INTRODUCTION How to Use This Manual ‘This manual contains service information for the CIVIC. Separate volumes are published regard. ing vehicle construction, engine, and transmission; the applicable reference manuals are listed below. This manual ie divided into sections. This first page of each section is marked with a black tab that lines up with one of the thumb index tabs on next page. You can quickly find the first page Of each section without looking through @ full table of contents, The symbols printed at the top ‘comer of each page can also be used as @ quick reference system Each section includes: 1. A table of contents, or an exploded view index showing * Parts disassembly sequence: + Bolt torques and thread sizes: + Page references to descriptions in text Disassembiy/essembly procedures and tools Inspection. Testing/*troubleshooting Repar: Adjustments. | Reference Manuals — Date Description Code No Remarks Published CIVIC Construction and Function 62SH310 Nov. 1987 2eSOHC 1-Carbureted Engine | Nov. 1987 34 SOHC 1-Carbureted Engine 4LSOHC 2-Carbureted Engine | D128/0138/014A/0168/D16A | 62PM100 | 1 1 1 1.5 1 SOHC 1-Cerbureted Engine 1 1 1 1 Engine Maintenance and Repair 5 ¢ SOHC 2-Carbureted Engine 5 i SOHC PGM-FI Engine 61 SOHC PGM-FI Engine 6 1 DOHC PGN-FI Engine | L3 Manual Transmission 62PL300 | 5 Speed Nov. 1987 Maintenance and Repait L4 Automatic Transmission 62PL400 | 4 Speed with lock-up Nov. 1987 Maintenance and Repait Special Information — — XIE incicates a strong possibility of severe personal injury or loss of tons are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are NOTE: Gives helpful information CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these ‘warnings cannot cover all conceivable ways in which service, whether or not recommend- ed by Honda Motor, might be done, or of the possible hazardous consequences of each ‘conceivable way, nor could Honda Motor investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda Motor. must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized. Al information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. First Edition 11/87 998 pages All Rights Reserved HONDA MOTOR CO... LTD. Service Publication Office| General Info ia Special Tools Ea Specifications specs | Maintenance Ea Engine pen Fuel and Emissions ea Transaxle ol Steering Kel Suspension kw Brakes Eo Body co Air Conditioner ElectricalGeneral Information Chassis and Engine Numbers Identification Number Locations Label Locations .... Lift and Support Points Towing .. Preparation of Work Symbol Marks Abbreviation 1-4 1-9 .1-15 1-15Chassis and Engine Numbers r- Vehicle Identification Number Tio: ppp vant, at on iil “IRM: HONDA MOTOR CO. LTD., | ae | Line/Sody and Engine type —— | £D1=CIVIC 1200 Sedan | £02: vie 1409 Sedan | £52: clvie 1600 Sedan D4 clvig 1600 Soden EDS: clvig 1900 Seder | £8. clvic 1800 fterback ' ED? clvig 1600 fotenovek ECT eli 1200 foteroack EC9: CIVIC 1400 Hatchback | Traamssion and Body ‘ype ——— 3 apend nonvl 2 Door fatchback 4: sped evomatie/2 Door || tathbock | 5: 6 spond man/4-DoorSadon 8 4 sped gutomate’ Dor Sedan Vehicle Grade 2: OX (ECT, ECB, EDI, E03: KA, | ‘eps, eps: ka ) GL /£C9, €02, £03, \ep6: Ky } 3: GL (EDS: Ka, ED6: Ka) EX (ED3: KY) 4: DX {ED3: KW", E08: KX/KW*) 5: GL (ED, KX/KS/AW, £06: KX/KS/KWW* | | 6: 1.61 (€04, €07) 7: 1.6i-16 (E07) Fixed code Model Year: — | 0: 1988 j Factory S: SUZUKA Factory Serial Number— — KW": for Austria, 1-2 ————_ [Engine Serial Number D1281-1000001 | Ensine Type tl | DraBt 24S0HC 1 carurte taping 01981: 1'31 SOHC 1-caburted Engine | | oraan.1"#rSonc 2-caruretes ogi 01881; 1'B SOHC POM Engine | with Catalytic Converter rons: 18 econ Sena prea. Tee SOne Pee Eating D16A9: 1.6£ DOHC PGM-FI Engine | Most ver Era ee | 0: Ex. PGM-FI Engine with Catalytic Converter, 7: PGM-FI Engine with Catalytic Converter Serial Number [— Transmission Number Transmission Type - L3: Manual LA: Automatic ial Number 13-1009001Identification Number Locations EE Engine Number Vehicle Identification Number JACK HOLDER ‘TRUNK Vehicle Identification Number (KS only) “Transmission Number Vehicle Identification Number (Attomate) *Label Locations SERVICE INFORMATION AIR CLEANER, OIL and FILTER SERVICE ALTERNATOR BELT DEFLECTION, BATTERY CAUTION COOLING FAN CAUTION RADIATOR CAP ‘CAUTION TIRE INFORMATION, 2.Door Hatchback 4-Do0r SedanLift and Support Points - Hoist Place the lift blocks as shown 2. Raise the hoist a few inches and rock the car to be sure it 1s firmly supported 3. Raise the hoist to full height and inspect lift points for solid support When heavy rear components such as suspension, fuel tank, spare tire and trunk lid/hatch are to be removed, place additional weight in the trunk before hoisting. When substantial weight is removed from the rear of the car, the center of gravity may change and can cause the car to tip forward on the hoist. NOTE: Since each tire/wheel assembly weighs approximately 14 kg (0 Ibs), placing the front wheels in the trunk will assist with the weight transfer. FRONT urTBLocks REAR (cont’ah 1-5Lift and Support Points (cont'd) [- Floor Jack 1. Set the parking brake and block the wheels that ae not being lifted ‘© Always use safety stands when working on or Under any vehicle that is supported by only a 2. When lifting the rear of the car, put the gearshift jack lever in reverse (Automatic in PARK! 1 Never attempt to use @ bumper jack for lifting or supporting the car 3. Raise the car high enough to insert the safety stands. 4, Adjust and place the safety stands as shown on page 1-7 so the car will be approximately level, then lower the car onto the stands. Front - \ Conter the jacking bracket inthe middle <= of jack it platform © JACK LIFT PLATFORM. Rear - Conter the'facking bracket in the madle of jack lift platform JACK LIFT PLATFORM 1-6[- Safety Stands FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINT 1-7Towing - Towing If towing is necessary. we recommended the following: Flat Bed Equipment: Entice car is winched on a flat bed vohicle. This is the best way of towing your Honda: Wheel Lift Type: Front or rear of the car is lifted at the wheels and is suitable for your Honda. CAUTION: If a sling type tow is used, the tow truck driver should position wood spacer blocks between your car's frame and the chains and lift straps to avoid damaging the bumper and the body. Do not use the bumpers to lift the car or to support the car's weight while towing. Check local regula- tions for towing. ‘TOWING HOOKS Emergency towing with all four wheels on the ground: Under certain emergency conditions, the car may need to be towed with all four wheels on the ground. If your Honda is towed with all four wheels on the ground, check local regulations and observe the following precautions: © Shift the transmission to neutral © Release the parking brake. © Turn the ignition to the the steering, © Do not exceed 55 kph (35 mph) or tow for distances of more than 80 km (50 miles) position to unlock I a frame mount tow bar is used with a four wheel tow: © Do not attach it to the bumper. © Follow the tow bar manufacturer's instructions, Never use tow chains or rope to tow a car; your ability to safely control the car may be adversely affected. 1-8Preparation of Work [— Special Caution Items For This Car 1. Fuel Line Servicing + Relieve fuel pressure by loosening the service bolt provided on the top of the fuel filter before disconnecting a fuel hose or a fuel pipe. SERVICE BOLT 12 Nem (1.2 kgm, 9 tote) SHOP ToweL FUEL FILTER + Be sure to replace washers, O-rings, and rubber seals with now ones when servicing fuel line parts, + Always apply oil to the surfaces of O-rings and seal rings before installation, Never use brake fluid, raaiator fluid, vegetable oils or alcohol: J BErome CUSHION RING RUBBER SEAL + When assembling the flere joint of the high pressure fue! line, clean the joint and coat with new engine oil + When installing an injector, check the angle of the coupler. The center line of the coupler should align with the setting mark on the injector holder, ‘SETTING MARKS. Inspection for fuel leakage + After assembling fuel line parts, turn ON che ig nition switch (do not operate the starter) so that, the fuel pump is operated for approximately two seconds and the fuel is pressurized. Repeat this ‘operation two or three times and check whether, any fuel leakage has occurred in any of the vari ous points in the fuel tine. Installation of an amateur radio for cars equipped with PGM-Fl Care has been taken for the FuelInjection, Car: buretor, contro! units (computer) and its wiring to prevent erroneous operation from extemal interfer- tence, but erroneous operation of the computer may be caused by extremely strong radio waves. Attention must be paid to the following items to prevent errone- (ous operation of the computer + The antenna and the bady of the radio must be PGM-FI at least 200 mm (7.9 in.) away from the computer The computer locations: + Fusl-injection, Carpuretor: Passenger’s side front flower panel + Do not lead the antenna feeder and the coaxial cable over a long distance parallel to the car's, ‘wiring, When crossing with the wiring és required, execute crossing at a right angle + Do not install a radio with a large output (max. 10. wy Apply liquid gasket to the transmission, oil pump cover, right side cover and water outlet. Use HONDA PART NO 08740~99986 as a liquid gasket + Check that the mating surfaces are clean and dry before applying liquid gasket, Degrease the ‘mating surtaces if necessary. + Apply liquid gasket evenly. being careful to cover all the mating surface To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. + Donot allow liquid gasket to stand for more then 20 minutes before assembly. + Wait at least 30 minutes before filing with the appropriate liqued (engine oil, coolant etc} 1-9Preparation of Work CAUTION: Observe all while working. ty precautions and notes 1. Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover. 2. Work safely and give your work your undivided atten tion. When either the front or rear wheels are to be raised, block the remaining wheels securely. Commu- rieate signals as frequently as possible when a work involves two or more workers. Do not run the engine Unless the shop or working area is well ventilated os BD x 3. Prior to removing or disassembling parts, they must be inspected carefully to isolate the cause for which service is necessary. Observe all safety notes and preceutions and follow the proper procedures as de- seribed in this manual ‘Mark or place all removed parts in order in a parts rack so they can be reassembled in theie original places 4 7 8 Use specia! tool when use of such @ tool is specified. Parts must be assembled with the proper torgue according to the maintenance standards established. When tightening a series bolts or nuts, begin with the center or larger diameter bolts and tighten them in crisscross pattern in two or more steps. Use new packings, gaskets, O-nngs and cotter pins whenever reassembling Use genuine HONDA parts and lubricants or those ‘equivalent. When parts are to be reused, they must be inspected carefully to make sure they are not damaged CF deteriorated and are in good usable condition Co gl 1-10Electrical 9. Coat or fill parts with specified grease as specifies (Page 4-2). Clean all removed parts in or with solvent Upon disassembly 10. Brake fluid and hydraulic components When replenishing the system, use extreme care pravent dust and dirt from entering the system. Do not mix different brands of fluid as they may not be compatible + Do nat reuse drained brake fluid + Brake fluid can cause damage to painted surfaces Wipe up spilled fluid at once. + After disconnecting brake hoses or pipes, be sure plug the openings to prevent loss of brake fluid Clean all disassembled parts only in clean BRAKE FLUID. Blow open all holes and passages with compressed air. + Keep disassembied parts from air-borne dust and abrasives, + Check that parts are clean before assembly 11. Avoid oil or grease getting on rubber parts and tubes, Unless, specified 12, Upon assembling, check every possible part for proper installation and movement or operation. + Before making any repairs on electric wires or parts disconnect the battery cables from the battery starting with the negative (—) termina After making repairs, check each wire or part for proper routing and installation. Also check to see that they are connected properly. Always connect the battery positive (+) cable fist, then connect the negative (—} cable. + Coat the terminals with clean grease after connecting the battery cables Don’t forget to install the terminal cover over the positive battery terminal after connecting. Before instaling @ new fuse, isolate the cause and take corrective measures, particularly when frequent fuse failure occurs, Use correct rating + Be sure to install the terminal cover over the connections after a wire oF wire harness has been connected cover TERMINAL (conta) 1-11Preparation of Work r— Electrical (cont’d) © When removing locking couplers, be sure to disengage: the lock before disconnecting © Couplers may be of two types, those in which the lock is pressed io remove, and those in which the lock is pulled Up to remove. Be sure to ascertain the type of locking device before beginning work. The following is a depic~ tion of the means of disconnecting various typical cou: plers. Press to disengage: © When disconnecting locks, first press in the coupler tightly (to provide clearance to the locking device), then operate the tab fully and remove the coupler in the designated manner + All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when re- connecting + When disconnecting a coupler, pull it off from the ‘mating coupler by holding on both couplers + Never try to disconnect couplers by pulling on their + Before connecting couplers, check to see that the termi nals are in place and are not bent or distorted + Insert couplers fully until they will ne longer go. + Some couplers have locking tabs that must be aligned and engaged securely. + Don't use wire harnesses with a loose wire or coupler coo) a + Place the plastic cover over the mating coupler after reconnecting. Also check that the cover is not distorted. (ARO eX Neate SS+ Before connecting, check each connector cover for damage. Also make sure that the female connector is tight and not loosened from the previous use. + Insert male connectors into the female connectors fully until they will no longer go + Be sure that plastic cover is placed over the connection + Position the wires so that the open end of the cover is not facing upward. + Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Position the wiring in the bands so that only the insulat- ed surfaces contact the wires or wire harnesses. + loose wire harness or cable can be a hazard to safety. ‘After clamping, check each wire for security in its clamp. “—\ O x + Do not squeeze wires against the weld when a weld-on clamp is used O x Oo, a + After calmping, check each harness to be certain that it is not interferring with any moving or siding parts of the vehicle. + Keep wire harnesses away from the exhaust pipes and other hot parts. + Always keep a safe distance between wire harnesses and . 27 ate | PO ° iF pds + Do not bring wire harnesses in direct contact with sharp edges or corners. ‘Also avoid contact with the projected ends of bolts, ‘screws and other fasteners. SN Keep sufficient dist + Route harnesses so they are not pulled taut or slackened excessively (cont'd) 1-13Preparation of Work r~ Electrical (cont'd) + Protect wires and harnesses with a tape or tube if they + After routing, chack that the wire hamesses are not ‘are in contact with a sharp edge oF corner. twisted or kinked ® oO 2» SS + Wire harnesses should be routed so that they are not pulled taut, slackened excessively, pinched, or inter fering with ‘adjacent or surrounding parts in all steering positions. + Clean the attaching surface thoroughly if an addhesive is, used. First, wipe with solvent or alcohol in necessary O Sigg ( eee + Seat grommets in their grooves properly ~~ + When using the Service Tester, follow the manufacturer's | O| wES ~ + Do not damage the insulation when connecting @ wire. + Do not use wiras or harnesses with a broken insulation Repair by wrapping with a protective tape or replace with new ones if necessary + Do not drop parts ane e + Rust is the enemy of all finished surfaces. Before con- necting connectors and couplers, check the terminals ‘and remove, if any, rust using a fine sand paper or emery cloth + After installing parts, make sure that wire harnesses are not pinched. od \ 1-14Symbol Marks Abbreviation The following symbols stand for: 7B] Arpiy engine cit :Apply grease. ‘Apply DEXRON® Il Automatic Transmission Fluid. Apply Power Steering Fluid aa a a oes Sequence for removal 2-door Hatchback 4-door Sedan Air Conditioner ‘Automatic Transmission DEXRON® 11 Automatic, Transmission Fluid Battery Catalytic Converter Electronic Air Control Valve PGM-FI Electronic Control Unit Exhaust Gas Recirculation Exhaust Ground Ignition Intoke Intermittent Left Side Left Hand Drive Manual Transmission Positive Crankcase Ventiation Programmed Carburetor Programmed Fuel-Injection Power Steering Right Side Right Hand Drive Switch Solenoid Valve Top Dead Center Parking Reverse Neutral Drive Range (1st~4th) Drive Range (1st~3ra) Fixed at 2nd range 1-15Special Tools New For This Model... sed 2 Existing Tools {Common with Other Models) ......2—3Special Tools New Tools Only new tools are listed below. As to other tools, refer to each section. Too! Number Description 07182-SH20100 | Engine RPM adaptor 2 | OTIAF—PM70100 Clutch Die Agent To! @ | O7JAD-SH30100 | Oi Seal Driver Attachment @ | o7vaF—sH20120 | Hub Dis/Assemby Shet 22.4% 25.4 mm O7JAF—SH20110 | Hub Dis/Assembly Pilot, 38 mm OTJAF—SH20200 | Ball Joint Remover Base ony Remarks 12 12 8 6ane Existing Tools (Common with Other Models) 5. Engine — No. Too! Number (07966-64001 079446110100 ® | 077570010000 ® | O7HAD—PJ70200 5 0742—0010100 e (077430020000 | O7HAH—PJ70100 ® | 07GMD—PH70100 9 077420010200 w@ | 079846570101 a (07947—$800100 « | 079736570002 is | 07973—6570500 i | 07973~$800100 «3 | 07973—PE00200 is | 07973-00400 i | 07973—PE00301 i@ | 07948-s800101 «@ | 079480080000 @ — 07HAD—PJ70100 2 077490010000 2 | 07912~6110001 @ | 07406-0030000 Description Engine Block Hanger Pin Driver 6 mm Valve Spring Compressor Valve Guide Seal Installer Valve Guide Driver 5.5 mm Adjustable Valve Guide Driver Valve Guide Reamer, 5.5 mm Valve Guide Seal Installer Valve Guide Driver, 6.6 mm Valve Guide Reamer, 6.6 mm Oil Seal Driver Piston Pin Dis/Assembly Tool Set Piston Base Piston Base Head Pilot Collar Piston Pin Base Insert ‘Adjustable Piston Pin Driver Driver Attachment Driver Attachment Driver Driver Oil Fiter Socket Wrench Oil Pressure Gauge Adapter Remarks {DOHC engine} Used to set the piston at TOC 079573290001 may also be used. i i For camshaft seal Crankshaft (Clutch side) for SOHC Crankshaft (Clutch side) for DOHC Crankshatt (Pulley side) Crankshaft (Clutch side) For pressure measurement 6. Fuel and Emissions No. Too! Number D (07JAZ—SH20100 | 07999—PD6000a, | 076140050100 | 07408—0040001 (074080040100 (074080040201 07HAZ—PJ70000 07HAZ—PJ70100 