No Replace intake air temperature sensor Is same Code No. present following after-repair procedure? c r page F1-38 Yes Go to next step No Intake air temperature sensor and cir­ cuit OK Are PCME terminals 2D and 2L voltages OK? c r page F1-81 Yes Replace PCME No Check for short circuit in wiring (Intake air temperature sensor—PCME) Does wire harness between intake air tempera­ ture sensor and PCME have continuity? Intake air thermosensor 3 4 5 ACTION PCME A 2L B 2D Is resistance of intake air temperature sensor be­ tween terminals A and B OK? Temperature Resistance (kfi) 25°C (77°F) 29.7-36.3 85°C ( 185°F) 3.3—3.7 c r page F1-81 46U0F1-031 Circuit Diagram 16E0F1-Q44 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 12 (THROTTLE POSITION SENSOR) STEP 1 2 INSPECTION Are there any poor connections in throttle posi­ tion sensor circuit? Does wire harness between throttle position sen­ sor and PCME have continuity? Throttle position sensor 3 4 ACTION Yes Repair connector and/or wiring No Go to next step Yes Go to next step No Repair wiring Yes Go to next step No Replace throttle body c r page F1-42 Yes Replace PCME c r page F1-81 No Check for short circuit in wiring (Throttle position sensor—PCME) PCME A 2K B 2M C 2D Are resistance between terminals B and C OK? Throttle valve Resistance Closed throttle position Below 1 kO Wide open throttle Approx. 5 kfi Is PCME terminal 2M voltage OK? c r page F1-81 46U0F1-032 Circuit Diagram F 1 -2 7 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 15 (HEATED OXYGEN SENSOR-INACTIVATION) Note • If Code Nos. 15 and 17 are both present, first perform the checking procedure for Code No. 17. INSPECTION STEP 1 2 A re th e re a n y p o o r c o n n e c tio n s in h e a te d o xya e n s e n s o r c irc u it? Is h e a te d o x y g e n s e n s o r h e a te r O K ? ACTION Y es R e p a ir c o n n e c to r a n d /o r w irin g No G o to n e xt step Y es G o to n e xt ste p No R e p a ir o r re p la c e re la te d pa rts Y es G o to n e xt ste p No R e p la ce h e a te d o x y g e n s e n so r Y es G o to n e xt ste p No R e p a ir o r re p la ce Y es G o to n e xt ste p No C h e c k fo r sh o rt c irc u it in w irin g (H e a te d o x y g e n s e n s o r— PC M E) Y es No C7 oaae F1-93 3 Is h e a te d o x y g e n s e n s o r o u tp u t v o lta g e O K ? c r naae F1—93 4 D o e s w ire h a rn e s s b e tw e e n h e a te d o x y g e n se n ­ cr page F I-9 3 R e p la ce P C M E cr page F1-81 T ry a k n o w n g o o d h e a te d o x y g e n se n ­ s o r a n d c h e c k if c o n d itio n im p ro ve s, cr page F1-93 sor anti P O M P term inal ? N have eontinuitv? 5 Is P C M E te rm in a l 2 N v o lta g e O K ? c r naae F1—81 6 Is s e n s itiv ity o f h e a te d o x y g e n s e n so r O K ? i~7 naae F1—93 46UQF1-034 Circuit Diagram IGNITION SWITCH HEATED OXYGEN SENSOR __i. C A B ---- - T 16E0F1-049 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 16 (EGR FUNCTION SENSOR) STEP 1 2 INSPECTION ACTION Does EGR function sensor circuit have a poor connection? Is EGR function sensor terminal C voltage OK with EGR function sensor connector disconneciea < Condition Voltage Ign switch ON Approx. 5.0V Yes Repair connector and/or wiring harness No Go to next step (California) Go to Step 3 (Except California) Yes Go to next step No Check for short or open circuit in wiring harness (EGR function sensor terminal C—PCME terminal 21) => If OK, replace PCME => If not OK, repair wiring harness 3 Is there continuity between EGR function sensor and PMCE? Yes California EGR function sensor PCME A 2J B Ground Check for short circuit in wiring harness (EGR function sensor terminal A— PCME terminal 2J) ■=> If OK, go to next step =!> If not OK, repair wiring harness No Repair wiring harness Yes Check for short circuit in wiring (EGR function sensor—PCME) No Replace EGR function sensor Except California 4 EGR function sensor PCME A 2J B 2D Is resistance of EGR function sensor 46U0F1-035 (EXCEPT CALIFORNIA) CALIFORNIA SENSOR EGR FUNCTION EGR FUNCTION SENSOR SENSOR F1—29 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. STEP 1 2 3 17 (HEATED OXYGEN SENSOR-INVERSION) INSPECTION Yes Go to next step No Check heated oxygen sensor circuit for poor connection => If OK, perform troubleshooting Code No. 15 c r page F1—28 ==> If not OK, repair or replace con­ nector Does monitor lamp of Self-Diagnosis Checker il­ luminate at idle after engine has been warmed up and run at 2,500—3,000 rpm for 3 min? Yes Go to next step Note • A/F mixture rich No Go to Step 5 Note • A/F mixture is lean or misfire occurring Yes Go to next step No High pressure Check if fuel return hose is clogged or restricted ■=> If OK, replace pressure regulator => If not OK, repair or replace hose Is fuel line pressure correct at idle? c r page F1-55 Fuel line pressure: 255—314 kPa {2.6—3.2 kgf/cm2, 37—46 psi) (vacuum hose to pressure regulator dis­ connected) 4 5 6 Is there fuel leakage from injectors? c r page F1-58 Disconnect each high-tension lead at idle; does engine speed decrease equally at each cylinder? Is fuel line pressure correct at idle? c r page F1-55 Fuel line pressure: 255—314 kPa {2.6—3.2 kgf/cm2, 37—46 psi) (vacuum hose to pressure regulator dis­ connected) 7 8 9 ACTION Is same Code No. present following after-repair procedure? c r page F1-38 Is there leakage of intake air system com­ ponents? Is there misfire of dead cylinder from Step 5 in­ spection? Is there injector operating sound at idle of dead cylinder from Step 5 inspection? Yes Replace injector No Check if engine coolant temperature sensor is OK "=> If OK, try a known good PCME => If not OK, replace engine coolant temperature sensor c r page F1-56 c r page F1-57 c r page F1-81 c r page F1-91 Yes Go to next step No Go to Step 8 Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose <=> If it quickly increases, check pres­ sure regulator c r page F1-55 => If it gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F1-53 Yes Try a known good PCME, and check if condition improves c r page F1-81 No Replace Yes Repair or replace ignition system com­ ponents) c r Section G No Go to next step Yes Try a known good injector and check if condition improves c r page F1-57 No Check for battery positive voltage at in­ jector connector terminal A ■=> If there is, replace injector c r page F1-57 => If there is not, check circuit in for short or open 46U0F1-037 F1—30 F1 ON-BOARD DIAGNOSIS SYSTEM 25 (PRESSURE REGULATOR CONTROL SOLENOID VALVE) CODE No. ACTION INSPECTION STEP Does solenoid valve circuit have a poor con­ nection? Is connector terminal A voltages OK with sole­ noid valve connector disconnected? Condition Ign switch ON Voltage Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (Solenoid valve terminal A—Main relay terminal F) Yes Check for short circuit in wiring from solenoid valve terminal B to PCME ter­ minal 2T Battery positive voltage Is there continuity between solenoid valve termi­ nal B and PCME terminal 2T? ■=J> If OK, go to next step ■=> If not OK, repair wiring harness Is solenoid valve OK? cr No Repair wiring harness Yes Replace PCME No Replace solenoid valve a - page F1-81 page F1-61 46U0F1-038 Circuit Diagram IGNITION SWITCH BATTERY PRESSURE REGULATOR CONTROL SOLENOID VALVE MAIN RELAY PRESSURE REGULATOR CONTROL SOLENOID VALVE MAIN RELAY E X A ■ rtn 16E0F2-C163 F1-31 F1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 26 (PURGE CONTROL SOLENOID VALVE) STEP INSPECTION Does solenoid valve circuit have a poor con­ nection? Is connector terminal A voltages OK with sole­ noid valve connector disconnected? Condition Voltage Ign switch ON ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit wiring har­ ness (Solenoid valve terminal A—Main re­ lay terminal F) Yes Check for short circuit in wiring from solenoid valve B to PCME terminal 2X Battery positive voltage Is there continuity between solenoid valve termi­ nal B and PCME terminal 2X? <=> If OK, go to next step ■=> If not OK, repair wiring harness Is solenoid valve OK? No Repair wiring harness Yes Replace PCME No Replace EGR solenoid valve cr page F1-81 o- page F1-71 46U0F1-039 Circuit Diagram IGNITION SWITCH BATTERY E{a===gi B PURGE CONTROL SOLENOID VALVE H MAIN RELAY PURGE CONTROL SOLENOID VALVE 16E0F2-063 F 1-3 2 F1 ON-BOARD DIAGNOSIS SYSTEM 28 (EGR SOLENOID VALVE-EXCEPT CALIFORNIA) CODE No. ACTION INSPECTION STEP Does solenoid valve circuit have a poor con­ nection? Is connector terminal A voltages OK with sole­ noid valve connector disconnected? Condition Ign switch ON Voltage Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit wiring har­ ness (Solenoid valve terminal A—Main re­ lay terminal F) Yes Check for short circuit in wiring from solenoid valve teminal B to PCME ter­ minal 2S Battery positive voltage Is there continuity between solenoid valve termi­ nal B and PCME terminal 2S? ■=> If O K, g o to n e xt ste p ■=> If not OK, repair wiring harness Is solenoid valve OK? a - No Repair wiring harness Yes Replace PCME No Replace solenoid valve cr page F1-81 page F1-65 46U0F1-040 Circuit Diagram F 1-33 F 1 ON-BOARD DIAGNOSIS SYSTEM CODE No. 28 (EGR SOLENOID VALVE-VACUUM) (CALIFORNIA) STEP 1 2 INSPECTION Does EGR solenoid valve circuit have a poor connection? Is connector terminal A voltages OK with sole­ noid valve connector disconnected? Condition Ign switch ON 3 Voltage ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring Battery positive voltage Is there continuity between solenoid valve termi­ nal B and PCME terminal 2S? relay terminal F) Yes Check for short circuit in wiring from solenoid valve terminal B to PCME ter­ minal 2S => If OK, go to next step ■=> If not OK, repair wiring harness 4 Is EGR solenoid valve (vacuum) OK? c r page F1-67 No Repair wiring harness Yes Replace PCME No Replace solenoid valve c r page F1-81 46U0F1-041 Circuit Diagram IGNITION SWITCH BATTERY MAIN RELAY EGR SOLENOID VALVE (VACUUM) EGR SOLENOID VALVE (VACUUM) ____ Q. B -c r 16E0F2-063 F 1 -3 4 ON-BOARD DIAGNOSIS SYSTEM CODE No. 29 (EGR SOLENOID VALVE-VENT) (CALIFORNIA) 2 Does EGR solenoid valve (vent) circuit have a poor connection? s connector terminal A /oltage OK with solenoid valve connector disconn ected? Condition Ign switch ON 3 ACTION INSPECTION STEP 1 F 1 Voltage Battery positive voltage Is there continuity between solenoid valve terminal B and PCME terminal 2R? Yes Repair connector and/or wiring harness No Go to next stop Yes Go to next step No Check for open or short circuit in wiring harness (Solenoid valve terminal A—Main relay terminal F) Yes Check for short circuit in wiring harness (Solenoid valve terminal B—PCME terminal 2R) => If OK, go to next step ■=> If not OK, repair wiring harness 4 Is EGR solenoid valve (vent) OK? cr page F1-67 No Repair wiring harness Yes Replace PCME No Replace EGR solenoid valve (vent) cr page F1-81 46U0F1-042 Circuit Diagram IGNITION SWITCH BATTERY MAIN RELAY EGR SOLENOID VALVE (VENT) MAIN RELAY E > < A 16E0F2-065 F1 ON-BOARD DIAGNOSIS SYSTEM 34 (IDLE AIR CONTROL VALVE) CODE No. INSPECTION STEP Does the idle air control valve circuit have a poor connection? Is connector terminal A voltages OK with control valve connector disconnected? Condition Ign switch ON Voltage ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (Control valve terminal A—Main relay terminal F) Yes Check for short circuit in wiring from solenoid valve terminal B to PCME ter­ minal 2W Battery positive voltage Is there continuity between control valve terminal B and PCME terminal 2W? => If O K , g o to n e xt ste p => If not OK, repair wiring harness Is control valve OK? c=r No Repair wiring harness Yes Replace PCME No Replace control valve cr page F1-81 page F1-46 46U0F1-043 Circuit Diagram ON-BOARD DIAGNOSIS SYSTEM 67 (COOLANT FAN RELAY) CODE No. 1 ACTION INSPECTION STEP F 1 Yes Disconnect connector from PCME; is there bat­ tery positive voltage at PCME terminal 1S wire with ignition switch ON? Check PCME terminal connector for poor connection ■=> If OK, replace PCME ■=> If not OK, repair or replace con­ nector 2 3 4 No Go to next step Is same condition as Step 1, is there battery positive voltage at coolant fan relay terminal wire BV Yes Repair wire No Go to next step In same condition as Step 1, is there battery positive voltage at coolant fan relay terminal wire A? Yes Go to next step No Look for short circuit in wiring (main relay—coolant fan relay) Is there continuity at coolant fan relay connector B and A? Yes Look for short circuit in wiring (coolant fan relay—PCME) No Replace coolant fan relay c r page F1-81 46UOF1-044 Circuit Diagram IGNITION SWITQH BATTERY COOLANT FAN RELAY 9 -1 PCME TERMINAL 1S COOLANT F A N ( m ) MOTOR V / COOLANT FAN RELAY ------- L_ c A D B 16E0F1-061 F 1 -3 7 F1 ON-BOARD DIAGNOSIS SYSTEM After-repair procedure Cancel the memory of malfunctions by disconnecting the negative battery cable and depressing the brake pedal for at least 20 sec. Reconnect the negative battery cable. Self-Diagnosis checker 1. Connect the SST (System Selector) to the data link con­ nector. 2. Set the switch A to position 1. 3. Set the test switch to SELF TEST. 4. Connect the SST (Self-Diagnosis Checker) to the System Selector and a ground. 5. Set the select switch of the Self-Diagnosis Checker to posi­ tion A. 6. Turn the ignition switch ON. 7. Start and warm up the engine; then run it at 2,000 rpm for 3 min. 8. Verify that no diagnostic trouble code numbers are dis­ played. 36U0F1-041 SWITCH MONITOR FUNCTION Individual switches can be inspected by the SST (Self-Diagnosis Checker). Preparation The TEN terminal of the data link connector must be grounded and the ignition switch turned to ON (en­ gine off). If either switch remains activated, the monitor lamp will be illuminated. 46U0F1-045 F1 ON-BOARD DIAGNOSIS SYSTEM Self-Diagnosis Checker (Monitor lamp) Light ON Light OFF Pedal released Pedal depressed In gear Neutral Pedal depressed Pedal released ON OFF Pedal depressed Pedal released Switch Clutch switch Neutral switch Idle switch Air conditioning sensor Stoplight switch Headlight switch Blower switch Rear window defroster switch Coolant fan relay ON OFF 3rd or 4th position ON OFF, 1st, or 2nd position OFF Fan operating Fan not operating Remarks In gear Clutch pedal released — Blower switch 1st — Parking brake applied (Canada) — — TEN terminal grounded and Idle switch OFF 46U0F1-046 HEATED OXYGEN SENSOR MONITOR FUNCTION With the System Selector test switch set to 02 Monitor, the heated oxygen sensor is monitored as described. Engine Running Condition System Selector Switch O2 monitor Item monitored Heated oxygen sensor output signal Function Heated oxygen sensor out­ put more than 0.45V moni­ tor lamp ON Heated oxygen sensor at put less than 0.45V monitor lamp OFF 46U0F1-199 Inspection Procedure 1. Perform preparation (Refer to page F1-38.) 2. Connect the SST (System Selector) to the data link con­ nector. 3. Set switch A to position 1. 4. Set test switch to SELF TEST. 5. Connect the SST (Self-Diagnosis Checker) to the System Selector and a ground. 6. Set the select switch of the Self-Diagnosis Checker to posi­ tion A. 7. Turn the ignition switch ON. 8. Check if Monitor Lamp illuminates when each switch is made to function as described below. 46U0F1-048 F 1-3 9 F1 ON-BOARD DIAGNOSIS SYSTEM Procedure 46U0F1-049 Neutral and Clutch switches 46U0F1-050 Idle switch 46U0F1-051 Air conditioning sensor (ACS) 46U0F1-052 ON-BOARD DIAGNOSIS SYSTEM F1 Stoplight switch 46U0F1-053 Headlight switch 46U0F1 -054 Blower switch 46U0F1-055 Rear window defroster switch 46U0F1-056 Coolant fan relay 46U0F1-Q57 F1-41 F1 INTAKE AIR SYSTEM INTAKE AIR SYSTEM COMPONENT PARTS Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Inspect the intake air system components and repair or replace them as necessary. 3. Install in the reverse order of removal, referring to Installation Note. 2.S—3.5 Nm (25—36 kgf-cm, 22—31 Inlbf] N-m (kgf-m, ft-lbf) 46U0F1-Q58 1. Fresh air duct Inspect for damage 2. Resonance chamber No.1 Inspect for damage 3. Air cleaner housing Inspect for excessive dirt and damage 4. Air cleaner element Inspection............................... page F I—15 5. Mass airflow sensor Inspection............................... page F1-90 6. Air hose Inspect for damage F 1 -4 2 7. Resonance chamber No.2 Inspect for damage Installation note................... page F1-43 8. Accelerator cable Inspection / Adjustment ... page F1-44 9. Throttle body Inspection........................... page F1-43 10. BAC valve Inspection........................... .... page F1-46 11. Intake manifold bracket 12. Intake manifold Installation note................... .... page F1-43 F1 INTAKE AIR SYSTEM THROTTLE BODY Inspection 1. Check the throttle body for wear, deposits, and coolant leakage. 2. Verify that the throttle valve moves smoothly when the throttle lever is moved from fully closed to fully open. 3. Replace the throttle body if necessary. Caution • Do not remove the thin seal coating from the throt­ tle valve or bore. It is necessary for proper operation. INTAKE MANIFOLD Installation Note 1. Tighten the bolts in the order shown in the figure. Tightening torque: 1 9 -2 5 Nm { 1 .9 -2 .6 kgf m, 1 4 -1 9 ftlbf) 2. Refill the radiator with the specified engine coolant. (Refer to page F1-14.) 3. Check for engine coolant leakage. 46U0F1-060 RESONANCE CHAMBER No.2 Installation Note 1. Slide the hose clamp onto the hose and push it onto reso­ nance chamber No.2. 16E0F1-360 2. Rotate the hose and hook it securely onto the locating knob. 3. Tighten the hose clamp. 16E0F1-362 F 1-43 F1 INTAKE AIR SYSTEM ACCELERATOR PEDAL Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 1. Accelerator cable Inspection / Adjustment...................... below 2. Cruise actuator cable Adjustment.. 1994 626/MX-6 body electrical troubleshooting manual Section Q 3. 4. 5. 6. 7. Retainer Clip Accelerator pedal Return spring Bracket ACCELERATOR CABLE Inspection / Adjustment 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.0mm {0.06—0.16 in) 3. If not as specified, adjust the cable free play by turning stop­ per B while pressing lock button A with the throttle valve fully closed. 4. Reset the cable lock. F 1 -4 4 IDLE-SPEED CONTROL SYSTEM F1 IDLE-SPEED CONTROL SYSTEM DESCRIPTION 36U0F1-246 The idle-speed control system controls the bypass air amount that passes through the throttle body to improve startability, warm-up, idle smoothness, and drivability. This system replaces the dashpot to control deceleration. F1 IDLE-SPEED CONTROL SYSTEM PREPARATION SST 49 B019 9A0 System Selector // For inspection of idle air control valve and air valve 36U0F1-247 SYSTEM OPERATION Air Valve 1. Verify that the engine coolant temperature is below 20°C {68°Fj 2. Connect the SST to the data link connector. 3. Set switch A to position 1 and the test switch to SELF TEST. 4. Start the engine. 5. Verify that the idle speed decreases gradually as the en­ gine warms up. 46U0F1-063 Idle Air Control Valve 1. Connect the SST to the data link connector. 2. Set switch A to position 1 and the test switch to SELF TEST. 3. Verify that the idle speed is within specification. (Refer to page F1-15.) 4. Disconnect the idle air control valve connector with the test switch SELF TEST. 5. If the engine speed decreases, replace the BAC valve. 6. Perform the after-repair procedure. (Refer to page F1-38.) 46U0F1-064 IDLE AIR CONTROL VALVE Inspection 1. Disconnect the idle air control valve connector. 2. Measure resistance of the valve. Resistance: 7.7—9.3 (at 23°C {73°Fj) 3. If not as specified, replace the BAC valve. 36U0F1-248 AIR VALVE Inspection 1. Remove the BAC valve. (Refer to page F1-42.) 2. Cool the BAC valve to below 0°C {32°F}. 3. Heat the BAC valve at point A by using a blow drier, and verify that part B moves in the direction of the arrow in the figure. 4. If not as specified, replace the BAC valve. 46U0F1-065 F 1-4 6 F1 FUEL SYSTEM FUEL SYSTEM DESCRIPTION PRESSURE REGULATOR INJECTOR ^ ► T O FUEL TANK FROM FUEL PUMP FUEL FILTER (HIGH-PRESSURE SIDE) FHFl PUMP FUEL FILTER VALVE (TWO-WAY) FUEL TANK 36U0F1-249 This system supplies the fuel to the fuel injectors at a constant pressure. Fuel is metered and injected into the intake manifold according to injection control signals from the PCME. The system consists of the fuel tank, fuel pump, fuel filters, pressure regulator, pressure regulator control solenoid valve, fuel injec­ tors, and fuel pump relay. F 1-4 7 F1 FUEL SYSTEM FUEL PUMP (GREEN) Fuel Pressure and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the en­ gine is not running. 46U0F1-066 Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the following “ Fuel Line Safe­ ty Procedures” . Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition swicth to OFF. 4. Install the fuel pump relay. B. Avoid leakage 1. When disconnecting a.fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. Use a fuel pressure gauge correctly; install hose clamps to secure the fuel pressure gauge to the fuel filter and the main hose to prevent leakage. Priming Fuel System After the fuel pressure has been released for repairs or inspec­ tion, the system must be primed to avoid excessive cranking when the engine is first started. Follow the steps below. 1. Connect the data link connector terminals F/P and GND with a jumper wire. 2. Turn the ignition switch ON for approx. 10 sec. and check for fuel leaks. 3. Turn the ignition switch OFF and remove the jumper wire. 36U0F1-065 FUEL PUMP (GREEN) SYSTEM OPERATION Fuel Pressure Hold Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” above. 46U0F1-068 F 1 -4 8 F1 FUEL SYSTEM 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel filter and the main fuel hose. (Install clamps as shown.) 3. Connect the negative battery terminal. INSTALL CLANMPS 46U0F1-069 nws GND F/P DATA LINK \CONNECTOR 4. Connect the data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min. Fuel pressure: More than 150 kPa {1.5 kgf/cm2, 21 psi) 8. If not as specified, perform the following inspections. • Fuel pump hold pressure. (Refer to page F1-52.) • Pressure regulator hold pressure. (Refer to page F1-56.) • Injector fuel leakage. (Refer to page F1-58.) 46U0F1-070 FUEL PUMP RELAY (GREEN) Fuel Line Pressure Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F1-48. 46U0F1-071 1. Disconnect the negative battery cable. 2. Install a fuel pressure gauge between the fuel filter and the main fuel hose. (Install clamps as shown.) 3. Connect the negative battery cable. INSTALL CLANMPS 46U0F1-072 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON. 6. Measure the fuel line pressure. Fuel line pressure: 260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi) 7. If • • • • 46U0F1-073 not as specified, perform the following inspections. Fuel pump maximum pressure. (Refer to page F1-53.) Fuel line clogging and restriction. Fuel filter clogging and restriction. Pressure regulator hold pressure. (Refer to page F1-56.) F 1-4 9 F1 FUEL SYSTEM FUEL TANK Removal / Inspection / Installation Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F1-48. Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repair­ ing it. 1. 2. 3. 4. Drain the fuel from the fuel tank. Remove in the order shown in the figure, referring to Removal Note. Inspect all parts and repair or replace as necessary. Install in the reverse order of removal, referring to Installation Note. Nm I kgfm, ft-lbf] 46U0F1-074 1. Connector 2. Fuel hoses Installation Note........................page F1-51 3. Evaporative hoses Installation Note........................page F1-51 F 1 -5 0 4. Fuel tank straps 5. Fuel tank Inspect for cracks and corrosion Removal Note.......................... page F1-51 FUEL SYSTEM F1 Removal Note 1. Remove the filler cap and insert a hose into the fuel tank through the filler pipe. 2. Start the pump and suck up the fuel into a container. Note • For easier work, prepare a hose of following size. Outer diameter: 13mm [0.51 in) Length: 2160mm [85.0 in) Installation Note 1. Push the ends of the main fuel hose, fuel return hose, and evaporative hoses onto the fuel tank fittings at least 25mm [1.0 in). 2. Push the fuel filler hoses onto the fuel tank pipes and filler pipes at least 35mm [1.4 in). 16E0F1-105 FUEL FILTER Replacement Low-pressure side (in-tank filter) (Refer to page F1-54.) 46U0F1-075 High-pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule. 1. Disconnect and plug the fuel hoses from the fuel filter. 2. Remove the fuel filter and bracket. 3. Install in the reverse order of removal. Tightening torque: 7.9—10.7 N m [80—110 kgf cm, 70—95.4 in-lbf} 4. Verify that the fuel hoses are pushed fully onto the fuel filter nipples. 5. Secure the fuel hoses with clips. 6. Start the engine and verify that the fuel line joints do not leak. F1—51 F1 FUEL SYSTEM FUEL PUMP Inspection Fuel pump operation 1. Connect the data link connector terminals F/P and GND with a jumper wire. 2. Remove the fuel filler cap. 3. Turn the ignition switch ON. 4. Listen at the filler inlet for the operational sound of the fuel pump. 5. Install the fuel filler cap. 6. If no sound was heard, measure the voltage between the fuel pump connector of wiring harness side terminal A to a ground. Voltage: Approx. 12V 7. If not correct, check the fuel pump relay and related wiring harness. (Refer to page F1-55.) 8. If the voltage is normal, check for continuity between fuel pump connector of fuel pump side terminal A and D. 9. If there is continuity, replace the fuel pump. 10. If there is none, repair the ground circuit. FUEL PUMP (GREEN) Hold pressure Perform this inspection if the fuel pressure hold inspection is not as specified. (Refer to page F1-48.) Warning • Fuel line spills and leaks can be dangerous. Fuel can ignite and cause serious injuries or death and dam­ age the vehicle. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F1-48. 46U0F1-078 16E0F1-111 \ DATA LINK 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Connect data link connector terminals F/P and GND with a jum per wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min.. Fuel pressure: More than 340 kPa {3.5 kgf/cm2, 50 psi) 8. If not as specified, replace the fuel pump. 36U0F1-070 F 1 -5 2 FUEL SYSTEM FUEL PUMP (GREEN) F1 Fuel pump maximum pressure Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F1-48. 46U0F1-079 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clamps as shown.) 3. Connect the negative battery terminal. 16E0F1-114 4. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON to operate the fuel pump. 6. Measure the pump maximum pressure. Fuel pump maximum pressure: 450—630 kPa {5.0—6.5 kgf/cm2, 64—92 psi) 7. Turn the ignition switch OFF and disconnect the jumper wire. 8. If not as specified, replace the fuel pump. 36U0F1-071 F1 FUEL SYSTEM Removal / Installation 1. Remove the fuel tank. 2. Remove the fuel pump, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. Note • Replace the fuel pump as an assembly. FUEL PUM P RING INSTALLATION REMOVAL FUEL TANK /F L A N G E 46U0F1-080 1. Fuel hose 2. Fuel pump ring Removal / Installation Note. 3. Fuel pump 4. Fuel pump gasket below Removal Note Rotate the fuel pump ring counterclockwise and remove it. Installation Note Rotate the fuel pump ring clockwise until the flange touches the stopper. F1—54 F1 FUEL SYSTEM FUEL PUMP RELAY (GREEN) FUEL PUMP RELAY Inspection Operation check Listen for clicking of the fuel pump relay while turning the ignition switch from OFF of START. 36U0F1-073 Continuity inspection Check continuity between the terminals of the relay. B + : Battery positive voltage Terminal A—B Terminal C—D Apply B + Yes B + not applied No 36U0F1-260 FUEL PUMP RELAY (GREEN) 16E0F1-121 FUEL PUMP RELAY (GREEN) 46U0F1-081 Replacement 1. Remove the relay from main fuse block No.1. 2. Install in the reverse order of removal. PRESSURE REGULATOR Inspection Fuel line pressure Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F1-48. 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge between the fuel filter and the main fuel hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Start the engine and run it at idle. 5. Measure the fuel line pressure. Fuel line pressure: 210—260 kPa [2.1—2.7 kgf/cm2, 30—38 psi) 6. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure. Fuel line pressure: 260—320 kPa [2.6—3.3 kgf/cm2, 37—46 psi) INSTALL CLAMPS 46U0F1-082 F 1 -5 5 F1 FUEL SYSTEM Hold pressure Perform this inspection if the fuel pressure hold inspection is not as specified. (Refer to page F1-48.) Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the ‘‘Fuel Line Safety Proce­ dures” on page F1-48. 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge between the fuel filter and the main fuel hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 46U0F1-084 4. Connect the data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Pinch the fuel return hose with a plier. 8. Observe the fuel pressure for 5 min.. Fuel pressure: More than 147 kPa (1.5 kgf/cm2, 21 psi) 36U0F1-074 9. If not as specified, replace the pressure regulator. Replacement Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F1-48. 46U0F1-085 1. 2. 3. 4. 5. Disconnect the vacuum hose. Disconnect the fuel return hose. Remove the pressure regulator. Install a new O-ring. Install in the reverse order of removal. Tightening torque: 7.8—10.7 Nm {80—110 kgf-cm, 70—95.4 inlbf) F1—56 FUEL SYSTEM F1 INJECTOR Inspection Operation check 1. Warm up the engine and let it idle. 2. Listen for the operational sound of each injector with a screw­ driver or a sound scope. 3. If no sound is heard, measure injector resistance. (Refer to page F1-59.) 4. If the injector resistance is OK, check wiring to the injector and the voltages of the PCME terminals 2U, 2V, 2Y and 2Z. (Refer to page F1-81.) Removal / Installation Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F1-48. 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal, referring to Installation Note. N m (kgf m, ft-lbf) 46U0F1 -087 1. Negative battery cable 2. Injector connector 3. Pressure regulator Inspection............... page F1-55 4. 5. 6. 7. Fuel hose Distribution pipe Injector Insulator F 1 -5 7 F1 FUEL SYSTEM Fuel leakage test 1. Remove the injectors together with the distribution pipe. (Refer to page F1-57.) 2. Fasten the injectors firmly to the pipe. Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 46U0F1-088 3. Connect the data link connector terminals F/P and GND with a jumper wire. 4. Turn the ignition switch ON. GND F/P DATA LINK \CO NNECTO R 36U0F1-075 5. Tilt the injectors approximately 60 degrees and verify that no fuel leaks from the injector nozzles. Leakage Specification If there is more than one drop per 2 minutes, replace the injector. 6. Turn the ignition switch to OFF and remove the jumper wire. 46U0F1-089 Volume test 1. Remove the injectors together with the distribution pipe. (Refer to page F1-57.) 2. Affix the injectors to the distribution pipe with wire. 3. Fasten the injectors firmly to the pipe. Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 46UQF1-090 49 L 0 1 8 901 4. Connect the SST to the battery and an injector. 5. Check the injection volume with a graduated container. Injection volumes: 47—68 ml [47—68 cc, 1.4—2.0 fl oz}/15 sec. 6. If not as specified, replace the injectors. 46 UOF1-091 F 1 -5 8 FUEL SYSTEM F1 Installation Install in the reverse order of removal, referring to Installa­ tion Note. Tightening torque Delivery pipe A: 1 9 -2 5 Nm {1.9—2.6 kgf m, 14—18 ft-lbf} B: 7.8—10.7 N m (80—110 kgf-cm, 70—95.4 in-lbf) -T f O-RING INJECTOR ml Installation note 1. Use new injector O-rings. 2. Apply a small amount of clean engine oil to the O-rings be­ fore installing them. c o r« c t t f GROMMET DELIVERY PIPE , as W RONG 16E0F1-137 3. Install new injector insulators. 4. Install the injectors. 16E0F1-138 Inspection Injector resistance 1. Disconnect the injector harness. 2. Measure resistance of the injector. Resistance: 12— 16Q (at 20°C (68°F)) 3. If not as specified, replace the injector. 16E0F1-139 FI___________ PRESSURE REGULATOR CONTROL SYSTEM PRESSURE REGULATOR CONTROL SYSTEM DISTRIBUTOR (NE-SIGNAL) ENGINE COOLANT TEMPERATURE SENSOR INTAKE AIR TEMPERATURE SENSOR PCME PRC SOLENOID VALVE IDLE SWITCH A ir MAIN RELAY FUEL (FROM DISTRIBUTION I PIPE) ▼ VACUUM IGNITION SW ITCH- <b © © I FUEL (TO FUEL TANK) Operating condition Coolant temperature Intake air temperature Engine condition Above 70°C [158°F| Above 20°C (68°F) Idle switch ON and engine speed below 1,500 rpm Operating time Approx. 102 sec. 16E0F1-140 To prevent vapor lock of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily cut and the fuel injection pressure is increased to slightly more than 284 kPa {2.9 kgf/cm2, 41.2 psi}. F1—60 PRESSURE REGULATOR CONTROL SYSTEM F1 PRESSURE REGULATOR CONTROL SOLENOID VALVE Inspection On-vehicle 1. Start the engine and let it idle. 2. Disconnect the vacuum hose (yellow) from the pressure regulator. Verify that vacuum is felt. 46U0F1-092 3. Ground the solenoid valve terminal B with a jumper wire. Verify that no vacuum is felt. 4. If vacuum exists, check the solenoid valve. 46U0F1 -093 Solenoid Valve 1. Remove the solenoid valve. 2. Blow through the solenoid valve from port A. 3. Verify that air flows from port B. 16E0F1-143 4. 5. 6. 7. 36U0F1-266 Apply battery positive voltage to solenoid valve terminal. Blow through the solenoid valve from port A. Verify that air flows from the valve air filter. If not as specified, replace the solenoid valve. F1 EXHAUST SYSTEM EXHAUST SYSTEM COMPONENT PARTS Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal. REPLACE 38—51 13.8—5.3, 28—38) REPLACE 20—28 {2.0—2.9, 15—20) 7.8—11 N-m {80—110 kgf-cm, 70—96 ln-lbf) GASKET, REPLACE 7.8—11 Nm (80—110 kgf-cm, 70—96 Inlbf) GASKET, REPLACE \ REPLACE GASKET, REPLACE, CALIFORNIA GASKET, REPLACE 46U0F1-094 1. Main silencer Inspect for deterioration 2. Pre-silencer Inspect for deterioration 3. Three-way catalyst Inspect for deterioration 4. Front pipe assembly Inspect for deterioration F 1 -6 2 and restriction and restriction and restriction and restriction 5. Warm-up three-way catalyst (California) Inspect for deterioration and restriction 6. Exhaust manifold Inspect for deterioration and cracks 7. Exhaust manifold insulator 8. Heated oxygen sensor Inspection................................ page F1-93 F1 OUTLINE OF EMISSION CONTROL SYSTEM OUTLINE OF EMISSION CONTROL SYSTEM STRUCTURAL VIEW The following systems are employed to reduce CO, HC, and NOx emissions. 1. Exhaust gas recirculation. 2. Positive crankcase ventilation (PCV) system 3. Fuel evaporative system 4. Three way catalyst FUEL PUMP FUEL FILTER (LOW-PRESSURE SIDE) CHECK VALVE (TWO-WAY) FUEL VAPOR VALVES FUEL TANK PURGE VALVE CATALYST CHARCOAL CANISTER EGR SOLENOID VALVE (VENT) SOLENOID VALVE (VACUUM) 46U0F1-095 F1—63 F1 EXHAUST GAS RECIRCULATION EXHAUST GAS RECIRCULATION (EXCEPT CALIFORNIA) DESCRIPTION The exhaust gas recirculation (EGR) recirculates a portion of the exhaust gas through the EGR control valve and the intake manifold into the combustion chamber. This lowers the combustion temperature and reduces NOx emissions. SYSTEM INSPECTION 1. Start the engine and let it idle. 2. Place a finger against the EGR control valve diaphragm. 3. Increase the engine speed to about 2,000 rpm. 4. Verify that the diaphragm moves. Cold engine: Diaphragm does not move Warm engine (coolant temperature above 50°C (122°F)): Diaphragm moves 46U0F1-097 F1—64 F1 EXHAUST GAS RECIRCULATION EGR CONTROL VALVE Inspection/Replacement 1. Let the engine idle. 2. Disconnect the vacuum hose from the EGR valve. 3. Connect a vacuum pump to the valve. 4. Apply 150 mmHg {5.91 inHg) vacuum and verify that the engine runs roughly or stops. 5. Replace the EGR valve if not as specified. Tightening torque: 7.8—10.7 Nm {80—110 kgf-cm, 70—95.4 inlbf} EGR FUNCTION CONTROL Inspection 1. Remove the EGR function control. 2. Plug the No.2 port and attach a vacuum pump to the No.1 port. 3. Blow into the exhaust gas port. Operate the vacuum pump and verify that the vacuum is held at the No.3 port. 4. Release the exhaust gas port and verify that the vacuum is released at the No.3 port. 5. Replace the EGR function control if not as specified. EGR SOLENOID VALVE Inspection 1. Remove the solenoid valve. 2. Verify that air flows between each part as below. Port Airflow A -B No A -C No B -C Yes 46U0F1-100 3. Connect the positive and negative battery terminals to the solenoid valve terminals. 4. Verify that air flows between each part as below. 46U0F1-101 Port Airflow A -B Yes A -C No B -C No EGR FUNCTION SENSOR Inspection / Replacement 1. Disconnect the EGR function sensor connector under the engine cold condition. 2. Measure resistance of the sensor. Resistance: 182—336 kfl (at 20°C {68°F}> 3. If not as specified. Replace the EGR control valve. Tightening torque: 7.8—10.7 N m {80—110 kgf/cm2, 70—95.4 inlbf) F1-65 F1 EXHAUST GAS RECIRCULATION EXHAUST GAS RECIRCULATION (CALIFORNIA) DESCRIPTION This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combustion temperature and reduce the NOx emissions. This system consists of the EGR control valve, EGR function sensor, two duty-solenoid valves, PCME, and input devices. EGR SOLENOID fg r SOLENOID POSITION SENSOR 1: DETECTION OF ENGINE RUNNING CONDITION 2: DETERMINATION OF EGR GAS AMOUNT 46U0F1-102 SYSTEM OPERATION Cold engine (coolant temperature: below 55°C {131 °F}) EGR operation is stopped to improve driveability when the engine is cold. Warm engine The ECU controls the solenoid valves (vacuum side and vent side) to supply EGR gases as described below. Operating condition EGR operation Idle Deceleration High speed/Low speed Idle switch: ON Stopped Heavy load Other F 1 -6 6 Above 4,250/Below 1,000 rpm — Acceleration Warming up Remark — Reduced EGR gas amount Controls supplied EGR gas amount by using sig­ nal from EGR function sensor Coolant temperature: Between 55°C (131°F) and 60°C (140°F) — F1 EXHAUST GAS RECIRCULATION ISE CONNECTOR A SYSTEM INSPECTION 1. Connect the SSTs to the PCME as shown. 2. Start the engine. 3. Drive the vehicle and verify that PCME terminals 2S and 2R voltage is battery positive voltage (B+) while the engine is still cold. 4. Warm up the engine to normal operating temperature. 5. Drive the vehicle and verify that the Engine Signal Monitor green and red lamps flash when the SST is set to 2S and 2R. 49 G 01 8 904 46U0F1-103 6. Stop the vehicle and let it idle. 7. Ground the PCME terminal 2R by using a jumper wire. 8. Verify that the engine runs roughly or stalls at idle. 46U0F1-104 EGR SOLENOID VALVE (VACUUM) Inspection 1. Disconnect the vacuum hoses. 2. Blow into the solenoid valve and verify that air does not flow. 3. Disconnect the solenoid valve connector. 4. Apply battery positive voltage and a ground to the solenoid valve as shown. 5. Blow through the solenoid valve and verify that air flows. 6. If not as specified, replace the solenoid valve assembly. 46U0F1-105 EGR SOLENOID VALVE (VENT) EGR SOLENOID VALVE (VENT) Inspection 1. Disconnect the vacuum hoses. 2. Blow through the solenoid valve and verify that air flows. 3. Disconnect the solenoid valve connector. 4. Apply battery positive voltage and a ground to the solenoid valve as shown. 5. Blow into the solenoid valve and verify that air does not flow. 6. If not as specified, replace the solenoid valve assembly. 46U0F1-106 EGR CONTROL VALVE Inspection 1. Start the engine and let it idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at more than the specified vacuum. Specification: 5.4—7.7 kPa [40—60 mmHg, 1.6—2.3 inHg} 4. If not as specified, replace the EGR control valve. 46U0F1-107 F 1 -6 7 F1 EXHAUST GAS RECIRCULATION Replacement Plug the water hoses after disconnecting them. 1. Remove the EGR control valve in the sequence shown below. (1) EGR hoses (2) Vacuum hose (3) EGR function sensor connector (4) EGR control valve and gasket 2. Install a new gasket, and then install the EGR in the reverse order of removal. 46U0F1-108 ISE CONNECTOR A EGR FUNCTION SENSOR Inspection of output voltage 1. Disconnect the PCME connector. 2. Connect the SST to the PCME as shown and connect a vacuum pump to the EGR control valve. 3. Turn the ignition switch ON. 4. Measure voltage at the terminals as shown in the table. 49 GO 18 903 49 G 0 1 8 9 04 46U0F1-109 Terminal PCME B A C 2K 2D 2J Vacuum 0 kPa 20.0 kPa {0 mmHg, 0 inHgj (150 mmHg, 5.90 inHgj 4.5—5.5V OV Approx. 0.8V Approx. 4.9V 5. If not correct at 2J terminal, check the wiring harness and 2K terminal of the PCME. Inspection of resistance 1. Disconnect the EGR function sensor connector, and con­ nect an ohmmeter. 2. Disconnect the vacuum hose from the EGR control valve, and connect a vacuum pump. 3. Measure the resistance between the terminals as shown while vacuum is applied. Terminal 46U0F1-110 A -B A -C B -C Vacuum 0 kPa 20.0 kPa (0 mmHg, 0 inHgj (150 mmHg, 5.90 inHgj Approx. 2.7 Mi Approx. 0.5 kQ Approx. 2.7 kfl Approx. 2.4 kt) Approx. 0.1 k$l 4. If not as specified, replace the EGR control valve. F1—68 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM F1 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM DESCRIPTION The PCV valve is operated by the intake manifold vacuum. When the engine is running at idle, the PCV valve is slightly open and a small amount of blowby gas is drawn into the intake manifold to be burned. As the engine speed rises, the PCV valve is opened further, allowing a larger amount of blowby gas to be drawn into the intake manifold. 16E0F1-153 PCV VALVE Inspection 1. Verify that the engine coolant temperatuer is below 20°C {68°F}. 2. Start the engine and let it idle. 3. Disconnect the PCV valve with the ventilation hose from the cylinder head cover. 4. Block the PCV valve opening. 5. Verify that vacuum is felt. 46U0F1-111 6. Remove the PCV valve. 7. Blow through the valve from port A and verify that air comes out of port B. 8. Blow through the valve from port B and verify that no air comes out of port A. 9. Replace the PCV valve if not as specified. 46U0F1-112 F 1 -6 9 F1 FUEL EVAPORATIVE SYSTEM FUEL EVAPORATIVE SYSTEM DESCRIPTION The fuel evaporative system consists of fuel vapor valve, two-way check valve, charcoal canister, purge control solenoid valve, PCME, and input devices. The amount of evaporative fumes introduced into the engine and burned is controlled by the solenoid valve to correspond to the engine’s operating conditions. To obtain the best engine performance, the solenoid valve is controlled by the PCME. Operation The solenoid valve (purge control) is controlled by duty signals from the PCME to perform purging of the charcoal canister. Purging is done when these conditions are met; (1) After warm-up (Coolant temperature above 80°C {176°F}) (2) Driving in gear (3) Engine speed more than 1,000 rpm (4) Accelerator pedal depressed (idle switch OFF) (5) Heated oxygen sensor functioning normally F 1-7 0 EVAPORATIVE EMISSION CONTROL SYSTEM F1 SYSTEM OPERATION 1. Warm up the engine to normal operating temperature and let it idle. 2. Disconnect the vacuum hose from the solenoid valve and plug it as shown in the figure. Verify that no vacuum is felt at the solenoid valve. 3. If not as specified, check the solenoid valve. 46U0F1-114 1 PURGE CONTROL SOLENOID VALVE Inspection 1. Disconnect the vacuum hoses from the solenoid valve. 2. Verify that no air flows through the valve. J ✓ /■— \ {j' < / Ni 0 .... _ D 46U0F1-115 3. Disconnect the solenoid valve connector and supply bat­ tery positive voltage as shown in the figure. 4. Verify that air flows through the valve. 5. If not as specified, replace the solenoid valve. GROUND 26U0F1-267 FUEL VAPOR VALVE Inspection 1. Verify that air flows through the valve from port A as shown in the figure. 16E0F1-160 2. Verify that no air flows through the valve from port A as shown in the figure. 3. Replace the fuel vapor valve if necessary. 16E0F1 -161 F1-71 F1 EVAPORATIVE EMISSION CONTROL SYSTEM CHECK VALVE (TWO-WAY) Inspection 1. Remove the valve. 2. Check the operation of the valve by using a vacuum pump. Apply approx. 3.5 kPa (26 mmHg, 1.0 inHgj vacuum at port A Valve opens Apply approx. 5.9 kPa (44 mmHg, 1.7 inHgj vacuum at port B Valve opens 36U0F1-256 CHARCOAL CANISTER Inspection 1. Visually check for damage. 2. Replace the charcoal canister if necessary, T 16E0F1-163 F1 FUEL-CUT CONTROL SYSTEM FUEL-CUT CONTROL SYSTEM DESCRIPTION This system is used to improve the fuel economy, to prevent engine bucking during deceleration, and to protect the engine from overreving. Deceleration fuel-cut (x 10* rpm) (-40) (32) (104) (176) {°F} 16E0F1-164 F 1-73 F1 FUEL-CUT CONTROL SYSTEM PREPARATION SST 46U0F1-116 i F 1-7 4 FUEL-CUT CONTROL SYSTEM USE CONNECTOR A 49 92 00 162 49 G 0 18 903 49 G 018 904 46U0F1-117 F1 SYSTEM OPERATION 1. Connect a tachometer to the data link connector terminal IG 2. Connect the SSTs to the PCME. 3. Warm up the engine to normal operating temperature and let it idle. Warning • Performing this test with the transaxle in any range other than neutral can be dangerous. Before per­ forming this test, verify that the transaxle is in neutral. 4. Set the SST (Engine Signal monitor) to the terminal 2U, 2V, 2Y and 2Z and verify that the green and red lamps flash alternately. 46U0F1-118 5. Increase the engine speed to 4,000 rpm and then suddenly release the throttle. 6. Verify that the red indicator lamp illuminates while the en­ gine speed is above approx. 1,500 rpm on deceleration. Caution • Holding the maximum rpm for more than 3 seconds can damage the engine. 7. Increase the engine speed and verify that the maximum rpm does not exceed approx. 6,800 rpm while the engine is at normal operating temperature. F1 A/C CUTOFF SYSTEM A/C CUTOFF SYSTEM DESCRIPTION An A/C cutoff system is used to improve idle smoothness just after starting the engine and to improve acceleration performance. DISTRIBUTOR (NE-SIGNAL) PCME THROTTLE POSITION SENSOR DETERMINATION OF AIR CONDITIONING SENSOR A/C CUT OFF A/C RELAY IGNITION SWITCH (START) \ ENGINE COOLANT TEMPERATURE SE N SO R ' O' -D_ ® © CONDENSOR NEUTRAL SWITCH IGNITION SWITCH FAN MOTOR MAGNETIC CLUTCH CLUTCH SWITCH BATTERY 46U0F1-120 Operation The A/C clutch operation is cancelled under the conditions below. Engine condition After engine starting Throttle valve fully open Coolant temp, above 116°C (241°F) Purpose Cutoff period Improve engine starting Approx. 4 sec. Improve drivability Approx. 5 sec. Prevent engine overheat Until coolant temp, decrease below 113°C (235°F) SYSTEM OPERATION 1. Turn the ignition switch ON. 2. Turn the blower switch and AIR CONDITIONING SENSOR ON. 3. Start the engine. 4. Verify that the additional fan stops for approx. 4 sec. after the engine starts. F 1 -7 6 DECHOKE CONTROL SYSTEM/COOLANT FAN CONTROL SYSTEM F1 DECHOKE CONTROL SYSTEM SYSTEM OPERATION 1. Turn the ignition switch to START and verify that the injec­ tor operating sound is heard. 2. Depress the accelerator pedal fully and turn the ignition switch to START. Verify that no injector operating sound is heard. COOLANT FAN CONTROL SYSTEM DESCRIPTION To improve reliability, the coolant fan is controlled by the PCME. This system consists of the coolant fan motor, fan relays, PCME, and input devices. PCME 46U0F1-121 Coolant fan operation Engine condition Coolant temperature above 97°C (207°F) Fan relay ON Air conditioning sensor ON TEN terminal ground and idle switch ON ECTS malfunction ON F 1 -7 7 F1 COOLANT FAN CONTROL SYSTEM SYSTEM OPERATION 1. Connect the data link connector terminals TEN and GND with a jumper wire. 2. Turn the ignition switch ON. 36U0F1-088 3. Rotate the throttle link by hand and verify that cooling fan operates. 16E0F1-176 CONTROL SYSTEM F1 CONTROL SYSTEM PREPARATION SST 46U0F1-122 F1 CONTROL SYSTEM STRUCTURAL VIEW 46U0F1-123 1. Fuel pump relay Inspection.................................page Replacement.............................page 2. Powertrain control module (Engine) Removal / Installation............... page Inspection.................................page 3. Mass airflow sensor Inspection.................................page Replacement.............................page 4. Crankshaft position sensor F -5 5 F -5 5 F -81 F -81 F -9 0 F -4 2 Inspection.....................................page F -9 0 5. Engine coolant temperature sensor Removal.................................... page Inspection............... ................. page Installation.................................page 6. Intake air temperature sensor Inspection.................................page Replacement.............................page 7. Throttle position sensor Inspection.................................page Adjustment................................page F 1 -8 0 F -91 F -91 F -9 2 F -9 2 F -9 2 F -9 2 F -9 3 8. Heated oxygen sensor Inspection.................................page F1-93 Replacement............................ page F1-93 9. Idle switch Inspection.................................page F1-94 10. Main relay Inspection................................ page F1-94 11. Coolant fan relay Inspection.................................page F1-94 12. Clutch switch Inspection.................................page F1-94 Replacement............................ page F1-95 13. Neutral switch Inspection.................................page F1-95 Replacement............................ page F1-95 14. Steering pressure sensor Inspection.................................page F1-95 Replacement............................ page F1-95 F1 CONTROL SYSTEM POWERTRAIN CONTROL MODULE (ENGINE) Removal / Installation 1. Disconnect the battery negative terminal. 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. 46U0F1-124 2. PCME connector 1. Console 49 9 2 0 0 162 3. PCME Inspection 1. Disconnect the PCME connectors. 2. Connect the SSTs. (Engine Signal Monitor and Adapter) to the PCME as shown. 49 G 0 18 903 46U0F1-125 3. Place the SST (sheet) on the Engine Signal Monitor. 4. Measure the voltage at each terminal. (Refer to pages F1-82 through F1-89.) 5. If any PCME terminal voltage is incorrect, check the relat­ ed input or output devices and wiring. If no problem is found, replace the PCME. (Refer to above.) 46U0F1-126 T E R M IN A L S Caution • Never apply voltage to SST terminals A and B be­ cause it will damage the SST. 46U0F1-127 F1-81 F1 CONTROL SYSTEM Terminal voltage (reference data) Terminal Input Output 1A — 1B O 1C — M a in relay O o 1D o 1E Test condition Connected to B a tte ry B+; O FF 0 ON B+ Ig n itio n sw itch Ignition switch (START) W h ile c ra n k in g 10 Ig n itio n s w itc h O N 0 D a ta lin k c o n n e c to r (M E N te rm in a l) T est sw itch a t S E LF TEST L a m p illu m in a t­ e d fo r 3 se c. a fte r ig n itio n sw itch O F F -O N 5 M a lfu n c tio n in d ic a to r la m p (M IL ) o D a ta lin k c o n n e c to r (FE N te rm in a l) L a m p n o t illu m in a te d a fte r 3 sec. 5 T est sw itch at O 2 M O N IT O R at idle L a m p n o t illu m in a te d B+ L a m p illu m in a te d fo r 3 sec. a fte r ig n itio n sw itch O F F -*O N L a m p n o t illu m in a te d a fte r 3 sec. o 1H 11 o 1L 1M o o o Fuel p u m p relay A /C relay D a ta lin k c o n n e c to r (TEN te rm in a l) B+ Remark For b a c k u p — — W ith SelfD ia g n o sis C h e c k ­ e r a n d S ystem S e le cto r W ith S ystem S e le cto r test sw itch at "S E L F -T E S T ” B e lo w 2 .5 V + B B u zze r s o u n d e d fo r 3 sec. a fte r ig n itio n s w itch O F F -*O N 0.4 B u zze r n o t s o u n d e d a fte r 3 sec. B + B e lo w 2 .5 B+ — — D aytim e running light (Canada) 0 1J 1K — B e lo w 2 .5 V L a m p n o t illu m in a te d B u zze r s o u n d e d — B+ T est sw itch a t 0 2 M O N IT O R a t id le L a m p illu m in a te d B u zze r n o t s o u n d e d 1G (V) B+ C o n sta n t L a m p illu m in a te d 1F Voltage <0|t>ge — Ig n itio n sw itch O FF • W ith selfD ia g n o sis C hecker and S ystem S e le c to r • W ith S ystem S e le cto r test sw itch a t S E LF TEST — B+ D u rin g c ra n k in g o r a t idle O N (P a rkin g b ra k e n o t a p p lie d ) O F F (P a rkin g b ra k e a p p lie d ) Ig n itio n sw itch O N 0 B+ 0 — • Ig n itio n sw itch ON B+ A /C s e n s o r O N a t id le 1.0 A /C s e n so r O FF at id le B+ S ystem S e le cto r te st sw itch at 0 2 M O N IT O R B+ S yste m S e le cto r te st sw itch at S E L F TEST 0 R ear w in ­ dow d e fro ste r relay R ear w in d o w d e fro s te r sw itch O N 0 .2 R ear w in d o w d e fro s te r sw itch O FF B+ V e h icle sp e e d s e n so r V e h ic le s to p p e d V o ltm e te r 4 .0 — 5 .0 o r 0 D riv in g (20 km /h) V o ltm e te r 2 .0 — 3 .0 — • W ith system se le cto r • Ig n itio n sw itch ON Ig n itio n sw itch ON — 46U0F1-128 F 1 -8 2 F1 CONTROL SYSTEM B -I-: Battery positive voltage Incorrect voltage Possible cause Always OV • ROOM 15A fuse burnt • Open circuit in wiring from ROOM 15A fuse to PCME terminal 1A Always OV • Main relay malfunction c r page F1-94 • Open or short circuit in wiring from main relay to PCME terminal 1B Always OV (starter turns) • Open or short circuit in wiring from ignition switch to PCME terminal 1C Always OV • Main relay malfunction c r page F1-94 • Open circuit in wiring from ignition switch to data link connector terminal +B • Open or short circuit in wiring from data link connector terminal MEN to PCME terminal 1D Always B + • • Always 5V • PCME malfunction Always below 2.5V MIL always ON • Short circuit in wiring from combination meter to PCME terminal 1E • PCME malfunction MIL never ON • Open circuit in wiring from combination meter to PCME terminal 1E Always B + Always below 2.5 V Poor connection at PCME connector PCME malfunction • Poor connection at PCME connector • PCME malfunction No display on SelfDiagnosis Checker • Main relay malfunction c r page F1-94 • Open circuit in wiring from ignition switch to data link connector terminal + B "8 8 ” displayed and buzzer sounds continuously • Open or short circuit in wiring from data link connector terminal FEN to PCME terminal 1F Always B + • Poor connection at PCME connector • PCME malfunction — — Always below 2.5V • Engine 15A fuse burnt • Open or short circuit in wiring from fuel pump relay wire to PCME terminal 1H • PCME malfunction Always B + • • Daytime running relay malfunction Combination switch malfunction • Open circuit in wiring from daytime running relay to PCME terminal 11 Always OV A/C relay malfunction • Open circuit in wiring from ignition switch to A/C relay • Open circuit in wiring from A/C relay to PCME terminal 1J A/C does not operate • Air conditioning sensor OFF but A/C operates • • Short circuit in wiring from A/C relay to PCME terminal 1J PCME malfunction Always B + • • Poor connection at PCME connector PCME malfunction Always below 1.0V • Short circuit in wiring from data link connector terminal TEN to PCME termi­ nal 1K Always B + • • Open circuit in wiring from data link connector terminal TEN to PCME ter­ minal 1K Open circuit in wiring from data link connector terminal GND to ground Always OV • Short circuit in wiring from rear defroster switch to PCME terminal 1L Always B + • Open circuit in wiring from rear defroster switch to PCME terminal 1L Always OV, 0 km/h, or 4.0—5.0V • Open or short circuit in wiring from vehicle speed sensor to PCME terminal 1M • Vehicle speed sensor malfunction Always below 2.5V 46U0F1-129 F 1 -8 3 F1 CONTROL SYSTEM B + : Battery positive voltage Terminal Input 1N O Output Connectedto Idle switch Test condition Voltage Accelerator pedal depressed 10 1P 10 1R O O o O O Ignition switch ON Ignition switch ON Brake pedal released Brake pedal depressed B+ Steering pressure sensor Ignition switch ON B+ Air condi­ tioning sensor A/C sensor ON A1C sensor OFF B+ Blower con­ trol switch Blower control switch OFF, 1st or 2nd position B+ Coolant fan relay Remark B+ Stoplight switch P/S ON (at idle) P/S OFF (at idle) B+ Blower control switch 3rd or 4th position 1S (V) 0 Accelerator pedal released Ignition switch ON and blower control switch ON Ignition switch ON Below 1.0 Coolant fan relay ON Coolant fan relay OFF B+ Headlights ON B+ TEN terminal grounded and idle switch OFF 1T 1U 1V O Headlights switch O Neutral and Clutch switches Headlight OFF Neutral position or clutch pedal depressed 2A Ground Constant 2B Ground' Constant 2C Ground Constant 2D Ground Constant Distributor (NE signal) Ignition switch ON 2E O B+ Others Idle 0 or 5 Oscilloscope Voltage (V) ne; Voltmeter 2F O Igniter 2.0 Ignition switch ON Idle Oscilloscope Voltage (V) 4V 2V f OV I Voltmeter -- I1 0.4 46U0F1-130 F 1 -8 4 F1 CONTROL SYSTEM B + : Battery positive voltage Incorrect voltage Possible cause Always OV • Idle switch malfunction • Short circuit in wiring from idle switch to PCME terminal 1N • PCME malfunction Always B + • Idle switch malfunction • Open circuit in wiring from idle switch to PCME terminal 1N Always OV (stoplights OK) • Open circuit in wiring from stoplight switch to PCME terminal 10 Always below 1.0V • Steering pressure sensor malfunction c r page F1-95 • Short circuit wiring from steering pressure sensor to PCME terminal 1P • PCME malfunction Always B + • Steering pressure sensor malfunction c r page F1-95 • Open circuit in wiring from steering pressure sensor to PCME terminal 1P • Open circuit in wiring from steering pressure sensor to ground Always below 2.5V (blower fan OK) • Air conditioning sensor malfunction c r 1994 626/MX-6 body electrical troubleshooting manual Section G • Short circuit in wiring from air conditioning sensor to PCME terminal 1Q • Poor connection at PCME connector • PCME malfunction Always B + (blower fan OK) • Air conditioning sensor malfunction c r 1994 626/MX-6 body electrical troubleshooting manual Section G • Open circuit in wiring from air conditioning sensor to PCME terminal 10 • Open circuit in wiring from air conditioning sensor to blower control switch Always below 1,0V (blower fan OK) • Short circuit in wiring from blower control switch to PCME terminal 1R • Poor connection at PCME connector • PCME malfunction Always B + (blower fan OK) • Open circuit in wiring from blower control switch to PCME terminal 1R Always below 1,0V (Coolant fan OK) • Open or short circuit in wiring from fan relay to PCME terminal 1S • PCME malfunction — — Always below 1.OV (Headlights OK) • Open or short circuit wiring from headlights switch to PCME terminal 1U Always below 1.OV • Neutral and Clutch switch malfunction c r page F1-94, 95 • Short circuit in wiring from PCME terminal 1V to neutral or clutch switch Always B + • Neutral and Clutch switch malfunction c r page F1-94, 95 • Open circuit in wiring from PCME terminal 1V to neutral or clutch switch Above OV • Poor contact at ground terminal • Open circuit in wiring from PCME to ground Always OV or 5V • Refer to Code No.03 Troubleshooting c r page F1-23 Always OV • Short circuit in wiring from igniter to PCME terminal 2F • PCME malfunction Always 5V • Open circuit in wiring from igniter to PCME terminal 2F • Open circuit in wiring from igniter to ground • PCME malfunction 46U0F1-131 F 1-8 5 F1 CONTROL SYSTEM B +: Battery positive voltage Terminal Input Output 2G Distributor (G signal) O Test condition Connected to Voltage Ignition switch ON (V) Remark 0 or 5 Oscilloscope Idle Voltage (V) — 20 ms Voltmeter 2H — — 21 — — 2J o 2K 2L 2M 2N o o 0 o 1.1 — — — — — Throttle position sensor Constant 4.5—5.5 Ignition switch ON Intake air temperature sensor Engine coolant temperature 20°C (68°F) 2.5 After warmup 1.5 Ignition switch ON Throttle position sensor (TVO) Accelerator pedal released 0.5 Accelerator pedal fully depressed 4.2 2Q o 2R 2S 2T 2U Mass air­ flow sensor — Ignition switch ON o EGR solenoid valve (vent) EGR solenoid valve 0 -1 .0 — 0 .5 -1 .0 0 Ignition switch ON 1.0-1.5 Engine running 1 .5-5.0 — — — — Engine coolant temperature 20°C (68°F) 2.5 After warmup 0.5 Ignition switch ON Idle B+ California only Driving B+ Idle (cold engine) B+ Engine speed 2,000 rpm (after warmup) 1.0 EGR solenoid valve (vacuum) Idle B+ Driving B+ o Pressure regulator solenoid valve Solenoid valve ON Refer to ON condition, page F1—60 1.5 Solenoid valve OFF B+ Injector (No.1) Ignition switch ON 0 Idle (after warmup) o o — 0 Idle (cold engine) — Engine coolant temperature sensor o — 3.2—4.9 Deceleration 2P — Idle Heated oxygen sensor o — EGR function sensor Increasing engine speed (after warmup) 20 — B+ Ignition switch ON Idle (after warmup) Oscilloscope Except California California only — *Engine Signal Monitor: Green and red lamps flash von«fl«<v) 5m» Engine speed above 2,000 rpm on deceleration (after warmup) Voltmeter 13.8* Voltmeter B+ 46U0F1-132 F 1 -8 6 F1 CONTROL SYSTEM B +: Battery positive voltage Incorrect voltage Possible cause Always OV or 5V • Refer to Code No.03 troubleshooting — — — — — — cr page F1—23 Always OV • Poor connection at PCME connector • Short circuit in wiring from PCME terminal 2K to throttle position sensor • PCME malfunction Always OV or 5V • Refer to Code No.11 Troubleshooting cr page F1-26 Always OV or 5V • Refer to Code No.12 Troubleshooting cr page F1-27 Always OV after warmup • Refer to Code No. 15 Troubleshooting • Refer to Code No.17 Troubleshooting cr cr page F1-28 Always 1V after warmup Always below 2V or 4V • Refer to Code No.08 Troubleshooting cr page F1-24 cr page F1-25 — page F1-30 — Always OV or 5V • Refer to Code No.09 Troubleshooting Always OV or B + • Refer to Code No.28 Troubleshooting c r page F1-34 Always OV or B + • Refer to Code No.28 Troubleshooting c r page F1-33 Always OV or B + • Always OV or B + • Refer to Code No.25 Troubleshooting c r page F1-31 Always OV • Main relay malfunction c r page F1-94 • Open or short circuit in wiring from injector to PCME terminal 2U Always B + • PCME malfunction Refer to Code No.29 Troubleshooting c r page F1-35 46U0F1-133 F1 CONTROL SYSTEM B + : Battery positive voltage Terminal 2V Input Output Connectedto O Injector (No.2) Test condition Voltage Ignition switch ON Idle (after warmup) B+ 2W O Idle air control valve 13.8* B+ Voltmeter Ignition switch ON Idle Remark 1Engine Signal Monitor: Green and red lamps flash Oscilloscope Voltmeter Engine speed above 2,000 rpm on deceleration (after warmup) (V) B+ Oscilloscope Voltage (V) Vb 2X O Purge control solenoid valve Ignition switch ON Idle B+ Oscilloscope Voltage (V) 40 20 V! 2Y O Injector No.3 Ignition switch ON Idle B+ Oscilloscope Voltage (V) go I Engine speed above 2,000 rpm on deceleration (after warmup) 2Z O Injector No.4 Voltmeter 13.8* Voltmeter B+ Ignition switch ON Idle B+ Oscilloscope * Engine Signal Monitor: Green and red lamps flash * Engine Signal Monitor: Green and red lamps flash Voltage (V) Ol-H0*-— 0-f— Engine speed above 2,000 rpm on deceleration (after warmup) Voltmeter 13.8* Voltmeter B+ 46U0F1-134 F1 CONTROL SYSTEM B +: Battery positive voltage Incorrect voltage Possible cause Always OV • Main relay malfunction c r page F1-94 • Open or short circuit in wiring from injector to PCME terminal 2V Always B + • PCME malfunction Always OV or B + • Refer to Code No.34 Troubleshooting c r page F1-36 Always OV or B + • Refer to Code No.26 Troubleshooting c r page F1-32 Always OV • Main relay malfunction c r page F1-94 • Open or short circuit in wiring from injector to PCME terminal 2Y Always B + • Always OV • Main relay malfunction • Open or short circuit in wiring from injector to PCME terminal 2Z Always B + • PCME malfunction PCME malfunction 46U0F1-135 F1 CONTROL SYSTEM MASS AIRFLOW SENSOR (HEAT RESISTOR TYPE) Inspection Caution • Do not drop the sensor, subject it to sharp shocks, put or allow anything in it. It is very sensitive and easily damaged. 1. Disconnect the mass airflow sensor connector. 46U0F1-136 2. 3. 4. 5. 46U0F1-137 USE CONNECTOR A 49 9 2 0 0 162 Remove the mass airflow sensor. (Refer to page F1-42.) Check for damage of the sensor. Install the mass airflow sensor. (Refer to page F1-42.) Connect the mass airflow sensor connector. 6. Disconnect the PCME connectors. 7. Connect the SSTs. Engine Signal Monitor and Adapter to the PCME as shown. 8. Place the SST (Sheet) on the Engine Signal Monitor. 9. Check the voltage of terminal 20. Specification 49 G 01 8 903 46U0F1-138 Condition Ign—ON (Engine stopped) Engine running Terminal voltage 1—1.5V 1.5—5V 10. If not as specified, replace the mass airflow sensor. Tightening torque: 7.9—10.7 Nm {80—110 kgfcm, 70—95.4 in-lbf) CRANKSHAFT POSITION SENSOR Inspection 1. Remove the distributor. (Refer to Section G.) 2. Disconnect the injector connector. 3. Verify that the distributor connector (6 pin) is disconnected. 4. Connect the distributor connector (4-pin) as shown in figure. 5. Disconnect the injector connector. 6. Turn the ignition switch ON. 7. Connect the SSTs (Engine Signal Monitor and Adapter Har­ ness) to the PCME as shown. 8. Set the SST (Engine Signal Monitor). 9. Rotate the distributor drive by hand and measure the out­ put voltage. 46U0F1-140 F 1 -9 0 F1 CONTROL SYSTEM Specification NE 5V SIGNAL ov G JU TTU ^ SIGNAL o v - __________ Signal Terminal Voltage NE 2E Approx. 5V (4 pulses/rev) G 2G Approx. 5V (1 pulse/rev) t l 46U0F1-141 10. After the (Refer to 11. Start the (Refer to inspection, install the distributor. Section G.) engine and adjust the ignition tinning. page F1-15.) Ignition timing: BTDC 11—13° 12. Tighten the distributor lock bolts to the specified torque. Tightening torque: 1 9 -2 5 Nm [1 .9 -2 .6 kgfm, 14—18 ft-lbf) 46U0F1-142 ENGINE COOLANT TEMPERATURE SENSOR Removal Note • The engine coolant temperature sensor is at the rear of the engine. 1. Disconnect the engine coolant temperature sensor con­ nector. 2. Remove the engine coolant temperature sensor. ENGINE COOLANT TEMPERATURE SENSOR 36U0F1-120 Inspection 1. Place the sensor in water with a thermometer and heat the water gradually. 2. Measure resistance of the sensor. Water Resistance (kfl) 20°C I 68°F) 2 2 -2 .7 40°C ( 104°F) 1.0-1.3 60°C ( 140°F) 0.50-0.65 80°C (176°F) 0.29-0.35 3. If not as specified, replace the engine coolant temperature sensor. Installation 1. Install a new washer and the engine coolant temperature sensor. Tightening torque: 25—29 Nm {2.5—3.0 kgf m, 19—21 ft-lbf) 2. Connect the engine coolant temperature sensor connector. 3. Start the engine and check for coolant leakage. F1-91 F1 CONTROL SYSTEM INTAKE AIR TEMPERATURE SENSOR Inspection 1. Disconnect the intake air temperature sensor connector. 2. Check resistance of the sensor. Temperature Resistance 25°C ( 77°F) 29.7-36.3 kQ 85°C ( 185°F) 3.3—3.7 kO 3. If not as specified, replace the intake air temperature sensor. 46U0F1-201 Replacement 1. Disconnect the intake air temperature sensor connector. 2. Remove the sensor. 3. Install the sensor and tighten it to the specified torque. Tightening torque: 7.9—11.7 Nm {80—120 kgf-cm, 70—104 in-lbf) 46U0F1-202 THROTTLE POSITION SENSOR Inspection 1. Disconnect the connector from the throttle position sensor. 2. Connect an ohmmeter between throttle position sensor ter­ minal B and C. 36U0F1-124 5 ( RESISTANCE (Ml) 3. Verify that the resistance increase is linear according to the throttle valve opening angle. Throttle valve condition Resistance (kQ) 4 Closed throttle position Below 1 3 Wide open throttle Approx. 5 2 1 0 4. If not as specified, adjust the throttle position sensor. THROTTLE VALVE OPENING ANGLE WIDE OPEN THROTTLE 46U0F1-144 Adjustment 1. Connect the SST to the PCME as shown. (Refer to page F1-81.) 2. Measure the voltage of terminal 2M. 3. Loosen the sensor screws. 4. Ignition switch ON. 5. Adjust the sensor output voltage by rotating the sensor. Specification Condition Terminal voltage (V) Accelerator pedal released Approx. 0.5 Accelerator pedal fully depressed Approx. 4.1 6. If not as specified, replace the throttle position sensor. 46L10F1-204 F 1 -9 2 F1 CONTROL SYSTEM Replacement 1. Disconnect the throttle position sensor connector. 2. Remove the screws. 3. Remove the throttle position sensor. 4. Install the throttle position sensor. 5. Adjust the throttle position sensor output voltage. (Refer to page F1-92.) 46U0F1-145 HEATED OXYGEN SENSOR Inspection of Terminal voltage 1. Warm up the engine to normal operating temperature and let it idle. 2. Disconnect the heated oxygen sensor connector. 3. Connect a voltmeter between the heated oxygen sensor ter­ minal A and a ground. 4. Run the engine at 3,000 rpm until the voltmeter indicates approx 0.55V. 46U0F1-146 5. Quickly increase and decrease the engine speed several times. Verify that when the speed is increased, the meter reads 0.5—1.0V, and when the speed is decreased it reads 0V—0.5V. 6. If not as specified, replace the heated oxygen sensor. 0 Voltmeter © o © 46U0F1-147 Inspection of Heated Oxygen Sensor Heater 1. Turn the ignition switch OFF. 2. Disconnect the heated oxygen sensor connector. 3. Connect an ohmmeter between the heated oxygen sensor terminals C and D as shown. 4. Measure the resistance of the heating element. Specification: Approx 6fl (at 20°C {68°F}) 5. If not as specified, replace the heated oxygen sensor. Replacement 1. Disconnect the heated oxygen sensor connector. 2. Remove the heated oxygen sensor. 3. Install in the reverse order of removal. Tightening torque: 30—49 N-m (3.0—5.0 kgf-m, 22—36 ft-lbf] 36U0F1-132 F1—93 F1 CONTROL SYSTEM IDLE SWITCH Inspection 1. Disconnect the idle switch connector. 2. Check continuity between the switch and a ground. Throttle valve Continuity Closed throttle position Yes Open No 3. If not as specified, check the condition of the wiring har­ ness of the idle switch. Replace the idle switch and the throt­ tle body (as an assembly), if necessary. (Refer to page F1-42.) MAIN RELAY Inspection 1. Verify that main relay clicks when the ignition switch is turned ON and OFF. 2. Apply battery positive voltage (B+) to terminal A and ground terminal B of the relay. 3. Check continuity of the relay as shown. B + : Battery positive voltage 36U0F1-135 Terminals B + not applied B+ applied C -D No. Continuity Continuity 4. If not as specified, replace the main relay. COOLANT FAN RELAY Inspection 1. Turn the ignition switch ON. 2. Ground the TEN terminal of the data link connector. 3. Rotate the throttle link by hand and verify that coolant fan relays click. 4. Remove the relays. 5. Apply battery positive voltage (B+) to terminal A and ground terminal B of the each relays. 6. Check continuity of the relay as shown. B + : Battery positive voltage Terminals B + not applied B+ applied C -D No continuity Continuity 7. If not as specified, replace the coolant fan relay. 36U0F1-137 CLUTCH SWITCH inspection 1. Disconnect the clutch switch connector. 2. Connect an ohmmeter to the switch. 3. Check continuity of the switch. Pedal Continuity Depressed Yes Released No 4. If not as specified, replace the clutch switch. 16E0F1-231 F 1 -9 4 F1 CONTROL SYSTEM Replacement 1. Disconnect the clutch switch connector. 2. Loosen the locknuts. 3. Remove the clutch switch. 4. Install in the reverse order of removal. 5. Adjust the pedal height. (Refer to Section H.) NEUTRAL SWITCH Inspection 1. Disconnect the neutral switch connector. 2. Connect an ohmmeter to the switch. 3. Check continuity of the switch. Transmission Continuity Neutral Yes Other ranges No 4. If not as specified, replace the neutral switch. Replacement Replace the neutral switch as shown in the figure. Tightening torque: 20—29 Nm {2.0—3.0 kgfm, 15—21 ft-lbf) STEERING PRESSURE SENSOR Inspection 1. Disconnect the steering pressure sensor connector. 2. Connect an ohmmeter to the sensor. 