Workshop Manual - A Manual Supplement - Compressed

TIMOR 5515 /SS15i
WORKSHOP
MANUAL
fo
h
F
4d
TIMOR
ssls & sslsi
CONTENTS
TITLE GROUP
FOREWORD GeneralInformation !i!
This WorkshopManualprovidesinformationcover-
Pre-Delivery
InspectionAnd
ScheduleMaintenance Service
il
ing normalservice,repairs,and maintenancefor all soHc(Bs,B 6)
systemof the mentor. ENGINE I
I
DOHC(Bs) a
This manualis organisedintoGroupscoveringgeneral

systems.WithineachGroup,the informationis further LubricationSystem
dividedinto Sections.Thereis one Sectionfor each CoolingSystem
componentor sub-system.SomeGroupscontaina
ServiceSectionto coverprocedures@mmonto several -System
cornponents or subsystems wihin tre Group.In general, Intakeand Exhaust I
each Section contains an Outline Description,

Emission 85 - Engine
Troubleshooting,Ad ustments,Removalard Irstallation,
control system
and Disassembly, Assemblyand Inspectionprocedures 86 - Enginer a
for the componentcoveredin the Section.Diagnosis

and Testingis includedin the first sectionof some FuelSystem
groups to help you systematicallylocateand correct
problemsencountered. In mostcases,spesifications lgnitionSystem
a r e i n c l u d e da t t h e b e g i n n i n go f e a c h S e c i i o n . StartingSystem cl
To aid in locatingspecificsubjectsin thismanual,use CharghingSystem

t h e T a b l e o f C o n t e n t so n t h e f o l l o w i n gp a g e s .
Cluth
iT
As a furtheraid,tirereis an indexon the firstpageof Manual 41
each Group which lists the Sectiontitle for each TranslaxF:
componentcoveredwithinthe group. Automatic 42
ThisGroupSecticnbreakdovrrr is alsoindrcated in the DriveshaftanclAxle
p a g e n u m b e r l o c a t e da t t h e i o p o f e a c h p a g e . 50
SteeringSystern 5'!
Example: 10-35= (Grollp)10,(Page)
Br'akeSystem 52
The descriptionsand specificationcontaineciin this manuaf Wheel and Tires 53
were in effe .t at the time ihis rnanualwasapprovedfor printing.
Tlmor Putra Nasionalreservesthe rightto discontinuemodets S uspensi on 54
at any tirne.or changs specificaiionor designwithoutnotice Bocjy 6C
and withoutincurringobligatiorr.
Body ElectricalSystem 6t
Published by PT. Timor Putra Naslonal,1998
Printed in Jakarta. Mei 1998 Air Conditioning
System 62
Only ( E ) fvlentionedat This Workshop 8ook.
GENERALINFORINA
?
t
F U N D A M E N T A LP R O C E D U R E S 00-3
ENTALPROCEDURES
FUNDAM
SYMBOLS
Thereare six symbolsindicatingoil, grease,and sealant.Thesesymbolsshow the pointsof applyingsuch
materialsduringseruice.
Meaning
N e w e n g i n eo i l o r g e a r o i l a s a p p r o p r i a t e
Applybrakefluid Only brake fluid
Applyautomatic
transaxle
fluid
Ap p l ys e a l a n t Appropriate
sealant
Applypetroleum
jelty Appropriate
Note
. Whenspecialloil or greaseis needed,
this is shovrnin the illustration.
NOTES,
CAUTIONS,
ANDWAHNINGS .
acrossNOTES,CAUTIONS, and WARNINGS.Each
r addedinformationthatwillhelpyou lo complete
a
:nt you frommakingan errorthatcoulddamagethe
;areful
in thoseareaswherecarelessness can cause
.'neralWARNINGS you shouldfoflowwhenyouwork
P R O T E C T I OO N F T H EV E H I C L E
A l w a y s b e s u r e t o c o v e r f e n d e r s ,s e a t s , a n d f l o o r a r e a s
beforestarlinbwork.
I
00-4 FIJNDAMENTFILPFIECEDUHES
A W O R DA B O U TS A F E T Y
The follcwingprecautions must be followedwhen jackingup
t h ev e h i c l e .
1 . B l o c kt h e w h e e l s .
2. Use only the specifiedjackingpositions.
3. Suppoflthe vehiclewith safetystands.
S t a r t t h e e n g i n eo n l y a f t e r m a k i n g c e r t a i nt h e e n g i n e
compartnrent is clearof toolsand people.
P R E P A R A T I OO
N F T O O L SA N D M E A S U R I N G
EQUIPMENT
Be sure that all necessarytools and measuringequipment
are availablebeforestartingany work.
S P E C I A LT O O L S
Use specialtoolswhen they are required.
REMOVAL OF PARTS
Whilecorrecting a problem, tryalsoto determine itscause-
B e g i nw o r k o n l y a f t e r f i r s t l e a r n i n gw h i c h p a r t s a n d
subassemblies mustbe removedand disassembled for
replacement of repair.
DISASSEMBLY
l f t h e d i s a s s e m b l yp r o c e d u r ei s c o m p l e x ,r e q u i r i n gm a n y
parls to be disassembled, all partsshouldbe disassembled
in a way that will not affect their performanceor external
a p p e a r a n c ea n d i d e n t i f i e ds o t h a t r e a s s e m b l yc a n b e
performedeasilyand efficiently.
I
t
F UN D A M E N T A LP R E C E D U R E S 00-5
l.lnspectionof parts
When removed,eachpartshouldbe carefully inspected
f o r m a l f u n c t i o n i ndge, f o r m a t i o rdr a
. m a g ea
, nd other
problems.
2.Arrangement of parts
All disassembled partsshouldbe carefullyarrangedfor
reassembly.
Be sureto separateor otherwiseidentifythe partsto be
replacedfromthosethatwillbe reused.
3. Cleaningpartsfor reuse
All partsto be reusedshouldbe carefullyand thoroughly
cleanedin theappropriate method.
REASSEMB LY
Standard values,suchas torquesand cerlainadjustments,
mustbe strictly obseruedin thereassembly'of allparts.
REfET tOSTANDARD B O L TA N D N U T T I G H T E N I N G
T O R Q UE i n S e c t i o nT D f o r t i g h t e n i n gt o r q u e sn o t
mentioned in themaintext.
lf removed, thesepartsshouldbe replaced withnewones:
1 .O i ls e a l s 2. Gaskets
3. O-rings 4. Lock washers
5. Cotterpins 6. Nylonnuts
D e p e n c i i n go n l o c a t i o n :
1 . S e a l a nst h o u l db e s p p l i e do r n e w g a s k e t su s e d .
2.Oil sho_uld be appliedto the movingcomponentsof parts.
3 . S p e c i f i e do i l o r g r e a s e s h o u l d b e a p p l i e d a t t h e
p r e s c r i b e dl o c a t i o n s ( s u c h .a s o i l s e a l s ) b e f o r e
reassembly.
00-6 FUNDAfuIENTAL PFIECEDURES
ADJUSTMENTS
Use suitabregauges and/or testers wrren
makirrg
adjustments.
RUBBER P A R T SA N DT U B I N G
Preventgasolineor oil from gettingon rubberparts or
tubing.
LIFTposrloNs
JACKAruoSnFETysrANDposrroNs,vEHtct-E 00-7
J A C K A N D S A F E T YS T A N DP O S I T I O N S
F R O N TE N D
J a c k P o s i t i o n: S a f e t ys t a n d p o s i t i o n s :
A t t h e l r o n tc r o s s m e m b e r O n b o t h s i c j e sc f t h e b o d v f r a m e
R E A RE N D
Jack position: Safetystand positions :
A t t he c ente r o f th e re a r c ro s s m e m b e r On both si des of the bodv frame
V E H I C L EL I F T ( 2 - S U P P O R TT Y P E ) P O S I I O N S
F R O I . J TE N D REAREND
Frame Frame
S i d es r l l s S i d es i l l s
00-B T O W I N G ,I D E N T I F T C A T I ONNU M B E RL O C T \ T I O N S
TOWiIIG
P r o p e ; ' t o w i r iegq u i p n r e ni ts n e c e s s a r yt o p r e v e n d
t a m a g et o
t h ev e h i c l e .
W H E E LD O L L I E S L a w s a n d r e g u l a t i o n sa p p l i c a b l et o v e h i c l e si n t c l , r m u s t
alwaysbe observed.
A s a g e n e r a lr u l e ,t o w e d v e h i c l e ss h o u l dt r e p u l l e dw i t h t h e
d r i v i n gw h e e l so f f t h e g r o u n d . l f e x c e s s i v ed a m a g eo r o t h e r
condilionp s r e v e n t o w i n gt h e v e h i c l ew i t h t h e d r i v i n qw h e e l s
o f f t h e g r o u n d ,u s e w h e e ld o l l i e s .
W i t h e i t h e ra u t o m a t i co r m a n u a lt r a n s a x l e:
1. Set the ignitionsvritchin the ACC position;
2. Placethe seleclorleveror shiftleverin N (Neutrai)
3 . R e l e a s et h e p a r k i n gb r a k e .
Caution
. Do not tow the vehicle backward with driving
wheels on tire grounC. Tliis rnay cause internal
d a m a g et o t h e t r a n s a x ! e s .
. Do not use the hook loops under the front and rear
of the vehiclefor towing purposes. These hook
l o o p s a r e d e s i g n e d O N L Yf o r t r a n s p o n t i e - d o w n . l f
tie-down hook loops are used fot'towing, the
f r o n t / r e a rb u t n p e rw i l l b e d a r n a g e d .
I D E N T I F I C A T I ONNU M B E RL O C A T I O N S
E N G I N EM O D E LA N D vEHlcLE IDENTIFICATIONUMBER(VlN)
UNITS/ABBREVIATIONS 00-9
UNITS
N'm (kg'm.or kg'cm,
lb- ltor lb- i n )....... T o rq u e
r pm . . . . . . ... .......R e v o l u l i o npse rm i nute
A . . . . . . . . . .... .......Amp e re (s )
V . . . . . . . . . . ... .......Vo tt(s )
0 . . . . . . . . ..... ......Oh m(s )(re s i s ta n ce)
kPa (kg/cmz, psi) Pressure
(usuallynegative)
mmHg(inHg) . Pressure
, (usuallynegative)
W ............ . . . . . .W. att
lit er s( USq t, l mpq t) ........ V o l u me
mm (in) Lengrth
ABBREVIATIONS
ABDC Afterbottomdead
center
NC . . . . . . . . . .......Ai r c o n d i ti o n e r
A CC . . . . . . .. .......A c c e s s o ri e s
A T X. . . . . . . .. .......Au to ma titra c n s a xl e
ATDC Aftertop deadcenter
A T F . . . . . . . .. .......Au to ma titra c n s a xl e
fluid
B A C. . . . . . . .. .......B y p a s sa i rc o n trol
BBDC Beforebottomdead
cenler
BTDC Beforetop deadcenter
CP U . . . . . . . . .......C e n trapl ro c e s s i nuni g t
DRL . . . . . . .. .......D a y ti m eru n n i n gl i g hts
EC.AT
automatic
transaxle
00-10 CAIJI'|Oi\J
CAUT!OI'J
4W o;'3.4\.{
E L E C ' T R I C ATLF O U8 L E S H O O T I N G TOOLS
Test Lighi
i n t h e f i g u r e ,L r s e sa 1 2 V b u l b ' T h e
- T l r e t e s l l i . j h t ,a s s h o t ' v n
tvroieacjwiresshoulcjbe connectedto probes'
T l r e i e s t l i q l - , its u s e d f o r s i m p l e v o i t a g e c h e c k s and for
c h e c k i n gf o r s h o r lc i r c u i t s .
Caution
, !\rhenctreckingthe controlunit, never use a bulb
o\rer3, 4W.
J u m p e rW i r e
acrossswitch
Thejlrnperwireis usedfortestingby shorting
terminals connections'
andgror-rncj
Cauticn
. Do trot connect a jumper wire from the power
source liire io a body ground; this may 9?use
burningorotherdamagetoharnessilbor
e l e c t r o ni c c o m P o n en t s '
Voltmeter
VOLTMETER The DC voltmeter is usedto measureof circuitvoltdge'.A
voltmeter rritha iunguof 15Vor moreis usedby connecting
pointwhere
tn. potitive(+) pr6be(red.leadwire)to the
i s t o U 6h e a s u r e d a n d t h e n e g a t i v e( - ) p r o b e
"(blacli
o r t i glead
. wire)to a bodyground'
R E DL E A D POWER
SOURCELII.IE
GROUND
Oh:nmeter
between
The ohrnmeteris used to m e a s u r et h e r e s i s t a n c e
c i r c u i ta n d a l s o t o c h e c k f o r c o n t i n u i t Ya n d
t w o o o i n i si n
diacrnosis of shortcircuits'
Cautioi't
to any
. Do not aitempt to connect the ohmmeter
v o i t a g e i s a p p l i e d ; t h i s m a y burn
circuit to vunifh
or other,'lisedamage the ohrnmeter'
OHI','iMETER
D ! a g n o s i sC o n n e c t o r
i v h e n c o n n e c t i n ga
l n s e r tt h e p r o b l ei n t o t h e s e r v i c eh o l e
j u i n p e rw i r et o t h e d i a g r r o s icso n n e c t o r '
Caution
into the
. Do trot insert the iumper wirg.p.robe
t e r m i n a l 'w h i c h m a y damage
O i u g n o s i sc o n n e c t o r
the iernrinal'
CAUTION 00-11
C A U T I O N\ ^ / I T HE L E C T R I C A LP A R T S
B a t t e r yC a b l e
B e f o r ed i s c o r r n e c t i rct o g n n e c t o r so r r e p l a c i n ge l e c i r i c a l
p a r t s .c i i s c o n n e tcht e n e o a t i v eb a t t e r yc a b l e .
Connectors
R e m o v a lo f c o n n e c t o r
F
N e v e r p u l l o n t h e s i r i n g h a r n e s sw h e n d i s c o n n e c t i n g
connectors.
:i
*
E
s iE
*
t; Connectorscan be removedby pressingor pullingthe lock
rF
\:, l e v e ra s s h o w n .
1i
:
t
4 1 .
l'-I
ii
a:
*
+-
l'1
ts
E
r
t{
if
F
L o c k i n go f c o n n e c t o r
When lockingconnectors, make sure lo listenfor a clickthat
w i l li n d i c a t e
t h e ya r e s e c u r e l yl o c k e d .
ry
'n
lnspection
1 . V / h e n a t e s t e r i s u s e d t o c h e c k f o r c o n l i n u i t yo r t o
m e a s u r ev o l t a g e ,i n s e r tt h e t e s t e rp r o b e f r o m t h e w i r e
h a r n e s ss i d e .
ne
ge
00-12 CAUTION
2. Check the terminalsof r,vaterproofconnectorsfrom the

connectorside,as the,/carrnoibe accessedfrom the wire
harnessside.
Caution
' U s e f i n e r v i r et o p r e v e n t d a m a g et o t h e t e r m i n a l .
' D o n o t d a m a g e t h e t e r t t r i r r aw l hen inserting the
t e s t e rl e a d .
Terminals
Inspection
r,vires
Pulllightlyon individ.ual to checkthat they are secured
in the terminal.
Replacementof terminals
Use the appropriatetoolsto removethe terminalas shown.
When installingthe terminal,be sure to inserl it untilit locks
securely.
<Female>
l n s e r ta t h i n p i e c e o f m e t a l f r o m t h e t e r m i n a ls i d e o f t h e
connector,and then, with the terminallocking tab oressed
down,pull the terminalout from the connector.
<Male>
Same as the femaletype.
Sensors,Switches,and RelaYs
Handlesensors, and relayscarefully.Do notdrop
switches,
themor strikethemagainstotherpads.
.
CAUTION 00-13
Wiringharness
Wiringcolor codes
Two-colorwiresare indicatedby a two-colorcode symbol.
The first letterindicatesthe base color of the lvire and the
secondthe colorof the stripe.
C OD E COLOR CODE C OLO R
B Black o Orange
BR Bnron P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG LightGreen
p
SCHEDULED
MAINTENANCE
SERVICES
SCTIEUJI-ED
MAINTENAhICE ..........O1. 3
SERVICES
" S C H E D U L EM
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ENGTNE(SOHC(85,86))
A S S E M B L Y. . . . . . . . . . 10A- 63
coMpRESStoN ........... . . . .1 0 A - 1 0
DISASSEMBLY .. 1OA-37
E N G I N ES T A N DD I S M O U N T I N G. . . . . . . . . . . 1OA-87
E N G I N ES T A N DM O U N T I N G. . . . . . . . . . 1 O A -3 4
E N G I N ET U N E - U PP R O C E D U R E. . . . . . . . . . . . . .1.O . .A. - 6
I N S P E C T T O/ NR E P A I R. . , . . . . . . . . 1 0 A - 51
INSTALLATION . 1OA- 89
O N - V E H I C L EM A I N T E N A N C E. . . . . . . . . 1OA. 11
OUTLINE 1OA. 3
R E M O V A L. . . . . . . . . . . . 104- 27
S P E C t F t C A T I O N .S. . . . . . . . . . . . . . . . . . . . r . .1. 0. .A - 9 B
T R O U B L E S H O O T I NG GU I D E 1OA. 4
E N G I N Eo u r L r N E 10A-3
OUTLINE
S T R U C T U R AVLI E W
'--4
\ffi a \-\
\
\
r0001
1. limingbelt .Ai . F r o n to i l s e a l
2. Cylinder
headgasket R e a ro i ls e a l
3. HL-A o. Engine
i
f
g
t
10A-4 ENGINErRouBLESHoolNGutDE T
f
T
r
i
TROUBLESHOOTING
GUIDE
T
t
Problem P o s s i b l eC a u s e Action
O i f f i c u l ts t a r t i n g M a i f u n c t i o no f e n g i n e - r e l a t e cdo m p o n e n t s
B u r n e dv a l v e Replace
W o r n p i s t o n .p i s t o nr i n g ,o r c y l i n d e r R e p l a c eo r r e p a i r
F a i l e dc y l i n d e rh e a d g a s k e t Replace
M a l fu n c t i o n o f f u e l s y s t e m R e fe r t o S e c t i o n2 2
M a l f u n c t i o no f i g n i t i o n s y s t e m R e f e rt o S e c t i o n3 0
Poor idling M a l f u n c t i o no f e n g i n e - r e l a t e dc o m p o n e n t s
M a l f u n c t i o no f H L A ' Feplace
Poor valve-to-valveseat contact R e p l a c eo r r e p a i r
F a i l e dc y l i n d e rh e a d g a s k e t Feplace
L
v
M a l f u n c t i o on f f u e ls y s t e m R e f e r t o S e c t i o n2 2 F
r
E
r:
M a l f u n c t i o no f i g n i t i o n s y s t e m R e f e r t o S e c t i o n3 0 F
T
F
E x c e s s i v eo i l O i l w o r k i n gu p F
consumption Wornpistonringgrooveor stickingpistonring Replace
W o rnp i s to nc y l i n d e r R e p l a c eo r r e p a i r
Oil working down

W o r n v a l v es e a l Replace
W o r n v a l v es t e m o r o u i d e Fleplace
Oil leakage R e f e rt o S e c t i o n 1 1
E N G IN E r R o u B L E S H o o l N G U i D E 104-s
P o s s i b l ec a u s e
l n s u f l i c i en t l n s u f i i c i e n tc o m p r e s s i o n
l ' , 4 a l f u n c t i oonf H L A ' lonleô
C o m p r e s s i o nl e a k a g ef r o m v a l v es c a t Repair
S e i z e c vi a i v e s t e m Replace
W e a k o r b r o k e n v a l v es p r i n g Replace
F a i l e dc y l i n d e rh e a d g a s k e t Replace
C r a c k e do r d i s t o r t e dc y l i n d e rh e a d Replace
S t i c k i n gd, a m a g e d ,o r w o r n p i s t o nr i n g Ronlrno
' ' v t / ' s . v v
C r a c k e do r w o r n o i s t o n Rp nlerô
, , v F , s v v
M a l fu n c t i o n o f l u e l s y s t e m H e f e ri o S e c t i c n2 2
*r r-r** tb a"r.*tr,",.; R e fe r t c S e c l i o n3 0
" "'
Others
S l i p p i n gc i u i c l r R e fe r l o S e c t i c r r4 0
D r a g g i n gb r a k e s R e l e , t o S e c t i o n5 2
Wronq size tires R e f e rt o S e c t i o n5 3
Abnormal l , 1 a luf n c i i o n o f e n g i n e - r e l a t e d. * n[-

combustion M a l f u n c t i o no f H L A ' ".-po Replace
S t i c k i n go r b u r n e d v a l v e Replace
t W e a k c r b r o k e nv a l v s s p r i n g Rcplaco
; C a r b o na c c u m u l a t i o ni n c o m b u s i i o nc h a m b e r E l i m i n a t ec a r b o n
ll
sT
* M a l f u n c t i o no f f u e l s y s t e m
I
n R e f e rt o S e c t i o n2 2
M a l f u n c t i o no f i g n i t i o n s y s t e m R e f e rt o S e c t i o n3 0
E n g i n en o i s e C r a n k s h a f l o r b e a r i n g - r e l a t e dp a r t s
E x c e s s i v em a i n b e a r i n go i l c l e a r a n c e R e p l a c eo r r e p a i r
M a i n b e a r i n gs e i z e d o r h e a t - d a m a g e d Replace
Excessivecrankshaftend play Repace or repair
't E x c e s s i v ec o n n e c t i n gr o d b e a r i n go i l c l e a r a n c e R e p l a c eo r r e p a i r
F. C o n n e c t i n gr o d b e a r i n gs e i z e do r h e a t - d a m a g e d Replace
f.
*tr _
k
t
P i s t o n - r e l a t e dp a r t s
i Worn cylinder R e p l a c eo r r e p a i r
f
il Wom piston or piston pin Replace
P S e i z e dp i s t o n Replace
; D a m a g e dp i s t o n r i n g Replace
: B e n t c o n n e c t i n gr o d
E
e'
Replace
}
F V a l v e s o r t i m i n g - r e l a t e dp a r t s
* M a l l u n c t i o no f H L A '
la
a Replace
, Broken valve spring Replace
F Excessivevalve guide clearance Replace
t
F
* M a l f u n c t i o on l c o o l i n gs y s t e m R e f e rt o S e c t i o n1 2
t:
ts
F
R.
E l t l a l f u n c t i o no f f u e l s y s t e m R eferto S ection22
s
f:
!
i Others
: M a l f u n c t i o no f v r a t e rp u m p b e a r i n g R e fe r t o S e c t i o nl 2
l m p r o p e rd r i v e b e l t t e n s i o n Adjust
M a l l u n c t i o no f a l t e r n a t o br e a r i n g R e fe r t o S e c t i o n3 2
E x h a u s tg a s l e a k a g e R e f e rt o S e c t i o n2 2
M a l f u n c t i o no f t i m i n gb e l l t e n s i o n e r Replace
T a p p e tn o i s em a y o c c u r i f t h e e n g i n eh a s s e t i d l ef o r a n e x l e n d e dp e r i o d . T h e n o i s es h o u l dd i s s i p a t ea ft e r t h e e n g i n eh a s
r e a c h e di t ' s n o r m a l o p e r a t i n gl e m p e r a t u r e .
1O.ilFo ENGINE ENGINE
TUNE.UP
PRocEDURE
E N G I N ET U N E - U PP R O C E D U R E
P RE P A R A T I O N
SST
0 K20i 189063 For

i n s p e c t i o no f
KJ-1 igniliontiming
a n d i d l es p e e d
ENGINE OIL
Inspection
1.Be surethevehicleis on a leve!grcund.
2. warm up lhe engineto thenormalcperating
temperature
andstopit.
3 Waitfor5 minutes.
4. Removethe oil levelgauge,and checkthe oil leveland
condition.
5. Addor replacean oil if necessan/.
r@o2
ENGINE COOLANT
ry
Inspection
Coolantlevel(coldengine)
Warning
. Neverremovethe radiatorcap while the engineis
hot.
. wrap a thickclotharoundthe cap whenremovingiL
1.Verifythatthecoolantlevelis nearthe radiatorfillerneck.

2. check if the coolantlevelis betweenthe "F' and "L" on
thecoolantleveldipstick.
BSX021006
3. Adda coolantif necessary.
C o o l a n qt u a l i t y
1.Verifythatthereis no buildupof rustor scalearoundthe
radiatorcapor the radiatorfillerneck.
2. Verifythatthecoolantis notcontaminatedwithan oil.
3. Replacethecoolantif necessary.
D R I V EB E L T
Inspection
1 . R e m o v et h e a i r i n t a k ep i p e .
2 . c h e c k t h e d r i v e b e l t s f o r w e a r , c r a c k s ,a n d f r a y i n g .
Replaceif necessary.
V - R I B B E tD 3 . V e r i f yt h a t t h e d r i v e b e l t s a r e c o r r e c t l ym o u n t e do n t h e
pulleys.
10A-7
EU N E - U P R O C E D U R E
ENGINE ENGINT
4 . C h e c kt h e d r i v eb e l t d e fl e c l i o nb y a p p l y i n ga r n o d e r a t e
p r e s s u r e9 8 N ( 1 0 k g , 2 2 l b ) t o t h e i ^ n r d v i abye t l e e n t h e
ALTERNATOR pulleys.
1O k g
WATER \. Note
$4r*+
PUMP ,r-'
9rilltrY , M e a s u r et h e b e l t d e f l e c t i o nb e t w e e n t h e s p e c i f i e d
pullevs.
A . A b e l i i s c o n s i d e r e d" N e w " i f i t h a s b e e n u s e d o n a
CFANKSHAi CRANKSHAfr / r u n n i n qe n q i n ef o r l e s s t h a n f i v e m i n u t e s .
PULLEY (utL:v V' S e t t h e " d e f l E c t i o snp e c i f i e db e l o w a c c o r C i n g l y '
. C h e c kt h e b e l t d e f l e c t i o nw h e n t h e e n g i n e i s c o l d ,
7 \_/ o r a t l e a s t3 0 m i n u t e sa f t e rt h e e n g i n eh a s s t o p p e d .
10 k g AI-TERNATOR I PrS
10006
Deflection mm (in)
1Okg
1Okg
ALTERNATOR Drive belt New Used Limit
\,
pd^\ Alternator
P/S, P/S + NC
8.0-9.0
(0.31-0.35)
8.0-9.0
9 . 0 -1 0 . 0
(0.3s-0.3e)
9.0-10.0
|1.3
(0.4s)
rl.)
cRANKSHATTdiVr-\ (0.31-0.3s) (0.34-0.3e) (0.4s)
PULLEY PRESSOR
r / \PULLEY NC 8.0-9.0 9 . 0 -1 0 . 0 11.5
( 0 . 3 -10 . 3 s ) (0.3s-0.3s) (0.4s)
5. lf the deflection adjustthe belt.

is notwithinthe specification,
A/c I P/s AND A/c
6 . I n s t a ltih e a i r i n t a k eP i P e .
10007
D r i v eb e l t t e n s i o n c h e c k
1 . R e m o v atl h e a i r i n t a k eP i P e .
2 . B y u s i n gt h e S S T ,c h e c kt h e b e l tt e n s i o n .
Tension N ( k g ,l b )
D r i v eb e l t New Used I uimit

rs
A l ternator .>GJ-qO I
6 ^
3o1-3E3 |
t F .
167 i
W H E NM E A S U R E D (39-47, (31-3e,
Es.8-103.4) 68.2-8s.8)
| ( 17, 37) I
P/S, P/S + NC 491-589 4n-491 | zas
t - A ^ ^ . . A
(JU-OU, I lU- rJZ,
. ^ 6 \
( 4 3 - 5s0s, - 1 1 0i ) ( 2 5 s, s )
W H E NS E T 491-589 422-491 | 245
)n ( 5 0 - 6 0i,i 0 - 1 3 2 ) es-1I o) |
(43-so, (zs.ss)
10003
3. lf thetensionis notwithinspecification, adjustthe belttension.
4 . l n s t a ltl h e a i r i n t a k eP i P e .
A l t e r n a t o rb e l t
1 . l f n e c e s s a r yl,o o s e nt h e a l t e r n a t o m r o u n t i n gb o l t s a n d
adjusting bolt.
2 . P u l l t h e a l t e r n a t oor u i w a r dt o a p p l ya t e n s i o nt o t h e b e l l ,
t h e nt i g h t e nt h e a l t e r n a t omr o u n t i n gb o l t sw i t ht h e s p e c i f i e d
t i g h t e n i ntgo r q u e .
T i g h t e n i n gt o r q u e :
@ : 3 7 - 5 2 N ' m ( 3 . 8 - 5 . 3k g - m ,2 7 - 2 8 l b - f t )
@ : 1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 9 l b - f t )
P/S belt, P/S + fuC belt
1 . l f n e c e s s a r yl o, o s e nt h e P i S o i l p u m pb o l t s ,@ a n d n u t @ ,
andO thenadjusithebeltdeflection by turningthe adjusting
bolt@.'
ng. \
2.Afterlhe adjuslrnent of beltdeflection, tightenlhe boltsrvith
the t l r es p c i f i eldi g h t e n i ni o
qr q t , e .
/",.-\
CRANKSHAFT t o r q u e:
Tightenirrg
PULLEY -40 lb-ft)
@ : 3 6 - 5 4 N ' m ( 3 . 7 - 5 . 5k g - m, 2 7
@ : 1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 9 l b - f t )
C : 3 1 - 4 6 N ' m ( 3 . 2 - 4 . 7k g - m ,2 3 - 3 4 l b - f t )
l 0 c1 0
Jf-
10A-8 E N G I N E E N G I NTEU N E . UPPR o c E D U R E
A/C belt
1 . l f n e c e s s a r yl,o o s e nt l r e l o c k n u l6 ! a n d a d j u s tt h e b e l t
deflectiob n y t u r n i n gi l r ea d l u s t i n g
b o l t( ) .
2 . A l t e rt h e a d j u s l m e n t ,i g h t e nt h e l o c k n u t
@.
'
3 1 - 3 4 N . m ( 3 . 2 - 3 . 5k g - m, 2 3 _ Z Sl b - f t )
NC
COMPRESSOR
r0011
HLA
Problem PossibleCause I A atinn
'1.
N o i s e w h e n e n g i n e i s s t a r t e di m m e d i - O i l l e a k a g ei n o i l p a s s a g e
a t e l ya f t e ro i l i s c h a n o e d . R u n . e n g i n e2 , 0 0 0 - 3 , O 0 0r p m .
2 . N o i s e w h e n e n g i n e i s " s t a r l e da f t e r s e t - l l n o i s es t o p s a f l e rZ s e c o n d - 1 0
I r n ga p p r o x . o n e d a y . m r n u t e s( ' ) , H L q i s n o r m a l .
ll not, replace Hl-A.
'
3 . N o i s e w h e n e n g i n e i s s t a r t e da f t e r Oil leakage in HLA ll.Tg iequired for engine oil to circulate
c r a n k i n gf o r 3 s e c o n d s o r m o r e . w i t h i ne n g i n e ,i n c l u d 6 st o l e r a n c ef o r
4 . N o i s e w h e n e n g i n e i s s t a r l e da f t e r e n g i n eo i l c o n d i t i o na n d a m b i e n tt e m -
now Hl-A is inst-alled. peraturo.
5 . N o i s ec o n l i n u e sm o r e t h a n 1 0 m i n u t e s . In s u ff i ci ent
oi tpressure C h e c kt h e o i l p r e s s u r e .
l f l o r v e rt h a n t h e s p e c i f i c a t i o nc, h e c k f o r
p o s s t b l ec a u s e .
Oifpressure; 294-392kpa
FaultyHLA
(3.0-4.0kg/cma,€-f/ psi|3000 rpm
Press down HLA by hand.
l f i t d o e s n o t m o v e , ' H L Ai s n o r m a l .
t
I
l l r t m o v e s ,r e p l a c eH L A .
I
M e a s u r ev a l v e c l e a r a n c e .
l f m o r e t h a n 0 m m ( O i n ) , r e p l a c eH L A .
l
p
t.
a;
i
I
6 . No i s eoc c ur sdur nin gi d tea fte rh i g h - ':
In c o rr ect
oi l amount Ch..k r'l l.*L
sp eedr unning. :'
D r a i n o r a d d o i l as necessary. -
5
D e te riorated
oi l C h e c ko i l q u a l i t v . G
l f d e t e r i o r a i e di,e p l a c ew i t h s p e c i f i e d F
t y p e a n d a m o u n to f o i l .
z:
t L
i"
!
I
ii
*
F'
L
:p
t"
r,
ENGINE ENGINE
TUNE.UPRoCEDURE 10 A - 9
IGNITION TIMING
i . W a r m u p t h e e n g i n ei o n o r m a o l p e i ' a t i ntge m p e i ' a l u i ' e .
2 . T u r na l l e l e c t r i lco a d sC F F .
3 . U s e a j u m p e rv r i r e c, o n n e c b t e i w e e nt h e e n g i n el e s t a n d
t h e g r o u n dt e r m i n ailn t h e d i a g n o s i sc o r r n e c t o r .
4 . C o n n e cat t i m i n gl i g h t .
5 . C h e c kv r h e t h e trl r el i r n i n gm a r k ( Y e l l o r vo)n t h c c r a n k s h at f
p u l l e ya n d t h e m a r ko n t h e t i m i n gb e l tc o v e ra r e a l i g n e d .
l g n i t i o nt i m i n g : B T D C7 ' t 1 " ( a t i d l es p e e d )
100t4
6 . l f t h e m a r k s a r e n o t a l i g n e d ,l o o s e nt h e d i s t r i b u t olro c k
b o l t sa n d t u r n t h e d i s t r r b u t ot or m a k e t h e a d j u s t m e n t .
7 . T i g h t e nt h e d i s t r i b u t orro c kb o l t st o t h e s p e c i f i e dt o r q u e .
1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m , 1 4 - 1 9 l b . t t )
I
l
I
t
t
T LOCKBOLTS
$
I
t
a
f rnnl<
3
F
t I D L ES P E E D
rF 1 . W a r mu p t h e e n g i n et o n o r m a o l p e r a t i n tge m p e r a t u r e .
t 6 2 . T u r na l l e l e c t r i cl o a d sO F F .
,t
3 . U s e a j u m p e rr , v i r ec,o n n e c lb e t w e e nt h e e n g i n et e s t a n d
*F
t h e g r o u n dt e r m i n ailn t h e d i a g n o s i sc o n n e c t o r .
I'
E
r- 4 .C o n n e c a t tachometer.
F
T:
5. Applythe parkingbrakeand move the transaxlein "P" or "N".'
F
* 6 . C h e c kw h e i h e rt h e i d l es p e e di s w i t h i nt h e s p e c i f i c a t i o n .
i.
|r
rt
t
A I RA D J U S T I N S
GC R E W l d l e s p e e d ( N e u t r a ol r P r a n g e ): 7 5 0 + 5 0 r p m
F
h
h
ti 10016 Caution
t:
J . C h e c k t h e i d l e s p e e d w i t h o u t t h e e l e c t r i cc o o l i n g
F F
fan operating.
F
g
7 . l f t h e i d l e s p e e d i s n o t w i t h i nt h e s p e c i f i c a t i o na ,d j u s tt h e
E
F i d l es p e e db y t u r n i n gt h e a i r a d j u s t i n gs c r e w .
r{
a
*
a-.
10A-10 ENGINE ooMPRESSIoN
COMPRESSION
l f t h e e n g i n es h o w sl o r vp o w e r ,p o o r f u e le c o n o m yo, r p o o ri d l e ,c l r e c kt h e f o l l o w i n g:
'l
. l g n i t i o ns y s t e m( R e f e rt o s e c t i o n3 0 )
2. Compression
3 . F u e l s y s t e m ( F e f e rt o s e c t i o n2 2 )
INSPECTION
t. Checkthat the batteryis fullycharged.Rechargeit if
necessary.
2. Warmup the engineto thenormaloperating temperature.
3.TumtheengineOFF.
4. Remove allsparkplugs.
5. Disconnect theignition
coilconnector.
6. Connect a compressiongaugeto theNo.1 sparkplughole.
7. Fullydepress theacceleratorpedalandcranktheengirre.
B.Record themaximum gaugereading.
9. Checktherestof cylinders by theabovesteps.
r0017
kPa (kg/cm',psilrpm
B5 B6
1,324
S tandard
( 1 3 . 5 1: s 2 ) - 3 0 0
93.2 868
Mi nj mum
(9.5,68.7)-300 ( 8 . 8 ,1 2 5 ) - 3 0 0
MAX.
difference
between 1 9 6( 2 . 0 2
, 6)
'/ W-zg<: cylinders
\ ./v zr\.,N) 10.lf thecompression in oneor morecylindersis low,poJra
smallamountof engineoil intothe cyiinder and recheck
thecompression.
(1) lf thecompression thepiston,pistonrings,
increases,
or cylinderwallmaybe worn.
(2)lf the compression stayslow,the valvemay be stuck
or seatingimproperly.
(3)lfthecompression in adjacent stayslow,the
cylinders
cylinder headgasketmaybe defective or thecylinder
headmaybe distorled.
11. Connect theiqnition
coilconnector.
1 2 .A p p l yt h e a n t i s e i z ec o m p o u n do r t h e n r o l y b r j e n u m - b a s e d
l u b r i c a ntto t h e s p a r kp l u gt h r e a d s .
1 3 . I n s t a ltlh e s p a r kp l u g s .
1 5 - 2 3 N ' m ( 1. 5 - 2 . 3k g - m ,1 1- 1 7 l b - f t )
E N G I N E O N . V E F I I c LMEA I N T E N A N C E 10A-11
O N - V E H I C L IM A I N T E N A N C E
T I M I N GB E L T
PRE P A R A T I O N
SST
0 K 2 0 11 1 10 0 1 For 0 K 5 9 01 1 10 0 1 For
r e m o v a la n d p r e v e n t i o no f
Lock tool, i n s t a l l a t i oo
nf R i n gg e a r b r a k e e n g i n er o t a t i o n
crankshaft t i m i n gb e l t p u l l e y sel
0 K 1 3 01 6 00 1 0 F or 0 K 1 3 01 1 10 0 4
i n stal l ati on
of r e m o v a la n d
C e n t e r i n gt o o l , clutchdisc H o l d e r ,c o u p l i n g i n s t a l l a t i o no f
clutch disc fl a n g e t i m i n gb e l t p u l l e y
Removal/ Inspection/ Installation

1. Disconnect battery
thenegative cable.
2. Liftup thevehicle.
3. Removein theordershownin thefigure,referring t o t h e R e m o v a lN o t e .
orderof removal,
4. lnstallin thereverse referring
to t h e l n s t a l l a t i o nN o t e .
1 9 - 2 5N m
( 1 . 9 - 2 . 6k g - r n .t 4 - 1 9 l b - t l )
\5
ll
h
Nt( ' ' ' , \ - r t * .
'\
@ ( 1 . 5 - 2 . k3g - m .
1- 1 7r b - n )
7 . 8 - 1 1N ' m
( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 l b - i n ) F
7.8-'l1N'm
( 8 0 - 1 1 0k g - c m ,
69-95 lb-in
i, rR-\
w./
a
\
a:' ./ ,u;;oT;Tflr'rbin)
i:
+
! ,
K\,
12-17N'm
..*NJ
( 1 . 2 s - 1 . 7 5k g - m .1 0 9 - 1 5 2t b - i n )
\
1 0A - 1 2 E N G I N E o N - v E H t c LM
EA T N T E N A N c E
1. P/S ancUorPJCdrivebelt B.Timingbeltcover,lower

2. A l t e r n a t oCr r i v eb e l i 9 . H i g h - t e n s i ol en a d
3. W a t e rp u r - p p u l l e y 1 0 .S p a r kp l u g
4. Plate 1 ' l. T i m i n gb e l l
'12.
5. C r a n k s h a tpt u l l e y Tensioner
'13.
6. B o s sp u l l e y T e n s i o n esr p r i n g
7. f-imingbelt cover,upper
R e m o v a ln o t e
Timing belt
1 .T u r nt h e c r a n k s h a fat n d a l i g nt h e m a r k s .
Note
. T h e p i n o n t h e p u l l e yb o s s m u s t f a c e u p w a r d .
Caution
. After setting the marks, do not turn the crankshaft
w h e n r e m o v i n gt h e p u l l e y l o c k b o l t a n d t h e p u l l e y
boss.
10021
2 . R e m o v et h e t i m i n gb e l t .
Note
l"1ARK . Mark the timing belt rotation for a proper reinstalla-
D I R E C T I OO
NF
ROTATION tion.
10022
Inspection
Inspectthe followingparts:
1 . l r m i n gb e l t .
2 . l r m i n gb e l t t e n s i o n ear n d s p r i n g .
3. l rmingbelt pulley.
PEELING 4. Camshaftpulley. '
10023
l n s t a l l a t i onno t e
T e n s i o n e tre, n s i o n esr p r i n g
1. Install thetensioner andtheiensioner spring.
2 . T e m p o r a r isl ye c u r et h e t e n s i o n ewr i t h t h e s p r i n gf u l l y
extended.
E N G I N E O N - V E H I C LMEA I N T E N A N C E 10 A - 1 3
T i m i n gb e l t
t . t / e r i f yt h a t t h e i i r n i n gb e i i p u i l e ' u
r n a r ki s a l i g n e Cv , r i t h
the
t i m i n om a r k .
< 6^)'\
2 . Y e r i t yt h a tt h e c a r n s h a fpt u l l e ym a r k sa r e a l i g n e dr v i t ht h e
c y l i n d ehr e a dc o v e rm a r k .
MARKS
CYLINDER
H E A OC O V E R
CYLINDER
H:AD
r ^ '11A
3 . I n s t a ltlh e t i m i n qb e l ts o t h a t t h e r ei s n o l o o s e n e s sa t t h e
i e n s i o ns i d e .
Caution
. D o n o t t u r n t h e c r a n k s h a f ct o u n t e r c l o c k w i s e .
10027
4 . T u r n t h e c r a n k s h a f t r , v oi u r n s c l o c k v r i s ea, n d a l i g n t h e
t i m i n gb e l tp u l l e ym a r kr v i t ht h e t i m i n gm a r k .
5 . V e r i l yt h a tt h e c a m s h a f pt u l l e ym a r k sa r e a l i g n e dw i t h t h e
c y l i n d e hr e a dc o v e rm a r k .
l f t h e m a r k sa r e , . n oat l i g n e d ,r e m o v et h e t i n n i n gb e l t a n d
r e o e a tf r o mt h e t e n s i o n eirn s t a l l a t i o n .
1C 0 2 3
6 . L o o s e nt h e t e n s i o n e lro c k b o l t t o a p p l y a t e n s i o nt o t h e
t i m i n gb e l t .
Caution
. B e s u r e n o t t o a p p l y t e n s i o no t h e r t h a n t h a t o f t h e
t e n s i o n e sr p r i n g .
7 . T i g h t e nt h e i e n s i c n elro c kb o l t .
T i g h t e n i n gt o r q u e:
1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m , 1 4 - 1 9 l b - f t )
10 0 3 0
10A-14 ENGINE o N - v E H t c L EM A I N T E N A N c E
8. Tum the crankshaft 2 turnsclockwise, and verifythatthe

marksarecorrectly aligned.
9 . c h e c k t h e t i m i n gb e l i d e f t e c t i obny a p p l y i n g
moderate
pressure 98 N (10kg, 22 lb) ic the midwaybetweenthe
c.rankshaft pulleyand thecamshaft pulley.
lf the timingbelt deflection is noi coriect,temporarilv
98N securethe tensioner lockboltso thatthe spnnqis i;iii
( 1 0k 9 ,2 2 l b ) extended, ald repeatsteps4-g aboveor'r.pi".L tni
lensioner spring.
Deflection :
1 1 . 0 - 1 3 .m
0 m ( 0 . 4 3 - 0 . 5i 1
n )a t 9 8 N ( 1 0k g , 2 2t b )
10.By usingthe ssr, removethepulleylockbolt
and pulrey
boss.
Pulleylock bolt
Installthe crank:lr{ puileyboss,and usingthe ssT, tight-
en thepulleylockbolt.
Tghteningtorque:
1 5 7 - 1 6 7N . m( 1 6 - 1 7k g - m ,1 1 6 _ 1 2f3t . t b )
rm32
StepsAfter Instailation
1.Connect the negative
batterycable.
2.Starltheengineandcheckis follows:
. lgnition
timing.
ENGINE oN-vEHrcLE
MATNTENANCE 10A-15
C Y L I N D E RH E A D G A S K E T
R eP l a c em en t
Warning
. R e l e a s et h e f u e l p r e s s u r e .( R e f e rt o s e c t i o n 2 2 )
, K e e ps p a r k s a n d o p e n f l a m ea w a y f r o m t h e f u e t a r e a .
Caution
. P o s i t i o nt h e h o s e c l a m p i n t h e o r i g i n a ll o c a t i o no n t h e h o s e , a n d s q u e e z et h e c i a m p l i g h t l y
w i t h l a r g e p l i e r s t o e n s u r ea g o o d f i t .
1. Disconnectthe negativebatterycable.
2. Drainthe enginecoolant.
3. R e m o v ei n t h e o r d e rs h o w ni n t h e f i g u r e .R e f e rt o l h e R e m o v a iN o t e d u r i n gt h e r e m o v a sl t e p s .
4. l n s t a l il n t h e r e v e r s eo r d e ro f r e r n o v a iR. e f e rt o t h e I n s t a l l a t i o nN c t e d u r i n gt h e i n s t a l l a t i osnt e p s .
4 . 9 - 8 . 8 f . J ' m( 5 C - 9 0 k g - c r n ,a 3 - 7 8 l b - i ; r )
/
I
II
7 . 8 - t ' lN ' m
( 8 0 -I l 0 k g - c m6. 9 - 9 5 l b - i n )
-
7 6 - 8 1N ' m
(7.7-fr. 3 k g - m , l\q-@
5 6 - 6 0l b - o
tr\----o
'
\,^
rr. u
%, l\
@
1 5 - 2 3N ' m
7.8-11 N'm
( 1 . 5 - 2 . 3k g - m . 1 1- 1 7 l b . f t ) @
l9-25 N m
1 . 9 - 2 . 6k g - m . l 4 - l 9 l b - l l )
R-d
-'-52
3 N'm
( 3 . 8 - 5 . 3k g - m , 2 7 - 3 8 l b . l t )
\------
3 7 - 5 2N ' m
( 3 . 8 - 5 . 3k 9 - m 2
, 7 - 3 8l b - f t ) \: rr'
1oA-1 6 E N G I N E o N - v E H t c LM
EATNTENANCE
1. A i r h o s ea s s e m b l y 1 0 .l l m i n g b e l tc o v e r ,u p p e r
2. A c c e l e r a t ocra b l e li.lrmingbelt
3 Tlrrottlecable(A/i) '12.
F r o n te x h a u spt i p e
4. Hoses 1 3 .I n t a k em a n i f o l d
biacke.
5. Harnesses 1 4 .C y l i n d e hr e a db o t t
6. W a t e rb y p a s sp i p e n u t 1 5 .C y l i r r d eh; e a d
7. Drivebelt 1 6 .C y l i n d e hr e a dg a s k e t
8. W a t e rp u m p p u l l e y
9. C y l i n d e rh e a dc o v e r
R e m o v a/l I n s t a l l a t i o note
n
Hoses
1. Disconnect thehoseswhichareshownin thefigure.
--__-/ ),
# )>,
I
I
,,.,-----\
-4;
V/ARNING
. KEEP SPARKS AND OPEN FLAME AWAY FROM THE
FUELAREA.
CAUTION
COVERTHE HOSEWITH A RAG BECAUSEFUEL
WILL
S P R A YO U T W H E N D I S C O N N E C T T N G .
P L U G T H E D I S C O N N E C T E DH O S E S T O
AVOIDFUEL
LEAKAGE.
:003.1
1 . B r a k ev a c u u mh o s e 3 . V a c u u mh o s e( p u r g ec o n t r o l )
2 - . F u e lh o s e 4 . l - J e a t ehro s e
E N G I N E o N - v E F { l c LIE, I A I N T E N A N C E 10 A - 1 7
H ar n e s s e s
1 . D i s c o n n e ct hi e h a r n e s sc o n n e c l o rvsr h i c ha r es h o v , ,inn i h e fi c u r e
f(1,
V
(
1l1n': <
1 . C zs e n s o r 6. l g n i t i o nc o i l
2. Distributor 7. U/ateriherrnoswitch
? lnionlnr
r r r J v v t v l
E. H e a tg a u g eu n i t
4 . T h r o t t l es e n s o r 9. Ground
5 . I S Cv a l ' r e
C y l i n d e rh e a d b o l t
-t I 1 . L o o s e ni h e c y l i n d ehr e a db o l t si n t w oo r t h r e es t e p si n t h e
o r d e rs h o ' r u inn t h e fi g u r e .
I
I
I
2 . R e m o v et h e c y l i n d ehr e a db o l t s .
I
_J
' tJ'JJ O
10A-18 E N G I N E o N - v E H t c LM
EA T N T E N A N c E
l n s t a l l a t i o nn o t e
C y l i n d e rh e a d b o l t
1. Applythecleanengineoirtothebcrt, ,;eadsandtheseatfaces
2 . l n s t a l tl h e c y l i n c l ehre a db o l t s .
3 . l l g . h t e nt h e c y l i n d e hr e a db o r t si n t w o o r t h r e es t e p si n t h e
ordershownin the figure.
7 6 - 8 1 N - m ( 7 . 7 - 8 . 3k g - m , 5 6 - 6 0 l b _ f t )
r 0037
- D E F L E C T I OC
NH E C K I N G
POINT A c c e l e r a t o rc a b l e
1 . I n s t a ltlh e a c c e l e r a t ocra b l e .
2. Checkthe accelerator cabledeflection.
lf the deflectionis not correct,it wiil be adjustedby tuming
nut@.
D e f l e c t i o n: 1- 3 m m ( 0 . 0 4 - 0 . 1 2i n )
r 0038
StepsAtter Installation
1 . F i l lt h e r a d i a t o wr i t h t h e s p e c i f i e da m o u n ta n d t h e t y p eo f e n g i n ec o o l a n t .
2 . C o n n e c t h e n e g a t i v eb a t t e r yc a b l e .
3. Startthe engineand checkas follows:
( 1 ) E n g i n eo i l a n d e n g i n ec o o l a n lt e a k a g e .
( 2 ) l g n i t i o nt i m i n g ,i d l es p e e d .
(3) Operationof emissioncontrolsystem.
4 . R e c h e c kt h e e n g i n ec o o l a n tl e v e l s .
sE
E N G I N E o N - v E l J l c L EN 4 A T N T E N A N C E 10A-19
HLA
F d m o v a l/ I n s t a l l a t i o n
1 . D i s c o n n e ct th e n e g a t i v eb a t t e r yc a b l e .
z . R e m o v ei n t h e o r d e rs h o w ni n t h e f i g u r e R . e f e rl o t h e R e m o v a lN o t e d u r i n g. i t er e m o v a l .
3 . I n s t a liln t h e r e v e r s eo r d e ro f r e m o v a lR . e f e ri o t h e I n s t a l l a t i o nN o t e d u r i n gl h e i n s t a l l a t i o n .
5.0-8.8N.m (5 k g - c m ,4 4 - 7 8 l b . i n )
22-28 N'm
(2.2-2.9kg-m,16-20 lb-ft)
@
t
7 . 9 - 1 0 . 7N ' m
( 8 0 - 1 1 0k g - c m ,
6 9 - 9 5l b - i n )
@"
,E Vru
C y l i n d e hr e a dc o v e r 5 . F o c k e rs h a f i
1. R o c k e ra r m a n d r o c k e rs h a f ta s s e m b l y A
\J.
IJI
| ilri1
A
R o c k e ra r m 7. O-r-ing
.A. t .
Rockerarm spring
10A-20 E N G I N E o N - v E H t c LMEA T N T E N A N c E
,6\
v, R o c k e ra r m a n d r o c k e r s h a f t a s s e m b l y
I 1 . L o o s e nt h e r o c k e ra r n nb o l i si n t h e o r i e r w h i c ha r e s h o r v n
i n t h ef i g u r e .
2 . R e m o v et h e r o c k e ra r m sa n d t h e r o c k e rshaftassembly
3 . C o d e a l l r o c k e ra r m s a n d s p r i n g ss o t h a t i h e y
r e i n s l a l l e di n t h e s a m e p l a c e si r o m u , , h i c ht h e"yuw ,'e
, ' r' be"
removed
I n s t a l l a t i o nn o t e
HLA
1 . P o u rt h e e n g i n eo i l i n t ot h e o i l r e s e r v o iirn the
rockerarm.
2. Applythe engineoil to the neWHLA.
3 . l n s t a ltl h e H L A i n t h e r o c k e ra r m .
Caution
' Be carefurnot to damagethe Gring
duringthe instar-
lation.
O I LR E S E R V O I R
N o . 1C Y L t h j D i R
R o c k e ra r m a n d r o c k e r s h a t t a s s e m b l y
N o . aC y L | N D E R
1 . A s s e m b l et h e r o c k e ra r m a n d t h e r o c k e rs h a f ta s s e m b l y
as sholn in thefiqure.
INTAKE
ffierq.Fs{FnqTU,ro
UU U
, = , ,w .FXI'{AUST
10012
Caution
o ge sure both rocker arm
shaft oil holes face
N o . 1C Y L I N D E R N o . 4C Y L I N D E R dovlnlvard.
INTAKE ' T h e i n s t a l l a t i o nb o l t h o l e s
a r e d i f f e r e n tb e t w e e n
t h e e x h a u s ta n d t h e i n t a k e s i d e a s s h o w n i n t h e
fi g u r e .
EXHAUST
A>B
10C'43
T h e r e a r e t w o t y p e s of rockerarrnswith different
o f f s e t s . Q n e t y p e i s f o r N o . 1 a n d N o .2 c y l i n d e r s
e x h a u s t a n d i n t a k e .a n d t h e o t h e rf o r c y l i n d e r s
N o . 3 a n d N o .4
N o . 1, 2 C Y L T N D E R S 4 CYLINDERS
( l N &E X ) (il'JE
EX)
'l
a.t.i
MATNTENANcE
ENGINE oN-vEHrcLE 10 A-21
2 . l n s t a ltl h e r o c k e ra ( m a n d t h e r o c k e rs h a f ta s s e m b l y .
Caution
' T h e b o l t s m u s t b e t i g h t e n e dg r a d u a l l yi n t h e o r d e r
shown in thefigure.
2 2 - 2 8 N ' m ( 2 . 2 - 2 . 9k g - m , 1 6 - 2 1 l b - f t )
C y l i n d e rh e a d c o v e r
1 . I n s t a ltlh e c y l i n d e hr e a dc o v e r .
T i g h t e n i n gt o r q u e
B o l t A : 4 . 9 - B . BN ' m ( 5 0 - 9 0 k g - c m, 4 3 - 7 8 l b - i n )
B o l t B : 7 . 8 - 1 1N ' m ( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 l b - i n )
Caution
. l f t h e h e a d c o v e r g a s k e ti s r e u s e d ,a p p l y s e a l a n ti n
t h e g r o o v ea s s h o w n .
) t e p sA t t e rl n s t a l l a t i o n
Connect thenegative battery
cable.
2. Starltheengineandfullywarmup.
l. Verifythatthereis no tappetnoise.
It
's
,s
104-22
ENGINE oN-VEHIcLE
MAINTENANcE
F R O N TO I L S E A L
Replacement
1 . D i s c o n n e ct th e n e g a t i v eb a t t e r yc a b l e .
2 . R e m o v ei n t h e o r d b rs h o w ni n i n e i i g u r e .
F e f e rt o t l r eR e m o v a lN o t ed u r i n g
3 . I n s t a l il n t h e r e v e r s eo r d e ro f r e m o v a l . t h e rernoval.
R e f e rr o t h e I n s t a l l a t i o n
N o t e d u r i n gt h e i n s t a l l a t i o n .
/
.' A
I
I
I
.rG$-
IJ\
1 5 7 -1 6 7N . m
( 16 - 17 k g . m 1, 1 6 - 1 2 3 1 b - f r )
I
I
I
L_
1@49
1. llminqbelt
2. Platc 3 . l l m i n g b e t tp u l l e y
3 . P u l l e l, o, c kb o l t 4. Cil seal
P u l f e yl o c k b o l t
1 . H o l dt h e r i m i n gb e t tp u l t e yw i t ht h e S S T .
2 . c o n n e c tt h e s s T a n d r o o s e nt h e p u i l e y
r o c kb o r t .
3 . R e r n o v et h e p u l l e yl o c kb o l t .
E N G I N E o N - v E F n c LMEA T N T E N A N c E 10A-23
T i m i n gb e l t p u l l e y
1 . R e m o v et h e t i m i n gb e l tp u l l e v .
Note
. l f n e c e s s a r yr, e m o v et h e p u l l e y b y t a p p i n g
lighily
w i t h a p l a s t i ch a m m e r .
2. Removethe pulleyWoodruffkey.
10050
O i ls e a l
1.Cuttheoilseallipwitha razorknife.
2. Removetheoil sealwitha screwciriver
whichis wrapped
witha cloth.
r005r
I n s t a l l a t i o nn o t e
Oilseal
1 . A p p l ya s m a l la m o u n to f c l e a n e n g i n eo i l t o t h e l i p o f a
n e wo i l s e a l .
2 . P u s hi n t h e o i l s e a ls l i g h t l yb y a h a n d .
Caution
. T h e o i l s e a l m u s t b e t a p p e di n w a r d u n t i l
it is
f l u s h e dw i t h t h e e d g e o f t h e o i l p u m p b o d y .
3 . T a p i n i h e o i l s e a l e v e n l yv r i t ha s u i t a b l ep i p e a n d a h a m -
mer.
O i l s e a l o u t e r d i a m e t e r: 4 4 m m ( 1 . 7 3i n )
A L I G NT H E K E Y
^ h n ^ r r -
\: r|\JL,/ V tr T i m i n gb e l t p u l l e y
1 . l n s t a ltlh et i m i n gb e l tp u l l e y .
2 . l n s t a l lt h e p u l l e yw o o d r u f fk e y w i t h t h e t a p e r e ds i d e
towardthe oil pump body.
P u l l e yl o c k b o l t
1 . I n s t a ltlh ep u l l e yl o c kb o l t .
2. Tightenthe'pulleylockbolt usingthe two SSTs.
1 5 7- ' 1€ 5 N - m ( 16 . 0 - 1 7 . 0k g - m ,1 1 6 - 12 2 t b _ t t )
S t e p sA f t e r ! r ' r s t a l l a t i o n
l . C o n n e c it h e n e g a t i v eb a t t e r yc a b l e .
2 . S t a r tt h s e ; i g i n ea n d c h e c kt h e i g n i t i o nt i m i n g .
r005{
10 A-24 E N G I N E o N - V E H I C LMEA I N T E N A N C E
R E A RO I L S E A L
Replacement
1 . D i s c o n r - ; et ch te n e g a t i v eb a t t e r yc a b l e .
2 . R e m o v er n t i r eo r d e rs l r o w n , i tnl t ef i g u r c R. e i e ri c t i r cR e m o v a lN o t e d u r i n gt h e r e m o v a l .
3 , I n s t a liln t h e r e v e r s eo r d e ro f r e m o v a lB. e f e rt o t h e I n s t a l l a t i o nN o t e d u r i n g
theinstallation.
I
'\
i\
.\
ffi
d
{_
I Mf
,,1
\V-
i'+c
9 6 - 1 0 3N ' m
( 9 . 8 -1 0 . 5k g . m , 7 1- 7 6 t b - t r )
I 0055
1.Transaxle 4. Driveplate(Arf)
2. Clutchccver,clutchdisc 5 . O i ls e a l
3. Flywheel(fv1/T)
Flywheel (Mff)
1. Hold the flywheelwith the SST.
2. Removethe flyvrheellockbolts.
3 . R e m o v et h e f l w v h e e l .
@I[@
E N G I N E o N . V E H I C LM
EA I N T E N A N C E 104-25
Drive plate (A,rr)

rl . l l -l{Vnl Vl d t\ h
l r vo
rv 'Jr rv vi , y p |n/ ll q: ltvp rY ,r vl l il tl h "\ ln. cv vQ $ J .
2 . R e m o v et h e C r i v ep l a t ei c : k b c l t s .
3 . R e n r o v et h e b a c k i n gp l a i e ,c j r i v ep i a t e ,a n d a d a p t e r .
1a,n<1
Oil seal
1 . C u tt h e o i l s e a ll i pw i t ha r a z o rk n i f e .
2.Removethe oil seal with a screwdriver which is wrapped
witha cloth.
O I LS E A LL I P
. nn<l
l n s t a l l a t i o nn o t e
Oilseal
1 . A p p l ya s m a l l a m o u n to f c l e a n e n g i n eo i l t o t h e l i p o f a
n e w o i ls e a l .
2 . P u s hi n t h e o i l s e a ls l i g h t l yb y a h a n d .
Caution
. T h eo i l s e a lm u s tb e t a p p e di n u n t i li t i s f l u s hw i t h
t h ee d q eo f t h er e a rc o v e r .
3 . T a p i n i h e o i l s e a l e v e n l yr v i t ha s u i t a b l ep i p e a n d a h a m -
t,1^<O mer.
O i l s e a lo u t e r d i a m e t e r: 1 0 0 m m ( 3 . 9 4i n )
Flywheel (MiT)
q
1 . R e m o v et h e s e a l a n tf r o m t h e f l y w h e e lb o l t h o l e s i n t h e
crankshaftand fromthe flyvrheelbolts.
oll
ilffi Caution
. l f a l l t h e p r e v i o u ss e a l a n tc a n n o tb e r e m o v e df r o m
a b o l t ,t h e b o l t h a v et o b e r e p l a c e d .
. D o n o t a p p l ys e a l a n ti f a n e w b o l t i s u s e d .
| 0060
2 . S e t t h ef i p v h e e o l n i ot h e c r a n k s h a f t .
3 . A p p l ya s e a l a n t o t h e f l y v r h e ebl o l t sa n d i n s t a l tl h e m .
4 . H o l dt h e f t y r v h e ewl i t ht h e S S T .
5 . 1 l g h t e nt h e b o l t si n t h e - o r d esrh o v i ni n t h e f i g u r e .
Tightening t o r q u e:
9 6 - 10 3 t , l ' m( 9 . 8 - 10 . 5 k g - m ,7 1 - 7 6 l b - f t )
10A-26 E N G I N E o N - V E H I C LM
EAINTENANCE
Drive plate (A/f)

1 . R e m o v et h e s e a l a n tf r o mt h e d r i v ep l a t eb o l t h o r e si n t h e
c r a n k s h a fat n d l r o n rt h e d r i v ep l a t eb o l t s .
Caution
. l f a l l p r e v i o u ss e a l a n tc a n n o t b e r e m o v e d f r o m
a
b o l t ,t h e b o l t h a v et o b e r e p l a c e d .
. D o n o t a p p l y n e w s e a l a n ti f a n e w b o l t i s u s e d .
l@62
2. lnstallthe adapter,driveplate,and backingplateonto the

crankshaft.
3. Applya sealantto the driveplateboltsand installthem.
4. Holdthe driveplatewith the SST.
5. llghten the boltsin the ordershownin the figure.
9 6 - 10 3 N ' m ( 9 . 8 - 10 . 5 k g - m, 7 1 - 2 6 t b - f t )
10063
S t e p sA f t e rI n s t a l l a t i o n
1. Connect thenegative cable.
battery
2. Starltheengineandperformtheengineadjustments as necessary.
ENGINE REMOVAL 10 A-27
RE M O V A L
V/arntng
. R e l e a s et h e f u e l P r e s s u r e '
PROCEDU RE
1 . D i s c o n n e ctth e n e g a t i v eb a t t e r yc a b l e .
Z . D r a i nt h e e n g i n ec o o l a n ta n d t r a n s a x i eoil.
3. R e m o v ei n t h e o r d e rs h o w ni n t h e f i g u r eR
. e f e rt o t h e R e m o v a lN o t e d u r i n gt h e r e m c v a l .
S t e P1
?
rru
ll -/7 Ra-\
t)K h)
q/\
| \-I I / t\
|-'Y-\,/ t\
q
/;\ @ -
---\u GFJ.,'
dF
10054
1. A i rc l e a n ear ssembly 7 . C o o l i n gf a n c o n n e c t o r
2. Batteryand batterycover 3. Oil coolerhose (Mf-)
3. Batterycarrier 9 . R a d i a t oar n d c o o l i n gf a n a s s e m b l y
4. Acceleratorcable 10.P/S and/orfuC drivebelt
5. R a d i a t ohr ose i 1 . PiS oil oump and bracket
6. Coolantreservoirhose 12.NC compressor
104-28 ENGINE REMoVAL
P / So i l p u m p
=ar=l Cautiorr
. D o n o t d a m a g et h e h o s e s .
1 . R e m o v et h e P / S o i l p u m pw i t ht h e h o s e ss t i l lconnected.
2. Positionthe pump away from the engine and affix it with a
wire.
A/C compressor
C au t i o n
. D o n o t d a m a g et h e h o s e s .
1. Removeti:e A/c compressorwith the hoses stillconnectec.

2. Place the compressorav/ay from the engine and affix it
w i t ha w i r e .
10066
Step 2
Disconnect
the harnessconnectors
whichare shovrnin the figure.
ALTERNATOR O I L P R E S S U R E
SV/ITCH
THROTTLE
SENSOR
\\\
STARTER ISC VALVE
INJECTOR
NEUTRALSWITCH(trT)
I G N I T I O NC O I L
n ))
\
HEAT GAUGE
___ _j
L ___ _ _ _ _cl1o_Ul,l_D_
ENGINE REMoVAL 10A-29
S t e P3
1 . D i s c o n n e ct ht eh o s e sw h i c l ra r e s h o v , r irnr t h e f i o u r c .
\.-
I
l^
@<i . --\--'
)
@--5,
{,8,l
K-=
\
-4/
100'68
1 . B r a k ev a c u u m
hose 3 . V a c u u mh o s e( P u r g ec o n t r o l )
2. Fuelhose 4 . H e a t e rh o s e
F u e lh o s e
Warning
. K e e ps p a r k sa n d o p e n f l a m ea w a y f r o m t h e
fuel
area.
Caution
. C o v e rt h e h o s e u r i t ha r a g b e c a u s ef u e l w i l l s p r a y
o u t v l h e nd i s c o n n e c t i n g .
. P l u g t h e d i s c o n n e c t e dh o s e s t o a v o i d f u e l l e a k a g e .
1 . D i s c o n n e ct th e f u e lh o s e s .
H e a t e rh o s e
Caution
. T h e h e a t e rh o s ej o i n t h a s O - r i n ga n d s p a c e r .
. D o n o t l o s e t h e n rr , v h e nr e n t o v i n g .
1 . P u s ht h eh e a t e h
r c s er e t a i n ear n d r e m c v et h e h e a t e rh o s e .
10A-30 ENGINE REMoVAL
Step4
'A',)4
' -\-/-
GASKET,
REPLACE
\o.ren prN ,R E pl A ce
1 .Speedometer cable
2 . !]utch releasecyfinder 6 . F r o n te x h a u s p
t ipe
2
ShiftcontrolroOqtrlff; 7. Stabilizer
4 . E::lension ' B.lle rod end
bar fViO
5 . Shiftconrrol.a'bte(Mf) 9 . E n g i n em o u n tm e m b e r
1 0 .D r i v e s h a f t
C l u t c h r e l e a s ec y l i n d e r ( M f f )
1' Removethe rereasecylinder
pipe
2. positionthe releasecVfinJJ bracketfromthe transaxle.
away from the transaxle
easierremovarwith the hose for
sti, conne,i,ril
Caution
. Do not damage
t h e p i p eo r t h e h o s e .
Tie-rod end
1 . R e m o v e t h e c o t t e rp i n a n c il o o s e n t h e n u t s o t h a t i t
f l u s h e sw i t ht h e b a l lj o i n te d g e .
2 . S e p a r a t et h e k n u c k l ea r m a n d tire ball-jointvriihthe SST.
Caution
. D o n o t r e u s et h e c o f t e r p i n .
1cc73
N o . 2E N G i N EM O U N T E n g i n em o u n t m e m b e r
1 .S u s p e n dt h e e n g i n ew i t h a c h a i nb l o c k .
2 . R e m o v et h e N o . 1 a n d N o . 2 e n g i n em o u n ln u t s .
3. Remclvethe engine mount member bolts and nuis, and
the enginemountmember.
Caution
. B e c a r e f u ls o t h a t t h e e n g i n e d o e s n o t f a l l w h e n
r e m o v i n gt h e m e m b e r .
Driveshaft
1. Remove theboltsandnutsat the left and rightlower arm
balljoints.
r0075
2. Pull the lower arm downwardto separatethem from the

knuckles.
Caution
. D o n o t d a m a g et h e b a l l j o i n t d u s t b o o t s .
r 0076
3. Separatethe driveshaftsfi'omthe transaxleby pryingwith

a b a r i n s e r l e db e t w e e nt h e s h a f ta n d t h e c a s e .
)))
Caution
/ ' D o n o t d a m a g et h e o i l s e a l .
L-
10077
\
j
Step 5
IVJ I6
1 . D y n a m idca m p e r 3 . N o . 4 e n g i n em o u n tr u b b e ra n d b r a c k e t
2 . N o .3 e n g i n em o u n tr u b b e r 4 . E n g i n ea n d t r a n s a x l e
!
i-
assemblv i
E
F
t:
R e m o v a ln o t e E.
!,
E n g i n ea n d t r a n s a x l ea s s e m b t y ,.
t
l'
Caution i
' D o n o t d a m a g ea n y c o m p o n e n t s r-
in the engine !
c o m p ar t m e n t . i-
t . L i f to u t t h e e n g i n ea n d t h e t r a n s a x l e
a s s e m b l ya s a u n i t .
S t e P6
SeParate t h e e n g i n ea n d t r a n s a x lien t h eo r d e rs h o w ni n t n e f i E u r e .
:w o
MT
ICCBt
'1.
lntakemanifoldbracket 5. l n i e g r a t e sd t i f f e n e r
2. Starterand bracket 6. Torqueconverlernuts (A/T)
3. Throttlecable (Afl) 7. Transaxlemountingbolts
4 . N o . 2 e n g i n em o u n tr u b b e ra n d b r a c k e t B. Transaxle
104-34
E N G I N E ENGINESTANDMOUNTING
E N G I N ES T A N DM O U N T I N G
PREPARATION
SST
0K 13099000 7
For 0 K 9 9 3 1 0 1A A O
disassembly rf->-. For
and
vl/
w
E ngines t and disassemblyand
assemblyof H a n g e r ,s e t ,
e n g i ne assembly of
e n g i n es t a n d
engine
0 K 9 9 31 0 1A O 1
For 0K 993101A 02
disassembly For
Plate. and
assemblyof d i s a s s e m b l ya n d
(Partof Arms
e n g ine a s s e m b l yo f
0K 993101A A O ) (Partof
engine
0K993101AAO) =
0 K 9 9 31 0 1A 0 1 3
For 0K 993101A O4
disassemblyand For
Hooks disassemblyand
assemblyof N uts
(Par1of assemblyof
engine (Partof
0K 993101A A o ) engi ne
0K993101AAO)
0K 993101A O 5
%
For 0K 993101406
disassemblyand For
Bolts disassemblyand
assembly of B ol ts
(Partof
0K993101AA0)
ffi engine (Partof
0K 9s3101A A 0)
assemblyof
engine
srANDhrouNTrNG
ENGINE ENGTNE 104-35
PBOCEDURE
SteP 1 -r-- -L^...- :- ri-^ r;^
i.'"{t.ove in t
GASKET.REPLACE
s\
w G A S K E IR E P L A C E
/@
O.RING.REPLACE
10082
1. Exhaust
manifoldinsulator A
a. A/C compressorbracketand idler
2. Exhaust
manifold Waterinletpipe
3. Waterbypasspipe
Step 2
irW Caution
. W h e ninstallingthe SST(engineh a n g e r ) ,u s e t h e
J@/dffie1 h o l e sshownin the figure.
rnail
10A-36
ENGINE ENGINE
S T A N DM o U N T I N G
' asshown
intherisurs,
niiLr*,:"t,?:8iT?il1,5:A"J:s
2 . A s s e m bef t h e S S T ( b o l t s a n d
p l a t e )i n t h e s p e c i f i e d
position.
-r
l-l
vv
a\
O I,
AO
3.Assemble theSST(nuts,hooks,and bolts).

4. lnstalltheSSTto the respective
arms.
TANALLT Note
. Adjust the ( b o l t s )t o e x p o s e l e s s t h a n
( 0 . 7 9i n ) o f t:hSrTe a d . 20 mm
. M a k et h e S S T ( p l a t e
a n d a r m s ) p a r a l l e lby adjusting
ENGINE the SST (bolts and nuts).
5 . T g h t e nt h e S S T ( b o l t s a n d n u t s )
t o a f f i xf h e SST firmly.
i'JUT \'"..'gi-.1cqtiUT LESS THAN

2Omm
( 0 . 7 9i n )
r\A/5 /
6 . M o u n tt h e e n g i n eo n t h e S S T ( e n g i n es t a n d ) .
ENGINE DISASSEMBLY 10A-37
DISASSEMBLY
IN
? R E P A R A TO
SST
cct
c K 5 e101 1
e
ll
Far
p r e v e n t i o no f rerno'tal/
?ing c earb ra k e e n g i n er o t a t i o n i n s i a i l a t i conf
,--g
l€-'"--/ VAIVES
ser
3 2 00 0 6
oK9e1 For 0 K 9 9 3 1 2 00 0 4
F removalof valve r e m o v a l/
?,emcver,val'te e@ seals P i v o t ,v a l v e i n s i a l l a t i o no f
\/'
seal s p r i n gl i f t e r valves
l,o^ro1110AAO r For oKzol110Ao2 F g For

,F, /--=\
removal/ rarno,lal
installalionol block
Support i*l i n s t a l l a t i oonf
i:,:l:::"settinsB$
I t c c ls e t t:uQ piston pins body I k p i s t o np i n s
(Parlof
i"" 0 K 2 0 1 1 1 0A A 0 ) V
I
j cxzo1
r 1 0A o s ! For 0K20'1
t 1 0A 0 7
ie\
i Sci'e',v
\ \
removal/
i n s t a l l a t i oo
nf r inslaller
P u l l e&
r e m o v a l/
i n s t a l l a t r oonf
p i s t o np i n s (P artof
ir:i
I o x z o l1 1 0A A o ) 0 K 2 0 11 1 0A A 0 )
p i s t o np i n s
\
I
i
o ' K 2 0 11 1 0 A 0 B For 0 K 2 0 11 1 0A 1 1 For

/_\ removal/ A r e m o v a l/
Guide \\ installationol C e n i e r i ntgo o l I R i n s t a l l a t i o no f
(Part of V piston pins (Parr
of t/1 p i s t o np i n s
c K 2 o 1 1 1 0A A 0 ) 0 K 2 0 11 1 0A A 0 )
0 K 2 0 11 1 04 1 2 For 0 K 2 0 11 1 00 0 2 Fnr
removal/ r e m o v a l/
Holder 3 i n s t a l l a t i oo
nf S u p p o r tb l o c k i n s t a l l a t i oonf
( P ar tof U p i s t o np i n s head p i s t o np i n s
0 K 2 0 11 1 0A A 0 )
1 . C o d ea l l i d e n t i c apl a r t s( s u c ha s p i s t o np, i s t o nr i n g s ,c c n n e c t i n gr o d s ,a n d v a l v es p r i n g s s) o t h a tt h e y
c a n b e r e i n s t a l l eidn t h e c y l i n d efrr o mw h e r et h e yl v e r er e m o v e d .
2. Cleanihe partswith a steamcleaner.Blowoff any rernaining lvatervritha compressedair.
Note
. D u r i n gd i s a s s e m b l yo f a n y p a r to r s y s t e m ,b e s u r e t o s t u d y i t s o r d e r o f a s s e m b l y .A l s o , n o t e
a n y d e f o r m a t i o n ,v / e a r ,o r d a m a g e .
10A-38 ENGINE DISASSEMBLY
A U X I L I A R YP A R T S
1 . D r a i nt h e e n g i n eo i l .
2. Disassemble in the ordershownin the figure.
"-$ \ GASKET,REPLACE
l-'
d
{ \
@
.*-__.--=-^
v./
^-r{-
I Distributor
andhigh-iension
lead
lntakemanifold 6 .O i l f i l t e r
? alsembly 7. oil pressureswitch
3. Alternator
anddrivebelt
4. Alternator B .. a p a r kp l u g
bracket t e v eg t a u g ea n d p i p e
5. No.3 enginemountbracket .9 9it
1 0 .E n g i n eh a n g e r
ENG INE DISASSEN4BLY 10A-39
T I"M BELT
OIi N
r uGr r e m b l ei n t h e o r d e rs h o w ni n t h e f i g u r er, e f e r r i n tgo t h e D i s a s s e m b l yN o t e .
,.
,$fl
-si* V ,/
-y'
r0090
1. Waterpumppulley 5. l l m i n g b e l tc o v e r u
, pper
2. Plate 6. T i m i n gb e l tc o v e r l, o w e r
3. pulley
Crankshaft 7. T l m i n gb e l t
4. pulleyboss
Crankshaft B. T e n s i o n e tre, n s i o n esr p r i n g
104-40 ENGINE DISASSEMBLY
D i s a s s e m b f yN o t e
ffi P u l l e yl o c k b o l t
1. Hold the flywheel(M/T) or drive plate (A,rT)wirh rhe SST
or equivalent.
2 . R e m o v et h e p u l l e yl o c kb o l t .
10091
Timing belt
lv'IARKS
1 . T u m t h e c r a n k s h a fat n d a l i g nt h e m a r k s .
IIARKS
M/YZ
DIRE 2. Markthetimingbeltrotation
fora properreinstallation.
10093
Caution
S*-aB . Neverforcefullytwist the timing belt. D o n o t t u m i t

i n s i d eo u t o r b e n d i t .
. B e c a r e f u ln o t t o a l l o w o i l o r g r e a s ec o n t a m i n a t i o
on the belt.
n
mu&
[=jf (1.0in)*,,uX*
25mm
10 c 9 4
C Y L I N D E RH E A D
1 . D i s a s s e m b lien t h e o r d e rs h o w ni n t h e f i g u r er,e f e r r i ntgo i h e D i s a s s e m b l yN o t e .
l
u
G A S K E TR. E P L A C E Y
I
\
, .=____JgFr{lI
./9---e9
,@e-#D
g-.-@
L-r2]nsn
-)\
EPLACE nsr@=-.r
a9--,O
@4
w
n
EflI
'u/ c
./
G A S K E T .R E P L A C E
GASKET,
REPLACE
10095
1 . C y l i n d e rh e a dc o v e ra n d g a s k e t 1 3 .C a m s h a f t
2. Thermostatcoverand gasket 1 4 .C y l i n d ehr e a db o l t s
3. Thermostat 1 5 .C y l i n d ehr e a d
4 . H e a tg a u g eu n i t 1 6 .C y l i n d ehr e a dg a s k e t
5. Bracket 1 7 .V a l v ec o t t e r
6 . R o c k e ra r m a n d s h a f ta s s e m b l v 1 8 .V a l v es p r i n gs e a t ,u p p e r
7 . R o c k e ra r m 1 9 .V a l v es p r i n g
B . R o c k e ra r m s p r i n g 2 0 . V a l v es p r i n gs e a t ,l o w e r
9 , R o c k e rs h a f t 2 1 .V a l v e
1 0 .H L A 2 2 .V a l v cs e a l
1 1. C a m s h a fpt u l l e y 2 3 . V a l v eg u i d e
1 2 .T h r u s tp l a t e : ' 4 .O i ls e a l
10 A-42 ENGINE DISASSEMBLY
Disassembly Note
Bockerarm and rockershaftassembty
1.Loosenthe rockerarm bortsin the ord.,,
showrrin the
figure.
2. Removetherockerarmandtherockershaft
assembry.
3. code all rockerarms anclspringsso tnai
iney can be
r e i n s t a l l ei dn t h e s a m ep r a c e lsr o m w h i c h
r h e yw e r e
removed.
@@@ o\
\, @
r 0097
Hydrauliclashadjuster(HLA)
'
RemovetheHt-Aby nanO.
lf it is difficult,
removetheHt-,A
by usingthepriers.
Caution
' Do not removethe HLAunressnecessary
because
oil leakagewit occur,if the o-ring-iiJJrnug.o.
I 0096
Camshaftpulley
1.Holdlhecamshaft
by usinga suitabrewrenchon thecast
hexagon.
2. Removethecamshaflpulleylock
bolt.
3. Removethecamshaft
iulley.
I v\Jyy
C y l i n d ehr e a db o l t
1.Loosenthecylinder headboltsin the order shov,,nin the
figure.
2. Remove thecylinder headbolts.
V a l v ek e e p e r
EE@ 1 .S e t t h e S S T a g a i n s it h e u p p e r v a l v e s p r i n g s e a i a s
s h o w ni n t h e f i g u r e .
2 . R e m o v et h e v a l v ek e e p e r s
r \(.' ll
l-xl' ) t \
: ' '4V-l
\ i /-,
i010t
V a l v es e a l
Removethe valvesealwith the SST.
10103
10444 ENGINE DISAsSEI4BLY
CYLTNDER B L O C K ( E X T E R N A LP A R T S )
1 . D i s a s s e m b lien t h e o r d e rs h o w ni n t h e f i g u r e r, e f e r n n gt o t h e D i s a s s e m b l yN o t e .
(i
fra
\:/
,r *Rfu G A S K E T ,R E P L A C E
RE ,9c, qa.
tr\
v. n
GA SK ET
R E PL A C (- L
G A SK ET ,
REPLACE
GA S K E T,
REPLACE
10104
'1
. W a t e rp u n t p B .O i ls l r a i n e r
2. B o s sp u l l e ya n d l o c kb o l t 9 . f , l a i nB e a r i n gS u p p o r P
l l a t e( M B S p )
3. C l u t c hc o v e r ,c l u t c hd l s c ( M / T ) 1 0 .O i lp u m p
1. F l p v h e e l( M l f ) 1 1. F r o n to i l s e a l
5. B a c k i n gp l a t e ,d r i v ep l a t e ,a n d a d a p t e r( A / T ) 1 2 .R e a rc o v e r
6. E n dp i a t e 1 3 .R e a ro i ls e a l
7. O i lp a na n d g a s k e t
D i s a s s e m b l yN o t e
T i m i n gb e l t p u l l e y
1. Holdtire flyvrheel(lrl/f o;'thedriveplate(,eT vyiththe SST.
2 . L o o s e nt h e p u l l e yl o c kb o l t .
3 . R e n r o v et h e p u l i e yl o c kb o l t .
4 . R e m o v et h e t i m i n gb e l tp u l l e y .
Note
. l f n e c e s s a r y ,r e m o v e t h e p u l l e y b y t a p p i n g l i g h i l y
w i t h a p l a s t i ch a m m e r .
5. Removethe pulleyWoodruffkey.
1c1c5
Clutch ccver (f\4ff)

1. Hold the flryrheelrviththe SST.
2. Loosenthe clutchcover lock bolts in the order shown in
thefigure.
3. Removethe clutchcover.
Flywheel (Mfr)
1. Holdthe flywheelwith the SST.
2. Removethe flyvrheellock bolts.
3. Removethe flyvrheel.
I@F 4. Removethe SST.
B a c k i n g p l a t e , d r i v e p l a t e ,a n d a d a p t e r ( 4 4 - 1
ffiIIIUT 1 . H o l dt h e d r i v ep l a t ew i t h t h e S S T .
/tr : !//
s
s
2. Removethe driveplatelock bolts.
3. Removethe backingplate,the driveplate,and the adapter.
4. Removethe SST.
{(("
\\\
\\\s
N
10A-46 ENGINE DISASSEMBLY
Oil pan
1. Rernovctlreoil ;,.annrountinct bolts.
2 . l n s e r ta s c r e w d r i v eorr a s u i i a u t et o o lb e t w e e n
i l r er v B s p
and the oil pan,and pry them.
Caution
. Do not inserl prying tool between the MBSp
a n d c y l i n d e rb ll h ".
ock.
. D o n o t d a m a g eo r s c r a t c h t h e c o n t a c t
surfaces.
M 1 n B e a r i n gS u p p o r t p t a t e ( M B S p )
1' Renrovethe MBS.Prncuntingboftsfrom the
mainbeanngcap.
2. lnserta screwdriveror r-ritabletool
u.t*r.n the MBSp
and the cyfinderblock,and " pry them.
Cautiorr
' Do not damage or scratch the
contact surfaces
w h e n r e m o v et h e o l d s e a l a n t .
Frontoll seal
P R O T E C TP U M P 1. Removethe oirsealvritha screwdriver
whichis wrapped
BODYWITHA witha cloth.
CLOTH
PROTECTREAR
R e a ro i l s e a l
COVERWITHA CLOTH 1. Removethe oil seal with a screwdriver
which is wrapped
witha cloth.
r 0 tl 3
c Y L t N D E RB L o C K ( I N T E R N A LP A R T S )
i . D i s a s s e m b lien t h e o r d e rs h o w ni n t h e f i g u r e r, e f e r r i n g
t o t h e D i s a s s e m b ! yN o t e .
ffi >:< |
!{f@
><r
w @
--'o
llllil-o
bh
lt- i.)
i naa- ri
YV
v
o
@
10114
1. Connecting rodcaP 7. Mainbearingcap

2. Connecting rod B. Crankshaft
3. Connecting rod'learing 9 . M a i nb e a r i n g
4. Pistonring 1 0 .T h r u s tb e a r i n g
5. Pislonpin 1i . Cylinderblock
6. Piston
104-48
ENGINE DISASSEMBLY
D i s a s s e m b t yN o t e
C o n n e c t i n gr o d c a p
'l-Beforc
r e r n o r r i ntgh e c c n ^ e c t i n gr o c lc a p s , r n e a s u r e
c o n n e c t i n roo d s i c j ec i e a r a n c e . the
Connectingrod
1 . B e f o r er e m o v i n gt h e c o n n e c t i n rgo d s ,f l - r € a s u r e
connecting he
rodoilclearance.
ffi,
101l6
il'w
2' Removetheprastigage
fromthecrankpin
joumars.
Caution
' D o n o t s c r a t c h t h e c r a n k s h a f tj o u r n a f
cylinderwall. or the
3. Usethehandre
of a hammerto removethepistonandthe
connecting
rod assembry
' through
o
the top Jt rn*
btock. "yriniri
Pistonring
Caution
. n o t a p p l y e x c e s s i v et e n s i o n w h l c h
.Do may cause
the ringsto snap out.
1 ' R e m o v et h e p i s t o n r i n g sw i t h p i s t o n
a ring expander.
( C o m m e r c i a lat yv a i l a b l e i
Pistonpin
Caution
. Mark the.connectingrod direction for
proper
r e a s s e m bvf .
1 . B e f o r ed i s a s s e m b l i nt h
g e p i s t o na n d t h e c o n n e c t i n g
rod,
c h e c kt h e o : l i a t i o nt o r q u ea s s h o w n .
l f t h e l a r g ee J d o e s n o t d r o p b y i t s o w n w e i g h t ,
replace
t h ep i s t o nc ' : r : p i s l o np i n .
2 . A s s e m b l et h e S S T a s s h o w n .
ryr-
",' SE{} [----)
6l@ll@
101?o
3.lnsertthe ssr No. 2 intothe pisionpin as shownand

