WILLA Turesa K3-VET-ENGINE Service and Technical Information Paga No. o1 12 13 7 23 34 37 39 56 57 60 64 67 69 70 73 Section General Information Maintenance Engine Tuning Engine Mechanical Intake & Exhaust Lubrication Cooling Engine Control System Emission Control Ignition System Automatic Transmission Front Suspension Rear Suspension Drive Shaft Braking System Body & Body Electrical Systam BBE Part No. 2220000000305 SGI-1 1-2-2 EUROPEAN SPECIFICATIONS Model code Sieering position | Grade | Engine | Drive | ‘hansmission Boay type iors omen M200LG-GMNEW LHD to ENE out M201RG-GMNEW LO neomesoew | © |i ‘201RG-GOGEW HI oo Tepe! io on M201LG-GMGEW. LHD HI K3VE_ 5-door M201LG-GONEW. LO Electronic control ese cose na TETAS NEW an ; 0 Econo cou were Sone a oo nes meee! | out heii soheW eaney | —__ ence con M201LG-GOSIW_ LHD. Turbo K3-VET 2wO 4AT eel onan 1-2-3 AUSTRALIAN SPECIFICATIONS eT M200RG-GMNFQ_ EU-DE wT M201RG-GNNEG RHD Lo K3.VE 2wD 7 5-door comer ao oa — oe sear a 1-3 EXPLANATION VEHICLE MODEL CODE cease ates Drive: Steering NLo None: General 0: 2WD tleft Door GH W: Europe Be A: i G fe Ss: ll Tce w2|[o jf 7 |[t je |—[e ][ mu jl |e [fw] wee ene oe) y90 Tmo fale OB G: Wagon M:SMT F:4 Valve ct ne or Sith cage SeG OE SPECIFICATIONS Speciications MZ0ORGAG M201RGILG M2iTAGILG lems 2WD 2wo ‘aWO. EybE | E/VE KSVE, KGET SVE Mi wr Jat [ar | wa Tap ‘General spac. 1360 1400 7 Gross vericle [australian spec. 1316 1350 = kg | European spec. 1960 7400 1420 | 1420 [780 Overat iength ‘3765 = = Overall with 1625 = = ‘Overal Reight 1850, 1880°7 = = Whee! base 2370 = = _]| 19 inch wheels 1390 = = 1380 ee Front [14 inch wheels 1380 = = 1380 ial 18 inch wheels = = 1380 = “‘Biinch wheels 1870 = = 1370 Rear [14 inch wheeis 1360 = = 1360 fam, $8 inch wheels = = 1360 = Max. Front kg 770 ~ = permissible axiemass [Rear 'g 760 ~ 785 Without brake i 350 = = Towra mies ih rae ig 780 a0 = Permissible root rack load kg 50 = = Displacement ‘an? 289 1288 = King of fue Petrol = = Recommended eclane number Win 80 (RON) = = Cycle 4 = = Number of eyinders & Arrangement Sinsing dining = Firing order 42.8 err = | ax Stroke im 72x81 Tex7a7 = Distance of bore center to canter mm] 20 78 = Compression ratio 1003 = 35E03 iox08 Engine service mass. a | 96 = 9. 94 oe [89 Max. power Fewfrom| 40.5'6200 | 43,096000 [63.0600 | 96/6400 | 63,0/6000 [igeition timing BDC degreeiom| _542"/650:50 6£2°/ 700450 = Engine valve mechanism OHS = = Opens pipe Heme 30° --12" BTOG - — 425° | 2-62" aunt Closes ase | oroe 10" -52" TDC - roe Opens Bape faeces 30° BBC ~ Exhaust 7 sere islets : [Lubricant usea SAE SW3O) = = "ith rear roof antenna oecons.08GI-3 —_—_—_—__————— Speciications M200RGLG | M201RGAG M21iRGAG tterns 20D 20D. AWD eye | IVE KANE KSVET | _KSVE MT wr | at | at [on | ar (Coolant capaci ters 30 44 40 43 [44 40 iat 3.182 = = 3.182 2rd 1.842 = = 1302 [ pane Sid) 1.250 = = 1250 [= iransmission gearraio [4th si7 0.865 = oes | — Sih 0.750 = = ‘o7s0 | = Fev. 3.143 = = 343 [= ist = = 2731 =| 27% ‘Automatio (20 = = 1.526 = [1526 transmission [Sed = = 7.000 = 000 gearratio [ath = = 0.696 = [0.696 Rew = = 2.290 =| 2280 Transfer gear ratio = = 1.000 Differential [Front 4.500 4267 |_ 4032 | 3749 [4267 | 4350 gearratio [Rear = = 3.077 ouspension ES Macpherson strut = erece} sion ‘ype Rear sa ticenencons - 8 Link ae [Front Cait = = Rear col = = Telescope with Shock eat couble acting - a absorber jeeinomscans wane bel | eouble ctning ei it Type Ball jont = = FToe-in am ° = = Frontaie [Camber o = = (Caster 28" = = Kingpin angie 1a = 18" tae Rearave (een mn 3 = ° [Camber =Or1s! = ° ‘Type Rack & Pinion = = ‘Steering (Goarratio [Power steering 17.0 72 wa we (Overall) | tanual 22.0 7 - TeKoRDateGI-4 "3 With rear roof antenna Vehicles mounted with T/C engine4 VEHICLE IDENTIFICATION 4-1 LOCATION 4-1-1 CHASSIS SERIAL NUMBER 4-1-2 ENGINE TYPE AND ENGINE NUMBER 4-1-3 MANUFACTURER'S PLATE POSITION GI-5 Vehicle identification number _{For GCC & EU specifications) Engine type Engine number Mafutacture’s plateGI-6 ree 5 ABBREVIATION CODES ABBREVIATION CODE ORIGINAL WORD ABBREVIATION CODE ORIGINAL WORD 210 Fiwo Whee! Drive MP Multipurpose 40 Four Wheel Dive Mir ‘Manual Transmission (ransaxe] ABS Anivlock Brake System NAL Natural Aspiration AC. Air Concitionsr NOx Nirogen Odes API Amierican Petroleum insta ‘OPT Option AT Automatic Transmission (Transaxie) OS Over Size AIDC After Top Dead Center PCV Positive Crankcase Ventilation ATE Automatic Transmission Fiuid PR Ply Rating Ay Assembly PIO. Power Take Off BTDC ‘Before Top Dead Center RH Right Hand ue Data Link Connector HD Fight Hand Drive DL Distributor Less Igniion FR Rear Dwr Dynamic Variable Valve Ting SK Sub Assembly 80 Electron Brake force Distiouton SAE Socisly of Automotive Engineers ECU Electronic Control Unit, SST Special Service Tool EFI Electronic Fue injection SID Standard EGR Exhaust Gas Recirculation System SW Switch EPS Electronic controlled Power Steering it Torque, ESA Electronic Spark Advance Te Turbocharger ZZ Xx [Exhaust TOC Top Dead Center Fi Fusibl Unk us Under Size Fa Front vav Vacuum Switching Valve NO Ground vv Vacuum Transmiting Valve HG Hydro Carbon Wi with 18 Tanition ® Bot iN Intake © [Screw 186 idle Speed Contot a) Nat 1c integrated Timer Control @ Washer lED Light Emitting Diode © [clip tH Left Hand HO sft Hand Dive LsPv [Load Sensing Proportoning Valva TESTES ‘-aBe-co006 JACKING POINTS 6-1 JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS 6-1-1 JACKING POINTS CAUTION + The jacking-up operation must be carried out only on a level flat place. + Never jack up the vehicle at the front and rear sides at the same time. * Be sure to set the garage jack in such a way that the jack may not interfere with the bumper. @ vecking points Font co Front Rear suspension Rear ae * Never use the rear suspension ‘beam as a jacking point. (For 26D vehicles) SaF 2 SUPPORTING POINTS OF SAFETY STANDS CAUTION + Never support the vehicle at points other than the specified points. GI-8 Safety stend suppor asGI-9 9-2 DATA LINK CONNECTOR 9-21 DATA LINK CONNECTOR TERMINAL ARRANGEMENT esmmouescd No. Terminal code No. Teeminal code 1 4 BAT (05-21), 9 T (TO) 2 = 40 7 S10 (08-21) 3 = 1" 7 4 TiECU) 12 E 5 ea) 13 E 6 W. 4 = 7 = 16 = 8 REV 16 VE Ta essomcocone 9-2-2 CONNECTION METHOD OF DATA LINK CONNECTOR 1. Perform it by connecting the engine control system inspection wire (SST) with the data link connector. Perform the system check of each system by using the terminal for short circuit (SST), the terminal for detecting engine speed and the terminal for VF output monitoring (SST). (1) CONNECTION METHOD OF EACH SYSTEM 1. Diagnosis code output of engine control system: Short circuit between T (EFI) - E Functioning check of 0: sensor for engine control system : Measure between VE - E Engine speed check of engine control system: Measure between REV - Body earth Diagnosis code output of ABS system: Short circuit between T (ECU) - E Diagnosis code output of airbag system: Short circuit between T (ECU) - Diagnosis code output of automatic transmission system: Short circuit between T (ECU) - E Functioning check of body integration controller and vehicle speed sensor: T (ITC)-E Diagnosis code output of immobilizer system: Short circuit between T (ITC) - E ONDARwN cinowc-scome13-1 BODY COLOR CODE GI-10 —_—_— ee 13 VEHICLE IDENTIFICATION 13-2 CHASSIS SERIAL NUMBER 1. The chassis serial number is stamped on the position as shown in the illustration. Bodycare Caras Serna Sa Beckmce we Ughtose mee Tis Ted 8 Sho nea ma 5 Sunonryetow v0? a eearcoprnare | cata | ax2 | ouronr ousumir | BAUD | SAE | cpaoe Ths wos | Bad | waded —[-DALNGS | ume [teas “| aos Silver metallic Sov DAHSO7 18842 DAI-SO7_ 81278 97076 S07, Bick ria wos | paeaos | wssse—| pavnns”[ Cvneie | reg [eee iiatresemetaia ris oaars | ease —[-partio | wires "| “sesso [ he Ted wea |" pawco | F700 | pains [aaa] sess | as Blue metallic mica B50. DAHESO M6981 DAI-BSO WVFSB. 