1 9 92 CONTENTS: F Mazda General Information oe Cesare Tn B2600i fet 32200 Workshop Lubrication System Manual Cooling System Fuel and Emission | Carburetor Control Systems Eq) FOREWORD Engine Electrical System This workshop manual is intended for use by service technicians of Authorized Mazda | Clutch ‘Dealers to help them service Mazda vehicles. Fot ‘proper repair and maintenance, a | Manual thorough familiarization with this manualisim- | Tranemission portant, and it should always be kept in a han- dy place for quick and easy reference. | Teanater.Cese Al the contents of this manual, including drawings and spectications, are the latest avai able al the {ime of printing. As modifications | Automatic affecting tepair or maintenance occur, relevant | Transmission Carona information supplementary to this volume will be made available at Mazda dealers. This Transfer Case manual should be kept up-to-date. Propeller Shaft Mazda Motor Corporation reserves the right to alter the specifications and contents of this _| Front and Rear Axles manual without obligation or advance notice. esering Allrights reserved. No part of this bookmay | Steering System be reproduced or used in any form or by any | means, electronic or mecharical—inclucing _Br@king System photocopying and recording and the use of | Wheels and Tires any kind of information storage and retrieval system—without permission in writing, ‘Suspension Mazda Motor Corporation HIROSHIMA, HIMA, JAPAN | Gody Electrical System APPLICATION: This manual is applicable to vehicles beginning | Heater and Alr Conditioner Systems with the Vehicle Identification Numbers (VIN) | Teghnical Data shown on the following page. Special Tools Parts index Wiring Diagram {bere gopcany © 1991 Mazda Motor Corporation PRINTED IN USA, JUL. ‘91 1269-10-91G (8999-95-022B-92)VEHICLE IDENTIFICATION NUMBERS (VIN) JM2UF123 «NO 250001 ~ JM2UF223 «NO 250001 ~ JM2UF323 «NO 250001 ~ JM2UF113 *NO 250001 ~ JM2UF213 «NO 250001 ~ ‘JM2UF313 «NO 250001 ~ JM2UF114«NO 250001 ~ ‘JM2UF314%NO 250001 ~ JM2UF414*NO 250001 ~ JM2UF614*NO 250001 ~ JM2UF514%NO 250001 ~ ‘JM2UF223+NO 250001 ~ a =FGENERAL INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS. SAFETY RISK. POSSIBLE LOSS OF WARRANTY WARNING ON LUBRICANTS AND GREASES. HOW TO USE THIS MANUAL. PROTECTION OF THE VEHICLE .. A WORD ABOUT SAFETY esse PREPARATION OF TOOLS AND MEASURING EQUIPMENT ... SPECIAL TOOL! REMOVAL OF PARTS.. DISASSEMBLY . REASSEMBLY ADJUSTMENTS RUBBER PARTS JACK AND SAFETY STAND (RIGID POSITIONS. a VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS. TOWING.. WITH MANUAL TRANSMISSION, WITH AUTOMATIC TRANSMISSION CHASSIS NUMBER LOCATION. ENGINE MODEL AND NUMBER LOCATION .. ABBREVIATIONS CAUTION ELECTR TOOLS .. CAUTION WITH ELECTRICAL PARTS. ‘ssvarcoat Gl PO onGl IMPORTANT INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS This workshop manual assumes that you have certain special tools that are necessary for the safe and eff cient performance of service operations on Mazda vehicles and that you know how to use them properly Italso assumes that you are familar with automobile systems and basic service and repair procedures. You should not attempt to use this manual unless these assumptions are correct and you understand the conse- ‘quences described below. SAFETY RISK This manual contains certain notes, warnings, and other precautionary information that you should carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possiblity that personal safety or vehicle safety will be jeopardized by the use of incorrect methods o tools. POSSIBLE LOSS OF WARRANTY ‘The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer. WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated uring service (e.g., engine sump ails) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact. ‘Wash skin thoroughly after work involving oil. Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con- taminated with oil. Dry clean or launder such clothing at regular intervals. sntusoc 002 GI-2 } SYGl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL PREPARATION PREPARATION points cut the needed SST for the service operation that follows. Itis best to gather al necessary SST before beginning work. Gl Example: N ie-Rop END BOOT AND STEERING GEAR BOOT ‘SST NUMBER, ‘TIE-ROD END BOOT AND STEERING GEAR BOOT ‘ssT NAME SST ILLUSTRATION omveixoas REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and visual parts inspections. If a damaged or worn partis found, repair or replace it ‘as necessary. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview istration, 8, Pages related 10 service procedures are shown under the illustration. Refer to this information when ser- vicing the related part. Example: sows Fao sows 5 ee Rae | |e. ea a n | ae = Wy oe Bohr |\ a eee Ne Se mexaasy | ORG UT 2 lode See, ee ‘shows § Seerpg et tee INSPECTION RELATED Sis INFORMATION te ee rapt sins a eh waa Sats sence fA BEY“ Keuanent ot hog ‘pepe nae a fl The numbering (ex@)y shows service procedure. *2: Units shown in Nm (m-kg, ft-lb) unless otherwise specified. GI-3GI How To usE THIs MANUAL/FUNDAMENTAL PROCEDURES SYMBOLS There are 6 symbols for oil, grease, and sealant. These show the points of applying oil, grease, or sealant during servicing. a = = Wawa Wow rg o'r geo 2 eprptte Sou oe i oo 1. _— — ee ere ao o Apply petroleum jelly Appropriate petroleum jelly a Note When special oil or grease is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS {As you fead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each ‘one is there for a specific purpose. NOTES give you added information that will help you to complete @ particular procedure, CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per- sonal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle, saavancoss FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas be- fore starting work. mEFUNDAMENTAL PROCEDURES Gl ava TOT ‘A WORD ABOUT SAFETY The folowing precautions must be folowed when jacking up the vehicle, 1. Block the wheels, 2. Use only the specied jacking postions 3. Support the vehicle wih safety stands Start the engine only after making certain the engine compart- ment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work ‘SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting @ problem, try also to determine its cause. Begin work only after first learning which parts and subassem- blies must be removed and disassembled ior replacement or repair. DISASSEMBLY IWthe disassembly procedure is complex, requiring many parts to be disassembled, al parts shouid be disassembled ina way that will not affect their performance or external appearance {and identified so that reassembly can be periormed easly and efficiently GI-5FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. ra 2. Arrangement of parts All disassembled parts should be carefully arranged for re- assembly, Be sure fo separate or otherwise identity the parts to be replaced from those that will be reused. mae Cleaning parts for reuse Al parts to be reused should be carefully and thoroughly cleaned in the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text If removed, these parts should be replaced with new ones: 4. Oil seals 2. Gaskets 3. Orings 4, Lock washers 55. Cotter pins 6. Nylon nuts RARER Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of pats. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. mao Gi-6FUNDAMENTAL PROCEDURES Gl ADJUSTMENTS Use suitable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING Prevent gasoline or ol from getting on rubber parts or tubing. GI-7Gl JACK AND SAFETY STAND (RIGID RACK) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT et Jack position: Safety stand positions: : At the center of the crossmember On both sides of the Jack point L EGO EROS \ 2 REAR Safety stand positions: Jack position: ‘On both sides of the ‘At the center of the differential diferential oy area oo Gi-8VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS Gl VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT Jack point: On both sides of the jack point AR Oo aq. TL % ie ; \ Bry BAY \ SA Eo Gi-9| gtategrleteee FOR au SEr THE REMOTE FREE WHEEL SYSTEM YO FREE MODE BUR TOWING TOWING Proper towing equipment is necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, anc set the ignition key in the ACC position. As a rule, towed vehi cles should be pulled with the driving wheels off the ground, WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels, it any of these components are damaged, use a towing dally WITH AUTOMATIC TRANSMISSION If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use a wheel dolly. With all 4 wheels on the ground, the vehicle may be towed only forward. In this case, do not exceed the following towing speed andlor distance or transmission damage could result we wa Toving speed 5 tanh G6 mph] | 66 ev 85 my “Towing tans 8 em (10-rites) —| 58 kr 5 rls) Ittowing speed andor distance will excead above-mentioned specifications, use one of three methods: 1, Place the rear wheels on a dolly 2. Tow with the rear wheels off the ground, 3. Disconnect the propeller shaft. (4x4: rear propeller shat) Ifthe transmission or rear axle is inoperative, tow the vehicle with its rear wheels off the ground or have the propeller shatt disconnected, CAUTION a) The power assist for the brakes is inoperable while the engine is off. b) When either of the towing hooks Is used, pull the cable or chain straight away from the hook and do not apply any sideways force to It. To further help prevent damage, do not take up slack too quickly in the cable or chain. ©) The rear towing hook should be used only in an emergency situation (for example, to pull the vehi- cle from a ditch, snow, or mud).CHASSIS & ENGINE NUMBER LOCATION/UNITS/ABBREVIATIONS. Gl CHASSIS NUMBER LOCATION UNITS Tm (kg Wb). Torque i Pareions per mine A Ampere(s) : von a Ot (estiance) 168 Want po) Prose (ual poet) mmtig (a He)... Presne (ety nog) Ie w Wa rm tenet Ta ENGINE MODEL AND NUMBER LOCATION ABBREVIATIONS Basoo! ETRBUTER 777 Se 186... Aer bolo dead car ABS. Antec eke avn & A0Attuootas & AiG AF conten, AV At conte A062 Aker op ea eer Mino Altona anarosen AE Alora aramid Sn Bypoo ar come BBD.” Bee oti Sead conor | Bio. Bote top das senor ECAT Ecvencabyconued sromate avarice EOU. Engi eae anh ED. Enegeaive ere conta oan EGR nnn Beha go touton Eu Emorgerby log eer EIR Beste Reg nae Bee ena Fg we PR Hiroe convoed erate weccicase HUA ou OE Lh eo heap cheat fac (ne Nam ane aR IN torment 180. sped cont So Rare 16. Lina a rete Was" our ade een Wi Mate ede nt A" Mant pera NF Macartney todo OB Ot agree OF Sten Se Sth on FEV Proeniing by pase vas Po polar sakes venoaion PB Power desing FEW" Ronee ee hoa hub Bee Riek han Sa Sete Ta te aut crow Toe top aed bance FPS eto toy iene aUaKoR Gi-11CAUTION ke aero “Se VOLTMETER aaa BaEKOe aca Gi-12 CAUTION ELECTRICAL TROUBLESHOOTING TOOLS Test Light ‘The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes. ‘The test light is used for simple voltage checks and for check ing for short circuits. Caution When checking the control unit, never use a bulb over 3.4W. Jumper Wire ‘The jumper wite is used for testing by shorting across switch terminals and ground connections. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or oth- er damage to harnesses or electronic components. Voltmeter The DC voltmeter is used to measure of circuit voltage. A vol meter with a range of 15V or more is used by connecting the postive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (-) probe {black lead wire) to a body ground, Ohmmeter ‘The ohmmeter is used to measure the resistance between two points ina circult and also to check for continuity and diagno- sis of short circuits. Caution Do not attempt to connect the ohmmeter to any cir- cuit to which voltage is applied; this may burn or other- wise damage the ohmmeter. CAUTION WITH ELECTRICAL PARTS Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable.CAUTION Gl eee = ra se ow » a EB RTT Connectors Removal of connector Never pull on the wiring harness when disconnecting con- neciors. Connectors can be removed by pressing or pulling the lock lever as shown, Locking of connector When locking connectors, make sure to listen for @ click that will indicate they are securely locked. Inspection When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side, Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal GI-13aaa \ CAUTION Replacement of terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks Gay securely. Insert @ thin piece of metal from the terminal side of the con- nector, and then. with the terminal locking tab pressed down, pull the terminal out from the connector. Same as the female type. Wiring Hamess Wiring color codes Two-color wires are indicated by a two-color code symbol The firs letter indicates the base color ofthe wire and the sec- cond the color of the stripe. ~ (CODE ‘coLon cope | COLOR : 3 Bleck ° Orange BR Brown P Pok | 6 Green a Rea oy Gray v Vile t Bue w wre | 18 ont Bue ¥ Yellow is Light Green 7 = Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.BUS Eero CAUTION Gl Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of specified capacity |'a fuse again fails after it hes been replaced, the circuit probably has @ short circuit and the wiring should be ‘checked. 2. Be sure the negative battery terminat is disconnected be- fore replacing a main fuse (804), 8. When replacing a pull out fuse, use the fuse puller supplied in the fuse box cover. GI-15PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE-DELIVERY INSPECTION .. PRE-DELIVERY INSPECTION TABL! SCHEDULED MAINTENANCE SERVI (USA)... « ‘SCHEDULE 4 {NORMAL DRIVING CONDITION) 82600) SCHEDULE 1 (NORMAL DRIVING CONDITION) 82200... A= 7 SCHED! (eNIovE ‘CaN CONDITION) B2600i.. SCHEDU (UNIQUE ‘DAIVING CONDITION) 82200 eos A> SCHEDULED MAINTENANCE SERVICES (CANADA) aesPRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. [4 EXTERIOR + INSPECT and, necessary, ADJUST the folowing tems to specications: 12 Gis, exarior bright metal, and paint for damage Gi Wheel tug nuts Nowsted 88-118 Ne» (0-120 mrtg, 6587 fe) Styiod! 118147 Nev (12.0—18.0 ekg, 87-106 tb) ‘Al waathorstips for damage ox detachment Overaton of haod release and lock 1D Operston 0! tua id opener (I eaupped) 5 Door oporeton and algnment 1 Heaigne arn * INSTALL tho folowing parts: i Wheel cantor caps ft equipped) 5 Outside rearview meron) 2. UNDER HOOD—ENGINE OFF * INSPECT and, necessary, ADJUST the folowing items 1 spectations: 1D Fue), coolant anc hydraulic ines, ftings, connections, and ‘components for leaks. Engine oF leve! 1 Ollfeval in steering gearbox 5 Power stoering fud level equipped) 1 Brake ana clutch master cylinder td levels 1D Windehlald washer resarvor fic level 1D Headlight cleaner reservor fd level (if equippec) 1D Raciator coolant level D Tightness of batiory terminals 3. INTERIOR = INSTALL the following pans: 1 Rubber stopper for inside rearview mirror © CHECK the operations of the folowing roms: 1D Seat coniros (siding and recining) and head rest 1D Boor Socks: 1D Foe-Down rear seats (Cab Pius only) ‘© Seat bets and warning system 5 Igaiton switch and steering iook Sartor interlock switch (MPT only) 5B Shitiock systen and inhibitor sutch (AIT only) D Al iat, Incucing warring anc incicator its (equipped) I Horn, windshield wipers, and washers (f equipped) 1D Headlight cloaner ( equipped) 5) Radio and antenna (i equipoec) 1 Cigaratie lighter and clock (f equippsc) INTERIOR (cont'd) i Healer, dose, and al conditioner at iferent modest eqarped + GREEK he folowing tems: D Fresence of spare fase 1 Upotsery and miro rich Following items must be done just before the delivery 1D Load test battery and charge if necessary vate 1B Adjust ire pressure tothe specification {Pater to Section Q) © Ciean outside of vehicie A-2 '» CHECK and, # necessary, ABMUST the folowing items: 1 Pedal ne ght Wah earoed and ree piay 0! breke and clutch pedal Pada heght mm Te] Free play mm (a) Caioh [BEBO [91207 (7527.8 ; pec) eze00 Her—rar g.1e=75q) °° $0028 Brake pedal 160185 (7 08—7.28)| 407.0 16-028) 1 Peting 660K wanna. 712 Nolchos!196N (20 kg, 44 Ib) UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE 4 CHECK the falowing Heme: 5 Trois sere (€) 1 Operation of loleu system for. = Airconditoner and automete tranemission (Carburetor) 1D Automate transmission uid leve Ci Operation of dashpot (Carburetor & Carburetor oat level intial igntlon tering: 6 & 1° BTDC (82200) & Idle speed: 800 “Y rpm AT; in P range (82200) © Operation of EGR contral valve (Carburetor) 1D Operation of lole switch (Carburetor) ‘ON HOIST ‘CHECK tne folowing tems: B Operation of remota freewhee! (4x4 only) 5 Manuel varemiesion of level 1G Transfer oo89 ol love (4x4 oni) 1D Front ade a level (x4 only). 1 Rear axe oll evel 1H Underside fuel, coolant and hydraulic nes tings, connec- ‘ions and components for leaks 1D Tres for cuts or bruisos| U Stosting Invage, suspension, exhaust sytem and all under- side harcware for looseness or damage 6, ROAD TEST © CHECK ihe folowing tems: 1D Brake oporaton © Clutch operation 5) Steering control 1D Operation of metere and gauge 1D Squeaks, ratles of unusual noises | Emergency lock relractore 5 Cruse contol eyetom (it equippec) 1B Operation of ranster caso (4x4 ony) 7 AFTER ROAD TEST = CHECK for necessary owner's information material, tool ‘and spare te in vehicle to your customer. 