1995 Mazda MX-3 Workshop Manual 1994. Mazda Moto tor Corporation * Pr INTED IN USA AUG "6 PRET NO. , 9996-96-0080-95WARNING Servicing a vehicle can be dangerous. you have not veceived service- felted aling he rsks of fury ancl property damage noresae, The recommended servicing procedures for the veriole in this workshop ‘manual ware developed with Mazda-trained techricians in mind, This, manual may be useful to noreMazda trained technicians, but a techni- lan with our service elated vralning ang experience will bat less risk ‘when performing servicing operations, However, all users of his manu= al are expected to know general safety procedures, ‘This manual contains "Warnings" end "Cautions" applicable torisks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk thal improper sarvico oF repair may damage the vehio'a or render itansale, ILis 2180 importamtto understand that the “Warnings” and "Cautions? aré nat ex- bhaustive, itis impossible to warn of all the hazardous consequences ‘hat might result from failure to follow the procedures. ‘The procedures recommenced and described in this manual are effec- ‘ive mothods of performing service and repair. Some raquire tools specifically designed for a specific purpose. Nonvecarrmended prace- dures and tools should include consideration for safety of the techni- cian and continued safe operation of the vehicle. Parts should be replaced with genuine Mazda replacement parts, not aris of lesser qualily. Uso of a rionrecommended replacemant part Should inolude consideration far safely of the technician and continued safe operation of the vehicle,1995 Mazda MX-3 Workshop Manual General information Pre-Delivery inspection and Scheduled Maintenance Engine Bg DOHC Lubrication System Cooling System Fuel and Emission Control Systems: FOREWORD For proper repair and maintenance, a thor- ‘ough familiarization with this manual Ig im- portant, and it should always be kept ina handy place for quick and easy reference. All the contents of this manual, including Grawings and specications, ar the latest available at the time of printing. As modifica- tions affecting repair or maintenance occur, relevant information supplementary to this volume wil be made available at Mazda daalers. This manual should be kept up-to- date. K8 DOHC Engine Electrical System Clutch Manual ‘Transaxle ‘Automatic Transaxle G25M-R Electronically Controlled Mazda Motor Corporation raserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this boo may be reproduced of used In any form or by any means, olectronis ar machanical—in- cluding photocopying anc recording and the use of any kind ofinformation slorage and re- trieval system—without permission in writ- ing. WARRANTY The manufacturer's warranty on Mazda vehicles and engines can be voided if im- Proper service or repairs are performed by Persons other than those at an Authorized Mazda Dealer. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vahiclas begin- ning with the Vehicle Identification Numbers (VIN) shown en the following page. Front and Rear Axles Steering System “Body Electrical System “Heater and Alr Conditioner Systoms Technical Data Special Tools wiring Diagram Form No. 5330-10-94G Part No, 9999-95-034G-85 2% Refer to the 1995 MX-3 Body Electr Troubleshooting Manual {Form No, 1474=10-94H, Part No. 9999-95-086F-95} for servicing of the body electrical components. ‘© 1994 Mazda Motor Corporation PRINTED IN THE U.S.A AUG, 94 Form No. 1472~10-944 Part No. 9999-98-0565-95VEHICLE IDENTIFICATION NUMBERS (VIN) JM EC433 + SO. 400001 — JM EC434 « $0 400001 —PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE PRE-DELIVERY INSPECTIGN .. PRE-OELIVERY INSPECTION SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE DA)A PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE ‘The following items may be done at any time prior fo delivery to your customer. EXTERIOR, INSPECT and ADJUST, if necessary, the following tems, to spacitication: 1 Glass, exterlor bright metal, and paint for damage 1 Wheel lug nuts and locks ( equiopec} 89-117 Nem (9-12 kgf, 60-86 feibi} © All weatherstrips for damage or detachment 1D Operation of hoad release and lock 1D Operation of rear hatch, and fue! id opener With irunk open, check for spare jack, tr, toots, and fasteners securing these ilems in place. 1D Sliding sunroof (it equiped) © Power door lock (if equipped) 10 Power outside mirrors (i equipped) 1 Power windows {if equipped) 0 Heater, detroster, and air conditioner at various mode selections (if ecuipped) CHECK the Toflowing items: U Presence of speré fuss Upholstery and interior finish _ CHECK and ADJUST, if necessary, the following items: 1 Pedal hoight and trae play of brake and clutch pedal © Door operation and alignment esate img ee iy mm 1 Heaiight aim T9-204:7. 858.65) INSTALL the following parts: hutch pedal ‘vein carpet S018 063 1 Wheel caps of rings (it equioped) Bakopeta | 195-100 i760-77) | a7 (Ote-0H) UNDER HOOD-ENGINE OFF © Paving brake INSPECT and ADJUST.if necessary thefollowingitems _5-/ natchesAVBN {10 kot, 22 lot} te specincation: anes. UNDER HOOD-ENGINE RUNNING AT 1 Feel, cootant and hydraufetines, tings, connections, Sdoonnanents faeleaes OPERATING TEMPERATURE. 1D Engine oll level CHECK the folowing items: 1D Power staering fuid level U Autornatc transaxte id eve G Braks and clutch master cylinder fd tevel 10 Windshield washer reservolt Fuld level ONHOIST © Radiator coolant level CHECK tho folowing Rome: U Tigntness of battery terminals 1G Manual transaxle oll level INTERIOR: INSTALL the following parts: 1D Rubyer stopper for rearview mirror CHECK operation of the following iter: 1 Seat contro's {slide and recline) and headrests 1 Folding rear seat 1B Doer tacks: 1 Seat betts and warning system 1 Ignition switch and steoring lock © Transaxle range sulich {ATX only) O Starter interlock switch (clutch pedal, MTX only) All ights, including waming and indicator igits 1B Sound warning system 5 Hom, wipers, and washers (front and rear, ¥ equipped} 1D Audio system {if equipped) 1D Cigarette lighter and clack 15 Underside fuel, coclant and hydraulic lines, fitings, connections, ard components for leaks Gi Tites for cuts or bruises 1 Steering tinkage, suspension, exnaust system, andall undarside hardware for looseness or damage ROAD TEST, CHECK the following items: 1 Brake operation a ‘operation © Steoriag zontrol 5 Operation of gauges 1 Squeaks rates or unusual noes 1 Emergency iocking retractors, 1 Cruise control system (F equipped) ‘AFTER ROAD TEST CHECK for owner information materials. ‘The following items must be done just before dolivery to your customer. Load test battery and charge if necessary Zl G Adjust tite pressure to specification Gattexrent (Refer to door label} 1 Glean outside of vehicle Az Install fusas far accessories U Rerrove seat and cabin caret protective covers Vacuum and clean interior of vehicle 1 Inspect installation of optional parts:SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) Schedule 1 (Normal driving conditions) ‘The vehicie is mainly operated where none of the “unique driving conditions” apply. Schedule 2 (Unique driving conditions) © Repeated shori-disiance criving. * Driving in dusty conditions. © Driving with extended use of brakes. * Driving in areas where road salt or other corrosive materials are used. © Driving on rough or muddy roads. ‘© Extended periods of idiing or low-speed operation. '* Driving for tong prolonges periods in cold temperatures or extremely humid climates. A3A SCHEDULED MAINTENANCE Schedule 4 (Normal driving conditions) atntonaros Number of manthe ar milea Wlomotany, wilchover somes fret Interval onthe [2 | « [= | 0 | o | «2 [ae sooo Kiometos | 1 | a [m0 | a | oo | me | a | 6 Maintenance om nas wows | 75 {13 | 25 | 20 [srs | os | es | 60 Engine Freire od - pF Te [es >a] | AA Otte: a |e [ep a la | aiata “Toneion of al eve BOBS 1 v Engwe tring bot op avery 6000 ils (98,000) Inept at 60.00 re (66000 on as Engine timing bat (Calfoia) gale at 90/00 rifles (C00 kn“ pions every 105200 ios (168,000 kn ‘Hose and ube fer emieion T ve Air cleaner ‘Ai lear lear a1 es ee Ignition system ‘Spark pga z A Fuel system 1a ar003 2 Fat ter Fuel knes and hoses ta Fusi hoses (Cellos) ingpec very 105,000 fs {768,000 4 Cooling system eta sytem iT 7 Ergie coolant at a Chassis and body rts Bren, hese, and connacions Brian brakes Disc brakes t t v ‘Sleering aperalon andineanee. v front suspension ball flnts U Drs sre cust baat L t t L Rov anchaits on crass ane bey Exhaust yarn eal nee Aloo and Fiages cpa er Air conditioner system (if equipped) Fotgrontamaure 1 T NG compressor operate 1 H f 1 Chart symbols: Inspect and repair, clean, or replace if necessary. R: Replace L: Lubricate Remarks: After 48 montis or 60,000 miles (96,000km}, continue to follow the described maintenance atthe recom- mended intervals. “1 This maintenance is required tor all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintonanco is rocommenciod by Mazda. However, itis not necessary for emission warranty coverage or manufacturer recall lability. A4SCHEDULED MAINTENANCE Schedule 2 (Unique conditions) Maintonance Tumber of onthe or Tales (elomeler), waichever Comes Mat tmtervel Wonihe ele «]o[a|mlelslelale ereee STS se [ae [oe [ao [foo] oo 2 | | os | we Mamtenance tem les 10 [as [20 [as Teo fos [0] 8 | oo | os Lo Engine Engine atalTaTayel@[alayalela Fngine ol (Puan Ris) Replace ore 9.000 nies 100m ord monte Oe aATeilayr[rl[ayalalalala Teasion a arva be 2 \ Ens ning bok Replace ey SRO es 65 G00 Trapeet a 69000 ies 85200 fo) an Engine tring bet (Calor saa at 90,000 ries {t= 00m Replace every 19,060 mies (158.000 Haro ard tbe fr emition = Air cleaner Leicceaner stemeat I 1 = a Ignition system Searcoes a ITT Fuel system Tale spose) Fost iter Fuct ines andes Fuat noses (Cater) Cooling system = ‘Coning S187 Endine coolant Chassis and body (Brave ins, hoses, and connectors Bombrakes Dive brakes ‘Steering oporetion and RRQ Front. eugpention bal joints (Drive Shafi dust boas Bots and nuts. on chassis and boa Exhaust syetern neat svokts ‘itbocke and hinges Air conditioner system (if equipped) Retigerartarount AIG comcreesor operation Chart symbole: T: Inspect and repair, clean, or replace if necessary. (inspect, and ifmecessary replace---Air cleaner element only) R: Replace Remarks: ‘After 48 months or 60,000 miles {96,000 kr}, continue to follow the described maintonance atthe recom- mended intervals. “1. This maintenance is required for all states except California, However, we recommend thatitalso be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, il Is not necassary for emission warranty coverage or manufacturer recall lability. ASA SCHEDULED MAINTENANCE ‘SCHEDULED MAINTENANCE TABLE (CANADA) ‘Humber of months OF miles (KIOTI¢ter), whichever comes Arst ‘Waimtenaneo ‘terval ‘Montho 5 [10 20 | 25 | 20 [48 1,000 Malntonance Hem 1s Kuemoters |e | 76 | o | 32 | 40 | we 6 % | ia |e|a| la |e] Milos | 3 | 10 20 | 25 [a0 [as Engine Engine of ‘Gi or “Tension of all crive bets Engine ling ett ‘cleaner Fireeaner element Ignition system Cooling system ‘Spak ghar 5 Enghe ecclart ovo! and etangih {Gooing system fortnaks Engine coolant Fuel system Ide pest Fuelinse and hoees Fuetarer POV wane Enso howes and bes Chassis and body ‘Automat Wanearis Fuld level Transeote oi @ANX and ATH) ‘rive shaft cust boats Brake tines and hoses Brake and circ tc ovat Broke fuid Divo brakes (Fort and ear) Rear drum brakes “Teg ilaon prewsure and Bre wear Tues Powor stoaing fudiovel ‘Steering operation ard inkage includes fou wheel alignment Front ard rear euaoeneian components ‘Altohaseis ang body nits and bole Eehaustsystern host shields Alllocks andinges ‘Wash fu Hoval ~|~|-|-|-|-] - (-|el-]-]-]al-[-/-[2]-] Funetin ofa lights Alr conditioner system (if equipped) Raivigarant amount ‘AIC cornpressex operation ASCHEDULED MAINTENANCE A Chart symbols: 1 inspect and repair, clean, or roplace if necessary, (Inspect, and if necessary replace.....Air cleaner element only} F: Replace L: Luoricate Rt: Rotation (tires) Remarks: ‘After 60 months or 60,000 miles {98,000 kia}, continue to follow the described maintenance at the recom- a mended intervals, “1 Replacement of the timing beltis required every 60,000 miles (28,000 km}. Fallure to replace this belt may result in damage to tie engine. *2 This maintenance is recommenced by Mazda. However, it is not necessary for emission warranty coveraga or manufacturer recall ability. “8 This maintenance is recommended by Mazda. ATBefore beginning any service procedu joting Mant B2 refer to the 1995 MX-3 see section § for ai TROUBLESHOOTING ENGINE TUNE-UP PREPARATION ENGINE OIL. ENGINE COOLANT DRIVE BELT . HLA TROUBLESHOOTING GUIDE. IGNITION TIMING, IDLE SPEED COMPRESSION PREPARATION INSPECTION . ON-VEHICLE MAI PREPARATION . TIMING BELT. CYLINDER HEAD GASKET FRONT OIL SEAL . REAR OIL SEAL, REMOVAL ... PROCEDURE, ENGINE STAND MOUNTING . PREPARATION PROCEDURE DISASSEMBLY . PREPARATION . AUXILIARY PARTS TIMING BELT... CYLINDER HEAD . CYLINDER BLOCK (EXTERNAL PARTS) «22. .0000+ CYLINDER BLOCK (INFERNAL PARTS) «0... .--eeeee ENGINE (K8) B2- B2- B2- Bl B2- B2- B2- B2- B2- B2- Ba B2. 40 B2- 10 B2- 10 Oe GAAADBOEN + BR it + Ba 11 - B2- 13 : B2 23 B2- 37 B2- 40 + B2~ 42 + B2- 44 + B2- 4d + B2- 62 + B2- 52 - B2- 63 + B2- 66 B2- 56 + B2~ 58 + B2- 60 + B2~ 62 INSPECTION / REPAIR PREPARATION . GYLINDER HEAD . VALVE MECHANIS! CAMSHAFT HLA .. CYLINDER BLOCK PISTON, PISTON RING, AND PISTON PIN. CONNECTING ROD CRANKSHAFT - BEARING . OILJET. TIMING BELT TIMING BELT TENSIONER, IDLER PULLEY .. TIMING BEL ASSEMBLY ... PREPARATION CYLINDER BLOCK (INTERNAL PARTS) . CYLINDER BLOCK (EXTERNAL PARTS) CYLINDER HEAD TIMING BELT. AUXILIARY PARTS ENGINE STAND DISMOl PROCEDURE . INSTALLATION PROCEDURE « B2-116 B26 B2-117 B27B2 INDEX INDEX INTAKE MABIFOLD ENING TOR COMPRESS ON INSPECTION, PABE_92-10 Teese m2 Seg STANDARD: 1998 KPa (‘O.glom?, 199 pa) 200 rpm 14-18 felt " MINIMUM: S87HPa (10.0 kagllom®, 142 pel)-$00 rpms ENGINE OIL INSPECTION’ SEAMIGE SECTION D2 pxnwwsrienaroun cereece ar Sgt 2) emi ENGST ES resem DRIVE BELT NEW USED LMT. GENERATOR |6.0-7.0024-027 { 7.0-3.0(.28-031}] 9,010.95) COMPRESSION. kPa {kgtiem?, pal}-rpm | [GENERATOR + AC /5.5-6.5 10.22-0.25 6.5-7.5 {0.26-0.29}] 8.04032}, STANDARD. 1,334 113.6, 193}-300 Ps [8.0-7.0 {0.24-0.273 7.0-8.0 {028-0.31}] 9.0 {0.35} SIRUIRAU 981 {10.0, 142} 4. Timing bolt 5. Rear oll seal Removal / Inspection / Replacement ... Installation -- pageB2-13 6, Engine 2. Cylinder head gasket Removal ............. 0 B2- 44 Replacement ......--.2. 20+ Engine stand mounting page 82- 52 3. HLA my... page B2- 56 Removal Installation .. Inspection ? Repair 4, Front oil seal Assembly Replacement ......-- Engine stand dismounting ... page B2-118 lnsiallation .. . B2-2OUTLINE ‘SPECIFICATIONS: OUTLINE, TROUBLESHOOTING GUIDE B2 Her Engine Ks DOHC Typo Gasctine, Faye ‘Gyno arangoroat and number GOV coniguaton, 6 ofiaders ‘Combustion chember Pentoot Valve system DOHC betven, Saves Displacement 0, cup Bae (804, 1924) Bere etre tom Gf 76 x 606 246 x 2.78) Compression alo a2 Compression pressure Pa feel irom 1384 (8.6, 165800 tN Span En e Close ‘ABDC ar ‘eotning Open e800 a tone arwe = 1N wa fe) Of} Maintenance bes Nae doarance & mann 0 (OF: atrtenance-ea Fimgerder 126-6 Cylinder Arrangement =H uk TROUBLESHOOTING GUIDE Problem Pasaible Cause: Action Page Dificult starting Malfuncion of engine-related components Burned valve Replace eos ern piston, piston rng, or oyinder Ropace orrenar | Boao Dameted oyinder head geskel place Boos Weattunetion of fue! system Fete to weston Fa Maitunetion of electrical system RelertosactonG Pooridling Mattunotion of enginerelated components Matfuncdon of HLA Retace 22-37 Pct valvevo-talve seat contact, Repairorvepiace | 22/6 Daaraged ayindoc hod gesket Replace Maifunetion of tue! systerm ofer to soclon F2 “Tappet noise may occur the engine tras not been started for an extended period of me. Tre noise should ston ater the engine reaches noimal operating temperature. (HLA troubleshooting: Refer le page B2~2.) B2-3B2 TROUBLESHOOTING GUIDE Problem Possible Cause ‘Action: Page Insufficient power fneutfiolent comprossion Molfunction of HLA Replace 82-37 Compression leakage from valve seat Repair 8-78 Stuck vaive Replace Ba-74 Weak or broken vaive spring Replace B77 Damaged cylinder head gasket Replace 82-25 Grackéd er cistorted oyinder head Replace B73 Stuck, damaged, or wern piston ring Replace 2-82 Cracked er worn pision Reeplaoe B82 Malfunction of fuel system Refer to section F2 ‘Others Dragging brake Refer to section F Wrong size tires Rotor o scction @ ‘Abnormal combustion | Malfunction of engine-related components Malfunction of HLA Reclace 6237 ‘Stuck or burned vaive Replace Bars Weak or brekn voive spring Replace BGT Carbon zocumulation in combustion chamber Eliminate caroon Malfunction of fuel system Rotor to section FO Excessive oll ‘Oil working wp ‘consumption ‘Worn piston ring groove or stuck piston ring Revlace 2B Worn piston of cylinder Replace o repair | B2-81,82 Oil working down Worn valve seal Ropizce 82-06 |Wemn valve stem or guide Roplcoo 62-76 ‘Olleakage Refer to section D2 Engine noise ‘Crankshaft or bearing-related parte Excussive main bearing ol loarancs Replace or repair B29 Main bearing hoatdamaged Replace Be 84 Excessive crankshaft end play Replace or repair 2-99 Excessive connecting 100 beating cil dearance Replace or repair eas Gonnecting red hearing heat-damaged Replace Bead Piston-rolatod parts Worn ojinder Replace oF repair e281 ‘Wom piston or piston pin Replace 2-82.83 Damaged piston ring Replace 82-62 Bent conrecting rod Replace 52-83 Valve train-retated parts Moifunesion of HLAY Replace B80 Broken valve spring Replace B77 Exaoosive valve guile oloeranoe Replace RO75 ‘Malfunction of timing belt auto tensioner Replace 52-25 Maltunction of trction gear Replace 8276 ‘Maifunction of cooting system efor io sostion ED Malfunction of fuel system eter 70 section F2 Others Malfunction of water pump bearing Replace — Improper ets belt tension Adjust B25 Maltunction of ganarator bearing Replace Exhaust gas leakage Repair = “Tappet noise may ooauritthe angine hes nathean startad iran evlended peri oftime. The nse should slop afar the engin reaoans ronmel operating emperate. (HLA taubseshooting: Re‘erto page E28) Warning * Continuous exposure with USED engine oll has caused skin cancer in laboratory mica. Protect your skin by washing with soap and water immediately after this work. B24ENGINE TUNE-UP B2 ENGINE TUNE-UP PREPARATION Sst 49.9200 0298 For 49 B019 940 For inspection of inspection of ‘ribbed belt drive belt tension | System selector ignition timing tension gauge and ide speed ENGINE OIL Inspection 1, Be sure the vehicle is on Isve! ground. 2, Warm up the engine te normal operating temperature and atop it, 8. Wait fer five minutes. 4, Remove the dipstick and check the oll level and condition. 5. Add or replace oil if necessary. 4 Note © Thedistanca batween tha Land F marks on the dipstick represents 1.0L (1.1 US at, 0.9 Imp qt}. ENGINE COOLANT Inspection Coolant level (engine cold) Warning © Removing the radiator cap or the coolant filler cap while the engine is running, or when the engine and radiator are hot is dangerous. Scaiding coolantand steam can shoot out and cause serious injury. It can also damage the engine and cooling system. ‘Turn off the engine and wait until It is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly tum it counter- clockwise to the first stop. Stop back while the Pressure escapes. When you're sure all the pressure Is gone, press down on the cap —still using a cloth —turn it, and remove it. 1. Verify that the coolant level is near the filler nec. 2. Verify that the coolant level in the coolant reservoir is be~ tween the FULL and LOW marks. 