69136 B50 Sule yew soy [ower | sere F pasor | ives] 888 |r — comseao Chassis serial number Vehicle identification number -{For GCC & EU specifications) HTi3-4-1 CONTENTS OF MANUFACTURER'S PLATE General, Australian specifications O-f—DAIHATSU MOTOR CO. LTD. JAPAN ® ows MCL TTT ET IIIT @— enone ELT TTT ttt }-+-® © peoton EEE tAMCEEOE O| Burt vate CLT TTT }-——J ENGINE NOCCTITTT+4 SS AA NY LHRRRKSH European Specification @-——DAIHATSU_ MOTOR CO..LTD CEEEPECoon k © Geen CEED Ks COOTITTETrea rer 5 CUO ks ea ells coo He Croitie OCtikg ttt tt+-8 @-pWECEELLEEEEET EEE | © enaine“ LTT ITTY) covor([T11+-7-® GI-11 © Manufacturer's name, Country ® Vehicle model @ Chassis No. @ Engine type engine displacement © Body colors Dim coce @Engine number @ Manufacturers name in Japanese Gross vehicle weight Gross combination weight @ Maximum permissie front axle weight (G Maximum permissibie rear exle weight { Production month-year (Only for AUS spec.) @ Authorized number of WTA. (Only for European spec:) eTMA-12 2 MAINTENANCE SCHEDULE 1. For improved maintenance, the maintenance schedule has been simplified. NOTE * Perform the periodical maintenance at the specified mileage or the time whichever comes first, un- less otherwise specified, 2, Continue to perform the periodical maintenance after 90,000 km (54,000 miles) at the same intervals as before 90,000 km. If the vehicle should be operated under severe driving conditions, operated occasionally, operated in dusty areas, repeating short trip, operated under extremely cold climate and/or on salted roads, it is necessary to perform some maintenance items more frequently than the regular maintenance schedule. This maintenance schedule has been prepared based on requirements mentioned in the owner's man- ual which are to be performed by the Daihatsu owner thoroughly. (©....Check or inspect _@....Change or teplace Whattoco ~i0ookm [15 | 30 | «5 | 60 | 7m | 90 Section Item Inspection “x 1000miles,_@ | 1a | 27 | 96 | 45 | 54 interval Years 1 2 3 4 s [6 Seeing ; Ched Aiccleaner element | CMC eo, eo} e]olole ‘Change Change (EJ,K3-VE engines) | @ | @ | @ | @ | @ | eo (Use API SH or higher") ‘Change (K3-VET engine) (Use API: SH or higher) Engine oil & ol fiter Every 10,000 km (6,000 miles) / 1 year Check Crack Fuelline & connections ‘eTightness ° ° 3° nine | CrebIng fst ses) | = aes * Damage Coolant | : | (Long lite coolant) Change | Every 2 years Orive bet Check (Aternator, Tension water pur. * Crack o}ofloflojol]fo power steering) $ Damage [Timng bet Grange Every 100,000 km (601000 miles) | Crean & check * Condition Spark Plug ceo ° ° ° *Damage Replace every 12,000 km / 1 year, whichever comes first when API SG mult grade ois used. "2: Only for Type EJ engine. Macs eosET-13 -3 CHANGE ENGINE COOLANT 1-8-1 CLEANING OF ENGINE COOLANT CIRCUIT 1. Drain the engine coolant 2, Fill the water and warm up the engine. 3. Stop the engine and drain the water. 4, Repeat the above steps 1. through 3, two or three times. ereaunccoie 1-3-2 DRAIN ENGINE COOLANT 1, Remove the radiator cap. 2. Drain the engine coolant by removing the drain plug located at the lower side of the radiator. 3. Install the drain plug to the radiator and tighten it. ercounoena 4-3-8 FILL ENGINE COOLANT 1. Fill the radiator with the engine coolant in accordance with the instructions of the manutacturer of the antifreeze solution and warm up the engine. 2. While the engine is warming up, check to see if the leakage is presented. %. Cool down the engine after the engine has been warmed up. Fill the engine coolant if the engine coolant ievel is low by checking it sans LOW/FULL 0.251098 raver raise capacity ialcdiced but not the reserve Poe Sie” | oxsose voaly Tota! the heater capacity, = era ‘Automatic | 4.08 tank capacity. ro EJDE Manuel 3.0 | Thisfigure includes EVE Total oe - the heater capacit TES ercoL RowenET-14 ———— 2 ENGINE OIL 2-1 INSPECTION 2-1-1 CHECK OF ENGINE OIL QUALITY 1. Pullout the oil level gauge. 2, Check the engine cil for deterioration, ingress of water, discoloring or dilution, IF oll quality is poor, change the engine oil NOTE * Use API grade SH or higher multi-grade viscosity, fuel efficient oil, 2-2 CHANGE OF ENGINE OIL WARNING * Never touch the cylinder black, exhaust manifold and/or the engine oil. Failure to observe this cautior will cause you get scalded. * Operate the engine in a well-ventilated area to avoid the damage of carbon monoxide. * Protect your eyes by wearing safety goggles. er es0- con: Engine type Capacity £ With oil titer: 3.6 Lede idea Without oi iter: 3.3, Engine oil With ofl fiter: 2.3 Oe Without oi ter: 2.1 TESORO rrecon zn,ET-15 —_—_—_—_—_—_——___—— 2 SPARK PLUG 1 INSPECTION 3-1-1 MEASUREMENT OF ELECTRODE GAP 1. Measure the electrode gap, using the plug gap gauge Hf the electrode gap is not within the specifications, adjust the gap by bending the base of the ground electrode, being careful not to touch the tip. K.VET Manufacturer [_DENSO | NGK Tyne, PK20PTR-S9_ | BKURGEKPA Electrode gap (mm) 08-09 - Width across flats (mm) 16 — TRTTOTES CAUTION * All four plugs should be the same heat range and be once manufactured by the same manufacturer, ersrcccem4 COMPRESSION PRESSURE 4-1 INSPECTION 1. Warm up the engine thoroughly. Stop the engine and remove al ignition coils and spark plugs. 2, Remove the fuel pump relay. 3. insert a compression gauge into the spark plug hole Depress the accelerator pedal fully. While cranking the engine, measure the compression pressure. SPECIFIED VALUE: Compression pressure (330rpm, difference between cylinders: Not to exceed 147 kPa) Specified Value («pe) Limit (koa) KS.VET 1196 ‘902 Tes NOTE * Be sure to use a fully-charged battery. Also the measurement should be performed in the shortest Possible length of time, srourc.zo%mEM-17 * OUTLINE 1 A DESCRIPTION Type K3-VET engine, which has newly been added to those vehicles destined for the EU, is equipped with @ turbocharger system, based on Type K3-VE engine. This engine is mounted transversely in the vehicle. As a result of the employment of a turbocharger system with an intercooler, some changes, such as the compression ratio, have been made from Type K3-VE engine, thus optimizing the specifi- cations. encoreEM-18 1-2 ENGINE PERFORMANCE CURVE 100 95kW [6400 rpm] 90 + eo 7b 41680 170N-m [2800 rpm] eof 4160 EB sof 4400 E = z 2 g “of 4m 2 sof 100 zat 420 woh 7 1 1 1 1. 