Air Fuel System Overhaul

Black plate (1,1)
Engine Overhaul
AIR FUEL SYSTEM OVERHAUL
2.3
S4P
13B FUEL SYSTEM <MPI>
17B EMISSION CONTROL <MPI>
Model YR 2006
English Edition RDWE-06HA020
Destination: MHR
April 2006 Printed in Malaysia
Copyright
Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)
Black plate (2,1)
Printed in Malaysia 21 April 2006 Eng

Black plate (3,1)
AIR FUEL SYSTEM OVERHAUL EO03

Content /I
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/1
INJECTOR AND THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/2

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/2
INJECTOR AND TROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/3

SERVICE POINTS OF REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/3
INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/3
SERVICE POINTS OF INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B/3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/1
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/1
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/2

S4P MPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/3
OXYGEN SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/3
Oxygen sensor (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/3
Oxygen sensor (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17B/4
ENGINE COOLANT TEMPERATURE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . 17B/5
EVAPORATIVE SOLENOID VALVE (TANK PURGE VALVE ) CHECK . . . . . . . 17B/6
All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.
Copyright
Perusahaan Otomobil
Nasional Berhad
(Company No.: 100995-U)

Black plate (4,1)

/1 SPECIFICATIONS
SPECIFICATIONS WEO13BSPECS003
GENERAL SPECIFICATIONS
Items Specifications
Electronic throttle body
Engine Injector part No. Part No. Throttle bore Throttle posi- Idle speed control-
tion sensor ler
S4P PW811635 PW811655 58.5 mm Variable resistor DC motor type
(2.303 in) type
SERVICE SPECIFICATIONS
Items Standard value

Injector coil resistance at 12-13
20 8C (68 8F)
TORQUE SPECIFICATIONS

Fuel rail attaching bolt 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)
Electronic throttle body attaching bolt 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)

Black plate (5,1)
FUEL SYSTEM <MPI> 13B

INJECTOR AND THROTTLE BODY /2
INJECTOR AND THROTTLE BODY WEO13BSASSY003
REMOVAL AND INSTALLATION
DOIGE13BR03001
— Lubricate all the injector O-ring with engine oil during reassembly
: Non-reusable part
Removal steps
1. Electronic throttle body 6. O-ring
2. Throttle body gasket 7. Fuel rail
3. Fuel pressure regulator hose 8. Injector clip
4. Clip 9. Injector
5. Fuel pressure regulator 10. O-ring
T1 : 0.9-1.1 kgm (9-11 Nm; 0.603-0.738 ft.lbs)

Black plate (6,1)

/3 INJECTOR AND TROTTLE BODY
INJECTOR AND TROTTLE BODY

WEO13BSPROC001
SERVICE POINTS OF REMOVAL

REMOVAL OF INJECTOR
1. Remove the injector clip (A) using screw
driver.
2. Pull out the injector (B) from fuel rail (C).
Take care not to drop the injectors.
DOIGE11AR03150
FUEL PRESSURE REGULATOR REMOVAL

1. Using the plier, grip and flick the fuel
pressure regulator clip (A), turning coun-
ter-clockwise.
2. Pull out the fuel pressure regulator (B).
INSPECTION
The inspection of the electronic throttle body, is
covered in Group 13– Fuel of the applicable
chassis Workshop Manual.
DOIGE11AR03151
INJECTORS
1. Measure resistance of the injector coils
using a circuit tester.
Standard value : 12-13
at 20 8C (68 8F)
2. If the resistance is out of specification,
replace the injector.
DOIGE13BR03002
SERVICE POINTS OF INSTALLATION

INSTALLATION OF INJECTORS
1. Fit a new O-ring (A), on the injector.
2. Coat the O-ring with spindle oil.
CAUTION
(1) Be sure not to let Spindle oil get into
the fuel rail.
(2) Beware not to insert injector slantingly
DOIGE13BR03003

Black plate (7,1)

INJECTOR AND TROTTLE BODY /4
3. Insert the injector (B) top end onto the fuel

rail (C) while turning the injector in both
directions. Make sure the injector turns
smoothly.
If the injector does not turn smoothly,
probable cause is the O-ring which can
bind in the fuel rail.
DOIGE11AR03148
4. Install a new injector clip (D) by sliding the

open end onto the fuel rail and the injector
slot (E).
Confirm that the injector clip is in close
contact with the fuel rail and the injector
slot.
DOIGE11AR03149
INSTALLATION OF FUEL PRESSURE

