—_ DATSUN) 1983 DATSUN NISSAN SENTRA SERVICE MANUALNISSAN SENTRA Model BII Series FOREWORD This service manual has been prepared pri- marily for the purpose of assisting service personnel in providing effective service and maintenance of the 1983 NISSAN SENTRA. This manual includes procedures for mein- tenance, adjustments, removal and installa- tion, disassembly and assembly of com ponents, and trouble-shooting. All information, illustrations and specifica- tions contained in this manual are based on the latest product information available at 1@ time of publication. If your DATSUN model differs from the specifications con- tained in this manual, consult your NISSAN/ DATSUN dealer for information. ‘The right is reserved to make changes in specifications and methods at any time with- out notice. NISSAN MOTOR CO., LTD. © 1982 NISSAN MOTOR CO,, LTD. Printed in Japan Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Com- pany Ltd, Tokyo, Japan. QUICK REFERENCE INDEX eC DCA DAL aN De eS an age Aa ee LL it Gay ia AH eT ead ee UNL FE ath CUCL CNL eg ATL 0a Pee Le Ne Ue CUBAN Pa Aa Ra chy Tad ey eA ch MTD> This manual deals with the engine, chassis, body and the electrical system. DA QUICK REFERENCE INDEX is provided on the first page. Refer to this index along with the index of the particular section you wish to consult. D> The first page.of each section lists the contents and gives the page numbers for the respective topics. D> SERVICE DATA AND SPECIFICATIONS are contained in each section. > TROUBLE DIAGNOSES AND CORRECTIONS are also included in each section. This feature of the ‘manual lists the likely causes of trouble and recommends the appropriate corrective actions to be taken. DA ist of SPECIAL SERVICE TOOLS is included in each section. The special service tools are designed to assist you in performing repair safely, accurately and quickly. For information concerning how to ‘obtain special service tools, write to the following address: Kent-Moore Corporation KentMoore of Canada, Ltd ‘29784 Little Mack 5466 Timberleo Blvd, Unit 2 Fosevile, Michigan 48066 Mississauga, Ontario Canada LAW 277 D> The measurements given in this manual are primarily expressed with the SI unit (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. : D> The back cover of the manual provides maintenance data for quick reference. D> In the text, the following abbreviations are used: S.DS. Service Data and Specitications LAH, BAHL: Left Hand, Right Hand Tiantening Torque MIT, AIT: Manual Tiansaxle, Automatic Transaxle D> The captions CAUTION and WARNING warn you of steps that must be followed to prevent personal injury and/or damage to some part of the car. IMPORTANT SAFETY NOTICE ‘The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the car. The service methods in this Service Manual are described in such a manner that the service may be per- formed safely and accurately. Special service tools have been designed to permit safe and proper performance of service. Be sure to use them. Service varies with the procedures used, the skills of the mechanic and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the car's safety will be jeopardized by the service method selected.GENERAL VIEWS MODEL VARIATION IDENTIFICATION NUMBERS Engine serial number Manual transaxle number Automatic transaxle number LIFTING POINTS AND TOWING .. GENERAL INFORMATION CONTENTS Gi2 Pantograph jack Gia Garage jack and safety stand Gi? Towing Gi Tie-down ‘4 ..GL7_ SPECIAL SERVICE TOOLS Gi?‘ TIGHTENING TORQUE OF Gi8.-—-« STANDARD BOLT ais als Gale Gis Gio aigGENERAL VIEWS GENERAL VIEWSCoupe GENERAL VIEWS 1,375 (54:1 1,395 (543). 1,620 (638 Unit: mm Gn) 2.400 (94.8) azs0tver3 | 985 (38.8)—») sonez Wagon 11,305 (54.9) = 1,620 (63.8) —+l 1,110 (43.71-) Unit: mm (ia)MODEL VARIATION MODEL VARIATION ; =] Mo ine] Transane | PORE whee sie. “| Destination: Body Che Model Engine | Tr Ke coffset_mm (in) Tire size ox | steriavy | cow” [awaraoa sro | pusiiasev 16 2-door PLBIIRFV RS5F30A Secon ‘SLBIIRFV CD17 PLB11RAV £16 | RL3FOIA 1SESR13 P155/80D13* ststinay [e017 | pNarona ausniry [ere : S608 § | 4door SLBNIFV cD17 | Sedan PLBITAV E16 | RL3FOIA ee Dx susizav [017 | ANarOTA . KPLenEV RSEF308 aoe 0 : KPLB11AV E16 RL3FO1A P185/80D13 WPLBIIFV, assrz0q | 4-vasets wsusnev [eo rota weson weusiav [ere [ausrora] sis «40 (1.57) weusiiav [oor [rwsrora] 4g, svo_| ptsriasru [ere [Aseraon | wnee atsniavo [ets pusniny [e168 _| mNAFo0A 2écor susnavu [cow vsamna 2 PLBIIRFU E16 P185/80013 t ox S804 £ SLB11RFU e017 3 pusninau [ere | mLsrora = SLBII1RAU CD17 | RN3FO1A musty ANAFSOA e6 ruBFU S504 cor foo susnfu [eon pusiiay [ere | Atarora susniav [oor | mNarora * Light weight spare tire GI-4MODEL VARIATION Road wheel size Destination Body | Class Model Engine | Transaxle | Pose whee! sit kPLBIU RNGF30A - wetauiFu a Dsneena . keLetiau | ete | RLSFOIA zis WeLet1U RNGF30A oe Dx $14 WeLet1FU z § RSBF30A 2 | wagon wsus1iFU | co17 wersitau | €16 | RLSFOIA wsus11au | co17 | RNSFO1A “PLBIIRSFN RSSF30A. sto e16 PLB11RSAN RLSFOIA 41/2313 ‘1BBSRIS HieiiRFYN | E15 . 2door rssraoa | ...42(1.65) | P155/80013 ot SLB11RFN co17 SUKI, PuBriRAN | £16 | RL3FOIA | ...40(1.57) (Aluminum SLB1IRAN — [CD17 | RNSFOIA | heel) PLBIIEN E16 RSBFS0A 4 4-door SLBTIFN 017 & | Sdn Pusan | e16 | ALSFOTA Dx SLBITAN 17 | RN3FOIA KPLBIIEN RS5F3OA 175/708R13 Coupe . KPLe11AN | E16 | RL3FOIA Pase/eoD13 WPLBITEN RSBFSOA wster1eN | cD17 185SR13, Wagon . weisitan | €16 | RL3FOIA fleseoDie wsus11an | co17 | RN3FOIA Light weight spare tire GI-5MODEL VARIATION Prefix and suffix designations S : CD17 engine Li: LH. drive Note: Ci means no indication. KHL BM RSF YN GI-6 + Non-California models for U.S.A. + California models + Canada models 1 MPG models + 4speed manual transaxle 1 Sspeed manual transaxle + Automatic transaxle + Deluxe model + Standard model Except 2-door Sedan 2door SedanIDENTIFICATION NUMBERS IDENTIFICATION NUMBERS cxrtification ube ‘Vehicle identification ‘umber plate scires ENGINE SERIAL NUMBER MANUAL TRANSAXLE AUTOMATIC TRANSAXLE ‘The engine serial number is stamped NUMBER NUMBER as shown in the illustrations, ‘The manual transaxle serial number ‘The automatic transaxle serial number label is attached on the clutch with- label is attached on the upper face of drawal lever.LIFTING POINTS AND TOWING LIFTING POINTS AND TOWING PANTOGRAPH JACK 7 Ue sonse WARNING: ‘Never get under the vehicle white it is supported only by the jack. ‘Always use safety stands to support frame when you have to get under the vehicle, . Place wheel chocks at both front and back of the wheel diagonally ‘opposite the jack position, Apply the pantograph jack furnished with the vehicle to the position indi- ‘cated in the figure in a safe manner. GARAGE JACK AND SAFETY STAND ‘sores WARNING: @ When carrying out operations with ‘the garage jack, be sure to support the vehicle with safety stands. b. When jacking up the rear (front) of the vehicle, place the chocks at the front (roar) of the front (rear) wheels to hold them. CAUTION: ‘Always place a wood block betwoon safety stand and vehicle body when supporting body with safety stand. Apply the garage jack and safety stand to the position indicated in the figure in a safe manner. TOWING ‘CAUTION: a. It is necessary to use proper towing equipment to avoid possible dam- ‘age to the vehicle during a towing operation. ‘Towing is in accordance with Tow- ing Procedure Manual at dealer GI-8 . All applicable State or Provincial {in Canada) taws and local laws re- garding the towing operation must ‘be obeyed. ©. Before towing, make sure that the transaxle, steering system and pow- ‘er train are in good order. If any unit is damaged, a dolley must bo used. d. Nevor tow an automatic transaxle ‘model with rear wheels raised (with front wheels on ground) as this may ‘causa serious damage to the vehicle, If it is necessary to tow it with rear wheels raised, always use a towing dolly under the front wheels, © If the transaxle is inoperative, tow the vohicle with the front wheels off the ground, f. When the vahicle is towed with its front wheels on the the steering wheel key turned in “OFF” position. 8. Release the parking brake and sot the gearshift lever in “Neutral” Position before starting to tow the vehict ‘h. When towing an automatic trans- axle model, try to restrict towing speed below 30 km/h (20 MPH) ‘and towing distance less than 30 km (20 mites), With manual transaxle model, try to restrict towing speed below 80 km/h (50 MPH) and towing dis- ‘tance less than 80 km (50 miles). i. Do not apply force to the towing hhook in a lateral direction. Keep the tow rope or similar device straight ahead, in line with the vehicle. TIE-DOWN CAUTION: Do not tow the vehicle with the rear tiesdown hooks.SPECIAL SERVICE TOOLS / TIGHTENING TORQUE OF STANDARD BOLT SPECIAL SERVICE TOOLS Special Service Tools play very im- portant role in the maintenance of cars. These are essential to the safe, accurate and speedy servicing. ‘The working times listed in the col- umn under FLAT RATE TIME in FLAT RATE SCHEDULE are com- puted based on the use of Special Service Tools. ‘The identification code of mainte- nance tools is made up of 2 alphabeti- cal letters and 8-digital figures. ‘The heading two letters roughly classify tools or equipment as: sTo0900000: Kvo0000000: ‘EMo0000000: ‘Gco0000000: LMo000000 HT00000000: ‘Special Service Tool Special Service Too! Engine Overhauling Machine General Gauge Garage Too! Hand Tool TIGHTENING TORQUE OF STANDARD BOLT or nut diam. Tightening torque Grade Bolt or nut size | Bolt or nut di Pitch mm. eter* mm. Nem kgm feb M6 6.0 10 3-4 03-04 22-29 125 : 8-1 8-8. a aa a-_[ 08-11 | 58-80 10 8-1 08-11 5.8-8.0 os aa a 15 16-2 | 16-22 | 12-16 1.25 16-22 1.6 -2.2 12-16 175; E 73. z M2 ae 26-36 | 27-37 | 20-27 1.25 30-40 | 31-41 | 22-30 M14 14.0 15 46 -62 4.7 -6.3 34-46 M6 6.0 1.0 6-7 0.6 -0.7 43-51 Ms 80 1.25 14-18 14-18 10-13 10 14-18 | 14-18 | 10-13 T Mio 100 1s 25-35 2.6 -3.6 19-26 125 26-36 | 27-37 | 20-27 M2 120 175 45-61 4.6 -6.2 33-45 1.25 50-68 | 51-69 | 37-50 MI4 14.0 1s 76 - 103 77-105 56-76 M6 60 10 a | o#-11 | 58-80 1.25 19-25 19-25 14-18 M8 8.0 10 20-27 | 20-28 | 14-20 15 36-50 | 37-51 | 27-37 or Mio 100 125 39-S1 4.0 -5.2 29-38 175 65-88 6.6 -9.0 48-65 MI2 no = =-— 4 Seraltaeeeeseccae| 125 m.97 | 73-99 | 53-72 Mi4 14.0 oa 109-147 | 11.1-15.0 80-108 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossod on the bolt head, Mark Grade aT ete ‘*: Nominal diameter M6 T_______ Nominal diameter of bott threads (Unit: mm) Metric screw threads GI-9MAINTENANCE HT onaTelt] V4 y 4 Wey CONTENTS PERIODIC MAINTENANCE ... MA 2, Engine difficult to start or does GENERAL MAINTENANCE ..........MA-5 not start . MA38 LUBRICATION CHART....... cee MA 8 Rough idle . pees es MA39. RECOMMENDED FUEL AND Excessive white or black smoke |... MA-40 LUBRICANTS fet nceerrer. cee MAS 9 Poor output . .MA41 Fuel -MA- 9 Excessive knocking . » MA42, Lubricants . ~MA- 9 Fuel consumption too high MA43 SAE viscosity number... =... ...MA: 9 CHASSIS AND BODY APPROXIMATE REFILL MAINTENANCE ....................MA44 CAPACITIES .... os ns wfc n MARIO! Exhaust systems ... se MAa4 ENGINE MAINTENANCE Clutch ~MA44 - MA-44 ~MA45 »MA45 »MA47 ~MA11 Manual transaxle ~MA11 Automatic transaxle (E15 & E16)... Before engine start . After engine warm-up . s oe MAIS Front axle and front suspension . DIAGNOSTIC PROCEDURE FOR Rear axle and rear suspension PROBLEMS oo... -..MA21 Brake system . MA-48, Diagnostic procedure for carburetor Wheel and tire +.» MASO engines .... -MA21 Steering system... . MASS, Diagnostic procedure for E.C.C. Bodyoorasiibe darts - MA56 engine............ 2 MA-28 SERVICE DATA AND ENGINE MAINTENANCE (CD17) .....MA2. SPECIFICATIONS (S.D.S.) MAS? Before engine start MA32 Engine maintenance (E15 & E16) ..... MA-S7 Timing belt replacement . . MA-34 Engine maintenance (CD17) MA-58 After engine warm-up...............MA35 Chassis and body maintenance ........ MA-59 TROUBLE DIAGNOSES AND SPECIAL SERVICE TOOLS ..........MA61 CORRECTIONS (CD17) .............. MA-38PERIODIC MAINTENANCE ~,,; , PERIODIC MAINTENANCE ‘The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent ‘maintenance will be required. Refer to “Maintenance under severe driving conditions”. ‘The periodic maintenance schedule is repeated beyond the last mileage and period shown. EMISSION CONTROL SYSTEM MAINTENANCE = Gasoline engine (U.S.A. and Canada 2-door Sedan MPG models) MAINTENANGE OPERATION MAINTENANCE INTERVAL riodic meintsnance should be performed Miles 1,000. 118» 800. -48"- 60 at numberof miles, kilometers oF months, (Kilometers x 1,000) (24) ” (48) (72) (96) cae icra comes frst. Months 2648 Drive bats H 1 WaT Air leaner iter ® ® MAST Air induction vv iter (Except PG & Calorie mode) ® R TWAT ‘Choka mchanism (coke valve and inkapo o 1 MAt2 Pose eronkestevetlation P.CxV.iter See NOTE MAI? Vanor lines r 7 MAA2 Fuel ine hone piping, connection te] r © MAA Fuel fer ‘See NOTET, MAIS Engine esol ® ® WAS Crane at er Tap 7 is wa Spork pugs ® ® Mata Tonition wires r 7 MATA Intake @ exhau valve Genranoe Sonate ia AA AA MAIS. tale Seo NOTE (Hie MAB “Automate tenparature contra ar ener r MAE Exhous gx snsor (MPG & California ode Sal) 1 1 MA NOTE: (1), If vehi mediately, (2). The first 1,000 mite (1,600 km) adjustment is required. (3) The first 1,000 mite (1;600.ktn) inspection:is required. (4) Maintenance items and into ‘nance items and intervals are required. ‘Abbreviations: A= Adjust R= Replace |= Inspect, Goorect or replace if necessary. MA-2 is operated under extremely adverse weather conditions or in areas whera ambient temperatures are either extremely low or extremely high, the filters might become cloggéd. In such an event, replace thom im- with “*-erp. recommended. by NISSAN MOTOR CO,,.LTD:, Other mainte:PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM MAINTENANCE = Gasoline engine (Canada models except 2-door Sedan MPG) AINTENANGE OPERATION THAINTENANGE WTERVAT erode meine hui pfomad ie a0 8 aD a8 : ‘at number of miles, kilometers or months, (Kilometers x 1,000) (24) (48) (72) (96) deatarald puenbabiey Mono ne SSS Brn a 7 T WATT ‘Ai natin we ar 7 7 maT Ck mace choko al and nia) eg tz Poste cankeesvrtlaton GV] er Te NOTENT, Mate Wor 7 r aia Fel ie os, i, Soo ET F a2 Fast er SaeNOTETT: ATS 7 i WaT Eni ot & oer Ties we 7 | Seaphee a a wae r ia wat SeNOWE AAA ats rear eae ee ttt (aero —ternove AAA Wat? Sean ees Seo TT wat? pee err res ae aS Fuel nk acu at ale i elope i i era cca — Diesel engine (Non-California) i HAINTENANGE OPERATION TWAINTENANGE WWTERVAL a ecodetmeanance shouldbe patomed Mnx1000 1B 30. 4B ‘et number of miles, kilometers or months, (Kilometers x 1,000) (24) (48) (72) (96) Fieteronoe pees ce eteeatil ioe res rie ets Samora TTT WE 7 ena ir a2 Waa? Ter oss va, ow. SE] WAST ihr SenoTETT, n m a Eos eo a m Wa = nove ca, Rapin ry 7D or age Tage ar Tse wary 700 ler During the first 18,000 miles (24,000 km): flptace avery 7-500 mies Mass. Replace every 16,000 miles ‘Aft he re 15,000 ils (24,000 mls ‘pln very 18,000 mies Mase inpeionnozie wp ot Tae Trike & exheur vale cores SeenOTE AAA MAD ‘em See NOTE 1 1 WA ul inecon ning 1 1 MAS Ting bas fae pen 00000 mer Mage NOTE: (1) If vehicle is operated under extremely advarso weather conditions or in areas where ambient temperatures are ‘either extremely low or extremely high, the filters might become clogged. In such an event, replace them i mediately. (2) Old engine oil should be drained completely, then new (3) The first 1,000 mile (1,600 km) adjustment is required. (4) The first 1,000 mile (1,600 km) inspection is required. (6) Maintenance items and intervals with “"*”" are recommended by NISSAN MOTOR CO., LTD. Other mainte- ‘hance items and intervals are required. Abbreviations: A= Adjust Replace Inspect. Coorect or replace i ‘added, Never mix new oil with old oil. necessary. MA-3PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE MAINTENANCE OPERATION MAINTENANCE INTERVAL Periodic maintanenca should be performed Miles x 1,000 18 30 4580 ‘stnumbor of miles, lometers oF months, (Kiloaarsx 1,000) (24) (48) (72) (98) eee whichovor comes fst. Monee 2 ee Brake Fines & hoes faeeaer VEEN WASD ‘Brake pods ics, drum & Tinos ae gE Mao Brake fluid m Made ‘Manuel and automatic onsale gor oll en euea eee] MA, 45 ower serig ines & hoses iaerere a aT MASS. ‘Storing goa & linkage, & surpanson pore ee eens WA-45, 47,65 ‘tering linkage ball Joints & ron surpenson bal joins o MAS Looks, hinges & hoed latch Paesuaeeceeee MASS Front wheal besrng ea i o MASE Exhustsysom i eceteeasaaeel Mage ‘Seat bot, buckles, revactor, enchon & adhusor aeeinaaea gee MASE Abbreviations: L = Lubricate R= Replace 1 = Inspect. Correct or replace if necessary MAINTENANCE UNDER SEVERE ‘Driving ‘Waintenance _ Maintananes __ Maintonanco DRIVING CONDITIONS em intone! ‘The maintenance intervals shown on the ¢..... Avdeara ftw @erinive —-R — Wore requenty preceding pages are for normal operating fon vie tte conditions. Ifthe vehicle is operated under. “8G. E. . . Emgneoll severe driving conditions ss shown below, ‘Gaotne engine) every 3,000mien more frequent maintenance must be per- ——__ 5200 nl or 3 monte formed on the following items as shown in (Diosot engine) ‘Every 3,750 milos en ee eee rr TGaotn engine) every 3,000miee i pecaes me a 15,000 kr) or 3 months Se at ona B__ Every 3,760%miee c eS Driving in dusty conditic Become Sorte = lot _ gd ‘(Diesel engine*2) R ‘Every 7,800 mitos D — Driving in extremely low or high {12,000 km) or monte ambient temperatures, c.ere. rake pede, dises, drums 1 ‘Every 7,500 mites E ~ Towinga traller ning {12,000 ml or 6 mont F — Driving in areas using road salt or rake told 8 ‘Every 16,000 miles other corrosive materials {24,000 kn) oF 12 manta G — Driving on rough andor muddy =e @,_ Manualand evtomaio wane Avery 30,00 mies roads tata ur {48,000 kn) oF 24 monte Hi — Diving in high humidity areas or in TE. Searing or T even 7500 mtn mountainous areas {i srpasin prt (12,000 kn) or 8 mont FG, Frontrive sete bow Tver 7,500 ile {2.000 em) or 6 mont © 0. F ©, Suminglinkage ballon 1 Evry 7.500 millon {font umpersion ball {12,000 tn) or monte Join F > beets hing &hood ech 1 re 7 EF 6. Sxhmurtenm ‘very 7500 mie (2.000 ml or 6 mont “ir Dring dhe fe 16/000 ros 24,000 kd 2: Afar to ist 18,000 mits (24,000 km) Mointananee operations: I= Inspect. Corrector replace Hf nacesiry R= Replace MA-4GENERAL MAINTENANCE GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. ‘They are essential if the vehicle is to continue operating properly. The owners can perform the checks and inspections them- selves or they can have their NISSAN/DATSUN dealers do them for a nominal charge. Item Reference item in MA section OUTSIDE THE VEHICLE Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear. CHECKING TIRE CONDITION ‘Wheel nuts When checking the tires, make sure no nuts are missing, and check for any loose nuts, Tighten if necessary. TIRE REPLACEMENT Wheel nut. Tire rotation Tires should be rotated every 24,000 km (13,000 miles), TIRE ROTATION ‘Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. CHECKING TIRE CONDITION Abnormal tire wear CHECKING WHEEL ALIGNMENT WHEEL INSPECTION ‘Windshield glass Check for abrasions or scratches. Windshield wiper blades Check for cracks or wear if they do not wipe properly. Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is, normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. INSPECTING MANUAL TRANSAXLE OIL INSPECTING AUTOMATIC TRANSAXLE FLUID INSPECTING FRONT AXLE AND SUSPENSION PARTS INSPECTING REAR AXLE AND SUSPENSION PARTS INSPECTING BRAKE LINES & HOSES CHECKING POWER STEERING LINE & HOSES ‘Doors and engine hood Check that al doors and the eingine hhood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. INSIDE THE VEHICLE LUBRICATING LOCKS, HINGES AND HOOD LATCH ‘The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, clean- ing the vehicle, ete. Lights Make sure that the headlights, stop lights, taillights, ‘urn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. MA-5GENERAL MAINTENANCE Item Reference item in MA section lights and buzzers/chimes Make sure that all wam- ing lights and buzzers/chimes are operating properly. Hor Make sure it operates properly. Windshield wiper and washer Check that the wipers and ‘washer operate properly and thatthe wipers do not streak. Windshield defroster Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner. Roar view mirror Make sure that is secure, ‘Sun visors Make sure that they can be moved freely and are secure, Steering wheel Check that it has the specified freeplay. Be sure to check for changes in the steering condition, such as, excessive freeplay, hard steering or strange noises. Specification Free play: Less than 3 mm (1.38 in) ‘Seats Check front seat position controls such as seat adjust- ters, seatback recline, etc. to ensure they operate smoothly and that all latches lock securely in every position. Check that the head restraints move up and down smoothly and that the locks (if so equipped) hold securely in all latched positions. Check that the latches lock securely for folding- down rear seatbacks. Soat belts Check that all parts of the seat belt system eg. buckles, anchors and retractors operate property and smoothly. Check the belt webbing for cuts, fraying, wear or damage. © INSPECTING SEAT BELTS, BUCKLES, ANCHORS, RETRACTORS AND ADJUSTER ‘Accelerator pedal Check the pedal for smooth operation and make sure the pedal does not catch or require uneven effort. Clutch pedal Make sure the pedal operates smoothly and check that it has the proper fee travel, © ADJUSTING CLUTCH PEDAL HEIGHT AND FREEPLAY Brakes Check that the brake does not pull the vehicle to ‘one side when applied. Brake pedal Check the pedal for smooth operation and make sure it has the proper distance under it when de- pressed fully. Check the brake booster function. © CHECKING BRAKE PEDAL DEPRESSED HEIGHT © CHECKING BRAKE BOOSTER FUNCTION Parking brake Check that the lever has the proper travel and confirm that your vehicle is held securery on a fairly steep hill with only the parking brake applied. ‘© CHECKING PARKING BRAKE ‘Automatic transaxle “Park” mechanism Check that the Tock release button on the selector lever operates properly and smoothly. On a fainy step hill check that your vehicle is held securely with the selector lever in the “P” position ‘without applying any brakes. MA-6GENERAL MAINTENANCE Item UNDER THE HOOD AND VEHICLE Reference Item in MA section ‘The maintenance items listed here should be checked periodically e.g. each time you check the engine oil or refuel. Windshield washer fluid Check that there is adequate fluid in the tank, Engine coolant level Check the coolant level when the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deforma- tion, rot or loose connections. Brake fluid level Make sure that the brake fluid level is ‘between the “MAX” and “MIN” lines on the reservoir. INSPECTING BRAKE LINES & HOSES Engine drive bolts Make sure that no belt if frayed, worn, cracked or oily. CHECKING AND ADJUSTING DRIVE BELT Engine ol level Check the level on the dipstick after park- ing the vehicle on a level spot and turning off the engine. Power steering fluid level Check the level on the dipstick when the fluid is cold and the engine is tumed off. CHECKING POWER STEERING FLUID LEVEL ‘Automatic transaxle fluid level Check the level on the dip- stick after putting the selector lever in “P” with the engine idling. CHECKING AUTOMATIC TRANSAXLE FLUID LEVEL Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual cr there is a smell of exhaust fumes, immediately locate the trouble and correct it. INSPECTING EXHAUST SYSTEM Underbody The underbody is frequently exposed to corro- sive substances such as those used on icy roads or to control dust. Itis very important to remove these substances, other- ‘wise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate.8-VN @ cuecn By cunce Guwoncare FRONT WHEEL BEARING.) GREASE vorryns MANUAL TRANSAXLE Automatic TRANSAXLE BRAKE FLUID ~: LOCKS, HINGES & Hoop LaTcH tr cl Ld_| - ENGINE ANTI-FREEZE COOLANT (ETHYLENE GLYCOL BASE) WINDSHIELD AND REAR WINDOW WASHER FLUID = 4----rowen sTeenine FLUID ==} = = ENGINE OIL (Gasoline) == P= = ENGINE OIL (Diese) ~@ FUEL FILTER (Gaon) -@ FUEL FILTER (Dies) = -ENGINE OIL FILTER (Gasoline) = =~ ENGINE O1L FILTER (Diese) {Wear is operated under extreme adverse weather ‘anaitons oF in areas where ambient temperatures ‘are either extremely low or extremely big the uel fiter might become clogged. In such an event, replace the parts immediately. LYVHO NOILVOINSNT AYVHO NOILVOINSNTRECOMMENDED FUEL AND LUBRICANTS RECOMMENDED FUEL AND LUBRICANTS FUEL SAE VISCOSITY NUMBER oa ay SROLNE EWENE OT temper | Fuel | "Cotane Diese) Chae ature umber (main) =e USA and RON _[ (Re00/2 cata |_| vteates : ASOLINE ENGINE OT cau | Seen too oer eee on 87 Tawa Tenao | vnteaded or 7 oo: tended Canaan Sedan MPG "2D Dieelfua ze shore |r equivalent Foy | blended dee = cto | fer oreo Diesel engine mar =? sat sow | ene blended diet Cro| & Check withthe ove station operator tobe ure you gt the ropey g ended fue. LUBRICANTS So se ae bbs hee oe “Tamara Rene Ansipted Tbr Speciation Renae vor hoc ene Gastne (apt | APSF Enemy NeG mesed | Conserving 8) Fare TAPS nay | or tte day ro Conserving O19 or | “Engin of ano iter Exgineot | romaten | an SHSECE SESE | mh Ovnrs Mana Dies Se/cD,srico or o For farther deta arto te Manual tans ger oi anicia feeommended SAE ico Sac ‘tomate wanes ad power = steering gear fluid iusluclamesmss Mul pupee sue Bain? Tina op ae Brake id ors US FHVES Ro. 16 Antieere = Etylne geo bae MA-9APPROXIMATE REFILL CAPACITIES APPROXIMATE REFILL CAPACITIES Liter US measure Imp measure Fuel tank 50 13-1/4 gal 11 gal M/T 47 Sat 41/8 at With heater AIT 53 5/8at 45/8 qt Engine coolant M/T 41 43/8 qt 3.5/8 at Without heater AIT 47 Sat 41/8 at Reservoir tank 07 3/4 qt 5/8 qt With oil filter ; 41/8 qt 33/8 qt Without oil filter Y 3-5/8 qt 3qt 4-speed 2 4-7/8 pt 4pt Sespeed 53/4pt 43/4 pt ‘Automatic r 6.3/8 qt 5-1/4 qt Windshield washer tank : 15/8 at 13/8 qt Power steering system 1-1/8 qt 7/8 qt Manual Airconditioning 5A floz 53 floz ie 1.8-221b 18-221b MA-10ENGINE MAINTENANCE (E15 & E16) ENGINE MAINTENANCE (E15 & E16) BEFORE ENGINE START CHECKING DRIVE BELTS 1. Inspect for cracks and wear. 2. Check drive belt deflections by pushing midway between pulleys. ‘Adjust if necessary. Replace if necessary. ‘Adjust deflection ‘Set deflection Drive belt deflection atta of used belt of new belt Alternator 13-17(0.51 -0.67) 10-14 (0.39 -0.55) Air conditioner Power steering ‘Applied pushing force _N (kg 1b) 9-11 (0.35 -0.43) 7-9 (0.28 -0.35) 7-9 (0.28 -0.35) 6.5 -8.5 (0.256 -0.335) 98 (10, 22) Adjusting bolt Lock bolt @31-42Nm (G2-43km, 23-31) Compressor Altemator. Double nuts ant ay Idler pulley: 2a Adjusting bolt {aler pulley lock nut su A209A Air conditioner belt 1, Loosen the idler pulley lock nut Alternator bett 1, Loosen the upper and loweralter- nator securing bolts until the alterna- tor can be moved slightly. 