Description RPM Connecting Adaptor PGM-Fl Test Harness Fuel Line Clip Fuel Pressure Gauge Set Pressure Gauge Hose Assy ECU Test Harness A ECU Test Harness B Remarks Component Tools D | O7GMJ—MLB0100 | Test Harness © | 074010010000 | Ficat Level Gauge [—7. Clutch. - No. Too! Number Deseri Remarks | 07924~P020003 (07JAF—PM70100 07460010100 (07749-00100 Ring Gear Holder Clutch Disc Alignment Too! Attachment, 32 x 35 mm Driver (07924-PD20002 may also be used cont'd) 2-3Special Tools Existing Tools (Common with Other Models) [— 8. Manual Transmission No. Too! Number Description | oy Remarks (077440010400 | Pin Driver, 5 mm | 07944—6110100 may also be used ® 1 @ 07936--6340000 Bearing Remover Set 1 a 077460010300 | Attachment, 42 x 47 mm 1 | 07974-61010 may also be used @ 077490010000 | Driver 1 | 079496110000 may also be used 5 07460010400 | Attachment, 52 x 55 mm. 1 | 078476340200 may also be used ® 07979-PJ40000 | Magnet Stand Base 1 2 | O7GAJ-PG20101_ | Mainshaft Clearance 1 Inspection Tool ® 07746—-0030100 | Driver joa ® 07748-0030400 | Attachment, 35 mm 1 ® (07844—SA00000 | Pin Driver 4.0 mm 1 i) | 079478110500 | Oi Seal Driver 1 @ 07948~-SC20200 | Oil Seal Driver 1 1 | 079478340500 Oil Seal Driver Attachment E 1 [—9. Automatic Transmission No. | _ Too! Number Description Remarks [a (079236890202 | Mainshaft Holder @ | O7HAC—PK40100 | Transmission Housing Puller 07GAE—PG40001 | Clutch Spring Compressor Set O7HAE—PL50100 | Compressor Attachment 07GAE~PG40200 | Compressor Bolt Assembly (07960~6120100 | Compressor Attachment 079366240000 | Bearing Remover Set O7GAC—PF40210 | Bearing Remover Attachment 07936~-6340000 may also be used 077490010000 | Driver (079496110000 may also be used 1 1 1 1 1 || Component Toots 1 1 1 1 077460010500 | Attachment, 62 x 68 mm 1 | 07947—6340400 may also be used. 1 1 1 1 1 1 1 1 1 07947—6340500 _ Driver Attachment E | 07947—6340201 | oil Seal Driver | 077480030100 Driver C (07944—SA00000 | 4.0 mm, Pin Punch 079476110500 | Driver Attachment E (07948-SC20200 | Oil Seal Driver (074060020003 | Oil Pressure Gauge Set 074060020201 | il Pressure Gauge Hose Attachment 07406—0070000 | Low Pressure Gauge | Component Too! 10. Driveshaft. No. | Tool Number ary Remarks @ 07749—0010000 | Driver 1 2 07746—0040800 | 38 mm Pilot . | 9 07746~-0040800 | 40 mm Pilot 1 @ 07965-SD30100 | Support Base 1 (| 07746-0010300 Attachment, 42 x 47 mm 1 ® | 077460010400 Attachment, 52 x 55 mm 1 @ | 07746-0010800 | Attachment, 62 x 68 mm 1 8 07947—$D90100 Oil Seal Driver Attachment 1 ® | O7GAD—SEOO100 | Oil Seal Driver Attachment 1 ® | OTJAD—SH3O100 Oil Seal Driver Attachment 1 @ 079658090200 | Support Collar 1 ® | 07947-SD80200 _ Oil Seal Driver Attachment Joa (@ | 07748-0030100 Inner Handle (C) 1aa (07GAE~SE00100 | spring Compressor 11, Manual Steering - No. | Too! Number Description ary Remarks © | @7216-SA50001 _ Stering Gearbox Lock Nut Wrench 1 078166820100 may ago be used % | 07841-8920008 | Ball Jot Remover 1 4} 07974 SA50E00 Ball Jomt Boot Cp Guide 8 1 11. Power Steering — No. | Tool Number Descroton avy Remarks D | 07408-01010 Bypass Tube Joint 1 2 07916—SAS50001 | Steering Gearbox Lock Nut Wrench joa 3 | 07806 0010200 PS Presure Gauge Set : 21 | 074060010300 Pressure Control Valve 1 D-2 07406—0010400 | Pressure Gauge 1 ‘Component Tools © | O7GAK—SE00100 P'S Presure Adaptor Set 1 @- 1+ | O7GAK-SE00110. | F/S Jot Adept (Pup) 1 | 07408-0011100 may aso be use 2" O7GAK-8E00120_| P/S Joint Adeptor (Hose) 1 | 674980011200 may ago be used S| 079416820008 Ball Jom Remover 1 5 | 07749-0010000 | Orver 1078498110000 may aso be used. | | 3 | 077460010300 Attachment, 42 47 mm 1 | | 079476340300 | Diver attachment : | o76m6-$D40800 | Too! Box 1 G7GAG—S040100 | Piston Sel Ring Guide 1 O7GAG—S040200 | Piston Sel Ping Sing Too ' component Tove O7GAG_S040200 | Cyinder End Seat Sher 1 O7GAG~S040400 | Syinder End Seal Gude 1 ct | 07974-8A0600 | imon Seal Gude : wb | 07725 -0030000 | Universe Holder 1 | 07725~0010101 may also be wed Da and 2" Component Tools 12, Suspension - No. | Too! Number Description avy Remarks | 7HGK-0010100 | Wheel Algnment Gauge ATtachmen 1 > | 078416920003 | Ball Joint Remover 1 3 078656340301 | Hub Dis Aesomly Base 1 «O7JAF-SH2O110 | Hub Dis/Asembly Pot, 38 mm ‘ | O7VAFSH20120 Hub Di/Assembly Sha : 22.44 25.4 mm 07748-01000 Diner 1 077480010400. Attachment, 52 x 58 mm 1 O7GAF Se00401 | Front Hub Driver Base 1 078656920201 Hub Di/Assombly Base 1 "| 077460010600. Attachment, 72x 75 mm 1 O7GAF S€00200__ Front Assembly Driver Atachment 1 2079688800100 | Ball Jomt Remover Istalr 4 3 O7JAF-SH20200 Bal Joint Remover Base 1 + | 07865800200 Bal Joint nstaler Base 1 S| 07874~SA50700__ Bal Joint Boot Cho & 1 07874~SA50800 | Bal Joint Boot Cip @ 1 1Special Tools Existing Tools (Common with Other Models) c (07920-$820000 Fuel Sender Wrench 13. Brakes. No. | Too! Number Description ary Remarks ® | 079210010001 | Fioir Nut Wreneh 1 | 975106340300 | Vacuum Joint Tube A 1 07404~5790300 | Vacuum Gauge Joa (07410~8790500 | Tube Joint Adaptor 1 © | 07408-57020 | Oil Pressure Gauge 2 ® | 07410--5790100 | Pressure Gauge Attachment C 2 ® | 075106340100 | Pressure Gauge Joint Pipe 2 @ | 07743-0010000 | Driver 1 | 07843--6110000 may also be used @ 077476890300 Driver Attachment C Joa @ | O7GAG—SE00100 | Pushrod Adjustment Gauge 1 ® | O7HAE—SGO0100 | Brake Spring Compressor ho4 07914~SA50000 | Snap Ring Plors 1 14, Body No Too! Number Description oy (07GAZ~SE3O100_ Torsion Rod Assembly Tool 1 [—15. Heater and Air Conditioner No Tool Number Description [ory Remarks (077460030100 | Driver C 1 | Pulley installation O7HAF—SF10300 | Seal Seat Remover (1 | Cover plate removal O7HAF—SF10400 | Seal Remover/Installer 1 | Shatt seat removal/instalation 16. Electrical No Tool Number | Description oySpecifications Standards and Service Limits Design Specifications Body SpecificationsStandards and Service Limits MEASUREMENT Compression 260 mi! (pm) and wide-open throttle 5. Engine/Cylinder Head, Valve Train (SOHC Engine) —— STANDARD (NEW) Unit: men in 1.28 kPa (13.0 kg/em 932 kea '5 xg 0m 185 psi 38 pal | Od 5.45-5.46 (0.2147—0.2150) ex 1201S tse | 3-2— 5. Engine/Cylinder Head, Valve Train (DOHC Engine) Unit: me fin.) MEASUREMENT STANDARD INEW) SERVICE LIMIT Compression | 250 min pm and wide-open Hotta Nomina! 1,326 kPa (13.5 xo/em!, 192 ps Mina 932 Kea (918 kglom, 138 al Maumom variation 196 Khe 2 baler 28 pl Cylinder head | Warpone — 0.05 (0.0021 Nee 191,95-192.05 = Comanat End ply 0.08-0.16 10 002_0.008) 0.5,10,02) Silane 8:950°0 089 {0.0020 .008) 8780-006) Ronout 86003 9.0011 max 8.03 {010001 Eamobe heaht W 33°03" (?'30007 & 32 382 [1 2749) = Vows Vane csrance W (0.139 17 0.005-0 0071 = & 8:18-0 19 10008 0.008, = Vato stom 0.0. i 8:58-8 59 (0.2591 0.2595) 6.55 10.2579) & 8'55-8 86 I 8 8210 2807) Stemto-gideclerence IN 9102-0.08 « 8.68 10.00) x 8:08-0 08 10002-0.008), 8.12 0-908), Stem instal heat i f3'ba5-46.019;1 7991-1 are) | $6 268 1 8215) & 48.7548 205 (1.7812—1.7797) | 45.485 1.7808) Vato sat) With iW and EX | 1.25-1.56 (0.089-0.061) 2.01008) ‘ave sorng | Free ength N “47.49 (1.8607) 46.45.1-8201) & 26:89 ( o40n) 45,93 118083), Squares iWex = 1687154 10-085/0.065) Valve auide 10. Wand EX | 6.61~6.63 (0.2602—0.2610) 6.65 (0.2579) - Unit i. — 5. Engine/Engine Bloeke -cmaaAaaA MEASUREMENT STANDARD (NEW) SERVICE Lin Cynder bck | Warpage of deck surface 0,07 (0.0028) max 0,10 (0,008) Bowe dameter Je 0s Feb BSea6-2 9505) | 75.0712 9865) Bore taper = 6°08 16.603" Reborin hit = S:soz? Paton Skt 0.0. AL 16 mm (0.63 0) 74.98-74.99 2.95202 9628 | 74.97 (2.98171 ~ from bottom oF ert Clearance in evince 6.01-9.04 10 0908-0.0016) 0.08 10.002) StontosingCesrance Top 8'03-0.08 (0 0012-0 024) 0:93 10.008) an 8:080°0-088 (0.0012-0.0022) | 0.13 (0.008) Piston ing | ‘Ring end gop Tee 0.18-0.35 0.006-9.014) 0810.07 an 8:15-9 38 10 006-0 014) 88 (0.02) ar 8'26-0.80 (0.008-0.028) 07 0.03 ‘Connecting od | Pinto-od interference 0,014-0 040 (0.0008-0.0076) = {Gtge ond tore dometer Nomina 45-0077) | nd play inated on crankshaft O78. 30 10.008-0.012) 0.400.016) Crankshaht | Man jourel dameter “44,976—45.000 (1.7707-1.7718) | ‘eper outa rounds main journal £1008 (0.0002) max 0.010 0.008) Rodfoumnal domeee 4 Sta, sae | S8'gne~40-000 Tt 67a9—1.5748) 184 48 sre—a2 000 (1 6526-1 8538) | ‘£8.976-48 000 (1.7707—1.9768) Toperout 0'0028 0.000" man 0.030,00,008) Ena pay 810-0138 (0.008"6.014) SSeioor8 Runeut 8.048 (6.0008) max 8°03 (0.0021, Bewinge Main bearing tourna! a cesrance tet ee 0.024~0.042 (0.9010-0.00171 | 9.5 0.0021 TG 1 No, 1.2.4 and 5 jrnals 8024-0:9e2 (2.0010-b0017| | 0.5 0-002) 18 No.3 uma 8.930-0.098 (0.0012-0.0013) | 05 (0.0021 fod bong tourna! ol clewance 8.020-0.098 (0.0008-0.0015) | 9.050.002)5. Engine/Engine Lubricat Unit: mn in.) {$A i i MEASUREMENT. STANDARD (NEW} | SERVICE UMIT Engine ol | Capacity #1USat. imp. al SOHC | 4014.2, 3.6) te engine deosenty ~ 3.5 (3.7, 31) After of change, meucing oer 3.013 2 2.81 trot change, wout fer Done | 4318.8: 3 8) Ate enge daar 3814.0. 35) Alero thange mating ol fiter 3.518°8; 2) Ate oh change, wet gu or Oi pum Dariacerent SOHE | 444 118US gol 9.7 mo gl} 0,250.mn (pm Bone | BPE ATTUS. gal: ta 7 tpl gal Se IB0 mn pm Inne-o-outer rotor ada clerance 2 141.008) | 9210 00m Pomp boat radi serance 8.100.178 (0.008-0.007 83 (0.008, 905-0 8 oreo 00s) 840000) ‘etal vai | Prssure ating BOC 1766! [lle SOHC | 167 KPa 7 Kalen 24 pal min Bone _| 137 kha ta Ag/em 20 pal ron 3.000% eon} BoC") 451 40a 14.8 ko/em: 65 pa Done _| S70kPe A 8kglem” Be pel -- 5. Engine/cooling tA MEASUREMENT STANDARD INEW) edor Genacty nel heated (US a Impar) | tarDORC MISS (58.48) ATSas7 4a) fields fos tank 0.40.48 6 36 Sone MTSSi57 48) Are siee.4) 1200 34,1 ae Misaierag aTsaibe a7 {Bt eon i xw.0%9 Misse7 48 ATS3I88 401 POM! (Omer! WISSisaeg Arsee) ag) {\Carourted Engine Wissi7as) aveaer ss) 2 Eiburete Eopne MTBSiE8 a8) ATSa(oT a8) Feast cap | Preston cap opening presiure 74103 Pe (0.751. 08 Aglon 1-15 ps) Themestat | Stare to open Wee 27229) Ful onee abc ines Wate a ft open 810.311 mn Water pune | Paley ato conkahah Toe Costin Gat nn i pe 108'127 U.S. go. 23 Imp. 9311/8,000 rom CCooing fan | Fan.to-coresesance 28001..0, ‘hermosmtch “ON temperatura 838 “s1°Sc 191-1676) Thermos “OFF tanpeare 85.5 8015 (182 —te0F! [-6. Fuel and Emission (PGM-F1) MEASUREMENT | STANDARD (NEW) Fuel pump | Dolvery esse 250 kPa 2 95 ka/em, 369s) ~| Bapiocerant 230 ce niates 10 pede min Rel vate opening pressure Sone tho a'5 “6 Oger 84—05 po) Pressure Pressure 230-270 We (2.38-2.75 agen, 33-39 ps) regtor Fuel Took Capacity 35 WT8US gl 89imp USM) tie WMT 1.900-2.000 min pm | AT 1'800-2:000 min tm lee soped with headahis and St 780 = $0 me (om) Cooing ten 1:8t, wm cata | 780 = 80mm (pm) 28: Bie’ ton veo wan cara 0.1% Man a Witmour ara {oesUni mm i. — 6. Fuel and Emissions (Carbureted Engine) MEASUREMENT STANDARD (NEW) Fu pump | Deiveryoressure 6,822.6 uP a (0.070 23 ng/en. 1.03.2 pot Steacemant | 835 deelmmutes 9 10 seconds ran Fu Tank Canaeiy 4541019 US. os. 89 imp US gol) Fonte MT 1,709-2.700 mi rm) BT 1:400-3.400 mn (om) Tae oped | wath hebaights and cooine on wr 790 = 50: om) I fexeot °N 0¢ °F 700 = 80 mn fom) tae CO KO 0.5% max ~ EX kc 7. Clutch (MEASUREMENT | STANDARD (NEW) I SERVICE LIMIT ‘cuter pecer” | Pedal pean 213 (6.391 0,00, Stone 140-180 (5 5-8.) Bosal lov 1592010 59°0.73), = tangagurent naaht 10 12 76) min 0 fooe = Five ‘loch surfs runout 0:08 (0.002) mse F018 10.006) ‘cuton isc) et hess doth 13 (0.05) min 02 10008) Soracs rout 0'3 (0.031 me 10.08) chess 81S 5101520 351 5710228) ‘chen eease | 10, 33,00-93.95 1 220-1 2261 31,211 228) Soing Roker | Holder to-guge sleeve ewrance '08".0'239 10 602~0 008" 08 10011) ‘Clutch cover | Uneveness of lephvagm sing 0.8 (0.09) mex 1.00.08) ‘cutch ease | eve pay 40-60 (016-0201 -- 8. Manual Transmission ! MEASUREMENT STANDARD (NEW! SERVICE MIT ‘Transmission ait | Capecity # (US. at..Imp.qt.) 1.8 (1.8, 1.6) at oll change 2412928) at anemny Marsha na lay 0,190.20 0.0089 008, Agate Durer of aeeate bescng contac ea Bils7P 6 $80 o727"" 0252) | 28'92"o20) Dimer ot tr gen contac roo 33 s04—34 900 (1 9360-12713) | 3339 1336) Diameter of tm, Stn gear contect rea 1.88026 999 [1 0622) 0027) | 28 98/1 060) Biamerer of oa barn contact bea 25°987—22 00 10 8656-0 8661) | 21.33 (0.863) Ronaut 5'6210-60081 max 605 10.002" Mansnate wd | 10 30,009-99.025 1 59581 5364) | 30,0711 538) ~ Gnd our | play gua | 168-0 27 (0.00120 008) onsen, ea Gm | 0,060.13 (0.00240, 0075) ost bor, Thoknase 3a | SoazS302raiges-visin — | Soistr 18 aR | 3012-3007 (1 185681 1878) 051183) Manahat fm | 1. 37,009-37 025 13 4570-14577) | 29.07 (1 538) ears Ed play 082,19 0 0024~0.0078) oat ioo12, ‘ns Baazcaeay nstes—t 1300) | 26.3611 176) Countershatt | End pl | 0,170.38 10,0067 0.0160 0.53,(0.021) | Blametr of neele beoring contact area $eio0s 0 SiS git tern | 2e9810 7%) Blames of Da arg eStart re 28 900-24 993 {0.9698-0.9840 | 24.93/10 261) Baamerer of low gear contact sree. Ss'see—30 000 |v at07—1 4173) | 38.9310 415) Ronout 2°02 1000081 mae do5 0.002) Countesnett | 10. “£1,008 44-025 (1 6145-1.6162) | 41.07 11817 ‘ow goer fi tey 168°, 10 40 0012~0.0038) 6122 (0 009), ‘helnate Beareze de is79-11891) | 29.38. 186) Counternatt | 10. “44 009-48 025 11 7328-1, 79331 | 44.07 1.795) Seen geor | Eo ley 010870, 11 19 0012-0 0043) 6429%0 008, Shoknate Geaacinlsy tr vet 1799) | 288875) TeontlStandards and Service Limits (cont'd) - 8. Manual Transmission (cont'd) MEASUREMENT |_stanpano wews senvice ut Spec ct 2 975-92 988 92000-12088) 39.99 9 200 | Becht | OB 35 80535 960 (1 2320-4 2328) | 33.93 282) sconigecl | Simin SSos%aocet feat ese | S008 taht Space coln 10 2 002-27 912 (1.06317 a8) 27 08 1 0951 meee an 34 $3831 8531 $8511 S805) 32 9811 S85 ie sn ah 3h 28032 980 38801 a0) Sr 3 ae) a Lana a Havareatiovas-noattn” aa ar am LG 2 lo sree oe 3881 0 S20) ewes 1D 15,038-15.009 1 59110 g922) | 18,08 0.888) os a toevre gor sat derance S828 BG STS ol” | oF 0EE) Simewo toa __| Rng tod ewan in putes ate gear]_0.73i.181.028-0.046 2410018 Shit fon] SR fork tinge tne € 4-6 6 0352-0285) = SEALS ORS Seance 8555048 Bose Sour 0000) feweas anti | SH fk pau saves wilh 12.7=13,0 0 800-0,632) — ix Be et aS Soe Saree Ser 85 Sab) veieom Sons ate $857 3 978-0205) ee Fen thre ant sien sn clearance | 0:96-0:58 1 608-0 619 05 0.00) Shit A) Bae of io coat ren 13,008-19 120 8120-0 50) Se A Sates SoBe a0 S668 SoSH | 0.38 00198) Snitems | Shoes ofshit wn statcontciaes | 18.973-14 000 (06801-0851 — Shia liam desrse Got erB SEED SSBB)” | 0 1810 0085) Sha Bsn pce wane B25 S plcorate diay 828 ezes, Sh ae as SPN Saran 129-120 (08078-05138) 12.78,0.8031) fog ew | oon 0.0790 130(0.0028-0.081) | 018 0007) Diterenisi | era ore drat 72,000-78 018 0 7087-07088 | ane Cae peitath eiance B89 8718 Gore 03180" | 0.088 10.000 Stren Soe Sam Borscreiaee eased era | 9088 Fe ee ace S'6teEo‘ou8 iB Gory“ c08t)”” | 0.14.6.c08) Ente Bicone Soh dorence 8096-894 ogesn-a.00es) | 8 1618 908) Sircosente 3iere Bifeonsi Seah 0.05-0.18 008-0008) sees wh 7 oe = pinion gear bore diametar 18.042— 18.066 (0.7103—0.7113) — eRe 'S888 8525 S0an | 0.186.006) Bian gear to imonanst learance MEASUREMENT STANDARD (NEW! SERVICE LIMIT ;- 9. Automatic Transmission 8£4-@.£——_ Tranamiscon ol ‘copesiye (US. at. mp. at) 4 (2.6.2) at ot change ‘ Hyaraue proto Une pressure et 2,000 min (pm 85834 kPa (8 08.6 kg/m 2 5:4 (8.7; 4.8) at assemoly % 114=121 ps 736 ko (78 kale, 09 pb 78 2ng. 3g, 4th clutch pressure 302,000 mun" pe) in {£12 a (4.2 kg/m, 60) ‘Trvotte coniat eer ficcoaed TSE are (6 0-8 5ea/em. Ta tt pb ‘Thor ont ever opened 2/8 or more 363 KPa (3.7 ken 53 ps 1796 KP 3 (7.5 kg/m’ 107 psi 2nd ten presse at 2,000 rin pm) n | TAS—834 KPa @ 0-8 Salem 736 kPa (7.6 aglow 107 psi T1a=124 pel 151 clutch pressure et 2,000 min rom) Governor pressure at (37.6 mph) 200-216 ¥Pa (2,102.20 kgiom:, | _203Pa (2.08 kg/cm 29 psi Boke 50°31 pal Throtta pressure 6 For corea 19 — Fl opmes | 7ap-a38 ura (8.0-2 B a/om, 138 Pa (7.5 kg/m’, 107 pb Throttle pressure A Fut cosed | 9-4-3 kPa (00.05 kg/cm, TS 8-07 ps Fullopenea | 805-520 kPa 15.15~8.30 Kg/em:, | S00.KPa 18.1 ka/em, 73 pi) 2°78 pat[ Stat speed ~ ~ luton ‘clutch nal clearance 1 ira, an Clute rear spring free eng 1st | Except st Chueh age mekness {uten pie taxase ts CGutch piste uchness Except tat {Guten one plate tciness Mak 1 fist ScNer, ena Man 2 Wel coroureted Engine) — Mark 3 | Mon 4 | Mae 5 Man 6 Mark & Mark 10 (Cue end plate heeness Mark aoa ae Te tnd 51 Carburied ‘ooge! Mark 18 Tranemission | Dameter of noodle bering contact ea on ‘ram and stator snot Imainshat 2nd gost ‘matnshat 4th gear colar Diameter of need Bearing contact area on ‘Ramnehat 1st ger caller Biamater of needa Bearing contact area on countorsha Ite) Biometer of macs bearing contact area on Counters Sa gear iameter of naoaia bearing contact area on Countershat ath gear Biameter of nee bearing contact area on lameter af needle bearing contact ores on Slameter af eed Beanng contact ares on ‘averse ide gear Marneaft 2n0 gear 0. Mamnahat fr ge 113 {Cournarahatt sth geo 0 ounterhatt Sed gee 1.0 Eeunteranatt tet gear 10. Countershete reverse gest 1.0 Reverse wie gear! © Reverse slr Shaft Reider 1.0, Moinenaft th gear ond Day Mannsnot 2nu gear end pay Mainenat it ger end lay” ountorhate tn gear end lay ountorshate 3rd gear end olay untershate Yat gear end olay Counterahate verse 9a" lay ;- 9. Automatic Transmission (cont'd) Unit: mn il STANDARD (NEW! SERVICE LIMIT 2300—2,800 min em 0 650-88 (0 026-0.033) 8 65-0.88 (0.026 0.033) 8.40-0'60 (0.160.028) $1012) 2901114) 28810 12) 074-0079) nit groowe worn ou 185-1 85 (0-063 -0 065) Brsceloretion 1.98-2.06 (0.077 0.079) 23° 2.410 081 0.088) 23-25 10 25-2610 28-3700 253800 i 28-2810 28-3010. 30-31 00 31-32 0 32-3300 23-3300 25-2600 i 282800 33520 34380 205-218, 395-2 43, 295 3.09, 365-305, | Discotration 19.980-19.993 (0.7266-0.7871) | Wear ar damage 96.975-96,991 (1.4169-1.4169) | 31.975-21.99) (1,2588—1.2594) 27.975-27.995 |1.1014—1.1022) .96,004~96 017 |1.4175-1.4380) 31,975~91 991 |7,2689-1.2595), 27,980-27 993 |1,1016-1.1021 13.990—14.000 10 s608~0.5512) 41 000-41 O18 (1 61821 33 000~33 018 (1 2902-1 33.000-33 016 (1.20024 38 o00—38 016 13780, 36 000-36 018 (1 3173, 18 007—18 020 (0 7083-0 7038) 2.216 14.234 (0.5876 0.5883), 109.22 10 0099~0 0087) § (0.0028 0 0059) {0.00310 0098) = {0'0028 0.0039) {0:0028-0 0089) = (6:0039 0.0177) (6.0029 0.0177), Wear or damage icant) 3-7Standard and Service Limits (cont'd) ;- 9. Automatic Transmission (cont'd) eAsuneMENT |__srawoano inews senvice unr Tianrisson | That eer mtg ona ane 247-150 0.1960-0 137 | wan or darn : 3988 1386-8 1508 é 32-340 8 1860-8 1409) i 5 Bera eeia tase 8 sae) 4 33900 Ieee 81a t 392-3 7810 1208-0 1a70) § BT 3 Bia 18k 8 eo, i 3a-3 aio 188e—8 18i0) i 3-3 Fo 0 185e—8 TES ana se ping 285-3 08 0 Hist8 en) sot basso ne ore Norse Ager 345-2 3610 bos) 8 onan) SNRI hase ge 72-4 oer -a seen Cree Sate F372 5818 Fide 888), ¢ 26-3 0810 1in9-8 Hon | é 367-3 (0 9. 1308-8 1290) j 5 29-3 18 0 1398 8 1240) | 2 3373158 1208 8 1200 | : 322-3 3810 1368-0 1200) § 32-210 8.13678 1288 ‘i 34-3 lo 1351-38 1319) ' B3F-84000 1297-0 1290) | wearer aage | counters tn rng dearan os (esas Vegey | OO | '5362-1.5374) —_ | | S81 Bed | | 1 4021-5413), _ | | ee | Bess sete | tarsal ang nar en ee) | mainshatt 1st gear colar length 0.9902) — Ore 1 SEA He cass eno damage Coimettad States ate mh sre | Na Some es 2 EAE ACA mean 3 GBs” | Wawro domino | Sm ae ts a | Bathe) | Na Somers to) See ctr ORC mckres 446025610. 