3. Start the engine and run it at idle. Check continuity of the sensor while turning the steering wheel. Steering wheel Continuity Turning Yes Not turning No 4. If not as specified, replace the steering pressure sensor. Replacement Replace the steering pressure sensor as shown in the figure. Tightening torque: 17—22 N-m (1.7—2.3 kgf-m, 13—16 ft-lbf} 36U0F1-141 F 1-9 5 F1 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE QUICK DIAGNOSIS CHART Section G I LL I F1-72 I F1-72 I F1-69 F1-65 F1-62 F1-55 F1-55 F1-51 F1-42 F1-16 F1-43 F1-15 F1-65 F1-57 * § H IL T— U LL CD | | I I I | | I I | I I I I I | I I I I I I I O0 0 1 Melts main or other fuse 2 Will not crank or cranks slowly Oo O No combustion 3 Cranks normally Partial combustion — when engine o 4 but will not cold start Partial combustion — after o 5 warm-up o o 7 Cranks nor­ Any engine temp. 0 When engine cold 8 mally but o 9 hard to start After warm-up ooO Idle at any engine temp. 10 Engine During fast idle 11 stalls Idle after warm-up 12 Idle with A/C, P/S, and/or E/L ON 13 Idle when shifted from N or P to 14 other ranges o o Driveaway 15 o Oo On acceleration 16 oO While cruising 17 oO On deceleration 18 o 0O Idle at any engine temp. 19 Engine During fast idle 20 rough Idle after warm-up 21 Idle with A/C, P/S, and/or E/L ON 22 Idle when shifted from N or P to 23 other ranges On deceleration 24 o Driveaway 25 Poor ac­ celeration o o On acceleration 26 High idle speed after warm-up 27 *1 1994 626/MX-6 Body Electrical Troubleshooting Manual F 1 -9 6 l y— LL 1—CM O) 03 1 1 LL ul Injector Fuel pump Fuel pump relay Pressure regulator Fuel filter Air leakage Idle speed misadjustment Throtle body Air cleaner element EGR solenoid valve Purge control solenoid valve EGR control valve, EGR function control Three-wav catalyst Fuel vapor valve Check valve (two-way) Charcoal canister PCV valve Distributor Igniter (in distributor) Ignition coil (in distributor) High-tension lead Spark plug Ignition timing Mass airflow sensor Engine coolant temperature sensor Throttle position sensor Heated oxygen sensor Crankshaft position sensor Vehicle speed sensor Item CM m l tLL I F1-93 Emissioncontrol system Ignitionsystem Control system I F1-90 Intake air system .] Possible Darts and reference page Fuel system 00 0 O O 0 O OO0 o 0 o O o o 0O 00o O 0 O o o OO 0 0 oo0 o o o oo Oo o o oO o oo o 00 00 O o o o o o 00 0o o o o o 0 o o o o o 0O TROUBLESHOOTING GUIDE LU LU LU CD CD CD F1-94 Section G Section E * * 2 2 2 I- I— \— I * * * LO CO o> 2 ■*r co s 5 2 1— l 1 LU 1 h- l~ I LJJ 1— h- LU LU t— LL CD LL LL CQ LL CD CD Possible parts and reference page Clutch and neutral switches I Steering pressure sensor I Stoplight switch I Idle air control valve I PCME I A/C relay I PRC solenoid valve 1 Blower switch Condeser fan relay I Coolant fan relay (Nos.1, 2) I Air conditioning sensor IHeadlight switch | Rear window defroster I Main relay I Starter, Starter interlock switch I 1-1-94,95 Control system F1 OO oO oO Melts main or other fuse o Will not crank or cranks slowly No combustion O O Partial combustion — when engine cold O Partial combustion — after warm-up O Any engine temp. O When engine cold O After warm-up O Idle at any engine temp. O During fast idle O Idle after warm-up O Idle with A/C, P/S, and/or E/L ON Oo O OOO O Idle when shifted from N or P to other ranges OO Driveaway O On acceleration O O While cruising O 0 On deceleration O OO Idle at any engine temp. OO During fast idle 0 O Idle after warm-up O Idle with A/C, P/S, and/or E/L ON 00 0 00 O o Idle when shifted from N or P to other ranges On deceleration O Dffiteaway O On acceleration O High idle speed after warm-up 00 *1 1994 626/MX-6 Body Electrical Troubleshooting Manual OO O O O Item 1 2 Cranks normally but will not start 3 4 5 Cranks normally but hard to start 7 8 9 Engine stalls 10 11 12 13 14 15 16 17 18 Engine rough 19 20 21 22 23 24 Poor acceleration 25 26 27 F 1 -9 7 TROUBLESHOOTING GUIDE F1—98 o > ■O o n a) o x: i- 1 F1-92 I F1-93 I F1-90 Section G I F1-69 F1—72 I F1-62 CM CVJ CD'CO m LO m T—^ i—CO CD I I 1 1 1 1 y— I I J_ 7— T— LL LL LL LL LL LL LL LL. LL 5> I i— LL * o 05 hI L U LL CO I I I I I \ O 28 Idle fluctuates/idle hunts OooO 29 Hesitates/Stumbles on acceleration 0 30 Surges while cruising O 0 31 Lack of power O 32 Poor fuel economy 33 A/C does not work 34 Knocking/Pinging 35 Fuel odor 36 Exhaust sulfur smell 37 High oil consumption 38 Self-Diagnosis Checker flashes 88 39 MIL never ON *1 1994 626/MX-6 Body Electrical Troubleshooting Manual Emissioncontrol system Ignitionsystem Control system Air cleaner element EGR solenoid valve Purge control solenoid valve EGR control valve, EGR function control Three-way catalyst Fuel vapor valve Check valve (two-way) Charcoal canister PCV valve Distributor Igniter (in distributor) Ignition coil (in distributor) High-tension lead Spark plug Ignition tinning Mass airflow sensor Engine coolant temperature sensor Throttle position sensor Headted oxygen sensor Crankshaft position sensor Vehicle speed sensor Item Intake air ayatem ' ■ Injector I Fuel pump Fuel pump relay I Pressure regulator I Fuel filter I Air leakage I Idle speed misadjustment F1-52 in in in in in I I I T— T— Li- U_ LL F1-51 Possible parts and reference page Fuel system f I [ I | f I I I I I I I I I F1 0 o O O OO o O o O o O O ooO 0 0 O o O 0 O TROUBLESHOOTING GUIDE LL CD LL CD * ■K * 2 2 ^r G) I— I-- I— I j LU LU LU CD CD CD LL Section G * B E TM " Section E F1-46 LU CO * 00 s 2 — I LU I ILU I— | i— Possible parts and reference page I | I I I I oO | I [ I | I I | I Clutch and neutral switches Steering pressure sensor Stoplight switch Idle air control valve PCME A/C relay PRC solenoid valve Blower switch Condeser fan relay Coolant fan relay (Nos.1, 2) Air conditioning sensor Headlight switch Rear window defroster Main relay Starter, Starter interlock switch I F1-94, 95 F1-95 Control system O O oo F1 O o Idle fluctuates/idle hunts Hesitates/Stumbles on acceleration Surges while cruising Lack of power Poor fuel economy A/C does not work Knocking/Pinging Fuel odor Exhaust sulfur smell High oil consumption Self-Diagnosis Checker flashes “ 88” MIL never ON *1 1994 626/MX-6 Body Electrical Troubleshooting Manual Item 28 29 30 31 32 33 34 35 36 37 38 39 46U0F1-153 F1 TROBLESHOOTING GUIDE 0 0 O0 IDLE SWITCH o 0 o THROTTLE POSITION SENSOR o 0 CRANKSHAFT POSITION SENSOR NE SIGNAL G SIGNAL MASS AIRFLOW SENSOR ENGINE COOLANT TEMPERATURE SENSOR INTAKE AIR TEMPERATURE SENSOR HEATED OXYGEN SENSOR o 0 o AIR CONDITIONING SENSOR STEERING PRESSURE SENSOR IGNITION SWITCH (START SIGNAL) o o O OO O O 0 O o 0 0 0 O o 0 o o o o o o o o o o o o o o o o o o o 0 o o o o O o o o o o o o o o E/L SIGNAL* DATA LINK CONNECTOR (TEN TERMINAL) VEHICLE SPEED SENSOR DAYTIME RUNNING LIGHT (CANADA) EGR FUNCTION SENSOR o 0 o STOPLIGHT SWITCH NEUTRAL AND CLUTCH SWITCHES SELF-DIAGNOSIS CHECKER (MONITOR LAMP) CONTROL VALVE PRESSURE REGULATOR SOLENOID VALVE EGR SOLENOID FAN RELAY COOLANT BAC VALVE [IDLE AIR CONTROL VALVE] A/C RELAY (A/C CUT-OFF) FUEL PUMP RELAY IGNITER INPUT DEVICE FUEL INJECTION TIMING FUEL INJECTION AMOUNT INJECTOR VALVE OUTPUT DEVICE PURGE CONTROL SOLENOID 'V SELF-DIAGNOSIS CHECKER (DIAGNOSTIC TROUBLE CODE) AND MALFUNCTION INDICATOR LIGHT (MIL) RELATIONSHIP CHART o o o o o o o 0 o o o o o o 0 46U0F1-154 * E/L SIGNAL: Blower fan control switch third position or higher, headlight ON, rear window defroster ON or coolant fan ON. F 1-1 00 F1 TROUBLESHOOTING GUIDE Output devices and Engine condition \ E N G I N E CONDITION OUTPUT DEVICE IN­ JECTOR \ CRAN­ KING WAR­ MING UP (DUR­ ING IDLE) (COLD EN­ GINE) FUEL INJECTION AMOUNT COLD Rich ACCE­ LERA­ TION WARM Normal FUEL PUMP RELAY HEAVY LOAD IDLE Rich Fuel cut* Normal No Injec­ tion ON Fixed at BTDC 6° IGNITER DECE­ LERA­ TION IG: ON (EN­ GINE NOT RUNN­ ING) MEDIUM LOAD Advanced: depends on engine condition OFF ON (Purge) OFF EGR SOLENOID VALVE (EXCEPT CALIFORNIA) OFF ON* OFF EGR SOLENOID VALVE (VACUUM) (CALIFORNIA) OFF O N* (Fixed) ON* (Closed loop) O N* (Fixed) OFF EGR SOLENOID VALVE (VENT) (CALIFORNIA) ON (Fixed) OFF ON (Closed loop) OFF ON PRESSURE REGULATOR CONTROL SOLENOID VALLVE BAC VALVE OFF (Vacuum to presure regulator) ON (Closed loop duty) A/C RELAY ON (Fixed duty) OPEN AIR VALVE OFF (A/C cut) “Engine speed: Above 1,500 rpm OFF PURGE CONTROL SOLENOID VALVE IACV REMARK CLOSED ON OFF (A/C cut) 'Engine speed: 1,300— 4,500 rpm •Engine speed: 1 ,0 0 0 -4 ,2 5 0 rpm O N* OFF ON (Closed oop duty) OFF •During hot start only — ON OFF 46U0F1-155 F1-101 F1 TROUBLESHOOTING GUIDE USING THIS SECTION Introduction Most of the fuel and emission control systems are electronically controlled, often making it difficult to diag­ nose problems, especially intermittent problems. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a drivabilitiy complaint. The customer is often a good source of information on such problems, especially the intermittent ones. Through a talk with the customer, you will usually find out what the symptoms are and under what conditions they occur. Work flow CHECK IN LISTEN TO CUSTOMER COMPLAINTS REFER TO TROUBLESHOOTING PAGE THATCORRESPONDS TO ACTUAL SYMPTOM CHECK FOR WHAT IS BAD IN SYSTEM- CHECK FOR WHAT PART IS BAD- DIAGNOSTIC INDEX (Refer to page F1-104) INSPECTION ACTION REPAIR/REPLACE- — ----------DETERMINE IF TROUBLE HAS BEEN ELIMINATED No Yes[ CHECK OUT 46U0F1-156 Diagnostic index Description: symptom. F 1-102 F1 TROUBLESHOOTING GUIDE Troubleshooting chart ENGINE STA LLS DESCRIP­ TION • ID L E WITH A /C , P/S , a n d /o r E/L ON | ‘ IDLE WHEN SHIFTED FROM N OR P TO OTHER I RANGES • Engine slops unexpectedly when A/C, P/S. and/or E/L turned ON at idle • Engine stops unexpectedly when shifted from N or P to other ranges at idle • Idle condition is normal when A/C. P/S. and E/L are OFF and in N and P [TRO U BLESH O O TIN G HINTS] © Monitor switch functions (SST) • A/C sensor • Headlight switch • Rear w indow defroster • Blower switch (2> Solenoid valve (ISC) • Solenoid valve stuck INSPECTION Are switches correct when checked by using SelfDiagnosis Checker monitor lam p while ignition switch ON? r r page F 2 -4 4 • Blower switch • Headlight switch • Rear w indow defroster switch • Selector lever Go to next step Lamp not ON/OFF with specified switch C heck for cause (Refer to specified check sequence) = page F 2 -4 S SYSTEM SELECTOR ~ SE LE CT SW: A Is " 0 0 " displayed on Sell-Diagnosis Checker with ignition switch ON? r r page F 2 -1 8 16E0F1-256 DESCRIPTION: ^ Further describes the system. Confirm that the chart addresses the actual symptom before beginning troubleshooting. TROUBLESHOOTING HINTS: This describes the possible point of malfunction. STEP: This shows the order of troubleshooting. Proceed with troubleshooting as indicated. INSPECTION: This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary to perform the INSPECTION, refer to the page specified by the “ c r ” mark. ACTION: This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to per­ form the action is described on the reference page specified by the “cr " mark. 16E0F1-257 F1-103 F1 TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX TROUBLESHOOTING ITEM 1 2 3 Melts main or other fuse Will not crank or cranks slowly Cranks normal­ ly but will not start F I—107 Starter does not work Starter cranks engine at slow speed Section G Starter cranks engine at normal speed but engine shows no indication of firing F1-108 Partial combustion — when engine coldz Starter cranks engine at normal speed and engine shows indication of firing but will not run when en­ gine is cold or at initial starting Engine will not continue running when cold when ig­ nition switch is returned from STA to IG position F1-108 Starter cranks engine at normal speed and engine shows indication of firing but will not run when en­ gine is warm Engine will not continue running when warm when IGN switch is returned from STA to IG position F1-110 Partial combustion — when engine warm 5 Cranks nor­ mally but hard to s tart PAGE No combustion 4 6 D P ^ P R IP T IO N TROUBLE No. Any engine temp. Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting at any engine temperature Engine starts after stalling a few times at any engine temperature When engine cold Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting when engine is cold Engine starts after stalling a few times when engine is cold 7 F1-111 After warm-up Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting after warm-up Idle at any engine temp. Engine stops unexpectedly at any engine temp. 10 During fast idle Engine stops unexpectedly during fast-idle operation 11 Idle after warm-up Engine stops unexpectedly at idle after warm-up 12 Idle with A/C, P/S, and/or E/L ON Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle F1-116 8 9 Engine stalls 13 14 15 16 Engine rough Driveaway Engine stops unexpectedly upon driveaway F1-117 On acceleration Engine stops unexpectedly at begining of accelera­ tion or during acceleration F1-118 While cruising Engine stops unexpectedly while cruising On deceleration Engine stops unexpectedly at begining of decelera­ tion or recovery from deceleration exhaust afterburn Idle at any engine temp. Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any engine temp. Idle speed too slow and excessive engine shake at any engine temp. During fast idle Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after warm-up 17 18 Idle after warm-up 19 20 21 F 1-104 F1-113 F I—120 F1-122 Idle with A/C, P/S, and/or E/L ON Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when A/C, P/S, and/or E/L ON F1-126 On deceleration Engine shakes at begining of deceleration, during deceleration, or recovery from deceleration Exhaust afterburn F1-128 F1 TROUBLESHOOTING GUIDE TROUBLESHOOTING ITEM TROUBLE No. 22 Poor acceleration 23 24 25 26 27 28 29 30 DESCRIPTION Driveaway Engine speed increases normally but vehicle speed slowly increases during driveaway On acceleration Engine speed increases normally but vehicle speed slowly increases during acceleration PAGE F1-130 High idle speed after warm-up Idle speed continues at fast idle after warm-up Engine returns slowly to idle after acceleration is released F1-132 Idle fluctuates/idle hunts Engine speed changes back and forth between specified idle speed and higher speed F1-133 Hesitates/Stumbles on acceleration Momentary pause at begining of acceleration or dur­ ing acceleration F1-135 Surges while cruising Momentary minor irregularity in engine output at steady vehicle speed F1-138 Lack of power Performance poor under load (i.e., power down when climbing hills) F1-139 Poor fuel economy Fuel economy unsatisfactory F1-140 A/C does not work A/C compressor magnetic clutch does not engage when Air conditioning sensor F1-140 Knocking/Pinging Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in combustion chamber) F1-140 31 32 Fuel odor Gasoline fuel smell or visible leaks F1-141 33 Exhaust sulfur smell Rotten egg smell from exhaust F1-141 34 High oil consumption Oil consumption excessive F1-141 35 Self-Diagnosis Checker flashes 88 Checker flashes 88 with test connector grounded F1-141 MIL never ON Self-Diagnosis Checker indicates Diagnostic Trouble Code No. but MIL never ON F I—141 36 46U0F1-157 F 1-105 F1 Description of STUMBLE HESITATION SURGE TROUBLESHOOTING GUIDE Drivability Problems : Mildly irregular performance during acceleration. : A dip or flat spot in performance just after the accelerator pedal is depressed. : Continuous irregular performance during cruising. Fuel Pressure Release and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the en­ gine is not running. Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safe­ ty Procedures” . Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakage. 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. Install hose clamps to secure the fuel pressure gauge to the fuel filter and the main hose. F 1-1 06 F1 TROUBLESHOOTING GUIDE SYMPTOM TROUBLESHOOTING MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Check the condition of the fuse Shorted harness Deterioration Repair shorted harness and replace fuse Replace fuse FUSE Damaged Fuse Related Wiring Harness MAIN (100A) Main fuse- Alternator BTN (60A) BTN fuse- ROOM fuse ROOM (15A) ROOM fuse- EGI INJ (30A) Main relay- Injectors PCME terminal 1B Distributor PRC solenoid valve EGR solenoid valve Idle air control valve Purge control solenoid valve Mass airflow sensor ENGINE (15A) ENGINE fuse- Main relay Fuel pump relay METER (15A) METER fuse- Data link connector terminal +B WIPER (20A) WIPER fuse- Heated oxygen sensor • PCME terminal 1A 46U0F1-161 F 1-107 F1 TROUBLESHOOTING GUIDE 3 CRANKS NORMALLY BUT WILL NOT START •N O COMBUSTION • Starter cranks engine at normal speed but engine shows no indication of firing DESCRIP­ TION [TROUBLESHOOTING HINTS] © Distributor • Poor conection of connector • Open in ignition coil © Main relay • Poor connection of connector • Malfunction of relay © PCME • No IGT signal output from PCME terminal 2F to igniter (in distributor) •N o START signal from ignition switch (Open in PCME 1C terminal circuit) C7- Section G c r page F1-94 c r Section G 46U0F1-162 4 CRANKS NORMALLY BUT WILL NOT START DESCRIP­ TION WHEN ENGINE COLD • Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is cold at initial starting • Engine will not continue running when cold when ignition switch is returned from STA to IG position • Refer to "ENGINE STALLS” if this symptom appears after engine stalls • Fuel in tank • Battery in terminal condition [TROUBLESHOOTING HINTS] © BAC valve • Malfunction of air valve • Idle air cintrol valve stuck © Injector • Poor connection © Fuel pump relay •Poor connection © Fuel pump • Poor connection of connector © Distributor • Cap and/or rotor damaged «Poor connection of connector © Mass airflow sensor • Poor connection of connector © PCME «No START signal from ignition switch (Open in PCME 1C terminal circuit) INSPECTION STEP 1 •PARTIAL COMBUSTION - Is “ 00” displayed on SST with ignition switch ON? c r page F1-18 ACTION Yes “ 00” or displayed Go to next step SYSTEM SELECTOR No MONITOR LAMP c r page F1-20 SELECT SW: A 2 Does engine start when throttle valve held Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) “ 88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Yes Check air valve operation q uarter open? c r page F1—46 No F 1-1 08 Go to next step TROUBLESHOOTING GUIDE STEP INSPECTION 3 ACTION Do Engine Signal Monitor lamps flash for specified terminals while cranking engine? c r pages F1-86 F1-88 Yes Go to next step No Check as follows according to results: Does not flash and OV indicated for individual terminals • Continuity of injector •Continuity between PCME and in­ jectors) • Condition of injector connector and PCME connector female terminals Repair or replace parts and/or wir­ ing harness as necessary Terminal: 2U, 2V, 2Y, 2Z 4 Connect jumper w/ire betweer F/P and GND terminals of data link COnnector; will engine start? • m GND F/P \m j f — jj \ DATA LINK \ CONNECTOR No t f I 5 Yes \ M / V \ . Check as follows: •1H terminal voltage at PCME • Continuity between 1H terminal and fuel pump relay connector terminal •Condition of PCME and fuel pump relay connector female terminals Check if fuel pump operating sound is heard • If yes, go to next step • If no, check fuel pump and wiring harness c r page F1-82 c r page F1-52 _ Are mass airflow sensor terminal voltage at PCME correct? c r pages F1-86 Yes Go to next step No Check as follows: • Ground of mass airflow sensor • Continuity between mass airflow sensor and PCME connector • Condition of mass airflow sensor and PCME connector female ter­ minals Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure 2 0 terminal: 1.0—1.5V (Ign. ON) 1.5—5.0V (Engine running) 6 F1 Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure correct with ignition switch ON? c r page F1-49 Fuel line pressure: 260—320 kPa (2.7—3.3 kgf/cm2, 37—46 psi) cr page F1-55 cr page F1-53 F1-109 F1 TROUBLESHOOTING GUIDE INSPECTION STEP Is a strong blue spark visible at each disconnect­ ed high-tension lead while cranking engine? 7 8 Are injectors OK? • No fuel leakage • Injectors not clogged ACTION Yes Go to next step No Check as follows • Distributor cap and rotor • High-tension leads Yes Go to next step No Replace injector(s) c r Section G c r Section G c r page F1-58 c r page F1-57 c r page F1-57 9 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-163 5 DESCRIP­ TION CRANKS NORMALLY BUT WILL NOT START •PARTIAL COMBUSTION — AFTER WARM UP • Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is warm • Engine will not continue running when ignition switch is returned from STA to IG position [TROUBLESHOOTING HINTS] © Pressure regulator • Hold fuel pressure low © Throttle body • Carbon ON throttle valve c r page F1-56 c r page F1 -4 3 46U0F1-164 F 1-1 10 TROUBLESHOOTING GUIDE 6, 7, 8 DESCRIP­ TION CRANKS NORMALLY BUT HARD TO START •ANY ENGINE TEMP •WHEN ENGINE COLD •AFTER WARM-UP • Starter cranks engine at normal speed but engine requires excessive cranking time before starting • Engine starts after stalling a few times • Battery in normal condition • Engine runs normally at idle (if idle condition not OK, refer to “ Rough idle” [Nos. 19—23]) [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Fuel pump • Malfunction of pump © Pressure regulator • Pressure regulator stuck © Spark plug • Dirty or worn spark plug(s) © PRC solenoid valve • PRC solenoid valve © Throttle body • Carbon on throttle plate STEP F 1 © EGR solenoid valve • Solenoid valve stuck © EGR control valve •EGR control valve stuck © EGR function control (Except California) • EGR function control stuck ©PCME • No START signal from ignition switch (Open in PCME 1C terminal circuit) INSPECTION ACTION Is “ 00” displayed on SST with ignition switch ON? c r page F1-18 Yes “ 00” displayed Go to next step SYSTEM SELECTO R No 49 H 018 9A1 MONITOR-#--? L A M P -5 .^ Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F1-20 S E L E C T SW : A "8 8 ” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure correct with ignition switch ON? c r page F1-49 Fuel line pressure: 260—320 kPa (2.6—3.3 kgf/cm2, 37—46 psij DATA LINK CONNECTOR Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator c r page F1-55 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F1-53 F1-111 F1 TROUBLESHOOTING GUIDE INSPECTION STEP 3 Is fuel line pressure held after ignition switch turned OFF? c r page F1-48 Fuel line pressure: More than 150 kPa [1.5 kgf/cm2, 21 psi) for 5 min. 4 5 Is throttle body clean internally? Disconnect vacuum hose from EGR valve and plug it; does condition improve? EGR CONTROl' ^ ^ E ^ ^ ^ ^ ^ 6 ACTION Yes • If symptom occurs at any engine temp., go to Step 6 • If symptom occurs when engine cold, go to next step • If symptom occurs after warm-up, go to Step 6 No Plug outlet of pressure regulator, Is fuel line pressure held after ignition switch turned OFF? • If yes, replace pressure regulator • If no, check fuel pump hold pressure If fuel pump OK, check injectors for fuel leakage Yes Clean throttle body No Go to next step Yes Check as follows: • EGR solenoid valve for sticking • Condition of solenoid valve connector female terminal(s) • EGR function control for sticking (Except California) No Check if EGR control valve moves smoothly • If yes, go to next step •If no, replace EGR valve c r page F1-48 c r page F1-56 c r page F1-52 c r page F1-58 c r page F1-65 c r page F1-65 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-165 F 1-112 F1 TROUBLESHOOTING GUIDE 9, 10, 11 ENGINE STALLS •IDLE AT ANY ENGINE TEMP •DURING FAST IDLE •IDLE AFTER WARM-UP • Engine stops unexpectedly at idle and/or during fast idle operation DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged @ Fuel pump • Maximum pressure low (3 ) Fuel pump relay • Poor connection of connector @ Air leakage in intake air system (D Distributor • Cap and/or rotor damaged • Poor connection of connector © Mass airflow sensor • Poor connection of connector @ Engine coolant temperature sensor • Poor connection of connector STEP __________________ INSPECTION_________ Is "0 0 ” displayed on SST with ignition switch ON? c r page F1-18 SYSTEM SELECTOR (8) EGR control valve • EGR control valve stuck (D BAC valve • Air valve stuck @ EGR function control (Except California) • EGR modulator valve stuck ACTION Yes ‘00” displayed * If symptom occurs at idle at any engine temp., go to next step * If symptom occurs during fast idle operation, go to Step 8 *lf symptom occurs at idle after warm-up, go to Step 9 No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H018 9A1 c r page F1-20 c r Section G Section G “ 88” flashes Refer to ” No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” SELECT SW: A No indication at all Refer to "No.39 SELF-DIAGNOSIS CHECKER WILL NOT WORK" Do Engine Signal Monitor lamps flash for specified terminals while cranking engine? c r pages F1-86 F1-88 Yes Go to next step No Check as follows according to results: Do not flash and OV indicated for in­ dividual terminal(s) • Continuity of injector(s) • Continuity between PCME and injector(s) • Condition of injection connector and PCME connector Repair or replace parts and/or wiring harness as necessary Yes Go to next step No Check as follows; • Distributor cap and rotor • High-tension lead(s) Terminal: 2U, 2V, 2Y, 2Z Is strong blue spark visible at each disconnected high-tension lead while cranking engine? c r F1 TROUBLESHOOTING GUIDE 4 ACTION INSPECTION STEP Connect jumper w ire between F/P and GND terminal of data link con nector; will engine run? Yes Check as follows: • 1H terminal voltage, at PCME c r page F1-82 • Continuity between 1H terminal and fuel pump relay connector terminal • Condition of PCME and fuel pump re­ lay connector female terminals No Check if fuel pump operating sound is heard? • If yes, go to next step • If no, check fuel pump circuit Yes Go to next step No Low pressure Check fuel line pressure while pinch­ ing fuel return hose • If pressure quickly increases, check pressure regulator c r page F1-55 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F1-53 Yes Repair or replace No Go to next step Yes Go to Step 9 No Check for cause Yes Check as follows: • Operation of air valve • Operation of EGR control valve \ UNU -— 5 h/K J ^ 4 \\\ DATA LINK CONNECTOR iftr Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? c r page F1-49 Fuel line pressure: 270—310 kPa (2.7—3.2 kgf/cm2, 39—46 psi) 6 7 Is air leakage felt or heard at intake air system com­ ponents while racing engine to higher speed? Is engine compression correct? c r Section B1 Engine compression (Minimum): 820 kPa (8.4 kgf/cm2, 120 psi)-300 rpm 8 Does engine start with throttle valve held quarter open? • Operation of EGR function control (Except California) 9 Does following terminal voltage at PCME increase smoothly? c r page F1-86 Terminal 2Q voltage: Approx. 0.5—2.5V F 1-1 14 No Go to next step Yes Go to next step No Check as follows: • Ground of engine coolant temperature sensor • Continuity between engine coolant temperature sensor and PCME con­ nector • Condition of engine coolant temperature sensor and PCME connector female terminals c r Section B1 c r page F1-46 c r pages F1-65 F1-67 c r page F1-65 TROUBLESHOOTING GUIDE STEP 10 INSPECTION Are spark plugs OK? WEAR AND CARBON PLUG GAP ACTION Yes »lf symptom occurs at any engine temp., go to Step 14 • If symptom occurs fast idle opera­ tion, go to Step 14 ►If symptom occurs at idle after warmup, go to next step No Clean or replace Yes Go to next step No Replace BAC valve cr page F1-42 Yes Replace BAC valve cr page F1-42 No Reinstall BAC valve and go to next step Yes Go to next step No Check as follows; • Poor connection of engine coolant temperature sensor connector Yes Go to next step No Replace injector(s) cr Section G BURNT DAMAGE AND DETERIORATION F1 cr Section G DAMAGE 11 Is resistance of idle air control valve correct? cr page F1-46 Resistance: 7.7—9.30 (at 20°C (6 8 °F )) BAC VALVE 12 13 Try a known good BAC valve; does condition im­ prove? Is the heated oxygen sensor operation OK? cr page F1-93 MEASURING TERMINAL 14 15 Are injectors OK? •N o fuel leakage • Injectors not clogged cr page F1-58 cr page F1-57 cr page F1-57 Try a known good PCME; does condition improve? cr page F1-81 46U0F1-166 F1 TROUBLESHOOTING GUIDE ENGINE STALLS 12 DESCRIP­ TION •IDLE WITH A/C, P/S, and/or E/L ON • Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle • Idle condition is normal when A/C, P/S, and E/L are OFF [TROUBLESHOOTING HINTS] © Monitor switch functions (SST) • Air conditioning sensor • Headlight switch • Rear window defroster • Blower switch (2) Idle air control valve • Solenoid valve stuck ACTION INSPECTION STEP Are switches correct when checked by using SST monitor lamp or indicator while ignition switch ON? c r page F1-38 • • • • Yes Go to next step No Lamp not ON/OFF with specified switch Check for cause (Refer to specified check sequence) c r page F1-39 Yes “ 00” displayed Blower switch Headlight switch Rear window defroster switch Air conditioning sensor Is "0 0" displayed on SST with ignition switch ON? c r page F1-18 Go to next step SYSTEM SELECTOR No 49 H 018 9A1 MONITOR'/ Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F1-20 - j ^ L A M P HjL- “ gg” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES "88” SELECT SW: A Is terminal voltage at PCME correct at idle? Yes Check BAC valve and replace c r page F1-46 No Try a known good PCME and check if condition improves c r page F1-81 c r p a g e F 1 —8 8 2W terminal: £ vs 46U0F1-167 F 1-1 16 F1 TROUBLESHOOTING GUIDE 13 ENGINE STALLS DESCRIP­ TION * DRIVEAWAY • Engine stops unexpectedly upon driveaway • Idle condition normal [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged © Pressure regulator • diaphragm damaged © Fuel filter • Fuel filter clogged @ Distributor • Poor connection of connector • Cap and/or rotor damaged INSPECTION STEP Is “ 00" displayed on SST with ignition switch ON? cr page F1-18 © Engine coolant temperature sensor • Poor connection of connector ACTION Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H01 8 9A1 MOS cr page F1-20 | f y SELECT SW: A Using Engine Signal Monitor, do voltage reading and lamp operation change as follows upon driveaway? c r page F1-81 Terminal 20 2Q 2U, 2V, 2Y, 2Z Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) Condition Voltage gradually increases Do not suddenly change voltage Flashing of green and red lamps becomes quicker Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? cr page F1-49 “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88" Yes Go to next step No Check as follows: • Condition of female terminals in related connector • Continuity between injector connector and PCME connector Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator cr page F1-55 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure cr page F1-53 Yes Try a known good PCME; does condi­ c r page F1-81 tion improved? No Replace injector Fuel line pressure: 260—-32QkPa (2.6—3 .3 kgf/cm2, 37—46 psi) INSTALL CLANMPS Are injectors OK? • No fuel leakage • Injectors not clogged cr page F1-58 cr page F1-57 cr page F1-57 46U0F1-168 F 1 TROUBLESHOOTING GUIDE 14, 15 ENGINE STALLS *ON ACCELERATION/WHILE CRUISING • Engine stops unexpectedly at beginning of acceleration or during acceleration DESCRIP­ TION • Engine stops unexpectedly while cruising [TROUBLESHOOTING HINTS] © Fuel pump © © INSPECTION STEP 1 © Mass airflow sensor • Poor connection of connector © Main relay • Poor connection of connector • Poor connection Pressure regulator • Diaphragm damaged Distributor • Poor connection of connector • Cap and/or rotor damaged Is "00" displayed on SST with ignition switch ON? c r page F1-18 ACTION Yes “ 00" displayed Go to next step SYSTEM SELECTOR No 1 MONITOR LAMP c r page F1-20 SELECT SW: A 2 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? <<gg” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES "88" Yes Check spark plugs c r Section G => If OK, go to next step ==> If not OK, clean or replace spark plug No y 3 4 1 Are mass airflow sensor connector terminals and connection good? c r page F1-90 Ground terminal F/P of data link connector with ig­ nition switch ON; is operation sound of fuel pump heard? GND F 1-1 18 \ \ \\ \ A k v |\\ F/P J ,[ W \DATA LINK \ Check as follows: • Distributor cap and rotor • High-tension leads • Condition of distributor connector female terminals Yes Go to next step No Repair connector terminal(s) Yes Go to next step No Check as follows: • Poor connection of fuel pump relay • Poor connection of fuel pump con- c r Section G c r Section G nector • Melted EGI INJ fuse (30A) c r page F1-107 Refer to "No.1 - MELTS MAIN OR OTHER FUSE" • Poor connection of main relay •Operation of main relay cr page F1-94 F1 TROUBLESHOOTING GUIDE STEP 5 INSPECTION Is fuel line pressure correct at idle? cr page F1-55 Fuel line pressure: 210—250 kPa [2.1—2.6 kgf/cm2, 30—36 psi) ACTION Yes Go to next step No Check pressure regulator cr page F1-55 Fuel line pressure: 260—320 kPa (2.6—3.3 kgf/cm2, 37—46 psi) 6 Try a known good PCME; does condition improve? cr page F1-81 46U0F1-169 F1 TROUBLESHOOTING GUIDE 16 DESCRIP­ TION •ON DECELERATION ENGINE STALLS • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration • Exhaust afterburn [TROUBLESHOOTING HINTS] © Fuel pump • Poor connection of connector © Idle speed • Idle speed too low © Distributor • Poor connection of connector @ Mass airflow sensor • Poor connection of connector © Idle air control valve • Solenoid valve stuck © EGR control valve • Solenoid valve stuck • EGR control valve stuck © EGR function control (Except California) • EGR function control stuck ACTION INSPECTION STEP Connect System Selector to data link connector and set test switch to SELF TEST; is idle speed correct after warm-up? cr page F1-16 Yes Go to Step 3 No Remove System Selector and Go to next step Yes Check as follows; • Circuit from idle air control valve to PCME for open and short c r page F1-81 • Idle air control valve for sticking c r page F1-46 No Adjust idle speed Yes “ 00” displayed Idle speed: 650—750 rpm DATA LINK CONNECTOR Does idle speed drop in following conditions? Condition • Electrical load ON • Air conditioner ON • P/S operating Is “ 00” displayed on SST with ignition switch ON? cr page F1-18 cr page F1-16 Go to next step SYSTEM SELECTOR No 49 H018 9A1 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) cr page F1-20 SELECT SW: A F 1-120 ‘88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” F1 TROUBLESHOOTING GUIDE STEP INSPECTION Are switch operation correct when checked by using SST monitor lamp or indicator while ignition switch ON? c r page F1-38 ACTION Yes Go to next step No Check for caused (Refer to specified check sequence) c r page F1-39 Are mass airflow sensor connector terminals and connection good? Yes Go to next step No Repair connector terminal Are following terminals and connections good? • Distributor connector • Fuel pump connector • Main relay •PCME connector Yes Go to next step No Repair connector terminal Disconnect vacuum hose from EGR control valve and plug it; does condition improve? Yes Check as follows: • EGR solenoid valve • Condition of solenoid valve connec­ tors female terminals • EGR function control for sticking (Except California) No Go to next step Try a known good PCME; does condition improve? c r page F1-81 ± 46U0F1-170 F1 TROUBLESHOOTING GUIDE 17, 18, 19 DESCRIP­ TION ENGINE ROUGH •IDLE AT ANY ENGINE TEMP/DURING FAST IDLE/IDLE AFTER WARM-UP • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any engine temp. •Idle speed too slow and excessive engine shake at any engine temp. • Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after warm-up [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged © Fuel pump • Maximum pressure low © Fuel pump relay • Poor connection of connector @ Air leakage • Leakage in intake air system © Distributor • Cap and/or rotor damaged • Poor connection of connector © Mass airflow sensor • Poor connection of connector © Engine coolant temperature sensor • Poor connection of connector © EGR control valve • EGR control valve stuck © EGR function control (Except California) • EGR function control stuck © BAC valve • Air valve stuck ACTION INSPECTION STEP Is “ 00" displayed on SST with ignition switch ON? c r page F1-18 SYSTEM SELECTOR Yes “ 00” displayed • If symptom occurs at idle at any engine temp., go to next step • If symptom occurs during fast idle operation, go to Step 6 • If symptom occurs at idle after warmup, go to Step 7 No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) cr 49 H 0 1 8 9A1 page F1-20 <<88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88" SELECT SW: A No indication at all Refer to “ No.39 SELF-DIAGNOSIS CHECKER WILL NOT WORK” Do Engine Signal Monitor lamp flash for speci­ fied terminals while cranking engine? c r pages F1-86 F1-88 Terminal: 2U, 2V, 2Y, 2Z F 1-122 Yes Go to next step No Check as follows according to results; Do not flash and OV indicated for individual terminal(s) • Continuity of injector(s) c r page F1-59 • Continuity between PCME and injector(s) • Condition of injector connector and PCME connector Repair or replace parts and/or wiring harness as necessary F1 TROUBLESHOOTING GUIDE STEP 3 4 INSPECTION Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure correct with ignition switch ON? c r page F1-49 ACTION Yes Go to next step No Check distributor cap and rotor Check as follows; • Distributor cap and rotor • High-tension lead(s) Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure Fuel line pressure: 260—320 kPa (2.6—3.3 kgf/cm2, 37—45 psi) 5 6 Is there air leakage at intake air system components while racing engine to higher speed? Is engine compression correct? c r Section B1 Engine compression (minimum): 820 kPa (8.4 kgf/cm2, 120 psi)-300 rpm Yes Repair or replace No Go to next step Yes Go to next step No Check for cause c r Section G c r Section G c r page F1-55 c r page F1-53 c r Section B1 F1 TROUBLESHOOTING GUIDE ACTION INSPECTION STEP Connect engine signal monitor to PCME and set the position 2Q Does following terminal voltage in PCME increase smoothly? c r page F1-86 Yes Go to next step No Check as follows: • Ground of engine coolant temperature sensor • Continuity between engine coolant temperature sensor and PCME connector • Condition in engine coolant temperature sensor and PCME conncetor female terminals Terminal 2Q voltage: Approx. 0.5—2.5V Yes • If symptom occurs at any engine temp., go to Step 12 • If symptom occurs during fast idle operation, go to Step 12 • If symptom occurs at idle after warmup, go to next step No Clean or replace Is resistance of idle air control valve correct? Yes Go to next step Resistance: 7.7—9.30 (at 20°C (6 8 °F |) No Replace BAC valve c r page F1-42 Yes Replace BAC valve c r page F1-42 No Reinstall BAC valve Go to next step Are spark plugs OK? c r Section G BAC VALVE 10 Try a known good BAC valve; does condition improve? F 1-124 F1 TROUBLESHOOTING GUIDE STEP 11 12 13 INSPECTION Is heated oxygen sensor operation correct? c r page F1-93 Are injectors OK? • No fuel leakage • Injectors not clogged c r c r page F1-58 page F1-57 ACTION Yes Go to next step No Replace heated oxygen sensor Yes Go to next step No Replace injector c r page F1-57 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-171 F1 TROUBLESHOOTING GUIDE ENGINE ROUGH 20 DESCRIP­ TION •IDLE WITH A/C, P/S AND/OR E/L ON • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when A/C, P/S and/or E/L ON [TROUBLESHOOTING HINTS] © Idle speed • Idle speed too low © Monitor switch function (SST) • Air conditioning sensor • Headlight switch • Rear window defroster switch • Blower switch • Coolant fan relay • Stoplight switch © Idle air control valve • Solenoid valve stuck INSPECTION STEP Correct System Selector to diagnosis connector and set test switch to SELF TEST; is idle speed correct after warm-up? c r page F1-16 ACTION Yes Go to next step No Adjust idle speed and go to next step c r page F1-16 Yes “ 00” displayed Idle speed: 650—750 rpm Is “ 00” displayed on SST with ignition switch ON? c r page F1-18 Go to next step SYSTEM SELECTOR No 49 H 018 9A1 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F1-20 SELECT SW: A **88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Are switches correct when checked by using SelfDiagnosis Checker monitor lamp with ignition switch ON? c r page F1-38 • • • • • • BO MONITOR BB SCLECTSV COO [01* F 1-1 26 Go to next step No Check for cause (Refer to specified check sequence) c r page F1-39 Air conditioning sensor Headlight switch Rear window defroster switch Blower switch Coolant fan relay Stoplight switch AO Yes F1 TROUBLESHOOTING GUIDE B +: Battery positive voltage STEP 4 INSPECTION ACTION Is following terminal voltage at PCME correct? Terminal 1P: B + (steering wheel turned fully) OV (steering wheel In straight-ahead position) 5 Warm-up engine Does idle speed change when idle air control valve connector disconnected? BAC 6 Yes Go to next step No Check as follows: • Wiring harness between steering pressure sensor and PCME terminal 1P for open circuit Yes Go to next step No Check idle air control valve for sticking c r page F1-46 Yes Check as follows: • Malfunction of A/C relay ; Does air conditioner operate continuously with ignition switch ON and A/C switch and blower switch OFF? c r 1994 626/MX-6 body electrical troubleshoot­ ing manual section G • Wiring harness between A/C relay and PCME terminal 1J for short circuit c r page F1-82 No 7 Go to next step Try a known good PCME; does condition improve? c r page F1-81 46U0F1-172 F 1 TROUBLESHOOTING GUIDE 21 DESCRIP­ TION ENGINE ROUGH *ON DECELERATION • Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration • Exhaust afterburn [TROUBLESHOOTING HINTS] © Fuel pump • Poor connection of connector © Injector • Fuel leakage from injector(s) © Idle speed • Idle speed too low ACTION INSPECTION STEP 1 @ Distributor • Poor connection of connector © Mass airflow sensor • Poor connection of connector © Idle air contol valve • Solenoid valve stuck Connect System Selector to data link connector and set test switch to SELF TEST; is idle speed correct after warm-up? c r page F1-16 Yes Go to Step 3 No Remove System Selector and go to next step Yes Adjust idle speed Idle speed: 650—750 rpnn l ~ ~ Z // f ----------2 1 1 ATA LINK C ONNECTOR / Does idle speed drop in following conditions? Condition: • Electrical load ON • Air conditioner ON • P/S operating c r page F1-16 No Check as follows: • Wiring harness from idle air control valve to PCME for short and open circuit • Idle air control valve stuck 3 Is "00” displayed on SST with ignition switch ON? c r page F1-18 Yes c r page F1-81 c r page F1-46 “ 00” displayed Go to next step SYSTEM SELECTOR S rS ) M O N IT O R ^ L A M P -i ps: SELECT SW: A No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F1-20 “ 88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88" F1 TROUBLESHOOTING GUIDE STEP INSPECTION Are switches correct when checked by using SelfDiagnosis Checker monitor lamp with ignition switch ON? c r page F1-38 ACTION Yes Go to next step No Check for caused (Refer to specified check sequence) c r page F1-39 Is there fuel leakage from injector nozzles or injector holder? c r page F1-58 Are mass airflow sensor connector terminal and connection condition good? Are following connections good? •Distributor connector • Fuel pump connector • Main relay • PCME connector Yes Reinstall or replace injector No Go to next step Yes Go to next step No Repair connector terminal Yes Go to next step No Repair connector terminal c r page F1-57 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-173 F1 TROUBLESHOOTING GUIDE 22, 23 DESCRIP­ TION •DRIVEAWAY •ON ACCELERATION POOR ACCELERATION • Engine speed increases normally but vehicle speed slowly increases during driveaway or acceleration [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Pressure regurator • Pressure regulator malfunction © Fuel filter • Clogged filter © Distributor • Poor connection of connector • Cap and/or rotor damage © Mass airflow sensor • Poor connection of connector ACTION INSPECTION STEP Is "00” displayed no SST with ignition switch ON? c r page F1-18 Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H 018 9A1 MONITOR'/ LAMP SELECT SW: A Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Is connection of mass airflow sensor connector OK? Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) page F1-20 c r Section G Section G *<gg” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Yes Check spark plugs ^ If OK, go to next step =*> If not OK, clean or replace spark plug No Check as follows: • Distributor cap and rotor • High-tension lead(s) • Condition of distributor connector femals terminals Yes No Go to next step Repair terminal Is intake manifold vacuum correct at idle? Yes Go to next step Vacuum: More than 60.0 kPa{450 mmHg, 17.7 inHgj No Check as follows: • Intake air system components and installation • Vacuum hoses for disconnection and damage F1—130 c r c r F1 TROUBLESHOOTING GUIDE STEP 5 INSPECTION Is fuel line pressure correct at idle? c r page F1-55 Fuel line pressure: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi) 6 ACTION Yes Go to next step No Low pressure Check as follows: • Fuel filter for clogging • Operation of pressure regulator • Fuel leakage from injector (s) c r page F1-55 c r page F1-58 Try a known good PCME; does condition improved? c r page F1-81 46U0F1-174 F1 TROUBLESHOOTING GUIDE 24 DESCRIP­ TION HIGH IDLE SPEED AFTER WARM-UP • Idle speed continues at fast idle after warm-up • Engine returns slowly to idle after accelerator is released [TROUBLESHOOTING HINTS] © Engine coolant temoerature sensor • Poor connection of connector © Throttle position sensor • Poor connection of connector • Incorrect adjustment (3) BAC valve • Idle air control valve or air valve stuck ACTION INSPECTION STEP Is ‘'00” displayed on SST with ignition switch ON? c r page F1-18 Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H01 8 9A1 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F1-20 SELECT SW: A •<88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Yes Check condition of engine coolant temperature sensor (CIS) and throttle position sensor connector female terminals <=> If OK, go to next step <=> If not OK, repair the female connector No Check if idle air control valve or air valve stuck If OK, go to Step 4 => If not OK, replace BAC valve Is following terminal voltage at PCME correct? Yes Go to next step Terminal 2M: 0.1—1.1V (throttle valve closed throttle position) 3.1—4.4V (throttle valve wide open throttle) No Replace throttle body Connect System Selector to the data link connector and set system select to position 1 Does idle speed down with the test switch SELF-TEST? 49 B0 1 9 9A0 DATA LINK CONNECTOR c r page F1-42 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-175 F1-132 F1 TROUBLESHOOTING GUIDE B + : Battery positive voltage 25 IDLE FLUCTUATES IDLE HUNTS • Engine speed changes back and forth between specified idle speed and higher speed DESCRIP­ TION [TROUBLESHOOTING HINTS] © PCV valve • PCV valve stuck © Spark plug • Spark plug(s) damaged STEP (D Idle air control valve •Solenoid valve stuck INSPECTION Is "00” displayed on SST with ignition switch ON? c r page F1-18 ACTION Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H 0 18 9A1 MONITORS LAMP i . SELECT SW: A Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) Yes Go to next step Terminal 1N: Below 1.0V (accelerator pedal released) B+ (accelerator pedal depressed) No Check as follows: • Wiring harness from idle switch to PCME for short and open circuit Replace throttle body if necessary 49 B 0 19 9 A0 page F1-20 c r page F1-42 “ 88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88" Is following terminal voltage at PCME correct? Connect System Selector to data link connector and set system select to position 1 Does idle hunting stop when test switch to SELF-TEST? c r Yes Check as follows: • Idle air control valve for sticking • Poor sealing between throttle body and BAC valve No Go to next step DATA LINK CONNECTOR F 1-133 F1 TROUBLESHOOTING GUIDE 4 5 ACTION INSPECTION STEP Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Is PCV valve stuck? Yes Check spark plug(s) => If OK, go to next step •=> If not OK, replace spark plug(s) No Check as follows: • Distributor cap and rotor for damage c r Section G Yes Replace PCV valve No Go to next step c r page F1-69 6 Try a known good PCME; does condition improve? c r page F1-81 46U0F1-176 F 1-1 34 TROUBLESHOOTING GUIDE 26 F 1 • HESITATES • STUMBLES ON ACCELERATION • Momentary pause at begining of acceleration or during acceleration DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Fuel pump • Poor connection of connector © Pressure regulator • Pressure regulator stuck © E G R control valve • EGR control valve stuck © EGR function control (Except California) • EGR modulator valve stuck © EGR solenoid valve • Solenoid valve stuck STEP © Distributor • Poor connection of connector • Cap and/or rotor damage © High-tension lead(s) • Lead(s) damaged © Mass airflow sensor • Poor connection of connector © Throttle position sensor • Poor connection of connector INSPECTION Is "00” displayed on SST with ignition switch ON? cr page F1-18 ACTION Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H 018 9A1 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) cr page F1-20 SELECT SW: A “ 88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Is strong blue spark visible at each disconnected high-tension lead? Is fuel line pressure correct at idle? c r page F1-55 Fuel line pressure: 2 1 0 — 21 kPa (2.1—2.7 kgf/cm2, 3 0 - 3 8 psi) Yes Go to next step No Check as follows: • Distributor cap and rotor for damage cr Section G • High-tension lead(s) for damage cr Section G •Condition of distributor and PCME connectors female terminals Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure cr page F1-55 c r page F1-53 INSTALL CLANMPS F 1-135 F1 TROUBLESHOOTING GUIDE 4 ACTION INSPECTION STEP Does fuel pressure increase when throttle valve opened? Yes Go to next step No Check pressure regulator C7- page F1-55 5 Yes Check as follows: • EGR solenoid valve for sticking • Condition of solenoid valve connectors female terminals • EGR function control for sticking (Except California) No Go to next step Is following terminal voltage at PCME correct? Yes Go to next step 2 0 terminal: Approx. 1.0—1.5V (Ign switch ON) Approx. 1.5—5V (engine running) c-c r page F1-86 No Check condition of mass airflow sensor and PCME connectors female terminals • If OK, replace mass airflow sensor • If not OK, repair female terminal Disconnect vacuum hose from EGR valve and plug it; does condition improve? EGR C O N TR O L --------v a lv e 6 F 1-1 36 y y F1 TROUBLESHOOTING GUIDE STEP 7 INSPECTION Is following terminal 2F voltage at PCME correct? Terminal 2M: 0.1— 1.1V (throttle valve closed throttle position) 3.1—4.4V (throttle valve wide open throttle) 8 Is there fuel leakage from injector(s) ACTION Yes Go to next step No Check the female terminal condition in throttle postion sensor connector and PCME connector • If OK, replace throttle position sensor cr page F1-42 •If not OK, repair female terminal Yes Check as follows: • Poor installation of injector cr page F1-57 No 10 Go to next step Try a known good PCME; does condition improve? cr page F1-81 46U0F1-177 F1 TROUBLESHOOTING GUIDE 27 SURGES WHILE CRUISING 'Momentary minor irregularity in engine output at steady vehicle speed DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Poor connection of connector © Spark plug • Spark plug(s) damaged © Mass airflow sensor • Poor connection of connector ACTION INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? c r page F1-18 Yes “ 00” displayed Go to next step SYSTEM SELECTOR No 49 H 0 1 8 9 A 1 M O N IT O R _T” L A M P - c r S E L E C T SW : A Does the mass airflow sensor operate correctly? c r page F1-90 Does idle become rough when shaking connector of injector? F 1-1 38 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” Yes Go to next step No Check as follows: • Condition of mass airflow sensor and PCME connectors female terminals Yes Check as follows: • Condition of injector and PCME connectors female terminals No Go to next step page F1-20 TROUBLESHOOTING GUIDE INSPECTION STEP 4 Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? 5 F 1 ACTION Yes Check spark plug(s) for damage ■=> If OK, go to next step => If not OK, replace spark plug(s) No Check as follows: • Distributor cap and rotor for damage c r Section G Try a known good PCME; does condition improve? c r page F1-81 46U0F1-178 28 LACK OF POWER • Performance poor under load (i.e., power down when climbing hills) DESCRIP­ TION [TROUBLESHOOTING HINTS] © Mass airflow sensor • Poor connection of connector © Intake air temperature sensor Poor connection of connector © Distributor • Damaged distributor cap or rotor © Injector • Injector harness shorted to ground © Fuel filter • Clogged filter © Air cleaner element • Clogged element © Three-way catalyst • Clogged three-way catalyst cr Section G cr page F1-15 c r page F1-62 46U0F1-179 F1 29 TROUBLESHOOTING GUIDE POOR FUEL ECONOMY • Fuel economy unsatisfactory DESCRIP­ TION [TROUBLESHOOTING HINTS] © A ir leakage • Poor installation of air intake hose, throttle body, intake manifold, EGR control valve and/or EGR function control • Vacuum hose damaged or disconnected © Heated oxygen sensor • Open in harness (Code No. 15 output) cr page F1-93 © Pressure regulator • Hold fuel pressure high c r page F1-56 • Vacuum hose disconnected or damaged 46U0F1-18Q 30 A/C DOES NOT WORK • A/C compressor magnetic clutch does not engage with air conditioning sensor ON DESCRIP­ TION [TROUBLESHOOTING HINTS] © A/C relay • Poor connection of connector • Relay malfunction cr 1994 626/MX-6 body electrical trobleshootlng manual Section G © Air conditioning sensor • Does not send signal to PCME terminal 1Q ©PCME • Does not send signal to A/C relay with ignition switch ON cr page F1-84 cr 1994 626/MX-6 body electrical trobleshootlng manual Section G 46U0F1-181 31 DESCRIP­ TION • KNOCKING • PINGING • Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in combustion chamber) [TROUBLESHOOTING HINTS] © Ignition timing • Incorrect ignition timing © Carbon deposits in cylinder • Carbon deposits in cylinder sensor cr Section B1 36U0F1-283 F 1-1 40 TROUBLESHOOTING GUIDE 32 F1 FUEL ODOR • Gasoline fuel smell or visible leaks DESCRIP­ TION [TROUBLESHOOTING HINTS] © Purge control solenoid valve • Open or short in harness (Code No.26 output) © Charcoal canister • Canister full of fuel and leaking c r page F1-71 46U0F1-182 33 EXHAUST SULFUR SMELL • Rotten egg smell (sulfur) from exhaust DESCRIP­ TION [TROUBLESHOOTING HINTS] High sulfer content fuel used 36U0F1-285 34 HIGH OIL CONSUMPTION • Oil consumption excessive DESCRIP­ TION [TROUBLESHOOTING HINTS] PCV valve • PCV valve stuck open c r page F1-69 46U0F1-183 35 SELF-DIAGNOSIS CHECKER FLASHES “ 88” • Checker flashes 88 with test terminal (TEN) grounded DESCRIP­ TION [TROUBLESHOOTING HINTS] © Short circuit in wiring between data link connector terminal FEN and PCME terminal 1F © PCME • PCME malfunction c r page F1-81 46U0F1-184 36 MIL NEVER ON • Self-Diagnosis Checker indicates Service Code No. but MIL never ON DESCRIP­ TION [TROUBLESHOOTING HINTS] © W irin g harness between PCME 1E terminal and MIL • Open in harness © Light burnt 46U0F1-185 F1-141 F1 SERVICE POINTS SERVICE POINTS OUTLINE [Power and ground] Main Relay (Battery Power) • If the circuit is open, the engine will not start. • If the circuit is shorted, the EGI INJ fuse (30A) will burn out. Room Fuse (PCME Memory Power) • If the circuit is open, the PCME memory function will not operate, and diagnostic trouble codes for inter­ mittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not produce any particular symptom. • If the circuit is shorted, the ROOM fuse (15A) will burn out. Ground (Output Devices, Injector, System) • If an output device, an injector or system has an open ground circuit, no particular symptom will be produced. If a related output device, injectors and system have open ground circuits, the engine stalls and will not start. Ground (Analogue) • If the circuit is open, Diagnostic trouble Code No.09, 11, 12, 14 output. [Input Device] Mass Airflow Sensor • If the Vs terminal of the mass airflow sensor has a open or short circuit, Diagnostic Trouble Code No.08 will be output, and the PCME determines intake air amount by the throttle valve opening angle. Intake Air Temperature Sensor • If the intake air temperature sensor has an open or short circuit, Diagnostic Trouble Code No.11 will be output, and the PCME uses a preprogrammed intake air temperature of 20°C |68°F}. • If the intake air temperature sensor system fails, no particular symptom will be noticed. Throttle Position Sensor • If the Vref terminal has an open circuit or the TVO terminal has an open or short circuit, Diagnostic Trouble Code No.12 is output. • If the Vref terminal has an short circuit, the engine stalls and will not start. • If the ground terminal has an open circuit, Diagnostic Trouble Code No. 12 is output. • In the above conditions, the PCME uses a preprogrammed throttle valve fully-open’s value. • If the throttle position sensor system fails, idle speed drops will result or engine stalls and will not restart when A/C, P/S, E/L ON. TEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker cannot perform diagnostic trouble code checks and switch monitoring checks. • If the circuit is shorted, the opening amount of the idle air control valve will not change, causing hard starting and rough idle. The ignition timing will be fixed, causing lack of power and poor acceleration. The Self-Diagnosis Checker cannot perform sensor monitoring checks. • If the circuit is shorted, the coolant fan operates whenever the throttle valve is opened. Daytime Running Light Unit (Canada) • If the circuit is open, idle speed may be slightly low. • If the circuit is shorted, idle speed may be slightly high. Idle Switch • The switch monitor function can confirm the presence of an open or short circuit. • If the circuit is open, fan operates continuously with TEN terminal grounded in data link connector or idle speed is high after warm up. • If the circuit is shorted, idle speed stays or hunts at approx. 2,000 rpm. F1 SERVICE POINTS Heated Oxygen Sensor • If sensor output voltage is not generated because of an open or short circuit, Diagnostic Trouble Code No. 15 or 17 is output. • If the heated oxygen sensor output voltage continues unchanged 40 sec. after the engine exceeds 1,500 rpm, Diagnostic Trouble Codes No. 17 is output. • In the above conditions, no closed loop control will be present and no symptom will be noticed. Crankshaft Position Sensor (NE, G Singnal) • If the NE signal circuit has an open or short, Diagnostic Trouble Code No.02 is output. • If the G signal circuit has an open or short, Diagnostic Trouble Code No.03 is output. Input X G signal O O X X X NE signal Diagnostic Fail-safe function trouble code 02 No injection/ignition 03 Cancels sequencial injection 02 No injection/ignition Symptom Engine does not start — Engine does not start O: Normal x : Malfunction Starter signal • A lack of starter signal input will cause hard starting. Steering Pressure Sensor • If the circuit is open or shorted, no symptom will be noticed. A/C Signal (Air Conditioning Sensor) • The switch monitor function can confirm the presence of an open or short circuit. • If the circuit is open, the air conditioner will not operate. • If the circuit is shorted, the air conditioner will constantly operate when the blower is ON. Engine Coolant Temperature Sensor • If the temperature sensor has an open or short circuit, Diagnostic Trouble Code No.09 is output, and the PCME uses a preprogrammed temperature value of 34°C (93°F). • A malfunction in the engine coolant temperature sensor system may cause hesitation, engine stalling, high idle speed after warm up or hard starting. Blower Signal • The switch monitor funciton can confirm the presence of an open or short circuit. • If the circuit has an open or short, no symptom will be noticed. Stoplight Signal • The switch monitor function can confirm the presence of an open or short circuit. • An open or short circuit will produce no symptom. Vehicle Speed Sensor • If the circuit is open or shorted, no symptom will be noticed. Neutral and Clutch Switches • The switch monitor function can confirm the presence of an open or short circuit. • An open or short circuit will produce no symptom. Rear Window Defroster Switch • The switch monitor function can confirm the presence of an open or short circuit. • If the circuit is open, no symptom will be noticed. • If the circuit is shorted, defroster operates continuously. Headlight Switch • The switch monitor function can confirm the presence of an open or short circuit. • If the circuit is open, or shorted, no symptom will be noticed. F1-143 F1 SERVICE POINTS EGR Function Sensor • If the circuit is open or shorted, Diagnostic Trouble Code No. 16 is output. [Output Device] Injector • If the circuit is open, the injector will not operate, causing rough idle, hard starting and poor acceleration. • If the circuit is shorted, the injector will inject fuel constantly, causing hard starting, engine rough or stall, and poor acceleration. IGT Signal (Igniter) • If no IGT signals are input to the igniter because of an open or short circuit, the engine stalls and will not start and tachometer will not operate. Idle Air Control Valve (IN BAC Valve) • If the valve or circuit has an open or short, Diagnostic Trouble Code No.34 is output. • If the circuit is open, the valve will be fully closed, causing hard starting, engine stalling, or engine rough at driveaway when engine is cold. • If the circuit is shorted, the valve will be fully opened and the idle speed stays or fluctuates at approx. 2,000 rpm. Fuel Pump Relay • If the circuit is open, the engine stalls and will not restart. • If the circuit is shorted, the fuel pump will operate whenever the ignition switch is ON. Purge Control Solenoid Valve • If the solenoid valve has an open or short circuit, Diagnostic Trouble Code No.26 is output. • If the circuit is open or shorted, no symptom will be noticed. • A short circuit may cause an improper air/fuel ratio, causing engine stalling, poor acceleration idle and hard starting. A/C Signal (A/C Relay) and Condencer Fan Relay • If the circuit is open, the air conditioner will not operate. • If the circuit is shorted, the air conditioner will constantly operate when the blower is ON. EGR Solenoid Valve (Except California) • If the solenoid valve has an open or short circuit, Diagnostic Trouble Code No.28 is output. • If the circuit is open or shorted, no symptom will be noticed. EGR Solenoid Valve (Vacuum-California) • If the solenoid valve has an open or short circuit, Diagnostic Trouble Code No.28 is output. • If the circuit is open or shorted, no symptom will be noticed. EGR Solenoid Valve (Vent-California) • If the solenoid valve has on open short circuit, Diagnostic Trouble Code No.29 is output. • If the circuit is open or shorted, no symptom will be noticed. PRC Solenoid Valve • If the solenoid valve has an open or short circuit, Diagnostic Trouble Code No.25 is output. • If the circuit is shorted, no symptom will be noticed. • If the circuit is open, the engine will be hard to start after heat soaked. Coolant Fan Relay No.1 • If the relay has an open or short circuit, Diagnostic Trouble Code No.67 is output. • If the circuit is shorted, the coolant fan will always operate while the ignition switch is ON. • If the circuit is open, the coolant fan will remain OFF when the water temperature exceeds 97°C {207°F}. F 1-1 44 SERVICE POINTS F1 Coolant Fan Relay No.2 • If the relay has an open or short circuit, Diagnostic Trouble Code No.68 is output. • If the circuit is shorted, the coolant fan will always operate with the ignition switch ON. • If the circuit is open, the coolant fan will remain OFF when the engine temperature exceeds 108°C {226°F}. MEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker monitor lamp will not illuminate. • If the circuit is shorted, the Self-Diagnosis Checker monitor lamp will stay on. FEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker buzzer will not sound during the diagnostic trouble code check. • If the circuit is shorted, code “ 88" will keep flashing and the buzzer will continue sounding, preventing a diagnostic trouble code check. 46U0F1-186 F1 SERVICE POINTS WIRING DIAGRAM 16U0F1-290 F 1-1 46 SERVICE POINTS F1 ©0 F 1-147 F1 SERVICE POINTS ELECTRICAL DIAGNOSIS SUPPORT Main Relay (Battery Power) Circuit PCME (1B)—Main relay Condition Short circuit EGI INJ fuse (30A) burns out with ignition switch ON Open circuit Engine stalls and will not restart Poor ground NA 46U0F1-187 Room Fuse (Memory Power) Circuit PCME (1 A)—Room fuse Condition Short circuit Room fuse (15A) burns out Open circuit No symptom Poor ground NA 36U0F1-171 Ground (Output Device, Injector, System, Analogue) Circuit PCME PCME PCME PCME (2A)—Ground (2B)—Ground (2C)—Ground (2D)—Ground (Injector) (Power) (System) (Analogue) Open circuit Engine stall and will not restart Condition Short circuit Poor ground Engine may not start NA Diagnostic trouble code No.9, 11,12 output 46U0F1-188 [input Device] Mass Airflow Sensor Circuit PCME (20)—Mass airflow sensor Open circuit Diagnostic trouble code No.08 output Lack of power Poor acceleration Hesitate at driveaway Vehicle shake on de­ celeration Main relay—Mass airflow sensor PCME (2C)—Mass airflow sensor Condition Short circuit Diagnostic trouble code No.08 output Lack of power Poor acceleration Hesitate at driveaway Vehile shake on de­ celeration Engine stall and will not restart Melts EGI INJ 30A fuse NA Poor ground NA — 46U0F1-189 Data Link Connector (TEN terminal) Circuit PCME (1K)— Data link connector Open circuit Cannot perform diagnostic trouble code checks and switch monitor checks Condition Short circuit Hard starting Rough idle Poor acceleration Poor ground NA 36U0F1-176 Throttle Sensor Circuit PCME (2K)—Throttle position sensor (Vref) PCME (2M)—Throttle position sensor PCME (2D)—Throttle position sensor N A : N o t a p p lic a b le F1-148 Open circuit Diagnostic trouble code No. 12 output Idle speed drops when A/C, P/S, or E/L ON Diagnostic trouble code No. 12 output Idle speed drops when A/C, P/S, or E/L ON Diagnostic trouble code No. 12 output Idle speed drops when A/C, P/S, or E/L ON Condition Short circuit Diagnostic trouble code No. 12 output Engine stalls and will not restart Diagnostic trouble code No. 12 output Idle speed drops when A/C, P/S, or E/L ON NA Poor ground NA — 36U0F1-178 F1 SERVICE POINTS Intake Air Temperature Sensor Circuit Open circuit Diagnostic trouble code No.11 output Diagnostic trouble code No.11 output PCME (2L)—Intake air temperature sensor PCME (2D)—Intake air temperature sensor Condition Short circuit Diagnostic trouble code No.11 output Poor ground NA NA — 36U0F1-177 idle Switch Circuit Open circuit Fan operates continuously with TEN terminal grounded High idle speed after warm up Fan operates continuously with TEN terminal grounded High idle speed after warm up PCME (1N)—Idle swicth Idle switch—Ground Condition Short circuit Idle speed stays or hunts at spprox. 2,000 rpm Poor ground NA NA — 36U0F1-179 Heated Oxygen Sensor Circuit PCME (2N)—Heated oxygen sensor Heated oxygen sensor—Ground Heated oxygen sensor (heater)— Ignition swicth Open circuit Diagnostic trouble code No.15/17 output Poor fuel economy Diagnostic trouble code No. 15/17 output Poor fuel economy No symptom Condition Short circuit Diagnostic trouble code No. 15/17 output Poor fuel economy Poor ground NA No symptom NA Melts WIPER 20A fuse — 36U0F1-180 Crankshaft Position Sensor (NE signal, G signal) Circuit PCME (2E)—Crankshaft position sensor PCME (2G)—Crankshaft position sensor PCME (2C)—Crankshaft position sensor Condition Open circuit Short circuit Diagnostic trouble code No.02 output Engine stalls and will not restart Diagnostic trouble code No.03 output No symptom No symptom NA Poor ground NA No symptom 36U0F1-181 Starter Signal (Ignition Switch) Circuit PCME (1C)—Ignition switch Open circuit Hard to start Condition Short circuit Melts IG KEY 40A fuse when ignition switch turn to STA position Engine stalls and will not restart Poor ground NA 36U0F1-182 Steering Pressure Sensor Circuit PCME (1P)—Steering pressure sensor NA: Not applicable Condition Short circuit Open circuit No symptom Poor ground — 36U0F1-183 F1 SERVICE POINTS A/C Signal (Air Conditioning Sensor) Circuit Open circuit Air conditioner will not operate PCME (1Q)—Air conditioning sensor Condition Short circuit Air conditioner will con­ stantly operate with blower ON Poor ground NA 36U0F1-184 Engine Coolant Temperature Sensor Condition Open circuit Short circuit Diagnostic trouble code No.09 output Hard to start after warm-up with TEN terminal grounded High idle speed after warm-up (approx. 1,000 rpm) Engine stalls at idle with TEN terminal grounded Hesitate at driveaway and acceleration Diagnostic trouble code No.09 output Hard to start after warm-up with TEN terminal grounded High idle speed after warm-up (approx. 1,000 rpm) Engine stalls at idle with TEN terminal grounded Hesitate at driveaway and acceleration Circuit PCME (2Q)—Engine coolant temperature sensor PCME (2D)—Engine coolant tem­ perature sensor Poor ground NA — 46U0F1-190 Blower Signal Circuit Condition Short circuit Open circuit No symptom PCME (1R)—A/C amplifier Poor ground — 36U0F1-188 Vehicle Speed Sensor Circuit Condition Short circuit Open circuit No symptom PCME (1M)—Vehicle speed sensor Poor ground NA 46U0F1-191 Neutral and Clutch Switches Circuit PCME (1V)—Neutral switch PCME (1V)—Clutch switch Open circuit No symptom Condition Short circuit No symptom Poor ground NA 46U0F1-192 Stoplight Signal (Stoplight Switch) Circuit PCME (10)—Stoplight switch Open circuit No symptom Condition Short circuit No symptom Poor ground NA 36U0F1-189 Rear Window Defroster Switch Circuit PCME (1L)— Rear window defroster switch Open circuit No symptom Condition Short circuit Defroster operates con­ tinuously Poor ground NA 36U0F1-192 Headlight Switch Circuit PCME (1U)—Headlight switch NA: Not applicable F 1-150 Condition Short circuit Open circuit No symptom Poor ground NA F1 SERVICE POINTS EGR Function Sensor (Except California) Condition Open circuit Short circuit Code No. 16 output Circuit PCME (2J)—EGR function sensor PCME (2D)—EGR function sensor Poor ground NA 46U0F1-203 EGR Function Sensor (California) Circuit PCME (2J)—EGR function sensor Open circuit Code No. 16 output No symptom Condition Short circuit Code No. 16 output No symptom Poor ground NA 46U0F1 -204 Daytime Running Light Unit (Canada) Circuit PCME (11)—Daytime running light unit Open circuit Idle speed may be slightly low Condition Short circuit Idle speed may be slightly high Poor ground NA 36U0F1-261 [Output Device] Injector Circuit PCME (2U, 2V, 2Y, 2Z)-lnjector Open circuit Hard to start, Rough idle Poor acceleration at low speed Condition Short circuit Will not start or hard to start Engine rough or stalls Poor acceleration Poor ground NA 36U0F1-194 IGT Signal (Igniter) Circuit PCME (2F)—Igniter Igniter—Ground Condition Open circuit Short circuit Engine stalls and will not restart Tachometer will not operate No symptom NA Poor ground NA Engine will not start 36U0F1-195 Idle Air Control Valve (IN BAC Valve) Circuit PCME (2W)—Idle air control valve Idle air control valve—Main relay Open circuit Diagnostic trouble code No.34 output Rough idle Engine stalls after racing Hard to start after warm-up Engine rough at driveaway when engine is cold Idle speed drops when A/C, P/S, or electrical load ON Condition Short circuit Diagnostic trouble code No.34 output Idle speed stays or fluc­ tuates at approx. 2,000 rpm EGI fuse (30A) burns out with ignition switch ON Poor ground NA 36U0F1-196 Fuel Pump Relay Circuit PCME (1H)—Fuel pump relay NA: Not applicable Open circuit Engine stalls and will not restart Condition Short circuit Fuel pump will continue operating with ignition switch ON Poor ground NA 36U0F1-197 F1-151 F1 SERVICE POINTS Purge Control Solenoid Valve Circuit PCME (2X)—Solenoid valve (purge control) Open circuit No.26 output No symptom Solenoid valve (purge control) —Main relay Condition Short circuit No.26 output Engine stalls, Hard starting Poor acceleration at driveaway EGI INJ fuse (30A) burns out with ignition switch ON Poor ground NA 36U0F1-198 A/C Signal (A/C Relay) Circuit PCME (1 J)—A/C relay Open circuit Air conditioner will not operate Condition Short circuit Air conditioner will remain operating with blower ON Poor ground NA 46U0F1-194 EGR Solenoid Valve (Except California) Circuit PCME (2S)—EGR solenoid valve Open circuit Diagnostic trouble code No.28 output No symptom EGR solenoid valve—Main relay Condition Short circuit Diagnostic trouble code No.28 output No symptom EGI INJ fuse (30A) burns out with ignition switch ON Engine stalls and will not start Poor ground NA 46U0F1-195 EGR Solenoid Valve (Vacuum-California) Circuit PCME (2S)—Solenoid valve (EGR) Open circuit Diagnostic trouble code No.28 output No symptom Solenoid valve (EGR)—Main relay Condition Short circuit Diagnostic trouble code No.28 output No symptom EGI INJ fuse (30A) burns out with ignition switch ON Engine stalls and will not start Poor ground NA 46U0F1-196 EGR Solenoid Valve (Vent-Caiifornia) Circuit PCME (2R)—Solenoid valve (EGR) Open circuit Diagnostic trouble code No.29 output No symptom Solenoid valve (EGR)—Main relay Condition Short circuit Diagnostic trouble code No.29 output No symptom EGI INJ fuse (30A) burns out with ignition switch ON Engine stalls and will not start Poor ground NA 46U0F1-197 PRC Solenoid Valve Circuit PCME (2T)—Solenoid valve (PRC) Solenoid valve (PRC)—Main relay NA: Not applicable F1—152 Open circuit Diagnostic trouble code No.25 output Hard to start after heat soaked Condition Short circuit Diagnostic trouble code No.25 output No symptom EGI INJ fuse (30A) burns out with ignition switch ON Engine stalls and will not start Poor ground NA 46U0F1-198 F1 SERVICE POINTS Data Link Connector (MEN terminal) Circuit PCME (1D)—Data link connector Open circuit Monitor lamp will not il­ luminate Condition Short circuit Monitor lamp will stay ON Poor ground NA 36U0F1-174 Data Link Connector (FEN terminal) Circuit PCME (1F)—Data link connector Open circuit Self-Diagnosis Checker buzzer will not sound dur­ ing diagnostic trouble code check Condition Short circuit Code "88” will keep flashing and buzzer will continue sounding during diagnostic trouble code check Poor ground NA 36U0F1-175 Coolant Fan Relay Circuit PCME (1S)—Coolant fan relay No.1 Coolant fan relay No.1—Ignition switch NA: Not applicable Condition Open circuit Diagnostic trouble code No.67 output Coolant fan will not op­ erate above the water temperature 97°C (207°F) Short circuit Coolant fan operates con­ tinuously ENGINE fuse (15A) burns out with ignition switch ON Poor ground NA 36U0F1-202 F2 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. FUEL AND EMISSION CONTROL SYSTEMS (KL) IN D E X .......................................................................................F 2 - 2 O U T L IN E ................................................................................. F 2 - 6 SYSTEM DIAGRAM..........................................................F 2 - 6 VACUUM HOSE ROUTING DIAGRAM ...................... F 2 - 7 WIRING DIAG RAM ..........................................................F 2 - 8 SPECIFICATIONS.............................................................F 2 - 10 COMPONENT DESCRIPTIONS....................................F 2 - 11 ENGINE TUNE-UP.................................................................F 2 - 14 PREPARATION.................................................................F 2 - 14 BASIC INSPECTION........................................................ F 2 - 14 ADJUSTMENT............................................................... F 2 - 15 ON-BOARD DIAGNOSIS S Y S T E M ................................. F 2 - 17 DESCRIPTION..................................................................F 2 - 17 PREPARATION.................................................................F 2 - 18 DIAGNOSTIC TROUBLE CODE N U M B ER ............... F 2 - 18 SWITCH MONITOR F U N C TIO N ...................................F 2 - 43 HEATED OXYGEN SENSOR MONITOR FUN CTIO N...................................................................... F 2 - 43 INTAKE AIR S Y S T E M ........................................................ F 2 - 48 COMPONENT PARTS.................................................... F 2 - 48 THROTTLE B O D Y ........................................................... F 2 - 49 ACCELERATOR P E D A L................................................ F 2 - 50 ACCELERATOR C A B LE................................................ F 2 - 50 AIR INTAKE PIPE/INTAKE MANIFOLD...................... F 2 - 51 IDLE-SPEED CONTROL S Y S T E M .................................. F 2 - 52 DESCRIPTION.................................................................. F 2 - 52 PREPARATION A .............................................................F 2 - 53 SYSTEM OPERATION.................................................... F 2 - 53 BAC V A LVE...................................................................... F 2 - 53 VARIABLE RESONANCE INDUCTION SYSTEM (V R IS )..................................................................F 2 - 54 DESCRIPTION..................................................................F 2 - 54 SYSTEM OPERATION.................................................... F 2 - 55 COMPONENT PARTS.................................................... F 2 - 56 VRIS SHUTTER VALVE ACTUATOR (No. 1, No. 2). F 2 - 57 CHECK VALVE.................................................................F 2 - 57 VRIS SOLENOID VALVE (No. 1, No. 2 ) .....................F 2 - 57 VACUUM CHAM BER......................................................F 2 - 57 FUEL S Y S T E M ...................................................................... F 2 - 58 DESCRIPTION..................................................................F 2 - 58 PREPARATION....................................................... .........F 2 - 59 SYSTEM OPERATION.................................................... F 2 - 59 FUEL T A N K ...................................................................... F 2 - 61 FUEL PUM P...................................................................... F 2 - 63 FULE FILTE R................................................................... F 2 - 65 INJECTOR.........................................................................F 2 - 66 PRESSURE REGULATOR............................................. F 2 - 70 FUEL PUMP RELAY....................................................... F 2 - 70 PRESSURE REGULATOR CONTROL SYSTEM ..........F 2 - 71 DESCRIPTION.................................................................. F 2 - 71 PRC SOLENOID VALVE................................................ F 2 - 72 EXHAUST S Y S T E M .............................................................F 2 - 73 COMPONENT PARTS.................................................... F 2 - 73 OUTLINE OF EMISSION CONTROL SYSTEM .............F 2 - 75 DESCRIPTION.................................................................. F 2 - 75 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM ....................................F 2 - 76 DESCRIPTION.................................................................. F 2 - 76 SYSTEM OPERATION.................................................... F 2 - 77 EGR SOLENOID VALVE (VACUUM ).......................... F 2 - 77 EGR SOLENOID VALVE (VENT).................................. F 2 - 77 EGR FUNCTION SENSOR............................................F 2 - 78 EGR CONTROL VALVE................................................. F 2 - 78 POSITIVE CRANKCASE VENTILATION (PCV) S Y S T E M ...................................................................F 2 - 80 DESCRIPTION................................................................. F 2 - 80 PCV VALVE.......................................................................F 2 - 80 FUEL EVAPORATIVE S Y S T E M ...................................... F 2 - 81 DESCRIPTION................................................................. F 2 - 81 SYSTEM OPERATION....................................................F 2 - 82 PURGE SOLENOID VALVE.......................................... F 2 - 82 FUEL VAPOR VALVE..................................................... F 2 - 83 CHECK VALVE (TWO-WAY)......................................... F 2 - 83 CHARCOAL CANISTER................................................. F 2 - 83 FUEL-CUT CONTROL SY S TE M ...................................... F 2 - 84 DESCRIPTION................................................................. F 2 - 84 PREPARATION................................................................ F 2 - 84 SYSTEM OPERATION....................................................F 2 - 85 A/C CUT OFF S Y S T E M ..................................................... F 2 - 86 DESCRIPTION.................................................................F 2 - 86 SYSTEM OPERATION....................................................F 2 - 86 DECHOKE CONTROL S Y S T E M ...................................... F 2 - 87 DESCRIPTION................................................................. F 2 - 87 SYSTEM OPERATION.................................................... F 2 - 87 COOLANT FAN CONTROL SYSTEM .............................F 2 - 88 DESCRIPTION................................................................. F 2 - 88 PREPARATION................................................................ F 2 - 88 SYSTEM OPERATION....................................................F 2 - 89 CONTROL S Y S T E M ............................................................F 2 - 90 PREPARATION................................................................ F 2 - 90 STRUCTURAL VIEW .......................................................F 2 - 91 POWERTRAIN CONTROL MODULE (PCME)........... F 2 - 92 MAIN RELAY........................................................ .......... . F 2 -1 0 4 VOLUME AIRFLOW SENSOR...................................... F 2 -1 0 4 CRANKSHAFT POSITION SENSOR No.1 (IN DISTRIBUTOR)..................................... .................. F 2 -1 0 5 CRANKSHAFT POSITION SENSOR No.2.................. F 2 -1 0 5 ENGINE COOLANT TEMPERATURE SENSOR ...... F 2 -1 0 6 THROTTLE POSITION SENSOR.................................. F 2 -1 0 7 HEATED OXYGEN SENSOR (RH, LH)........................F 2 -1 0 8 KNOCK SENSOR............................................................ F 2 -1 1 0 CLUTCH SWITCH (MTX)................................................F 2-111 NEUTRAL SWITCH (MTX)............................................. F 2-111 STEERING PRESSURE SENSOR................................. F 2-111 TROUBLESHOOTING G U ID E .......................................... F 2 -1 1 2 QUICK DIAGNOSIS CHART......................................... F 2-1 1 2 RELATIONSHIP CHART.............................. ......... .........F 2 -1 1 6 USING THIS SECTION...................................... ............F 2 -1 1 8 DIAGNOSTIC INDEX.......................................................F 2 -1 2 0 SYMPTOM TROUBLESHOOTING................................F 2 -1 2 4 SERVICE P O IN T S ......................................................... F 2-161 OUTLINE........................................................................ . F 2-161 WIRING DIAGRAM ......................................................... F 2-1 6 6 ELECTRICAL DIAGNOSIS SUPPORT.........................F 2 -1 6 8 46U0F2-001 — ... F2 INDEX -v INDEX 46U0F2-002 1. Fresh airduct Removal / Inspection / Installation............................ . page F2- 48 2. Air cleaner element Removal / Installation............. . page F2- 48 Inspection..............................., page F2- 15 3. Volume airflow sensor Removal / Installation............. page F2- 48 Inspection............................... page F2- 104 4. Throttle body Removal / Installation............. page F2- 48 Inspection............................... page F2- 49 5. BAC valve Removal / Installation............. page F2- 48 Inspection............................... page F2- 53 6. Air intake hose Removal / Installation............. page F2- 48 7. VRIS shutter valve actuator (No. 1, No. 2) Inspection............................... page F2- 57 F 2 -2 8. Vacuum chamber Removal / Installation........ ....page Inspection......................... ....page 9. Check valve Removal / Installation........ ....page Inspection......................... ....page 10. Intake manifold Removal / Installation........ ....page Inspection......................... ....page 11. Air intake pipe Removal / Installation........ ....page Inspection......................... ....page 12. Accelerator pedal Removal / Inspection / Installation....................... ....page 13. Accelerator cable Inspection / Adjustment..... ....page F2- 56 F2- 57 F2- 56 F2- 57 F2- 48 F2- 51 F2- 48 F2- 51 F2- 50 F2- 50 INDEX *s F2 46U0F2-185 1. Fuel pump relay Inspection.... page F2- 70 2. Pressure regulator Inspection....page F2- 70 Removal / Installation ................... page F2- 66 3. Fuel Injector Inspection (On-vehicle) .................. page F2- 66 Removal / Installation ................... page F2- 66 Inspection.... page F2- 68 4. VRIS solenoid valve (No. 1, No. 2) Removal / Installation ................... page F2- 56 Inspection....page F2- 57 5. PCV valve Inspection....page F2- 80 6. Purge solenoid valve Inspection.... page F2- 82 7. Charcoal canister Inspection.... page F2- 83 8. Powertrain control module (PCME) Removal / Installation ................... page F2- 92 Inspection....page F2- 93 9. Volume airflow sensor (with intake air temperature sensor) Inspection.... page F2-104 Removal / Installation ................... page F 2 - 48 10. Throttle position sensor (with idle switch) Inspection.... page F2-107 Replacement ................... page F2-108 11. EGR control valve Inspection.... page F 2- 78 Replacement ................... page F 2- 79 12. Fuel filter (High-pressure) Replacement ................... page F 2- 65 13. Engine coolant temperature sensor Removal / Installation ................... page F2-106 Inspection.... page F2-106 14. Crankshaft position sensor No. 2 (NE2 signal) Inspection.... page F2-105 Removal / Installation ................... page F2-106 15. Crankshaft position sensor No. 1 (G signal, NE1 signal) Inspection.... page F2-105 16. Heated oxygen sensor Inspection....page F2-108 Replacement ................. page F2-109 17. Knock sensor Removal I Installation ................. page F2-110 18. Main relay Inspection....page F2-104 19. Steering pressure sensor Inspection....page F2-11 20. Clutch switch (MTX) Inspection....page F2-11 Replacement ................. page F2-11 21. Neutral switch (MTX) Inspection....page F2-11 Replacement ................. page F2-11 22. EGR function sensor Inspection....page F2- 78 23. EGR solenoid valve (vacuunn Inspection....page F2- 77 24. EGR solenoid valve (vent) Inspection....page F2- 77 25. PRC solenoid valve Inspection....page F2- 72 F 2 -3 F2 INDEX 46U0F2-004 1. Fuel tank Removal / Inspection / Installation...............................page 2. Fuel filter (Low-pressure) Removal / Installation............... page 3. Fuel pump Inspection.................................page Removal / Installation............... page F2-61 F2-65 F2-63 F2-64 4. Check valve (Two-way) - Inspection.......... ......................page F2-83 Removal / Installation............... page F2-61 5. Fuel vapor valve Inspection.................................page F2-83 INDEX v F2 CALIFORNIA 46U0F2-005 1. Main silencer Removal / Inspection / Installation.......................pages 2. Pre silencer Removal / Inspection / Installation.......................pages 3. Three way catalyst Removal / Installation....... pages 4. Front pipe Removal / Inspection / Installation.......................pages F2-73, 74 F2-73, 74 F2-73, 74 5. Insulator Removal / Installation....... pages F2-73, 74 6. Exhaust manifold Removal / Inspection / Installation...................... pages F2-73, 74 7. EGR pipe Removal / Inspection / Installation...................... pages F2-73, 74 F2-73, 74 F 2 -5 THRO TTLE POSITION SENSOR (O ■< (0 H m IDLE AIR CONTROL VALVE PRC SOLENOID VALVE SHUTTER VALVE ACTUATOR (VRIS 2) PURGE SOLENOID VALVE * ■n to VOLUME AIRFLOW SEN SO R VACUUM CHAMBER AIR CLEANER HOUSING i O 3D > m ONE-WAY CHECK VALVE SUTTER VALVE ACTUATOR (VRIS 1)- BAC VALVE INTAKE AIR * TEM PERATURE SENSOR VRIS SOLENOID VALVE (No.2)[ 1 PRESSURE REGULATOR FRESH AIR DUCT EGR-VENT SO LENO ID VALVE CHARCOAL CANISTER CHECK VAL (TWO-WAY) EGR-VACUUM SOLENOID VALVE PCV VALVE FUEL FILTER (LOW PRESSURE SIDE) ------INJECTOR -EG R CONTROL VALVE KNOCK SENSOR VRIS SOLENOID VALVE (No.1) FUEL VAPOR VALVE . „ r \ CRANKSHAFT ' ° 9 POSITION SENSOR No.1 (NE1, G) -E G R FUNCTION SENSOR HEATED OXYGEN SENSOR WARM UP THREE-W AY CATALYST (CALIFORNIA) FUEL FUEL (HIGH-PRESSURE SIDE) \NKSH AFT POSITION SENSOR No.2 (NE2) HEATED O XYGEN SENSOR ENGINE COOLANT TEM PERATURE SENSOR WARM UP THREE-W AY CATALYST (CALIFORNIA) THREE WAY CATALYST * TO PCM E o c H n z m F2 OUTLINE VACUUM HOSE ROUTING DIAGRAM VRIS SOLENOID VALVE No.1 VRIS SOLENOID VALVE No.2 VRIS SHUTTER VALVE ACTUATOR No.2 PURGE SOLENOID VALVE VRIS SHUTTER VALVE ACTUATOR No.1 CHECK VALVE I SOLENOID VALVE (VENT) VACUUM CHAMBERS PRESSURE REGULATOR EGR SOLENOID VALVE (VACUUM) TO POWER BRAKE UNIT CHARCOAL CANISTER EGR CONTROL VALVE PRC SOLENOID VALVE F2_________________ _________ OUTLINE WIRING DIAGRAM CLUTCH HEATED OXYGEN SENSOR (CALIFORNIA) $ (LEFT BANK) VEHICLE SPEED SENSOR HEATED OXYGEN SENSOR (CALIFORNIA) (RIGHT BANK) ^ HEATED $ OXYGEN •S SENSOR * (FEDERAL « CANADA) ^ (RIGHT BANK) BATTERY F 2 -8 16E0F2-Q09 F2 OUTLINE PRC SOLENOID VALVE IDLE AIR CONTROL VALVE VRIS SOLENOID VALVE No.2 EGR SOLENOID EGR VALVE (VENT) \ SOLENOID \ VALVE (VACCUM) 1 VRIS / PURGE STEERING SOLENOID / SOLENOID DATA LINK PRESSURE! VALVE No.1/ VALVE ' I _JL CONNECTOR SENSOR \ ______ \ 2 utuUJ o io m INJECTOR No.1 No.3 No.5 INJECTOR No.2 No.4 No.6 O OIOIOIO ra m fn i OIOIOIOOIO fflnltrn I B ii A i ) -------------- (ao) (bi)------------- ( jj) (;o) — ■ (3 m) — (3 p )---------(3 Q > - — {a u )— (jw ) — ( jy ) - CONNECTOR I TACHOMETER DISTRIBUTOR (IGNITER, IGNITION COIL, AND CRANKSHAFT POSITION SENSOR No.1) . BLOWER SWITCH F 2 -9 F2________________ _________ OUTLINE SPECIFICATIONS Specification Item rpm Idle speed* BTDC Ignition timing* 6 00 -7 00 (650 ± 50) 9 °—11° (10° ± 1°) Throttle body Horizontal draft Type mm {in) Throat diameter 60 {2.4) Fuel pump Impeller (in-tank) Type kPa {kgf/cm2, psi) Maximum output pressure 640 {6.5, 92) Fuel filter Type Low-pressure side Nylon element (in fuel pump) High-pressure side Paper element Pressure regulator kPa {kgf/cm2, psi) Regulating pressure 280 {2.9, 41) Injector High-ohmic, side-feed Type Voltage Type of drive 1 2 -1 6 (at 20°C (68°F)) Resistance Idle air control valve Solenoid resistance fl 10.7-12.3 (at 20°C {68°F)) 0 3 0 -3 4 (at 20°C {68°F)) Purge solenoid valve Solenoid resistance Crankshaft position sensor No.1 (Ne1, G signal) Hall effect pick-up Type Volume Airflow sensor Measuring core type Type Closed throttle position E2 <- VS Wide open throttle Resistance 12 E2 «• VC 2 0-1,000 200 -4 00 E2 <*• THA (Intake air temperature sensor) Engine coolant temperature sensor Resistance 2 0 -6 0 0 kfi -2 0 °C {-4 °F ) 10,000-20,000 20°C {68°F) 2,000-3,000 60°C { 140°F) 4 00 -7 00 - 2 0 °C {-4 °F ) 13.5—16.5 20°C {68°F) 2.20-2.70 80°C { 176°F) 0.29-0.35 91°C { 196°F) 0.226-0.241 97°C {207°F) 0.193-0.205 108°C (226°F) 0.145—0.153 110°C {230°FJ 0.137-0.146 Fuel tank Capacity L {US gal, Imp gal) 58.5 {15.5, 12.9) Air cleaner housing Element type Oil permeated Fuel Specification * TEN terminal of data link connector grounded. F 2 -1 0 Unleaded— (R + M)/2 method 91 or higher F2 OUTLINE COMPONENT DESCRIPTIONS Component Function A/C relay Air cleaner housing Air valve Controls A/C compressor magnetic clutch Filters air entering throttle body Supplies bypass air into intake manifold (engine cold) Barometric absolute pressure sensor Bypass air control (BAC) valve Charcoal canister Check valve (two-way) Crankshaft position sensor No.1 IG signal \ \Ne1 signal/ Crankshaft position sensor No.2 (Ne2 signal) Data link connector Detects barometric absolute pressure; sends signal to PCME Supplies bypass air into intake manifold EGR control valve EGR function sensor EGR solenoid valve (vent) EGR solenoid valve (vacuum) Engine coolant temperature sensors Fuel filter Fuel pump Fuel pump relay Fuel vapor valve Heated oxygen sensor Idle air control valve Igniter Ignition switch (START position) Injector Intake manifold Intake air temperature sensor Knock sensor Stores fuel tank fumes (engine stopped) Controls pressure in fuel tank Detects No.1 cylinder TDC; sends signal to PCME (G signal) Detects crank angle at 60° intervals; Sends signal to PCME (Ne1 signal) Detects crank angle at 60° intervals; sends signal to PCME Concentrated sevice connector terminals: 1. CIS on-board diagnosis 2. EC-AT on-board diagnosis [ATX] 3. Initial set 4. Fuel pump check 5. Engine speed output 6. Switch and heated oxygen sensor monitor 7. Supply battery positive voltage 8. Ground 9. ABS self-diagnosis 10. A/C self-diagnosis 11. Cruise control self-diagnosis Recirculates portion of exhaust gas Detects EGR control valve position Controls vacuum to EGR control valve (vent side) Controls vacuum to EGR control valve (vacuum side) Detect coolant temperature; send signals to PCME Filters particles from fuel Provides fuel to injectors Voltage for fuel pump while engine running Prevents fuel from flowing into charcoal canisters Detects oxygen concentration; sends signal to PCME Supplies bypass air into intake manifold Receives spark signal from PCME and generates high voltage in ignition coil Sends engine cranking signal to PCME Injects fuel into intake port Supplies intake air to all cylinders Detects intake air temperature; sends signal to PCME Detects engine knocking; sends signal to PCME Remark • Engine speed increased to shorten warm­ up period • Thermowax type • Installed in BAC valve In PCME Consists of air valve and idle air control valve — — Installed in distributor Installed at crankshaft pulley 25-pin (located near front left fuse box) 1. FEN terminal 2. FAT terminal [ATX] 3. TEN terminal 4. F/P terminal 5. IG- terminal 6. MEN terminal 7. 8. 9. 10 11. + B terminal GND terminal TBS and FBS terminals TAC and FAC terminals TSC and FSC terminals — Installed on EGR control valve • Controlled by duty signal from PCME • Controlled by duty signal from PCME • Installed in engine (for CIS and fan) — • Operates while engine running • Installed in fuel tank — — • Zirconic and platinum coating • With heater • Controlled by duty signal from PCME • Installed in BAC valve • Installed in distributor — • Controlled by signal from PCME (side-feed type) — • Installed in volume airflow sensor — F2-11 F2 OUTLINE Component Main relay Neutral and clutch switch (MTX) One-way check valve Park/Neutral switch (ATX) PCV valve Powertrain control module (PCME) Supplies current to output devices and PCME Detects in-gear condition; sends signal to PCME Prevents malfunction of VRIS shutter valve and EGR valve during heavy—load operation Detects load condition; sends signal to PCME Controls blow-by gas introduced into engine Detects the following: 1. A/C operation 2. Air/fuel ratio (oxygen concentration) 3. Barometric absolute pressure 4. Braking signal 5. Cranking signal 6. E/L operation 7. Engine coolant temprerature 8. E n g in e s p e e d PRC solenoid valve Pressure regulator Purge solenoid valve Resonance chamber Shutter valve actuator F2—12 Remark Function — • Switch ON in neutral • For VRIS and EGR • Switch ON in P, N range — 1. 2. 3. 4. 5. 6. 7. 8. 9. ignition ON signal 10. In-gear condition 9. 10. 11. Intake air amount 12. Intake air temperature 11. 12. 13. EGR control valve position 14. No.1 piston TDC 13. 14. 15. P/S operation 16. Test mode signal (ignition timing, idle speed, diagnostic trouble code No.) 17. Throttle valve opening angle 18. Throttle valve closed throttle position Controls operation of following: 1. A/C (Cut-off) 2. On-board diagnosis function 3. Fuel injection system 4. Idle speed control 5. Ignition system (electronic spark advance) 6. Monitor function 7. Purge control system 8. VRIS control system 9. EGR function control system 10. Pressure regulator control system 11. Coolant fan control system 12. Condenser fan control 13. Lockup control system 14. Slip control system Controls vacuum to pressure regulator Adjusts fuel pressure supply to injectors Controls evaporative fumes from charcoal canister to intake manifold Reduces intake air noise Opens/closes shutter valve to inprove torque characteristics 15. 16. Air conditioning sensor Heated oxygen sensor Barometric absolute pressure sensor Stoplight switch Ignition switch (START position) Blower motor switch, coolant fan relay, headlight switch, and rear window defroster switch Engine coolant temperature sensor Crankshaft position sensor No.2 (Ne2 signal) Ignition switch Neutral and clutch switches (MTX) or Park/Neutral switch (ATX) Volume airflow sensor Intake air temperature sensor (in volume airflow sensor) EGR function sensor Crankshaft position sensor No.1 (G signal) Steering pressure sensor Data link connector (TEN terminal) 17. Throttle position sensor 18. Idle switch (in throttle position sensor) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. A/C relay Self-Diagnosis Checker Injector Idle air control valve Igniter Monitor lamp (Self-Dagnosis Checker) Purge solenoid valve VRIS Solenoid valve EGR solenoid valve PRC solenoid valve Coolant fan relay Condenser fan relay Powertrain control module (PCMT) Powertrain control module (PCMT) — — • Controlled by duty signal from PCME — • For variable resonance induction system (VRIS) F2 OUTLINE Component Steering pressure sensor Stoplight switch Three way catalyst Throttle body Throttle position sensor Vehicle speed sensor Volume airflow sensor VRIS Solenoid valve (No.1 and No.2) Warm up three way catalyst Function Detects P/S operation Detects braking; sends signal to PCME Reduces HC, CO, NOx by chemical reaction Controls intake air amount Detects throttle valve opening angle Remark • Steering pressure sensor ON when steering wheel turned — Monolith type — • Installed on throttle body Detects vehicle speed; sends signal to PCME Detects intake air amount; sends signal to PCME Controls vacuum to shutter valve actuator • Installed in instrument cluster Intake air temperature sensor included Reduces HC, CO, NOx by chemical reaction Monolith type — 46U0F2-007 F2 ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST 49 B019 9A0 System Selector )) For inspection of ignition timing and idle speed ^ 2 ? 16E0F2-012 BASIC INSPECTION Engine Oil 1. Remove the dipstick and check the engine oil level and con­ dition. 2. Add or change oil as necessary. 6 16E0F2-013 Coolant (engine cold) 46U0F2-008 Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth - turn it, and remove it. 1. Verify that the coolant level is near the radiator filler neck. 2. Verify that the coolant level on the coolant dipstick is be­ tween the F and L marks. 3. Add coolant if necessary. Battery Removing the label on the top of the battery or removing the vent caps will void the battery’s warranty. 1. Clean any corrosion on the clamps or battery posts. 2. Verify that the battery top is clean. If necessary, clean with baking soda and water. 3. Verify that cables are in good condition and not frayed or corroded. Repair or replace if necessary. 4. Verify that cable clamps are tight. Note • Because this is a maintenance free battery, it is not neces­ sary to check the fluid level. F 2 -1 4 F2 ENGINE TUNE-UP Air Cleaner Element Inspection 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution • Cleaning the element with compressed air will re­ duce the element’s ability to filter the air. Don’t use compressed air to clean the element. 2. Replace the element if necessary. ADJUSTMENT Preparation 1. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. • Headlight switch • Blower switch • Rear window defroster switch • A/C sensor 3. Connect the SST to the data link connector. 4. Connect a timing light to the engine. 5. Connect a tachometer to the data link connector terminal IG - as shown. Ignition Timing 1. Perform Preparation. (Refer to above.) 2. Verify that the idle speed is within the specification; if not, adjust it. (Refer to page F2-16.) Idle speed (Neutral): 600—700 (650 ± 50) rpm 3. Set switch A to position 1. 4. Set test switch to SELF TEST. 5. If the SST is not used, connect a jumper wire between the TEN terminal and the GND terminal of the data link con­ nector. 6. Vefiry that the idle speed is within the specification. Idle speed (Ground the terminal TEN): 550—750 rpm 7. Verify that the timing mark (yellow) on the crankshaft pulley and the mark on the timing belt cover are aligned. Ignition timing: BTDC 9 °—11° (10° ± 1 ° ) 8. If the marks are not aligned, loosen the distributor lock bolts and turn the distributor to make the adjustment. 9. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 Nm {1.9—2.6 kgf m, 14—18 ft-lbf} 46U0F2-013 F 2-1 5 F2 ENGINE TUNE-UP 9. Disconnect the SST. 10. Verify that the ignition tinning is within the specification. Ignition timing: BTDC 6—18° Idle Speed 1. Perform Preparation. (Refer to page F2-15.) 2. Set switch A to position 1. 3. Set test switch to SELF TEST. 4. With the coolant fan off, verify that the idle speed is within specification. Idle speed (Neutral): 600—700 (650 ± 50) rpm 46U0F2-014 F 2 -1 6 5. If not within the specification, adjust the idle by turning the air adjusting screw. 6. Disconnect the SST. ON-BOARD DIAGNOSIS SYSTEM F2 ON-BOARD DIAGNOSIS SYSTEM DESCRIPTION When trouble occurs in the main input or output devices, check for the cause by using the SST. Failure of input and output devices is indicated and retrieved from the powertrain control module (PCME) as diag­ nostic trouble codes. For input devices, the PCME continuously checks for malfunction. For output devices, it checks for mal­ functions only in a three-second period after the ignition switch is turned to ON, or the TEN terminal of the data link connector is grounded. PCME 46U0F2-015 F2—17 F2 ON-BOARD DIAGNOSIS SYSTEM PREPARATION SST DIAGNOSTIC TROUBLE CODE NUMBER Inspection Procedure Self-diagnosis checker 1. Connect the SST (Self-Diagnosis Checker) to the data link connector. 2. Set switch select to position 1. 3. Set the test switch to SELF TEST. 36U0F2-017 4. 5. 6. 7. NEGATIVE BATTERY CABLE Connect the SST to the System Selector and a ground. Set the select switch to position A. Turn the ignition switch ON. Verify that "88” flashes on the digital display and the buzz­ er sounds for 3 sec. after turning the ignition switch ON. 8. If “ 88” does not flash, check the main relay (refer to page F2-104), power supply circuit, and data link connector wiring. 9. If 88 flashes and the buzzer sounds continuously for more than 20 sec., check for a short circuit between the PCME terminal 1F and the data link connector. Replace the PCME if necessary and perform Steps 3 and 7 again. 10. Note any code numbers and check for the causes by refer­ ring to the check sequences shown on pages F2-22 through F 2-41. Repair as necessary. 11. After repairs, cancel the code numbers by performing the “ After-repair procedure” . (Refer to page F2-42.) ON-BOARD DIAGNOSIS SYSTEM F2 Principle of Code Cycle Diagnostic trouble codes are determined as shown below. 36U0F2-022 1. Code cycle break The time between diagnostic trouble code cycles is 4.0 seconds (the time the buzzer is off). DIAGNOSTIC TROUBLE CODE 1 CYCLE CYCLE BREAK ON IT OFF 4.0 SEC. 36U0F2-023 2. Second digit of diagnostic trouble code (ones position) The digit in the ones position of the diagnostic trouble code represents the number of times the buzzer sounds 0.4 second during one cycle. 1 CYCLE ON DIAGNOSTIC TROUBLE CODE 1 2 3 n DIAGNOSTIC TROUBLE CODE: 03 CYCLE BREAK i OFF 0.4 SEC. 0.4 SEC. 4.0 SEC. 36U0F2-024 3. First digit of diagnostic trouble code (tens position) The digit in the tens position of the diagnostic trouble code represents the number of times the buzzer is on 1.2 seconds during one cycle. The buzzer is off for 1.6 seconds between the long and short pulses. 1 CYCLE DIAGNOSTIC TROUBLE CODE 1 2 - 0.4 1.2 SEC. SEC. 1.6 h SEC, FIRST DIGIT CYCLE BREAK fir nr DIAGNOSTIC TROUBLE CODE: 22 4.0 SEC. SECOND DIGIT 36U0F2-025 F 2-1 9 F2 ON-BOARD DIAGNOSIS SYSTEM Diagnostic Trouble Code Numbers Indicator flashing pattern No. ON 02 OFF ON 03 OFF ON 04 OFF Point Memo­ rized • Crankshaft position sensor No. 2 connector • Wiring from crankshaft position sensor No. 2 to PCME • C rankshaft position sensor No. 2 Yes F 2 -2 2 Yes F 2 -2 3 Yes F 2 -2 4 O pen o r short circuit • K nock sensor co n ­ nector • W iring from knock sensor to PCME • K nock sensor Yes F 2 -2 5 O pen o r short circuit • V olum e airflow sensor con necto r • Wiring from volume air­ flow sensor to PCME • Volume airflow sensor Yes F 2 -2 6 E ngine coolant tem perature sensor • Engine coolant temper­ ature sensor connector >Wiring from engine coolant temperature sensor to PCME >Engine coolant temper­ ature sensor resistance Yes F 2 -2 7 Intake air tem prerature sensor (in volum e airflow sensor) >V olum e airflow sensor con necto r »Wiring from volume air­ flow sensor to PCME > Intake air tem p e ra ­ ture sensor re­ sistance Yes F 2 -2 8 Throttle position sensor * T hrottle position sen­ sor con necto r »W iring from throttle position sensor to PCME «Throttle position sensor Yes F 2 -2 9 Barom etric absolute pressure sensor (in PCME) -P C M E Yes F 2 -3 0 • H eated oxyg en sen­ sor con necto r >Wiring from heated oxy­ gen sensor to PCME • H eated oxygen sensor Yes F 2 -3 0 > EGR fun ction sensor con necto r • Wiring from EGR func­ tion sensor to PCME > EGR fun ction sensor Yes F 2 -3 1 »Fuel pressure > Injection fuel leakage • Ignition system >A ir leakage >PCME Yes F 2 -3 2 Diagnosed circuit NE 2 signal, crankshaft position sensor No. 2 Condition N o NE 2 signal G signal, crankshaft position sensor No. 1 N o G signal NE 1 signal, crankshaft position sensor No. 1 N o NE 1 signal ON K nock sensor 05 OFF ON 08 V olum e airflow sensor OFF ON 09 OFF ON 10 O FF O pen o r short circuit ON 12 OFF ON 14 OFF ON 15 OFF ON 16 OFF ON 17 OFF F 2-2 0 H eated oxygen sensor (Inactivation) S ensor ou tput c o n ­ tinues less than 0.55V 100 sec. after engine exce eds 1,500 rpm EGR function sensor O pen or short circuit H eated oxygen sensor (Inversion) S ensor o u tp u t not ch a n g e d 50 sec. after engine exce eds 1,500 rpm • D istributor con necto r • W iring from m ain relay to distributor >W iring from distribu­ tor to PCME > C rankshaft position sensor No. 1 F2 ON-BOARD DIAGNOSIS SYSTEM Indicator flashing pattern No. ON 23 OFF ON 24 O FF ON • 25 Diagnosed circuit Condition 26 28 29 OFF 34 Yes F 2 -3 2 PRC solenoid valve > PRC solenoid valve connection >Wiring from PRC sole­ noid valve to PCME > PRC solenoid valve continuity No F 2 -3 4 Purge solenoid valve > P urge solenoid valve connection »Wiring from purge sole­ noid valve to PCME • P urge solenoid valve con tinuity No F 2 -3 5 EGR solenoid valve (vacuum ) ■ EGR solenoid (vacu­ um ) valve connection * Wiring from EGR solenoid valve (vacuum) to PCME • EGR solenoid valve (vacuum ) continuity No F 2 -3 6 EGR solenoid valve (vent) » EGR solenoid valve (vent) connection * Wiring from EGR solenoid valve (vent) to PCME » EGR solenoid valve (vent) continuity No F 2 -3 7 Idle air control valve » Idle air control valve con necto r »Wiring from idle air control valve to PCME » Idle air control valve continuity No F 2 -3 8 VRIS Solenoid valve 1 • VRIS solenoid valve 1 connection >Wiring from VRIS sole­ noid valve 1 to PCME >VRIS solenoid valve 1 continuity No F 2 -3 9 VRIS solenoid valve 2 • VRIS solenoid valve 2 connection • W iring from VRIS sole­ noid valve 2 to PCME • VRIS solenoid valve 2 continuity No F 2 -4 0 C oolant fan relay (No.1) • C oolant fan relay con necto r ' W iring from relay to PCME 1C oolant fan relay No F 2 -4 1 OFF ON 41 OFF ON 46 OFF ON 67 O FF F 2 -3 0 > Fuel pressure • Injection fuel leakage > Ignition system • A ir leakage •P C M E O pen o r short circuit ON Yes S ensor ou tput not ch a n g e d 50 sec. after en gine exceeds 1,500 rpm C losed loop system (RH) OFF ON Page » H eated oxygen sen­ sor con necto r • Wiring from heated oxy­ gen sensor to PCME • Heated oxygen sensor H eated oxygen sensor (RH) OFF ON Memo­ rized S ensor ou tput co n ­ tinues less than 0.55V 100 sec. after engine exce eds 1,500 rpm O FF ON Point 46U0F2-018 The buzzer sounds only for the ones position when using the Digital Code Checker. To judge the correct diagnostic trouble code number, refer to the digital display. Refer to Section F1 when using the Digital Code Checker. Note • If more than one failure is present, the code numbers will be indicated in numerical order. After repairs, cancel the code numbers by performing the “ After-repair procedure” . (Refer to page F2-42.) F2-21 F2 ON-BOARD DIAGNOSIS SYSTEM Troubleshooting If a diagnostic trouble code numbers is shown on the SST, check for the cause by referring to the related chart. 02 (CRANKSHAFT POSITION SENSOR No.2 NE 2 SIGNAL) CODE NO. 1 2 3 4 ACTION INSPECTION STEP Yes Repair connector and/or wiring No Go to next step Is resistance of crankshaft position sensor OK? Yes Go to next step Resistance: 520—5800 No Replace crankshaft position sensor No.2 Does crankshaft position sensor circuit have poor connection? Is there continuity between ground and 3F or ground and terminal 3H? (at harness side) Disconnect connector from PCME; is resistance between terminals 3F and 3H OK? Resistance: 520—580(2 Yes Check for short circuit in wiring (Crankshaft position sensorterminal 3F or 3H) No Go to next step Yes Replace PCME No Check for open circuit in wiring (Crankshaft position sensorterminal 3F or 3H) c r page F2-105 46U0F2-019 Circuit Diagram 16E0F2-035 F 2 -2 2 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 03 (CRANKSHAFT POSITION SENSOR No.1 G SIGNAL) INSPECTION STEP 1 2 3 Is Code No.04 also present? Does distributor circuit have poor connection? Is connector terminal 1B voltage OK with d is tri­ utor connector disconne cted? Condition Voltage Ign switch ON 4 ACTION Battery positive voltage Is connector terminal (1D) voltage OK with dis­ tributor connector disconnected? Condition Voltage Ign switch ON Yes Go to next step No Go to Step 4 Yes Repair connector and/or wiring harness No Go to next step Yes Repair or replace distributor No Repair distributor terminal 1B wire Yes Repair or replace distributor No Check for short circuit in wiring harness (Distributor terminal [1D]—Ground) c r Section G o - Section G Approx. 5.0V If OK, replace PCME ■=> If not OK, repair wiring harness 46U0F2-020 Circuit Diagram FROM IGNITION SW ITCH DISTRIBUTOR TO IGNITION SWITCH FROM BATTERY IGNITION COIL TO TACHO­ METER MAIN RELAY TO DATA LINK CO NNECTOR ^ PCME CRANK­ SHAFT POSITION SENSOR G SIGNAL J - G SIGNAL +B NE1 SIGNAL i NE1 SIGNAL DISTRIBUTOR 1F|i E11D11C11B11A | l2C|2B|2A 16E0F2-037 F 2-2 3 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 04 (CRANKSHAFT POSITION SENSOR No.1 NE1 SIGNAL) 1 2 3 Is Code No.03 also present? Does distributor circuit have poor connection? Is connector terminal 1B voltage OK with d is tri­ utor connector disconne cted? Voltage Condition Ign switch ON 4 ACTION INSPECTION STEP Go to next step No Go to Step 4 Yes Repair connector and/or wiring harness No Go to next step Yes Repair or replace distributor No Repair distributor terminal 1B wire Yes Repair or replace distributor No Check for short circuit in wiring har­ ness (Distributor terminal 1C Ground) c r Section G c r Section G Battery positive voltage Is connector terminal 1C voltage OK with distrib­ utor connector disconnected? Condition Ign switch ON Yes Voltage Approx. 5.0V =0 If OK, replace PCME => If not OK, repair wiring harness 46U0F2-021 Circuit Diagram DISTRIBUTOR --- ------ |lF |lE |lD |lC |lB |lA i S—--------------------' ^ ^ |2C |2B |2A | ' -V 16E0F2-039 F 2 -2 4 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. INSPCTION STEP 1 2 05 (KNOCK SENSOR) Does knock sensor circuit have a poor con­ nection? Is there continuity between knock sensor and PCME terminal 2M? ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Check continuity between PCME ter­ minal 2M and ground ■=!> If continuity, repair or replace wiring ■=> If no continuity, go to next step 3 Try known good knock sensor; is same code No. present? No Repair wiring harness Yes Replace PCME c r page F2-92 No Replace knock sensor c r page F2-110 46U0F2-022 Circuit Diagram KNOCK SENSOR 16E0F2-041 F 2-2 5 F2 ON-BOARD DIAGNOSIS SYSTEM 08 (VOLUME AIRFLOW SENSOR) CODE No. INSPECTION STEP ACTION Is there continuity between volume airflow sensor terminal A and a ground? Is volume airflow sensor terminal B voltage OK with volume airflow sensor connector discon­ nected? Yes Repair wiring harness No Go to next step Yes Go to next step No Check for short or open circuit in wiring harness (volume airflow sensor terminal B PCME terminal 21) Voltage Condition Approx. 5.0V Ign switch ON o If OK, replace PCME ■=> If not OK, repair wiring harness Is resistance of volume airflow sensor OK? Volume airflow Closed throttle position (fi) sensor A—B 20—600 B -D Wide open throttle (Q) Yes Replace PCME cr page F2-92 No Replace volume airflow sensor cr page F2-48 2 0-1,000 2 0 0 -4 0 0 46U0F2-023 Circuit Diagram VOLUME AIRFLOW SENSOR (j j f l D l C l B l A l ) ) 16E0F2-043 F 2 -2 6 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 09 (ENGINE COOLANT TEMPERATURE SENSOR) INSPECTION STEP 1 2 Does the engine coolant temperature sensor cir­ cuit have a poor connection? Is engine coolant temperature sensor terminal A voltage OK with engine coolant temperature sen­ sor connector disconnected? Condition Ign switch ON ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for short or open circuit in wir­ ing harness (engine coolant tempera­ ture sensor terminal A—PCME terminal 2E) Voltage Approx. 5.0V => If OK, replace PCME <=> If not OK, repair wiring harness 3 4 Is there continuity between engine coolant tem­ perature sensor terminal A and a ground Is resistance of engine coolant temperature sensor OK? Coolant temp. Resistance (kfi) -2 0 °C (—4°F) 13.5-16.5 20°C (68°F) 2.20-2.70 80°C { 176°F) 0.29-0.35 Yes Go to next step No Repair wiring harness Yes Replace PCME c r page F2-92 No Replace engine coolant temperature sensor c r page F2-106 46U0F2-024 Circuit Diagram ENGINE COOLANT TEMPERATURE SENSOR ( n n ;n . 1 Bl A I, ---n---' 16E0F2-045 F 2 -2 7 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 10 (INTAKE AIR TEMPERATURE SENSO R-IN VOLUME AIRFLOW SENSOR) STEP INSPECTION 1 2 Does the volume airflow sensor circuit have a poor connection? Is volume airflow sensor terminal E voltage OK with volume airflow sensor connector disconnected? Condition Ign switch ON 3 Voltage ACTION Yes Check volume airflow sensor connec­ tor for poor connection and repair as necessary No Go to next step Yes Go to next step No Check for short or open circuit in wiring harness (Volume airflow sensor terminal E—PCME terminal 2K) Yes Replace PCME c r page F2-92 No Replace volume airflow sensor c r page F2-48 Approx. 5.0V Is resistance of intake air temperature sensor OK? Intake air temp. Resistance (kQ) -2 0 °C (—4°F) 1 0 -2 0 20°C |68°F) 2 -3 60°C { 140°F) 0.4—0.7 46U0F2-025 Circuit Diagram VOLUME AIRFLOW SENSOR 16E0F2-Q47 F 2 -2 8 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 12 (THROTTLE POSITION SENSOR) INSPECTION STEP 1 2 ACTION D o e s th ro ttle p o sitio n s e n so r c irc u it h a ve a p o o r c o n n e c tio n ? Is th ro ttle p o s itio n s e n so r te rm in a l A v o lta g e O K w ith th ro ttle p o s itio n s e n s o r d is c o n n e c te d ? Condition Voltage Y es R e p a ir c o n n e c to r a n d /o r w irin g h a rn e ss No G o to n e xt ste p Yes G o to n e xt ste p No C h e c k fo r o p e n o r sh o rt c irc u it in w irin g harness (Throttle position sensor term inal A — P C M E te rm in a l 21) A p p ro x . 5 .0 V Ig n s w itch O N o If O K, re p la c e PC M E => If n o t O K , re p a ir w irin g ha rn e ss 3 4 Is th e re c o n tin u ity b e tw e e n th ro ttle p o sitio n se n ­ sor and PCM E? Throttle position sensor PCME B 2F D G ro u n d Is th e re c o n tin u ity b e tw e e n te rm in a ls A a n d B w ith th ro ttle v a lv e c lo s e d th ro ttle p o sitio n to w id e o p e n th ro ttle ? Y es C h e c k fo r s h o rt c irc u it in w irin g h a rn e s (T hrottle p o sitio n se n so r te rm in a l B — P C M E te rm in a l 2F) => If O K , g o to n e xt ste p => If n o t O K, re p a ir w irin g h a rn e ss No R e p a ir w irin g h a rn e ss Yes R e p la ce P C M E cr page No R e p la ce th ro ttle p o sitio n se n so r cr page F2-108 F2-92 46U0F2-026 Circuit Diagram THROTTLE POSITION SENSOR /----- n n —- i l D 1 C I B I A ll 16E0F2-O49 F 2-2 9 F2 ON-BOARD DIAGNOSIS SYSTEM 14 (BAROMETRIC ABSOLUTE PRESSURE SENSOR—IN PCME) CODE No. ACTION STEP R e p la c e P C M E 1 c r page F2-92 46U0F2-199 CODE No. 15 and/or 23 (HEATED OXYGEN SENSOR—INACTIVATION) Note • If Code No.15 and 17 are both present, first perform the checking procedure for Code No.17. INSPECTION STEP D o e s h e a te d o x y g e n s e n s o r c irc u it h a ve a p o o r c o n n e c tio n ? 1 2 Is h e a te d o x y g e n s e n so r o u tp u t v o lta g e O K? 3 Is th e re c o n tin u ity b e tw e e n h e a te d o x y g e n sen­ s o r a n d P C M E te rm in a l 2 D (R H : 2C)? ACTION Yes R e p a ir c o n n e c to r a n d /o r w irin g ha rn e ss No G o to n e xt step Yes G o to n e xt step No R e p la ce h e a te d o x y g e n se n so r Y es C h e c k fo r s h o rt c irc u it in w irin g a- page F2-109 If O K, re p la ce PC M E => If n o t O K, re p a ir w irin g ha rn e ss No R e p a ir w irin g h a rn e ss 36U0F2-036 Circuit Diagram HEATED OXYGEN SENSOR r.— — LH A D B c HEATD OXYGEN SENSOR r ---RH A D B C A L IF O R N IA : B O D Y G R O U N D c — — 16E0F2-052 F 2 -3 0 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 16 (EGR FUNCTION SENSOR) INSPECTION STEP ACTION D o e s EG R fu n c tio n s e n so r c irc u it h a ve a p o o r c o n n e c tio n ? Is EG R fu n c tio n s e n s o r te rm in a l C v o lta g e O K w ith EG R fu n c tio n s e n so r c o n n e c to r d is c o n ­ n e c te d ? Condition Ig n sw itch O N Y es R e p a ir c o n n e c to r a n d /o r w irin g h a rn e ss No G o to n e xt ste p Yes G o to n e xt ste p No C h e c k fo r sh o rt o r o p e n c irc u it in w ir­ in g h a rn e ss (EGR fu n c tio n s e n so r te r­ m inal C — P C M E te rm in a l 21) Voltage A p p ro x . 5 .0 V => If O K, re p la c e PC M E O K , re p a ir w irin g h a rn e ss < = >If n o t Is th e re c o n tin u ity b e tw e e n EG R fu n c tio n s e n so r and PCME? EG R fu n c tio n s e n so r PCM E A 2j B G ro u n d Yes ■=£> If O K , g o to n e xt ste p ^ If n o t O K, re p a ir w irin g h a rn e ss m R e m o v e EG R fu n c tio n se n so r; is s e n so r rod dam aged? cr page F2-78 Is th e re u n b ro k e n c o n tin u ity b e tw e e n te rm in a ls A a n d C w h ile EG R fu n c tio n s e n so r ro d is m o v e d fro m fu lly e x te n d e d to fu lly d e p re s s e d ? C h e c k fo r sh o rt c irc u it in w irin g h a r­ ness (EGR fu n c tio n s e n so r te rm in a l A — P C M E te rm in a l 2J) No R e p a ir w irin g h a rn e ss Yes R e p la ce EG R fu n c tio n s e n so r No G o to n e xt ste p Yes R e p la ce P C M E No R e p la ce EG R fu n c tio n se n so r cr page F2-92 46U0F2-027 Circuit Diagram SENSOR 16E0F2-054 F2-31 F2 ON-BOARD DIAGNOSIS SYSTEM 17 and/or 24 (HEATED OXYGEN SENSOR-INVERSION) CODE No. 1 ACTION INSPECTION STEP Is th e s a m e C o d e N o. p re s e n t fo llo w in g a fte r­ re p a ir p ro c e d u re ? c r page F2-42 Yes G o to n e xt ste p No C h e c k h e a te d o x y g e n s e n so r c irc u it fo r a p o o r co n n e c tio n ^ 2 D o e s m o n ito r la m p o f S e lf-D ia g n o sis C h e c k e r il­ lu m in a te a t id le a fte r th e e n g in e has b e e n w a rm e d u p a n d run a t 2500—3000 rpm fo r 3 min? Yes If O K, p e rfo rm d ia g n o s tic tro u b le C o d e N o. 15 G o to n e xt ste p Note • No A /F m ixtu re rich G o to S te p 5 Note • 3 Is fu e l lin e p re s s u re c o rre c t a t idle? c r Is th e re fu e l le a k a g e at in je cto r? c r 5 G o to n e xt ste p page F2-70 Fuel line pressure: 210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi) (vacuum hose to pressure regulator disconnected) 4 Yes A /F m ixtu re is lean o r m isfire is o c ­ c u rrin g No High pressure C h e c k if fuel re tu rn hose is c lo g g e d o r re stricte d ■=> If O K , re p la ce p re ssu re re g u la to r c r page F2-66 Yes R e p la ce in je cto r c r page F2-66 No C h e c k e n g in e c o o la n t te m p e ra tu re se n so r? c r page F2-106 •=> If it is O K, re p la c e h e a te d o x y g e n se n so r o If it is n o t O K , re p la c e it c r page F2-106 page F2-68 D is c o n n e c t e a ch h ig h -te n s io n le a d at idle; d o e s e n g in e s p e e d d e c re a s e e q u a lly at e a ch c y lin d e r? Yes G o to n e xt ste p No G o to S te p 8 46U0F2-028 Circuit Diagram F 2 -3 2 F2 ON-BOARD DIAGNOSIS SYSTEM B +: Battery positive voltage INSPECTION STEP 6 Is fu e l line p re s s u re c o rre c t at idle? cr ACTION Yes G o to n e xt ste p page F2-70 Fuel line pressure: 210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi) (vacuum hose to pressure regulator disconnected) No Low pressure C h e c k fuel line p re s s u re w h ile p in c h ­ in g fuel re tu rn hose ^ ^ 7 8 9 Is th e re a ir le a ka g e in intake air system co m p o n e n ts? Is th e re a m isfire o f a d e a d c y lin d e r fro m S te p 5 in ­ s p e c tio n ? Is th e re an in je c to r o p e ra tin g s o u n d at id le o f d e a d c y lin d e r fro m S te p 5 in sp e ctio n ? If it quickly in crea se s, c h e c k p re s ­ s u re re g u la to r If it gradually in crea se s, c h e c k fo r c lo g g in g b e tw e e n fu e l p u m p a n d p re s s u re re g u la to r If h o se is n o t c lo g g e d , c h e c k fuel p u m p m a xim u m p re s s u re Yes G o to n e xt ste p No R e p la ce h e a te d o x y g e n s e n so r Y es R e p a ir o r re p la c e ig n itio n syste m c o m ­ p o n e n ts ) No G o to n e xt ste p Yes G o to n e xt ste p No C h e c k fo r a p p ro x . B + at in je c to r te r­ m inal A ■=> If th e re is, re p la ce in je c to r => If th e re is not, c h e c k fo r a sh o rt o r o p e n c irc u it in w ire h a rn e ss 10 R e p la c e in je c to r a t d e a d c y lin d e r fro m S te p 5 in ­ s p e c tio n cr page F2-32 Is th e s a m e C o d e N o. p re s e n t fo llo w in g a fte r re p a ir p ro c e d u re ? cr Y es T ry k n o w n g o o d PC M E No S ystem O K cr page F2-70 cr page F2-63 cr page F2-109 cr page F2-66 page F2-42 46U0F2-029 Circuit Diagram F 2-3 3 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 25 (PRESSURE REGULATOR CONTROL SOLENOID VALVE) INSPECTION STEP 1 2 Does PRC solenoid valve circuit have a poor connection? s connector terminal A /oltage OK with PRC solenoid valve connecto disconnected? Voltage Condition Ign switch ON 3 ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (PRC solenoid valve terminal A—Main relay terminal D) Yes Check for short circuit in wiring harness (PRC Solenoid valve terminal B— PCME terminal 3M) Battery positive voltage Is continuity between PRC solenoid valve termi­ nal B and PCME terminal 3M? ■=> If OK, go to next step ^ If not OK, repair wiring harness 4 Is PRC solenoid valve OK? c r page F2—72 No Repair wiring harness Yes Replace PCME No Replace PRC solenoid valve c r page F2-92 46U0F2-030 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY PRC SOLENOID VALVE 16E0F2-059 F 2 -3 4 F2 ON-BOARD DIAGNOSIS SYSTEM 26 (PURGE SOLENOID VALVE) CODE No. INSPECTION STEP 1 2 Does purge solenoid valve circuit have a poor connection? • Is connector terminal A /oltage OK with purge solenoid valve connecto disconnected? Condition Ign switch ON 3 Voltage Battery positive voltage Is there continuity between purge solenoid valve terminal B and PCME terminal 20? ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wir­ ing harness (Purge solenoid valve ter­ minal A—Main relay terminal D) Yes Check for short circuit in wiring har­ ness (Purge solenoid valve terminal B—PCME terminal 20) If OK, go to next step => If not OK, repair wiring harness 4 Is purge solenoid valve OK? c r page F2-82 No Repair wiring harness Yes Replace PCME No Replace solenoid valve c r page F2-92 46U0F2-031 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY MAIN RELAY PURGE SOLENOID VALVE ? PURGE SOLENOID VALVE b F a! 16E0F2-061 F 2-3 5 F2 ON-BOARD DIAGNOSIS SYSTEM 28 (EGR SOLENOID VALVE-VACUUM) CODE No. INSPECTION STEP 1 2 Does EGR solenoid valve circuit have a poor connection? Is connector terminal A voltages OK with EGR solenoid valve (vacuum) connector discon­ nected? Voltage Condition Ign switch ON 3 ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (EGR Solenoid valve (vacuum) terminal A—Main relay terminal D) Yes Check for short circuit in wiring from EGR solenoid valve (vacuum) terminal B to PCME terminal 3P Battery positive voltage Is there continuity between EGR solenoid valve (vacuum) terminal B and PCME terminal 3P? => If OK, go to next step => If not OK, repair wiring harness 4 Is EGR solenoid valve (vacuum) OK? a - page F2-77 No Repair wiring harness Yes Replace PCME No Replace EGR solenoid valve (vacuum) o- page F2-92 46U0F2-032 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY EGR SOLENOID VALVE (VACUUM) n n JibJu a-IS _______________ 16E0F2-063 F2—36 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 29 (EGR SOLENOID VALVE VENT) STEP 1 2 INSPECTION Does EGR solenoid valve (vent) circuit have a poor connection? Is connector terminal A voltage OK with EGR solenoid valve (vent) corinector disconnected? Condition Ign switch ON 3 Voltage ACTION Yes Repair connector and/or wiring harness No Go to next stop Yes Go to next step No Check for open or short circuit in wiring harness (EGR solenoid valve (vent) terminal A—Main relay terminal D) Yes Check for short circuit in wiring harness (EGR solenoid valve (vent) terminal B— PCME terminal 30) Battery positive voltage Is there continuity between EGR solenoid valve (vent) terminal B and PCME terminal 30? ■=£> If OK, go to next step ^ If not OK, repair wiring harness 4 Is EGR solenoid valve (vent) OK? cr No Repair wiring harness Yes Replace PCME No Replace EGR solenoid valve (vent) cr page F2-92 page F2-77 46U0F2-033 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY 16E0F2-065 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 34 (IDLE AIR CONTROL VALVE) 1 2 Does idle air control valve circuit have a poor connection? Is connector terminal A /oltage OK with idle air control valve connector disconnected? Voltage Condition Ign switch ON 3 ACTION INSPECTION STEP Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (Idle air control valve terminal A—Main relay terminal D) Yes Check for short circuit in wiring harness (Idle air control valve terminal B—PCME terminal 30) Battery positive voltage Is there continuity between idle air control valve terminal B and PCME terminal OK? => If OK, go to next step => If not OK, repair wiring harness 4 Is idle air control valve OK? c r page F2-53 No Repair wiring harness Yes Replace PCME c r page F2-92 No Replace idle air control valve c r page F2-48 46U0F2-034 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY IDLE AIR CONTROL VALVE O bT a D 16E0F2-067 F 2 -3 8 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 41 (VRIS SOLENOID VALVE No.1) INSPECTION STEP 1 2 Does VRIS solenoid valve No.1 circuit have a poor connection? s connector terminal A voltage OK with VRIS solenoid valve No.1 con nector disconnected? Condition Ign switch ON 3 Voltage ACTION Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (VRIS solenoid valve No. 1 termi­ nal A—Main relay terminal D) Yes Check for short circuit in wiring harness (Solenoid valve No.1 terminal B—PCME terminal 31) Battery positive voltage Is there continuity between VRIS solenoid valve No.1 terminal B and PCME terminal 31? => If OK, go to next step => If not OK, repair wiring harness 4 Is VRIS solenoid valve No.1 OK? No Repair wiring harness Yes Replace PCME cr No Replace VRIS solenoid valve No.1 cr page F2-56 page F2-92 c r page F2-57 46U0F2-035 Circuit Diagram FROM IGNITION SWITCH FROM BATTERY MAIN RELAY 'A VRIS SOLENOID VALVE No.1 VRIS SOLENOID VALVE No.1 i I | GY | R / B | 16E0F2-069 F 2 -3 9 F2 ON-BOARD DIAGNOSIS SYSTEM 46 (VRIS SOLENOID VALVE No.2) CODE No. 1 2 Does VRIS solenoid valve No.2 circuit have a poor connection? Is connector terminal A voltage OK with VRIS solenoid valve No.2 connector discon­ nected? Voltage Condition Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (VRIS solenoid valve No.2 termi­ nal A—Main relay terminal D) Yes Check for short circuit in wiring harness (VRIS solenoid valve No.2 terminal B— PCME terminal 3J) Battery positive voltage Ign switch ON 3 ACTION INSPECTION STEP Is continuity between VRIS solenoid valve No.2 terminal B and PCME terminal 3J? ■=> If OK, go to next step ■=> If not OK, repair wiring harness 4 Is VRIS solenoid valve No.2 OK? c r page F2-57 No Repair wiring harness Yes Replace PCME c r page F2-92 No Replace VRIS solenoid valve No.2 c r page F2-56 46U0F2-036 Circuit Diagram FROM IGNITION SWITCH 1 f t FROM BATTERY °6/ — r» 0/ MAIN RELAY VRIS SOLENOID VALVE No.2 / 16E0F2-071 F 2 -4 0 F2 ON-BOARD DIAGNOSIS SYSTEM CODE No. 67 (COOLANT FAN RELAY No.1) STEP 1 2 Is connector terminal A voltage OK with relay connector disconnected? Condition Ign switch ON 3 4 ACTION INSPECTION Does relay circuit have a poor connection? Voltage Yes Repair connector and/or wiring harness No Go to next step Yes Go to next step No Check for open or short circuit in wiring harness (Relay terminal A—Ignition switch terminal IG1) Yes Go to next step No Replace relay Yes Check for short circuit in wiring harness (Relay terminal B to PCME terminal 3L) Battery positive voltage Is there continuity between relay terminals A and B? Is there continuity between relay terminal B and PCME terminal 3L? ■=> If OK, replace PCME => If not OK, repair wiring harness No c r page F2-92 Repair wiring harness 46U0F2-037 Circuit Diagram COOLANT FAN RELAY No.1 COOLANT FAN RELAY No.1 c A D B 16E0F2-Q73 F2 ON-BOARD DIAGNOSIS SYSTEM After-repair Procedure Cancel the memory of diagnostic trouble code by discon­ necting the negative battery cable and depressing the brake pedal for at least 20 sec.. Reconnect the negative battery cable. 46U0F2-038 Self-Diagnosis Checker 1. Connect the SST (System Selector) to the data link con­ nector. 2. Set system select to position 1. 3. Set the test switch to SELF TEST. 36U0F2-049 4. Connect the SST (Self-Diagnosis Checker) to the System Selector and a ground. 5. Set the select of the Self-Diagnosis Checker to position A. 6. Turn the ignition switch ON. 7. Verify that no diagnostic trouble codes are displayed. 46U0F2-039 F 2 -4 2 F2 ON-BOARD DIAGNOSIS SYSTEM SWITCH MONITOR FUNCTION Individual switches can be inspected by the SST (Self-Diagnosis Checker). Preparation The TEN terminal of the data link connector must be grounded and the ignition switch turned to ON (en­ gine off). If either switch remains activated, the monitor light will be illuminated. Self-Diagnosis Checker (Monitor lamp) Switch Remarks Light ON Light OFF Clutch switch (MTX) Pedal released Pedal depressed Neutral switch (MTX) In gear Neutral Park/Neutral switch (ATX) L, S, D, or R range N or P range — Idle switch (in throttle position sensor) Pedal depressed half Pedal released fully — Stoplight switch Pedal depressed Pedal released Headlight switch ON OFF Positionlight ON A t 3 rd o f 4th p o sitio n Blower switch ON OFF Rear window defroster switch ON OFF In gear Clurch pedal released — — Air Conditioning sensor ON OFF Blower switch at 1st or 2nd position Daytime running light (CANADA) ON OFF ON; Parking lever relased 46U0F2-040 HEATED OXYGEN SENSOR MONITOR FUNCTION With the System Selector test switch set to 02 Monitor, the heated oxygen sensor is monitored as described. Condition Engine Running System Selector Switch O2 monitor Item monitored Heated oxygen sensor output signal Function Heated oxygen sensor out­ put more than 0.45V Monitor lamp ON Heated oxygen sensor out­ put less than 0.45V Monitor lamp OFF 36U0F2-054 F2 ON-BOARD DIAGNOSIS SYSTEM Inspection Procedure Self-Diagnosis Checker 1. Perform Preparation. (Refer to page F2-18.) 2. Connect the SST (System Selector) to the data link con­ nector. 3. Set system select to position 1. 4. Set TEST SW to SELF-TEST. 46U0F2-041 5. Connect the SST (Self-Diagnosis Checker) to the System Selector and a ground. 6. Set the select switch of the Self-Diagnosis Checker to posi­ tion A. 7.Turn the ignition switch to ON (engine off). 46U0F2-042 ON-BOARD DIAGNOSIS SYSTEM F2 Procedure 46U0F2-Q43 Neutral and Clutch switches (MTX) Idle switch Stoplight switch 46U0F2-046 F2—45 F2 ON-BOARD DIAGNOSIS SYSTEM Headlight switch 46U0F2-047 DRL Blower switch 46U0F2-049 Air conditioning sensor 46U0F2-050 Rear window defroster switch 46U0F2-051 F 2-4 6 ON-BOARD DIAGNOSIS SYSTEM F2 Park/Neutral switch (ATX) 46U0F2-052 F2 INTAKE AIR SYSTEM INTAKE AIR SYSTEM COMPONENT PARTS Removal / Inspection / Installation 1. Remove in the order shown in the figure, referring to Removal Note. (Refer to page F2-49.) 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to Installation Note. (Refer to page F2-49.) 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 inlbf) O-RINQ, REPLACE O-RING, REPLACE 19—25 (1.9—2.6, 14— 18) GASKET, REPLACE GASKET, REPLACE O-RING, REPLACE 19—25 |1 .9 —2.6, 14— 18) WASHER, REPLACE 7 .9 -1 0 .7 N m 180— 110 kgfcm, 70—95.4 Inlbf) 19—25 (1.9—2.6, 14— 18) 7.9—10.7 N-m (80— 110 kgf-cm, 70—95.4 In-lbf) 7.9— 10.7 N-m [80— 110 kgf-cm, 70—95.4 ln-lbf) N-m |kgf-m, ft-lbf) 46UOF2-053 1. Fresh air duct Inspect for damage and cracks 2. Air cleaner housing Inspect for damage and cracks 3. Volume airflow sensor Inspection...............................page F2-104 4. Air intake hose Inspect for damage 5. Accelerator cable Inspection / Adjustment.......... page F2- 50 F 2 -4 8 6. Fuel pipe 7. Intake manifold Inspection................................ page 8. Throttle body Inspection................................ page 9. BAC valve Inspection................................ page 10. Air intake pipe Inspection................................ page 11. Fuel distributor F2-51 F2-49 F2-53 F2-51 INTAKE AIR SYSTEM F2 Removal Note Fuel hose Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures’’ on page F2-59. 46U0F2-054 Water hose 1. Loosen the drain plug and drain the coolant from the radi­ ator. (Refer to Section E2.) 2. Remove the water hose from the BAC valve. 3. After installation of the throttle body, refill the radiator. (Refer to Section E2.) 46U0F2-186 Installation Note Air intake pipe 1. Apply a small amount of clean engine oil to new O-rings before installing them. 2. Install the air intake pipe. O-RINGS, REPLACE Tightning torque: 7.9—10.7 N m {80—110 kgf cm, 70—95.4 inlbf) 46U0F2-187 THROTTLE BODY Inspection 1. Check the throttle body for wear, coolant leakage, and deposits. 2. Verify that the throttle valve moves smoothly from closed throttle position to wide open throttle. 3. Replace the throttle body, if necessary. (Refer to page F2-48.) F 2-49 F2 INTAKE AIR SYSTEM ACCELERATOR PEDAL Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal. 1. Accelerator cable Inspection / Adjustment 2. Actuator cable 3. Retainer 4. Clip below 5. Accelerator pedal Inspect for damage 6. Return spring 7. Bracket ACCELERATOR CABLE Installation / Adjustment 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5—4.5mm {0.06—0.17 in) 3. If not as specified, turn stopper B while pressing lock but­ ton A to release the lock. 4. Push the spring in direction C and adjust the cable free play. 5. Lock stopper A after locking stopper B. 36U0F2-074 F 2 -5 0 INTAKE AIR SYSTEM F2 AIR INTAKE PIPE/INTAKE MANIFOLD Inspection 1. Check for damage and cracks. 2. Verify flatness of the air intake pipe and intake manifold con­ tact surface as shown. 3. Replace the air intake pipe and/or intake manifold, if necessary. F2-51 F2 IDLE-SPEED CONTROL SYSTEM IDLE-SPEED CONTROL SYSTEM DESCRIPTION The idle-speed control system controls the bypass air amount that passes through the throttle body to improve idle stability, warm-up, and driveability. This system consists of the idle air control valve, air valve, powertrain control module, and input devices. THROTTLE POSITION SENSOR ENGINE COOLANT TEM PERATURE SENSOR CLUTCH SW ITCH (MTX) POWERTRAIN CONTROL I MODULE IDLE AIR CONTROL VALVE CRANKSHAFT POSITION SENSOR No.2 (NE2 SIGNAL) \ NEUTRAL SWITCH (MTX) PARK/NEUTRAL SWITCH (ATX) 36U0F2-076 F 2-52 F2 IDLE-SPEED CONTROL SYSTEM PREPARATION SST For inspection of idle air control valve and air valve 49 B019 9A0 System Selector f/T 36U0F2-259 SYSTEM OPERATION 1. Warm up the engine to normal operating temperature. 2. Turn all electric loads OFF. 3. Connect a tachometer to the data link connector terminal IG - as shown. 4. With the cooling fan off, verify that the idle speed is within specification. TACHOMETER Idle speed (Neutral): 600—700 (650 ± 50) rpm DATA LINK CONNECTOR 46U0F2-056 5. Verify that the idle speed is within the specification under the conditions below. Condition No load Electrical load ON (headlights, rear window defroster, etc) Air Conditioner ON P/S operating Idle speed (rpm) 6 00 -7 00 (650 ± 50) 6 00 -7 00 (650 ± 50) 7 75 -8 75 (825 ± 50) 6 00 -7 00 (650 ± 50) BAC VALVE Inspection Air valve 1. Verify that the engine coolant temperature is below 20°C {68°F}. 2. Connect the SST to the data link connector. 3. Set the system select to position 1 and test switch to SELF TEST. 4. Start the engine. 5. Verify that the idle speed decreases gradually as the en­ gine warms up. Idle air control valve BODY 1. Remove the throttle body. (Refer to page F2-48.) 2. Measure the resistance of the idle air control valve. Resistance: 10.7—12.3 O [at 20°C (68°F)] 3. If not as specified, replace the BAC valve. Removal / Installation (Refer to page F2-48.) 46U0F2-058 F2—53 F2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) DESCRIPTION The inside of the dynamic chamber is divided into two sections, interconnected by two shutter valves and connecting pipes for variable resonance induction operation. This system opens and closes the shutter valves according to the engine speed to improve the charging efficiency by utilizing the pressure waves of the intake air. There are two vacuum chambers under the left bank of the intake manifold that are used to supply con­ stant vacuum to the VRIS shutter valve actuators during wide-open throttle operation and other low-vacuum, low-speed situations. VRIS VRIS SHUTTER VALVE No. VALVE VALVE No.2 VACUUM CHAMBERS SHUTTER VALVE ACTUATOR No.1 SHUTTER VALVE ACTUATOR No.2 TORQUE CHARACTERISTICS Nos.1 AND 2 CLOSED No.1 OPEN, No.2 CLOSED Nos.1 AND 2 OPEN 3,250 4,250 6,250 (RPM) ENGINE SPEED 36U0F2-101 Operation Engine speed 0 -3 ,2 5 0 3,250-4,250 4,250-6,250 6,250-7,500 Shutter valve No.1 Closed Open Open Closed Shutter valve No.2 Closed Closed Open Closed F 2 -5 4 (rpm) VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) F2 SYSTEM OPERATION 1. Start the engine and let it idle. 2. Open the throttle valve quickly. 46U0F2-188 3. Verify that the rod of shutter valve actuator No.1 and No.2 operates. SHUTTER VALVE ACTUATOR No.1 46U0F2-059 F2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) COMPONENT PARTS Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 46U0F2-060 1. VRIS solenoid valve No.1 Inspection.................................page F2-57 2. VRIS solenoid valve No.2 Inspection.................................page F2-57 3. Shutter valve actuator Inspection.................................page F2-57 F2—56 4. Intake manifold (Refer to page F2-51) 5. Vacuum chamber Inspection.................................page F2-57 6. Check valve Inspection.................................page F2-57 F2 VARIABLE RESONANCE INDUCTION SYSTEM (VRIS) VRIS SHUTTER VALVE ACTUATOR (No.1, No.2) Inspection 1. Disconnect the vacuum hose from the shutter valve actuator. 2. Connect a vacuum pump to the actuator. 3. Apply vacuum and verify that the rod is pulled into the ac­ tuator. 46U0F2-061 W HITE ____ GREEN _ X /ff I'v-.V CHECK VALVE Inspection 1. Remove the check valve. 2. Blow through A and verify that air flows from B. 3. Blow through B and verify that air does not flow from A. (( y ; .‘V)- s y / 16E0F2-109 VRIS SOLENOID VALVE (No.1, No.2) Inspection 1. Disconnect the solenoid valve. 2. Verify air flow between each-port as shown below. Port Airflow A -B No A -C No B -C Yes 46U0F2-062 3. Apply battery positive voltage and a ground to the termi­ nals of the solenoid valve. 4. Verify air flow between each port as shown below. Port Airflow A -B Yes A -C No B -C No 46U0F2-189 VACUUM CHAMBER Inspection 1. Visually check the vacuum chambers for clogging, dam­ age, and cracks. 2. Replace if necessary. 16E0F2-110 F 2 -5 7 F2 FUEL SYSTEM FUEL SYSTEM DESCRIPTION This system supplies fuel to the fuel injectors at a constant pressure. Fuel is metered and injected into the intake manifold ports according to injection control signals from the PCME. The system consists of the fuel tank, fuel pump, fuel filters, fuel distributor, pressure regulator, fuel injectors, and fuel pump relay. FUEL INJECTOR ASSEMBLIES PRC SOLENOID VALVE TO FUEL TANK FROM FUEL PUMP PUMP FUEL FILTER VALVE (TWO-WAY) FUEL TANK 36UOF2-080 F 2 -5 8 FUEL SYSTEM F2 PREPARATION SST 16E0F2-117 Fuel Pressure Release and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easly ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the en­ gine is not running. 46U0F2-063 Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the following “ Fuel Line Safe­ ty Procedures” . Fuel Line Sately Procedures A .Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakage 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. Install hose clamps to secure the fuel pressure gauge to fuel filter and the main hose. SYSTEM OPERATION Fuel Pressure Hold Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” above. 1. Disconnect the negative battery cable. 46U0F2-065 F 2-5 9 F2 FUEL SYSTEM 2. Install a fuel pressure gauge. 3. Connect the negative battery cable. 16E0F2-121 4. Connect the data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min. Fuel pressure: More than 150 kPa {1.5 kgf/cm2, 21 psi] 36U0F2-082 8. If • • • not as specified, perform the following inspections. Fuel pump (Refer to page F2-63.) Pressure regulator (Refer to page F2-70.) Injector fuel leakage (Refer to page F2-68.) 46U0F2-185 Fuel Line Pressure Inspection Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F2-59. 1. 2. 3. 4. JUMPER Disconnect the negative battery cable. Install a fuel pressure gauge. (Install clamps as shown.) Connect the negative battery cable. Connect data link connector terminals F/P and GND with a jumper wire. 5. Turn the ignition switch ON. 6. Measure the fuel line pressure. Fuel line pressure: 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi) Pressure low DATA LINK CONNECTOR Pressure high 46U0F2-067 F 2 -6 0 — Measure fuel pump maximum pressure. (Refer to Page F2-63.) If as specified, fuel line or fuel filter might be clogged or restricted. — Replace pressure regulator. FUEL SYSTEM F2 FUEL TANK Removal / Inspection / Installation Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Warning • Fuel line spilis and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F2-59. Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repair­ ing it. 1. Remove in the order shown in the figure, referring to Removal Note. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to Installation Note. 1. 2. 3. 4. Pre silencer Insulator Connector Fuel hoses Installation Note. 5. Evaporative hoses Installation Note. page F2-62 6. Fuel tank straps 7. Fuel tank Inspect for cracks and corrosion 8. Check valve (Two-way) Inspection................................ page F2-83 page F2-62 F2-61 F2 FUEL SYSTEM Removal Note Before removing the fuel tank, drain the fuel from the tank. 1. Remove the fuel pump relay. 2. Start the engine. 3. After the engine stalls, turn off the ignition switch. 4. Install the fuel pump relay. FUEL PUMP RELAY 36U0F2-087 HOSE deg. ---------2160mm 5. Remove the filler cap and insert a hose into the fuel tank through the filler pipe. 6. Start the pump and suck up the fuel into a container. ^ 85.0 in)-------- Note • For easier work, prepare a hose of following size. Outer diameter: 13mm (0.51 in) Length: 2,160mm (85.0 in) 46U0F2-205 Installation Note 1. Push the ends of the main fuel hose, fuel return hose, and evaporative hoses onto the fuel tank fittings at least 25mm [1.0 In). 2. Push the fuel filler hose onto the fuel tank pipe and filler pipe at least 35mm (1.4 In). 25mm (1 16E0F2-131 F 2 -6 2 FUEL SYSTEM F2 FUEL PUMP Inspection Fuel pump maximum pressure Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F2-59. JUM PER WIRE DATA LINK CONNECTOR 36U0F2-091 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge to the main fuel pipe and plug the outlet of the gauge as shown. (Install clamps as shown.) 3. Connect the negative battery cable. 4. Connect data link conector terminals F/P and GND by us­ ing a jumper wire. 5. Turn the ignition switch ON to operate the fuel pump. 6. Measure the pump maximum pressure. Fuel pump maximum pressure: 500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi) 7. Turn the ignition switch OFF and disconnect the jumper wire. 8. If not as specified, replace the fuel pump. Continuity Inspection 1. Disconnect the fuel tank unit connector. 2. Check for continuity between the fuel tank unit connector ® and (6). 3. If there is none, replace the fuel pump. 36U0F2-092 F2 FUEL SYSTEM Removal / Installation 1. Remove the fuel tank. (Refer to page F2-61.) 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of disassembly, referring to Installation Note. 46U0F2-070 1. Fuel hose 2. Fuel pump ring Removal / Installation Note................ Below 3. Fuel pump 4. Fuel pump gasket Removal Note Rotate the fuel pump ring counterclockwise, and remove it. Installation Note Rotate the fuel pump ring clockwise until the flange touches the stopper. F 2 -6 4 FUEL SYSTEM F2 FUEL FILTER Replacement High-pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule. 1. Disconnect the fuel hoses from the fuel filter. 2. Remove the fuel filter and bracket. 3. Install in the reverse order of removal. 4. Verify that the fuel hoses are pushed fully onto the fuel filter nozzles. N m (kgf m, ft-lbf) 46U0F2-071 1. Negative battery cable 2. Air cleaner housing 3. Harness 4. Fuel filter (High-pressure side) Low-pressure side (in-tank filter) (Refer to page F2-64.) FUEL 46U0F2-072 F2 FUEL SYSTEM INJECTOR Inspection (On-vehicle) 1. Warm up the engine and let it idle. 2. Listen for operational sound of each injector with a screw­ driver or a sound scope. Note • The best way to judge the performance of an injector is to compere its sound with the sound of other injectors. Removal / Installation Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F2-59. 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal, referring to Installation Note. 46U0F2-O74 1. Negative battery cable 2. Air cleaner housing 3. Injector connector 4. Fuel hose and fuel pipe 5. Fuel distributor (RH) 6. Fuel distributor (LH) 7. Insulator 8. Accumulated connector 9. Spacer 10. Injector 11. Pressure regulator Inspection.................................page F2-70 F2 FUEL SYSTEM Installation Note Injector installation 1. Install new O-rings. 2. Apply a small amount of clean engine oil to the O-rings be­ fore installing them. 3. Verify that the injector holder is clean. 4. Clean the holder with gasoline, if necessary. 5. Install the injector squarely into the distribution pipe while turning it back and forth. 6. Fit the injector tab into the notch in the distribution pipe. 7. Install the harness. Tightening torque: 2.5—3.5 N m (25—36 kgf cm, 22—31 in lbf) 16E0F2-147 Fuel leakage test 1. With the injector assembly removed, install the fuel hoses as shown in the figure. 16E0F2-148 2. Connect the data link connector terminals F/P and GND with a jumper wire. 3. Turn the ignition switch ON and check for fuel leaks from the fuel distributor. 4. If fuel leaks, check the injector O-rings and fuel distributor for damage. 46U0F2-075 46U0F2-076 Fuel distributor installation 1. Install new injector insulators. 2. Install the insulators, making sure that each is pressed in fully, and that it is not twisted or bent. Incorrectly installed insulators can cause rough idle. F 2 -6 7 F2 FUEL SYSTEM Inspection Note • It is not necessary to remove the injectors to perform the following procedures. Injector resistance 1. Disconnect injector connectors. 2. Measure resistance of the injectors. Harness Right Bank RIGHT BANK Left Bank Terminal a—b a—c a—d d—c d—b d—a Injector No. 1 5 3 2 4 6 Resistance: Approx. 13.8Q (20°C {68°F}) No.2 No.4 LEFT BANK No.6 3. If not as specified, check continuity of the harness and check for poor connection. 4. If the harness is OK, replace injector. Fuel leakage test 1. Remove the fuel distributor assembly from the intake mani­ fold. (Refer to page F2-66.) 2. Connect the fuel hoses. 46U0F2-078 JUMPER WIRE 3. Connect the data link connector terminals F/P and GND by using a jumper wire. 4. Turn the ignition switch ON and check for fuel leaks from the injectors. Fuel leakage: Less than 1 drop/2 min. DATA LINK CONNECTOR 36U0F2-104 5. If not as specified, remove the leaking injector and check the O-rings and fuel distributor for damage. Replace as necessary. 6. Install the injector. 7. Turn the ignition switch ON and check for fuel leaks from injector. 8. If not as specified, replace the injector. 46U0F2-079 F 2 -6 8 FUEL SYSTEM F2 Volume Test 1. Remove the injectors and fuel distributor assembly. 2. Connect the SST as shown in the figure. Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 3. Measure the injection volume of each injector by using a graduated container. Injection volume: 48—56 cm3 {48—56 cc, 2.9—3.4 cu in)/15 sec. 4. If not as specified, replace the injector. 16E0F2-157 F2—69 F2 FUEL SYSTEM PRESSURE REGULATOR Inspection Fuel line pressure Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Proce­ dures” on page F2-59. 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and the main fuel hose. (Install clamps as shown.) 3. Connect the negative battery cable. 4. Start the engine and let it idle. 5. Measure the fuel line pressure. Fuel line pressure: 210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi} 6. Disconnect the vacuum hose from the pressure regulator and plug it. 7. Measure the fuel line pressure again. Fuel line pressure: 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi) 8. If not as specified, replace the pressure regulator. FUEL PUMP RELAY FUEL PUMP RELAY Inspection Operation check Listen for clicking of the fuel pump relay while cranking the engine. 36U0F2-095 Continuity inspection 1. Apply battery positive voltage (B + ) and check continuity between terminals of the relay. B +: Battery positive voltage Terminal A—B Terminal C—D B + applied Yes B + not applied No 2. If not as specified, replace fuel pump relay. 46UQF2-200 F 2 -7 0 PRESSURE REGULATOR CONTROL SYSTEM F2 PRESSURE REGULATOR CONTROL SYSTEM DESCRIPTION To prevent percolation of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily cut and the fuel injection pressure is increased to slightly more than 280 kPa {2.9 kgf/cm2, 41 psi). Pressure in the fuel line at idle is approx. 230 kPa {2.3 kgf/cm2, 33 psi). F2-71 F2 PRESSURE REGULATOR CONTROL SYSTEM PRC SOLENOID VALVE Inspection On-vehicle 1. Start the engine and let it idle. 2. Disconnect the vacuum hose from the pressure regulator. Verify that vacuum is felt. 46U0F2-082 3. Ground the solenoid valve terminal wire (GYIG) by using a jumper wire. Verify that no vacuum is felt. 4. If vacuum exists, check the solenoid valve. 16E0F2-160 Solenoid valve 1. Remove the solenoid valve. 2. Blow through the solenoid valve from port A. 3. Verify that air flows from port B. 16E0F2-161 4. 5. 6. 7. 16E0F2-162 F 2 -7 2 Apply battery voltage to solenoid valve terminal. Blow through the solenoid valve from port A. Verify that air flows from the valve air filter. If not as specified, replace the solenoid valve. EXHAUST SYSTEM F2 EXHAUST SYSTEM COMPONENTS PARTS Inspection (On-vehicle) Start the engine and verify that there is no exhaust gas leakage from the exhaust system components. Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Check all parts and repair or replace as necessary. 