ENGINE — EF! SYSTEM. £6-153 EFI SYSTEM DESCRIPTIONeae ENGINE SYSTEM The EFI system is composed of threa basic sub—systems: Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake manifold in accordance with signals from the ECU (Engine Control Unit). AIR INDUCTION SYSTEM The air induction system provides sufficient air for engine operation. ELECTRONIC CONTROL SYSTEM The 3S—FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which centrally controls the EFI, ESA, ISC, Diagnosis systems etc. by means of an ECU—formerly EFI computer employing a microcomputer. The ECU controls the following functions: 1. Electronic Fuel injection (EFI) ‘The ECU receives signals from various sensors indicating changing engine operating conditions such as: Intake manifold pressure Intake air temperature Engine coolant temperature Engine speed Throttle valve opening angle Exhaust oxygen content ate. re utilized by the ECU to determine the injection duration necessary for an optimum ir—fuel ratio. 2. Electronic Spark Advance (ESA) ‘The ECU is programmed with data for optimum ignition timing under all operating conditions. Using data provided by sensors which monitor various engine functions (rpm, coolant tempera- ture, etc), the microcomputer (ECU) triggers the spark at pracisely the right instant. 3. Idle Speed Control (ISC) ‘The ECU is programmed with target idling speed values to respond to different engine conditions {coolant temperature, air conditioning ON/OFF, etc.). Sensors transmit signals to the ECU which control the flow of air through the thrattlo valve bypass and adjust idle speed to the target value, gnosis ‘The ECU detects any malfunctions and abnormalities in the sensor network and lights a check ‘engine warning light in the combination meter. At the same time, trouble is identified and a diagnostic code is recorded by the ECU. The diagnostic corde can be read by the number of blinks jine warning light when terminals TE! and E1 of the check connector are connected.The diagnistic code are referred to in a later page. (See page EG—171) 5. Self—Correction Function If any sensor malfunctions, an average value recorded in the back—up circuit is substituted to make driving possible. if danger is predicted, the engine is stopped and the check engine warning fight will ight up. 6. Fail—Safe Function In the event of the sensor malfunctioning, a back—up circuit will take over to provide minimal driveability, and the check engine warning fight will illuminate. feeeeceeENGINE ~ EFI SYSTEM bathed OPERATION FUEL SYSTEM sT202 Fuel Tank Fuel Pump. Fuel Pressure Regulator Prat Fuel Pulsation Dampar Fuel pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector at a set pressure maintained by the fuel pressure regulator. The fuel pressure regulator adjusts the pressure of the fusl from the fuel line (high pressure side) to a pressure 284 kPa (2.9 kaf/em’, 41 psi) higher than the pressure inside the intake manifold, ‘and excess fuel is returned to the fuel tank through the retum pipe. Fuel is injected into the intake manifold according to signals from the ECU.EG-166 ENGINE — EF! SYSTEM AIR INDUCTION SYSTEM ‘$7202 Intake Manifold intake Manifold (Air intake Chamber) aio ‘Air is filtered through the air cleaner and the amount flowing to the air intake chamber is determined according to the throttle vaive opening in the throttle body and the engine speed. Intake air controlled by the throttle valve opening is distributed from the air intake chamber to the manifold of each cylinder and is drawn into the combustion chamber. At low temperatures the ISC valve opens and air flows through the ISC valve and the throttle ‘engine warming up, even if the throttle vaive is ir flows to the air intake chamber, thereby increasing the idle speed (first idie operation). The air intake chamber prevents pulsation of the intake air, It also prevents intake air interference in each cylinder.ENGINE — EFI SYSTEM. EG-157 ELECTRONIG CONTROL SYSTEM = ‘sT202 oa Ce Intake Alr ‘Temperature Sensor Water Temperature ‘Sensor srist ‘Variable Resistor*?. VV for ER AIC idle-Up Kock Sonsée Hee *1 Europe , EFI Main Re a — ‘Temperature Sensor er Temperature bene! ‘Oxygen Sensor** rae The control system consists of sensors which detect various engine conditions, and an ECU which determines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air pressure, engine speed, oxygen density in the exhaust ‘gas, engine coolant temperature, intake air temperature and atmospheric pressure etc, and convert the information into an electrical signal which is sent to the ECU. Based on these signals, the ECU calculates the optimum ignition timing for the current conditions and operates the injectors. The ECU not only controls the fuel i jing, but also the self~-diagnostic function which records the occurrence of a malfunction, ignition timing control, idle speed controt and EGR control. 7 ——Lacie ENGINE — EFI SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) wes (09268-41045 Injection Meauuring Tool Set . 5 mer" (99288-41000) “Wor? Union” = (6H0E 06018) Not Union ‘08268-46012 EFI Fuel Pressure Gauge 09631-22020 Power Steering Hose Nut Ful bine flare nut ez : 14217 mm Wrench Sat (09816-30010 OW Preceura Switch Socket ‘Knock veneer ‘09642-20070 Wiring °F EFI Inspection ‘Q8643—16020 « Diagnosis Check Wire RECOMMENDED TOOLS a Ze. ‘HO62 00060 TOVOTA Beatical Toor Set aS 09200-00010 Engine Adiust Kn == ==Y GHRE8=00000 Hos Fea ba Plog fr vata hoo, fal de « Sr 7ENGINE — EFI SYSTEM. EG-169 EQUIPMEMT — Gad ane = Toa —— ‘Sound scope neotr Tahaan ‘Torque wrench Vacuum gaugecone ENGINE —'EF! SYSTEM PRECAUTION 1, Before working on the fuel system, disconnect the negative {—) terminal cable from the battery. HINT: Any diagnostic code retained by the computer will’be eresed when the negative (—-) terminal cable is disconnected. ‘Therefore, if necessary, read the diagnosis before dis- connecting the negative (—) terminal cable from the Negative (-) Terminal Cable 2. Do net smoke or work near an open flame. when working on the fuel system. 3. Keep gasoline away from rubber or leather parts. MAINTENANCE PRECAUTIONS 1. CHECK CORRECT ENGINE TUNE—UP {See page EG—13) 2. PRECAUTION WHEN CONNECTING GAUGE {a) Use battery as the power source for the timing light, tachometer, ets. {b) Connect the tester probe of a tachometer to the termi- nal IGG of the check connector. 3. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN {a) Check proper connection of battery terminals, etc. {b) Handle high—tension cords carefully. {c) After repair work, check that the ignition coil termi- nals and all other ignition system lines ere reconne- oted securely. {d) When cleaning the engine compartment, be especially careful to protect the electrical system from water. 4, PRECAUTIONS WHEN HANDLING OXYGEN ‘SENSOR {2} Do not allow the oxygen sensor to drop or hit against an object. {e) Do not allow the sensor to come into contact with water.ENGINE — EFI SYSTEM lated IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM. CB, ETC.) If the vehicle is equipped with 2 mobile communica- tion system, refer to the preaution in the IN sectic AIR INDUCTION SYSTEM 1, Separation of the engine oil dipstick. oil filler cap. PCV. hose, etc. may cause the engine to run out of tune, 2. Disconnection, looseness or cracks in the parts of the air induction system between the throttie body and cylinder head will cause air suction and cause the ‘angine to run out of tune. ‘Negative (-) Terminal Cable ELECTRONIC CONTROL SYSTEM 1, Before removing EF! wiring connectors, terminals, stc,, first disconnect the power by sither turning the ignition switch OFF or disconnecting the negative (—) terminal cable from the battery. HINT: Always check the diagnostic code before dis- connecting the negative (—) terminal cable from the battery. 2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative {-) cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all EF! parts carefully, especially the ECU. 4, Do notbe careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles. 5. Do not open the ECU cover. 8. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the EFI parts and wiring connectors. 7. Parts should be replaced as an assembly.£G-162 Insert ENGINE — EFI SYSTEM 8. Care is required when pulling out and inserting wiring connectors. (2) Release the lock and pull out the connector, pulling on the connectors. fs Fully insert the connector and check that it is locked. 9. . Use SST for inspection or test of the injector or its ing connector. SST 09842~30070 FUEL SYSTEM 1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe the following procedures: {@) Disconnect the fuel pump connector. {b) Start the engine. After the engine has stopped on its ‘own, tum the ignition switch OFF. (©) Put a container under the connection, (d) Slowly loosen the connection. (0) Disconnect the connection. (f) Plug the connection with a rubber plug. (9) Reconnect the fuel pump connector.ENGINE — EF! SYSTEM EG-163 or Grommet ssulator Injector 2, When connecting the flare nut or union bott on the high pressure pipe union. observe the following proce- dures: Union Bolt Type: (2) Always use @ new gasket. (b) Tighten the union bolt by hand. {c)_ Tighten the union bolt to the specified torque. Torque: 29 N-m (300 kgf-em, 22 ftubf) Flare Nut Type: (a) Apply a light coat of engine oi! to the fiare nut, and tighten the flare nut by hand. (b) Using SST, tighten the flare nut to specified torque. SST 00831-22020 Torque: - Fuel pump side: 24 N.m (240 kgf-om, 18 ftlbf) Others: 30 Nem (310 kaf-om, 22 ft-lbf) HINT: Use a torque wrench with a fulorum length of 30 om (11.81 in). 3. Observe the following precautions when removing and installing the injactors. * (2) Never rausa the O-ring. (b) When placing a new O-ring on'the injector, take care not to damage it in any way. (c) Coat a new O-ring with spindle oil or gasoline before installing —never use engine,.gear-or brake oils. 4, Install the injector to the delivery pipe and intake ‘manifold as shown in the illustration. 5. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system. (a) Using SST, connect terminals +B and FP of the check connector. SST 09843-18020Ea164 ENGINE — EFI SYSTEM fb) ‘Turn the ignition switch ON. NOTICE: Do not start the engine. Pinch the fuel return hose. ‘The pressure in the high pressure line will rise to approx. 392 kPa (4 kaf/em*, 57 psi). In this state, check to see that there are no leaks from any part of ‘the fuel system. 