NO.2 fullyscrewin theSSTNo.1.
NO.1
I
1 0 12 1
4 . l v l o u n t h e p i s t o na n d t h e c c n n e c t i n gr o d i n t h e s S T a s
shorvn..
5. Pressout the pistionpin.
while removingthe pistonpin, check the pressure. lf it is
l o w e rt h a n 4 - 9 0 5N ( 5 0 0 k g , 1 , 1 0 0l b ) , r e p l a c et h e p i s t o n
pinor theconnectinq rod.
't0122
M a i nb e a r i n gc a p
1 .B e f o r er e m o v i n gt h e m a i n b e a r i n gc a p s , m e a s u r et h e
crankshafl endplay.
J\,
-Ti-
\e)-
1 0 12 3
2 . L o o s e nt h e m a i n b e a r i n gc a p b o l t si n t h e o r d e rs h o w ni n
thefigure.
3 . R e m o v et h e m a i nb e a r i n gc a p s .
1oA-so ENGINE DISASSEMBLY
Crankshaft
1 .B e f o r er e m o v i n gt h e c r a n k s h at ,f m e a s u r et h e m a i n
bearingoil cleai'ances.
ENGIN E TNSPECTIoN/REPAIR 10A-51
I N S P E C T I O/NR E P A I R
PBEPARATION
5Jl
1. Cleanall the partswiih beingsuie to removeall gasketfi-agments,

dirt,oil or grease,carbcn,moisiure
and othertoreignmaterials.
residue,
2. Theinspections and repairsmustbe performed in theorderspecified.
Caution
, Do not damagethe jcints or triction surtacesof alunrinumalloy components(such as the
cylinderhead or pistons).
0 K 1 3 01 2 00 0 6 For
removal/
RemoveranC ffi lnstallation
valvg
irrslaller, of val,reguide
guide
l . l n s p e c t t h e c y l i n d e rh e a d f o r d a m a g e , c r a c k s , a n d
leakageof water and oil. Replace the cylinderhead if
necessary.
2. Measurethe cylinderhead distortionin the six directions
shownin the figure.
D i s t o r t i o n: 0 . 1 5 m m ( 0 . 0 0 6i n ) m a x .
Caution
. Before grinding the cylinder head, check the
f o l l o v r i n ga n d r e p a i r o r r e p l a c e t h e c y l i n d e r h e a d
10r26 as necessary;
( 1 ) S i n k i n go f v a l v es e a t s
( 2 ) D a m a g eo f m a n i f o l dc o n t a c t s u r f a c e
( 3 ) C a m s h a f to i l c l e a r a n c e sa n d e n d p l a y
3. lf the cylinderhead distortionexceedsspecification, grind

the cl,iinderhead sur{ace.
l f t h e c y l i n d e rh e a d h e i g h ti s n o t r v i t h i nt h e s p e c i f i c a t i o n ,
r e p l a ^ ei t .
Heiglrt i 1O7.4-107.6mm (4.228-4.236in)

G r i - ' - ' n g : 0 . 2 Cn n m( 0 . 0 0 8i n ) m a x .
tot27
10A-52 ENGINE lNSpEclqN/REpAlR
4. Measure the manifold

coniactsurfacedistortion
in the six
Cirections
shownin thefigure.
D i s t o r t i o n: 0 . 1 5m m ( 0 . 0 0 6i r r ,fpf i d X .
5. lf the distortionexceedsspecification, grindthe surfaceor

r e p l a c et h e c y l i n d e h
r ead.
V A L V EM E C H A N I S M
V a l v ea n d V a l v e G u i d e
l . I n s p e c te a c h v a l v e s f o r r h e f o i l o w i n gi t e m s . R e p l a c eo r
resudacethe valveif necessary.
( 1 ) D a m a g e do r b e n ts t e m
( 2 ) F o u g ho r d a m a g e df a c e
( 3 ) D a m a g e do r u n e v e n l yw o m s t e m t i p
n
Z ' M e a s u r et h e v a l v eh e a d m a i ' g i nt h r c k n b s o
S T E MT I P s f e a c hv a i v e .
Replacethe valveif necessairl.
M a r g i nt h i c k n e s s( M i n i m u m )
mm (in)
UJ B6
VALVEFACE
IIARGIN IN 0 . s( 0 . 0 2 0 ) 0 . 81 0 . 0 3 1 )
THICKNESS 1 . 0( 0 . 0 3 e ) 1 . 1( 0 . 0 4 3 )
'I
0 12 9
3. Measrrre
l h e l e n g t ho f e a c hv a l v e s .
Length mm (in)
85,B6
Standard 103.77(4.085)
IN
Minimum 1 0 3 . 2 7( 4 . 0 6 6 )
Slandard 102.67(4.042\
EX
Minimum 1 0 2 . 1 7( 4 . 0 2 2 )
4 . M e a s u r et h e s t e md i a m e t e o
r f e a c hv a l v e s .
Diameter
l N : 6 . 9 7 0 - 6 . 9 8 5m m p . Z T 4 4 - O . 2 7 S O in)
E X : 6 . 9 6 5 - 6 . 9 8 0m m ( 0 . 2 7 4 2 - 0 . 2 7 4 8i n )
5 . M e a s u r et h e i n n e r d i a m e t e ro f e a c h v a l v e g u i d e a t t h e
pointsshown.
I n n e rd i a m e t e r
l N , E X : 7 . 0 1- 7 . 0 3 m m ( 0 . 2 7 6 0 - 0 . 2 7 6 8i n )
l0l3t
6. Calculatethe valves.temto guiclethe clearance.

s u b t r a c tt h e o u t e r d i a m e t e io f t h e v a l v e s t e m f r o m t h e
innerdiameterof the corresponding valve guide.
VALVE"'4H"]::., Clearance
l N : 0 . 0 2 5 - 0 . 0 6 0m m ( 0 . 0 0 1 0 - 0 . 0 0 2 i4n )
E X : 0 . 0 3 0 - 0 . 0 6 5m m ( 0 . 0 0 1 2 - 0 . 0 0 2 i6n )
q \Yl M a x i m u m: 0 . 2 0m m ( 0 . 0 0 8i n )
7. lf the clea;anceexceedsthe specification,

ancl/orlhe valvecuide.
replacethe vatve
ENGINE rNSPEcloN/REPAtR 10A-53
1 .M e a s u r et h e p r o i r u s i ohne i g h ot f e a c hv a l v eg u i d e s .
V A L V EG U I O E R e p l a c et h e v a l v eg u i d ei f n e c e s s a r y .
H e i g h t( A )
l N , E X : 1 3 . 2 - 1 3 . 8m m ( 0 . 5 2 0 - 0 . 5 4 i3n )
C Y L I N O EH
RE A O
t0133
R e p l a c e m e not f v a l v e g u i d e
rri-n
I
tt t:l
Note
IIIII
ilt:l
. T h e v a l v e g u i d e s a r e d i t f e r e n tb e t w e e n i n t a k e a n d
t t I t l
e x h a u s t ,s o u s e t h e c o r r e c t v a l v e g u i d e .
l t l ' l
a I t l
ffi
l l I r l
Iltrl
mil I
IN EX
10134
Removal
1' . R e m o v et h e v a l v e g u i d e f r o m t h e s i d e o p p o s i t et o t h e
c o m b u s t i o cnh a m b e rw i t h the SST.
10r35
Instailation
1 . A s s e m b l et h e S S T s o t h a td e p t hL i s a s s p e c i f i e d .
DepthL
l N : 1 3 . 2 - 1 3 . 8m m ( 0 . 5 2 0 - 0 . 5 4 3 in)
E X : 1 3 . 2 - 1 3 . 8m m ( 0 . 5 2 0 - 0 . 5 4 3i n )
Z . T a p i n t h e v a l v e g u i d e f r o m t h e s i d e o p p o s i t et o t h e
c c m b u s t i o nc h a m b e ru n t i l t h e S S T c o n t a c t st h e c y l i n d e r
head.
3. Verifythatthe valveguideheightis rvithinthe specification.
10A-s4
ENGINE INsPEcTIoN/REPAIB
Vafve Seat
t oreach
varve
lffi;iln:,furrace sear
andvarve
iry?::
(1)Roughness
(2)Damaoe
2'rf necessiry,
resurfacethc varve.seat
seatcutterand/orresurface with a 45" vafve
lhe valveface.
r0r38
3' Apprya thincoatof prussian

- brueto thevafveface.
vatv..."r,-i"giip,,rrrins
rh;.J"ru.
lil:rr??,.the asainsr
(1) lf blue does not appear
360' around the valve
& . replacethe valve. face,

(2) If blue does not appear
360" around the valve
resurfacethe seat. seat,
10r39
5. Measuretheseatcontact
width.
Width: 0.7mm (0.028in)
SEATCONTACTWIOTH
t0t40
a y;,ly,f$.rhevatve
searing
posirion
isatrhecenrer
ofthe
( 1 )l f t h es e a i i n o
wirha zs",,,_*flllgf(i u;Iueseat
varve j:9" h!oh,
correcilhe
(r)$,11.,'."9'1,'_inlpffi
il','1,'J1,
rr t) * :fl ^ T1". i',"""J':
y-'J ?utl
:l:,"S"f3
?;..vXiJ;seat
. ur s D E d U r r g p O S t t t O n i
wilha 3s' (tN) 15"i 1',ifi
7.seatthevalve'toor 11 ffn cuner
anda 45"
ir"Le
uiruJl?'.iilji,il,ili,i
nr!;;::'n,
r0 1 4 1
B.lnspect
thesinkilOoi thevalve
Measure theprotruding sear.
stem. lenglh
ldimension
L) of thevalve
D i m e n s i oL
n
3 8 . 5 5 - 3 9 . 4m
5 n,
, 1 . 5 17 7 _ 1 . 5 5 3i1n )
MeasDEtEnt mm (in)
!98:3sr-1i5s-LG
No correctionneeo'eC
J.J- _, j.5S5_l.Sg4) A!1u-;twith washer on sprrne
'''vis,r,. .
-- s e a i a r e a o f c y l i n d e rh b a d "
40.5 (1.S91)
R e p l a c e r y l i n c i e rh e a d
ENGINE INSPEcIoN/REPAIR 10A-55
V a l v eS p r i n g
l . l n s p e c te a c hv a l v es p r i n gf o r c r a c k so r d a n r a g e .
2 . M e a s u r et h e f r e e l e n g l ha n d t h e o u t - o f - s q u a r eR.e p l a c e
the valvespringif necessary.
F r e el e n g t h
( i n ) .M i n i m u m . . . N( k q , l b ) i m m( i n )
Standard...rnm
Slandard i 4 3 . 7 0( 1 . 7 2 0 5 ) 4 3 . 6 0( 1 . 7 1 6 s )
224-253
Minimum | (22.8-25.8,50-57)
/ 3 s . s( 1 . 3 s 8 )
10;4{
4 3 . 7 0( 1 . 7 2 0 5 ) 4 3 . 6 0( 1. 7 16 5 )
224-253
Minimum ( ? 2 . 8 - 2 s .s80, - s 7 )
/ 3 s . s( 1 . 3 e 8 )
Out-of-square
l N ,E X : 1 . 5 2m m ( 0 . 0 6 0i n ) m a x .
10145
CAMSHAFT
1 . S e t t h e f r o n ta n d r e a rj o u r n a l so n V - b l o c k s .
2 . M e a s u r et h e c a m s h a f tr u n o u t . R e p l a c et h e c a m s h a f t
necessary.
R u n o u:t0 . 0 1m m( 0 . 0 0 0i n
4 )m a x .
10146
3. Inspectthe camshafl for wearor damage.Replacethe

camshaft if necessary.
4. Measure thecamlobeheiohts at thetwooointsas shown.
t+
fitr
rT
l N : S t a n d a r d: 3 6 . 4 5 1 m m( 1 . 4 3 5 1i n )
M i n i m u m: 3 6 . 2 5 1 m m( 1. 4 2 7 2 i n )
E X : S t a n d a r d: 3 6 . 4 5 1m m ( 1 . 4 3 5 1i n )
Itlinimum : 36.251mm (1.4272inl'
10A-56 ENGINE rNSPEcloN/REPAtR
5 . M e a s u r et h e i o u r n a ld i a m e t e r sX a n d Y d i r e c t i o n sa t t h e
t w o p o i n t s( A - a n dB ) s h o w n .
Diameter
F r o n ta n d R e a r: 4 3 . 4 4 0 - 4 3 . c u 0m m
( 1 . 7 1 0 2 - 1 . 7 1 1i n0)
Center : 43.430-43.455mm
( 1 . 7 0 e 8 - 1 . 7 1 0i n8)
Out of round: 0.05m m ( 0 . 0 0 2i n ) m a x .
r0t48
6 . M e a s u r et h e o i l c l e a r a n c e sb e t w e e nt h e c a m s h a f ta n d
t h e c y l i n d e hr e a d .
( 1 ) R e m o v ea l l f o r e i g nm a t e r i a l sa n d o i l f r o m t h e j o u m a l s
and the camshaftbore.
(2) Measurethe camshaftbore diameter.
mm (in)
B5 trto
43.553-43.515 43.515-43.535
Frontand R ear
( 1. 7 14 6 -1. 714 0 ) ( 1. 7 1 3 2 1 - . 7 13 s )
43.485-43.505 4 3 . 5 1 5 - 4 3 . 5 3 5
Center
( 1 . 7 1 2 0 - 1 . 7 2 8 ) ( 1. 7 1 3 21- . 7 1 3 9 )
10119
(3) Subtractthe journaldiameterfrom the bored i a m e t e r .
mm(in)
B5 Eb
0.035-0.075 0.05s-0.095
F r o n ta n d R e a r
( 0 . 0 c 1 4 - 0 . 0 0 3 0 )( 0 . 0 0 2-10 . 0 0 3 7 )
0.050-0.095 0.060-0.105
Center
( 0 . 0 0 2 0 - 0 . 0 0 2 1 )( 0 . 0 0 2 3 - 0 . 0 0 4 1 )
lr4aximum 0.1s (0.006) 0 . 1 s( 0 . 0 0 6 )
( 4 ) l f t h e c l e a r a n c ee x c e e d st h e m a x i m u m ,r e p l a c et h e
c a m s h a fot r t h e c y l i n d ehr e a d .
7 . M e a s u r et h e c a m s h a f te n d p l a y . l f i t e x c e e d st h e m a x i -
m u m , r e p l a c et h e t h r u s tp l a t eo r t h e c a m s h a f t .
E n d p l a y : 0 . 0 5 - 0 . 1 8m m ( 0 . 0 0 2 0 - 0 . 0 0 7i 1
n)
M a x i m u m: 0 . 2 0m m ( 0 . 0 0 8i n )
10'r50
ENGIN E TNSPECIoN/REPAIR 10A-57
R o c k e rA r m a n d R o c k e r A r m s h a f t
l . C h e c k f o r w e a r o r d a m a g et o t h e c c n t a c ts u r f a c eo f t h e
r o c k e ra r m s h a f io r t h e r o c k e ra [ m . R e p l a c ei f n e c e s s a r y .
2 . C h e c kt h e o i l c l e a r a n c eb e t v r e e nt h e r o c k e ra m r a n d t h e
s h a f t ,t h e nr e p l a c ei f n c c e s s a r y .
( 1 ) M e a s u r et h e r o c k e ra r m i n n e rc j i a m e t e r .
Diameter
7 r n ( 0 . 7 0 8 7 - 0 . 7 0 9i7n )
l N , E X : 1 8 . 0 0 0 - 1 8 . 0 2m
rC152
( 2 ) M e a s u r et h e r o c k e ra r m s h a f td i a m e t e i - .
Diameter
l N : 1 7 . 9 5 3 - 1 7 . 9 8 0m m ( 0 . 7 0 7 0 - 0 . 7 0 7 9i n )
E X : 1 7 . 9 5 9 - 1 7 . 9 8 0r n m ( 0 . 7 0 7 0 - 0 . 7 0 7 9i n )
(3) Srrbtractrhe shaftdiameterfrom thc rockerarm diarn-
eter.
Oil clearance
l N , E X : C . 2 0 - 0 . 0 6 3m r n ( 0 . 0 0 0 8 - C . 0 0 2i7n )
M a x i m u m: 0 . 1 0 m m ( 0 . 0 0 ai n )
H Y D R A U L I CL A S H A D J U S T E R( H L A )
C h e c kt h e H L A f a c e f o r v / e a ro r d a m a g ea n d r e p l a c ei f n e c -
essary.
Caution
. T o p r e v e n td a m a g i n gt h e O - r i n g ,d o n o t r e m o v e
the HLA unless necessary.
r0153
C Y L I N D E RB L O C K
1 .C h e c k t h e c y l i n d e rb l o c k f o r t h e f o l l o w i n ga n d r e p a i ro r
replacethe cylinderblockas necessary.
( 1 ) L e a k a g ea n d d a m a g e
(2) Cracks
(3) Scoringof wall
2. Measurethe distortionof the top surfaceof the cylinder
blockin the six directionsshown in figure.
m m ( 0 . 0 0 6i n ) m a x .
Distcrtion:0.15
l0lt1
3. lf the distortionexceedsthe maximum,repairby grinding

o r r e p l a c et h e c y l i n d e b
r lock.
H e i g h t : 2 2 1 . 5 m m ( 8 . 7 2 0i n )
G r i n d i n g: 0 . 2 0 m m ( 0 . 0 0 8i n ) m a x .
10A-58
E N G I N EINSPECTION/FIEPAIR
4' Measurethe cyliqderboresin

X and y directionsat three
levels(A, B, ario C1in;;icytinder
--r-l-- as shor.rn.
I
oa
ot-"= o C y l i n d e rb o r e
S t a n d a r d:
7 8 . 0 0 6 - 7 s ^ . g l m m ( 3 . 07 1 1_ 3 . 0 7 1
t-Y- 0.2s_ (0.010 ? 4 in)
3\zs
-i_J-.--..-
rym_zB^.?99
zB.zs6 T.r
0.s0TT (0.020in)
in)o"ii.ii"
,
* ai.daod_s.oe
ovJi.ii" ,
7 8 . s 0 6 - 7 8 . S 1m
12 in)
3 m (S.OSOg_S.OS11
in)
Caution
' The boringsizeshourdbe
based-onthe size of an
oversizepistonand be the sarne
roi aii'iytino.r".
(1) exce
I"l[.^:l,j:* i^?:,:1 edsrhe rnaxim
um,
'o':1re bore.J rh
r r:J\.,, I e
lindelto
cylrnder to oversize.
oversize.
(2)
en rneasure
Lgr"ôln?r:Tg..p:J.f ments A and
themaximumtaper,-Aoor'e'
i;;'".fii n d e r to
:J::j9:
oversize.
Taper: 0.019mm (0.0002
in) max.
) L-__ (3) if the difference

betweenX and Y m e a s u r e m e n t s
exceedsthemaximumoutof_round,
oa_so reborethecylinder
zfrv lo oversize.
O u t - o f - r o u n d: 0 . 0 1 9m m ( 0 . 0 0 0 7
in) max.
[-"fr
j\'/s
5' lf the upperp.artof a cyrinder
wa, showsunevenwear,
removethe ridgewitha hdge-reamer.
ptsToN R.ING,
AND ptsToN ptN
lfsToN,
Piston
Caution
OIL RING
' lf the pistonis repfaced,
the pistonrings have to
GBOOVE
alsobe repiaced. '
1 6 . 5m m '1.
( 0 . 6 5 0i n ) Inspect, re oute.r
circumferences
of ail pistonsfor seizure
O U T E RD I A M E T E R
z fli"'f3,lii,1^,?l{yi3?
s,:HSlS?_[is3?1,'ahon abet6w
riqhr
an3le(3'r")ro.rhe ;; [0-.#0",
piiion'pir'r6.s
the - , r,r tandlower
in)
=: edqe.
ENGINE TNSPECToN/REPATR 1oA-ss
P i s t o nd i a m e t e r
S t a n d a r d:
7 7 . 9 5 4 - 7 7 . 9 7 4m m ( 3 . 0 6 9 0 - 3 . 0 6 9i n
8)
0 . 2 5m m ( 0 . 0 1 0i n ; o v e r s i z e:
78.211-78.217 m m ( 3 . 0 7 9 2 - 3 . 0 7 9i na)
0 . 5 0m m ( 0 . 0 2 0i n ) o v e r s i z e:
7 8 . 4 6 1- 7 8 . 4 6 7m m ( 3 . 0 8 9 0 - 3 . 0 8 9i n 2)
3. Measurethe piston-to-cylinder
clearance.
C l e a r a n c e: 0 . 0 3 9 - 0 . 0 5m
2 m ( 0 . 0 0 1 5 - 0 . 0 0 2i n0)
M a x i m u m : 0 . 1 5m m ( 0 . 0 0 6i n )
4.lf the ciearanceexceedsthe maximum,replacethe piston

or reborethe cylinde'sto fit the oversizepistons.
1016J
Pistonand PistonRings
1. Measure lhe pistonringto ringlandclearance
aroundthe
entirecircumference usinga newpistonring.
Clearance CIopand Second)

Standard: 0.030-0.070 mm (0.0012-0.A028
in)
M a x i m u m : 0 . 1 5m m ( 0 . 0 0 6i n )
10162
2. lf lhe clearanceexceedsthe maximum,replacethe piston.

3 . I n s p e c tt h e p i s t o nr i n g sf o r d a m a g e ,a b n o r m a w
l e a r ,o r
breakage.Replacethe pistonringsif necessary.
4. lnsertthe pistonringintothe cylinderby handand use the
pistonto push it to the bottomof the ringtravel.
10153
5. Measureeach pistonring end gaps lvith a feelergauge.

Replacethe pistonringif necessary.
End gap
Top 0 . 1 5 - 0 . 3 0m m ( 0 . 0 0 6 - 0 . 0 1i 2n )
Second 0 . 3 0 - 0 . 4 5m m ( 0 . 0 1 2 - 0 . 0 1i 8n )
Oilrail 0 . 2 0 - 0 . 7 0m m ( 0 . 0 0 8 - 0 . 0 2i 8n )
Ma:imum 1 . 0m m ( 0 . 0 3 9i n )
10164
104-60
ENGINE rNSpEcrtoN/FEpAtR
P i s t o na n d p i s t o n p i n
1 ' M e a s u r ee a c hp i s t o np i n h c i . :d r a r n e l e ri sn
t i o n sa t I ' o u pr o r n : s X andy direc-
D i a m e t e r: t 9 . 9 B B - 2 0 . 0 0m0 m ( 0 . 7 8 6 9 _ 0 . 7 8 2 4
in)
2 - M e a s u r ee a c h p i s t o np i n d i a n r e t e r s
in X and y directions
a t f o u rp o i n t s ,
Diamete
r : 1 9 . 9 7 4 - 1 9 . 9 8m
0 m (0.7864-0.7866
in)
3. Calculatethe pistonpin_to-piston
clearance.
C l e a r a n c e: 0 . 0 0 8 _ 0 . 0 2m
6m 1 0 . 0 0 0 3 _ 0 . 0 0 i1n0)
4 ' l f r h e c l e a r a n c ee x c e e d st h e
s p e c i f i c a t i o nr e
, p r a c et h e
pistonand/orthe pistonpin.
CONNECTING ROD
1 ' M e a s u r ee a c hc o n n e c t i n g
r o d b u s h i n gi n n e rd i a m e t e r s .
D i a m e t e r: 1 9 . 9 4 3 - 1 9 . 9 6m
1m (0.7g52-o.z's9
in)
2 ' c a r c u r a t et h e c l e a r a n c eb e t i v e e n
t h e c o n n e c t i n gr o d
b u s h i n ga n d t h e p i s t o np i n .
I n t e r f e r e n c :e0 . 0 1 3 - 0 . 0 3 7
m m ( 0 . 0 0 0 5 - 0 . 0 0 1i 5
n)
tv tDl
3 ' l r / e a s u r e a c hc o n n . e c t i nr go d s
f o r t h e b e n d i n g .R e p a i ro r
r e p l a c et h e c o n n e c t i n g
r o O; l n e c e s s a r y .
B e n d i n g: 0 . 0 7 5m m ( 0 . 0 0 3 0i n )
r n a x ./ 5 0 m m ( 1 . 9 7i n )
CRANKSHAFT
t c h e c k t h e j o r r r n a ras n d p i n s f o r c J a m a g e ,
s c o r i n ga, nd oir
h o l ec l o q o i n o
? . 9 . t t h e 6 i a n ( s h a fot n r h e V - b t o c k s .
3 . M e a s u r ei h e c r a n k s h a frtu n o u ta t
the
4 . R e p l a c et h e c r a n k s h a ti tf n e c e s s a r yc.e n t e ro f t h ej o u r n a r .
R u n o u t: 0 . 0 4r n m ( 0 . 0 0 1 6
i n )m a x .
5 ' f v 4 e a s u€r €: ; j o u r n a di i a m e t e r s
i n X a n d Y d i r e c t i o nast
t w op o i a t s .
EN G IN E TNSPECTtoi\r/REpAiF 10 4 - 6 1
llainjournal
D i a m e t e:r 4 9 . 9 3 8 - 4 9 . 9 5m5m ( 1 . 9 6 6 1 - 1 . 9 6 6
i ng)
O u t - o f - r o u n:d0 . 0 5m m ( 0 . 0 0 2 0
in)max.
C r a n k p i nj o u r n a l
D i a m e t e :r 4 4 . 9 4 0 - 4 4 . 9 5m0m ( 1 . 2 6 9 3 - 1 . 7 6 9i n9)
O u t - o f - r o u n d: 0 . 0 5m m ( 0 . 0 0 2 0i n ) m a x .
6 . l f i h e d i a m e t e irs l e s st h a n t h e m i n i m u mg, r i n dt h e j o u r -
n a l st o i n a t c ha n u n C e r s i zbee a r i n o .
U n d e r s i z eb e a r i n g:
0 . 2 5m m ( 0 . 0 1 0i n ) ,0 . 5 0m m ( 0 . 0 2 0i n )
0 . 7 5m m ( 0 . 0 3 0i n )
M a i nj o u r n a ld i a m e t e ru n d e r s i z e mm(in)
B e a r i n gs i z e J o u r n a ld i a m e t e r
X 0 . 2 5( 0 . 0 1 0u) n d e r s i z e 49.7M-19.708(1.956S-1.9570)
0.50(0.020)unCersize 49.454-49.458(1.9470-1.9472)
l._J_-l 0.75(0.030)
undersize 4s.204-49.208
(1.937
2- 1.9373)
Y
\1/ journad
Crankpin l i a m e t eur n d e r s i z e
B e a r i n gs i z e J o u r n a ld i a m e t e r
mm(in)
I
0 2 5 ( 0 0 1 0 )u n d e r s i z e | 4 4 . 6 9 0 - 4 4 . 7 0( 5
1. 7 5 9 4 - 1 . 7 6 0 1 )
0.50(0.020)
undersi ze
_ | 44yg-44.456(1.749 6- 1. 7502)
0.75(0.030)
unCersize I u.t 9o-4.f.2c6(1.7398-1
.74a/.)
BEARING
Il | ! [[
M a i n B e a r i n ga n d C o n n e c t i n gR o d B e a r i n g
u joJEEm
1 . c h e c k t h e m a i nb e a r i n gas n d t h e c o n n e c t i nrgo d b e a r i n g s
f o r p e e l i n gs, c o i ' i n ga, n Co t h e rd a r n a g e .
1017?
T I M I r . . *B
GE L T
s*'B Caution
. N e v e r f o r c e f u l l yt w i s t , t u r n i n s i d e o u t , o r b e n d o f
t h e t i m i n gb e l t .
/^\
n - \ \
. D o n o t a l l o l vo i l o r g r e a s eo n t h e b e l t .
All \u&
7li '
fa-25
x
r n m ( 1 . 0i n ) m i n .
r0173
1 . F e p l a c et f r et i n ' r i nbqe l ti f t h e r ei s a n y o i l o r g r e a s eo n i t .
2 . C h e c ki h e t i r n i n c - b ef lot r d a m a g e ,w e a r ,p e e l i n gc, r a c k s ,
a n d i r a i ' d e n i n g" ., 9 e p l a ct he
e t i m r n gb e l ti f n e c e s s a r y .
P € : I -I } J G
1OA€2 ENGINE INSPECTION/REPAIR
T E N S I O N E R I, D L E R
Caution
. D o n o t c l e a n t h e t e n s i o n e ro r i d l e r w i t h c l e a n i n g
fluids. lf necessary,use a soft rag to wipe them
c l e a n ,a n d a v o i d s c r a t c h i n gt h e m .
1. check the tensionerand the idler for a smooth rotation

a n d a n a b n o r m a ln o i s e . R e p l a c et h e i e n s i o n e ro r t h e
idlerif necessary.
10176
T E N S I O N E RS P R I N G
1. Measurethe free lengthof the tensionerspring. Replace
the tensionerspringif necessary.
Free length : 64.0 mm (2.520in)
r0r76
PULLEY
TimingBelt Pulley,CamshaftPulley
Caution
. Do not cleanthe pulleyswith the cleaningfluids. lf
necessary, use a soft rag to wipe them clean,and
avoidscrltchingthem.
1. Inspectthe pulleyteethfor wear,deformation,
and other
damage.Replace thepulleyif necessary.
r0177
@
ENGINE ASSEMBLY 104-63
ASSEMBLY
PREPARATION
SST
0K 201110A A 0 For 0 K 2 0 1r r o A 0 2
r e m o v a la n d r e m o v a la n d
PistonPin setling i n s t a l l a t i oo
nf S u p p o r tb l o c k i n s t a l l a t i oonf
tcol sel p i s t o np i n s body p i s t o np i n s
( P a r io f
0 K 2 0 1 1 1 0A A 0 )
0 K 2 0 11 1 0A 0 5 For 0 K 2 0 1 11 0 4 0 6 For
removaland r e m o v a la n d
S c r ew i n s t a l l a t i oo
nl S t o p p e rb o l t installation of
f arl ot p i s t o np i n s ( P a r to f p i s t o np i n s
0t<201110 AA0) 0 K 2 0 11 1 0 A A 0 )
't10
0t<201 A07 For 0 K 2 0 11 1 0A 0 8 For
r e m o v a la n d r e m o v a la n d
r inslallcr
P u l l o& installalion of Guide i n s t a l l a t i oonf
( P ar tof p i s t o np i n s (P arlof p i s t o np i n s
0 K 2 0 11 1 0A A 0 ) 0 K 2 0 11 1 0A A 0 )
at<201110 41 ' For 0 K 2 0 111 04 1 2 For

o removal and r e m o v a la n d
tool
Cent er ing { A i n s t a l l a t i oo
nf Holder E i n s l a l l a t i oonl
of
(Part p i s t o np i n s (P artof U p i s t o np i n s
t/1
0 K 2 0 11 1 0A A 0 ) 0K 201110 A A 0)
0 K 2 0 11 1 00 0 2 For oKseo
1 1 1o o 1 * For
Supporb
i lock
r e m o v a la n d
i n s t a ! l a t i oonf Ringgearbrake
It p r e v e n t i o no f
e n g i n er o t a t i o n
head p i s t o np i n s sgl ,__{q
L-+-/
0 K 9 9 31 2 0 0 0 1 For 0K710 120 008 For

r e m o v a la n d /^_ remcval and
A r m ,v a l v e s p r i n g i n s t a l l a t i oo
nf Pivot,valve installation
of
f$
lifter valves spri ngl i fter \)v valves
0 K 9 9 31 2 00 0 4 For 0 K 1 3 01 6 00 1 0 For
removal/ i n s t a l l a t i o no f
P i v o l , V d t v€ i n s t a l l a t i oo
nf u e n t e r i n gt o o l , c l u t c hd i s c
s o r i n gl i f t e r valves c l u t c hC i s c
0 K 1 3 01 2 00 0 6 For
removal/
Removerand ffi lnstallation
i n s t a l l e rv, a l v e ol valve guides
guide
10A-64 ENGINE ASSEMBLY
C Y L | N D E RB L O C K ( fN T E R N A L P A R T S )
1 C l e a na l tp a r l sb e f o r et h e r e i n s t a l l a t i o n .
2. Apprya nev/engineoirto alrslicjing'a-nd
rotatingparls.
i f,3f;'€:""iffiil3':,ffirun .ll,orotherwise
il:'Jr::?,3?1,$il!f damaseo
TorqueSpecifications
Caution
. D o n o t r e u s e t h e g a s k e t so r t h e
oil seals.
{fw lA
\<
>u-
tr4
;:9al
xtt
|l\--.1../ ,
t\- \ /
,/
\-ttv
t ---- /Y \
^ \ \\
vd -l>E{{'r
/il]il
JOURNAL &
C R A N KP I N
#4_
R$ryg
;"w
0n 85 : 29-34 N'm
I
( s . 0 _ 35. k g . m , Z Z - ? S t b . n )
o{Y- B 6 : 4 7 - 5 0N ' m
( 4 8 _ s .1 k g . m , 3 5 - 3 7 f b . f l )
Tffi
5 4 - 5 9N m ( 5 . 5 - 6 . 0
u
k g _ m4, 0 _ 4 3t b - , r )
10178
C o n n e c t i n gR o d
r,rarnr'r.iz 1 .A s s e m b l et h e S S T a s s l r o r v n .
I
ENGINE ASSEMBLY 10A-65
2 . s e t t h e s t o p p e rb o l t ( 0 t ( 2 0 11 1 04 0 6 ) s o t h a tt h e d e p t hL
is as specified.
t
D e p i h L : 5 6 . 9 - 5 7 . 1m m ( 2 . 2 4 0 - 2 . 2 ai8n )
3 . l l g h t e nt h e l o c k n u t .
4. Insertthe ssr No. 2 intothe pistonpin as shownand
,,)4
fullyscrewin theSSTNo.1.
5. Applytheengineoilto thepistonpin.
."t?Y
{
.,c141
9. |ut thepistonon thessr vriththeF markfacingupward.

7. Assemble the pistonand the connecting
rodin-thedirec-
tionfromwhichtheyweredisassembledl
I D E N T i F I C A T I O Ni ! 4 A R K
' i 018 2
B. Press ll^rgp,:Lo! pin into the piston and the connecting

rod uniilthe SST contactsthe stopperbolt.
9. while insertingthe pistonpin, check the pressureforce.
lf it is less than the specification,
repracethe pistonpin or
the connectingrod.
Pressureforce :
4 , 9 0 5 - 14 , 7 1 5N ( 5 0 0 - 1 , 5 0 0k g , 1 , 1 0 0 - 3 , 3 0 l0b )
'10.
Checl<the oscillation
torqueof the connectingrod.
P i s t o n Ri n g
1 . l n s t a l tl h e t h r e e - p i e coei l r i n g so n t h e p i s t o n s .
(1) Applya cleanengineoitio theoil rinqspacerand rails.
( 2 ) l n s t a l il h e o i l r i n gs p a c e rw i t ht h e e n d su o w a r d .
Note
. T h e u p p e r r a i l a n d t h e l o w e r r a i la r e t h e s a m e .
. Tr a i l s m a y b e i n s t a l l e dw i t h e i t h e rf a c e u p w a r d .
(3) :' - i l t h e u p p e rr a i la n d t h e l o w e rr a i l .
'
SPACER
U P P E RR A I L
?f{ltq[!ff ifi3?i,'T
fiy,l1,1 :ni,
:rJ[:^'?f;:"ij?, ?;
s m o o t h l yi n b o t hi i r e c t i o n s .
-
OIL RING
SPACERENDS
L O W E RR A I L
PISTON
r0 l 8 S
Caution
'
. TOP
! . r i n g s m u s t b e i n s t a i l e dw i t h t h e y m a r k s
Tupward.
I '
///' . mustbeinstailed
withthescraper
SECOND Ij"?"."ff1*:'f,?
3. Applya cleanengineoir
to thetopandsecondpistonrinos.
4.Instattthesecon? i; jh; ;til
1ns
ring. Usea pistonrinfexpani., ; ift,nj1'{rr"rr
rhe,roo
(commerciarfy
avairabre)..
10186
5' Position
theendgapsof theringsas
OILRING
shownin thefigure.
UPPERRAIL
OILRING
SPACER
OIL RING SECOND

L O W E RR A I L RING
10187
Oil FilterJoint
rsffi-fo.zs inl ,zX--- 1. lnstalltheoilfilterjointso that protrudes
.9ig.-l-----:- Protrusion
: 19 mm (0.75in)
it as specified.
\ rs../
\_
t-_
/-
PLASTIGAGE
Crankshaft
1 . B e f o r ei n s t a i l i n tgh e c r a n k s h a f t ,
inspect he mainbearing
oil cfearanceas follows.
O i l c l e j r r a n c ei n s'pf oercet ii o
gnn.
( r / H e r p q v ea l l
a n d t h e b e a r i n q s l m a t e r i aand
l oil from the journals
Caution
. I n s t a l ' , e g r o o v e d u- rpr p- e r m a i n
cYlinc- ''lo6k. bearingsin the
' I n s t a l l. e t h r u s t , b- e
" 'a r i n g w
s ith the oir groovefac-
rngthe .;,-i.nkshaft
E N GI NE A S S E M B L . / 10A-67
(2) I n s i a lilh e u p p e rr n a i nb e a r i n g as n d t h e t h r u s bt e a r i n g s .
/ " \ S a t l h e c r a n k s h a fi tn t h e c y l i n d ebr l o c k .
T H R U S TB E A R I N G
Caution
. D o n o t r o t a t et h e c r a n k s h a f w
t h e n m e a s u r i n gt h e
oil clearances.
( 4 ) P o s i t i o na P l a s t i g a gaet o po n t h e j o u r n a l si n t h e a x i a l
ciirection.
iOi9)
( 5 ) l n s t a l tl h e l o v r e rm a i n b e a r i n g sa n d t h e m a i n b e a r i n g
c a p sa c c o r d i n g t o t h e c a p n u m b e ra n d € m a r k .
(6) lighten the mainbearingcap boltsin the ordershovrn
in thefigure.
s 4 - s s N . m ( 5 . 5 - 6o. kg-m, 40-43 lb-ft)
|
1019
( 7 \ R e m o v et h e m a i n b e a r i n gc a p s , a n d m e a s u r et h e
Plastigage a t e a c hj o u r n a la t t h e w i d e s tp o i n tf o r t h e
smallestclearanceand at the narrotvestpointfor the
l a r g e s ct l e a r a n c e .
' lf the oil clearanceexceedsthe specification,
(8) grindthe
crankshafl and use undersize mainbearings.
6 m ( 0 . 0 0 0 7 - 0 . 0 0 1i n
O i l c l e a r a n c e: 0 . 0 1 8 - 0 . 0 3 m 4)
Maximum : 0 . 1 0m m ( 0 . 0 0 ai n )
10192
2. Applya liberalamountof a clean engineoil to the main

b e a r i n g st,h e t h r u s ib e a r i n g sa n d t h e m a i nj o u r n a l s .
3. lnstallthe crankshaftand the main bearingcaps accord-
ing to the cap numberand € mark.
10193
4 . l l g h t e n t h e m a i n b e a r i n gc a p b o l t si n t h e o r d e rs h o v r ni n
t h ef i g u r e .
5 4 - 5 9 l . l ' m( 5 . 5 - 6 . 0k g - m , 4 0 - 4 3 l b - f t )
n\
\L/
104-68 ENGINE ASSEMBLY
5 . M e a s u r et h e c r a n k s h a fet n d p l a y .
E n d . p l a y: 0 . 0 8 0 - 0 . 2 8m
2 m i0.0031-0.011
i n1)
M a x i m u m: 0 . 3 0m m ( 0 . 0 1 2i r i )
6.lf the end play exceeds the maximum grind

the
WIDTH c r a n k s h at f a n d i n s t a l la n o v e r s i z et h r u s i b e a r i n g
repfacethe crankshaftthrustbearino.
or
T h r u s t b e p r i n gw i d t h
S t a n d A r d:
2.500-2.550 mm 0 . 0 9 8 4 - 0 . 1 0 0i4n )
0 . 2 5m m ( 0 . 0 1 0i n oversize :
2.625-2.675 mm 0 . 1 0 3 3 - 0 . 1 0 5i3n )
0.50mm (0.020in oversize :
2.750-2.800 mm 0 . 1 0 8 3 - 0 . 1 1i 0n2 )
0.75mm (0.030in oversize:
10196 2.875-2.925 mm 0 . 1 1 3 2 - 0 . 1 1i n5 )2
Pistonand Connecting
RodAssembly
Caution
. Protectthe connectingrod boltswith rubbersleeves
to preventdamageto the crankpinjoumafs.
C o n n e c t i n gR o d C a p
1 . M e a s u r et h e c o n n e c t i n gr o d b e a r i n go i l c l e a r a n c e s
using
t h e s a m ep r o c e d u r ea s f o r t h e m a i nb e a r i n go i rc r e a r a n c e .
Caution
. Align the matching mqrks on the cap and
the con-
nectingrod vvheninstallingthe conn"tting rod cap.
B5: 2e-31 (q.g-3.s zz_zstb-fr)
B S : . 1 7 - 5l{.*
0' n ( + . q- s _ l,g_rn,
IIATCF]INGIIARKS
oil crearance N t. d
1 -n.3_s_3 7_ni
rU
: o.cizb-o 068iir'rri'(b.'otli-olocilz
in)
Maximurn : 0 . 1 0m m ( 0 . 0 0 4i r i )
2 . l f t h e o i l c l e a r a n c ee x c e e d st h e n r a x i m u m g, r i n d l h o
crankshait and use the undersize bearings.
r o d s i d ec l e a r a n c e s .
3 . M e a s u r et h e c o n n e c t i n g
S i d e c l e a r a n c e: 0 . 1 i A - } . 2 6 2m m ( 0 . 0 0 4 3 - 0 . 0 1 0i 3
n)
M a x i m u r n : 0 . 3 0m m ( 0 . u 1 2i n )
4 . l f t h e c l e a r a n c ee x c e e d st h e m a x i m u m ,r e p l a c et h e c o n -
n e c t i n gr o d a n d t h e c a p .
rrrlQC
5. Apply a liberalamountof clea;rengineoil to the crankpin

journalsand the connectingrod bearings.
6. lnstallthe connectingrod caps with the matchingmarks
aIgned.
7.1ightenthe connectingrod cap nuts.
85 : 29-34 N'm (3.0-3.5kg-m, 22-25!b-ft)
8 6 : 4 7 - 5 0 N ' m ( 4 . 8 - 5 . 1k g - m , 3 5 - 3 7 l b - f t )
M A T C H I N GM A R K S
10200
10A-70
E N G I N EASSEMBLY
c Y L t N D E RB L . O g I T E X T E R N APLA R T S )
T o r q u eS p e c i f i c a t i o n s
N ' m ( 1 . 9 - 2 . 6k g - m . 1 4 _ 1 9t b - , t )
GASKET.
NEW
1 9 - 2 5N . m
( 1 . 9 - 2 . 6k g - r n .' 1 4 - 1 9t b - f l ) GASKET,
NEW
96-103N.m
. 8 - 1 0 . 5k o - m 7
. 1 - 7 6t b - t r )
7 . 8 - 1 1N ' m
( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 t b - i n ) 7 . 8 - 1 tN . m
( 8 0 - 11 0 k g - c m 6
, 9 - 9 5l b - f r )
^ ^ t t F -
uAJntr l.
16-21N.m
( 1 . 6 - 2 . 1k g - m . ' t 2 - 1 5 l b - f t )
A),
-4€
7 . 8 - 1 1 N'.-i
( 8 0 - 1 j 0 k g - c m ,69-95 lb-in)
(e.B-r
o.sxe.m.
i t'qa'r.nfl\
GASKET,
NEW
1 8 - 2 6N . m
( 1 . 8 - 2 . 7k g . m .1 3 - 2 0t b . f r )
R e a rC o v e r
t. Apply a smail amounrof crean engine oir to
new oil seaf. the rip of a
2.Push in the oil seal slighily
by hands.
Caution
' T h e o i r s e a rm u s t b e p r e s s e d
i n u n t i ri t i s f r u s h w i t h
the edgeof the r"rr iov"r.
3. Pressin the oil seal evenlywith
a suitablepipe.
O i rs e a l o u t e r d i a m e t e r: 1 0 0 m m ( 3 . 9 4
in)
o a siriconesearantto the shadedarea

fltll
ttQUre. shown in the
10203
5. lnstallthe rearcover.
lll
rtl
7 . 8 - 1 1N ' m ( 8 0 - 1 1 Ck g - c m , 6 9 - 9 5l b - i n )
A
1a?U
O i lp u m p
1.Applya smallamountof cleanengineoil to the lip of a
newoilseal.
2. Pushin theoilsealslightly
by hands.
Caution
. Theoil sealmustbe pressedin until it is flushwith
the edgeof the oil pumpbody.
3. Pressin theoilsealevenlywitha suitable
pipe.
Oilsealouterdiameter: 44 mm (1.73in)
10205
theoilpumpanda newgasket.
4. Install
Tightening torque:
1 9 - 2 5N ' m( 1 . 9 - 2 . k6 g - m ,1 4 - 1 9 1 b - f t )
r0206
Caution
. Do not scratchthe oil pump.
5. Cutawaythe portionof the gasketthatprojectsfromthe
bodytowardtheoilpanside.
I 0207
M a i n B e a r i n gS u p p o r tP l a t e( M B S P )
1. Removeall foreignmaterialfrom the contactsur{acesof
t h e c y l i n d ebr l o c ka n d t h e M B S P .
C a -u[thi o
en
. o i l p a n r n u s tb e s e c u r e dw i t h i n 5 m i n u t e sa f t e r
t h e s e a l a n it s a p p l i e dt o t h e M B S P .
2. Appt''a siliconsealantto the shadedareasshownin the fig-
ure.
104-72
ENGINE ASSEMBLY
' searanr
rorhe
i3:,{,il?#ll:%fi*'S3,il;,ill"e MBsp
4. I,nslall
theMBSlSlto thecylinder
5. TTghten btock.
rheMBSPUofti i-njf,; ordershown
in thefigure.
Tig!leningtorque:
16-21N.m(1.6_2.1kg-m,12_15
lb-ft)
ooso.-o
Oil Strainer
1 . I n s t a ltlh e o i l s t r a i n ear n d a
newgasket.
o T i g h t e n i n gt o r q u e :
7 . 8 - 1 1N . m ( a O _ t 1 0k g _ c m , 6 9 _ 9 5
lb-.in)
-----._c
1 S 2t 1
Oil pan
1' Removeail foreignmateriar
fromthecontactsurfaces.
' silicone sJatant
to theshaded-JirlI'rnown-in'tne
ffi;ll
3. lnstalln.e_w
gasketsonto the oil pump
coverwrththe projectionsin bodyand the rear
the notches
shownin thefig-
ure.
Ii'JGltiE 10 A - 7 3
fq; j , . ' - ' i l ' , - . : : . 1 : < . ' .r . ' i . . : . - , ' i ' i : r \ t1 , , l , ;

; , 1 r , ;, y 1 . : - ' ' l i '
; 1 i r j 1 1 1i i; ; - ; ' ' . , : . ; ; .( . , 1t ,' , . : . ' , l : . i c . l , : . . , ' l 1al ) ' . , ( i r i i l ; !; l l r . , , . '
t l r s l l ri l i l i ' : :,:l i-'?.
-i'lr-;
iitenino lorqrre :
7 . 8 - 1 1 l . l ' r r (t 8 0 - 1 1 0 k g - c r r r .6 9 - 9 5 l L t - i n )
End Plate
1 .! n s t a llll ' t . e. r i n l ; i i e
T i g h t e n i r ' gi o r q u e :
7 . 8 - 1 1f J ' m( 8 0 - 1 1 Ck g - c r n . 6 9 - 9 5l b - i n )
ia215
Flyr.rheel(l,AfT)
1 . R e r r o " v ei h e s g a l a n tf r o ; ' nt h e i i y r v h e ebl o l t h o l e s I n i h e
c i ' a n k s h a fat . n rijr o m t l r ef l r n ' . ' h e b
eoi its.
Caution
. l f a l l t h c p r e v i o u ss e a l a n tc a n n o tb e r e m o v e dl r o m
a b c l t , r e p l a c et h e b o l t .
. D o n o t a p p l y s e a l a n ti f a n e v /b o l t i s u s e d .
2 . S e t t i r e i 1 1 " , ' , ' hC

e en l Oi h e c r a n k s h a r t .
3 . A p p l ya s e a l a ; ' itto t h e f l ; + ' . , h eLe:lo l t sa n c ji n s i a i lt l r e " n .
!1
. H C i d 1 n ' 3f i r ,, ' . ':fe e i ' . . , r fi 1 l ' r eS S T .
lrOhlen ih't calls rr t',? Cri?r ShOr.,'n.
T i g h t e n i n gt o r c p r e:
9 5 - i 0 3 r ' l ' n r( 9 . E -1 0 . 5k g - m . 7 1 - 7 6 l b - f t )
f\ I r r I a )r
vtLltL,rl Discani Clutch Cover (f'IiT)
. !,. ^r.. ' ''-:
l : i I i 7 ' ; : . i : . i ' , 1Ct l ' - r i i : n C : . ' , ' , r : .: ,l - " : : SST
J| -' i\ r- ,r l hr rl \ol rr, rr ir r' -r Jr r
1B - : / t j l ' . 1 7 kg-m. 13-20 lb-lt)
1 0 2 13
Drive Plate (Aff)

1 - R e m o v et h e s e a l a n tf r o m r h e d r i v ep r a t eb - -o r th o r e si n t h e
c r a n k s h a fat n d f r o m i h e d r i v en l a r et i o i t r .
Caution
' l f a r r p r e v i o u s s e a r a n tc a n n o t b e
removed from a
"$: \" bolt, the bolt haveto be replac--
n D o n o t a p p r y a s e a r a n ti f a n e w b o r t
is used.
2. Installthe adaprer,
the driveprare,and the backingprare
ontothe crankshaft.
9.Appty.asealant.to thedriveR.late
boltsand instailtherrr.
A1ild\ 1. HolothedriveptatewitnrneSSf.
5. Tightentheboitsin theorO* shown.
-(sW; Tighteningtorque:
96-103N.m(9.a_10.5
kg-m,71_76tb.ft)
Timing Eleltpuiley
1. Reversethe directionof the ssr on the frywheer.
2. Installthe timingbeltpulley.
3. Install.the pul[eyWboOr'utt k e y w i t h t h e t a p e r e ds i d e
. towardthe oil pumobodv.
a. lstalt thepulteytobf Uori.
b. ngnrenthepulleylockbolt.
Tigh.t_ening torque :
10 B - 1 ' tB N . m ( 1 1. 0 - 12 . 0 k g _ m ,8 0 _ 8 7 l b f t )
Water Pump
1 . R e m o v ea l l f o r c i g nm a t e r i a fl r o m t h e w a t e r p u m p
ing surface. mounr-
2 . P l a c ea n e w w a t e rp u m p g a s k e ti n p o s i t i o n .
'
3 . l n s t a ltl h e w a t e rp u m p . r - ' -
1 9 - 2 s N . m ( 1 . 9 - 2 . 6k g _ m ,1 4 _ 1 9l b - , f t )
a
c Y L I N D E RH E A D
l ' o r q u eS P e c i f i c a t ! o n s
4 . 9 - 8 . 8N . m
( 5 0 - 9 0 k g - c m .a 3 - 7 8 l b . i n )
I
I
I
GASKET.
NEW
22-28 N'rn
( 2 . 2 - 2 . 9k g - m , i 6 - z t t o - t l )
76-8'l N'm
( 7 . 7 - 8 . 3k 9 - q , s 6 - 6 0 l b - f l ) ;
,8F-Gfl
4 9 - 6 1N ' m
5l- \ ,,s
,"€
,s
€--ssn
5
s
t:
(re
ra
J
ffbN
N
*"*
%ru
( 8 0 - l 1 0 k g - c m .6 9 - 9 5 t b - i n )
\,/
GASKET.
NEW
6 . 4 - 9 . 3N . m
I9-25 N ;n ( 6 5 - 9 s k g - c m ,5 6 - 8 2 l b - i n )
( 1. 9 - 2 . 6 k g - n r .l 4 - 1 9 t b - f l ) l9-25 N.m
( 1 . 9 - 2 . 6k g - m .l 4 - 1 9 l b . t t )
f.
V a l v eS e a l
1 . A s s e n r b lteh e s s T s o t h a tt h e d e p t hL i s a s s p e c i f i e d .
DepthL
lN : 14.9-15.2 m m ( 0 . 5 8 7 - 0 . 5 8i 9n )
E X : 1 4 . 9 - 1 5 . 2m m ( O . S a z _ 0 . 5 8i r9r i
2.Tap the valve seal on untilthe SST contacts

the cylinder
head.
Valveand ValveSpring
1.Install
thelowerspringseat.
2. Installthevalve.
Caution
GREATER
nrnt.r @ . lnstallthe spring with the closerpiich toward
the
cylinderhead.
3. Installthevalvespringandthe upperspringseat.
CYUNDER
HEADSIDE
r023t
4. Compress the valvespringwith the SST, and installthe

valvekeeoers.
5. RemovetheSST.
6. Tapthe end of the valvestem lightlytwo or three
times
with a plastichammerto verifythat the keepersare
fullyseated. all
14232
ENGINE ASSEMBLY 1AA-77
C y l i n d e rH e a d G a s k e t
'1
. R e m o v ea l l f o r e i g nn ' r a t e r i af ,.ol n nt h e t o p o f t h e c y r i n c e r
block.
2 . P l a c et h e n e r vc y l i n d e h
r e a c gi a s k e ti n p o s i t i c n .
iC2+t
C y l i n d e rH e a d
1 . I n s t a ltl h e c y l i n d e rh e a d .
2 . A p p l y a c l e a n e n g i n eo i l t o t h e bolt threadsand the seat
laces.
3. lighten the cylinderhead boltsin the ordershown.
@,
7 6 - 8 1 N ' m ( 7 . 7 - 8 . 3k g - m , 5 6 - 6 0 l b - f t )
ra
(,
CamshaftOil Seal
1.Applya thincoatof an engineoil to the camshaftoil seal
andthecvlinderhead.
Z.Tapthe iamshaftoil sealintothe cylinderhead with a
pipe.
suitable
Caution
. The oil seal must be tapped in until it is flush with
t h e c y l i n d e rh e a d .
10237
Camshaft
1.Applyan engineoilto the journalsand the bearings; then
insertand mountthe camshaftinto the positionwith the
t h r u s tp l a t e .
T i g h t e n i n gtorque:
7 . 8 - 1 1 N ' m( 8 0 - 1 1 0
k g - c m , 6 9 - 9 l5b - i n )
I 023E
104-78 ENGINE ASSEMBLY
C a m s h a f tP u l l e y
1 . I n s t a itlh e c a m s h a fpt u l l e vo n r ^the dor,vel
pin with the pin
g r o o v ef a c i n gs t r a i g h ut p w a r d "
Noie
. B e s u r e t h a t t h e d o r v e lp i n o f t h e c a m s h a f t
also
T I M I N Gt ' l n n k f a c e s s t r a i g h tu p w a r d .
2 . T i g h t e nt h e c a m s h a tf p u l l e vb o l t . H o l d t h e
camshaft
usinga suiiablewrenchon th'ecast hexagonas
sh<-lwrr.
T i g h t e n i n Et o r q u e :
4 9 - 6 1 N . m ( 5 . 0- 6 . 2 k g - m ,36-4s tb-,ft)
HydraulicLashAdjuster(HLA)
1. forl an engineoirintotheoilreservoir
in therockerarm.
2. Applyan engineoil to thenewHLA.
3. InstalltheHLAin the rockerarm.
Caution
. Be carefurnot to damagethe o-ringwheninstailing.
RESERVOIR
RockerArm and RockerShaftAssembly

No.l CYLINDER
1.Assemble the rockerarm and the rockeishaftassembry
N o . aC Y L I N D E R
as shownin thefigure.
EXHAUST
Cautio''
- B e s L r r eb o t h r o c k e r a r m s h a f t o i l h o l e s f a c e
down-
N o . 1C Y L T N D E R rvard.
N r r . aC Y L I N D E R
INTAKE . T h e i n s t a r i al ' c n b o r t h o r e s a r e d i ff e r e n t
for the
e x h a u s ta n d i n t a k es i d e sa s s h o w n i n t h e ' i i o r r " .
EXHAUST
A>B
Note
. There are two types o f r o c k e r a r m s w i t h d i f f e r e n t
offsets. One type is f o r N o . 1 a n d N o . 2 c y l i n d e r s
e x h a u s ta n d i n t a k e ,a n d t h e o t h e r i s f o r c y l i n d e r
N o .3 a n d N o .4 .
N o . 1 , 2C Y L I N D E R S N o . 3 . 4C Y L I N D E R S
(rN & EX) (tN & EX)
102.45
2. Installthe rockerarmandthe rockershaftassembly.

@ @ O 3. Tightenthe rockerarmboltsin the ordershownin the fig-
ure.
Caution
. The bolts haveto be tightenedgraduallyand in the
ordershown.
T i g h t e n i ntgo r q u e :
18\ /\Y/\ 22-28 N.m (2.2-2.9kg-m, 16-21 ltrft)
\, @
r0 2 4 6
B r a c k e ta n d H e a tG a u g eU n i t
1 .l n s t a ltlh e h e a tg a u g eu n i ti n t ot h e c y l i n d ehr e a dw i i h a
sealtapeon thethreads.
Tighteningt o r q u e:
6.4-9.3N.m(65-95kg-cm, 57-82 tb-in)
2. lnstallthebracket.
Tighteningtorque:
HEATGAUGEUNIT
il , \\\ /r\\ I 19-25N'm (1.9-2.6kg-m,14-18tb-ft)
|0249
Thermostatand ThermostatCover
1 .R e m o v ea l l f o r e i g nm a t e r i aflr o m t h e t h e r m o s t acto v e r
mountingsurface.
2. lnstallthethermostat withthejigglepin facingupward.
3. lnstalla newgasketandthethermostat cover.
Tightening t o r q u e:
J I G G L EP I N 1 9 . - 2 5N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 8t b - f t )
I0250
C a u t i on
. T h e p r i n t e ds i d e o f t h e g a s k e tm u s t f a c et h e t h e r -
mostat.
PRINTED
SIDE ^.-,6F.]
10A-80
ENGINE ASSEMBLY
SEALANT CylinderHeadCover
H E A DC O V E R
GASKET 1. lnstallthecylinder
headcover.
I
Tighteningtorque:
5 . 0 - 8 . 8N . m( 5 0 - 9 0k g - c m, 4 4 - 7 9 l b - i n )
Caution
. lf the covergasketis reused,applya sealantin
the
grooveas shown.
10252
ENGINE AssEf,/BLY 10A-81
T I M I N GB L E T
T o r q u eS P e c i fc a t i o n s
1 9 - 2 5N ' m ( 1 . 9 - 2 . k6g - m .1 4 - 1 9r b - f t )
Timing Belt Tensioner

1 . I n s t a tl lh et e n s i o n earn dt h et e n s i o n esrp r i n g .
2. Temporarily securethe tensioner with fullyextending the
spnng.
1029
T i m i n gB e l t
1.Verifythat the t i m i n gb e l tp u l l e ym a r k i s a i i g n e dl v i t h t h e
timingmark.
2 . V e r i f yt h a i t h e c a m s r i a np u l i e ym a r k sa r e a l i g n e dr v i t ht h e
CYLINDER
HEAD IIARKS
cylindeh i ' e a d c o v e rm a r - k s .
CYLINDER
HEAD
MARKS
1025,6
3. lnstallthe timingbeltso thatthei,eis no tooseness

at the
tension side.
Caution
. Do not turn the crankshaftcounterclocklise.
TENSION
SIDE
10257
4. Turn the crankshaft hvo turnsclockwise,

and alignt L . ^ t t t F
MARKS
timingbeltpulleymarkwiththetimingmark.
5. Verifythatthe camshaftpuileymarki are alignedvritht h e
cylinder headcovermark.
ff nol aligned,removethetimingbeltand repeatfromruL tû
tensionei' installation.
MARKS
10258
6. Loosenthe tensioner
rockboltto applya tensionto the
timingbelt.
Caution
. Be surenot to applya tensionotherthan thatof the
t e n s i o n esrp r i n g .
-lighten
7. thetensioner lockbolt.
T i g h t e n i ntgo r q u e:
1 9 - 2 5N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 9l b - f t )
10 2 5 9
B.TurnIhc crarrlislraf t 2 trrrnsclocl<rviso and vorifytha.tthe

t i m i n gn r a r k a
s r ec o r r e c'cjefr6ction
tal vl i o n e o
9. Measurethe.tjnilg betr b5iapplyingnrcderare
p r e s . s u ; ' e .N9(B1 0k g , D l b )t o t h e n i i d r vra yb d t v r e e nt h e
crankshail pulleyanCthecamshalt pulley.
!l tnqtinring belt'defiection is notcoirect,iemporanlv secui.e
t h et e n s ; o n e l or c kb o l ts o t h es p r i n gi s f u l l v ' e x t e n b ae nd d
repeatthesteps4-B aboveor reiplace thetensioner spring.
( 1O k g .2 2 l b )
D e fl e c t i o ' r :
1 1 . t ' 3 . 0 m m ( 0 . 4 3 - 0 . S 1i n ) a t 9 8 N f i 0 k q . 2 2 l b )
E N G I NE A S S E M B U / 10 A - 8 3
TimingBeltCove(
g e l i c o ' v e r sa n C n ? \ , 'g/ a s -
l n s t a l lt h e l o v r e ra n d u p p e i 't i i - n i n b
kets.
TII.IING BELT
COVER
7 . 8 - 1 1 | t l ' m( 8 0 - i 1 0 k g - c m ,6 9 - 9 5 l b - i n )
1 0 2 6r
CrankshaftPulley
l . l n s i a l tl h ec r a n k s h aPf tu l l e y .
2.1ighten thelockboltsrviththeSST.
12-17N'm (1.25-1.75 kg-m,9.04-12.66
ib-ft)
3. Removethe SST.
10262
4. Installthecrankshaft
PulleY.
theplate.
5. Install
Tighteningtorque:
12-17N'm (1.25-1.75 lb-ft)
kg-rn,9.04-12.66
10263
WaterPurnpFuliey
1. lnstalltirewaterpumpPuiley.
T g h t e n i n gt o r q u e:
7 . 8 - 1 1N ' m ( 8 0 - 1 i 0k g - c m , 6 9 - 9 5l t r i n )
F,
B
I
p
B
I 0254
104-84
E N G I N EA S S E M B L Y
AUXILIARY PARTS
1 8 - 2 7N - m( 1. B _ 2 . 7k g . m ,1 3 _
16lb.,l)
3 7 - 5 2N . m
(3.8-5.3kg.m,27-38
tb-in)
1 2 - 1 8N . m
(l 20- 1B0 kg-cm,j 04_j56;;)
Q-- GASKETNEW
f
3 7 - 6 3. /
( 3 . 8 - 6 . 4k g . m ,Z z _ 4 6t b - f t )
1 9 - 2 5N ' m
( 1 . 9 - 2 . 6k g - m ,
1 4 - 1 9t b . f i )
1 5 - 2 3N . m ( 1 . S _ 2 .k3g - m .
t 1 _ r 7t b . ,
i u<C5
!f
I
FRONT
a
E n g i n eH a n g e r }.
1 . l n s t a l ti h e f r c n ta n d r e a re n g i n e F
hanqers. f
I
T i g h t e n i n tgo r q u e
Front: 37_63N.m( 3 . 8 - 6 . 4
/r\ k g - m ,2 7 - 4 6 l b - f r )
'\.r, R e a r : 1 g - 2 5N . n r( 1 . 9 - 2 . 0
k g - m, 1 4 - 1 9l b _ f t i
\
,=5'i\
{---,r,i
SparkPlug
l . A p p l y a n a n t i s e i z ec o m p o u n do r a m o l y b d e n u m - b a s e c j
l u b r i c a ntto t h e s p a r kp i u gt h ; ' e a d s .
2 . I n s t a ll!h e s p a r kp l u g s .
1 5 - 2 3 N ' m ( 1. 5 - 2 . 3 k g - m , 1 1 - 1 7 l b - f t )
O i l L e v e lG a u g e
i . I n s t a l tl h e o i l l e ' , , ee1a u c e .
l 0?57
O i l - P r e s s u r es v r i t c h
1 . I n s t a ltlh e o i l p r e s s u r es r v i t c h .
1 2 - 1 8 N ' n r ( 1 2 C - 1 8 0k g - n n ,1 0 4 - 1 5 Gt b - i n )
Oi!Filter
l62gie
t,
1 . R e m o v ea l l f o r e i g nm a t e r i aflr o mt h e o i l f i l t e rm o u n t i n g
sudace.
2. Applya smallamountof cleanengineoil to the rubber
sealof theoil filter.
\ \
F \--l
3 . l n s t a ltlh e o i l f i l t e a
sealcontacts the base.
r n dt i g h t e ni t b y h a n d su n t i tl h e r u b b e r
4. Tightenthefilter1 and 1/6turnswitha filterwrench.
No. 3 Engine Mount Bracket

1 . I n s t a ltl h e N o . 3 e n g i n em o u n tb r a c k e t .
9 3 - 1 1 3 N ' m ( 9 . 5 - 1 1. 5 k g - m , 0 9 - 8 3 l b - f t )
ffiN Alternator
1 . l n s t a l tl h e a l t e r n a t osr t r a p .
3 7 - 5 2 N ' m ( 3 . 8 - 5 . 3k g - m , 2 7 - 3 8 t b - f t )
2 . l n s t a l lt h e a l t e r n a t o ar n d t h e a l t e r n a t odr r i v eb e l t . L o o s e l y
t i g h t e nt h e a l t e r n a t o irn s t a l l a t i o bn o l t .
3 . A d j u s tt h e d r i v eb e l td e f l e c t i o n .
T i g h t e n i n gt o r q u e
A l t e r n a t o ri n s t a lfa t i o nb o l t Q .
3 7 - 5 2 N ' m ( 3 . 8 - 5 . 3k g - m , 2 7 - 3 8 rb-ft)
B e l t - a d j u s t i n gb o t t @ :
1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m , 1 4 - 1 9 rb-ft)
-1
I
104-86 {
ENGINE ASSEMBLY
i
l
fntakeManifoldAs_.enrbly
'l Remove
. all foreignmaterial
fror the intakemanirord
tactsurface. con-
2. tnstalla newgasketancithei.takemaniford
assernbry.
1 9 - 2 5f t . m ( 1. 9 _ 2 . 6k g - m ,1 4 _ 1 9t b _ f r )
Distributorand High-tension Lead

t tpply an enginebit to the o-ring,andposition
it on rhe
distributor.
2. Applyan engineoil ro the blade.
3. Installthe distributor
with the bradefit into rhe camshaft
groove.
1 Te.Tpcrarily,loosetytightenthe disiributcrinstatting
bolt.
5. Adjustthe ignitiontimiirgafterthe engine
installation.
6. Connectthe high-tensio-n leads
ENGINE E N G I N ES T A N DO I S I v I O U I ' I T I N G 10A-87
E N G I N ES T A N DD I S M O U N T I N G
PROCE D URE
1. Remove theenEinefromtheSST(enginestand).
Z. Renrove theSST(enginehanger)fromtheengine.
3. lnstalltheparlsshownin thefigure.
1 9 - 2 5N . m
3 7 - 5 2N ' m
( 3 . 8 - 5 . 3k g . m ,2 7 - 3 8 l t - f l )
o o6
N.\/n
\rhi
w GASKETNEW
7 . 8 - 1 1N ' m
(80-ll0kg-cm.
6 9 - 9 5l b - i n )
'19=25
N ' m ( 1 . 9 - 2 . 6k g - m . 1 4 - l 9 l b - n ) l 6 - 2 3 N ' m ( 1 . 6 - 2 . 3k g - m .1 2 - 1 7 l b - l t )
W a t e rl n l e t P i p e
1 . R e m o v ea l l f o r e i g nm a t e r i a lf r o m t h e w a t e r i n l e t p i p e
mountingsurface.
2 . l n s t a lal n e w g a s k e ta n d t h e w a t e ri n l e tp i p e .
1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 9 l b - t t )
3. Applya smallamountof enginecoolantto the new O-ring.

4. lnstallthe waterbypasspipe.
r0 2 7 6
104-88
E N G I N E ENGINESTANDDISI./OUNTING
A / C C o m p r e s s o rB r a c k e t
1 . l n s l a l lt h e f u C c o m p r e s s obr r a c k e f
.
T i g h i e n i n gt o r q u e
@ ' 1 s - 2 sN . m( 1 . s _ 2 .k6g - m 14-1s
, ib-ft)
@ : 37-52N.mis.e_s.3 ,,J_*,27-38 tb_fr)
E x h a u s tM a ni fo l d
1 . R e m o v e a l l f o r e i g nm a t e r i a l
f r o m t h e e x h a u s tm a n i f o l d
contactsurface.
2. Instaila newgaskeiandtheexhaust
rnan;fold.
Tightening torque:
1 6 - 2 3N . m( 1 . 6 _ 2 .k3g _ m ,1 Z _ 1 7
tb-ft)
Exhau.st Manifoldlnsufator
1.fnstalltheexhaustmanifold
ffi7n
insulator.
Tightening
torque:
7.8-11N.m(BO_110
kg_cm,69_95lb-in)
10 2 8 0
ENGINE TNSTALLAIoN 10A-89
I N S T A L L A TN
IO
PROCEDURE
torques'
lightenallboltsandnutsto thespecified
S t e P1
.,lointneengineandthetransmission.
T o r q u eS P e c i f i c a t i o n s
NIIT
i 9 - 2 5 N ' m( 1 , 9 - - 2k. 6
g - m 1, 4 - 1 9 l b ' f i )
3 7 - 5 2N ' m
( 3 . 8 - s . 3k g - m ,2 7 - 3 8 l b - f t )
3 7 - 5 2N ' m ( 3 . 8 - 5 . 3k g - m , 2 7 - 3 E
lb-ft) 6 4 - 8 9 N ' m ( 6 . 5 - 9 . 1k g - m , 4 7 - 5 6 l b ' f t )
1 9 - 2 5N ' m( 1 . 9 - 2 . k6g - m 1, 1 - 1 9 l b ' f t )
--V-
3 7 - 5 2N . m
( 3 . 8 - 5 . 3k g - m ,2 7 - 3 8l b ' l t )
3 7 - 5 2N ' m ( 3 . 8 - 5 . 3k g - m , 2 7 - 3 8l b - f t )
5 5 - 8 0 N ' m ( 5 . 6 - 8 . 2k g ' m . 4 1 - 5 9 l b - f t )
10A-90 ENGINE INSTALLATIoN
Step2
Warning
. Be surethe vehicleis securelysupportedon safetystands.
7 4 - 1 0 3N ' m ( 7 . 5 - 1 0 . k5 g ' m . 5 4 - 7 6l b ' l t )

5 5 - 8 0N ' m
( 5 . 6 - 8 . 2k g - m .4 1 - 5 9l b - f t )
6 7 - 9 3N ' m N'rn
6.8-9.5kg-m,a9-69 lb'tt) , 32-45 tt-lb)
i
)
1
6 7 - 9 3N ' m
(6.8-9.5kg-m,49-69 lb'tt)
10 2 8 1
E n g i n em o u n tm e m b e r
1. lnstall theenginemountmember.
6 4 - 8 9N ' m( 6 . 5 - 9 . k1 g - m, 4 7 - 6 6 l b - f t )
10 2 8 5
ENGINE INSTALT-ATroN 10A-91
E n g i n ea n dt r a n s a x l e
assembly
1. Suspend theengine thetransaxle
and assembly.
Caution
. D o n o t d a m a g ea n y c o m p o n e n t si n t h e e n g i n e
compartment.
2 . A l i g nt h e N o . 1 a n d N o . 2 e n g i n em o u n tb o l t sv r i t ht h e
enginemountmember mounting holes.
$2*
N O . zE N G I N E E n g i n em o u n t
MOUNTNUTS 1.Install mountnutandtighten
theNo.1 engine it.
Tighteningtorque:
37-52 N'm (3.8-5.3kg-m, 27-38 lbft)
theNo.2 enginemountnutandtightenit.
2.Install
N O . 1E N G I N E
MOUNTNUTS
Tighteningtorque:
37-52 N'm (3.8-5.3kg-m, 27-38 lbft)
10287
3. Installthe enginemountrubberwith a new washerand

tightenthenut@.
Tightening
torque:
N
kg-m,54-76lb-ft)
74-103N.mC/.5-10.5
4. lnstallthe bolt@ whilealigningthe enginelocation,

and
tightenthenut@.
Tightening
torque:
67-93N'm (6.8-9.5kg-m,49-69lb-ft)
10288
5. lnstallthedynamicdamper.
Tighteningtorque:
55-80N'm (5.6-8.2kg-m,41-59lb-ft)
6. Installthe No. 4 enginemountrubberand the bracket,

andlooselytightenthenuts@.
7. Alignthebracketboltholeswiththe bodysideholes,and
i n s t a ltlh e b o l t@ , t h e nt i g h t e nt h e mi n t h e s e q u e n c e
shownin thefigure.
Tightening
torque:
43-61N'm (4.4-6.2
kg-m,32-45lb-ft)
NT
8.1ighten
thenuts@.
Tightening
torque:
67-93N'm (6.8-9.5
kg-m,49-69lb-tt)
10290
10A-92
E N G I N EINSTALI-ATION
Step 3
6 . 9 - 1 1N . mO 0 - 1 1 0k g - c m . 6 1 _ 9t 5
b-fr)
7 . 8 - 1 1N . m
6 9 - 9 5l b - i n )
| '.'
q\'
3 1 - 4 6N . m
\\ ( 3 . 2 - a . 7k g . m ,
\,
23-34 tb-ft)
GASKET.NEW
31-46N.m
( 3 . 2 - 4 . 7k g . m .2 3 - 3 4t b - f r )
-59 N'm
3 7 - 5 2N ' m
( 3 . 8 - 5 . 3k g . m ,2 7 - 3 8 t b . f i )
'16-23
N.m
(1.6-2.3 ( 4 . 3 - 5 . 8k g . m ,3 1- 4 2 t b . f l )
k g . m ,1Z - 1 7 b . n )
6 . 9 - 9 . 8N . m
( 7 0 -1 0 0k g - c m 6, 1- 8 7 t b - i n )
Driveshaft
1. Applya greaseto theendof thedriveshaft.
\
Caution
. when instarfingthe driveshaft,be carefut
damagetheoil seal. not to
. Afterthe insta.ilation,
puil the front hub outwardto
confirmthatthe driveshaftis securet/herJ
clip. tylh;
2. Installthedriveshaft
anda newclip.
10 2 9 2
3. Install
thelowerarmball-joint
to the knuckle;
thentighten
thelocknut.
Tightening
torque:
43-59N.m(4.4-6.0kg-m, gZ_43lb.ft)
IV<JJ
ENGINE TNSTALI-ATIoN 104-93
Tie-rodend
thetie-rod
1.lnstal! endtc theknuckle.
Tightening toi'que:
4 2 - 5 7N ' m( 4 . 3 - 5 . 8
k g - m, 3 1 - 4 2 1 b - f t )
2 . I n s t atlhl en e ws p l i pt i n .
1c?gt
Stabilize
r
and
1.Instali adjustthestab'ilizer.
Dimension@ z 17-19mm (0.67-0.75

in)
I0295
Extensionbar ('\4fi')
1. Installtheextensionbarto thetransaxle.
Tighteningtorque:
31-46N.m(3.2-4.7kg-m,23-34!b-ft)
Shift control rod (M/T)

1. Installtheshiftcontrolrodto thetransaxle.
Tighteningtorque:
16-23N.m(1.6-2.3kg-m,12-17lb-ft)
10296
Clutchreleasecylinder(Mff)
1. Installtheclutchreleasecylinder.
Tighteningtorque:
16-23N'm (1.6-2.3kg-m,12-17lb-ft)
2. Setthepipebracketin itsposition
Tighteningtorque
@ : 6 . 9 - 9 . 8N . m( 7 0 - 1 0 0k g - c m , 6 1 - 8t7b - i n )
@ : 16-23N.m(1.6-2.3kg-m,12-17tb,tt)
Shift controlcable(Mf)
ATX
-\rkl\) 1. Installtheshiftcontrolcableto thetransaxte.
{fry Tightening torque:

6 . 9 - 1 1N ' m( 7 0 - 1 1 0
k g - c m , 6 1 - 9l5b - i n )
r0298
10A-94 ENGINE tNSrALu,rloN
Speedometercable
t..lnstallthe .speedomeler
cable
7 . 8 - 1 1N . m ( 8 0 - r 1 0 k g - c m , 6 9 - 9 5 t b - i n )
Exhaustpipe
l.lnstalltheexhaust pipeanda gasket; thenlooselytighten
thelocknuts.'
2. Looselytightenthe bracketbolis.
3.'lrghtenth-elocknut.
Tighteningtorque:
31-46 N.m (3,2-4.7 kg-m,Zg-94lb-ft)
4.Tighten
thebracketbolts.
Tighteningtorque:
r0300 37-52N.m (3.8-5.3kg-m,2Z-gBlb-ft)
Step4
1. Connect
thehosesshownin thefigure.
Cautlon
. Positionthe Lot" clampin the orlginattocation
on the hose,andsqueeze
the ctamplightly
witha largepllersto ensurea goodfit.
G
ltt'
)
(-\/! 5-
'iry.
l';'t
'\-
_-<1
./../
" ' I
|
ENGINE INSTALLATIoN 10A-9s
S t e P5
1 . C o n n e c t h e h a r n e s sc o n n e c t o rssh o r v ni n t h e f i g u r e .
A L T E R N A T O RO I LP R E S S U RSEI V I T C H
THAOfiL€ SENSOR
.I
.(
ISCVALVE
INJECTOR
NEUTRALSy/rTCiJ (l.l/T)
IGNITION
COIL
.\
HEAr
oorte r*'t
\.
l-^n<l?J
WATERTH
')^
{7- lx
n
fl
\
Jr' 7
LgIg{gf _Lr_GHr_s-wrIgU-
-.i I (G
J rA
{ UOUU
NUNO - - - - - J
r
r0302
Step 6
18-27N'm (1.8-?.7kg-m,13-20tb-ft) 2 . 9 - 5 . 9N ' m

(30-60kg-cm,26-52 lb-in)
7.8-11N'm
6
,/
(80-110kg-cm,69-95 lb-in) i
R:
1E
J,GI
86 SOHC
lf,-,|") I
\{z gJ
l
7 . 8 - 1 1N ' m
( 8 0 - 11 0 k g -
cm.69-95
tcZ lb-in)
37-52 N'm
IE\ ./
(3.8-5.3kg-m.27-38 rb-fr)
2 4 - 3 5N ' m
( 2 . 4 - 3 . 6k g . m .t 7 - 2 6 l b - f t )
r0303
104-96 ENGINE InISTALLATIoN
A/C compressor
1 . I n s t a tllh e A / C c o m p i , e s s o r .
2 4 - 3 5 N ' m ( 2 . 4 - 3 . 6k g - m, 1 7 - 2 6 l b - f t )
P/Soil pump and bracket

theP/Soilpumpandthebracket.
1.Install
Tighteningtorque:
37-52 N'm (3.8-5.3kg-m, 27-38lb-ft)
I 0305
Drivebelt
1. lnstallthe P/Sancl/orA/Cdrivebelt.
2. Adjustthedrivebeltdeflections.(Referto page10-7).
CRANKSHAFT,,a/C\
PULLEY CO\4PRESSOR
PUI,.LEY
P/S AND A/C
10305
R a d i a t o ra n d c o o l i n g f a n a s s e m b l y
1 . l n s t a ltl h e r a d i a t oar n d c o o l i n gf a n a s s e m b l y .
7 . 8 - 1 1N ' m ( 8 0 - 1 1 0k g - c m , 6 9 - 9 5l b - i n )
2. Tghten the A/C pipe bracketto the radiator.
6 . 4 - 9 . 3N ' m ( 6 5 - 9 5k g - c m ,5 6 - 8 2 l b - i n )
3 . C o n n e c t h e u p p e ra n d l o w e rr a d i a t ohr o s e s .
Caution
. P o s i t i o nt h e h o s e c l a m p i n t h e o r i g i n a ll o c a t i o no n
t h e h o s e , a n d s q u e e z et h e c l a m p l i g h t l y w i t h a
l a r g ep l i e r st o e n s u r ea g o o d f i t .
4 . C o n n e c t h e c o o l a n tr e s e r v o ihr o s e .
5 . C o n n e c t h e c o o l i n gf a n c o n n e c t o r .
6 . C o n n e c t h e o i l c o o l e rh o s e . ( M I ' )
ENGINE INSTALLAIoN 10A-97
A c c e l e r a t o rc a b l e
1. l n s t a ltl h e a c c e l e r a t ocra b l e .
b y t u r n i n gt h e n u t ( 0 .
2 . A d j u s ti h e c a b l ed e f t e c t i c n
D e f l e c t i o n: 1 - 3 m n t ( 0 . 0 4 - 0 . 1 2i n )
Batteryciuct,batterycarrier,and baitery
duct.
l.lnstallthebattery
7.8-11N'm (80-110kg-cm,69-95lb-in)
,
2. fnsiallthe battery carrier.
Tighterting torque:
7 . 8 - 1 1N ' m( 8 0 - 1 1 0k g - c m 6
, 9 - 9 5l b - i n )
3. lnstallthebatteryarrdtitebatterybi'auket.
r0310
2.9-5.9N'm (30-60kg-cm,26-52lb-in)
StepsAfter lnstallation
1. lf theengineoilwasdrained, fillwiththespecifiedamountandtypeof engineoil.
2. Fillthe radiatorwiththespecified amountandtypeof enginecoolant.
3. lf thetransaxle oilwasdrained, amountandgpe of transaxle
fillwiththespecified oil.
4. Connectthenegative batterycable.
5. Startthe engineandcheckthefollowings ;
(1) Engineoil,transaxle andenginecoolant
o!1, leakage
(2) lgnitiontiming,idlespeed
(3) Operation of emissioncontrolsystem
6. Performa roadtest.
7. Recheck the engineoil andenginecoolantlevels.
10A-98 ENGINE sPEctFtcATtoNS
SPECIFICATIONS
S E R V I C ED A T A
=-
Engine
\ Bs(soHc) B6(SoHc)
II \ |
ittem - \--
4-cycle
Gasoline,
ltrr__
ln-line,4 cylinders
i Cy linderar r an g e m e natn d n u mb e r
I Combustionchamber Multispherical
l Valvesyslem OHC,behdrivenB valves
Displacemenl cc (cu in) 1 , 4 9 8( 9 1 . 4 ) (97.4 )
1,597
Boreand slroke mm (ini 78.0x 78.4(3.07x 3.09) 78.0x83.6(3.07x329)
9.4 oe
ratio
Conrpression
CompressionpressurekPe (kg'orP, - rpm
psr) 1, 3 2 4( 1 3 . 5 1, 9 2 ) - 3 0 0
I
Open BrDcl 14'
IN 50'
Close A BD C
Valvetiming
Open B BD C 52'
EX
Closo ATDC 12'
IN 0:Maintenance-free
Valve clearance mm (in)
EX 0:Maintenance-free
MTX 700-800
ldle speed rpm 700-800(P range)
ATX
lgnitiontinring BTDC 6'-B'
Firingorder 1-3-4-2
T I G H T E N ! NTGO R O U E
E ngi ne N'm (kg-m, lb-ft)
Item -
Cylinderheadcover x Cylinderhead 4.9-8.8(50-90kg-cm,43-78 l b-i n)
CrankshaftmainbearingcaPbolts 54-59 (5.5-6.0,40-43)
Connec t inrgo d c a p n u ts 85 : 29-34 (3.0-3.5,22-25) 86 : 47-50 (4.8- 5. 1,35- 37)
Rear cover x Cylinder block 7 . 8 - 1 1 ( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 l b - i n )
Oil pumpbolts x Gasket 1 9 - 2 5( 1 . 9 - 2 . 61, 4 -1 s )

MBSPbolts x Cylinderblock 1 6 - 2 1 ( 1 . 6 - 2 . 11, 2 - 1 5 )
Oil strainerx Gasket 7.8-11(80-' 110 kg-cm,69-95 l b-i n )

Flywheelbolts 9 6 - 1 0 3( 9 . 8 -1 0 . 5 7, 1- 7 6 )
Clutch cover bolls 1 B - 2 6( 1 . 8 - 2 .,71 3 - 2 0 )
Waterpumpbolls x Cylinderblock 1 9 - 2 5 ( 1. 9 - 2 . 6 ,1 4 - 1 9 )
Tensionerlockbolt 1 9 - 2 5 ( 1. 9 - 2 . 6 ,1 4 - 1 9 )
Timingbeltcover 7 . 8 - 1 1( 8 0 - 1 1 0k g - c m , 6 9 - 9 5l b - i n )
7 . 8 - 11 ( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 l b - i n )
--;
E nginlr ang e rb o l ts I F ro n t
3 7 - 6 3( 3 . 8 - 6 . 4
2 ,7 - 4 6 )
I Rear 1 9 - 2 5( 1 . 9 - 2 . 6 1
, 4 -1 9 )
Spark plug r 5 - 2 3( 1 . 5 - 2 . 31,1 - 1 7 )

Oil pressuresrvitch 1 2 - 1 B ( 1 2 0 -1 8 0 k g - c m ,1 0 4 -15 6 l b - i n )
9 3 -1 1 3( 9 . 5 -11. 5 ,6 s - 8 3 )
i No. 3engin em o u n tb ra c k e t
A l t e r n a l o rs t r a p b o l t s 37-s2 (3.8-s.3,27-38)
I n t a k em a n i f o l d x G a s k e l 1 9 - 2 5( 1 . 9 - 2 . 61,4 -1 s )
ENGTNE
(DOHC85)
A S S E M B L .Y. . . . . . . . . . . . . . . . . . : . . . . . 1 O B -6 6
COMPRESSION 108- 10
DISASSEMBLY . . 1 O B .4 1
ENGINE S T A N DD I S M O U N T I N G . . . .1 O B .9 1
E N G I N ES T A N DM O U N T I N G ........... 1 O B .3 8
ENGINE T U N E - UP R O C E D U R E . . . . . . . 1 O B . 6
I N S P E C T I O/ NREPAIR . . . .1 O B .5 4
INSTALLATION . 1OB. 93
O N . V E H I C LM EA I N T E N A N C. .E. . . . . . . 1 O B .1 1
OUTLINE
B E M O V A .L. . . . . . . . . . . . . . .1 0 8 - 3 1
SPECIFICAT|ONS . . .1 0 8 - 1 0 3
TBOUBLESHOOTIG NG UIDE 1OB. 4
J
I
I
l
_l
_l
I
1 t'
l
-l I
)
J
-l
J
I
I
)
ENGINE oUTLINE 108-3
OUTLINE
s T R U c T U R AVLI E W
S T A I { O A R D1: , 3 3 4k P a( 1 3 . 6k g / c m ' .1 9 3p s i ) . 3 0 r0p n r
INTAKEMANIFOLD
TIGHTEtllNG TOROTJE
in
1 9 - 2 5N . m 1 1 . 9 - 2 .k6g . m ,t 4 - 1 9 t b - f r ) 5
\
(D
I
I
I
\i\
:Y
+>- .-1
Walerpump @
I
Crankshaft
EXHAUSTMANIFOLD
T I G H T E N I NTGO R O U E
3 8 - 4 6N . m( 3 . 9 - 4 . 7k g . m ,2 8 - 3 . 1t b . f r )
DEFLECTION
mm (in)
DRI V EBE L T NEW USED
ALTERNATOR 8 . 0 - 9 . 0( 0 . 3 1 - 0 . 3 5 )9 .0-10.0(0.35-0.39)
P/S, P/S + tuC 8 . 0 - 9 . 0( 0 . 3 1 - 0 . 3 s )9 . 0 - 1 0 . 0( 0 . 3 5 - 0 . 3 9 )
1.lrmingbelt 4 . F r o n to i l s e a l
head
sasket 5 . R e a ro i l s e a l
3:fiffter 6. Engine
108-4 E N G fN E r R o u B L E S H o o t NGGU T D E
TROUBLESHOOTING UIDE
Problern P o s s i b l eC a u s e
D i f f i c u l ts l a ; ' l i n g Action
M a l fu n c ti o rro f e n g i nu-r" tffi
Burnedvalve
Wornpiston,pistonring,or cylinder Replace
R epl aceor repa ir
Failedcylinderheadgasket
llaffunction of fuet ,.yrt", R eptace
R e f e r t o S e c r i o n2 2
Malfunctionof ignitio;;vsffi'
P ooridling R e f c r t o S e c l i o n3 0
Malfunctionof engin.-rul.t"o[l]ffif,'
Mallunction
of Hl-A.
Poorvalve-lo-valve R epl ace
seatcontact
R epl aceor rerai r
l"iles .tli1lu r n t
".9Sg!. R epl ace
l{gltg1glionof fuet sysrem
R e f e r t o S e c t i o n2 2
Ma l fu n c ti o no f i g n i tions
E x c es s lv eoit Oil worklng up l . t e t t o S e c t i o n3 r J
consumption Wornpistonring grooveor stickingpiston
ring
Wornpistonor cylinder Replace
R e p l a c eo r r e p a i r
Oil working down
Worn vatveseal
Wornvalvestem or ouide Replace
Reptace
I ns uf f ic ientpow e r lnsufflclantcompression R e f e r t o S e c t i o n1 1
Malfunctionof Hl_A.
Compression Replace
leakagefromvalveseal
Seizedvalveslem Repair
Weakor brokenvatvespring Replace
Failedcyfinoerheadgasker Replace
Crackedor dislortedcylinderhead Fleplace
Sticking,damaged,or wornpiston Replace

ring
Crackedor lvornpiston Replace
Malfunctionof fuel system Replace
Ma l fu n c ti o no f i g n i ti o n,yG f{"r to Section22

Others R eferto S ecti on30
Slippingclutch
Draggingbrakes R e f e r t o S e c t i o n4 0
Wrongsize tires R e f e r t o S e c t i o n5 2
MatfunctionoI engino-rol.tuolipoilill
Malfunction of Ht-A.
Stickingor burnedvatve Replace
Weakor brokenvalvespring Replace
Carbonaccumulation Replace
in combustion
chamber E l i m i n a t ec a r b o n
Ma l fu n c ti o no f fu e l s y stem
Ma l fu n c ti o no f i g n i ti o nffi R e f e r t o S e c t i o n2 2
E N G I N E T R o U B L E S H o o I NG
GU I D E 108-5
Problem P o s s i b l eC a u s e Action
l--l i
norse
tnn,ne C ra n k s h a fto r b eari ng-rel ated
parts
Excessive mainbearingoil clearance Replace or rep'air
I
I Mainb e a
Excessive
ri ng
s e izedor heat-damaged
crankshaft
endplay
Replace
Replace or regair
Excessive
connecting
rodbearingoil clearance R e p l a c eo r r e p a i r
Connecting rodbearinqseizedor heat-damaqed Replace
P i s to n -re l a tepdarts
Worncylinder R epl aceor re pair
Wornpistonor pistonpin R epl ace
Seizedpiston Replace
Damagedpistonring R epl ace
Eenlconnecting
rod Replace
Valvesor timlng-relatedparts
Malfunctionof Ht-{' Replace
Brokenvalvespring Replace
Excessivev?lveguideclearance R epl ace
Ma l fu n c tl o no f c o ol i ngsystem R eferto S ecti on12
Ma l fu n c tl o n
o f fu el sysl em Referto Section22
Olhers
Mallunction
of waterpumpbearing R eferto S ecti o n12
lmproperdrivebelttension Adjust
Malfunction
of alternator
bearing Referto Section32
Exhaustgasleakage R eferto S ecti o n21
Malfunction
of timingbelttensjoner Replace
' Tappelnoisemay occurif the enginehasset idlefor an extendedperiod.The noiseshoutdbe dissipated
afterthe engine
has reachedthe normaloperatingtemperature.
108-6 E N G I N E E N G I NTEU N E . UPPR O C E D U R E
E N G I N ET U N E - U PP R O C E D U R E
PREPARATION
SST
0 K201189063 For
inspection of
KJ.1 ignitiontiming
and idlespeed
ENGINE OIL
lnspection
1.Be surethevehicleis on a levelground.
temperature
2. Warmup the engineto the normaloperating
andstopit.
3. Waitforfiveminutes.
4. Removethe oil levelgaugeand checkthe oil leveland
condition.
5. Addor replacean oil if necessary.
't08002
ENGINE COOLANT
lnspection
f\ C o o l a n tl e v e l( e n g i n ec o l d )
Warning
. Neverremovethe radiatorcapwhilethe engineis
hot.
Wrapa thickclotharoundthecapwhenremovingit'
1.Verifythattlrecoolant fillerneck.
levelis neartheradiator
2. Che6kif the coolantlevelis betweenthe "F" and "Lnon
108003 thecoolantleveldiPstick.
ry C o o l a n tq u a l i t y
1.Verifythatthereis no buildup
theradiator capor radiator
2.Ventythatthecoolantis freeof oil.
3. Replace
of a rustor a scalearound
fillerneck.
thecoolantif necessary.
BSX021006
D R I V EB E L T
V.BELT Inspection
1 .C h e c k t h e d r i v e b e l t f o r w e a r , c r a c k s ,a n d f r a Y i n g .
R e p l a c ei f n e c e s s a r y .
pv-lornted
2 . Y e r i f yt h a t t h e d r i v e b e l t s are correctl5r on the
pulleys.
V R I B B E DB E L T
MtMtM
X o X
ENGINE ENGINE
TUNE-UP
PRoCEDURE 108-7
3 . c i r e c k t h e d r i v e b e l t d e fl e c t i o nb y a p p l y i n ga m o c J e r a t e
WA.TER
PUMP pressu:'e(98 N, 10 kg, 22 lb) to the mid'ryay betlveenthe
PULI-E'/ pulleysas shown.Adl'.ls1 the Ceflection if necessary.
D e fl e c r i o n . rnm (in)
ALTERNATOR
D A I V EP U L L E Y Drive belt
Alternator 8.0-9.0
't 9 . 0 -1 0 . 0
(0.31-0.3s) (0.3s- 0. 3e)
DRIVEBELT
ALTERNATOA
8.0-9.0 9 . 0 -1 0 . 0
-0.ss)
(0.31 (0.3 s- 0. 3s)
PiS OIL PUI,IP

ur1rvtr c'trLl
4. Checkthedriveb'elttension
witha tensiongauge.
Note
. A belttersioncanbe measured
on the midwaybetween
anypulleys,
WHSNSET
Tension N (kg, lb)
D ri vebel t New Used
Alternator 383-461 304-383
WHENMEASUREO
(39-47,85.8-103.4) ( 3 1 - 3 9 6
, 8.2-85.8)
108008 P/S,P/S+AIC 4 9 1- 5 8 9 422-491
(50-60,110-132) (43-509
, 5 -1 1 0 )
Adjustment
Caution
. lf a new belt is used,adjustthe belt deftectionat
the midpointof newbeltspecification.
1.Alternator
belt
(1) Loosenthe alternator
mountingbolt@ and adjusting
lockbolt@.
(2) Leverthe alternator
outward,and applya tensionto
loBo'c€ thebelt.
(3) Ighten theadjusting
lockbotr@.
Tighteningtorque:
19-25N'm (1.9-2.6kg-m,14-19tb-ft)
(4) Ighten themounting

bott@.
37-52 N'm (3.8-5.3kg-m, 27-38 tb-fr)
(5) Recheck
thebelttension
or deflection.
108-8 ENGINE EruCIruE PROCEDURE
TUNE-UP
2- pts bett,P/s* A/c belt.