3. Install in the reverse order of removal. Federal and Canada 46U0F2-Q83 1. Main silencer Inspect for deterioration and restriction 2. Pre silencer Inspect for deterioration and restriction 3. Three way catalyst Inspect for deterioration and restriction 4. Transverse member 5. Front pipe Inspect for deterioration and cracks 6. Insulator 7. EGR pipe Inspect for deterioration and cracks 8. Exhaust manifold Inspect for deterioration and cracks F2—73 F2_____________ _______ EXHAUST SYSTEM California 7.9—10.7 N m (80—110 kgf cm, 70—95.4 In-lbf) 59—74 ( 6.0—7.6, 44—54) 7.9—10.7 N-m (80—110 kgf-cm, 70—95.4 In-lbf) GASKET. REPLACE 20—28 1 5 -2 0 ) 16—22 38—51 13.8—5.3, 28—38) GASKET, REPLACE 38—51 (3.8—5.3, SELF LOCK NUT, REPLACE 38—51 (3.8—5.3, 28—38 SELF LOCK NUT, REPLACE GASKET, REPLACE SELF LOCK NUT, REPLACE 7.9—10.7 N-m (80—110 kgf cm, 70—95.4 ln-lbf) (6.5—9.1, 4 8 -6 5 ) SELF LOCK NUT, REPLACE (9.5—13.4, 69—96.9) N m (kgf m, ft-lbf) 46U0F2-084 1. Main silencer Inspect for deterioration and restriction 2. Pre silencer Inspect for deterioration and restriction 3. Three way catalyst Inspect for deterioration and restriction 4. Transverse member F 2 -7 4 5. Front pipe Inspect for deterioration and cracks 6. Insulator 7. EGR pipe Inspect for deterioration and cracks 8. Exhaust manifold (with warm-up three way catalist) Inspect for deterioration and cracks F2 OUTLINE OF EMISSION CONTROL SYSTEM OUTLINE OF EMISSION CONTROL SYSTEM DESCRIPTION To reduce exhaust gas emissions, the positive crankcase ventilation (PCV) system and fuel evaporative system are employed. This system consists of the deceleration control system, fuel evaporative system, EGR function control system, and PCV system. The purpose of these systems is to reduce CO, HC and NOx emissions. FUEL PUMP FUEL FILTER VALVE (TWO-WAY) FUEL TANK RGE SOLENOID VALVE PCV VALVE EGR SOLENOID VALVE (VENT) EGR CONTROL VALVE CHARCOAL CANISTER THREE WAY CATALYST I EGR SOLENOID VALVE 36UOF2-108 F2—75 F2 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM DESCRIPTION This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combustion temperature, and reduce the NOx emissions. This system consists of the EGR valve, EGR function sensor, two solenoid valves, powertrain control mod­ ule (PCME) and input devices. EGR SOLENOID VALVE (VACUUM) TO AIR CLEANER HOUSING EGR SOLENOID VALVE (VENT) TO VACUUM CHAMBER THROTTLE VALVE PCME EGR FUNCTION SENSOR EGR CONTROL VALVE VOLUME THROTTLE AIRFLOW POSITION SENSOR SENSOR CRANK ANGLE SENSOR No.2 (1) (NE2 [NE1] SIGNAL) (ENGINE COOLANT TEMPERATURE SENSOR 1: DETECTION OF ENGINE RUNNING CONDITION 2: DETERMINATION OF EGR GAS AMOUNT 36U0F2-110 Operation Cold Engine (Coolant temperature less than 55°C {131 ° F }) EGR operation is stopped to improve driveability when the engine temperature is cold. Warm Engine The powertrain control module controls the solenoid valves (vacuum side and vent side) to supply EGR gases as described below. Operating condition EGR operation Idle Deceleration High speed Idle switch: ON Stopped Heavy load Other F 2-7 6 Above 5,500 rpm — Acceleration Warming up Remark — Reduced EGR gas amount Control supply of EGR gas amount by using signal from EGR function sensor Coolant temperature: Between 55°C {131°F) and 60°C [140°F) — F2 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM 49 92 00 162 49 G 0 18 903 EGR FUNCTION SENSOR Output voltage inspection 1. Disconnect the PCME connector. 2. Connect the SST to the PCME as shown and connect a vacuum pump. 3. Turn the ignition switch to ON (engine OFF). 4. Measure voltage at the terminals as shown in the table. Terminal 46U0F2-089 PCME C 21 B A 3D 2J Vacuum 0 kPa 20.0 kPa {0 mmHg, 0 inHgj {150 mmHg, 5.90 inHg) 4.5—5.5V ov Approx. 0.8V Approx. 4V 5. If not correct at 2J terminals, check the wiring harness and 21 terminals of the PCME. Resistance 1. Disconnect the EGR function sensor connector, and con­ nect an ohmmeter. 2. Disconnect the vacuum hose from the EGR control valve, and connect a vacuum pump. 3. Measure the resistance between the terminals as shown while vacuum is applied. Terminal A -B A -C B -C Resistance 0 .7 -5 kfi 0 .7 -5 kfi Approx. 5 kfi EGR CONTROL VALVE Inspection 1. Start the engine and let it idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at more than the specified vacuum. Specification: 5.4—7.9 kPa {40—60 mmHg, 1.6—2.3 inHgj 4. If not as specified, replace the EGR control valve. F 2 -7 8 EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM F2 Replacement Plug the water hoses after disconnecting them. 1. Remove the EGR control valve in the sequence shown below. (1) EGR hoses (2) Vacuum hose (3) EGR function sensor connector (4) EGR control valve and gasket 2. Install a new gasket, and then install the EGR in the reverse order of removal. 46U0F2-092 F 2-7 9 F2 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM DESCRIPTION The PCV valve is operated by the intake manifold vacuum. When the engine is running at idle, the PCV valve is slightly open and a small amount of blowby gas is drawn into the dynamic chamber to be burned. As the engine speed rises, the PCV valve is opened further, allowing a larger amount of blowby gas to be drawn into the dynamic chamber. 36U0F2-109 PCV VALVE Inspection 1. Verify that the engine coolant temperature is below 20°C (68°F). 2. Start the engine and let it idle. 3. Disconnect the PCV valve along with the ventilation hose from the cylinder head cover. 4. Block the PCV valve opening. 5. Verify that vacuum is felt. 46U0F2-093 6. Remove the PCV valve. 7. Blow through the valve from port A and verify that air comes out of port B. 8. Blow through the valve from port B and verify that no air comes out of port A. 9. Replace the PCV valve if not as specified. 46U0F2-094 F 2-8 0 ____________________ FUEL EVAPORATIVE SYSTEM_________________ F2 FUEL EVAPORATIVE SYSTEM DESCRIPTION The fuel evaporative system consists of the fuel vapor valve, check valve (two-way), charcoal canister, purge solenoid valve, PCME, and input devices. The amount of evaporative fumes introduced into the engine and burned is controlled by the solenoid valve to correspond to the engine’s operating conditions. To provide the best engine performance, the solenoid valve is controlled by the PCME. Operation The purge solenoid valve is controlled by duty signals from the PCME to perform purging of the charcoal canister. Purging is done when these conditions are met: (1) After warm up (2) Driving in gear (3) Accelerator pedal depressed (idle switch OFF) (4) Heated oxygen sensor functioning normally F2 FUEL EVAPORATIVE SYSTEM SYSTEM OPERATION 1. Warm up the engine to normal operating temperature. 2. Run the engine at idle. 3. Disconnect the vacuum hose from the solenoid valve. 4. Check that no vacuum is felt. 5. Input a load signal to the PCME. MTX model Disconnect the neutral switch connector. ATX model Position the vehicle on a chassis roller and shift the selec­ tor lever to D range. 6. Connect a tachometer and increase the engine speed to 1,000 rpm. 7. Verify that vacuum is felt after approx. 2 sec. 16E0F2-179 PURGE SOLENOID VALVE Inspection 1. Remove the purge solenoid valve. 2. Blow through the purge solenoid valve from hose A and verify that no air flows. 46U0F2-097 3. Apply battery positive voltage to the purge solenoid valve and verify that air flows through the valve from A to B. 4. If not as specified, replace the purge solenoid valve. 46U0F2-098 F 2 -8 2 F2 FUEL EVAPORATIVE SYSTEM FUEL VAPOR VALVE Inspection 1. Verify that air flows through the valve from port A when the valve is held as shown in the figure. 2. Verify that no air flows through the valve from port A when the valve is held as shown. 3. If not as specified, replace the fuel vapor valve. CHECK VALVE (TWO-WAY) Inspection 1. Remove the valve. 2. Check the operation of the valve by using a vacuum pump. Apply approx. 4.9 kPa (37 mmHg, 1.5 inHg) vacuum at port A Apply approx. 5.9 kPa (44 mmHg, 1.7 inHg) vacuum at port B Airflow Airflow CHARCOAL CANISTER Inspection 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage and leakage. 3. Blow through each port and verify that air flows. F 2-8 3 F2 FUEL-CUT CONTROL SYSTEM FUEL-CUT CONTROL SYSTEM DESCRIPTION This system is used to improve fuel economy, to prevent engine bucking during deceleration, and to pro­ tect the engine from overreving. NEUTRAL AND CLUTCH SWITCHES DETECTION DETERMINATION OF OF DECELERATION FUEL CUT FUEL CUT THROTTLE POSITION SENSOR PARK/NEUTRAL SIGNAL ■ (PCMT) (CRANKSHAFT POSITION SENSOR No.1 STOPLIGHT SW ITCH CRANKSHAFT POSITION SENSOR No.2 (NE 2 SIGNAL) [NE 1 SIGNAL]) ENGINE COOLANT TEM PERATURE SENSOR 46U0F2-099 PREPARATION SST 46U0F2-100 F 2-8 4 FUEL-CUT CONTROL SYSYTEM SYSTEM OPERATION 1. Connect a tachometer to the data link connector terminal IG-. TACHOMETER m F2 DATA LINK CONNECTOR 36U0F2-118 2. Connect the SST to the PCME. 3. Warm up the engine to normal operating temperature and let it idle. 49 G 018 903 46U0F2-101 4. Set the SST to positions 3U through 3Z and make sure the green and red lamps flash alternately at each position. 5. Increase the engine speed to 4,000 rpm; then suddenly release the throttle. 6. Verify that the red indicator lamp illuminates while the en­ gine speed is above approximately 1,200 rpm (MTX)/1,500 rpm (ATX) on deceleration. 7. Increase the engine speed and verify that the maximum rpm does not exceed the specification. Caution • Holding the maximum rpm for more than 3 seconds can damage the engine. Specification: Approx. 7,500 rpm F2—85 F2 A/C CUT OFF SYSTEM A/C CUT OFF SYSTEM DESCRIPTION An A/C cut off system is used to improve idle smoothness immediately after starting the engine and to improve acceleration performance. 36U0F2-126 Operation Engine condition After engine started Purpose Improved idle Cut off period Approx. 3 sec. Throttle valve fully open Improved driveability Approx. 5 sec. Water temperature over 113°C |236°FJ Prevent engine from over heating Water temperature under 107°C (225°F) SYSTEM OPERATION 1. Turn the ignition switch to ON. 2. Turn the blower switch and air conditioning sensor ON. 3. Turn the ignition switch to START and verify that the con­ denser fan stops for approx. 3 sec.. Note • The magnetic clutch and the additional fan operate to­ gether. 46U0F2-103 F 2 -8 6 F2 DECHOKE CONTROL SYSTEM DECHOKE CONTROL SYSTEM DESCRIPTION To facilitate starting the engine when the spark plugs become fouled, such as when the engine is flooded, fuel injection is cut if the throttle valve is held wide open during cranking. This allows the spark plugs to dry and purges excess fuel from the cylinders. PCME IGNITION SW ITCH (START) ENGINE SPEED BELOW 500 RPM _ THROTTLE VALVE WIDE OPEN THROTTLE . FUEL CUT 16E0F2-195 SYSTEM OPERATION 1. Turn the ignition switch to START and verify that injector operating sound is heard while the engine is cranking. 2. Depress the accelerator pedal fully and turn the ignition switch to START. Verify that no injector operating sound is heard while cranking. 3. If operating sound is heard, check the PCME terminal 1C voltage. (Refer to page F2-94.) 46U0F2-104 F 2 -8 7 F2 COOLANT FAN CONTROL SYSTEM COOLANT FAN CONTROL SYSTEM DESCRIPTION To improve idle smoothness and engine reliability, the PCME and the coolant tan control system control the electric fan operation. This system consists of the coolant fan, condensor fan, fan relays, PCME, and input devices. PREPARATION SST 36U0F2-264 COOLANT FAN CONTROL SYSTEM F2 SYSTEM OPERATION 1. Connect the SST to the data link connector. 2. Set system select to position 1 and the test switch to SELF TEST. 36U0F2-128 3. Rotate the throttle link by hand and verify that the coolant fan operates. 36U0F2-129 F2 CONTROL SYSTEM CONTROL SYSTEM PREPARATION SST 49 9200 162 Engine Signal Monitor 49 H018 9A1 Self-Diagnosis Checker 49 H018 001 Wrench, knock sensor For inspection of PCME For inspection of heated oxygen sensor For replacement of knock sensor 49 G018 Adapter harness 49 B019 9A0 System Selector 49 G018 904 Sheet For inspection of PCME For inspection of heated oxygen sensor For inspection of PCME 46U0F2-105 CONTROL SYSTEM F2 STRUCTURAL VIEW 1. Powertrain control module (PCME) Removal / Installation.... ........ page F2- 92 Inspection..................... ........ page F2- 93 2. Volume airflow sensor Inspection...................... ........ page F2-104 3. Throttle position sensor Inspection..................... ........ page F2-107 Replacement................. ........ page F2-108 4. Engine coolant temperature sensor Removal / Installation.... ........ page F2-106 Inspection...................... ........ page F2-106 5. Crankshaft position sensor No. 2 Inspection..................... ........ page F2-105 Removal / Installation.... ........ page F2-106 6. Crankshaft position sensor No. 1 Inspection..................... 7. Heated oxygen sensor Inspection........................ ..... page F2-108 Replacement.................... ..... page F2-109 8. Knock sensor Removal / Installation....... ..... page F2-110 9. Main relay Inspection........................ .....page F2-104 10. Steering pressure sensor Inspection........................ ..... page F2-111 11. Cultch switch Inspection......................... ..... page F2-111 Replacement..................... ..... page F2-111 12. Neutral switch Inspection......................... .....page F2-111 Replacement..................... ..... page F2-111 F2-91 F2 CONTROL SYSTEM POWERTRAIN CONTROL MODULE (PCME) Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 36U0F2-133 1. Negative battery cable 2. Cover 3. Front console (Refer to Section S) F 2-92 4. PCME CONTROL SYSTEM 49 92 00 162 F2 Inspection 1. Disconnect the PCME connector. 2. Connect the SSTs to the PCME as shown. Use connector A of the Adapter to check the voltages at terminals 1A through 1V and at terminals 3A through 3Z. Use connector B to check the voltages at terminals 2A through 2P. 49 G 01 8 903 46U0F2-107 3. Place the SST on the Engine Signal Monitor. 4. Measure the voltage at each terminal. (Refer to pages F2-94 through F2-103.) 5. If any PCME terminal voltage is incorrect, check the relat­ ed input or output devices and wiring. If no problem is found, replace the PCME. (Refer to page F2-92.) Caution • Applying voltage to SST terminals A and B will dam­ age the SST. 46U0F2-108 F2 CONTROL SYSTEM Terminal voltage B + : Battery positive voltage Terminal Input Output 1A — 1B 1C Test condition Connected to Correct voltage Battery Constant O Main relay Ignition switch O Ignition switch (START) While cranking Ignition switch ON Below 1.0V Data link connector (MEN terminal) Test switch at SELF TEST Light illuminated for 3 sec. after ignition switch OFF-»ON 4.5—5.5V — OFF ON o 1D Malfunction indicator light (MIL) Light not illuminated after 3 sec. Light illuminated for 3 sec. after ignition switch OFF-* ON Data link connector (FEN terminal) o Igniter Below 2.5V B+ With System selector test switch at "SELF-TEST” Below 2.5V B+ Buzzer sounded for 3 sec. after ignition switch OFF->ON Below 2.5V B+ Buzzer not sounded after 3 sec. Below 2.5V Buzzer sounded B+ Ignition switch ON Idle With SelfDiagnosis Check­ er and System Selector B+ Buzzer not sounded 1G — B+ Light not illuminated o ov 4.5—5.5V Light not illuminated after 3 sec. Light illuminated 1F For backup B+ Test switch at O2 MONITOR, idle light not illuminated o B+ Approx. 10V Test switch at O2 MONITOR, idle light il­ luminated 1E Remark • With SelfDiagnosis Checker and System Selector • With System Selector test switch at SELF TEST Below 1.0V Voltmeter Oscilloscope Approx. 0.6 (V) 4 2I/ 0 A ! 10 msec. 1H 11 1J 1K o o o o Headlight switch Headlights ON B+ Headlights OFF Below 1,0V Data link connector (TEN terminal) System Selector test switch at O2 MONITOR B+ System Selector test switch at SELF TEST 0V Rear window defroster switch OFF B+ Rear window defroster switch ON Below 1.0V Rear window defroster relay PCMT (Torque re­ duce sig­ nal/water thermo signal) Water temperature: Above 60°C (140°F) B+ Water temperature: Below 60°C (140°F) Below 1.0V Torque control during shifting Below 1,0V • With SelfDiagnosis Checker and System Selector • Ignition switch ON Ignition switch ON 46U0F2-109 F 2 -9 4 F2 CONTROL SYSTEM B +: Battery positive voltage Incorrect voltage Possible cause Always OV • ROOM (15A) fuse burnt •Open circuit in wiring from ROOM (15A) fuse to PCME terminal 1A Always OV • Main relay malfunction (Refer to page F2-104) • Open or short circuit in wiring from main relay to PCME terminal 1B Always OV (starter turns) •Open or short circuit in wiring from ignition switch to PCME terminal 1C Always OV • Main relay malfunction (Refer to page F2-104) • Open circuit in wiring from ignition switch to data link connector terminal B + • Open or short circuit in wiring from data link connector terminal MEN to PCME terminal 1D Always approx. B + • Poor connection at PCME connector •PCME malfunction Always approx. 5V • PCME malfunction Always below 2.5V MIL always ON • Short circuit in wiring from combination meter to PCME terminal 1E • PCME malfunction MIL never ON • Open circuit wiring from combination meter to PCME terminal 1E Always approx. B + Always below 2.5V • Poor connection at PCME connector •PCME malfunction No display on SelfDiagnosis Checker • Main relay malfunction (Refer to page F2-104) • Open circuit in wiring from ignition switch to data link connector terminal B + “ 88” displayed and buzzer sounds continuously • Open or short circuit in wiring from data link connector terminal FEN to PCME terminal 1F Always approx. B + • Poor connection at PCME connector • PCME malfunction Always OV •Short circuit in wiring from igniter to PCME terminal 1G Always below 1.0 (headlights OK) • Open or short circuit in wiring from headlight relay to PCME terminal 1H Always below 1,0V •Short circuit in wiring from data link connector terminal TEN to PCME termi­ nal 11 Always approx. B + • Open circuit in wiring from data link connector terminal TEN to PCME termi­ nal 11 • Open circuit in wiring from data link connector terminal GND to ground Always OV • Short circuit in wiring from rear window defroster switch to PCME terminal 1J Always B + • Open circuit in wiring from rear window defroster switch to PCME terminal 1J Always B + or OV • Open or short circuit in wiring from PCMT terminal 1K to PCME terminal 1K 46U0F2-110 F2 CONTROL SYSTEM B + : Battery positive voltage Terminal Input Output o 1L 1M 1N 10 1P 1Q 1R O O o o o 1S o 1U o 1V 0 o 2B o Air conditioning sensor OFF B+ Vehicle speed sensor Ignition switch ON OV or approx. 5.0V Driving Approx. 2.5V Ignition switch ON B+ Steering pressure sensor ON at idle Below 1,0V Steering pressure sensor OFF at idle B+ Air condition­ ing sensor Air conditioning sensor ON Below 1.0V Air conditioning sensor OFF B+ Blower switch Fan speed control 3rd or 4th position Fan speed control OFF, 1st, or 2nd po­ sition Stoplight switch Brake pedal released Neutral and clutch switches (MTX) PCMT (ATX) No load PCMT*1 At shifting Brake pedal depressed Load Accelerator pedal released Throttle posi­ tion sensor (Idle switch) Accelerator pedal depressed Ground (MTX) Ignition switch ON Open (ATX) Ignition switch ON PCMT*2 At shifting PCMT (Barometric absolute pressure sen­ sor signal) Ignition switch ON 100 kPa (760 mmHg, 30 inHg) Volume air­ flow sensor (VS) Ignition switch ON Reduce torque signal 1 2 Reduce torque signal 2 F 2 -9 6 Ignition switch ON Below 2.5V Other 2A Remark Air conditioning sensor ON Other 1T Correct voltage A/C relay, Condenser fan low relay Steering pressure sensor o Test condition Connected to Idle Below 1.0V Ignition switch ON and blower motor ON Ignition switch ON B+ Below 1.0V -- B+ Below 1.0V Ignition switch ON B+ Below 1.0V -- B+ OV Ignition switch ON 10—12V Below 1.0V -- B+ Below 1.0V -- B+ Approx. 3.9V Approx. 4V Approx. 2.8V 46U0F2-111 F2 CONTROL SYSYTEM B +: Battery positive voltage Incorrect voltage Always below 2.5V Possible cause A/C does not operate • A/C relay malfunction •Open circuit in wiring from ignition switch to A/C relay •Open circuit in wiring from A/C relay to PCME terminal 1L Air conditioning sensor OFF but A/C operates •Short circuit in wiring from A/C relay to PCME terminal 1L •PCME malfunction Always B + • Poor connection at PCME connector •PCME malfunction Always OV •Open or short circuit in wiring from vehicle speed sensor to PCME terminal 1M Always below 1.OV •Steering pressure sensor malfunction (Refer to page F2-111) •Short circuit in wiring from steering pressure sensor to PCME terminal 1N • PCME malfuction Always B + •Steering pressure sensor malfunction (Refer to page F2-111) • Open circuit in wiring from steering pressure sensor to PCME terminal 1N • Open circuit in wiring from steering pressure sensor to ground Always below 1.5V • Short circuit in wiring from A/C amplifier to PCME terminal 10 • Air conditioning sensor malfunction •PCME malfunction Always 4 .5 -5 .5 V •Open circuit in wiring from A/C amplifier to PCME terminal 10 • Air conditioning sensor malfunction Always below 1,0V •Short circuit in wiring from A/C amplifier to PCME terminal 1P •A ir conditioning sensor malfunction •PCME malfunction Always B + • Open circuit in wiring from A/C amplifier to PCME terminal 1P •A ir conditioning sensor malfunction Always below 1,0V (stoplights OK) •Open circuit in wiring from stoplight switch to PCME terminal 10 Always below 1.0V (neutral and clutch switch (MTX) OK Park/Neutral switch (ATX) OK) • Short circuit in wiring from neutral and clutch switch to PCME terminal 1R (MTX) •Short circuit in wiring from PCMT terminal 1D to PCME terminal 1R (ATX) Always B + •Open circuit in wiring from neutral and clutch switch to PCME terminal 1R •Open circuit in wiring from PCMT terminal 1D to PCME terminal 1R (ATX) Always OV •Open or short circuit in wiring from PCMT terminal 1J to PCME terminal 1S Always below 1,0V • Short circuit in wiring from throttle position sensor to PCME terminal 1T • PCME malfunction •Throttle position sensor misadjustment Always B + •Open circuit in wiring from throttle sensor to PCME terminal 1T •PCME malfunction Always B + (MTX) •Poor contact at ground terminal • Open circuit in wiring from PCME Always OV •Open or short circuit in wiring from PCMT terminal 1L to PCME terminal 1V Always B + •PCME malfunction Always below 2.0V or Approx. 4V •Refer to Code No.08 Troubleshooting (Refer to page F2-26) 46U0F2-112 F2—97 F2 CONTROL SYSYTEM B +: Battery positive voltage Terminal Input Output 2C 2D O Heated ox­ ygen sensor (RH) O Test condition Connected to Correct voltage Below 1,0V Ignition switch ON Idle Remark Approx. OV Cold engine After warm up (V) 5 Heated ox­ ygen sensor (LH) 0.5 sec. Increasing engine speed (after warm up) Approx. 0.8V Deceleration 2E 2F 2H O Engine coolant temperature sensor O O Approx. OV Engine coolant temperature 20°C (68°F) Approx. 2.5V After warm up Throttle po­ sition sensor (TVO) Accelerator pedal released Approx. 0.5V Accelerator pedal fully depressed Approx. 3.7V A/C pressure sensor A/C pressure sensor ON Below 1.0V A/C pressure sensor OFF B+ 21 O Throttle position sensor/volume air­ flowsensor/EGR function sensor Ignition switch ON 5.0V 2J O EGR func­ tion sensor Ignition switch ON Approx. 0.8V 2K O Intake air temperature sensor Ambient air temperature 20°C (68°F) 2L O DRL relay (CANADA) Parking brake pulled with ignition switch ON Engine running * O Knock sensor Ignition switch ON Approx. 0.8—4.5V Approx. 2.5V Ignition switch ON B+ Parking brake downed with ignition switch ON 2M’ Ignition switch ON Below 0.5V Below 2.5V Ignition switch ON Approx. 2.4V Idle Approx. 2.4V Measure the termi­ nal voltage by us­ ing a digital type voltmeter. 2N 20 O Purge sole­ noid valve B+ Ignition switch ON Idle • Engine warm up • Idle switch OFF after approx. 3 sec. • Load condition (V) M T X m odel Disconnect neutral switch connector ATX model shift selector lever to D range with vehicle on chassis roller Vb The pulse width varies according to the engine load. 46U0F2-113 *: Diagnostic Trouble Code No.05 may be memorized by the PCME when the Engine Signal Monitor is set to position 2M. F2 CONTROL SYSYTEM B +: Battery positive voltage Incorrect voltage Possible cause OV after warm up • Refer to Code No.23 Troubleshooting (Refer to page F2-30) Always approx. 1V after warm up • Refer to Code No.24 Troubleshooting (Refer to page F2-32) OV after warm up •Refer to Code No. 15 Troubleshooting (Refer to page F2-30) Always approx. 1V after warm up •Refer to Code No.17 Troubleshooting (Refer to page F2-32) Always approx. OV or approx. 5V • Refer to Code No.09 Troubleshooting (Refer to page F2-27) Always constant •Open circuit in wiring from PCME terminal 2F to throttle position sensor Always above 1V •Throttle position sensor misadjustment Always OV • Short circuit in wiring from A/C pressure sensor to PCME terminal 2H Always B + • Open circuit in wiring from A/C pressure sensor to PCME terminal 2H Always OV • Short circuit in wiring from PCME terminal 21 to throttle position sensor, PCME, or volume air flow sensor • Poor connection at PCME connector • PCME malfunction Always approx. OV or approx. 5V • Refer to Code No.16 Troubleshooting (Refer to page F2-31) Always OV •Refer to Code No.10 Troubleshooting (Refer to page F2-28) Always OV (DRL system OK) • Open or short circuit in wiring from DRL relay to PCME terminal 2L Always OV or B + •Refer to Code No.05 Troubleshooting (Refer to page F2-25) — Always OV or approx. 5V — • Refer to Code No.26 Troubleshooting (Refer to page F2-35) 46U0F2-114 F 2-9 9 F2 CONTROL SYSYTEM B +: Battery positive voltage Terminal Input Output O 2P Connected to Coolant fan relay No.2 and No.3 Test condition Correct voltage Ignition switch ON Idle B+ Engine coolant temp. Above 108°C (226°F) Below 1.0V Other B+ • Ignition switch ON • Ground data link connector terminal TEN • Idle switch OFF Approx. 1.3V 3A Ground (Output) Constant OV 3B Ground (Output) Constant OV 3C Ground (CPU) Constant OV Ground (Input) Constant Crankshaft position sensor No. 1 (in distrib­ utor) [NE 1 signal] Ignition switch ON 3D 3E O Idle Remark OV Approx. OV or 5V Oscilloscope NE10 I I I I I I " 20 m sec. Approx. 3.5V Voltmeter 3F O Crankshaft position sensor No. 2 (Crank­ shaft pully) [Ground] Constant 3G O Crankshaft position sensor No. 1 (in distrib­ utor) [G signal] Ignition switch ON Idle OV Approx. OV or 5V Oscilloscope (V), I i I 20 m se c. Voltmeter 3H O Crankshaft position sensor No. 2 (Crank­ shaft pully) [NE 2 signal] Approx. 2.5V OV Ignition switch ON Idle Oscilloscope % -t- \H r ' V 1/ 1/ " 1 0 m sec. 31 O VRIS solenoid valve (No.1) 3J O VRIS solenoid valve (No.2) Shutter valve closed B+ Shutter valve open Approx. 1V S h u tte r v a lv e o p e n Approx. 1V Shutter valve closed B + 3K 46U0F2-115 F2 CONTROL SYSYTEM B +: Battery positive voltage Incorrect voltage Possible cause Always OV or B + •Open circuit in wiring from PCME • PCME malfunction Above OV • Poor contact at ground terminal •Open circuit in wiring from PCME Always approx. OV or approx. 2V •Refer to Code No.04 Troubleshooting (Refer to page F2-24) Above OV • Poor connection at ground terminal •Open circuit in wiring from PCME Always approx. OV or approx. 5V •Refer to Code No.03 Troubleshooting (Refer to page F2-23) Always approx. OV or difference in output wave • Refer to Code No.02 Troubleshooting (Refer to page F2-22) • Damaged crankshaft pully Always approx. OV or B + • Refer to Code No.41 Troubleshooting (Refer to page F2-39) Always approx. OV or B + •Refer to Code No.46 Troubleshooting (Refer to page F2-40) — — 46U0F2-116 F2-101 F2 CONTROL SYSYTEM B +: Battery positive voltage Terminal Input Output Connected to O 3L Coolant fan relay No.1 Test condition Correct voltage Ignition switch ON Idle B+ Engine coolant temp. Above 100°C (212 °F ) Below 1.0V Other B+ • Ignition switch ON • Ground data link connector terminal TEN • Idle switch OFF Approx. 0.6V Hot condition: Engine coolant temp, above 70°C (158°F) and intake air temp, above 75°C (167°F) for 120 sec. after engine starting Approx. OV 3M O PRC Solenoid valve Other B+ 3N O Condensor fan high relay No.1 and No.2 Ignition switch ON B+ Idle Engine coolant temp. 108°C (226°F) Below 1.0V Other B+ 30 O EGR solenoid valve (vent) Idle B+ Driving* B+ 3P O EGR solenoid valve (vacuum) Idle B+ Idle air control valve Ignition switch ON O 30 Remark Driving* Engine Signal Monitor: Green and red lamps flash after warm up B+ Approx. 6V Idle (Ground data link connector terminal TEN) Oscilloscope H 2 msec. 3R 3S O 3T 3U O Injector No.1 3V O Injector No.2 3W O Injector No.3 3X O Injector No.4 O Injector No.5 3Y B+ Idle Approx. OV Ignition switch ON B+ Idle* Engine Signal Monitor: Green lamp flash Oscilloscope — ^ 5 msec. Injector No.6 O 3Z Ignition switch ON Fuel pump relay 46U0F2-117 Control Module Connector (Control Module Side) B 3 -0 1 B/n 06 * CL) POWERTRAIN CONTROL MODULE * * W/G G /B G /R (YAJ R/W Y /B BR G /Y L /B L / Y G/W F 2-1 02 Y W L R /Y B /L L /R W R /B L/W W GY/B G /L P /L R /G Y * (e/o) W/B * G G R 2P 2N 2L so SB R /B W/R P /G 2J SH SF W L /R R/W W/G R /Y L/W 3Z 3X 3V * BR/B GY/R P /B GY/G * W/L R * GY P LG B /R B L / 0 L /R G L B /L B F2 CONTROL SYSTEM B +: Battery positive voltage Incorrect voltage Possible cause Always OV or B + • Open or short circuit in wiring from coolant fan relay to PCME terminal 3L • PCME malfunction Always below 1.0V or B + • Refer to Code No.26 Troubleshooting (Refer to page F2-35) Always below 2.0V • Open or short circuit in wiring from condenser fan relay to PCME terminal 3N • PCME malfunction Always OV • Refer to Code No.28 Troubleshooting (Refer to page F2-36) Always OV • Refer to Code No.29 Troubleshooting (Refer to page F2-37) Always OV or B + • Refer to Code No.34 Troubleshooting (Refer to page F2-38) — — — — Always below 1.OV • Open or short circuit in wiring from fuel pump relay to PCME terminal 3T Always OV •Open or short circuit in wiring from injector to PCME terminal 3U, 3V, 3W, 3X, 3Y or 3Z • Main relay malfunction (Refer to page F2-104) 46U0F2-118 F 2-103 F2 CONTROL SYSTEM MAIN RELAY Inspection Operation check Listen for operational sound of the main relay while crank­ ing the engine. 36U0F2-174 RJ!jL (c)— ( d) Continuity inspection 1. Remove the main relay. 2. Apply battery positive voltage (B + ) and check continuity between terminals of the relay. B +: Battery positive voltage 0 Terminal A—B Terminal C—D B + applied Yes B + not applied No 3. If not as specified, replace the main relay. _________________________________________ 36U0F2-175 VOLUME AIRFLOW SENSOR Inspection 1. Check the volume airflow sensor body for cracks and dam­ age. Replace as necessary. 2. Verify that the measuring core opens smoothly. 3. Measure resistance of the volume air flow sensor. MEASURING CORE Terminal Resistance (0) E2«V s o > t CM LU 46U0F2-119 E2«-*THA (intake air temperature sensor) 2 0 -6 0 0 (Closed: 20°C (68°F)) 2 0-1,0 0 0 (Open: 20°C (68°F)) 2 00 -4 00 (Closed♦+Open: 20°C (68°F)) -20 °C |-4 ° F ) 20°C (68°F) 60°C (140°F) 10,000—20,000 2 ,0 0 0 - 3,000 400700 4. If not as specified, replace the volume airflow sensor. Removal / Installation (Refer to page F2-48.) 46U0F2-12Q F2 CONTROL SYSTEM CRANKSHAFT POSITION SENSOR No. 1 (IN DISTRIBUTOR) Inspection 1. Remove the distributor. (Refer to Section G.) 2. Disconnect the injector connector. 3. Verify that the distributor connector (3 pin) is disconnected. 46U0F2-121 4. Connect the distributor connector (6-pin) as shown in the figure. 5. Turn the ignition switch ON. 46U0F2-122 1 CYCLE NE 1 SIGNAL 5V OV “L_n_nnrLrui 6. Connect the SSTs (Engine Signal Monitor and Adapter Har­ ness) to the PCME. 7. Set the SST (Engine Signal Monitor). 8. Rotate the distributor drive by hand and measure the out­ put voltage. Specification 5V OV — G SIGNAL Position Voltage 3E (NE 1 signal) Approx. 5V (6 pulses/rev) 3G (G signal) Approx. 5V (1 pulse/rev) 46U0F2-123 9. After the inspection, install the distributor. (Refer to Section G.) 10. Start the engine and adjust the ignition timing. (Refer to page F2-15.) Ignition timing: BTDC 9 °—11° (10° ± 1°) 11. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 N m {1.9—2.6 kgf m, 14—18 ft-lbf} CRANKSHAFT POSITION SENSOR No.2 ^CONNECTOR CRANKSHAFT POSITION SENSOR No. 2 Inspection 1. Disconnect the crankshaft position sensor 2 connector. 2. Measure the resistance between terminals A and B. Resistance: 520—580Q (20°C {68°F}) 3. Replace crankshaft position sensor No. 2 if not as specified. 46U0F2-193 F 2-105 F2 CONTROL SYSTEM Removal / Installation 1. Disconnect the negative battery cable. 2. Remove the idler pulley bracket. 3. Remove the dipstick pipe. 4. Remove crankshaft position sensor No. 2. 5. Install in the reverse order of removal. 6. Adjust the drive belt deflection. (Refer to Section B2.) N-m (kgf-m, ft-lbf) 46U0F2-194 .E N G IN E COOLANT TEM PERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR Removal / Installation WASHER, REPLACE 46U0F2-124 Warning • Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counter­ clockwise to the first stop. Step back while the pres­ sure escapes. When you’re sure all the pressure is gone, press down on the cap - still using a cloth - turn it, and remove it. 1. Remove the radiator cap. 2. Disconnect the engine coolant temperature sensor con­ nector. 3. Remove the engine coolant temperature sensor. 4. Install a new gasket and the engine coolant temperature sensor. Tighting torque: 16—23 N m (1.6—2.4 kgf m, 12—17 ft Ibf) Inspection 1. Place the sensor in water with a thermometer and heat the water gradually. 2. Measure resistance of the sensor. Coolant 20°C (68°F) 80°C { 176°F) 91°G { 196°F) 97°C (207°F) 108°C |226°F) 110°C (230°F) Resistance (kQ) 2 2 -2 .1 0.29-0.35 0.226-0.241 0.193-0.205 0.145-0.153 0.137-0.146 3. If not as specified, replace the engine coolant temperature sensor. 46U0F2-125 F 2-1 06 F2 CONTROL SYSTEM 49 92 00 162 THROTTLE POSITION SENSOR Inspection 1. Connect the SSTs (Engine Signal Monitor and Adapter Har­ ness) to the PCME. 2. Set the SST (Engine Signal Monitor) to position 2F. 3. Turn the ignition switch ON. 49 G 0 18 903 46U0F2-126 4. Rotate the throttle link by hand and verify that the voltage is within the specification, and make sure that the voltage change is linear. Specification PCME terminal 2F Throttle valve position Closed throttle position Wide open throttle 0.1—1.1V 3.1-4 .4 V 5. If not as specified, adjust the throttle position sensor. V IDL . Idle switch The throttle adjust screw is set at factory and must not be ad­ justed. Any adjustment will negatively effect the engine per­ formance. 1. Disconnect the throttle position sensor connector. 2. Connect an ohmmeter to terminals IDL and GND. GND 46U0F2-201 3. Insert a feeler gauge between the throttle adjust screw and the stopper lever. Check continuity of the switch. Specification Clearance 0.15mm {0.006 in) 0.50mm {0.020 in) Continuity Yes No 4. If not as specified, loosen the throttle position sensor screws. 5. Insert a 0.15mm {0.006 in} feeler gauge between the throt­ tle stop screw and stopper lever. 6. Rotate the throttle position sensor clockwise approximate­ ly 30 degrees, then rotate it back counterclockwise until there is continuity. 7. Replace the feeler gauge with a 0.50mm {0.020 in} feel­ er gauge and verify that there is no continuity. 8. Tighten the attaching screws. Tightening torque: 1.6—2.3 N m (16—24 kgf cm, 14—20 inlbf) 36U0F2-155 F2-107 F2 CONTROL SYSTEM TAB B TANG A TAB A THROTTLE POSITION SENSOR 46U0F2-195 46U0F2-128 Replacement 1. Disconnect the throttle position sensor connector. 2. Remove the attaching screws. 3. Replace the throttle position sensor. 4. Verify that the throttle valve is fully closed. 5. Open the throttle valve slightly and catch the tang of the throttle body on the throttle position sensor plastic tabs. Align tang A on throttle body with tab A on throttle position sen­ sor. Note tangs on the throttle body mate with the tab on the throttle position sensor on the side of the tab without a slot. 6. Position the throttle position sensor on the throttle body so that the mounting holes align. 7. Release the throttle. 8. Adjust the throttle position sensor output voltage and idle switch. (Refer to page F2-107.) HEATED OXYGEN SENSOR (RH, LH) Terminal voltage inspection 1. Connect the Engine Signal Monitor to the PCME. 2. Connect a voltmeter (set to 1V range) to the special output connectors of the Engine Signal Monitor as shown. 3. Set the Engine Signal Monitor to position 2C (RH) or 2D (LH). 4. Run the engine at 4,500 rpm until the voltmeter indicates approx. 0.7V. 5. Measure.the voltage while increasing and decreasing the engine speed suddenly several times. Note • With the brake pedal depressed, the monitor light shows operation of the right heated oxygen sensor. • With the brake pedal released, the monitor light shows operation of the left heated oxygen sensor. Specification 46U0F2-129 Engine condition While deceleration While acceleration Voltage (V) Appox. 0 Above 0.8 Sensitivity self-diagnosis checker 1. Connect the SSTs to the data link connector as shown. 2. Set system select to position 1. 3. Set test switch to O2 MONITOR. 4. Increase the engine speed from 2,000 to 3,000 rpm, and verify that the monitor lamp flashes for 10 sec.. If not as specified, replace the heated oxygen sensor. Monitor Lamp: Flashes more than 8 times/10 sec. 5. Replace the heated oxygen sensor if not as specified. Heater 1. Measure resistance between terminals C and D. Resistance: 6fl (20°C {68°F}) 2. Replace the heated oxygen sensor if not as specified. 46U0F2-131 F 2-1 08 F2 CONTROL SYSTEM Replacement Federal and Canada 1. Disconnect the heated oxygen sensor connector. 2. Remove the heated oxygen sensor. Note • Secure the harness of the heated oxygen sensor (RH) with the power steering hose. 3. Install in the reverse order of removal. Tightening torque: y 30—49 N m {3.0—5.0 kgf m, 22—36 ft-lbf} California 1. Disconnect the heated oxygen sensor connector. 2. Remove the exhaust manifold. (Refer to page F2-74.) 3. Remove the heated oxygen sensor. / 4. Install in the reverse order of removal. Tightening torque: 30—49 N m {3.0—5.0 kgf m, 22—36 ft Ibf} F2—109 F2 CONTROL SYSTEM KNOCK SENSOR Removal / Installation Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete the “ Fuel Line Safety Procedures” on page F2-59. 1. Remove in the order shown in the figure, referring to Removal Note. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal, referring to Installation Note. 19—25 (1.9—2.6, 14—18) N m | kgf m, ft-lbf) 46U0F2-135 1. Air hose 2. Intake manifold Removal Note 3. Bypass pipe Below 4. Water pipe 5. Knock sensor Removal / Installation Note................ Below Removal / Installation Note Intake manifold Drain the coolant into a container before removing the in­ take manifold. (Refer to Section E2.) Knock sensor Use the SST to remove and install the knock sensor. ( V 46U0F2-196 F 2-1 10 F2 CONTROL SYSTEM CLUTCH SWITCH (MTX) Inspection 1. Disconnect the clutch switch connector. 2. Check continuity of the switch. Pedal Continuity Depressed Yes Released No 3. If not as specified, replace the clutch switch. Replacement 1. Loosen the nuts and remove the clutch switch. 2. Install the clutch switch. 3. Adjust the clutch pedal height referring to the above and the height specifications. (Refer to Section H.) 4. Tighten the nuts to the specified torque. Tightening torque: 14—17 N m [1.4—1.8 kgf m, 11—13 ft-lbf) 16E0F2-248 NEUTRAL SWITCH (MTX) Inspection 1. Disconnect the neutral switch connector. 2. Check continuity of the switch. Transaxle Continuity Neutral Yes Other ranges No 3. If not as specified, replace the neutral switch. Replacement 1. Disconnect the neutral switch connector. 2. Remove the neutral switch. 3. Install in the reverse order of removal. Tightening torque: 20—29 N-m {2.0—3.0 kgf-m, 15—21 ft Ibf) 46U0F2-137 STEERING PRESSURE SENSOR Inspection 1. Disconnect the steering pressure sensor connector. 2. Start the engine, and check continuity of the switch. Steering wheel Continuity Turned Yes Straight ahead No 3. If not as specified, replace the steering pressure sensor. F2-111 F2__________________TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE QUICK DIAGNOSIS CHART This Quick Diagnosis Chart shows the relationship between troubleshooting items and inspection points, Possible parts and reference page Melts main or other fuse Will not crank or cranks slowly No combustion Cranks nor­ mally but will Partial combustionnot start when engine cold Partial combustionafter warm-up Any engine temp. Cranks nor­ mally but When engine cold hard to start After warm-up Idle at any engine temp. Engine runs rough Idle after warm-up Idle with A/C, P/S, and/or E/L ON Idle when shifted from N or P to other ranges Driveaway On acceleration While cruising On deceleration Idle at any engine temp, Idle after warm-up Idle with A/C, P/S, and/or E/L ON Idle when shifted from N or P to other ranges On deceleration Driveaway Poor ac­ celeration On acceleration High idle speed after warm-up F 2-112 Fuel system Emissioncontrol system Control system F2 TROUBLESHOOTING GUIDE Automatic transaxle system O O O O O O O o O O o O o O O o o O O O O 0 0 O O O O o O O O O 0 O o O o O o O O o O o o o O O I I I | / Melts main or other fuse Will not crank or cranks slowly Cranks normally but No combustion Partial combustion — will not start when engine cold Partial combustion — after warm-up Cranks normally but Any engine temp. hard to start When engine cold O o / Section K I I I I I I I CO Vehicle speed pulse generator Park/Neutral switch Hold switch Lock up solenoid Lock up control solenoid PCMT Oil pump Control valve body ATF thermosensor Torque converter Reverse clutch Reduce torque signal 1 Reduce torque signal 2 Clutch and neutral switches Steering pressure sensor Stoplight switch Idle air control valve PCME A/C relay, Condenser fan low relay PRC solenoid valve VRIS solenoid valve (Nos.1, 2) Blower switch Condenser fan high relay (Nos.1, 2) Coolant fan relay (Nos.1, 2 and 3) Knock sensor Air conditioning sensor Headlight switch Rear window defroster Main relay CD tr 03 o O Possible parts and reference page i ! i CM LL F 2 -1 11 Section T j F2-53 F2-93 Section U F2-72 F2-57 Section U Section U I Section E F2-110 Section U Section T Section T F2-104 Section G Control system o O o o O o After warm-up Engine stalls Idle at any engine temp. During fast idle Idle after warm-up Idle with A/C, P/S, and/or E/L ON Idle when shifted from N or P to other ranges Driveaway On acceleration While cruising On deceleration Engine runs rough Idle at any engine temp. During fast idle Idle after warm-up Idle with A/C, P/S, and/or E/L ON Idle when shifted from N or P to other ranges On deceleration Poor acceleration Driveaway On acceleration High idle speed after warm-up Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 F 2-113 CO CD CO CJl CO rv> w CO o INJ CD IV) oo VO Possible parts and reference page O Qo CO CO Idle fluctuates/idle hunts Hesitates/Stumbles on acceleration Surges while cruising Lack of power Poor fuel economy A/C does not work Knocking/Pinging T l c CD_ CO \ CO - n| Item CO 00 Exhaust sulfur smell I High oil consumption Self-Diagnosis Checker flashes ''88” MIL never ON F2-114 CO CD O O O O O O O O o o O O O O O o O o OOO Oo Injector Fuel pump Fuel pump relay Pressure regulator Fuel filter Air leakage Idle speed Throttle body Air cleaner body Vacuum chamber Check valve EGR solenoid valve (vacuum) EGR solenoid valve (vent) Purge solenoid valve EGR function sensor EGR control valve Fuel vapor valve Check valve (two-way) Charcoal canister PCV valve Distributor Igniter (in distributor) Ignition coil (in distributor) High-tension lead Spark plug Ignition timing Volume airflow sensor Engine coolant temperature sensor Throttle position sensor Heated oxygen sensor (RH or LH) Crankshaft position sensor No. 2 Vehicle speed sensor F2-68 F2-63 F2-70 F2-70 F2-65 F2-48 F2-16 F2-49 F2-15 F2-57 F2-57 F2-77 F2-77 F2-82 F2-78 F2-78 F2-83 F2-83 F2-83 F2-80 Section G F2-104 F2-106 F2-107 F2-108 F2-105 Section T Fuel systemIntake air system Emission control system Ignition system Control system O TROUBLESHOOTING GUIDE \ OOO o o o O O O O O O CD GUIDE CD / (Y> t\o Possible parts and reference page o Item 46U0F2-138 CO CO / Idle fluctuates/idle hunts Hesitates/Stumbles on acceleration Surges while cruising Lack of power Poor fuel economy A/C does not work Knocking/Pinging Fuel odor Exhaust sulfur smell High oil consumption Self-Diagnosis Checker flashes “ 88” MIL never ON F 2 -1 1 5 CO CO CO CO CO CO 0 0 CO CD 0 0 'N l 05 cn CO rv> Section K TROUBLESHOOTING o Automatic transaxle system O F 2 -1 11 F 2 -1 11 Section T F2-53 F2-93 Section U F2-72 F2-57 Section U Section U Section E F2-110 Section U Section T Section T F2-104 Section G Control system o OOo O O O Clutch and neutral switches Steering pressure sensor Stoplight switch Idle air control valve PCME A/C relay, Condenser fan low relay PRC solenoid valve VRIS solenoid valve (Nos.1, 2) Blower switch Condenser fan high relay (Nos.1, 2) Coolant fan relay (Nos.1, 2 and 3) Knock sensor Air conditioning sensor Headlight switch Rear window defroster Main relay Starter Vehicle speed pulse generator Park/Neutral switch Hold switch Lock up solenoid Lock up control solenoid PCMT Oil pump Control valve body ATF thermosensor Torque converter Reverse clutch Reduce torque signal 1 Reduce torque signal 2 ro F2 TROBLESHOOTING GUIDE G SIGNAL O IDLE SWITCH o o o o O O o THROTTLE POSITION SENSOR o o 0 VOLUME AIRFLOW SENSOR 0 o ENGINE COOLANT TEMPERATURE SENSOR o o INTAKE AIR TEMPERATURE SENSOR o HEATED OXYGEN SENSOR 0 O o 0 O o O o o o O o o o O STEERING PRESSURE SENSOR IGNITION SWITCH (START SIGNAL) o STOPLIGHT SWITCH o PARK/NEUTRAL SWITCH (ATX) o 0 o 0 o O o O 0 0 o o o o O o o 0 o AIR CONDITIONING SENSOR o O o o o 0 o o o o o o o o o 0 o o o o o o o o o o DATA LINK CONNECTOR (TEN TERMINAL) 0 EGR FUNCTION SENSOR o o O o E/L SIGNAL* o SELF-DIAGNOSIS CHECKER (MONITOR LAMP) (MEN TERMINAL) PCMT (TORQUE REDUCI THERMOSIGNAL) PRESSURE REGU­ LATOR CONTROL 0 O KNOCK SENSOR SELF-DIAGNOSIS CHECKER (DIAGNOSTIC TROUBLE CODE) (FEN TERMINAL) SOLENOID VALVE EGR CONTROL CONTROL PURGE o O VEHICLE SPEED SENSOR tn O o BAROMETRIC ABSOLUTE PRESSURE SENSOR cc UJ < £ _i < z o O O o NEUTRAL AND CLUTCH SWITCHES (MTX) VRIS (No.1 AND No.2) CONTROL No.1 FAN RELAY COOLANT No.2, No.3 FAN RELAY COOLANT RELAY IGNITER A/C RELAY (A/C CUT-OFF) AND CONDENSER FAN LOW RELAY O FUEL PUMP 0 NE1 SIGNAL CRANKSHAFT POSITION SENSOR 2 (NE2 SIGNAL) THROTTLE POSITION SENSOR FUEL INJECTION TIMING CRANKSHAFT POSITION SENSOR 1 \ FUEL INJECTION AMOUNT INPUT DEVICE CONDENSER FAN HIGH RELAY No.1, No.2 OUTPUT DEVICE INJECTOR \ BAC VALVE (IDLE AIR CONTROL VALVE) RELATIONSHIP CHART 0 0 0 0 o o o o o o o o o o 0 o o o 46U0F2-139 * E/L SIGNAL: Blower fan control switch third position or higher, headlights ON, or rear window defroster ON. F 2-116 TROUBLESHOOTING GUIDE F2 Output devices and Engine condition 36U0F2-265 F2 TROUBLESHOOTING GUIDE USING THIS SECTION Introduction Most of the fuel and emission control systems are electronically controlled, often making it difficult to diag­ nose problems, especially intermittent problems. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveabilitiy complaint. The customer is often a good source of information on such problems, especially the intermittent ones. Through a talk with the customer, you will usually find out what the symptoms are and under what conditions they occur. Work flow CHECK IN LISTEN TO CUSTOMER COMPLAINTS REFER TO TROUBLESHOOTING PAGE THAT........................................................ DIAGNOSTIC INDEX CORRESPONDS TO ACTUAL SYMPTOM (Refer to page F2-120) CHECK FOR WHAT IS BAD IN SYSTEM..............................................................INSPECTION CHECK FOR WHAT PART IS BAD..................................................................ACTION REPAIR/REPLACE -------------- DETERMINE IF TROUBLE HAS BEEN ELIMINATED................................. No Yes CHECK OUT 36U0F2-183 tom. F 2-1 18 F2 TROUBLESHOOTING GUIDE Troubleshooting chart 13, 14 DESCRIP­ TION ENGINE STALLS •IDLE WITH A/C, P/S, and/or E/L ON •IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES • Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle • Engine stops unexpectedly v/hen shifted from N or P to other ranges at idle • Idle condition is normal when A/C. PIS, and E/L are OFF and in N and P [TROUBLESHOOTING HINTS] © Monitor switch functions (SST) • Air conditioning sensor • Headlight switch • Rear window defroster • Blower switch (2) Idle air control valve • Idle air control valve stuck INSPECTION Are switches correct when checked by using SelfDiagnosis Checker monitor lamp while ignition switch ON? ZT page F2-44 • Blower switch • Headlight switch • Rear window defroster switch •Selector lever Yes Go to next step Lamp not ON/OFF with specified switch Check for cause (Refer to specified check sequence) czr page F2-45 SYSTEM SELECTOR ~ SELEC T SW: A Is "00" displayed on Self-Diagnosis Checker with ignition switch ON? r r page F2-18 Yes 46U0F2-140 "OO” displayed Go to next step Service Code No. displayed Check for cause (Refer to specified check sequence) c r page F 2 -2 0 , SELF-DIAGNOSIS DESCRIPTION: Further describes the system. Confirm that the chart addresses the actual symptom before beginning troubleshooting. TROUBLESHOOTING HINTS: This describes the possible point of malfunction. STEP: This shows the order of troubleshooting. Proceed with troubleshooting as indicated. INSPECTION: This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary to perform the INSPECTION, refer to the page specified by the " c r ” mark. ACTION: This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform the action is described on the reference page specified by the " c r ” mark. 36U0F2-256 F 2-119 F2 TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX TROUBLESHOOTING ITEM No. 1 2 3 □ c & C m r T IU N TROUBLE Melts main or other fuse PAGE F2-124 Will not crank or cranks slowly Starter does not work Starter cranks engine at slow speed Cranks normal­ ly but will not start No combustion Starter cranks engine at normal speed but engine shows no indication of firing F2-125 Partial combustion — when engine coldz Starter cranks engine at normal speed and engine shows indication of firing but will not run when en­ gine is cold or at initial starting Engine will not continue running when cold when ig­ nition switch is returned from STA to IG position F2-125 Starter cranks engine at normal speed and engine shows indication of firing but will not run when en­ gine is warm Engine will not continue running when warm when IGN switch is returned from STA to IG position F2-127 4 Partial combustion — when engine warm 5 6 Will start in other than P and N ranges 7 Cranks nor­ mally but hard to s tart Engine starts in P, N and other ranges Any engine temp. Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting at any engine temperature Engine starts after stalling a few times at any engine temperature When engine cold Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting when engine is cold Engine starts after stalling a few times when engine is cold 8 Section G Section K F2-128 After warm-up Starter cranks engine at normal speed but engine re­ quires excessive cranking time before starting after warm-up Idle at any engine temp. Engine stops unexpectedly at any engine temp. 11 During fast idle Engine stops unexpectedly during fast-idle operation 12 Idle after warm-up Engine stops unexpectedly at idle after warm-up 13 Idle with A/C, P/S, and/or E/L ON Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle *14 Idle when shifted from N or P to other ranges Engine stops unexpectedly when shifted from N or P to other ranges at idle 15 Driveaway Engine stops unexpectedly upon driveaway F2-134 On acceleration Engine stops unexpectedly at begining of accelera­ tion or during acceleration F2-136 While cruising Engine stops unexpectedly while cruising On deceleration Engine stops unexpectedly at begining of decelera­ tion or recovery from deceleration exhaust afterburn 9 10 Engine stalls 16 17 *18 Engine runs rough 19 20 21 Idle at any engine temp. F2-133 Section K F2-138 Section K Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any engine temp. Idle speed too slow and excessive engine shake at any engine temp. During fast idle Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up Idle after warm-up Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after warm-up * Refer to Section F2 before referring to K Sections. F2—120 F2-130 F2-140 F2 TROUBLESHOOTING GUIDE TROUBLESHOOTING ITEM 22 UCOV/nlr 1lUN TROUBLE No. Engine runs rough 23 Idle with A/C, P/S, and/or E/L ON Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when A/C, P/S, and/or E/L ON Idle when shifted from N or P to other range Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when shifted from P or N to other range On deceleration Engine shakes at begining of deceleration, during deceleration, or recovery from deceleration Exhaust afterburn Driveaway Engine speed increases normally but vehicle speed slowly increases during driveaway On acceleration Engine speed increases normally but vehicle speed slowly increases during acceleration *24 *25 Poor ac­ celeration *26 27 28 29 *30 *31 *32 33 PAGE F2-144 F2-146 Section K F2-148 Section K High idle speed after warm-up Idle speed continues at fast idle after warm-up Engine returns slowly to idle after acceleration is released F2-150 Idle fluctuates/idle hunts Engine speed changes back and forth between specified idle speed and higher speed F2-151 Hesitates/Stumbles on acceleration Momentary pause at begining of acceleration or dur­ ing acceleration F2-153 Surges while cruising Momentary minor irregularity in engine output at steady vehicle speed F2-156 Section K Lack of power Performance poor under load (i.e., power down when climbing hills) F2-157 Section K Poor fuel economy Fuel economy unsatisfactory F2-158 Section K A/C does not work A/C compressor magnetic clutch does not engage when Air conditioning sensor ON F2-158 Knocking/Pinging Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in combustion chamber) F2-158 34 35 Fuel odor Gasoline fuel smell or visible leaks F2-159 36 Exhaust sulfur smell Rotten egg smell from exhaust F2-159 37 High oil consumption Oil consumption excessive F2-159 38 Self-Diagnosis Checker flashes 88 Checker flashes 88 with test connector ground F2-159 39 MIL never ON Self-Diagnosis Checker indicates Diagnostic Trouble Code No. of input device but MIL never ON F2-160 40 41 42 Vehicle does not move in D, S, L and/or R ranges No creep at all Vehicle does not move when accelerator pedal depressed after shifted to D, S, L and/or R range Section K Vehicle moves in N range Vehicle creeps in N range Vehicle moves when accelerator pedal not depressed Section K Vehicle moves in P range Vehicle rolls in P range, and drivetrain not locked up Section K Excessive creep Vehicle moves quickly in D, S, L and R range (ac­ celerator pedal not depressed) 43 Note • Excessive N to R range and N to D range shift shock felt Section K * Refer to Section F2 before referring to K Sections. F2—121 F2 TROUBLESHOOTING GUIDE TROUBLESHOOTING ITEM No. TROUBLE No shift U t d u n lr 1IUN Single range shift (1st-»2nd, 2nd->3rd or 3rd->0/D) only. Sometimes shifts correctly 44 PAGE Section K Note • Gear position held in hold mode. Abnormal shift Shifts incorrectly (incorrect shift pattern) (ex) Vehicle shifts 1st->0/D directly when accelerating with accelerator pedal depressed slightly Section K Frequent shifting Downshift occurs when accelerator depressed slightly in D, S and L ranges (except hold mode) Section K Shift point high or low Shift points do not match shift diagram Shifts delayed when accelerating Shifts occur too fast when accelerating and engine speed does not increase Section K No lockup No lockup when vehicle speed reaches lockup range Section K No kickdown Does not downshift when accelerator pedal depressed more than 7/8 within kickdown range Section K 45 46 47 48 49 50 Engine speed flares up 51 52 Excessive shift shock 53 When accelerating Engine speed flares up on acceleration Section K When upshifting and/or downshifting Engine flares up when accelerator pedal depressed for upshifting Engine flares up suddenly when accelerator pedal depressed for downshifting Section K P, N to R and/or N to D Strong shift shock felt at idle when shifting from N to D or R range Section K When upshifting and/or downshifting Excessive shift shock felt when accelerating at upshifting During cruising, excessive shift shock felt when ac­ celerator pedal depressed at downshifting Section K Engine speed drops to idle but vehicle does not slow when accelerator pedal released during cruising at medium to high speed Engine speed drops to idle but vehicle does not slow when accelerator pedal released when in L range at low vehicle speed Section K Mode does not change to/from normal mode in D range Hold mode not selected or not cancelled Section K Transaxle noisy in all ranges when vehicle is idling Section K Abnormal noise from transaxle in D, S, L, R Section K ATF smells burnt and/or is discolored Section K No engine braking 54 55 56 No mode change All ranges 57 Transaxle noise 58 Transaxle overheats D, S, L, R ranges 46U0F2-141 F 2-1 22 F2 TROUBLESHOOTING GUIDE Description of STUMBLE HESITATION SURGE Driveability Problems : Mildly irregular performance during acceleration. : A dip or flat spot in performance just after the accelerator pedal is depressed. : Continuous irregular performance during cruising. ENGINE SPEED 46U0F2-197 Fuel Pressure Release and Servicing Fuel System Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam­ age. Fuel can also irritate skin and eyes. To prevent this, always complete the following “ Fuel Line Safe­ ty Procedures” . Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn the ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakge. 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C. Install hose to secure the fuel pressure gauge to the fuel filter and the main hose. Pinching Hose When pinching an air hose or a fuel hose with pliers, wrap the hose with a rag to prevent damage. 16E0F2-261 F2—123 F2 TROUBLESHOOTING GUIDE SYMPTOM TROUBLESHOOTING 1 MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Check the condition of the fuse Related Wiring Harness Damaged Fuse MAIN (100A) BTN (60A) R T M fl I'-'n ROOM (15A) EGI INJ (30A) Fuel pump relay ....... "■ Fuel pump ----------------- PCME terminal 1B ----------------- Distributor ----------------- Heated oxygen sensor ------------------- Solenoid valve (PRC) ------------------- Solenoid valve (VRIS1) ------------------- Solenoid valve (VRIS2) ------------------- Solenoid valve (EGR. Vacuum) -------------------Solenoid valve (EGR. Vent) -------------------Idle air control valve -------------------Solenoid valve (purge control) ENGINE (15A) F M r ilM P fiioo METER (15A) 46U0F2-144 F 2-124 F2 TROUBLESHOOTING GUIDE 3 CRANKS NORMALLY BUT WILL NOT START •NO COMBUSTION • Starter cranks engine at normal speed but engine shows no indication of firing DESCRIP­ TION [TROUBLESHOOTING HINTS] © Distributor • Poor conection of connector • Open in ignition coil © Main relay • Poor connection of connector • Malfunction of relay ® PCME • No IGT signal output from PCME terminal 1G to igniter (in distributor) c r Section G c r page F2-104 c r page F2-94 46U0F2-145 4 CRANKS NORMALLY BUT WILL NOT START DESCRIP­ TION • Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is cold at initial starting • Engine will not continue running when cold when ignition switch is returned from STA to IG position • Refer to “ ENGINE STALLS” if this symptom appears after engine stall • Fuel in tank • Battery in terminal condition [TROUBLESHOOTING HINTS] © BAC valve • Malfunction of air valve • Idle air control valve stuck © Injector • Poor connection ® Fuel pump relay • Poor connection @ Fuel pump • Poor connection of connector STEP 1 • PARTIAL COMBUSTION — WHEN ENGINE COLD (D Distributor »Cap and/or rotor damaged • Poor connection of connector © Volume airflow sensor • Measuring core stuck INSPECTION Is “ 00” displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00” displayed Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F2-20 M O N I T O R l -^ L A M P “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A 2 Does engine start when throttle valve held quar­ ter open? Yes Check air valve operation No Go to next step c r page F2-159 c r page F2-53 F2-125 F2 TROUBLESHOOTING GUIDE STEP INSPECTION ACTION Do Engine Signal Monitor lamps flash for speci­ fied terminals while cranking engine? c r page F2-102 Yes Go to next step No Check as follows according to results: Does not flash and OV indicated for in­ dividual terminals • Continuity of injector • Continuity between PCME and in­ jectors) Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z 49 92 00 162 c r page F2-68 c r page F2-102 c r page F2-63 •Condition of injector connector and PCME connector female terminals Repair or replace parts and/or wir­ ing harness as necessary 49 G 018 903 Connect jumper wire between F/P and GND ter­ minals of data link connector; will engine start? Yes JUMPER WIRE Y l I I GT GND No Check as follows: •3T terminal voltage at PCME •Continuity between 3T terminal and fuel pump relay connector terminal •Condition of PCME and fuel pump relay connector female terminals Check if fuel pump operating sound is heard • If yes, go to next step • If no, check fuel pump and wiring harness DATA LINK CONNECTOR Is following terminal voltage at PCME correct? c r page F2-96 2B terminal: Approx. 4.0V (ign. ON) Yes Go to next step No Check as follows: • Movement of measuring core in volume air flow sensor • Ground of volume airflow sensor • Continuity between volume airflow sensor and PCME connector • Condition of volume airflow sensor and PCME connector female ter­ minals Yes Go to next step No Low pressure Check fuel line pressure while pinch­ ing fuel return hose • If pressure quickly increases, check pressure regulator • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure 49 9200 162 49 G 0 18 903 Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure correct with ignition switch ON? c r page F2-60 Fuel line pressure: 270-310 kPa (2.7—3.2 kgf/cm), 39-45 psi) DATA LINK CONNECTOR F 2-126 c r page F2-70 c r page F2-63 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Are injectors OK? • No fuel leakage • Injectors not clogged c r c r ACTION Yes Go to next step No Check as follows •Distributor cap and rotor • High-tension leads Yes Go to next step No Replace injector(s) c r c r Section G Section G Section G c r page F2-66 c r page F2-68 page F2-69 Try known good PCME; does condition improve? c r page F2-92 46U0F2-146 5 DESCRIP­ TION CRANKS NORMALLY BUT WILL NOT START •PARTIAL COMBUSTION — AFTER WARM UP • Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is warm • Engine will not continue running when ignition switch is returned from STA to IG position [TROUBLESHOOTING HINTS] © Pressure regulator • Hold fuel pressure low © Throttle body •Carbon on throttle valve c r page F2-59 c r page F2-49 46U0F2-147 F 2-1 27 F2 7, 8 ,9 DESCRIP­ TION TROUBLESHOOTING GUIDE CRANKS NORMALLY BUT HARD TO START •ANY ENGINE TEMP •WHEN ENGINE COLD • AFTER WARM-UP • Starter cranks engine at normal speed but engine requires excessive cranking time before starting • Engine starts after stalling a few times • Battery in normal condition •Engine runs normally at idle (if idle condition not OK, refer to “ Engine runs rough” [Nos. 19, 20, 21, 22 or 23]) [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Fuel pump • Malfunction of pump © Pressure regulator • Pressure regulator stuck © Spark plug • Dirty or worn spark plug(s) © Solenoid valve (PRC) • Solenoid valve stuck © Throttle body • Carbon on throttle plate © Solenoid valve (EGR, vacuum or vent) • Solenoid valve stuck © EGR control valve •EGR control valve stuck INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00” displayed Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H 018 9A1 c r page F2-20 “ 88” Flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 c r page F2-159 SELECT SW: A Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? c r page F2-60 Fuel line pressure: 270—310 kPa [2.7—3.2 kgf/cm2, 39—45 psi) JUMPER WIRE F/P DATA LINK CONNECTOR GND Yes Go to next step No Low pressure Check fuel line pressure while pinch­ ing fuel return hose • If pressure quickly increases, check pressure regulator c r page F2-70 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F2-63 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Is fuel line pressure held after ignition switch turn- ACTION Yes • If symptom occurs at any engine temp., go to Step 6 • If symptom occurs when engine cold, go to next step • If symptom occurs after warm-up, go to Step 6 No Plug outlet of pressure regulator, Is fuel line pressure held after ignition switch turned OFF? c r page F2-59 • If yes, replace pressure regulator c r page F2-66 • If no, check fuel pump hold pressure c r page F2-70 If fuel pump OK, check injectors for fuel leakage c r page F2-67 ed OFF? c r page F2-59 Fuel line pressure: More than 150 kPa (1.5kgf/cm2, 21 psi) for 5 min. Is throttle body clean internally? Disconnect vacuum hose from EGR valve and plug it; does condition improve? Yes Clean throttle body No Go to next step Yes Check as follows: • Solenoid valve (EGR, vacuum) for sticking • Solenoid valve (EGR, vent) for sticking • Condition of solenoid valve connector female terminal(s) No Check if EGR control valve moves smoothly • If yes, go to next step • If no, replace EGR valve N c r page F2-78 c r page F2-79 Try known good PCME; does condition improve? c r page F2-92 46U0F2-148 F 2-129 F2 10, 1 1 ,1 2 TROUBLESHOOTING GUIDE ENGINE STALLS •IDLE AT ANY ENGINE TEMP •DURING FAST IDLE •IDLE AFTER WARM-UP • Engine stops unexpectedly at idle and/or during fast idle operation DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged © Fuel pump • Maximum pressure low © Fuel pump relay • Poor connection of connector © Air leakage in intake air system © Distributor • Cap and/or rotor damaged • Poor connection of connector © Volume airflow sensor • Measuring core stuck INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? cr page F2-18 ACTION Yes “ 00” displayed • If symptom occurs at idle at any engine temp., go to next step • If symptom occurs during fast idle op­ eration, go to Step 8 • If symptom occurs at idle after warm­ up, go to Step 9 No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR 49 H 018 9A1 cr page F2-20 *<g3 ’’ ^lashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 c r page F2-159 MONITOR LAMP '-Sr SELECT SW: A Do Engine Signal Monitor lamps flash for specified terminals while cranking engine? Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z ©Engine coolant temperature sensor • Poor connection of connector © EGR control valve EGR control valve stuck © BAC valve • Air valve stuck Yes Go to next step No Check as follows according to results: Does not flash and OV indicated for in­ dividual terminal(s) •Continuity of injector(s) • Continuity between PCME and injec­ cr page F2-68 tors) • Condition of injection connector and PCME connector Repair or replace parts and/or wiring harness as necessary Yes Go to next step No Check as follows; • Distributor cap and rotor • High-tension lead(s) 49 92 00 162 49 G 0 18 903 Is strong blue spark visible at each disconnected high-tension lead while cranking engine? F2-130 cr Section G F2 TROUBLESHOOTING GUIDE STEP INSPECTION Connect jumper wire between F/P and GND ter­ minal of data link connector; will engine run? ACTION Yes Check as follows: •3T terminal voltage at PCME c r page F2-102 • Continuity between 3T terminal and fuel pump relay connector terminal • Condition of PCME and fuel pump relay connector female terminals No Check if fuel pump operating sound is heard? • If yes, go to next step • If no, check fuel pump circuit Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator c r page F2-70 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F2-63 I I GND F/P DATA LINK CONNECTOR Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? c r page F2-60 Fuel line pressure: 270—310 kPa (2.7—3.2 kgf/cm2, 39—45 psi) DATA LINK CONNECTOR Is air leakage felt or heard at intake air system com­ ponents while racing engine to higher speed? Is engine compression correct? Yes Repair or replace No Go to next step Yes Go to Step 9 No Check for cause c r Section B2 Yes Check as follows: • Operation of air valve • Operation of EGR control valve c r page F2-53 c r page F2-78 c r Section B2 Engine compression (Minimum): 981 kPa (10.0 kgf/cm2, 143 psi)/250 rpm Does engine start with throttle valve held quarter open? Does following terminal voltage at PCME increase smoothly? c r Go to next step Yes Go to next step No Check as follows: • Movement of measuring core in volume airflow sensor • Ground of volume airflow sensor • Continuity between volume airflow sen­ sor and PCME connector • Condition of volume airflow sensor and PCME connector female terminals p a g e F 2 —9 8 (2E terminal: Engine coolant temperature sensor) (V) 5 0 40 80 (32) (104)(176) No ( °C \ WATER U ° F )) t e m p . F2-131 F2 TROUBLESHOOTING GUIDE STEP 10 INSPECTION Are spark plugs OK? WEAR AND CARBON PLUG GAP cr ACTION Yes • If symptom occurs at any engine temp., go to Step 14 • If symptom occurs fast idle operation, go to Step 14 • If symptom occurs at idle after warm-up, go to next step No Clean or replace Yes Go to next step No Section G BURNT DAMAGE AND DETERIORATION cr Section G Replace BAC valve c r page F2-48 Yes Replace BAC valve cr page F2-48 No Reinstall BAC valve and go to next step Yes Go to next step No Check as follows; • Poor connection of engine coolant temperature sensor connector • Incorrect installation of throttle position sensor cr page F2-66 DAMAGE 11 Is resistance of idle air control valve correct? cr page F2-53 Resistance: 10.7—12.3(2 (at 2 0°C (68eF)) THROTTLE BODY 12 13 Try known good BAC valve; does condition im­ prove? Is the heated oxygen sensor operation OK? c r page F2-108 SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR 49 H 018 9A1 SELECT SW: A 14 15 Are injectors OK? •N o fuel leakage • Injectors not clogged cr c r Yes Go to next step No Replace injector(s) page F2-68 page F2-69 Try known good PCME; does condition improve? c r page F2-92 46U0F2-149 F 2-132 F2 TROUBLESHOOTING GUIDE 13, 14 DESCRIP­ TION ENGINE STALLS •IDLE WITH A/C, P/S, and/or E/L ON •IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES • Engine stops unexpectedly when A/C, P/S, and/or E/L turned ON at idle • Engine stops unexpectedly when shifted from N or P to other ranges at idle Idle condition is normal when A/C, P/S, and E/L are OFF and in N and P [TROUBLESHOOTING HINTS] © Monitor switch functions (SST) • Air conditioning sensor • Headlight switch • Rear window defroster • Blower switch © idle air control valve • Idle air control valve stuck INSPECTION STEP Are switches correct when checked by using SST monitor lamp or indicator while ignition switch ON? c r page F2-43 ACTION Yes Go to next step No Lamp or indicator not ON/OFF with specified switch Check for cause (Refer to specified check sequence) • B lo w e r sw itch • Headlight switch • Rear window defroster switch • Selector lever c r page F2-45 SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR 49 H 018 9A1 SELECT SW: A Is “ 00" displayed on SST with ignition switch ON? c r page F2-18 Yes “ 00" displayed Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H 018 9A1 “ 88” flashes displayed Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A Is terminal voltage at PCME correct at idle? c r page F2-102 Yes 3Q terminal: Approx. 