1 1 2 2 4 5 8 7x10? Engine revorution speed (rpm) K3-VET SP BRSEM-19 7 ~ ENGINE MAIN SPECIFICATION Engine type K3-VET King Gasoline, water-cooled, 4-cycie (Cylinder number and arrangement Inning, 4-cylinder, transversely mounted Valve mechanism DOHC chain-criven (intake 2, Exhaust 2) (Combustion chamber type Pent of type Intake, exhaust leyout Gross flow type Total displacement ce) 1208 Bore x stroke riwn| 72 x 79.7 ‘Compression ratio 25 ‘Maximum output ‘eW/ rpm | 95 / 6400 Maximum torque Nem rpm] 170 / 2800 nko ‘Open sor = 12" BTC Valve timing Chose 10" §2° ABDC fue Open 30° BBDC Close 2° TOC “ake system Turbo we! supplying system Electronic fuel injection (EFI) Igition system Fulltransistorized, OL type, battery ignition {oling speed 700. Fuel used Unieaded regular gasoiine Gilused SAE 5W-30__ API SH or higher TERT eu.oursmteEM-20 1-4 ENGINE SECTIONAL VIEW epaitea ” ENGINE PROPER « ‘CYLINDER HEAD 1. On Type K3-VET engine, as a result of the change in blow-by passages, the location of the blow-by tube has been altered from the side to the top section. CYLINDER BLOCK Water outlet port (tor turbocharger) ‘Turbocharger lubrication oll out. Oil pressure switch installation portion On Type K3-VET engine, as a result of the addition of lubrication oil passages and cooling water pas- sages for the turbocharger, the following parts have been added to the cylinder block to accommodate the turbocharger oil inlet pipe, turbocharger oi outlet pipe, and turbocharger water hose. EM-21 Blow-by tube (K3-VET) Knock sensor installation portion SecoEM-22 2-3 PISTON 1. On Type K3-VET engine, exclusive pistons have been adopted. In these pistons, the volume of the re cessed section at the top of the piston has been increased according to the compression ratio. As re gards the identification mark, an “N" mark is cast at the reverse side of the piston in the case of Typ K3-VE engine, whereas a “T” mark is cast in the case of Type K3-VET engine. Identification mat Hard almite treatment ‘Assembling condition 2-4 PISTON RING Leneozoone. ee, 1. On Type K3-VET engine, exclusive parts for the engine equipped with a turbocharger have been er ployed. ‘Compression ring No.1 ‘Compression ring No.2 Oil ving Engine type K3-VET = = Materials Steel Gastron Steel Parkerizing Parkerizing Surface alloying Outer periohery: hard Parkerizing uier periphery: hard chromium plating chromium plating Thickness (mm) 23 26. 2.25 With (oom) 12 = 2 Upper surface symbol f R = a TORE ev.comonre 1 “UTLINE 1, On vehicles mounted with Type K3-VET engine, as a result of the addition of a turbocharger system, parts of the exhaust system have been changed. e-cureon2 COMPONENTS 2-1 AIR CLEANER 1. Type K3-VET engine has adopted a resin-made air clean- er case (3.95 2). 2-2 EXHAUST MANIFOLD AND EXHAUST MANIFOLD GASKET 1... Type K3-VET engine has employed a cast iron exhaust manifold and stainless exhaust manifold gas ket. The exhaust manifold is provided with a turbocharger with a turbo-to-exhaust manifold gasket ir terposed. Furthermore, at the outlet port of the exhaust side of the turbocharger, the exhaust manifol No.2 is provided with an exhaust manifold No,’ case gasket interposed. Turbocharger to ‘exhaust manifold gasket Oxygen sensor Exhaust manifold No.2 Exhaust manifold No.1 case gasket1E-25 ee ~ 3 TURBOCHARGER SYSTEM _ 3-1 TURBOCHARGER 1. Type K3-VET engine has employed a small-sized water-cooling type turbocharger that features an en- hanced response under the low load range of the engine. A floating metal has been adopted at the bearing section of the turbine shaft of the turbocharger. no LS Intake air temperature sensor 2-3-2 INTERCOOLER 1. On Type K3-VET engine, a drawn-cup type intercooler has been employed. An intake air temperature sensor is provided on the pipe at the outlet side of the intercooler in ‘order to correct the air density by the intake air tempera- ture.IE-26 2-3-3 BOOST PRESSURE CONTROL SYSTEM (1) Description 1. On Type K3-VET engine, the EFI ECU is controlling the boost pressure in order to prevent the boost pressure of the turbocharger from rising excessively. The signal sent from the EF! ECU activates the boost control VSV, thus controlling the pressure to be applied to the waste gate actuator. Any fluctua- tion of the pressure to be applied to the waste gate actuator causes the waste gate vaive to be opened orclosed. In this way, the boost pressure is prevented from rising excessively. > Inerccler =“ t = Boost ar vee it Boost coil VSv EFIECU wase gate acualer Arcleaner ‘Turbocharger ‘intake air OE (2) VSV ( Boost pressure control ) 1. The boost control VSV has employed a normal closed type VSV. This VSV, controlled by the EFI ECU, controls air continuity between the air cleaner and the air inlet pipe. \e-couecoa!1E-27 OO >8-4 AIR BYPASS VALVE CONTROL 1) Description 1. On Type K3-VET engine, the air bypass valve (ABV) control is provided in order to prevent the boost Pressure from rising due to a sudden closing of the accelerator pedal. When the EFI ECU detects a sudden closing of the accelerator pedal, the VSV for ABV control is tumed ON. When the VSV for ABV control is turned ON, the negative pressure of the intake manifold acts on the diaphragm chamber of the ABY, thus releasing the boost pressure at the outlet side of the compressor to the inlet side of the compressor. In this way, the boost pressure is prevented from ri FFL ecu ABV control VSV Turbocharger ee (2) Air bypass valve 1. The air bypass valve is so constructed that the circuit of the port A (connected to the intercooler) and port B (connected to the air cleaner hose) is opened and closed by means of the valve, as indicated in the following figure. When the negative pressure applied to the port C (connected to the VSV for ABV control) exceeds a certain value, the valve opens, thus opening the passage. Cport | spor —e [T ( ) [Jere als (Airinlt pipe) (Air cleaner hose) } Aport —> fiero es B port Cpon {ABV control VSV) Inner construction1E-28 (8) VSV ( ABV control ) 1. The VSV for ABV control has employed a three-way type. When the power supply is OFF, air continuity exists between the ABV and the air inlet pipe. Conversely, when the power supply is ON, air continuity exists between the ABV and the intake manifold, 1 cowoanee2 INTERCOOLER 2-1 REMOVAL AND INSTALLATION 2-1-1 REMOVAL AND INSTALLATION PROCEDURE (1) COMPONENTS TE5EES * —: Non-reusable parts T Tightening torque Unit: Nem (2) REMOVAL AND INSTALLATION PROCEDURES 1 10 8 GoverS/A engine upper 6 5 F Gasket 2 9b Hose.airiakeNe.t 7 4 9 tercooer ayy 3 Bc Hose S/A, vacuum (VSV for ABV conto -itercoole) © 9h Mose SIA, vacuum (Pressure sensor intake manteld) 47 6 conenactor Ay, intake ae © 2 1 Preseur sensor 5 5 © hiakoairtempertur sensor 10 + Bracket intercooler recom:3-1-3 POINTS OF INSTALLATION 1. Install the exhaust manifold gasket. CAUTION * Install the exhaust gasket to the cylinder head so that it's protruded section faces to the cylinder head side. 2. Installation of exhaust manifold (1) Tighten the bolts and nuts in the sequence as indi- ‘cated in the figure on the right.4 “6 POINTS OF INSTALLATION Installation of turbocharger (1) When the turbo oil outlet pipe S/A is installed, be sure to instell a new O-ring. (2) Securely tighten the two attaching bolts of the turbo oil outlet pipe subassembly with a new turbo cil outlet gasket interposed. (3) Temporarily install the turbocharger to the exhaust Turbo pipe Sia manifold with a new turbo-to-exhaust manifold gasket cil outlet interposed. At this time, insert the turbo oi! outlet pipe subassembly into the hole of the cylinder block. (4) Securely tighten the bolt and nut attaching the turbocharger to the exhaust manifold. (8) Assemble the turbo oil outlet pipe subassembly to the engine mounting bracket Assemble the ABV in such a way that the arrow mark provided at the side faces the air cleaner hose side. Install the air bypass hose No.1, air bypass hose No.3 and air bypass hose No.2, as indicated in the following figure given below. 