(1) Loosenlhe P/Soilpumpbolt@ andthenuts@, O.
(2) Adfusttlrebeitterrsion turningihe
and deflection.by
adjustingbolt@.
(3) l rghtentheadfustinglocknut@ andtheP/S.oiipump
bolt@ andnutO.
Tighteningtorque:
@ : 36-54N.m(3.7-5.5kg'm,27-4Alb-tt)
@ : 19-25N.m(1.9-2.6kg-m,14-19lb-ft)
@ : 31-46 N.m(3.2-4.7kg-m,23-34|b'ft)
Problem P ossi bl eC ause A cti on

1. Tappetnoiseoccurswhen engine
afterengineoil
startedimmediatgly
replaceme;rt
2. Tappetnoiseoccurswhen engine
starledaltersettingmorethan one
day No oil in HLA withina
Tappetnoiseshouldbe dissipated
3. Tappetnoiseoccurswhenengine lew secondsto ten minutes
startedaftercrankingby starlermore
thanthreeseconds
4. Tappetnoiseq:curs when engine
:
startedafterHl-{ replaced
5. TappetnoisEconlinuecmore lhan len Low oil pressure Checkoil pressure
minules DelecliveHLA lnspectHl3
6. Tappetnoiseoccursat idle high- Low oil level Add engineoil
speeddriving Degenerated oil Replaceengine oil
E N G I N E E N G I NTEU N E . UPPR o c E D U R E 108-9
I G N I T I OTNI M I N G
1. Warmup theengineto normaloperating temperature.
2.Turnaflelectric loadsOFF.
3 . B y u s i n ga j u m p e rw i r e ,c o n n e ctth e e n g i n et e s ta n d
groundlerminals in thediagnosis connector.
4.Connect thetiminglight.
5. checkif the timingmarkon thecrankshaft

pulteyand the
markon thetimingbeltcover arealignccl.
t g n i i i o nt i m i n g: 8 " + 1 ' B T D C( a ti d l es p e e d )
r08012
6. lf the marksare not aligned,loosenthe distributor

lock
boltsandturnthedistributorto maketheadjustment.
7.Tightenthedistributorlockboltsto thespecified
torque.
Tighteningtorque:
19-25N'm (1.9-2.0kg-m,14-19tb-fr)
LOCKBOLTS
I D L ES P E E D
1.W"rr up theengineto thenormaloperatingtemperature.
2.Tumall electricfoadsOFF.
3.By usinga jumperwire,connectthe enoinetestand the
groundterminalsin thediagnosis
connecjor.
4. Connecta tachometor.
5.Applya parkingbrakeandshiftthe transaxle
in "P"or "N"
range.
6 . C h e c kt h a tt h e i d l es p e e di s w i t h i nt h e s p e c i f i c a t i o n .
l d l e s p e e d( N e u t r a o
l r P r a n g e ): 7 5 0 f 5 0 r p m
Caution
. c h e c k t h e .i d l e s p e e d w i t h o u t t h e e l e c t r i cc o o l i n g
fan operating.
7 . l f n o t w i t h i n t h e s p e c i f i c a t i o na,d j u s t t h e i d l e s p e e d b y
tumingthe air adjustingscrew
108-10 ENGINE coMPRESStoN
C O M P RE S S I ON
exhibits
lf theertgine p o o rf u e le c o n o m yo, r p o o ri d l e ,c h e c kl h e f o l l o w i n :g
loivPower,
1. lgnition
system
2. Compression
3. Fuelsystem
INSPECTION
1.Checkthatlhe batteryis fullycharged.Recharge it if
necessary.
2. S/armup theengineto thenormaloperatingtemperature.
3. TurntheengineOFF.
4.Remove allsparkplugs.
5. Disconnectthe ignitioncoilconne.ctor.
t0g0l 5
6. Connecta compression gaugeto the No.1sparkplug

hole.
pedalandcranktheengine.
7. Fullydepresstheaccelerator
B.Recordthemaximum gaugereading.
9. Checkeachcvlinder.
Compression:
1,334kPa(13.6kg/cmz,
193psi)-300
rpm
r c B cI 6
10.lf thecompression in oneor morecylindersis lovr,poura

smallamountof engineoil intothe cylinder and recheck
thecompression.
(1) lf thecompression the piston,pistonrings,
increases,
or cylinderwallmaybe worn.
(2) lf the compression stayslow,the valvemay be stuck
or seatingimproperly.
(3) lf thecompression in adjacent
cylinders
stayslow,the
cylinder headgasketmaybe defective or thecylinder
headis distorted.
11. Connect theignition
coilconnector.
1 2 .A p p l y a n a n t i s e i z ec o m p o u n do r a m o l y b d e n u m - b a s e d
l u b r i c a ntto t h q s p a r kp l u gt h r e a d s .
1 3 . l n s t a ltl h e s p a r kp l u g s .
w
1 5 - 2 3N ' m ( 1 . 5 - 2 . 3k g - m ,1 1 - 1 7 l b - f t )
E N G I N E o N . v E H t c LM
EATNTENANcE 108-11
l C t - EM A I N T E N A N C E
ON - V E H
PREPARATION
5ST
111001
.Wl
0 K 1 3 01 1 10 0 4 For
I r e m o v a la n d
l::'*n' a*-.
removal and
loxzol
H o t d g r ,c o u P l i n g installationof i n s t a l l a l i o no l
flange timing belt pulley t i m i n gb e l i p u l l e y
0 K 5 9 01 1 10 0 1 For 0 K 1 3 01 6 00 1 0 For
prevention
of i n s i a l l a t i o no f
Brake,ringgear enginerotation C enteri ng
tool , c l u t c f rd i s c
clutchdisc
-
108-12 ENGINE oN.VEHIcLE
MAINTENANoE
T I M I N GB E L T
R e m o v a/l I n s t a l l a t i o n
7.8-ll N.m
lr
( 8 0 - 1 1 0k g . c m 6, 9 - 9 5t b . i n ) ':t
@'/ \\
ii (,
37-5? N . M I I
(3.8-5.3kg-m,27-33 th.fr)
\
7.8-ll N.m 7.8-ll N.m

(80-lt0 kg.cm,69-95 tb.in) (80-110
kg.cm.
6 9 - 9 5|
-#ryd
7 . 8 - 1 1N . m
( 8 0 - 1 1 0k 9 -
cm, 69-95
lb-in)
37-52 N.m
(3.8-s.skg-m.27-38 tb_f$
( 8 0 -| l 0 95 lb-in)
w @
t;
I
I
1. Undercover andsidecover 9. liming beltcover,middle

F
a
2. P/Sand/orA/C drivebelt
3. Alternator 10.Tmingbeltcover,lower
drivebelt 11.High-tension
4. Waterpumppulley lead
5. Crankshaft 12.Sparkplug
pulfey 13.Tmingbelt
6. Lockbolt
7. Pulleyboss 14.Tensioner,tensionerspring
B.llmingbeltcover,upper 15.fdler
ENGI N E orl-vEHtcLE
MAINTENANcE 10 B - 1 3
Removalnote
Timingbelt
1. Turnthecrankshaft
andalignthemarks.
Note
. M a r k t h e t i m i n g b e l t r o t a t i o nf o r t h e p r o p e r
reinstallation.
t08020
2. Loosenthetensioner
lockbolt.
Caution
. To preventdamageto the tensioner,secureit vlith
a rag.
3.Temporarily
securethe tensionerby fuilyextendingthe
spring.
4. Removethetimingbelt.
t0802|
Installationnote
Tensloner, tensionerspring
1. Installthelensioner
andthetensioner
spring.
-extending
2. Temporarily securethe tensioner
by rirtty the
spnng.
1080z2
Timingbelt
1.Verifythatthetimingbeltpuileymarkis aligned
withthe
timingmark.
108-14 E N G I N E O I V . V E H I c LMEA I N T E N A N c E
2.Veri\ thatthecamshaft putleymarksarealigned

rviththe
\
\ s e a lp l a t em a r k s ,
T,i)
-a'-2.
3. Installthe timingbeltso thatthereis no looseness

at the
idlersideor betweenthetwocamshaft pulfeys,
Caution
. Do not turn the crankshaftcounterclockrvise.
4. Turnthe crankshafttwo turnscroclcwise, and align the

_ timing beltpulleymarkwiththe timing
mark.
5. Verifythatthe.camshaft pulleymarkJarealignedwith'the
sealplatemarks.
ff no] aligned,removethe timingbeltand repeatfromthe
tensioner installation.
6. Turn the crankshaft1 and 5/6 turn cloclcwise,
and align
thetimingbeltpulleymarkwiththetensionset mark
o\s(pf. YVi ,-\6
7. Loosenthe tensioner
lock boltto applya tensionto the
timingbelt.
8.lightenthetensioner
lockbolt.
Tighteningtorque:
37-52 N'm (3.8-5.3kg-m,27-38 lb-ft)
9. Turnthe crankshaft
2 and1/6iu'rnsclockwise
and verifu
thatthetimingmarksarecorrectly
aligned.
r09027
1 0 .M e a s u r e t h e t i m i n g b e l t d e f l e c t i o n b y a p p l y i n g a
O E F L E C T I OC
NH E C K I N G
POINT moderatepressure(98 N, 19 Xg, 22 lb) to the midway
- betweenthe two camshaftpulleys.
lf the deflectionis not correct,repeatfrom step 7 above.
D e f l e c t i o n:
9 . 0 - 1 1 . 5m m ( 0 . 3 5 - 0 . 4 i5n ) a t 9 8 N ( 1 0 k g , 2 2 t b )
ic302a
ENGINE oll-veHtcLEMATNTENANcE 108-1s
Sparkplug
1.Applyan antiseize compoundor a molybdenum-baseo
lubricantto thesparkplugthreads.
tlresparkpli.;gs.
2.Install
Tightening
torque:
15-23N.m(1.5-2.3kg-m,11- 17 tb.tt)
AflerInstalfationstePs
i. Connectthe negative batlerycable.
z. Stariihe engineandclreckthefollowing
items;
. lgnitiontiming
108-16 ENGINE oru-veHtcLE
MATNTENANcE
CYLINDERHEADGASKET
Replacement
Warning
. Releasethe fuel pressure.
. Keepsparksand openflamealray trom the fuelarea,
Caution
' rocation
orthehose'
andsqueeze
thecramp
rishtry
iitflt:::,$"r?':f 3:T3,[:T;'i1n€r
1. Disconnect thenegativebanerycable.
2. Draintheenginecoolanl.
3. Bemovein theordershownin theligure,reterring to theFlemovalNote.
4' Installin thereverseorderof a remo,-val,
refening-to
ttreInsialationNote.
4.9-8.8N.m
(50-90 kg-cm.43-78 tb-in)
7 . 8 - 1 1N . m
(80-110kg-cm.6!-95 tb-ln)
(80-110 kg-cm,69-95 ttsin)
7 . 8 - 1 1N . m
(80-110kg+m. 69-95 tb.in)
o
@
(8G.ll0rgcrq -
6s-ssrbh) @
7 . 8 - 1 1N . m
(80- I 10 kg-crn,69-95 lb-in) /
\ -q,a\
3w (^
@ x
@ \
7d .8-11N.m
t"5gP'iflf-'
lo'
io8:i i #*T*n.,,
6e-e5*rin)
N'm (kgrm, tFft)

ENGINE oN-vEHtcLE
MAINTENANcE 108-17
siciecover
t. Unciercove(and 1 2 .W a t e rp u m p p u l l e y
chamber 1 3 .I r m i n gb ' e l tc o v e r ,u p p e r
2-.Resonance
3. Airhose 1 4 . l l m i n gb e l tc o v e r m , iddle
q. Acceiei'atorcable 1 5 .T l m i n gb e l t
S. Tnrottlecable (NT) 1 6 .F r o r ret x l r a u spt i p e
O.nign-t"nsionlead 1 7 . I n t a k em a n i f o l db r a c k e t
7. Hoses 1 8 .C y l i n d e h
r e a dc o v e r
8. Hamesses 1 9 .C y l i n d e h
r e a db o l t
9. Water bYPassPtPe 2 0 . C y l i n d eh
r ead
10. P/S and/orArC drive belt 2 1 . C y l i n d ehr e a dg a s k e t
11. Altematordrive beft
R e m o v a l/ I n s t a l l a t i o nn o t e
Hoses
1. Disconnectthe hoses shown in the figure.
BRAKEVACUUI"IHOSE VACUUMHOSE
( P U R G EC O N T R O L )
\
-\
\\
FUELHOSE
/.
ATERHOSE
WARNING
. KEEP SPARKS AND OPEN FLAME AWAY FROM
THE FUEL AREA.
CAUTION
. COVER THE HOSE WITH A RAG BECAUSE
FUEL
WILL SPRAYOUT WHEN DISCONNECTING.
. PLUG THE DISCONNECTED HOSES TO AVOTD
THE FUEL LEAKAGE
10F.18 ENGINE oIv.veHIcLEMAINTENANcE
Harnesses
1. Di-econnect
lhe harrress
connectors
shownin thefigure.
THROTTLESENSOR
,SCVALVE
OISTRIEUTOR
oxYGEN
Seruson
\ cauceUrur
Water bypass plpe,
*lffifi;
I Hffi||i]|"tffi-:l.^Y,g{f Trt* $o* inthengure.
;il:I'i,.,lff,11,il,i
3:ffillf in::t" ilBlil
t.l:,ggr^"^,thewareruypasso'oJ'rlJ;"fi:T,,ff
assembty.
Tming belt
Note
' Remove all spark plugs
for easier rotation of
crankshaft. the
1. Tum the crankshaftand alignthe marks.

ENGINE oN-vEHtcLE
MATNTENANcE 108-19
2. Locserrthe tensionerlockbolt.
Caution
. To prevent damage to the iensioner,secure it with a
rag.
3. Temporarily
securethe tensionerby fullyextendingthe spring.
Caution
. Do notallowanyoil or greaseon thetlmingbelt.
4. Removethetimingbeltandsecureit ouiof thewayto prevent

a clamagedunnga removaland an installation
of the ryrinder
head.
Cylinderhead bolt
i. Loosenthe cylinderhead boltsin the ordershownin the
figure.
2. Flemove therylinderheadbolts.
Installationnote
Cylinderhead bolt
1. AppVa deanengineoilto the bottthreadsandtheseatfaces.
2. Installthe
cylinderheadbolts.
3. Tightenthe cylinderheadboltsin the ordershownin the
figure.
Tighteningtorque:
76-81N'm(7.7-8.3kg-m,56-G0
tb-ft)
ro803{t
Cylinderheadcover
l.Appty a siliconeseafantto the shadedareasas shownin the
figure.
2. Installthe
cylinderheadcover.
Tighteningtorque:
4.9-8.8N'm(50-90kg-cm,43-78lb-in)
108-20 MAINTENANcE
ENGINE oru-veHlcLE
Timing belt
1 .C h e c kt h a t t h e i g n i t i o nt i r n i n gm a r k ( y e l l o w )o n t h e
crankshaft putleyand the timingmark on the tirningbelt
coverarealigned.
2. Veri.! thatthe camshaftpulleymarksa.realignedwith the

sealplatemarks.
Caution
. For the intakeslde, allgn the I mark
. For the exhaustside, allgn the E mark.
3. Installthe timingbelt so that thereis no loosenessat the

U ,f?=\.'/r/ idle:'sideor betweenthc two camshattpulleys.
/
v/,,tTWOTURNS
\ CLOCKWISE Caution
, Do not turn the crankshaft countercloclcwlse.
4. Turn the crankshafttwo tums clochrise, and align the

timingbeltpulleymarkwiththe timingmark.
5. Veritythatthe camshaftpulleymarksare alignedwith the
sealplatemarks.
lf not aligned,removethe timingbelt and repeatfromthe
r0go.? tensloner installation.
6. Tum the crankshaft1 and 5/6 tums cloclcwise, and align
thefourthtoothfromtho I.T"tk with the seal platemad<.
1080€
7. Loosen the tensioner lock bolt to apply a tension to the
% timingbelt.
8. Tightenthe tensionerlock bolt.
Tighteningtorque :
37 -52 N'm (3.8-5.3 kg-m, 27 -38 lbft)
9. Turn the crankshaft2 and 1/6 turns clockwiseand verify

thatthe timingmarks are correctlyaligned.
--/.'
ENGINE oI'I.vEHICLE
MA{NTENANcE 108-21
10.Measure ihetimingbeltcjeflectionby applving

a moderate
oerlEc@ pressure(98N, 10 kg, 22 lb) to the miciway betweenthe
two camshaft pulleys.
lf the deflection
is notcorrecl,repeatfromstep7 above.
ffiB
'Def
lection:
9.0-11.5 mm (0.35-0.45 in) at gBN (10kg,ZZlb)
r0BO15
Harness
1.Connecttheharness
connectors.
Hose
1.Connectthehoses.
Accelerator cable
1. Instaflthe accelerator
cable.
2. Check the acceleratorcabledeflection.
lf the deflectionis not correct,adjust the deflectionby
tuming
nut@.
Deflection
: 1-3 mm(0.04-0.12
in)
Steps After Installation

1. Filltheradiator*il! t9 specified
amountandtype
' of enginecoolant.
2. Connectthe negativebatterycabfe.
3. 9.Ft tre engineandcheckfre followingitems;
(l) Fngineoilandenginecootanr teakale
(2)lgnitiontiming,idtespeed
LSI Operation of emission
controlsTstem
4. Recheck theenginecoolantlevels.
108.22
ENGINE oT,I.veHIcLE
MAINTENANcE
HI.A
Removaf/ lnstatfation
1. Disconnect
the negativebatterycable.
3 Instau
3. in,rior*,referrins
fl:lny;.,lLrl:,,:l*,^rl.^yiji torheRemovat Note.
inrhereverse orderof ;;dftffi::,ffffilXJlil?;.
";;;;'r;r,
1 1 . 3 - 1 4 .N 2 .m . 4 . 9 - 8 . 8N . m
( 1 . 1 5 - t . 4 Sk g - r n 1
, 0 0 - 1 2 6t b - i n ) (50-90 kg-cnr,a3-78 lb-in)
7 . 8 - 1 1N - m
( 8 0 - 1 1 0k g - c m , '
69-95 tb-in) ,..0-3.n,u.|-ou,o,.rN
t Eqry
7.8-11N.m
( 8 0 - 1 1 0k g - c m ,
69-95 lb-in)
F
O.RINGREPI-ACE
T:
19-25 ( 1 . s - 2 . 61, 4 _ 1 9 )
7 . 8 - ' t 1N . m
( 8 0 - 11 0k g - c m 6
. 9-95tb_in)
N'm (kg-rn,tb-n) |
1. High-tensionlead
2. Distributor B.Timingbelt
3. P/S and/orA/C drivebelt 9. Cylinder headcover
4. Alternatordrivebelt 10.Camshaft pulley
5. Waterpumppulfey 1 1 .S e a p
l late
12.Camshaft
I lrlng beltcover,upper
r. lr-t-lrflgbelt cover, middfe 1 3 .H L A
ENGIN E or.t-vEHrcLE
MATNTENANcE 108-23
C a m s h a f tp u l l e y
1. Hold the camshaftwith a wrench.
2. Removethe camshaftpulleylock bolt.
3. Removethe camshaftpulley.
Camshaft
1.Loosenlhe camshattcap bollsin the ordershownin the
figure.
2. Removethe camshaft€ps.
3. Removethe camshaft.
4. Removethe carnshaft
oii sealfromthecamshaft.
HLA
Caution
. Mark the HLA with a felt pen so that they can be
reinstalledin the position from which they were
removed.
1. Removethe HLAfromthe rylinderhead.
Installationnote
HLA
1. Applya cleanengineoil to the frictionsurfaces.
2. lf the Hl-A are beingreused,installthem in the position
from whichthey wererernoved.
3. Verifythatthe HLAmovesmoothlyin theirbores.
r0805r
Camshaft
Note
. The intake camshaft is grooved for the tiistributor
drive.
1- Apply a clean engineoil to the camshaftjournatsand the

bearings.
2. Installthe camshaft in position.
DISTRIBUTOR
DRIVEGROOVE
10B.24 ENGfNE oru-veHfcLE ,
MAINTENANcE
Caution
I . , any seatanton the camshaftjournal
3;#::l],"*
, S.Appjya siriconesearantto theshaded
areasshownin the
a
a
4. Instailthe camshaftcaps according

to the cap number
and the arow mark.
5. Instailthe carn;ha.itcap bortsand

tightenihem in the
Tighteningtorque :
11.9-14.2N.m (1.1S_1.45
kg_m,100_126tbin)
6' Applya smallamountof cteanengine

oif to the fip of a
new camshaftoil seal.
7. Pushin the oitseatslighilyby hand.
Caution
. The oir searmust be tapped in
untir it Is frush with
the edge of the camshati
""p.
B.Tap in the oir sear evenrywith a
suitabrepipe and a
hammer.
Oil seal outerdiameter: 4g mm (1.g9

in)
Camshaftpulley
'1.Turn the camshafts
untirthe camshaftdowerpins face
straightup.
2. Instailthe camshaftpuileyswith
the r mark
- (intakeside)
or the E mark(exhaustside)straightup. "
ENGINE oN-vEHtcLE
MATNTENANcE 108-2s
pulleylockbolts.
3. lnstallthe camshail
4. Holdthecamshait witha wrench.
5.f ightenthecamshatt pulleyfockbolt.
Tighteningtorque:
49-51 N.m(5.0-6.2kg-m,36-45 tbft)
r08038
Distributor
1.Applya'greaseto a newO-ringandthe btade.
2.Installthe andloosely
distributor tightentheinstaflation
bolt.
3. Connectthe distributor
connector.
108059
Steps After Installation

1. Connectthenegativebatterycable.
2. Startthe engineandcheckthefollowing
items;
. lgnitiontiming.
108-26 ENGI NE OII.VeHIcLEMAINTENANcE
FRONTOIL SEAL
Replacement
1. Disconnect the negativebatterycable.
2. Remove in the ordershownin lhe figure,referring
to the RemovalNote.
3. lnstallin the reverseorderof a removal,refeningto the InstallationNote.
r08O€O
1.Tmingbeftcover. 4.'l'imingbelt.
2. Pulleylock bolt. 5. Timing belt pulley.
r.Pulleyboss. 6. Oil seal.
Removal note
Pulley lock bolt
1. Hold the timingbelt pulleywiththe SST.
2. Connectthe SST and loosenthe pulleylock bolt.
3. Remove the pulley lock bolt.
E N G f N E o N - v E H t c L EM A I N T E N A N c E 108-27
T i m i n gb e l t o u l l e y
Note
. l f n e c e s s a r y ,r e m o v e t h e p u l l e y w i t h a s t e e r i n g
r v h e e lp u l l e r( c o m m e r c i a l l ya v a i t a b l e ) .
1 . R e n t o v et h e t i m i n gb e t tp u l l e y .
2.Removethe puileyWoodruffkey.
10050
OIL SEAL LIP O i ls e a l

1. Cutthe oil seallipwitha razorknife.
2. Removethe oil sealwitha screwdriver whichis protected
witha rag.
Installationnote
Oilseal
1.Applya smaltamountof cleanengineoil to the lip of
a
newoil seal.
2. Pushin theoil seatstightty
by hand.
Caution
. The oil seal must be tapped in untit it is ftush with
the edgeof the oil pump body.
3. Tapin theoilsealevenlywitha suitablepipeanda
hammer.
Oil sealouterdiameter: 44 mm (1.73in)
Timing belt putley

1. Installthe timingbettpulley.
2. Install.th" pulleywoodruffkey with the taperedside
towardthe oil pumpbody.
Pulleylock bott
1.Instafl
thepulleylockbolt.
2.'lTghtenthepulleylockboltby usingthe two sSTs.
Tighteningtorque :
157-166 N-m.(16.0-17.0kg-m,115_123 tb-ft)
StepsAfter Instatlation
1.Connectthenegativebatterycable.
2. Startthe engineandcheckthe followingitems;
. lgniliontiming.
108-28 ENGI NE oru-vEHtcLEMATNTENANcE
REAR OIL SEAL

Replacement
1. Disconnect batterycable.
the negative
2. Removein the ordershownin the figure,referring to the Removalnote.
3. Installin the reverseorderof a removat,referringto the InstallationNote.
18-2611.8-2.7,13-20)
gEr
96-f03 (9.8-r0.5,
71-76i
rqlll
REPL.ACE 96-103
(9.8-.10.5.
7r -76)
1.Transaxle. 4. Driveplate(ArD
2. Clutchcover,clutchdisc (M/T) 5.Oilseal
3. Flywheel(M/T)
Removal note
Flyvheel (MrD
1. Hold the flyvvheel
with the SST.
@
2. Remove the flyvvheellock bolts.
3. Removethe flpruheel.
EgI@
r0006a
E N G I N E O N - V E H I C LMEA I N T E N A N C E 108-29
Drive plate (Mf)

1. Holdrhedriveplatewiththe SST.
2.Removethedriveplatelockbolts.
3. Removethebacking plate,driveplate,andadapter.
r06069
Oil seal
1.C.utthe oil seallipwitha razotknife.
2. Removethe oil seal with a screwdriverprotectedwith a
rag. '
OIL SEALLIP
lnstalfationnote
Oil seal
1.Applya smallamountof cleanengineoil to the lip of a
newoil seal.
2. Pushin theoilsealslightlyby hand.
Caution
. The oil sealmust be tappedin until it is flush with
the edgeof the rearcover.
3. Tapin theoilsealevenlywitha suitablepipeanda hammer.

r0B07l
Oil seal outerdiameter: 100mm (3.94in)
Flywheel(MrD
APPLYSEAI.ANT
1. Removethe sealantfrom the flyruheelbolt holesin the
(-)ll
fromthe flywheelbolts.
crankshaft'and
r I l@lELiltr I
! | trEu5ttrl
f-{ nltrilnnu Caution

t_-f . lf all the previoussealantcannotbe removedfrom
a bolt, replacethe bolt.
. Do not applya sealantif a new bolt is used.
t08072
2. Set the flywheelontothe crankshafl.

3.Applya sealantto theflyrheelboltsand installthem.
4. Holdthe fly,vheelwiththe SST.
5.Tightenthe boltsin the ordershownin the figure.
Tighteningtorque:
96-103N'm(9.8-10.5
kg-m,71-76lb-ft)
108-30 ENGINE oI,I.veHrcLE
MAINTENANcE
Drive plate (A/f)

1.Removethe sealantfrom the driveptate
holes in the
crankshaftand fromthe drivepfatelockbolis.
Caution
lf allJhepreviousseatantcannotbe removed
a boft,replacethe boll from
Do not appfya searantif a newbortis
used.
10807.
2. Set the adapter,drive plate,and

plateontothe
crankshaft.
9. flpplv.aseatant.torhe.drivep,l1teborrsand instauthem.
4. Holdthe driveplatewiththe'SST.
5. lTghtenthe boltsin the ordershownin
the figure.
Tighteningtorque :
96-103 N.m (9.8_10.5kglm, T7_76tbft)
After lnstallation steps

1. Connectthe negativebatterycabfe.
2. start the engineand per{ormthe engineadjustments
as necessary.
ENGINE REMoVAL 108-31
REITIOVAL
W
'.'Ad"ise
arning
the fuel Pres.sure'
PROCEDURE
negativebatterycable'
t.'-Dir.onnectthe
; Orainthe engine coolantand the transaxleoil.
irrthe shown in the figure,refer;'ing
orcjer to the Removal Note.
A'. Remove
SteP 1
?
4..i
1v
[ -/f\
,l\7 ll
I lv I
ar g
N
,(
O
ro8076
1. Undercoverand side cover 9. Oil coolerhose (Mf)

2. Air hose 1 0 .C o o l i n gf a n c o n n e c t o r
3. Air cleanerassembly 1 ' l. R a d i a l o ra n d c o o l i n gf a n a s s e m b l y
4. Battery 1 2 . D r i v eb e l t
5. Batterycarrier 13. P/S oil pump
6. Acceleratorcable 14.NC compressor(if equipped)
7. Radiatorhose
B. Coolantreservoirhose
Rernovalnote
Caution
. Do not damagethe hoses.
1. Removethe P/S oil pumpand the bracketwiththe hoses

stillconnected.
2. Positionthe pumpawayfromthe engineand affixit witha
wire.
A/C compressor
Caution
. Do not damagethe hoses.
1 .F e m o v e t h e A / C c o ! ' n p r e s s ow! 'i t h t h e h o s e s s t i l l

connected.
2. Positionthe compressor awayfromthe engineand affixii
witha wire.
S t e p2
the harnessconnectorsShownin thefigure.
1. Disconnect
r:40;9
1 . l g n i t i o nc o i l 7. ISCvalve 13. Neutralswitch (Mff)

2 . O x y g e ns e n s o r B. Throttlesensor 14. Backup light switch (il rf)
3. Distributor 9. Alternator 15. Inhibitorswitch (A/f)
. 4 .W a t e r t h e r m os w i t c h 10. Oil pressureswitch 16. Solenoidvalve (Aff)
5 . E n g i n eg r o u n d 1 1. S t a r t e r
6. lniector 12 . G r o u n d
ENGINE REMbVAL 108-33
S t e P3
hosesshownin ihe figure.
i.--Oirronnectthe
BRAKEVACUUMHOSE PURGECONTROLVACUUMHOSE
\
\
\\
WATERHOSE
Removalnote
Fuel hose
Warning
. Keep sparks and open flame'awayfrom the fuel
area.
Caution
. Coverthe hose with a rag becausea fuel will spray
out when disconnecting.
. Plugthe disconnectedhosesto avoidthe fuel leakage.
the fuelhoses.
1. Disconnect
Heaterhose
1. Removethe heaterhose.
10B,-94
ENGINEREMOVAL
Step 4
PIN. REPIJCE
r08063
1.9peeOometer cable
2. Clutchreleasecylinder 6. Exhaustpioe
I (l,Atf)
'v' ! ' 7. Stabilizei
3. ShiftcontrofroO
4. Extension ifrffn
' 8. Tie-rodend
bar (lvirD
s. Shiftcontrotcabb (,am .9. _Enginemountmember
10.Driveshaft
Removatnote
Clutchreleasecylinder(Mff)
1.Removethe releaseiylin'derpil p e
lransaxle. from th
,i.,.i I j
. Caution -
. Do not damagethe pipeor hose.
2. Positionthe release.cylinder
awaVfrornthe
theeasierremovar t
withthehosestirfconn".,"En."xre fri
ENGINE REMoVAL 108-3s
T i e - r o de n d
l . R e m o v e t h e c o t t e rp i n a n d l o o s e n t h e n u t s o t h a t i t
f l u s h e sw i t ht h e b a l lj o i n te d g e .
Caution
. Do not reuse the cotter pin.
2. separatethe knucklearm and the balljointwith the SST.
Driveshaft
1.Removethejointshaft.
2. Removethe boltsand nutsat the leftand rightrowerarm
balljoints.
t09086
Caution
. Do not damagethe balljoint dust boots.
3. Pullthe lowerarm downwardto separatethem fromthe

knuckles.
r08087
4. Removethe enginemountmember.(Mf)
No.2 ENGINE Caution

MOUNTNUTS . Supportthe enginebeforeremovingthe member.
(1) Suspendtheenginewitha chainblock.

(2) Removethe No.1andNo.2enginemountnuts.
(3) Removethe enginemountmemberboltsand nuts,
No.1ENGINE
MOUNTNUTS and removethe enginemountmember.
r08088
Caution
. Do not damagethe oil seal.
5. Separatethe driveshafts
fromthe transaxleby pryingwith
a barinsertedbetweentheshaftandthe case.
108-36 ENGINE REMOVAL
Step5
1. No.3 enginemountrubber assemblY

3. Engineandtransaxle
2. No.4 enginemountrubberand bracket
Removalnote
Engineand transaxleassemblY
Caution
. D o n o t d a m a g ea n y c o m p o n e n t si n t h e e n g i n
comPartment.
1.Lifttheengineandtransaxle
assembly
out as a unit.
r000e I
..: :1
ENGINE FEMOVAL.:-.
1. Intakemanifofdbracket 4. No2 enginemountrubberandbracket

2. Starter 5. Toque converternuts (Afn
3. Throttlecable(Mf) 6. Trarsaxlemountingbolts
108-38
ENGINESTANDMOUNTING
P RE P A R A T I O N
SST
0K 130990 0C 7 For 0K993101AA0 For
Ensine
stand If,
dlcassemblyand
assemblyol Hangersel, s disassemblyand
ffi
assemblyof
R\
engine enginestand OH
engine
ts
108-39
PROCEDURE
SteP 1
1. Removein theordershowninthefigure.
''
\/ ),
GASKET.REPLACE
O,RING.REPLACE
\.
GASKFT.REPLACE
roFo:t
1. Exhaustmanifoldinsulator 4. A/C ccirnpressorbracket(if equipped)
2. Exhaustmanifold 5. Waterinlet PiPe
3. Waterbypasspipe 6. ExhaustprPebracket
.-:
Caution
. when install the ssT (engine hanger), use the
holesshown in the figure- ';--- -.:
- ---.
, f
: ' . .:
108-40 ENGINE EruENESTANO
MOUNTING
1. lnstallthe SST (arms)to the holesas shownin the figure,

Iiro and looselytightenthe SST(botts).
ro€G)lt
2. Assemblethe SST (bolts and plate) in the specified

position.
-o = o
oL
o
@A" t
r0809€
3. Assemblethe SST (nuts,l'rooks,and bolts).

4. Installthe SST to the respectiveanns.
Note
PAFALLEL
o Adjust the SST (bolts) so that less than 20 mm
. (0.79in) of thread is exposed.
. Make the SST (plate and arms) paratlel by
adiusting the SST (bolts and nuts).
5. Tghten lhe SST (bolts and nuts) to affixthe SST firmfy.
NUT WASHER NUT LESSTHAN .

2Qmm (0.79In)
r08098
6. Mountthe engineon theSST(enginestand).

ENGINF DtsAssErvlBLy 108-41
DISASSEMBLY
PREPARATION
SST
0 K 5 9 0 1 1 ' l0 0 1 .For
I o x e s s1 z oo c l For
p r e v e n t i o no l
r e r n C v aal n d
B r a k e .r i n g g e a r engine rotation
I erm, vatve spring| // i n s t a t l a t i o no l
val'.,e
0K99.3120 004 For 0K993 120006

'removal For
and removal ol
Pivot, valve insiallaticnof Remover. valve valve seafs
spring lifter valve seaf
0 r ( i 3 01 2 00 0 6 Fgt
removaland
Remover& in- ..installation
of
staller,piston pin pistonpins
'1. code
all the identicar
p"tt. (:l:.f-T pistonrings,connecting rods.and varvesprings)so rhat
can be reinstalled
in the cylinderiiston,
from
tey which theyr,iereremoved.
2' clea thepartswitha steamcieaner.Browoffanyrdmaining waterwitha compressed air.
Note
' Duringthe disassembry,,or
any partor sysiem,be sureto studyits orderot assembty.Also,
noteany deformation,wear,cr damage.-
10842 ENGINE OISESSEMBLY
AUXILIARYPAFTS
1. Draintheengineoil.
in the ordershownin the figure.
2. Disassemble
tr'\
(
go
L.
is'3':'-\J
1. Distributor and high-tension

lead 7. Oil prersureswitch
d- 2. lntakemanifold assemblY 8. SparkPlug
9. Oillevelgauge
t
I
3. lnjectoranddistribution PiPea s s e m b l y
-:.Alternator and drivebelt 10.OillevelgaugePipestay
5. No.3enginemountbracket hanger
1 1 .E n g i n e
$
lr. 6 .C : l , i i i e r
.ri
ENGINE DISASSEMBLY 108-43
rlMlN-G BELI, . ^L- ^--J , ,,- - :- rL r:-

o rd e r s h o w n i n l he fi gure,referri ngto the D i sassembl y N ote.
i. ' O i*r s e m b l e i n th e
f=r-{-i.
r08rol
1. Waterpumppulley 6. Timingbeltcover,lower
2. Crankshaftpulley 7. Timingbelt
3. Fulleyboss 8. Tensioner,
tensionerspring
4.1imingbeltcover,upper 9. fdler
Timingbeltcover,middle
!,
1OB4 ENGINEosnssEMBLY
DisassemblyNote
Timing belt
1. Loosenthetensioner
lockbolt.
Caution
. To prevent damageto the tensioner,secure it with
a rag.
securethe tensionerby fully extendingthe

2. Temporarily
spring.
toEl@
-orneEnb'iv-ari Note
. Mark the timing belt rotation for the proper
. reinstallation
3. Removethe timingbelt.
ENGINE DtsAsssMBLy
1. Disassemble in the orier shownin the figure.referrirrg
to ihe D.isasserrrbly
Note.
OlL SEAL.REPLACE
@e
lsfr
l*Tr
f{!rl
{
I
I
' 1. Cylindei
headcover '
2. Camshaftpulfey ' 11.Cylinder head
12. Cyfinderheadgasket :
3. Sealplate - 13. Valvekeeper
4. Camshatt
14.Valvespringseal,upper
5. HLA . ,-
15.Valvespring
6. Thermostatcover 16.Valvespringseat,lower
7. Therrnostat
17.Valve
8. Waterthermoswitch
18. Valves€af
9. Heatgaugeunit
19. Vafveguide'
10. Cyfinderheadbolt
108.46 ENGINEotsnssEMBLY
DlsassemblYNote
CamshattpulleY
1. Holdthe carnshattwith'awrench.
2. Removethe camshaftpulleylockbolt'
3. Romovethe camshaftPulleY.
w
Camshaft
cap boltsin the ordershownin the
1.Loosenthe camshatt
figure.
2. Rbmo,rethecamshaftcaPs.
3. Rbmovetltecamshaft.
4. Remove oilsealfromthecam'shaft'
thecamshatt
ro€r0a
HLA
Cautlon
. Mark the Hl*A with a fett Pen so that they can be
i
1. Removethe Ht-A fromthe cylinderhead'
! ' . '
. : - . a
.':
.\ ' - j - - ,
.:!
'' cyllndei head bolt -

in the
l. Loqsenthe.cylinderhead bolts in the orrdershown
: . - - . -f i g u r e-. - . : , " , t ' . ,- ; ,
', headbolts'
z.Rlpov9tle rylinder
j '
. ' ' . t
€
s
.: ENGINE oISasSEMBLY 108-47
rS
i+= V a l v es e a l
i}
{l
Removethe valveseal with the SST.
{
't;, 1
&
ti
EJ
4
't4:':
:'-'!t
p
Fi
tn
.+
:'i'
108-48 ENGINEoIsessEMBLY
CYLINDERBLOCK(FJffERNALPARTS)
1. Disassemble
in the ordershownin thefigure,refeningto the DisassemblyNote.
.REPL,ACE
q
@
ASKET.
ua
REPLACE -c
A
@ neeurce
@
r08t il
1.Waterpump 8. Oil strainer

2.Iiming beltpulldyand lockbolt 9. MainBearingSupportPtate(MBSP)
3. Clutch.cove( clutchdisc (MrT) 10.Oilpump .
a. Flparheet(WT) '11. Frontoil seal
5. Backingplate,driveplate.and adapter(A/T) 12. Rearcover
6. Endplate 13.Rearoil selal
7. Oil pan and gasket
ENGfNEorsnssEMBly 108-4s
Disassembly Note
T i m i n g b e l t p u fl e y
1. Hold the flywheelor the driveplate with the SST.
2. Loosenthe pulleylock bolt.
3. Rernovelhe pulleylcck bolt.
ir
Note
. lf necessary,remove the pulley with a steering
wheel pu ller (commercialfyavailibfe).
W
4. Removethe timingbelt oulley.
5. Remove the puliey Woodrurfkey.
()
10050
Flywheel (MiT)
1. Hold the flf//heel with the SST.
2. Remove the fly,rrheellock bolts.
3. Remove the fly,.rheel.
Backingplate,drive plate,and adaptef (Aff)

1. Holdthe driveplatewiththe SST.
2. Removethe driveptatelockbolts.
3. Removethe backingplate,driveplate,and adapter.
Oil pan
1. Rernoveth.eoil panmountingbolts.
<a'b Caution
. Do not'forcg a plying tool betweentfie cylinde
block and the oi[ pah, which may d'amagd-th
JW contactsurfaces.
- Do not damageor scratch the contact surface
' when remove
the old sealant.
2. Inserta screwdriveror a suitabletooronly at the poin.

shownin the figure.
3.Removetheoilpan.
108-50 ENGINE OISESSEMBLY
Main BearingSuPPortPlate(MBSP)
1. Removethe MBSPmountingbolts-
Caution
. Do not damage or scratch the contact surfaces
when removingthe old sealant-
2. Inserta screwdriveror a suitabletool at the pointsshown

in the figure. ,:
3. Removethe MBSP.
r08il7
Front oit seal

1. Removethe oil seal with a screwdriverwhichis protected
with a rag.
Rearoil seal
1. Removethe oil seal with a screwdriverwhichis protected
with a rag.
ENGINEorsAssEMaLY 108-51
c Y L I N D E RB L o c K ( I N T E R N APLA R T S )
1. Disassemble in lhe'order shownin thefiqure,referring
to ihe Disassembly
Note.
ffi G
p-
i.- I Ig|
,6'
;p\
-6
h
\
\
Ocsrr
{
I
I
I
I
t.
I
t
1. Connecting rodgap .
7. Mainbearingcap
2 . C o n n e c t i n g r o- d
:.: ' 8. Crankshaft
'3. 9.onnecting
rod bearing 9. Mainbearing
4. Pistonring 10. Thrustbearing
5. Pistonpin 11. Cylinderblock
6. Piston
108-52 ENGINEorsessEMBLY
DisassemblyNote
Connectingrod cap
LOCATION
I,.IEASURING 1.Beforeremovingtl-ieconnecting
rod caps,measurethe
rodsideclearance.
connecting
r0Br2l
Ccnnectingrod
1.Beforeremovingthe connecting
rods,measurethe
connecting
rodoil clearance.
rc8r22
fromthe crankpinjoumals.
2. Removethe Plastigage
Caution
. Do not scratch the crankshaltfournal or thr
cylinderwall.
3. Use the handleof a hammerto rernovethe piston anr

the connectingrod assemblythroughihe top of thr
rylinderblock. . '.:.
':-'. \
- --' : \. -..
' 'Piston
ring :
:'.
: Caution :
. i .. '. Do_not apply excessive tension, which may caus{
the rings to snap ouL
. ., - : :-
. i
"'-l-.1.Removethe piston ringswith a piston ring expande

(commeqcially
avaitable).
l','812a
ENGINE DTSASSEMBLY 108-53
t v l a i nb e a r i n g c a p
l . B e f o r e r e m o v i n gi h e m a i : - ,b e a r r n gc a p s . r n e a s u : ei h e .
crankshaflend piay.
E n d p l a y : 0 . 0 8 0 - 0 . 2 4 2 m m( 0 . 0 0 3 1 - 0 . 0 0 9i 5n )
M a x i m u m : 0 . 3 0m m ( 0 . 0 1 2i n )
2. Loosen the main bearing cap bolts in the order shorvn in

the figure.
3. Flemovethe main bearingcaps.
Crankshaft
1.Beforeremovingthe crankshaft,
measurethe mainbear-
ingoil clearances...
oil clearance: 0.018:.0.036

mm (0.0007-o.oola
in)'
Maximum : 0.10mm (0.004in)
108r?a
108-54 ENGINE rruspecnolvFtFlatn
/ REPAIR
INSPECTION
PFIEPAFATION
SST
1 . Clean all partswith make sure lo removeall gasketfragments,dirt, oil or grease,carbon,moisturr

residue,and otherforeignmaterials.
and repairsmustbe performedin the specifiedorder.
2 . The lnspections
I
Caution I
I
. Do not dantagetha jcints or friction surfacesof aluminum allov components (such as thr I
cylinderheador pistons). t
f
t
tt
1
I
I
CYLINDERHEAD
1. Inspectthe rylinderhdad for damage,cracks,and.leal.
age of waterand oil. Replacethe rylinderhead if nece-.
sary . - .' ,. --
2. Measurethe rylindef head distortionin the'six direction
shownin the figure-'
Distoftion: 0.15mm (0.005in) max.
Caution
. Beforegrindingthe cylinderh e a d , c h e c k t h e f o .
lowing and repairor replacet h e c y l i n d e r h e a d a
necessary; ' ."
(1) Sinkingof the valveseats
(2) Damage of the manifold contact surface
(3) Cams"h"Sojl clearancesand end play .
.;''
3. lf the cylinderhead distortionexceeds lhe specificatior
grindthe cylinderhead surface.
lf the cylinderhead height is not wiihin the specificaiior
.
.replaceit. . .':.,,1,:-i.-,
Helght ' : 1g3.e:r5i.0 mnl (s.258-5.276 in)
G r i i d i n g : 0 . 2 0 m m ( 0 . 0 0 8i r i ) m a x .
ENGIN E truspecrtoN/REpAtR 1.08-ss
4. Measurethe manifotdcontactsurfacedistortion
in the
fourdirections
shownin thefigure.
Distortion: 0.20mm (0.008in) max.
5.lf distoriion
exceeds
thespecificarion,
grindthe sudaceor
replacethe cylinder
head.
VALVEMECHANISfvI
. . S T E MT I P Valveand ValveGuide
1. Inspecteachvalveforthe following
items,and replaceor
resurface
the valveif necessary:
(1)Damaged or bentstem
(2)Roughor damaged face
(3)Damaged or unevenlywornstemtip
2. Measurethevalveheadmarginthickness of eachvalve.
MAAGIN VALVEFACE
THICKNESS ANGLE45'
Reptacethe valveif necessaiT.
Marginthickness
r03r32
l N : 1 . 0m m ( 0 . 0 0 i4n ) M i n .
'A- E X : 1 . 0m m ( 0 . 0 0 i4n ) M i n .
I
3. Measure
the lengthof eachvalveattheshowlnoilrs.
Length
Standard
lN : 105.29mm (4.1452in)
E X: 1 0 5 . 3 9
m m( 4 . 1 4 9
in)
Minimum
lN : 1A4.79 mm (4.1255 in)
EX : 104.89mm (4.1295 in)
4. Meapure
thestemdiameter
of eachvalves.
_1:r.-
i.
Diameter
. . . tN : 5.970-5.985
mm (0.2350-0.2356
in)
-_" .EX
"'-'= : 5.965-5.980
mm (0.2349-0.235a
ini
5. Meisurethe innerdiameterof eachvalveguideat the
- -
shownpoints. _ .: -', .,;r,
-'a. 1'-:::
,., .*'' 'i
, ._.. --_-' ,
^t'- 1'-':
' t'- ''
. ,. ...'..;
"'tt
lc8 I 3a
:
6. cafculatethe valvestemguideclearanceby followingmethod.

VALVESTEM s u b t r a c tt h e o u l e r d i a m e t e ro f t h e v a l v e s t e m - f r o mt h e
innerdiameterof thb corresponding valve guide.
VALVEGUIOE
Clearance
lN : 0.04-0.045'mm ( 0 . 0 0 1 5 - 0 . 0 0 1i 7
n)
CLEARANCE
E X : 0 . 0 4 5 - 0 . 0 5m
0 m ( 0 . 0 0 1 7 - 0 . 0 0 1i 9 n)
M a x i m u m : 0 . 2 0m m ( 0 . 0 0 8i n )
7. lf the clearanceexceedsthe specification,replace the

valve andlor the valvequide.
t08135
109.56
8. Measurethe heightA of eachvafveguide. Replacethe

valveguidelf necessary.
mm (0.520-0.543
Heightz 13,2-13.8 In)
of valvegulde
Replacement
NotE
. The valve guldes are dlfferentbetweenthe lntake
and the exhaustsldes, trus use the correct valve
gulde.
t0€r3t
ffi
IN EX
Removal
1.Removethevalveguidefromtheopposite
sideto the
combustion
chamber byusingtheSST.
l06r3ll
it
ENG I N E INSPEcTIoT!/REPAIR 108-57
Valve seat
1 . I n s p e ct h e c o n t a c ts u r f a c eo f e a c h v a l v es e a t a n d v a l v e
face for the follovrinEs:
(1)Roughness
(2)Damage
2.lf necessary,resurfacethe valveseatwith a 45. valve
seatcutter and/orresunacethe valveface.
3.Applya thincoatof Prussian blueto thevalveface.-

4.Inspectthe valveseatingby pressingthe valveagainst
theseat.
(1) lf blue does not appear360" aroundthe valve,faee,
replacethevalve.
(2) !f hluedces not 3ppear300' aroundthe valveseal.
resurface the seat. :
5. Measure
theseatcontactwidth.
W i d t h: 0 . 8 - 1 . 4m m ( 0 . 0 3 1 - 0 . 0 5i n5)
SEATCONTACTWIOTH
6. Verifythat the valveseatingpositionis at thecenterof the

valveface.
7, Seatthevalveto the valvesealwitha lappingcompound.
POSTTTON
_29.8 rnrn IZS.O nvn

( r . t 7 3h ) l ( 0 . 9 8
In)
r 0 0t . a
8. Inspectlhe sinkingof thevalveseat. -

108-59
9.Measure
theprotruding
length(dimension
L) of thevalve
stem.
DimensioL
n : 4 4 . 5 5 - 4 5 . 4r 5
n m( 1 . 2 5 3 9 - 1 . 7 8i 9n 4)
( 1 ) I ! L i s 4 3 . 5 - 3 4 . 0m m ( 1J 1 Z - 1 . 2 3 2i n ) , n o c o r r e c .
tion needed.
(2) lf L is 44.0-.45.0 (1]3Z-1.TT1in), adjust wiif
Tm
washerol the springseatareaof a cylrnoerheaJ.
( 3 ) l f ! i l q g . Om m ( 1. 7 2 1 i n ) o r m o r e j r e p r a c et h - e
cytinderhead.
r 0 0I r 3
ValveSprlng
1. Inspecteachvalvespringfor a cracksor a damage.
2. Measurethe.freelengthand out-of-square. Reilacethe
valvespringif necessary.
Freelength:
Standard: 45.6mm (1.795in)
Minimum: 44.4rnm (1.7a8!n)
l C8l.t
'Out-of-square'i.59
: mm (C.063in) max.
CAMSHAFT
1. Sei the frontand rearjournatson the V-blocks.
2. Measurethe camshahrunout. Replace
,thecamshaft
n e c e g s a r y, ., * . , ,
".'. ':...
Runout: 0.03mm (0.0012
in) max.
:
. t
t
I
3 -
' 9
l0glso
ENG I N E lNsPEcrtoN/REPAIR 108-59
5 . l v l e a s u r et h e j o u r n a lc j i a m e t e r si n X a n d Y d i r e c t i o n sa t
the l'.'/opoints(A and E) shorvn
Diameter:
25.940-25.955mm (1.0?-13-1.0222in)
O u t - o f - r o u n d: C . 0 3m m ( 0 . 0 0 1i n ) m a x .
6 . M e a s u r et h e c a m s h a fjto u r n a o
l ilclearances.
Caution
. D o n o t i n s t a l lt h e H L A w h e n m e a s u r i n gt h e o i l
clea:'ance. .':
( 1 )Removeall foreignmaterialand oil fromthe journals
andthebearingsudaca.
(2j Setthecamshaft ontothecylinderhead.
(9)Positlona Plastigageatopon thejoumalsin the axial
direction.
(4) lnstatl
thecamshaft
caosaccording
to thecap number
andthearrowmark.
@B8 88
ffi8BBB
(5) Installthecamshaft
cap bolts,and tightenthemin the
ordershownin thefigure.
Tightening torque:
, .-,11.3-14.2N.m(1.15-1.45 kg-m,100-126lb-in)
:
,'-'*'
r c 8| 5 {
(6) Loosenthe.camshaftcap bolts in lhe order shown ir

the figure.
(7) Removethe camshaftcaps.
D-C-@-@t(D
t08r55
108-60 EN G IN E rvspEcnoN/REpAtR
E
-T
-
(8) Measurelhe oil ctearances.
O i l c l e a r a n c :e
0.035-0.081_ mm (0.0014-0.0032in)
'
M a x i m u m: 0 . 1 5m m ( 0 . 0 0 5i n )
(9) lf the oil clearanceexceedsthe specification,

replace
lhe cylinderhead.
7. Measurethe.camshaft end piay.rf the end prayexceeds

the specification,
reptacethd cdmshaftanct/orthe cylinder
heaci.
End.ptay , q.9g-0.19.mm
(0.c031-0.0075
in)
Maxlmum: 0.20mm (0.00ain1
!-ILA
Cautlon'
. Do not attemptto repairthe HLA.
1.Inspect
theHt-Afriction surfaces
fora wearor a damage
ReplacetheHl-{ if necessarv.
2.Holdthebucketbodyandpiesstheprunger
lheplunger ' e by hands r:
moves, riplace'the
Hl_A.
\-.
r00l5t
C Y L I N D EBRL O C K
1.Inspectthe cylinderblockfor the following items,anc
i:p?iTl11qla.ce the rytrnderbtock as necessry.
[1] leat(agedamage
(2) Cracks
(3) Scorinsof wall
2. Measurethe distortion of the top surfaceof the rylinder
blockin thesixdirections shownin thefiil;.
Dlstortlon
: 0.15mm(0.006
in)max.
r08r39
3. lf the distortion
exceedsthe specification,
repairit b1
grinding or replace.the
cylinder
block.
leJSht :221.5mm (8.720 in)

Grinding: 0.20mm (ci.o08
ln)inax.
r00 t60
E N G I N E INSPECTION/REPAIR 108-61
4 . M e a s u r et h e c y l i n d e bores
r in X and Y directionsat thlee
l e v e l s( A , B , a n d C ) i n eacncylinderas shown
C y l i n d e rb o r e mrn (in)
{
t,
i i
9 (3.071-3.072l,
78.C06-78.01
!
I
i I
l
f t
I
I
t00t6l
Caution
. The boringsizeshouldbe basedon the sizeof an
oversizepistonand be the samefor all cylinders.
(1) lf the cylinderboreexceedsthe maximum, reborethe

cylinderto theoversize.
( 2 )l t t h e d i f f e r e n cbee t w e e nm e a s u r e m e n A
tsand C
exceedsthemaximumtaper,reborethe cylinderto the
oversize.
Taper: 0.15mm (0.0006

in) max.
:c8 I 62
t s a n dY
( 3 )l f t h e d i f f e r e n c be e t w e e nm e a s u r e m e n X
exceedsthe maximum out-of'round, rebore the cylin'
oa so d.er.to the oversize.
nffi" : 0.019mm (0.0007'in)
Out-of-round max.
F'H
.u\!i 3
Y
r08r63
5. lf the upper part of a cylinderwall shows uneven wear,

removethe ridgewith a ridge reamer.
r 0 8 r e ..
1AE,,82 EPAIB
EN G IN E IruSPECTPN/R
PIN
PlsToN,PlsToNRING,ANDPISTON
Plgton
Cautlon
theplston.
. lf thaplrtonls rcplaced, rlngsmustalso
olL Rll be replac.d,
0Roo
.|7,6
mrn
(0,699In) l , l n e p c ctth e o u l e rc i r c u m f e r e n coef sa l l p i s t o n fso r a
OUTER gelzurE ora scoring. Replace thepislonlf necessary.
OIAMETEH 2 .M e a e u rteh e o u t e r d l a m e t eorf e a c hp i s t o na t a r i g h t
angle (90')to the plston pin, 17.6mm (0.693in) below
todta3 the oil ring land lower edge.
Pistondiameter mm (in)
Dlametcr
n .954-77.974(3.0690-3.0698)
0.25(0.010)overclre 78.204-78.224(3.0788-3.0796)
78.454-78.474(3.0887-3.0895)
thepiston.to
3. Measure clearance.
cylinder
mm(0.0012-0.0025
: 0.032-0.065
Clearance in)
Maximum: 0.15mm(0.006In)
4. lf theclearance
exceeds themaximum, replacethepistor
fit
to the
or reborethecylinders oversizepistons.
roilti
PlstonandPlstonRings
1. Measurathe pistonringto makethe ringlandclearanct
usesa newpistonring.
aroundtheentirecircumference
Cleannce
Topandsecond: :-
mm (0.0012-0.0026
0.030-0.065 In)
Maxlmum: 0.15mm(0.006
- . . : in) ,
2. l[ the cleamac; ;."d. the rnaxi*u*, reptace the pts

ton.
3. lrspect the piston rings for a darnage,an abnonnal wear
or a breakage. Replacethe pistonrings it necessary
4. Insert the pbton ring into the cylinder by hands and us
the pbhln to push it to the bottomof the ring tranel.
loa\€
ENGIN E tNSPECTIoN/REPATR 108-63
5 . M e a s u r ee a c h p i s i o n i ' i n ge n c i g a p w i t h a f e e l e r g a u g e .
R e p l a c ei h e p i s t o nr i n gi f n e c e s s a r y .
Endgap
ToP 0 . 1 s - 0 . 3 0m m ( 0 . 0 0 6 - 0 . 0 1i 2n )
Second 0 . 3 0 - 0 . 4 5m m ( 0 . 0 0 6 - 0 . 0 1 i7n )
+.r-
I
Oilrail 0 . 2 0 - 0 . 70 m m ( 0 . 0 0 8 - 0 . 0 2 8i n )
Maximum 1 . 0m m ( 0 . 0 3 9 i n )
t
I
i
t
{
I P i s t o na n d P i s t o nP i n
1.Measure in X and y direc-
eachpistonpin holediameter
tionsat theshownfourpoinis.
Diameter: 19.988-20.000
mm (0.7869-0.797a
in)
r0altc
x
2. Measure in X andy directions
eachpisionpindiameter at
't theshownfourpoints.
Diamete
r : 19.974-19.990
mm (0.7863-0.7866
in)
3. Calculate
thepistonpin-to-piston
clearance.
Clearance : 0.008-O.OZO mm.(0.0003-O.O0O7
in)
M a x i m u m: 0 . 0 5m m ( 0 . 0 0 1 i9n )
4. lf the clearance
exceedsthe specification,
replacea pis-
rogrTl ton and/ofa pistonpin.
C O N N E C T I NR
GO D
1. Meisureeachconnecting
rodbushinginnerdiameter.
D i a m e t e:r1 9 . 9 4 3 - 1 9 . 9m
0 1m ( 0 . 7 8 5 1 - 0 . 7 gi5ng)
- 2. calculatethe clearance
betweena connecting
rod bush-
inganda pistonpin.
C t e a r a n c:e' 0 . 0 1 3 - 0 . 0 3
m7m ( 0 . 0 0 0 5 - 0 . 0 0i1n4)
M a x i m u m: 0 . 0 5m m ( 0 . 0 0 1i9n )
ro8:n
3. Measureeachconnecting rod for a bending. Repairor

' replacethe connecting
rodif necessary.
- Bending: 0.04mm (0.0015

in) max-/100
mm (3.937in)
108-64 ENGIN E lNspEcTtor\yFr
EpAtB
CRANKSHAFT
1.Checkthejournals andpinsfora damage,a scoring,
and
_ an oilholecfogging.
2. Set thecranksnatt-on
lheV-blocks.
3' Measurethecrankshart
runoutat thecenterjournar.
Replacethecrankshaft
if necessaqy.
Runout: 0.04mm (0.0016
in) max.
108| 7.
4. Measureeachjoumardiameter
in X and y directionsat
theshowntwopoints.
X
Mainjournal
O Diameter: 49.983_49.956-Tp
out-of-round: 0.0s
Crankpinjournal
Diameter: 44.940-44.956
Out-of-round
: 0.05mm IO.OOZO
(1.9661_1.966S
mmi,6.oozo
'
in;.rn"i.
inl.r"i.
-
in)
in)
TT.(1.76s3-1.7699
5. lf the diameterisressthanth_e.minimum,
grindthe jour.
CRANKPIN nalsto matchan undersize-beanng.
Undersizebearing:
0.25mm (9.919 0.50mm (0.020
fn), in)
o.zs mm (0.030in).
Mainjournaldiameterundersize
MAINJOURNAL mm (in)
Boresize
Diameter
t06 | 76
0.25(0.010)undersize
-
49.454-49.458
(1.9470_
1.gq7a
Crankpinjournaldiameterundersize
mm (in)
Journal diameter
44.590-44.706(1.7594_1.7601
0.50(0.020)undersize )
4.40-4.4s6 (1.74s6_1.7soz).
++.rso-aa.eoe
(r.zss8_r
.7404)
BEARING
Bearingand ConnectingRod Bearing
.'
Yll
1.check the main bearings tn"
I n ! [f] ingsfora peeling,u ,"oinglano
"-no other
"onn.iting
damage.
rod bear-
d ffiJE Eh
r08rt7
ENG I N E lruspEcrtoNrnEpAtR
108-65
T I M I N GB E L T
s -k--G
x i-a
Cauiion
' N e v e r f o r c e f u l l yt v r i s t ,t u r n i n s i C e
o u t , o r b e r r dt h e
m
t i m i n gb e f t .
D o n o t a l l o r va n o i l o r :a g r e a s e c o n t a m i n a t e s
the
belt.
r i' .X
2 5 m m ( 1. 0 r n ) L , i l N .
1 . R e p f a c et h e timingbelt if an oil or a grease

contaminates
ir.
2 .C h e c k t h e
f i m i n gb e l t f o r a d a m a g e ,w e a r .p e e l i n g ,
cracks,and hardening. Repiaceihe timing
belt it n...i-
PE€LING sary.
CR^CK
T E N S I O I I I E RI D
, LFR
:
Caution
' Do not crean the tensioner or
the idrer with a
c r e a n i n g f r u i d s . r f n e c e s s a r y ,u s e a
soft rag to
w i p e t h e m c l e a n ,a n d a v o i d s c r a t c h i n g
them.
1. check the tensionerand the idrer
for a smooth rotation
a n d a n a b n o r m a rn o i s e . R e p r a c er h e
t e n s i o n e ro r t h e
idlerif necessary.
T E N S I O N E RS P R I N G
1. Measurethe free rengthof the rensionerspring.
Reprace
the tensionerspringiinecessary.
F r e e l e n g t h : 5 9 . 5 m m ( 2 . 3 4 2i n )
59.5mrn (2.3-t2in)
rcotSr
PULLEY
T i m i n g B e l t p u l l e y ,C a m s h a f tp u l l e y
N Caution
' D o n o t c r e a nt h e p u i l e y s w i t h t h e
c r e a n i n gf r u i d s .
tw l f n e c e s s a r y ,u s e a s o i t , a g t o w i p e
in", clean,
a n d a v o i d s c r a t c h i n gt h e m .
1' Inspectthe puileyteethfor a wear,

deformation,
-- - and other
.ciamage;Repfacethe pulleyif necessary.
to8r82
108-66 ENGINE AsSEMBLY
ASSEMBLY
PREPARATION
SST
T
0 K 1 3 01 6 00 1 0 F csr I
install:rtion
of I 0 K 2 0 t1 2 00 l l
I
For
i n s i a l l a t i o no f
Centeringlool. clutch disc Instal l er
set, v a l v es e a l a n d
valveseal& v a l v eg u i d e
valveguide
0K 993120001 For 0 K 9 9 3 1 1 10 0 1 For

/:\
removaland
Arm,vafve preventionof
sprins Jt insialtationo! 8rake. ring gear
l:fter W engi nerotat ion
valve
t
1. Cleanallpartsbebrethe reinstaltation. 3
Il
? Applya nev/engineoil to all sticiing and rotatirrg
parts.
3' Replace theplainbearings if theyire peeting, {
..+.Tightenail the bottsand iurs 6urned,or
- othercamaged. *
ine rpb.irird'iorques.'
1o i
I
Caution I
. Do not reusethe gasketsor the oil seats t
IT
--
I
ENGINE.ASSEMBLv.. 108-67
( I N T E R N AP
L ARTS)
c y L t N D E RB . L . O C K
i
i o r q u eS P e c f c a t i o n s
5
JOURNALSANO
C R A N KP I N S
zr .t -zi.t)
(3.0-3.s.
2s.4-34.3
't08-68 ENGINEesseMeuy
Connectingrod
1.Assemble
theSSTasshown.
t'l?: bolt(0K201
110406)sorharrhedepth
frt;:TflT
DepthL : 56.g-57.1mm (2.240_2.2ag
in)
3.1ightenthe tocknut.
4. lnserlthessT No.2iatothepislon.pin
andfurtyinserta
screwin theSSTNo.1asshown;n tiieiigrr..
5.Apptyan engineoitio rn. pirionpin.
No.2
t-e
?t
IZ'
tr
rottet
6.Setthepistonon thessr withtheF mark

' Assemble piston facingupward.
the. anotheconnecting rodin thedirec-
tion
. ' ' fromwhicfitheywereOir"rr.rnbled.
IOENTIFICATlON
MARK
7'Prg.:: the
dston pin into the pistonrod- connecting.rod
--r
untiltheSSTcontacts thestopperbolt.
8. wlrile inserting thepistol.pin,'
in".r,ln. pressureforce.
9. lf it is lessthanthe'specificatlon,
reptacethepistonpin or
the connecting rod.
Pressureforce :
4 , 9 0 5 - 1 4 , 2 1NS( S O 0 _ 1 , Sk0g0, 1 , 1 0 0 _ 3 , 3 0 0
lb)
10.check theosciilation torqueof the connecting rod.
ENGINE nsseueLy 108-69
Piston Ring
1. lnstalllhelhree-piece oil ringson thepistons.
(1) Applya cleanengineoir to the oir ringspacerand
rails.
(2) Installtheoil ringspacerwiththeendsupward.
Note
. The upperrailand the lowerrailarethe same.
- The railsmay be installedwith eitherface upward.
(3) Installthe upperrailand thelowerrait.

r06lE8
z-v9ntythatboth-rails are expandedby the spacertagsps

s h o w ni n t h e f i g u r eb y m a k i n gc e r t a i nt h e r a i l st u r n
UPPERRAIL smoothlyin bothdirections
t08tE9
Caution
TOP . T h e r i n g s m u s t b e i n s t a i l e dw i t h t h e y m a r k s
: uiward.
. The secondring must be installedwith the scrap-
. sEcoNo er facesdownward.
3. Applya clean.engineoifto the top and the secondpiston

nngs.
4. Installthe secondring to the piston;then installthe top
ring.Usea pistonring-expander (commercially availablef
rogr90
5r Positiontheend gapsof the rilos as shownin th-efigure.

.OIL
RING
U P P E RR A
' !
OIL RI RISTON
SPACER PIN
O I LR I N G SECOND
LOWERRAIL RING
'108-70 ENGINEasseMeLy
1 Crankshaft.
I 1. Beforeinstalring
the crankshaft,
inspectthe mainbearing
I
I
II oi!clearancesas follows.
Oil clearanceinspection
(1)Removeartthe foreignmaterfarand oir
from the jour-
nalsand thebearingi.
Caution
. Install ,h?^9,r-oovedupper main bearingsin the
cylinderbrocx.
r0Et92
. rnstailthe thrust bearinqswith the oit groove
ing the crankshaft. i fac-
PLASTIGAGE
(2) lnstallihe uppermainbearingsand the
thrustbearings.
(3) Setthe crankshattin thecylinderblock.
Cautioh
. Do not rotatethe crankshattwhen
measuringthe
oil clearances.
1a)Positiona prastigage
atop - - ' -joumars
' on rhe -- in the axial
direction.
r08t9!
(5) Inslallthe fowermainbearingsand

the main bearing
capsaccording. to thecapnuiber and € mark.
(6)l rghtenthe mainuearingicipboftsin
tn! oro"r shown
in the figure.
Tighteningtorque:
54-59N.m(5.5-6.0kg_m,40_43lb,ft)
ro3t9a
(7) Femovethe main bearingcaps,

and measurethe
Plastigag!,3teachjournatat ttie widestpoint
smailestcrearance, for the
and at the narrowestpointfor the
largestclearance. ':_
(8) lf the oil clearanceexceedsthe.specification,
grind
thecrankshaft
anduserheunde"ii5 ,"i1 o.irinir.'-
Oilclearance,
Tm (9.0007_0.001a
9.g18-0.036
Maximum : 0.10 mm(O.OO4
in)
in)
.-.t .
2. Applya liberaf l.orn, of .r."n engineoirto rne main

thrust
Pearilg.s, bearings andmainloirnits-.
3. Installthecrankshaftaio tnemain'ueinng capsaccord-
ingtothecapnumber and€ mark.
ENGINE ASSEMtsLY I0B-71
4 . l l c : h l e nt h e m a i n b e a r i n gc a p b o l t si n t h e o r c e r s h o v . , inn
thc fir;r;r'c.
T i g h t e n i n gt o r q u e : ..
5 4 - 5 9 N ' m ( 5 . 5 - 6 . 0k g - n r ,4 0 - 4 3 l t s i r r )
! o Ot 9 ;
5; Measurethecrankshaft
endplay.
End.play : 0.080-0.?42
nrrn(0.0031-0.0095
in)
f\laxinrum:0.30rnm(0.012in)
t t .l f t h e e n d p l a y e x c e e d s t h e m a x i m u n , g r i n c i t h e
c r a n k s h a f ta n d ' i n s t a l la n o v e r s i z et h r u s t b e a rr'i 'v
n oo
v'r
replacethe crankshaftand the thrustUearing.
T h r u s t b e a r i n gw i d t h
S t a n d a r d:
2.s00-2.550 mm.(0.0984-0.1
004in)
0.25mm (0.010in) oversize:
2.625-2.675 mm.(0.1
033-0.1053in)
0.50mm (0.020in)'oversize :
2.7s0-2.800_mm.(0.1 083-0.1102 in)
0.75mm (0.030in) oversize:
rc3 r J€
2.87s-2.925 mm (0.11
32-0.1152in)
1Q f J -/ 2 ENGINE AssEMBLy
- - R U B B E RS L E E V E
P i s t o na n d C o n n e c t i n gR o d A s s e m b l y
n
-.Caution
. P r o t e c t h e c o n n e c t i n gr o o b o i t s
r v r t ha r u b b e r
sleevesto preverrta cJahageto the
c r a n k p i r ri c r u r -
nals.
1.Applya liberalamounrof creanengine

oir to the cylincler
^ walfs,pistons,andpistonrinqs.
2. checkthepistonringsfor i dorrect
endgap atignment.
3. Insed.eachpi.stona-sserury tne
- the F lnlo c,iririaerbtockwith
rq markfacinglhe korrrtol the_.;g;;;."'ur" a pisrcn
\"s
tr\E
i
nO,_:
orp.:.,9.ror (i ommerciatIy . ;r"oj. j,
""
ConnectingRod Cap
1' Measurehe con.ectingrod bearng
cfrdearancesby fcrbr,dng
crhe sarTeprocedureas he mainb""*rg olrJ"rrr,""
i -_.
i . 1 : : . . . . - , . - l i r . _ .-_:
Caution,-.'.
. A l i g n t h e m a t c h i n g marks on
the cap and the con-
,.;,D€9tingrod when installing
the connecting rod
. c ? P ' . ' j , - i . . . - ., ' '---;
,.:rt
.. :
: 1 .i " ' , , -
:
kg-m,21.2-25.3lb-ft)
Oil clearance:O.OZ8-0.068
rnm (p.00f
- -110.0027.
-.'r' in)
Maximum : 0.10mm (0.004i;) .!
l
'r !
:-1ii ,- t.t -' /:-. r, F ' f ^ .r .-,
2 ti.i#:i,;;A';;#; ih.'-,i,u,,'srind rhe {

t
2
r-l
crankshaft ";;ijr:
andusetheundersiz nd;:-
'.-.
. . i t .- : , r . l : f
il: : , . , . - , . i . . : . : t. : . : . .. . .
t t
l , f : i i . : . ; , : . : 1 i; i r - - - . .. i
.. 1
:
J
i
3
!
n
!
' t;
t
3. Measuretheconnecting
rodsideclearances. t
t
1
a
j
:
in) t
::. I
:
4. maximum,replacelhe con-
.a
.e
:t
.t
t
t
t
TI
1|
it
ENGINEnsseuaLY 108-73
I
I
I
I
I
-
MATCHIIJG M.CRKS
5.Applya liberalamountof cleanengineoil to the crankpin
journals
6.Install,
andthccortnecling
the connecting
aligned.
7.1ighten
rod
rodbcarinqs.
capswiththe matchingmarks
rodcapnuts.
llreconnecting
i
!
i torque:
Tightening
,
t
l
N'm (3.0-3.5kg-m, 21.7-25.3
29.4-34.3 lb-ft)
Ii
t
,
T
i
t
t I
to8Z35 ..
cYLtNDERtsLOCK(EXTERNAL
PARTS)
Ii
TorqueSPecifications
i't
i
f'
t
I
t
I
I
I 1 9 - 2 5( 1 . 9 - 2 . 6t,4 - 1 9 )
t
YR^
108-118
( 1 1 . 01- 2 . 0 .
80-87)
1 9 - 2 5( 1 . 9 - 2 . 61, 4 - 1 9 )
GASKET,
NEW
tua>
'a
7 . 8 - 1 1N . m
1eo-tiOkg<m, 69-95 tb-in)
r 6 - 2 r( t . 6 - 2 . 1t :2 - 1 5 )
| ^- ., t8-26(1.8-2.7.13-20)
_.. 7.8-ll N.m (80-tt0 kg-cnr.69-95lb-in)
96-103(9.8-10.5.7r -76)
108-7 4 ENGINE ASSEMBLY
R e a ?C o v e r
1. A p p l y a s m a l l a m o u n t o f c l e a n e n o i n e o i l t o t h e l i p
of a
n e v ro i l s e a l .
2 . P u s hi n t h e o i ts e a t s l i g i i t l yb y h a n d s .
C au t i o n
. Theoil sealmust be pressedin until it is flush
with
the edgeof the rearcover.
3. Pressin theoilsearevenryrvitha suitabre

pipe.
O i ls e a io u t e rd i a m e t e r :1 0 0 ' n l m( 3 . 9 ai n )
4. Applya siiiconesealantto the slradedareashownin
the
figure.
5. Installthe.rear
cover.
Tighteningtorque:
7.8-11N.m(80-110kg-cm,59_95tb_in)
Oil Pump
1.Applya smallamountof cteanengine ," the lip of e
newoilseal. ::l
2. Pushin the oil seatslighttyby hands.
Caution
. The oil seal must be pressedin until it is flush witt
the edge of the oil pump body.
a
3. Pressin the oil seal evenlywitha suitablepipe.

- Oil sealotter diamete
r :44 mm (1.73in)
4. Installtheoit pumpand a new gasket..
Tighteningtorque :
ffi
19-25N-m(1.9-2.6kg-m,14-19 lb-.tt)
w
ENGINE ASSEMBLY 10El-7s
Caution
. D o n o t s c r a t c ht h e o i l p u m p .
5 . C u t a w a y t h e p o r i i o no f t h e g a s k e tt h a tp r c j e c t sf r o n rtt're
body tourardthe oil pan side.
- r C 3 2t 2
M a i nB e a r i r r gS u p p o r tP i a t e( M E S P )
1.Removeall foreignmaterial fromthecontact
surfaces.
i Caution
. T h e o i l p a n m u s t b e s e c u r e dw i t h i n3 0 m i n u t e s
afterthe sealantis appliedto the MBSp.
2.Applya silicone
sealantto theshadedareasshownin the
figr.lre.
3 . A p p l y a c o n t l n u o u sb e a d o f a s i l i c o n es e a l a n t o t h e
- MBSP aiongwith the insideof theboliholes.
..
4. InstalltheMBSP.
' ,5.Ighten
theMBSPboltsin theordershownin lhe figure.
'-' . . .' :'.
,., Tightening torque:
;',' :"-',,,i16-21 N.m(1.6-2.1kg-m,12-1s
l?-rtl
r o 8 2t 5
'Oil Straine'i
l.,lnstafltheoilstrainer
anda newgasket.
1.08-76 ENGINE ASSEMBLY
Oil Pan
1.Removeall foreignmateriatfromthe contaclsurfaces.
Applya siliconeseatantto the shadedareassno*n ir..,-
figure. rn.
3. Installthe new gasketsonto the oil pump body an..J

the
rcar ccver with rhe projectionsin the noicnes-shovn
in
thefigure.
4.Applya continuousbeadcf siliconesealantto the oil pan

alongwith the inside of the bott hotesanc overtap'the
ends.
5. Installthe oil pan.
Tighteningtorque :
7.8-11N-m(80-110kg-cm,69-95 tbin)
ro8:lre
End Plate
1. Installtheend plate.
Tlghtenlngtorque :.
7.8-11N.-m(80-110kg-cm,69-95 tbin)
Flywheel(MrD
1. Removethe sealantfrom the flyr,.rheel bolt holes in the
crankshaftand from the fly,rrheelbolts.
Caution
. lf allthe previoussealantcannot be removedfrom
. Do not apply a sealantif a new bolt is used.
2. Setthe flywheelontothe crankshaft.

3. Applya sealantto the flywheet
boltsand installthem.
E N G I N EASSEMBLY 108-77
4. Hold the flvwheetwith the SST.

5 . f i g h t e nt h e b o l t si n t h e o r C e rs h o w n .
9 6 - 10 3 N . m ( 9 . 8 - 10 . 5 k g - m, 7 1 - 7 6 l b - f t )
ClutchDisc and ClutchCover(M/T)

1.lnstalllhe clutchdiscandthectutchcoverusingthe ssr.
Tighteningtorque:
, 18-26 N.m(1.B-2.7kg-m,13-20lbtt)
r08223
Drive Plate (Mf)

1. Removethe sealantfrom the driveplateholesin the
crankshaftand fromthe driveplatelockbolts
@
trffi
Caution
. lf all the previoussealantcannotbe removedfrom
. Do not apply'asealantif a new bolt is used.
r0822r
2. set !h9 qdapter,driveplate,and backingplate onto the

crankshaft.
3. Applya sealantto thedriveplateboltsand instaltthem.
4. Holdthe driveplatewiththe SST.
5.Tightenthe boltsin theordershown.
Tighteningtorque:
96-103 N.m(9.8-10.5kg-m,71-26 tb-ft)
r0B?25
TimingBelt Pulley
1. Reversethedirection
of theSSTon the flyrruheel.
108-78
ENGINEnsseMeLy
2. fnstallthe timingbeltpullev.
3. lnsta' the pufGv wboJi'.iit key
wirh rhe raperedside
lo,uardthe oil purnpbodv.
4.
Fstaftthepuileytockboti.
c. irghtenlhe pulleylockbolt.
Tlghteningtorque:
1 0 8 - 1 1 8N . m( 1 1 . 0 _ 1 2k. 0g _ m8, 0 _ 8 7
tb-ft)
WaterPump
1. Removeail foreignmateriarfrom
the waterpumprnount-
ing surface.
2 Installthe rvaterpumpanCa
new gasket.
Tighteningtorque:
1 9 - 2 SN . m( 1 . 9 _ 2 .k6g - m ,1 4 _ 1 9 l b _ f t )
r08?26
' , i -
.: ENGINE nssEMBLY 108-79
Tolgue SPecifications
1 1 . 7 - 1 3 . 7( l -1.4,8.2-10.1) 4 . 9 - 8 . AN'm (50-30.kg-cm.