REGULATOR
1. Fit a new O-rings (A), on the fuel pressure
regulator.
DOIGE11AR03152

Black plate (8,1)

/5 INJECTOR AND TROTTLE BODY
2. Insert the fuel pressure regulator (B) sqarely

into the fuel rail.
Make sure that the fuel pressure regulator
turns smoothly.
3. Set the nipple (C) direction 908as shown.
4. Install a new clip and turn clip (D) clockwise
to the fuel rail slot.
DOIGE13BR03005
INSTALLATION OF THROTTLE BODY GASKET

1. Install the gasket bend point (A) into slot
(B) as shown in the illustration.
DOIGE13BR03006

Black plate (9,1)

INJECTOR AND TROTTLE BODY /6
NOTE

Black plate (10,1)

/1 SPECIFICATIONS
SPECIFICATIONS WEO17BSPECS002
GENERAL SPECIFICATIONS
Items Specifications
Oxygen sensor Zirconia type
Coolant temperature sensor Thermistor type
Evaporative solenoid valve Duty cycle type
SERVICE SPECIFICATIONS

Coolant temperature sensor
Resistance
At 20 8C (68 8F) Terminal 2 ! Connect terminal 3 2.2-2.7 k
Terminal 4 ! Connect terminal 1 5.7-6.6 k
At 80 8C (176 8F) Terminal 2 ! Connect terminal 3 0.3-0.34 k
Terminal 4 ! Connect terminal 1 0.59-0.652 k
Evaporative solenoid valve (Tank purge valve)

Resistance
At 23 8C (73.4 8F) 26
G 1.8
Oxygen sensor
Resistance
At 23 8C (73.4 8F) G 5 8C (41 8F) 4.5
G 0.5
TORQUE SPECIFICATIONS

Coolant temperature sensor 2.5-2.9 kgm (25-29 Nm; 1.677-1.946 ft.lbs)
Oxygen sensor (front) 3.4-4.4 kgm (34-44 Nm; 2.281-2.952 ft.lbs)
Oxygen sensor (rear) 4.0-5.0 kgm (40-50 Nm; 2.684-3.355 ft.lbs)
SEALANTS
Items Specified sealant Quantity

Coolant temperature sensor 3M Nut Locking Part No.4171 or As required
threaded part equivalent

Black plate (11,1)
EMISSION CONTROL <MPI> 17B

PARTS LOCATION /2
PARTS LOCATION WEO17BPLOCA002
S4P MPI
DOIGE17BR03002
— Sealant
Items
1. Oxygen sensor (front)
2. Coolant temperature sensor
3. Evaporative solenoid valve (Tank purge valve)
4. Oxygen sensor (rear)
T1 : 3.4-4.4 kgm (34-44 Nm; 2.281-2.952 ft.lbs)
T2 : 2.5-2.9 kgm (25-29 Nm; 1.677-1.946 ft.lbs)
T3 : 4.0-5.0 kgm (40-50 Nm; 2.684-3.355 ft.lbs)

Black plate (12,1)

/3 INSPECTION
INSPECTION WEO17BINSPC002
OXYGEN SENSOR CHECK

Oxygen sensor (front)
1. Disconnect the oxygen sensor connector
and connect the special tool (test harness)
to the connector on the oxygen sensor side.
Symbol Description
A Oxygen sensor (front)
DOIGE17BR03003
B Equipment side connector
2. Make sure that there is continuity

Standard value: (at 23 8C (73.4 8F) D
5 8C (41 8F))
Terminal No. Standard value

Terminal No.1 connect 4.5
G 0.5
!terminal No.3
Symbol Description
A Oxygen sensor equipment
side connector
DOIGE17BR03004
B Blue (No.3 terminal)
R Red (No.1 terminal)
3. If there is no continuity , replace the oxygen
sensor.
4. Warm up the engine until engine coolant is
80 8C (176 8F) or higher.
5. Use the jumper wire to connect terminal 1

(red clip) of the oxygen sensor connector to
the battery (+) terminal and terminal 3
(blue clip) to the battery (-) terminal.
Symbol Description
A Jumper wire
B Black
C Blue
R Red
DOIGE17BR03005 E White
Caution
Be very careful when connecting the jum-
per wire;
incorrect connection can damage the oxy-
gen sensor.