8. Add coolant i necessary. B2-5ENGINE TUNE-UP- doga! laanal Wrage x oO x [GENERATOR GENERATOR Coolant quality 1 Verity that there is no buildup of rust or soate around the radiator cap, fillar cap, or filler neck. 2, Verify that tha coolants free of cil. 3. Replace the coolant if necessary. DRIVE BELT Inspection 1. Cheok the crive belts for wear, cracks, and fraying. Replace if necessary, 2. Verify thatthe drive bells are correctly mounted on the pul leys, 8. Check the drive belt deflection when the engine is cold, or at ieasi 30 minules after the engine has stopped. Apply moderate pressure 98 N{ 10kgf, 22 Ibf} midway between DAS PULLEY the specified pulleys. Defleotion rman) Driva bolt New" Used Limit 30-79 70-80 $0 CRAMKSHAPT Generator | yozeozn | @2e051) (0.35) PULLEY Generator + 55-65 65-75 8.0 NG 22025) | 202) | 034 [GENERATOR PS 6070 7.086 30 wae GENERATOR pron | 2003n | oa9 RIVE PULLEY ©) CRANKSHAFT PULLEY. * A bet that has been cn a runing engine for less than five minutes. 4. Ifthe deflection is not within the specification, adjust it (Refer to page 22-7.)ENGINE TUNE-UP B2 Drive belt tension check Belt tension can be checked in place of belt deflection. 41. Check the drive be'! tension whan the engine Is cold, or at Jeast 30 minutes ater tne engine has stopped. Using the SST, check the belt tension between any two pulleys, ‘Tension IN af, tp Drive bert New" sed ‘Gimit Generator ‘peo, oo, rN ene 0, 8 180-196) ¥ig-180) ca Generator =| 90-600 500-860 40 AC {70-0,160-109) | 0-70,170-159} | £45.89) PS ‘540-860 90-660 340 195-70.196-150} | (40-65.90-120) | _ (35.7 ‘TBST nat has baer on a running ergine for less than Fve minutes, 2, | the tension is not within the spectfication, adjust it, (Refer to below) Adjustment Generator + A/C, Generator 1. Loosen idler pulley locknut @. 2, Adjust the belt deflection by turning adjusting bolt ®. Deflection (Generator + A/G) New : 6.5-8.5mm {0.22-0.25 in} Used: 6.5-7.5mm {0.26-0.29 in} (Generator) N 0 mm {0.24-0.27 in} Used: 7.0-8.0 mim {0.28-0.31 in} 3, Tighten pulley ocknut ©. Tightening torque: 32-46 Nom {3.2-4.7 kgf-m, 24-33 fbf} PIS 1. Loosen idler pulley locknut®. 2, Adjust the belt deflection by turing adjusting bolt &. Deflection New : 6.0-7.0mm {0.24-0.27 in} Used: 7.0-8.0mm {0.28-0.31in} 3. Tighten pulley locknut @. Tightening torque: 32-46 Nem (3.24.7 kgf, 24-89 fll B2-7B2 ENGINE TUNE-UP HLA TROUBLESHOOTING GUIDE { Problem Possible Cause ‘ation Tae aben angels atawiedatirorw | fgullwrtolin HA | Runengine 000-0000 cm, tarps i ta | Faget 3 : PMO ny secceemacang, | Stbsave tons [Pane aps eter 2 secenda-10 minutes approx. one day “3 Nalee whon engine lp sarod afer orang for ‘Sgeconds o move. 4. Nee whon engi is startod after now HLA is instal HLA is normal FEnot, replace HLA. “Time required for engine ollo crculste ‘within org’re inaludos folorance fer es ‘gine oil condition and ambient tempera ture. 5, Nese continues more than 10 minutes Inpuficient ok preseue | Ohock ol pressure Ir lower than epectficatio, check for eaucs, Oil pressure: 504490 kPa (8:4 0 kpliom?, 48-71 po) 2,000 rpm (Reler to page 8-73) Frees down fILA by nena. if toes not move, HLA is normal. Ititmoves. rapiana HLA, Faulty HA Measure valve oleararce. I more than Omm (Dir, replace HLA. 0, Nese daring ile ator high speed evry Thoarredt oll ameunt Check of level. Drain or add 3 ag necessary Deterfovated oil Check of quailty. IFeterterated, replace with specified type and atrount of oi IGNITION TIMING, Preparation 4. Warm up the engine to normal oporating temperature. 2, Tum all eiectric loads off © Headlight switch # Blowor switch © Rear window defroster switch 3. Connect the SST io the data link cannactor. 4. Connect a timing light. 5. Connect a tachometer to the data link connector terminal 1G-. IDLE SPEED GND Ignition timing 1. Perform “Preparation, * (Refer to above.) 2, Make sure the idle speedis within the specitication. Ifnot, adjust the idle speed. Idle speed (MTX in Neutral, ATX in P range) 3650-710 rpm 3. Set switch @ to position 1. 4, Set TEST SW to SELF-TEST. 5. ifthe SST is not used, jump across the TEN and GND ter- minals of the data link connector. B2-8 6. Make sure the timing mark (yellow) on the crankshatt pulley and the mark on the timing bell cover are aligned. Ignition timing: 9-11° BTDCENGINE TUNE-UP B2 7. Ifthe marks are not aligned, Icosen the distributor mount- ing bolts and turn the distibutor to make the adjustment. 8, Tighten the distributor bolts to the specified torque. Tightening torque: 19-25 Nim {1.9-2.6 kgm, 14-48 frlb} 9, Disconnect the jumper wire or the SST. Idle Speed 4. Apply parking breke. 2, Pertorm *Preparation.” (Refer to page B2-.) 8. With the coolant fan off, verify that the idle speed is within the specification. Idle speed {Neutral or P range) : 640-700 rpm 4.1 not, adjust the idle speed by turning the air acjusting screw (AAS) 6, Discorinect the jumper wira or the SST. B2-9B2 COMPRESSION COMPRESSION ifthe engine exhibits low power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to section G.) 2. Compression (Refer to below.) 3. Fuel system (Refer to section F2.) PREPARATION SST 48 HO10 103 For 49. HOTC 194 For cespen ERE fee Ce | emt gauge INSPECTION 1. Verify that the battery is fully charged. Recharge it ifnec- essary. 2. Warm up the engine to the normal operating temperature, 3. Stop the engine and allow i to coo! for about 10 munutes. 4. Remove the all spark plugs. 5. Disconnect the distributor connector. 6 Install $ST Into the No.1 spark plug hole. 7. Fully depress the accelerator pedal and crank the angina. 8, Note the maximum gauge reading, 9. Gheck each cylinder as above. Compression kPa kotor? psi, ‘Standard 1.384 (18,6,168} 900 Minin 84 (10.6, 142}-300 ‘Maximuen atference “ 198 (2.0, 28) 10. f the compression in one or more cylinders is low, pour a ‘small amount of clean engine oll inte the eylinder and re check the compression, (1) Ifthe compression increases, the piston, piston rings, ar cylinder wall may be worn. (2) Ifthe compression stays low, the vaive may be stuck or improperly seated. (@) Ifthe compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 11. Remove the SST, 12. Connect the distributor connector. 13.{nsta! all spark plugs. Tightening torque: 45-22 Non (1.52.3 kgf-m, 1116 Flbh} B2-10ON-VEHICLE MAINTENANCE ON-VEHICLE MAINTENANCE B2 PREPARATION SST sewn ver seat iat Soerimot Holder. coupling eS | Santana Set, holder ts wan <9eonio1 er seo ste rer CIES prevention ot prevention of Holder corankehatt Bolts & crangshatt Pariot rotaton (Part of rotation BES ia cos BES an 49GOI7 BAO For 49017 501 For : a spor eae = Parl of 49 GO17 5AQ) 49 GO17 602 For 49. GOIT 603 For support of ‘support of eispet ae vexk oe (Partof (Part of Ses) SSS sam 49 E011 140 For 49 E011 103 For Sevan anton — see | sun sore gone anon | Bas wae Sa a) eon we fer sean 1 tr Senter (enton cover SEER | cee Eo Partof rotation (Part of rotation 49 BOTT 1A0} 49 E11 1A0) a> ores fer sacereot7 Fa q fehon at ‘Slatatonst Puller, ball joint tie rod end Installer, rear oil seal cake | SS 49 F401 3808 For 49 FA01 2378, For Flas of Fella or instar set Somtatee | stan c ee sane oa a Part of 49 F401 $308} B2-11B2 ON-VEHICLE MAINTENANCE Waming © Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work, B2-12ON-VEHICLE MAINTENANCE TIMING BELT Removal / inspection / Installation 1. Disconnect the negative battery cable, 2, Remove the right front wheel. B2 8. Remove in the order showa In the figure, referring to Removal Note. 4, Install in the reverse order of removal, referring to instaliation Note. 79-1027 Nan (20-4 katom, ‘o-05.ciny 94070 {90-210 rgtem, Tose em orate] 4. Splash shield (RH) 9. Engine hamess bracket 2, Drive bait 10. Timing belt cover Removal / Installation ....... page B2- 6 Femovei Note . - page B2-15, 3, Water pump pulloy Installation Note * page B2-19 4. Idler pulley and bracket 11. Timing belt 5. PIS oll pump Removal Note . - page B2-18 Removal Note. «page B24 Incpection ... page B2-85, Installation Note + page B2-21 Installation Note: page 82-17 8. Crankshaft pulley 12,Timing bett auto tensioner Removal Nota . page B2-15 Ingpeation 0. page B2-85, Installation Note « page B2-21 Installation Note . . . page B2-17 7. Dipstick and pipe 19. Tensioner pulley Removal Note. + page B2-1S 14. No.2 idler pulley Instattation Note page B2-20 15.No.1 idler pulley 8. Crankshafl position sensor hemess bracket B2-13B2 ON-VEHICLE MAINTENANCE B2-14 Removal Note P/S oll pump 1. Disconnect the P/S oi! pump hose from the engine. 2. Disconnec! the steering pressure sensor connector. 8. Remove the bots shawna in the figure and secure the P/S cil reservoir away from the engine. 4. Loosen the pulley nut as shown, 5. emove the pulley. 6. Remove the bolt shown, 7. Remove the bolts shown in the figure and remove the P/S cil pump. 8. Position ihe P/S oil pump away from the engine and se- cure it with wire,ON-VEHICLE MAINTENANCE B2 Grankshatt pulley a Caution # The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily. 1. Install the SST to the crankshaft pulley with bolts (M10 X 2. emve the crankshaft pulley bot and te pulley. Dipstick and pipe 1. Disconnect the crankshaft position sensor connecter. 2. Remove the cip from the dipstick pipe. 3. Remove the cipstick and pipe, 4: Plug the hofe in the engine after removing the pipe. Timing belt cover 1. Support the engine by using the SST {engine support}. B2-15B2 ON-VEHICLE MAINTENANCE 2. Remove the No.3 engine mount 3. Remove the right and leit timing belt covers. Timing belt 1. Install the crankshaft pulley bolt into the crankshaft. 2. Turmthe cranksha'? clockwise and afign the timing marks. (No.f piston is al TDC of the compression stroke.) 3. Mar the timing bolt rokaon on te bal for proper rela- stallation. 4, Loosen the auto tensicner bolts and remove the lower bott Caution * When removing the bolt, hald the tensioner so that the bolt holes are aligned, otherwise the threads. can be damaged. 5. Remove the No.1 idfer pulley and remove the timing bett. Caution © When removing the pulley bolt, hold the pulley so that the bolt hoies are aligned, otherwise the threads can be damaged. © The following will damage the belt and shorten tts life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.ALIGN THE HOLES ON-VEHICLE MAINTENANCE B2 Inspection Inspect the following and repair or replace as necessary. (1) Timing belt (Refar to paga B2-85.) 2) Timing belt auto tensioner (Reefer to page B2-85.) (8) Timing belt pulley (Refer to page 32-86.) (4) Camshaft pulleys (Refer to page B2-85.) Installation Note Timing belt auto tensioner 4. Slowly press the tensioner rad into the tansioner body by using @ press, Caution © Applying pressure of more than 9,807 N{1,000 kgf, 2,200 Ibf} can damage the tensioner. 2. insert a pin into the second hole in the body as shown to hold the tensioner rod. Note # Pin diameter: 1.6mm {0.063 in} 8. Set the tensioner in piace and snugly tighten the tensioner upper bolt. Note # This must be done to reduce the timing bett resistance when the idler pulley is inslalled. Timing belt 4. Turn the camshaft pullays clockwise and align the timing marks. B2-17B2-18 ON-VEHICLE MAINTENANCE 2. Using the crankshaft bolt, tum the crankshaft clockwise and align the timing marks of the timing balt pulley andthe oil pump. 2. Install the timing belt on the pulleys in the order shown be- , low. © Timing belt putey ® No? idler pulley © LH camshaft pulley ® Tensioner pulley © RH camshaft pulley 4. Verity that there is tens'on between pulleys ® and ©, and between pullays @ and ©. 5. Install the No. 1 idler pulley while applying pressure on the timing belt. Tightening torque: 38-51 Nem {(3.8-5.3 kgf-m, 28-38 ftlbf} 6. Push the auto tensioner in the direction of the arrow and lighten the bolts. Tightening torque: 19-25 Nem {1.9-2.6 kgtm, 14-18 ttf} 7. Remove the pin from the auto tensioner to apply tension to the belt.ON-VEHICLE MAINTENANCE B2 8. Turn the crankset cloclse twice, and align the timing 9 ony hat all timing marks are correctly aligned. lineces- sary, repeat the procedure beginning from installation of the timing belt auto tensioner. 10.Cheok the timing belt deflection by applying moderate pressure 98 N{10 kgf, 22 Ibf} micway between the crank shaft pulley and the auto tensioner. # not correct, replace the auto tensioner. Deflection: 6.0-8.0mm {0.24-0.31in) Timing belt cover 1 Install the right liming belt caver. htening torque: 910.7 Nem {80-110 kgf-om, 7095.4 in- Ib} 2. Install the left timing belt cover. Tightening torque: 7.9-10.7 N-m {80-110 kgf-cm, 70-95.4 in-tbh 3. Install the crankshaft position sensor connector bracket ‘on the left timing belt cover. Tightening torque: 79-1 10.7 New (80-110 kgf-cm, 70-95.4 in- tof B2-19B2-20 ON-VEHIGLE MAINTENANCE 4. Insiall the harness brackel on the right timing belt cover. Tightening torque: 7.9-10.7 Nem {80-110 kgf-om, 7095.4 in-Ibf} 6. Install the No.3 engine mount. Tightening torque & : 74-102 N-m (7.5-40.5 kyf'm, 55-769 it Ib} © : 86-116 N.m (8.7-11.9 kfm, 63-86.0 feb} 6. Remove the SST (engine support). Dipstick and pipe 1. Apply clean engine oiltoa new O-ring, and installiton the pipe. 2. Remove the plug irom the engine and install the pipe. Tightening torque: 7.9-10.7 N-m {80-110 kgt-om, 70-95.4 intbf} 3. Install the dipstick. 4, Install the crankshaft position sensor harness and clip to the dipstick pipe. 5. Connact the connector.ON-VEHICLE MAINTENANCE B2 Crankshaft pulley 1. Remove the crankshatt pulley bolt. 2. Install the crankshaft pulley and hand tighten the bolt, 3. Mount the SST on the crankshatt pulley to hold the crank shaft 4. Tighten the crankshatt pulley Delt Tightening torque: 157-166 N-m {16.0-17.0 kgfm, 116-122 flbf} P/S oil pump 1. Install the P/S oil pump, Tightening torque @ : 32-46 N-m {9.2-4.7 kgf-m, 24-93 ftibh Gf 19-25 N-m {1.9-2.6 kgtm, 14-78 ftlbf) 2. Install the P/S oit pump pulley and hand tighten the pulley HL rut. 3, Tighten the pulley nut by using a 12mm {0.47 In} socket on the P/S oil pump mount belts, Tightening torque: 3-03 Nim (6.4-9.8 kgfm, 46-69 fbf} 4. Install the P/S oil reservoir. Tightening torque: 6.9-9.8 N-m {70-100 kgf-om, 61-86.8 In-Ibf B2-21ON-VEHICLE MAINTENANCE Drive belt 1 Jnstall the water pump pulley and hand lighten the bolts. 2. install he P/S oil pump and water purnp drive belt on the ileys. 3. Siac the drive belt dettection. (Refer to page 82-6.) 4, Tighten the weter pump pulley, Tightening torque: 7.9-10.7 Nem {80-110 kgf-cm, 70-95.4 in-IbA} GENERATOR z 5. Install the A/C compressor drive bett on the pulleys, and +c é ‘GENERATOR adjust the belt deflection. (Refer to page 82-6.) cannon say Senay ‘Steps After Installation 1. Install the right front wheel. 2.Fill the radiator and coolant reservoir with the specified amount and type of engine coofant. . Perform the necessary engine adjustments. (Refer to ENGINE TUNE-U®, page B2-5.) B2-22ON-VEHICLE MAINTENANCE B2 CYLINDER HEAD GASKET Roplacement ‘Warning * Fuel line spills and leaks aro dangerous. Fuel can ignite and cause serious injuries or death ‘and damage. Fuel can also irritate skin and eyes, To prevent this, alvays complete the “Fuel Line Safety Procedures” on section F2. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to soction E2.) 3. Remove the timing belt. (Refer to page 22-12) 4, Remove in the order shown in the figure, referring to Removal Note. 5, Install in the reverse order of removal, referring 10 Installation Note. POO igrer tease ‘9-26 (281m, (ore 29-107 ¥en oot geen, baer) (eens ay a (sat B2-23B2 ON-VEHICLE MAINTENANCE 1. Fresh-air duct 8. Intake manifold assembly _15. Seal plate 2. Air cleaner assembly Removal Note page B2-26 16. Water outlet 3. Battery and cartier Installation Note 17-Exhaust pipe 4, Accelerator cable seseeeeeee page B2-84 18.Engino hanger installation Note 10. Distributor 19. Camshaft cap and oil seal ange B2-86 Installation Note Removal Note page 82-27 eTrotieabieIX nan page B2-83 installation Note (nstatiation 11. Cylinder head cover coos page B2-80 Agjustment ...... section k " Removel Note page B2-26 20.Camshatt” 6. High-tension lead Installation Note installation Note 7. Hamess page B2-33 --.- page B2-30 Removal Note page 82-25 12. Camshaft pulley 21.Cylinder head batt Installation Note Flemoval Note page 82-27 Rlemoval Note page B2-28 . +++ Page 82-36 Installation Note 22. Generator strap 8. Hoses page 82-2 28. Cylinder head Removal Note page 82-25 13. Rac Installation Note Installation Note 1. Ho, 3 engine mount bracket page 82-20 secssseeses page 82-35 Removal Note page 82-27 24.Gyinder head gasket and O- Installation Note ting toveestenes page B2-31 B2-24ON-VEHICLE MAINTENANCE B2 Removal Note Harness: Disconnect the harness connectors shown. Lore WATER TERIPERATURE SENDERUNTT 7 o IS OIL PRESSURE SWITCH VAIS. SOLENOID VALVE = HEATED GXY@EN SENSOR, EGR SOLENOID VALVE (VENT) FOR SOLENOID VALVE (VACUULA, (RGTTLE POSITION SENSOR, \ ENGINE COOL FURLINECTOR TePenaTORE Sense x (PCM) Sea Top aR OORTRON VALVE HEATEG OXYGEN SENSOR UPPER. RADIATOR HOSE B2-25B2 ON-VEHICLE MAINTENANCE B2-26 Fuel hose Warning * Fuel lino spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam- age. Fuel can also irritate skin and eyes. To prevent ‘this, always complete the “Fuel Line Safety Proce- dures” on section F2. Plug the disconnected hoses to avoid fuel leakage. Intake manifold assembly 4, Temporarily install the No.3 engine mount bracket to sup- port the engine. 2. Remove the SST installed for the timing belt removal. 3. Remove the intake manifo'd stay. 4, Loosen tie mounting bolts in two or thrae steps. Cylinder head cover 1. Remove the cylinder head cover bolts. 2: Disconnect the ventilation pipe (left cylinder head) 3, Remove the cylinder head cover.ON-VEHICLE MAINTENANCE B2 Camshaft pulley 1. Hold the camshaft by using a wrench on the cast hexagon ‘as shown, and loosen the camshaft pulley lock bolts. 2. Remove the camshatt pulleys. No.3 engine mount bracket 1, Install he SST and support the engine, 2. Disconnect the No.3 engine mount bracket from the en- gine mount rubber. 3. Ramove the No.3 engina mount bracket from the engine. Camshaft cap and oil seal Caution © When the front camshaft lobe is pressing on the HLA, removing the camshaft caps can damage the cylinder head thrust journal support. Perlorm this same procedure for the right and left oylinder heads. 4 Tum the camshatt clockwise by using a wrench on the cast hexagon and align the camshaft Knock pin and cylin der head marks as shown. 2, Loosen the front camshait cap bolls in five or six steps in the order shown. 3. Remove tha front camshaft cap. Note Bott © fits only for right cylinder head. B2-27ON-VEHICLE MAINTENANCE Note * Belore removing the camshaft caps, note their loca ions. 4, Loosen the camshaft cap boils in five or six steps in the order shown, 5, Remove the camshait caps. Caution # Remove the thrust cap only after removing all cam- shalt caps. Otherwise, the thrust cap can be dam- aged, Cylinder head bolt 1. Temporarily install the No.3 engine mount bracket to sup- port the engine. 2. Remove the SST. ‘3. Loosen the cylinder head bolts in two or three stepsin the order shown, 4, Remove the cylinder head bolts.ON-VEHICLE MAINTENANCE B2 1387-1943 mm (6.284 5.287 in} Installation Note Cylinder head 1, Measure the amount of oil contro! plug projection from the eck of the cylinder black, Projection: 8.0-9.0 mm {0.315-0.354 in} 2. Apply clean engine oll to new O-rings and install them to the cil control ge 9. Thoroughly remove all dirt oil, and other material from the decks of the cylinder block. 