1D Install fuses tor accessories [U1 Remove seat and foor mat protective covers 1D Vacuum and clean interior of vehicle 1B Inspect instalation of option pans with invelce eeuaaccozSCHEDULED MAINTENANCE SERVICES (USA) owo}ed eq O32 Tei PuewuIOD9: am “JOADMO}, "BWLOMED Klooxe SaIES Ife PUE ’pBUED 40} Poulnbe: S| coUEUEIUIEL SIL ¢, IOeINUEW 10 @BErGAOD AIUELsEM UO|SSHWWE 10} KtBSSBOSU JOU SI “OASMOH| "EPZEW Aq PapUeWUIOOEI s| BOUEUOINTEW SL ZL “SQUBUSTUIB PACLOSEp OY 167 sOTPO;PUY UOHOUNIEWY 94 ‘9IOIYOA BIUIOWED 10) OOK] L HO} 94) 910U “ueYD BOUEUO|UIEL SIM UI SWOY PEW , 10} Sy 10} 01 enuyuaD "(w4 000'96) SAIL OOO‘OR 40 SYUOW O9 JOMY TOMEWO ‘NO S8LUOO 1 41 ‘S9)tU O0'DR PU SA! 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Tum the crankshaft to align the $1 mark of the camshaft pulley with the front housing matching mark. 2, Remove the tensioner and spring, Timing belt DIRECTION Mark the timing belt rotation for proper reinstallation if itis ARaOW reused | Caution Be careful not to allow oil, grease, or water on the belt.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Bi CYLINDER HEAD GASKET Removal Warning: Release the fuel pressure. (Refer to Sections F1, F2.) 1, Disconnect the negative battery cable, 2. Remove the engine undercover. 3. Drain the engine coolant. 4, Remove in the order shown in the figure referring to the Removal note. (CARQURETOR ® 4 f ® = peoil B1 ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) FRONT OIL SEAL Preparation ssT [rowan 11a Crankshatt lock j= eg TINT fF | 2 Removal § : 1, Disconnect the negative battery cable. 2. Drain the engine oil 3. Remove the timing bettON-VEHICLE MAINTENANCE (REAR OIL SEAL) REAR OIL SEAL Preparation Removal 1, DisconnedREMOVAL B1 1. Air cleaner assembly 2. Cooling fan and radiator cowling 3. Accelerator cable 4. Fuel hoses 5. Heater hoses 6. Brake vacuum hose 7. Three-way solenoid valve assembly 8. Vacuum solenoid valve assembly 9. Canister hoses 10. Engine harness [eARBURETOR 11. Engine ground 12, Secondary air pipe assembly (Carburetor) 18. Radiator hoses 14 Radiator 15. Exhaust pipe 18. AIC compressor 17. PIS oil pump pulley 18. PIS oil pump 19. Engine mount nuts veunstces Removal note Fuel hose ‘Warning ‘@) Cover the hose with a rag because fuel will sprayDISASSEMBLY (AUXILIARY PARTS) B1 AUXILIARY PARTS Remove in the order shown in the figure. ‘CARBURETOR|| 1. Remove in the order shown in the figure referring to the Disassembly note, {|} Inspect all parts and repair or replace as necessary. | oe ; B1 DISASSEMBLY (TIMING BELT) TIMING BELT| B1 DISASSEMBLY (CYLINDER BLOCK) 1 I ———__ Disassembly note i ConISPECTION AND REPAIR B1 Installation 1. Assemble the SST th Lis as specitied Depth L: 19,1—19.6mm (0,752—0.772 in) ighten the locknut.INSPECTION AND REPAIR diameter in X and Y Main journal Diameter: 59.937—59.955mm (2.3597—2.3606 in) Out-of-round: 0.05mm (0.0020 in) max. Crankpin journal Diameter: 50.940—50.955mm (2.0055—2.0061 in) Out-of-round: 0,05mm (0.0020 in) max.INSPECTION AND REPAIR B1 Caution a) Never forcefully twist turn inside out, or bend the timing belt. 'b)Be careful not to allow oil or grease on the belt. Timing Belt Tensioner and Idler Pulley Check the timing bett tensioner and idler Caution Do not clean the tensioner with cleaning fl a soft raa tg wine it cleaB1 ASSEMBLY (CYLINDER BLOCK) Saeaaeeeoaaaee ihe stopper bolt (49 LOt tthe depth L is fi fed.ASSEMBLY (CYLINDER BLOCK)ASSEMBLY (CYLINDER BLOCK) B1 Pilot Bearing 4. Apply engine ol tot umference of the bearingASSEMBLY (CYLINDER BLOCK) 4. Apply a liberal ammount of engine ol tothe erankpin journal ‘and connecting rod bearing. 5. Install the connecting rod cap with the alignment marks aligned. Tightening torque: ‘@5—69 Nm (6.6—7.0 m-kg, 4851 ft-lb)ASSEMBLY (CYLINDER BLOCK) Pn Caution Do not allow any sealant to get into the oil hole.ASSEMBLY (CYLINDER BLOCK) Flywheel (M/T), Drive Plate (A/T)ASSEMBLY (CYLINDER HEAD) ali arASSEMBLY (CYLINDER HEA\ 1 ‘Apply silicone sealant to the shaded areas shown in the figure. 3. Apply liberal amount of clean engine oil to the cam lobes, and journals. 4, Install the rocker arm and shaft assemblies. Tighten the bots in two or three steps in the order shown in the figure. Tightening torque:ASSEMBLY (AUXILIARY PARTS) Cooling Fan Bracket Install the cooling fan br htening torqu 6393 Nem (6.4—9.5 m-kg, 46—69 ft-lb) Alternator and Alternator Bracket 1. Install the alternator Tightening torqu 37—63 Nim (3.8—~6.4 m-kg, 27—46 ft-lb) 2. Install the ator. Tightening torque Bolt A: 31—46 Nm (3.2—4.7 mkg, 23—34 ft-1b) Bolt B: 37—52 Nan (3.85.3 mkg, 27—38 ft-lb) Intake Manifold Assembly 4 Place the new gasket inENGINE STAND REMOVAI Tightening torque: 37—63 Nm (3.86.4 mekg, 27—46 ft-1b)B2 ON-VEHICLE MAINTENANCE (TIMING CHAIN) ON-VEHICLE MAINTENANCE TIMING CHAIN Preparation Pre-inspection Timing chain 1 th protrudes 13 notchesON-VEHICLE MAINTENANCE (TIMING CHAIN) B2 Release the fuel pressure. (Refer to Section F2.) 1. Disconnect the negative battery cable, 2. Drain the engine oil and cooiant 3. Remove the radiator cowiing and cooling fan. (Refer to Section E.) 4. Remove the cylinder head. (Refer to page B2-14,) 8. Remove the oll pan. (Refer to Section D.) 6. Remove in the order shown in the figure referring to the Removal note.Tightening torque: 49-25 Nan (1.9—2.6 m-kg, 14—19 ft-lb)ON-VEHICLE MAINTENANCE (TIMING CHAIN)ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 1. Accelerator cable 2. Air intake pipe and resonance chamber 3. AIC drive belt and idier 4. High-tension lead and spark plug 5. Radiator upper hose 6. Brake vacuum hose 7. Oil cooler water hose 8. Canister hose 9. Fuel hose 10. Oxygen sensor connector 11. Solenoid valves (008 em (3.7 in a ste oR 12. Emission hamess connectors 13. Cylinder head cover 14. Distributor 18. Distributor drive gear 16, Camshaft pulley 17. Intake manifold bracket 18, Exhaust pipe and bracket 19. Cylinder head bolt 20, Cylinder head 21. Cylinder head gasket ouvoscose Removal note Fuel hose Note 4) Cover the hose with a rag because fue! will spray ‘out when disconnecting. b)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid fuel leakage, Distributor 1. Turn the crankshaft pulley until the timing mark of the cam- shaft pulley is 99° degrees to the right as shown, 2, Check that the crankshaft pulley timing mark (yellow) is aligned with the indicator pin 8. Remove the distributor. Caution Do not turn the crankshaft during removal and instal. lation. Distributor drive gear 1. Lock the crankshatt pulley with the SST. 2, Remove the distributor drive gear, Camshaft pulley 1. Remove the service cover on the chain cover. 2. Push the chain adjuster sleeve in toward the left and insert the pin as shown into the lever hole to hold it Caution Be especially careful that the pin does not fall. * B2-15ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) 2, Secure the camshaft pulley and the chain with a wire 2s shown. 4, Remove the camshaft pulley off the camshaft dowel pin. Cylinder head bolt 1, Remove the bots ®. 2. Logsen the remaining cylinder head bolts in two or three steps in the order shown in the figure.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 Installation Install in the reverse order of removal referring to the Installation note. Note Position the hose clamp In the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications 1e23 6-25, 2219 re2s1.9-46, 19)B2 ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Installation note Cylinder head gasket 1. Thoroughly remiove all dirt and oil from the top of the eylin- ~ der block with a rag. 2. Apply silicone sealant to the shaded area. 3, Place a new cylinder head gasket in postion, Cylinder head 1. Set the oylinder head in place. 2. Apply engine oil to the bolt threads and seat faces. 3. Tighten the cylinder head bolts in two or three steps in the ‘order shown in the figure. ~ Tightening torque: ‘80—86 Nm (8.2—8.8 m-kg, 59—64 ft-lb) 4, Tighten the remaining small cylinder head bolts @. Tightening torque: 16—23 Nem (1.6—2.3 m-kg, 12—17 ft-lb) ‘Camshaft pulley 1. Install the camshaft pulley onto the camshaft dowel pin. sseguting the camshaft pulley and the chain.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B2 Distributor drive gear 1. Install the distributor drive gear with a new washer and lock bolt. 2. Hold the camshaft with a screwdriver as shown in the figure. 3. Tighten the lock bolt Tightening torque: 49-61 Nm (6.0—6.2 m-kg, 36—45 ft-lb) 4. Apply sealant to the shaded area as shown, and install the new seal cover. Distributor 1. Verify that the timing mark on the camshaft pulley is 90 degrees to the right, as shown, 2. Verily that the crankshaft pulley timing mark (yellow) is aligned with the indicator pin. 3. Apply engine oil to the new O-ring and install it onto the dis. tributor. 4. Apply engine oil to the distributor driven gear. 5. Align the marks and install the distributor. 6. Loosely tighten the distributor mounting bolt. Cylinder head cover ‘AngiON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET)ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) B2 FRONT OIL SEAL Preparation ssT 49 8120 710 Holder, couping ==, flange wana Removal 1, Disconnect the negative battery cable, 2. Drain the engine oi. 3, Remove in the order shown in the figure referring to the Removal note. ® 7.811 em (80110 om, #995 inh) zx | — | “WT seus | en (vg, 0) aECaN 1. Radiator cowling 2. Cooling fan 3. Drive belis AUSIMERE eer Page B2-5 4. Water pump pulley 5. Crankshaft pulley 6. Front oil seat B2-21ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) — Removal note Crankshaft pulley Remove the crankshaft pulley with the SST. Front oil seal Installation i in the reREAR OIL SEAL Preparation O11 180 at brake ON-VEHICLE MAINTENANCE (REAR OIL SEA\REMOVAL |] 2 |) 49 woes 5360 i] ft ween Qe Ve S SEE { | orm Release the fuel pressure. (Refer to Section F2.) Disconnect the negative battery cable and remove the battery. Remove the starter Refer to Section G) and transmission. (Refer to Section J2.) | |B. Drain the engine oil and coolant. | | Remove in the order shown in the figure referring to the Removal note. > STEP 4 { TaeREMOVAL B2 4. Undercover 8. Accelerator cable 2. Solenoid valve 9. Air cleaner 3. Cooling fan and radiator cowiing 10. Resonance chamber assembly 4. Drive belts 11. Canister hose 5. Upper and lower radiator hoses 12. Brake vacuum hose 8. Of cooler hose (A/T) 13, Heater hoses 7. Radiator 14. Fuel hoses ceuoegon3 STEP 2 eum 1. Emission harness connectors 5. PIS oll pump 2. Ground wire 6. Exhaust pipe and bracket 3. AIC compressor 7. Lett engine mount nut 4. PIS oll pump ‘pulley 8.Right engine mount nut B2-25REMOVAL Removal note Fuel hose Warning a) Cover the hose with a rag because fuel will spray out when disconnecting. b)Keep sparks and open flame away from the fuel ar Plug the disconnected hoses to avoid fuel leakage. P/S oil pump pulley Remove the PIS oil pump pulley with the SST. P/S oil pump, A/C compressor Remove the PIS oll pump and A/C compressor with the hoses til connected to them; secure the pump and compressor as shown in the figure.ENGINE STAND INSTALLATION B2 ENGINE STAND INSTALLATION PREPARATION SST 49 0107 6808 Engine stand 49 L010 180 ‘Hanger, engine & Plate oe Be | ata | Sisto 0 Cee 49 L010 101 49 Loto 102 49 Lo10 105, 49 L010 104 Arms Hooks Nuts 6 (an of (Past of ar of 49 LOt0 1A0) 49 L010 140) 49 LO1O 140) TREO Botts Botts (Par of | ar ot “91010 140) qa oe [i INSTALLATION 4. Exhaust manifold insulator 2. Exhaust manifold 3. Engine mount 4. Oil level gauge 1. Remove the parts in the order shown in the figure. 2. Install the engine to the engine stand referring to the Installation note. 5. Oil level gauge pipe and stay 6. A/C compressor bracket 7. Coolant bypass pipe 8. Cooiant inlet pipe B2-27(62h) ENGINE: BOLTS 198mm ‘Ga3 in) | Er eo” } i ae 01 TeSinm_ ) ENGINE STAND INSTALLATION ef] are Daw WASHER Hoo | | Bout Nor [SS THaw Zorn (@.79 in OES “awe Installation note Engine hanger +. install the SST (arms) to the block holes as shown in the figure and loosely tighten the SST (bolts A). 2, Assembie the SST (bolts, nuts, hooks and plate). 8 instal the SST assembly to the respective arms while ad- justing parallelism between the arms and plate by turning the bolts and nuts. Warning Use special caution while turning the engine stand handle to prevent hand Injury. | 4 Tighten the bots and nuts to fx the ssr. 5. Install the engine on the SST.DISASSEMBLY PREPARATION ssTB2 DISASSEMBLY (AUXILIARY PARTS) | RUXILIARY PARTS ‘Remove in the order shown in the figure ou 4. Distributor and high-tension lead 8, Alternator 2. Spark plug 9. Altemator bracket and strap 3. Rear engine hanger 40. PIS oil pump bracket 4. Front engine hanger 14. 01 fiter 5. Thermostat and thermostat cover 12. Oil cooler Servic seen Section E 13. Oil pressure switch 6. Water outlet 14, AIC idler bracket 7. Intake manifold assembly 15. PIS idler bracket B2-30DISASSEMBLY (CYLINDER HEAD) CYLINDER HEAD B2 }; Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or f | L 1. Cylinder head cover and gasket 2.Seal cover 3. Distributor drive gear Inspect for wear or damage 4. Rocker arm and shaft assembly IN8POCtION «reine 5. Hydraulic lash adjuster (HLA) Inspection mun 6 Service cover 7. Camshaft Inspection ..., 8. Timing chain cover 9. Cylinder head bolt 10. Cylinder head Inspection page B2~45 age B2-45 Page B2-44 19 boit ovens PAGE B2-B9 place as necessary Tae 11. Cylinder head gasket 12. Valve keepers 13. Upper spring seat 14. Valve spring Inspection... 18. Lower spring seat 16. Valve Inspection 17. Valve seal Inspect for wear or damage 18. Valve guide Inspection... Replacement. - Page B2-43 page B2-40 page 82-40 Page B2-41 B2-312em ieee = ae @® @ mace DISASSEMBLY (CYLINDER HEAD) Disassembly note During disassembly, inspect the following. iat +. Camshaft end play eter to page B2-45,) 3. Gamshait journal ol clearance (Refer to page B2-44,) Distributor drive gear + Set the SST of equivalent against the flywheel (MIT) or drive plate (AMT). 2, Remove the distributor drive gear. Rocker arm and shaft assembly + Loosen the boits in two or three steps in the order shown in the figure. 2. Remove the rocker arm and shaft assembly together with the bolts, Caution Do not mix up the parts of assembly. the rocker arm and shaft Hydraulic lash adjuster (HLA) Remove the FILA by hand. Ithisis dificult, remove it with pliers. Caution ‘Do not remove the HLA unless necessary because oll Teakage will occur if the O-ring is damaged. Camshatt 7. Remove the service cover on the chain cover 2. Push the chain adjuster sleeve in toward the eft and insert the pin as shown into the lever hole to hold it Caution Be especially careful that the pin does not fall. 3, Remave the camshaft, Cylinder head bolt 1. Remove the boit @ 2. Loosen the remaining cylinder head bolts in two or three steps in the order shown in the figure.DISASSEMBLY (CHAIN CASE AND OIL PAN) B2 ~ ee] CValve ING IEE) Remove the valves from the eylinder head with the SST. X~%* SS 2, AB. RS CHAIN CASE AND OIL PAN 2. Remove in the order shown in the figure referring to the Disassembly note. 2 Inspect all parts and repair or replace as necessary [ aaa 1. Water pump pulley 4. Ol! pan 2. Water pump Inspect for damage Service so ronnecnneces Section E__§, =B2 DISASSEMBLY (BALANCER CHAIN AND TIMING CHAIN) Disassembly note Crankshaft pulley +. Set the SST of equivalent against the flywhee! (M/T) or drive ie plate (NT). 2, Remove the crankshaft pulley. eed |BALANCER CHAIN AND TIMING CHAIN PARamove in the order chown in the figure referring to the Disassembly note. 2. inspect all parts and repair or replace as necessary. ‘eaace coo 4. Spacer 9. Right balance shaft assembly 2 Idler sprocket assembly look bolt Inspection... sven PGE B2-5O 3. Chain guide A 40. Chain adjuster page B2- 8 Inspect for wear or damage Inspection 4. Chain guide B 11. Camshait pulley Inspect for wear or damage Inspect for wear or damage 5. Chain guide C 42. Timing chain and timing gear Inspect for wear or damage Inspection sen : 6. Crankshaft sprocket 43. Key inspect for wear or damage 44. Chain lever 7. Balancer chain Inspect for wear or damage a ide page 82-51DISASSEMBLY (BALANCER CHAIN AND TIMING CHAIN) B2 Disassembly note Idler sprocket assembly lock bolt Loosen the idler sprocket assembly lock bol, before remov- ing the chain guides. Left and right balance shatt assembly 1. Remove the thrust plate lock bolts 2. Pull out the balance shaft assembly, Caution Do not damage the bal ing when pulling out the ice shaft journal and bush- sssembly. 3. Disassemble the balance shaft assembly. Caution Do not use a vise on the journals during disassembly. 4. Distinguish the left and right balance shaft for correct as- sembly because the both shafis and the thrust plates are shaped the same, B2-35' ' | : ' : } ||P Remove in the order shown in I B2 DISASSEMBLY (CYLINDER BLOCK) YLINDER BLOCK | the figure reterring to the Disassembly note. | inspect all parts and repair of replacs WASHER, Restace ae aU 4. Clutch cover (MT), Plate (A/T) 40, Main bearing cap 2 Clutch disc (MIT), Drive plate (AT) 41. Crankshaft 3, Flywheel (MIT), Adapter (A/T) Inspection .. page B2-49 4. End plate 42. Pilot beating (MI) 6. Rear cover 43, Main bearing 6 Connecting rod cap inspect for peeling, scoring, or damage 7, Connecting rod bearing 14, Oil jet Inspect for peeling, scoring, or damage 45. Balance shaft bushing 8. Connecting rod, piston and piston pin Replacement page B2-50 Inspection... pages B2-47, 48 16. Blind plug and screw 9. Piston ring Replacement osone--emnnnss Page B2-B1 Ingpection... ss vnnes PAge B2-AT 47. Cylinder block Inspection. sneenes page B2-45 Disassembly note Clutch cover and flywheel (M/T) or drive plate Remove the clutch cover and flywheel (MT), or drive plate (AT) with the SST or equivalent. B2-36DISASSEMBLY (CYLINDER BLOCK) B2 MEASURING PLACE aan Ne Now — Connecting rod and cap Before removing the connecting rod, clean the bearing, con- ecting rod, and crankpin, and measure the following: 1. Connecting rod side clearance (Refer to page B2-58.) 