2. Move the alternator with a prying bar until the belt deflection is within ‘the specified range. Then tighten the bolts securely. and adjusting bolt double nuts for the belt being adjusted. 2. Adjust the adjusting bolt until the belt deflection is within the specified range 3. Tighten the adjusting bolt double nuts and idler pulley lock nut secure yy. MA-11 Powor steering belt 1. Loosen the power steering oil pump adjusting lock bolt and its secur- ing bolt for the belt being adjusted. 2. Adjust the adjusting bolt until the belt deflection is within the specified range. 3, Tighten the adjusting bolt lock bolt and oil pump securing bolt secure- y. REPLACING AIR CLEANER FILTER Air cleaner filter is a viscous paper type and does not require cleaning. 1. Remove air cleaner cover and re- move air cleaner filter. 2. Install new air cleaner filter and install air cleaner cover. REPLACING AIR INDUCTION VALVE FILTER ‘Stop engine and remove air indue- tion valve case, and remove filter.ENGINE MAINTENANCE (E15 & E16) CHECKING CHOKE MECHANISM (Lubrication and cleaning of choke plate and linkage) US.) 1. Check choke valve and linkage for free operation, and clean choke valve ‘of lubricate choke linkage if necessary. 2. Before starting engine, fully open throttle valve and ensure ‘that choke valve closes properly. CHECKING CHOKE MECHANISM (Choke plate and linkag (Canada) 1. Check choke valve and mecha- nism for free operation, and clean or replace if necessary. Binding can result from petroleum gum formation on choke shaft or from damage. 2. Before starting engine, fully open throttle valve and ensure that choke valve closes property. 3. Push choke valve with your finger, and check for binding, 4. Check to be sure that bimetal cover index mark i set atthe center of choke housing index mark as shown below. Do not set bimetal cover index ‘mark at any position except the canter of choke housing index mark, FILTER Remove air cleaner cover, and re- place filter. smaaoral CHECKING VAPOR LINES 1. Check all hoses and fuel tank filler cap. 2. Disconnect vapor vent line con- ‘necting carbon canister to fuel tank. ‘smaoraa] 3. Connect 3.way connector, mano- meter and cock (or equivalent 3-way charge cock) to end of vent line. 4. Slowly supply fresh air into vapor vent line through cock until pressure reaches 3923 kPa (400 mmHl,O, 155 inH1,0). < 5. Shut cock completely. 6. After 2-1/2 minutes, measure height of liquid in manometer. 7. Variation in height should remain 0.245 kPa (25 mmHH,0, 0.98 inHl,0). 8. When filler cap does not close completely, height should soon drop tozer0. 9. If height does not soon drop to zero when filler cap is removed, the cause is a clogged hose. Af vent line is clogged, breathing in ‘fuol tank is poor, thus causing insuf- ficient delivery of fuel to engine of vapor tock, It must, therefore, be ropaired or replaced, 3.923 kPa (400 mmHz0, 16.75 inHz0) CHECKING FUEL LINES (Hore, piping, connections, te.) Check fuel lines for loose connec- tions, cracks and deterioration. Re- tighten loose connections and replace any damaged or deformed parts. MA-12ENGINE MAINTENANCE (E15 & E16) REPLACING FUEL FILTER Disconnect battery cable. 1. Disconnect fuel hoses from fuel filter and replace it. 2. Check filter for contamination and water deposit. Plug open of fuel hose immediately ‘after fuel hose has beon removed from fuel filter. Coolant capacity: Liter (US gt, Imp a) Mit AT With 47 33 heater | (5, 41/8)_|¢5-5/8, 45/8) Without 41 47 heater |(4-3/8,3:5/8) | (5, 4-1/8) Reervorr a 0.27. 3/4, 5/8) 20-30mm (ara 1174 in) CHANGING ENGINE COOLANT WARNING: To avoid being scalded, never change the coolant when the engine ishot. ‘© When replacing engine coolant, set heater “TEMP” control lever to fully “HOT” position, 1. To flush system, open drain cock at bottom of radiator. Then thorough- ly flush until clear water comes out. 2. Close drain cock. 3. Fill radiator with coolant up to specified level. Follow instructions at- tached to anti-freeze container for ‘mixing ratio of anti-freeze to water. 4, Install filer cap and fill reservoir tank with coolant up to “MAX” level. 5. Start engine and warm up engine ‘until water temperature indicator points to the middle of gauge. 6. Stop engine and cool engine off completely. 7. Refill radiator with coolant up to filler opening if the coolant level is lever the specified level, 8, Also, refill reservoir tank with ‘coolant up to “MAX” level CHANGING ENGINE OIL AND REPLACING OIL FILTER 1, Start engine and warm it up until water temperature indicator points to ‘middle of gauge, then tur off engine. 2. Remove oil filler cap and oil pan drain plug, and allow oil to drain. WARNING: Use care as the engine oil is hot. MA-13 smaoraal ‘© A milky oil indicates the presance of cooling water. Isolate the cause and take corrective measure. An oil with extremely low viscosity indicates dilution with gatotine, 3. Using oil filter wrench, remove oil filter. 4, After draining engine oil, wipe oil pan drain hole with a clean rag. $. Clean and install oil pan drain plug with washer. © : Oil pan drain plug 35-47 Nem (3.6 -4.8 kgm, 26 - 35 ft1b) 6. Wipe oil filter mounting surface with a'clean rag. 7, Smear a little engine oil on rubber seal of new oil filter. 8. Install new oil filter by hand. Do not use oil filter wrench to tighten the fitter. 9. Refill engine with the appropriate ‘new engine oil by referring to Recom- mended Lubricants. Check oil level with dipstick.Oil capacity: With oll filter 3.9 liters (4-1/8 US qt, 33/8 Imp at) Without oil fitter 3A liters (3-5/8 US qt, 3 Imp qt) 10. Install oil filler cap and start en- sine. 11. Check area around drain plug and oil filter for any sign of oi leakage. If leakage is evident, retighten or replace. 12, Run engine until water tempera- ture indicator points to middle of gauge. Then turn off engine and wait several minutes. Check oil level with oil level gauge. If necessary, add en- gine oil. When checking oil lovel, park car on level surface, REPLACING SPARK PLUG 1, Remove air cleaner, 2. Disconnect spark. plug wire at boot. Do not pull on the wires. ENGINE MAINTENANCE (E15 & E16) Ox. 3. Remove spark plugs with spark plug wrench. 4, Install new spark plugs are recon- nect high tension cables. ‘Spark plug type: USA and ‘Canade | *cenade Me, | modes models ‘Standard | persesiil perses | Hotwpe | BPRAESI| BPRAES Cold ype | BPREESi| _BPREES 10-11 | o8-o9 Puss | (o039- | ost aos) | 0035) Not including Canada MP. model @ : Spark plug 20-29Nm (2.0 -3.0 kgm, 14- 22 ft-lb) CHECKING IGNITION WIRES 1, Visually check wiring for eracks, and damaged and burned terminals. 2, Using an ohmmeter, measure the resistance between cable terminal on the spark plug side and corresponding electrode inside cap. MA-14 © Shake the wire while measuring re- sistance to ckeck for intermittent brakes, Los then 30402 smaois) CHECKING ENGINE COMPRESSION PRESSURE 1, Warm up engine until water tem- perature indicator points to middle of gauge. 2. Remove air cleaner and all spark plugs. 3, Disconnect anti-dieseling solenoid valve connector. 4. Properly attach a compression tester to spark plug hole in cylinder being tested. 5. Depress accelerator pedal to fully ‘open throttle and choke valve. 6. Crank engine and read gauge indi- cation. © Run engine at about 350 rpm. Engine compression measurement should be made as quickly as possi- ble. ‘Compression prossure: kPa (kg/em?, psil/at rpm ‘Standard 1,245 (12.7, 181/350 um 981 (10.0, 142)/350ENGINE MAINTENANCE (E15 & E16) 7. Af cylinder compression in one or ‘more cylinders is low, pour a small amount of engine oil into cylinders ‘through the spark plug holes and retest ‘compression. © adding oll helps tho compression prossure, chances are that piston rings are worn or damaged. ‘© If pressure stays tow, valve may be sticking or seating improperly. © cylinder compression in any two jacent cylinders is low, and if adding oil does not halp tho com- pression, there is leakage past the gasketed surface. il and water in combustion cham- bers can result from this problem. CHECKING AUTOMATIC ‘TEMPERATURE CONTROL (AT.C) AIR CLEANER 1. Check that vacuum hoses (Intake ‘manifold to temperature sensor, idle compensator and vacuum motor) are securely connected in correct position. 2. Check each hose for cracks or dis- tortion. 3. Check A.T.C. system for function by proceeding as follows: Confirm that engine is cold before starting test. With engine tured off, check posi- tion of air control valve by hand or mirror. SeFz198 ‘Air control valve is in correct post- ton if its cold air inlet is open and hot air inlet is closed. 4, Start engine and keep idling. Immediately after starting engine, sir control valve is in correct position if its cold air inlet is closed and hot air inlet is open. $. Check that air control valve gradually opens to cold air inlet side as engine warms up. When environmental temperature around. temperature sen- sot is low, allow more time for engine ‘warming up to facilitate smooth opera- tion of air control valve. If the above test reveals any prob- lem in the operation of air control valve, carry out the further inspection described in Section EF. AFTER ENGINE WARM-UP ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE Adjustment should be made while ‘engine is warm but not running. 1. Start engine and warm it up until ‘water temperature indicator points to middle of gauge. Then turn off engine 2. Remove air cleaner securing bolts. 3. Remove valve rocker cover. 4. Rotate crankshaft. 5. Set No. 1 cylinder in top dead center on its compression stroke, and adjust valve clearance ©, @, @ and ©. 6. Set No. 4 cylinder in top dead center on its compression stroke and adjust valve clearance @), @), @and @. MA-15 ‘Valve clearance (Hot): Intake and exhaust (0.28 mm (0.011 in) (2) Loosen valve rocker adjusting screw lock nut and tum adjusting screw until specified clearance is obtained. (2) After adjustment, tighten lock nut ‘and recheck clearance. @ : Adjusting screw lock nut 16-21 Nem (18-21 kgm, 12-16 feb) [sMao174ADJUSTING IDLE RPM (U.S.A. and Canada M.P.G. models) Preparation 1. Connect engine tachometer in its proper position. 2. On air conditioner equipped models, the air conditioner system should be “OFF”. 3. Apply parking brake and block ‘both front and rear wheels with chooks. 4. ‘The electrical components (lights, heater, all accessories, et.) should be tumed off so that idle speed can be inspected and/or adjusted accurately. (Refer to EF & EC section.) 5. Make the check after the radiator cooling fan has stopped. If itis oper- ating, wait until it stops. WARNING: 4, Inspections should bh ‘out while shift lever is in position on automatic transaxle equipped models and in “Ne tral” on manual transaxle eq ped models, . On automatic transaxle equip- ped models, racing the engine should be carried out while shift lever is in “N" or “P” position and brake pedal should be depressed. After adjustment has been me shift the lever to “N" or “PY position. ENGINE MAINTENANCE (E15 & E16) Maintenance procedure (CstarT__) ‘Start engine and warm it up until water tempera- ture indicator points to middle of gauge and en- sure that engine speed is below 1,000 rpm. Run engine at idle speed for 2 minutes. Race engine (2,000 - 3,000 rpm) 2 or 3 times under no-load, and nun engine at idle speed. (Check idle speed. IDLE SPEED Except MPG. modol MIT: 750280 rpm AIT: 650850 rpm (in “D” position) . modal 700250 rpm NG. ¥ f smasoza ‘Adjust idle speed by turning throttle adjusting MA-16ENGINE MAINTENANCE (E15 & E16) ADJUSTING IDLE RPM, ADJUSTING IGNITION TIMING AND CHECKING MIXTURE RATIO (Canada model excopt M.P.G.) Prepare 1. Make sure that the following parts are in good order. © Ignition system ¢¢ Engine oil and coolant levels Valve clearance 2. Connect engine tachometer and timing light in their proper positions. 3, Insure that these switches and units are in the following positions: Maintenance procedure Headlamp switch: OFF Heater blower: OFF Air conditioning switch: OFF (if equipped) © Steering: = KEEP WHEELS. STRAIGHT AHEAD (if equipped with power steering) 4. Make the check after the radiator cooling fan has stopped. If itis oper- ating, wait until it stops. 5. Apply parking brake and block both front and rear wheels with chocks. 6. When measuring “CO” percent. age, insert probe more than 40 cm (15.7 in) into tail pipe. => ‘Start engine and warm it up until water tempera- ‘ure indicator points to middle of gauge and ensure that engine speed is below 1,000 rpm. I ‘Turn off engine and open engine hood. v WARNIN( ‘a Inspections should be car out while shift lever is in “D’ position on automatic transaxle equipped madels and in “Neu- ‘tral on manual transaxle equip- ped models, b. On automatic transaxle equip- ped models, racing the engine should be carried out white shift lever is in “"N" or “P" position and brake pedal should be depressed. . After adjustment has been made, shift the lever to “N” or “P” Disconnect ai induction hose from air pipe and Install eap on ar pipe. pene ‘Start engine and run itat fle peed for 2 minutes, I 1s this maintenance interval 1,600 km (1,000 miles)? No Disconnect distributor vacuum hose on distribu. tor diaphragm side and install blind plug o hose, + f Race engine (2,000 3,000 rpm) 2 or 3 times under no-load and run engine at idle speed. ‘Check ignition timing. IGNITION TIMING (A.7.0.¢.) MrT: Sa? AMT:_ 622" (in "D" postion) “Adjust ignition timing by turing distributor, loosening distributor securing bolt. MA-17Idle limiter cap ‘A Metal idle limitor cap hes been adopted, 40 edjurt ilo adjusting screw with idle adjusting sorowdrver. ENGINE MAINTENANCE (E15 & E16) i diaphragm. ‘Connect distributor vacuum hose to distibutor | Race engine (2,000 - 3,000 rpm) 2or 3 times under ‘nodoad, and run engine at ide speed. ‘Race engine (2,000 - 3,000 rpm) 2 or 3 times lander nodoad, and run engine atid speed. Cheek idle “CO"%. DLE “co"%, wt: Ar an 2¢1 (in “” position) ‘Adjust idle "CO"% by turing ile adjusting sorew, Refer to NOTE for ide limiter cap Kv10108300 SMATO98 “Turn off engine and connect ar induction hose to air pipe. Start engine, ‘Race engine (2,000 - 3,000 rpm) 2 or 3 times under no4oad and run engine at idle speed, IDLE SPEED (MIT: 750250 rem ‘AIT: 650250 rpm (in ‘Adjust idle speed by turning throttle adjusting MA-18ENGINE MAINTENANCE (E15 & E16) CHECKING EXHAUST GAS ‘make sure that the following parts are ® E.C.C. component parts SENSOR in good order. © Main harness connectors (California and N.P.G. models) © Battery © Hoses Preparation «Ignition system © Oil filler cap and oil level gauge Seas ¢ Valve clearance, engine compres: When checking exhaust gas sensor, © Fuses ee Maintenance procedure ‘START ‘Connect harness connector for exhaust 25 sensor inspection. kel Verity that hanes connector for ECC. {inspection is disconnected. on] Tx Disconnect harness connector. ‘Start engine and warm up engine until water temperature indicator points to the mile of gauge. Run engine at about 2,000 rpm for about 5 minutes under no-load. ¥ Verify that inspection lamp on instrument [ NG. panel isnot turned on, OX] Connect harness connector for BCC. Inspection. q Make sue that inspection lamp on instr ‘ment panel goes on and off more than $ es dung 10 sro, ox] Te ee ea aE Check nd anesthe mad by oo stoning to Dugosts Pete for I ECC Engin of Seton BF & BC MA-19ENGINE MAINTENANCE (E15 & E16) 48,000 km (30,000 miles) or 24 Months Service Exhaust gas sensor should be check- ed after 48,000 km (30,000 miles) or 24 months of operation. After car has been operated for 48,000 km (30,000 miles), exhaust gas sensor warning lamp will come on to indicate that sensor should be inspected. For Califomia and US.A.MP.G. models After inspection, disconnect warn- ing lamp harness connector so that warning lamp will not come on there- after. MA-20 If sensor should be checked on the 24th month before 48,000 km {30,000 miles) of operation, also dit- connect warning lamp harness con- nector. For Canada M.P.G, models After inspection, disconnect the hold relay so that warning lamp will not come on thereafter.DIAGNOSTIC PROCEDURE FOR PROBLEMS DIAGNOSTIC PROCEDURE FOR PROBLEMS DIAGNOSTIC PROCEDURE FOR CARBURETOR ENGINES DRIVEABILITY (Hesitation, surging, flat spot, backfire, afterfre, lack of power, run-on, excessive fuel consumption, etc.) 1. Inspect engine for air leaks, ete. PNG __J"Tocate air leak and repair. Ox] 2. Check fuel supply system. ]NG. Repair or replace components as necessary. Ox] Correct, repair or replace components as follows: © Distributor cap © Ignition coil © Rotor © Distributor air gap © Secondary wires © IC ignition unit © ‘Spark plugs fp + 4. Check engine compression pres- | N.G. Correct, repair or replace components as follows: sure. [>] Valve clearance ra © Engine ol © Piston rings or cylinder © Cylinder head gasket © ‘Spark plug gasket or tightening torque Valve valve seat and spring ‘5. Check deceleration devices. _ [NS-__, "Repair or replace parts and circuits as necessary. Ox] fp 6. Check ignition timing and idle LN-S- “Adjust to specifications. RPM. Ox] oo NG. 7. Check idle COR. & “Adjust to specifications, — OK Ox] [2 eon f 8. Perform driveability check. Ox. END. Correct or replace carburetor. 9. Check carburetor. |NG.__f Correct, adjust or replace components of carburetor as necessary. f_ 10. Perform driveability test. MA-21DIAGNOSTIC PROCEDURE FOR PROBLEMS IMPROPER IDLING (Rough idle, no return to idle, high idle, ete.) oo NG. 1. Inspect engine for airleaks. | °S*—————4f "Locate air leak and repair. a NG. 7 2. Check fuel supply system, | 4] Repair or replace components as necessary. OK) ee | | Sa a ei ee + 3. Perform ignition oxcillorope _ [NG. Repair or replace components as follows: check. © Disctributor cap © Spark plugs a © Distributor airgap © Ignition coil © Rotor © IC ignition unit © Secondary wires NG. 4. Check deceleration devices, |S: _________” Repair or replace components as follows OK © Throttle opener sa © Speed switch and circuits © Transmission switch fp 'S. Check ignition timingand idle }NS-__,aiust to specifications. RPM, or] 6. Check idle COR. }8S-__.fajus to specications. Ox] Adjustable i- adjustable sy 77, Overhaul carburetor or replace it with a new one. t 8. Check engine compression NG. Correct, repair or replace components as follows: pressure. aa *| © Valve clearance © ‘Spark plug gasket or ra Engine oil tightening torque Piston rings or cylinder @ Valve, valve seat and Cylinder head gasket spring MA-22DIAGNOSTIC PROCEDURE FOR PROBLEMS ENGINE STARTABILITY (Hard start, no start, hard restart, no restart, eto.) 1. Inspect engine for air leaks, ete. }¥G-—____s] Locate air leak and repair. Ox] 2. Check battery and charging -S-_____. Correct, repair or replace components as applicable. system for battery. OX] ee = NG. 3. Check starting system. |NG.__ J Repair or replace parts and circuits as necessary. Ox] Face NG. - ; 4. Check fuel shutoff system. NG: __.1 Repair or replace parts and circuits as necessary. Ox] (Sooe eee eee = NG. 5. Check fuel supply system. |S: _______.1 Repair or replace components as necessary. Ox, f_— eae a 6. Perform ignition oscilloscope | N.G. Correct or replace the following parts as applicable. check. i eecacaasaesiereie| = 2 6: Dintbaitar cep, © ‘Spark plugs OK] © Distributor air gap ® ‘Ignition coil © Rotor © IC ignition unit © Secondary wires fp 77, Check engine compression NG. Correct, repair or replace components as follows See pressure. © Valve clearance © Spark plug gasket or OK © Engine oil tightening troque © Piston rings or cylinder @ Valve, valve seat and © Cylinder head gasket spring + 8. Check carburetor. ‘Repair or replace components as necessary. OK, 7 NG. leva cack an Coe cles 9. Perform startability test, [NS.