4, Turn the crankshaft clockwise and appiy engine oll to the cylinder walls, 5, Place a new cylinder head gasket (marked L) on the left bank. 6. Place anew cylinder head gasket (marked ®} on the right bank, 7. Instail the cylinder heads to the cylinder lock. 8, Tighten the cylinder head bolts as described below. (1) Before installation, measure the length of each batt. Replace the boit if it exceeds the maximum length. Length: 183.7—134.3 mm {6.264-6.287 in} Maximum: 135.0 mm {5.315 in} (2) Apply clan engine ollto the threads and the seat face: of each bolt, and instell them and the washers. (8) Tighten the bolts in two or three steps in the order shown. Tightening torque: 23.1-26.9 Nun {2.35-2.65 kgt-m, 17.0-19.4ft bf} (4) Puta paini mark on each bolt head. {8} Using the marks as a reference, tighten the bolts by turning each 85° 95° in the sequence shown. (6) Further tighten each bolt by tuming anather 85°-95°. B2-29B2 ON-VEHICLE MAINTENANCE 2. Support the engine by using ihe SST. 10. Disconnegl the No.3 engine mount bracket. 11. Remove the No.3 engine mountbracket from the engine. Camshaft Caution * Camshafts must be assembled in the following procedure, Otherwise, camshaft can be broken or damaged because there is little camshaft thrust clearance. 1. Apply a liberal amount of clean engine oil to the journals, cam lobes, and camshatt gears. 2.Align the timing mars of intake camshaft and exhaust ‘camshaft, 3. Install the camshafts on the eyfinder head. Note © The thrust plate positions for the right! and laft cylinder head camshafts are different, Camshaft cap and oil soal 1. Remove the oil, dt and other foreign material from the mating surfaces between the tront camshaft cap and the ‘oylinder head, and degrease. 2. Apply silicone sealant to the shaded areas shown. Caution © Install the thrust caps first. Otherwise, camshaft can be broken or damaged. 3. Instaii the thrust cans onto the cylinder heads. Hand light- ‘en the bolts in five or six steps in the order shown, until the camshafl caps fully seated on the cylinder head.ON-VEHICLE MAINTENANCE B2 4. Install the camshatt caps, and hand tighten the camshatt cap batts. 5. Tighten the camshaft cep bolts gradually in five or six steps in the order shown. Tightening torque: 11.3142 Nm {115-146 kgf-om, 100-126 intbh} 6, Retighten the bolts in the order shown. Tightening torque: 11.3-14.2 N.m {118-445 kgf-cm, 100-128 in-Ibf} 7. Install the distributor cap. (LH cylinder head} Tightening torque: 41.3-44.2 Nm (118-145 kgf-cm, 100-128 in-Ibf 8. Apply alight coat of clean engine illo the new oll seal and the cylinder read. the cartshatt oll seal into the cylinder head by using a IT and a hammer. EOGOES Protrusion: 0-0.5mm {0-0.019 ing 10. Tap in the new blind cap by using a plastic hammer. No.3 engine mount bracket 1. Install the No.3 engine mount bracket to the engine. Tightening torque: 44-60 Nem (4.4-6.2 kgf m, 92-44 fbf) B2-31B2 ON-VEHICLE MAINTENANCE B2-32 2. Temporarily install the No.3 engine mount bracket to the engine mount ruber. 3. Remove the SST. Camshaft pulley 4. Install the RH camshaft pulley so that the “R” mark can be Been anche iming mark ago wih the camshaft knock ia. 2. Install the LH camshatt pulley so that the “L” mark can be seen and the timing mark aligns with the camshaft knock pin, 3. Apply clean engine oil to the look bolt threads and tempo- rarly tighten the camshaft pulley lock bol, 4. Hold the camshaft by using a wranch on the cast hexagon as shown, and tighten the camshaft pulley lack bolts. Tightening torque: {23-140 Nem {12.5-14.9 kgm, 91-109 ftbf}ON-VEHICLE MAINTENANCE B2 Cylinder head cover 1, Remove all old silicone sealant from the cylinder head and cover. 2.Apply silicone sealant to the cylinder head cover as shown. 3. Remove all dirtand other material from the cylinder head, and apply sealant as shown. 4. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown. Tightening torque: 5,0-8.8 Nan (50-90 kgt-om, 44-78 in, thf} 5. Ratighten the bolts. (RH @ ©, LH © @) Tightening torque: 5.0-8.8 N-m {50-90 kgt-cm, 44-78 in-Ibf} 6. install the ventilation pipe to the let! cylinder head cover. Tightening torque: 7.9-10.7 Nem {80-110 kgf-om, 70-95.4 in-Ibf} Distributor 1-Aply clean engine ol to sew O-ring and pasion it on the distributer 2. Apply clean engine cil othe dive blade. 3. Align the matching marks on the distributor body and the camshaft gear. B2-33B2 ON-VEHICLE MAINTENANCE B2-34 4. Instat! the distributor with the blade fit into the camshaft ‘groove. §. Fland tighten the distributor mounting bolt. Intake manifold assembly 1. Install a new gasket and the intake manifold. Hand tighten the bolts and nuts. 2. Install the intake manifold stay. Tightening torque: 19-25 Nem {1.9-2.6 kgt-m, 14-18 ft-lof} 3. Tighten the boits and nuts in two or three steps. Tightening torque: 19-28 N-m (1.9-2.8 kgf-m, 14-18 feibf}ON-VEHICLE MAINTENANCE B2 Hoses Connect the hases shown, i - ws & »y VENTILATION HOSES Le \ BRAKE VACUUM KOBE FUEL HOSES: LOWER RADIATOR HOSE: B2-35B2 ON-VEHIGLE MAINTENANCE Hamess: ‘Connect the hamness connectors shown, YP piso Fogasune sare Accelerator cable 1. Install the accelerator cable, 2. Adjust the cable deflection by tuning nuts @. Free play: 13mm {0.04-0.11in} Steps After Installation 1. Install the timing belt, (Refer fo page B213.) 2. Fill the radiator with the specified amount and type of engine coolant. (Refer to section £2.) 3. Start the engine and (1) check the engine oil and engine coolant leakage. (2) check the ignition timing and idle speed. (Ftefer to pages B2-6,9.) (8) check the operation of ihe omission control system, (Reler to section F2.) 4. Recheck the engine coolant and off levels. B2-36ON-VEHICLE MAINTENANCE B2 HLA Removal / installation 1. Disconnect the negative battery cable. 2. Remove the timing belt. (Refer to page B2-12.) 3, Remove in the order shown in the figure, referring to Removat Note. 4. Install in the reverse order of removal, referring to Installation Note. 10-25(1.002.6, 14018) so-aenm 450-20 kgf-em, 44-78 int 1925 (1.92.5, 14-48), 508th 90 torn, 44-76 into 113-442Nm 25-148 Kerem 190-426 19-25(1.0008, 1418) 123-140 (126-14.3, 81-106) Nem flgtm, fb) B2-37B2 1. Accelerator cable installation Note 2. Throttle cable (ATX) Adjustment . .. 3. High-tension leads 4, Hamess and hoses » page B2-36 Removal f installation Note ........ below 5, Intake manifold assembly Ramoval Note .. « page 82-28 installation Note + page 82-34 6. Cylinder head cover Fismaval Note ... page 32-28 installation Note page 82-23 Removal / Installation Note Harness and hoses ON-VEHICLE MAINTENANCE 7. Distributor Installation Note 8, Camshe#t pulley Removal Note Installation Note $, Gamshait cap and oil seal Removal Note Installation Note 10. Camshatt installation Note 11. HLA Inspection ... page B2-33 page B2-27 page B22 » page B2-30 page B2-80 1. Disconnect the hamess connectors and hoses shown. 2. Connect the harness connectors and hoses in the reverse order of disconnection. HARNESS waTeR TEMPERATURE, SENDER UNIT ENGINE COOLANT. TEMPERATURE SENSOR (ELECTRIC COOLANT Fan -VRIS SOLENOIO VALVE ~ HEATED OXYGEN SENSOR EGR SOLENOID VALVE (VENT) EGR SOLENCIO VALVE (VACUUM) THROTTLE FOSITION SENSOR B2-38ON-VEHICLE MAINTENANCE B2 or seb HOSES ‘Steps After Installation 1. install the timing belt, (Refer to page 82-13.) 2. Fillthe radiator witn the specified amount and type of engine coolant. (Refer to section E?.) 3. Start the engine and (1) check the engine oil and engine coolant feakage. {2} check the ignition timing and idle speed. (Refer to pages B2-8, 2.) (8) check the operation of the emission contre! system. (Refer to section F2.) 4. Recheck the engine coolant and cil levels. B2-39B2 FRONT OIL SEAL Roplacement 1. Disconnect the negative batiery cable. ON-VEHICLE MAINTENANCE 2. Remove in the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, reterring to Instaitation Note. 1. Timing belt Removal / Installation . 2. Timing belt pulley Removal Noi Installation Note page B2-13 page 82-41 page B41 B2-40 3.Ollseal Removal Note page 52-41 Installation Note. page B2-41ON-VEHICLE MAINTENANCE B2 ‘Steps After Installation ‘Start the engine and check the following. © Ignition timing (Refer to page B2-8.) Removat Note Timing belt pulley Note © If necessary, remove the pulley with a steering wheal puller. 1. Remove the timing batt pulley. 2, Remove the crankshaft key. Oil seal 4. Cut the oil seal lip with a razor knife, 2. Remove the olf seal by using a screwdriver protected with arag. Installation Note Oil seal 1. Apply clean engine cil to the lip of a new oil seal 2. Push the oil seal slightly In by band. 3, Tap the oil seal in evenly with a pipe and a hammer. Protrusion: 0-0.8mm {0-0.019 in} Note # Oil seal outer diameter: 48.0 mm {1.89 in} © Oil seal inner diameter: 34.0 mm {1.34 in} Timing belt pulley 4. Install the timing belt pulley. 2. Install the crankshalt key with the tapered side toward the oll pump booy. B21B2 ON-VEHICLE MAINTENANCE REAR OIL SEAL Replacement 1. Disconnect the negative battery cable. 2. Remove In the order shown in the figure, referring to Removal Note. 3. Install in the reverse order of removal, referring to Installation Note, MIX 18-281.8-27,14-19) Nom thgtem, fa 1. Transaxle 4. Drive plate, bagking plate, adapter (ATX) MD Removal Note below + Section J2 Installation Note - B23 x Removal /instafation . AIX 5. Gil seal Femovel / Installation section K Removal Note. page 82-43 2. Clutch cover, clutch disc installation Note . age B2-43 Service . section H 3. Flywheel Removal Nate :balow Installation Not B2~43 Removal Note Flywheel (MEX) 1. Hold the fiywheel by using the SST. 2, Remove the flywhee| mounting bots. 3. Remove the fywhee!. Drive plate (ATX) 1. Hold the drive plate by using the SST. 2. Remove the lock bolts. 3. Remove the backing plate, drive plate, and adapter. CETTE B2-42ON-VEHICLE MAINTENANCE B2 ADAPTE DRIVE FLATE BACKING PLATE Oil soal 1, Cut the oil seal lio with a razor knife. 2, Remove the oil seal by using a screwdriver protected with arag installation Note Oil seal 1. Apply clean engine oil fo the lip of the new oil seal. 2. Push the off seal slightly in by hand. 3. Tap the oil soal in evenly with the SST and a hammer. Protrusion: 0-0.7mm {0-0.03 in} Flywheet (MTX) 1. Set the flywhzel onto the crankshaft. 2. Hand tighten the lock bolts. 3, Hold the fiywheel by using the SST. 4. Tighten the bolts In two or three steps in the order shown. Tightening torque: 81-87 Num (6.2-89 kof-m, 45-49 tb} Drive plate (ATX) 4. Install the adapter, drive plate and backing plateas shown and hand tighten the lock bolts. 2. Hold the drive plate by using the SST. 3. Tighten the bolts in two or three steps in the order shown. Tightening torque: ster Nim (2°89 kaf.m, 45-49 fb Steps After Installation Siarl the engine and perform engine adjustments as nec essary. B2-43B2 REMOVAL REMOVAL Warniny + Fut line spitis and leaks are dangerous. Fuel can ignite andi cause serious injuries or death and damage. Fue! can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Satety Procedures” on section F2, PROCEDURE 1, Disconnect the negative battery cabie. 2. Drain the engine coolant and transaxle oil. 3. Remove the hood and front wieals. 4, Remove in the order shown in the figure, referring to Removal Note. Step 1 1. Splash shield 41. Shroud upper panel 2. Fresh-air duct 12. Radiator and coolant fan assembly 8. Air cleaner assombly 18. Drive belt 4. Coolant reservoir Romoval 2.2... page B2- 7 5.Battery duct 14S ol pune 6. Battery and carrier Removal Note .............. page B2-45 7. Accelerator cable 15. A/C compressor {if equipped) 8. Radiator hose Removal Note ... «+ page B2-46 9. Oil cooler hose (AEX) 16.Contro! cabte (ATX) 10. Cootant fan motor connector B2-44REMOVAL B2 Removal Note PIS oil pump 1. Disconnect the P/S oil pump hose from the engine. 2 Disconnect the steering pressure sensor connector. 8. Remove the bolts shown and secure the P/S oil reservoir away from the engine. 4. Loosen the pulley nut as shown, 5. Remove the pulley. 6. Remove the bolt shown, 7. Remove the bolts shown and remove the P/S ail pump. 8. Position the P/S oll pump away fram the engine and se- cure it with wire, B2-45B2 REMOVAL AIC compressor L 1. Reeve the A/C compresor with the hoses still con- Hi \ 2, Bostton the cocpressor away ftom the engine end 9¢- ure with wire, Step 2 Disconnect the hamess connectors shown. ENGINE COOLANT, TEMPERATURE SENSOR (ECM) VAIS SOLENOID VALVE WATER TEMPERATURE os ‘SENDER UNTT EATED OXYGEN SENSOR THROTTLE POSITON SENSOR CBANKEHAFTPQSITION ‘SENSOR SR SOLENOID VALVE (VENT) GROUND GR SOLENOID YALVE (VACUUM) FUBLINJECTOR GeNeRaZOR " y ue Aockyag.vave OWL PRESSURE SwITgH DISTAL ete — - — ee} B2-46Step 3 Disconnect the hoses shown, REMOVAL B2 HEATER HOSES: Ge MUSE Removal Note Fuel hose ‘Warning * Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. * Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and dam- age. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Proce- dures” on section F2. Disconnect the fuel hoses. Heater hose Press the heater hose retainer tabs and remove the heal- er hoses, B2-47B2 REMOVAL Step 4 REPLACE SELF LOK OT, REPLACE 2 ® 1. Clutch ralease cylinder (MTX) 7. Tié-tod end ball joint Removal Note .. Removal Note ....eeec0+2++ page B2-49 2. Transverse member 8, Engine mount member 3. Exhaust front pipe Removal Noto .....6..0202+ page B2~49 4. Shift control rod (MTX) 9. Drive shaft Removal Note .........-2-+ page B2-49 5. Extension bar (MTX) 6. Stabilizer control link Removal Note ‘Clutch release cylinder (MTX) "-Unbot the release cyinder pls brackets trom the trans le. ‘Caution © Bending the pipe can cause kinks or cracks. 2. Remove the release oylinder and position itaway from the transaxle with the hose still connected.REMOVAL B2 Tie-rod end ball joint 1, Remove the cotter pin and toosen the nut so that itis flusn with the end of the bali joint stud. 2, Separate the knuckle arm and ball joint by using the SST. Engine mount member Warning # Removing the member without first suspending the engine can cause the engine to tift or fall and cause injury. Suspend the engine properly before removing the member. 1. Suspend the engine by using a chain block, 2. Remove the No.1 and No.2 engine mount nuts. 3. Remove the engine mount member bolts and nuts and re- move the engine mount member. Drive shaft Remove the bolts and nuts atthe left and tight lower arm ball joint, Caution © The ball joint dust boots and oil seals are damaged easily If this procedure Is not done correctly. Remove the joint shatt. 2. Pry the lower arms downward to separate them from the knuckles. 4. Separate the drive shafts from the transaxle by prying with @ bar inserted between the shaft and the case. B249B2 REMOVAL Step 5 1.. No.3 engine mount rubber 3. Engine and transaxle essembly 2. No.4 engine mount rubber and bracket Removal Note ....2.0eeseseeeeeee below Removal Note Engine and transaxle assembly Mt the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into compo- nents in the éngine compartment. Lift the engine and transaxle assembly out as a unit.B2 REMOVAL Step 6 8. Transaxle mounting bolts 1. Starter 2. Throtiia cable (ATX) 7, Manual iransaxto (MTX) 3.No.2 engine mount rubber and bracket 8, Automatic transaxle (ATX) 4. Seal plate 9, Engine assembly 5, Torque converter nuts (ATX) B2-51B2 ENGINE STAND MOUNTING ENGINE STAND MOUNTING PREPARATION SsT ‘80107 680A For ‘@Lo10 140 For oe PO | Eosen a Engine stand assembly of Hanger so, Bry | 2semaly ot eare mrave cad B | Sone spvott 01 Fr apto%o 102 For Easserly and oy Emassemby ara te sseeribal | Arm scoorny Pate ogre Poet orgie 49 L010 tA0) 43.L010 140) 291010708, ie souotoros fer = disassembly and cisascembly anc oa lf scone 2" | sue coonsyal Partor ogre Part crane 49 L010 1A0) 49 L010 1A0), so1010 105 fer «91010105 For disassembly and disassembly and Bolt assemaly oF Bott assembly of (Pato enging. (Part of engine 49 LOI 1A0) 49 L010 10) sn eor0 tad For 49 £010 101 for ‘eosomtiy ond ascenyane Haagor ct eon | Body Soon engine engine (Part of engine 49 E010 1A0) 49 €010 102 For 49 ECI0 IAT For disassembly and re disassembly and Batt assombly of Hanger sel, ongine ESS oe | asses ot Patt ngine && | crane SSE DTO x40 COS oes, 49 E010 108 fer 48£010 102 ter disassembly ard &h, © | Sossortiy are Hanger ascenbiyol | Bolt © | sssenisvot (Par ot engine iPartof engine G83 san Cuan © 29 E010 108 fer disassembly and Bot soontiyol acat came SSEetosan B2-52ENGINE STAND MOUNTING B2 PROCEDURE ‘When using 49 E010 1A0 1, Remove the right exhaust manifold insulator, 2. Remove the EGR vaive bolts. 3. Remove the right exhaust manifold and gasket together with the EGR valve and pipe. 4. trstall the SST al tha positions shown. 5. Mount the engine on the SST. When using 49 E010 141 and 49 L010 1A0 1. Remove the right exhaust manifold insulator. 2. Remove the right exhaust manifold and gasket, 3. Install the SST as shown. pai B2-53B2 ENGINE STAND MOUNTING ENGWNE wasien NUT LESS THAN nur eA LESS TaN B2-54 4. Install the SST (arms) to the holes as shown, and hand tighten the 8ST (Bolts). 5. Assemble the SST (bolts, nuts and plate) as shown inthe figure. 6. Install the SST assembled in step 5 to the SST installed in step 4. 7. Adjust the SST (bolts) so that loss than 20mm {0.79 in} of ‘thread is: eposed. 8. Make the S§T (plale and arms} peralie! by adjusting the SST (bolts and nuts). 9. Tighten the SST {bolts and nuts) to affix the SST firmly. 10. Mount the engine on the SST. Coolant Draining 1. Attar installing the engine to the engine stand, disconnect ‘he oil cooler hoses as shown in the figure (left cylinder head).ENGINE STAND MOUNTING B2 2. Remove the blind cover and drain the engine coolant. 3. After draining the coolant, install a new O-ring to the blind ‘cover. Tightening torque: 19-25 Nim (1.9-2.6 kgfm, 14-18 fib B2-55B2 DISASSEMBLY DISASSEMBLY PREPARATION Sst 1 #9 censt006 ree 461011 9908 fer Ar ounce of in ite of rm, veh Tuliténat [Totes A. gfe | eehaton ‘pring iter valves piaton pin eating! & 2s piston pina wee sso sot foe ao.on 008 rer reo! foo Body support instafiation of Installer, piston installation of Dh piston pine pin. piston pins Bator Part foot 9908 SStbtt ono sseon oe fee 490011 0028 For ronal Fear Sorow installation of | Head, support installation of piston pins: block piston pins: (Patof Gost os soeonan foe soaoissat Fer Popova ‘ror Gato, pte Fedataten ot | Wien, tiation of oe feet | Siete ier AQ HOGS 001 For 499120 170 For fool Kerovalof Wrench, instaltation of Remover, valve seals: Bo ene eckson | wave sel soe0H1 10 For s9011 408, rer prevention of prevention of Brake se, Santon | at Benoret iragear rton thatot ace ES s10y w@ sse0rt 104 fer 98017105, rer Prevention of prevent of Cota Berean | stopper Serer Patet cmon eae roan 49 £017 1A0) 49 E011 1A0) 49 6012 CAR For 498012 012 For fonoud/ renova Pht fractiainet | Bey Ielaton of anes trator wee 49 BO12 042) B2-5649 BO12 013 Foot instalation of anot valves 49 B02 OA2) 49 B12 014 Lockmut ant of 498072 942) 1.Code or arrange all identical parts (such as HLA, pistons, piston rings, connecting rods, and valve springs) so thai they ean be reinstaitad in the cylinder from which they were removed. 