2. Crankpin oil clearance (Refer to page 82-57 ) Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the folowing points, 1. Crankshaft end play (Refer to page B2-56.) 2. Main journal oll clearance (Refer to page B2-56.) Pilot bearing 1. Before removing the pilot bearing, ingpect for sticks or ex- cessive resistance by turning the bearing while applying force in the axial direction 2, Remove the pilot bearing from the crankshaft with the SST if necessary. lacing and/or cleaning the crankshaft, re- ‘move the pilot bearing. Piston and connecting rod 1. Before disassembling the piston and connecting rod, check the oscillation torque as shown, Ifthe large end does not drop by its own weight, replace the piston or the piston pin, 2. Assemble the SST as shown. B2-37DISASSEMBLY (CYLINDER BLOCK) 3. Insert the SST No.2 into the piston pin as shown and fully screw in the SST No.1. 4, Mount the piston and connecting rod in the SST as shown, 5. Press out the piston pin. While removing the piston pin, check the pressure. If itis ower than 4,905 N (500 kg, 1,100 Ib), replace the piston ppin or connecting rodINSPECTION AND REPAIR B2 INSPECTION AND REPAIR PREPARATION ‘SST 1. Clean all parts, being sure or other foreign materials, 2. Inspection and repairs must be performed Caution Do not damage the joi der head or pistons). ints or friction surte Saar 3 49 0248 0104, 49 L012 AO LF | 49.012 002 Romover & Installer set, valve B,® | Beay installer, = sed 8 vag Remove the SST from the engine. 1). Inetall in the following sequence. : Torque Specifications m20 (22-28, 16-21) 4-61 (44-92, 32-49) | : to-an 9a, 20 § ee ae 37-82 (9.853, 27-3) aaa OSES —| Coolant Inlet Pipe and Bypass Pipe 1. Install the coolant inlet pipe with @ new gasket Tightening torque: 19—25 Nim (1.92.6 m-kg, 14—19 ft-lb) | 1 | 1 i | | | | t | ' 1 t | 1 | i i ' | | { | | | | | i | aaa | |ENGINE STAND REMOVAL. B2 EEE 2. Apply vegetable oil to the new O-ring, 3. Install the coolant bypass pipe. Tightening torque: 37—52 Nem (3.8—5.3 m-kg, 27—38 ft-1b) 4. Tighten the intake manifold nut Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 6. Tighten the bot Tightening torque: 19-25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 6. Connect the water hose to the BAC valve. AIC Compressor Bracket Install the AIC compressor bracket Tightening torque ‘37-52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) Oil Level Gauge Pipe and Left Engine Mount 1. Tap in the oil level gauge pipe. 2. Slide the oil level gauge stay over the gauge pipe. 3. Apply sealant to the shaded area in the figure. 4. Install the left engine mount and gauge stay. Tightening torque: 43—61 Nim (4.4—6.2 m-kg, 32—45 fb) 5. Install the oil level gauge. B2-77ENGINE STAND REMOVAL Right Engine Mount Install the right engine mount. Tightening torque: ‘43—61 Nim (4.4—6.2 m-kg, 32—45 ft-lb) Exhaust Manifold 4. Install the exhaust manifold with a new gasket. 2. Tighten the nuts in two or three steps. Tightening torque: 22—28 Nm (2.22.9 m-kg, 16—21 fb) Exhaust Manifold Insulator Install the exhaust manifold insulator. Tightening torque: 19-30 Nm (1.9—3.1 m-kg, 14—22 ft-Ib) ~INSTALLATION B2 INSTALLATION PREPARATION ssT 49 Wo2s 585A, Adjust wrench TS Tighten all botts and nuts to the specified torques. Warning: Be sure the vehicle is securely supported. STEP 1 Torque SpecificationsINSTALLATION Engine 1, Suspend the engine horizontally. 2. Install the engine in the engine compartment being careful not to damage the piping. 8. Tighten the engine mount nuts, Tightening torque 34—49 Nm (3! .0 mekg, 25—36 ft-lb) Exhaust Pipe and Bracket 1. Install the exhaust pipe Tightening torque Nut: 34—49 Nn (3.5—5.0 m-kg, 25—36 ft-lb) 2. Tighten the bracket bolt. Tightening torque Bolt; 21—27 Nm (2.1—2.8 m-kg, 15—20 ft-Ib) PIS Oil Pump 1. Install the PIS oll pump. Tightening torque: 31—46 Nan (3.2—4.7 m-kg, 23—34 ftb) 2. Install the P/S oil pump pulley with the SST. 6.0 m-kg, 29—43 ft-lb) AIC Compressor Insta the AIC compressor. Tightening torque: '39—54 Nm (4,0—5.5 m-kg, 29—40 ft-lb)INSTALLATION B2 Emission Harness Connectors aaaeT 1.1G coil 6. Intake air thermosensor 2. Distributor 7. Oxygen sensor 3. Water thermosensor 8. Idle switch 4. Heat gauge unit 9. Oil pressure switch 5. Injector harness 10. Alternator B2-81INSTALLATIONINSTALLATION B2 Heater Hose Conneot the heater hoses. Canister Hose Connect the canister hose. oma Fuel Hoses Connect the fuel hoses. Solenoid Valve 1. Install the solenoid valve, Tightening torque: 7.8—11 Nm (80—110 cm-kg, 68—95 in-Ib) 2. Connect the emission harness connector. B2-83INSTALLATION Resonance Chamber Assembly the resonarINSTALLATION B2 4. Connect the upper and lower radiator hoses. Note 4) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to en- sure a good omuoee 249 Cooling Fan and Radiator Cowling Install the cooling fan and radiator cowiing, Tightening torque: 7.8—11 Nm (80—110 cm-kg, 69—95 in-Ib) Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. Itthe fan touches the cowling, adjust the radiator cow!- a ing mounting position. Engine Olt ‘Add the specified amount and type of engine oil. (Refer to Section D.) ‘Transmission Install the manual transmission. (Refer to Section J2.) Install the automatic transmission, (Refer to Section K2.) Starter Install the starter. (Refer to Section G.) Check Engine Condition 1. Check for leaks. 2, Perform engine adjustments i necessary. 3. Pertorm a road test 4, Recheck the oil and coolant levels. B2-85LUBRICATION SYSTEM INDEX. OUTLINE. SPECIFICATIONS. TROUBLESHOOTING GUIDE. ON-VEHICLE INSPECTION... PREPARATION. ENGINE OIL... OIL PRESSURE. ON-VEHICLE MAINTEN, ENGINE OIL. OIL FILTER’ OIL COOLE} OIL PAN... OIL PUMP... PPPPPPPPPPPPPP ee oBucoxoo1INDEX dINDEX 182200 (F2 ENGINE) HYDRAULIC LASH ADJUSTER (HLA) SERVICE, SECTION BY i ENGINE OL sPecincaTion — | ® ® APISERVICE 86 (EC) ‘TOTAL capaciTy Seis (05 US ct 4.0 Imp ad : BK 1. 04 pump 4, Oil pan Removal page D-11 Removal page D- 8 Installation ... page D-15 Installation page D-10 Disassembly “page D-12 —§. Oil pressure Assembly. page D-14 Inspection. page D- 6 Inspection: page D-14 6. Engine oil 2.0il strainer Inspection. page D- 5 Removal and Installation... page D=11 Replacement page D- 7 8. Oil fiter Replacement sve page D= 7 D-2INDEX D a 1826001 (@6 ENGINE) HYDRAULIC LASH ADJUSTER (HLA) ‘SERVICE, SECTION 82 WL CONTROL PUG: ow ver SERVICE, ‘SECTION 82 \, ENGINE OIL SPECIFICATION [API SERVICE 50 (ECiT) TAL CAPs "ACT. 5 ters (6.8 US at, 4.8 Imp a) oo 1. Oil pump 4. il cooler Removal 7 page D-12 Removal and Installation... pago D- 7 Installation page D-iS 5. 0il pan Disassembly page 0-13 Removal pages D- 8, 9 ABSSEMIY nnn page D-14 instalation Page 0-10 Inspection page D-14 6. Oil pressure 2. Ol strainer Inspection. page D- 6 3. Gi iter 7. Engine oil Replacement, page D~ 7 Inspection. page D- 5 Replacement wo page D- 7 D-3iD OUTLINE — OUTLINE SPECIFICATIONS F2 ENGINE | Lubrication eystem Force/ed type | Tp Tread gear {| 01 pure Reet prema kPa Io. eh 734002 0-40. 8-57) “pe Fulton, pape denen {Jo mer { al prot ioral KPa elo, pa 75118 08-12 1-1) I Oll pressure switch activation pressure kPa (kg/om’, psi) 2-25 (0.02—-0.25, 0.28—3.60) k Tota (ry engine) fos US ah mp a 4669.40) Oteapecty [oirpan tos 8 at iro a) 3 n.8a) Otter Ber US at npg 022 (028, 018) Eng ol 7? onice 86 Energy Consrving HEC H) |}.G6 ENGINE {TY Laercation system Foroeed (ype | pe Teechid gear es |] 0 pure ) i at presse Wa Walon ed 32401 40-80, 6771) il Type Fudlfiow, paper element joie = cE - ole pesos cirtal KPa fain? pe) 7e—119 (08-1811) Ol pressure switch activation pressure kPa (kgicm*, psi) 29 (0.3, 4.3) Tova fy engine) Hore (US a imp a 356848 | ol capacity Oil pan Iters (US at, imp.qt) 4.5 (4.8, 4.0) Oi fr ier 08 a mp a) 02 (028, 0.19) 1 [enone ot AP sevice 86 Eneray Gonsoreng HEC H) ! aa || Recommended SAE Viscosity i a ee er ee er |] | Temperature a ae i ee ee ee Engine oil GED i THs t ae smunoeens | peaTROUBLESHOOTING GUIDE, ON-VEHICLE INSPECTION (ENGINE. OIL) D TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard starting | improper ongine ol Replace D7 Insufficient engin of Ads ol o-7, Excessive ol! ‘ll working up or down Refer to Section ‘consumption 81 (2 engine) or 2 (G6 engine) Oil leakage Repair - Oil preesure drop | Insuficient of ‘had of DT Gi Oil leakage Repair fae ‘Worn and/or damaged oll pump gear Replace D2, 13 Worn plunge (inside ol pum) or weak spring Replace D4 Clogged of strainer Coan es Excosave main bearing or connecting rod beating Fer to Socton loarance 1 (2 engine) or B2 (G6 engine) Waring tamp ‘Ol pressure drop ‘As desctibad above = Muninates white Malfunction of ol pressure switch Ree to Section T engine is running | Walunction of electrical systom Feter to Section T TSO ON-VEHICLE INSPECTION PREPARATION ssT 49.0187 280 Otrpressure ‘gauge ENGINE OIL 1. Be sure the vehicle is an level ground. 2. Warm up the engine to normal operating temperature and stop it 3. Wait for five minutes. 4, Remove the oiMevel gauge and check the oil level and con- dition. 5. Add or replace oil if necessary.D ON-VEHICLE INSPECTION (OIL PRESSURE) I [OIL PRESSURE I | i i | | | i | | i 1, Remove the oil pressure switch 2. Screw the SST inio the pressure switch installation hole, 3. Warm up the engine to normal operating temperature. 4, Run the engine at 3,000 rpm, and note the gauge reading, Oil pressure kPa (holon, ps) Engine Fe 66 71000 Be 147245 (15—2.5, 21-36) 105-206 (1.12.1, 16-80) 3.000 v0 ‘oa--382 (20-400, 42-87) 304-402 @.1—4.1, 44-58) 1. If the pressure is not as specified, check for the cause, and repair. (Refer to Troubleshooting Guide.) F2 ENGINE, OS NY ea (TAN G6 ENGINEON-VEHICLE MAINTENANCE (ENGINE OIL, OIL FILTER, OIL COOLER) D ON-VEHICLE MAINTENANCE ENGINE OIL Replacement 1. Warm up the engine to the normal operating temperature and stop i 2. Remove the oil filler cap and the oil pan drain plug. 3. Drain the ail inio a suitable container. Warning Be careful when draining; the oil is hot. go 4. Install the drain plug and a new gasket. Tightening torque: 29—41 Nm (3,0—4.2 m-kg, 22—30 ft-b) 5. Refil the engine with the specified type and amount of en- gine oil 6. Refit the oil filer cap. Oil pan capacity: 3.9 liters (4.1 US gt, 3.4 Imp qt) 4.5 liters (4.8 US qt, 4.0 Imp qu 7, Recheck the oil level after the engine has been run. OIL FILTER Replacement 1. Remove the oil fiter with a suitable wrench, 2. Use a clean rag to wipe off the mounting surface on the engine. 3. Apply a small amount of engine oil to the rubber seal of the new filter. 4. Install the oil fiter until the rubber seal contacts the base, and then tighten the filter 1-1/6 turn with a wrench. 5, Start the engine and inspect for leaks around the filter seal 6. Check the il level and add oil if necessary. Oil filter capacity: 0.22 liter (0.23 US qt, 0.19 Imp qt) suo COOLER (G6 ENGINE) oval and Installat oOmy D ON-VEHICLE MAINTENANCE (OIL PAN) OIL PAN | Removal 1. Disconnect the negative battery cable. || 21 Drain the engine oi, | 3. Remove the undercover. UG. Remove the front dlfferential assembly (G6 Engine: Refer to Section M) and center link (Refer to Section N). |. Remove in the order shown in the figure, referring to the Removal note, 6, Inspect all parts and repair or replace as necessary. F2 ENGINE | a) 1 | 711 Wm (60-170 ears, 6998 nse) G 29-41 80-42, 22-20) tHe (vt 0) aoa 4. Gusset plate 4, Drain plug 2. Clutch undercover Inspect for damage to threads 3. Oil pan Inspect for cracks, deformation, or damageON-VEHICLE MAINTENANCE (OIL PAN) D G6 ENGINE 78-11 he (20-110 emg, 69-95 in) heal Ny ms 1. Gusset plate 3. Drain plug yoee Inspect for damage to threads Inspect for cracks, deformation, or damageON-VEHICLE MAINTENANCE (OIL PAN) Ea D-10 aU Removal note Oil pan 1. Remove the oil pan mounting bots. 2 Insert a scraper or a suitable tool between the oil pan and the cylinder block to separate them. 3, Remove the oil pan. Caution Do not bend the oll pan when prying it loose. Installation Install in the reverse order of removal referring to the instal- lation note. Installation note Oil pan 1. Remove any old sealant from the bolts and bolt holes. If the old sealant can not be removed, replace the bolts as necessary. 2, Remove any dit or other material from the contact surfaces. 3. (With gasket) ‘Apply sealart to the shaded areas shown in the figure (6 engine). Then install a new gasket. (Without gasket) Apply sealant continuously to the oil pan around the inside (of the bolt holes and overlap the ends. Caution a) Do not apply sealant to both the cylinder block side and oil pan side. b) After the sealant Is applied, the oll pan must be se- cured within 30 minutes. 4, Apply locking agent to the bo threads. (G6 engine) Note New bolts of the G6 engine do not need extra locking agent because they come with it already applied. 5. Install the oil pan. Tightening torque: 6.9—12 Nm (70-120 cm-kg, 61—104 in-b) 7.8—11 Nm (80-110 em-kg, 69—95 in-tb).. . F2 Engine .. G6 Engine Step After Installation 1. Add engine oll to the specified leve's. 2. Connect the negative battery cable. 3, Start the engine and do the following: (1) Check for leakage of engine oil 2) Perform engine adjustments if necessary. 8) Recheck the oil levels. suusoro%0ON-VEHICLE MAINTENANCE (OIL PUMP) D lL PUMP Preparation sst 49 $120 710 Holder, coupling <._—_-¢=: flange — SORTS Removal F2 Engine 1. Remove the engine. (Refer to Section B1,) 2, Remove in the order shown in the figure, referring to the Removal note. 1981926, 19 | arse asa, 27am ‘O-FING REPLACE LO=12 W (00-120 emg, 68104 indy 85-12 Nem (0120 ems, 61—104 nay ‘2041 (90-42, 22-20) Non nk, ay UOT 1. Timing belt (Refer to Section B1) 4. Oil strainer 2. Timing belt pulley 6. Stiffener 3. Oil pan 6. Oil pump D-11ON-VEHICLE MAINTENANCE (OIL PUMP) Removal note Crankshaft pulley lock bolt Hold the crankshaft pulley with the SST and remove the look bot Removal || G6 Engine 1. Remove the engine. (Refer to Section B2.) 2. Remove the chain case, referring to Section B2 (TIMING CHAIN ON-VEHICLE MAINTENANCE), Disassembly || Disassemble in the order shown in the figure. | Fe ENGINE FACE, THE DIMPLE TOWARD SAE Pum COVER WHEN ASSEMBLING aOR 1, Pump cover 4, Pressure relief valve 2. Outer rotor 5. Oil seal 3. Inner rotor 6. Oil pump body D-12ON-VEHICLE MAINTENANCE (OIL PUMP) D G6 ENGINE FACE THE DIMPLE TOWARD THE PUMP COVER WHEN ASSEMBLING en ekg, 0) ‘oMUeOK Ces 1. Pump cover 4. Pressure relief valve 2. Outer roior 5. Oil soai 3. Inner rotor 6. Oil pump body 7. Water inlet pipe gasket D-132. Measure ine folowing clearances. | F2 ENGINE i : 06 ENGINE ON-VEHICLE MAINTENANCE (OIL PUMP) Inspection 1. Check the following and replace any faulty parts. (1) Distorted or damaged oil pump body or cover, (2) Worn or damaged plunger {@) Weak or broken plunger spring Free length: 46.4mm (1.827 In)ON-VEHICLE MAINTENANCE (OIL PUMP) Installation lation note. Installation note Crankshaft pulley lock bolt Tightening torqu wmoxee Steps After Installation {install he crankshatt lock bolt with the SST. D Install in the reverse order of removal, referring to the Instal- 187—167 Nm (16.0—17.0 m-kg, 116—123 ft-lb) 1. Add engine oil and coolant to the specified levels. 2. Connect the negative battery cable 3. Start the engine and do the following: (1) Check for leakage of engine oil or coolant. (2) Perform engine adjustment it necessary. (3) Recheck the oil and coolant levels. D-15COOLING SYSTEM INDEX. OUTLINE SPECIFICATIONS TROUBLESHOOTING GUIDE... ON-VEHICLE INSPECTION PREPARATION .. ENGINE COOLANT. REPLACEMENT AIR BLEEDING ANI RADIATOR CAP COOLING FAN. eo ON-VEHICLE MAINTENANCE... RADIATOR... WATER PUMP THERMOSTATTo HEATER INDEX || 32200 (F2 ENGINE)B2600i (G6 ENGINE) on cooten SERVICE, SEGTION D INDEX BAC VatvE sence, SecTionF ENGINE COOLANT 68 ites (72 US Mt, 60 Imp at RENTS 41. Radiator 3, Water pump Removal, Inspection, and Femoval, Inspection, and Installation... page E- 7 Installation pages E~ 8, 9 2.Cooiing fan 4, Thermostat Removal and Installation page E~ 7 Removal. sree Page E~10 lnspection page E- 6 Inspection .ccnnnnnnnns page E-11 Instafation “page E~11 5. Coolant reservoirE OUTLINE, TROUBLESHOOTING GUIDE DUTLINE BPECIFICATIONS be a Engine model 5 as Cooing system Watecacled, forced srculston With boster 7578, 68) 7579.66) Coola capacity — Hers (US at Imp ct) Without heater 6973.61) 6973.61) | Tyee Centritugal Water pump Winer 20a) Urifed mechanical seat Type Wox Wax, wostage | Opening temperature coer | 9ss-a9s re6—109) | Nam 985808 (188-199 Thexmestat Fultopen temperature soe) 00 72) 100 32) Fullopen itt smn ¢o) 8.5 (0.3) min. ar oo oe mn Type Corugeted fin Radiator Cap valve epering Proeae A os) 74108 (0751.05, 11-18) Type Thermo-modblaod T ae Me 55-65 (191140) Hew | 68-92 (154-106)... NCO [OFF ON CCA ar 65-75 (149-167). linear | — Cosi fan wi 7 2 Number of blades ar 3 7 Outer dameter of lado | MT Seneca ao ren (6) | at 410 (18.4) = oo TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page ‘Overheating Ineufiet coolant ‘de 8 Godan lnekage Repair 7 Redieo: fins cogged Green e7 Raclstor cap matron Replace £6 Cosing fan malfunction Replace a STrerotatmafuncton piace E10 Water pessage cogged Cioan a Wate: pump malunction Repl E68 Corrosion Impurities in coolant epiace Les IGORON-VEHICLE INSPECTION (ENGINE COOLANT) E ON-VEHICLE INSPECTION PREPARATION ssT 49 9200 145 49 9200 146 49 9200 147 pecan hesous sears ee a Ose a ES ey a waa RIDE ENGINE COOLANT Bo Coolant Level (Engine cold) 1. Check that the coolant level is near the radiator inlet port, 2. Check that the coolant level in the coolant reservoir is be- tween the FULL and LOW marks. ‘Add coolant if necessary. Warning a) Never remove the radiator cap while the engine is hot. b) Wrap a thick cloth around the cap when removing It. Coolant Quality 11. Check that there is no build up of rust or scales around the radiator cap or radiator filler neck, 2. Check that coolant is free of oll 3. Replace the coolant it necessary. Coolant Leakage 1. Connect a tester and SST to the radiator inlet port 2. Apply 103 kPa (1.05 kg/em’, 15 psi) pressure to the system, 8. Check that the pressure is held, IF not, check for coolant leakage. Warning When removing either the radiator cap or the tester, loosen it slowly until the pressure in the radiator is released, and then remove it.