3, Throttle body \VSV for purge contrat SV for ABV control Boost control VSV To canister On CIO To intercooler Toair cleaner hosé Turbocharger1E-32 F 3OOST PRESSURE CONTROL SYSTEM ot ABV sat INSPECTION (1) SYSTEM DIAGRAM Negative pressure VSV for ABV control (ON) Engine control computer Turbocharger @) OPERATION CHECK Disconnect the ABV at the air cleaner side. 2 During the idling state after starting the engine, there shall be no discharge of the sucked air from the ABV. 3. Depress the accelerator suddenly from the idling state. When the pointer of the tachometer registers 4000 rpm, release your foot suddenly from the accelerator. There shall be a discharge of the sucked air from the ABV. (9) UNIT INSPECTION Remove the air bypass valve. 2 When's negative pressure is applied progressively to the sensing port (diaphragm chamber) of the air bypass valve, ensure that the ABV valve opens. Furthermore, when the negative pressure is retained under this state, there shall be no significant drop of the negative pres- sure NOTE * Check negative pressure 53.3 kPa 3, After the check has been made, assemble the air bypass valve in such a way that the arrow mark provided at the side faces toward the air cleaner hose. eee5-2 INSPECTION 5-2-1 ARTICLES TO BE PREPARED Shape Partnumber par name Use. sst (09992-00242-000 Measure turbocharger pressure and a ‘Turbocharger pressure gauge —_| cheok for actuator operation “Too! | Dial gauge. Torque wrench Lubiicant_| Engine oll eacsrcany 5-3 TURBOCHARGER BOOST PRESSURE 5-3-1 INSPECTION (1) DRIVING TEST WARNING * Conduct a driving test in a site where the full open acceleration running can be conducted safely in the (2) range, with two persons riding. 1. Connect a three-way pipe and a turbocharger pressure gauge between the surge tank (intake man!- fold) and the pressure sensor. Put the gauge at the vehicle interior. 2, After warming-up the engine, perform a full open acceleration in the (8) range until the engine attains 4400 rom. 3. “Check the pressure at the time’ when the engine attains 4200rpm. If the pressure is not the specified value, replace the turbocharger Ay. ‘SPECIFIED VALUE: 35-61kpa CAUTION * Never perform adjustment or disassembly on the turbocharger Ay. eal 5-4 WASTE GATE VALVE 5-4-1 OPERATION CHECK SST: 09992-00242-000 1, Disconnect the waste gate actuator hose at the actuator side. 2, With a turbocharger pressure gauge connected, apply a pressure of 67 kPa. Ensure that the rods and links operate and, when the pressure Is released, they return to the ‘original positions without any binding. 3. Check the hoses for signs of cracks and damage. CAUTION * Do not apply a pressure exceeding 78 KPa to the waste gate actuator. Failure to observe this caution may damage the diaphragm, epomso00tLU-34 * OUTLINE 1-1 DESCRIPTION 1, On Type K3-VET engine, a passage for lubricating the turbocharger has been added, based on Type K3-VE engine. In addition, the discharging amount of the oil pump has been increased Lao Se Sa te ee, aiatat A pe | Co pn Vv Vv v v Cranksnak crannahit pin | Cankenat sin igual /| Ko} ieuma /| fo 4 oz er oy Cif ‘il pen1-2 TURBOCHARGER LUBRICATION METHOD 1 The oil for lubricating the turbocharger bearing section is sui LU-35 pplied to the boss leading to the mair gallery of the cylinder block through the turbo oil inlet pipe, which is connected by means of the union bolt. Then, the oil is returned from the turbo oil outlet pi pe to the oil pan. Oritice Turbocharger oil inlet pipe union portion (Block side)LU-36 *OMPONENTS OIL PUMP: On Type K3-VET engine, the thickness of the rotor section of the oil pump has been changed. Thus, the discharging amount of the oil pump has been increased. SPECIFIED VALUE: 36.5 2 /min or more (At time of 5040 rom / 290 kPa) w-couenoo1 NUTLINE 1-, DESCRIPTION CO-37 1. On Type K3-VET engine the passage for cooling the turbocharger has been added, based on the coo ing system for Type K3-VE engine. 1-2 COOLING SYSTEM LAYOUT co-curaio19 Water outlet Throttle body Turbocharger Radiator Turbocharger Radiator CO-38 2 COMPONENTS 2-1 RADIATOR 4. On the vehicles mounted with Type K3-VET engine the radiator has different core dimensions and heat radiating rate, taking into consideration the heat emitting rate of the engine. co-conenrs 2-1-1 Radiator Specifications: wT a Toa acathg rie wa Radiator ee mensions erm sSOxS7K 27 [Coolant capacity (g) 1.37 Radiator cap valve-opening pressure (kPa) 108 Oil cooler Heat radiating rate {kW) 1.50 — co-soncos iad COOLING FAN AND RADIATOR RESERVER TANK As a result of the change in the radiator, a fan and a fan motor for the vehicles mounted with Type K3- VET engine have been set. Furthermore, the mounting location for the radiator reservoir tank is at the radiator upper support in the same way as with the vehicles mounted with Type K3-VE engine. The tank capacity remains unchanged. 2-comeoon 2-2-1 Radiator Fan Specifications: aT Type Diest current frie Motor Rated voltage (V) 12 Output (Wi) 120 Fan Outer diameter (mm) $320 Blade number 7 co o.com 2-3 COOLANT 1. The capacity of the cooling water for the vehicle mounted with Type K3-VET engine has been altered due to changes in the radiator specifications and the addition of a cooling water passage. SPECIFIED VALUE: 4.3 £ (W/O Reserve tank capacity ) co coMooot2EF-39 ————— 1 WUTLINE 1-, DESCRIPTION 1. The engine control system for K3-VET engine is a system which totally controls, using an engine control computer, various control systems, such as the EFI (fuel injection control), ESA (Electronic spark ad- vance), dynamic variable valve timing control (DVVT), ISC (idle speed control), boost control, air by- pass control (ABV). The power distribution to spark plugs of each cylinder uses the DL (distributor-less ignition) method where the distribution is performed directly trom the ignition coil. The vehicles with European specifications are equipped with an onboard diagnostic system which has complied with the 1999/102/EC directive (generally called EURO-OBD). This system tells the driver that the engine ECU has detected @ malfunction which will affect the exhaust gas adversely by flashing or illuminating the malfunction indicator lamp (MIL). Vehicles other than European specifications are also equipped with an onboard diagnostic system, though this system does not have so diversified functions as the diag- nostic system for European specifications has. Moreover, the vehicles are equipped with a failsafe function. eonene 1-1-1 FUEL INJECTION AMOUNT CONTROL (EFI) 1. For optimum fuel injection, corrections by signals from sensors are added to the basic injection time salculated according to the engine conditions. © Use of air-to-fuel ratio feedback control by front and rear oxygen sensors (for improved contro! accuracy) @® Use of fuel return-less system (for reduced temperature inside fuel tank) ® Use of constant fuel pressure control (for improved control accuracy) ee ounce» 41-2 IGNITION TIMING CONTROL (ESA) 1. For appropriate ignition, corrections by signals from sensors are added to the basic ignition timing cal- culated according to the engine conditions. © Use of $-DLI (for improved control accuracy of ignition timing) eros 1-1-3 KNOCK EVALUATION CONTROL (KCS) 4. The