2. Clean the parts by using a steam cleaner. Blow dry with compressed air. ‘Wamins + Continuous exposure with USED engine ol has caused skin cancarn faboratory mice. Protect your skin by wasing with soap and water immediately after this work. B2-57B2 DISASSEMBLY AUXILIARY PARTS: 1. Remove the oil drain plug and drain the engine oil. After draining the engine cil, install the oil drain plug. Tightening torque: $0-41 N-m {3.0-4.2 kgm, 22-30 ftbh, 2, Disassemble in the order shown in the figure, referring to Disassembly Note. 1. AC compressor bracket 7. Intake manifold assembly 2. Genarator 8. Engine hanger 8: Braoket ard tensioner $. Spark plug 4, Extiaust manifold insulator(LH) 10.011 fitter 5. Exhaust manifold(LH) Disassembly Note ........... page B2-69 6. Distributor and high-tension lead B2-58ETT DISASSEMBLY Disassembly Note Remave the oil filter by using the SST. B2 B2-59B2 DISASSEMBLY TIMING BELT Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Crankshaft pulley 8. Timing belt Disassembly Note .......... page B2-81 Disassembly Note .......... page B2-61 2. Water pump pulley 9. Timing bet: auto tensioner 9. Dipstick and pipe 10. Tensioner pulley 4, Crankshaft position sensor 11. No.2 idler pulley 5, Timing belt cover (LH) 42.No.1 idler pulley 6. Timing belt cover (RH) 18, Timing belt pulley 7. No.3 engine mount bracket Disassembly Note = page 32-64 B2-60DISASSEMBLY B2 Disassembly Note Crankshatt pulley ‘Hold the Rye! (ATX) or dive plate (ATX) By using the 2. Remove the pulley bolt. 8. Remove the crankshaft pultey. Timing belt 1. Temporarily install the crankshalt pulley dott, 2.Turn the crankshaft clockwise to align the timing marks of ‘the pulleys. 3, Mark the timing belt rotation for proper reinstaltation, Caution © When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged. 4, Remove the auto tensioner bolts gradually in five or six steps in the order shown, Caution * The following will damage the belt and shorten its life; Forcefully twisting it, turning It inside out, bending it, oF allowing ofl or grease on it, 5. Remove the timing bell, Timing belt pulley 1. Remove the timing belt pulley. 2. Remove the crankshaft key. Note ® If necessary, ramave the pulley with a steering wheel puller. B2-61B2 ISASSEMBLY CYLINDER HEAD Disassemble in the order shown in the figure, referring to Disassembly Note. 1. Cylinder head cover 2 Camshaft pulley Disassembly Note Inspection ......4.4 3. Seal plate 4. Water outlet 5, Camshaft cap Disassombly Note .. 6.Blind cap 7. Camshaft Inspection 8, Camshaft oil seal 9 HLA Disassembly Note Inspection B2-62 . page B2-63 * page B2-85 ++ page 22-63 .. page B2-64 » page B2-64 + page B2-80 10. Cylinder head bolt Disassembly Noto... +6 page B2-64 11, Cylinder head Inspection ... 12. Cylinder head gasicet 18. Valve keeper Disassembly Note .......... page B2-64 14. Upper valve spring seat 16. VeWve spring Inspection -... 16. Lower valve spring se 47. Nalve Ingpection 18. Valve seal Disassembly Note .......--- page B2-65DISASSEMBLY B2 Disassembly Note ‘Camshaft pulley 1. Hold the camshaft by using a wrench on the cast haxa- gon. 2. Remove the camshaft pulley bolts. 3, Remove the camshaft pullays, Camshaft cap 1. Align the camshaftknockpinas shownto reduce the pres- sure of the HLA, Caution © When the front camshaft tobe is pressing an the HLA, removing the camshaft caps can damage the cylirider head thrust journal support, 2. Loosen the front camshatt cap bolis in five or six steps in the order shown. 3. Remove the front camshatt cap. 4, Loosen the camshaft cap bolts in five or six steps in the order shown. Caution © Remove the thrust oap only after removing all cam- shaft caps. Othernise, the thrust cap can be dam- aged. 5, Remove the camshaft caps. B2-63B2-64 DISASSEMBLY Note * Before removing the camshaft caps, note their loca tions, They are identified as follows; Right head: numbers Left heed: letters. Camshaft Inspect the following when removing the camshatt. 1. Camshatt end play (Refer to page B2-79,) 2, Camshatt journal ail clearance (Refer to page -79,) HLA Caution © The HLA must bo reinstalled in the same positions from which they were removed. ff they are not, it can cause premature and uneven wear. Note © Mark the HLA to show their original positions. J. Remove the HLA from the cylinder head. 2. Store the HLA upside down in an oililled container. Cylinder head bolt 1, Loosen the cylinder head bolts in two or three steps in the order shown in the figure. 2. Remove the cylinder head bolts. Valve keeper 1. Set the SST against the upper valve spring seat as shown. 2. Compress the spring and remove the valve keepers.DISASSEMBLY B2 Vatve seal Using the SST, remove and discard the valve seal. B2-65B2 DISASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Disassemble in the order shown in the figure, referring to Disassembly Note, 1. Cluich cover, clutch disc (MTX) 7. Oil pan Disassenbiy Note . Disassembly Note .......4++ page 82-68 2. Flywheel (MTX) 8. Oilstrainer Disassembly Note . 8. Oil baffle 3. Backing plate, drive plate, fapter 10, Water pump Disassembly Note . 11.08 pump 4, Oilcooler and of fier body 12, Front oil seat Disassembly Note ...-..-..- page B2-68 5. Water pipe and thermostat housing Disassembly Note ss» page B2-67 6. Knock sensor Disassembly Note .......... page B2-68 B2-66DISASSEMBLY B2 Disassembly Note Clutch cover, clutch disc (MTX) 1. Hold the flywheel by using the SST. 2. Remove the clutch cover bolts in two or three steps. 3. Remove the clutch cover. 4, Remove the olutch caver and disc. Flywheel (MTX) 3. Hold tho flywheel by using the SST, 2. Remove the flywheel bolts in two or three steps in the or- dar shown. 3, Remove the flywheel. 4. Remove the SST. Backing plate, drive plate, and adapter (ATX) 1. Hold the drive plate by using the SST. 2. Remove the drive plate bolts in two or three steps. (Refer to above.) 8. Remove the backing plate, drive plate, and adapter. 4, Remove the SST. Water pipe and thermostat housing 1. Disconnect the clip and separate the knock sensor har- ness from the water pipe. 2. Remove the waterpipe and thermostat housing as an as sembly. B2-67DISASSEMBLY Knock sensor Remove the knock sensor by using the SST. Oil pan 7. Remove the oil pan mounting volts. 9. Remove the old sealant from the bot threads. 3. Turn aboltinto the boll beie as shown to make 2 sali gap: between the oli pan and the lower cylinder block, 4. Separate the oil pan trom the lower cylinder block by using a sorew driver or suitable tool. Front oll seat Remove the cil seal by using a screwdriver protected with, arag. B2-68DISASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) B2 Disassemble in the order shown in the figure, referring to Disassembly Note, 1. Connecting rad cap Disassomoly Note ........... page B2-70 2. Lower connecting rod bearing Inspection ...............--. page B2-84 8. Piston and connecting rod assembly Disassembly Note ........... page B2-70 4, Piston ring Disassembly Note . - page 82-70 Inspection + page B2-82 5, Piston pin Disassembly Note . = page B2-70 Ingpection 2.) * page B2-82 8. Connecting rod Disassembly Note - ses page B2-70 Inapection .... “page B2-83 Inspection .........2....+2.- page B2-8t 8. Lower cylinder block Disassembly Note .. -- page B&-71 9, Lower main bearing and thrust bearing 10.Crankshaft ingpection page .... -- B28, 11. Rear oil soa 12.Upper main bearing and thrust bearing 18.0 jet Inspection «+ page B2-84 14. Gylinder block Inspection... eee e cee page B2-81 B2-69B2-70 DISASSEMBLY Disassembly Note ‘Connecting rod cap Before removing the connecting rod caps, measure the connecting rod side clearance. (Refer to page 52-95.) Piston and connecting rod assembly 1. Before removing the piston and connecting rod assembly, measure the connecting rod bearing oil clearance by us- ing Plastigage. (Refer to page B2-94.) 2. Remove the Plastigage from the crank pin journals. 3, Use the handle of a hammer to push the piston and con- nealing rod aesambly through the top of the cyfiner Piston ring Remove the piston rings by using a piston ring expander. Piston pin Caution ® The connecting rods must be reinstatled in the ‘same positions from which they were removed. If they are not, it can cause premature and uneven wear. Note ‘ Mark the connecting rods to show their original posi- tions. 1.Before disassembling the piston and connecting rod, check the oscillation torque as shown. Ifthe large end does not drop by its own weight, repiane the piston or the piston pin.= = 2 POTEET DISASSEMBLY B2 2. Use the fotlowing SSTs shown in the figure and a press. 8. Insert the $8T into the piston pin as shown, 4. Verify that the SST fits squarely into the piston bafere pressing. 5. Set the piston and connecting rod on the SST as shown. 5. Prass out the piston pin, While removing the piston pin, check the pressure. Ifitis lower than 4,903 N {500 kgf, 7,100 Ib), replace the pis- ton pin or connecting rod. Lower cylinder block 1, Before removing the lower cylinder block, measure the crankshatt end lay. (Refer to page B2-92.) B2-71B2-72 DISASSEMBLY 2. Loosen the cylinder block bolts and crankshaft cap bolts in two or three steps in the order shown in the figure. 3.insert a screwdriver only at the points shown and pry loose the lower oylinder block. Caution * Donotuse a seraper to separate the cylinder block sections. Itcan easily scratch the contact surfaces. 4, Tap the lower cylinder block with a plastic hammer,INSPECTION / REPAIR B2 INSPECTION / REPAIR PREPARATION Sst 49 8042.005 For 49 10:2 090 ae For removal / B® installation of Remover & instalation of | Instater ect, ®* vale guides instar, valve valve guides | vavesod op. guide valve quite 491012 002 For soLor2 008 installation of instellation of Body valve quides: Instalier valve guides (Part of (Part of 49 L012 040) a9 Lave 040} 49uo2004 For instalation of fue valve quices (Patot 491.012.040) 1. Clean all parts, being sure to remove all gasket fragments, ditt, oil, etc. 2. Perform the inspections and repairs in the order spacified. CYLINDER HEAD 1. Inspect the cytinder head for damage, cracks, and leak- age of walor and oil. Ropiace if necessary. 2. Measure the cylinder head for distortion in the six direc+ tions shown. Distortion: 0.10mm {0,004 in} max. B2-73INSPECTION / REPAIR arain 4, PuicKNESS F ‘VALUE FACE| ANGLE 45° i= B2-74 8. Inspect (or the following and repair or replace the cylinder headit necessary. (1) Sunken valve seats 2) Dameged intake and exhaust manifold contaot sur- faces (9) Excessive camshait oll clearances and end play 4. ifthe cylinder head distortion exceeds the spacification, replace the cylinder head cr grind the cylinder head sur- face. Grinding: 0.18mm {0.008 in} max. 5. Hf the cylinder head height is not within the specification, replace it Height: 133.4~133.6mm {5.252-5.259 in} 6,Measure the intake and exhaust manifold contact sur- faces for distortion in the six directions as shown. Distortion: 0.10mm {0.004 in} max. 7.lf distortion exceeds the specification, grind the surface or replace the cylinder head. VALVE MECHANISM Valve and Vatve Guide 1. Inspect each valve for the following. Replace or resurface the valve as necessary. (1) Darnaged or bent stem (2) Rough or damagod face (3) Damaged o: unevenly worn stem tip 2.Measure the valve head margin thickness. Replace the valve if necessary. ‘Margin thicknoss IN: 0.9mm {0.035 in} min. EX: 1.0mm {0.039 in} min. 3: Measuré the valvetength. Replace the valvei necessary. Lengtt EX: 94,69mm {3.7279 in} 4. Measure the valve stem diameter. Replace the valve if necessary, WN; §.970-6.865mm {0.2951~0.2956 in} '5.965-5.980mm {0.2349-0.2354 In} Minimum. IN: 5.920mm {0.2331 in} EX; 5.915mm {0.2928 in} 5.Meagure the vaive guide inner diameter. Replace the guide if necessary. Inner diameter IN: 6.01-6.03mm {0.2367~0.2374 In} EX: 6.01-6,03mm {0.2367-0.2374 in}INSPECTION / REPAIR B2 VALVE STEM VALVE GUIDE ‘CLEARANCE DIMENSION & 6. Calculate the vatve stem-to-guide clearance. ‘Subtract the outer diameter of the valve stem from the in ner diameter of the corresponding valve guide, Ciearance IN: 0,025-0.060mm {0.0040-0.0023 in} EX; 0,030-0,065mm {0.0012-0.0025 in} Maximum: 0.20mm {0.008 in} 7. if the clearance exceeds the maximum, replace the valve and/or valve guide. 8. Measure the valve guide projection height (dimension A). Replace the guide if necessary. Height A IN: 14,7-15.3mm (0.579-0.602 in} EX: 12.2-12.8mm {0.481-0.503 in} Replacement of valve guide Note © The intake and exhaust valve guides are the same. 1, Remove the valve guide from the combustion chamber side by using the SST. 2. Assemble the SST so that deoth L is as specified. L IN: 14.7-15.3mm {0.579-0.602 in} EX; 12.2-12.8mm {0.481-0.503 in} 8. Tighton the nut B2-75‘SEAT GONTAGTWADTH —— 99am 8.4rim 82 or 3 fess ios ey 45° Bim Barman testi} aor B2-76 INSPECTION / REPAIR 4, Tap the valve guide in from the side opposife the combus- tion chiamber until he SST contacts the cylinder head. 5. Verify that the valve guide projection height is within the specification. (Refer to page B2-75.) 6. Ifnot, repeat steps 2—4, Valve Seat 1. Inspect tha contaet surface of each valve seat and valve face for the following: (3) Roughness (2) Damage 2. Ifnecessaty, resurtace the valve seat by usinga 45° valve seat cutter andior resurface tho valve face. 3. Apply a thin coat of Prussian blue to the valve face. 4. Check the vaive seating by pressing the valva.against tre seal. (1) If blue does not appear 360° around the valve face, replace the valve. (2) If blue does not appear 360° around the valve seat, reaurface the seat. S.Measure the seat contact width. Width: 0.8-1.4mm {0.032-0.055 in} 8. Vorily that tho valve seating position is at the center of tne valve fece. (1) if the seating position is too high, correct the valve seat with a 75° (2) Ifthe seating position is toolow, corectthe valve seat with 2 46° cutter. 7.Seat the valve tothe valve seat by using lapping com- pound.INSPECTION / REPAIR B2 DIVENSION L ia rrour-oF-souare 7, Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem, Dimension L: 41.5mm {1.634 in} (1) IfLis as below, it can be used as itis. 41.5-42.0mm {1.634—1.653 in} (2) If Lis as below, insert a washer onto the spring seat area so that L will be as specified. 42.1-43.0mm (1.658—1.682 in} (8) If Lis as below or more, replace the cylinder head, 43.4mm {1.697 in} Valve Spring 1. Inspect the valve springs for cracks and damage. 2. Check the tree length of each spring. Free length ‘Standard: 46.92mm {1.847 in} Minimum: 38.7mm {4.524 in} with a set load of 233,0-263.6 N- {28.75-26.88 kgf, 52.25-58.14 Ibf} ‘3. Measure spring pressure when the spring length is com- pressed to 35.5mm {1.398 in). Replace if necessary. 4, Check the out-of-square of the springs. Replace as nec- essary. Qut-of-square: 1.63mm {0.064 in} max. B277B2 B2-78 INSPECTION / REPAIR. CAMSHAFT 1. Visually inspect the helical gears andthe friction gear. Ra- place the camshaft assembly ifa problem is found withthe helical gear. Repface the friction gearifa problem is found with 2, Secure the camshaft cast hexagon in a vise protected with aluminum plates. 8. Logsen the focknut and ramave the friction gear, 4-Assembla the ‘Mellon gear $0 that the matching marks align. Tightening torque: 68-78 Nem (7.0-8.0 kgf'm, 51-57 feb 5. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary. Funout: 0.02mm {0.0008 in} max. 6. Check the camshaft for wear and damage. Replace it it necessary. 7, Measure the camshaft lobe height at the two points as shown, Replace the camshait if necessary. Height IN: 42,665mm {1.6797 in) EX: 43.516mm {1.7132 in} Minimum IN: 42.465mm {1.6748 in} EX: 43.316mm {1.7054 in} 8. Measure the journal diameters in X and Y directions at the ‘wo points (A and B) as shown, Replace the camshaft If Recessary. Journal diameter sun {0 voureals Standard Minimum Wo.t (RH EX, LIN) | 25.940-26.960 25.690 and Nos {1.0213-1.0220} £10183} NoSiRHIN,LR SQ | 20575-29905 20.925 £7.1800-1.1808) 4.1781} No.2Hio 25.910-25:990 ‘25,860 {102011 208) acs 9. Measure the camshaft journal oil clearances with the HLA. removed. (1) Remove ell foreign material and oil from the journals and the camshait saddles. (2) Install the camshatts on the cylinder head.INSPECTION / REPAIR B2 Rei [IF THRUST CAP >) DisTRUBUTSR cae {8) Position Plastigage atop each journal in the journat axial direction. {4) De not rolate the camshaft when measuring the oil clearances. Caution © Install the thrust caps {RH is 4) mark, LH is [AJ mark) first. Otherwise, camshaft can be broken or damaged. {6) Install the thrust caps onto the oylinder heads, Hand tigten the bolts in five or six steps in the order shown, untl the thrust cape fully seated on the cylinder 128 (6) Install the camshaft caps onto the cylinder heads. Hanc tighten the bolts in five or six steps in the order shown, uni the camshafl cape fully seated in the cyl inder Heads. (% Tighten the bots in the order shown, Tightening torque: 11.3-14.2 N-m {115-145 kgf-cm, 100-125 In-Ibf} (8) Retighten the boits in the order shown. Tightening torque: 11.3-14.2 Nem (115-145 kgfom, 100-125 Inbf} Caution * Remove the thrust cap only after removing all am- shaft caps. Otherwise, the thrust oap can be dam- aged. (8) Loosen the camshaft cap bolts in five or six stops in ‘ihe order shown. B2~-79B2 INSPECTION / REPAIR (10) Loosen the camshaft cap bolts in five or six steps in the order shown. (61) Measure the oil clearance. ii clearance No.1, No.5: 0.040-0.081mm {0.0016-0.0031 in} No.2-No.4: 0.070-0.111 mm {0.0028-0.0043 In} laximum No.1, No.5: 0.420mm {0.0047 in} No.2-No.4; 0.150mm {0.0059 in} (12) If the oil clearance exceeds the maximum, replace the camshaft or the cylinder head, 10. Measure the camshaft end piay, If it exceeds the maxi- mum, replace the camshaft or the cylinder head. End play: 0.05-0.10mm {0.0020-0.0039in} Maximum: 0.14mm {0.0055 in} HLA 1.With the HLA filled with engine oil, hold @ and press @ by hand. li moves, replace the HLA~-do not attemptto re~ pair it. B2-80INSPECTION / REPAIR B2 2.Measure the HLA bures inX and ¥ directions at two points (A and B) as shown, Distortion: 30.000-30.025mm {1.1811—1.1820 in} 3.Measure the HLA diameters in X and Y directions at two points (& and B) 2s shown, Diameter: 29.959-29.975mm (1.1795—1.1801 In} 4.Galculate the cleatrance between the HLA dlameter and the related HLA hare. Replace the HLA and/or eylindar head if necessary. Clearance: 0.025-0,086mm {0.00099-0,00259 in} Maximum: 0.180mmn {0.0071 in) CYLINDER BLOCK 1. Check the eylinder block for the following and repair orte- place as necessary. (1) Leakage damage (2) Cracks @) Scoring of wall 2. Using e straightedge, measure the aylinder block decks for distortion in six directions as shown, Distortion: 0.15mm {0.006 in} max. 8. the distortion exceeds the specification, rapiace the cyt indar block. 4, Measure the eylinder bores in X and Y direotions at three points (A, B, and C) as shown. Cylinder bore Base the boring diameter on the diameter of an oversize pis- ‘ton. All cylinders must be of the same diameter. tm ram fin Bore Ez Tanaer ‘Standard 75.000-15.022 (2.5658 2.0536) (0.25,0.01}oversize | 76:250-75.272 2. 9628-2.0604) 0.50 0.02} oversize | 78600-78500 (2. 9725-29733) (i) ifthe cylinder bore exceeds the standard, replace the oylindor block or robore the oylinder to oversize, (2) Ifthe difference between measurements A and Cex- ceeds the maximum taper, replace the cylinder block or rebore the cylinder to oversize. Taper: 0.022mm {0.0009 in} max, 62-81B2 INSPECTION / REPAIR 2) Ifthe difference between measurements X and Y ex- 9 ceeds the maximum out-of-raund, rebore the cylinder A to oversize. Out-of-rounds 0.020mm {0.0009 in} max. 5. the upper partot a cylinder wall shows uneven wear, re- move the ridge with a ridge reamer. © PISTON, PISTON RING, AND PISTON PIN Piston 1. Inspect the outer circumferences of all pistons for seizing and scoring. Replace as necessary. 