<3-78 rb.in)
I
'
4 9 - 61
(s.o-6.2.
.36-4s)
orr-
sEAL,l.*
S
eu
EI
E
JOURNALSANO
CAM FACES s
h
7 . 8 - 1 1N . m
(80-110kg-cm.69-95 tb.in)
EOLTTHREADS
AND SEAL FACES
s
5.9-8.8 N.m (6o-90kg-cm,52-78tb-in)
KET.ruEW
SEATFACE
-.ftr"t{ \
-@../
s,P @
e\c
?
N.m (kg-m, tb-fr)

108-80 ENGINERsseueuy
Valveseal
l.lpqY an engineoitto the insideof the newvarvesear.
2. Instatlthevatveseatontothe valveguidewiththe
Sa;
Valveand ValveSpring
1. tnstalllhe lowerspringseat.
2. Installthevalve.
Caution
. lnstaflthe spring rvith the closer piich
cylinderhead. ' ---- toward the
3. Installthevartve
springand the upperspringsear.
CYLINOER
HEADSIOE
4. compressthe valvespringwith the sST. and install

vafvekeepers. the
5. Removethe SST.
6. T?p the end of the valvestem lightlytwo or
three times
yiln pfastichammerto verify inaf tneleepers are atl
"
fullyseated.
CylinderHeadGasket
1. Removeall foreignmateriatfrom the top of the
rylinder
ffi block.
2. Placethe new cytinderheadgasketin its position.
ffi
C y l i n d e rH e a d
1.Install thecylinder head. .'
2 . A p p l ya ' c l e a r e
r n g i n eo i l t o t h e b o l t t h r e a d sa n d s e a t
faces
3.Tighten thecylinder headbottsin the ordersholvn.
Tightenirrg
torque:
76-81 N'm (7.7-8.3kg-m, 5G-G0tbft)
r0821.
WaterThermoswitch, HeatGaugeUnit
1. lnstal!thewaterthermosrvitch.
Tightenlngtorque :
5.9-8.8tt.ni 1OO-90
kg-cm,52-Zg lb-in)
2. lnstalltheheatgaugeunit.
7 t ---f\r
HEATGAUGEUNIT Tighteningtorque:
// //)\l I ll 6.8-8.8N.m(70-90kg-cm,01-78lb-in)
Thermostat,ThermostatCover
1. Removeall foreignmaterialfrom the thermostat cover
_ mounting sur{ace.
2. Installthe thermostat
withthejigglepin facingupward.
t!" gasketmust face the
14-1etb-ft)
r08237 J .r-
HLA
1. Applya cleanerigineoilto the frictionsurfaces.'
2. lf the HIA are beingreused,installthemin the position
fromwhichtheywereremoved. ,_
'3. Vejfy thatthe HLAmove smoothly in theirbores.
j. -i. I ---:-.-
'-,- :
_._*i':..j
t0823{t
108-82 ,ENGINEassErvrguy
Camshatt
Note
' 'l'he exhaust camshaft is groovecr
tor the
distributordriver. .
1.Applya cleanengineoil to'thecamshaftjouma'is

' and.the
bearings.
2. Instalithocamshaftin itsposition.
OISTRIEUTOR Caution
DRIVEGROOVE . Do not allow any seafanron the camslraftjourna!
r0g2t0
surfaces
3. Applya siliconesealantto the shadedareasshownin the

\ figure.
4. Installthe camshaftcaps accordingto the cap number
, and the arrowmark.
a
,
r002.0
5. Installthe camghaltcap bortsand t:ghienthem in the

Tightening
- torque :
11.2-15.2Nlrn 1i.2-1.4 kg-m,g.6-10.1 lb-ft)
6. Applya smallamountof clean engineoil to the lip of a

'
new camshaftoil seal.
7. Pushin the oil se9!-s]ighily
by hand.
- Cautlon , "'
' ihe oil seal must be tapped In until
lt ls ftush wlth
: , ... the.edge of the camshafi cap. :,.-
8.I.p in the oil seal evenlywith a suitablepipe and a

hammer.
Oil sealouterdiameter: 4g mm (1.g9In)
ffi
ENGINE ASSEMaLY 108-83
oov/EL Ptf'j
C a m s h a f tP u l l e y
1 .T u r n t l r e c a m s h atfs u r r t i li h e c a m s h a f tc i o w e lp i n s f a c e
tire s t r a i g hut p .
2 . I n s t a l l h e c a r n s h a fpt u l l e y sw i t h t h e i m a r k ( i n t a k eside)
o r t h e E m a r k ( e x h a u ssr i d e )f a c i n gs t r a i g h u
t pvrard.
t\e
na!
3 . I n s t a ltlh e c a m s h a f pt u l l e yl o c kb o l t s .
the 4. Hold the camshaftwith a wrench.
5.1ightenthe camshaftpulleylock boit.
ber
w T i g h t e n i n gt o r q u e:
4 9 - 6 1 N ' m ( 5 . 0 - 6 . 2k g - m , 3 6 - 4 5 l b - f t )
:he C y l i n d e rH e a dC o v e r
1. Applya siliconesealantto the shadedareasshorvnin the
figure.
2. Inltallthe cylinderhe.adcover.
Tighteningtorque:
4.9-8.8N'rn(50-90kg-cm, 43-78lb-in)
fa
ith
la
108:84 ENGfNEasseuery
T'M'NG BELT ;
Torque Specifications
I
I
I N.m
:
fr
I
7 . 8 _l 1
( 8 0 - 1 1 0k g < m , 69-95fb.tn)
I
t
,/
7.8-t1 N.m
(80-ltO kg.cm.eS+S tU-ln;
37-52 (3.8_5.3.27_33)
N'm (kg-m, tb-fr)
ldler
1. Installthe idfer..
Tigllening torque :
37_52i{.m (3.9_5.3kg-m,
27_38 tb-ft)
Tensionerand TensionerSpring
1.Installthe tensioner
and the tensioner
' spring.
u"t". tn" t.^.ilnerwirhfufry-exrendins
];ffi:rarily rhe
Timing Belt
1.Turn ihe cranksiraftand align the timingbelt pulley mark
I I
I
with the timingmark.
Tri
Z.verrtythatthe camshaftpulleymarksare arignedwiththe

sealplatemarks.
3. Installthe timingbeltso that thei'eis no lcoserress

at the
idlersideor betweenthe two camshaftpulleys.
Caution
.. . Do not turn the crankshaftcountercloclovise.
4.Turnthe ci'ankshaft two turns.ctockwise, and alignthe

_ timing beltpulley mark with the timingmark.
5. veritythatthe camshaftpulleymarki are atigned'with the
sealplatemarks.
lf theyare not aligned,removethe timingbeltand repeat
fromthe tensioner installation.
6. Tum the crankshaft1 and 5/6 tum cloclo,vise,
and align
the timingbeltpulleymarkwiththe tensionsetmark
APPROX60'
,r*r, ll
7. Loosenlhe lensionerlock bolt to applytensionto the
timingbelt.
8.Tightenthetensionerlockbolt.
Tighteningtorque:
37-52 N'm (3.8-5.3kg-m,27-38 lb-ft)
9.Turnthe crankshaft2 and 1/6 turnsclockwiseand verify

thatthe timingmarksare correctly
aligned.
10E}-86 ENGINE assenaeLy
1 0 .M e a s u r er h e t i m i n gb e l t . d e f l e c t i o n
O E f : L E C T I OC
NH E C K T NP
GO I N T b y a p1 p t y i n gq
moderaiepressure1seru,10 kg, 22-lblL--t'v1"9 -'upnldW8y a
betweenthe
between tnetyro
t'"o camshaft
camshafr orrllovs
pufteys.
lf thecefrection is notcorrect, repeatfromstep 7 above.
Deflection
:
9.0-11.m 5 m ( 0 . 3 5 _ 0 . 4i n5) a t 9 8 N ( 1 0
k g , 2 2t b )
TimingBelt Cover
1. Installthe lower,middle,and upper
covers.
Tighteningtorque:
7.8-11N.m (80_110kg_cm,69_95tb-in)
V/ater Punnp'puttey
1. Instatfthe w?Je.(pupp pultey.
_ --_ | .. - - " ' ' - ' . - ' -'- l
T i g h t e n i n gt o r q u i i ,
"
7 . 8 - 1 1N . m ( B O _ 1 1 0 k g _ c m ,6 9 _ 9 5l b _ i n )
. .. , (
' ) '. i
ENGINE nSSEMBLY 108-87
9a PARTS
way AUXILIARY
?.ique SPecifications
!o
O . R I N GN = W
) r 9 - 2 5( 1 . 9 - 2 . 6l r.- r 9 ) l-tZ
1 9 - 2 5 ( 1 . 9 - 2 . 6 .l t l - 1 9 )
GASKET.
N=Y/
q
I
ls ( 1 . 9 "- l2t -. 2
6i 45. - 1 9 )
I
I
I
I
p
.5) 3't-s2
.,
' vt - s. 3.27- 38)
NEW
INSUT-ATOR.
dp
P
' 1 2 - 1 8N ' m
{ 1 2 0 - 1 8 0k g - c e .
1 0 4 - 1 5 6 ! b - i n\ )
93-117
( 9 . 5 -1 r. 9 .
69-e6) 15 - 2 3
( 1 . 5 - 2 . 31,r - r 7 )
12-25
( 1. 9 - 2 . 6 ,1 4 -1 9 )
37-52
(3.8-s.3.27-381
:_
N'm(kg-m. lb-tt)
t08257
' '
FRONT Engin'eHanger-'. ----
, 1. Install'thefrontand the rear enginehangers.
r&
A\-- Tighteningtorque:'.'
til i 37-52 N'm (3.8-5.3kg-m,Z7-38 lb-ft)
vl
t- - '-' , t -
\o+-
'\R
108258
E--Ct
-rn
108-88 ENGINEasseueLy
L"y:f GausepipeStay
9il
1.Install
theoilleveigaugeiip" ,t"y.
Tightening torque :
7 . 9 - 1 1 N . m ( 9 0 _ 1 1 0k g - c m ,
69_95 tb-in)
Oil Level Gauge
1. lnstaflthe levelgauge.
SparkPfug
1.Applyan antiseize comnould
^2. fubricant.to :, " morybdenum-based
thesparkplugthreads.
lnstaflthesparkilugsi
nglleningtorque:
1S-23N.m(1.S_2.3
kg-m,11_17lb,,ft)
Oll PressureSwltch
1,fnstafl
theolfpressuro
ewftch.
Tlglllentngtorque:
12-18N.m(120_1g0kg-cm'104_f56lb.ln)
OllFlltcr
1.Removoail forergnmaterrar from! ' | the
r ' ' v voil
' flrtor
rrr mountrnc
- , , ,, .
gurfacg.
t'
loq'y.a.smailamount
soal
of creanenglneoilto therubber
_ ol thoollfiltor.
u' Instailthooil andtrghtcn
lltût - rt by handunilftherubber
,c' leql contacts thobaro.
ngnt€n thoflltor1 and1/6turnawltha flftor wronch.
A l t e r n a t o ra n d D r i v e B e l t
1 . I n s l a ltl h e a l l e r n a t oar n d l o o s e l yt r g h t e ni h e m o u n t i n g
bolts.
2 . I n s t a ltlh e a l t e r n a t odr r i v eb e l t .
3. Adjustthe drivebeltdeflections.
rc82A3
ed I n j e c t o ra n d D i s t r i b u t i o nP i p e A s s e m b l y
1.Installthe new injectorinsulatorsto the cylinderhead.
{t,(€Zt}ffi,
t7. //t;\
2. lnstallthe injectorand t h e d i s t r i b u t i opni p e a s s e m b l yto
thecylirrderhead.
:
Tightening torque:
1 9 - 2 sN ' m( 1 . 9 - 2 . kg-m,
6 14-19 lb-tt)
irl I
ng IntakeManifoldAssembly
1. Removeall foreignmaterialfrom the intakemanifold
) ef contactsurface.
2. Installa newgasketandtheintakemanifold
assembly.
) el
Tightening
torque:
19-25N'm (1.9-2.6kg-rn,14-19lb-ft)
l0B:57
3. Connectthe harnessand hose.

108-90
E N G T N EA S S E M B L Y
D i s t r i b u t o ra n d
H i g h _ t e n s i o nL e a d
1 . A p p l ya q r e a _ s e
l o a n e i vO - , - i n g
and
. rheoisrributor;;looseryt h e b l a C e .
ffi
,!:l[', rislhren rrrer r s l a l l a t i e n
3 . C o n n e c tt h e h i g h . t e n s i o n
leads.
E N G I N E E N G T N sEr A N D D t s f v t o u N T t N c . 108-91
DISMOUNTING
E N G I N ES T A N D
PBOCEDURE
f r o mi h e S S T ( e n g i n es t a n d ) .
1 . R e m o v et h e e n g i n e
, g e n r o v t
e h e S S T ( e n g i n eh a n g e r ) .
2
3 Installthe pa;tssho',vnin the {igure.
T o r q u eS P e c i f i c a t i o n s
z\.,r{.\
/-\\Dnri'
--/-> l':*
q--$/6
Kril$sjrr\\i
Wil i 3 8 - 4 6 ( 3 . 9 - 4 . 7 .2 8 - 3 4 )
c\W.'-lcor*.r, NEW
.RING,
E
1 9 - 2 5( 1 . 9 - 2 . 61. 4 - 1 s )
37-52 (3.E-5.3.27-38)
1 9 - 2 5 ( 1 . 9 - 2 . 5 l. 4 - 1 9 )
7 . 8 - 1 1 N . m ( 8 0 - 1 1 0k g - c m . 6 9 - 9 5 t b - i n )
N'm (kg-m. lb-h)
ExhaustPipe Bracket
1. Installthe exhaustpipe bracket.
37 -52 N-m (3.8-5.3kg-m, 27 -38 lb-ft)
r0327r
108-92 ENGINE erucrruE
srANDDrsMouNnNG
Water lnlet pipe

1 . R e m o v e a i l f o r e i g n m a t e r . i aflr o m
t h e v r a t e ri n l e t p i p e
m o u n t i n gs u r f a c e .
2 . l n s t a l al n e w g a s k e ta n d t h e w a t e r
i n l e tp i p e .
T i g h t e n i n gt c r q u e :
1 9 - 2 5 N - m ( 1 . 9 _ 2 . 6k g - m , 1 4 _ 1 9i b - f t )
WaterBypass pipe
1.Applya smalramountof enginecootant
to the new O-
ring.
2. lnstallthewaterbypasspipe.
A/C CompressorBracket(lf equipped)

1. Installthe fuC compressor
6ffi Tighteningtorque:
brackei.
aJlt-oj A t l9-2! lv.r (t.s-2.6l,s-r, 14_1s

tb-ft)
@ : 37-s2N.mis.e_s.s r,6-rn,27_3a
iu-ttl
ExhaustManifold
Removeail foreignmateriarfrom the exhaust
manifold
contactsurface.
Installa new gasketandthe exhaustmaniford.
\.il Tighteningtorque:
38-46 N.m (3.9_4.7kg_m
, Zg_34tb_ft)
ir"-r}'n}
.-r.--=l E::-=: ExhaustManifoldInsutator
1. Inslallthe exhaustfnanifoldinsulator.
7 . 8 - 1 1 N . m ( 8 0 - 1 1 0k g - c m , 6 9 _ 9 5l b - i n )
ENGINE TNSTAL'LAIoN 108-93
N
INSTALLATIO
PROCEDURE
and nuts to the specifiedtorque.
i. fignrcn all bolts
S t e P1 .-.
iotqu" SPecifications
34-49
( 3 . 5 - 5 . 02. 5 - - 1 6 )
37-52
\ (3.8-5.3.27-3sl
19 - 2 5
( 1. 9 - 2 . 6 .1 4 -l 9 )
)-
tl
ri './?
aKaF'x
s\e^l
\4 lc
u
S
\ lq,q
5 5 - 8 0( 5 . 5 - 8 . 2 . 4 1 - 5 9 )
3 7 - s 2( 3 . 8 - s . 3 . 2 7 - 3 8 )
37-s2 (3.8-5.3.27-381
rd
37-52 (3.8-5.3.?7-381 6 4 - 8 9( 6 . 5 - 9 . r4. 7 - 6 6 )
N'm (kg-m,lb-ft)
M a n u a lt r a n s a x l e
1. Join the engineand the transaxle.
2. lnstallthe transaxlemountingboltsshownin the figure.
3. Tightenthe bolts.
@ : 6 4 - 8 g N ' m ( 6 . s - 9 . 1k g - m , 47-66 tb-ft)
@ : 37-52 N'm (3.8-s.3 kg-m, 27-38 tbft)
r 08278
1U.8-94
ENGINE INSTALLATIoN
A u t o m a t i ct r a n s a x l e
1 .. , o i nt h e e n g i n ea n d
thetransaxle.
z . r n s t a lilh e t r a n s a x l emounilng
3 . l - i g h i e nt h e b o t r s . boltsSh91..,y-1
in the figure.
r J r : 5 5 _ 8 CN . m ( 5 . 6 _ 6 . 2
k g - r n ,4 1 - S 9
@ : 3 7 - 5 2N . mi s . B _ i . lkg-m, 27 -38 l b f t )
lb-fti
4. Arrgnthe torqueconverter
bolts
Instaiirhetorqueconverter and thedrivepiatehoies.
nuts,and tightenthem.
Tiglleningtorque:
3Z-SZN.m (3.8_5.3 kg-m,27_36tb-ft)
No.2engine mount rubbe:,

and bracket
1. Instalirhe mount rubber
and the br;;;t:
3Z-s2 N.m (3.8_s.3kg-m,
2T_3|lO-tt)
Throtile Cabte
6m
1.Connectthethrottl!cable
'v qr
and
(Referto Sectio ' adjustit.
n el--
Starter
.1:lnstallthestarler'ro
,h" transaxle
housino.
\4 Tigllening torque :
37-SZN.m 1a.e_S.3kg_m,2T_3|tbft)
I n t a k em a n i f o l d b r a c k e t
1 . I n s t a l tl h e i n t a k em a n i f o l db r a c k e t .
H
-\ 'f, -]r-
-
\t,l-t iI -/\ \\
37_SZN.m (3.8_5.3_ kg-m, 27_gllb-ft)
#:FE
ENGINE tNSTArrATtoN 108-9s
SteP 2
Warning
. B e s u r e t h e v e h i c l ei s s e c u r e l ys u p p o r t e do n t h e s a f e t ys t a n d s .
TorqueSPecifications
5 s - 9 0i s . 6 - 8 . 2 .
s 5 - 8 0( 5 . 6 - 8 . 2 . 4 1 - s 9 )
67-s?(6.a-s.s4 9 - 5 3 )
\
\ 4 3 - 6 1( 4 . 4 - 6 . 2 . 3 2 - . r 5 1
-l
I
I
74- 103 I
r.5-10.s. 54-76)
I
\
II
\
37-52 (3.8-5.3.27-38)
37 -52 (3.8-5.3.27 -38')
'/
6 4 - 8 9 ( 6 - . 5 - 9 . 14
. 7-66) 6 4 - 8 9 ( 6 . 5 - 9 . 1 .4 7 - 6 6 )
N'm (kg-m. lb-ft)
Engine mount member (A/f)

1. Installthe enginemountmember.
Tightening torque :
54-89 N.m (6.5-9.1kg-m, 47-66 tb-ft)
ol fFlE
h=
-rNA
108-96
ENGIryE TNSTALLATIoN
E n g i n ea n d t r a n s a x t ea s s e m b l y
t . s r s p c n c ir h e e n c j i n ea n d t h e t r a n s a x r e
assernbrv.
Cautiorr
. Do not damage any components
in the enginr
compartment.
2 . l n s t a l lt h e e n g i n e a n d t h e t r a n s a x t e
eltgineroom.
a s s e m b t yi n i h r
3 . A l i g nt h e e n g i n em o u n t srviththe engine
m o u n t i n gh o l e s .
mcuntmembe
,
E n g i n em o u r r t
- N o . Ze N G t N =
1 'r n s t a itrh e e n g i n em o u n tn u t s o f
I . M O U NNT IITS the No.2and No.i
mounts,andlightenthern.
. TiEhtening
torque:
37-52N.m (3.8_5.3kg_m,ZT_3Blb-ft)
2. InstalltheNo.3enginemountrubber.
Tighteningtorque:
@ :74-191.N.* 0.s-10.5kg-m, s4_26tb-fr)
@ : 67-e3N.m (6.8_s.5kg_,i,qb_oglU_ttl
3. Installthedynamicdamper.
Tightening
torque:
55-BCN.m(5.6_e.Zkg-m,41_S9tb-ft)
ENGTNE
suppoAre Caution
l 2
' B e f o r ei n s t a t i n g t h e e n g i n e
supf ort
a r r a n g et h e c l u t c h r e t e a s ec y fi h b e r - "bnr'aJci lk; ;e t ,
N
assembly.'
4. Installtheenginesupportbracket(MfD.
'-:\-,$: Tightening torque:

+_JNJ
/ cLUrcHRELEASE pipi
cvlrr.rbsn
5 5 - 8 0N . m( 5 . 6_ g . Zk g - m ,4 1 _ S 9l b _ t t )
t-
5. InstalltheNo.4.engine mountrubberand the bracket,anc

^ loosely tighten the nuts @.
6. Instailthe borts@ on the bodyside,and
tightenthemin
. theordershown.. ._
'
T i g h t e n i ntgo r q u e: , .. -
43-6j N.m(4.4_6.2kg-m,32_45tb_tt)
7. lightertthenuts@.- . ,_.]r.
..
Tighteningtorque:- . --,
6 7 - 9 3N . m ( o . a _ s . ks g - m ,4 9 _ 6 9l b - f t )
. .l .._.
ENGlNE INSTALLAIoN 108-97
?5# speciiications
6 . 9 - 9 . a l . J ' . n( ; 0 - 1 0 0 k g . c n r .6 t - A 7 l b - i n l
16 - 2 3 ( 1 . 6 - 2 . 3 . t 2 _ 1 7 ' )
t
i
4 2 - 6 2( 1 . 3 - 6 . 3 , 3 i - 4 6 )
1 5 - 2 3( 1 . 6 - 2 . 31. 2 - 1 7 )
42-57 (4.3-5.8.31-42)
37-52 (3.8-5.3,27-38)
N'm (kg-m. lb-ft)
Driveshaft
1. Applya greaseto the end of the driveshaft.
C au t i on
- - w h e n i n s t a l l i n g t h e d r i v e s h a f t ,b e c a r e f u t n o t t o
d a m a g et h e o i l s e a l .
. A t t e r t h e i n s t a l l a t i o np
, ull the front hub outwardto
c o n f i r m t h a t t h e d r i v e s h a f ti s s e c u r e l y h e l d b y t h e
- cilp . :"
2. lnstallthe driveshaftand a new clip.
-3.
I n s t a l tl h e l o w e ra r m b a l l - j o i ntto t h e k n u c k l e t; h e n t i g h t e n
il,"\ the lock nut. .'
.
4 . I n s t a ltlh e j o i n ts h a l t .
5. Tghten the boltsin the ordershown
!n the figure.
..
4 2 - 6 2N . m ( 4 . 3 - 6 . 3k g - m , 3 1 - 4 6 t b - f t )
i$ ifl
108-98 ENGINE rrvsrnLlAloN
..1 | Tie-rodend
' 1 .I n s t a l l
,i I
i; lJ I:
t h e t i e - r o de n d t o t h e k n u c k l e . .
I
li
rl
't T i g h t e n i n gt o r q u e:
fl
t 4 2 - S TN . m ( a . 3 _ S . B
k g - m , 3 1 _ 4 Zl b - f t )
tr
ii
1i 2 . I n s t a ltl h e n e w s p i i rp i n .
;
Stabitizei
1. Installandadjustthestabilizer.
Dimension
A :17-19 mm (0.67_0.75
in)
-) Extensionbar (Mff)
i. Installtheextension
bartc the transaxle.
Tighteningtorque:
31-46 N.m (3.2_4.Tkg_m,23_34fb-fr)
Shift controt rod (M/T)

1. Installtheshiftcontroirodto rhetransaxre.
Tighteningto;.que: .
16-23N.m(1.6_2.3kg-m, 12_17lb_ft)
Ctutchreleasecylinder(MfD
1. Installtheclutchrelease-cylinder.
Tighteningtorque:
16-23N.m(1:6_?.3
ks_Tr1z_1Irb,ft)
thepipebracket
in irsposition.
- ?.f?t
Tighteningtorque: . : _
1 6 - 2 3 N . m ( 1 . 6 _ 2 . 3k g - m , _ Z
1_17tb-ft)
Shift controt cable(MD

'1.lnstalltheshiftcontror
cabreto rhetransaxre.
Tighteningtorque: ..
. 6.9-9.8N.m(70_.100
kg-cm,61_87tb_in)
ENGINE INSTALLAIoN 108-99
Speedometer cable
1 . I n s t a l lt h e s p e e d o m e t e rc a b l e .
Exhaustpipe
1.Inslallthe exhaustpipe and a gasket;then looselytighten
' the lock nuts.
2. Looselytightenthe bracketbolts.
3.f ightenrhe lock nuts.
Tighteningtorque :
37-52 N-m (3.8-5.3 kg-m, 27_38 tbft)
4.Tghten lhe bracketbolts.
rcEl300
37-52 N-m (3.8-5.3kg-m,22_gBtbtt)
Step 4
Conneclthehosesshownin thefigure.
1. Connectthehosesshownin thefigure.
Caution
. ' Positionthe hose clampin the originallocationon the
hose, and squeeze the clamp lighily
with ihe largepliersto ensurea goodfit.
BRAKEVACUUMHOSE
<\ \
FUELHOSE
\
WATERHOSE
10E}-100 ENGINE INSTALt_ATloN
Step5
1 ' c o n n e c t r h e h a r n e s sc o n n e c r o r
s h o r v ni n t h e f i g u r e .
GHOUi';O
Af,T
lcr^
scL=r,jolo
BALBE -GRouNo
rtJHretroe
S'#ITCH
/4
A
,4 Y
'd{
\\ )
DrsrRrBuronT \
\ \----
GRouNo--ENBUS'
\>s**r$-)*;{"
\-sEr.rsoa
$-/-WÊf;o
I G I J I T I O NC O : L
SACK.UPLIGHT
SWITCH
Step 6
7.8-ll N.m (80-ll0 kg.cm,69_95

tb.in)
7 . 8 - t ' tN ' m
( 8 0 - 1 t Ok g - c m 6
, 9 _ 9 5t b - i n )
€ 2.9-5.9 N-m
ffi l','-;:';qj'.
).. \ ffi
\[/
37-52(3.8-5.3.27-38)
\ ,r'l(
( 2. 1-" 3. 6.
17 -2 6 ) F r* \
i\)4
YO
7 . 8 - 1 1N . m ( 8 0 - l t O k g . c m . 6 9 _ 9 5 56-82lb.in)
tb.in)
N ' m ( k g - m ,t b - f r
ENGINE TNSTALLAIoN 108-101
A/C compressor (if equipped)

i.Install ihe P/C comoresscr.
2 4 - 3 5 N ' m ( 2 . a - 3 . 6k g - m , 1 7- 2 e l b f t )
Z . T i g h t e nt h e A / C p i p e b r a c k e t t o t h e e n g i n . ' m g u n !
member.
6 . 8 - 8 . 8N ' m ( 7 0 - 9 0k g - c m , 6 1 - 7 8 l b - f t )
6(\ 1 . I n s t a ltlh e P / S o i l p u m pa n d t h e b r a c k e t .
37 -52 N'm (3.8-5.3kg-m, ?7 -39 lbft)
Drive belt
1. Installthe P/S androrthe tuC cirivebelt.
2. Adjustthe drivebeltdeflections.
R a d i a t o ra n d c o o l i n g f a n a s s e m b l y
1. lnstallthe radiatorand the coolingfan assembly.
" 7 . 8 - 1 1 N ' m ( 8 0 - 1 10 k g - c m , 6 9 - 9 5 l b - f t )
2. lnstallthe A/C pipe to the radiator.
6 . 4 - 9 . 3N ' m ( 5 5 - 9 5 k g - c m , 5 6 - 8 2 l b - i n )
r30]?7
theupperandtlre lo*.r' radiator

3. Connect hoses.
I
Caution
. P o s i t i o nt h e h o s e c l a m p i n t h e o r i g i n a tl o c a t i o n
o n t h e h o s e ,a n d s q u e e z et h e c l a m p l i g h t l yw i t h
targepliersto ensurea goodfit.
4. Connect
thecoolant hose.: :
reservoir
5. Connect
thecoolingfanconnector.
6. Connecttheoil coolerhose.(A/T), " .:,
| 083CE
108-102 ENGINE tNSTALt-AloN
A c c e l e r a t o rc a b l e
1 . l n s t a ttlh e a c c e l e r a t ocra b l e .
2 . A d j u s t h e c a b l ed e f t e c t i o bn y t u r n i n gt h e n u t @ .
D e f l e c t i o n: 1 - 3 m m ( 0 . 0 1 - 9 . 1 2 i r t )
OEFLECTION
. HECKING POINT
. . . . . .C
Batteryduct, batterycarrier,and battery

1. Installthebatteryduct.
torque:
Tightening
7.8-11N'm (80-110kg-cm,69-95lb-in)
2. Instailthe batterycarrier.
Tightening torque:
7 . 8 - 1 1N ' m ( 8 0 - 1 1 0k g - c m , 6 9 - 9 5l b - i n )
3. Installthe batteryandthe batterybracket.
Tighteningtorque:
2.9-5.9N'm (30-60kg-cm,26-52lb'in)
A i r c l e a n e ra s s e m b l Y
1.Installthe aircleanerassembly.
R e s o n a n c ce h a m b e r
1. lnstallthe resonance chamber.
Tighteningtorque:
7.8-11N'm (80-110kg-cm,69-95 lb-in)
Undercover and side cover

1. lnstallthe undercoverandsidecover.
StepsAfter lnstallation
1. lf theengineoilwasdrained,fillwiththespecifiedamountandtypeof the engineoil.
2. Fillthe radiatorwiththe specifiedamountandtypeof theenginecoolant.
3. lf the transaxleoilwas drained, amountandtypeof the transaxle
fillwiththespecified oil.
4. Connectthenegative batterycable.
'5. Startthe engineandcheckthefollowing ;
(1)Engine'oil,transaxleoil,andenginecoolant leakage
(2)lgnitiontiming,andidlesPeed
(3)Operation of emissioncontrolsystem
6, Performa roadtest.
7. Rechecktheengineoil and theenginecoolantlevels.
ENGINE sPEctFtcATtoNS 108-103
SPECIFICATIONS
- Engine
- 85 00HC
Item
-
TYge Gasoline. 4-cycle
C y l i n d e ra r r a n g e m e n at n d n u m b e r l n - ! i n e .4 c y l i n d e r s
C o m b u s t i o nc h a m b e r Pentrool
Valve system D O H C , b e l t - d r i v e n' t 6 valves
Oisplacement cc (cu in) 1 , 4 9 8( 9 1 . 4 )
Eorqilq {e!e mm (in) 78.0x 78.4(3.07x 3.09)
Compression ratio 9.3
Compression pressure psi)-rpm
kPa (kg/cmz, 1, 1 7 7 ( 12 . 0 , 1 7 1 )- 2 8 0
IN
Open ETDC J
Close ABDC 40'

Valve timing
Open BBOC JJ
EX
Close ATDC 5
IN 0 : Maintenance-free
Valve clearance mm (in)
EX 0 : Maintenance-free
|\I/T 750 t 50
ldles peed ' rp m
Afi 800 t 50
'
lgnitiontiming' ETDC f i1
Firingorder 1-3-1-2
'TEST terminal grounded
connector
of diagnosis
LUBRICATION
SYSTEM E
OUTLINE 11- 3
TROUBLESHOCTTNG G U T D E. . . . . . . . . . . 11- 4
OILPRESSUHE 11. 5
E N G T N EO t L . . . . . - . 1 1 _6
o l L F T L T E R. . . . . . . . 11- 6
OIL PAN 11- I
orL PUMP........... 11-11
SPEC|F|CAT|ONS 11_14
OUTLINE(srnucrunAL
vtEW) 11-3
OUTLINE
VIEW
STFUCTURAL
HYORAULTC
LASHAOJUSTER
(Hr..A)
1.Oilpressure 4. Oilpanandmainbearing
supportplate(MBSP)
2. Engineoil 5.Oilpump
3. Ollfilter
11-4 T R O U E L E S H O O T I NGGU I D E
R e c o n rm e n d e c l S A E r / i . s c o si t y
-2t) - lC
Tcirnperarure
l:B
_ -v (.U
60 gO .12.O
100
5W-30
5W.20
Erigine oil
20w.40 20tN.50
_,
Artticipated
ambienttemperarure
rangebeforesueceeding
oitcrranEe,
t (, F)
T R O U B L E S H O O T IG
NUGI D E
a
Pfobleni p o s s l b lecaU se
Remedy
Englnehardstertlng t.Ot
lnsufficient
engineoil Fleplace
=:--
A dd oi l
Exceeslve
oli Oilworktngup or down
COnEurlptlOrr Oil l€akage : R el erto S ecti on.10
R epal r
I oit pressure
drop lrtsufticient
Add oil
.Oill€akdge Flepair
Worn dndtoidarnagedOilpump gear
ptunger,(irrsidc _ Fleplace
19f oilpumpioi*eaflsprinE
Cl6Eg)ed
0itstfainer Fleplace
Excessiv€
rnairibearing
or cortnecting 0l ean
eledlani€
rodbeaiinE R eferto S ecti on10
Warnlng lamp oitpressuru;
lllumlnales whfle Matfunetiorr As desgibedabove
€ f l E l nleo r u n n i n g ol oitpiessure
swireh
Mafiunctiorr
of eleclridal
sygtom .. -..: H eferto S ecti on61
Flelerto Section61
, .?
I
i O I L P R E S S U R E ,E N G T N EO I L ( t N S p E c l o N ) 11 - 5
OILPBESSURE
pnrpnnATlcN
SST
o K 6 7 o 1 4 00 1 5 For
inspection
of oil
Gauge' pressure
cil pressure
INSPECTION
'1.
R e m o v el h e i n t a k em a n i f o l db r a c k e t .
2. Removethe oil pressureswitch.
I
J
'lI 3. Screwthe SST intothe oil pressureswitchinstallation
hole.
4. Warm up the engineto normaloperatingtemperature.
J 5. Run the engineat 1,000rpm and 3,000rpm, and note the
g a u g er e a d i n g .
O i l p r e s s u r e:
196-294 kPa (2.0-3.0kg/cm?,28-4;:psi)-1,0O0 rpm
294-392 kPa (3.0-4.0 kg/cm2,€-57 psi)--3,00r?rpm
O.'li tne pressureis not as specified,check for the cause

and repair. (Referto Troubleshooting.Guide)
7. Removethe SST and installthe oil pressureswitch.
1 2 - 1 8 N ' m ( 1 . 2 - 1 . 8k g - m ,1 0 4 - 1 5 6l b - i n )
-8.
l n s t a ltl h e i n t a k em a n i f o l db r a c k e t .
@ : 37-52 N'm (3.8-5.3kg-m, 27 -38 lb-ft)
@ : 1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m ,1 4 - 1 9 l b - f t )
- ...:'..
11-6 E N G I N EOlL, Otf FILTER (REnLAcEMENT)
EwGti\tE
OtL
INSPECTICN
s u r et h e v e h i c l ei s o n l e v e l
'l . B " up rlreengineronormar-operaring _oround.
:T#T remperarure
and
3.Wait for five minutes.
. oit leuergaugeandcireckrhe
i.jffi,::.rhe oitteverand
5.ROOor repiaceoil
as necessary.
u
REPLACEMENT
Warning
. Be careful
when draining ; the cil is hot.
1' wai'm up the engineto
nornar operatingtemperature
stop it. and
2. Removelhe clilfillercap
and the oil pan drain plug.
3. Dra;nthe oil into a ,":60f"
tntainer.
4. Instafla new gasketand
the drainp,rg.
. T i g h t e n i n qt o r s u e :
29-41ll.m (s.o_c.z kg-m, 22_30
tb-rt)
5. Retill the engine with ghs ' v -cpecified
sFvv'rrss type
t y P E and
'iI amount of
engine oil.
6. Refitthe oil fiilercap.
I lyn theengineand checkfor teaks.

u. uneckthe oil leveland add oil if necessary.
Ir0r0
OIL FTLTEFI
.
REPLACEN/lENT
1. Removethe oil filterwith a
suitablewrench.
2' Use a clean rag to wipe off
the ,'orntin! surface on the.
engine.
3' Apply a s,mailamount of
crean engine oir to the.rubber
seal of the nel filter.
OIL FILTER (REpLAcEMENT) 11-7
4. Installthe oil fitterand tightenit by hand untilthe rubber

sealcontactstlte base.
5. Tightenthe filter1 and 1/6 tums with a filterwrench.
6. Startthe engineand checkfor leaks.
7. Checkthe oil leveland add oil if necessary.
Oil filter capacity :

0.20 liter (0.21US qt, 0.18 lmp qt)
3'
11 - 8 olL PAN (REMOVAUTNSPECT|oN/TNSTALLATION)
OIL PAN
F I E M O V A L/ I N SP E C T I O N/ I N S T A L L A T I O N
1. Disconnectthe negativebatterycabte.
2. Drainthe engineoil.
3. Removethe undercover and side cover.
4. Remove in the ordei shown in the figr;: referring
ro Removar Note.
5. Instailin thereverseorderor remiu;[ ,.f";;i"g i; r";"f
il;;;',i:",;
"4
rgE{l
GASKET, ,/y' {rt

\ 3 1- 4 6
( 3 . 2 -4 . 7 ,
REPLACE
o *q 23-:34)
1 6 - 2 1( 1 . 6 - 2 . 1 . 1 2 _ 1 5 ) I
I
37-52
(3.8-s.3.
7.8-11 N.rn- 2 7- 38)
(80-110kg-cm,69-95 tb-in)
GASKET.
REPLACE
-e4 (7 . 0 - 9 . 65. l - 6 9 )
REPLACE
-;S GASKET"
REPLACE
29- 41 ( 3. 0- . 4 .2 , 2 2 -3 0 ) 3 7- 5 2 ( 3 . 8 - 5 . 32. 7 - 3 8 )
7 . 8 - l l N . m( 8 0 - ' 1 1k0g . c n r . 6 9 - 9 5
tb.in)
N.m(kg-m,tb.fr)
1. Frontexhaustpipeandbracket. 4. Oilstrainer
2. lntegrated
stiffener 5. Me.inbearingsupportplate(MBSp)
3. Oilpan
OIL PAN (REMovAUtNSpEcrloN/tNSTALLATtoN) 11 - 9
Oil pan
1 . R e m o v et h e o i l o a n m o u n t i n ob o l t s .
C a u t i on
. Do not force a prying tool between the cyllnder
b l o c k a n d t h e o i l p a n , w h i c h m a y d a m a g et h e c o n -
tact sui-faces.
" Do not damage or scratch the contact surfaces
v r h e n r e m o v i n gt h e o l d s e a l a n t .
2. lnsert a screwdriveror a suitabletool only at the points

shown in the figure.
3 . R e m o v et h e o i l p a n .
M a i n b e a r i n gs u p p o r t p l a t e( M B S P ) ,..
1. Removethe MBSPmountingboltto the mainbearingdil.
2. lnsert a screwdriveror other suitabletool between the
MBSP and cylinderblock,and pry them.
C a u t i on
. D o n o t d a m a g eo r d e f o r m t h e M B S P .
. Do not damage or scratch the contact surfacbs.
Installation Note
M a i n b e a r i n g s u p p o r t p fa t e ( M B S P )
1. Remove all foreignmaterialfrom the contactsurfacesof
the cylinderblockand MBSP.
.
Caution
. T h e o i l p a n m u s t b e s e c u r e dw i t h i n 3 0 m i n u t e s
after the sealantis appliedto the MBSP.
MAINEEARINGSUPPORTPIJTE :r 2. Applya continuous beadof siliconesealantto the MBSP

alohgthe insideof theboltholes
3. lnstalltheMBSP.
SUPPORTPLATE(MBSP)
MA|NBEAATNG in twoor threesteps.
4. lightentheMBSP.bolts
r-f!r"Jo'*' torque:
Tightening
16-21N'm(1.6-2.1kg'm,12-1slb-ft)
/o)lA- Caution
. tf the boltsare reused,removethe ofd sealant
from the bolt threads.
Tightening the boltwithold sealanton lt may
causecrackinginsidethe bolt holes.
11-10 OIL PAN (HEMovAutNSpEcrtoN/tNSTALLATtoN) {
T
t
Oil Pan
1. Removeall foreignmaterialfrom ihe contactsurfaces.
i
I
2. Applysiliconesealantto the contactsurfacesof a new oit I
pan gasket,shorvnin the figure.
3. Installnew gasketsontothe oir pumpbody and the rear

coverwiththeprojections
in thenotchesshownin thefigure.
a. Applya continuous beadof siliconesearantto the oil oan

_ alongthe insideof theboltholesandoverlapthe ends.
5. Install
theoil pan.
Tighteningtorque:
7.8-11N.m(80-110kg-cm,69-95lb-,in)
StepsAfter Installaticin i
1. Install
the undercoverandsidecover.
2.Ftllwiththespecified amountandtypeof engineoil.
3. Connectthe negativebatterycable.
4. Starttheengineandcheckforleaks.
5. Checkthe oil levelandaddoil if necessary.
OIL PU MP lneuovAUrNsrALLAloN) 1 1 - 11
OIL PUMP
PREPARATION
SST
0 K 1 3 0 1 1 10 0 4
Holder,
c o u p l i n gf l a n g e
For
removaland
installationof
"'r:@
;:1'::,1
ror
removal and
installationof
timing belt pulley crankshart *6 timing belt pulley
REMOVAL/ INSTALLATTON
1. Disconnect thenegativebatterycable.
2. Draintheengineoil.
3. Removethetimingbelt.
4. Removetheoilpanandmainbearingsupportplate(MBSP).
5. Removein theordershownin the figure,referring to RemovalNote.
6. Installin the reverseorderof removal,
referring
td lnstaltationNote.
O (3.8-s.3
37-52N.m zz-ae
ro.trJ
\9,
F$ I
37-52t{'m
(3.8-s.3kg-m.27-38 lb-tt)
e-ffFi
19-25N'm
19-25N.m (1.9-2.6kg-m.
( 1 . 9 - 2 . 6k g - m .1 a - 1 9l b - f t ) 14-19tb-fr)-
24-35N'm
(2.4-3.6 kgrn,
@ Frfr 17-28 tb-ft)
.
1. Alternator 5.1-iming beltpulleyandbosspulley'
2. NC compressor 6 .O i ls t r a i n e- -r ; . - -.
-':
3. NC compressor bracket 7. ottpumt .
4. Pultey
lockbolt
11-12 OIL PUMP (rNSPEcloN)
#
{
-:t
e
t
--r
'x
PROTECTPUN4P
Oil seal a
EODY'//ITH RAG 1. Removethe oil seallvitha screwdriver
protectedwitha rag. { 1
I
t
I
{
ts
I
i
{
II
a
{.
't
t-
INSPECTION
PressureSpring
1. Inspectthespringforweaknessor breakage. f
i
2. Measurethe freelength.Replacethe springif necessary. ' nI
I
,
Freetength: 45.5mm (1.791in) .tt
*
I
t
t
Rotor Clearance
1 . M e a s u r et h e f o l l o w i n gc l e a r a n c e s . Replace the rotor if
necessary.
: 0.20mm(0.0079
Toothtip ctearance in)max.
Outerrotor to pump body clearance:

0.22mm (0.0087in) max.
.-
S i d e c l e a r a n c e: 0 . 1 4 m m ( 0 . 0 0 5 5i n ) m a x .
OIL PUMPlr.rseecloN) 11 - 1 3
Assembly l.lote
Cil seal
1. A p p l y a s m a l l a m o u n to f c l e a n e n g i n eo i l t o t h e l i p o f a
n e wo i ls e a ! .
2 . P u s ht h e o i l s e a ls l i q h t l yi n b y h a n C .
Cauiion
. T h e o i l s e a l m u s t b e p r e s s e di n u n t i l i t i s f l u s h w i t h
the edge of the cil pump body.
3. Pressthe oil seal in evenlywith a suitablepipe.
11 - 1 4 SPECIFICATIONS (sERVtcE
oATA,TTGHTENtNG
ToRouE)
SPECIFICATIONS
DATA
SERVICE
--_ Engine B5
tto,n
L.ubrication syslern Force-fed type
Type Trocfroidgear
Oil pump
Retiel Pressure kPa (kg/cm2, Psi) 343- 441(3.5-4.5.sO-64)
Type Full-flow.paper element

oiltitter
Rellefpreli{ire diflerentlbt kPa (kg/cm2,psi) 7 8 - 1 1 8( 0 . 8 -1 . 2 , 1 1 - 1 7 )
Oil pressureswitchactivationpressure kPa (kg/cm2,psi) 2s (0.2.5,

3.5)
Total(dryengine) llters(US qt. lmo qt) 3 . 4( 3 . 6 , 3 . 0 )
Oil capaoty Oil pan litcrs(US qt, lmp qt) 3.0 (3.2,2.6)
Oil filtgr litor(US qt. lmp qt) 0 . 2 0( 0 . 2 1 . 0 . 1 8 )
Engine oil nPl service SG
TOROUE
TiGi{TENING
Engine N'm (kg-m, lb-ft)
itern
Oilpreesureswitch. 1 2 : 1 8( 1 . 2 - 1 . 81. 0 4 - 1 5 6l b - i n )
Dralnplug 29-41 (3.0-4.2,22-30)
MBSPbotts 1 6 - 2 1( 1 . 6 - 2 . 11, 2 - 1 5 )
Oil pan botts 7.8-11(80-100kg-cm,69-95l b-i n)
I
COOLINGSYSTEM
OUTLINE 12- 3
T R O U B L E S H O O T I N GG U I D E 12- I
E N G I N EC O O L A N T . . . 11- s
R A D I A T O RC A P 12-6
TH E R MOS TA T 12- 8
W A TE R P U MP 12-10
E L E C T R I CC O O L I N G FA N S Y S TE M 12-11
FA N MOTOR .............. 12-12
WATERTlIERMOSWTTCt-t 12-13
FAN REI_AY.....-..... 12-14
SPECIFICATIONS 12-15
OUTLINE (srnucrunAlvrEW) 12-3
OUTLINE
VIEW
STRUCTUR,{L
EtE880BE
D@@.E:
t:l it f tr.tt. nrtr -, I
1, Fladiator
cap coolingfan
5. Electric
2. Radiator 6. Waterthermoswitch
3. Thermostat 7. Fanrelay
4. Waterpump
12-4 THOUBLESHOOTING
GUIDE
T R O U B L E S H O O T I NGGU I D E
Froblerr, P o s s i b ! ec a u s e Re'nedy
Overheatlng Coolant level insuificient Add
Coolant leakage Repair
Radiatorfins clogged Clean
Radiatorcap malfunction Replace
Cooling fan malfunction Replace
Thermoslat malfunction Replace
Water passage clogged Clean
Water pump malfunction Replace
Corroglon in coolant
lmpurities Replace
I
I
!
ENGINE COOLANT 1lruseEclor.l,
REeLAcEMET.JT) 12-5
,i
E N G I N EC O O L A N T
INSPECTICI{
Warning
. Neverrernovethe radiatorcap while the enqineis hot.
. !II"p a thick cloth a'ound the cap when rtmoviiq-it.-
. when renrovingthe radiator cap, loosen it slo*Tv
to the f irst stop until the pressule in the raliiiol is
r e l e a s e d a, n d t h e n r e m o v e i t .
C o o l a n tL e v e l ( E n g i n ec o l d )
1. Yprirythatthe.coolantlevelis near the radiatorfiilerneck.
2. Checkthe coolantlevel.
Note
F u l ! L e v e l: 0 . 7 /
Lorv Level : A.2 I
C o o l a n tQ u a t i t y
1. Verify'that ihere is no buitdupof rust or scale around the
radiatorcap or radiatorfillerneck.
2. Verify tliat coolant is free of oil. Replace the coolant if
necess?.ry.
Coolant Leakage
1. Connecta radiatortester(commercially
available).
2.Apply 103 kPa (1.05kg/cm2,1Spsi)pressureto the sys-
lem.
..3.Verifythat the pressureis held.
4. lf not,checkfor coolantleakaoe.
*zzU
REPLACEMENT
Warning
. Never open the radiator cap while the engine is hol
. Wrap a thick cloth around the cap when loosenlng.
. U s e c a u t i o nw h e n d r a i n i n gh o t c o o l a n t .
Caution
. Do not use alcohol-ormethanol-basedcoolant. .
. Use only soft (demineralized)water in the coolant
mixture.
1. Removethe radiatorcap and loosenthe drainplug.

2. Drainthe coolantintoa suitablecontainer.
3 . F l u s h t l r e c o o l i n gs y s t e mw i t h w a t e r u n t i l a l l t r a c e s o f
colorare gone;thenlet the systemdraincompletely.
4 . l n s t a ltth e d r a i np l u g .
5. Fill with the properamountand mixtureof ethyleneglycol
basedcoolantby referringto the table above.
Coolant capacity
With Heater: 6.0 /
W i t h o u t H e a t e r: 5 . 5 /
12-6 E N G I N E C O O L A N T ( R E p L A c ER) . A D | A T O R C
' $P (tNSpEcloN)
6. Run the eirgine v.rilhtlre radiatorcap removed until the

' upperradiatorhose is hot.
'enqine
7. With the idling,add coolant to the radiatoruntil it
reachesthe lrottomr-rfthe iillerneck.
8 . I n s t a ltl h e r a d i a t o rc a p .
R A D I A T ' O RC A P
INSPECTION
RadiatorCap Valve
1. Removeforeignmaterial(such as water residue)from
betweenthe radiatorcap varveand thevalveseat.
2-Attachthe radiatorcap to a radiatorcap iester(commer-
ciallyavailatrle).
Applyp!'essuregraduallyio 74-103 kpa
^ (0.75-1.05 kg/cffi2,
11-15psi)
3. wait about10 seconds. Verifythatthe pressurehai
not
decreased.
NegativePressureVatve
1. Pullthe negativepressurevarveto open it. Verifythat it
_ closescompletely whenreleased.
2 . c h e c k f o r d a m a g eo n t h e c o n t a c ts u r f a c e sa n d f o r
crackedor deformedsealpacking.
3. Replacethe radiatorcap if necessary. .
RADIATOR (neuovAutNspEcloN) 12-7
FIADIATOR
/ INSPECTION
REMOVAL
Caution
. Positionthe.-hose clampin the originaflocationon the hose,and sque€zethe lamplightiy
with largepliersto ensure'agoSOtit.
1. Disconnect thenegativebatterycable.
2. Draintheenginecoolant
3. Removein the ordershownin thefigure.
4. lnstallin the reverseorderof remo'zal.
7.8-11N.m (80_-110
kg-cm.69-95 tb-in!
1. Coolingfan connector - -- -- '- '-.

- 5. Radiatorbracket .
2. Coolantreservoir
hose 6. Radiator
3. Radiatorhose 7. Coolingfan and radiatorcowlingassembly
4. Oilcoolerhose(ATX) .t'
- . . . J
'.: :
1Z-g RADIATOR lrruseecloN),THERMOSTAT (REMovAUtNsPEcrtor.r/lNsrALLAloN).
INSPECTION
Checkfor the followingand repairor replaceas necessary.
1 . C r a c k s ,d a m a g e ,a n d w a t e rl e a k a g e .
2. Bent fins (repairwith a screwdriver).
3. Distortedor bent radiatorinlet.
Steps After tnstallation

1 . F i l l t h e r a d i a t o rw i t h t h e s p e c i f i e da m o u n t a n d t y p e o f
enginecoolant.
2. Connectthe negativebattery cable.
3. Startthe engineand checkfor leaks.
THERMOSTAT
REMOVAL/ INSPECTION
/ INSTALLATION
Cautlon
. Positionthe hoseclampin the originallocationon the hose,and squeezethe clamplightly
with largepliersto ensurea goodfit.
1. Disconnect the negativebatterycable.

2. Draintheenginecoolant.
3. Removein theordershownin thefigure.
4. lnstallin the reverseorderof removal.
REPLACE
1. Waterthermoswitch
connector 4. Thermostatgasket
hoseupper
2. Radiator 5. Thermostat
cover
3. Thennostat
INSPECTION
2 Stages
is airtight.
l.Viiiatty checkthat the thermostatvalve
i. pi"." fhe and
thermostat a thermometer in water.
5. Hejt the waterand checkthe following:
Initial-opening temPerature 'r)
Main: eo.5-4g.5c (188-193
t (i 82-188" F)-- -.
sub : 83.5-86.5
F u l t - o p e nt e m p e r a t u r e: 1 0 0 C ( 2 1 2 - F )
Full-openlift
fUdin: 8.0mm (0.31in) min'
S u b : 1 . 5m m ( 0 . 0 6i n ) m i n '
T H E R M O STAT (REMovAUtNSpEcloN/t NsrALr-ATt
o N) 12-9
1 Stage
1. Visuallycheck that the thermostatvalve is airlight.
2.Place the thermostatand a thermometerin water.
FULL.OPEN LIFT
3. Heatthe waterand checkthe following:
Initial-openin g temperature
M a i n : 8 0 . 5 - 8 3 . 5 C( 1 7 7 - 1 8 2 ' F )
Full-opentemperature : 95 C (203 ' R
Full-open lift
M a i n : 8 . 0 m m ( 0 . 3 1i n ) m i n .
lnstallationNote
J I G G L EP I N I Thermostat
1.Installthethermostat
intothe cylinder
headwiththejiggle
-@f1-l; pinat thetop.
Thermostatgasket
1.Installa new gasltetwith the seal printside facingthe
cylinderhead.
StepsAfter Ingtaliatlon
1. Fillthe radiator
withthe specified
amountandtypeof enginecoolant.
2. Connectthe negative batterycable.
g. Startthe engineandcheckfor leaks.
12-10 WATER P U M P lnel,lovAutNSTALLATtoN)
WATERPUMP
REMOVAL / INSTALI,-ATION
Caution
' Do not disassemblethe waterpump. tf a problemis found,reptacethe pump as
a unit.
1. Disconhect the negativebatterycable.
2. Draintheenginecoolant.
3. Removein the ordershownin thefigure,referring
to RemovatNote.
4. Installin the reverseorderof removil.
l--o
,$ @
@nser-e{
1 9 - 2 5N ' m ( 1 . 9 - 2 . 6
k g - m ,1 4 - 1 9 l b . t l )
1. Timing.belt
assembly 4. Waterpumpassembly
2. Waterinletpipeandgasket 5. Waterpumpgasket
3. Waterbypasspipeand O-ring
StepsAfter Instatfation
1. Fillthe radiator
withthespecified
amountandtypeof enginecoolant.
2. Connectthe negativebatterVcable.
3. Startthe engingandcheckforleaks.
ELECI?IC @OUNG FANSYSTEM(sysrEMcrncurD,FAN MOTOR(rNspEclor'o12-11
COOLINGFANSYSTEM
ELECTRIC
S Y S T E MC I R C U I T
EATTERY
8OAMAIN
30ACrrAN I s:)J v)-\Ec I swrrcH

3 0 AA O O
NC
rn=)5uFttr
SWITCH
?
HAGNET
CLUTCH
FANMOTOR
INSPECTION
Single-Speed Type
1. Check thatthe batteryis fullycharged.
2. Disconnect the fanmotorconnector.
3. Connectthe batteryand an ammeterto the fan motor
connector.
4. Verifythatcurrentis asspecified
C u r r e n(t A ) : 1 2 - 1 5 A
'
MTX:6.6t 1
A T X: 6 . 6 1 1
and/or.thefan does
5. lf currentis not withinspecification
notturnsmoothly, replacethefan motor.
12-12 FAN MOTOR (REpLA.cEM=Nr)
REPLACEMENT
Caution
. Position the hose clamp in the original locationon the hose, and squeezethe clamp ligh y
with largepliers to ensurea good fit.
1. Oisconnectthe negativebanerycable.
2. Drainthe enginecoolant.
3. Removein the ordershownin the tioure.
4. Installin the reverseorderof removil.
7 . 8 - 1 1N . m( 8 0 - 1 1 0k g - c m , 6 9 - 9 5t b . i n )
1. Coolingfan connector 4. Coolingfan

2. Radiatorhoseupper 5. Fanmotor
3. Radiatorcowling
WATER THERMOSWITCH (REMovAUrNSpEcroN/rNSrALLAloN) 12-13
THERMOSWITCH
WATER
REMOVAL / INSPECTION / INSTALLATION
1. Disconnect thenegative baiterycable.
Z. Removein'theordershownin thefigure.
3. lnstallin the reverse
orderof removal,referring
to lnstallation
Note.
O.RING
REPLACE
@ s.s-a.e
ru..
(60-90cm-kg,52-78 in-lb)
1.Waterthermoswitch
connector 2. Water thermoswitch
INSPECTION
1. Placethe switchand a thermometerin water.
2. Heat the water graduallyand check continuityof the
switchwith an ohmmeter.
Coolanttemperature Cf F) Continuity
Morethan97 e07\: ForU S A
Yes
More than 91(196): For Europe,General
Less than 90 (194) No
- -3.lf notas specified,

replacethewaterthermoswitch.
,. .:
InstallationNote
Waterthermoswitch
t. Applya s.mallamountof enginecoolantto the new O-
nng.
--l .
Caution
- ---. Do not usean impactwrenchfor installation'
- torque:
Tightening
-
s.e-B.dN'm'(60-90cm-kg,52-78in-lb) 5ii I
12-14 FAN R ELAY (FEftlovAutNsPEcrroN)
FAN RELAY
R E M O V A L/ I N S P E C T I O N
1. Disconnectthe negativebatterycable.
2. Remove the fan relayin a place shownin the figure.
8880ffi
FP.N REI.AY
[]@F*--'fi'f
03( tlt 0(tlsrttt0 tUttt trtr
12t20
INSPECTION
. -1. Oheckcontinuityas shownwith an ohmmeter.
'Termlnal C ontl nui tv
A-C No
B-O Yes
2. Appfy12Vbetweenterminals B and D.
Checkforcontinuity betweenterminals A and C.,
ieplacethe fan relay
3. lf notas specified,
sPEClFlcATloNS (sERVrcE
DATA,
TrcFiTEr,rrr'jc
rcriiouE) 12-15
SPECIFICATIONS
S E B V I C ED A T A
I t em W i l h o u th e a t e i I utitnn*trt
eoolingsystem W a t e r - c c c l e df,o r c e . Jc i r c u l a t i o n
C o o l a n tc a p a c i i y l i ters(U Sqt, l mpqt) s.s(s.E,
4.8) 5 . 0( 6 . 3s, . 3 )
Water I rvpe I C e n r r iuf g a l
pump I Waterseal I U n i f i e cm
i e c h a n i c a sl e a l
Typ" V / a x ,t w o s t a g e s
In i ti aol p e n i -n q M ai n 8 6 . s - 8 9 .(s18 a -1 9 3 )
temperature
.; e C F ) Sub 8 3 . s - 8 6 .(s1 e 2 -1 8 8 )
Thermostat Full-open temperature
100(212)
c ('F)
Full-openlitt M a i n 8 . 0 ( 0 . 3 ' l )m i n
m m (i n ) S u b '1.5
( 0 . 0 6 )m i n
Type fin
Corrugated
Cap valveopening
7 4 - 1 0 3( 0 . 7 51- . 0 5 1, 1 -1 5 )
pressure kPa (kg/cm2,psi)
width 647(?5.47)
Coresize
mm (in) Hei!ht 376 (14.80)
Depth 16(4.06)
Radiator
Heat dissipationcapacity
36100-39900 39900- 44100
kcal / h
Type Doubletubetype
Transaxle H e at
o i lc o o l e r dissipation
1425-1575
capacity
kcal/h
Type E l ectri c
N u mb e or f b l a d e s
Cooling fan Outerdiameter mm (in) 3 2 0( 1 2 . 6 )
_ Capacity M-V 120- 12
C u rre n t A 8- 11
T I G H T E N I NTGO R Q U E
Engine N'm (kg-m, lb-fl)

I t em
R a d i a t o r x R a d i a t o rb r a c k e i 7 . 8 - 1 1 ( 8 0 - 1 1 0k g - c m ,6 9 - 9 5 l b . i n )
T her m os tacto v e rx Ga s k e t 1 9 - 2 6( 1. 9 - 2 . 6 1, 4 -1 9 )
Waler thermosvritch 5 . 9 - 8 . 8( 6 0 - 9 0 k g - c m ,5 2 - 7 8 l b - i n )
INTAKEANDD(HAUSTSYSTEM
AIR INDUCTION
SYSTEM 21. 3
INTAKEAIR SYSTEM......... 21- 4
|DLESPEEDCONTFTOL (tSC)
SYSTEM 21- 7
EXHAUSTSYSTEM........... 21- 9
SPECIFICATIONS 21.11
A I R l N D U c r l o N S Y S T E M( o e s c R r p r o N
A N Do p E R A r o N ) 20-3
A I R I N D U C T I O TS' JY S T E M
D E S C R I P T I O NA N D O P E R A T I O I i
The air inductiortsystem suppliesfilteredair to the engine to mix rviththe fuel for combustion. lt con-
sists of :
. A i r c l e a n e ra s s e m b l y
. R e s o n a n c ec h a m b e r
. Airflowmeter
. Throttle body
. l n t a k em a n i f o t d
. ldle speed control(iSC) valve
. Air,.ralve
The Airflow meter is used to measure volumn air flovr passing into the engine. The Airflow meter
detectsthe volumn of air flow and notifiesthe E.C.U with an input signal.
The resonancecharnbersuppressair inlet noise caused by airflowpulsation.
The throttlebody controlsintakeair quantitiesand consistsof :
Throttle Position(TP) sensor

Dash pot
ldle speed controlvalve
:
The idle air controlsystem suppliessmall quantitiesof air during engine idle by regulatingthe bypass
air amount that
!.assi.s through the throttlebody. This system cbnsiits of the ldle ipeed iontrol valve
and air valve. The Throttl6 Position(TP) sensor detects the throttlevalve positionand provides the
E.C.U with this infonnation.
20-4 pARrs)
INTAKEAIR SYSTEM tcoMpoNENr
INTAKEAIR SYSTEtr,l
COMPONENT PARTS
Removal / Inspection / lnstallation
1 . R e m o v e i n t h e o r d e r s h o w n i n t h e f i g u r e ,r e f e r r i n gt c R e m o v a t N o t e .
2. Inspectthe intake air system componentsvisuallyand repairor replace if necessary.
3. install in the reverse order of removal,referringto Instaltation Note.
r 9- 2 5 N ' m ( l . 9 - 2 . 6 k 9 . n r .r 4 - 1 9 r b . t r )
I G A S KE T
I PI-ACE
P
4.5-5.5N.m
(4.6-6.6kg-m,40-5Elb-in)
2.L4.Ct}m
A9'4.lkqm.
'25-$dn}.'
1 9 - 2 5N ' m .
( 1 . 9 - 2 . 5k g - m .1 4 - 1 9l b t r )
I
'+
!.
GASKET
REPTJCE i
19-25N'm {
( 1 . 9 - 2 . 6k g - m ,
14-191b-ft)
1. Resonance duct 8. Throttlebody

2. Aircleaner 9. Dashpot
3. Air cleanerelement 1 0 .I S Cv a l v e
4. Airflowmeter 1 1 .S u r g et a n k
5. Resonance chamber 1 2 .A i rv a l v e
6. Air hose 13.lntakemanifoldbracket
7. Acceleratorcable 14.lntakemanifold
INTAKE AIR SYSTEM gxnorrLE BoDy,DyNAMrccHAMBER,
TNTAKEMANIFoLD)
20-5
T H R O T T L EB O D Y
Inspection
1. Clteckthe tlrrottlebody for wear and Ceposiis.
2 . C h e c k i f t h e t h r o t t l ev a l v e m o v e s s m o o t h l yw h e n t h e
throttleleveris movedfrom fully closedto fullyopen.
3. Replacethe throttlebody if necessary.
Caution
. D o n o t r e m o v et h e t h i n s e a l c o a t i n g l r o m t h e t h r o t -
t l e v a l v e so r b o r e .
DYNAfvllC CHAMBER
Removalnote
. Raisethe vehicleto remove the three bolls shown in
the figure.
INTAKEMANIFOLD
Installationnote
l.f ightenthe boltsin the ordershown in the figure.
Tighteningtorque:
19-25 N'm (1.9-2.6kg-m, 14-19 lFft)
DoD Ooa
2. Refillthe radiatorwith the specifiedenginecoolant.
3. Checkfor enginecoolantleakage.
2S-6 pEDAL.,\ccELER/rroR
INTAKE AIR SYSTEttl tnccELERArcR c^BLE)
A C C E L E R A T O RP E D A L
Re'rfioval/ | nstal !atlon
1 . R e m o v ei n t h e o r d e r s h o w n i n t h e f i g u r e .
2. Installin tho reverse orrJerof removal.
B
7.8-11N'm(8.0-1.1kg-m.69-95lb.in)
WITH CRUISECONTROL
#
REPLACE
7.8-11N'm
( 8 . 0 - 1. 1 k g - m . 6 9 - 9 5 l b ' i n )
cable
1. Accelerator 4. Returnspring
2. Retainer pedal
5. Accelerator
3. Clip
A C C E L E R A T O RC A B L E
lnspection/ Adjustment
t. Depress the iccelerator pedal fully. Check if the throt-
t l e v a l v ei s f u l l yo P e n e d .
2 . I n s p e c tt h e p l a y o f t h e a c c e l e r a t o rc a b l e .
P l a y : 1 - 3 m m ( 0 . 0 4 - 0 - 1 2i n )
3. Loosen the nuts @ to adiust the play if necessary'

- "=.i -,n -
-f.1i::;'
I D L E S P E E DC O N T R O L( l S C ) S Y S T E I \ I( o es c R r p r r o r . r ) 20-7
C O N T R O L( l S C )S Y S T E M
r D L ES P E E D
g::,n"#?J':[ smoothness, the lsc systemconirotsthe intakeair amountby regutatingthe bypass

ji, thatpasseslhroughthethrottle
body.Thissystemconsists of theISCvalve,airvalve,ECU
inPutdevices'
Ina"|nount
(,/,
(//,
9;
h*l {:
ffio6hF
A^''t--
/ i"o.' w(
;;::Jb,g
'0,*t[#.j
{f
P/Spressur.r-:r
"@
\I
I
I
J
N e u t r a lS W ( l , , 4 T X )
I n h r b i t o rS W ( A T X )
2O-8 IDLE SPEED CONTROL (+SC)SYSTEiVIt.sysrEMopERAloN. tsc vALVE.
AtRvALVE)
Sy5lem sslsqt s'.vilch: SYSTET\/lOPERATION

Air Valve
l',lote
. T h i s i n s p e c t i o nm u s t b e d o n e w i t h t h e e n q i n e c o l d .
- E n g i n ec o o l a n t b e l o w 2 0 C ( 6 8 " F ) .
1. Connectthe SST tc the diagnosisconnectoi'.

2. Push the selectorNo. 1 buttonand TEST SW io SELF-
TEST.
3. Startthe engine.
4 . C h e c k i f t h e i d l e s p e e d d e c r e a s e s g r a d u a l l ya s t h e
enginewarmsup.
ISC Valve
1. Warm up the engine.
Z . C h e c ! <i f c l i c k n o i s e i s h e a r d a n C t h e e n g i n e s p e e d
increaseslo approx. 1,200:'pm when ihe ISC valvecon-
nectoris disconnectedat idle.
3 . l f t h e e n g i n es p e e d d o e s n o t c h a n g e , r e p l a c et h e I S C
valve.
4. Reconnectthe connector.
ISCVALVE
Inspection
the ISCvalveconnector.
1. Disconnect
.2.Checktheresistance
of the ISCvalve.
: 11-13a (at20e (68'Fl)

Resistance
replacethe ISCvalve.
AIRVALVE
Inspection
1. Removetheair valve.
2. Coolthe airvalveat below0 e (32'h').
3. Heatthe air valve at @ by using a drier and veritythat
part@ movesin the directionof the arrowin the figure.
E X H A . u s r S Y S T E M1 o es c n i r - , r ' r c^ u
NDo p E F A n o l r ) 20-9
E X I J A U S TS Y S T E M
DESCRIPTIOA NN D O P E R A T I O N
T h e e n g i n ee x h a u s tc o n s i s t sm a i n l y9 l \ i ] r o _ S e(nN r ) ,h o w e v e r ,i t a l s o c o n t a i n sC a r b o nM o n o x i d e( C O ) ,
C a r b o nD i o x i d e( C O ' ) ,W a t e rV a p o r . ( H r O O ) , r y g l . ( O , ) . N i t r o g e nO x i d e s( t r t g x ) .a n d l l y d r o g e n
1 H r ;a i
w e l l a s v a r i o u s ,u n b u r n e dh y d r o c a r b o n (sH C ) . T h r e e o f t l r e s ee x h a u s tc o m p o n e n t s- C O , N O x , - a n d
H C ' a r e m a j o r a i r p o l l u t a n t ss,o t h e i re m i s s i o nt o t h e a t m o s p h e r em u s t b e c o n t r o l l e c l .
T h e t h r e ew a y c a t a l y t i c( T W C )c o n v e r t e rm . o u n t e di n t h e e n g i n ee x h a u s ts v s t e m ,w o r k s a s a o a s r e a c -
t o r t o c o n v e r ta n d r e d u c et h e p o l l u t a nlte v e l st o w i t h i nl e g a l l yp r e s c r i b e dl i m i t s .
T h e c a t a l y s tm e t a l s a r e t h i n c o a t e d o n t o a n d s u p p o r i e db y a h o n e y c o m bs h a p e d h i g h t e m p e r a t u r e
c e r a m i c ,m o u n t e di n s i d et h e c o n v e r t e rs h e l l . T h e r e s u l ti s a h i g h l ye f f e c t i v ec o n v e r t e id e s i g nh a v i n g
m i n i m u mr e s t r i c t i o n
t o e x h a u s tg a s f i o w a n d g o o d d u r a b i l i t v .
S H E L LA S S . Y TO fvluFFLER
EXHAUST
GASES
FROM
ENG
THREE WAY
? CATALYST
FLOW
2oor2 THREEWAy CATALYTIC
CONVEATER
2A-10 pAnrs)
EXI-IAUSTS YSTEM lcorurpoNENrr
COF/tPOl{ENTPABTS
R e m o v ai / l n s p e c t i o n/ l n s t a l a t i c n
1 . R e m o v ei n t h e o r d e rs h o w ni n t h e f i q u r e .
2. Check the exhaustcomponentpartsand rripairor replaceif necessary.
3. Installin the reverseorderof removal.
R G A S K E TR. E P L A C E
GASKET.
REPLACE
REPLACE
SS-AgN'rn
(3.9-+.?kg-cm.
28-34tb-in) /
REPI-ACE
EZ,..-
./
\
\-'-1*---
\\ge- 53N'm
-5.3k9-m.
29-49N'm
\\r":
cnsxer.\
3alb-tr)
(3.0-5.0k9-m. REPLAcE
22-361b-fr) B
26-3Btb.tl)
1. Mainsilencer manifold
5. E>:haust
2. Pre-silencer manifold
6. Exhaust insulator
3. Catalyticconverter 7. O>:ygen
sensor
4. Frontpipeassembly
20-11 SPECIFICATIOI{S (sERVrcE
DArA,lGHrEr.lNGTonouE)
SPECIFICATIONS
SER\,ICEDATA
Engine
Item B6
l d l e s p e e d c o n t r o l ( l S C )v a l v e
TYPe Rotary
Resistance a 1 2 -1 6
Alrflow meter
E:*Vs Fullyclosed 20-600
Fully open 20- 1.200
Er*Vc 200-400
Er*THAn -20e ( -a.p) 1 3 , 6 0 0 -1 8 , 4 C 0
Resistance kA
(lntake air i 2oi ( 6s'F) I 2.21C-26.900
thermosensor) 60c (140'F) 493-667
Fully closed @
E:*Fc
F u l l yo p e n 0
Alr cleaner
Elementtype Oil permeated
T I G H T E N I N GT O R Q U E
lntake manifold 1 9 - 2 5 N ' m ( 1 . 9 - 2 . 6k g - m . 1 4 - 1 9 ! b - f t )

EMISSION
CONTROL SYSTEM
(85 ENGTNE)
A/C CUT-OFFSYSTEM ....21A. 45
C o N T R O LS Y S T E M. . . . . . . . . . . 21A- 4s
E N G I N ET U N E . U P 21A. 13
EVAPORATIVE EMISSIONCONTRO L
SYSTEM 21A. 42
FUEL CUT CONTROLSYSTEM........... 21A- 45
I D L ES P E E DC O N T R O LS Y S T E M. . . . . . . . . . . . . . . . 2 14A7-
l G N t T r o Nc o N T R O LS Y S T E M. . . . . . . . . , . 21A- 48
. ouTLtNE ......:........ 21A- 3
O U T L I N EO F E M I S S I O N CONTROL
SYSTEM 21A. 40
POSTTIVE CRANKCASEVENTILATION
(PCV)SYSTEM 21A- 41
s E L F - C t A G N O S tFSU N C T T O.N. . . . . . . . . . 21A- 1s
SPECIFICATIONS 214.109
TROUBLESHOOTIN GGUIDE 21A. 58
E M I S S I O NC O N T R O LS Y S T E Mo u r L r N = 21A-3
ouTLlNE
D E S C R I P T I OA NN D o P E R A T I O N
Sephia r u n s o n a s i m u l t a n e o u fsu e l i n j e c t i o ns y s t e m .T h e s e s y s t e m ss u p p l i e st h e a i r / t u e l m i x t u r et o
ihe e n g i n ef o r t h e c o m b u s t i o nA. n a i r i n d u c t i o ns y s t e ma n d a f u e l i n j e c t i o ns y s i € r nr ^ r o r ki n c o n i u n c t i o n
witn e l e c t r o n i ce n g i n ec o n t r o ls y s t e mw h i c h c o n s i s t so f v a r i o u ss e n s o r s ,s v r i t c h e sa n c j P o w e r t r a i n
" n M o C u t e( P C M ) .A l l s e n s o r sa n d s w i t c h e sa r e c o n n e c i e dt o t h e P C M w h i c h i n i e r p r e t st h e
bontrol
l e c e i , r i n gd a t a a n d c o m p u t e st h e t i m i h ga n d t h e d u r a t i o ns c t h a t t h e e l e c t r i c a l loy p e i ' a t e di n j e c t o r sc a n
be energized.
T h e b a s i c f u e l r e q u i r e m e not f t h e e n g i n ei s d e t e r m i n e Cf r o m t h e d a t a v r h i c ha r e s u p p l i e dt o t h e P C M
b y t h e e n g i n el o a d ,w h i c h m e a s u r e st h e a m o u n to f a i r b e i n g d r a u r ni n t o t h e e n g i n e .O t h e r s e n s o r sa n d
s i v i t c h e si r e u s e d t o m e a s u r et h e f o l l o w i n g s ;
. Air temperature
. Atmosphericpressure
. Coolanttemperature
. E n g i n es p e e d
. Exhaustoxygen content
The varioussensorsand switchesdetect any changes in the operatingconditionsand send signalsto

t h e P C M .T h i s p e r m i t st h e P C M t o c o n t r o lt h e o p e n i n gd u r a t i o n( p u t s ev r i d t h )o f t h e i n j e c t o r sa n d m a i n '
tain the optimum exhaustemissioncontroland the engine performancefor all operatingconditions.
21A4 EMISSIONCONTROL SYSTEMourLtNE
SYSTEM DIAGRAM
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21p.-6 EMISSIONCONTROL SYSTEM ourLtNE
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21A-8 EMISSIONCONTROLSYSTEMourLtNE
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E M I S S I O N C O N T F I O LS Y S T E M o u r L r N E 2 1A - 1 1
c O M P O N E N TD E S C R I P T I O N S
ccmponenl I Function Remark
--
I
A i rc l e a n e r I
F i l t e ra i r e n t e r i n gt h r o t i l eb o d y
-*r* M o n o l i t hi y p e
:
I reaction
Char c oacl a n i s te r I S t o r e sl u e l t a n k l u m e s w h i l e e n g i n es t o p p e d
I
II or engine working
Check valve Controls pressurs in lucl tank Two-way tyoe
C r r : u i i o P e n i n gr e l a Y Voltage for fuel purnp while engir,eiur,ning
Clutch switch (Mff) Detects clutch condition;sends signal to Swilch OFF when clutch pedal released
PCM
D i a g n o s i sc o n n e c t o r ConceniraieCser;ice connecior 20 pin
Concentratedterminals:
1 . E G I s e l f - d i a g n o s t itce r m i n a l
2. Aff seif-CiaEncsi;c
terminal
3. Test terminal
4. Fuel pump check terminal
. 5. Cooling fan check.terminal
6. Engine rpm output terminal
Surge tank lnterconnects

all rylinders
Pourertrain ControlModule Detects the lollowing:
(P.cM) 1. A/C operation 1. A/C switch
2. Airltuelratio (Orygen concentration) 2. Orygen sensor
3. Engine coolant temperature 3. Water lhermosensor
4. Engine speed 4 . D i s t r i b u t o (r N e - S i g n a l )
5. lgnitionON signal 5. lgnitionswitch
6. In-gearcondition 6. Inhibirorswircn 1441y
7. Intake air temperature 7. Intake air lhermosensor
.- 8. G-Signal 8. Distributor
9. P/S operation 9. P/S pressureswitch

'10.
Test signal (lgnitiontiming.idle speed, 1 0 . D i a g n o s i sc o n n e c t o r
M a l f u n c t i o nC o d e N o . ) (Test terminal)
1'1T
. h r o t t l ev a l v e o p e n i n ga n g l e 1 1 .T h r o t t l es e n s o r
1 2 . D e t e c t st h e i n t a k ea i r p r e s s u r e 1 2 .M A P r " n r o ,
1 3 . D e t e c t st h e s p e e d o l v e h i c l e 13.Speedsensor
."(
.E
ts
t+:
?
4
21A.-12 EMISSION CONTROL SYSTEM oUTLINE
-
Component Function Remark
PowertrainControlModule Controls operation ol the lollowing :

(PcM) t. A/C (Cut-off) 1. A/C relay
(Cont ' di 2. Fail.safefunction 2 . S e l f - D i a g n o s i sC h e c k e r
3. Fuel injectionsystem 3. Injector
4. ldle speed control 4. ldle speed conrrol (lSC) vatve
5. lgnition timing control system 5. lgniter
Fuel filter Filters particleslrom fuel
F u e lp u m p Providesfuel to injectors OperateswhiteenEinerunning

Installedin luel tank
lgniter Receives spark signal lrorn PCM and
generales high voltage in ignitioncoil
Detects in-gear condition;sends siqnat to Switch ON in N or p range

PCM
I nlec t or Injects fuel into intake port . C o n t r o l t e db y s i g n a t sl r o m p C M
. High-ohmic injector
lntake air thermosensor Detectsintakeair temperaturc;
sendssignal l n t a l l e coi n A i r c l e a n e r
lo PCM
ldle speed control (tSC) Controlsbypassair amount Controlledby duty signal from pCM
valve
Main relay pCM,

Supplieselectriccunentto injectors.
(FUEL INJ retay) etc.
O x y gens ens or Oetectsorygen concentration;
sendssignat Zrconia ceramic and platinum coating
IOPCM
PCV valve Controls blowby gas introducedinto engine
P / Spr es s ur es w i tc h DetectsP/S operation:sendssignalto pCM P/S : ON when steeringwheeltumedright
or left
P r es s ur er igula to r Adjustsfuel pressuresuppliedto injectors
R es onanc ec ha mb e r Reducesintakeair noise
S epar at or Preventsluel from flowingintocharcoat
canister
Solenoid valve Controls evaporalive fumes from canister to Controlledby duty signal from pCM
(Purge control) intake manifold
Throttle body Controls intake air quantity lntegratedthrottle sensor,dashpot. and
ISC valve
Throttle sensor . Detects throttlevalve.fullyclosed/fully
opened ccndition (Mfi')

. Detecls lhrottle valve opening angle (Afl)
. Sends signals to PCM & A/T controlmodule

Water thermosensor D e t e c t sc o o l a n tl e m p e r a t u r e s; e n d s s i g n a l t o
EMISSIONCONTSOL SYSTEMerucrruE
ruNE-up 21A-13
-l 4re
',2H
E N G I N ET U N E - U P
l B , A S I CI N S P E C T I O N
E n g i n eO i l
I 1 . R e m o v et h e e n g i n eo i l l e v e lgauge and check the engine
I oil ierreland condition.

2. Add or changelhe engineoil as necessary.
Coolant
Warning
. Never remove the r a d i a t o r c a p w h i l e t h e e n g i n e i s
hot.
. Wrap a thick cloth carefully around the cap before
removing it.
1. Removethe coolantlevel gauge frcm the coolant reser-
voir'.
2. Check if the coolantlevel i s b e t w e e nt h e ' F " a n d " L ' o n
the coolantleveldiostick.
3. Add a coolantif nebessary.
2t@5
Battery
1. check for a corrosionon the terminalsand for the loose
cableconnections. lf necessary, cleanthe clampsand
tightenthemfirmly.
' 2. check that the electrolytelevelis betweenthe uppER
LEVELandthe LOWERLEVELmarks.
3. Adda distilled
waterif necessary.
2r6
4. CheckthespecificAravitywith a hydrometer.
- Gravity:1.27-1.29(at 20e [68T])
$
2 1007
A i r C l e a n e rE l e m e n t
Inspection
l.check the air cleanerelementfor the excessivedirt,dam-
a g e ,o r o i l .
Caution
. D o n o t u s e a c o m p r e s s e da i r t o c l e a n t h e e l e m e n t .
2. Replacethe elementif necessary.
2 r00{t
2tA-14 EMISSION CONTROL SYSTEM ENGINT
EU N E - U P
ADJUSTMENT
Preoaration
1 .w a r m u p t h e e n g i n et o t h e n o r m a lo p e r a i i n gt e n n p e r a t r r r e .
Z.Turnall electricloads OFF.
3. Connectthe SST to ilre diagnosisconnector.
4. Set the.selectorswitch to the enginecheck position.
2r0c9
l g n i t i o nT i m i n g
$s ]. ferfoim'Preparation"steps.(Referto above.)
2. check if the timing mark on the crankshaftpulleyand the
mark on the timingbelt coveraie aligned.
l g n i t i o r ri i m i n g a t i d l e s p e e d :
soHc:T + 1' (BTDC)
D O H C: 8 o+ 1 ' ( B T D C )
3. lf the marksare not aligned,roosenthe distributorlock

bolts,and turnthe distributor
to makean aojustment.
4. f ightenthedistributor
lockboltsto thespecified
torque.
Tighteningtorque:
19-25N.m(1.9-2.6kg-m,14-19tb-ft)
2 l 0 rr
ldleSpeed
1. Perform,'Preparation'
steps(Referto above). :
' 2. Applythe parkingbrake
3. checkthatthe idlespeedis withinthe specification..
l d l es p e e d( N e u t r aol r p r a n g e ): S O H C : 7 5 0 t 5 0 r p m
DoHc : 75ot5o rPm
-K--i={=!,!/ttt -
caution
-- 'il-----_-=J)'-Z . check the idle speed without the electriccooling
f a no p e r a t i n g .
4. lf it is not withinthe specification,
checkthe intakeair
: _ leakageandthe controlmodule.
5. Disconnect theSST.
E M I S S I O N C O N T R O L S Y S T E M s E L F - D r A G N oF
s tusN c l o N 21A-15
FUNCTION
SELF-DIAGNOSIS
OF:SCRIPTION
Whentroublesoccui in the maininputCevices or outputde,/ices,checklor the cauie by usingrhe SST.
Failuresof eachinputand outputdeviceare indicatedand retrievedkonr the PowerlrainContiolModute
(PCM)as maltunciioncodenumbers.
Note
. The PCM checks constantlyior a nralfunctionof input devices. The PCM can check a
malfunction of outputdevicesonly in a secondafterthe ignitionswitch is turnedon and the
test terminalof the Ciagnosisconnecioris grourrded.
POWERTRAIN
CONTROL
OUTPUT
OEVIC=S
SELF.
INPUT
C:AGNOSTIC.
SIGNALS FUNCTION
MALFUNCTION
DISPLAY
FUNCTION
SELF.OIAGNOSIS
cHECKER(KJ-1)
MONITOR
FUNCTION
21A-16 EMISSIONCONTROL SYSTEM sELF-DtAGNosts
FUNcroN
MALFUNCTION C O D EN U M B E R
I n s p e c t i o nP r o c e d u r e
1 . T u r n t h e i g n i t i o ns w i t c ho f i .
2. Connectthe SST(KJ-1)to the diagnosisconnector.
Caution
. N e v e r c o n n e c t o r d i s c o n n e c t a c o n n e c t o : ,w h i l e a r
e n g i n ei s r u n n i n g .
3. Tum the igniticnswitchon.

4. Performthe diagnosisprocedurewi'ththe SST.
Note
. Cancel the matfunction code numbers b
penorming the after-repairprocedure.
j1-..jsrl:
F*uNcrroN
EMISSIONCONTROLSYSTEMsELF-orAcNosts 21A.-17
C O D EN U M B E R S
'
M a l f u n c t i o nd i s p l a y
Sensor or
Condition Fail-safe
subsYstem
CodeNo. I
Ne'signal No Ne-signal
02
::,-JlJi_
G-signal No G-signal
03
::,-JlJl]l-
Waterthermosensor Open or shortcircuit lviainiainsconstant
lemperature
20e (6eT)
command
09
::,ffi
lntaka air Openor shoricircuit Maintains
constant
lhermosensor temperature
20t(68T) r0 oNn
command O F FJ L
Throltlesensor Openor shortcircuit Mainlainsconstant

tArn commandof throttle
ON
valvefullyopen 12
OFF
MAPsensor Openor shortcircuit
13 ON
OFF
Oxygensensor Sensoroutput Cancelsengine

continuesless than feedbackoperation
0.55V 95 sec. 15 ON
afterengine
OFF
starts(1,5@rpm)
Feedbacksystem Sensoroutputcon- Cancels engine
\ tinuesunchanged feedback operation
50 sec.afterengine 17 ON
exceeds1,50Orpm OFF
214-18 E-.:
MISSION
.
C O N T R O LS Y S T E Ms E L F - D r A G N oFsut sN c l o N
f , 4 a l f u n c t i o nd i s p l a y
Sensoror
Condition F a l l - s af e
subsystem
O u t p u t s i g n a lp' ;a t t e r n
lnjector # 1
Open or short ciicuit 18 l::,ffi

I n j e c t o r# 2
19
:), JUIffU]J1JI
20 l* JllL
l niec t or
::, _flnl*
Main relay
24 l::' -;IIJ',,,,'L
Solenoid valve
(Purge control)
A/C cut-of I relay
Cooling-fan
relay _'f l1
*1
$l
nt
*l
+-l
Er
€t,
S peeds ens or rr
- al
€t
?.
.+t
ei
*
3:
*l
C a u t i on j
- l f t h e r e i s m o r e t h a n o n e f a i l u r e p r e s e n t ,t h e c o d e n u m b e r s w i l l b e i n d i c a t e d i n n u m e r i c a q
o r d e r ,l o w e s t n u m b e r f i r s t . '3
. A f t e r r e p a i r i n g a f a i l u r e ,t u r n o f f t h e i g n i t i o n s w i t c h , d i s c o n n e c t t h e n e g a t i v e b a t t e r y c a b l e rl
a n d d e p r e s s t h e b r a k e p e d a l f o r a t l e a s t- f i v e ( 5 ) s e c o n d s t o e r a s e t h e m a l f u n c t i o nc o d e ( s -.-:
i 5
': frorn the PCM memory 1
*4
I
' j :
'i
^*
';I
t *
i .F
+q
E M I S S I O N C O N T R O L S Y S T E M S E L F . D I A G N O SFI U
SNCTION 21A-1s
n":"ffim:]i!?"-0", onthessr, checkrorthecausebyusingthecharlrelated

is shown to the
He number sho*n'
0 2 ( O I S T A I B U T o RN e - S l G l l A L )
C O D EN o '
INSPECTION A C T I ON
STEP
Check di3tributorcircuitfor poor connection R e p a i ro r r e p l a c ec o n n e c t c r
1.
Go to next3iep
Cneck whether Cocje No 03 presents together /es Go to nextstep

z
No G o to step5
J Cha;k PCM terminalwire No 31 (B.tG) Yes Go to next step

lcr continuitY?
No Check fcr open circuit between distributor
and ground
a
Checkbatte'rypositivevoltageexistal Cistributcr Yes Go to nexl.step
terminalwiri(C) withignitionswitchON
*? Check for open circuit (ignitionswitch)
Checkfor terminalwirecontinuitybetween Yes Go to nextstep

_l_ 3 and PCM terminalNc.33
distibutortermina.l
No Check lor open circuit in wiring from.terminalB
to terminalNo.33
I
o Checkif appiox.SVexistsat PCM terminalNo.33 Yes Replacedistributor

connectordisconnected)
(Withdistributor
No Go to nextstep
-7 Checkil approx.5VexistsdistributorterminalB Yes Replace distributor

(Withconnectordisconnected)
No Checklor shortcircuitin wiringfromdistributor
to PCM
CircuitDiagram
PCM
BAG
YA
t
?
IGNITION Bn//
-trG
swrTcH G F
?
r
l
t
I
tta
c) (a) (o) (e
OISTRIBUTOR
2 l o t7
21A-20 E M I S S I O NC O N T R O LS Y S T E Ms E L F - D t A G N oFsur N
s cloN
CODE No. 0 3 ( D T S T R T E U T OGR- S t c N A L )
STEP INSPECTION ACTION'
I ChecP. circuitfor poorconnection

distributor Yes R e p a i r o r r e p l a c ec o n n e c l o r
No G o to r'rexts l e p
2 Check whether Code No. 02 presenis together Yes Go to nexl step
No G o to step 5
3 for
CheckPCM terminalwire No.31(BILG) Yes Go to next step
conlinuity No Repair or replace vrire harness
4 Checkbatterypositivevoltageexistsat Yes Go to next step
distributor
teiminalwire(L)withignitionswitchON No Check for open circuit between distributor
and ignition switch
5 Cneck for terrginalwire (G/L) continuitybelween Yes Go to nextsteP
distributorand'PCM terminal No.42 No Flepairor replacervireharness
o Checkif approx.5V existsat distributor

No.42 Yes Go to nextstep
(Withdistributorconnectordisconnected) No R epai rP C M
7 Checkif approx.5V existsat distributorNo.42 Yes Replacedistributor
terminalwire(G/L) No to pCM
Checkfor shortcircuitfromdistributor
(Withconnectordisconnected) terminalwire
C i r c u i tD i a g r a m
@(a(a6)
P9M
tllllttttttttttttttt
:l
:+l
$
,l3fllll
YA 8/LG
.xI
,,1"11,
,,,,:, ;l
IGNITION Bi
swtTcH
:*l
9e o A), ;l
6l : T
: +l
OISTRIEUTOR {l
fl
el
.*l
Fl
ql
s
,."s
t-j-
E M I S S I O N C O N T R O L S Y S T E M S E L F . D I A G N oFSU
I SN c T I o N 21p.-21
*=*.I os (W A TE R
TH E R MOS E N S OR )
STEP INSPECTION ACTION

1 Check water lhermosensorcircuitlor poor con- Yes Repair or replaceconnector
nection
No Go lo next siep
J 2 Check wire harness betweenwater lhermosen- Yes Go to nextstep

I
I
I sor and PCM for continuity

No Check for open circuitbetweenvraterthermosensor
Waterthermosensor PCM
I and PCM
I
I A (L/w) 15
-1
I
I
I
I (B/R) 46
I
I
I
: .t Check if resistance ol water thermosensoris OK Yes Go to nextstep
C o o l a n tt e m p R e s i stance (k 0 ) No Replacewaterthermosensor
-20c (4T) 1 6 . 2 t1 . 6
20e (68T) 2 .45+ 0.24
80e (176T) 0 .3210.03
A
Checkif samecodeNo.is presentfoltowing Yes Go to nextstep
procedure
after-repair
No Waterthermosensor
and circuitOK
5 Checkif PCM terminals15 and46 voltagesare Yes Replace PCM

OK
No Checkforshortcircuitin wiringfromwaterthermosersor
to P C M
MAP SENSOR
l*corrnoLuNrr
J
WATER
THERMOSENSOR
THROTTLE
SENSOR
21A-22 E M I S S I O NC O N T R O LS Y S T E M s E L F - D r A G N oFsUr sN c r o N
CODENo. 1 o ( T N T A K EA r R T H E R M O S E N S O R )
STEP INSPECTION ACTION .