knocking correction control is carried out by judging the occurrence of knocking by means of the signal of the knock sensor, thus retarding the ignition timing, e-ouromea 4 TORQUE CONTROL AT TIME OF GEAR SHIFTING 1. For reduced gear shifting shooks, the ignition timing is retarded at time of gear shifting of A/T vehicles. Sours 1. IDLE SPEED CONTROL (ISC) 1. The fast idle speed according to the engine coolant temperature and idle speed after engine warming up are controlled by means of the ISC valve. erouranon 1-1-6 DVVT CONTROL 1. The intake valve timing is controlled in accordance with the engine conditions. es ourenou 1-1-7 BOOST PRESSURE CONTROL 1. The boost control is carried out by operating the boost contro! VSV by means of the EFI ECU in order to. Prevent the boost pressure from rising excessively. ours 1-1-8 AIR BY-PASS CONTROL (ABV) 1. The ABY control is carried out by operating the VSV for ABV by means of the EFI ECU in order to re- lease the boost pressure. ee-omr-on8tEF-40 LL 1-2 SUMMARY OF CONTROL SPECIFICATION O: Applicable _—: Not applicable Controt Function K3-VE K3-VET For other than EU For EU For eu Front and rear oxygen ‘sensor heater control ‘The oxygen sensor heaters are turned ON or OFF ‘according to the engine coolant temperature and. ‘riving conditions. ° ° Fuel pump contro! ‘The fuel pump is tuned ON or OFF by the IG switch signal and engine revolution signal Canister purge control ‘The canister purge flow rate is controled according to the engine congitions. Air conditioner cut control “The air Conditioner magnet clutch Is turned ON or OFF according to the engine conditions after idle-up ‘control so that the engine can be stabilized (variation cf the idle speed can be reduced). The magnet Clutch is turned OFF temporarily during acceleration, atc. Electric tan control ‘The radiator fan is tutned ON or OFF according to the engine coolant temperature and air conditioner ‘operation, ‘The radiator fan is turned ON when the coolant temperature sensor fats. a A (only when air | (only when air conditioner | ‘conditioner isworking) | is working) By using the DS-21 diagnosis tester or OBD I {generic scan tool, the diagnosis codes specified by | the [SO standards and ECU data can be read out. Moreover, the actuator driving function can be used to drive the actuator by means of the DS-21 Giagnosis tester. This has made it possible to conduct accurate and efficient trouble shooting, Diagnosis Although itis not possible to identify malfunctioning Sections es precisely as in the case of the EU specifications, the matfunction code can be read out from the MIL flashing pattern. ‘When the DS-21 diagnosis tester is used, the diagnosis codes specified by the ISO standards and ECU data can be read out. Moreover, the actuator driving function can be used to drive the actuator by means of the DS-21 ‘Giagnosis tester. This has made it possible to ‘conduct efficient trouble shooting. Failsafe When abnormality takes place in signals from Sensors or actuators, the Control is Continued by Using the standard values in the engine ECU. ° ° Teraatc00e ops ureaEF-41 I; ‘-UMMARY OF SENSOR FUNCTIONS 1. ihe following table given below summarizes the roles of each sensor and related control items. (©: Applicable —: Not applicable ala 8 KSVE 1GVET Sensors, signals Function B1e|8 For other S [Foomer | roreu | roreu Vacuum sensor “This sensor detects re ntake mantis pressure |O]O]O fo] o o | o mosphere pressure | ris sensor detocts th atmosphere pressure. | O - | olo can eguaear This sensor aes we OWTaarercear@® | 5 |S Baas ealaee Crankangloserer | [RESSHIE dese ng Tovouon olo Sitio uate: Linear vont sensor | Bsensor denise ratlevabe opening TOTO! [oO] 0 ° ° Coolantiemperature | This sensor detecs the engine coolant olo 7 ode te ser temperature Int ar temperature | This sensor detecs theintakeairtemperate. | O| | 0 o | o Front onygen sensor | This sensor deteos fe oxygen concenvatonin | c a Gaui tHe. (win eater) the exraust emissions Rear oxygen sensor ‘This sensor detects the oxygen concentration in | oy | eu ° ° (wth eater} the exhaust emissions Onygen sensor This sensor detects he oxygen concentration in | c 7 eae (ont only, without heater) | he exhaust erssions This ignitor unit detecs ihe on curent during | o | _ combustion to petfown mitre and erock - Janitor unit (with fon current detection) ryig ignitor unit detects the ion current during olo ° combustion to perform mise. - = Knock sensor, This sensor detects the knocking condition. ° °o oe oO ‘Neutral start swtoh | This sensor detects the AT range. ofofe fel _o o | 0 ‘Vehicle speed signal__| This sensor detects the vehicle speed. olfolo ° ° ° 7 Pe steeringhyeraulia_| This sensor detects the power steering 7 © Seo Basra mitch nydraule pressure I Terns otEF-42 ———— eee 1-4 SUMMARY OF ACTUATOR FUNCTIONS 1. The following table given below summarizes the roles of each actuator and relay, and related control items. ©: Applicable —: Not appiicable Bdslela Kove | Kover Actuator, relay Function B88 2/8/18 | & lroone 2a) > ForEU | ForEU Se than EU THis ey suprice re aa power EF Main lay EeR ee On Serer Oo} oj ofo] o ° ° aapnei Tia pps pve - . TT nec an optimum avout of Ful injector fuel at an optimum timing, ° 2 ° ae Tes eaters heal he on/gen sors © Erontand car owen | Tne ine feadeuck cool rte oe ° ~|olfo e r Period. ‘Wis un une ON or OFF re orfon ca iz lair nit Eurattat an oper ring ° ° Ob conta (oo) | Ts ve conto te nate cam at a of o | o “Ths ve contol the IS va opering 'SC vane degree according to the engine conditions. e 7 i ° Wav or ovaporaive” |The VE ineeases or cocraases te Bat eae eee ‘emission purging canister purge amount. Tis VB contls ABV to eloaso ho boost eee eee VSV for ABV pressure, ° ° WV forboost Ths VV provers he boos pressueom | 3 pressure control rising excessively. a2 om eaeEF-43 1-5 COMPONENTS LAYOUT Linear throttie sensor DLC Valve for ISC SV for purge ABV control VSV bane TB .s TR és VAN ck SeEF-44 1-6 SCHEMATIC DIAGRAM Veticte speed sensor Feel pump tosy 8 ecu) a ecuy*—*] ae ECU Atmospheric prescure vsvierpuge ale for 1S Charcost canister Povvaive Manifold qbsolut pressure sensor ear oxygen Intercooler BeeEF-45 7 “STEM WIRING DIAGRAM oneny eeeEF-46 Se 2 BOOST PRESSURE CONTROL a -1 DESCRIPTION The boost control is carried out by operating the boost control VSV by means of the EF! ECU in order to prevent the boost pressure from rising excessively. it can be classified into two kinds of control: Fully- closed control and feedback control. The boost pressure is controlled by performing the duty opera- tion of the boost contro! VSV in accordance with signals sent from the pressure sensor and vehicie speed sensor, which are to be inputted into the EF! ECU, and engine revolution speed, thus controlling the pressure to be applied to the actuator of the waste gate valve. Mainrelay EFI Cam angle sensor Absolute pressure sensor Coolant temperature sensor Linear throttle sensor Vehicle speed sensor 2-2 CONTROL MODE 2-2-1 FULLY-CLOSED CONTROL MODE 1, When any one of the following three conditions is satisfied, the EFI ECU will not energize the VSV. As a result, the VSV will be fully closed. Consequently, the boost pressure will be applied to the waste gate actuator, ® When the engine is cold, or when the cooling water temperature is high ® During the engine starting period © When the pressure sensor or the water