2, Measure the outer diameter of each piston atarightangle (80°)10 the piston pin, 16.5mm {0.65in} below the oll ring land lower edge. Piston diameter mm fej oe lamoter Sander TE SOOT O28 (O0ioversize | 7520G-7E.236 BSO0C-2.9620) | CSO {0 B}oversine | TASTER SOE IT IG | 8. Measure the piston-to-cylinder clearance. Clearance: 0.028-0.056mm (0.0011-0.0022 in} Maximum: 0.43mem {0.005 in} 4. Ifthe dearance exceeds the maximum, replace the piston cr rebore the cylinders to fit oversize pistons. 5. the piston is replaced, the piston rings must also be re- placed. Piston and Piston Rings +1. Measure the piston ring-to-ring land clearance around the entire circumference ay using a naw piston ring. ‘Clearance: 0.020-0.065mm {0.0008-0.0025 in} (Top) 0.030-0.065mm {0.0012-0.0025 in} nd) 0,025-0.052mm {0.0010-0.0020 in} (Oil) Maximum: 0.15ram (0.006 in} 2. If the clearance exceeds the maximum, replace the pis- ton, 3. Inspect the piston rings for damage, abnormal wear, and breakage. Replace the piston ting if necessary. 4. Insert the piston ring into the cylinder by hand anduse the piston to push it to the bottom of the ring trave!. B2-82INSPECTION / REPAIR B2 5, Measure each piston ring end gap by using a fester gauge. Replace the piston ring if necessary. End gap Top: 0.15-0.28mm (0.006-0.011 In} ‘Second: 0.25—-0.38mm {0.010-0.014 in} Piston and Piston Pin 1. Measure the piston pin bore diameter in X and Y direc tions at four points. Diameter; 18.988-19.000mm {0.7476-0.7480 in} 2. Measure the piston pin ciameter in X and Y directions at four points. Diameter: 18.974-18.980mm {0.7470-0.7472 in} 3. Calsulate the piston pin-to-piston clearance, Clearance: 0.008~-0.026mm {0,0004-0.0010 in} 4, if the clearance exceeds the specification, replace the piston andfer piston pin. CONNECTING ROD 7. Measure each connecting rod small end bore, Diameter: 18.943-18.961 mm {0.7458-0.7464 in} 2.Calulate the interference between the smal! end bore and piston pin. Interference: 0.013-0.037mm {0.0006-0.0014 in} 3, Check each connecting rod for bending. Replace the con- necting rod if necessary. Bending: 0.0mm {0.0020 in}/S0mm {1.969 in} max. ite connecting rods repiacea the connecting rod cap, bolts,and nuts must also be raplaced because they are a matched set. B2-83B2 INSPECTION / REPAIR taatn JOURKAL, B2-84 CRANKSHAFT 1. Check the journals and pins for damage, scoring, and oil fol clogging. 2. Set the crankshaft No.1 and No.4 main journals on V- blocks. 3. Measure the crankshait runout at No.2 and No.4 journals. Repiace the crankshaft if necessary. Runout: 0.015mm {0.0006 in} max. 4, Measure each journal diameter in X and Y directions at ‘two points (A and B) as shown. Main journal Diameter: 61.955mm {2.4385-2.4391 in} ‘Out-of-round: 0,05mm {0.0020 In) max. Crank pin journal Diameter: 47.940-47.955mm {1.8874—1.879 in} ‘Out-of-round: 0.95mm (0.0020 in} max. 5. Ifthe diamater is less than the specification, grind thé jour- nals to macch undersize bearings. Undersize bearing: 0.25 {0.01 in} Undersize main journal diameter ane fin Bearing size Journal diameter 9.25 (0.07) undersize 31 65-61.705 4287-2. Undersize crank pin journal diameter am in) Bening ara Tournal Famater Ez 6. i —— 2 eS wan] BEARING Main Bearing and Connecting Rod Bearing ‘Check the main bearings andthe connecting rod bearings ot peeling, scoring, and other damage.INSPECTION / REPAIR B2 ap ee Dos ssn in Nas OIL JET Check the ol ets for clogging by applying compressed air. Replace if necessary. TIMING BELT 41, Replace the timing belt if there Is any oll or grease on it. 2, Check the timing belt far damage, weat, peeling, cracks, and hardening. Replace the timing belt if necessary. Caution © The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing olf or grease on it, TIMING BELT AUTO TENSIONER, IDLER Caution * Using cleaning fluids or a steam cleaner to clean the tensioner can dissolve the grease in its sealed bearing. 7.Use a clean, softag 9 wipe the fensionercr ier contact surieco, 2. Ifthe tensioner or idler does not rotate smacthly, replace it. 3. Itthere are silicone oilleaks, scratches or abnormal noise vihan turning the tensioner or idler, replace it, 4, Check the tensioner pulley for rough rotation and ebaor- mal noise. Replace it if necessary. 8, Check the auto tensioner for oilleakage. Replace it if nec- essary. 8. Cheok ‘the tensioner rod projection @®. Replace the auto tensioner if necessary. Projection ® (free length): 44~16 mm {0.56-0.62 in} PULLEY ‘Timing Belt Pulfey and Camshaft Pulley Inspect the teath of each pulley for wear, deformation, and other damage. Replace If necessary. TIMING BELT COVER Inspect the timing belt covers for damage and racks. Roplace if nacessary. B2-85B2 ASSEMBLY ASSEMBLY PREPARATION ssT t, aolonons {Ay Fer 49L011 Cor For SS | instalation oF Trettaten of Teal set, Pty, tala piston pin sexing SLE | Boras support black piston pins gh SONS (Partot % 49 LOM CAGE) saioit 008 for 491.011 008, For terval) Fonoual/ Bolt, stopper installation of Puller & installer installavon of Partot piston ping (Partol piston pins 49: L011 OAOB) 49 LO11 CADB) 49 For 001 Fer spot oe For forovald fomoval Guide fi installation of Screw installation of Partof mF pins piston pins Ao L014 003) aon 49.0011 oon For sa vora091 removal f removal i Hoss, Italalon of | Yona irctaeton ot ‘support block ‘piston pins knock sensor ‘knock sensor {part of Biot ano #9011 140 for sa e011 108 For Feevann of everton a Brake sei, engine rojation Shaft ‘engine rotation sing gear (Partof eon 140) 49 O11 104 For 49 E014 105 For prevention of Prevention of Collar ‘engine rotation ‘Stepper ‘engine rotation ater ae eo va Soe 140) 49101209 ayy fer 49.3601 3108 ree elation o retalaon of Instr set, on Soe @ — fvaesecte” — | cemering tol aero ave sea auroras vavve gue 491012 001 For 49 L012 002 For Frain of Fetalaton of wate HY ERD ST nay ent Gate fetes {Site ona) spur2 949) B2-86ASSEMBLY B2 401012 908 ror a9 696 7000 for Fetlion of ronova! ‘Spacer valve seals Arm, valve installation of (Parot ‘spring litter valves, Ao L0HE ony soeoi2on For sounizow2 For fonowst! roost Pivot freatitenet | Boxy Kroll of ‘hee Palo thee 49 BO12 OA2) 49 BO12013 For 49 BO12 014 For femeal anova? Foot installation of Locknut installation of (baker whee eae thee Sseoi0m Seioie ox 49.0014 001 For 49 C019 017 So) tee rororal/ Fal of vtrenc, Wasa ot | state, wearel'aa oe ote oe sa rot0 401 For wre OO. |r Peltatn of & | Fett Inataer, fontol cea | isaterst Gebel Steal testy tae ao F401 391 For a9 F401 337A for Installation of Installation of Body camshaft ol! Allachnent © ‘carnshat oll Cater Se ese Sas Soa aco) SoFsot ee) 1. Do not reuse gaskets or oil seals. 2.Clean all parts before reinstallation, 8. Apply clean engine oil to all sliding and rotating parts. 4. Replace piain bearings if thay are peeled, bumed, or otherwise damaged. 5. Tighten alt bolts and nuts to the specified torque. B2-87B2 ASSEMBLY CYLINDER BLOCK (INTERNAL PARTS) ‘Torque Specifications OVLINDER WALLS Ao hen 130-59 igtom, 27-4810 BAA 25.0 (2.96-265178-10.11 65" 15496 (b- —ts-2seceas-26s, 10-40.ge79 2547939 Kom tugtm, Rion Gonnecting Rod piston 1. Assemb the ‘SST (too! set, piston pin setting) to the pis- 2. Apply clean engine oi to the piston pin. B2-88DIMENSION FISHOLE PISTON PININSTALLER PISTONPr PISTON: CONNESTING ROD- PisTONeIN Gul STOPPER Bour SUPPORT BLO¢ ®) = ASSEMBLY B2 3. Set the SST (stopper bly sothalthe deph Lisa sect ied. Depth L: 61.4mm (2.42 in} 4. Tighten the locknut. 5. Assemble the piston and the connecting rod 6. insert the SSTs (too! set, piston pin setting) assembled in slep 1 into the piston pin hole. 7. Mount the piston and connecting rod onto the SST (Sup- port block). 8. Variy tal te SSTs fis squarely into the piston before pressing. 9. Press the piston pin info the piston and connecting rodun- tilthe SST (piston pin guide) contacts the stopper bolt. 10. While inserting the piston pin, check the pressing force. It itis less than specitied, replace the piston pin andor the connecting red. Pressing force: 3,924-12,753 N {400-1300 kgf, 880-2,860 Ibf} 11. Check the connecting red asaillation torque. (Refer to page 82-89.) Piston Ring Caution © if reusing an oil ring, it must be reinstalled in the same place and face the same direction as when re- moved. If this is not done, it can cause premature and uneven wear. Note # The upper and lower rails are the same, They can be installed with aither face upward. 1. Install tha thre piace oil rings cn the pistons. (1) Apply clean engine cil to the oil ring specer and rails, Q) Install the oilring spacer so that the opening faces up- ward. (3) Install the upper rail and lower rail. B2-89B2 S6COND RMARKS Jou rns UPPER RAL TOF RING clans. eo PISTON SPACER PIN ‘SECOND CL RING RING TOWER RAR, 06-8. 7orm (OBi7—0201 4 ® 1957~196 3am (6.44-8.57 in} 745-7 55irm (0738-0.297 np ® 11987-1863 (624-6.97 om L_________| e720 SumfAT ATR B2-90 ASSEMBLY 2. Verily thal the spacer tang separates tha rails, andthatthe rails fun smoothly in both directions. 3. Install the rings with the marks upward, 4, Using a piston ring expander, install the second ring with the scraper face downward. 5. Using a piston ring expander, install the top ring. 8. Apply a liberal amount of clean engine cil fo the piston rings, 7. Position the end gap of each ring as shown. Oil jet +. Apply thread locking compound to the oil jet threads. 2. Install the oil jets into the upper cylinder block, Tightening torque: 3.04.9 N-m {30-50 kgf-cm, 27-43 in-tbf} Crankshaft 1. Measure the main bearing oil clearances as described below. il clearance inspection (1) Remove any foreign material and oil from the foumals. and bearings, {2) Install the upper main bearings {with oil groove) and the upper thrust bearings. Note * No.4 bearing is wider than other bearings. (3) Install the lower cylinder block along with the lower main bearings and thrust bearings. (4) Measure the length of lower cylinder block bolt, Replace iti the length exceeds the maximum. Bolt @ and ® Length |: 135.7_136.8mm {6.343-5.381 in} Maximum: 138.5mm {5.459 in} Bolt Length ; 119.7-120.8mm {4.713-4.736 in} Maximum: 121.0mm {4.764 in}ASSEMBLY B2 @ ® © mae ee <5 PAINT MARKS, & 8 © 4 * rae PAINT MARKS (8) Apply clean engine oil to the bo't threads and seat faces of the lower cylincer block bolts. {6} Tighten the bolts in two or three steps in the order shown. Tightening tos Bolt ® and @ : 23.1-25.9 Nem {2.35-2.65 kgf.m, 17.0-19.1 ftibA Bolt © : 18.2-21.0 Nm {1.85-2.15 kgf, 13.4-15.5 ftbf) Note © Bolts ® have a mark 4” on each bott head. © Bolts @ have a mark“I* on each boit head. (@ Put paint marks to the lower cylinder block witich fit the ®, ®, © bol flange marks as shown. (8) Using the marks as a reference, further tighten the olts %, ®, and @ in the order shown. Main bolt @ (No.4 journals): 75° -85° Main bolt & (No.1-No.3 journals): 65° ~75° ‘Sub bolt @ : 55° -65° (9) Tighten the bolts until the mark on each bolt flange aligns with the corresponding paint mark, (10) Further tighten each bolt by performing steps (7), (8) (11) After tightening, measure the cylinder blook No.1- No.4 journal bore diameters. (12) Subtract the crankshaft joumal diameter from the bore diameter. (13) I the oil clearance exceeds the maximum, replace the bearing or grind the crankshaft and install the un- dersize main bearings. (Rofer to page B2-84,) Oi! clearance: 0.037-0.057mm {0.0015-0.0022 in} Maximum: 0.064r0m {0.0025 in} B2-91B2 ASSEMBLY (CRANK PIN Main journal diameter dards 61.938=61.955mm {2.4905-2.4391 in} 0.25mm {0.01 in} undersize: ‘61.688-61.705mm {2.4287-2.4203 In} (14) Loosen the lower oylinder block bolts in fwo or three steps in the erder shown. 2. Install the lower cylinder block as follows: (1} Install the upper thrust bearings in the upper cylinder block. (2) Apply clean engine oll to the main bearings, thrust bearings, and main journals. {3) Install the crankshaft in the upper cylinder block. (4) Remove any foreign material, oll, and sealant from the contact surfaces of the upper cylinder block and tower cylinder block. (©) Apply @ continucus bead of silicone sealant to the contact surface as shown. (6) Install the lower cylinder bleck, lower main bearings, and lower thrust bearings within five minutes of apply- ing the silicone sealant. (7) Install the lower cylinder block along with the lower main bearings and lower thrust bearings. (8) Apply clean engine oll to the threads and seat faces of the bearing cap bolts. (9) Tighten the main bolts, @ and sub bolts © as in step ‘1={6) through i-(10). (10) Tighten the lower cylinder block bolts @ in the order shown. Tightening tor To25 Nm (19-26 kgf, 14-48 ftlbfASSEMBLY B2 FRONT MARK ao. 3. Measure the crankshaft end play. End play: 0.080-0.282mm (0.002-0.0111 In} Maximum: 0.32mm {0.013 in} 4. lf the end play exceeds the maximum, grind the crank- shaft and instal, oversize thrust bearings or replace the crankshaft and thrust bearing. Thrust bearing width ‘Standard: 2.000-2.060mm {0.0788-0.0807 In} 0.26mm {0.01 in} oversize: 2.4 78mm {0.0837-0.0886 in) 9.50mm {0.02 in} oversize: 2.260-2.300mm {0.0886-0.0905 in} 5. Apply asmallamount ofclean engine oilto the lip ofa new rear oi seal, 6, Push the rear oil seal slightly in by hand. 7. Tap the oil seal in evenly by using the SST and a hammer, Protrusion: 0-0.7mm {0-0.021 In} Note © il seal outer diameter: 93mm {3.66 ir) © Oil seal inner diameter: 76mm {2.87 Piston and Connecting Rod Assembly 1. Rotate the engine as shown. Note ® Assombly is easior if the pistons are installed with the crankpin at the BDC position. 2, Remove any foreign material and oil from the connecting rod journals and bearings. 3. Install the upper connecting 706 bearings in the connect- ing rods. 4. Apply a liberal amount of clean engine ail to the cylinder walls, pistons, piston rings and connecting rod cap bolts. 5. Check the piston rings for proper end gap positioning. 8. Insert the piston and connegting rod assembly into the oylindsr block with the & mark (lett bank) and the Ri mark (Font bank) facirg the front of the engine, Use a piston in- staller too! to install, B2-93467-47 Sorin ft 841.00) MAIN JOURNAL B2-04 ASSEMBLY Connecting Rod Cap 4. Measure the connecting rod bearing oil clearances es fol lows. (i) Measure the oil ctearanee with the connecting rod in BDG postion (2) Do not rotate the crankshaft when measuring the oil clearances. (3) Position Plastigage atop the joumals in the axial direction. (@) Remove any foreign matarial and oil from the lower connecting rod Bearing and connecting rod cap. (6) Install the lower connecting rod bearing to the cap. 8) Measure the length of connecting rod cap bolt. Re- place iti the length exceeds the maximum, Length: 46.7—47.3mm {1.84-1.88 in} Maximum: 48.0mm {1.89 in} (7) Apply clean engine clo the threads and seal faces of the connecting rod cap bolts. (8) Install the connecting rod caps. (9) Tighten the connecting rod cap bolts. Tightening torque: 22.1-26.9 Nem {2.25-2.75 kytim, 16.-19.8 fells} {10) Puta paint mark on each bolt head. {11) Using this mark as a reference, tighten the bolts 83°_97°. (12) Remove the connecting rod caps. (13) Measure the Plastigage at each joumial at the widest point for the smallest clearance, and the narrowest point ‘or tha largest clearance, il clearance: 0.023-0.43mm {0.0009-0.0016 in} Maximum: 0.08mm {0.003 in} (14) ithe oil clearance exceeds the maximum, grind the crankshaft and install undersize bearings. (Refer to page B2-84.)ASSEMBLY B2 2, Install the connecting rod caps as follows, {t} Remove the Plastigage from the joumals and bear- ings. (2) Apply clean engine cil to the connecting rodbearings. {8} Install the connecting rod bearings and caps. (4) Apply engine oil to the threads and seat faces of the cap bolts and tighten them as in step 1. (6) Verify that the crankshaft rotates smoothly by hand. 3. Measure the connecting rod side clearances. (1) Measure each connecting rad side clearance, Side clearance: 0.178-0.330mm (0.0070-0.0129 in} Maximum: 0.40mm {0.016 in} @) lf the clearance exceeds the maximum, replace the connecting rod and cap assembly. B2-95B2 ASSEMBLY CYLINDER BLOCK (EXTERNAL PARTS) Torque Specifications ‘SHORT! BOLTS: CONTACT SURFACES 7.9-40.2W-m(80-110 gem, 70-06. bn bf} Nem Ckgts, tbe) ‘Oil Pump 1. Apply clean engine oil to the new oil seal 2. Install the il seal into the oil pump body by hand. 3. Press the oil seal into the off pump body by using the SST. Protrusion: 0-0.7mm {0-0.03 in}ASSEMBLY B2 4. Remove any dirt or other materia! from the contact sur- faces. 5. Apply a continuous bead of silicone sealantto the contact surface of the oll pump. 6. Apply clean engine oll to anew O-ring andinstalitintothe purnp body. Caution * Keep the oi damage. ole free of seatant to provent engine 7. Apply clean engine oil to the oil seal lip. 8. Install the off pump within five minutes of applying the sealant, making sure that the O-ting does not come out. Tightening torque: 19-25 Nem {1,9-2.6 kgt-m, 14-18 fHibf} Bolt :40mmn {1.87 in} Bolt @:25mm {0.88 in} 9, Cutaway the portion of the sylicone sealant thal projects toward the oil pan, Water Pump 1.Remove ali dirt, grease, and other material from the water pump mounting surface. 2. [Install a new rubber gasket and the water pump. Tightening torque: 19625 Nm {1,942.6 kati, 14-18 fbf} Oil baffle 1.Remove any dirt or other material from the oil baffle. 2. Install the gil baffle, Tightening torque: 19-25 Nem (1.9-2.6 kgt-m,14—18 ft bf} Oil Strainer 1. Install a new gasket and the oil strainer anto the oll pump ‘ody. 2. Tighten boits @, then tighten bolts ®. Tightening torque: 7.9-10.7 Nem {80-110 kgf-cm, 70-98.4 in-Ibf} B2-97B2 CRACKS ‘OLD SEALANT fe > ff ASSEMBLY QilPan 1. Romove the sealant from the oil pan bolts andbott holes in ‘the lower cylinder black. Caution © Ifthe bolts are reused, remove the old sealant from the bolt threads. Tightening the bolt that has old sealant on tt can cause thread damage. 2. Remove any dint or oll from the contact surfaces. 3. Apply a continuous bead of silicone sealant tn the oil pan along the inside of the bolt holes, and overlap the ends. 4. Install the oif pan within five minutes of applying the seal- ant. Tightening torque @ 219-25 Nm {1.9-26 kotm, 14-48 ftlbh ® :7.9-10.7 N.m (80-110 kgf-om, 70-95.4 In-Ibf} Knock Sensor Install the knock sensor by using the SST. Tightening torque: 20-34 Nem (2.0-3.5 kgf, 15-25 fbf} Water Pipe and Thermostat Housing 1. Install anew gasket and install ne water pipe and thermo- ‘stat housing as an assembly. Tightening torque: 19-25 Nem (1.9-2.6 kgt-m, 14-18 fbf} 2, Secure the knock sensor hamess to the water pipe with the clip as shown,ASSEMBLY B2 Oil cooler and oil cooler body 1_Install a new gasket and the oil cooler body. Tightening torque: 19-25 Nem {1.9-2.6 kgf-m, 14-18 ftlbf 2. Connect the water hoses. Flywheel (MTX) 1. Set the flywheel onto the crankshaft, 2'Hold the flywheel by using the SST. 3. Tighton the bolts in two or threo steps in the order shown. Tightening torque: 61-87 Nem (6.2-8.9 kgt-m, 45-49 ft-lbf Cluch Disk and Clutch Cover (MTX) lastatl the clutch disk and clutch cover by using the SST. (Refer to section H.) Tightening torque: 18-26 Nim (1.8-2.7 kgt-m, 14-19 ftb TDAP DANE PINE Drive plate (ATX) ra [= BACK NG PLATE Caution yt © Verify that the adapter and the backing plate are mounted in the directions shown. Incorrect mount- Ing can damage the engine and transaxle. 