7 NOTICE: Alwaye pinch the hose, Avoid bending es it may couse the hose to crack. Turn the ignition switch to LOCK. Remove the SST from the check connector. ‘SST 09643-18020ENGINE cates EFI SYSTEM DIAGNOSIS SYSTEM DESCRIPTION ‘The ECU contains a bullt—in self—diagnosis system by which troubles with the engine signal network are detacted and the check engine warning light on the combination meter lights up. By analyzing various signals as shown in the later table (See page EG—171) the ECU detects system maifunctions relating to the sensors or actuators. The self—diagnosis system has 2 modes, a normal mode and a test mode. If a malfunction is detected when in the normal mode, the ECU lights up the check engine warning light to inform the driver of the occurrence of a malfunction. (For some codes the light does not come on.) The light goes OFF automatically when the malfunction has been repaired. But the diagnostic code(s) remains stored in the ECU memory (except for code No.16). The ECU stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch OFF. The diagnostic code can be read by the number of blinks of the check engine warning light when TE1 and Et terminals on the check connector are connected. When 2 or more codes are indicated, the lowest number (code) will appear first. If a malfunction is detected when in the test mode, the ECU lights up the check engine warning light to inform the technician of the occurrence of a maffunction (except for code Nos.42, 43 and 51). In this case, TE2 and Et terminals on the check connector should be connected as shown: later. (See page EG— 168). {In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECU mamory even when the ignition switch is OFF (except code Nos. 42, 43 and 51). This also applies in the normal mode, The diagnostic mode (normal or test) and the output of the check engine warning light can be selected by connecting the TE1, TE2 and E1 terminals on the check ‘connector, as shown later. (See page EG—166) A test mode function has been added to the functions of the self—diagnosis system of the normal mode for the purpose of detecting malfunctions such as poor contact. which are difficult to detect in the normal mode. This function fills up the self-diagnosis system. The test mode can be implemented by the technician following the appropriate procedures ‘of check terminal connection and operation described later. (See page EG— 168) CHECK ENGINE WARNING LIGHT CHECR™ 1. The check engine warming light will come on when the ignition switch is turned ON and the engine is not running. 2. When the engine is started, the check engine warning CHECK" Engine Waring Light light should go off, Hf the light remains on, the diagnosis system has i detected a malfunction or abnormality in the system.cectee ENGINE — EF SYSTEM DIAGNOSTIC CODES OUTPUT (Normal mode) ‘To obtain an-output of diagnostic codes, proceed as follows: 1. Initial conditions (2) Battery voltage 11 V or more {b) Throttle valve fully closed {throttie position sensor IDL points closed) {e) Transmission in neutral range {@) Accessories switched OFF ! operating temperature n switch ON. NOTICE: Do not start the engine, 8. Using SST, connect terminals TE1_and E1-of the check connector. SST 09843-18020 4, Read the diagnostic code as indicated by the number of flashes of the check engine warning light, Diagnostic Codes (See page EG—171) (2) Normal System Operation (no malfunction) © The light will alternately blink ON and OFF at 0,26 second intervals, ‘No Malfunction 0.28 (Seconds)£G-167 {b) Malfunction Code Indication © In the event of 2 malfunction, the light will blink ‘every 0.62 seconds. The first number of blinks will equal the first digit of a 2 digit diagnostic code and, after a 1.5 second pause, the 2nd number of blinks will equal the 2nd. If there are 2 ‘or more codes, there will be 2 2.5 second pause between each cod © After all the codes have been output. there a 4.5 second pause and they will all be repeated ‘as {ong the terminals TE1 and E1 of the check connector are connected. HINT: In the event of a number of codes, indication will begin from the smaller value and continue to the larger. (c) 2 Trip Detection Logic Diagnostic codes 21 and 26 use “2 trip detection logic’. With this logic, when a malfunction is first detected, the malfunction is temporarily stored in the ECU memoty. If the same case is detected again during the second drive test, this second detection The 2 trip repeats (Howev- er, the ignition switch must be turned OFF between. the 1st time and 2nd time.) In the Test Mode, the check engine warming light lights up the 1st time @ malfunetion is detected. 5. After the diagnosis check, remove the SST from the check connector. SST 09843-18020ee ENGINE (Test mode) EFI SYSTEM. HINT: © Compared to the normal mode, the test mode has high sensing ability to detect matfunctions. © It can also detect malfunctions in the starter signa! citcutt, air conditioner signal and neutral start switch signal. ¢ Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the test mode. To obtain an output of diagnostic codes, proceed as follows: 1. Initial conditions (a) Battery voltage 11 V or more (b) Transmission in neutral range (0) Accessories switched OFF (d)_ Engine at normal operating temperature 2. First, using SST, connect terminals TE2 and E1 of the check connector, SST 09843-18020 ‘Turn the ignition switch ON to begin the diagnosis in the test mode. HINT: To confirm that the test mode is operating, Fshing check that the check engine warning light flashes when the ignition switch is turned ON. ‘ON 4. Start the engine and drive the vehicle at a speed of 10 ore: km/h (6 mph) or higher. afhe 5. Simulate the conditions of the malfunction described 0.131 Seconds by the customer.IGINE — EFI SYSTEM 6 Using SST, connect terminals TE1 and E1 of the check connector. SST 09843-18020 Read the diagnostic code as indicated by the number of flashes of the check engine warning light. (See page EG-171) a After the diagnosis check, remove the SST from-the check connector. SST 09843—18020 HINT: The test mode will not start if terminals TE2 and E1 are connected after.the ignition switch is tumed on. é The starter signal and vehicle speed signal will be diagnosed by the ECU as malfunctions, and code Nos, 42, and 43 will be output, if the operation in Stop 4 is not performed. ‘When the automatic transmission shift lever is in the “D", "2", “L" or “R” shift position, or when the air conditioner is ON or when the accelerator pedal is depressed, code No. 51 (Switch Condi- tion Signal) is output, but this is not abnormal.mete ENGINE ~ EFI SYSTEM DIAGNOSTIC CODE CANCELLATION 1, After repair of the trouble area, the diagnostic code retained in memory by the ECU must ba cancelled out by, removing the EF? fuse 15A for 10 seconds or more, depending on ambient temperature (the lower the temperature, the longer the fuse must be left out) with the ignition switch OFF. HINT: © Cancellation can also be done by removing the negative (—) terminal cable from the battery, but in this case, other memory systems (clock, etc.) will also be cancelled out. © If the diagnostic code is not cancelled out, it will be retained by the ECU and appear along with a new code in the event of future trouble. © If it is necessary to work on engine components requiring removal of the battery terminal, a check. must first be made to see if a diagnostic code has. been recorded. 2. After cancellation, perform road test of the vehicle to check that a normal code is now read on the check engine warning light. If the same diagnostic code appears, it indicates that the trouble area has not been repaired thoroughly. DIAGNOSIS INDICATION 1. When 2 or more codes are indicated, the lowest num- bered code will appear first. 2. All detected diagnostic codes, except code Nos, 16, 43, 51 and 42 under the test mode will be retained in memory by the ECU from the time of detection until cancelled out. 3. Once malfunction is cleared, the check engine warn- ing light on the combination meter will go off but the diagnostic code(s) remains stored in ECU memory (except for code Nos. 16, 43, 51 and 42 under the test mode).ENGINE — EF| SYSTEM Panae DIAGNOSTIC CODES HINT: . © Ifa malfunction is detected during the diagnostic code check, refer to the circuit indicated in the table, and turn to the corresponding page. © Your readings may vary from the parameters listed inthe table, depending onthe instruments used. ode | Haar etint of Chat | coonetameaten —— Cingese Tee Ane semen ate | He tan natn ae - AUNT | mr Bp ee bpm : Soba seve ee ne fatemermeemersta |" grou ” JUL. rows =| on | a. | temon + Same o | ws Coralterarngasecy | + Opmershonin STAs vee fern ormere oe eee) 1 Opener ane NE coat » SUUA_ | resem Saosiiee | aor o | me Sa © Opemarenon micron oT « FLIUMIIL | orients | on | na |sctomcnsters | eatomimmmsey | | os sue same = <=] nenmmnm. |e] ow | nan | tertaennecmen | coy ele * Soe romeo, 1 Opawamnm ee eatctener eee stecerenam | « ofa tanintenr al “Sirol oF oxygen seetoe + Spy i ‘Sansor oF | KA ° et =} SUL. | ee Eat + Coens siti men + Seguros ta sve > Opener ania = wowrtare | ae ILL | Serta - 2 tomo te panera mat a me | FULIMIIIIIL| Breer | om | on | Ste emcee aco © | sone Sai Sacorece a eva oar let 0 erbeaior nae . ro] 3 Reatename = JULI. | Ban cor | ow | rate ciyen emer | * fear tae o | Ba see mes + Duvernois Semacenies |, See, rasa Siena aang ee » | UL | ox | on | creer, | | era 0 | wom basi ensor Grea . pal ra =i ENGINE — EFI SYSTEM DIAGNOSTIC CODES (Cont'd) mee eerste. Digna moun Aes tamer*| sescaoe — SS 4 See eee - «| NLL |e oe | ow [eee | Se | o vara So See |S Serene Faces EDU for at lenat 8 sacle — a Seen Sorat cone | one | suring tign taad cing GE er-gerltyerl ° - Sever Sloat mieravesseeasoce |S yicerued ers a Eo an cor | TIMLINIL | vumesnse | na | on (semen | eee aen | x | com cease fo sau mameeae [teers = one eco e | nan | 2 errs rome | | oe see |S sa Zee a fae ‘Diephayad when ASCH OM, "© A/C peice nyster =e © | TIMMAM_)fe= | an | ow [ERR |i | | te ‘Sera check terminals Et and TED + Aemoteretor pedal cable a == emma REMARKS: “ a “ 8 “ON” displayed in the diagnosis mode column indicates that the check engine warning light Is lit up when a malfunction is detected. “OFF” indicates that the check engine: light does not during malfunction diagnosis, even if e malfunction is detected. “N.A.” indicates that the item is not included in malfunction diagnosis. “O* in the memory column indicates that a diagnostic code is recorded in the ECU memory when 8 malfunction occurs. °X" indicates that a diagnostic code is not recorded in the ECU memory evenifa malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is performed with the ignition switch ON. “2° trip detection logic” (See page EG-167) AIT wf Oxygen SensorENGINE — EFI SYSTEM cele DIAGNOSTIC CODE DETECTION DRIVING PATTERN Purpose of the driving pattern, {e} To simulate diagnostic code detecting condition after diagnostic code is recorded. {b)_ Tocheck that the malfunction is corrected when the repairis completed, confirming that diagnostic code is not longer detected. Code No.| 21. | Oxygen Sensor Circuit Matfunction: Deterioration of Oxygen Sensor (ehicle speed? ‘80 km/h (60 mph) 64 km/h (40 mph) tating 1G SW OFF Itis vital that test routine is adhered to detect the malfunction: @® Disconnect the EFI fuse (15A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminals TE2 and €1 of check connector with IG switch OFF). @ Start the engine and warm up with all ACC switched OFF. @® Idle the engine for 3 minutes. @ With A/C switched ON, A/Tin D range {M/T in Sth gear), accelerate gradually within the range 1,300 - 1,700 rpm centered around 1,500 rpm. HINT: © Ensure engine speed does NOT fall below 1,200 mpm. © Gradually depress the accelerator pedal at a suitable rate to comply with the test requirements on the above graph. © Never allow engine speed to drop at any time during the test. @® Maintain the vehicle speed at 64 - 80 km/h (40 - 50 mph). ® Keep the vehicle running for 1-2 min, after starting acceleration. HINT: If a malfunction exists, the check engine warning light will light up after approx. 