6.0V (at idle) No Check BAC valve and replace if necessary If OK, go to “ ENGINE STALLS IDLE WHEN SHIFTED FROM N or P TO OTHER RANGES” in Section K of this manual Try known good PCME and check if condition improves c r page F2-20 c r page F2-159 c r page F2-53 c r page F2-92 46U0F2-150 F2-133 F2 TROUBLESHOOTING GUIDE 15 ENGINE STALLS DESCRIP­ TION •DRIVEAWAY • Engine stops unexpectedly upon driveaway • Idle condition normal [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged © Pressure regulator • diaphragm damaged STEP (3) Fuel filter • Fuel filter clogged ® Distributor • Poor connection of connector • Cap and/or rotor damaged INSPECTION Is “ 00” displayed on SST with ignition switch ON? © Engine coolant temperature sensor • Poor connection of connector ACTION Yes “ 00" displayed Go to next step SELF-DIAGNOSIS CHECKER ^ Pa 9 e F 2 _ 1 8 SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F2-20 49 H 018 9A1 “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A Uing Engine Signal Monitor, do voltage reading and lamp operation change as follows upon driveaway? Condition Voltage gradually increases Does not suddenly change voltage Flashing of green and red light becomes quicker Terminal 2B 2E 3U, 3V, 3W, 3X, 3Y, 3Z ! c r page F2-159 Yes Go to next step No Check as follows: • Condition of female terminals in related connector • Continuity between injector connector and PCME connector Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check pressure regulator c r page F2-70 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F2-63 ■ ■ K W a i 49 9200 162 g f B M □ i. 49 G 0 18 903 Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? c r page F2-60 Fuel line pressure: 265—314 kPa (2.7—3.2 kgf/cm2, 38—46 psi) JUMPER WIRE F/P DATA LINK CONNECTOR F 2-134 GND F2 TROUBLESHOOTING GUIDE STEP 4 5 INSPECTION Are injectors OK? • No fuel leakage • Injectors not clogged ACTION Yes Go to next step No Replace injector c r page F2-68 c r page F2-69 c r page F2-66 Try known good PCME; does condition improve? c r page F2-92 46U0F2-151 F2-135 F2 16, 17 DESCRIP­ TION TROUBLESHOOTING GUIDE ENGINE STALLS •ON ACCELERATION/WHILE CRUISING •Engine stops unexpectedly at beginning of acceleration or during acceleration • Engine stops unexpectedly while cruising [TROUBLESHOOTING HINTS] © Fuel pump • Poor connection © Pressure regulator • Diaphragm damaged © Distributor • Poor connection of connector • Cap and/or rotor damaged © Volume airflow sensor • Poor connection of connector • Measuring core stuck © Main relay • Poor connection of connector STEP __________________ INSPECTION___________ Is “ 00” displayed on SST with ignition switch ON? cr page F2-18 ACTION Yes “ 00” displayed Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H 018 9A1 c r page F2-20 MONITORS -T -L ^ M P 'i “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Volume are air flow sensor connector terminals good? Ground terminal F/P of data link connector within ignition switch ON; is operation sound of fuel pump heard? DATA LINK CONNECTOR F2-136 Yes Check spark plugs ■=> If OK, go to next step If not OK, clean or replace spark plug No Check as follows: • Distributor cap and rotor • High-tension leads • Condition of distributor connector female terminals cr page F2-159 cr Section G cr Section G cr Section G Yes Verify that measuring core of volume airflow sensor moves smoothly • If OK, go to next step •If not OK, replace air flow sensor No Repair connector terminal(s) Yes Go to next step No Check as follows: • Poor connection of fuel pump relay • Poor connection of fuel pump con­ nector • Melted EGI INJ fuse (30A) cr page F2-124 Refer to “ No.1-MELTS MAIN OR OTHER FUSE" • Poor connection of main relay cr page F2-104 • Operation of main relay F2 TROUBLESHOOTING GUIDE STEP 5 ACTION INSPECTION Is fuel line pressure correct at idle? cr page F2-70 Fuel line pressure: 210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi Yes Go to next step No Check pressure regulator cr page F2-70 Pressure regulator vacuum hose discon­ nected: 2 7 0 -3 1 0 kPa [2.7—3.2 kgf/cm2, 3 9 - 4 5 psi) 6 Try known good PCME; does condition improve? cr page F2-92 46U0F2-152 F2—137 F2 TROUBLESHOOTING GUIDE 18 DESCRIP­ TION •ON DECELERATION ENGINE STALLS • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration • Exhaust afterburn [TROUBLESHOOTING HINTS] © Fuel pump • Poor connection of connector @ Idle speed • Idle speed too low ® Distributor • Poor connection of connector © Volume airflow sensor • Poor connection of connector • Measuring core stuck © Idle air control valve • Idle air control valve stuck © EGR control valve • Solenoid valve stuck • EGR control valve stuck open INSPECTION STEP Connect System Selector to data link connector and set test switch to SELF TEST; is idle speed correct after warm-up? cr page F2-16 Idle speed: 600—700 (650 ± 50) rpm Does idle speed drop in following conditions? ACTION Yes Go to Step 3 No Remove System Selector and Go to next step Yes Check as follows; •Circuit from idle air control valve to PCME for open and short cr page F2—38 • Idle air control valve for sticking c r page F2-53 No Adjust idle speed Yes “ 00” displayed Condition • Electrical load ON • Air conditioner ON • P/S operating Is “ 00” displayed on SST with ignition switch ON? cr page F2-18 cr page F2-16 Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H 018 9A1 SELECT SW: A F 2-138 cr page F2-20 “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 cr page F2-159 F2 TROUBLESHOOTING GUIDE STEP ACTION INSPECTION Are switch operation correct when checked by using SST monitor lamp or indicator while igni­ tion switch ON? c r page F2-43 Yes Go to next step No Lamp or indicator not ON/OFF with specified switch Check for caused (Refer to specified check sequence) SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR c r page F2-45 c r page F2-78 49 H 0 18 9A1 SELECT SW: A Are volume airflow sensor connector terminals and connection good? Connect engine signal monitor to PCME and set to position 2J Does following terminal voltage at PCME in­ crease smoothly when vacuum applied to EGR control valve? Yes Verify that the measuring core of vol­ ume airflow sensor moves smoothly • If OK, go to next step • If not OK, replace air flow sensor No Repair connector terminal Yes Go to next step No Check EGR control valve for sticking Terminal 2J voltage: kPa 9) ( (mmHg, inHg] VACUUM Are following terminals and connections good? • Distributor connector •Fuel pump connector • Main relay • PCME connector Yes Go to “ ENGINE STALLS - ON DECELERATION” in Section K of this manual No Repair connector terminal 46U0F2-153 F2-139 F2 TROUBLESHOOTING GUIDE 19, 20, 21 ENGINE RUNS ROUGH ‘ IDLE AT ANY ENGINE TEMP/DURING FAST IDLE/IDLE AFTER WARM-UP DESCRIP­ TION • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any engine temp. • Idle speed too slow and excessive engine shake at any engine temp. • Fast idle speed too slow and excessive engine shake during fast idle, but returns to normal after warm-up • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after warm-up © Distributor • Cap and/or rotor damaged • Poor connection of connector © Volume airflow sensor • Measuring core stuck © Engine coolant temperature sensor • Poor connection of connector © EGR control valve • EGR control valve stuck © BAC valve • Air valve stuck [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) • Injector(s) clogged © Fuel pump •Maximum pressure low © Fuel pump relay • Poor connection of connector © Air leakage • Leakage in intake air system INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00” displayed • If symptom occurs at idle at any engine temp., go to next step • If symptom occurs during fast idle op­ eration, go to Step 9 • If symptom occurs at idle after warm­ up, go to Step 10 No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR 49 H018 9A1 c r page F2-20 <<3 8 ” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88” SELECT SW: A c r page F2-159 Do Engine Signal Monitor lamps flash for specified terminals while cranking engine? Terminal: 3U, 3V, 3W, 3X, 3Y, 3Z 49 92 00 162 49 G 01 8 903 F2-140 Yes Go to next step No Check as follows according to results; Do not flash and 0V indicated for in­ dividual terminal(s) • Continuity of injector(s) c r page F2-68 • Continuity between PCME and injec­ tors) • Condition of injector connector and PCME connector Repair or replace parts and/or wiring harness as necessary F2 TROUBLESHOOTING GUIDE ACTION INSPECTION STEP Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Connect data link connector terminals F/P and GND with a jumper wire; is fuel line pressure cor­ rect with ignition switch ON? c r page F2-60 Yes Go to next step No Check distributor cap and rotor Check as follows; • Distributor cap and rotor • High-tension lead(s) Yes Go to next step No Low pressure Check fuel line pressure while pinching fuel return hose • If pressure quickly increases, check c r page F2-70 pressure regulator • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure c r page F2-63 Fuel line pressure: 270—310 kPa (2.7—3.2 kgf/cm2, 39—45 psi) c r Section G DATA LINK CONNECTOR Is there air leakage at intake air system com­ ponents while racing engine to higher speed Connect engine signal monitor to PCME and set to position 2J Does following terminal voltage at PCME increase smoothly when vacuum applied to EGR control valve? Yes Repair or replace No Go to next step Yes Go to next step No Check EGR control valve for sticking c r page F2-78 Terminal 2J voltage kPa \ (5 0 ,2 .0 ) (1 0 0 ,3 .9 ) \( mmHg, inHg)] VACUUM F2-141 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Is engine compression correct? ACTION Yes Go to next step Engine compression (minimum): 981 kPa {10.0 kgf/cm2, 143 psi]/250 rpm No Check for cause Connect engine signal monitor to PCME and set to position 2B Does following terminal voltage in PCME increase smoothly? c r page F2-104 Terminal 2B voltage: Approx. 4V (Ignition SW: ON) Yes Go to next step No Check as follows: • Movement of measuring core in volume airflow sensor • Ground of volume airflow sensor • Continuity between volume airflow sen­ sor and PCME connector • Condition in volume airflow sensor and PCME connector female terminals Yes • If symptom occurs at any engine temp., go to Step 13 •If symptom occurs during fast idle op­ eration, go to Step 13 • If symptom occurs at idle after warm-up, go to next step No Clean or replace Yes Go to next step No Replace BAC valve c r page F2-48 Yes Replace BAC valve c r page F2-48 No Reinstall BAC valve Go to next step ccr Section B2 cr Section B2 49 92 00 162 49 G 0 18 903 Are spark plugs OK? WEAR AND CARBON ^ Section G BURNT PLUG GAP — DAMAGE AND DETERIORATION DAMAGE 10 Is resistance of idle air control valve correct? Resistance: 10.7— 12.312 (at 20°C (68°F )) THROTTLE BODY 11 Try known good BAC valve; does condition improve? F 2-142 F2 TROUBLESHOOTING GUIDE STEP 12 ACTION INSPECTION Is heated oxygen sensor operation correct? c r page F2-108 Yes Go to next step No Check as follows: • Poor connection of engine coolant temperature sensor connector • Incorrect installation of throttle position sensor SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR M O N IT O R ^ LAMP SELECT SW: A 13 14 Are injectors OK? • No fuel leakage • Injectors not clogged c r c r Yes Go to next step No Replace injector page F2-68 page F2-69 cr page F2-66 known good PCME; does condition improve? c r page F2-92 46U0F2-154 F2-143 F2 TROUBLESHOOTING GUIDE 22, 23 DESCRIP­ TION ENGINE ROUGH •IDLE WITH A/C, P/S AND/OR E/L ON •IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when A/C, P/S and/or E/L ON • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when shifted from P or N to other range [TROUBLESHOOTING HINTS] © Idle speed • Idle speed too low @ Monitor switch function (SST) • Air conditioning sensor • Headlight switch • Rear window defroster switch • Blower switch © Idle air control valve • Idle air control valve stuck INSPECTION STEP Correct System Selector to diagnosis connector and set test switch to SELF TEST; is idle speed correct after warm-up? c r page F2-16 ACTION Yes Go to next step No Adjust idle speed and go to next step c r page F2-16 Yes “ 00” or "No diagnostic trouble codes” displayed Idle speed: 600—700 (650 ± 50) rpm Is “ 00" displayed onSST with ignition switch ON? c r page F2-18 Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No 49 H 018 9A1 c r page F2-20 MONITOR - 7 - LAMP '-3L- “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A Are switches correct when checked by using SST monitor lamp or indicator while ignition switch ON? c r page F2-43 • • • • Blower switch Headlight switch Rear window defroster switch Selector lever SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR 49 H 018 9A1 SELECT SW: A F 2-144 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F2-159 Yes • If symptom occurs at idle with P/S ON, go to next step • If symptom occurs at idle when shifted from N or P to other range, go to Step 5 No Lamp or indicator not ON/OFF with specified switch Check for cause (Refer to specified check sequence) c r page F2-45 F2 TROUBLESHOOTING GUIDE INSPECTION STEP ACTION Is following terminal voltage at PCME correct? Yes Go to next step 1N terminal: 12V (steering wheel in straight­ ahead position) OV (steering wheel turned fully) No Check as follows: • Wiring harness between P/S pressure switch and PCME terminal 1N for open circuit Yes »If symptom occurs at idle with A/C, P/S and/or E/L ON, go to next step •If symptom occurs at idle when shifted from N or P to other range, go to “ ENGINE RUNS ROUGH IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGE” in Section K of this manual No Check idle air control valve for sticking c r page F2-53 Yes Check as follows: • Malfunction of A/C relay c r Section U • Wiring harness between A/C relay and PCME terminal 1L for short circuit c r page F2-96 No Go to next step 49 9200 162 49 GO 18 903 Warm-up engine Does idle speed decrease when idle air control valve connector disconnected? Does air conditioner operate continuously with igni­ tion switch ON and A/C sensor and blower switch OFF? Try known good PCME; does condition improve? c r page F2-92 46U0F2-155 F 2-145 F2 TROUBLESHOOTING GUIDE 24 DESCRIP­ TION ENGINE RUNS ROUGH •ON DECELERATION • Engine shakes at beginning of deceleration, during deceleration, or recovery from deceleration •Exhaust afterburn [TROUBLESHOOTING HINTS] © Fuel pump • Poor connection of connector © Injector • Fuel leakage from injector(s) © Idle speed • Idle speed too low STEP @ Distributor • Poor connection of connector © Volume airflow sensor • Poor connection of connector • Measuring core stuck © Idle air contol valve • Idle air contol valve stuck INSPECTION Connect System Selector to data link connector and set test switch to SELF TEST; is idle speed correct after warm-up? c r page F2-16 ACTION Yes Go to Step 3 No Remove System Selector and go to next step Yes Adjust idle speed No Check as follows: • Wiring harness from idle air control valve to PCME for short and open circuit Idle speed: 600—700 (650 ± 50) rpm Does idle speed drop in following conditions? Condition: • Electrical load ON • Air conditioner ON • P/S operating • Idle air control valve stuck Is "00” displayed on SST with ignition switch ON? SELF-DIAGNOSIS CHECKER ^ Yes c r page F2-16 c r c r page F2-38 page F2-53 c r page F2-20 c r page F2-159 "00” displayed Go to next step Pa 9 e F 2 “ 18 SYSTEM SELECTOR No 49 H01 8 9A1 SELECT SW: A F 2-146 Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) <<gg’» flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 F2 TROUBLESHOOTING GUIDE STEP 4 ACTION INSPECTION Are switches correct when checked by using SST monitor lamp or indicator while ignition switch ON? c r page F2-43 SELF-DIAGNOSIS CHECKER Yes Go to next step No Lamp not ON/OFF with specified switch Check for caused (Refer to specified check sequence) SYSTEM SELECTOR c r page F2-45 'fceo! MONITOR LAMP SELECT SW: A 5 6 7 8 Yes Reinstall or replace injector No Go to next step Yes Verify that the measuring core of volume airflow sensor moves smoothly. • If OK, go to next step • If not OK, replace volume airflow sensor No Repair connector terminal Are following connections good? • Distributor connector • Fuel pump connector • Main relay • PCME connector Yes Go to next step No Repair connector terminal Try known good PCME; does condition improve? c r page F2-92 Yes Replace PCME No Go to "ENGINE RUNS ROUGH - ON DECELERATION” in Section K of this manual Is there fuel leakage from injector nozzles or injec­ tor holder? c r page F2—67 Are volume airflow sensor connector terminal and connection good? c r page F2-66 46U0F2-156 F 2-1 47 F2 TROUBLESHOOTING GUIDE 25, 26 DESCRIP­ TION POOR ACCELERATION •DRIVEAWAY •ON ACCELERATION • Engine speed increases normally but vehicle speed slowly increases during driveaway or acceleration [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Pressure regurator • Pressure regulator malfunction (D Fuel filter • Clogged filter © Distributor • Poor connection of connector • Cap and/or rotor damage © Volume airflow sensor • Poor connection of connector •Measuring core stuck INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00” displayed Go to next step S E L F -D IA G N O S IS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) c r page F2-20 49 H 018 9A1 “ 88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 S E L E C T SW : A Is a strong blue spark visible at each disconnected high-tension lead while cranking engine? Does measuring core in volume airflow sensor move smoothly? c r page F2-104 Yes Check spark plugs => If OK, go to next step ■=> If not OK, clean or replace spark plug No Check as follows: •Distributor cap and rotor • High-tension lead(s) •Condition of distributor connector femals terminals Yes Check condition of volume airflow sensor connector female terminals ■=t> If OK, go to next step ■=> If not OK, repair terminal No Replace volume airflow sensor Is intake manifold vacuum correct at idle? Yes Go to next step Vacuum: More than 60.0 kPa {450 mmHg, 17.7 inHg) No Check as follows: •Intake air system components and in­ stallation •Vacuum hoses for disconnection and damage • Shutter valve actuator for damage MESSURING CORE F2—148 c r page F2-159 c r Section G c r Section G F2 TROUBLESHOOTING GUIDE STEP 5 Is fuel line pressure correct at idle? c r page F2-70 Fuel line pressure: 210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi) 6 ACTION INSPECTION Try known good PCME; does condition improve? c r page F2-92 Yes Go to next step No Low pressure Check as follows: • Fuel filter for clogging • Operation of pressure regulator • Fuel leakage from injector (s) Yes Replace PCME No Go to “ POOR ACCELERATION DRIVEAWAY/ON ACCELERATION” in Section K of this manual c r page F2-70 c r page F2-67 46U0F2-157 F2—149 F2 TROUBLESHOOTING GUIDE 27 DESCRIP­ TION HIGH IDLE SPEED AFTER WARM-UP • Idle speed continues at fast idle after warm-up • Engine returns slowly to idle after accelerator is released [TROUBLESHOOTING HINTS] © Engine coolant temoerature sensor • Poor connection of connector © Throttle position sensor • Poor connection of connector • Incorrect adjustment (3) BAC valve • Idle air control valve or air valve stuck INSPECTION STEP Is “ 00” displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00” displayed Go to next step S E L F -D IA G N O S IS CHECKER SYSTEM SELECTOR No 49 H 018 9A1 c r page F2-20 c r page F2-159 c r page F2-107 “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 S ELEC T SW : A Connect System Selector to the data link connector and set system select to position 1 Does idle speed decrease with TEST SWITCH set to SELF TEST? Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) Yes No Check condition of engine coolant temperature sensor (CIS) and throttle position sensor connector female ter­ minals => If OK, go to next step => If not OK, repair the female con­ nector Check if idle air control valve or air valve cti ipk o If OK, go to Step 4 ■=> If not OK, replace BAC valve Is following terminal voltage at PCME correct? Yes Go to next step Terminal 2F: 0.1—1.1V (throttle valve fully closed) 3.1—4.4V (throttle valve fully open) No Adjust or replace throttle position sensor 49 92 00 162 49 G 0 18 903 Try known good PCME; does condition improve? c r page F2-92 46U0F2-158 F2-150 TROUBLESHOOTING GUIDE_________________ F2 B +: Battery positive voltage 28 • IDLE FLUCTUATES • IDLE HUNTS >Engine speed changes back and forth between specified idle speed and higher speed DESCRIP­ TION [TROUBLESHOOTING HINTS] © PCV valve • PCV valve stuck (2 ) Spark plug • Spark plug(s) damaged (3) Throttle position sensor • Incorrect adjustment @ Idle air control valve • Idle air control valve stuck STEP __________________ INSPECTION________ Is “ 00" displayed on SST with ignition switch ON? c r page F2-18 ACTION Yes “ 00" displayed Go to next step S E L F -D IA G N O S IS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) 49 H 018 9A1 c r page F2-20 c r page F2-159 c r page F2-107 M O N IT O R '; ^7-LAMP i “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 S E L E C T SW : A Is following terminal voltage at PCME correct? Terminal 1T: Below 1.0V (accelerator pedal released) B + (accelerator pedal depressed) Yes Go to next step No Check as follows: •Throttle position sensor adjustment 49 92 00 162 49 G01 8 903 Connect System Selector to data link connector and set system select to position 1 Does idle hunting stop when test switch to SELF­ TEST? Yes Check as follows: • Idle air control valve for sticking • Poor sealing between throttle body and BAC valve No Go to next step F2-151 F2 TROUBLESHOOTING GUIDE INSPECTION STEP 4 Is a strong blue sp ark visible at each disconnected high-tension lead while cranking engine? e j 5 6 IP pi /-jQ pJhP / Is PCV valve stuck? ACTION Yes Check spark plug(s) =!> If OK, go to next step => If not OK, replace spark plug(s) No Check as follows: • Distributor cap and rotor for damage c r Section G Yes Replace PCV valve No Go to next step c r page F2-80 Try known good PCME; does condition improve? c r page F2-92 46U0F2-159 F2 TROUBLESHOOTING GUIDE 29 • HESITATES • STUMBLES ON ACCELERATION • Momentary pause at begining of acceleration or during acceleration DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Fuel leakage from injector(s) © Fuel pump • Poor connection of connector @ Pressure regulator • Pressure regulator stuck @ EGR control valve • EGR control valve stuck © Solenoid valve (EGR, vacuum) • Solenoid valve stuck ® Distributor • Poor connection of connector • Cap and/or rotor damage © High-tension lead(s) • Lead(s) damaged © Volume airflow sensor • Poor connection of connector • Measuring core stuck © Throttle position sensor • Poor connection of connector STEP __________________ INSPECTION___________ Is “ 00” displayed on SST with ignition switch ON? cr page F2-18 ACTION Yes “ 00” displayed Go to next step S E L F -D IA G N O S IS CHECKER SYSTEM SELECTOR No Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) cr page F2-20 49 H 0 1 8 9A1 M O N IT O R / LA M P -~- “ 88” flashes Refer to “ No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 S E L E C T SW : A Is strong blue spark visible at each disconnected high-tension lead? Is fuel line pressure correct at idle? cr page F2-70 Fuel line pressure: 210—250 kPa (2.1—2.6 kgf/cm2, 30—36 psi] cr page F2-159 Yes Go to next step No Check as follows: • Distributor cap and rotor for damage cr Section G •High-tension lead(s) for damage cr Section G • Condition of distributor and PCME connectors female terminals Yes Go to next step No Low pressure Check fuel line pressure while pinch­ ing fuel return hose •If pressure quickly increases, check pressure regulator cr page F2-70 • If pressure gradually increases, check for clogging between fuel pump and pressure regulator If hose not clogged, check fuel pump maximum pressure cr page F2-63 F2-153 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Does fuel pressure increase when throttle valve opened? ACTION Yes Go to next step No Check pressure regulator c r page F2-70 Disconnect vacuum hose from EGR valve and plug it; does condition improve? Connect engine signal monitor to PCME and set the position 2J. Is following terminal voltage at PCME increase smoothly when vacuum applied to EGR control valve? Yes Check as follows: • Solenoid valve (EGR, vacuum) for stick­ ing • Solenoid valve (EGR, vent) for sticking • Condition of solenoid valve connectors female terminals No Go to next step Yes Go to next step No Check EGR control valve for sticking Yes Verify that measuring core of volume air­ flow sensor moves smoothly • If OK, go to next step • If not OK, replace volume airflow sensor No Check condition of volume airflow sen­ sor and PCME connectors female ter­ minals • If OK, replace volume airflow sensor • If not OK, repair female terminal c r page F2-78 Terminal 2J voltage: (V) OUTPUT 3 VOLTAGE2 6.7 13.3 ' I kPa \ (50,2.0) (100, 3.9)UmmHg, inHg)] VACUUM Is following terminal voltage at PCME correct? 2B terminal: Approx. 4V (ign switch ON) Approx. 2.8V (idle) 49 92 00 162 49 G018 903 F 2-154 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Is following terminal 2F voltage at PCME correct? 2F terminal: 0.1—1.1V (throttle valve fully closed) 3.1—4.1V (throttle valve fully open) ACTION Yes Go to next step No Check the female terminal condition in throttle postion sensor connector and PCME connector • If OK, replace throttle position sensor c r page F2-107 • If not OK, repair female terminal 49 92 00 162 49 GO 18 903 Is there fuel leakage from injector(s) Yes Check as follows: • Poor installation of injector Fuel leakage: Less than 1 drop/2 min. c r No page F2-66 Go to next step TO FUEL TANK FROM FUEL FILTER 10 Try known good PCME; does condition improve? c r page F2-92 46U0F2-160 F2 TROUBLESHOOTING GUIDE 30 SURGES WHILE CRUISING • Momentary minor irregularity in engine output at steady vehicle speed. DESCRIP­ TION [TROUBLESHOOTING HINTS] © Injector • Poor connection of connector © Spark plug • Spark plug(s) damaged © Volume airflow sensor • Poor connection of connector • Measuring core stuck INSPECTION STEP Is "00” displayed on SST with ignition switch ON? cr page F2-18 ACTION Yes “ 00” displayed Go to next step SELF-DIAGNOSIS CHECKER SYSTEM SELECTOR No /I Diagnostic Trouble Code No. displayed Check for cause (Refer to specified check sequence) cr page F2-20 49 H 018 9A1 <<88” flashes Refer to "No.38 SELF-DIAGNOSIS CHECKER FLASHES 88 SELECT SW: A Connect engine signal monitor to PCME and set to position 2B Does output voltage of volume airflow sensor gradu­ ally increase in conjunction with increase of engine speed? Yes Go to next step No Check as follows: • Smooth movement of measuring core in volume airflow sensor • Condition of volume airflow sensor and PCME connectors female terminals Yes Check as follows: • Condition of injector and PCME connectors female terminals No Go to next step 49 92 00 162 49 G 01 8 903 Does idle become rough when shaking connec­ tor of injector? F 2-156 cr page F2-159 F2 TROUBLESHOOTING GUIDE INSPECTION STEP Is a strong blue spark visible at each disconnected high-tensio n lead while cranking engine? 4 — 5 1 Try known good PCME; does condition improve? c r page F2-92 ACTION Yes Check spark plug(s) for damage => If OK, go to next step => If not OK, replace spark plug(s) No Check as follows: • Distributor cap and rotor for damage c r Section G Yes Replace PCME No Go to “ SURGE WHILE CRUISING” in Section K of this manual 46U0F2-161 31 LACK OF POWER • Performance poor under load (i.e., power down when climbing hills) DESCRIP­ TION [TROUBLESHOOTING HINTS] © Volume airflow sensor • Open or short circuit in wiring of intake air temperature sensor (Code No. 10 output) • Poor connection of connector © Distributor • Damaged distributor cap or rotor © Injector • Injector harness shorted to ground © Fuel filter • Clogged filter © Air cleaner housing • Clogged element © Three way catalyst • Clogged three way catalyst cr page F2-28 cr Section G cr page F 2 -1 5 cr page F2-73 46U0F2-162 F2 32 TROUBLESHOOTING GUIDE POOR FUEL ECONOMY • Fuel economy unsatisfactory DESCRIP­ TION [TROUBLESHOOTING HINTS] © A ir leakage • Poor installation of air intake hose, throttle body, intake manifold and/or EGR valve • Vacuum hose damaged or disconnected © Heated oxygen sensor • Open in harness (Code No. 15, 23 output) © Pressure regulator • Hold fuel pressure high • Vacuum hose disconnected or damaged c r page F 2 -7 c r page F2-30 c r page F2-65 c r page F 2 -7 46U0F2-163 33 A/C DOES NOT WORK • A/C compressor magnetic clutch does not engage when air conditioning sensor ON DESCRIP­ TION [TROUBLESHOOTING HINTS] © A/C relay • Poor connection of connector • Relay malfunction © Air conditioning sensor or A1C amplifier • Does not send signal to PCME terminal 10 © PCME • Does not send signal to A/C relay when ignition switch ON c r Section U c r page F2-96 c r page F2-96 46U0F2-164 34 DESCRIP­ TION • KNOCKING • PINGING • Sound produced when air/fuel mixture is ignited by something other than spark plug (i.e., hot spot in combustion chamber) [TROUBLESHOOTING HINTS] Knock sensor • Open or short in harness (Code No.05 output) c r page F2-25 46U0F2-165 TROUBLESHOOTING GUIDE 35 F2 FUEL ODOR • Gasoline fuel smell or visible leaks DESCRIP­ TION [TROUBLESHOOTING HINTS] © Solenoid valve (purge control) • Open or short in harness (Code No.26 output) © Charcoal canister • Canister full of fuel and leaking c r page F2-35 46U0F2-166 36 EXHAUST SULFUR SMELL • Rotten egg smell (sulfur) from exhaust DESCRIP­ TION [TROUBLESHOOTING HINTS] High sulfer content fuel used 36U0F2-285 37 HIGH OIL CONSUMPTION • Oil consumption excessive DESCRIP­ TION [TROUBLESHOOTING HINTS] PCV valve • PCV valve stuck open c r page F2-80 46U0F2-167 38 SELF-DIAGNOSIS CHECKER FLASHES “ 88” • Checker flashes 88 with test connector (TEN) grounded DESCRIP­ TION [TROUBLESHOOTING HINTS] © Short circuit in wiring between diagnosis connector terminal FEN and PCME terminal 1F © PCME • PCME malfunction c r page F2-94 46U0F2-168 F2 39 TROUBLESHOOTING GUIDE MIL NEVER ON • S e lf-D ia g n o sis C h e c k e r in d ica te s S e rvice C o d e N o. o f in p u t d e v ic e b u t M IL n e ve r O N DESCRIP­ TION [TROUBLESHOOTING HINTS] ® © B u lb b u rn t P o w e rtra in c o n tro l m o d u le (P C M E ) 1E te rm in a l c irc u it o p e n 46U0F2-169 F 2-160 SERVICE POINTS F2 SERVICE POINTS OUTLINE Main Relay (Battery Power) • If the circuit is open, the engine will not start. • If the circuit is shorted, the EGI INJ fuse (30A) will burn out. Room Fuse (PCME Memory Power) • If the circuit is open, the PCME memory function will not operate, and diagnostic trouble codes for inter­ mittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not produce any particular symptom. • If the circuit is shorted, the ROOM fuse (15A) will burn out. Ground (Output Devices, Injector) • If an output device or an injector has an open ground circuit, no particular symptom will be produced. If a related output device and injectors both have open ground circuits, the engine will not start. Ground (System, Analogue) • An open circuit will not produce any symptom. TEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker cannot perform diagnostic trouble code checks and switch monitoring checks. • If the circuit is shorted, the opening amount of the idle air control valve will not change, causing hard starting and rough idle. The ignition timing will be fixed, causing lack of power and poor acceleration. The Self-Diagnosis Checker cannot perform sensor monitoring checks. • If the circuit is shorted, the coolant fan operates whenever the throttle valve is opened. MEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker monitor lamp will not illuminate. • If the circuit is shorted, the Self-Diagnosis Checker monitor lamp will stay on. FEN Terminal (Data Link Connector) • If the circuit is open, the Self-Diagnosis Checker can not perform the diagnostic trouble code check. • If the circuit is shorted, code “ 88” will keep flashing, preventing a diagnostic trouble code check. Malfunction Indicator Light (MIL) • If the circuit is open, the MIL will not illuminate with the ignition switch ON. • If the circuit is shorted, the MIL will not go off after the engine is started. [Input Device] Volume Airflow Sensor (With Intake Air Temperature sensor) • If the intake volume air temperature sensor (within the volume airflow sensor) or circuit has an open or short, Diagnostic Trouble Code No. 10 is output, and the PCME uses a preprogrammed intake air temper­ ature of 20°C {68°Fj. • If the intake air temperature sensor system fails, no particular symptom will be noticed. • If the Vs terminal of the air flow sensor has a short circuit, Diagnostic Trouble Code No.08 will be output, and the throttle position sensor and idle switch signal will be used to adjust the basic injection amount as to the following three modes. 1) Idle switch ON 2) Small throttle angle 3) Large throttle angle F2-161 F2 SERVICE POINTS Throttle Position Sensor (Refer to Section K) • If the Vref terminal has an open circuit or the TVO terminal has an open or short circuit, Diagnostic Trouble Code No. 12 is output. • If the 21 terminal has a short circuit, the engine will not start. • If the ground terminal has an open circuit, Diagnostic Trouble Code No. 12 is output. • In the above conditions, the PCME uses a throttle valve wide open throttle program. • If the throttle position sensor is not properly adjusted or the throttle position sensor system fails, poor ac­ celeration or shift shock (ATX) will result. Idle Switch (In Throttle Position Sensor) • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • If the circuit is open, rough idle or engine stalling may appear because of inoperative idle speed control. • If the circuit is shorted, fuel will be cut when the accelerator pedal is pressed, causing hunting. Heated Oxygen Sensor • If sensor output voltage is not generated because of an open or short circuit, Diagnostic Trouble Code No. 15 (left bank sensor) and/or 23 (right bank sensor) is output. • If the heated oxygen sensor output voltage condinues unchanged 20 sec. after the engine exceeds 1,500 rpm, Diagnostic Trouble Codes No.17 (left bank sensor) and/or 24 (right bank sensor) is output. • In the above conditions, no feedback control will be present and no symptom will be noticed. Crankshaft Position Sensor 2 (NE2 Signal), Crankshaft Position Sensor 1 (NE1, G Singnal) • If the NE2 signal circuit has an open or short, Diagnostic Trouble Code No.02 is output. • If the NE1 signal circuit has an open or short, Diagnostic Trouble Code No.04 is output. • If the G signal circuit has an open or short, Diagnostic Trouble Code No.03 is output. Input NE1 signal G signal Diagnostic Trouble code O X 03 S im u lta n e o u s in je ctio n L a c k of p o w e r, p o o r a c c e le ra tio n X X 04 S e q u e n tia l in je ctio n N o s y m p to m X X 0 3, 04 N o in je c tio n /ig n itio n E n g in e d o e s n o t start O 02 S e q u e n tia l in je ctio n N o s ym p to m X O O X 02, 03 S im u lta n e o u s in je ctio n L a c k of p o w e r, p o o r a c c e le ra tio n X X O 02, 04 N o in je c tio n /ig n itio n E n g in e d o e s n o t start X X X 02, 04 N o in je ctio n /ig n itio n E n g in e d o e s n o t start NE2 signal O O o X O : N o rm a l Fail-safe function Symptom x : M a lfu n c tio n Starter Signal • A lack of starter signal input will cause hard starting. Steering Pressure Sensor • An open or short circuit can cause a momentary drop in engine speed when steering at idle or low-speed driving. Air Conditioning Sensor • The switch monitor function can confirm the presence of an open or short circuit. • If the circuit is open, the air conditioner will not operate. • If the circuit is shorted, the air conditioner will constantly operate when the blower is ON. Engine Coolant Temperature Sensor • If the engine coolant temperature sensor or circuit has an open or short, Diagnostic Trouble Code No.09 is output, and the PCME uses a preprogrammed temperature value of 80°C {176°F}. • A malfunction in the engine coolant temperature sensor system may cause rough idle, engine stalling, or hard starting. F 2-162 SERVICE POINTS F2 Blower Signal (A/C Amplifier) • The switch monitor funciton of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • If the circuit has an open or short, the idle speed may drop when in the 3rd or 4th position. Stoplight Signal • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • An open or short circuit will produce no symptom. Vehicle Speed Sensor • If the vehicle speed signal circuit has an open or short, Diagnostic Trouble Code No.06 is output. • If the circuit is open or shorted, hold mode will not operate. Park/Neutral Signal (ATX; Refer to Section K) • If the circuit is open, the idle speed will be slightly low in P and N ranges. • If the circuit is shorted, the idle speed will be slightly high in R, D, S, and L ranges. Reduce Torque Signal (ATX; Refer to Section K) • If a malfunction occurs in the reduce torque signal, the torque reduction control system is inhibited and line pressure will be high at shifting. Shift shock may be slightly increased. Knock Sensor • If the knock sensor or circuit has an open or short, Diagnostic Trouble Code No.05 is output. • In the above conditions, ignition timing is retarded. EGR Function Sensor • If the EGR function sensor or circuit has an open or short, Diagnostic Trouble Code No. 16 is output. • In the above conditions, the EGR control valve will be fully closed. Neutral and Clutch Switches (MTX) • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • If the circuit is open, the idle speed will drop when A/C, P/S, or electrical load is ON. Rear Window Defroster Switch • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • An open or short circuit can cause a low idle speed when the switch is ON. Headlight Switch • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • An open or short circuit can cause a low idle speed when the switch is ON. Daytime Running Light (Canada) • The switch monitor function of the Self-Diagnosis Checker can confirm the presence of an open or short circuit. • An open or short circuit can cause a low idle speed when the switch is ON. [Output Device] Injector • If the circuit is open, the injector will not operate, causing rough idle and misfiring. • If the circuit is shorted, the injector will inject fuel constantly, and the engine will not start or will start hard. IGT Signal (Igniter) • If no IGT signals are input to the igniter because of an open or short circuit, the engine will not start. F2 SERVICE POINTS Idle Air Control Valve (BAC Valve) • If the idle air control valve or circuit has an open or short, Diagnostic Trouble Code No.34 is output. • If the circuit is open, the idle air control valve will be fully closed, causing rough idle, engine stalling, and acceleration hesitation when cold. • If the circuit is shorted, the idle air control valve will be wide opened throttle and the idle speed will be increased, causing hunting. Fuel Pump Relay • If the circuit is open, the engine will not start. • If the circuit is shorted, the fuel pump will operate whenever the ignition switch is ON. Purge Solenoid Valve • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.26 is output. • If the circuit is open, no symptom will be noticed. • If the circuit is shorted, the engine will stall at low speed. • A short circuit may cause an improper air/fuel ratio, causing rough idle and hard starting. VRIS Solenoid Valve 1 • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.41 is output. • If the circuit is open, the solenoid valve will stay OFF and the shutter valves will stay closed, causing a power drop. • If the circuit is shorted, the solenoid valve will stay ON and the shutter valves will stay open, causing a power drop. VRIS Solenoid Valve 2 • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.46 is output. • If the circuit is open, the solenoid valve will stay OFF and the shutter valves will stay closed, causing a power drop. • If the circuit is shorted, the solenoid valve will stay ON and the shutter valves will stay open, causing a power drop. A/C Signal (A/C Relay) and Condenser Fan Low Relay • If the circuit is open, the air conditioner will not operate. • If the circuit is shorted, the air conditioner will constantly operate when the blower is ON. Torque Reduced Signal (Refer to Section K) • If a malfunction occurs in the torque reduced signal, the torque reduction control system is inhibited and the line pressure characteristics will be high shifting. Shift shock may be slightly increased. EGR Solenoid Valve (Vent) • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.29 is output. • If the circuit is open or shorted, no symptom will be noticed. EGR Solenoid Valve (Vacuum) • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.28 is output. • If the circuit is shorted, the EGR control valve will remain open, causing engine stalling and hard starting. • If the circuit is open, no symptom will be noticed. PRC Solenoid Valve • If the solenoid valve or circuit has an open or short, Diagnostic Trouble Code No.25 is output. • If the circuit is shorted, no symptom will be noticed. • If the circuit is open, the engine will be hard to start when warm. Coolant Fan Relay No.1 • If the relay or circuit has an open or short, Diagnostic Trouble Code No.67 is output. • If the circuit is shorted, the coolant fan will always operate while the ignition switch is ON. • If the circuit is open, the coolant fan will not operate until the engine coolant temperature exceeds 100°C {212°F}. SERVICE POINTS F2 Coolant Fan Relay No.2 and No.3 • If the circuit is shorted, the coolant fan will always operate while the ignition switch is ON. • If the circuit is open, the coolant fan will remain OFF when the engine coolant temperature exceeds 108°C Condenser Fan Low Relay • If the circuit is shorted, the condenser fan will always operate while the ignition switch is ON. • If the circuit is open, the condenser fan will remain OFF when engine coolant temperature exceeds 100°C {212°F}. Condenser Fan High Relay No.1 and No.2 • If the circuit is shorted, the condenser fan will always operate while the ignition switch is ON. • If the circuit is open, the condenser fan will remain OFF when the engine coolant temperature exceeds 108°C (226°F). 46U0F2-170 F 2-165 F2 SERVICE POINTS WIRING DIAGRAM 16E0F2-290 F2-166 F2 SERVICE POINTS PRC SOLENOID VALVE EGR SOLENOID VALVE (VENT) No.2 SOLENOID IDLE AIR CONTROL VALVE pressure! valve DATA LINK CONNECTOR DISTRIBUTOR (IGNITER, IGNITION COIL, AND CRANKSHAFT POSITION SENSOR No.1) 4r BLOWER SWITCH F 2-167 F2 SERVICE POINTS ELECTRICAL DIAGNOSIS SUPPORT Main Relay (Battery Power) Circuit P C M E (1 B)— M ain relay Condition Short circuit Open circuit EGI IN J fu se (30A ) b u rn s o u t w h e n ig n itio n sw itch ON E n g in e w ill n o t start Poor ground NA 36U0F2-213 Room Fuse (Memory Power) Circuit P C M E (1 A )— R o o m fu se Open circuit N o s y m p to m Condition Short circuit Poor ground Room fuse (15A) burns out NA 36U0F2-214 Ground (Output Device, Injector, System, Analogue) Circuit P C M E (3A )— G ro u n d (O u tp u t d e vice ) P C M E (3B )— G ro u n d (Injector) P C M E (3C )— G ro u n d (System ) Open circuit (O ne sid e o p e n circu it) N o sy m p to m (B oth sid e s o p e n circu it) E n g in e w ill n o t start Condition Short circuit Poor ground E n g in e m a y n o t start H a rd sta rtin g NA N o sy m p to m P C M E (3D )— G ro u n d (A n a lo g u e ) 36U0F2-215 Data Link Connector (TEN terminal) Circuit P C M E (11)— D a ta lin k c o n n e c to r Open circuit C a n n o t p e rfo rm s e rvice c o d e c h e c k s a n d sw itch m o n ito r c h e c k s Condition Short circuit H a rd starting R o u g h id le P o o r a cce le ra tio n Poor ground NA 36U0F2-216 Data Link Connector (MEN terminal) Circuit P C M E (1 D)— D a ta lin k c o n n e c to r Open circuit S e lf-D ia g n o sis C h e c k e r m o n ito r la m p w ill n o t il­ lu m in a te Condition Short circuit Poor ground S e lf-D ia g n o sis C h e c k e r m o n ito r la m p w ill stay O N NA 36U0F2-217 Data Link Connector (FEN terminal) Circuit P C M E (1 F)— D a ta lin k c o n n e c to r Open circuit S e lf-D ia g n o sis C h e c k e r b u zze r w ill n o t s o u n d d u r­ in g d ia g n o s tic tro u b le code check Condition Short circuit C o d e “ 8 8 ” w ill ke e p fla s h in g a n d b u zze r will c o n tin u e s o u n d in g d u rin g d ia g n o s tic tro u b le c o d e check Poor ground NA 46U0F2-171 Malfunction Indicator Light (MIL) Circuit P C M E (1 E)— M IL NA: Not applicable F2-168 Open circuit M IL w ill n o t illu m in a te w ith ig n itio n sw itch ON Condition Short circuit M IL w ill not g o off after e n g in e is sta rte d Poor ground NA 46U0F2-172 F2 SERVICE POINTS [Input Device] Volume Airflow Sensor (Intake Air Temperature sensor Included) Circuit Open circuit Condition Short circuit P C M E (2B )— V o lu m e a irflo w se n so r Lack of pow er P o o r a c c e le ra tio n C o d e N o .0 8 o u tp u t L a ck o f p o w e r P o o r a cce le ra tio n P C M E (21)— V o lu m e a irflo w se n so r C o d e N o .0 8 o u tp u t Lack of pow er P o o r a c c e le ra tio n E n g in e stall a n d w ill not restart P C M E (2K )— V o lu m e a irflo w se n so r C o d e N o. 10 o u tp u t N o sy m p to m C o d e No. 10 o u tp u t N o s y m p to m P C M E (3 D )— V o lu m e a irflo w s e n so r (O n e sid e o p e n circu it) N o sy m p to m (B o th s id e s o p e n circu it) C o d e N o .0 8 10 o u tp u t P o o r a c c e le ra tio n V o lu m e a irflo w s e n s o r— G ro u n d Poor ground NA P o o r a cce le ra tio n NA 46U0F2-173 Crankshaft Position Sensor No. 2 (NE2 Signal), Crankshaft Position Sensor No. 1 (NE1, G Signal) Circuit Open circuit Condition Short circuit P C M E (3 H )— C ra n k s h a ft p o sitio n s e n s o r N o. 2 C o d e N o .0 2 o u tp u t N o s y m p to m P C M E (3F)— C ra n k s h a ft p o sitio n s e n s o r N o. 2 C o d e N o .0 2 o u tp u t N o s y m p to m P C M E (3E )— C ra n k s h a ft p o sitio n s e n s o r No. 1 H a rd sta rt until c o d e N o .0 4 o u tp u t H a rd sta rt until c o d e N o .0 4 o u tp u t P C M E (3G )— C ra n k s h a ft p o sitio n s e n s o r N o. 1 H a rd sta rt until c o d e N o .0 3 o u tp u t Lack of pow er H a rd sta rt until c o d e N o .0 3 o u tp u t Lack of pow er M a in re la y — C ra n k s h a ft p o sitio n s e n s o r N o. 1 C o d e N o .0 3 o r 0 4 o u tp u t E n g in e w ill n o t start C o d e N o .0 3 o r 0 4 o u tp u t EGI fu se (30A ) b u rn s o u t w h e n ig n itio n sw itch O N C ra n k s h a ft p o s itio n s e n s o r N o. 1 — G ro u n g C o d e N o .0 3 o r 0 4 o u tp u t E n g in e w ill n o t start Poor ground C o d e N o .0 2 o u tp u t N o sy m p to m NA NA NA E n g in e m a y not s ta rt S y m p to m d iffe rs w ith c o m b in a tio n s o f N E 2, N E 1, a n d G sig n a l m a lfu n ctio n . (R efer to p a g e F -6 0 .) Engine Coolant Temperature Sensor Open circuit Condition Short circuit P C M E (2E )— E n g in e c o o la n t te m p e ra tu re s e n so r C o d e N o .0 9 o u tp u t R o u g h idle, h a rd sta rtin g C o o la n t fa n a n d a d d itio n a l fa n o p e ra te c o n tin u o u s ly C o d e N o .0 9 o u tp u t R o u g h idle, h a rd sta rtin g C o o la n t fa n a n d a d d itio n a l fa n o p e ra te co n tin u o u s ly E n g in e c o o la n t te m p e ra tu re s e n s o r— G ro u n d C o d e N o .0 9 o u tp u t R o u g h idle, h a rd sta rtin g C o o la n t fa n a n d a d d itio n a l fa n o p e ra te co n tin u o u s ly NA Circuit Poor ground NA R o u g h idle H a rd sta rtin g C o o la n t fa n a n d a d d itio n a l fa n o p e ra te c o n tin u o u s ly 46U0F2-174 F2-169 F2 SERVICE POINTS Throttle Position Sensor (Idle Switch Included) Circuit PCME (21)—Throttle position sensor PCME (2F)—Throttle position sensor PCME (IT)—‘Throttle position sensor Throttle position sensor—Ground Open circuit Code No. 12 output Poor acceleration Strong shift shock (ATX) Code No. 12 output Poor acceleration Strong shift shock Rough idle Code No. 12 output Poor acceleration Strong shift shock Condition Short circuit Code No. 12 output Engine will not start Code No. 12 output Poor acceleration Strong shift shock Fuel cut when accelerator pedal is pressed, causing hunting NA Poor ground NA Poor acceleration Strong shift shock 36U0F2-224 Heated Oxygen Sensor Circuit PCME (2C)—Heated oxygen sensor (RH) Heated oxygen sensor (RH)— Ground PCME (2D)—Heated oxygen sensor (LH) Heated oxygen sensor (LH)— Ground Open circuit Code No.23 output Poor fuel economy Code No.23 output Poor fuel economy Code No. 15 output Poor fuel economy Code No. 15 output Poor fuel economy Condition Short circuit Code No.23 output Poor fuel economy NA Code No. 15 output Poor fuel economy NA Poor ground NA No symptom NA No symptom 36U0F2-225 Starter Signal (Ignition Switch) Circuit PCME (1C)—Ignition switch Open circuit Hard starting Condition Short circuit Starter signal IG KEY fuse (60A) burns out when cranking Poor ground NA 36U0F2-226 Steering Pressure Sensor Circuit PCME (1N)—Steering pressure sensor Open circuit Engine speed may drop when steering at idle or low-speed driving Condition Short circuit Engine speed may drop when steering at idle or low-speed driving Poor ground Engine speed may momen­ tarily drop when steering at idle or low-speed driving 36U0F2-227 Air Conditioning Sensor Circuit PCME (10)—Air conditioning sensor Open circuit Air conditioner will not operate Condition Short circuit Air conditioner will constantly operate with blower ON Poor ground NA 46U0F2-175 Blower Signal Circuit PCME (1P)—A/C amplifier NA; Not applicable F2-170 Open circuit Idle speed may be low in 3rd or 4th position Condition Short circuit Idle speed may be low in 3rd or 4th position Poor ground NA 36U0F2-229 F2 SERVICE POINTS Stoplight Signal (Stoplight Switch) Circuit Open circuit No symptom PCME (1Q)—Stoplight switch Condition Short circuit No symptom Poor ground NA 36U0F2-230 Vehicle Speed Sensor Circuit Open circuit Code No.06 output (ATX) Hold mode will not operate PCME (1M)—Vehicle speed sensor Condition Short circuit Code No.06 output (ATX) Hold mode will not operate Poor ground NA 36U0F2-231 Park/Neutral Signal (EC-AT CU) Circuit Open circuit PCME (1R)—PCMT Idle speed slightly lower in P and N ranges Condition Short circuit Idle speed slightly higher in R, D, S, and L ranges Poor ground NA 46U0F2-176 Reduce Torque Signal (PCMT) Circuit PCME (1S)—PCMT Open circuit Shift shock may be slight­ ly stronger Condition Short circuit Shift shock may be slight­ ly stronger Poor ground NA 36U0F2-233 Knock Sensor Circuit PCME (2M)—Knock sensor Open circuit Code No.05 output Lack of power Knocking Condition Short circuit Code No.05 output Lack of power Knocking Poor ground NA 36U0F2-235 EGR Function Sensor Circuit PCME (2J)—EGR function sensor Open circuit Code No.16 output No symptom Condition Short circuit Code No. 16 output No symptom Poor ground NA 36U0F2-235 Neutral and Clutch Switches (MTX) Circuit PCME (1R)—Neutral switch PCME (1R)—Clutch switch NA: Not applicable Open circuit Idle speed drop when A/C, P/S, or electrical load is ON Condition Short circuit No sysmptom Poor ground NA 36U0F2-236 F2-171 F2 SERVICE POINTS Rear Window Defroster Switch Circuit PCME (1 J)—Rear window defroster switch Open circuit Idle speed may be low when switch ON Condition Short circuit Idle speed may be low when switch ON Poor ground NA 36U0F2-237 Headlight Switch Circuit PCME (1H)—Headlight switch Open circuit Idle speed may be low when switch ON Condition Short circuit Idle speed may be low when switch ON Poor ground NA 36U0F2-238 Daytime Running Light (Canada) Circuit PCME (2L)—Daytime running light Open circuit Idle speed may be low when switch ON Condition Short circuit No symptom Poor ground NA 36U0F2-239 [Output Device] Injector Circuit PCME (3U, 3V, 3W, 3X, 3Y, 3Z)— Injector Open circuit Rough idle Poor accelation at low speed Condition Short circuit Will not start or hard start Engine rough or stall Poor ground NA 36U0F2-240 IGT Signal (Igniter) Circuit PCME (1G)—Igniter Igniter—Ignition coil Igniter—Ground Open circuit Engine stall and will not start Condition Short circuit Engine stall and will not start NA Poor ground NA Engine will not start 36U0F2-241 Idle Air Control Valve [IN BAC Valve] Circuit PCME (30)—Idle air control valve Open circuit Code No.34 output Rough idle Engine stalls Hard start Idle air control valve—Main relay Condition Short circuit Code No.34 output Hunts Idle speed stays or fluc­ tuates at approx. 1,500 rpm EGIINJ fuse (30A) burns out when ignition switch ON Poor ground NA 36U0F2-242 Fuel Pump Relay Circuit PCME (3T)—Fuel pump relay NA: Not applicable F2-172 Open circuit Engine stall and will not restart Condition Short circuit Fuel pump will operate whenever ignition switch ON Poor ground NA 3 6 UOF2-243 F2 SERVICE POINTS Purge Solenoid Valve Circuit PCME (20)—Solenoid valve (purge control) Open circuit Code No.26 output No symptom Solenoid valve (purge control) —Main relay Condition Short circuit Code No.26 output Hard starting Engine stall at low speed EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-177 VRIS Solenoid Valve No.1 Circuit PCME (31)—VRIS solenoid valve 1 Open circuit Code No.41 output Lack of power VRIS solenoid valve 1—Main relay Condition Short circuit Code No.41 output Lack of power EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-178 VRIS solenoid Valve No.2 Circuit PCME (3J)—VRIS solenoid valve 2 Open circuit Code No.46 output Lack of power VRIS solenoid valve 2—Main relay Condition Short circuit Code No.46 output Lack of power EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-179 \ __„ A/C Signal (A/C Relay) and Condenser Fan Low Relay Circuit PCME (1L)—A/C relay Open circuit Air conditioner will not operate Condition Short circuit Air conditioner will operate whenever blower ON Poor ground NA 36U0F2-247 Torque Reduced Signal (PCMT) Circuit PCME (2P)—PCMT Open circuit Shift shock may be slight­ ly stronger Condition Short circuit Shift shock may be slight­ ly stronger Poor ground NA 46U0F2-180 EGR Solenoid Valve (Vacuum) Circuit PCME (3P)—EGR solenoid valve (vacuum) EGR solenoid valve (vacuum)— Main relay NA: Not applicable Open circuit Code No.28 output No symptom Condition Short circuit Code No.28 output Engine stalls Hard start (must depress accelerator pedal) EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-181 F2—173 F2 SERVICE POINTS EGR Solenoid Valve (Vent) Circuit PCME (30)—EGR solenoid valve (vent) EGR solenoid valve (vent)—Main relay Open circuit Code No.29 output No symptom Condition Short circuit Code No.29 output No symptom EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-182 PRC Solenoid Valve Circuit PCME (3M)—PRC solenoid valve Open circuit Code No.25 output Hard start after heat soak PRC solenoid valve—Main relay Condition Short circuit Code No.25 output No symptom EGI INJ fuse (30A) burns out when ignition switch ON Poor ground NA 46U0F2-183 Coolant Fan Relay No.1 Circuit PCME (3L)—Coolant fan relay No.1 Coolant fan relay No.1—Ignition switch Open circuit Code No.67 output Coolant fan contimues OFF when water temperature exceeds 100°C (212°F) Condition Short circuit Coolant fan will always operate while the ignition switch is ON ENGINE fuse (15A) burns out when ignition switch ON Poor ground NA 36UOF2-252 Coolant Fan Relay No.2 and No.3 Circuit PCME (2P)—Coolant fan relay No.2 and No.3 Coolant fan relay No.2 and No.3—Main relay Open circuit Coolant fan will not op­ erate at high speed when water temperature ex­ ceeds 108°C (226°F) Condition Short circuit Coolant fan will always operate while the ignition switch is ON ENGINE fuse (15A) burns out when ignition switch ON Poor ground NA 36U0F2-252 Condenser Fan Low Relay Circuit PCME (1L)—Condenser fan low relay Condenser fan low relay—Main relay Open circuit Condenser fan continues OFF when water temperature exceeds 100°C (212°F) Condition Short circuit Condenser fan will always operate while the ignition switch is ON ENGINE fuse (15A) burns out when ignition switch ON Poor ground NA 46U0F2-204 Condenser Fan High Relay No.1 and No.2 Circuit PCME (3N)—Condenser fan high relay No.1 and No.2 Condenser fan high relay No.1 and No.2—Main relay NA: Not applicable F 2-174 Open circuit Condenser fan continues OFF when water temperature exceeds 108°C (226°F) Condition Short circuit Condenser fan will always operate while the ignition switch is ON ENGINE fuse (15A) burns out when ignition switch ON Poor ground NA 46U0F2-184 Before beginning any service procedure, refer to the 1994 626/MX-6 Body Electrical Troubleshooting Manual; see section S for air bag system service warnings and section J for audio antitheft system alarm conditions. FUEL AND EMISSION CONTROL SYSTEMS (FS ATX) INDEX..................................................................... F3- 2 OUTLINE................................................................. F3- 5 SYSTEM DIAGRAM........................................... F3- 5 WIRING DIAGRAM............................................ F3- 6 VACUUM HOSE ROUTING DIAGRAM..............F3- 7 SPECIFICATIONS.............................................. F3- 8 COMPONENT DESCRIPTIONS.........................F3- 9 ENGINE TUNE-UP.................................................. F3- 12 PREPARATION.................................................. F3- 12 BASIC INSPECTION.......................................... F3- 12 ADJUSTMENT................................................... F3- 13 ON-BOARD DIAGNOSIS SYSTEM.........................F3- 15 DESCRIPTION................................................... F 3- 15 PREPARATION.................................................. F3- 15 DIAGNOSTIC TROUBLE CODE NUMBER........ F3- 22 INTAKE AIR SYSTEM............................................ F3-111 COMPONENT PARTS....................................... F3-111 THROTTLE BODY............................................. F3-112 INTAKE MANIFOLD........................................... F3-112 RESONANCE CHAMBER No.2..........................F3-112 ACCELERATOR PEDAL.................................... F3-113 ACCELERATOR CABLE.................................... F3-113 IDLE-SPEED CONTROL SYSTEM.........................F3-114 DESCRIPTION................................................... F3-114 SYSTEM OPERATION....................................... F3-115 IDLE AIR CONTROL VALVE..............................F3-115 AIR VALVE......................................................... F3-115 FUEL SYSTEM....................................................... F3-116 DESCRIPTION................................................... F3-116 SYSTEM OPERATION....................................... F3-118 FUEL TANK........................................................ F3-120 FUEL FILTER..................................................... F3-121 FUEL PUMP....................................................... F3-122 FUEL PUMP RELAY.......................................... F3-125 PRESSURE REGULATOR................................ F3-125 INJECTOR.......................................................... F3-127 PRESSURE REGULATOR CONTROL SYSTEM................................................................ F3-130 PRESSURE REGULATOR CONTROL SOLENOID VALVE.......................................... F3-131 EXHAUST SYSTEM............................................... F3-132 COMPONENTS.................................................. F3-132 OUTLINE OF EMISSION CONTROL SYSTEM................................................................ F3-133 STRUCTURAL VIEW......................................... F3-133 EGR FUNCTION CONTROL SYSTEM DESCRIPTION................................................... F3-134 SYSTEM OPERATION....................................... F3-134 SYSTEM INSPECTION...................................... F3-135 EGR SOLENOID VALVE (VACUUM)..................F3-135 EGR SOLENOID VALVE (VENT)........................F3-135 EGR CONTROL VALVE..................................... F3-135 EGR FUNCTION SENSOR.................................F3-136 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM..................................................... F3-137 DESCRIPTION................................................... F3-137 PCV VALVE........................................................ F3-137 FUEL EVAPORATIVE SYSTEM.............................F3-138 DESCRIPTION................................................... F3-138 SYSTEM OPERATION........................................F3-139 PURGE SOLENOID VALVE................................F3-139 FUEL VAPOR VALVE.........................................F3-139 CHECK VALVE (TWO-WAY)..............................F3-140 CHARCOAL CANISTER.....................................F3-140 FUEL-CUT CONTROL SYSTEM.............................F3-141 DESCRIPTION................................................... F3-141 PREPARATION.................................................. F3-142 SYSTEM OPERATION........................................F3-143 A/C CUTOFF SYSTEM............................................F3-144 DESCRIPTION................................................... F3-144 SYSTEM OPERATION........................................F3-144 DECHOKE CONTROL SYSTEM.............................F3-145 SYSTEM OPERATION........................................F3-145 COOLANT FAN CONTROL SYSTEM.....................F3-145 DESCRIPTION................................................... F3-145 SYSTEM OPERATION........................................F3-146 CONTROL SYSTEM............................................... F3-147 PREPARATION.................................................. F3-147 STRUCTURAL VIEW..........................................F3-148 POWERTRAIN CONTROL MODULE (PCM)..... F3-149 MASS AIRFLOW SENSOR.................................F3-160 CRANKSHAFT POSITION SENSOR..................F3-161 ENGINE COOLANT TEMPERATURE SENSOR. F3-162 INTAKE AIR TEMPERATURE SENSOR............ F3-162 THROTTLE POSITION SENSOR....................... F3-163 HEATED OXYGEN SENSOR.............................F3-164 MAIN RELAY...................................................... F3-165 COOLANT FAN RELAYS....................................F3-166 STEERING PRESSURE SENSOR.....................F3-166 TROUBLESHOOTING GUIDE................................F3-167 USING THIS SECTION.......................................F3-167 DIAGNOSTIC INDEX..........................................F3-169 SYMPTOM TROUBLESHOOTING.....................F3-171 SERVICE POINTS........................................... ...... F3-208 OUTLINE............................................................ F3-208 ELECTRICAL DIAGNOSIS SUPPORT..............F3-211 46U0F3-001 F3 F3-2 INDEX 16E0F1-002 INDEX 1. Fresh air duct Inspection / Replacement....... page F3-111 2. Air cleaner element Inspection............................... page F3- 12 Removal / Installation............. page F3-111 3. Resonance chamber Inspection / Replacement....... page F3-111 4. Throttle body Inspection................................ page F3-112 Replacement........................... page F3-111 5. Idle air control valve Inspection................................ page F3-115 Replacement........................... page F3-111 6. Air valve Inspection................................ page F3-115 Replacement........................... page F3-111 7. Intake manifold Removal / Installation..............page F3-111 8. Accelerator cable Inspection / Adjustment...........page F3-113 9. Fuel filter (High-pressure side) Replacement........................... page F3-121 10. Fuel pump relay Inspection............................... page F3-125 Replacement........................... page F3-125 11. Pressure regulator Inspection............................... page F3-125 Replacement........................... page F3-126 12. Injector Inspection............................... page F3-127 Removal.................................. page F3-127 Installation............................... page F3-127 13. Pressure regulator control solenoid valve Inspection............................... page F3-131 14. EGR control valve Inspection / Replacement...... page F3-135 EGR function sensor Inspection / Replacement...... page F3-136 F3 15. EGR solenoid valve (Vent, Vacuum) Inspection...................... ........ page F3-135 16. PCV valve Inspection...................... ........ page F3-137 17. Purge solenoid valve Inspection...................... ........ page F3-139 18. Charcoal canister Inspection...................... ........ page F3-140 19. Powertrain control module (PCM) Removal / Installation.... ........ page F3-149 Inspection...................... ........ page F3-149 20. Mass airflow sensor Removal / Installation.... ........ page F3-160 Inspection...................... ........ page F3-160 21. Crankshaft position sensor Inspection...................... ........ page F3-161 22. Engine coolant temperature sensor Removal......................... ........ page F3-162 Inspection...................... ........ page F3-162 Installation...................... ........ page F3-162 23. Intake air temperature sensor Inspection...................... ........ page F3-162 Replacement................. ........ page F3-162 24. Throttle position sensor Inspection...................... ........ page F3-163 Adjustment..................... Replacement................. ........ page F3-163 25. Heated oxygen sensor Inspection...................... ........ page F3-164 Replacement................ ........ page F3-164 26. Main relay Inspection...... .'......................page F3-165 27. Coolant fan relays Inspection............................... page F3-165 28. Steering pressure sensor Inspection...................... Replacement................. ......... page F3-166 46U0F3-002 F3-3 F3 INDEX J ^=»- © iffl-—® 46U0F1-023 1. Fuel tank Removal / Inspection / Installation............................page 2. Fuel filter Replacement..........................page 3. Fuel pump Inspection..............................page Removal / Installation............page 4. Fuel vapor valve Inspection..............................page F3-4 F3-120 F3-121 F3-122 F3-124 F3-139 5. Check valve (Two-way) Inspection..............................page F3-140 6. Exhaust system Removal / Inspection / Installation............................page F3-132 7. Three way catalyst Removal / Inspection / Installation............................page F3-132 (0 < O —i m 2 O > z <n PRESSURE REGULATOR CONTROL SOLENOID VALVE CHARCOAL CANISTER FUEL VAPOR VALVE CRANKSHAFT POSITION SENSOR c m o n > INTAKE AIR TEMPERATURE SENSOR (IATS) o c m AIR CLEANER ELEMENT \ EGR SOLENOID VALVE (VENT) [EGRA] EGR SOLENOID VALVE (VACUUM) [EGRV] THREE WAY CATALYST HEATED OXYGEN SENSOR (H02S) EGR CONTROL VALVE 36UOF1-004 F3-5 Gd F3 F3-6 OUTLINE 46U0F3-003 F3 OUTLINE VACUUM HOSE ROUTING DIAGRAM PURGE SOLENOID VALVE EGR SOLENOID VALVE (VENT) [EGRA] PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE EGR SOLENOID VALVE (VACUUM) [EGRV] CHARCOAL CANISTER EGR CONTROL VALVE 16E0F1-006 F3-7 F3 F3 OUTLINE SPECIFICATION Engine Item Idle speed * ' rpm Ignition timing*' Throttle body BTDC Type FS 650— 750 (700 ± 50) 9— 11 (10 ±1°) Horizontal draft Throat diameter mm {in} Fuel pump Maximum output pressure kPa {kgf/cm2, psi} 55 {2.2} 640 {6.5, 92} Fuel filter Type Low-pressure side Nylon element (in fuel pump) Paper element High-pressure side Pressure regulator Regulating pressure kPa {kgf/cm2, psi} 260—320 {2.6—3.3, 37— 46} Injector Type Type of drive Resistance Volume High-ohmic Voltage n [20°C {68°F}] ml {cc, fl-oz} /15 sec. 12— 16 47—68 {47—68, 1.41—2.04} Idle air control valve n [23°C {73°F}] Resistance Purge solenoid valve [20°C {68°F}] Resistance n Pressure regulator control solenoid valve n [20°C {68°F}] Solenoid resistance 7.7—9.3 30—34 36.4—42.9 EGR solenoid valve Solenoid resistance Crankshaft position sensor a [20°C {68°F}] Type 30—45 Photo diode Mass airflow sensor Type Engine coolant temperature sensor/lntake air temperature sensor 20°C {68°F} kn Resistance 60°C {140°F} 80°C {176°F} Hot wire 35.473— 39.207 7.171— 7.925 1.131— 1.251 Fuel tank Capacity Air cleaner housing L {US gal, Imp gal} Element type 58.5 {15.5— 12.9} Oil permeated Fuel Specification Unleaded— (R+M)/2 method 87 or higher 46U0F3-004 *’ Remove the shorting bar from the double wire SPOUT connector. F3-8 F3 OUTLINE COMPONENT DESCRIPTIONS Remark Function Component — A/C relay Controls A/C Air cleaner housing Filters air entering throttle body • Intake air temperature sensor mounted in housing Air valve Supplies bypass air into intake manifold (engine cold) • Engine speed increased to shorten warm-up period • Thermowax type • Installed in BAC valve Bypass air control (BAC) valve Supplies bypass air into intake manifold • Consist of air valve and idle air control valve Charcoal canister Stores fuel tank fumes (engine stopped) — Check valve (two-way) Controls pressure in fuel tank — Crankshaft position sensor [G signal, Ne signal] Detects No.1 cylinder TDC; sends signal to PCM (G signal) Detects crank angle at 180° intervals; sends signal to PCM (Ne signal) Data link connector Concentrated service connector terminals — EGR control valve Recirculates portion of exhaust gas — EGR function sensor Detects EGR position to detect EGR control valve open condition; sends signal to PCM EGR solenoid valve [Vacuum, Vent] Controls vacuum and vent to EGR control valve • Controlled by duty signal from PCM Engine coolant temperature sensor Detects coolant temperature; sends signals to PCM Fuel filter Filters particles from fuel Fuel pump Provides fuel to injectors Fuel pump relay Voltage for fuel pump while engine running controlled by PCM — Fuel vapor valve Prevents fuel from flowing into charcoal canister — Heated oxygen sensor Detects oxygen concentration; sends signal to PCM • Zirconic and platinum coating With heater Idle air control valve Supplies bypass air into intake manifold • Controlled by duty signal from PCM • Installed in BAC valve Ignition control module Receives spark signal from PCM and gener­ ates high voltage in ignition coil — ignition switch (START position) Sends engine cranking signal to PCM — Injector Injects fuel into intake port • Installed in distributor • Installed in EGR control valve • Installed in engine — • Operates while engine running Installed in fuel tank • Controlled by signals from PCM F3-9 F3 OUTLINE Function Component Remark Intake air temperature sensor Detects intake air temperature; sends signal to PCM Intake manifold Supplies intake air to all cylinders — Main relay Supplies current to output devices and PCM — Mass airflow sensor Detects amount of intake air; sends signal to PCM Transmission range sensor Detects in-gear condition; sends signal to PCM — PCV valve Controls blowby gas introduced into engine — Powertrain control module (PCM) Detects the following: 1. A/C operation 2. Air/fuel ratio (oxygen concentration) 3. Braking signal 4. Cranking signal 5. E/L operation 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature Engine speed Ignition ON signal In-gear condition Intake air amount Intake air temperature No.1 position TDC (compression stroke) P/S operation Test mode signal Throttle valve opening angle Vehicle speed Controls operation of following; 1. A/C (cut-off) 2. On-board diagnosis system 3. fuel injection system 4. Idle speed control 5. Ignition system 6. Purge control system 7. EGR control system 8. PRC control system 9. Coolant fan control 10. Fuel pump control • Installed in air cleaner housing • Hot wire type 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Air condition sensor Heated oxygen sensor stoplight switch Ignition switch (START position) Blower motor switch, headlight switch, and rear window defroster switch Engine coolant temperature sensor Crankshaft position sensor (Ne signal) Ignition switch Transmission range sensor Mass airflow sensor Intake air temperature sensor Crankshaft position sensor (G signal) Steering pressure sensor Data link connector (STI terminal) Throttle position sensor Vehicle speedometer sensor 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. A/C relay SUPER STARE tester Injector Idle air control valve Ignition Control Module Purge solenoid valve EGR solenoid valve (EGRA, EGRV) PRC solenoid valve Coolant fan relay Fuel pump relay PRC solenoid valve Controls vacuum to pressure regulator control valve — Pressure regulator Adjusts fuel pressure supply to injectors — Purge solenoid valve Controls vacuum to pressure regulator control valve — Resonance chamber R e d u c e s in ta k e a ir s u c tio n n o is e a n d in ­ c re a s e s e n g in e to rq u e — Steering pressure sensor D e te c ts Stoplight switch D e te c ts b ra k in g ; s e n d s s ig n a l to P C M Three way catalyst Reduces HC, CO, NOx by chemical reaction Throttle body Controls intake air amount F3-10 P/S o p e ra tio n ; s e n d s s ig n a l to PCM • Steering pressure sensor ON when steering wheel turned — • Monolith type — F3 OUTLINE Component Function Throttle position sensor D e te c ts th ro ttle v a lv e o p e n in g a n g le ; s e n d s s ig n a l to P C M Vehicle speedometer sensor D e te c ts v e h ic le s p e e d ; s e n d s s ig n a l to P C M Remark • In s ta lle d on th ro ttle b o d y — 46UQF3-005 F3-11 F3 ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST 46U0F3-006 BASIC INSPECTION Coolant Warning • Removing the radiator cap or the coolant drain plug while the engine is running or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. • Turn off the engine and wait until it is cool. Even then, be vary careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure is gone, press down on the cap-still using cloth—turn it, and remove it. 46U0F3-007 1. Verify that the coolant level is near the filler neck of the radiator. 2. Remove the coolant level d ip stick from the coolant reservoir and verify that the coolant level is between the F and L marks. Add coolant if necessary. Battery Removing the label on the top of the battery or remov­ ing the vent caps will void the battery’s warranty. 1. Remove any corrosion on the clamps or battery posts. 2. Verify that the battery top is clean. If necessary, clean with backing soda and water. 3. Verify that cables are in good condition and not frayed or corroded. Repair or replace if necessary. Note • Because this is a maintenance free battery, it is not necessary to check the fluid level. Air Cleaner Element Inspection 1. Check the air cleaner element for excessive dirt and for oil and damage. Caution • Cleaning the element with compressed air will reduce the element’s ability to filter the air. Don’t use compressed air to clean the if necessary 2. Replace the element if necessary. 46U0F3-010 F3-12 F3 ENGINE TUNE-UP ADJUSTMENT Preparation 1. Warm up the engine to normal operating temperature. 2. Shift the selector lever to P range. 3. Turn off all electric loads. • Headlight • Blower • Rear window defroster • Power steering 4. Wait until the coolant fan is stopped. 46U0G3-011 Note • If the climate control panel is in DEFROSTER mode, the A/C compressor will be on. Do not set this mode during ignition timing and idle speed adjustment or self-diagnosis start-up. Ignition Timing 1. Perform Preparation (Refer to above.) 2. Connect a tachometer to the number one spark plug wire. 3. Verify that the idle speed is within the specification. Idle speed (Neutral): 650— 750 (700 ± 50) rpm SHORTING 4. If not within the specification, adjust the idle speed. (Refer to page F3-14.) 46U0F3-012 5. Remove the shorting bar from the double wire SPOUT connector. 6. Verify that the idle speed is within the specification. SPOUT CONNECTOR 46U0F3-013 Idle speed (Remove the shorting bar): 500—800 rpm 7. Connect a timing light to the engine. 8. Verify that the timing mark (yellow) on the crankshaft pulley and the mark on the tim ing belt cover are aligned. Ignition timing: BTDC 9— 11° (10 ± 1°) 46UOF3-O14 9. If the marks are not aligned, loosen the distributor lock bolts and turn the distributor to make the adjustment. 10. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 N m {1.9— 2.6 kgf m, 14—18 ft Ibf} 46U013-015 F3-13 F3 ENGINE TUNE-UP 11. Install the shorting bar to the double wire SPOUT con­ nector. 12.. Verify that the ignition timing is within the specification. Ignition timing: BTDC 6— 18° 46U0F3-016 idle speed 1. Perform Preparation. (Refer to page F3-13.) 2. Connect the SST to the data link connector. 3. Verify that the idle speed is within specification using the SST. (1) Activate the Key On Engine Running self-diagnosis inspection. (Refer to page F3-17.) (2) After DTC 111 has been displayed, unlatch and within 4 sec. latch the “HOLD TEST” button. (3) A single pulse indicates the entry mode. Then, observe the STO (self-test output) of the SST in the following. (A) A constant tone or STO LO readout means idle speed is within specification. (B)A beeping tone or STO LO readout at {8 Hz} indicates that the throttle position sensor is out of range. Adjust the throttle position sensor. (Refer to page F3-163.) Note • Idle speed adjustment may be necessary after throt­ tle position sensor adjustment. (C)A beeping tone or STO LO readout at {4 Hz} indicates the idle speed is too fast. (D)A beeping tone or STO LO readout at {1 Hz} indicates the idle speed is too slow. 4. If not within the specification. Remove the shorting bar from the double wire SPOUT connector. 5. Adjust the idle speed by turning the air adjusting screw. Idle speed (Remove the shorting bar): 650—750 (700 ± 50) rpm 6. Install the shorting bar to the connector. 7. Disconnect the SST. 46U0F3-025 F3-14 ON-BOARD DIAGNOSIS SYSTEM F3 ON-BOARD DIAGNOSIS SYSTEM DESCRIPTION The Diagnosis system is divided into three specialized diagnosises: Key On Engine OFF-Diagnosis, Engine Running Diagnosis, and Continuous Diagnosis. The Diagnosis is not a conclusive diagnosis by itself, but is used as a part of the functional Quick-Test diagnostic procedure. The PCM stores the Diagnosis program in its permanent memory. When activated it checks the EEC system by testing its memory integrity and processing capability, and verifies that various sensors and actuators are con­ nected and operating properly. The Key On Engine Off and Engine Running Diagnosises are functional diagnosises which only detect faults present at the time of the Diagnosis. Continuous Diagnosis is performed during normal vehicle operation and stores any fault information in Keep Alive Memory (KAM) for retrieval at a later time. 46U0F3-02Q PREPARATION SST F3-15 F3 ON-BOARD DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE NUMBER Inspection Procedure Key On Engine Off (KOEO) Self-Test 1. Check vacuum houses for damage and proper connection. 2. Check EEC system wiring harness for proper connection. 3. Service as necessary about 1. and 2. 4. Apply parking brake. 