0060"9 fo08| | Weare arage Same tna only ee eet 74 s14-14.440 2.9287~2 9207) | Weare damage Sarto! potna ar on-way ea re 67,7587. 788,0.2728-2.27401 | Weare dae mia type 8 0.0.18 mm tomant) $ 2h SiS Sey os g see | Masa ieehoes 88.8 er iSsmmon sah 857-885 9 28812380) | 888 8.3500 Caine ip 8 te 20 en | remenat 7 97-199 0 2128-0 3140 7.95,03130) [HEI sing ang 22 wm mcm SOR BBoe Seba) | TESST | Meamh sa, 58858 685 (99408-99974) § 048 8 2801 fora Bate 3 Gop8 018 0. ses8-0 ey | 9.95316 Zee Cetra 0 208-ger8 (0 sse-9 ase) | 038.0 ae Bde xe wey Soze-$.03 (ory oabit, | 3089 Gant SNOUGMRa 10% mal 3eBto ae or9 Wonae- Poses) | 309360 Bate elo ehe|-Seing ang contacts dame [32070-32026 1 2698-1 2608" | 2 0800 278 fay Shing deve | Rocce at on eee 590-6 0010200807382 §20 02126) Shh axe Peg te hp = Site Sa es Sea SNS se Wet ih et FR a stnoer 1a5-18.6:0.728-0.730) ee Seve boty) ‘Shion saftboe LD 14 060-14 008 @ 5612-95518) | — : HEGe8-14 9869 seiz-9 fete) | i HES ESIe 8 seo S618) | Shit fo eat atone. 35810-9780 2807-14888) | 97 05.4500 Ve Soy |i pmo ar ce race 903-0.95,0 0912-00020 | 007100028) Sime i Once | Bz oRuG 8K | De ogee 3 — omen; 8 660.08 _ Dre: ba” Soa . Sutra nz being vr. we] 26000-28313 (18838-10241) | Wee or damane Sts cepa nae Beng aad a8 ecm 24,000-24 091 (99429-0 9457) | Wea or daage Sr San gear FES0G- TE G8, 8 SSBB 8650) Wes droge oi nine Sete 15800—15 Sn0 0 s80e—o.8800) Whar: SnagsOiterentia Diferentt pinson geet 9. Automatic Transmission (cont'd) —————_— Pnionshat bore @amater amor torninsonshafteeerance Corman to-dnvsshatt csrance ‘Side Seorance Backieh Pinion gear to povorshalt clearance 0.086-0 143 (0.0034~0.0056) 18 000—18.078 (0.70870 7094) 001720 649 10.0609~-0 0019) 26 008 26.028 (1.02987 O24 S045 0089 10.001 70 003. 6.0780 111 10,0000 aosd) 0,050.18 10.002 -0 008) 18,0421 066 10.7103-0.71:3) 01088" 0 1098 (0 0023-6 6007) units men fn.) SERVICE LIMIT 0.25 1000) _ 0.096 (0.004) 0.14 (9.008), 0.18 (0.008), ‘Selecton with 7 type of ashore 0.18 0.006) Onverhatt - 10. Driveshaft MEASUREMENT “Right with ntemadite shaft i eft with intermadias shaft without termediate shaft STANDARD (NEW! ars 486.5 (18. 96-19 15) 485-490 (19.09. 19.29) 774 5-778.8 (20,49--20.69) SeRvice Limrr Steering whe! ‘Geer box Power steeung fiade Power steenng (11. Steering Nem gem “anh BS “The anaie of rack-aude-not loosens lacked pasion wih PIS Purp oreaare with vate closed YO! tom. Soeed “406 [104 F} male Bo not rar for Dellecton mdway between puleysiiosd | Floating toraue Nem tka mbt STANDARD (NEW) | 1010.39) max i 0.491 67 (0,050.17, 0.36-1.27) 61088 (6.01, 0.0721 40 =60 7,.845~8,828 (80-80, 1.138—1,280) 0.41 (42 U Sah 0.35 Imp. at fopont 2 SUS at 7-10 (0 280. 39)/98N (10 Ks, 0.48~2 84 (0 05-0 3, 0.36-1.27) ‘8-12 (0 35 0.47)/98N (10 kg, 22 1b) for used bert SEAVICE LIMIT 22 Wy stor replacement of batt 3-9Standard and Service Limits (cont'd) r- 12. Suspension MEASUREMENT STANDARD (NEW! service umir Wine! agnment Fron eer ‘ oe Pee 2032 {0.98 =0.08) Bort Sasori 380 21 oes ©2022) Tring angle MAX.) toward west | 813023 Siive'whew | 3330 = 3 Wrest Rin rout Sie 9-1.010-0 036) 29.08 Shown 8-07 16-0028) +3 88) Ptch-crl ameter too ia Bah Stee aan Whee! beanng | End ply Front ° 9.05 for 8 008 ‘By Maxam sewing angle a wich font ad eb whee in pace. rp 13. Brake MEASUREMENT STANDARD INEW) SERVICE MIT Paning bake | Payinsvoxe 200N 120g, 48 Bs) To be wcked when pute 6-10 ier rene Foot bate pedo!” Pel hight BHO | 181 (© 3 tom oor = TH | 153 6.0, tam for — Free poy 1500040120) 020) ‘aster evndee | Paton to-pun rod eronce (0-04 (0-0 016) = Des brake | Ose etness Front J-CoburtealEy,1 641 12.01.47) 79.9039) gee eed | 1791087 10 es PEt 84) 1781087 180089) ae Poker 1901075 17,0,0.671 ese 1091038) worsa, ae rout = 9° (0.608) 8a pursleam — 8.018 006) Pad Grcness” From PMI XX | 19,010.20) $8 '0.08) Bone | 3.01038) 391013) caouewa KYO | 10.0103) 3013) Signe? f° | Soot 301013) Sines | 8810 37 1810.08) oor | 851033 131008) Batson | 1D 20.7001 38) a3 ting mictnesn Pete 20 8.08) ‘Brae booster | Craracterites [vacuum im 45) ea Pressure tg (=) ine Patare Ke a/em pa ° 29 14) ma 7 209 3 (aa 35) 300 20 (a4) 883) oe Paw ° 2 aa! 23) omer carburetes 309 Zoles) 738) sane! 383 poled) Hon BPG ° car 138 309 at a8) 00 poles) Sec), 3-1016. Electrical eit en li} MEASUREMENT STANDARD (new) a avers Pre no vance | 0376-0.262 ons Secondary winding resance 3440-14160 obme renin wie | Rewonce 25,000 ons man Soo ng | oe See Secon 18 ore 0-11 088-0008 Tgnton ening] Atating POM SOHC Te =? they sT0e " * DOHC 16 = 2 (Red) BTOC 1 gamrtes Ene eure 1g =2 ines 700 SaStun.wisean | 1223 ey sre ken ges Pe datos 0°22" ac 422 5 RS sree 20.2 ines ero 22 eaetoe fo "Rle atic 13 23 ines bro onc Cahir capac Osho at) 10, 48,47 nage ae eating xpsiy ase, eee Fiemaior I No TsUBo Saat Sav 7608 : ERSUREWENT | Stanbano weer [_SeRvict mmr” sTaNOARD INEWT [~ SERVICE UT Cotesia (i STEaoom [> stom 38-3 8am) 02 hm Siping 00 Sapa) 32128) ews) EET Ssh enh ‘sewer | ssn BD S03 va coon wasn »3c0- 5009 ” 3008 = ean Sr | Re eS Saran mer aTACHTO Bw ND 6 50 OTD iw 1 Phy MTSURRY Ow Tw “seasumawenr /STRWERO' SERVICE | STAWDANO | SPAVEE STanDARD SERVICE TSTaNDERO | SeRviCE maar | Seavic® | STAM | Stine Stir | Sthwes | Saat | SUA as-98 as-08 ae-08 tos 02 02 9 ons mendes — | (8898 °) | ode) | (8870, )| late, (28%,) ohodn (2815) | Pee cums Bo) OR} ous} 04 0-008 | 995 1 S90 | 0.05 . BS) | ota | Gor | ois lode | Coy | ava | wor comunmae’ a0 RDP ae) ag BBB) a9 ae0-2a1 27s roo) 495 | ae | AN | don | Maa] ais [akoe8h| Fok common 7 AETSET no figeigeT oe estas) es iaa tay) a3 oh Gatos, oad foeinoes 0) Asda) eaH B85, wan Sens Tar 3e7 0 "30-2 ao 36 9 Pressure | 6 kg. — 11.6 kg, — (1. 85-2 4g, — {2,052.7 kg, — ine 538 Beas eA ieee 3-11Design Specifications 2D H/B rrews. MerRic eNGUSH ores DIMENSIONS | Overall Length 3,965 mm 156.1 3°390 mm 1871 in | wien bumper guare vera With 4/880 mm 58 1 | 1.870 mm 857 | s2ecae vera Height 1/330 mm S24 1/380 mm 53.5 Kv whestoase 2°300 mm 384m ‘Traok, Front/Rear 1,480/9.488 mm 57.1879 | 1885/1440 mom 569/56.) i xy Ground Clearance ¥0'mm an 180 mm £3mn care wih cata Seating Copscty ‘Stomang. Pron eae 770/698 mm 303/274 795/698 mm 33/27 4m warn pumper guava WeIcHTs. Engine Weight (Wet hae 2349 205 13e 28 ke 200 rat 88 ho ee 154 -corburetes 3ehg dors 1 St2.Carnuretes fons 2a 1 sepcwe 100 ke 230m hersone 102 ks 338m Veroone Take 2am cure Weigt i aewer 235 bs veers oar cae 1885 idem B20 be 1882 835 ta ies 840 bs 1882 8 navat 860 ts 11886 858 ts 1835 1aemT 850 ks Vere & 85 be 1885 © 565 ks 1307 1atart 870 ko 138m | eye ts 1/928 | B35 ko 1951 | 154m (Oxi 859 be 1804 Be5 ko 4807 fe 1 SEMI (ot B97 ke 1378 880 ks 1862 1 | 870 to 13ie | | 880 te 1920 1-SEAT (Ox) 885 to 1351 be y 84a eur S13 ee 2.024 S10 00 2'008 880 ks 11962 800 ke 1/384 1 61s0MC 800 ke 1984 fe 508 ks 1986 1.81 00He 833 ta 2017 | 820 ks 21028 WF, ND \Woght Distribution (Front Rese! Sana 510/325 ka 1124/76 Ke. KT. KU ed 520/28 ko 3:188/718 Ke KT: KU air 515/326 kg 138/718 & en RU | 510/328 k3 $128/738 w Ke, Ke! Re, Kw 515/326 bo 1snew. | RWISE, N) 3-12WEIGHTS ENGINE res TaeaT 1 5eMT 0% samy Gu 1 Start On heeaT (our 1 eesone 1 6400He Max, Permissbie Weight EC) at ie nee Macmnum Loaded Vehicle Weight Comping (Wovaing) Weght Capacty | crinderaangement Bbreand Soke 1.2 Vat ie Dispacement 12 Vat vat 1st hee Compression Ratio iat Vet {St Wimout cate vave Tran ewinout eat Orne Lubication System “Engine with cate. | BaMie DOHC mimout cata 525/325 to 3.179716 w 530 995 t3 3.168718 tp 525 998 ba 3152718 be 520/990 ta 188/718 540 325 43 190/718 Bap 398 ba 42027718 350 325 ba 1213716 560 925 ba 1338 /718 566/383 tg 4392/738 | Beet 4379/78 32 303 09 1220/786 585 949 0a 1:302/761 540/330 «a 1390/7286 350 930 03 1319/738 56 330 4g 1328/7380 508/943 ka 135/786 308/248 tg Vase | 360/330 as Ysa | 390/330 ka 131128 | 350/380 to yaa. | 565/360 ts 4324/772 ® 565/380 to 1316/72 370/380 ts 4:359/772 1.3108 2,888 340 bo 2.950 Wb 138063 21822» 1270 kg 5:02 137046 3.020 V370 Ke 5:02 ‘5h ito Water cooled d cycle SOHC Water Sood d-ryee 0.0.4 rycen STs 0 0 Behe PBs Ute gene | read en PRS 7590 mm 2.953 54in, | 1g ar Ben Be RES HB BER 4Uiaves pe nde, angle overhead comaholt ress fed \Unegced gasoline with 1 research cctane number or higher “Gasolne arth 91 researem etane number oF hier coca gaseive with 89 ressecn octane momoer Or Nahe Notes. Ke. KT. KU KB. KE KE KW kw (se, Ni ke Ke. KF, KG, KW kw (se, NI ‘Both leaded a0 Snleaded gasoline canbe eed 3-13Design Specifications | rrems: METRIC ENGLISH | ores ‘STARTER n og kw Direct ee PO RW, 12, 1k Gea todueton Normal Output OeAW, NEWT 2IW, 144 Normal Vologe tay how ating 0 seconde rection of Rotation Clockwise ag viewed Irom gear ond Woant ‘KW HITACHIIND aa s' OkW mirsuaa ag 738 NO. 3.85 49 5 12 kw NB Bass cas 1S kw mirsuBa See 82 TRANSMISSION | Clutch we ‘Sole gt iy. danhag sing Transmission Type MT 5 specds forward. synehromash 1 speed reverse, aT 4 seeede forward, wih lek-up cute, 7 speed reverse Primary Redueson "000 Gear Rat wT 1.6 DOHC MIT aT tet 3250 9.250 2.708 ana 1698 1580 br 1389 1 a2? an 0837 O78 5m om a" Reverse 3.159 1966 Fiat Reducton Mw /TA.2¢ Single helical gear, 4.088 Ks Single etal Sear. 4 250 RP. KT, KU tae Shale Petal gear, 4.058 Vat BSialeheteal gear’ 4.250 | 16 Sine hetcal gear, 4 088 x, KW, KS: Sle hele! gear, 4.250 ka 1gesone Singe nes! gear” #250 P8r0one Single hela! goo 3-888 Clute Facing Aree 148 om" 227 sa. in hee | 180 6m 268m IR GONDI. | Comoressor MASTUSHITA lower Ceatng Coseny | 3.850 Keath ‘Compression min * om) 1.800 min (rom) ‘Guise Ae Temperature 20 | are utsige Ar Kumatey 50% | Condenser ir Terserature 350 oer Condenser Arr Vetosty ees 14.8 fae Siawer Capecty | ‘aad ms 18.118eu hm | Compressor Type, ‘Von rotary type Namer of Vane ? Dispscemen 12088 Fo 9.93 eum. row Mae ou pm) 7,500 mn tr Uobecant Canecty 130ce Pe a3cu Recover Dryer With Descent Includes fusible safety piss. Condenser Comugated fn pe Fvaporater ‘Gomugated fin type 3-14fionen STEERING sysrem ‘SUSPENSION sysrew AUGNMWENT BRAKE res Speed Como! Max Capacity Com rch Type Power Consumetion Retngerant Tyre Ona reat Ratio Manoa ‘uns, Locktosack Manes! Steering Whee! Dameter” Oy Store Shock Absorber Font Wheel Alpnment Comber Front coster Front ™ Pear Type Front 2e. 138 fearee 4 Bike cea From t2t. tat 144, 1.88 yeeiee Fttocte Oise Domater Front at R Parking Srake Kin and Type ter Woe. 14e,158¢ MernIc T grec fon vowu2v 1 Sova ENGUSH | Acme ype ry, single wate. V batt ‘aM 12. | ma 0.90.08 «g 1.980.118 i887 wee iee20.41.1 ‘ae 36 237 nm 30mm | Independent by double wishtone, coll pings “ekacope, atogen ges filed Telescopes, strogen gested wan 146i 000-41 ree=7 923 mm 02012 i 222 mm jg 9.980 08 in Power assisted sal adjusting disc Power asssted se seustng vetiated disc ower assated se-sguatng ise 13,779 ou. tin 1.8 toniy Carturetad engine Sram Dacit.6e) Ccarouetes engine Pome Front Rear 12et3e naetse vee Soar (€C) 36.8 mm 5709 0 285 im 6.88 eqn 50.2 mar 378 54m Samm 32589. 19 190 mm 7.48 0 138 mm 16am 208 mm 19m 180 mm 5.08 Mecharicly actuating, rear two wel brakes 155513, 1858919, 6.15-13-49R oF 1658813, Tessin 165/708819, 165/708H"9 or 178/70HR12 res/eonta 92H 05/800 18 KB. KG KF, KE, KW ka KRKE KW(tae) 3-15Design Specifications 2D H/B Sow ravo.enw, (DAWA aw, vanw | Ass te da on 103 fon | sotto ‘on fost sg toni eth | rar set va | Eilat Ee | SEPA Bone eae selene wat EAE i | Sate 4.3 were? she TRESS an Lo ae onl aS ueo kane meat on Wee 3-16Design Specifications Tews METRIC ENGUSH Notes DIMENSIONS | Overall Length 4.230 mm 168 50 £238 mm tes 7a xa Wits bumper guard 2268 mm 169 8m EW ISR, Ny) Sect Neon 2/580 tm S351 Wheetase 2300 mm seam Yack, Front/Rear 1.456) :488 mem 57187 3. 12888, /440 mm 50.9987 Ky | round Cewarce 60'mm 83m come 180 mm 5300 Cars with cota, sting Capacity Biethng tron’ Rew 770/960 mm 209/978 m Inches bumper ‘ween bumper auars 498/860 mm B37 em Ines bumper weignts Engine Weight (Wet sae 9349 205.» wt a3te ee. 1'5¢ 1-cwoureted 3aig 307». 151 2caroureted 101k Be 1 Stew 19083 300. 1 6rsonc 107 As 238.6 coro Weight view a70b8 rata > F| Engine ol! and of fier T ® Every 5,000 km 13,000 miles) or 3 months toe tte e| Transmission oi | R Every 20,000 km (12,000 miles) or 12 months AB + DE F| Front brake discs and calipers 1 Every 10,000 km (6,000 miles) oF & months AB + DE F| Rear brakes (discs, calipers and pads) | 1 Every 20,000 km (12,000 miles) or 12 months AB C+ £ +| Clutch release arm travel | 1 Every 10,000 km (6,000 miles) or & months 7 8 GE «| Power steering system l H Every 10,000 km (6,000 miles) or & monthsEngine Engine Tune-up . 5-1 Timing Belt . Cylinder Head, Engine Removal/Installation Exhaust Pipe and Muffler Radiator -5-57 .5-69 5-71Engine Tune-up Radiator Cap Testing ... Coolant Level Inspection Engine Oil Level Inspection Engine Oil Replacement Air Cleaner Inspection/ Replacement . Compression Pressure Inspection Spark Plug Inspection. Alternator Belt Adjustment P/S Pump Belt Adjustment A/C Compressor Belt Adjustment Valve Clearance Adjustment... Idle Speed Inspection/Adjustment Tailpipe Emissions Inspection Ignition Timing Inspection and Setting .......... aaan 14 WONN 1 ser oaryvyoaaa aaanannaaa 1 a 1 NEngine Tune-up > Radiator Cap Testing FERIEMIN system is under high pressure when tngine is hot. To avoid danger of releasing scalding Coolant. remove cap only when engine fs cool 1. Remove the radiator cap, wet its seal with coolant, them install it on the pressure tester. 2. Apply pressure of 74—103 kPa (0.75—1.05 kg/em? 1118 ps). 3. Check for a drop in pressure. 4. If there is @ drop in pressure, replace the cap RADIATOR CAP 1 3, - Coolant Level Inspection Check whether the coolant level in the coolant reser: voir tank is between “MAX” and “MIN UPPER LeveL LOWER Level Supply the coolant reservoir tank with coolant 10 "MAX", ifthe coolant level is lower than “MIN” or near to "MIX NOTE © Use only HONDA-RECOMMENDED anti-freeze/ coolant. @ For best corrosion protection, the coolant concen- tration must be maintained year-round at 50% MINIMUM. Coolant concentrations less than 50% ‘may not provide sufficient protection against corro- sion oF freezing ‘© Coolant concentrations greater than 60% wil cooling efficiency and are not recommended, impair CAUTION © Do not mix different brand anti-freeze /coolants © Do not use additional rust inhibitors or antirust products: they may not be compatible with the recommended coolant. Radiator Coolant Refill Capacity: wt aT _ WW Sat, at) [izle aa we. 39/8905, 38) 1.64 (1-Capureted) a4 (6.6. 9.9)4 9146, 3.9) 15 2.Cabweted) [8.516,7. 4.0/8.6146, 3.9) 1.58 (PGM-FIl 70 ps |4.4 (4.6, 9.9)/4.9 (4.5, 3.8) TsrpGwF 4547 -40)44 46.9.9) Tero0We 4547-40) 1ersone aa ae ga (including the reservoir tank capacity: 0.4¢ (0.42 U.S.qt., 0.36 Imp. at.)) ‘See page 5-78 for refiling- Oil Level Inspection ———————_ 1. Check engine oil with the engine off and the car parked (on level ground 2, Make certain that the oil level indicated on the dipstick is between the upper and lower marks, 3. If the level has dropped close to the lower mark, add oil unt it reaches the upper mark CAUTION: Insert the dips bonding it ick carefully to avoid UPPER oipstick—>| Lower [ Engine Oil Replacement ————_ 1. Warm up the engine 2. Drain the engine oi NOTE: Remove the fi Ot PAN DRAIN PLUG 45 Nem (4.5 kg-m. 33 Ib-f) 3. Reinstall the drain plug with a new washer, and refill with the recommended oi! Capacity | SOHC 3.0 it (3.2 US at, 2.7 Imp. at) DOHC 3.3 lit (3.5 US gt, 2.9 Imp. qtl ‘excluding oil filter SOHC: 3.5 It (3.7 US at, 3.1 Imp. at) DOHC 3.8 lit (4.0 US qt, 3.4 Imp. ath at change, including fier SOHC: 4.0 lit (4.2 US at, 3.5 Imp, at) | | DOHC 4.3 tit (4.6 US at, 3.8 Imp. at) Every 10,000 km (6,000 miles) for 6 months | ‘change Recommended Engine Oil [SE or SF Grade only) NOTE: Oil filter should be replaced at each oil change. 5-3Engine Tune-up r- Air Cleaner Element Inspection/ — Replacement Inspection 1. Remove the air cleaner element 2. Check the air cleaner element for fouling NOTE: No cleaning is necessary for the air cleaner element, because its filter takes in ol (: viscous type} Repl 10: every two years © The air cleaner element should be replaced more frequently on cars normally used under severe riving conditions. Replacement 1. Remove the sir cleaner cover 1-Carbureted Engine: nur AIR CLEANER COVER Fuol-Injected Engine sours AIR CLEANER cover 2. Replace the element, install the air cleaner cover and tighten the clip, aut or bolts securely -- Compression Pressure Inspection 5 1. Before inspection, run the engine until it warms up (radiator fan comes on} 2. Disconnect spark plugs (4) 3. Disconnect the 2-P connector (ignition coil primary lead) from the distributor. 2.P CONNECTOR 4. Fit the compression gauge adapter into a plug hole. (© Measure compression pressure at each cylinder Compression pressure: SOHC Engino: 1,275 kPa (13.0 kg/em?, 185 psi) ‘at 250 min’ (rpm) DOHC Engine: 1,324 kPa (13.5 kg/em?, 192 pail at 250 min" (rpm) 992 kPa (9.5 kg/em?, 135 psi) at 250 min’ (rpm) Difference between oylinders: 169 kPa (2.0 kg/cm?, 28 psi Limit: NOTE: Use a full charged battery. 5. If compression pressure is low, itis caused by wear or damage of piston rings or head gasket, and improper seated valves. 5-4Ignition System [— Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: Worn or deformed Improper 0 Oiltouting Carbon deposi jos insulator | ! i Burned or worn electrodes may be caused by Lean fuel mixture Advanced ignition timing + Loose spark plug + Plug heat range too high Insufficient cooling Fouled plug may be caused by’ Rich fuel mixture Retarded ignition timing Oil in combustion chamber Incorrect spark plug gap Plug heat range too low Excessive idling/low speed running Clogged air cleaner element Deteriorated ignition coil or ignition wires bs] 2. Replace the plug if the center electrode is rounded as shown below: Spark Plug Stondard Optional T BCPREEV-NIT Uneaded [NGK) BCPREE-11 BCPRTE-11 going BCPRTEY-NIt [No fozopR-UTi —jazaPR-ui1 - "ecPRsE-11 (*) NGK 8CPROE-11 Scene 16PR-UTT O#) toes 2opa-uti sePR-ULIT (+) gevoine |ND FOP UT) [2OPR-UTT (+) 22PR-UI1 tL 22PR-ULIT (x) (): 1.6 DOHC oniy 1.0-1.1 men (0.039 01043 m) ROUNDED ELECTRODE 3, Adjust the gap with a suitable gapping tool Electrode Gap: 1.0- 1.1 mm (0.039— 0.043 in) 4. Screw the plugs into the cylinder head finger tight, then torque them to 18 Nem (1.8 kg-m, 13 lb-ft) NOTE: Apply 2 small quantity of antiseize com: pound to the plug threads before installing 5-5Engine Tune-up Drive Belts Inspection Drive Belts Deflection: (When applying a force of 9.8 N (10 kg, 22 Ibs)) 7 TU Ber 4 9-11 mm {DAerntor Belt 9.360.431.) (0.28-0'38 in| GNC Compressor | 8-11 mm | 7-8 mm Bett (0.35~0.43 in.}|{0.28—0.36 in.) 9-12 mm | 710 mm t [OPS Bart [(0.35~0.47 in.) (0.28-0.38 in.) CRANKSHAFT PULLEY ,- Alternator Belt Adjustment 1. Apply 2 force of 98 N (10 kg, 22 Ib) and measure the eflection betwaen the alternator pulley and the crank: shaft pulley. Deflection: 9-11 mm (0.35-0.43 in.) NOTE: On a brand-neve belt, the deflection should be 7-9 mm (0.28— 0.36 in.