60 sec. from the start of acceleration. NOTICE: ifthe conditions in this test are not strictly followed, detection of the malfunction will not be possible,EG-174 DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN (Cont'd) Purpose of the driving pattern, {a) To simulate diagnostic code detecting condition after diagnostic code is recorded. {b) To check that the malfunction is corrected when the repair is completed, confirming that diagnostic code is no longer detected. Code No. 25 Air-Fuel Radio Lean Malfunction Engine Speed 4,000 rem 2,000 rpm + ating (GSW OFF HINT: Before this test, check the feedback voltage for oxygen sensor. @ Disconnect the EFI fuse (154) for 10 see: or more, with IG switch OFF. Initiate test mode {Connect terminals TE2 and E1 of check connector with IG switch OFF). @ Stertthe engine and warm up. @® die the engine for 3 minutes. @ Quickly race the engine to 4,000 rpm 3 times using the accelerator pedal. @® Race the engine at 2,000 rpm for 90 secs. : HINT: If a malfunction exists, the check engine waming light will light up during step @. NOTICE: the conditions in this test are not strictly followed, detection of the malfunction will not be possible,EG-175 FL SYSTEM. DIAGNOSIS CIRCUIT INSPECTION 2 Does “CHECK™ engine warning light come on when ignition switch is ON? ‘System Normal. Ignition switch. : ‘Check wiring between Does “CHECK™ engine warning light come on iconic ‘when ECU terminal W is grounded to the body? ‘round. T sap Check bulb, fuse, and wiring between ECU and Repair or replace. Repel or roplece, Does “CHECK” engine warning ight 90 off when] YES Tose the engine fe etarted? é TNO Check wiring between ECU and "CHECK" engine| BAD [— warning ight, deat 0K Is tere clagnostic code output when check |_NO_| Check wiring between ECU terming/ TE? and [NO _| check connectorterminal TE! andECUterminal connector terminals TE and £1 are connected? Lisi prcnioholetn tls [ves Tox ‘Does “CHECK™ engine warning lighi go off after |_NO- z “Ty another repair according to malfunction code? | ecu. TL ves. ‘System OK Seeae ENGINE — EFI SYSTEM TROUBLESHOOTING w/ VOLT, OHMMETER HINT: ee ‘The following troubleshooting procedures are designed for inspection of each separate system. and therefore the actual procedure may vary somewhat. However, troubleshooting should be performed, while referring to the inspection methods described in this manual. Before beginning inspection, it is best to first make a simple check of the fuses, fusible link and the condition of the connectors. The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit within the computer. If engine trouble occurs even though proper operating voltage is detected in the computer connector, then it can be assumed that the ECU is faulty and should be replaced. FUSES AND FUSIBLE LINK LOCATION MAIN H-Fuse-ENGINE — EFI SYSTEM boned EFI SYSTEM CHECK PROCEDURE PREPARATION (a) Disconnect the connectors from the ECU. {b) Remove the locks as shown in the illustration so that the tester probe(s) can easily come NOTICE: Pay attention to sections illustration which can be easily broken. {) Reconnect the connectors to the ECU. HINT: * Perform all voltage measurements with the con- nectors connected. © Verify that the battery voltage is 11 V or more when the ignition switch is in the “ON” position. Using 8 voltmeter with high impedance (10 kQ/V minimum), measure the voltage at each terminal of the wiring connectors, NOTICE: The ECU shown in the illustrations for measur- ing the voltage at each torminal of the wiring connectors, on pages EG—182 to EG—194, is the ECU used for the '$T191 (A/T) and $T202. For the ECU of the ST191 (M/ T), refer to EG—179 or EG—181. nd “B" In the£G-178 ENGINE — EFI SYSTEM. ECU Terminals (ST202) rehetets [=| cel) [eTap7 Z|we frm majons] vel foc] Tee Le [Tex Les fesslrenfrezpore fo [rea] Tez] Syabet Terrial Nee] Sb |___Tormine Name ‘Sumber Terminal are Eoi__ | POWER GROUND 31 EETSOLENOD ci | A/CAMPUFER E02 | POWER GROUND 32 | EcTsouENOD “ACT | AIGAMPUBER #10 [ RUECTOR SL | ECTSOLENOID SF0__| SPEED SENSOR = £1 [ENGINE GROUND (001_| CRUISE CONTROLECU 70 | IRETOR VF | exEoK CONNECTOR ‘ATs _| AIC AMPUFIER = 721 | SENSOR GROUND L_ [ NEUTRAL START SWITCH 1600 _| CVALVE "TT___| CHECK CONNECTOR o02_| O/D SwTcH = Tet | CHEEK CONNECTOR 2 [ NEUTRAL STRAT SWiTGH BeVAINE : = = Tia _ | GHECK CONNECTOR SE] GROUND 3 TAF | VARIABLE RESTOR W | WARNING UGH = NK [ ENOGK SENSOR i _[ FUEL CONTROL CONNECTOR Se | AC OLEUP VEY “iw [ WATER TEMP SENSOR B7K_| STOP UGHT SWATCH var [sewer wo | Zineon . = TH _ RAKE Aik TEMP SENSOR : z va) TROT osrON el eoreseares) = vr | ecuceeon as [aE Gr BSTRBUTOR a e ves |osmmeuon ve MRE on | eat [earn &_[pstasuToR | SENSOR GROUND 7B [ ERMAN RELAY ier [iowa ‘STA _ | STARTER SWATH : Tis NEUTRAL START SWITCH ECU TerminateENGINE — EFI SYSTEM ECU Terminals (Cont'd) (ST191 M/T) [Syrabot Terminal Neme [Symbol “Terminal Name [Symbol ‘Terminal Name £o1_| POWER GROUND NEs_ | DISTRIBUTOR ‘THA_| INTAKE AIR TEMP SENSOR VACUUM SENSOR, £02 | PoweR GROUND Ne- | DISTRIBUTOR ve || THROTTLE POSITION SENSOR: WO _| INJECTOR (GF_|IGNITER PiM_| VACUUM SENSOR THROTTLE POSTION 20. | mectoR - vra_ | TaROT HT*" | OXYGEN SENSOR HEATER | STA | STARTER RELAY VAF*? | VARIABLE RESISTOR {7 E1__[ENGINE GROUND = 2 [SENSOR GROUND. 1SCO_| 1SC VALVE 'scv_|A/GIDLE-UP VBV ‘ACT _| A/C AMPLIFIER " * TAILLIGHT RELAY, eGR" | EGRVSV ep* | ED MONITOR eis | TALUGHT RELAY, 1SCC_| 1S VALVE VF _| CHECK CONNECTOR = IGT | IGNITER E21_| SENSOR GROUND ‘SPD_| SPEED SENSOR = Te2__ | CHECK CONNECTOR FC | CIRCUIT OPENING RELAY - TE? | CHECK-CONNECTOR =a FUEL CONTROL R/PHe CONNECTOR a OXYGEN SENSOR ACT | A/C AMPLIFIER = KNK_| KNOCK SENSOR BATT | BATTERY - = W_}| WARNING LIGHT G_[ DISTRIBUTOR THW_| WATER TEMP SENSOR | 081 EFI MAIN RELAY THROTTLE POSITION G | DisTRIBUTOR wo | ROT (48 | EFI MAIN RELAY: ECU Terminals: *) Europe "2° GeneralENGINE — EFI SYSTEM ECU Terminals (Cont'd) (ST191 A/T) Symbol |____‘Tarminal Nome ‘Symbet “Terminal Name ‘Symbol ‘Terminal Nome OY. | POWER GROUND 51 | ECTSOLENO = 02 _ | POWER GROUND ‘s2__[ ECT SOLENOID “AGT _| AIGAMPLIIER 0 | INJECTOR St_[ ECTSOLENOD FO | SPEED SENSOR SELYE | GROUND, 1__[ ENGINE GROUND = #20_| INJECTOR VF_| CHECK CONNECTOR ‘ATS _| A/CAMPLIFIER T?_| OXYGEN SENSOR HEATER | _€21_| SENSOR GROUND = 1500_| IBC VAIVE TT | CHECK CONNECTOR ‘002 _| O/D SWITCH EGat? | EGR VSV. Tet _| CHECK CONNECTOR Z = 1806 _| 16C VALVE ‘OXI? [ OXYGEN SENSOR KSW=?_[ KIGKCOOWN SATOH ?_| PATTERN SELECT SWITCH TE? _| CHECK CONNECTOR = ED _| ED MONITOR ‘VAFeT_| VARIABLE RESISTOR W__| WARNING LIGHT = NK | KNOCK SENSOR RrP*t_| FUEL CONTROL CONNECTOR ‘VisC_[ A/G IDLEUP VEY THW | WATER TEMP. SENSOR B/K_ | STOP UGHT SWITCH "THROTTLE POSITION Wot | iGNreR wo [eon : 2 _ | NEUTRAL START SwiTCH THA__| INTAKE AIR TEMP SENSOR = t | neurraL starr swerch via | TERCTILE POSITION Fo | CIRCUIT OPENING RELAY "TAILLIGHT RELAY, NE- | DISTRIBUTOR pia | VACUUM SENSOR ee | reeeneeeray G+ _ | DISTRIBUTOR | at _ [ERMAN LAY VACUUM SENSOR. Bree: | eeccrereennet ve | ruporTicrosmonsenson | BATT | BATTERY & _ | DSTRIBUTOR 2 __| SENSOR GROUND = __[ ER MAINRELAY ioe [)aniTeR 'STA_| STARTER SWITCH 'Sr2_| SPEED SENSOR NSW _[ NEUTRAL START SWITCHENGINE — EFI SYSTEM ECU Wiring Connectors Voltage EG-181 No. Condition See pape 1 16 SWON 6-182 2 i 5 G8 ! Throttie valve open 3 i 1GSWON — £G-184 i Trrottie valve fully closed Throttle valve fully open 4 56-106 c= isswon #0 _ E07 5 | 420 “02 ae Zee Intake alr temp. 20 °C (68°F) 05-34 £6168 em ce Coolant temp. 80°C (176°F) 02210 EGa8e & | _StA-€1_| Cranking Gormore | E190 @ | _1GT=€1 | Cranking orig Pulse generation | EG-101 wo | (Soe | isswon ECU connectors disconnected 9-4 6-192 ve | weer | Ratoebin Grek eine woming bt of and ercng aay a ECU Terminals sri (M/7) sTig1 (A/T)ENGINE — EFI SYSTEM No. [Terminate “Trouble Condition | Bee No vattage (aswon teva (ON) ‘no votage between ECU terminals +B or +B1 and E1. and body ground. (1G SW ON} @ Check that ther a voltage between ECU terminal +B or «B1 nook ‘Check wiring between ECU terminal E1 and body ® ground. OK BAD Try another ECU, Repair or replace. Thacker ad 0 So eae oe fs | 240 napa or oplce OK ‘Check EFI main relay. BAD (See page EG-281 or 262) place, OK Check wiring between EF! main BAD sey Checking | 280 Pepa or ele.ENGINE — EFI SYSTEM €0-183 Condition STD Voltage BATT -E1 No voltoge, MAIN FL. ECU BATT eye (@ There is no vokage between ECU terminals BATT and Et. (Check that there is voltage between ECU tarminel BATT and and battery. ® body ground. NO OK Check wiring between ECU terminalE and body ® ground. me % ic Try enother ECU. Repair or replace, ‘heck oe nd aio | 242. Rocce Tex Chock wing between ECU toominal | BAD To orroniace,cae ENGINE — EFI SYSTEM. No. [Terminals [Trouble Condition TL -&2 Thvcttie vive open eee lta Ignition = = . es da ‘swith ON ‘Throttle valve fuby closed ae [Tattle valve Fully open. ecu Thole Position Sensor © IDL-E2 “There ig no voltage betwoon ECU terminals IDL and E2. © ug sw On throttle valve open) I Chock that there is volage between ECU terminal +8 or4B1 ® and body ground. 1G SW ON) ‘Check wiring between ECU terminal ET and body ‘ground. ic Teo Try another ECU. [Repair or repice Refer to +B- Et trouble section (No.1). (G28 page EG-182) Cheek that postion - sensor, (See page EG-248) omnia” | a > Cat —_— Repair or replace Check wiring between ECU and: throttle position r ‘ Thi Postion Sensor || Oi japoation seroor. | | thot postion senso Ox ve-| “Ty another ECU. vi IDL- a a rarnlENGINE — EFI SYSTEM 56-185 ol ve (DYE ites between ECU tarminale VE and 2. AG sw on Chock that there is voltage batwaen ECU terminal +8 or +B1 ‘and body ground. (1G SW ON} NO Reter to +8 — E1 trouble ‘Check throttle position sensor. ® (See page E6-248) soso ete te (See page EG-162) Tao = ‘Check wiring between ECU and thr eee | a wm — ix 7 oo 0 VTA - £2 ‘No specified voltage at ECU torminala VTA and E2. oa ew ont Throttle Position Sensor ‘Check that there Is voltage between ECU terminals VC and E2. a sw ont ® ‘Check throtde positon seneor. | BAD. © tSee page £6248) Se [ox Check wiring between ECU and BAD throttle position sensor. Repel or replsce. OK “Tey another ECU.ENGINE — EF! SYSTEM Condition ‘STD voltage 33-48V " Is SW ON oT ecu ne Vacuum Sensor (anil Achat Pressure Sensor There i no voltage batwean EGU terminals PIM or VC and E2. Dacswon i ‘Check that there is voltage between ECU terminal +B of +81, }® and body ground. 1G SW ON) OK Refer to «B-ET trouble section (No.1), (See page EG-182) @ Check wiring between ECU terminal E1 end body arovtd. OK [sao eer Aeon eae [eo 7 [ Reptoce vacuum (Cheek wiring between ECU and tareon aon senaoe Tee [es ‘Try another ECU, Repair or replace.ENGINE — EF1 SYSTEM ee IG WON ‘There is no voltage between ECU terminals #10 and/or #20 ® and E01 and/or E02. 1G SW ON) Check that there is voltage between ECU terminal #10 and/or ® feo antsy ound. wo fee Check wig bniwows EGU wrnnal ED araor ana body ground, Tox [= Try another ECU. Repair or replace. switch, 1 ‘Check fuse, fusible links and ignition |_BAD [- BAD.) Repsir orreplace.| OK SS Check resiatance of each injector © stp resistance: Approx 13.8.0 OK BAD Replace injector. ‘Check wiring between ECU terminal |_BAD : #10 and/or #20 and battery. et eeeeee ENGINE ~ EFI SYSTEM No.[ Terminals [Trouble Condition ‘STD voltage @ | THA-£2 | Novoltege | I@SWON | Intake sir temperature 20°C (65°F) 05-34V ECU Intake Air Temp. Sensor row “There is no voltage betwoen ECU terminals THA and E2, ®ocswom ‘Chock thet ther is voltage between ECU terminal «Bor +B1 © and body around. RG SW ON) ox No Rafer +8 -E1 trouble section No.1. {See page EG-182) ‘Check wiring between ECU terminal EV and body ground. OK BAD ‘Check intake’ sir tomp. senor. [ote ror OK ‘Check wiring betwoon ECU and intoke ‘irtemp. sensor. ox BAD Repair or replace,ENGINE — EFI SYSTEM EG-189 (No. [Terminals Trouble Condition STD voltage THW-E2 | Novahage | KGSWON | Coolant temperature 60°C (176°F) | _02-10V ecu row “There is no voltage between ECU terminale THW and E2. usswom ‘Check that there is vokage between ECU terminal +B or +B1 ® and body ground. 