5. Place shift lever firmly in P range. 6. Block drive wheels. 7. Turn off all electrical loads. 8. Connect appropriate test equipment to the Self-Test Connector in order to run Self-Test. 9. Start engine and run until at operating temperature. 10. Turn engine off and wait 10 seconds. 11. Set EEC-1V/MECS Switch to position EEC-1V. 12. Select fast cods mode with the mode selector switch. 13. Turn on the power to the SUPER STAR Dtester. The tester will briefly display 888. It will also all the prompts on the left side of display and speaker will beep. 14. Depress the test button on the tester to the test position. 15. Turn on the vehicle ignition key. 16. Record all trouble codes displayed. 46U0F3-022 F3-16 ON-BOARD DIAGNOSIS SYSTEM Inspection Procedure Key On Engine Running (KOER) Self-Test 1. Connect appropriate test equipment to the Self-Test Connector in order to run Self-Test. 2. Start and run engine at 2,000 rpm for two minutes. This action warms up the H02S. 3. Turn engine off and wait 10 seconds. 4. Set EEC-IV/MECS Switch to position EEC-IV. 5. Select fast cods mode with the mode selector switch. 6. Turn on the power to the SUPER STAR Htester. The tester will briefly display 888. It will also all the prompts on the left side of display and speaker will beep. 7. Start engine. 8. After the ID code depress and release the brake pedal if appropriate. See Special Note on previous page. 9. After the ID code click twice on the HOLD switch button. 10. After the ID code, within 1 to 2 seconds, turn the steering wheel at least one-half turn and then release it, if appropriate. See Special Note above. 11. If a Dynamic Response Code occurs, perform a brief wide-open throttle (WOT). 12. Record all Diagnostic Trouble Codes (DTC’S) displayed. 46U0F3-026 F3-17 F3 ON-BOARD DIAGNOSIS SYSTEM After-Repair Procedure How to Clear the Continuous Memory 1. Run the key On Engine Off Self-Test. 2. When the DTC’S begin to be displayed. Deactive Self-Test: —SUPER STAR n: Unlatching the center button (up position) 3. Continuous Memory will be erased in the PCM. 46U0F3-029 Note • Do not disconnect battery to clear C ontinuous Memory. This will erase the Keep Alive Memory (KAM) information which may cause a driveability concern. 46U0F3-030 How to Clear THE Keep Alive Memory (KAM) Disconnect the negative side of the battery for a mini­ mum of five minutes. Note • The PCM stores information about vehicle operating conditions and uses this information to compensate for component tolerance. When an emission related component is replaced, Keep Alive Memory (KAM) should be cleared to erase the information stored by the PCM from the original component. 46U0F3-031 How to Memory the Keep Alive Memory (KAM) After KAM has been cleared, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle 10 miles or allow the processor to relearn values for optimum driveability and perfor­ mance. 46U0F3-032 F3-18 ON-BOARD DIAGNOSIS SYSTEM F3 Code Output Format The EEC system communicates service information through the Diagnostic Trouble Codes (DTC’s). These DTC’s are three-digit numbers representing the results of Self-Diagnosis. The DTC’s are transmitted on the Self-Test Output (STO) circuit found in the Data Link Connector (DLC). They are in the form of timed pulses, and are read by the technician on a circuit-tester, SUPER STAR n, Malfunction Indicator Light (MIL) or Hold Indicator Light. Diagnostic Trouble Code (DTC) Format 1. Key On Engine Off and Continuous Memory DTC Format 2. Engine Running DTC Format Fast DTC’s / Slow DTC’s Fast DTC’s are issued prior to slow service DTC’s. These DTC’s contain the identical information as the slow DTC’s, but are transmitted at 100 times the normal rate. These DTC’s are interpreted by special equipment at the assembly line by the Body and Assembly Division as well as the SUPER STAR Htester. Note • After Slow DTC’s have been output, Self-Diagnosis should not be exited (remove jumper, unlatch button, etc) until all the Slow DTC’s have been output. Doing so will erase any Continuous Memory DTC’s. F3-19 F3 ON-BOARD DIAGNOSIS SYSTEM Continuous Self-Diagnosis The Continuous Memory DTC’s are separated from the Key On Engine Off DTC’s by a single separa­ tor pulse. Note • During this mode of testing of testing the PCM continuously monitors inputs for opens and shorts. The Continuous Memory DTC’s must be retrieved within 80 engine temperature warm up cycles. On the 81st Engine Temperature cycle, the DTC will be automatically erased. The Continuous Memory DTC’s can also be erased by deactivating Self-Diagnosis while the DTC’s are being out­ putted. 46U0F3-035 Continuous Monitor Diagnostic Test Mode (Wiggle Test) Special Note: • The technician can ATTEMPT to re-create and detect an intermittent fault using the Continuous Monitor DTM (Wiggle Test) procedures. Key on Engine Off Wiggle Test Procedure 1. Hook up a SUPER STAR HTester 2. Turn the ignition key to the ON position. 3. For SUPER STAR n Tester activate, deactivate and reactivate Self-Test. You are now in the Continuous Monitor Diagnostic Test Mode (DTM). 4. Tap, move, and wiggle the suspect sensor and / or harness. When a fault is detected, a Continuous Memory DTC will be stored in memory. This will be indicated as follows depending on the type of equipment being used: • SUPER STAR n Tester: Red LED lights and /or continuous tone. (STAR LED) • Malfunction Indicator Light (MIL): Lights • Hold Indicator Light Engine Running Wiggle Test Procedure Special Note: • The Engine Running Wiggle Test may be activated any time the engine is running. 1. Hook up a SUPER STAR HTester 2. Key off. 3. Start the engine. 4. For SUPER STAR HTester, activate Self-Test, deactivate and reactivate Self-Test. DO NOT shut the engine off. You are now in the Engine Running Continuous Monitor DTM. 46U0F3-218 F3-20 ON-BOARD DIAGNOSIS SYSTEM F3 5. Tap, move, and wiggle the suspect sensor and / or harness or drive the vehicle. When a fault is detected, a Continuous Memory DTC will be stored in memory. This will be indicated as follows depending on the type of equipment being used: • SUPER STAR n Tester: Red LED lights and / or continuous tone. (STAR LED) • Malfunction Indicator Light (MIL): Lights • Hold Indicator Light 46U0F3-219 F3-21 F3_________________ ON-BOARD DIAGNOSIS SYSTEM Diagnostic Trouble Code (DTC) Number No. 111 112 Indicator Light Flash Pattern Diagnosed circuit System pass Intake air temperature sensor (IATS) 113 116 118 123 157 M F3-28 F3-29 M F3-29 F3-30 F3-31 M F3-28 F3-29 M F3-30 F3-32 F3-33 F3-34 Throttle position sensor (TPS 122 Mass airflow sensor (MAF) 158 M F3-35 F3-36 M F3-37 F3-38 M F3-40 M 159 172 Heated Oxygen sensor (H02S) F3—43 M F3-45 M F3-45 179 F3-54 181 F3-54 Ignition system F3-57 212 F3-58 213 214 O F3-44 173 211 Page Pass Engine coolant temperature sensor (ECTS) 117 121 MIL Diagnosis F3-61 Cylinder identification display M (CID) 244 F3-63 F3-63 EGR function sensor M F3-66 F3-67 332 M F3-69 F3-71 337 M F3-67 F3-72 327 F3-22 ON-BOARD DIAGNOSIS SYSTEM Note: M: MIL function O: Key On Engine Off self-test C: Continuous self-test R: Key On Engine Running self-test F3 46U0F3-036 F3-23 F3 ON-BOARD DIAGNOSIS SYSTEM Troubleshooting If a diagnostic trouble code number is shown on the SST check for the cause by referring to the related chart. CODE No. No DTC’s DESCRIP­ TION If using a SUPER STAR n to run Self-Test, verify that correct procedure is used for your application. STEF INSPECTION 1 CHECK VREF VOLTAGE AT DATA LINK CONNECTOR (DLC) NOTE: Aftermarket devices such as an alarm system may cause Self-Test to abort it wiring is connected to certain EEC components. PRIOR TO SERVICING VEHICLE, inform customer that disconnection of the device is necessary for the proper diagnosis and function of the EEC sys­ tem. Restore EEC system to original configura­ tion before proceeding with this Pinpoint Test. • Key off. • Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. • Install breakout box and connect PCM to break­ out box • Key on, engine off • Measure voltage between Test Pin 26 at the breakout box and SIG RTN circuit in the DLC • Is voltage between 4.0 and 6.0 volts? 2 Key off. Breakout box installed Disconnect PCM Measure resistance between STI circuit in the Selt-Test single pin pigtail connector and Test Pin 48 at the breakout box • Is resistance less than 5.0 ohms? No Go to next Step Yes Go to Pinpoint Test C Step 1 «■ page F3-104 No SERVICE open circuit RECONNECT PCM RERUN Quick Test Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK STO CIRCUIT CONTINUITY • Key off. • Breakout box installed, PCM disconnected • Measure resistance between STO circuit in the DLC and Test Pin 17 at the breakout box • Is resistance less than 5.0 ohms? 5 Go to Step 3 CHECK STI CIRCUIT CONTINUITY • * • • 4 Yes CHECK SIG RTN CIRCUIT CONTINUITY • Key off. • Breakout box installed, PCM disconnected • Measure resistance between SIG RTN circuit in the DLC and Text Pin 46 at the breakout box • Is resistance less than 5.0 ohms? 3 ACTION Yes Go to next Step No SERVICE open circuit REMOVE breakout box RERUN Quick Test CHECK H02S SIGNAL FOR SHORT TO POWER NOTE: Due to the internal circuitry of the PCM, a Yes H02S signal short to power could cause EEC strategy NOT to enter on-demand Self-Test • Breakout box installed, PCM disconnected • Key on, engine off • Measure voltage between H02S signal Test Pin 29 or 44 and Test Pin 40 or 60 at the breakout box. • Is resistance less than 5.0 ohms? F3-24 No Go to next Step Go to Step 7 F3 ON-BOARD DIAGNOSIS SYSTEM 6 ISOLATE SHORT TO HARNESS OR H02S • • • • Breakout box installed, PCM disconnected Disconnect H02S Key on, engine off Measure voltage between H02S signal Test Pin 29 or 44 and Test Pin 40 or 60 at the breakout box • Is voltage greater than 2.0 volts? 7 No REPLACE H02S REMOVE breakout box RECONNECT all components RERUN Quick Test Yes SERVICE STO or MIL circuit for short to ground REMOVE breakout box RECONNECT PCM RERUN Quick Test No Go to next Step Yes RECONNECT PCM Go to Step 10 No Go to next Step CHECK VPWR CIRCUIT FOR SHORT TO POWER • • • • Key off Breakout box installed, PCM disconnected Disconnect EEC Power Relay Measure voltage between Test Pin 37 or 57 and Test Pin 40 or 60 at the breakout box • Is voltage greater than 1.0 volt? 10 SERVICE H02S signal circuit for shorts to power REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK IF POWER RELAY IS ALWAYS ON • Key off • Breakout box installed, PCM disconnected • Connect a voltmeter to Test Pin 37 or 57 and to Test Pin 40 or 60 at the breakout box • Turn key on and then off. Wait 10 seconds • Does voltage change from greater than 10.5 bolts to less than 1.0 volt? 9 Yes CHECK STO CIRCUIT FOR SHORT TO GROUND • Key off • Breakout box installed, PCM disconnected • Measure resistance between STO circuit in the DLC and engine block ground • Is resistance less than 5.0 ohms? 8 ACTION INSPECTION STEP Yes SERVICE VPWR circuit short to power REMOVE breakout box RECONNECT all components RERUN Quick Test No REPLACE EEC Power Relay REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK MIL FUNCTION • Are any of these conditions present? Malfunction indicator light (MIL): Always REMOVE breakout box RECONNECT PCM ON Go to Pinpoint Test next Step Always REMOVE breakout box OFF RECONNECT PCM Go to Pinpoint Test Step 12 Function REPLACE the PCM ing RERUN Quick Test normary F3-25 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 11 INSPECTION NOTE: If vehicle will not start perform Pinpoint Test A Step 1 «■ page F3-97 • If any Key On Engine Off Diagnostic Trouble Codes or Continuous Memory Diagnostic Trouble Codes are present, service before proceeding. If pass codes are present, con­ tinue with this Test Step • Key off • Disconnect powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessry • Install Breakout box, leave PCM disconnected • Measure resistance between Test Pin 17 and Test Pin 40 at the Breakout Box • Is resistance less than 5.0 ohms? 12 ACTION MALFUNCTION INDICATOR LIGHT (MIL) ALWAYS ON: CHECK STO/MIL CIRCUIT FOR SHORTS TO GROUND Yes SERVICE short circuit between Test Pin 17 and Malfunction Indicator Light (MIL), or between Test Pin 17 and the Data Link Connector REMOVE Breakout Box RECONNECT PCM RERUN Quick Test No REPLACE PCM REMOVE Breakout Box RERUN Quick Test MALFUNCTION INDICATOR LIGHT (MIL) NEVER ON: CHECK FOR B(+) AT MIL FUSE (GROUND SIDE) NOTE: If vehicle will not start go to Pinpoint Test A Step 1 «■ page F3-97 • If vehicle has electronic instrument cluster, refer to 1994 626/MX-6 BETM for Manual for Malfunction indicator light (MIL) diagnostic pro­ cedure • Key on, engine off • Measure voltage from battery negative post to “Ground” side of the MIL fuse «• section T • is voltage greater than 10.5 volts? F3-26 Yes Go to Step 14 No Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM STEP 13 INSPECTION • Key on, engine off • Measure voltage from battery negative post to B+ side of the MIL fuse • Is voltage greater than 10.5 volts? 14 Yes REPLACE the MIL fuse VERIFY service by turning ignition key to the ON position No SERVICE open in the MIL/B+ circuit VERIFY service by turning ignition key to the ON position Yes Go to next Step No SERVICE open between MIL fuse and MIL bulb VERIFY service by turning ignition key to ON position CHECK FOR B+ AT MIL BULB/SOCKET • Key on, engine off • Measure voltage from battery negative post to B+ side of MIL bulb/socket • Is voltage greater than 10.5 volts? 15 ACTION CHECK FOR B+ AT MIL FUSE CHECK MIL BULB RESPONSE TO GROUNDING Yes • Key off • Attach one end of jumper wire to battery nega­ tive post or chassis ground • Attach other end of jumper wire to ground side of the MIL bulb/socket No • Turn ignition key to ON position • Is the MIL on? 16 Turn ignition key to OFF position REMOVE jumper wire Go to next Step Turn ignition key to OFF position REMOVE jumper wire REPLACE MIL bulb/socket VERIFY the service by turning ignition key to ON position CHECK MIL CIRCUIT CONTINUITY • Key off • Disconnect powertrain control module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 17 at breakout box and MIL • Is resistance less than 5.0 ohms? Yes REPLACE PCM REMOVE breakout box VERIFY the service by turning ignition key to ON position No SERVICE open in ground side of MIL circuit REMOVE breakout box RECONNECT PCM VERIFY the service by turning ignition key to ON position 46U0F3-037 F3-27 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 112 (INTAKE AIR TEMPERATURE SENSOR), 117 (ENGINE COOLANT TEMPERATURE SENSOR) DESCRIP­ TION DTC 117 (ECT) or 112 (IAT) indicates that the corresponding sensor’s signal is less than the Self-Test minimum. The IAT and ECT sensor minimum is 0.2 volts [Possible Cause] • Grounded circuit in harness • Faulty Powertrain Control Module (PCM) STEP 1 INSPECTION Yes REPLACE sensor RECONNECT harness RERUN Quick Test No Go to next Step CHECK VREF CIRCUIT VOLTAGE AT THROTTLE POSITION SENSOR (TPS) • • • • • Key off. Suspect temperature sensor disconnected Disconnect TPS Key on, engine off Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 volts and 5.5 volts? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 117 OR 112: INDUCE OPPOSITE CODE 118 OR 113 • Key off. • Disconnect vehicle harness from suspect sensor Inspect for damaged, corroded, pushed out pins or loose wires, etc. Service as necessary • Run Key On Engine Off Self-Test • Is DTC 113 or 118 present? 2 • Faulty sensor • Faulty connection Yes RECONNECT TPS Go to next Step No Go to Pinpoint Test C Step 1 w page F3-104 CHECK TEMPERATURE SENSOR SIGNAL CIRCUIT FOR SHORT TO GROUND • Key off. • Suspect temperature sensor disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected Measure resistance between Test Pin 7 (EC T) or 25 (IAT) and Test Pins 40, 46 and 60 at the breakout box • Is each resistance greater than 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SENSOR short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-038 F3-28 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 112,113 (INTAKE AIR TEMPERATURE SENSOR), 117,118 (ENGINE COOLANT TEMPERATURE SENSOR DESCRIP­ TION Continuous Memory DTC’s 118 and 113 indicate that the sensor signal was greater than, the Self-Test maximum of 46 volts. The DTC was generated under normal driving conditions Continuous Memory DTC’s 117 and 112 indicate that the sensor signal was less than the Self-Test minimum of 0.2 volts. The DTC was generated under normal driving conditions Sensor Continuous Memory DTC's IAT 113 and 112 ECT 118 and 117 [Possible Cause] • Faulty sensor • Grounded circuit in harness STEP OPEN circuit in harness Faulty PCM INSPECTION ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 112, 113, 117, OR 118: CHECK SENSOR • Enter Key On Engine Off Continuous Monitor Yes Diagnostic Test Mode (DTM) Refer to Quick Test Appendix «*■ page F3-20 DISCONNECT and inspect connectors If OK, REPLACE the sensor CLEAR Continuous Memory • Observe STAR LED indication of a fault while performing the following: — Tap on the sensor to simulate road shock — Wiggle the sensor connector • Is a fault indicated? RERUN Quick Test No »■ page F3-18 Go to next Step CHECK EEC-IV VEHICLE HARNESS • Still in Key On Engine Off Continuous Monitor DTM • Observe STAR LED for fault indication while per forming the following: — Grasp the vehicle harness close to the sensor connector. Wiggle, shake or bend a small section of the EEC system vehicle harness while working your way to the dash panel. Also wiggle, shake or bend the EEC system vehicle harness from the dash panel to the PCM • Is a fault Indicated? Yes ISOLATE fault and SERVICE as necessary CLEAR Continuous Memory ■a- page F3-18 RERUN Quick Test No Go to next Step CHECK PCM AND VEHICLE HARNESS CONNECTORS Key off Disconnect Powertrain Control Module (PCM) Disconnect sensor connector. Inspect for dam­ age, loose or pushed out pins, loose or poorly crimped wires Is connectors and terminals OK? Yes Unable to duplicate and/or identify fault at this time Intermittent Fault Diagnosis All others, CLEAR Continuous Memory «■ page F3-18 RERUN Quick Test No SERVICE as necessary CLEAR Continuous memory «• p a g e F 3 -1 8 46U0F3-Q39 F3-29 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 113 (INTAKE AIR TEMPERATURE SENSOR), 118 (ENGINE COOLANT TEMPERATURE SENSOR) DESCRIP­ TION DTC 118 (ECT) or 113 (IAT) indicates that the corresponding sensor signal is greater than the Self-Test maxi­ mum. The maximum for ECT and IAT sensors is 4.6 volts [Possible Cause] • Open in harness (IAT or ECT) • Faulty sensor STEP 1 INSPECTION ACTION DIAGNOSTIC TROUBLE CODE (DTC) 113 OR 118: INDUCE OPPOSITE DTC 112 OR 117 • Key off. • Disconnect suspect temperature sensor • Connect a jumper wire between the sensor sig­ nal circuit and SIG RTN circuit at the tempera­ ture sensor vehicle harness connector • Run Key On Engine Off Self-Test • Is DTC 112 or 117 present? 2 • Faulty connection • Faulty Powertrain Control Module (PCM) Yes REPLACE suspect sensor REMOVE jumper wire RECONNECT vehicle harness RERUN Quick Test No REMOVE jumper wire Go to next Step CHECK CONTINUITY OF SENSOR SIGNAL AND SIG RTN CIRCUITS • Key off. • Suspect temperature sensor disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between sensor signal cir­ cuit at the temperature sensor vehicle harness connector and Test Pin 7 (ECT) or 25 (IAT) at the breakout box • Measure resistance between SIG RTN circuit at the temperature sensor vehicle harness connec­ tor and Test Pin 46 at the breakout box • Is each resistance less than 5.0 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-040 F3-30 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 116 (ENGINE COOLANT TEMPERATURE SENSOR) DESCRIP­ TION DTC 116 (ECT) indicates that the corresponding sensor is out of Self-Test range. Correct range of measure is 0.3 to 3.7 volts [Possible Cause] • Low coolant level (ECT) • Faulty harness connector STEP 1 • Ambient temperature below 10°C {50°F} (IAT) • Faulty sensor INSPECTION ACTION DIAGNOSTIC TROUBLE CODE (DTC) 116: CHECK OPERATION, INSTALLATION OF TEMPERATURE SENSOR • Run engine for two minutes at 2000 rpm For NO STARTS: — Go to Step 3 For vehicle STALLS: — Go to Pinpoint test D Step 1 «■ page F3-107 Yes Go to next Step No SERVICE other DTC’s as necessary • Check that upper upper radiator hose is hot and pressurized • Return Quick Test • Is DTC 116 present? 2 CHECK VREF CIRCUIT VOLTAGE AT THROTTLE POSITION SENSOR (TPS) • Key off • Disconnect TPS • Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 volts and 5.5 volts? 3 Yes RECONNECT TPS Go to next Step No Go to Pinpoint Test C Step 1 «• page F3-104 CHECK RESISTANCE OF TEMPERATURE SENSOR WITH ENGINE OFF • Key off • Disconnect suspect temperature sensor • Measure resistance between sensor signal cir­ cuit and SIG RTN circuit at the temperature sen­ sor. Refer to the corresponding chart at the beginning of this pin point Test for resistance specifications. • Is resistance within specifications? For ECT sensor with a NO START: Do not service DTC 116 at this time, Go to Pinpoint Test A Step 1 «■ page F3-97 Note: Engine may have cooled down. Always warm engine before taking ECT sensor resistance measurements. Check for open thermostat. 46U0F3-041 F3-31 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 121 (KOEO) THROTTLE POSITION SENSOR (TPS) DESCRIP­ TION • Throttle Position Sensor’s rotational setting may be out of Self-Test range [Possible Cause] • Binding throttle linkage • TPS may not be seated properly (tightened down) STEP 1 INSPECTION Go to next Step No SERVICE as necessary RERUN Quick Test Yes Go to next Step No Go to Step 4 CHECK VREF CIRCUIT VOLTAGE • • • • Key off. TPS disconnected Key on, engine off Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 and 5.5 volts? 4 Yes DIAGNOSTIC TROUBLE CODE (DTC) 123: ATTEMPT TO GENERATE DTC 122 • Key off. • Disconnect TPS. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Rerun Key On Engine OFF Self-Test • Is DTC 122 present (ignore all other DTCs)? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 121: CHECK FOR STUCK THROTTLE PLATE • Visually inspect carburetor / throttle body and throttle linkage for binding or sticking • Verify the throttle linkage is at mechanical / closed throttle. Check for: binding throttle linkage, speed control linkage, vacuum line / electrical harness interference, etc. • Does throttle move freely and return to closed throttle position? 2 • Damaged Powertrain control Module (PCM) • Damaged TPS Yes REPLACE TPS RERUN Quick Test No Key off. RECONNECT all components. Go to Pinpoint Test C Step 1 w page F3-104 CHECK TP CIRCUIT FOR SHORTS TO POWER • Key off. • TPS disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 47 and Test Pins 26 and 67 at the breakout box • Is each resistance greater than 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT TPS RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN quick test 46U0F3-042 F3-32 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 121 THROTTLE POSITION SENSOR (TPS) DESCRIP­ TION • Throttle Position Sensor’s rotational setting may be out of Self-Test range [Possible Cause] • Binding throttle linkage • TPS may not be seated properly (tightened down) STEP 1 INSPECTION PROCEED as directed with DTC 327 page F3-67 No Go to next Step Yes Go to next Step No SERVICE as necessary RERUN Quick test DIAGNOSTIC TROUBLE CODE (DTC) 123: ATTEMPT TO GENERATE DTC 122 • Key off • Disconnect TPS. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary. • Rerun Key On Engine Off Self-Test • Is DTC 122 present (ignore all other DTCs)? 4 Yes DIAGNOSTIC TROUBLE CODE (DTC): CHECK FOR STUCK THROTTLE PLATE • Visually inspect carburetor / throttle body and throttle linkage for binding or sticking • Verify the throttle linkage is at mechanical / closed throttle. Check for: binding throttle linkage, speed control linkage, vacuum line / electrical harness interference, etc. • Does throttle move freely and return to closed throttle position? 3 ACTION ENGINE RUNNING DIAGNOSTIC TROUBLE CODE (DTC) 121: CHECK FOR OTHER DTCs • Check for DTC in Key On Engine Running SelfTest • Are either of the above DTCs present with Code 121? 2 • Damaged TPS • Damaged Powertrain Control Module (PCM) Yes Go to next Step No Go to Step 5 Yes REPLACE TPS RERUN Quick test No Key off. RECONNECT all components. Go to Pinpoint Test C Step 1 CHECK VREF CIRCUIT VOLTAGE • Key off • Key on, engine off • Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 and 5.5 volts? «*■ page F3-104 5 CHECK TPS CIRCUIT FOR SHORTS TO POWER • Key off • TPS disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 47 and Test Pins 26 and 57 at the breakout box • In each resistance greater than 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT TPS RERUN Quick Test No SERVICE Short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-043 F3-33 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 121 (Cont) MASS AIRFLOW SENSOR DESCRIP­ TION STEP 1 Continuous Memory Diagnostic Trouble Code (DTC) 121 indicates throttle position was inconsistent with MAF value INSPECTION • Key off. • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • Connect a voltmeter from Test Pin 47 to Test Pin 46 at the breakout box • Key on, engine off • Rotate throttle slowly to WOT, release throttle slowly to closed position • Does the voltage change smoothly between 0.4 and 4.5 volts? 2 ACTION THROTTLE POSITION SENSOR INTEGRITY Yes Go to next Step No VERIFY TPS properly installed to the throttle body. If OK, REPLACE TPS REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK MAF SENSOR • Key off. • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • Start engine and allow to idle until engine is at normal operating temperature • Measure voltage between MAF signal and Test Pin 40 / 60 • Is voltage within the acceptable range? Yes Sometime during the last 80 warm-up cycles the MAF sensor signal indicated out of range. However, at this time EEC system is operating OK REMOVE breakout box RECONNECT PCM. RERUN Quick Test No REPLACE MAF sensor REMOVE breakout box RECONNECT PCM RERUN Quick Test Note: If further description is required for the In-Range Test, refer to page F3-15. F3-34 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 122 THROTTLE POSITION SENSOR (TPS) DESCRIP­ TION • Throttle Position Sensor (TPS) signal is less than the Self-Test minimum value [Possible Cause] • TPS way not be seated properly (tightened down) • Damaged TPS • Open harness INSPECTION STEP 1 • Grounded harness • Damaged Powertrain control Module (PCM) ACTION DIAGNOSTIC TROUBLE CODE (DTC) 122: ATTEMPT TO GENERATED DTC 123 OR 121 • Key off. • Disconnect TPS. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Jumper VREF circuit to TP circuit at TPS vehicle harness connector • Run Key On Engine Off Self-Test Yes REPLACE TPS REMOVE jumper RERUN Quick test No REMOVE jumper Go to next Step Yes Go to next Step No KEY off. RECONNECT all components, go to Pinpoint TestC Step 1 NOTE: If no DTC’s are generated, immediately remove jumper and go directly Go to Step 4 • Is DTC 123 or 121 present (ignore all other DTC’s)? 2 CHECK VREF CIRCUIT VOLTAGE • • • • Key off. TPS disconnected Key on engine off Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 and 5.5 volts? 3 CHECK TP CIRCUIT CONTINUITY • Key off. • TPS disconnected • Disconnect Powertrain control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between TP circuit at the TPS vehicle harness connector and Test Pin 47 at the breakout box • Is the resistance less than 5.0 ohms? 4 «• page F3-104 Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components CHECK TP CIRCUIT FOR SHORTS TO GROUND • Key off. • TPS disconnected • Disconnect Powertrain control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 47 and test Pins 40, 46, and 60 at the breakout box • Is each resistance greater than 10,000 ohms? R E R U N Q uick Test 46U0F3-045 F3-35 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 122 (Cont) THROTTLE POSITION SENSOR (TPS) CIRCUIT DESCRIPTiOhi • Throttle position sensor (TPS) signal is less than Self-Test minimum value STEP 1 INSPECTION • Enter Continuous monitor Diagnostic Test Mode (DTM). Refer to Quick Test Appendix • Connect STAR LED to STO • Observe STAR LED for indication of a fault while performing the following: — Move throttle slowly to WOT position — Release throttle slowly to closed position — Lightly tap on TPS (simulate road shock) — Wiggle TP harness connector • Is a fault indicated? 2 Yes Key off. Inspect connectors If connectors and terminals are good, REPLACE TPS, REFER to Fuel / Engine Group in Service Manual, CLEAR Continuous Memory «■ Page F3-18 RERUN Quick Test No Go to next Step CHECK EEC VEHICLE HARNESS • Still in Key On Engine OFF continuous Monitor DTM • Observe STAR LED for a fault indication while performing the following: — Grasp the vehicle harness close to the sen­ sor connector. Wiggle, shake or bend a small section of the EEC system vehicle har­ ness while working your way to the dash panel. Also wiggle, shake or bend the EEC vehicle harness from the dash panel to the PCM • Is a fault indicated? 3 ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 122: MONITOR TP CIRCUIT UNDER SIMULATED ROAD SHOCK Yes ISOLATE fault, SERVICE as necessary. REFER to appropiate figure, CLEAR continuous Memory gf Page F3-18 RERUN Quick Test No Go to next Step Yes SERVICE as necessary CLEAR Continuous Memory CHECK PCM AND HARNESS CONNECTORS • Key off • Disconnect PCM. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. • Are connectors and terminals? «• Page F3-18 RERUN Quick Test No Unable to duplicate and / or identify fault at this time. For further diagnosis, REFER to page F3-167 Intermittent Fault Diagnosis all others, CLEAR Continuous Memory «*■ Page F3-18 RERUN Quick Test 46U0F3-046 F3-36 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 123 (KOEO) THROTTLE POSITION SENSOR (TPS) CIRCUIT DESCRIP­ TION • Throttle Position Sensor (TPS) signal is greater than the Self-Test maximum value [Possible Cause] • TPS may hot be seated properly (tightened down) • Damaged TPS INSPECTION STEP 1 Yes Go to next Step No Go to Step 3 Yes REPLACE TPS RERUN Quick Test No Key off. RECONNECT all components. Go to Pinpoint Test C Step 1 CHECK VREF CIRCUIT VOLTAGE • • • • Key off. TPS disconnected Key on engine off Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 and 5.5 volts? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 123: ATTEMPT TO GENERATE DTC 122 • Key off. • Disconnect TPS. Inspect for damaged of pushed out pins, corrosion, loose wires, etc Service as necessary • Rerun Key On Engine Off Self-Test • Is DTC 122 present (Ignore all other DTCs)? 2 • Short to Power in harness • Damaged Powertrain control module (PCM) **• Page F3-104 CHECK TP CIRCUIT FOR SHORTS TO POWER • Key off. • TPS disconnected • Disconnect Powertrain Control Module (PCM), Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 47 and Test Pins 26 and 57 at the breakout box • Is each resistance greater than 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT TPS RERUN Quick Test No SERVICE Short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-047 F3-37 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 123 THROTTLE POSITION SENSOR (TPS) DESCRIP­ TION STEP 1 • Throttle position sensor circuit above maximum voltage INSPECTION • Enter Key On Engine Off Continuous Monitor Diagnostic Test Mode (DTM). page F3-18 • Connect STAR LED to STO • Observe STAR LED for indication of a fault while performing the following: — Move throttle slowly to WOT position — Release throttle slowly to closed position and lightly tap on TPS (simulate road shock) — Wiggle TP harness connector • Is a fault indicated? 2 Yes Go to next Step No Go to Step 3 MEASURE THROTTLE POSITION CIRCUIT VOLTAGE WHILE EXERCISING TP SENSOR • Key off • Disconnect powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • STAR LED still connected to STO • Connect a voltmeter from Test Pin 47 to Test Pin 46 at the breakout box • Key on, engine off • While observing voltmeter and STAR LED, repeat Step 1 • Does the fault occur below 4.25 volts? 3 ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 123: MONITOR TP CIRCUIT UNDER SIMULATED ROAD SHOCK Yes Key off, DISCONNECT and INSPECT Connectors If connectors and terminals are good, REPLACE TPS REFER to Fuel / Engine Group in Service Manual CLEAR Continuous Memory «• page F3-18 RERUN Quick Test No Throttle position Sensor over­ travel may have caused the continuous Memory DTC 123 VERIFY vehicle harness integrity, Go to next Step CHECK EEC VEHICLE HARNESS • Still in Key On engine Off Continuous Monitor DTM • Observe STAR LED for a fault indication while performing the following: — Grasp the vehicle harness close to the sen­ sor connector. Wiggle, shake or bend a small section of the EEC system vehicle har­ ness while working your way to the dash panel. Also wiggle, shake or bend the EEC vehicle harness from the dash panel to the PCM • Is a fault code indicated? F3-38 Yes ISOLATE fault SERVICE as necessary REFER to appropriate figure CLEAR Continuous Memory «*■ page F3-18 RERUN Quick Test No Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM STEP 4 INSPECTION ACTION CHECK PCM AND HARNESS CONNECTORS • Key off. • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Are connectors and terminals OK? Yes SERVICE as necessary CLEAR Continuous Memory **■ page F3-18 RERUN Quick Test No Unable to duplicate and / or Identify fault at this time. For further diagnosis REFER to page F3-167 Intermittent Fault Diagnosis Memory es- page F3-18 RERUN Quick Test 46U0F3-048 F3-39 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 157 (Cont) MASS AIRFLOW SENSOR (MAF) CIRCUIT DESCRIP­ TION • Continuous Memory DTC 167 indicates that the Mass Airflow sensor (MAF) signal went below 0.4 volt sometime during the last 80 warm-up cycles [Possible Cause] • Poor continuity in MAF harness or connectors • Intermittent open or short in MAF or harness • Damaged MAF • Idle Air Control (IAC) system (possible closed throttle posi­ tion indication) • Open MAF circuit STEP 1 • • • • • • Open VPWR circuit to MAF Open PWR GND circuit to MAF Open MAF RTN circuit to MAF MAF circuit shorted to ground Air leak before or after MAF MAF disconnected INSPECTION ACTION CHECK FOR INTERMITTENT SENSOR • Clear Continuous Memory Yes Go to Step 4 No Go to next Step is- page F3-18 • Start engine and run at idle for approximately 5 to 10 minutes • Run Key On Engine Off Self-Test • Is continuous Memory DTC 157 present? 2 MONITOR MAF CIRCUIT UNDER SIMULATED ROAD SHOCK • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, reconnect PCM • Connect a voltmeter between Test Pin 50 and Test Pin 9 at the breakout box • Key on, engine running • Lightly tap on MAF and wiggle harness connec­ tor to simulate road shock Yes DISCONNECT and INSPECT MAF connector If OK, REPLACE MAF CLEAR continuous Memory «ap page F3-18 RERUN Quick Test No LEAVE the voltmeter and PCM connected Go to next Step NOTE: MAF voltage is normally above 0.4 volt A sudden change down from this minimum limit indicates a fault • Is a fault indicated? 3 CHECK VEHICLE HARNESS FOR INTERMITTENT OPENS OR SHORTS • Key on, engine off DVOM connected between Test Pin 50 and Test Pin 9 at the breakout box — Grasp the vehicle harness closest to the MAF sensor connector. Shake and bend a small section of the vehicle harness while working your way to the dash panel, also wiggle, shake and bend the vehicle harness from the dash panel to the PCM • Is a fault indicated? 4 Yes ISOLATE fault and SERVICE as necessary. CLEAR Continuous Memory is- page F3-18 RERUN Quick Test No RECONNECT all components Unable to duplicate and / or identify fault at this time For further diagnosis, Refer to page F3-167 AIR LEAK AT MAF SENSOR • Check for broken / loose air outlet tube clamps (throttle body and air cleaner assembly ends), cracks / holes in air outlet tube, worn gaskets between MAF and air cleaner assembly • Is a fault indicated? F3-40 Yes SERVICE as necessary RECONNECT all components RERUN Quick Test No Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM 5 CHECK CONTINUITY OF MAF AND VPWR CIRCUITS • Key off. • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between VPWR circuit at the MAF vehicle harness connector and Test Pins 37 and 57 at the breakout box • Measure resistance between MAF circuit at the MAF sensor vehicle harness connector and Test Pin 50 at the breakout box • Is each resistance less than 5.0 ohms? 6 Key off. MAF disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 50 and Test Pins 9, 40 and 60 at the breakout box • Is each resistance greater than 10,000 ohms? Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Go to next Step No SERVICE short circuit(s) REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK PWR GND CIRCUIT CONTINUITY • • • • Key off. MAF disconnected Breakout box installed, PCM disconnected Measure resistance between PWR GND circuit at the MAF vehicle harness connector and bat­ tery negative post • Is resistance less than 10 ohms? 8 Yes CHECK MAF CIRCUIT FOR SHORTS TO GROUND AND MAF RTN CIRCUIT • • • • 7 ACTION INSPECTION STEP Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK MAF RTN CIRCUIT CONTINUITY Yes Key off. MAF disconnected Breakout box installed, PCM disconnected No Measure resistance between MAF RTN circuit at the MAF sensor vehicle harness connector and Test Pin 9 at the breakout box • Is resistance less than 5.0 ohms? • • • • 9 SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK MAF CIRCUIT FOR SHORT TO GROUNC • • • • • Key off. MAF disconnected Breakout box installed Connect PCM to breakout box Disconnect SUPER STAR nfrom data link con­ nector • Measure resistance between test Pin 50 and Test Pins 9, 40 and 60 at the breakout box • Is resistance less than 10,000 ohms? 10 Go to next Step Yes RECONNECT SUPER STAR H Go to next Step No REPLACE PCM REMOVE breakout box RECONNECT MAF RERUN Quick Test CHECK MAF CIRCUIT OUTPUT • • • • • Key off. Reconnect MAF Breakout box installed, PCM connected Key on, engine running Measure voltage between Test Pin 50 at the breakout box and negative battery post • Is voltage between 0.6 and 0.7 volts? Yes Go to next Step No REPLACE MAF assembly REMOVE breakout box RECONNECT PCM RERUN Quick Test F3-41 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 11 INSPECTION ACTION CHECK MAF CIRCUIT OUTPUT • Key off. • Reconnect MAF Breakout box Installed, PCM connected Key on, engine running Measure voltage between Test Pin 50 and Test Pin 9 at the breakout box • Is voltage between 0.36 and 1.50 volts? Yes REPLACE PCM REMOVE breakout box RERUN Quick Test No REPLACE MAF sensor REMOVE breakout box RECONNECT PCM RERUN Quick Test 46U0F3-049 F3-42 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 158 MASS AIRFLOW SENSOR (MAF) CIRCUIT DESCRIP­ TION • DTC 158 indicates that the Mass Airflow sensor (MAF) signal went above 4.5volts during normal engine operation (continuous) or during self test STEP 1 INSPECTION DIAGNOSTIC TROUBLE CODE (DTC) 158: RERUN SELF-TEST WITH MAF SENSOR DISCONNECTED • • • • • • 2 ACTION Key off Disconnect MAF Start engine, idle one minute Key off Run Key On Engine Off Self-Test Is DTC 157 present? Yes REPLACE MAF RERUN Quick test No Go to next Step Yes REPLACE PCM REMOVE breakout box RECONNECT MAF RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK MAF CIRCUIT FOR SHORT TO VPWR • Key off • MAF disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. • Disconnect SUPER STAR I from data link con­ nector • Measure resistance between MAF circuit and VPWR circuit at the MAF vehicle harness con­ nector. • Is resistance greater than 10,000 ohms? 46U0F3-050 NOTE: DTC 158 could be generated by foreign material blocking the Mass Airflow sensor screen causing an air flow restric­ tion. If contaminants are found on the screen, check air filter installation in air cleaner tray and proper sealing of air cleaner/tube before proceeding. F3-43 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. DESCRIP­ TION 159 MASS AIRFLOW SENSOR (MAF) • DTC 159 indicates that the Mass Airflow sensor (MAF) is out of Self-Test range and that the MAF signal was greater than 0.70 volts during Key On, Engine Off self test. • Engine running DTC 159 indicates that the MAF signal was not between 0.20 and 1.5 volts during Key On Engine Running Self-Test. [Possible Cause] • Damaged idle Air Control (IAC) solenoid. • Damaged MAF sensor. • MAF sensor partially connected. • Damaged Powertrain Control Module (PCM). • Air leak before or after MAF. INSPECTION STEP 1 DIAGNOSTIC TROUBLE CODE (DTC) 159: CHECK VPWR CIRCUIT VOLTAGE • Is DTC 411/412 Present? 2 Yes For DTC 411 Go to Step 1 For DTC 412 Go to Step 1 No Go to next Step Yes Go to next Step No SERVICE open in VPWR circuit RERUN Quick Test Yes Go to Step 4 No SERVICE open PWR GND circuit RECONNECT MAF RERUN Quick test «■ page F3-73 «■ page F3-75 CHECK VPWR CIRCUIT VOLTAGE • • • • Key off Disconnect MAF Key on, engine off Measure voltage between VPWR circuit at the MAF vehicle harness connector and battery negative post. • Is voltage greater than 10.5 volts? 3 ACTION CHECK MAF SENSOR GROUND • Key on, engine off • MAF sensor disconnected • Measure voltage between VPWR circuit and PWR GND circuit at the MAF vehicle harness connector • Is voltage greater than 10.5 volts? 46U0F3-051 NOTE: DTC 159 could be generated by the garage exhaust ventilation system. Remove ventilation system and properly vent to outside atmosphere, Rerun KOEO Self-Test. F3-44 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 172 HEATED OXYGEN SENSOR, 173 HEATED OXYGEN SENSOR (H02S) DESCRIP­ 172: Heated oxygen sensor not switching indicates lean condition 173: Heated oxygen sensor not switching indicates rich condition TION [Possible Cause] • Fuel injectors • H02S • PCV/House • Vacuum • Electronic Ignition Coil Failure • CANP (Purge solenoid valve) STEP 1 INSPECTION ACTION CHECK FOR FUEL DILUTED ENGINE OIL • Key off • Remove the PCV valve from the valve cover. Inspect both rocker cover hole and PCV for damage, sludge build up, blockage and move­ ment of valve plunger. Service as necessary. • Run KOEO, KOER Quick Test. • Address any continuous ignition DTC’s before servicing KOER DTCs. Yes REINSTALL PCV valve Go to next Step No CHANGE engine oil and filter REINSTALL PCV valve DRIVE vehicle 5 miles/55 mph Rerun Quick Test NOTE: For a No Start Go directly to nest Step • Are any of the above DTC’s present In KOER Quick Test? 2 CHECK FUEL PRESSURE WARNING: THE FUEL SYSTEM WILL REMAIN PRESSURIZED WHEN ENGINE IS NOT RUNNING. TO PREVENT INJURY OR FIRE USE CAUTION WHEN WORKING ON THE FUEL SYSTEM. » • Key off • Install fuel pressure gauge • Verify that manifold vacuum is connected to the fuel pressure regulator if applicable. If engine will start: • Start and run engine at idle. Note fuel pressure. • Increase engine speed to 2000 rpms and main­ tain for one minute. Note fuel pressure. • Refer to Fuel Pressure Specification « ' page F3-125 Yes Go to next Step No CHECK the Fuel system o- page F3-116 If engine will not start: • Cycle the key off and on several times. Note fuel pressure. • Refer to Fuel Pressure Specification ra- page F3-125 • Is fuel pressure within specification for the engine being tested? F3-45 F3 ON-BOARD DIAGNOSIS SYSTEM 3 CHECK SYSTEM'S ABILITY TO HOLD FUEL PRESSURE • Pressurize fuel system per Step 2 • Visually look for fuel leaking at the injector 0ring, fuel pressure regulator, and the fuel lines to the fuel charging assembly. Service as nec­ essary. • Key on, engine off • Does fuel pressure remain at specification for 5 minutes? 4 ACTION INSPECTION STEP Yes For No Starts: Go to next Step For Service Codes or other Symptoms: Go to Step 5 No INSPECT the Fuel system m’ page F3-116 FUEL DELIVERY TEST • Key off • Fuel pressure-gauge installed • Run the fuel pressure hold inspection cr page F3-118 Yes The EEC system is not the case of the No Start REMOVE the fuel pressure gage REFER to page F3-167 No REMOVE fuel pressure gauge Go to Step 6 Yes Go to nest Step No For DTC 173: Go to Step 18 For all others: Go to Step 9 • The fuel pressure OK? 5 CYLINDER BALANCE DIAGNOSTIC TEST MODE (DTM): The DTM switches each injector OFF and ON one at a time. Diagnostic Trouble Codes (DTC) corre­ spond to the cylinder number (i.e., Service DTC 30 indicates a problem with cylinder No.3, a DTC 90 indicates a pass.) The Cylinder Balance (DTM) is designed to aid in the detection of a weak or non­ contributing cylinder. The Pinpoint Test Steps are designed to isolate only EEC related problems. a- page F3-20 • • • • Run the Engine Running Quick Test After the last repeated code, wait 5-10 seconds "Goose" throttle lightly (not wide-open-throttle) Cylinder Balance (DTM) will be performed. Time of test is approximately 2-3 minutes. • Are there any DTCs requiring service? F3-46 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 6 INSPECTION ACTION CHECK RESISTANCE OF INJECTORS AND HARNESS • Key off • Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. Yes Go to Step 14 NOTE: This erases Continuous Memory • Install breakout box, leave PCM disconnected • Measure resistance between the suspect INJECTOR circuit Test Pin and TEST Pin 37 at the breakout box. Record resistance. • For No Starts: — Pick any injector and measure resistance between that INJECTOR circuit’s Test Pin and Test Pin 37 at the breakout box. Record resistance. • Refer to Injector Resistance Specification s- page F3-129 « No For No START: SERVICE open in VPWR circuit For others: Go to next Step • Is each resistance within specification for the appropriate engine? 7 CHECK CONTINUITY OF FUEL INJECTOR HARNESS • Key off • Breakout box installed, PCM disconnected • Disconnect injector vehicle harness connector at the suspect injector • Measure resistance between Test Pin 37/57 at the breakout box and the VPWR pin the injector vehicle harness connector • Measure resistance between the injector test pin(s) at the breakout box and the same injector circuit signal pin at the each injector vehicle harness connector • Is each resistance less than 5.0 ohms? 8 Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT PCM and injectors DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK INJECTOR HARNESS CIRCUIT FOR SHORT TO POWER OR GROUND • Key off • Breakout box installed, PCM disconnected • Suspect fuel injector vehicle harness discon­ nected • Measure resistance between the injector test pin(s) and Test Pin 37/57, 40, 46 and 60 at the breakout box • Measure resistance between the injector test pin(s) at the breakout box and chassis ground • Is each resistance greater than 10,000 ohms? Yes REPLACE injector per Cylinder Balance DTM fault code RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT PCM and injectors DRIVE vehicle 5 miles/55 mph RERUN Quick Test F3—47 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 9 ACTION CHECK H02S INTEGRITY H02S always lean, slow to switch or lack of switching; fuel at adaptive limit could be caused by: — Moisture inside the H02S harness connector resulting in a short to ground — H02S coated with contaminants — H02S circuit open — H02S circuit shorted to ground • Key off • Inspect the H02S harness for chafing, burns or other indications of damage. Service as neces­ sary. • Inspect H02S and connector for indication of submerging in water, oil coolant, etc. Service as necessary. • Run engine at 2000 rpm for two minutes • Key off • Run Engine Running Self Test • Are fault codes present? F3-48 Yes Go to next Step No Go to Step 15 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 10 ACTION CHECK H02S NOTE: The purpose of this test is to verify the H02S can generate greater than 0.5 volt during Engine Running Quick Test. • • • • • Any vacuum/air leaks in non-EC areas could also cause DTC 172. Check for: — Leaking vacuum actuator (e.g. A/C control motor) — Engine sealing — EGR system — PCV system — Unmetered air leak between Mass Airflow sensor (MAF) and throttle body — Lead contaminated H02S Key off Disconnect appropriate H02S from vehicle har­ ness — Connect a voltmeter to H02S circuit and H02S SIG RTN or H02S GND at the H02S connector Run engine at approximately 2000 rpm for two minutes Rerun Engine Running Quick Test and monitor H02S voltage Does the indicate greater than 0.5 volt at the end of Quick Test? Yes Go to next Step No REPLACE H02S RERUN Quick Test V 11 CHECK CONTINUITY OF H02S AND H02S GROUND CIRCUITS • Key off • Breakout box installed, PCM disconnected • Disconnect suspect H02S from vehicle har­ ness. Inspect both ends of connector for dam­ aged or pushed out pins, moisture, corrosion, loose wires, etc. Service as necessary. • Measure resistance between H02S circuit Test Pin at the breakout box and H02S circuit at the vehicle harness connector. — Measure resistance between SIG RTN Test Pin at the breakout box and H02S SIG RTN at the vehicle harness connector — Where applicable measure resistance between H02S GND and SIG RTN at the breakout box • Is each resistance less than 5.0 ohms? 12 « Yes Go to next Step No SERVICE open circuit Remove breakout box RECONNECT PCM, H02S, and any other components that have been disconnected. DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK H02S CIRCUIT FOR SHORT TO GROUND • Key off • Breakout box installed, PCM disconnected • H02S disconnected • Measure resistance between the H02S circuit Test Pin at the breakout box and Test Pin 40, 46 or 49 where applicable at the breakout box • Is each resistance greater than 10,000 ohms? Yes Go to next Step No SERVICE short circuit REMOVE b reakout box RECONNECT PCM, H02S, and any other components that are disconnected. DRIVE vehicle 5 miles/55 mph RERUN Quick Test F3-49 F3 ON-BOARD DIAGNOSIS SYSTEM 13 CHECK H02S FOR SHORT TO GROUND • • • • Key off Breakout box installed, PCM disconnected H02S disconnected Measure resistance between PWR GND and H02S circuit at the H02S connector. • Also measure resistance between H02S GND and/or SIG RTN at the H02S connector. • Is resistance greater than 10,000 ohms? 14 ACTION INSPECTION STEP Yes REMOVE breakout box RECONNECT H02S REPLACE PCM DRIVE vehicle 5 miles/55 mph RERUN Quick Test No REPLACE H02S REMOVE breakout box RECONNECT PCM DRIVE vehicle 5 miles/55mph RERUN Quick Test CHECK INJECTOR DRIVER SIGNAL Requires standard non-powered 12 volt test lamp • Key off Yes • Breakout box installed • Connect PCM to breakout box — Connect test lamp between Test Pin 37 and the suspect injectors Test Pin at the break­ out box. • Crank or start engine «■ page F3-116 Also refer to ignition section for other possible causes After any servicing, DRIVE vehicle 5 miles/55 mph RERUN Quick Test and Cylinder Balance DTM No NOTE: Properly operating systems will show a dim glow on the lamp • Is glow on lamp dim? 15 REMOVE breakout box RECONNECT PCM Inspect the Fuel system No light/Bright light: REPLACE PCM REMOVE breakout box DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK RESISTANCE OF HEATER ELEMENT ON H02S • Key off • Disconnect suspect H02S from vehicle harness • Inspect both ends of the connector for dam­ aged or pushed out pins, moisture, corrosion, loose wires, etc. Service as necessary • Measure resistance between KEY PWR circuit and PWR GND circuit at H02S connector page F3-164 Yes Go to next Step No REPLACE H02S RERUN Quick Test — Room temperature resistance specification is approx. 6 ohms • Is resistance within specification? 16 CHECK FOR POWER AT H02S HARNESS CONNECTOR • Key on, engine off. • H02S disconnected • Measure voltage between KEY POWER circuit and PWR GND circuit at the H02S vehicle har­ ness connector «■ page F3-164 Yes RECONNECT H02S H02S system OK Fuel delivery is OK H02S sensor may have cooled prior to Engine Running Quick Test. If symptom persists, problem is in an are com­ mon to all cylinders, i.e. air/vacuum leak, fuel contamina­ tion, EGRA. Check ignition system etc. Service as necessary. No Go to next Step • Is voltage greater than 10.5 volts? F3-50 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 17 • Key off. • H02S disconnected • Measure resistance between PWR GND circuit at the H02S vehicle harness connector and battery negative post • Is resistance less than 5.0 ohms? 18 ACTION CHECK CONTINUITY OF POWER GROUND CIRCUIT Yes SERVICE open in KEY PWR circuit RECONNECT H02S sensor RERUN Quick Test. No SERVICE open in PWR GND circuit RECONNECT H02S sensor RERUN Quick Test CHECK H02S SIGNAL FOR SHORT TO POWER • • • • • H02S always rich could be caused by: — Moisture inside H02S harness connector resulting in a short to power. — H02S circuit shorted to power Key off Disconnect the suspect H02S from vehicle har­ ness Inspect both ends of the connector for dam­ aged or pushed out pins, moisture, corrosion, loose wires, etc. Service as necessary Key on, engine off Measure voltage between H02S circuit and PWR GND at the H02S vehicle harness con­ nector ra* page F3-164 Yes Go to Step 20 No Go to next Step • Is voltage less than 0.5 volt? 19 CHECK FOR SHORT TO POWER • Key off. • Inspect H02S GND and H02S circuit harness for chaffing, burns or other indications of short to power. Service as necessary. • Disconnect Powertrain Control Module (PCM). Inspect for damaged, or pushed out pins, corro­ sion, loose wires etc. Service as necessary. • Install breakout box, leave PCM disconnected • Measure resistance between H02S circuit, and KEY PWR at the breakout box • Is the resistance greater than 10,000 ohms? 20 Yes REPLACE PCM REMOVE breakout box RECONNECT H02S DRIVE vehicle 5 miles/55 mph RERUN Quick Test No SERVICE short to power REMOVE breakout box RECONNECT PCM DRIVE vehicle 5 miles/55 mph RERUN Quick Test Yes Go to next Step No REPLACE H02S DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK H02S FOR SHORT TO IGNITION FUN CIRCUIT • Key off. • H02S disconnected • Measure resistance between KEY PWR circuit and H02S SIG circuit at the H02S connector «■ page F3-164 • Is resistance greater than 10,000 ohms? F3-51 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 21 • Key off • H02S disconnected • Jumper H02S circuit at the H02S vehicle har­ ness connector to battery negative post • Rerun Engine Running Quick Test • Is DTC 172 present? 22 Yes REMOVE jumper wire Go to next Step No REMOVE jumper RECONNECT H02S DISCONNECT PCM 60 pin connector. Inspect for dam­ aged or pushed out pins, corrosion, loose wires, etc. SERVICE as necessary. If OK REPLACE PCM. DRIVE vehicle 5 miles/55 mph. RERUN Quick Test H02S CHECK • Key off • H02S disconnected — Connect a voltmeter to H02S circuit and H02S GND or SIG RTN at the H02S con­ nector • Create a vacuum leak to cause H02S to go lean • Disconnect any vacuum hose from the manifold vacuum tree • Start engine and run at approximately 2000 rpm • Does the voltmeter indicate less than 0.4 volt within 30 seconds? 23 ACTION ATTEMPT TO GENERATE DTC 172 Yes Go to next Step No REPLACE H02S RECONNECT vacuum hoses DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK CONTINUOUS MONITOR DIAGNOSTIC TEST MODE (DTM) • Key off • Verify engine at operating temperature • Start engine and run at 2000 rpm for two min­ utes • With engine rpm at idle enter Engine Running Continuous Monitor (DTM) **■ page F3-20 • Observe STAR LED for indication of fault • Wiggle, shake or bend a small section of the EEC harness while working your way from the H02S to the PCM • Wiggle, shake or bend a small section of the EEC harness while working your way from the H02S GND to the PCM • Is a fault indicated? F3-52 Yes ISOLATE fault and SERVICE as necessary REMOVE breakout box CLEAR Continuous Memory «■ page F3-18 RERUN Quick Test No REMAIN in Engine Running Continuous Monitor DTM Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM STEP 24 INSPECTION CONTINUOUS MONITOR DTM TEST DRIVE CHECK • Remain in Engine Running Continuous Monitor DTM • Test drive vehicle at 55 mph with minimum road load for five miles • Continue to drive on a rough road at 55 mph for five miles • If possible drive vehicle through a pool of water on the road to shower the H02S and/or con­ nector • Is a fault indicated? 25 ACTION Yes ISOLATE fault and SERVICE as necessary REMOVE breakout box CLEAR Continuous Memory Code. «*■ page F3-18 RERUN Quick Test No EXIT Engine Running Continuous Monitor DTM Go to next Step CHECK H02S SWITCHING • Key off • Inspect EEC wire harness for proper routing and insulation; burnt, chafed, intermittently shorted or open. Service as necessary. • Disconnect PCM 60 pin connector and inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary. • Inspect the H02S terminal voltage «■ page F3-164 • Did H02S voltage switch? Yes Unable to duplicate or identify fault at this time Clear Continuous Memory DTCs «*■ page F3-18 For futher diagunosis, REFER to page F3-167 No REPLACE H02S REMOVE breakout box RECONNECT PCM RERUN Quick Test 46U0F3-052 F3-53 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 179 (Cont) FUEL SYSTEM 181 (Cont) FUEL SYSTEM DESCRIP­ TION 179: Adaptive fuel lean limit reached at part throttle, system rich 181: Adaptive fuel rich limit reached at part throttle , system lean [Possible Cause] • Fuel pressure • Fuel injector electrical circuit 3 ACTION CHECK FOR OTHER DIAGNOSTIC TROUBLE CODES (DTC’S) Yes SERVICE them as required No Go to next Step WARNING: THE FUEL SYSTEM WILL REMAIN PRESSURIZED WHEN ENGINE IS NOT RUNNING. TO PREVENT INJURY OR FIRE USE CAUTION WHEN WORKING ON THE FUEL SYSTEM Yes Go to next Step • Key off • Install fuel pressure gauge • Verify that manifold vacuum is connected to the fuel pressure regulator if applicable • Start and run engine at idle. Note fuel pressure • Refer to Fuel Pressure Specification • Is fuel pressure within specification? No VERIFY integrity of fuel pressure regulator, vacuum line, fuel filter and fuel lines is- page F3-116 • Are any other DTC’s present? 2 • Air intake • Air cleaner element • Fuel filter INSPECTION STEP 1 • Fuel injector • Vacuum CHECK FUEL PRESSURE CHECK SYSTEM’S ABILITY TO HOLD FUEL PRESSURE • Cycle the key on and off several times. Note the fuel pressure • Visually lock for fuel leaking at the injector O-ring, fuel pressure regulator, and the fuel lines to the fuel charging assemble. Service as nec­ essary • Does fuel pressure remain at specification for 5 minutes? F3-54 Yes VERIFY integrity of air intake air filter, no vacuum leaks, EGR control valve closed Go to next Step No INSPECT the Fuel system <sr page F3-116 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 4 INSPECTION ACTION DIAGNOSTIC TEST MODE (DTM) The DTM switches each injector OFF and ON one at a time. Diagnostic Trouble Codes (DTC) corre­ spond to the cylinder number, (i.e. DTC 30 indi­ cates a problem with cylinder No.3, a DTC 90 indicates a pass.) The DTM is designed to aid in the detection of a weak or non-contributing cylin­ der. The Pinpoint Test Steps are designed to iso­ late only EEC related problems ra- page F3-20 Yes Go to next Step No Go to next Step • • • • Run the Engine Running Self-Test After the lest repeated code, wait 5-10 seconds “Goose" throttle lightly (not wide-open-throttle). DTM will be performed. Time of test is approxi­ mately 2-3 minutes • Is Code 90 pressure? 5 CHECK RESISTANCE OF INJECTORS AND HARNESS • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary Yes Go to Step 8 No Go to next Step Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNEC PCM and injectors DRIVE vehicle 5 miles/55 mph RERUN Quick Test NOTE: This erases Continuous Memory • Install breakout box, leave PCM disconnected • Measure resistance between the suspect INJECTOR circuit Test Pin and Test Pin 37 at the breakout box. Record resistance • Is each resistance within specification? 6 CHECK CONTINUITY OF FUEL INJECTOR HARNESS • Key off • Breakout box installed, PCM disconnected • Disconnect injector vehicle harness connector at the suspect injector • Measure resistance between Test Pin 37/57 at the breakout box and the VPWR pin at the injec­ tor vehicle harness connector • Measure resistance between the injector test pin(s) at the breakout box and the same injector circuit signal pin at the each injector vehicle har­ ness connector • Is each resistance less than 5.0 ohms? F3-55 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 7 ACTION CHECK INJECTOR HARNESS CIRCUIT FOR SHORT TO POWER OR GROUND Yes • Key off. • Breakout box installed, PCM disconnected • Suspect fuel injector vehicle harness disconnect­ ed • Measure resistance between the injector test pin(s) and Test Pin 37/57, 40, 46 and 60 at the breakout box No • Measure resistance between the injector test pin(s) at the breakout box and chassis ground • Is each resistance greater than 10,000 ohms? 8 REPLACE injector per Cylinder Balance DTM fault code RERUN Quick Test SERVICE short circuit REMOVE breakout box RECONNECT PCM and injectors DRIVE vehicle 5 miles/55 mph RERUN Quick Test CHECK INJECTOR DRIVER SIGNAL Requires standard non-powered 12 volt test light. • Key off. • Breakout box installed. • Connect PCM to breakout box — Connect test lamp between Test Pin 37 and the suspect injectors Test Pin at the breakout box • Crank or start engine NOTE: Properly operating systems will show a dim glow on the light Yes REMOVE breakout box RECONNECT PCM Also refer to section G for other possible causes After any servicing, DRIVE vehicle 5 miles/55 mph RERUN Quick Test and Cylinder Balance DTM No No light/Bright light: REPLACE PCM REMOVE breakout box DRIVE vehicle 5 miles/55 mph. RERUN Quick Test • Is glow on light dim? 46U0F3-Q53 \ F3-56 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 211 PROFILE IGNITION PICKUP (PIP) CIRCUIT DESCRIP­ TION DTC 211 indicates two successive erratic Profile Ignition Pickup (PIP) pulses occurred, resulting in a possible engine miss or stall [POJisible Cause] • Lc>ose wires/connectors • At cing secondary ignition components (coil, cap, rotor, w res, plugs, etc.) STEP 1 • Audio system ( if equipped) INSPECTION ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 211: ERRATIC IGNITION • Verify a radio and condenser installations Carefully follow manufacturer’s installation instructions regarding the routing of antenna and power leads • Are any of the above present? Yes SERVICE as necessary CLEAR Continuous Memory ■®- page F3-18 RERUN Quick Test No For No starts Go to 1 «■ page F3-97 All others Go to Code No. 212 Step 1 «*■ page F3-58 46U0F3-Q54 F3-57 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 212 (Cont) LOSS OF IGNITION DIAGNOSTIC MONITOR (IDM) CIRCUIT DESCRIP­ TION DTC 212 indicates a loss of IDM input to the PCM [Possible Cause] • Open harness circuit • Damaged Ignition Control Module (ICM) STEP 1 • Damaged Powertrain Control Module (PCM) • Shorted harness circuit ACTION INSPECTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 212 • Is vehicle a No Start? Yes INSPECT the Engine Electrical system ■s- section G 2 No Go to next Step Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT PCM CLEAR Continuous Memory CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 212: CHECK IDM CIRCUIT CONTINUITY • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Disconnect Ignition Control Module (ICM) • Measure resistance between Test Pin 4 at the breakout box and IDM circuit at the ICM vehicle harness connector • Is resistance less than 5.0 ohms? «■ page F3-18 RECONNECT all components RERUN Quick Test 3 CHECK IDM CIRCUIT FOR SHORTS TO POWER (EXCLUDING VREF) • • • • Key off Breakout box installed PCM and ICM disconnected Measure voltage between Test pin 4 at the breakout box and battery negative post • Key on, engine off • Measure voltage between Test pin 4 and Test Pins 40 and 60 at the breakout box • Is any voltage reading greater than 10.5 volts? F3-58 i Yes SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 4 ACTION CHECK IDM CIRCUIT FOR SHORTS TO VREF AND PIP • • • • Key off. Breakout box installed, PCM disconnected ICM disconnected Disconnect SUPER STAR I from Data Link Connector NOTE: For proper results of this test, the Breakout box must be disconnected. Due to the circuitry of the SUPER STAR Hand the vehicle, voltage can be fed to the VREF circuit giving the false indication of a short to power Yes RECONNECT SUPER STAR I Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components and SUPER STAR n RERUN Quick Test For Shorts To VREF: — Measure resistance between Test Pin 4 and Test Pin 26 at the breakout box For Shorts To PIP circuit: — Measure resistance between Test Pin 4 and Test Pin 56 at the breakout box • Is each resistance greater than 10,000 ohms? 5 CHECK IDM CIRCUIT FOR SHORT TO GROUND NOTE: During this check when H02S is con­ nected to the vehicle harness a short to SIG RTN (Pin 46) may be indicated in conjunction with an actual PWR GND short • • • • Key off. Breakout box installed, PCM disconnected ICM disconnected Measure resistance between Test Pin 4 and Test Pins 20, 40, 46 and 60 at the breakout box • Is each resistance above 10,000 ohms? 6 Yes Go to next Step No REMOVE breakout box SERVICE short to ground in IDM circuit RECONNECT all components CLEAR Continuous Memory RERUN Quick Test Yes DISCONNECT and INSPECT connectors If connector and terminals are good, REMOVE breakout box, RECONNECT all components Inspect Electrical igni­ tion system <&■ section G No Go to next Step CHECK ICM • • • • • • • • • • • Key off. Breakout box installed Connect PCM to breakout box Reconnect ignition coil and ICM Connect a voltmeter between Test Pin 4 and Test Pin 16 at the breakout box Start engine Observe voltmeter when voltage is allowed to stabilize Lightly tap on ICM to simulate road shock Wiggle ICM connector A sudden charge in voltage indicates a fault Is a fault indicated? F3-59 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 7 ACTION CHECK EEC HARNESS • The voltmeter still connected between Test Pin 4 Yes and Test Pin 16 at the breakout box • Key on, engine running • While observing a voltage change like in Step 5 perform the following: — Grasp vehicle harness closest to ICM connec­ tor Shake and bend a small section of the EEC harness while working your way to the dash No panel. Also wiggle, shake and bend the EEC harness from dash panel to PCM • Is a fault indicated? 8 ISOLATE fault and SERVICE as necessary REMOVE breakout box RECONNECT all components CLEAR Continuous Memory «■ page Fa-18 RERUN Quick Test Goto next Step CHECK PCM AND HARNESS CONNECTORS • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. • Are connectors and terminals OK? Yes Go to next Step No SERVICE as necessary REMOVE breakout box RECONNECT all components CLEAR Continuous Memory «*• page F3-18 RERUN Quick Test 9 CHECK PCM FOR SHORT TO POWER • • • • • Key off Breakout box installed PCM connected to breakout box Disconnect Crankshaft Position sensor Measure voltage between Test Pin 4 and chas­ sis ground • Key on, engine off • Measure voltage between Test Pin 4 and Test Pins 40 and 60 at the breakout box • Is any voltage reading greater than 10.5 volts? 10 Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step CHECK PCM FOR SHORT TO GROUND • • • • • Key off Breakout box installed PCM connected to breakout box ICM and CPS sensor disconnected Measure resistance between Test Pin 4 and Test Pins 40, 46 and 60 at breakout box • Is each resistance greater than 10, 000 ohms? Yes REMOVE breakout box RECONNECT all components Inspect the Electronic ignition system (Refer to section G) No REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-055 F3-60 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. INSPECTION STEP 1 213 (ER) NO SPARK CONTROL [SPOUT CKT OPEN] NOTE: Before proceeding with this Pinpoint Test, verify that the base timing check in Pinpoint Test F Step 4 has been performed. «■ page F3-110 • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Key on, engine off • Measure voltage between Test Pin 37 and Test Pin 40 at the breakout box • Measure voltage between Test Pin 57 and Test Pin 60 at the breakout box • Is each voltage greater than 10.5 volts? 2 ACTION CHECK FOR POWER TO PCM Yes Go to next Step No Go to Pinpoint B Test Step 1 «■ page F3-102 CHECK SPOUT CIRCUIT CONTINUITY • • • • Key off Breakout box installed, PCM disconnected Disconnect Ignition Control Module (ICM) Measure resistance between Test Pin 36 at the breakout box and SPOUT circuit at the ICM vehicle harness connector • Is resistance less than 5.0 ohms? Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components CHECK timing as in Step 4 ear page F3-110 3 CHECK SPOUT CIRCUIT FOR SHORT TO B+ (EXCLUDING VREF) • • • • • Key off Breakout box installed, PCM disconnected ICM disconnected Key on, engine off Measure voltage between Test Pin 36 and Test Pin 40 or 60 at the breakout box • Is voltage reading greater than 10.5 volts? Yes SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test No INSPECT the throttle body and the fuel system ra- page F3-112 «• page F3-116 F3-61 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 4 INSPECTION ACTION CHECK SPOUT CIRCUIT FOR SHORT TO VREF GROUND AND PIP • Key off. • Breakout box installed, PCM disconnected • ICM disconnected — Measure resistance between Test Pin 36 and Test Pin 26 at the breakout box For Short to Ground: — Measure resistance between Test Pin 36 and Test Pins 16, 20, 40, 46 and 60 at the break­ out box For Short to PIP: — Measure resistance between Test Pin 36 and Test Pin 56 at the breakout box • Is each resistance greater than 10,000 ohms? Yes RECONNECT all components INSPECT the electronic ignition system <9- section G No SERVICE Short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-056 F3-62 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 214 (CONT) CYLINDER IDENTIFICATION DISPLAY (CID) CIRCUIT 244 (KOER) CID CIRCUIT DESCRIP­ TION • Continuous Memory DTC 214 indicates an error has been detected in the Cylinder Identification Display (CID) input signal. The error could be due to a “hard fault” or an intermittent condition [Possible Cause] • Open or shorted harness • Damaged Crankshaft Position sensor (CPS) INSPECTION STEP 1 ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE 214: DIAGNOSTIC CIA TSC • Will engine start? 2 • Damaged Ignition Control Module (ICM) • Damaged Powertrain Control Module (PCM) Yes Go to next Step No Go to Step 8 Yes Go to next Step No DTC 214 is intermittent Go to Step 9 Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CLEAR AND ATTEMPT TO RE-GENERATE DTC: 214 • Clear Continuous Memory page F3-20 • Start engine • Increase rpm to greater than 1500 rpm for 10 seconds. Repeat two times • Key off • Rerun Key On Engine Off Self-Test • Is Continuous Memory DTC 214 present? 3 CHECK CID CIRCUIT CONTINUITY TO PCM • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box. Leave PCM disconnected • Disconnect Crankshaft Position sensor • Measure resistance between the CID / CID(+) Signal Test Pin at the breakout box and the CID CID(+) circuit at the crankshaft position sensor vehicle harness connector • Is each resistance less than 5.0 ohms? 4 CHECK CID CIRCUIT FOR SHORT TO POWER • • • • Key off Breakout box installed, PCM disconnected Crankshaft position sensor disconnected Disconnect SUPER STAR I NOTE: For proper results of this test, the SUPER STAR I must be disconnected. Due to the circuitry of the SUPER STAR I and the vehi­ cle, a CID signal short to SIG RTN could appear as a CID short to power Yes Key off Go to next Step No SERVICE short to power REMOVE breakout box RECONNECT all components RERUN Quick Test • Key on • Measure voltage between the CID / CID(+) Signal Test Pin and Test Pin 40 at the breakout box • Is voltage less than 1.0 volt? F3-63 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 5 ACTION INSPECTION CHECK CID CIRCUIT FOR SHORT TO GROUND • • • • Key off. Breakout box installed, PCM disconnected Crankshaft position sensor disconnected Disconnect SUPER STAR D Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT PCM RERUN Quick Test NOTE: For proper results of this test, the SUPER STAR I must be disconnected. Due to the circuitry of the SUPER STAR I and the vehi­ cle, a CID signal short to SIG RTN could appear as a CID short to power • Key on • Measure voltage between the CID / CID(+) Signal Test Pin and Test Pin 40 at the breakout box • Is voltage less than 1.0 volt? 6 CHECK FOR SHORTS IN PCM • • • • • Key off. Breakout box installed Connect PCM to breakout box Crankshaft position sensor disconnected Measure resistance between Test Pin 24 and Test Pins 37, 67, 40, 46 and 60 at the breakout box • Is each resistance greater than 500 ohms? 7 Go to next Step No REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No REPLACE crankshaft position sensor REMOVE breakout box RECONNECT all components RERUN Quick Test Yes RECONNECT crankshaft position sensor INSPECT the electronic ignition system «• section G No SERVICE open VPWR circuit between crankshaft position sensor and power relay RECONNECT crankshaft position sensor RERUN Quick Test CHECK CKP SENSOR OUTPUT • • • • Key off. Breakout box installed, PCM connected Reconnect crankshaft position sensor Measure voltage between Test Pins 24 and 40 at the breakout box while varying engine rpm • Does CPS voltage correct? is- page F3-152 8 Yes CHECK FOR VPWR TO CRANKSHAFT POSITION SENSOR • • • • Key off. Disconnect crankshaft position sensor Key on, engine off Measure voltage between the VPWR circuit at the crankshaft position sensor vehicle harness connector and the battery negative post • Is voltage greater than 10.5 volts? F3-64 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 9 ACTION INSPECTION CHECK CID WIRING • Enter Engine Running continuous Monitor diag­ nostic Test Mode (DTM) • Observe STAR LED for a fault indication while performing the following: CAUTION: While performing this test, do not touch any moving engine parts — Shake, wiggle, bend the crankshaft position sensor wiring form the PCM to as close as possible to the crankshaft position sensor — If possible, lightly tap on the crankshaft posi­ tion sensor / connector (to simulate road shock) • Is a fault indicated? Yes ISOLATE fault SERVICE as necessary CLEAR continuous Memory «■ page F3-18 RERUN Quick Test No Key off For further diagnosis, REFER to 1994 626/MX-6 BETM 46U0F3-057 F3-65 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 327 (KOEO / ER) EGR FUNCTION CIRCUIT DESCRIP­ TION • DTC 327 indicates the EGR function sensor signal is less than the Self-Test minimum [Possible Cause] • Damaged EGR function sensor • Open in sensor harness circuit • Short to ground in sensor harness circuit INSPECTION STEP 1 RTN circuit at the EGR function sensor vehicle harness connector • Is voltage between 4.5 and 5.5 volts? REPLACE the EGR function sensor / EGR valve assembly REMOVE jumper RERUN Quick Test No REMOVE jumper Go to next Step Yes Go to next Step No Go to Pinpoint Test C Step 1 «■ page F3-104 CHECK EGR CIRCUIT CONTINUITY • Key off. • EGR function sensor disconnected • Disconnect PCM. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave the PCM disconnect­ ed • Measure resistance between EGR function cir­ cuit at the EGR function sensor vehicle harness connector and Test Pin 27 at the breakout box • Is resistance less than 5 ohms? 4 Yes CHECK VREF CIRCUIT VOLTAGE • Key on, engine off. • EGR function sensor disconnected • Measure voltage between VREF circuit and SIG 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 327: ATTEMPT TO GENERATE DTC 337 • Key off. • Disconnect EGR function sensor Jumper VREF circuit to EGR function sensor signal circuit at the sensor vehicle harness con­ nector • Rerun Key On Engine Off (KOEO) and Key On Engine Running (KOER) Self-Test • Is DTC 337 present (ignore all other DTC out­ put)? 