+004 BOB B BiBuihy By iSoriocicn ‘COOLANT TEMPERATURE °C (7) REPLACEMENT, AIR BLEEDING AND REFILLING SYSTEM Coolant Protection Caution a) Do not use alcohol- or methanol-based coolant. b)Use only soft (demineralized) water in the coolant mixture. +. Measure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2, Determine the coolant protection by referring to the graph shown. if the coolant protection is not proper, add water or coolant. Antifreeze solution mixture percentage coon SE a ee REPLACEMENT Warning a) Never open the radiator cap while the engine is hot. b) Wrap a thick cloth around the cap when loosening. ¢) When removing the radiator cap, loosen it slowly to the first stop until the pressure in the radiator is released, and then remove it. )Use caution when draining hot coolant. Caution a) Do not use alcohol- or methanol-based coolant. b) Use only soft (demineralized) water in the coolant mixture. ¢) Before loosening the radiator drain plug, verify that the radiator drain hose faces straight down. 4. Remove the radiator cap and loosen the drain plug. 2. Drain the coolant into @ suitable container. 3 Fill with the proper amount and mixture of ethylene glycol based coolant. AIR BLEEDING AND REFILLING SYSTEM When the coolant is drained, bleed the cooling system after refiling it ‘| Slowly pour the coolant into the radiator up to the coolant filler port Filling pace: 2 ¢ (2.1 US gt, 1.8 Imp qt)/min. max. 2. Fill the coolant reservoir up to the FULL level. 53 Install the radiator cap securely and start the engine. LCE O0RADIATOR CAP, COOLING FAN E 4. Run the engine at idle speed untl it reaches normal oper- ating temperature. Caution If the temperature increase beyond normal, there is excessive air in the system. Stop the engine, allow the engine to cool, and repeat Steps 1—3. | 5. Run the engine above idle several times as specitied wane —- Speed: 2,200-2,800 rpmx5 sec. g 6. Stop the engine and wait tl the system is cooled down, Remove the radiator cap and check the coolant level tithe coolant level has dropped, repeat the operation from Step 1 RADIATOR CAP Radiator Cap Valve 1. Remove foreign material (such as water residue) from be. tween the radiator cap valve and the valve seat. 2. Attach the radiator cap to a tester with the SST. Apply pres- sure gradually to 74—103 kPa (0.75—1.05 kg/em’, 11—15 psi). 3, Wait about 10 seconds; then check thal the pressure has not decreased. wo Negative Pressure Valve 1. Pull the negative-pressure valve to open it. Check that it ai I | | i Hi | | | | we | | | | i | ‘A SOREWDAWER) | 8, DISTORTED Of BENT“ | RADIATOR WET = ON-VEHICLE MAINTENANCE (RADIATOR) N-VEHICLE MAINTENANCE iADIATOR jemoval, Inspection and Installation . Drain the engine coolant. 2 Remove in the order shown in the figure. Inspect all parts and repair or replace as necessary. 4. Install in the reverse order of removal. Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. It the fan touches the cowling, adjust the radiator cowling mounting position. Note Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. | CHECK FOR ‘THe FOLLOWING AND REPAIR OR REPLACE TF NECESSARY 1. GRACKS, DAMAGE, OR WATER LEAKAGE 2, BENT FINS (REPAIR WITH ey ao io eg, 2-25 fo) S/ aON-VEHICLE MAINTENANCE (WATER PUMP) E WATER PUMP Removal, Inspection, and Installation 1. Disconnect the negative battery cable. 2. Turn the crankshaft so that the No.1 cylinder is at TOC of compression. (F2 Engine) 3. Drain the engine coolant. 4. Remove in the order shown in the figure, 5. Inspect all parts and repair or replace as necessary. 6. Install in the reverse order of removal After radiator cowling installation, rotate the cooling fan by hand and verity that the fan blade does not touch the radiator cowling, If the fan touches the cowling, adjust the radiator cowling mounting position. B Note Do not disassemble the water pump. if a problem is found, replace the pump as a unit. F2 ENGINE asker, @RePLACE 1825 (10-126, 1499) Nor (vag, to) a Teer 1. Timing belt Reter to Section B1,) 3. Water pump 2. Timing belt idler pulley Inspect for body cracks and damaged gasket surface 4. GasketEe Wi E ON-VEHICLE MAINTENANCE (WATER PUMP) G6 ENGINE EY ras um | (O70 em, 6325 in) aaa 4. Drive belt 4. Water pump Adjustment... Section B2 Inspect body cracks and damaged gasket 2. Cooling fan and radiator cowiing surface 3. Water pump pulley 5. Gasket Steps After Installation 4. Add engine coolant to the specified levels. 2. Connect the negative battery cable. cae 3. Start the engine and do the following: * (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (@) Recheck the coolant levels. | E-10 SU aaa ‘yoexc00|ON-VEHICLE MAINTENANCE (THERMOSTAT) E THERMOSTAT Removal 1. Drain the engine coolant. 2, Remove in the order shown in the figure. [Fe encine cro | REPLACE / 2 1 > @ _wsnsas ww SEAL PRINT SIDE FACING THE CYLINDER HEAD Ge ENGINE THE JIGGLE PIN SHOULO BE up (EE| E ON-VEHICLE MAINTENANCE (THERMOSTAT) Inspection Check the thermostat and replace if necessary. 1, Visually check that the vaive is airtight. 2. Place the thermostat in water with a thermometer. increase the water temperature, and check the following. (LE vaenane Non Engine = a Intab opening 65-895 |Main: 86.589: (188—199) femperature °C (°F) | (188-183) _|Sub - 69.5~86.5 (182188) Fulkopen temperature 26 (°F) | 10012) 100 (212) Fuikopen lit Main: 8.0 (0.81) min mm Gay | 85.039) min. | Su: 1.5 (0.06) min. ser Installation Install in the reverse order of removal. ee Note Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. ‘Steps After installation 1, Add engine coolant to the specified levels. 2, Connect the negative battery cable. Get ese emai heatonINDEX Fi 1. ACV solenoid vaive 20. No.1 Air control valve Inspection page F1— 60 Inspection page F1- 59 2. Air cleaner element 21. No.1 purge control vaive Inspection. s page F1— 80 Inspection page Fi- 70 3. Air vent solenoid vaive 22, No.2 Air control vaive Inspection : page Fi— 72 Inspection. page Fi- 60 4. Airftual (IF) solenoid vaive 23, No.2 purge control valve Inspection page F1- 54 Inspection... page F1~ 71 5. Atmospheric pressure sensor 24, No.3 purge control valve Inspection... .. page F1-106 inspection page F1~ 71 6. Clutch switch 25. Oxygen sensor Inspection .. .. page F1~105 Inspection... page F1— 55 7. Coasting richer solenoid valve 26. PCV valve Inspection .- page Fi- 67 Inspection... page F1- 79 8. Dashpot (lor MT) 27. PTC heater Inspection page F1- 68 Inspection : . page FI- 75 9. Duty solenoid valve 28. Purge solencid valve” Inspection - page Fi— 63 Inspection ... page F- 72 10. EGR control valve 29. Rear catalytic converter Inspection .. ‘i page Fi- 62 Inspection .. 11. EGR postion sensor 30. Reed valve inspection page F1~ 63 Replacement. 12, Engine control unit 31, Servo diaphragm Precaution page F1-109 Adjustment. page FI~114 Inspection nn page F1-109 32. Siow fuel cut solenoid 13. Front catalytic converter InSB2CtiOM wenn page F1~ 67 Inspection ssone Page FI- 74 — 83, Vacuum control valve 14. High-altitude compensator Inspection page Fi— 80 Inspection... page Fi- 76 34. Vacuum sensor 16. Idle compensator Inspection page F1-107 Inspection page FI- 78 35, Vacuum solenoid valve 16. Idle switch Inspection page F1— 67 Inspection page F1-105 36. Water temperature switch 17. Intake air thermosensor Inspection page F1~105 Inspection page F1-107 37. Water thetmosensor 18. Mixture control valve Inspection ... page F1-106 Inspection page FI- 68 38, Water thermovaive 19, Neutral switch Inspection page F1— 71 Inspection .- page F1-105 avon Fi-3ORR INDEX VEHICLE WITH AT 1. Check and cut valve 6. Fuel main pipe Inspection page FI-74 Removal. page F1-84 | 2. Evaporation pipe Installation page F1-84 | Removal... page F1-84 7 Fuel return pipe Installation page F1-84 Removal page F1-84 3 Fuel cut valve Installation. page F184 Inspection page F1-84 8. Fuel tank 4, Fuel filter Removal page F1-84 Replacement. page F1-83 Installation page F184 Fuel main hose Inspection vrs page F1-84 F1-4INDEX FA ‘VEHICLE WITH MT 1. Check and cut valve Inspection... 2, Evaporation pive Removal. Installation 3. Fuel filter Replacement. 4. Fuel main pipe Removal. Installation. page F1-71 + page F184 page F184 page F1-83 page Fi-84 page F1-84 5. Fuel pump Fuel pressure... Flow Rate (Volume) Replacement... 6. Fuel return pipe Removal instalation 7. Fuel tank Removal... Installation eur ear page F1-83 page F1-83 page F183, page F1-84 page F1-84 Page F1-84 page F1-84 F1i-5soe po ReaaRSSR ee eae Sa oo. ; jana, fe awa | aaa usw wos) -OWUHL ana | —— t oa WEYM | GIONSTOS ALAG A= ! Dey b= + ooo a He Y3LSINVD: and Tan eee Z| ts es = ( 3OuNd CON] ‘Waits 73nd | SATA AOd: 5 anwn 1n9 734 y um voa ou! , 3 : ; So et ee 5 ae J 8 @ = SAI SATA GIONTOS 3OUNE . be [POUINGO MANOVA —“SASvn cionTIOs WnNOWA. a SATWA GIONSTOS AOW: f] { aWHOIH 5 f cae tu ama rouinco uv ron NIWA HOLINS NANOVA ABS creas ‘BATA G33H ‘LWW YO) HOLIMS HOLTTO- | anwnrouncoun ens | basa | (Uy 802) anT¥A GIONSTOS dr-stal (uy #0) NOWUMAWIO OnUaS Houms welin3n WBNS NOWISOd YOR INN TOLNOO BNIONS | SYSTEM DIAGRAM OUTLINEOUTLINE FunctionOUTLINE Fi ‘Component Function Remarks No.1 air control valve Supplies secondary air to reed valve A according to intake marilols vacuum No.1 purge control valve Purges fuel vapor (stored in canister) into intake manolc duaing tunding No.2 air control valve ‘Supplies secondary air to reed valve A when ACY solenoid valve is ON, ‘No.2 purge control Pressure and vacuum valves operate in prevents cing valve ‘accordance with tue tank pressure ‘No.3 purge control Purges fuel vapor (stored in caristet) nto valve’ intake manifold when purge solenoid valve 8 ON ‘Oxygen sensor Detects exhaust oxygen concentraion: ‘sends signal fo control unt : PTC heater ‘Heals throtile body of carburetor and urge solenoid valve Applies vacuum to No.3 purge contel valve ‘according to signal rom engine contr unit (except for Canada) ear catalytic converter Reduces HO & CO by oxidation ‘Converts into O02 and HeO Honeycomb consirucion ‘Rood valves. Reed valve A cians nic nae _§_ ‘Supplies secondary air to exhaust manfola (valve 4) ‘One-way valve on ai CleanerOUTLINE F1 Hose Color Code ‘Component Color Connected to: ‘AGV solenoid vaive Yetow No2 ar corral valve I Groen Intake maniold Canister Green No. purge contol valve Black Intake manifold Brown Water thormovalve Black Evaporative pipe Distributor Black Intake manfola Duty solenoid valve Red EGA control valve Bue Intake manila 7 Black A cleaner High-altitude compensator Ble Carburetor Primary rainy Black Carburetor Intake marci) Brown Carburetor (Secondary main) Idle compensator Black Intake manila af ‘No.1 air control valve Brown to green Intake mantola ‘No.3 purge control vaive ‘White Purge solenoid valve Orange to back Intake mantola Grean Canstor Purge solenoid valve write No purge coniral valve Black to brown Intake manitole ‘Vacuum control valve Rod Intake mantos White Secondary vertu (in carbu Yellow Foat chamber (in carburetor) | Vacuum sensor white Intake manifold ‘Vacuum solenoid valve Groen Intake manifols Black Desribuior TanaTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Fi DIAGNOSTIC INDEX No. ‘TROUBLESHOOTING ITEM. REMARK 1 | Hard stator wont sant ging cranks al norral speed but shows fo Sign oF xing” oF will not Continve to run after ignition switch is moved froin START postion or requires excessive L cranking tie betore staring 2_| Engine stale during warm ua Engine stops running only when engine is GoW FA-20 3 _| Hard restaring when hot Engine stars normally when engine © cold but hard | F1=2a _ to Stet aftr running at high speed or aftr heat soak 4 | High dle speed ater warm up Engine iale is excessive for operating mode Fi-28 5 | Enoine ides roughiy or sas Engine vibraios excessively or sope running durng | F1—30 ie [6 | Hestaion on accsleration Lag between imme acceoraior @ depressed and FI-3e acceleration begins 7_| Lack of power Performance is inadequate under load Fi-38 8 | Alterburn on decdleration ‘Abnormal combustion in exaust system producing | FI=#2 backfire ‘8 _| High fost canaumplon Fusl economy i uneaisiactory Fas 70_[ No erank or exank slowly Section & ‘800-8TROUBLESHOOTING GUIDE np salle during warm uDTROUBLESHOOTING GUIDE STEP 1 |TROUBLESHOOTING GUIDE STEP 11TROUBLESHOOTING GUIDE Hard restarting when hot ‘QUICK INSPECTION neTION POSSIBLE CAUSE AND, Has Ga wave To ay Geen | Yon | Goo Noa Sep ‘when engine is hot No | Check voltage at choke ‘Yes | Replace automatic 1-87 eae ae ae | vonage: 6-av catia) [S® | Popa or ace wi ares hack at oval alzpeed [Yer] Go w Newt Sep mark on carburetor sight glass ‘No | (Higher than specified) ‘Check needle and Fi-90 Cree ar cursor and | Sat fr wea orn ‘check points shown ‘Gheok feet for F190 rave Stat ve Fai ‘Tawar han [Fe [os Set et ove Fat mee io lace fuel seas To [Reps ut pimp] FI=89 Shes or bec Soot peaire Fuel resere: pena ra (0.26-—0.33 kgiem?, 3.7—4.7 | pat (cova Par spied) | Vs | Ohoak a posers | FIC Gene i ‘Check for tuel pump oper- eee: eicet Spec ot ao oT Gok a a Sa unt pet Henle we pun | FIRE lon ON, pp con depts and (B/W) jumped) Tach OT Tans and reek [Yeo | Rola PCV vee ‘condition improves No | Go to Next SeoTROUBLESHOOTING GUIDE Hard restarting when hot (Cont'd) POSSIBLE CAUSE ANDTROUBLESHOOTING GUIDE STEP 6 | eases ray. 10 [PWELLMETER READING: AT IDLETROUBLESHOOTING GUIDE High idle speed after warm up ea POSSIBLE CAUSE AND QUICK INSPECTION ACTION DETAILED INSPECTION hroator (YL) wire Voltage: 6—8V (At idle) Chek ‘tes play Free play: ‘1—3mm (0.038—0.188 in)TROUBLESHOOTING GUIDE F1 STEP 1 STEP 5 —— (RCE (CHOKE VALVESFULLY OPEN WHEN ENGINE IS HOT STEP2 IDLE-UP SOLENOID VALVE DIAPHRAGMTROUBLESHOOTING GUIDE Engine idles roughly or stalls T POSSIBLE CAUSE AND ues neers fetes DETAILED INSPECTION ‘Chock (or air leakage by Ttening | Yes | Check poinis shown Tniake alr system component for sucking noise damaged ‘Vacuum hose disconnected or damaged Bots or nuts loose ‘Gasket damaged No | Got Nex Step ‘Gheok fod level i at speciied | Yes | Go to New Sten ae | mark on carburetor sight glass hig | (Higher than speotied) Check neede and | ‘FI-80 Disassemble cerouetor and | seat for wear oF rust check poinis shown (Gaack boaa for co damage ‘Set float level Ft-ot (Lower than F183 | Yoo | Set fot level Fi-ot ‘spectied) ice fuel pam speed No | Replace fuel pump | F1-63 Check for spec | fied fue pressure Fuol pressure: 26—32 kPa (0.26—0.33 kgicm? 