0G SW ON) Refer to 0B ET trouble section No.1). {Sea page EG-182) ‘Check wiring between ECU terminal £1 and body ground. ‘Check water temp. sensor }® 1300 page EG-271) Roplece water ‘temp. senor, [eo Repair or replace.EG-190 No. ENGINE — EFI SYSTEM ‘STD voltage 6Vormere (@ THe ino voltage between ECU terminals STA and E1, ‘0G SW START) Case (Check starter | ox | Check wiring between ECU terminal STA\ operetion. Checkwiring between ECU er ® ground, Tox Tey another ECU. Repair or replace. Check fuse, fusible links, battery, a wiring, atarta relay and ignition switah. [~~] "esto replace. (sep cemreneieeee | Cheek that there is wohtage at terminal BO of tater. UG SW START) STD voltage: "6 V or more ‘Chack wiring between 1). St2 and ‘starter relay, and 2). battery and starter terminal 60. Check starter,EG-191 IE — EFI SYSTEM No.| Terminals | Touble Condition ‘STD voltage 2 | 1eT-e9 No voltage ‘ang [Pulse generation ‘Thare is no voltage between ECU terminals IGT and E1. ® Gainer (Check that there is voltage between ECU terminal IGT and ® body sraund. desing) NO OK Check wiring between ECU |_Bap_[ Repair or ® rermninal E1 and body ground. replace. OK ‘Try another ECU. (Check fusible links and ignition BAD J repair or replace. (Cheek distributor. BAD. I Repair or replace. Repair or replace. BAD Check igniter. (See page IG-11) | 42. Rapsir or replace.cee ENGINE. EFI SYSTEM No. Terminals Trouble Condition ‘STD voltage 10] SoS-e No voitege |1G SW ON| ECU connectore-dieconnected s-4V There is no voltage between ECU tarminals ISCC or iSCO and E1. Diaswom ‘Check that thera is voltage between ECU terminal +B or 4B 1 and body ground. 1G SW ON} OK NO Refer to +B-E1 trouble section (No.1). (See page EG-122) ‘Check resistance between ISC valye terminals «8 and ISCC or ap, | nepiacetse @'sco. eee ts STD resistance: Aprox. 193-2239 OK Cheek wiring between ECU and. BAD. eae [BAD Repair or reptoce.|" Weer Novokeage ‘No trouble "CHECK" engine warning light off Seay _and engine running. To Ignition Switch 1161) Theres no volage botweon ECU tominole Wand ET, ® patina) (@ Check that there ie voltage between ECU terminal W and body ground. NO (Check wiring between ECU terminal E1 and body. ® ground. ‘Try another ECU. Repair or replace. ‘Check GAUGE fuse (10 A) and “CHECK” engine warning light. OK BAD Repair or replace. Repair or replace.faut ENGINE — EF! SYSTEM ‘To EFI Main Relay (There is no voltage between ECU terminals VF and Er. ‘Check that there is vahage between ECU terminal VF and body ound. ‘Chack distributor and Ignition systom. (See page IG-7) Check fuel pressure. BAD {See page EG-195) | ieee Check vacuum sensor. BAD (See pate EG-275) Repair (@ Check operetion of oxygen oK senaor. (See page EG-284) Ea} earn] OK i aaaoe ee FUEL PUMP SYSTEM CIRCUIT s ON—VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION (a) Using SST, connect terminals +B and FP of the check connector. SST 09843-18020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine.ENGINE. ~ EFI SYSTEM cC) @ fe) Negative (-) Terminal Cable 2 fa) (b) Check that there is pressure. the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the following parts: © ~~ Fusible link = H-fuse Fuses EFI main relay Neutral start switch ecu Fuel pump Wiring connections the fuel inlet hose from ‘Turn the ignition switch to LOCK. Remove the SST from the check connecter. ‘SST 09843-18020 CHECK FUEL PRESSURE Check that the battery voltage is above 12 V. Disconnect the negative (—) terminal cable from the battery.ENGINE — EF] SYSTEM. ews NeW SST (Union) SS Gasker aus Sst (0) (a) ®) @ (h) £6-197 S202: Remove the union bolt and 2 gaskets, and disconnect ‘the fuel inlet ose from the fuel filter outlet. ST191; Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel inlet pipe. CAUTION: © Put a suitable container ar shop rag under the fusl {filter of fuel Inlet pipe. ‘© Slowly loosen the union bolt, ©. When removing the unlen bolt, fix the fuel filter in place using @ spanner. $7202: Install the fuet inlet hose and SST (pressure gauge) to the fuel filter with 3 new gaskets and SST (union bolt). ST191: Install the fuel inlet hose and SST (pressure gauge) to the fuel inlet pipe with 3 new gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N-m (300 kgf-cm, 22 ft-lbf) Wips off any splatterad gasoline. Using SST, connect terminals +B and FP of the check connector, SST 09843-18020 Reconnect the negative (—) terminal cable to the battery.Eanee ENGINE — EFI SYSTEM (Turn the ignition switch ON. (j) Measure the fuel pressure. Fuel pressure: 265 — 304 kPa (2.7 — 3.1 kgf/cm’, 38 — 44 psi) If prassure is high, replace the fuel pressure regulator. If pressure is low, chack the following parts: © Fuel hoses and connections 7 © Fuel pump © Fusl filter — Fuel pressure regulator {k) Remove the SST from the check connector. pa SST 09483-18020 () Start the engine. (m) Disconnect the vacuum sensing hose from the fuel Pressure regulator, and plug the hose end.EG-199 ENGINE — EF! SYSTEM ‘sT202 {o) tes sTist / H, fRecgnnect = () {n) Measure the fue! pressure at idle. Fue! pressure: 265 — 304 kPa (2.7 ~ 3.1 kgt/om’, 38 — 44 pai) Reconnect the vacuum sensing hose to the fuel pres- sure regulator. Measure the fuel pressure at idle. Fuel pressure: 206 — 255 kPa (2.1 — 2.6 kaf/om’. 31 — 37 psi) If pressure is not as specified, check the vacuum ‘sensing hose and fuel pressure regulator.£G-200 ENGINE — EFI SYSTEM ‘st202 For 5 Minutes After Engine has Stopped (gq) Stop the engine. (1) Chock that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: a 147 kPa (1.6 kgf/em?, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and cerefully remove the SST to pravent gasoline from splashing. ) ‘SST 09268-45012 {) 81202: Reconnect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt. ST191: Reconnect the fuel inlet hose to the fuel:inlet pipe with with 2 new gaskets and the union bolt. ‘Torque: 29 N-m (300 kgf-cm, 22 fbf) CAUTION: When instelling the union bolt, fix the fuel filter in place using a spanner. (u) Reconnect the negative (—) terminal cable to the battery. (¥) Check for fuel leaks. (See page EG—163)ENGINE — EFI SYSTEM £e-201 COMPONENTS FOR REMOVAL AND INSTALLATION Rear Seat Cushion Fuet Pump and ‘Sender Gauge Tim tkgfem, fbi) | : Specified torque $ Nor-rusabe Forse with S61"6-202 ‘Negative (-) Terminal Cable sT202 ‘ST191 Type A ‘Type 8 & . Ee & eS < WY _ a 18 vase ENGINE — EFI SYSTEM. FUEL PUMP REMOVAL (See Components for Removal and Installation) 3. fa) @) @) CAUTION: Do not smoke or work near an open flame whan working on the fuel pump. DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY REMOVE REAR SEAT CUSHION REMOVE SERVICE HOLE COVER $7202: Remove the 4 screws, service hole cover and clamp, ‘ST191; ‘Type A: Remove the 5 screws and service hole cover. ‘Type B: Disconnect the sub—wire harness. Remove the 5 screws and service hole cover. REMOVE FUEL PUMP AND SENDER GAUGE ‘ASSEMBLY Disconnéot the following connector, pipe and hose: (1) Fuet pump & sender gauge connector (2) Fuel outlet pipe (8) Fuel return hoseENGINE — EFi SYSTEM ewes (b) Remove the @ bolts. {c} Remove the fuel pump, sender gauge assembly and gasket. FUEL PUMP INSPECTION 1, INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 ~ 3.0 Q at 20°C (68°F) If the resistance is not as specified, replace the fuel pump, lead wire or connector. 2. INSPECT FUEL PUMP OPERATION Connect a tester eed from terminal 4 of the connector to the positive (+) terminal of the battery; connect another tester lead from terminal 5 of the connector to tha negative (—) terminal of the battery. NOTICE: © — These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out. ‘© Keep the fusl pump as far away from the battery as possible. © — Always connect or disconnect at the battery. {f operation is not as specified, replace the fuel pump, lead wire or connector.EG-204 ENGINE — EFL SYSTEM Fuel Sender Gauge Lead Wire for Fuel Pump Connector. Support risen © Non-reusable pert —— — eS COMPONENTS FOR DISASSEMBLY AND ASSEMBLY Fuel Pump "+ oii GQ tiecsion aoe FUEL PUMP DISASSEMBLY {See Components for Disassembly and Assembly) 1. REMOVE FUEL PUMP FROM PUMP BRACKET (2) Disconnect the lead wire from the connector. (b} ~ Pull out the lower side of the fuel pump from the pump bracket. {c) Remove the rubber cushion from the fuel pump. {d) Disconnect the fuel hose from infet port of the fuel pump, and remove the fuel pump.ENGINE — EFI SYSTEM beatae 2. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Remove the clip. (b) Pull out the fuel pump filter, 3. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET (@) Disconnect the tuel sender gauge connector from the “sonnector, {b) Remove the 2 screws and sender gauge. 4, REMOVE CONNECTOR Remove the 2 screws, connector support, connector and gasket. FUEL PUMP ASSEMBLY {See Components for Disessembly and Assembly) 1.” INSTALL CONNECTOR Install a new gasket, the connector and connector ‘Support with the 2 screws. 2. INSTALL FUEL SENDER GAUGE TO FUEL PUMP BRACKET {e) Install the sender gauge with the 2 screws. {b) Connect the fuel sender gauge connector to the con- rector.EG-206 ENGINE — EFI SYSTEM 3. INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the fuel pump filter with a new clip. |. INSTALL. FUEL PUMP TO FUEL PUMP BRACKET {e) Connect the fus! hose to the outlet port of the fuel pump. (b) Install the rubber cushion to the fuel pump. (0) Install the fuel pump by pushing the lower side of the fuel pump. : {a} Connect the lead wire to the connector. FUEL PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY (a) Install a gasket to the fuel pump bracket. (b) insert the fuel pump and sender gauge assembly into the fuel tank. Install the fuel pump bracket with the 8 bolts, Torque: 4.0 N-m (40 kgf-cm, 36 in.lbf) ©)ENGINE — EFI SYSTEM eee (d) Connect the folt connector, pipe and hose: (1) Fuel pump & sender gauge connector: (2) Fuel outlet pipe HINT: Use SST. (See page EG— 163) SST 09631-22020 Torque: ‘$7202; 28 N-m (280 kaf-om, 21 ft-lbf) sT 30 N-m (310 kgf-om, 22 ft-Ibf) (3) Fuel return hose CONNECT NEGATIVE (—) TERMINAL CABLE TO BATTERY CHECK FOR FUEL LEAKS {See page EG—163) INSTALL SERVICE HOLE COVER ‘$T202: Install the service hole cover with the 4 screws. STI191: Type A: Install the service hole cover with the 5 screws. ‘Type 8: Connect the sub—wire haness, Install the service hole cover with the 5 screws. 4. INSTALL REAR SEAT CUSHIONENGINE — EFi SYSTEM FUEL PRESSURE REGULATOR (ST202) ON—VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page EG— 196)ENGINE — EFI SYSTEM Looe COMPONENTS FOR REMOVAL AND INSTALLATION AIC tdle-Up Valve AIC Idlo-Up Valve ctor (w/ Air Hose} : ‘Conneat FUEL PRESSURE REGULATOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY 2, REMOVE A/C IDLE—UP VALVE {a) Disconnect the following connector and hoses: (1) A/C Idle—up valve connector {2} Air hose from intake manifold (3) Air hose from air tubeENGINE — EFI SYSTEM (b) Remove the 2 bolts and idle—up valve. 3. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 4. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR Remove the union bolt and 2 gaskets, and disconnect the return pipe from the pressure regulator. CAUTION: © Puta sultable container or shop rag under the Pressure regulator. © Slowly loosen the union bolt. 5, REMOVE FUEL PRESSURE REGULATOR (a) Remove the 2 bolts, and pull out the pressure regulator. {b) Remove the O—ring from the pressure regulator.ENGINE — EFI SYSTEM Lac FUEL PRESSURE REGULATOR INSTALLATION {See Components for Removal and Installation) 1. INSTALL FUEL PRESSURE REGULATOR (2) Apply a light coat of gasoline to 2 new O—ring, and install it to the pressure regulator. {b) _ Attach the pressure regulator to the dalivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If It does not rotate smoothly, the O—ring may be pinched, so remove the pressure reguletor and perform again steps (b) and {c) above. (4) install the pressure regulator with the 2 bolts. Torque: 6.4 N.m (55 kgf-cm, 48 inwibf) 2. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR Install the return pipe with 2 new gaskets and the union bolt, Torque: 19 Wm (196 kat-om. 14 FtibfEG-212 ENGINE — EF! SYSTEM. 3. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR INSTALL A/C IDLE—UP VALVE {e) Install the A/C idle—up valve with the 2 bolts. ) Connect the following connector and hoses: {1) A/C idle—up valve connector (2) Air intake manifold 43) Air hose to air tube _ 5. CONNECT NEGATIVE (—) TERMINAL CABLE TO” BATTERY " ®. CHECK FOR FUEL LEAKS {See page EG— 163)ENGINE — EF! SYSTEM Eo-213 FUEL PRESSURE REGULATOR (ST191) ON—VEHICLE INSPECTION INSPECT FUEL PRESSURE ge EG—196}Ene ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION Accelerator Bracket ‘with Control Cable PS Oil Reservoir. Reson Hose gE i i Engine Wire Protector Fuel Proseure. Reguletor [Kem gfe, RIB] : Specified torque ‘@ Non-revsabie part — someENGINE — EFI SYSTEM. ti FUEL PRESSURE REGULATOR REMOVAL (See Components for Removal and Installation) 1. - DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY 2. REMOVE ACCELERATOR CABLE BRACKET (a) Disconnect the control cables from the throttle linkage. {b) Remove the 2 bolts and accelerator bracket. 3. REMOVE CYLINDER HEAD COVER (2) Disconnect the high — tension cords at the rubber boot. NOTICE: Pulling on or bending the cords may damage the sonductor inside. Do not pull on the high—tension cords. {b) Disconnect the 2 PCV hoses from the intake manifold and throttle body. (6) Disconnect the PS oil reservoir return hose from the ‘engine wire protecter. (d) Disconnect the 2 clamps of the engine wire protector from the mounting bolts of the No.2 timing belt cover in the sequence shown.EG.216 ENGINE — EFI SYSTEM. {e) Remove the 4 nuts, grommets, cylinder head cover and gasket. NOTICE: Cover the cylinder head with a clean cloth to Prevent dirt, ste. getting into the oylinder head. 4, DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 5. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR Remove the union bolt and 2 gaskets, and disconnect ‘the return pipe from the pressure regulator. CAUTION: Puta suitable container or shop rag under the Pressure regulator. ‘© Slowly ioosen the union bolt. 6. REMOVE FUEL PRESSURE REGULATOR {a} Remove the 2 bolts, and pull out the pressure regulator. (b) Remove the O—ring from the pressure regulator,ENGINE — EFI SYSTEM caeae FUEL PRESSURE REGULATOR INSTALLATION (See Components for Removal and Installation) 1, INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new O—ring, and install it to the pressure regulator. (b) Attach the pressure regulator to the delivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If It doos not rotate smoothly, the O-ring may be pinched, so remove the pressure regulator and perform again steps (b) and (c) above. Regulator {d) Install the pressure regulator with the 2 bolts. Torque: 5.4 N-m (55 kgf-cm, 48 in.Ibf) 2. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR Install the return pipe with 2 new gaskets and the union bolt, Torque: 19 N-m (198 kat-om, 14 fells)ENGINE — EFI SYSTEM 3. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR 4. INSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material, (b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No, 08826-00080 or equivelent (©) Install the gasket to the cylinder head cover. (6) Install the cylinder head cover with the 4 grommets and nuts. Torque: 23 Nem (230 kaf-em, 17 tt4bf] ) Install the 2 clamps of the engine wire protecter'to the mounting bolts of the No.2 timing belt cover in the ‘sequence shown. {f) Install the PS oil reservoir return hose to the engine wire protector. a Prat Wire Protector coal (9) Connect the 2 PCV hoses to the intake manifold and ‘throttle body. (h) Connect the 4 high—tension cords to the spark plugs.ENGINE ~ EFI SYSTEM Ea2te 5. INSTALL ACCELERATOR GABLE BRACKET (a) Install the accelerator cable bracket with the 2 bolts. {b) Connect the contro! cables to the throttle linkage. 6. CONNECT NEGATIVE (—) TERMINAL CABLE TO BATTERY 7. CHECK FOR FUEL LEAKS {See page EG— 163)bestia ENGINE — EF! SYSTEM INJECTOR (ST202) Injector {2Sanactor Color: Green) Engine (ECT ECU To Ignition Switch 4NG2)ENGINE ~ EFI SYSTEM So.22t ON-—VEHICLE INSPECTION 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. (2) With the engine running or cranking, use a sound scope to check thet there is 2 normel operating noise in proportion to engine speed. o If you have no sound scope, you can check the injec- tor transmission operation with your finger. Hf no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the Ecu, ‘2. INSPECT INJECTOR RESISTANCE (2) Disconnect the injector connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 — 14.2 © at 20°C (68°F) If the resistance is not as specified, replace the injector. (c) Reconnect the injector connector. we&G-222 ENGINE — EFL SYSTEM. COMPONENTS FOR REMOVAL AND INSTALLATION HighTension Cord Aecelerator Bracket with Control Cable Fuol Inlet Hose ijector tj f Pov ~ >) Nem (kgfem, fib} : Specified torque ‘@ Nor-reusable partENGINE — EFi SYSTEM INJECTORS REMOVAL Negative (-) Termine! Gable EG-223 {See Components for Removal end Installation) 1 (2) DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY DISCONNECT INTAKE AIR TEMPERATURE ‘SENSOR FROM AIR CLEANER CAP REMOVE AIR CLEANER CAP DISCONNECT ACCELEARTOR CABLE FROM THOTTLE BODY DISCONNECT A/T THOTTLE CABLE FROM THOTTLE BODY DISCONNECT THROTTLE BODY FROM INTAKE ‘MANIFOLD Disconnect the following hoses: (1) w/ EVAP: Vacuum hose (2) PCV hose Type A: Remove the 4 bolts. ‘Type B: Remove the 2 bolts and 2 nuts. Disconnect the throttle body from the intake manifold. Remove the gasket. REMOVE CYLINDER HEAD COVER Disconnect the 4 high—tension cords fram the clamp ‘on the cylinder head cover. Disconnect the high — tension cords at the rubber boot. Do not pull on the high—tension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside.ENGINE — EF} SYSTEM. {c) Remove the 2 bolts, and disconnect the accelerator cable bracket from the intake manifold, {d) Disconnect the PCV hose from the intake manifold. (0) Disconnect the engine wire protector from the 2 mou- nting bolts of the No.2 timing belt cover in the ‘sequence shown. {f) \ Remove the 4 nuts, grommets, cylinder head cover and gasket. NOTICE: Cover the cylinder head with a clean cloth to Prevent dirt, etc. getting into the cylinder head. HINT: Arrange the grommets in the correct order, so that they can be rainstalled into their original posi- tions. This minimizes any possibility of oil leakage due to reuse of the grommets in different positions. 8 REMOVE DELIVERY PIPE AND INJECTORS (2) Disconnect the vacuum sensing hose from the fuel Pressure regulator,ENGINE — EFI SYSTEM cone (b) Remove the bolt, and disconnect the engine wire protector from the LH side of the intake manifold. (0) Disconnect the 4 injactor connectors. {d) Disconnect the engine wire protector from the 2 brackets on the front side of the intake manifold. {0} Remove the union bolt and 2 gaskets, and disconnect the fus! inlot hose from the delivery pipe. {f) Disconnect the fuel return hose from the return pipe. (9) Remove the 2 bolts holding the delivery pipe to the cylinder head.Grommet ze ENGINE —-EF! SYSTEM th) i) 0 Remove the delivery pipe from the 4 injectors, and remove the delivery pipe. Pull out the 4 injectors. NOTICE: Be careful not to drop the injectors. Remove the 4 insulators and 2 spacers from the intake manifold. Remove the O-ring and grommat from each injector.ENGINE — EF! SYSTEM bects INJECTORS INSPECTION 1, INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. sst (Hose) Fuel Pressure Regulator q oe Eas a i—s., a sst (Clamp! Injector Fuel Return Hose 40n Vehicle} rsa {a) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet. CAUTION: When removing or instaliing the union bolt, fix the fuel filter in place using » spanner. {b) Connect SST (union and hose) to the fuel filter outlet es ee with 2 new gaskets and union bolts. a {Wnion}, New ‘SST 09268~ 41046 (90405-09016) fil BAD > Gasket ‘Torque: 28 N.m (300 kgf.cm, 22 ftibf) Fuel FitterEG-228 Pressure. Regulator New Saat of eRe Hose New O-Ring: Injector Viny! Hose: Fuel 8 AO sst (oi —f sst ENGINE — EFI SYSTEM soe “O {union} tien!) = (Hose) (Clamp) Grommont (o) ) (@) Ci} (@) th) @ a ky wo Remove the pressure regulator from the delivery pipe. {See step 5 on page EG—210) Inst intet. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts, SST 08268~41045 (09268-41080) Torque: 5.4 N-m (55 kgf-om. 48 ftlbf) Connect the fuel return hose to the’ fuel pressure regulator outlat with SST (union), 2 new gaskets and union bolt, SST 08268-41045 (09268-41080) ‘Torque: 18 N-m (180 kgf-cm, 13 ft-4bf) Install the grommet and a new O—ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). ‘SST 09268-41045 Put the injector into a graduated cylind. CAUTION: Install o suitable vinyl hove onto the injector ‘to prevent gasoline from splashing-out. a new O~ring to the fuel pressure regulator Using SST. connect termin: connector. SST.09843-18020 Reconnect the negative (~) terminal cable to the battery. +B and FP of the check ‘Turn the ignition switch ON. NOTICE: Do not start the engine,ENGINE — EF! SYSTEM eoaee (mm) Connect-SST (wire) to the injector and battery for 15 seconds, and measure the injection volume. with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 49 — 59 em* (3.0 — 3.6 cu In.) per 16 sec. Difference between each injector: 5 cm' (0.3 cu in) or leas If the injection volume is not as specified, replace the injector. . INSPECT LEAKAGE (a) In the condition above, disconnect the tester, probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fusl drop: (One drop or less per minute. {b) Turn the ignition switch to LOCK. (©) Disconnect the negative (—) terminal cable from the battery. : {d) Remove the SST. SST 09268-41045, 09842-30070, 09843-18020 fe) Reinstall the pressure regulator to the delivery pipe. (See step 1 on page EG—211) (f) Reconnect the fuel inlet hose to the fuel filter outlet with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgt-em, 22 ftibf) CAUTION: When removing or Installing the union bolt. fix the fuel filter in place using a spanner.eaceees ENGINE — EFI SYSTEM INJECTORS INSTALLATION (See Components for Removal and Installation) — 1. INSTALL INJECTORS AND DELIVERY PIPE Osning (a) Install a new grommet to each injector. {b) Apply a light coat of gasoline onto a new Oring, and install it to each injector. (0) Install the following parts to the intake manifold: (1) 2 spacers (2) 4 new insulators (d) Place the delivery pipe bétween the intake manifold and cylinder hes (©) While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors. (f) ‘Position the injector connector upward. i) Attach the 4 injectors and delivery pipe assembly’ to the oylinder head. (h) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. @ Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable ‘cause is incorrect installation of O—rings. Replace the O-rings. (Position the injector.connector upward.ENGINE — EFI SYSTEM. EG-231 (k) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N-m (130 kgf-om, 9 ftbf) () Connect the fuel inlet hose to the delivery pipe with 2 new gaskets and the union bolt. ‘Torque: 34 N-m (350 kof-em, 26 ftlbf) NOTICE: Be careful of the fuel inlet hose installation direction. (m) Connect the fuel return hose to the return pipe. Install the the engine wire protector to the 2 brackets ‘on the front side of the intake manifold. () (©) Connect the 4 injector connectors. HINT: The No.1 and No.3 injector connectors. are brown, and the No.2 and No.4 injactor connactors are gray. Install the engine Wire protector to LH side of the intake manifold with the bolt.EG.232 cee ea eee @) @ ® ©) (a) @ Connect the vacuum regulator. to the fuel pressure {INSTALL CYLINDER HEAD COVER: Remove any old packing (FIPG) material. Apply seal packing to the cylinder head.as shown in the illustration. Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the cylinder head cover with the 4 grommets and nuts, Torque: 23 Nem (230 kgf-cm, 17 ft-lbf) Install the engine wire protector to the 2 mounting bolts of the No.2 timing belt cover in the sequence shown. ‘Connect the PCV hose to the intake manifold. Install the cable bracket with the 2 bolts, ‘Connect the 4 high—tension cords to the spark plugs. Install the 4 high—tension cords to the clamp on the cylinder head cover,ENGINE — EFI SYSTEM — datas 3. INSTALL THROTTLE BODY (@) Attach # new gasket to the intake manifold, facing the protrusion downward. {b) Type A: Install the throttle body with the.4 bolts. ‘Torque: 19 N.m (195 kgf-om. 14 tlbf} HINT: Different bolt lengths are used for the upper and lower sides, Bolt length: Upper side: 40 mm (1.89 in.) Lower side: 85. mm (2.17 in) () Type B: Install the throttle body with the 2 bolts and 2 nuts. Torque: 19 Nom (198 kgf-om. 14 telbt) (d) Connect the following hoses: (1) w/ EVAP: Vacuum hose (2) PCV hose A/T: CONNECT A/T THROTTLE CABLE TO THROTTLE BODY CONNECT ACCELERTOR CABLE TO THROTTLE BODY @. INSTALL AIR CLEANER CAP 7. CONNECT INTAKE AIR TEMPERATURE SENSOR TO AIR CLEANER CAP 8, CONNECT NEGATIVE (—) TERMINAL CABLE TO BATTERY 9. CHECK FOR FUEL LEAKS {See page EG— 163)Paaae ENGINE ~ EF! SYSTEM INJECTOR (ST191)ENGINE — EFI SYSTEM Lent ON—VEHICLE INSPECTION 1. INSPECT INJECTOR OPERATION Check operation sound fram each injector. (2) With the engine running or cranking, use a sound scope to check that there is a normal operating noise in proportion to engine speed. {b) If you have no sound scope, you can check the injector transmission operation with a screwdriver. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECU. 2, INSPECT INJECTOR RESISTANCE @) injector connector. o , Measure the resistance between the terminals, Resistance: 13.4 — 14.2 © at 20°C (68°F) If the resistance is not as specified, replace the injector. {c) Reconnect the injéctor connector.ates ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION High-Tension PS Oil Reservoir ‘Accelerator Bracket oy Qos #0-Ring—— + Grommet Spacer: © Gacket. Injector Fuel Pulsstion Damper: : Vacuum Hose ¢ Insulator tarcorh No.2 Intake Manifold Stay: ‘Throttle Body ti DZ me DA. Nm ikgFem, fbf) : Specified torque ‘@ Non-reusabie part * For use with SSTENGINE — EFI SYSTEM Lien INJECTORS REMOVAL (See Components for Removal and Installation) fa) tb) fo REMOVAL THROTTLE BODY {See page EG—251) REMOVE LH ENGINE HANGER AND No.2 INTAKE MANIFOLD STAY Remove the bolt, nut, engine hanger and manifold stay. w/ EGR: REMOVE EGR VALVE AND PIPE Disconnect the following hoses from the EGR valve: (1) Vacuum hose (from port E of VSV) (2) EGR hose (from vacuum modulator) Loosen the cylinder head side of the EGR pipe union nut. Remove the 2 nuts, the EGR valve, pipe assembly and gasket. - REMOVE NO.1 INTAKE MANIFOLD STAY Remove the 2 bolts and manifold stay.EG-238 ENGINE — EFI SYSTEM ror 5. fe) @ fe) (d) @ Cc) te) REMOVE CYLINDER HEAD COVER (See steps 1 and 2 on page EG— 19) DISCONNECT FUEL INLET HOSE AND FUEL RETURN HOSE Disconnect the clamp of the engine wire from the wire bracket. Using SST. loosan the fuel pulsation damper. SST 09612-24014 (09617—24011) Remove the fuel pulsation damper end 2 gaskets, and disconnect the fuel inlet hose from the delivery pipe. Disconnect fuel return hose from return pipe. REMOVE DELIVERY PIPE AND INJECTORS Disconnect the 2 clamps of the engine wire from the wire brackets on the intake manifold, Disconnect the vacuum sensirig hose from the fuel pressure regulator. Disconnect the 4 injector connectors.ENGINE — EFI SYSTEM EG-239 (d)_ Reriove the 2 bolts holding the delivery pipe to the cylinder head. (0) Remove the delivery pipe together with the 4 injectors by following the instructions as shown in the illustrations. NOTICE: Be careful not to drop the injectors when rem- oving the delivery pipe. (f) Remove the 4 insulators and 2 spacers from the cylinder head, @ Pull out the 4 injectors from the delivery pipe. th) Remove the O—ring and grommet from each injector. 0-Ring Grommet reneoe ENGINE — EFI SYSTEM INJECTORS INSPECTION 1, INSPECT INJECTOR INJECTION CAUTION: Koop injector clear of sparks during the test. Fuel Pressure Regulstor sst (Union) sst {Union} Sst (Ctarnp) Injector Fuel Iniet Pipe (On Vehicle} {2} Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel inlet pipe. (b) Connect SST (union and hose) to the fuel inlet pipe with 2 new gaskets and union bolts. SST 09268-41045 (90405-09015) Torque: 26 N.m (300 kgf-cm, 22 ftlbf)ENGINE — EFI SYSTEM Pressure. (Union) Fuet New SST Regulator z New cs Gasket ) ‘ssf Hove) eo z= eB BA hn Fuel Return New O-Ring: (Clamp) Injector: Gromment Vinyl Hose: rosie Sst or EG-241 {c) Remove the fuel pressure regulator from the delivery pipe. {See step 4 on page EG—216) (4) Install a new O-ring to the fuel pressure regulator inlet. {e) Connect SST (hose) to the fuel pressure regulator inlet with SST (union) and the 2 bolts. SST 09268-41045 (09268-41090) Torque: 5.4 N.m (65 kgf.om, 48 in.-Ibf) (Connect the fuel return hose to the pressure regulator outlet with SST (union), 2 new gaskets and union bolt. SST 09268-41046 (09268-41080) Torque: 18 N-m (180 kgf-om, 13 ft-tbf) (9) Install the grommet and a new O-ririg to the injector. (h) Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41045 (Put the injector into the graduated cylinder. CAUTION: Install » suitable viny! hose onto the injector to prevent gasoline from splashing out. fi) Using SST, connect terminals +B and FP of the check connector. SST 09843-18020 {k) Reconnect the negative (—) terminal cable to the battery. @ Turn the ignition switch ON. NOTICE: Do not start the engine.FG-242 ENGINE — EFI SYSTEM (m) Connect SST (wire) to the injector and battery for 15 seconds. and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 49 — 59 cm’ (3.0 — 3.6 cu in.) por 15 sec. Difference between each injector: 5 cm? (0.3 cu In.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE {a)_ In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the Injector. SST 09842-30070 Joss per minute {b) Turn the ignition switch to LOCK. {c) Disconnect the negative (—) terminal cable from the battery. (a) Remove the SST. SST 09268-41045, 09842-30070, 09843-18020 ) Reinstall the fuel pressure regulator to the delivery pips. (See step 1 on page EG—217) (f) Reconnect the fuel inlet hose to thé fuel inlet pipe with 2 new gaskets and the union bolt. ‘Torque: 29 N-m (300 kgf-em, 22 ftbf)ENGINE — EFI SYSTEM eaeae INJECTORS INSTALLATION (See Components for Removai and Installation) 1 f@) tb) © td) @) INSTALL INJECTORS AND DELIVERY PIPE Install a new grommet to the injector. Apply a light coat of gasoline onto a new O-ring, and install it to each injector. Place 4 new irisulators and the 2 spacers in position on the cylinder head. ‘While turning the injector left and right, install it to the delivery pipe. install the 4 injectors. Position the injector connector upward. Install the 4 injectors and delivery pipe assembly to: ‘the cylinder head by following the instructions as shown in the illustration. ‘Temporarily install the 2 bolts holding the delivery pipe to the cylinder head.Lal ENGINE ~ EFI SYSTEM {h) Chock that the injectors rotate smocthly. HINT: If injectors do not rotate emoothly, the probable cause is incorrect installation of O—rings. Replace the O-rings. (0 Position the injector connector upward. @- Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N-m (130 kgf-em, 9 ft-Ibf) {k) Connect the vacuum sensing hése to the fuel pressure regulator: () Install the 2 clamps of the engine wire to the wire brackets on the intake manifold. (m) Connect the 4 injector connectors. CONNECT FUEL RETURN HOSE TO RETURN PIPE ‘CONNECT FUEL INLET HOSE TO DELIVERY PIPE ) Temporarily connect the fuel inlet hose with 2 new gaskets and fuel pulsation damper. (b) Using SST, tighten the fuel pulsation damper. SST 09612-24014 (09617-24011) Torque: 34 Nem (350 kgf-om, 26 frlbf) 29 N.m (300 kat-om. 22 ttlbf) for use with SST eerENGINE ~ EFl SYSTEM EG-245 HINT:Use a torque wrench with a fulcrum length of 30 cm (11.81 in,). {c) Install the clamp of the engine wire to the wire clamp. 4. INSTALL CYLINDER HEAD COVER (See step 6 on page EG—24) 6. INSTALL NO.1 INTAKE MANIFOLD STAY Install the manifold stay with the 2 bolts. Torque: 42 N-m (425 kgfiem, 31 fbf) 6. w/ EGR: INSTALL EGR VALVE AND PIPE {a) Install a new gasket, the EGR valve and pipe assembly with the union nut and 2 nuts. Torque: Nut: 19 Nem (130 kgf-em, @ ftlbf) Union nut: 68 N-m (600 kaf-om, 43 ftlbf) (b) Connect the following hoses to the EGR valve: (1) Vacuum hose (from port E of VSV) (2) EGR hose (from vacuum modulator)ENGINE — EFI SYSTEM 7 INSTALL NO.2 INTAKE MANIFOLD STAY AND LH ENGINE HANGER Install the No.2 intake manifold stay and LH engine hanger with the bolt and nut. Torque: 42 Nim (425 kef-cm, 31 fbf) INSTALL THROTTLE BODY (See page EG—255)EG-247 ENGINE — EF! SYSTEM THROTTLE BODY éENGINE — EFi SYSTEM. ON~VEHICLE INPSECTION Throttle Body INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (0) Check the vacuum at each port. © Start the engine. * Check the vacuum with the vacuum hoses pick your finger. Por ilo ‘Other than ile Ne vecuam Vacuum =z ‘Ne vacuum Vacuum © ‘No vacuum Ne vecuum Throttle Position Sensor INSPECT THROTTLE POSITION SENSOR (a) Disconnect the sensor connector. (b)_w/ Throttle Opener: © Disconnect the vacuum hose from the throttle opener. ‘© Apply vacuum to the throttle opener. (c) Insert a feeler gauge between the throttle stop screw and stop lever. (d)_ Using an ohmmeter, measure the resistance between each terminal. Gearance orwwen |" aetwsan terminals Resletance lever and stop sorew. Oram (im VIA-e, 0257 Ko (0.50 mom (0020 in} DL-e 23 KO or les 10.70 mmm (00028 Ia) wm - Tefiniey Lapialniohent VTA- 2 20-102ko oven = vo- = 25 — 59Ko {e) w/ Throttle Opener: Reconnect the vacuum hose to the throttle opener, (f) Reconnect the sensor connector.ENGINE — EF! SYSTEM EG-249 1,300 - 1,600 rpm RPM Techometer Throttle Opener 1. WARM UP ENGINE . Allow tha engine to warm up to normal operating. temperature, 2. CONNECT TACHOMETER (See step 2 on page EG—26) ee) 3. CHECK IDLE SPEED (Ses page EG—27) Idle speed: 700 + 50 rpm 4, CHECK AND ADJUST THROTTLE OPENER SETTING SPEED (a) Disconnect the vacuum hose from the throttle