Workshop Manual 1996 - 2000

Workshop Manual
1996 - 2000
http://www.hmaservice.com/viewer/content.asp?vehicletype=Pass...HY%5ERD13%5E1998%5Eall%5E0%5Enone%5Enone%5E34653%5Eshop%5E%24
Ebay User ID: reveleus1
INSPECTION
Inspect for damage, cracking or deterioration. Replace if faulty.
The catalytic converters require the use of unleaded gasoline only. Leaded gasoline will destroy the effectiveness
of the catalysts as an emission control device.
Under normal operating conditions, the catalytic converters will not require maintenance. However, it is important
to keep the engine properly tuned. Engine misfiring may cause overheating of the catalysts. This may cause heat
damage to the converters or vehicle components. This situation can also occur during diagnostic testing if any
spark plug cables are removed and the engine is allowed to idle for a prolonged period of time.
Email: suzlever@gmail.com
http://www.hmaservice.com/viewer/content.asp?vehicle...%5E1998%5Eall%5E0%5Enone%5Enone%5E34653%5Eshop%5E%2412/03/2009 3:46:52 PM
INSPECTION
CLOSE COUPLED CATALYTIC CONVERTER
Inspect for damage, cracking or deterioration. Replace if faulty.
The catalytic converters require the use of unleaded gasoline only. Leaded gasoline will destroy the effectiveness
of the catalysts as an emission control device.
Under normal operating conditions, the catalytic converters are maintenance-free. However, it is important to
keep the engine properly tuned. Engine misfiring may cause overheating of the catalysts, which may cause heat
damage to the converters or vehicle components. Heat damage can also occur during diagnostic testing if any
spark plug cables are removed and the engine is allowed to idle for a prolonged period of time.
Precautions For A Catalytic Converter

If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To
prevent this, observe the following precautions and be sure to explain them to the customer.
a.Use only unleaded gasoline.
b.Avoid prolonged idling. Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed
for more than 20 minutes.
c.Avoid spark jump test. Spark jump only when absolutely necessary. Perform this test as rapidly as possible
and, while testing, never race the engine.
d.Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as
possible.
e.Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra
load on the converter.
f.Avoid coasting with ignition turned off. Avoid prolonged braking.
g.Do not dispose of used catalyst along with parts that are contaminated with gasoline or oil.

COMPONENTS
http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34625%5Eshop%5E%24 (1 of 2)12/03/2009 3:41:14 PM



EMISSION CONTROL
A. PCV Valve
B. EVAP Canister Purge Solenoid Valve
C. EVAP Canister

D. Catalytic Converter
E. CCV & Two-Way Valve


EMISSION CONTROLS LOCATION
ENGINE COMPARTMENT - Top view
Muffler Assembly - Side View
FUEL TANK AND CANISTER



EMISSION CONTROLS LOCATION
ENGINE COMPARTMENT - Top view
Muffler Assembly - Side View
FUEL TANK AND CANISTER

SCHEMATIC DRAWING

System Diagram

CANISTER
For evaporation monitoring, there are a CCV, a two-way valve and an air filter as the illustration.
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.
3. After removing the EVAP Canister, inspect for cracks or damage.
Check of canister close valve operating

1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.
3. Inspect that CCV is close when attaching the wire to (-) of battery.
4. Inspect that CCV is open when detaching the wire from (-) of battery.
In this case, if you use a very thin paper and attach

Email:itsuzlever@gmail.com
to hose to CCV, you can check easy the CCV condition.

a.If the paper is absorbed into or out, CCV is open.

b.If not, CCV is close.
Two-way valve
1. Inspect whether air flows as shown.
2. Check to connect correctly such as the arrow mark on the valve.
Air filter
Look for distortion, cracks


Evaporative (EVAP) Canister
A CCV, a two-way valve and an air filter are used for evaporation monitoring.
1. Check for loose connections, sharp bends or damage to the fuel vapor lines.
2. Check for distortion, cracks or fuel leakage.
3. After removing the EVAP canister, inspect for cracks or damage.
Check of canister close valve operating

1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.