__] "10. check idle CO% and adjust it if necessary. Ox] MA-23DIAGNOSTIC PROCEDURE FOR PROBLEMS ENGINE STALL 1. Inspect engine forairieaks, ete, WG: __{"Tocate airieak and repair. OK 7 NG. ; 2. Check idle RPM. [NS __ J jajust to specifications. Ox. 3. Check F.LCD. system or dash JN _ J" pajust to specifications. pot. OK, dg eee 7 NG 4. Check fuel shut-offsystem. _ JNS-__1 Repair or eplace components as necessary OR] fp_——____ 5. Overhaul carburetor or replace it with a new one. ] 6. Adjust idle rpm, ignition timing ‘and idle CO% to the specified value. MA-24DIAGNOSTIC PROCEDURE FOR PROBLEMS EXCESSIVE OIL CONSUMPTION NG. 1. Inspect engine foroilleaks, _ XG-__JTocate ol eaks and repair OK © Oil drain plug © oi fiter © Oil pan gasket © Oil pressure switch (© Front and rear © Oil pump oil seal © Oil strainer, ete. © Rocker cover gasket . NG. : 2. Check oil [8S _____. pat or change to the recommended oil. OK, eee im NG. 5 3. Check cooling system, }8S-__ Correct, repair or replace components as necessary OK ‘© Engine coolant level : © Fan belt © Thermostat © Water pump © Radiator and filler cap, etc. + 4, Check sliding parts of engine JN. Repair or replace them as necessary. components. [|e tinder and piston OK, «© Piston ring © Valve oil sel lip © Valve stem 7 N, 5. Check oil pressure, }NS:_______ Repair or replace components as necessary. Ox, — SS 6. Check lubrication system. MA-25DIAGNOSTIC PROCEDURE FOR PROBLEMS OVERHEATING NG. 1. Check coolant level. | NS. _ J” Refi with coolant. Ox, = NG. 2. Check cooling system. [NS.__ Cheek the following: © Thermostat of Water pump © Radiator & filler cap ‘© Electric cooling fan Te necessary, repair or replace them ——— ee + NG. 3. Check fan bet. }NS_J adjust or replace it as necessary. Ox] =. NG. ‘4. Check ignition timing, [YS] aajusri OK feos ree cee a NG. '. Check engine ol |*S__J Replace with the recommended oil. Ox] MA-26DIAGNOSTIC PROCEDURE FOR PROBLEMS NOISY ENGINE 1. Check vehicle knocking. Bo) (Check the following: © Ignition timing ne © Fuel © Spark plugs © Gear position Then, correct, repair or replace them as necessary. ¥ 2. Check mechanical components | Yes ‘Check the following and then adjust, repair or replace for knocking noise. as necessary. No Piston and piston pin © Camshaft, valve rocker, © Connecting rod valve, valve stem & guide © Crankshaft, end play and valve spring and main bearing © Valve clearance © Water pump © Oil pump ee 3. Check other than engine components as follows: © Dragging brake © Clutch slipping © Clutch pilot bushing © Other MA-27DIAGNOSTIC_PROCEDURE FOR PROBLEMS DIAGNOSTIC PROCEDURE FOR E.C.C, ENGINE INTERMITTENT PROBLEM DIAGNOSTIC CHARTS CANNOT BE USED TO DIAGNOSE INTERMIT- TENT FAILURES. This is because ‘many intermittent problems are caused at electrical connecitons, and if intermittent problems are not correct- ed, unnecessary component replace- ment will be indicated and the pro- blems may remain. Therefore, DIAGNOSIS OF INTERMITTENT PROBLEMS SHOULD START WITH A VISUAL AND PHYSICAL IN- SPECTION OF THE CONNECTORS involved in the circuit, especially con- ‘rol unit, water temperature sensor and exhaust gas sensor connectors. ‘CAUTION: When connecting or disconnecting E.C.C. harness connector to or from any E.C.C. unit, ensure that the tion switch is in the “OFF” position and that the negative battery terminal is disconnected. Removing and install- ing these connectors with the ignition switeh left in the “ON” position will damage control unit. DRIVEABILITY (Hesitation, surging, flat spot, backfire, afterfire, lack of power, run-on, excessive fuel consumption, etc.) Locate air leak and repair. N. for air leaks, etc. Ox] 2. Check fuel supply system, NG. 3, Perform ignition oscilloscope | N.G. check. OK. pressure. OK. 5. Check deceleration devices. bis N, 1. Inspect engine and E.C.C. system }©-S-______] PNG eeSeeeeeeeesE Repair or replace components as necessary. OK, eee eee Correct, repair or replace components as follows: © Distributor cap © Spark plugs © Distributor air gap ® ‘Ignition coil © Rotor © IC ignition unit © Secondary wires f_@ 4, Check engine compression NG. 6. Check ignition timing, idle RPM J-__f Correct, repair or replace components as follows: © Valve clearance © Engine oil ‘© Piston rings or cylinder @ Valve, valve seat and © Cylinder head gasket © Spark plug gasket or tightening torque spring Repair or replace parts and circuits as necessary. oR ‘Adjust to specifications, 10. Check ECC. system. oxy 11, Perform driveability test. and throttle valve switch, Ox, 7. Check idle CO%, NG. - Check idle CO%, [8S ______ hajust to specifications +— OK) Ox, ING. Corrector replace carburetor. 3, Perform driveability check, OX: ____.[exp NG] 9. Check carburetor. |NS._1-~“Correc, adjust or replace componente of carburetor OK] as necessary. ee | *. N, Correct, repair or replace components as necessary. MA-28DIAGNOSTIC PROCEDURE FOR PROBLEMS IMPROPER IDLING (Rough idle, no return to idl 1. Inspect engine and E.C.C. NG. system for air leaks. ox] 2. Check fuel supply system. OK] NG. 3, Perform ignition oscilloscope | N.G. check. Ox, 4. Check deceleration devices. OK. [XS.__.) Locate air leak and repair. ING. st Correct, repair or replace components as follows: igh idle, et.) oT [|—————+] Repair or replace components as necessary. © Distributor cap © Spark plugs © Distributor airgap © Ignition coil © Rotor © IC ignition unit © Secondary wires Repair or replace components as follows: © Throttle opener © Speed switch and circuits ‘© Transmission switch %. Check ignition timing and idle NS.__[“Aajust to specifications. NG. RPM. OK] 6. Check idle COR. a OK 8. Check E.C.C. system. NS. Ox] 9. Check engine compression NG. pressure, Ox. ES] ajust to specifications. fp fp fp Adjustable y adjustable 77. Overhaul carburetor or replace it with a new one. [NG.__,T'” Repair or replace components as necessary. Correct, repair or replace components as follows: © Valve clearance @ ‘Spark plug gasket or © Engine oil tightening torque © Piston rings or © Valve, valve seat and cylinder spring © Cylinder head gasket MA-29DIAGNOSTIC PROCEDURE FOR PROBLEMS ENGINE STARTABILITY (Hard start, no start, hard restart, no restart, etc.) 1. Inspect engine and E.C.C. system for air leaks, etc. NG. UNO Sees Locate air leak and repair. oA Correct, repair or replace components as applicable. Repair or replace parts and circuits as necessary. ‘Check battery and charging JG. system for battery. Ox. + 3. Check starting system. [NG seca OK] t 4, Check fuel shutoff system. WG-__f Repair or replace components as necessary. 5. Check fuel supply system, NG. Ox) ‘Repair or replace parts and circuits as necessary. fe 6. Perform ignition oscilloscope check, NG. Ox] Correct or replace the following parts as applicable. © Distributor cap © ‘Spark plugs © Distributor air gap ition coil © Rotor © IC ignition unit © Secondary wires fe 7. Check E.C.C. system, NG. Ox] Repair or replace components as necessary. 8. Check engine compression pressure. NG. Ox, Correct, repair or replace components as follows. © Valve clearance © Spark plug gasket or © Engine oil tightening torque © Piston rings or © Valve, valve seat and cylinder spring © Cylinder head gasket 9. Check carburetor. NG. Repair or replace components as necessary. Ox] ea 10. Perform startability test. NG. OK. 11. Check idle CO% and adjust it if necessary. MA-30DIAGNOSTIC PROCEDURE FOR PROBLEMS ENGINE STALL 1. Inspect engine and E.C.C. system ‘Locate air leak and repair. for air leaks, etc. OX] a = NG. 2. Check E.C.C. system. |NS.__ "Repair or replace components as necessary. Ox, ae RP NG. : 3. Check idle RPM. [NG.__ fF pajust to specifications Ox, 4. Check FLC.D. system or dash [XG _,f”“adjust to specifications. pot. OX] fp a NG. 8. Check fuel shut-off system, |S: + Repair or replace components as necessary. Ox] _ CC | 6. Overhaul carburetor or replace it with a new one. + 7. Adjust idle rpm, ignition timing and idle CO% to the specified value, For diagnostic procedures for excessive oil consumption, overheating, noisy engine, refer to DIAGNOSTIC PROCEDURE FOR CARBURETOR ENGINES. MA-31ENGINE MAINTENANCE (CD17) ENGINE MAINTENANCE (CD17) BEFORE ENGINE START CHECKING AND ADJUSTING DRIVE BELT (© The belts should not touch the bot- tom of the pulley groove. © Check belt tension by pushing it when it is cold (30 minutes or moro after engine stop). © If alternator and compressor belts ‘are not installed properly when replacing either or both of them, they may rub against the idler for the compressor and we Crank damper: alley Alternator ‘Compressor #1 with air conditioner "2 without ai conditioner SMAIB9A Belt deflection Alternator Compressor Belt deflection mm (in) New belt 9-11 (035-043) 1-13 043-051) Used belt 11-13(043-0.51) | 12-14(.47-055) Deflection limit 16 (0.63) 16 (0.63) Pushing force N (kg, Ib) REPLACING AIR CLEANER FILTER Clean inside of air cleaner housing and ‘cover with compressed 98 (10, 22) CHANGING ENGINE COOLANT WARNING: To avoid being scalded, never at- tempt to change the coolant when ‘engine is hot, Always remove cylinder block drain plug when changing coolant. (55-75 kom, 40-84 ft-lb) MA-32 1, Set heater “TEMP” control lever to fully “HOT” position, 2. Fill radiator with coolant up to filler opening. 3. Install filler cap and fill reservoir tank with coolant up to “MAX” level, 4. Start engine and warm up engine until water temperature indicator Points to the middle of gauge, 5. Stop engine and cool engine off completely. 6. Refill radiator with coolant up to filler opening if the coolant level is lower the specified lov 7. Also, refill reservoir coolant up to “MAX” lovel, tank with Unit: liter (US qt, Imp qt) _ 70 With heater (73/8, 61/8) 65 Without heater 6.7/8" 5.34) Reservoir tank 0.7 (3/4, 5/8) © When using antifreeze coolant (LLC), follow instruction at- tached to antifreeze container for mixing rCHANGING FUEL FILTER Install fuel filter sensor to new filter, ENGINE MAINTENANCE (CD17) Make sure that No. 1 cam of cam- shaft is in the position as shown. [sMaso3a ‘9 Hand-tighten ONLY. b Bleed fuel system, DRAIN WATER Remove fuel filter sensor and drain water. 1, Be sure to place a container or rug beneath fuel filter. b, Pumping priming pump will ‘quicken water draining. ©. Bleed fuel system, ADJUSTING INJECTION TIMING (Plunger tft) 1, Set No. 1 cylinder at Top Dead Center on its compression stroke, Make sure that indicator and crank damper pulley mark are aligned with ach other. ‘sMazo2A\| 2. Remove all injection tubes. 3. Set cold start device to free. (1) Tum cold start device linkage clockwise. @) Set block [length about 15 mm (059 in)]} between cold start device and linkage. 4, Remove plug bolt from rear side of injection pump and, in its place, at- atch Tool. 5. Loosen pump nuts and bracket bolt, MA-33 6, Plunger lift measurement and ad- justment, (1) Tum crankshaft counterclockwise 15 to 20 degrees from No. I cylinder at Top Dead Center. (2) Find dial gauge needle rest point, then set the gauge to zero. (3) Tum crankshaft clockwise until No. 1 cylinder is set at Top Dead Center on its compression stroke. (4) Read dial gauge indication. Plunger lift For low altitudes, Unit: mm (in) M/T _0.9440.03 (0.037040.0012) AIT 0.8840.03 (0.034640.0012) For high altitudes Unit:_mm (in) MIT AIT 0.944003 (0.037040.0012) 1,040.03 (0,039420.0012) (S) If dial gauge indication is not, within the above range, turn pump body until it does,ENGINE MAINTENANCE (CD17) Always replace plug bolt gasket, connect return hose. @: Plug bott If engine will not start, loosen in- 14-20N-m jection tubes at nozzle side and crank (1.4- 2.0 kg-m, ‘engine until fuel overflows from in- 10 - 14 ft-b) jection tubes. Injection pump nut ‘Tighten injection tube flare nuts. 13-18 Nm (1.3 - 1.8 kgm, 9.13 felb) INJECTION NOZZLE Injection pump to rear bracket Inspection 40-GONan ‘. Check initial injection pressure by (5.0-6.0 kom, imping testor handle slowly (one 36 - 43 fetb) time per second). 7. Connect fuel injection tube:in the order of 4, 3,2 and 1. a ee ©: Injection tube flare nut 12,259 - 13,230 kPa 22-25 Nem (125 - 136 kg/em?, (22-25 kom, 1,778 - 1,920 psi) 16-18 ftib) New 13,238 14,026 kPa (195 - 143 kg/em?, 1,920 - 2,033 psi) SEFesaA| BLEEDING FUEL SYSTEM Air should be bled out of fuel system EFTO1A when injection pump is removed or fuel system is repaired. 1. Loosen priming pump vent screw and pumping, Make sure that fuel overflows at vent screw and tighten b. A now nozzle is always used to ‘check initial injection pressure. 'b. Check spray pattern by pumping tester handle 4 to 6 times per second or more. TIMING BELT REPLACE- MENT VALVE TIMING BELT ‘Support engine with a jack and remove right side engine mounting. Then jack up the engine to make room to work in, 1. Set No. 1 cylinder at Top Dead Center on its compression stroke. 2. Remove alternator and compres- sor drive belt. 3. Remove crank damper pulley. 4. Remove timing belt. (1) Loosen tensioner pulley and set it to “free” position. (2) Remove idler pulley. PU EF 7044 ‘SMADE7A If the injection nozzle operation is not Wrong, ‘normal, correct injection nozzle. For details, refer to INJECTION NOZZLE ASSYMBLY in EF section, 2. Disconnect fuel return hose on fuel line side. : 3. Prime priming pump to make sure that fuel overflows at hose end and : MA-34 timing belt.ENGINE MAINTENANCE (CD17) 5. Install timing belt. ‘CAUTION: a. Clean parts, such as pulley, ten- sioner, etc., which touch timing 1b 1b, Ensure timing belt is clean and free from oil or dust when installing it & When installing the crank pulley plate, install in the direction as follows: INJECTION TIMING BELT Remove air cleaner housing with air duct. 1, Set No. 1 cylinder at Top Dead Center on its compression stroke. 2. Remove timing belt. (1) Set tensioner to free position. (1) Put a mark on the timing belt at the 39th cog, if necessary. (2) Align each mark and install erank- shaft pulley with timing belt. ‘sMadooa (3) Install idter pulley. (4) Loosen tensioner bolt and tum crankshaft two times in its normal rotating direction, Never turn crankshaft against its normal rotating direction, (8) Tighten tensioner while holding it. If tensioner rotates, it may cause timing bett to be overloaded, short- ening its service life, (2) Remove timing belt. 3. Install timing belt. ‘cauTi a. Clean parts, such as pulley, ten- sioner, etc., which touch timing bolt. bb, Ensure timing belt is clean and free from oil or dust when installing it. (2) Put a mark on the timing belt at the 23rd cog, if necessary. (2) Align each mark. (3) Loosen tensioner and turn crank- shaft two times in its normal rotating direction. (4) Tighten tensioner while holding it. AFTER ENGINE WARM-UP ADJUSTING VALVE CLEARANCE Adjustment should be made while ‘engine is hot. Warm up engine sufficiently. Checking valve clearance 1, Set No. 1 or No. 4 cylinder at Top Dead Center on its compression stroke. ‘Make sure that cam of camshaft is in ‘the position as shown. 2. Adjust valve clearance as shown in the following illustration, No.1 TDC. Front « No.4 TDC.ENGINE MAINTENANCE (CD17) VALVE CLEARANCE Unit: mm (in) Intake _ 0.20 -0.30 (0.008 -0.012) Exhaust 0.40 - 0.50 (0.016 - 0.020) Measure clearance between cam and valve lifter. ‘Changing lifter plate © The valve clearance adjustment is performed to set each cylinder at Top Dead Center on its compres- sion stroke. (© Make sure that cam of camshaft is in the same position as No. 1 cyl- inder at Top Dead Center. (1) If clearance is not specified, select suitable lifter plate and change it. Valve clearance is adjusted one cyl- inder at a time a a oe xvit102600 WG smasora| (2) Recheck valve clearance, Example: Intake Exhaust Specified clearance 020-0.30 mm 0.40- 0.50 mm (0.008 - 0.012 in) (0.016 - 0.020 in) ‘Measured clearance 0.32 mm (0.013 in) (0.36 mm (0.014 in) 0.02 -0.12 mm 0.04- 0.14 mm (Clearance (0.001 -0.005 in) large (0.002 - 0.006 in) small Thickness of plate ; ; ara ae 3.60 mm (0.142 in) 3,55 mm (0.140 in) ‘Thickness of plate 3.65 or 3.70 mm 3.45 or 3.50 mm to be used (0.144 or 0.146 in) (0.136 or 0.138 in) Refer to a Lifter plate in $.DS. sMasooa MA-36 CHANGE ENGINE OIL AND OIL FILTER WARNING: Be careful not to burn yourself, as the engine oil may stil be hot. © A milky oil indicates the prosence Isolate the cause © An oil with extremely low viscosity indicates the presonce of diesel fucl.. 1. Smear a little engine oil on rubber lip of new oil filter. 2. Tum the oil filter until it touches the ol filter bracket. ‘Then tum it 1/2 tum further by hand, If itis turned too far, oil leakage may occur. Oil capacity: (Reference) Unit: liter (US qt, Imp qt) naa 4.1 Wit 7 ith oil filter Goesce 35 wit 7 » thout oll ter ag CHECKING AND ADJUSTING IDLE SPEED When checking and adjusting the idle speed, make sure to check that shit fever is Neutral (M/T model) or “D” range (A/T model). Preparation (© Make sure that all electrical acces- sories are off.ENGINE MAINTENANCE (CD17) WARNING: ‘a, When selector lever is shifted to “D" position, apply parking brake ‘and block both front and rear wheols with chocks, b. Depress brake pedal while ac- clerating engine to prevent car from surging forward. . After adjustment has been made, shift lever to “N” or “P” position and remove wheel chocks. Checking 1. Srart engine and warm it up until water temperature indicator points to the middle of gauge. 2. Attach a diesel tacho tester’s pick- ‘up to No. 1 injection tube, In order to obtain a m ‘of engine spect ‘lamps on No. 1 injection tube. accurate 3, Run engine at about 2,000 rpm for two minutes under no-load. ‘two oF three times. that it retums to idle If not, check acceleration linkage for binding. 4. Run engine for one minute at idle speed. 5. Check idle speed. +100 750 +1) rom Idle spe a Adjusting Loosen idle serew lock nut and adjust idle speed. sMaaion, MA-37 CHECKING RUBBER HOSES (Water, air, fuel, blow-by, oil hoses) 1, Check all hoses for leakage. 2. Tighten any loose connections and replace any damaged or deformed parts. CHECKING FUEL LINES (Hoses, piping, connections, tc.) (Check fuel lines for loose connections, cracks and deterioration. Retighten oose connections and replace any damaged or deformed parts.TROUBLE \GNOSES AND CORRECTIONS (CD17) TROUBLE DIAGNOSES AND CORRECTIONS (CD17) Battery is fully charged. | Fuel is in fuel tank. ENGINE DIFFICULT TO START OR DOES NOT START ‘Check fuel cut solenoid for “clicking” sound and check NOT OX. circuit. | OK. ‘© Repair circuit. © Replace fuel cut solenoid, Check operation and circuit of auto glow system. NOT OK. |e Check fuel apply by loosening injection tube fare nut on nozzle side (Crank engine) © Repair circuit. Replace faulty parts. NOT OX, OK. Bleed air from fuel line, fuel filter and injection pump. [* Check injection nozzle operation. Check fuel supply by disconnecting fuel return hose NOT OK. and prime priming pump. OK. Check for clogged fuel iter and ful tine. NOT Ok. Repar/Replace fuel filter or fuel line. [° K NoT OX. ‘© Repair/Replace faulty pars. . Adjust and clean. [ Check engine compression pressure and valve cle NOT OK. F Repait/Replace faulty parts. Adjust valve clearance. ie Nor o4 are set properly. Check injection timing (Plunger lift). Adjust. I OK. Che jection timing belt_|_NOT OK. heck that valve timing belt and injection timing bel ae [* Replace injection pump. MA-38TROUBLE DIAGNOSES AND CORRECTIONS (CD17) ROUGH IDLE as NOT OK. ‘Replace faulty parts. Check injection tube for eracks and loose connection, L-NOTOX. __f ae I OK. NoT OK. Replace Check engine mounting for racks and loose connection, pO OX _| © Tighten, I Ox. NOT OX. : Check idle speed. RCE CR +} Adjust. I OK. NOT OK. uel filter or (Check for clogged fuel filter and fuel line. | ee I OK. Bleed air from fuel line, fuel filter and injection pump. I Ox. NOT OK. ‘© Repair/Replace faul Check injection nozzle operation. cae I OK. CCheck engine compression pressure and vale clearance, | NOT OK. | ¢ einer parte. I OK. Check injection timing (Plunger lift) [NOT OK. 4) Adjust. I OK. (Check that valve timing belt and injection timing belt |_NOT OK. Fra are st properly. [ OK. Replace injection pump. MA-39TROUBLE DIAGNOSES AND CORRECTIONS (CD17) EXCESSIVE WHITE OR BLACK SMOKE OK. ‘1: If there is black smoke, start here, #2: If there is white smoke, start here. MA-40 "1 Check for clogged air cleaner element. pS Sn "2 Check for olor similar material on tail pipe. eS I OK. NOT Check ofl level, of I OK. ‘Check E.G.R. control system and throttle valve for pean: Repair/Replace. I Ox, Bleed air from fuel line, fuel filter and injection pump/ Drain water. I ord Check injection nozzle operation, bees . hn cane parts, I OK. ‘© Repair/Replace faulty parts, he ce Check engine compression pressure and valve clearance. (“NOT OK. a Aig ans cataee ee K. Check injection timing (Plunger lift) oF 0) Adjust. I OK. ‘Check that valve timing belt and injection timing belt |_NOT OK. co are set properly. just. iG K. Replace injection pump.TROUBLE DIAGNOSES AND CORRECTIONS (CD17) POOR OUTPUT Check controt lever contact and maximum speed NOT OX. ‘© Adjust accelerator cable. Repair accelerator system. adjusting serew. J OK. operation. ‘Check for clogged air cleaner element. eo Replace. I OK. Check for clogged fl ine and fue ter. [ROTOR al Repair Replace. I Ox. Check EGR, control system and throtte valve for |_NOT O.K. are 3 Bleed air from fuel line fuel filter and injection pump. [ Ox. Check injection nozzle operation. NOT OX. ‘© Repair/Replace faulty parts. Adjust and clean, are set properly. Ox. e NoT Ox. : K © Repair/ Replace faulty parts essure and valve clearance, | Check engine compression pressure and valve clearance. Sie ae Ox. . NOT OX. Check injection timing (Plunger lift). +] Aajust. OK. 7 NOT OK ‘Check that valve timing belt and injection timing belt K ha I OK. Replace injection pump. MA-41TROUBLE DIAGNOSES AND CORRECTIONS (CD17) EXCESSIVE KNOCKING KNOCKING ‘Check nozzle knock by loosening injection tube on STOPS ‘© Repair/Replace faulty parts. nozzle side. *|_© Adjust and clean the nozzle. I KNOCKING DOSE NOT STOP Check engine compression pressure and valve cfearance, [ACT OK: @ Repair/Replace faulty parts. Adjust valve clearance, I OK, NOT OX. MA-42 Check injection timing (Plunger lift). Adjust. I OK. Check that valve timing belt and injection timing belt |_NOT OK. ae are set properly. [feeeeecceed| coe OK. Replace injection pump.FUEL TROUBLE DIAGNOSES AND CORRECTIONS (CD17) CONSUMPTION TOO HIGH NOT OK. Check for clogged air cleaner clement. [ROOK | Repace. I OK. Check for Fuel system leakage. [ROE OK) pais Replace. | OK. NoT OK. Check idle speed. ee adiust OK. Check injection nozzle operation. [acrok fs RepatrRepl Faye OK. TOK. Check engine compreson pressure and valve cearnee, [NOT eae OK. z NOT OK. Check injection timing (Plunger lift). 7 Adjust. I OK. ‘Check that valve timing belt and injection timing belt |_NOT OK. = are set properly. see I OK. Replace injection pump. MA-43.CHASSIS AND BODY MAINTENANCE CHASSIS AND BODY MAINTENANCE EXHAUST SYSTEMS INSPECTING EXHAUST SYSTEMS Visually check the exhaust pipes, muffler, and hangers for proper attachment, leaks, cracks, chafing, abrasion, deterioration, ete. SMAzITA CLUTCH ADJUSTING CLUTCH PEDAL HEIGHT AND FREE TRAVEL Pedal stopper Lock aut @ 16-22Nm (18-2.2kem, 12-16 fel) SMAi744, Withdrawal lever play “B": 2-4 mm (0.08 - 0.16 in) Depress and release clutch pedal over its entire stroke to ensure that the clutch linkage operates smooth- ly without squeak noise, inter- ference and binding. 