1 C h e c k i n t a k e a i r t h e r m o s e n s o rc i r c u i tf o r p o o r Yes R e p a i r o r r e p l a c ec o n n e c t o r
connection
No Go to next step
? C h e c k r v h e t h e rC o d e N o . 1 3 - p r e s e n t st o g e t h e r Yes C h e c k f o r c o n t i n u i t va t P C M t e r m i n a lN o . 4 4
(B/R) to ground .
No Go to next step I
J C h e c k w i r e h a r n e s sb e t w e e n i n t a k ea i r
thermosensorand PCM for continuity
lntake air thermosensor
Yes
No
Go to nextstep
Repairor replace
lI
I
(ln airflorv meter) PCM
Gnr 20
R.^/ 44
4 Checkif resisianceof air thermosensor

between Yes Go to nextstep
Gl/ and Rl/ is OK
No R epl aceIntakeai r thermosensor
T em p e ra tu re R e s i s t a n c(ek 0 )
.20e 15
20e 2.5
60c 0.603
5 Check if same code No. is present following Yes Go to nextstep

after-repairprocedure
No lntakeair thermosensor
and circuitOK
b Checkif PCMterminalsNo.20and44 voltages Yes R epl aceP C M

are OK
No Checkfor shortcircuitin wiringfrom intakeair
thermosensorto P C M
i
t-
I
fi
I
A 4
T N T A K EA I R
THERMOSENSOR
MAP SENSOR
2 1 0 2r
E M I S S I O N C O N T R O L S Y S T E f u lS E L F . C I A G N OFSUI S
NcTIoN 21A.-23
1 2 ( T H R O T T L ES S N S O R)
C O D EN o '
INSPECTION A C T I ON
C h e c k t h r c n l es e n s c rc l r c u l (r o r p o o r c o n n e c l l o n Yes r { e p a r ro r r e p i a c ec o n n e c t o
I
No Go to nextstep
C h e c k w i r e h a r n e s sb e t l v e e nt h r o R l es e n s o ra n d Yes Go to nextsiep
PCM for ccntinuity
No R e p a i ro r r e p l a c e
Throttle sensor PCI\,l
D 46
19
c 45
check voltage of throttlesenso.rwith throttle Yes Go to nextsiep

sensor connectordisconnected
No A d j u s to r r e p l a c et h r o t i l es e n s o r
f-ruity ctos-o I npprox.o.6V I

F u l l yo p e n I A p p ro x .over
4V I
I
A
C h e c ki f P C Mt e r m i n aNl o . 1 9 , 4 5 , 4v6o l t a g e s Yes Replace PCl,,l
areOK
No Checkfor shortcircuitin wirinofromthrottlesensor
to P C M
PClv{
1s) (46) (1s) (cS
MAP SENSOR.
_l
IAn
C ON TaOL
U Nt r
J
A D
WATER
THERMOSENSOR
I
T } . i R O T T L ES E N S O R
21022
21A-24 EMISSION CONTROL SYSTEN4SELF.OIAGNOSIS
FUNCTION
C O DE N o .
13(MAPSENSOR)
INSPECTTON
ACTION
Checkthrottlesensorcircui-o-fficonnection
Repair or replac-onnector
Go to nextstep
Check for continuitybetween |URF sensor

Go to next step
and PCt"i
MAP Sensor Repairor replacewireharness

PCM
A 45
tt 16
c 44
CheckMAP sensorlor pressure

Go to next step
Replace MAP sensor
Chec kif P C Mte rmi n aNl o .1 6a n d4 5 v o tta g es

R epl aceP C M
are OK
Checkfor shortcircuitin wiringfromMAp sensor

to P C M
CircuitDiagram
E M I S S I O NC O N T R O LS Y S T E Ms E r F - D r A G N oFsul sN c l o N 2't A-25
lo**. I 1 5 ( O X Y G E NS E N S O R- I N A C T I V A T I O N )
Note
. l f C o d e N o s . 1 5 a n d 1 7 a r e p r e s e n t t o g e t h e r ,f i r s t p e r f o r m t h e c h e c k i n g p r o c e c i u r ef o r C o d e N o . 1 7
l Check orygen sensor circuitfor poor connection Yes R e p a i ro r r e p l a c ec o n n e c t o i
No Go to next step
2 Check if oxygen sensor outputvoltage is OK Yes Go to next step
No Replaceorygensensor
o Check vrire hamess betwaen orygen senscr and Yes Go to nerit step
PGM lerminal 17 for continuity
No Repair or replace
I
a
Check it PCM terminal 17 voltage is OK Yes Go to nen step
No Checkfor shorlcircuitin wiringlrom oxygensensorlo

PCM
5 Checkif sensitivityol orygensensoris OK Yes ReplacePCM
No Try with knowngoodorygen sensorand checkif con-

ditionimproves
CircuitDiagram
OXYGEN
SENSOR
21A-26 E M I S S I o N c o N T R o L S Y S T E M s E L F - D r A G N oFsurN
s CroN
c o oE N o . 1 7 ( F E D B A C KS Y S T F M )

1 Check if same Code No. is present after prer- Yes Go l o nextstep
f orming after-reoairprocedure
No Checkorygensensorcircuitlor poorconnection
O l f OK , performi roubl eshooti ng C odeN o. 15
c) l f not OK . repai rcr repl aceconnector
2 Check if cutput vollage ol oxygen sensot Yes G o t o n e x ts t e p

i s 0 . 5 V o v e r a t i d t e a l t e r w a r m i n g - u pe n g i n e a n d Note
t
r u n n ; n gi t a t 2 , 5 0 0 - 3 , C 0 0r p m i o r 3 m i n u t e s . N F r n i x t u r er i c h
Nc Go to Step 5
Note
. AlF rnixture is lean or misfire cccurring
3 Checktor correctfuellinepressureat idle Yes G o to nextstep
F u e ll i n ep G s s u r e: No H i g hp r e s s u r e
2 6 5 - 3 1 4k P a ( 2 . 7 - 3 . 2k g / c m z , 3 8 - a p
5si) C hecki l fuelreturnhosei s cl oggedor restri ct ed
( V ac uu mh o s e to p re s s u rere g u l a to r A l f OK , repl acepressureregul ator
disconnected) c) l f not OK , repai ror repl ace
a
Check injectors for fuel leakage Yes Replace injector
No C h e c k i f w a t e r t h e r m o s e n s o ri s O K
c) lf OK, Go to Step 11
c ) l f n o t O K , r e p l a c ev / a t e rl h e r m o s e n s o r
D Disconnecteachhigh-tension
leadat idleand Yes Go to next step
checkif enginespeeddecreasesequailyat each
cylinder No Go to S tept'
t-
I
I ol
Y
.
MAIN
REI-AY l.-
I
;l
_n+
=B/Y I wR I
fi,,rrr.=fir=rr-, ,.4 ;l
t99 @-t il
ll/
ttB
llti ;l :l
O X Y G E NS E N S O F J-*,
210?4
E M I S S I O N C O N T R O L S Y S T E M s E L F - D i A G N o sFlusN C l o N 21A.-27
INSPECTIOI{ I ACTICN
{rzel
i l ; r e c t f o i c o r r e c il u e l l i n e p r e s s u r e iJle ne;4step
Ca
Fuel o r e s s u r e: Lorv pressure

2 6 5 - 3 1 4 k P a ( 2 . 7 - 3 . 2 k g / c m 2 ,3 8 - a 6 p s i ) C h e c k l u e l l i n e p r e s s l r r er v h r i ep i n c h ; n g
| I
( V a c u u mh o s e t o p r e s s u r e r e g u l a t o r | |
f u e i r e t u r nh o s e
disconnected) | I
c ) l f f u e l l i n e p r e s s u r eq u i c k i yi n c r e a s e s ,
| |
I I c h e c k p r e s s u r er e g u l a i o r
c ? l f f u e l l i n e p r e s s u i ' eg r a d r r a l l yi n c r e a s e s .c h e c k
l o r c l o g g i n gb e t r v e e nf u e l p u m p a n d p r e s s u r e
regulaior
l f n o t c l o g g e d ,c h e c k f u e l p u m p m a x i m u m
2re3sui'e
7 Check intake air system componentsfor air Yes Check rviih spray eic. I
leakage
No I relrr(;vv
"--* I
I Check for misfire of dead cylinderfrom Step 5 Yes R e p a i r o r r e p l a c ei g n i t i o ns y s t e m

inspection
No Go to nextsteo
9 Check for injectoroperatingsound at idle of Yes G o t o n e x ts t e p

dead cylinderfrom Step 5 inspection
No C h e c k f o r a p p r o x . 1 2 V a t i n j e c t o rc o n n e c t o r
terminal-u;ira(Y/3)
* l f Y e s . r e p l a c ei n j e c t o r
C l f N o , c h e c k w i r e h a r n e s sf o r s h o r t o r o p e n
1 0 Replaceiniectorat deadcylinderfromStep5 in- Yes Go to nextstep

spection
Checkif sameCode No. is presentfollowing
pertormingafter-repairprocedure No Removed injectorat fault
11 Try withknowngood PCM and checkif condjtion.

improves
21A-28 EMISSION CONTROL SYSTEM sELF-DtAGNosrs
FUNcloN
CODE No. 1 E( T N J E C T O#
F1 )
STEP INSPECTION ACTTON

1 Check injector circuil for pcor connection Yes R e p a i r o r r e p l a c ec o n n e c t o r
No Go to next slep
2 After PCM connector is disconnectedwith ignition Yes C h e c k p C M c o n n e c t c rf o r p o o r c o n n e c t i c n

srvith CFF. check banery positive voltage exists at Q l f O K . r e p l a c eP C M
PCM terminal No.30 wire with ignitionswitch ON c) lf not OK, repair oi replace connector
No Go to next step
3 Checkbatterypositivevoltageexislat injector Yes Repairor replacewire harness

terminalA(Y)in sameconditionas Step2
No Go to nextstep
A
Check ii injector is OK Yes Check lor open or short circuit lrom main relay to
. R e s i s t a n c e :1 4 . 5 Q injector wire harness
. Check for injector operating sound
No R epl acornj ector
CircuitDiagram
IGNITION
EATTERY swtTcH
PCM
/N\A
I
r
$
30ArNJ\ rSneruc
r-,-
@@@(D6') \ .\
/
MAIN RELAY Y Y/B F/W

8/W
w/G
@F--@ :: TO
tSCANO
t \
87 - CANISTERPURGE
:: SoLENO|OVALVE
\: ,,.l*^
t It II INJECTOR
INJECTOR
,(
JA,
12 INJECTOR
T3 INJECTOR
14
,e
ro
...- 2 r 026
fl C O D EN o '
E M l s s l o N c o N T R o L S Y S T E Ms E r F - D r A G N oFsur sN c r r o N
1 9 ( l n j e c t o r# 2 )
p.cTroN
21A-29
s'rer INSPECTION
I Check iniectorlor poor ccnneclion Yes R e p a i ro , ' r e p l a c ec o n n e c l o r
No Go to nextstep
2 Alter PCM connector is disconnectedwith ionition Yes C h e c k P C M c o n n e c t o rf s r p o o r c o n n e c t i o n

switch OFF, check batterypositirevortageexistsat c ) . l f C K . r e p l a c eP C M
PCM terminalNo.53 wire with ignitionswitclrON r:-;lf not OK. repair or replace connector
No Go to nextstep
3 Chc"ckbattery positive voltage exists at Yes Repair or replacewire harness

injector terminal A(Y,ts) in sa:'neco:rditlcn
as Step 2 No Go to nen step
4 Checkif injecloris OK Yes Check for open or short circuit from main relay to
. R e s i s ta n c:e1 4 .5o injectorwire harness
. Checklor injectoroperaiingsound
No Replaceinjector
CircuitDiagram
I
IGNITION
BATTERY SWITCH
3OAINJ tsA ENG
MAINRELAY
l\:::'1\
!)@
Lor_J
TNJECTOR 12 TNJECToR
f r |NJ€CTOR t3 truECTOn
f1
21A-30 E M l s s l o N c o N T R o L S Y S T E Ms E L F - D r A G N oFsur N
s CroN
c o DE N o . I z o ( T N J E C TRC1 3 )
STEP INSPECTION I
I n aTta\At
I C h e c k i n j e c t o rc i r c u r tf o i p a o r c o n n e c t i o n /es R e p a i r o r r e p i a c ec c n n e c t o r
No Go to next steo
2 Alter PCtvlconnectoris disconnEtedv/ithignition Yes C h e c k P C M c o n n e c t o rf o r p o o r c o n n e c t i o n

srvitch OFF, check battery positivevottage exists at c " l f O K , r e p t a c eP C M
PCM terminal No.4 rvire with ignitionswitch ON c ) l f n o t O K , r e p a i ro r r e p l a c ec o n n e c i o r
No Go to next slep
3 Checkbatterypositivevoltageexistsat injector Yes Repair or replace wire harness

terminalA (BR) in same conditionas step2
No Go to next step
A
Checkif injectoris OK Yes Check for open or short circuit from main relay to
. R e s i s t a n c e1: 4 . 5O injector rvire harness
. Checklor inje'ctor operatingsounC
No Replace injector
IGNITION
BATTERY
:Frr swlTcH
o I
PCM
A
@G il@o(e
A o
3OAINJ \ 15A ENG
: : : : : :: \ y'?:
-t
I
*
Y Y/B RA
PUW
\ a:
7- $
TO a
*
\ lsc AND '€
T 72 CANISTERPURGE
SOLENOIOVALVE
\
t:::: 4
IR w/R
\ r,l \:: /
a,9 a9e e(' @-€
tlaj tlU ttaj toaj
INJECTORII INJECTOR
f2 I N J E C T O R
1 3 T N J E C T OtR
4
E M I S S I O N C O N T R O L S Y S T E M S e T T . D I A G N oFSU
I SN c T I o N 21A-31
,-l
i Nruo'
I cooe o.l 1 I
NJ ECTC
I
g.'l i r r j e c l o c
r
INSPECTION
r r c u i lf o r p o o r c o n n e c l i o n
___.1
'/es -RepaTor
repa;.;ffi
Check I
N" G" !. r"rt tl.p

-Y;
2 AfterPCMconnecloris disconnet"O C h e c k P C M c c n n e c l o rl o r p o o r c o n n e c t i o n
"riillniti*
yoltageexistsat
srvltchOFF,chechbatterypositi're ." ll OK, reptacePCtul
PCMterminal No.25wirewithignition switchON O l l n o t O K , r e p a i ro r r e p l a c ec o n n e c t o r
No G o t o n e x ts l e p
Checkbatterypositivevoltageexistsat injector Yes R e p a i r c r r e p l a c er . r i r eh a r n e s s

terminalA (R/W)in sameconditionas Step2
l.io Go to next step
4 Check il injectoris OK Yes C h e c k f o r o p e n o r s h o r t c i r c u i tf r o m m a i n r e l a y t o

. R e s i s t a n c e: 1 4 . 5 A i n j e c t o rv r i r eh a r n e s s
. Check for i5r;ecto;operatingsound '\
No R e p l a c ei n j e c t o r
IGNITION
BATTERY swtTcH
PCfvi
1 5 AE N G
MAINRELAY
TO
R\
rsc ANo
a CANISTERPURGE
SOLENOIDVALVE
INJECTOR
'I INJECTOR:2INJECTOR
' 3 I I . U E C T O 1R4
-J
214-32 EMISSIONCONTROL SYSTEM sELF-DrAGNosts
FuNcloN
cooi No. 24 (MA|N RELAY)
STEP I N S PE C T I O N r ACTION
.t
I After PCfulconnecior is disconnecledwith ignitior Yes C l t e c k P C M c o n n e c l o rf o r p o o r c o n n e c t i o n
swith OFF, check if battery positivevoltage exists C lt OK. repta:e PCM
a t P C M t e r m i n a lN o . 4 8 Q l f n o t O K . r e p a i r o r r e p l a c ec o n n e c t o r
No Go to nextslep
2 Checkbatterypositivevaltageexistsat main Yes R e p a i ro r r e p l a c ew i r e h a r n e s s

relayterminalwire (8/R) in samecondition
as Step 1
No Go to nextslep
3 Check batterypositivevoltageexistiat main Yes Go to nextstep

relayterminalwire (B/W)in sarneconcjition
as Step 1
No Checkfor open cr shortcircuitof rfire harnessfrorn
ignitionswitchto main relay
4 betweenmainrelay
Checkfor continuity Yes Checkfor shortcircuitol vrireharnesstrom main relay
connectorlerminal85 (B/R)and 86 (BllV) IOP C M
No Replace main relay
-:;
-.li
+..}
-,F
'{F
CircuitDiagram -€ fi
:,'f
IGNITION .:-:
fr'
BA]TERY SWTTCH
:rj1
.i,=i
TO lSC AND CANISTER

I
I
PURGE
tl SOLENOIOVALVE
.l
-rl
rli
t' r l '
TO INJECTOR
. t\
I
ilrJ
i
I
l,
ll zr0?6
{
E M I S S I O N C O N T R O L S Y S T E M s E L F . D t A G N o sFrU
s NcloN 21A-33
C O D EN o . 2 6 ( S O L E N O I DV A L V E - P U R G EC O N T R O L )
STEP INSP€CT!ON ACTION

Check solenoid valve connectcr for poor Yes R e p a i ro r r e p l a c ec o n n e c t o r
conneclion
Go to nextstep
Checkif the resistarrce

of solerroid
valve Go to next step
is OK
. Resistance: over 22.6A (at 20"C.68ts)
Replace solenoid valve
Checkil batterypositivevoltageexists Go to nextsiep

at solemoiCvalve termina!A
Check for open circuit in wiring from main relay to
solenoid valve
Checkfor continuitybeweensolenoidvalve Yes Go to nextstep

terminalI and PCM terminalNo.50
Check for open circuit in wiring from solenoid
vatve to PCM
Checkif the voltageof PCMterminalNo.50 Yes It PCM connection is OK. replace PCM
is OK
Check for short circuit in wiring lrom solenoid
vafue to PCM
CircuitDiagram
IGNITION
EATTERY SWITCH
MAIN RE|.AY
w/R
INJECTOR
PURGE rsc
CONTROL SOLENOID
SOLENOIO VALVE
VALVE
214-34 EMISSION CONTROL SYSTEM SELF.DIAGNosIS
FUNcTtoN
C O O EN o . 34 (lSC VALVE)
STEP lNSPECTION ACT!ON

I C l r e c k I S C v a l v e c o n n e c t o rl o r p o o r Yes R e p a i r o r r e p l a c cc o n n e c t o r
connection
No Go to nextstep
2 C h e c k i f t h e r e s i s t a n c eo f I S C v a l v e i s O K Yes Go to next step

. R e s i s t a n c e: E . 6 - 1 0 . 6 O ( a t 2 O ' C .6 8 t s )
No R e p t a c eI S C v a l v e
3 Check if battery positive voltage exists Yes Go i o nextstep

at ISC vaive connector ternrinalI
No Check lor circuit in wiring from Main Relay
to ISC valve
4 Check for continuity between PCM terminal Yes Go to nextstep

No.54 and ISC valve terminalA
No Check for open circuit in wirirrg lrom PCM and
ISC valve
Check if the voltage of PCM terminal Yes lf PCM connectionis OK, replacePCM
No.54 is OK
No Check lor short circuit in wiring from PCM
to ISC valve
Circuit Diagram
IGNITION PCM
BATTE R y
(oco
SWITCH
@
MAIN RELAY UO
BAil ./ Oal-- l6c
-
:: i - 7 w v
\^//G; \r wiR
@-i@ i: wn
€ > INJECTOR
\ :: : \:::
l . 9ay e99
'I
t'
tloj taaj
t-
l . PURGE ISC
!. t:
CONTROL SOLENOIO
SOTENOIO VALVE
VALVE
a;t
ta.
D:
l 1
[:1 21026- _ -_.

TI
'i
Ir
I
I.
EMISSION CONTROL SYSTEM SELF-DTAGNOS
F IUSN C T I o N 21A-3s
*..
"OO, I
4 5 ( A / C C U T - O F FR E L A Y )
STEP INSPECTION ACTICN

I P.f:erPCM cor,necto:'isdrsconnectedw:th ignitiorr Yes C h e c k .P C l t l c o n n e a l o rf o r p o o r c o n n e c l i o n
swilch OFF, check if batterypositivevoltaEeexists O l f O K , r e p l a c eP C M
at PCM terminalNo.47 with ignitionswitch ON Q l f n o t O K , r e p a i rc r r e p l a c ec o n n e c l o r
No Go to nextsteo
2 Check if battery positive voltage exists at A/C Yes C h e c k P C M c o n n e c t o rl o r p c t o rc o n n e c t i o n

cut-off relay terminalrviring(UE) in same
c o n d i t i o na s S t e p 1 I
No I Go to nextstec
3 Checkif batterypositivevoltageexistsat A/C Yes Go to nextstep

cut-offreiayterrninal
wiring(L) in samecondition
as Step 1
Check for sho,1circuit in wiring from ignitionsvrithto
A/C cut-off relay
Checkfor conlinuity
in A/C cut-offrelay Checkfor shortcircuitin wiringfrom
ccnnectorrviringUE and L fuC cut-oft relaytc PCi"l
R e p l a c ef u C c u t - o f ir e l a y
t\
IGNITION
SWITCH
,r,r,rr,,rrra
COMPRESSOR > I G N I T I O NS W I T C H
214-36 EMlssloN coNTROL SYSTEM selF-DtAcNosrs
FuNcloN
CODE No. 57 (COOL|NGFAN RELAY)

I Altcr PClvl connector is disconnectedwith igniticn Ycs Clrs6k PCM conncctor lor 1>oorconnection
switch OFF. check if battery positivevoltage exists c) lf OK. replace PCM
at PCM terminal No.23 with ignitionswitch ON c? lf not OK, repair or reptace connector
No Go to next step
? Check if battery positivevoltage exists at AJC Yes Check PCM conneclor for poor conneclion
cut-ofl relay lerminatwiring (B/G) in same
condition as Step 'l
No Go to next step
3 Checkif batterypositivevoltageexistsat A/C Yes Go to nexi slep

cut-oi1relayterrninalwi;ing
(8.1V)in same
c ondit io n
a s S te p1
No Check for short ciicrritin wiring from ignitionsrvitchto
cooling lan relay
4 Checkfor continuityin A/C cut-otfrelay Yes Chec!<for shortcircuitin wiringfrorn

connectorwiringB/G and BAil coolingfan relayto PCM
No Replace cooling fan relay
BATTERY
COOLINGFANMOTOR I G N I T I O NS W I T C H
FUNcrloN
EMISSION CONTHOL SYSTEM sELF-DtAGNosls 21A-37
CODE No. 7 6 ( S P E E DS E N S O R )
INSPECTION
Checkil speedsensoris OK Go to nextsteP
( R e te rto 6 1 G r)
Replacespeedsensor
. Check PCM terminalNo.12 voltage Go to tlext steP

. Put shifl lever in to neutral
. lgnition switch ON with front wheels lifted
. White tuming the wheel, check il the voltage
change makes four pulses a turn between
the PCM torminalNo.12 and the ground
Checkspeedsensorcircuit
+ lf OK, replacePCM
Q lf not OK, replacespeedsensor.
Checktor continuityin wiringfromPCM

terminalNo.12to soeedsensor
Checkfor shortcircuitin wiringfromPCM to
speedsensor
ClrcuitDiagram
METERSET
2t026
214-38 EMISSIONCONTROLSYSTEM sELF-DrAGNosts
FUNcloN
After-repairProcedure
1. Cancelthe memoryof malfunctions by disccnnecting the
negative batterycableand depressing the brakepedal
f o r a t l e a s t f i v e s e c o n d s .R e c o n n e ctth e n e g a t i v e
batterycable.
2. ConnecttheSST to thediagnosisconnector.
3. Tumtheignition switchON.
4. Afterstartingand warming-up the engine,run the engine
for3 minuteat 2,000rpm.
5. Verifythatno codenumbersare displayed.
E M I S S I O N C O N T R O L S Y S T E M S E L F . D I A G N OFSUI N
ScTIoN 21A-39
S W I T C H i l l O N I T O RF U N C T I O N
tfLe
dat l n d i v i d u asl' ' v i t c h ecsa n b e i n s p e c t e db y t h e S S T ( S e l f - D i a g n o sCi sh e c k e r ( K J - 1 ) ) .
ive
S e l f - D i a g n o s i sc h e c k e r ( K J - 1)
Switch Bemark
ON OFF
ine
lnhibitorswitch (A/T) L.S .Dor R range N or P range
F a n s p e e d c o n t r o la t 1 s t
A/C switch ON OFF position
O X Y G E N S E N S O RM O N I T O R
Engine Condition Item rnonitored Remark
Oxygensensorout put
morethan0. 48V
Running(after warm-up) Orygensensoroutputsignal
out put
Orygen' sen sor
lessthan0.48V
Inhibitorswitch (A/T)
Shifttransaxleinto L, S, D, or R range
_=+NO
PC : . Inhibitorswitch malfunction
Checkthat the SST displaysON
. Open or short circuitin relatedwire harness
IY t.. . PCM terminalNo.9 voltage incorrect
.. . PCM malfunction
InhibitorswitchOK
Shittinto P or N range
A/C Switch
Turn A/C switch and blower switch ON NO
------>
PC : . A/C switch,blowerswitchmalfunction
Check that SST displa,.,s
ON
. Openor shortcircuitin relatedwireharness
. P C Mtermi nal , o.6andN o . 47.
N o.S N
YE S
voltageincorrect
. Duatpressureswitch.thermosrvitchmaifunction
A/C switchOK
21A4o EMISSION CONTROL SYSTEM ourLtNEoF EMfssroN
coNrFroLsysrEM
O U T L I N EO F E M I S S I O NC O N T R O LS Y S T E M
S T R U C T U R A LV I E W
To reduceCO, HC, and NOx emissions,the followingsystems
are employed.
1. PositiveCrankcaseVentitation(pCV) system.
?. Evaporativeemissioncontrolsyslem.
3. Catalyticconverter.
SEPARATOR
CHECKVALVECrwo-wAY)
CHARCOALCANISTER
CATALYTIC
CONVERTER
PCV VALVE
I
I
I\
SOLENOIDVALVE
(PURGECONTROL)
:{
:i
-
':i
EMfSSION CONTROLSYSTEM posmvEcRANKcAsEvENTtLATIoN(pcv)sysrEM
21A41
P O S I T I V EC R A N K C A S EV E N T I L A T I O N
( P C V )S Y S T E M
DESCRIPTION
The PCV valveis operatedby the intakemanifoldvacuum.
When the engineis runnfngat idle,the PCV valve is openedslighilyand a smallamountof blowbygas is
drawninto the dynamicchamberto be burned.
As the.enginespeedrisesthe PCV valveis openedfurther,allowinga largeramountof blowbygas to be
drawninto the dynamicchamber.
PCVVALVE
Inspection
1.warm up the engineto the normalopdrating temperature
and runit at idle.
2-Disconnect the Pcv valvewith the ventilation
hosefrom
the rylinderheadcover.
3. Blockthe PCVvalveopening.
a. Verifythatvacuumis felt.
5. Removethe PCVvalve.
6. Blowan air throughthe valveport @ and verifythatthe
air comesout fromport@.
7. Blowan air throughthevalveport@ andverifythatno air
comesout fromport@. .
8._Replace PCVvalveif necessary.
lhe
21A-42 EMISSION CONTROL SYSTEM EVApoRAIvEEMtsstoNcoNrRoL sysrEM
E V A P O R A T I V EE M I S S I O NC O N T R O LS Y S T E M
DESCRIPTION
SOLENOIOVALVE
(PURGECONTROL)
CHECKVALVE
[rwo.wAY)
SEPARATOR TO ENGINE
2 1038
The.evap-retiveemissioncontrolsystemconsistsof the separaior,the wo-way check valve,the charcoal

canister,t;re purgecontrolsolenoidvalve,the PowertrainControl.Module(PCM),and the hput devices.
Ine amou't of evaporativefumesareintroduced intothe engineand a burningis conkolledby the solenoid
valveio c.iiespond to the engine'soperatingconditions.1o maintainthe bist enginepeiormance,the
solenoidvalveis conlrollEd
by the PCM.
'
operation
The solenoidvalve(purgeconkol)is controlled by the dutysignalskom the PCM to performa purgingof
the charcoalcanister.A-.lrgingis donewhenthe'following'conditionsare met:
(i ) Afterwarmino-uo
(2) Drivinggearis operating
(.rJAccelerator
pedalis depressed (idleswitchOFF)
(4)Orygensenior functioning nornially
EMfSStON CONTROL SYSTEM evepoRAlvEEr,rrssroN
coNrRoL sysrEM 21A43
S Y S T E MO P E R A T I O N
1 . W a r mu p t h e e n g i n et o t h e n o r m a lo p e r a t i n gt e m p e r a t u r e
and runit at idle.
2 . D i s c o n n e ctth e v a c u u mh o s e f r o m t h e s o l e n o i dv a l v ea s
s h o v r ni n t h e f i g u r e ,a n d v e r i f yt h a t n o v a c u u mi s f e l t a t
t h e s o l e n o i dv a l v e .
3.lf it is notas described a b o ' r e ,c h e c kt h e s o l e n o i dv a l , r e .
S O L E N O | DV A L V E( P U R G EC O N T R O L )
Inspection
l . D i s c o n n e ctth e v a c u u mh o s e sfrom the solenoidvalve.
2-Verirythat no air flows throughlhe valve.
2ror0
GROUNO 3. Disconnectthe solenoidvalve connectorand supplybat-

'dL+ tery',7e11tge (12V)as shown in the figure.
*ri)
C'-
\-: ' i z v 4. Verirythat air flowsthroughthe valve.
5. lf it is not as describedabove,replacethe solenoidvalve.
2 1 0 {t
SEPARATOR
Inspection
'l.
Removetheleftsidetrim.
2. Removetheseparator.
3. Visuallycheckthe separator
f o r d a m a g e . R e p l a c ei t i f
necessary.
CHECKVALVE(TWO-WAY)
I N S T A L L A T I O NOI P E C T I O N
tnspection
t
1.Removethevalve.
of thevalvewitha vacuumpump.
2. Checktheoperation
tfi A
-J
-t IT
lll.t- c+6 A p p l y a p p r o x .3 7 m m H g ( 1 . 4 6 i n H g )
Air{low
t_ vacuurn at porl A
A p p l y a p p r o x .4 4 m m H g ( I . 7 3 i n H g )
Airf lovr
vacuum at port B
L-/
21A44 EMISSION CONTROL SYSTEM EVAPORATIvE
EMtsstoNcoNTBoL sysrEM
CHARCOALCANISTER
Inspection
1.Visuallycheck for damageand replacethe charcoal
can-
isterif necessary.
EMISSION CONTROL SYSTEM rueu cw coNrRoL sysrEM 21A-4s
SYSTEM
FUELCUTCONTROL
DESCRIPTION
ilis system is used to improvethe fuel economy,to prevent an engine buckingduring the deceleration,
andto'protectthe enginefrom the overspeeding-
OETERMINATION
OF
OETECTION OF
DECELEMTION FUELCUT
ALL INJECTORS
SENSOR
THROTTLE WATERTHERMOSENSOR
DISTRtEUTOR(Ne-SIGNAL)
2to.t
SYSTEMOPERATION
1.Connectthe SST(KJ-1) connector.
to thediagnosis
2.Warmup the engineto the normaloperating
temperature
andrunit at idle.
Warning
. Confirmthat transaxleis in Neutral(fulfDor P range
-
!Aro'
3. Confirmthatan idleinjection timeis in 1.O-4.5ms.
4. Increasethe enginespeedto 4,000rpm and then sud'
denly releasetheaccelerator pedal.
5. Confinna fuelctrton arwnd 1,500rpmduringa deceleration.
6. lncreasethe enginespeedand verifythat the maximum
rpmdoesnot exceedthe specification.
Max.rpm :
(85 SOHC)approx.6,300rPm
' I (85 DOHC)apProx.6,500rPm
21A46 EMISSIONCONTROLSYSTEM A/ccur-oFFsysrEM
A/C CUT-OFFSYSTEM
OESCRIPTION
An A/C cut-oifsystemis usedto improvean idlesmoothness
iust aftersta(ingthe engineand to improvg
performance.
the acceleration
THROTTLESENSOR
P/S PRESSURE
swrTcH
A/cswrTcH
AOOITIONAL
FAN RETAY
IGNITIONSWITCH
rNHrSrTOR (A/T)
SWTTCH IGNITIONSWITCH
MAGNETIC
CLUTCH
BATTERY
2 r O 5I
Operation'
The A/C is cut off underthebelowconditions
Englne condition Purpose Cut-off perlod
Afterenginestarting. tmprovement
of engini starting Approx.4 sec.
Fully opening of throttlevalve lmprovement of drivability . ' Approx.10 sec.
SYSTEMOPERATION
JUMPER 1.Warmup the engineto the normaloperating temperature
ffi
WIRE .and runit at idle.
WITH
APPROX.
2. Tum the blowerswitchandA/C switchON.
4.7k0 3. Disconnectthe throtttesensorconnector.
..".' RESISTOR 4. Witha jumperwire,connectthe.throttle
sensorconnector
terminalsas shownin the figureand checkwhetherthe
ffi JUMPER
WIRE
Note
fanstopsforapprox.10 sec.
additional
. The magneticclutchand the additionalfan operate

together.
2rO32
EMISSION CONTROL SYSTEM TUEI cUT cONTROL
SYSTEM 21A147
I D L ES P E F DC O N T R O L( I S C )S Y S T E M
DESCRIPTION
To improvethe icjlesmoolhness,the ISC systemcontrolst h e i n t a k ea i r a m o u n tb y r e g u l a t i n tgh e b y p a s sa i r
amountthat passesthroughthe throttlebody.
()
7=\,
INTME AIR
r--
ll
U
OOLANT
Inspection
1.Disconnect
theISCvalveconnector.
2.Check'the
resistance
of theISCvalve.
'C,
: 8.6-10.6O (at20 0AT;
Resistance
3.lf it is notOK,replace
theISCvalve.
t0.0
8SXO2
21A-48 EMISSION CONTROL SYSTEM lcNfloN coNrnol Sysreu
C O N T R O LS Y S T E M
IGNTTION
DESCRIPTION
To improve the drivablity,PCM controlsthe ignitiontimingthroughthe signalscf varioussensors.
& v/ArERrEMP.sENSoR
T
THNOTTLE
Ne-SIGNAL POSITIONSENSOR
G.SIGNAL
MAPsENsoR
ry
IGNITIONCOILASSEMBLY
DISTRIBUTOR
SPARKPLUG
II
I G N I T I OT
NI M I N G
E nglnec o n d i ti o n l g n l ti o ntl mi n g (B TD C )
Cranking 6 0 - 10 0
Running lgnitiontiming depends on englne speed, water temperaturesensor. and fuel Injection.
' I
I
'21A-49
ft
EMISSIONCONTROL SYSTEM coilrnol sysrEM
C O N T R O LS Y S T E M
S T R U C T U R AV
LIEW
{
{
ald.s
&
=l
il
il
1. Powertrain contro!module(PCM) 7. Solenoidvalve(Purgecontrol)
2. Circuitopeningrelay 8. Main relay(FUELINJ relay)
3. P/S pressureswitch 9. Oxygensensor
4 . I S Cv a l v e 10. Neutralsrvitch(Mn-)
5. Throltlesensor 1'l. Inhibitorswitch(Mf)
6. Waterthermosensor 12. Diagnosisconneclor
1#l
-*frI
21A-50 E M I S S I O NC O N T R O LS Y S T E M c o N T R o S
L YSTEM
P O W E R T R A TC NO N T R O LM O D U L E( P C M )
. Removalllnstallation
1 .D i s c o n n e ci th e n e g a t i v et e r m i n afl r o m t h e b a t t e r v .
2 . R e m o v et h e b c l t sa n d n u l s .
3. Disconnectthe PCM connbctors.
4.Installa r)ew PCM in the.ieiverse order of a removal.
lnspecticn
=\.-2 1.Turnthe ignitionswitchOFF.
't
t 2. Connectthe SST to the diagnosisconnector.
._!jtti! r'.
:il 3.Turn the ignitionswitchOf.l.
-- 4. check the voltage or correcta conditionof each terminal.
5.lf any PCM terminalvortageor conditionof each terminal
is incorrect,check the relatecinput or outputdevicesand
wiring.
l:
.&
*
- ?.
-i
EMISSIONCONTROLSYSTEMcolnnoL svsrEr',r 21A-51
T E R M I N A LV O L T A GE ( R e f e r e n c eo n l y ) Va : tsatteryvoltage
Term' ln Out Correct

C o n n e c t i o nt o
inal put Put Voltage
1 o lgniter t g n i t i o ns w i t c hO N V8
ldle Approx.0.4-0.7V
2 o G r o u n d( P W R ) Constant Eelow0.5V
3 c Gro u n d(P WR ) Constant Eelo'a 0.5V
o Injecicr l g n i t i o ns w i t c hO N V3
ld!e Approx.Va
5 o A/C thermosvritch A/C srvitch ON at ldle OV
A/C srvitchOFF at ldle Ve
o o A/C switch A/C switch oN at ldle OV
n/C s''ritchOFF at lCle V8
7 o connector(TENterminal)
Diagnosis lgnition I T E Nt e r m i n aol p e n .VB
Sv/itchON T E N t e r m i n a lg r o u n d e d Eelow1.0V
9 Inhibitorswitcn1R4'1 N or P range OV
Others. VB
12 o Speedsensor While vehiclestop 0or5V
While vehicledrivinq 2-3V
13 o Diagnosisconnector(FEN terminal) When no malfunctioncode displayed V8
When malfunctioncode displayed Below1.OV-Vg
15 o Waterthermosensor 20'C (68ts)

Enginecoolanttermeraiure Appr ox. 2. 5V
Afterwarm-up Approx.0.4V
16 o MA Ps e n s o r lgnitionswitch ON 4.8V
ldle (afterwarm-up) 2. 5V- 3. 5V
17 o Orygensensor lgnitionswitch ON Approx.0V
l d l e ( c o l de n g i n e ) Approx.0V
ldle (afterwarm-up) 0- 1.0v
ldle (afterwarm-up) 0 . 5 -1 . 0 v
D c c e l e r a t i o n( a f t c rw a r m - u p ) 0-0.4v
18 o Ground (Oxygen sensor) Constant Belol 0.5V
19 o Throtlle sensor A c c e l e r a t o rp e d a l r e l e a s e d 0.5v
A c c e l e r a t o rp a d a l d e p r e s s e d A p p r o x .4 V
21A.-52 EMlssloN coNTRoL sysrEM coNrRoL
sysrEM
f eHn,|tNAL
VOLTAG
F(Reference
onty)
Ve : Bafieryvciragc
r €iffi- ln Out
C o n n e c t i o nt o
T-- T e s tc o n d i t i o n I Correct
inal Put put I
I Volta.to
2C o Inlake air therrno sensor
i
II Ambientair temperature
O"C(32"F) 3.5V
-
II Ambientair temperature
zO'C(69"F) 2.5V
go"C(176"F)
ambientair temperatui.e 0.6 v
J
.J o Cooling fan switch Fan operating(Coolantlemperarure Below 2V
over97'C (206"F))
Fan not operating VB

24 o lgnitionswitch
OV
Approx.10V
30 o Injectorf 1 lsnition
swirchON
I Va
-
ldle Approx.
Va
I
31 o Ground Constant Below0.5V
32 o Battery Constant Ve
33 o Dlstributor(NE siEnat) lgniticnswitchON 0 or 5\,
ldle A pprox. 2V
34 o Ground Constant Below0.5V
35 o P/S pressureswitch P/S ON at idle Below 1.0V
P/S OFF at idle 5V

41 o Diagnosisconnector(MENterminal)
lgnitionswitch Any monitoredswitch
in ON position VB
ON after
groundingTEN
Any monitoredswitch
terminal Below1.0V
in OFF position
Orygensensormonitoring
(ldte) 0.1-0.9v
.42 o Distributor
(G-signal) lgnitionswitchON 0or5V
ldle Approx.2.5V
44 o Ground_ Constant Below0.5V
45 o. Vref. Constant 5V
46 .| Ground Constant Below0.5V
47 o A/C cut-off A/C ON Eelow 2V
A/C OFF Va
48 o Main relay lgnitionswitch ON Va
lgnitionswitch OFF Below2V
EMISSION CONTROL SYSTEM COTqTRoL
SYSTEM 21A-53
V B : 8 a i t e r yv c t t a g e
erfi' ln Out Correct

Connection to Test conditlon
inal Put Put Voltage
50 o Purge colrlrolsolenoidvalve !gnitionswitch ON Va
While purge controlsolenoidvalve ON Below2V
52 o V8R lgnitionsvritchON Ve
lgnitionswitch OFF Va
53 o l n j e c t o r# 2 lgnirionswitch Oi.l Ve
ldle Approx.Va
# o ISC valve lgnilion svritchON VB
ldle Approx.10V
21 A-54 E M { S S I O NC O N T R O LS Y S T E M c o N r R o Ls y s r E M
MAPSENSOR
C BA lnspection
l.;) 1 . D i s c o n n e ct th e M A P s e n s o rc o n n e c t c r .
2 . C h e c ki f M A P s e n s o rv o l t a o ei s O K .
After warm-up
Approx 4.8V 2.5V - 3. 5V
2 t068
V a c u um I n s p e c t i o n
1. Disconnecta vacuum hose from the throttlebody.
2- After making a vacuum with a vacuum pump, check if a
vacuumis keeping.
3. tf it b rnt keeping,replacesre laa.un l'pse arcilorfre l,llqp sensoc
4 - c h e c k t h e p r e s s u r eb e t w e e n t h e M A p s e n s o r a n d t h e
throttlebody with a vacuum Eage.
ConCition P ressure
lgnition svritchON 1 0 1 3m b a r
ldle (After r.rarm-up) 400-450 mbar
W A T E RT H E R M O S E N S O R
Removal
Note
. W a t e rt h e r m o s e n s o r i s p l a c e d a t i n t a k e m a n i f o t d .
1. Disconnectthe water thermosensorconnector.

2. Removethe water thermosensor.
tnspection
1. Placethe sensorin waterwith a thermosensorand heat
WATERTHERMOSENSOR
!!e watergradually.
2. Measurethe resistance
of the sensorwithan ohmmeter.
Coolant Resistance(KO)
-2UC (-4.F) 1 6 . 2t 1 . 6
200c (68.F) 2.aStO.25
8 0 0 c ( 1 7 6 .F ) 0.32+ 0.03
3. lf it is not as specified,replacethe water thermosensor.

2r07t
lnstallation
1 . I n s t a lal n e w w a s h e ra n d t h e r v a t e rt h e r m o s e n s o r .
REPLNCE WASHER
25-29 N'm (2.5-3.0 kg-m, 18-22|b-ft)
2. Connectthe water thermosensorconnector.

3. Startthe engineand check for a coolantleakage.
EMISSION CONTROL SYSTEM coTvTRoL
SYSTEM 21A-ss
T H R O T T L ES E N S O R
AECD lnspection
l d l es w i t c h
1. while arrigrrition s v . , i t cihs o F i d i s c c n n e ctth e c o n n e c l o r
from lhe ihrottlesensoi'.
2. While a throttlevalve is fully closed,check the continuity
betweenthe throttlesensorternrinalsA and D.
3. lf the continuityis not OK, adjustthe throtilesensor.
? i0;.3
4. I n s e r t0 . 4 m m ( 0 . 0 1 6i n ) f e e l e rg a u g e b e t e e nt h e s t o p p e r
and the throttlelever.
5 . Check for no continuihT betweenrhe throttlesensortermi-
n a l sA a n d D .
e. lf it is not as specified.adjustthe throttlesensor.
T e r m i n a lv o l t a g e
1. Connectthe SST (KJ-1)to the diagnosconnector.
2. Tum the ignitionswitch ON, and check the PCM terminal
voltagewhile tuming the throttlelever,by hands.
Throttle valve
PCM terminal
Futlyclosed Fullyopen
19 A pprox.0.5V A ppr ox. 4V
3. lf the voltageis not as specified,adjustthe throttleposi-

2r07t tionsensor.
214-56 EMISSIONCONTROL SYSTEM covrRoL sysrEM
Adjustment
Note
. Do not aojust the throttle adJustmentscrew.

ldle switch
1. With the ignitionswitch OFF, disconnectthe connector
from the throttlesensor.
2. Loosenthe throttlesensor installationscrews.
Whilethe throttlevalve is fully closed,adjustthe position

n a c D of throttlesensorfor a continuitybetweenthe throttlesen-
sor terminals A and B.
Feei ergauge Continuity
0.3mm o
0.4mm X
4. lighten the throttlesensorinstallation

screws.
Terrninalvoltage
1. Connectthe SST (KJ-1)to the diagnosisconnector.
2. Verifythatthe throttlevalveis fullyclosed.
3. Loosenthe installationscrews,turn the ignitionswitch
oN.
4. A.djustthe throttlesensorto makethe voltageof PCMter-
minal19 as the specification.
Specification
Fullyclosed: Approx.0.6V
Fullyopen : Approx.!.2V
Note '
'
. Check that the voltage is gradualtyincreasedas
the throttlevalve is graduallyopen.
+ 5. f ightenthe throttlesensorinstallation
lnspectionof operation
screws.
1. Checkthe throttlebodyfor a weamessand a clog.

2. Checkthe throttlevalvefor a smoothoperationby tuming
thethrottleleveropenandclose.
3. lf necessary,replacethethrottlebody.
Caution
2r079 . Donot removetfrecoatedfilm on theinsideof throttle\rah/e.
Replacement
1. Turnthe ignitionswitchoff.
2. Disconnect the connectorof throttlesensorand loosen
the throttlesensorinstallation
screws.
3. Replacethe throttlesensorand adjustit.
4. lighten the throttlesensorinstallationscrewsand con-
nectthe connectorof throttlesensor.
i
I
I
f
' lI EMISSIONCONTROLSYSTEMcolrrnoLsysrEM 21A-s7
,l,
I
O X Y G E NS E N S O R
inspection
1. Warm up the engineto the normaloperatingtemperature
a n d r u ni t a t i d l e .
?. Disconnectthe oxygensensorconnectot
3. Connecta voltmeterbetweenthe oxygensensorahd the
ground.
4. Rurrthe engineat 3,000 rpm untilthe voltmeterincicates
approx.0.55 \/.
5. Increaseand decreasethe enginespeedsudcienlysever-
a l t i m e s . V e r i f y t h a t w h e n t h e s p e e d i s i n c r e a s e dt h e
m e t e r r e a c i s0 . 5 V - 1 . 0 V , a n c i w h e n t h e s p e e d i s
decreasedit reads 0 V-C.4 V.
6. check the resistancebetweena terminafB and a terminalc.
Resistance : approx. GC)(at 20"C,68'F)
7. lf the resistanceis not as specified,replacethe orygen sensor.
Replacemeni
1. Disconnectthe batterynegativeconnector.
2. Disconnectthe orygen sensorconnectoc
3. Removethe orygen sensor.
Tighteningtorque :29-49 N.m (3-5 kg-m, Z2-361b-ft)
MA|NRELAY(FUELtNJRELAY)'
Inspection
A B 1. Verifythat the mainrelayclickswhenturningthe ignition
switchON andOFF.
l:l 2. Check'fora continuityon the terminalNo.85and No.86,
lr:rl whbn'12Vis appliedto terminalNo.30andNo.87.
3. lf necessaryreplacethemainrelay.
lol
2t@{
P O W E RS T E E R I N GP R E S S U R ES W I T C H
lnspection
1. Disconnectthe P/S pressureswitchconnector.
2. Connectan ohmmeter.
3. Start the engineand run it at idle. Check for a continuity
of the switchwhileturningthe steeringwheel.
P/S C onti n uit y
Tuming Yes
Not turning No
2lol{
.At . lf the continuityis not as specified,replacethe p/S pres-
sure suriich.
21A-58 EMlssloN coNTRoL SYSTEMrRouBLESHoolNG
GUIDE
USINGTHISSECTION
lntroduciion
Mostol the tuel and emissioncontrolsystemis electrically controlled,ottenmakingit difficultto diagnose
the.sys.ter.nl.especially
lor the pr6blerns.
intermittent Before uldertatiir':gthe actualchieckq
Pj:_!':T"
IaKea lewlnmtnulesto talk lvith a customerwho has a drivabilitycomplaint. The customeris often a good
source of informationon such problems,especiallytor the interminentones. Through tatkingwitli thi
customer, one can findout what the symptomsare and underwhat conditionsthey occur.
Work flow
CHECK IN
I
Y
LISTENTO CU-STOMER
COMPLAINTS
I
Y - D TA GN OS TIC
R EF E RT O T R OU BL E SH O OTINPGA GETH A T IN D E X
CORRESPONDS TO ACTUALSYMPTOM
I
Y
C H E C KF ORW H ATIS BA DIN S Y S TE M-...---- IN S P E C TION
I
Y
CHECKFORWHATPARTtS BAD--_ r_____--_ ACTTON
I
V
)l ENT --.-..---....---J
+
REPAIR/REPI-ACEM
OE T ER M IN E
IF T R O U EL EH A S B E E NE LIMIN A TE O
I
] Yes
T
CHECKOUT
Diagnosticindex
DESCRIPTION : -
Describes
eachtroubleshooting
item.
No:
Eachtroublephooting
itemis
assigned
a number.
:$l
*
}..:r
E
qr
et
PAGE: 1l
nel
Shows the referencepage. li
e
s
s.t
.- a
. tll
*r
.*r
T R O U B L E S H O O T I INTG
Thereare27 troubleshooting
E M: Sr
{l
*i
items.Choosethe itemforthe :*1
mostcloselycorrelspcnds
theactualsymptom.
to t*
*
$
E M l s s l o N c o N T R O L s Y s r E M r n o u B L E s H o o l NG
GU I D E 21A-59
DESCRIPTION:
Furtherdescriptionof the symptom. Confirmthat the chart addressesthe actdal symptombefore
beginninga troubleshooting.
T R O U B L E S H O O T I NHGI N T S:
This describesthe possiblepointof malfunction.
STEP :
This shows the orderof tioubleshooting.P roceedwith a troubleshooting
as indicated.
I N S P E C T I O: N
Thisdescribes an inspection
to determine of parlsquickly.
the malfunction
ACTION:
Thisrecommends
theappropriate
actionto takea result(Yes/No)
of the INSPECTION.
21A€O EMlssloN coNTRoL SYSTEMrRouBLESHoorNG
GUIDE
D I A G N O S T I CI N D E X
No. T R O U E L E S H O O T I N GI T E M DESCRIPTION PAGE

1 Willnot crankor cranksslowly Refer to Engine EteclricalSystem
2 Cranksnormallybut No combustion Engine cranks at normal speed but shows no 214-63
will not start sign of liring
3 Partialcombustion- Engine cranks at normal speed but shows 21A- 65
When warm-up only partial combustion and will not continue to run
4 Partialcombustiorr- Enginestartsnormallywhencold,bul wilt not start 214-67
After warm-up afterrunningand hot soaked
5 Cranksnormallybut Always Enignecranksat normalspeedbut requires 21A- 69
hard lo start excessivecrankingtime beforestarting
6 When engineis cold Same conditionas No.Safterrunningand cold 214-71
Restartsnormallyafterwarm:lp
7 After warm-up Sameconditionas No.Safterrunningand hot 21A-73
soaked
Startsnormallvwhen cold
8 Roughidle Afways Enginestallsor vibralesexcessivety
at idle 214-75
9 (Low ldle speed)/ Beforewarm-up Enginestallsor vibratesexcessively
at idle during 214-77
Enginestallsat idle warm-up
10 Afterwarm-up Enginerunsnormallyat idle duringwarm-upbut 214-79
vibratesexcessively
9r stallsafterwarm-up
11 When A/C, P/S, Enginestallsor vibratesexcessively
at idlewhen 21A-81
of UL ON A/C, P/S, or E/L ON
12 Roughidle/Enginestallsjust afterstarting Enginestallsor vibratesexcessively
ontyjust after 21A-82
starting(acceleration
from idle)
13 Highidle speedafterwarm-up ldle speed excessive after warm-up
21A-83
14 ldle movesup and down/ldtehunting Enginespeedsup and downperiodicalty at idle 21A- 85
15 Enginestallson deceleration Engineunexpectedly stopsrunningwhiledecelerat- 21A-87
ing or afterdeceleration
16 Enginestallssuddenly(lntermittent) Engineintermittentlystops running 214- 89
17 Hesitates/Stumbles on acceleration Flatspot occursjust afteraccelerator
aepre-eO or 21A-90
mildjerkingoccursduringacceleration
18 Surgeswhitecruising Unexpectedchangein enginespeedwhichis 21l.-92
usuallyrepetitive
19 l-ack of power Performance poor undertoadwhenthrottlevalve 214-94
wide open
Maximumspeedreduced
20 Pooracceleration Performance
poor whileaccelerating 21A-97
21 Runs rough on deceleration/Eackfire Engine runs rough white deceleratr'ngand abnormai 21A-100
combustion occurs in exhaust system
22 Knocking Abnormal combustion accompanied by audible 214-102
'pinging'noise
23 Fuelodor Gasolineodorin cabin 2 1 A t-f :

: 24 Exhaustsulfursmell Exhaustgas srneltsabnormal 21A-105
: 25 Highgilconsumption Oil consumption excessive 21A-105
26 Poor fuel economy Fueleconomyunsatisfactory
l. 21A.106
27 A/C does not work Blowerfan operatesbut magneticcrutchdo"" not-pGE 214-108
F.
:f
lili :
Its. :
;t.
2.
E M I S S I O N C O N T R O L S Y S T E M r n o u B L E S H o o l N GG u r D E 214-61
D E S C R I P T I O NO F D R I V A BLI I T Y
STUMBLE : Mild jerkingduringacceleration.
HE S I T A T IO N : F l a t s p o t o c c u rri n gj u st afterthe accel erator
pedal i s depressed.
SURGE : Continuoussoftjerkingduringcruise.
E N G I N ES P E E D
No.ls SURGE
N o. 17 S TU MB LE
-l
,/ I No.17HESITATION
-Z)
No.21
R U N SR O U G HO N
, DECELERATTON
TIF
21A-62 EMISSION CONTROL SYSTEM TRoUELEsHooTIG

NGUIDE .I
.'t
, 'r
F U E LP U M P NNECTOR
PRECAUTION
F u e l P r e s s u r eR e l e a s ea n d S e r v i c i n gF u e l S y s t e m
I
I
I
F u e l i n t h e f u e ts y s t e mr e m a i n su n d e r h i g h p r e s s u r ee v e n
w h e n t h e e n g i n ei s n o t r u n n i n g .
a) Beforedisconnecting any fuel line, releasethe fuel pres-
s u r e f r o m t h e f u e l s y s t e m t o r e d u c e t h e p o s s i b i l i t yo f
injuryor fire.
1 . S t a r tt h e e n g i n e .
2- Push the rear seat cushionbuttonsand removethe
REAR SEAT CUSHION BUTTON cushion.
3. Disconnectthe fuelpump connector.
?r097
A
Afterthe enginestalls,turnoff the ignitionswitch.
5 . R e c o n n e c tf u e l p u m p c o n n e c t o ri n d i n s t a l lt h e r e a r
I N S T A L LC L A M P S seat cushion.
b) use.aragas a proteclionfroma fuelspraywhendiscon-
nectingthehoses.
Plugthehosesaftera removal.
c) when inspecting
the fuelsystem,usea suitable
fuelpres-
suregauge.
Caution
. Installthe hoseclampsto securethe fuerpressure
gaugeto the fuel filter and the fuel main hose to
preventa fuel leakage.
P i n c h i n gH o s e
whgn pinchingan air hoseor a fuel hosewithpliers,wrap
thehosewitha ragto preventa damage.
2 t099
E M I S S I O N C O N T R O L S Y S T E M r a o u B L E S H o o l N GG u t o E 214-63
S Y MP T O MT R OU B L E S H O O T I N G
2 C R A N K SN O R M A L L YB U T W | L L N O T S T A R T( N O C O M B U S T T O N )
Enginecranks at normalspeed but shows no sign of 'firing"

8atteryin normal condition
D6CFPTE\ Throttlevalve not held fully open urhilecranking(Dechoke system not oper'ale)
F u e li n t a n k
[ r B O UI L E S H O O T T N G
H!NTS]
Secauseof no combustion,possiblyno fuel is injectedto engine or no ignitionat all cylinCers
O No sPar'<
. lgnitioncontrolmalfunction
o
Low fuel line pressure
@ Low engine compression
. lgnitionsystemcomponenl malfunction
@ No fuel injection
. Fuel pump inoperative
. lnjectorsinoperative
I Checkif strongbluesparkis visibleat discon- Yes Go to Step3
nectedhigh-tensionlead
Caution No Go to nextstep
' Crankthe enginefor only1-2 seconds
2 Checkthatmalfunction codeis displayed Yes Malfunction Code No. displayed

on the SSTwithignitionswitchON Check for cause (Refer to specifiedcheck sequence)
-4':
:tt
.r? No Go to nextstep
!'!
+
v
.4.
i:E
:h]
t5
*
3 Connect diagnosis connector lerminals F/p and Yes Check if engine starts in this condition
8+ with jumper wire and check for fuelpump
operating sound with ignitionswitch ON cO lf starts.check circuit opening relay
Q lf does not start, go to Step 5
'm#F/P
No Go to nextstep
21A-64 EMISSION CONTBOL SYSTEM TROUBLESHooTING
GUIDE

4 C h e c k i l a p p r o x . 1 2 V e x i s t sa t f u e l p u m p c o n - Yes C l r e c kc o n t i n u i t yo f f u e l p u m p
necior terminalA wire rvilh ignitionswitch ON ( E e l w e e nl e r m i n a l sA a n d I )
No Check circuit opening relay
5 Check for injector operating sound while Yes Go to step 7

cranking engine.
No Go to nexl slep
6 Checkif approx.12V existsat injectorconnector Yes Checkvoltageat PCM terminals30. 53. 4 and25
terminalB with ignitionswitchON
No Check for open circuit in wiring between main

relay (FUEL INJ relay) and injector
7 ConnectdiagnosisconnectorterminalsFIP and Yes Go to nextstep

B* withjumperwire and checkfor conectfuel
line pressurewith ignitionswitchON
No Low pressure
Checkfuel line pressurewhilepinchingfuel return
hose
Q lf fuel line pressurequicklyincreases,
checkpressureregulator
c) ll fuellinepressuregraduallyincreases,
checkfor cloggingbetweenfuelpumpand
pressureregulator
ll not ctogged,checkfuelpump
maximumpressure
High pressure
Checkif fuel retumhose is cloggedor restricted
+ lf OK, replacepressureregulator
Q lf not OK, repairor replace
*
t
t
.1
E M I S S I O NC O N T R O LS Y S T E Mr A o u B L E S H o o l NGGu r D E 21A-65
3 c R A N K S N O R M A L L YB U T W I L L N O T S T A R T ( P A R T T A LC O M E U S T I O N )- W H E N E N G I N EC o L O
Enginecranksat normalspeedbut showsonly partialcombustionandwill not continuelo run

DECFPrcrt Batteryin normalcondition
Fuelin lank
r T RouBL ES H OOT IN G H IN T SI
6 eirlfuel mixturetoo rich @ Low engine compression
. Air cleanerelementclogged
. Aidlowmeterstuck
@ AirlFuelmirlure too lean
. Fuelinjectionconlrolmalfunction
(Correctionfor coolanttemperature)
. Lovrfuellinepressure
. Air leakageof intakeairsyslem
STEP IN S PE C T ION IN S P E C TION

1 Check that malfunction codeis displayedon Yes MalfunctionCodeNo. displayed
the SST with ignitionswitchON Checkfor cause(Referto specifiedchecksequence)
No Go to nextstep
:F
i4
.!c-
!3
2 Checkif strongbluesparkis visibleat each Yes Go to'nextsiep

disconnected high-tension
lead
C a u tl o n .No Check d'stributorcap and rotor

. Crankthe enginefor only1-2 seconds
J ConnectdiagnosisconnectorterminalsF/Pand Yes Go to nextbtep

B' withjumperwire and checkfor correctfuel
linepressurewith ignitionswitchON '.. -No Low pressure
-: CheckfuellineprEssurewhilepinching
F u e ll i n e p re s s u re: fuetretumhose
2 6 5 -3 1 4k P a (2 .7 -3 .2k g /c m t ,38-46psi ) 4 lf fuellinepressurequicklyincreases,check
pressureregulator. .
Q ll fuel linepressuregraduallyincreases,checkfor
cloggingbetweenluel pumpand pressureregulator
ll not clogged.checkfuelpumpmaximumpressure
High pressure
Checkif fuelreturnhoseis cloggedor restricted
+ lf OK. replacepress{rreregulator
O ll not OK, repairor replace
C
oo
21A-66 EMISSION CONTROL SYSTEM rRouBLESHoolNG
GUTDE
INSPECTION ACTION
C h e c k i f P C M t e r m i n a lv o l t a g e sa r e O K G o t o n e x ts t e o
( E s p e c i a l l fyo r t e r m i r t aNl o . 1 5 ,1 6 a n d 2 4 ) __
check for cause
Check for air teakage of intake air system com- Repairor replace
ponents
Go to nextstep
Chec ki f MA Ps e n s o ri s O K Go to nextstep
CBA
Repair or replace
Checkfor correctenginecompression Go to nextstep
Checkenginecondition
E ngin ec o mp re s s i o n:
932 k P a (9 .5k g /c m' ' ,1 3 5p s i )-3 0 0rpm . Worn piston,pistonringsor cylinderwall
. Defectivecylinderheadgasket
. Distorteddlinder head
. lmpropervalveseating
. Valvestickingin guide
Chec ki l a l l s p a rkp l u g sa re O K
'.
i
.:
i
WEARANOCARBONEUILOUP
.;.
.:. -r
P L U GG A P Clean or replace
1.0-l.l rnm
,11
(0.039-0.0.t3 in)
.I
:
t / l
'-;.
",.,1 '
|
r,a
j'l
ti-
ti; 1
ls.,'.
F.'i'
Fi: Try with known good PCM and check il conditionimproves
i1 i'. l;
f - ' t .
kilt
C'1 l:r
...--.-.:
f,l'
il
tl :' rl
{,-;
&i:
r*. )
ft.i
la!
*:
l{,i
lr, i
Hii
Q*i
lii''
&{j
Si'.'
lif .t.
!+-t .
rst ':
st
Il;'
F:
E M l s s l o N c o N T R O L S Y S T E Mm o u B L E s H o o r NG
GU r D E 21A-67
c R A N K S N O R M A L L YB U T W I L L N O T S T A R T( P A R T | A LC O t r , , t B U S T | O-N
A )F T E R W A B M - U P
Enginecranksatnormalspeedandshowspartialcombustionbutviil|"ot.o@
OESCRIP. and hot soaked
TION E a l i e r yi n n o r m a lc o n d i t i o n
Engine starts normallywhen cold
T T R O U BL E S H O O T I N GH I N T S I
@ AirlFuel rni:lure too rich @ Vapor lock
. Insufficientfuel injectioncontrol . F u e l p r e s s u r en o t h e l d i n f u e l l i n e a f t e re n g i n e s t o p p e d
(Correctionfor coolant temperature) . High RVP (r,rinter)fuel used in warm weather
. l n j e c t o rf u e l l e a k a g e o Praqsure regulatorcontrolsygem cralfurciion
STEP INSPECTION A C TION

1 Warm-upengineto normaloperating tempera- Yes C h a n g e f u e l t o a n o t h e rb r a n d
tureand stopit
Connectdiagnosis connector terminalsF/Pand
8* \Mithjumperwire lor 3 minuteswithignition
switchON, then checki[ enginestarls No' Go to nextstep
2 Disconnect thevacuumhoselrompressurereg- Yes Checkpressureregutdlor

ulatorand checkif enginestart
No Go to nextstep
J Connect diagnosisconnectorterminalsFIP and Yes Go to nextstep

GNO with jumper wire and check forcorrect fuel
line pressurervith ignitionswitchON
Fuel line pressure :

I
2 5 5 - 3 1 4 k P a ( 2 . 7 - 3 . 2 k g / c m z ,3 8 - 4 6 p s i )
No Low pressure
Checkfuellinepressurervhilepinching
fuelreturnhose
Q lf fuellinepressurequicklyincreases,check
pressureregulator
C lf fuellinepressuregraduallyincreases,
check
fuellineand filterfor clogging
lf notclo€ged,
ch€ckfuetpumprnax'mumpress{Jre
High pressure
Check if fuel return hose is clogged or restricted
c) It OK, replacepressure regulator
Q l f n o t O K , r e p a i ro r r e p l a c e
A
Remove vacuum hose from pressureregula- Yes Go to step6
tor and plug it. Check if fuel line pressureis
held after ignitionsrvitchis turnedOFF
F u e l l i n e p r e s s u r e: M o r e t h a n 1 4 7 k p a
(1.5 ky'cmr, 21 psi) for 5 min.
No Go to nextstep
21A-€8 EMISSION CONTROL SYSTEM TnoUBLESHooTtNG
GUIDE
INSPECTION
P lugout letof p re s s u rere g u l a toarn dc h e c ki f Replacepressure regulatcr
f uellinepr es su rei s h e l da fte ri g n i l i o ns w i tc h
is t ur nedO F F
F uel line pr ess u re:

M or e t han 14 7 k Pa (1 .5k g /c m r,2 1 p s i )
for5 min Check fuel pump hotd pressure
O lf OK, check injectorfor fuel leakage

Q lf not OK, replacefuel pump
Check that matfunction code is displayed on the Malfunction Code No. displayed
SST with ignitionswitch ON Check for cause (Refer to speiified check sequence)
I
I
Go to nexlstep
(P
Checkif PCM terminalvoltagesare OK Go to next step

(Especially
for 48, 15 and46)
Check for cause
Try with knowngood pCM and checkif condition

rmproves
Changefuel to anotherbrand
E M I S S I O N C O N T R O L S Y S T E M T N O U B L E S H O O TGI N
UGIDE 214-69
5 C R A N K S N O F I M A L L YB U T H A R D T O S T A R T _ A L W A Y S
Enginecranksat normalspeedbut requiresexcessivecrankingtimebeforestarting

DECFPrcN 8attoryin normalcondition
a E n g i n eru n sn o rma l lay t i d l e[i f i dl econdi ti on
notOK , referto' R oughi dl e' (N o.8-12)j
r r F O u 8 L E S H O O T I N GH I N T S I
@ Air/Fuelmixturetoo lean @ AirlFuel mixture too rich
. Fuel mixtureloo lean . Air cleaner element clogged
(Correctionfor coolanttemperature) . Airflow meter stuck
. Lolv fuel line pressure o Poor ignitionspark
. Air leakage
STEP INSPECTION I N S PE C T I O N
1 Check that malfunctioncode is d'splayed on the Yes Malfunctlon Code No. dlsplayed
SST with ignitionswitch ON Check for cause (Refer to specifiedcheck sequence)
No Go to nextstep
2 Checkfor correctintakemanifold
vacuumat idle Yes Go to nexlstep
V a c u u m: M o reth a n4 5 0 mmH g(17.7InH g) No Checkfor air leakagoof intakeairsystemcomponents
3 Checkif air cleanerelementis clean Yes Goto nextstep
No Replaceair cleanerelement
4 Checkif enginestartseasilywhenthrottlevafue Yes Check throttlevalvefor carbondepositand then go to

is quarteropen S tep6
No Go to nextstep
5 Checkfor correctfuellinepressureat idle Yes Go to nextstep
F u e ll l n e p re s s u re:
265-314kPa (2.7-3.2kg/cmr,38-46 psi)
(V a c u u mh o s eto p re s s u rere g ul atordi s- No Low pressure
c o n n e c te d ) Check fuel line pressure while pinching fuel retum hose
Q lf fuel line pressurequicklyincreases.check

INSTALL CLAMPS pressure regulator
Q lf fuel line pressuregraduallyincreases,check for
clogging beteween fuel pump and pressure regulator
lf not clogged. check fuel pump maximum pressure
21A-70 EMISSION CONTROL SYSTEM
T R O U B L E S H O O TGI N
UGIDE
INSPECTION
Check.ii strong blue spark is visjble discon- ACTION
at
n e c t e d h i g h - t e n s i o nl e a d w h i l e . n g ; * G o t o n e x ts l e p
cranking
Caution Check ignitionsystem

. Crank the engine
for only .l_2seconds
Cl::k for the operating sound of

each injection
at idle G o t o 1 0s t e p
Go to nextstep
Checkit 12Vexistsat tnjectorterminatAwith
ignitionswitchon Checkfor the resistance
of injeclor
Fl esi stance
: approx14.5n
. It OK, check lhe
wire hamess between injector
and
PCM
. lf not OK, replace
Injector
Checkthe wirehamessbetweeninjector
and main
relay
Check for correct engine compression

Go to nextstep
Engine compression :
932 kPa (9.5 kg/cm', 135 psi)-300
rpm
. Wornpiston,piston
ringsor cylinderwail
. Defectivecylinder
headgasket
. Distortedcylinder
head
. lmpropervalve
seating
. Valvestickingin
guide
Check if ail spark plugs are

OK
WEARANOTARBONEUtLOUP Go to nextstep
PLUGGAP g1 BURNS
t.0_t.l mrn iSlf
(0.03e_0.043intEj_DAMAGE ANO
DETERIoRATIoN Cleanor replace
€
M- OAMAGE
g
E M I S S I O NC O N T B O LS Y S T E Mr n o u ' a l E s H o o l NG
c UrDE 21A-71
C R A N K SN O R M A L L Y8 U T H A R D T O S T A R T_ V / H E NE N G I N EC O L O
E n g i n ec , ' a n k sa i n o r m a ls p e e db u t r e q u i r e se x c e s s i v ec r a n k i n gt i m e b e f o r es t a r t i n g
3 a t t e r yi n n o r r n a lc o n d i t i o n
RestartsOK aiter \varm-up
E n g i n e r u n s n o r m a l l ya t i d l e f l l i d l e c o n d i t i o ni s n o t O K . r e f e r t o " R o u g hi c l e '
NG HIN
Ta o u a tE s Hc o TltoorichTs l
lt" Airrcr"l
' n t ^ P mixiure '' AirlFuelmixture too lean
-
. s e n s o rm a l f u n c l i o n . F u e l i n j e c t i o nc o n t r o lr n a l l u n c t i o n
, A i r c l e a n e re l e m e n tc l o g g e d ( C o r r e c t i o nf o r c c o l a n ii e r n p e i a t u r e )
. l d l e s P e e dc o n t r o lm a l f u n c t i o n Poor atomization
. L o r . rR V P ( s u m m a r )f u e l i s u s e d i n c o l d w e a t h e r
INSPECTION INSPECTION
Check that malfunctioncode is displayedon the M a l f u n c t i o nC o d e N o . d i s p l a y e d
SST with ignitionswitch ON Check lor cause
N o I G o t o n e x ts l e p
C h e c k i f P C M t e r m i n a lv o l t a g e sa r e O K Go to nextstep
C h e c kl o r c a u s e
Check if engine starts easilywhen throttlevalve C h e c k i f I S C v a l v ai s O K

is open at cranking
Go to nextstep
Checkfor correctintakernanifold
vacuumat idle Go to nextsteo
V a c u u m :M o r et h a n4 5 0m m H g( 1 7 . 7i n H g )
N o I C heckl or ai rl eakageof i ntakeai rsysl emcom ponent s
C h e c k i f a i r c l e a n e re l e m e n ti s c l e a n I y.. Go to nextsleo
N o I R e p l a c ea i r c l e a n e re l e m e n t
C h e c k i f e n g i n es p e e d i s d e c r e a s e da t e n g i n e Y es I Go to nextstep
warm-up
R e p l a c eI S C v a l v e
21A-72 E M I S S I O NCONTROL SYSTEM
TRoUBLESHooTING
GUIDE
'NSPECTTON
diagnosisconnectorrerminats
3:::,":l
.no;;;;;':;1;:l[:l. Ftp and vesGo to nextstep
,?^^:llj::*,*;,"
tinepressurewirhignirion
swi;;;b;'rtrLr
ru I
Low pressure
fuettinepressurewhitepinching
Fuel line pressure: fl"J.- fuetretum
265-314 kpa (2.t_3.2kg/cmt,38_46
psi) Q lf fuefrinepressurequickry
increases,check
pressureregulator
O lf fueffinepressuregraduafly
INSTALLCLAMPS increases,checkfuel
between
rr"rpr,npandpressure
l'ff i:iiJ"ssins
lf not ctogged,checkfuelpump
maximumpressure
High pressure
Checkif fuetreturnhose is
cloggedor restricled
+ tt OK, replacepressureregulalor
O lf not OK, repairor replace
hose
}r1::i!r<nowngo
tmproves ReplacepCM
Changefuetto anolherbrand
E M I S S I O N C O N T R O L S Y S T E M T R o U B L E S H o o T IGNUGI D E 21A.-73
TT
l-1
t
*l soaked
C R A N K S N O R M A L L YB U T H A R O T O S T A R T _ A F T E R V / A R M . U P
Engine cranks at normal speed but requiresexcessivecrankingtime before startingafter running and hot
Batteryin normal condition

Engine starts normallywhen cold
Engine runs normallyat idle (if idle conditionnot oK. refer to 'Rough idle'
r r Rou E L ES H OOT INH GIN T S I

h'l
\z AirlFuel
mixturetoo rich @ Vapor lock
. Fusl injection control matfunctjon . Fuel pressu;e not held in fuel line after engine slopped
. lniector fuel leakage . High RVP (winter) fuelused in warm weather
. Pressure regulator control system malfunction

1 Checkthatmalfunctioncodeis displayed
on the Yes Malfunction Code No. displayed
SSTwithignitionswitchON Check for cause
No Go to nextsteo
2 Check if PCM terminalvoltagesare OK Yes Go to nexlstep

(Especiallyfor terminalNo. 15, 46 and 50)
No Checkfor cause
3 Runengineat idle and checkif fuellinepres. Yes Go to nextstep

sureis held atterignitionswitchtumedOFF
F u e ll l n e p re s s u re: M o reth a n 1 4 7kP a

(1.5kg/cmr,.21 psi) for 5 mfn
No Plugoutletof pressureregulatorand checkil fuelline
pressureis heldafterignitionswitchtumedOFF
INSTALLCLAMPS
c) It OK. replacepressureregulator
Q lf not OK.checkfuelpumpholdpressure
lf luel pumpis OK. checkinjectorsfor fuelleakage
-:-a
d
dr.
*:
t.l
-;r'
;i!
214-74 EMlssloN coNTBoL SYSTEMrRouBLESHoorNG
curDE

4 W a r m - u p e n g i n e t o n o r m a l o p e r a t i n gt e m p e r a . Yes C h a n g e l u e l t o a n o t h e rb r a n d
t u r e a r r ds t o p i t
Connect diagnosis connector terminalsFlP and
B ' w i t h j u m p e r w i r e f o r 3 m i n u t e sw i t h i g n i t i o n
switch ON. then check il engine starts easily
F/?
8i ).n rn
ffi No Go to next step
5 Try with knowngood PCM and checkif condition Yes R epl aceP C M
improves
No Changefuel to anotherbrand
EMISSIONCONTROL SYSTEM rRouBLESHoolNG UIDE 21A-75
I R O U G H I D L E / E N G I N ES T A L L S A T I D L E - ALWAYS
I
. Engine starts normallybut stalls or vibratesexcessivelyat idle in every conditicn

DESepTeNl --
ffi*rr rnixiuretoo lean O Incorrectidie speed
\iir"
v iirl]pu"l . ldlespeedmisadiustment
. Air leakage
. F u e l i n i e c t i o nc o n t ; o l m a l f u n c t i o n . l d l e s p e e d c o n t r o lm a l f u n c t i o n
) One or more spaik plugsnot firing
. L o r vf u e l l i n e p r e s s u r e O
or rnore iniectors clogged or nol operating Low engine compression
@ One A
M A P s e n s o rM a l f u n c t i o n
@
STEP
TNSPECTION ACTION
on the Yes M a l f u n c t i o nC o d e N o . d i s p l a y e d
SSTwithignitionswitchON Checkfor cause
No Go to nextstep
2 Check if PCM terminalvoltagesare OK Yes Go io nextstep

( E s p e c i a l l yf o r t e r m i n a lN o . 1 6 ,1 5 a n d 4 6 )
No Check for cause
J Disconnecthigh-tensionlead at idle and check if Yes Go to S tep8

enginespeed decreases equallyat each clinder
No Go to nextstec
-4 soundat idle
Checklor injectoroperating Yes Go to Step6
No Go to Step5
5 Checkif approx.12Vexistsat injectorsconnector Yes Check if injectorresistanceis OK

t e rm i n a l A
R e s i s t a n c e: A p p r o x . 1 4 . 5 0
c) lf OK, check vriringbetween PCM and injector

Q lf not OK, replace injector
No Check wiring between main relay and injector
Check if strong blue spark visible at disconnect- Yes Go to nextstep

: ed high-tensionlead
Caution No Checkignition.system
. C r a n kt h e e n g i n e f o r o n l y 1 - 2 s e c o n d s
21A-76
STEM TRoUBLESHooTING
GUIDE
INSPECTION
ACTION
Check if spark ptugsare OK
C h e c k f o r c o r r e c te n g i n e
V / E A AA N OC A R B O NS U I L O U P compression
d + It OK, replace injector
PLUG
G^p ffit'^t" c) lf not OK, check for
.^ L-0-r.r,nrn [€Ji.-Oar"rncEAND
(0.03e-0.043
cause
tn)
€ OgfgnrOnnf,Or.r
Ff'- DAMAGE
g Clea;l or replace
Check for correct fuel line prrrrur.

iC,. Go to nextstep
",
F uel line pr e s s u re:
265- 314k p a (Z .t-3 .2k g y ' c mr,3 8 _ a B Low pressure
psi)
( V ac uumho s e to p re s s u re check fuerrinepressurewhirepinching
re g u l a to r fuerreturnhose
dis c onnec te d )
c) lf fuetiinepiessurequickly
irrcreases.
check
Fressureregulator
o lf fuelrinepressuregraduaily
increases,checkfor
cloggi;rgbelweenfuelpump
and oressureregulator
lf not crogged.checkru"rpl.p-nl"rimum
pressure
Checkil MAp sensoris OK

Go to nextstep
Repairor replace
lo airreakage
I _*"*.for "ffi Repair or replace
I ponent s
Go to nextstep
Checkfor correclengine.o.pr".t.,-
Go to nextstep
E n g i n ec o m p r e s s l o n( M i n l m u m ) ;.
:
932 kpa (9.s kg/cmr,135 psil -ibo
rpm
Check for cause
Checkfor correctignitiontiming
atte after
warm-up knownsoodpCMandcheckit
3:il!
rmproves condirion
l g n i t i o nt l m i n g( B T D C )
Adjustignitiontiming
EMISSION CONTROL SYSTEM TnoUBLESHooTING
GUIDE 21A.-77
l el F O U G H I D L E / E N G I N ES T A L L S A T I D L E . - B S F O R E W A R I ( I . U P
I
I
. Engine speed tovr or engine stalls or vibrates excessively at idle during warm-up
O6gtrfu.{ I
II rTBouB LESHOOTING HINTSJ
6) Uowintakeair amount @ Low fuel injectioncontrol
I . MAP sensorMallunction
. Air cleanerelementcloggeC
. Fuel injection control mallunction
J
(Correction for coolant temperature)
. ISCVafue @ Poor atomization
. Low RVP (summer)fuel used in cold weather

1 Checkthat malfunction
codeis displayedon the Yes Malfunction Code No. displayed
SST ignhionswitchON Checx lor cause (Reter to specifiedcheck sequence)
't;i
-ri
-:a
a No Go to nextsiep
'.E
2 Checklor corqectlntake manifoldvacuun at Yes Go to nextstep

idle afterwarm-up
V"ruur : Morethan 4S0mmHg 1ilt.ZInHg)
No Checkfor air leakageof intakeii'ir'systemcomponents
J Checkif air cleanerelementis clean Yes Go to nextstep
No Replaceaircleanerelement
4 Checkif PCMterminalvoltages are OK Yes Go to nextstep

(Especially
for terminalNo.l6, l5 and 46)
No Checklor cause
5 DisconnectISCvalveconnectorand checkif Yes Go to nextstep

enginespeedincreasesor decreases
No Replaco ISC valvo

21A-78 EMISSIoN CONTRoL SYSTEM TRoUBLESHooTING
GUIDE
INSPECTION
ACTION
C h e c k f o r c o r r e c l w a l e r l h e r n t o s e n s o rr e s i s t a n c e
Y e s G o i o n e x ts t e p
I
RESISTANCT
(k0)
?0
t0
7
5
3
2
No R e p l a c ew a t e i l h e ; m c s e n s o r {
I
-i
o7
0.5
0.3
o.2
o 40 80
(3?) (r04) (l 76)
coouNT TEMPERATUnE
cr F) t,
Checkfor correctignitiontimingat idleafter .:':

war m - up Go to next step )-
+
lsnition
timins
(BrDC)
: g3i;;:
i;:
I
,+l
. t t
I
: I
., I
,\djusI ignitiontimir.:g
Try with knovrn good pcM and check

if condition R e p l a c eP C M
rmproves
N o I C h a n g e f l ' e l t o a n o t h e rb r a n d
E M I S S I O N C O N T R O L S Y S T E M T n o U B L E S H O O T IG
NUGI D E 21A-79
I
-l
I 10 S T A L L SA T I D L E _ A F T E R W A R M - U P
R O U G HI D L F J E N G I N E
I
I
I
fffeNl
.
.Engine
r u n s n o r m a l l ya t i C l ed u r i n gw a r m - u p b u t e n g i n e s t a l l s o r v i b r a t e se x c e s s i v e l ya t l e rr v d r m . u p
I H IN T SI
q
r r RouE L ES H OOT IN G
I
I 6) ldlespeedcontrolsystemrnallunction o AirlFuel mixture too rich
6 eirtFr"l mixturetoo lean . F u e ! i n j e c t i o nc o n t r o lm a l f u n c t i o n
I . A ir l e a k a g e ( C o r r e c t i o nf o r c o o l a n tt e m p e r a t u r e )
I I
I
. Lowluellinepressure ) o
o
Poor ignit;on
Lovr engine compressio;r
I STEP INSPECTION ACTtOt'l

I I Check that malfunctioncode is displayedon the Yes M a l f u n c t i o nC o d e N o . d i s p t a y e d
SST ignitionsrvitchOlt Check for cause
lI
I
I
- 1I
JI
I
II
I
I
/t
it
No Go to next siep
I 2 Check if PCM terminal voltages are OK Yes Go to nextstep

I' (Especiallyfor lerminal No.16, 15 and 46)
No Check for cause
3 Disconnecthigh-tensionlead at idle and check if Yes Go to nextstep

engine speed decreases equallyat all cylinders
No G o t o S t e p1 0
4 Checklor correctintakemanifoldvacuumat idle Yes Go to nextstep
V a c u u m: M o re th a n 4 5 0 mmH g(1 7.7i nH g)
No Checkior air leakageof intakeair systemcomponents
Check if air cleaner element is clean Yes Go to next step
No R e p l a c e a i r c l e a n e re l e m e n t
6 Disconnect ISC valve connector at idle and Yes Go to nextstep

check if engine speed increases
No ReplaceISC valve
2 1 A - 80 EMISSION CONTROL SYSTEM
TNOUBLESHOOTING
GUTDE
INSPECTION
Checkfor correc!waler thermosen"or AfiION
r"r,rOnITE Go to nextstep
Fuel llne prdasure : Low pressure

265-314 kpa (2.7_3.2 kg/cmr, chcck fuel tinepressurewhilo
38_46 psl) pinchingfuel retum hose
(Vacuum hose to pressure
regulalor
dlsconnected) Q lf fuel line pressureguicklyincreases.
check
pressureregulator
INSTALL CLNA,IPS
c) ff fuet line pressuregraduafly
ii-rcreases,check lor
ctoggingbetwee.nfuet pumj
and presure regularor
tf not clogged.checkfr"rplrp-ri.r,rm
pressure
Check for correct enition tirr,inl

after Go to neld step
warm-up "Gte
l g n i t i o nt i m i n g( 8 T D C ): D O H C
: B.+ 1.
D O H C :/ t 1 .
Adjustignitionsystem
Disconnectwater thermosenso,
ao**tor and
checkif engineconditionirpior"". " Replacewaterihermosensor
I:::'l*o'un
rmproves
check for injectoroperaringsounoaG
Go to next step
No I Ctrect<if injector
resistanceis OT
R esl stance:14.5ft
c) lf OK, checkwiring pCM
behrueen
and injeclor
c) lf not OK, replaceinjector
Check for correct engine .ornpr.Gi
Go to nextslep
t r ngt n€c om pr e s s l o n(M l n i m u m l

:
932 kpa (9.5 kg/cmr, tSS ps[-iOO
rprn',
Chqckif strong btuespark is visible

at discon- Go to nextstep
ne:ted high-tensionlead
Check high-tensionlead
c) It OK: check distributor

cap and roror
ci lf not OK, replace high_ten"ionl""O
Checkif sparkplug.sare OK
I:!,n rno*n
rmProves
Repairor reptace
EMISSION CONTROL SYSTEM TRoUBLEbHooTtNG
GUIDE 21A-81
Engine stalls or vibratesexcessivelyat i,Jlewhen AtC, PlS, or UL ON

A/C, P/S. headlights.blower lan and eiectriccooling lan ope:ate normally
oesffifti ldle conditionis normal when A/C. P/S. and EA is OFF
T T R o U B L E S H O O T IHNl G
NTSJ
iO tOt. speedcontiolsystemmalfunction
*z
. Enginespeedleedbackcontrolinoperative
INSPECTION ACTION
STEP-
1 Check that malfunctioncode is displayedon the Yes Malfunction Code No. displayed
SST with ignition switch ON
Check for cause
No Go to nextstep
2 Checkswitchesfor correctoperationby tho Yes Go to nextstep

SSTwithignitionswitchON
No Checkfor cause(Referto specifiedchecksequence)
Ahrays ON
Checkwire hamessbetweenPCMterminal41
and SST
3 Checkit PCMterminalNo.7voltage'sOK Yes Try with knowngood PCMand checkif condition

improves
V o l ta g e: Ap p ro r. 1 2 V (a t i d l e )
No Check for short circuit in wiring between diagnosis

connector terminal test and ground
I
I
I
I
I
I
I
: I
-,
21A-82 EMISSION CONTROL SYSTEM TROUBI.ESHOOTING
GUTDE
R OU G HID L E /EN G INSETA LLSJU S T A FTE R

S TON Ti l 6
I-l
I
ldle speed misadjustment

l g n i t i o nt i m i n g m i s a d j u s t m e n t
INSPECTION
ACTION
Check that malfunctioncodc is displayedon the
Yes Malfunction Code No. displayed
SST with ignition swirch ON
C h e c k f o r c a u s e ( F e f e r t o s p e c i f i e dc h e c k
sequence)
No Go to nexl step
Check if PCM terminal voltages are OK

Go to ne:l step
( E s p e c i a l l yf o r t e r m i n a tN o . t 9 )
Checkfor cause
Checkfor correctigniliontimingat idleafter

warnn.up Go to nextstep
l g n i t i o nt i m i n g( B T D C :) O O H C :B " t
1o
SOHC:7o+1"
Adjustthe ignitiontiming
Check throtttesensor
Try with known good pCl.dand check if condition

improves
E M I s s l o N c o N T R o L S Y S T E M- r R o u B L E S H o o r N
GG
ri I
I1
'l
urDE 21A-83
.l
I
-.t
I
13
|
I { I G HI D L E S P E E D A F T E R W A R I , , 4 - U P
'' ldtespeeCexcessive
afterwarm-up
DEO;|zTnNl
r T HouBLES H OOT IN GH IN T S I
Lxcessiueintakeair suppliedto engine
6) Throttlevalve not fully closed I S C v a l v e c o n n e c t o rd i s c o n n e c t e d
6 l d l e s p e e d c o n t r o lm a l l u n c t i o n A/C, P/S, or UL signal sent to PCM
. Air vaive not closed i n c o r ; e c tc o o l a n l t e r n g e r a t u r es i g n a l
. ISC valvestuck
n cTtoN
I 1 Check if throttlevalve is lully closed when Yes Go to Step 3
acceleratoreleased
No Checkif thronlelinkageis correctlyinstalledand
operates l reel y
+ i f OK , go to S tep2
c) lf noi OK, clean,adjustor replacelinkage
2. code is displayedon the Yes M a l f u n c t i o nC o d e N o . d i s p l a y e d

oti
C h e c k f o r c a u s e ( R e l e r t o s p e c i l i e dc h e c k s e q u e n c e )
il
tl No Go to nextsl ep
il
il
3 Checkswitchesfor correctoperationby the Yes Go to nextstep
SST with ignitionswitchON
No Check for cause (Refer to specifiedcheck sequence)
IJ
.F
Always ON
Check wire harness between PCM teminalNo.41 and SST
I
A
DisconnectISC valve connectorat idle and Yes Go to next slep
check il engine speed increases
No Replace ISC valve