opener, and plug the hose end. b) Maintain the engine speed at 2,500 rpm. {c) Release the throttle valve. {d) Check that the throttle opener is set. Throttle opener satting speed: 1,300 — 1,500 rpm (w/ Cooling fan OFF) If setting is not as specified, adjust the throttle valve.ENGINE — EFI SYSTEM (0) Adjust the throttle opener setting speed by turning the throttle opener adjusting screw. ‘Throttle opener setting speed: 1,400 rpm (w/ Cooling fan OFF} Reconnect the vacuum hose to'the throttle opener. DISCONNECT TACHOMETERENGINE — EFI SYSTEM EG-251 COMPONENTS FOR REMOVAL AND INSTALLATION Vacuum Hose AST Throttte Control Cable ‘Throttle Position ‘Sensor Connector Fe uaa (Ee J Tyee a aoe & 180 Valve Connector om >) al sirvos Nim (kgfem, RIbi ) : Specified torque [Hkoten, eA] Weter Sypees @ Nomreusable pan Hose THROTTLE BODY REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY 2. DRAIN ENGINE COOLANT 3. DISCONNECT INTAKE AIR TEMPERATURE SENSOR FROM AIR CLEANER CAP 4, REMOVE AIR CLEANER CAP 5. DISCONNECT ACCELERTOR CABLE FROM THOTTLE BODY 6. A/T: DISCONNECT A/T THOTTLE CABLE FROM THOTTLE BODYENGINE — EFI SYSTEM (b) (eo) (a) r} (9) DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLD Disconnect the following connectors: (1) Throttle position sensor connector (2) ISC valve connector Disconnect the following hoses: (1) w/ EVAP: Vacuum hose (2) w/ EGR: Vacuum hoses (3) PCV hose Type A: Remove the 4 bolts. Type B: Remove the 2 bolts and 2 nuts. Disconnect the throttle body from the intake manifold, - Remove the gasket. Disconnect the following hoses from the throttle body, and remove the throttle body: (i) Water bypass hoses (2) Air hoseENGINE — EFI SYSTEM 9.500" 4 70mm Stop Lever EG-253. THROTTLE BODY INSPECTION Throttle Body 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner, clean the cast parts. {b} Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the ‘throttle position sensor and throttle opener. 2 INSPECT THROTTLE VALVE (2) w/ Throttle Opener: © Disconnect the throttle opener vacuum hose from the throttle body. * Apply vacuum to the throttle opener. (b) Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. w/ Throttle Opener: Reconnect the throttle opener vacuurn hose ‘to the throttle body. (0) Throttle Position Sensor 1. INSPECT THROTTLE POSITION SENSOR {a) w/ Throttle Opener: Apply vacuum to the throttle opener. (b) Insert a 0.50 mm (0.020 in) or 0.70-mm (0.028 in) feeler gauge between the throttle stop screw.and stop lover. (c) Using an ohmmeter, measure the resistance between each terminal.£G-254 ENGINE — EFI SYSTEM Bacwean tarminale Reristance laver a stop sorew ‘Omm (0 i) Vane, 02-6740 050 mm (0.020%) tLe 23 KO or less 0:70 own (0.028 in) Le Tefinny ba VTA ~ E2 20 ~ 10.2kO open = veo 25 - 55K0 2. IF NECESSARY, ADJUST THROTTLE POSITION ‘SENSOR (a) Loosen the 2 set screws of the sensor. (0) Insert a 0.60 mm (0.024 in. feeler gauge between the throttle stop screw and stop lever. {c) Connect the tester probe of an ohmmeter to the terminals IDL and £2 of the sensor. (d)_ Gradually turn the sensor clockwise until the ohmmeter deflects, and secure it with the 2 set screws.ENGINE — EFI SYSTEM cone (@) Recheck the continuity between terminals IDL and E2. Clearance between as lever and stop sorow (0550 mm (0.020 9) Continuity 1070 won (0.028 in} No eontinulky (). w/ Throttle Opener: Reconnect the throttle opener vacuum hose to the throttle body. ‘ THROTTLE BODY INSTALLATION (See Components for Removal and Installation) 1. INSTALL THROTTLE BODY (2) Connect the following hoses to the throttle body: (1) Water bypass hoses (2) Air hose (©) Place # new gasket on the intake manifold, facing the protrusion lowerward. (c) Type A: Install the throttle body with the 4 bolts. Torque: 19 N-m (195 kgf-cm, 14 ftibf) HINT: Different bolt lengths are used for the upper and lower sides,EG-256 = EFI SYSTEM. Bolt length: Upper side: 40 mm (1,59 in.) Lower side: 85 mm (2.17 in) (d) Type B: install the throttle body with the 2 bolts and 2 nuts. Torque: 19 N-m (198 kgf-om, 14 fribt) {e) Connect the following hoses: (1) w/ EVAP: Vacumm hose (2) w/ EGR: Vacumm hoses (3) PCV hose (f) Connect the following connectors: (1) Throttle position sensor connector (2) ISC- valve connector p A/T: CONNECT A/T THROTTLE CABLE FROM THROTTLE BODY . CONNECT ACCELERTOR CABLE FROM. THROTTLE BODY INSTALL AIR CLEANER CAP CONNECT INTAKE AIR TEMPERATURE SENSOR TO AIR GLEANER CAP FILL WITH ENGINE COOLANT CONNECT NEGATIVE (—) TERMINAL CABLE TO BATTERY - “MB 9p ©EG-257 ENGINE — EFI SYSTEM ISC VALVEeee ENGINE — EFI SYSTEM. ON-—VEHICLE INSPECTION 1. INSPECT ISG VALVE OPERATION (2) Initial conditions: © Engine at normal operating temperature © Idle speed set correctly ‘© Transmission in neutral position (b) Using SST, connect terminals TE1 and E1 of the check connector. SST 09843-18020 (c) After engine rpm is kept at 900 — 1,300 rpm for 5 seconds, check that it returns to idle spe If the rpm operation is not as specified, check the ISC valve, wiring and ECU. (¢)_ Remove the SST form the check connector. SST 09843-18020 2. INSPECT ISC VALVE RESISTANCE {a} Disconnect the ISC valve connector. {b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (ISCC, ISCO). Resistance: 19.3 — 22.3 0 at 20°C (68°F) If resistance is not as specified, replace the ISC valve, () Reconnect the ISC vaive connector.ENGINE — EFi SYSTEM poms COMPONENTS FOR REMOVAL AND INSTALLATION AIT Throttle Control Cable + Specified torque “@ Non-reusable part rime ISC VALVE REMOVAL {See Components for Removal and Installation) 1. REMOVE THROTTLE BODY : (See page EG—251) 2. REMOVE ISC VALVE Remove the 4 screws, ISC valve and gasket.ENGINE — EF! SYSTEM 1SC VALVE INSPECTION INSPECT ISG VALVE OPERATION (2) Connect the positive {+) lead from the battery to terminal +B and negative (-) lead to terminal ISCC, and check that the valve is closed. 0) Connect the positive (+} lead from the battery to ‘terminal +8 and negative (—) lead to terminal ISCO, arid check that the valve is open. {f operation is not as specified, replace the ISC valve. ISC- VALVE INSTALLATION (See Components for Removal and Installation) 1. INSTALL ISC VALVE (a) Place a new gasket on the throttle body. (b) Install the ISC valve with the 4 screws. 2. INSTALL THROTTLE BODY (See page EG—255)ENGINE — EFI SYSTEM Eeae! EFI MAIN RELAY (ST202) Engine (& ECT) ECU EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY LOCATION: In the engine compartment relay box. INSPECT EFI MAIN RELAY Inspect relay continuity (@) Using an ohmmeter, check that there is, continuity between terminals 1 and 2, (b) Check that there is rio continuity between terminals 3 and'6. If continuity is not as specified, replace the relay. pe B. Inopect relay operation (a) Apply battery voltage across terminals 1 and 2. (0). Using an ohmmoter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAYoa ENGINE — EFI SYSTEM. EFI MAIN. RELAY (ST191) cr! EFIMain Retey Engine (@ ECT) ECU 154, Battery| roe EFI MAIN RELAY INSPECTION 1. REMOVE EFI MAIN RELAY LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (2) Using an chmmeter, check that there is continuity betwesn terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. . Inspect relay operation (e) Apply battery voltage across terminals 1 and 2. (b) Using an chmmeter, check that there is continuity betw nals 3 and 6. {f operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAYENGINE — EFI SYSTEM EG.263 CIRCUIT OPENING RELAY ToFuse St (M/T) ToECUI+B) ‘To Neviral Start Switch (A/T) To ECU (STAY TOEFI Main Relay ae A DARA B FP. Check Connector FC a Fuel Pump To ECU IFO) ™ aes COMPONENTS FOR REMOVAL AND INSTALLATION sT202EG.264 ENGINE — EF] SYSTEM. CIRCUIT OPENING RELAY INSPECTION (See Components for Removal and Instaltation) 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY . Inspect relay continuity (2) Using and ohmmeter, check that there is continuity between terminals STA and E1. (b) Chock that there is continuity between terminats +B and FC. (©) Check that there is no continuity between terminals + Band FP. If continuity is not as specified, replace the relay. B. inspect relay operation (2) Apply battery voltage across terminals STA and E1. (b) Using an ohmmetsr, check that there is continuity between terminals +B and FP. {e) Apply battery voltage across terminals +B and FC. {d) Check that there is continuity between terminals +8 and FP. If operation is not as specified, replace the relay. 3. REINSTALL CIRGUIT OPENING RELAYENGINE — EFI SYSTEM VSV FOR EGREG-266 ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION VSV INSPECTION (See Components for Removal and Installation) 1. REMOVE VSV . INSPECT VSV Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 — 89.0 at 20°C (68°F) If there is no continuity, replace the VSV.ENGINE -- EFI SYSTEM Fe-267 ‘Ohmmetor B. Inspect VSV for ground init Using en ohmmeter, check that there is no continuity No Continuity between each terminal and the body, oe: Hf there is continuity, replace the VSV. C. Inspect VSV operation {a} Check that air does not flow from ports E to G. (b) Apply battery voltage across the terminals, (6) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSVG-268 ENGINE — EF! SYSTEM A/C IDLE—UP VALVEEG.269 ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND ~~ INSTALLATIONEG-270 ENGINE — EFI SYSTEM ‘Continuity A/C IDLE—UP VALVE INSPECTION (See Components for Removal and Installation) 1. REMOVE A/C IDLE—UP VALVE 2. INSPECT A/C IDLE—UP VALVE A. Inspect A/C idle—up vaive for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 — 34 Q at 20°C (68°F) If there is no continuity, replace the A/C idle—up valve. B. Inspect A/C Idle Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity. replace the A/C idle—up valve. C. Inspect A/C idle—up valve operation {2) Check that air does not flow from port E to port F. (b) Apply battery voltage across the terminals. (e) Check that air flows from port E to port F. If operation is not as specified, replace the A/C i up valve. ‘3. REINSTALL A/C IDLE—UP VALVEENGINE ~ EFI SYSTEM EG-271 WATER TEMPERATURE SENSOR Engine (& ECT) ECU COMPONENTS FOR REMOVAL AND INSTALLATIONEG-272 ENGINE — EFI SYSTEM WATER TEMPERATURE SENSOR INSPECTION {See Components for Renmioval and Installation) 1, DRAIN ENGINE COOLANT 2. REMOVE WATER TEMPERATURE SENSOR 3. INSPECT WATER TEMPERATURE SENSOR Using an chmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the water ‘temperature sensor. Acceptable Li a 200 20 40 60 80. 100 (4) (32) (68) (104) (140101762129 ‘TEMPERATURE °C (°F) 4. REINSTALL WATER TEMPERATURE SENSOR 6. REFILL WITH ENGINE COOLANTENGINE ~ EFI SYSTEM EG-273 INTAKE AIR TEMPERATURE SENSOR Engine {& ECT) ECU Intoke Air Temperature Sensor COMPONENTS FOR REMOVAL AND INSTALLATION ‘Sensor Conn£6274 ENGINE — EFI SYSTEM INTAKE TEMPERATURE SENSOR INSPECTION {See Components for Removal and Installation) 4. REMOVE INTAKE TEMPERATURE SENSOR 2. INSPECT INTAKE TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the sensor. 