3.74.7 psi) (Cower than speciied) ee AMT vehle: Toate I Pca toe fy pap ope Set oatTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Engine idles roughly or stalls (Cont'd) POSSIBLE CAUSE AND Ctl ihe DETAILED INSPECTION Repair ck and (2L) terminal Voltage: 2k—Battery voltage 2L—Battery voltage (At idle) 7 cioking” is heard from fuel cut solenod valve when xs ons T check sow tion switch is turned OFF + ON 7 clenoid valSTEP 9 > | IDLE? 5: TROUBLESHOOTING GUIDE .ENOID VALVE (FOR A/T) MIXTURE CONTROL VALVE VACUUM CONTROL VALVE ER STEP 13 HOSE cou 8: BLACK : GREEN BR: BROWN LBwue O: ORANGE Ww. WHITE ¥: YELLOWTROUBLESHOOTING GUIDE Hesitation on acceleration or start-up pe TLL [ster] ‘QUICK INSPECTION ‘ACTION POSSIBLE CAUSE AND i T | Check f fuel level i at speciied | Yes | Go to New Stop } mark on sight glass No | (Higher than specified) ‘Check needie and F1-90 | Serie cabutter and | seat for wear ort WHY oneek pales shown Chock oat or Fe ae canage ' Se fost va Aa } | (Lower than F1-83 | Yes | Set float lever Fist i specie) i>] Repiece ful pa | speed) No] Reece fl pm | PIB i heck or spe fied fuel pressure Fuel pressure: 26—32 kPa (0.26—0.33 kglom’, 3.7—4.7 i pai) I i ‘(Lower than spectieg) | Yes | Check uel pressure | FIW82 See ek el i ee eon riot Goo eT ur oP FS ack fl puri conan port Replace fuel pump | FI-62 {ign ON, fue! pump con trol unit ieiminabwire (7) ‘anc (BN) jumped]TROUBLESHOOTING GUIDE STEP 5TROUBLESHOOTING GUIDE Hesitation on acceleration or start-up (Cont'd) QUICK INSPECTION ‘ACTION ee Tao ogo and wn ae [ Yas] Goo Ve Sap cons duane check son | | FHREHOD EEN end | Fre Sere ee eh iolnter rating = within Creek pins to (By wma) Fe voltage Eu fovea PFI was Te a) eeu (emma) PFO Sa fo nee Vacuum hose routing | _F1=10 eeu more PFO ay Sige ay ecu ta ening FIT Eo ches porte hom ‘Focusing ou ‘ae ro ag FD aoe an ECU (1A) terminal Fito sus chek on sown tae ‘Oxygen sensor FI55 Sean Sea amd me Hi Tes ava | FC .STEP 8 a) STEP 8 @) STEP 9 a) STEP 9 (2) TROUBLESHOOTING GUIDE Fi | STEP 10 (2) ADVANCE (OEGREE) fo 48 8 7 206 8800 560 ENGINE SPEED (APM) @) Sip. 1” | vacuUM ADvANGE ‘STEP 10 @ 70094) 260 (10.2) F< cysce vouletron VACUUM mmtg (inHg) WHITE: STEP 11 DWELLMETER READING: ‘ABOVE 4,500 RPMTROUBLESHOOTING GUIDE ‘Afterburn on deceleration —————— POSSIBLE CAUSE AND QUICK INSPECTION ACTION DETAILED INSPECTION Tosa gal advance: Disovior mane insaficient F110 | Yes | Dstib tum adh Not Check for vac outingTROUBLESHOOTING GUIDE F1 ‘STEP 1 STEP 2 (1) ) aa aaa = 16 : g 3 |. fe ao 2 WRI —BeTon arenes STEP 1 STEP 3 2) sm Leaver ELEMENT (OL, PERMEATED) STEP 2 STEP 4 {s TEST CONNECTOR w | RRS NN? < range ‘Se OK range / X\ranee eho RaNes OK etm) (roo Low STEP 10) a) MONITOR LAMP STEP 10)F1 FEEDBACK SYSTEM FEEDBACK SYSTEM EDNOATIONFEEDBACK SYSTEM Fi Seaaee) (were: PIN} DWELLMETER READING 0 ° (FIXED DUTY) BRET DWELLMETER READING 27° (FIXED DUTY) aera DWELLMETER READING | 36° (FIXED DUTY) od ‘SYSTEM INSPECTION Note Troubleshoot with the Self-Diagnosis Checker before performing the following steps. 4. Warm up the engine and run it at idle 2, Connect a dwelimeter to the check connector (White: 1-pin), and note the dwellmeter reading. 5. Ifthe dwellmeter reading is fixed at 0°, check the following. 1) Ignition puise signal for the engine control unit 2) Characteristics of the vacuum sensor. 8) Characteristics of the water thermosensor. 4. Ifthe dwellmeter reading is fixed at 27°, check the following, 1) Characteristics of the intake air thermosensor, 2) Vacuum hose routing, 3) Oxygen sensor. 5. I the dwellmeter reading is fixed at 36°, check the following, 1) Characteristics of the water thermosensor. 6. the dwellmeter reading is fluctuating out of the 20°—7 Tange, check the following, 1) Vacuum hose routing, 2) Oxygen sensor. 8) AIF solenoid valve and wiring harness. 4) Clogged jets and air bleeds in the carburetor. Note If all these items are in good working condition, ad- Just the Idle mixture (duty) with the mixture adjust screw. F1-53FEEDBACK SYSTEM AIR/FUEL (A/F) SOLENOID VALVEFEEDBACK SYSTEM .FEEDBACK SYSTEM Monitor lamp: Flashes ON and OFF more than 8 times/10 sec ReplacementFEEDBACK SYSTEM F1 Ear 5. With the transmission in gear, check the monitor lamp while depressing the clutch pedal Conation T Lemp ‘Clutch pedal released ON, ‘Gutch pedal depressed OFF if itmalfunctions, check the 1N terminal of the engine control unit and the clutch switch, 6. Check the monitor lamp while(IR INJECTION SYSTEM usa i i Now ACY } A Af) peep vawve == WATER TEMPERATURE SWITCH No.1 AIR CONTROL VALVE FA AIR INJECTION SYSTEM REED VALVE: Nowt ACY: ACY SOLENOID VALVE No. AIR GONTROL VALVE loontROL UNIT ‘cai OLE SWITGH IGNITION CON, |i CHAMBER REED VALVE {NOT USED FOR CANADA)AIR INJECTION SYSTEM, EGR SYSTEMEGR SYSTEM sontrol valve, Tightening torqu 8-11 Nan (0.8—1.2 m-kg, 6—8 ft-lb) EGR POSITION SENSOR Inspection of Terminal Voltage 1. Remo from the um hose fr um pump.EGR SYSTEM Inspection of Vacuum Valve Disconnect the vacuum hoses. >. Biow through the vacuum hose and verity that air does not flow. 3. Disconnect the duty solenoid valve connector. Apply battery power and ground the solenoid valve as shown, Blow through the vacuum hose and verity that air passes. IF problem is found, replace the duty solenoid valve. BO Po ‘GROUND. BATTERY POWER, Inspection of Voltage 1. Remove the rubber boot from the connector. 2. Turn the ignition switch ON. 3, USING A VOLTMETER, verify that voltage at each termi- nal is battery voltage. 4. fon any terminal itis not, check the duty solenoid valve, the wiring of the valve, and the 2K and 2L terminals of the ‘engine control unit.DECELERATION CONTROL SYSTEM Fi DECELERATION CONTROL SYSTEM PRIMARY SLOW ‘ ‘AIR BLEEDS, Eo PRIMARY stow Jet | -—e/ (CoaSTING RICHER SOL VAL JENGiNE CONTROL UNIT InvuerToR swiroH f ‘OLUTGH swrTcH / NEUTRAL SWITCH Ienmon cou. MIXTURE CONTROL VALVE This system controls the air/tuel mixture and advances ignition timing to reduce CO and HC engines to re- duce fuel consumption, and to prevent the front catalytic converter from overheating. The system comprises the siow fuel cut solenoid valve, coasting richer solenoid valve, vacuum solenoid valve, dash pot, and Mixture control valve. The slow fuet cut solenoid valve closes the primary slow fuel passage on command from the engine control unt The coasting richer solenoid valve supplies extra air/luel mixture to add to the primary slow fuel on com: mand from the engine control unit The vacuum solenoid valve applies intake manifold vacuum to the vacuum contol unit of the distributor on command from the engine contro! unit The mixture control valve supplies air into the intake manifold during the first period of deceleration. The dashpot commands the throttle valve to close gradually. F1-65DECELERATION CONTROL SYSTEMDECELERATION CONTROL SYSTEM Fi ‘VACUUM SOLENOID VALVE WE TUBES TLR Coasting advance system 13. Connect a voltmeter to terminal (WIG) of the coasting ad- vance solenoid valve. 14, Increase the engine speed to 3,000 rpm, and lift the idle switch arm, 15. Verify that the voltmeter indicates as shown in the following table. Engine speed Vormeier oie than 2,500 rom “pattery votage '2,500—1,700 tbe Less than 1.5V Tass than 1,700 ipa battery voliage 16. Itany of these voltages are not indicated, check the 1S ter: minal of the engine control unit and the vacuum solencid valve. SLOW FUEL CUT SOLENOID VALVE Inspection 1. Run the engine at idle, 2. Disconnect the carburetor connector. 3. Verify that the engine stops. COASTING RICHER SOLENOID VALVE Inspection 1. Run the engine at idle. 2. Ground H terminal (BRIS) of the carburetor connector. 8. Verify that the engine speed increases. VACUUM SOLENOID VALVE Inspection 1. Femove the vacuum solenoid valve, F1-67DECELERATION CONTROL SYSTEMEEC SYSTEM F1 EVAPORATIVE EMISSION CONTROL (EEC) SYSTEM ‘AIR VENT SOLENOID VALVE. 1 rayon cot \ TOE nos unge contmo. vanveN, vacuUM No2 PURGE CONTROL SENSOR A ‘CARBURETOR ee t A To Noa PuRGe - CONTROL VAL WATER cif [waren ERAN, | THersosens6a] | Ae tovb ve) HEKO-AND beri ; cur VALVE PURGE SOLENOID VALVE, il Noa PURGE CONTROL i VANE FLOAT VALVE! CHRISTER CHECK-AND-CUT VALVE ro canisren a LSI a f I SOLENOID VALVE : 10 Fue. ere 8 TO ATMOSPHERE ae This system stores fuel vapor generated within the fuel tank in the canister and draws the fuel vapor into the intake manifold, burning it there when the engine is started. The system consists of the canister, No.3 urge control valve, water thermovalve, check-and-cut valve, purge solenoid valve, and air vent solenoid valve. ‘The water thermovalve opens the vacuum passage to the No.1 and No.3 purge control valves.EEC SYSTEM SYSTEM INSPECTION Note Troubleshoot with the Self-Diagnosis Checker before performing the following steps. Check ‘outinEEC SYSTEM F1 No.2 PURGE CONTROL VALVE Inspection pipe. into the hose and verify that air flows free!EEC SYSTEM AIR VENT SOLENOID VALVE Inspection 4. Remove the air cleaner. 2. Touch th ‘olenoid valve on the carburetor. urn the ignition and OFF, and verify that a ck ing is felt and heard PURGE SOLENOID VALVE Inspection of Valve 4, Remove the solenoid vF1 CATALYTIC CONVERTERPTC HEATER SYSTEM F1 PTC HEATER SYSTEM| Fi ALTITUDE COMPENSATION SYSTEM fi ALTITUDE COMPENSATION SYSTEMAIR INTAKE TEMPERATURE CONTROL SYSTEM F1 AIR INTAKE TEMPERATURE CONTROL SYSTEM _ ‘CONTROL VALVE L aes ost ‘This syste controls air intake temperature to prevent icing and operates depending on air temperature around the control vaive, CONTROL VALVE Inspection Move the control valve inside the air cleaner, and verity that it does not stick, and that spring force of the bimetal is fet F1-77a ‘Fl HOT-IDLE COMPENSATION SYSTEM, ACCELERATOR CABLE (HOT-IDLE COMPENSATION SYSTEM IDLE COMPENSATOR.PCV SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM. Fi NR CLEANER POV VALVE: CYLINDER HEAD COVER INTAKE MANIFOLD TO INTAKE MANIFOLD FROM CRANKCASE <2 CLEAN AIR = sLowsy cas << ocruRE: This system reburns the combustion blowby gases. The system consists of tie PCV v while the engine is run | Ta lve, which operatesFUEL SYSTEM FUEL PUMP (MECHANICAL TYPE) Fuel Pressure 1. Dis tthe hiFUEL SYSTEM F1 CARBURETOR Removal 711 Ne (20-110 mtg, 62-25 ny |FUEL SYSTEMFUEL SYSTEM Disassembly in the ‘onnecting rod, spring, andFUEL SYSTEM Air Bleeds and Jets 1 iatFUEL SYSTEM Fl Throttle Body Caution 10. Throtte fink (disconnect) 11. Vacuum diaphragm connecting rod (disconnect) 12. Throttle return spring (disconnect) 13. Throttle body (separate from main body) Note One bolt is inside the throttle body Tightening torque: 4—11 Nm (0.4—1.2 m-kg, 3—8 ft-tb) 14. Vacuum diaphragm assembly and gasket 16, Diaphragm cover screws and cover 16. Spring and diaphragm 17. Throttle lever hanger screws When removing the mixture adjust screw, tap out the spring pin as shown in the figure. Do not remove the throttle valve and shaft, the ventures, or the choke valve and shaft. Tee |—89FUEL SYSTEM Fi Unloader system 1CONTROL SYSTEM CONTROL SYSTEM PREPARATION ssTCONTROL SYSTEM | Control unit failsafe ~ Sumer function | siow tet cut sotenoid vave | ON _ | or cout OFF. | Coasting richer solencie on | ea valve or circuit OFF Purge solenoid valve oF on | cheat OFF ! ‘ON Duty solencid vacuum valve ie or orcut OFF. FT Duty solencid vent valve or = oreut OFF. oN ACV solenoid valve or circuit _ OFF. ‘ON Inlo.up sotenoid vaive (or = AG) or ckcutt ae Idleup solenoid valve or | ON - — NM) or ereut fa Location of matfunction ‘ON ‘Vacuum solenoid valve or' | | 4 CONTROL SYSTEM | st than yh Jeasure 1E terminal votage of engine control unit Possible Cause: oe eee ee ara res a |_| oben teat e wing hanes em © seminal of Se cr cancer 1 ware! exe ei | Possible Cause | Sree wing harness cornctd to veewsn } Less than 0.25V__| sensor he ‘Open oireut of wiring harness fromm 8 terminal of ‘vacuum sensor connecter 12 1G torminal of engine | ‘oni unit i 4 0.25—4.9v | SS + Perform after-repair procedure i weuoriore || f p.14 code display (Atmospheric pressure sensor) apes ves. || fF pinere poor connecton at connector? iepair oF ‘here poor connecton at TESA Repair or reiace ic || fp itor batery votage at C tominalofatmosshere | No_| Possible Cause he sure sensor connector”? | NO Open circa in icing harness trom igniton switch to fer to page F1~106) “almosphetic pressure sensor | be [ve + [there 458.80 at B tominal of amosprerc no_| Possible Cause: |bresoure saneor connector? Short cout in wing harness from B terminal ofa Fert page F106) tmospvere pressure tensor to engine conto! unt Engine corral unt taulty YES More than \aeaaure 1H torninei votiage of emission control unt | 4-2¥ | Possible Cause: 1B fReter to page F108) Open crout of ground harness ee Gpen oreult of wring harness from D terminal of ftmosphere pressure Sensor connector 10 1H terminal Pa {of engine contol unt Posse Cause i than 1.8V__| Stor oro n wing harness fm B tial of i Strosprere preesue soar connector to femal | a enaine cof vn i | 144.99 Perform afererair procedure )| F1-102CONTROL SYSTEM Fi No.1 code display (Oxygen sensor) 's oxygen sensor output vaiage OK? Rater to page F155) No. YES Ig senitvty of oxygen sensor OK? eter to page F1~55) Replace oxygen sensor Replace oxygen sensor No.16 code display (EGR position sensor) Note Yes, Peco afte-tepalt procedure Inspect the vacuum hose to the EGR control valve for air leakage, blockage and damage if the MIL illuminates only during cruising. | there poor connection at connector? irs Repair or replace NO Ig resistance In EGR position censor OK? Reter 0 page Fi-62) No, Replace EGR postion sencor YES Is there 4.5—8.8V at C ter connector? (Refer to page F inal of EGR postion sensor No, Possible Cause: Open or short circu in wing harness from C terminal to engine control unit YES. More than Measure 1F terminal volage of the engine control urit eter to page Fi~108) av oav 02—4.0v Possible Cause, (Open circuit in wiring hares of ground ‘Open circult in witing harness from A terminal to 1F terminal of engine contro! unt Possible Cause: Short Crout inviting harness trom A terminal to 1F terminal of engine control unit Engine contro unit fauty Perfotm after repair procoaure moron F1-103par rh i F1 CONTROL SYSTEM No.17 code display (Feedback system) Does monitor lamp of Selt-Diagnosis Checker NO, huminate at cle? YES Possible Cause Air leak in vacuum hoses oF emission components Contaminated oxygen sensor Clogged fue! jets) ‘Ae spark plage clean? lean oF ropiace Yes Ee {2 cxygon soneny ouput voltage OK? |-NO_S Possite Cause: Oxygen sendor fauly {Reser to page F1-55 ccs yes Ig 1A terminal voltage of engine control unit OK? NO. | Possible Cause: Open or shor circuit in wiring harness | {Poter to page F1-108) from axygen sensor connecior to engine control unt No.18, 22, 23, 26, 28, 29, 30, 34, 35, and 45 code Is there poor connection st connector in wiring circuit of indicated solenoid vaive? YES No LYES | Repair or replace Perm altertepai procesure displays (Solenoid valves) Is signal or vatage of connector for indicated eolencid | NO Possible Cause: valve OK? Open or shot crcult in wiring hamess of indicated solencis valve F1—104 L____Y8S Tarim atercepal procedure Engine contro! unt toutyCONTROL SYSTEM Fi BST WATER TEMPERATURE SWITCH Inspection 1. Remove the switch from the radiator. 2. Place the switch in water with a thermometer, and heat the water gradually. 3. Check for continuity between the terminals as specified. Specification: less than 15—-19°C (59—66.2°F) 4.1f continuity is not evident, replace the water temperature switch, IDLE SWITCH Inspection 1. Warm up the engine and run it at idle. 2. Connect a tachometer to the engine, 8. Connect a voltmeter to the idle switch terminal (LG/R) as shown, 4. Increase the engine speed to more than 2,000 rpm; de- celerate gradually and verity that the voltmeter indicates as follows. Engine speed Votags ALieie Datiery voltage: ‘More than #,000—1,200 Less than 1.5 TEOSE TR 5. If not as specified, tum the adjust screw to adjust, CLUTCH SWITCH Inspection 1. Disconnect the switch connector. 2. Check continuity between the terminals. Contry I ‘Conciion Yes Pedal released Ne Pedal depressed 3. If not correct, turn the clutch switch to adjust NEUTRAL SWITCH Inspection 1. Disconnect the switch connector. 2. Check continuity between the terminals. c ‘Continuity Condition No. Tn neutral postion Yes In ether postions 3.If not correct, replace the neutral switch. F1-105CONTROL SYSTEM INHIBITOR SWITCH Inspection 1. Disconnect the switch connector. 2. Check continuity between A and B terminals. Conti Condition Yes TaN oP range No, In other ranges 8. If not correct, replace the inhibitor switch, ATMOSPHERIC PRESSURE SENSOR Inspection of Terminal Voltage 1, Remove the right side kick panel. 1 2. Attach a vacuum pump to the sensor port 3. Turn the ignition switch ON. 4. Check votage between each terminal and ground while ap- plying and releasing vacuum to the sensor. Vacuum: 0—760 mmHg (0—29.9 inHig) Terminal Voltage BLG Less than 1.5V ‘GY 144.9 a. Bw t 45550 5. If the voltage at A or C terminal is not correct,check the wiring hamess. 6. If the voltage at A and C terminals is correct but is not correct at B terminal, replace the atmospheric pressure sensor. WATER THERMOSENSOR Inspection of Terminal Voltage 4. Warm up the engine and run it at idle. 2. Remove the rubber boot from connector es shown: 3. Turn the ignition switch ON. 4. Verity that voltage between terminal (IR) and the ground is as specified. ‘Specification: approximately 0.5V 6. Ifthe voltage is not correct, check the resistance of the sen- sor, and check the wiring harness for an open or short circuit Inspection of Resistance 1. Remove the water thermosensor.CONTROL SYSTEM ENGINE CONTROL UNIT [Engine Signal Monitor ( and Adapter (49 U018CONTROL SYSTEM Ve: Battery voltage [ Condition Terminal Connected veitage 33-3 [wae inna, | Oxyoen sensor ire an 0 67 [Dunn asta Toes that 0480 —| Dung dooseraion 7B tne _| Seiagran oeok omnes ve | Check connect Net ganda 6 twa armor Fppion TST — | Wars. enone Theresa OB) Wie ferosenson FG pos Drown | Unsere Vaoum serman AY | se han 189 Take a omosoncr pion 1B RBF1 CONTROL SYSTEM Vo: Battery voltage Terminal Connected to Votage Condition v8 Raat OFF : Sel. Dagnoes Checker Taser TS] Bier OW 2E (Ou Soh Dagnoss a cline Code sonal_| When sof ianoss Mortar vaca ioeay Gucusing | atid | Airtuet Actual volt Fromm — | atid vehe aoe thrcvetngIDLE ADJUSTMENT IDLE ADJUSTMENT Caution a) Before adjusting the idle speed and idle mixture, verify that such things as ignition timing, spark plugs, and carburetor float level are all in normal operating condition. b) Tur off all lights and other unnecessary electrical loads. ¢) This adjustment must be done while the cooling fan motor is not operating. IDLE SPEED 1. Connect F to the @ and veriIDLE ADJUSTMENT 1. Warm up the engine and run it at idle Idle speed: 800—850 (800 *%) rpm in neutral or P range 4. Adjust the idle mi mixture adjIDLE-UP SYSTEM IDLE-UP FOR AUTOMATIC TRANSMISSION (A/T) WITH AIR CONDITIONER (A/C) (QUAL SERVO DIAPHRAGM)IDLE-UP SYSTEM, MALFUNCTION INDICATOR LIGHT (MIL) F1 Inspection of Signal (for A/C) 1. Run the engine at idle 2, Connect a voltmeter to terminal (B/R) of the idle-up sole- Noid valve for AIC as shown. 