3. Note whether or not the CCV is closed when attaching the wire to the (-) negative terminal of battery.
4. Note whether or not the the CCV is open when detaching the wire from the (-) negative terminal of battery.
To easily check the CCV condition, use a very thin piece of paper attached to the hose and to the CCV.
a.If the paper is sucked in or out, the CCV is open.
b.If the paper is not sucked in or out, the CCV is closed.
Two-way valve
1. Inspect whether air flows as shown in the illustration.
2. Check the connection (arrow mark). It should be as shown in the illustration.
Air filter
Look for distortion and cracks. Email: suzlever@gmail.com

Purchased
from Ebay seller
Reveleus1
Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
CHECKING PURGE SYSTEM

INSPECTION
When disconnecting the vacuum hose, make a mark on it so that it can be reconnected in its original position.
1. Disconnect the vacuum hose from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the evaporative emission canister purge solenoid valve
and when the voltage is discontinued.
Battery voltage Normal condition

When applied Vacuum is released
When discontinued Vacuum is maintained
5. Measure the resistance between the terminalsEmail:

of the solenoid valve.
suzlever@gmail.com


Vacuum Hose
Engine coolant temperature: 80-95°C (176-205°F)
1. Disconnect the vacuum hose from the intake manifold purge hose nipple and connect a hand vacuum pump to
the nipple.
2. Start the engine and check that, after raising the engine speed by racing the engine, vacuum remains fairly
constant.
If there is no vacuum created, it is possible that the intake manifold port may be clogged and require cleaning.
COMPONENTS

COMPONENTS
EXHAUST EMISSION CONTROL SYSTEM

Exhaust emissions (CO, HC, NOx) are controlled by a combination of engine modifications and the addition of
special control components.
Individual modified components include the combustion chamber, intake manifold, camshaft and ignition system.
The individual modifications have been integrated to create a highly effective system which controls exhaust
emissions while maintaining good driveability and fuel economy.
AIR/FUEL MIXTURE RATIO CONTROL SYSTEM

Multiport Fuel Injection (MFI) System
The MFI system is a system which employs the signals from the heated oxygen sensor to activate and control
the injector installed in the manifold for each cylinder, thus precisely regulating the air/fuel mixture ratio and
reducing emissions.
This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three
way catalyst. The three way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2)
carbon monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. There are two operating
modes in the MFI system.
a.Open loop air/fuel ratio is controlled by information programmed into the ECM.
b.Closed loop air/fuel ratio is varied by the ECM based on information supplied by the oxygen sensor.
INSPECTION
Check the fuel filler cap and the fuel filler cap gasket for damage or deformation. Replace the cap if necessary.

FUEL TANK PRESSURE SENSOR
This is the sensor to detect the fuel tank leakage in way which it measures the differential pressure between
inside and outside fuel tank.
Inspection
Check to look that fuel level is over 15%. If not, this inspection is not available.
The vehicle must be in turn-on and at idle. Don't forget it.
1. Prepare a voltmeter and connect it to FTP pins as shown.

2. After 20 min. idling, inspect the voltage .

3. At idle, inspect that voltage fluctuates up to accelerate rpm up and down .
If voltage is not within spec.as procedures, there is leakage and inspect the fuel tank and hoses toward
canister and fuel neck. Then repair or replace relevant parts.


FUEL TANK PRESSURE SENSOR: Evaporative & ORVR Emission Control System
By measuring the differential pressure between the inside and the outside of the fuel tank, the fuel tank pressure
sensor detects fuel tank leakage .
Inspection
To perform this inspection, the fuel level must be over 15% and the vehicle must be idling.
1. Connect a voltmeter to the FTP pins as shown.
2. After the vehicle has idled for 20 minutes, check the voltage.
3. At idle, inspect voltage fluctuation as engine is accelerated and decelerated.
If voltage is not within specification, there is leakage. Inspect the fuel tank and hoses toward the canister and
fuel neck. Repair or replace affected parts.


CHECKING PURGE SYSTEM
SPECIFICATIONS
Crankcase Emission System
Components Function Remarks

Positive crankcase ventilation (PCV) valve HC reduction Variable flow rate type
Evaporative Emission System

Evaporative emission canister HC reduction |
EVAP Canister Purge Solenoid Valve | Duty control solenoid valve
Fuel Tank Pressure Sensor Monitoring EVAP |
Canister close valve Monitoring EVAP |
Exhaust Emission System

MFI system (air-fuel mixture control device) CO, HC, NOx reduction Heated oxygen sensor feedback type
Three-way catalytic converter CO, HC, NOx reduction Monolith type
MFI : Multiport Fuel Injection