temperature sensor is malfunctioning er -esrem 2-2-2 FEEDBACK CONTROL MODE 1. When all of the following three conditions are satisfied, the EF! ECU will perform the feedback contro! for the energizing duty ratio to the VSV so that the boost pressure may become the target value. @ After the engine has warmed up. @® Arter the engine has started @ When the pressure sensor and the engine coolant temperature sensor are normal er astoon:EF-47 3 *8V CONTROL 3-, JESCRIPTION 1. When all of the following three conditions are satisfied, the EFI ECU will turn ON the VSV for ABV in order to open the ABY, thus releasing the boost pressure. @ When the rise of the pressure in the intake manifold is the set valué or more, or when the change in the throttle valve (closing side) is the set value or more. @ The pressure in the intake manifoid is the set value or more at the time when the condition (1) is satisfied @® The throttle valve opening degree is the set value or less at the time when the condition (1) is satisfied. [Absolute pressure Linear throte sensor5 COMPONENTS 5-1 BOOST PRESSURE CONTROL VSV 1. The boost control VSV controls the pressure to be applied to the waste gate valve actuator by means of the duly sig- nal from the EFI ECU so that the pressure may become the target pressure. 5-2 ABV CONTROL VSV 1. The VSV for ABV control switches the pressure to be ap- plied to the diaphragm of the ABV by means of the signal from the EF! ECU, thus preventing the boost pressure from rising at a time when the throttle valve is suddenly closedEF-49 1 EFI SYSTEM 1 SYSTEM DESCRIPTION 1-1-1 LOCATION OF ELECTRONIC CONTROL PARTS Linear throttle sensor OLE Vaive for Isc VSV for purge ABV control VSV ‘Boost control VSV Ignition colt ee IAS i a e A soa Front oxygen sensor Injector Engine coolantEF-50 4 CONNECTORD Re, ‘Cattants of connection Re, Conteris ofeomecion “1 BAT] Weiner bacicup supply ‘$3 |ATNE]| Engine soeed signalto WT ECU [FCT | Fuel pump relay (With iB) ‘34_[ Ve _{ VE monitor tema ‘S_[W[ Malfunciios incieator amp. ‘35 [FEOF | Fuei pump relay OFF 4 ATI Serial data tensmission to ATECU ‘36 | 482 | Fower supp) [8102 | Serial por ter vB fe2_Tvoo | — ‘6 TAROT — 3 = 7 [481 | Power supph 64 IDLO | — 25. |E21_T AIG Evaporaicrlemp. sensor ground. 8 | co |= '30_|"FO2| Fuel ume relay (vthout MB) 66 [TPR ‘S1[ REV} Engine speed signal er lact | — '32 [ATX Serial dala recepion ram AT ECU 66 STA | Starter aigrel 1-2 DIAGNOSIS 1-2-1 ARTICLES TO BE PREPARED ers eeioronn c Sass Faas anber oats i (09842-97203-000 For inspection of computer ‘Sub-harness, EFI computer check inpuvoutput vottage sz eer oe SEZ seo ERSTE | crrapesin utes 2, = aon S lene = eS) | gessnoroceo alaliteatlad SS Pie iit cotati Vid inj uel at jaeeeess | eed ana tora oop nes For shorting terminal T — iia cepa ae For shorting terminal T 09268-87701-000 Gauge, EF! fuel pressure For inspection of fue! pressure Tiana Ses te, Compson panaae ga TT — sional 1-3 FUNCTION CHECK 1-3-1 VOLTAGE CHECK 1. Install the SST between the engine ECU and the vehicle harness and measure the voltages between the respective terminals of the SST connectors. Check to see if the measured values conform to the pecification in accordance with the following table.1-4 TROUBLE SHOOTING ACCORDING TO DTC 1 1 BOOST PRESSURE CONTROL SYSTEM CIRCUIT EF-51 (1) WIRING DIAGRAM ECU Boost control SV Main relay eA 15a vsvt 2 —_4 STI oN. 0S o- Lo wie ia sw fH 104 1G2 aM 60a | 4 a Ls] Et Boost control VSV ‘Main relay (Hamess side) (Relay box side) ‘Tela alr 23[fsr 32] aloe las e2faa ECU-connection vehicle hamess side connector (2) CIRCUIT DESCRIPTION (1) Check the hoses of the boost pressure control system for disconnection, breakage, etc. (2) Check that the waste gate valve operates normally. (3) Check that the power supply voltage is applied properly to the boost control VSV. (4) Check that the harness between the boost control VSV and the ECU exhibits no open wire and short circuit, (5) Check that the boost control VSV operates normally. ses sezeF-52 (3) INSPECTION PROCEDURE (Check to 526 the hoses of the ‘boos! pressure cortrcl eystem are ‘disconnected or damaged. operation OK OK Check the waster gate valve NG Repair or epic NG 1 <£CU output signa check 1. Connect the SST (sub-herness) ‘SST: 09842 -97208- 009 2 Measure ths vohage betweon SST terminals SV and E1 ouing ig (cola). (Cooling water temperature 60°C 0: below) ‘Speciied Value: Battery votage 3. Measure the vollage between SST terminals VSV1 and 1 during faling ater warming). Specifad value: 0-1 4 Measure me votage between SST temminals VSV1 and EY during ‘running test (2nd, lv-open acceleration = 4400%pm). ‘Specie value: More than the value in step @ above NO. Replace tne turbocharger SA ox OK “ 1. Disconnect the VSV connecter. [2 Measure the voltage between the terminal 2 of VV and the body ‘ground ‘Speci value: Batley votage Check andior repair te harness Denween the batery and VSV. SV connector. { Uni inepection &f VEV>. (CRepais tne hamess and comecior NG. I Feplace to V8V. Ne ‘conction of each con: ok Gheck the connecting 2EF-53 1 2. AIR BYPASS VALVE CONTROL SYSTEM CIRCUIT (Q, AIRING DIAGRAM ECU AaVcontel VV Mainrelay fA 154 vsveo—Lap 2 4 So S00 J ae cule = IGSW 0A 12 aM 80a FL 7 2.0; 2 GE) OFT ABY control VSV_ Main relay (Hamess side) (Retay box side) 6 soon fee DPep melo) [er eS erase 2a Sef saleo[ar[a] [so] selecles[e[es]soL Tso] [eipnTsresa eleTsalsleol]e ralel [rebrebeinL Cte teat 22 veve ‘eres ay [sos [s2[oa1 4] 525 ez [es) Disconnect the VSV connecter. 2, Measure the votage betwoon the terminal 2 of VSV and the body ‘round, Speciied valecBattery votage | Fe ; —— Seu ana uae Pe) Check andor rai the harness ECU and VSV'> He dl Check ‘the harness betwoen | \ belween he bettery ang teminal VSV2 of ECU connector _and lerrinal 2 of VSV connector. ox NG Repair the harness anc connecter. ‘Check the connecting ‘conattion ofeach cone actor, Replace ine sv. Inspect the ECU,2 “NIT INSPECTION a BOOST PRESSURE CONTROL VSV Check to see If there is air continuity between the respec- tive ports of the VSV. SPECIFIED VALUE: No continuity exists. 2. When the power supply voltage is applied across both terminals of the VSV connector, check air continuity be- tween the respective ports. SPECIFIED VALUE: Continuity exists. 3. Check the resistance between both terminals of the VSV connector, SPECIFIED VALUE: Approx. 32.9 (at 20°C ) eeuPoze000 2-2 AIR BYPASS CONTROL VSV 1. Check air continuity between the respective ports of the vsv. SPECIFIED VALUE: Air continuity should exist, (Between AandB) No air continuity should exist. (Between A and C; Between B and c) 2. When the power supply voltage is applied across both terminals of the VSV connector, check air continuity be- tween the respective ports. SPECIFIED VALUE: Air continuity should exist. (Between B and C) No air continuity should exist. (Between A and B; Between A and C) 3. Measure the resistance between both terminals of the VSV connector. SPECIFIED VALUE: Approx. 40.2 (at 20°C ) eeupnzo%016 BLOW-BY GAS RECIRCULATION DE- VICE et DESCRIPTION ‘The blow-by gas in the crank case is flown into the cylin. der head through the biow-by gas passage of the cylin- er block. The oylinder head cover is provided with an cit separator, which separates oil from the blow-by gas. After oil separation, the blow-by gas is sucked into the com- bustion chamber to be burnt again. A PCV valve is pro- vided to get a blow-by gas recirculation amount suited to the running conditions. ‘Surge tank1G-57 * DESCRIPTION For Type K3-VET engine, platinum plugs, featuring excellent durability, have newly been provided. 