3. As a final check, measure pedal free travel “A” at center of pedal pad. MANUAL TRANSAXLE INSPECTING MANUAL TRANSAXLE OIL LEVEL Nover start engine while checking oil level, SHASSA, Pedal height “H” Refer to S.D.S. Pedal free travel “A: 11-24 mm (0.43 - 0.83 in) 1. Adjust pedal height with pedal stopper. Then tighten lock nut 2. Adjust withdrawal lever play “B” with adjuster or lock nuts. SMAtaan MA-44 Visually inspect for signs of leakage. SMAs20A REPLACING MANUAL TRANSAXLE OIL, 1. Drain oil completely. eg Drain @ ©25-36Nm (25-35kom, 18-25 fb) [SMAz55A 2. Refill transaxle and check oil evel. © 25-24Nm 125-35 kom, 18-25 Hb) suazsea| Oil capacity: S-spood 2.7 titers (5-3/4 US pt, 4.3/4 Imp pt) 4speod 233 liters (47/8 US pt, 4 Imp pt)CHASSIS AND BODY MAINTENANCE AUTOMATIC TRANSAXLE INSPECTING AUTOMATIC TRANSAXLE FLUID LEVEL The transaxle has the proper amount of fluid if, 10 minutes after engine start and with the engine idling, the level is within the values described in the following table. selector lever through each gear range, ending in “P”. 3. Check the fluid level with the engine idling. 4. Remove the dipstick and clean it lint-free paper. Reinsert it into the charging pipe as far as it will go. 5. Remove the dipstick and note the reading 6. Visually inspect for signs of leakage. Proceed with fluid level check as 4 follows: Keep the fluid at the proper level. vd 4 1. Park the vehicle on a level surface Overfilling may blow off the fluid and set the parking brake. ‘or break the transaxle, 2. Start the engine and idle it for © Underfiling may cause the clutches swasaon about 10 minutes and then move the to slip, and finally breck them, Unit: mm (in) —_ Fluid level ot Fluid level ] temperature temperature Type. Tal tA 30- 50°C 2000)-—| 2100) | -10- 10°C OFS 5 (020) (66 -122°F) | type 2, = (14-50°F) 20 10.78) Cor Tnor Coww~ TaHor al Ea 10-30°C 5 (0.20) -30--10°C OK 1s (0.59) 0- 86°F) (-22-14°F) Ox. L CGouo~ ajnor FRONT AXLE AND FRONT SUSPENSION INSPECTING FRONT AXLE AND SUSPENSION PARTS 1. Block rear wheels with chocks and raise front of vehicle, and then support it with safety stand. Refer to Section Gu. 2. Shake each front wheel by hold- ‘saTer ing upper and lower surfaces of tires as shown. Check suspension parts for loose- ness, wear, or damage. Retighten all loose nuts. and bolts to the specified torque. Refer to Sec- tion FA for tightening torque. Replace all worn parts as described under Front Suspension (Section FA). MA-45CHASSIS AND BODY MAINTENANCE 3. Check strut (Shock absorber) for oil leakage or damage Mania, 4, Remove wheel and tire assembly. 5. Check front axle parts for crack ‘or damage. Replace worn parts. Refer to Front Axle (Section FA). 6. Remove brake pads. Refer to section BR. 7. Check wheel bearing. If there is any axial end play or if wheel bearing does not smoothly turn, adjust bearing to specifications. Replace worn or damaged bearings. Refer to Front Axle (Section FA). SMAI664 CHECKING DRIVE SHAFT BOOTS Check for damage, looseness and leakage of grease. INSPECTING FRONT WHEEL BEARING GREASE 1. Block rear wheel with chocks and raise front of ear, and then support it with safety stands. Refer to Lifting Points and Towing (Section GI). 2. Remove wheel and tire. 3. Check for grease leakage from front wheel bearing grease seals by observing the area around them. Re- place worn or damaged grease seal. Refer to Front Axle (Section FA). 4. Check wheel bearing, AF there is any axial end play or if wheel bearing does not turn smoothly, adjust bearing to specifications. Replace worn or damaged bearings. Refer to Front Axle (Section FA). INSPECTING STEERING LINKAGE BALL JOINT & SUSPENSION BALL JOINT Check the ball joints for damage, looseness and grease leakage. CHECKING WHEEL ALIGNMENT Before checking front wheel align- ‘ment, be sure to make a preliminary inspection of all front end parts. © Tire pressure ‘© Whee! bearing axial play © Suspension ball joint © Steering gear housing looseness at frame ‘Steering linkage and connections ‘Shock absorber operation ‘© Tighten each front axle and suspen sion parts. (© Measure vehicle height (when not loaded) © Repair or replace the damaged por- tion or parts. ‘Camber and caster Camber and caster are preset at factory and cannot be adjusted. The vehicle requires only toe‘n and vehicle posture adjustment, If camber or caster alignment is not within specications, chock associated parts, Repair or replace as necessary. MA-46 Camber, caster and kingpin ination: Refer to $.D. Tooin Measure toesin, and make necessary adjustment. Use the following pro- cedure when making adjustments. 1. Raise front of vehicle and mark a base line across the tread of left and right wheels. smaiz9 2. Set wheels in a straight-head position, and then lower front of vehicle. ‘After lowering front of vehicle, ‘move it up and down to eliminate frie- tion. 3. Measure toe-in and make neces: sary adjustments. Lines parallel to centerline of body Toein= A-B Z Town = 20 4 Front”? ‘SMAi24 Toon (Untaden) and Side slip: Refer to $.08. “Unladen” Fuel tank, radiator and engine oil tank all full, ‘© Spare tire, jack, hand tools, mats in position. © Ail tres inflated to specified pres- sure.CHASSIS AND BODY MAINTENANCE © All accumulation of mud, dirt and road deposits removed from chassis and underbody. Toein can be adjusted by varying the length of steering tie rods. Loosen lock nuts, and turn left and right adjusting bars equally. If tie rods have been disassembled, set the distance between lock nuts to the specified value “L” prior to re- asembling. “L" dimension: 25S 175.9 mm (6.93 in) PR25s 175.9 mm (6.93 in) ) sst992 After correct toe-in has been ob- tained, tighten tie rod lock nuts. @ : Tie rod outer socket lock nuts 37-46 Non (38-47 kom, 27-34 fb) Tie rod inner socket lock nuts 78-98 Nem (8- 10kg-m, 58-72 fttb) Front wheel turning angle 1. Set wheels in straight ahead posi- tion and then move vehicle forward ‘until front wheels rest on turning ra- ‘ius gauge properly. 2. Rotate steering wheel all the way right and left; measure turing angle ‘on inner wheel. If it is not within specification, check arck stroke. ‘Turning angle: Refer to $.0.S. Rack stroke “2” (both sides): E engine equipped model (Without rack spacer) 73.5 mam (2,894 in) CD engine and manual transaxle ‘equipped model (With rack spacer) 70.0 mm (2.756 in) CD engine and automatic transaxle equipped model (With rack spacer) (65.5 mm (2,579 in) R258 ‘Newtral position ey ee spacer ssT0924| MA-47 REAR AXLE AND REAR SUSPENSION CHECKING REAR AXLE AND SUSPENSION PARTS Check for damage looseness and leak- age of oil or grease. Retighten all loose nuts and bolts to the specified torque. Refer to Sec- tion RA for tightening torque. Replace all worn parts as instructed under Rear Suspension (Section RA). ‘SMAI208 ADJUSTING WHEEL BEARING PRELOAD ‘After wheel bearing has been re- pplaced or rear axle has been reassem- bled be sure to adjust wheel bearing preload as described below. 1, Before adjustment, thoroughly clean all parts to prevent possible en- try of dirt 2. Apply recommended multi-pur- pose grease sparingly to the following parts. ‘¢ Threaded portion of spindle. @ Contact surface between wheel bearing washer and outer wheel bearing, @- Hub cap and O-ring.CHASSIS AND BODY MAINTENANCE © Grease seal lip. Install adjusting cap and align any of its slots with hole in spindle, If the Mult-purpose grease point snaszg above procedure fails to align hole and slot together, then tighten tock nut as much as 15 degrees until hole in spindle is aligned with any slot. CAUTION: Do not overtighten wheel bearing nuts, as this can cause wheel bearing seizur 7. Turn hub in both directions two 3. Tighten wheel bearing nut. ‘smaisaa| 4, Tum wheel hub several times in both directions to seat wheel bearing correctly. smasoo| ot three times, measuring its turning torque and axial play to see if they are within the specified ranges. If they are not, adjust. ‘Axial play: 0 mm (0 in) ‘Wheel bearing starting torque: ‘With new grease seal Less than 08 Nm (8 kg-cm, 6.9 in) ‘As measured at whee! hub bolt Less than 13.7 N (1.4 kg, 3.1 Ib) ‘used grasa soal Less than 0.4 Nem (4 kg-cm, 3.5 in-b) ‘As measured at wheel hub bolt Less than 6.9N (0.7 kg, 1.5 Ib) 8, Spread cotter pin, 9. Install hub cap with new O-ring BRAKE SYSTEM REPLACING BRAKE FLUID 1. Change brake fluid. Use same procedure os in air bleod- ing to chango brake fluid in system, ‘This operation should be done for one wheol at a time, Refer to Section BR. CAUTION: Never reuse brake fluid because its characteristic is changed by oxidiza- tion as well as contains the foreign material and dirt, Recommended brake fluid specification: DOTS (F.M.V.SS. No. 116) Refill when there i ‘small amount of uid, 5. Again tighten wheel bearing nut. 6. Tum back wheel bearing nut with- in 90°, ‘With castle nut Return angle: Within 80° SMAISAA Repeat above procedures until cor- rect stating torque is obtained, a. Correctly measure rotation starting force toward tangential direction against hub bolt. b. Above figures do not include ing’ resistance. When moas- turing whee! bearing starting torque, bbe sure to confirm no “dragging” resistance exists. ‘c. Any slightest wheel bearing axial SMAZ79A play cannot be tolerated. MA-48 @7-9Ne (0.7-0.9kom, 5.1 SMAZ61ACHASSIS AND BODY MAINTENANCE 2. Check brake fluid level. 3. Check for leaks, INSPECTING BRAKE LINES & HOSES Check the brake lines and hoses including brake booster vacuum, hhoses, connections & check valve) for proper attachment, leaks, cracks, chafing, abrasion, deterioration, ete. SMAIS7A INSPECTING BRAKE PADS & DISCS Check condition of disc brake com- ponents. Pad wear limit Lining wear limit 20 mm (0.0791) « ost + ~— Qe Ling wont: suaassn TS (0050 9) ayaarae Refer to Section BR for pad replace- ment, Rotor repair limit 10.0 mm (0-394 in) smazsoal INSPECTING BRAKE DRUMS & LININGS. Check the brake lines and hoses including brake booster vacuum hhoses, connections & check valve) for proper attachment, leaks, cracks, ‘Chesk caliper operation chafing, abrasion, deterioration, etc, ‘nd inspedt for leaks Check condition 5 ee ere, Cf rere \oruear eck Fads Gp heck Gperation of forwea ston and inspect : swAa73A © forteakaees soya) [OE N-m dorm, fb) suaasan Refer to Section BR for shoe re- placement. Drum repair limit ‘Check condition of inner surface of drum Drum repair limit (Innor diametor) 161.0 mm (7.13 in} sMa139 CHECKING FOOT BRAKE Check brake pedal free height from ‘melt sheet. ‘Adjust if necessary. MA-49CHASSIS AND BODY MAINTENANCE Pedal free height “h”: Refer to 8 Clearance “C' between pedal stopper rubber and threaded end of brake lamp switch: (0-11 mm (0 -0.04 in} (A) Adjust pedal free height with brake booster input rod. Then tighten Tock mut. Q) Adjust clearance “C” with brake lamp switch. Then tighten lock nut, Make sure that no depressing force is on brake booster input rod and that brake lamp is off when pedal is re- leased. CHECKING BRAKE PEDAL DEPRESSED HEIGHT Check brake pedal depressed height with engine running. Deprossed hoight [Under force of 490 N (60 ke, 1101) with engine running] : Refer to $.0.S, If depressed height is below the specified value, check brake system for leaks, accumulation of air or any ab- normality regarding component parts (master cylinder, adjuster, etc.}, and ‘make the necessary repairs. CHECKING BRAKE BOOSTER FUNCTION Check the brake booster function in accordance with the following pro- cedures. 1. Park the vehicle on a level surface and set the parking brake. 2. With the engine stopped, depress the brake pedal several times to make sure that the pedal travel distance does not change. Then, while depress- ing the brake pedal, start the engine, At this time, the pedal should go down a little. 3. Depress the brake pedal while running the engine. With the brake Pedal depressed, stop the engine. Keeping the pedal depressed for about 30 seconds, make sure that the de- pressed pedal height does not change. 4, Run the engine for a minute and then stop it. Depress the brake pedal several times and make sure that the pedal travel distance decreases gradual- ly with each depression. CHECKING PARKING BRAKE 1. Pull lever with specified amount of force. Measure lever stroke. 3. Bend hand brake warning lamp switch plate down so that brake warn- ing light comes on when ratchet at hhand brake lever is moved back one notch and goes out when returned to its original position. MA-50 WHEEL AND TIRE CHECKING TIRE CONDITION Tire condi 1, Tires are provided with “tread wear indicator” at six places around tire circumference, indicating 1.6 mm (1/16 in) tread depth. When tires wear and then marks appear, replace them with new ones, wnoza] 2. Remove pebbles, glass or any ‘other foreign material embedded in tire treads 3. Check tread and side walls for cracks, holes, separation or damage. 4. Check tire valves for air leakage. Tire inflation 1. Check tire pressure. If necessary, adjust it to the specified value indi- cated in the label attached to the car, also found in SDS. Tico prossure should be measured when tre is cold. 2. After inflating tires, valves should be checked for leakage. Whenever tire pressure is checked, be sure to tighten valve caps firmly by hand to keep dust and water out,CHASSIS AND BODY MAINTENANCE ‘Abnormal tire wear Correct abnormal tire wear ac- ‘cording to the chart shown below. Probable cause Corrective action (both Measure and adjust © Underinfl sides wear) pressure, «@ Incorrect wheel camber | © Repair, or replace (one side wear) axle and suspension pars Hard cornering # Reduce speed ¢ Lack of rotation Rotate tires. © Overinflation © Measure and adjust pressure. Lack of rotation «Rotate tires Fauterededge | Inconect toe © Adjust toein. tions Uneven wear © Incorrect camber or | Repair, or replace caster ade and suspension parts. © Malfunctioning suspen- | sion necessary, reinstall. ‘¢ Unbalanced whee! Balance or replace. # Out-of-round brake Correct or replace. drum ‘© Other mechanical condi- | « Lack of rotation Repair, replace or, if Correct or replace. Rotate tires. ‘sMa0se MA-51 TIRE ROTATION 1, Tires tend to wear unevenly and become unbalanced after a certain running distance. Uneven tire wear often results in tire noise which is attributed to rear axle gears, bearing, etc, Front tires also tend to wear un- evenly because of improperly aligned front wheels. . 2. Accordingly, to equalize tire wear, it is necessary to rotate tires periodi- cally. Bias and Bias Belted Tires, Right front Right rear cS— — a) Leftfront ——Leftrear ‘4 WHEELS Radial Tire Right front Right rear o-—ce ee) Leftfront Left rear 4 WHEELS SMAASBA,CHASSIS AND BODY MAINTENANCE TIRE REPLACEMENT CAUTION Different types of tires, such as bias, bias belted and radial tires, must not be mixed under any circumstances. Mixed use of different tynes of can adversely affect vehicle handling ‘and may cause driver to lose control. Wheri replacing a worn or’ damaged use a replacement tire of the fame size and load carrying eapaci- ty as that with which the car was equipped when manufactured, The use of different size and/or load capacity tires will not only shorten tire service life but may also result in a serious accident. b, Do not use tires and wheels other than those recommended, and do ‘not mix tires of different brands or ‘tread patterns. ‘The use of tires and whoels other ‘than those recommended or the mixed use of tires of different brands or tread patterns can ad- versely affect the ride, braking, andl body- tortie clearance, and speedometer calibration. €. It is recommended that new tires be installed in pairs on the same axe. When replacing only one tire, it should be with the most tread, to equalize braking traction, 4, When replacing original tires with those tires of an optional recom- mended size and of different diam- eter, the speedometer must be ro- calibrated. . When tire is installed, refer to the procedure 7 described in TIRE RE- PAIR. 1. To replace a tire with a jack in a safe manner, refer to Lifting Points (Section GI) for jacking up. WARNING: Never get under vehicle while it is ‘supported only by jack. ‘Always use safety stands to support side member of body construction when you must get beneath vehicle, 2. To install wheel, tighten wheel nuts in crisscross fashion. ‘sMAg69 Aluminum wheel To install an aluminum wheel, pro- ceed as follows: 1. Snugly tighten four nuts after the wheel is positioned. Screw nut onto hub bolt sMao70 2. Slightly pull the wheel back to properly align the nuts with bolt holes in the wheel, and tighten the nuts as, much as possible with your fingers. Align muts with bott holes in wheel and evenly tighten nuts seach one alittle smao7i| 3. Tighten wheel nuts evenly with a wheel wrench in eriss-cross fashion, MA-52 Be sure to check the wheel nuts for tightness, after the aluminum wheel hhas been run for the first 1,000 km (600 miles) (also in case of repairing flat tres, tire rotation, ete). Replace if necessary. CAUTION: ‘Two types of wheel nuts are used; one is designed for use with steel wheel and the other for use with aluminum wheel. Do not mix different types of wheel nuts. For steel For aluminum wheels only wheels only \ © 78-98N-m (8.0. 10.0 Kem, 68-72 feb) ‘SMAa3B Bo careful not to smear thread- ed portion of bolt and nut, and seat of ut with oil or grease. LIGHT WEIGHT SPARE TIRE (Size P155/80013) ‘The light weight spare tire is designed for emergency use only. ‘The spare tire can be used repeatedly for emergency situations. Precautions when using light weight spare tire © Periodically check tire inflation pressure, and always keep it at 35, pt (240 kPa) © Do not drive vehicle at speed faster ‘than 80 km/h (50 MPH). © The light weight spare tire is de- signed only for temporary use as @ spare. Dismount it and keep it as @ spare as soon as the standard tire repair has been completed. © Do not use tire chains on a light ‘woight spare tire,CHASSIS AND BODY MAINTENANCE © Do not use the light weight spare tire on other vehicles. © Do not make a sharp turn, or apply the brake suddenly while driving. © As soon as the tread wear indicator becomes visible, replace the tire with a new one, © Mounting and dismounting to and from the road wheel can be carried ‘out in the same manner as any ordi- nary tire, (© Use of whee! balance is unnecessary. CAUTION: |f the vehicle is equipped with alumi- ‘num wheels, be sure to use the whee! ‘huts for steel wheel on the light weight spare tire wheel. Never use the wheel for aluminum wheel on the spare tire wheel, The spare tire whee! may come off the axle and cause personal injury if the wheel nuts for aluminum wheels are used on the spare tire wheel. TIRE REPAIR Inspect tire, following the proce: dure shown below. If any defect is pre- sent, repair or replace as necessary 1. Apply soapy solution or submerge tire and wheel or tube in water after inflating it to specified pressure. 2. Inspect for leaks. 3. Specially inspect for leaks around valve or wheel rim and along tread. 4, Note bead and rim where leakage occurs. Wipe water away from any area which leaks air bubbles and then ‘mark place with chalk. 5. Remove object which Puncture and seal the point. ‘2, When repairing @ puncture, use a tire repair kit furnished by any tire dealer, following instructions pro- vided with kit. b. If a puncture is too large or there some damage ta tire fabric, repair should be carried out by authorized tire dealer. 6. Discard when any of the following problems occurs: © Broken or damaged bead wire «Ply or tread separation. caused @ Wom fabric damage on tubeless tire © Cracked or damaged side wall. © Tires with tread wear indicator showing, etc. CAUTION: When replacing tire, take extra care not to damage tire bead, rim-flange and bead seat. Do not use tire irons to force beads away from wheel rim ‘that is, always use tire replacement device ‘whonover tire is removed. 7. Install tire, noting the following items: 2. Install valve core and inflate to proper pressure. Check the locating rings of the tire to be sure they show around the rim flanges on both side b. Check valves for leakage after in- lating tres. €. Be sure to tighten valve caps firmly by hand, WARNING: When, while tire is being inflated, bead snaps over safety hump, it might break, Thus, to avoid serious personal injury, never stand over tire when inflating it. Never inf to a pressure greater than 40 (275 kPa), If beads fail to seat at that pressure, deflate the tio, lubri- If the tire is overinflated, the head might break possibly resulting serious personal injury. WHEEL INSPECTION Inspect wheel, taking care of the following points, in order to ensure satisfactory steering condition as well as maximum tire life. If any defect is ‘present, repair or replace as necessary. 1. Check wheel rim, especially rim flange and bead seat, for rust, distor- tion, eracks or other faults which might cause air leaks. Function of MA-53 tubeless tire depends on a good seal between tire bead and wheel rim. 2, Thoroughly remove rust, dust, oxidized rubber or sand from: wheel rim, Rim bead seats should be cleaned with the following. ‘Steel whee! Wire brush, coarse steel wool, etc. ‘Aluminum wheel: ‘Neutral detergent, cloth, etc. 3. Examine wheel rim for lateral and radial runout, using dial gauge. Lara! runout (A) and radial runout (J ‘Sto! whoo. Les than 110 em (0.039 in) ‘Aluminum whl «. Less then ‘05 mm (0.020 in) Difforenco betwoon right and teft lateral hoes than 05 mm (0.020 in} ‘Aluminum wheal. Less then 10.2 mm (0,008 in} 4. Replace wheel when any of the following problems occurs, Bent, dented or heavily rusted Elongated bolt holes Excessive lateral or radial runout Air leaks through welds Wheel nuts will not stay tight Wheol balance Inspect wheel and tire for wheel balance and correct it if unbalance is present, taking the following points unbalance when the 1. Correct symptom of unbalance appears as ‘wheel tramps and wheel shimmy. 