} when first measured. ALTERNATOR NUT 22 Nem (2.2 kg-m, 16 to) Measure here \ ALTERNATOR THROUGH BOLT 45 Nem (4.5 ko-m. 238 lb-ft) CRANKSHAFT PULLEY ALTERNATOR BELT 2. Loosen the alternator nut and through bolt 3. Move the alternator by turning the adjust nut to obsain the proper belt tension, then retighten the bolt and nut. 4. Recheck the deflection of the belt1 4 ; P/S Pump Belt Adjustment ——— Apply 8 force of 98 N (10 kg, 22 Ib) and measure the deflection, between the P/S pump pulley and the crankshaft pulley Deflection: 9~12 mm (0.35~0.47 in.) NOTE: On a brand-new belt, the deflection should be 7-10 mm (0.28~0.39 in.) when first measured. P/S PUMP PULLEY CRANKSHAFT PULLEY Loosen the P/S adjust pulley bolt Turn the adjust nut to get the proper belt tension, then retighten the bolt and nut Recheck the deflection of the belt. 4 be] - A/C Compressor Belt Adjustment 5 Apply @ force of 98 N (10 kg, 22 Ib) and measure the deflection, between the A/C compressor adjusting pulley and the crankshaft pulley. Deflection: 9-11 mm (0.35—0.43 in.) NOTE: On a brand-new belt, the deflection should be 7-9 mm {0.28-0.35 in.) when first measured. ADJUST PULLEY NUT Loosen the adjust pulley nut Turn the adjust bolt to get the proper belt tension, then retighten the bolt and nut Recheck the deflection of the belt.Engine Tune-up [ Valve Clearance Adjustment SOHC Engine: NOTE: Valves should be adjusted cold when the cylinder head temperature is less than 38°C (10°F), Adjustment is the same for intake and exhaust valves. 1, Remove valve cover. INTAKE EXHAUST 2. Set No. 1 piston at TDC. "UP" mark on the pulley should be at top, and TOC grooves on the pulley should align with cylinder head surface. The distributor rotor must be pointing towards No. 1 plug wite Number 1 piston at TDC “UP MARK ‘TD GRoOvES 3. Adjust valves on No.1 cylinder Intake: 0,170.22 mm (0.007.009 in.) Exhaust: 0.22—0.27 mm (0.009~0.011 in.) 4, Loosen locknut and turn adjustment screw until feeler gauge slides back and forth with slight amount of drag, LOCKNUTS 7 x 0.75 mm 14 Nem (1.4 kgm, 10 Io) 5. Tighten locknut and check clearance again. Repeat adjustment if necessary 6. Rotate crankshaft 180° counterclockwise (cam pulley turns 90°), The "UP" mark should be at ex- hhaust side. Distributor rotor should point to No. 3 plug wire. Adjust valves on No. 3 cylinder. Number 3 piston at TDC “UP MARK 7. Rotate crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TOC grooves are once again visible and distributor rotor points to No.4. plug wire. Adjust valves on No.4 cylinder. Number 4 piston at TDC "UP" MARK hooves. 8. Rotate crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The "UP" mark should be at intake side. Distributor rotor should point to No. 2 plug wire. Adjust valves on No. 2 cylinder. Number 2 piston at TDC Up" MARKbe} DOHC Engine NOTE: Valves should be adjusted cold when the cylinder head temperature is less then 38°C (10°F), Adjustment is the same for intake and exhaust valves 1. Remove the valve cover EXHAUST NO.1.NO.2 NO.3 NO. NO.1NO.2 NO.3 Noa INTAKE 2. Set the No. 1 piston at TDC. “UP” marks in the pulleys should be at top, and the TDC grooves on back side of pulley should align with cylinder head surface. The distributor rotor must be pointing towards No. 1 plug Numbor 1 piston at TOC TDC. GROOVES "Up" MARK “UP” MARK 3. Adjust valves on No.1 cylinder Intake: 0.13—0.17 mm (0.000.007 in.) Exhaust:0.15—0.19 mm (0.006—0.007 in.) 4. Loosen locknut and turn agjust screw until feeler gauge slides back and forth with slight amount of drag, LOCKNUT 7 x0.75 mm 25 Nem (2.5 kgm, 13 Ibo) 5. Tighten locknut and check clearance again. Repeat adjustment if necessary 6. Rotate crankshaft 180° counterclockwise (cam pulley turns 90). The "UP" marks should be at exhaust side Distnbutor rotor should point to No.3 plug wire ‘Adjust valves on No. 3 cylinder. Number 3 piston at TOC “UP™ MARKS EXHAUST CAM PULLEY INTAKE CAM PULLEY 7. Rotate crankshaft 180° counterclockwise to bring No 4 piston to TDC. Both “UP” marks should be at bottom and distributor rotor points to No.4 plug wire. Adjust valves on No.4 cylinder Numbor 4 piston at TDC “UP” MARKS 8. Rotate crankshaft 180° counterclockwise to bring No. 2 piston to TDC, "UP" marks should be at intake side. Distributor rotor should point to No.2 plug wire Adjust valves on No.2 cylinder Number 2 piston at TOC “UP” MARKS.Engine Tune-up 3 4 Carburoted Engi CO Me 2 [Idle Speed Inspection/Adjustment (ka) CO Meter Method Do not smoke during this procedure, Keep any open flame away from your work area NoTe © Check that the carburetors are synchronized prop: erly, self diagnosis indicator, clutch pedal {section 7} before making idle speed and mixture inspec © Snap the accelerator pedal several times and check the idle speed with the accelerator pedal fully retur ned ¢ Method Warm up and calibrate the NDIR CO Meter in accor dance with the manufacturer's recommended proce: dures Insert exhaust gas sampling probe into the tail pipe at least 40 cm and connect a tachometer ‘TACHOMETER R.P_M. CONNECTING ADAPTOR 07Ja2—SH20100 Start the engine and warm up to narmal operating temperature (the cooling fan comes on) Check the fast idle lever Fast idle lever should not be seated against fast idle cam. FAST IDLE CAM — LV ff FAST IDLE LEVER | © IF not, replace the left carburetor (page 6-67) 5 Check idle speed with the headlights, heater blower, rear window defogger, cooling fan and air conditioner off ale speed should be: [Manual [750=50 min" 0pm] Automatic | 700: 50 min om) except-N or-P*) Adjust the idle speed, if necessary, by turning the throttle stop screw. NOTE: If the idle speed is excessively high, check the throttle control (page 6-88) ‘THROTTLE STOP SCREW 5-10be] 6. Disconnect the 2P connector from the EACV and disconnect the hose from vacuum hese manifold, then cap the hose end : Disconnect #2 vacuum hose from vacuum hose mani- fold, then cap the hose end cap #2vacuUM HOSE 7. Warm up the engine further for more than 2 minutes with the engine speed 3,000 min (rpm) 8. Check specification for idle CO with no load Specified CO %: 2.0-3.0 % 8. If not within specification, remove mixture adjusting screw hole plug and adjust by turning mixture adjust- ing screw to obtain proper CO reading MIXTURE ADJUSTING SCREW HOLE CAP’ Turning mixture adjusting screw clockwise CO reading decreases counterclockwise: CO reading increases © Reagjust idle speed if necessary, and recheck idle co. 10. Turn the ignition switch OFF, Reconnect the con rector and hose. 11, Remove HAZARD fuse for 10 seconds to reset control unit and recheck idle speed Idle speed should be: Manual 1750280 min om) ‘Automatic | 700450 min~ rpm) [except "N" oF "P') ‘Specified CO %: 0.5 % © IF idle speed is not as specified, adjust by turning throttle stop screw, then repeat step 6 (cont'd) 5-11Engine Tune-up 12. Reconnect air cleaner intake tube on the air intake duct 13. Reinstall the mature adjusting screw hole cap, 14, Discnnect the #20 vacuum hose from the idle boost, throttle controller and connect a vacuum pump. #20 VACUUM HOSE 15. Apply vacuum, then check the idle speed with the headlight, heater blower, rear window deffogger and ‘cooling fan on. Idle speed should be: 700 +50 min” (rpm) ADJUSTING SCREW A Adjust the idle speed, if necessary by turning the adjusting screw A ‘Idle Speed Inspection/Adjustment (cont'd) 16. If equipped with air conditioner, check the idle speed with the A/C on. Idle speed should be: 75050 min * (rpm) ADJUSTING SCREW 8 Adjusting the idle speed, if necessary, by turning the adjusting screw 8 17. If the idle speed does not reach the specified idle speeds in steps 14 though 16, go to idle control system testing (page 6-30) 5-12ex, Ka} NOTE: © Ignition timing and valve clearance must be correct, and engine must be normal operating temperature; the coo ling fan will come on. ‘© Snap the accelerator pedal serveral times and check the ‘dle speed with the accelerator pedal fully returned. © Check the clutch pedal (section 7) before making idle speed and mixture inspections [CRIMI 00 not smoke during this procedure. Keep ‘any open flame away from your work area CO Meter Method 1. Warm up and calibrate the NDIR CO Meter in accor dance with the manufacturer's recommended proce- dures 2. Insert exhaust gas sampling probe into the tall pipe at least 40 cm and connect 2 tachometer TACHOMETER R.P.M. CONNECTING ADAPTOR 07Az~SH20100 3. Check the idle speed with no load Idle speed should be: Manval [760260 min om) ‘Automaiie | 7002 60 min (rpm 4. If not within specification, adjust by turning throttle stop screw to obtain proper idle speed If idle speed cannot be adjusted properly, check for proper throttle cable adjustment. [1-Carbureted Engine] ‘THROTTLE STOP screw [2-Carbureted Engine] ‘THROTTLE ‘STOP SCREW 5. Check specification for idle CO with no load. Speified CO %: below 0.1 % 6. If not within specification, remove mixture adjusting screw hole plug and adjust by turning mixture adjust- ing screw to obtain proper CO reading [1-Carbureted Engine) ADJUSTING SCREW HOLE CAP (1-Carbureted Engine, Ex. KP, KT, KU] HOLE cap, (cont'a 5-13Engine Tune-up [2-Carbureted Engine) MIxTURE ) ADJUSTING SCREW HOLE CAP Turning mixture adjusting screw clockwise: CO reading decreases counterclockwise: CO reading increases © Readjust idle speed if necessary, and recheck idle co. 7. Install the hole plug If unable to obtain @ CO reading of specified % by this procedure, check the engine turn-up condition 8. If equipped with air conditioner, check the idle speed with the A/C on. Idle speed should bo: ee Kem [750250 min Womb KG Mit 950250 min (rpm) if not KG M/T; go to idle conttol system (page 6-32), Ex. KG M/T; adjust the idle speed by turning the adjusting screw. [1-Carbureted Engine] ADJUSTING scREW (—Idle Speed Inspection/Adjustment (cont'd): [2-Carbureted Engine) ADJUSTING screw 5-14POM-FI (1.54): 1. Start the engine and warm it up to normal operating temperature (the cooling fan comes on) 2. Connect 2 tachometer RPM CONNECTING ADAPTER (07A2~SH20100 3 acy 4. Check idling in no-load conditions in which the head- lights, blower fan, rear defogger, cooling fan, and air conditioner are not operating Idle speed should be: Manual 62550 min’ (rpm) Automatic | 62650 min (rpm) (in Nor®h Adjust the idle speed, # necessary, by turning the idle adjusting screw. NOTE: If the idle speed is excessively high, check the throttle control system (page 6-236) IDLE ADJUSTING SCREW Reconnect the 2P connector on the EACV, then remove HAZARD fuse in the main fuse box for 10) seconds 10 reset ECU. Idle the engine with aa-load conditions in which the headlights, blower fan, rear defogger, cooling fan. and air conditioner are not oparating for one minute, then check the idle speed. Idle speed should be: Manual [780250 min * (rem) Automatic | 780250 min (rpm) (in Nor) Idle the engine for one minute with headlights (Hi) and rear defogger ON and check the idle speed Hf applicable, with Automatic transmission models, idle the engine for one minute in gear (except Nor P) and ccheck the idle speed. Idle Speed should be: 78050 min-* (rpm) Idle the engine for one minute with heater fan switch ‘at HI (ight end) and air conditioner on. then check the idle speed. Idle Speed should be: 78050 min * (rpm) NOTE: If the idle speed is not within specifications, see System Troubleshooting Guide on page 6-192. leont’a) 5-15Engine Tune-up 4 PGM-FI (1.62): Start the engine and warm it up to normal operating temperature Ithe cooling fan comes on) Connect 2 tachometer. RPM CONNECTING ADAPTER ‘O7JAZ-SH20100 Disconnect the 2P connector from the EACV. acy ‘Check idling in no-load conditions in which the head- lights, blower fan, rear defogger, cooling fan, and air conditioner are not operating Idle speed should be: 65060 min ° (rpm) Adjust the idle speed, if necessary, by turning the idle adjusting screw NOTE: If the idle speed is excessively high, check the throttle control system (page 6-237), [—Idle Speed Inspection/Adjustment (cont'd) | IDLE ADJUSTING SCREW 6 SOHC With CATA SOHC Without CATA boHc 7 ‘SOHC With CATA Reconnect the 2P connector on the EACV, then remove HAZARD fuse in the main fuse box for 10 seconds to reset ECU Idle the engine with no-load conditions in which the headlights, blower fan, rear defogger, cooling fan, and air conditioner are not oparating for one minute, then check the idle speed ] 750250 min * (rpm) —_|— “ee 78060 min * (spm) 180050 min ' (cpm) Idle the engine for one minute with headlights (Hi) and rear defogger ON and check the idle speed. Idle Speed should be: 75050 min- (rpm) SOHC Without CATA 78050 min * (rpm) jpoHe 800+50 min“ (rpm) B. Idle the engine for one minute with heater fan switch at HI (right end) and air conditioner on, then check the idle speed. Idle Speed should be: SOHC 780250 min~ (rpm) boxe 80050 min ' (rpm) NOTE: Ifthe idle speeds not within specifications, see System Troubleshooting Guide on page 6-192. 5-16[—Tailpipe Emissions Inspection Carbureted Engine: NOTE: Itis not possible to use a CO meter to adjust the idle mixture: the effect of the catalytic converter pre vents accurate tracking of such small changes i air- fuel ratio, Do not smoke during this procedur ‘ny open flame away from your work Keon 1. Follow steps the propane enrichment method. 2. Warm up and calibrate the CO meter according to the meter manufacture’s instructions 3. Check idle CO with the headlights, heater blower, rear window defogger, cooling fan, and air conditioner off Spocitied CO%: Ka: 0.5% Ex. KQ Others: 1.0% 1, Pam FERIEIMY 06 not smoke during this procedure. Keep any open flame away from your work area 1. Start the engine and warm up to normal operating Temperature icooling fan comes on) 2. Connect tachometer 3. Check idle speed and adjust the idle speed, necessary (page 6-204 or 205) 4. Warm up and calibrate the CO meter according to, the meter manufacturer's instructions 5, Check idle CO with the headlights, heater blower reat window defogger, cooling fan, and air condi tioner off Specified CO% With CATA: 0.1% maximum Without CATA: 1.0 = 1.0% © 1 unable to obtain this reading; On With CATA, see ECU troubleshooting (page 6-144 or 148) On other models, adjust by turning the adjusting screw of the IMA sensor. ADJUSTING SCREW ~ If unable to obtain a CO reading of specified % by this procedure, check the engine tune-up condi- 5-17Engine Tune-up —Ig Pome 1. Start the engine and allow it to warm up (cooling fan ‘comes on} 2, Remove the rubber cap {YEL) from the ignition timing adjusting connector located left rear engine compart ment and connect the BRN and GRN/WHT terminals with a jumper wire RUBBER CAP (VEL! IGNITION TIMING ADJUSTING CONNECTOR JUMPER WIRE 3. Connect a timing light to the engine; while the engine idles, point the light toward the pointer on the timing belt cover. TIMING UGHT ion Timing Inspection and Setting 4. Adjust ignition timing, if necessary, 10 the following specifications Ignition Timing 1.82 SOHC: 18+ 2;BTDC (RED) at 780+50 min-' (rpm) in neutral 1.6¢ SOHC (With CATA) 18'+2;BTDC (RED) at 750+50 min- (rpm) in neutral 1.62 SOHC (Without CATA) 18 £2'BTDC (RED) at 78050 min-' (rpm) in neutral 1.62 DOHC: 16 2;BTDC (RED) at 80050 min-' (rpm) in neutral POINTERS. WHITE MARK CRANKSHAFT PULLEY RED MARK 5. Adjust as necessary by loosening the distributor adjust ing bolts, and turn the distributor housing counter- clockwise to advance the timing, or clockwise to retard the timing To ADVANCE % ADJUSTING BOLTS 6. Tighten the adjusting bolts and recheck the timing 7. Remove the jumper wire and install the rubber cap to the ignition timing adjusting connector 5-18be] 1-Carbureted Engine Ex. KG (A/T) model? 1. Disconnect the vacuum hose from the vacuum ‘advance diaphragm, then connect the vacuum pump) {gauge to the vacuum hose vacuum PUMP/GAUGE VACUUM HOSE 2. Start the engine and let it ide 3. Check the vacuum hose for vacuum. The vacuum hose should have vacuum @ if the vacuum hose has no vacuum, check the vacuum hose of proper connection, cracks, block: age or disconnected hose. 4, Connect the vacuum hose to the vacuum advance ‘aphragm and allow the engine to warm up (cooling fan comes on} 5. Disconnect the vacuum hose from the vacuum advance diaphragm and plug them. 6 vacuum Hose Connect a timing light and an advance tester ADVANCE TESTER ADVANCE — conrrot KNOB TIMING LIGHT While the engine idles, point the light toward the pointer on the timing belt cover Align the timing mark {White} on the crankshaft pulley to the pointer by turning the advance control knob of the advance tester, CRANKSHAFT POINTERS PULLEY RED MARK WHITE MARK (cont'd) 5-19Engine Tune-up 8. Read initial timing when timing mark (white) is aligned to the pointer. Initial Ti TS ~_[otoe 126 . = [otters 4 aTDe 1.32 [Al models ” BTDC [180 [atmoaeis |? etoc © Manual Transmission [at 750 + 50 min-' (rpm) in neutral) © Automatic Transmission{at 700 * 50 min: (rpm) in gear) 10. Adjust as necessary by loosening the distributor adjust ing bolts, and turn the distributor housing clockwise to retard the timing, or counterclockwise to advance the timing SE ADJUSTING BOLTS. 11, Tighten the distributor adjusting bolts, then recheck the timing, —lIgnition Timing Inspection and Setting (cont'd) 12. Connect the vacuum hose to the vacuum advance diaphragm and inspect ignition timing at idle Ignition Timing fra (ses eat Others: 20° = 2° BTOC (Red) i [KG (M/T only) [12 = 2° BTOC (Red) (XS Others 18 = 7° BTOC (Red) KYAT ony) [12° = 2° BDC (ea Others 18+ F BTDC thea) {© Manat Transmission [at 750 = 60 min pm) «© Aetomatie Transmission [at 700 = 60 min pm) ingeed W advance is not as specified, check the vacuum advanee digphragm and distributor advance mecha- 5-201 2-Carbureted Engine: (Ex. KG model 1. Disconnect the vacuum hoses from the vacuum advance diaphragm, then connect the vacuum pump/ ‘gauges to the vacuum hoses. vacuum PUMP/GAUGE Hoses Hoser2 2. Start the engine and let it idle 3. When the engine is cool Coolant temperature is below [KQ: 70°C (158°), others: 45°C {113°F)] Check each hose for vacuum. The #2 and #5 hoses should have vacuum @ If the #2 hose has no vacuum, check the #2 hose of proper connection, cracks, blockage or discon: ected hose. K@Q model (1.54, PGM-CARB). © IF the #5 hose has no vacuum, check the ¥5 and #12, hoses for proper connections, cracks, blockage or disconnected hoses, and the check valve is not clogged I the #5 and #12 hoses, and the check valve have ‘no problem, check the vacuum control solenoid valve and recheck the §5 hose for vacuum Others model (1.42). €@ Ifthe #5 hose has na vacuum, check the #5 and #10 hoses for proper connections, cracks, blockage or disconnected hoses, and the check valve is not clogged If the #5 and #10 hoses, and the check valve have no problem, replace the thermovalve and recheck the #5 hose for vacuum. 