EVAP : Evaporative Emission
SERVICE STANDARD
EVAP Canister Purge Solenoid Valve
Coil resistance 26 Ω [at 20°C (68°f)]
TIGHTENING TORQUE
| Nm kg.cm lb.ft
Positive crankcase ventilation valve 8-12 80-120 6-8
TROUBLESHOOTING
Symptom Probable Cause Remedy

Engine will not start or hard to start Vacuum hose disconnected or Repair or replace
damaged
Malfunction of the EVAP Canister Repair or replace

Purge Solenoid Valve
Rough idle or engine stalls Vacuum hose disconnected or Repair or replace

damaged
Malfunction of the PCV valve Replace
Malfunction of the evaporative Check the system; if there is any

emission canister purge system problem, check its component
parts
Excessive oil consumption Positive crankcase ventilation line Check positive crankcase
clogged ventilation system

Removal
1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve
from the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum is felt.
The plunger inside the PCV valve will move back and forth.
3. If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent or replace if necessary.
INSPECTION
1. Remove the positive crankcase ventilation valve.
2. Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger
moves.
3. If the plunger does not move, the positive crankcase ventilation valve is clogged. Clean it or replace.
INSTALLATION

Install the positive crankcase ventilation valve and tighten to specified torque.

Workshop Manual 1996 - 2000

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop Manual 1996 - 2000

Uploaded by

Copyright:

Available Formats

Workshop Manual

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Precautions For A Catalytic Converter

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34625%5Eshop%5E%24 (1 of 2)12/03/2009 3:41:14 PM

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34625%5Eshop%5E%24 (2 of 2)12/03/2009 3:41:14 PM

Ebay User ID: reveleus1

B. EVAP Canister Purge Solenoid Valve

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34622%5Eshop%5E%24 (1 of 2)12/03/2009 3:41:30 PM

Ebay User ID: reveleus1

E. CCV & Two-Way Valve

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34622%5Eshop%5E%24 (2 of 2)12/03/2009 3:41:30 PM

Ebay User ID: reveleus1

Muffler Assembly - Side View

FUEL TANK AND CANISTER

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34619%5Eshop%5E%24 (1 of 2)12/03/2009 3:41:43 PM

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34619%5Eshop%5E%24 (2 of 2)12/03/2009 3:41:43 PM

Ebay User ID: reveleus1

Muffler Assembly - Side View

FUEL TANK AND CANISTER

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Check of canister close valve operating

In this case, if you use a very thin paper and attach

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34637%5Eshop%5E%24 (1 of 2)12/03/2009 3:43:55 PM

a.If the paper is absorbed into or out, CCV is open.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34637%5Eshop%5E%24 (2 of 2)12/03/2009 3:43:55 PM

Ebay User ID: reveleus1

Check of canister close valve operating

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36422%5Eshop%5E%24 (1 of 2)12/03/2009 3:44:11 PM

1. Connect the CCV pins to a wire as shown.

Ebay User ID: reveleus1

2. At idle, disconnect the CCV connector.

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36422%5Eshop%5E%24 (2 of 2)12/03/2009 3:44:11 PM

Thank-you for purchasing from me, it

Ebay User ID: reveleus1

CHECKING PURGE SYSTEM

Ebay User ID: reveleus1

Battery voltage Normal condition

When discontinued Vacuum is maintained

5. Measure the resistance between the terminalsEmail:

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34646%5Eshop%5E%24 (1 of 2)12/03/2009 3:44:49 PM

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34646%5Eshop%5E%24 (2 of 2)12/03/2009 3:44:49 PM

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Ebay User ID: reveleus1

Ebay User ID: reveleus1

EXHAUST EMISSION CONTROL SYSTEM

AIR/FUEL MIXTURE RATIO CONTROL SYSTEM

Ebay User ID: reveleus1

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34660%5Eshop%5E%24 (1 of 2)12/03/2009 3:45:46 PM

2. After 20 min. idling, inspect the voltage .

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E34660%5Eshop%5E%24 (2 of 2)12/03/2009 3:45:46 PM

Ebay User ID: reveleus1

http://www.hmaservice.com/viewer/content.asp?vehi...1998%5Eall%5E0%5Enone%5Enone%5E36432%5Eshop%5E%24 (1 of 2)12/03/2009 3:46:04 PM

Ebay User ID: reveleus1