3, Check vottage in the following conditions. Valage "Ar conaitione? Less than 157 ON Battory voltage OFF = Fa MALFUNCTION INDICATOR LIGHT (MIL) BATTERY 1G PULSE clAcUTT. ENGINE CONTROL UNIT WATER THERMOSENSOR OA CIRCUIT. fas MIL (MALFUNCTION INDICATOR iGHT) UL} —Hoerecnon | VACUUM SENSOR OR CIRCUIT oF | : MALFUNCTION [ATMOSPHERIC PRESSURE SENSOR. on CIRCUIT 7 ‘OXYGEN SENSOR OR CIRCUIT => output vevices J ‘CODE NUMBER on. = —— SELF-DIAGNOSIS CHECK CONNECTOR [seen 0 waz aur ny FESERAL a cannon SPECICATION J Saar 2 The MIL (Malfunction Indicator Light) is equipped on California and Federal specification vehicles, and is installed in the instrument panel IV an input device malfunctions, the MIL stays ON (without Self-diagnosis check connector grounded), or it flashes to indicate a warning code number for input and output device malfunctions, (with Self-diagnosis check connector grounded). On Federal specification vehicles, the MIL also comes ON and stays on 60,000 miles and 80, 000 miles to indicate that Il ] i] ustam ie rantirar Abthie time, the Ril |FUEL AND EMISSION CONTROL SYSTEMS VACUUM HOSE ROUTING DIAGRAM -esssssesue WIRING DIAGRAM . ‘SPECIFICATIONS COMPONENT DESCRIPTIONS TROUBLESHOOTING GUIDE... RELATIONSHIP CHART ... ENGINE CONTROL OPERATION HOW TO USE THIS St ENGINE TUNE-UP BASIC INSPECTION ADJUSTMENT... TROUBLESHOOTING WITH SST. PREPARATION .. INSPECTION PROCEDURE, AFTER-REPAIR PROCEDURE. PRINCIPLE OF CODE CYCLE CODE NUMBERS. ‘SWITCH MONITOR FUNCTION. PREPARATION .. INSPECTION PRC INTAKE AIR SYSTEM. ‘STRUCTURAL VIEW. THROTTLE BODY oe ‘s (EG) PRESSURE REGULATOR CONTROL (PRC) SYSTEM... DESCRIPTION . SOLENOID VALVE (PRC) EXHAUST SYSTEM ‘COMPONENTS, OUTLINE OF EMISSION ‘CONTROL SYSTEM STRUCTURAL VIEW. POSITIVE CRANKCA: VENTILATION (PCV) SYSTEM .. DESCRIPTION, PCV VALVE. 7 EVAPORATIVE EMISSION ‘CONTROL SYSTEM.. DESCRIPTION. SOLENOID VALVE (PURGE CONTROL)... SEPARATOR .. TWOWAY CHECK VALVE. CHECK-AND-CUT VALVE. CHARCOAL CANISTER, FUEL VAPOR VALVE... CATALYTIC CONVERTEI DESCRIPTION CATALYTIC CONVERTER AIC CUT-OFF SYSTEM.. DESCRIPTION INSPECTION... a BURN-OFF CONTROL SYSTEM. F2 F2~159 F2-159 F2—160 2-161 F2-161_F2 OUTLINE 1) QUTLINE | | 3YSTEM DIAGRAMOUTLINE VACUUM HOSE ROUTING DIAGRAM F2 BLACK Jo vacuu "ACTUATOR) BLACK (TO ONE-WAY (CHECK VALVE) | 0 soLeNoID VALVE | [PURGE conTROL)F2 w y : Zz i z wal z= 8 =x 3 au aniva oud aeea, la2~¢| WaLs]OUTLINEOUTLINE ‘SPECIFICATIONS Specification Throttle body Paper element Dasha BAC valve (solenoid valve [Idle speed contromDF2 OUTLINE ‘Component Function Remarks Fuel fiter Fiters particles from fuel Fuel pump Provides fuel o injectors ~ Operates whi engine running 1 Insiled In fuel tani Fuel vapor valve Provonts fuel from flowing into Gharooal canister idle switch Detects wien throtle valve Tuy closed; sands | Inealed on twrotte body ‘Signal o engine contro unit Tgniter Receves spark Signal from signal ECU and {generates high voilage to ignition col ignition switch ‘Sends engine cranking signal to engine (START position) Control unt Injector Tojects fuel Into inake pon * Contoled by signals from engine control unt | « Hignonmic injsctor {+ Two port injector nozzle (6) intake air Detecis intake air temperature; sends signal | Instaled on eynaric chamber thermosensor to engine contol unit Main relay ‘Supplos oleic current to injectors and or sine control unt. MIL (Malfunction (For Federal and Canada) Every 60.000 an 80,000 miles (Federa) oF Indicator lamp) Lamp iluminates to indicate the maintenance | 90,000 and 130,000 ken (Canacss) ‘schedule fer the omission contol system (For California) Test connector not grounded Lamp iluminates when input device mab fonctions (For Calfornia) ‘Test connector grounded Lamp flashers to indecate maltunction code | No. at input and output devices Neutral switch ‘Detects in-gear condition: sande signal to en- | Swish ON when neutral gine contro! unit Detects oxygen concentration, sends signal o engine control unt Zirconia cstamie and platrum ooaing Conirols amount of owby gas iniroduced into engine ——=TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE RELATIONSHIP CHART ‘TEST CONNECTOR IGNITION SwiTcH (ON POSITION) IGNITION SWITCH | (START POSITION) HEADLIGHT AND. BLOWER SWITCH P/S PRESSURE SWITCH| F2 TROUBLESHOOTING GUIDE NGINE CONTROL OPERATION CHART nput Devices and Engine Conditions ~ INPUT DEVICES | arpaon, ‘SENSORS, ering [DISTRIBUTOR ra (axseo on J water TAKE A hoseren oxvaen |ainrtow Twrome entercer Ter ‘es pressure s2-o0F | (SIGNAL) | pestonnt) | wosenson | SENSOR | SENSOR | yosenson | S=NEOR | senson ste) recy “ | sect [ra ern sate TEAR ENSNE | ze0 mele noeect” [ro sted | no oteet 2 Oe Suan onecd |enecu Jenecu |onecu con — coms a zr | | le Eo Pintos redim | | ee a : : a hse j@S¥ and | cosa: Bee O2-0M * | [Soren | | 9 | 1 Td | ae. Bal | | | coup ain | torases 7 COLD CooLaNT WARM ORIVEAWAY "ART THROTTLE — | Teoo WARM AIR rinutos WARM COOLANT | HOT RuseTROUBLESHOOTING GUIDE F2 eae Srones ay TGnifion SWIG stor. Hea. ou won | we sLowen st torr Pressure | ice pee | sure |yren [Srae, Swren Son |suarcn |SWTOH | STAFT | Om oy | COMER Sort |store! [sgn Sinat | grat [signa srr |S igat—_| nd rasro |natco jrasno hacrofruemm [has [hero [899% Thang | aero Gfetin |eecton |oecton |eferen | hocion fetatan | let on fez on |r en eeu fess fer EERO ET esto fimo dec [ES T T — in noura Low tow vt Soraio eae eles a ' | on me ce |_| wheel Headight | Blower Cone AIC ewich | tured: ‘partoh | ‘switch ON: ee ON towvor: |ON tow iow vot | notices rcs [age srs |ataae’ | Soe sgn gon sgnalto [to ECU | signalto |to ECU we Drwngin {ECU [foeiow | ECU toe- | (below sends sg: | Sapa yaa [feat (285" [wih [9H — |aesana [Spee |S Ihghwot frotags | eee icy Teo | totry sears ng | owe | enon | SECO |acemn famed” [meen Sem JOSS" Jootny |g) (atery | OFF: ‘straight OFF: OFF: high oF) votage) [no-signal |eheac: [righ vot | votago | ed |Rghvot- | age sora | rato thsew [egesema osc” | eu TEy" |ieec0™ | Bacery | oaey teatery —|Yotage) | vot seteot)TROUBLESHOOTING GUIDE F2 ne ya ont ni on comm | SSS SER Ne [Goma TEX re conrcte aon Sn ganooa Sinanoteertscouary” % [Saag | ck cca TI STEP: This shows the order of troubleshooting. Proceed with troubleshooting by steps. QUICK INSPECTION: This describes an easy inspection necessary to determine the malfunction of parts quickly. ACTION: This recommends the appropriate action to take as a result (Yes or No) of the QUICK INSPECTION. How to perform the action is shown on the reference page. POSSIBLE CAUSE AND DETAILED INSPECTION: This shows the possible point of malfunction. The detailed inspection is shown on the reference page. snuorzar2 F2-25TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX No. TROUBLESHOOTING ITEMSTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE ‘Cranks normally but hard to start (Always) (Cont'd) POSSIBLE CAUSE AND QuIck INSPECTION ACTION Posen Cavan ne Fuel preseu | sie reSTEP7 TROUBLESHOOTING GUIDE | WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE FUEL PRESSURE FROM FUEL SYSTEM TO REDUCE POSSIBILITY ‘OF INJURY OR FIRE (REFER TO PAGE F2—144) (YELLOW: 2PIN) F2 F2-33TROUBLESHOOTING GUIDE al ‘Cranks normally but hard to start (Only when engine is cold) eae POSSIBLE CAUSE AND ‘ACTION DETAILED INSPECTION 5 —TBeation G|TROUBLESHOOTING GUIDE INS POINTTROUBLESHOOTING GUIDE ‘Cranks normally but hard to start (Only when engine is warm) POSSIBLE CAUSE AND QUICK INSPECTION ACTION Oeeuen tiaseenon ‘Ghack for mafneton code wih | Yes | Chack for cause by refering fo creck sequence, Fae Sst io | Goto Nex S {IGN ON, Test connector Green: | N° | G2 '© Nex! Sep ‘upin) grounded) Y Disconnect water thermosensor | Yes | Gheck water thermosensor | Yes | Cheok water thor F178 ‘connector ‘connector condition as osensar Chace i condition improves folows inal Psreseiact ower are 1 Snake connector and ‘heck if condition changes 2. Check concdon of ter ‘minal (burned or damaged) '8, Connoct a good term fal to harness side ‘connector and check sensor connecter serve fuel pressure for § minutes Fuel pressure: More than for looseness No | Goto Nex Step _ zt} | Operate fuel pune Yes | Go to Newt Step [IGN ON, Test connector (Yoon: [Kg | Cheok fuel pump [F210] No | Replace fuel pump | F2-162 2epin) connected) pressure drop | ‘Tum ignition suiich OFF end ob- t ‘Check pressure |F2-154| regulator pros: Yes Check nestor el | F2-187 jeakace, Soar |e Recs wae requiatorTROUBLESHOOTING GUIDE ‘Cranks normally but hard to start (Only after heat soak) ‘POSSIBLE CAUSE AND QUICK INSPECTION ACTION [Reppeprer onal by relering en "| Fe-122TROUBLESHOOTING GUIDE F2 ‘STEP 1 \ / TEST coNwecTOR (ELLOW: 2P1N) STEP 2TROUBLESHOOTING GUIDE ‘Cranks normally but won't start (Intermittent) ‘QUICK INSPECTION ‘Shake connector of ignition cal, POSSIBLE CAUSE AND DETAILED INSPECTION ‘ACTION [ F230 Aways)” witing THE Yes | There may be @ poor contact of the Connector. Repair or replace the No | Go to Troubleshouing “Cranks nowally but hard to Sart main relay and ECU while cranking Check i the engine startsTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE F2 STEP 5 STEP 1 STEP2 STEP 6 = WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE FUEL PRESSURE FROM FUEL | ‘SYSTEM TO REDUCE POSSIBILITY OF INJURY OR FIRE | | (REFER TO PAGE F2-144) aoTROUBLESHOOTING GUIDE F2 STEP 8 F2—45,TROUBLESHOOTING GUIDE Rough idle (Only when engine is cold) POSSIBLE CAUSE AND QUICK INSPECTION ACTION DETAILED INSPECTION malfunction code wath Ge to New SapTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Rough idle (Only when engine is warm) TEP {QUICK INSPECTION ‘ACTION POSSIBLE CAUSE AyD + Fan sane a0 pm Tor crs Yo | Ch cas iy efeing Sa Segvence rata Ro av asconds ae Check for matfunction code with No | Goto Next Sup ser aK ON, Test connector Green tr gone | heck le send ar wars op [You] Gow Now Sop lie speeds a0_r70.spm qumy [18 | AS41190 Soed CF DOE) aa sree TS tom ‘arr, P range) [Test conocer Gren: i) | sence S| Shack tesigo SST mover [Ves | Gove Newt Sep ' Pe eee ane No Replace oxygen F2—183 taeor || treet connector (een 19 not | nade | 97 econ cave cometer at [es | Goto New Sep ream oP oa al Na ce ome [8 Shak BS vee Fae S| Diconac wat! eroemsar [Yes] Oreo alo or Yeo| Gheckwats hor | FATS coder a rrosaor CRE Contin improves rock conten a ime tener 28 folows 11 Shake connector and ‘cheok if condition changes Check concition of tor ‘minal (oured or damaged) 8. Connect a good termTROUBLESHOOTING GUIDE STEP 1 STEP 5 5S TEST CONNECTOR Z~(GREEN NAN WTR Cas Seatiecfon SHE INE 10 Negalive wATTERY TERNAL 5 STEP 6 a Sy | STEP2 Arar STEP 3 GOWEDTOR GREEN BPI SarTROUBLESHOOTING GUIDE F2 ‘STEP7 F2-51TROUBLESHOOTING GUIDE Rough idle (Only after heat soak)TROUBLESHOOTING GUIDE TOR] STEP 4 ¢——TROUBLESHOOTING GUIDE ough idle (Only after heat soak) (Cont'd) P POSSIBLE CAUSE AND eeren DETAILED INSPECTIONSTEP7 TROUBLESHOOTING GUIDE F2 F2—55TROUBLESHOOTING GUIDE POSSIBLE CAUSE AND DETAILED INSPECTION Rough idle just after starting ‘ACTION warn up Ignition timing: BIDE 4-6* (08) * (F2) or (Green: 1 ‘Speed ator 730-770 rpm (MT) 750—790 rpm tor (Green: 1-pn)TROUBLESHOOTING GUIDE Y zi Pa 7 STEP 1 EERIE) Swe ee a Hi St / ) X Nat Lo dud. / REN CAN) /3g1 gonngcron [18 NEGATIVE BATTERY TERMINAL (GREEN SEN) a, Ss ~) =) ane STEP 2 STEP 5 STEP 3TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE improves High Idle speed after warm up POSSIBLE CAUSE AND ____auICK INSPECTION ACTION CoTRES INSPECTION Ghesk for malluncion eode with [Yas | Check for cause by refering to check sequence Faa123 Sst io | Go to Ne» TION ON, Test connector (Green: _| No | Got Next Step 4-9) grounded) ‘Cheek igalion timing at de ater | Yes | Go to Next Ste warm up Te} Aaiust ignition ting Fat7 Ignition timing: BTDC 4—5" (G6) | 8-7 (F2) {Test connector (Green: 1-pin) grounded} ‘Check I trate valve is fuly dosed | Yes | Go to Next Step ha el aseceerl etna No | Check I thvatie linkage & correctly installed and operates | F2-137 freely ‘Ghook icle epeod ater warm up| Yes Check 50 valve F142 jo | Ty w ads le P2118] Yes] Idle speed misadjustment tate speed: 720-770 rpm curry |N® f Te sce P2-110] ves lle spod misaumert Idle speed: 750—780 rpm pe No | Go to Nex Step (AMT, P range) {Test connector (Green: 1-pin) | ‘grounded Disconnect ISC valve connector at | Yes | Go to Nex Step idle when ongine is cold ana Check i idle speed decreases i kee fea during warm Up a zi ‘Disconnect wator thermosensar ‘Ghesk water thermoseneor Check water thermo | F2-179 ‘connector and check i condition ‘connector condition 2s sensor follows: 41_Shake connector and 1 sensnuconngetor Poor contact of water thermoTROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE STEP 5 WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE | FUEL PRESSURE FROM FUEL ‘SYSTEM TO REDUCE POSSIBILITY OF INJURY OR FIRE (REFER TO PAGE F2~144) SEHeck CONNES (GREEN: CN} BATTERY TERMINALTROUBLESHOOTING GUIDE Engine stall at idle (Always) POSSIBLE CAUSE AND ‘QUICK INSPECTION ACTION DETAILED INSPECTION for malian sN ON, Test conn “-pin) grounded} Tantton initionTROUBLESHOOTING GUIDE F2 ‘STEP 1 STEP2 STEPS WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE FUEL PRESSURE FROM FUEL ‘SYSTEM TO REDUCE POSSIBILITY OF INJURY OR FIRE (REFER TO PAGE F2—144)STEP 1 ig TROUBLESHOOTING GUIDE F2 F2-67TROUBLESHOOTING GUIDE Engine stall at idle (Only when engine is warm) {QUICK INSPECTION I ACTION POSSIBLE CAUSE ANDTROUBLESHOOTING GUIDE STEP 1 (gpg STEP2 Hi EEN: ‘TO NEGATIVE BATTERY TERMINAL BOR \ F2 F2-69TROUBLESHOOTING GUIDE Engine sta at idle (When A/C, P/S, E/L is ON) (aCe EAuse AND \srer ‘Quick msPECTION ‘acon OSSIALE CAUSE AND 7 Tar mainton Sods wh [You | Chock Tor cae by refering wo Sak sequen F212? ‘SST ‘No | Go to Next Step TIGN ON, Test connector (Green: *-pin) grounded} Check swiiches wih SST + Heaatignt swatch * Biower switch TIGN ON, Test connector (Green: ‘pin grounded) Yes Goto Next Step ‘No ‘Check for cause by referring to check sequence F134TROUBLESHOOTING GUIDE F2TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Engine stall on deceleration step ‘QUICK INSPECTION ACTION eoeeae capes [| Check for maltunaion code with | Yes | Check for cause by refering to check sequence Fa-tae sst aE [1G ON, Test connector (Green: | NO | Go to Newt Step {-in) grounded} F2[ Check idle ewiton and stoplight | Yes | Go to Next Stop ‘sutch with SST io jor ealte by refering to check sequence m3 [IGN ON, Test connector (Green: | No | Chek by eng ent ree ‘-pin} grounded} | Check for fashing of monitor lamp | Yes | Go to Nex Step, eee: No Replace oxygen Fa-183 Monitor lamp: Flashes more ae than 8 times/10 seconds at | | 2,000—2,000 rpm [The connector (Groen: ‘-pin) not Lf: ‘rounded | | [79 T eneck for tat et operation during | Yes [ Go to New Step q cee No | Check water [F2-178] Yes | Replace ECU FRA Fuel cut: after warm up ee No | Replace waloe 2-178 ‘Above 1,600 rpm (G6) thernoserisor 4 ‘Above 1,900 rpm (F2)TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE F2 STEPS 6 F2-77TROUBLESHOOTING GUIDE Engine stall at idle (Intermittent) DETAILED INSPECTION POSSIBLE CAUSE AND ACTION wing F268 ROR Go to toubleshooting "Engine stall a ale Always)” ‘QUICK INSPECTION Yes | There may be @ poor contact at ihe connector. Repair ar replace the Ne. man relay and ECU while cranking ‘Shake connector of inition col, Check ithe engine starsTROUBLESHOOTING GUIDE Hesitates/Stumbles on acceleration AN POSSIBLE CAUSE AND eee teablaaa |__ DETAILED INSPECTION y referring to check seque I 22 ck for cause by rearing to oh wwol fiter «| P2148 Fue! line pressure: Keeps Replace pressure | ‘PB-168 265-314 kPa regulate 2.73.2 kglem’, 98—46 pel) wiht open by listening forTROUBLESHOOTING GUIDE F2 STEP 1 re i cote R BEEN SAF L xO NeGATive BATTERY TERMINALTROUBLESHOOTING GUIDE Jerking on acceleration SOSSIBLE CAUSE AND QUICK INSPECTION DETAILED INSPECTION un engine al 2,000 rpm for 20, seconds and sop i Check To: malfunction code with Sst N ON, Test connector (Groen ‘Chock ile switch wath SST {IGN ON, Test connector (Groen: 1-9) grounded)TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Knocking ACTION watm up Ignition timing: art ane g s—7° (AMT, P range) Green: tpn) not ‘POSSIBLE CAUSE ANDTROUBLESHOOTING GUIDE Poor acceleration QUICK INSPECTION "ACTION POSSIBLE CAUSE AND = matoncton in [ve Ka by refering ks 7TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Poor acceleration (Cont'd) | POSSIBLE CAUSE AND ACTION DETAILED INSPECTIONTROUBLESHOOTING GUIDE Lack of power oes ape CASE AD tonition timing: BTDC 4—6* (G6)TROUBLESHOOTING GUIDE Bucking at high speed | POSSIBLE CAUSE AND ‘QUICK INSPECTION ACTION POssSLE CAlae aeSTEP 1 STEP 2 STEP 3 TROUBLESHOOTING GUIDE F2 STEP 5 WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE FUEL PRESSURE FROM FUEL ‘SYSTEM TO REDUCE POSSIBILITY OF INJURY OR FIRE (REFER TO PAGE F2-144) F2-97TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE F2 STEP 1 Bick Sonne / ‘(Ghee SON] TO NEGATIVE BATTERY TERIMNAL STEP 2 J0_.,jesL connector ] STEP 5 (GREEN HPIN 3 : VAs 7 Ve A ACY WES: — JI Ses cance ro agente aatreny naan STEP 6 /rest éévbcron / (GREEN: 1-PIN) STEPS