4. Conneet the vacuum hoses to the vacuum advance diaphragm and allow the engine to warm up. (cooling fan comes on} 5. Disconnect the #5 hose from the vacuum advance diaphragm and connect the vacuum pump/gauge to the #5 hose: 6. Check the #5 hose for vacuum. ‘The #5 hose should have no vacuum. KQ model (1.52, PGM-CARB) @ if the #5 hose has vacuum, check the vacuum control solenoid valve and the recheck the #5 hose for vacuum. Others model (1.4 £): @ Ifthe #5 hose has vacuum, replace the thermovalve and recheck the #8 hose for vacuum, 2. Disconnect the vacuum hoses from the vacuum advance diaphragm and plug them 8. Connect a timing light and an advance tester ADVANCE VAC\UM HOSES TESTER TIMING LIGHT 9. While the engine idles, point the light toward the pointer on the timing belt cover. (cont'd) 5-21Igition System —Igni 10. Align the timing mark (white) on the crankshaft pulley to the pointer by turning the advance control knob of the advance tester CRANKSHAFT PULLEY POINTERS RED MARK WHITE MARK 11. Read initial timing when timing mark (white) is eligned to the pointer. Initial Timing All models: 2° BTDC © Manual Transmission [at 750 + 50 min-' (tpm) in neutral) (© Automatic Transmis gear] jon [at 700 = 50 min-' in ‘ion Timing Inspection and Setting (cont'd) 12. Adjust as necessary by loosening the distributor adjust- ing bolts, and turn the distibutor housing clockwise to retard the timing, or counterclockwise to advance the timing ZA Le ARS PS ADJUSTING BOLTS 13 Tighten the distributor adjusting bolts, then recheck the timing 14, Connect the vacuum hose to the vacuum advance diaphragm and inspect ignition timing at idle Ignition Timing KQ models (1.52. PGM-CARB): 20° + 2 BTOC (Red) Othors models (1.4) 18 * 2 BTDC (Red) © Manual Transmission [at 750 * 50 min’ (rpm) in neutral] © Automatic Transmission [at 700 + 50 min-* in gear) If advance is not as specified, check the vacuum advance diaphragm and distributor advance mecha: 5-22be] Carbureted Engine-KG model: (Ex. 1-Carbureted Engine (M/T) NOTE: Skip the step 7 through step 13 for automatic transmission 1. Disconnect the vacuum hose from the vacuum advance diaphragm, then connect the vacuum pump/ ‘gauge to the vacuum hose, vacuum PUMP/GAUGE—»_ HOSE #5 2. Start the engine and let it idle 9. When the engine is coo! [coolant temperature is below ABC (113°F)), check the #5 hose for vacuum ‘The #5 hose should have vacuum. Automatic Transmission: © If the #5 hose has no vacuum, check the #5, #10 ‘and #17 hoses for proper connections, cracks, blockage or disconnected hoses, and the check valve is not clogged H the #5, #10 and #17 hoses, and the check valve have no\ problem, replace the thermovalve and recheck the #5 hose for vacuum. Manual Transmission (2-Carbureted Engine): @ ‘if the #5 hose has no vacuum, check the #5 and #10, hoses for proper connections, cracks, blockage or disconnected hoses, and the check valve is not clogged. I the #5 and #10 hoses, and the check valve have no problem, replace the thermovalve and recheck the #5 hose for vacuum 4, Connect the vacuum hose to the vacuum advance diaphragm and allow the engine to warm up. (cooling fan comes on} 5. Disconnect the #5 hose from the vacuum advance Giaphragm and connect the vacuum pump/gauge to the #5 hose 6. Check the #5 hose for vacuum. Automatic Transmission: ‘The #5 hose should have no vacuum. © If the #5 hose has vacuum, check the vacuum control solenoid valve (See section 6) Replace the thermovalve and recheck the #5 hose for vacuum if the vacuum control solenoid valve is OK. Manual Transmission (2-Carbureted Engine). ‘The #5 hose should have vacuum © If the #5 hose has no vacuum, replace the ther movalve and recheck the #5 hose for vacuum, 7. Disconnect the #5 hose from the vacuum advance digphgram and plug them. 8. Connect a timing light and an advance tester. ADVANCE TESTER VACUUM Hose ADVANCE CONTROL feont'd) 5-23Igition System 8. While the engine idles, point the light toward the pointer on the timing belt cover 10. Align the timing mark (white) on the crankshaft pulley, to the pointer by turning the advance control knob of the advance tester CRANKSHAFT POINTERS RED MARK WHITE MARK. 11. Read initial timing when timing mark (white) is aligned to the pointer Initial Timing Manual Transmission (2-Carbureted Engine): 2° BTDC at 750 = 50 min (rpm) in neutral [—Ignition Timing Inspection and Setting (cont'd) 12 13 14 Adjust as necessary by loosening the distributor adjust- ing bolts, and turn the distributor housing clockwise to retard the ming, oF counterclockwise to advance the timing ADJUSTING BOLTS. Tighten the distributor adjusting bolts, then recheck the timing, Connect the vacuum hose to the vacuum advance iaphragm and inspect ignition timing at ide. Ignition Timing Automatic Transmission: 2° + 2'BTDC (Red) at 700 + 50 min (rpm) in ‘gear © Adjust as necessary by loosening the distributor adjusting bolts, and turn the distributor housing Clockwise to retard the timing, or counterclockwise t0 advance the timing © Tighten the distributor adjusting bolts, then recheck the timing, Manual Transmission (2-Carbureted Engine): 12" 2 BTDC (Red) at 750 + 50 min * (cpm) in noutr © If advance is not as specified, check the vacuum advance diaphragm and distributor advance mecha- 5-24Timing Belt SOHC DOHC .Timing Belt Illustrated Index............+ Inspection .... sete Tension Adjustment Replacement Positioning Timing Belt . 5-28Timing Belt Illustrated Index NOTE Refer to page 5-32 for positioning crank and pulley before installing belt © eter to page 86, for ateroter be austen @ eter to page 8.7, for PIS pump bet adjustment © eter to pege £7, for A/G compressor belt assent © Mark dracon of rotation before moving CROWN NUT 6.1.0 mm TIMING BELT WASHER and 10 Nem (1.0 kgm, 7 Wo-f) Inspecton, page 5-29 GROMMET wf Adjustment, page 5-28 \e 8x12 om, ValvEcoveR @ see ‘Apply lubricant. CAMSHAFT Panter aouust Bout sem te Sign. 28 of tecadcmnet ony Scslemre imine seur UPPER COVER BACK COVER ex1.0mm 10 Nem (1.0 kgm, 7 tos) Lower covER Remove the four bolts. 6x1.0mm 10m (1.0 kgm, 7 to, {install with concave surface facing in ‘CRANKSHAFT install with concave TIMING BELT PULLEY surface facing out RUBBER SEAL 1261.25 mm 118 Nm (11.5 kgm, 83 tb-ft) CRANKSHAFT PULLEY SPECIAL WASHER Install withthe unchamfared edge facing pulley 5-28[- Inspection —————————————__- Tension Adjustment NOTE: CAUTION: Always adjust timing belt tension with the © Replace belt if oil soaked, engine cold. '® Remove any oil or solvent that gets on the belt. NOTE: Tensioner is spring loaded to apply proper tension to the belt automatically after making the following adjustment: 1. Set the No. 1 piston at TDC. 2. Loosen adjust bolt ‘ADJUST BOLT 45.Nem (4.5 kgm, 33 tos) Inspect this area for wear Direction of Rotation 3. Rotate crankshaft counterclockwise 3-teeth on camshaft pulley to create tension on timing belt 4, Tighten adjust bolt. 5. If pulley bolt broke loose while turning crank, retorque it to 115 Nem (11.5 kg-m, 83 lb-ft. NOTE: Put transmission in gear and set parking Rotate pulley brake before retorquing pulley bolt and inspect bet. 5-29Timing Belt Replacement 1. Remove the whee! well splash shield ae WHEEL WELL SPLASH SHIELD 2. Remve the power steering (P/S) (with P/S) 3. Remove the A/C compressor adjust pulley with bracket and the belt (with A/C) 101.25 mm 45 Nem (4.8 kg-m, 33 Ib-f) P/s PUMP: ‘A/C ADJUST PULLEY BRACKET 8x 1.25 mm 24 Nem (2.4 kg-m, 17 Ib) pis BELT alc BELT 4. Remove the P/S bracket 5. Loosen the alternator adjust bolt and through bolt, then remove the belt ALTERNATOR ADJUST BOLT 8x1.25 mm 5, 24 Nem (2.4 kgm, 17 I-A) P/S BRACKET ‘THROUGH BOLT 101.25 mm 245 Nem Aes kom. 101.25 mm S3 be 45 Nem (8.5 kg-m. 33 Ibn) ALTERNATOR BeuT 6. After installation, adjust the tension of each belt. See Section 5-6 for alternator belt tension adjustment. See Section -7 for A/C compressor belt tension adjustment. See Section 5-7 for P/S pump belt tension adjustment. 7. Remove the engine support bolts and nut, then remove the side mount rubber. 101.25 mm 55 Nem (5.5 kgm, 40 Ib-A) ENGINE SIDE MOUNT RUBBER 5-30be) 8. Remove the valve cover CROWN NUT 6x 1.0 mm 9, Remove the special bolt, then remove crankshaft pulley 10 Nem (1.0 kgm. 7 tote) 10, Remove the timing belt upper cover and the lower cover. WASHER AND GROMMET 11, Loosen the adjust bolt, then remove the timing belt VALVE COVER UPPER COVER 6x1.0 mm 10 Nem (1.0 kgm, 7 toe) Ne ‘SEAL RUBBER: TIMING BELT ‘Adjustment, page 5-28 Lower cover Remove the four a ex1.0mm For 10 Nim (1.0 kgien, 7 1b) key ADJUST BOLT 45.Nem (4.5 kam, 33 bs) For adjustment only do not remove 121.25 min 115 Nem (11.5 kgm, 83 bf) CRANKSHAFT PULLEY ‘SPECIAL WASHER 12. Install in the reverse order of removal; adjust the valve timing (page 6-32). BELT TENSIONER 13. Carry out timing belt tension adjustment (page 5-2) 5-31Timing Belt [- Positioning Crankshaft Before Installing Timing Belt NOTE: Install the timing belt with the No. 1 piston at TOC (Top Desd Center) of the compression stroke: “UP” MARK POINTER ON BELT COVER toc MARK Ye mask aed win TOC MARK {he yimder head Upper sitaze DIRECTION OF ROTATION ‘with engine installed, turn crank with socket wrench land extension as shown 5-32Timing Belt Illustrated Index. 5-34 Inspection 5-35 Tension Adjustment. 5-35 Replacement .... 5-36 Positioning Timing Belt 5-38Timing Belt Illustrated Index NoTE CROWN NUT 61.0 mm Reter to page 5-38 for positioning crank and pulley before instaling belt YO Neen (9.0 kgem, 7 oe) © Refer to page 6-6 for altornator belt adjustment WASHER AND Y @ eter to page 5-7 for A/C compressor belt adjustment Gromer @ Mark direction of rotation before removing. Ne VALVE COVER 8x1.25 mm 38 Nem (3.8 kgm, 27 eh) ‘Apply hibricant RUBBER SEALS TIMING BELT 6x1.0mm Inspection. page 8-35 10 Nim (1.0 kg-m. 7 Ib) Aagjustment, page 8-35 TIMING BELT ‘ADJUST BOLT 45 Nem (4.5 kgm, 33 te) CAMSHAFT For adjustment only, do not remove UPPER COVER _ LOWER COVER. Femovo the Sg four bok. 10 Nem (1.0 kg-m, 7 ios) 6x1.0 mm! 10 N-m (1.0 kgm, 7 tot) Insta with concave surface facing in CRANKSHAFT Install with concave SiamNG BELT PULLEY surface facing out 121.28 mm 115 Nm (115 kom, 83 Ib.) RUBBER SEAL CRANKSHAFT PULLEY SPECIAL WASHER Install wth the unchamfered edge facing pulley 5-34(- Inspection NOTE: @ Replace belt if oil soaked. @ Remove any oll or solvent that gets on the belt Inspect this area for weer, Rotate pulley and inspect bet. re CAUTION: Always adjust timing belt tension with the ‘engine cold. — Tension Adjustment NOTE: Tensioner is spring-loaded to apply proper tension to the belt automatically after making the following adjustment 1. Set the No. 1 piston at TOC. 2. Loosen adjust bolt. ADJusT BOLT 45 Nem (4.5 kam, 33 toot) Direction of Rotation 3. Rotate crankshaft counterclockwise 3-teeth on camshatt pulley to create tension on timing belt 4. Tighten adjust bolt. 5. If pulley bolt broke loose while turning crank, retoraue it to 115 Nem (11.5 kg-m, 83 Ib-ft NOTE: Put transmission in gear and set parking brake before retorquing pulley bolt 5-35Timing Belt Replacement 1. Remove the whee! well splash shield WHEEL WELL SPLASH SHIELD 2. Loosen the air conditioning (A/C) idle pulley and remove the A/C belt A/C ADJUST PULLEY BRACKET 8x 1.25 mm 24 Nem (2.4 kgm, 17 lb-ft) ave BELT 3. Loosen the alternator adjust bolt and through bolt then remove the belt. ALTERNATOR THROUGH BOLT ADJUST BOLT 10% 1.25 mm 8x1.25 mm 45 Nm 24 Nem (2.4 kgm, 17 tot) (4.5 kom, 33 bt) ALTERNATOR BELT 4. After instalation, adjust the tension of each belt. ‘See page 5-6 for alternator belt tension adjustment. See page 5-7 for A/C compressor belt tension adjust 5. Remove the engine support bolts and nut, then remove the side mount rubber. 101.25 mm. 55 Nem (5.5 kg-m, 40 tot) ENGINE SIDE MOUNT RUBBER 121.25 mm 101.25 mm 55 Nem (5.5 kom, 55 Nem (5.5 kom, opm 40 ibs) 5-366. Remove the timing belt upper cover 7. Remave the valve cover 8. Remove the special bolt, then remove crankshaft pulley 9. Remove the timing belt lower cover. (CROWN NUT 6x1.0 mm 10. Loosen the adjust bolt, then remove the timing belt. 10 Nem (1,0 kgm, 7 Ibe) 6x1.0 mm / 10 Nery (1.0 kg-m. 7 Io-f) 4 WASHER AND GROMMET VALVE COVER UPPER COVER —— | Lowen cover Remove the four | —_——Timinc sett Alustment, page 5-95 AbuusT BOLT 45 Nem (4.5 kgm, 33 tbs) For adjustment only o not vemove ‘CRANKSHAFT PULLEY SPECIAL WASHER 1241.26 mm 115 Nem (11.5 kgm, 83 1b. BELT TENSIONER, 11, Install in the reverse order of removal; adjust the valve timing (page 5-38). 12. Carry out timing belt tension adjustment (page 5-35) 5-37Timing Belt - Positioning Crankshaft Before Installing Timing Belt NOTE: Install the timing belt with the No. 1 piston at TDC {Top Dead Center) of the compression stroke. “UP” MARK POINTER ON BELT COVER ‘TOC mark aligned with the cylinder head upper surtace CRANKSHAFT PULLEY oncerion or NE ROTATION With engine installed, ture crank with socket wrench land extension a shown 5-38Cylinder Head Removal/Installation SOHC . DOHC .Cylinder Head Removal/Installation Removal ... InstallationCylinder Head ,- Removal (engine removal not required) CAUTION: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (100°F) before removing it. NOTE: Use new O-rings and gaskets whenever reassembling. CYLINDER HEAD BOLTS 101.25 mm 68 Nem (6.8 kg-m, 49 Ib-A) ‘Apply clean engine ol to serew thread and ‘under heads SPECIAL WASHER CARBURETOR WWTAKE MANIFOLD CYLINDER HEAL GASKET Replace FX TIMING BELT G Inspecion/adusiment, ff | \ page 5-28 ™ Replacement 3 pove 6-20 Ee HAG p INTAKE MANIFOLD BRACKET ApgusT BOLT 43 Nem (4.3 kg-m, 31 Ib-A Loosen but do not remove 8x1.28 mm 24 Nem (2.4 kg-m, 17 Ib-R) 5-42be] CAUTION: To avoid damaging the cylinder head, wai nti the coolant temperature drops below 38°C (100°F) before loosening the retaining bolts NOTE: © Inspect the timing belt before removing the cylinder head (© Turn the crankshaft pulley so that the No. 1 cylinder is at top-dead-center. © Mark all emissions hoses before disconnecting them 1. Disconnect the negative terminal from the battery 2. Drain the cooling system (See page 5-78) 3. Remove the brake booster vacuum hose from the brake muster power booster 4. Remove the engine secondary ground cable from the valve cover. 5. Remove the air cleaner cover and sir cleaner (carburet- ed engine) 6. Remove the air intake hose and the air chamber (1.54 PGM-FI engine} 7. Remove the air intake hose from the throttle body (1.6 {PGM-FI engine) 8. Reliove fuel pressure (See Section 6) FRIED. not smoke while working on fue system, keep open flame or spark away from work area, Drain fuel only into an approved container 9. Disconnect the fuel hose and fuel return hose 10. Remove the air intake hose and resonator hose. 11. Disconnect the throttle cable at the throttle body (See Section ) 12, Disconnect the throttle control cable at the throttle body (A/T only) 13. Disconnect the charcoal canister hose at the throttle valve. 14. Disconnect the vacuum hoses and the water bypass hoses from intake manifold and the throttle body. 1-Carbureted En PCV HOSE CONTROL BOX CONNECTORS 15. Remove the PCV hose, charcoal canister hose and vacuum hose from intake manifold, and remove the vacuum hose from the brake muster power booster, CHARCOAL CANISTER HOSE 1-Carbureted Engine: A/C SOLENOID VALVE WATER BYPASS } HOSE 2-Carbureted Engine: A/C SOLENOID VALVE FUEL HOSE canter FueL Hoses NOSE BRAKE BOOSTER WATER BYPASS HOSE HOSES, 2-Carburated Engine: CONTROL BOX ~ gi, ot WATER BYPASS HORE cont'd) Pcv Hose 5-43Cylinder Head 1.54 PGM-FI Engine: INTAKE HOSE, WATER BYPASS HOSE 1.5.1 PGM-FI Engine: CHARCOAL CANISTER HOSE fue ae vacuuM Hose POWER BOOSTER 1.61 PGM-FI Engine: BREATHER TUBE CONTROL BRACKET CANISTER HOSE WATER BYPASS HOSE CHARCOAL CANISTER - Removal (engine removal not required) (cont'd) 1.61 PGM-FI Engine: BRAKE BOOSTER HOSE j / FUEL RETURN Pov HOSE vel Mose 16. Remove the upper radiator hose and the heater hose from the cylinder head HEATER HOSE UPPER RADIATOR HOSE 17. Disconnect the engine wire connectors end clamps from the cylinder head, throttle body, and IN/EX manifolds + Ignition coll connector (from distributor) + EACV connector + Engine ground wire + Thermounit connector Coolant temperature sensor connector Carburetor solenoid valve, automatic choke con- nector (1-Carbureted) Carburetor solenoid valve, inner bent solenoid valve connector (2-Carbureted) Air leak solenoid valve connector (2-Carbureted) + L.earburetor solenoid valve connector (2- Carbureted) 5-441, 101.25 mm 45N-m (4.5 kg-m, 33 Ib-t) ‘A/C COMPRESSOR 8x1.25 mm 24 Nem (2.4 kom, 17 bt) Intake air temperature sensor connector (PGM-Fl) Throttle angle sensor connector (PGM-Fi) Injection connectors (PGM-FI) + TOC/CRANK sensor connector (from distributor) 18, Remove the P/S belt. 19, Remove the P/S hoses and P/S pump, 20. Remove the P/S bracket, 21, Remove the alternator belt 101.25 mm 45 Nem (1.2 kom, 33 bh) ALTERNATOR BELT P/S PUMP BRACKET 22, Remove the intake manifold bracket 23. Remove the exhaust manifold bracket, then remove the header pipe. P/s BELT NOTE: Release the tensioner bracket with a diver Do nor push the belt TENSIONER BRACKET 24. Remove the exhaust manifold shroud, then remove exhaust manifold 25. Remove the distributor and valve cover. 26. Remove the timing belt upper cover 27. Loosen the timing belt adjust bolt, then remove the ‘ming belt from the camshaft pulley CAUTION: DO not crimp or bond timing belt more than 90° or less than 25 mm (1 in.) in diameter x 28. Remove the cylinder head. 29. Remove the intake manifold from the cylinder head 5-45Cylinder Head r- Installation 11. Intall the cylinder head in reverse order of removal © Aways use @ new head gasket © Cylinder head and engine block surface must be clean © “UP” mark on timing belt pulley should be at the top. 2. Cylinder head dowel pins and oll control jet must be aligned CYLINDER HAED. GASKET Replace OL CONTROL JET ee one rence INTAKE ‘MANIFOLD, 8x1.25 mm 24 Nm (2.4 kom, 17 bs) 3. Install the intake manifold and tighten the nuts in a criss-cross pattern, beginning with the inner nuts. 1-Carbureted Engine: o Ce INTAKE MANIFOLD o\, Gasker Revie 821.250 INTAKE ManiFoLD BNmasbem. 17 bry Be \ A inrace manirovo Bracke 841.28 mm: 2aNmias kom, ae 2-Carburoted Engine canBuRETOR INTAKE MANIFOLD GASKET Replace 821.25 mm 23 Nem (2.3 ko-m, 17 tb) o INTAKE MANIFOLD BRACKET 5-46be] 1.5 PGM-FI Engine: x“ SIR Replace a 3 INTAKE 24 Nim (2.4 kom. 17 A 8x1.25 mm 23 Nem (2.3 kgm, 17 lot) 1.6 PGM-FI Engine: INTAKE MANIFOLD INTAKE MANIFOLD BRACKET 8x 1.25 mm 23 Nem (2.3 kom. 17 we) 4. Tighten cylinder head bolts in two steps. Inthe first stop tighten all bolts and nuts, in sequence, to about 30 Nem (3.0 kg, 22 lb-ft); in the final step tighten, in same sequence, to 68 Nem (6.8 kg-m, 49 lb-ft NOTE: Apply engine oil to the cylinder head bolts and the washers CYLINDER HEAD TORQUE SEQUENCE CYLINDER HEAD BOLT 101.25 mm 6B Nem (6.8 kg-m, 49 1b-R) 5. Adjust the valve timing 6. Install the exhaust manifold and bracket. 