214-84 EMISSION CONTROL SYSTEM TROUBLESHOOTING
GUIDE
STEP INSPECTION
P i n c l r P C V h o s e w i t h p l i e r sa n d c h e c k i f e n g i n e
speed decreases
Yes Check PCV vatve
t
No Go to nextstep
6 Checkif PCM terminalvoltage are OK Yes TrywithknowngoodpcM and.n**tliln

(Especiaily
for terminalNo.t5. i6 and 46) trnproves
No Checkfor cause
' E M I S S I O N C O N T R O L S Y S T E M r n o u B L E S H o o l N GG U I D E 21A-85
: I D L EM O V E SU P A N D O O W N / I D L E H U N T I N G
I . Engine speeds up and down periodicallyat idle
lI STEP IN SP EC T IO N ACTION
1 Check that mallunction code is displayedon lhe Yes Malfunction Code No. displayed
l
SST with ignition switch ON
Check for cause (Refei to speciiiedcheck sequence)
_l No Go to nextstep
l
2 Check for conect intake manifoldvacuum at idle Yes Go to nextstep
lntake manifotdYacuum :
More than 450 rnmHg (17.7 InHg)
No Low vacuum
Checkfor air leakageat intakeair system
3 Checkif air cleanerelem€nlis clean Yes Go to nextslep
-Ji.
..,
4 Disconnect high-tension lead at idle and check if Yes Go to nextstep
engine speed decreases equally at each cylinder
No Go to Step7
.i
1*
t
5 areOK
Checkif PCMterminalvoltages Yes Go to nen step
.E
No Check for cause
6 -;:eck lor correctignitiontimingat idlealter Yes Go to nextstep

warm-up
l g n i t i o nt l m l n g( B T D C ) :D O H C : 8 "t 10
No Adjustignitiontiming
S O H C: 7 ' + 10
21A-86 EMISSION CONTROL SYSTEM TRoUBLESHooTIN
GGUIDE
INSPECTION
C h e c k f o r i n j e c t c :o p e r a t i n gs o u n d a t i d l e Go to Step 11
ACTION
t
NO Go to nextStep
C h e c k i l a p p r o x . 1 2 V e x i s l s a t i n j e c t o rc o n n e c t o r Y e s I C h e c k i f i n j e c t c rr e s i s t a n c ei s O K
l e r m i n a lB
R e s i s t a n c e : a p p r o x ' ! 4 . 50
a lf OK. check wiring bellveen pCN4 and injector

c) li nol CK, replace injecto;
Check wiring berrveenPCM and injector
Checkil strongbluespaik is visibleat Go to nextstep

disconnectedhigh-tensionfead
N o I C n e c t h i g h - r e n s i o nl e a d
+ lf OK, checkdisrributor
cap and rotor
Q lf not OK, replacehigh-tension
lead
10 | Checkif sparkptugsare OK Check for correct engine compression
Compression (Miliimum) :
932 kPa (14.4kg/cmr, 135 psi)-300 rpm:
WEARAT. cAREoNEUrLDUP
j
PLUGGAP EII
f91- BuRNs c) lf OK. go to next step
- l.o-l.l rnrn fS4-Onf.,lAGE ANO c ) l f n o t O K , c h e c k f o r c a u s g .. . .
(o.o3s-0.043 i^) OETERIORATION
€
DAMAGE
'g
w
Clean or replace
Checkfor iniectorleakage Replaceinjector
Go to nextstep
Try with knowngood PCM and checkif conditionimproves

I
I
I E M l s s l o N c o N T R O L S Y S T E Mr n o u B L E S H o o r NGGU I D E 21A-87
I
-1
II
I ?
15 E N G I N ES T A L L SO N D E C E L E R A T I O N
-t
t-
I
t
E n g i n eu n e x p e c t e d l ys t o p s r u n n i n gw h i l e d e c e l e r a i i n go r a f t e rd e c e l e r a t i o n
CESCRPrcN l d l e
c o n d i t i o nn o r m a l
[ r R o u B L E S H O O T I NH
GI N T S I
E ngines p e e dd ro p sto omu c hw h e nre l e a si ng or poorconnector
accel erator connecl i on
di sconnected
by deceler at ion
Iorce
O ldlespeedcontrolmalfunction @ ldlespeedmisadjustment
6 F uelc u i c o n troma l l fu n c ti o n
1 Check if idle conditionis normal Yes Go to nextstep
No Adjusi or perform troubleshooting

N o . 8 - 1 1' R O U G H I D L E '
SST with ignitionswitch ON.
Check for cause (Refer to specifiedcheck sequence)
No Go to nextstep
3 Checkswitchesfor correctoperation
withthe Yes Go to nextstep
No Checkfor cause
(Referto specifiedchecksequence)
AlwaysON
CheckwireharnessbetweenPCMterminal41 and
.SST
4 Checkif PCMterminalvoltagesare OK Yes Try with known good PCM and check il condition improves
(Esp€cia$y No.16,15,46.30,$.4 and25)
forterminal
No Checklor cause
5 Checkfor poorconnection parts

of following Yes R e p a i ro r r e p l a c e
. lgnitioncoil
. l g n i te r
, Distributor
. High-tension lead No Go to nextstep
. Injector
. Circuitopeningrelay(Mainrelay)
. PCM
214-88 EMlssloN coNTRoL sysrEM rnouBLESHoorNG
GU,DE
IN SPEC T IO N
D i s c o n n e c tI S C v a l v ec o n n e c t o ra t i d t ea n d
Go to nexl step
c h e c k i f e n g i n e s p e e di n c r e a s e s
Replace ISC vatve
Try with known good pCM and check if condition

improves
EMlssloN coNTRoL SYSTEM-rnouBLESHoolNG
GurDE 21A-89
15 E N G T N ES T A L L S S U D OE N L y ( t N T E R M | T T E N T )
*uErtlT'"'| I . Engineintermittently
stopsrunning
. Belorestalling.enginecondition
OK
r T B O UI L E SH O OT IN H
GIN T S J
@ Intermittently no sparkor no fuelinjeclioncausedby vehictevibration,
acceleration,
or deceleration
. Poorconnectionin wireharness

1 Checklhat malfunctioncodeis displayed
on the Yes Malfunction Code No. disptayed
SSTwith ignitionswitchON
Check lor cause (Refer to specified check sequence)
No Go to nextstep
2 Checkfor poorconnectionol followingparts; Yes Repairor replace

. lgnitioncoil
. lgniter
. Distributor
. High-tension lead
. lnjector No Go to nextstep
. Circuitopeningrelay
. PCM
3 Checkif PCMterminalvoltagesareOK Yes Go lo Troubleshooting

No. 2
(Especialfy
lor terminalNO.1B,2A.28 and2Cl ,CRANKS
NORMALLYBUT WILLNOT START
(NO COMBUSTTON)'
Note
. Wh e nc h e c k l n gv o l ta g e sta, p ,move,and No Checkfor cause
w i g g l eh a rn e s sa n d c o n n e c torto rccrcatc
p ro b l e m
21A-90 EMlssloN coNTRoL sysTEM rRouBLESHoorNG
GUIDE
HESITATES/STUM
B LES ON ACCELERATION
mscngrCnrl' Flatspotoccursjust afteracceleralor

cJepressed
or mildjerkingoccursduringacceleration
r r R o u BL E s H O
OT|NG
H|NTSI
@ AirlFuel mixture becomes lean when depressingaccelerator
. Fuel injection control mallunction
(Correction {or acceleratingcondition)
. Air leakage
. Fuel line pressure decreasei'
. Spark advance control malfunction
IN S PE C T ION
Check that matfunctioncode is disptayedon the MalfunctionCode No. displayed
SST with ignitionswitch ON
Check for cause (Refer to specifiedcheck sequence)
Go to nextstep
Checkfor correctintakemanifotdvacuumat idle Go to nextstep
V a c u u m: M o r et h a n 4 5 0m m H g( 1 7 . 2i n H g )
Checklor airleakageat intakeair systemcomponents
C h e c k i f a i r c l e a n e r e l e m e n ti s c l e a n Go to nextstep
R e p l a c ea i r c l e a n e re l e m e n t
Checkif PCM terminalvoltages(connected

with Go to nextstep
throttfesensor)are OK
Check if throttle linkage is correctlyinstalledand Go to nextstep

operales treely
Correct.clean.or replaceas requiredany bindinqor

damagedlinkageand adjustcabledefreciionat tirottle
body
Checkthe vottageof throttlesensor Go to nextstep
T h r o t t l es e n s o r Voltage
Fullyclose Approx.0.6V
Fully open Approx.4.2V
E M I S S I O N C O N T R O L S Y S T E M T h O U E I - E S H O O TGI N
UGIDE 21A-91
-nr-e ACTION
l
l
tNSPEcTIoN
J l - .
C h e c k f o r c o r r e c tf u e l l i n e p r e s s u r ea t i d l e C h e c k i f f u e l l i n e p r e s s u r ed e c r e a s e s acceleraling
"vhen
quickly
F u e l l i n e P r e s s u r e:
C l f d e c r e a s e sc. h e c k f u e l l i n e a n d f i l t e r
2 6 5 - 3 1 4 k P a ( 2 . 7 - 3 . 2k g / c m r ,3 8 - 4 6 p s i )
for clogging
( V a c u u m h o s e t o P r e s s u r er e g u l a t o rd i s '
Q 1 f n o d e c r e a s e ,9 o t o n e x t s t e P
connected) \
INSTALL CLAMPS Low pressure
Check fuel line pressure vrhile pinching fuel return hose
O lf fuel line pressure quickly increases,check Pressure

regulator
O lf fuel line pressure graduallyincreases,check for
cloggingbetween fuel pump and pressure regulator
. ll not'clogged,check fuel pump maximum pressure
Check for conect ignitiontiming at idle after Go to next steP

warm-up
l g n i t i o nt i m i n g( B T D C ) :D O H C8 ' t 1 '
s o H cT t 1 '
Adjust the ignitiontimming
Check if air duct and air hoses are correctly Go to nextsteP

installed
Checkif exhaustsystemis restricted r repl ace

R epai or
Go to nextsteP
Try with knowngoodPCM and checkif conditionimproves

21A-92 EMISSION CONTROL SYSTE,M TROUBLESHOOTING
GUIDE
SURGESWHILECRUISING
Unexpecred change in engine speed which is usuaily reperitive
[3o u e LESHooTtNG HtNTSj

@ Air/Fuelmixtureloo efan
@ Misfire
O Poor connectionin wiringharness
INSPECTION
check that malfunction code is disptayed
on the MalfunctionCodeNo. Oispffi
S S T with ignition switch ON
Check for cause (Refer to

specified check sequence)
Go to nexl slep
't
Check switchesfor conect operalionby

the SST Go to nerl step
with ignitionswitchON
(Refer to specified check

sequence)
Check wire harness between' pCM

! Y." terminal
te No.41 and
ssr -
Checkil throttlesensoris OK
Go to nextstep
9i.:"LL""t-oxygens€nsorconnector
andcheck Checkoxrygen
rl condition
improves sensor
+
*
Go to nextsteo
-s
.r3
f
. l
il
.t
.$
?
,li
Check if PCM termi..:alvottages(connected *-
with Go to next step
throttle sensor) are lK
:
C heckfor cause 3
't
t
EMISSIONCONTROLSYSTEM rRouBLESHoolNG
GurDE 21A-93
6 Check it thronlelinkage is correcllyinstalledand Yes Go to next steP

operateslreely
I
No Correct.clean,or replaceas requiredany bindingor

damagedlinkage.and adiustcabledeftectional throttte
body
7 Check lor correct intake manilold vacuum at idle Yes Go to next sleP
Vacuum : More than 450 mmHg (17.7InHg)

No Check lor air leakage of intake air system components
I Checkif aircleanerelementis clean Yes Go to nexlsteP
No Replace air cleaner element
9 Checkfor correctignitiontimingat idle after Yes Go to nexlsteP

warm-up
l g n i t i o nt l m i n g( B T D C ) :D O H C: 8 ' t 1 '
SOHC:7+1'
No Adjust the ignitiontimming
10 Checklor correctfuellinepressureat idle Yes Checkif fuellinepressuredecreases

whenacceleratino
quickly
F u e ll i n e p re s s u re:
265-314kPa (2.7-32 kg/cm:,38-45 psl) O lf decreases.checkfor fuelpumpmaximumpressure
(Vacuumhosc to presaureregulatordls- ll OK. checkfuel lineand fitterfor clogging
c o n n e c te d ) 4 lf no decrease,go to nextstep
No Low pressure
INSTATLCLAA,{PS
Checkluel linepressurewhilepinchingfuel retum hose
Q lf fuelline pressurequicklyin.creases,check pressure

regulalor
c? ll fuelline pressuregraduallyin-creases,checkfor
cloggingbetweenfuelpumpand pressureregulator
lf not clogged.checkfuelpumpmaximumpressure
H i gh pressure
Checkif fuelreturnlineis clogged
e lf OK. replacepressureregulator
4 lf notOK, rePlace
l1 Checkif exhaustsystemis restricted Yes Repair or rePlace
No Go to ncxtsteP
12 Try with knowngood PCM and checkil conditionirnproves

214-94 EMlssloN coNTROL SYSTEMrRouBLESHoorNG
GurDE
19 LACK OF POWER
Pedormance poor under load when throttlevalve wide open

DSCRPID\ Reduced maximum speed
ldle conditionnormal
[rRo uB LESHOOTTNG HTNTSJ

@ Factorsotherthanenginemallunction @ Air/Fuel mixture too lean
. Clutchslipping . Fuel line pressure decreases
. Afi slipping . Fuel injectionmalfunction
. Erakedragging o Poor ignition
. Low lire pressure
. Incorrecttiresize
. Overloaded
E Low engine compression
Alcohol blended fuel used
@ Low intakeair amount

. Throttlevalvenot open fully
. Cloggedintakeair system
STEP IN SPE C T ION A C TION

1 Checkfactorsotherthanengine; Yes Go to nextstep
. Clutchslipping
. Nf slipping
. Brakedragging No Repair
. Low tire pressure
. lncorrecttire size
2 Chockil throttlovalvslullyoponedwhen Yos G o t o n o x ts l e o
acceleratordepressedlutly
No Check if acceleratorcable is correctly installed
c) lf OK, check throttlebody

O lf not OK, install acceleratorcable correcily
3 Checkthat maliunctionis displayedon the SST Yes Malfunction Code No. dlsplayed
with ignitionswitchOl.l
Check for cause (Refer to specified check sequence)
No Go to nextstep
4 Checkfor correctignitiontimingat idleafter Yes Go to nextstep

warm.up
l g n i t i o nt i m l n g( B T D C ) :D O H C8 ' t 1 '
_ soHc7' t 1 '
No Adjustthe ignitiontimming
E M I S S I O NC O N T R O LS Y S T E Mr R b u B L E S H o o l NGGu r o E 21A-95
INSPECTION ACTION
STEP
i f s P a r kP l u g sa r e O K Yes Go to nexlstep
1 0 Check
WEAAANOCAESONBUILOUP
BURNS
PLUG GAP OAMAGE ANO

1.1mrn OETERIORATION
(0.043 h)
No Cleanor replace
OAMAGE
6 leadsare OK
Checkif resistanceof high-tension Yes Go to nextstep
R e s i s t a n c e : ' 1 k5Q per 1m (3.28tt)
No Replace
7 Checkif resistance
ol ignitioncoilis OK Yes Go to ne:l step
R e s l s ta n c e(a t 2 0 C [6 8 ' F J ):
Prl m a ryc o l l w i n d i n g .......... 0.765-1.0354
...
No Replace
8 Checkfor correctenginecompression Yes G o to nextstep
No Checkenginecondition
E n g l n ec o m p r e s s l o n :
932 kPa (9.5kg/cmr,135 psi)-300rpm . Wornpiston.pistonringsor cylinderwalt
. Oefectivecylinderheadgasket
. Distortedcylinaerhead
q
Checkif the vacuumof surgeis OK Yes Go to nextstep
V a i u u m i q S Om m Hg (1 7 .7i n H g) No Checklor air leakageat intakeair system

components
10 Check il air cleaner element is clean Yes Go to nextstep
No R e p l a c ea i r c l e a n e re l e m e n t
arrrr{;f
21A-96 :i+:9+
STEI!4 TRouBLEsHoolNG .:
GutDE
INSPECTION
Clreck for the operating,ornd
of tnl".tor at idle Yes co ronexrsrep
I
No
I C o ro nextsrep
Checkil bartry
votr"g"
conneclorlerminal "rEGffiffi check the resisranceof inl"cto@
PCMand feuetteakag";;I;',"'^""r,
srep 1
R e s t s t a n c:e1 4 . 5e
checkwirehamess
between
ecr'n-tffi
-)*
9j*t il PCM terminatvotrage ara OK
Go to neritstep -*
( E s pec :alf y1 5 ,4 6 ,a n d 1 6 )--
Checkfor cause
Checklor correctfuellinepr.rrr[ ,-G
F uel llne pr es s u re : "f rueltinepressure
a""r"""".@
i,lff[tt
(2-7-3.2
ks/cmr,
3s_a6
prr)
(19:::11kP_a
v s c uum hos e to p re s s u rere g u l a to r Q lf docreases..!::k lor fuel pump
connecled)
dls- It OK. checkfuelilne anOlifier-tJ maximumpressur€
c) lf not decrease,go to ctogging
next step-'
Checkfueltinepressurewhile pincfring
fuel retum hose
I lf fuet rinepressurequicrdyincreases.
regutator check pr€ssure
I It fuerrinepressuregraduaily
increases,checkfor
cloggingbetweentuLtpump
lf not cfogged,checktJel p',!mpi regutator
"nj'pr"r"ure pressure
"r,.rr
H l ghpressure
Checkif fuelretumtineis ctogged
? ll Ot(.reptacepressure regutator
I lf notOK,replace
jtioleanJ@
.Rynglgine
is heldafterignition
switchturneO
oft
Go to next step
Fuel:llnepressure: More than

(1.5 ltg/cmr,21 pst) tor S min 147 kpa Checkfor fuel teakageof injectol
when.disconnectn"rffi
idle,checkil enginespeedis'graOuatfy Go to next step
dccreaser
ReplaceIniector
Try with known good pCfU
"
EMISSIONCONTROLSYSTEMrnouBLESHoorlNG
GUIDE 21A-97
POOR ACCELERATION
Pedormance poor while accelerating

ldle conditionnormal
Air/Fuelmixture loo lean

. Fuel line pressuredecreases
. Fuel injectionmallunction
. P{f sliPPing
Poor ignition
. Erafe dragging
Low engine compression
. Low tire Pressure
. lncorrect ure slze Alcohol blended fuel used
. Over'loaded
air amount
\Y Low intake
/?)
. Tnronte valve not oPen fullY
. Clogged intaka air sYstem
IN SP EC T IO N A C TION
Checkfactorsotherthanengine Go to nextstep
. ClutchsliPPing
. Brakedragging
. Low tire Pressure
. tncorrecttire sizo
Checkil thronlevalvefullyopenedwhen Go to nextstep

depressingacceleratorfultY
cableis conectlyinstalled
Checkif accelerator
4 lf OK, checkthronlebody
c) lf not OK, instajlaccelerator
cableconectly
Checkthat malfunctioncodeis displayedon the Malfunction Code No. displayed

SST with ignitionswitcltON Check for cause (Refer to specifiedcheck sequence)
-
Go to nextstep
,L
4 | Checkthrottlesensor Go to nextstep
Adjustor replace
21A-98 EMISSIONCONTROLSYSTEM rnouBLESHoolNG
GUTDE

3 C h e c k f o r c o r r e c ti g n i t i o nt i m i n ga t i d l e a f t e r Yes C h e c k i f i g n i t i o nt i m i n ga d v a n c e sv r h e n a c c e t e r a t i n g
\"a itn-ui)
r O l f a d v a n c e s ,g o t o n e x t s t e p
c i l f n o t a d v a n c e .c h e c k P C M t e r m i n a lv o l t a g e s
l g n i t i o nt i m i n g( B T D C ) :D O H C8 ' t 1 '
soHcr + 1 '
No Adjust the ignitiontimming
6 Checkil PCM terminalvoltagesare OK Yes Go l o nextstep
No Check for cause
7 Checkfor correctintakemaniloldvacuumat idle Yes Go to nextstep
lnt ak em anif o l dv a c u u m: No Checkfor air leakageof inlakeair systemcomponents

M o r e t h a n4 5 0m m H g( 1 7 . 7i n H g )
8 Checkfor correctfuellinepressureat idle Yes Checkif fuel line pressuredecreaseswhen accelerating

quickly
F u e l l i n e p r e s s u r e:
2 6 5 - 3 1 4k P a( 2 , 7 - 3 . 2k g / c m r , 3 S - ap5s i ) Q tf decreases,checkfuelpump maximumpressure
( V ac uumhose to p re s s u rerd g u l a to rd i s ' lf OK, checkfuellineand filterfor clogging
connected) Q lf not decrease,go to nextstep
:
No Low pressure
Checkfuellinepressurewhilepinchingfuelretumhose
INSTALL CI.AMPS
Q ll fuellinepressurequicklyin-creases,check
pressureregulator
c) lf fuellinepressuregraduallyin-creases,
checkfor
lf not clogged,checkfuelpump maximumpressure
H i gh pressure
Checkif fuel line is clogged
O lf OK, replacepressureregulator
Q lf not OK, replace
4?fi.'
'r_:*t- +i
E M I S S I O N C O N T R O L S Y S T E M T R o U B L E S H o o T IG
NUGI D E 21A-99
INSPECTIOII ACTION
Checkif MAP sensor is OK G o t o n e x ts i e p
R e p a i ro r r e p l a c e
10 C h e c ki f s P a rkPl u g sa reO K Yes Go to nextstep
WEARAf.!O
CAR9ON
BUILOUP
/-rro",
PLUGGAP OAMAGEAND
1.0-l.l mrn OETERIORATION No Cleanor replace
(0.03s-0.Oc3in)
OAMAGE
Checkif resistanceof ignitioncoil is OK Go to next step
R e s i s t a n c{ea t 2 0 { : , 6 8 ' F ):
P ri ma ryc o i l w i n d i n g ..............
0.756-1.035Q
Replace
12 | Checkfor correctenginecompression Go to nextstep

E n g i n ec o m p re s s l o n:
932 kPa (9.5 kg/cmr,135 psi)-300rpm Checkenginecondition
. Worn piston,pistonringsor cylinderwall

. Defectivecylinderheadgasket
. Distortedcylinderhead
. Valvestickingin guido
Changefuel and checkif acceleration

improves Changefuelto anotherbrand
Go to nextstep
Checkif A/C cut-offcontrolsystemis OK Go to nexlstep
Repair or replace
Try with knowngood PCMand checkil conditionimproves

21A-100 EMlssloN coNTRoL SYSTEMrRouBLESHoorNG
GUrDE
RUNS ROUGH ON DECELERATIOT.UBACKFIRE
Engine runs rough while deceleratingand abnormatcombustionoccurs in exhausl system

Transaxlein nornral condition
frPo uB LE S HO O T TNHGT N T S I
@ nirffuel mixturetoo nch
. Airlcleanerelementcloqoed
. Fuel injectionconlrolmilfuncticn
(Fuelcut control)
. Inieclorluel leakaoe
. Throttlesensor(ldL terminal)malfunction
. Dashpotmalfunction
IN S PE C T ION
Check that malfunction code is disptayed on the Yes Mallunctlon Code No. displayed
SST with ignitionswitch ON Cireck lor cause (Refer to specified check sequence)
No Go to next step
2 Checkswitcheslor conect operatiorr

by the SST Yes Go to next step
withignitionswitchON
No Checkfor cause
(Referto specifiedchecksequence)
Always ON
CheckPCM terminalNo.41voltage
3 Checkfor correctintakemanifoldvacuumat idle Yes Goto nextstep

V ac uum: M or e th a n 4 5 0 mmH g (1 1 .TIn H g )
No Checkfor air leakageat intakeair system
compon€nts
4 Checkif air cleanerelementis clean Yes Go to nextstep
5 Checki( PCM terminalvoltage(relatedto throtile Yes Go to nexl step

sensorand injector)are OK
No Check for cause
EMlssloN coNTROL SYSTEMrnouBLESHoolNG
GUIDE 21A-101
INSPECTION ACTION
STE?
is
o Cn""f if fuelcut operation OK Yes Go to next step
No Try with known good PCM and check if condition improves
7 Checkif MAP sensoris OK Yes Go to nextstep
I
ffi
Checkif throttlesensoris OK
No
Yes
Repairor replace
Go to nextstep
No Adjust
9 Checkiniectorfor fuel leakage Yes Replace
No Go lo nexlstep
11 Try with knowngood PCM and checkil conditionimproves

21A402 E M I S S I O N C O N T R O L S Y S T E M T R O U B L E S H o o T IG
NUGT D E
KNOCKING
-pinging'
Abnormal cornbuslion ilcr--ornpilnicd
b';-audiblc noise
ITHo U B LE S iJ O O T T NHGT N T S J
O !ncorrectignitiont;ming(Tooadvanced) @ AirlFuel mixlure too lean
@ Carbondepositsin cylinder . Fuel injection amount not correct
@ Overheating . Fuel line pressure decreases while accelerating
I N S PE C T I O N ' ACTION
Check for correct ignition timing at idle after Go to nextstep
warm-up
l g n i t i c n t i m i n g ( B T D C ): D O H C 8 ' + 1 '
s o H c7 ' + 1 '
Adjustthe ignitiontimming
Checkthat malfunctioncode is displayedon the Mal functl onC ode N o. di spl ayed
SST with ignitionswitchON Checkfor cause(Referlo specifiedchecksequence)
Go lo nextstep
Check for correctintakemanifoldvacuumat idle Go to nextstep
V ac uum: M or e th a n 4 5 0 mmH g (1 7 .7i n H g )

Check for air leakage of intake air system components
Check'forcorrectenginecompression Go to nextstep
E n g i n ec o m p r e s s i o n . : _
932 k P a ( 9. 5 k g /c m t,1 3 5 p s i )-3 0 0rp m
High compression
Check engine condition
. Carbon deposits
EMlssloN coNTRoL SYSTEM r.RouBLESHoorNG
GUIDE 21A-103
sfeP INSPECTION ACTION

3 Checkfor correcttuellinepressureat idle Yes C h e c k i f f u a l l i r ' t €p : E S S U rdee c r e a s e sw h e n a c c e l e r a t i n g
quicklv
F u e ll i n e p re s s u re:
2 6 5 -3 1 4k P a (2 .7 -3 .2k g /c mr,3 8-46psi ) c) lf decreases.check for clogging between
( V a c u u mh o s e to p re s s u rere g u l atcrdl s- fuef pump and piessure regulalol
c o n n e c te d ) O lf not decrease,go to next step
INSTALL'EL.AMPS
No Low pressure
Checkfuellinepressurewhitepinchingfuelreturnhose
c) lf fuellinepressurequicklyincreases.
check
pressurereoulator
c) lf fuellinepressuregraduallyincreases,
checklor
li not clogEed,
checkfuelpumpmaximumpr.essur€
6 Checkil coolingsystemis OK Yes Go to nextstep
No Repairor replace
. Thermostat
. Electriccoolinqfan
. R adi ato(
I Trywithknowngood PCM and checkif conditlon Yes ReplacePCM
improves
No Change fuel to another brand or use higher octane luel
214-104 EMlssloN coNTRoL sysrEM rRouBLESHoorNG
GUIDE
F U E LO D O R
. Gasoline odor in cabirr
rrRou BLESHOOTTNG HTNTSJ

a Poorconneclionor Camaged at fuelsystemor evaporali.re
emissionconlrolsystem
@ Charcoalq?nisteroverllowduelo evaporativeemission
controlsry.stem
malfunction
IN SP EC T IO N
Check if fuel leakage or damage of fuel syslem Yes I Repair or replace
and evaporative emission control syslem
Go l o nexlstep
Check that mallunctioncode is displayedcrnlhe Mal functi onC ode N o. di spl ayed
SST with ignitionswirchON Chacklor cause (Referto speiitied checksequence)
No I Go to nelit step
Check if vacuum is tett at sotenoid Go to Step5

";;Grrg.
control)with enginerunningand throttle valve
opened (Neulralsrvirchconnectordisconnecled)
Chcck lor solenoidvalveoperatingsound
O lf OK, checkvacuumhoses for clogging

c) lf not OK, go to nerilstep
Appty 12V and groundto solenoidvalve(purge CheckPCM terminalvoltages

conlrol)and check it vacuumis teh al solenoid
vatveat idle
Replacesolenoidvafue
Try with knowngood PCM and checkif conditionimproves

EMlssloN coNTRoL sysrEM'rnouBLEsHobrrr.rc
curDE 21A-105
EXHAUST
' Exhaustgas smellsabnormally
t**t* I
rrRCUB LESHOOTTNG HTNTSI

sulfurcontentfuelused
INSPECTION
Changofuel to anotherbrand
25 H I G { OIL C ON S U MP TTON
DE5( Htr . Oilconsumptionexcessive

TION
ITBOUB LESHOOTTNG HTNTSI
O PCVsysremmalfunction
@ Enginemallunction(oil workingup. workingdown.or leakage)
sTEPf - IN S PE C T ION A C TTON
I Checkif PCV hose,ventilalionhoseor lheir Yes Repairor replace
attachingnipplesar€ separated,damaged,
clogged.or reslricted
No Go to ner:tstep
I Checkif ai; prassuieor oii is pr-esenial Yes Go to nexistep

ventilationhose
No Checkenginecondtion
. Oil leakage
. Wom valveseal
. Wom vafuestem
. Wom vafueguide
- 3 - - Checkil vacuum b fett at PCV valve at ide Yes Ch€ck enginecondtion
. Worn pistonring groove

. Stuckpistonrings
. Wom pistonor cylinder
No Replace PCV valve
.tr:,
21A-106 EMISSION CONTROL SYSTEM TROUBLESHOOTING
GUTDE
26
POORFUELECONOMY
|'
OeSCngrCrq Fuel c c o n o m y u r r s a l r s f a c t o r y
rrRo u B LESHOOTtN.c HTNTS J

while a fuel consurnptionis drasrically
warm'upperiods'and etc" as opposeg-'? i1c1e1s9o by a city driving.shorr-run.operation.
'ltlot.l6tgi. stop and go driving,extendedwinter
confronted 'poor an ailemptshourdbe madeio oJelm,ne
with mileage-conditions.However. thesefacrcrswhen
i;n." the opera(oris not alwaysat fault,
the fottowingis offered.
t accelcralor
morefhanusua!duero
sliillG:fffi'ns @ AirtF.uer
mixrure
roorich @ Fuer-cur
syslem
. fooiigniiion " Hish.luellinepressure N,talfunction
O Alcoholblendedfuetuseo
" Low iniakeair amount @ Highidtespeed
. ql"grf""l"
si"rr advance
conrrot
system matfuncrion o I'n?J.,1':,;r,;J.1,"
-' ---"' r"e"v"v
. Clutch stipping/ A/T slipping
. Incorrect tire size
_ : Exhaust compcnent restrictEd
. n_-,.
Erake _
draggi
INSPECTTON
ACTION
Checkfactorsotherthan enti,re
. Low tirepressure Go to next slep
. Unrecornmended tiresize
. Clutchstipping
. Brakedragging
. Exhaustcomoonentrestricted
Checkif air hosesare connectedcorrecily
Go to nextstep
Check that malfunctioncode is displayed

on the Malfunction Code No. dlsptay"O
Check for cause (Refer to ,b"difi.d
check sequence)
Go to nexlstep
---'-
Chect<for correctintakemanifoldvacuumat
idle Go to nextstep
V ac uum: M o re th a n 4 5 0 mmH g
' - : - : - ' l l t.Z .l n H g ) checkfor air teakage int"rffi
"t
Chec kif air c l e a n e e
r l e m e n its c te a n
Go to nextstep
R e p l a c e a i r c l e a n e re l e m e n t
# :
EMISSION CONTROL S Y S T E M T R o U E L E S H o o T I NG
GU I D E 214-107
-)
-l
I
I
I I6 INSPECTION
C h e c k i f P C M l e r m i n a lv o l t a g e sa r e O K Yes G o t o n e x ts t e p
ACTION
I (especi*y for terminalNO.17,20. 15,46. 16,30. 53. 4

-l I
and 25)
No C h e c k f o r p o s s i b l ec a u s e
It
I
I 7 Checkif {uel-cutsystemis ok'atdeceration Yes Go to nextstep
I
I Fuelcut : Morelhan 1,000rpm (atterwarm-up)
I
I No R e p l a c eP C M
I
I Checkfor correctigniticntimingat idteafter Yes Go to next step
J : Wirm-up
-{I
I
I
l g n i t l o nt i m l n g( B T D C :) D O H Cg ' t
1'
--t soHc 7'+ 1'
-1
II No
-1
I 9 Checkfor correctfuellinepressureat idle Yes Go to nextstep
I F u e ll i n e p re s s u re:
I 2 1 5 -2 6 5R Pa(2 .2 -2 .7k y ' c mr.3 1-38 psi )
1 I
(a t d i s c o n n e c te dv a c u u mh o s e from
p re s s u rere g u l a to r)
I
I
I
1
I
INSTALLCLAMPS
1
I :F;
;bf
....-;
No H i g hp r e s s u r e
Checkif vacuumhoseto pressureregulator
I
I
is damagedor poorlyconnected
-49
I t'df'
II F
3B' c) lf OK, replacepressureregulator
* 4 lf not OK. repairor replacehose
I
I
--#{
I :H
I
-.{ I
10 Run engineat idlEand checkif fuet line pressure Yes Go to nexl step
I is heldafterignitionswitchtumedOFF
I
I
1
I
F u e ll l n e p r e s s u r e: M o r et h a n 1 4 7k p a
(1 .5k g /c m r.2 1p s i ) fo r 5 ml n .
!
I INSTALLCLAMPS
I
J Yes Check injectorsfor fuel leakage
11 C h a n g e l u e l t o a n o t h ^ rb r a n d
"tj
e
I
tl 214-108 EMISSION CONTROL SYSTEM
u
TNOUBLESHOOTING
GUIDE
A/C DOESNOTWORK
. Blorverfan operales but magenl
clutch does not operale
rrRou8 LESHOoTTNG
HtNtil
. Open or shortcircuilin wirini hamess
. relay.A/Cswitch.orrn"inJricciutch
.
1!
PCM matfunction
mqllunclion
INSPECTION
Check it pCt/ No.47 terminalvoffage
is OK Checkit pCMNo.6termin"t,on"glG
c) lf OK, checkA/C system

c) ll nct OK. replacepCM
Checklor cause
'i-
*--
-
a1
i:
*r'
:E
.-r,ti
gl
{fl
fl
€l
EI
fir I
.#l
#
rb,F-.
..ff EMISSIONCONTROL SYSTEM SPEcIFIcATIoNS 21A-'109
l # SPECIFICATIONS
-lffi
H DATA
SEFVICE
Engine
Bs(soHc,DoHc)
I# Item
J sl l d l es p e e d ' t rPm 750+ 50

,#l timing't BTDC S O H C : 7 0 ! 1 0D O H C : 8 o t 1 o
st ignit ion
Ig nrrg" solenoidvalve
control
a I x-27
l
Waterlhermosensor
-20oc ( -40 oF) 1 6 . 2t 1 . 6
Flesistanco kQ 20oc ( 68 oF) 2.45!O.25
J 80oc (176 oF) 0.32t 0.03
tClesPoedcontrolv a l v
tyP€ Pi-ctontype
8 . 6 - 1 0 . 6n
Air Cleaner
W et type
Unleaded
SST
u<2a1189063 Eleclroniccontrolsystem
KJ.1 tunableDiagnosis.
EMISSIONCONTROLSYSTEM
(86 ENGTNE)
A/C CUT-OFFSYSTEM:.............. ...218- 41
CONTROLSYSTEM.......... 218- 43
DECELERATION CONTROLSYSTEM......... 218. 39
DECHOKECONTROLSYSTEM........ 21e.-42
E N G I N ET U N EU P . . . . . . . . . ...218- 13
EVAPORATIVE EMISSION CONTROL
SYSTEM 21B- 3o
FUELCUT CONTROLSYSTEM....,...... 218- 40
ouTLtNE 21F'- 3
O U T L I N EO F E M I S S I O N CONTROL
SYSTEM 21B_ 34
POSITIVECRANKCASE VENTILATION.
(PCV)SYSTEM 218- 3s
sELF-D|AGNOS|S FUNCTTON ........... 218- 15
SPECIFICATION 218-114
TROUBLESHOOTING GUIDE........... 218. 59
F:*r-
E M I S S I O NC O N T R O LS Y S T E Mo u r L r N E 2 1B - 3
ouTLlNE
/stem.Thesesystemssuppliesthe airI luelmixture

;ystemand a fuel injectionsystenn
work in conjunc-
rich consistsof varioussensors,svritchesand a
J switchesare connectedto the PCM which.inter-
and the durationso that the electrically
operated
The basicfuel requirementof the engineis determinedfrom l,hedata whichare suppliedto the PCM
by the Airflowmeter,whichmeasuresthe amountof air beingdrawninto the engine.Othersensors
ahd switchesare usedto measurethe followings;
. Air temPerature
, Atmosphericpressure
. Coolanttemperature
. Enginespeed
. Exhaustorygen content
Tha vario,Ss6nscrsanCswitchesdeteciany changesin the operatingconditionsand send slgnalsto

the PCM.This permitsthe PCMto controlthe openingduration(pulsewidth)of the injectorsan-dmain-
tainthe optimumexhaustemissioncontroland the engineperformance for all operating
conditions.
218-4 E M I S S I O NC O N T R O L S Y S T E M o u r L r N E
S Y S T E MD I A G R A M
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E M I S S I O NC O N T R O LS Y S T E Mo r r r l t N E 21B-s
DIAGRAM
wtFlNG
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E M I S S I O NC O N T R O LS Y S T E Mo u r L r N E 218-7
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E M I S S I O NC O N T R O LS Y S T E Mo u r L r N E 218-11
C O M P O N E N TD E S C R I P T I O N S
Component Function Remark
Aircleaner Filterair enteringthrottlebody
Atrtlow meter D e te c ts a mountol @ Intakeai rthermosensor
and f uelpum p
to PCM switch included
Air valve .Supplies
bypassairinto?ynamEZiFEE . Engirrespeed increasedto snorten
when engine is cold
warm-upperied
. Therrnowaxtype
. Installedin surgetank
Atmosphericpressure DetectsatmospnericpreffiE Builtin PCM
s ens or signalto PCM
Caialyticconverter Reduces
HC,CO.anottOxEffiGi6i
-Charcoal
canister storesfueltankfumesw@
Controlspressurein full tank Two-waytype
Clrcuit opening relay Voltageforluelpum@
Clutch switch (Uff) DetectsclutchconOition:-EnOs signffi SwrtchOFF when clutch peOatreteaseO
Diagno s l sc o n n e c to r Concentrated serviceconnector

Concentrated terminals:
1. EGIself-diagnostic terminat
2. Aff self-diagnosticterminal
3. Testterminal
4. Fuelpumpcheckterminal
5. Coolinglan checkterminal
6. Enginerpm outputterminal
lnterconnectsall cytinde-
PowerlralnControl Detectsthe following:
M odule(P C M) 1. NC operation 1. A/C switch
2. Air/ fuel ratio(Orygenconcentration) 2. Orygensensor
3. Atrnosphericpressure 3. Atmosphericpressuresensor
4. Brakingsignal 4. Stoplightswitch(l*,lff)
5. Crankingsignal 5. lgnitionswitch(STARTposirion)
6. E/t operation 6. Blowermotorswitch,coolingfan relay,
headlightswitch.and rearwindow
defrosterswitch
7. Enginecoolanttemperature 7. Waterthermosensor
8. Enginespeed 8. Distributor (Ne-Signat)
9. lgnitionON signal 9. lgnitionswitch
| 0. In-gearcondition 10.Neutraland clutchswitches(Mff)
Inhibitor switch(A/f)
- 11. lntake :
air amounl 1l. Air{lowmeter
12.Intakeair temperature 12.Intakeai r thermosenso r
(ln airllovrmeter)
13.P/Soperation 13.P/S pressureswitch
14.Testsignal(lgnitiontiming.idtespeed.' 14.Oi agnosiconnecl
s or
MalfunctionCodeNo.) (Teslterminal)
15.Throttlevalvelullyctosed/ lullyopen 15.Throttlesensor(Mfi)
condition
16.Throttlevalveopeningangle 16.Throttl e
sensor(A /T)
17.Downshift condition 17. AITcontrolunit(A/T)
18.DRL(Daytimerunningtight)operation 18.D R LFl el ay
21B-12 EMtsstoN coNTRoL SYSTEMeurLrNE
.C.onrponent
Povertrain control
module (PCM)
(Cont'C) 1. NC retay
2. Fail-safefunction
2 . S e l f . D i a g n o s i sC h e c k e r
3. Fuelinjectionsystem .'
3. Injector
4. ldfespeedcontrol
4 . l d l e s p e e d c o n t r o l( t S C ) v a t v e
5. lgnitiontimingcontrolsystem
5. lgniter
6. Lockupcontrolsystem
7. Monitoifunctiorr
Q. Purge control svstem
Fuel filter Filtersparticleslrom fuei
F u e lp u m p Providesluel to injectors
Operatesrvhileengine.""i",
lgniter l nstal l ed
i n fueltank
R-eceives
s.p.a1k
signattqorneCt"t
generareshigh vofiagein igniiicrn
"nO
Eiiit
lgnition sr.ritch _
trngtne crant(,ngsignalsent to pCM
(ST A RT Spos ir ion )
In h ibit ors v r ilc h( Oe te c tsi n
inNorPrange
PCM
Injector In1ectstuetintointakeporl
Conlro;t-@
lntake airlnETffilensor High-ohmicinjector
etectsintakeair temperature;
sen@i?i Intaltedon oinEmiEFEEEE
tatespeeoconEi@j ls bypassalr arnount
Contrciled@
SuppliesetetGi-urient to
(FU E LI NJ r et ay )
Ne u t r als wit c n uetectsin-gearcon@
ON in neturat
PCM
o xy gen s E ns oT iects oxygenconcenlratioiffi
nraceramicandptarn-umEElii!'
PCV valve
ControlsOtowb
P/S pressureEi etectsP/S operario@
/S : ON vrne
Pre ss ur er egulat or or l eft
Adjuststuet
pres@
R e s o n a n c ec h a m b e r Reducesintakeairnoise
eparator Preventslu
Stoplight switch Detectsorating@

lendssignatto pCM
Solenoidvalve Controlserapor
(Pu r gec ont r ol) Controtieduyo@
hrottle bo ontrolsintakeair quEn@
tntegraredthrotrl e@
T h r o t t l es e n s o r IS Cval ve
r tJ€t€ctsthrotttevatvelutiyct@
openedcondition(Mff)
. Oetectsthrottlevalveopeningangle(A/T)
. s e n d s l i g n a tsto P C M& Tcu
W a t e rt h e r m o s e n s o r Detects
coolant
temperature:
Gn@nliG
PCM
E M I S S I O N C O N T R O L S Y S T E M E N G I NTEU N E . U P 2 1B - 1 3
E N G I N ET U N E . U P
B A S I CI N S P E C T I O N
E n g i n eO i l
1 . R e m o v et h e e n g i n eo i l l e v e lg a u g ea n d c h e c kt h e e n E i n e
oil leveiand oil condition.
2. Add or change the oil as necessary.
Coolant
Warning
. Neverremovethe radiatorcap while the engineis
hot.
. Wrap a thick cloth aroundthe cap beforecarefully
removingit.
1. Removethe coolantlevelgaugefromthe coolantreser-
voil'. 'Fi' and 'L' on
2. Checkif the coolantlevelis betweenthe
thecoolantleveldipstick.
2rco5
Battery
1. Checkfor a corrosionon the terminalsand for the loose-
nessof cableconnections. lf necessary,
cleantheclamps
andtightenthemfirmly.
2. Checkthat the electrolyte levelis betweenthe UPPER
LEVELand LOWERLEVELmarks.
3. Adddistilledwaterif necessary.
2r@'6
4. Checkthe specificgravitywitha hydrometer.
Gravityz 1.27-1.29(at 20C [68'FJ)
2 r007
A i r C l e a n eE
r lement
Inspection
1.Checkthe air cleanerelementforan ,r..rrlue dirt,dam-
age,or oil.
Caution
i . D o n o t u s e a c o m p r e s s e ad i r t o c l e a nt h e e l e m e n t .
2.Replace if necessary.
theelement
214-14 EMlssloN coNTRoL sysTEM ENGTNE
ruNE-up
ADJUSTMtrNT
GROUNO Preparation
1.warrnup theengineto thenormaloperating temperature.
2.TuinallelectricloadsOFF.
3 . U s e a .j u m p e rw i r e b e t w e e nt h e e n g i n et e s t a n d t h e
groundterminals in thediajnosisconndctor.
4. connecta timinglightand i tachometer to the engine.
ENG.TESTTERivIiNAL
lgnitiontiming
1. Perforrntlre"Preparation'
steps.(Referto above.)
2. check if the timingmarkon the crankshaftpuileyanc the
markon thetimingbeltcoverare aligned.
fgnitiontiming : BTDCT" !.1' (at idle speed)
3. lf the marksare not aiigned,locsenthe distributor lock

bolts,andturnthe distributor
to makethe adjustment.
4. Tightenthe distributor
rockboltsto the specifieotorque.
Tighteningtorque:
19-25N.m(1.9-2.6kg-m,14-19tb-ft)
LOCK BOLTS
ldlespeed
1. Performthe 'Preparation',
steps.
!.{potV a parkingtirake.
3.checkthatthe idlespeedis withinthe specification.
ldlespeed(Neutralor P range): 750+50 rpm

Caution
. 'fan
c h e c k t h e ' i d l es p e e dw i t h o u tt h e e l e c t r i cc o o l i n g
AIR ADJUSTING operating.
SCREW
4. lf it is not within.thespecification,
adjustthe idleby tum-
?r0tl
ingtheair adjusting screw.
FUNCTION
EMISSION CONTROL SYSTEM SEIF.DIAGNOSIS 2 1B - 1 5
S E L F - D I A G N O S IFSUN C T I O N
DESCHIPTION
ffnrn troublesoccurin tfremain inputor outputdevices,check for the cause by usingthe SST. Failuresof
c- eachinput and output devicesare indicatedand retrievedfrom the PowertrarnControlModule (PCM) as
the malfunctioncode numbers
Note
. The PCM constantly checks for the malfunction of the input devices. The PCM checks for the
malfunction of output devices only in a three seconds period after the ignition switch is
turned ON and the test terminal of the diagnosis connector is grounded.
POWERTRAIN
CONTROLMOOULE
SELF. .
OIAGNOSTIC
FUNCTION
SELF.OIAGNOSIS
CHECKER (KJ-1)
2 1B - 1 6 EffllSSlONCONTROL SYSTEM sELF-DrAGNosts
FUNcloN
M A L F U N C T I OCNO D EN U M B E R
S I G N A LA O A P T O R A InspectionProcedure
fvlogUl.AR
1.Turntheignition suritch
cfi.
WIRE I{ARNESSI 2.Conneci theSSTto thePCI/.
Caution
. Neverconnector disconnecta connectorwhilean
e n g i n ei s r u n n i n g .
3.Tumtlreignitionswitchon.
4. Performthe diagrrosis
proceCure
witirthe SST.
Note
. Cancelthe code numbers by performingthe after-
repairprocedure.
E M I S S I O NC O N T R O LS Y S T E MS E L F . D I A G N O S I SF U N C T I O N
218-17
cooeNUMBERS
Sensor cr M a l f u n c t i o nd i s p l a y
subsystem Condition Fail.sale Itlatfunction
Code No.
oulput signal pattern
Ne'signal No Ne-signal
02
::,-J]JL
Aidlow meter Openor shortcircuit Basic fuel injection
a m o u n tf i x e d a s l o r
2 driving modes 08
( 1 ) l d l c s w i t c h: O N
(2) ldleswitch: CFF
Waterthermosensor Openor shortcircuit Maintains

constant
20e(68:F)
command 09
:),Jiirltfil1f[|J
lntakeair Open or shortcircuit Maintains
constant
thermosensor 20e (58T)
command 10 Of.l n
OFF
JL
Throttlesensor Open or shortcircuit Maintains constant
VM commandof throttle
valvefullyopen 12 ON
OFF
Atmospheric Openor shortcircuit' Maintainsconstant

pressure
sensor commandof sea
(inPCM) levelpressure 14 ON
OFF
Orygensensor Sensoroutput Cancelsengine

Continuesless than feedbackoperation
0.55 V 95 sec. 15 ON
afterengine
starts(1.500rpm) OFF
Feedbacksystem Sensoroutputcon- Cancelsengine

linuesunchanoed feedbackoperation
50 sec. aftereigine 17 ON
exceeds1,500rpm
OFF
2 1B - 1 8 EMlssloN coNTRoL SYSTEMseur-DrAcNosrs
FUNcloN
Sensor or M a l f u n c t i o nd i s p l a y
Condition Fail-safe
subsystem illallunction i
;d;;ii;-." I ourpursisnatpauern
So!enoidvalve
(Purgecontrol)
zo
t
ISC valve
Openor shorl circuit
t
Caution
. tf there is more than one failure Present,the code nurnberswilt be Indicated in numerical
order; the lowestnumber connesout first.
. After-rePairinga failure, tu.tl
9ff the-ignition sw.itch,disconnectthe negative battery cable,
?nd deprqB_s-the brake Pedal for at least five (5) seconds to erase the matfunctioncode(si
from the PCMmemory.
E M l s s l o N c o N T R o L S Y S T E Ms E L F - D l A G N oFsUr sN c r o N 2 1B - 1 9
tTaouBLESHOOTING
'.-rlf' code number is shown on the SST, check for the cause by using the charrrelatectto the
^- mrltunction
'rno*n
codenumber
0 2 ( D I S T R I B U T O RN e - S l G l . l A L)
CO O EN o '
IN SP EC T IO N ACTION
s7e?
1 Checkdistributorcircuitlor poorconnection Yes Repairor replaceconnectcr
No Go to nextstep
'2 Checkterminal'wirefor continuity Yes Go to nextstep
No Repairor replace
e Checkif batteryvoitageexistsat distributor Yes Go to nextstep

terminal'wire
rl No Check for open circuit in wiring lrom distributorto
main relay
I- l
;) 4 tetweendislributorand
Checkterminal-wire Yes G o to nextstep
PCMterminal2E for continuity
No R e p a i ro r r e p l a c e
D Checkit PCM terminal2E voltageis OK Yes ReplacePCM
No Go to nextstep
6 Checkif 0V or 4.5V-5.5Vexistsat distributor Yes Replacedistributor

terminalwire(Y/L)
No Go to neH step
7 Gheckif 4.5V-5.5Vexistsat PCM terminal2E Yes Checkfor shortcircuitin wiringfrom distributor

to PCM
Wilh distributorconnectordisconnected)
No ReplacePCM
I/AIN RELAY
(FUELrNJREl,iY)
OISTRIEUTOR
iql,l,-'-: r: I
1:r.
-;ii: ,. i e t
q?r:t'-t- j 'i
F
2 r 0 t7
F+toirt
i{ {;
218-20 E M I S S I O NC O N T R O LS Y S T E MS E LF.D IA GN OS IS FU N C TION
coD RFLOW
brEP'
:iE
..-d-
E#
J?
+3
14i
2 1Fi
'i*
No
3 Checkif resistanceol airllowIneleris OK Go to next step
Airnor rne*er d c € d ( o ) FulVopen( 0 )

R e p i a c ea i l f l o w m e t e r
E(EyR).F(R/4 20-600 ?0-1.200
E(BIR)- D (LCa/T|) 200-400
4 Checkwire harnessbetweenairflowmeterand j Ves Go to nextstep

PCM lor continuity I
No Repair or replace wire harness
Airflorvmeter PCM
D (LCln) 2K (LGi/R)
F (Rft') 20 Fry)
5 Checkif PCM terminals2C,2K, and 20 voltages Yes ReplacePCtvt

ar e O K
No Checklor shortcircuitin rviringlrom aidlowmeterto
PCM
.
_47
C i r c u i tD i a g r a m lg
,5'
;.
!F'
r.f
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.#
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-'r*
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3'
FROMCIRCUTT
O P E N I N GR E L A Y
H
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: l
' ! l
.f
r'Cf
.i
'+
ri
s
5i'
*'
AIRFLOWMETER
E M I S S I O NC O N T R O LSYSTEM' sEur-DtAGNosts
FuNcnoN 218-
i
coo= No. os(wArER T H E F I I v I O S E N S O R )
I
-step INsPECTION
--T_-
I ACTION
I Check walei thermosensorcircuit for poor con- Yes R e p a i ro r r c p l a c ec o n n e c t o r
nection
No Go to nextstep
2 Check rvire harness between waler lhermosen- Yes Go to nextstep

ffi sor and PCM for continuity
No hepai ,or repl ace
Waterthermosensor PCM
A (LryU- 20 (L v)
B (B/R) 2D(B/R)
3 Checkif resistanceol walerthermosensor

is OK Yes Go to nextsiep
No Replacewaler thermosensor
4 Check if same Code No. is present following Yes Go to nextstep

afie r-repairprocedure
No Waterthermosensor
and circuitOK
3 Checkif PCM terminals2D and 20 voltagesare Yes Heplace PCM

OK
No uhecl( lor short circuit in wiring from water thermosensor
to PCM
CircuitDiagram
218-22 EMISSION CONTROL SYSTEM SELF.DIAGNoSIS
FUNcTtoN
C O D EN o . 1 0 ( T N T A K EA t R T H E R M O S E N S O R l N A T R F L O WM E T E H )

1 Check intake air lhermosensorcircuit for poor Yes Repair or replace conneclor
connection
No Gc to nextstep
2 Checkif Code No. 08 is also present Yes Checkfcr open circuitirrwiringfrom airflowmeter
terminalwires(B/R)to ground
No Go to next step
3 Checkwire harnessbetweenintakeair Yes Go to nextslep

thermosensorand PCM for continuity
lntakeair thennosensor No Repairor replace
(ln airflowmeter) PCM
c (B/R) 20 r8/F)
G (F/B) 2P(R/B)
4 Checkif resi-stance
o! airflcwmeterbetween Yes Go to next step
terminalsC (B/R)and G (F/8) is OK
No Replaceairflorvmeter
Temperature (k Q)
Resistance
.20e 16.012.4
20e 2.45!0.24
60e 0.580=0.087
5 Checkif same Code No. is presentfollowing Yes G o to next step

'af
ter-repairprocedure
No Intakeair thermosensor
and circuitOK
5 Checkif PCM terminals2O and 2P voltagesare Yes Replace PCM

OK
No Checkfor shortcircuitin rviringfrom intakeair
thermosensorto PCM
FROMCIRCUIT
OPENINGRELAY
A I R F L O WM E T E R
INTAKE AIR THERMO SENSOR
2r02r
EMISSIONCONTROL SYSTEM sELF-DtAqNosts
FuNcloN 218-2:
12 (THROTTLESENSOB- A/T)
STEP II.ISPECTION A C TION

1 Check throtilesensor circuitfor poor connection Yes Repairor replaceconneclor
No Go to nextstep
2 Checkwire harnessbetweenthrcttlesensorand Go to nextstep

PCM lor continuig
Repairor repiace
Throttlesensor PCM
A (LCvR) 2K(LG/R)
'
B (LC./O) 2M (LCa/O)
o Fn) 2D(B/n)
3 Checkif PCM terminal2Dand 2K voltages Yes Go to nextstep

are OK
No Replacethe PCM
4 Check if resistancesbetweenterminalsB (LCr.,tO) Yes Cancelthe code No. then recheckthe same code
and D (B/R) are OK No. is displayed. lf same code No. is displayed,
replacethe PCM
- Throttle valve Resistance
Fullydosed Appor 0.5V No Adiustor replacethrottlesensor
Fullyopen A;'por 4V
CircuitDiagram
SENSOR(A/T)
THROTTLE
218-24 E M I S S I O NC O T T N O L S Y S T E MS E LF.D IA GN OS ISFU N C TION
COOE No. 1 4 ( A T M O S P H E R t Cp R E S S U R ES E N S O R - t N p c M )
STEP
R e p l a c eP C M
C O D EN o . 1s (oxycEt{SENSoR- |NACTIVArtoN)
liote
. l f C o d e N o J 5 a n d 1 7 a re p re s e n tto g e t her,fi rst perform
the c h e c k i n g p r o c e d u r e f o r C o d e N o . 1 7
INSPECTION
ACTION
Checkoxygen-qensorcircuitfor poor connection Yes Regairor replaceconnector
Go to next step
Checkif oxygensensoroutputvoltageis OK Go to nextstep
No I Reptaceorygensensor
Checkwiie harnessbetweenoxygensensorand Go to nextstep
PCM terminal2N lor continuity
R epai ror repl ace
Check'ifPCMterminal2N votrageis OK Go to nextstep
Checkfor shortcircuitin wiringtrom orygen sensor

to PCM
Checkif sensitivity
of oxygensensoris OK R epl aceP C M
Try with knowngoodoxygensensorand checkif

conditionimproves
C i r c u i tDiagram
SENSOR
2tC23
EMlssloN coNTRoL SYSTEM s€LF-DrAGNosrs
FuNcrroN 218-2s
c o DE N o . i 7 ( F E ED B A C KS Y S T E M )

I Check if same Code No. is present after per- Yes Go to nextstep
forming after-repairprocedure
No Checkoxygensensorcircuitfor poorconnection .
+ lf OK, performtroubleshcoting
Codeflo. t5
c) !f not OK, repairor replaceconnector
2 Checkmonitorlampof Self-Oiagnosis Checkerii- Yes Go to nexts'rep

luminateat idle afler warming-upengineand
r.rnning
it at 2,500-3,000rpm for 3 minutes N ote
. N F mi xtureri ch
No Go to Step 5
Note
. NF mixture is lean or misfire occurrino
3 Checkfor correctfuel linepressureat idle Yes Go to nextstep
Fuel line pressure: No H i gh pressure

255-314kPa (2.7-3.2kg/cmr,38-46 ps!) Checkif fue!retumhoseis cloggedo:,restricted
(Vacuumhose to pressureregulator
. d i s c o n n e c te d )
c) lf not OK, repairor replace
4 Checkinjectorsfor fuelleakage Yes Replace injector
Checkif waterthermosensor
is OK
Q l f OK . Go to S tepl 1
c) lf not OK. replacewaterthermosensor
5 Disconnecteach high.tension
iead at idleand Yes Go to nextstep
checkif enginespeeddecreasesequallyat each
cylinder No - Go to StepI
CircuitD i a g r a m
OXYGENSENSOR
218-26 EMISSION CONTROL SYSTEM
SET.F.DIAGNOSIS
FUNCTION
STEP INSPECTION
I6 Clrc.cktor .ort
Ys'S
ACTTON
Go. to l:exl :llelr
Fuel line pressure:

No Low pressure
255-314kpa (2.1_3.2kgy'cm2,
38_a5psi)
(Vacuumhose to pressure Checkfuel linepressurewhilepinching
regulator fuel return
dis c on n e c te d ) hose
c) ll fueiline pressurequickry
increases.check
pressureregulator
cl I fuerrinepressuregraduaity
increases.check
lor croggingbetweenruerpump
and pressure.
regulalor
lf not clogged,checkfueloump
rrlaximum
pressure
Check intakeair systemcomponent;;
leakage Go to Step t 1
EMlssloN coNTRoL SYSTEM selp-DrAcNosrs
FuNcroN 21B.-27
I
-a coo i No. 26 (SOLENOTD
V A L V E . PU R G E C O N T R O L )
I
I
1 Disconnecl connectcrfromPCMand checkil Yes CheckPCMterminalconnectorfor poorconnection
bat'\eryvoltageexistsat PCMternninal
2X wire
harness(W/L)with ignitionswitchON
+ lf OK. replacePCM
+ lf not OK. repairor repiaceconnector
No Go to nextstep
2 In samecondition as Step1,checkif battery Yes Repair or replacevrire harness (WL)

voltageexistsat solenoidvalveconnector
(WL)
terminal-wire No Go to nextstep
3 Check if solenoid valve is OK Yes Checkfor shortor opencircuitin wiringfrom main

ielay tc solenoid.,'alve
No Replacesolenoidvalve
CircuitDiagram
VALVE
SOLENOIO
(PURGECONTROL)
MAIN RELAY
(FUELTNJECT|ONRELAY)
218-28 EMISSION CONTROL SYSTEM SELF.DIAGNOSTS
FUNCTION
34 (tSCVALVE)
INSPECTION
Disconnectconnectorffi
Yes Cireckta"
baneryvoltageexistsat pCM terminatZW wire
(UO) with ignitionswirchON
I l f OK , repl acepC M
c) ll not OK, repaircr replace
conneclor
Go l o nextsteo
In sameconditionas Step 1 checkil battery

Repair
ot r"pr.ffi1GT-
voltageexistsal l-SCvalveconnectorterminal-
vrire(UO)
Go to next slep
:.t+?
ChecktSC Valvefor correctresistance *ft'
Checklor shortor open circuitin wiring '4
from main -if
relay(FUELtNJ retayjto iSC vatve
---
...:
R e s i s t a n c e : 1 10
- 1[ 3a t2 0 c ( 6 8 T ) l
ReplaceISC valve
:.
QircuitDiagram
FROM ISC VALVE

EATTEAY
FROM
IGNITION
swtTcH
MAIN HEI.AY
(FUEL|NJECT|ONREI-AY)
EMISSION CONTROL SYSTEM sELF-DtAGNosts
FUNcloN 218-29
After-repairprocedure
1. Cancel the menroryof malfunctionsby disconnectingthe
negativebatterycableand depressingthe brake pedalfor
at least five seconds. Reconnectthe negativebattery
cable.
2. Connectthe SST to the diaqnosisccnnector.
3. Turn the ignitionswitchON.
4. After startingand warming-upthe engine,run the engine
for 3 minuteat 2,000 rpm.
5. Verifythat no ccde numbersare displayed.
218-30 EN4ISSION CONTROL SYSTEM
SCIF.DIAGNOSIS
FUNCTION
SWITCH MCNITORFUI.ICTION
Individualswiiches
can be inspectedby the sST
(serf-Diagnosis
checker).
Note
. fh" test terminalof the
diagnosisconnectormust
(enginestopped). be-groundedand the
ignitionswitch
NEUTRALSwtTCH (M,/T)
CLUTCHSwlTcH (Mrr)
rNHtErToR
SwtTcHfA/r)
:
SToPLtGHT
SWrcH(t\//T)
HEADLIGHTSWTCH
REAP WINOOW
DEFROSTERSW|TC.L{--
SELF.DtAGNOStS
A/C SWITCH CHECKERKl.r1
BLOWER_SWtrcH
THROTTLESENSOR
COOLINGFAN SWITCH
Switch SDi"gnosis ctre"kum
Neulralswitch Pedalreleased
(Mrf)
L. S. D or R range
Pedal depressed
Headtights/ smalt lights

Blowerswitchat 2nd or : ON
B l o w e rs w i t c h a t 1 s t
Waler lhermoswitch
Fan opera!inq
Fan not operating
EMISSIONCONTROL SYSTEM seu-F-DrAcNosts
FUNcloN 218-31
Inspection Procedure
SIGNAL AOAPTOR&
r,400ut-AR
1 . T u r nt h e i g n i t i o ns w i t c hO F F .
2.Connect the SST (KJ-1, lvlodula;,Signaladaptor)to the
rr'tReH4iNESS PCM.
3.Turn the ignitionswitchOhl.
4.Perlormthe diagnosisprocedurewith the SST.
2r0r1
Procedure
Set conditionsto deactivateeachswitch Check each switch and related wire harness
. All accessoriesOFF . Clutch and Neutralswitch
in neutral
. Transaxle . Throttlesensor
. All pcdalsreleased . Stcplighrswitch
Verifythat the SST displaysswitchcheckingstatus . Headlightswitch
( ' O N' or' O F F ' ). . Rear defrosterslvitch
. 8lov.'ersvritch
. lnhibitorswitcn
. A/C srvitch
Check each srvitch as described
. Water thermoswitch
Neutraland Clutchswitch (M/T)
PC: . Neutralswitch
malfunction
. Clutchswitchmalfunction
. Open circuitin relatedwireharness
. PCM terminal1V voltageincorrect
. PCM malfunction
Depressclutchpedal
Checkthatthe SSTdisplaysON No- PC: . Clutchswitchmalfunction
Returntransmission
to neutral
21A42 EMISSION CONTROL SYSTEM SELF.DIAGNOSTS
FUNCTION
H e a d l i g h ts w i t c h
Turn headtight s,*itch ON

. H e a d l i g h ts w i t c h m a l f u n c t r o n :
C h e c k r h a t r h e S S T d i s p t a y sO N
. Open circuit in wire harness lrom
headlight switch to pCM
.
.PCM terminai 1U voltage incorrecf
Headlight srvitch OK . PCM malfunction
Tum headt;ghtswitch OFF
Rearwindow defrosierslvitch
o Rearwindowdefrosterswitch
malfunction
o Opencircuitin wire harnesslrom rear
windowdefrosterswitchto pCM
. PCM terminallTvoltage incorrect
. PCM malfunction
Inhibitorswitch (A/f)
PC : e lnhibitorswitchmalfunction
o Open or shortcircuitin relatedwire
harness
o PCM terminal1V voltagetncorrect
. PCM malfunction
E M I S S I O NC O N T B O LS Y S T E M s e l F - D t A c N o sFt su N c l o N 21 B-33
Throttlesensor
. T h r o t t l es € r r S o rm a l l u n c t i o n
. Short circuit in vrireharness from throtrle
s e n s o rt o P C M
YES
. PCM terrninal1N voltage incorrect
. PCfu1malfunction
D e p r e s s a c c e l e r a t o rp e d a l l u l l y a n d c h e c k t h a t t h e . ThroU esensormal functi on

No -y
SST disPtaYsOFF . Opencircuiiin vrireharnesslrcm throttte
-
ves s3nsorl o P C M
I . PCM terminal2L (M/T),2M (A,T)voltage
Y incorrect
ThrottlesensorOK
Releaseaccelerator
Peclal
I
Stoplight switch
DepressbrakePedal PC : . Stoplightswitchmalfunction
No-
Checkthatthe SSTdisplaysON . Opencircuitin wireharnessfromstoplight
srvitchto PCl,l
I ves . PCMlerminal1O voltageincorrect
Y
Stoplightswitch OK . P C Mmal functi on
R e l e a s eb r a k e p e d a l
Blowerswitch
Tum blowersvritchto 2nd or higherposition. No- PC : . Blower svritchmalfunction

Checkthdtthe SST displaysON . Open circuit in wire harness from blower
I ves
svritch to PCM
. PClvlterminal 1S voltageincorrect
Y
. PCM malfunction
Elovrersvritch OK
218-34 EMlssloN coNTRoL sYsTEM
outfNEoF EMrssroN
coNrRoL
sysrEM
O U T L I N EO F E M I S S I O NC O N T R O LS Y S T E M
S T R U C T U R AVLI E W
To reduceco, Hc, and Nox em;ssions, the foilowing
1. PositiveCrankcase systernsare emptoyed.
Ventilation
(pCVi,vri.,
-r'Y'.v''
?. Evaporative emi.ssioncontrotsystem
3. Catalyticconverter
SEPARATOR
€@3
CHECK VALVE(TWO-WAY)
cnancoALcANtsrER
CATALYTICCONVERTER
SOLENOIOVALVE
(PURGECONTROL)
CONTROL SYSTEM postTtvEcRANKcAsE vENlt-ArroN(pcv)sysrEM 21 B-35
(PCV)SYSTEM
vENTTLATTON
oEscRtPI^l3i'
f:;;;ivatve is operatedby thbintakemanifoldvacuum.
is
engir':e
i.'^|i.,'"nIne ruttning
1t
idle,.the
PCVvalveis
is openedsIishtrvandasnrallamountof blolvbygas is
oper
iu:: il #'ff;ilTJ :lH#J:'SJ:"3::rva'e
ii";;k"L"-ll
: :n:T':"'*"il:
Tll,',:"?
:J:'"
varve
isopened
further,
arrowins
a largeramouniof blorvbygas to.be
:ffil;.;pif
'fr;;;into *::*:s.e;gijtu
thedYnamicchamber'
PCVVALVE
lnspection
1.Warmup the engineto the normaloperating temperature
and'runit at idle.
2. Disconnect the PCVvalvewith the ventilation
hosefrom
thecylinderheadcover.
3. Blockthe PCVvalveopening.
4. Verifythatvacuumis felt.
5. Removethe PCVvalve.
6. Blowthroughthe valvefrom port @ and verifythatair
comesout of port@.
7. Blowthroughthe valvefromport@ and verifythatno air
comesout of port@.
8. Replacethe PCVvalveif necessary.
Iii
il{: 21E}-36EMlsstoN coNTRoL SYSTEM
EVAP.RAI'EEMrssroN
t :
i \ coNrRoLsysrEM
il
EVAPORATTVE
E M I S S I O NC O N T R O LS Y S T E M
DESCRIPTION
I
Foi€ireAJ\l
CONTROL !}IRJT
MOOULE SlGtlAtS
SOLENOIDVALVE
(PURGECONTROL)
CHECKVALVE
(Two.wAY)
SEPARATOR
TO ENGTNE
Operation . .
, uury
, ), -t-
komthepCMto perform
" . , srqnals purging
onsaremet: of the
C O N T R O LS Y S T E M 2 1 8 . 3 7
S Y S T E M E V A P O R A T I VEEM I S S I O N
E M I S S I O NC O N T R O L
1 . W a r mu p t h e e n g i n et o t h e n o r m a lo p e r a t i n gt e m p e r a t u r e ,
a n d r u ni t a t i d l e .
2. Disconnectthe vacuum hose frorn the solenoidvalve as
sholvn in the figure,and verify that no vacuum is felt at
the solenoidvalve.
3.lf it is not as specified,checkthe solenoidvalve.
S o L E N O I DV A L V E( P U R G EC O N T R O L )
lnspection
1. Disconnectthe vacuumhosesfrom the solenoidvalve.
2.Verifythat no air flows throughtire valve.
3. Disconnect the solenoidvalve connectorand supply

batteryvoltage(12V)as shownin the figure.
4. Veritythatairflowsthroughthe valve
valve.
replacethe solenoid
5. lf it is not as specified,
SEPARATOR
Inspection
1. Removetheleftsidetrim.
2. Removetheseparator.
3. Visuallycheckthe separatorfor a damage.Replaceit if
necessary.
rl
;.
d' 2tOl2
I
cHECKVALVECrWO-WAY)
lnspection
DIRECTION
INSTALLATION
1. Removethe valve.
2. Checkthe operationof the valvewith a vacuum pump.
A p p l ya p p r o x3. 7 m m H g( 1 . 4 6i n H g ) Aidlow
vacuumat port@
A ppl yapprox.44 mmH g (1.73InH g) Airflow
vacuumat port@
21Et-38EMISSION.GONTROL SYSTEM EVAPoRATIvE
EMrssroN
coNrRoLsysrEM
CHARCOAL CANISTER
lnspection
l . V i s u a l l y c h e c k f o r a d a m a g e a n d r e p l a c er h e c h a r c o a l
canisterif necessary.
E M I S S I O N C O N T R O L S Y S T E M D E C E [ E R A T I OCNO N T R O S
L YSTEII 2 18 . 3 9
D E C E L E R A T I OC
NC N T R C LS Y S T E M
D E S C RI P T I O N
The Cashpotis used lo preventthe thrcttlevalvefrom a suddenclosing.
DASHPOT
lnspection
1.Fullyopenthe throttlevalve. Pushthedashpotrodwitha
tingerandverifythatit goesintothedashpotslowly.
2. Releasethe rodandcheckthatit cornesoutquickly.
3. Replaceihe dashpotif it doesnotworkas specified.
-,4+
<:*
"+
's
Az
zruS
4. W'armup ihe enEineatrdrunii at idle.
5. Connecta tachometer to the diagnosi5 connbctorlG-ter-
minalandincreaseenginespeedto 4,000rPm.
6. Slowlydecreasethe enginespeedand checkthat the
levertouchesthe dashpotrodat thespecifiedspeed.
: Approx.3,000rpm
Specification
loosenihe locknutandturnthe
7. lf it is not as specified,
daslgotto adjust
_
:.--':'.
. --:
2rOtt
218-40 E M I S S I O NC O N T R O LS Y S T E M
FUELCUTCONTROT-
SV'sferur
F U E L C U T C O N T R O LS Y S T E M
DESCRIPTION
This system is used to improve the
fuer
protectthe enginefrom overspee,Jrng. economy,to preventerrginebuckingduring deceleration,
and to
OETECTIOT.J
OF
DECELERATION
ALL IN.JECTOR.S
THROTTLESENSOR WATERTHERMO
OISTRtBUTOR(Ne.S
TGNAL)
SIGNALAOAPTOR& SYSTEMOPERATTON.
, MOOULAR 1. theSST
38ffi.r", !KJ-l,Modutar,
Signatadaptor)
to rhe ,?,
!{
2' waT up..theengineto normar

runit at idle.
operatingtemperatureand ."7 s
Warning
. confirm that transaxfeis in
r r Neutraf (run;-or
(AfD.
':v='q'
\rv' R '"ng"
r timeis about2.3 ms.

to 4,000 rpm and then sud-
rrpedaf.
,200rpm on thedeceleraticr,.
and verify that the maximum
rpm.
E M I S S I O N C O N T R O L S Y S T E M f u Cc U T . o F F
SYSTEM 214-41
N C C U T - O F FS Y S T E M
DESCRIPTION
An NC 9ut-o1systemis used to irnprovethe idle smoothness,iustafler the enginestaringand to improve
Per{ormance'
ihe acceleration
OISTRIBUTOR
(NE.SIGNAL)
THROTTLE
SENSOR
P/S PRESSURE
swtTcH DETERT,UI.IANON
A/C SWITCH
OF
A/CCIJT€FF
AOOlTlOl,lAL
FAN RETSY
A/C REI-AY
swtTcH
(sTARr)
IGNITIONSWITCH
MAGNETIC
lNHlElTORSWITCH(Arr') CLUTCH
EATTERY
2r05t
Operation
The A/C is cut otf underthe followingconditions
Engineconditlon Purpose Cut-oft perlod
Afterenginestarting lmprovementol enginestarting Approx.2 sec.
Thronlevalvefullyopen Approx.10sec.
Accelerationfromstop lmprovemenlof drivability
Approx.3 sec.
SYSTEM OPERATION ,-
JUMPER . 1.warmup theengineto thehoniraloperating
temperature
WIRE andrunit at idle..
WITH
APPROX. . 2.TurntheblowerswitchandtheA/CswitchON.
4 . 7k O 3. Disconnectthethrottle
sensor
connector.
RESISTOR 4.connectthethrottle sensorconnectorterminals witha
ilrmpgtwireas shownin thefigureandcheckif theaddi-
JUMPER tionalfanstopsforapprox.1plec.
WIRE
Note
. The magneticclutch and the additlonatfan operate
together.
218-42 EMISSION CONTROL SYSTEM DEcHoKE
c o N T R o LS Y S T E M
D E C H O K EC O N T R O LS Y S T E M
DESCRIPTTON
T o f a c i l i t a t es t a r t i n q . t he n g i n ew h e n t h e s p a r kp l u g s b e c o m ef o u l e d ,
s u c h a s w h e n i h e e n g i n ei s f l e e 6 s 6 ,
fuel iniectionis cut if the throttlevalveis heio wide rJponwhilgciankirrg
ano ti,L enginecoolanttemperaturs
0 e (32"F) or belorv.This allowsthe sparkplugs to dry and purges
excessfuel from the cylinders.
rGNrTroN
swtTct-t(srART)
. E N G I N ES P E E OB E L O W5 0 0r p m
. THROTTLEVALVEFULLYOPEN
. ENGINECOOLANTTEMPERATURe
FUELCUT
E E L O W0 c ( 3 2 . F )
SYSTEMOPERATION
l.checkif the enginecootanttemperature is below 0c
(32'F).
2. lf.the enginecoolanttemperature is above Oe (32.F),
disconnectthe water thermosensor connectorand con-
nectan applgx. 10 k 0 resistorto theconnector.
3.Turnthe ignitionswitchto srART and checkthat the

injectoroperating
soundis heard.
4. Depressthe acceleratorpedaffullyand turn the ignition
switchto srART. Verifythat no injectoroperatingiound
is.hbard.
E M I S S I O NC O N T B O LS Y S T E Mc o N r R o Ls y s r E M 218-43
c o N T R O LS Y S T E M
t, s T B U C T U R AVL! E w
3
""oo
IJ
@
''i'l
ro*"rtrain controtModute(PcM) 9. Mainrelay(FUELINJrelay)
2. Circuitopeningrelay 10.Neutralswitch(Mff)
3. P/Spressureswitch 11.Oxygensensor
4. Airflowmeter(Withintakeairthermosensor) 12.Clutchswitch(Mff)
5. ISCvalve switch(Mf)
13.Inhibitor
6. Throttlesensor 14. Diagnosisconnector
7. Waterthermosensor
8. Solenoidvalve(Purgecontrol)
t
I
I
r
218-44 E M I S S I O N C O N T R O L S Y S T E M c o N T R o LS Y S T E M
il'
P O W E R T R A TC NO N T R O LM O D U L E( P C M )
1.Removethe boltsand nut.s.
2 . D i s c o n n e ctil r eP C M c o r i n e c t o r s .
ffi- 3.lnslalla nelv PcM in rhe r'€V€r.s? orcjerof a renrcvar.
.SIGNAL
Inspection
AOAPTOR&
MOOULAR 1.TurntheignitionswitchOFF.
2.connectthe ssr (KJ-1,signaladaptor,Modular)
to the
PCM.
3.TurntheignitionswitchON.
4. checkthevoitageor theconnecting
condition
of eachtenninal.
5.lf any PcM terminar voltageor conditionof pcM termirilf
is incorrect,
checkrheretJtedinputor outfui oevicesani
wiring.
E M I S S I O N C O N T R O L S Y S T E M c o T T R o LS Y S T E M 214-45
V O L T A G E( R e f e r e n c eo n l y )
TEFMINAL V a : 3 a i t e r yv o l t a g e
Outrut C o n n e c i i o nt o Testcondrtion
TerminatI n P u t Conect voftage Remark
1A 3 a tte ry Ccnstant vil Forbackup
13 o M a i nr e l a y '
lonitionswitch
OFF A pprox.0V
( F U E LI N J r e l a y ) ON V3
o l g n i t i o ns w i t c h While cranking
(START) lgnitioh switch ON
lo o Diagnosis First 3 seconds af'.erignition While

connector s v r i t c hO F F - ON A pprox.5V pedorming
( E N G .M O N . s w i t c hm o n i t o r
terminal) After3 seconds Va fu n c t i o n
Any monitored
switchin ON position
Any monitored
switchin OFF position
il.
ral
'ld 1F q Oiagnosis First3 secondsafter B el ow2.5V
COnrleCtor ignitionswitchOFF-'ON
(EN G .F ArL
terminal) After3 seconds V8
1G o lgniter lgnitionswitchON A pprox.0V

ldle A pprox.0.2V
1H
1l
1J o A/C relay lgnitionswitchON Vs
A/C switchON at idle Eelow2.5V
A/C switchOFF at idle Vg
lK - o Diagnosis ENG.TESTterminalopen VB
conneclor
(ENG.Testterminal) ENG.TESTterminalgrounded
E e l o w1 . 0 V
IL o ORLrelay Parkingbrakepulledwith ignitionswitch v8 . DRL:

oN (DRLOFF) Oaytime
Running
ldle (DRLON) Below2.5V Lights
U
2Y 2w 2U 2 S ?o 20 2u ?K ?r 2C 2E 2C 2a'
22 2X ?v 2T 2R 2e 2N 2L ? t 2H 2r 2 0 ? s
C O N T F OSLY S T E M
V s : 8 a r t e r yv o l t a g e
Incorrect voltage
P o s s i b l ec a u s e
Alrvly5 gY
ROOM l0A iusc bur,rect
9gn circrritin wirinq fronr R O O M
Alrvays 0V t0A tuse to pCM terminat
lA
M a i n r e l a ym a l f u n c t i o n
A l w a y s 0 V ( S t a r t e rt u r n s )
Alrvays0V
Mainretay(FUELll.JJ;Aay)manncri;
open circuitin rviringfrommainreray
to diagnosisconnecrorterminat
open or shorrcircuitin wiringfrom B.
diagnosisconnecrorterminat
MON to pCM ENG.
terminall D
Alwaysapprox.12V
Poorconnection
at pCM
PCMmalfunction "onn".to]
Alwaysapprcx.5V
PCMmalfunction
Mainretay(FUELrrvtrerig mffiffi
open circuitin wiringfrommain relayto
diagnosisconnectorterminalg.
open or sho( circuitin wiringfromdiagnosis
connectorterminar
to pC M termi natt F
E N G.FA IL
Ahvays approx. l2V

Poorconnection
at pCM
"onn""to]
shortcircuitin wiringtrorffi
A/C does not opeiate NC relaymalfunctron

upen circuitin wiringrromignitionswitch
to A/c reray
A/C switchOFF bur terminaitJ
Shortcircuiti
A/C operates PCM malfunction
Alvraysapgrox. 12V
Poorconnectionat ECU
"on*.to,
Alrvaysbelow 1.0V
Shortcircuilinwiringlromdiagnosisconnec|orlermin"rffi.
PCM terminalt K
Alwaysapprox.t2V
opencircuitin wiringtror o-.gnoF.onnector
trrrin.tffiE3iT
PCMterminal IK
OR LO N w h e n I G N Ot oo r o u n c
Shortcircuitin wiringtrom Onl relayto pCM
terminal
Shortcircuitin wiringlrom ORL relayto DRL
DRL neverON unit
Alwaysapprox.t 2V lrom DRL relayto ignitionswitch
Parkingbrakesyitch
"l*"yffi
ORLunitmalfunction.
E M I S S I O NC O N T R O LS Y S T E M c o r u r R o S
L YSTEM 218-47
Ve : 8attery vottage
Ternunal l n p u t Oulgrt Connectionto Test condition Conect votbge Remark
IM
IN o Thrott!e sensor Acceleratorpedal released Eelow1.0V lEniticnswitch
(ldleswitch). Acceleratorpedal depressed V6 ON
(MtT t A/tl
A/T conlrol unit 1a41
10 o Stoplightswitch Brake pedal released Below1.0V

(Arr) Brakepedaldepressed VB
A/T control Throttlevalveopen 1/4 or more 12V
unit (A/T) Other B el ow1.5V
IP o P/S pressure switchON Va
switch P/S ON at idle B el ow1.0V
P/S OFF at idle Va
10 o A/C swilch A/C switchON Below2.5V lgnitionswitch

A/C switchOFF Va ON and blower
motorON
;i
F
nr?
li'
.xa
i:4
.>*
1R o Water (Enginecoolanttempera-
Fanoperating Below 1.0V
.rE
thermoswitch lureover97e (2O7'F)or diagnosis
,F
connectorterminalFAN grounded
''JC.
;f:
'd
Fan not operating(ldle) Vg

1s o Blowercontrol BlowercontrolswitchOFF or lst position Ve lgnition.switch
switch Bfowercontrolswitch2nd or higher Below1.0V ON
position
IT o Rearwindow RearwindowdefrosterswitchOFF Below1.0V lgnitionswitch
delrosterswitch RearwindowdefrosterswitchON Ve ON
IU o Headlight switch HeadlightsON Ve

HeadtightsOFF Below l.0V
IV o N e u tra l /C l u tc h Neutralpositionor clutchPedal E el ow1.0V
switches(Mrf) depressed
Others V8
lnhibitor switch N or P range E el ow1.0V
(Arr) Others Vg
21B-48 EMISSION CONTROL SYSTEM
CONTROL
SYSTEM
lncorrect voltage Ve : Batteqyvottage

Possibfecause
J;fr
Throtttesensormisadjustmeni 6
.n?
'shorrcircuitin uriring ffi:

-**
rromrhrottesensorto pcM -#"
PCMmaltunction rerminar
1N
,*,
Always approx.12V
. ThrottlesensormisaOjrstffi 4l
.rr I
' open circuitin wiringfrom throtile .;; i

sensorto pcM terminar1N
' open circuirin wiringfrom .,,a I
throttfesensorto pcM rerminar2D .:.: 1
Always betow 1.OV(SroptighrOK)

' open circuitin wiringfrom
sroptightswiichto pcM temrinal
1o
Always below 1.5V
opencircuirinwiringu"t"""nffi
A/T control unit connector
short circuit in wiring from p/s pressure

switch to pcM terminarI p
PCM malfunction
Always approx.12V
a P/S pressureswitch rnalfunction
a open circuitin wiringfromp/s pressure
switchto pcM terminar
1p
c Openclrcuitin wiringlrom p/S pre-ssure
sr.;itch!o greun6
Always below2.5V (Blowerlan OK)
a
a short circuirin wiringfrom A/c switch pcM

to terminar1Q
a Poor connectionat pCtvt.onn".tor-
a PCM matfu;ction
Atways"ppi@
A/C switch maffunction
open circuitin wiringfromA/c switch pcM
to terminalle
open circuitin wiringrromNCrt"i*r
Alwaysbelow l.0V to browercontrorswitch
Openor shortcircuittn *trtnn
(Electricatcoolingfan OK)
PCMmatfunction
Ah , v ay s belowl. @
Short circuit tn *
Poor connectionat pCM connector
PCM mallunciion
Alwaysapprox.
1@
Ahrays below Flr.windowdefroster . Openor
short
1.0v indicatorON when. lerminaf1T
r.earwindowdefroster
switch ON
Open circuit l
Rear windowdefrosterrefaymalfunction ; .--
1]*Lvrbetow1.0V(Headtighr,
oE . openorshorr
circuitGffiffi switchto PCM terminal1U
Always betow 1.0V (M/fJ
a Neutratswitcnrnattuffii
a Clutchswitchmalfunclion
a Short circuitin wiringfrom pCM terminal
Always approx. 12V (M/T)
Neutralswitchmallunction 1!!o neutralor clutchswirch
Clutchswitchmalfunction
.l1ir inwiring
frorhpcM rerminar
1Vroneurraf
3Tl connection pCM
Poor
orcrutch
switch
at connector
Alwaysbelow 1.OV(A/T)
o lnhibitorswitchmalfunction
a shjl,circuit in wiringfrominhibitor
switchto pcM terminal1V
Inhibitor
switchmalfuncrifiT
open circuirin wiringtrominrr;uitor
switchto pcM terminaliv
EMISSIONCONTROLSYSTEMcorurnoL
sysrEM 218-49
Va : Batteryvoltage
Tertnirg I n p u t Ontput
Connectionlo Test condltion Conect vottage Remark
?A Ground (lnjector) Constant OV
29 Constant OV
2c Ground(CPU) Constant OV
20 Ground(lnput) Constanl OV
2e o Distributor lgnitionswitchON A pprox.0V
(Ne-signal) or 5V
ldle a.pprox.2V
2F
2l
2J o Open (hd/f) Ccnslant Appor 1-2.5V
Main relay(FUEL lgnitionswitchON Va
INJ relay)(A/r)
2K o Throttlesensor Constanl 4.5-5.sV
(Afiyl/f control
unit (l/1174irflow
meler
2L o Throttlesensor Acceleratorpedalreleased Approx.5V

(Powerswitch) Acceleratorpedalfully depressed B el ow1.0V
([rrf)
2M o Throttlesensor Acceleratorpedal released Approx.0.5V

(AmlMf contro! pedalfully depressed
,Accelerator A pprox.4.0V
unil (A/T)
2N o Orygensensor lgnitionswitchON OV
ldle (Coldengine) OV
ldle (Afterwarm-up) 0-1.0v
enginespeed(Afterwarm-up)
Increasing 0.5-1.0v
Deceleration 0-0.4v
20 o' Aidlow meter lgnitionswilchON Appior 3.8V
ldle Appfox.3.bv
2P o Intakeair ther- 20tr (68'F)
Ambientairlemperature Ap/rox.e.bV Builtin aldlow
mosensor meter
20 o Waterlhermo- Enginecoolanttemperalure20t (58'F) Approx.2.5V
sensor Afterwarm-up Below0.5V
2R
21E}-50 E M I S S I O NC O N T R O LSYSTEMCONTROL
SYSTEM
VB : Batteryvoltage
lncorrectvoltage
Possible cause
UV P o orconl acta l g r o u r r dl e r n t i r r a l ..
Opencircuitin wiring lrom pCM to groun,J
Alway,sapprox.OVor apyox.2V . Referto CodeNo. 02 Troubleshooling
Approx.5V (M/T)
Alr,zays0V (A/T) :Cpencircuitin vriringtrorn

Allays 0V 3
. Srcrlc
A./Tccntroiunit (,l,Ti, or airltowmeier
. Poorconnectionat pCM connector
. PCM malfunction
E e l o r v4 . 5 V o r a b o v e S . 5 V
Alrvays 0V
a
a short circuitin wiringfrom pcM terminar2L to throttte

sensor
a Poorconneclionat pCM connector
a PCM malfunction
Al way sappr ox 5V
. Throttlesensormisadjustmeni
open circuitin wiringrrompcM terminar2Lto
throttresensor
open circuitin wiringfrom pcM terminar2D to
throtttesensor
Al'aa;,sconstanl
. Opencircuittn
. open circuitin wiringlrom pcM terminal2K
to throttlesensor
- open circuitin wiringfrom pcM rerminar
2D to throtttesensor
Always above 1V
. Throltlesensormisadjustment
0 V alt erwar m . up
. Referto Code No. l S Troubl
Ah.raysapprox.1V alterwarm-up
l7 Troubleshooting
Alrvaysapprox.0V o-rapprox.5V . Referto Code No. 0g Troubleshooting
Alwaysapprox.0V or approx.SV . I Referto CodeNo. 10 Troubleshooting
Al ,. l, ayappr
s ox 0V
. o r a p p ro x ..5 V
._ ..
_ ._ .,' -.. -Referto CodeNo. 09.Troubteshooting
EMISSIONCONTROL SYSTEM coruTRoL
SYSTEM *21 B-51
lge Vs : Earreryvottage
Outprl Connection to Test conclition
Tenrrinal l n p u t Conect voltage Remark
2U o Injector(N,.rs.
1, 3) lgnitionswitch ON VB
!dle V3
2v o Injector(Nos. 2, 4) lgnitionswitch ON V8
ldle VB
2w o ISC valve lgnitionswitch ON A pprox.TV
ldle Approx.9V
2x o_ Solenoidvalve lgnitionswitch ON Ve
(Purgc cont:'ol) ldle VS
2Y
2z o A/T controlunit Sngine coolant lemperature belcrv 72 E Belorv2.5V
'(A/r) (162'F)at idle
Engine coolant tenrperaiureabove 72C V8
(162'F)atidle
U
IU rS to rolru IK rl rcl re rC IA
IV IT IR re I rr.r I L I J I H I F r O r g
21B.s2 EMlsstoNco NTROLsysTEMcoNrnor_sysrEM
Incorrectvoltage
Possibte cause
Alrvays approx. 0V
Main reiay (FUEL tNJ retay) nratfunction
.'.
Openor shortcircuitin wirinqfrom ini to PCM terminatZIJ or ZV
-rs
itr
Alwaysapprox.12V h*:
19:
ft
Alwaysapprox.0V or approx.12V Referto CodeNo. 34 Troubleshooting
Ahvaysapprox.0V or approx.12V .Referto Code No. 26 Troubteshooting
Alwaysapprox.0V or approx.12V Open or short circuitin wiring tronr pCtutt"

lerminal1N
EMISSIONCONTROLSYSTEM colrRoL sysrEM 21 B-53
;
ATRFLOW METER(W!THTNTAKE AtRTHERMOSENSOR)
lnspection
1.Removetheairflowmeter.
2. Checkthe air{lowmeterbodyforthe cracks.
3.Verityihatthe measuringplatemovessmoothly.
4.Move the measuringplate and checkfor a resistance
betweenthe terrninals
withan ohmmeter.
Specification
l
R esi stance( 0 )
Terminal
Fully closed I futty open
Ez,-'Vs 20-600 | 20-t,zoo
Ez.-. Vc 200-400
Ez* THA^ -20e (-4' F): 13. 6- 18. 4k 0
(lntakeair thermosensor) 20e (68'F) :2. 21- 2. 69k 0
60e (-140' F): 493- 667 0
Er .- Fc @ 0
21059
WATERTHERMOSET.ISOR
Removal
Note
. Waterthermosensoris placedat intakemanifold.
1. Disconnect
thewaterthermosensor connector.
2. Removethe waterthermosensor.
Inspection
1. Placethe sensorin waterwitha thermosensor, and heat
WATERTHERMOSENSOR
- the watergradually.
2. Measurea resistance of the sensorwithan ohmmeter.
Coolant Resistance(k I )
-20c ( -4' F) 1 6 . !+ 1 . 6
2oe ( 68'F) 2.45tO.25
80g (176'F) O.32+ O.O3
replacethewaterthermosensor.
2 t o 7|
Installation
1. Installa newwasherandthewaterthermosensor.
Tighteningtorque:
25-29 N'm (2.5-3.0kg-m,18-22lb-.ft)
2. Connectthewaterthermosensor connector.
3. Startthe engineandcheckfora coolantleakage.
I
rl 218-54 E M I S S I O NCONTBOL SYSTEM coNrRoL
j:l sysrEM
T H R O T T L ES E N S O R
I n s p e c t i o n( M / T )
' 1 . D i s c o n n e ctrh e c o r r n e c t ofrr o m
t h e i h r o t t r es e n s o r .
2. Connectan ohmmetertc the th,-cttle .r.nror.
3' lnserta feerergaugebetweenthe

throttre
thestoprever,ancicheckthecontinuity stop screwand
betweentermi'ars.
Feeler gauge C oati nui rybetw .en ter m inals
IDL +-' E
0.1mm(0.00ai n)
1.Omm(0.033in)
Wide.openthrotile
Inspection(A/T)
1. Disconnectthe connectorfromthe throttre
sensor.
2. connectan ohmmeterbetweenthe tnrottte
nalsE and lDL. sensortermi-
3. Inserta feerergaugebetweenthe throttre
the stoplever. stopscrewand
. 4. Checkthecontinuitybetween'terminals.
Feeler gauge
C onti nui ty
0J mm (0.00ain)
0.6 mm (0.02ain)
5. Connectan onmmbt er to the throttlesensorterminalVr

and
a E.
t tu E .
6. Verifythat the resistanceincreases
lineallyaccordingto
the throttlevalveopeningangte.
Throttl evatvecondi ti on
R esi stance(k A )
Fultyclosed
Belorv 1
Fully open
Approx.S
O P E N I N GA N G L E
FULLYOPEN
Adjustment(M/T)
1. Disconnect theconnector fromthe throtilesensor.
2. Gonnectan ohmmeterto thethrotile,.nror't.rminars
and E. rDL
3 ' I n s e r ra 0 ' 4 m m ( 0 . ! 1 . 0i n l f e e r e rg a u g e
-v - b e t w e e nt h e
throttle stopscrewandthesfopfever.--
E M I S S I O N C O N T R O L S Y S T E M C O I v T R OSLY S T E M 218-55
4. Locsenthe frvcattachingscrews.
5. Rotatethe ihrottlesensorclockviiseapprox. 30 degrees,
{itttl):'ir
then rotaie it back counterclockrvise until the continuity
exisis.
6. Replacethe feelergaugewith a 0.7mm (0.027in) gauge.
T.Verifythat the continuitydoes not exist.
8.lf it exists,repeatSteps3 through6.
0.7 mrr,(0.027in)
2r07t
9.Iighten the two attachingscrews.
Note
. Do not move the throttle sensor from the set posi-
t i o n w h e n t i g h t e n i n gt h e s c r e w s .
10.Openthe throttlevalve fullya few times.