1e-ouracoos1G-58 2 COMPONENTS 2-1 SPARK PLUG KS-VET Manufacturer DENSO NGK) Type PK2OPTR-S9__| BKURGEKPA Electrode gap (mm) 08-09 With across flats (mm) 161G-59 { IGNITION COIL 1-1 REMOVAL AND INSTALLATION 1-1-1 ARTICLES TO BE PREPARED Gauge] aoe wnsh Tone Tan serecoraae 1-1-2 REMOVAL AND INSTALLATION PROCEDURES (1) COMPONENTS we oy a OF, b t er? @® > i ‘ Ts Tigteing wre f aoa N sasoonnss end Unit «2) REMOVAL AND INSTALLATION PROCEDURES, + 2 a CoverS/A, engine upper 2 1 b Coll ignition ieiscorocorAT-60 —_—_—_—_—_—_—_—_—___ NE + OUTLINE «The automatic transaxle for Type K3-VET engine-mounted vehicles, which has been newly added, em- Dloys a four-speed automatic transaxle of the A4B-D1 type electronic hydraulic control method, as is the case with the conventional Type K3-VE engine-mounted vehicles. However, in the automatic transaxle for Type K3-VET engine-mounted vehicles, the characterisctis and gear reduction ratios of the torque converter of the transaxle have been altered in order to cope with the increased torque of Type K3-VET engine with a turbocharger. Furthermore, changes have been made on the shape of the shift lever knob and the installation position of the steering shift selection switch, The electronic contro! specifications of the automatic transaxle have also been partially changed. s.08ca00 1-1 SPECIFICATIONS Traneaxie ype BD Drive method 2D aD Engine type RENE Raver HAVE Three-elemem, one-stage, two-phase type type (with lockup mechanism) ~ sve converter Sia torque ato / 7267 7.887 1867 Revolution speed (rpm) 1800-2400 2200-2700 1900 - 2400 ‘Autoraile gear shit Four foward speeds, One reverse speed iat 27H nd 1.526 : Gear ratio rd 7.000 ath 0.696 Reverse 2.200 pee Flea educlon gear ratio 402 3740 2350 Shit control method Electron hyeraullo pressure control method Wot ype multiple clutch: Geets Shit control element Wot type multiple brake: 2sets One Way clutch : tset Te DEXAON® Hort) Lubrication fais [capaaiy ‘About 5.0 Cilesoing system Waler-coolea (radiator bulrin ype) ‘al contd patern P-R-N-Ds3-2 IER ar oscomeaAT-61 2 AUTOMATIC TRANSAXLE ELECTRONIC CONTROL SYSTEM 2-1 OUTLINE 1. The diagnostic trouble codes (DTC) of No.31/P1706 and No.41/P1711 have been added to the self-di- agnosis function. Moreover, the fail-safe functions corresponding to these codes have been set Although the changes above have been made, no sensor or actuator has been added or no contro! function has been changed. arenesAT-62 2x DIAGNOSIS FUNCTION 2-4-1 CONTENTS OF DIAGNOSIS (Code No. Warning inaication | Code Memory Contents of mattunction 2digis | 4digiee 31 P1706 6 x [Abnormal engine toraue 37__| Ports ° ° [No turbine revoiution input 38__| _PoT10 3 ° |Open wie or short of thie temperature sensor Seu = ae 4 5 Aone sing reacties oi temperate ofa 44 P1711 fe) x [Throttle sensor malfunctioning 42 P0720 [e) ° No output revolution input 55 PO7O5. oO x No neutral start switch input 56 PO70S. oO ° |Multi-input of neutral start switch 57, P1704 ° x |Short of steer shift mode switch circuit [56 P1705 o x | Short of steer shift up/down switch circut 7 81 PO7SS: ° oO Open wire or short of solenoid No. 1 (81) circuit 62 PO7SS ° °° [Open wire or short of solenoid No. 2 (C2) circult, 63 P0763 2° Q |Open wire or short of solenoid No. 3 (C3/82) circuit 64 P0768 3 ° [Open wire or short of Duty solenoid circuit 65 | po7S ° ° [Open wire or short of LUC solenoid circuit 66 P1780. 2 ° Open wire or short of switch solenoid circuit 72 | P1703 3 ° Lockup revolution speed not matching ez | Piso ° 2 Faulty communication with EF/-ECU 86 P0725, 3° ° No engine revolution input * Denotes those output code wien the 5-21 is used. At 008*5 FAIL-SAFE FUNCTION 5-1 FAIL-SAFE SPECIFICATIONS AT-63 Code NO! Contents of mattunction Contents of fail-safe contro! Conditions for releasing aigtslaciats, failsafe control + The engine torque is set toa constant value. ‘+ When the malfunction is detected, a shifting to| After the normal state has been 31 [P1706] Abnormal engine torque | the 3rd gear takes place. Afterward, the 1-3] stored, when the vehicle speed is shifting takes place, depending upon the| 0 km/h in P or N range, the fall- vehicle speed and throttle opening, safe function is released. 37. |P0715| Noturbine revolution input 38 [Porto] Open wire or short ofo| | / when the malfunction is detected, a shiting to | After the normal stale has been lemPerature sensor citcull | ine Src gear takes place. Afterward, the 1-3 | stored, when the vehicle speed is shitting takes place, depending upon the | 0 kmh in P or N range, the alk Abnormal rising vehicle speed and throttie opening, safe function is released characteristics of fhid 88 /POTTH| temperature af ol temperature sensor “The throttle opening is set to a constant valve. ‘After the normal state has been 41 |p1714| Throitie sensor ‘*When the malfunction is detected, a shifting | stored, when the vehicle speed is maltunctioning to the 3rd gear takes place. Afterward, the 1- | 0 km/h in P ot N range, the fail- 3 shifting takes place, depending upon the | safe function is released. vehicle speed Jswhen the sensor system is ‘maitunctioning, alter the normal state has been restored, when ‘*When the sensor system is mettuntioning | the vehicle speed is 0 km/h in P and the vehicle stops once, the vehicle | or N range, the fail-safe function 42 |p0720| No output revolution input | Speeds fixed at the 1st gear. is leased, : ‘When the A/T itself is malfunctioning, the |*When the ATT itseli is vehicle speed is fixed at the 1st gear. ‘maifunctioning, after the normal state nas been restored, if the IG is once tured OFF, the fai-safe function is released 55 lporos| NOneutral start switch | «With the shift position set to the Ds range, | Released when normal state is input ‘normal gear shitting control takes place. restored, 56 {po705| Muli-input of neutral stat | «with the shift position set to the Da range, | Released when normal state is switoh normal gear shiting control takes place. restored, Released when the turning OFF of 57 [P1704] Shertin steer shitt mode | « The stoor shit mode is prohited the steer shit mode switch is switch circuit detected. Released when the turning OFF of 58 [P1705] Shor in steer shit +The steer shift mode is prohibited. the steer shift UPIOOWN switch is UP/DOWN switch circuit isohactee: RORFS-64 ——————— *RONT SUSPENSION 1-1 OUTLINE 1. As @ result of the setting of the 15-inch tires, some components have been additionally provided. 2. The wheel alignment remains unchanged. Fs.r8-c0000 1-2 COMPONENTS 1-2-1 SHOCK ABSORBER 1. Exclusive parts whose damping force has been optimized for the 15-inch tires have been additionally set, 2. The construction remains unchanged. 15.79.0021 1-2-2 COIL SPRING 1. Exclusive parts whose spring constant has been optimized for the 15-inch tires have been additionally set. 2. The construction remains unchanged. Fs.45.002FS-65 2 TIRE 2-1 OUTLINE 1. 