3%, 20 10 Acceptable 3 4 3 $2 1 05} 03 02 oa oo 20 9 2 4 60 9 100 {A (32) (68) (roayeaaoyer7eNe212) TEMPERATURE °C (°F) res pew am 3. REINSTALL INTAKE TEMPERATURE SENSORsT202 Vacuum Sensor (Preesre Sensor”) ENGINE — EF! SYSTEM VACUUM SENSOR EG-275ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND ~~ INSTALLATIONENGINE — EFI SYSTEM. VACUUM SENSOR INSPECTION (See Components Removal and Installation) 1, INSPECT POWER SOURCE VOLTAGE OF VACUUM SENSOR (a) Disconnect the vacuum sensor connector. b) Turn the ignition switch ON. {e) Using a voltmeter, measure the ‘voltage between con- nector terminals VC and E2 of the wiring harness side, Voltage: 45-55V (d)_ Turn the ignition switch to LOCK. (2) Reconnect the vacuum sensor connector.ae EFI SYSTEM ENGINE 2. INSPECT POWER OUTPUT OF VACUUM SENSOR (a) Turn the ignition switch ON. {b) Disconnect the vacuuri hose from the vacuum sensor. (c) Connect @ voltmeter toterminals PIM and E2 of the ECU, and measure the output voltage under ambient atmospheric pressure. (6) Apply vacuum to the vacuum sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 68.7 kPa (500 mmHg, 19.69 in.Hg). (e) Measure the voltage drop from step (c) above for each segment. Voltage drop Applied: Ee ‘Vacuum 133 | 267 | 400 | 535 | 667 kPa mmtig (100) | (200) | - 300 | 400 |r 500 inte) | (Se) | (Far) | (ovat) | (te75) |(s398) cee |es-oslo7-oafts 13 ]15-19] 19-24 {f) Reconnect the vacuum hose to the vacuum sensor. ReconnectENGINE — EF! SYSTEM £e-279 VARIABLE RESISTOR Engine &@ ECT ECU VARIABLE RESISTOR INSPECTION 1, INSPECT POWER SOURCE VOLTAGE OF VARIABLE RESISTOR {) Disconnect the variable resistor connector. o ‘Tum the ignition switch ON. Using a voltmeter, measure the voltage between con- nector terminals VCC and E2 of the wiring hamess side. ‘Voltage: 45-5.5V (o)ENGINE — EFI SYSTEM (d)_ Turn the ignition switch to LOCK, (e) Reconnect the variable resistor connector. es 2. INSPECT POWER OUTPUT OF VARIABLE RESISTOR (2) Turn the ignition switch ON. {b) Connect a voltmeter to terminals VAF and E2 of the ECU, and measure the voltage while slowly turning ‘the idle mixture adjusting screw first fully counter— clockwise, and then fully clockwise using SST. SST 09243-00020 {c) Check that voltage changes smoothly from 0 V to ‘87181 (A/T). ST202 approx. 5 V. ecu HINT: There is no sudden jump up to 5 V or down to ‘Voltmeter ov. Var lO: 2ENGINE — EFI SYSTEM. EG-281 3. fa) (b) fe) (d) ) INSPECT RESISTANCE OF VARIABLE RESISTOR Disconnect the variable resistor connector. = Using an ohmmeter, measure the resistance between terminals VCC and E2 of the variable resistor. Resistance: 4-6kQ Using SST, turn the idle mixture adjusting screw fully cunterolockwise. SST 09243-00020 Connect the ohmmeter to terminals VAF and E2 of the variable resistor, and turn the idle mixture adjusting screw fully clockwise and’check that the resistance value changes from approx. 5 kQ to 0 kQ according- ly. Reconnect the variable resistor connector.ENGINE — EFI SYSTEM KNOCK SENSOR COMPONENTS FOR REMOVAL AND ~~ INSTALLATIONENGINE — EFI SYSTEM EG-283 —— ____ENGINE = EFISYSTEM KNOCK SENSORS INSPECTION (See Components for Removal and Installation) 1 (@) (b) DISCONNECT NEGATIVE (—) TERMINAL CABLE FROM BATTERY REMOVE KNOCK SENSORS Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09816-30010 INSPECT KNOCK SENSORS Using an chmmeter, check that there is no continuity between the terminal and body. If there is continuity. replace the sensor. REINSTALL KNOCK SENSORS Using SST. install the knock sensor. SST 09816-30010 ‘Torque: 44 N-m (450 kgf-cm, 33 ftlbf) Connect the knock'sensor connector. RECONNECT NEGATIVE (—) TERMINAL CABLE TO BATTERYfoeee ENGINE — EF! SYSTEM OXYGEN SENSOR OXYGEN SENSOR INSPECTION 4. WARM UP ENGINE Allow the engine to reach normal operating tempera- ture 2. INSPECT FEEDBACK VOLTAGE Connect the positive (+) probe of 2 voltmeter to terminal VF1 of the check connector, and negative (—} probe to terminal E1, Perform the test as follows: ‘Warm up the oxygen sensor with the engine at 2,500 tpm for approx. 90 seconds. i Zero again” Pr - Sores ato sinner elcing Snr ate cp sped 2860 pm. {eon 1 ; ‘Check the number af times the vohmeter needle fluctuates in 10 seconds. Less than 8 times ‘Worm up the oxygen sensor with the engine at 2.500 rpm for approx. 90 seconds. Maintain engine at 2,500 rpm. ‘Check the number of times the voltmeter needle fluctuates in 10 seconds, [seein cen Disconnect terminals TE1 and Et of the check connector. Maintain engine speed et 2,500 rpm, ee ‘Measure voltage between terminals VF1 and & Read and record diagnostic codes. (See pages EG-171, 172), ‘Normal code, code | Malfunction code(s) More than 0 V @ @ ® @ CONTINUED ON PAGE EG-285CONTINUED FROM PAGE EG-284 ® ENGINE — EF! SYSTEM. (Except code Nos. 21, 25) Read and record diagnostic codes. (See pages EG-171, 172) Normal code, code Nos. 21,25 Disconnect terminals TE1 and £1 of the check connector. Maintain engine at 2,500 rpm. ‘Measure voltage between terminals VF1 and Ft. Tow w ‘Disconnect the PCV hose. ae ‘Measure voltage between terminals VF1 and E1. ow Repair (Over rich) Disconnect the water temp. sensor connector and connect resistor with a resistance of 4-8 kor another caded water temp. sensor. | ‘Connect terminals TE1 and E1 of the check connector. ‘Warm up the oxygen sensor withthe engine at 2.500 rpm for apprax. 80 seconds. Maintain engine speed 82,500 rpm. ‘Measure voliage between terminals VF1 and E1. BV Replace the oxygen sensor. EG.285£G-286 ENGINE — EFI SYSTEM 3 INSPECT HEATER RESISTANCE OF OXYGEN SENSOR Using an ohmmeter, measure the resistance between the terminal +B and HT. Resistance (Cold): 5.1 — 6.3 Q at 20°C(68°F) If the resistance is not as specified, replace the sensor.ENGINE — EFI SYST eae ECU ECU INSPECTION HINT: The EFI circuit can be checked by measuring the resistance and voltage at the wiring connectors of the ECU. 1. PREPARATION fa) Disconnect the 3 connectors from the ECU. (bo) Remove the locks as shown in the illustration so that the tester proba(s} can easily come in. NOTICE: Pay attention to sections A and B in the illustre- ‘tion which can easily broken. (c) Reconnect the 3 connectors to the ECU. 2, INSPECT VOLTAGE OF ECU (2) Tum the ignition switch ON. {b) Measure the voltage between ST 191 (A/T) and ST202 wiring connectors. ecu HINT: © Perform all voltage measurements with the con- nectors connected. © Verify that the battery voltage when the ignition switch is ON. ch terminal of the 11 V or moreENGINE — EFI SYSTEM. ECU Wiring Connectors Voltage ‘Terminals Condition ‘STD voltage (V) +B i Boe | ieswon o-16 cart =e : a Dez Three vale open 3-4 car} HeSWON Three viv aly owed ta-08 “Thro valve fly open 32-43 PM-e 33-39 ve -E2 1G SWON 45-55 Fo -em ; foe ; 7 Cr a THA ~EZ Iaswon Intake air temp. 20°C (68°F) 5-34 Taw =e Engine coolant temp. 60°C 73°F) oa-10 ‘STA -E1 Cranking 6ormore Tet =e [tang False generion Ec-e1 | ieswon ECU connector daconected o-14 WET | No Woublaoheck opine wasp Toh off and engine anning oe Ter 1 ‘Check connector TE 1—E1 not connected 9-14 ‘TE2” or TET — | 0-3 IG SWON Check connecter ‘TE1-E1 connected NaW_e1 Tout stat sich Por W poston = tar oan Except naval srt wich PrN potion 3-14 ECU TerminalsENGINE — EFI SYSTEM £e-269 3. INSPECT RESISTANCE OF ECU {2} Tum the ignition switch OFF. (b) Disconnect the 3 connectors fram the ECU. Measure the resistance betwean each terminal of the wiring connectors. NOTICE: © Do not touch the ECU terminals. © The tester probe should be inserted in the wiring ‘connector from the wiring side. ST191 (A/T) and $1202 « eaeae ENGINE — EF1 SYSTEM ECU Wiring Connectors Resistance Terminals Condition ‘Throttle valve fully open: Wt -E2 ‘Throttle valve fully closed (Throttle opener must be cancelled first) Throttle valve fully open vTa £2 Throttle vaive fully closed Throttle opener must be cancelled fist) ve-e2 = THA —E2 Intake air temp. 20°C (68°F) 4 THW Ez Coolant amp. 80°C (176°F ofe Cold (-10°C (14°F) to 50°C (122°F)) Hot {50°C (122°F) to 100°C (212°F I) NEt -NE= Cold (-10°C (14°F) to BO*C (122°F)) Hot (80°C (12°F) to 100°C {212°F i 1SCO_48 - ISCO "481 com 28, ; = ECU Terminals aan ee * EuropeENGINE ~ EFI SYSTEM ‘Tachometer 2,500 epm reno EG.291 FUEL CUT RPM FUEL CUT PRM INSPECTION 1. WARM UP ENGINE ie Allow the engine to warm up to normal operating ‘temperature. : 2. CONNECT TACHOMETER TO ENGINE Connect the test probe of a tachometer to terminal 1G © of the check connector. NOTICE: © Never allow the tachometer terminal to touch ground a8 It could result in damage to the Igniter and/or ignition coil. © _ As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use: 3. INSPECT FUEL CUT RPM (a) Increase the engine speed to at least 2,600 rpm. (b) Using a sound scope, check for injector operating noise, {ce} Check that when the throttle lever is released, injector ‘operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,800 rpm 4, DISCONNECT TACHOMETERae ENGINE — EFI SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Fuel pressure | Fuel pressure ‘tno vecuum | 268 — 304 KPo(27 — 3:1 ket/ont, 38 — 44 pe) regulttor Fuel pump Resistance waorc earn | 02-300 Injector Resistance 134 1420 Injection volume. 49 — 80 cm’ (2.0 — 3.6 ev in} por 15 200. Difference betwaen each oyinder om (0.9 eu in} or less Ful leakage One drop or less por minute : Throttle body | Throttle body fully cloesd angie e ‘Throttle opener setting speed 1,900 — 1,500 rpm (iw/ Cooling fon OFF) Throtue ‘Clearance between stop screw and lever osition Omm in} via~ ez | 02-5740 sensor (0350 mm (0.020 in} WL ~ £2 | 2340 or ose 0.70 mm (0.028 in} WL — Ez | Infinity ‘Throtie valve fully open, vta—e2 | 20- 10240 - Vo~E2 | 28-5940 15 vate, Resistance (+8 — 1S0C oriSCO) 20°C @a'A | 193 ~ 2230 3-0 30-30 Water Temp. | Resistance wt -20°C(=4F) | 10 = 20K0 sensor morcarh | 4-710 we zorc ea") | 2-3kO st 40°C (104°F) | 09 ~ 1.3K stev'c 40"A) | 04-070 morc (176A) | 02 -04kO Tetake ‘Raslstence wt -20C(-#F) | 10—20K0 Air Teme. arorc@2"A | 4-7kO sensor at20"C 8") | 2—9kO m40"C (04°F) | 08 — 1.340. at aotc (14°F) | 04 — 0.7 KO acsorc (176m | 02-04k0 ‘Drygen eoneor | Hester ool resitance 81-630 Fuel aut rpm | Fusl return rpm 1500 cpmENGINE — EFI SYSTEM EG-293 SERVICE DATA (Cont'd) ECU Voltage +8—e1 tsswon +01-e1 se sw OW Bart — et IL-2 1 SW ON Tivo va open) VTA ~ E216 SW ON (Trott vate fuly losed) 16 SW ON (TRrota valve fly open) pu — a2 teswon ve~e2 1 swoN #10 oF #20-E01 Is sw on #10 07 #20- E02 1a SW ON THA — EZ 1G SW ON (Intake air temp, 20°C erry THW—E2 IG SWON (Coolant temp. 20°C . 76D STA- Et Cronin tot —e1 ‘aio © yoo - et 1G SW ONIECU connectors: disconnected) ‘sco - Et 16 SW ONECL conneotors disconnected WET No rouble (Check angine warning Hat off and ensine runing TEI 1 IG SW ON (Check connector terminals TE! ~ E1 not connected 1G SW ON (Check connactor terminals ‘TEI — E1 connected) Resistance wwe - Ez at theotle valve open, ‘at theottie valve fully eloasd VTA ~ ER at throttle vale fully open ‘a thvottle valve fully lowed vo~ Ez THA E2 _at inte air temp. 20°C (@8"F) THW ~ E2 ‘at coolant temp, 20°C (176°F) G+ - 6 st cold (= 10°C (14°F) to 50°C (122°FY at hot (50°C (122°F) to too'e 212A NEt — NE~ at oold (10°C (14°F) to Bore (12°F) at hot (60°C (122°) to tore wt") 4B.or #B1 ~ 1806 oF ISCO g-14y an 14y -iav o-tay 03-08 32-49V 3a-a9V 43 -55¥ aay oy 05 —34V 02-10 6V oF more, Puise ganerstion 9-14 e-14y o-uy o-ay; a EG-294 ENGINE — EF! SYSTEM TORQUE SPECIFICATIONS _ Pan waht wm tahen wer Feat Usion bot ype 2 300 2 Flare nut 60 Ful pump ede $1202 for S37 23 20 2 suit ferset | 30 210 2 Othe 0 310 2 Foal pane x Foal ane 2 2 Bat nl pressure epulater x Ooo Be 5a ‘ine Fou rir ie x Fun presaure rut 78 786 14 Detey ove x Onde ead 13 130 3 Oyinder head x Grommet Ey 230 7 Tus irit po x Dalvery ibe 3 350 2 ulation dap x Davey be srit Es 7 3s ST101 tor SSF 2 300 2 Tiree bey x reake manifold 8 185 2 Tsk ice mario aty x ake manitoid oe [aes 31 Ned ike mani ey x Gyodr hand stot = eo a1 ER valve x rake manor STI8t or Nt 73 730 ? 57191 for Vion nut se 200 “ Trak tart nd Bok a 250 3 Sayer enter x Exhaust mand 20 200 ia