1. Install the following parts to the crankshaft. {1) Adapter (2) Drive plate 3, Hold the drive plate by using the SST. 4. Tighten the bolts in two or three steps in the order shown. ‘Tightening torque: 61-87 Nom £6.2-8.9 kgt-m, 45-49 ft1bf} B2-99B2 ASSEMBLY CYLINDER HEAD Torque Specifications 50-88Nm {500004grom, 44-78 nay 50-88Nm {60-00 kgfom, 44-78 inp s1.a420m (115-148 kgt om, 100-125in tbe HEAD COVER CONTACT SURFACES 1h-14.2Nem (15-145 kghom, 100-125 int <= HEAD COVER Contact SURFACES N (20-1404 A v2s-aorins-443,91-109,<4 BO amen eee BE gates on-s25 fe _ Pon ted LEP ee HEAD COVER wo-140 cox . ge CORTAGT SUAFAGES| 7.9-10.70m {20~190 kgkem, /70-05.4 ines) 19-25 (1.9-26,18-19) 7.8-40,7 Nan (90-110 Rgt om, Z0-95.4 NOE Nem Cegtm, tg ‘Valve Seal 1. Assemble the SST so that depth L is as specified. RETEST Depth L IN: 16.8mm (0.644 in} EX: 13.8mt {0.64 in}ASSEMBLY B2 ray Riee 2. Slide the valve seal onto the valve guide with the SST. Caution © Tho intake and exhaust valve seals are different as ‘GRAY shown. AND, > {GREEN \ i \ Ridge Cele , 4] Intake Noor One cay, Exhaust Teo Gray or Gicon 8. Set the SST against the valve seal. Caution © Using a hammer will damage the valve seal. 4, Using the SST, press the valve seal an by hand untl the ‘SST contacts the cylinder head. Valve and Valve Spring 1. Install the lower spring seat, 2 Install the valve, 8 Install the spring with the closer pitch toward the oylinder head. 4. Install the upper spring seat, ©. Compress the vaive spring with the SST, and install the valve keepers, 6. Remove the SST. 7. Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that tha keepers are fully seated. Cylinder Head 1. Measure the amount of oil control plug projection trom the deck of the cylinder block. Projection @: 8.0-9.0mm {0.31 5-0.354 in} 2. Apply clean engine oil to new O-rings and install them to the oll contro! plugs. B2-101ASSEMBLY 198.7-19.3enm (6:264-5.287 in} 3. Thoroughly remove alc ol, and other materiahrom the deoks of the cylinder «Tuam he crane cosine and apply engine oil to the oylinder was. 5. Place the new cylinder head gaskets an the oylinder lock. 6. Install the cylinder heads to the cylinder black. 7. Tighten the cylinder head bolts as described below. (1) Before installation, measure the Fength of each bolt. Replace a boltifit exceeds the maximum length. Length: 183.7-134.3mm {5.264-6.287 in} Maximum: 135mm {5.31 {a} 2) Apply clean engine oilto the threads and the seat face of Gach bolt and install them and new washers, (3) Tighten the bolts in two or three steps in the order shown, Tightening torque: 23.1-26.9 Num {2.35-2.65 kgf-m, 17.0-19.1 ftlbf} 44) Puta paint mark on each bolt had. 45) Using the marks as a reference, tighten the bolts by tuming each 85°=95° in the sequence shown. 46) Further tighten each bolt by turning another 85°-95°. 8. Connect the water pipe to the water pipe elbow and se- cure 10 the cylinder head. Tightening B10 Wen (60-110 kaf-om, 70-98.4 Intbs,ASSEMBLY B2 HLA 1. Apply clean engine oil to the friction surfaces. 2.1¢the HLA are being reused, install them in the positions, from wihich they were removed. 8. Verify that the HLA move smcothly in their bores. Camshatt Caution © Camshafts must be assembled in the following procedure. Otherwise, camshaft can be broken or damaged because there is little camshaft thrust clearance. 1. Apply clean engine oll to the camshatt journals and the 8 supports. ; 2. install the camshafts so that the intake camshaft gear mark and exhaust camshert gear mark align. 3, Remove the oil, dirt from the mating surfaces between the front camshaft cap and the cylinder head, and degrease. 4. Apply a light coat of silicone sealant to the shaded areas as shown, 6. Install the thrust caps onto the cylinder heeds. Hand tight- ‘enthe bolts in five or six steps inthe order shown, unt the thrust caps fully seated an the cylinder heads. 6. Install the camshaft caps and hand tighten the bolts. 7. Tightan the camshaft cap bolts in five or six steps in the order shown, ‘Tightening torque: 113-142 N-m (115-145 kgf-em, 100-125 In-Ibf 8. Retighten the bolts in the order shown. Tightening torque: 11.3-14.2 Nan {115-145 kgf-cm, 99,9-125 inibf} B2-103ASSEMBLY 9. Install the distributor cap. (LH cylinder head) Tightening torque: 71.9-14.2 Nm (115-145 kgbom, 100-125 ints 10. Apply clean engine ail to the lip of the new camshatt oit seal 11. Push the oil seal slightly in by hand. 12, Tap the camshaft oll seal in evenly by using the SST anda hammer, Protrusion: 0-0.5mm {0-0.020 in) 11. Tap in the new blind cap by using 2 plastic hammer, ‘Water outlet Instal the water outlet with new O-rings. Tightening torque: 18-25 Nem {1.9-2.6 kgf-m, 14-18 felbf} Seal Plate Insta! the seal plate. Tightening torque: °7.9-10.7 N-m {80-110 kgf-cm, 70-95.4 in-tbfyASSENBLY B2 Camshatt Pulley 1, The right and left pulleys are different and must be installed on the same head that they were removed from. 2. install the camshait pulley so that the “R" mark can be '9on andthe timing mark tins wih tho camshatt knock pin. 3. install the camshaft pulley so that the “L” mark can be seen and the timing mack aligne wil te camshatt knock pin. ‘Camshaft Pulley Lock bolt +. Apply clean engine oll to the lock bolt threads. 2! Hold the camshait by using a wrench on the east hexagon as shown, and tighten the bolt. Tightening torque: 123-140 N-m {12.5-14.3 kgf-m, 91-103 ft lbh Gylinder Head Cover 1. Remove all old silicone sealant from the cylinder head and cover. 2. Apply silicone sealant to the cylinder head cover as shown in the figure, 3. Install the new cylinder head caver gasket into the cylin- der head cover. B2~105.ASSEMBLY 4, Install the eylinder head cover and tighten the bolts in two or three steps in the order shown, Tightening torque: 8.0-8.8 Nem (50-90 kgt-om, 44-76 in-Ibf} 5. Retighten cylinder head cover bolts. RH © © and LH O@ Tightening torque: 5.0-€.8 Nom {50-90 kgf-cm, 44-78 in-Ibf} B2-106ASSEMBLY B2 TIMING BELT Torque Specification sore tos SOP to05(19-28, 14 RnB WK : ° msossn Go WS e ro ayers OS ep er \e 79-1074m {80-110 kgf om, TOn95.4 N08 ‘187-106 (16.0-17.0,116-122), T9-407Nm (@o-110 Kgt-em, 10-25.4 bf) ‘pout THREADS, 79-107 nm f e seagate” ye ‘DING, Z — ew 7.9107 Nan{$0-110kgtcm,70-95.4in Sy i ® Nam {kgfan, feof ‘Timing Belt Pulley 1. Hold the flywheel (MTX) or drive piate (ATX) by using the ss. 2, Install the crankshaft key end the liming belt pulley on the crankshatt. 3. Temporarily tighten the timing beit pulley bolt. B2~107AUGNTHE HOLES B2-108 ASSEMBLY No.2 Idler Pulley Install the No.2 idler pulley to the cylinder block. Tightening torque: 38-61 Nun {3.8-6.3 kgf-m, 28-38 ft-bo} Timing Belt Auto Tensioner 1. Press in the tensioner rod slowly, using a press, Caution * Do not press the tensioner rod 10 more than 9,810 {1,000 kgf, 2,200 Ibf}. Iwill damage the tensioner. 2. Insert a pin into the second hole in the body as shown to hold the tensioner rod. Note ‘* Pin diameter: 1.6 mm {0.063 in} 3. Sethe tensioner inplace and snugly tighten the tensioner upper bolt. Note © This must be done to reduce the timing belt resistance when the idler pulley is installed, 4. Instatl the fensianor pulley. Tightening torque: 98-44 Nom (3.8-4.5 kgf-m, 28-92 ttt} Timing Belt 1, Tum the pulleys clockwise, and align the timing marks.ASSEMBLY B2 2. Install the timing belt on ihe pulleys in the order described bel low. ® Timing belt pulley No.2 Idler pulley LH camshaft pulley Tensioner pulley BH camshaft pultey esas 3. Verify thet the belt has no looseness at the tension side. 4. Install the No. 1 idler pulley weile applying the pressure an the timing belt. Tightening torque: 1 Nem {3.8-8.3 kgt'm, 28-98 fbf} 5. Push the auto tensioner in the direction of the arrow and, ingtall the fower bolt, 8. Tighten the upper ard lower tensioner botis to the saeci- fied torque. Tightening torque: Sous Nei (1.9-2.6 kgtim, 14-18 feb 7. Remove the pin from the auto tensioner, and apply ten- sion to the belt. 8. Tighten the tensioner pulley. Tightening torque: 38-44 Nom (3.8-4.8 kgf-m, 28-32 fbf) 9. Tum the crankshaft clockwise twice in the direction of rotation, and align the timing marks. 10. Verity that the timing marks are correctly aligned. If not, repeat the procedure from “Timing Belt Auto Tension- er”. (Refer to page B2~108,) B2-109ASSEMBLY 11. Check the timing belt deflection. If it is incorrect, replace the auto tensioner. Deflection: 6-Gmm {0.24-0.31 in} No.3 Engine Mount Bracket Install the No.3 engine mount bracket. Tightening torque: 44-60 N-mi4. .2 kgm, 32-44 ttf Timing Belt Cover 4. Install the right timing belt cover. Tightoning torque: 7.9-10.7 N-m {80-110 kgf-cm, 70-95.4 in-Ibf} 2. Install the feft timing belt cover. Tightening torque: 7.9-10.7 N-m {80-110 kgf-om, 70-95.4 in-Ibf) Crankshaft Position Sensor Install the crankshaft position sensor Tightening torque: 910.7 Nem {80-110 kgt-om, 70-25.4 |ASSEMBLY B 2 Dipstick and Pipe Insta the dipstick and ploe with the clip. Tightening torque: 7.9-10.7 N-m {80-110 kgf-om, 70-95.4 in-Ibf} Water Pump Pulley install the water pump pulley. Tightening torque: 7.9-10.7 N-m {80-140 kgf-m, 70-95.4 in-tbf Crankshaft Pulley 1 Ho! the flywheel (MTX) or drive plate (ATX) by using the. 2. Remove the crankshaft pulley bo't. Caution # Install the crankshaft pulley carefully. The crank- shaft position sensor rotor is on the rear of the pulley, and can be damaged easily. 9. Install the crankshatt pulley onto the crankshaft. 4. Apply clean engine oi to the bolt threads. 5. Tighten the crankshaft pulley. Tightening torque: 157-166 N-m {16.0-17.0 kgfim, 116-122 frlbf} B2-111ASSEMBLY wweaeis28, 1-16 Nan fegtm, feo Oil Fitter 1. Apply a small amountofciean engine oil othe rubber seal of the new oi filter, 2, Install the filter end tighten it by hand until the rubber seal contacts the mounting base. 3. Tighten the filer 1~1/6 turns by using the SST,ASSEMBLY B2 Plug Install the spark plugs. Tightening torque: 15-22 Nm (1.5-2.3 kgf-m, 11-16 ftlbf} AIC Compressor Bracket (If equipped) Install the A/C compressor bracket. Tightening torque: 38-51 Nom (3.8-6.3 kefm, 28-88 fbf} Engine Hanger 1. install the front engine hanger and the ground hamess. Tightening torque: 19-25 Nn (1.9-2.6 kgf, 14~18 ft-lb 2. Install the rear angine hanger. Tightening torque: 38-51 Nim {3.8-5.3 kgf-m, 28-38 fib} Intake Manifold Assembly 1. Install new gaskets and the intake manifold assembly. Hand tighten the bolts and nuts. 2. install the intake manifold oracket. Tightening torque: 49-25 Nem {1,9-2.6 kat'm, 14=18 febi 8, Tighten the intake manifold boits and nuls in two or three sleps. Tightening torque: 19-25 N-m{1.9-2.6 kgtan, 14-18 ftlbf 4. Connect the hoses. B2-113ASSEMBLY Distributor 1. Apply clean engine oil to a naw O-ring and pesition it en the distributor. 2. Apply engine cil to the drive blade. 3. Align the groove of the distributer body and shaft gear mark, 4. Install th distributor with tha blade fit into the camshatt yoove. 5. Hand tighten the distributor mounting bolts. 6. Connect the high tension leads. Exhaust Manifold Assembly (LH) 1, Place a new gasket in position. 2. Install the left exhaust manifold. Tightening torque: 19-25 Nem (1.9-2.6 kaf-m, 14-18 ftibh} Exhaust Manifold Insulator (LH) Instat! the left exhaust manifold insulator. Tightening torque: ‘7.9-10.7 N-m {80-110 kgf-cm, 70-95.4 in-Ibf} Bracket and Tensioner 1. Install the bracket and tensioner. 2. Hand tighian the bolt ®, then bolt @, 3. Tighten the bolt @, then bolt © to the specified torque. ‘Tightening torque: 19-28 Nem {1.9-2.6 kgf-m, 14-18 fbi}ASSEMBLY B2 Generator install the generator and the bracket. Tiamening worque: @: 38-51 Nem (3.8-6.3 kgf-m, 28-38 ftbf ©: 19-25 Nm {1.8-26 kgf-m, 14-48 fbf} B2-115B2 ENGINE STAND DISMOUNTING ENGINE STAND DISMOUNTING PROCEDURE 1. Remove the engine from the SST (Engine stand}. 2. Remove the SST {Engine hanges) from the engine in the reverse order of installation. {Refer to page B2-53.) 2. Install a new gasket and the right exhaust manifold (RH) together with the EGR pipe, Tightening torque: 19-25 N-m {1.9-2.6 kafm, 14-18 fbf} 4, Tighten the EGR pips. Tightening tor 54-00 Nim (25-70 kgfan, 40-60 ftlbhy 5. Install the right exhaust manifold insulator (RH). Tightening torque: 7.9-10.7 Nem (80-110 kaf-om, 70-95.4 in-tbf} B2-116INSTALLATION B2 INSTALLATION PROCEDURE Tighien all bolts and nuts to the specified torques. Step 1 Torque Specifications Transaxle 1. Join the engine and transaxle. 2. Install the transaxle mounting bo'ts. 3, Tighten the bos shown, Tightening torque: 68-99.0 Nem {6.9-10.1 kgf.m, 50-73.0 ft-lb} B2-117B2-118 INSTALLATION No.2 engine mount rubber and bracket Install he mount rubber and bracket Tightening torque: 38-51 N-m (3.8-5.3 kgf-m, 28-38 ftlbf rier Install the starter to the transaxle housing. Tightenin torque: 1-81 N-m (3.8-5.3 kgf-m, 26-38 ftIb Seal plate ‘install the seal plate. Tightening torque: 38-51 N-m {3.8-5,3 kgt-m, 28-38 ftlbt} Throttle cable (ATX) Install the throttle cable, Tightening torque: 6.9-9.8 Nem (70-100 kgf-om, 61-86.8 in-Ibh Torque converter nut (ATX) 1. Hold the drive plate by using a sorewdriver inserted ‘through the service hole from the converter housing side. 2. Insert @ torque wrench through the service hale from ‘the oil pan side. Tighten the nuts evenly and gradually. Tightening torque: S49 Nm {3.5-5.0 kgf-m, 26-36 ft-lbfINSTALLATION B2 Step 2 Warning *® A vehicle that Is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death ar serious injury. Never work around or under a lifted vehicle if itis not se- curely supported on safety stands. Torque Specifications 7107.05, 0-980 MST(94-54, 20-49 Wem {kgtm, fp Engine mount member Install the engine mount member, Tightening torque: -89 N-m (6.5-9.1 kgf-m, 48-65 ftlbf} B2-119B2-120 INSTALLATION Engine and transaxle assembly 1. Suspend the engine and transaxle assembly. 2. Slowly lowerthe engine and transaxle assembly asa unit, Keep the engine from swinging or bumping into compo- nents in the engine compartment. 3. install the engine and transaxle assembly in the engine compartment. 4. Align the engine mounts with the engine mount member mounting holes. Engine mount 1. Install and fighten the engine mount nuts of the No.1 and No.2 mounts. Tightening torque: 38-52 Nem {3.8-6.3 kgt-m, 27~38 ftlbf 2, Install the No.3 engine mount rubber. Tightening torque: @: 74-103 Nm {7.5~10.5 kgf-m, 54-75.9 ft-lb} ®: 67-93 Nm {6.8-9.5 kgfm, 49-68 ftlbf 3. Insiall the No.4 engine mount rubber and bracket, and hand tighten nuts @. 4, Install bolts @ and tighten them in two or three steps inthe ‘order shown. Tightening torque: 44-60 Nom {4.4-8.2 kgt-m, 32~44 ftlbf 5. Tighten nuts ®, Tightening torque: 67-83 Nem {6.8-8.5 kgtm, 49-68 fribfINSTALLATION B2 Step 3 Torque specifications se22(15-29, 12-16) 44-60 {64-62 32-44) S M468 14.46.0, 82-49) SPRIT FIN, NeW 45-06 49-5.9,22-41) shss1e.4-00,02-45) 44-60464-02, 32-24) Nm tkgtm, fbf, Drive shaft 41. Apply grease to the end of the drive shafts. ‘Caution * The oil seals are damaged easily if this procedure is not done correctly. 2. Install a new clip with the end gap facing upward. 8, Install the drive shat, 4, Push the drive shaft into the joint shatt, 5. Install the joint shaft. 6. Tighten the bois in the order shown. Tightening torque: 43-61 Nim {4.3-6.3 kof-m, 32-45 fbf} 77 Atter installation, pull the front bub outward to confirm that the drive shaft is sacurely held by the clip. B2-121SELFLOGK INSTALLATION 8. Install the lower arm ball joint to the knuckle and tighten the throug’ bol. Tightening torque: 44-58 Nim {4.4-6.0 kgf-m, 32-43 ft-lb} Tie¢-rod end ball joint 1. Install the tie-rod ends to the knuckles and tighten, Tightening torque: 43-86 N-m (4.3-88 kof-m, 32-41 fbf, 2, Install new cotter pins. Stabilizer control link Install the stabilizer controt link. Tightening torque: 44-60 Nem (4.4-6.2 kgf, 3244 ftlbf Extension bar (MTX) Install the extension bar to the transax‘o. Tightening torque: 92-46 Nem {3.2-4.7 kof-m, 24-83 ttf} Shift control rod (MTX) Install the shift control rod to the transaxle. Tightening torque: 16-22 Nom {1.6-2.3 kgf-m, 12—16 ttibt Front exhaust pipe 1. Connect the front exhaust pipe to the exhaust pipe witha new gasket, Hand tighten new nuts. 2. Tighten the nuts. Tightening torque: 84-89 Nem (6.5-9.1 kaf-m, 48-85 ftbf,INSTALLATION B2 4. Install the front exhaust pipe with new gaskets. 5. Tighten new nuts. jntening t ET Sa nem (825.6 kgtim, 30-20 fbn ‘Transverse member Install lhe transverse member. Tightening torque: 84-126 N-m (8.5-12.9 kgf-m, 69-93.3 ftlbf} Clutch release Cytinder (MTX) 1. Install the clutch release cylinder. Tightening torque: 16-22 Nim (1.6-2.3 kgf-m, 12-46 fttbf} 2. Mount the pipe brackets in position. Tightening torque: 16-22 Nem (1.6-2.3 kat-m, 12-16 ttlbs} B2-123B2 INSTALLATION Step4 ‘Connect the hoses shown. B2-124INSTALLATION B2 Step 5 1, Connect the harness connectors shown, ENGINE COOLANT TEMPERATURE SeNBOR PIS OIL PRESSURE STTCH co) Yo KNOCK SENSOR ace rerenainé nis So EkOD ALE eemaceunerrgomon vemTen oxvGEN SBH908 SOR THROTTLE POSITION SENSOR EGR SOLENOID VALVE (VENT) EGR SOLENOID \VBLVE (YACUUM cone : Yoh Es oi ‘ oF ‘SPEEDOMETER, 2. Install the harness bracket and the fuel filter. Tightening torque: 7.9-10.7 N-m {80-110 kgf-om, 70-95.4 In-Ibf B2-125B2 INSTALLATION Step 6 ‘Torque Specifications ‘ATX SPAUT PN, NEW 89-98N.m{70-400Kgtem, 51-985 tbh PAHO Nm (BO-H10 Ugh, 70-44 int T9nT hen (e0-noKgeam, J0-96-4ine9 {40-110 eater, 70-954 to ‘S9.asim (ro-tdOKgte, 81-86. Nem ceghan, B2-126INSTALLATION B2 AIG compressor Install the A/C compressor to the bracket. Tightening torque: 98-51 Nem (3.8-6.3 kgf.m, 28-36 ftlbh P/S oll pump and bracket +-Install the P/S of! pump, Tightening torque: 2 82-46 Nm {3.2-4.7 kgf m, 24-93 fb} 5 19925 Nem {1.942.6 kghm, 14-18 ftibf} 2. Tighten the bolt shown, Tightening torque: 32-46 N-m {3.2-4.7 kgf-m, 24-33 ft-lbf 3.{nstall the P/S oil hose to the engine. Tightening torque: 7.8-10.7 Nem {80-110 kgf-cm, 70-95.4 in-Ibf} 4. Connect the steering pressure sensor connector. 5. Install he P/S oll pump pulley to the pump body and hand tighten the nut. 6. Hold the pulley by using a 12mm (0.47 in) socket wrench through the pulley hole, and tighten the pulley nut. Tightening torque: 63-03 Nim {8.4-9.5 kgf-m, 47-68 flibf} B2-127INSTALLATION 7. Install he P/S oil reservoir and the engine ground. Tightening torque: 38.8 Wm {70-100 kof-em, 6186.6 IntbA, Drive beit 1. Install the P/S and/or A/C drive belt. 2. install the generator drive belt. 3. Adjust the drive belt deflection. (Refer to page B2-7.) Control cable (ATX) Instait the contro! cabie. Battery duct Install the battery duct. Coolant reservoir install the cootant reservoir. Tightening torque: 6.9-9.8 N-m {70-100 kgf-cm, 61-86.8 in-Ibf} Radiator and coolant fan assembly 1. Install the radiator and coolant fan assembly. Secure the shroud upper panel. Ihtenin: ue: vee as Nan {76-100 kgf-cm, 61-86.8 intbt}INSTALLATION B2 2. Connect the upper and lower radiator hoses. 3. Connect the coolant reservoir hose. 4. Connect the coolant tan motor connector. 5. Connect the oll cosler hoses (ATX). Accelerator cable 1, Install the accelerator cable. 2. Adjust the cable deflection by turning nuts @. Deflection: 13mm §0.04~0.51 in} Battery and carrier 1. Install the battery carrier, Tightening torque: 7.9-10.7 Nem {80-110 kgf-om, 70-96.4 In-Ibf} 2. Install the engins harness to the carrier. B2-129INSTALLATION 3. install the battery. Tightening torque: 2.4-8.9 N-m (30-60 kgf-om, 26-52 In-Ibf 4, Connect the posftive battery terminal. Alr cleaner assembly 1. Install the alr cleaner assembly. 2, Connact the hoses. Tightening torque: 19-25 Nem (1.9-2.6 kgt-m, 14-18 ft-lbf 3. Connect the mass air flow sensor connector. Fresh-air duct Install the fresh-air duct. Tightening torque: 7.8-10.7 N-m {80-110 kgf-om, 70-95.4 in- thf} Splash shield Install the splash shield. Steps After Installation 7. Fill the engine with the specified amount and typo of engine oil. (Refer to section D2.) 