STEP 4 -—>—_—_____——_ WARNING BEFORE CONNECTING FUEL PRESSURE GAUGE, RELEASE FUEL PRESSURE FROM FUEL SYSTEM TO REDUCE POSSIBILITY OF INJURY OR FIRE (REFER TO PAGE F2—144) F2-101TROUBLESHOOTING GUIDE High oll consumption/White exhaust smoke QUICK INSPECTION ACTION POSSIBLE CAUSE AND DETAILED INSPECTION Check for Gl leak from engine | Yes | Repair or replace No | Go to Newt Step ‘Disconnect POV valve fram engine | Yes | Go to Next Step (Chock Hf vacuum is fot at idle No | Check PCV valve |F2—163] Yes | POV hose clogging No | Replace POV vaive Check tat verdiation hose iv [Yes | Goto Next Step [ated porrenty, [[No [instal ventilation hose correctly . Possible mafanation of engine (Check for cause by refering tothe check sequence of Section B2 worSTEP 2 STEP 3 TROUBLESHOOTING GUIDE F2 F2-103TROUBLESHOOTING GUIDE ‘Atterburn on de POSSIBLE CAUSE AND DETAILED INSPECTION ‘ACTIONTROUBLESHOOTING GUIDE STEP 4TROUBLESHOOTING GUIDE F2 STEP1 F2-115ENGINE TUNE-UP S Idle Speed 1. Ground the test connector to the body with a jumper wire.TROUBLESHOOTING WITH SSTTROUBLESHOOTING WITH SST Hfamaltun ris sho SST, ch ing chart along with the wiring diagram. Code No.02 (Distributor Ne-signal) PC: Possible Cause-2 TROUBLESHOOTING WITH SST tode No.17 (Oxygen sensor—Inversion)| F2 TROUBLESHOOTING WITH SST ode No.34 (Solenoid valve—Idle speed control (1SC)) PC: Possible Cause Yes >—— TeSWITCH MONITOR FUNCTION = INSPECTION PROCEDURE ating toon peratire andF2 FUEL SYSTEM Fuel Line Pressure qs sibility of injury or fire. (Refer to page F2—144.) Ny) Sx He I \ WW Warning -_ i Before performing the following operation, release the | fuel pressure from the fuel system to reduce the pos- | | Tue 1. Disconnect the negative battery terminalFUEL SYSTEM F2 4. Connect the terminals of the test connector (Yellow: 2-pin) with a jumper wire. 5, Turn the ignition switch ON to operate the fuel pump. 6. Measure the fuel pump maximum pressure, Fuel pump maximum pressure: 441589 kPa (4.5—6.0 kg/cm’, 64—85 psi)FUEL SYSTEM llation InstalPRESSURE REGULATOR CONTROL (PRC) SYSTEM F2 PRESSURE REGULATOR CONTROL (PRC) SYSTEM DESCRIPTION WATER THERMOSENSOR, Bl peer eee ENGINE GONTROL, eee pon aera | SOLENOID vaLvE INTAKE AIR THERMOSENSOR (PRESSURE REGULATOR CONTROL) beessune 7 REGULATOR ae pe any i Hay [ES iguon rue, + Lat row beuveny PE) vACUUM coor HANES + a d — FUEL (70 FUEL TANK) To prevent percolation of the fuel during idle shortly alter the engine is restarted, vacuum to the pani [F2 outune oF em IN CONTROL SYSTEM OUTLINE OF EMISSION CONTROL SYSTEM STRUCTURAL VIEW dh HC, and 0,EVAPORATIVE EMISSION CONTROL SYSTEM SOLENOID VALVE (PURGE CONTROL) On-vehicle 4, Warm up WHITECATALYTIC CONVERTER SYSTEM F contains platinum 370 cc (144.6 cu in)AIC CUT-OFF SYSTEM F2 A/C CUT OFF SYSTEM 1d to improve idle smoothness just after starting the engine and to improve celeration performance.F2 CONTROL SYSTEM a hee rerminal voltage Ve: Battery voltage Hrermina| input |Output| Connection to Test condition ignition svatch {lamp umingtes) ae (Lamp Tin ip ONCONTROL SYSTEM F2 Terminal voltage Voi Battery voltage [Tremina] mput [output Test condition VonageF2 CONTROL SYSTEM Terminal voltage Vo: Battery voltage MonitorENGINE ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE BATTERY. DISTRIBUTOR ON-VEHICLE ALTERNATOR PREPARATIONTROUBLESHOOTING GUIDEBATTERYALTERNATOR G ALTERNATOR PREPARATION ssT 149 9200 020 Tension gauge, vribbed bet aS F2 CARBURETOR, F2 EGI Io REGULATOR IC REGULATOR aR e35ALTERNATORALTERNATOR G ‘TROUBLESHOOTING Preliminary Check 1. Turn the ignition switch ON, and check that the alternator warming lamp illuminates. 2. Start the engine, and check that the alternator warning lamp goes off. HARCE, 1. Alternator warning lamp will not illuminate 1er warning lamps illuminate with ignition NG. EE ee eo ‘Aternator warring lamp eiteuit oF IC regulator ma function caveaxoeTERNATOR release the brakeALTERNATOR G DISASSEMBLY AND ASSEMBLY 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. S078 Na (6.88.0 mag, 40-69 1)ALTERNATOR INSTALLATION Note When installing the alternator, tighten the bolts to the specified torque. Install in the Tightening torque F2 CARBURETOR Bolt (): 31—46 Nm (3.2—4.7 m-kg, 23-34 ft-lb) F2 EG! 37—52 Nem (3.85.3 m-kg, 27—38 ft-lb) ee 9—6.9 Nm (0.5—0.7 m-kg, 43—61 in-lb) a 19 26 a4IGNITION SYSTEM IGNITION SYSTEM PREPARATION SST 49 NO18 007 49 F018 002 Adapter harness lgniter Checker(iG DISTRIBUTOR | [FECARBURETOR| 77 | | INSTALLATION ; om Note - / After installing the distributor, adjust the ignition tim- I ; x ing. (Refer to page G_24.) ris inter andiG STARTING SYSTEM Reduction Type (1.2 kW)—G6 MT, (1.4 KW)—G6 A/T PULLAN COIL, TLE ae ON-VEHICLE INSPECTION © Charge the battery fully before starting the following inspection. aes 4, Turn the ignition switch to the start postion.STARTING SYSTEM G F2 (CARBURETOR, EG) MIT REMOVAL AND INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the wiring from the starter. 3, Raise the front of the vehicle and suppor it with safety stands. 4, Remove the starter bots. 5, Draw out the starter from lower side of the vehicle. Note Remove the lowest starter bolt last. Install in the reverse order of removal Tightening torque F2 (Carburetor, EGI)—M/T. A/T Nut (1): 8.8—13 Nm (90—130 cm-kg, 78—113 in-tb) Bolt (2): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) G6—M/T, AT Nut (1): 9.8—12 Nm (100—120 em-kg, 87—104 in-lb) Bolt (2): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) G-33G STARTING SYSTEM | DISASSEMBLY AND ASSEMBLY 1. Disassemble in the order shown in the figure. Inspect the component parts. 3, Assemble in the reverse order of disassembly. F2 (CARBURETOR, EG M/T (NON-REDUCTION TYPE 0.95 kW) 44-75 a7, 8 EY 7.819 (60-190, 6119 2k (Aas, 21-29) 38-74 @d-72, 4-82) tem em sb) TBLOGKaT 1. Magnetic switch 5, Lever Inspection. page G-38 6. Front cover 2, Rear housing 7. Drive pinion 3. Brush holder assembly 8. Armature > Inspection reser page G-39 INSPECHION. eee nsnennnneeres PAGS G-B7 4.Fieid coll Inspection page G-38 G-34STARTING SYSTEM F2 (CARBURETOR, EGI A/T (COAXIAL REDUCTION TYPE 1.4 kW) 41-75 «2477, en 2K 2448, 21-20) 379 9-72, a6) “ow : oJ) 7.818 a0-190, 69-119) en em.) TauGKaT 1. Magnetic switch 7, Planetary gear Inspection... page G-38 8. Magnet coil 2, Rear housing Inspection. page G-38 3. Front cover 9. Armature 4. Drive pinion Inspection. . page G-37 5. Internal gear 10. Brush holder assoriby 6. Gear shaft Inspection. wssssteteereeeees PAQE G—39 G-35,STARTING SYSTEM ‘Ge (MIT, AIT) (REDUCTION TYPE MT 1.2 KW, A/T 1.4 Ke) 7-13 (90190, 6-19) BAA LAB 2I—-3) 9g 7g @ en (omg, tb) TSE 1, Magnetic switch 7. Armature inspection... .. page G-38 Inspection. page G-37 2, Rear housing 8. Field coil 8, Drive pinion Inspection.. . page G-38 4, Front cover 9. Brush holder assembly 5, Reduction gear Inspection nrnrne v» page G-39 6. Center bracketSTARTING SYSTEM G oe re INSPECTION Armature 1. Ground of armature coil Check for continuity between the commutator and the core with a circuit tester. Replace the armature if there is con: tinuity. 2. Insulation of armature call Check for continuity between the commutator and the shaft with a circuit tester. Replace the armature if there is con- tinuity. 3, Vibration of the commutator (1) Place the armature on V blocks, and measure the vibra- tion by using dial gauge, (2) Ifthe vibration is at limit or more, repair with a lathe so that it becomes standard or replace the armature. Engine Fra arbarcior, EG] [es ‘Standard vibration mmm Ga) | 0.05 (0.000) 2.03 (000%) Limit mmm (in) [0.1 (0,004) 0.05 0.008) Note Before checking, be sure that there is no play in the bearings. 4, Outer diameter of the commutator Replace the armature if the outer diameter of the commu- tator is grind limit or less, 5. Roughness of the commutator surfaceSTARTING SYSTEM (s) TERMINAL,STARTER INTERLOCK SYSTEM (M/T) STARTER INTERLOCK SYSTEM (M/T) INTERLOOK switcH 7 E ¥ Y ‘STARTER WaTINDEX FLUID SPECIFICATION SaewiT (OR FMVSS116 DOTS STARTER INTERLOCK SWITCH, ‘SERVICE SECTION G ‘TRANSMISSION, SERVICE SECTION J2OUTLINE, TROUBLESHOOTING GUIDE H OUTLINE ‘SPECIFICATIONS SS tem (Cuch cone Fiyarauie Cutch cover Tyee + Diaphragm sprit Set load Nike 5 AOs (660. 1.232) “4.867 (40, 1,076) clr anor — Ta 750 34) 25 38) ie dara — nin eh Tes Tea hich dsc i eee 35.018 41010 Thickness Fea se 35019 7 Spend a ca Sea Ful etroke mm Ge) | 135 6.8) ca ra Oa) | TOI RETO | aT Tiara wr air Thy 1587 @a35)H CLUTCH FLUID (CLUTCH FLUID PREPARATION ssT | | i | | | id in the reserve tank must be maintained at the 3/4 level or higher during replacement. Caution a) Be careful not to spill clutch fluid on a painted sur- face. Hf this should happen, wash it off immediately. b)Do not mix different brands of clutch fluid. €) Do not reuse the clutch fluid which was drained out. Draw the fluid from the reserve tank with a suction pump. Remove the bleader cap from the clutch release c and altadCLUTCH PEDAL H CLUTCH PEDAL 12-47 He ee ADJUSTMENT Geeeemany | ADIUSTMENT Inspection Qu Measure the distance from the upper surface of the pedal pad (4-18 ma, 19) | to the carpet Pedal height 'B2600i: 191—201mm (7.52—7.91 in) 82200 : 181—191mm (7.13—7.52 in) (With carpet) I necessary, adjust the pedal height. Adjustment 1, Loosen locknut @®and turn clutch switeh @unti the height is correct 2. Tighten locknut @. ol Tightening torque 14-18 Nm (1.4—1.8 mr-kg, 10—13 ft-lb) 3. After the adjustment, inspect the pedal free play. Clutch Pedal Free Play Inspection Depress the clutch pedal by hand until clutch resistance is ftt. Pedal free play: 0.6—3.0mm (0.02—0.12 in) Total pedal free play: 5—13mm (0.20—-0.51 in) If necessary, adjust the pedal free play. DISENGAGEMENT HEIGHT Adjustment waonmom 1 Loosen locknut @and turn push rod until pedal ree play is correct, 2. Check that the disengagement height from the upper sur fave of the pedal height to the carpet is correct when the pedal is ful depressed. Minimum disengagement height B2600i: 71mm (2.80 in) B2200 : 66mm (2.60 in) (With carpet) 8, Tighten looknut © Tightening torque: 12-17 Nm (1.2—1.7 m-kg, 8.7—12 ft-lb) 4. After adjustment, inspect the pedal heightCLUTCH PEDAL MOVAL, INSPECTION, AND INSTALLATION phe ordCLUTCH PEDALCLUTCH MASTER CYLINDER 49 0259 708 Viren, fare ut — SDT ‘REMOVAL AND INSTALLATION jemove in the order shown in the figure, referring to Removal note install in the reverse order of removal, referring to Installation note. Caution Clutch fluid will damage painted surfaces. Be sure to use a container or rags to collect it. If fluid does get on a painted surface, wipe it off immediately with a rag.CLUTCH MASTER CYLINDER Disassembly note Sy aSnap ring Note Do not damage the push rod contact surface of the piston. le pr Jn, install the featCLUTCH RELEASE CYLINDER H Removal note Flexible hose Caution ) After disconnecting the flexible hose, plug the flex- ible hose to avoid fluid leakage. b) The flexible hose must not be twisted. Disconnect the flexible hose. Installation note Flexible hose Tighten the flexible hose. 2.7 mekg, 16—20 ft-lb) Air Bleeding ‘After installation, bleed the clutch system, fess oziee dOCLUTCH UNIT H Removal note Clutch cover and disc 1. Install the SST or equivalent. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. Then remove the clutch cov- er and disc. Flywheel 1. Hold the flywheel with the SST or equivalent, 2, Remuve the flywheel Installation note Flywheel 1. Remove any old sealant from the bolts and bolt holes. It (ld sealant can not removed from the bolt, replace it (82200) 2. Apply sealant to the bolt threads. (82200) 3, Install the flywheel and SST or equivalent. 4. Tighten the botts in the pattern shown, Tightening torque B2600i: 91—98 Nan (9.3—-10.0 m-kg, 67—72 ftb) Tightening torque 52200: 96—103 Nm (9.8—10.5 m-kg, 71—76 ft-lb) Clutch disc 1, Clean the clutch disc splines and main drive gear splines, then apply Mori White TA No.2 or equivalent organic Molybdenum grease. 2. Set the clutch disc into position with the SST.J1 MANUAL TRANSMISSION (B2200) DISASSEMBL| INSPECTION, ASSEMBLYOUTLINE OUTLINE SPECIFICATIONSTRANSMISSION J1 REMOVAL AND INSTALLATION 1, Disconnect the negative battery cable. 2. Raise the vehicle and support it with safely stands. 8. Drain the transmission oil into a suitable container. 4, Remove in the order shown in the figure. 5, Install in the reverse order of removal. 16-99 (16-22, 2-9)open | J1 TRANSMISSION | Main and Countershaft parts Disassemble in the order shown in the figure, referring to Disassembly Note,TRANSMISSION J1 17. Reverse gear 18, Neadie bearing 49. Inner race 20. Washer 21. Counter reverse gear 22. Reverse idle gear shaft 23. Washer 24, Reverse idle gear 25, Washer 26. Ball bearing Removal 27. Ball bearing (front) Removal scence: PAGE IMTS 28. Bearing housing assembly REMOVAL ersnner rr page J1~14 29. Mainshaft and gear assembly 30. Main drive gear 31. Synchronizer ring 32. Countershaft gear 33. Spacer page S113 Disassembly note Bearing 1. Remove the snap ring, washer, retaining ring, and C wash- ers; then remove the mainshatt rear beating with the SST. 2, Remove the focknut (Refer to page J1—14) and the coun- tershatt rear bearing with the SST.TRANSMISSIONTRANSMISSION Ji INSPECTION Inspect all parts, and repair or replace as necessary. ee Each gear and main drive gear 1. Inspect synchronizer cones for wear. 2, Inspect individual gear teeth for damage, wear, cracks. 3, Inspect synchronizer ring matching teeth for damage or wear. 4, Inspect main drive gear splines for damage or wear. Mainshaft 1. Measure the mainshaft runout. ‘Maximum: 0,03mm (0.0012 in) 2. Inspect splines for damage or wear. ure Countershaft 1. Inspect gear teeth for damage, weer, cracks. 2. inspect splines for damage or wear. UNI Clutch hub assembly 1. Inspect for clutch hub sleeve and hub operation. 2. Inspect individual gear teeth for damage, wear, cracks, 3. Inspect synchronizer key for damage, wear, cracks, J1-17TRANSMISSION ASSEMBLY Precaution 1. All Otings and gasket mu: 2. Assemble the parts within 10 minutes after applying after y before filing the transm ith transTRANSMISSION 3. Insert the snap ring by using snap ring pliers. 4, After mounting the 2nd gear and synchronizer ring on the mainshaft, use a suitable piece of pipe to press on the clutch hub assembly (ist/2nd). Caution ‘Same as the caution for Step 2. 5, Aiternstaling the synchronizer ring, inner race, needle bear- ing, 1st gear, and washer to the mainshatt, instal the nee dle bearing, synchronizer ring, and main drive gearTRANSMISSION J1 8, Install the bearing cover to the bearing housing, Tightening torque Bearing cover: 16—23 Nan (1.6—2.3 m-kg, 12—17 ft-lb) Shaft bracket (black bolt: 36—54 Nem (3.7—5.5 m-kg, 27—40 ft-lb) 9.(1) Place the spacer on the roller bearing. Note Replace spacer and bearing as a set. (2) Place the mainshatt and main drive gear assembly and the counter gear. (8) Use a suitable round bar to press in the countershatt. 10. (1) Secure the reverse idle gear and 2 washers to the re- verse idle gear shaft Tightening torque: 7.8—11 Nem (80—110 cm-kg, 69—95 in-Ib) (2) Install the counter reverse gear, washer, inner race, nee dle bearing, reverse gear, and clutch hub assembly Gthireverse) . 11. Secure the bearing housing in a vise installed the pads. 12. Slide the clutch hub sleeves onto 1st and reverse gears to lock the mainshatt 13, (1) Install the clutch hub assembly (Sth/reverse), and tight en a opw lorTRANSMISSIONTRANSMISSION J1 uae FOR SHIFT ROD OTHERS (6TH AND REVERSE) 22. Drive on the ball bearing to the countershatt with the SST. 23. Shift the olutch hub sleeves to first gear and reverse gear to put the gears in a double-engaged condition 24.(1) Install the SST on the mainshat, and piace them se- curely in a vise. (2) Tighten the countershaft rear bearing new locknul. Tightening torque: 118—157 Nm (12—16 m-kg, 87—116 ft-1b) (3) Use a chisel to crimp the locknut, 26. Insert the spring and ball (Sthireverse) into the bearing housing, Note There are 2 types of springs; be sure to install them correctly. 26. Press the spring and ball (Sthvreverse) with the SST and a fiattipped screwdriver to install the shift rod, J1-233 3 3i i i i TRANSMISSION 37. Mount the ball and speedometer drive gea them with the new snap ring ing with 39, While turning the rod end to the left, mount tension housing Coat the surfa he transmissi and bi| J2 INDEX ‘TRANSMISSION OL SPECIFICATION [APL SERVICE: GL-4, OR GLS OUTSIDE TEMP. 10°C (60*F) OR ABOVE: SAE GOW-20 ALL SEASON TYPE: SAE 751-20 CAPADITY LITERS [US at, Imp qi: 22 (24, 28) NEUTRAL SWITCH SERVICE, SECTION F2 - “PROPELLER SHAFT SERVICE, SECTION L- PeOUTLINE J2 OUTLINE SPECIFICATIONS = L 83500 RMD REND Item oo a Forward: Synchromesh Tranemission a ‘Synctromesh system Reverse: Synohromesh Traneler caso - Constantnesh a OA Shit ype ee A mH VOsr Transter case S ee i 3.730 2d 2.158 310 1.396 Je “Transmission ~ ah 1.000 Goar ratio - 8th ate | Reverse 3521 Low = 2.210 Transie case High = +000 Grade API Senice GL4 oF GLS ‘Above 10°C (50°F) SAE 80W90 Visoosty on Al season 48 ‘SAE 75W-90 aOUTLINE J2 POWERFLOWi; J2 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE TRANSMISSION Difficult to shiftPATRANSMISSION ‘Transfer Case, Clutch Housing, and Extension Housing (4x4) he order shown in the figure, re to DisassiTRANSMISSION 2 eee Clutch Housing and Extension Housing (4x2)TRANSMISSION 3th/Reverse Gear and Housing Parts Disassemble in the order shown in the figure, referring to Disassembly Note. | eruace Grepiace ie Maal 1 SS 7 PACKING, REPLACETRANSMISSION J2 1. SthiReverse shift rod end Installation... page J2-35, 2, Srdiath shift rod end Installaton...... page J2-35 3, 18nd shift rod end Installation... page J2~36 4, Beating housing Removal... page J2-13 Installation... page J2-36 5. Snap ring 6. Thrust washer 7. C-washer 8. Retaining ring 8. Mainshaft rear bearing Removal ..... page J2-13 Ingpeetion’”. page J2-22 Installation... page J2-34 10, C-washer and retaining ring 11. Locknut 12. Countershaft rear bearing Removal... page J2-14 Inspection... page J2-22 Installation... page J2~34 19. Counter Sth gear Inspection... page J2-21 5 Set bolt and washer Center housing Removal... page J2-14 Installation...... page J2-33 Biind cover Cap plug, spring, and detent bail Thrust lock washer Stee! ball Bearing Inspection... page J2-22 sth gear Inspection... page J2-21 Installation... page J2~31 Retaining ring Synchronizer ring (6th) Inspection... page J2-22 sth/Reverse shitt rod Removal........ page J2—14 Installation... page J2—32 sthiReverse shift fork Installation... Page J2-G2 Interiock pin Brdiath shitt rod Removal ..n.... Page J2—15 30. Interlock 31. 1st/2nd shift rod Removal... page J2-15 Installation... page J2-32 982. Locknut 33. Clutch hub assembly (Gth/Reverse) Removal... page J215 Ingpection...... page J2-22 34, Synchronizer ring (Reverse) Inspection....... page J2—22 35, Reverse gear Inspection....... page J2-21 Installation... page J2~31 36. Bearing Inspection... page J2-22 37. Inner race 38. Thrust washer 39, Bearing cover 40, Thrust washer 41, Reverse idler gear shaft Inspection... page J2-23 42. Reverse idler gear Inspection... page J2-23 42. Thrust washerTRANSMISSION Countershaft rear bearing Caution - Do not reuse the locknut. 4. Unerimp the tab of the locknut 2, Shift the clutch hub sleeves to frst gear and reverse gear to put the gears in a double-engaged condition. Note Use the protective plates to prevent damage to the ssT. 3, Hold the mainshalt with the SST and a vise. 4, Remove the locknut. 5, Remove the ‘countershaft rear bearing with the SST. 1. Remove the cap sorews from the center housing 2. Remove the center housing. If necessary, tap the housing with a plastic hammer.TRANSMISSION J2 ‘1st/2nd, and 3rd/4th shift rods 4. Remove the blind covers and gaskets. 2. Shift the transmission into 4th gear, This will provide adequate space to drive out the roll pin, Drive the roll pin from the Srdvath shift fork. 3. Slide the 3rd/4th shift rod out from the rear of the transmis- sion case, 4, Drive the roll pin from the 1sv/2nd shift fork. Slide the 1st/2nd shift rod out from the rear of the transmis: sion case. 5, Remove the interlock pins. Sth/Reverse clutch hub assembly 1. Unorimp the tab of the locknut. 2. Shift into 1st gear and 4th gear to lock the rotation of the mainshatt Caution Do not reuse the locknut. 3. Remove the locknut with the SST.TRANSMISSIONTRANSMISSION J2 Countershaft nith the SST.v2 TRANSMISSION 2, Position the SST between 2nd and 3rd gears, Caution Hold the mainshaft with one hand so that it does not fall. 3. Press the mainshatt out of Srd gear and 3rd/th clutch hub assembly, 1st/2nd clutch hub assembly Caution Hold the mainshaft with one hand so that it does not fal Press the 1st/2nd clutch hub assembly and 1st gear sleeve from the mainshatt Countershaft center bearing inner race Caution Hold the countershaft with one hand so that it does not fall. ~ Note Replace the countershaft center bearing and counter- shaft center bearing inner race as one assembly. Remove the inner race of the countershait center bearing from the countershaft with the SST. Countershaft front bearing spacerTRANSMISSION J2 INSPECTION Inspect all parts, and repair or replace as necessary, canis Each gear and main drive gear 1. Inspect synchronizer cones for wear. 2. Inspect individual gear teeth for damage, wear, cracks. 3, Inspect synchronizer ring matching teeth for damage or wear. 4. Inspect main drive gear splines for damage or wear, ALTER - Mainshaft 1. Measure the mainshaft runout, Maximum: 0.03mm (0.0012 In) 2. Inspect splines for damage or wear. 3. Measure the clearance between mainshaft and gear (or bust). ‘Maximum: 0.15mm (0.006 in) | Countershaft 1. Inspect gear teeth for damage, wear, cracks. 2. Inspect splines for damage or wear. TARR Control lever and shift rod Measure the clearance between the contra lever and the gate ‘of the shit rod, Clearance: 0.8mm (0.032 in) max.TRANSMISSION Assembly note Mainshaft nd gear and th n hub assembly onTRANSMISSION J2 EXE Countershatt front bearing spacer Note Replace the countershaft front bearing and counter- shaft front bearing spacer as one assembly. 1. Install the friction gear, diaphragm spring, and countershatt front bearing spacer. 2, Press the countershaft front bearing spacer onto the coun- tershaft with the SST. Measurement of Bearing Thrust Play Mainshatt bearing 1, Measure the depth of the mainshatt bearing bore in the rear of the transmission case. 2, Measure the mainshaft bearing height. ‘The difference between the two measurements indicates the required thickness of the adjustment shim, Standard thrust play: ‘0—0.1mm (0—0.004 in) Adjustment shim thickness: ‘0.1mm (0.004 in), 0.3mm (0.012 in) Countershaft frent bearing 1, Measure depth B of the countershatt front bearing bore in the transmission case.TRANSMISSION Install and needle bearing 0.118 c inthe and hold them with the retaining rin Note If the C-washers are not pushed fully forward in the mainshaft groove the measurement will be incorrect.TRANSMISSION 4. Install the sy inter Sth gear.TRANSMISSION J2 aTRANSMISSION J2 Tua EI Assembly note Extension housing 1. Apply oil to the new oil seal lip, and instal it in the exten- sion housing with the SST. 2. Install the control rod in the extension housing, 3. Coat the contacting surfaces of the extension housing and bearing housing with sealant. 4. Install the extension housing on the bearing housing. Tightening torque: 31—46 Nm (3.2—4.7 m-kg, 23—34 ft-1b) 5. Install the back-up light SW. Tightening torqué 39—-59 Nm (4.0—6.0 m-kg, 29—43 ft-lb) Transfer case 1. Install the input sleeve, Coat the contacting surfaces of the transfer case and ex- tension housing with sealant, 2, Install the control iever end when the transfer case is set on the extension housing, 3. Apply sealant to the threads of bolts, and tighten them, Tightening torquJ3 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE TRANSFER CASE [ Problem Possible Cause | | Abnormal noise Worn bearingi, M3 TRANSFER CASE }) (TRANSFER CASETRANSFER CASE 7. Remove the bearing with the SST.TRANSFER CASE 13, Remove the oil passage by lightly tapping it with a plastic hammer. 14. Tap out the roll pin and remove the H-L shit rod, spacer, and shift fork.TRANSFER CASETRANSFER CASE input shaft gear a ged teeth, 9¢TRANSFER CASE J3 TT 9. Bearings for rough operation or noise while turning. 10. Shift fork or shift rod for wear or damage. 11. Shift spring for weaking. J3-17J3 TRANSFER CASE ASSEMBLY an scifiTRANSFER CASE J Assembly procedure transfer case housing with theTRANSFER CASE J3 NEEDLE BEARING Ea Tae a7 ama ADJUSTING SHIN ‘TRANSFER CASE ‘HOUSING (5) Center the inside needle bearing, and slide the coun- tershatt into the case. (6) Install the lock plate and tighten the bolt Tightening torque: 19—26 Nem (1. 2.6 m-kg, 14—19 ft-lb) 10. Install the input shaft assembly as follows. (1) Measure the bearing bore depth (A) of the housing with, vernier calipers. (2) Measure the height (8) of the bearing clip with vernier calipers and a surface plate, (G) Calculate the difference between (A) and (8) to deter- mine the clearance. Difference (Clearance) (4) Select and install the proper shim to obtain the standard Clearance. Adjusting shim thickness: ay 07 (028) 08 082) 09 (6.055) 100.089), 4.4 (0.043) 12 (@0a7 ‘Standard clearance: 0—0.1mm (0—0.004 in) J3-21TRANSFER CASE (6) Press the bearing onto the input shaft gear with the SST, } 8 Install the snap ring. } } { FE TaueTAT Be (7) Install the input shaft assembly into the housing by lightly i tapping the outer race of the bearing with a plastic { hammer. r ~ tf i 11. Install the needle bearing and HL hub sleeve onto the in VE” tan put shaft. Note To identity the H-L hub sleeve from the 2W-4W sleeve, the thickness of the H-L hub sleeve is 2.4mm (0.88 in); A/T, 21.0mm (0.83 in); M/T and the 2W-4W hub sleeve is 18.0mm (0.71 in). 12. Install the output shaft into the housing by lightly tapping the outer race of the bearing with a plastic hammer.TRANSFER CASE J3 Tae ea 18. Set the thrust washer on the output shaft. 14. Apply oil to the needle bearings, and install them onto the drive sprocket along with the spacer. 15. Install the chain on the ctive sprocket assembly and the front Grive sprocket, and expand the chain with the SST to set the center-to-center distance for easy installation into the housing. Note Do not overtighten the chain expansion tool. 16. Install the front drive sprocket assembly into the housing ‘by lightly tapping it wth a plastic hammer, keeping the chain horizontal 17. Atter installation, verify that the chain rotates smoothly, 18. Tap in the 2W-4W clutch hub with the SST. J3-23TRANSFER CASE I the 2W-4W shift fork onto the shift rod as folio (1) Slide the retainer onto the shift rod, and secure it with the ne Q Inst acer (20mm, 0.79 in), spring, 2W-4W shift ther retainer,TRANSFER CASE 34. Apply a chain cover, and s, and tighten, Tightening torque: 19-26 Nam (1.9—2.6 mkg, 14—19 fb) 9A Anniv sealant to the threads of the plus.AUTOMATIC TRANSMISSION (Hydraulically-Controlled) INDEX.. OUTLINE CONNECTING SHELL AND )D PLANETARY (OD SUN GE! 1B)... K1— 54 Ki- 56 FLUID Kin ot ‘TROUBLESHO! eomonraeon 2ND BAND. FRONT CLU’ REAR CLUTCOUTLINE OUTLINE SPECIFICATIONS ~__Transmission/EngineIN eee ese eee FLUID PASSAGE LOCATIONSOUTLINE Parking Gear (TROUBLESHOOTING K1 ON VEHICLE +}. Inspection point and |Pre | Electronic feference page | Rica l'cyetem| Hydraulic control system | | Kia 1-28 1-107 ‘caw sono ad wing | K1=26.27 noe POR ‘speed and condion phragm and piping noid eT! C00TROUBLESHOOTINGELECTRICAL SYSTEM INSPECTION K1MECHANICAL SYSTEM TEST TIME LAG TEST he engine is idling, there will be a certain time lapse, or time lat this time I orifice check Preparation| \ (Ki ELECTRONIC SYSTEM COMPONENTSELECTRONIC SYSTEM COMPONENTS toth OPEN wTK1 ELECTRONIC SYSTEM COMPONENTS G6 engine pagesAUTOMATIC TRANSMISSION FLUID (ATF) K1 fae f- i Taree AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION Level 1. Apply the parking brake and position wheel chooks securely to prevent the vehicle from rolling, Note Place the vehicle on a flat, level surface. 2.Warm up the engine until the ATF reaches 60—70°C (140—158°F), ‘8. While the engine is idling, shift the selector lever from P to 1 and back again. 4. Let the engine idle. 5. Shift the selector lever to P. 6. Ensure that levp| je petween the,K1 TRANSMISSION TRANSMISSION TRANSMISSION UNIT (REMOVAL AND INSTALLATION) PreparationTRANSMISSION 20. Install the SST to the oil pump assembly.TRANSMISSION move the snap ring from the ov ft with snap riTRANSMISSION TORQUE CONVERTERK1 TRANSMISSION )D CONNECTING SHELL AND OD PLANETARY GEAR UNIT 0D SUN GEAR, OD PLANETARY PINION CARRIER, OD CLUTCH HUB) disassembly and Inspection mbly, referring to Assembly procedure.TRANSMISSION Disassembly and InspectionTRANSMISSION K1 aaa Assembly procedure 1. Apply ATF to a new O-ring and install it onto the rear clutch drum. 2. Apply ATF to a new seal ring and install it onto the piston. 8. Apply ATF to the inside of the direct clutch drum. Caution Apply even pressure to the outer edge of the piston to avoid damaging the seal rings when installing. 4. Install the piston in the direct clutch drum.TRANSMISSION Disassembly noteTRANSMISSION K1 Install and tighten the bolts, Tightening torque: 9.8—14.7 Nm (1.0—1.5 mkg, 7.2—10.8 ft-Ib)Ki | Dlsasuembly and inspection F2. ENGINE TRANSMISSION isassembly Note. erting to Assembly procedure. sexewve aTRANSMISSIONK1 TRANSMISSION ‘Assembly procedure 1. Apply ATF to a new O+ing and install it onto the front cluteh | drum - 2. Apply ATF to a new seal ring and install it onto the piston, NE Caution pil Apply even pressure to the outside edge of the pis-TRANSMISSION K1 Caution Align the flats of the retaining plate with the lubrica- tion hole of the clutch drum, then set it into the drum, 9. Install the retaining plate with the step facing upward. Caution Do not deform the snap ring. 10. Install the snap ring. |TRANSMISSION Disassembly note Snap ring Caution Do not damage the snap ring.TRANSMISSION K1 ‘Assembly procedure 1 ‘TF to.@ new O-ting and install tonto the rear clutchTRANSMISSION GOVERNOR Preinspection Governor valve operation aa Caution ‘The compressed air must be less than 500 kPa (5.0[FREE LENGTH TRANSMISSION Inspection Secondary and primary governor springs 1. Measure the spring specifications. K1 one Specifications Siren Hem | Outer dia. [Free length Wire dia. | wee ‘Spring mm (in)| mm in) [N° °F €Ol8) rm Gn) DIAMETER Petat [8.0 0356 [21.7 858] 100 [08 @.09t) Second: Fz eal] 92 (0.362) [252 (0.882)| 75 [0.7 (0.028) [es [e035 [21.7 a5] 100 fos oosn wae © [Pamary lars ©54a[21.8 (0.858) 7.0 [oes 0.010) 2. If not within specification, replace the spring, Assembly procedure 1. Apply ATF to the primary governor valve, primary spring,TRANSMISSION K1 Disassembly Procedure 4. Remove the manual valve, 2. Remove the oil strainer. 3. Hold the ower vaive body and separate plate together with a large clip. 4. Remove the bolts. 5. Remove the lower valve body. 6. Remove the orifice check valve and spring (F2 engine) from the upper valve body. 7. Remove the halding clip, Caution Remove the separate plate gently to avoid losing the orifice check valves and springs and the throttle re- lief ball and spring in the valve body. 8. Remove the separate plate. wueeTO K1~99TRANSMISSION Note ‘Tag the orifice check valves as shown for proper reas~ sembly. ee 9. Remove the office check valves, throttle relief ball, and springs. 10. Remove the roll pin. 11, Remove the 3-2 timing valve and spring. Sao rescrerraaiceU 4 Be Inspection 4. Measure the spring specifications. {iil ae en If not within specification, replace the spring(s).. HL O ' || Sacre ] WIRE DIAMETER TERE yah Wem | Outer die. | Free length A | Wire dia. bo) [spring ‘men (in) ‘mm (in) pes ot cane: ‘im (in) Oriice check 500.197) | 185 (0610) 120 1029 (0.008) 1 Throttle relief 6.5 (0.256) 26.8 (1.055) 16.0 0.9 (0.035) 1 Fo 780299 | 23.2(0919) 74.0 08 (0031) 32 tming os [_ 7402 | 2070819 110 0.9 (0.085) TRIOTRANSMISSION K1 UPPER VALVE BODY Disassembly and Inspection Disassemble in the order shown in the figure, Inspect all parts, and repair or replace as necessary | Gore sPecineo are 10 womouaL Paars 1. Side plate D 2. Second lock spring Inspection ... page K1=102 3, Second lock valve Inspect for sticking, scoring, or scratches 4, Pressure regulator sleeve Inspect for sticking, scoring, or Soratches 5. Pressure regulator plug Inspect fof sticking, scoring, or scratches 6. Pressure regulator valve Inspect fot sticking, scoring, or soratches 7. Pressure regulator spring Inspection .. page Kt—-102 8. Pressure regulator vaive Inspect for sticking, scoring, or scratches 9, Side plate B 10, Vacuum throttle valve Inspect for sticking, scoring, or soratches 11. Downshift valve Inspect for sticking, scoring, oF scratches 12. Downshift spring Inspection ... page K1-102 13. Throttle backup spring Ingoection .. page K1~102 14. Throttle backup valve Inspect for sticking, scoring, of scratches 15.34 shift sleeve Inspect for sticking, scoring, oF scratches 16. 3-4 shift valve Inspect for sticking, scoring, or scratches 17.3.4 shift spring Inspection ... page K1-102 18. 3-4 shift plug Inspect for sticking, scoring, or scratches 19. Side plate A UOT 20. Separators (G6 engine) 21,23 shift valve Inspect for sticking, scoring, or scratches 22.2.8 shift spring Inspection ... page K1—102 23. 2:8 shift plug Inspect for sticking, scoring, of scratches 24.1.2 shift valve Inspect for sticking, scoring, or scratches 25.1-2 shift spring Inspection .... page K1-102 26. Pressure modifier vaive Inspect for sticking, scoring, oF scratches 27, Pressure modifier spring Inspection .... page K1-102 28. Upper valve body Inspect for damage or scoring K1-101K1 TRANSMISSION . ee Inspection i 1 Measure the sorings specication. 2. If not within specification, replace the spring(s). int vane i Si AAW O i vane | DieNETER i WETS i aan | Galordia. | Fea en] yo orca | al 1 Toes a | Pama | oom | a Second ck asso79 | wscsi | 19d | 9580 1 [rescue esueor vi7eas) | socem | 150 12 (6047 | | Bownshit 5550219 | 21.8 0.862) 740 0.86 (0.022) | 2 7a 2 | ssonay | 160 08 (002) {|| Throttle backup ests | ee zac | meer | os 09 085 | F2EGI 7.2 (0.283) 28.1 (1.108) 12.0 0.8 (0.031) | Joc F2cab zaoan | a2oe | 120 | cose A ee ce 0700) | mans | we 08 0021) | ree coz | sone | 200 a7 (28 | | 2s so Fe ab ‘ao2m | sienam | 1925 | coca i i os yas | wotee | 78 | aves vp [eae ee ona | seca | 160 | ce oo2e ity, : F2EGL, 66 8603s) | 155 060 75 06 (0.024) 1 | pes oat [Fe cate 31 oss | 185 0720) 74 06 0.024) | ———_ Assembly 1 Insert the pressure regulator valve, spring, sping seat, plug, and sleeve into the lower valve body. 2, insert the second lock vaive and spring into the lower valve boy.