2, Balarice. wheel and tire both statically and dynamically.CHASSIS AND BODY MAINTENANCE Balancing wheels CAUTION: Do not spin balance front wheels on the vehicle, ‘Transaxle damage will result. Cause ‘Wheel static unbalance Wheel dynamic unbalance Symptom Wheel tra i Weel amp | Whee shimmy unbalance Corrective Balance statically Balance dynamically salon ace aace, ‘Wheel shimmy MA-54 Balance weight: 10-60 g(0.35 2.1202) a 10.9 (0.35 02) interval suao7s| 4, Be sure to place correct balance weights on inner edge of rim, , Do not put more than two weights on each side. ¢. Two types of balance weights are designed for use with and the other for use with aluminum wheel. Do not mix differont types of balance weights, d. Properly rebalance the wheel and tire whenever puncture is repaired,CHASSIS AND: BODY: MAINTENANCE STEERING SYSTEM INSPECTING STEERING GEAR AND LINKAGE Check for damage, looseness and leakage of oll or grease. CHECKING POWER STEERING FLUID LEVEL Check the fluid level in reservoir by observing the dipstick when the fluid is cold. Add fluid as necessary to bring the level into the proper range (on dipstick, CAUTION: Do not overfill, fe K. smaro7A SMart INSPECTING POWER STEERING LINES & HOSES Check the lines & hoses for proper attachment, leaks, cracks, chafing, abrasion, deterioration, etc, sMaA3294 | MA-55CHASSIS AND BODY MAINTENANCE BODY LUBRICATING LOCKS, HINGES AND HOOD LATCH Lubricate all locks and hinges on all doors including trunk lid, back hatch and hood latch, When driving in areas using road salt or other corrosive materials, inspection should be performed more frequently. Coupe are CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTER (Check for damage, deterioration, proper functioning, smooth operation and loose mounting. ‘SMAI244, ® Anchor bote 26-31 Nm (24-32 kgm, 17-23 feb) (Check buckles and tongues for function when buckled and released, ‘SMAS2BA MA-56SERVICE DATA AND SPECIFICATIONS (S.D.S.) SERVICE DATA AND SPECIFICATIONS (S.D.S.) ENGINE MAINTENANCE (E15 & E16) INSPECTION AND ADJUSTMENT Ignition timing, idle speed and idle “CO"% (For USA.) Except MP.G. Basic mechanical system Menuat | Automatic | Manvel Take 0.28 (0011) Hot eee vse | sees | caer eras Exhout | 0.28 (0.011) Geman! | eenceo' | socen som (in) ‘ake 0.22 (0.008), re —] oid" cosa je mixture srew ip Extout | 0.22 (0.008) "CO" at idle speed | seed at factory. Drive belt detection (Cold) Ua? Now's 13-17 10-14 Ignition timing, ile “CO"% (For Cs Alternator mm tn} ost- (039- ee ee — oss Except MP. MPS. an 7 7 Ar conditioner em (in) (035- (o28- Menuat [Automatic | Manual oe on Tenition timing? ae era een {ale speed ~ i ui 7-9 65-95 70:50 | 650250 | 700260 Power steering mm (in) (028 (0.256 - (AT.0.6, degre/eom) om = ale mixture Pushing force (ko, 1) 38 (10,22) = i son's *"00"% atte speed 1 se on Engine comprestion pressure ed a fac- Pa tkg/em, psd ory. = — "iether wae hoe ered nd rum Minium 981 (10.0, 142) hose plusoed up. "1 After checking valve clearance while engine scold, also check i ‘when engine is hot to se if remains within the specific range. Wit does not readjust it, *2 Adjust defection of used batt *3 Set deflection of new belt Ignition and fuel system ion control system Unit: KPa (mmH,0, inl, 0) epor tine | Sueatied pressure 3.923 (400, 18.78) Veakage tet Pressure variation | _ Less than 0.246 (25, 0.98) ‘Spark plugs poe Type ep nation [Sunaao [vor] caw] mm int TIGHTENING TORQUE 10-14 Unit wm [tom | feb usa. | serses-1] spraesas| senses.t1] 49°14, aan Nawerockerediusting | ag.o1 | 16-21 | 12-16 Conade | senses |eeraes |esrnees |.,29°09 (il pan drain plug 38-47 26-35 igh tonson cable resistance po Less than 30,000 Sperk plug 20-20 | 20-30 | 14-22 MA-57SERVICE DATA: AND SPECIFICATIONS (S.D.S. ENGINE MAINTENANCE (CD17) Injection system INSPECTION AND ADJUSTMENT —- late weed ‘0m 70" 1 ‘ate cera sm a) intake 0.20-0300.008-0.012) a aerial ; For low stnudes baal hanndiccachndabh tonal wT 0.9420.03 (0.037020.0012) Drive bat Defaction a ane ue ee an (088:0008 (00946300012) anne a an 140561 For high atuces (0.38-043) (043-051) wr 1.003008 (0.090410.0012) ‘Compressor ppd 12-14 | 160.59) Ar 0.9420.03 (0.037020.0012) (0.43 -0.61) (0.47-0.68) Rcmiosanres Initial injection pressure 98 (10,22) Pa kale, pa) 1 Oh, 1) a 19,299-14024 : (136 -143, 1,920 -2.033) 12289-13209 ome (125-136, 1,778- 1,920) Lifter plate Partnumber ‘Thickness mm (in) __Identifiation TIGHTENING TORQUE 19232.16A00 3.010.176) 300 unit Nm 1323216001 3.05 0.1201 308 13232-16A02 3.10 0.1220), 310 ‘Aircleaner bracket bolt 26-94 2.7-38 20-25 13232-16A03 3.15,0.1240) 315 13232-16004 3.2010.1280), 320 pore corer ge rere 13732-16808 3.25 0.1200), 335 Aerator to adjusting bar 91-118 099-1.2 13232-16A08 33010.1299) 330 Crank damper pulley bolt 123-132 128-13.5 90-88 13232:16A07 33610.1319) 335 13232:16A08 3.40 0.1330), 340 ee See Cacee see 13232-16400 3.48 (0.1358) 345 lator uttey bote 36-44 3.7-48 27-33 1923216010 3.8010.1378) 350 siccain ete : 7 sam2t6ant 3.85 (0.1398) 355 acne gate eter eerie yaeazieat2 360 (0.1417) seo Injection pump toreer 49-89 80-80 36-43, 1328216013 3.65 0.1497) 365 brocket y Wazszasata 3.70 0.1457) 370 Injection tube flaeut 22-25 22-25 16-18, 1323246Ai8, 3.7510.1476) 375 1375246016 3.90 (0.1496) 380 Ol pen cain plug eee 132526017 3.85:0.1816) 385 Plug bolt 14-20 14-20 10:14 1325216018, 3.90 0.1835) 390 an : : ‘i 1323216A19 3.95 (0.1855), 305 ae re ftas 09°23 1323216020 4.00 (0.1575), 400 Rocker cover 1-3 04-03. 07-22 1320216821 405 0.1504) 405 Front tensioner 36-440 37-45 27-33 1373216022 4.100.161) 410 btn Sacre 4 Foor tensioner 16-21 18-24 12-15 19232-16024 420 0.1654) 420 Wiotor drain lug 84-74 85-75 40-64 MA-58SERVICE DATA AND SPECIFICATIONS (S.D.S.) ————— CHASSIS AND BODY MAINTENANCE ake sim INSPECTION AND ADJUSTMENT Dictate on Unit: mm (ind Pad minimum thickness 2.0 (0,079) Paden Toa 204 764-809) Rotor minima tke 700 0394) Ped py“ 11 03-088) Drom bake Tinie in kee 1510088 Ww ir ny 2-4 (0.08-0.16) rom masa ne 13 2082 (800) Pea Front axle and front sus Free height “h’ een ut 194 - 204 (7.64 - 8.03) - ie at 107-207 0.78838) = er Deprned bi {Unser treo 490 N 60k, Kingpin inclination 12°10" - 13°40" 110 Ib) with engine running) More than 85 (3.35) Tewin 3-810,72-020 Faking bate ‘ube of noth Ouid-ins {atpuling re 96 (20, (owt 006 -Im0a96) fan 6-7 notes Stand rod ion mtn] 1789680) eens Tora tne Uise/owsde) dagen | 20n730" Full turn {lanaldachet CiieyOveis) dagen ees ee : {nna prea seul oe bea a0 ea a measured when tires are cold.) co 37° - 41° /29° -. em Mr 298-33" t658R19 al (kPa) sm conotell coin 30° 37 RT 31 178/708R13 psi (kPa) 26 (180) reeroore ‘Soret re Rear axl and rear suspension fay mata] ote a Vea Bearing in being et | “Auras wm tn) | Lew tan 08 (020 smthge tet) fo0-48 (40-48, 29-3 ea ttl ano a — of ‘Stee! wheel mm (in) | Less the 0.6 (0.020) erg vr ore Vina beng ening tr “inure! wnt) | a han 02 (0.008) Wm tegen, int) | Les tan 08 16 691 omer (Morimomalowable gr fo) to1038) Rirpamwed aha bat |N kg, tb). Less than 13.7 (1.4, 3.1) cee =n eae 0. c00a8 210) With used grease seat ‘Tire balance weight gr (oz) 7 Nem (kg-om, int) Less than 0.4 (4, 3.5) ee caesanste sua ‘1 Only fon whl of E18 and CD17 ene speed mod ta Lew tan 88 (07,18) MA-59.SERVICE DATA AND SPECIFICATIONS (S.D.S.) TIGHTENING TORQUE Unit Nem kom feb Cluten | Pedal topper tock nut | 16-22 | 16-22 | 12-16 Gable adjuster tock nut | 12-15 | 12-15 | 87-108 ‘Manual transaxle Drain and filer plugs | 28-34 | 25-35 | 18-25 Front axle and front suspension ‘Side rod outer socket Fock nut ava | 38-47 | 27-34 Side rod Inner socket oe 7e-08 | 8-10 | 58-72 Brake system ‘Al bleed valve 7-8 | 07-09 | 51-65 Broke tom aw wpewien 1 6-22, | 16-22 | 12-16 lock nut Brake booster Input arpa we-22 | 16-22 | 12-16 ‘Whee! and tie Wheel nut 78-98 | 80-100| 58-72 MA-60SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS aol mmber Tool name Ee (Kent: Moore No.) EIS &E16 p17 sT19320000 il filter wrench (925664) : KV10108300 Tle adjusting screwdriver ) : o KV11229352 Measuring device 28827) @kv11229350 Holder As C=) @®kv11229360 Nut | - x C=) © @kv11229370 Pin E i) i @kv11254410 Dial gauge Kv11102600 Lifter plate replacer =) . x MA-61ENGINE MECHANICAL CONTENTS JE15 & E16(_ J j¢D17(_ J ENGINE COMPONENTS ENGINE SERVICE (Onvehicle) .. EM-21 (Outer parts) x EM. 2 Compression pressure . . EM-21 ENGINE COMPONENTS Cylinder head ........ ~ EM-22 (Internal parts) ae EM 4 Camshaft and camshaft oil ENGINE DISASSEMBLY ... . EM 6 seal replacement ...... EM-27 Precautions . -. EM 6 Valve stem seal replacement . + EM-2B Engine overall ise . EM 6 Crankshaft oil seal replacement... .... EM-28 Piston and connecting rod... ..—M- 8 ENGINE COMPONENTS EM.29 Cylinder head . . EM. 8 Outer parts A iis - EM-29 INSPECTION AND REPAIR EM. 9 Internal parts - EM30 Cylinder head ty .EM-9 ENGINE DISASSEMBLY -. EM31 Camshaft and camshaft bearing EM-11 Mounting engine on work stand . . EM31 Cylinder block 0.2.0.2. seve EMAL Engine overall........+4 sees EMI Piston, piston pin and piston ring ...... EM-12 Piston and connecting rod... . . EM32 Connecting rod . ...—M-13 INSPECTION AND REPAIR .. - EM33 Crankshaft . : EM-13 Cylinder block . - EM33 Main bearing and connecting Piston, piston pin and piston ring .. .... EM-33 rod bearing . - EM13 Connecting rod . - EM34 Jack shaft and jack shaft bushing ...... EM-14 Crankshaft . . . EM34 Miscellaneous components EM14 Miscellaneous components EM35 ENGINE ASSEMBLY EM15 ENGINE ASSEMBLY .. EM-36 Precautions... . EM-15 Piston and connecting rod. . EM-36 Cylinder head eeant . EM-15 Engine overall . . - EM-36 Piston and connecting rod EM-16 Engine overall........ see owe EMH (_JE145, £16 & cp17(7___) SERVICE DATA AND SPECIFICATIONS (S.D.S.)............ EM-39 Inspection and adjustment ........... EM39 Tightening torque... - +. Em43. Inspection and adjustment . EM44 Tightening torque . EM47 SPECIAL SERVICE TOOLS . EM49ENGINE COMPONENTS (Outer parts) — E15 & E16 ENGINE COMPONENTS (Outer parts) seM706ENGINE COMPONENTS (Outer parts) — E15 & E16 ® 31-42 (32-43, 23-30 @: Nem (kgm, fed) seM707 EM-3ENGINE COMPONENTS (Internal parts) — E15 & E16 ENGINE COMPONENTS (Internal parts) eLo wx ° (18-24, 12-15) © 99 74 0.0-78, 51-54) into o thee sags. @ sEM798 . . :nasene ShaeENGINE COMPONENTS (Internal parts) — E15 & E16ENGINE DISASSEMBLY —E15 & E16 PRECAUTIONS ‘Arrange the disassembled parts on the parts stand in accordance with their assembled locations, sequence, etc., so that the parts will be reas- sembled in their original locations. Place mating marks on the parts if necessary. ENGINE OVERALL MOUNTING ENGINE ON ENGINE STAND 1, Remove parts at the rear of the engine. © Transaxle assembly with starter 2. Install engine attachment on the engine. 3. Place engine on work stand. ENGINE DISASSEMBLY 2. Parts on the left side of the en- gine. (2) Disconnect E.G.R.andE.AL pipe. (2) Remove exhaust manifold cover. @) Remove B.A. pipe. (@) Remove exhaust manifold. Exhaust manifold conter nut has @ different diameter from the other nut. 4. Drain engine oil and coolant, OUTER PARTS 1, Parts at the rear of the engine. (1) Remove distributor together with high tension cable. (2) Remove E.AJ. pipes bracket and E.GR. tube at EGR. valve side, (5). Remove cooler compressor brack- cet and power steering pump bracket. 3. Parts on the right side of the en- sine. (1) Remove intake manifold with car- buretor. (2) Loosen water pump pulley bolts. (3) Remove alternator, altemator bracket and drive belt. (4) Remove oil filter. (5) Remove oll pump assembly with gasket. (©) Remove fuel pump assembly with spacer. INTERNAL PARTS 1. Bottom parts (1) Remove oil pan, gasket and oil seal. (2) Remove oil strainer, 2. Rear side parts (2) Remove thermostat housing. @) Remove flywheel or drive plate, then remove rear plate. 3. Front side parts 1) Remove water pump pulley. (2) Remove crankshaft pulley.(@) Remove water pump assembly (S) Remove tensioner pulley. © Remove timing belt. ‘Mark rotating direction mark on timing bett. (7) Remove jack shaft pulley. ENGINE DISASSEMBLY — E15 & E16 (4) Separate them. 5. Jack shaft (1) Remove front cover. Be careful not to damage oil seal lip. (2) Remove jack shaft locating plate. (®) Remove crankshaft timing pulley with spacer. 4. Separate cylinder head from eylin- der block, 1) Remove spark plugs. (2) Remove valve rocker cover. (@) Remove cylinder head bolts. ‘The bolts should be loosened in ‘wo or three stages, (@) Take out jack shaft. 6. Piston and connecting rod assem- bly. (1) Remove connecting rod caps and bearings. (2) Take out pistons together with connecting rods toward cylinder head side, EM-7 4. Piston can be easily removed by: seraping carbon off top face of cylinder with a scraper. b. Numbers are stamped on the con- necting rod and cap corresponding to each cylinder. Care should be ‘taken to avoid @ wrong combi- nation including bearing. 7. Crankshaft (1) Remove oil seal retainer. (2) Remove main bearing cap to- gether with bearing. (3) Remove crankshaft and bearings.ENGINE DISASSEMBLY — E15 & E16 PISTON AND 2, Remove cylinder head cover. CONNECTING ROD Be careful not to damage oil soa! 1. Remove piston rings. bea seMso4 sems2a| {Be careful not to seratch piston. 2, Press out piston pin, 3, Remove rocker shaft assembly. Kv10107409, Koop disassembled parts in order. ROCKER SHAFT ASSEMBLY Remove rocker shaft springs and retainers, Keep the paris in correct order, CYLINDER HEAD 1. Remove camshaft pulley. 5. Temporarily install rocker shaft and remove valve component parts, Keep them in correct order.INSPECTION AND REPAIR — E15 & E16 INSPECTION AND REPAIR CYLINDER HEAD CHECKING CYLINDER HEAD MATING FACE 1. Make a visual check for cracks and flaws, 2. Measure the surface of cylinder head (on cylinder block side) for warpage. Warpage of surface: Less than 0.1 mm (0.004 in) If beyond the specified limit, cor- rect with a surface grinder, Surface grinding limi ‘The grinding limit of eylinder head is determined by the cylinder block ‘rinding in an engi Depth of cylinder head grinding is oe Depth of cylinder block grinding A+B = 0.2mm (0.008 in) VALVE GUIDE Measure the clearance between valve guide and valve stem. If the clear- ance exceeds the specified limit, re- place the worn parts or both valve and valve guide. In this case, it is essential to determine if such a clearance has been caused by a worn or bend valve stem or by a worn valve guide, Determining clearance 1. Precise method (1) Measure the diameter of valve stem with a micrometer in three places; top, center and bottom. 2) Measute valve guide bore at center using telescope hole gauge @) Subtract the highest reading of valve stem diameter from valve guide bore to obtain the stem to guide clea ance. Stem to guide clearance: Maximum Limit 0.10 mm (0.0038 in) 2. Expedient method Pry the valve in a lateral direction, and measure the deflection as stem tip with dial gauge. eye AIGA N Max. allowable deflection: (Dial indicator reading) (0.2 mm (0.008 in) Valve should be moved in parallel ‘with rocker arm. (Generally, a large amount of woar occurs in this diree- tion.) EM-9 Replacement of valve guide To remove old guides, use a press [under a 20 KN (2 t, 2.2 US ton, 20 Imp ton) pressure] or a hammer, and suitable tool. 1. Drive them out toward rocker cover side using suitable tool. Heating the cylinder head will facilitate the operation. 2. Ream cylinder head valve guide hole using Reamer ST11081000 [12.2 ‘mm (0.480 in) dia.] at room tempera- ture 3. Install a service valve guide on cylinder head so that it protrudes about 15 mm (0.59 in) above the cyl inder head surface. Heat cylinder head to 150 to 160°C (302 to 320°F) and press the guide onto cylinder head. 14.7 - 15.3 mm (0.879 - 0.602 in)INSPECTION AND REPAIR — E15 & E16 4. Ream the bore using Tool KV10107700. Reaming bore: 7.005 - 7.020 mm (0.2768 -0.2764 in) 5. Correct valve seat surface with new valve guide as the axis, VALVE SEAT INSERTS Check valve seat inserts for any evidence of pitting at valve contact surface, and reseat or replace if worn ‘out excessively, Correct valve seat surface with suit- able cutter or grinder and grind with a grinding compound, ‘@, When repairing valve seat, check valve and valve guide for wear beforehand. If worn, replace them, ‘Thon correct valve seat. b. The cutting should be done with both hands for uniform cutting. VALVE 1. Check each of the intake and ex- hhaust valves for worn, damaged or de- formed valve head or stem. Correct or replace the valve that is faulty. 2. Valve face or valve stem end sur- face should be refaced by using a valve srinder. When valve head has been worn down to 0.5 mm (0.020 in} in-margin- ‘thickness, replace the valve, Grinding allowance for valve stem ‘end surface is 0.2 mm (0.008 in) or fess, If spring is out of square “S” more than specified limit, replace with new Squaroness limit: 2.0 mm (0,079 in) ‘SEMaRS, 2. Measure the free length and the tension of each spring. If the measured. value exceeds the specified limit, e- place spring, Refer toSDS. ematg VALVE SPRING 1. Check valve spring for squareness using a steel square and surface plate. EM-10 VALVE ROCKER ARM AND SHAFT 1, Check rocker arm bore and shaft for scores or scuffs, 2, Check valve end contact surface of rocker arm for abnormal wear or scuffs.INSPECTION AND REPAIR — E15 & E16 CAMSHAFT AND CAMSHAFT BEARING CAMSHAFT BEARING CLEARANCE ‘Measure the inside diameter of cam- shaft bearing with an inside dial gauge and the outside diameter of camshaft journal with a micrometer. If any mal- function is found, replace camshaft or cylinder head assembly. ‘Max. tolerance of camshaft bearing clearance: No. 1, 3,5 0.15 mm (0.0059 in) No. 2,4 (0.20 mm (0.0079 in) CAMSHAFT RUNOUT 1. Check camshaft, camshaft journal and cam surface for bend, wear or damage. If beyond specified limits, re- place them. 2. Camshaft can be checked for bend by placing it on V-blocks and using a dial gauge with its’ indicating finger resting on center journal. Wear limit of cam haight: 0.20 mm (0.0079 in) 4, Measure camshaft end play. If be- yond the specified limit, check cam- shaft contact surface part and replace faulty parts. End play timit: 0.4 mm (0.016 in} CYLINDER BLOCK 1. Visually check cylinder block for cracks or flaws, 2. Measure the top of cylinder block (cylinder head mating face) for warp- age. If warpage exceeds the specified limit, correct with a grinder. ‘Camchah runout (TEAST Limit 0.10 mm ‘+ Total indicator reading ema0a| 3, Measure camshaft cam height. If beyond the, specified limit, replace camshaft, Qe SFL Werpage of surface: Less then (0.1 mm (0,004 in) EM-11 4 Surface grinding limit; The grinding limit of cylinder block | determined by the cylinder head sorinding in an engine, Depth of cylinder head grinding is a Depth of cylinder block grinding ae" ‘The limit is as follows: A+B= 02mm (0.008 in) 3. Using a bore gauge, measure cyl- inder bore for wear, outofround or taper. If they are excessive, rebore the cylinder walls with a boring machine. ‘Measurement should: be taken along bores for taper and around bores for out-of-round. Refer to SDS. Outofround ...... x Topo eee eeeee AB ray pes Ls. C20 0.70) 4, When wear, taper or outofround is minor and within the limit, remove the step at the topmost portion of cyl- inder using a ridge reamer or other similar tool. When installing service cylinder liner, interference. fit of cylinder liner in cylinder block should be 0.080 to (0.090 mm (0.0031 to 0.0035 in).INSPECTION AND REPAIR — E15 & E16 CYLINDER: BORING When any° cylinder needs boring, all other cylinders must also be bored at the same time, Determining bore size 1, _ Determine-piston oversize accord- ing to amount of cylinder wear. Refer to SDS. 2. The size to which, cylinders must be honed is determined by adding pis- ton-tocylinder clearance to the piston skirt diameter. Lo ‘© Bore the cylinders in the order of 2-4-1 to: prevent heat strain due ‘to cutting. 3. Hone the cylinders to the required size referring to SDS. © Use clean sharp stones of proper grade. © Crosshatch pattern should be ap- proximately 45°. 4, Measure the finished cylinder bore for outof-round and taper. Measuring piston-to-cylinder clearance Measure the extracting force, and pull feeler gauge straight upward. It is recommended that piston and cevlinder be heated to 20°C (68°F). Feoler gauge thickness: (0.04 mm (0.0016 in} (0.5 - 1.5 kg, 1.1-3.8 1b) Rebored size calculation D=A+B-C=A+ [0.0050 0.025 mm (0.0002 to 0.0010 in) where, Honed diameter ‘Skirt diameter as measured Piston-to-wall clearance Honing allowance (0.02 mm (0.0068 in) oa>ro 1. Install main bearing caps in place, and tighten to the specified torque to prevent distortion, of, the cylinder bores in final assembly. 2. Cut cylinder bores. © .Do not cut too much out of the ‘oylinder bore at a time. Cut only 0.05; mm (0.0020 in) ‘or’ so in diameter at a timo, 'o Ooh sean PISTON, PISTON PIN AND. PISTON RING 1. ‘Setape carbon off piston and ring grooves with a carbon scraper and a curved steel wire. Clean out oil slots in bottom land of oil ring groove. 2. Check for damage, scratches and ‘wear. Replace if such a fault is detect- ed. 3. Measure the side clearance of rings in ring grooves as each ring is installed, EM-12 ‘Max. tolerance of side clearance: 0.2 mm (0.008 in) If side clearance exceeds the speci- fied limit, replace piston together with piston ring, PISTON RING Measure ring gap with a feeler ‘gauge, placing ring squarely in eylinder using piston. Ring should be placed to diameter at upper or lower limit of rin travel ‘Max. tolerance of ring gop: 1.0 mm (0.039 in) ‘2, When piston rinig only is to be ro- placed, without eylinder bore being ‘corrected; measure the gap at the bottom of cylinder where the woar is minor, b, Oversize piston rings are aveileble for service. 1. Cheek piston'pin and piston pin hole for signs of sticking and other ab- ‘normalities.INSPECTION AND REPAIR — E15 & E16 2, Measure piston pin hole in rela- tion to the outer diameter of pin. If wear exceeds the limit, replace such piston pin together with piston on which itis installed. Piston pin to piston clearance: 0,008 -0.012 mm (0.0003 - 0.0005 in) Determine the fitting of piston pin into piston pin hole to such an extent that it can be pressed smoothly by fingor at room temperature. CONNECTING ROD 1, If a connecting rod has any flaw fon both sides of the thrust face and the large end, correct or replace it 2. Check connecting rod for bend or torsion using connecting rod aligner. If bend or torsion exceeds the limit, ccottect or replace. ‘Bend and torsion [per 100 mm (3.94 in) tength ‘Less then (0.05 men (0.0020 in) 3, Install connecting rods with bear- ings on to corresponding crank pins and measure the thrust clearance. If the measured value exceeds the limit, replace such connecting rod. semssa CRANKSHAFT CRANK JOURNAL AND PIN 1. Repair or replace as required. If faults are minor, correct with fine crocus cloth. 2. Check journals and crank pins with a micrometer for taper and out- ofsound. Measurement should be taken along joumals for taper and around journals for out-of-round. If out-of-round or taper exceeds the specified limit, replace or repair. Out-of-round (X-Y) ond Taper (AB): Less than 0.01 mm (0.0904 in) M767} EM-13 3. After regrinding crankshaft, finish it to the necessary size indicated in the chart under SDS, by using an ade- quate undersize bearing according to the extent of required repair. RUNOUT AND END PLAY 1. Crankshaft can be checked for runout by placing it on V-blocks and using a dial gauge with its indicating finger resting on the center journal. Runout value is half of the gauge read- ing obtained when crankshaft is turned “one full revolution, If bend exceeds the specified limit, re- place or repair. 2. Install crankshaft in cylinder block and measure cranksahft free end play at the center bearing. MAIN BEARING AND CONNECTING ROD BEARING 1. Thoroughly clean all bearings and check for scratches, melt, score or wear.INSPECTION. AND REPAIR — E15 & E16 Replace bearings, if any fault is de- tected. 2. Measure bearing clearance as follows: (1) Cut a plastigage to the width of bearing and place it in parallel with crank journal, getting clear of the oil hole. Plastignge (2) Install crankshaft, bearings and bearing cap, with the bolts tightened to the specified torque. @: Main bearing cap 49-591 (5.0-60kgm, 36-43 Fetb) Do not tum crankshaft while the plestigago is being insortod. (3) Remove cap, and compare width Of the plastigage at its widest part with the scale printed in the plastigage en- velope. Max. tolerance of main bearing clearance: 0.10 mm (0.0039 in) value, replace bearing with an undei- size bearing and grind . crankshaft journal adequately. Refer toSDS. CONNECTING ROD BEARING 1. Measure connecting rod bearing clearance in the same manner as above. ©: Connecting rod bearing cap 31-37Nm ‘Max. tolerance of connecting ‘od bearing clearan (0.10 mm (0.0039 in} 2. If clearance exceeds the specified Value, replace bearing with an under. size bearing and grind the crankshaft journal adequately. Refer to SDS. JACK SHAFT AND JACK SHAFT BUSHING JACK SHAFT BEARING CLEARANCE Journal diameters should be check- ed with a micrometer, and bearings with an inside dial gauge. Measure- ments should then be compared to determine whether bearings are worn. Max. tolerance of jack shaft bearing clearance: 0.15 mm (0.0959 in) Replacing Jack shaft bushing 1. Remove jack shaft bushings with suitable tool. 2. Install new bushings with suitable tool. Align cylinder block oil hole and bushing oil hole. —EM-14 b, Check bushing clearance, ¢. Install welch plug into block, applying sealant. ‘SeMs55| MISCELLANEOUS COMPONENTS CAMSHAFT PULLEY 1, Check tooth surface for flaws or wear. Replace pulley if any fault is found. 