Black plate (13,1)

INSPECTION /4
6. Connect a digital voltage meter between

terminal 2 (black clip) and terminal 4 (white
clip).
7. While repeatedly racing the engine , mea-
sure the oxygen sensor output voltage.
Standard value:
Engine Oxygen sensor output

voltage
When racing 0.8-0.92 V
the engine
Remarks If you make air/fuel ratio
rich by racing the engine
repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.8-0.92 V
8. If the sensor is defective , replace the
oxygen sensor.
NOTE
For removal and installation of the oxygen
sensor, refer to GROUP 15–Exhaust Pipe
and Main Muffler (MODULE 1.3 Workshop
Manual Chassis).
Oxygen sensor (rear)

1. Disconnect the oxygen sensor connector
and connect the special tool (test harness)
to the connector of the oxygen sensor side.
Symbol Description
A Rear oxygen sensor
B Equipment side connector
DOIGE17BR03009
2. Make sure that the specified resistance (

4.5
G 0.5
at 23 8C (73.4 8F) G 5 8C (41 8F))
between terminal 1 (red clip of special tool)
and terminal 3 (blue clip of special tool) at
the oxygen sensor connector.
Symbol Description
A Oxygen sensor equipment
side connector
B Blue
R Red
DOIGE17BR03004
3. If the resistance value is out from specifica-
tion, replace the oxygen sensor.

Black plate (14,1)

/5 INSPECTION
4. Use the jumper wire to connect terminal 1

(red clip) of the oxygen sensor connector to
the battery (+) terminal and terminal 3
(blue clip) to the battery (-) terminal.
Symbol Description
A Jumper wire
B Black
C Blue
R Red
DOIGE17BR03005 E White
Caution
Be very careful when connecting the jum-
per wire;
incorrect connection can damage the oxy-
gen sensor.
5. Connect a digital voltage meter between
terminal 2 (black clip) and terminal 4 (white
clip).
6. Measure the oxygen sensor output voltage.
Standard value:
Oxygen sensor output

Engine
voltage
Ignition On. 278.1795 mv
7. If the voltage value of sensor is out from
specification, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen
sensor, refer to GROUP 15–Exhaust Pipe
and Main Muffler (MODULE 1.3 Workshop
Manual Chassis).
ENGINE COOLANT TEMPERATURE

SENSOR CHECK
CAUTION
Be careful not to touch the connector (resin
section) with the tool when removing and
installing.
1. Use special tool (MD998770) to remove the
engine coolant temperature sensor (A).
DOIGE17BR03001

Black plate (15,1)

INSPECTION /6
2. With temperature sensing portion of

engine coolant temperature sensor
immersed in hot water, check resistance.
Standard value: (at 20 8C (68 8F))

Terminal No.2 connect 2.2-2.7 k
!terminal No.3
!terminal No.1
Standard value: (at 80 8C (176 8F))
DOIIE17BR9006

!terminal No.3
!terminal No.1
3. If the resistance deviates from the standard
value greatly, replace the sensor.
4. Apply sealant to threaded portion.

Specified sealant : 3M Nut Locking No.
4171 or equivalent
5. Use special tool (MD998770) to install the
coolant temperature sensor and tighten it
to the specified torque.
Specified torque :
2.5-2.9 kgm (25-29 Nm; 1.677-1.946 ft.lbs)
DOIGE11AR03039
EVAPORATIVE SOLENOID VALVE (TANK

PURGE VALVE ) CHECK
CAUTION
Be careful not to touch the connector (resin
section) with the tool when removing and
installing.
1. Remove the tank purge valve (A).
DOIGE17BR03006

Black plate (16,1)

/7 INSPECTION
2. Check the tank purge valve inductance

value.
Symbol Description
A Tank purge valve equipment
side connector
B Blue
R Red
Standard value: (at 23 8C (73.4 8F) at
frequency 0-20 Hz)
DOIGE17BR03007
Terminal No.1 connect 50mH approx
!terminal No.2
3. The figure shows how the resistance values

are measured. The test harness : MB 991223
and jumper wire are used to connect the
connector of tank purge valve.
Symbol Description
A Tank purge valve equipment
side connector
B Blue
R Red
To measure the resistance continuity.
DOIGE17BR03008
Standard value: (at 23 8C (73.4 8F) )

Terminal No.1 connect 26
G 1.8
!terminal No.2
4. If there is no continuity, replace the tank
purge valve.

Black plate (17,1)
AIR FUEL SYSTEM OVERHAUL EO03

INDEX /1

3
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S4P Model YR 2006 English Edition RDWE-06HA020 April 2006 Printed in Malaysia

Air Fuel System Overhaul

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Air Fuel System Overhaul

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Black plate (1,1)

17B EMISSION CONTROL <MPI>

Printed in Malaysia 21 April 2006 Eng