2.Fill the radiator with the specified amount and type of engine coolant. (Reter to section EZ.) 3. I the traneaxle oil was drained, fil i with the specified amount and type of transaxle oil. (Refer to section J2, K.) 4. install the front wheels, 5. Start the engine and {1) check the engine cil, transmission ol, and engine coolant leakage. 2) check the ignition timing and idle spead. (Refer to section F2.) (8) check the operation of the emission control system. (Refer to section F2.} 6. Turn off the engine and check drive belt deflection. (Refer to page B2-6.) 7. Perform a roat test. & Recheck the oil and coolant levels. B2-130Body Electrical Troubleshooting Manual; see section 8 for alr bag system service warnings. 2 3 3 TROUBLESHOOTING GUIDE 3 OIL PRESSURE D2 4 PREPARATION D2 4 INSPECTION D2 4 ENGINE OIL D2- 5 INSPECTION . 46 D2- § REPLACEMENT . D2- § OIL FILTER . D2- 6 PREPARATI D2- 6 REPLACEMENT . D2- 6 ON_COOLER.. D2-7 PREPARATION D2-7 REMOVAL/INSTALLATION . 02-7 OIL PAN .......... D2- 8 REMOVAL/NSTALLATION . D2- 8 INSPECTION D2~ 9 OIL PUMP .. Dei PREPARATION D214 DISASSEMBLY / ASSEMBLY . INSPECTION ....D2 INDEX INDEX Senvce seoronse 5) ENGINE OL SPEciFCATION & D agi SERVICE 5G, SHENEAGY CONSERVING ECU), TOTAL CAPAGTTY 49 L(62US 9,43 inp 9b 1. Oll pressure: 4, Oil cooler Inspection Removal / tnstallation . . page 02-7 2. Engine oll 5. Oil pan Inspection Removal / Installation . page D2- 8 Replacemer Inspection ...... page D2- 9 3. Oil filler 6. Oil pump Replacement .......eeeeeeee page D2 6 Disassembly / Assembly ..... page D211 Inspection page D212 D2-2OUTLINE, TROUBLESHOOTING GUIDE D2 OUTLINE ‘SPECIFICATIONS Engine tem Keone ibstatoneysem Force ed ype Tipe Techs ear Ctpane | Retelproue Palen? et, W568 03.0, 7285) come | Foon paper omer Reve pressure deren Wrage pa TNF 05-12, 1217) “eal iy enaine) TUS Imp a $0462.43) Oteapeciy [Engine ol replzcomert LYS a.Imp a 87 89,23) Erne ot tol errepicenet — LUSA mea 40 42,85) ‘APL SG. BH Enoxey Corsening WECM Engine ot aes Recommended SAE Viscosity 00 om 6M Temporotue * "or + + a r to é * # % 1028 —_ 0 Engine 1H * Anipeted anions aciperat.z ang bates evecoedng ol hana. TROUBLESHOOTING GUIDE Protdam Possible cae, Remocy Page Enginehard etarting | iceroper engine ol epiroe oo § inavrert engin ot Aah O25 Excesalve ol ‘09 watking up er down node eter to secion consumation Shtecrace Repair = ‘Oil pressure drop Trevino Batol D6 Glteakage Repair — Wem andor damaged ot pump tar piace tet Wein plunger (rats ll pump} creak ecting Rerlece Beat Blogger or stainer Sean - Exeseeive main bearing or canrecting ratbearng clearance | Relerosecton 2 Waring fat Oi gressure cop ‘An described abave = urainatés wre Mauneton oct pressure sytch Fetertosscton C= engine fsroncing Maluncton of eeccel system Hotere seston G2* 72995 MS Bedy Elecineal Trocbeshoctng Manat Warning © Continuous exposure with USED engine oll has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. D2-3D2 OIL PRESSURE PREPARATION ‘SST 490107 200, s2., Coy Te D2-4 OIL PRESSURE INSPECTION 1, Remove the oi pressure switch. 2. Sorew the SST into the ofl pressure switch installation hole. 3. Warm up the engine to normal operating temperature. 4; Run the engine at 1,000 rom and 3,000 rpm, andi note the gauge reading. Oil pressure 1.000 rpm: 196 kPa {2.0 kgt/cm?, 28 psi} 3,000 rpm: 334-490 {3.4-6.0 kgficm?, 49-71 psi} Note © Oil pressure varies with oll viscosity and tempereture. 5. lithe prassureisnotas specified, check forthe cause and repair. (Refer to Troubleshooting Guide, page D2-3.) 6. Apply sealant to the oil pressure switch threads. 7. Remove the SST and install the cll pressure switch. Tightening torque: 11.8-17.6 Nem {120-180 kgf-om, 105-166 in-Ibf} 8, Start the engine end check for oil leaks.ENGINE OIL D2 ENGINE OIL, INSPECTION 1.Be sure the vehicle is on level ground. 2! Warm up the engina tonermal operating temporature and stop it. 3. Wail for five minutes. 4; Remove the cipstick and chack the oillavel ard condition. 5. Add or replace oil as necessary, Note @ Thedistanoe between the Land F marks on the dipstick represents 1.0L {1.1 US qt, 0.99 imp qi}. REPLACEMENT Warning # When the engine and the oil are hot, they can badly burn, Don't burn yourself with either. + Warm up the engine to normel operating temperature and stop it. 2. Remove the oil filler cap and the gil pan drain plug. 3. Drain the gif into 2 container. 4. Install a new gasket and the drain plug, Tightening torque: 30-41 Nem (3.0-4.2 kgfm, 22-90 fb, 5. Refi the engine with the specitied type and amount of en- gine ot. Oil capacity L{US et, Imp oth Total (ory engine), 43482, 4.3) Eegine ol paca vent 8709, 23) Engine ol = ior eolacon) 40 6. Refit the oif filer cap. 7. Run the engine and check for leaks. 8. Chesk the oil level and add oil if necessary. 02-6D2 OIL FILTER PREPARATION 8st OIL FILTER 96014001 oi ter won For replacement of D2-6 REPLACEMENT 1. Remove the oil filler by using the SST. 2, Useaclean rag to wipe offthe mounting surtace on the olf cooler base. 3. Apply a small amount of clean engine oil to the O-ting of ‘the new filter. 4. Insta the ail fiter and tighten it by hand until the O-ring contacts the oil cooler base. 5. Tighten the filer 1 and 1/6 turns by using the SST. Tightening torque: 18.8-17,6 Nam {140-180 kgf-cm, 122-186 in-Ibf} 6. Start the engine and check for leaks. 7. Check the oil level and add oll if necessary. Oil fitter capacity: 0.3 L {0.32 US qt, 0.26 Imp at}OIL COOLER D 2 OIL COOLER PREPARATION SST REMOVAL / INSTALLATION 1. Disconnect the negativa battery cable. 2. Drain the engine coolant, (Reefer to section £2.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. BemGgtn ioe 4. Oilfilter 4. O-ring Replacement . pageD2-6 5. Oil fiter body. 2. Oil cooler hoses. 8. Gasket 3. Oil cooler 9's After Installation Fill with the specified amount end type of engine coolant. (Refer to section £2.) 2. Start the engine and check for leaks. D2-7D2 OIL PAN OIL PAN REMOVAL / INSTALLATION i. Disconnect the negative battery cable. 2. Drain the engine oil, (Refer to page 02-5.) ‘3, Remove in the order shown in the figure, refering to Removal Note. 4_Instal in the reverse order of remavai, referring to Instaitation Note. ‘GASKET, replack OHS, < Soto feategon, meanatsog SELF LOOK NUT, REPLACE 78-1078 {200 katom, Seownttn Ou GyLINDER BLOC Sonar SURFACES w2iie28 5H) 29-167 Hen{ot—NOkstem, TOES Si Heathotn, fbn 4. Splash shield 4.0ilpan 2. Transverse member Removal Note - page 2-9 a. Front exhaust pipe Inspection .. © page 2-3 Installation Noto = page D2-2 5. Oil strainer D2-8OIL PAN D2 Removal Note Ol pan 1. Remove the oll par, mounting bolts. Caution * Pry tools can easily scratch the lower cylinder block and oil pan contact surfaces. Prying off the oil pan canalso easity bend the oil pan flange. Reter to the following instructions before removing the oil pan, 2, Remove the sealant on the bolt threads. Screw a bolt into the weld nut to mae a gap between the block and oil pan. 9. Insert a screwdriver or a suitable tool. 4, Remove the ail pan. INSPECTION Oil Pan Visually check for eracks, deformation and damago. Re- pair or replace if necessary. Installation Note Oil pan Caution *# ff the bolts are reused, remove the old sealant from the bolt threads. Tightening abok that has old seal- ant on it can cause thread damage. 1. Remove all foreign material from the contact surfaces. D2-9Atter Installation QIL PAN 2. Apply silicone sealant to the contact surfaces of olpanas skown in the figure. 8. Install the oil pan within five minutes of applying the seal- ant, Tightening torque @: 7,9-10.7 Nan (80-110 kaf-om, 70-95.4 in-tbf} Gz 19-25 Nim {1.9-2.6 kgf, 14-18 fttbf) Steps 1.Fill with the specified amount and type of engine oll. (Refer to page D2-5.) 2, Start the engine and check for leaks. 8. Check the oil level and add ofl if necessary. D210OIL PUMP D2 OIL PUMP: PREPARATION Sst 491070401 neta, ot goal DISASSEMBLY / ASSEMBLY J, Disassemble inthe order shown in the iqure, referring to Disassembly Note, 2. Assemble in the reverse order of disassembly, referring to Assembly Note. so-sanm 80—00 Karem, £970 tbe) eh REPLACE steps 7a.aa-) g-9 Nem Ghat, Bion, 1. Oil seat 4. Inner rotor Disassembly Note page D212 inspection ....... page D212 Assembly Note . page D213 Assembly Note page D2-13 2, Pump cover 8. Blind plug Disassembly Note page D2=12 6. Spring seat Assembly Note - page 02-13 7, Pressure spring 8. Outer rotor Inspection Inspection .... page D212 8. Control plunger Assembly Noie page 02-13 8. Pump body s+ Page D212 D211Ol, PUMP” D2-12 Disassembly Note ‘Ol seal Remove the ail seal with a screwdriver protected with a fag. Pump cover 1. Remove the pump cover mounting bolts with an impact screwdriver. 2, Remove the pump cover. INSPECTION Pressure Spring 1. Inspect the spring for weakness and damage. 2. Measure the spring free length. Replace the Soring if nec- essary. Free length: 46.79 mm {1.842 in} Rotor Clearance Measure the following clearances. Replace the rotor if necessary. ‘Tooth tip clearance: 0.02-0.18 mm {0.0008-0.0070 in} Maximum: 0.22 mm {0.0087 in} Outer rotor-to-pump body clearance: 0.113-0.186 mm {0.0045—0.0073 In} Maximum: 0.20 mm {0.0078 in}OL PUMP D2 Side clearance: 0.03-0.09 mm {0.0012-0.0035 in}. Maximum: 0.13 mm {0.0051 in} Assembly Note Inner and outer rotor 1. Apply clean engine oil to the friction surface of the pump body anc the rotors. 2. Install the inner and outer rotors into the oil pump baby with the marks aligned as shown. Pump cover 1. Install the pump cover. Tightening torque: 5.9-8.8 Nem (60-80 kgf-cm, 53-78 In-Ibf} 2 Neri ‘that the oil pump rotates smocthly when turned by Oil seal 1_Apply clean engine oil to the new cil seal, 2. Install the oil seal into the oft pump body by hand. 3. Press the oll seal into the oii pump body by using a SST. Protrusion: 0-0.7 mm {0-0.03 In} D213E2 ‘Before beginning any servi Body Electrical Troubl bag system service war rocedure, refer to the 1995 MX-3 ‘Manual; see section S for alr COOLING SYSTEM (K8) +E2~ 2 1E2- 3 +s E2= 3 TROUBLESHOOTING -E2- 3 ENGINE COOLANT . E24 PREPARATION -E2= 4 INSPECTION E24 REPLACEMENT -E2- 5 RADIATGR CAP sree E2e & PREPARATION -E2- 6 INSPECTION +E2- 8 RADIATOR... E27 REMOVAL / INSTALLATION -E2-7 INSPECTION -E2-7 THERMOSTAT .... -E2-8 REMOVAL / INSTAI -E2-8 INSPECTION +E2- 9 WATER PUMP | E210 REMOVAL / INST E210 COOLANT FAN SYSTEM E2n11 ‘SYSTEM CIRCUIT . E211 SYSTEM INSPECTION E211 COOLANT FAN MOTOR... E2412 INSPECTION .. E212 REPLACEMENT . E2413 ENGINE COOLANT TEMPERATURE ‘SENSOR . E214 REMOVAL Eot4 INSPECTIO! eo44 INSTALLATION E214 COOLANT FAN REI F244 REMOVAL .. Ea44 INSPECTION E244E2 INDEX INDEX (COOLANT SDENGNE COOLANT Fora carson T5L(79 US gL 6.6 lp qe 1. Engine coolant page E2- 4 page E2- 5 page E2- 6 3, Radiator Removal / Installation . page E2- 7 Inspection page £2- 7 4, Thermostat Removal / installation . page E2- 8 Inspection page F2- 9 5. Water pump Removal / Installation ........ page £2-10 2-2 6. Coolant fan system System circuit. + page E2-14 System inspection . + page E211 7. Coolant fan motor Inspection . ©. Coolant fan relay Removal / Inspection ........ page E214OUTLINE OUTLINE, TROUBLESHOOTING GUIDE SPECIFICATIONS E2 ne Engine se Coaira sveiem ‘Witer-oonea, frees ereuation Coalantcopacey LASah Mog 7517 9,605 7 Tipe ‘Canintagal ‘Wow pare [vate seal Uniied mocharical seal 0 ‘ax, botor-nypace rremosat [PSR Raeperanie sofa | 0-84 {175-485} Fullopentemperare eee 95 7205) Fullooen it enfin 35 (058) ie orga fi ap waive oporing pressure tPa halon? pa 75-102 (0.75-1.08,10.7-74.9) editor ven 800 B72} 247 ER Core sina mm fink [ Heiaht 3504158), S206. Bont 288 Finpion men 7.340051) “We Bieitic vsce Saeccanetr ima fink HONS Seotartian om 5 Fan speed = oe High Motor ‘cures: A eo 20 788 ‘Speed oe 70 1650 2,009) TROUBLESHOOTING GUIDE Problem Possible Cause ‘elon Page Overheating Secant versuri a ‘Sooke leakege = Faciair fins clogged a7 Racin cep raitnetion Bo (Geeta fan maltsrebon ea Tremastat raltinon Be Water passage cogzed ea ‘Water pu ate F200 raion mores in coolant Ea 5 E23E2 ENGINE COOLANT PREPARATION Sst 49.9200 148, apr at, Factor 3p tester Gr ENGINE COOLANT For Inspection of ‘cooling system pressure 499200 146. For Ingpection of ‘Adapter A ccootng system (Panot pressure 49.9200 145 INSPECTION Warning ‘© Removing the radiator cap or the coolant filler cap while the engineis running, orwhen the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. ‘Tum off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. ‘When you're sure all the pressure is gone, press down on the cap — stil using a cloth - turn it, and remove it. E24 Coolant Level (Engine Cold) 1. Verify that the coolant level is near the filer neck of the ra- diator.. 2. Verify that the coolant level ia the coolant reservoir is be- tween the FULL and LOW marks. Add coolant if neces sary. Coolant Quality 1. Verify that there is no buildup of rust or scale around the filler cap and filer neck, 2. Verify that the coolant is (ree of oll. Replaca the coolant if necessary. Coolant Leakage 1. Remove the fresh-air duct. 2. Connect a radiator tester and the SST to the radiator filler neck, 3. Apply 103kPa{ 1.05 kaffem?, 15 psi} pressure to the sys- tem. 4. Verify that the pressure és held. I not, check for coolant leakage. Caution © Applying more than 103 kPa (1.05 kgffcm?, 15 psi} can damage the hoses, fittings and other compo- nents, and cause leaks.(COOLANT PROTECTION aaa vox 1.000} Sots oe ee om 4) ey) al ea ont a3 ENGINE COOLANT E2 Coolant Protection Caution # The engine has aluminum parts that can be dam- aged by alcoho! or methanol antifreeze. Da not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant, * Use onty soft {demineralized} water In the coolant mixture, Water that contains minerals will cutdown ‘on the coolants effectiveness. 1. Meesure the coolant temperature and specific gravity with a thermometer and a hydrometer. 2, Determine te coolant protection by referring tothe graph shown. 3. Ifthe coolant prolection is not proper, add water ar coolant as necessary. Antifreeze solution mixture percentage . Se Coo.a TEMPERATURE SCE Soctart protection a ee et) Above 16°C {8°F} $5. 38 1,084 Fave BEC FSF) Ea « “088 Rote are (SF) % B 978 REPLACEMENT Draining Warning @ Removing the radiator cap or the coolant filler cap While the engineis running, or when the engine and radiator are hots dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. © Turn off the engine and wait until it is coal. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn It counter- clockwise to the first stop. Step back while the Sure escapes, « When you're sure all the pressure is gone, press down on the cap — still using a cloth —turn it, and remove it. 1. Remove the cootant filer cap, radiator cap and loosen the radiator drain plug. 2. Disconnect the ail cooler hoses. 3. Drain the coolant into a container. 4, Flush the cooling system with water untl alltraces of color are gore, 5. Let tne system drain completely, 8. Tighten the ¢rain plug and connect the oil cooler hoses. £2-5E2 RADIATOR CAP PREPARATION Sst ENGINE COOLANT Refilling Use the proper amount and mixture of ethylene-glycal based coolant. (Refer to Coolant Protection, page E2-5.) 1. Slowly paur ihe coolant into the radiator up to the coolant filer por, Filling pace: 4.0 L (4.4 US qt, 0.9 imp qf/min. max. 2. Fill the coolant reservoir up to the FULL mark, 3. Fully install the cootant filer cap. 4, Slart tho engine and let tide until warms up. 5.lf the temperature increases beyond normal, there is ex- cessive air in the system. Slop the engine and allow it to ‘cool; then repeat steps 1-3. 6. Run the engine at 2,200—2,809 rpm for five minutes. . Stop the engine and allow it to cool. 8 Repeat steps 1-7; then go to step §, 8. Ramovo the ‘iler cap and verify that the engine coolant level is near the filer neck. If not, repeat steps 1-8. 10. Fill the reservoir up to the FULL mark. 49.9200 145 Adapter set, radlsior cop ester E2-6 =, [ene «, races ee & ise seas 2 Bein INSPECTION Radiator Gap Valve 1. Remove foreign material (suchas water residue) frombe- tween the radiator cap valve and the valve seat. 2. Aitach the redialor cap to a radiator cap tester with the SST. Appl ure gradually to 73.5102 kPa {0.75-1.08 katiom?, 10.7- 14.9 psB. ‘8. Wait about 10 seconds. Verify ihat the pressure has not decreased. Negative Pressure Valve 1. Pull the negative pressure valve to open il. Vorify that it closes completely when released. 2.Check for damage on the contact surfaces and for cracked or deformed seal packing. 8. Replace tho radiator cap if necessary.RADIATOR E2 RADIATOR REMOVAL / INSTALLATION . Disconnect the negative battery cable, 2 Drain the engine coolant. (Refer to page E25.) 8. Remove in the order shown in the figure. 4, Install in the reverse order of removal. PAO: NemsO-TI0 gE, 78541910). geen f-t10 baton, 7O-DRAINE 1. Freshvair duct 6. Shroud upper panel 2. Coolant fan connector 7. Radiator 3, Coolant reservoir hose Ingpection below 4, Upper and lower radiator ho & Coolant fen 5. Ol coo'er hoses (ATX) assembly INSPECTION ‘Cheok for the following and repair or replace if necassary. 1. Cracks, damage, and water leakage, 2! Bent fins (Repair with a screwcriver), 8. Distorted or bent radiator inlet. ‘Steps After Installation 1. Fill the radiator with the specified amount and type of ene gine coolant, (Refer to page E2-6.) 2. Connect the negative battery cable. 3. Start the engine and check for leaks. E27E2 THERMOSTAT THERMOSTAT REMOVAL / INSTALLATION 1. Disconnest the negative battery cable. 2. Drain the engine coolant. (Refer to page E2-5.) 3, Remove in the order shown in the figure. 4. Install in the reverse order of removal, referring to Installation Note. em ‘AT THE TOP ® > east 26, 1418) Nem fit, A 1. Water inlet pipe 5. Thermostat 2. Engine hamess bracket Inspection .... 3. Thermostat cover Installation Note . 4, Thermostat gasket Installation Nate .....eeece0+8 page E2-9 E2-8THERMOSTAT E2 After Installation 1. Fill the radiator with the specified amount and type of engine coolant. (Refer to pago E2-6.) 2. Start the engine and check for leaks. INSPECTION 1. Visually check that the thermostat valve is airtight. 2. Place the thermostat and a thermometer in water. -Heal the water and check the following. Initial opening temperature: 80-84°C {176-183°F} Full-open temperature: 95°C (203°F} Full-open lift: 8.5mm {0.33 in} min. 4. Check the thermostat gasket. If damaged, replace the ‘thermostat assembly. Installation Note Thermostat Install the thermostatinto the cylinder head with the jiggle pin at the top. ‘Thermostat gasket Install a gasket with the projaction facing the same diac ‘ion as the jiggle pin. E2-9E2 WATER PUMP. WATER PUMP REMOVAL / INSTALLATION Caution © Applying oll to the water pump rubber seat will damage it. 1, Disconnect the negative battery cable. 2. Drain the engine coclant. (Refer to page E2-S.) ‘9, Remove in the order shown in the figure. 4. Install in the reverse order of removal. Nepgin, hb 1. Timing bett 9. Water pump assembly Removal/insiallation .......... section B2 Inspect for cracks, damaged mounting 2.No.3 engine mount bracket surlace, bearing condition, and leakage. If the water pump is damaged, replace it. Do not repair it 4, Water pump rubber seal E210COOLANT FAN SYSTEM E2 COOLANT FAN SYSTEM SYSTEM CIRCUIT Eo ENGINE COOLANT ouesnstine LS SENSOR ind L (NO SWITCH Low el aN MEDUMHIGH ition HoH es cigsen __ aa finite me “ERSTE ewmon _ j SWATCH DATALINK ‘CONNECTOR auror Og BATTERY SYSTEM INSPECTION 1. Turn the ignition switch to OFF. 2. Ground the TEN lerminal of the data fink connector and open the throttle slightiy. SUUPER WIRE 3. Turn tha Ignition switch on and verify that the fan oper- ates. TEN 4. Ifthe fan does not operate, inspectihe coolant fansystem: componants and wire harness. 