1-Carbureted and 1.4 Engine: EXHAUST MANIFOLD GASKET Replace CYLIDER HEAD extausT SHROUD MANIFOLD SELE LOCKING NUT 8x1.25 mm Bat28 ow 24 Nom (2.4 kgem, 17 Ib) 34 Nem (04 kom, 25 Replace 101.25 mm ° 34.Nem (3.4 kgm, 25 ibe) (conta) 5-47Cylinder Head r Installation (cont'd) 1.5 (6x. T-carbureted), 1.6. with CATA EXHAUST MANIFOLD SHROUD MANIFOLD GASKET Replace Orn CYLINDER HEAD é | Zs Be nm a kom, ex1.25 0m 26 Nm Sona a kom, 25 81.25 mm. 34 Nem (3.4 kg-m, 25 lb-ft) 1.62 with out CATA: EXHAUST MANIFOLD MANIFOLD GASKET Replace 8x1.25 mm 24 Nem (2.4 kom, ‘sHROUD SHROUD PSN 841.25 mm 34. Nem a Axnaust——71 J @ ay 4 ROM. 25 MANIFOLD 9g? BRACKET 8x1.25 mm 22 Nem (2.2 kg-m, 8x 1.25 mm 16 ibs) 24 Nem (2.4kg-m, 17 Ist EXHAUST MANIFOLD TORQUE SEQUENCE £O.OYO Oy ® a ® ® 5-48Cylinder Head Removal/Installation Removal . Installation .Cylinder Head -- Removal (engine removal not required) CAUTION:To avoid damaging the cylinder head. wait until the coolant temperature drops below 38°C (10°F) before removing it NOTE: Use new O-rings and gaskets whenever reassembling ‘CROWN NUT 8x1.0 mm 10 Nem (1.0 kgm, 7 to-A) wasnen anoonowuer | CP 6x1.0mm e Tnminokem, @ 7 Ife) @ e RUBBER UprER COVER t Replace o inspect for signe car co CovUNvER SENSOR of wear ana damage. a’ SEN “7 x1.0 mm 12 Nem (1.2 kg-m, TaNmiN2kam OA BEN ea kgm 9 Ib) By 9 Ibe) » 17 Ib-ft) te a i EX hn tt We 1 te ius NN { 3 CAMSHAFT HOLDER EXHAUST CAMSHAFT HOLDERS. ae ce DISTRIBUTOR INTAKE CAMSHAFT exHausT CAMSHAFT Lock nuy 25 Nem (2.5 kg-m, 18 Ib) “> Key 81.25 mm — SPECIAL WASHER 38 Nem (3.8 kom, 27 bt) CAMSHAFT PULLEY SEAL 5-50CYLINDER HEAD BOLTS 111,25 mm 66 Nem (6.6 kg-m, 48 Ib-f) Apply clean engine of VALVE KEEPERS —___ SPRING RETAINER fT Shvegge and e ‘under the Bolt ‘SPRING RETAINER, EXHAUST VALVE SPRING wraxe vatve \ VALVE KEEPERS a STEM SEAL re eno pivor got Replace B EXHAUST VALVI Ce a ie Repice vai Spano —= NC race vavve Sear oA a ao SPRING EXHAUST VALVE: INTAKE VALVE GUIDE GUIDE & CYLINDER HEAD. INTAKE VALVE ‘Adjustment, page 5-8 CYLINDER HEAD GASKET Replace TIMING BELT Inspeciton/Adjustment, page 5-35 Replacement, page 5-26, 6x1.0 mm! 10 Nem (1.0 kgm. 7 Ibe) apuust B6LT 145 Nem (4.8 kg-m. 33 Ib-F) Loosen, but do not remove (cont'd) 5-51Cylinder Head CAUTION: To avoid damaging the cylinder head, wait Lntil the coolant temperature drops below 38°C (100°F) before loosening the retaining bolts. NOTE: © Inspect the timing belt before removing the cylinder head. (© Turn the crankshaft pulley so that the No. 1 cylinder is at top-dead-center. © Mark all emissions hoses before disconnecting them Disconnect the negative terminal from the battery, Drain the coolant system. Relieve fuel pressure (See Section 6) Disconnect the fuel feeder hose and fuel return hose, * Do not smoke while working on fuel system, keop open flame or spark away from work are Drain fuel only into an approved container. 5. Remove the brake booster vacuum hose 6. Disconnect the PCV hose. BRAKE BOOSTER Pov Hose Hose “FUEL RETURN HOSE Disconnect the breather tube and air intake hose. Disconnect the vacuum hose from the intake manifold Disconnect the charcoal canister hose. 10. Disconnect the water bypass hose, r Removal (engine removal not required) (cont'd) 11. Disconnect the engine wire connectors and clamps from the cylinder head, throttle body, and IN/EX manifolds. + Ignition coil connector (from distributor) EACV connector Engine ground wire ‘Thermounit connector Coolant temperatuer sensor connector BREATHER VACUUM HOSES. Ope | TUBE WATER BYPASS HOSE AIR INTAKE HOSE + Intake air pressure sensor connector + Throttle angle sensor connector Injection connector + TDC/CRANK sensor connector 12, Disconnect the radiator upper hose at the engine. 13, Remove the heater hose. Vuron UPPER HOSE HEATER HOSE 5-521 8x 1.25 mm 24 Nem (2.4 kom. 17 tt) 14, Loosen the air conditioning (A/C) idle pulley end remove the A/C belt. 16. Remove the alternator belt. 101.25 mm 45 Nem (4.5 kam, es 33 tot) ALTERNATOR BELT 16. Remove the bolts from the intake manifold bracket 17. Remove the exhaust mandfold shroud. 18. Remove the bolts from the exhaust manifold bracket. 19. Remove the self lock nut from the exhaust header Pipe 20. Remove the exhaust manifold assy. 21. Remove the timing belt upper cover. 22. Remove the valve cover A/C ADJUST PULLEY BRACKET alc BELT 23. Loosen the timing belt adjust bolt, releasing the timing belt, and fx the bolt ApuusT BOLT ee NOTE: Release the tensioner bracket with a drver. Do not push the belt. ‘TENSIONER BRACKET 24, Remove the timing belt from the driven pulleys. CAUTION: DO not crimp or bend timing a 2 belt more than 90° or \ less than 25 mm (1 in.) in diameter. | id [Roe | mm | x I 25, Remove the cylinder head CAUTION: Loosen the head bolts diagonally from the inside to outside 26. Remove the intake manifold from the cylinder head. 5-53Cylidner Head r Installation 1, Install the cylinder head in reverse order of removal: © Always use a new head gasket © Cylinder head and engine block surface must be clean © “UP” mark on timing belt pulley should be at the top. NOTE: Cylinder head dowel pins and oil control jet must be aligned CYLINDER HEAD Dowel PIN 2. Tighten cylinder head bolts in two steps. In the first step tighten all bolts, in sequence, to about 30 N-m {3.0 kg-m, 22 Ib-ft); in the final step tighten, in same sequence, to 68 N-m (6.8 kg-m, 49 lb-ft} NOTE: © Apply engine oil to the cylinder head bolts and the washers. 0 the longer bolt as shown, CYLINDER HEAD BOLTS TORQUE SEQUENCE 3. Install the intake manifold and tighten the nuts in a criss-cross pattern in 2 or 3 steps, beginning with the inner nuts 8x 1.25 mm 23 Nem (2.3 kg-m, 17 Ib) 4. Install the exhaust manifold and bracket. MANIFOLD GASKET Replace N ar 821.25 mm 34 Nem (3.4 kgm, 34 Nem (3.4 kgm, 25 loot) 25 Woe) 8.0%1.25 mm 24 Nem (2.4 kom, 17 t-te) 5-54es CAUTION: © Make sure that the keyways on the camshafts are facing up. (NO. 1 cylinder TOC). © Valve locknuts should be loosened and adjust screws backed off before installation. © Replace the rocker arms in these original positions. 5. Place the rocker arms an the pivot bolts and the valve stems, 6. Install the camshafts and the camshaft seals with the ‘open side (spring) facing in NOTE: er or holders, © Do not apply oil to the holder mating surface of camshaft seals E" marks are stamped on the camshaft EXHAUST CAMSHAFT HOLDERS INTAKE CAMSHAFT HOLDERS 7. Apply liquid gasket to the head mating surfaces of the No. 1 and No. 6 camshaft holders, then install ther, ‘along with the No. 2. 3. 4 and 5 8. Tighten the camshaft holders temporarily. @ Make sure that the rocker arms are properly positioned on the valve stems ‘Apply non-hardaning sealant to these ‘areas (algo opposite sides) before instaling ‘camshaft halders 9. Press in the camshaft oil seal securely with the special too! Seal housing surface should be dry. Apply a light cost of oll to camshaft and inner ip of se CAMSHAFT SEAL DAIVER (07947-S800100 (cont'a) 5-55Cylinder Head - Installation (cont'd) 10. Tighten each bolt two turns at a time in the sequence shown below to insure that the rockers do not bind on the valves. 6x1.0 mm 12. Nem (1.2 kgm, 9 tot) 11. Insta keys into grooves in camshafts. NOTE: To set the No. 1 piston at TDC, align the hole fon the camshaft with the hole in the No.1 camshaft holders and drive §.0 mm pin drivers into the holes, PIN DRIVERS, 5.0 mm key 07344-6110100 CAMSHAFT PULLEY 27 mm SPANNER SPECIAL RETAINING BOLTS WASHERS 8x1.25 mm 38 Nem (3.8 kg-m, 27 Ib-h) 12. Push camshaft pulleys onto camshafts. then tighten retaining bolts to torque shown, 13. Adjust the valve timing (page 5-9) 14, After installation, check that all hoses and connectors are installed correctly 5-56Engine Removal/InstallationEngine Removal/Installation © Make suro jacks and safety stands are placed properly and hoist brackets are attached to cor- rect positions on the engine, (See Section 1) © Apply parking brake and block rear wh car will not roll off stands and fall on you whi ‘working under it. CAUTION: Use fender covers to avoid damaging Painted surfaces. 1. Disconnect the battery negative terminal frst then the positive terminal, Remove battery. 2. Unbolt the hood brackets and remove the hood © Disconnect the washer fluid tube, CAUTION: Use c: demaging the paint. ‘when storing the hood to avoid Carbureted Engine: 8~13 PGM-FI Engine: 14~19 LHD: Drain the engine oil. Remove the oil filer cap to speed. draining. Reistall the drain plug with a new washer. Drain the coolant from the radiator into a clean pan so it may be re-used. Remove the radiator cap to speed draining [ERIE Use care when removing radiator cap to avoid scalding by hot coolant or steam. Drain transmission cil/fiuid.Use @ 3/8" drive ratchet ‘wrench to remove the drain plug. Remove the cil filler plug to speed draining. Reinstall the drain plug with a new washer Remove the air intake duct and front air intake duct, Remove the battery base. AIR INTAKE DUCT FRONT AIR INTAKE DUCT ENGINE GROUND CABLE SPEEDOMETER CABLE THROTTLE CABLE 5-581 Carbureted Engine 8. Disconnect the engine compartment hamess con- unper-#000 nectors, battery wires and transmission ground cable 1 RELAY BOX BATTERY wires 7 ENGINE COMPARTMENT . HARNESS CONNECTORS HARNESS CLAMP / BRAKE BOOSTER / VACUUM HOSE ENGINE GROUND. CABLE FUEL PUMP, ‘TRANSMISSION GROUND CABLE DISTRIBUTOR FUEL HOSES ‘SHOP ToweL 9. Disconnect the fuel hoses at the fuel pump. Do not smoke while working on fuel system. Keep open flame away from work area Drain fuel only into an approved container. VACUUM Hoses CAUTION: © Place a shop towel over the fuel fil fuel from spraying over the engine. to prevent 10. Disconnect the engine wire connectors and spark plug Replace wires. 951.25 mm _~ 11. Remove the cap and bolts, then remove the distributor 24 Nem (2.4 kg-m, 17 tot) from the cylinder head. (cont'd) 5-59Engine Removal/Installation (cont'd) Carbureted Engine: 12. Remove the throttle cable by loosening lock the nut and the throttle cable adjust nut, then silp the cable 1-carbureted tend out of the throttle bracket and accelerator linkage. NOTE: Take care not to bend the cable when removing it, Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one. casteeND |G ~ LOCKNUT ADJUST NUT THROTTLE CABLE 2-Carbureted: AbuusT NUT 6 mm BOLT. ‘THROTTLE CABLE 12 Nem (1.2 kgom, 9 Ib) 13. Remove the mounting bolts and V-belt for the power, steering pump, then without disconnecting the hose, pull the pump away from its mounting bracket 26 Nem (2.4 kgem, 17 Io) SHOP TOWEL “10x 1.25 mm 45 Nem (4.5 kg-m, 33 Ibo) POWER STEERING PUMP 5-60b=] PGM-FI Engine SERVICE BOLT 14. Relieve fuel pressure by slowly loosening the service 12. Nem (1.2 kgm, 9 Ibe) bolt on the fuel filler about one turn. (Section 6) [ERIM 0 not smoke while working on fuel system. Keep open flame away from work area Drain fuel enly into an approved container. Disconnect the connectors CAUTION © Bofore disconnecting any fuel line, the fu ‘sure should be relieved as described above. hop towel ove /] ‘SEALING WASHERS. Replace. ‘BANJO BOLT 22 Nem (2.2 kom, 16 tbe) / FUEL FILTER DISTRIBUTOR 15. Disconnect the engine compartment harness con- nectors, battery wires and transmission ground cable. ‘TRANSMISSION GROUND CABLE ~ 16, Disconnect the engine wice connectors and spark piug wires 17. Remove the cap and bolts, then remove the distributor from the cylinder head. sone: Done: o-nne a Replace, Ce DistAIBUTOR —o-RING 841.28 om Replace 24 Wim (2.4 kgm, 17 tbe)Engine Removal/Installation (cont'd) PGM-FI Engine: 18, Remove the throttle cable by loosening lock the nut apsust NUT and the throttle cable adjust nut, then sip the cable fend out of the throttle bracket and accelerator linkage. NOTE: Take care not to bend the cable when removing it. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one. ter: FUEL RETURN HOSE cantteno 42° CABLE END THROTTLE CABLE es HARNESS CONNECTORS ENGINE GROUND caBLe HARNESS CLAMP BRAKE BOOSTER VACUUM HOSE Locknut ADJUST NUT 6 mm BOLT 12 Wim (1.2 kgm. 9 Ios) ENGINE GROUND. CABLE ‘SUB-ENGINE HARNESS HARNESS CONNECTOR CLAMP o-nING Replace. FUEL RETURN HOSE Do not smoke while working on fuel system, Keep open flame away from work area. Drain fuel only into an approved container. 19. Remove the mounting bolts and V-belt for the power, steering pump, then without disconnecting the hose, pull the pump away from its mounting bracket. 81.28 nm ; Bo fem kom, 17 (2.4 tp a ‘SHOP Fowet 10x1.26 mm POWER STEERING PUMP AS hms i# pm, 39) 5-62be 20. Disconnect the radiator hoses and heater hoses 21, Disconnect the transmission fluid cooler hoses. 22, Remove the speedometer cable. AUTOMATIC TRANSMISSION FLUID COOLER HOSES. (AIT Only) ‘SPEEDOMETER CABLE RADIATOR Hose RADIATOR HOSE HEATER HOSE ‘cur CAUTION: Do not remove the holder because the speedometer gear may fall into the transmission housing. 23. Remove the alternator: (LHD only) © Disconnect the alternator wire harness connectors. Remove the adjust bolt and remove the belt. © Remove the belt alternator mount bolt and remove the alternator 8X1.25 mm 24 Nem (2.4 kgm, 17 Ios) ALTERNATOR BELT 45 Nem (4.5 kg-m, 33 Ib-A) 24. On cars with A/C: © Loosen the belt adjust bolt and idle pulley nut '@ Remove the compressor mount bolts, then lift the ‘compressor out of the bracket with hoses attached, and wire it up to the front beam. NOTE: The compressor can be moved without dischar- sing the air conditioner system BELT ADJUST BOLT 61.0 mm. 10 Nem (1.0 kg-m, 7 tb) 10X1.25 mm 45 Nem (4.5 kg-m, 33 lb-ft) CoMPREsson BELT If necessary: © Disconnect the suction and discharge hoses from the compressor. SUCTION HOSE (cont'a) 5-63Engine Removal/Installtion (cont'd) 40 Nem (4.0 kgm, 29 1b-f) On Automatic Cars:) 23.Nem (2.3 kom. 17 A) gp 26. Remove the header pipe, header pipe bracket. torque HRADER PIPE converter cover and cable holder. BRACKET 26. Remove the shift control cable by removing the cotter pin, control pin and control lever roller from the control lever. CABLE NOTE: On reassembly, check the cable adiustment HOLDER (Section 9) SHIFT CONTROL 12 Nem (1.2 kgm, STR) as Cte COTTER PING” ToRavE Sovlace CONVERTER COVER 27. Remove the shift lever torque rod, shift rod and clutch cable ™— NOTE: On reassembly, side the retainer back into ace after driving in the spring pin — Pk 19 In the spring pi CONTROL ROLLER 28. Remove the right and left driveshafts. (See Section 10) ‘SPRING PIN CLUTCH CABLE ADJUST NUT (Manual only) WHEELWELL SPLASH SHIELD AC eC SHIFT LEVER (7 Torque ROD Jour uever ‘TORAUE RoD jx potr SELF LOCKING NUT 5 nim (6.5 up, 47 Kot) DAMPER FOr Gasket Replace. Replace. a Nur vockina nur NOTE: Cot es 5B Wem (6.5 kom. 40 tot) Tie Plastic bags over the drivehatt ends. Replace. 5-64be} 29, Attach a chain hoist to the engine block hoist brackets 31, Remove the bolts from the front transmission mount and raise the hoist just enough to remove slack from the chain, 32. Remove the bolts from the engine side mount. Nore: 33. Remove the bolts from the side transmission mount To attach rear engine chain, remove the plastic radia- (a) tor hose bracket and hook chain to top of clutch cable bracket. 34, First remove the mount nut from under the transmis- sion housing and remove the bolt from the side trans- 30. Remove the rear transmission mount bracket ‘mission mount (MT). 55 Nem (6.5 kg-m. 40 tb-A) SIDE TRANSMISSION MOUNT SPECIAL BOLT 55 Nem (6.5 kg-m, 40 Ib-f) Do not loosen the bolt \, loosened. replace the bot, art: 40 Nem (4.0 Kom. 23 Ib) SIDE TRANSMISSION Mount wr: SIDE TRANSMISSION MOUNT Cle . | Pages a g. "BB Nem (6.5 kg-m, 40 lb-ft) + FRONT TRANSMISSION — MouNT 40 Nem (4.0 kg:m, 29 Ib-A) Mount Nut GA ime stem smn — CRKL/7E ‘SPECIAL BOLT 35. Check that the engine/transaxte 6 completely free of So neq 0 kgm, 43 lot) vacuum, fuel, and coolant hoses, and electrial wires. ba Wor igeen ioe bose If loosened, replace the bolt 36. Slowly raise the engine approximately 6” and stop. Check once again that all wires and hoses have been disconnected from the engine/transaxle. 37. Raise the engine/transaxle all the way and remove it from the car (cont'd 5-65Engine Removal/Installation (cont'd) 38, Install the engine in the reverse order of removal After the engine is in place: © Torque engine mount bolts in sequence shown. CAUTION: Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration, and reduce bushing life: check that the bushings are not twisted or offset, © Check that the spring clip on the end of each driveshaft clicks into place CAUTION: Use new spring clips on installation. © Inspection for fuel leakage After assembing fuel line parts, turn on the igni- tion switch (do not operate the starter) so that the fuel pump is operated for approximately two seconds and the fuel is pressurized. Repeat this ‘operation two or three times and check whether any fuel leakage has occurred at any point in the fue! line ENGINE MOUNT TORQUE SEQUENCE NOTE: Check the mount and bracket for damage MOUNT SPECIAL BOLT Replace. SIDE TRANSMISSON FRONT TRANSMISSION 260 N-m (6.0 kg-m, 43 tb) © Bleed air from the cooling system at the bleed bolt with the heater valve open ‘Adjust the throttle cable tension. (See Section 11) ‘Adjust the alternator belt tension. Check the clutch pedal free play. CCheck that the transmission shifts into gear smooth- y. Reinstall the A/C compressor and A/C wiring Clean battery posts and cable terminals with sand- Paper, sssemble, then apply grease to prevent corrosion. Check the ignition timing. (See Section 16) Charge the system and test performance. (See Section 15) Speedometer cable Installation © Align tab on cable end with slot in holder (page 5-63) © Install clip so bent leg is on groove side After installing, pull speedometer cable to make sure itis secure REAR TRANSMISSION MOUNT BRACKET ‘SPECIAL BOLT (60 N-m (6.0 kg-m, 43 Ib-f) Replace: ENGINE SIDE MOUNT @BBN-m(6..5kg-m, 401b-A) 5-66‘Additional Torque Specifications: 7 (@, SIDE TRANSMISSION MOUNT AND RACKT 40 Nem (4.0 kg-m, 29 Ib) mr: XQ | i | — 55 Ym (6.5 kgm, 40 bt 66 Nem (5.5 kom, 40 Ib) | OSNMIB.Skgm, (65 ke an 27 bea) [fs \ ar, re Op = | sense of) eh) e fos Nem (2.4 kom. BOLT Replace 17 be) 60 Nem (6.0 kgm, 43 tot _ 45 Nem (4.5 kgm. 33 lb-ft) 40 Nem (4.0 49-m, 29 Ib-A) FRONT TRANSMISSION got MOUNT Replace fo 60 N-m (a. .\ /e =P 2 \ 40 Nem (4.0 kam, 29 be) EPL (6.0 kg-m. f ALTERNATOR BRACKET 55 Nem (6.5 kg-m. 40 Ib-f) ENGINE SIDE 10%1.25 mm MOUNT BRACKET 45 Nem (4.5 kg-m, 39 Ib-f) 10%1.25 mm 45 Nem (4.5 ko-m. 33 ft) 155 Nem (6.5 kg-m, 40 Ib-F) COMPRESSOR BRACKET 5-67Exhaust Pipe and MufflerExhaust Pipe and Muffler Replacement 1.64 Engine Ex. 1.62 Engine: EXHAUST 7 TIP easeer el © Replace a &S ; MUFFLER 61.0. mm 10 Nem (1.0 kg-m, 70 EXHAUST PIPE DOHC Engine without CATA: en HEADER pipe ee wi e asker Replace 8x 1.25 mm 22 Nem (2.2 kgm, 16 tb) ‘SOHC Engine without CATA: 8x 1.25 mm 22 Nem (2.2 kgm.) 16 to) o SELF-LOCKING —_» NUTS. 10x 1.25 mm 34 Nem (3.4 kom, HEADER PIPE Rennes 25 tosh) GASKETS. Replace HEADER PIPE HEAT SHIELO a oasxer Y Ohegee