2. Install camshaft pulley in posi- tion and check for runout, If runout exceeds the specified Limit, replace camshaft pulley. Runout: (Total indicator reading) Less than 0.1. mm (0.004 in) ‘seMs57 TIMING BELT 1. Check for oil or water. If soaked with oil or water, replace it, 2. Check for cracks and wear. If necessary, replace it.ENGINE ASSEMBLY — E15 & E16 3. If grooves of timing belt are damaged, replace it, = Cs TENSIONER 1. Check to see that it turns smooth- ly. fit binds, replace assembly. semsse PRECAUTIONS 1, When installing sliding parts such as bearings, be sure to apply engine oil on the siding surfaces. 2. Use new packings and ol seli 3. Be sure to follow the specified order and tightening torque. 4. Applying sealant Use sealant to eliminate water and oll leaks. Do not apply too much soalant. Part requiring sealant is: Mating surfaco of oil pan guiket ‘and olf seals. 2. Check tensioner surface. If neces- sary, clean it, Do not use oil or grease. 3. Check for spring wear. If worn, replace it. FLYWHEEL 1. Check the clutch disc contact sur- face on flywheel for damage or wear Repair or replace if necessary. 2. Measure runout of the clutch disc ‘contact surface with a dial gauge. If it exceeds the specified limit, replace it. Runout: (Total indicator reading) ‘Less than 0.15 mm (0.0059 in) 3. Check tooth surfaces of ring gear for flaws or wear. Replace ifinecessary. Install ring gear on fly wheel, heat- ing ring gear to about 180 to 220°C (356 10 428°F) OIL SEAL Check front, and rear oil seals for wom or folded over sealing lip and oil leakage. If necessary, replace with a new seal. When installing a new front or rear seal, pay attention to its ‘mounting direction. It is good practice to renew oil seat whenever engine is overhauled. CYLINDER HEAD CYLINDER HEAD 1, Install valve oil seal, EM-15 semeENGINE ASSEMBLY — £15 & E16 2, Install valve component parts. ‘8. When installing valve, apply engine oil to the valvo stem and lip of valve if sal. b, Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder hoad side. head side SEMOS2 &. Make sure the valve face is free from foreign matter. 3. Install camshaft assembly. '&. Apply engine oil to camshaft and bearing interior. 'b. Be careful not to damage the bear- ing interior. © When No. 1 cylinder is sot at its ‘compression stroke, the camshaft front face is as follows, SeMse4 4. Install valve rocker shaft assem- by. 5. Install cylinder head cover. 2. Be careful not to damage oil seal b. Apply ongine face and oil sea! lip. 6. Install camshaft pulley. ©: Camshaft pulley bolt 6-8N-m (0.6 -0.8 kg-m, 4.3-5.8 ftib) ROCKER SHAFT Assemble rocker shaft in the reverse order of removal, noting the follow. ing: 1. Apply engine oil to rocker shaft and interior of valve rocker. 2. Ensure that oil hole in rocker shaft faces downward when rocker shaft is installed. 3. Also ensure that cutout in center retainer of rocker shaft faces toward exhaust manifold. 21Nm (1.6-2.1 kom, 12-15 ftb) PISTON AND CONNECTING ROD 1. Assemble pistons, piston pins and connecting rods of the designated cyl- inders. 1. Piston pin is pressed into connect ing rod, and fitting force should be within tho specified limit, Piston pin fitting foree: 49-167 KN (05 -1.5t,0.6-1.7 US ton, 0.49 - 1.48 Imp ton) EM-16 When pressing piston pin in con- necting rod, apply engine oil to pin ‘and small end of connecting rod. Kyv10107400. b. Arrange so that oil hole of connect- ing rod big end is directed toward the right side of eylinder block. ‘¢. Connecting rods are marked at side of big end for identifying the desig- nated cylinder. 4. Connecting rod with same weight ‘tolerance is available onty os a sot of four. 2. Install piston rings. Install so that stamped mark on ring faces upward, semsesENGINE ASSEMBLY — E15 & E16 ENGINE OVERALL INTERNAL PARTS First, mount cylinder block on engine stand (refer to Engine Disas- sembly). 1. Crankshaft (1) Set upper main bearings at the proper portion of cylinder block, & Only center bearing (No, 3) is a flange type. b. Front bearing (No. 1) is also the same type as rear bearing (No. 5). ©. Other inter bearings, except center bearing, are the same type. No.1 No.5 ‘bearing Center bearing No, 2& No, 4 bearing (2), Apply engine oil to main bearing surfaces in both sides of cylinder block and cap. (2) Install crankshaft. (4) Install main bearing cap and tighten bolts to specified torque. @:: Main bearing cap bolts 49-59Nm (5.0 -6.0 kgm, 36 - 43 ftb) ‘Tighten in numerical order. Loosen in reverse order. SEMS69 ‘8. Arrange the parts so that the figure fon bearing cap faces toward the water pump. b. Prior to tightening bearing cap bolts, place bearing cap in proper position by shifting crankshaft in the axial direction. ©. Tightan bearing cap botts gradually in separating two to three stages ‘and in sequence outwardly from center bearing. . After securing bearing cap bolts, ascertain that crankshaft turns smoothly by hand. (5) Make sure that there exists proper end play at crankshaft. 8, When installing oil seal retainer, ‘tivo coating of engine oll to mating shaft to prevent scratches and fold- €d lip. Also apply coating of oil to periphery of oil seal. b. Install oil seal in the direction that ‘dust seal lip faces to the outside of ‘orankease, 2. Piston with connecting rod. (1) Install them into corrésponding oylinders. ‘seMe7t 2. Apply engine oil to sliding parts. 'b, Arrange £0 that the front mark on piston head faces to the front of ‘engine. ¢. Sot piston rings as shown below. sew7a7 (2) Install connecting rod caps. @ : Connecting rod cap nuts 31-37 im (3.2 - 3.8 kg-m, (23-27 ft-lb) sems7a|ENGINE ASSEMBLY ~ E15 & E16 ‘Arrange connecting rods and con- ‘necting rod caps so that the cylinder ‘numbers face in the same direction. (@) Make sure that there exists proper end play at connecting rod big end. Refer to Inspection and Repair. 3. Rear plate and flywheel or drive plate, ©: Flywheel fixing botts 78-88N-m (8.0-9.0 kom, 58 - 65 fib) Drive plate fixing bolts 93-103 Nem (9.5 - 10.5 ke-m, 69 - 76 ftib) semsie Do not lock at ring gear. 4, Install jack shaft, Be careful not to damage the inner surface of jack shaft bushing, ‘5. Install jack shaft locating plate. 6. Install water pump assembly with new gasket. 7. Install crank oil thrower, then install cylinder block cover together with ol seal collar. Bo careful not to damage the oil seal lip. sems7a ‘8, Install jack shaft pulley. Tighten jack shaft pulley bolt by holding pulley with hand. @ : sack shaft pulley fixing bott 6-8Nm (0.6 -0.8 kg-m, 4.3-6.8 fb) 9. Install crankshaft timing pulley. sems7s| 10. Temporarily install tensioner. 11. Cylinder head assembly. Install it through gasket by accommodating knock pin of cylinder block as follows: (1) Thoroughly clean cylinder block and head surface, Do not apply sealant to any other part of cylinder block and head sur- face. @) Tum crankshaft and set No. 1 cylinder at top dead center. on compression stroke. This causes crank- shaft timing pulley mark to be aligned with cylinder block cover mark. jsems77 (3) Align camshaft pulley mark with cylinder head cover matk. This causes valves for No. 1 cylinder to position at top dead center on compression stroke. ‘Camshaft pulley mark (EIS & E16 Z engines) ‘Camshaft pulley mark (E10-and E13 engines) semseeENGINE ASSEMBLY — E15 & E16 (A) Install eylinder gasket and eylin- der head assembly. G) Tighten cylinder head bolts. @ : Cylinder head bott, 1st 39-44 Nem (4.04.5 km, 29-33 fetb) 2nd = 74 Nem (70-75 kom, 51-84 ftb) Retighten head bolts after engine has been warmed up. ‘Camshaft pulley mark lS & E16 engines) (E0 and £13 engines) seMos OO OOo Tighten in numerical order. Loosen in reverse order. semseo| ‘. Do not rotate crankshaft and cam- shaft separately, because valves will hit piston heads. b. Always use new cylinder head gas- ket. ©. There are three kinds of cylinder head bolts with different lengths. (© Install spark plugs. © :18-20Nm (15 -2.0 kgm, 11-14 feb) TIMING BELT 1, Ensure that marks on camshaft pulley and cylinder hesd cover and ‘marks on crankshaft timing pulley and cylinder block cover are properly aligned. 2. Rotate tensioner clockwise about 70 to 80° and temporarily tighten lock 3. Place timing belt on pulleys. ‘8, Whon using used belt, be sure to in- stall it with rotating direction mark facing engine rotating direction, b. Ensure that bett is not loose around jack shaft and camshaft pulleys. 4. Loosen tensioner lock mut so that tensioner pushes on timing belt. 5. Tum camshaft pulley about 20° 2 cogs) clockwise. sem7e7 6. Tighten nut while preventing ten- sioner from turning in “free” direc- tion. @ : Tensioner tock nut 16-21N-m (1.8-2.1 kom, 12-15 feb) FRONT SIDE PARTS 1. Install water pump pulley. 2. Install spacer and upper and lower dust cover. : 3. Install erankshaft pulley. ® : Crankshaft pulley bolt 113-147 Nem (115-15.0 kgm, 83-108 feb) LEFT SIDE PARTS 1, Install exhaust manifold. @:: Exhaust manifold fix 16-21Nm (1.6-2.1 kom, 12-15 feb) rut 2. Install cooler compressor bracket and power steering bracket. RIGHT SIDE PARTS 1. Insta oil pump assembly with new gasket. + Oi pump bote & nuts 91-118Nm (0.93 - 1.2 kg-m, 6.7 -8.7 fttb)ENGINE ASSEMBLY — E15 & E16 2. Install fuel pump assembly with insulator. @: Fucl pump nuts 98.4-11.8.Nem (0.93-1.2kg-m, 6.7 -8.7 feb) Always replace gaskets, 3. Install of filter. 4. Install alternator bracket and alternator. @: Alternator bracket fixing bolt 9.1-11.8N-m (0.93-1.2kgm, 67 -8.7 feb) Alternator to bracket bolt 43-58. Nem 44 -5.9 kom, 32-43 ftdb) 5. Install intake manifold with car- buretor, @ : Intake manifold fixing ruts 16-21Nm (1.6 - 2.1 kgm, 12-15 felb) EM-20 1. Install thermostat housing with distributor. © : Thermostat housing fixirig bolt 37-5.0Nm (0.38 -0.51 kg-m, 2.7 - 3.7 ft-lb) 2. Install clutch unit using Tool KV30100900. @ : Clutch unit fixing bolt 7-10Nem (0.7-1.0 kg-m, 5.17.2 feb)ENGINE SERVICE (On vehicle) — CD17 ENGINE SERVICE (On vehicle) COMPRESSION PRESSURE 1, Warm up engine sufficiently. 2, Remove spill tube assembly. To provont spill tube from broaking, remove it by gripping nozzle holder. 6. Crank engine and read gauge indi- cation. Crank speed: 200 rpm ‘Compression pressure: ‘Standard 2,942 -3,236 kPa (30 - 33 kg/em?, 427 - 469 psi) Limit 3. Remove injection nozzles and nozzle gaskets. 4. Fit compression gauge adapter to cylinder head. Gauge indication 1,961 kPa (20 kg/em? , 284 psi) Differential limit betwoon (5 kg/em?, 71 psi) 7, If the pressure is low, pour about 3 m& (0.10 US fl oz, 0.11 Imp f1 02) (of engine oil into cylinders through the nozzle hole and test again. Condition Trouble points semas? Increased reading © Piston rings are worn or damaged. Same reading maintained © Two adjacent cylinders are low, gasket is damaged. Valve is sticking. © Valve seat or valve contact surface is incorrected. EM-21ENGINE SERVICE (On vehicle) — CD17 8. Install nozzle gaskets and injec- tion nozzles. New nozzle gasket installation diree- tion is as follows: CYLINDER HEAD chamber side seresan ® : Nozzle to cylinder head 59-69.N-m (6.0-7.0k¢m, 43-51 fb). 9. Install spill tube by holding nozzle holder. ® : Spill tube nut 39-49.N-m, (4-5ko-m, 29-36 ftb) Rocker cover © w- Rocker cover get @ 27-80 iose-051, 27-271 102 (94-1044, 68 -75) @es-03 (oea0.25, Front back cover see ‘Valve stem seat Valve spring j Spring seat O02. af ‘Vale a- aT, Swirl chamber 68-76) ‘Combustion chamber) ©. = Nem (kgm, fb) (87°45,27-20 ae Front camshaft pulley semeso REMOVAL 4, Remove valve timing belt on cam- 1, Drain coolant and disconnect water hose. 2. Disconnect exhaust tube, 3. Set No. 1 cylinder at Top Dead Center on its compression stroke. shaft pulley side. 5. Remove injection timing belt. Refer to section MA for timing belt replacement. Refer to section EM for timing belt inspection. EM-22 ‘& Ensure timing belt is clean and free from oll or water when installing it. Do not bend it. 'b. Timing belt removed from camshaft pulley should not be rotated from ‘the removed position.6. Loosen pump: pulley nut and remove the pulley. ENGINE SERVICE (On vehicle) - CD17, 'ST27180001| End play limit: Remove all injection tubes, Remove cylinder head. 0.17 mm (0.0067 in) Runout limit: 0.1. men (0.004 in) 2. Remove intake and exhaust mani- fold. 3. Remove camshaft pulleys. INSPECTION AND REPAIR Mating face 1. Make a visual check for cracks and flaws, 2. Measure the: surface of oylinder hhead (on eylinder block side) for warpage. If beyond the specified limit, correct with a surface plate and grinding com- 4, Remove camshaft bracket caps. pound, Warpa oo Oo 6 oO Limit 0.1 mm (0.004 in) =! rey semoss DISASSEMBLY 1, Measure camshaft end play and camshaft pulley runout, If the end play is not within specifica. 5. Remove camshaft and cil seals. tions. replace camshaft or bracket 6. Take out valve lifter together with Correct amount limit caps. : lifter plate, (including eylinder block side If the runout is not within specifica- 7. Remove valve retaining parts, correct amount): tions replace camshaft pulley. valve spring and valves. 0.1 mm (0.004 in) EM-23cp17 Valve guide Insert the valve stem and move it back, forth and slide it. If valve stem makes a clatter and moves back and forth excessively out of line, or if it does not slide well, replace valve or valve guide, or both. Determining clearance 1. Install valve into the valve guide. 2. Measure the deflection. ‘Stem to guide clearance li (0.1 mm (0.004 in) Replacing valve guide 1, Heat cylinder head 150 to 160°C (302 to 320°F) in oil. 2, Remove the guide with suitable tool. je 2 SeMa7t 3. Drive in the new guide until it projects out 10 mm (0.39 in) seme72, 4, Ream the bore using suitable tool. Roaming bore: 7,000 - 7.015 mm (0.2756 - 0.2762 in) Combustion chambar replacement Usually combustion chamber should not be removed. However, if there are cracks or exten- sive damage, it should be replaced. 1. Remove glow plug connecting plate and glow plugs. 2. Remove combustion chamber so that cylinder head will not be dam- seMe7a Be careful not to scratch inside of nozzle hole. 3. Install combustion chamber. @) Cool combustion chamber with dry ice for approximately 5 to 10 minutes. WARNING: Do not touch cooled combustion ‘chamber with bare hands. EM-24 (2) Align combustion chamber knock pin with cylinder head notch, and install it into cylinder head using a plastic-tip hammer. sewers Valve seat insorts 1, Check valve and valve seat inserts for contact. Coat the valve face with prussian red lead. If contact is wrong, correct valve seat, If the valve red lead appears 360° around face, the valve stem and face are concentric. If not, repair or replace valve. semo7s Valve seat contact W: Intake 1.7 mm (0.067 in} Exhaust 1.8 mm (0.071 in) 2. Check valve seat inserts for any evidence of pitting on valve contact surface, and reseat or replace if worn cout excessively. Correct valve seat surface, When repairing valve saat, check valve and valve guide for wear beforchand, If worn, replace thom. Then correct valve seat,ENGINE SERVICE (On vel le) — CD17 Replacement 1. Old insert can be removed by boring it out until it collapses. The machine depth stop should be set so ‘that boring cannot continue beyond the bottom face of the insert recess in the cylinder head. 2. Select a suitable valve seat insert and check its outside diameter. 3. Machine the cylinder head recess in concentric circles which center on the valve guide. 4, Ream the cylinder head recess at room temperature. 5. Cool valve seat with dry ice for approximately 5 to 10 minutes. 6. Fit insert, ensuring that it bends fon the bottom face of its recess, and caulk more than 4 points. Resurfacing 1. Resurface the valve se toSDS. ‘Tho cutting should be done with both hands for uniform cutting. Refer oo 2. Apply small amount of fine grind- ing compound to valve contacting face and put valve into guide. Lap valve against its seat until proper valve seating is obtained. Remove valve and then clean valve and valve seat, Valve 1. Check valve head diameter, stem diameter and seat angle. Repair or replace foulty parts. emoao| 2. Check each of the intake and ex- hhaust valves for wor, damaged or ‘deformed valve head or stem. Correct or replace any valve that is faulty. 3. Valve face or valve stem end sur- face should be refaced by using a valve grinder, When valve head has been worn down to 0.5 mm (0,020 in) in-margin-thick- ‘ness, replace the vah Grinding allowance for valve stem end surface is 0.5 mm (0.020 in) or less, Valve spring 1. Check valve spring for squareness Using a steel square and surface plate. If spring is out of square “S” more than specified limit, replace with new one. Out of square: Outer 2.1 mm (0.083 in) Inner 1.9 men (0.076 in) EM-25 2. Measure the free length and the tension of each spring. Ifthe measured value exceeds the specified limit, re- place spring. Refer to SDS. M119] Valve lifter 1, Check valve lifter for scratches and excessive deformation. 2. Measure outside diameter of the lifter and inside diameter of valve lifter hole. sema7e, Valve lifter eloarance limit: (0.1mm (0.004 in)ENGINE SERVICE (On vehicle) — CD17 Lifter plate Check plate surface (cam lobe con tacting surface) for uneven wear and ‘burss. If wom unevenly, replace. If burred, smoothen with oil stone, ete. ‘Camshaft and cam bracket (Camshaft oil clearance 1. Wipe off oil from camshaft journal and bracket caps. 2. Set camshaft and lay the plasti- gage on each camshaft journal. 5. If clearance exceeds the limit; replace cam bracket caps, camshaft or cylinder head. ‘Camshaft alignment 1, Check camshaft, camshaft journal and cam surface for bend, wear or damage. If beyond the specified limits, replace the parts. Camshaft bend: 0.08 mm (0.0020 in) semis) 3. Tighten cam bracket caps, ® : Cam bracket nut 18-22Nm (1.8-2.2 kom, 13-16 fetb) Do not turn the camshaft. 4, Remove the cam bracket caps and measure the width of the Plasti- gage at its widest point. Oil clearance: ‘Standard 0.02 - 0.06 mm {0.0008 - 0.0024 in) Lit (0.1 men (0.004 in) 2. Measure camshaft cam height. If beyond the specified limit, replace camshaft. Wear limit of cam hoight: Intake 44.295 mun (1.7439 in) Exhaust 45,295 mm (1.7833 in) ASSEMBLY Assemble cylinder head in reverse order of disassembly. Note the follow. ing. 1. Drive in valve stem seal until it contacts guide. ¥ 4 xvioi07900 ( semasa 2. Set valve lifter plate so that mark faces the valve lifter side. EM-26 smaaoon Make sure that the valve lifter rotatos smoothly by hand, 3. Set camshaft and adjust valve clearance. (2) Measure valve clearance, Zoo re SMAGO7A Unit: mm (in) (2) If out of specification, remove camshaft and replace lifter plate. 8. Use thick plate when clearance is large. . Use thin plato when cloarance is small.ENGINE SERVICE (On vehicle) — CD17 4. Install cam bracket caps. @ : Cam bracket nut 18-22.Nm (18-22 kgm, 13-16 ft1b) INSTALLATION Install cylinder head in reverse order of removal. Note the following: 1, Install cylinder head with new gasket, semosa 5. Apply engine oil to new oil seal and install them. ‘The now gasket should be the same as the one which was removed. (6.0-7.0kgm, 43-51 fttb) 2nd 98-108 Nem (10.0- 11.0kem, 72-80 feb) @o9 0 9 ® 2, Install valve timing belt. ‘Be sure to use proper oil seal for front and rear as there is a difforent dia- meter for front and rear. Install oil seal so that an arrow mark (on oil soal surface is as shown below. 3. Install injection timing belt. Refer to section MA for timihg belt re- placement. Ensure timing belt is clean and free from oil or water when installing it. Do not bend it. CAMSHAFT AND CAMSHAFT OIL SEAL REPLACEMENT 1. Remove timing belts. Refer to section MA for timing belt replacement. 2. Remove front and rear camshaft pulleys. 3. Remove front and rear back Whon removing front back cover, loosen tensioner to remove the bolt at back of tensioner. : 4 © Camshaft (2) Remove cam bracket caps. (2) Remove camshaft and oil seals, EM-27 © Camshaft oll seal Do not remove camshaft. (1) Remove oil seals, (2) Insta ol seals. Refer to cylinder head for assembly. 5. Install front and rear back covers, ‘Set tensioner to free side (turn coun- ‘torclockside) after installing front back cover. : Front back cover 6.3-8.3Nm (0.64 - 0.85 kgm, 4.6-6.1 ftlb) Rear back cover 3.7-5.0Nem (0.38 -0.51 kom, 2.7-3.7 ftlb) 6. Install cylinder head. Refer to cylinder head for installation, 7. Install timing belts. Refer to section MA for timing belt replace- ‘ment. Ensure timing belt is clean and free from oil or water when installing it, Do not bond it.ENGINE SERVICE (On vehicle) — CD17 VALVE STEM SEAL REPLACEMENT 1, Remove camshaft. Refer to CAM- SHAFT AND CAMSHAFT OIL SEAL. REPLACEMENT. 2. Remove valve spring retainer 3. Replace valve stem seals. Refer to cylinder head for assembly. 4. Install cam shaft. Refer to CAM- SHAFT AND CAMSHAFT OIL SEAL. REPLACEMENT. CRANKSHAFT OIL SEAL REPLACEMENT FRONT OIL SEAL 1. Remove valve timing belt. Refer to section MA. 2. Remove oil seal. and install it. 4, Coat new oil seal with engine oil and install it, seMss2 4, Installation is the reverse order of disassembly. Refer to section LC. REAR OIL SEAL 1, Remove transmission assembly. Refer to setion MT/AT. 2. Remove flywheel. EM-28 5. Install flywheel, @ :98-108Nm (10.0- 11.0 kgm, 72-80 fttb) 6. Install transmission, Refer to section MT/AT.ENGINE COMPONENTS — CD17 ENGINE COMPONENTS OUTER PARTS Oe ; (03-05,22-34) \N ‘Alternator/compressor bracket \ b ® 16-21 (16-21, 12-18) @ 43-64 144-585,32-40) @ 91-118 (089-12,67-87) ©: Nm teem, 8) pressor 69-78 (7.0-80, 61-58) = . semoze Pump support ©, 39-49 (6-8, 29-38) Gow connecting plate Spit tube 27 Glow plug @ 18-20 (18-20, 11-14) Injection nozzle © 69-69 (6.0-7., 43-51) @ 13-18 (13-1.8,9- 13) @ 48-5015.0 -6.0, 35-43) @ 22-25(2.2-25, 16-18)O€-Wa4 ocewas re, ey N : V ? © 26-44(97-45,27-39) mn I Bm © 129-132 strainer (128-135, 90 -98 @ 10-14 (1.0-14,7- 10) Of pan © 44-56 (45-55, 33-40) ®: Nom tepm, t1b) SLUVd TWNYBLNI £109 — SLN3NOdWOD 3NIDNIENGINE DISASSEMBLY — CD17 MOUNTING ENGINE ON WORK STAND 1. Remove outer parts. 2. Install engine attachment and mount it on work stand. "$T05015000 3. Drain out engine oil and coolant. 4. Install flywheel stopper. ENGINE DISASSEMBLY ‘s127180001 a semeco 6. Remove injection pump. 7. Remove oil pan and oil pump. 8. Remove cylinder head. C18. 6.8. ENGINE OVERALL 1. Remove front side pats. 2. Remove valve timing belt. Refer to TIMING BELT REPLACE- MENT in section MA. 3. Remove rear side parts. 4. Remove injection timing belt. Refer to TIMING BELT REPLACE- MENT in section MA. 5. Loosen nut and remove injection ‘pump pulley. 9. Remove piston & connecting rod. (1) Measure connecting rod end play. If it exceeds the limit, replace con- necting rod. End play limit: (0.3 mm (0.012 in) EM-31 (2) Remove connecting rod caps and bearings. (3) Push them out toward cylinder head side. 10, Remove crankshaft. (1) Measure crankshaft end play. If the end play is not within specifica- tions, replace main bearings as a set. End play limit: 0.3 mm (0.012 in) (2) Remove main bearing caps and bearings. Do not mix the main bearings. (3) Remove oil seal retainer together with ol seal. (@ Remove crankshaft. 11, Check oil clearance, (1) Clean crankshaft journals, main ‘bearings and cap.