5, Remove the filer cap and place a thermometerin the filer neck. ore 6. Start tho engine. 7. Netty that the fan operates when the coolanttemperature: ono ara use reaches approx. 100°C {212°F}. CONNECTOR 8, Ifit does, check the engine coolant temperature sensor. (Refer to pace E2-14.) E2-11COOLANT FAN MOTOR COOLANT FAN MOTOR INSPECTION ) MIK (Single-speed type 1, Check that the battery is fully charged. 2. Disconnect the coolam fan motor connector. 3. Connect the battery and an ammeter to the fan motor can- Fal neclor. aft 4. Verify that the fan motor operates smoothly at the stan dard current. Current: 11.0 A 6. If the fan motor is faulty, replace the fan motor. ATX (Two-Speed Type) Mode taet ne tater is fully charged. 2. Disconnect the coolant faa motor connector. 8. Connect the battery and an ammeterto the fan motor con nector forlow-speed inspection. 4, Verify that the fan motor operates smocthly at the stan- dard current, Current: 12.04 5. Connect the battery and an ammeter to the fan motor con- nector for high-speed inspaction. 6. Verily that the fan motor operates smoothly at the stan- dard current. Current: 16.8 A 7. ihe fan motor is faulty, replace the fan motor. E2-12COOLANT FAN MOTOR E2 REPLACEMENT 1. Disconnect the negative battery cable, 2. Remove in the order shown in the figure. 3. install in the reverse order of removal. “F907 Wan {GOOD Nghe, TORE Ai AE U2 Nem 16-22 gto, 19 nt, 2-27 Hn treo nate, 24-sote 1, Fresh-air duct 4, Radiator cowling 2, Shroud upper panel 5. Coolant fan 3. Coolant fan connector 6. Coolant fan motor F213E2 ENGINE COOLANT TEMPERATURE SENSOR P eNaI= COOLANT ‘TEMPERATUR SENSOR, E2-14 ENGINE COOLANT TEMPERATURE SEN- REMOVAL, 1. Disconnect the engine cootant temperature sensor con- nector. 2, Remove the engine coolant temperature sensor, INSPECTION 1. Place the sensorin water with athermometerand heatthe water gradually. 2, Measure resistance of the sensor with an ohnmeter. Conant Fairanos BoeeA SEs 7° GOFAL Tan 1050 Ge) Tosi | 8.[f not as specified, replace tho engine coolant tempera ‘ture sensor. INSTALLATION 1. Install the engine coolant temperature sensor and a new washer. htening torque: ees Nim {1.6-24 kgtm, 12-17 ftlbf} 2. Connect the engine coolant temperature sensor connec- ‘tor. COOLANT FAN RELAY REMOVAL 1. Disconnect the negative battery cable, 2. Remove the coolant tan rolay. INSPECTION 1. Chack continuity of the coolant fan relay as shown, earn Canny Ao Ne 20 Yer 2. Apply battery positive voltage between terminals B and D. ‘Check for continuity between terminals A and C. 3.If not as specified, replace the coclant fan relay.Before beginning any service procedure, refer to the 1995 MX-S F2 Body Electrical Troubleshooting Manual; see section $ for air bag system service warnings. FUEL AND EMISSION CONTROL SYSTEMS (K8) INDEX... 2 POSITIVE CRANKCASE VENTILATION ‘OUTLINE: SYSTEM OIAGRAM VACUUMHOSE ROUTING DIAGRAM ‘WIRING DIAGRAM... [SPECIFICATIONS ‘COMPONENT DESCRIPTIONS « ‘TROUBLESHOOTING QUIDE «....-1 "QUTPUT DEVICES AND ENGINE CONDITION voc sesscceeessseseeerereee EGR SOLENOID VALVE (VAGULRN - RELATIONSHIP CHART EGR SOLENOID VALVE (VENT) = EGR VALVE EVAPORATIVE FL SYSTEM PREPARATION’. DIAGNOSTIC THOUBLE GODE NUMBER AFTER-REPAIR PROCEDURE SWITCH MONITOR FUNCTION: DITAKE-AIR SYSTEM — COMPONENTS «-.2scssccasseseeose ‘CATALYTIC CONVERTER § THROTILE BODY scr screecesearcneresesceere DESCRIPTION . AIR INTAKE PIPE/INTAKE MANIFOLD » gappRReRaRRRaRTD SESSSAESSRASRSSSES a 8 Ho.1 AND No2 \VRIS SOLENCID VALVE No.1 AND No . ‘CHECK VALVE VACUUM CHI FUEL SYSTEM OUTLINE OF EMISSION CONTROL ‘SYSTEM DESCRIPTION | soy F223, Feza ELECTRONIC SPARK ADVANCE (ESA) DESCRETION ‘SYSTEM OPE! PURGE SOLENOID VaivE CHARCOAL GANISTER .—"” TWO.WAY CHECK VALVE. (CHECK-AND-CUT VALVE SEPARATOR THREE WAY CATALYTIC. VOLUME AIR FLOW SENSOR THROTTLE POSITION SENSOR . GRISRAFE POSTION SENSOR HEATED OXYGEN SENSOR KNOCK SENSOR, EGR VALVE POSITION SENSOR OSCILLOSCOPE SIGNAL PATTERN +222.F2 INDEXINDEX F2 1, Fresh-air duct 12. Air intake pipe Removal / inspection / Removal / Installation . page F2- 95 Installation . + page F2~ 95 Inspection ....... page F2- 96 2. Air cleaner 13. Accelerator pedal Removal / Installation page F2- 95 Removal / Inspection / Inspection ... page F2- 70 Installation =... cece page F2- 97 8. Volurne air flow sensor 14, Accelerator cable Removal / Installation page F2- 95 Inspection /Adjusiment ..... page F2- $7 Inspection page F2-150 15. Main sitencer 4, Resonance duct Removal / Inspection / Inspection » page F2~ 95 Installation ss... cece page F2-121 5. Throttle body 16. Presilencer Removal / Installation page F2- 95 Removal / Inspection | Inspection . page F2- 96 Installation . . page F2-124 6. BAC valve 17, Three way catal Removal / instafiation . page F2- 95. Resnoval / Installation . page F2-121 Inspection | page F2- 99 Inspection... page F2-182 7. Alr intake hose 18, Front pipe Removal / Installation ....... page F2- 95 Removal / Inspection / 8. VRIS shutter valve actuator Installation -.... 2.022.600. page F2-121 Inspection -----. 2-22... eee page F2-103 19. Insulator 9. Vacuum chamber Removal / Installation ...... » page F2-121 Removal / Installation . .. page F2-102 20. Exhaust manifold Inspection ..... : page F204 Removal / Inspection / 10. Chack valve Installation ......e--e eee page F2-121 Removal / Installation . page F2-102 21. EGR pipe page F2-103 Removal / Inspection / Installation - If OK, check connectors of engine ‘coolant temperature sensor and Boe cerned page FE-181 col nl OK replace engine cciant tempore soreer Te [Bote nantstep 7 | 5 ailaved an SST wih ton wich] Ves | "00" deployed be pagore-7a Gotoreneten ser uanosie sere? srsneseizorea) NO | Blapnonie weuble Gods Wo di Ee Bro cause (tert speciiog com az ne chook spores vepage Fo is enor Sirk nowree ua 3] Are EON tal ages OR? Ye [Gono ‘iain rcey SE engi covet torpor gins Sober experts sensor : pore sone ag, [Ro | Goer eae cxpageFEnval 7 ys know goad ECM aw canon | Von J Reon FOM page FT Peer expageFantat [ig ‘Change to another brand of fuel F2-26‘TROUBLESHOOTING GUIDE F2 3 CRANKS NORMALLY BUT HARD TO START — ALWAYS 7 Erghe annie a vomal apsod but equren exensve raring ne baer ea gegen | tbe retstza pnt reine bioaeerha # Engina runs normaily at idle (If idle condition not OK, refer to "Rough Idle” No. &-1)) TTROUELESHOOTING HINTS] ‘Ale/Fual mture teo lean ‘Fuel injection control matfunction ‘SAL uel mixture too rch, # Air cleaner housing element clogged (Conect for coniant temparanite) * Volum ai “low sensor stuck ¢ Low tuet ine preseure ‘Poor ignition spaak © Airkeakaga ‘STEP INSPECTION ACTION + | 1g G0" daplaye'on 8ST wihignonauten | Yeo | “00" alsplayed e=page F2-73 Go tonext step SELE-DIAGNOSS GHEGKER == Wo | apneic rouble Gods. d- aS [EM SELECTOR) ‘Check for cause (Refer to specified - check sequence) sepege F274 ees SelrcT sve a MONITOR user 2 | Isinteke manfoud vacuum aticte? Yea | Goto next step ‘Vacuura: More than 480 minfig {17.7 inHg} Tho | Check for ait leakage af intake-air sys- tem components 3 | Weaircleanor element loan? Yes | Gotonentsiep seepage F2ar0 No | Raplece ai dearer element 4 | oes engine stant easily when trotie valve | ves | Check throttle vaive for carbon depose ‘quecteny open? then go step 6 No | Gore nextotop % [Is tuel Ine pressure atidie corrser? Yes. | Go to next step repage F2-118 Fao tino pressure: 20S Ka (260.2 ng, 2745 ps (Vacuumhose to prossure regulator discon- [No | Lew pressure ectec) Gneck fv! line pressure white pinching fc return howe INSTALL CLAMPS ol pressure quickly inereases, chick prossure regulator vapage F2-113 sll pressure gradually increases, heck for caging between fuel pump and pressure regulator Those isnot clogged, check tl pump maximum pressure espage F2-110 F2-27F2 TROUBLESHOOTING GUIDE ‘STEP INSPECTION, ACTION 8 Siscomect idle air contra! vaiva connector at Yes | Go to next siep fe OSes engine speed nceaee? eT cnoge F208 No] Replace idle air control value werpage F295 ean ia SOREL Eg) 7 [hee BOM Trrinalvotages OF Yes | Galena cep 1S stoner dial 2E-Engino cacfant tamporature sensor SD.Soteor ground No Ohack orcas pageroaal mpage roan 8 ‘Connect dala fink connector terminals F/P and | Yes | Cheex fuel pump relay wwpage F2-113 GND by using jumper vare; does engine stat ronal? SF OK, rapa or replace wie hamese : . Bi natR replae egy UU No | Gato next step oxo be 9 ‘Connect System Selector to data link Yes | Goto next step: Sousdbr eee cctten Sud s-SELE ove ignition trang ate caret ater warm-up? sapage 2-70 tpnton ming BtOGE 840° (10 9 = D No | Agjest ignition tring empage F2-70 redrsutroa Go| Te one compres comet Ye | Seo rete Engine comresnten (eum ——F SE aD tate ee ped 900 rpm No | Check engite condition # Worn piston, piston rings, or cylinder wall * Detective cylinder head gasket 4 Distrad ojincer neae Sper ave catnn # Vave scking in guide 1 Tiy @ known good ECM and check if condion improves. sxpage F216 F2-28TROUBLESHOOTING GUIDE F2 8 GRANKS NORMALLY BUT HARD TO START — WHEN ENGINE COLD '# Engino cranks at normal speed but raquires excessive cranking time before starting DESCRIP. | ¢ Baitery in rormal condition TON * Restarts OK after warmup # Engine runs nermally at idle (| idle condition is not OK, refer to “Rough idle” [Nes. 8-12)} [TROUBLESHOOTING HINTS] @AbFuel rixture too ich @AirFust modure too ean Volume alr flow sensor stuck ‘© Fuel infoction controf matfunction * irclesner element clogged {correction for coosnt emperalere) ¢ Idle air conivol maltunction Poor atomization ‘STEP INSPECTION ‘ACTION 1 | giao delayed on Set Dizon Yea | Gotonant sep (Checker ignition evita * No | Diagnostic trouble code No, dis SELF-DIAGNCSIS non Fa78 played CHEOKER Giteck or cause (Relerto speciid —sepage F274 check sequence) wouter lent 2 Are ECM terminal voltages OK? Yes | Goto next step: 1G-Starter signal 2E-Lngina coaiant temperature sensor = ab Serge 2a r2-ta1 | No | Check for cause wepage P2141 ‘S| Does engine star easily when trottevalveis | Yes | le idle ar contol vave OK? wepage F299 quarterly open? eoftis, heck ar valve sxpage F2-29 elt itis not, replace kde eir contral valve seepage F2-05 No] Gow nest sep 4 Is intake manifold vacuum oorregt at icla? Yes | Goto next stop ‘Vacuum: More than 450 mmHg{17,7 inet "Ha | Check for alr leakage of Intake 6ye- tom components | leawdearer slomant sean? Yea | Goto next siep sepogere-70 No | Replace air cleaner element @ | Disconnect dle ai contri valve connestorat | Ves | Goto next dep idle. Does engine speed increase? page F288 No | Replace icte air contol valve: wepage F2-90 LEAR m CONTROL VALVE =" F2-29F2 TROUBLESHOOTING GUIDE ‘STEP INSPECTION ‘ACTION 7 | Sonnedt data link connector terminals FIP and "| Yes | Goto next top GND by using jumper wi: is ful line preseure camect ith griffon evita ON? No | Low prosoure expage F2-107 ‘Check fuel ine pressure whis pincbing Fuel tine pressure: ‘uel rotirn hose 260-310 KPa {26-82 Kglom®, 37-45 000 weit pressure qu increases, check INSTALL CLAMPS ressure remuiator sxpage F2-419 ct pressure gradually iereasas, ‘shack Tuel Ine for clogging between {uel pump and pressure regulator I hose is nol clogged, check fuel pump maximum presture sopage F210 High prosoue uel return hose olegged or restictec? ‘lit isncl, replace pressure regulator "*PAg® F2-115 INTs, repair oF replace 8 | Try awn good ECM: dows conationim- | Yos | Replace ECM ewpage F214 prove! empeue 2-161 sg Change to another Brand of fuel F2-30F2 TROUBLESHOOTING GUIDE 7 CRANKS NORMALLY BUT HARD TO START — AFTER WARRGUP ‘Engine cranks al normal speed bul eaqures excessive cranking line belore slaring aller runing and pescrip. |, being hot soaked gege ¢ Battey in normal condion # Engine starts noxmalty when cold Engine nuns morally ate (Sle concltion is not OK, refer to “Rough Kile [No, 8-42) [TROUBLESHOOTING HINTS) Aide! mixture too sch Vapor look # Fuel injection control atfunction * Fas pressure not held in fuel ine tar engine (© Fusl injector ‘val leakage stopped «Pressure reguletor control system maifunotion ‘STEP INSPECTION. ‘ACTION 1] 5 Oo" dslayed on B87 wih gation svtah] Yes | “BO” leployed ° sxpage F275 Goto nent step SELF-DIAGHOSIS CHECKER Diagnostic trouble coda No, dis- played Check for cause (Reler lo specitied check sequence) sepage F2-74 2 | Remove vacuum hos rom presse regustor | Yes | Shenk presse requis corral aye: arpaga Fa dnd plug it tem Does engine start ormally? 2 & ae No | Golonaxt step 3 _| Arp FOM terminal voteges O7 Yes | Goto next alep 1C-Starter signal ]2E-Sng ne ccolant temperature sensor 30-Sensor ground No | Ghesk for cause wapage F2141 expage F2-121 4 | Pion engine atidle: cose fuel line pressure held | Yes | Go lonext step afler ignition switch is turned OFF? 'No_| Plug outlet of pressure regulator outel: uct ne preseure: Moro tran 150 KFA {1.5kgtiom, 21 psi tor rin, INSTALL CLAMP, PRESSURE GAUGE, is ual ne pressure held altergnition wich Is tmed OFF? sspage F218 If It does, replace pressure roguletor mpage 2-115, 2 das not chock fuel pump hod presewe sepageF2-101 iEfvel pump is OK, check tek injeo- tors for fue leakace sepage F2-116 F2-31F2 TROUBLESHOOTING GUIDE ‘STEP INSPEGTION ‘ACTION, 5 | Warm up engine te normal oporating iompera- | Yes | Change fo anolher brand of uel ture and stop it Connect data link connector terminals FIP ard GND by using jumper wire for 3 minutes wit \gnilion switch ON; does engine siart easily? DATA LINK CONNECTOR No | Goto next step @ | Trya known good FGM; doea conaition im | Yes | Replace ECM wepage F214 prove? eepaye F2-141 & ‘Change to another brand oftuel Lo F2-32TROUBLESHOOTING GUIDE F2 : ROUEN EGNEaTAILS AF HE ALAS DESCRIP. +» Engine starts normally but elalis er vibrates oxoossivoly at \dle in every condition TRovBLEs OOM GHAI ‘WAirusl mixture too lean Dincorect cle spoon © Air leakage ete speed misad)ustrent Fuel injection cenirol malfunction * Kiel ar control malfunction: soa ance eg ‘One or More fuel injectors oogged or net operating ‘@Law engine compression Sears ete Etec STEP INSPECTION ACTION 1 {s (0° depleyec on ‘SST with ignition switch Yes | “00” displayed . joF273 Goto SELFDIAGNOSIS. srpess nest step = 7 | gown aos : ‘SYSTEM SELF! ‘Check for cause (Refar tc specified G check soquence) wepage F2-74 y Ss saccrows {so icis 041 | watson is 2 Aro ECM terminal voltage OK? Yes | Goto next atep 16-Siarer signal Bemesetereremstesm a Sacra sais — 3 Diseonnect high-4tension load at |dle; does en» | Yes | Go to step 8 gine speed decreases equally al each cylin= dere No | Goto next step a Is there fuel Injector operating sound at idle? Yes | Goto stepé No | Goin next step 3} oss io ways | Vs) bl oar sine 7 Fels Salta oar creer it Resistance: 12-16 9 [20°C (68°F}] sity keg tetron EO and fuel injector Thats cn papers 3] Sek wing ono ECan a injootor 7 Bieri patseieaamowared | Ve | Soot ipeemner min Sa a al wanton spit OK, check distributor cap and rotor pif not OK, replace high-tension lead F2-33F2 TROUBLESHOOTING GUIDE STEP INSPECTION, ACTION 7 | Reape pige OR? Yer | leew conpreionconoek? —vwseeon Bi (20, repo uelinpeer sopage FI SHO sheck or tecoe ean AND CARBON BLEU on te rasow girounis see =n aMAa AD fooai Botany CHM A, [io [ ean oeiae space caseaton 6 ana © | Teal pressure coven TT Yar | Gowan pie Rad Ko Puc! line prossure: Shock fue! lina pressure while pinching 260-310 kPa (2.6-9.2 katcm?, 37-48 pst} fue! return hese oarbea ora apa eon vue cif pressre que nereaes, heck pressure regulator erpage F2-113 alison grat ereseo, Seer a Revco tat pump and pressure requiator ‘olf hose is not clogged, check fuel nap naan ears sepogoF2-110 2 | Does vane ar tow sensor wove snoaiiy | Vos ] Governed oe porn nntac caren eecsone trates Ne par place ale ow oe ta WS Me 75 tree a onkage a naiacrajeiam com | Yew | Rapa orraaee ran No | Goto next step an ts angine compression carrect? on 82 Yes | Go tonaxt stop ecmnresion (nr = eagreente i eguent, aa pah 300 pm No | Check for cause: section B2 12 | Connect System Selector to data link connector | Yes | Try @ known good ECM and check if and set Test Switch lo “SELF TESTS fs ignition condition improves eepage F2-141 timing correct at idle alter warm-up? AP gern gion Teg (BOOP A400 6 [ic Rasa ig capoge F271 F2-34TROUBLESHOOTING GUIDE F2 9 ROUGH {DLE/ENGINE STALLS AT IDLE — BEFORE WARM-UP DESCRIP | # Engine speed low cr engine sts or vibrates excessively aie during warmup IN [TROUBLESHOOTING HINTS) Low intake sic arsount # Volume air flow sensor stuck ©Low fuel infection control Fuel injection control mattunction * Air cleaner element clogged {Correction tor coolant temperature) # Airvaive Poor atomization ‘STEP INSPECTION ACTION 1] R520" eaplayed on SST wih igniten such] You | "0" aera eopage F273 Go tonext step SELF-DIAGNOSIS GHESKER (No | Olegnosic wouble code aeplayed (Check for cause (Reter to spaatied check sequence) spage F274 2 | Tes imteko mantiord vacua correct atidleatter | Yes } Go to next step warm-up? acai: Mora than 450 mmig {17.7 inHg No | Check for air leakage of inako-air 57s {ern components 2 | Ieeircleaner element dean? Yes | Go tonem step sepago F270 No_ | Fleplace air eleanor housing oement 4 | Are ECM terminal wolages OK? Yes | Goto next step 1€-Stariar signal 2E-Engine coolant temperature sensor 3D-Seneor ground Ho | Check for cause wwpage F2-t41 ccpage F184 % | Disconnectidie air contol valve ocaneclor | Yas | Ga tonextstep Does engine epead increase after warmup? No | Flaplace AC valve ‘epege F205 IAG VALVE: F2-35F2 TROUBLESHOOTING GUIDE STEP INSPECTION _ ‘AGRON ts engine coolant temperature sensor resi- tance correct? SISTANCE seepage F2-182 Goto nem step (, 36 i t 3 No | Replace engine coolant temperature ? sponsor of 33 83 oz oO £0 80, cic COOLANT TEMPERATURE °C 7 | Connect System Seteciort cata ink Yeo | Goto aad sip ilps set Tost ‘Switch to “SELF TEST" ‘when engine i cold Does engine speed decrease 2s engine No | Check alr valve warms up? cxhage F2-29 | Gone Syator Socter to data nk Yoo | Go tenant aap Conner and sot Test Swich io"SELF TEST*: is ignition timing at idle correct after warm-up? sxpage F2-70 Ignition Gining (BTOG} 811° (10 247) | Tio | Adjust ignition timing page F270 Test SWITCH ‘2 | Thyaimown good ECM; does condition m- | Yes | Replace ECM expoge F214 prove? sepageF2-141 Tho | Change to another orand of fuel F2-36TROUBLESHOOTING GUIDE F2 19 ROUGH IDLEENGINE STALLS AT IDLE — AFTER WARM-UP VALVE IDLE AIR CONTROL a! @ DEgarm [+ Engin eine nemnly ate dng warmup ulate or valve OoRENOH slr WATT TROUBLESHOOTING HINTS] © lde-speed control system mallancton ‘© ue inte too sch © Aue stare too Yeon ‘Ful irjecton contol altunetion * Arfeakage {Gorecton fo" cootet emperatre) * Love fue! ne pressure Poor igriion Slow engine comaression rer WSPECTION ‘ACTION 1 | Boar deplaedon SST wahigntionawion | Yes [=O aapiyea * sepage F2-T3 Goto next step SLR DIAGNOSIS caecKen Diagnostic rouble cade NO. a played Chock for cause (Refer o specited check sequence) sxpage F2-74 ‘SELECT OW: A MONITOR tour |~2 | Are ECM tormrinal voltages OK? Yeu | Go tonartstep 40-Stater signal 2E-Engine cooler lemparature sensor 80-Sensor gourd snpogera-sa, | o| Ghai came page Fis ‘S| Bisconnedt highension toad al lz doze en- | You | Golonat sen gine speed decreace equally a al cyincers? No | Gotoaap 9 4 | Te itake mariid vacuum atiae-corech? | Yes | Gotonestep Vacuum: More than 480 mmiig (17.7 ing} No. | Ohosk for ar leakage ofntake-cr sye-spage F205 temoomporsits | Isairdearerelementoeant? Yer | Gotonextclop pager270 hg | Replace a clearer lamont @ | Dlkoonnestidie ar contol velo connector at | Yes | Go to next stop ‘ele: does engine speed inorease? No. | Peplave ie ar control valve aepage F266 F2-37