aD ~ COOLANT RESERVOIR FAN MOTOR Test for operation with 12V OC applied FAN SHROUD Note: © Check all cooling system hoses for damage, leaks or deterioration and replace if necessary. © Check all hose clamps and retighten if necessary, © Use new O-rings whenever reassembling, RADIATOR Refiling, page 6-78 Leak test, page 5-79 Inspect seams between core fina and tanks for oaks Blow diet out from between core fins with compressed at IF insects, ete., er clogging radiator, wash them off with low pressure wate. ee UPPER RADIATOR Hose '§ Fle |rowanerun HOSE Oo | Gauoe NOW| senoine uni WATER PUMP: 9 Nem (0.9 kg-m. s s 13 Ib-ft} HOUSING 7a 16 Nem (1.8 kgm. 13 be HEATER HOSES 5-75DOHC Fucl-Injected Engine ‘under high pressure when oni 2+ of releasing scalding coolant. remove cap only when engine is cool. Total Cooling System Capacity (Incl. heater, and reser- voir tank 0.4 liters): 5.5 liters (5-8 U.S. qt., 4.8 Imp. gt.) RADIATOR CAP aces Pressure test, page 8-79 p> —— coon SD ~ RESERVOIR : NY aN servos Test for operation with 12V OC applied AN 6x1.0 mm, 10 Nem (1.0 kg-m, 7h) FAN SHROUD WATER PUMP INLET PIPE 5-76 NOTE: © Check all cooling system hoses for damage, leaks or deterioration and replace if necessary. © Check all hose clamps and retighten if necessary. © Use new O-rings whenever reassembling, RADIATOR Refilling, page 6-78 Leak test, page 5-79 Inspect seams between core fing and tanks for leaks. Blow dirt out from benween core fins with compressed ait It insects,etc., ara clogging radiator, wash them off with low pressure water UPPER RADIATOR HOSE Lower RADIATOR TEMPERATURE HOSE GAUGE SENDING UNIT 9.Nem (0.9 kg-m, 7 teh) THERMOSENSOR 18 Nem (1.8 kgm, THERMOSTAT 13 be) HousING ae HEATER HOSESRadiator [- Replacement 1. Brain the coolant from the radiator 3. Disconnect the upper and lower reiator hoses from »"femove the radtor cap to speed draining, cinder heed 4. Disconnect the ATF cooler hose (A/T) (EATING Use care when removing 1 avoid scalding by hot coolant or steam. NOTE: Plug the hoses and pipes. 2, Remove the connectors from the cooling fan motor ‘and thermoswitch, 5. Remove the radiator bracket and radiator 6x1.0 mm 10 Nem (1.0 kgm, 0.7 lb-ft) RADIATOR BRACKETS 6x1.0mm 10 Nim (1.0 kg. UPPER CUSHION UPPER RADIATOR HOSE RADIATOR Lower CUSHION ATF COOLER HOSE FAN MOTOR LOWER RADIATOR HOSE FAN MOTOR, NOTE: + Install the radiator in the reverse order of removal + Before installing the radiator, set the radiator lower cushion securely under it. 5-77Radiator — Refilling and Bleeding Set the heater temperature lever to maximum heat. When the radiator is cool, remove the radiator cap and drain plug. and drain the radiator. Reinstall the radiator drain plug and tighten it se curely. Remove, drain and reinstall the reserve tank. Fill the tank halfway to the MAX mark with watt then up to the MAX mark with coolant. Mix the recommended anti-freeze with an equal amount of water, in a clean container NOTE © Use only HONDA-RECOMMENDED anti-freoze/ coolant, © For best corrosion protection, the coolant con. centration must be maintained year-round at 50% MINIMUM. Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing © Coolant concentrations greater than 60% will impair cooling efficiency and are not recom- mended. CAUTION: © Do not mix different brand anti-freeze/coolants. © Do not use additional rust inhibitors or anti-rust products: they may not be compatible with the recommended coolant. Radiator Coolant Refill Capacity including reservoir tank 0.4 liters) mi at US at ino. at) [iat a0 iar [aa 6, 30/43, 45, 38) 151i-Cobueted) ]44 46.39)44, (46.39) 151 (2Caburied) [4547 40]44, (66.3.9) TSCPGM- 7098 [4.4 4.6,9.9)/4.3, 18.5, 3.8) TSEPGM-FI 93 pe 145, 4,7, 4.0)/4.4, 166,39) 1.6 DOHC 45,147, 4.01] =] [isrsone [446 a9[ UPPER RADIATOR HOSE DRAIN PLUG Loosen the air bleed bolt in the water outlet, then fil the radiator to the bottom of the filler neck with the coolant mixture. Tighten the bleed bolt as soon {8 coolant starts to run out in a steady stream without bubbles BLEED BOLT 101.28 mm 9 N-m (0.9 kgm, 7 lb-ft) DRAIN BOLT 45 Nem (6.5 kom, 33 Ib-f) With the radiator cap off, start the engine and let it run until warmed up (tan goes on at least twice) I necessary add more coolant mix to bring the level back up to the bottom of the filer neck. Put the radiator cap on, then run the engine again and check for leaks. 5-78Radiator be Cap Testing 1. Remove the radiator cap, wet its seal with coolant, then install it on the pressure tester 2. Apply a pressure of 74-103 kPa (0.75—1.05 kg/em?, 1115 psi, 3. Check for a drop in pressure. RADIATOR PRESSURE TESTER PRESSURE CAP r— Radiator Tes: 1. Wait uti the engine i col, then carefully remove the pressure cap anil the radiator with coolant to SADIATOR PRESSURE the top ofthe fier neck 2. Attach the pressure tester to the radiator and apply a pressure of 74—103 kPa (0.75— 1.05 kg/em?, a 11-15 psi. 3. Inspect for coolant leaks and @ drop in pressure. 4, Remove the tester and reinstall the pressure cap. ss NOTE: Check for engine oil in coolant and/or cool ant in engine oil 5-79Thermostat r- Replacement NOTE: Use new gaskets and O-rings whenever reassem- a 2 RS o INLET PIPE. / ip Replace ! } \ ~ THERMOSTAT HOUSING Testing Shown \_——eiwomeren 2. Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens and at full lift. CAUTION: Do not let thermomet of hot container. F touch bottom 3. Measure lift height of thermostat when fully open. STANDARD THERMOSTAT Lift height: 8 mm (0.31 in.) Starts oponing:78 C +2 C (172 F +3 F) Fully open: 90 C (194 F) 5-80Water Pump -- Replacement 1. Remove the timing belt (SOHC: page 5-30, DOHC page 5°38) 2. Remove the water pump by removing five bolts. WATER PUMP Inspect for signs of seal leakage or bearing deterioration, NOTE: Small amount of “weeping” from bleed hole 18 normal Replace 6x1.0 mm 12m (1.2 kgm, m/s 101.25 mm 45 Nem (4.5 kgm. ALTERNATOR 33 Wt) BRACKET 3. Install the water pump in the reverse order of removal 5-81Fuel and Emission Carbureted Engine PGM-FI Engine ...Fuel and Emissions (Carbureted Engine) Special Tools Component Locations Index System Description Vacuum Connections Electrical Connections Symptom-to-System Chart. Carburetor Idle Control System .... Power Valve Slow Air Jet Control System .. Vacuum Piston Control System 6-48 Primary Slow Mixture Cut-off Solenoid Valve... Idle Speed/Mixture. Float Level Accelerator Pump . Vacuum Controlled Secondary Automatic Choke and Fast Idle Choke Linkage . Choke Opener Fast Idle ... Manual Choke and Fast Idle Choke Opener ..6-60 6-61 6-62 6-63 6-65 Removal... 6 -66,69,72 Replacement. 6-67, 70,73 Reassembly .. so -74 Synchronization 6-75 Fuel Supply System ‘Symptom-to-Sub System Chart 6-76 Fuel Filters. 6-77 Fuel Pump... 6-77 Fuel Tank 6-79 Air Intake System ‘Symptom-to-Sub System Chart 6-80 Throttle Cable ....... 6-81 Intake Air Control System 6-84 Emission Control System Symptom-to-Sub System Chart 6-85 Tailpipe Emissions .. 6-86 Catalytic Converter 6-86 Feedback Control System 6-87 Throttle Control 6-88 Positive Crankcase Ventilation ...6-90 Evaporative Emission Controls ...6—-91 Troubleshooting [KQ] Self-Diagnostic Procedures ......6-98 How to Read Flow Charts .........6- 100 PGM-CARB Control System (KQ] Troubleshooting Flow Charts Oxygen Sensor 6-102 Vehicle Speed Sensor 6-104 Manifold Absolute Pressure Senser.... . 6-105 Vacuum Switch .... 6-109 Coolant Temperature Sensor ...6-112 Ignition Coil Signal .....esseeee6— 114 EACV ... 6-115 Input Troubleshooting Flow Charts .. 6-117 Power Source (IG1, Bat) and Ground senses 8118 Clutch Switch Signal 6-119 A/T Shift Position Signal........6— 121 P/S Oil Pressure Switch Signal6 — 123 Air Conditioning Signal 6-125 AJC Clutch Relay 6-126Special Tools [Special Tools Ref. No, ‘Too! Number Description ary | Remarks 2 | (07401-00100 Float Level Gauge 1 | Smuz-areose | ECU TES asx 3 $ | Siarenone | ecvrernmes 6 i 074110020000 Digital Circuit Tester Test Harness 1 6-2Component Locations Index (1 sarburated Engine. RHO! INTAKE AIR A/c IDLE CONTROL BOOST SOLENOID AIR CLEANER ELEMENT DIAPHRAGM, vaLve EC, KO: Replace every Testing, page 6-84 Troubleshooting, page 6-41 2 years or 40,000 km (24,000 miles} whichever comes fst ‘*O1ners: Replace every 1 year or 20,000 km (12,000 miles) ‘whichever comes frst an LEX ZA Za BA ‘THROTTLE CABLE Inspection/Adjustment, page 6-82 Replacement, page 6-81 ‘arbureted Engine, LHD) A/C IDLE BOOST SOLENOID VALVE [Ex. KG M/T] INTAKE AIR ‘Troubleshooting, page 6-41 CONTROL DIAPHRAGM Testing, page 6-84 IDLE BOOST SOLENOID VALVE (KG M/T] Troubleshooting, page 6-39 AIR CLEANER ELEMENT ‘®EC: Replace every 2 years or 40,000 km (24,000 miles) = whichever comes frst ‘Others: Replace every 1 year ar 20,000 km (12,000 miles) {whichever comes fst SS THROTTLE caste Inspection/ Adjustment, page 6-82 Replacement, page 6-81 (cont'd) 6-3Component Locations Index (cont'd) 2-Carbureted Engine, RHD) AIR CLEANER ELEMENT EC, KQ: Replace every 2 years oF 40,000 km (24,000 mies) whichever comes frst. Others: Replace every 1 year ot 20,000 km (12,000 mies} whichever comes frst. INTAKE AIR CONTROL, DIAPHRAGM, AC IDLE BOOST SOLENOID VALVE [KE] ‘Troubleshooting, page 6-41 THROTTLE CABLE AIR INTAKE, Inspection/Adustment, page 6-82 TUBE Replacement, page 6-81 [2-Carbureted Engine, LHD] AIR CLEANER ELEMENT ‘®EC: Replace every 2 years or 40,000 km (24,000 res} whichever comes frst TEx. KG MT! f@ Others: Replace every 1 year or ‘Troubleshooting, page 20,000 km {12,000 mies} whichever 6-81 comes first. IDLE Boost ‘SOLENOID VALVE [ke M/T] Troubleshooting, page 6-39 INTAKE AIR CONTROL AIC IDLE BOOST DIAPHRAGM. SOLENOID VALVE = - AIR INTAKE THROTTLE CABLE TUBE Inapection/ Adjustment, page 6-82 Replacement, page 6-81rz ‘1-Carbureted Engine] FUEL GAUGE SENDING FUEL TANK rust reeo ripe UNE Reotcaman, oe 6-78 FUEL VAPOR PIPE CANISTER Testing, page 6-91 FUEL FILTER Replacement, page 6-77 FUEL PUMP Testing. page 6-77 Replacement, page 6-78 ‘TWO-WAY VALVE =/ suet nerunn Tetra: Page 6:99 CARBURETOR pire Removal, page 6-72 Replacement, page 6-73 ‘Carbureted Engine) FUEL TANK FUEL GAUGE Replacement, page 6-79 SENDING UNIT Section, 16 FUEL FILLER CAP FUEL FEED PIPE FUEL VAPOR PIPE CANISTER [KQ) FUEL FILTER Replacement, page 6-77 ‘TWO-WAY VALVE FUEL PUMP, Testing, page 6-93, ‘Testing, page 6-77 Replacement, page 6-78 FUEL RETURN PIPE CARBURETOR FUEL FILTER (KQ} Removal, page 6-66, 69 Replacement, page 6-77 Replacement, page 6-67, 70 {eont’é) 6-5Component Locations Index (cont'd) (kaj AIR LEAK SOLENOID VALVE INNER VENT soLENoin TOsbleshootng, page 6-46 VALE Troubleshooting, page 6-94 contRoL Box page 6-14 AIC IDLE BOOST SOLENOID VALVE Troubleshooting, page 6-37 P/S OIL PRESSURE SWITCH ‘Troubleshooting, page 6-123 AIR BLEED VALVE Testing, page 6-84 THERMOVALVE: EAcV Troubleshooting, page 6-115 COOLANT OXYGEN (0,) SENSOR TEMPERATURE (TW) Troubleshooting, page 6-102 SENSOR Troubleshooting, page 6-112 (ka) [ke mT} PGM-CARB CONTROL UNIT DEVICE CONTROL UNIT Troubleshooting, page 6-100 Testing, page 6-32 6-6System Description Vacuum Connections 1-Carbureted Engine, Ex. KG A/T, KY] Ex. KG MT ONLY FOR VEHICLE WITH an CONDITIONER 8 (cont‘a) 6-7System Description Vacuum Connections (cont'd) 1-Carbureted Engine, K@ A/T! ONLY FOR | VEHICLE | witw ain CONDITIONE! 6-8[1-Carbureted Engine, KY] ONLY FOR VEHICLE WITH AIR CONDITIONER to Two.way , VALE i (conta 6-9System Descriptions Vacuum Connections (cont'd) [2-Carburoted Engine, KB, KF, KW, KE] ONLY FOR VEHICLE WITH AIR CONDITIONER 6-10N (2-Carbureted Engine. KG A/T) (cont'd 6-11System Description Vacuum Connections (cont'd) [2-Carburoted Engine, KG M/T! 6-12System Description Vacuum Connections (cont'd) [2-Carbureted Engine, KA) Control Box POWER VALVE CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE PRESSURE Troubleshooting, page 6-44 (map) SENSOR Troubleshooting, page 6-105 IDLE BOOST SOLENOID VALVE Troubleshooting, page 6-35 IGNITION CONTROL SOLENOID VALVE Section 16 vacuum switch ‘Troubleshooting, page 6-109 6-14[1-Carbureted Engine, Ex. KG A/T, KY ese8e AIR CONTROL DIAPHRAGM IR BLEED VALVE. (CHECK VALVE POWER VALVE PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE ‘THROTTLE CONTROLLER CHECK VALVE ‘SECONDARY DIAPHRAGM IDLE BOOST THROTTLE CONTROLLER, ‘A/C IDLE BOOST SOLENOID VALVE [Ex. KG M/T J IDLE BOOST SOLENOID VALVE [KG M/T] (cont'd 6-15System Description Vacuum Connections (cont'd) — —@ (1-Carbureted Engine, KG A/T) AIR CONTROL DIAPHRAGM, AIR BLEED VALVE (CHECK VALVE POWER VALVE PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE 66680 ® ® ® @ ‘THROTTLE CONTROLLER CHECK VALVE SECONDARY DIAPHRAGM IDLE BOOST THROTTLE CONTROLLER A/C IDLE BOOST SOLENOID VALVE[1-Carbureted Engine, KY] AIR CONTROL DIAPHRAGM ‘AIR BLEED VALVE. CHECK VALVE POWER VALVE PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE THROTTLE CONTROLLER CHECK VALVE ® ® @ ® ‘SECONDARY DIAPHRAGM IDLE BOOST THROTTLE CONTROLLER A/C IDLE BOOST SOLENOID VALVE CHARCOAL CANISTER TWO-WAY VALVE PURGE CONTROL VALVE (cont'd) 6-17System Description Vacuum Connections (cont'd) —£_ —O@—W_—_. 2-Carbureted Engine, Ex. KG, KO] AIR CONTROL DIAPHRAGM. AIR BLEED VALVE ) CHECK VALVE ) POWER VALVE PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE eo08e 6-18 seca THROTTLE CONTROLLER (CHECK VALVE IDLE BOOST THROTTLE CONTROLLER A/C IDLE BOOST SOLENOID VALVEesses Carbureted Engine, KG: AIR CONTROL DIAPHRAGM ® [AIR BLEED VALVE @ CHECK VALVE ® POWER VALVE ® PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE ® THROTTLE CONTROLLER CHECK VALVE IDLE BOOST THROTTLE CONTROLLER IDLE BOOST SOLENOID VALVE (MT) AIC IDLE BOOST SOLENOID VALVE CHOKE OPENER tcont'a) 6-19System Description Vacuum Connections (cont'd) [2-Carbureted Engine, KO] eeIseRane AIR CONTROL DIAPHRAGM ‘AIR BLEED VALVE CHECK VALVE POWER VALVE PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE ‘THROTTLE CONTROLLER CHECK VALVE IDLE BOOST THROTTLE CONTROLLER, IDLE BOOST SOLENOID VALVE AIC IDLE BOOST SOLENOID VALVE CHOKE OPENER VACUUM SWITCH 6-20 ELECTRONIC AIR CONTROL VALVE (EACV) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR THERMOVALVE INNER VENT SOLENOID VALVE ‘AIR LEAK SOLEONID VALVE POWER VALVE CONTROL SOLENOID VALVE CHARCOAL CANISTER PURGE CONTROL VALVE ‘TWO-WAY VALVE ‘THERMOWAX VALVE AIR VENT CUT-OFF SOLENOID VALVE(ke M/7} BATTERY IGNITION swiTcH FUSE 80x Electrical Connections AAA 1 L > A € 9 PRIMARY slow MIXTURE CUT-OFF SOLENOID VALVE (tort) | | ! Loe PRIMARY SLOW MIXTURE CUT-OFF SOLENOID VALVE RED Le goost ‘SOLENOID VALVE 301 (2.Carbureted Engine) No.14 BLK DEVICE CONTROL UNIT vet CHOKE PILOT Lamp: aL /RED CHOKE switch eLK Gao {cont’a) 6-21System Description Electrical Connections (cont'd) ke am) Fuse 80x artery tenumion ewtten Ore \p- € 3 cy | | ! | | | cue vee | | | | | | | | reco | primary | SENSOR | stow | | | Qfmocrune curore | | “ ! men CHOKE. | ; 3) ast | Cher | pameany | | stow” | | lonmron mixture | tonrion SOLENOID | VALVE au vawe | gle | | ssn | | Sars, | | oie | ! BLK | | = ! a2 | e201 | aos wos aot L______J [2-Carbureted Engine] 6-22[kal e e 3 MAIN FUSE BOX 7°. ‘SWITCH FUSE BOX BATTERY 1G1 (50a) No.14 O--ee ox a Sion yysre + vacuum SENSOR cae a T vo | T ‘SENSOR | j Lb { SOLENOID PRESSURE iS See SWITCH Ie ‘SENSOR ® i some Ee} {z|Sereon | fe] ie Eso en AIR LEAK SOLENOID | IGNITION CONTROL aaa a a OOODOCO00O OODOOOO00CO OOOOCC000O OOOCO00CC0C0O Bie Als Al4 Ald Al2 All AIO AS AS Bi6als Blé B13 Bi2 Bll BIO BS BB 6-23Carburetor Symptom-to-System Chart [1-Carbureted Engine] NOTE: ‘© Across each row in the chart, the sub systems that could be sources of @ symptom are ranked in the order they should be inspected, starting with @. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next system @), etc © Before starting inspection, check that other items that affect engine performance are within specification. Check the valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function of the vacuum and centrifugal advance, {and the condition of the spark plugs. If those items are all within specifications, begin with the troubleshooting listed in pages 6-24 and 6-25, PAGE - | sus sysrem | ] manual) - wove speeo/ | ite cHoKE/ MIXTURE contro. | FasTinye POWER VALVE | system SYMPTOM 3 ae ENGINE WON'T START . — | | WHEN coLo ® DIFFICULT To START 4 _ ENGINE WHEN COLD WHEN WARM | ® - WHEN COLD FAST IDLE OUT OF ® SPECIFICATION | | WHEN WARM ENGINE SPEED TOO ® ® ® IRREGULAR HIGH - | . IDLING WHEN WARM ENGINE SPEED TOO ® ® Low’ ROUGH IDLE/ ¢ | FLUCTUATION ® ® WHILE | WARMING UP @® FREQUENT | STALLING AFTER ® WARMING UP ~ | MISFIRE OR ROUGH RUNNING Loss oF ® POOR POWER S PERFORM : - ! - ANCE AFTERBURN Oo | HESITATION, ® SURGE 6-24CARBURETOR {Pawar accu. VacUOM | pyey SioheuRe | arom | suoar ever | controuies | iY | | See vawe | PUMP || Seconpany | SUPPLY | (ssa [ss a | | | , ® | [i ] | @ ® ® | a in os nn ee | Oo | ] | \ 6-25Carburetor Symptom-to-System Chart [2-Carbureted Engine, KO] NOTE {© Across each row in the chart, the sub eystems that could be sources of a symptom are ranked in the order they should be inspected, starting with . Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column, If inspection shows the system is OK, try the next system 2), etc © Before starting inspection, check that other items that affect engine performance are within specification. Check the selt- diagnosis indicator, valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function of the vecuum land centifugel advance, and the condition of the spark plugs. If those items are all within specifications, begin with the troubleshooting listed in pages 6-26 and 6-27. ~ CARBURETOR ] ——— ——~ mixture |IOLECONTROL Fast iove Nes vewn | SYSTEM SOLENOID VALVE SYMPTOM ~~ 63 | 30 60 84, 96 Naiwe WONT START | | ® wen cot ® ® DIFFICULT TO START | _ whew wan Oo | ‘WHEN COLD FAST l | - weeoseer ® ew Wan ENGINE SPEED TOO ® @ ® IRREGULAR | HIGH je 4. —__|—_______| ___ IDLING WHEN WARM a | ENGINE SPEED TOO ® ® in FLUCTUATION ® ® write WARMING UP ® ® recover k } — ae we o ® ® ‘WARMING UP | a ~ MISFIRE OR | | — rosin | - (oss oF POOR POWER | ® PERFORM- _ — — T _ ‘ aNct AFTERBURN ) wesraTION 6-26CARSURETOR rower ve iio Aver | Meron" faron” |rue.suerer| am mane | EMESOM 43, so 48 ne ee 80 85 ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® ® | o ® ® ® ® ® ®)|@®|o ©) o ® o ® ® ® 6-27Carburetor Symptom-to-System Chart (2-Carburoted Engine, Ex. KO) Nore: '@ Across each row in the chart, the sub systems that could be sources of a symptom are ranked in the order they should be inspected, starting with (7. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next system 2), etc ‘© Before starting inspection, check that other items that affect engine performance are within specification. Check the valve clearance, air cleaner, and PCV valve. In addition, check the ignition timing, function of the vacuum and centrifugal advance, land the condition of the spark plugs. If those items are all within specifications, begin with the troubleshooting listed in this a T T __caraureTor —J PAGE sysTeM MANUAL PAMARYSIOW accrues. | vouespeeo/| ioe | CHOKE! | power |uixtune "| ACCELE |) eye, ——_j—_ Mine | Conrao. | fasribie | Valve’ feurore | SATOR | Suppuy | | sysrew Isowopvave! POMP | OT SYMPTOM SS 6 a 63 a 52 76 t — {— | ENGINE WON'T START @ ® L irricuur to | WHEN COLD ® ® ® StaRy - Engine WHEN cou Wen WARM ® ® WHEN COU Fast a {bee our oF | ® ® SPECICATION 1 - WHEN WARM Meneses | @ ® ® wrecuian [00H | | ‘WHEN WARM | Wane set ‘TOO LOW ® ® ROUGH IDLE/ FLUCTUATION ® @ |wane | WARING UP ® ® ® ® Engauent ~ STALLING asTER WARMING UP ® ® ® ® I __ 4 _ MISFIRE OR | RouGH I 2 RUNNING ® @ Loss oF POOR POWER ® ® ® PERFORM- } _ } — _— ANCE | AFTERBURN ® | HesmaTIOn/ | Sunce | @ ® 6-286-29Carburetor [- Idle Control System Testing [ka] NOTE: Snap the accelerator pedal several times and check the idle speed with the accelerator pedal fully returned, 1. Start the engine and warm up to normal operating temperature (the cooling fan comes on). 2. Check the idle speed with headlights, heater blower rear window defogger, cooling fan and air conditioner off Idle speed should be: (i 750250 min-* rami [Automatic [70050 min (rpm) (except "N" or © IF OK, go to step 4. © IF not, go to step 3. 