2 • Damaged Powertrain Control Module (PCM) • Damaged EGR control valve Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes REPLACE the PCM REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK EGR CIRCUIT FOR SHORT TO GROUND • • • • Key off. EGR function sensor disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 27 and Test Pins 40, 46 and 60 at the breakout box • Is each resistance greater than 10,000 ohms? SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test NOTE: Because the EGR function sensor is preloaded when attached to the EGR control valve, a failure in the EGR valve causing the EGR function sensor to lose the preload may also set DTC 327. F3-66 No 46U o g x - os8 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 327 (Cont) EGR CIRCUIT 337 (Cont) EGR CIRCUIT DESCRIP­ TION Continuous memory DTC 327 indicates that the EGR function sensor input to the Powertrain Control Module (PCM) was below the minimum acceptable voltage sometime during vehicle operation Continuous memory DTC 337 indicates that the EGR function sensor input to the Powertrain Control Module (PCM) was above the maximum acceptable voltage sometime during vehicle operation [Possible Cause] DTC 327: • Damaged EGR function sensor / EGR control valve assembly • Intermittent open in EGR function signal circuit • Intermittent short to ground in EGR function signal circuit • Intermittent open in EGR VREF circuit INSPECTION STEP 1 DTC 337: • Damaged EGR function sensor / EGR control valve assembly • Intermittent open in EGR signal return circuit • Intermittent short to power in EGR function signal circuit ACTION CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE (DTC) 327 OR 337: CHECK FOR INTERMITTENT SENSOR DAMAGE Enter KOEO Continuous Monitor DTM. (Refer to Yes Quick Test Appendix) • Observe STAR LED for indication of a fault while performing the following: Lightly tap on the EGR function sensor and wig­ gle the sensor vehicle harness connector to sim­ ulate road shock • Is a fault indicated? • INSPECT EGR function sensor connector and connector terminals If OK, REPLACE the EGR function sensor / EGR control valve assembly CLEAR continuous Memory ■s- page F3-18 RERUN Quick Test 2 No Go to next Step Yes ISOLATE fault and SERVICE as necessary CLEAR Continuous Memory CHECK FOR INTERMITTENT HARNESS DAMAGE • Still in KOEO Continuous Monitor DTM • Observe STAR LED for indication of a fault while performing the following: — Grasp the vehicle harness closest to the EGR function sensor vehicle harness connector Wiggle, shake or bend a small section of the EEC-IV vehicle harness while working your way towards the dash panel Also wiggle, shake and bend the EEC-IV vehi­ cle harness from the dash panel to the PCM • Is a fault indicated? <&• page F3-18 RERUN Quick Test No Go to next Step F3-67 F3 ON-BOARD DIAGNOSIS SYSTEM 3 ACTION INSPECTION STEP CHECK PCM CONNECTOR • Key off. • Disconnect PCM connector • Inspect both connectors and connector termi­ nals for damaged or pushed out pins, corrosion, loose wires, etc • Is damage detected? Yes SERVICE as necessary CLEAR Continuous Memory «*■ page F3-18 No Unable to duplicate fault at this time For farther diagnosis, REFER to page F3-167 46U0F3-059 F3-68 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 332 (ER) EGR SYSTEM CONTROL DESCRIP­ TION DTC 332 indicates that the EGR function sensor input did not change after the Powertrain Control Module (PCM) commanded the EGR control valve to be opened [Possible Cause] • Damaged vacuum lines • Damaged EGRV solenoid STEP 1 INSPECTION No REMOVE vacuum gauge Go to next Step Yes RECONNECT EGR control valve vacuum line Go to next Step No SERVICE EGR control valve vacuum line as necessary RERUN Quick Test Yes REMOVE vacuum gauge RECONNECT vacuum line Go to next Step No CHECK vacuum source line to the EGRV solenoid SERVICE as necessary RERUN Quick Test Yes REMOVE vacuum gauge Go to next Step No REMOVE vacuum gauge REPLACE the EGRV solenoid assembly RECONNECT all components RERUN Quick Test CHECK EGRV SOLENOID-VALVE FUNCTION • Key off • Disconnect the EGRV solenoid input port vacu­ um line at the solenoid output port • Install a vacuum gauge at the output port of the EGRV solenoid • Rerun Key On Engine Running (KOER) Self-Test while observing the vacuum gauge • Does vacuum increase above 1.0 in-Hg {3.4 kPa}? 5 REMOVE vacuum gauge REPLACE the EGR function sensor / EGR control valve assembly RERUN Quick Test CHECK VACUUM TO EGRV SOLENOID • Key off • Disconnect the EGRV solenoid input port vacu­ um source line • Install a vacuum gauge at the input port vacuum source line • Key on, engine idling • Observe the vacuum gauge reading • Is vacuum greater than 10 in-Hg {33 kPa}? 4 Yes CHECK EGR CONTROL VALVE VACUUM LINE • EGR control valve vacuum line disconnected • Inspect the EGR control valve vacuum line from the EGR control valve to the EGRV / EGRA solenoids for obstructions, cracks, kinks and loose connections, etc • Is EGR control valve vacuum line in good condition? 3 ACTION CHECK VACUUM AT EGR CONTROL VALVE • Key off. • Disconnect EGR vacuum line at the EGR control valve • Connect a vacuum gauge to the EGR vacuum line • Return Key On Engine Running (KOER) SelfTest while observing the vacuum gauge • Does vacuum increase above 1 in-Hg {3.4 kPa}? 2 • Damaged EGR function sensor / EGR control valve assembly • Damaged EGRA solenoid CHECK EGRV SOLENOID OUTPUT PORT VACUUM LINE • EGRV solenoid output port vacuum line discon­ nected • Inspect the EGRV solenoid output port vacuum line for obstructions, cracks, kinks and loose connections, etc • Is the vacuum line in good condition? Yes RECONNECT the vacuum line Go to next Step No SERVICE vacuum line as necessary RERUN Quick Test F3-69 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 6 ACTION CHECK EGRA SOLENOID VACUUM LINE • Disconnect the EGRA solenoid vacuum line • Inspect the EGRA solenoid vacuum line for obstructions, cracks, kinks and loose connec­ tions, etc • Is the vacuum line in good condition? Yes REPLACE the EGRA solenoid assembly RECONNECT the EGRA solenoid vacuum line RERUN Quick Test No SERVICE vacuum line as necessary RERUN Quick Test 46U0F3-060 F3-70 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 332 (Cont) EGR SYSTEM CONTROL DESCRIP­ TION Continuous memory DTC 332 indicates that the EGR control valve did not open when load and EGR requested conditions had been met sometime during vehicle operation. [Possible Cause] • Damaged EGR function sensor/EGR control valve assembly • Damaged EGR control valve vacuum line • Damaged EGRV solenoid vacuum lines STEP 1 • Damaged EGRA solenoid vacuum line INSPECTION ACTION CHECK EGR CONTROL VALVE FUNCTION • Key off • Disconnect and plug EGR control valve vacuum line at the EGR control valve • Connect a hand vacuum pump to the EGR con­ trol valve • Apply 10 in-Hg (34 kPa) of vacuum to the EGR control valve and release while observing valve for movement • Does the EGR control valve function proper­ ly? Yes REMOVE vacuum pump UNPLUG vacuum line Go to next Step No REMOVE the EGR function sensor/EGR control valve assembly INSPECT the EGR control valve for blockage, binding, contamination and leakage, etc. SERVICE as necessary CLEAR Continuous Memory page F3-18 RERUN Quick Test 2 CHECK EGR CONTROL VALVE VACUUM LINE • EGR control valve vacuum line disconnected at both ends • Inspect the EGR control valve vacuum line from the EGR control valve to the EGRV/EGRA solenoids for obstructions, cracks and kinks, etc. • Is EGR control valve vacuum line in good condition? Yes RECONNECT EGR control valve vacuum line Go to next Step No SERVICE EGR control valve vacuum line as necessary CLEAR Continuous Memory **■ page F3-18 RERUN Quick Test 3 CHECK EGRA SOLENOID VACUUM LINE AND EGRV SOLENOID INPUT/OUTPUT PORT VACUUM LINES • Vacuum lines disconnected one at a time • Inspect the vacuum lines for obstructions, cracks and kinks, etc. • Is each vacuum line in good condition? Yes RECONNECT the vacuum lines Go to next Step No SERVICE vacuum lines as necessary CLEAR Continuous Memory <3- page F3-18 RERUN Quick Test 4 CHECK EGRV/EGRA SOLENOIDS AND HARNESS CIRCUITS FOR INTERMITTENT FAULT • Key off • Disconnect vacuum line at the EGR control valve and connect vacuum line to a vacuum gauge • Key on, engine idling • Look for on increase in vacuum while perform­ ing the following: — Tap the EGRV and EGRA solenoids — Wiggle the EGRV and EGRA solenoid vehi­ cle harness connectors and harness circuits • Does the EGR vacuum increase? Yes ISOLATE fault and SERVICE or REPLACE as necessary RECONNECT all components CLEAR Continuous Memory ■a- page F3-18 RERUN Quick Test No Unable to duplicate and/or identify fault at this time INSPECT the EGR function control system ■a- page F3-134 46U0F3-061 F3-71 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 337 (KOEO/ER) EGR (FUNCTION) CIRCUIT DESCRIP­ TION DTC 337 indicates that the EGR function sensor signal is greater than the Self-Test maximum [Possible Cause] • Damage EGR function sensor • Short to power in sensor harness circuit • Open in sensor harness SIG RTN circuit • Damaged Powertrain Control Module (PCM) INSPECTION STEP 1 • Key off. • Disconnect EGR function sensor • Rerun Key On Engine Off (KOEO) and Key On Engine Running (KOER) Self test • Is DTC 327 present (ignore all other DTC output)? 2 Yes Go to next Step No Go to Step 3 Yes REPLACE the EGR function sensor/EGR control valve assembly RERUN Quick Test No RECONNECT all components Go to Pinpoint Test C Step 1 CHECK VREF CIRCUIT VOLTAGE • Key on, engine off • EGR function sensor disconnected • Measure voltage between VREF circuit and SIG RTN circuit at the EGR function sensor vehicle harness connector • Is voltage between 4.5 and 5.5 volts? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 337: ATTEMPT TO GENERATE DTC 327 page F3-104 CHECK EGR CIRCUIT FOR SHORT TO POWER • Key off • EGR function sensor disconnected • Disconnect PCM. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary. • Install breakout box, leave PCM disconnected • Measure the resistance between Test Pin 27 and Test Pins 26 and 37/57 at the breakout box • Is each resistance that 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT the EGR function sensor RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-062 F3-72 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 411 (ER) UNABLE TO CONTROL RPM DURING SELF TEST LOW RPM CHECK DESCRIP­ TION DTC 411 indicates that during Engine Running Self-Test, engine rpm could not be controlled with the Self-Test lower limit band. [Possible Cause] • Improper idle air flow set • Throttle linkage blinding • Improper ignition timing • IAC solenoid contamination STEP 1 • • • • Damage IAC solenoid Vacuum leaks Throttle plates open IAC circuit short to ground INSPECTION ACTION CHECK IDLE • Does engine idle speed appear normal? Yes REMOVE IAC solenoid and INSPECT for contamination. If contamination is present No contamination present or solenoid cannot be cleaned: REPLACE IAC solenoid RERUN Quick Test Solenoid is contaminated and can be cleaned: CLEAN as necessary ra-page F3-18 RERUN Quick Test. If DTC/symptom is still present, REPLACE IAC solenoid. No 2 RESET idle airflow to specification REFER to page F3-14 for idle speed adjust procedure. If UNABLE to RESET idle to specification, Go to next step. CHECK FOR CONDITIONS AFFECTING IDLE • Check engine vacuum hoses for leaks. Refer to vacuum hose routing diagram page F3-7 • Check throttle linkage and/or speed control link­ age for binding • Check for induction system leaks, (i.e. IAC solenoid to throttle body gasket, EGR flange gasket, loose IAC/EGR/PCV, etc.) • Check idle-speed control system for proper operation a- page F3-114 Yes Go to next Step No SERVICE as necessary RERUN Quick Test • Verify ignition timing is to specification ■s- page F3-13 • Verify that purge solenoid valve is not stuck open • Are all the above checks OK? 3 CHECK FOR INTERNAL SHORT TO IAC SOLENOID CASE • Key off • Disconnect IAC solenoid • Measure resistance from either IAC solenoid pin to IAC housing • Is resistance greater than 10,000 ohms? Yes Go to next Step No REPLACE IAC solenoid RERUN Quick Test F3-73 F3 ON-BOARD DIAGNOSIS SYSTEM 4 CHECK IAC CIRCUIT FOR SHORT TO GROUND • Key off • IAC solenoid disconnected • Disconnect the Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 21 and Test Pins 40, 46 and 60 at the breakout box • Are all resistances greater than 10,000 ohms? 5 Key off Breakout box installed Reconnect PCM to breakout box Reconnect IAC solenoid Connect a voltmeter between Test Pin 21 and Test Pin 40 at the breakout box • Is voltage correct? i®- page F3-152 Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Go to next Step No REPLACE PCM REMOVE breakout box RERUN Quick Test CHECK FOR PROPER ENGINE COOLANT FLOW TO BYPASS AIR (BPA) VALVE • Verify that engine coolant is warming up prop­ erly • Check for proper engine coolant level • Check engine coolant hoses to and from the air valve for kinks, leaks, blockage, etc. • Are the above checks OK? 7 Yes CHECK PCM OUTPUT • • • • • 6 ACTION INSPECTION STEP Yes REMOVE BAC valve solenoid and INSPECT for contami­ nation No contamination present or solenoid cannot be cleaned: REPLACE BAC valve solenoid RERUN Quick Test Solenoid is contaminated and can be cleaned: CLEAN as necessary RERUN Quick Test. If DTC/symptom is still present, REPLACE BAC valve solenoid No SERVICE as necessary REMOVE breakout box RECONNECT PCM Yes REFER to page F 3-115 No REPLACE BAC valve RE-EVALUATE symptom LACK OF HIGH IDLE WITH COLD ENGINE: VERIFY THAT BAC VALVE IS NOT STUCK CLOSED • Key off • Remove the BAC valve from the engine • When the valve is cold (room temperature), low through the air passage and check if air flows freely • Does air flow freely through the valve when it is at room temperature? 46U0F3-063 F3-74 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 412 (ER) UNABLE TO CONTROL RPM DURING SELF TEST HIGH RPM CHECK DESCRIP­ TION DTC 412 indicates that during Engine Running Self-Test, engine running Self-Test, engine rpm could not be con­ trolled within the Self-Test upper limit band. [Possible Cause] • Open or shorted circuit • Throttle linkage binding • Improper idle airflow set • IAC solenoid contamination STEP 1 INSPECTION ACTION DIAGNOSTIC TROUBLE CODE (DTC) 412 CHECK FOR RPM DROP • • • • • 2 • Items external to Idle Air Control system that could affect engine rpm • Damaged IAC solenoid • Damaged PCM Key off Connect the engine tachometer Start the engine Disconnect IAC harness connection Does rpm drop or stall? Yes Go to next Step No Go to Step 3 CHECK FOR OTHER DTCS Are DTCs 213, 327, 332 present? Yes RECONNECT IAC solenoid No Go to next Step Yes RECONNECT IAC solenoid page F3-114 3 CHECK FOR OTHER DTCS Are DTCs 172,173, present? «• page F3-114 4 Key off IAC solenoid disconnected Measure solenoid resistance Is resistance between 7.7 and 9.3 ohms (at 23°C {73°F})? Go to next Step No REPLACE IAC solenoid RERUN Quick Test Yes Go to next Step No REPLACE IAC solenoid RERUN Quick Test CHECK VPWR CIRCUIT VOLTAGE • Key on, engine off • IAC solenoid disconnected • Measure voltage between VPWR circuit at the IAC solenoid vehicle harness connection and battery ground • Is voltage greater than 10.5 volts? 7 Yes CHECK FOR INTERNAL SHORT TO IAC SOLENOID CASE • Key on, engine off • IAC solenoid disconnected • Measure resistance either IAC solenoid pin to IAC housing • Is resistance greater than 10 kft? 6 Go to next Step MEASURE IAC SOLENOID RESISTANCE • • • • 5 No Yes Go to next Step No SERVICE open circuit RERUN Quick Test CHECK IAC CIRCUIT CONTINUITY • Key off • IAC solenoid disconnected • Disconnect PCM and inspect both 60 pin con­ nectors for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. • Install brake out box, leave PCM disconnected • Measure resistance between test pin 21 at the breakout box and IAC circuit at IAC solenoid vehicle harness connector • is resistance less than 5.00? Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test l F3-75 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 8 • • • • Key off Break out box installed, PCM disconnected IAC solenoid disconnected Measure resistance between Test pin 21 and Test pin 40, 46 and 60 at the breakout box • Is each resistance greater than 10k£2? 9 Key off Breakout box installed, PCM disconnected IAC solenoid disconnected Mesure voltage between Test pin 21 at the breakout box and chassis ground • Is voltage less than 1.0 volts? Key off Breakout box installed Reconnect PCM to breakout box Reconnect IAC solenoid Connect a voltmeter between Test pin 21 and Test pin 40 at breakout box • Start the engine • Slowly increase rpm to 3,000 rpm • Is voltage between 7 and 11.0V? No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test If DTC or symptom is present, REPLACE PCM Yes Go to next Step No REMOVE IAC solenoid and VERIFY that it is not stuck open. If OK, REPLACE PCM. REMOVE breakout box RERUN Quick Test Yes REPLACE IAC solenoid RERUN Quick Test No Go to next Step Yes REPLACE IAC solenoid RERUN Quick Test No SERVICE as necessary REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK IDLE Does engine idle speed appear normal? 12 Go to next Step CHECK FOR IAC SIGNAL FROM PCM • • • • • 11 Yes CHECK IAC CIRCUIT FOR SHORTED POWER • • • • 10 ACTION CHECK IAC CIRCUIT FOR SHORTED GROUND CHECK FOR PROBLEMS AFFECTING PROPER ENGINE SPEED • Check throttle linkage and/or speed control link­ age for binding • Inspect throttle body for proper operation »*■ page F3-112 • Check engine vacuum hoses «■ page F3-7 • Check for leaks around IAC solenoid (i.e. mounting gasket, etc.) • Are all the above check OK? 46U0F3-064 F3-76 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 452 INSUFFICIENT INPUT FROM VEHICLE SPEEDOMETER SENSOR (VSS) DESCRIP­ TION Continuous Memory 452 indicates that sometime during the last 40 or 80 warm-up cycles, the PCM detected an error in the vehicle speed sensor output signal [Possible Cause] • Damaged vehicle speedometer sensor • Damaged harness circuit • Damaged PCM STEP INSPECTION 1 • Perform VSS Drive Cycle at least three times as outlined below VEHICLE SPEEDOMETER SENSOR (VSS) DRIVE CYCLE: — Record and clear Continuous Memory DTCs — Worm engine to operating temperature — Place gear selection in D range — Obey all local traffic laws. Accelerate heavi­ ly to 35 mph. — Coast down to an idle and stop the vehicle — Shut the engine off — After the drive cycle is completed, run KOEO self-test and record the continuous Memory DTCs displayed • Did Continuous Memory DTC 452 repeat? 2 Go to nest Step No Unable to duplicate and/or identify fault at this time For further diagnosis, REFER to page F3-167 All others, CLEAR Continuous Memory «• page F3-18 Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components REPEAT Step 1 INSPECTION to verify elimination of DTC or the drive complaint CHECK VSS SIGNAL HARNESS CIRCUITS FOR SHORTS TO POWER OR GROUND • • • • Key off VSS disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 3 and Test Pin 6,37 and 40 at breakout box • Is each resistance within specification? «• 1994 626/MX-6 BETM 4 Yes CHECK CONTINUITY OF VSS HARNESS CIRCUIT • Key off • Disconnect PCM. Inspect for damaged or pushed out pins, corrosion, loose wives, etc, service as necessary. • Install breakout box. PCM disconnected. • Disconnect VSS • Measure resistance between test pin 3 at the breakout box and VSS (+) circuit at VSS vehi­ cle harness connector • Is each resistance within specification? «• 1994 626/MX-6 BETM 3 ACTION COMPLETE VSS DRIVE CYCLE: VERIFY DTC OR DRIVE COMPLAINT Yes RECONNECT the PCM Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components REPEAT Step 1 INSPECTION to verify the elimination of DTC or drive complaint CHECK VSS RESISTANCE • • • • Yes Key off REPLACE PCM VSS disconnected REPEAT Step 1 INSPECTION to verify the elimination of Measure the resistance of the VSS Is resistance within specification? DTC or drive complaint ■S’ 1 9 9 4 b Z b /M A -b O t 1M No REPLACE VSS REMOVE breakout box REPEAT Step 1 INSPECTION to verify the elimination of DTC or drive complaint 46U0F3-217 F3-77 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 512 (Cont) ELECTRONIC CONTROL ASSEMBLY (ECA) (KAM) TEST DESCRIP­ TION Continuous Memory DTC 512 indicates that the PCM has experienced a power interrupt in its Keep Alive Memory (KAM) circuit [Possible Cause] • Powertrain Control Module (PCM) STEP 1 ACTION CHECK KAPWR TO PCM • Key off • Disconnect PCM Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure voltage between Test Pin 1 and Test Pin 40 or 50 at the breakout box • While observing a voltmeter, grasp the EEC-IV harness and wiggle, shake or bend a small sec­ tion while working your way from the PCM to the dash panel. • Does the voltmeter indicate less than 10.5V? 2 • Harness circuit: KPWR INSPECTION Yes SERVICE open circuit REMOVE breakout box RECONNECT PCM RERUN Quick Test No RECONNECT PCM Go to next Step INSPECT ENGINE COMPARTMENT WIRING FOR PROPER ROUTING • Inspect EEC-IV wiring for closeness to ignition components or wires. If EEC-IV wiring is close, reroute as necessary • Clear Continuous Memory DTC ■s- page F3-18 • Wait five minutes to allow DTC 512 reset. • Rerun Key On Engine Off Self-Test • Is DTC 512 still present on retest? Yes Replace PCM REMOVE breakout box RERUN Quick Test No REMOVE breakout box RECONNECT PCM SERVICE other DTC’s as necessary If none, testing is complete NOTE: If KAPWR is interrupted to the PCM, for example when installing a breakout box, or when battery is disconnected, DTC 512 may be stored in Continuous Memory. F3-78 46U0F3-065 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 519 (KOEO) STEERING PRESSURE SENSOR (SPS) CIRCUIT DESCRIP­ TION DTC 519 indicates that the SPS circuit is closed [Possible Cause] • Damaged SPS • Damaged PCM STEP 1 • Open harness INSPECTION • Key off • Disconnect SPS • Jumper SPS circuit to SIG RTN circuit at the SPS switch vehicle harness connector • Rerun Key On or Engine Off Self-Test • Measure resistance between Test Pin 28 and test Pin 46 at the breakout box • Is DTC 519 still present? 2 ACTION DIAGNOSTIC TROUBLE CODE 519: ATTEMPT TO ELIMINATE DTC 519 Yes Go to next Step No REPLACE SPS RERUN Quick Test CHECK SPS CIRCUIT FOR SHORTS • Key off • SPS disconnected • Disconnect PCM inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test pin 28 and Test pin 46 at the breakout box • Is resistance within specification? rar section P Yes SERVICE shot in harness REMOVE breakout box RECONNECT all components RE-EVALUATE symptom No REPLACE PCM REMOVE breakout box RECONNECT all components RE-EVALUATE symptom 46U0F3-066 F3-79 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 521 (ER) STEERING PRESSURE SENSOR (SPS) DESCRIP­ TION DTC 521 indicates that the SPS did not change state due to the switch staying either open or short [Possible Cause] • Damaged SPS • Open or shorted harness INSPECTION STEP 1 Yes Go to next Step No RERUN Quick Test DETERMINE IF THE PCM CAN IDENTIFY A CLOSED CIRCUIT • Key off • Disconnect SPS • Jumper SPS circuit to SIG RTN circuit at the SPS vehicle harness connector • Run Key On Engine Off Self-test • Is DTC 519 present? 3 ACTION DTC CODE 521: VERIFY OPERATOR INTERACTION • Did you turn the steering wheel at least onehalf turn within one to two seconds after engine ID DTC? 2 • Damaged PCM • Wheels turned not centered? Yes REMOVE jumper Go to Step 4 No REMOVE jumper Go to next Step Yes REPLACE PCM REMOVE breakout box RECONNECT all components RE-EVALUATE symptom No SERVICE open in harness REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK CONTINUITY OF SPS CIRCUITS • Key off • SPS disconnected • Disconnect PCM Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 28 at the breakout box and SPS circuit at the SPS vehicle harness connector. • Is each resistance less than 5.0ft? F3-80 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 4 ACTION CHECK SPS SWITCH STATE WITH ENGINE RUNNING AND LOAD VS. NO LOAD • • • • Engine speed at idle Breakout box installed PCM connected SPS switch connected Measure resistance between Test Pin 28 and Test Pin 46 at the breakout box • Turn the steering wheel at least on-half turn then back to center position • Inspect SPS «*■ page F3-116 • SPS OK? Yes REMOVE breakout box Testing completed No REPLACE SPS REMOVE breakout box RERUN Quick Test 46U0F3-072 F3-81 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 536 BRAKE SWITCH CIRCUIT FAILURE DESCRIP­ TION DTC 536 indicates that when the brake pedal was depressed and released during Engine Running Self-Test the stoplight switch signal did not cycle high and low [Possible Cause] • Brake pedal not depressed and released during the Engine Running Self-Test • Brake pedal depressed during entire Engine Running Self test 1 ACTION DIAGNOSTIC TROUBLE CODE 536 VERIFY BRAKE WAS PRESSED NOTE: It is necessary to depress and release the brake after the Dynamic Response Code 10 but before the brief WOT. • Did you press brake during the Engine Running Self-Test? Yes Go to next Step No RERUN Engine Running Self-Test PRESS brake once during test CHECK OPERATION OF STOPLIGHTS • Key on • Check stoplamp operation • Does stoplights operate normally 3 Yes Go to next Step No If stoplights never on Go to Step 4 If stoplights always on Go to Step 5 CHECK FOR BOO CIRCUIT CYCLING Yes • Key off • Disconnect PCM Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure voltage between brake switch Test Pin No and Test Pin 40 at the breakout box while depressing and releasing brake • Dose the voltage cycle? 4 • Key off • Disconnect stoplight switch (located on brake pedal) • Measure voltage between B+ input to stoplight switch and chassis ground • Is voltage greater than 10 volts? SERVICE open in stoplight switch circuit between PCM and stoplight switch connection to stoplight circuit RERUN Quick Test Yes VERIFY operation of stoplight switch. If OK, SERVICE open circuit between stoplight switch and stoplight ground RECONNECT stoplight switch connector RERUN Quick Test No SERVICE open B+ circuit to brake switch RECONNECT stoplight switch connector RERUN Quick Test VERIFY BRAKE SWITCH IS NOT ALWAYS CLOSED • • • • 6 REPLACE PCM REMOVE breakout box RERUN Quick Test CHECK FOR POWER TO BRAKE SWITCH NOTE: Using a 12V test light, verify integrity of related fuses in fuse panel and check condition of stoplight bulbs 5 Open brake switch/Stoplight circuit Short to GROUND or POWER Damaged stoplight switch Damaged PCM INSPECTION STEP 2 • • • • Key off Stoplight switch disconnected Key on, engine off Are stoplights still on? Yes Go to next Step No VERIFY proper installation of brake switch. If OK, REPLACE stoplight switch. RECONNECT harness con­ nector. RERUN Quick Test CHECK FOR SHORT TO POWER IN PCM • • • • • Key off Stoplight switch disconnected Disconnect Powertrain Control Module (PCM) Key on, engine off Are stoplights still on? F3-82 Yes Go to next Step No REPLACE PCM RECONNECT stoplight switch RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM 7 ACTION INSPECTION STEP CHECK FOR SHORT TO POWER IN SHIFTLOCK ACTUATOR • • • • Key off PCM disconnected Stoplight switch disconnected Disconnect shiftlock actuator, cruise control module and ABS module (if equipped) to isolate stoplight switch wiring • Key on, engine off • Are stoplights still on? Yes SERVICE short to power in stoplight switch/Stoplight circuit RECONNECT PCM stoplight switch and accessories RERUN Quick Test No SERVICE short in accessories (i.e. shiftlock actuator, ABS module, etc.) RECONNECT all components RERUN Quick Test 46UQF3-067 F3-83 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 538 (ER) CYLINDER BALANCE TEST DESCRIP­ TION Invalid cylinder balance test due the throttle movement STEP 1 INSPECTION • Rerun Engine Running Self-Test. Be sure oper­ ator is familiar with the Engine Running format which proceeds as follows: — Activate Engine Running Self-Test — Start engine — ID Code start of test — Dynamic Response code 10; perform brief WOT — Testing over — DTC output begins • Is DTC 538 still present? 2 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 538: SYSTEM FAILED TO RECOGNIZE BRIEF WOT Yes Go to next Step No Dynamic Response Test passed SERVICE any other DTC(s) received as necessary DID ENGINE ACHIEVE GREATER THAN 2000 RPM • During the WOT in the Dynamic Response Test, did the engine achieve greater than 2000 rpm? Yes REPLACE PCM RERUN Quick Test No CHECK for conditions that would prevent engine form achieving greater than 2000 rpm (binding throttle linkage, etc.) REFER to 1994 626/MX-6 BETM 46U0F3-068 F3-84 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 539 (KOEO) A/C, REAR WINDOW DEFROSTER ON DURING SELF-TEST DESCRIP­ TION DTC 539 indicates that the A/C demand input to the Powertrain Control Module (PCM) was low (A/C on) during KOEO Self-Test INSPECTION STEP 1 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 539: CHECK A/C INPUT Yes Key off A/C off Disconnect Low pressure (LP) switch No Measure resistance between A/C demand switch side of LP switch vehicle harness connec­ tor and chassis ground • Is resistance greater than 10,000 ohms? • • • • 2 VERIFY operation of A/C demand switch REFER to 1994 626/MX-6 BETM If OK, SERVICE short to ground RECONNECT all components RE-EVALUATE symptom CHECK LOW PRESSURE (LP) SWITCH • Key off • LP switch disconnected • Measure resistance between chassis ground and both pins of LP switch • Are both resistances greater than 10,000 ohms? 3 Go to next Step Yes Go to next Step No REPLACE LP switch RECONNECT all components RE-EVALUATE symptom Yes REPLACE PCM RECONNECT all components RE-EVALUATE symptom No SERVICE short to ground RECONNECT all components RE-EVALUATE symptom CHECK ACD CIRCUIT TO PCM FOR SHORT TO GROUND • Key off • LP switch disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Measure resistance between PCM side of the LP switch vehicle harness connector and chas­ sis ground • Is resistance greater than 10,000 ohms? NOTE: Before entering this test, verify A/C selector is off. If A/C was on, rerun KOEO Self-Test. If DTC 539 is present, continue with this test. 46U0F3-069 F3-85 F3 ON-BOARD DIAGNOSIS SYSTEM CODE NO. 554 (KOEO) PRESSURE REGULATOR CONTROL (PRC) CIRCUIT FAULT DESCRIP­ TION DTC 554 indicates a failure in the Pressure Regulator Control (PRC) solenoid circuit [Possible Cause] • Damaged PRC solenoid • Damaged Vacuum hose(s) • Open in harness STEP 1 INSPECTION Yes REMAIN in Output State DTM Go to next Step No DEPRESS throttle to WOT and RELEASE If STO voltage does not go high leave equipment hooked up and Go to Step 8 CHECK FUEL PRESSURE REGULATOR CONTROL SOLENOID ELECTRICAL OPERATION • Key on, engine off. • Disconnect PRC solenoid • Connect a voltmeter positive test lead to VPWR pin and negative test lead to PRC circuit at the PRC solenoid vehicle harness connector • While observing the voltmeter depress and release throttle several times to cycle solenoid output • Does PRC solenoid output voltage change greater than 1.0 volt? 3 ACTION KOEO DTC 554: ENTER OUTPUT STATE DIAGNOSTIC TEST MODE (DTM) • Key off. • Disconnect electrical connector on the speed control servo, if equipped • Connect a voltmeter negative test lead to STO circuit at Data Link connector (DLC) and posi­ tive test lead to battery positive • Jumper STI circuit to SIG RTN at DLC • Perform Key On Engine Off Self-Test until com­ pletion of Continuous Test Memory DTCs • The voltmeter will indicate less than 1.0 volt when test is completed • Depress and release throttle • Does voltage increases? 2 • Short (to power or ground) in harness • Damaged PCM Yes RECONNECT PRC solenoid REMOVE jumper wire Go to next Step No REMOVE jumper wire Go to Step 5 CHECK VACUUM SIGNAL BETWEEN FUEL PRESSURE REGULATOR AND FPRC SOLENOID • Key off. • Disconnect and inspect vacuum hose between fuel pressure regulator and PRC solenoid for blockage, kinks, etc. Service as necessary • Start and idle engine for about five minutes to allow it to reach normal operating temperature • Key off • Tee in a standard vacuum gauge between fuel pressure regulator and PRC solenoid • Start and idle engine while observing vacuum gauge needle. Observe vacuum gauge needle for about five minutes • Did va cu um s ig n a l appear after a b o u t tw o minutes o f engine idle? F3-86 Yes REMOVE vacuum gauge INSPECT the Pressure Regulator «■ page F3-125 No Remove vacuum gauge Go to next Step F3 ON-BOARD DIAGNOSIS SYSTEM 4 CHECK VACUUM SIGNAL BETWEEN FPRC SOLENOID AND MANIFOLD VACUUM SOURCE • Key off. • Tee in a standard vacuum gauge between the PRC solenoid and manifold vacuum source • Start and idle engine while observing the vacu­ um gauge needle • Was any vacuum signal present? 5 Key off. PRC solenoid disconnected Key on, engine off Measure voltage between VPWR at PRC solenoid vehicle harness connector and battery ground • Is voltage greater than 10.5 volts? REPLACE FPRC solenoid REMOVE vacuum gauge RERUN Quick Test and / or VERIFY elimination of drive symptom No REPLACE vacuum hose between PRC solenoid and source vacuum REMOVE vacuum gauge RERUN Quick Test and / or VERIFY elimination of drive symptom Yes Go to next Step No SERVICE open in VPWR harness circuit RECONNECT PRC solenoid RERUN Quick Test and / or VERIFY elimination of drive symptom CHECK FPRC CIRCUIT CONTINUITY • Key off. • PRC solenoid disconnected • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wire, etc. Service as necessary • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 32 at the breakout box and PRC circuit at solenoid vehi­ cle harness connector • Is resistance less and 5.0 ohms? 7 Yes CHECK FPRC SOLENOID VPWR • • • • 6 ACTION INSPECTION STEP Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test and / or VERIFY elimination of drive symptom CHECK FPRC CIRCUIT FOR SHORT TO POWER AND GROUND • • • • Key off. PRC solenoid disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 32 and Test Pins 37 and 57 at the breakout box • Measure resistance between Test Pin 32 and Test Pins 40, 46 and 60 at the breakout box • Is each resistance greater than 10,000 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test and / or VERIFY elimination of drive symptom No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test and / or VERIFY elimination of drive symptom F3-87 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 8 INSPECTION ACTION CHECK FOR DIAGNOSTIC TROUBLE CODES (DTC) 121, 122 or 123 • Key off. • Perform Key On Engine Off Self-Test • Are any of these DTC’s (121,122 or 123) pre­ sent? Yes Go to Quick Test and SERVICE appropriate DTC as instructed DTC n Go to next step No DTCs Go to Pinpoint Test A Step 1 is- page F3-108 9 CHECK THROTTLE LINKAGE • Check throttle and throttle linkages for sticking and binding • Is throttle OK? Yes REPLACE TPS RERUN Quick Test No SERVICE as necessary RERUN Quick Test NOTE: If vehicle is equipped with speed control, the speed control servo must be electrically disconnected. This prevents the speed control system from affecting the throttle plate movement daring Output State DTM. Quick Test or Output State DTM. F3-88 46Uofx -o75 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 559 (KOEO) AIR CONDITIONING ON RELAY (ACON) CIRCUIT DESCRIP­ DTC 559 indicates an A/C relay primary circuit fault TION [Possible Cause] • Open or shorted circuit • Damaged A/C relay • Damaged Powertrain Control Module (PCM) INSPECTION STEP 1 • • • • Key off Disconnect A/C relay Key on Measure voltage between IGN RUN circuit at A/C relay vehicle harness connector and chas­ sis ground • Is voltage greater than 10.5 volts? 2 Go to next Step No VERIFY condition of related fuses If OK, SERVICE open circuit RECONNECT all components RERUN Quick Test. Yes Go to next Step No REPLACE A/C relay RECONNECT all components RERUN Quick Test CHECK ACON CIRCUIT FOR SHORT TO POWER • Key off • A/C relay disconnected • Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corro­ sion, loose wire, etc. Service as necessary. • Install breakout box, leave PCM disconnected • Key on, engine off • Measure voltage between Test Pin 54 at the breakout box and chassis ground • Is voltage specification? o ' 1994 626/MX-6 BETM 4 Yes CHECK A/C RELAY • Key off • A/C relay disconnected • Check A/C relay coil resistance: — Measure resistance between ACON pin and IGN RUN pin at the A/C relay • Check A/C relay for internal shorts: — Measure resistance between ACON pin and the following pins at the A/C relay: B+, power-to-clutch, ground • Are all resistance checks OK? <3-1994 626/MX-6 BETM 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 559: CHECK FOR IGN RUN VOLTAGE TO A/C RELAY Yes Go to next Step No SERVICE short to power REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK ACON CIRCUIT FOR SHORT TO GROUND • • • • Key off A/C relay disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 54 at the breakout box and chassis ground • I s r e s is t a n c e gre a te r th a n 10,0 0 0 o h m s ? Yes Go to next Step No SERVICE short to ground REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 5 ACTION CHECK ACON CIRCUIT CONTINUITY • • • • Key off A/C relay disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 54 at breakout box and ACON circuit at A/C relay vehicle harness connector • Is resistance less than 5.0 ohms? Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-078 F3-90 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 563 (KOEO) HIGH SPEED ELECTRODRIVE FAN (HEDE) CIRCUIT 564 (KOEO) LOW SPEED ELECTRODRIVE FAN (EDF) CIRCUIT DESCRIP­ TION DTC 563 indicates an High Fan Control (HFC) primary circuit failure DTC 564 indicates an Low Fan Control (LFC) primary circuit failure [Possible Cause] • Open or short circuit • Damaged fan relay « Damaged Powertrain Control Module (PCM) INSPECTION STEP ACTION DIAGNOSTIC TROUBLE CODE (DTC) NOTE: During diagnosis, use the chart below to determine the correct pin number, circuit and relay being tested Code Circuit/ Relay Test Pin Number 563 HFC 31 564 LFC 13 Yes Go to next Step No VERIFY integrity of fuse/fuse link for IGN Start/Run voltage supply to LFC/HFC relay If OK, SERVICE open circuit RECONNECT LFC/HFC relay RERUN Quick Test • • • • Key off Disconnect LFC or HFC relay Key on Measure voltage between IGN Start/Run circuit at the LFC/HFC relay vehicle harness connec­ tor and chassis ground • Is voltage greater than/0.5 volts? ENTER OUTPUT STATE DIAGNOSTIC TEST MODE (DTM)____________________________ NOTE: USE VOM/DVOM for this Step Key off, wait 10seconds DVOM on 20 volt scale Disconnect electrical connector on the speed control servo, if equipped Connect a voltmeter negative test lead to STO at the Data Link Connector (DLC) and positive test lead to the battery positive post Jumper STI to SIG RTN at the Data Link Connector Perform Key on Engine off Self-Test until the completion of the Continuous Memory DTCS The voltmeter will indicate less than 1.0 volt when test is complete Depress and release throttle Does voltage increase to greater than 10.5 volts? Yes REMAIN in Output State DTM Go to next Step No DEPRESS throttle to WOT and RELEASE If STO voltage does not go high, leave equipment hooked up and Go to Step 7 F3-91 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP • • • • Key off LFC or HFC relay disconnected DVOM on 20 volt scale Connect a voltmeter positive test lead to the LFC or HFC circuit at the LFC/HFC relay vehi­ cle harness connector • Depress and release throttle to cycle outputs off • While observing DVOM, depress throttle again. For LFC, wait until the MIL flashes once (10seconds). For HFC, wait until the MIL flash­ es twice (15 seconds). Release throttle. The LFC or HFC output is now “on”. To cycle “off”, depress and release throttle. • Does voltage cycle high ad low (about 1.0 volt change)? 4 Yes REPLACE LFC or HFC relay REMOVE jumper RERUN Quick Test No REMOVE jumper Go to next Step CHECK CONTINUITY OF LFC/HFC CIRCUIT • Key off • LFC or HFC relay disconnected • Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. • Install breakout box, leave PCM disconnected • For DTC 563: — Measure resistance between applicable Test Pin at the breakout box and HFC circuit at the HFC relay vehicle harness connector • For DTC 564: — Measure resistance between applicable Test Pin at the breakout box and LFC circuit at the LFC relay vehicle harness connector • Is resistance less than 5.0 ohms? 5 ACTION CHECK FOR LFC/HFC CIRCUIT CYCLING 3 Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK LFC/HFC CIRCUIT FOR SHORT TO POWER • • • • Key off Breakout box installed, PCM disconnected LFC or HFC relay disconnected Measure voltage between applicable Test Pin (HFC or LFC) at the breakout box and battery negative post. • Is voltage less than 1.0 volts? F3-92 Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test If DTC is still present REPLACE PCM F3 ON-BOARD DIAGNOSIS SYSTEM 6 CHECK LFC/HFC CIRCUIT FOR SHORT TO GROUND • • • • Key off Breakout box installed, PCM disconnected LFC or HFC relay disconnected Measure resistance between applicable Test Pin (LFC or HFC) and Test Pins 40 and 60 at the breakout box. • Is resistance greater than 10,000 ohms? 7 ACTION INSPECTION STEP Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Replace TPS RERUN Quick Test No SERVICE as necessary RERUN Quick Test CHECK THROTTLE LINKAGE • Check throttle and throttle linkages for sticking and binding • Is throttle OK? 46U0F3-079 F3-93 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 565 (KOEO) PURGE SOLENOID VALVE CIRCUIT FAULT DESCRIP­ TION DTC 565 indicates a failure in the purge solenoid valve circuit [Possible Cause] • Damaged purge solenoid valve • Open harness STEP INSPECTION 1 Key off Disconnect appropriate purge solenoid valve Inspect purge solenoid valve? Purge solenoid valve OK? page F3-139 No REPLACE purge solenoid valve RERUN Quick Test Yes Go to next Step No SERVICE open harness circuit RECONNECT purge solenoid valve RERUN Quick Test Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK PURGE SOLENOID VALVE CIRCUIT FOR SHORT TO GROUND • • • • Key off Appropriate purge solenoid valve disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 11 (15, 31 or Pin 54 refer to schematic) and Test Pins 40, 46 and 60 at the breakout box. • Is each resistance greater than 10,000 ohms? 5 Go to next Step CHECK CONTINUITY OF PURGE SOLENOID VALVE CIRCUIT • Key off • Appropriate purge solenoid valve disconnected • Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary. • Install breakout box, leave PCM disconnected • Measure resistance between Test Pin 11, (15, 31 or Pin 54 refer to schematic) at the purge solenoid valve vehicle harness connector • Is resistance less than 5.0 ohms? 4 Yes CHECK VPWR CIRCUIT VOLTAGE • Key on, engine off • Appropriate purge solenoid valve disconnected • Measure voltage between VPWR at the purge solenoid valve vehicle harness connector and battery ground • Is voltage greater than 10.5 volts? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 565: CHECK PURGE SOLENOID VALVE RESISTANCE • • • • 2 • Shorted (power or ground) harness • Damaged Powertrain Control Module (PCM) Yes Go to next Step No SERVICE short to ground REMOVE breakout box RECONNECT all components RERUN Quick Test Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE short to power REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK PURGE SOLENOID VALVE CIRCUIT FOR SHORT TO POWER • • • • Key off Purge solenoid valve disconnected Breakout box installed, PCM disconnected Measure resistance between Test Pin 11 (15, 31 or Pin 54 refer to schematic) and Test Pins 37 and 57 at the breakout box • Is each resistance greater than 10,000 ohms? 46U0F3-080 F3-94 F3 ON-BOARD DIAGNOSIS SYSTEM CODE No. 571 (KOEO) EGR SOLENOID VALVE (VENT) OUTPUT CIRCUIT 572 (KOEO) EGR SOLENOID VALVE (VACUUM) OUTPUT CIRCUIT DESCRIP­ TION DTC 571 indicates a failure in the solenoid circuit DTC 572 indicates a failure in the EGRV solenoid circuit [Possible Cause] • Damaged EGRA/EGRV solenoid • Short in harness circuit INSPECTION STEP 1 Key off Disconnect EGRA/EGRV solenoid Inspect solenoid valves Solenoid valves OK? «■ page F3-135 Yes Go to nest Step No REPLACE appropriate solenoid RERUN Quick Test CHECK VPWR CIRCUIT VOLTAGE • Key on, engine off • Solenoid disconnected • Measure resistance between battery negative post and VPWR circuit at the solenoid vehicle harness connector • Is voltage greater than 10.5 volts? 3 ACTION DIAGNOSTIC TROUBLE CODE (DTC) 571 AND DIAGNOSTIC TROUBLE CODE (DTC) 572: CHECK EGR/EGR SOLENOID RESISTANCE • • • • 2 • Open in harness circuit • Damaged Powertrain Control Module (PCM) Yes Go to next Step No SERVICE open circuit RECONNECT solenoid RERUN Quick Test CHECK SOLENOID CIRCUIT CONTINUITY • Key off • Solenoid disconnected • Disconnect PCM. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary. • Install breakout box, leave PCM disconnected For EGRA solenoid: • Measure resistance between Test Pin 12 at the breakout box and EGRA circuit at the solenoid vehicle harness connector. For EGRV solenoid: • Measure resistance between Test Pin 33 at the breakout box and EGRV circuit at the solenoid vehicle harness connector. • Is resistance less than 5.0 ohms? Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 4 ACTION CHECK SOLENOID CIRCUIT FOR SHORT TO POWER AND GROUND • Key off • Solenoid disconnected • Breakout box installed, PCM disconnected For EGRA solenoid: • Measure resistance between Test Pin 12 and Test Pins 40,46 and 60 at the breakout box For EGRV solenoid: • Measure resistance between Test Pin 33 and Test Pins 40, 46 and 60 at the breakout box Yes REPLACE PCM REMOVE breakout box RECONNECT solenoid RERUN Quick Test No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test • Is each resistance greater than 10,000 ohms? 46U0F3-081 F3-96 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test A INSPECTION STEP 1 ATTEMPT TO CRANK ENGINE • Does engine crank? 2 Key off Disconnect TPS Key on, engine off Measure voltage between VREF circuit and SIG RTN circuit at the TPS vehicle harness connec­ tor • Is voltage between 4.5 volts and 5.5 volts? Go to next Step No INSPECT the starter and the ignition switch «*■ section G «■ section T Yes RECONNECT TPS Go to next Step No Go to Pinpoint Test C Step 1 «• page F3-104 CHECK FOR SPARK AT PLUGS • Disconnect the spark plug wire to any accessible cylinder • Connect spark tester between spark plug wire and engine ground • Crank engine and check for spark • Reconnect the spark plug wire to the spark plug • Was spark present and consistent? 4 Yes CHECK FOR VREF AT THROTTLE POSITION (TP) SENSOR • • • • 3 ACTION Yes Go to next Step No Go to Step 11 Yes Go to Step 10 No Go to next Step SPOUT SIGNAL VERIFICATION • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • Ensure timing switch is in “Computed” position on breakout box • Measure voltage between Test Pin 36 and Test Pins 40 and 60 at the breakout box during crank • Is voltage between 3.0 and 6.0 volts? F3-97 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 5 INSPECTION • • • • • • Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS Key on Measure voltage between Test Pin 36 (SPOUT) at breakout box and battery negative post • Measure voltage between Test Pin 56 (PIP) at breakout box and battery negative post • Is voltage greater than 10.5 volts? 6 Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS Measure resistance between Test Pin 36 (SPOUT) and Test Pins 16, 20, 40, 46, 60 (short to GROUND) and 56 (short to PIP) at breakout box • Measure resistance between Test Pin 56 (PIP) and Test Pins 16, 20, 46, 60 (short to GROUND) at breakout box • Is each resistance greater than 10,000 ohms? SERIVCE short circuit to the START circuit or to the VPWR circuit in the harness REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test If vehicle does not start Go to next Step Yes RECONNECT all components Go to next Step No REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step ISOLATE SHORT(S) IN PCM • • • • • Key off Breakout box installed Disconnect PCM to breakout box Disconnect ICM and CPS Measure resistance between Test Pin 36 (SPOUT) and Test Pins 37 and 57 (short to POWER). Also Test Pins 40 and 60 (short to GROUND) at breakout box • Measure resistance between Test Pin 56 (PIP) and Test Pins 37 and 57 (short to POWER) at breakout box • Is each resistance greater than 500 ohms? 8 Yes CHECK SPOUT AND PIP CIRCUITS FOR SHORTS TO GROUND • • • • • 7 ACTION CHECK SPOUT AND PIP CIRCUIT FOR SHORT TO POWER CHECK CONTINUITY OF PIP CIRCUIT • Key off • Breakout box installed, PCM connected • Measure voltage between Test Pin 56 and Test Pin 40 /60 at breakout box at idle. • Is voltage approx. 7 volts? F3-98 F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 9 CHECK CONTINUITY OF PIP CIRCUIT • • • • • Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS sensor Measure resistance between Test Pin 56 at breakout box and PIP circuit at the following connectors as appropriate: ICM, CPS sensor • Is resistance less than 5.0 ohms? 10 ACTION Yes •a- section G No • Connect fuel pressure gauge • Note initial pressure reading • Observe pressure gauge as you pressurize fuel system. (Turn key to RUN for one second, then turn key to OFF. Wait 10 seconds. Repeat five times.) • Does fuel pressure increase? Key off Disconnect Crankshaft Position (CPS) sensor Key on, engine off Measure voltage between VPWR circuit at CPS sensor vehicle harness connector and battery negative post. • Is voltage greater than 10.5 volts? 14 «*■ page F3—107 TURN key OFF REFER to the Fuel / Engine group in the Service Manual Yes Go to next Step No Go to Step 21 Yes CHECK the electronic ignition system CHECK FOR SPARK AT COIL • Remove high tension coil wire from distributor and install spark tester • Check for spark while cranking • Reconnect high tension coil wire to distributor • Was spark present during crank? 13 No Go to Pinpoint Test D Step 1 CHECK VPWR CIRCUIT VOLTAGE • • • • 12 SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK FUEL PRESSURE WARNING: IF FUEL STARTS LEAKING, TURN Yes KEY OFF IMMEDIATELY. NO SMOKING 11 REMOVE breakout box RECONNECT all components es- section G No Go to next Step Yes • Key off • Disconnect Powertrain Control Module (PCM) 60 pin connector. Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected No • Disconnect ICM module connector • Measure resistance between Test Pin 16 at breakout box and ICM or CPS sensor vehicle harness connector IGN GND circuit • Is resistance less than 5.0 ohms? Go to next Step CHECK CONTINUITY OF IGN GND CIRCUIT SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test ISOLATION OF PROBLEM TO SPOUT CIRCUIT • • • • • • Reconnect ICM and CPS sensor, as applicable Breakout box installed Connect PCM to breakout box Timing switch to “DIST" position on breakout box Attempt to start vehicle Does the vehicle start? Yes Timing switch to “Computed” position on breakout box Go to Step 19 No Go to next Step F3-99 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 15 INSPECTION • • • • Key on, engine off Breakout box installed, PCM connected Timing switch to “DIST" position on breakout box Measure voltage between Test Pin 36 at break­ out box and battery negative post during crank • Is voltage between 3.0 and 6.0 volts? 16 Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS sensor Key on Measure voltage between Test Pin 36 (SPOUT) at breakout box and battery negative post • Measure voltage between Test Pin 56 (PIP) at breakout box and battery negative post. • Is voltage greater than 10.5 volts? EEC system OK REMOVE breakout box RECONNECT all components CHECK the electronic ignition system «■ section G No REPLACE timing switch to “Computed" position and go to next Step Yes SERVICE short circuit to the START circuit or to the START circuit or to the VPWR circuit in the harness REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step Yes Go to next Step No SERVICE short circuit REMOVE breakout box RECONNECT all components RERUN Quick Test If vehicle does not start, Go to next Step CHECK SPOUT AND PIP CIRCUITS FOR SHORTS TO GROUND • • • • • Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS sensor Measure resistance between Test Pin 36 (SPOUT) and Test Pins 16, 20, 40, 60 (short to GROUND) and 56 (short to PIP) at breakout box • Measure resistance between Test Pin 56 (PIP) and Test Pins 16, 20, 40, 46, 60 (short to GROUND) at breakout box • Is each resistance greater than 10,000 ohms? 18 Yes CHECK SPOUT AND PIP CIRCUITS FOR SHOR1 TO POWER • • • • • • 17 ACTION CHECK SPOUT SIGNAL ISOLATE SHORTS IN PCM • • • • • Key off Breakout box installed Reconnect PCM to breakout box Disconnect ICM and CPS sensor Measure resistance between Test Pin 36 (SPOUT) and Test Pins 37 and 57 (short to POWER). Also Test Pins 40 and 60 (short to GROUND) at breakout box • Measure resistance between Test Pin 56 (PIP) and Test Pins 37 and 57 (short to POWER). Also Test Pins 40 and 60 (short to GROUND) at breakout box • Is each resistance greater than 500 ohms? F3-100 Yes RECONNECT all components Go to next Step No REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM 19 CHECK PIP SIGNAL • Key off • Breakout box Installed, PCM connected • Measure voltage between Test Pin 56 and Test Pin 40 / 60 at breakout box • Crank engine, record reading • Is voltage between 3.0 and 7.0 volts? 20 Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No Go to next Step Yes REMOVE breakout box RECONNECT all components CHECK the electronic ignition system CHECK CONTINUITY OF PIP CIRCUIT • • • • • Key off Breakout box installed Disconnect PCM Disconnect ICM and CPS sensor Measure resistance between Test Pin 56 at breakout box and PIP circuit at the following connectors as appropriate: ICM, SPS sensor and / or GCM • Is resistance less than 5.0 ohms? 21 ACTION INSPECTION STEP section G No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK VPWR CONTINUITY • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box, leave PCM disconnected • CPS disconnected • Measure resistance between VPWR circuit at Test Pin 37 / 57 at the breakout box • Is resistance less than 5.0 ohms? Yes Go to Pinpoint Test B Step 1 «■ page F3-102 No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-082 F3-101 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test B STEP INSPECTION 1 • Key on, engine off • Measure voltage across battery terminals • Is voltage greater than 10.5 volts? 2 5 Go to next Step No SERVICE discharged battery REFER to Charging / Electrical Group Yes Go to next Step No SERVICE open in PWR GND circuit REMOVE Breakout box RECONNECT PCM RERUN Quick Test CHECK FOR OPEN BETWEEN SIG RTN AND PWR GND CIRCUITS AT PCM • Key off • Breakout box installed, PCM connected • Measure box installed, PCM connected Test Pins 40 and 60 at the breakout box • Is each resistance less than 5.0 ohms? 4 Yes CHECK PWR GND CIRCUIT CONTINUITY • Key off • Disconnect Powertrain Control Module (PCM) Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • Measure resistance between battery negative post and Test pins 40 and 60 at the breakout box • Is each resistance less than 5.0 ohms? 3 ACTION CHECK BATTERY VOLTAGE CHECK SIG RTN CIRCUIT CONTINUITY • Key off • Breakout box installed, PCM connected • Measure resistance between Test PIP 46 at the breakout box and SIG RTN circuit in the Data Link Connector (DLC) • Is resistace less than 5.0 ohms Yes Go to next Step No REPLACE PCM REMOVE breakout box RERUN Quick Test Yes Go to next Step No SERVICE open in SIG RTN circuit REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK KAPWR CIRCUIT VOLTAGE AT EEC POWER RELAY • • • • • Key off Breakout box installed, PCM connected Disconnect EEC power relay Key on, engine off Measure voltage between KAPWR circuit at the EEC power relay connector and battery negative post • Is voltage greater than 10.5 volts? F3-102 Yes Go to next Step No SERVICE open in KAPWR circuit between EEC power relay and battery positive post REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 6 CHECK IGNITION CIRCUIT VOLTAGE AT EEC POWER RELAY NOTE: Vehicles equipped with Power Distribution (Network) Boxes have a diode that serves as power surge protection for the Ignition Control Module (ICM) and ignition switch. A continuity check across this diode may be nec­ essary for a No Start / No DTC situation before proceeding with this Pinpoint Test • • • • Key on, engine off Breakout box installed, PCM connected. EEC power relay disconnected Measure voltage between the battery negative post and ignition switch circuit at the EEC power relay connector • Is voltage greater than 10.5 volts? 7 Key off Breakout box installed, PCM connected. EEC power relay disconnected Measure resistance between PWR GND circuit at the EEC power relay vehicle harness connec­ tor and battery vehicle harness connector and battery negative post • Is the resistance less than 10 ohms? Go to next Step No SERVICE open in ignition switch circuits REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Go to next Step No SERVICE open circuit REMOVE breakout box RECONNECT all components RERUN Quick Test Yes Go to next Step No SERVICE open in VPWR circuit between the EEC power relay connector and PCM REMOVE breakout box RECONNECT all components RERUN Quick Test Yes SERVICE open or short to ground in VPWR circuit between PCM and EEC power relay REMOVE breakout box RECONNECT PCM RERUN Quick Test No REPLACE EEC power relay REMOVE breakout box RECONNECT PCM RERUN Quick Test CHECK VPWR CIRCUIT CONTINUITY • • • • Key off Breakout box installed, PCM connected. EEC power relay disconnected Measure resistance between Test Pin 37 / 57 at the breakout box and the VPWR terminal of the EEC power relay connector • Is resistance less than 5.0 ohms? 9 Yes CHECK PWR GND CIRCUIT CONTINUITY • • • • 8 ACTION CHECK VPWT CIRCUIT VOLTAGE • • • • • Key off Breakout box installed, PCM connected. Install EEC power relay Key on, engine off Measure voltage between Test Pin 37 / 57 and Test pins 40 / 60, at breakout box • Is voltage greater than 10.5 volts? 46U0F3-082 F3-103 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test C INSPECTION STEP 1 2 ACTION CHECK VEHICLE BATTERY POWER CIRCUIT • Key off Yes Go to next Step • Disconnect Powertrain Control Module (PCM) • Inspect for damaged or pushed out pins, corro­ sion, loose wires, etc. Service as necessary • Install breakout box and connect PCM to break­ out box • Key on, engine off • Measure voltage between Test Pin 37 at the breakout box and SIG RTN circuit in the Data Link Connector. Note voltage • Measure voltage across battery terminals. Note voltage • Are both voltages greater than 10.5 volts, and are both voltages within 1.0 volt of each other? No Key off, RECONNECT sensor Go to Step 1 «■ page F3-102 CHECK VREF VOLTAGE • Key on, engine off • Breakout box installed, PCM connected • Measure voltage between Test Pin 26 and Test Pin 46 at the breakout box • What is the voltage? Greater than 6.0 volts Go to Step 4 Less than 4.0 volts Go to Step 5 Between 4.0 Go to next Step volts and 6.0 volts 3 CHECK VREF AND SIG RTN CIRCUITS FOR CONTINUITY • • • • • Key off Sensor that sent you here disconnected Breakout box installed Disconnect PCM Measure resistance between Test Pin 26 at breakout box and VREF circuit at vehicle har­ ness connector of the sensor that sensor you here • Measure resistance between Test Pin 46 at breakout box and SIG RTN circuit at vehicle har­ ness connector of the sensor that sent you here • Is each resistance less than 5.0 ohms? F3-104 Yes Reference voltage OK REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE open in VREF or SIG RTN circuits REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM INSPECTION STEP 4 ACTION CHECK FOR EXCESS VOLTAGE ON VREF CIRCUIT • • • • Key off Breakout box installed Disconnect PCM Disconnect SUPER STAR n Tester NOTE: For proper results of this test, the SUPER STAR n must be disconnected. Due to the circuitry of the STAR Tester and the vehicle, voltage can be fed to the VREF circuit giving the false indication of a short to power Yes REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test No SERVICE short to power in vehicle harness REMOVE breakout box RECONNECT PCM and sensor RERUN Quick Test • Key on, engine off • Measure voltage between Test Pin 26 at the breakout box and battery ground • Is voltage less than 0.5 volts? 5 CHECK FOR SHORTED THROTTLE POSITION SENSOR (TPS) • Key off • Breakout box installed, PCM connected • Disconnect Throttle Position sensor (TPS) from vehicle harness • Key on, engine off • Measure voltage between Test Pin 26 and Test Pin 46 at the breakout box • Is voltage less than 4.0 volts? 6 Yes Key off, RECONNECT TPS: For vehicle equipped with EGR function sensor: go to Step For all other vehicles: go to Step 7 No REPLACE TPS REMOVE breakout box RECONNECT all components RERUN Quick Test CHECK FOR SHORTED EVP / PFE / DPFE SENSOR • • • • • Key off Breakout box installed, PCM connected Disconnect EGR function sensor Key on, engine off Measure voltage between Test Pin 26 and Test Pin 46 at the breakout box • Is voltage less than 4.0 volts? Yes Key off, RECONNECT EGR function sensor; go to next Step No REPLACE EGR function sensor REMOVE breakout box RECONNECT all components RERUN Quick Test F3 ON-BOARD DIAGNOSIS SYSTEM STEP 7 INSPECTION ACTION CHECK VREF CIRCUIT FOR SHORT TO GROUND • • • • • • Key off Breakout box installed Disconnect PCM Disconnect TPS Disconnect EGR function sensor if so equipped Measure resistance between Test Pin 26 and Test Pins 20, 40, 46 and 60 at the breakout box • Is any resistance less than 1000 ohms? Yes SERVICE short to ground REMOVE breakout box RECONNECT all components RERUN Quick Test No REPLACE PCM REMOVE breakout box RECONNECT all components RERUN Quick Test 46U0F3-084 F3-106 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test D INSPECTION STEP 1 ACTION IAC CHECK • Attempt to start engine at part throttle • Will engine run smooth at part throttle? Yes Go to Code No. 412 (Step 4) •a- page F3-75 2 Go to next Step Yes Reconnect IAC solenoid Go to next Step No Go to Code No.412 (Step 4) CHECK FOR RPM DROP • • • • • 3 No Key off Connect engine tachometer Start engine Disconnect IAC solenoid Does rpm drop or stall? page F3-75 CHECK EGR VACUUM NOTE: The next two test steps will attempt to determine if the EGR system is the cause of the current symptom and / or NO START Yes For vehicles with EGRV sensors: Go to Step 5 No Go to next Step • Disconnect vacuum line at EGR control valve, and plug the vacuum line • Start engine NOTE: When verifying drive symptom, a DTC may possibly be stored in memory; erase Continuous Memory before proceeding with procedure. «• page F3-20 For Drive Symptom: - Was drive symptom eliminated? For No Start: - Does engine start? 4 CHECK EGR CONTROL VALVE • Check EGR control valve for housing leaks or EGR gasket blow-by. Service as necessary • Remove EGR control valve and check for prop­ er seating • Does EGR control valve seat properly (fully closed)? Yes RECONNECT original EGR control valve Go to Code No 172 and 173 (Step 2) «• page F3-45 No RECONNECT original EGR control valve INSPECT EGR control valve page F3-135 5 CHECK VACUUM HOSE BETWEEN EGRV SOLENOID AND EGR CONTROL VALVE • Carefully check EGR vacuum hose from EGR control valve to EGRV solenoid for obstructions, cracks, loose connectors, blockage, kinks, leaks, etc • Is vacuum hose in good condition? Yes CHECK EGRV solenoid filter for obstructions REPLACE as necessary If OK, REPLACE EGRV solenoid assembly RECONNECT vacuum hose. RERUN Quick Test No SERVICE vacuum hose as necessary RERUN Quick Test 46U0F3-085 F3-107 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test E STEP 1 INSPECTION ACTION CHECK FOR DIAGNOSTIC TROUBLE CODES (DTC) 121,122 or 123 NOTE: If vehicle is equipped with speed control, the speed control servo must be electrically dis­ connected. This prevents the speed control system from affecting the throttle plate move­ ment during Output State DTM. Rerun Quick Test or Output State DTM • Key off. • Perform Key On Engine Off Self-Test NOTE: If additional information is required on Output State DTM page F3-20 Yes Go to Quick Test and SERVICE appropriate DTC as instructed DTC 111 Go to next Step CHECK the wiring from data link connector to PCM No DTCs • Are any of these DTC’s 121,122 or 123) pre­ sent? 2 CHECK THROTTLE LINKAGE • Check throttle and throttle linkages for sticking and binding • Is throttle OK? Yes REPLACE TPS RERUN Quick Test No SERVICE as necessary RERUN Quick Test 46U0F3-Q86 F3-108 F3 ON-BOARD DIAGNOSIS SYSTEM Pinpoint Test F INSPECTION STEP 1 ACTION VEHICLE PREPARATION AND EQUIPMENT HOOKUP • • • • • Apply parking brake Place shift lever firmly in PARK Block drive wheels Turn off all electrical loads Connect appropriate test equipment to the Data Link Connector in order to run Self-Test Yes Go to next Step No REPEAT this test Step NOTE: If additional information is required for vehicle Preparation and Equipment Hookup, refer to page F3-15 • Is vehicle prepared to run Self-Test? 2 PERFORM KOEO SELF-TEST • Start engine and idle until vehicle is at operating temperature. If engine does not start or stalls, continue to perform KOEO Self-Test • Key off, wait 10 seconds • Activate KOEO Self-Test • Key on, engine off NOTE: If additional information is required for KOEO Self-Test, refer to page F3-15 Yes Go to next Step No Go to the EEC-IV DTC charts at the end of this section for Pinpoint Test direction • Record all KOEO and Continuous Memory Diagnostic Trouble Codes (DTC’s) • Key off • Is a PASS DTC “ 111” present in KOEO SelfTest? 3 CHECK BASE TIMING • • • • • Key off Transaxle in PARK Turn off electrical loads (A/C, heater, etc.) Disconnect the in-line SPOUT connector Start engine (do not use a remote starter, only use the ignition key to start engine) NOTE: If engine stalls, reconnect SPOUT con­ nector and go to Pinpoint Test Step 2 «■ page F3-107 If engine is now a NO START (will not “Fire” at all), reconnect SPOUT connector and CHECK the electronic ignition system «■ section G • Check ignition timing. (For use exhaust side plug. If timing light does not “light”, go to Step 5) page F3-13 Yes Go to next Step No ADJUST as necessary and RERUN Quick Test. If unable to adjust to specification, check proper distributor orientation, timing chain / belt, etc. «■ section B «■ section G • Is base timing within specification? **■ page F3-13 46U0F3-216 F3-109 F3 ON-BOARD DIAGNOSIS SYSTEM STEP 4 INSPECTION ACTION VERIFY PCM CONTROL OF TIMING • • • • In-line SPOUT connector disconnected Start engine and let idle Reconnect the in-line SPOUT connector Does timing change from base timing when the SPOUT connector is reconnected? Yes Go to Diagnostic next Step No Go to Diagnostic next Step While performing the Engine Running (ER) Self-Test, CHECK for DTC 213 If ER DTC 213 is present: Disregard any other codes. Refer to the EEC-IV DTC charts for proper Pinpoint Test Step direction for the DTC 213 If ER DTC 213 is NOT present: Continue as directed in Diagnostic next Step 5 PERFORM ENGINE RUNNING SELF-TEST • Start engine and idle until vehicle is at operating temperature • Turn engine off • Activate Engine Running Self-Test • Start engine Yes Go to Diagnostic next Step No Go to the EEC-IV DTC charts at the end of this section for Pinpoint Test direction FMEM: Failure Mode Effects Management NOTE: If engine stalls during Engine Running Self-Test, go to Pinpoint Test D Step 2. page F3-107 If additional information is required for Engine Running Self-Test refer to page F3-17 • Record all service codes displayed NOTE: Engine Running DTC 998 indicates vehicle is in FMEM mode and Engine Running Self-Test cannot be performed. Go to the EECIV DTC charts at the end of this section for DTC 998 direction (Refer to section K2) • Is a PASS DTC (111) received during Engine Running Self-Test? 6 ADDRESS CONTINUOUS MEMORY DTC • Was a Continuous Memory PASS DTC (11110-111) received during Key On Engine Off Self-Test? Yes Refer to page F3-167 No Go to the EEC-IV DTC charts at the end of this section for Pinpoint Test direction 46U0F3-216 F3-110 INTAKE AIR SYSTEM F3 INTAKE AIR SYSTEM COMPONENT PARTS Removal / Inspection / Installation 1. Remove in the order shown in the figure, referring to Removal Note. 2. Inspect the intake air system components and repair or replace them as necessary. 3. Install in the reverse order of removal, referring to Installation Note. 1. Fresh air duct Inspect for damage 2. Resonance chamber No.1 Inspect for damage 3. Air cleaner hosing Inspect for excessive dirt and damage 4. Air cleaner element Inspection............................. . page F3- 12 5. Mass airflow sensor Inspection............................. . page F3-160 6. Air hose Inspect for damage 7. Resonance chamber No.2 Inspect for damage Installation note................. ....page F3-112 8. Accelerator cable Inspection / Adjustment..... ....page F3-113 9. Throttle body Inspection......................... ....page F3-112 10. BAC valve Inspection.......................... .... page F3-115 11. Intake manifold bracket 12. Intake manifold page F3-112 Removal note.................... F3—111 F3 INTAKE AIR SYSTEM THROTTLE BODY Inspection 1. Check the throttle body for wear, deposits, and coolant leakage. 2. Verify that the throttle valve moves smoothly when the throttle lever is moved from fully closed to fully open. 3. Replace the throttle body if necessary. Caution • Do not rem ove the thin seal c o a tin g form the throttle valve or bore. INTAKE MANIFOLD Removal Note 1. Tighten the bolts in the order shown in the figure. Tightening torque: 19— 25 N m {1.9— 2.6 kgf m, 14— 1 8 ftlb f} 2. Refill the radiator with the specified engine coolant. (Refer to page F3-12.) 3. Check for engine coolant leakage. 16E0F1-084 RESONANCE CHAMBER No.2 Installation Note 1. Slide the hose clamp onto the hose and push it onto resonance chamber No.2. 16E0F1-360 2. Rotate the hose and hook it securely onto the locating knob. 3. Tighten the hose clamp. 16E0F1-362 F3-112 F3 INTAKE AIR SYSTEM ACCELERATOR PEDAL Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 16E0F1-086 1. Accelerator cable Inspection / Adjustment.....................below 2. Cruise actuator cable Adjustment.................................. section T 3. Retainer 4. Clip 5. Accelerator pedal 6. Return spring 7. Bracket ACCELERATOR CABLE Inspection / Adjustment 1. Verify that the throttle valve is fully closed. 2. Measure the free play of the accelerator cable. Free play: 1.5— 4.0mm {0.06— 0.16 in} 3. If not as specified, adjust the cable free play by turning stopper B while pressing lock button A with the throttle valve fully closed. 4. Reset the cable lock. F3-113 F3 IDLE-SPEED CONTROL SYSTEM IDLE-SPEED CONTROL SYSTEM DESCRIPTION ■BAC VALVE THROTTLE POSITION SENSOR STEERING PRESSURE SENSOR DATA LINK ■CONNECTOR (STO) DATA LINK CONNECTOR (STI) D IS T R IB U T O R TRANSMISSION RANGE SENSOR 36U0F1-246 The idle-speed control system controls the bypass air amount that passes through the throttle body to improve startability, warm-up, idle smoothness, and drivability. This system replaces the dashpot to control deceleration. F3-114 F3 IDLE-SPEED CONTROL SYSTEM SYSTEM OPERATION Air Valve Note • This inspection must be done with the engine cold.— Engine coolant below 20°C {68°F}. 1. Start the engine. 2. Verify that the idle speed decreases gradually as the engine warms up. 46UOF3-089 Idle Air Control Valve 1. Verify that the idle speed is within specification. (Refer to page F3-14). 2. Disconnect the idle air control valve connector. 3. If the engine speed does not decrease, replace the BAC valve. 4. Perform the after-repair procedure. (Refer to page F3-18) 46UOF3-090 IDLE AIR CONTROL VALVE Inspection 1. Disconnect the idle air control valve connector. 2. Measure resistance of the valve. Resistance: 7.7— 9.3Q (at 23°C {73°F}) 3. If not as specified, replace the BAC valve. 36U0F1-248 AIR VALVE Inspection 1. Remove the BAC valve. (Refer to page F3-111.) 2. Cool the BAC valve to below 0°C {32°F}. 3. Heat the BAC valve at point A by using a blow drier, and verify that part B moves in the direction of the arrow in the figure. 4. If not as specified, replace the BAC valve. 16E0F1-093 F3-115 F3 FUEL SYSTEM FUEL SYSTEM DESCRIPTION PRESSURE REGULATOR INJECTOR ^ ► T O FUEL TANK FROM FUEL PUMP FUEL FILTER (HIGH-PRESSURE SIDE) FUEL PUMP FUEL FILTER VALVE (TWO-WAY) FUEL TANK 36U0F1-249 This system supplies the fuel to the fuel injectors at a constant pressure. Fuel is metered and inject­ ed into the intake manifold according to injection control signals from the PCM. The system consists of the fuel tank, fuel pump, fuel filters, pressure regulator, pressure regulator control solenoid valve, fuel injectors, and fuel pump relay. F3-116 FUEL SYSTEM F3 PREPARATION SST For inspect of injector 49 L018 901 Checker, injector f 35U0FX-049 Fuel Pressure and Servicing Fuel System Warning • Fuel vapor is hazardous. It can vary easily ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system remains under high pressure when the engine is not running. Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, alw ays com plete the follow ing “Fuel Line Safety Procedures”. 46U0F3-091 Fuel Line Safety Procedure A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakage 1. When disconnecting a fuel line hose, wrap a rag around it to product against fuel leakage. 2. Plug the hose after removal. C.Use a fuel pressure gauge correctly; install hose clamps to secure the fuel pressure gauge to the fuel fil­ ter and the main hose prevent leakage. 46U0F3-093 F3-117 F3 FUEL SYSTEM SYSTEM OPERATION Fuel Pressure Hold Inspection Warning • Fuel vapor is hazardous, it can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 46U0F3-094 1. Disconnect the negative battery terminal. 2. Install a fuel pressure gauge between the fuel filter and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 16E0F1-099 4. Ground fuel pump terminal of the DLC by using jumper wire as shown. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min. Fuel pressure: More than 150 kPa {1.5 kgf/cm2, 21 psi} 8. If not as specified, perform the following inspections. • Fuel pump hold pressure. (Refer to page F3-124.) • Pressure regulator hold pressure. (Refer to page F3-126.) • Injector fuel leakage. (Refer to page F3-128.) F3-118 F3 FUEL SYSTEM Fuel Line Pressure Inspection Warning • Fuel vapor is hazardous, it can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. 46U0F3-096 1. Disconnect the negative battery cable. 2. Install a fuel pressure gauge between the fuel filter and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery cable. 4. Ground fuel pump terminal of the DLC by using jumper wire as shown. 