(2) Set plastigage on each journal pin ‘and install bearing caps, Do not turn the crankshaft. © : Main bearing cap bolt 44-84.Nem (45-55 kom, 33-40 feb) @ : Connecting rod cap nut 31-37 Nem {3.2-3.8 kg-m, 23-27 ftlb) (3) Measure oil clearance. ENGINE DISASSEMBLY — CD17 Oil cloarance limit: Crank journal 0.12 mm (0.0047 in) Connecting rod 0.12 mm (0.0047 in) PISTON AND CONNECTING ROD 1, Remove piston rings with ring expander. EM-32 ‘SeMa01 2. Heat piston to between 60 and 70°C (140 and 158°F) using oil heater or hot water and take out piston pin with hand or suitable tool,INSPECTION AND REPAIR ~ CD17 INSPECTION AND REPAIR CYLINDER BLOCK 1. Visually check cylinder block for cracks or flaws. 2. Measure the top of cylinder block (Cylinder head mating face) for warp- age. If it exceeds the specified limit, comrect with surface plate and grinding compound. Warpage of surface: Limit 0.1 mm (0.004 in) ie gemoos seMoor Correct amount limit (Including cylinder head side correct amount): (0.4 mm (0.004 in) 3, Using a bore gauge, measure cylin- der bore for wear, out-of-round or taper. If, those are excessive, rebore the cylinder walls. by means. of a boring machine, Measurement should be taken along -bores for taper and around bores for out-of-round. Out-of-round: xY 0.20 mm (0.0079 in) Taper: "ABS 0.20 mm (0.0079 in} Unit: mm Gn) seMoo2 4, When wear, taper or out-of-round is minor and within the limit, remove the step at the topmost portion of cylinder using a ridge reamer or other similar tool. CYLINDER BORING CAUTION: a. To provent strain due to cutting hhoat, bore the cylinders in the order of 241-3, bb. Before boring any cylinder, install main bearing caps in place and tighten to the specification so that the crankshaft bearing bores will not become distorted from the boring operation. . All oylinders should be bored at the same time. 4. The amount cut at one time should bbe 0.06 mm (0.0020 in). @. Check piston and cylinder clear- ance, {. Check cylinder bore for outof- round and taper Refer to SDS. ‘Measuring piston-to-eylinder clearance Check piston and cylinder clearance. Feoler gauge used: 0.05 - 0.07 mm (0.0020 - 0.0028 in) Extracting force: 147 -17.7N (15-18 kg, 33-40 1b) When measuring clearance, slowly pull feoler gauge straight upward. EM-33 01 9!) senso PISTON, PISTON PIN AND PISTON RING PISTON 1, Scrape carbon off piston and ring ‘gooves with a carbon scraper and & ‘curved steel wire. The wire’ will be useful in cleaning bottom land of ring groove. Clean out oil slots in bottom land of oil ring groove. 2. Check for damage, scratches and wear, Replace if such a fault is de- tected. 3. Check for wear. 79.94 -79,99 mm (3.1472.- 3.1492 in) PISTON RING 1. Measure the side clearance of rings in ring grooves as each ring is installed. If side clearance exceeds the specified mit, replace piston together with piston ring.INSPECTION AND REPAIR — CD17 Side clearance: Top ring (0.20 mm (0.0079 in) Second ring (0.16 mm (0.0059 in) it ring (0.10 mm (0.0039 in) 2, Measure ring gap with a feeler sauge, placing ing squarely in cylinder using piston, Ring should be placed to diameter at upper or lower limit of ring travel. If ring gap exceeds the specified limit, replace ring. Ring oop: Top ring 1.0 mm (0,039 in) Second ring 0,7 mm (0.028 in) Oit ring 0.6 mm (0.024 in) When piston ring only is to be re- placed, without cylinder hore being corrected, measure the gap at the bot- tom of cylinder where the wear is PISTON PIN Check piston pin and piston pin hole for signs of sticking and other ab- normalities. CONNECTING ROD 1. If a connecting rod has any flaw ‘on both sides of the thrust face and the large end, correct or replace it. 2. Check connecting rod for bend or torsion using a connecting rod aligner. If bend or torsion exceeds the limit, correct or replace. Bend and torsion per 100 mm (3.94 in) length) = ‘Standard Bend Less than 0.15 mm. (0.0059 in) Torsion Less than 0.30 mm_ (0.0118 in) CONNECTING ROD BEARING REPLACEMENT 1. Replace bearing with suitable tool and press. Align ol ote on semo07 2. Grind the bore, 24.025 - 24.038 mm (0.9459 - 0.9464 in) CRANKSHAFT CRANK JOURNAL AND PIN 1. Repair or replace as required. If faults are minor, correct with fine crocus cloth. 2. Check journals and crank pins for taper and out-of-round. If outof-round or taper exceeds the specified limit, replace. Out-of-round (X-VI: it 0.03 mm (0.0012 in) Taper (4-8): Limit 0.03 mm (0.0012 in) ‘. Coat new bearing with engine oil, b. Align oil hole. EM-34 i 3. Check crankshaft for runout. If bend exceeds the specified limit, replace.INSPECTION: AND REPAIR — CD17 Runout: Limit 0.05 mm (0.0020 in) MISCELLANEOUS COMPONENTS: TIMING BELT CAUTION: ‘a, Do not bend, twist or tum the belt inside out. b. Ensure timing belt is clean and free from oil or water when install 1. Cheek for oil or water. If soaked with oil or water, replace it. 2. Check for cracks and wear on the belt face. If there is noticeable cracks for wear, check the tensioner pulley. If necessary, replace it. 3. Check for cracks and damage on the cog face. If there is noticeable ‘racks or damage, check if any pulleys are locked. ‘TENSIONER, 1. Check to see that it tums smooth- ly. If it binds, replace assembly. 2. Check tensioner surface. If neces- sary, clean it, Do not use oil or grease. 3. Check for spring wear. If wor, replace it. EM-35 PULLEY 1, Remove oil and clean. 2. Check for harmful burrs. If burr- ed, smoothen with oil stone, et. FLYWHEEL 1. Check the clutch disc contact surface on flywheel for damage or ‘wear. Repair or replace if necessary. 2, Measure runout of the clutch disc contact surface with a dial gauge. If it exceeds the specified limit, replace it. Runout: (Total indicator reading) Limit 0.15 mm (0.0059 in) 3. Check tooth surfaces of ring gear for flaws or wear. Replace if necessary. Replace ring gear, at about 180 to 220°C (356 to 428°F).ENGINE ASSEMBLY — CD17 PISTON AND CONNECTING ROD a, Ensure connect piston leaf are tion. rod oil hole and the same direc Grade mark sewa12 bb Ensure mark side of ring faces up. ¢. Align teflon tube and ring gap. . , Make sure that the expander coil joint is at opposite side of ring gap. ‘efi tube set position semat4, 1. Heat piston to between 60 and 70°C (140 and 158°F) using oil heater or hot water and install the pin. 2. Install the snap rings. 3. Install piston rings. ENGINE OVERALL 1. Install crankshaft. (2) Set main bearings on block. 4. Do not coat block side and back of the bearings with oil, ENGINE ASSEMBLY b. The block side bearing has an oil hole and oil groove but cap side does not. (2) Install crankshaft, (3) Install main bearings and caps. ® : Main bearing cap bolt 44-54N-m (4.5 -5.5 kom, 33-40 ftlb) Make sure that crankshaft rotates smoothly by hand. @) Install rear oil seal retainer, © : Oit seal retainer 6.3-8.3Nm (0.64-0.85 kgm, 4.6- 6.1 ftlb) (S) Measure the end play. 2._ Install piston and connecting rod, (1) Set piston rings as shown below. (2) Install piston into corresponding cylinders. Ensure number on piston head faces front side. (3) Install connecting rod caps. ® : Connecting rod cap nut 31-37 Nm {3.2 -3.8 kom, 23-27 feb) ‘© Apply engine oll to thread and seat. © Ensure connecting rod numnbors are aligned. (4) Measure the end play. 3. Select cylinder head gasket. (1) Clean cylinder block surface. (2) Measure all piston projections. \\ semoro| Be sure to measure the projection at two points for every cylinder. Oiling me Z tube f EM-36ENGINE ASSEMBLY - CD17 G) Obtain average values of all piston projections and then determine gaskets to be used. Relation between piston projection and cylinder head gasket eae ah ee Number of, JGrade | Average values piston projections | Gasket thickness | Number 9 A. | Less than 0.52 (0.0205) 1.15 (0.0453) 1 B_ | 0.52-0.57 (0.0205 -0.0224) 1,20(0.0472) 2 | More than 0.57 (0.0224) 1.25 (0.0492) 3 ‘When maximum value of piston pro- — @ : Cylinder head bolt {ection is larger by 0.050 mm (0.0020 Ist in) than the average values of piston 59-69N-m projections in each grade, use a gasket (6.0-7.0kgm, Which is 1 grade thicker. 43-51 feb) 4. Install cylinder head, and (1) Make sure that No. 1 cylinder is 98-108 Nem at Top Dead Center. (10.0-11.0 kom, 72-80 flb) (2) Make sure that No. 1 cam of cam- shaft is inthe position as shown, (@) Tighten cylinder head bolts in the order shown. semoas INSTALLING VALVE TIMING BELT 1, Install water pump. +: Water pump to eylinder block © 16-20Nm (16-2.0kg-m, 12-14 feb) © 16-21Nm (16-21 kgm, 12-15 fetb) Install camshaft pulley. +: Camshaft pulley bolt 92-102 Nem (9.4- 10.4 ke-m, 68 - 75 felb) @r 3. Install oil pump and oil pan, Refer to section LC. 4, Install crank pulley plate. 5. Install valve timing belt. Refer to TIMING BELT REPLACE- ‘MENT in section MA. ©: Dust cover 3-5Nm (03-05 kom, 2.2 -3.6 felb)ENGINE ASSEMBLY — CD17 6, Install crank damper pulley. @ : Crank damper pulley bolt 123-132 Nem (12.5 -13.5 kom, 90-98 ft-lb) INSTALLING NECTION TIMING BELT 1. Install water pipe. 2. Set pump support before install ing back cover. © : Injection pump bracket support 24-27.Nm (24-2.8k¢m, 17-20 felb) semore 3. Install camshaft pulley. ® : Comshatt pulley bott 92-102 N-m (9.4104 ko-m, 68 - 75 ft-lb) 4. Install injection nozzles, glow plugs and glow connecting plate. @ : Glow plug to cylinder head 15-20 Nem (15-20 kom, 11-14 fttb) Nozzle to cylinder head 59-69.Nm (6.0-7.0 kom, 43-51 ft4b) 5. Install injection pump bracket and injection pump temporarily EM-38 6. Adjust injection timing. Refer to ADJUSTING INJECTION TIMING in section MA. ® : Pump bracket bolt mito 31-37 Nm (3.2-3.8kgm, 23-27 feb) ws 16-21Nm (16-21 kom, 12-16 fttb) 7. Install injection pump pulley ® : Injection pump pulley 59-69 Nam (6.0-7.0 kgm, 43-51 felb) 8. Install injection timing belt. Refer to TIMING BELT REPLACE- MENT in section MA.SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 SERVICE DATA AND SPECIFICATIONS (S.D.S:) : Co IE18 & E16) ave guide Unit mm tin) Siders sevice INSPECTION AND ADJUSTMENT vate auige 2009. 12006 | vaa8e 12.278 CYLINDER HEAD Outer diameter (0.4737 - 0.4742) | (0.4828 -0,4832) Unit: nin awe aide Inner amet 7.008. 7.020 (02788-02764) bemoan [Finished size) Tied toe Haines | ont, | 0.1 (ooo Cylinder head vave | 11.970-11.988 | 12.200-12211 . fuideholecomerer | (04713-04720) | (04803-04807 inverteence of vone = 0.048 -0.074,0.0018- 0.0020) VALVE Unit: mm tin) Stender 02-008 Intake aut ‘Sean, 0.0008 - 0.0020) toate 0. 0.008) couse 0048-0076, a Exhaust | (0.0018 - 0.0080) ate detection iit 02 (0.008) a Valve seat Unit:_mm (ind INTAKE semse| Standard J Teak 370 0.A8n a ‘lamer “0 eeu woo en 1.5 (0.059) Ca a6 ee eee ‘2 | 50", mune | 1ea-1190 | 1184-1170 ; ao (aee-ae0) | tas8-aen) ' t ~ Exhaun | 11775-11838 | 11575-11635 (pe.4ee) | 36-40 “Ba (384-1360 dia 6.970 - 6.985 (0.2744 -0.2750) ees see et ee 7 (1487-1448) i. 948 6860 (02794-02780) sears Valve face angle 48°18" - 45°45" ee Standard Vale magia Vane 3 ate nem end wrtace aero 1.8 (0.071) Free beioht 46,70 (18906) [ ‘Assembled big 30.2770.78 Tmm/N (mmf, ino) | (0.22.40, 1849/5168) Out of square “S” mm (in) 2.0 (0.079) aa eee rheies ae. seuss EM-39SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 ‘CAMSHAFT AND CAMSHAFT BEARING JACK SHAFT AND JACK SHAFT BUSHING ‘Unt me Unie: an Gnd ‘Standard ‘Max. tolerence Terre tte rn sk satura Cana out to esi 0020-0098 cane ura = Shoe 02-2288. 945 0.0801 ser. 138 | ggts-297%, | os 0.080) mR 078-0110 Taser amar eR | .000—52065 (2606-1 Bo) no.2.4 | 007-2118 | 920 0070 ton dame Setnng aR | ane20- 25005 (1260-11250 teow meer ot | an000-«a028 | —_ Cimanetteowig | 658) Orman eR _| atge7 anon nate 12500 eka Outer tre of foumal RR) ane7- 20600 07288-11280) carat oom We. | 19-4305 sects ondpiny | 0048-0.105 00010-a0041 S Pet pure em No.2,4 | 41.906 -41.922 eume fe (1.6498 - 1.6505) camiotebonarraney | gtr, | 0.1 0.008) dD oa 038-020 canmatindoiy — | ,838-929 | asia some oy me-279 conan (1.094 1.086) = CYLINDER BLOCK ‘Unit: me tin) smear | ert tur rare Burts tne aman, | ero 0000 Trose [ant -a0rae Warze- aaa canto ioe nse eae Exheon | ant 9590 04001-14130) Gamer _|2oee"- zoo) | (oo000 rs : ar rertaa omg anna one [20 | nn : tow” |romt | Seip tones * Ys nde ating ton | uaa [ ie) | ce oom iter n tae an | ow on [ orbetwnen pincers” | 008 0020) Pinon cence» | azo 000 : nar bck tooo cot EM-40SERVICE DATA AND SPECIFICATIONS — E15, E16.& CD17 PISTON, PISTON RING AND PISTON PIN CONNECTING ROD [Unit imi Bend, tonion 32° 100 mm Limit (394 in) 10.05 (0.0020) Piston pin bore di, 18.962 - 18.978 (0.7465 - 0.7472) Standard | 0.1 -0.57 (0.004 -0.0146) Big ond play Limit (05 (0.020) CRANKSHAFT Unit: mem find ‘Main journal dia, “Drm” 49.943 - 49,984 (1.9863 - 1.9671) Pin journal ai. “Op” 39.954 - 39,974 (1.5750- 1.5738) ‘Outotround | standara OCY) and ‘Less than 0,01 (0,0004) taperita.e) | Umit (0.03 10.0012) ‘Standerd] Less than 0.05 (0.0020), (Bond (7.1.F.) Limit 0.10 10.0038) Standard] 0.05 0.18 (0.0020 -0,0071) Free end play Limit (030 10.0118) Piston ne "eae reav7 ‘Standard (2.9908 - 2.9928) Pani 7087-76007 Serer coaroowe)| 7598-76007 ‘a Oversize re? -78817 280 co.or971 (3.0108 - 3.0125) “¥ non 75 680 = ‘oa 0002 Pon pa oe cores 07) n ring Unit: mm fin) a Tre cow 0078 oo (0.0016 - 0.0029) ; 2 0008 sin [| om ones Somes ‘ooo -aceae erate amen osea ua coats -oa0sn " 0.20-0.35 To (0.0079 - 0.0138) Ring gap | 2nd” 1.0 (0.039) on tan) Piston pin 7 Unit: mm (in) Pion nor demeer | 18995-19000 (07478-07480) fieonpintiton | ggnp.o0r2 000-0008) imarownes tot pian Inwreeretotiten | gory. oan 0a007 00018) EM-41SERVICE DATA AND SPECIFICATIONS — E15, 16 & CD17 BEARING Main bearing undersize Units me iad Bearing clearance ‘Crank main journal iometer Except MP.G. model foweat ale ania Standard 49.943 - 49.966 (1.9663- 1.9671) ee tne 0.25 0.0098) | 49.701 - 49.714 (1.9567 - 1.9572) ee eee Undersizo | 0:50(0.0187) | 49.461 - 49.464 (1.9460 1.9674) Nos. + and a (0.0012 -0.0030) 75 (06 201 «49.214 (1.9970 1.9376) Cane 0.76 (0.0298) [49.201 - 49.214 (1.9370 Now2dana4 | oot? 0.0008) Connecting rod bearing undersizo Connecting rod bearing | 0.050 -0,080 Unter Dad clearance {o.0012- 0.0024) | 9412 0.0090) (Crank pin journel diameter “Dp” MPG. model Standard 99.954. 39,974 (1.5730. 1.5738) Unit: mm tn 0.08 (0.0031) | 30.974 20.004 (1.5608 1.5706) Standerd Limit 0.28 (0.0068) | 30.704 -9.726 1.8631 - 1.5690) Undersize Main bosrng clearance 0.50 /0.0197) | 39.4547-09.474 (1.5539. 1.5541) Nos. 1,3 and sora eee) | 9-10-0.0030) F ooo1g-o-00s0) | © 0.78 (0.0798) [20.206 39.224 (1.5495 1.5442) 0.081 -0.082 Nos. 2and 4 (0m 082.) | 0.10 0.0038) asa ; MISCELLANEOUS COMPONENTS nneeting rod besring | 0.030--0.060 clearance (o012-0.0024) | 94100-0088) Unit: mm find ‘Camshaft pulley msn en Les than 0.1 0.008) Fives! = Runout (T.L.R.] Serenata EM-42SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 TIGHTENING TORQUE Engine outer parts Engine internal parts EM-43 eet test eal ine aE [eat gases isiesioasair’ |feicna Gas See [tote [Temata isemcresered celeste | Seamer oa sara] ote san francs |itmas Clutch cowrfixingbott | 7-10 | o7-10 | 81-72 eee eal Sasa aaa cae eee (ae zm | [eaemrmron Tap.no |oan-osr| a7-ar = a See sree | uaa [tar emcee [ues [ooo | ase | [eesmnn [em | eemsf oe ter] [mre [aso [oawsnnt 33-9 ao Doo meee eras rare) | | oomarece| as csi[eoran eared sic Raintmanooneel aes aa fixing bolt oe oe econ ‘Tensioner lock nut 16-21 12-168 mnraacarel|isiccollewtenifisrasl| [reese iam ar sarees [enteral Goes asia eaeoel iar ar-anll oe Saison aaa |acealiieswe Sater i iazcent[aarramnliarst anweetan | wee as ieee Pw ‘eacescecesea|fassnad| ocs-eor fataSERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 (Pesaeeeeeeecea| ODA ¢ (seaaaeecceseeeea vee oe Free height vam fin) Outer 46.40 (1.8268) INSPECTION AND ADJUSTMENT CYLINDER HEAD —: oo Unit: mm (in) ‘Assembled height ‘mmiN (mm, nb) Heed surface fate eae 305/150.0 ‘Standard Less than 0.05 (0.0020) (99.5/183, 1.585/33.7) Limit = 0.1 (0.004) ie 36.0/88.3 (96.0787, 1.417/19.2) ‘Out of square ‘en tind Outer 21(0083) VALVE Inner 1.910.075) Unit: em (nd T Valve guide Unit: mm (ind Standard Service Volve guide 5 11.023 - 11.034 et cae (0.4240 0.4944) semsee 7.000 -7.018. a (0.2786 -0.2763) ‘Valve head diameter “O* - Intake 36.00 (1.4173) Cylinder hoad valve guide 10,975 - 10.996 hole diameter (0.4321 -0.4329) Exhaust 31.00 (1.2208) Interference fit of vlve ‘Valve length “L? ul ia 100.48 - 100.750 (3.9847 -3.9665) oe 100.28-100:880 ‘Stem to guide clearance (2.9468 -3.0087) Intake 0.1,(0.04) ‘Velve stom diameter “a” eas 6.965 -6.980 Exhaust 0.1 (0.08) (0.2742 -0.2748) exhaust 945-6900 Valve deflection timit 02 (0.008) (0.2734 -0.2740) Valve set angle “a! 45°30" Valve marg oT" Limit 05 (0.020) ‘Valve stem end surface grinding 05 020) EM-44SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 Valve seat resurfacing Unie: mm ta} CAMSHAFT AND CAMSHAFT BEARING ist Unit: mam (in) ‘Standerd ‘Standard Max. tolerance ‘Camshaft journal to 0.02 -0.06 fe v bearing clearance (0.0008 -0.0028) 91 0.004) Inner dlamater of ‘30.000 - 30.021 camshaft bearing (1.1811-1.1819) - ‘Outer diameter of 28.960 -29.980 2,920.05 - (0.11420.0020) ‘camshaft journal (1.1795 - 1.1803) ‘Camshaft bend beyapeat (0.08 10.0020) 0.02 (0.0008) > ‘Camchaft end play 0.17 (0.0067) eae semor7 Standerd a eMe71 3,220.05 ‘Cam height “A (.126+0.0020) Intake (44.495 - 44.500 (1.7518 - 1.7820) sn gun tte ial Exhaust 45.495 «46,600 (1.7911 - 1.7913) ‘Wear limit of cam height 0.18 (0.0080) 4s CYLINDER BLOCK Units mm ind VALVE LIFTER Units mm Gnd a tone) ‘Valve fer outer ameter 34.959 -34.975 Standard (13763 -1.3770) on ee (23,1496 -3.1816) ‘Cylinder heed valve lifter hole 34.988 -35.013 ciamator (13775-1.3785) indi ame Cearanes Outofround (XY) ‘Wear limit 0:2(0.008) 0.013 -0.084 eee (0.0005 - 0.0021) Limit ieee 0.2 (0,008 Difference in inner between cylinders = eae =o Bama monoamaans cons pa ‘Fooler gauge extracting force [with gauge thickness 0.08 mm (0.0024 in)) NN Cig, to) 78-147 (08-18,18-3.) EM-45SERVICE DATA AND SPECIFICATIONS — £15, E16 & CD17 Cylinder boring Unit: mm fn) Piston size ‘vlinder hone diameter 120.500 - 80.560 eee (3.1693 -3.1713) 81.000-61.050 erent (3.1890. 3.1900) PISTON, PISTON RING AND PISTON PIN Piston Piston skirt lametor 79.98.7999 Stonderd (3.1472-3.1492) 05 (0.020) coven! 110 (0.038), ‘Measure position (From top) 60 (2.36) eee 723.991 - 23.990 eae (0.9445 - 0.9448) Piston ring Unt a Thame oe sana lonne 00020 tun 02,0208) wma fo contie-2oosn unt 018 0088 3 Senn tocora 0.0028) un 21 0008 Fras 2 tooo 02138 Lin 1910030 ws Sondre vost -2atae Lint a7 02m Tai ate oo omews woaita-aorm Line 05 0220 Piston pin Ua Fon in ute det eae Piston pin to piston clearance (0 -0.008 (0 -0.0002 Interference fit of piston pin to.connecting rod 0.028 - 0.044 (0.0010 -0.0017) CONNECTING ROD Unit: mm (in) ‘Bend (per 100 mm (3.98 int] Standard han 0.16 (0.0069) Torsion ‘Standard Les than 0.30 (0.0118) "24,026 - 24.088 Piston pin bore oe ones Big end pay Limit 0.3 (0.012) EM-46SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 CRANKSHAFT Unit: enfin) 52951 -52.964 anne (2.0847 - 2.0852) 44.961 44.974 Pin journal dia ee ‘Qut-ofound (X-¥) and taper ws Standard Les than 0.01 (0.0008) Limit 0.03 (0.0012) ‘Bend ‘Standard Less than 0.025 (0.0010) 0.05 (0.0020) 0.05 -0.18 (0.0020-0.0071) BEARING Daring cearance ‘an berins dooms Sree (o00rs ooze) Lint 0.2 tooo etn a bring race oe woos 02028) Lint our 10.0047) MISCELLANEOUS COMPONENTS Unit: mm (ind (Camshaft sprocket unout (71.7) Less than 0.1 (0.004) Flywhoo! unout (7.7) ‘Less thon 0.16 (0.0059) TIGHTENING TORQUE ENGINE OUTER PARTS Unit ‘Adjusting bar to engine mounting Alternator bracket ‘Alternator to bracket Alternator to adjusting bor ‘Compressor bracket ‘Compressor to bracket (Crank damper pulley bolt Front dust cover Engine mounting bracket Engine stinger Glow plug to ylinder head {eer pulley bracket {elor pulley nut Injection pump nut Injection pump bracket M10 Injection pump bracket Injection pump to rear bracket Injection pump bracket support Injection pump pulley nut Injection tube fare nut Nozzle to eylindor heed Manifold (ter brackat Far dust cover EGR. waive E.G. tube fare nut EM-47 Nem 16-21 43-68 49-59 er-n8 0-78 43-54 123-132 3-8 44-54 30-40 18-20 16-21 19-25 13-18 31-37 16-21 24-27 49-59 2-27 59-69 72-25 50-69 18-22 16-21 1-3 18-23 48 kom 16-24 44-59 50-60 099-12 70-80 44-55 125-135 03-05 45-55 34-44 18-20 18-24 19-26 13-18 32-38 16-24 24-28 50-60 24-28 60-70 22-25 60-70 19-22 16-24 04-03 18-23 35-45 Teb 12-18 32-43 26-43 67-07 51-58 32-40 22-36 33-40 22-30 We14 12-18 14-19 9-13 23-27 12-5 17-20 36-43 17-20 43-81 16-18 43-81 13-16 12-18 07-22 13-17 23-33SERVICE DATA AND SPECIFICATIONS — E15, E16 & CD17 ENGINE BODY PART ni Nem kom ft ‘Cam bracket nut 18-2 18-22 13-16 ‘Camshatt pulley bolt «92-102 84-104 68-75 Connectingrodesprut «31-37 3.2-38 28-27 ‘vind hesd bot te 59-69 60-70 2nd 98-108 100-110 Front back cover 3-83 064-086 Front tensioner 38-4837 Flywheel 98-108 100-110 72-80 leer pulley bolt 36-46 37-48 27-33 Moin besringeapbolt 44-54 45-55 33-40 i pen 5-7 05-07 36-6: Ot pan cra plug 37-48 98-48 77-33 il pump tocylinder block 12-16 12-18 9-12 i strainer 0-16 10-44 0 sea retainer 65-83 064-085 Roar back cover 37-50 0338-051 Rear tonsionor 16-21 18-28 Rocker cover 1-3 04-03 Water pump tocylinder 16.20 16-20 block 16-21 18-21 Wotar dein plug 64-74 55-75 EM-48SPECIAL SERVICE TOOLS — E15, E16 & CD17 SPECIAL SERVICE TOOLS CIE15 & E167) Tool number ae (Kent-Moore No.) | Toolmame 'sT05018000 Engine stand assembly 926023) @ stos011000 Engine stand (26023-2) @® s105012000 Base 26023-1) Engine attachment assembly Okvioo710 Engine attachment aes ® kv10102500 Sub attachment 726097) @ st11081000 | Reamer (12.2 mm (0.480 in) dia.) 256183) @kv10107700 | [7mm (0.28 in) dia] (925618-2) ® Ca ® KV10107500 Valve lip seal drift Cie): Kv10107280 Valve spring compressor Cae), @kvioio7210 Handle eee @xkvi0107220 Gea) EM-49SPECIAL SERVICE TOOLS — E15, £16 & CD17 Tool number Seana, (Kent-Moore No.) Ev1o10740 Piston pin pres stand Oxnors.0 Center shaft ® @sisowor0 | sunt ® sn s4oc30 C - ) @kv10107320 eee | @st13040050 Ca) ‘Spring f V30101000 ¢ d (Clutch aligning bar eS KV10107900 ¢ d Valve lip seal puller \SPECIAL SERVICE TOOLS ~ E15, E16 & CD17 [eereeeeeece CD Ag ference mnan Tool number (Kent Moore No) | Teolname '$T0501S000 Engine stand assembly (26023) @ st0so11000 Engine stand (26023-2) ® s105012000 Bose (26023-1) ® Kvi0i08101 | Engine attachment - ) ® kv10106500 | Engine stand shaft @ Ce): or ® Kv10102500 26097) a e ? KV10108980 Valve lifter c-) @ Kvi0108910 Body Heed eee): ® kv10108920 ¢ ) off KV10107900 Valve lip seal puller \ Kv1010s6s0 Engine stopper re @ kvi0105610 ae). ® kvi10105630 ¢ ) EM-51SPECIAL SERVICE TOOLS — E15, E16.