11.Rechecktire adjuistmant of the throttlesensor.'
?1079
Adjustment(AfD
1. Disconnect theconnectorfromthe throttlesensor.
2. Connectan ohmmeter between the throttleSensortermi-
nalsE and lDL.
3. Loosenthe two attachingscrews.
4. Inserta 0.25 mm (0.01in) feelergauEebetweenthe
throttlestopscrewand the stoplever.
5. Rotatethe throttlesensorclockwise.approx. 30 degrees'
thenrotateit backcounterclocklviseuntilthereis continu'
ity.
2r080
6. Replacethe feelergaugewitha 0.4 mm (0.016in) gauge'

: snd verifythatthereis no continuity.
repeatSteps4 through6.
7. lf thereis continuity,
8. Tighten the two screws..:. _ ,t
attaching
, .
Note
- .. Do not movethe throtttesensorfrom.the set posi-
"--
tion whentighteningthe screws. .
9. Openthe throttlevalvefullyand veriflthat,the-resistance
betweenthe throttlesensorterminalE and Vr is aPProx.
2108r
5 ko.
21 8-56 EMISSIONCONTROLSYSTEMcoNrBoLsysrEM
Replacement
1. Disconnect the th:'ottle
sensorconnector.
2. Removethethrottlesensormounting screws.
3. Removethethrottlesensor.
4. Installin thereveiseorderof a removal.
Tighteningtorque:
1.6-2.4li'm (16-24 kg-cm,14-21 tbin)
OXYGENSENSOR
Inspectionof TerminalVoltage
1.warm up the engineto the noi'rnaloperatingtemperalure
and runit at idle.
2. Disconnect the orygensensorconnector.
3. connecta voltmeterbetweenthe o{ygensensorand the
grcund.
OXYGENSENSOR 4. Run the engineat 3,cc0 rpm untilthe voltrneterindicates
approx.0.55V.
5. Increaseand decreasethe enginespeedsuddenlysever-

al times. Verifythat when the speed is increaCed, the.
m e t e r r e a d s 0 . 5 V - 1. 0 V , a n d w h e n t h e s p e e d i s
decreased, it reads0V-0.4V.
5. lf not as specified,replacethe oxygensensor.
Voltmeler
o o
2t08.
lnspectionof Sensitivity
1.ryarmup the engine!o the normaloperatingtemperature.
2. Gonnectthe SST to the PCM.
3. Seta functionselectto Oz MONITORCHECK.
4. Increasethe enginespeedto between2,000and 3,000
rpffi, andveritythatthe dutyvalueis in 30-80.
'
lf not as specified,replacethe oxygensensor.
rE
-t
2rot. *
* q"i
.dl6
$.
'42
'f.
€
*
SYSTEM
EMISSION CONTROL SYSTE.M COT{TROL 218-57
---
5.Turnthe ignitionsr.ritchOFF.
6. Disconnectthe negativebatteryte;minaland depressthe
brake pedal for at least 5 sec. to eliminateihe malfunc-
tion code from the PCM memory that was createdduring
the inspection.
Replacement
1.Disconnect the oxygensensorconnector.
2. Removethe orygensensor.
3.Installin the reverseorcierof the removal.
Tighteningtorque:
29-49 N'm (3-5 kg-m, 22-36lb'ft)
MA|NRELAY(FUELINJ RELAY)
Inspection..
t. Verifythat the main relayclickswhenturningthe ignition
switchON and OFF.
2. Apply12V to the terminal@ and the groundterminal@
of themainrelay.
3. Checka continuityof the terminalsas shown.
Terminals 12V not appl l ed 1 2 Va p p l i e d
c-o No continuity Continuity
replacethe mainrelay.
4. lf it is.notas specified,
CLUTCHSWITCH
lnspection
theclutchswitchconnector.
1. Disconnect
2. Connectan ohmmeterto the switch.
of the switch.
3. Checka continuity
Pedal C onti nuit y
Depressed Yes
Released No
replacetheclutchswitch.
4. lf it is notas specified,
2 rO90
Replacement
1. Disconnect theclutchswitchconnector.
2. Loosenthe locknuts.
3. Removethe clutchswitch.
4. lnstallin thereverseorderof a re 'oval.
S.Adiustthepedalheight.
LOCKNUT
2r0€r
:l
-{ 218-58 EMlssloN coNTRoL sysrEM coNrRoL
:11 sysrEM
N E U T B A LS W I T C H
A*
Inspection
1. Disconnectthe neuiralswitchconnectcr.
3. Check a continuityof the switch.
Transmi ssi on C onti nui ty

Neutral Yes
Other ranges No
4' lf it is notas specified,

reprace
the neutrar
switch.
Reolacement
Replacethe neutrarswitchas shownin the figure.
POWERSTEERING PRESSURE SWITCH

Inspection
1. Disconnect the p/s pressureswitchconnector.
2. connect an ohmmeterbetweentheswitchandtheground.
3. start the.engineand run it at idle. cnecf i- continuity
of
theswitchwhileturningthesteering wheel.
P/S C onti nui ty
Turning Yes
Not turning No
4. lf it is notas specified,replacethe p/S pressureswitch.

Replacement
. Replace
the P/s pressureswitchas shownin the figure.
. !l
I
I! E M I S S I O N C O N T R O L S Y S T E M T R o I J B L E S H o o TG
I NUGI D E 21 B-59
.l
I
.t
i
E N G I N EC O N T R O LO P E R A T I O N CHART Note
I n p u t D e v i c ea n d E n g i n eC o n d i t i o n s . T h e d a t a i n t h i s c h a r t i s f o r r e f e r e n c eo n l y .
i
-1
I N P U TD E V I C E S SENSORS
-1I APPROXI.
I
I
I"IATET]ME T H R O T T L ES E N S O R
-1 (tsASED ON IMTAKE
J
I O X Y G E N A I R F L O W A;R
ENGINE S E N S O R T . I E T E R THERMG TERIdINALI TERMINAL roL
SEIISOR TERI\TNAL
CONDITIONS
CRANKING
-COLD ENGINE Signalhas Signalhas S i g n a l h a s Signalhas
r COLDAIR no effect no effect no effect no eilect
on PCM on PCM on PCM on PCM
I o COI-OCOOL-ANT
COLOS TART Closed

-FAST IOLE i
throtUe: I
. COLDAIR LowvoltageI
. COLOCOOLANT (Appror I
0v) |
COLODRIVEAWAY
_PART THROTTLE
e COLDAIR
. COLOCOOLANT Ne-SIGN
S e r r c i sa l l
cylinders
WARM ORIVEAYJAY TOC signal Sensor l'loderate
hot: .rolume air-
_PART THROTTLE IO PCM
Switching rlrll: Lor b
o WARM AIR lrom high medimum Part
voltage
Part throttle:
O WARM COOL'.NT (0.sv) thronle: Medium
(1.G3sv) Medium Open
vollage
l voltage Approx. throttle:
High
HOT CRUISE I (0.8-3.0v) s.0v) vollage
o WARMAIR Y (battery
o IVARMCOOLANT lo lo'a voltage)
voltage
(0.1v)
I
HOT ACCELERATION II
-.40% THROTTLS l/cderale
to sEcng Cool to
ldurne of warm
airiov: [-20.40e
Loavdt- (4.104'F)l
HOT ACCEL€RATION Hot: Low
age (0.5 :1.$4.3V W i d e o p e n W i d e o p e n
More voltage -1.sv) throltle : l h r o t t l e:
-WIDE OPEN (8elow High volt. High volt.
lhan four I
THROTTLE 0.sv) age a9e
minutes II (Above (Approx '
3.0v) 0v)
OECELERATION
--cLosEo
THROTTLE Lorv
volume o[
airliorv :
(Above
3.0v)
H O TC U R EI D L E
_EXTENDED
Sensor
hot: Low
voltage
OFF ( 0 . 1 V )u n l i l
sen50r
cools
l l
21 8-60
, l
E M I S S I O NC O N T R O LS Y S T E MTROUELESHOOTING
GUIDE
,i
fl
SENSORS
STOP. NEUTRAL rI G
oNNrI T
I rIuONN sSw
Wt T
I TCCHH
ANO I D I A G N O S-I S
UGHT
CLUTCH
cor.rNe-c
-
swTrcH | | roRrEN
(M/r) SWITCHES SIART ioN ITERML
fivt/f, posmoN eosmo*
I lH_TFilr
Sigal fras SendssrTal I
I SVtaJfras I S6nattns S'€nalhas I Signaffras -
no eftectm ro pCM | Signal has OFF
I rrc effea on I no effecton m effecton I m effecton
PCM lpcu lpcu (Ea[e;.yvdt- I ro efl:d on (Banery
PCM I pCt,l ag€) PCM
| voltage)
Erake F,BJa,
depressed:
S€ids stignal
tr PCM
(Eafterylol.
age)
Headt'[or
tearwindon
dekos,er
S\,vildl '
Otrt Ffgh
!'dtagedg
nal b PCM
Seerng (Ba[erywtt-
whed age)
No sQnai AlCsv,/itdl tuntect OFF: tor,,r
Of.l: tourvonag vdtage{1
S€rdsdg trtgrqrn+
s{fral !l nal h PCM qJ:
nallo PCM PCM (B€k:r DRLON:
(Beb!,, H€hvolr-
(8€btv rsv) (APPROK
rsv) r.5v) Sends sig.
ageSipd
b PCM
0v)
A/Cswildl Steerng Bloi€r nalto PCM
OFF:l.b (Bauery
vrheel S\'!itCttz (Sanery
toiage) DRLOFF:
dgftallo sr'aig|-t or Beadcaj rcfta9e) (Banery
PCM Tenrtnd voltage)
ahead fan grqrtd€d
@aneryvdt. t{gh\oi- Of.{:Lon
age) torrvdtage
ages*gnal \dtag€sgF qlnaltr)
IoPCM r € Jb P C M ECU
(Banery (Beill/, (B€bll
wlage) rsv) l5'v)
OFF:F69h
vdtage{1
na,b PCM
(Baneryrci-
age)
Erake
pe.dal
depressed:
SerrJs
siqnalto
PCM
(Battory
rollage)
'z Blower
Switch : Znd positicncr more
#
.-Fi
-r+l
..i.|
rfj- l E M I S S I O N C O N T R O L S Y S T E M T R O U B L E S H O O TGI N
UGIDE 218-61
'rl
I
-j R E L A T I C N S H iC
PHART
O U T P U TO E V I C E
j
zl o
3l
ol
F
z
UJI o
()
2l f
o
tr.
tlt
Ltl
.l a ll. )<
LL o
tt
ll
l o
F
I
F
z
o
()
tt
()
zo t o l l= I t!
l
C)
o
3d (5
=
9,
o
l-lr-l
O ltr
urlrul
I UJ o
a
aE =
F
o
=
g
s
2ZI Z" i z o
q
=* z
J cEo
J=l JZ I
z
UJ
J
tl,
c)
8g HE
o
IL
I
I NP UTD E VIC E
5=
tL<
|I 5=
tlF
|I o
a o
a a tq
<g 6s UJ
U)
.qrrcoNTRouUtqtr o
C O N N E C T OR
O I A G NOS IS
crESTTERMINAL)
o o o
tcNrT!ONSWITCH(STARTPOSTT|ON) o o o o o
E/1-SIGNAL'I o o:
P / SP RES SU R E
S WIT C H o o
A/C SWITCH o o o
SR
tNHTBTTO W I T C H( A r r ) o o o o o o
N E U T R A LA N D C L U T C H
S W I T C HE S o o o o o o
S T o P L I G HS
T W T T C (HM r r ) o o
A T M O S P H E R IPCR E S S U R E
SENSOR
( r NP C M ) o o o o
T HRO TT L E
SE N S O R o o o o o o o
I N T A K EA I R T H E R M O S E N S O R o o o
A I R F L O WM E T E R o o o
O X Y G E NS E N S O R o o o o
W A T E RT H E R M O S E N S O R o o o o o
0 I S T R I B U T o (RN e - S I G N A L ) o o o o o o
'r E / t S I G N A L: B l o w e r f a n c o n t r o l s w i t c h s e c o n d p o s i t i o n o r h i g h e r ,c o o l i n g f a n o p e r a t i n g ,h e a d l i g h t sO N , o r r e a r
w i n d o w d e l r o s t e rs w i t c h O N
218-62 EMISSIoN coNTROL SYSTEMTnoUBLEsHooT.I.NG
GUIDE
U S I N GT H I S S E C T I O N
Introduction
Mostoi the fueland emissioncontrolsystemis glectricallv
problems in cc ridirficurr
tnesvsrern,-Js-pec;arry
inte'rmitieni
p;i;;J: ii?.119"90':t'"".making diagnose ro
minures
rotarr<
withu *r'o o,""lil[v'?1i,fr:ili Li
goodsource ",s6,ne'
of information "pp;.;i.,;;;i;" ;;i:rrrnenr
onsucr,prddtems, fi,T.::",""11_t1g-"
t"n .
&;;ry
tomer,onecanfindoutwhatthesymbtoms .ni-rnJ,j,- ones.Throuoh lllj..:f
t"rr.=withthecus--
*irarconditions
theyoccur.
"r.
Work florv
C H E C Kt N
I
Y
LISTENTO CUSTOMERCOMPLAINTS
I
REFERTo TRoUaLgJHooTING
PAGETHAT ---- DlAGNoSTlc.INDEX
CORRESPONDS TOTACTUeT-
SVupfOl"r
C H EC KF ORW H ATIS BA
t
- . , vD IN
r.! S
!, Y
r eSITE r ...-....
q r yM ---- INSPECTION
i-
Y
CHECKFOR WHATPARTtS BAD----_-___-__-r _-__A C TtoN
Ir
ll
*r ,l
REPAtR/REpL-AcEM
ENT----_---____-___-i
D ET E R MIN E
+
tF T R OU EL EH AS B E E NE LIMIN A TE D
yes
t
C H EC KO U T
Diagnosticindex
D E S C R I P T I O: N
Describeseachtroubleshooting
No: item.
Eachtroubleshooting
- itemis
assigneda number {
:
t
P A G E:
Shows the referencepage.
E M l s s l o N c o N T R o L S Y S T E Mr R o u B L E S H o o r NGGu r D E 218-63
DESCRIPTIOI-l:
F u r t h e rd e s c r i b e st h e s y m p t o m .C o n f i r mt h a t t h e c h a r i a d C r e s s e st h e a c t u a ls y r n p t o nbi e f o r eb e o i n -
n i n gt r o u b l e s h o o t i n g .
T R O U B L E S H O O T I NHGI N T S:
This describesthe possiblepointof malfunction.
*
irEp '
This showsthe orderof troublesfrooting.
Proceedrvithtroubleshocting
as indicated.
INSPECTION:
This describesan inspectionto determinethe malfunctionof partsquickiy.
A C T I O N:
. This reconnmends
the appropriate
actionto take as a result(Yes/No)of the INSPECTION.
td
irl
218-64 EMlssloN coNTRoL SYSTEMrnouBLEsHoorNG
GUIDE
ti
i
No. TFiOUBLESHOOTING
ITEM DESCRIPTION PAGE
1 Will not crank or cranks slowly Refer to Engine ElectricalSystem
2 Cranks normally but No combustion Enginecranksat normalspeedbut showsno 218-67.
will not sta( signof liring
3 Partialcombustion- Enginecranksat normalspeedbut shcws 218-e9
When warrn-up orrlypartialcorabustion
and wili not continueto run
4 Partial combustion- Engine starts normally when cold. bul wilt not start 218-71
After vrarm-up alter running and hot soaked
5 Cranksr:ormallybut Always EniEnecranksat normalspeedbut requires 218-73
hard to start excessivecrankingtime beforestarting
B When engineis cold Sameconditionas No.5 alter runningand cold 21B-75
Restarlsnormallyafterwarm-up
'l
Afterwarm-up Sameconditicnas No.Saflerrunningand hot 218-77
soaked
Startsnormallywhen cold
I Roughidle Always lqgine stallsor vibratesexcessivelyat idle zt g.rc
9 (Low idle speed)/ Beforewarm.up Enginestallsor vibratesexcessivelyat idle during 218.81
Enginestallsat idle warm-up
10 Afterwarm-up Enginerurrsnormallyat idle duringrvarm-upbut 218- 83
vibratesexcessivelyor stallsafterwarm-up
11 When A/C. P/S, Enginestallsor vibratesexcessivelyat idle when 218-85
ol E/L ON A/C, P/S, or EA ON
12 Roughidle/ Enginestallsjust afterstarting Enginestallsor vibratesexcessivelyonlyjust after 218-86
starting(acceleration
lrom idle)
13 Highidlespeedafterwarm-up ldle speedexcessivealter warm-up 218-87
14 ldle movesup and down /ldte hunting Enginespgedsup and down periodicallyat idte 218-89
15 Enginestallson deceleration Engineunexpectedly stopsrunningwhiledecelerat- 218-91
ing or alterdeceleration
16 Enginestallssuddenly(lntermittent) Engineintermittently
stops running 218-93
17 Hesitates/Stumbles
on acceleration Flatspotoccursjust afteracceleratordepressedor 218-94
mildjerkingoccursduringacceleration
18 Surgesyvhilecruising Unexpectedchange in engine speed which is 218.96
usually repetitive
19 Lack of power Performance
poor underload when throttlevalve 218-98
wide open
Maximumspeedreduced
20 Pooracceleration Pedormance poor while accelerating 218-101
21 Runs roughon deceleration/Eackfire Engine runs rough while deceleratingand abnormal 218-105
combustion occurs in exhaust system
22 Knocking Abnormal combustion accompanied by audible 2 1B - 1 0 7
'pinging'noise
23 Fuelodor Gasolineodor in cabin 1B-10s

24 Exhaustsulfursmell Exhaustgas smellsabnormal 2 18 - 1 1 0
25 Highoil consumption Oil consumotion excessive 218-110
26 Poorfueleconomv Fueleconomyunsatisfactory 218-111
27 A/C does not work Blower lan operates but magnetic clutch does not operate 2 1 8 - 1 1 3
tt
;l
l E M t s s l o N c o N T R o t - s Y d T E M r R o u B L E S H o o r NGGU I D E 21 8-65
I
. l
DESCRiPTION OF DRIVABILITY
'
. S T UM B L E : Mi l dj e rk i n gd u ri ;rga c c el erati on.

HE S I T A T i O N : F l a ts p o t o c c u rri n gj u s t afterthe accel eratorpedai i s depressed.
S URG E : C o n ti n u o u ss o ftj e rk i n gduri ngcrui se.
I E N G I N ES P E E D
II
No.18SURGE
No. 17 STUMBLE
-l
-/ l No. 17 HESITATION
-Z'
I;l
R U N SB O U G HO N
D E C E LE R ATI O N
g 2 10)6
H
#il
ffi
218.66 EMISSION CONTROL SYSTEM TROUBLESHOOTING
GUIDE
F U E LP U M P
PRECAUTION
.zl
FuelPressureRerease anc servicingFuerSystem
Fuelin the fuersystem,"r"in,
'.vhen.the unde-rhigh pressUr€ €Veq
engineii noi running.
a) Eeforedisconnecting any fiet rine,rereasethe fuerpres-
\ sure from the fuersysremto reduce
the possibiritycf
injuryor fire.
1. Staritheengine.
\---- 2. Pu.sh the rearseatcushionbuttonsand remove
F E A R S E A ' I ' C U S H I O N BurroN o the
cushion.
3. Disconnect the fuelpumpconnector.
4. Aiterrheenginesrarls, turnoff theignitiorr
5. Reconnecr switch.
!NSTALLCLAI.4PS the fuerpumpconnector and instailtherear
seatcushion.
b) Use a
i3g as a protectionfrom the fuerspraywhen dis.
connecting the hoses.
. .Plrgthe hosesaftera removat.
c/ when inspeciing the fuersystem,usea suitaore
suregauge. fuerpres-
(-) Caqtion
. I n s t a l lh o s e c l a m p s t o s e c u r e
o the fuel pressure
g a u g et.o t h e f u e l f i l t e ra n d t h e fuel
main hose to
preventa fuel leakage.
P i n c h i n gH o s e
Whenpinchingan air hoseor a fuel hose
- withpliers,wrap
thehosewitha rag to preventa damage.
EMISSION CONTROL SYSTEM TnoUBLESHooTIN
GGUIDE 214-67
S Y MP T o f v 1T R O UB L E S HO O T IN G
3n
z c tl A N K S N OA MA LLYB U T w l LL N OTS TA R T(N OcOl vl E U S ' l ' l ON )
)s- I
' fi ri nE '
cf | . E n g i n ec ra n k sa t n o rmasl peedbutshow sno si gnof
DE S CRIPl - . B a tte i
ry n n o rma l
c o n d i ti on
TION I .. Throftle valvenot heldlullyopenrvhilecranking(Dechokesystemnot operate)
F u e ii n ta n k
I
r T B o u BL E S t I O O T I NH GI N T S J
b" " aus eo f n o c o mb u s ti o np.o s s i b l n
v o tu eli s i nj ected
to engi neor no i E ni ti on
at al lcyi i nders
6) No spark O Low fuellinepressure
. lgnitioncontrclmalluncticn @ Lorvenginecornpression
. lgnitionsystemcomponentmalfunction
@ No fuelinjection
. Fuelpumpinoperative
i Injectorsinoperative
STEP INSPECTION ACT!ON
1 Check if strong blue spark is vislble at discon- Yes G o t o S t e p3
necied high-tensionlead
re
to
No Go to nextsteo
1p
2 Checkthat malfunctioncode is displayed Yes Mal functi onC odeN o. di spl ayed
on the SSTwithignitionswitchON Checklor cause(Relerto specified
checksequence)
SIGNALADAPTOR&
MOOULAR
WIREHARNESS
No Go to ne:l step
3 Connect diagnosisconnector terminalsFiP and Yes Check if engine starts in this condition
GNO with jumper wire and check for fuel pump
o p ' r a t i n g s o u n d w i t h i g n i t i o ns w i t c hO N c) lf starts.check circuit opening relay
Q l f d o e s n o t s t a r t ,g o t o S t e p 5
No Go to nexl step
---._..
218-68 E^TISSION CONTROL SYSTEM
TNOUBLESHOOTING
GUIDE
INSPECTION
Check if approx.12Vexists ACTION
af fuelpump con.
nector B/R urirervithignilion
switch'ON 9j.:.* .onrin,ry.G;;
(uetween terminalsg/H
a;rd B)
No I Checkcircuitopening
retay
Checklor injector
operating
sounOGil
cranking engine Go to step 7
Go to nexl step
it
9.!::.-wire rev
.apgrox. "*i"tffi
(W/R) wirh ignitionsrvirchO'n''- c.heck
vorrage
at PcMt.r.ffi
2V
check,oropencircuir
inurn! uilJffi
relay(FUELtNJ retay)anO
inilcror'
9:.T.:, diagnosis connector ter6;n3f,Sfr Yes Go to nen step

',":?:11iru.n:: wire anJ in..il'r.,.orrecr
fuel i
line pressurewith ignition
swircn-Oiv
Low pressure
fuet tinepressurewhile pinching
f["j- fuet return
c) lf.fuelline pressureq.uickly
' increases,
'--'-
^ .9!eckpressurereguiator
+ line press.ure-
graduailyincreases,
{juef
checkfor ctogg betweenfuelpump
pressure,.grr"'ito? and
ii3,t_.1:!ged, checkfuerpunrp
maxrmum pressure
High pressure
Checkif fuet relurnhose is clogged
or restricted
? flOK,leptacepressureregufator
c) lf not OK, repairor replace-
Checkfor correctengine
.orpr"Gi
Go to nextstep
E nginec om p re s s i o n: Checkenginecondition
932 k pa ( 9. 5k g /c m .,1 3 5 p s i )-3 0 0
rp m . piston, piston rings or
_YVo-rn cytinder walt
. Defective cyfinderhead gasXet
. Distortedcylinder head
. lmproper valve seating
. Valve sticking in guide
Check if alt spark ptggs
are oK
wEARANogAREor.r Go to nextstep
eurioue
PLrrc6APg- EURNS
,' il;l;]J;1.,_g D{rvrAGE
AND
caiial6tijoru Cleanor repface
€
- FOAMAGE
t" *n **rn good pCM and chetk ,,
.ono,,,on*Olr"r -
EMtssloNcoNTRoL SYSTEMrnouBLESHoorNG
GurDE 2 18 - 6 9
lI '
oe_scnre-l
TION
E:fl:;;l*;:l::'j:ii#"ed
B U T W I L L N O T S T A R T ( F A R T I A L C O M B U S T I C N )' - W H E N E N G I N EC O L D
CBANKSNORIvIALLY
pai a l c o m b u s t i o na n Cv r i l ln o t c o r : t i n r r el o r u n
onrv
butsho*s
-l I . F u e ti n ta n k
mixturetoo rich O L o w e n g i n ec o m p r e s s i o n
\ Y nirlFr"l
ln
. A i r c l e a n e re l e m e n lc l o g g e d
-l 6)
. Airflovrmster stuck
v AirlFuel
mixturetoo lean
. Fuel injeciioncontrol malfunclion
(Corrcctionfor coolant temperature)
. Low fuel line Pressure
. Air leakageof intake air systenr
l STEP
I
!NSPECT:ON
Check that malfunctioncode is displayedon
the SgT rvithignitionswitch ON
Yes
INSPECT!CN
Malfunction Code No. Cisplayed
Check lor cause (Re{erto s2ecifiecicheck sequence)
l I
WIRET.IARNESS
SIGNALAOAPTOR&
MOOULAR
No Go to nextstep
l
2 Check il strong blue spark is visible at each Yes Go to ne:l step
disconnectedhigh-tensionlead
I
l No Check distributorcap and rotor
l
J Connect diagnosis connector terminals F/P and Yes Go to nextstep
GND with jumper wire and check for correctfuel
line pressurewith ignitionswitch ON No Low pressure
C h e c k f u e l l i n e p r e s s u r ew h i l e p i n c h i n g
II Fuel line pressure : f u e l r e t u r nh o s e
2 6 5 - 3 1 4 k P a ( 2 . 7 - 3 . 2k g / c m r , 3 8 - a 6 p s i ) ci ll luel line pressurequickly increases.check
I pressure regulator
)
I O lf luel line pressuregraduallyincreases,check for
I clogging between fuel pump and pressure regulator

lf not clogged, check fuel pump maximum pressure
High pressure
Check if fuel return hose is clogged or restricted
c ) I t O K . r e p l a c ep r e s s u r er e g u l a t o r
c . i l l n o t O K , r e p a i ro r r e p l a c e
218-70 EMISSION CONTROL SYSTEM TROUBLESHOOTING
GUIDE
INSPECTION
ACTION
C h e c k i f P C I U t e r m i n a lv o t t a g e sa r e
OK Go to next steo
( E s p e c i a l t yf o r t e r i n a tN o . 1C . Z O
a n c !2 e )
No I Check for cause
A I
u n e c K t o r a t r l e a k a g eo f i n t a k e a i r
s y s t e n rc o m .
ponents Repairor replace
Go to next step
check if engir':estarts when water
rhermosensor Check v/ater lhermosensor
is disconnected
Go l o nextstep
Manuallycheckil airllowmeter
movessmoothty
from fullyclosedto fullyopen Go to nextstep
Checkfor correctenginecompression
Go to nextstep
Engtne compression : Check engine condition

932 kpa (9.5 kg/cm', 135 psi)-300
rpm . Worn piston,pistonringsor cylinder
wall
. Oefeclivecylinderheadgastet
' Dislortedcytindsrhead
Checkif attsparkplugsare OK
Go to nextstep
.
WEARAND CAREONEUILOUP
J EURNS
GAP gi-
PLUG
1 . 0 _ l . rl n m R : t q Cleanor replace
(o.o3e-o.o{3 ;61[€i DAMAGEAND
DETERIORATION
@i
\--l
i=-. oAMAGE
U
and check if condition improves

fl E M I S S I O N C O N T R O L S Y S T E M T R o T J B L E S H o o IG
NGUrDE 21B-71
IJ c R A N K S N O R M A L L Y B U T W I L L N O T S T A R T ( P A R T T A LC O M B U S T I O N -) A F T E n WARIII-UP
I
I E n g i n ec r a n k s a t n o r m a ls p e e d a n d s h o w s p a r l i a lc o m b u s t i o nb u t v r i l ln o i c o n i r i l u et o r u n a f t e r r u n n i n g
-l DE
E 5S\ C R I P and hot soakei I
I ION 8 a i i e r y i n q o r c r a lc c n d i t i o n I
-l' l E n g i n es t a r t s n o r m a l l yi v h e n c o l d .-1 t
TTROUB L E S H O O T I N GH I N T S I I
-1 I 6 n i t l f r . l m i x t u r ei o o r i c h (, Vaporlock I
. I n s u f f i c i e nftu e l i n i e c t i o nc o n t r o l . F u e l p r e s s u r en o i h e l d i n f u e l l i n e a l t e r e n g i n e s t o p p e d I
( C o r r e c t i , . rf n
o r c o o l a n tt e m p e r a t u r e ) . High RVP (vrinter)fuel used in \'.'armrveather i
. l n j e c t o rf u e l l e a k a g e @ Pressurereguratorccnl;cls)stem rrraliurrtbn I
INSPECTION ACTION
STEP
{
I Warm-upengineto normaioperatingtempera' Yes C h a n g e f u e l t o a n o i h e rb r a n d
I tureand stopit
ConnectdiagnosisconnectorterminalsF/Pand
I Gl.lOwithjumperwire lor 3 nrinuteswithignition

switchON, thencheckif enginestarts i.lo Go io ne:<tsiep
2 ConnectdiagnosisconnectorterminalsFIP and Yes Go to nextstep

GND withiumperwire and checkfor correctluel
linepressurewith ignitionswitchON
F u e ll i n ep r e s s u r e:
2 6 5 -3 1 4k P a (2 .7 -3 .2k g /c mr,3 8-46 psi )
No Low pressure
Check fuel line pressurewhile pinching
t u e l r e t u r nh o s e
4 lf fuel line pressurequicklyincreases,check Pressure
regulator
Q l f l u e l l i n e p r e s s u r eg r a d u a l l yi n c r e a s e s .c h e c k f u e l
l i n e a n d f i l t e rf o r c l o g g i n g
l f n o t c t o g g e d ,c h e c k l u e l p u m p m a x i m u m p r e s s u r e
H i g hp r e s s u r e
Checkif fuelreturnhoseis cloggedor restricted
c) lf not OK, repairor replace
J Remove vacuum hose from Pressureregula' Yes Go to step 5

tor and plug it. Check if luel line pressureis
held after ignitionswitch is turned OFF
Fuel !!ne pressure : More than 147 kPa

(1.5 kg/cmr,21 Psi) for 5 min.
No G o t o n e x ts l e p
21B-72 E M I S S T O NCONTROL SYSTEM
TRoUBLEsHooTING
GUIDE
INSPECTION
Plug.ouilel of pressure ACTION
regulator and check if
r u e rt r n cp r e s s u r ei s h e l d R e p l a c ep r e s s u r er e g u t a t o r
a f t e r i g n i t i o nswilch
is tr-rrned OFF
F uel line p re s s u re:

M or e t ha n 1 4 7 k p a (1 .5
k g y ' c mr,2 l p s i )
f or 5 m in
Check fuef pump holOpressu-
c) lf OK. check injector

for fuel leakage
c) !f nct OK, repface
fuef pump
Disconnectwater thermosenro,
checkil enginestarts .onnGl
Checkwaterlhermosensor
* ,;3^:,jl:::#:?"crions ofwarer
rhermosensor
and
+ [ r'to,OK. replacewater
thermosensor
No Go to nextstep
checkthatmatfunction
.o0.ffi
'v v'rvr(
SST with ignition switcn l!'lalfunction Code
Or.r- fVo.
Gheck for cause (Refer
to sp#ifiJO check sequence)
Go to nextstep
cleckifpcMr"r'ni*ffi
(Especiaryfor terminaf Go to nextstep
N;.-i;, ;;d ZO)
.!4
lir'.
Checklor cause
Tv wirhknowngoodpcrur
.no ;fr. I
rmProves "iffiiilr., ReplacepCM Ff,l
Changefuelto anotherbrand
H E M I S S I O N C O N T R O L S Y S T E M T f i O U B L E S H O O TGI N
UGIDE 218-73
l rl ;i
5 t'
.
DESCFIP' .
C R A N K S N O R M A L L Y B U T H A R D T O S T A T-
Engine cranks at normal speed but requiresexcessivecranking time before stariing

Battery in normal condition
'Rough
ALWAYS
Il
TION . E n g i n e r u n s n o r m a l l ya t i o l e [ i f i d l e c o n d i t i o nn o t O K . r e l e r t o i d i a "( N o s . 8 - 1 2 ) ]
n n o u a L E S H O O T I N GH I N T S I
it 'nirlFuel
. rnixttrretoo lean @ Air/Fuel mixture toc rich
-
F u e l m i x t u r et o o t e a n , A i r c l e a n e c e l e m e nct l o g g e d
lCorrectionfor coolant temperature) . Airtlourmeter stuck
. Lovr fuel iine pressure o ?oor ignitionspark
. Air leakage
srEPI INSPECTION INSPECTION

Checkthat malfunctioncodeis displayedon the '/es Malfunction Code No. disolaYed
I
SSTwith ignitionswitchON Check for cause (Refer to specifiedcheck sequence)
IJ ,,yr
Rs HARN
Essr{frfFit
t'o*^lb33AProR&
-lI il|\:J
No Go to nextstep
r-J I lml
I +q-
lecrrrl
h._J
| ffil
I IKJ'I
2 Checkfor correctintakemanifoldvacuumat idle Yes Go to nextsteo
V a c u u m: M o reth a n 4 5 0 mmH g(1 7.7InH g) No Checkfor air leakageof intakeair systemcomponents
3 C h e c k i f a i r c l e a n e re l e m e n ti s c l e a n Yes Go to nextstep
4 Check il engine starts easily when throttle valvo Yes Check throttle valve for carbon deposit and then go to
is quarteropen Step 6
No Go to nextstep
5 Check lor correct fuel line pressureat idle Yes Go to nextstep
Fuelllne pressure:
265-314 kPa (2.7-3.2kg/cmt, 38-a6 psi)
( V i . r c u u mh o s e l o p r e s s u r e r e g u l a t o r d l s - No Low pressure
connected) Check fuel line pressurewhile pinching fuel return hose
O lf fuel line pressurequickly increases,check

INSTALL CLAMPS pressure regulator
4 l f f u e l l i n e p r e s s u r eg r a d u a l l yi n c r e a s e s c. h e c k l o r
c l o g g i n gb e t e w e e nf u e l p u m p a n d p r e s s u r er e g u l a t o r
l f n o t c l o g g e d ,c h e c k f u e l p u m p m a x i m u m p r e s s u r e
218-74 EMlssto.NcoNTRoL sysrEM rRouBLESHoorNG
GUrDE
INSPECTION
ACTION
lo D i s c o n n e c lI S C v a t v ec o n n e c t o ra t i d l e a n d
G o t o f r e x !s t e p
c i r e c k i i e n g i n es p e e d i n c r e a s e s
Checkif PCM terminalvottaqes are Ol( Go to nextstep

( E s pec ially
f o r te rmi n aNt o . 1 C ,Z O a n d 2 0 )
No I Check for cause
Connect diagnosis connector terminalsFtp and Check circuit opening retay

GNO rvith jumper vrire and check if engine starts
c) lf relay OK, repair or reptace wire
harness
O lf relay not OK. replace relay
Go to nextstep
9 | Checkfor correctignitiontimingat idleafter Go to nextstep

warm.up
I
t g n i t i o nt i m i n g( B T D C ) :7 . t l . I
10 Check for correct engine compression

| Go to nextstep
Engine compression (Minimum):
. piston, piston rings or cylinder wall
9 3 2 k P a ( 9 . 5 k g / c m ' , 1 3 5 p s i ) - 3 0 0r p m lVorn
. Defectivecylinder head gasket
. Distortedcylinder head
. lmpioper valve seating
, Valve sticking in guide
11 rny wirh knovrn,good pcM and check if conditionimproves

|
EMISSION CONTROL SYSTEM TaoUELESHooTIN
GGUTDE 218-75
C R A N K S N O R M A L L YB U T H A B D T O S T A R T _ W H E N E N G I N E C O L D
E n g i n e c r a n k s a t n o r m a l s p e e d b u t requiresexcessivecranking time before starting
DESCRIP. Battery in normal condition
TION Restarts OK after v/arm-up
Engine runs normattyat idle ftf idte conditi O K f e r t o " R o u g h i d l ( N os. 8 - 1 2 ) l
rrBoUr/Fuet
B L E S H O O T T N GH I N T S I
oAi mixture
Airflow meter sticking
too rich ,o AirlFvelmixture too lean
. Fuel injectionconlrol malfunction
A i r c l e a n e re l e r n e n tc l o g g e d (Correctionfor coolant temperature)
a ldle speed control maliunction
o Poor atomization
. Low RVP (summer) fuel is used in cold weather
STEP I N SP E C T I O N INSPECTION
1 Checkthatmallunction codeis displayedon the Yes Malfunction Code No. displayed
SST withignitionswitchON C h e c k f o r c a u s e ( R e l e r t o s p e c i f i e dc h e c k s e q u e n c e )
''o\ibllebroia
wrRExon*ess.{if l-0i-iL
--til ln'lj, No Go to nextsl ep
f:r llffil
+a llffil
I I KJ-1
t"ct',J
2 Checkif ECUterminalvoltages are OK Yes Go to nextstep

(Especially
for terminatNo. 1C, ZO,and 2e)
No Checklor cause
3 Checkil engineslarts easilywhen throttlevalve \?s Check if ISC valve is OK
is quarteropen c? It OK, check air valve
Q lf not OK. replace ISC valve
No Go to nextstep
4 Check for correct intake manifoldvacuum at idle Yes Go to nextstep
Vacuum : More than 450 mmHg (12.7inHg)

No Check for air leakage ol intake air system components
5 Check if air cleaner element is clean Yes Go to nextstep
6 DisconnectISC valve connector at idle and Yes Go to next step

c h e c k i f e n g i n es p e e d i n c r e a s e s
ISC VALVE
218-76 EMISSIONCONTROL SYSTEM rReuBLESHoolNG
GutDE
STEP INSPECTIQN
ACTION
C o n n e c t d i a E n o s i sc c n n e c t o rt e r m i n a l sF t p a n d
Go to next step
GND rvithjumper rvire and check for cor;ect fuel
line pressurervith igniticn switch ON
Low pressure
Check fuel line pressure wlrile pinching fuel
relurn hose
Fuel line pressure : Q lf fuel line pressure quickly increases. check
2 6 5 - 3 1 4 k P a ( Z . Z - 3 . 2 k g y ' c m r , 3 S _ 4 6p s i ) pressure regulator
Q lf fuel line pressure gradually increases, check
fuet
line for clogging between fuel pump arrd pressure
regulator
ll not clogged. check fuet pump maximum pressure
High pressure
Checkil luel relurnhoseis ctoggedor restricted
cC ll OK. replacepressureregulator
Q lf not OK. repairor replacehose
Try rvithknowngood pCM and checkif condition

ReplacePCM
im pr ov es
Change fuel to another brand
EMISSIONCONTROL SYSTEM rfiouBLESHoorrNG
GutDE 218-77
-l C R A N K S N O R M A L L YB I ' T H A R D T O S T A R T _ A F T E R W A R M . U P
J . Engine cranks at normal speed but requires excessive cranKingtime before startingalter running and hot
II soaked
. Battery in normal condition
l . Engin6 starts normallywhen cold
I
I . Enoineruns at idlelif idleconditionnr.rtOK. referto 'Roughidle' (No.8- 12)l
I
I
I @ Vaporlock
I
. ruet
a pressuro
Fuelpressur€notnets
norheldIn
in ruet
fuelltne
lineatler
aft enQlnestoppe,J
. lnjactor fuel leakage o High RVP (winterifuelusedin warm*eather
Pressureregulatorcontrolsystemmatfunction
l
1 Checkthat malfunctioncode is displayedon the Yes Malfunction Code No. disolaved
SST with ignitionswitchON Check for cause (Refer to specifiedcheck sequence)
$oîibSSAProR&'
wrRExnnNess-fl ior0i-[-,
-fl| lo- #-'
.{r"!ll r
f-] No Go to nextstep
I tL-Jl
I r ',-r-.,t
| | im1
J
I ts+
ecul
| tEJ
I lKr'l
I f
J L___i
2 Removevacuumhose lrom pressur€regulator Yes Checkpressureregulatorcontrolsystem

and plughose.
Checkif enginestartsnormally No Go to nextstep
3 Checkif PCM terminalvoltages are OK Yes Go to nextstep

(Especialty
for terminalNo. 1C,20,20)
No Check for cause
4 Run engineat ldle and checkil fuel line pres- Yes Go to nextstep
sureis held afterignitionswitchturnedOFF
Fueffine pressure: Morethan 147 kPa

(1.5kg/cmr,.21 psi) for 5 min
No Plugoutletof pressureregulatorandcheckil fuelline

pressureis heldafterignitionswitchturnedOFF
a lf OK. replacepressureregulator
c) ll not OK. checkfuelpumpholdpressure
lf fuelpumpis OK. checkinjectors
for luel leakage
218-78 EMISSION CONTROL
SYSTEM TROUBLESHOOTING
GUIDE
STEP I N S PE C T I O N
Vlerm-up enginc to normal ACTION
o p e r a t i n gi e m p e r a -
i u r e a n r Js t o p i l Yes C h a n g ef u e l . t oa n o l h e r
brand
9: . T o: , c l i a g n o s icso n n e c tore
r rmi n a lF/p
s and
G ND withj u m p e rrv i refo r : .i " rre s
rv i thi gni ti on
sr.ritchON. then checkif engine
sfarrseasily
--__
Go to next step
knorvn
goodpcMand.h".t.Glilfi
!11itn
rmproves Replace pCM
C h a n g el u e l t o a n o l h e rf r r a n J
'
..
EI\lISSIONCONTROL SYSTEM TFoUBLESHooTIN
GGUIDE 218-79
-1
I
I
I
DEScRIP'I
. Engine
startsnorrnalty
butstallsorvibrates
excessivety
R O U G H I D L 9 E T . I G I I i ES T A L L S A T I D L E _ . A I - W A Y S
ai idtein every.oncil
TioN I
I
I TTBoUBLESHOOTING HINTSJ
@ e i r t F u e lm i x t u r et o o l e a n
I . Air leakage
O I n c o r r e c ti d t e s p e e d
. ldle speed misadju*stment
II . F u e l i n j e c t i o nc o n t r c l m a l f u n c t i o n
. Low fuelline pressure
o o n e o r m o r e r n j e c t o r sc l o g g e do r n o t o p e r a t i n q
@ L o w i n t a k ea i r m o u n t
. t d l e s p e e d c o n t r o lm a l f u n ? t i o t -t - . . _ .
A One or moresparkptugsnot fi ri ng
@ Lovrengi necompressi on
@ Airfto'gmeterstuck
I SlEr
i
Yes ^-trnc,tr" code N o:
Checkfor carrse(Referto specifiedchecksequence)
r'"^llbSSAProR&
I -Ltth--#-
wrREHnnruessJffiil-tL
rr-l
l ll I
I
(gJJ
lFFSrl
No G o t o n e x ts t e p
l ++
leo"rl
h_J
|I lffil
-l-?-r-r
2 Checkif ECUterminalvoltagesare OK Yes Go to next step

( E s p e c i a l lfo
y r te rm i n aNl o .2 D .2 0 a nd20)
No Check for cause
J Disconnecthigh-tensionlead at idle and check if Yes Go to Step 8

engine speed decreases equally at each cylinder
No Go to nextstep
'4
Checklor injectoroperatingsoundat idle Yes Go to S tep6
No Go to S tep5
5 Checkif approx.12V existsat injectorsconnector Yes Check if injectorresistanceis OK

(WR) wire
R e s i s t a n c e: A p p r o r . 1 2 - 1 6 0
ca It OK, check wiring between pCM and injector

c) lf not OK. replace injector
No Check wiring beNveenPCM and injector
6 Check if strong blue spark visible at disconnect- Yes Go to next step

ed high-lensionlead
No C h e c k h i g h - t e n s i o nl e a d
..f,
' 3{_!
c + l f O K . c h e c k O i s rf i U u t o c, a p a n d r o t o r
tY:
..+i Q l l n o t O K , r e p l a c eh i g h - t e n s i o nl e a d
;-..:
.r#
'.tr
€\'
*-r
tar. 1
rg.l
-:.il
1ti I
f,n
,,ir:;
4*?
- l
il
,l
I 218-80 EMISSION CONTROL SYSTEM
I TNOUBLESHOOTING
GUIOE
STEP INSPECTION
Checkil sparkptugsare OK ACTION
Yes Check for correct engine compression
BURNS A lf OK. reptaceinjecror

PLUGGAP
1 . 0 -l . l m r n c) lf not OK. checkfor
DAIv{AGEAND cause
(0.039-0.O13inl DETERTORATION
DAITAGE
Clean or replace
I Checklor correclfuel line pressure

I at idle Go to next step
Fuel line pressure:
265-314 kpa (2.7-3.2 kg/cmr,38_48psi) Low pressure
(Vacuumhose to pressure regulator Checkfuel tinepressurewhilepinching
disconnected) fuel retumhose
c) lf fuel line pressurequickly
INSTALL CLAMPS increases,check
pressureregulator
Q if fuel iine pressuregraduafiyi;rcreases,
checklor
cloggingbetweenfuel.pumpand
pressureregulator
ll not clogged,checktuefpump-riaximum
pressure
Manuatlycheckil airflorrrn"tuiroils
smoothty Go to nextstep
from futlyctosedto fuilyopen
Repairor replace
Checklor air leakageal intakeair

systemcom- Repairor replace
ponenls
Go to nextstep
Checklor correctengine
"ornp*ion Go to nextstep
E 19in: c om p re s s l o n(M i n i m u m )
:
932 kpa (9.5kg/cmr,135 psi|5OO
rpm
Checkfor cause
Check for correct ignition timing at idle

-w_arm-up after Try with known good pCM and check
if condition
rmproves
l g n i t i o nt i m i n g( B T D C )i 7 . t 1 .
Adjustignitionriming
E M I S S I O N C O N T R O L S Y S T E T VTI R O U 3 L E S H O O TGI N
UGIDE 2 1B - 8 1
S T A L L SA T I D L E -
I
R O U G HI D L E / E N G I N E B E F O H EW A R l v l - U P I
[ r F O UBL E S H O O T I NH G! N T S J
C Lowin ta k sa i ra m o u n t @ L o r v l u e l i n j e c t i o nc o n l r o l
. A id l o wm e te rs tu c k . Fuel injectior': control mallunction
. A ir c l e a n eer l e m e nct l o g g e d ( C o r r e c t i o nf o r c o o l a n i t e m p e r a t u r e )
. A ir v a l v e o Poor atomization
. L o w R V P ( s u m m e r )f u e l u s e d i n c o l d w e a i h e r
INSPECTION ACTION
Check that malfunctioncode is displayedon the Malfunctlon Code No. displayed

SST ignitionswitch ON Check for cause (Refer to specified
checksequence)
SIGNAL AOAPTCR&
MOOULAR
',VIRE|{ARNSSS
No Go to nextstep
Check lor correct intake manilold vacuum al Go to nelrt step

idle after warn-up
Vacuum : More than 450 mmHg F7.7 InHg)
Check lor air leakage of intake air system com-

ponenls
Checkif aircleanerelementis clean Go to nextstep
Replace air cleaner element
Check if PCM terminalvoltagesare OK Go to nen step

(Especiallyfor lerminal No. 20. 20 and 2Q)
Checkforcause
DisconnectISC valve conneclorand check if Go to nexl step

engine speed increases after warm-up
R e p l a c eI S C v a l v e
.v\
..:::,.
Jf.
_:1=
;j+i
.t.;:
218-82 E M l s s l o N c o N T R o L s y s T E M r R o u B L E S H o o rG
NUGI D E
STEP INSPECTION
ACTION
C h e c k f o r c o r r e c ! r . r a t e rt h e r m o s e n s o rr e s i s r a n c e Go to ncxt
RESISTANCE
(kil)
?0
t0
7
5
3
2 R e p l a c er v a t e rt h e r m o s e n s o r
I
o7
05
o3
o.2
O40OO
(32)
(r04) 1176)
COOIJNT TEMPERATURE ET F)
Connectthe SST tc pCM antj set tlrefunction Y es I Gc to nextsl ep

s e i e c t o ' i G N I T E RC H E C I ( ' w h e ne n g i n ei s c o t d .
Chec kif eng i n es p e e dd e c re a s e sa s e n g i n s
war m sup
SlGirALAOAPTORE
MOOULAR
C heckai r val ve
W I R EH A R N E S S
Checkfor correctignitiontimingat idtealter

I V., Go to nextstep
warm-up
l g n i t i o nt i m i n g ( B T D C ): t ' ! , 1 .
Try with knowngood pCM and checkif condition R epl aceP C M

r m pr ov es
C h a n g e f u e l t o a n o l h e rb r a n d
EMISSION CONTROL SYSTEM TnoUBLESHooTIN
GGUIDE 21B-83
<
-l 10 | . R o u c H T D L E J E N G i NsET A L L S A T I D L E - AFTERwARt4-up
I I
DESCRIP' E n g i n e r u n s n o r m a l l ya t i d i e d u r i n gw a r m - u pb u l e n g i n e s t a l l so : ' v i b r a t e se x c e s s i ' r e l ya f t e rw i r r m . u p
TION
r R o u B L E S H O O T I NH GI N T S J
h ldles p e e dc o n trosl y s te mma l fu n c ti o n o AirlFuelmixture too rich
\? eirtFuelmixturetoo lean
7s . F u e l i n j e c t i o nc o n t r o lm a l f u n c t i o n
, Air leakage ( C o r r e c t i o nf o r c o o l a n tt e m o e r a t u r e )
. Lowfu e ll i n ep re s s u re o Poor ignition
o Lorv engine colnpression
STEP INSFECTION ACTION
1 Check that malfunctioncocjers displayedon the Yes M a l f u n c t i o nC o d e N o . d i s p l a y e J

SST ignitionswitch CN C h e c k f o r c a u s e ( R e f e rt o s p e c i f i e dc h e c k s e q u e n c e )
S|o*nbffiAProR&
wrne
xenr,ress-d70-Tb
lg=J No Go to nextstep
ll I
F
-
|ffi|
|
I
lu-:-lJl
IKJ'1
lno.rl
t_J
2 Checkif PCM terminalvoltagesareOK Yes Go to nextstep

( E s p e c i a ll o
y r 2 D ,2 0 a n d2 0 )
No Checkfor cause
3 high-tension
Disconnect leadat idleand checkif Yes Go to nerl step
enginespeeddecreasesequallyat all cylinders
No G o t o S t e p1 0
A
Check for correct intake manifold vacuum at idle Yes Go to nextstep
V a c u u m : M o r e t h a n 4 5 0 m m H g ( 1 7 . 7i n H g )
No Check for air leakage of intake air system components
5 C h e c k i f a i r c l e a n e r e l e m e n ti s c l e a n Yes Go to next step
o DisconnectISC valve connectorat idle and Yes Go to next slep

check il engine speed increases
--=-qR\ No R e p l a c eI S C v a l v e
zA\11
'lJL t^-*.
\ ./ t; --6€or
Y
{-/
'H)'v/
-tV
x6K:
(}(se4vAwE
218-84 E M I S S I O N C O N T R O L S Y S T E M T R O U B L E S H O O TGI N
UGIDE
STEP IN SP EC T IO N
ACTION
C h e c k f o r c o r r e c tw a l e r l h e r m o s e n s o rr e s i s t a n c e
Go to next step
No Low pressure
F u e ll i n e p r e s s u r e: chcck fuellinepressurewhirepinchingfuetreturnhose
265- 3 1 4k Pa (2 .7 -3 .2k g y ' c m r,3 8 _ apsi6 )
( V ac u u mh o s e l o p re s s u rere g u l a tor c) ll fuellrnepressurequicklyincreases.
disconnected) check
pressureregulator
INSTALLCLAMPS Q ll fuellinepressuregraduallyincreases.checklor
cloggingbeiweenluel pumpand pressureregulator
ll not clogged.checkfuel pump maximumprJr.uru
Checkfor correctignitiontimingat idleafter Go to nextstep

war m . u p
l g n i t i o nt i m i n g( B T D C|) 7 ' t 1 .
Adjustignitionsystem
Disconnect water thermosensorconnectorand Replace water thermosensor

check if engine conditionimproves
Trywith knowngoodpCM and checkif condition
Check for injector operatingsound at idle

Go to nextstep
Checkif injectorresistance
is OK
Resistance : 1 2 - 1 60
c) lf OK. checkwiringbetweenpCM and injector
O ll not OK. replaceinjector
Checkfor correclenginecompression
Go to nextstep
E nginec o mp re s s l o n(Mi n i mu m):

932 kPa (9.5 kg/cmr,135 psi)-300rpm
Check if strong blue spark is visible at discon. Go to ne:l step

n e c t e d h i g h - t e n s i o nl e a d
Check high-tensionlead
c ) I t O K , c h e c k d i s t r i b u t o cr a p a n d r o t o r
Q l f n o t O K , r e p l a c eh i g h - t e n s i o nl e a d
Check if sparkplugsare OK Try with known good PCM and check it condition
improves
il
. i:l!l
-f,
EMISSION CONTROL SYSTEM THoUEjLESHooTING
G1IDE 21 B-85
l ial
':*l
11
frffi-Trl^l
R O U G H T O L F J E N G T NSET A L L S A T I D L E -
Engine stalls or vibratesexcessivelyat idle when A/C, P/S. or UL ON

A/C. P/S, headlights.blower lan and electriccooling fan operate normally
ldle conditionis normalrzhen A/C. P/S, and UL is OFF
V/HEN4/C, P/S,OR E/L ON
,s,l r r Rou E LE SH O OT IN H
GIN T S I
*?l ln tate controlsystemmallunction
spee.C
*l *v
. Eq4inespeedleedbackcontrolinoperative
.Fl
:.€"1
'r" c -(EP INSPECTICN ACTION
I
trtl -Check Yes Mallunction Code No. displayed
t' that mallunction code is displayed on the
. rl.t SST with ignition switch ON Check lor cause (Refer to specihedcheck sequence)
.l
3f SIGNALAOAPTOR&
MQOUI-AR
WIRE HARNESS
r3f No Go to nextstep
:.'*'l
,'if
I
j
2 by the
Checkswitcheslor correctoPeration Yes Go to ne:l step
SST with ignitionswitchON
I
I SIGNALAOAPTOR&
MOOUIJR
WIREHARNESS
No Checklor cause(Referto specifiedchecksequence)
3 Checkil PCMterminal1K voltageis OK Yes Try with knowngood PCM and checkil condition
improves
Vo l ta g e: Ap p ro r. 1 2 V(a ti d l e )
No Check for short circuit in wiring between diagnosis

1K (LC1^/) connectorlerminal test and ground
21E}-86 EMISSION CONTROL SYSTEM
T R O U B L E S H O O TGI N
UGIDE
i''. ROUGHIDLSENGINESTALLS
f oesceLe ngine starts normall.rbrr vrhr:rrn.^-^-;::l',:-.----

i TION
[ T R o U BL E S H O O T t N G
o F uelinjec t io n c o n tro rs y s te m
o r i d res p e e cci o nrrol
syslem mallunction ldlespeed misadjustment
. Start signat not input to pCM lgnition timing misadjustment
i
STEP INSPECTIOI.I
Checkthatmaflunction A C TION
code is displayedon the Yes
SST with ignitionswitchON Malfunction Code No. displaved
Check for cause (Refer ro ,-p"iriJo
check sequence)
SIGNALAOAPTOR&
MOOULAR
No
I Go to nextsi ep
C h e c k i f P C M t e r m i n a tv o t t a g e s. r u
Of Go to nexl step
( E s p e c i a t l yf o r 1 N )
Check for cause
Check for correct ignition tirningat

idle affer ln sameconditiona-sg,op 3.inspectiol,
v/arrn-uP
brakeand checkfor corrccttOfe-s-peeoapptyparking
ldle speed : 750 -F 50 rpm
l g n i t i o nt i m i n g( B T D C ) :7 o + 1 o ? lf!lOf,po ronextsrep
c) not OK. adjustidlespeed
Checkcontinuitybetweenthrotilesensor
t er m inalsI D La n d E Go to nextstep
Clearance behveen throttte

lever and stopper Continuity
0.1 mm (0.00nin) Yes

MlT
1 . 0m m ( 0 . 0 3 9i n ) NO
0 . 1 m m ( 0 . 0 0 ri n ) Yes
MI
0 . 6 m m ( 0 . 0 2 ri n ) NO
T q yw i t h k n o v r ng o o d p C M
a n d c h e c k i l c o n d i t i o ni m p r o v e s
EMISSION CONTROL SYSTEM TRoUBLESHooTING.GUIDE 214-87
'' 3 '[-- H I G HI D L E S P E E D A F T E R W A R M . U P
: '
Or:;Cf|Prui
_.1 f r R o U B L E S H o o ' l ' l NG H I N T S I
I L x c e s s i v ei n t a k e a i r s u p p l i e dt o e n g i n e
6) Throttlevalve not fully closed . I S C v a l v e c o n n e c t o rd i s c o n n e c t e d
I 6 l d l e s p e e d c o n t r o lm a l t u n c l i e n
. Air valvenot closed
' . N C , P / S , o r A L s i g n a ls e n t t o P C M
. I n c o r r e c tc o o l a n l t e m p e r a t u r es i g n a l
lI STEP
1
. ISC valvesiuck
INSPECTION
Checkif thiottlevalveis fullyclosedwhen Yes Go to S tep3
ACTION
I ac c e l e ra torer l e a s e d
No Check if throttle linkage is correctlyinstalledand
I 6};r#{|ir o p e r a t e sl r e e l y
I
ffi"
c) lf OK. go to Step 2
c) lf not OK. clean. adjust or replace
-{ I linkage
I
I
/
/ . FULLYCLOSEO
2 Check if dashpot is correctlyadjusted Yes Check if throttlevalve is contaminated

I
I
I Q l f c o n t a m i n a t e d c. l e a n t h r o t t t eb o d y
.l
I Q l f n o t c o n t a m i n a t e d r. e p l a c et h r o t t l e
body
_j Dashpotset soeed :
Approx. 3,000 rpm
l" No Adjust
I
-l
I
I
on the Yes Mal functi onC ode N o. di spl ay' ed
C heckfor cause(R eferto speci fi ed chec ksequence)
II SIGNALAOAPTOR&
MODULAR
I
I
I
WIREHARNESS
No Go to nextstep
IJ
I
I
I 4 Checkswitchesfor correcloperationby the Yes Go to nextstep
I
.at
I
--{
I
I
I
SIGNAL AOAPTOR&
MOOULAR
W I R EH A R N E S S
,I
I No C h e c k l o r c a u s e ( R e f e r t o s p e c i l i e dc h e c k s e q u e n c e )
I
I
I
-l
I J C h e c k i f P C M t e r m i n a lv o l t a g e sa r e O K Yes Try with known good PCM and check if condition
t. (Especiallylor terminal No. 20) improves
J
No C i r e c kf c r c a u s e
218-88
YSTEM TRoUBLESHooTING
GUIDE
s
-'.-
I
I
INSPECTTON I
ACTION I
C o n n e c l r l r eS S T t o p C M a n d s e t t h e f u n c t i o n I
Yes Go to next step
s e l e c tt o ' I G N I T E R C H E C K . w h e n e n g i n e . i s :
cold
Check if engine speed decreases as engine i
warrns up -i
I
I
I
,
SIGNALAOAPTOR& I
MOOULAR
V/IRE HA.RNESS
Check air valve
DisconnectISC vatveconnectorit iOleanO

checkil idlespeedincreases Go to nexl step
CheckISC vatve
PinchPCV hose with pliersanOchecf

if engine
s peeddec re a s e s
Go to nextstep
Checkit pcM rerminalvoltage

(Especiafly TrywithknowngoodpcM and;;ffilEi*
for terminatNo. iD. "*F
20 and 2e) lmproves
Checkfor cause
ss
E f u l I S S I O NC O N T R O L S Y S T E M T n o U B L E S H O O T IGNUGI D E 21B-89
'5.1
-,l
t','l
a
'i l'+- I D L E M O V E SU P A N D D O V / N / I D L EH U N T I N G I
I
i
a
-'-
': i E"rr" t@"tl"dl.r,ly I
DECffipN ",',d|e
i r n o u a u E S H o o l N GH I N T S I
( b u i l ti n t h r o t t l es e n s o r )O F F a t i d l e
O ldleswitch
@ Air leakage
@ F u e l i n j e c t i o na m o u n t i n c c n s t a n t
. Poor contact point inside airflow meter
@ P oorignition
srEPI INSPECTION ACTION

{ I Check that malfunctioncode is displayedon the Yes M a l f u n c t i o nC o d e N o . d i s p l a y e d
SST with ignitionswitch ON C h e c k f o r c a r r s e( R e f e r t o s p e c i f i e dc h e c k s e q u e n c e )
SlGNALAOAPTOR&
MODUIJR
WIREHARNESS
No Go to nelit step
2 Checkfor conectintakemanifoldvacuumat idle Yes Go to nen steP
I n ta k ema n l fo l dv a c u u m:
Mo reth a n 4 5 0 m m H g (1 7 .7In H g) No Low vacuum
Check lor air leakage at intake air system
3 Checkif air cleanerelementis clean Yes Go to nexlstep
No Replace aii' cleaner element
4 leadat idleand checkif

Disconnecthigh-tension Yes Go to nextsteP
enginespeeddecreasesequaltyat eachcylinder
No Go to Step9
5 Checkif PCMterminalvoltagesare OK Yes Go to nerl step
No Check for cause
6 Check lor correct ignitiontiming at idle alter Yes Go to nextstep

warm-up
l g n i t i o nt i m i n g ( B T O C ) : 7 ot 1o
No
2 1B - 9 0 E M I S S I O NC O N T R O LS Y S T E MT R O U B L E S H O O T I N G
GUIDE
STEP
i INSFECTIOIi
ACTION
Try r..'ilhLno,,..,n pct"1
,3JC
G o i o n e x ls i e p
C h e c k i f a i r f l o r vm e t e r i s O K
Go toSiep1a
R e p l a c ea : r f l o r .rrn e t e r
Checkfo'inlectorffi
Yes Go to Stepi 1
No Go to nextStep
Che_ck ii approx. ' " t2V

' € v sexists r,t linffi
^rJt> d nJeclor cOnneclor
( \ r , / r , R ), , . ; i r e Yes C h e c k i i i : r j e c i o rr e s i s l a n c ci s
I OK
R e s i s t a n c e :1 2 - 1 5 e
A l i O K , c h e c k r v i r i n gb e t v r e e np C M
'
4 lf not OK. repface'injectoi-" v'' and injector
Checkrviring pcpr
between
C h e c k i f s t r o nr g -b. Yt vu e esFp, qar ^r k ri )s
"noffi
vv t i5st ( iJ b
l g t ea
a[ ] | res
Yo^
d i s c o n n e c i e dh i g h - t e n s i o n
read G o t o n e x ts t e p
I
C h e c k h i g h . t e n s i o nr e a d
c) l f OK ,checkdi stri butor

cap and rotor
c) l f not OK , repl acehi gh-tensi on
l ead
12 C h e c ki f s o a r kp t u g s, r . O K
|
C heckfor correctengi ne.o.pru.ri on
Compression
( M i n i m u m :)
WEARAN C A R S O NE U | L O U P 9 3 2k i r a ( 9 . 5k g / c m r 1
, 3 5p s i ) - 3 0 0r p m
EURNS
P L U GG A P c x l f O K ,g o t o n e x ts t e p
I C-l.t riril
( C0 3 9 - 0 . 0 : 3i n ) -OAMAG= ANO ; C l l n c t C K , c h e c kf o i . c a u s e
\ O=T=RIORATIO.\J
'
f\ . t a A-
- vnrvr/-\\)=
C l e a no r r e p l a c e
C h e c k f o r i n j e c t o rl e a k a g e
Yes I Repiace
injecrcr
G o l o n e x ts t e p
14 t o v r ir hk nowng o o c ,'
J cM a n c ,c h e c ki r c c n d i ti on
I i mproves
E M I S S I O N . C O N T R O L S Y S T E M T R O U B L E S H O O TGI N
UGIDE 2 1B - 9 1
--l
E N G I N ES T A L L S O N O S C E L E R A II O N
I eco'mn |
.
[?:,ff":ffi#::i"jy
sropsrunnins or afrerdeceleraticn
whiledecelerarins
-l
I I
I
T fR o U a L E S H O o T I NH
GI N T S I
Lngines p e e dC ro p sto o m u c hw h e n;e l e a si ng or poorconnector
accel erator di sconnected
connec:i on by dec eler at ion
O l d l e s p e e d c o n t r o lm a l l u n c t i o n ' : O ldle speed misadiustment

I 6 Fref cut conttol .alfffi
INSPECTION ACTION
Check if idle conditionis normal v*To*ttp
ngo.3- 11 'RCUG H
A dj ustor pedormtroubl eshooti N
IOLE'
Check that rnalfr:nctio;r

code is CisplayeCcn the Yes MalfunctionCode No. dlsPlaYcd
SST with ignitionswitch ON C h e c k l o r c a u s e ( H e i e r t o s p e c i f i e dc h e c k s e q u e n c e )
Go to next steP
Check switches for correct operationwith the Go to nextstep

WIREHARNES
Check for cause

(Refer to specifiedcheck sequence)
Checkif PCM terminalvoltagesare OK Go to nextslep

( E s p e c i a l loyr t e r m i n aNl o .1 V 2 D , 2 0 , 2 U , 2 V
a n d2 Q ) Check forcause
Check for poor connectionol lollowingparts Fepair or replace

. lgnitioncoil
. lgniter
. Distributor
. H i g h - t e n s i o nl e a d Go to nextstep
. lnjector
. Circuit opening relay
I
. PCM
I
I
I
I
I
_J
218-92 enhssroNcoNTRoLsysrEM rRouBLEsHoorNG
GU'DE
INSPECTION
ACTION
6 | C h e c k i f d a s h p o t i s c o r r e c t l ya d j u s t e d
Go to next step
D a s h p o ts e t s p e e d:
A ppr ox . 3 ,0 0 0rp m -- __-
Adjustdashpot
Disconnect
tsc vatve.onn..toEffiil
check if engine speed increases Go to next step
ReptaceISC valve
rsc VALVE
Trywithknow-n
goodPCMand.n""ffi
E M I S S I O NC O N T R O LS Y S T E Mr n o u B L E S H o o r t N
GGUrDE
'1E E N G T N ES T A L L S S l . ' O D E N L Y( I N T E R M I T T E N T )
l , Engino intermittentlyetops running
EfrTg.^l . Betore staliing,engine ccndition OK
T T F O UB L E SH oI ol N ti F l l NI 5 J
no sparkor no fuelinjectioncausedby vehiclevibration, or deceleration
acceleration.
b lntermittently
. Poorconnection in wireharness
l
I I
_1
INSPECTION
Checkthat mallunctioncode'isdisplayedon the I Yes
SST rvithignitionswitchON
ACTION
Malfunction Code No. displayed
Check for cause (Reler to specifiedcheck sequence
I
SIGNALAOAFTOR&
MOOULAR
No Go to nextstep
-2 Chcckfor poor connectionof followingparts Yes Repairor replace

. lgnition'coil
. lgniter
. Distributor
. High-tension lead' No Go lo nextstep
. Injector
. Circuitopeningrelay
. PC M
3 Checkit ECU terminalvoltages are OK Yes Go to Troubleshooting
No. 2
.CRANKSNORMALLYBUT WILL NOTSTART
(Especiallylg(terminalNo. 1B,2A,28 and 2C)
(NO COMBUSTION)'
No Check lor cause
_:_
T N O U B L E S H O O TG
I NUGI D E
r-iESTTATES
/ STUMBLES
oN acEGqrronr
F l a t s p c t o c c u r s y u s ta f t e r a c c e l e r a t o
[ r R o u I L E S H O O T t THcr r u r
e il'rn,"n."depressins
accereraror
1',lf::H:lyl:
. ?:::l"imalfuncrion
injeclioncontrol I
lJ.l
(Correctionlor accelerating
. Air leakage "onOitionl
. Fuelline pressuredecreases
. Sparkadvanceconlrolmalftinction
INSPECTION
Check that matfunctioncode is
O;splayeOon the Yes MalfunctionCode No. disptayed
SST with ignitionswircir ON
Check lor cause (Refer to ,b..ifi"O
check sequence)
SIGNAL ADAPTOR&
MODULJqR
WIRE H/.RNESS
Go to nextsteo
-
Go to nurtrt"p-----
Vacuum: More than 450 mmHg
( 1 7 . 2i n H g )
Check lor air leakage int"
"t
Check if air cleaner element is
ctean Go to nextstep
R e p l a c ea i r c l e a n e r e l e m e n t
checkifpcMt.rrin"rffi
forterminat
[Especiaily Go to nextstep
No.rfrf,-''' -'-'
' ei. ZUf,#rfn,ZL
(MrDl
Check for cause
check it rhrotretinkage
operatestreely @ Go to nextstep
Correct,
clean,or r@
g:T:grd tinkage 1e_njac9
and "r .;ts6ierrecrion
adjusi arrhrotrte
Check continuitybetvreen throttle
,"n*l, G o t o n e x ts t e p
t e r m i n a l sI D L a n d E
Mrr
@,".;&.
Clearance between throttle Adjust
rever and stopper Continuity
0.1 mm (0.00ain) Yes

MN
1.0mm (0.039 in) No
0 . 1m m ( 0 . 0 0 ai n ) Yes
Alr
0.6mm (0.02ain) No
E M I S S I O N C O N T R O L S Y S T E M T H O U B L E S H O O TGI N
UGIDE 21B-gs
lNSPECTION
Ch e c kfo r c o rre c ltu e ll i n ep re s s u r at

e i dl e
F u e ll i n eP r e s s u r e:
c? ll decreases.check luel line and filter for ciogging
2 6 5 -3 1 4k Pa (2 .7 -3 .2k g /c mt,3 8-46psi )
c ) l f n o d e c r e a s e ,g o t o n e x t s t e p
( V a c u u mh o s e to p re s s u rere g u l atordi s'
connected) ",.
INSTALL CLAMPS
Low pressure
Check tuel line pressure while pinching fuel return hose
Q ll fuel line pressure quickly lncreases,check

pressureregulator
lf fuellinepressuregraduallyincreases,
checkfor
cloggingbetweenluel pumpand pressureregulator
.C lf notclogged,checkfuelpumpnraximumprcssure
o
o
8 Checkforcorectignitiontimingat idleafter Yes Checkif ignition
timingadvances whenaccelerating
I I
warm'uP
I I e lf advances,go to nextstep
Q ll not advance, replace PCM
| |
fsnitfontlming(BTDC)zf!1' I I
tl
i- N" I Adj*,
9 Checkif air duct and air hosesare correctly Yes Go to nextstep

installed
No R epai r
10 Checkif exhaustsystcmis restricted Yes Repairor replace
No Go to nen step
11 Try with knowngood PCM and checkil condilionimproves

.
{ . r
L I
218-96 EMISSIONcoNTRoL sysrEM rRouBLESHoonNG

f,
I GU,DE
18
S U R G E SW H I L E C R U I S I N G
DeSCnPr|f{ . Unerpected change in engine speed rvhir:h is usually

repctitive
[rRou8 LESHOOTTNG H|NTSI

@ AirlFuel mixlure too elan
@ Mislire
@ Poor connectionin wiringharness
STEP IN SP EC T IO N
1 Check that rnallunsticncode is disptayedon lhe j'es
SST with ignitiqnswitchON Checkfor cause(Referto speiified checksequence)
416;q4lnOaPTOR&
wrRE
xanxess-dfJi-}L
No Go to next step
F=Jl
-o.-\
rll
lffi
I Iq:::r
i F C t \ I4 . lK,.l
r_J
2 Checkswitcheslor conecl operationby the SST Yes Go to nextstep
No Checklor cause
(Relorto specifiedchecksequence)
3 Checkif throtilesensoris OK Yos Go to next slep
N o . Adiust
4 Disconnectoxlg€n s€nsor connectorand clreck Yes Checkorygensensor

if conditionimproves
l{
;i
r.{.
:l
rl
,1.
r I'
;: No Go to nexlstep
I
l- ,
:
f ' .
t
f.
5 Checkif PCM terminalvoltagesare OK Yes Go to nextstep
No Check for cause

E M l s s l o N c o N T R o L S Y S T E Mr n o u B L E S H o o r r G
NGurDE 218-97
STEP INSPECTION AC'nON

6 Check if lhrotttelinkage is correctlyinstailedand Yes Go to nextsteo
operates Ireely
No Correct.clcan. or replace as requiredany binding or

damaged linkage.and adjust cable deflectionat throrrte
body
7 Check lor correct intake manifoldvacuum at idle Yes G o l o n e x t step
V a c u u m : M o r e t h a n 4 5 0 m m H g ( 1 7 . 7i n H g )
No Check tor air leakage ol intake air system components
I Checkif air cleanerelementis clean Yes Go to nexlstep
.No R e p l a c ea i r c l e a n e re l e m e n t
9 Checkfor correctignitiontimingat idteafter Yes Check il ignitiontiming advances when accelerating

warm-up
r) lf advances.go to next step
c'7 lf not advance. replace PCM
l g n i t i o nt i m i n g( B T D C :)T + 1 '
No Adiust
10 Checklor correctluel line pressureat idte /es Check if luel line pressure decreaseswhen accelerating
quickly
F u e l l i n e p re s s u re:
25 5 -3 1 4k Pa (2 .7 -3 .2k g /c mt,3 8-45psi ) 4 ll decreases.check for luel pump maximum pressure
(Vacuumhosc to pressureregulatordis- lf OK, check fuel line and filter lor clogging
connecled) c? lf no decrease. go to next step
No Low pressure
INSTALLCI-AMPS Check fuel line pressure while pinching fuel return hose
ciz lf fuel line pressure quickly increases.check pressure

regulator
t'-.2ll fuel line pressure graduallyincreases.check for
cloggingbetween luel pump and pressure regulator
l f n o t c l o g g e d .c h e c k l u e l p u m p m a x i m u m p r e s s u r e
, I
Hlrh pr"t*""
Check il fuel return line is clogged
:,, ll OK. replace pressure regulator

:'.2 lf not OK. replace
11 Check il exhaust system is restricted Yes Repair or replace
No Go to nextslep
12 Try with known good PCM and check il condition improves

:l I
i' I
il 218-98 EMlssloN coNTRoL sysTEM rnouBLESHoorNG

GurDE
LACK OF POWER
DESCRIP Performancepoor unrjer fnu,L
TION RecjucerJrnaximurnspced
ldle condition ncrmat
rrRo uBLESHOO;|NGt_itNis
r
t U F a c t o r so t h e r i h a n e n g i n e m a l f u n c t i o n
.
!lutcn stipprng @ Air/Fuelmixture too lean
. A/T.stipping . line pres.suredecreases
lu.l
. dr ak edr a g g i n g o r U € t r n l e c t r o nm a l f u n c t i o n
. Low lire psa"rrro
. lncorrecltirg5;2g
. Overloaded
(D Low intakeair amount
..
. Throtilevalvenot opentultv
H Poor ignition
Low engine compression
A l c o h o tb l e n d e df u e l u s e d
. ctogged intakeair jyltem',
INSPECTION
Cn19kfactorsotherthanengine A C Ti ON
. gl:t"l sripping Go to nextstep
. Mf stippini
. BrakeOrag-ging
r LOlvltrepressure
Incorrecltiresize
Checkif throillevalvefultyopeneOwhen
acceterator G o r o n e x ts l e p
depressedfully
No C necki f accel erator

cabl ei s correctty
I i nstal l ed
c) lf OK, check throtrtebody
c) lf not OK. install accelerator
cable correclly
Check that matfuncrionis displayed

on the SST Malfunction Code No. displayed
with ignitionsvritchON
Check for cause (Refer to .-p#fi"O check
sequence)
SIGNALAOAPTOR&
MOOULAR
Check il ignition timing advances when

acceleraling
: ? l f a d v a n c e s ,g o t o n e x t s t e p
c ) l f n o t a d v a n c e ,c h e c k p C M
t e r m i n a lv o l l a g e s
Check if pCM terminatvofiages

IEspeciailytor terminat tto. iX. " r " bZt
X G9 to nextstep
(A/r). 1rrr, (M/T). 2M
and 2KJ
Check for cause
g
,-.: EtvllSSlON G UI D E
CONTROL SYSTEMrnouELesiloor.trug
... : 21 B-99
. ll
:l INSPECTION
ACTION
:-I
vacuumat idle I Ves

C h e c k f o r c o r i a c t i n i a k er n a n i f o l C G o t o n e x ts t e p
l n t a k e m e n i f o l dv a c u u m : N o I C n e c X l o r a i r t e a k a g eo f i n t a k a a i r s y s t e mc o m p o n e ; r t s
l v l o r el h a n r i 5 0 m m H g ( 1 7 . 7i n H g ) I
C h e c k i f a i r c l e a n e re l e m e n ti s c l e a n Go to nextslep
a t i dl e
t e ll i n ep re s s u re
Ch e c kfo r c o rre cfu Yes c h e c k i l f u e l l i n e p r e s s u r ed e c r e a s e sw h e n a c c e l e r a t i n g
quickly
F u e ll i n e p r e s s u r e: l l d e c r e a s e s ,c h e c k f o r f u e l p u m p m a x i m u m p r e s s u r e
4
2 6 5 - 3 1 4k P a ( 2 , 7 - 3 . 2k y ' c m t , 3 8 - 4 6p s i ) l f O K , c h e c k f u e l l i n e a n d f i l t e rf o r c l o g g i n g
( V a c u u mh o s et o p r e s s u r er e g u l a t odr i s - Q l l n o t d e c r e a s e ,9 0 t o n e x t s t e p
connected)
Low pressure
c h e c k l u e l l i n e p r e s s u r ew h i l e p i n c h i n gl u e l r e t u r n h o s e
INSTALL CI-AIVIPS
c l f f u e l l i n e p r e s s u r eq u i i t t y i n c r e a s e sc' h e c k
p r e s s u r er e g u l a t o r
Q l f f u e l l i n e p r e s s u r eg r a d u a l l yi n c r e a s e s c, h e c k f o r
c l o g g i n gb e M e e n f u e l p u m p a n d p r e s s u r er e g u l a t o r
l f n o t c l o g g e d ,c h e c k l u e l p u m p m a x i m u m p r e s s u r e
H i g hp r e s s u r e
Checkif fuelreturnlineis clogged
:'
i egul ato-r'
+ l f OK , repl acepre' ssure
Q l l notOK , reP l ace ' ''
C h e c k i f a i d l o v rm e t e r i s O K Go to nen step
I. Check il measuring plate moves smoothly
I I . C h e c kr e s i s t a n c e R e p a i ro r r e P l a c e
Termina R e s i s t a n c e( 0 )
Rrlty cbsed futV open
Ez.-Vs 2 0 - 6 0 0 20- 1.200

Ez*-Vc 200-400
Er-Fc G' 0
2l8:10a . '''''O,{ CONTROL SYSTEM TNOUBLESHOOTING
GUIDE
INSPECTION
Check if spark plugs are OK
Ycs Go lo next step
WEARANO CARBONEUILDUP
BURNS
P L U GG A P
:.O- t. t rnrn OAMAGEANO
(o.039-C.O43 in) DETERIORATION
Cleanor repface
DAMAGE
Check if resistance
of high-t"n"ionGGi
Yes Go to nextstep
flesfstancer 16 k 0 par fm (3.2g

fr)
Replace
Check if resistance
collts OK Yos Go tQnexl slep
Reslstance(ar20e
[g-O..FJ)i
Prlrnarycoil wlndfng...;....,.:
g.gt_e.gg (,
sccondrry coti r,riili?ig
.,..:.j io_f , kr=i
Primarycoil
wtnotng Secondarv
coilwindin(
checkfor"orr""@
Go to next step
En ginec om pr es s l o n:
932 kpa (9.5 kg/cmr,135
psi)-300rpm
. piston,pistonringsor cylinder
. !/o,rn cytinder neaj 9".r,Ji
"" watl
!.elecfive
. utStott€d cylinderhead
. Valve sticking in guide
Changetuetandcheckit.onoi,i*IiiG
C h a n g el u e l t o a n o t h e r
brand
Go to next step
Trywithknown
goodPCMand.ffi
E M I S S I O NC O N T R O LS Y S T E Mr h o u e L E S H o o l NcGu r o E 2 18 . 1 0 1
,o-l POORACCELERATION
a Performancepoor while accelerating

ffi1p.t a ldle condition ncrmal
T T F oUB L E SH O OT IN HG
IN T S I
iD Factorsolherthan enginemallunction O AirlFuel mixturetoo lean
. ClutchsliPPing . F u e l l i n e p r e s s u r ed e c r e a s e s
. AfTsliPPing . Fuel injeclionmalfunction
. Brakedragging @ Poor ignition
. Low tirePressure @ Low engine corr,pression
'+,!.,: . Incorrecttire sire @ A l c o t r o lb l e n d e dl u e l u s e d
3r.-
. Over-loaded
6) Lowintakeair amount
. Throttlevalvenot openfully
. Clogrgediniakeair system
' . ! . ;

A:E
1 Checklaclorsotherlhan engine Yes Go to next sleg
::' gr. ,' Ctutchslipping
+,f;
. Brakedragging
.r-t
.r+t,
. Low tire pressure No R epai r
-ra
. Incorrect tiresize
. Mf sliooino
2 Checkif throttlevalvefullyopenedwhen Yes Go to nextstep
depressingacceleratorfully
No Checkif accelerator
cableis correctlyinstatted
":a
+ lf OK. checkthrottlebody
.-* Q lf not OK, installacceteratorcableconectly
.*f
.*
3 Checklhal malfunctioncode is displayedon thd Yes Malfunction Code No. displayed

SST withignitionswitchON Check lor cause (Refer to specifiedcheck sequence)
SIGNALADAPTOR&
MOOULAR
No Go to ngxtstep
4 Checkcontinuitybe_tween
throttlesensor Yes Go to nextstep
lerminalslDLandE _ __
No Adjust
Claaranco between thronlc Contlnuity
lever_and _stopp_er-
0.'l mm (0.004 h) Yes
it/T"
1.0 mrn (0.039 in) NO
0.1 mm (0.00ain) Ye,s.