16-inch tires have been adaltionally set. s-nnoo0oe 2-2 SPECIFICATIONS M200RG M2018 MaTIRG -GMINF CEcnE new GMNEW “GQNEW P Toueo—f-oMnew = | S0NEEuew = [C050 caNew -GONEQ | -GOGEW . ° rasieon1s =| STEEL (200123}) | (2301231) - - = - a = ° ° . | STEEL (z2012.2)) | (220(22)) | (220122) | (220(2.2}) i (2201221) T6SI65R 14S, + + z = x ALUMINUM | (2202.21) | (22012.2)) | (22012.2)) | (220122) ) 7 ( 220(2.2} ) 2 ~ 2 STEEL ia oa (220(2.2}) | ( 220(2.2)) A ( 220(2.2} ) 175160R 14H x z x ALUMINUM ~ - (220122}) | (220122)) FF (220221) = . vveissisv | ALUMINUM - - 7 - (24072.4)) = ‘SPARE TIRE x T ‘STD TRE 145/6013 (200231) - _ aietasfeieiecy - 2 * STO TIRE 165/65R14 ( 220(2.21) - (2012.2) 7 es if a STD TIRE 175/60R14 - i (220/22) ) in = ia : ° ° ° ° ° ‘T105/70 Dia (420162}) | (a20ta2iy | (420142)) | (420142)) | (420142) = 7 7 7125/70 Di4 - - - - - (42014.2) ) ‘@ = Standard equipment, a = Optional equipment, Figures in parentheses (_) are the frontrear air pressure (kPalkglicm'} ‘rsxoso03 otFS-66 ———— 3 DISC WHEEL 3-1 OUTLINE 1, 15-inch disc wheels have been additionally set. 5-¥et.o0008 3-2 SPECIFICATIONS WHEEL] 13 x4508] 14x86) | 14x5) | 15x58) tem STEEL ‘ALUMINUM: ‘A: Rim width fmmJ] 114 127 = [| = B:Rim diameter [mm] 3204 | 3548 = 280.2 C:PCD [mmy} 100 = = = ‘D: Hub hole diameter = ce Se = {me]] E: Offset {oonj| 35 40 = = F: Boltdiameter —_{mmj] 14 = 3 —RS-67 SS UU apapanaeypapepeaye cea 1 NEAR SUSPENSION te1 OUTLINE 1. Asa result of the setting of the 15-inch tires, some components have been additionally provided. 1-2 COMPONENTS 1-2-1 SHOCK ABSORBER 1. Exclusive parts whose damping force has been optimized for the 15-inch tires have been additionally set. 2. The construction remains unchanged 5.85-c0022 5.95-co0ne 1-2-2 COIL SPRING 1. Exclusive parts whose spring constant has been optimized for the 15-inch tires have been additionally set 2. The construction remains unchanged. 3. On 16-inch tire-equipped vehicles, a spacer has been added at the rear spring bumper section. fs-Rs-conts7’ SOIL SPRING (TORSION BEAM TYPE) 1-1 REMOVAL AND INSTALLATION 1-1-1 REMOVAL AND INSTALLATION PROCEDURES (1) COMPONENTS 1 2 a 4 5 (2) RI © 5 4 3 IEMOVAL AND INSTALLATION PROCEDURES ‘Absober, shock ear Bumper, rear spring ‘Spacer, bumper black ‘Sheo!, ear spring upper ‘Sheet, rear spring #1:Vehicles equipped with 18-inch tres [res.2ti2.3 Unvesiia7 Tightening torque Unit: Nm ® © F Spring, coil rear ascoro-rontotDPS-69 ac 1 TRIVE SHAFT 1+. OUTLINE 1. Asa result of mounting of Type K3-VET engine, additional setting has been made. 2. The construction remains unchanged esos.) ‘4-1-1 SPECIFICATIONS Drive methoo WO. aNd Engine type Ed K3-VE_ KS-VET, K3-VE_ “Transmission type MT MTAT | AT MT Distance up tojoint [RH (mm) 625.8 (with] [622.2 (with) 620.2 (wiih [474.0 [without [Damper] LH (mm) 408.7 [Without] | 404.8 [Without] 402.8 [Without] 404.8 [Without] Joint type Front axle side Belltype | = 7 - Ditferential side | Double oftset type | Tripod type = = TORT vesoszcnureBR-70 —_———— 1 WTLINE 1. On vehicles mounted with Type K3-VET engine, 14-inch ventilated disc brakes have been employed at the front wheels. BR curcowne 2 BRAKE MASTER CYLINDER 2-1 OUTLINE 1. The construction remains unchanged, except the external appearance. 8 c-o12 3 BRAKE BOOSTER 3-1 OUTLINE 1, On LHD vehicles mounted with Type K3-VET engine, an 8-inch single brake booster with brake assist- ing mechanism has been provided. 2. The construction remains unchanged. en-esroo010 4 RONT BRAKE 4-1 OUTLINE 1. For assured sufficient braking force, 14-inch ventilated disc brakes have been employed on vehicles mounted with Type K3-VET engine. 4-< SPECIFICATIONS Engine type EW-DE EJ-VE KaVE K3-VET Disc pe (Wentilated) ai 7 - Piston diameter (mm) 50.8 = = Sit Disc rotor diameter (mm) Ea = = 206 Disc rotor thickness (mm) 16 = = 17 Pad area (em') 36 = = 35 TERETE en encecor1 FRONT DISC BRAKE PAD (14 INCH) « INSPECTION 1 Check the pad thickness through the inspection hole of the cylinder for the inner side or from the rear of the caliper for the outer side, SPECIFIED VALUE: 9.5 mm ALLOWABLE LIMIT: 1.5 mm 1-2 REMOVAL AND INSTALLATION 1-2-1 REMOVAL AND INSTALLATION PROCEDURES (1) COMPONENTS fe Unit : (2) REMOVAL AND INSTALLATION PROCEDURES, D7 2 6 3 © 64 5 3 Bol, brake alse cylinder Pin, cylinder side Pad, disc brake No.1 Pad, aise brake No.2 ‘Shim, ant-equeat Pate, disc brake pad guide Plate disc brake pad guide Tightening torque Nm mssosooare ead enroro-romceBR-72 * SRONT DISC CALIPER (14 INCH) 3-1 DISASSEMBLY AND ASSEMBLY 3-1-1 INSPECTION (1) BRAKE PAD THICKNESS 1. Check the thickness of the disc brake pad, and replace it if the thickness is less than the limit, ‘SPECIFIED VALUE: 9.5 mm ALLOWABLE LIMIT: 1.5 mm wrccacence 3-1-2 DISASSEMBLY AND ASSEMBLY PROCEDURES (1) COMPONENTS & TeSES * : Non-reusable parts T Tightening torque Unit : Nem =: Rubber grease senses (| ISASSEMBLY AND ASSEMBLY PROCEDURES 112 a Bot, ess brake cylinder 7 6 9 Shim, ant-squeal @ 11 bv Pin. syinder slide 6 Sh Boot. pin 3 10 © Mounting, esc brake cylinder © 4 1 Boot eyinder 4 8 d- Pad,dise brakaNo.t @ 3 | Piston, dise brake @ 8 © Piate, dscbrake pad guide @ 2 & Seakpiston © 7 {Pad dso brake Noz 12 1 1 Oybnder, disc brake enroce reconeBBE-73 1 “XTERIOR 1-1 HOOD i On turbocharger-equipped vehicles, a hood air scoop has newly been provided to feed outside air to the intercooler, 2 SEAT 2-1 REAR SEAT 1, A saddle type headrest has been provided as option on the rear seat.3 LAMPS te 1 FRONT FOG LIGHT (On turbocharger-equipped vehicles, SSW fog lamps have been set as standard equipment 2. On natural aspiration vehicles destined for the EU specifi- cations, SSW fog lamps have been set as optional equip- ment, except some grades. 7 2 REAR COMBINATION LIGHT On turbocharger-equipped vehicles, clear type rear com- bination lamps have been provided as standard equip- ment, 2. On 1.32 natural aspiration vehicles, clear type rear combi- nation lamps have been set as optional equipment, ex- cept those destined for the AUS specifications, 4 WIPER AND WINDSHIELD WASHER 4-1 WINDSHIELD WASHER TANK 1. On T/C LHD vehicles the location of the washer tank has been changed to the underside of the left headlight esenanac 5 AUDIO SYSTEM 5-1 ANTENNA 1. The toof rear antenna has employed a tiltable type. The new antenna is detachable, as is the case with the hither- to-employed type. NOTE * To listen to the radio, adjust the antenna approximately 60" rearward. There are cases where the radio cannot be tuned in when the antenna is at an angle other than approximately 60° rearward.f 9OWER WINDOW 6-1) POWER WINDOW SWITCH 1, Anillurtination has been added to the AUTO switch of the ) power window switch at the driver's seat side. SS NOTE Or * The lamp goes on when the IG is turned ON. ft SC Se 6-2 CIRCUIT DIAGRAM Power window ub switch Power window ‘sub switch Power window ‘sub switch (Passengers ear ett) (Rear right) seat side) Driver seat Passenger seat Rear passenger ear passenger seat (Right) seat (Left) BcBBE-76 1 HOOD ._. REMOVAL AND INSTALLATION 1-1-1 REMOVAL AND INSTALLATION PROCEDURES sanesomcn2 ccd 14a Guide Ay, cool air init 2 3 b Spacer 3 2 ¢ Gamishassy, hood air duct 41d Hood sia seeHoD0-7. 0001 2 HEAD LIGHT LEVELING 2-1 UNIT CHECK 2 _HEAD LIGHT LEVELING SWITCH 1. Ensure that resistance between the respective terminals as conforms to following specifications. SPECIFIED VALUE: Resistance between respective terminals. Position 0 TApprox. 2.1K Postion 1 TAppIOX. 199 Terminal 1-2 Postion? ADPIOK. 14KO Connsetor on fear (Head light leveling switeh side) Position 4 [Approx 09 ka Fi 5 Terminal 1-8 Each position ABpIOK 2.4K TEREST s[/4{3]2}4