& CD17 ‘Tool number (Kent-Moore No.) || Too!name KV101092S0 ‘Valve spring compressor c-) @ kKvi0109210 Compressor C- @® Kv10109220 Adapter c=) KV10109300 Pulley holder os) ED19600000 Compression gauge set c-) KV11100300 ‘Nozzle holder socket i Ge EM-52ENGINE LUBRICATION & COOLING SYSTEMS eee Lo CONTENTS CEs & £16 eS) ENGINE LUBRICATION SYSTEM Lc. 2 Lubrication circuit . Le. 2 i Lc- 3 Le. 4 TEM . COOLING Le. 5 Cooling circuit Le 5 Water pump .. Le- 6 Thermostat. . Le. 7 Radiator and cooling fan. Le- 8 eS =Iepa7 rd LUBRICATION SYSTEM ~ LC Lubrication circuit . Lc Oil pump . Le12 Oil pressure regulator valve Lc-13 Oil pressure relief valve . Lc-13 Oil cooler... Le13 COOLING SYSTEM . Le-15 Cooling circuit Lc-15 Radiator and electric cooling fan ...... LC-16 ‘Thermostat . . Lets Water pump .... Lc-19 CO JE15, £16 & cp17(_ SERVICE DATA AND SPECIFICATIONS (S.D.S.) . Engine lubrication system Engine cooling system . Inspection and adjustment Tightening torque SPECIAL SERVICE ~ LC-20 LC-20 Lc-20 Lc-21 Lc-21 Lc-22ENGINE LUBRICATION SYSTEM — E15 & E16 ENGINE LUBRICATION SYSTEM LUBRICATION CIRCUIT Lc-2 Note: ON 5.160 392 (4,57) *ore) bial Pump unit Unit: mm fa) TIGHTENING TORQUE utor rotor to body clearance es o 0.12 (0.00471 Unit nm | kom | fi 015-021 Rotor tip lerance @) istine aaoaal wawroumoweniog | ote | o9.14 | 65-101 {Gap betwean outer rotor and inner Lass than arcana rotor @ 0.06 (0.00201 bie s-11 | os-11 | 58-80 Gap between rotor and body @) | Lest than 0.02 (0.0008) TIGHTENING TORQUE Unit nm | kom | feb Sree wernebor Torre | 093-12 | 67-07 Olipumpcovrbo | 38-61 [029-082 | 28-08 Regulator valve copnut | 30-49 | 40-80 | 20-06 Lc-20.SERVICE DATA AND SPECII E15, E16 & CD17 C= OY eee) INSPECTION AND ADJUSTMENT 1 PUMP Unit: eam in) 0.17-02 ‘ody to outer ger clearance fants ‘oadil 012-023 Inner gear to crescent clearance aoa onl 021-032 ‘Outer gear to crescent clearance mas oni RADIATOR Unit: KPa Ukalem?, pal (Cap relat pressure 3810.9, 13) 187 (16,23) Leakage test pressure ‘THERMOSTAT ‘Standard Frigld type ‘Valve opening temperature °C FF) 82(180) 88 (190), 8198 8/100 Mox-vae merclinF) 937203) (031/212) WATER PUMP ‘Alternator belt deflection 9-15 (0.35 -0.59)/ {inl Cg, to) 98 (10,22) TIGHTENING TORQUE Unit Naw kom ft (Oil pumpmountingbolk 12-16 «12-16 9-12 (011 pump cover bolt a8 04-05 29-36 Olt pan 5-7 08-07 36-51 Oil cooler fixing bok = 16-21 18-21 12-18, gulator valve cap 99-49 4-5 28-38 ‘Water pum securing 16-20 12-14 bolt 2-15 Lc-21SPECIAL SERVICE TOOLS —E15-.& E16 SPECIAL SERVICE TOOLS rie (Kent-Moore No.) Tool name 8725051001 Oil pressure gauge (025695-1) ST25052000 Hose 28695.) O $T25053000 Joint pipe (25695-3) . $T25054000 Adapter (625695-4) oreseiso1 CP & (Part No.) Lc-22ENGINE FUEL & EMISSION CONTROL SYSTEM CONTENTS ENGINE AND EMISSION CONTROL SYSTEM CHART OF ELECTRONIC CONTROLLED CARBURETOR (E16 E.C.C.) ENGINE FOR CALIFORNIA .... ENGINE AND EMISSION CONTROL SYSTEM. DIAGRAM A OF E16 E.C.C, ENGINE FOR CALIFORNIA ...... ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B OF E16 E.C.C. ENGINE FOR CALIFORNIA : ENGINE AND EMISSION CONTROL SYSTEM TABLE OF CARBURETOR ENGINES FOR NON-CALIFORNIA............ EF&EC- 6 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM EF&EC 3 - EF REC 4 EF REC 5 A FOR NON-CALIFORNIA ......EF &EC- 7 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR NON-CALIFORNIA......EF&EC- 8 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM A FOR NON-CALIFORNIA OF HIGH ALTITUDES ENGINE AND EMI CONTROL SYSTEM DIAGRAM B FOR NON-CALIFORNIA OF HIGH ALTITUDES . ENGINE AND EMISSION CONTROL SYSTEM CHART OF ELECTRONIC CONTROLLED CARBURETOR (E.C.C.) ENGINE FOR MP.G. .... EF&EC- 9 EF &EC- 10 EF &EC. 11 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM A OF E.C.C. ENGINE FOR MPG. EF &EC- 12 ENGINE AND EMISSION — CONTROL: SYSTEM DIAGRAM B OF E.C.C. ENGINE FOR MPG. ve csscestecesee eee neees EF & EC- 13 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM A FOR CANADA........ EF &EC- 14 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR CANADA .. EF &EC- 15 ELECTRICAL CIRCUIT DIAGRAM . -EF &EC- 16 E.C.C. circuit diagram (California) ... 02.0.2... 26 ee EF & EC 16 E.C.C. circuit diagram (MPG) . sos EF & EC: 17 Electrical circuit of emission control system (Non-California) - +. EF &EC 18 Electrical circuit of emission control systems (Canada) - EF & EC: 19 DIAGNOSTIC PROCEDURE FOR PROBLEMS .............. EF & EC: 20 Diagnostic procedure for E.C.C. engine .... ces es EF & EC: 20 Diagnostic procedure for carburetor engine . cesses EF &EC 30 AUTOMATIC TEMPERATURE CONTROL (A.T.C.) AIR CLEANER ... EF &EC- 37 Operation -- EF & EC 37 Inspection . EF &EC- 38CONTENTS IDLE. COMPENSATOR Description . Inspection . FUEL FILTER . Description .. FUEL PUMP Operating test ..... Inspection ....... CARBURETOR Structure and operation Inspection and adjustment Major service operation ..... CRANKCASE EMISSION CONTROL SYSTEM....... Description . Inspection EXHAUST EMISSION. CONTROL SYSTEM........ Air induction system (Non-California models) . . Air induction system (MP.G. models) . Exhaust gas recirculation (E.G.R.) control system Air -fuel ratio control system . . Fuel shut-off system (Non- California models) Fuel sutoff system (California models) . . . Fuel shut-off system EF & EC. 39 EF &EC- 39 LER &EC- 39 .. EF & EC: 39 EF &EC- 39 EF & EC: 40 - EF & EC: 40 - EF & EC: 40 EF &EC 41 EF & EC. 46 EF & EC- 61 EF & EC: 59 EF &EC- 60 EF &EC- 60 EF &EC- 60 . EF & EC 61 EF & EC: 61 EF & EC. 63 EF &EC- 64 EF &EC- 69 EF & EC: 73, ++ EF & EC: 76 (MP.G. models) ............. Catalyst warm-up system (M.P.G. modetsh ......... Mixture heating system (Non-California and Canada models) ‘Spark timing control system .. . Throttle opener control system (T.0.C.S.) for Canada . . EF & EC. 7 EF & EC. 79 EF &EC- 80 EF & EC- 82 EF & EC: 83 Catalytic converter on ‘Vacuum hoses of emission control systems ........... : HIGH ALTITUDE EMISSION CONTROL SYSTEM Description... Installation and modification procedure . ce EVAPORATIVE EMISSION CONTROL SYSTEM........ Description Operation ....... Inspection a INJECTION SYSTEM .. Injection pump Fue! supply control system Checking priming pump . . Injection nozzle assembly... .. EMISSION CONTROL DEVICE GENERAL DESCRIPTION... CRANKCASE EMISSION CONTROL SYSTEM Description .. . Inspection ...... EXHAUST EMISSION CONTROL SYSTEM....... Description Exhaust gas recirculation (E.G.R.) control system High altitude emission control system SERVICE DATA Al SPECIFICATIONS (S.D.S. General specifications . Inspection and adjustment Inspection and adjustment Tightening torque : SPECIAL SERVICE TOOLS . EF & EC-2 EF & EC EF & EC- EF & EC. EF & EC. + EF & EC. + EF & EC. - EF & EC- EF & EC. ++ EF & EC. + EF & EC. + EF & EC + EF & EC. + EF & EC. EF & EC. - EF & EC. + EF & EC. EF & EC. EF & EC. - EF & EC. EF & EC- - EF & EC. . EF & EC. 86 88 89 91 91 1 92 93, 93 94 94 94 97 97 98 98 98 99 99 99 - EF & EC-103 + EF & EC-105 + EF & EC-105 - EF & EC-105 - EF & EC-107 -- EF & EC-107 + EF & EC-108€-94 3 43 pe D Woter temperature sensor @ Exhaust gas sensor @ Air-fuet ratio control system oa @ Tote vale switch gcc, | Output 9 ition ol control Be urn Input Sore © Fost shutot system ose © Neutral switch 04/7) E00 input Electronic Controlled ® Vacoum switch (M/T) @ Mixture heating system @® ® Inhibitor switch (A/T) Carburetor (ECC) System @ tantric Related fenton & ‘Sensors & switches Output, switche ECC. inpectontamp |O @ Mainjet ° Fuel flow system Fuel tank © Fuel filter © Fuel pump © Flot camber 5 solenoid controlled & Throttle chamber © Intake manifold fuel orifice Air flow system Air cleaner © Choke chamber 2 bemiatrs ‘Throttle chamber © Intake manifold D airbleeds 2 "© inate mani EGRcontrol | © EGR. control valve “> Thermal vacuum valve system (Grport wax type) ‘Aicuelratio | © Alrfuel aio solenoid © Water temperature sensor © ‘Ignition coll ° ECU. contol ysiem | © Exhaust ges sensor © Throtue ve switch Vacuum switch 4/7) ‘Exhaust, Fuel shut-off (© Anti-dieseling solenoid = ition coll © Clutch switch (M/T) © ECU. tmision | system Towle vale wich 5 Mata vita oun 3 Water temperature sensor contol a as ‘Spark timing (© Thermal vacuum valve control ystem | ¢ Vacuum delay valve coats + Say etait comerter ‘Evaporative emision control | Carbon canister stem {Thermal vacuum valve (5-port wax type) ‘Crankcase ventilation contol — POV. vave VINYOAIIVO YO4 ANIDN3 (0°O'S 913) YOLAYNGYVD GATIOULNOSD SINOY.LOATS 4O LYVHO WALSAS TOHLNOO NOISSIWA GNV ANIDN3 9148 91a— VINYOSITVO HOd 3NIONA ('0'0"3 913) HOLaUNEUVO G31TO¥LNOD DINOYLOZ1a 40 LUVHO W3LSAS TOHLNOD NOISSIWS ONY 3NIONSv0] 8 43 ‘Water temperature Anti-deseling solenoid AST. air cleaner: Engine coolant Mixture heater Ignition oil Distributor Coe Nearer swlich (MT ao Inhibitor switch (A/T mo From float chamber ‘Vent switching valve “Ais fuel ratio solenoid valve ‘Temperature sensor le compensator ‘Vacuum switeh (O4/T model only) Spark plug ‘Exhaust gas VINHOSITVD YO4 ANIDNA ‘O'S 913 4O V WVHDVIC WALSAS TOULNOS NOISSIN] GNV SNIDN3 9138 SL3- VINYO4ITV9 YOd 3NIDN] ‘0''3 913 40 W WWHOVIC WILSAS TOULNOD NOISSIWS ONY 3NIDN3ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B OF E16 E.C.C. ENGINE FOR CALIFORNIA —E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B OF E16 E.C.C. ENGINE FOR CALIFORNIA ‘way catalytic converter oat EGR. tube Distributor ‘Vacuum switch MT model) To ir leaner "Thermal vacuum ‘To ile compensator AAT. sensor From fuel tank Ported vacuum (Distributor) ‘Carbon canister Ported vacuum (E.G.R. & canister) WEEE Manifold vacuum Aic ‘ZERERELZEE Canister purse EIEN. Vent a EF & EC-5ENGINE. AND EMISSION CONTROL SYSTEM TABLE OF CARBURETOR ENGINES FOR NON-CALIFORNIA — E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM TABLE OF CARBURETOR ENGINES FOR NON-CALIFORNIA Car model USA. Canada tem Non-California CCrankease emission control 2 aia P.CY. valve pe Air induction valve (2 valves) © Air induction valve (I valve) ase © Air induction pipe (2 pipes) © Airinduction pipe (1 pipe) Sean © AB. valve © AB. valve © EGR. control valve EGR. control V.V-T. valve - eas system (© Thermal vacuum valve (3-port wax type) (pore bimeta ype) [50°C (122°F)] ‘a m © Anti-ieseling solenoid valve Engine revolution switch Fuel shut-off © Throttle valve switch © Ignition coil a system © Inhibitor switch (A/T) Neutral switch (M/T) emission © Clutch switch (M/T) oat (acrostaning | © iar ber ve system, © Water temperature switch ‘Spark timing © Thermal vacuum valve (3-port wax type) 7 control system Vacuum delay valve © Throttle opener servo dia phragm © Throttle opener solenoid valve ibelanicts - © Vacuum control valve aoe ee © ‘Speed detecting switch and amplifier (M/T) © Inhibitor switch (A/T) Catalyzer Oxidation catalytic converter 7 Evaporative emission control system Carbon canister ‘Thermal vacuum valve (3-port wax type) EF & EC-6 © Carbon canister£-94 3 44 veusas ‘Temperature sensor: ‘Antiieseling | ‘solenoid valve EGR. vane Distributor ‘Vacuum deley| Tgition ‘Transaxle ——] ‘Neutral switch QM/T model) Inhibitor switeh (A/T model) Engine revolution switch £.G.R, tube From battery ‘Air induction tube’ Sa ae ‘Oxidation catalytic converter VINYOSIIV9-NON HOS V WVHSVIC WALSAS TOULNOO NOISSIWA GNV SNIDNS 9L3 8 GL3— VINHOSITVO-NON HO4 V WVHDVIG W3LSAS TOULNOD NOISSINS GNV 3NION3ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM .B FOR NON-CALIFORNIA — E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR. NON-CALIFORNIA tion catalytic converter oo From fuel tank amma, Fortes vacuum (Distributor) a, Posted vacuum (EGR. & canister) SEE Venturi aca ‘EERE Manifold vacuum Ait ‘REE Canister purge ‘MMMM Vent air SEF7I98 EF & EC-86-03 8 43 voecsas ‘Temperature sensor ee Idle compensator hutch switch (M/T model) ‘Vacuum delay valve Engine revolution switch E.G.R. tuk ‘From battery ‘ Lae Mater ‘Oxidation catalytic converter Air induction tube Tinton coll ‘Tans Nouteal oviteh (4/7 model) Inhibitor switch (A/T model) S3GNLILTV HDIH JO VINHOSITVO-NON YO4 V WVHDVIG WALSAS TOULNOOD NOISSINS GNV SNIDNS ‘913 8 Sa — SIGNLILTW HOIH JO VINHOSIIVO-NON YOd V WVHDVIG WISAS TONLNOOD NOISSINS GNV 3NIONSENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR NON-CALIFORNIA OF HIGH ALTITUDES — E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR NON-CALIFORNIA OF HIGH ALTITUDES an catalytic converter ‘Vacuum tank (AIT model) Vacuum switch (AT model) “Altitude compensator: One-way valve (AIT model) VV. vale To idle compensator BAT sensor pom, From fuel tank zz Ported vacuum (Distributor) (Carbon canister I, Ported vacuum (E.G.R. & canister) EEE Vent view SEF 7AZA EF & EC-10LL-03 3 43 Electronic Controlled Carburetor (E.C.C) System @ Water temperatare sensor @ Exhaust gas sensor @ Thott valve switch Q Ieniton oi @ Ghtch switch © Neatel switch © Engine revolution switch @ Battery voltage ‘Sensors & ewitehes Input ir-fuel ratio control system D®@® Ecc. | Output Ores ee emma ©0® control nae anit ® Fad shutoff system ecu o® ‘nou |B Cats warmup aye O® PN] Exhaust airinducton yiem | © Se Related Nee sensors & Switches E.C.C. inspection lamp 2 @®@ Owe inj 3 Fl flow stem Foeliak © Fuser © Fuel pump © Float ehanter & steno contoed © Throttle chamber c> Intake mano fu once Ventas gy ‘Air flow system Air cleaner © Choke chamber @ ‘Throttle chamber C> Intake manifold - . Airbeds a ‘iriducton | Ainducton vae > Vacuum sithing ave —~«® “AD. he a aynem (Ais) | + Atinduton contol ave 2 Aivinduction pipe 2 Water temperature enor EGR consol |» EGR conwolvave © Thermal acsum wave Stem Gor wan po ‘Aivfonatio |» Aifoelatto soleoia Wateremperture sensor» Igton cou + Bau. eaman [_comntsnten | ¢ Exon arse + Tarotte ve sich 2 Engine revelation wich emision | Fuctautont | © Aniiaiting minal © tain co > Giich sit + Baw contol | gm 3 Trot vate ptch Neva witch Water temperature sensor orton Gatyst wap | Vacoum slicing valve © Water tempenturswnsor Vacuum dehy wae + Bou. ‘tem Trot opener sero diaphragm ‘Neat sich + Dial lapragm dsubutr Spark ting | © Themal ecwum ve contolaysem | Vacuum dey rave cauiyie Je commer Gtr + Sway catalyecomverte raporave eminion control | «Cabo cise oem "Thermal coum ve (port wax p=) ‘Crankease ventilation control system © PCV. valve “O'd'W YOd ANIONS ('0°0"S) HOLSYNEYVS GATIOY.LNOD SINOYLO373 40 LYVHD WALSAS TIOULNOOD NOISSIINS GNV SNIDN3 9138913 —‘O'dW HOS SNIDNA ('9'9'3) HOLAUNSYVI GITIOULNOD SINOYLOF13 JO LYVHD WALSAS TOULNOD NOISSIN GNV JNIDN|ZL-O4 8 4a ‘Vacuum switching valve ‘Anti-iesling solenoid -Air-fuel rato solenoid valve (or air induction contro) ‘Temperature ALT. ait cleaner: ‘Tempe dle compensstor 4. auction vane-y Water ‘temperature sensor Ai induction tube- Spatk plus Exhaust gat E.G.R. tube ‘Vacuum delay valve From float chamber ‘Vacuum switching valve for catalyst warm-up system Vent switching valve is etalon ee verssas “O'd'W YO4 ANIDN3 ‘0°03 40 V WVHYDVIC WALSAS TIOULNOOD NOISSIWA GNV ANIDN3 913 8913 — ‘Od W HOd ANIDNA ‘9'9'3 40 V WVHDVIC W3LSAS TOULNOD NOISSIN3 GNV 3NIDNaENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B OF E.C.C. ENGINE FOR M.P.G. — E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B OF E.C.C. ENGINE FOR M.P.G. port catalytic converter a ee Exhaust gas sensor Exhaust manifold EGR. ube a fi Sh induction pipe- iis Disubutor ie i Vacuum setching valve taetnnase tony Neca hing vale Toi deer | KR Can ut ey 1 | ley . 7 | / “Thermal + valve y | induction valve- im ‘induction \ — EGR.vike ‘ ‘Throttle opener- = Cate : fa Compensators “A.B. valve ore Tosircloer maz Pore astm (Disb) amma ored nomm (BO 8 cate) Zana Vea vce (caton cnr ‘om ee (EEE Manifold vacuum =a —— ome Yor | EF & EC-13VL-93 8 43 vortsas Ignition coll ‘Vacuum delay valve, (AIT model only) ‘ALT.C. air cleaner Antisleseling solenoid valve ‘Temperature sensor dle compensator Distributor Canister Main muller Post muffler TOS, solenoid ® TOC, control vale Speed detecting switch (for M/T) Inhibitor switch (for A/T) induction tube VAVNVO HO4 V WVHDVIC WALSAS TOULNOOD NOISSIWA GNV ANIDN3 913 8 913 — VaVNVO HOd Vv WVHOVIG W31SAS TOULNOD NOISSIW] GNV 3NIDNAENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR CANADA ~ E15 & E16 ENGINE AND EMISSION CONTROL SYSTEM DIAGRAM B FOR CANADA CEN \ Exhaust manifold sense | [222 (( Distebutor— 0) ass ] “To air cleaner TOCS. ‘Vacuum delay valve (A/T model only) solenoid aces ae / EGR | ‘onirol valve L1.0.C.S, control valve il | \ “Thermal valve ‘Ar induction valve “To aie leaner A.B. valve To idle compensator and A-T.C. sensor S ofiane ZI: tot acs Ds) / IZZIE Wott cn (EGR and Se) Z een catbon saint a RE Cer pee EF & EC-15ELECTRICAL CIRCUIT DIAGRAM — E15 & E16 ELECTRICAL CIRCUIT DIAGRAM E.C.C. CIRCUIT DIAGRAM (California) Refer to Harness Diagram, EF & EC-16ELECTRICAL CUIT DIAGRAM — E15 & E16 E.C.C. CIRCUIT DIAGRAM (M.P.G.) § 8 ge Be g 85 an ‘YOSNaS | = aunuvusanal waivm fal 1 HOLNS a: " HOLATD voumsanrvn | Fa FULLOWHL " SL. ous BH Was svp asnvHxa, alta ual [- L— fa] aionaros + JNouonant uw ( Houms| Noumonse fF Jaronar0s BINION | _ Repair or replace components as necessary. 3. Perform ignition oscilloscope check. OK. NG. Rotor Correct, repair or replace components as follows: © Distributor cap Secondary wires Spark plugs Ignition coil switch, ‘4. Check ignition timing, idle RPM and throttle valve OK. ING. ¥ 5. Check idle CO%, ING. fe >| Adjust to specifications. >| Adjust to specifications, a OK. onl. 2 6. Perform driveability check. OK. END NG. ¥ 7. Check carburetor. OK. NG. B.Check ECC. system. [NS OK. ¥ 9, Perform driveability test. [x Correct or replace carburetor. as necessary. | Correct, adjust or replace components of carburetor Correct, repair or replace components as necessary. EF & EC-20DIAGNOSTIC PROCEDURE FOR PROBLEMS — E15 & E16 IMPROPER IDLING a ¥ le 3. Check ignition timing and idle RPM. 4. Check idle CO%. NG. NG. 1, Inspect engine and E.C.C. system for air leaks, [——»|_ Locate air leak and repair. OK. ea eae 2. Perform ignition oscilloscope check. ‘Repair or replace components as follows: © Distributor cap Ox. NG. © Rotor Ce’) Secondary wires © ‘Spark plugs © Ignition coil a NG. |-——>| adjust to specifications. Ox. NS. _,} Adjust to specifications, OK. 5. Check B.C.C. system. (NG i END jee eee seed Adjustable ¥ Not adjustable 5. Overhaul carburetor or replace it with a new one. [sereee reas eer en eee eee eee ‘Repair or replace components as necessary. EF & EC-21DIAGNOSTIC PROCEDURE FOR PROBLEMS — E15 & E16 ENGINE STARTABILITY 1, Inspect engine and E.C.C. system for air leaks, etc. Locate air leak and repair. ¥ Ox. a NG. 2. Check battery and charging system for battery. [-—»| _ Correct, repair or replace components as applicable, Ox. le fa NG. 3. Check starting system, [W&__,J "Repair or replace parts and circuits as necessary. ox], re NG. 4. Check fuel supply system. [WG_f "Repair or replace components as necessary. OK], k ¥ 5. Perform ignition oscilloscope check. Correct or replace the following pars as applicable. cE © Distributor cap 7 NG. © Rotor Raceerecm| | © Seconiay wi © Spark plugs © Ignition coil ———————————————— - NG. 6. Check ECC system. [| NS__,”” Repair or replace components as necessary. Ox. 7, Check fast idle system for air conditioner. [— —| ‘Repair or replace components as necessary. 8. Check carburetor. x 9, Perform startabiity tet. XS; oxy END f———___________] — _——— Repair or replace components as necessary. 10. Check idle CO% and adjust it if necessary. EF & EC-22DIAGNOSTIC PROCEDURE FOR PROBLEMS ~ E15 & E16 ENGINE STALL 1. Check ECC. stem, -YS-_________a] Repair or replace components as nezesary. ox] NG. 2. Check idle RPM, >_>} Adjust to specifications. OK. 3. Check fuel shut-offsystem. LYS] Repair or eplace components as necessary. OK. + 4, Overhaul carburetor or replace it with a new one. 5. Adjust idle rpm, ignition timing and idle CO% to the specified value, ¥ END EF & EC-23DIAGNOSTIC PROCEDURE FOR PROBLEMS — E15 & E16 DIAGNOSTIC STEPS FOR DRIVEABILITY 1, Inspect engine and E.C.C. system for leaks. (1) Check clamps at all air intake components, (2) Check vacuum hoses for leakage, (3) Check air cleaner filter for clog- ging. @) Visually inspect for leaks at the following: Dipstick ABB. valve hose Air induction hose (M.P.G. only) Intake mianifold gasket Valve rocker cover EGR. valve gasket © Oilfiller cap (S) Check EGR. valve seat and ‘operation. © Check air induction control valve operation. (MPG. only) (7) Check A.B. valve operation, 2. Check fuel supply system (1) Make sure proper fuel i used. (@) Visually check fuel filter for clog. sing. ) Visually check fuel lines for leaks. @) With engine idling, visually check fuel level. Ifnot correct, adjust as follows. a) Tum off engine and remove choke chamber. ) Tum down choke chamber and ad- just “H” by bending float seat. oat: epproximately 12 mm (0.47 in) ©) Adjust “h” by bending float stop- per as required. on: 1.31.7 mm (0.051 - 0.087 Ser27A If necessary, adjust to the specified rpm by turning the idle speed ad- justing screw. 4) Install, choke chamber and recheck fuel level with engine idling. 3. Perform ignition oscilloscope test. (()) Warm engine to operating temper- ature, (2) Check ignition system for unusu- ally high or low firing voltage, (@) If firing voltage is abnormal, determine cause and repair, 4. Check ignition timing, idle rpm and throttle valve switch. (1) Checking and adjusting ignition timing and idle rpm. Checks and adjustments are made with the air conditioning compressor “OFF”. 4) Disconnect sir induction hose and install proper cap on air induction pipe. (M.P.G. only) b) Verify that the engine is still at operating temperature, ©) Rev the engine to 2,000 to 3,000 rpm two or three times under no-load, then allow it to run at idle speed for one minute. 4) Disconnect distributor vacuum hose from distributor vacuum controller, and plug hose with proper plug. Then, check ignition timing with a timing light, E15 (MP.G.) 242 AT.DC. £16 Sa? ATO. Adjust as necessary. ©) Connect distributor vacuum hose and check idle speed. €15 (mP.G) "7002100 rpm E16 MT 7502100 rpm AT 6502100 rpm in “D” position) EF & EC-24 (2) Check throttle valve switch adjust. ment, a) Tum off engine and disconnect harness connector on carburetor. ) Connect proper wires between the anticieseling solenoid harness ter- rminals, EIS (MPG) Black oc Ls SeF6724 E16 Yellow Yellow with red stripe ‘Yellow with ed stripe Yellow LS seF672A\DIAGNOSTIC PROCEDURE FOR PROBLEMS — E15 & E16 ©) Verify that continuity does not exist between the throttle valve ‘switch harness terminals. EIS (MPG) Black: Red ‘SEFS7IA EI6 Yellow. 3 SEFS7aA E16: Bend plate until the ohmmeter indi- cates an open circuit. E16 4) Start engine and increase engine speed to about 2,000 rpm. ©) At this time, verify that continuity exists between the throttle valve harness terminals. ) Then, decrease engine speed gradu- ally to 1,200250 rpm, and at that point the circuit should break and cause the ohmmeter to indicate an open circuit. If incorrect, adjust as follows: 1) Hold engine speed at 1,200 rpm by ‘manually opening the throttle. Important: Do not use the idle speed screw. 2) EIS (MPG): Slowly rotate the adjusting screw counterclockwise or clockwise until the ohmmeter indicates an open cir- uit. 3) Recheck the adjustment, 4) Reset idle speed if necessary. 8) Connect carburetor hamess con- nector. 5. Check idle CO%. The checking or adjustment ‘CO% requires the use of a CO meter. It is essential that the meter be fully ‘warmed up and calibrated before any (2), Make sure that air induction hose is disconnected. (2) Verify that the engine is at operat- ing temperature, (8) With the hood open, run the en- gine at 2,000 rpm for 2 minutes at no-load to stabilize its condition. (@) Tum the ignition switch to the “OFF” position, (5) Disconnect air-fuel ratio solenoid hhamess connector. sersoral (6) Rev the engine to 2,000 to 3,000 rpm 2 or 3 times under no-load, final- ly, allow it to run at idle speed for one minute, (7) Reset idle speed to the specified speed. (8) Check COR as per Table A, Column 1 and if necessary, adjust to the specified point as per Table A, Column 2. The CO% adjustment is made by tuming the idle mixture adjustment is made, screw. Table A Check idle CO% |] Adjust idle CO% Lae ime Column 1 Column 2 EIS MIT 4.022.0% 4081.0% MIT E16 300.0% 3.041.0% AIT (9) Stop engine, and reconnect air- (2) If unsatisfactory, proceed to step fuel ratio solenoid harness connector. 7. (10) Check the idle speed. Readjust 7. Check carburetor. to the specified speed. (1) With engine stopped, check each (11) Connect air induction hose. linkage and throttle valve for smooth, O4P.G. only) operation. At the same time), make 6. Perform driveability test. (1) Evaluate effectiveness of adjust- ‘ments by driving vehicle. EF &-EC-25 sure fuel is injected smoothly through ‘the abcelerating injection nozzle,