3. Disconnect the two vacuum hoses at idle boost throt te controller and check each for vacuum. ‘There should be no vacuum in both hoses. PUMP/GAUGE IDLE BoosT THROTTLE CONTROLLER #20 VACUUM HOSE © If there is no vacuum, check the throttle valve shaft for binding or sticking and replace the idle boost throttle controller. © If there is vacuum at the #20 vacuum hose, go to idle boost solenoid valve troubleshooting (page 6-35) © If there is vacuum at the outside vacuum hose, go to A/C idle boost solenoid valve throubleshooting (page 6-37) Disconnect the 420 vacuum hose at idle boost throttle controller and check vacuum. NOTE: The engine coolant temperature must be below 80°C (1767) There should be vacuum. #20 vacuUM HOSE © IF there is vacuum, check the throttle valve shaft for binding or sticking and replace the idle boost throt- tle controller © If there is no vacuum, go to the idle boost solenoid valve troubleshooting (page 6-35) (Check the idle speed with the A/C on. Idle speed should be: 750+50 min? (rpm) © IF not, disconnect the two vacuum hose at idle boost throttle controller and check each for vac- tuum. There should be vacuum in both hoses. — If there is vacuum in both hoses, replace the idle boost throttle controller — If there is mo vacuum at the #20 vacuum hose, {90 to idle boost solenoid valve troubleshooting (page 6-35). — If there is no vacuum at the outside vacuum hose," go to A/C idle boost solenoid valve troubleshooting (page 6-37) 6-30Ei (ex. Ka, KG MIT} NOTE: Snap the accelerator pedal several times and check the idle speed with the accelerator pedal fully returned. 1. Start the engine and warm up to normal operating temperature (the cooling fan comes on). 2. Check the idle speed with headlights, heater blower rear window defogger, cooling fan and sir conditioner off. Idle speed should be: Manual [760280 min rom) ‘Automatic | 70060 min (rpm) (except © IF OK, go to step 4 © IF not, go to step 3. 9. Disconnect the vacuum hose from the idle boost throt= ‘le controller and check the vacuum. ‘There should be no vacuum, [1-Carbureted Engine} vacuum von ILE Boost GAUGE THROTTLE CONTROLLER [2-Carbureted Engine) IDLE BOOST THROTTLE CONTROLLER vacUUM PUMP/ GAUGE €@ ‘IF there is no vacuum, check the throttle valve shaft for binding oF sticking and replace the idle boost throttle controller. © if there is vacuum, go to troubleshooting (page 6-41). 4. Check the idle speed with the A/C on Idle speed should be: 760250 min” (rpm) © If not, disconnect the vacuum hose from the idle boost throttle controller and check the vacuum. There should be vacuum. — if there is vacuum, check the throttle valve shaft for binding or sticking and replace the idle boost throttle controller — If there is no vacuum, go to troubleshooting (page 6-41) (conta) 6-31Carburetor [ke M/T] NOTE: Snap the accelerator pedal several times and check the idle speed with the accelerator pedal fully returned. 1. Connect a tachometer TACHOMETER P.M. CONNECTING ADAPTOR (07A2~SH20100 2. Start the engine end warm up to normal operating temperature (the cooling fan comes on). ‘And warm up the engine further for more than 4 ‘minutes with the engine speed 2,000 min (rpm) 3. Disconnect the #20 vacuum hose from the idle boost throttle controller and check the vacuum, There should be no vacuum (1-Carburoted Engine) vacuum f PUMP/GAUGE i #20 VACUUM LY IDLE BOOST THROTTLE CONTROLLER [2-Carbureted Engi IDLE Boost . ‘THROTTLE CONTROLLER vacuum PUMP/GAUGE © If there is vacuum, go to troubleshooting (page 6-39). 4, (Idle Control System (eort’d) AAA aA Place choke control knob in 1/8 position, then check the vacuum. There should be no vacuum, © If there is vacuum, go to troubleshooting (page 6-29) Check the choke lamp. ‘The choke lamp should come on © If it does not come on, go to step 6 through 8. — If OK, replace the device control unit and retest Disconnect the 2P connector on the choke switch, and measure voltage between BLU/RED (+) terminal ‘and body ground: ‘There should be voltage. © IF there is voltage, inspect open in BLK wire between the choke switch and G-401, If OK, replace the choke switch and retest. © If there is no voltage, inspect open in BLU/RED wire between the choke switch and the device control unit. Check the choke lamp bulb, © If not, inspect open in BLU/BLK wire between the combination meter and device control unit, and inspect open in YEL wire between the combination meter and ignition switch as well ag No.1 fuse. If OK, replace the choke lamp bulb and retest. 6-32A 8 10 " Disconnect the 2P connector an the TW sensor, and measure voltage between BLK/YEL (+) terminal and body ground ‘TW SENSOR ‘There should be voltage © IF there is voltage, inspect open in RED/WHT wire ‘between the TW sensor and the control unit. IF OK, replace the TW sensor and retest © IF there is no voltage, inspect open in BLK/YEL wire ‘between the TW sensor and the ignition switch as well as No.14 fuse. Disconnect the 2P connector on the TW sensor and check the choke lamp. ‘The choke lamp should not come on. © If it comes on, inspect short in BLU/BLK wire betwaen the combination meter and the device control unit Check the vacuum There should be vacuum. © If there is no vacuum, go to troubleshooting (page 6.39) Warm up the engine further for more than 2 minutes with the engine speed 2,000 min (rpm) 12. Connect the TW sensor and place choke control knob ‘1/8 position, then check the choke lamp and vac- The choke lamp should not come on and there should bbe vacuum, © IF not, replace the device control unit and retest, 13. Recheck the choke lamp and the vacuum, The choke lamp should come on and there should be no vacuum within 4 minutes. © IF not, replace the device control unit and retest, 14, Place choke control knob in full open position. Connect @ vacuum pump to the idle boost throttle controller [1-Carbureted Engine] vacuum PUMP/GAUGE Li; j { OLE BOOST THROTTLE CONTROLLER {2-Carbureted Engine] IDLE Boost THROTTLE CONTROLLER vacuum PUMP/GAUGE 15. Apply 400 mm Hg (16 in. Hg) vacuum to the idle boost ‘throttle controller, then check the idle speed Idle speed should be: 1.500 + 100 min (rpm) (cont’a) 6-33Carburetor [- Idle Control System (cont'd) Adjust the idle speed, it necessary, by turning the adjusting [1-Carbureted Engine] ADJUSTING ‘SCREW [2-Carbureted Engine] ADJUSTING SCREW & 6-34[Idle Control System (ka) Troubleshooting Flow Chart Idle Boost Solenoid Vaive of lle Boost Solenoid ‘Open the control box —_| IDLE BOOST SOLENOID VALVE Disconnect the lower vacuum hose of the solenoid valve from the 4 way joint and connect a vacuum pump. Disconnect 20 vacuum hose of | the solenoid vahe from the voc tum howe manifold and connect # vacuum one | — —_—— 120 VACUUM Hose Start the engine. NOTE: Engine coolant temperature must be below 80°C (176) ‘Aoply vacuum Measure voltage between RED (+) {terminal anc BLK (—) terminal on | the contro! box ves — _ Convnausm macatedon te gouge? SS ‘Warm up engine to normal oper ing temperature (cooling fan ‘comes on) | ‘Apply vacuum \ or (From page 6-38) Measure voltage between RED (+) ‘terminal and body ground No Check the self-diagnosis indica | tor (page 6-101). If OK. inspect ‘open in RED wire between the fe and control unit Measure voltage between RED (+) | terminal and BLK (=) terminal on the contol box. | < tsthere voltage? = 1 No ~ Repair open in BLK nthe 6301 | Check the str kagosis indicator (page 6. 101) WOK. check the input | troubleshooting (page 6.117) 6-36tka] Troubleshooting Flow Chart AIC Idle Boost Solenoid Valve Inspection of A/C Idle Boost Solenoid Valve, Disconnect the lower vacuum hose of the solenoid vaive from the ‘vacuum hose manifold and con __- [__ eet vacuum pump AIC IDLE BOOST SOLENOID VALVE Disconnect the upper vacuum hose of the solencid valve from the ‘le boost throttle controler and ‘connect a vacuum gauge Stat the engine. | —__L ‘Apply vacuum. [sar on cero ew — ve Se (To page 6-38) — — vacuum PUMP/GAUGE Inspect short in BLU/ RED wire between the solenoid valve and A/ C ewiteh (cont'd 6-37Carburetor t-Idle Control System (cont'd) (From page 6-37) A. ————\. no T ves Turn tre A/C swten OFF. | is «= No ee Check the vacuum line for proper connection, cracks, blockage oF disconnected hose. Disconnect the connectors. near the solenoid valve. | Measure vottage between BLK/ | YEE) conector ana BLu/meD (=) connector on the wie har- ues

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vss Disconnect the connector from the TW sensor and place choke co trol knob in 1/8 position, the apply vacuum. ee" (To page 6-40) Idle Boost Solenoid Valve PET Jp =f ro ‘20 vacuum [MQ sese / = 12 vacuum HOSE _| Disconnect the 4? connector near the solenoid valve. ‘Measure voltage between RED (+) terminal and BLK (=) terminal on the wire harness: No Replace the solenoid valve. vacuum PUMP/GAUGE Substitute a known: ‘900d device cont Unit and recheck. If symptom got away. replace the (cont’ah 6-39Carburetor (From page 6-39) —|__ ves ,— Idle Control! System (cont'd) No -” the solenoid vaive Measur Diconerte arcmin | terminal and BLK (~) terminal on the wie harness No ®2 | Donan ves. Measure voltage between RED(+) | terminal end bady ground, yes Is there battery voltage? No Inspect open in RED wire borwoen the solenoid valve and compressor control unit. W wire is OK, check the com: pressor control unit (section 16). Turn the AIC switch OFF ‘Cievacuumindeated onthe gauge? >" | Replace ta aatroid ave. | No Check the vacuum line for proper connection, cracks, blockage oF disconnected hose. 6-421 r Power Valve Testing (1-Carbureted Engine) Disconnect the #14 vacuum hose from the vacuum. hose manifold and connect @ vacuum pump. Apply vacuum and listen for a clicking noise from the power valve #14 VacuuM Hose VACUUM PUMP/GAUGE © Ifa clicking sound is heard, go on to step 2 © IF no sound is heard, replace the carburetor and retest. Start the engine and wait for it to warm up. Disconnect the #14 vacuum hose from the carburetor and connect @ vacuum gauge to the hose Check that there is vacuum at idling © If there is no vacuum, check the vacuum hose for proper connection, cracks, blockage or discon nected hose arbureted Engine] Disconnect the #14 vacuum hose from the vacuum hose manifold and connect @ vacuum pump. Apoly VACUUM PUMP/GAUGE © IF it does not hold vacuum, replace the diaphragm and retest (page 6-68, 71) Start the engine and disconnect the #14 vacuum hose from the vacuum hose manifold, and connect a vac- ‘uum pump, KQ model ‘There should be no vacuum for about 10 seconds after the engine is started. ‘And there should be vacuum within 18 seconds after the engine is started. NOTE: The engine coolant temperature must be below 30°C (86) Ex. KQ: There should be vacuum KQ: go to troubleshooting (page 6-44) Ex. KQ: check the vacuum hose for proper conneo- tion, cracks, blockage or disconnected hose tka] Warm up the engine (the cooling fan comes on), and check the vacuum, There should be vacuum © If not, go to troubleshooting (page 6-44) (cont'd) 6-43Carburetor r— Power Valve (cont'd) [kay ‘Troubleshooting Flow Chart Power Valve Control Solenoid Valve Inspection of Power Valve Con: ‘ual Solenoid Valve. ———— POWER VALVE Open te contol box, CONTROL SOLENOID Disconnect the lower vacuum | hose of the solenoid valve from the 4 way joint and connect» vacuum pum NOTE: The engine coolant VACUUM temperature must be below PUMP/GAUGE. 30°C (86) : Disconnect #14 vacuum hose of the solenoid valve from the vac~ tuum hose manifold and connect 3 [_ seem ance favacuum HOSE ‘Apply vacuum for about 10 sec- gine is started. ves [Mem vag tein terminal on the wire harness No auK ‘Warm up engine 10 normal operat- 1 in me ° iether bates wtp? o Rion to ot Tro Measure voltage between YEL/ | RED (+) terminal and body ground (To page 6-45) (To page 6-45) 6-44(From page 6-44) | - No Cenc indent on gouge? Chock the vacuum line for proper connection, cracks. blockage or disconnected hose. (From page 6-44) \yes Cte treater vate? > No Check the self-diagnosis indice tor (page 6-101). If OK. inspect ‘open in BLU/RED wire between | the solenoid vaive and control unit (810) Measure voltage between BLU/ RED (+) terminal and BLK (~} terminal on the wire haeness. N yes Replace the solenoid valve Repair open in BLK wire between the solenoid valve and G301 Check the colt diagnosis indicator (page 6-101). WOK, check the input ‘woublashooting (page 6-117) 6-45Carburetor vel Inspection of [Slow Air Jet Control System [KQ] Troubleshooting Flow Chart Disconnect the #2 vacuum hose from the vacuum hose manifold v4 connect @ vacuum pump. Start the engine, Leak Solenoid 6-46 ‘Apply 100 mmHg (4 in.Hg) vac~ ‘uum to the hose. (To page 6-47) Alir Leak Solenoid Valve #2 VACUUM Hose vacuum PUMP/GAUGE —| Turn the ignition switch OFF Disconnect the BLU/YEL con rector near the air cleaner. Start the engine BLU/YEL Menace vtage born BLU - no | wae tion woe < sn Tee aerate ves solenoid valve and control unit (86). Replace the solenoid valve.(From page 6-46) —_| ‘Open the thrttle wide open then lose it suddenly. =n ves ——_—____ -= ——[ Tu he ton site OFF No Disconnect the BLU/YEL con. rector near the air cleaner. Start the engine Open the throttle wide open then close it suddenly. Measure voltage between BLU/ YEL (+) and body ground: _ Check the self diagnosis indicator ~ - YES__| (page 6-101). < Is there voltage —| WOK, cheat ty Tho ‘troubleshooting (page No 6-117) 6-47Carburetor (Vacuum Piston Control System [KQ] Troubl hooting Flow Chart Air Leak Solenoid Valve Inspoction of Valve. Leak Solenoid ey ~ Disconnect the vacuum hose from the carburetor and connect # vac- ‘uum pump, Start the engine | .). VACUUM PUMP/GAUGE ‘Apply 100 mmig (4 in Ha) vac ] uum to the hase ves oe 7 oes solenoid valve hold vacuum? >==———| Turn the ignition switch OFF ——er— | No Start the engine im up te engine. ] Warm up the engi BLU/vEL 1 —_I Measure voltage between BLU/ YEL (+) ond body ground Check the self diagnosis indicator wo _| 101). If OK, Is there battery voltage? repair open in BLU/ ves nl untae. "| (To page 6-49) 6-48(From page 6-48) l (Open the throttle wide open then close it sudden 4 _ No does solenoid valve hold vacuum? >~o— N — ves ‘Check the vacuum line for proper ‘connection, cracks, blockage or disconnected hose. “Turn the ignition switch OFF. Disconnect the BLU/YEL con- ‘nectar near the si cleaner. ‘Open the thrortle wide open then close it suddeniy. Measure voltage between BLU/ | YEL (+) and body ground. T ————— ves Is there voltage? No Check the self diagnosis indicator (page 6-101). IFOK, check the input ‘troubleshooting (page 6-117) 6-49Carburetor (ka) Troubleshooting Flow Chart Ingpection of Primary Slow Mi ‘ture Cut-off Solencid Valve. [ tern te anton switch ON CCheck the clicking sound of each solenoid valve by means ofa steth- | < Does the solencd valve click? t— Primary Slow Mixture Cut-off Solenoid Valve No Primary Slow Mixture Cutoff Solenoid Valve Turn the ignition switen OFF. ‘normal operating temperature (the Start the engine and warm up t0 cooling fan comes on) (To page 6-51) Connect the ECU test harness 8 between the contral unit and con- rector (page 6-98) Left solenoid valve: Turn the ignition switch ON. Right solenoid valve: Meas voltage between 83 (+) terminal and BB (>) termina Left solenoid valve: Measure volt ‘age between B2 (+) terminal and BB (+) termina < there bs CCheck the solf-diagnosis indica ‘tor (page 6-101). If OK, chock the input troubleshooting (page 117) B2(+) OOO THO 00009 12? 9000 yes, ei] | ight solenoid vaive: Repair open or short in YEL wire botwaon the solenoid valve and control unit (B3). OK. replace the Repair open or short in GRN/RED wire between the solencid valve and control unit (82), OK. inspect open in BLK wire between the solenoid valve and 201. and replace the solencid valve. 6-50(From page 6-50) (apm) and close the throttle sud- deny < Boss te solenoid vane ick? >"° {Tun me gnton ston OF. | ves ‘Solenoid valve is OK alae engine speed to 5,000 min"! Connect the ECU test hamess B between the control unit and con- rector (page 6-98), Star the engine. | [rpm} and close the throtte sud- deny. Raise engine speed to 6,000 min =e | Right solenoid valve: Measure voltage between 83 (+) terminal and BB (=) terminal Left solenoid valve: Measure volt- ‘age between 82 (+) terminal and 88 (+) terminal No for a moment? ves Roplace the solenoid valve Right solenoid valve: oe Bait), Check the self | diagnosis indicator (page 6-101). WOK. check the input ‘woubleshooting (page 6-117) (cont'd) 6-51Carburetor [Primary Slow Mixture Cut-off Solenoid Valve (cont'd) (ex. Kaj Troubleshooting Flow Chart Primary Slow nary Slow Min | [V-Carbureted Engine] (>) _—_([2-Carbureted Engine) 10 Cut-off Solenoid Valve Inspection of Primary Slow Mix: ‘ture Cut-off Solenoid Valve. Turm te ignition switch ON. CCheck the clicking sound of each ‘solenoid valve by means of steth- scope. —_____} PRIMARY SLOW MIXTURE, CUT-OFF SOLENOID VALVE —_ No rr 1 Does the solenoid valve click? - Turn the ignition switch OFF. ves BLK /vEL im) Disconnect the 8P connector. “Turn the ignition switch ON. BLK/YELwire betwoen Menvre votage between BUX the solo ve and YEL {+) terminal and body Ti Cevterened Begine] ground, Hf OK; replace the pair open or short in | solenoid val ——__| (2-Carburoted Engine) | Soleo va is OX tee ane vote? replace the solenoid no valve. left solenoid valve: ——_——|___ Inspect open in BLK lopair open or short in BLK/YEL wire botw: ‘wire between the 8P connector and the ignition switch as wel No. 14 fuso. 6-52[- Idle Speed/Mixture (kal CO Metor Method Do not smoke during this procedure. Koop any open flame away from your work area. NOTE © Check that the carburetors are synchronized prop- crly, self diagnosis indicator, clutch pedal (section 7) before making idle speed and mature inspec- © Snap the accelerator pedal several times and check the idle speed with the accelerator pedal fully retur- ned CO Meter Method 1. Warm up and calibrate the NDIR CO Meter in accor- dance with the manufacturer's recommended proct dures. 2. Insert exhaust gas sampling probe into the tail pipe at least 40 em and connect @ tachometer. ‘TACHOMETER R.P.M. CONNECTING ADAPTOR (07JAZ—SH20100 3. Start the engine end warm up to normal operating temperature (the cooling fan comes on). 4, Check the fast idle lever. Fast idle lever should not be seated against fast idle FAST IDLE LE\ © If not, replace the left carburetor (page 6-67) E' Check idle speed with the headlights, heater blower, rear window defogger. cooling fan and air conditioner off. Idle speed should be: {Manvai [780350 min rom —_ {Automatic 1700: 50 min om) (except Adjust the idle speed, if necessary, by turning the throttle stop screw. NOTE: If the idle speed is excessively high, check the throttle control (page 6-88) i? Y THROTTLE STOP SCREW (cont'd) 6-53Carburetor ,— Idle Speed/Mixture (cont'd) 6. Disconnect the 2P connector from the EACV and disconnect the hose from vacuum hose manifold, then cap the hose end Disconnect #2 vacuum hose from vacuum hose mani- fold, then cap the hose end. cap #2vAcuuM HOSE 7. Warm up the engine further for more than 2 minutes with the engine speed 3,000 min (rpm 8. Check specification for idle CO with no loed. Spocified CO %: 2.0-3.0.% 9. If not within specification, remove mixture adjusting serew hole plug and adjust by turning mixture adjust- ing screw to obtain proper CO reading 10. " MIXTURE ADJUSTING SCREW HOLE cap Turning mixture adjusting screw clockwise: CO reading decreases counterclockwise: CO reading increases © Readjust idle speed if necessary, and recheck idle co. Turn the ignition switch OFF. Reconnect the con- ector and hose. Remove HAZARD fuse for 10 seconds to reset control unit and recheck idle speed. Idle speed should be: Manual 75050 min" (rpm) ‘Automatic [700350 min rpm) (except Specified CO %: 0.5 % © If idle speed is not as specified, adjust by turning throttle stop screw, then repeat step 6. 6-54