NT
0.6 mm (0.024h) No
218-102 E M I S S I O NC O N T R O L
S Y S T E MT R O U B L E S H O O T I N G
GUIDE
INSPECTION
Checkforcorrecrffi
war m . up C h e c k i f i g n i t i o nr i r i n g
en acceleratlng
c ) l f a d v a n c e s ,g o
lo nextslep
l g n i t i o nt i m i n g( B T D C ) cc lf not advanci,
: 7. t 1. .n..r,'p6ruiterminat
voltaoes
.Adjusr
checki(pcMt"r@
Gc to nextstep
Checkfor cause
7 Cnec<forcorrecr
inr.
| i * Go to nextstep
Int ax em anif olJv a c u u m
:
M o r et h a n4 5 0 m m H g ( l . t
inHg) Checktor airleakaoe -
.f intake
tge of i^,,r-F---
air system.orpon.n,l
Checkfor correctfr"f lffi
C h e c k i f frvv'|'"c
u e l l i n e pr€SSUt'e
o r e s e , , decreases
F uêlline pr es s u re: quickly when acceterailf
265- 314k pa e.7 _ 3 .2
k g /c mr,
( V ac uumhos e trc p re s s u re 3 B _ 4 Gp s i ) o checkfuetpumo
fl 1::reases.
c onnec t ed)
re g u l a to rd i s ' t, oK. checkfuerrin";;j;;;; m:
c) lf notdecrease, ;;::i&rf,pressure
go to next"'C-.
Lor..,pressure
INSTALL CLAMPS check fuerrinepressure
whirepinchingfuerrerurn
hose
c) ff fuerrinepressure
qr;ickry
increases,
_ v , vcheck
regurator pressure,
r.sv^ p lEssure;
c) lf fuel line pressure
. . . _ ^ ^gradualty
-^ J ..
increases.checkfor :
cloggingbetweenfuetpump'"nO'Or"rrure
tt ylctogsed. checkr;.t regulator
il;;",rl.rirrm pressure
H i gh pressure
Checkif fuellineis ctogged
3 lfll9j,::pt1"9
c)
pressure
resutaror
not OK, reptace
E M I S S I O N C O N T R O L S Y S T E M T n b U E L E S H O O TG
I NUGI D E 2 1B - 1 0 3
INSPECTION
l C h e c ki f a i d l o wm e t e r i s O K Go lo nextstep
I
II
J . C h e c k i f m e a s u r i n gp l a t em o v e s s m o o t h l y
I
I
I
I
I
I
J I I . C h e c kr e s i s t a n c e R e p a i ;o r r e p l a c c
lI Terminal
Ez*Vs
&*Vc
R e s i s t a n c eI Q )
Fully closed
20-600
200-400
fullyopen
20-1,200
1I fe €. V: Er Vr ?xrr
Er-Fc € 0
10 Che c ki f s p a rkp l u g sa re O K Go to nextstep
WEARANO CAREONBUILOUP
P L U GG A P OAMAGEAND
).* 1 . 0 - 1 . 1m r n No Cleanor replace
OETERIORATION
._- l
(C.039-c.0a3 in)
:.1
OAMAGE
J '
..ii,: 11 | Check if resistanceof ignitioncoil is OK Go to nexl step

'g'
it.'-
R e s i s t a n c(ea t 2 0 1 [ 6 8 ' F J :)
t;r
3 : . P ri ma ryc o i l w i n d i n g ............. .....
0.81-0.990
fe' S e c o n d a ryc o i l w i n d i n g .......... ...
10-15 k A
'r*l
?;i
Primarycoil Secondarycoil
tutu
winding winding
Check for correct engine compression Go to next step

Enginecompression :
9 3 2 k P a ( 9 . 5 k 9 / c m t ,1 3 5 p s i ) - 3 0 0 r p m Check engine condition
. Worn piston. piston rings or cylinderwall

. Delectivecylinderhead gasket
. Distortedcylinderhead
. Valve stickingin guide
218-104 E M I S S I O N C O N T R O L S Y S T E M T R O U B L E S H O O TGI N
UGIDE
STEP INSPECTION I ACTION

13 C h a n g e f u e l a n d c h e c k i l a c c e t e r a t i o ni m p r o v e s Yes C h a n g el u e l i o a n o l h e rb r a n d
No G o t o n e x ts t e p
14 Check it NC cut-off control system is OK Yes Go to next step
No Repair or replace
15 Try with knowngcod PCM and checkif conditionimprovas

a:*-
.: "
;t EMISSION CONTROL SYSTEM TnoUBLESHooTIN
GGUIDE 2 1B - 1 0 5
R U N S R O U G HO N D E C E L E R A T I ' C N / B A C K F I R E
. Engine runs rough while deceleratingand abnormatcombustion occurs in exhaust 3ystem

. Transaxie in normal condition
r T R o u B LLE
ESSH
H OOOOT
TIN NHGITNNTTSSI
TG I
hl mixture too rich
\Y eirlFuel
. Air/cleanerelement cloqqed
. Fuel injectionccntrol mEllunction
(Fuelcutcontrol)
. iniectorluel leakaqe
. Thronle sensor (lOL terminal)malfunction
. Dashpot malfunction
STEP !NSPECTION ACTION
SST with ignitionswitch ON C h e c k f o r c a u s e ( R e f e rt o s p e c i l i e dc h e c k s e q u e n c e )
-i'
- : s!
#,
s
SIGNALAOAPTOR&
MOOUI-AR
,.t:ff WIREHARNESS
#'
'.#,
' 8 L
--s No Go to nextstep
s.
:.61'
.ip
-)it-:
'd'
*;
tta.
:El
**i 2 Checkswitchesfor correctoperalionby the SST Yes Go to nextstep

-{'.1
a:r
4
ift
:*\ i
No Check for cause

(Refer to sp.if,"d check sequencel
3 Checkfor correctintakemaniloldvacuumat idle Yes Go lo nextstep
V a c u u m: Mo reth a n 4 5 0 mmH g (1 7.7InH g)

No Check for air leakage at intake air system componenls
I Check il air cleaner element is clean Yes Go to ne:l step
No Replace air cleanerelement
5 Checkif PCM terminalvoltage are OK Yes Go to nextstep

(Especially
for terminalNo. 1N,2A. 2V,2V)
No Check lor cause
2 ' t8 . 1 0 6 E M I S S I O NC O N T R O L
S Y S T E I V IT R O U B L E S H O O T I N G
GUIDE
INSPECTION
Chec kil f u e l .r,ro p ..ri o l F t
:
.1
I
r
Go lo nexl step
Repair or reptace
Terminal ResistanceI e I
-_- @
Ez.-.vs ,o{oo.i ,o-rE6-
Ez...Vc 200-aOO
Er . - , F cI
I
tfo
c
Chec kif t hr o rtte
s e n s o rtD L te rmi n af,O?
f
G o t o n e x ts t e p
Checkil dashpotis correcily

adjustej
Checkif rhrorrte
vatve;, .onEiilE
D a s h p o ts e t s p e e d:
A ppr ox . 3 ,0 0 0rp m r$ lf contaminated.
clean throtile boOy
c) lf not contaminated,
reptace throttfebody
Check
rnjeaor
roir*GxG
Go to nexl step
T r y r v it hk nowng o o dPc M
a n d .h m
EMISSIONCONTROL SYSTEM rRouBLESHoolNG
GuloE 218-107
rI K N O CK I N G
-+ Gffi1g'l
A b n o r m a lc o m b u s t i o na : c o m F a n i e db y a u d r b l e ' p i n g i n g 'n o i s e
-n-{o s tE s Ho or ING HINTs I

u
j
advanced) A i r l F u e l m i x t u r et o o l e a n
S t''.o"".idePosits
is11l?ll3:,s_lr:
in cYlinder . F u e l i n j e c t i o na m o u n t n o t c o r r e c t
6 CarOon
. F u e l l i n e p r e s s u r ec j e c r e a s e sw h i l e a c c e l e r a t i n g
5 o""th.uti^g
INSPF.CTION ACTION
Check lor correct ignitiontiming at idle after Go to next step

warm'up
I l g n i t i o n t i m i n g ( B T D C ): 7 ' t
'l'
-l
I
I 2 C h e c k t h a t m a l f u n c t i o nc o d e i s d i s p l a y e do n t h e
Yes MalfunctionCode No. displayed
C h e c k f o r c a u s e ( R e f e r t o s p e c i f i e dc h e c k s e q u e n c e )
l WIREHARNESS
SIGNALAOAPTOR&
MOOUI.-AR
No Go to nextstep
3 Checkfor correctintakemaniloldvacuumat idle Yes Go to nextstep
V a c u u m: Mo reth a n 4 5 0 mmH g (1 7.7i nH g) No Check for air leakage ol intake air system components
4 Check lor correct engine compression Yes Go to nextstep
Enginecompression:
9 3 2 k P a ( 9 . 5 k g / c m t , 1 3 5 p s i ) - 3 0 0r p m
No High compression
C h e c k e n g i n ec o n d i t i o n
. Carbondeoosits
218-108 EMISSIONCONTROL SYSTEM TROUBLESHOOTING
GTJIDE
STEP INSPECTION
Chec kf or c orre c fu
t e ll i n ep re s s u rea t i d l e Yes
quickly :
265- 314k Pa (2 .7 -3 .2k g y ' c m r,3 3 -4p6s i ) Q lf decreases.checklor cloggingbetweenfuel pump
(Vacuumhose to pressurerogutatordis- and pressureregulator
connected) c) lf not decrease,go to next slep
INSTALL
CI-AMPS
No Low pressure
lvk
t-c.r check fuel line pressurewhirepinchingfuerreturnhose
c) lf luel line pressurequickryincreases,

checkpressure
regulalor
c) lf fuel line pressuregraduaflyincreases,
checkror
I
cloggingbetwee.n luetpump and pressureregutator
lf nol clogged,checkfuel pump marimumprJ.rrr"
Checkil coolingsystemis OK Yes Go to nextstep
No Repairor replace
. Thermostat
. Electriccoolinofan
I . Radiato(
3 with knowngood pCM and checkif condition Yes ReplacePCM
I Iry
tmProves
I :
No change fuelto anotherbrandor use highero"t"* tu"r
E M I S S I O N C O N T R O L S Y S T E M T R O U B L E S H O O TGI N
UGIDE 2 1B - 1 0 9
FUELODOR
l -oescntp G a s o t i n eo d o r i n c a b i n
I
INSPECTION
'-ri'
:k
't3;
Check if fuel leakage or damage of fuel syslem Repair or replace
and evaporativeernissioncontrolsystem
No I Go to nextstep
Checkthat mallunctioncode is displayedon lhe Yes Mal functl onC odeN o. di sP l aY ed

SST with ignitionswitchON Checkfor cause(Referto specified checksequence)
SIGNALAOAPTOR&
MOOULAR
---+ WIRE HARNESS
+:
+-
€ No I Go to nexlsteP
5{.
.:J,
r'l:
.3.
:.
:-.
<,:r
' at'
-.
'*
:9
-*a
Checkif vacuumis felt at solenoidvalve(purge
-s
'tl-*
control)with enginerunningand lhrottlevalve
+.. opened(Neutralswitch.connector disconnected)
f.r
*-
_qF
*;
s
---+
Check lor solenoid valve operating sound
Q lf OK, check vacuum'hoses for clogging

c) ll not OK. go to next step
Apply 12Vand groundto solenoidvalve(purge Check PCM terminalvoltages

control)and checkil vacuumis feltal solenoid
valveat idle
Replace solenoidvalve
Try with known good PCM and check if conditionimproves

21F-11A E M I S S I O NC O N T R O L
SYSTEM rnouBLEsr.tooTtNc
GutDE
____ E X H A T ' S TS U L F U R
SMELL
-,i1
mscnnlnr'rf. Exlrausr
Oort-urrr-Goilfr r,l
:t'r'l
LT:"y: :es
s ulf
xo-r nrc rrTruiq
urc ont entf u e lu s e d {t
.=.f
_
INSPECTION
unange tuefto anolher
_
,l
-t
brand ACTION .;
HIGH OIL CONSUMPTION

. Oif consumption
excessive
flRgg.?LEsxooffi Emt
PCV'systemrrarfuncr;;;'-,
I trngrne
\t, malfunction
(Oitworking
wort up. workingdown.
or leakage)
I N S PE C T I O N
Checkif pCVhose.venritarion -lcrloN
attaching nipples are
nor"llillF I
separated, damaged, Repair or replace
clogged, or restricted
Go to nextstep
Cnlgf if airpressrG
ventilationhose Go to nextstep
. Oif feakaoe
. Wornvalie seal
. Worn valvestem
. Worn valveguide :'i;
{q
:
Checkit u".r, -tf
:;t
Check engine l {:
"onOition :.:.
.
IgT pistonring groove
. Stuckp.istonrinlJ
. Wornpistonor jyfinder
_ x l
-tl
'i.i
I
Replace pCV vafve

E M I S S I O N C O N T R O L S Y S T E M T d O U E L E S H O O T IGNUGI D E 2 1B - 1 11
P O O R F U E L .E C O N O T . I Y
: gESCBiP Fuel economy urrsatisfactory
J
i 10N
ilnou s uESHooTl NGHINTSI

_l lvi,l[]r"r consumptionis drastlcarlv
etc.,as opposedio'trip- mileage.an attemptshouldbe made to determinethesefactorswhen
llrir-rp periods,
winter
increS'"9!1 citl-o1J'l!'.?1?1::ii?e:'^1?]'-,t3t.T,t^::i'::i9:,:1".1,1i1
_l :;;;;;;i"'d with
'poormileage'conditions.Horvever,
sincethe operatoris not alwaysat fault.the followingis oflered-
-J depressingacceleratormore ihan usua! due to @ RirlFuel mixture too rich
- Operator power
6)
. High fuel line Pressure
lcw engine
. Poor ignition @ Alcohol blended fuel used
. Low intake air amount @ High vehicle load
. Etectronicspark advance control system malfunction . Low lire Pressure
/ A/T sliPPing
. ClutchsliPPing . lncorrect tire size
. ExhaustcomPonent restricteC . grake dragging
INSFECTION
Checklactorsoiherthanengine Go to next step
. Low tirepressure
. Unrecommended tiresize
Clutch slipping' Repair
Brake dragging
Ex h a u s t ent restr'rcted
C h e c k i f a i r h o s e s a r e c o n n e c t e dc o r r e c t l y Go to next step
No I Repair
Check that malfunctioncode is displayedon the Malfunction Code No. disPlaYed

SST with ignitionswitch ON Check lor cause (Refer to specilied check sequence)
SIGNALAOAPTOR&
MCOUT-AR
WIREHARNESS
Go to nextstep
Go to nerl steP
Check for air teakage at.intake air system components
Check if air cleaner element is clean Go to nextsteP
R e p l a c e a i r c l e a n e re l e m e n t
218-112 EMISSION
CONTROL SYSTEM
rRouBLEsHoonNG
.GutDE
INSPECTTON
C h e c k t f p C M t e r m i n a fv o l i a g e s
( E s p e c i a l l yf o r t e r m i n a l are OK
No.2D.2N.ZO. Go to next step
and 2V)
Checkfor cause
Checkforconecrign;Uon
ft!ffi
warm-Up Yes Go to nexl slep
lgnit ionr im i n g (BT D C }

: 7 , t t.
Checklor"orr".@
F uel. lir r epf es s u re :

k p a (2 .2 _ 2 .tk g /c mr,3 1 _ 3 8
. 216- 265 psi)
INSTALL
CLAMPS
Hlgh pressure
Checkif vacuumhoselo pressure
regufator
is damageoo,, a
io-,ilo"nn"",uo
+ reptace
pressure
llOK regulator "
a
Q ll notOK,repairor repface
hose
Run.engine at idfe :aa
=Yi,
is held after ignition Go to nextstep
switch turned OFF 1--Ll
- !
.?l
'il
fygf_ti1enressure: More
(1.5kg/cme21 psi)tor than147kpa
s min.
INSTALL CLAMPS
Checkinjectors-ol,*t
f""k" g"
7',i
Change fuef to
brand
"*tn",
EMISSIONCONTROL SYSTEM rnouBLESHoolNG
GutDE 2 1B - 1 1 3
-zt A/C DOES NOT WORK

I
I.
t'
Elower tan operates but magent clutch does not operate
E#frl^l I
I l N L iF l l N| 5 J
nnO
'-' UgUE S} i U U
Oprn or short circuit in wiringharness
. UC rclay,A/C switch.or magneticclutchmaltunction
ercpl lNSPEcTloNrAcTloN I
C h e c k i f P C M 1 Q t e r m i n a l v o t t a g eO K Yes Check if PCM 1J terminal voltage OK
'10lJ O lf.OK. check A/C system

c? ll not OK, replace PCM
No Checkfor cause
218-114
EMISSION CONTROL
SYSTEM SPECIFICATIONS
SPECIFICATIONS
SERVICEDATA
:;-
ror€Sp€€o r -
l g n i l i o nt i m i n g - t
a
Purge.onrrorJor"]iGE
I
Water thermosensor
2 0 e ( - 40.F)
Re s is t anc e 1 6 . 2 +r . 6
k0 20e ( 56-F)
(r 7 6' F) 2.45+ 9.95
'r ENG. 0.32t 0.03
TEST
rerrninar
oroi"gnf,'ffi
.:
:^
I
)2.
FUEL SYSTEM
FUEL 22- 3
..
i.
FUEL SYSTEttf pescntploN ANDopERAnoN) 22-3
-OttttlPTlON
AND OPERATION i
Thefuelsysiemconsistsof : i
. Electiicfuelpump
. Fuelfilters(2)
. Fuelrail
. Fuelpressureregulator ,
. Fuelinjectcrs(4)
; FuelPumPrelaY
The etectricfuel.Pumpsupptiesfiltered,pressurized fuel to each injectorthroughthe fuel rail. The fuel

pumpis mountedin the fuel:tank to minimizeoperatingnoise
The fuel pressureis regulatedOya fuel pressureregulator.The injectorsare directlysuppliedwith battery
voltagethroughlhe mainrelay-
i
Fuel is metered and injectedintothe iniakeportsaccordingto the injectionsignalsreceive6fromthe ECU.
When!nt:g iniectionsigna.ls are appliedto the solenoidcoil of the injector.th6 needlevalveis pulledoff its
seat. Fuel is theninjectedinto the intakeport.
The amountof fuelsuppliedto the engineCepends on thedurationof timethe injectorsstayopen.
22-4 FUEL SYSTEM(oescnfprroN)
FUELSYSTEM
DESCRIPTION
Thissystemsuppliesthe r
rneter6dandi"i"il"J i"ii i ronat a constantpressureto thefuel
ording iniecrors.
Fuelis
trotunir.Theifiil#.i toiniectign.controtsigniGilin'riieengrne
regulator, ,n" luelrilters,
rtt"i.riu.rv-plp"- con-
their1eil;i;;iil thepressure
l|to'
PRESSURE
REGUT-ATbF
INJECTOR
-b TO FUEL TAI'JK
FROMFUELPUMP
FUELFILTEB
(HrcH PRESSUREStDE)
FUELFILTER
(LOw PRESSUREStoE)
FUELPUMP
FUELTANK
FUEL SYSTEM lenecRuTfoN,
sysrEMopERAloN) 22-5
PRECAUTION
FUEL PUIilP F u e l P r e s s u : ' eR e l e a s ea n d S e r v i c i n gF u e l S y s t e m
. Fuel in the luel system remainsunder high pressureeven
w h e n t h e e n g i l r ei s n o t r u n n i n g .
a) Beforedisconnecting any fuel line, releasethe fuel pres-
sure fronr the fuel system to reduce th'e possibilityof
injury
or fire.
1 . S t a r tt h e e n g i n e .
2. Push the rear seat cushion buttons and remove the
. cushiorr.
REARSEATCUSFIION
EUTTON
3. Disconnectthe fuel pump connector.
4. After the enginestalls,turn otf the ignitionswitch.
5. Reconnectthe fuel pump connectorand installthe rear
seat cushion.
b) Use a rag as protectionfrom fuel spray when disconnect-

ing the hoses.
Plug the hcses after removal.
c) When inspectingthe fuel system,use a suitablefuel pres-
s u r eg a u g e .
Caution
. Install hose clamps to secure the fuel pressure
gauge to the fuel filter and the fuel main hose to
prevent fuel leakage.
Priming Fuel System

After releasingthe fuel pressure for repairs or inspection,
the system must be primed to avoid excessivecranking
when firststartingthe engine.Followthe steps below.
1. Connectthe diagnosisconnectorlerminalsF/P and GND
with a jumperwire.
2 . u r n t h e i g n i t i o ns w i t c h O N f o r a p p r o x . 1 0 s e c . a n d
T
check for fuel leaks.
3. Turn the ignitionswitchOFF and removethe jumperwirp.
OISCONNECT CONNECTOR F u e l P r e s s u r eH o l d I n s p e c t i o n
T O R E L E A S EF U E LP R E S S U R E
Warning
. B e f o r e p e r f o r m i n gt h e f o l l o w i n g o p e r a t i o n ,r e l e a s e
the fuel pressure from the fuel system to reduce
the possibility of iniury or fire. (Befer to above)
REARSEATCUSHTO
TBUTTON
22-6 FUEL SYSTEM (sysrEMopER^noN)
1. Disconnect thenegativebaiterylerminal.
2- Instafla fuelpressuregaugebetweenthe fuel pipeand
thefuelmainhose.(lnstatt
Clamps . ' '
as shown.)
3. Connecttirenegativebatterytenninal.
4. connecttlrediagnosisconneclorterminalsF/p and GND

witha jumperwire.
5. Tumthe ignition
switchON for 10 sec. to operatethe fuel
pump
6.Tum the ignitionswitchoFF and disconnect
the jumper
wire.
7. Observethefuelpressrrre
after5 min.
Fuelpressure:
Morethan 141kpa (1.5kg/cmr,21 psi)
performthe followinginspections.
. Fuelpumpholdpressure.(Refer to pige Z2-g)
. Pressureregulator holdpressure.(RefEr to page 2z-1zl
. lnjectorfuelleakage.(Refer
to page 2Z-15)
FuelLinePressurehtspection
OISCONNECT
CONNECTORTO
RELEASEFUEL PRESSURE
Warning
- Beforeperformingthe following operation,release
the fuel pressure from the fuef system to reduce
the possibilityof injury or fire.
INSTALLCI-AMPS 1. Disconnect the negativebatterycable.

2. lnstalla fuel pressuregaugebetweenthe filterand lhe
fuelmainhose.(lnstallclampsas shown.)
3. Connectthe negativebatterycable.
4. connectdiagnosisconnectorterminalsF/p and GND

witha iumpeiwire.
5. Tumthe ignitionswitchON.
6. Measurethefuellin'epressure.
Fuelline pressure:
265-314kpa (2.7-3.2kg/cmr,38-46psi)
low -
Pressure Measurefuelpumpmaximumpressure. rf
as specified,
fuellineor fuelfilterrniglrtbe
cloggedor restricted.
Pressurehigh- Replacepressureregulator.
FUEL SYSTEM lrueurANK) 22-7
FUELTANK
lemoval / Inspection/Installation
'' Warning
.-., . Beforeperformin-g..lhe followingoperation,releasethe fuel pressurefrom the fuel system to
reducethe possibilltyof iniury or fire.
. When removingthe fuel tank, keep sparks, cigarettes,and open flames away from lt.
. Beforerepairthe fuel tank,cleanit throughlywith steamto removeall explolive gas.
1. Removein thg ordershownin thefigure.

2. Inspeclth€ tueltankcompon€ntsvisuallyand repairor replaceif necessary.
3. Installin lhe reverseorderof removal,referringt9 InstallationNote.
7.8-l1N.m(80-11Okg-cm,
69-95lb.ln)
h
@
37-52N'm(3.8-5.3kg-m,27-38 lb-ft)
1. Fuelpumpcover 5. Fueltankstraps
.'.: 2. Fuelpumpconnector 6. Fueltank
3. Fuelhoses 7. Separator
,,J:;'4. hoses
Evaporative 8. Checkvalve(Two-way)
-
22-g FUEL SYSTEM (FUEL
FILTER.
FUELPUMP)
Instatlation
Note
1' push the ends of the main
hose,
noses o;i;.fuer. fuef..retum
the'uer-tlnl"rTi',ns,
atrea.si
hose.
l!ffiiiflil:"
I |,;:il'Ej:iig'ffi5;,il:" rheruer
iank
pipeandri,er
FUELFILTER
Replacement
Low-pressuresicie(ln-tank
fitter)
High-pressure
side
atrheintervars
n Jffl,jl*gTJ^::J,T,"ced ouuined
in
Warning
. Alwayswork away from
sparks or open flames.
1' Disconnect
the fuer hosesfromthe fueffirter.
2.Remove rhetrerliriei-Jni
3. Instafl bracket.
in the reverseorcjerof removal.
Note.."
. firter,
push
thefuer
Hffiilnlili';fl",1" hoses
fulry
FUELPUMP
Inspection
ectorterminalsF/p and GND
thefuelpLrmp
at thefillerinlet.
6' lf no'o'no was heard,meqsure

the vortagebetr.reenrhe
fuetpumpconnecror rvire Btl;g;;;;;:'.,
Voltage: Approx.lZV
t corre*, checkrhe circuiropening

xrllS: relayand irs cir-
I tf'e vortageis normar.checkfor
lf
puntp corrtinuity
betweenfuel
^ connectorB/R and B.
9. lf thereis continuity,
replace.the
10' rf thereis no continuity, fuelpump.
rip^n rnegrouncJcircuit.
FUEL SYSTEM(ruel I,UMP) 22-9
Hoiapressure
DISCONNECTCONNECTOR TO if the fuglpressureholdinspection
Performthisinspection
38, RELEASEF U E LP R E S S U R E
is
,.t: notas specified.
ler Warning
. Beforeperformingthe followingoperation,release
the fuel pressurefrom the fuel systemto reduce
the possibilityof injuryor fire.
FEAR SEATCUSHIONEUTTONO
1.Disconnect thenegativebatteryterminal.
2.Connecia fuelpressuregaugeto the fuelnrainpipeand
plug the outletof the fuel pre.ss(tre
gaugeas shown.
(lnstallclampsas shown.)
3.Connect battervterminal.
the neEative
INSTALLCLAMPS
In
4. Connectdiagnosisconrlector terminalsF/P artd GND

uritha jumperwire.
5. Turn'theignitionswitchON for 10 sec.to operatethefuel
pump.
6. Turn the ignitionsrvitchOFF and disconnectthe jumper
wire.
7. Observethe fuelpressureafter5 min.
Fuelpressure:
Morethan 343kPa (3.5kg/c6r' 50 psi)
replacethefuelpump.
FuelpumpmaximumPressure
Warning
. Before performing the following operatlon. Release
the fuel pressure from the fuel system to reduce
the possibility of iniury or fire.
1. Disconnect thenegative batteryterminal.

2. Connecta fuelpressuregaugeto the fuelmairtpipeand
p l u g t h e o u t l e to f t h e f u e lp r e s s u r eg a u g ea s s h o w n .
(lnstall clamPs as shovrn.)
3. Connect thenegative battery terminal.
(l
o
I N S T A L LC L A M P S
22-10 FUEL SYSTEM (ruel puMp)
4.Connectdiagnosiscor':nector terminarsF/p and GND

witha jumperwire.
5' Tumthe ignitionswitchoN to operatethe
fuerpump.
6. Measui'ethepumpmaximumpressure.
Fr91pump maximurnpressure:
441-589kpa (4.5-O.O
kg/cmz,64_85psi)
7. Turn the ignitionswitchoFF and disco'.ecr
the jurnper
replacethe fuelpump.
DISCONNECT
CONNECTOR
TO Replacement
RELEASE
FUELPRESSURE
Warnlng
he foilowing procedures.
rre trom ilre fuel system
to
rf injury or fire.
I system parts, keepsparks,
tmesaway fronr the fuet.
REAR SEAT CUSHIONBUTTON
1. Pushthe rearseatcushionbuttons
and renroverhecuslr-
ion.
2. Removethe fuelpurnpcover.
3. Disconnect
the fuetpumpconnector.
4. Disconnect
the fuel hoses.
5. Removethe fuerpump and fuertank gauge
assembly. senderunit
Caution
. Securethe fuel hoses tightty.
. a new seal rubber.
.Use
6. lnstallin the reverseorderof removal.
@
FUEL SYSTEM(rueuPUMP) 22-11
DisassemblY / AssemblY
t Disassemble in theordershownin thefigure.
Z.Arrr-ble in the reverseorderof disassembly, to Assenrbly'Note.
referring
O.RINGSET
1 .B a n d 4 . F u e lp u m p
2. Bracket 5. Fuel filter
3. Rubbermount
. .Assemblynote
MAIN PIPE
stuck.
Shakethe fuelpumptwoor threetimesandrecheck.
Fuepl ump
tfe fuel pump to the bracket,Pullthe
1.Afterinstalling
pumpdownso thatit is tightagainstthe bracket.
22-12 FUEL SYSTEM (crncur opENrNGRELAy,
pRESsuREREGuLAToR)
C I R C U I TO P E N I N GR E L A Y
lnspection
Voltage inspection
1 . c h e c k v o l t a g e b e t w e e n t h e f o l l o w i n g t e r m i n a t sa n d
a
ground using a voitmeter.
lgnirionswitch
ldling (V)
oN(v) START(V)
Fp(B/P) 0 Approx. t2 Approx.l2
Fc (LG) Approx.12 0 0
B (wR) A pprox.12 Apgrcx.t2 no--ilE
sTA (v) 0 Apgrox.l2 0
Et 0 c 0
Resistanceinspection
't. Checkr.esistance
hetweenthe lermlnalsusingan ohnn-
meter.
Terminal R qsi stance
(0)
STA-Er 21-43
B-Fc 109-226
B-Fp co
Replacement
1. Disconnect the relayconnector.
2. Removethe relayfromECUbracket.
3. Installin the reverseorderof removat.
-
OISCONNECTCONNECTORTO bnessuREREGULAToR
. RELEASEFUELPRESSURE lnspection
_Fue[ line p.ressure
-'
Warning
'.''_- Beforeperforming
the followingoperation,release
the fuel pressurefrom the fuel system to reduce
of injury or fire. -
the'possibility
REARSEATCUSHIONEUTTON rtteryterminal.
'.i::"33 eIfirte
rand
Y,":ilJffi
.i
:ry
terminal.
at idle.
5. Mea,syrethe fuel line pressure.
2 0 6 - 2 5 5k P a ( 2 . 1- 2 . 6 k g / c m 2 ,3 0 - 3 7 p s i )
6. Disconnectthe vacuum hose from the pressureregulator

a n d m e a s u r et h e f u e ll i n ep r e s s r r r e .
2 6 5 - 3 14 k P a ( 2 . 7 - 3 . 2k g / c m 2 ,3 8 - 4 6 p s i )
FUEL SYSTEM lenessunEHEGULAToR) 22-13
OISCONNECT CONNECTOR Hold pressure

TO RELEASE FUEL PRESSURE Performthis inspectionif the fuel pressurehold inspectionis
not as specified.
Warning
. Before performing the following operation, release
the fusl pressure from the fuel systern to reduce
t h e p o s s i b i l i t yo f i n i u r y o r f i r e .
REARSEATCUSHIONBLITTON
INSTALLCI..AMPS 1. Disconnectthe negativebatteryterminal.

2.Connecta fuelpressure gaugebetweenthefuelfilterand
the fuelmainhose. (lnstall
clampsas shown.)
3.Connectthe negativebatteryterminal.
4. Connect the diagnosisconnectorterminalsF/P and GND

with a jurnperwire.
5. Tum the ignitionswitchON for 10 secqnds to operatethe
tuelpump.
swilchOFFanddisconnect
6. Tumtheignition theiumperwire.
withpliers.
7. Pinchthefuelretum.hose
8. Observethefuelpressure
for 5 minutes.
F u e lp r e s s u r e :
psi)
Morethan 147kPa(1.5kg/c112,21
replacethepressureregulator
9. lf not as specified,
CONNECTOR
OISCONNECT
Replacement
Warning
. Befoieperformingthe followingoperation,release
the fuei pressurefrom the fuel system to reduce
the possibilitY of iniuryor fire.
. V / h e n r e p t a c i n gf u e l s y s t e m c o m p o n e n t sk, e e p
sparks,cigareRes, and o'penflamesawayfrom tbe
fuel.
thevacuumhose.
1. Disconnect
thefuelreturnhose.
2. Disconnect
3. Removethe regulalor.
Pr0ssure
T i g h t e n i n tgo r q u e:
7 . 8 - 1 1N ' m( 8 0 - 1 1 k0 g ' c m , 6 9 - 9 l5b ' l n )
4. lnstalla newO'ring
in thereverse
5. Install orderof removal
22-14 FUEL SYSTEMlrrwecroR)
INJECTOR
Inspectlon
Operationcheck
24,2U and2V
Injectorresistance
1. Disconnectthe injector.harness.
2. Measureresistance of the injectorwilhan ohrnmeter.
Flesistance
: 12-160
replacethe injector.
Removal
ciscoNi.lEcTCoNNECTOR
TO RELEASE FUELPRESSURE
Warnlng
REAR SEAT CUSHIONEUTTON O
1. Disconnect
the connectorsfromthe injectors.
2. Removethe injectorhamessfromthe deliverypipe.
3. Removethe boltsfromthe intakemanifold.
4. Removethe deliverypipewith the injectorsand the pres-
sureregulator.
5. Removetheinjeclors,
grommets,
and insulators.
GROMMET
lNSULATOR
FUEL SYSTEM lrru.lecroR) 22-15
Fuefleakagetest
1. Removethe injectors withthe deliverypipe.
the
2.Affix injectors
to the deliverypipewithwire.
Caution
. Affir the injectorsfirnrlyto the deliverypipe so that
no movementof the infectorsis possible.
Warning
. Be extremelycarefulwhen workingrvithfuel.
Alwayswork awayfrom sparksor open flames.
:iI 3.Connectthe diagnosisconnectorterminalsF/P and GND

witha jumperwire.
-l 4.TumtheignitionswitchON.
:.1
I
- -:'?i
-,.j1
-t
t
-:j
-l
: I
5.Tilt the iniectorsapprox. 60 degreesand verifythat no

fuelleaksfromtheinjectornozzles.
6. lf fuelleaksfroman injector,replaceit.
Note
. After 2 minute a drop of fuel from the iniector is
acceptable.
7. Turnthe ignitionswitchOFFand removetheiumperwire.
Volumetest
1. Removethe iniectors withthedeliverypipe.
2. Aflixthe injectorsto the deliverypipewithwire.
Caution
. Affix the iniectorsfirmly to the deliveri pipe so tlrat
no movementof the iniectorsis possible.
Warning
. B e e x t r e m e l yc a r e f u l w h e n w o r k i n g w i t h f u e l .
Alwayswork awayfrom sparksor openflames.
volumewitha graduated
3. Checkthe injection container.
tnjectionvolumes:
32-4066r (2.0-2.4cu in) / 15 sec.
replacetheinjeclors.
22-16 FUEL SYSTEMlrrv.lecroR)
lnstallation
Installin the reverseorderof removat.
referring
to Instattation
Note.
Tighteningtorque:
Deliverypipe
'!9-25
N.m (1.9-2.6kg-m,14-19 tb-ft)
lnstallationnote
1. Usenew injectorO-rings.
2. Applya smallamourrt of cleanenginecil to the o-rings
beforeinstalling.
CROMMET OEI.IVERY
PlPE
3. Installnew injectorinsulators.
4. fnstallthe injectors.
SPECIFICATIONS(senvtcEDArA) 22-17
SPECIFICATIONS
)n
s?nvtcrDATA
."--
Item I
-
F uelP um P
-trtaximum
outputpressure kP1(k/.tr, p.i) | aal -589 (4
Fuelfllter
I Low-pressure
side I Nylonelemenl(in fueipump)
lyge
Pagerelement
P r es s ur er e g u l a to r
Flegulating pressure kPa (kg/cm2,psi) 265-3 14 (2.7-3.2, 38-46)
I
Injecior
Tyge HiEh-ohmic
Type of drive Electromechanical

Resistance 0 1 2 -1 6
F uelt ank
CaPacitY liters(US gal, lmp gal) 5 0 ( 1 3 . 21
. 1.0)
F uel
Specification Unleadedregular
I
IGNITIONSYSTEM
OUTLINE ............... 3(F 3

CHECKAND ADJUSTMENT 3$ 5
SPARKPLUGS .. 3G 6
lGNmcN cotL ..3& 7
DISTRIBUTOR ... 3(F 8
IGNITER ...;........... 3G11
SERVICESPECTAL TOOL 30-12
SPECTF|CAnON 3tr12
TTGHTENTNG TOROUE ....30-12
-a_
OUTLINE(sPectFtcATtoNS)
e
N
\
IGNITION TIMING.
PAGE 30.6
1. Sparkplugs 4: lgniter
2. Distributor 5. High-tension
lead
3. lgnitioncoil
30-4 OUTLINE(crRcutTDTAGRAM)
CIRCUITDIAGRAM
ia
1!t-
-,,(9,
i1
,I
.+- |
.l
Yrl
:.'-.
*l I
. .-1
CHECK AND AOJUSTMENT (tcNrroNTIMTNG
/ HtcH.TENstoN
LEAD)
\s CHECKANDADJUSTMENT
IGNITION
1.Warm
TIMING
Adiustment
uptheengine to normal tenrperature.
operating
2.Tumallelectrical
loadsOFF.
3.TumtheA/CswitchOFF.
I 4.ConnecttheSST.
5. Pushthe selectorbuttenand then make the No. 1 lamp

illurninated.
Note
. To create the test conditlon wlthout uslng the
System Selector,connect terminals ENGINETEST
and GND of the diagnosisconnectorwith a fumper
wire.
6. Checkthe ignitiontiming.
Specillcation
'
7,lf the ignitiontimingis not as specified,loosenthe distrib

. - utor lock boltsand tum the distributorto rnakethe adiust'
nlent..
.. .-,-S.Tighteqthe distributorlock boltsto the speciliedtorque.
LOCK SOLTS
HIGH-TENSION LEAD :
Inspection -- :
of the high'tensionlgals.
1. Measureresistancb
Specification: 16 K Per 1 m (3.28tt)
30-6 SPARK PLUGS (NCNAOVAt
NNSTALT.ATION
/ INSPEETTON)
SPARKPLUGS
' REMOVAL / INSTALLATTON I
1, Removeand irrstallthe high-ten.sion

leadscardfully. 1t
s
Caution
. When the spark plug lead is to be pulled off, be
sure to pulf the boot itself, not the wire.
2. Rerfloveand installthe sparkplugwitha plugsocket. I

I
It
Caution I
- Be sure the socket is fit squarely over the spark :
plug.
,
I
3. Applyanti-seize compoundoi molybdenum-based lubri- ;
cantto the sparkplugthreads. I
4. Tightenthd sparkplugto lhe specifiedtorque. I
rcog SparkplugTighteningtorque:
1 5 . 2 3N ' m ( 1 . 5 - 2 . 3k g - m ,1 1 - 1 7l b - f t )
TNSPECTION
1. Removethesparkplug.
2. Connectthd sparkplugto a high-tensionlead.
3. H-ol{the spdrk plug with insulatedpliers 5-10mm (0.
20-0.39in) frOma ground.
4. Crankthe engineand verifythat there is a strongblue
spark.
Note
. lf there is no spark,replacethe spark plug.
5. Checkthe followingpoints.lf a problemis found,replace
. Damagedinsulation
' '. Wornelectrodes.
. Carbondeposits
' '',,'-lf
cleaningis necessary.usea plug cleaneror a wire
_: --..
; j
. :" ' brush.Clian the

i. a. upperinsulator;b;.
BURNT
. Damagedgasket.
. Burntcondition.
Pluggap : 1.0-1.1mm(0.039-0.043
in)
IGNITIONCOIL (tNspEcloN) s0-7
I G N I T I O NC O I L
INSPECTION
Sparktest
1.Disconnect the high-tensionleacfromthe distributor.
2.Holdit withinsulaiedpliers5-1Omm(0.20-0.39 in)froma
ground.
3.crank the engineand verifythat a strongblue sparkis
visible.
4.lf tnere is no spark, disconnectthe corrnectorfrom the

ignitioncoil and check for voltageat the positive(+) termi-
nal of the connectorwith the ignitionswitch in the oN
pcsition.
V o l t a g e: A p p r o x. 1 2 V
5.lf there is no voltage,check the main fuse, ignitionswitch,

and wire harness.
Primarycoil winding
1. U9ean ohmmeterand measureresistance of the primary
coilwinding.lf notwithinspecification,
replacethecoil.
Primarycoil resistance: 0.81-0.99a (at 20et6gTl)
Secondary coil winding

1. Use an ohmmeter and measure resistanceof the sec-
ondary coil winding.lf not within specificatio.n
replacethe
coil.
Secondary coil resistance: 10-16 k 0 (at 209[O8TJ)
Insulation of case
1 . U s e a 5 0 O V r h e g g e rt e s t e r t o m e a s u r e t h e i n s u l a t i o n
resistancebetweeneach terminaland the case.
Specification: 10 M 0 min.
e]t ,
iff" :
30-8 DISTRIBUTOR (tNSpEcloN) .1

t
DISTRIBUTOB
INSPECTION
SparkTest
1. Disconn€ctthe rrigh-tension
readfromeachsparkprug.
2. Hold each insulatorwith priers5-1Omm
froma ground 1o.zo-d.r-s''ln1
3. crank the engineand verifythat a strongbrue
sparkis
visible.
ElectronicAdvanceInspection
1. verifythatthe ignitiontimingadvanceswith engineaccel_
eration.
DISTRIBUTOR(REMOVAL / TNSTALLATTON)
REMOVAL/ INSTALLATION
1. Remove in the order shown in the figure.
2. lnstallin the revei'seorder of removal.
FIRINGOROERANO POSITION
1. Air hose 3. Connector

2. High-tension
lead 4. Distributor
30-10 DlsrHlBUTOR (DhssEMBLy
/ ASsEMBLv
/ rNspEcrroN)
D I S A S S E M B L Y/ A S S E M B L Y
'1
. Disassenrblein the order shown in the figure.
2. Assemble in the reverseorder of disassemblv.
1.6-3.0N.m(16-30kg-cm.t4-26 tb-fr)
REPLACE
1.6-3.0N.m (16-3okgcm.14-251b-ft)
1 .C a p 3. Cover
2. Rotor 4. Crankanglesensor
5. O-ring
CAP
INSPECTION
R OT OR
Cap and rotor
1. Checkfor corrosion.
damage.and cracks.
2. Replaceif necessary.
il
kl
#i
li
,- , IGNITER (rNspEUrtoNi spARKTEST/ voLTAGETEST) 30-11
IGNITER
INSPECTION
1. Disconnectthe igniterconnector.
I 2.Connect the SST between the igniier and the wire har-
ness.
3.Connectthe connector(a-pin) of the lgniterCheckerto the
adapterharness.
4.Connectthe power leads of the ignitercheckerto the bat-
tery.
SPARK TEST
1.Turnthe ignitionswitchON.
2. Disconnectthe high-tensioncoil lead from the distributor
and hold it 5-1Omm (0.20-0.39 in) from a ground.
-Caution
. Holdthe SW2ON for no longerthan one second.
3. Flip the SW2 ON and OFn and verifythat strongblue

sparksare discharged
from the high-tension
lead.
VOLTAGETEST
1.TurntheignitionswitchON.
2. Connecta voltmeterto the terminalof the black wire of
'theadapterharness.
Caution
. Holdthe SW2ON for no longerthan one second.
- 3. Flipthe SW2 ON and OFF,and veritythat the voltmeter

pointerfluctuates.
. vOLTtuIeTER
O
@ o
3O-12 SERVICESPECIAL TOOUSPECIFICATIONUTIGHTENING
TOROUE
S E R V I C ES P E C I A LT O O L
0l€01 189 048 For
SysterrrSelector inspection o!
iEnition
liming
It
SPECIFICATION
Engine / Transarle
Electronicspark advance (photodiode)

lgnition timing BTDC
ENGINETEST tenninalof diagnosisconnector
0.81-0.990
Resistance
(at 20trt68:r'l)
l0-15 k0
BPRsES.11
Plug gap mm (in) 1.0-1.1(0.039-0.043)
T I G H T E N I N GT O R Q U E
rltem
Torque N.m (kg-m, lb-ft)
Distributorlock bolts 1 9 - 2 5( 1 . 9 - 2 . 6 1. 4 - 1 9 )
Sparkplug 1 5 - 2 3( 1 . 5 - 2 . 31. 1 - 1 7 )
:at)
:::l
-{
STARTINGSYSTEM
OUTLINE 31.3
TROUBLESHOOTING GUIDE ........... 31. 5
STARTER 31. 7
STARTERlN]EaLoCK SWITCH ........ 31-12
SPEC|F|CAT|ONS 31-13
I
OUTLINE 31-3
OUTLINE
\ /'jr
4#--'-:i)
f'--..
\
2. Staterinterlockswitch
31-4 OUTLINE (ctnculr DIAGRAM)
C I R C U I TD I A G B A M
ER S1,!lTCFl'ATX
lNH18f1
STAFTTER INTERLCCK
tGNiTlOt.tswlTcH svJITCfi' MTX
o*
I
FIELOCOIL
ARMATURE
8 TERMINAL
S TERMINAL
TRoUBLESHooTING GUIDE (DlAcNosrtc
tNoEX
/ syMproMTRouBLESHSSING)31-5
TBOUB LESHOOTIT.IG
GUIDE
No Troubleshootlng ltems
- Pagc
1 i Wiil not crank- startermotordoesnot operate
31-5
2 I Will not crank- startermotorspins
31-5
3 Cranksslowly
31-6
4 Alternatcrwaming ramp ilruminareswhen engine running
31-6
n;-^L^--^-l l--..--.
YvrJ vdrKtl y
31-6
Misfire
31-6
S Y M P T O MT R O UB L E S H O O T I N G
1 Will not crank-S tarter motor does not operate
STEP IN S PE C T ION ACTIOt'l

1 Check if engine cranks with fulty charged Yes Check chargingsystem (Refer to page 32-B)
battery
No Go to nextstep
2 Check if battery voltage is applied at B Yes Go tc nexl stap
terminal
B TERMINAL
No Check wire hamess
3 Check if batteryvoltageis apptiedat S Yes . Qheckmagneticswitch(Referto page32-9)

terminalwhenclutchpedaldepressed(MTX) . Qhecklieldcoil (Referto page32.10)
and ignitionswitchin STARTposition . Checkarmature(Referto page 32-10)
S TERMINAL No . Checkdarterilertock s'nidt (tufnQ(Referto page'32-12)

o Checkinhibitorswitch(Referto section42.)
o Qheckignitionswitch(Referto section61.)
..Check wirehamess
2 Will not crank - Starter motor spins
1 Checkif drivepinionis pulledout while Yes Removbstarlerand checkttlnrheelringgear teethend

cranking(Clickheardwhenpultedout) starler.drivepinionteeth
No a Check magnetic switch (Refer to page 3Z-9)

a Check field coil (Reler to page 32-10)
31-6 TRoUBLESHooilNG GUIDE (syMproNrRouBLESHoorNG)
(
I
{ Cranks slovrly
I
i I N SP E C T I O N
Cheek if engine cranks normallywith lully

Check charging system(Refer to page 32-g)
charEed batrery
No Go to nextstep
Check starter cable conne:tion for looseness Yes Repair or replace connection
and corrosion
CH€CK
|vrlEUA
Ito' C h e c k l o r s t u c k s t a r t e r( b r u s h , d r r r a r u r € .€ f c . )
I
4 Atternator warnlng lamp illuminates when engine ,u-nning
STEP INSPECTiOTi ACTlON

1 Checkfor correctbatteryvottageat idle Yes check wire hamessbetweenarternator
: 14.1-14.7V
Specification L terminarand
al ternal or
w arni ngl amp
No C h e c k c h a r g i n gs y s t e m ( R e f e r t o p a g e 3 2 - g ) |
5 D i s c h a r g rld battery

1 Check charging system Yes Turn ignition switch oN and check dark ctrrrentas shown
(Refer to page 32-B)
(e
-)
Darkcurrent:Below20mA
No Repairor replacepartsas necessary
6 Misfire

1 Disconnect high-tension
teadlromeach Yes Check sfiark plug (Refer to page 30.7)
sparkplugand checklor strongbtuespark lf OK. engine electricalsyetem normal
.,vhilecranking
lf not OK, clean or replace spark ptrrg
No Checkignitionsystem(Referto page30.6)
tb
STARTER tRE MOVAL / | NSTALLATTON) 31-7
STARTER
REMOVAL/ INSTALLATION
1. Remove in the order shown in the figure.
?.lnrpqgl all parts and repairor replacl as.necessary.
3. Installin the rev€rseorder of removal.
37-52 N'm (3.6-5.3 kg.m.27-38 tb.ft)
1 9 - 2 5 N m ( 1 . 9 - 2 . 6 k 9 . m 1. 4 - 1 9 l b - f t )
37-52 N.m
(3.8-5.3 kg-m. 27 -38 lb-fr)
37-52 N.m (3.8-5.3kg-m.27-38 lb-ft)
9.8-12N'm
(10O-120kg-crn.
87-104rbfr)
37-52 N'm
(3.8-5.3kg-m.
27-38 rb-rr)
REMOVETHE STARTER
.AS SHOWNIN THE FIGURE
1. Battery 4. B terminalwire
2. Intakemanifoldbracket 5. Starter
3. S terminalwire- 6. Starterbracket
31-8 STARTER (DISASSEMBLY
/ ASSEMBLY)
DISASSEMBLY/ ASSAMBLY
1. Disassemblyin the order shown in the figure,referringto Disassembly Note.
2. lnspectall parts and repairor replaceas necessar),.
3. Assemblein the reverseorder of disassembly,referringto Assembly Noie.
3 . 8 - 7 . 1N r n
(39-72 kgcm. g-62tb.in)
o
4.1-7.5N'm 67lbin;
2 . 4 - 4 . 4N . m
(24-45kgcm. 2t -3glbh)
1. Magneticswitch 6. Lever
2. Rearcover 7. Drivepinion
3. Brushholderassembly 8. Armature
4. Fieldcoil 9. Bearing
5. Frontcover
DisassemblyNote
Drivepinion
1. Removethe stopperfor the overrunningclutch with a
pipeas shownin the figure.
AssemblyNote
Drivepinion
1. Setthe drivepiniononto the armatureand installthe ring.
2. Installthe stopperand an arbor press as shown in the
figure.
STARTER (TNSPECTION) 31-9
INSPECTION
Magnetic switch
1. Continuity(S terrninal- M terminal)
Check for continuitybetween S and M terrninalswith
ohmmeter. F(eplacethe magnetic switch it there is nc
continuity.
2. Continuity(S terminal- Body)

check for continuitybetweenthe s terminaland the body
withohmmeter. Replacethe magneticswitchif thereis n6
continuity.
3. Grounding
check continuitybetween M and B terminalswith an
. o h m m e t e r .R e p l a c e t h e m a g n e t i c s w i t c h i f t h e r e i s
continuig.
Brushand brush holder

1. lnsulation
Checkcontinuitybetweeneach insulatedbrushand the
platewithan ohmmeter.Replacethe brushholderif there
is continuig.
2. Measurethe force of the brush springwith a spring

- balance.
Drive belt 86 (MTX,ATX)
Standard 18.9-23.1
N (ks. lb) ( 1 . 8 9 - 2 . 3 1 . 4 . 18 - 5 . 1 2 )
ERUSHSPRING Maximum
N (kg, lb) 7 (0.7,1.5)
3. Replacethe springif necessary.

31-10 STARTER (lNspEcrtoN)
Brush
lf a brush is worn almostto or beyondthe wear limit,replace
U/EAR I-IMIT
atl of the brushes.
86 (MTX,ATX)
Standard mm (in) 17 (0.67)
I srlNoAno
Minimum mm (in)
310r2
Field coil
1.Checkfor continuity betweenthe M termirralwire and
brusheswithan ohmmeter. Replacethe yokeassemblyif
thereis no continuity.
3 1 01 3
2. Check continuitybetweenthe M terminalwire and yoke

with an ohmmeter.Replacethe yoke assemblyif thereis
continuity
3 .C h e c k i f t h e f i e l d c o i l i s l o o s e . R e p l a c e the yoke
assemblyif necessary.
Armature
1. Check continuitybetween the commutatorand the core
w i t h a n o h m m e t e r . R e p l a c e the armatureit there is
'
continuity.
2. Checkcontinuitybetweenthe commutatorand the shaft

w i t h a n o h m m e t e rR
. e o l a c et h e a r m a t u r ei f t h e r e i s
continuity.
a
:&
E
:E
iF
fi
fr
s
tr
TF
3r0t6
STARTER (rNSPEcloN) 31-11
3. Place the arrnatureon V-blocks,and measurethe runout

with a dial indicator.
lf tfre i'unoutis not within specification,repair it with a
latheor replacethe armature.
Runout : 0 . 0 5 r n m( 0 . 0 0 2i n )
M a x i m u m : 0 . 1 m m( 0 . 0 0 ai n )
4 . R e p l a c et h e a r m a t u r ei f t h e o u t e r d i a m e t e ro f t h e
commutator is almostat or lessthanthegrindlimit.
5.lf the commutator surfaceis dirty,wipeit witha cloth;if it
is rough,repairit witha latheor finesandpaper.
86 (MTX,ATX)
mm (in) 3 1( 1 . 2 2 )
6. Segmentgroovedepth
lf the depthof the mold betweensegmentsis almostat or
l e s s t h a n t h e m i n i m u m , u n d e r c u t t h e g r o o v e st o t h e
standarddepth.
D e p t h : 0 . 5 - 0 . 8 m m( 0 . 0 2 - 0 . 0 3i n )
M i n i m u m : 0 . 2 m m( 0 . 0 0 8i n )
Bearing(if equipped)
1. Checkforabnormal noise,looseness,or sticking.
p. Replacethe bearing(s)
if necessary.
5
*
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31-12 STARTERINTERLOCK
SWITCH(TNTERLOCK
SWtTcH)
STARTERTNTERLOCKSWTTCH(MTX)
CONTACTPT.AT
IGNITION
SWTTCH
INTERLOCK
SWITCH
For operatorsafety,if the clutchpedalis not depressedduringstarting,batterypowerwill

not be suppliedto
lhe slarterand the enginewill not crank.
INTERLOCK SWITCH
Inspection
1. Disconnectthe interlockswitchconnector.
3. Checkthe continuity.
Glutch pedal Corrtintrity
Oepressed Yes
Released No
4. Replacethe switch if necessary.

SPECIFICATIONS
Englne / Trenrerle
Startet
17(0.67)
i 1.s(0.4s3)
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CHARGINGSYSTEM 2,
OU TL.IN E 32- 2
T R O U B L E S H O O T I N G. 32- 3
BATTERY 32- 6
A LTE R N A TOR ...,......... 32- 8
DRIVEBELT 32-12
S P E C t F I C A T I O N S. . . . . . . 32-13
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OUTLINE
OUTLINE
32-4 OUTLTNE(ctRcutTDTAGRAM)
C I R C U I TD I A G R A M
o to o ET R | O
STATORCOIL
IC REGULATOR
IGNITION
SWTTCH
The arternatorhas a serf-diagnostic

functionto warn of the followingproblems
system. in the charging
cr warninglampilluminates.
TROUBLESHOOTING
32-5
TROUBLESHOOTING
1 Check batteryvoltage Yes Go to nen step
Specificatlon : Above 12.4V No Checkbattery(Referto page 3Z-7)

2 Start engine and check if alternatorwaming Yes Go to Step 4
lamp goes out
No Go to nexl step
CHARGE
3 Check if voltages at altemator terminalsare Yes Check wire harness between battery and terminal g
correct
Specification:
Terminal lgn: on(V) ldle (V)

I Ao o ro x 1
.2 14.1-14.7
L Approx.1 14.1-14.7
S Ap p ro x 1
.2 14.1-14.7 No o Check wiring harness
o Replace altemator(Refer to page 3Z-B)
4 1. Connect an ammeter (70A min.) between Yes Charging system normal

lerminal I and harness'
2 . S t a r te n g i n e
3. Turn ali elect;icallcaCs Ol{ and deoress
brake pedal
4. Check if output current is 654 or more at
2,500-3,000 rpm
Caution
c Do not ground terminal 3 G" .,"tr
";.rt
\:-' . t ! t:
.:i t.,
++.1
-..';l
.:{ l
FI
+-l
5 Check if drive belt tension is OK Yes Replacealternator(Referto page.32-e)
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9r:vebelt I New I Usee
N t e r n a t o rl 3 6 H A l 1304-383
l.l(kg.lb):' I 1fS-cZ. 1 (31-39.
':-
| 85.8-103.4,I 6S.2-S5.8) Adjust drive belt tension
A/Cand P/S I 491--5a9 | cZZ--{st
N.(kg.
tb) .r I (sr€o. | {ra-+o.
: .- -1.11r-132) | 9F110) J ! i
- a l
32-6 BATTERY (tNSpEcnoN)
BATTERY
INSPECTION
Electrolyte level
1. check whetheror not the erectrolytelevel lies beh,rreen
the'UPPERLEVEL'andthe 'LOWERLEVEL.lines.
2. lf low add distilledwaterby the 'UppER LEVEL-.
Do not overfill.
Specific gravity of electrolyte

l.Ieasurethe specificgravitywith a hydrometer..
a!= Specification: i.ZT-1.29(at 20e [68.FJ)
Note
. lf the battery charge indicator is not blue when
the specific aravity is normal, the indlcetor could
be defective.
Battery discharge test
Measure open circuit voltage of batteqr with a digitat voltmeter capable

of reading0.01V
Ouick charge for 2 hours

and recheckvoltage
o Apply lest load (see test load chart) to the battery

usinga battoryload testor Baltery Load (A)
o Recordbatteryvoltage at the end of 15 seconds: is
PT48.25ER 150
voltagemore than specification?
Eattery voltage with load
ApproximateI Minimum
batterytemp I voltage (V)
21tr(70:F)| s.5
15e(60' F) | 9. 5 - ? l
l
l oC (50' F) | 9. 4 .i
I
it
4 e(40:F') | 9.3 -t
.t e(3o'F') | 9.1
I
:7e(20.F) | 8.9
ir2e1ror1| ..t
.18U(0.t.) ; 8.5
BATTERY (rNsPEcric:;i 32-7
Terminaland cable
1. check the tightnessof the terminalslo ensure good elec-
RUBgER
PROTECTOR
trical connections.
2. Check for corrodedor lrayed batterycables.
3. Check the rubber protector on the positive terminal for
propercoverage.
4. Clean the terminals if necessary,and coat them with
grease.
UJ
Recharging
Battery Slow charge Ouick charge
d 1.28 (A) (A)
>g
5 <-l
4 ! t.za
E [rJ
PT48.25ER U nder5 Max.20
o
H 1.2c
6
UJ
o- Slow charging
a
6 1t6e) 8o (176) It is not necessaryto removethe vent caps to performa
TEMPERATURE[e('F)l
slowcharge.
Quickcharging
Removethe batteryfrom the vehicleand removethe vent
capsto performa quickcharge.
Warning
. Before performingmaintenanceor rechargingthe
battery, turn off all accessories and stop the
engine.
. The negativecable must be removed flrst and
installedlast.
. Set the batteryin water when quick chargingto pre-
vent overheatingthe battery.
32-8 ALTERNATOR(REMOVAL/ tf,rsTAt-LATtON)
ALTEHNATOR
REMOVAL / INSTAL I..ATIO
N
Catrtlon
' B€ aure the batteryconnectionsare not reversed,
becausethis will damagethe rectlfler.
' Do not use hlgh-voltagetesters such as a megger,
becausethey wiil damage the rectlfler.
' Rernemberthat.U"tt".Vvoltage-isalwaysapplfed
to the alternatorB terminal.
. Po not ground the L termlnaiwhilethe'engineis
'unning.
' Do not start the enginewhile the connectol is disconneited
from the L and s terminals.
1. Removein the ordershownin the figure.
!. lnsnectall partsand repairor repra.i as necessary.
7 . 8 - 1 1 . 0N . m ( 0 . 8 - 1 . 1k g . m . 5 . g - B . Ot b - t r )
-^x
\
37-SZN.m (3.8-5.3kg-m.27-38tb-tr)
19-25N.m
(1.9-2.6kg-m.14-19tb-ft)
1. NeEativebatterycable 4. B terminalwire
2. Solenoidbracket(tfequippeC) 5. Drivebelt
3. Connector 6. Alternalor i
Ei
ALTERNATOR (DtAssEMs'-y
; ASSEMBLv) 32-9
1 . D i s a s s e m b l ei n t h e o r d e rs h o w n i n t h e f i g u r e .
2. Inspectall parts and repairor replaceas necessary.
3. Assemblein the reverseorder of disassembly.
5 9 - 9 8N ' m ( 6 - 1 0k g - m . 4 3 - 7 2l b - t t )
o
*B
2.0-5.4 N'm (20-55 kg-cm. 1.4-4.0 lb-ft)
2.f 5.4N'm
(20-55 kg'cm. 1.4-4.01b{t),
2e-04 .^/
(30-65kg-cm.2.2-4.7lb-ft)
l@
I
2.0-5.aN'm
(20.55 kg-cm.1.,1-4.0lb-tt)
I --
- - l
t
I
- ':'
'-:
.l
i 1. Pulley 5. Stator
_i 2. Frontcover 6. Rectifier
3. Rotor 7. Brushholderassembly
=.:;
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4. Rearbracket 8. Bearing
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.
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El
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32-10 'ALTERNATOR
(rNSpEcloN)
INSPECTION
Rotor
1. Measurethe resistancebetweenthe srip
rings with an
ohmmeter.
Specification: 3.5-4.50
[at 20C(68"1.)J
lf not withinspecification,
replacethe rotor.
2.(1) checkcontinuity betweeneachslip ring and the core

withan ohmmeter.
12)Replacethe rotorif thereis continuitv.
3- check if the sripringsurfaceis rough.'ur"
perto repairit if necessary fine sandpa-
Stator
1. check for continuitybetweenthe statorcoil leads
ohmmeter. with an
2. Replacethe statorit thereis no continuity.
3. check continuitybetweenthe statorcoil leads

ancithe
corewithan ohmmeter.
4. Replacelhe statorif thsreis continuity.
ALTERNATOR (tNSPEcrroN) 32-11
Rectifier
1.Checkcontinuityof the diodeswith an ohmmeter.
Negative Positive Continuily
E Yes
I P n ,P r , P z .P : No
T No
tr No
P " .P t . ? z . P t
I Yes
Pr. Pz,Pt Yes
T
Pn No
2. Feplacethe rectifierif necessary.
Brush
lf a brushis wornalmostto or beyondthe limit,replacethe
brushes.
Standard : 21.Smm(0.8a6In)
WEAR
LIMIT Minimum : 8.0mm(0.315in)
Brushspring
1. Measuretheforceof the brushspringwitha springpres-
suregauge.
2. Replacethesprlngif necessary.
Standardforce:
3.1-4.3N (320-4409, oz)
11.3-15.5
Minimum:i.6-2.4N (160-2409,5.6-8.5
oz)
Note
. Readthe springpiessurerviththe brush tip prolect-
ing 2mm(0.079in).
Bearing
1.Checkforabnormal noise,looseness,or sticking.
if necessary.
2. Replacethebearing(s)
32-12 D RIVE B ELT (INSPEcTIoN,AoJuSTI.,tgNT,
REPLAcEMENT)
DRIVEBELT
INSPECTION
t. checkthe dri.vebeltand puileyfor wear,cracks,and fray-
ing.Replaceif necessary.
Measurethedrivebelttensionwitha tensiongauge.
Tension N (kg.tb)
Orive belt New Used
WHEN MEASURED
Alternator 383-461 304-383
(39-47. 85.8-103.4) (31-39. 68.2-€5.8)
A/C and P/S 491-589 422491
WATERPUMP (50-60. 110-132) (43-50, 95-110)
P/SOIL PUMP
3. Measurethe de_fl.ectiol by appryingmoderatepressure

(.98N, 10 kg, 22 lbl midwaybetweenthe puileyi. eOjiri
if necessary.
Deflection mm (in)
Drive belt New Used
Alternator 8-9 9-10
(0.31--0.3s) (0.3s-{.3s)
A/C and P/S 8-9 9-10
(0.31-{ .3s) (0.3s-{.3s)
Adiustment
1. Loosenthealternatormountingboltand adjustingbolt.
2. Movethe altematorto set the specifieddeflectiori.
3. Tightenall boltsand recheckthe tension.
Replacement
'1.RemovetheA/C and P/S
drivebelt,if equipped.
Note
..Referio section11.
-
2. Loosenthealternatormountingboltand adjustingbolt.
3. Removethealternatorbelt.
4. lnstallthe newalternatorbeli ancJadjustit to speclfication.
5.1ightenall boltsto the specifiedtorque.
Tighteningtorque
- Alternatorbolt :
37-52 N.m (3.8-5.3kg-m,2T-39 tb-ft)
Adjustingbolt :
19-25N.m(1.9-2.6kg-m,14-19tb-ft)
6. Installthe A/C and P/S drivebelt if equipped,and adjust

tc specilication
Note
. Referto section11. i'
,l
SPECIFICATIONS 32-ir
SPECIFICATIONS
Engine / Transaxle
85
Item
Voltage V 12
Battery Type and capacity
P T 4 8 . 2 5 E R( 4 8 A H )
(20-hourrate)
D a r kc u r r e n t ' t mA Max.20.0
Type A.C
Output V-A 12-70
Regulatortype Transistorized(built-inlC regulator)
Regulatedvoltage V r4.1- 14.7
Alternator
Brushlength Standard 2 1. s ( 0 . 8 4 6 )
mm (in) Minimum 8 . 0( 0 . 3 1 s )
Drive belt deflection New 8-e (0.31-0.3s)
98 N (10 kg,22 lb)
mm (in) Used e-10 (0.3s-o.3e)
'1
Dark currentis the constantflow of currentwhile the ignitionswitchis OFF.
(enginecontrolunit, EC-ATcontrolunit,audio,etc.)
?'I
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I
CLUTCH
OUTLINE 4G 3
TROUBLESHOOTING GUIDE ........... 4(F 4
AIR BLEEOING . 40. 5
CLUTCHPEDAL 4$ 6
CLUTCHMASTERCYLINDER........... 40. 8
CLUTCHRELEASECYLINDER........ 4C11
CLUTCHUNIT ... 4tr13
RELEASEBEARING........ .i.............
40-16
CLUTCHCOVER 4tr16
CLUTCHDISC ... 4C16
PILOTBEARING 4S.17
FLWHEEL ......... 40-17
"l
OUTLINE 40-3
OUTLINE
VIEW
STRUCTURAL
\ cr_uTcH
\ swrrcH
I
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;
.:.!
1.Clutchpedal 6. Clutchcover
2. Clutchmastercylinder 7. Clutchdisc
3. Clutchreleasecylinder 8. Pilotbearing
4.
'5. Releasebearing s. Flywheel
Clutchreleasefork
4(F4 T R O U B L E S H O G T I N GG U I D E t
Problem possible cause
Remedy
Sllpplng
Replace
Repair or replace
Repair or replace
Replace
Adjust
Repair or replace
Repair or replace
Faulty dfsen- tsxcess,ve runout or damaged clutch
gagcment disc Replace
Clutch disc splines rusted or wom
Oil on facing Remove rust or replace
Diaphragm spring weakened Repair or replace
Excesslve ctutch podat ptay Replace
lnsutliclent ctutch fluid Adjust
Leekage of ctutch ltuid Add Fluid or
Locate and repair or
replace
Clutch vlbratqc Oil on faclno
when eccelerrtlng Torsi,tin rub5ers weakened Repair or replace
Reptace
Repair or replace
Replace
Replace
Repair or replace
Tighten or replace
Clutch p.d!l
rttcklng Lubricate or replace
Abnonnal nolte Clutch release bearing damaged

Poor tubrication of retEase b;;;;9 Replace
- steeve
-' Lubricate or repface
Torsion rubbers weakened
Excessive crankshaft end play Replace
Ue.aring wom or damage'd Repair
.fitot Replace
Wo;n pivot point of release jork
Repair or replace
AIR BLEEDING 40-5
AIR BLEEDING
The clutch hydraulicsystem must be bled to remove air that
enteredwhen the pipes were disconnected.
This bleedingis done as describedbelow.
Note
a) The fulid In the reserve tank must be malntalned at
the 3/4 level or hlgher during air bleedlng.
b) Use only the specified ftuid type.
c) Be careful not to spill clutch fluid onto a patnted
surface.
1- Removethe bleedercap, and attacha vinyl hose to th€

bleederscrew.
2. Place the other end of the vinyrtube in a glass container
of the appropriatecapacity.
9.9lgyty pump the ctutchpedat severattimes by hand.
4. while the clutch pedal is depressed,toosenthe bleeder
screw to let fluid and air escape.
' Then close
the bleederscrew
5- Repeatstep 3 and 4 untilno more air bubblesare ln the
fluid.
6. Check for correctclutchoperation.
I
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I
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:f
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4S.6 CLUTCHPI:DAL
CLUTCH PEDAL
ADJUSTMENT
1 4 -1 8 ClutchPedalHeight
( 14 0 - 18 0 . 12 2 - 15 6 ) lnspection
16-23 1.Measurethedistancefromthe uppersurfaceof the pedal
(160-230.139-200) padto thecarpet.
Pedalheight: 196-204mm (7.72-8.03in)

(Withcarpet)
2, lf necessaryadjustthepedalheigaht.
Adjustment
1. Disconnect the clutchswitchconnector.
2. Loosenlocknut@ and turn clutch switch@ until the
heightis correct.
3.1rghten locknut@.
Tighteningtorque:
14-18N'm (1.4-1.8 kg-m,10-13 lb-ft)
measurethe pedalfreeplay.
4. Afteradjustment,
Clutch PedalFreePlay
Inspection
1.Depressthe clutchpedalby hand untilclutchresistance
is felt.
Pedalfreeplay : 3-9 mm (0.12-0.35

in)
2. lf necessaryadjustthe pedalfree play.
Adjustment
N'm (kg-cm. lb-in) 1. Lcrosenlocknut@ and turn push-rod@ untilpedalfree
play is correct.
2. Cfreckthat the disengagement height(fromthe upoer
surfaceof the pedal to the car.oet)is correctwhen the
pedalif fullydepressed.
height: 41 mm (1.61in)
Minimumdisengagement
(Withcarpet)
Tightenlocknut@.
13.
torque :
Tighterring
16-23 N'm (1.6-2.3kg-m,12-17 lb-tt)
.4.Afteradjustment,
inspectthe pedalheight.
CLUTCH PEDAL 40-7
REMOVAL/ INSPECTION/ INSTALLATION

1. Removein the order shown in the figure,referringto Removal Note.
Z. Inspectall partsand repairor replaceas necessary.
Note
. Apply lithium based grease to the bushing and pins before installation.
:r lf
3. Installin the reverseorderof removal,referringto InstaltationNote.
16-23N'm
(150-230 kg-cm, 139-200 lb-in)
(2.0-3.5kg-m
14-25rb-tt)
\ L--r
1 4 - 1 8N . m
(140-180 kg-cm.
: ._ l_22:1sq lb-in) -
(
:
(?
1.Splitpin 7. Washer
2. Pin B.Bolt
3. Pushrod 9. Spring,
4. Nut 10.Clutchpedal
5. Springwasher 11.Bushing
6.Washer 12.ClutEhpedalpad
I
40-8 CLUTCH MASTER CYLINDER
CLUTCHMASTERCYLINDER
REMOVAL / INSPECTION/ TNSTALLATION
Caution
' clutch fluid will damagepaintedsurfaces-
Be sure to
lluld gets on a paintedlurface, wipe ii;ff i,,,-"di"[r-v use a containeror rags to collect lt. if
*itn a rag.
1 . Removein the ordershownin the figure,referring
ro RemovarNote.
2. fn.pg"t all partsand repairor replac-"
3. Installin the reverseorderof removarreter;ng
"r'n""".i"qy.
t InstartationNote.
1. Clutchpipe
2. Nut
3. Mastercylinder
After installation
1. Performair bleeding.
?. Yeritythatthereis nb teakage.
3. Performa rcad test. i
I
=4
v.4
CLUTCH MASTER CYLINDER 40-9
Caution
. Clean the digagsembledparts in solvent and blow through all ports and passages
with corrF
pressed air.
if 1 . Disassernble in theordershownin thefigure.
2 . Inspectall partsandrepairor replaceas necessary.
3 . Assemble in the reverseorderof disassenrbly.
@
e
Onr
1. Reservoirtank 6. Spring
2. Snapring 7. Valvestopper.
3. Pushrod 8. Spring
4. Piston 9. Valveassembly
5. Pistonstopper
DisassemblyNote
Snapring
Caution
. Do not damagethe push rod contactsurlaceof the
piston.
:
1. Pressthe push rocjdownand removelhe snapringwith
snapringpliers.
2. RemovJine pushrpdandpiston.
40-1C C L U T C H M A S T E RC Y L | N D F ' R
Piston and Piston assembly
Caution
. Hotd a rag over the master cylinder to prevent the
p i s t o n a s s e m b l yf r o m j u m p i n g o u t .
1. Remove the piston assembly,by applyingcompressedair

throughthe clutch pipe installationhole.
2. Raisettreclipoi tl'repiston,s;topper
witha suitabte
tool.
Caution
. Holdtrhepistonassembtyto preverttthe piston
from jurnpingout.
AssemblyNote
Caution i
. Beforeassembry,makesure ail parts are com- I

t
pletelyclean. =t
. Do not mix differentbrandsof clutchftuid.
- Do not reusethe crutchfruidthat was drained.
. Applythe specifiedclutchfruidto the each part of
the pistonassembryand cyrinderbore befoie
' assembly.
- Replacepartswith new oneswheneverspecified
to do so.
Pistoncup assembly
1. Pushtheclipof the pistonstopperwithsuitabletool.
rod cohtact surface of
llre push rod. installthe snap ring.

CLUTCH RELEASE CYLINDER 40-1':
C L U T C HR E L E A S EC Y L I N D E R
PREPARATION
SST
O K 1 3 04 3 00 1 9 | For
disconnecting
Wrench.flarenut and connecting
ffi. clutch pipe
R E M O V A L/ I N S T A L L A T I O N
Caution
. Ctutch fluid will damage painted surfaces. Be sure to use a container or rags to collect lt.
lf fluid does get on a painted surface, wipe it off immediately with a rag.
1. Removein the ordershown in the figure,referringto Removal Note.

2. Installin the reverseorderof removal,referringto Instaltation Note.
o
EI
13-22
(1.3-?.2,9-161
E (MOLYBOENUM
DTSULFtOE)
r 9 - 2 6( 1 . 9 - 2 . 6: .4 - 1 9 )
N.m (kg-m. lb.fi)
1. Clutchpipe 3. Clulchreleasecylinder
2. Bolt
RemovalNote
Clutchpipe
Caution
. . - After removlngthe clutch plpe, plug the clutch
plpeto avoidfluid leakage.
theclutchpipewiththe SST.
1. Disconnect
4S.12 C L U T C HR E L E A S EC Y L I N D E R
lnstallation Note
Clutch pipe
1. Trghtenthe clutch pipe with the SST'
Tightening torque :
13-22 t't'm (t 3-2-2 kg-m, 10-16 lb-ft)
Air Bleeding
bleed the clutchsystem'
1. Afterinstaltation,
(Referto Pagebelow)
OVERHAUL
all ports and passageswlth corn-

:tEi:l" the dlsassembtedparrsin solventand btowthrough
oressedair.
. 5"iot" makesureall partsare comPletelyclean'
"".".b|y, pist"n and assemblyand cylinder bore before
. Apply the sPeclfied "uf
assemblY. "ruich-rrui[G1tre
Note'
Disassemble in the ordershownin the figure,referrin!to Disassembly
inspectall partsand repairor replaceas'nec.essary.
AJemble in the reverseorderof disassembly'
@ s.s-e.a(60-eo.52-761
N'm (kg'cm. lb'in)
)',;.' ''
. - :i - -- . . 5. Bleedercap .
1. Boot screw
- ; ,. - '' o --6. Bleeder
2 . P u s hr o d f l . '
g. Pitton and cu-fissemblY 7. Steelball
8. ReleasecYlinderbodY
4. Spring
C L U T C HR E L E A S EC Y L I N D T R C
, L U T C HU N | T 40-13
Pistorrand cup assembly
Caution
. Hold a rag over the release cylinder to prevent the
piston and cup assembly from suddenly popplng
out.
1. Remove the piston and cup assemblyby applyingcom-

pressedair throughthe clutchpipe installationhole.
t C L U T C HU N I T
I PREPARATION
SST
0 K 5 9 0 1 1 10 0 1 For 0 K 1 3 01 6 00 1 0 For
prevention of support of clutch
Brake. ring gear engine rotation clutchdisc disc
centeringtool
0 K 4 1 01 1 10 1 2 0 K 4 1 0 1 1 10 2 6
For For
removal of pilot Check removalof pilot
Puller,bearing bearing bearing
40-14 CLUTCH Ui.iIT
REMOVAL I INSTALLATION
Note
. Remove the clutch release cylinder with the clutch pipe connected.
. Do not remove the pilot bearing if not necessary.
1. Remove in the shown in the figure,referringto Removal t'lote

2. lnstallin the reverseorder of removal,referringto lnstallation Note.
18-26
v
(1.8-2.7_.
13-20)
@s
16-23
(Dr<rr \
(1.6-2.3.12-171 @ EEII
@Eff
E
fl
.:t
EI
:ill
N'rn (kg-m. lbJt)
1. Clutchreleasecylinder 7. Clutchdisc
2. Transaxle 8. Pilotbea:'ing
3. Boot 9. Flywheel
4. Releasebearing
fork
5. Clutchr:elease
6. Clutchcover
CLUTCH UNIT 40-1s
Removal Note
Clutch cover and disc
1. Installthe SST or equivalent.
2. Looseneach bolt one turn at a time in a crisscrosspattem
re
until spring tensionis released. Then remove ths clutch
cover and disc.
Pilot bearing
1. Removethe pilotbearingwith the SST if necessary.
Flyrhee!
Note
. After removing the flyrheet, inspect for oil leak-
-
age past the crankshaft rear oil seal.
ff necessary,replacethe oil seal.
(Refer to Section 10)
1. Hold the fly,rrheel

with the SST or equivalent.
2. Removethe flyruheel.
!nstallationNote
Flywheel
l. Wipe the boltsclean and apply sealantto the bolt threads.
2. Inslallthe flywheeland the SST or equivalent.
' : '
3. Tghten the boltsin the patte!'nshcwn.
Tighteningtorque:
,t. N'm(9.8-10.5kg-m,71-7Alb-ft)
r 103
P.ilotbearing
.. _Ncte _.
. Install the pilot bearing flush with the flyruheel.
1. Installthe newbearingwitha suitablepipe.

- ' a
B_earing
outerdiameter: 35 mm (1-378in)
'-'-: i
=: "'
CLUTCH UNIT 40-1s
Removal Note
Clutch cover and disc
1. Installthe SST or equivalent.
2. Loosen each bolt one turn at a time in a crisscrosspattem
until spring tensionis released. Then remove the clutch
cover and disc.
Pilot bearing
1. Removethe pilotbearingwith the SST if necessary.
Flyrhee!
Note
. After removing the flyrheet, inspect for oit teak-
-
age past the crankshaft rear oil seal.
ff necessary,replacethe oil seal.
(Refer to Section 10)
1. Hold the flyarheelwith the SST or equivalent.

2. Removethe flywheel.
!nstallationNote
Flywheel
l. Wipe the boltsclearrand apply sealantto the bolt threads.
2. Inslallthe flywheeland the SST or equivalent.
' : .
3.1ighten the boltsin the patte!'nshcwn.
Tighteningtorque:
tt. N'm(e.8-10.5kg-m,71-76 lb:ft)
, 103
Pilot bearing
_ _Ncte _.
. Install the pilot bearing flush with the flpvheel.
-'- 1. Installthe new bearingwith a suitablepipe.

- _ a
Bearingouterdiameter:35 mm(13=?'_9
1.".1
40-16 CLUTCHUNlr,RELEASEBEAR|NG,
clurcH covER, CLtTTCHD|SC
Clutch disc
1. clean the cfutchdisc splinesand main drive gear
spilnes;
apply organicmotybdenumsutfide!r""i". -
^ lf".n.
2. Hold the clutch disc in positionwith the SSf.
Clutchcover
1. Installthe SSTor equivalent.
2- Alignthe dowerhoreswith the fry,rrheer
dowers.
3.Tightenthe bolts evenryand'grad;"rt in the pattern
shown.
Tighteningtoruqe :
1g-26N.m (1.g_Z.Zkg-m,13_20tb-ft)
RELEASEBEARING
INSPECTION
Note
. The clutch rereasebearingis a searedbearing \,
and
must not be washedin solvent.
1.Turnthe bearingwhileapplyingforcein the
axiafdirection.
lf thebearingsticksor hasexcessiveresistance,replaceit.
CLUTCHCOVER
INSPECTION
- Note
. Minorscoringor burnrngshoutdbe remcved
with
1. Inspectthe contactsurfaceof the clutch

disc for scoring,
cracks,and buming. Repairo1 as necessary.
leptace
2. lnspectthe-contactsurfice of ihe clutch
*1""r" bearing
for wearand cracks.
lf thereis wearor cracks,repracethe crutchcover.
CLUTCHDISC
INS.PECTION
Note
. . . Usesandpaperif the troubleis minor.
l. Inspec!thg iiningsr.rrfacetor burningand oil contamina-
tlon, Repracerf,e crutchdisc ii ii F b;;ri burned
'r or oil
^ soaked.
2. lnspectfor loosefacingrivetsand rubba;r.
Replacethe ctutchOis6if eitheria lo-os;'''
CLUTCHDISC,PILOI BEAFIT{G,FLYWHEEL !tc-17
3. Measurethe thicknessof the lining at a rivet head on both

sideswithvemiercalipers.
Replacethe clutchdisc if its thicknessis less than minimum.
Thickness : 0.3 mm (0.012in) min.
4. Measurethe clutchdisc runoutwith a dial indicator.

Replacethe clutchdisc if runoutis excessive.
Runout : 0.7 mm (0.027in) max.
P I L O TB E A R I N G
INSPECTION
1. Tum the bearingwhile applyingforce in the axialdirection.
lf the bearingsticksor has excessiveresistance,replaceit.
.Gtil
FLYWHEEL
INSPECTION
Note
. Mincr scorlngor burnlng should be removedwlth
emerypaPer.
1. Inspectthe contactsurfaceof the clutchdiscfor scoring,
craeks,andbuming;repairor replaceas necessary.
2. Inspectthe ringgearteethfor wearanddamage.lf nec'

replacethe ringgear.
essar),,
3. lleasure the flywheelrunout with a dial indicator.
Repiacethefiyrheelif runoutis excessive.
* ilunout : 0.2mm (0.008In)max.
I
l:0-'! 8 SPECIFICATIONlsenvtcEDArA)
SPECIFICATION
SERVICE DATA
- Engine/Transarte
nafi l\---
Cldch control I Hydraulic
,
Clutch cover
TyPe O i a p h r a g ms p r i n g
Set load N (kg. b ) 3 , 6 3 0 ( 3 7 0 ,8 1 4 )
O u t e rd i a m e t e r mm (in) zOO(7.87)
l n n e rd i a m e t e r mm (in) 1 3 0( s .l 2 )
Clutch disc P r e s s u r ep l a t e
3 . 8( 0 1 s 0 )
side mm (in)
Thickness
Fty,,rheelside
3 . s( 0 . 1 3 A )
mm (in)
Type Suspended
Pedalratio 6-4
C l u t c hp e d a l
F u l ls i r o k e mm (in) 1 3 2( s . 2 )
Frergnr(s/rtn carpet) mm (rn 1 9 6 - 2 0 4( 7 . 7 2 - 8 . O 3 )
Mastercylinder lnnei'diameter mm (in) 1 s . 8 7( 0 . 6 2 s )
R e l e a s ec y l i n d e r I n n e rd i a m e i e r mm (in) 1 9 . 0 5( 0 . 7 5 0 )
Clutch fluid S A E J 1 7 0 3 o r F M V S S 1 1 5D O T - 3
'
W TIMORPUTRANASIONAL

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TIMOR 5515 /SS15i

This manualis organisedintoGroupscoveringgeneral

each Section contains an Outline Description,

for the componentcoveredin the Section.Diagnosis

To aid in locatingspecificsubjectsin thismanual,use CharghingSystem

Applybrakefluid Only brake fluid

2. Check the terminalsof r,vaterproofconnectorsfrom the

C OD E COLOR CODE C OLO R

LB Light Blue Y Yellow

Oil working down

Abnormal l , 1 a luf n c i i o n o f e n g i n e - r e l a t e d. * n[-

0 K20i 189063 For

1.Verifythatthecoolantlevelis nearthe radiatorfillerneck.

5. lf the deflection adjustthe belt.

D r i v eb e l t New Used I uimit

10A-8 E N G I N E E N G I NTEU N E . UPPR o c E D U R E

Removal/ Inspection/ Installation

1. P/S ancUorPJCdrivebelt B.Timingbeltcover,lower

8. Tum the crankshaft 2 turnsclockwise, and verifythatthe

Drive plate (A,rr)

Drive plate (A/f)

2. lnstallthe adapter,driveplate,and backingplateonto the

1. Removeti:e A/c compressorwith the hoses stillconnectec.

2. Pull the lower arm downwardto separatethem from the

3. Separatethe driveshaftsfi'omthe transaxleby pryingwith

104-32 ENGINE REMoVAL

3.Assemble theSST(nuts,hooks,and bolts).

i'JUT \'"..'gi-.1cqtiUT LESS THAN

l,o^ro1110AAO r For oKzol110Ao2 F g For

o ' K 2 0 11 1 0 A 0 B For 0 K 2 0 11 1 0A 1 1 For

S*-aB . Neverforcefullytwist the timing belt. D o n o t t u m i t

Clutch ccver (f\4ff)

I@F 4. Removethe SST.

1. Connecting rodcaP 7. Mainbearingcap

3.lnsertthe ssr No. 2 intothe pisionpin as shownand

1. Cleanall the partswiih beingsuie to removeall gasketfi-agments,

3. lf the cylinderhead distortionexceedsspecification, grind

Heiglrt i 1O7.4-107.6mm (4.228-4.236in)

4. Measure the manifold

5. lf the distortionexceedsspecification, grindthe surfaceor

6. Calculatethe valves.temto guiclethe clearance.

7. lf the clea;anceexceedsthe specification,

3' Apprya thincoatof prussian

& . replacethe valve. face,

3. Inspectthe camshafl for wearor damage.Replacethe

3. lf the distortionexceedsthe maximum,repairby grinding

4' Measurethe cyliqderboresin

) L-__ (3) if the difference

4.lf the ciearanceexceedsthe maximum,replacethe piston

Clearance CIopand Second)

2. lf lhe clearanceexceedsthe maximum,replacethe piston.

5. Measureeach pistonring end gaps lvith a feelergauge.

1. check the tensionerand the idler for a smooth rotation

Free length : 64.0 mm (2.520in)

at<201110 41 ' For 0 K 2 0 111 04 1 2 For

0 K 9 9 31 2 0 0 0 1 For 0K710 120 008 For

4. Insertthe ssr No. 2 intothe pistonpin as shownand

9. |ut thepistonon thessr vriththeF markfacingupward.

B. Press ll^rgp,:Lo! pin into the piston and the connecting

OIL RING SECOND

2. Applya liberalamountof a clean engineoil to the main

6.lf the end play exceeds the maximum grind

5. Apply a liberalamountof clea;rengineoil to the crankpin