5. Turn the ignition switch ON. 6. Measure the fuel line pressure. Fuel line pressure: 260— 320 kPa {2.6—3.3 kgf/cm2, 37— 46 psi} 7. If not as specified, perform the following inspections. • Fuel pump maximum pressure. (Refer to page F3-123.) • Fuel line clogging and restriction. • Fuel filter clogging and restriction. • Pressure regulator hold pressure. (Refer to page F3-126.) F3-119 F3 FUEL SYSTEM FUEL TANK Removal / Inspection / Installation Warning • Fuel v a p o r is h a za rd o u s . It can very e a s ily ig n ite, c au sin g s e rio u s in ju ry and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam age. Fuel can also irritate skin and eyes. To prevent this, always com plete the “Fuel Line Safety Procedures” on page F3-117. • R e p a irin g a fu e l tan k that has not been p ro p e rly steam clean e d can be d an g ero u s. Explosion or fire may cause death on serious injury. Always properly steam clean a fuel tank before repairing it. 1. Suck up the fuel from the fuel tank. (Refer to Removal Note, on page F3-121.) 2. Remove in the order shown in the figure. 3. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal, referring to Installation Note. GASKET, REPLACE N-m {kgfm, ftlbf) 46U0F3-116 1. Pre-silencer 2. Insulator 3. Connector 4. Fuel hoses Installation N o te ....................page F3-121 F3-120 5. Evaporative hoses Installation N ote....................page F3-121 6. Fuel tank straps 7. Fuel tank Inspect for cracks and corrosion FUEL SYSTEM F3 Removal Note 1. Remove the filler cap and insert a hose into the fuel tank through the filler pipe. 2. Start the pump and suck up the fuel into a container. Note • For easier work, prepare a hose of following size. Outer diameter: 13mm {0.51 in} Length: 2160mm {85.0 in} Installation Note 1. Push the ends of the main fuel hose, fuel return hose, and evaporative hoses onto the fuel tank fittin g s at least 25mm {1.0 in}. 2. Push the fuel filler hoses onto the fuel tank pipes and filler pipes at least 35mm {1.4 in}. 16E0F1-105 FUEL FILTER Replacement Low-pressure side (in-tank filter) (Refer to page F3-120.) 16E0F1-106 High-pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule. 1. Disconnect the fuel hoses from the fuel filter. 2. Remove the fuel filter and bracket. Tightening torque: 7.9—10.7 N m {80—110 kgf cm, 70— 95.4 in lbf} 3. Install in the reverse order of removal. 4. Verify that the fuel hoses are pushed fully onto the fuel filter nozzles. F3-121 F3 FUEL SYSTEM FUEL PUMP Inspection Fuel pump operation 1. Ground fuel pump terminal of the DLC by using jumper wire as shown. 2. Remove the fuel filler cap. 3. Turn the ignition switch ON. 4. Listen at the filler inlet for the operational sound of the fuel pump. 5. Install the fuel filler cap. 6. If no sound was heard, measure the voltage between the fuel pump connector terminal No.1 to a ground. Voltage: Approx. 12V 7. If not correct, check the fuel pump relay and related wiring harness. (Refer to page F3-125.) 8. If the voltage is normal, check for continuity between fuel pump connector terminal No.1 and 2. 9. If there is continuity, replace the fuel pump. 10. If there is none, repair the ground circuit. Hold pressure Perform this inspection if the fuel pressure hold inspec­ tion is not as specified. (Refer to page F3-118.) 46U0F3-101 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clam ps as shown.) 3. Connect the negative battery terminal. 16E0F1 -111 4. Ground fuel pump terminal of the DLC by using jumper wire as shown. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min.. Fuel pressure: More than 340 kPa {3.5 kgf/cm2, 50 psi} 46U0F3-102 F3-122 8. If not as specified, replace the fuel pump. F3 FUEL SYSTEM Fuel pump maximum pressure 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clam ps as shown.) 3. Connect the negative battery terminal. 16E0F1-114 4. Ground fuel pump terminal of the DLC by using jumper wire as shown. 5. Turn the ignition switch ON to operate the fuel pump. 6. Measure the pump maximum pressure. Fuel pump maximum pressure: 450—630 kPa {5.0—6.5 kgf/cm2, 64— 92 psi} 7. Turn the ignition switch OFF and disconnect the jumper wire. 8. If not as specified, replace the fuel pump. F3-123 F3 FUEL SYSTEM Removal / Installation 1. Remove the fuel tank. 2. Remove the fuel pump, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note. Note • Replace the fuel pump as an assembly. FUEL PUMP RING INSTALLATION STOPPER FUEL TANK 46U0F3-105 1. Fuel hose 2. Fuel pump ring Removal / Installation N o te ................ below 3. Fuel pump 4. Fuel pump gasket Removal Note R otate the fuel pum p ring c o u n te rc lo c k w is e and remove it. Installation Note Rotate the fuel pump ring clockw ise until the flange touches the stopper. 36U0F1-253 F3-124 F3 FUEL SYSTEM FUEL PUMP RELAY (GREEN) FUEL PUMP RELAY Inspection Operation check Listen for clicking of the fuel pump relay while turning the ignition switch from OFF to START. 46U0F3-106 Continuity inspection Check continuity between the terminals of the relay. B+: Battery positive voltage Terminal A— B Apply B+ Terminal C— D B+ not applied No Yes 36U0F1-260 FUEL PUMP RELAY (GREEN) Replacement 1. Remove the relay from main fuse block No.1. 2. Install in the reverse order of removal. 16E0F1-121 PRESSURE REGULATOR Inspection Fuel line pressure 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge between the fuel filter and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 4. Start the engine and run it at idle. 5. Measure the fuel line pressure. INSTALL CLAMPS 36U0F1-261 Fuel line pressure: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 6. Disconnect the vacuum hose from the pressure regula­ tor and measure the fuel line pressure. Fuel line pressure: 260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi} F3-125 F3 FUEL SYSTEM Hold pressure Perform this inspection if the fuel pressure hold inspec­ tion is not as specified. (Refer to page F 3-118.) 46U0F3-108 1. Disconnect the negative battery terminal. 2. Connect a fuel pressure gauge between the fuel filter and the fuel main hose. (Install clamps as shown.) 3. Connect the negative battery terminal. 16E0F1-125 4. Ground fuel pump terminal of the DLC by using jumper wire as shown. 5. Turn the ignition switch ON for 10 sec. to operate the fuel pump. 6. Turn the ignition switch OFF and disconnect the jumper wire. 7. Pinch the fuel return hose with a plier. 8. Observe the fuel pressure for 5 min.. Fuel pressure: More than 147 kPa {1.5 kgf/cm2, 21 psi} 9. If not as specified, replace the pressure regulator. Replacement Warning • When replacing fuel system components, keep sparks, cigarettes, and open flames away from the fuel area. 1. 2. 3. 4. 5. Disconnect the vacuum hose. Disconnect the fuel return hose. Remove the pressure regulator. Install a new O-ring. Install in the reverse order of removal. Tightening torque: 7.8—10.7 N m {80—110 kgf-cm, 70—95.4 in lbf} 36U0F1-262 F3-126 F3 FUEL SYSTEM INJECTOR Inspection Operation check 1. Warm up the engine and run it at idle. 2. Listen for the operational sound of each injector with a screwdriver or a sound scope. 3. If no sound is heard, measure injector resistance. (Refer to page F3-129.) 4. If the injector resistance is OK, check w iring to the injector and the voltages of the PCM terminals 35, 39, 58 and 59. 46U0F3-111 Removal / Installation Warning • When removing the fuel system components, keep sparks, cigarettes, and open flames away from the fuel area. 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal, referring to Installation Note. 7.8—10.7 N-m (80—110 kgf-cm, 70—95.4 in-lbf) 7.8 -1 0 .7 N-m 8 0 -1 1 0 kgf-cm, 70—95.4 in-lbf) N-m {kgf m, In-lbf) 46U0F3-112 1. Negative battery cable 2. Injector connector 3. Pressure regulator Inspection ................................pageF3-131 4. 5. 6. 7. Fuel hose Distribution pipe Injector Insulator F 3 -1 27 F3 FUEL SYSTEM Fuel leakage test 1. Remove the injectors together with the distribution pipe. (Refer to page F3-127.) Caution • Affix the injectors firmly to the pipe to prevent any possibility of their movement. Warning • Be extrem ely careful when working with fuel. Always work away from sparks and open flames. 3. Ground fuel pump terminal of the DLC by using jumper wire as shown. 4. Turn the ignition switch ON. 46U0F3-114 5. Tilt the injectors approx 60 degrees and verify that no fuel leaks from the injector nozzles. 6. If fuel leaks, replace the injector. Note • ONE drop per 2 m inutes’ pressurization is accept­ able. 7. Turn the ignition switch OFF and remove the jum per wire. Volume test 1. Remove the injectors together with the distribution pipe. (Refer to page F3-1 27.) 2. Affix the injectors to the distribution pipe with wire. Caution • Affix the injectors firmly to the pipe to prevent any possibility of their movement. 16E0F1-134 49 L018 901 Warning • Be extrem ely careful when working with fuel. Always work away from sparks or and open flames. 3. Connect the SST to the battery and an injector. 4. Check the injection volume with a graduated container. Injection volumes: 47—68 ml {47—68 cc, 1.41—2.04 fl-oz}/15 sec. 5. If not as specified, replace the injectors. 46U0F3-115 F3-128 FUEL SYSTEM F3 Installation Install in the reverse o rder of rem oval, re fe rrin g to Installation Note. Tightening torque Delivery pipe A: 19—25 N-m {1.9—2.6 kgf m, 14— 18 ft-lbf} B: 7.8—10.7 N-m {80—110 kgf-cm, 70—95.4 in-lbf} 36U0F1-263 O-RING INJECTOR Installation note 1. Use new injector O-rings. 2. Apply a small amount of clean engine oil to the O-rings before installing them. C0H_S WRONG GROMMET DELIVERY PIPE WRONG 16E0F1-137 3. Install new injector insulators. 4. Install the injectors. INSULATOR O-RING A DISTRIBUTION PIPE INTAKE MANIFOLD 16E0F1-138 Inspection Injector resistance 1. Disconnect the injector harness. 2. Measure resistance of the injector. Resistance: 12—16Q (at 20°C {68°F}) 3. If not as specified, replace the injector. 16E0F1-139 F3-129 F3 PRESSURE REGULATOR CONTROL SYSTEM PRESSURE REGULATOR CONTROL SYSTEM DISTRIBUTOR (NE-SIGNAL) ENGINE COOLANT TEMPERATURE SENSOR INTAKE AIR TEMPERATURE SENSOR PRC SOLENOID VALVE THROTTLE POSITION SENSOR' A if MAIN RELAY FUEL (FROM DISTRIBUTION PIPE) VACUUM FUEL (TO FUEL TANK) Operating condition Operating time Coolant temperature Intake air temperature Engine condition — — While in crank During crank Above 90°C {194°F} Above 35°C {95°F} Close throttle When the time since the engine started is less than 10 seconds. Above 90°C {194°F} Above 35°C {95°F} Close throttle and engine speed is less than equal 1,000 rpm. Engine has been started less than 2 minutes. 16E0F1-140 To prevent vapor lock of the fuel during hot restart idle, vacuum to the pressure regulator is momentarily cut and the fuel injection pressure is increased to slightly more than 284 kPa {2.9 kgf/cm2, 41.2 psi}. F3-130 PRESSURE REGULATOR CONTROL SYSTEM F3 PRESSURE REGULATOR CONTROL SOLENOID VALVE Inspection On-vehicle 1. Start the engine and run it at idle. 2. Disconnect the vacuum hose from the pressure regula­ tor. Verify that vacuum is felt. 3. Ground the solenoid valve terminal (upper side) with a jumper wire. Verify that no vacuum is felt. 4. If vacuum exists, check the solenoid valve. Solenoid Valve 1. Remove the solenoid valve. 2. Blow through the solenoid valve from port A. 3. Verify that air flows from port B. 4. Apply battery positive voltage to solenoid valve termi­ nal. 5. Blow through the solenoid valve from port A. 6. Verify that air flows from the valve air filter. 7. If not as specified, replace the solenoid valve. 36U0F1-266 F3-131 F3 EXHAUST SYSTEM EXHAUST SYSTEM COMPONENTS Removal / Inspection / Installation 1. Remove in the order shown in the figure. 2. Inspect all parts and repair or replace as necessary. 3. Install in the reverse order of removal. 1. Main silencer Inspect for deterioration and restriction 2. Pre-silencer Inspect for deterioration and restriction 3. Three way catalyst Inspect for deterioration and restriction F3-132 4. Front pipe assembly Inspect for deterioration and restriction 5. Exhaust manifold Inspect for deterioration and cracks 6. Exhaust manifold insulator 7. Heated oxygen sensor Inspection............................... page F3-164 OUTLINE OF EMISSION CONTROL SYSTEM F3 OUTLINE OF EMISSION CONTROL SYSTEM STRUCTURAL VIEW The following systems are employed to reduce CO, HC, and NOx emissions. 1. EGR control system 2. Positive crankcase ventilation (PCV) system 3. Fuel evaporative system 4. Three way catalyst xFUEL PUMP FUEL FILTER VALVE (TWO-WAY) FU EL TANK EGR CONTROL VALVE PURGE SOLENOID VALVE THREE WAY CATALYST PCV VALVE CHARCOAL CANISTER </ EGR FUNCTION SEN EGR SOLENOID VALVE (VENT) EGR SOLENOID VALVE (VACUUM) 36U0F1-077 F3-133 F3 EGR FUNCTION CONTROL SYSTEM EGR FUNCTION CONTROL SYSTEM DESCRIPTION This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combus­ tion temperature and reduce NOx emissions. This system consists of the EGR control valve, EGR function sensor, two duty-solenoid valves, PCM, and input devices. EGR SOLENOID VALVE (VACUUM) 1: D E T E C T IO N O F E N G IN E R U N N IN G C O N D IT IO N 2: D E T E R M IN A T IO N O F EGR G A S A M O U N T 46U0F3-118 SYSTEM OPERATION The EGR valve position can be precisely varied depended on engine operating conditions. Spark advance can be adjusted to compensate for EGR flow. Cold engine (coolant temperature: below 26°C {78°F}) EGR operation is stopped to improve drivability when the engine is cold. Function EGR operates when the follow conditions are met. __________________________________________ Operating condition TPS, MAF, ECTS, IAT or EGR function sensor have not failed________ While not in crank After warm up (warming up) Engine speed above 1,000 rpm Except in heavy load F3-134 F3 EGR FUNCTION CONTROL SYSTEM SYSTEM INSPECTION 1. Connect the SST to the PCM as shown. 2. Start the engine. 3. Drive the vehicle and verify that PCM terminals 12 and 33 voltage is battery positive voltage (B+) while the engine is still cold. 4. Warm up the engine to normal operating temperature. 5. Drive the vehicle and verify that the 12 and 33 voltage is set to change. 6. Stop the vehicle and run it at idle. 7. Ground the PCM terminal 33 by using a jumper wire. 8. Verify that the engine runs roughly or stalls at idle. 46U0F3-120 EGR SOLENOID VALVE (VACUUM) Inspection 1. Disconnect the vacuum hoses. 2. Blow into the solenoid valve and verify that air does not flow. 3. Disconnect the solenoid valve connector. 4. Apply battery positive voltage and a ground to the solenoid valve as shown. 5. Blow through the solenoid valve and verify that air flows. 6. If not as specified, replace the solenoid valve assembly. EGR SOLENOID VALVE (VENT) Inspection 1. Disconnect the vacuum hoses. 2. Blow into the solenoid valve and verify that air does not flow. 3. Disconnect the solenoid valve connector. 4. Apply battery positive voltage and a ground to the solenoid valve as shown. 5. Blow through the solenoid valve and verify that air flows. 6. If not as specified, replace the solenoid valve assembly. EGR CONTROL VALVE Inspection 1. Start the engine and run it at idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at more than the specified vacuum. Specification: 5.4—7.7 kPa (40—60 mmHg, 1.6— 2.3 inHg} 4. If not as specified, replace the EGR control valve. 16E0F2-172 F3-135 F3 EGR FUNCTION CONTROL SYSTEM Replacement Note • Plug the water hoses after disconnecting them. 1. Remove the EGR control valve in the sequence shown below. (1) EGR hoses (2) Vacuum hose (3) EGR function sensor connector (4) EGR control valve and gasket 36U0F2-262 Note • Before installing the EGR control valve, install new gaskets. 2. Install the EGR control valve in the reverse order of removal. EGR FUNCTION SENSOR Inspection of output voltage 1. Disconnect the PCM connector. 2. Connect the SST to the PCM as shown and connect a vacuum pump to the EGR control valve. 3. Turn the ignition switch ON. 4. Measure voltage at the terminals as shown in the table. Terminal PCM B 26 A 46 C 27 Vacuum OkPa 20.0 kPa {0 mmHg, 0 inHg} {150 mmHg, 5.90 inHg} 4.5— 5.5V 0V Approx. 0.8V Approx. 4.9V 5. If not correct at 27 terminals, check the wiring harness and 26 terminals of the PCM. Inspection of resistance 1. Disconnect the EGR function sensor connector, and connector an ohmmeter. 2. Disconnect the vacuum hose from the EGR control valve, and connect a vacuum pump. 3. Measure the resistance between the term inals as shown while vacuum is applied. Vacuum Terminal A— B 46U0F3-124 F3-136 OkPa {0 mmHg, 0 inHg} 20.0 kPa {150 mmHg, 5.90 inHg} Approx. 2.7 k£2 A— C Approx. 0.5 k£2 Approx. 2.7 k il B—C Approx. 2.4 k£2 Approx. 0.1 k£2 F3 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM DESCRIPTION The Positive Crankcase Ventilation (PCV) System cycles crankcase gases back through the engine where they one burned. The PCV valve regulates the amount of ventilating air and blow-by gas to intake manifold and prevents backfire from traveling into the crankcase. 46U0F3-125 PCV VALVE Inspection Note • Perform this inspection while the engine is cold. 1. Run the engine at idle. 2. Disconnect the PCV valve with the ventilation hose from the cylinder head cover. 3. Block the PCV valve operating. 4. Verify that vacuum is felt. 5. Remove the PCV valve. 6. Blow through the valve from port A and verify that air comes out of port B. 7. Blow through the valve from port B and verify that no air comes out of port A. 8. Replace the PCV valve if necessary. 16E0F1-155 F3—137 F3 FUEL EVAPORATIVE SYSTEM FUEL EVAPORATIVE SYSTEM DESCRIPTION The fuel evaporative system consists of fuel vapor valve, two-way check valve, charcoal canister, purge solenoid valve, PCM, and input devices. The amount of evaporative fumes introduced into the engine and burned is controlled by the solenoid valve to correspond to the engine’s operating condi­ tions. To obtain the best engine performance, the solenoid valve is controlled by the PCM. Operation The purge solenoid valve is controlled by duty signals from the PCM to perform purging of the charcoal canister. Purging is done when these conditions are met: (1) After warm-up (2) Driving in gear (3) Accelerator pedal depressed (4) Heated oxygen sensor functioning normally F3-138 FUEL EVAPORATIVE SYSTEM F3 SYSTEM OPERATION 1. Warm up the engine to normal operating temperature and run it at idle. 2. Disconnect the vacuum hose from the solenoid valve and plug it as shown in the figure. Verify that no vacu­ um is felt at the solenoid valve. 3. If not as specified, check the solenoid valve. 16E0F1-157 PURGE SOLENOID VALVE Inspection 1. Disconnect the vacuum hoses from the solenoid valve. 2. Verify that no air flows through the valve. 46U0F3-127 3. Disconnect the solenoid valve connector and supply battery positive voltage as shown in the figure. 4. Verify that air flows through the valve. 5. If not as specified, replace the solenoid valve. 26U0F1-267 FUEL VAPOR VALVE Inspection 1. Verify that air flows through the valve from port A as shown in the figure. 16E0F1-160 2. Verify that no air flows through the valve from port A as shown in the figure. 3. Replace the fuel vapor valve if necessary. 16E0F1-161 F3-139 F3 FUEL EVAPORATIVE SYSTEM CHECK VALVE (TWO-WAY) Inspection 1. Remove the valve. 2. Check the operation of the valve by using a vacuum pump. Apply approx. 3.5 kPa {26 mmHg, 1.0 inHg} vacuum at port A Valve opens Apply approx. 5.9 kPa {44 mmHg, 1.7 inHg} vacuum at port B Valve opens 36U0F1-256 CHARCOAL CANISTER Inspection 1. Visually check for damage. 2. Replace the charcoal canister if necessary. 16E0F1-163 F3-140 FUEL-CUT CONTROL SYSTEM F3 FUEL-CUT CONTROL SYSTEM DESCRIPTION This system is used to improve the fuel economy, to prevent engine bucking during deceleration, and to protect the engine from overreving. Deceleration fuel-cut (x 10J rpm) 16E0F1-164 F3-141 F3 FUEL-CUT CONTROL SYSTEM PREPARATION SST 46U0F3-128 F3-142 FUEL-CUT CONTROL SYSTEM F3 SYSTEM OPERATION Breakout Box 1. Connect a tachometer to the number one spark plug wire. 2. Connect the SST to the PCM. 3. Warm up the engine to normal operating temperature and rum it at idle. Warning • Confirm that the transaxle is in P range. 4. Measure voltage of the terminal 35, 39, 58 and 59. (Refer to page F3-149.) 5. Increase the engine speed to 4,000 rpm and then sud­ denly release the throttle. 6. Verify that the terminals voltage while the engine speed is above approx. 1,500 rpm on deceleration. Caution • Do not hold maximum rpm over 3 sec. 7. Increase the engine speed and verify that the maximum rpm does not exceed approx. 6,800 rpm. 46U0F3-130 F3 A/C CUTOFF SYSTEM A/C CUTOFF SYSTEM DESCRIPTION The A/C relay is controlled by the PCM with an output signal and is used as circuit cut-off for the compressor magnetic clutch when the relay activated. CRANKSHAFT POSITION SENSOR PCM THROTTLE POSITION SENSOR AIR CONDITIONINGSENSOR DETERMINATION OF A1C CUT OFF A/C RELAY IGNITION SWITCH (START) IGNITION SWITCH TRANSMISSION RANGE SENSOR- CONDENSOR FAN MOTOR ENGINE COOLANT ■ TEMPERATURE SENSOR MAGNETIC CLUTCH © Q BATTERY 46U0F3-132 Operation The A/C clutch operation is cancelled under the conditions below. Engine condition After engine starting Throttle valve fully open Acceleration from idle Coolant temp, above 117°C {242°F} Purpose Cutoff period Improve engine starting Approx. 4 sec. Approx. 8 sec. Improve drivability Prevent engine overheat Approx. 2 sec. Until coolant temp, decrease below 107°C {224°F} SYSTEM OPERATION 1. Turn the ignition switch ON. 2. Turn the blower switch and air conditioning sensor ON. 3. Start the engine. 4. Verify that the condenser fan stops for approx. 4 sec. after the engine starts. F3-144 F3 COOLANT FAN CONTROL SYSTEM DECHOKE CONTROL SYSTEM SYSTEM OPERATION 1.Turn the ignition switch to START and verify that the injector operating sound is heard. 2. Depress the accelerator pedal fully and turn the ignition switch to START. Verify that no injector operating sound is heard. COOLANT FAN CONTROL SYSTEM DESCRIPTION To improve reliability, the coolant fan is controlled by the PCM. This system consists of the coolant fan motor, fan relays, PCM and input devices. PCM ECTS [ENGINE COOLANT TEMPERATURE SENSOR] ____ ^ AIR CONDITIONING SENSOR f CRANKSHAFT------------------POSITION SENSOR VEHICLE SPEEDOMETER SENSOR IGNITION SWITCH — •I'M — BATTERY 46U0F3-133 Coolant fan operation Engine condition Fan relay No.1 Fan relay No.2 Fan relay No.3 Fan speed Coolant temperature above 98°C {208°F} ON OFF OFF LOW Air conditioning sensor ON ON OFF OFF LOW Coolant temperature above 109°C {228°F} ON ON ON HIGH ECTS malfunction ON ON ON HIGH HEAVY LOAD (engine speed above 2,500 rpm and vehicle speed blow 40 km/h {25 MPH}) ON ON ON HIGH F3-145 F3 COOLANT FAN CONTROL SYSTEM SYSTEM OPERATION 1. Start the engine, and run it at idle. 2. Verify that the coolant fan operates at low speed when engine coolant tem perature 98°— 109°C {208°F — 228° F}. 3. Racing the throttle and verify the coolant fan operates at high speed when engine coolant temperature above 109°C {228°F}. 4. If not as specified, inspect the input signals and fan relays. 46U0F3-131 CONTROL SYSTEM F3 CONTROL SYSTEM PREPARATION SST F 3-147 F3 CONTROL SYSTEM STRUCTURAL VIEW 46U0F3-135 1. Powertrain control module (PCM) Removal / Installation ........... page F3-149 Inspection .............................. page F3-149 2. Mass airflow sensor Inspection .............................. pageF3-160 Removal / Installation ........... page F3-160 3. Crankshaft position sensor Inspection .............................. pageF3-161 4. Engine coolant temperature sensor Removal................................. page F3-162 Inspection .............................. pageF3-162 Installation.............................. page F3-162 5. Intake air temperature sensor Inspection .............................. pageF3-162 Replacement..........................page F3-162 F3-148 6. Throttle position sensor Inspection ........................ ..... page Adjustment....................... ..... page Replacement.................... ..... page 7. Heated oxygen sensor Inspection ........................ ..... page Replacement.................... ..... page 8. Main relay Inspection ........................ ..... page 9. Coolant fan relays Inspection ........................ ..... page 10. Steering pressure sensor Inspection .............................. page Replacement.................... ..... page F3-163 F3-163 F3-163 F3-164 F3-164 F3-165 F3-165 F3-166 F3-1 66 CONTROL SYSTEM F3 POWERTRAIN CONTROL MODULE (PCM) Removal / Installation Caution • Powertrain control module is sensitive to static electrical charges. If exposed to these charges, damage may result. If service of powertrain control module is required, use the following safeguards to avoid damage to components. 1. Leave the PCM in their original packaging until ready to install in vehicles. 2. Avoid touching PCM connector pins. 3. Avoid laying modules on nonconductive surfaces. 1. Remove in the order shown in the figure, reffering to Removal Note. 2. Install in the reverse order of removal. 46U0F3-136 1. Negative battery cable 3. PCM connector 2. Console 4. PCM Removal Note • The PCM stores information about vehicle operating conditions and uses this information to compen­ sate for component tolerance. When an emission related component is replaced, Keep Alive Memory (KAM) should be cleared to erase the information stored by the PCM from the original com­ ponent. Inspection Breakout box 1. Disconnect the PCM connectors. 2. Connect the SST to the PCM as shown. 3. Measure the voltage at each terminal. (Refer to pages F3-150 through F3-159.) 4. If any PCM terminal voltage is incorrect, check the related input or output devices and wiring. If no prob­ lem is found, replace the PCM. (Refer to above.) 46U0F3-137 F3-149 F3 CONTROL SYSTEM Terminal voltage (reference data) B+: B attery p ositive vo ltag e Terminal Input Output C o n nected to V o lta g e (V) Battery Constant O Stoplight switch Brake pedal released O Vehicle speedometer sensor (+) Idle (AC range) 48 km/h {30 mph} (AC range) Approx. 8.0 88 km/h {55 mph} (AC range) Approx. 12.7 O O Ignition control module Brake pedal depressed For backup B+ Approx. 0.1 Ignition switch ON B+ Idle 0.2—0.5 Idle (AC range) Approx. 0.5 (AC range) Approx. 0.8 88 km/h {55 mph} (AC range) Approx. 1.4 O Vehicle speedometer sensor (VSS) (-) Constant (AC range) Approx. 0.1 O Engine coolant temprature sensor Engine coolant temperature 20°C {68°F} 2.5 After warmup 0.5 Fuel pump relay .✓ During cranking or at idle Mass airflow sensor Constant O Air conditioning sensor A/C sensor ON (A/C ON) Purge solenoid valve Ignition switch ON O Ignition switch ON Ignition switch ON O 11 R em ark B+ 48 km/h {30 mph} Turbine shaft speed (TSS) sensor O 10 T est condition B+ A/C sensor OFF (A/C OFF) Driving Ignition switch ON and blower switch ON B+ B+ Oscilloscope V o lta g e (V ) 40 20 VB 0 10 m s 12 O EGR solenoid valve (vent) [EGRA] Idle Driving B+ i'l, f 13 14 O O F3-150 Coolant fan relay (LOW) Daytime running light After warm up Oscilloscope r Electric fan relay ON Electric fan relay OFF B+ ON (Parking brake not applied) OFF (Parking brake applied) B+ Ignition switch ON Canada only F3 CONTROL SYSTEM B+: Battery positive voltage Incorrect voltage Possible cause Always OV • ROOM 15A fuse burnt • Open circuit in wiring from ROOM 15A fuse to PCM terminal 1 • Refer to Code No.512 Troubleshooting «• page F3-22 Always OV (stoplights OK) • Open circuit in wiring from stoplight switch to PCM terminal 2 Always OV or B+ • Refer to Code No.536 Troubleshooting cr page F3-22 • Refer to Code No.452 Troubleshooting page F3-22 • Open or short circuit in wiring from vehicle speed sensor to PCM terminal 3 Always OV • Short circuit in wiring from ignition control module to PCM terminal 4 • Refer to Code No.211,212, 213 Troubleshooting a-p a g e F 3-22 Always B+ • Open circuit in wiring from Ignition control module to PCM terminal 4 • Open circuit in wiring from Ignition control module to ground PCM malfunction Always OV » Section K2 Always OV • Refer to Code No.452 Trouble shooting • Poor connection at ground terminal • Open circuit in wiring from PCM Always OV or 5V • Refer to Code No.116, No,117 and No.118 Always B+ or below 2.5V • Engine 15A fuse burnt • Open or short circuit in wiring from fuel pump relay wire to PCM terminal 8 Always OV • Refer to Code No. 157, No.158, and No. 159 Troubleshooting «• page F3-22 • Open circuit in wiring from mass airflow sensor to PCM terminal 9 Always below 2.5V (blower fan OK) • Air conditioning sensor malfunction «• Refer to 1994 626/MX-6 BETM. • Short circuit in wiring from air conditioning sensor to PCM terminal 10 • Poor connection at PCM connector Always B+ (blower fan OK) • Air conditioning sensor malfunction ** Refer to 1994 626/MX-6 BETM. • Open circuit in wiring from air conditioning sensor to PCM terminal 10 • Open circuit in wiring from air conditioning sensor to blower control switch Always OV or B+ • Refer to Code No.565 Troubleshooting «■ page F3-22 • Open or short circuit in wiring from purge solenoid valve to PCM terminal 11 Always OV or B+ • Refer to Code No.571 Troubleshooting Always OV or B+ (Coolant fan OK) • Open or short circuit in wiring from fan relay to PCM terminal 13 • Refer to Code No.564 Troubleshooting «■ page F3-22 Always B+ • Daytime running relay malfunction • Combination switch malfunction • Open circuit in wiring from daytime running relay to PCM terminal 14 Always OV «■ page F3-22 «• page F3-22 <&■ page F3-22 F3-151 F3 CONTROL SYSTEM B+: Battery positive voltage Termlna Input Output Connected to 15 16 Voltage (V) Remark — — — — — — — — Ground Constant 0 o MILor STO: OFF B+ MILor STO: ON 0 17 18 19 20 21 Test condition — — — Data link connector (MIL/STO) — — — — — — — — — — — — — — — — — B+ — 9.6 - 9.7 — o o 22 Idle air control valve Fuel pump relay o Rear window defroster relay o Distributor (GSignal) 23 24 Ignition switch ON Idle(after warm up) Ignition switch ON During cranking or at idle B+ Below0.5 Rear windowdefroster switch ON Rear windowdefroster switch OFF Ignition switch ON Oscilloscope Idle Below 1.0 B+ 0or5 — Ignition switch ON Voltage (V) 0 20ms O 25 26 27 O 28 o 29 o Intakeairtem­ perature sensor o Reference voltage (Vref) EGRfunction sensor Steering pressure sensor Engine coolant temperature 20°C {68°F} After warmup Ignition switch ON Idle 3.4—5.0 Ignition switch ON P/SONat idle P/S OFFat idle B+ Below 1.0 B+ Blower switch Blower switch OFF, 1st or 2nd position Blower switch 3rd or 4th position F3-152 (1994 626/MX-6) Approx. 3 Approx. 1.5 4.5—5.5 B+ Ignition switch ON — — — Ignition switch ON Below 1.0 Revised 3/94 NEW — B+ F3 CONTROL SYSTEM B+: Battery positive voltage Possible cause Incorrect voltage — — Above OV • Poor contact at ground terminal • Open circuit in wiring from PCM to ground MIL always ON • MIL malfunction • Short circuit in wiring instrument cluster to PCM terminal 17 MIL never ON always B+ • MIL malfunction • Open circuit in wiring from instrument cluster to PCM terminal 17 — — — — — — Always OV or B+ • Refer to Code No.411 and No.412 Troubleshooting page F3-22 Always OV or B+ • Engine 15A fuse burnt • Open or short circuit in wiring from fuel pump relay wire) to PCM terminal 22 Always OV • Short circuit in wiring from rear window defroster switch to PCM terminal 23 Always B+ • Open circuit in wiring from rear window defroster switch to PCM terminal 23 Always OV or 5V • Refer to Code No.211, No.212 and No.213 Troubleshooting «■ page F3-22 Always below 1,5V or above 3V • Refer to Code No.112, No.113, and No.114 «• page F3-22 Always OV • Poor connection at PCM connector • Short circuit in wiring from PCM terminal 26 to throttle sensor Always OV • Refer to Code No.327, No.332, No.337 Troubleshooting page F3-22 • Open or short circuit in wiring from EGR function sensor to PCM terminal 27 Always OV • Steering pressure sensor malfunction Always B+ • Steering pressure sensor malfunction «*■ page F3-166 • Short circuit in wiring from steering pressure switch to PCM terminal 28 or ground Always below 1.OV (blower fan OK) • Short circuit in wiring from blower switch to PCM terminal 29 Always B+ (blower fan OK) • Open circuit in wiring from blower switch to PCM terminal 29 «■ page F3-166 • Short circuit in wiring from steering pressure switch to PCM terminal 28 46U0F3-212 F3-153 F3 CONTROL SYSTEM B+: B attery p ositive vo ltag e T est condition Terminal Input Output C o n nected to V o lta g e (V) R em ark 30 31 O Coolant fan relay (HIGH) Ignition switch ON Idle B+ Approx. 0.6 Engine coolant temp. Above 100°C {212°F}___________ Other 32 O PRC Solenoid valve 33 O EGR solenoid valve (vacu­ um) [EGRV] B+ Hot condition: Engine coolant temp, above 70°C {158°F} and intake air temp, above 75°C {167°F} for 120 sec. after engine starting_________________ ______ Approx. 0 Other B+ Idle B+ Driving Oscilloscope 5 < o '7■-"l- 85 “ 5 34 O Hold lamp Idle SWOFF B+ SW ON (HOLD) 35 O Injector No.4 Below 1.0 Ignition switch ON B+ Idle Oscilloscope m Voltmeter 36 O 37 38 39 O O SPOUT connector 13.8 Connector: connected B+ Connector: disconnected MAIN RELAY Ignition switch ON Electronic pressure control (EPC) solenoid Injector (No.2) Idle B+ Approx. 9.0 48 km/h {30 mph} Approx. 10.0 88 km/h {55 mph} Approx. 12.0 Ignition switch ON B+ Idle (after warm up) Oscilloscope d±b:i r± t! Vb 5 ms Engine speed above 2,000 rpm on deceleration (after warmup) F3-154 m Voltmeter 13.8 Voltmeter B+ Ignition switch ON F3 CONTROL SYSTEM B+: Battery positive voltage Incorrect voltage Possible cause — — page F3-22 Always OV or B+ • Refer to Code No.563 Troubleshooting Always OV or B+ • Refer to Code No.554 Troubleshooting Always OV • Refer to Code No.572 Troubleshooting ra? page F3-22 • Open circuit in wiring from EGR valve (vacuum) solenoid to PCM terminal 33 Always OV or B+ • Open or short circuit in wiring from hold lamp O/D off lamp to PCM terminal 34 • Hold switch O/D off switch malfunction Always OV or B+ • Open or short circuit in wiring from injector No.4 PCM terminal 35 Always OV or B+ • Open or short circuit in wiring from SPOUT connector to PCM terminal 36 Always OV • PCM power relay malfunction • Open or short circuit in wiring from PCM power relay to PCM terminal 37 Always OV or B+ • Open or short circuit in wiring from EPC solenoid to PCM terminal 38 Always OV • Main relay malfunction >®-page F3-165 • Open or short circuit in wiring from injector to PCM terminal 39 Always B+ • Open or short circuit in wiring from injector No.2 to PCM terminal 39 w page F3-22 46U0F3-213 F3 CONTROL SYSTEM B+: Battery positive voltage Test condition Terminal Input Output Connected to 40 — 41 O — Ground Constant Hold switch HOLD SW Release Push O 42 43 — 44 o Headlights switch — Voltage (V) Remark 0 — 9.5 Below 1.0 Headlights ON B+ Headlight OFF 0 Ground Constant 0 Heated oxy­ gen sensor (H02S) Idle — Below 1.0 Ignition ON Cold engine Approx. 0 After warm up 0.1—0.9 — Inceasing engine speed (after warm up) Deceleration 46 — — 47 o 45 48 49 50 51 52 53 54 F3-156 — — o o o o o o o — Approx. 0.8 0 — — 0 Ground Constant Throttle posi­ tion sensor (TPS) Accelerator pedal released Approx. 0.5 Accelerator pedal fully depressed Approx. 4.1 Data link connector (STI) Idle Transmission fluid tempera­ ture (TOT) sensor After warm up (Idle) Mass airflow sensor Ignition switch ON Idle 0.6— 0.7 Shift solenoid 1 (SS1) ON B+ OFF 0 ON B+ OFF 0 Shift solenoid 2 (SS2) — — Ignition switch ON 3.3—4.8 — Approx. 0.7 — Transmission range sensor Constant A/C relay Ignition switch ON 0 B+ — B+ A/C sensor ON at idle Below 1.0 A/C sensor OFF at idle B+ — F3 CONTROL SYSTEM B+: Battery positive voltage Incorrect voltage Possible cause Above OV • Poor connector at ground terminal • Open circuit in wiring from PCM terminal 40 Always below 1.OV or B+ • Open or short circuit in wiring from Hold switch to PCM terminal 41 Always below 1,0V (Headlights OK) • Open or short circuit wiring from headlights switch to PCM terminal 42 Above OV • Poor connector at ground terminal • Open circuit in wiring from PCM terminal 43 Always OV or 1.OV after warm up • Refer to Code No.172,173,179,181 Troubleshooting — » page F3-22 — Above OV • Poor contact at ground terminal • Open circuit in wiring from PCM terminal 46 Always OV or 5V • Refer to Code No.121, No.122 and No.123 Troubleshooting «• page F3-22 Always below 1.OV • Short circuit in wiring from data link connector teminal STI to PCM terminal 48 Always B+ • Open circuit in wiring from data link connector terminal STI to PCM terminal 48 • Open circuit in wiring from data link connector terminal GND to ground Always OV • Refer to section K2 Always OV or B+ • Refer to Code No.157,158, 159 Troubleshooting Always OV or B+ • Refer to section K2 Always OV or B+ • Refer to section K2 Always OV • Refer to section K2 Always below 1.OV or B+ • Refer to Code No.559 Troubleshooting «*• page F3-22 «■ page F3-22 46U0F3-214 F3-157 F3 CONTROL SYSTEM B+: Battery positive voltage F3-158 (1994 626/MX-6) Revised 3/94 F3 CONTROL SYSTEM B+: Battery positive voltage Possible cause Incorrect voltage Always OV • Refer to section K2 Always OV or 5V • Refer to Code No.211 Troubleshooting Always OV • Main relay malfunction Always OV • Open or short circuit in wiring from injector No.3 to PCM terminal 58 Always B+ • Open or short circuit in wiring from injector No.1 to PCM terminal 59 Always OV • Poor contact at ground terminal • Open circuit in wiring from PCM to ground «*■ page F3-22 page F3-165 • Open or short circuit in wiring from main relay to PCM terminal 57 46U0F3-215 F3-159 F3 CONTROL SYSTEM MASS AIRFLOW SENSOR (MAF) (HOT WIRE TYPE) Removal 1. Disconnect the MAF connector. 2. Disconnect the Intake air temperature (IAT) sensor con­ necter. 3. Loosen the MAF clamp at the air duct. 4. Remove air cleaner housing upper cover. 5. Remove the four MAF mounting bolts. 6. Remove the MAF from air cleaner housing upper cover. 46U0F3-138 Installation To install, reverse order of removal. 46U0F3-139 Inspection Caution • Do not drop or subject the sensor to sharp shocks. • Do not put or allow anything in the sensor. 46U0F3-140 1. Check for damage contaminated of the sensor. .j*v. I 46U0F3-141 2. Disconnect the PCM connector. 3. Connect the SST. Breakout box and Adapter to the PCM as shown. 4. Connect voltmeter to the breakout box terminal 50 and 9. 5. Measure the voltage of terminal 50. HARNESS Specification 49 UN01 46U0F3-142 F3-160 Condition Ign— ON (Engine stopped) Idle Terminal voltage (V) 0 0.6— 0.7 6. If not as specified, replace the mass airflow sensor. F3 CONTROL SYSTEM CRANKSHAFT POSITION SENSOR Inspection 1. Remove the distributor. (Refer to section G.) Warning • Before performing following operation, discon­ nect the injector connector. • When checking the crankshaft position sensor, never connect the distributor connector (6-pin). 36U0F1-116 2. Connect the distributor connector (4-pin) as shown in figure. 3. Disconnect the injector connector. 4. Connect the SST to the PCM as shown. (Refer to page F3-160.) 5. Turn the ignition switch ON. 6. Rotate the distributor drive by hand and measure the output voltage. 46U0F3-143 Specification SIGNAL SIGNAL o v Voltage Signal NE Terminal 56 B+ (4 pulse) G 24 B + (1 pulse) _jh ________r u 46U0F3-144 7. After the inspection, install the distributor. (Refer to section G.) 8. Start the engine and adjust the ignition timing. (Refer to page F3-13.) Ignition timing: BTDC 9— 11° 9. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19—25 N m {1.9—2.6 kgf-m, 14— 18 ft lbf} Revised 3/94 (1994 626/MX-6) F3-161 F3 CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal Note • The engine coolant temperature sensor is at the rear of the engine. 1. Disconnect the engine coolant temperature sensor con­ nector. 2. Remove the engine coolant temperature sensor. Inspection 1. Place the sensor in water with a thermometer and heat the water gradually. 2. Measure resistance of the sensor. Water temperature Resistance (kft) 20°C {68°F} 35.473—39.207 60°C{140°F} 7.171— 7.925 80°C {176°F} 1.131— 1.251 3. If not as specified, replace the engine coolant tempera­ ture sensor. Installation 1. Install a new washer and the engine coolant tempera­ ture sensor. Tightening torque: 25—29 N-m {2.5—3.0 kgf-m, 19—21 ft Ibf} 2. Connect the engine coolant temperature sensor connector. 3. Start the engine and check for coolant leakage. INTAKE AIR TEMPERATURE (IAT) SENSOR Inspection 1. Disconnect the intake air thermosensor connector. 2. Check resistance of the sensor. 3. If not as specified, replace the intake air temperature sensor. Water temperature 20°C {68°F} Resistance (k£i) 35.473—39.207 60°C{140°F} 7.171— 7.925 80°C{176°F} 1.131— 1.251 46U0F3-149 Replacement 1. Disconnect the intake air thermosensor connector. 2. Remove the sensor. 3. Install the sensor and tighten it to the specified torque. Tightening torque: 7.9— 11.7 N-m {80— 120 kgf-cm, 70— 104 in lbf} 36U0F1-123 F3-162 F3 CONTROL SYSTEM THROTTLE POSITION SENSOR Inspection 1. Disconnect the connector from the throttle position sen­ sor. 2. Connect an ohmmeter between throttle position sensor terminal B and C. 36U0F1-124 3. Verify that the resistance increases linearly according to the throttle valve opening angle. , RESISTANCE 5 (kfl) Throttle valve condition 4 3 Resistance (kft) Closed throttle position Below 1 Wide open throttle Approx. 5 2 1 THROTTLE VALVE OPENING ANGLE 4. If not as specified, adjust the throttle position sensor. u WIDE OPEN THROTTLE 46U0F3-150 Adjustment 1. Connect the SST to the PCM as shown. (Refer to page F3-160.) 2. Connect voltmeter to breakout box terminals 47 and 46. 3. Loosen the sensor screws. 4. Ignition switch ON. 5. Adjust the sensor output voltage by rotating the sensor. Specification Condition Terminal voltage (V) Accelerator pedal released Approx. 0.5 Accelerator pedal fully depressed Approx. 4.1 6. If not as specified, replace the throttle position sensor. Replacement 1. Disconnect the throttle position sensor connector. 2. Remove the screws. 3. Remove the throttle position sensor. 4. Install the throttle position sensor. 5. Adjust the throttle position sensor output voltage. (Refer to above.) F3-163 F3 CONTROL SYSTEM HEATED OXYGEN SENSOR Inspection of Terminal voltage 1. Warm up the engine to normal operating temperature and run it at idle. 2. Disconnect the heated oxygen sensor connector. 3. Connect a voltmeter between the heated oxygen sen­ sor and a ground. 4. Run the engine at 3,000 rpm until the voltmeter indi­ cates approx 0.55V. 36U0F1-126 5. Increase and decrease the engine speed suddenly sev­ eral. Verify that when the speed is increased, the meter reads 0.5— 1.0V, and when the speed is decreased it reads 0V—0.5V. 6. If not as specified, replace the heated oxygen sensor. 36U0F1-127 Inspection of Heated Oxygen Sensor Heater 1. Turn the ignition switch OFF. 2. Disconnect the heated oxygen sensor connector. 3. Connect an ohmmeter between heated oxygen sensor terminals as shown. 4. Measure the resistance of the heater. Specification: Approx 6ft (at 20°C {68°F}) 5. If not as specified, replace the heated oxygen sensor. Replacement 1. Disconnect the heated oxygen sensor connector. 2. Remove the heated oxygen sensor. 3. Install in the reverse order of removal. Tightening torque: 30—49 N-m {3.0—5.0 kgfm, 22—36 ft lbf} 36U0F1-132 F3-164 F3 CONTROL SYSTEM MAIN RELAY Inspection 1. Verify that main relay clicks when the ignition switch is turned ON and OFF. 2. Apply battery positive voltage (B+) to terminal A and ground terminal B of the relay. 3. Check continuity of the relay as shown. B+: Battery positive voltage Terminals C— D B+ not applied No continuity B+ applied Continuity 36U0F1-135 4. If not as specified, replace the main relay. COOLANT FAN RELAYS Inspection 1. Remove the relays. 2. Apply battery positive voltage (B+) to terminal A and ground terminal B of the each relays. 3. Check continuity of the relay as shown. B+: Battery positive voltage Terminals C— D B+ not applied B+ applied No continuity Continuity 4. If not as specified, replace the coolant fan relay. 46U0F3-153 V F3-165 F3 CONTROL SYSTEM STEERING PRESSURE SENSOR Inspection 1. Disconnect the steering pressure sensor connector. 2. Connect an ohmmeter to the sensor. 3. Start the engine and run it at idle. Check continuity of the sensor while turning the steering wheel. Steering wheel Continuity Turning Yes Not turning No 4. If not as specified, replace the steering pressure sensor. Replacement Replace the steering pressure sensor as shown in the figure. Tightening torque: 17— 22 N m {1.7— 2.3 kg fm , 13— 16 ft-lbf) 36U0F1-141 TROUBLESHOOTING GUIDE F3 TROUBLESHOOTING GUIDE USING THIS SECTION Introduction Most of the fuel and emission control systems are electronically controlled, often making it difficult to diagnose problems, especially intermittent problems. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a drivability complaint. The customer is often a good source of information on such problems, especially the intermittent ones. Through a talk with the customer, you will usually find out what the symptoms are and under what conditions they occur. Work flow CHECK IN LISTEN TO CUSTOMER COMPLAINTS I REFER TO TROUBLESHOOTING PAGE THAT.........................DIAGNOSTIC INDEX CORRESPONDS TO ACTUAL SYMPTOM (Refer to page F3-169) -► CHECK FOR WHAT IS BAD IN SYSTEM.............................. INSPECTION CHECK FOR WHAT PART IS BAD. ACTION I REPAIR/REPLACE. -DETERMINE IF TROUBLE HAS BEEN ELIMINATED No Yes | CHECK OUT 46U0F3-220 Diagnostic index F3-167 F3 TROUBLESHOOTING GUIDE Troubleshooting chart ENGINE STALLS DESCRIP­ TION •ID L E WITH A /C , P/S, a n d /o r E/L ON •IO LE WHEN SH IFTED FROM N OR P TO OTHER RANGES • Engine s;ops unexpected'/ when A/C, P/S. and/or E /l turned ON at idle • Engine stops unexpected1/ when shifted from N or P to other ranges at idle • Idle condition is normal when A/C. P/S. and E/L are OFF and in N and P (TRO UBLESHO O TING HINTS) © Monitor switch functions (SST) • A/C switch • Headlight switch • Rear w indow defroster STEPl • Blower switch © Solenoid valve (ISC) • Solenoid valve stuck INSPECTION Are switches correct when checked by using SelfDiagnosis Checker monitor lam p while ignition switch ON? r r page F 2 -4 4 • Blower switch • H e a d lig h t s w itc h • Rear w indow defroster switch • Selector lever Go to next step Lamp not ON/OFF with specified switch Check for cause (Reler to specified check sequence) ro - page F 2 -4 5 SYSTEM SELECTOR SELECT SW: A is "OCT displayed on Self-Diagnosis Checker with ignition switch ON? z r page F 2 -1 8 Service C ode No. d is p la y e d Check for cause (Reler to specified check sequence) S E L F -D IA G N O S IS 16E0F1-256 DESCRIPTION: Further describes the system. Confirm that the chart addresses the actual symptom before begin­ ning troubleshooting. TROUBLESHOOTING HINTS: This describes the possible point of malfunction. STEP: This shows the order of troubleshooting. Proceed with troubleshooting as indicated. INSPECTION: This describes and inspection to quickly determine the malfunction of parts. If a detailed procedure is necessary to perform the INSPECTION, refer to the page specified by the “ra*" mark. ACTION: This recommends the appropriate action to take as a result (Yes/No) of the INSPECTION. How to perform the action is described on the reference page specified by the “«*■” mark. 16E0F1-257 F3-168 TROUBLESHOOTING GUIDE F3 DIAGNOSTIC INDEX 5 TROUBLESHOOTING ITEM TROUBLE Main fuse Will not crank Hard start/long crank/erratic start/ erratic crank After start Engine stalls At idle Cranks normally but will not start 6 Slow return to idle 7 8 Engine runs rough/rolling idle Fast idle/runs on 9 Low idle/stalls during deceleration 10 Engine stalls/ quits Acceleration/cruise Engine runs rough Misses Buck/jerk Acceleration/cruise No. 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Hesitation/ stumble Surges Backfires Lack/lose of power Knocking/ pinging At idle Acceleration/cruise Acceleration/cruise deceleration Acceleration Acceleration/cruise Idle/acceleration/ deceleration Acceleration/cruise Acceleration/cruise Poor fuel economy Emission compliance MIL never on Upshift/downshift/ Automatic engagement transmission concerns High oil consumption/leaks Overheating Cooling system concerns Runs cold Cooling system concerns Exhaust smoke Fuel odor (in engine compartment) Engine noise Vibration concerns (engine) A/C does not work A/C always on/ A/C compressor runs continuously A/C does not cut off under wide open throttle conditions Exhaust sulphur smell Intermittent concerns n P « r R ID T ID K I PAGE — F3-171 F3-172 F3-173 Starter does not work Starter cranks engine at normal speed but engine requires excessive cranking time before starting Engine stops unexpectedly at idle and/or after start Starter cranks engine at normal speed but engine will not run Engine takes more time than normal to return to idle speed Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake Idle speed too slow and excessive engine shake Engine speed continues at fast idle after warm-up Engine runs after ignition switch is turned off Engine stops unexpectedly at beginning of deceleration or recovery from deceleration Engine stops unexpectedly at beginning of acceleration or during acceleration Engine stops unexpectedly while cruising Engine speed fluctuates during acceleration or cruising Engine misses during acceleration or cruising Vehicle bucks/jerks during acceleration, cruising, or deceleration Momentary pause at beginning of acceleration, or during acceleration Momentary minor irregularity in engine output Sound produced from exhaust system Performance poor under load (i.e., power down when climbing hills) Sound produced when air/fuel mixture is ignition by something other than spark plug (i.e., hot spot in combustion chamber) Fuel economy unsatisfactory fails emission test Malfunction indicator light never on Automatic transmission concerns not related to engine performance F3-175 F3-178 F3-180 F3-181 F3-183 F3-184 F3-185 F3-185 F3-185 F3-185 F3-185 F3-188 F3-190 F3-191 F3-193 F3-194 F3-196 F3-198 section K2 Oil consumption excessive Engine runs at higher than normal temperature/ overheats Engine does not reach normal operating temperature F3-199 F3-199 Blue, black, or white smoke from exhaust system Gasoline fuel smell or visible leaks Engine noise from under hood Vibration from under hood or driveline A/C compressor magnetic clutch does not engage when A/C is turned on A/C compressor magnetic clutch does not disengage F3-201 F3-203 F3-204 F3-205 F3-205 A/C compressor magnetic clutch does not disengage under wide open throttle Rotten egq smell (sulphur) from exhaust Symptom occurs randomly and is difficult to diagnose F3-200 F3-206 F3-206 F3-207 F3-208 46U0F3-155 F3-169 F3 TROUBLESHOOTING GUIDE Description of Drivability Problems STUMBLE : Mildly irregular performance during acceleration. HESITATION : A dip or flat spot in performance just after the accelerator pedal is depressed. SURGE : Continuous irregular performance during cruising. 46U0F1-158 Fuel Pressure Release and Servicing Fuel System Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure when the engine is not running. Warning • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel Line Safety Procedures”. Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1. Start the engine. 2. Remove the fuel pump relay. 3. After the engine stalls, turn OFF the ignition switch to OFF. 4. Install the fuel pump relay. B. Avoid leakage. 1.W hen disconnecting a fuel line hose, w rap a rag around it to protect against fuel leakage. 2. Plug the hose after removal. C.Install hose clamps to secure the fuel pressure gauge to the fuel filter and the main hose. F3-170 F3 TROUBLESHOOTING GUIDE SYMPTOM TROUBLESHOOTING 1 MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Check the condition of the fuse Related Wiring Harness Damaged Fuse MAIN (100A) BTN (60A) b I IN Tuse ......... “ ROOM (15A) EGI INJ (30A) nUUM TUS6 1 I • 1 rOM Terminal 1 _ PCM terminal ------------------- Distributor PRC solenoid valve EGR solenoid valve Idle air control valve Purge solenoid valve ------------------- Mass airflow sensor ENGINE (15A) ENGINE fuse Main relay Fuel pump relay METER (15A) METER fuse Data link connector terminal B+ Transmission range sensor WIPER (20A) WIPER fuse Heated oxygen sensor 46U0F3-156 F3-171 F3 TROUBLESHOOTING GUIDE WILL NOT CRANK 2 DESCRIP­ TION 2 ACTION INSPECTION STEP 1 • Starter does not work Is a clicking sound heard from the starter relay when the ignition switch is turned to START? Check the starting system Yes Go to next Step No Go to Step 3 Yes Check for seized/hydrolocked engine, flywheel (Refer to section B1) No Service as required (Refer to section G) Yes Go to next Step No Check the charging system (Refer to section G) Yes Pass diagnostic trouble code displayed Go to next Step No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause «■ section G Is the starting system OK? 3 4 5 Do any other electrical accessories work? Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection? «■ page F3-16 Verify test results. If OK, return to diagnostic index to service any additional symptoms 46U0F3-157 F3-172 F3 TROUBLESHOOTING GUIDE HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK 3 DESCRIP­ TION INSPECTION STEP 1 2 3 4 5 6 • Starter cranks engine at normal speed but engine requires excessive cranking time before start • Battery in normal condition ACTION Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? «■ page F3-15 Yes Pass diagnostic trouble code displayed Go to next Step No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause (Refer to related chart) Connect a jumper wire between FP terminal of data link connector and a ground Is fuel line pressure correct with ignition switch ON? a- page F3-125 Fuel line pressure: 260—320 kPa {2.6— 3.3 kgf/cm2, 37—46 psi} Yes Go to next Step No Zero or low: • Check fuel pump circuit • Check pressure regulator diaphragm High: • Check pressure regulator for high pressure cause • Check for clogged fuel return line **■ page F3-122 w page F3-125 **■ page F3-125 Is fuel line pressure held after ignition switch is turned off? cr page F3-118 Fuel line pressure: More than 150 kPa {1.5kg f/cm2, 21 psi} for 5 min. Yes Go to next Step No Check pressure regulator diaphragm condition If condition is OK, check injector If condition is not OK, replace pressure regulator Disconnect the vacuum hose from the pressure regulator and plug hose. Start the engine Does the fuel line pressure remain within ±20 kPa {0.21 kgf/cm2, 3 psi} while driving vehicle? Yes Go to next Step No Check for clogged fuel filter Connect the vacuum hose to the pressure regula­ tor. Install a vacuum gauge to the intake mani­ fold. Start the engine. Does fuel pressure gauge reading increase as the vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as the vac­ uum gauge reading increases? Yes Go to next Step No Connect vacuum pump to pressure regulator. Start the engine. Check that fuel pressure reading changed as vacuum changes • If changes, check vacuum line • If no change, replace pressure regulator Is idle speed correct? Yes Go to next Step No Adjust idle speed page F3-125 **■ pageF3-127 w page F3-121 ■a- page F3-14 MF1401-B1 F3-173 F3 TROUBLESHOOTING GUIDE INSPECTION STEP 7 Is there a restriction in the exhaust system? «■ page F3-132 8 9 10 11 Remove PCV valve and shake PCV valve Does PCV valve rattle? Check for contaminated mass airflow sensor. Is there any contamination? Disconnect vacuum hose from EGR control valve and plug it. Does condition improve? Check starting system ACTION Yes «*• page F3-132 No Go to next Step Yes Go to next Step No Replace PCV valve Yes Replace the mass airflow sensor No Go to next Step Yes Check as follows: • EGR solenoid valve [vacuum] for sticking • Condition of EGR solenoid valve [vacuum] connector female terminal(s) No Check if EGR control valve moves smoothly • If yes, Go to next Step • If no, replace EGR control valve Yes Verify test results If OK, return to diagnostic index to service any additional symptoms No Repair or replace components as required «• section G Is starting system normal? MF1401-B2 F3-174 Check exhaust system 46U0F3-158 F3 TROUBLESHOOTING GUIDE DESCRIP­ TION • Engine stops unexpectedly at idle and/or after start INSPECTION STEP Does the vehicle stall at idle in park/neutral with 1 all accessories off? 2 3 4 • AFTER START • AT IDLE ENGINE STALLS 4 ACTION Yes Go to Step 3 No Go to next Step Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and/or Key On Engine Running inspection? is- page F3-15 Yes Pass diagnostic trouble code displayed Go to Step 4 No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection? us- page F3-15 Yes Pass diagnostic trouble code displayed Go to Step 11 No Diagnostic trouble code no. displayed or no diagnostic trouble code displayed Check for cause Yes Go to next Step No Adjust timing If not adjustable, check as follows: • Distributor Yes Check idle air control solenoid and wiring harness Disconnect in-line SPOUT connector and start engine NOTE: • If engine stalls, reconnect SPOUT connector and go to next step • If engine is now a No Start, reconnect SPOUT connector and check ignition system (Refer to section G) Is base timing correct? Base timing: BTDC 9— 11° (10±1°) 5 Attempt to start engine at part throttle Will engine run smooth at part throttle? ■a- page F2-114 6 7 Disconnect vacuum hose from EGR control valve and plug it Is drive symptom eliminated? Does EGR control valve seat properly (fully closed)? No Go to next Step Yes Check EGR vent on vacuum hose to EGR control valve for obstruction or leak • If OK, replace EGR solenoid (vacuum) • If not OK, repair or replace vacuum line No Go to next Step Yes Go to next Step No Check as follows: • EGR control valve malfunction • EGR flange gasket leaking • EGR control valve attaching nuts or bolts loose or missing • EGR control valve contamination • EGR solenoid (vacuum) malfunction MF1402-B1 F3-175 F3 TROUBLESHOOTING GUIDE INSPECTION STEP 8 9 10 11 12 Connect jumper wire between FP terminal of data link connector and a ground Is fuel line pressure correct when the ignition switch is cycled ON and OFF? page F3-125 Fuel line pressure: 260—320 kPa {2.6— 3.3 kgf/cm2, 37—46 psi} Go to next Step No Zero or low: • Check fuel pump circuit • Check pressure regulator diaphragm High: • Check pressure regulator for high pressure cause • Check for clogged fuel return line «■ page F3-116 **• page F3-125 «• page F3-125 Visually look for fuel leakage at injector O-ring, pressure regulator, and fuel line. Service as nec­ essary. Connect jumper wire between FP termi­ nal of data link connector and a ground Does fuel pressure remain at specification for 60 seconds? «• page F3-125 Yes Go to next Step No Check pressure regulator diaphragm condition Is strong blue spark visible at each disconnected high-tension lead while cranking engine? Yes • If symptom occurs during parking maneuvers, Go to next Step • If symptom occurs during A/C ON, go to Step 13 No Check as follows: • Distributor cap and rotor • High-tension lead(s) • Ignition control module «■ page F3-125 • If condition is OK, check injector «■ page F3-127 • If condition is not OK, replace pressure regulator »*■ section G Disconnect the steering pressure sensor (if equipped) Does rpm increase? Yes Replace steering pressure sensor No Check for short circuit in wiring harness from steering pressure sensor to PCM Is there correct voltage at terminal 10 of PCM when the A/C is ON? Yes Replace PCM No Check for open circuit in wiring harness from A/C pressure switch to PCM Yes Check exhaust system No Go to next Step Specification: More than 10.5V 13 ACTION Yes Is there a restriction in the exhaust system? «*■ page F3-132 MF1402-B2 F3-176 «■ page F3-149 <&■ page F3-132 F3 TROUBLESHOOTING GUIDE INSPECTION STEP 14 Is air leakage felt or heard at intake air system components while racing engine to higher speed? 15 Are spark plugs OK? ACTION Yes Repair or replace No Go to next Step Yes Go to next Step No Clean or replace Yes Go to next Step No Check for cause «■ section G v\ 'EAR /W D CARBON PLUG. GAP , — BURNT ^—-D A M A G E AND ^ DETERIORATION **• section G □ 3— ‘ f 16 7 __ __DAMAGE Is engine compression correct? «■ section B1 17 «■ section B1 Verify test result. If OK, return to diagnostic index to service any additional symptoms MF1402-A3 46U0F3-159 F3-177 F3 TROUBLESHOOTING GUIDE 5 CRANKS NORMALLY BUT WILL NOT START DESCRIP­ TION • • • • Starter cranks engine at normal speed but engine will not run Refer to “ENGINE STALLS” if this symptom appears after engine stall Fuel in tank Battery in normal condition STEF INSPECTION 1 Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection? **■ page F3-15 Yes No 2 Disconnect the throttle position sensor connector Is there correct voltage at terminal of the throttle position sensor connector with the ignition switch ON? Specification: 4.5—5.5 V 3 Is a strong blue spark visible at each disconnect­ ed high-tension lead while cranking engine? ft ( / / Y (n'($<2/ 4 ® \ Go to next Step No Check voltage at PCM terminals 1, 26, 37, and 57 Yes Go to Step 5 No Go to next Step n Is a strong blue spark visible at disconnected high-tension lead from coil while cranking engine? f ^ Install SST (breakout box) between wiring har­ ness and PCM. Set the timing switch to the “COMPUTED" mode on the SST. Is there correct voltage at pin 36 on the SST while cranking engine? Specification: 3.0— 6.0V 6 Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Yes Yes No 5 ACTION Pass diagnostic trouble code displayed Go to next Step Connect the jumper wire between FP terminal of data link connector and a ground Is fuel line pressure correct when the ignition switch is cycled ON and OFF 5 times? Check as follows: • Ignition control module • Distributor cap • Rotor • High-tension leads Check the spark output signal and crankshaft position sensor signal at PCM page F3-161 • If OK, go to Step 12 • If not OK, check wiring harness Yes Go to next Step No Check the spark output signal and crankshaft position sensor signal at PCM page F3-161 Yes Go to next Step No Check fuel pump «• page F3-122 Fuel line pressure: 260—320 kPa {2.6—3.3 kgf/cm2, 37—46 psi} ' MF1403-B1 F3-178 cr section G F3 TROUBLESHOOTING GUIDE 7 8 9 10 11 12 13 ACTION INSPECTION STEP Visually look for fuel leakage at injector O-ring, pressure regulator, and fuel line. Service as nec­ essary. Connect jumper wire between FP termi­ nal of data link connector and a ground Does fuel pressure remain at specification for 60 seconds? Yes Go to next Step No Check pressure regulator diaphragm condition «■ page F3-125 • If condition is OK, check injector «■ page F3-127 • If condition is not OK, replace pressure regulator Disconnect the inertia fuel shutoff switch connec­ tor. Crank engine for 5 sec. Does pressure drop more than 34 kPa {0.35 kgf/cm2, 5 psi} by the end of five second crank cycle? Yes Go to next Step No Check resistance of injector(s) at PCM connector w page F3-127 • If resistance is OK, check as follows: • Injector drive signal • Injection flow rate • PCM • If resistance is not OK, check as follows: • Open circuit in injector circuit Does engine start when throttle valve held quarter open? Yes Check idle air control solenoid and wiring harness «*■ page F3-114 No Go to next Step Yes Check EGR vent or vacuum hose to EGR control valve for obstruction or leak • If OK, replace EGR solenoid valve (vacuum) If not OK, repair or replace vacuum line No Go to next Step Yes Go to next Step No Check as follows: • EGR control valve malfunction • EGR flange gasket leaking • EGR control valve attaching nuts or bolts loose or missing • EGR control valve contamination • EGR solenoid valve (vacuum) malfunction Disconnect vacuum hose from EGR control valve and plug it is drive symptom eliminated? Does EGR control valve seat properly (fully closed)? Is there a restriction in exhaust system? «■ page F3-132 Is engine compression correct? Yes Check exhaust system «3T page F3-132 No Go to next Step Yes Go to next Step No Check for causes ■a- section B1 ■a- section B1 14 Verify test results. If OK, return to diagnostic index to service any additional symptoms MF1403-B2 46U0F3-160 F3-179 F3 TROUBLESHOOTING GUIDE 6 SLOW RETURN TO IDLE DESCRIP­ TION STEP 1 2 3 4 • Engine takes more time than normal to return to idle speed INSPECTION ACTION Pass diagnostic trouble code displayed Go to next Step Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? w pageF3-15 Yes No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Is the throttle body free of contamination? «■ page F3-112 Yes Go to next Step No Clean or replace the throttle body Yes Repair or replace No Go to next Step Is air leakage felt or heard at intake air system components while racing engine to higher speed? Verify test results. If OK, return to diagnostic index to service any additional symptoms MF1404-B F3-180 46U0F3-161 F3 TROUBLESHOOTING GUIDE DESCRIP­ TION • Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake • Idle speed too slow and excessive engine shake INSPECTION STEP 1 Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? <s- page F3-16 2 • AT IDLE ENGINE RUNS ROUGH/ROLLING IDLE 7 Disconnect the in-line SPOUT connector. Start the engine Is base timing within specification at idle? ACTION Yes Pass diagnostic trouble code displayed Go to next Step No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Yes If symptom is rough idle: Go to next Step If symptom is other: Go to Step 4 No Adjust base timing If not adjustable, check as follows: • Distributor Yes Go to next Step No Check the idle air control solenoid and wiring harness Base timing: BTDC 9— 11 °(10 ± 1°) 3 4 5 6 7 Start the engine and disconnect the idle air control solenoid connector Does the rpm drop or does the engine stall? Disconnect the vacuum hose from the EGR con­ trol valve and plug it Is the drive symptom eliminated? Does EGR control valve seat properly? Start engine and run it at idle. Measure fuel line pressure at idle Is fuel line pressure correct at idle? page F3-125 Fuel line pressure: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} Connect a jumper wire between FP terminal of data link connector and a ground. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned ON? »*■ page F3-125 page F3-114 Yes Check EGR vent or vacuum hose to EGR control valve for obstruction or leak • If OK, replace EGR solenoid (vacuum) • If not OK, repair or replace vacuum line No Go to next Step Yes Go to next Step No Check as follows: • EGR control valve malfunction • EGR flange gasket leaking • EGR control valve attaching nuts or bolts loose or missing • EGR control valve contamination • EGR solenoid (vacuum) malfunction Yes Go to next Step No Low: • Check pressure regulator diaphragm • Check fuel pump maximum pressure High: • Check pressure regulator for high pressure cause • Check for clogged fuel return line Yes Go to next Step No Check pressure regulator diaphragm «■ page F3-125 «■ page F3-122 «• page F3-122 <&■ page F3-116 «• page F3-125 MF1405-B1 F3-181 F3 TROUBLESHOOTING GUIDE INSPECTION STEP 8 Perform Cylinder Balance Test Are there any diagnostic trouble codes? **• page F3-15 ACTION Yes Check resistance of injector(s) at PCM connector • If • • If • 9 10 is- page F3-149 resistance is OK, check as follows: injector drive signal resistance is not OK, check as follows: open/short circuit in injector circuit No Go to next Step Run engine at 2000 rpm for two minutes Are there any diagnostic trouble codes? page F3-15 Yes Check heated oxygen sensor harness No Check heated oxygen sensor heater harness Go to next Step us- page F3-164 Are spark plugs OK? Yes Go to next Step No Clean or replace ef page F3-164 ■s- section G WEAR AND CARBON p^ | | r BURNT f f i B i~ - D A M A G E AND ■s- section G Jte.... DETERIORATION N = = = |f^ -D A M A G E 11 12 13 Yes Go to next Step No Replace PCV valve Start the engine and bring to normal operating temperature. Disconnect hose from remote air cleaner. Place a stiff piece of paper over the hose end Does vacuum hold the paper? Yes Go to next Step No Check fuel evaporative system as follows: Disconnect evaporative hose and place a stiff piece of paper over hose Does vacuum hold paper? ■s- page F3-138 • If yes, malfunction of fuel evaporative system • If no, check for vacuum leak in PCV system, oil cap, PCV valve, rocker cover for bolt torque/gasket leak Remove a plug line to charcoal canister. Remove gas cap and install a vacuum pump/gauge gas cap. Apply air pressure Yes Repair or replace Air pressure: 20—27 kPa {0.21—0.28 kgf/cm2, 3—4 psi} No Go to next Step Remove PCV valve and shake PCV valve Does PCV valve rattle? Is either a vacuum or fuel leak detected? 14 Check for blockage/restrictions or opens (hoses) between engine vacuum port and charcoal canis­ ter. Check for blockage in fuel tank vent system Is a fault detected? MF-1405-B2 F3-182 Yes R eplace vacuum hose No Go to next Step F3 TROUBLESHOOTING GUIDE INSPECTION STEP 15 Check canister purge solenoid Is the solenoid operating properly? <*■ page F3-139 16 Is there a restriction in the exhaust system? «• page F3-132 ACTION Yes Go to next Step No Go to next Step Yes check exhaust system «■ page F3-132 17 Is there air leakage at intake air system components while racing engine to higher speed? 18 Is engine compression correct? No Go to next Step Yes Repair or replace No Go to next Step Yes Go to next Step No Check for cause ■a* section B1 ■a- section B1 19 Verify test results. If OK, return to diagnostic index to service any additional symptoms MF1405-A3 46U0F3-162 FAST IDLE/RUNS ON 8 DESCRIP­ TION INSPECTION STEP 1 2 • Engine speed continues at fast idle after warm-up • Engine runs after ignition switch is turned off Yes Pass diagnostic trouble code displayed Go to next Step No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Disconnect the in-line SPOUT connector. Start the engine Is base timing within specification at idle? Yes Go to next Step No Adjust base timing If not adjustable, check as follows: • Distributor Yes Repair or replace parts as necessary No Go to next Step Base timing: BTDC 9-11 °(10 ± 1°) 3 4 ACTION Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? page F3-15 Is there air leakage felt or heard at intake air sys­ tem components while racing engine to higher speed? Verify test results. If OK, return to diagnostic index to service any additional symptoms MF1406-B 46U0F3-163 F3-183 F3 TROUBLESHOOTING GUIDE LOW IDLE/STALLS DURING DECELERATION 9 DESCRIP­ TION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration STEP INSPECTION 1 Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? ® pageF3-15 2 Disconnect in-line SPOUT connector. Start the engine. Is base timing within specification? Base timing: BTDC 9— 11°(10 ± 1°) 3 Does idle speed drop in the following conditions? ACTION Yes Pass diagnostic trouble code displayed Go to next Step No Diagnostic trouble code no. displayed or no diagnostic trouble codes displayed Check for cause Yes Go to next Step No Adjust base timing If not adjustable, check as follows: • Distributor Yes Condition • Air conditioner ON Check as follows: • Circuit from idle air control solenoid to PCM for open and short **■ page F3-149 • Idle air control solenoid for sticking is- page F3-114 No Adjust idle speed **■ page F3-14 4 Check the following: • EGR control valve • EGR vacuum regulator solenoid Are any of the components faulty? 5 Are the following terminals and connections good? • Distributor connector • Ignition control module connector • Fuel pump connector • Main relay • PCM connector MF1407-B F3-184 Yes Repair or replace No Go to next Step Yes Verify test results. If OK, return to diagnostic index to ser­ vice any additional symptoms No Repair connector terminal 46U0F3-164 F3 TROUBLESHOOTING GUIDE 10 DESCRIP­ TION 2 • • • • • • 4 5 6 ACTION Pass diagnostic trouble code displayed Go to next Step Is the pass diagnostic trouble code displayed dur­ ing Key On Engine Off inspection and Key On Engine Running inspection? **• page F3-15 Yes No Diagnostic trouble code no. displayed or no diagnostic trou­ ble codes displayed Check for cause Disconnect the in-line SPOUT connector Is base timing within specification at idle? Yes Go to next Step No Adjust base timing If not adjustable, check as follows: • Distributor Yes Check as follows: • EGR vacuum regulator solenoid for sticking No Go to next Step Yes Go to next Step No Check as follows: • EGR control valve operation • EGR contorl valve contamination • EGR solenoid (vacuum) • Pressure/vacuum signal hose leak Base timing: BTDC 9— 11 °(10 ± 1°) 3 ACCELERATION/CRUISE ACCELERATION/CRUISE ACCELERATION/CRUISE ACCELERATION/CRUISE/DECELERATION ACCELERATION Engine stops unexpectedly at beginning of acceleration or during acceleration Engine stops unexpectedly while cruising Engine speed fluctuates during acceleration or cruising Engine misses during acceleration or cruising Vehicle bucks/jerks during acceleration, cruising, or deceleration Momentary pause at beginning of acceleration or during acceleration INSPECTION STEP 1 • • • • • ENGINE STALLS/QUITS ENGINE RUNS ROUGH MISSES BUCK/JERK HESITATION/STUMBLE Disconnect vacuum line at EGR control valve and plug it Is drive symptom eliminated? Does EGR control valve seat properly (fully closed)? Start engine and run it at idle. Measure fuel line at idle Is fuel line pressure correct at idle? a- page F3-125 Fuel line pressure: 210— 260 kPa {2.1—2.7 kgf/cms, 30—38 psi} Does fuel pressure remain at specification for 60 seconds? Yes Go to next Step No Low: • Check pressure regulator diaphragm • Check fuel pump maximum pressure High: • Check pressure regulator for high pressure cause • Check for clogged fuel return line Yes Go to next Step No Check pressure regulator diaphragm • If condition is OK, check injector • If condition is not OK, replace pressure regulator «■ page F3-125 page F3-125 «■ page F3-125 «*■ page F3-125 s ’ page F3-127 MF1408-B1 F3-185 F3 TROUBLESHOOTING GUIDE STEF INSPECTION 7 Perform the Cylinder Balance Test. a- page F3-17 Yes ACTION Check injector resistance • If OK, check injector drive signal If no drive signal, replace PCM • If not OK, check continuity between injector and PCM «■ page F3-149 8 Run engine at 2000 rpm for two minutes Are diagnostic trouble codes present? No Go to next Step Yes Check heated oxygen sensor wiring harness « ' page F3-164 No Check heated oxygen sensor heater «*■ page F3-164 If OK, go to next Step 9 10 11 12 13 Is a strong blue spark visible at each disconnect­ ed high-tension lead while cranking engine? Check that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug Are any faults present? Is there air leakage felt or heard at intake air sys­ tem components while racing engine to higher speed? Remove PCV valve and shake PCV valve Does PCV valve rattle? Start the engine and bring to normal operating temperature. Disconnect hose from remote air cleaner. Place a stiff piece of paper over the hose end Does vacuum hold the paper? MF148-B2 F3-186 Yes Check spark plugs «■ section G • If OK, go to next Step • If not OK, clean or replace spark plug No Check as follows: «■ section G • Distributor • High-tension leads • Ignition control module • Condition of distributor connector female terminals Yes Adjust as necessary No Go to next Step Yes Repair or replace par